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FOR YOUR SAFETY
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.
WARNING
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 explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
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.
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
© 2012 Rapid Engineering LLC
RAPID
The Economical Unitary
Infrared Heater
Installation, Operation &
BH-100
BH-115
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.
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Rapid Engineering LLC
1100 Seven Mile Road NW
Comstock Park, MI 49321
Telephone: +1.616.784.0500
Fax: +1.616.784.1910
Toll Free: 800.536.3461
www.rapidengineering.com
BH
™
Service Manual
BH-40
BH-125
BH-60
BH-140
BH-80
BH-150
BH-175
BH-200
Installer
Owner
P/N RPBH170101NA Rev. B 02/12
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Summary of Contents for Rapid Engineering BH-40
- Page 1 Rapid Engineering LLC 1100 Seven Mile Road NW Comstock Park, MI 49321 Telephone: +1.616.784.0500 Fax: +1.616.784.1910 Toll Free: 800.536.3461 www.rapidengineering.com P/N RPBH170101NA Rev. B 02/12 © 2012 Rapid Engineering LLC...
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Page 3: Table Of Contents
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 Rapid Engineering LLC. Printed in U.S.A. - 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 ............. 6 Figure 4: One Side Reflector............. 6 Figure 5: Two Side Reflectors ........... 6 Figure 6: 45°...
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Page 7: Section 1: Heater Safety
1.2 Safety Labels and Their Placement Product safety signs or labels should be replaced by the product user when they are no longer legible. Please contact Rapid Engineering LLC or your RAPID independent distributor to obtain 1 of 59... -
Page 8: Figure 1: Top And Bottom Panel Label Placement
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 1: Top and Bottom Panel Label Placement Gas Connection Label Top Panel Vent Length Label Logo Label Description Part Number Logo Label 91031102 Vent Length Label 91039500 Gas Connection Label 91018123 Bottom Panel 2 of 59... -
Page 9: Figure 2: Side And Back Panel Label Placement
SECTION 1: H EATER AFETY FIGURE 2: Side and Back 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 3 of 59... -
Page 10: Section 2: Installer Responsibility
• To provide access on all sides for burner servicing in product damage. and removal. Rapid Engineering LLC cannot be responsible for • To provide the owner with a copy of this ensuring that all appropriate safety measures are Installation, Operation and Service Manual. -
Page 11: Section 3: Clearances To Combustibles
SECTION 3: C LEARANCES TO OMBUSTIBLES SECTION 3: CLEARANCES TO COMBUSTIBLES WARNING 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. -
Page 12: Figure 3: Standard Reflector
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 (inches) (centimeters) Model BH-40 BH-60 BH-80 BH-100 BH-115/125 BH-140/150 BH-175/200... -
Page 13: Figure 6: 45° Tilt Reflector
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 6: 45° Tilt Reflector (inches) (centimeters) Model BH-40 BH-60 BH-80 BH-100 BH-115/125 BH-140/150... -
Page 14: Figure 9: U-Tube, Opposite 45° Reflector
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 9: U-Tube, Opposite 45° Reflector (inches) (centimeters) Model - UNAPPROVED - - UNAPPROVED - BH-40 BH-60 BH-80 BH-100 BH-115/125 BH-140/150 BH-175/200 FIGURE 10: 2-Foot Deco Grille and Protective Grille... -
Page 15: Figure 12: Venting
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 12: Venting (inches) (centimeters) Model BH-40 Unvented BH-60 Vent Pipes Radiant Tubes BH-80... -
Page 16: Section 4: National Standards And Applicable Codes
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Gas Codes 4.3 Public Garages The type of gas appearing on the nameplate Installation in garages must be in accordance must be the type of gas used. Installation must with the following codes: comply with national and local codes and United States: Refer to Standard for Parking... -
Page 17: Section 5: Major Components
SECTION 5: M AJOR OMPONENTS SECTION 5: MAJOR COMPONENTS FIGURE 13: Major Component Descriptions Reflector (Aluminum or Burner with Tube Gasket Stainless Steel) Must be installed with the Alternate overlap as shown on flame observation window overview and on Page 17 , facing down. -
Page 18: Standard Parts List
ERVICE ANUAL 5.1 Standard Parts List Table 1: Contents of BH-Series Burner Carton Part No. Description BH-40 BH-60 BH-80 BH-100 BH-115 BH-125 BH-140 BH-150 BH-175 BH-200 RP71XXXXX Burner (Rate and Fuel Varies) 90709700 Blower Assembly with Cord 02568200 Gasket (Burner to Burner Tube) -
Page 19: Table 3: Bh-Series Component Package Guide
SECTION 5: M AJOR OMPONENTS Table 3: BH-Series Component Package Guide Tubing Length Core Packages Model 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) -
Page 20: Section 6: Heater Installation
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 6: HEATER INSTALLATION Expansion and contraction of the tube dictates that the minimum suspension lengths must be WARNING maintained. See table on Page 15, Figure 14. Severe Injury Hazard Secure burner to burner tube with bolts and lockwashers. -
Page 21: Figure 14: Critical Hanger Placement
SECTION 6: H EATER NSTALLATION FIGURE 14: Critical Hanger Placement Typical Suspension Details Beam Clamp Concrete Beam Wood Beam Anchor Locknut Screw Hook 3/8" Chain Size 3/16" Washers Rod 3/8" Minimum 24" min.* (61 cm) “X”* S-hooks Turnbuckle * Allows for thermal expansion of system Not Included S-hooks Hanger... -
Page 22: Figure 15: Linear Heater Assembly Overview
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 15: Linear Heater Assembly Overview 16 of 59... -
Page 23: Figure 16: Linear Heater Layout Overview
SECTION 6: H EATER NSTALLATION FIGURE 16: Linear Heater Layout Overview LEGEND Burner Reflector (3 m) Tube Length Tube Tube/Reflector Hanger Coupling Assembly Vent Adapter a = 14" (36 cm) reflector width (not shown) (6.1 m) Tube Length b = 2" (5 cm) end cap to burner c = 2"... -
Page 24: Burner Tube Installation
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 17: Linear Heater Layout Overview (Continued) (18.3 m) Tube Length (21. 3 m) Tube Length (24.4 m) Tube Length Step 6.1 Burner Tube Installation NOTE: Tubing requires a downward slope of 1/2" (13 mm) Offset mounting per 20' (6 m) away hole must be... -
Page 25: Tube Clamp Package Installation
SECTION 6: H EATER NSTALLATION Step 6.2 Tube Clamp Package Installation Bolt Tube Clamp Flat Washer (Torque 120 in/lb 13.56 Nm) Description Part Number Tube Clamp Package 01318901 Tube Clamp 01396801 Bolt 97113940 Flat Washer 95211600 92113900 Step 6.3 Coupling and Tube Assembly Close coupling Start slide bar/coupling lock with tab. - Page 26 See Page 20, Step 6.3.2 • Repeat Step 6.3 A - D until all tubes are assembled. Step 6.3.2 Coupling and Tube Assembly (Continued) Tube Length Model Minimum BH-40 10' (3 m) BH-60 20' (6 m) BH-80 20' (6 m)
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Page 27: Turbulator Installation
BH-200 Turbulator section 2.5' Pull String (76.2 cm) (stainless) used in Fold tab around outside BH-40 heaters must be in the of tube nearest to the vent to section of turbulator nearest hold turbulator in place. to the burner. Description Part Number Turbulator Adapter 2.5' (76.2 cm) -
Page 28: Reflector Installation
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 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. NOTE: All tube surfaces must be covered by a reflector, except for a U-tube. - Page 29 SECTION 6: H EATER NSTALLATION Step 6.5.1 Reflector, U-Clip and Reflector Support Installation The pictorial drawings of the heater construction in reflector supports and U-clips depend on the Section 6 are schematic only and provide a general individual installation. Use either pop rivets or sheet guideline of where hangers, reflector supports and metal screws instead of u-clips when installing end U-clips are to be installed.
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Page 30: Burner Installation
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 6.6 Burner Installation Extra chain min. 12" (30 cm) S-hook Burner Tube Burner Gasket Lock Washer Description Part Number Bolt 94273914 Burner RP71XXXXX Lock Washer 96411600 Gasket 02568200 24 of 59... -
Page 31: Section 7: Optional Heater Accessories
Edges are sharp. Failure to follow these instructions can result in injury. 7.1 U-Tube Configuration Heaters (except BH-40) are approved for optional U-tube configurations. The U-tube may be installed in either a standard horizontal position, a 45° position or in an opposite 45°... -
Page 32: Figure 18: U-Tube Heater Assembly Overview
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 18: U-Tube Heater Assembly Overview U-tube Support Bracket Reflector Support Vent Adapter Burner Turbulator (With Select Reflector Models) Tube Clamp Tube Burner Package Tube U-tube, Standard Couplings U-clips Reflector End Caps U-tube, 45°... -
Page 33: Figure 19: U-Tube Heater Layout Overview
SECTION 7: O PTIONAL EATER CCESSORIES FIGURE 19: U-Tube Heater Layout Overview LEGEND Burner Reflector Tube 10' (3.0 m) (6.1 m) Tube Length* Tube 5' (1.5 m)** Tube/Reflector Hanger Coupling Assembly U-tube Vent Adapter (Not Shown) a = 14" (36 cm) (9.1 m) Tube Length** Reflector Width (Not Shown) b = 2"... -
Page 34: Elbow Package Configuration
(24.4 m) Tube Length 7.2 Elbow Package Configuration Step 7.2.1 Elbow Installation Tube Minimum Distance Required Coupling Between Burner and Elbow Minimum Model Distance BH-40 10' (3 m) BH-60 10' (3 m) BH-80 10' (3 m) 90° Elbow Description Part Number BH-100 15' (4.5 m) - Page 35 SECTION 7: O PTIONAL EATER CCESSORIES Step 7.2.2 Elbow Installation Tube Coupling Step 7.2.3 Reflector Joint Installation Step 7.2.4 Reflector Joint Installation 29 of 59...
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Page 36: Figure 21: Reflector Joint Detail
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.2.5 Reflector Joint Detail FIGURE 21: Reflector Joint Detail 30 of 59... -
Page 37: Reflector Side Extension
SECTION 7: O PTIONAL EATER CCESSORIES 7.3 Reflector Side Extension Step 7.3.1 Bracket Installation Tube Reflector Tube and Reflector Hanger Reflector Support Reflector Side Extension Bracket (2 per Reflector) Use additional supports in high air movement applications. Description Part Number Reflector Side Extension Package 02712700 Reflector Side Extension... -
Page 38: Lower Clearance Shield Installation
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 7.4 Lower Clearance Shield Installation Step 7.4.1 Shield Support Strap Assembly Reflector 12" (30 cm) 17" (43 cm) Align Pilot Holes Lower Clearance Shield Locknuts Washers Description Part Number Lower Clearance Shield Package 01397501 Shield Support Strap 01397500... - Page 39 SECTION 7: O PTIONAL EATER CCESSORIES Step 7.5.2 Frame Shield Installation Description Part Number Deco Grille Shield 01365900 Step 7.5.3 Reflector Side Extension Installation for Decorative Grilles Distance "A" Extension Minimum Maximum Part No. Width 2" (4 cm) 6" (15 cm) 01370408 8"...
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Page 40: Protective Grille Installation
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 7.6 Protective Grille Installation Step 7.6.1 Silicone Cap Installation Silicone Cap Grille Description Part Number Finger Grille Section 08050001 Grille End Cap 08050002 Silicone Cap 91915951-6P Step 7.6.2 Grille End Cap Installation Grille Grille End Cap Bend up 90°. -
Page 41: Section 8: Venting
SECTION 8: V ENTING SECTION 8: VENTING combustible wall must have an approved thimble to conform with the above listed codes. WARNING Vent pipe must be sloped downward away from the heater 1/2'' (1 cm) for every 20' (6 m). The heater may be individually vented or common vented. -
Page 42: Unvented Operation
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.2 Unvented Operation A vent shall not extend less than 2' (0.6m) above the highest point where it passes through a flat roof of a Sufficient ventilation must be provided in the amount building. -
Page 43: Vertical Ventilation 4'' (10 Cm) Pipe
SECTION 8: V ENTING 8.8 Vertical Ventilation 4'' (10 cm) Pipe Description Part Number Vent Cap 4" (10 cm) 90502300 8.9 Common Side Wall Venting TOP VIEW Vent Terminal Tjernlund VH1-6 or Equivalent Outside Wall Outside Wall Sweeping 'T' 6" (15 cm) Single Wall Pipe Vent Adapter Connection Vent Adapter... -
Page 44: Common Vertical Venting
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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. -
Page 45: Outside Combustion Air Supply
SECTION 8: V ENTING 8.11 Outside Combustion Air Supply 8.11.1 Length Requirements IMPORTANT: If the building has a slight negative Follow the constraints listed on Page 36, Section 8.6. pressure or corrosive contaminants, such as halogenated hydrocarbons, are present in the air, an outside combustion air supply to the heater is required. - Page 46 BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.11.4 Vertical Outside Air Supply for Double Heater Installation Vent Cap Roof 6" (15 cm) Single Wall Pipe Sweeping 'T' Connection Flex Hose (Recommended) Burner Burner 4" (10 cm) Flex Hose Band Clamp (Recommended) Single Wall Pipe (Recommended)
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Page 47: Section 9: Gas Piping
SECTION 9: G IPING SECTION 9: GAS PIPING Install the gas hose as shown on Page 42, Figure 23. WARNING 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. -
Page 48: Figure 23: Gas Connection With Flexible Gas Hose
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 23: Gas Connection with Flexible Gas Hose CORRECT POSITIONS CAUTION Product Damage Hazard Shut-Off Valve (included with gas hose) must Hold gas nipple securely with pipe wrench be parallel to burner gas inlet. The 3" (8 cm) when attaching gas hose. -
Page 49: Section 10: Wiring
SECTION 10: W IRING SECTION 10: WIRING Heaters can be controlled using several methods. DANGER Normally thermostats are used to control the heaters but they can also be controlled by an energy management system. Section 10.1 illustrates the connection for heaters controlled by a line voltage thermostat. -
Page 50: Low Voltage Thermostat Wiring
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 10.2 Low Voltage Thermostat Wiring FRONT VIEW BACK VIEW SPST Transformer Relay Low Voltage Thermostat Black COIL COIL Black 120 V-60 Hz White Supply Circuit Additional Burners Gnd. Gnd. Gnd. Maximum 8 Burners Per Relay Burner 1 Burner 2... -
Page 51: Internal Wiring
SECTION 10: W IRING 10.3 Internal Wiring 45 of 59... -
Page 52: Ladder Diagram
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 10.4 Ladder Diagram 10.5 Electrical Connection to the Burner Connect wires together with suitable approved wire connections. Green White Black Green to Gnd. White to L2 Gnd. Black to L1 Internal Wire Bundle Burner Box Electrical Cord or Flexible Conduit... -
Page 53: Section 11: Operation And Maintenance
SECTION 11: O PERATION AND AINTENANCE SECTION 11: OPERATION AND MAINTENANCE WARNING DANGER Electrical Shock Hazard Explosion Hazard Burn Hazard Cut/Pinch Hazard Turn off gas supply to Allow heater to cool Wear protective gear Disconnect electric heater before service. before service. during installation, before service. -
Page 54: Maintenance Checklist
For best performance, the gas, electrical, thermostat installation and service of equipment sold and connections, tubing, venting, suspensions and supplied by Rapid Engineering LLC and conform to overall heater condition should be inspected all requirements set forth in the RAPID manuals thoroughly. - Page 55 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 Rapid Engineering LLC or your RAPID independent distributor to obtain replacement signs or labels. See Page 2, Figure 1 through Page 3, Figure 2.
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Page 56: Section 12: Troubleshooting
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 12: TROUBLESHOOTING 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. WARNING Fire Hazard Explosion Hazard Burn Hazard Cut/Pinch Hazard Keep all flammable... -
Page 57: Troubleshooting Flow Chart
SECTION 12: T ROUBLESHOOTING 12.1 Troubleshooting Flow Chart 51 of 59... - Page 58 BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 52 of 59...
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Page 59: Manifold Gas Pressure Setting
SECTION 12: T ROUBLESHOOTING 12.2 Manifold Gas Pressure Setting 53 of 59... -
Page 60: Section 13: Replacement Parts
BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 13: REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Carbon Monoxide Hazard Fire Hazard 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. 54 of 59... - Page 61 SECTION 13: R EPLACEMENT ARTS 55 of 59...
- Page 62 BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Part Number Mica Window Assembly 02553203 Electrode Gasket 02558501 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...
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Page 63: Section 14: General Specifications
BH-40, 60, 80, 100, PIPE CONNECTION: 115, 125, 140, 150 4.6" wc Minimum 1/2" NPT (for BH-40, 60, 80, 100, 115 & 125) for BH-175, 200 5.0" wc Minimum 3/4" NPT (for BH- 140, 150,175 & 200) 14.0" wc Maximum... - Page 64 BH-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 58 of 59...
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Page 65: Section 15: The Rapid Bh Warranty
Should you need Replacement a manufacturing or material defect. Parts or have additional questions, call or write: Rapid Engineering LLC will require the part in question to be returned to the factory. Rapid Engineering LLC will, at Rapid Engineering LLC...