Rapid Engineering CGTH-30 Installation & Operation Manual Download

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CGTH I

NSTALLATION

, O

PERATION

AND

ERVICE

ANUAL

50 of 55

SECTION 15: REPLACEMENT 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

Summary of Contents for CGTH-30

Page 1: ...rical 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 Fire Hazard Keep all flammable objects liquids and vapors the minimum required safe distances to combustibles away fro...

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Page 3: ...irements 12 6 4 Venting Requirements 13 6 5 Non Residential Installations 13 SECTION 7 Required Safe Distances From Combustibles15 SECTION 8 Installation 17 8 1 Safety Equipment 17 8 2 Installation Tools 17 8 3 Installation Materials 17 8 4 Choose Location for Heater 18 8 5 General Venting Guidelines 18 8 6 Hang the Heater 21 8 7 Remove Shipping Screw from Control Housing Door 21 8 8 Heater Assemb...

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Page 5: ...e View 29 Figure 20 Bird Screen Installation 29 Figure 21 Horizontal Installation Top View 30 Figure 22 Elbow Assembly End View 31 Figure 23 Elbow Assembly Cross Section View 31 Figure 24 Elbow Assembly 31 Figure 25 Elbow Assembly for Vent Collar 31 Figure 26 Vent Collar and 5 Vent Attachment 31 Figure 27 Horizontal Installation Side View Cox Geelen Venting 33 Figure 28 Flue Collar and Adapter 33 ...

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Page 7: ...nces from combustibles are also found on Pages 15 and 16 of this manual After the installation is complete check product operation as provided in these instructions 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 men...

Page 8: ...Manpower Requirements To prevent personal injury and damage to the heater two persons will be required to remove the heater from the carton Both ends of the heater should be lifted from the carton at the same time The burner should be lifted by gripping the bottom The reflector of the heater should be lifted using the hanger 2 2 2 Safety Protective gear is to be worn during installation oper ation...

Page 9: ...nd Side Panel Label Placement Side Panel Operating Instruction Label Logo Label Bottom Panel Clearances to Combustibles Label Description Part Number Logo Label 91031102 Operating Instruction Label 91037100 Clearances to Combustibles Label 91037800 ...

Page 10: ... Back Panel Label Placement Description Part Number Shock Hazard Label 91037901 Wiring Diagram Label 91037600 Fire Hazard Label 91037900 Cord Shock Hazard Label 91037500 Thermostat Connection Label 91037902 Carbon Monoxide Hazard label 91037300 Proposition 65 Warning Label 91070015 ...

Page 11: ...80000 B 1 Reflector End Cap P N 02750800 C 4 U Clips P N 91107720 B A C 1 Flue Collar P N 08031500 1 Vent Termination P N 08031001 1 Bird Screen P N 08036000 1 3 8 10 mm Manual Gas Shut off Valve P N 90100200 Protective Grille Kits Included with select models Also available as an accessory under kit part numbers CGTH 30 Kit P N 08051000 includes 1 Grille End Cap P N 08050002 2 Grille without End C...

Page 12: ...U Clips P N 91107720 B A C Protective Grille Kits Included with select models Also available as an accessory under kit part numbers CGTH 30 Kit P N 08051000 includes 1 Grille End Cap P N 08050002 2 Grille without End Cap P N 08050001 2 Silicone Cap P N 91915951 6P CGTH 40 and CGTH 50 Kit P N 08051001 includes 3 Grille without End Cap P N 08050001 1 Grille End Cap P N 08050002 3 Silicone Cap P N 91...

Page 13: ...ameter Spring 6 15 cm 2 75 6 cm Vent Terminal Extension P N 08037000 90 Elbow Kit P N 08038000 includes 1 5 13 cm Diameter Elbow P N 90503000 1 3 8 cm Diameter Elbow P N 90503100 1 Coil Spring Spacer P N 90503200 5 1 5 m Balanced Flue Vent P N 08039000 includes 1 5 13 cm Vent Pipe 60 152 cm P N 90502800 1 3 8 cm Flue Pipe 66 168 cm P N 08035000 ...

Page 14: ...N 90506001 Roof Venting Kit P N 08032100 includes 1 Burner Vent Adapter P N 90506012 1 Wall Terminal 25 4 cm with wall plate P N 90506011 includes 4 Screws P N 94118106 2 Wall Plates P N 90506013 Wall Venting Kit P N 08032200 includes Concentric Flue 10 25 cm P N 90506003 Concentric Flue 20 50 cm P N 90506004 Concentric Flue 39 100 cm P N 90506005 Concentric Flue 79 200 cm P N 90506006 Elbow 45 39...

Page 15: ... equipment or your gas supplier Removal of this service door provides access to the electrical and gas distribution components Gas Line Must only be installed and serviced by a licensed contractor or gas fitter Wall Termination Plate Placed on the outside wall over the venting Venting Installer must properly exhaust the heater outside The 5 13 cm outer duct carries fresh air to the burner The 3 8 ...

Page 16: ...Rating 120 V 60 Hz 1 Ø 1 A Connection 3 pin molded plug GAS INLET CONNECTION Connection 3 8 Male NPT GAS INLET PRESSURE Natural Gas Minimum Inlet 5 0 wc 12 4 mbar Maximum Inlet 14 0 wc 34 8 mbar LP Gas Propane Minimum Inlet 11 0 wc 37 4 mbar Maximum Inlet 14 0 wc 34 8 mbar MANIFOLD PRESSURE Natural Gas 3 5 wc 8 7 mbar LP Gas Propane 10 5 wc 26 1 mbar VENTING SPECIFICATIONS VENT FLUE Length 10 3 m ...

Page 17: ...ation given in this manual together with the cited codes and regulations to perform the installation The heater must be installed in accor dance with the minimum required safe distances from combustibles and must be vented outside If any aspects of the installation are unclear consult your RAPID independent distributor for clarification The installer must furnish all needed materials that are not ...

Page 18: ... line connection immediately upstream of the burner that is farthest from the gas supply meter The tap is required for checking system gas pressure 6 2 3 Meter and Service Meter and service must be large enough to handle all the heaters 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 maxi mum pressure drop of ...

Page 19: ...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 6 4 2 Balanced Flue Construction The balanced flue consists of a 3 8 m diameter flue which is concentrically positioned inside a 5 13 cm diameter vent pipe See Figure 5 The 5 13 cm diameter vent supplies outside air for combustion while the 3 8 cm diame...

Page 20: ... in public garages must be in accordance with the following codes United States Refer to Standard for Parking Structures NFPA 88A lat est revision or the Code for Motor Fuel Dispensing Facil ities and Repair Garages NFPA 30A latest revision Canada Refer to Natural Gas and Propane Installation Code CSA B149 1 latest revision Heaters must be installed a minimum of 8 2 4 m above the floor Required sa...

Page 21: ...inal locations It is important to keep the minimum required safe dis tances from combustibles at all times Clearances from vehicles parked beneath heaters must be main tained The thermostat tag included with the heater must be posted to identify any possible violation of the minimum required safe distances from combusti bles from the heater in vehicle areas Maximum allowable stacking height in sto...

Page 22: ...e distances from combustibles Dimensions C and E DO NOT indicate the required mounting height The minimum mounting height is 7 2 1 m except for aircraft hangars and public garages See Page 13 Sections 6 5 1 and 6 5 2 Flue clearances from combustibles are zero It is not necessary to provide additional clearance on penetrations through the wall or roof Know your model number Model number is found on...

Page 23: ...m Stud Finder if garage is finished 8 3 Installation Materials Materials required for the installation of the CGTH Series heater include at a minimum the following High temperature silicone sealant such as Gen eral Electric RTV106 or Permatex Form A Gas ket Red Suspension hooks capable of supporting 75 lbs each Sheet metal screws The following items may be required for your particu lar installatio...

Page 24: ...tural members rafters beams etc are accessible for attaching the heater To ensure the heater is placed in a approved application 8 5 General Venting Guidelines Regardless of the venting arrangement that will be connected to the heater the following general guide lines for venting must be followed 1 See Page 19 Figure 8 for allowable vent terminal locations 2 The 3 8 cm flue pipe must be centered i...

Page 25: ...Locations V V V V V V V V V V X X J B B B M I B E D L A X J F B G H B C FIXED CLOSED INSIDE CORNER DETAIL OPERABLE Vent Terminal Air Supply Inlet Area Where Terminal Is Not Permitted Canadian Installations1 US Installations2 A Clearances above grade veranda porch deck or balcony 12 30 cm 12 30 cm B Clearances to window or door that may be open 12 30 cm 9 23 cm C Clearances to permanently closed wi...

Page 26: ... in accordance with local installation codes and the requirements of the gas supplier F Clearances to outside corner G Clearances to inside corner 18 46 cm 18 46 cm H Clearances to each side of center line extended above meter regulator assembly 3 91 cm within a height 15 4 5 m above the meter regulator assembly I Clearances to service regulator vent outlet 3 91 cm J Clearances to non mechanical a...

Page 27: ...nside the control housing will fall loose It is not mandatory to remove the washer from the control housing FIGURE 9 Shipping Screw FIGURE 10 Suspension Details WARNING Severe Injury Hazard 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 WARNING Cut Pinch Hazard Wear protective gear during ins...

Page 28: ...UAL 22 of 55 8 8 Heater Assembly Slide rear movable hanger onto reflector as shown on Page 22 Figure 11 Attach reflector end cap with U Clips as shown on Page 22 Figure 11 FIGURE 11 Heater Assembly Rear Movable Hanger Reflector End Cap 4 U Clips ...

Page 29: ...at the selected mounting site will satisfy the measurement parameters vent length not to exceed 10 3 m described in that section 8 11 Horizontal Installation For Horizontal Installation 1 See Page 19 Figure 8 for allowable vent terminal locations 2 Using snap hooks attach two equal lengths of welded steel chain 75 lbs 33 kg to the two uppermost holes in the front fixed hanger 3 Slip the free end o...

Page 30: ...t for left or right tilting Two sus pension points must be used for the front hanger 2 The uppermost snap hook can now be installed on the suspension hardware that you have installed for suspension of the unit An addi tional length of chain may also now be installed if required to lower the heater FIGURE 14 45 Tilted Installation Front Fixed Hanger Rear Movable Hanger Snap Hooks Tilted Right Use b...

Page 31: ... Installation Step 1 Silicone Cap Installation See Page 25 Fig ure 15 Silicone caps P N 91915951 are to be placed along each side of the grille at both end fingers and the center finger FIGURE 15 Silicone Cap Installation Step 2 Attach grille end cap to final grille section See Page 25 Figure 16 Step 3 Install grille sections as follows on Page 26 Figure 17 Attach first grille section s P N 080500...

Page 32: ...ON AND SERVICE MANUAL 26 of 55 FIGURE 17 Reflector and Grille Grille End Cap Burner Front Fixed Hanger Reflector First Grille Sections Final Grille Section Description Part Number Grille Section 08050001 Grille End Cap 08050002 ...

Page 33: ... 1 m above grade when located adjacent to public walkways For galvanized venting seal all joints with high tem perature silicone sealant To avoid frost and condensation forming in the bal anced flue set thermostat to 50 F 10 C and above if outside air temperature falls below 20 F 28 C 9 1 1 United States Requirements Vent must terminate at least 3 9 m above any forced air inlet located within 10 3...

Page 34: ...eral venting requirements See Page 27 Section 9 1 3 Using the tape measure measure the distance between the rear surface of the heater and the exterior wall Note this dimension here _________ NOTE If the distance between the rear surface of heater and the exterior wall is greater than 5 1 5 m a 5 1 5 m balanced flue vent exten sion kit P N 08039000 will be required 4 From the reference mark made i...

Page 35: ...r in the vent terminal extension avail able as an option Both screen installations are described below Installing bird screen in 3 8 cm flue pipe 1 Insert the bird screen into the inside diameter of the 3 8 cm flue pipe as shown on Page 29 Figure 20 2 Secure the bird screen in position with a sheet metal screw Installing bird screen in optional vent terminal extension 1 Insert the bird screen into...

Page 36: ... D as shown in Figure 21 Note these dimensions here A ______ B ______ C ______ D ______ and add them together NOTE If the total of dimensions above are greater than 5 1 5 m a 5 1 5 m balanced flue vent extension kit P N 08039000 will be required FIGURE 21 Horizontal Installation Top View 4 From the reference mark made in step 2 mea sure down vertically 1 4 6 cm per foot mea sured in step 3 Cut 5 1...

Page 37: ...25 FIGURE 25 Elbow Assembly for Vent Collar 11 Attach the vent collar to the heater Hold the 5 13 cm vent material up to the 3 8 cm vent and mark the required length Note the length must be sufficient for a minimum of 1 1 2 4 cm overlap at both ends Cut the vent to length from the non crimped end Wrap the 3 8 cm tube with the 5 13 cm vent and snap the vent together Attach the 5 13 cm vent at both ...

Page 38: ...structures i e stud to prevent penetration Also check that the outlet of the vent does not compromise the gen eral venting requirements See Page 27 Section 9 1 Cut 5 13 cm vent terminal clearance hole as required 3 Using the tape measure measure the distance between the rear surface of the heater and the exterior wall Note this dimension here _________ A The following combinations will result in d...

Page 39: ...ure 27 Note the dimension here __________ C Separate the 3 8 cm and the 5 13 cm vent by pulling the 3 8 cm vent out from the end with the internal silicone gasket Remove the internal spring from the non sili cone gasket end of the 5 13 cm vent D Add 3 5 9 cm to the dimension noted in step B this is to allow for the internal joint of the vent Cut both the 3 8 cm and 5 13 cm vent to this length and ...

Page 40: ... Measure the distance to the center of the hole from the vent adapter Note this dimension here _________ If the concentric vent has to be cut use the following guidelines A Subtract 1 5 3 8 cm to allow for the elbow and both joints B Separate the 3 8 cm and the 5 13 cm vent by pulling the 3 8 cm vent out from the end with the internal silicone gasket Remove the internal spring from the non silicon...

Page 41: ...gh the 5 13 cm hole From the inside ensure the vent is square Secure the vent clamp to the inside of the roof See Figure 30 D Apply silicone sealant between base and roof Drill and fasten flashing to surface Use a blunt tool to press base into sharp corners of valleys while drilling and against to insert rivet or screw E Follow the sequence drill two holes on oppo site sides of aluminum base throu...

Page 42: ...stat for cor rect wire sizing 10 4 Thermostat Placement For best results locate the thermostat as follows Mount the thermostat on an interior wall whenever possible Mount the thermostat approximately 60 15 2 cm from the floor Mount the thermostat so that it is shielded from the heat that is radiated from the heater Mount the thermostat over the thermostat tag that is provided in the accessories ba...

Page 43: ...onnect thermostat wires to the THERMOSTAT CONNECTION on the rear su face of the burner as follows A Using an appropriate crimping tool install the female terminals included in accessories bag on the two wires from the thermostat B Push the female terminals on the male terminals The thermostat terminals are not polarity sensitive FIGURE 33 Thermostat Installation Rear View INSIDE FRONT COVER 50 60 ...

Page 44: ...ese instructions can result in death or electrical shock WARNING Fire Hazard Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Failure to follow these instructions can result in death injury or property damage DANGER Electrical Shock Hazard Plug heater into grounded three prong ceiling rec...

Page 45: ...IGURE 35 Ladder Diagram PRESSURE SWITCH BROWN YELLOW TRANSFORMER BLACK THERMOSTAT CONNECTION BLOWER GAS VALVE 3 4 RED 1 5 WHITE POWER SUPPLY WHITE GREEN BLACK GND V2 R L1 IND NC V1 PSW TH YELLOW FC FC LED GREEN RED BLACK BROWN BLUE BLUE S1 BLACK GREEN BLACK BLACK RED MALE FEMALE CONNECTOR ...

Page 46: ...ought iron or wrought steel pipe and mal leable iron fittings The use of copper tube and brass fittings is acceptable when such use is in compliance with local codes All pipe tube and fittings should be new and free from defects Carefully ream the pipe and tube ends to remove obstructions and burrs 3 Use LP gas resistant joint compound on all threads 4 Check the pipe and tube connections for leaks...

Page 47: ... 4 Turn off the manual gas valve in the heater supply line 5 Wait five 5 minutes to clear out any gas If you then smell gas STOP If you do not smell gas go to the next step 6 Open the manual gas valve in the heater supply line 7 Turn on electric power to the heater 8 Set the thermostat to the desired setting 9 If the heater will not operate See Page 41 Sec tion 12 2 and call your service technicia...

Page 48: ...ical supply is available to the heater With the gas supply turned off at the gas valve and the electrical supply isolated by switching off at the local switch and removing the appliance electrical plug open the control chamber secured by the four screws Remove the sealing screw from the outlet pressure tap with a 3 16 Hex Key Allen Wrench and install a test tap and hose Remove the cover cap from t...

Page 49: ...objects liquids and vapors the minimum required safe distances 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 T...

Page 50: ...rease thermostat temperature setting DSI module needs to be reset Unplug heater power cord from the electrical outlet wait for a minimum of five seconds Plug heater cord back into outlet No power at electrical outlet Replace fuse or reset circuit breaker Faulty thermostat wiring or Install jumper wire across THERMOSTAT faulty thermostat CONNECTION wires on the rear of the burner If blower starts r...

Page 51: ...ressure Check gas inlet pressure at the supply line Gas inlet pressure should be as follows Natural Gas 5 0 wc 12 4 mbar minimum 14 0 wc 34 8 mbar maximum LP Gas 11 0 wc 27 4 mbar minimum 14 0 wc 34 8 mbar maximum If gas inlet pressure does not meet inlet pressure requirements contact the gas company Gas valve does not open Check for 24 V across valve terminals IF NO Check wiring between the ignit...

Page 52: ...CGTH INSTALLATION OPERATION AND SERVICE MANUAL 46 of 55 FIGURE 38 Manometer Reading ...

Page 53: ...y sealed exhaust gases BURNER CYCLES ON AND OFF TOO QUICKLY Possible Cause Try this Anticipator setting on Adjust the anticipator setting to 0 6 See Page 25 Figure 15 the thermostat is too low BURNER MAKES VIBRATING NOISES WHILE RUNNING Possible Cause Try this Motor Vibration Ensure that the shipping screw has been removed from the control housing door See Page 21 Section 8 7 Protective Grille met...

Page 54: ... and labeling of the equipment To help facilitate optimum performance and safety Rapid Engineering LLC recommends that a qualified contractor conduct at a minimum annual inspections of your RAPID equipment and perform service where necessary using only replacement parts sold and supplied by Rapid Engineering LLC Cut Pinch Hazard Wear protective gear during installation operation and service Edges ...

Page 55: ...of cracks or holes Clean and replace as required Blower Scroll Wheel and Motor 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 Direct Spark Igniter Inspect the igniter Replace igniter if there is excessive carbon residue ero sion of electrodes...

Page 56: ...TS 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 57: ...This section contains the part numbers and pictorials for components of the CGTH Series heater Call out letters on the illustrations refer directly to the associated parts list FIGURE 39 Illustrated Parts List D E F G H I J M O N A B C K L ...

Page 58: ...indow Assembly 1 1 1 E 08018000 Adapter Orifice Holder 1 1 1 F 90710201 P Motor Blower 1 1 1 G 90434009K Ignition Module 1 1 1 H 90436900K Transformer 1 1 1 I 90439806K Pressure Switch 1 90439804K Pressure Switch 1 90439802K Pressure Switch 1 J 90034500 Gas Valve Natural Gas 1 1 1 90034600 Gas Valve LP Gas 1 1 1 K 91201618 Pipe Nipple 1 1 1 L 08031500 Flue Collar 5 13 cm 1 1 1 M 08115100 Door Gask...

Page 59: ... Bolt Rolok Hex HD 5 16 18 x 7 8 4 4 4 C 96411600 Lockwasher 5 16 Helical Spring 4 4 4 D 08023000 Support Plate 1 1 1 E 08070000 Burner Tube Gasket 1 1 1 F Screw 8 x 3 8 4 4 4 G 08090000 Reflector 80 203 cm 1 08090001 Reflector 120 305 cm 1 1 H 02750800 End Cap 1 1 1 I 91107720 U Clips 4 4 4 J 08080000 Rear Reflector Hanger Moveable 1 1 1 K 08061000 Support Plate 1 1 08062000 Support U bolt 2 2 Pa...

Page 60: ...CGTH INSTALLATION OPERATION AND SERVICE MANUAL 54 of 55 ...

Page 61: ...ed defaced modified or altered in any way The ownership of the RAPID GH is moved or transferred This warranty is nontransferable Rapid Engineering 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 ...

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