Rapid Engineering CTHN-40 Installation & Operation Manual Download

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SECTION 19: R

EPLACEMENT

ARTS

IST

85 of 91

SECTION 19: REPLACEMENT PARTS LIST

Carbon Monoxide Hazard

WARNING

Use only

enuine RAPID™ replacement parts per this installation, operation and service manual.

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

Explosion Hazard

DANGER

Electrical Shock Hazard

Fire Hazard

Summary of Contents for CTHN-40

Page 1: ...your gas supplier call the Fire Department Fire Hazard Keep all flammable objects liquids and vapors the minimum required clear ances to combustibles away from heater Some objects will catch fire or...

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Page 3: ...Length Requirements 54 12 6 Flue Connection Detail 55 12 7 Horizontal Ventilation 4 10 cm Pipe 55 12 8 Vertical Ventilation 4 10 cm Pipe 56 12 9 Common Side Wall Venting 56 12 10 Common Vertical Vent...

Page 4: ......

Page 5: ...eries Layout 36 Figure 23 T Layout 37 Figure 24 Fork Layout 38 Figure 25 Herringbone Layout 39 Figure 26 Reflector Joint Detail 48 Figure 27 Fan Termination 54 Figure 28 Tailpipe Connection Points 58...

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Page 7: ...is 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 wit...

Page 8: ...TION OPERATION AND SERVICE MANUAL 2 of 91 FIGURE 1 Top and Bottom Panel Label Placement Description Part Number Logo Label 91031104 Rating Plate Label 91010406 Gas Connection Label 91018122 Propositio...

Page 9: ...el Control Side Panel Inside Wiring Label Description Part Number Clearances to Combustibles Label 91013419 Wiring Label 91015601 Vent Length Label 91039500 Thermostat Connection Label 91037902 Lighti...

Page 10: ...he wall tag 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...

Page 11: ...partitions storage racks hoists building construction etc In locations used for the storage of combustible materials signs must be posted to specify the maximum permissible stacking height to maintai...

Page 12: ...8 6 77 68 20 15 196 170 CTHN 200 8 6 79 70 20 15 201 175 A C D B FIGURE 5 TWO SIDE REFLECTORS inches centimeters Model A B C D A B C D CTHN 40 5 16 47 16 13 41 119 41 CTHN 60 5 18 56 18 13 46 142 46...

Page 13: ...20 112 191 66 CTHN 200 8 47 76 30 20 119 193 76 FIGURE 8 U TUBE 45 inches centimeters Model A B C D A B C D CTHN 40 UNAPPROVED UNAPPROVED CTHN 60 8 4 47 40 20 10 119 102 CTHN 80 8 4 54 46 20 10 137 1...

Page 14: ...150 5 39 71 39 13 99 180 99 CTHN 175 8 44 74 44 20 112 188 112 CTHN 200 8 47 76 47 20 119 193 119 A C D B FIGURE 11 LOWER CLEARANCE SHIELD inches centimeters Model A B C D A B C D CTHN 40 5 25 22 25 1...

Page 15: ...visions 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 S...

Page 16: ...8 for details Multiburner systems consist of more than one burner and more than one run of radiant tubing The runs of radiant tubing are connected together by manifold tubing The manifold tubing conne...

Page 17: ...e CTHN 40 60 and 80 For installation see Page 25 Step 8 8 EP 100 Pump Package For more information refer to the EP 100 Installation Operation and Service Manual P N 127201NA EP 201 Pump Package For mo...

Page 18: ...tibles 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 configuratio...

Page 19: ...ystem 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 Par...

Page 20: ...n CTHN 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 RP52XXXXX Burner Rate and Fuel Varies 1 1 1 1 1 1 1 1 07730400 Restrictor Plate 1 25 3 2 cm dia 1 07730100 Restrictor Plate 1 50...

Page 21: ...er Tube ALUMI THERM Steel 10 3 m 1 1 1 1 03051601 Burner Tube HT ALUMI THERM Steel 10 3 m 1 1 1 01312700 Coupling Assembly 1 2 3 1 2 3 1 2 3 4 1 2 3 4 02750303 Standard Reflector 8 2 4 m 3 4 6 2 3 4 6...

Page 22: ...Reflector Side Extension Support 03050010 Reflector Support Package Tubing 02712700 Reflector Side Extension 2 Clips 2 Screws 02750303 Reflector Aluminum 027503SS Reflector Stainless Steel 02750800 Re...

Page 23: ...overview of a CTHN unitary heater CTHN unitary heaters are controlled by thermostat Table 5 summarizes the design requirements for a CTHN unitary heater Table 5 Unitary Heater Design Requirements Bur...

Page 24: ...of 91 8 3 Unitary Linear Heater Layouts FIGURE 15 Linear Heater Assembly Overview Tube Reflector Reflector End Cap Reflector Support Burner Coupling U Clips Burner Tube Tube and Reflector Hanger Tube...

Page 25: ...36 cm reflector width not shown b 2 5 cm end cap to burner fan c 2 5 cm end cap to hanger d 7 6 229 cm distance first hanger e 10 305 cm distance between hangers f 9 5 24 cm burner height g 17 5 44 cm...

Page 26: ...N OPERATION AND SERVICE MANUAL 20 of 91 FIGURE 17 Unitary Linear Layout Overview Continued c b d e b e e e e c b d e b e e e e e c b d e b e e e e e e 60 18 m Tube Length 70 21 m Tube Length 80 24 m T...

Page 27: ...tube For turbulator installation See Page 25 Step 8 8 The burner must never be operated in a tilted position The heater must be properly supported at all locations See Page 13 Figure 14 FIGURE 18 U t...

Page 28: ...f 5 153 cm distance between last full tube hanger and half tube hanger g 17 5 44 cm burner length h 9 5 24 cm burner height 20 6 m 50 15 m tube length heaters require the last reflector before the u...

Page 29: ...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 T...

Page 30: ...ling 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 Coupling 01329600 Slide Bar Coup...

Page 31: ...to hold turbulator in place Turbulator Section Turbulator Adapter Description Part Number Turbulator Adapter 03051503 Turbulator Section 03051504 Turbulator Section Stainless 03051505 Tube 91409XXX T...

Page 32: ...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 03090...

Page 33: ...ing 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 eithe...

Page 34: ...late and Warning Tag 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 942...

Page 35: ...20000 NONE CTHN 100 05220000 07730500 2 25 dia CTHN 125 05220000 07730500 2 25 dia CTHN 150 05220000 07730700 2 75 dia CTHN 175 05221000 07730600 2 50 dia CTHN 200 05221000 NONE Vent Adapter Fan Assem...

Page 36: ...N 40 CTHN 60 CTHN 80 CTHN 100 CTHN 125 CTHN 150 CTHN 175 CTHN 200 RP52XXXXX Burner Rate and Fuel Varies 1 1 1 1 1 1 1 1 07730400 Restrictor Plate 1 25 3 2 cm dia 1 07730100 Restrictor Plate 1 50 3 8 c...

Page 37: ...urner Tube ALUMI THERM Steel 10 3 m 1 1 1 1 03051601 Burner Tube HT ALUMI THERM Steel 10 3 m 1 1 1 01312700 Coupling Assembly 1 2 3 1 2 3 1 2 3 4 1 2 3 4 02750303 Standard Reflector 8 2 4 m 3 4 6 2 3...

Page 38: ...509SS Reflector Joint Stainless Steel 027127SS Reflector Side Extension Stainless Steel 03090100 Tube and Reflector Hanger 91907302 S hook 91903201 Turnbuckle 91903300 Spring Hook 91903202 Turnbuckle...

Page 39: ...ed on Page 34 Table 10 CTHN multiburner heaters are typically shipped as burner packages and tube and accessory packages The tube and accessory packages contain enough tube reflector and hanging parts...

Page 40: ...10 3 m 10 3 m 10 3 m Maximum Manifold Tube Length per Burner 30 9 m 35 10 5 m 40 12 m 45 13 5 m 50 15 m 55 16 5 m 60 18 m 60 18 m Minimum Distance from Burner to Elbow or U tube 10 3 m 10 3 m 10 3 m 1...

Page 41: ...diagrams of each layout type The diagrams show very simple examples of each layout type Actual layouts will vary in total number of burners in the system as well as the overall shape of the system Ad...

Page 42: ...e between joining tee and pump Manifold tube between radiant tube ends Burner furthest from pump does not need a damper coupling First Tee Burner Pump Multiple rows of burners pump placed at the end o...

Page 43: ...tube length twice Now refer to Page 34 Table 10 and find the maximum manifold tube length for each burner Add together the maximum manifold tube length on the table for each burner in the system this...

Page 44: ...Last Cross Manifold tube between radiant tube ends Damper Couplings located at the end of the rows Burner Radiant Tube Tee 2 Multiple rows of burners Manifold tube between the last tee or cross and t...

Page 45: ...f manifold tube before the connecting tee or cross According to Table 10 each burner must have at least 40 12 m of radiant tube also each burner must have between 6 2 m and 45 13 5 m of manifold tube...

Page 46: ...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...

Page 47: ...Close coupling with tab B Start slide bar coupling lock onto coupling C Insert tubes into coupling D Tighten coupling to join tubes Description Part Number Coupling 01329600 Slide Bar Coupling Lock 0...

Page 48: ...nt to hold turbulator in place Turbulator Section Turbulator Adapter Description Part Number Turbulator Adapter 03051503 Turbulator Section 03051504 Turbulator Section Stainless 03051505 Tube 91409XXX...

Page 49: ...p 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 B...

Page 50: ...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 eit...

Page 51: ...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 942...

Page 52: ...ce Edges are sharp Failure to follow these instructions can result in injury Tube 90 Elbow Coupling Description Part Number Elbow Package 02718702 90 Elbow 01335801 Coupling 01312700 Reflector End Cap...

Page 53: ...SECTION 10 OPTIONAL HEATER ACCESSORIES 47 of 91 Step 10 1 3 Reflector Joint Installation Step 10 1 4 Reflector Joint Installation Step 10 1 5 Reflector Joint Detail...

Page 54: ...int Reflector Side Extension Bracket 2 per Reflector Use additional supports in high air movement applications Tube and Reflector Hanger Reflector Tube Reflector Support Description Part Number Reflec...

Page 55: ...t relief notches for supports and hangers Reflector Side Extension 8 x 3 8 3 9 x 9 5 mm Sheet Metal Screw 12 30 cm Reflector Lower Clearance Shield 17 43 cm Washers Screws Locknuts Align Pilot Holes D...

Page 56: ...ANUAL 50 of 91 10 4 Two Foot Decorative Grille Installation Step 10 4 1 Grille Installation Step 10 4 2 Frame Shield Installation Description Part Number Aluminum Grille 2 x 4 6 m x 1 2 m 91407000 Des...

Page 57: ...tor Side Extension Installation for Decorative Grilles 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...

Page 58: ...nstallation Step 10 5 2 Grille End Cap Installation Step 10 5 3 Grille Installation Silicone Cap Grille Finger Description Part Number Grille Section 08050001 Grille End Cap 08050002 Silicone Cap 9191...

Page 59: ...one sealant Vent terminal must be beyond any combustible overhang For vertical venting vent shall not extend less than 2 0 6 m above the highest point where it passes through a flat roof of a building...

Page 60: ...minal with a screen must be installed at the exhaust end of the fan Vent terminal design shall not incorporate backdraft flap FIGURE 27 Fan Termination 12 3 Horizontal Venting In noncombustible walls...

Page 61: ...pe over fan outlet and pre drill Secure with 3 sheet metal screws Vent adapter in core package is not used 4 10 cm Single Wall Pipe Vent Terminal Combustible or Non Combustible Wall 18 46 cm Min Vent...

Page 62: ...put Heaters must be controlled by a common thermostat Description Part Number Vent Cap 4 10 cm 90502300 Vent Cap 6 15 cm 90502302 SIDE VIEW 4 10 cm Single Wall Pipe Outside Wall Sweeping T Connection...

Page 63: ...ts Maximum of 4 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 positione...

Page 64: ...equirements The layout drawing shows the general location of the pump Specific pump location and discharge details must meet general venting requirements see Page 53 Section 11 and Page 58 Section 13...

Page 65: ...bottom horizontal Any other arrangement will permit condensate to collect in the scroll FIGURE 29 Roof Venting of Pump WARNING Severe Injury Hazard Pumps are shipped partially assembled Do not operat...

Page 66: ...downward away from pump 1 4 6 mm for every 10 3 m 4 10 cm Band Clamp 25 8 m and 3 Elbows Maximum for EP 100 10 3 m Maximum and no Elbows for EP 200 10 3 m Maximum and 1 Elbow Approved Thimble Vent Te...

Page 67: ...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 14 1 Length Requirements Foll...

Page 68: ...rements Heaters 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 Fl...

Page 69: ...ttaching duct to the burner Mount the blower according to the manufacturer s instructions Additional mounting materials are provided by the contractor 14 7 Outside Air Blower Internal Wiring FIGURE 31...

Page 70: ...ring materials having a temperature rating of at least 105 C and 600 volts 15 2 Internal Wiring DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be...

Page 71: ...used to control the heaters but they can also be controlled by an energy management system Page 66 Section 15 5 illustrates the connection for heaters controlled by a line voltage thermostat For sing...

Page 72: ...thermostat CTHN 175 200 3 9 burners per thermostat depending on maximum amp load of thermostat chosen Burner 1 Fan 1 L1 L2 Burner 2 Fan 2 L1 L2 L1 L2 L1 L2 T Additional Burners Burner Fan 1 L1 L2 Burn...

Page 73: ...A transformer relay operated system will not give any post purge pump operation to completely exhaust products of combustion from the system or provide indication of operating conditions 15 7 2 SPDT T...

Page 74: ...ion without Control Panel Multiburner 1 2 3 4 5 6 COIL COIL R C W G Y Thermostat Pump Motor Pressure Switch Pump SPST 12A Transformer Relay Zone 1 Burners N L L N Nine Burners Maximum Black White Red...

Page 75: ...SECTION15 WIRING 69 of 91 FIGURE 33 Two Zone Operation without Control Panel Multiburner Description Part Number DPST Transformer Relay 90436300...

Page 76: ...ssure drop of 1 2 wc When gas piping is not included in the layout drawing the local gas supplier will usually help in planning the gas piping Gas lines must meet applicable codes United States The Fl...

Page 77: ...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 instructio...

Page 78: ...the module will reset automatically and return to steps 3 and 4 5 If a flame is detected the gas valve remains open When the call for heat is satisfied the thermostat turns off the burner and fan powe...

Page 79: ...s one at a time waiting to see that all burners in a zone start When the burner ignites a blue flame will be observed through the viewer window 4 If any abnormal operation occurs see Page 78 Section 1...

Page 80: ...oximately 1 0 of vacuum differential is required at the burner when the system is cold Normal operating hot differential of the burners should be adjusted to 75 wc Vacuum adjustments are made by means...

Page 81: ...rformance 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 replace...

Page 82: ...osed wire or damage to the thermostat See Page 66 Section 15 5 Suspension Points Make sure the heater is hanging securely Look for signs of wear on the chain or ceiling See Page 13 Figure 14 Decorativ...

Page 83: ...s 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 installat...

Page 84: ...500 Repair or Replace switches as necessary No Yes Yes Yes Yes Yes Yes No No No No Yes No No No No Yes Is there power 120V to the control panel H and N terminals Test thermostat by placing a jumper wi...

Page 85: ...reset spark gap to 1 8 Replace igniter and ignition wire as needed Check vacuum differential reading Is it okay Reset dampers Remove the blue and yellow wires from the transformer Is there 24 V at the...

Page 86: ...ve terminals Is there 24V during ignition period Replace gas valve Natural P N 90032500 LP P N 90032502 Is the knob on the gas valve in the on position Are the wires connecting the ignition module OK...

Page 87: ...are satisfied Disconnect all thermostat wires from COM Does the pump continue to run after a 45 sec post purge period Reconnect thermostat wires Disconnect W1 wire from pump relay Does the pump still...

Page 88: ...20 V Check wiring between the power cord fan motor and transformer Replace igniter and ignition wire as needed Carefully reset igniter gap to 1 8 Are the air hoses to the pressure switch secure and le...

Page 89: ...SECTION18 TROUBLESHOOTING 83 of 91 TROUBLESHOOT ENDS If problems persist contact your RAPID Independent Distributor Contact Rapid Engineering LLC at www rapidengineering com...

Page 90: ...HN SERIES INSTALLATION OPERATION AND SERVICE MANUAL 84 of 91 18 3 Manifold Gas Pressure Setting 10 5 Natural Propane 6 5 4 3 2 1 0 1 2 3 4 5 6 3 5 6 5 4 3 2 1 0 1 2 3 4 5 6 Top View of Heater Manomete...

Page 91: ...rbon 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...

Page 92: ...TALLATION OPERATION AND SERVICE MANUAL 86 of 91 Burner Cup Assembly Mica Window Assembly Air Adapter Collar Pressure Switch Electrode Door Switch Gas Valve Transformer Tube Gasket Ignition Module TOP...

Page 93: ...atural 90032500 Gas Valve LP 90032502 Burner Cup Assembly 03020100 Mica Window Assembly 02553203 Electrode 90427400 Electrode Gasket 02558501 Ignition Module 90439500K Ignition Wire 90427706 Transform...

Page 94: ...ONS 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 CTHN 40 60 80 100 125 150 4 6 wc Minimum for C...

Page 95: ...ll Load Amp Amps 9 1 6 4 8 2 4 6 6 3 3 2 4 2 2 1 1 12 8 11 5 5 5 5 2 2 6 R P M 3200 3200 3450 3450 3500 3450 3450 Motor Frame 56 56 56 90 90 Motor Enclosure TENV TENV TEFC TEFC TEFC Noise Level 5 DBA...

Page 96: ...CTHN SERIES INSTALLATION OPERATION AND SERVICE MANUAL 90 of 91...

Page 97: ...e removed defaced modified or altered in any way The ownership of the RAPID NP is moved or transferred This warranty is nontransferable Rapid Engineering LLC is not permitted to inspect the damaged eq...

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