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Combustion Research reflect-o-ray eds 3.5 Installation Operation & Maintenance

Oil fired low intensity infrared vacuum vented infrared heating systems
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FOR YOU SAFTEY
If you have a Fuel Oil leak:
Open windows
1.
DO NOT try to light any appliance.
2.
DO NOT use electrical equipment.
3.
Shut off Fuel Oil supply.
4.
Leave the building.
5.
Immediately call your local Fuel Oil
6.
supplier after leaving the building.
Follow Fuel Oil supplier's
instructions.
If you cannot reach your Fuel Oil
7.
supplier, call the Fire Department.
WARNING
!
Fire Hazard
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Some objects will catch fire or explode
when placed near this heater.
Failure to follow these instructions can
result in death, injury or property
damage.
!
Read and understand these installation,
operating and maintenance instructions
thoroughly before installing or servicing
this equipment. Only trained, qualified gas
installation and service personnel may
install or service this equipment.
Please take 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 the necessary information.
Combustion Research Corp.
2516 Leach Rd.
Rochester Hills, MI 48309-3555
Telephone: 248.852.3611
Fax: 248.852.9165
www.combustionresearch.com
Issue Date: 4/12/1997
COMBUSTION RESEARCH CORPORATION
Reflect-O-Ray
Oil fired, Low Intensity Infrared Vacuum
WARNING
Installer
Owner
Revision Date: 10/28/08
Oil Fired EDS 3.5
Vented Infrared Heating Systems
Installation, Operating, Maintenance
Rev. 9
and Parts Manual
TM
Bulletin RL3597102
®
TM

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Summary of Contents for Combustion Research reflect-o-ray eds 3.5

  • Page 1 COMBUSTION RESEARCH CORPORATION ® Reflect-O-Ray FOR YOU SAFTEY If you have a Fuel Oil leak: Open windows DO NOT try to light any appliance. Oil Fired EDS 3.5 DO NOT use electrical equipment. Shut off Fuel Oil supply. Leave the building.
  • Page 2 ® Reflect-O-Ray EDS 3.5 Installation, Operation & Service WARNING FIRE OR EXPLOSION HAZARD Can cause death, severe injury and/or property damage. 1. Read this manual carefully before installing or servicing Vehicles: Minimum clearances must be maintained from this equipment. Improper installation, service vehicles parked, below the heater.

  • Page 3: Table Of Contents

    All rights reserved. No part of this work covered by the copyrights hereon in 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 written permission of COMBUSTION RESEARCH CORPORATION, Inc.

  • Page 5: Oil Fired Eds

    2. In other sections of aircraft hangers, such as shops or evident upon receipt of shipment must be reported to carrier offices communicating with airplane storage or servicing and Combustion Research Corporation Sales area, heaters shall be installed in accordance with their Representatives within 72 hours.

  • Page 6: Installer Qualification & Responsibility

    GENERAL CONSIDERATIONS Canada: Refer to Canadian Electrical Code CSA C22.1 Part 1 (latest edition). Combustion Research Corporation Factory Representatives OIL SUPPLY SYSTEM are experienced in the application of this equipment and can be called on for suggestions about installation which can The method of pipe sizing must conform to the U.S.

  • Page 7: Installation Notes

    * - In multiple burner systems the radiant Vacuum 40’ tubing runs do not have to be equal or Exhauster balanced in length. 40’ + 10’ + 40’ = 90’ From Vacuum Exhauster to either burner Combustion Research Corporation Page 3...

  • Page 8: Clearance To Combustibles

    6” 60” 30” 36” 36” 0520.R 6” 60” 30” 36” 36” * B1 – Bottom Clearance when P/N 0304.INSUL.25 radiant tube is used “B” Clearances (bottom) can be reduced to 15”, 25’ downstream of burner Page 4 Combustion Research Corporation...
  • Page 9 0500.R - “B” Clearances (bottom) can be reduced to 40”, 20’ downstream of burner 0510.R - “B” Clearances (bottom) can be reduced to 40”, 20’ downstream of burner 0520.R - “B” Clearances (bottom) can be reduced to 24”, 20’ downstream of burner Combustion Research Corporation Page 5...
  • Page 10 5” 0360.00 or 0360.02 Reflector With an Inverted 0360.00 or 0360.02 Reflector. 4” Gap - Applies To All Inputs - 40” 40” 22” “U” BEND END CLEARANCE ROOF Min. 18” Clearance “U” Tube Reflector End Page 6 Combustion Research Corporation...

  • Page 11: System Installation

    IRON, ETC. hangers NOTE – THE WELD SEAM ON THIS FIRST (AND If chain is not supplied by Combustion Research SECOND IF PROVIDED) SECTION OF TUBE MUST BE Corporation, furnish a chain with a minimum 90 lb. workload POSITIONED SO THAT IT IS ON THE BOTTOM OF THE (trade size #3 or larger).
  • Page 12 58" 118" 58" 118" 5" 0304.AS.16 – Aluminized Tube HANGER & SUPPORT LOCATIONS – “INSL” TUBE SYSTEM Hanger Hanger Hanger Hanger Hanger Hanger Hanger 59" 59" 118" 5" 59" 59" 59" 0304.INSL.25 – “INSL” Tube Page 8 Combustion Research Corporation...

  • Page 13: Damper Types

    Rotate 180° and reassemble - take care so as not to "strip out" handle. When turning the damper handle, the center-retaining spud on the opposite side should rotate simultaneously. Combustion Research Corporation Page 9...
  • Page 14 To Vacuum Exhauster To Vacuum Exhauster 0307.AS.C - Damper Single To Vacuum Exhauster Burner Flow Single Burner Flow 0307.AS.XB - "X" Fitting With Dampers From Upstream Burner Flow(s) Single Single Burner Flow Burner Flow To Vacuum Exhauster Page 10 Combustion Research Corporation...

  • Page 15: Suspension Methods

    Secure turnbuckle Chain with JAM nuts or wire to prevent unwinding Concrete Wood Beam Beam Eye Bolt Screw with Washer and Suitable Expansion Locknut Anchor Chain Chain All ”S” Hooks MUST Be Manually Closed By Installer Combustion Research Corporation Page 11...

  • Page 16: Seismic Restraint Suspension

    Twist the ends of the wire together and trim as required. This retention wire may be installed on both sides, or edges of the reflector for severe wind conditions. Page 12 Combustion Research Corporation...

  • Page 17: Reflector Installation

    - see the following expansion joint illustration. f. Check all reflector hangers and supports for location and make sure reflectors are straight and in line. g. Make sure all combination hanger hooks are closed. Burner Combustion Research Corporation Page 13...
  • Page 18 NOTE: DO NOT (P/N 0366.0050) screw the expansion joints together. TO TUBE WITH 0366.00 S/M SCREW SIDE SHIELD SECURE WITH S/M SCREW FIELD FAB RELIEF NOTCH SECURE SIDE SHIELD HANGER WITH S/M SCREW Page 14 Combustion Research Corporation...
  • Page 19 Use Sheet Metal Screws To Secure "Tee" In Place For "X" fittings (PN 0307.AS.X) use the same technique shown, cutting and another relief hole on the opposite side of the reflector and installing a second reflector tee. Combustion Research Corporation Page 15...

  • Page 20: Decorative Grille Installation

    Accommodate Tube & Reflector Hangers Reflector and Radiant tube Decorative Grille Side Shield (10’ Long) P.N. 0369.11 Decorative Grille "T" Bar Heat Shield Suspended Ceiling 2 ft. (60 cm) Wide P.N. 0369.21 "T" Bar Framing Page 16 Combustion Research Corporation...

  • Page 21: Radiant Tube Wall Penetration

    No. 54 for the United States and the CAN/CGA B149 (current standard) for Canada. 6" - "B" Vent 6" - "B" Vent - Use only all steel construction Install Reflector Install Reflector End Cap End Cap Reflector Reflector Min. 18" Min. 18" Combustion Research Corporation Page 17...

  • Page 22: Connecting Burner To Radiant Tube

    Drawband Coupler – Mount bolt assembly on top of tube. Un-swaged end of P/N 0304.AS.16 combustion tube This backside surface of the Oil Burner Secure with sheet housing is to be plumbed level. metal screws Page 18 Combustion Research Corporation...

  • Page 23: Oil Supply

    National Fire Protection Association. In Canada the installation must conform to C.S.A. B139, Installation Code for Oil Burning Equipment. It must be understood that Combustion Research Corporation cannot and does not represent that the following information for oil circuits will satisfy any particular local code requirements.

  • Page 24: Oil Supply - Day Tank System

    Link Valve Check Valve ® ® ® Reflect-O-Ray Reflect-O-Ray Reflect-O-Ray Oil Burner Oil Burner Oil Burner Oil Filter Fusible Link Oil Filter (Typ.) Valves (Typ.) Fusible Link Valve Day Tank Return Line Oil Supply Tank Page 20 Combustion Research Corporation...

  • Page 25: Oil Supply - "Loop" System

    TIGER LOOP Oil De-Aerator Oil Filter (Typ.) Fusible Link Return Line Valves (Typ.) ® Reflect-O-Ray Oil Burner Fusible Link Valve Oil Filter Check Valve Fusible Link Valve Pressure Gauge Oil Supply Pump Oil Supply Tank Combustion Research Corporation Page 21...

  • Page 26: Flexible Oil Connector Installation

    2” – 3” (5 – 7.6cm) Hold oil fittings securely with Cold Displacement wrenchs when connecting flexible Oil Hose and fittings. INCORRECT POSITIONS Use 36” long steel braided flexible rubber oil hose with 3/8” MPT ends for connections Page 22 Combustion Research Corporation...

  • Page 27: Combustion Air

    1810.VT.400, 1810.VT.600 & 0614.00 may also be used. When used as an elbow, form flex into a "SOFT" sweeping elbow Burner Assembly Galvanized sheet metal TEE and cap by installer. DO NOT USE AN ELBOW Combustion Research Corporation Page 23...

  • Page 28: Vacuum Exhausters

    NOTE - Motor substitutions can occur, always refer to the motor manufacturer nameplate for electrical information and wiring instructions. Housings and inlets made with stainless steel are also available – the last two-digit designation will be SS. Page 24 Combustion Research Corporation...

  • Page 29: Exhaust Flex Connections

    PN - 0334.SS Flex & Clamps PN - 0334.SS Flex & Clamps PN - 0307.AS - TEE PN - 0307.AS - TEE Vacuum Exhauster Secure with sheet Vacuum Exhauster Secure with sheet metal screws metal screws Combustion Research Corporation Page 25...

  • Page 30: Venting

    3. Vertical discharge must be arranged furnished by Combustion Research Corporation. as shown on page 28. ♦ Where the vent pipe passes through areas where the...

  • Page 31: Venting

    Min. 2" isolators. Max. 12" For combustible walls a minimum of 2" clearance around exhaust duct is required. If necessary installer shall fabricate exterior wall flashing (Min. 16 ga. galvinized steel construction) Combustion Research Corporation Page 27...
  • Page 32 Use "B" vent for wall penetration. Approved vent cap Min. 2' (61 cm) PN - 0306.AS 90° Elbow (If Used) PN - 0334.SS Exhaust Flex Vacuum Exhauster Square to round adapter Minimum 6" dia. vent, Tee & cap. Page 28 Combustion Research Corporation...
  • Page 33 WEATHER COVER MUST COME TO INSTALL BIRD SCREEN BOTTOM OF MOTOR IN OUTLET WALL MOUNTING BRACKET ASSEMBLY BY INSTALLER INSTALL 0334.SS FLEX ON THE INSIDE OF THE BUILDING – USE RADIANT TUBE FOR WALL PENITRATION. Combustion Research Corporation Page 29...

  • Page 34: Electrical Wiring & Control Panels

    In order to assure proper operation of the electrical ® components of the Reflect-O-Ray OIL FIRED EDS 3.5 system , it is essential that the voltage to the exhauster Page 30 Combustion Research Corporation...
  • Page 35 Consult the factory for alternate voltage requirements. LEGEND 115V - 60Hz - 1 PHASE FUSED BY OTHERS BREAKER - BY INSTALLER 1 POLE, 115 V THERMOSTAT VACUUM EXHAUSTER 1 HP, 60 Hz, 115 VOLT 1 POLE 15 AMP DISCONNECT SWITCH BURNER Combustion Research Corporation Page 31...
  • Page 36 Please note that the timings listed may vary slightly from system to system. 5500.00 CONTROL PANEL PRE & POST PURGE W/115V T/STAT Custom control panels can be made. Consult your representative or Combustion Research Corporation with your requirements. Page 32 Combustion Research Corporation...

  • Page 37: Burner Wiring Schematic

    Pipe dope or Teflon tape may be used on the NPT side of the connector only. NOTE: Use pipe dope and Teflon NPT/Metric Adapter Combustion Research Corporation Page 33...

  • Page 38: Burner Technical & Setup Data

    0520.R 1.5” 1/8” NPT TEST PLUG (Location may be on chamber side) 1/8” NPT TEST PLUG (Use this test port when REAR VIEW a differential vacuum (Air Inlet side of Burner reading is required) Assembly) Page 34 Combustion Research Corporation...

  • Page 39: Sequence Of Operation & General Safety Information 35

    BEFORE BURNER SYSTEM STARTUP 1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC) and the 1. System has been installed to Combustion Research Occupational Safety and Health Act (OSHA). Corporation recommendations in Installation Manual 2.

  • Page 40: System Shut Down & Maintenance

    When the system is initially fired, any oil that is on the burner. Operate system through one complete cycle to pipe work and fittings will burn off and form a light ensure all controls operate properly. haze in the building which can best be removed by Page 36 Combustion Research Corporation...
  • Page 41 Inspect oil nozzle for correct size, replace at least replaced with appropriate product as manufactured by once ever season. Combustion Research Corporation. Disconnect power and check spade connections or The Radiant Tubing should be inspected at the beginning broken wires.
  • Page 42 Attempted disassembly or repair may damage the oil ignition control. Improper cleaning or re-assembly may cause oil leakage. When cleaning, ensure that the burner assembly is reassembled properly and inspected for oil leaks. Page 38 Combustion Research Corporation...
  • Page 43 1. Before turning on the main electrical power switch, be 7. Reset the burner and operate system through one sure all oil supply lines are purged of air. complete cycle to ensure all controls operate properly. Combustion Research Corporation Page 39...
  • Page 44 D. Replace adapter, with nozzle installed, into the drawer the appropriate nozzle as shown on page 34. assembly and secure with screw (1). Remove the nozzle adapter (2) from the drawer assembly by loosening screw (1). Page 40 Combustion Research Corporation...
  • Page 45 Remove the drawer assembly as described on page 40 to gain access to the spark assembly. Do not force or over tighten screws, as damage to porcelain will occur. 5/32” 13/64” 5/64” – 7/64” 2 – 2.5mm Combustion Research Corporation Page 41...
  • Page 46 1. Remove the PUMP COVER (1) by removing the four directly to pump ports. An NPT / metric adapter must be SCREWS (8). used when connecting other gauge models 40 F3 BURNER ASSEMBLY MECTRON 3 BURNER ASSEMBLY Page 42 Combustion Research Corporation...

  • Page 47: Trouble Shooting Flow Chart 43

    Check wiring and repair Is there 120 volts at the Replace pressure as needed. burner terminals switch. Is the burner motor Is there 120 volts at the Replace ignition control operating? motor? Replace motor and capacitor. Combustion Research Corporation Page 43...
  • Page 48 Replace damaged Replace ignition control. component. Replace ground wire. Does the burner and vacuum exhauster shut Replace thermostat. off when the temperature is satisfied? END OF TROUBLE SHOOTING Page 44 Combustion Research Corporation...

  • Page 49: Vacuum Exhauster Parts List 46

    ½ HP Motor – 3450 RPM – 115v/230v, 50 Hz 5320.00 1 HP Motor – 3450 RPM – 115v/230v, 50 Hz 1063.11 3/8” x 16 x1” Long Hex Bolt w/Spot Lock 1112.01 5/16” Plated Flat Washer Combustion Research Corporation Page 45...
  • Page 50 3/16” Key – Provided with Motor 201.05 Mounting Plate 1491.00 Rubber Grommet 5323.00 1/4 HP Motor – 3450 RPM – 115v/230v, 50 Hz 1063.11 3/8” x 16 x1” Long Hex Bolt w/Spot Lock 1112.01 5/16” Plated Flat Washer Page 46 Combustion Research Corporation...

  • Page 51: Burner Parts List

    Combustion Chamber End Piece 5002.00 Combustion Chamber 504.R1-B Fresh Air Box Mounting Flange 504.R1-A Fresh Air Box 500.100.R Complete Chamber Assembly Less Riello Burner Head & Air Box Riello Burner Assembly – See Next Page For Exploded View Combustion Research Corporation Page 47...

  • Page 52: Replacement Parts

    ® Reflect-O-Ray Oil Fired EDS 3.5 Installation, Operation & Service REPLACEMENT PARTS Riello 40 F3 Series Hydraulic Air Damper Electric Air Damper Page 48 Combustion Research Corporation...
  • Page 53 3006968 Turbulator Disk 3006966 Electrode Support 3006965 Nozzle Adapter 3006969 Nozzle Oil Tube 3006324 Regulator Assembly 3006330 Electrode Assembly 3005869 Electrode Porcelain 3007592 Air Tube C7001081 40 F3 Replacement Air Damper Kit (Post Nov. 1996) Combustion Research Corporation Page 49...

  • Page 54: Accessories & Optional Equipment

    90 lbs. – For radiant tube and reflector suspension only. Wt. 6.5 lbs. 1800.SH.000 "S" HOOKS - Box of 50 "S" hooks. WT. 2.0 lbs. 1A-25A OIL FILTER – Fuel oil filter with 3/8” FPT connections. Wt. 4.0 lbs. Page 50 Combustion Research Corporation...
  • Page 55 COMBINATION HANGER - Heat tube & standard reflector hanger for 3.5" tube, plated 1/4" dia. wire. Wt. 0.75 LB 0362.00 REFLECTOR SUPPORT - Intermediate support for standard reflector for 3.5" tube, plated 1/4" dia. wire. Wt. 0.75 LB Combustion Research Corporation Page 51...
  • Page 56 0360.00 reflectors. Wt. 1.0 lbs. 0368.0010 SIDE SHIELD SUPPORT - Side shield support for use with 0812.00 reflectors. Wt. 0.75 lbs. 0342.WH REFLECTOR END CAP - Aluminum end cap. Used on 0360 reflector. Wt. 0.25 lbs. Page 52 Combustion Research Corporation...
  • Page 57 ® Reflect-O-Ray Oil Fired EDS 3.5 Installation, Operation & Service - NOTES - Combustion Research Corporation Page 53...

  • Page 58: Warranty Statement

    In addition, to the one-year warranty on all product components, Combustion Research Corporation also offers the Buyer an Extended Warranty on the radiant heater tubing (Infrared Emitter), which is installed as original equipment with a Combustion Research Corporation infrared radiant energy heating system.
  • Page 59 LIMITATIONS ON STANDARD AND EXTENDED 10 YEAR WARRANTY These Warranties are the only warranties offered by Combustion Research Corporation (CRC) and are in lieu of all other warranties either express or implied. CRC shall not be liable for any special, incidental or consequential damage, such as damage to a building or persons or things within a building due to any kind of radiant energy heating system failure.
  • Page 62 COMBUSTION RESEARCH CORPORATION 2516 Leach Road, Rochester Hills, Michigan 48309-3555 Telephone No. 248.852.3611 www.combustionresearch.com...

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