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Roberts Gorden Combat CTU 100, Installation, Commissioning, Operation & Service Manual

The Roberts Gorden Combat CTU 100 is a high-performance heating system. Ensure seamless installation, commissioning, operation, and service with our comprehensive manual conveniently available for download, absolutely free. Visit our website to get the detailed Installation, Commissioning, Operation & Service Manual and unlock the full potential of your product.

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SECTION 16: R

EMOVAL

 

AND

 R

EPLACEMENT

 P

ARTS

35

SECTION 16: REMOVAL AND REPLACEMENT PARTS

See warnings and notes 

on Page 30, Section 13

 

before removing or replacing parts.

Burner Components

 

All serviceable burner parts are accessed by the 
door on the right side of the heater. Use a 
screwdriver to turn the latch 90°. 

See Page 5, 

Section 4

.

16.1 Gas Valve

Remove the gas supply pipe at the heater inlet.

16.1.1 

Disconnect

wire harness

Unplug

control

from

valve

Remove

fixing

screw

Ignition

Control

Description

Part Number

Gas Valve VR4105A

90033403

Ignition Control

90434010

Models 22 - 60

16.1.2 

Step 1

Unscrew

gas pipe

from the

valve inlet.

Step 2

Unscrew valve from the

burner manifold

or

unscrew the fixing screws for

the inlet and outlet flanges.

Unplug

electrical lead.

(rectifier harness)

Ignition

Control

Description

Part Number

Gas Valve VR4605

90033404

Ignition Control

90434020

Models 75 - 115

16.1.3 All Models

Replace in reverse order. Verify that the gas flow 
direction of the valve is correct. Use a minimum 
amount of gas seal on the thread joint. Re-use the 
"O" ring seal in the outlet flange where fitted. Check 
that all the joints are leak free. Reset gas valve. 

See 

Page 26, Section 11.4.2

.

 

IT IS IMPORTANT THAT ONLY THE CORRECT 
GAS VALVES SPECIFIED FOR EACH MODEL

TYPE ARE USED WHEN REPLACING THESE 
CONTROLS.

Summary of Contents for Combat CTU 100

Page 1: ...pment or your gas supplier Improper installation adjustment alteration service or maintenance can result in death injury or property damage Read the installation operation and service manual thoroughly before installing or servicing this equipment Installer Please take the time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the owne...

Page 2: ......

Page 3: ...2 Remote Controls 15 10 3 CTUA Wiring Diagram Models 22 60 16 10 4 CTUA Wiring Diagram Models 75 115 17 10 5 CTUB C Wiring Diagram Models 22 40 18 10 6 CTUB C Wiring Diagram Models 50 60 19 10 7 CTUB C Wiring Diagram Models 75 115 20 10 8 CTUD Wiring Diagram Models 22 60 21 10 9 CTUD Wiring Diagram Models 75 115 22 10 10 CTUD External Motor Alternative Wiring Optional Thermostat Time Switch 23 SEC...

Page 4: ......

Page 5: ...e 11 Figure 6 Vertical and Horizontal Flue Termination Type C12 C32 C62 Appliances 11 Figure 7 Heaters Installed in Isolated Equipment Rooms 12 Figure 8 Ducting 13 Figure 9 Gas Connection with Stainless Steel Flex Connector 14 Figure 10 Automatic Burner Control Box Sequence 25 Figure 11 Gas Valve for Heater Models 22 60 25 Figure 12 Gas Valve for Heater Models 75 115 26 Figure 13 Heater Operating ...

Page 6: ......

Page 7: ...ained in accordance with these instructions These instructions refer to appliances designed to operate in the European Union Appliances designed for other countries Non European Union are available on request This appliance must be installed in accordance with the local and national codes in force and used only in a sufficiently ventilated space as specified in these instructions Before installati...

Page 8: ... suspend anything from heater To ensure that there is sufficient ventilation in the area to comply with the requirements of all relevant local and national codes 2 1 Clearances to Combustibles In all situations clearances to combustibles must be maintained Caution must be used when running the heater near combustible materials such as wood paper rubber etc A wall tag P N 91040028 is on the back co...

Page 9: ...d correct operation 3 4 Clearances to Combustibles Clearances must be as indicated on Page 4 Figure 1 If clearances to combustibles are not indicated then installation clearances apply 3 5 Ventilation It is important to ensure that there is adequate air circulation around the heater to supply air for combustion ventilation and distribution in accordance with local and national codes 3 6 Gas Supply...

Page 10: ...rminal Air Intake Flue 50 cm 50 cm 30 cm 15 cm Clearances to Combustibles 15 cm 2 5 3 5 m 3 m 60 cm Installation Clearances If installed at low levels where individuals can come in contact with hot heat exchanger components adequate guarding must be provided All distances are minimum clearance requirements for service access air flow and safety The heater must always be installed at least 2 5 m ab...

Page 11: ...12 12 3 312 12 3 312 12 3 312 12 3 312 12 3 312 12 3 312 12 3 E Support Spacing mm in 315 12 4 315 12 4 315 12 4 315 12 4 315 12 4 315 12 4 388 15 3 388 15 3 388 15 3 388 15 3 F Centre of Flue mm in 240 9 5 240 9 5 240 9 5 240 9 5 430 16 9 430 16 9 346 13 6 346 13 6 537 21 1 537 21 1 G Centre of Flue Air Intake mm in 140 5 5 140 5 5 140 5 5 140 5 5 140 5 5 140 5 5 225 8 9 225 8 9 225 8 9 225 8 9 H...

Page 12: ...0 24 610 24 895 35 2 895 35 2 1100 43 3 1100 43 3 1380 54 3 1380 54 3 M CTUC Height mm in 610 24 610 24 610 24 610 24 895 35 2 895 35 2 1100 43 3 1100 43 3 1431 56 3 1431 56 3 N Inlet Outlet Duct Spigot Height mm in 534 21 534 21 534 21 534 21 817 32 817 32 1024 40 3 1024 40 3 1233 48 5 1233 48 5 P Inlet Outlet Duct Spigot Width mm in 709 27 9 709 27 9 709 27 9 709 27 9 707 27 8 707 27 8 888 35 88...

Page 13: ... Medium Medium Medium Medium Medium Medium Medium High Run Current A 5 5 5 5 5 5 5 5 14 0 14 0 14 0 14 0 21 0 21 0 High Start Current A 13 6 13 6 13 6 13 6 17 2 17 2 17 2 17 2 25 8 25 8 Air Flow m3 h 3300 3300 3300 3300 5500 5500 6400 6400 9400 9400 Sound Pressure Level at 3 m NR dB A 59 59 5 59 59 5 59 59 5 59 59 5 61 61 5 61 61 5 62 61 8 62 61 8 63 64 2 63 64 2 CTUD Duct Heater with No Fan Minim...

Page 14: ...Pressure 25 mbar 10 in WG Min 20 mbar 7 8 in WG Max 30 mbar 12 in WG Burner Pressure mbar 12 2 12 7 12 5 14 0 13 6 13 2 9 2 9 3 9 2 10 2 Gas Rate m3 h ft3 h 3 03 107 3 33 117 4 31 152 4 78 169 6 14 217 6 98 247 9 49 335 11 06 391 11 86 419 13 43 474 LPG Gas Propane G31 Data Inlet Pressure 37 mbar 14 6 WG Min 25 mbar 10 in WG Max 45 mbar 18 in WG Alternative where permitted 50 mbar 20 in WG Min 42 ...

Page 15: ...ng and installation When handling or supporting the heater from below ensure that the weight is taken at the support points 5 3 Shelf Mounting and Suspension WARNING Crush Hazard Use 10 mm steel drop rod minimum Failure of the supports can result in death injury or property damage For typical suspension See Page 9 Figure 2 Figure 2 Suspension Methods 10 mm Steel Drop Rod Washer Nut Unistrut Channe...

Page 16: ...bear the weight of the pipes For flue termination See Page 10 Figure 3 through Page 11 Figure 6 6 2 Type C12 C32 C62 Appliance Room Sealed The heaters are designed to be installed as room sealed appliances The flue and air intake are run as separate pipes to the special concentric wall or roof terminal See Page 11 Figure 6 6 3 Type B22 Appliance The flue must terminate outside the building and be ...

Page 17: ...Sleeve 25 mm air gap to Combustible Material Figure 6 Vertical and Horizontal Flue Termination Wall Plate Wall Terminal Flue Roof Terminal 90 Bend Flue Air Intake Air Intake Manifold Manifold Vertical Option Horizontal Option Plastic Cup Masterflash The minimum gap must be positioned at bottom End View Max wall thickness 335 mm Model Concentric Flue Diameter 22 60 Cover 100mm 150mm 75 115 Cover 13...

Page 18: ...bove 70 kW 7 3 Building Ventilation Where ventilation is required air must be taken from an outside point where it is not likely to be contaminated or obstructed Where natural ventilation is used suitable ventilation with outside air at low level must be provided in accordance with Section 7 2 1 and local and national codes Where mechanical ventilation is used extract rate must be 5 10 less than t...

Page 19: ...is at least that specified in the Data Sheet on Page 6 Section 4 2 and in the correct direction across the heat exchanger as indicated by the arrow on the heater Higher air flows are permitted but will cause a lower exiting air temperature It is recommended that the fan is positioned to blow the air through the heat exchanger The duct must be designed as described on Page 13 Section 8 1 and Figure...

Page 20: ...ensuring that the final connections are as follows Gas supply pipe work is run in medium or heavy gauge tubing in compliance with local and national codes The gas supply pipe is adequately sized to carry the total volume of gas for the complete installation An isolating valve and union connection should be used and fitted into the supply adjacent to the heater For suspended heaters use an approved...

Page 21: ... servicing Failure to follow these instructions can result in death or electrical shock 10 2 Remote Controls The heater is designed to be operated by controls installed remote from the heater See Page 16 Section 10 3 through Page 17 Section 10 4 10 2 1 Burner Controls Thermostat Controls to operate the burner must be voltage free contacts connected between terminals 2 3 of the main terminal block ...

Page 22: ...ail WHITE YELLOW BLACK Thermostat Limit Thermodisc N C BROWN BROWN RED RED AXIAL FAN COMBUSTION FAN N L E N L REMOTE LOCKOUT RESET REMOTE LOCKOUT INDICATION THERMOSTAT REMOTE FAN ON LINE NEUTRAL GROUND YELLOW BLACK WHITE PRESSURE SWITCH GREEN YELLOW BLACK BROWN BROWN BROWN YELLOW BLUE WHITE PINK PURPLE GREY NO P 3 C P 1 NC P 2 GREEN YELLOW BLUE BROWN BLUE BROWN Time Delay Relay LOCKOUT RESET NOTE ...

Page 23: ...h Detail NO P 3 C P 1 BLACK YELLOW WHITE PRESSURE SWITCH AXIAL FAN BLUE PINK GREY PURPLE LOCKOUT RUN GREEN YELLOW BLACK WHITE YELLOW GREEN YELLOW BROWN BLUE BROWN BLUE BLUE BROWN MAINS FILTER GREEN YELLOW BLACK SENSE IGNITION BLACK BROWN BLUE L N E Thermostat Limit Thermodisc N C BROWN Time Delay Relay BLUE BROWN BROWN LOCKOUT RESET NOTE If any of the original wire supplied with the heater must be...

Page 24: ...L REMOTE LOCKOUT RESET REMOTE LOCKOUT INDICATION THERMOSTAT REMOTE FAN ON LINE NEUTRAL GROUND YELLOW BLACK WHITE PRESSURE SWITCH GREEN YELLOW NO P 3 C P 1 NC P 2 GREEN YELLOW WHITE N LOW RED CENTRIFUGAL FAN HIGH BLACK MEDIUM BLUE Thermostat Limit Thermodisc N C BROWN BLUE BROWN Time Delay Relay BLACK BROWN BROWN BROWN YELLOW BLUE WHITE PINK PURPLE GREY LOCKOUT RESET NOTE Unused speed setting wires...

Page 25: ...HERMOSTAT REMOTE FAN ON LINE NEUTRAL GROUND YELLOW BLACK WHITE PRESSURE SWITCH GREEN YELLOW BLACK BROWN BROWN BROWN YELLOW BLUE WHITE PINK PURPLE GREY NO P 3 C P 1 NC P 2 GREEN YELLOW WHITE N LOW RED HIGH BLACK MEDIUM BLUE CENTRIFUGAL FAN 2 CENTRIFUGAL FAN 1 GREEN YELLOW WHITE N LOW RED HIGH BLACK MEDIUM BLUE COMBUSTION FAN Thermostat Limit Thermodisc N C BROWN BLUE BROWN Time Delay Relay LOCKOUT ...

Page 26: ...RESET REMOTE LOCKOUT INDICATION THERMOSTAT REMOTE FAN ON LINE NEUTRAL GROUND 230 V 1 Ø 50 Hz CENTRIFUGAL FAN 1 CENTRIFUGAL FAN 2 MEDIUM BLUE LOW RED RELAY GREEN YELLOW WHITE N HIGH BLACK LOW RED HIGH BLACK WHITE N GREEN YELLOW MEDIUM BLUE LOW RED GREEN YELLOW WHITE N HIGH BLACK CENTRIFUGAL FAN 3 models 100 115 only Thermostat Limit Thermodisc N C BROWN Time Delay Relay BLUE BROWN BROWN LOCKOUT RES...

Page 27: ...YELLOW BLACK BROWN COMBUSTION FAN E N L REMOTE LOCKOUT RESET REMOTE LOCKOUT INDICATION THERMOSTAT LINE NEUTRAL GROUND YELLOW BLACK WHITE PRESSURE SWITCH GREEN YELLOW BLACK BROWN BROWN BROWN YELLOW BLUE WHITE PINK PURPLE GREY NO P 3 C P 1 NC P 2 RED RED Thermostat Limit Thermodisc N C BROWN BLUE BROWN Time Delay Relay LOCKOUT RESET NOTE For external fan wiring See Page 23 Section 10 10 If any of th...

Page 28: ...N BLUE BROWN BLUE MAINS FILTER BLACK SENSE IGNITION BLACK BROWN BLUE SITE WIRING N L 1 2 3 7 8 REMOTE LOCKOUT RESET REMOTE LOCKOUT INDICATION THERMOSTAT LINE NEUTRAL GROUND 230 V 1 Ø 50 Hz BROWN RED Thermostat Limit Thermodisc N C BROWN Time Delay Relay BLUE BROWN BROWN LOCKOUT RESET NOTE For external fan wiring See Page 23 Section 10 10 If any of the original wire supplied with the heater must be...

Page 29: ...rotection must be provided at the motor or contactor Room Thermostat Frost Thermostat 230 V 50 Hz Time Switch RDW 1565 be provided at the motor N L 1 2 3 2A 230 V Contactor or Relay Single Phase Motor with Load over 7 Amps N L Overload protection must or contactor 230 V 50 Hz supply Single Phase Motor with Load Over 7 Amps Room Thermostat Frost Thermostat 230 V 50 Hz Time Switch Optional Thermosta...

Page 30: ...ge 11 1 2 Electrical Checks All pre commission checks must be carried out before commissioning the heater 1 Check that all site wiring is connected in accordance with the appropriate wiring dia grams on Page 16 Section 10 3 through Page 23 Section 10 10 2 Check the correct fuse size is fitted See Page 15 Section 10 1 11 2 Gas Supply All aspects of the gas installation including the gas meter must ...

Page 31: ...change over ts Safety time S4563C 3 seconds alternate 5 seconds S4565C 5 seconds Required Incoming Signals If at any stage the flame fails the control will go to lockout The red light will illuminate and the control will need to be manually reset before any further start attempt can be made Figure 11 Gas Valve for Heater Models 22 60 Regulator Under Cover Inlet Pressure Gas Inlet Ignition Control ...

Page 32: ...ure adjustment allow the heater to operate for at least 15 minutes and then re check settings 2 Remove the manometer and refit all covers to the valve and tighten the screw of the outlet pressure tap 3 Check gas flow rate at gas meter 11 5 Combustion Testing The only adjustment to alter combustion performance is burner pressure Combustion quality must be tested to prove correct heater operation In...

Page 33: ...missioning Ensure that all covers are fitted correctly and all test points are properly sealed 11 9 Instruction to the User Explain the controls of the heater to the user including how to turn it on and off using the controls fitted on site Give this manual to the user Ensure that the user is shown and understands the importance of maintaining clearances to combustibles and the user instructions o...

Page 34: ...nd reset devices to give further protection against fan failure NOTE To reset the heat exchanger must be cool Description Part Number All Models 90412100 WARNING Explosion Hazard If control locks out do not make more than 3 attempts to restart the heater Dangerous gas mixtures can build up The fault must be traced and repaired by a registered installer or service engineer Failure to follow these i...

Page 35: ...e for any reason it will go to lockout This will be indicated by the red light on the heater or at the remote indicator if fitted 1 Press in and release the lockout reset button If a remote reset is not fitted a reset button is on the rear panel of the heater See Page 5 Section 4 1 Lockout should not occur during normal operation of the heater and indicates there is a fault condition which must be...

Page 36: ...and do not need lubrication Before cleaning turn off gas and electrical supply Remove the fan s and use a small brush or duster to clean the fan blades from each side Replace fan s when done 13 3 1 For CTUB CTUC Centrifugal Fan Models CTUB and CTUC models are fitted with thermally protected three speed fans The number of fans can be found on Page 41 Section 16 9 and the standard air flow for each ...

Page 37: ... Section 16 1 for gas valve removal 3 Remove the manifold from the burner assembly by removing the screws at the top and bottom See Page 36 Section 16 2 1 4 Remove the main burner injectors 5 Replace with the injectors for the new gas ensuring a gas tight seal 6 Refit all components in reverse order 14 3 Gas Valves All gas valves used on the CTU have pressure regulators that may be set to operate ...

Page 38: ...and service of gas fired heating equipment or your gas supplier Failure to follow these instructions can result in death injury or property damage For your safety and optimum heater performance use only ROBERTS GORDON replacement parts Conduct Commissioning procedure as shown on Page 24 Section 11 Installation Code and Annual Inspections All installations and service of ROBERTS GORDON equipment mu...

Page 39: ...tat limit thermodisc operated or light faulty Reset or replace as necessary Is 230 V supply at fan connections Does flue fan run No Are external controls on Yes Yes Is the green light on No Yes Is red lockout light on No Yes Press in lockout reset button on rear of heater or remote reset button if fitted Turn on supplies Are gas electrical supplies on Yes Start No Yes No If problems persist contac...

Page 40: ...t 1 µA DC flame current Connect a DC ammeter in series with the flame probe Yes No Yes Yes No START If problems persist contact ROBERTS GORDON at Tel 44 0 121 506 7709 www rg inc com NOTE Minimum flame probe current 1 μA DC Typical flame probe current 3 5 μA DC 15 4 Troubleshooting for Solenoid Valves Valve faulty Replace with one of correct type Fault elsewhere Fault elsewhere Valve Operating TRO...

Page 41: ...ntrol 90434010 Models 22 60 16 1 2 Step 1 Unscrew gas pipe from the valve inlet Step 2 Unscrew valve from the burner manifold or unscrew the fixing screws for the inlet and outlet flanges Unplug electrical lead rectifier harness Ignition Control Description Part Number Gas Valve VR4605 90033404 Ignition Control 90434020 Models 75 115 16 1 3 All Models Replace in reverse order Verify that the gas f...

Page 42: ... of injectors Ensure correct alignment with burners Ensure all pipe joints are gas tight Burner Injectors MODEL CTU 22 CTU 30 CTU 35 CTU 40 CTU 50 CTU 60 CTU 75 CTU 90 CTU 100 CTU 115 Injector Quantity 5 5 6 7 9 11 12 14 15 17 Natural Gas G20 and G25 Injector size mm Ø 2 08 2 25 2 25 2 25 2 25 2 25 2 71 2 71 2 71 2 71 in Ø 0 0819 0 0886 0 0886 0 0886 0 0886 0 0886 0 1067 0 1067 0 1067 0 1067 Marki...

Page 43: ...n Electrode Remove Screw Ignition Electrode Burners Flame Probe Burners Burner Compartment Front Views Remove all burner compartment screws to remove the burner compartment and access the Front View Thermostat Limit Thermodisc 120 3 mm spark gap To replace the ignition electrode or flame probe remove the electrical lead and screw Pull out from mounting Refit in reverse ensuring that the gap to bur...

Page 44: ...d MODEL CTU 22 CTU 30 CTU 35 CTU 40 CTU 50 CTU 60 CTU 75 CTU 90 CTU 100 CTU 115 Flue Fan Torin DSA 508 128 077272 Torin DSA 508 128 077272 Torin DSA 508 128 077272 Torin DSA 508 128 077272 Torin DSA 524 202 077273 Torin DSA 524 202 077273 AO Smith JFIG098NS AO Smith JFIG098NS AO Smith JFIG098NS Torin DSF 146 052 077274 RG P N 90710430 90710430 90710430 90710430 90710440 90710440 90710001 90710001 ...

Page 45: ...cause unsafe condition Failure to follow these instructions can result in death or serious injury WARNING Carry out a commission after working on or changing a pressure switch See Page 24 Section 11 Pressure Switch CTU 22 CTU 30 CTU 35 CTU 40 CTU 50 CTU 60 CTU 75 CTU 90 CTU 100 CTU 115 RG P N 90439801 90439810 90439804 90439803 90439810 90439802 90439811 90439807 90439811 90439807 Colour Code pink...

Page 46: ...embly reverse the procedure shown above Fit rubber washers to the guard mountings to reduce vibration Check that the fan blades are free to rotate before turning on the power to the fan Strictly comply with the colour code of the fan wires to ensure correct operation See Page 16 Section 10 3 through Page 17 Section 10 4 wir ing diagrams Use only genuine ROBERTS GORDON replacement parts 16 8 CTUB C...

Page 47: ...B C 100 115 16 9 Fan Data MODEL CTU 22 CTU 30 CTU 40 CTU 50 CTU 60 CTU 75 CTU 90 CTU 100 CTU 115 Axial Fan Type CTUA Models EBM S4E420 AA06 02 EBM S4E420 AA06 02 EBM S4E420 AA06 02 Ma Vib V02 C100 Ma Vib V02 C100 EBM S4E420 AA06 02 EBM S4E420 AA06 02 Ma Vib V02 C100 Ma Vib V02 C100 RG P N 90710418 90710418 90710418 90710419 90710419 90710418 90710418 90710419 90710419 Quantity 1 1 1 1 1 2 2 2 2 Fa...

Page 48: ......

Page 49: ......

Page 50: ......

Page 51: ...7709 Service Fax 44 0 121 506 7702 E mail uksales rg inc com E mail export rg inc com Roberts Gordon LLC 1250 William Street P O Box 44 Buffalo NY 14240 0044 USA Roberts Gordon Europe Limited Unit A Kings Hill Business Park Darlaston Road Wednesbury West Midlands WS10 7SH UK Telephone 44 0 121 506 7700 50 cm 50 cm 30 cm 15 cm Clearances to Combustibles 15 cm 2 5 3 5 m 3 m 60 cm Wall Terminal Roof ...

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