Roberts Gorden VANTAGE CTH3-80, VANTAGE CTH3-150, Vantage Modulating CTH3-80, VANTAGE CTH3-115, Vantage Modulating CTH3-150 Installation, Operation & Service Manual

...

Page 1

FOR YOUR SAFETY

WARNING

Installation must be done by a 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.

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. Extinguish any open flame.

6. Leave the building.

7. Immediately call your local gas supplier after leaving the building. Follow the gas supplier’s instructions.

8. If you cannot reach your gas supplier, call the Fire Department.

Gas-Fired, Low Intensity

WARNING

Fire Hazard

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

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.

Unitary Heater

Installation, Operation &

Service Manual

CTH3-80 CTH3-115 CTH3-150 CTH3-200

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. Bo x 4 4 Buffalo, New York 14240-0044 Telephone: +1.716.852.4400 Fax: +1.716.852.0854 Toll Free: 800.828.7450

www.rg-inc.com www.radiantheaters.com

P/N 134100NA Rev K 02/12

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Roberts-Gordon LLC

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

TABLE OF CONTENTS

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

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

1.2 Safety Labels and Their Placement ............................. 1

1.3 California Proposition 65 .............................................. 1

SECTION 2: Installer Responsibility ..................................... 4

2.1 Wall Tag .......................................................................4

2.2 Corrosive Chemicals.................................................... 4

2.3 National Standards and Applicable Codes ..................4

SECTION 3: Clearances to Combustibles............................. 5

3.1 Required Clearances to Combustibles.........................5

SECTION 4: National Standards and Applicable Codes .....9

4.1 Gas Codes................................................................... 9

4.2 Aircraft Hangars ........................................................... 9

4.3 Public Garages ............................................................9

4.4 Electrical ...................................................................... 9

4.5 Venting.........................................................................9

4.6 High Altitude ................................................................ 9

SECTION 5: Major Components .......................................... 10

5.1 Standard Parts List .................................................... 11

SECTION 6: Heater Installation............................................ 12

6.1 Burner Tube Installation ............................................ 16

6.2 Tube Clamp Package Installation..............................16

6.3 Coupling and Tube Assembly....................................17

6.4 Turbulator Installation ................................................18

6.5 Reflector Installation .................................................. 19

6.6 Burner Installation...................................................... 21

SECTION 7: Optional Heater Accessories.......................... 22

7. 1 U - Tube Configuration..................................................22

7.2 Elbow Package Configuration.....................................25

7.3 Reflector Side Extension ............................................27

7. 4 L o wer Clearance Shield Installation ...........................28

7. 5 Two-Foot Decorative Grille Installation .......................28

7.6 Protective Grille Installation ........................................30

SECTION 8: Venting.............................................................. 31

8.1 Venting.......................................................................31

8.2 Unvented Operation................................................... 31

8.3 Horizontal Venting......................................................32

8.4 Vertical Venting..........................................................32

8.5 Unvented Operation Tube Termination ......................32

8.6 Length Requirements ................................................32

8.7 Horizontal Ventilation 4" (10 cm) Pipe........................32

8.8 Vertical Ventilation 4" (10 cm) Pipe ............................33

8.9 Common Side Wall Venting ....................................... 33

8.10 Common Vertical Venting ........................................34

8.11 Outside Combustion Air Supply ...............................35

SECTION 9: Gas Piping........................................................ 37

SECTION 10: Wiring.............................................................. 39

10.1 Standard Heater Configuration ................................ 39

10.2 Central and Satellite Heaters (Zoning Capability).... 40

10.3 Communication Wiring within a Zone of Heaters..... 42

10.3 Communication Wiring within a Zone of Heaters

(continued).............................................................. 43

10.4 Heat Demand Control Wiring................................... 44

10.5 Internal Wiring.......................................................... 52

10.6 Ladder Diagram ....................................................... 53

10.7 Line Voltage Power Wiring....................................... 54

10.8 Electrical Connection to the Burner ......................... 54

10.9 Low Voltage Control Wiring Installation.................... 55

SECTION 11: Operation and Maintenance.......................... 56

11.1 S e q uence of Operation ............................................ 56

11.2 To Shut Off Heater.................................................... 56

11.3 To Start Heater ......................................................... 56

11.4 Pre-Season Maintenance and Annual Inspection..... 56

SECTION 12: Troubleshooting............................................. 59

12.1 Control LED ............................................................. 60

12.2 General LED Codes ................................................ 60

12.3 Troubleshooting Flow Chart ..................................... 62

12.4 Manifold Gas Pressure Measurement...................... 64

12.5 Pneumatic Connections........................................... 65

SECTION 13: Replacement Parts ........................................ 66

SECTION 14: General Specifications .................................. 69

14.1 Material Specifications............................................. 69

14.2 Heater Specifications............................................... 69

14.3 Suspension Specifications....................................... 69

14.4 Controls Specifications ............................................ 69

SECTION 15: The ROBERTS GORDON

MODULATING Warranty................................ 71

VANTAGE®

There are references in this manual to various trademarks. All trademarks mentioned herein, whether registered or not, are the property of their respective owners. Roberts-Gordon LLC is not sponsored by or affiliated with any of the trademark or registered trademark owners, and make no representations about them, their owners, their products or services. Roberts-Gordon LLC is not sponsored by or affiliated with BACnet® or LonWorks®.

Prin ted in U.S.A.

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Page 5

TABLE OF FIGURES

Figure 1: Top and Bottom Panel Label Placement ....................2

Figure 2: Side and Back Panel Label Placement...................... 3

Figure 3: Standard Reflector .....................................................5

Figure 4: One Side Reflector.....................................................6

Figure 5: Two Side Reflectors ................................................... 6

Figure 6: 45° Tilt Reflector ........................................................ 6

Figure 7: U-Tube, Standard Reflector........................................ 7

Figure 8: U-Tube, 45°................................................................ 7

Figure 9: U-Tube, Opposite 45° Reflector .................................7

Figure 10: 2-Foot Deco Grille and Protective Grille ................... 8

Figure 11: Lower Clearance Shield ........................................... 8

Figure 12: Venting ..................................................................... 8

Figure 13: Major Component Descriptions.............................. 10

Figure 14: Critical Hanger Placement ..................................... 13

Figure 15: Linear Heater Assembly Overview ........................ 14

Figure 16: Linear Heater Layout Overview.............................. 15

Figure 17: U-Tube Heater Assembly Overview ......................23

Figure 18: U-Tube Heater Layout O

Figure 19: Reflector Joint Detail ..............................................26

Figure 20: Tube Termination................................................... 32

Figure 21: Gas Connection with Flexible Gas Hose ...............38

Figure 22: Zone Sensor Wiring Diagram.................................39

Figure 23: Central Heater Jumper Settings.............................40

Figure 24: Satellite Heater Jumper Setting..............................41

Figure 25: Communication Wiring within a Zone of Heaters ... 42 Figure 25: Communication Wiring within a Zone of Heaters

(continued)............................................................. 43

Figure 26: Thermostat Control Wiring Diagram....................... 44

Figure 27: Analog Control Signal Wiring Diagram................... 47

Figure 28: Potentiometer Control Wiring Diagram...................48

Figure 29: Modulating Thermostat Wiring Diagram

(LonWorks

[4-20 mA] optional).............................49

Figure 30: Modulating Thermostat Wiring Diagram

(LonWorks® [2-10Vdc with 500 Ohm resistor]

optional).................................................................50

Figure 31: Modulating Thermostat Wiring Diagram

with BACnet

(optional) .........................................51

verview ........................... 24

LIST OF TABLES

Table 1: Contents of Burner Carton........................................ 11

Table 2: Contents of Core and Extension Packages .............. 11

Table 3: CTH3-Series Component Package Guide ................11

Table 4: Cable Requirements ................................................. 46

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SECTION 1: HEATER S AFETY

SECTION 1: HEATER SAFETY

Yo ur 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.

Protective gear is to be worn during installation, operation and service. Thin sheet metal parts, including the aluminum 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.

This heater must be applied and operated under the general concepts of reasonable use and installed using best building practices. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do no play with the appliance.

For additional copies of the Installation, Operation and Service Manual, please contact Roberts-Gordon LLC.

1. 1 M an p o we r R e

quirements

To p revent personal injury and damage to the heater, two persons will be required for installation.

1.2 Safety Labels and Their Placement

the product user when they are no longer legible. Please contact Roberts-Gordon LLC or your ROB-

ERTS GORDON

independent distributor to obtain replacement signs or labels. See Page 2, Figure 1 through Page 3, Figure 2.

1.3 California Proposition 65

In accordance with California Proposition 65 require- ments, a warning label must be placed in a highly visible location on the outside of the equipment (i.e., near equipment’s serial plate). See label placement drawing on Page 2, Figure 1 for label location. Avoid placing label on areas with extreme heat, cold, corrosive chemicals or other elements. To order additional labels, please contact Roberts-Gordon LLC or your ROBERTS GORDON

independent distributor.

Product safety signs or labels should be replaced by

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Logo Label

Rating Plate Label

Bottom Panel

Top Panel

Gas Connection Label

Proposition 65 Label

Description Part Number

Logo Label 91013212 Rating Plate Label 91010401 Gas Connection Label 91018122 Proposition 65 Label 91070015

FIGURE 1: Top and Bottom Panel Label Placement

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FIGURE 2: Side and Back Panel Label Placement

Lighting Instruction Plate Label

Vent Length Label

Carbon Monoxide Hazard Label

Back Panel

Inside Bottom Panel

Low Voltage Connection Label

COM

N.O.

Description Part Number

Clearances to Combustibles Label 91013415 Wiring Label 91013303 Carbon Monoxide Hazard Label 91039501 Low Voltage Connection Label 91039700 Vent Length Label 91039500 Lighting Instruction Plate Label 91029602

Control Side Panel

SECTION 1: HEATER S AFETY

Clearances to Combustibles Label

Control Side Panel (Inside) Wiring Label

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

CAUTION

Product Damage Hazard

Do not use heater in area containing corrosive chemicals.

Refer to appropriate Material Safety Data Sheets (MSDS).

Failure to follow these instructions can result in product damage.

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 LLC 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.

• 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.

on the burner and in the Installation, Operation and Service Manual. See Page 5, Figure 3 through Page 8, Figure 12. Write the proper clearance dimensions in permanent ink according to your model number and configuration in the open spaces on the tag.

2.2 Corrosive Chemicals

• To never use heater as support for a ladder or other access equipment and never hang or sus- pend anything from heater.

• To ensure there is adequate air circulation arou the heater and to supply air for combustion, venti- lation 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).

• To ensure the heater is placed in a approved application.

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 LLC 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

Roberts-Gordon LLC 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

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.

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SECTION 3: CLEARANCES TO COMBUSTIBLES

WARNING

Fire Hazard

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

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.

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, that 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 the burner of the heater and on Page 5, Figure 3 through Page 8, Figure 12 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

• The stated clearance to combustible represents a surface temperature of 90° F (50°C) above room temperature. Building materials with a low heat tolerance (su vas,triply, etc.) may be subject to degradation at lower temperatures. It is the installer’s responsibil- ity to assure that adjacent materials are protected from degradation.

• Maintain clearances from heat sensitive 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.

ch as plastics, vinyl siding, can-

SECTION 3: CLEARANCES TO COMBUSTIBLES

• 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 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 sus- pension requirements

• 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.

on Page 13, Figure 14.

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 3: STANDARD REFLECTOR

Model A B C D A B C D

CTH3-80 6 38 66 38 16 97 168 97

CTH3-115 6 46 77 46 16 117 196 117

CTH3-150 6 50 80 50 16 127 204 127

CTH3-200 8 52 82 52 21 133 209 133

(inches) (centimeters)

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CTH3-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 4: ONE SIDE REFLECTOR

Model ABCDABCD

CTH3-80 6 9 70 54 16 23 178 138

CTH3-115 6 9 83 65 16 23 211 166

CTH3-150 6 9 86 69 16 23 219 176

CTH3-200 8 9 88 73 21 23 224 186

(inches) (centimeters)

FIGURE 5: TWO SIDE REFLECTORS

Model ABCDABCD

CTH3-80 6 25 72 25 16 64 183 64

CTH3-115 6 32 84 32 16 82 214 82

CTH3-150 6 35 88 35 16 89 224 89

CTH3-200 8 40914021102232102

FIGURE 6: 45° TILT REFLECTOR

Model ABCDABCD

CTH3-80 8 8 66 60 21 21 168 153

CTH3-11510 8 78692621199176

CTH3-150 12 8 84 74 31 21 214 188

(inches) (centimeters)

CTH3-20012 8 85793121216201

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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 7: U-TUBE, STANDARD REFLECTOR

Model ABCDABCD

CTH3-80 6 38 69 37 16 97 176 94

CTH3-115 6 46 79 43 16 117 201 110

CTH3-150 6 50 84 47 16 127 214 120

CTH3-200 8 54875121138221130

SECTION 3: CLEARANCES TO COMBUSTIBLES

(inches) (centimeters)

FIGURE 8: U-TUBE, 45°

Model ABCDABCD

CTH3-80 8 8 66 46 21 21 168 11 7

CTH3-115 8 8 78 61 21 21 199 155

CTH3-150 8 8 84 66 21 21 214 168

CTH3-200 8 8 85 70 21 21 216 178

FIGURE 9: U-TUBE, OPPOSITE 45° REFLECTOR

Model ABCDABCD

CTH3-80 8 60 66 22 21 153 168 56

CTH3-115 10 70 78 22 26 178 199 56

CTH3-150 12 74 84 22 31 188 214 56

(inches) (centimeters)

CTH3-200 12 76 85 22 31 194 216 56

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Radiant Tubes

Vent Pipes

Unvented

Vented

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 10: 2-FOOT DECO GRILLE AND PROTECTIVE GRILLE

(inches) (centimeters)

Model ABCDABCD

CTH3-80 6 38 66 38 16 97 168 97

CTH3-115 6 46 77 46 16 117 196 117

CTH3-150 6 50 80 50 16 127 204 127

CTH3-200 8 52825221133209133

FIGURE 11: LOWER CLEARANCE SHIELD*

Model ABCDABCD

CTH3-80 6 40 38 40 16 102 97 102

CTH3-115 6 54 48 54 16 138 122 138

CTH3-150 6 55 50 55 16 140 127 140

CTH3-200

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

FIGURE 12: VENTING

Model A E F A E F

CTH3-80 20 24 18 51 61 46

CTH3-115 20 24 18 51 61 46

CTH3-150 20 30 18 51 77 46

(inches) (centimeters)

- UNAPPROVED -

(inches) (centimeters)

CTH3-200 20 30 18 51 77 46

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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 NFPA 54/ANSI Z223.1 - latest revision.

Canada: Refer to Natural Gas and Propane Installation Code CSA B149.1 - latest revision.

4.2 Aircraft Hangars

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

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

Canada: Refer to Natural Gas and Propane Installation Code CSA B149.1 - latest revision.

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: Refer to 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 Natural Gas and Propane Installation Code CSA B149.1 - latest revision.

• 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 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 National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest revision.

Canada: Refer to Natural Gas and Propane Installation Code CSA B149.1 - latest revision.

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).

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Burner with Tube Gasket

Must be installed with the

flame observation window facing down.

Reflector (Aluminum or Stainless Steel)

Alternate overlap as shown on overview and on Page 15, Figure 16. Minimum overlap is 6" (16 cm).

Tube and Reflector Hanger with Clamp Package

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

Coupling Assembly with Lock

Reflector End Cap

Punch out center section to accommodate tube.

Tube and Reflector Hanger

Suspend system from these hangers.

Flex Gas Line with Shut Off Cock

Tube

Heat treated aluminized tube supplied in 10' (3 m) lengths.

Burner Tube

Supplied in 10

(3 m) lengths. Burner tube is always the first tube after the burner.

Reflector Support Strap & Wire Form

Turbulator

Turbulator must be installed in the last standard section of tube. Turbulator is not required on the CTH3-200. For installation see Page 18, Section 6.4.

Vent Adapter

SECTION 5: MAJOR COMPONENTS FIGURE 13: Major Component Descriptions

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SECTION 5: MAJOR COMPONENTS

5.1 Standard Parts List Table 1:

*Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory.

Contents of Burner Carton

Part No. Description CTH3-80 CTH3-115 CTH3-150 CTH3-200

034XXXXX Burner Assembly (Rate and Fuel Varies) 1 1 1 1

02568200 Gasket (Burner to Burner Tube) 1 1 1 1

134100NA Installation, Operation and Service Manual 1 1 1 1

94273914 Hex Head Bolts 5/16-18 Rolok 4 4 4 4

96411600 Split Lock Washer 4 4 4 4

91201708 Pipe Nipple (Black) 1/2" NPT x 4" 1 1 1 1

*91412200 Flexible Stainless Steel Gas Hose - 1/2" NPT (US Models Only) 1 1 - -

*91412204 Flexible Stainless Steel Gas Hose - 3/4" NPT (US Models Only) - - 1 1

03051503 Turbulator Adapter 1 1 1 -

03051504 Turbulator, Aluminized Steel 3 3 1 -

91317310 Wire Terminal Receptacle.187 x.032 8 8 8 8

91309605 Cable Grommet with Tie 1 1 1 1

See Page 37, Section 9

Table 2: Contents of Core and Extension Packages

Core Packages (Aluminized) Extension Packages (Aluminized)

Part No. Description 10

91409408 Tube, HT Aluminized, 10' (3m) - 1 2 3 1 2 3 4

03051101

03051601

01312700 Coupling Assembly - 1 2 3 1 2 3 4

02750303 Standard Reflector, 8

02750800 End Cap 2 2 2 2 - - - -

03090100 Tube and Reflector Hanger 2 3 4 5 1 2 3 4

91907302 S-Hook 2 3 4 5 1 2 3 4

03050010 Reflector Support Package (Strap, Wire Form, Screws) 1 2 3 5 2 3 4 6

91107720 U-Clip Package 1 1 1 1 1 1 1 1

90502700 Vent Adapter 1 1 1 1 - - - -

01318901 Tube Clamp Package 1 1 1 1 - - - -

Burner Tube, ALUMI-THERM

Burner Tube, HT ALUMI-THERM

Steel, 10' (3m)

(2.6m) 2 3 4 6 2 3 4 6

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

--11--- -

11 - - - - - -

Part Number

Table 3: CTH3-Series Component Package Guide

Model Tubing Length Core Packages

Minimum Aluminized

CTH3-80 20' (6m) CP20ALUM

CTH3-115 30' (9m) CP30ALUM

CTH3-150 40' (12m) CP40ALUM

CTH3-200 50' (15m) CP30ALUM + EXP20ALUM

Additional tubing length may be added to heater. Tubing must be heat-treated, aluminized or porcelain coated. Any additional tubing lengths are considered as vent length for length determination. Maximum venting length for minimum heater length is 45' (13.7 m) total.

CP10ALUM

CP20ALUM

CP30ALUM

CP40ALUM

EXP10ALUM

EXP20ALUM

EXP30ALUM

EXP40ALUM

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

Failure to follow these instructions can result in injury.

SECTION 6: HEATER INSTALLATION

WARNING

Severe Injury Hazard

Secure burner to burner tube with bolts and lockwashers.

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

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

Expansion and contraction of the tube dictates that the minimum suspension lengths in the table on Page 13, Figure 14 be maintained.

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

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

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

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

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

The gas inlet pressure must be maintained as indicated on the rating plate.

Typical installation configurations are shown on Page 13, Figure 14.

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Page 19

FIGURE 14: Critical Hanger Placement

Hanger

Side View

Must Be Within 4" (10 cm) Front View

S-hooks

Reflector

Hanger

45° Angle

* Allows for thermal expansion of system

Typical Suspension Details

Rod 3/8"

Beam Clamp

Concrete Beam

Wood Beam

Washers

Locknut

Screw Hook

3/8"

24" min.*

(61 cm)

X*

Anchor

S-hooks

Chain Size

3/16"

Minimum

Turnbuckle

Not Included

Description Part Number

S-Hook 91907302 Tube/Reflector Hanger 03090100

Run Length Typical Expansion Minimum “X” Length

10' - 50' ±1" (3 cm) 12" 51' - 60' ±2" (5 cm) 18" 61' - 70' ±3" (8 cm) 24"

SECTION 6: HEATER I NSTALLATION

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Tube

Reflector

Reflector End Cap

Reflector Support

Burner

Coupling

U-Clips

Burner Tube

Tube and Reflector Hanger

Tube Clamp

Package

Vent Adapter

Turbulator

(With Select Models)

FIGURE 15: Linear Heater Assembly Overview

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Page 21

FIGURE 16: Linear Heater Layout Overview

Burner

Reflector

Tube

Tube/Reflector Hanger

Coupling Assembly

Vent Adapter

LEGEND

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

b = 2" (5 cm) 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 = 9.5" (24 cm) burner height

g = 17.5" (44 cm) burner length

e e e e

e e e

e e

20' (6 m) Tube Length

30' (9 m) Tube Length

40' (12 m) Tube Length

50' (15 m) Tube Length

60' (18 m) Tube Length

e e e e e

70' (21 m) Tube Length

e e e e e

80' (24 m) Tube Length

SECTION 6: HEATER I NSTALLATION

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

7' 6" ± 1'

(229 cm ± 25 cm)

NOTE:

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

S-hook

Burner Tube

Hanger

Offset mounting hole must be to the top.

Weld seam must be to the bottom of the tube.

Description Part Number

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

Bolt

Tube Clamp

Flat

Washer

Nut

(Torque 120 in/lb

13.56 Nm)

Description Part Number Tube Clamp Package01318901

Tube Clamp 01396801 Bolt 97113940 Flat Washer 95211600 Nut 92113900

Step 6.1 Burner Tube Installation

Step 6.2 Tube Clamp Package Installation

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Page 23

Step 6.3 Coupling and Tube Assembly

Tube

Orient coupling so that

the impact block is in the

2:00 or 10:00 oclock

positions.

Closed

Open

Tab

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

Slide Bar/Coupling Lock

Coupling

Wide End

Coupling

Tube

Slide Bar/Coupling Lock

Close coupling with tab.

Start Slide bar/Coupling Lock.

Insert tubes into coupling.

Tighten coupling to join tubes.

Description Part Number

Coupling 01329600 Slide bar/Coupling Lock 01329700 Tube 91409XXX

Incorrect slide bar

position

Correct slide bar

dimensions

± 2" (5 cm)

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

• Repeat Step 6.3 A - D until all tubes are assembled. See Page 18, Section 6.3.2.

Tighten slide bar as shown below.

SECTION 6: HEATER I NSTALLATION

Step 6.3.1 Coupling and Tube Assembly (Continued)

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

10' ± 1'

(3 m ± .25 m)

Total Overall Tube Length

7' 6" ± 1'

(2.3 m ± .25 m)

Model

Tube L e n gth

Minimum

CTH3-80 20' (6 m) CTH3-115 30' (9 m) CTH3-150 40' (12 m) CTH3-200 50' (15 m)

Pull String

Tab

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

Turbulator Section

Turbulator Adapter

Description Part Number

Turbulator Adapter 03051503 Turbulator Section 03051504 Tube 91409XXX

Turbulator Installation

CTH3-80 2nd 10' Section CTH3-115 3rd 10' Section CTH3-150 4th 10' Section CTH3-200 N/A

Turbulator must be installed in the last standard section of tube. Turbulator is not required on the CTH3-200.

Step 6.3.2 Coupling and Tube Assembly (Continued)

Step 6.4 Turbulator Installation

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Page 25

6.5 Reflector Installation

WARNING

Fire Hazard

Support reflector with reflector hanger and support strap.

Reflector must not touch tube.

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

Hanger

Burner Tube

Reflector

Description Part Number

Tube/Reflector Hanger 03090100 Burner Tube 03051XXX Reflector 02750303

NOTE: All tube surfaces must be covered

by a reflector, except for a U-Tube.

SECTION 6: HEATER I NSTALLATION

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Page 26

CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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

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

(No reflector support needed.)

b.) using a reflector support with

loose screws at the reflector overlap.

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

sheet metal screws may be used.

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

Reflector End Cap

U-clips

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

First Reflector

(16 cm)

Overlap must be a

minimum of 6" (16 cm).

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

2 A

Slip Overlap

Reflector

Support

2 B

Slip Overlap

Reflector

Tight

Screws

3 B

Non-Slip Overlap

U-clip

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

Reflector

3 A

Non-Slip Overlap

Wire Form

Reflector Support

Strap

Tight

Sheet Metal

Screw

Description Part Number Reflector Suppor t Package 03050010

Wire Form 91908004 Reflector Support Strap 03050000 Screw #8 x 3/4 94320812 U-Clip Package 91107720 Reflector End Cap 027508XX

Step 6.5.1 Reflector, U-Clip and Reflector Support Installation

The pictorial drawings of the heater construction in Section 6 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 depends 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.

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Page 27

Step 6.6 Burner Installation

Lock Washer

Gasket

Burner

Bolt (Torque 120 in/lb

13.56 Nm)

S-hook

Burner Tube

Burner must be installed

with the flame observation

window facing down.

Description Part Number

Bolt 94273914 Burner 034XXXXX Lock Washer 96411600 Gasket 02568200

SECTION 6: HEATER I NSTALLATION

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

Failure to follow these instructions can result in injury.

SECTION 7: OPTIONAL HEATER ACCESSORIES

7.1 U-Tube Configuration

Heaters are approved for optional U-Tu be configurations.

The U-Tube may be installed in either a standard horizontal position, a 45° position or in an opposite 45° position as shown on Page 7, Figure 7 through Figure 9. When using a U-Tube configuration, the following additional rules must be adhered to:

• A minimum of 10' (3 m) on CTH3-80 and a minimum of 15' (4.5 m) on CTH3-115/150/200 is required between the burner and the U-Tube.

• The correct turbulator (See Page 18, Figure 6.4) must be installed in the last standard section of tube.

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

• The heater must be properly supported at all locations. See Page 24, Figure 18.

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Page 29

FIGURE 17: U-Tube Heater Assembly Overview

SECTION 7: OPTIONAL H EATER ACCES SORIES

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

LEGEND

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

b = 2" (5 cm) 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

*Requires the last reflector before the u-tube to be cut in half for use on both sides.

**Requires the last tube before the u-tube to be cut in half for use on both sides.

U-tube

Burner

Reflector

Tube 10' (3 m)

Tube/Reflector Hanger

Coupling Assembly

60' (18 m) Tube Length

40' (12 m) Tube Length

50' (15 m) Tube Length* **

20' (6 m) Tube Length*

Tube 5' (1.5 m)**

30' (9 m) Tube Length**

70' (21 m) Tube Length**

80' (24 m) Tube Length

FIGURE 18: U-Tube Heater Layout Overview

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Page 31

7. 2 E l b ow P a c k a ge Configuration

Tube

90° Elbow

Coupling

Description Part Number Elbow Package 02718702

90° Elbow 01335801 Coupling 01312700 Reflector End Cap 02750800 Reflector Joint Piece 02750900

U-Clip Package 91107720

Minimum Distance Required Between Burner and Elbow

Model

Minimum

Distance

CTH3-80 10' (3m) CTH3-115 CTH3-150 15' (4.5m) CTH3-200

Tube

Coupling

Step 7.2.1 Elbow Installation

Step 7.2.2 Elbow Installation

SECTION 7: OPTIONAL H EATER ACCES SORIES

Step 7.2.3 Reflector Joint Installation

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 7.2.4 Reflector Joint Installation

Step 7.2.5 Reflector Joint Detail

FIGURE 19: Reflector Joint Detail

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Page 33

7.3 Reflector Side Extension

Reflector Side

Extension Bracket

(2 per Reflector)

Use additional supports

in high air movement

applications.

Tube and Reflector Hanger

ReflectorTube

Reflector Support

Description Part Number Reflector Side Extension Package 02712700

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

Step 7.3.1 Bracket Installation

SECTION 7: OPTIONAL H EATER ACCES SORIES

Step 7.3.2 Side Reflector Installation

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

12"

(30 cm)

Reflector

Lower Clearance Shield

17"

(43 cm)

Washers

Screws

Locknuts

Align Pilot Holes

Description Part Number Lower Clearance Shield Package 01397501

Shield Support Strap 01397500 Lower Clearance Shield 8' 02793000 Locknut #8 92311400 Flat Washer #8 95310800 Screw #8 x 3/8" 93511406

Description Part Number

Aluminum Grille 2’ x 4’ 91407000

7.4 Lower Clearance Shield Installation Step 7.4.1 Shield Support Strap Assembly

7.5 Two-Foot Decorative Grille Installation Step 7.5.1 Grille Installation

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Page 35

Step 7.5.2 Frame Shield Installation

Description Part Number

Deco Grille Shield 01365900

Distance "A" Extension

Minimum Maximum Part No. Width

2" (4 cm) 6" (15 cm) 01370408 8" (20 cm) 6" (15 cm) 10" (26 cm) 01370412 12" (30 cm) 10" (26 cm) 14" (37 cm) 01370416 16" (40 cm)

Description Part Number

Reflector Side Extension 01370412

SECTION 7: OPTIONAL H EATER ACCES SORIES

Step 7.5.3 Reflector Side Extension Installation for Decorative Grilles

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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

Grille

End Cap

Reflector

Final Grille Section

40"

(101 cm)

7.6 Protective Grille Installation Step 7.6.1 Silicone Cap Installation

Step 7.6.2 Grille End Cap Installation

Step 7.6.3 Grille Installation

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Page 37

SECTION 8: VENTING

WARNING

Carbon Monoxide Hazard

Heaters installed unvented must be interlocked with sufficient building exhaust.

Heaters must be installed according to the installation manual.

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

WARNING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

Failure to follow these instructions can result in injury.

SECTION 8: VENTING

Vent pipe must be sloped downward away from the burner 1/2'' (1 cm) for every 20' (6 m).

The heater may be individually vented or common vented. When venting horizontally, a maximum of two heaters can be commonly vented. See Page 33, Section 8.9. When venting vertically, a maximum of four heaters can be commonly vented. See Page 34, Section 8.10.

The heater may also be installed unvented in certain circumstances according to building Refer to the above codes and Page 31, Section 8.2 for further information. Unvented operation also requires compliance with the clearances to combustibles given on Page 8, Figure 12.

The bottom of the vent or air intake terminal shall not be located less than 1' (.3 m) above grade level.

The vent shall not terminate less than 7' (2.1 m) above grade where located adjacent to public walkways.

Vent terminal must be installed at a height sufficient to prevent blockage by snow and building materials protected from degradation by flue gasses.

Secure all joints with #8 x 3/8 sheet metal screws. Seal all joints with high temperature silicone sealant.

ventilation codes.

8.1 Venting

This heater must be vented in accordance with the rules contained in this manual and with the following national codes and any state, provincial or local codes which may apply:

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

Canada: Refer to Natural Gas and Propane Installation Code CSA B149.1 - latest revision.

Exhaust end of heater will accept a 4 pipe using the vent adapter (P/N 90502700). To prevent leakage of condensation, install the vent adapter with the seam on top and seal the joint using

a high temperature silicone sealant.

Any portion of vent pipe passing through a combustible wall must have an approved thimble to conform with the above listed codes.

" (10 cm) vent

Vent terminal must be beyond any combustible overhang.

8.1.1 United States Requirements

Vent must terminate at least 3' (.9 m) above any forced air inlet located within 10' (3.1 m).

Vent must terminate at least 4' (1.2 m) below, 4' (1.2 m) horizontally from, or 1' (.3 m) above any door, operable building.

8.1.2 Canadian Requirements

The vent shall not terminate within 6' (1.8 m) of a mechanical air supply inlet to any building.

The vent shall not terminate within 3' (.9 m) of a window or door that can be opened in any building, any non-mechanical air supply inlet to any building, or of the combustion air inlet of any other appliance.

8.2 Unvented Operation

Sufficient ventilation must be provided in the amount of 4 cfm per 1000 Btu/h firing rate (United States); 3 cfm per 1000 Btu/h firing rate (Canada).

Use of optional outside combustion air is not recommended with unvented heaters.

If exhaust fans are used to supply ventilation air, an interlock switch must be used to prevent the heater from coming on when the fans are off. This may be done using a pressure switch.

window, or gravity air inlet into any

31 of 71

Page 38

CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

4" (10 cm)

Single Wall Pipe

Vent Adapter

Vent Terminal

Combustible or

Non-Combustible Wall

Vent Adapter

18" (46 cm)

Min.

Vent Terminal

4" (10 cm) Single Wall Pipe

Non-Combustible Wall Only

SIDE VIEW

Description Part Number

Vent Terminal (Comb. Wall) 90502100 Vent Terminal 02537801-XX

8.3 Horizontal Venting

In noncombustible walls only, vent terminal (P/N 02537801-1P) may be used.

For 4" (10 cm) vents in either combustible or noncombustible walls, use Tjernlund VH1-4 (P/N

90502100) or equivalent, insulated vent terminal. Follow the manufacturer's instructions for proper installation.

For 6" (15 cm) common vents in either combustible or noncombustible walls, use Tjernlund VH1-6 (P/N

90502101) or equivalent, insulated vent terminal. Follow the manufacturer's instructions for proper installation.

8.4 Vertical Venting

For 4" (10 cm), an approved vent cap (P/N 90502300) must be used. For 6" (15 cm) common vent, an approved vent cap (P/N 90502302) m

ust be used. For common vertical venting of more than two heaters, See Page 34, Section 8.10. A vent shall not extend less than 2' (.6m) above the highest point where it passes through a flat roof of a building.

8.5 Unvented Operation Tube Termination

Turndown type vent terminal with a screen must be installed at the exhaust end of the tube. Vent terminal design shall not incorporate backdraft flap.

FIGURE 20: Tube Termination

8.6 Length Requirements

The maximum vent length allowed is 45' (13.7 m). The maximum outside air supply duct length allowed is 45' (13.7 m).

The total vent length, plus outside air duct length and any extensions to minimum heat exchanger lengths, cannot exceed 65' (19.8 m).

Vent length should be limited to less than 20' (6 m). If using extended heater lengths or vent lengths greater than 20' (6 m), condensation will form in the vent pipe. Insulation and additional sealing measures (high temperature silicone at all seams) are required. Optional heat exchanger beyond minimum lengths are considered as vent length for length determination.

Subtract 15' (4.6 m) of maximum allowed vent or duct length per vent elbow if more than two are used.

8.7 Horizontal Ventilation 4" (10 cm) Pipe

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Page 39

8.8 Vertical Ventilation 4" (10 cm) Pipe

Description Part Number

Vent Cap 4" (10 cm) 90502300

4" (10 cm) Single Wall Pipe

Outside Wall

Vent Adapter

Sweeping 'T'

Connection

Sweeping 'Y'

Connection

Outside Wall

6" (15 cm) Single Wall Pipe

Vent Terminal

Tjernlund VH1-6 or Equivalent

Outside Wall

4" (10 cm) Single Wall Pipe

Vent Adapter

Vent Terminal

Tjernlund VH1-6 or Equivalent

Vent Adapter

TOP VIEW

4" (10 cm) Single Wall Pipe

6" (15 cm) Single Wall Pipe

Description Part Number

Vent Terminal 6" (15 cm) 90502101

SECTION 8: VENTING

8.9 Common Side Wall Venting

Requirements:

• Maximum of two heaters can be commonly vented through a side wall.

• Heaters must be of the same BTU output.

• Heaters must be controlled by a common thermostat.

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

8.10 Common Vertical Venting

Requirements:

• Maximum of four heaters can be commonly vented through the roof.

• Heaters must be of the same BTU output.

• Heaters must be controlled by a common thermostat.

• Connections to a common stack must be positioned to avoid direct opposition between streams of combustion gases.

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Page 41

8.11 Outside Combustion Air Supply

Description Part Number

Vent Cap 4" (10 cm) for 80,000 Btu/h and 115,000 Btu/h models

90502300

Vent Cap 5" (13 cm) for 150,000 Btu/h and 200,000 Btu/h models

90502301

SIDE VIEW

Band Clamp

(Recommended)

Flex Hose

(Recommended)

Vent Cap

Wall

For 80 and 115 models, 4" (10 cm) Single Wall Pipe. For 150 and 200 models, 5" (13 cm) Single Wall Pipe.

Burner

(10 cm)

Min.

SIDE VIEW

Description Part Number

Vent Cap 4" (10 cm) for 80,000 Btu/h and 115,000 Btu/h models

90502300

Vent Cap 5" (13 cm) for 150,000 Btu/h and 200,000 Btu/h models

90502301

IMPORTANT: If the building has a slight negative pressure or corrosive contaminants such as

8.11.1 Length Requirements

Follow the constraints listed on Page 32, Section 8.6.

halogenated hydrocarbons are present in the air, an outside combustion air supply to the heater is required. Seal all combustion air pipe joints.

The air supply duct may have to be insulated to prevent condensation on the outer surface. The outside air terminal must not be more than 1' (31 cm) above the vent terminal.

Use of optional outside combustion air is not recommended with unvented heaters.

8.11.2 Vertical Outside Air Supply for Single Heater Installation

SECTION 8: VENTING

8.11.3 Horizontal Outside Air Supply for Single Heater Installation

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Sweeping 'T'

Connection

For 80 and 115 models, 6" (15 cm) Single Wall Pipe. For 150 or 200 models, 7" (18 cm) Single Wall Pipe.

Vent Cap

Band Clamp

(Recommended)

BurnerBurner

Flex Hose

(Recommended)

Flex Hose

(Recommended)

Roof

For 80 and 115 models, 4" (10 cm) Single Wall Pipe. For 150 or 200 models, 5" (13 cm) Single Wall Pipe.

Description Part Number

Vent Cap 6" (15 cm) 90502302

SIDE VIEW

Sweeping 'Y' Connection

Vent Cap

Outside Wall

For 80 or 115 models, 4" (10 cm) Single Wall Pipe. For 150 and 200 models, 5" (13 cm) Single Wall Pipe.

Flex Hose

(Recommended)

Band Clamp

(Recommended)

Burner

(10 cm)

Min.

For 80 or 115 models, 6" (15 cm) Single Wall Pipe. For 150 and 200 models, 7" (18 cm) Single Wall Pipe.

Description Part Number

Vent Cap 6" (15 cm) 90502302

TOP VIEW

8.11.4 Vertical Outside Air Supply for Double Heater Installation

Requirements:

• Heaters must be controlled by a common thermostat.

8.11.5 Horizontal Outside Air Supply for Double Heater Installation

Requirements:

• Heaters must be controlled by a common thermostat.

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Page 43

SECTION 9: GAS P IPING

WARNING

Explosion Hazard

Leak test all components of gas piping before operation.

Gas can leak if piping is not installed properly.

Do not high pressure test gas piping with heater connected.

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

SECTION 9: GAS PIPING

WARNING

Fire Hazard

Tighten gas hose fittings to connect gas supply according to Figure 21.

Gas hose can crack when twisted.

Gas hose moves during normal operation.

Use only 36" (91 cm) long connector of 1/2" or 3/4" nominal ID.

Connector supplied with heater for U.S. models (not with Canadian models).

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

There is an expansion of the tube with each firing cycle. This will cause the burner to move with respect to the gas line. This can cause a gas leak resulting in an unsafe condition if the gas connection is not made in strict accordance with Figure 21.

Meter and service must be large enough to handle all the burners being installed plus any other connected load. The gas line which feeds the system must be large enough to supply the required gas with a maximum pressure drop of 1/2" wc When gas piping is not included in the layout drawing, the local gas supplier will u

Gas lines must meet applicable codes: United States: The Flexible Stainless Steel Gas Hose (US models) supplied with the heater is certified per the Standard for Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 - latest revision. Canada: The Rubber Type 1 Gas Hose (Canadian models) optional with the heater is certified as being in compliance with the Standard for Elastomeric Composite Hose and Hose Couplings for Conducting Propane and Natural Gas, CAN/CGA 8.1 - Latest revision.

• Check the pipe and tubing ends for leaks before placing heating equipment into service. When checking for gas leaks, use a soap and water solution; never use an open flame.

sually help in planning the gas piping.

Install the gas hose as shown in Figure 21. The gas hose accommodates expansion of the heating system and allows for easy installation and service of the burner. Before connecting the burners to the supply system, verify that all high pressure testing of the gas piping has been completed.

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Page 44

CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Shut-Off Valve (included with gas hose) must be parallel to burner gas inlet. The 3" (8 cm)

displacement shown is for the cold condition. This displacement may reduce when the system is fired.

CORRECT POSITIONS

Horizontal

45°

End View

Vertical

(as shown left)

Alternate positions okay

Flexible Gas Hose 36" (91 cm) length

3" (8 cm) max. displacement

Side View

Heater Movement

12"

(30 cm)

CAUTION

Product Damage Hazard

Hold gas nipple securely with pipe wrench when attaching gas hose.

Failure to follow these instructions can result in product damage.

INCORRECT POSITIONS (WRONG INSTALLATION)

Heater Movement

Heater Movement Heater Movement

Description Part Number

1/2" Flexible Stainless Steel Gas Hose (US Models) 91412200 3/4" Flexible Stainless Steel Gas Hose (US Models) 91412204 1/2" Rubber Type 1 Gas Hose (Canadian Models) 91412206 3/4" Rubber Type 1 Gas Hose (Canadian Models) 91412207

FIGURE 21: Gas Connection with Flexible Gas Hose

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Page 45

SECTION 10: WIRING

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Heater must be properly grounded.

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

MODULATION CONTROL WIRING TO SATELLITE HEATERS

CENTRAL HEATER CONTROL

OFF

-LCD++FAN-SEN

ZONE SENSOR

SET

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

MODULATION CONTROL WIRING

TO ADDITIONAL SATELLITE

HEATERS CONTROL TERMINALS

T28 and T29.

*OPTIONAL

SWITCH

SATELLITE HEATER CONTROL

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

* Separate on/off switch is optional for "satellite" heaters (install at user level). On/ Off switch is used to disable heater operation or reset a heater that is in "lockout" mode. If on/off switch is not desired, leave jumper wire between R and W terminals in place.

Description Part Number

Zone Sensor, 40° - 75° 10081530

SECTION 10: WIRING Heater must be grounded in accordance with

applicable codes: United States: refer to National Electrical Code

NFPA 70 - latest revision Canada: refer to Canadian Electrical Code, CSA C22.1 Part I - latest revision.

If any of the original internal wiring must be replaced, it must be replaced with wiring materials having a temperature rating of at least 105°C and 600 Volts.

10.1 Standard Heater Configuration

From the factory, the heater is configured for zone sensor control. Connect zone sensor to the heater control as shown on Page 39, Figure 22. If additional heaters are in the same heating zone, control wiring must be installed between the heaters’ controls as shown on Page 39, Figure 22. For additional details or for use with heat demand control devices other than the zone sensor, see Page 40, Section 10.2 through Page 48, Section 10.4.9.

FIGURE 22: Zone Sensor Wiring Diagram

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

10.2 Central and Satellite Heaters (Zoning Capability)

The heater can be configured so that several heaters within the same heating zone will modulate

simultaneously with connection to a single heat demand control device. The heat demand control device (See Page 44, Section 10.4) will be wired directly to a single heater configured as the central heater. The remaining heaters in the zone will be configured as satellite heaters and will modulate based on control signaling from the central heater. Zoning capability allows any CTH3-Series heater (regardless of input) to modulate based on the signal from the central heater. During modulation, each satellite heater will operate at the same percentage

10.2.1 Central Heater Configuration

Central heater configuration is set by positioning of jumpers on pin blocks (J10 and J9) located on the control inside the heater compartment, See Page 40,

Figure 23. Jumper position on J10 shown in Figure 23, will configure heater as a central heater and at

the same time configure the heater for the desired heat demand device (zone sensor, thermostat, analog input, or 10K Ohm pot.). If j positioned for "analog", jumper on J9 must be positioned for either 0-10 Vdc or 4-20 mA. If jumpers on J10 are not positioned for "analog", the J9 jumper may be left alone.

of full rated input as the central heater.

FIGURE 23: Central Heater Jumper Settings

umpers on J10 are

40 of 71

Page 47

10.2.2 Satellite Heater Configuration

Satellite heater configuration is set by positioning of jumpers on pin block J10 located on the control board inside the heater compartment, See Page 41, Figure

24. Jumper position on J10, shown on Page 41, Figure 24 will configure heater as a satellite heater.

(The jumper position for satellite is the same as the jumper position of a central heater using a zone sensor). Jumper on J9 may be left alone.

FIGURE 24: Satellite Heater Jumper Setting

SECTION 10: WIRING

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

CENTRAL HEATER CONTROL

10.3 Communication Wiring within a Zone of Heaters

Satellite heaters will be wired in series to the central heater via low voltage control wiring.

Communication wiring uses the T28-T31 terminals on the control, see Page 42, Figure 25.

FIGURE 25: Communication Wiring within a Zone of Heaters

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SECTION 10: WIRING

10.3 Communication Wiring within a Zone of Heaters (continued)

Satellite heaters will be wired in series to the central heater via low voltage control wiring. Communication wiring uses the T28-T31 terminals on the control, See Page 42 through Page 43, Figure 25.

FIGURE 25: Communication Wiring within a Zone of Heaters (continued)

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

*OPTIONAL

SWITCH

SATELLITE HEATER CONTROL

J10 JUMPER POSITION SHOWS "SATELLITE" DESIGNATION.

MODULATION CONTROL WIRING TO ADDITIONAL SATELLITE HEATER CONTROL TERMINALS T28 AND T29.

MODULATION CONTROL WIRING TO SATELLITE HEATERS

CENTRAL HEATER CONTROL

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

J10 JUMPER POSITION SHOWS "CENTRAL" DESIGNATION AND "THERMOSTAT" CONTROL METHOD.

* Separate on/off switch is optional for "satellite" heaters (install at user level). On/Off switch is used to disable heater operation or reset a heater that is in "lockout" mode. If on/off switch is not desired, leave jumper wire between R and W terminals in place.

10.4 Heat Demand Control Wiring

The heater input can be controlled by any one of the following heat demand control devices (control devices are wired to central heaters only):

10.4.1 Zone Sensor

The zone sensor (P/N 10081530) offers automatic control of heater input. Heater(s) modulates based on difference between sensed air temperature and the temperature setpoint. Heater modulation in response to air temperature changes is immediate. Setpoint is adjusted with the slide bar adjustment at the bottom of the sensor. ON/OFF switch (used to disable heater operation or reset heater from lockout) is located on the side of the sensor. See Page 39, Figure 22 for wiring details.

10.4.2 Thermostat

A thermostat offers automatic control of heater input. The heater control is designed for use with a standard 2-wire or 4-wire low voltage electronic thermostat (not for use with thermostats that have a heat anticipator). Typical wiring connects the R and

FIGURE 26: Thermostat Control Wiring Diagram

W wires to the heater control and does not connect the Y (cooling) and G (fan) wires to the heater control.

The heater can be used with thermostat, 24V (p/n

90425100) if set to 5 cycles per ho

ur. Any other electronic thermostat without heat anticipator can be used if set to 5 or 6 cycles per hour.

On the control, the T24 and T25 (R and W) terminals supply 24 V to power an electronic thermostat. See Page 44, Figure 26 for wiring details. Consult the factory for other thermostat wiring configurations.

Heater(s) modulates based on heater and thermostat cycle timing, history and desired setpoint by using a pre-programmed algorithm. When using thermostat control, heater modulation response to rapid air temperature change is not immediate. Thermostat control is not recommended for use in areas with frequent or high air changes.

It is important to note that during normal operation, heater cycle continues beyond meeting thermostat setpoint.

44 of 71

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SECTION 10: WIRING

10.4.3 Analog Signal Modulating Thermostat (P/N

90425105)

A programmable, 7-day programming, modulating thermostat can be installed to supply an analog (420mA) or (2-10Vdc with 500 Ohm resistor) control signal to dictate the heater(s) firing rate. The thermostat shall energize the T24 and T25 (R and W) terminals. For thermostat wiring, See Page 49, Figure 29 and Page 50, Figure 30. Optional room sensors (P/N 10081520) and outdoor air sensors (P/N 10081521) are available.

Room temperature averaging networks can be created with up to nine room sensors (P/N

10081520). Refer to thermostat installation instructions for wiring.

10.4.4 Analog Signal Modulating Thermostat with

LonWorks

If LonWorks

Communication (P/N 90425104)

communication is required, a modulating thermostat can be installed to supply an analog (4-20mA or 2-10Vdc) signal to control the heater(s) firing rate. For thermostat wiring, See Page 49, Figure 29 and Page 50, Figure 30. Optional room sensors (P/N 10081520) and outdoor air sensors (P/N 10081521) are available for this thermostat, as well.

The modulating thermostat with LonWorks networking capability in a LonWorks

system.

provides

Communications port running at 78 kilobits per second (kbs), this thermostat can be configured to perform a variety of activities in which data is sent or

received on the LonWorks

. Information that can be

shared, viewed and modified with network includes:

• Current year, month, day, hour, minute, second.

• System Mode.

• Space Temperature

• Outdoor air temperature

• Current setpoint

• Occupied/Unoccupied schedule commands.

• Space Temperature

allow integral peer to peer BACnet

MS/TP LAN network communications with configurable baud rates and can easily integrate with a building automation system.

MS/TP Wiring

Connect the -A terminal in parallel with all other -A terminals on the network and the +B terminal in parallel with other +B terminals.

10.4.6 Sequence of Operation for Modulating Thermostats

The thermostat will control the heater(s) firing rate based on the demand signal communicated from thermostat program taking into account space temperature. The thermostat will energize T25 (W) terminal. At high heat, a demand signal will turn the heater(s) on at maximum heater(s) firing rate. Once the room temperature gets close to the thermostat set point, then the thermostat program will slow the heater(s) firing rate down until the room temperature reaches the thermostat set point.

10.4.5 Analog signal Modulating with BACnet Programmable Thermostat (P/N 90425109).

If BACnet

communication is required, a BACnet® enabled modulating thermostat can be installed to supply an analog output (0-10VDC) signal control to dictate the heater(s) firing rate. For thermostat wiring, See Page 51, Figure 31.

This thermostat is a flexible wall-mounted stand- alone control with combined controller/sensor. Temperature sensing is standard with optional humidity and motion sensing. BACnet

connections

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

10.4.7 Cable Termination

Tab le li s t s wiring types, sizes and distances for modulating thermostat with LonWorks

communication (P/N 90425104), modulating thermostat without communication (P/N 90425105)

and BACnet

programmable thermostat

(P/N 90425109)

Table 4:

Digital Outputs 18 AWG (0.75 sq mm) Standard thermostat wire 1000 ft (304 m) Modulating Outputs 18 AWG (0.75 sq mm) 1 pair 500 ft (152 m) Outdoor Air Temperature Sensor 18 AWG (0.75 sq mm) 1 pair 500 ft (152 m) Remote Sensor 18 to 22 AWG

Power Wiring 18 to 14 AWG

LonWorks

MS/TP (P/N 90425109) 18 AWG (0.75 sq mm) Shield Belden cable #82760 or equivalent Refer to Thermostat Installation Guide

Cable Requirements

Wire Function Recommended Wire Size

(Minimum)

(0.75 to 0.34 sq mm)

(P/N 90424104 only)

( 0.75to 2.0 sq mm) 18 AWG

(0.75 sq mm) nonshielded

Specification or

Distance (Maximum)

Requirement

Twisted pair wire 1000 ft (304 m)

NEC Class II 140ºF (60°C ) Limited by line-loss effects on power

consumption.

1 pair Refer to E-bus Wiring Guide 74-2865

for maximum length and generic cable specifications.

Power Requirements

Modulating thermostats require 24 volts, AC power.

10.4.8 Remote Analog Signal

Remote Analog Signal 0-10 Vdc or 4-20mA output from external controller or Building Management System (BMS) directly dictates heater(s) firing rate. An algorithm must be programmed into the BMS or external controller to receive zone air temperature signals from its own temperature sensors and then deliver an output signal to the heater(s) for the desired firing rate.

For 0-10Vdc control of the heater(s) firing rate, the following control conditions apply:

ON/OFF relay at the external controller or BMS must be wired to R and W terminals on the heater control board to turn the heater ON and OFF.

Minimum rated input at 1% of signal (0-1Vdc). Full rated input at 90% of signal (9Vdc). Input varies linearly between 1Vdc and 9Vdc.

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SECTION 10: WIRING

*OPTIONAL

SWITCH

SATELLITE HEATER CONTROL

FOR SATELITTE CONTROLLERS, J9 JUMPER CAN BE LEFT IN ORIGINAL POSITION REGARDLESS OF CONTROL METHOD.

J10 JUMPER POSITION SHOWS "SATELLITE" DESIGNATION.

MODULATION CONTROL WIRING TO ADDITIONAL SATELLITE HEATER CONTROL TERMINALS T28 and T29.

ON/OFF SWITCH REQUIRED

MODULATION CONTROL WIRING TO SATELLITE HEATERS

CENTRAL HEATER CONTROL

REMOTE ANALOG CONTROL SIGNAL FROM SEPARATE CONTROLLER 0-10Vdc OR 4-20mA

ANALOG INPUT CONTROL IS USED TO SELECT ANALOG SIGNAL TYPE 0-10Vdc OR 4-20mA (4-20mA POSITION SHOWN).

J10 JUMPER POSITION SHOWS "CENTRAL" DESIGNATION AND "ANALOG" CONTROL METHOD.

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

A B

* Separate on/off switch is optional for "satellite" heaters (install at user level). On/Off switch is used to disable heater operation or reset a heater that is in "lockout" mode. If on/off switch is not desired, leave jumper wire between R and W terminals in place.

For 4-20mA control of the heater(s) firing rate, the following control conditions apply:

ON/OFF relay at the external controller or BMS must be wired to R and W terminals on the heater control board to turn the heater ON and OFF. (Open Circuit = OFF, Closed Circuit = ON). Minimum rated input at 1% of signal (0-4 mA). Full rated input at 90% of signal (18 mA). Input varies linearly between 4 mA and 18 mA.

BMS controllers often offer PID loop control that can optimize output signal and rate of change of the output signal. Common analog application is defined as follows:

1. BMS sensors that monitor zone air temperatures are located in the heating space.

FIGURE 27: Analog Control Signal Wiring Diagram

2. Based on sensed temperatures, the BMS will output an analog signal for the desired heater(s) firing rate.

3. As heater(s) receive the analog signal from the BMS, the heater(s) modulate to the corresponding firing rate.

4. As sensed air temperature rises closer to the desired temperature setpoint, the BMS will reduce the output signal, in turn reducing heater firing rate.

5. Upon satisfying temperature setpoint, the BMS will either:

a. Tu

rn off the heater.

b. Reduce the signal so that the minimum

heater firing rate is maintained until the sensed temperature rises above the setpoint to a cut-off limit temperature when the BMS turns off the heater.

47 of 71

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

*OPTIONAL

SWITCH

SATELLITE HEATER CONTROL

J10 JUMPER POSITION SHOWS "SATELLITE" DESIGNAT ION.

MODULATION CONTROL WIRING

TO ADDITIONAL SATELLITE HEATER CONTROL TERMINALS T28 AND T29.

MODULATION CONTROL WIRING TO SATELLITE HEAT ERS

CENTRAL HEATER CONTROL

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

J10

OUT

RATE

FIRING

RATE

FIRING

EXT. POT

GND

WIPER

HIGH

GND

BAR

SLIDE

GND

THERMISTOR

INPUT

ANALOG

THERMOSTAT

T31

T29

T19

T18

T16

T14

T27

T25

T30

T28

T17

T15

T13

T26

T24

ON/OFF SWITCH or THERMOSTAT

A B

J10 JUMPER POSITION SHOWS "CENTRAL"

DESIGNATION AND "POTENTIOMETER" CONTROL METHOD.

POTENTIOMETER

(10K Ohm)

* Separate on/off switch is optional for "satellite" heaters (install at user level). On/Off switch is used to disable heater operation or reset a heater that is in "lockout" mode. If on/off switch is not desired, leave jumper wire between R and W terminals in place.

10.4.9 Potentiometer Control Device

Potentiometer (10K Ohm"Linear Taper") device offers manual control over heater(s) firing rate. This type of potentiometer can be found at Radio Shack

. Potentiometer dial position directly dictates heater(s) firing rate. Dial positions range between "Min" and "Max". Minimum and maximum heater firing rates (inputs) are marked on the heater's rating plate. ON/ OFF switch or thermostat is used to disable heater operation or reset heater from lockout.

FIGURE 28: Potentiometer Control Wiring Diagram

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SECTION 10: WIRING

Description Part Number

Thermostat, modulating 90425105 Thermostat, modulating LonWorks

90425104

* Separate on/off switch is optional for "satellite" heaters (install at user level). On/Off switch is used to disable heater operation or reset a heater that is in "lockout" mode. If on/off switch is not desired, leave jumper wire between R and W terminals in place.

NOTE: 1. For non-communicating thermostats without LonWorks

bus, thermostat terminals marked "EB"

will be marked "_____" and no LonWorks

bus communication wires are used.

FIGURE 29: Modulating Thermostat Wiring Diagram (LonWorks

[4-20 mA] optional)

49 of 71

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

* Separate on/off switch is optional for "satellite" heaters (install at user level). On/Off switch is used to disable heater operation or reset a heater that is in "lockout" mode. If on/off switch is not desired, leave jumper wire between R and W terminals in place.

NOTE: 1. For non-communicating thermostats without LonWorks

bus, thermostat terminals marked "EB"

will be marked "_____" and no LonWorks

bus communication wires are used.

Description Part Number

Thermostat, modulating 90425105 Thermostat, modulating LonWorks

90425104

FIGURE 30: Modulating Thermostat Wiring Diagram (LonWorks optional)

[2-10Vdc with 500 Ohm resistor]

50 of 71

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SECTION 10: WIRING

Description Part Number

Thermostat, modulating BACnet

90425109

NOTES:

1. A j umper is pre-installed between phase R(24VAC) and SC1-3 (24VAC Relay).

2. Ground ONLY ONE END of the shielded cable.

* Separate on/off switch is optional for "satellite" heaters (install at user level). On/Off switch is used to disable heater operation or reset a heater that is in "lockout" mode. If on/off switch is not desired, leave jumper wire between R and W terminals in place.

FIGURE 31: Modulating Thermostat Wiring Diagram with BACnet

(optional)

51 of 71

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

10.5 Internal Wiring

See Page 39, Section 10.1 through Page 48, Section

10.4.9 for temperature control device options and

wiring schematic.

52 of 71

Page 59

10.6 Ladder Diagram

24V

120V

CONTROL

GAS VALVE

SURFACE

IGNITER

HOT

MOTOR

FLAME SENSOR

SWITCH

DOOR

AIR SWITCH

BLK

WHT

BLK

WHT

BLU

YEL

ORG

BLU

PRP

BRN

BLU

BLK

GRN

BLU

GRN

SECTION 10: WIRING

See Page 39, Section 10.1 through Page 48, Section 10.4.9 for temperature control device options and wiring schematic.

53 of 71

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Gnd.

120 V-60 Hz

Supply Circuit

L1 L2

Gnd.

Burner 2

Burner 3

Gnd.

Burner 1

NOTE: The burners must have an uninterrupted 120 V, 60 Hz, 1 Ø power supply.

BX or Romex Connector

Junction Box

Electrical Cord or

Flexible Conduit

Burner

Connect wires together

with suitable approved

wire connectors.

Green to Ground

White to L2

Black to L1

L1 L2

Ground

Black

White

Green

10.7 Line Voltage Power Wiring

10.8 Electrical Connection to the Burner

54 of 71

Page 61

10.9 Low Voltage Control Wiring Installation

Description Part Number

Cable Grommet with Tie 91309605

SECTION 10: WIRING

55 of 71

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 11: OPERATION AND MAINTENANCE

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Heater must be connected to a properly grounded electrical source.

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

11.1 Sequence of Operation

The control inside the heater's control compartment is equipped with a tri-color LED. The LED offers comprehensive diagnostic capability. The LED status will be referenced throughout this section.

1. When the control is powered and there is no call for heat from external heat demand device, the LED on the control flashes slow green; LED is ON for the same period it is OFF.

2. On a call for heat from the heat demand device, the heater will go to PRE-PURGE. The LED indicates one green flash. The blower speed will

vary as the pressure switch setpoints are verified. When the PRE-PURGE is successfully

completed, the heater will go into the PRE-IGNITION state and power the hot surface igniter (H.S.I.).

3. After the igniter warms up, the heater will go to the IGNITION state. Power is supplied to the gas valve operator, gas flows, ignites and the flame is proven. The LED shows two green flashes on the LED. If a flame is not sensed, the heater will RETRY, See Item 6 below for further details.

4. When the IGNITION state is completed, the heater will go to WARM UP state. The unit will fire at maximum input for 15 seconds. When the WARM UP state is completed the device will go into RUN state. The control board will monitor the heat demand device and modulate the heater input to meet the demand. The LED still shows two green flashes.

5. When the call for heat has been satisfied, the heater closes the gas valve. The blower

Explosion Hazard

Turn off gas supply to heater before service.

WARNING

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

continues to run for a 45 second post-purge period. After the post-purge, the heater turns OFF and the LED on the control board flashes slow green.

6. If flame is lost at any time during heater operation, the heater will RETRY for ignition. Upon RETRY the LED shows a fast yellow flash (LED rapidly flashes). The heater will RETRY for ignition three times. After four ignition attempts, the heater will lockout for one hour or until reset. To reset the heater, remove power for 10 seconds, then re-apply power. Turn heater ON with call for heat from the heat demand device.

11.2 To Shut Off Heater

Set external heat demand dev Turn OFF electric power to heater. Turn OFF manual gas valve in the heater supply line.

11.3 To Start Heater

Turn gas valve and electric power OFF and wait five minutes for unburned gases to vent from heater.

Turn ON main gas valve. Turn ON electric power. Set heat demand device to desired temperature.

Burner should light automatically.

11.4 Pre-Season Maintenance and Annual Inspection

To e n s ure your safety and years of trouble-free operation of the heating system, service and annual inspections must be done by a contractor qualified in the installation and service of gas-fired heating equipment.

Turn off gas and electric supplies before performing

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

ice to lowest setting.

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SECTION 11: OPERATION AND MAINTENANCE

service or maintenance. Allow heater to cool before servicing.

Before every heating season, a contractor qualified in the installation and service of gas-fired heating equipment must perform a thorough safety inspection of the heater.

For best performance, the gas, electrical, thermostat connections, tubing, venting, suspensions and overall heater condition should be thoroughly inspected.

NOTE: Gas flow and burner ignition are among the first things that should be inspected.

Please See Page 57 for suggested items to inspect.

Installation Code and Annual Inspections:

All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts-Gordon LLC and conform to all requirements set forth in the ROBERTS GORDON

manuals and all applicable governmental authorities pertaining to the installation, service, operation and labeling of the equipment.

To help facilitate optimum performance and safety, Roberts-Gordon LLC recommends that a qualified contractor conduct, at a minimum, annual inspections of your ROBERTS GORDON

equipment and perform service where necessary, using only replacement parts sold and supplied by RobertsGordon LLC.

The Vicinity of the Heater Do not store or use flammable objects, liquids or vapors near the heater.

Immediately remove these items if they are present.

See Page 5, 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 5, Section 3.

Reflector Support reflector with reflector hanger and support strap.

Reflector must not touch tube.

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. See Page 20, Section 6.5.1.

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 d

ust. Clean as required.

Remove any carbon deposits or scale using a wire brush.

See Page 31, Section 8.

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.

Tubes Make sure there are no cracks.

Make sure tubes are connected and suspended securely.

See Page 12, Section 6.

Make sure there is no sagging, bending or distortion.

Clean or replace as required.

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Gas Line Check for gas leaks. See Page 37, Section 9. Burner Observation

Window

Blower Scroll, Wheel and Motor

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

Clean and replace as required.

Compressed air or a vacuum cleaner may be used to clean dust and dirt.

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

Carefully remove any dust and debris from the burner.

Hot-Surface Igniter Replace if cracked or broken. Heat Demand Device:

Thermostat, Zone Sensor, External Pot or 0-10 Vdc or

There should be no exposed wire or damage to the device or wiring.

See Page 39, Section 10.

4 - 20 mA wiring Suspension Points Make sure the heater is hanging securely.

Look for signs of wear on the chain or ceiling.

See Page 13, Figure 14.

Decorative and Protective Grille (optional)

The grille must be securely attached.

Check that the side reflector extensions are installed correctly and secured in place if necessary. (Decorative grille only.)

See Page 28, Section 7.5 and Page 30, Section 7.6

Make sure shield is installed correctly and secured in place if necessary.

Lower Clearance Shield (optional)

(Decorati The lower shield must be securely attached.

Inspect shield support straps and lower clearance shield anchor points.

ve grille only.) See Page 29, Section 7.5.2.

See Page 28, Section 7.4.

Make sure shield is installed correctly and secured in place if necessary.

See Page 28, Section 7.4.

Silicone Tubing Ensure tight, secure fit on all pressure fittings at gas valve, pressure switch,

pressure sensor, burner partition, and blower outlet.

Gas Valve Verify silicone tubing has a tight secure fit on "vent" fitting.

Verify that plastic cap on covering pressure regulator adjustment screw is secure and has not been tampered with.

Do not remove plastic regulator cap or attempt to adjust valve pressure regulator.

Verify all wiring connections.

Wall Tag

If wall tag is present, make sure it is legible and accurate. Please contact Roberts-Gordon LLC or your ROBERTS GORDON

independent distributor, if

you need a wall tag. See Page 4, Section 2.1.

Safety Labels Product safety signs or labels should be replaced by the product user when

they are no longer legible. Please contact Roberts-Gordon LLC or your ROB-

ERTS GORDON

independent distributor to obtain replacement signs or

labels. See Page 2, Figure 1 through Page 3, Figure 2.

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SECTION 12: TROUBLESHOOTING

Fire Hazard

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

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

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

WARNING

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

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

Explosion Hazard

Turn off gas supply to heater before service.

DANGER

Electrical Shock Hazard

Disconnect electric before service.

More than one disconnect switch may be required to disconnect electric from heater.

Heater must be properly grounded to an electrical source.

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

SECTION 12: TROUBLESHOOTING

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

12.1 Control LED

The control inside the heater's control compartment is equipped with a tri-color LED. The LED offers comprehensive diagnostic capability. The LED is showing some form of status signal at all times when the control is powered. The color of the LED differentiates normal from error conditions as follows:

GREEN indicates normal operation. RED indicates an error condition. YELLOW (fast flashing) indicates a RETRY attempt. LED NOT LIT indicates no power to control.

12.2 General LED Codes

No LED: No Power to control.

Slow Green: LED slowly flashes on and off,

indicates power to the control board but no call for heat.

GREEN, 1 flash: Call for heat indicates the

heater is performing the safe start pre-purge function or H.S.I. warm-up.

GREEN, 2 flashes: Call for heat indicates the

heater is performing light off, heater warm-up, or heater run.

GREEN, 3 flashes: *Only applicable for

thermostat control* Gas ON - No call for heat, unit

modulating from single stage thermostat.

AMBER, 1 flash: Call for heat when flame signal

is below 1µA

AMBER, Fast Flashing: Heater is in RETRY mode.

RED Steady LED: Control FAILURE,

No 24 V power supply.

RED, 1 flash: Lockout- Insufficient sensed

air pressure when blower is on. Condition could be caused by:

• Air Side Door

• Blower

• Obstruction in inlet or outlet

• Pressure hose fittings

• Pressure Switch

RED, 2 flashes: Lockout- Blower air pressure

reads above zero level when blower is off. Condition is caused by a pressure sensor failure or complete blockage of air intake or exhaust vent.

RED, 3 flashes: Lockout- Flame is sensed on

when it should be off or off when it should be on.

Could be caused by:

• Flame Rod

• H.S.I.

• Gas Supply

• 120 V Supply Polarity

• Board Fault

RED, 4 flashes: Locko

ut- Gas Valve. Condition caused by main valve on gas valve. Check gas valve wiring.

AMBER, 2 flashes: Gas ON - Call for heat when

flame signal is below 1µA

AMBER, 3 flashes: *Only applicable for

thermostat control* Gas ON - No call for heat, unit

modulating from single stage thermostat when flame signal is below 1µA.

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RED, 5 flashes: Lockout- Board Failure.

Board must be replaced.

RED, 6 flashes: Not used.

RED, 7 flashes: Lockout- Fuse Open.

Condition could be caused by:

• Fuse blown

• High Limit Switch open a

board location J3

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RED, 8 flashes: Lockout- Pressure switch

failed to operate or modulation current was incorrect. Condition could be caused by:

• Pressure Sensor

• Pressure Switch

(faulty or hoses reversed)

• Gas Valve Modulation Coil

• Wire Harness (6 wire)

RED, 9 flashes: Lockout- Air Supply.

Condition could be caused by:

• Blower

• Pneumatic Conections to Pressure Sensor

• Blockage in flue or inlet

SECTION 12: TROUBLESHOOTING

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

12.3 Troubleshooting Flow Chart

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SECTION 12: TROUBLESHOOTING

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

Carbon Monoxide Hazard

Do not adjust gas valve pressure regulator.

Do not tamper with sealed parts.

Pressure regulator is factory calibrated for safe operation.

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

12.4 Manifold Gas Pressure Measurement

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12.5 Pneumatic Connections

SECTION 12: TROUBLESHOOTING

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Carbon Monoxide Hazard

WARNING

Use only genuine ROBERTS GORDON® replacement parts per this installation, operation and service manual.

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

Explosion Hazard

DANGER

Electrical Shock Hazard

Fire Hazard

SECTION 13: REPLACEMENT PARTS

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SECTION 13: REPLACEMENT PARTS

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Gas Valve (Natural) 90033105K Gas Valve (LP) 90033104K Tube Gasket 02568200 Blower Inlet Gasket (80, 115 models) 03050900 Blower Inlet Gasket (150, 200 models) 90709910 Blower Assembly (80, 115) 90708602-P Blower Assembly (150, 200) 90709900-P Air Collar (80, 115 models) 91911700 Air Collar (150, 200 models) 91911701 Inlet Screen (80, 115) 03050800 Inlet Screen (150, 200) 09050001 Door Switch 90436800 Burner Cup Assembly 03020100 Hot Surface Igniter 90436600K Mica Window Assembly 02553203 Flame Sensor 90439300 Transformer 90436900K Fuse (Control) 3 A 91321403 Pressure Switch (80 NG, 80 LP, 115 NG, 115 LP) 90439812K (150 NG, 150 LP, 200 NG, 200 LP) 90439803K Control 80NG 90320109K 80LP 90320110K 115NG 90320111K 115LP 90320112K 150NG 90320113K 150LP 90320114K 200NG 90320115K 200LP 90320116K

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SECTION 14: GENERAL SPECIFICATIONS

Turbulator

(Select Models)

Side View

Reflector

17.5"

(44 cm)

Minimum Length "A"

End View

13.5"

(34 cm)

9.5"

(24 cm)

Burner Tube

Heat Input Rate

(NG)

Heat Input

Rate

(LP)

Length “A”

Recommended

Minimum Mounting Height*

Model

(Btu/h) X (1000)

Min. to Max.

(Btu/h) X

(1000)

Min. to Max.

Minimum Space Spot

CTH3-80 52 to 80 55 to 80 20' (6m) 12'-15' (3.6 - 4.5 m) 11' (3.3 m)

CTH3-115 75 to 115 78 to 115 30' (9m) 15'-20' (4.5 - 6 m) 15' (4.6 m)

CTH3-150 100 to 150 105 to 150 40' (12m) 20'-25' (6 - 7.6 m) 20’ (6.1 m)

CTH3-200 130 to 200 135 to 190 50' (15m) 25' (7.6 m) 23' (7 m)

14.1 Material Specifications

14.1.1 Reflectors

.024 Aluminum (Optional .024 Stainless Steel Type 304)

14.2 Heater Specifications

14.2.1 Control System

Modulating Gas Valve and Hot Surface Electronic Ignition Control with Four-try, 100% shut-off, Prepurge, Post-Purge, Auto Reset, Tri-color LED Status/Fault Indicator.

General Specifications for the heaters are as follows:

SECTION 14: GENERAL SPECIFICATIONS

14.3 Suspension Specifications

Hang heater with materials with a minimum working load of 75 lbs (33 kg). See Page 13, Figure 14.

14.4 Controls Specifications

Time switches, sensors, etc. can be wired into the electrical supply. External controls supplied as an optional extra.

*See Page 5, Section 3 for clearances to combustibles.

GAS PRESSURE AT MANIFOLD:

Natural Gas: 4.5" wc LP Gas: 11.0" wc

GAS INLET PRESSURE: Natural Gas:

for 80, 115 & 150 models 5.5" wc Minimum

PIPE CONNECTION:

1/2" NPT (for 80 & 115 models) 3/4" NPT (for 150 & 200 models)

DIMENSIONS:

Vent Connection Size: 4" (10 cm) Outside Air Connection Size: 5" (13 cm) for 150 & 200 models 4" (10 cm) for 80 & 115 models

for 200 6.0" wc Minimum

LP Gas: 12.0" wc Minimum

ELECTRICAL RATING (ALL MODELS):

120V - 60 Hz., 4.8 A (start), 1.3 A (run)

Refer to figure above for dimensional information.

14.0" wcMaximum

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CTH3-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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SECTION 15: THE ROBERTS GORDON® VANTAGE® MODULATING WARRANT Y

SECTION 15: THE ROBERTS GORDON VANTAG E

MODULATING WARRANTY

ROBERTS-GORDON WILL PAY FOR:

Within 36 months from date of purchase by buyer or 42 months from date of shipment by Roberts-Gordon LLC (whichever occurs first), replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect.

Roberts-Gordon LLC will require the part in question to be returned to the factory. Roberts-Gordon LLC will, at its sole discretion, repair or replace after determining the nature of the defect and disposition of part in question.

ROBERTS GORDON

Replacement Parts are warranted for a period of 12 months from date of shipment from Roberts-Gordon LLC or the remaining ROBERTS GORDON

VANTAGE® MODULATING warranty.

ROBERTS-GORDON WILL NOT PAY FOR:

Service trips, service calls and labor charges. Shipment of replacement parts. Claims where the total price of the goods have not

been paid. Damage due to:

• Improper installation, operation or maintenance.

• Misuse, abuse, neglect, or modification of the ROBERTS GORDON

VANTAGE® MODULATING in

any way.

• Use of the ROBERTS GORDON

VANTAGE® MODULATING for other than its intended purpose.

• Incorrect gas or electrical supply, accident, fire, floods, acts of God, war, terrorism, or other casualty.

• Improper service, use of replacement parts or accessories not specified by Roberts-Gordon.

• Failure to install or maintain the ROBERTS GORDON VANTAGE® MODULATING as directed in the Installation, Operation and Service manual.

• Relocation of the ROBERTS GORDON

VANTAGE®

MODULATING after initial installation

• The use of the ROBERTS GORDON

VANTAGE® MODULATING in a corrosive atmosphere containing contaminants.

• The use of the ROBERTS GORDON

VANTAGE® MODULATING in the vicinity of a combustible or explosive material.

• Any defect in the ROBERTS GORDON

VANTAGE® MODULATING arising from a drawing, design, or spec- ification supplied by or on behalf of the consumer.

• Damage incurred during shipment. Claim must be filed with carrier.

WARRANTY IS VOID IF:

The ROBERTS GORDON® VANTAGE® MODULATING is not installed by an electrician qualified in the installation and service of gas fired heating equipment.

Yo u cannot prove original purchase date and required annual maintenance history.

The data plate and/or serial number are removed, defaced, modified or altered in any way.

The ownership of the ROBERTS GORDON

VANTAGE® MODULATING is moved or transferred. This warranty is nontransferable.

Roberts-Gordon LLC is not permitted to inspect the damaged controller and/or component parts.

READ YOUR INSTALLATION, OPERATION AND SERVICE MANUAL

If you have questions about your controller, contact your installing professional. Should you need Replacement Parts or have additional questions, call or write:

Roberts-Gordon LLC

1250 William Street P. O . B o x 4 4 Buffalo, New York 14240-0044 Telephone: +1.716.852.4400 Fax: +1.716.852.0854 Toll Free: 800.828.7450

www.rg-inc.com www.radiantheaters.com

Roberts-Gordon LLC's liability, and your exclusive remedy, under this warranty or any implied warranty (including the implied warranties of merchantability and fitness for a particular purpose) is limited to providing replacement parts during the term of this warranty.

Some jurisdictions do not allow limitations on

how long an implied warranty lasts, so this limitation may not apply to you. There are no rights, warranties or conditions, expressed or implied, statutory or otherwise, other than those contained in this warranty.

Roberts-Gordon LLC shall in no event be responsible for incidental or consequential damages or incur

liability for damages in excess of the amount paid by you for the ROBERTS GORDON

VANTAGE® MODULATING. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so this limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from jurisdiction to jurisdiction.

Roberts-Gordon LLC shall not be responsible for failure to perform under the terms of this warranty if caused by circumstances out of its control, including but not limited to war, fire, flood, strike, government or court orders, acts of God, terrorism, unavailability of supplies, parts or power. No person is authorized to assume for Roberts-Gordon LLC any other warranty, obligation or liability.

LIMITATIONS ON AUTHORITY OF REPRESENTATIVES:

No representative of Roberts-Gordon LLC, other than an Executive Officer, has authority to change or extend these provisions. Changes or extensions shall be binding only if confirmed in writing by Roberts-Gordon LLC's duly authorized Executive Officer.

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Roberts Gorden VANTAGE CTH3-80, VANTAGE CTH3-150, Vantage Modulating CTH3-80, VANTAGE CTH3-115, Vantage Modulating CTH3-150 Installation, Operation & Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual