Combustion Research Reflect-O-Ray EDS 6, Installation, Operating, Maintenance And Parts Manual

Page 1: ...r building 5 Leave the Building 6 Immediately call your local gas supplier after leaving the building Follow gas supplier s instructions 7 If you cannot reach your gas 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 he...

Page 2: ...et and entangle with impeller wheel Keep hands and fingers away from inlet and outlet Install exhaust duct with bird screen or approved vent cap on vacuum exhauster outlet Mechanical Hazard Suspension Use appropriate suspension hardware beam clamps rod or perforated strap and turnbuckles at predetermined locations The weight and normal movement of the heating system may cause support failure if th...

Page 3: ... to radiant tube 15 Gas supply 16 17 Combustion air supply 18 Vacuum exhausters 19 Venting 20 26 Electrical wiring control panels 27 29 Burner wiring schematics 30 Burner technical data 31 Burner setup 31 32 System sequence of operation 33 35 System shut down maintenance 36 38 Trouble shooting flow chart 39 40 Burner parts list 41 42 Vacuum exhauster parts list 43 System accessories 44 47 Warranty...

Page 4: ...Reflect O Ray EDS 6 Installation Operation Service Combustion Research Corporation This Page Intentionally Left Blank ...

Page 5: ... edges The use of gloves will also help in reducing the transfer of dirt and oils to the surface of the reflectors If additional Installation Operation and Service Manuals are needed contact your Combustion Research Corporation independent representative or Combustion Research Corporation The IOM s can also be found at www combustionresearch com In order to help prevent personal injury and damage ...

Page 6: ...Corporation Page 2 Wiring Diagram Label P N 800 21F Control Cover Inside Top View Control Cover Control Side Access Burner Side View Operating Instructions Label P N 900 2701 Indicator Light Label P N 800 06 Rating Plate Label P N 900 2601 Gas Connector Label P N 900 2713 ...

Page 7: ...ODES In the absence of local codes the installation must conform to the latest edition of United States National Fuel Gas Code ANSI Z223 1 NFPA 54 Canada CAN CGA B149 1 and 2 Canadian Electrical Code C22 1 AIRCRAFT HANGERS Heaters for use in aircraft hangers must be installed in accordance with United States Refer to Standard for Aircraft Hangars ANSI NFPA 409 latest edition In Canada Refer to Sta...

Page 8: ...ximum stacking height so as to maintain the required clearance to combustibles GENERAL CONSIDERATIONS Combustion Research Corporation Factory Representatives are experienced in the application of this equipment and can be called on for suggestions about installation which can give the owner of the building a more satisfactory and economical installation When installing the Reflect O Ray system tak...

Page 9: ...tube A 19 9 long turbulator tube section P N 0604 AS TURB 2 shall be incorporated at least 40 downstream of the burner Tee s and dampers must be installed after any turbulator tube DO NOT install turbulated tube in sections carrying two burner flows Each single flow of radiant tube shall incorporate an adjustable damper for regulating burner airflow DESIGN TUBE LENGTH REQUIREMENTS FOR OPTIMUM EFFI...

Page 10: ...t is recommended that the system not be mounted lower than 20 above the floor The following illustrations and information give minimum acceptable clearance to combustibles Minimum clearances to combustibles must be maintained for wall floor ceiling temperatures The stated clearance to combustibles represents a surface temperature of 90ºF 32ºC above room temperature Building materials with a low he...

Page 11: ... BEND END CLEARANCE U bend is to be installed at least 35 downstream of burner Model No E U Bend With Reflector Installed As Shown Exposed U Bend Without Reflector Distance Measured From Edge of Radiant Tube 0610 NG LP 0600 NG LP 18 36 UN VENTED CLEARANCE E Page 7 18 46 cm 18 46 cm TOP ...

Page 12: ...NOT install anchors in existing cracks or joints 4 Determine suspension chain lengths and proceed to cut and pre assemble suspension components NOTE Each Reflect O Ray EDS 6 burner assembly is equipped with a suspension point Adjust as required to keep the burner assembly level and square to the radiant tubing 5 Install beam clamps eyebolts etc at predetermined suspension locations refer to the in...

Page 13: ...l Combination hangers should be position so that the locking loop 45 suspension point face the same direction Combination hanger s 0661 00 shall be positioned at all elbows and tee s so as to provide support for the adjoining reflector 5 Position the intermediate reflector supports 0465 00 between the combination hangers illustrated below 6 Using two or more men raise the length of pre assembled t...

Page 14: ... Corp furnish a chain with a minimum 90 lb workload trade size 3 or larger A minimum of 12 30 cm of hanging chain is recommended This allows for system expansion and contraction reducing the likelihood of reflector and radiant tube warping and or expansion noise CAUTION Infrared tube systems expand and contract upon each call for heat System expansion of up to 4 can be expected Provisions must be ...

Page 15: ... connecting chains or threaded rod to Z purlin use beam clamp or drill a hole through Z purlin and secure with two 3 8 nuts and a lock washer If the system is a straight system no elbows or tee s apply an anti sway chain or wire rope which is parallel to the radiant tube at approximately the middle of the run If there are any questions regarding what method is best suited for your application cons...

Page 16: ...nimum 1 2 2 5 5 cm overlap e Overlapped joints are secured with sheet metal screws Make sure expansion joint is in every straight run see next page 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 PERIMETER MOUNTING In areas of high heat loss such as doorways and the perimeter of some build...

Page 17: ...for freedom of movement or expansion during normal heat up and cool down Expansion joints are to be placed at approximately the center of each straight run of reflectors with a maximum of three 3 reflectors connected together Additional expansion joints in each straight run may be necessary All other reflector joints reflector elbows and reflector tee s should be overlapped 1 2 and sheet metal scr...

Page 18: ... hold the blade and setting plate in place Rotate setting plate 180 and reassemble take care so as not to strip out handle When turning the damper handle the retaining spud on the opposite side should rotate simultaneously NOTE 0641 00 damper assembly for use with single burner systems and when DAMPER TEE S are not used Install Handle On Side Or Bottom Of Tube Position locating holes as shown 0441...

Page 19: ...e existing building structure using angle Iron Uni strut etc and then suspend the chain so that it hangs vertically GAS SUPPLY PIPING Meter and service must be large enough to handle all the burners being installed plus any other connected load When gas piping is not included in the layout drawing the local gas supplier will usually help in planning the gas piping To check system supply pressure a...

Page 20: ...e in the burner gas train which will result in unsafe operation of the burner s For proper and safe test procedures observe the provisions of Part 4 of the National Fuel Gas Code ANSI Z223 1 current standard Inspection Testing and Purging or refer to equivalent local In Canadian see gas code CAN CGA B149 1 CAN CGA B149 2 NOTE It is important that the entire system up to the burner gas connection b...

Page 21: ...e system Before connecting the gas connector verify that all high pressure testing has been completed Do not high pressure test the gas piping with the burner connected Failure to follow these instructions can result in property damage Check the pipe and tubing ends for leaks before placing heating equipment into service When checking for gas leaks use a soap and water solution never use an open f...

Page 22: ...imum 48 of straight inlet install a 4 tee as shown below 1 The outside air intake consists of 1 6 Inlet hood 1 40 long 6 0 dia flex duct 2 hose clamp 2 It is recommended outside air intake assembly be used This offsets problems of positive or negative building pressures contaminated building air etc Combustion air may be drawn from the space that is being heated 3 It is recommended that a maximum ...

Page 23: ...16 4 1 8 10 1 1 6 7 3 8 5 3 4 6 1 4 6 2 7 8 Approx 9 5 Approx 19 5 8 NOTE Motor substitutions can occur always refer to the motor manufacturer nameplate for electrical information and wiring instructions Three phase and alternate voltage motors are available as a special order Housings and inlets made with stainless steel are also available the last two digit designation will be SS EXHAUST FLEX CO...

Page 24: ... 1 2 m horizontally from or 1 ft 0 3 m above any window or door that opens or gravity air inlet to a building Vent must terminate at least 4 ft 1 2 m horizontal clearance from gas and electric meters regulators and relief equipment CANADA specific horizontal vent requirements Vent must terminate at least 6 ft 1 8 m of a mechanical air supply inlet to any building Vent must terminate at least 3 ft ...

Page 25: ...ct to vacuum Exhauster with minimum four 10 SM screws Min 2 Max 12 Provide UNISTRUT or Angle Iron and secure to buildings wall framing Vacuum Exhauster Secure to UNISTRUT or Angle Iron by bolting through vibration isolators Trim any insulation so that a minimum of 6 15 cm clearance is maintained around exhaust duct Use RTV silicone supplied with rectangular vent duct to seal joint Secure duct to v...

Page 26: ... used The horizontal vent pipe must be securely supported every 5 1 5 m All joints are to be sealed with RTV Silicone sealant such as General Electric RTV 106 or Permatex Form A Gasket Red High Temperature Silicone Adhesive Sealant Single wall and dual wall Category III vent materials provided by the installer may also be used for the horizontal venting requirements Horizontal Venting Non Combusti...

Page 27: ...fficient mechanical fans are to be used to supply ventilation air and an interlock switch must be used to prevent the heater from operating when the fans are off This can be done using a pressure switch On U tube systems maintain at least 3 ft 1 m lateral distance from the combustion air inlet of the burner to the exhaust outlet Add ducting to the combustion air supply to achieve the separation as...

Page 28: ...venting sections of the vent pipe must be installed with an upward slope from the appliance at a pitch of 1 4 inch per foot 21mm per meter and must be supported every 5 1 5 m The vent terminal must extend a minimum of 6 15cm above the anticipated snow depth but no less than 2 ft 61cm above the roof Vertical Venting Category I Total inputs up to 250 000 BTUH Use a maximum of 20 6 m of vent pipe and...

Page 29: ...elbows supplied by Combustion Research Corp may be used The vent pipe must be securely supported All joints are to be sealed with RTV Silicone sealant such as General Electric RTV 106 or Permatex Form A Gasket Red High Temperature Silicone Adhesive Sealant Since the systems are also certified for un vented operation local authorities may waive this provision to use Category III vent materials The ...

Page 30: ...e Maintain a minimum of 3 feet above exhaust outlet to roof or overhang and a minimum of 6 feet to adjoining building or parapet Exhaust outlet must be at least 6 15cm above anticipated snow depth Page 26 Combustible Wall Provide wall thimble Non Combustible wall Seal with RTV Silicone Weather Cover by Installer Install Bird Screen In Outlet Weather Cover must come to bottom of motor Install 0634 ...

Page 31: ...cent of the nameplate rating under all conditions to assure satisfactory operation It is preferable that it be within 5 percent Almost all complaints of motor not starting or not reaching operating speed are caused by low voltage reaching the motor This voltage is dependent upon three things 1 The voltage furnished by the Power Company 2 The size gauge of the electrical wiring to the motor 3 The l...

Page 32: ...115 V A C 5484 00 Thermostat Contact rating 9 8 amps 24 VAC to 115 V A C BASIC SYSTEM HOOK UP WARNING FIRE OR EXPLOSION HAZARD IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE DEATH SEVERE INJURY AND OR PROPERTY DAMAGE The thermostat must control both the vacuum exhauster and burner s DO NOT CONTROL SEPARATELY Burner s MUST NOT be wired HOT Refer to the electrical wirin...

Page 33: ...n within the radiant tubing The system must not be allowed to short cycle as required and outlined in the warranty statement It is recommend ed that a line voltage thermostat be used when a 24V thermostat control is required Please note that the timings listed may vary slightly from system to system NOTE Reflect O Ray EDS 6 burners require the use of one 24 VAC 40VA transformer per burner assembly...

Page 34: ...DS 6 Installation Operation Service Combustion Research Corporation BURNER INTERNAL WIRING Point To Point Diagram Ladder Diagram Internal Wiring Diagram for Reflect O Ray EDS 6 Systems Fenwall Ignition Control Page 30 ...

Page 35: ...e GAS INLET PRESSURE Natural Gas 7 0 Minimum 10 0 Maximum LP Gas 11 0 Minimum 13 5 Maximum ALTITUDE United States 0 2 000 Ft 0 609 m Canada 0 4 500 Ft 0 1 370 m MANIFOLD PRESSURE SETTINGS 1 8 NPT 3 2mm Manifold Pressure Tap Manifold Pressure Adjustment Under Cap Inlet Pressure Tap 1 8 NPT 3 2mm 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 7 6 5 4 3 2 1 7 6 5 4 3 2 1 3 5 W C Natural Gas 10 0 W C Propane Gas Pre...

Page 36: ... 13 5 W C 3 35 Kpa for Propane Gas The installer must provide a 1 8 NPT 3 2mm plugged tapping accessible for test gauge connection immediately upstream of the gas supply 1 Set thermostat above room temperature 2 Allow the system to operate for at least twenty 20 minutes for temperature to normalize before setting the vacuum Connect manometer to the pressure ports shown below NOTE The plugs must be...

Page 37: ...ated load and voltages Modern motors are designed to operate at higher temperatures 5 Protect the power cable from coming in contact with sharp objects 6 Do not kink power cable and never allow the cable to come in contact with oil grease hot surfaces or chemicals 7 Make certain that the power source conforms to the requirements of your equipment 8 When cleaning electrical or electronic equipment ...

Page 38: ...must be adequately sized so that a minimum of 7 W C and maximum of 10 W C pressure at the burner can be obtained for natural gas and 11 W C minimum 13 5 W C maximum pressure for propane The gas pipe work should also have been tested with soap and water at all joints as specified by local codes It should be noted that all service cocks on individual burner should be closed prior to testing to avoid...

Page 39: ...switch which should be mounted within two feet of the unit Close the gas supply to burners at the individual burner gas cocks 2 To service the thermostat turn off the electrical power at the main power disconnect box 3 Before servicing any gas component shut off the gas supply at the meter by closing the main gas valve BURNER INDICATOR LIGHTS 1 DEAD MODE The burner power supply has been interrupte...

Page 40: ...the beginning of every heating season Look for cracks holes physical damage etc Replace as needed NOTE Use only approved Reflect O Ray EDS 6 tube which has been specifically designed and manufactured for the Reflect O Ray EDS 6 system Use of substitute materials can result in an unsafe condition and will void any and all warranties DIAGNOSIS AND TESTING Reflect O Ray EDS 6 BURNER ASSEMBLY If the b...

Page 41: ... HEAT 1 Ensure gas control knob is in the ON position 2 Adjust thermostat several degrees above room temperature 3 Using AC voltmeter measure voltage across MV terminals at gas control 4 If no voltage is present check control circuit for proper operation 4 If proper control system voltage is present replace gas control STOP READ ALL WARNINGS The flame is lit automatically If the appliance does not...

Page 42: ...nce these environments can cause the gas control to deteriorate more rapidly the system should be checked more often The gas control should be replaced if 1 It does not perform properly on checkout or trouble shooting 2 The gas control knob is hard to turn or push down or it fails to pop back up when released 1 The gas control is likely to have operated for more than 200 000 cycles CHECKOUT PROCED...

Page 43: ...there 24 volt power at the ignition control Is there 24 volts to the pressure switch NO Replace motor NO Is blower obstructed YES Remove obstruction and realign blower wheel YES Replace Transformer YES Is the vent pipe air inlet or blower wheel blocked or obstructed YES NO Is there 24 volts through the 2 amp fuse NO Are the air hoses connected to the pressure switch leak free and secure NO Repair ...

Page 44: ...essure at the manifold pressure tap NG 3 5 LP 10 0 Check gas orifice for blockage proper size YES Replace gas valve NO Adjust supply gas pressure to proper levels see name plate YES Repair or replace gas piping to correct size NO YES Does the burner and vacuum exhauster shut off when the temperature is satisfied YES NO Replace thermostat END OF TROUBLE SHOOTING YES Check wires and replace as neede...

Page 45: ...Reflect O Ray EDS 6 Installation Operation Service Combustion Research Corporation REPLACEMENT PARTS BURNER ASSEMBLY Page 41 ...

Page 46: ...027 00 Igniter 1 9 5286 00 Valve Honeywell 3 4 NPT 1 10 5060 07B Differential Pressure Switch 1 11 5241 07 Ignition Control Specify Manf Manf Part No 1 12 5060 01 Toggle Switch 1 13 1601 00 Fuse 2 AGC 1 14 1601 01 Fuse Block 1 15 1286 00 Indicator Lights 3 16 800 06 Label Plate Indicator Lights 1 17 1240 50 Insulating Bushing 1 18 1476 06 Tube 1 4 Poly 1 19 1476 15 Tube 1 4 Poly 1 20 1300 00 Inspe...

Page 47: ...hauster Wheel Stainless Steel 6 1032 03 5 16 x 18 Set Screw Provided with exhauster wheel 7 401 06 Vacuum Exhauster Housing 8 1463 31 25 x 1 1 4 Stand Off 9 1122 01 5 16 Plated Lock Washer 10 1092 00 5 16 x 18 Plated Hex Nut 11 3 16 Key Provided with Motor 12 201 05 Mounting Plate 13 1491 00 Rubber Grommet 14 5321 00 HP Motor 3450 RPM 115v 230v 50 Hz 5320 00 1 HP Motor 3450 RPM 115v 230v 50 Hz 15 ...

Page 48: ...Wt 21 lbs 0660 00 REFLECTOR Aluminum reflector bright finish 10 long designed to direct radiant energy towards the floor area Wt 7 5 lbs 0661 00 COMBINATION HANGER Radiant tube hanger formed from diameter zinc plated steel Wt 2 lbs 0662 00 INTERMEDIATE SUPPORT Reflector support hanger formed from diameter zinc plated steel Wt 2 lbs 0660 WH REFLECTOR END CAP WITH CUT OUT Aluminum reflector end cap ...

Page 49: ...eel 90 elbow Both ends swaged to fit into 6 0 standard radiant tube Wt 7 lbs R 9 14 75 14 75 5 0636 AS 45 ELBOW 6 0 DIA Aluminized steel 45 elbow Both ends swaged to fit into 6 0 standard radiant tube Wt 6 lbs R 9 5 10 10 0607 AS STANDARD TEE 6 0 DIA Aluminized steel TEE All three legs swaged to fit into 6 0 standard radiant tube Wt 16 lbs 35 17 5 5 0607 AS B STANDARD TEE W DAMPERS 6 0 DIA Alumini...

Page 50: ...X AND CLAMPS 6 0 ID high temperature stainless steel flex with a black fiberglass wrap 40 long and two hose clamps Wt 5 lbs 0419 00 EXHAUST DUCT Side wall exhaust duct for use with 0401 060 and 0402 060 vacuum exhauster Aluminized steel construction with stainless steel bird screen powder coated Wt 6 lbs 19 0420 01 RECTANGULAR TO ROUND EXHAUST ADAPTER Adapter for connection to vacuum exhauster to ...

Page 51: ...0 00 reflector 10 long Wt 5 0 lbs 0664 00 SIDE SHIELD HANGER Side shield support Used on 0663 00 side reflector Wt 1 lb 1800 CH 100 HANGING CHAIN Double loop zinc plated hanging chain 100 work load rating of 90 lbs Wt 6 5 lbs 1800 SH 000 S HOOKS Box of 50 zinc plated S hooks Wt 2 lbs S 5221 04 HIGH PRESSURE REGULATOR For Natural gas 2 lbs to 7 0 W C NPT Wt 1 5 lbs Page 47 ...

Page 52: ... EVENT SHALL CRC BE LIABLE FOR SPECIAL INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY TYPE OR DESCRIPTION WHETHER ARISING UNDER CONTRACT WARRANTY TORT NEGLIGENCE STRICT LIABILITY OR ANY OTHER THEORY OF LIABILITY SUCH DAMAGES INCLUDE BUT ARE NOT LIMITED TO LOSS OF PROFITS LOSS OF USE OF THE PRODUCTS DAMAGE TO PROPERTY INCONVENIENCE AND CLAIMS OF THIRD PARTIES SOME STATES DO NOT ALLOW THE EXCLU...

Page 53: ...te courts maintaining jurisdiction over all controversies in the State of Michigan VOIDING OF WARRANTIES Each of the following listed events conditions acts or omissions by any person or entity may void the Warranty 1 Improper installation i e installation which is not in accordance with the instructions in the service and installation manual 2 Running the burner s with intake combustion air drawn...

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Page 55: ... provide signs that specify the maximum stacking height so as to maintain the required clearance to combustibles The following is a temporary sign that can be used until a permanent label is obtained from your representative or Combustion Research Corporation Request P N 5566 006 Attach this label near the Reflect O Ray heater or by the thermostat Page 51 ...

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Page 58: ...COMBUSTION RESEARCH CORPORATION 2516 Leach Road Rochester Hills Michigan 48309 3555 Telephone No 248 852 3611 www combustionresearch com ...