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Roberts Gorden CoRayVac CRT-10, Installation, Operation & Service Manual

The Roberts Gorden CoRayVac CRT-10 is a trusted heating solution for commercial spaces. Ensure a seamless installation and maximize performance with the comprehensive Installation, Operation & Service Manual. Download it free from manualshive.com for step-by-step instructions and expert guidance, empowering you to effortlessly operate and maintain your CoRayVac CRT-10.

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CORAYVAC

®

 I

NSTALLATION

 O

PERATION

 

AND

 S

ERVICE

 M

ANUAL

12 of 54

Figure 10: 

CORAYVAC

®

 Assembly Overview 

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Summary of Contents for CoRayVac CRT-10

Page 1: ...g 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 installation Installer must give a copy of this manual to th...

Page 2: ......

Page 3: ... 7 2 Reflector Joint 20 7 3 Reflector Side Extension 22 7 4 Two Foot Decorative Grille Installation 23 7 5 Protective Grille Installation 25 7 6 Sports Hall Guard Installation 26 7 7 Sports Hall Filter 27 SECTION 8 General Venting Requirements For Pumps 28 8 1 Venting Requirements 28 8 2 Mounting Wall Bracket Assembly 29 8 3 Building Ventilation 31 8 4 Ventilation Requirements 31 8 5 Condensate Dr...

Page 4: ......

Page 5: ...nstallation 30 Figure 16 Pump Discharge Side 30 Figure 17 Pump Inlet Side 100 mm 31 Figure 18 Pump Inlet Side 150 mm 31 Figure 19 Condensate Drain Assembly Horizontal Flue 32 Figure 20 Condensate Drain Assembly Vertical Flue 33 Figure 21 Silencer 33 Figure 22 Acoustic Enclosure 34 Figure 23 Junction Box Wiring Diagrams 34 Figure 24 Filter Housing Assembly 35 Figure 25 Outside Air Supply 35 Figure ...

Page 6: ......

Page 7: ...intained in accordance with these instructions These instructions refer to appliances designed to operate in the European Union Appliances designed for other countries Non European Union are available on request This appliance must be installed in accordance with the local and national codes in force and used only in a sufficiently ventilated space as specified in these instructions Before install...

Page 8: ...t 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 adjust ment of the appliance are compatible The heater must be applied and operated under the general concepts of resonable use This appliance is not intended for use by persons including children with reduced physical sensory or...

Page 9: ...k Panel Label Placement Back Panel Rating Plate Label Gasline Caution Label Front Panel Running Label Start Lockout Label Description Part Number Start Lockout Label 91038300 Running Label 91038301 Rating Plate Label 91031300 Gasline Caution Label 91018100 ...

Page 10: ...arances to combustibles Please contact Rob erts Gordon or your ROBERTS GORDON indepen dent 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 CORAYVAC heater e g thermostat or Controller A copy of the wall tag P N 91037912 is illustrated on the back cover This copy of the wall tag must be af...

Page 11: ...at 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 signs must be posted t...

Page 12: ...EARANCES TO COMBUSTIBLES Figure 3 STANDARD REFLECTOR Model A B C D CRT 10 150 510 1220 510 CRT 15 150 510 1220 510 CRT 20 150 510 1220 510 CRT 25 150 920 1530 920 CRT 30 150 920 1530 920 B C D A Figure 4 ONE SIDE REFLECTOR Model A B C D CRT 10 150 305 1430 510 CRT 15 150 305 1430 510 CRT 20 150 305 1430 510 CRT 25 150 305 1530 1070 CRT 30 150 305 1530 1070 A B C D Figure 5 TWO SIDE REFLECTORS Mode...

Page 13: ...urner and burner tube connect 3 All measurements are in Millimeters CLEARANCES TO COMBUSTIBLES Figure 6 2 FOOT DECO GRILLE Model A B C D CRT 10 150 305 1220 305 CRT 15 150 305 1220 305 CRT 20 150 305 1220 305 CRT 25 150 460 1430 460 CRT 30 150 460 1430 460 A B C D Figure 7 PROTECTIVE GRILLE Model A B C D CRT 10 150 510 1220 510 CRT 15 150 510 1220 510 CRT 20 150 510 1220 510 CRT 25 150 920 1530 92...

Page 14: ...e 6 Figure 3 through Page 7 Figure 7 Install appro priate suspension hardware beam clamps chain or rod at predetermined locations Figure 8 Major Component Descriptions Burner Tube Hot rolled heat treated or coated aluminized tube supplied in 3 000 mm lengths 45 Elbow 90 Elbow End Vent Coupling Assembly with Lock Flex Gas Line with shut off cock Combustion Chamber Tee Reflector Aluminum or Stainles...

Page 15: ...de Extension Non Return Valve ISO 7Rc Reflector End Cap Aluminum or Stainless Steel Remove center section to accommodate tube when necessary Bow Shackle Tube and Reflector Hanger Reflector Support Package Deco Grille Turnbuckle Protective Grille Sports Hall Guard RG 30 and RG 45 Pump S Hook Spring Hook ROBERTS GORDON NRG Control ...

Page 16: ...48 mm Tube E0009326 100 mm Tail Pipe Tube Hanger 03020700 150 mm Tail Pipe Tube Hanger Venting and Fresh Air Supply Accessories C1376B 100 mm Outside Air Flex Duct 10 m F323 150 mm Roof Wall Masterflash F322 100 mm Roof Wall Masterflash F074A Roof Wall Terminal F116 Roof Wall Terminal Reflectors and Related Accessories 01329910 Reflector Side Extension Support 91107720 U Clip Package 20 off 027503...

Page 17: ...d to the system operation and performance required by the building being heated Every effort should be made to follow the dimensions on the layout drawing If deviations are necessary either contact the company responsible for the layout design ROBERTS GORDON or consult the CRT Series Design Manual P N 128500UK ...

Page 18: ...r Hanger Burner Reflector Tube Coupling Reflector End Cap Reflector Support Flexible Boot Reflector with Hole Pump Exhaust to Outside Pressure Switch S Zone 1 Sensor Starter and Overload ROBERTS GORDON Controller or Building Management System consult ROBERTS GORDON U Clips Minimum reflector overlap 180 mm Damper Coupling Power Supply Pump ...

Page 19: ...ximum gas inlet pressures must be maintained as indicated in this manual Typical installation configurations are shown in Figure 11 Expansion and contraction of the tube dictates that the minimum suspension lengths must be main tained See table on Page 14 Figure 11 For mounting height and tube lengths See Page 52 Section 16 6 NOTE Some models will receive S hooks P N 91907302 or Spring Hooks P N 9...

Page 20: ...0 mm 610 mm min X see table Locknut typical Anchor Hanger Front View Snap Hook Turnbuckle Reflector 2 300 mm Chain size 5 mm minimum Description Part Number Turnbuckle 91903201 S hooks 91907302 Spring Hooks 91903300 Bow Shackle E0007576 Tube Reflector Hanger 03090100 Run Length Typical Expansion Minimum X Length 15 000 mm 25 mm 300 mm 31 000 mm 50 mm 600 mm 46 000 mm 75 mm 900 mm 61 000 mm 100 mm ...

Page 21: ...uires a downward slope of 25 mm per 6 000 mm away from burner Description Part Number Tube 91409XXX Turnbuckle 91903201 Tube Reflector Hanger 03090100 Tube Tube Orient coupling so that the impact block is in the 2 00 or 10 00 o clock positions Closed Open Tab 76 mm to 101 mm Slide Bar Coupling Wide End Coupling Tube Slide Bar A Close Coupling with tab B Start Slide Bar Coupling Lock onto Coupling ...

Page 22: ...ar should be within tolerance listed below Repeat Section Step 6 2 on Page 15 A D until all tubes are assem bled Tighten Slide Bar as shown below Tube 90 Elbow Coupling Minimum Distance Required Between Burner and Elbow Model MinimumDistance CRT 10 1 500 mm CRT 15 1 500 mm CRT 20 3 000 mm CRT 25 3 000 mm CRT 30 4 500 mm Description Part Number Elbow Package 02718702 90 Elbow 01335801 Coupling 0131...

Page 23: ...e Reflector with hole through hanger Unhook combustion chamber from chain and insert through hole Reconnect chain Reflector with hole Description Part Number Tube Reflector Hanger 03090100 Tube 91409408 Reflector with Hole 02750304 Reflector Wire Form Tube Reflector Support Strap Sheet Metal Screw U Clip 2 clips per alternate overlaps per side NOTE Minimum reflector overlap must be 180 mm Descript...

Page 24: ...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 th...

Page 25: ...ket Burner Combustion Chamber End Vent NOTE Install end vent at end combustion chamber position only Burner Combustion Chamber End Vent End Vent Clips Rating Number Description Part Number Bolt E0007588 Burner E000XXXX Lock Washer 96411600 Gasket 01367800 End Vent E00094XX ...

Page 26: ...r Joint Installation WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury Tee Tube Coupling Description Part Number Tee 01330XXX Tube Reflector Hanger 03090100 Tube 91409408 Coupling 01312700 Reflector Reflector Joint Flatten Edge 250 mm Maximum Scribe Contour ...

Page 27: ...ON 7 OPTIONAL HEATER ACCESSORIES 21 of 54 Step 7 2 2 Reflector Joint Installation Step 7 2 3 Reflector Joint Detail Figure 12 Reflector Joint Detail Cut away contour with tin snips Punch drill six 2 mm holes ...

Page 28: ...pports in high air movement applications Tube and Reflector Hanger Reflector Tube Reflector Support Description Part Number Reflector Side Extension Package S7377K 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 Extensi...

Page 29: ... 23 of 54 7 4 Two Foot Decorative Grille Installation Step 7 4 1 Grille Installation Step 7 4 2 Frame Shield Installation Description Part Number Aluminum Grille 600 mm x 1200 mm 91407000 Description Part Number Deco Grille Shield 01365900 ...

Page 30: ...7 4 3 Reflector Side Extension Installation for Decorative Grilles Distance A Extension Minimum Maximum Part No Width 40 mm 150 mm 01370408 2000 mm 150 mm 260 mm 01370412 3000 mm 260 mm 370 mm 01370416 4000 mm Description Part Number Reflector Side Extension 01370412 ...

Page 31: ...ation Step 7 5 2 Grille End Cap Installation Step 7 5 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 1010 mm ...

Page 32: ... Guard Connection Tube and Reflector Hanger Reflector Tube Reflector Support Strap Stainless Steel Mesh Guard Description Part Number Mesh Guard 2438 mm E0009855 Mesh Guard 1524 mm C2329B Strap Stainless Steel S5218W Tube and Reflector Hanger Reflector Tube Strap Stainless Steel Mesh Guard Nut Spire Screw 8 x 3 8 Description Part Number Nut Spire C1088B Screw 8 x 3 8 C1089B ...

Page 33: ...rd Door Step 7 7 2 Install New Door Filter Cylindrical Filter Door Remove the burner door with the cylindrical filter Filter Media Peel off Remove backing of the adhesive strips from the filter and affix to the inside of the burner door with louvers Use existing screws to install new filter door ...

Page 34: ...ufficient to prevent blockage by snow and building materials protected from degradation by flue gases Secure all joints with 8 x 3 8 sheet metal screws Seal all joints with high temperature silicone sealant Vent terminal must be beyond any combustible overhang 8 1 1 Vertical Venting See Page 33 Figure 20 for recommended vertical venting options 8 1 2 Horizontal Venting See Page 32 Figure 19 for re...

Page 35: ... will give equal to or greater than 907 kg 2000 lbs ultimate pull out strength Figure 13 Wall Bracket Assembly Figure 14 Mounting Platform Options WARNING Crush Hazard Mount pump with materials with a minimum working load of 181 kg Failure to follow these instructions can result in death injury or property damage Mounting Angle Hex Head Bolt Flat Washer Lockwasher Hex Nut Flat Washer Description P...

Page 36: ...ump boot to the pump outlet using the150 mm band clamp provided See Figure 16 Connection should be made using 150 mm mini mum diameter aluminium or stainless steel flue material All flue material must conform to the rele vant National Standards Mount the 150 mm flue to the pump boot securing it with the 150 mm band clamp The flue length must not exceed 15 000 mm including 2 x 45 offset bands The f...

Page 37: ...yed the minimum proven airflow rate shall be 2 35 m3 h per kW of heat input 8 4 Ventilation Requirements Detailed recommendations for air supply are given in the relevant National Standards There must be an adequate supply of air for both combustion and general ventilation Air vents should have negligible resistance Do not locate air vents where they can be easily blocked or flooded or adjacent to...

Page 38: ...Tee Drain Cap Pump Inlet Wall 1 BSP threaded hole Use 1 x reducer not supplied Must be connected to a drain system in accordance with local codes 100 mm minimum vertical drop between pump and non return valve 3 4 CPVC Pipe flow Non Return Valve 3 4 CPVC Pipe 3 4 female Description Part Number Tee 100 mm 4 01330203 Tee 150 mm 6 01330204 Drain Cap 100 mm 4 02718851 Drain Cap 150 mm 6 02718852 Non Re...

Page 39: ...a 10 3 m 01330204 Tee 6 150 mm Aluminized 91409420 Tube Aluminized 6 150 mm dia 10 3 m 01331900 Damper Coupling 4 100 mm 91412800 Flexible Boot 4 100 mm 01335801 Elbow 4 100 mm Aluminized 90 91412801 4 Flexible Boot 1 2 13 mm 02718851 Drain Cap 4 100 mm 91412802 Flexible Boot 6 150 mm 02718852 Drain Cap Assembly 6 150 mm 91901300 Boot Clamp 4 100 mm 90502300 Vent Cap 4 100 mm Metalbestos 91913703 ...

Page 40: ...ment surface Values given below are at 3 m distance from the object Tailpipe Connection Flue Discharge Junction Box wiring diagram inside From Pressure Switch From Fan Motor Blue Brown Brown Blue Black Earth Common NO U1 V1 W1 3 Ø Motors From Pressure Switch From Fan Motor Blue Brown Brown Blue Earth Common NO 1 Ø Motors RG30 and RG45 Pump Data Sound Pressure Level dB A NR No acoustic enclosure 59...

Page 41: ...d Single wall pipe duct may be attached to the burner and end vent Duct Design Rules 150 mm 6 diameter duct must not exceed 27 m 90 maximum 30 flow units 100 mm 4 diameter ductmust not exceed 27 m 90 maximum 12 flow units Elbows are equivalent to 3 m 10 of duct length Figure 24 Filter Housing Assembly Figure 25 Outside Air Supply Wing Nut Filter Housing Filter Top Gasket and Disk Bottom Gasket Doo...

Page 42: ...to handle all the burners being installed plus any other con nected load The gas hose which feeds the system must be large enough to supply the required gas with a maximum pressure drop of 1 5 mbar When gas piping is not included in the layout drawing the local gas supplier will usually help in planning the gas piping IMPORTANT the complete installation must be tested for gas soundness and be purg...

Page 43: ...displacement shown is for the cold condition This displacement may reduce when the system is fired CORRECT POSITIONS 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 Description Part N...

Page 44: ...ly with current wiring regula tions and any local regulations which may apply Always switch off the supply to the burner and dis connect by removing the plug before removing the burner side panel 3 phase motors can be reversed by interchanging 2 phase connections The control of the CORAYVAC system must via a Roberts Gordon Europe Limited approved control to ensure that the necessary safety systems...

Page 45: ...GNITION MODULE Yellow Yellow Yellow Green Green Yellow Brown Blue Blue Blue Brown Brown Green Yellow SPARK Blue MAINS INLET WITH FILTER Brown Brown RUN START L N Brown Blue 230 V 50 Hz Brown Blue 3 2 1 4 2 1 CONNECTOR LOCKOUT INDICATOR DOTTED LINE WIRES ARE AN OPTION If any of the original wire supplied with the heater must be replaced it must be replaced with wiring material having a temperature ...

Page 46: ... 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 connected to a properly grounded electrical source KEY TO SYMBOLS T0 T8 T3 T5 ...

Page 47: ... The system will continue to run until the power sup ply or gas supply is interrupted Interruption of the electrical supply results in shutdown of the burners after which the pump will continue to run for two minutes to clear products of combustion from the system Restoration will restart the whole sequence Interruption of the gas supply will result in loss of flame followed by 3 attempts to reign...

Page 48: ...ar CRT10 10 kW 5 7 CRT15 15 kW 6 5 CRT20 20 kW 7 0 CRT25 25 kW 6 7 CRT30 30 kW 7 0 Repeat this procedure for each branch of the system 12 4 System Checks Turn the system off and restart it to ensure smooth ignition Carry out the following system checks 1 When running turn off the gas supply at the appliance isolating cock The heater will imme diately shut down followed by 3 attempts at res toratio...

Page 49: ...f the reflector with a soft damp cloth use a household detergent if necessary Never use abra sive cleaners on the reflectors Reassemble the burner in reverse order Carry out the Commission ing and Testing Procedure on Page 41 Section 12 3 13 2 Component Removal Isolate the heater from the gas and electrical sup plies Remove the plug from the burner Entry to the burner assembly is gained by removin...

Page 50: ...d recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equip ment and perform service where necessary using only replacement parts sold and supplied by Rob erts Gordon Europe Limited The Vicinity of the Heater Do not store or use flammable objects liquids or vapours near the heating system Immediately remove these items if they are present See Page ...

Page 51: ...in or ceiling See Page 14 Figure 11 Protective Grille optional The grille must be securely attached See Page 25 Section 7 5 through Page 25 Section 7 5 3 Pump With pump operating check for excessive vibration or noise Vibration is usually a sign that the impeller is out of balance Turn off the system insure power is shut off and remove the inlet plate Check the shaft seal and replace it if worn or...

Page 52: ...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 53: ...SECTION 14 TROUBLESHOOTING 47 of 54 14 1 Troubleshooting Flow Chart ...

Page 54: ...at the module properly connected Are the Live and the Neutral reversed No Yes Is the continuity of the earth wire established No Yes Verify that the couplings have been installed properly Yes No Is the rotation of the pump motor correct Adjust system for proper vacuum at the end vent Follow burner check procedure given above No Yes Are there any dead burners in a branch Is the vacuum setting too l...

Page 55: ...r 6 5 4 3 2 1 0 1 2 3 4 5 6 6 5 4 3 2 1 0 1 2 3 4 5 6 Insert tubing about 150 mm 6 Combustion Chamber at end position Cold Suction Approximate reading after adjusting damper couplings 9 mbar Hot Suction Approximate reading after adjusting damper couplings 7 mbar End Vent ...

Page 56: ... 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 ...

Page 57: ...ner Head Assembly 02721702 N S Filters box of 24 with gaskets 01312400 F Gasket 2 required Burner Head to Mixing Block 01351100 N S Gasket Burner Head to Combustion Chamber 01367800 N S Replacement Burner Head 02721700 N S Mica Window Assembly 02553203 G Electrode 90430700 N S Lockout Indicator Connector 91324000 91324001 H Electrode Gasket 02558501 N S Combustion Chamber Gasket 01367800 I Jet see...

Page 58: ...e will be 150 mm dia duct Flue material must conform to National Codes The flue must be self supporting 16 4 Suspension Specifications Hang heater with materials with a working load of 33 kg 75 lbs See Page 14 Figure 11 16 5 Controls Specifications Factory assembled control panels time switches and thermostats are available Consult your factory representative for proper connection to electrical su...

Page 59: ...End Vent Plate Orifice Size G20 G25 G31 G30 CRT 10 01 2 35 black 3 0 mm fluor yellow 2 4 mm fluor red 44 silver CRT 15 15 2 3 4 mm fluor orange 3 7 mm fluor pink 35 black 2 6 mm fluor green CRT 20 6 3 22 rose 19 red 30 yellow 3 0 mm fluor yellow CRT 25 8 4 14 purple 10 orange 3 7 mm fluor pink 3 5 mm fluor blue CRT 30 30 5 7 white 3 drk green 22 rose 25 brown 51 cm 24 4 cm 9 cm 36 cm 24 cm 4 cm 19...

Page 60: ...30 3 RG45 3 Part No 90710108 90710109 90710111 90710112 Weight kg 41 5 43 5 41 5 43 5 Power W 750 1100 750 1100 Run Current A 3 25 4 8 2 75 2 75 Start Current A 14 25 23 0 8 5 13 2 Supply V 230 V 1 Ø 50 Hz 230 V 1 Ø 50 Hz 400 V 3 Ø 50 Hz 400 V 3 Ø 50 Hz Pump Dimensional Data mm Model A B C D E F RG30 1 650 630 386 430 124 545 RG30 3 650 630 386 430 124 545 RG45 1 674 650 396 435 121 567 RG45 3 674...

Page 61: ......

Page 62: ...HE HEATER Service Telephone 44 0 121 506 7709 Service Fax 44 0 121 506 7702 E mail uksales rg inc com E mail export rg inc com Roberts Gordon LLC 1250 William Street P O Box 44 Buffalo NY 14240 0044 USA Telephone 716 852 4400 Fax 716 852 0854 Toll Free 800 828 7450 WARNING Roberts Gordon Europe Limited Unit A Kings Hill Business Park Darlaston Road Wednesbury West Midlands WS10 7SH UK Telephone 44...

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