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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 registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment or your gas supplier.
© 2011 Roberts-Gordon Europe Limited
CoRayVac
Custom-Engineered,
Low-Intensity Infrared
Heating Systems
Installation, Operation &
Service Manual
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.
Roberts-Gordon Europe Limited
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands WS10 7SH UK
Telephone: +44(0)121 506 7700
Fax: +44 (0)121 506 7701
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
www.rg-inc.com
CRT-10
CRT-15
CRT-20
CRT-25
CRT-30
Installer
Owner
128100UK Rev. E 05/11
®
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Related Manuals for Roberts Gorden CoRayVac CRT-10
Summary of Contents for Roberts Gorden CoRayVac CRT-10
- Page 1 FOR YOUR SAFETY If you smell gas: 1. Open windows. CoRayVac ® 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1: Heater Safety ..........2 SECTION 15: Replacement Parts.......50 1.1 Manpower Requirements ........2 SECTION 16: Specifications........52 1.2 Safety Labels and Their Placement ....2 16.1 Material Specifications........52 SECTION 2: Installer Responsibility......4 16.2 Burner Specifications........52 2.1 Low Level User Instructions........4 16.3 Venting Specifications........52 2.2 Corrosive Chemicals...........4 16.4 Suspension Specifications......52... - Page 5 TABLE OF FIGURES Figure 1: Top and Side Panel Label Placement ....2 Figure 2: Front 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: 2-Foot Deco Grille ..........7 Figure 7: Protective Grille ..........7 Figure 8: Major Component Descriptions......8 Figure 9: Major Component Descriptions (Continued) ..9...
- Page 7 Product Approval ROBERTS GORDON appliances have been tested and CE certified as complying with the essential ® requirements of the Gas Appliance Directive, the Low Voltage Directive, the Electromagnetic Compatibility Directive and the Machinery Directive for use on natural gas and LPG when installed, commissioned and maintained in accordance with these instructions.
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Page 8: Section 1: Heater Safety
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 1: HEATER SAFETY conditions, nature of gas and pressure, and adjust- ment of the appliance are compatible. Your Safety is Important to Us! This symbol is used throughout The heater must be applied and operated under the the manual to notify you of possi- general concepts of resonable use. -
Page 9: Figure 2: Front And Back Panel Label Placement
SECTION 1: H EATER AFETY Figure 2: Front and Back Panel Label Placement Start/Lockout Label Running Label Front Panel Rating Plate Label Back Panel Gasline Caution Label Description Part Number Start/Lockout Label 91038300 Running Label 91038301 Rating Plate Label 91031300 Gasline Caution Label 91018100 3 of 54... -
Page 10: Section 2: Installer Responsibility
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 2: INSTALLER RESPONSIBILITY rear surface and position the tag on a wall near the CORAYVAC ® heater (e.g. thermostat or Controller). The installer is responsible for the following: A copy of the wall tag (P/N 91037912) is illustrated •... -
Page 11: Section 3: Clearances To Combustibles
SECTION 3: C LEARANCES TO OMBUSTIBLES SECTION 3: CLEARANCES TO COMBUSTIBLES 3.1 Required Clearances to Combustibles WARNING Clearances are the required distances that combus- tible objects must be away from the heater to pre- vent serious fire hazards. Combustibles are materials, which may catch on fire and include com- mon items such as wood, paper, rubber, fabric, etc. -
Page 12: Clearance Data
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 3.2 Clearance Data NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, tees, elbows and crosses. 2. Clearances B, C and D can be reduced by 50% after 7.5 m (25') of tubing downstream from where the burner and burner tube connect. -
Page 13: Figure 6: 2-Foot Deco Grille
SECTION 3: C LEARANCES TO OMBUSTIBLES NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, tees, elbows and crosses. 2. Clearances B, C and D can be reduced by 50% after 7.5 m (25') of tubing downstream from where the burner and burner tube connect. -
Page 14: Section 4: Major Components
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Optional reflector configurations are shown on Page SECTION 4: MAJOR COMPONENTS 6, Figure 3 through Page 7 , Figure 7. Install appro- The figures in this section provide a general over- priate suspension hardware, beam clamps, chain or view of component placement in a CORAYVAC ®... -
Page 15: Figure 9: Major Component Descriptions (Continued)
SECTION 4: M AJOR OMPONENTS Figure 9: Major Component Descriptions (Continued) ROBERTS GORDON ® NRG Control RG-30 and RG-45 Pump Reflector End Cap (Aluminum or Stainless Steel) Remove center section to accommodate tube when necessary. Tube and Reflector Side Extension Reflector Hanger Reflector Support... -
Page 16: Standard Parts List
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 4.1 Standard Parts List ® Table 1: Contents of CORAYVAC Burner Carton Reflectors and Related Accessories Part No. Description Quantity 01329910 Reflector Side Extension Support E000XXXX CORAYVAC Burner (Rate and Fuel Varies) ® 91107720 U Clip Package - 20 off E0007565... -
Page 17: Section 5: Design Requirements
SECTION 5: D ESIGN EQUIREMENTS SECTION 5: DESIGN REQUIREMENTS The CRT-Series system’s design is related 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... -
Page 18: Figure 10: Corayvac
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Figure 10: CORAYVAC ® Assembly Overview 12 of 54... -
Page 19: Section 6: Heater Installation
SECTION 6: H EATER NSTALLATION SECTION 6: HEATER INSTALLATION Section 16.6. WARNING NOTE: Some models will receive S-hooks (P/N 91907302) or Spring Hooks (P/N 91903300), rather than Bow Shackles. Severe Injury Hazard Secure burner to combustion chamber with nuts and lockwashers. Hang heater with materials with a minimum working load of 33 kg. -
Page 20: Figure 11: Critical Hanger Placement
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Figure 11: Critical Hanger Placement Typical Suspension Details Concrete Beam Beam Clamp Wood Beam Anchor Locknut Screw Hook (10 mm) Chain size 5 mm minimum Washers (10 mm) 610 mm min. Turnbuckle "X" Snap Hook (see table) -
Page 21: Tube Installation
SECTION 6: H EATER NSTALLATION Step 6.1 Tube Installation NOTE: Tubing requires a downward slope of 13 mm per 6,000 mm away from burner. Tailpipe tubing requires a downward slope of 25 mm per 6,000 mm away from burner. End View Combustion Chamber Weld... -
Page 22: Elbow Configuration
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 6.2.1 Coupling and Tube Assembly (Continued) Tighten Slide Bar as shown below. Drive slide bar until tight. End of slide bar should be within tolerance listed below. ± 50 mm Correct Slide Bar Incorrect Slide Bar dimensions position... -
Page 23: Reflector Installation
SECTION 6: H EATER NSTALLATION Step 6.4 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. Step 6.4.1 Reflector Installation with Hole Reflector with hole Slide Reflector... - Page 24 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 6.4.3 Reflector, U-clip and Reflector Support Installation The pictorial drawings of the heater construction in supports are used. The positioning of reflector supports Section 6 are schematic only and provide a general and u-clips depend on the individual installation.
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Page 25: Burner Installation
SECTION 6: H EATER NSTALLATION Step 6.5 Burner Installation Burner Burner Combustion Chamber Gasket Vent NOTE: Install end vent at end combustion chamber position only Part Number Description Bolt E0007588 Burner E000XXXX Lock Washer 96411600 Gasket 01367800 End Vent E00094XX 19 of 54... -
Page 26: Section 7: Optional Heater Accessories
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: OPTIONAL HEATER ACCESSORIES WARNING Cut/Pinch Hazard Wear protective gear during installation, operation and service. Edges are sharp. Failure to follow these instructions can result in injury. Step 7.1 Tee Installation Tube Coupling Part Number Description... -
Page 27: Figure 12: Reflector Joint Detail
SECTION 7: O PTIONAL EATER CCESSORIES Step 7.2.2 Reflector Joint Installation Cut away contour with tin snips. Punch/drill six 2 mm holes. Step 7.2.3 Reflector Joint Detail Figure 12: Reflector Joint Detail 21 of 54... -
Page 28: Reflector Side Extension
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 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. Part Number Description S7377K Reflector Side Extension Package... -
Page 29: Two-Foot Decorative Grille Installation
SECTION 7: O PTIONAL EATER CCESSORIES 7.4 Two-Foot Decorative Grille Installation Step 7.4.1 Grille Installation Description Part Number Aluminum Grille 600 mm x 1200 mm 91407000 Step 7.4.2 Frame Shield Installation Description Part Number Deco Grille Shield 01365900 23 of 54... - Page 30 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 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 Description Part Number 150 mm 260 mm 01370412 3000 mm Reflector Side Extension 01370412 260 mm...
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Page 31: Protective Grille Installation
SECTION 7: O PTIONAL EATER CCESSORIES 7.5 Protective Grille Installation Step 7.5.1 Silicone Cap Installation Silicone Cap Part Number Description Grille Section 08050001 Grille End Cap 08050002 Grille Silicone Cap 91915951-6P Finger Step 7.5.2 Grille End Cap Installation Grille Grille End Cap Bend up 90°. -
Page 32: Sports Hall Guard Installation
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 7.6 Sports Hall Guard Installation Step 7.6.1 Grille Installation Strap - Stainless Steel Tube and Reflector Hanger Reflector Tube Reflector Support Part Number Description Mesh Guard 2438 mm E0009855 Mesh Guard 1524 mm C2329B Strap Stainless Steel S5218W... -
Page 33: Sports Hall Filter
SECTION 7: O PTIONAL EATER CCESSORIES 7.7 Sports Hall Filter Step 7.7.1 Remove Standard Door Remove the burner door with the cylindrical filter. Door Cylindrical Filter Step 7.7.2 Install New Door Filter Remove backing of the adhesive strips from the filter and affix to the inside of the burner door Peel off... -
Page 34: Section 8: General Venting Requirements For Pumps
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 8: GENERAL VENTING REQUIREMENTS FOR PUMPS Seal all joints with high temperature silicone sealant. WARNING Vent terminal must be beyond any combustible overhang. 8.1.1 Vertical Venting See Page 33, Figure 20 for recommended vertical venting options. -
Page 35: Mounting Wall Bracket Assembly
SECTION 8: G ENERAL ENTING EQUIREMENTS UMPS 8.2 Mounting Wall Bracket Assembly The pump may be mounted by using mounting angles as shown in Figure 13 and Figure 14. The WARNING two mounting angles form a mounting platform to which the pump will be attached using the anti-vibra- tion mounts. -
Page 36: Figure 15: Pressure Switch Installation
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 8.2.2 Attaching Pressure Switch 8.2.3 Flue Installation Drill two holes in the fan base housing to accept the The fan outlet must always discharge horizontally. pressure switch mounting bracket and attach the Mount the 150 mm pump boot to the pump outlet switch by means of 2 self-tapping screws. -
Page 37: Building Ventilation
SECTION 8: G ENERAL ENTING EQUIREMENTS UMPS 8.2.4 Pump Inlet Adapter for 100 mm (4") Tubing 8.3 Building Ventilation Apply a bead of silicone sealant 316° C to the 150 The space containing the heaters must have a mm inside of the reducer 150 mm x 100 mm. Mount permanent outside air vent with a minimum effective the reducer to the inlet of the pump scroll using the 3 area of 4.5 cm... -
Page 38: Condensate Drain Assembly
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 8.5 Condensate Drain Assembly The condensate drain assembly is composed of a The condensate drain assembly in the pump tee, draincap, and a non return valve. discharge line can be eliminated if the discharge line is horizontal through the wall and pitched down at A condensate drain assembly must be installed on the least 6 mm per 3048 mm. -
Page 39: Acoustic Enclosure (Optional)
SECTION 8: G ENERAL ENTING EQUIREMENTS UMPS Figure 20: Condensate Drain Assembly - Vertical Flue Approved Vent Cap Roof 150 mm Flue 150 mm Minimum Wall Drain Cap 150 mm Pump Discharge 1" BSP threaded hole. 3/4" CPVC Pipe Use 1" x ¾" reducer. (not supplied) 300 mm 3/4"... -
Page 40: Figure 22: Acoustic Enclosure
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL an electrical junction box on its side. Pressure switch The mounting of the enclosure must be done as control wires and electrical power connection need described in Section 8.2 on Page 29. to be connected here. A wiring diagram is inside the junction box. -
Page 41: Section 9: Outside Air Supply
SECTION 9: O UTSIDE UPPLY SECTION 9: OUTSIDE AIR SUPPLY All joints and seams in the air supply system must be airtight. The filter housing attaches to the burner ® The CORAYVAC system is approved for use with assembly by using the wing nut provided. Single an outside air system. -
Page 42: Section 10: Gas Piping
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: GAS PIPING testing of the gas piping has been completed. WARNING There is an expansion of the tube with each firing cycle. This will cause the burner to move with respect to the gas hose. This can cause a gas leak resulting in an unsafe condition if the gas connection is not made in strict accordance with Figure 26. -
Page 43: Figure 26: Gas Connection With Stainless Steel Flex Gas Connector
SECTION 10: G IPING Figure 26: Gas Connection with Stainless Steel Flex Gas Connector CORRECT POSITIONS CAUTION Product Damage Hazard Shut-Off Valve must be parallel to Hold gas nipple securely with pipe wrench burner gas inlet. The 80 mm when attaching gas hose. displacement shown is for the cold condition. -
Page 44: Section 11: Wiring
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 11: WIRING Connect to the electrical supply using a 3 pin plug via a locally mounted double pole fused switch hav- ing a minimum disconnection of 3 mm on each pole. DANGER The burner is fused at 1 A. -
Page 45: Figure 28: Crt Burner Internal Wiring
SECTION 11: W IRING Figure 28: CRT Burner Internal Wiring INTERNAL MIXING WIRING DIAGRAM CHAMBER Blue Brown Green/ Green/Yellow If any of the original wire Yellow ELECTRODE supplied with the heater SPARK must be replaced, it must 3 2 1 Sense be replaced with wiring material having a... -
Page 46: Section 12: Operation And Maintenance
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 12: 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. -
Page 47: Sequence Of Operation
SECTION 12: O PERATION AND AINTENANCE Figure 30: Burner Sequence of Operation Chart KEY TO SYMBOLS Thermostat Lockout Neon Start/Run Ignition Valve Flame Sensing Lockout Alarm (optional) 3 try Interuption of main 55 sec approx. flame sensing 12.1 Sequence of Operation minutes to clear products of combustion from the system. -
Page 48: System Checks
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 2. Ensure that all dampers are in the fully open 12.4 System Checks position. Turn the system off and restart it to ensure smooth 3. Turn off the electrical supply to the heaters. ignition. -
Page 49: Section 13: Servicing Instructions
SECTION 13: S ERVICING NSTRUCTIONS SECTION 13: SERVICING INSTRUCTIONS DANGER WARNING 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 50: Maintenance Checklist
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Withdraw the connection block. Remove the ground 13.3 Maintenance Checklist wire from the gas valve and from the air shutter Installation Code and Annual Inspections: screw. The gas train can now be withdrawn from the All installation and service of ROBERTS GORDON ®... - Page 51 SECTION 13: S ERVICING NSTRUCTIONS Tubes Make sure there are no cracks. Make sure tubes are connected and suspended securely. See Page 14, Figure 11 through Page 16, Section 6.2.1. Make sure there is no dirt, sagging, bending or distortion. Clean or replace as required.
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Page 52: Section 14: Troubleshooting
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 14: 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 53: Troubleshooting Flow Chart
SECTION 14: T ROUBLESHOOTING 14.1 Troubleshooting Flow Chart 47 of 54... - Page 54 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Troubleshooting Flow Chart 48 of 54...
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Page 55: Figure 31: Vacuum Reading
SECTION 14: T ROUBLESHOOTING Figure 31: Vacuum Reading Combustion Chamber at end position End Vent Insert tubing about 150 mm (6"). Manometer Cold Suction Hot Suction Approximate reading after adjusting Approximate reading after adjusting damper couplings. (9 mbar) damper couplings. (7 mbar) 49 of 54... -
Page 56: Section 15: Replacement Parts
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Carbon Monoxide Hazard Fire Hazard ® 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. 50 of 54... - Page 57 SECTION 15: R EPLACEMENT ARTS Item Description Part Number Item Description Part Number Ignition Module 90435203 N/S Sense Lead Wire 02950003 Gas Valve 90033101 N/S Gas Valve Harness 02950006 Regulator 90207102 N/S Ignition Wire 90427704 Mixing Block 02790400 N/S Filter 90707000 Burner Head Assembly 02721702...
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Page 58: Section 16: Specifications
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL SECTION 16: SPECIFICATIONS LP Gas (Propane or Butane): 16.1 Material Specifications Minimum - Inlet 32 mbar (13 in wc) 16.1.1 Combustion and Tubes Maximum - Inlet 50 mbar (20 in wc) 100 mm dia 16 gauge heat treated aluminised mild 16.3 Venting Specifications steel. -
Page 59: Burner Specifications
SECTION 16: S PECIFICATIONS 16.7 Burner Specifications ® General Specifications for CORAYVAC heaters are as follows: 32 cm 19 cm 24 cm 17 cm 19 cm 9 cm 24.4 cm .4 cm 36 cm 51 cm *See Page 5, Section 3 for clearances to combustibles. BURNER COMPONENTS Orifice Size End Vent... -
Page 60: Pump Dimensions And Specifications
CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 16.8 Pump Dimensions and Specifications Pump Dimensional Data (mm) Model RG30-1 RG30-3 RG45-1 RG45-3 150 mm 150 mm 205 mm 230 mm (mounting holes) (mounting holes) 62 mm Pump Specifications Model RG30-1 RG45-1 RG30-3 RG45-3 Part No. - Page 62 ® Attach this information to a wall near the ROBERTS GORDON heater. ® I n f r a r e d H e a t i n g Read the Installation, Operation, and Service Manual thoroughly before installation, operation, or service. Know your model number and installed configuration.