Rapid Engineering BH-40 Installation, Operation & Service Manual Download Page 67

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Summary of Contents for BH-40

Page 1: ...n the installation and service of gas fired heating equipment or your gas supplier Improper installation adjustment alteration service or maintenance can result in death injury or property damage Read the Installation Operation and Service Manual thoroughly before installing or servicing this equipment Installer Please take the time to read and understand these instructions prior to any installati...

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Page 3: ...ies 25 7 1 U Tube Configuration 25 7 2 Elbow Package Configuration 28 7 3 Reflector Side Extension 31 7 4 Lower Clearance Shield Installation 32 7 5 Two Foot Decorative Grille Installation 32 7 6 Protective Grille Installation 34 SECTION 8 Venting 35 8 1 Venting 35 8 2 Unvented Operation 36 8 3 Horizontal Venting 36 8 4 Vertical Venting 36 8 5 Unvented Operation Tube Termination 36 8 6 Length Requ...

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Page 5: ...ng 9 Figure 13 Major Component Descriptions 11 Figure 14 Critical Hanger Placement 15 Figure 15 Linear Heater Assembly Overview 16 Figure 16 Linear Heater Layout Overview 17 Figure 17 Linear Heater Layout Overview Continued 18 Figure 18 U Tube Heater Assembly Overview 26 Figure 19 U Tube Heater Layout Overview 27 Figure 20 U Tube Layout Overview Continued 28 Figure 21 Reflector Joint Detail 30 Fig...

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Page 7: ...e 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 ...

Page 8: ...RVICE MANUAL 2 of 59 FIGURE 1 Top and Bottom Panel Label Placement Logo Label Vent Length Label Top Panel Bottom Panel Gas Connection Label Description Part Number Logo Label 91031102 Vent Length Label 91039500 Gas Connection Label 91018123 ...

Page 9: ...Panel Label Placement Description Part Number Rating Plate Label 91010406 Lighting Instruction Plate Label 91029602 Wiring Label 91030301 Clearances to Combustibles Label 91013412 Proposition 65 Label 91070015 Thermostat Connection Label not shown 91037902 ...

Page 10: ...g P N 91037920 is illustrated on the back cover For an immediate solution you may affix this copy on the wall near the heater Know your model number and installed configuration Model number and installed configuration are found on the burner and in the Installation Operation and Service Manual See Page 6 Figure 3 through Page 9 Figure 12 Write the proper clearance dimensions in permanent ink accor...

Page 11: ...ility 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 In locations used for the storage of combustible materials sign...

Page 12: ...4 117 BH 140 150 6 50 79 50 16 127 201 127 BH 175 200 8 52 82 52 21 133 209 133 FIGURE 4 One Side Reflector inches centimeters Model A B C D A B C D BH 40 6 9 52 44 16 23 133 112 BH 60 6 9 62 47 16 23 158 120 BH 80 6 9 69 54 16 23 176 138 BH 100 6 9 76 59 16 23 194 150 BH 115 125 6 9 82 65 16 23 209 166 BH 140 150 6 9 85 69 16 23 216 176 BH 175 200 8 9 88 73 21 23 224 186 C B D A FIGURE 5 Two Side...

Page 13: ...H 140 150 12 8 83 74 31 21 211 188 BH 175 200 12 8 85 79 31 21 216 201 FIGURE 7 U Tube Standard Reflector inches centimeters Model A B C D A B C D BH 40 UNAPPROVED UNAPPROVED BH 60 6 35 62 30 16 89 158 77 BH 80 6 38 68 37 16 97 173 94 BH 100 6 40 75 39 16 102 191 100 BH 115 125 6 46 78 43 16 117 199 110 BH 140 150 6 50 83 47 16 127 211 120 BH 175 200 8 54 87 51 21 138 221 130 B D C A FIGURE 8 U Tu...

Page 14: ...96 56 BH 140 150 12 74 83 22 31 188 211 56 BH 175 200 12 76 85 22 31 194 216 56 B A C D FIGURE 10 2 Foot Deco Grille and Protective Grille inches centimeters Model A B C D A B C D BH 40 6 27 52 27 16 69 133 69 BH 60 6 35 62 35 16 89 158 89 BH 80 6 38 65 38 16 97 166 97 BH 100 6 40 70 40 16 102 178 102 BH 115 125 6 46 76 46 16 117 194 117 BH 140 150 6 50 79 50 16 127 201 127 BH 175 200 8 52 82 52 2...

Page 15: ... after 25 7 5 m of tubing downstream from where the burner and burner tube connect FIGURE 12 Venting inches centimeters Model A E F A E F BH 40 14 18 18 36 46 46 BH 60 14 18 18 36 46 46 BH 80 20 24 18 51 61 46 BH 100 20 24 18 51 61 46 BH 115 125 20 24 18 51 61 46 BH 140 150 20 30 18 51 77 46 BH 175 200 20 30 18 51 77 46 Radiant Tubes Vent Pipes Unvented Vented A E F ...

Page 16: ...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 ...

Page 17: ...n 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 Hot rolled or 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...

Page 18: ...3 3 92311800 Keps Nut 4 4 4 4 4 4 4 4 4 4 03051503 Turbulator Adapter 1 1 1 1 1 1 03051504 Turbulator 2 5 76 cm Aluminized Steel 2 4 4 1 3 1 03051505 Turbulator 2 5 76 cm Stainless Steel 1 Table 2 Contents of Core and Extension Packages Core Packages Extension Packages Hot Rolled Aluminized Hot Rolled Aluminized Part No Description 20 6m 30 9m 40 12m 10 3m 20 6m 30 9m 40 12m 10 3m 20 6m 30 9m 40 1...

Page 19: ... 45 13 7 m total Table 3 BH Series Component Package Guide Model Tubing Length Core Packages Minimum Standard Aluminized BH 40 10 3 m CP10ALUM BH 60 20 6 m CP20HRS CP20ALUM BH 80 20 6 m CP20HRS CP20ALUM BH 100 30 9 m CP30HRS CP30ALUM BH 115 30 9 m CP30HRS CP30ALUM BH 125 40 12 m CP40HRS CP40ALUM BH 140 40 12 m CP40HRS CP40ALUM BH 150 50 15 m CP30HRS EXP20HRS CP30ALUM EXP20ALUM BH 175 50 15 m CP30H...

Page 20: ...bles as indicated on the rating plate and in this instruction manual The minimum and maximum gas inlet pressures must be maintained as indicated on the rating plate Typical installation configurations are shown on Page 15 Figure 14 Expansion and contraction of the tube dictates that the minimum suspension lengths must be maintained See table on Page 15 Figure 14 WARNING Severe Injury Hazard Secure...

Page 21: ...pical 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 3 m 50 15 2 m 1 3 cm 12 30 5 cm 51 15 5 m 60 18 3 m 2 5 cm 18 45 7 cm 61 18 6 m 80 24 4 m 3 8 cm 24 61 ...

Page 22: ...ERVICE MANUAL 16 of 59 FIGURE 15 Linear Heater Assembly Overview 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 ...

Page 23: ...7 6 2 3 m distance first hanger e 10 3 m distance between hangers f 12 5 32 cm burner height g 11 28 cm burner length Vent Adapter Burner Reflector Tube Tube Reflector Hanger Coupling Assembly LEGEND g c b d f g c b d e f g c b d e f e g c b d e f e e g c b d e f e e e 10 3 m Tube Length 20 6 1 m Tube Length 30 9 1 m Tube Length 40 12 2 m Tube Length 50 15 2 m Tube Length ...

Page 24: ...g c b d e f e e e e e e 60 18 3 m Tube Length 70 21 3 m Tube Length 80 24 4 m Tube Length 7 6 1 229 cm 25 cm NOTE Tubing requires a downward slope of 1 2 13 mm 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 ...

Page 25: ...lat Washer 95211600 Nut 92113900 Tube 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 A Close coupling with tab B Start slide bar coupling lock onto coupling C Insert tubes into coupling D Tighten coupling to join tubes Description Part Number Co...

Page 26: ... 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 20 Step 6 3 2 Tighten slide bar as shown below 10 1 3 m 25 m Total Overall Tube Length 7 6 1 2 3 m 25 m Model Tube Length Minimum BH 40 10 3 m BH 60 20 6 m BH 80 20 6 m BH 100 30 9 m BH 115 30 9 m BH 125 40 12 m BH 140 40 12 m BH 150 50 15 m BH 175 50 ...

Page 27: ...ction 2 5 76 2 cm Stainless 03051505 Tube 91409XXX Turbulator must be installed in the last standard section of tube Turbulator is not required on the BH 125 150 175 200 Turbulator Installation Model Tube Section BH 40 1st 10 3 m Section BH 60 2nd 10 3 m Section BH 80 2nd 10 3 m Section BH 100 3rd 10 3 m Section BH 115 3rd 10 3 m Section BH 125 N A BH 140 4th 10 3 m Section BH 150 N A BH 175 N A B...

Page 28: ...ector 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 ...

Page 29: ...ector 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...

Page 30: ...VICE MANUAL 24 of 59 Step 6 6 Burner Installation Lock Washer Gasket Burner Bolt Torque 120 in lb 13 56 Nm S hook Burner Tube Extra chain min 12 30 cm Description Part Number Bolt 94273914 Burner RP71XXXXX Lock Washer 96411600 Gasket 02568200 ...

Page 31: ...e following additional rules must be adhered to A minimum of 10 3 m on BH 60 80 and a minimum of 15 4 5 m on BH 100 115 125 140 150 175 200 is required between the burner and the U tube The correct turbulator See Page 21 Step 6 4 must be installed in the last standard section of the tube The burner must never be operated in a tilted position The heater must be properly supported at all locations S...

Page 32: ...rner Tube Tube U tube Support Bracket Reflector Support Couplings U tube Standard Nut Lock Washer Lock Washer Nut U bolt 1 2 1 2 U tube Opposite 45 Vent Adapter 1 U tube 45 2 Tight U bolt 4 10 cm u bolt secured to burner tube with 1 4 6 cm lockwashers and 1 4 6 cm 20 hex nuts Loose U bolt 4 10 cm u bolt secured to bracket with 1 4 6 cm lockwashers and 1 4 6 cm 20 hex nuts on top and bottom to allo...

Page 33: ...e Hanger and Half Tube Hanger g 12 5 32 cm Burner Length h 11 28 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 0 m Tube Reflector Hanger Coupling Assembly Tube 5 1 5 m c b d e g h 40 12 2 m Tube Length c b d f g h 30 9 1 m Tube ...

Page 34: ...Tube Length 80 24 4 m Tube Length 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 BH 40 10 3 m BH 60 10 3 m BH 80 10 3 m BH 100 15 4 5 m BH 115 15 4 5 m BH 125 15 4 5 m BH 140 15 4 5 m B...

Page 35: ...SECTION 7 OPTIONAL HEATER ACCESSORIES 29 of 59 Step 7 2 2 Elbow Installation Step 7 2 3 Reflector Joint Installation Step 7 2 4 Reflector Joint Installation Tube Coupling ...

Page 36: ...BH SERIES INSTALLATION OPERATION AND SERVICE MANUAL 30 of 59 Step 7 2 5 Reflector Joint Detail FIGURE 21 Reflector Joint Detail ...

Page 37: ... air movement applications Tube and Reflector Hanger Reflector Tube 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...

Page 38: ...tep 7 5 1 Grille Installation 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 2 4 m 02793000 Locknut 8 92311400 Flat Washer 8 95310800 Screw 8 x 3 8 93511406 Description Part Number Aluminum Grille 2 x 4 61 x 122 cm 91407000 ...

Page 39: ... Extension Installation for Decorative Grilles Description Part Number Deco Grille Shield 01365900 Description Part Number Reflector Side Extension 01370412 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 ...

Page 40: ...nstallation Step 7 6 2 Grille End Cap Installation Step 7 6 3 Grille Installation Silicone Cap Grille Finger Description Part Number Grille Section 08050001 Grille End Cap 08050002 Silicone Cap 91915951 6P Bend up 90 Pull outward Grille Grille End Cap A B C D Grille Grille End Cap Reflector Final Grille Section 40 101 cm ...

Page 41: ...ustibles given on Page 9 Figure 12 The bottom of the vent or air intake terminal shall not be located less than 1 0 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 gases Secure all joi...

Page 42: ... of more than two heaters See Page 38 Section 8 10 A vent shall not extend less than 2 0 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 22 Tube Termination 8 6 Length Require...

Page 43: ... 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 Vent Adapter TOP VIEW 4 10 cm Single Wall Pipe 6 15 cm Single Wa...

Page 44: ...enting 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 ...

Page 45: ...s 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 8 11 1 Length Requirements Follow the constraints listed on Page 36 Section 8 6 8 11 2 Vertical Outside Air Supply for Single Heater Installation 8 11 3 Horizontal Outside Air Supply for Single Heater Installation Description Par...

Page 46: ...s must be controlled by a common thermostat Sweeping T Connection 6 15 cm Single Wall Pipe Vent Cap 4 10 cm Single Wall Pipe Band Clamp Recommended Burner Burner Flex Hose Recommended Flex Hose Recommended Roof Description Part Number Vent Cap 6 15 cm 90502302 Sweeping Y Connection Vent Cap Outside Wall 4 10 cm Single Wall Pipe Seal All Joints 6 15 cm Single Wall Pipe Flex Hose Recommended Band Cl...

Page 47: ...ble Stainless Steel Gas Hose US models supplied with the heater is certi fied per the Standard for Connectors for Gas Appli ances 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 Lat...

Page 48: ...ax displacement Side View Heater Movement 12 30 cm 45 Burner Assembly Shown Without Blower Assembly Pipe Nipple Rear View 45 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 Heater Movement Descriptio...

Page 49: ...er 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 Line Voltage Thermostat Wiring DANGER Electrical Shock Hazard Disconnect electric before service Heater must...

Page 50: ... 4 5 6 COIL L1 L2 Gnd N H Gnd N H Gnd Additional Burners 120 V 60 Hz Supply Circuit Low Voltage Thermostat Burner 1 Burner 2 Maximum 8 Burners Per Relay Black SPST Transformer Relay Black Red White COIL FRONT VIEW BACK VIEW Description Part Number SPST Transformer Relay 90417600K Low Voltage Thermostat 90425100 ...

Page 51: ...SECTION 10 WIRING 45 of 59 10 3 Internal Wiring ...

Page 52: ...agram 10 5 Electrical Connection to the Burner Conduit Hole BX or Romex Connector Burner Box Internal Wire Bundle Green White Black L1 L2 Gnd Connect wires together with suitable approved wire connections Green to Gnd White to L2 Black to L1 Electrical Cord or Flexible Conduit ...

Page 53: ...he unit is shut off 11 2 To Shut Off Heater Set thermostat to lowest setting 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 thermostat to desired temperature Burner should light automatically...

Page 54: ...nd 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 ha...

Page 55: ...ed correctly and secured in place if necessary Decorative grille only See Page 32 Section 7 5 and Page 34 Section 7 6 Make sure shield is installed correctly and secured in place if necessary Decorative grille only See Page 33 Section 7 5 2 Lower Clearance Shield optional The lower shield must be securely attached Inspect shield support straps and lower clearance shield anchor points See Page 32 S...

Page 56: ...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 Tubin...

Page 57: ...transformer secondary Reconnect transformer wires Place a jumper wire across the pressure switch Is there a spark Check wiring between the power cord blower motor and transformer Replace igniter and ignition wire as needed Carefully reset spark gap to 1 8 Are the air hoses to the pressure switch secure and leak free Repair replace or tighten hoses as necessary Is the vent pipe or the inlet of the ...

Page 58: ...BH SERIES INSTALLATION OPERATION AND SERVICE MANUAL 52 of 59 ...

Page 59: ...SECTION 12 TROUBLESHOOTING 53 of 59 12 2 Manifold Gas Pressure Setting ...

Page 60: ...PARTS Carbon Monoxide Hazard WARNING Use only genuine RAPID 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 ...

Page 61: ...SECTION 13 REPLACEMENT PARTS 55 of 59 ...

Page 62: ...501 Tube Gasket 02568200 Burner Cup Assembly 03020100 Gas Valve Natural 90032500 Gas Valve LP 90032502 Electrode 90427400 DSI Ignition Module 90439500K Transformer 90436900K Pressure Switch 200 90439801K 115 140 175 90439802K 150 90439803K 60 80 100 125 90439805K 40 90439808K Motor Blower Assembly 90709700 P Blower Outlet Gasket 90709801 ...

Page 63: ...00 115 125 3 4 NPT for BH 140 150 175 200 DIMENSIONS Vent Connection Size 4 10 cm Outside Air Connection Size 4 10 cm Refer to figure above for dimensional information GAS INLET PRESSURE Natural Gas for BH 40 60 80 100 115 125 140 150 4 6 wc Minimum for BH 175 200 5 0 wc Minimum 14 0 wc Maximum LP Gas 11 0 wc Minimum 14 0 wc Maximum ELECTRICAL RATING ALL MODELS 120 V 60 Hz 1 A Turbulator select mo...

Page 64: ...BH SERIES INSTALLATION OPERATION AND SERVICE MANUAL 58 of 59 ...

Page 65: ...removed defaced modified or altered in any way The ownership of the RAPIDTM BH is moved or transferred This warranty is non transferable Rapid Engineering LLC is not permitted to inspect the damaged equipment and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your equipment contact your installing professional Should you need Replacement Parts or...

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