Roberts Gorden CRT-10, CRT-15, CRT-30, CRT-20, CRT-25 Installation, Operation & Service Manual
WARNING
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Leave the building.
6. Immediately call your local gas
supplier after leaving the building.
Follow the gas suppliers
instructions.
7. If you cannot reach your gas
supplier, call the Fire Department.
Fire Hazard
Do not store or use petrol or other
flammable vapours 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
damage.
Roberts-Gordon
Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: +44(0) 1902 494425
Fax: +44(0) 1902 403200
Service Telephone: +44(0) 1902 498733
Service Fax: +44(0) 1902 401464
E-mail: uksales@rg-inc.com
E-mail: export@rg-inc.com
www.rg-inc.com
WARNING
Installation must be done by a registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment 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 owner.
Owner
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
© Copyright 2004 Roberts-Gordon
Quality in Any Language™
CoRayVac
®
Custom-Engineered,
Low-Intensity Infrared
Heating Systems
Installation, Operation &
Service Manual
CRT-10
CRT-15
CRT-20
CRT-25
CRT-30
128100UK Rev. B 09/04
© 2004
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.
Printed in U.K.
TABLE OF CONTENTS
SECTION 1: Heater Safety ............................................2
1.1 Manpower Requirements ...................................2
SECTION 2: Installer Responsibility ...........................2
2.1 Low Level User Instructions................................2
2.2 Corrosive Chemicals...........................................3
2.3 National Standards and Applicable Codes .........3
SECTION 3: Critical Considerations............................4
3.1 Required Clearances to Combustibles ...............4
3.2 Clearance Data...................................................5
SECTION 4: Major Components ..................................7
4.1 Standard Parts List .............................................9
SECTION 5: Heater Installation..................................10
5.1 Tube Installation ...............................................12
5.2 Coupling and Tube Assembly...........................12
5.3 Reflector Installation .........................................13
5.4 Burner Installation.............................................16
SECTION 6: Optional Heater Accessories ................17
6.1 Elbow Configuration .........................................17
6.2 Reflector Side Extension ..................................18
6.3 One Foot Decorative Grille ...............................19
6.4 Protective Grille Installation ..............................21
6.5 Sports Hall Guard Installation...........................22
6.6 Sports Hall Filter...............................................23
SECTION 7: Pump Installation and Venting .............24
7.1 Mounting Wall Bracket Assembly .....................24
7.2 Building Ventilation ...........................................26
7.3 Condensate Drain Assembly ............................27
7.4 Acoustic Enclosure (Optional) ..........................28
SECTION 8: Outside Air Supply.................................30
SECTION 9: Gas Piping ..............................................31
SECTION 10: Wiring....................................................32
SECTION 11: Operation and Maintenance................34
11.1 Sequence of Operation...................................34
11.2 Commissioning and Testing............................35
11.3 System Checks...............................................35
11.4 User Instructions.............................................35
11.5 ECA Approved Systems .................................35
SECTION 12: Servicing Instructions .........................36
12.1 Annual Service Procedure..............................36
12.2 Component Removal ......................................36
12.3 Maintenance Checklist ...................................37
SECTION 13: Troubleshooting ...................................39
13.1 Troubleshooting Flow Chart ............................39
SECTION 14: Replacement Parts...............................42
SECTION 15: Specifications ......................................43
15.1 Material Specifications....................................43
15.2 Burner Specifications......................................43
15.3 Venting Specifications ....................................43
15.4 Suspension Specifications..............................43
15.5 Controls Specifications ...................................43
15.6 CORAYVAC
®
Heater.......................................43
15.7 Burner Specifications......................................44
15.8 Pump Dimensions and Specifications ...........45
TABLE OF FIGURES
Figure 1: Standard Reflector ...........................................5
Figure 2: One Side Reflector ..........................................5
Figure 3: Two Side Reflectors .........................................5
Figure 4: 2-Foot Deco Grille............................................6
Figure 5: Protective Grille and 1 Foot Deco Grille...........6
Figure 6: Major Component Descriptions .......................7
Figure 7: Major Component Descriptions (Continued)....8
Figure 8: Critical Hanger Placement.............................10
Figure 9: CORAYVAC
®
Assembly Overview ................11
Figure 10: Wall Bracket Assembly ................................24
Figure 11: Mounting Platform Options ..........................24
Figure 12: Pressure Switch Installation .........................25
Figure 13: Pump Discharge Side ..................................25
Figure 14: Pump Inlet Side 100 mm (4") .......................26
Figure 15: Pump Inlet Side 150 mm (6") .......................26
Figure 16: Condensate Drain Assembly -
Horizontal Flue .............................................27
Figure 17: Condensate Drain Assembly -
Vertical Flue .................................................28
Figure 18: Silencer ........................................................28
Figure 19: Acoustic Enclosure ......................................29
Figure 20: Junction Box Wiring Diagrams .....................29
Figure 21: Filter Housing Assembly ..............................30
Figure 22: Outside Air Supply .......................................30
Figure 23: Gas Connection with Stainless Steel
Flex Gas Connector .....................................31
Figure 24: External System Wiring ...............................32
Figure 25: CRT Burner Internal Wiring .........................33
Figure 26: CORAYVAC
®
System
Sequence of Operation Chart ......................34
Figure 27: Burner Sequence of Operation Chart ..........34
Figure 28: Vacuum Reading..........................................41
1
Product Approval
ROBERTS GORDON® appliances have been tested and CE certified as complying with the essential
requirements of the Gas Appliance Directive, The Low Voltage Directive, The Electromagnetic
Compatibility Directive and the Machinery Directive for use on natural gas and L.P. gas when installed,
commissioned and maintained 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 installation, check that the local gas distribution systems, nature of gas and pressure, and
adjustment of the appliance are compatible.
CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL
2
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, such as the reflector portion
of the heater and the various 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 2: INSTALLER RESPONSIBILITY
The installer is responsible for the following:
• To ensure the system is designed in accordance
with the parameters of the CORAYVAC
®
design
manual (P/N 128500UK).
• To install the heater, as well as the gas and electrical supplies, in accordance with applicable
specifications and codes. Roberts-Gordon recommends the installer contact a local building
inspector or Fire Marshal for guidance.
• To use the information given in a layout drawing
and in the manual together with the local and
national codes to perform the installation.
• To install the heater in accordance with the
Clearances to Combustibles.
• To furnish all needed materials not furnished as
standard equipment.
• To plan location of supports.
• To provide access to burners for servicing on all
sides, for burner removal.
• To provide the owner with a copy of this
installation, operation and service manual.
• To never use heater as support for 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 and ventilation in accordance with local and
national codes.
• To safely and adequately install heater using
materials with a minimum working load of 33 kg
(75 lbs).
2.1 Low Level User Instructions
In all situations, clearances to combustibles must be
maintained. Signs should be posted in storage
areas to specify the maximum stacking height of
items placed below heater to maintain required
clearances to combustibles. Minimum clearances
must be maintained from vehicles parked below the
heater. Caution should be used when running the
system near combustible materials such as wood,
paper, rubber, etc. Consideration should be given to
partitions, storage racks, hoists, building construction,etc.
A laminated wall tag is available for the CORAYVAC
®
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 CORAYVAC
®
heater (e.g. thermostat or
ROBERTS GORDON
®
BZC Controller).
A copy of the wall tag (P/N 91037912) is illustrated
on the back cover. This copy of the wall tag can be
affixed on the wall near the heater. 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. Write the largest clearance dimensions with
permanent ink according to your model number and
configuration in the open spaces on the tag.
See Page 5, Section 3.2.
SECTION 2: INSTALLER RESPONSIBILITY
3
2.2 Corrosive Chemicals
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 compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These compounds are
frequently used in refrigerants, cleaning agents, solvents, etc. If
these compounds enter the air supply of the burner, the life
span of the heater components will be greatly reduced. An outside air supply must be provided to the burners whenever the
presence of these compounds is suspected. Warranty will be
invalid if the heater is exposed to halogenated hydrocarbons.
2.3 National Standards and Applicable Codes
All Appliances must be installed in accordance with
the latest revision of the applicable standards and
local 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.
CAUTION
Do not use heater in an area containing corrosive
chemicals.
Avoid the use of corrosive chemicals to ensure a
longer life of the burner, tubing and other parts.
Failure to follow these instructions can result in
property damage.
CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL
4
SECTION 3: CRITICAL CONSIDERATIONS
3.1 Required Clearances to Combustibles
Clearances are the required distances that combustible objects must be away from the heater to prevent serious fire hazards. Combustibles are
materials, which may catch on fire and 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
Page 5, Figure 1 through Page 6, Figure 5 in this
manual. Check the clearances 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
vapours 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 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 Building Inspector, Fire Insurance
Carrier or other authorities for approval of proposed installation when there is a possibility of
exposure to combustible airborne materials or
vapours.
• Hang heater in accordance to the minimum
suspension requirements on Page 10, Figure 8.
• If 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.
WARNING
Fire Hazard
Some objects will catch fire or explode when placed
close to heater.
Keep all flammable objects, liquids and vapours the
required distance away from the heater.
Failure to follow these instructions can result in death,
injury or property damage.
SECTION 3: CRITICAL CONSIDERATIONS
5
3.2 Clearance Data
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, tees, elbows and
crosses.
2. Clearances B, C and D can be reduced by 50% after 7.5 m (25') of tubing
downstream from where the burner and burner tube connect.
3. All measurements are in Millimeters.
CLEARANCES TO COMBUSTIBLES
Figure 1: STANDARD REFLECTOR
Model A B C D
CRT-10 150 510 1220 510
CRT-15 150 510 1220 510
CRT-20 150 510 1220 510
CRT-25 150 920 1530 920
CRT-30 150 920 1530 920
B
C
D
A
Figure 2: ONE SIDE REFLECTOR
Model A B C
|
D
CRT-10 150 305 1430 510
CRT-15 150 305 1430 510
CRT-20 150 305 1430 510
CRT-25 150 305 1530 1070
CRT-30 150 305 1530 1070
A
B
C
D
Figure 3: TWO SIDE REFLECTORS
Model A B C D
CRT-10 150 305 1430 305
CRT-15 150 305 1430 305
CRT-20 150 305 1430 305
CRT-25 150 305 1530 305
CRT-30 150 305 1530 305
A
B
C
D
CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL
6
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, tees, elbows and
crosses.
2. Clearances B, C and D can be reduced by 50% after 7.5 m (25') of tubing
downstream from where the burner and burner tube connect.
3. All measurements are in Millimeters.
23
CLEARANCES TO COMBUSTIBLES
Figure 4: 2-FOOT DECO GRILLE
Model A B C D
CRT-10 150 305 1220 305
CRT-15 150 305 1220 305
CRT-20 150 305 1220 305
CRT-25 150 460 1430 460
CRT-30 150 460 1430 460
A
B
C
D
Figure 5: PROTECTIVE GRILLE AND 1 FOOT DECO GRILLE
Model A B C D
CRT-10 150 510 1220 510
CRT-15 150 510 1220 510
CRT-20 150 510 1220 510
CRT-25 150 920 1530 920
CRT-30 150 920 1530 920
A
B
C
D
SECTION 4: MAJOR COMPONENTS
7
SECTION 4: MAJOR COMPONENTS
The figures in this section provide a general overview of component placement in a CORAYVAC
®
system. The location of some components such as
supports and couplings is crucial for proper installation. Assemble the heater components as shown on
Page 11, Figure 9.
Optional reflector configurations are shown on Page
5, Figure 1 through Page 6, Figure 5. Install appropriate suspension hardware, beam clamps, chain or
rod at predetermined locations.
Figure 6: Major Component Descriptions
Burner
Tube
Heat Treated Aluminized Tube
supplied in 3 m (10’) lengths.
45° Elbow
90° Elbow
End Vent
Coupling Assembly
with Lock
Flex Gas Line
Combustion Chamber
Tee
Reflector
(Aluminum or
Stainless Steel)
Reflector with Hole
(Aluminum or
Stainless Steel)
Reducer
Cross
CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL
8
Figure 7: Major Component Descriptions (Continued)
Reflector Side
Extension Bracket
Reflector Side Extension
Non Return
Val ve
(ISO-7Rc)
Reflector End Cap
(Aluminum or Stainless
Steel)
Remove center section to
accommodate heat
exchanger tube when
necessary.
Bow Shackle
Tube and
Reflector
Hanger
Reflector Support
Package
Deco Grille
Turn buck le
Protective Grille
Sports Hall Guard
ROBERTS GORDON® BZC 700
Controller
ROBERTS GORDON
®
BZC 300
Controller
ROBERTS GORDON
®
BZC 100
Controller with Sensor
RG-30 and RG-45 Pump
SECTION 4: MAJOR COMPONENTS
9
4.1 Standard Parts List
Table 1: Contents of CORAYVAC® Burner Carton
Table 2: Common CORAYVAC
®
Components
Part No. Description Quantity
E000XXXX
CORAYVAC
®
Burner (Rate and Fuel Varies)
1
E0007565 Accessory Package -
01361200 Filter Support Disk 1
01367800 Combustion Chamber Gasket 1
02904000 Door Assembly w/ Hole 1
91119500 U-Clip 4
91905500 Filter Support 1
E0007588 Nut M8 Brass 2
92511601 Wing Nut #10 - 24 1
96411600 Lockwasher 5/16" 2
01312401 Filter and Gasket 1
Part No. Description
Combustion Chamber:
02722302-1P Aluminised Combustion Chamber
E0009400 1/2" Flex Gas Line Kit
E00094XX End Vent Plate
Tubing and Related Accessories
01312700 100 mm Coupling and Lock
01312700 150 mm Coupling and Lock
01331900 100 mm Coupling with Damper and Lock
E0009356 150 mm Coupling with Damper and Lock
01330203 100 mm Aluminised Tee
01330204 150 mm Aluminised Tee
01330903 100 mm Aluminised Cross
E0009167 150 mm Aluminised Cross
01335801 100 mm Aluminised 90° Elbow
T0100320 150 mm Aluminised 90° Elbow
01336101 100 mm Aluminised 45° Elbow
91409408 16 Ga. Heat Treated Aluminised 100 mm dia 3048 mm Tube
E0009105 16 Ga. Heat Treated Aluminised 150 mm dia 3048 mm Tube
E0009326 100 mm Tail Pipe Tube Hanger
03020700 150 mm Tail Pipe Tube Hanger
Venting and Fresh Air Supply Accessories
C1376B 100 mm Outside Air Flex Duct (10 m)
F323 150 mm Roof & Wall Masterflash
F322 100 mm Roof & Wall Masterflash
F074A Roof & Wall Terminal
F116 Roof & Wall Terminal
Reflectors and Related Accessories
01329910 Reflector Side Extension Support
91107720 U Clip Package - 20 off
02750303 Aluminium Reflector
S5163W Stainless Steel Reflector
02750304 Aluminium Reflector with Hole
S5164W Stainless Steel Reflector with Hole
02750800 Aluminium Reflector End Cap
C2331B Stainless Steel Reflector End Cap
C2332B Stainless Steel Reflector End Cap with Hole
01329910 Reflector Side Extension Support
02751200 Retainer Side Extension Reflector
03090100 Tube and Reflector Hanger
E0007575 Turnbuckle Assembly
Controls and Thermostats
BZC100
ROBERTS GORDON
®
BZC 100 Controller
BZC300
ROBERTS GORDON
®
BZC 300 Controller
BZC700
ROBERTS GORDON® BZC 700 Controller
C2343B BZC Sensor
S7418K Starter RG-30 Pump
S7445K Starter RG-45 Pump
Deco Grille 305mm x 2438mm
01363003 Bracket
91406700 305 x 2438 mm Protective Grille
Deco Grille 610mm x 1219mm
01365900 Shield Frame
01370412 Reflector Side Extension 305 x 1219 mm
91407000 Aluminium Grille 610 x 1219 mm
Protective Grille
08050001 40" Protective Grille
08050002 Protective Grille End Cap
Pump Packages and Accessories
S7421K Vacuum Pump Kit RG30-3Ø
S7423K Vacuum Pump Kit RG45-3Ø
S7425K Vacuum Pump Kit RG30-1Ø
S7426K Vacuum Pump Kit RG45-1Ø
Accessories
E0007074 Pressure Switch
02718851 100 mm Drain Cap
02718852 150 mm Drain Cap
90201200 Non Return Valve
CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL
10
SECTION 5: HEATER INSTALLATION
To ensure your safety, and comply with the terms of
the warranty, all heaters 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 it is
readily accessible for servicing.
The heater must be installed with clearances to
combustibles as indicated in this instruction manual.
The minimum and maximum gas inlet pressures
must be maintained as indicated in this manual.
Typical installation configurations are shown in
Figure 8.
For mounting height and tube lengths See Page 43,
Section 15.6.
Figure 8: Critical Hanger Placement
WARNING
Crush Hazard
Hang heater with materials
with a minimum working
load of 33 kg (75 lbs).
Failure of the supports can
result in death, injury
or property damage.
Side View Towards Pump
Typical Suspension Details
Turnbuckle
Rod
(10 mm)
Beam Clamp
Concrete Beam
Wood Beam
Washers
Locknut
Screw Hook
(10 mm)
610 mm
min.
(24")
"X"
(see table)
Locknut
(Typical)
Anchor
Hanger
Front View
Bow Shackle
Turnbuckle
Reflector
2.3 m (7'6" )
Chain size
5 mm minimum
Description Part Number
Turnbuckle 91903201
Bow Shackle E0007576
Tube/Reflector Hanger 03090100
Run Length Typical Expansion Minimum “X” Length
15m (50’) ±25 mm (1") 300 mm (12")
31m (100’) ±50 mm (2") 600 mm (24")
46m (150’) ±75 mm (3") 900 mm (36")
61m (200’) ±100 mm (4") 1200 mm (46")
76m (250’) ±125 mm (5") 1450 mm (57")
SECTION 5: HEATER INSTALLATION
11
Figure 9: CORAYVAC
®
Assembly Overview
End
Vent
Combustion
Chamber
Tube &
Reflector
Hanger
Burner
Reflector
Tube
Coupling
Reflector
End Cap
Reflector
Support
Flexible
Boot
Reflector
with Hole
Pump
Exhaust
to Outside
Pressure Switch
S
Zone 1 Sensor
Starter and
Overload
ROBERTS GORDON
®
BZC Controller,
Economy Controller or
Building Management System
(consult ROBERTS GORDON
®
)
U-Clips
Minimum reflector
overlap 180 mm
Damper
Coupling
Power Supply
Pump
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