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 suppliers
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: [phone]
Fax: [phone]
Service Telephone: [phone]
Service Fax: [phone]
E-mail: [e-mail]
E-mail: [e-mail]

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

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

12

Step 5.1 Tube Installation

Step 5.2 Coupling and Tube Assembly

Combustion

Chamber

2.3 m

(7' 6")

Combustion

Chamber

3 m (10')

maximum

End View

Weld

Seam

Bottom
of Tube

Hanger

Turnbuckles

Tube

3 m (10')

maximum

Towards

Pump

NOTE: Tubing requires a downward

slope of 13 mm (1/2") per 6 m
(20') away from burner. Tailpipe
tubing requires a downward
slope of 25 mm (1") per 6 m
(20') away from burner.

Description Part Number

Tube 91409XXX
Turnbuckle 91903201
Tube/Reflector Hanger 03090100

Tube

Tube

Orient coupling so that

the impact block is in the

2:00 or 10:00 oclock

positions

Closed

Open

Tab

76 mm to
101 mm

Slide Bar

Coupling

Wide end

Coupling

Tube

Slidebar

A

Close Coupling with tab

B

Start Slide Bar/Coupling Lock onto Coupling

C

Insert Tubes into Coupling

D

Tighten Coupling to join Tubes

Description Part Number

Coupling 01329600
Slide Bar/Coupling Lock 01329700
Tube 91409XXX

SECTION 5: HEATER INSTALLATION

13

Step 5.2.1 Coupling and Tube Assembly (Continued)

Step 5.3 Reflector Installation
Step 5.3.1 Reflector Installation with Hole

Incorrect Slide Bar

position

Correct slidebar

dimensions

± 50 mm

(2")

Drive Slide Bar until tight.
End of slidebar should be
within tolerance listed below.

Repeat Step 5.2 on Page 12, A - D until all tubes are assembled.

NOTE: If Coupling is not tight, loss of vacuum can occur.

Tighten Slide Bar as shown below.

Tube

Hanger

Combustion

Chamber

Slide Reflector

with hole

through hanger.
Unhook combustion
chamber from chain

and insert through hole.

Reconnect chain.

Reflector
with Hole

Description Part Number

Tube/Reflector Hanger 03090100
Tube 91409408
Reflector with Hole 02750304

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

14

Step 5.3.2 Reflector Installationg

Reflector

Wire Form

Tube

Reflector Support

Strap

Sheet Metal

Screw

U-Clip

(2 clips per

alternate overlaps

per side)

NOTE: Minimum reflector overlap must be 180 mm.

Description Part Number
Reflector Support Package 03050010

Wire Form 91908004
Reflector Support Strap 03050000

Screw #8 x 3/4 94320812
U-Clip Package 91107720
Reflector End Cap 027508XX

SECTION 5: HEATER INSTALLATION

15

Step 5.3.3 Reflector, U-Clip and Reflector Support Installation

The pictorial drawings of the heater construction in
Section 5 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 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

screws

Loose screws
loosened 2 mm (1/16")
to allow slippage.

Reflector
End Cap

U-Clips

Wire Form

Reflector Support

Strap

Tight

Sheet Metal

Screw

The first reflector after the burner must be affixed in the
middle of the reflector with a reflector support
and tight screws.

First Reflector

1.

The joint at the first and second reflector is a slip joint.
Thereafter every third reflector joint is a slip joint.
A slip joint is achieved by:
a.) both reflectors lay inside a hanger.

(no reflector support needed).

b.) using a reflector support with

loose screws.

Slip Joint

Option A

2.

The remaining reflector overlaps require
a non-slip joint connection. To affix the
reflectors together in a non-slip overlap,
use reflector supports and tight screws.
*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.

Non-slip Joint

*U-Clip

(2 clips per

non-slip overlap

inside a hanger)

3.

Reflector

Support

Slip Joint

Option B

Reflector

Reflector

Description Part Number
Reflector Support Package 03050010

Wire Form 91908004
Reflector Support Strap 03050000

Screw #8 x 3/4 94320812
U-Clip Package 91107720
Reflector End Cap 027508XX

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

16

Step 5.4 Burner Installation

Gasket

Burner

Combustion

Chamber

End

Vent

NOTE:

Install End Vent
at end combustion
chamber position only

Burner

Combustion

Chamber

End Vent

End
Vent
Clips

Rating

Number

Description Part Number

Bolt E0007588
Burner E000XXXX
Lock Washer 96411600
Gasket 01367800
End Vent E00094XX

SECTION 6: OPTIONAL HEATER ACCESSORIES

17

SECTION 6: OPTIONAL HEATER ACCESSORIES

6.1 Elbow Configuration
Step 6.1.1 Elbow Installation

Step 6.1.2 Elbow Installation

Step 6.1.3 Tee Installation

Tube

90° Elbow

Coupling

Description Part Number

90° Elbow 01335801
Coupling and Lock 01312700

Tube

Coupling

Tee

Tube

Coupling

Description Part Number

Tee 01330XXX
Tube/Reflector Hanger 03090100
Tube 91409408
Coupling 01312700

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

18

6.2 Reflector Side Extension
Step 6.2.1 Bracket Installation

Step 6.2.2 Side Reflector Installation

Reflector Side

Extension Bracket

(2 per reflector)

Use additional supports

in high air movement

applications.

Tube and Reflector Hanger

Reflector

Tube

Reflector Support

Description Part Number
Reflector Side Extension Package S7377K

Reflector Side Extension 01368000
Retainer Clips 02751200
Sheet Metal Screws 94118106

Order Separately

Reflector Side Extension Bracket 01329910

Retainer Clip
(2 per side)

Cut relief notches for
Supports and Hangers

Reflector Side Extension

#8 x 3/8 (3.9 x 9.5 mm) Sheet Metal Screw

SECTION 6: OPTIONAL HEATER ACCESSORIES

19

Step 6.3 One Foot Decorative Grille
Step 6.3.1 Decorative Grille Bracket (One Foot Grille)

Step 6.3.2 One Foot Decorative Grille

Step 6.3.3 Joint Piece and Reinforcement (One Foot Grille)

Sheet Metal Screws

Cut relief notches for
supports and hangers.

Decorative Grille Bracket

50 mm

Minimum

Bracket
Overlap

Description Part Number

Bracket 01363003

Spread apart brackets
and install
Decorative Grille.

Description Part Number

Decorative Grille 2440mm x 305mm 91406700

Sheet Metal Screws

Joint Piece

Reinforcement

Slip joint piece into
support bracket
and fasten to
bracket on one side
of the joint only.

Joint Piece

Description Part Number

Joint Piece 01365903
Reinforcement 01365902

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

20

Step 6.3.4 End Piece and Reflector End Cap (One Foot Grille)

Fasten end piece
to brackets using two
sheet metal screws and
replace reflector end cap.

Insert end piece
between grille and
brackets.

End Piece

Reflector
End Cap

Description Part Number

End Piece 01365901

SECTION 6: OPTIONAL HEATER ACCESSORIES

21

6.4 Protective Grille Installation
Step 6.4.1 Silicone Cap Installation

Step 6.4.2 Grille End Cap Installation

Step 6.4.3 Grille Installation

Silicone Cap

Grille
Finger

Description Part Number

Grille Section 08050001
Grille End Cap 08050002
Silicone Cap 91915951-6P

Bend up 90°

Pull outward

Grille

Grille End Cap

A

B

C

D

Grille

Grille
End Cap

Reflector

Final Grille
Section

101 cm

(40 ")

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

22

6.5 Sports Hall Guard Installation
Step 6.5.1 Grille Installation

Step 6.5.2 Fastener Installation

Step 6.5.3 Mesh Guard Connection

Tube and

Reflector Hanger

Reflector

Tube

Reflector Support

Strap - Stainless Steel

Mesh Guard

Description Part Number

Mesh Guard 2438 mm E0009855
Mesh Guard 1524 mm C2329B
Strap Stainless Steel S5218W

Tube and Reflector Hanger

Reflector

Tube

Strap - Stainless Steel

Mesh Guard

Nut Spire

Screw 3.9 x 9.5 mm (#8 x 3/8)

Description Part Number

Nut Spire C1088B
Screw #8 x 3/8 (3.9 x 9.5 mm) C1089B

SECTION 6: OPTIONAL HEATER ACCESSORIES

23

6.6 Sports Hall Filter
Step 6.6.1 Remove Standard Door

Step 6.6.2 Install New Door Filter

Cylindrical

Filter

Door

Remove the burner door
with the cylindrical filter.

Filter

Media

Peel off

Remove backing of the
adhesive strips from the
filter and affix to the
inside of the burner door
with louvers.
Use existing screws to install
new filter door.

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

24

SECTION 7: PUMP INSTALLATION AND VENTING

7.1 Mounting Wall Bracket Assembly 7.1.1 Mounting Platform

The standard method of mounting the RG-30 and
RG-45 pump is on an outside wall and venting
directly through the wall or roof.

The pump may be mounted by using mounting
angles as shown in Figure 10 and Figure 11. The
two mounting angles form a mounting platform to
which the pump will be attached using the anti­vibration mounts.

Fix the mounting frame to the wall using anchors.
Select an anchor that will give equal to or greater
than 907 kg (2000 lbs) ultimate pull-out strength.

Figure 10: Wall Bracket Assembly

Figure 11: Mounting Platform Options

WARNING

Crush Hazard

Mount pump with materials
with a minimum working
load of 181 kg (400 lbs).

Failure of the supports can
result in death, injury
or property damage.

Mounting
Angle

Hex Head Bolt

Flat Washer

Lockwasher

Hex Nut

Flat Washer

Description Part Number

Mounting Angle 01365000
Bolt M8 x 25 mm S280
Nut M8 S248
Washer S264
Lockwasher S260

27 cm

(10 5/8)

20.5 cm
(8)

Anti-Vibration

Mount

Anti-Vibration

Mount

Anti-Vibration

Mount

Description Part Number
Anti Vibration Mounting Kit E0009238

Anti Vibration Mount 91906100
Hex Nut 92113900
Washer 95211600
Lockwasher 96411600

SECTION 7: PUMP INSTALLATION AND VENTING

25

7.1.2 Attaching Pressure Switch

Drill two holes in the fan base housing to accept the
pressure switch mounting bracket and attach the
switch by means of 2 self-tapping screws. The
switch should be mounted vertically with the cable
restraint gland on top.

The silicone tubing is installed according to Figure

12. Care must be taken that the tubing cannot kink
or be squeezed together.

Figure 12: Pressure Switch Installation

7.1.3 Flue Installation

The fan outlet must always discharge horizontally.
Mount the 150 mm (6") pump boot to the pump out­let using the 6" 150 mm (6") band clamp provided.
See Figure 15.

Connection should be made using 150 mm mini­mum diameter aluminium or stainless steel flue
material. All flue material must conform to the rele­vant National Standards.

Mount the 150 mm flue to the pump boot securing it
with the 150 mm band clamp. The flue length must
not exceed 15 m including 2 x 45° offset bands. The
flue must be self supporting.

Figure 13: Pump Discharge Side

Pressure

Switch

Cable Restraint Gland

Description Part Number

Pressure Switch E0007074

Band Clamp
150 mm (6")

Pump Boot

150 mm (6")

CONNECT

TO SYSTEM

TUBING

150 mm (6")

Description Part Number

Pump Boot 150 mm (6") 91412802
Band Clamp 150 mm (6") 91913703

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

26

7.1.4 Pump Inlet Adapter for 100 mm (4") Tubing

Apply a bead of silicone sealant 316° C to the 150
mm (6") inside of the reducer (150 mm x 100 mm)
(6" x 4"). Mount the reducer to the inlet of the pump
scroll using the 3 - #10 self drilling screws provided.
See Figure 14.

IMPORTANT: To prevent leakage of condensate, do
not install screws at the 6 o’clock position.

Mount the pump boot to the inlet reducer using the
band clamp provided. See Page 26, Figure 14.

7.1.5 Pump Inlet for 6" (15 cm) Tubing

Attach 150 mm (6") pump boot to the inlet See Fig­ure 15, then See Section 7.1.3.

7.2 Building Ventilation

The space containing the heaters must have a
permanent outside air vent with a minimum effective
area of 4.5 cm

2

per kW of heat input. If mechanical
ventilation is employed, the minimum proven airflow
rate shall be 2.35 m

3

/h per kW of heat input. If venti­lation is required, air must be taken from an outside
point where it is not likely to be contaminated. The
building ventilation must be in accordance with local
and national codes.

Figure 14: Pump Inlet Side 100 mm (4")

Figure 15: Pump Inlet Side 150 mm (6")

Inlet

Assembly

Band Clamp

100 mm (4")

Pump Boot

100 mm (4")

CONNECT

TO SYSTEM

TUBING

100 mm (4")

100 mm x 150 mm

Adapter

Condensate

Te e

Band Clamp
150 mm (6")

Description Part Number

Pressure Switch 90430600
Pump Boot 100 mm (4") 91412800
Band Clamp 100 mm (4") 91901300
Inlet Assembly 90713454
101 mm (4") x 150 mm (6") Adapter 02719903

Band Clamp
150 mm (6")

Pump Boot

150 mm (6")

CONNECT

TO SYSTEM

TUBING

150 mm (6")

Description Part Number

Pressure Switch 90430600
Pump Boot 150 mm (6") 91412802
Band Clamp 150 mm (6") 91913703

SECTION 7: PUMP INSTALLATION AND VENTING

27

7.3 Condensate Drain Assembly

The condensate drain assembly is composed of a
tee, draincap, and a non return valve.

A condensate drain assembly must be installed on the
inlet side of the pump assembly if there is horizontal
venting of the pump, See Figure 16.

A seperate condensate drain on the pump dis­charge side is required if there is vertical venting of
the pump or if
there is a vertical rise in the discharge line away
from the pump. See Figure 17.

The condensate drain assembly in the pump
discharge line can be eliminated if the discharge line
is horizontal through the wall and pitched down at
least 6 mm per 3 m (1/4" per 10'). This arrangement
will permit drainage of condensate through the
pump and outside via the horizontal (pitched) dis­charge line.

Figure 16: Condensate Drain Assembly - Horizontal Flue

Te e

Drain Cap

Pump

Inlet

Wall

1" BSP threaded hole.

Use 1" x ¾" reducer.

(not supplied)

Must be connected
to a drain system
in accordance with
local codes.

1 m (36") minimum

vertical drop
between pump
and non-return

valve.

3/4" CPVC Pipe

flow

Non-Return

Valve

3/4" CPVC

Pipe

3/4" female

Description Part Number

Tee 100 mm (4") 01330203
Tee 150 mm (6") 01330204
Drain Cap 100 mm (4") 02718851
Drain Cap 150 mm (6") 02718852
Non-Return Valve C2383B

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

28

Figure 17: Condensate Drain Assembly - Vertical Flue

7.4 Acoustic Enclosure (Optional)

The acoustic enclosure is used to reduce noise from
the pump installed inside the building. The enclo­sure can also be used as a weatherproof enclosure
if the pump is installed outside. For outside applica­tions a master flash must be attached over the tail
pipe and flue discharge connection. In some appli­cations the noise from the pump discharge needs to
be reduced. A silencer attached to the discharge
side must be used. See Page 28, Figure 18.

Figure 18: Silencer

The acoustic enclosure comes fully assembled with
an electrical junction box on its side. Pressure
switch control wires and electrical power connection
need to be connected here. A wiring diagram is

inside the junction box. See Page 29, Figure 19.

The mounting of the enclosure must be done as
described in Section 7.1.

Flue

150 mm (6") Minimum

Roof

Te e

150 mm (6")

Drain Cap

150 mm (6")

Pump

Discharge

Wall

Approved
Vent Cap

1" BSP threaded hole.

Use 1" x ¾" reducer.

(not supplied)

Must be connected
to a drain system
in accordance with
local codes.

flow

Non-Return

Valve

3/4" CPVC

Pipe

3/4" female

3/4" CPVC Pipe

300 mm

(12")

Description Part Number

Tee 150 mm (6") 01330204
Drain Cap 150 mm (6") 02718852

Pump

Discharge

Silencer

600 mm

725 mm

250 mm

Description Part Number

Silencer C0996B

SECTION 7: PUMP INSTALLATION AND VENTING

29

Figure 19: Acoustic Enclosure

Figure 20: Junction Box Wiring Diagrams

7.4.1 Noise Data

All noise data has been determined according to EN ISO 3746:1995, survey method "Parallelepiped
measurement surface". Values given below are at 3 m distance from the object.

Tailpipe

Connection

Flue

Discharge

Junction Box

(wiring diagram

inside)

From

Pressure Switch

From Fan Motor

Blue Brown Brown BlueBlack Earth

Common NO U1 V1 W1

3 Ø Motors

From

Pressure Switch

From Fan Motor

Blue Brown Brown Blue Earth

Common NO

1 Ø Motors

RG30 and RG45 Pump Data

Sound Pressure Level

dB (A)

NR

No acoustic enclosure 59 53

No acoustic enclosure with 600 mm silencer 59 53

With acoustic enclosure 57 51

With acoustic enclosure and 600 mm silencer 55 49

Flue Data

Straight outlet duct 69 63

Straight outlet duct with 600 mm silencer 60 54

Burner Data

CRT 10 - 30 located at end vent plate 58 52

CRT 10 - 30 located in middle of branch 49 43

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

30

SECTION 8: OUTSIDE AIR SUPPLY

The CORAYVAC® system is approved for use with
an outside air system. Halogenated hydrocarbons or
other corrosive chemicals in the air can be drawn
into the equipment and seriously damage the sys­tem components. Avoid the use of such chemical
compounds near the air inlet to the heaters.

IMPORTANT: If the building has a slight negative
pressure or contaminants are present in the air, an
outside combustion air supply to the heaters is
strongly recommended.

All joints and seams in the air supply system must
be airtight. The filter housing attaches to the burner
assembly by using the wing nut provided.

Figure 21: Filter Housing Assembly

Figure 22: Outside Air Supply

Wing Nut

Filter Housing

Filter

Top Gasket

and Disk

Bottom Gasket

Door-Control

Housing

Filter

Support

Description Part Number

Filter Housing 01326801
Filter and Gaskets 01312401
Filter Support 91905500
Wing Nut 92511601

Vent Cap or
Bird Screen

Outside Wall

Burner

Spiral Duct

or PVC

Clamp

100 mm (4")

Take Off

100 mm (4")

Air Flex Duct

Filter

Housing

Description Part Number

Filter Housing 01326801
100 mm (4") Take Off C1361B
100 mm (4") Air Flex Duct (10 m sections) C1376B
100 mm (4") Bird Screen 01365400
100 mm (4") Vent Cap 90502300
150 mm (6") Vent Cap 90502302

SECTION 9: GAS PIPING

31

SECTION 9: GAS PIPING

A gas meter is connected to the service pipe by the
Gas Supply Company. An existing meter should be
checked, preferably by the gas company, to ensure
that the meter is adequate for the rate of gas supply
required.

Installation pipes should be fitted in accordance with
National Standards. Pipe work from the meter to the
heater(s) must be of adequate size. Pipes of smaller
size than the heater inlet gas connection should not
be used.

Connect the heater to the gas supply using an
approved flexible gas hose of 1 m (39") length and a
shut-off valve. See Page 31, Figure 23.

IMPORTANT - the complete installation must be
tested for gas soundness and be purged in accor­dance with local and national codes.

Figure 23: Gas Connection with Stainless Steel Flex Gas Connector

WARNING

Fire Hazard

Connect gas supply according to Figure 21.

Gas line moves during normal operation.

Gas can leak if not installed properly.

Failure to follow these instructions can result in death,
injury or property damage.

Horizontal

45°

Rear ViewBurner

50 mm (2")

Stainless

Steel Flex

Gas Connector

Shut-Off Valve

300 mm

(12")

Hold gas nipple securely with
pipe wrench when attaching the
flex gas connector.

Shut-Off Valve must be parallel to burner gas inlet. The 50 mm
(2") displacement shown is for the cold condition. This displace­ment may reduce when the system is fired.

Do not bend flexible gas connector sharply.

Description Part Number

1/2" Flex Gas Line E0009397
Shut Off Valve C0514B

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

32

SECTION 10: WIRING

Connect to the electrical supply using a 3 pin plug

via a locally mounted double pole fused switch hav­ing a minimum disconnection of 3 mm on each pole.
The burner is fused at 1 A. There are no control con­nections in the standard burner. Control is effected
by interruption of the main power inlet. See Page 32,
Figure 24 for external and Page 33, Figure 25 for
internal wiring.

All wiring must comply with current wiring regula­tions and any local regulations which may apply.
Always switch off the supply to the burner and dis­connect by removing the plug before removing the
burner side panel.

3 phase motors can be reversed by interchanging 2
phase connections.

The control of the CORAYVAC

®

system must via a
Roberts Gordon approved control to ensure that the
necessary safety systems are in place and proper
post purge occurs at close down.

Figure 24: External System Wiring

WARNING

Electrical Shock Hazard

Disconnect electrical power and gas supply before
servicing.

This appliance must be connected
to a properly earthed electrical source.

Failure to follow these instructions can result in
death or electrical shock.

Burner Receptacles
4 Zone Max

Maximum 10 A Total

Sensors

Pump Motor
400 V Operation, 3 Ø
230 V Operation, 1 Ø

Pressure
Switch

BZC Controller,

Economy Controller or

Building Management System

(consult ROBERTS GORDON

®

)

IEC contactor and
overload rated for
the pump motor

L

N

E

L

N

E

L

N

E

Pump
Power
Supply

L

Power

Supply

N

SECTION 10: WIRING

33

Figure 25: CRT Burner Internal Wiring

If any of the original wire as supplied with the heater must be replaced, it must be replaced with
wiring material having a temperature rating of at least 105° C and 600 V.

32 1 576 43 2 1

sense

FILTER

RECTIFIER/
GAS VALVE

ELECTRODE

MIXING CHAMBER

IGNITION MODULE

Yellow

Green/

Green/Yellow

Brown

Blue

Blue

Brown

Yellow

Green/

SPARK

Brown

Blue

yellow

yellow

blue

brown

Blue

MAIN
INLET

Blue

Brown

Brown

DOTTED LINE
WIRES ARE
AN OPTION

RUN START

CONNECTOR
VOLT FREE

RELAY

1

2

4

3

2

A1

A2

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

34

SECTION 11: OPERATION AND MAINTENANCE
Figure 26: CORAYVAC

®

System Sequence of Operation Chart

Figure 27: Burner Sequence of Operation Chart

11.1 Sequence of Operation

On connection of the power supply, the pump will
start creating a suction in the tube. The pressure
switch at the pump will change contacts when suc­tion is created. A pre-purge cycle which lasts 30

seconds is initiated. Once complete, power to the
burners is enabled.

The burner sequence begins with the red lockout
neon illuminated. This indicates that the burner has
begun the ignition sequence.

KEY TO

SYMBOLS

T

0

T

8

T

3

T

5

T

4

T

6

T

2

T

1

2 minute

post purge

Loss of Pressure

Switch Signal

30 sec approx.

T

7

Pressure
Switch

PS

Thermostat

Pump
Operating

Power to
Burners

PS

T

9

KEY TO

SYMBOLS

Start/Run

T

0

T

8

T

3

T

5

T

4

T

6

T

2

T

1

T

S

T

S

10

sec

45

sec

Interuption of main

flame sensing

55 sec approx.

Thermostat

Ignition

Gas
Valve

Flame
Sensing

Lockout Alarm
(optional)

Neon

Lockout

T

7

3 try

10

sec

SECTION 11: OPERATION AND MAINTENANCE

35

Power to the burner sequence controller initiates an
approximate 45 second purge period. Following the
purge period, the solenoid valve opens. This allows
the vacuum, created in the tube to lift the diaphragm
in the zero governor thereby allowing the passage of
gas to the burner. At the same time, a spark is cre­ated and ignition should take place. If ignition of the
gas is not successful, the spark will cease and the
solenoid will close after approximately 10 seconds.
The ignition sequence is repeated for 2 more times
before lockout occurs. The lockout neon will remain
lit indicating the condition. When the gas is ignited,
the detection circuit is energised and switches off
the ignition circuit. The run neon (green) will illumi­nate indicating full running condition.

The system will continue to run until the power sup­ply or gas supply is interrupted. Interruption of the
electrical supply results in shutdown of the burners,
after which, the pump will continue to run for two
minutes to clear products of combustion from the
system. Restoration will restart the whole sequence.
Interruption of the gas supply will result in loss of
flame followed by 3 attempts to reignite, if unsuc­cessful, lockout occurs.

11.2 Commissioning and Testing

Commissioning of the system must be carried out by
a registered installer/contractor qualified in the
installation and service of gas-fired heating equip­ment or your gas supplier.

11.2.1 Establish that a satisfactory purged gas sup­ply and an electrical supply is available to the
heater.

11.2.2 Ensure that all dampers are in the fully open
position.

11.2.3 Turn off the electrical supply to the heaters.

11.2.4 Switch on the electrical supply at the main

isolator. This will start the exhaust fan.

11.2.5 Ensure that all time clocks and thermostats
are set to call for heat.

11.2.6 Balancing Cold Suction

Starting at the branch furthest from the pump, check
the end vent vacuum. Do this by connecting a
manometer by inserting the test probe a minimum of
150 mm into the hole. See Page 41, Figure 28.
Adjust the damper at the end of the radiant run so
that the suction is approximately 9 mbar. Repeat for
each branch.

11.2.7 Switch off the electrical supply at the main
isolator. The exhaust fan will stop.

11.2.8 Turn on the electrical supply to the heater.

11.2.9 Switch on the electrical supply at the main

isolator.

11.2.10 Balancing Hot Suction

The start up sequence described on Page 34, Sec-
tion 11.1 should take place. Allow the system to

reach full temperature (approximately 30 minutes).
Set the dampers at each branch to achieve the set­tings for the installed burner model as listed in

11.2.11.

11.2.11 Suction Settings

Model Heat Input Hot Suction

all Gas Types

(mbar)

CRT10 10 kW 5.7

CRT15 15 kW 6.5

CRT20 20 kW 7.0

CRT25 25 kW 6.7

CRT30 30 kW 7.0

Repeat this procedure for each branch of the
system.

11.3 System Checks

Turn the system off and restart it to ensure smooth
ignition. Carry out the following system checks.

11.3.1 When running, turn off the gas supply at the
appliance isolating cock. The heater will immedi­ately shut down followed by 3 attempts at restoration
followed by lockout.

11.3.2 When running, disconnect the fan electrical
supply. The burner should shut down within a few
seconds proving operation of the pressure switch.

11.3.3 When running, turn down the thermostat to a
point below room temperature. Check that the fan
continues to run on for two minutes after shut down
of the burners.

11.4 User Instructions

After satisfactory testing, ensure that the client is
fully aware of the operation of the system. Bring this
manual to the attention of the user or purchaser;
instruct them in the safe operation of the heater(s).

11.5 ECA Approved Systems

On ECA approved systems, it must be verified that
the requirement of 91% net combustion efficiency is
met. Measurements of temperature and CO2 con-

centration in the exhaust gasses have to be done.
The net combustion efficiency calculates as follows;

100 - [ (t

E

- tR) (A/CO2m - B) ] = net comb. efficiency

t

E

- Exhaust Temperature °C

t

R

- Room Temperature °C

A - G20 = 0.37, G31 = 0.42

B - G20 = 0.009, G31 = 0.008

CO

2m

-Measured CO2 Concentration %

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

36

SECTION 12: SERVICING INSTRUCTIONS
IMPORTANT: Never use the heater as a support for

ladders or other access equipment. Always test for
gas soundness with a suitable detection fluid after
completing any servicing or exchange of gas carry­ing component. On completion of any service/fault
finding tasks which require the breaking and remak­ing of electrical connections, recheck the following:
A:Earth Continuity, B:Polarity and C:Resistance to
Earth.

12.1 Annual Service Procedure

Carry out the following service procedure annually.
The preferred time would be immediately before the
winter heating period. If very dirty conditions arise, it
may be necessary to carry out this procedure more
often. If the unit takes in air through an air duct or
filter assembly, less frequent service may be
necessary.

12.1.1 Isolate the heater from the gas and electricity
supply by shutting off the appliance cock and dis­connecting the union connector, switching off the
local electrical supply and removing the appliance
plug.

12.1.2 Remove the mains plug from the burner.
Remove the two nuts that secure the burner head to
the combustion chamber. The burner can now be
removed.

12.1.3 Remove the burner to the floor level and
clean internally using a soft brush and compressed
air if available. Take care not to damage the internal
parts of the burner. When removing the burner, take
care not to disturb the gasket on the combustion
chamber.

12.1.4 The electrode is an integral part of the burner
head. Check that the spark gap is approximately 3
mm.

12.1.5 With the burner removed, clean the outer sur­faces of the tubes using a brush and wipe the inner
surface of the reflector with a soft damp cloth - use a
household detergent if necessary. Never use abra­sive cleaners on the reflectors.

12.1.6 Reassemble the burner in reverse order.
Carry out the Commissioning and Testing Proce­dure on Page 35, Section 11.2.

12.2 Component Removal

First, isolate the heater from the gas and electricity
supply; shut off appliance cock and disconnect the
gas union connection. Switch off the local electrical
supply and remove the appliance plug.

Entry to the burner assembly is gained by removing
the two (2) door screws and removing the side
cover.

12.2.1 Electrode (See Page 36, Section 12.1.4)

Remove the electrode cover and the two allen
screws that secure the electrode to the burner head.
Inspect the electrode gasket; replace as required.

12.2.2 Injector Jet

When the side cover is removed completely, the
burner assembly is exposed. The jet is located in the
mixing block behind the pipe plug. Remove brass
injector jet (orifice). Replace in reverse sequence.

12.2.3 Solenoid Valve/Governor

Remove the electrode cover from the burner head
and unplug spark and sensor leads. Remove burner
head by unscrewing the two allen screws. Remove
the tagged wires from the burner run neon. Remove
the cross-head screw retaining the valve connec­tion. Withdraw the connection block. Remove the
ground wire from the gas valve and from the air
shutter screw. The gas train can now be withdrawn
from the compartment. The gas train can now be
dismantled. Replace part and reassemble in reverse
order.
NOTE: When reassembling, a suitable sealant must
be used to ensure that no gas leaks occur. Further
to this, the assembly must be square so that all the
components are upright.

12.2.4 Automatic Flame Control Unit

Remove ignition lead, sense wire and other
connectors. Unscrew two (2) screws from the cover.
Replace if faulty. Refit in reverse sequence.

12.2.5 Neons

Remove the two push connectors from the neon.
Remove the neons by depressing the retaining tabs
inward. Replace in reverse sequence.

SECTION 12: SERVICING INSTRUCTIONS

37

12.3 Maintenance Checklist

Installation, Service and Annual Inspection of the 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.

The Vicinity of the Heater Do not store or use flammable objects, liquids or vapours near the heating

system. Immediately remove these items if they are present.

See Page 4, Section 3.

Vehicles and Other
Objects

Maintain the clearances to combustibles.

Do not hang anything from, or place anything on, the heater.

Make sure nothing is lodged underneath the reflector, in between the tubes
or in the decorative or protective grilles (included with select models).

Immediately remove objects in violation of the clearances to combustibles.

See Page 4, Section 3.

Reflector Make sure there is no dirt, sagging, cracking or distortion.

Do not operate if there is sagging, cracking or distortion.

Make sure reflectors are correctly overlapped.

Clean outside surface with a damp cloth.

Vent Pipe Venting must be intact. Using a flashlight, look for obstructions, cracks on

the pipe, gaps in the sealed areas or corrosion.

The area must be free of dirt and dust.

Remove any carbon deposits or scale using a wire brush.

Outside Air Inlet Inlet must be intact. Look for obstructions, cracks on the pipe, gaps in the

sealed areas or corrosion.

The area must be free of dirt and dust. Clean and reinstall as required.

Tube s Make sure there are no cracks.

Make sure tubes are connected and suspended securely.

See Page 10, Figure 8 through Page 13, Section 5.2.1.

Make sure there is no dirt, sagging, bending or distortion.

Clean or replace as required.

Gas Line Check for gas leaks. See Page 31, Figure 23.

Combustion Chamber
Window

Make sure it is clean and free of cracks or holes.

Clean or replace as required.

Burner Head and Orifice Clear of obstructions (even spider webs will cause problems).

Carefully remove any dust and debris from the burner.

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

38

Electrode Replace if there are cracked ceramics, excessive carbon residue, or erosion

of the electrode.

The electrode gap should be 1/8” (3 mm).

Thermostat There should be no exposed wire or damage to the thermostat.

Suspension Points Make sure the heater is hanging securely. The chains must hang vertical.

Look for signs of wear on the chain or ceiling.

See Page 10, Figure 8.

Protective Grille (optional) The grille must be securely attached.

See Page 19, Section 6.3.1 through Page 20, Section 6.3.4.

Pump With pump operating, check for excessive vibration or noise. Vibration is

usually a sign that the impeller is out of balance. Turn off the system, insure
power is shut off and remove the inlet plate. Check the shaft seal and
replace it if worn or missing.

With the Power off:

Check the inlet and outlet of the pump for blockage or excessive soot and
clean as necessary.

Check boots for cracking or deterioration and replace if necessary.

If a condensate drain is installed, check the condition of the drain and the
non return valve attached.

Check the condition of the motor anti vibration mounts. Lift the motor from
the rear; look for breaks in the rubber and replace if necessary.

Check the condition and operation of the pressure switch.

SECTION 13: TROUBLESHOOTING

39

SECTION 13: TROUBLESHOOTING

13.1 Troubleshooting Flow Chart

Inspect the electrodes on

the affected burners. Are

they burned or damaged?

Ye s

Replace electrode.

(P/N 90430700)

Troubleshoot Ends

Does the burner light?

No

Ye s

Check fan for rotation,

reverse wiring (3 Ø only),

if required.

Pump motor must have

failed. Replace motor.

Remove obstruction.

Is there an obstruction

in the pump impeller?

No

Ye s

Is the motor connected

properly? Refer to the wiring

diagrams on the motor and

in the installation manual.

Motor may have tripped

overload switch. Wait 10-15

minutes and activate reset.

No

Check external wiring

for continuity.

Disconnect power to the

motor. Does the motor

turn freely?

No

Is there power output

(230/400 V) to the

pump?

No

Yes

Troubleshoot Ends.

Adjust damper to obtain

correct vacuum. After

adjustment does burner

operate?

Yes

No

Check wiring to the burner.

Make sure the burner is

plugged in.

Check clock program.

Reset as required.

Check circuit breaker and/or

fuse on panel supply circuit.

Is the clock set to on?

Yes

Is there power (230 V) to

the control panel?

Yes

No

START

No

Ignition module may have

failed. Replace module.

(P/N 90435201)

Yes

No

No

Yes

No

Yes

No

Yes

After 45 seconds pre-purge

period, do the burners light?

No

Turn up thermostat.

Does the fan turn on?

No

Yes

Ye s

Is there power (230 V) at

the burner receptacle?

Is there proper gas pressure

and flow to the burners?

No

Check fuse in main inlet.

Replace as required.

Correct gas problem. See Gas

Piping Section for details.

Unplug the burner, wait 10

seconds, then plug it in

again. Does the ignition

module begin ignition

sequence by sparking?

Is there 9 mbar vacuum at

the end vent?

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

40

Troubleshooting Flow Chart

No

TROUBLESHOOT ENDS.

If problems persist, contact

your

ROBERTS GORDON

®

Independent Distributor.

Contact

ROBERTS GORDON

®

at www.rg-inc.com

Re-establish continuity.

No

Ye s

Is the insulation on the

igniter/sensor leads OK?

Re-establish connections.

No

Ye s

Ignition module may have

failed. Replace module.

(P/N 90435201)

Is there power to the

solenoid coil after the

purge period?

No

Restart burner ignition cycle.

Troubleshooting ends.

Using a manometer, check

vacuum at the mixing

chamber. Is the vacuum 1-3

mbar?

No

Ye s

Is the vacuum setting

too high?

Yes

Adjust system for proper

vacuum at the end vent.

Re-establish continuity.

Reverse polarity.

Is the wiring at the module

properly connected?

Are the Live and the

Neutral reversed?

No

Ye s

Is the continuity of the

earth wire established?

No

Ye s

Verify that the couplings have

been installed properly.

Ye s

No

Is the rotation of the

pump motor correct?

Adjust system for proper

vacuum at the end vent.

Follow burner check

procedure given above.

No

Ye s

Are there any "dead"

burners in a branch?

Is the vacuum setting

too low?

No

Ye s

Is the system leaking water?

No

Ye s

Does the burner stay on?

Ye s

No

Consult wiring instructions in

pump manuals listed below

for reversal instructions.

No

Do all the burners ignite

smoothly?

No

Ye s

No

Wrong end vent plate may

be installed. Make sure plate

and burner match.

Adjust the gap or replace

electrode. (P/N 90430700)

Ensure ignition lead is

securely fitted and that

electrode gap is correct. Is the

gap 3 mm?

Ye s

No

Regulator may have failed.

Replace regulator.

(P/N 90207102)

Ye s

Ignition module may have

failed. Replace module.

(P/N 90435201)

Yes

SECTION 13: TROUBLESHOOTING

41

Figure 28: Vacuum Reading

Manometer

6

5

4

3

2

1

0

1

2

3

4

5

6

6

5

4

3

2

1

0

1

2

3

4

5

6

Insert tubing

about 150 mm (6").

Combustion Chamber

at end position

Cold Suction

Approximate reading after adjusting

damper couplings. (9 mbar)

Hot Suction

Approximate reading after adjusting

damper couplings. (7 mbar)

End Vent

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

42

SECTION 14: REPLACEMENT PARTS
Use only genuine ROBERTS GORDON

®

replacement parts.
Use of parts not specified by Roberts-Gordon voids warranty.
Failure to follow these instructions can result in property damage.

Item Description Part Number Item Description Part Number

A Ignition Module 90435201 N/S Rectifier Harness 02950001
B Gas Valve 90033400 N/S Ignition Wire 90427704
C Regulator 90207102 N/S Fuse (250 V, 1 A, 5 mm x 20 mm) E0007915
D Mixing Block 02790400 N/S Filter 90707000
E Burner Head Assembly 02721702 N/S Filters (box of 24 with gaskets) 01312400

F

Gasket - 2 required
(Burner Head to Mixing Block)

01351100 N/S

Gasket
(Burner Head to Combustion Chamber)

01367800

N/S Replacement Burner Head 02721700 N/S Mica Window Assembly 02553203

G Electrode 90430700 J

Relay Volt Free Contact (optional)

Relay Volt Free Base (optional)

C1049B

C1050B

H Electrode Gasket 02558501 N/S Combustion Chamber Gasket 01367800

I

Jet (see Section 2)
located behind pipe plug

K Electrode Cover E0008108

N/S Main Wire Harness 02950004
N/S Sense Lead Wire 02950003

F

A

B

C

I

E

D

H

G

J

K

RELAY

SECTION 15: SPECIFICATIONS

43

SECTION 15: SPECIFICATIONS

15.1 Material Specifications

15.1.1 Combustion and Tubes

100 mm dia 16 gauge heat treated aluminised mild
steel.

15.1.2 Reflectors

NS3 H14 aluminium or 1.4016 2R stainless
steel (option).

15.2 Burner Specifications

15.2.1 Sequence Controller

Fully automatic three try direct spark 100% shut off
ignition flame rectification module.

15.2.2 Electrical

Rating: 230 V, 50/60 Hz, 1 Ø, 1 A

Connection: 3 pin moulded plug.

15.2.3 Gas Supply

Connection: Rc-1/2 (1/2" BSP int)

Natural G20: Minimum - Inlet 11 mbar (4.4 in wc)

Maximum - Inlet 50 mbar (20 in wc)

Natural G25: Minimum - Inlet 15 mbar (6 in wc)

Maximum - Inlet 50 mbar (20 in wc)

LP Gas (Propane or Butane):

Minimum - Inlet 32 mbar (13 in wc)

Maximum - Inlet 50 mbar (20 in wc)

15.3 Venting Specifications

15.3.1 Pumps

RG-30-1 Ø RG-30-3 Ø

RG-45-1 Ø RG-45-3 Ø

Consult the manufacturer for availability of alternate
pumps.

15.3.2 Flue

Flue will be 150 mm dia duct. Flue material must
conform to National Codes. The flue must be self
supporting.

15.4 Suspension Specifications

Galvanised straight link welded chain.

Working load of 33 kg (75 lbs).

15.5 Controls Specifications

Factory assembled control panels, time switches
and thermostats are available. Consult your factory
representative for proper connection to electrical
supply circuits.

* Based on Gross Calorific Value.

15.6 CORAYVAC

®

Heater

CRT10

CRT15

CRT20

CRT25

CRT30

Input - Gross (kW) 10 15 20 25 30

Input - Net (kW) 9 13.51822.527

Heated Area (m

2

) 16-105 24-158 32-210 40-263 48-316

Minimum Installation Height (m) 2.5 3.0 3.5 4.0 4.5

Weights:

Burner and Combustion Chamber 9.5 kg / burner

Radiant Tube with reflector,
brackets, etc.

4.3 kg/m

Flow Units/burner 1.0 1.5 2.0 2.5 3.0

Flow Units/end vent 2.0 2.0 3.0 4.0 5.0

Maximum Burners/Branch 65433

Maximum Flow Units/Branch 8.0 10.5 12.0 12.5 15.0

Gas Consumption*

G20 (m

3

/h)

0.95 1.43 1.91 2.38 2.86

G25 (m

3

/h)

1.11 1.66 2.22 2.77 3.32

G30 (m

3

/h)

0.37 0.56 0.75 0.94 1.13

G31 (m

3

/h)

0.28 0.43 0.57 0.72 0.86

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

44

15.7 Burner Specifications

General Specifications for CORAYVAC® heaters are as follows:

*See Page 4, Section 3 for clearances to combustibles.

BURNER COMPONENTS

NOTE: fluor = fluorescent.

Air Shutter

End Vent

Plate

Orifice Size

G20 G25 G31 G30

CRT 10

#01 #2 #35 (black)

3.0 mm

(fluor yellow)

2.4 mm

(fluor red) #44 (silver)

CRT 15

#15 #2

3.4 mm

(fluor orange)

3.7 mm

(fluor pink)

#35 (black)

2.6 mm

(fluor green)

CRT 20

#6 #3 #22 (rose) #19 (red) #30 (yellow)

3.0 mm

(fluor yellow)

CRT 25

#8 #4 #14 (purple) #10 (orange)

3.7 mm

(fluor pink)

3.5 mm

(fluor blue)

CRT 30 #30 #5 #7 (white) #3 (drk green) #22 (rose) #25 (brown)

51 cm

(20")

24.4 cm
(10")

9 cm

(3 1/2")

19 cm

(7 5/8")

36 cm

(14 1/4")

24 cm

(9 1/2")

.4 cm

(5/32")

19 cm

(7 1/2")

17 cm

(6 7/8")

32 cm

(12 1/2")

10 cm

(4")

SECTION 15: SPECIFICATIONS

45

15.8 Pump Dimensions and Specifications

A

150 mm

C

D

62 mm

205 mm

(mounting holes)

B

F

E

150 mm

230 mm

(mounting holes)

Pump Specifications

Model RG30-1 RG45-1 RG30-3 RG45-3

Part No.

90710108 90710109 90710111 90710112

Weight (kg)

41.5 43.5 41.5 43.5

Power (W)

750 1100 750 1100

Run Current (A)

3.25 4.8 2.75 2.75

Start Current (A)

14.25 23.0 8.5 13.2

Supply (V)

230 V 1 Ø 50 Hz 230 V 1 Ø 50 Hz 400 V 3 Ø 50 Hz 400 V 3 Ø 50 Hz

Pump Dimensional Data (mm)

Model A B C D E F

RG30-1

650 630 386 430 124 545

RG30-3

650 630 386 430 124 545

RG45-1

674 650 396 435 121 567

RG45-3

674 650 396 435 121 548

CORAYVAC® INSTALLATION OPERATION AND SERVICE MANUAL

46

Infrared Heating

Maintain ???? cm clearance

to the side and

???? cm clearance below

the heater from vehicles

and combustible materials.

www.rg-inc.com Printed in the U.S.A. P/N 91037912

Attach this information to a wall near the ROBERTS GORDON

®

heater.

Installation Code: ROBERTS GORDON® products are to be installed only in accordance with local laws, codes and regulations, and only by a contractor qualified in the installation and service of gas-fired
heating equipment.

For optimum product performance and safety, installation, service and annual inspections must be completed by a contractor qualified in the installation and service of gas-fired heating equipment.

© 2004 ROBERTS GORDON® 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.

Read the Installation, Operation, and Service Manual thoroughly before installation, operation, or service.

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 below.

OPERATING INSTRUCTIONS

1. STOP! Read all safety instructions on this information sheet.

2. Open the manual gas valve in the heater supply line.

3. Turn on electric power to the heater.

4. Set the thermostat to desired setting.

1. Set the thermostat to off or the lowest setting.

1. Set the thermostat to off or the lowest setting.

2. Turn off electric power to the heater.

3. Turn off the manual gas valve in the heater supply line.

4. Call your registered installer/contractor qualified in the installation
and service of gas-fired heating equipment.

IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY,

FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER

Fire Hazard

Some objects can catch fire or explode when placed close
to heater.

Keep all flammable objects, liquids and vapors the required
clearances to combustibles away from heater.

Failure to follow these instructions can result in death,
injury or property damage.

TO TURN OFF THE HEATER

Service Telephone: [phone]
Service Fax: [phone]
E-mail: [e-mail]
E-mail: [e-mail]

WARNING

Roberts-Gordon

1250 William Street
P.O. Box 44
Buffalo, NY 14240-0044 USA
Telephone: [phone]
Fax: [phone]
Toll Free: 800.828.7450

Roberts-Gordon

76 Main Street West, Unit 10
Grimsby, Ontario L3M 1R6 Canada
Telephone: [phone]
Fax: [phone]

Roberts-Gordon

Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: [phone]
Fax: [phone]

®