Roberts Gorden BH-40 Electric Heater User Manual
Contents
1. Radiant Model Tube Length CTHN 40 10 4 5 m CTHN 60 20 6 m CTHN 80 20 6 m CTHN 100 30 9 m CTHN 125 40 12 m CTHN 150 40 12 m CTHN 175 50 18 m CTHN 200 50 18 m Total Overall Tube Length Step 8 8 Turbulator Installation eee Section Turbulator Adapter Turbulator section My stainless used in A CTHN 40 heaters must be in the section of tube nearest to the burner Description Part Number Turbulator Adapter 03051503 Turbulator Section 03051504 Turbulator Section Stainless 03051505 Tube 91409XXX Turbulator must be installed in the last standard section of radiant tube Turbulator is only required on the CTHN 40 CTHN 60 and CTHN 80 lt s Turbulator Installation Model Tube Section CTHN 40 1st 10 3 m Section CTHN 60 2nd 10 3 m Section CTHN 80 2nd 10 3 m Section CTHN 100 N A CTHN 125 N A CTHN 150 N A CTHN 175 N A CTHN 200 N A Pull String Fold tab around outside of tube nearest to the vent to hold turbulator in place 21 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 9 Reflector Installation Burner Tube Description Part Number Tube Reflector Hanger 03090100 Burner Tube 03051XXX Reflector 02750303 NOTE All radiant tube surfaces must be covered by a r2. 36 9 9 Coupling and Tube Assembly 37 9 10 Turbulator Installation 38 9 11 Reflector Installation 39 9 12 Burner Installation 41 SECTION 10 Optional Heater Accessories 42 10 1 Elbow Package Configuration 42 10 2 Reflector Side Extension 44 10 3 Lower Clearance Shield Installation 45 10 4 Two Foot Decorative Grille Installation 45 10 5 One Foot Decorative Grille Installation 47 10 6 Protective Grille Installation 49 SECTION 11 Venting General see 50 11 1 General Venting Requirements 50 SECTION 12 Venting Unitary Heater 51 12 1 Unvented Operation seen 51 12 2 Unvented Operation Termination 51 12 3 Horizontal Venting u 51 12 4 Vertical Venting u 51 12 5 Length Requirement 51 12 6 Flue Connection Detail
3. 01326801 Reinforcement 01365903 Joint Piece 91406700 1 x8 3 m x 2 4 m Protective Grille Deco Grille 2 x 4 6 m x 1 2 m 01365900 Shield Frame 01370408 Reflector Side Extension 8 x 48 20 cm x 122 cm 01370412 Reflector Side Extension 12 x 48 30 cm x 122 cm 01370416 Reflector Side Extension 16 x 48 40 cm 122 cm 91407000 Grille Aluminum 2 x 4 6 m x 1 2 m Protective Grille 08050001 Grille 40 102 cm Protective 08050002 Protective Grille End Cap Fan and Pump Packages 05220000 Fan Package 40 150 05221000 Fan Package 175 200 02719105 EP 100 Pump Package 02719100 EP 100 Pump 02724700 Accessory Package 02716305 EP 201 Pump Package 01312001 EP 201 Pump 01317805 Accessory Package 02712034 EP 203 Pump Package 01312002 EP 203 Pump 01317805 Accessory Package 02723014 EP 301 Pump Package 4 10 cm 02730101 EP 301 Pump Assembly 02730104 Accessory Package 02723016 EP 301 Pump Package 6 15 cm 02730101 EP 301 Pump Assembly 02730106 Accessory Package 02723034 EP 303 Pump Package 4 10 cm 02730103 EP 303 Pump Assembly 02730104 Accessory Package 02723036 EP 303 Pump Package 6 15 cm 02730103 EP 303 Pump Assembly 02730106 Accessory Package Pump Access ories 90430600K Pressure Switch Starters and Contactors
4. 15 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 15 Unitary Linear Layout Overviews Continued ee 60 18 m Tube Length 70 21 m Tube Length 80 24 m Tube Length 16 8 4 Unitary U tube Heater Layouts CTHN Series heaters except CTHN 40 are approved for optional u tube configurations The u tube may be installed in either a standard horizontal position 45 position or in an opposite 45 position as shown on Page 5 Figure 5 through Figure 7 When using a u tube configuration the following additional rules must be adhered to FIGURE 16 U tube Assembly Overview SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION A minimum of 10 3 m on CTHN 60 80 a minimum of 15 4 5 m on CTHN 100 125 and a minimum of 20 6 m on CTHN 150 175 200 is required between the burner and the u tube For turbulator installation See Page 21 Step 8 8 The burner must never be operated in a tilted position The heater must be properly supported at all locations See Page 10 Figure 12 U tube Support Reflector Support Turbulator D With Select X Models Tube Clamp Package 1 Tight U bolt 4 10 cm u bolt secured to burner tube with 1 4 6 mm lockwashers and 1 4 20 hex nuts U tube Opposite 45 Bracket A U clips Reflector 2 Loose U bolt 4 10 cm u bolt Secured to bracket with 1 4 6 mm lockwashers and 1 4 20 hex
5. To plan location of supports To provide access to burners on all sides for burner servicing and removal To provide the owner with a copy of this Installation Operation and Service Manual To never use heater as a support for a ladder or other access equipment and never hang or suspend anything from heater To ensure there is adequate air circulation around the heater and to supply air for combustion Failure to follow these instructions can result in property damage Roberts Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation this is entirely the responsibility of the installer It is essential that the contractor the sub contractor or the owner identifies the presence of combustible materials corrosive chemicals or halogenated hydrocarbons anywhere in the premises Halogenated Hydrocarbons are a family of chemical ventilation and distribution in accordance with compounds characterized by the presence of halogen elements local codes fluorine chlorine bromine etc These compounds are frequently used in refrigerants cleaning agents solvents etc If e To safely and adequately install heater using these compounds enter the air supply of the burner the life span ni of the heater components will be greatly reduced An outside air materials with a minimal working load of 75 Ibs supply must be provided to the burners whenever the prese
6. 60 18 m 61 18 6 m 80 24 m Typical Expansion 1 3 cm x2 5 cm x3 8 cm Minimum X Length 12 30 cm 18 46 cm 24 61 cm Part Number 91907302 03090100 Description S Hook Tube Reflector Hanger 10 SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION 8 1 Standard Parts Table 1 Contents of CTHN Burner Carton Part No Description CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 052XXXXxX Burner Rate and Fuel Varies 1 1 1 1 1 1 1 1 07730400 Restrictor Plate 1 25 3 2 cm dia 1 7 n 07730100 Restrictor Plate 1 50 3 8 cm dia 1 3 P 07730500 Restrictor Plate 2 25 5 7 cm dia 1 1 07730600 Restrictor Plate 2 50 6 4 cm dia 1 07730700 Restrictor Plate 2 75 7 cm dia E 1 B 03051503 Turbulator Adapter 1 1 1 s P 03051504 Turbulator Section 2 4 4 03051505 Turbulator Section 1 i 2 lt 3 Stainless Steel 91412200 Flexible Stainless Steel Gas Hose 1 2 NPT 1 1 1 1 1 US Models Only 91412203 Flexible Stainless Steel Gas Hose 3 4 NPT 1 1 1 US Models Only 02568200 Gasket Burner to Burner Tube 1 1 1 1 1 1 1 1 94273914 Hex Head Cap Screw 5 16 18 x 7 8 4 4 4 4 4 4 4 4 96411600 Split Lock Washer 4 4 4
7. 52 12 7 Horizontal Ventilation 4 10 cm Pipe 52 12 8 Vertical Ventilation 4 10 cm Pipe 53 12 9 Common Sidewall Venting 53 12 10 Common Vertical Venting 54 SECTION 13 Venting Multiburner Systems 55 13 1 General Requirements sss 55 13 2 Manifold Tube Requirements 55 13 3 Venting the Pump 55 13 4 EP 100 Pump Models eene 56 13 5 EP 200 Pump Series 56 13 6 EP 300 Pump Series sse 56 13 7 Installation Precautions 56 SECTION 14 Outside Combustion Air Supply 58 14 1 Length Requirements 58 14 2 Vertical Non Pressurized Outside Air Supply for Single Heater Installation 58 14 3 Horizontal Non Pressurized Outside Air Supply for Single Heater Installation 58 14 4 Vertical Non Pressurized Outside Air Supply for Double Heater Installation sessssse 59 14 5 Horizontal Non Pressurized Outside Air Supply for Double Heater Installation 59 14 6 Pressu
8. Clearances are the required distances that combustible objects must be away from the heater to prevent fire hazards Combustible materials that may catch fire include common items such as wood paper rubber fabric etc Maintain clearances to combustibles at all times for safety Clearances for all heater models are located on the burner of the heater and on Page 3 Figure 1 through Page 6 Figure 10 in this manual Check the clearances on each burner for the model heater being installed to make sure the product is suitable for your application and the clearances are maintained Read and follow the safety guidelines below Keep gasoline or other combustible materials including flammable objects liquids dust or vapors away from this heater or any other appliance Maintain clearances from heat sensitive material equipment and workstations Maintain clearances from vehicles parked below the heater Maintain clearances from swinging and overhead doors overhead cranes vehicle lifts partitions storage racks hoists building construction etc In locations used for the storage of combustible materials signs must be posted to specify the maximum permissible stacking height to maintain SECTION 3 CRITICAL CONSIDERATIONS WARNING Fire Hazard Some objects will catch fire or explode when placed close to heater Keep all flammable objects liquids and vapors the required clearances to combustibles away from he
9. Tee 2 e Last Cross 9 6 3 Herringbone Layout and Manifold Tube Length Rules The herringbone layout is essentially several T layouts stacked together Therefore the same principle for manifold tube calculation as used for T layouts is used for herringbone layouts with one exception In a herringbone layout the manifold tube length between tees or crosses as well as between the last tee or cross and the pump is calculated by dividing by 1 5 as shown in the T example on Page 33 Section 9 6 2 The only manifold tube length in a herringbone layout that is not divided by 1 5 is any manifold tube length located between the end of the radiant tube and a tee or cross Example Consider a herringbone layout similar to the layout on the left in Figure 23 having ten CTHN 100 burners Assume that each heater has 40 12m of radiant tube and 10 3m of manifold tube before FIGURE 23 Herringbone Layout SECTION 9 MULTIBURNER HEATER INSTALLATION the connecting tee or cross According to Table 10 each burner must have at least 40 12m of radiant tube also each burner must have between 6 2m and 45 13 5m of manifold tube Each burner has already met the minimum manifold pipe requirement due to the 10 3m of manifold tube before the connecting tees and crosses The maximum manifold tube length for the entire system is 10 burners X 45 13 5m 450 135m Subtract the 100 30m that has already been used before
10. 10050001 Starter 120 Vac for EP 203 3 10050003 Starter 120 Vac for EP 201 1 10050008 Starter 120 Vac for EP 301 1 10050009 Contactor Package 120 Vac Coil for EP 301 230 V 2 HP 10050010 Starter 120 Vac for EP 303 3 28 9 2 Multiburner System Design Requirements A CTHN multiburner system has a number of radiant tube sections interconnected by manifold tube to a pump to form a complete system Reflectors can be used over the manifold tube but are not required The system design parameters are such that the manifold sections are not subjected to condensate when the system is fully heated up It is required that heat treated aluminized or coated tubing is used for the manifold to increase system life and to handle initial condensation during start up Damper couplings may be necessary to balance system vacuum Design requirements for a CTHN multiburner system are summarized on Page 30 Table 10 SECTION 9 MULTIBURNER HEATER INSTALLATION CTHN multiburner heaters are typically shipped as burner packages and tube and accessory packages The tube and accessory packages contain enough tube reflector and hanging parts for the radiant section of one CTHN heater Elbows tees manifold tube pumps controls damper couplings and any other parts used beyond the burner radiant tube and reflector must be purchased separately See Figure 18 for a general overview of a simple CTHN multiburner system Depending on sy
11. 4 4 4 4 4 91201708 Pipe Nipple 1 2 NPT x 4 1 1 1 1 1 1 1 1 152101NA Installation Operation and Service Manual 1 1 1 1 1 1 1 1 Canadian Models Rubber Type 1 Gas Hoses available as an accessory See Page 69 Section 16 Table 2 Contents of Core and Extension Packages Core Packages Extension Packages Hot Rolled Aluminized Hot Rolled Aluminized Part No Description 20 30 40 10 20 30 40 10 20 30 40 10 20 30 40 6m 9m 12m 3m 6m 9m 12m 3m 6m 9m 12m 3m 6m 9m 12m 91409300 Tube Hot Rolled Steel 10 3 m 1 2 3 1 2 3 44 91409408 Tube HT Aluminized 10 3 m 1 2 3 1 2 3 4 03051101 Burner Tube ALUMI THERM Steel 10 3 m 1 1 1 1 03051601 Burner Tube HT ALUMI THERM Steel 10 3m 1 1 1 f fe 01312700 Coupling Assembly 1 2 3 1 2 383 1 2 3 4 1 2 3 4 02750303 Standard Reflector 8 2 4 m 3 4 6 2 3 4 6 2 3 4 6 2 3 4 6 02750800 End Cap 2 2 22 2 2 2 03090100 Tube and Reflector Hanger 3 4 5 2 3 4 5 1 2 3 4 1 2 3 4 91907302 S hook 3 4 5 2 3 4 5 1 2 9 3 1 2 3 4 03050010 Reflector Support Package 2 3 5 1 2 3 b 2 3 4 606 2 3 4 6 Strap Wire Form Screws 91107720 U clip Package 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 90502700 Vent Adapter Not used on CTHN 1 1 1 1 1 1 1 01318901 Tube Clamp Package 1
12. CODES The type of gas appearing on the nameplate must be the type of gas used Installation must comply with national and local codes and requirements of the local gas company United States Refer to National Fuel Gas Code ANSI Z223 1 latest revision same as NFPA 54 Canada Refer to CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances 4 3 Public Garages 4 2 Aircraft Hangars Installation in aircraft hangars must be in accordance with the following codes United States Refer to Standard for Aircraft Hangars ANSI NFPA 409 latest revision Canada Refer to Standard CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances In aircraft storage and servicing areas heaters shall be installed at least 10 3 m above the upper surface of wings or of engine enclosures of the highest aircraft which may be housed in the hangar The measurement shall be made from the wing or engine enclosure whichever is higher from the floor to the bottom of the heater In shops offices and other sections of aircraft hangars communicating with aircraft storage or servicing areas heaters shall be installed not less than 8 2 4 m above the floor e Suspended or elevated heaters shall be so located in all spaces of aircraft hangars that they shall not be subject to injury by aircraft cranes movable scaffolding or other objects Provisions shall be made to assure accessib
13. CTHN 80 2nd 10 3 m Section CTHN 100 N A CTHN 125 N A CTHN 150 N A CTHN 175 N A CTHN 200 N A V b Turbulator Adapter Turbulator section stainless used in E f CTHN 40 heaters must be me Pull String uL old tab around outside in the section of tube nearest EN of tube nearest to the ve t lo to the burner E hold turbulator in place Description Part Number Turbulator Adapter 03051503 Turbulator Section 03051504 Turbulator Section Stainless 03051505 Tube 91409XXX Step 9 11 Reflector Installation Description Part Number Tube Reflector Hanger 03090100 Burner Tube 03051 XXX Reflector 02750303 Reflector SECTION 9 MULTIBURNER HEATER INSTALLATION NOTE All radiant tube surfaces must be covered by a reflector except for a u tube Manifold tube may or may not be covered 39 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 9 11 1 Reflector U clip and Reflector Support Installation The pictorial drawings of the heater construction in Section 9 are schematic only and provide a general guideline of where hangers reflector supports and u clips are to be installed To ensure proper expansion and contraction movement of the reflectors a combination of u clips and reflector supports are used The positioning of 1 The first reflector after the burner must be affixed in the
14. Specification 83 20 2 Heater Specifications 83 20 3 Suspension Specifications 83 20 4 Controls Specifications 83 SECTION 21 The ROBERTS GORDON Vantage NP Limited Warranty 85 2006 Roberts Gordon LLC All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Roberts Gordon LLC Printed in U S A TABLE OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Standard Rellector a 3 One Side ReflectorF u UU L AU u u l 4 Two Side Reflectors 4 45 Tilt Reflector oo suu ul un a 4 U Tube Standard Retll
15. cm wa Burner Tube Supplied in 10 3 m lengths j Burner tube is always the first a tube after the burner Tube Hot rolled or heat treated aluminized tube supplied in 10 3 m lengths Oo im Y P Coupling Assembly with Lock EP 100 Pump Package For more information refer to the EP 100 Installation Operation and Service Manual P N 127201NA EP 201 Pump Package For more information refer to the EP 200 Series Installation Operation and Service Manual P N 127200NA SECTION 6 MAJOR COMPONENTS cuu ua Turbulator must be installed in the last standard section of tube Turbulator is only required on the CTHN 40 60 and 80 For installation See Page 21 Step 8 8 Flex Gas Line with Shut Off Cock Tube and Reflector Hanger with Clamp Package Position this hanger no more than 4 10 cm away from the burner assembly Tube and Reflector Hanger Suspend system from these hangers Reflector Support Strap amp Wire Form Reflector End Cap Punch out center section to accommodate tube Restrictor Plate Used at fan assembly inlet for unitary heaters only See fan assembly below Fan Assembly EP 300 Series Pump Package For more information refer to the EP 300 Series Installation Operation and Service Manual P N 127202NA CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 7 GENERAL SUSPENSION DETAILS A WARNIN
16. 05220000 Maximum Number of Burners Allowed 1 1 1 1 1 1 per Fan Assembly P N 05221000 n i S i 1 Minimum Radiant Tube Length 10 3m 20 6m 20 6m 30 9m 40 12 m 40 12 m 50 15 m 50 15 m Minimum Distance from Burner to Elbow or U Tube 10 3m 10 3m 10 3m 15 4 5 m 15 4 5m 20 6m 20 6m 20 6m CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL 8 3 Unitary Linear Heater Layouts FIGURE 13 Linear Heater Assembly Overview sdil N e quiess C V UeJ sI polN 1919S UM J0je ngun egny ywoddns 10j29 jeH Buidno2 JeBuep 10128 jeH pue eqni eqn seuing oDexyoeg dwe qnl deo pug 1092H 14 SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION FIGURE 14 Unitary Linear Layout Overviews LEGEND g L j Burner 10 3 m Tube Length Reflector ENN Tube Em Tube Reflector Hanger Lm Coupling Assembly EN 20 6 m Tube Length b b d Fan Assembly d b c a 14 36 cm g reflector width not shown b 2 5 cm end cap to burner fan aa c 2 5cm end cap to hanger 30 9 m Tube Length d 7 6 229 cm distance first hanger e 10 305 cm distance between hangers f 9 5 24cm burner height g 17 5 44 cm Burner length ri 40 12 m Tube Length 50 15 m Tube Length
17. 0904 Cross 6 15 cm Aluminized 027508SH Reflector End Cap Stainless Steel with Hole 01335801 Elbow 4 10 cm Aluminized 90 02750900 Reflector Joint 10100320 Elbow 6 15 cm Aluminized 90 027509SS Reflector Joint Stainless Steel 0133580D Elbow 4 10 cm Coated 90 027127SS Reflector Side Extension Stainless Steel 01336101 Elbow 4 10 cm Aluminized 45 03090100 Tube and Reflector Hanger 0133610D Elbow 4 10 cm Coated 45 91907302 S hook 91409300 Tube 4 10 cm dia Hot Rolled Steel 10 3 m 91903201 Turnbuckle 91409403 Tube 4 10 cm dia Non Heat Treated Aluminized 91903300 _ Spring Hook 10 3 m 91903202 Turnbuckle with Eyebolt 91409408 Tube 4 10 cm dia Heat Treated Aluminized 10 3 m Thermostats 91409420 Tube 6 15 cm dia Non Heat Treated Aluminized 02770002 System Control 10 8 m 05023000 Load Relay Package 9141030D Tube 4 10 cm dia Coated 10 3 m 90417600 Transformer Relay SPST 12 A E0009105 Tube 6 15 cm dia 10 3 m 90436300 Transformer Relay DPST 12 A Heat Treated Aluminized 90423000 Thermostat 24 V Low Voltage Marked 1 5 91418200 Tube Adapter 6 15 cm dia x 4 10 cm dia 90424300 Thermostat Guard Aluminized 91240010 Tube Hanger 6 15 cm Deco Grille 1 x 8 3 m x 2 4 m 91308001 Pipe Compound High Temperature 11b can 01363003 Bracket 01365901 End Piece 27 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL
18. 1 1351 1 1 iJ 11 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Table 3 Component Package Guide Model Tubing Length Core Packages Minimum Standard Aluminized CTHN 40 10 3 m CP10ALUM CP10ALUM CTHN 60 20 6 m CP20HRS CP20ALUM CTHN 80 20 6 m CP20HRS CP20ALUM CTHN 100 30 9 m CP30HRS CP30ALUM CTHN 125 40 12 m CP40HRS CP40ALUM CTHN 150 40 12 m CP40HRS CP40ALUM CTHN 175 50 15 m CP30HRS EXP20HRS CP30ALUM EXP20ALUM CTHN 200 50 15 m CP30HRS EXP20HRS CP30ALUM EXP20ALUM Additional tubing length may be added to heater Any additional tubing lengths are considered as vent length for length determination Maximum venting length for unitary heater is 45 13 7 m For manifold tubing on multiburner systems heat treated aluminized or porcelain coated tubing is required Table 4 Common CTHN Series Components Part No Description Venting Accessories Tubing and Related Accessories 01324401 Air Supply Takeoff 4 10 cm Outside 01312700 Coupling 4 10cm Plan 90707501 Air Supply Blower Power Venter 01312706 Coupling 6 15 cm Plain 91409601 Air Flex Duct 4 10 cm Outside 01312701 Coupling 4 10 cm Lined Box of 8 8 2 4 m sections 01331900 Coupling 4 10 cm Damper E0009356 Coupling 6 15 cm Damper Reflectors and Related Accessories 0133022D Tee 4 10 cm Coat
19. ER HEATER INSTALLATION manifold tube length on the table for each burner in the system this is the maximum manifold tube length for the entire system To determine the maximum manifold tube allowed between the last tee or cross and the pump Subtract the manifold tube length between the radiant tube and the last tee or cross from the maximum manifold length for the entire system then divide that number by 1 5 Example Consider a T layout with two CTHN 100 burners See Page 33 Figure 21 Assume that 15 4 5 m of manifold was used from each radiant tube end to the last tee Page 30 Table 10 indicates that each CTHN 100 burner can have a maximum of 45 13 5 m of manifold tube Therefore the maximum manifold tube length amount allowed between the last tee and the pump in this case is 45 45 15 x 2 1 5 40 or in metric 13 5 m 13 5 m 4 5 m x 2 1 5 12 m a Last Tee Manifold tube between joining tee and pump Pe Pump 33 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 22 Fork Layout Multiple rows of burners Manifold tube between the last tee or cross and the pump is perpendicular to the manifold tube joining the rows Pump is not required to be placed in the center of the system as shown Manifold tube between radiant tube ends I M Damper Couplings located at the end of the rows l Radiant Tube 34 Pump Manifold tube between joining cross and pump
20. FOR YOUR SAFETY SW RG ROBERTS GORDON If you smell gas Open windows DO NOT try to light any appliance DO NOT use electrical switches DO NOT use any telephone in your building Leave the building Immediately call your local gas Follow the gas suppliers Negative Pressure Reunion ned o MN Unitary or Multiburner A WARNING Infrared Heater Installation Operation amp Service Manual CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 Fire Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property Installer A WARNING Please take the time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the owner 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 Owner Keep this manual in a safe place in order to provide your serviceman with necessary information Installation must be done by a contractor qualified in the installation and service of gas fired heating equipment or your gas supplier Roberts Gordo
21. G Suspension Hazard Burner is secured to burner tube by bolts and lockwashers Hang heater with materials with a minimum working load of 75 Ibs 33 kg Failure of the supports can result in death injury or property damage To ensure your safety and comply with the terms of the warranty all units must be installed in accordance with these instructions The gas or the electrical supply lines must not be used to support the heater Do not locate the gas or electric supply lines directly over the path of the flue products from the heater The heater must be installed in a location that is readily accessible for servicing The heaters must be installed in accordance with clearances to combustibles as indicated on the rating plate and in this instruction manual The minimum and maximum gas inlet pressures must be maintained as indicated on the rating plate Typical installation configurations are shown in Figure 12 FIGURE 12 Critical Hanger Placement Typical Suspension Details Beam Clamp Concrete Beam Wood Beam Pd Locknut Screw Hook 3 8 C Y Chain Size n 3 16 Washers 4 Minimum 4 O Turnbuckle Not Included Allows for thermal expansion of system Hanger Must Be Within 4 10 cm Front View 45 Angle Run Length 10 3 m 50 15 m 51 15 5 m
22. Rolled Steel 10 3 m 1 2 3J 1 2 3 4 91409408 Tube HT Aluminized 10 3 m 1 2 3 1 2 3 4 03051101 Burner Tube ALUMI THERM Steel 10 3 m 1 1 1 1 03051601 Burner Tube HT ALUMI THERM Steel 10 3 m 1 1 1 01312700 Coupling Assembly 1 2 3 1 2 3 1 2 3 4 1 2 3 4 02750303 Standard Reflector 8 2 4 m 3 4 6 2 3 4 6 2 3 4 6 2 3 4 6 02750800 End Cap 2 2 22 2 2 2 03090100 Tube and Reflector Hanger 3 4 5 2 3 4 5j 1 2 3 4 1 2 3 4 91907302 S hook 3 4 5 poe S3 4 5 1 2 3 41 1 2 3 4 03050010 Reflector Support Package 2 3 5 1 2 3 b 2 3 4 606 2 3 4 6 Strap Wire Form Screws 91107720 U clip Package 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 90502700 Vent Adapter Not used on CTHN 1 1 1 1 1 1 1 01318901 Tube Clamp Package 14114 4 1 1 1 1 26 Table 8 Component Package Guide SECTION 9 MULTIBURNER HEATER INSTALLATION Model Tubing Length Core Packages Minimum Standard Aluminized CTHN 40 20 6 m CP20HRS CP10ALUM CTHN 60 30 9 m CP30HRS CP20ALUM CTHN 80 30 9 m CP30HRS CP20ALUM CTHN 100 40 12 m CP40HRS CP30ALUM CTHN 125 50 15 m CP30HRS EXP20HRS CP40ALUM CTHN 150 50 15 m CP30HRS EXP20HRS CP40ALUM CTHN 175 60 18 m CP30HRS EXP30HRS CP30ALUM EXP30ALUM CTHN 200 60 18 m CP30HRS EXP30HRS CP30ALUM EXP30ALUM Addition
23. al tubing length may be added to heater Any additional tubing lengths are considered as manifold tube length for length determination See Page 29 Section 9 2 through Page 31 Section 9 6 design requirements and allowed manifold tube lengths For manifold tubing on multiburner systems heat treated aluminized or porcelain coated tubing is required Table 9 Common CTHN Series Components Venting Accessories 01324401 Air Supply Takeoff 4 10 cm Outside Part No Description 90707501 Air Supply Blower Power Venter Tubing and Related Accessories 91409601 Air Flex Duct 4 10 cm Outside 01312700 Coupling 4 10 cm Plain Box of 8 8 2 4 m sections 01312706 Coupling 6 15 cm Plain 01312701 Coupling 4 10 cm Lined Reflectors and Related Accessories 01331900 Coupling 4 10 cm Damper 01329910 Reflector Side Extension Support E0009356 Coupling 6 15 cm Damper 03050010 Reflector Support Package Tubing 0133022D Tee 4 10 cm Coated 02712700 Reflector Side Extension 2 Clips 2 Screws 01330203 Tee 4 10 cm Aluminized 02750303 Reflector Aluminum 01330204 Tee 6 15 cm Aluminized 027503SS Reflector Stainless Steel 0133092D Cross 4 10 cm Coated 02750800 Reflector End Cap Aluminum 01330903 Cross 4 10 cm Aluminized 027508SS Reflector End Cap Stainless Steel 0133
24. and Fuel Varies 1 1 1 1 1 1 1 1 07730400 Restrictor Plate 1 25 3 2 cm dia 1 i a z 07730100 Restrictor Plate 1 50 3 8 cm dia 1 07730500 Restrictor Plate 2 25 5 7 cm dia 1 1 07730600 Restrictor Plate 2 50 6 4 cm dia E 1 E 07730700 Restrictor Plate 2 75 7 cm dia 1 P B 03051503 Turbulator Adapter Di 1 1 03051504 Turbulator Section 2 4 4 R 03051505 Turbulator Section Stainless Steel 1 E 91412200 Flexible Stainless Steel Gas Hose 1 2 NPT 1 1 1 1 1 US Models Only 91412203 Flexible Stainless Steel Gas Hose 3 4 NPT 1 1 1 US Models Only 02568200 Gasket Burner to Burner Tube 1 1 1 1 1 1 1 1 94273914 Hex Head Cap Screw 5 16 18 x 7 8 4 4 4 4 4 4 4 4 96411600 Split Lock Washer 4 4 4 4 4 4 4 4 91201708 Pipe Nipple 1 2 NPT x 4 1 1 1 1 1 1 1 1 152101NA Installation Operation and Service Manual 1 1 1 1 1 1 1 1 Canadian Models Rubber Type 1 Gas Hoses available as an accessory See Page 69 Section 16 Table 7 Contents of Core and Extension Packages Core Packages Extension Packages Hot Rolled Aluminized Hot Rolled Aluminized Part No Description 20 30 40 10 20 30 40 10 20 30 40 10 20 30 40 6m 9m 12m 3m 6m 9m 12m 3m 6m 9m 12m 3m 6m 9m 12m 91409300 Tube Hot
25. ater Failure to follow these instructions can result in death injury or property damage required clearances from the heater to the combustibles Signs must be posted adjacent to the heater thermostat In the absence of a thermostat signs must be posted in a conspicuous location Consult local Fire Marshal Fire Insurance Carrier or other authorities for approval of proposed installation when there is a possibility of exposure to combustible airborne materials or vapors Hang heater in accordance to the minimum suspension requirements on Page 10 Figure 12 e f the radiant tubes must pass through the building structure be sure that adequate sleeving and fire stop is installed to prevent scorching and or fire hazard NOTE 1 All dimensions are from the surfaces of all tubes couplings and elbows 2 Clearances B C and D can be reduced by 50 after 25 7 5 m of tubing downstream from where the burner and burner tube connect FIGURE 1 STANDARD REFLECTOR Model CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 T CTHN 150 CTHN 175 CTHN 200 lt B D cb o ci O01 c cc oc inches centimeters B C D A B C D 20 41 20 13 51 104 51 27 51 27 13 69 130 69 30 58 30 13 76 147 76 32 60 32 13 81 152 81 35 65 35 13 89 165 89 39 71 39 13 99 180 99 44 74 44 20 112 188 112 47 76 47 20 119 193 119 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL NOTE 1 All dimensions are from the s
26. d for each burner is shown on Page 30 Table 10 9 5 Manifold Tube Any tube beyond the radiant tube length is considered manifold Manifold tube can be used to lengthen tube runs beyond the radiant tube length to connect multiple runs of tubing and connect the system to the pump Minimum and maximum manifold tube lengths are shown on Page 30 Table 10 The table must be used in conjunction with the additional rules for the diameter and length of manifold in a system as described on Page 31 Section 9 5 1 through Page 35 Section 9 6 3 9 5 1 Manifold Diameter 1 Manifold diameter for systems containing less than 320 000 Btu h input can be 4 10 cm or 6 15 cm 2 Manifold diameter for systems containing 320 000 Btu h input and greater must be 6 15 cm Exception If total manifold tube length is 70 21 m or less 4 10 cm diameter manifold tube can be used for systems up to 800 000 Btu h SECTION 9 MULTIBURNER HEATER INSTALLATION 9 6 Multiburner System Layouts and Manifold Tube Length Rules Most CTHN multiburner layouts can be classified as one of the following five layout types Flag Modified In Series T Fork or Herringbone Please refer to Page 31 Section 9 6 1 through Page 35 Section 9 6 3 for explanation of manifold rules and basic diagrams of each layout type The diagrams show very simple examples of each layout type Actual layouts will vary in total number of burners in the system as well as the ov
27. dINI 24 SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION Step 8 12 Restrictor Plate Installation Attach restrictor plate see chart below right to fan inlet and replace inlet collar Model Fan Assy P N Restrictor Plate P N CTHN 40 05220000 07730400 1 25 dia CTHN 60 05220000 07730100 1 50 dia CTHN 80 05220000 NONE CTHN 100 05220000 07730500 2 25 dia CTHN 125 05220000 07730500 2 25 dia CTHN 150 05220000 07730700 2 75 dia Description Part Number CTHN 175 05221000 07730600 2 50 dia Restrictor Plate 07730XXX CTHN 200 05221000 NONE Step 8 13 Fan Installation i Fold tab around outside of tube nearest to the vent to hold turbulator in place Remove warning tag from fan inlet and install restrictor plate if required See Step 8 12 Last Tube Turbulator not required for all models See Page 21 Step 8 8 for details Tighten securely until tube cannot be removed Vent Adapter Description Part Number Fan Assembly 40 150 05220000 Fan Assembly 175 200 05221000 25 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 9 MULTIBURNER HEATER INSTALLATION 9 1 Standard Parts Table 6 Contents of CTHN Burner Carton Part No Description CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 052XXXXxX Burner Rate
28. ector 5 U T be 45 in beenden ee crece rec Lee dex 5 U Tube Opposite 45 Reflector 5 2 Foot Deco Grille 1 Foot Deco Grille and Protective Grille uu 2 u anm an etes 6 Lower Clearance Shield 6 Venting ride oe et et 6 Major Component Descriptions 9 Critical Hanger Placement 10 Linear Heater Assembly Overview 14 Unitary Linear Layout Overviews 15 Unitary Linear Layout Overviews Continued 16 U tube Assembly Overview 17 Unitary U Tube Layout Overviews 18 Typical CTHN Multiburner System Installation 29 Flag Layout uu cL ere eet 32 Modified In Series Layout 32 T Layout sec pete mtt eee 33 Fork Layout n Re es 34 Herringbone Layout eene 35 Reflector Joint Detail a 43 Fan Termination eee 51 Tailpipe Connection Points 55 Roof Venting of Pump 56 Side Wall Venting Configurations 57 General System Control Wiring Multiburner 64 External Wiring Diagram EP 100 and EP 201 120 V 1 Pump Mu
29. ed 01329910 Reflector Side Extension Support 03050010 Reflector Support Package Tubing 01330203 Tee 4 10 cm Aluminized 01330204 Tee 6 15 cm Aluminized 02712700 Reflector Side Extension 2 Clips 2 Screws 0133092D Cross 4 10 cm Coated 02750303 Reflector Aluminum 01330903 Cross 4 10 cm Aluminized 027503SS Reflector Stainless Steel 01330904 Cross 6 15 cm Aluminized 02750800 Reflector End Cap Aluminum 01335801 Elbow 4 10 cm Aluminized 90 027508SS Reflector End Cap Stainless Steel T0100320 Elbow 6 15 cm Aluminized 90 027508SH Reflector End Cap Stainless Steel with Hole z FS FH 0133610D Elbow 4 10 cm Coated 45 027127SS Reflector Side Extension Stainless Steel 91409300 Tube 4 10 cm dia Hot Rolled Steel 10 3 m 03090100 Tube and Reflector Hanger 0133580D Elbow 4 10 cm Coated 90 02750900 Reflector Joint 1 1 91409403 Tube 4 10 cm dia Non Heat Treated Aluminized 91907302 S hook 10 3m 91903201 Turnbuckle 91409408 Tube 4 10 cm dia Heat Treated Aluminized 91903300 Spring Hook 10 3m 91903202 Turnbuckle with Eyebolt 91409420 Tube 6 15 cm dia Non Heat Treated Aluminized SS me 10 3m Control Packages and Thermostats 9141030D Tube 4 10 cm dia Coated 10 3 m 02770002 S
30. eflector except for a u tube Manifold tube may or may not be covered Reflector 22 SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION Step 8 9 1 Reflector U clip and Reflector Support Installation The pictorial drawings of the heater construction in Section 8 are schematic only and provide a general guideline of where hangers reflector supports and u clips are to be installed To ensure proper expansion and contraction movement of the reflectors a combination of u clips and reflector supports are used The positioning of 1 The first reflector after the burner must be affixed in the middle of the reflector with a reflector support and tight screws Reflector Overlap must be a minimum of 6 16 cm 2 The overlap at the first and second reflector is a slip overlap Thereafter every third reflector joint is a slip overlap A slip overlap is achieved by either a both reflectors lay inside a hanger No reflector support needed b using a reflector support with loose screws at the reflector overlap 3 The remaining reflector overlaps require a non slip overlap connection To affix the reflectors together in a non slip overlap either a use reflector support and tight screws b if both reflectors lay inside a hanger u clips or sheet metal screws may be used This section of three reflectors joined together must be affixed to the tube with at least one reflector support wit
31. erall shape of the system Additional pieces such as elbows may change the overall layout appearance but are usually considered a variant of one of the five multiburner layout types 9 6 1 Flag and Modified In Series Layouts and Manifold Tube Length Rules See Page 32 Figure 19 through Page 32 Figure 20 for diagrams of Flag and Modified In Series layouts Minimum and maximum manifold tube length applies to all tubing between the end of a radiant tube run and a tee or cross all tubing between any tees and or crosses and all tubing between the last tee or cross and the pump See Page 30 Table 10 Example Consider a Flag or Modified In Series layout with five CTHN 100 burners Page 30 Table 10 shows a minimum of 6 2 m and a maximum of 45 13 5 m of manifold tube required per burner Therefore the entire five burner system must have between 30 10 m and 225 69 m of manifold tubing The manifold tubing is in addition to the 40 12 m of radiant tube per burner Radiant tube may end at a tee or runs may be lengthened by adding some manifold tube between the end of the radiant tube and a tee Each burner in the system except for the burner furthest from the pump must use a damper coupling to properly adjust the vacuum at each burner The damper coupling may be placed anywhere between the end of the radiant pipe and the tee 31 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 19 Flag Layout FIGURE 20 Modif
32. from where the burner and burner tube connect FIGURE 8 2 FOOT DECO GRILLE 1 FOOT DECO GRILLE AND PROTECTIVE GRILLE inches centimeters A Model A B C D A B C D CTHN 40 5 20 41 20 13 51 104 5 CTHN 60 5 27 51 27 13 69 130 69 r CTHN 80 5 30 58 30 13 76 147 76 c CTHN 100 5 32 60 32 13 81 152 81 n Dot CTHN 125 5 35 6 35 13 89 165 89 CTHN 150 5 39 71 39 13 99 180 99 CTHN 175 8 44 74 44 20 112 188 112 CTHN 200 8 47 76 47 20 119 193 119 FIGURE 9 LOWER CLEARANCE SHIELD inches centimeters A Model A B C D A B C D CTHN 40 5 25 22 25 13 64 56 64 CTHN 60 5 30 27 30 13 76 69 76 CTHN 80 5 37 37 37 13 94 94 94 CTHN 100 5 39 39 39 13 99 99 99 CTHN 125 5 41 41 41 13 104 104 104 CTHN 150 5 43 50 43 13 109 127 109 CTHN 175 UNAPPROVED UNAPPROVED CTHN 200 UNAPPROVED UNAPPROVED When installed in the first 10 3 m FIGURE 10 VENTING inches centimeters Model A E F A E F E gt CTHN 40 14 18 18 36 46 46 ud vem CTHN 60 14 18 18 36 46 46 Pipes CTHN 80 20 24 18 51 61 46 Radiant Tubes CTHN 100 20 24 18 51 61 46 y CTHN 125 20 24 18 51 61 46 Vented E CTHN 150 20 30 18 51 76 46 7 CTHN 175 20 30 18 51 76 46 CTHN 200 20 30 18 51 76 46 SECTION 4 NATIONAL STANDARDS AND APPLICABLE CODES 4 1 Gas Codes SECTION 4 NATIONAL STANDARDS AND APPLICABLE
33. fter 25 7 5 m of tubing downstream from where the burner and burner tube connect FIGURE 5 U TUBE STANDARD REFLECTOR inches centimeters Model A B C D A B C D CTHN 40 UNAPPROVED UNAPPROVED CTHN 60 5 27 56 19 13 69 142 48 CTHN 80 5 30 61 20 13 76 155 51 CTHN 100 5 32 63 20 13 81 160 51 CTHN 125 5 35 66 20 13 89 168 51 CTHN 150 5 39 73 21 13 99 185 53 CTHN 175 8 44 75 26 20 112 191 66 CTHN 200 8 47 76 30 20 119 193 76 FIGURE 6 U TUBE 45 inches centimeters Model A B C D A B C D CTHN 40 UNAPPROVED UNAPPROVED CTHN 60 8 4 47 40 20 10 119 102 CTHN 80 8 4 54 46 20 10 137 117 CTHN 100 8 4 57 48 20 10 145 122 CTHN 125 8 4 63 53 20 10 160 135 CTHN 150 8 4 66 56 20 10 168 142 CTHN 175 8 4 69 59 20 10 175 150 CTHN 200 8 4 73 63 20 10 185 160 FIGURE 7 U TUBE OPPOSITE 45 REFLECTOR inches centimeters Model A B C D A B C D CTHN 40 UNAPPROVED UNAPPROVED I CTHN 60 8 45 45 10 20 114 114 25 CTHN 80 9 55 54 10 23 140 197 25 a at CTHN 100 10 56 57 10 25 142 145 25 CTHN 125 10 58 63 10 25 147 160 25 Y CTHN 150 10 61 66 20 25 155 168 51 CTHN 175 10 68 69 20 25 173 175 51 CTHN 200 10 71 73 20 25 180 185 51 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL NOTE 1 All dimensions are from the surfaces of all tubes couplings and elbows 2 Clearances B C and D can be reduced by 50 after 25 7 5 m of tubing downstream
34. g Slide Bar Coupling Lock us Wide End lt S Coupling 3 8 cm to bs _ 4 10 cm Ww D Tighten coupling to join tubes Slide Bar Coupling Lock Orient coupling so that gt Coupling the impact block is in the T 2 00 or 10 00 o clock positions Description Part Number Coupling 01329600 Slide Bar Coupling Lock 01329700 Tube 91409XXX Step 9 9 1 Coupling and Tube Assembly Continued Tighten slide bar as shown below Drive slide bar until tight End of slide bar should be within tolerance listed below Bs Correct Slide Bar Dimensions Position Repeat Step 9 9 on Page 37 A D until all tubes are assembled See Page 38 Step 9 9 2 NOTE If coupling is not tight loss of vacuum can occur CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 9 9 2 Coupling and Tube Assembly Continued Radiant Model Tube Length CTHN 40 10 4 5 m CTHN 60 20 6 m CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 7 6 1 i 2 3m 25m Total Overall Tube Length Step 9 10 Turbulator Installation Turbulator must be installed in the last standard section of radiant tube Turbulator is only required on the CTHN 40 CTHN 60 and CTHN 80 B ee Secti Turbulator Installation ection Model Tube Section d CTHN 40 1st 10 3 m Section CTHN 60 2nd 10 3 m Section
35. h tight screws Part Number 03050010 91908004 03050000 94320812 91107720 027508XX Description Reflector Support Package Wire Form Reflector Support Strap Screw 8 x 3 4 U clip Package Reflector End Cap reflector supports and u clips depend on the individual installation Use either pop rivets or sheet metal screws instead of u clips when installing end caps and joint pieces in areas where impact and high wind may be a factor The following rules must be observed Tight Sheet Metal Screw Reflector Support Strap 2B Slip Overlap Reflector J Reflector Loose screws loosened 1 16 16 cm to allow slippage Reflector Tight Screws U clip 2 Clips per Non slip Overlap Inside a Hanger CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 10 Burner Installation LEX Gasket KKR SELES Burner Tube Burner must be installed with the flame observation Lock window facing down Washer Torque 120 in Description Part Number 13 56 Nm Bolt 94273914 Burner 052XXXXX Lock Washer 96411600 Gasket 02568200 Step 8 11 Fan Inlet Plate and Warning Tag Remove the warning tag and inlet collar from fan inlet q4 eut o1 Ue Duiqui8s 910J8q ere d 10jou1s81 eui amp e1sui pue He siu snowy LLNV LtIOdINI 910J8q erejd 10jou1seJ OU egni eui oi UR Buijquiesse esu pue Bei siu e oueH iLNVLYO
36. he sum of their inputs a EP 100 up to 500 000 Btu h max but not more than 4 burners Table 11 Number of Burners Allowed Per Pump Pump Model Altitude CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 b EP 200 up to 750 000 Btu h max but not more than 6 burners c EP 300 up to 1 600 000 Btu h max number of burners is limited to the maximum number of burners listed in Table 11 for the largest input model used 0 2 000 4 4 4 4 4 3 2 2 2 001 3 000 4 4 4 4 3 3 2 2 3 001 4 000 4 4 4 4 3 2 2 2 EDAD 4 001 5 000 4 4 4 4 3 2 2 2 5 001 6 000 4 4 4 4 3 2 2 2 6 001 7 000 4 4 4 3 3 2 2 2 7 001 8 000 4 4 4 3 3 2 2 1 8 001 9 000 4 4 4 3 2 2 2 1 0 2 000 6 6 6 6 6 5 4 4 2 001 3 000 6 6 6 6 6 5 4 3 3 001 4 000 6 6 6 6 5 4 4 3 EP 200 Serles 4 001 5 000 6 6 6 6 5 4 4 3 5 001 6 000 6 6 6 6 5 4 3 3 6 001 7 000 6 6 6 6 5 4 3 3 7 001 8 000 6 6 6 6 5 4 3 3 8 001 9 000 6 6 6 6 5 4 3 3 0 2 000 16 16 14 12 12 10 8 8 2 001 3 000 16 16 14 12 12 9 8 7 3 001 4 000 16 16 14 12 11 9 8 7 EP 300 Series 4 001 5 000 16 16 14 12 10 9 7 6 5 001 6 000 16 16 14 12 10 8 7 6 6 001 7 000 16 16 14 12 10 8 7 6 7 001 8 000 16 16 14 12 10 8 6 6 8 001 9 000 16 16 14 12 10 8 6 6 30 9 4 Radiant Tube Length The radiant tube length fixe
37. ied In Series Layout Multiple rows of burners Multiple burners pump placed at the end of the manifold tube pump placed at the end of the manifold tube A variation on the flag layout Burner furthest from pump does not need a damper coupling c First Tee Manifold tube between radiant tube ends FO Last Tee Last Tee Burner S Manifold tube between joining tee and pump 32 9 6 2 T and Fork Layouts and Manifold Tube Length Rules See Page 33 Figure 21 through Page 34 Figure 22 for diagrams of T and Fork layouts The T and Fork layouts have a tee or cross called the last tee or last cross where the combustion gases in the system enter the tee or cross with directly opposing flow directions which creates an added source of pressure drop in the system This additional source of pressure drop requires some difference in how the allowed manifold length is calculated In this case we have to differentiate manifold tube that is located between the radiant pipe and the last tee or cross from manifold tube that is located between the last tee or cross and the pump First determine the length of manifold tube between the radiant tube end and the last tee or cross Do not count any tube length twice Now refer to Page 30 Table 10 and find the maximum manifold tube length for each burner Add together the maximum FIGURE 21 T Layout One pair of burners B a SECTION 9 MULTIBURN
38. ility to suspended heaters for recurrent maintenance purposes Installation in garages must be in accordance with the following codes United States Standard for Parking Structures NFPA 88A latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 30A latest revision Canada Refer to CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances Heaters must not be installed less than 8 2 4 m above the floor Minimum clearances to combustibles must be maintained from vehicles parked below the heater When installed over hoists minimum clearances to combustibles must be maintained from the upper most point of objects on the hoist 4 4 Electrical The heater must be electrically grounded in accordance with the following codes United States Refer to National Electrical Code ANSI NFPA 70 latest revision Wiring must conform to the most current National Electrical Code local ordinances and any special diagrams furnished Canada Refer to Canadian Electrical Code CSA C22 1 Part 1 latest revision 4 5 Venting The venting must be installed in accordance with the requirements within this manual and the following codes United States Refer to NFPA 54 ANSI 2223 1 latest revision National Fuel Gas Code Canada Refer to CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances 4 6 High Altitude The
39. ious venting components have sharp edges To prevent injury the use of work gloves is recommended The use of gloves will also prevent the transfer of body oils from the hands to the surface of the reflector Before installation check that the local distribution conditions nature of gas and pressure and adjustment of the appliance are compatible 1 1 Manpower Requirements To prevent personal injury and damage to the heater two persons will be required for installation SECTION 1 HEATER SAFETY CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 2 INSTALLER RESPONSIBILITY The installer is responsible for the following and configuration in the open spaces on the tag To install the heater as well as the gas and electrical supplies in accordance with applicable ee i hemical specifications and codes Roberts Gordon 2 2 Vartosive Gnemicals recommends the installer contact a local Building Inspector or Fire Marshal for guidance CAUTION To use the information given in a layout drawing Do not use heater in an area containing corrosive and in the manual together with the cited codes chemicals and regulations to perform the installation Avoid the use of corrosive chemicals to ensure a To install the heater in accordance with the longer life of the burner tubing and other parts clearances to combustibles requirements To furnish all needed materials not furnished as standard equipment
40. ltiburner 65 External Wiring Diagram EP 301 230 V 1 Pump Multiburner 65 External Wiring Diagram EP 203 or EP 303 3 Pump Multiburner 66 One Zone Operation without Control Panel Multiburner 67 Two Zone Operation without Control Panel Multib r er eese 68 Gas Connection with Flexible Gas Hose 69 Vacuum Differential Reading 72 SECTION 1 HEATER SAFETY Your Safety is Important to Us This symbol is used throughout the manual to notify you of possible fire electrical or burn hazards Please pay special attention when reading and following the warnings in these sections Installation service and annual inspection of heater must be done by a contractor qualified in the installation and service of gas fired heating equipment Read this manual carefully before installation operation or service of this equipment This heater is designed for heating nonresidential indoor spaces Do not install in residential spaces These instructions the layout drawing local codes and ordinances and applicable standards that apply to gas piping electrical wiring venting etc must be thoroughly understood before proceeding with the installation Thin sheet metal parts including the aluminum reflector and the var
41. middle of the reflector with a reflector support and tight screws Reflector Overlap must be a minimum of 6 16 cm 2 The overlap at the first and second reflector is a slip overlap Thereafter every third reflector joint is a slip overlap A slip overlap is achieved by either a both reflectors lay inside a hanger No reflector support needed b using a reflector support with loose screws at the reflector overlap 3 The remaining reflector overlaps require a non slip overlap connection To affix the reflectors together in a non slip overlap either a use reflector support and tight screws b if both reflectors lay inside a hanger u clips or sheet metal screws may be used This section of three reflectors joined together must be affixed to the tube with at least one reflector support with tight screws Part Number 03050010 91908004 03050000 94320812 91107720 027508XX Description Reflector Support Package Wire Form Reflector Support Strap Screw 8 x 3 4 U clip Package Reflector End Cap reflector supports and u clips depend on the individual installation Use either pop rivets or sheet metal screws instead of u clips when installing end caps and joint pieces in areas where impact and high wind may be a factor The following rules must be observed Tight Sheet Metal Screw Reflector Support Strap 2B Slip Overlap Reflector Reflector Loose scre
42. mp Accessories 08050001 Grille 40 102 cm Protective 90430600K Pressure Switch 08050002 X PProtective Grille End Cap Starters and Contactors 8 2 Unitary Heater Requirements CTHN unitary heaters are typically shipped as a burner package fan assembly and a tube and accessory package The tube and accessory packages contain enough tube reflector and hanging parts for one unitary CTHN heater Elbows u tubes controls and any other parts must be purchased separately Table 5 Unitary Heater Design Requirements Burner Model Fan and Pump Packages 10050001 Starter 120 Vac for EP 203 3 05220000 Fan Package 40 150 10050003 Starter 120 Vac for EP 201 1 05221000 Fan Package 175 200 10050008 Starter 120 Vac for EP 301 1 02719105 EP 100 Pump Package 10050009 Contactor Package 02719100 EP 100 Pump 120 Vac Coil for EP 301 230 V 2 HP 02724700 Accessory Package 10050010 Starter 120 Vac for EP 303 3 02716305 EP 201 Pump Package 01312001 EP 201 Pump 01317805 Accessory Package 02712034 EP 203 Pump Package 01312002 EP 203 Pump See Page 14 Figure 13 for a general overview of a CTHN unitary heater CTHN unitary heaters are controlled by thermostat Table 5 summarizes the design requirements for a CTHN unitary heater CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 Maximum Number of Burners Allowed per Fan Assembly P N
43. n LLC 1250 William Street P O Box 44 Buffalo New York 14240 0044 Telephone 716 852 4400 Fax 716 852 0854 Toll Free 800 828 7450 Quality in Any Language www rg inc com Copyright 2006 Roberts Gordon LLC P N 152101NA Rev A 10 06 TABLE OF CONTENTS SECTION 1 Heater Safety 1 1 1 Manpower Requirements 1 SECTION 2 Installer Responsibility 2 2 1 Wall Jag crei crate he 2 2 2 Corrosive Chemicals see 2 2 3 National Standards and Applicable Codes 2 SECTION 3 Critical Considerations 3 3 1 Required Clearances to Combustibles 3 SECTION 4 National Standards and Applicable Codes 7 4 1 Gas Codes sii ead is allan 4 2 Aircraft Hangars esee 4 3 Public Garages epe reete 4 4 El treal za 4 5 Venting a unn uQ Sua es a u ae 4 6 High Altitude rettet ees SECTION 5 Heater Descriptions 5 1 Unitary vs Multiburner u SECTION 6 Major Components SECTION 7 General Suspension Details SECTION 8 Unitary Linear amp U Tube Heater Installation 11 8 1 Standard Parts eese rettet vus 11 8 2 Unitary Heater Requireme
44. nce 83 kg of these compounds is suspected Warranty will be invalid if the heater is exposed to halogenated hydrocarbons 2 1 Wall Tag A laminated wall tag is available for the heater as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles Please contact Roberts Gordon or your ROBERTS GORDON independent distributor to obtain the wall tag Affix the tag by peeling off the backing of the adhesive strips on the rear surface and position the tag on a wall near the heater e g thermostat or ROBERTS GORDON Controller A copy of the wall tag P N 91037912 is illustrated on the back cover For an immediate solution you may affix this copy on the wall near the heater 2 3 National Standards and Applicable Codes All appliances must be installed in accordance with the latest revision of the applicable standards and national codes This refers also to the electric gas and venting installation Note Additional standards for installations in public garages aircraft hangars etc may be applicable Know your model number and installed configuration Model number and installed configuration are found on the burner and in the Installation Operation and Service Manual See Page 3 Figure 1 through Page 6 Figure 10 Write the proper clearance dimensions in permanent ink according to your model number 2 SECTION 3 CRITICAL CONSIDERATIONS 3 1 Required Clearances to Combustibles
45. nts 13 8 3 Unitary Linear Heater Layouts 14 8 4 Unitary U tube Heater Layouts 17 8 5 Burner Tube Installation 19 8 6 Tube Clamp Package Installation 19 8 7 Coupling and Tube Assembly 20 8 8 Turbulator Installation 21 8 9 Reflector Installation 22 8 10 Burner Installation 24 8 11 Fan Inlet Plate and Warning Tag 24 8 12 Restrictor Plate Installation 25 8 13 Fan Installation 25 SECTION 9 Multiburner Heater Installation 26 9 1 Standard Parts sess 26 9 2 Multiburner System Design Requirements 29 9 3 Burners Per Pump 30 9 4 Radiant Tube Lenglth a 31 9 5 Manifold Tube 31 9 6 Multiburner System Layouts and Manifold Tube Length Rules uite iem Perte RARE RR 31 9 7 Burner Tube Installation 36 9 8 Tube Clamp Package Installation
46. nuts on top and bottom to allow for tube expansion and contraction i U tube 18 457 mm Center to Center U bolt Nut Lock Washer Lock Washer Nut 17 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 17 Unitary U tube Layout Overviews LEGEND Burner 20 6 m Tube Length J Reflector Tube Tube Reflector Hanger Coupling Assembly 30 9 m Tube Length U tube Fan Assembly not shown a 14 36 cm reflector width not shown 40 12 m Tube Length end cap to burner c 2 5 cm end cap to hanger d 7 6 229 cm distance first hanger e 10 305 cm distance between hangers 50 15 rn Tube Length f 5 153 cm distance between last full tube hanger and half tube hanger g 17 5 44 cm burner length h 9 5 24 cm burner height 20 6 m amp 50 15 m tube length i heaters require the last reflector 50 U8 m before the u tube to be cut in upe Lengt half for use on both sides 70 21 m Tube Length 80 24 m Tube Length 18 SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION Step 8 5 Burner Tube Installation NOTE Tubing requires a downward slope of 1 2 1 3 cm per20 6m away 7 from burner Offset mounting hole must be to the top Burner Tube Weld seam must be to the bottom of the tube 76 1 J i 229 cm 25cm Description Pa
47. rized Outside Air Supply 60 SECTION 15 Wiring IU 61 15 1 Internal Wiring 61 15 2 Internal Wiring sen 61 15 3 Ladder Diagram sene 62 15 4 External Wiring Unitary Heaters Only 62 15 5 Line Voltage Thermostat Wiring Unitary Heaters Only 63 15 6 Low Voltage Thermostat Wiring Unitary Heaters Only 63 15 7 System Control Methods and External Multiburner WIRING onset iieri ukasa Tumasa SERERE DONE ca SECTION 16 Gas Piping eere SECTION 17 Operation and Maintenance 171 Checking the Gas Line 172 Unitary Heater Sequence of Operation 70 17 3 Multiburner System Operation 70 174 MaiIrltenance u u l U Ska Sa assasi 73 17 5 Maintenance Checklist 74 SECTION 18 Troubleshooting eese 76 18 1 Troubleshooting Flow Chart Unitary 76 18 2 Troubleshooting Flow Chart Multiburner 78 18 3 Manifold Gas Pressure Setting 80 SECTION 19 Replacement Parts List 81 SECTION 20 General Specifications 83 20 1 Material
48. rt Number Burner Tube 03051 XXX S hook 91907302 Tube Reflector Hanger 03090100 Step 8 6 Tube Clamp Package Installation Description Part Number Tube Clamp Package 01318901 Tube Clamp 01396801 Bolt 97113940 Flat Washer 95211600 Nut 92113900 t Torque 120 in Ib 13 56 Nm CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 7 Coupling and Tube Assembly A Close coupling B Start slide bar coupling lock with tab onto coupling an Slide Bar Coupling Lock _ Z Wide End Pa Coupling 3 8 cm to d Ou 4 10 cm Sy Side Bar Coupling Lock Orient coupling so that Eos T Coupling the impact block is in the he gt N 2 00 or 10 00 o clock positions i I P Tube t Description Part Number Coupling 01329600 Slide Bar Coupling Lock 01329700 Tube 91409XXX Step 8 7 1 Coupling and Tube Assembly Continued Tighten slide bar as shown below Drive slide bar until tight End of slide bar should be within tolerance listed below 2 5 cm lt Correct Slide Bar La Dimensions lt Incorrect Slide Bar d l Position Repeat Step 8 7 A D until all tubes are assembled See Page 21 Step 8 72 NOTE If coupling is not tight loss of vacuum can occur SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION Step 8 7 2 Coupling and Tube Assembly Continued
49. se heaters are approved for installations up to 2000 610 m US 4500 1370 m Canada without modification Consult factory if US installation is above 2000 610 m or Canadian installation is above 4500 1370 m CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 5 HEATER DESCRIPTIONS 5 1 Unitary vs Multiburner CTHN Series burners may be used for unitary heaters or for multiburner systems Unitary heaters consist of a single burner a single run of radiant tubing and a single fan assembly See Page 14 Figure 13 or See Page 17 Figure 16 for details Multiburner systems consist of more than one burner and more than one run of radiant tubing The runs of radiant tubing are connected together by manifold tubing The manifold tubing connects to a single pump that exhausts the flue gases outdoors See Page 32 Figure 19 through Page 35 Figure 23 for common multiburner system layouts Since this manual addresses installation of both unitary heaters and multiburner systems pay close attention to section and figure titles to verify relevance to unitary heaters or multiburner systems SECTION 6 MAJOR COMPONENTS FIGURE 11 Major Component Descriptions Burner with Tube Gasket Must be installed with the flame observation window facing down Turbulator Reflector Aluminum or Stainless Steel Alternate overlap as shown on Page 15 Figure 14 or on Page 18 Figure 17 A Minimum overlap is 6 16
50. stem requirements CTHN multiburner systems may be controlled by either a ROBERTS GORDON System Control shown or by a relay system FIGURE 18 Typical CTHN Multiburner System Installation Zone 1 Thermostat Turbulator if required Optional Reflector Exhaust to Outside Radiant Tube Manifold Tube Burners Drawing Not to Scale Zone 2 Thermostat CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Table 10 Multiburner Design Requirements Burner Model CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 Radiant Tube Length 20 6m 30 9m 30 9m 40 12m 50 15m 50 15m 60 18m 60 18m Minimum Manifold Tube Length per Burner 3 1 m 3 1m 3 1m 6 2m 6 2m 10 3 m 10 3 m 10 3 m Soa Manifold Tubs Length per 30 9 m 35 10 5 m 40 12 m 45 13 5 m 50 15 m 55 16 5 m 60 18m 60 18m hist Distance from Burner to Elbow 40 3 mm 10 3m 10 3m 15 4 5m 18 45m 20 6m 20 6m 20 6m Elbows Allowed per Burner 2 2 2 2 2 2 2 2 U tube 2 elbows 9 3 Burners Per Pump 1 The maximum number of burners per pump is shown in Table 11 2 When combining different burner inputs in a system the number of burners per pump 0 2 000 altitude is given by t
51. the connecting tees crosses and 350 105m remains Since the remaining manifold is located either between or after connecting tees or crosses the manifold length must be divided by 1 5 350 105m 1 5 233 70m Therfore up to 233 70m can be used between the branches and also between the last cross and the pump Multiple opposing rows of burners pump placed at the end of the manifold tube or somewhere between the burners Tee T Manifold tube between radiant tube ends Last Cross 7 Manifold tube between joining tee and pump Tee CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 9 7 Burner Tube Installation Burner Tube Description Burner Tube 76 x1 NOTE Tubing requires a downward slope of 1 2 1 3 cm per20 6m away 7 from burner Offset mounting hole must be to the top Weld seam must be to the bottom of the tube 229 cm x 25 cm Part Number 03051XXX S Hook 91907302 Tube Reflector Hanger 03090100 Step 9 8 Tube Clamp Package Installation Description Part Number Tube Clamp Package 01318901 Tube Clamp 01396801 Bolt 97113940 Flat Washer Nut 95211600 92113900 Washer t Torque 120 in Ib 13 56 Nm SECTION 9 MULTIBURNER HEATER INSTALLATION Step 9 9 Coupling and Tube Assembly A Close coupling B Start slide bar coupling lock with tab onto couplin
52. urfaces of all tubes couplings and elbows 2 Clearances B C and D can be reduced by 50 after 25 75 m of tubing downstream from where the burner and burner tube connect FIGURE 2 ONE SIDE REFLECTOR inches centimeters n Model A B C D A B C D A CTHN 40 5 6 46 35 13 15 117 88 CTHN 60 5 6 55 44 13 15 140 110 CTHN 80 5 6 64 49 13 15 163 123 C CTHN 100 5 6 66 51 13 15 168 128 l CTHN 125 5 6 69 58 13 15 175 145 CTHN 150 5 6 75 60 13 15 191 150 CTHN 175 8 6 77 68 20 15 196 170 CTHN 200 8 6 79 70 20 15 201 175 FIGURE 3 TWO SIDE REFLECTORS inches centimeters Model A B C D A B C D li CTHN 40 5 16 47 16 13 41 119 41 CTHN 60 5 18 56 18 13 46 142 46 CTHN 80 5 21 65 21 13 53 165 53 CTHN 100 5 23 68 23 13 58 173 58 i CTHN 125 5 26 73 26 13 66 185 66 T CTHN 150 5 30 76 30 13 76 193 76 CTHN 175 8 32 88 32 20 81 224 81 CTHN 200 8 33 90 33 20 84 229 84 FIGURE 4 45 TILT REFLECTOR inches centimeters Model A B C D A B C D n CTHN 40 8 4 35 43 20 10 89 109 CTHN 60 8 4 45 45 20 10 114 114 CTHN 80 9 4 54 55 23 10 137 140 CTHN 100 10 4 57 56 25 10 145 142 CTHN 125 10 4 63 58 25 10 160 147 Y CTHN 150 10 4 66 61 25 10 168 155 CTHN 175 10 4 69 68 25 10 175 173 CTHN 200 10 4 73 71 25 10 185 180 SECTION 3 CRITICAL CONSIDERATIONS NOTE 1 All dimensions are from the surfaces of all tubes couplings and elbows 2 Clearances B C and D can be reduced by 50 a
53. ws loosened 1 16 16 cm to allow n slippage 2A Tight Screws U clip 2 Clips per Non slip Overlap Inside a Hanger Step 9 12 Burner Installation Burner must be installed with the flame observation window facing down Description Part Number Bolt 94273914 Burner 052XXXXX Lock Washer 96411600 Gasket 02568200 Lock Washer Gasket Bolt lt Torque 120 in lb 13 56 Nm SECTION 9 MULTIBURNER HEATER INSTALLATION Burner Tube 41 CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 10 OPTIONAL HEATER ACCESSORIES 10 1 Elbow Package Configuration Step 10 1 1 Elbow Installation Z Coupling Minimum Distance Required Between iS gt Burner and Elbow 9 Minimum _ Model Distance CTHN 40 10 3 m Description Part Number 90 Elbow CTHN 60 10 3 m Elbow Package 02718702 CTHN 80 10 3 m 90 Elbow 01335801 CTHN 100 15 4 5 m Coupling 01312700 CTHN 125 15 4 5 m Reflector End Cap 02750800 CTHN 150 20 6 m Reflector Joint Piece 02750900 CTHN 175 20 6 m U Clip Package 91107720 CTHN 200 20 6 m Step 10 1 2 Elbow Installation Coupling Reflector Scribe Contour Maximum 42
54. ystem Control E0009105 Tube 6 15 cm dia 10 3 m 05023000 Load Relay Package Heat Treated Aluminized 90417600 Transformer Relay SPST 12 A 91418200 Tube Adapter 6 15 cm dia x 4 10 cm dia 90436300 Transformer Relay DPST 12 A Aluminized 90423000 Thermostat 24 V Low Voltage Marked 1 5 91240010 Tube Hanger 6 15 cm 90424300 Thermostat Guard 91308001 Pipe Compound High Temperature 11b can 12 SECTION 8 UNITARY LINEAR amp U TUBE HEATER INSTALLATION Deco Grille 1 x 8 3 m x 2 4 m 01317805 Accessory Package 01363003 Bracket 02723014 EP 301 Pump Package 4 10 cm 01365901 End Piece 02730101 EP 301 Pump Assembly 01326801 Reinforcement 02730104 Accessory Package 01365903 Joint Piece 02723016 EP 301 Pump Package 6 15 cm 91406700 1 x8 3 m x 2 4 m Protective Grille 02730101 EP 301 Pump Assembly 02730106 Accessory Package Deco Grille 2 x 4 6 m x 1 2 m 02723034 EP 303 Pump Package 4 10 cm 01365900 Shield Frame 02730103 EP 303 Pump Assembly 01370408 Reflector Side Extension 8 x 48 20 cm x 122 cm 02730104 Accessory Package 01370412 Reflector Side Extension 12 x 48 30 cm x 122 cm 02723036 EP 303 Pump Package 6 15 cm 01370416 Reflector Side Extension 16 x 48 40 cm 122 cm 02730103 EP 303 Pump Assembly 91407000 jGrille Aluminum 2 x 4 6 m x 1 2 m 02730106 Accessory Package Protective Grille Pu
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