Roberts Gorden CTHN-125, CTHN-150, CTHN-175, CTHN-40, CTHN-80 User Manual

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.

®

Vantage

NP

Negative Pressure

Unitary or Multiburner

WARNING

Fire Hazard

Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.

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

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

Infrared Heater

Installation,

Operation &

Service Manual

CTHN-40
CTHN-60

CTHN-80
CTHN-100
CTHN-125
CTHN-150
CTHN-175

CTHN-200

WARNING

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.

Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.

Quality in Any Language™

© Copyright 2006 Roberts-Gordon, LLC

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.

Roberts-Gordon, LLC

1250 William Street
P.O . B o x 4 4
Buffalo, New York 14240-0044
Telephone: [phone]
Fax: [phone]
Toll Free: 800.828.7450

www.rg-inc.com

P/N 152101NA Rev A 10/06

TABLE OF CONTENTS

SECTION 1: Heater Safety......................................................1

1.1 Manpower Requirements ............................................. 1

SECTION 2: Installer Responsibility .....................................2

2.1 Wall Tag .......................................................................2

2.2 Corrosive Chemicals....................................................2

2.3 National Standards and Applicable Codes .................. 2

SECTION 3: Critical Considerations......................................3

3.1 Required Clearances to Combustibles.........................3

SECTION 4: National Standards and Applicable Codes .....7

4.1 Gas Codes...................................................................7

4.2 Aircraft Hangars ...........................................................7

4.3 Public Garages ............................................................7

4.4 Electrical ......................................................................7

4.5 Venting.........................................................................7

4.6 High Altitude ................................................................7

SECTION 5: Heater Descriptions...........................................8

5.1 Unitary vs. Multiburner.................................................8

SECTION 6: Major Components ............................................ 9

SECTION 7: General Suspension Details ........................... 10

SECTION 8: Unitary Linear & U-Tube Heater Installation.. 11

8.1 Standard Parts........................................................... 11

8.2 Unitary Heater Requirements .................................... 13

8.3 Unitary Linear Heater Layouts................................... 14

8.4 Unitary U-tube Heater Layouts ..................................17

8.5 Burner Tube Installation ............................................19

8.6 Tube Clamp Package Installation ..............................19

8.7 Coupling and Tube Assembly....................................20

8.8 Turbulator Installation ................................................ 21

8.9 Reflector Installation ..................................................22

8.10 Burner Installation....................................................24

8.11 Fan Inlet Plate and Warning Tag.............................24

8.12 Restrictor Plate Installation.....................................25

8.13 Fan Installation ........................................................25

SECTION 9: Multiburner Heater Installation....................... 26

9.1 Standard Parts...........................................................26

9.2 Multiburner System Design Requirements ................29

9.3 Burners Per Pump .....................................................30

9.4 Radiant Tube Length..................................................31

9.5 Manifold Tube ............................................................31

9.6 Multiburner System Layouts and Manifold Tube

Length Rules..............................................................31

9.7 Burner Tube Installation ............................................36

9.8 Tube Clamp Package Installation ..............................36

9.9 Coupling and Tube Assembly....................................37

9.10 Turbulator Installation .............................................. 38

9.11 Reflector Installation ................................................39

9.12 Burner Installation....................................................41

SECTION 10: Optional Heater Accessories........................42

10.1 Elbow Package Configuration ..................................42

10.2 Reflector Side Extension..........................................44

10.3 Lower Clearance Shield Installation.........................45

10.4 Two-Foot Decorative Grille Installation..................... 45

10.5 One-Foot Decorative Grille Installation .................... 47

10.6 Protective Grille Installation......................................49

SECTION 11: Venting - General............................................50

11.1 General Venting Requirements.................................50

SECTION 12: Venting - Unitary Heater ................................51

12.1 Unvented Operation.................................................51

12.2 Unvented Operation Termination ............................. 51

12.3 Horizontal Venting.................................................... 51

12.4 Vertical Venting........................................................ 51

12.5 Length Requirements .............................................. 51

12.6 Flue Connection Detail ............................................ 52

12.7 Horizontal Ventilation 4" (10 cm) Pipe...................... 52

12.8 Vertical Ventilation 4" (10 cm) Pipe.......................... 53

12.9 Common Sidewall Venting ....................................... 53

12.10 Common Vertical Venting ..................................... 54

SECTION 13: Venting - Multiburner Systems..................... 55

13.1 General Requirements............................................. 55

13.2 Manifold Tube Requirements ................................... 55

13.3 Venting the Pump .................................................... 55

13.4 EP-100 Pump Models .............................................. 56

13.5 EP-200 Pump Series ............................................... 56

13.6 EP-300 Pump Series ............................................... 56

13.7 Installation Precautions............................................ 56

SECTION 14: Outside Combustion Air Supply .................. 58

14.1 Length Requirements .............................................. 58

14.2 Vertical Non-Pressurized Outside Air Supply for

Single Heater Installation ......................................... 58

14.3 Horizontal Non-Pressurized Outside Air Supply for

Single Heater Installation ......................................... 58

14.4 Vertical Non-Pressurized Outside Air Supply for

Double Heater Installation........................................ 59

14.5 Horizontal Non-Pressurized Outside Air Supply for

Double Heater Installation........................................ 59

14.6 Pressurized Outside Air Supply ............................... 60

SECTION 15: Wiring.............................................................. 61

15.1 Internal Wiring.......................................................... 61

15.2 Internal Wiring.......................................................... 61

15.3 Ladder Diagram....................................................... 62

15.4 External Wiring (Unitary Heaters Only).................... 62

15.5 Line Voltage Thermostat Wiring

(Unitary Heaters Only) ............................................. 63

15.6 Low Voltage Thermostat Wiring

(Unitary Heaters Only) ............................................. 63

15.7 System Control Methods and External Multiburner

Wiring....................................................................... 64

SECTION 16: Gas Piping...................................................... 69

SECTION 17: Operation and Maintenance.......................... 70

17.1 Checking the Gas Line............................................. 70

17.2 Unitary Heater Sequence of Operation ................... 70

17.3 Multiburner System Operation.................................. 70

17.4 Maintenance............................................................. 73

17.5 Maintenance Checklist ..............................................74

SECTION 18: Troubleshooting............................................. 76

18.1 Troubleshooting Flow Chart - Unitary ...................... 76

18.2 Troubleshooting Flow Chart - Multiburner................ 78

18.3 Manifold Gas Pressure Setting ................................ 80

SECTION 19: Replacement Parts List................................. 81

SECTION 20: General Specifications.................................. 83

20.1 Material Specification .............................................. 83

20.2 Heater Specifications............................................... 83

20.3 Suspension Specifications....................................... 83

20.4 Controls Specifications ............................................ 83

SECTION 21: The ROBERTS GORDON

Warranty.......................................................... 85

®

Vantage® NP Limited

© 2006

All rights reserved. No part of this work covered by the copyrights herein may be reproduced
or copied in any form or by any means - graphic, electronic, or mechanical, including
photocopying, recording, taping or information storage and retrieval systems - without the
written permission of Roberts-Gordon, LLC.

Roberts-Gordon, LLC

Prin ted in U.S.A.

TABLE OF FIGURES

Figure 1: Standard Reflector .....................................................3

Figure 2: One Side Reflector.....................................................4

Figure 3: Two Side Reflectors ...................................................4

Figure 4: 45° Tilt Reflector ........................................................4

Figure 5: U-Tube, Standard Reflector........................................5

Figure 6: U-Tube, 45°................................................................5

Figure 7: U-Tube, Opposite 45° Reflector .................................5

Figure 8: 2-Foot Deco Grille, 1-Foot Deco Grille and

Protective Grille ..........................................................6

Figure 9: Lower Clearance Shield.............................................6

Figure 10: Venting .....................................................................6

Figure 11: Major Component Descriptions ................................ 9

Figure 12: Critical Hanger Placement ..................................... 10

Figure 13: Linear Heater Assembly Overview......................... 14

Figure 14: Unitary Linear Layout Overviews ........................... 15

Figure 15: Unitary Linear Layout Overviews (Continued) ....... 16

Figure 16: U-tube Assembly Overview....................................17

Figure 17: Unitary U-Tube Layout Overviews.......................... 18

Figure 18: Typical CTHN Multiburner System Installation ....... 29

Figure 19: Flag Layout ............................................................32

Figure 20: Modified In-Series Layout ......................................32

Figure 21: T Layout................................................................. 33

Figure 22: Fork Layout............................................................34

Figure 23: Herringbone Layout................................................ 35

Figure 24: Reflector Joint Detail..............................................43

Figure 25: Fan Termination .....................................................51

Figure 26: Tailpipe Connection Points..................................... 55

Figure 27: Roof Venting of Pump ............................................56

Figure 28: Side Wall Venting Configurations...........................57

Figure 29: General System Control Wiring (Multiburner) ........ 64

Figure 30: External Wiring Diagram EP-100 and

EP-201 120 V 1 Ø Pump (Multiburner) .................. 65

Figure 31: External Wiring Diagram EP-301 230 V 1 Ø Pump

(Multiburner) ..........................................................65

Figure 32: External Wiring Diagram EP-203 or

EP-303 3 Ø Pump (Multiburner) ............................66

Figure 33: One Zone Operation without Control Panel

(Multiburner) ..........................................................67

Figure 34: Two Zone Operation without Control Panel

(Multiburner) ..........................................................68

Figure 35: Gas Connection with Flexible Gas Hose ............... 69

Figure 36: Vacuum Differential Reading..................................72

SECTION 1: HEATER SAFETY

Your Safety is Important to Us!
This symbol is used throughout
the manual to notify you of
possible fire, electrical or burn
hazards. Please pay special
attention when reading and
following the warnings in these

sections.
Installation, service and annual inspection of heater
must be done by a contractor qualified in the
installation and service of gas-fired heating

equipment.

Read this manual carefully before installation,
operation or service of this equipment.

This heater is designed for heating nonresidential
indoor spaces. Do not install in residential spaces.
These instructions, the layout drawing, local codes
and ordinances, and applicable standards that apply
to gas piping, electrical wiring, venting, etc. must be
thoroughly understood before proceeding with the
installation.

SECTION 1: HEATER S AFETY

Thin sheet metal parts, including the aluminum
reflector 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.

1

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 2: INSTALLER RESPONSIBILITY

The installer is responsible for the following:

• 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 cited codes
and regulations to perform the installation.

• To install the heater in accordance with the
clearances to combustibles requirements.

• To furnish all needed materials not furnished as
standard equipment.

• To plan location of supports.

• To provide access to burners on all sides for
burner servicing and removal.

• To provide the owner with a copy of this
Installation, Operation and Service Manual.

• To never use heater as a support for a ladder or

other access equipment and never hang or
suspend anything from heater.

• To ensure there is adequate air circulation around

the heater and to supply air for combustion,
ventilation and distribution in accordance with
local codes.

• To safely and adequately install heater using

materials with a minimal working load of 75 lbs
(33 kg).

and configuration in the open spaces on the tag.

2.2 Corrosive Chemicals

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.

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.

2.1 Wall Tag

A laminated wall tag is available for the heater as a
permanent reminder of the safety instructions and
the importance of the required clearances to
combustibles. Please contact Roberts-Gordon or
your ROBERTS GORDON

®

independent distributor
to obtain the wall tag. Affix the tag by peeling off the
backing of the adhesive strips on the rear surface
and position the tag on a wall near the heater (e.g.
thermostat or ROBERTS GORDON

®

Controller).

A copy of the wall tag (P/N 91037912) is illustrated on
the back cover. For an immediate solution, you may
affix this copy on the wall near the heater.

Know your model number and installed configuration.
Model number and installed configuration are found
on the burner and in the Installation, Operation and
Service Manual. See Page 3, Figure 1 through Page
6, Figure 10. Write the proper clearance dimensions
in permanent ink according to your model number

2

2.3 National Standards and Applicable Codes

All appliances must be installed in accordance with
the latest revision of the applicable standards and
national codes. This refers also to the electric, gas
and venting installation. Note: Additional standards
for installations in public garages, aircraft hangars,
etc. may be applicable.

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 fire hazards. Combustible materials that may
catch fire include common items such as wood,
paper, rubber, fabric, etc. Maintain clearances to

combustibles at all times for safety.

Clearances for all heater models are located on the
burner of the heater and on Page 3, Figure 1 through
Page 6, Figure 10 in this manual. Check the
clearances on each burner for the model heater
being installed to make sure the product is suitable
for your application and the clearances are
maintained. Read and follow the safety guidelines
below:

• Keep gasoline or other combustible materials
including flammable objects, liquids, dust or
vapors away from this heater or any other
appliance.

• Maintain clearances from heat sensitive material,
equipment and workstations.

• Maintain clearances from vehicles parked below
the heater.

• Maintain clearances from swinging and overhead
doors, overhead cranes, vehicle lifts, partitions,
storage racks, hoists, building construction, etc.

• In locations used for the storage of combustible
materials, signs must be posted to specify the
maximum permissible stacking height to maintain

SECTION 3: CRITIC AL C ONSIDERATIONS

WARNING

Fire Hazard

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

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

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

required clearances from the heater to the
combustibles. Signs must be posted adjacent to
the heater thermostat. In the absence of a
thermostat, signs must be posted in a
conspicuous location.

• Consult local Fire Marshal, Fire Insurance Carrier
or other authorities for approval of proposed
installation when there is a possibility of exposure
to combustible airborne materials or vapors.

• Hang heater in accordance to the minimum
suspension requirements on Page 10, Figure 12.

• 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.

NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.

2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.

FIGURE 1: STANDARD REFLECTOR

Model A B C D A B C D

CTHN-40 5 20 41 20 13 51 104 51

CTHN-60 5 275127136913069

CTHN-80 5 30 58 30 13 76 147 76

CTHN-100 5 326032138115281

CTHN-125 5 35 65 35 13 89 165 89

CTHN-150 5 397139139918099

CTHN-175 8 44 74 44 20 112 188 112

CTHN-200 8 47 76 47 20 119 193 119

(inches) (centimeters)

3

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.

2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.

FIGURE 2: ONE SIDE REFLECTOR

Model ABCDABCD

A

B

C

D

CTHN-40 5 6 46 35 13 15 117 88

CTHN-60 5 6 55 44 13 15 140 110

CTHN-80 5 6 64 49 13 15 163 123

CTHN-100 5 6 66 51 13 15 168 128

CTHN-125 5 6 69 58 13 15 175 145

CTHN-150 5 6 75 60 13 15 191 150

CTHN-175 8 6 77 68 20 15 196 170

CTHN-200 8 6 79 70 20 15 201 175

.

(inches) (centimeters)

FIGURE 3: TWO SIDE REFLECTORS

Model ABCDABCD

A

B

C

D

CTHN-40 5 16 47 16 13 41 119 41

CTHN-60 5 18 56 18 13 46 142 46

CTHN-80 5 21 65 21 13 53 165 53

CTHN-100 5 23 68 23 13 58 173 58

CTHN-125 5 26 73 26 13 66 185 66

CTHN-150 5 30 76 30 13 76 193 76

CTHN-175 8 32 88 32 20 81 224 81

CTHN-200 8 33 90 33 20 84 229 84

FIGURE 4: 45° TILT REFLECTOR

Model ABCDABCD

CTHN-40 8 4 35 43 20 10 89 109

CTHN-60 8 4 45 45 20 10 114 114

CTHN-80 9 4 54 55 23 10 137 140

CTHN-100 10 4 57 56 25 10 145 142

CTHN-125 10 4 63 58 25 10 160 147

CTHN-150 10 4 66 61 25 10 168 155

CTHN-175 10 4 69 68 25 10 175 173

CTHN-200 10 4 73 71 25 10 185 180

(inches) (centimeters)

(inches) (centimeters)

4

NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.

2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.

FIGURE 5: U-TUBE, STANDARD REFLECTOR

Model ABCDABCD

CTHN-40

CTHN-60 5 27 56 19 13 69 142 48

CTHN-80 5 30 61 20 13 76 155 51

CTHN-100 5 32 63 20 13 81 160 51

CTHN-125 5 35 66 20 13 89 168 51

CTHN-150 5 39 73 21 13 99 185 53

CTHN-175 8 44 75 26 20 112 191 66

CTHN-200 8 47 76 30 20 119 193 76

SECTION 3: CRITIC AL C ONSIDERATIONS

(inches) (centimeters)

- UNAPPROVED - - UNAPPROVED -

FIGURE 6: U-TUBE, 45°

Model ABCDABCD

A

B

D

C

CTHN-40

CTHN-60 8 4 47 40 20 10 119 102

CTHN-80 8 4 54 46 20 10 137 117

CTHN-100 8 4 57 48 20 10 145 122

CTHN-125 8 4 63 53 20 10 160 135

CTHN-150 8 4 66 56 20 10 168 142

CTHN-175 8 4 69 59 20 10 175 150

CTHN-200 8 4 73 63 20 10 185 160

FIGURE 7: U-TUBE, OPPOSITE 45° REFLECTOR

Model ABCDABCD

A

B

C

D

CTHN-40

CTHN-60 8 45 45 10 20 114 114 25

CTHN-80 9 55 54 10 23 140 137 25

CTHN-100 10 56 57 10 25 142 145 25

CTHN-125 10 58 63 10 25 147 160 25

CTHN-150 10 61 66 20 25 155 168 51

CTHN-175 10 68 69 20 25 173 175 51

CTHN-200 10 71 73 20 25 180 185 51

(inches) (centimeters)

- UNAPPROVED - - UNAPPROVED -

(inches) (centimeters)

- UNAPPROVED - - UNAPPROVED -

5

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.

2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream
from where the burner and burner tube connect.

FIGURE 8: 2-FOOT DECO GRILLE, 1-FOOT DECO GRILLE AND PROTECTIVE GRILLE

(inches) (centimeters)

Model ABCDABCD

A

C

B

D

CTHN-40 5 20 41 20 13 51 104 51

CTHN-60 5 27 51 27 13 69 130 69

CTHN-80 5 30 58 30 13 76 147 76

CTHN-100 5 32 60 32 13 81 152 81

CTHN-125 5 35 65 35 13 89 165 89

CTHN-150 5 39 71 39 13 99 180 99

CTHN-175 8 44 74 44 20 112 188 112

CTHN-200 8 47 76 47 20 119 193 119

FIGURE 9: LOWER CLEARANCE SHIELD*

Model ABCDABCD

A

B

C

D

CTHN-40 5 25 22 25 13 64 56 64

CTHN-60 5 30 27 30 13 76 69 76

CTHN-80 5 37 37 37 13 94 94 94

CTHN-100 5 39393913999999

CTHN-125 5 41 41 41 13 104 104 104

CTHN-150 5 43 50 43 13 109 127 109

CTHN-175

CTHN-200

*When installed in the first 10' (3 m).

FIGURE 10: VENTING

Model A E F A E F

CTHN-40 14 18 18 36 46 46

CTHN-60 14 18 18 36 46 46

CTHN-80 20 24 18 51 61 46

CTHN-100 20 24 18 51 61 46

CTHN-125 20 24 18 51 61 46

CTHN-150 20 30 18 51 76 46

CTHN-175 20 30 18 51 76 46

CTHN-200 20 30 18 51 76 46

Unvented

Radiant Tubes

Vented

A

E

Vent
Pipes

F

(inches) (centimeters)

- UNAPPROVED - - UNAPPROVED -

- UNAPPROVED - - UNAPPROVED -

(inches) (centimeters)

6

SECTION 4: NATIONAL STANDARDS AND
APPLICABLE CODES

SECTION 4: NATIONAL STANDARDS AND APPLICABLE C ODES

4.1 Gas Codes

The type of gas appearing on the nameplate
must be the type of gas used. Installation must
comply with national and local codes and
requirements of the local gas company.

United States: Refer to National Fuel Gas Code,
ANSI Z223.1 - latest revision (same as NFPA

54).

Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances.

4.2 Aircraft Hangars

Installation in aircraft hangars must be in
accordance with the following codes:

United States: Refer to Standard for Aircraft
Hangars, ANSI/NFPA-409 - latest revision.

Canada: Refer to Standard CAN/CGA B149.1
and B149.2: Installation Codes for Gas Burning
Appliances.

• In aircraft storage and servicing areas, heaters
shall be installed at least 10' (3 m) above the
upper surface of wings or of engine enclosures
of the highest aircraft which may be housed in
the hangar. The measurement shall be made
from the wing or engine enclosure (whichever is
higher from the floor) to the bottom of the heater.

• In shops, offices and other sections of aircraft
hangars communicating with aircraft storage or
servicing areas, heaters shall be installed not
less than 8' (2.4 m) above the floor.

• Suspended or elevated heaters shall be so
located in all spaces of aircraft hangars that they
shall not be subject to injury by aircraft, cranes,
movable scaffolding or other objects. Provisions
shall be made to assure accessibility to
suspended heaters for recurrent maintenance
purposes.

4.3 Public Garages

Installation in garages must be in accordance
with the following codes:

United States: Standard for Parking Structures
NFPA-88A - latest revision or the Code for Motor
Fuel Dispensing Facilities and Repair Garages,
NFPA-30A - latest revision. Canada: Refer to
CAN/CGA B149.1 and B149.2: Installation
Codes for Gas Burning Appliances.

• Heaters must not be installed less than 8'
(2.4 m) above the floor. Minimum clearances to
combustibles must be maintained from vehicles
parked below the heater.

• When installed over hoists, minimum
clearances to combustibles must be maintained
from the upper most point of objects on the hoist.

4.4 Electrical

The heater must be electrically grounded in
accordance with the following codes:

United States: Refer to National Electrical

®

Code

, ANSI/NFPA-70 - latest revision. Wiring

must conform to the most current National

®

Electrical Code

, local ordinances, and any

special diagrams furnished.

Canada: Refer to Canadian Electrical Code,
CSA C22.1 Part 1 - latest revision.

4.5 Venting

The venting must be installed in accordance with
the requirements within this manual and the
following codes:

United States: Refer to NFPA-54/ANSI Z223.1 ­latest revision, National Fuel Gas Code.

Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances.

4.6 High Altitude

These heaters are approved for installations up
to 2000' (610 m)(US), 4500' (1370 m)(Canada)
without modification. Consult factory if US
installation is above 2000' (610 m) or Canadian
installation is above 4500' (1370 m).

7

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 5: HEATER DESCRIPTIONS

5.1 Unitary vs. Multiburner

CTHN-Series burners may be used for unitary
heaters or for multiburner systems.
Unitary heaters consist of a single burner, a single
run of radiant tubing and a single fan assembly. See
Page 14, Figure 13 or See Page 17, Figure 16 for
details.
Multiburner systems consist of more than one burner
and more than one run of radiant tubing. The runs of
radiant tubing are connected together by manifold
tubing. The manifold tubing connects to a single
pump that exhausts the flue gases outdoors. See
Page 32, Figure 19 through Page 35, Figure 23 for
common multiburner system layouts.

Since this manual addresses installation of both
unitary heaters and multiburner systems, pay
close attention to section and figure titles to
verify relevance to unitary heaters or multiburner
systems.

8

SECTION 6: MAJOR COMPONENTS
FIGURE 11: Major Component Descriptions

Burner with
Tube Gasket

Must be installed
with the flame
observation window
facing down.

Reflector (Aluminum or Stainless Steel)

Alternate overlap as shown on Page 15,
Figure 14 or on Page 18, Figure 17.

Minimum overlap is 6'' (16 cm).

SECTION 6: MAJOR COMPONENTS

Turbulator

Turbulator must be installed in the last standard section
of tube.Turbulator is only required on the CTHN-40, 60
and 80. For installation, See Page 21, Step 8.8.

Flex Gas Line
with Shut Off Cock

Tube and Reflector Hanger
with Clamp Package

Position this hanger no more
than 4'' (10 cm) away from
the burner assembly.

Tube and Reflector Hanger

Suspend system from these
hangers.

Burner Tube

Supplied in 10' (3 m) lengths.
Burner tube is always the first
tube after the burner.

Tube

Hot rolled or heat treated aluminized
tube supplied in 10' (3 m) lengths.

Coupling Assembly
with Lock

EP-100 Pump Package -

For more information, refer to the
EP-100 Installation, Operation and
Service Manual
(P/N 127201NA).

EP-201 Pump Package ­For more information, refer to
the EP-200 Series Installation,
Operation and Service Manual
(P/N 127200NA).

Reflector Support
Strap & Wire Form

Reflector End Cap

Punch out center section to
accommodate tube.

Restrictor Plate

Used at fan assembly inlet
for unitary heaters only.
See fan assembly below.

Fan Assembly

EP-300 Series

Pump Package ­For more information,
refer to the EP-300
Series Installation,
Operation and
Service Manual
(P/N 127202NA).

9

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 7: GENERAL SUSPENSION DETAILS

WARNING

Suspension Hazard

Burner is secured to burner tube
by bolts and lockwashers.

Hang heater with materials
with a minimum working
load of 75 lbs (33 kg).

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

To ensure your safety and comply with the terms of
the warranty, all units must be installed in
accordance with these instructions.

FIGURE 12: Critical Hanger Placement

Typical Suspension Details

Beam Clamp

The gas or the electrical supply lines must not be
used to support the heater.

Do not locate the gas or electric supply lines directly
over the path of the flue products from the heater.

The heater must be installed in a location that is
readily accessible for servicing.

The heaters must be installed in accordance with
clearances to combustibles as indicated on the rating
plate and in this instruction manual.

The minimum and maximum gas inlet pressures
must be maintained as indicated on the rating
plate.Typical installation configurations are shown in
Figure 12.

Concrete Beam

Anchor

Screw Hook

3/8"

Locknut

Wood Beam

Side View

24" min.*

(61 cm)

Rod 3/8"

Turnbuckle

Not Included

Hanger

Reflector

X*

S-hooks

Chain Size

3/16"

Minimum

S-hooks

* Allows for thermal expansion of system

Washers

Hanger

Must Be Within 4" (10 cm) Front View

Description Part Number

S-Hook 91907302
Tube/Reflector Hanger 03090100

10

45° Angle

Run Length Typical Expansion Minimum “X” Length

10' (3 m) - 50' (15 m) ±1" (3 cm) 12" (30 cm)
51' (15.5 m) - 60' (18 m) ±2" (5 cm) 18" (46 cm)
61' (18.6 m) - 80' (24 m) ±3" (8 cm) 24" (61 cm)

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

8.1 Standard Parts
Table 1: Contents of CTHN Burner Carton

Part No. Description CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200

052XXXXX Burner (Rate and Fuel Varies)

07730400 Restrictor Plate 1.25'' (3.2 cm) dia.

07730100 Restrictor Plate 1.50'' (3.8 cm) dia.

07730500 Restrictor Plate 2.25'' (5.7 cm) dia.

07730600 Restrictor Plate 2.50'' (6.4 cm) dia.

07730700 Restrictor Plate 2.75'' ( 7 cm) dia.

03051503 Turbulator Adapter

03051504 Turbulator Section

03051505 Turbulator Section,

Stainless Steel

*91412200 Flexible Stainless Steel Gas Hose , 1/2'' NPT

(US Models Only)

*91412203 Flexible Stainless Steel Gas Hose , 3/4'' NPT

(US Models Only)

02568200 Gasket (Burner to Burner Tube)

94273914 Hex Head Cap Screw 5/16'' -18 x 7/8''

96411600 Split Lock Washer

91201708 Pipe Nipple 1/2'' NPT x 4''

152101NA Installation, Operation and Service Manual

111 1 1 1 1 1

1-- - ----

-1- - ----

--- 1 1---

--- - - - 1 -

--- - - 1 - -

111 - ----

244 - ----

1-- - - ---

1111 1---

--- - - 1 1 1

111 1 1 1 1 1

444 4 4 4 4 4

444 4 4 4 4 4

111 1 1 1 1 1

111 1 1 1 1 1

*Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory. See Page 69, Section 16.

Table 2: Contents of Core and Extension Packages

Core Packages Extension Packages

Hot Rolled Aluminized Hot Rolled Aluminized

Part No. Description

91409300

91409408

03051101

03051601

Tube, Hot Rolled Steel, 10

Tube, HT Aluminized, 10

'

(3 m)

'

(3 m)

Burner Tube, ALUMI-THERM

Burner Tube, HT ALUMI-THERM® Steel, 10' (3 m)

01312700 Coupling Assembly

02750303

Standard Reflector, 8

'

(2.4 m)

02750800 End Cap

03090100 Tube and Reflector Hanger

91907302 S-hook

03050010 Reflector Support Package

(Strap, Wire Form, Screws)

91107720 U-clip Package

®

Steel, 10' (3 m)

20

'

30

'

40

'

10

'

20

'

30

'

40

'

10

'

20

'

30

'

40

'

10

'

20

(6m)

(9m)

(12m)

(3m)

(6m)

(9m)

(12m)

(3m)

(6m)

(9m)

(12m)

(3m)

'

(6m)

123----1234----

----123----1234

-11--11--------

1--11----------

123-12312341234

346234623462346

2222222 --------

345234512341234

345234512341234

235123523462346

111111111111111

30

(9m)

'

40

'

(12m)

90502700 Vent Adapter (Not used on CTHN)

01318901

Tube Clamp Package

1111111 --------

1111111 --------

11

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Table 3: Component Package Guide

Model

Tubing Length Core Packages

Minimum Standard Aluminized

CTHN-40 10' (3 m) CP10ALUM CP10ALUM

CTHN-60 20' (6 m) CP20HRS CP20ALUM

CTHN-80 20' (6 m) CP20HRS CP20ALUM

CTHN-100 30' (9 m) CP30HRS CP30ALUM

CTHN-125 40' (12 m) CP40HRS CP40ALUM

CTHN-150 40' (12 m) CP40HRS CP40ALUM

CTHN-175 50' (15 m) CP30HRS + EXP20HRS CP30ALUM + EXP20ALUM

CTHN-200 50' (15 m) CP30HRS + EXP20HRS CP30ALUM + EXP20ALUM

Additional tubing length may be added to heater.
Any additional tubing lengths are considered as vent length for length determination.
Maximum venting length for unitary heater is 45' (13.7 m).
For manifold tubing on multiburner systems, heat-treated aluminized or porcelain coated tubing is required.

Table 4: Common CTHN-Series Components

Part No. Description
Tubing and Related Accessories

01312700 Coupling, 4" (10 cm) Plain
01312706 Coupling, 6" (15 cm) Plain

0131270I Coupling, 4" (10 cm) Lined
01331900 Coupling, 4" (10 cm) Damper
E0009356 Coupling, 6" (15 cm) Damper
0133022D Tee, 4" (10 cm) Coated
01330203 Tee, 4" (10 cm) Aluminized
01330204 Tee, 6" (15 cm) Aluminized
0133092D Cross, 4" (10 cm) Coated
01330903 Cross, 4" (10 cm) Aluminized
01330904 Cross, 6" (15 cm) Aluminized
01335801 Elbow, 4" (10 cm) Aluminized 90°
T0100320 Elbow, 6" (15 cm) Aluminized 90°
0133580D Elbow, 4" (10 cm) Coated 90°
01336101 Elbow, 4" (10 cm) Aluminized 45°
0133610D Elbow, 4" (10 cm) Coated 45°
91409300 Tube, 4" (10 cm) dia Hot Rolled Steel 10' (3 m)
91409403 Tube, 4" (10 cm) dia Non-Heat Treated Aluminized

10' (3 m)

91409408 Tube, 4" (10 cm) dia Heat Treated Aluminized

10' (3 m)

91409420 Tube, 6" (15 cm) dia Non-Heat Treated Aluminized

10' (3 m)
9141030D Tube, 4" (10 cm) dia Coated 10' (3 m)
E0009105 Tube, 6" (15 cm) dia 10' (3 m)

Heat Treated Aluminized
91418200 Tube Adapter, 6" (15 cm) dia x 4"(10 cm) dia

Aluminized
91240010 Tube Hanger, 6" (15 cm)
91308001 Pipe Compound, High Temperature 1lb can

Venting Accessories

01324401 Air Supply Takeoff, 4" (10 cm) Outside
90707501 Air Supply Blower/Power Venter
91409601 Air Flex Duct, 4" (10 cm) Outside

(Box of 8 - 8' (2.4 m) sections)

Reflectors and Related Accessories

01329910 Reflector Side Extension Support
03050010 Reflector Support Package (Tubing)
02712700 Reflector Side Extension, 2 Clips, 2 Screws

02750303 Reflector, Aluminum
027503SS Reflector, Stainless Steel
02750800 Reflector End Cap, Aluminum
027508SS Reflector End Cap, Stainless Steel

027508SH Reflector End Cap, Stainless Steel with Hole

02750900 Reflector Joint
027509SS Reflector Joint, Stainless Steel
027127SS Reflector Side Extension, Stainless Steel
03090100 Tube and Reflector Hanger
91907302 S-hook
91903201 Turnbuckle
91903300 Spring Hook
91903202 Turnbuckle with Eyebolt

Control Packages and Thermostats

02770002 System Control
05023000 Load Relay Package
90417600 Transformer Relay - SPST (12 A)
90436300 Transformer Relay - DPST (12 A)
90423000 Thermostat, 24 V Low Voltage (Marked 1-5)
90424300 Thermostat Guard

12

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

Deco Grille (1' x 8' [.3 m x 2.4 m])

01363003 Bracket
01365901 End Piece
01326801 Reinforcement
01365903 Joint Piece
91406700 1' x 8' (.3 m x 2.4 m) Protective Grille

Deco Grille (2' x 4' [.6 m x 1.2 m])

01365900 Shield Frame
01370408 Reflector Side Extension 8" x 48" (20 cm x 122 cm)
01370412 Reflector Side Extension 12" x 48" (30 cm x 122 cm)
01370416 Reflector Side Extension 16" x 48" (40 cm 122 cm)
91407000 Grille, Aluminum 2' x 4' (.6 m x 1.2 m)

Protective Grille

08050001 Grille, 40" (102 cm) Protective
08050002 Protective Grille End Cap

Fan and Pump Packages

05220000 Fan Package 40-150
05221000 Fan Package 175-200
02719105 EP-100 Pump Package

02719100 EP-100 Pump
02724700 Accessory Package

02716305 EP-201 Pump Package

01312001 EP-201 Pump
01317805 Accessory Package

02712034 EP-203 Pump Package

01312002 EP-203 Pump

01317805 Accessory Package
02723014 EP-301 Pump Package 4" (10 cm)
02730101 EP-301 Pump Assembly
02730104 Accessory Package
02723016 EP-301 Pump Package 6" (15 cm)
02730101 EP-301 Pump Assembly
02730106 Accessory Package
02723034 EP-303 Pump Package 4" (10 cm)
02730103 EP-303 Pump Assembly
02730104 Accessory Package
02723036 EP-303 Pump Package 6" (15 cm)
02730103 EP-303 Pump Assembly
02730106 Accessory Package

Pump Accessories

90430600K Pressure Switch

Starters and Contactors

10050001 Starter, 120 Vac for EP-203, 3 Ø
10050003 Starter, 120 Vac for EP-201, 1 Ø
10050008 Starter, 120 Vac for EP-301, 1 Ø
10050009 Contactor Package-

120 Vac Coil for EP-301, 230 V, 2 HP

10050010 Starter, 120 Vac for EP-303, 3 Ø

8.2 Unitary Heater Requirements

CTHN unitary heaters are typically shipped as a
burner package, fan assembly and a tube and
accessory package. The tube and accessory
packages contain enough tube, reflector and hanging
parts for one unitary CTHN heater. Elbows, u-tubes,

See Page 14, Figure 13 for a general overview of a
CTHN unitary heater. CTHN unitary heaters are
controlled by thermostat.

Ta b l e 5 summarizes the design requirements for a
CTHN unitary heater.

controls, and any other parts must be purchased
separately.

Table 5: Unitary Heater Design Requirements

Burner Model: CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200

Maximum Number of Burners Allowed
per Fan Assembly (P/N 05220000)

Maximum Number of Burners Allowed
per Fan Assembly (P/N 05221000)

Minimum Radiant Tube Length

Minimum Distance from Burner to Elbow or
U-Tube

111111 - -

------11

10' (3 m) 20' (6 m) 20' (6 m) 30' (9 m) 40' (12 m) 40' (12 m) 50' (15 m) 50' (15 m)

10' (3 m) 10' (3 m) 10' (3 m) 15' (4.5 m) 15' (4.5 m) 20' (6 m) 20' (6 m) 20' (6 m)

13

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

8.3 Unitary Linear Heater Layouts
FIGURE 13: Linear Heater Assembly Overview

U-Clips

Fan Assembly

Turbulator

Tube

(With Select Models)

14

Reflector End Cap

Burner

Reflector

Burner Tube

Package

Tube Clamp

Coupling

Tube and Reflector Hanger

Reflector Support

FIGURE 14: Unitary Linear Layout Overviews

LEGEND

f

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

b

c

g

d

Burner

Reflector

Tube

Tube/Reflector
Hanger

Coupling Assembly

Fan Assembly

a = 14" (36 cm)
reflector width (not shown)

b = 2" (5 cm)
end cap to burner/fan

c = 2" (5 cm)
end cap to hanger

d = 7'6" (229 cm)
distance first hanger

e = 10' (305 cm)
distance between hangers

f = 9.5" (24 cm)
burner height

10' (3 m) Tube Length

b

c

g

f

g

f

g

de

20' (6 m) Tube Length

b

c

de

30' (9 m) Tube Length

b

c

de

b

b

e

b

e e

g = 17.5" (44 cm)
burner length

f

40' (12 m) Tube Length

b

c

g

f

de

50' (15 m) Tube Length

e e e

b

15

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 15: Unitary Linear Layout Overviews (Continued)

b

c

g

f

g

f

de

60' (18 m) Tube Length

b

c

de

70' (21 m) Tube Length

e e e e

e e e e e

b

b

b

c

g

f

de

80' (24 m) Tube Length

e e e e e e

b

16

8.4 Unitary U-tube Heater Layouts

CTHN-Series heaters (except CTHN-40) are
approved for optional u-tube configurations.

The u-tube may be installed in either a standard
horizontal position, 45° position or in an opposite 45°
position as shown on Page 5, Figure 5 through
Figure 7. When using a u-tube configuration, the
following additional rules must be adhered to:

FIGURE 16: U-tube Assembly Overview

U-tube

Support Bracket

Reflector

Support

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

• A minimum of 10' (3 m) on CTHN-60/80, a
minimum of 15' (4.5 m) on CTHN-100/125, and a
minimum of 20' (6 m) on CTHN-150/175/200 is
required between the burner and the u-tube.

• For turbulator installation, See Page 21, Step 8.8.

• The burner must never be operated
in a tilted position.

The heater must be properly supported at all
locations. See Page 10, Figure 12.

Burner

Tube Clamp

Package

U-tube, Standard

12

U-tube, Full 45°

2

1

Turbulator

(With Select

Models)

Burner

Tube

Tight U-bolt

12

4" (10 cm) u-bolt,

secured to burner tube

with 1/4" (6 mm)

lockwashers and

1/4-20 hex nuts.

Tube

Couplings

Loose U-bolt

4" (10 cm) u-bolt,

secured to bracket with

1/4" (6 mm) lockwashers

and 1/4-20 hex nuts on

top and bottom to

allow for tube expansion

and contraction.

Reflector

U-clips

Reflector

End Caps

U-tube

18" (457 mm)

Center to Center

U-tube, Opposite 45°

12

U-bolt
Nut
Lock Washer
Lock Washer
Nut

17

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 17: Unitary U-tube Layout Overviews

b

c

20' (6 m)*
Tube Length

30' (9 m)
Tube Length

g

h

b

c

g

h

b

c

g

e

d

f

de

LEGEND

Burner

Reflector

Tube

Tube/Reflector
Hanger

Coupling Assembly

U-tube

Fan Assembly
(not shown)

a = 14" (36 cm)
reflector width (not shown)

40' (12 m)
Tube Length

50' (15 m)*
Tube Length

60' (18 m)
Tube Length

70' (21 m)
Tube Length

b = 2" (5 cm)

h

b

c

g

de

f

h

b

c

g

de

e

h

b

c

g

de

e

f

end cap to burner

c = 2" (5 cm)
end cap to hanger

d = 7'6" (229 cm)
distance first hanger

e = 10' (305 cm)
distance between hangers

f = 5' (153 cm)
distance between last full tube
hanger and half tube hanger

g = 17.5" (44 cm) burner length

h = 9.5" (24 cm) burner height

*20' (6 m) & 50' (15 m) tube length
heaters require the last reflector
before the u-tube to be cut in
half for use on both sides.

h

b

c

g

de

e e

18

80' (24 m)
Tube Length

h

Step 8.5 Burner Tube Installation

S-hook

Hanger

NOTE:

Tubing requires a downward
slope of 1/2" (1.3 cm)
per 20' (6 m) away
from burner.

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

Offset mounting
hole must be
to the top.

Burner Tube

7' 6" ± 1'

(229 cm ± 25 cm)

Description Part Number

Burner Tube 03051XXX
S-hook 91907302
Tube/Reflector Hanger 03090100

Step 8.6 Tube Clamp Package Installation

Description Part Number
Tube Clamp Package 01318901

Tube Clamp 01396801
Bolt 97113940
Flat Washer 95211600
Nut 92113900

Tube Clamp

Flat

Washer

Weld seam
must be to the
bottom of the tube.

Bolt

Nut

(Torque 120 in/lb

13.56 Nm)

19

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 8.7 Coupling and Tube Assembly

Close coupling

A

with tab.

Open

Closed

Tab

Start slide bar/coupling lock

B

onto coupling.

3" (8 cm) to
4" (10 cm)

Slide Bar/Coupling Lock

Wide End

Coupling

Insert tubes into coupling.

C

Orient coupling so that

the impact block is in the

2:00 or 10:00 oclock

positions.

Tube

Tube

Step 8.7.1 Coupling and Tube Assembly (Continued)

Tighten slide bar as shown below.

Drive slide bar until tight.
End of slide bar should be
within tolerance listed below.

Tighten coupling to join tubes.

D

Tube

Description Part Number

Coupling 01329600
Slide Bar/Coupling Lock 01329700
Tube 91409XXX

Slide Bar/Coupling Lock

Coupling

± 2" (5 cm)

Correct Slide Bar

Dimensions

• Repeat Step 8.7, A - D until all tubes are assembled. See Page 21, Step 8.7.2.

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

20

Incorrect Slide Bar

Position

Step 8.7.2 Coupling and Tube Assembly (Continued)

2.3 m .25 m

3 m .25 m

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

Radiant

Model

CTHN-40 10' (4.5 m)
CTHN-60 20' (6 m)
CTHN-80 20' (6 m)
CTHN-100 30' (9 m)
CTHN-125 40' (12 m)
CTHN-150 40' (12 m)
CTHN-175 50' (18 m)
CTHN-200 50' (18 m)

Tube Length

Step 8.8 Turbulator Installation

Turbulator
Section

Turbulator
Adapter

Turbulator section
(stainless) used in
CTHN-40 heaters must be in the
section of tube nearest to the burner.

Description Part Number

Turbulator Adapter 03051503
Turbulator Section 03051504
Turbulator Section (Stainless) 03051505
Tube 91409XXX

Ta b

Turbulator must be installed in the last
standard section of radiant tube.
Turbulator is only required on the

T

w

i

s

t

Fold tab around outside
of tube nearest to the vent to
hold turbulator in place.

CTHN-40, CTHN-60 and CTHN-80.

Model Tube Section

CTHN-40 1st 10' (3 m) Section
CTHN-60 2nd 10' (3 m) Section
CTHN-80 2nd 10' (3 m) Section
CTHN-100 N/A
CTHN-125 N/A
CTHN-150 N/A
CTHN-175 N/A
CTHN-200 N/A

Turbulator Installation

Pull String

21

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 8.9 Reflector Installation

Hanger

Burner Tube

Description Part Number

Tube/Reflector Hanger 03090100
Burner Tube 03051XXX
Reflector 02750303

Reflector

NOTE:

All radiant tube surfaces
must be covered by a reflector,
except for a u-tube. Manifold tube
may or may not be covered.

22

Step 8.9.1 Reflector, U-clip and Reflector Support Installation

The pictorial drawings of the heater construction in
Section 8 are schematic only and provide a general
guideline of where hangers, reflector supports and
u-clips are to be installed.

To ensure proper expansion and contraction
movement of the reflectors, a combination of u-clips

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.

and reflector supports are used. The positioning of

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

Reflector
End Cap

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

Tight

Sheet Metal

Wire Form

Screw

First Reflector

U-clips

Overlap must be a

minimum of 6" (16 cm).

2. The overlap at the first and second reflector is a slip overlap.

Thereafter, every third reflector joint is a slip overlap. A slip
overlap is achieved by either:
a.) both reflectors lay inside a hanger.

(No reflector support needed.)

b.) using a reflector support with

loose screws at the reflector
overlap.

3. The remaining reflector overlaps require a non-slip

overlap connection. To affix the reflectors together in
a non-slip overlap either:
a.) use reflector support and tight screws.
b.) if both reflectors lay inside a hanger, u-clips or

sheet metal screws may be used.

6"

(16 cm)

2 A

Slip Overlap

Reflector Support

Strap

2 B

Slip Overlap

3 A

Non-Slip Overlap

Reflector
Reflector

Support

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

Reflector

This section of three reflectors joined together must
be affixed to the tube with at least one reflector support
with tight screws.

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

Tight

Screws

3 B

Non-Slip Overlap

U-clip

(2 Clips per
Non-slip Overlap
Inside a Hanger)

23

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 8.10 Burner Installation

Burner

Burner must be installed

with the flame observation

window facing down.

Description Part Number

Bolt 94273914
Burner 052XXXXX
Lock Washer 96411600
Gasket 02568200

Lock
Washer

Gasket

S-hook

Burner Tube

Bolt
(Torque 120 in/lb

13.56 Nm)

Step 8.11 Fan Inlet Plate and Warning Tag

Remove this tag and install

the restrictor plate before

assembling fan to the tube.

IMPORTANT!

Remove this tag and install

the restrictor plate before

assembling fan to the tube.

IMPORTANT!

Remove the warning tag and inlet collar
from fan inlet.

24

Step 8.12 Restrictor Plate Installation

Attach restrictor plate (see chart below right) to
fan inlet and replace inlet collar.

Description Part Number

Restrictor Plate 07730XXX

SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION

Model Fan Assy. P/N Restrictor Plate P/N

CTHN-40 05220000 07730400 1.25'' dia
CTHN-60 05220000 07730100 1.50'' dia
CTHN-80 05220000 NONE
CTHN-100 05220000 07730500 2.25'' dia
CTHN-125 05220000 07730500 2.25'' dia
CTHN-150 05220000 07730700 2.75'' dia
CTHN-175 05221000 07730600 2.50'' dia
CTHN-200 05221000 NONE

Step 8.13 Fan Installation

Last Tube

Turbulator not required
for all models. (See Page 21,
Step 8.8 for details.)

Description Part Number

Fan Assembly 40 -150 05220000
Fan Assembly 175-200 05221000

Fold tab around outside
of tube nearest to the
vent to hold turbulator
in place.

Tighten securely
until tube cannot
be removed.

Vent Adapter

Remove warning tag from fan inlet
and install restrictor plate if required.
See Step 8.12.

Fan Assembly

25

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 9: MULTIBURNER HEATER INSTALLATION

9.1 Standard Parts
Table 6: Contents of CTHN Burner Carton

Part No. Description CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200

052XXXXX Burner (Rate and Fuel Varies)

07730400 Restrictor Plate 1.25'' (3.2 cm) dia.

07730100 Restrictor Plate 1.50'' (3.8 cm) dia.

07730500 Restrictor Plate 2.25'' (5.7 cm) dia.

07730600 Restrictor Plate 2.50'' (6.4 cm) dia.

07730700 Restrictor Plate 2.75'' ( 7 cm) dia.

03051503 Turbulator Adapter

03051504 Turbulator Section

03051505 Turbulator Section, Stainless Steel

*91412200 Flexible Stainless Steel Gas Hose , 1/2'' NPT

(US Models Only)

*91412203 Flexible Stainless Steel Gas Hose , 3/4'' NPT

(US Models Only)

02568200 Gasket (Burner to Burner Tube)

94273914 Hex Head Cap Screw 5/16'' -18 x 7/8''

96411600 Split Lock Washer

91201708 Pipe Nipple 1/2'' NPT x 4''

152101NA Installation, Operation and Service Manual

111 1 1 1 1 1

1- - - - - - -

-1- - - - - -

--- 1 1 - - -

--- - - - 1 -

--- - - 1 - -

111 - - - - -

244 - - - - -

1- - - - - - -

111 1 1 - - -

--- - - 1 1 1

111 1 1 1 1 1

444 4 4 4 4 4

444 4 4 4 4 4

111 1 1 1 1 1

111 1 1 1 1 1

*Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory. See Page 69, Section 16.

Table 7: Contents of Core and Extension Packages

Core Packages Extension Packages

Hot Rolled Aluminized Hot Rolled Aluminized

Part No. Description

91409300

91409408

03051101

03051601

Tube, Hot Rolled Steel, 10

Tube, HT Aluminized, 10

'

(3 m)

'

(3 m)

Burner Tube, ALUMI-THERM

Burner Tube, HT ALUMI-THERM® Steel, 10' (3 m)

01312700 Coupling Assembly

02750303

Standard Reflector, 8

'

(2.4 m)

02750800 End Cap

03090100 Tube and Reflector Hanger

91907302 S-hook

03050010 Reflector Support Package

(Strap, Wire Form, Screws)

91107720 U-clip Package

®

Steel, 10' (3 m)

20

'

30

'

40

'

10

'

20

'

30

'

40

'

10

'

20

'

30

'

40

'

10

'

20

(6m)

(9m)

(12m)

(3m)

(6m)

(9m)

(12m)

(3m)

(6m)

(9m)

(12m)

(3m)

'

(6m)

123----1234----

----123----1234

-11--11--------

1--11----------

123-12312341234

346234623462346

2222222 --------

345234512341234

345234512341234

235123523462346

111111111111111

30

(9m)

'

40

'

(12m)

90502700 Vent Adapter (Not used on CTHN)

01318901

Tube Clamp Package

26

1111111 --------

1111111 --------

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

Table 8: Component Package Guide

Model

CTHN-40 20' (6 m) CP20HRS CP10ALUM

CTHN-60 30' (9 m) CP30HRS CP20ALUM

CTHN-80 30' (9 m) CP30HRS CP20ALUM

CTHN-100 40' (12 m) CP40HRS CP30ALUM

CTHN-125 50' (15 m) CP30HRS + EXP20HRS CP40ALUM

CTHN-150 50' (15 m) CP30HRS + EXP20HRS CP40ALUM

CTHN-175 60' (18 m) CP30HRS + EXP30HRS CP30ALUM + EXP30ALUM

CTHN-200 60' (18 m) CP30HRS + EXP30HRS CP30ALUM + EXP30ALUM

Tubing Length Core Packages

Minimum Standard Aluminized

Additional tubing length may be added to heater.
Any additional tubing lengths are considered as manifold tube length for length determination, See Page 29,
Section 9.2 through Page 31, Section 9.6, design requirements and allowed manifold tube lengths.
For manifold tubing on multiburner systems, heat-treated aluminized or porcelain coated tubing is required.

Table 9: Common CTHN-Series Components

Part No. Description

Tubing and Related Accessories

01312700 Coupling, 4" (10 cm) Plain
01312706 Coupling, 6" (15 cm) Plain

0131270I Coupling, 4" (10 cm) Lined
01331900 Coupling, 4" (10 cm) Damper
E0009356 Coupling, 6" (15 cm) Damper
0133022D Tee, 4" (10 cm) Coated
01330203 Tee, 4" (10 cm) Aluminized
01330204 Tee, 6" (15 cm) Aluminized
0133092D Cross, 4" (10 cm) Coated
01330903 Cross, 4" (10 cm) Aluminized
01330904 Cross, 6" (15 cm) Aluminized
01335801 Elbow, 4" (10 cm) Aluminized 90°
T0100320 Elbow, 6" (15 cm) Aluminized 90°
0133580D Elbow, 4" (10 cm) Coated 90°
01336101 Elbow, 4" (10 cm) Aluminized 45°
0133610D Elbow, 4" (10 cm) Coated 45°
91409300 Tube, 4" (10 cm) dia Hot Rolled Steel 10' (3 m)
91409403 Tube, 4" (10 cm) dia Non-Heat Treated Aluminized

10' (3 m)

91409408 Tube, 4" (10 cm) dia Heat Treated Aluminized

10' (3 m)

91409420 Tube, 6" (15 cm) dia Non-Heat Treated Aluminized

10' (3 m)
9141030D Tube, 4" (10 cm) dia Coated 10' (3 m)
E0009105 Tube, 6" (15 cm) dia 10' (3 m)

Heat Treated Aluminized
91418200 Tube Adapter, 6" (15 cm) dia x 4"(10 cm) dia

Aluminized
91240010 Tube Hanger, 6" (15 cm)
91308001 Pipe Compound, High Temperature 1lb can

Venting Accessories

01324401 Air Supply Takeoff, 4" (10 cm) Outside
90707501 Air Supply Blower/Power Venter
91409601 Air Flex Duct, 4" (10 cm) Outside

(Box of 8 - 8' (2.4 m) sections)

Reflectors and Related Accessories

01329910 Reflector Side Extension Support
03050010 Reflector Support Package (Tubing)
02712700 Reflector Side Extension, 2 Clips, 2 Screws
02750303 Reflector, Aluminum

027503SS Reflector, Stainless Steel

02750800 Reflector End Cap, Aluminum
027508SS Reflector End Cap, Stainless Steel
027508SH Reflector End Cap, Stainless Steel with Hole

02750900 Reflector Joint
027509SS Reflector Joint, Stainless Steel
027127SS Reflector Side Extension, Stainless Steel

03090100 Tube and Reflector Hanger

91907302 S-hook

91903201 Turnbuckle

91903300 Spring Hook

91903202 Turnbuckle with Eyebolt

Thermostats

02770002 System Control

05023000 Load Relay Package

90417600 Transformer Relay - SPST (12 A)

90436300 Transformer Relay - DPST (12 A)

90423000 Thermostat, 24 V Low Voltage (Marked 1-5)

90424300 Thermostat Guard

Deco Grille (1' x 8' [.3 m x 2.4 m])

01363003 Bracket

01365901 End Piece

27

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

01326801 Reinforcement
01365903 Joint Piece
91406700 1' x 8' (.3 m x 2.4 m) Protective Grille

Deco Grille (2' x 4' [.6 m x 1.2 m])

01365900 Shield Frame
01370408 Reflector Side Extension 8" x 48" (20 cm x 122 cm)
01370412 Reflector Side Extension 12" x 48" (30 cm x 122 cm)
01370416 Reflector Side Extension 16" x 48" (40 cm 122 cm)
91407000 Grille, Aluminum 2' x 4' (.6 m x 1.2 m)

Protective Grille

08050001 Grille, 40" (102 cm) Protective
08050002 Protective Grille End Cap

Fan and Pump Packages

05220000 Fan Package 40-150
05221000 Fan Package 175-200
02719105 EP-100 Pump Package

02719100 EP-100 Pump
02724700 Accessory Package

02716305 EP-201 Pump Package

01312001 EP-201 Pump
01317805 Accessory Package

02712034 EP-203 Pump Package

01312002 EP-203 Pump
01317805 Accessory Package
02723014 EP-301 Pump Package 4" (10 cm)
02730101 EP-301 Pump Assembly
02730104 Accessory Package
02723016 EP-301 Pump Package 6" (15 cm)
02730101 EP-301 Pump Assembly
02730106 Accessory Package
02723034 EP-303 Pump Package 4" (10 cm)
02730103 EP-303 Pump Assembly
02730104 Accessory Package
02723036 EP-303 Pump Package 6" (15 cm)
02730103 EP-303 Pump Assembly
02730106 Accessory Package

Pump Accessories

90430600K Pressure Switch

Starters and Contactors

10050001 Starter, 120 Vac for EP-203, 3 Ø
10050003 Starter, 120 Vac for EP-201, 1 Ø
10050008 Starter, 120 Vac for EP-301, 1 Ø
10050009 Contactor Package-

120 Vac Coil for EP-301, 230 V, 2 HP

10050010 Starter, 120 Vac for EP-303, 3 Ø

28

9.2 Multiburner System Design Requirements

A CTHN multiburner system has a number of radiant
tube sections interconnected by manifold tube to a
pump to form a complete system. Reflectors can be
used over the manifold tube but are not required.
The system design parameters are such that the
manifold sections are not subjected to condensate
when the system is fully heated up. It is required that
heat-treated aluminized or coated tubing is used for
the manifold to increase system life and to handle
initial condensation during start-up. Damper
couplings may be necessary to balance system
vacuum.

Design requirements for a CTHN multiburner system

CTHN multiburner heaters are typically shipped as
burner packages and tube and accessory packages.
The tube and accessory packages contain enough
tube, reflector and hanging parts for the radiant
section of one CTHN heater. Elbows, tees, manifold
tube, pumps, controls, damper couplings and any
other parts used beyond the burner, radiant tube and
reflector must be purchased separately. See Figure
18 for a general overview of a simple CTHN
multiburner system. Depending on system
requirements, CTHN multiburner systems may be
controlled by either a ROBERTS GORDON
Control (shown) or by a relay system.

are summarized on Page 30, Table 10.

FIGURE 18: Typical CTHN Multiburner System Installation

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

®

System

Zone 1 Thermostat

T

System Control (optional)

Pressure Switch

Pump

Exhaust to

Outside

Turbulator (if required)

Cross

Radiant Tube

Burners

Optional Reflector

Te e

Manifold Tube

Drawing Not to Scale

T

Zone 2 Thermostat

29

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Table 10: Multiburner Design Requirements

Burner Model: CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200

Radiant Tube Length 20' (6 m) 30' (9 m) 30' (9 m) 40' (12 m) 50' (15 m) 50' (15 m) 60' (18 m) 60' (18 m)

Minimum Manifold Tube Length per Burner 3' (1 m) 3' (1 m) 3' (1 m) 6' (2 m) 6' (2 m) 10' (3 m) 10' (3 m) 10' (3 m)

Maximum Manifold Tube Length per
Burner

Minimum Distance from Burner to Elbow
or U-tube

Elbows Allowed per Burner* 2 2 2 2 2 2 2 2

30' (9 m) 35' (10.5 m) 40' (12 m) 45' (13.5 m) 50' (15 m) 55' (16.5 m) 60' (18 m) 60' (18 m)

10' (3 m) 10' (3 m) 10' (3 m) 15' (4.5 m) 15' (4.5 m) 20' (6 m) 20' (6 m) 20' (6 m)

* U-tube = 2 elbows

9.3 Burners Per Pump

1. The maximum number of burners per pump is
shown in Ta b l e 11 .

2. When combining different burner inputs in a
system, the number of burners per pump (0' ­2,000' altitude) is given by the sum of their
inputs:

b. EP-200 up to 750,000 Btu/h max, but not

more than 6 burners.

c. EP-300 up to 1,600,000 Btu/h max, number

of burners is limited to the maximum
number of burners listed in Ta b l e 11 for the
largest input model used.

a. EP-100 up to 500,000 Btu/h max, but not

more than 4 burners.

Table 11: Number of Burners Allowed Per Pump

Pump Model Altitude CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200

0' - 2,000' 4 4 4 4 4 3 2 2

2,001' - 3,000' 4 4 4 4 3 3 2 2

3,001' - 4,000' 4 4 4 4 3 2 2 2

EP-100

EP-200 Series

EP-300 Series

4,001' - 5,000' 4 4 4 4 3 2 2 2

5,001' - 6,000' 4 4 4 4 3 2 2 2

6,001' - 7,000' 4 4 4 3 3 2 2 2

7,001' - 8,000' 4 4 4 3 3 2 2 1

8,001' - 9,000' 4 4 4 3 2 2 2 1

0' - 2,000' 6 6 6 6 6 5 4 4

2,001' - 3,000' 6 6 6 6 6 5 4 3

3,001' - 4,000' 6 6 6 6 5 4 4 3

4,001' - 5,000' 6 6 6 6 5 4 4 3

5,001' - 6,000' 6 6 6 6 5 4 3 3

6,001' - 7,000' 6 6 6 6 5 4 3 3

7,001' - 8,000' 6 6 6 6 5 4 3 3

8,001' - 9,000' 6 6 6 6 5 4 3 3

0' - 2,000' 16 16 14 12 12 10 8 8

2,001' - 3,000' 16 16 14 12 12 9 8 7

3,001' - 4,000' 16 16 14 12 11 9 8 7

4,001' - 5,000' 16 16 14 12 10 9 7 6

5,001' - 6,000' 16 16 14 12 10 8 7 6

6,001' - 7,000' 16 16 14 12 10 8 7 6

7,001' - 8,000' 16 16 14 12 10 8 6 6

8,001' - 9,000' 16 16 14 12 10 8 6 6

30

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

9.4 Radiant Tube Length

The radiant tube length fixed for each burner is
shown on Page 30, Table 10.

9.5 Manifold Tube

Any tube beyond the radiant tube length is
considered manifold. Manifold tube can be used to
lengthen tube runs beyond the radiant tube length; to
connect multiple runs of tubing and connect the
system to the pump. Minimum and maximum

manifold tube lengths are shown on Page 30,
Ta b l e 10. The table must be used in conjunction

with the additional rules for the diameter and
length of manifold in a system, as described on

Page 31, Section 9.5.1 through Page 35, Section

9.6.3.

9.5.1 Manifold Diameter

1. Manifold diameter for systems containing less
than 320,000 Btu/h input can be 4" (10 cm) or
6" (15 cm).

2. Manifold diameter for systems containing
320,000 Btu/h input and greater must be 6"
(15 cm).
Exception: If total manifold tube length is 70'
(21 m) or less, 4" (10 cm) diameter manifold
tube can be used for systems up to
800,000 Btu/h.

9.6 Multiburner System Layouts and Manifold
Tube Length Rules

Most CTHN multiburner layouts can be classified as
one of the following five layout types:

Flag, Modified In-Series, T, Fork or Herringbone.
Please refer to Page 31, Section 9.6.1 through Page
35, Section 9.6.3 for explanation of manifold rules
and basic diagrams of each layout type. The
diagrams show very simple examples of each layout
type. Actual layouts will vary in total number of
burners in the system as well as the overall shape of
the system. Additional pieces such as elbows may
change the overall layout appearance but are usually
considered a variant of one of the five multiburner
layout types.

9.6.1 Flag and Modified In-Series Layouts and
Manifold Tube Length Rules

See Page 32, Figure 19 through Page 32, Figure 20
for diagrams of Flag and Modified In-Series layouts.
Minimum and maximum manifold tube length applies
to all tubing between the end of a radiant tube run
and a tee or cross; all tubing between any tees and/
or crosses; and all tubing between the last tee or
cross and the pump. See Page 30, Table 10.

Example: Consider a Flag or Modified In-Series
layout with five CTHN-100 burners. Page 30, Table 10
shows a minimum of 6' (2 m) and a maximum of 45'
(13.5 m) of manifold tube required per burner.
Therefore the entire five-burner system must have
between 30' (10 m) and 225' (69 m) of manifold
tubing. The manifold tubing is in addition to the 40'
(12 m) of radiant tube per burner. Radiant tube may
end at a tee, or runs may be lengthened by adding
some manifold tube between the end of the radiant
tube and a tee. Each burner in the system (except for
the burner furthest from the pump) must use a
damper coupling to properly adjust the vacuum at
each burner. The damper coupling may be placed
anywhere between the end of the radiant pipe and
the tee.

31

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 19: Flag Layout FIGURE 20: Modified In-Series Layout

Multiple rows of burners:
pump placed at the end of the manifold tube.

Burner furthest from pump
does not need a damper coupling.

First Tee

Manifold tube
between radiant
tube ends.

Multiple burners:
pump placed at the end of the manifold tube.
A variation on the flag layout.

First Tee

Burner

Last Tee

Pump

Burner

Last Tee

Manifold tube
between joining
tee and pump.

Pump

32

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

9.6.2 T and Fork Layouts and Manifold Tube
Length Rules

See Page 33, Figure 21 through Page 34, Figure 22
for diagrams of T and Fork layouts. The T and Fork
layouts have a tee or cross (called the "last tee" or
"last cross") where the combustion gases in the
system enter the tee or cross with directly opposing
flow directions, which creates an added source of
pressure drop in the system. This additional source
of pressure drop requires some difference in how the
allowed manifold length is calculated. In this case,
we have to differentiate manifold tube that is located
between the radiant pipe and the last tee (or cross)
from manifold tube that is located between the last
tee (or cross) and the pump.

First determine the length of manifold tube between
the radiant tube end and the last tee (or cross). Do
not count any tube length twice. Now refer to Page
30, Table 10 and find the maximum manifold tube
length for each burner. Add together the maximum

manifold tube length on the table for each burner in
the system, this is the maximum manifold tube length
for the entire system.

To determine the maximum manifold tube allowed
between the last tee (or cross) and the pump:
Subtract the manifold tube length between the
radiant tube and the last tee (or cross) from the
maximum manifold length for the entire system, then
divide that number by 1.5.

Example: Consider a T layout with two CTHN-100
burners. See Page 33, Figure 21. Assume that 15'
(4.5 m) of manifold was used from each radiant tube
end to the last tee. Page 30, Table 10 indicates that
each CTHN-100 burner can have a maximum of 45'
(13.5 m) of manifold tube. Therefore the maximum
manifold tube length amount allowed between the
last tee and the pump in this case is
([45' + 45']-[15' x 2])/1.5 = 40' or in metric,
([13.5 m + 13.5 m]-[4.5 m x 2])/1.5 = 12 m.

FIGURE 21: T Layout

One pair of burners.

Last Tee

Manifold tube between joining tee
and pump.

Pump

Burner

33

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 22: Fork Layout

Multiple rows of burners:
Manifold tube between the last tee or cross and
the pump is perpendicular to the manifold tube
joining the rows. Pump is not required to be
placed in the center of the system (as shown).

Pump

Damper Couplings

located at the end of

the rows.

Radiant Tube

Burner

Manifold tube between

radiant tube ends.

Manifold tube between

joining cross and pump.

Tee (2)

Last Cross

34

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

9.6.3 Herringbone Layout and Manifold Tube
Length Rules

The herringbone layout is essentially several T
layouts stacked together. Therefore, the same
principle for manifold tube calculation as used for T
layouts is used for herringbone layouts, with one
exception. In a herringbone layout, the manifold
tube length between tees (or crosses) as well as
between the last tee (or cross) and the pump is
calculated by dividing by 1.5 as shown in the T
example on Page 33, Section 9.6.2. The only
manifold tube length in a herringbone layout that is
not divided by 1.5 is any manifold tube length located
between the end of the radiant tube and a tee or
cross.

Example: Consider a herringbone layout similar to
the layout on the left in Figure 23, having ten CTHN­100 burners. Assume that each heater has 40' (12m)
of radiant tube and 10'(3m) of manifold tube before

FIGURE 23: Herringbone Layout

the connecting tee or cross.

According to Ta b l e 10 each burner must have at least
40' (12m) of radiant tube, also each burner must
have between 6' (2m) and 45' (13.5m) of manifold
tube. Each burner has already met the minimum
manifold pipe requirement due to the 10' (3m) of
manifold tube before the connecting tees and
crosses. The maximum manifold tube length for the
entire system is 10 burners X 45' (13.5m) = 450'
(135m). Subtract the 100' (30m) that has already
been used before the connecting tees/crosses and
350' (105m) remains.

Since the remaining manifold is located either
between or after connecting tees or crosses, the
manifold length must be divided by 1.5. 350' (105m)/

1.5 = 233' (70m). Therfore, up to 233' (70m) can be
used between the branches and also between the
last cross and the pump.

Multiple opposing rows of burners: pump placed at the end of the manifold tube or somewhere between
the burners.

Te e

Manifold tube between
radiant tube ends.

Last Tee

Burner

Te e

Cross (3)

Pump

Last Cross

Manifold tube
between joining
tee and pump.

Pump

35

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 9.7 Burner Tube Installation

S-hook

Hanger

NOTE:

Tubing requires a downward
slope of 1/2" (1.3 cm)
per 20' (6 m) away
from burner.

Offset mounting
hole must be
to the top.

Burner Tube

7' 6" ± 1'

(229 cm ± 25 cm)

Description Part Number

Burner Tube 03051XXX
S-Hook 91907302
Tube/Reflector Hanger 03090100

Step 9.8 Tube Clamp Package Installation

Description Part Number
Tube Clamp Package 01318901

Tube Clamp 01396801
Bolt 97113940
Flat Washer 95211600
Nut 92113900

Tube Clamp

Flat

Washer

Weld seam
must be to the
bottom of the tube.

Bolt

36

Nut

(Torque 120 in/lb

13.56 Nm)

Step 9.9 Coupling and Tube Assembly

Close coupling

A

with tab.

Open

Closed

Tab

Start slide bar/coupling lock

B

onto coupling.

3" (8 cm) to
4" (10 cm)

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

Slide Bar/Coupling Lock

Wide End

Coupling

Insert tubes into coupling.

C

Orient coupling so that

the impact block is in the

2:00 or 10:00 oclock

positions.

Tube

Tube

Step 9.9.1 Coupling and Tube Assembly (Continued)

Tighten slide bar as shown below.

Drive slide bar until tight.
End of slide bar should be
within tolerance listed below.

Tighten coupling to join tubes.

D

Tube

Description Part Number

Coupling 01329600
Slide Bar/Coupling Lock 01329700
Tube 91409XXX

Slide Bar/Coupling Lock

Coupling

± 2" (5 cm)

Correct Slide Bar

Dimensions

• Repeat Step 9.9 on Page 37, A - D until all tubes are assembled. See Page 38, Step 9.9.2.

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

Incorrect Slide Bar

Position

37

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 9.9.2 Coupling and Tube Assembly (Continued)

2.3 m .25 m

3 m .25 m

Radiant

Model

CTHN-40 10' (4.5 m)
CTHN-60 20' (6 m)
CTHN-80 20' (6 m)
CTHN-100 30' (9 m)
CTHN-125 40' (12 m)
CTHN-150 40' (12 m)
CTHN-175 50' (18 m)
CTHN-200 50' (18 m)

Tube Length

Step 9.10 Turbulator Installation

Turbulator
Section

Turbulator
Adapter

Turbulator section
(stainless) used in
CTHN-40 heaters must be
in the section of tube nearest
to the burner.

Description Part Number

Turbulator Adapter 03051503
Turbulator Section 03051504
Turbulator Section (Stainless) 03051505
Tube 91409XXX

Ta b

Turbulator must be installed in the last
standard section of radiant tube.
Turbulator is only required on the

T

w

i

s

t

Fold tab around outside
of tube nearest to the vent to
hold turbulator in place.

CTHN-40, CTHN-60 and CTHN-80.

Model Tube Section

CTHN-40 1st 10' (3 m) Section
CTHN-60 2nd 10' (3 m) Section
CTHN-80 2nd 10' (3 m) Section
CTHN-100 N/A
CTHN-125 N/A
CTHN-150 N/A
CTHN-175 N/A
CTHN-200 N/A

Turbulator Installation

Pull String

38

Step 9.11 Reflector Installation

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

Hanger

Burner Tube

Description Part Number

Tube/Reflector Hanger 03090100
Burner Tube 03051XXX
Reflector 02750303

Reflector

NOTE:

All radiant tube surfaces
must be covered by a reflector,
except for a u-tube. Manifold tube
may or may not be covered.

39

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 9.11.1 Reflector, U-clip and Reflector Support Installation

The pictorial drawings of the heater construction in
Section 9 are schematic only and provide a general
guideline of where hangers, reflector supports and
u-clips are to be installed.

To ensure proper expansion and contraction
movement of the reflectors, a combination of u-clips

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.

and reflector supports are used. The positioning of

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

Reflector
End Cap

Wire Form

Tight

Sheet Metal

Screw

First Reflector

U-clips

Overlap must be a

minimum of 6" (16 cm).

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

(No reflector support needed.)

b.) using a reflector support with

loose screws at the reflector
overlap.

3. The remaining reflector overlaps require a non-slip
overlap connection. To affix the reflectors together in
a non-slip overlap either:
a.) use reflector support and tight screws.
b.) if both reflectors lay inside a hanger, u-clips or

sheet metal screws may be used.

6"

(16 cm)

2 A

Slip Overlap

Reflector Support

Strap

2 B

Slip Overlap

3 A

Non-Slip Overlap

Reflector
Reflector

Support

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

Reflector

This section of three reflectors joined together must
be affixed to the tube with at least one reflector support
with tight screws.

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

40

Tight

Screws

3 B

Non-Slip Overlap

U-clip

(2 Clips per
Non-slip Overlap
Inside a Hanger)

Step 9.12 Burner Installation

Burner

Burner must be installed

with the flame observation

window facing down.

Description Part Number

Bolt 94273914
Burner 052XXXXX
Lock Washer 96411600
Gasket 02568200

Lock
Washer

SECTION 9: MULTIBURN ER HEATER I NSTALLATION

Gasket

S-hook

Burner Tube

Bolt
(Torque 120 in/lb

13.56 Nm)

41

CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 10: OPTIONAL HEATER ACCESSORIES

10.1 Elbow Package Configuration
Step 10.1.1 Elbow Installation

Tube

Description Part Number
Elbow Package 02718702

90° Elbow 01335801
Coupling 01312700
Reflector End Cap 02750800
Reflector Joint Piece 02750900
U-Clip Package 91107720

Step 10.1.2 Elbow Installation

Coupling

90° Elbow

Coupling

Minimum Distance Required Between
Burner and Elbow

Minimum

Model

CTHN-40 10' (3 m)
CTHN-60 10' (3 m)
CTHN-80 10' (3 m)
CTHN-100 15' (4.5 m)
CTHN-125 15' (4.5 m)
CTHN-150 20' (6 m)
CTHN-175 20' (6 m)
CTHN-200 20' (6 m)

Distance

Tube

Step 10.1.3 Reflector Joint Installation

Reflector

Scribe
Contour

42

Reflector
Joint

Flatten Edge

1" (2.5 cm)
Maximum