Roberts Gorden Electric Heater CTHN 100 User Guide
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.  
®
Vantage NP  
5. Leave the building.  
6. Immediately call your local gas  
supplier after leaving the building.  
Follow the gas supplier’s  
instructions.  
7. If you cannot reach your gas  
supplier, call the Fire Department.  
Negative Pressure  
Unitary or Multiburner  
Infrared Heater  
WARNING  
Installation,  
Operation &  
Service Manual  
Fire Hazard  
Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
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.  
Installer  
WARNING  
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.  
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.  
Owner  
Keep this manual in a safe place in order to provide  
your serviceman with necessary information.  
Installation must be done by a contractor qualified  
in the installation and service of gas-fired heating  
equipment or your gas supplier.  
Roberts-Gordon, LLC  
1250 William Street  
P.O. Box 44  
Buffalo, New York 14240-0044  
Telephone: 716.852.4400  
Fax: 716.852.0854  
Toll Free: 800.828.7450  
Quality in Any Language™  
www.rg-inc.com  
P/N 152101NA Rev A 10/06  
© Copyright 2006 Roberts-Gordon, LLC  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
SECTION 1: Heater Safety......................................................1  
1.1 Manpower Requirements .............................................1  
SECTION 2: Installer Responsibility .....................................2  
2.1 Wall Tag.......................................................................2  
2.2 Corrosive Chemicals....................................................2  
2.3 National Standards and Applicable Codes ..................2  
SECTION 3: Critical Considerations......................................3  
3.1 Required Clearances to Combustibles.........................3  
SECTION 4: National Standards and Applicable Codes .....7  
12.2 Unvented Operation Termination............................. 51  
12.3 Horizontal Venting.................................................... 51  
12.4 Vertical Venting........................................................ 51  
12.5 Length Requirements .............................................. 51  
12.6 Flue Connection Detail ............................................ 52  
12.7 Horizontal Ventilation 4" (10 cm) Pipe...................... 52  
12.8 Vertical Ventilation 4" (10 cm) Pipe.......................... 53  
12.9 Common Sidewall Venting....................................... 53  
12.10 Common Vertical Venting ..................................... 54  
4.1 Gas Codes...................................................................7 SECTION 13: Venting - Multiburner Systems ..................... 55  
4.2 Aircraft Hangars ...........................................................7  
4.3 Public Garages ............................................................7  
4.4 Electrical ......................................................................7  
4.5 Venting.........................................................................7  
4.6 High Altitude ................................................................7  
SECTION 5: Heater Descriptions...........................................8  
5.1 Unitary vs. Multiburner.................................................8  
13.1 General Requirements............................................. 55  
13.2 Manifold Tube Requirements................................... 55  
13.3 Venting the Pump .................................................... 55  
13.4 EP-100 Pump Models .............................................. 56  
13.5 EP-200 Pump Series ............................................... 56  
13.6 EP-300 Pump Series ............................................... 56  
13.7 Installation Precautions............................................ 56  
SECTION 6: Major Components ............................................9 SECTION 14: Outside Combustion Air Supply .................. 58  
SECTION 7: General Suspension Details ........................... 10  
SECTION 8: Unitary Linear & U-Tube Heater Installation.. 11  
8.1 Standard Parts........................................................... 11  
8.2 Unitary Heater Requirements .................................... 13  
8.3 Unitary Linear Heater Layouts................................... 14  
8.4 Unitary U-tube Heater Layouts .................................. 17  
8.5 Burner Tube Installation ............................................19  
8.6 Tube Clamp Package Installation..............................19  
8.7 Coupling and Tube Assembly....................................20  
8.8 Turbulator Installation................................................21  
14.1 Length Requirements .............................................. 58  
14.2 Vertical Non-Pressurized Outside Air Supply for  
Single Heater Installation ......................................... 58  
14.3 Horizontal Non-Pressurized Outside Air Supply for  
Single Heater Installation ......................................... 58  
14.4 Vertical Non-Pressurized Outside Air Supply for  
Double Heater Installation........................................ 59  
14.5 Horizontal Non-Pressurized Outside Air Supply for  
Double Heater Installation........................................ 59  
14.6 Pressurized Outside Air Supply ............................... 60  
8.9 Reflector Installation ..................................................22 SECTION 15: Wiring.............................................................. 61  
8.10 Burner Installation....................................................24  
8.11 Fan Inlet Plate and Warning Tag.............................24  
8.12 Restrictor Plate Installation.....................................25  
8.13 Fan Installation ........................................................25  
SECTION 9: Multiburner Heater Installation.......................26  
9.1 Standard Parts...........................................................26  
9.2 Multiburner System Design Requirements ................29  
9.3 Burners Per Pump .....................................................30  
9.4 Radiant Tube Length..................................................31  
9.5 Manifold Tube ............................................................31  
9.6 Multiburner System Layouts and Manifold Tube  
15.1 Internal Wiring.......................................................... 61  
15.2 Internal Wiring.......................................................... 61  
15.3 Ladder Diagram....................................................... 62  
15.4 External Wiring (Unitary Heaters Only).................... 62  
15.5 Line Voltage Thermostat Wiring  
(Unitary Heaters Only) ............................................. 63  
15.6 Low Voltage Thermostat Wiring  
(Unitary Heaters Only) ............................................. 63  
15.7 System Control Methods and External Multiburner  
Wiring....................................................................... 64  
SECTION 16: Gas Piping...................................................... 69  
Length Rules..............................................................31 SECTION 17: Operation and Maintenance.......................... 70  
9.7 Burner Tube Installation ............................................36  
9.8 Tube Clamp Package Installation..............................36  
9.9 Coupling and Tube Assembly....................................37  
9.10 Turbulator Installation..............................................38  
9.11 Reflector Installation................................................39  
17.1 Checking the Gas Line............................................. 70  
17.2 Unitary Heater Sequence of Operation ................... 70  
17.3 Multiburner System Operation.................................. 70  
17.4 Maintenance............................................................. 73  
17.5 Maintenance Checklist ..............................................74  
9.12 Burner Installation....................................................41 SECTION 18: Troubleshooting............................................. 76  
SECTION 10: Optional Heater Accessories ........................42  
10.1 Elbow Package Configuration ..................................42  
10.2 Reflector Side Extension..........................................44  
18.1 Troubleshooting Flow Chart - Unitary ...................... 76  
18.2 Troubleshooting Flow Chart - Multiburner................ 78  
18.3 Manifold Gas Pressure Setting ................................ 80  
10.3 Lower Clearance Shield Installation.........................45 SECTION 19: Replacement Parts List................................. 81  
10.4 Two-Foot Decorative Grille Installation.....................45 SECTION 20: General Specifications.................................. 83  
10.5 One-Foot Decorative Grille Installation ....................47  
10.6 Protective Grille Installation......................................49  
SECTION 11: Venting - General............................................50  
11.1 General Venting Requirements.................................50  
20.1 Material Specification .............................................. 83  
20.2 Heater Specifications............................................... 83  
20.3 Suspension Specifications....................................... 83  
20.4 Controls Specifications............................................ 83  
SECTION 12: Venting - Unitary Heater................................51 SECTION 21: The ROBERTS GORDON® Vantage® NP Limited  
12.1 Unvented Operation.................................................51  
Warranty.......................................................... 85  
© 2006 Roberts-Gordon, LLC  
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 Roberts-Gordon, LLC.  
Printed in U.S.A.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF FIGURES  
Figure 1: Standard Reflector .....................................................3  
Figure 2: One Side Reflector.....................................................4  
Figure 3: Two Side Reflectors ...................................................4  
Figure 4: 45° Tilt Reflector ........................................................4  
Figure 5: U-Tube, Standard Reflector........................................5  
Figure 6: U-Tube, 45°................................................................5  
Figure 7: U-Tube, Opposite 45° Reflector .................................5  
Figure 8: 2-Foot Deco Grille, 1-Foot Deco Grille and  
Protective Grille ..........................................................6  
Figure 9: Lower Clearance Shield.............................................6  
Figure 10: Venting .....................................................................6  
Figure 11: Major Component Descriptions................................9  
Figure 12: Critical Hanger Placement ..................................... 10  
Figure 13: Linear Heater Assembly Overview......................... 14  
Figure 14: Unitary Linear Layout Overviews ........................... 15  
Figure 15: Unitary Linear Layout Overviews (Continued) ....... 16  
Figure 16: U-tube Assembly Overview.................................... 17  
Figure 17: Unitary U-Tube Layout Overviews.......................... 18  
Figure 18: Typical CTHN Multiburner System Installation .......29  
Figure 19: Flag Layout ............................................................32  
Figure 20: Modified In-Series Layout ......................................32  
Figure 21: T Layout.................................................................33  
Figure 22: Fork Layout............................................................34  
Figure 23: Herringbone Layout................................................35  
Figure 24: Reflector Joint Detail..............................................43  
Figure 25: Fan Termination .....................................................51  
Figure 26: Tailpipe Connection Points.....................................55  
Figure 27: Roof Venting of Pump ............................................56  
Figure 28: Side Wall Venting Configurations...........................57  
Figure 29: General System Control Wiring (Multiburner) ........64  
Figure 30: External Wiring Diagram EP-100 and  
EP-201 120 V 1 Ø Pump (Multiburner) ..................65  
Figure 31: External Wiring Diagram EP-301 230 V 1 Ø Pump  
(Multiburner)..........................................................65  
Figure 32: External Wiring Diagram EP-203 or  
EP-303 3 Ø Pump (Multiburner) ............................66  
Figure 33: One Zone Operation without Control Panel  
(Multiburner)..........................................................67  
Figure 34: Two Zone Operation without Control Panel  
(Multiburner)..........................................................68  
Figure 35: Gas Connection with Flexible Gas Hose ...............69  
Figure 36: Vacuum Differential Reading..................................72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 1: HEATER SAFETY  
SECTION 1: HEATER SAFETY  
Your Safety is Important to Us!  
This symbol is used throughout  
the manual to notify you of  
possible fire, electrical or burn  
hazards. Please pay special  
attention when reading and  
following the warnings in these  
sections.  
Installation, service and annual inspection of heater  
must be done by a contractor qualified in the  
installation and service of gas-fired heating  
equipment.  
Read this manual carefully before installation,  
operation or service of this equipment.  
This heater is designed for heating nonresidential  
indoor spaces. Do not install in residential spaces.  
These instructions, the layout drawing, local codes  
and ordinances, and applicable standards that apply  
to gas piping, electrical wiring, venting, etc. must be  
thoroughly understood before proceeding with the  
installation.  
Thin sheet metal parts, including the aluminum  
reflector and the various venting components, have  
sharp edges. To prevent injury, the use of work  
gloves is recommended. The use of gloves will also  
prevent 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  
adjustment of the appliance are compatible.  
1.1 Manpower Requirements  
To prevent personal injury and damage to the heater,  
two persons will be required for installation.  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
SECTION 2: INSTALLER RESPONSIBILITY  
The installer is responsible for the following:  
and configuration in the open spaces on the tag.  
• To install the heater, as well as the gas and  
electrical supplies, in accordance with applicable  
specifications and codes. Roberts-Gordon  
recommends the installer contact a local Building  
Inspector or Fire Marshal for guidance.  
• To use the information given in a layout drawing  
and in the manual together with the cited codes  
and regulations to perform the installation.  
• To install the heater in accordance with the  
clearances to combustibles requirements.  
• To furnish all needed materials not furnished as  
standard equipment.  
2.2 Corrosive Chemicals  
CAUTION  
Do not use heater in an area containing corrosive  
chemicals.  
Avoid the use of corrosive chemicals to ensure a  
longer life of the burner, tubing and other parts.  
Failure to follow these instructions can result in  
property damage.  
• To plan location of supports.  
• To provide access to burners on all sides for  
burner servicing and removal.  
• To provide the owner with a copy of this  
Installation, Operation and Service Manual.  
• To never use heater as a support for a ladder or  
other access equipment and never hang or  
suspend anything from heater.  
• To ensure there is adequate air circulation around  
the heater and to supply air for combustion,  
ventilation and distribution in accordance with  
local codes.  
• To safely and adequately install heater using  
materials with a minimal working load of 75 lbs  
(33 kg).  
Roberts-Gordon cannot be responsible for ensuring  
that all appropriate safety measures are undertaken  
prior to installation; this is entirely the responsibility of  
the installer. It is essential that the contractor, the  
sub-contractor, or the owner identifies the presence  
of combustible materials, corrosive chemicals or  
halogenated hydrocarbons* anywhere in the  
premises.  
* Halogenated Hydrocarbons are a family of chemical  
compounds characterized by the presence of halogen elements  
(fluorine, chlorine, bromine, etc.). These compounds are  
frequently used in refrigerants, cleaning agents, solvents, etc. If  
these compounds enter the air supply of the burner, the life span  
of the heater components will be greatly reduced. An outside air  
supply must be provided to the burners whenever the presence  
of these compounds is suspected. Warranty will be invalid if the  
heater is exposed to halogenated hydrocarbons.  
2.1 Wall Tag  
2.3 National Standards and Applicable Codes  
A laminated wall tag is available for the heater as a  
permanent reminder of the safety instructions and  
the importance of the required clearances to  
combustibles. Please contact Roberts-Gordon or  
your ROBERTS GORDON® independent 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 heater (e.g.  
thermostat or ROBERTS GORDON® Controller).  
All appliances must be installed in accordance with  
the latest revision of the applicable standards and  
national codes. This refers also to the electric, gas  
and venting installation. Note: Additional standards  
for installations in public garages, aircraft hangars,  
etc. may be applicable.  
A copy of the wall tag (P/N 91037912) is illustrated on  
the back cover. For an immediate solution, you may  
affix this copy on the wall near the heater.  
Know your model number and installed configuration.  
Model number and installed configuration are found  
on the burner and in the Installation, Operation and  
Service Manual. See Page 3, Figure 1 through Page  
6, Figure 10. Write the proper clearance dimensions  
in permanent ink according to your model number  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 3: CRITICAL CONSIDERATIONS  
SECTION 3: CRITICAL CONSIDERATIONS  
3.1 Required Clearances to Combustibles  
WARNING  
Clearances are the required distances that  
combustible objects must be away from the heater to  
prevent fire hazards. Combustible materials that may  
catch fire include common items such as wood,  
paper, rubber, fabric, etc. Maintain clearances to  
combustibles at all times for safety.  
Fire Hazard  
Clearances for all heater models are located on the  
burner of the heater and on Page 3, Figure 1 through  
Page 6, Figure 10 in this manual. Check the  
clearances on each burner for the model heater  
being installed to make sure the product is suitable  
for your application and the clearances are  
maintained. Read and follow the safety guidelines  
below:  
Some objects will catch fire or explode when placed  
close to heater.  
Keep all flammable objects, liquids and vapors the  
required clearances to combustibles away from heater.  
Failure to follow these instructions can result in death,  
injury or property damage.  
required clearances from the heater to the  
combustibles. Signs must be posted adjacent to  
the heater thermostat. In the absence of a  
thermostat, signs must be posted in a  
conspicuous location.  
• Consult local Fire Marshal, Fire Insurance Carrier  
or other authorities for approval of proposed  
installation when there is a possibility of exposure  
to combustible airborne materials or vapors.  
• Keep gasoline or other combustible materials  
including flammable objects, liquids, dust or  
vapors away from this heater or any other  
appliance.  
• Maintain clearances from heat sensitive material,  
equipment and workstations.  
• Maintain clearances from vehicles parked below  
the heater.  
• Hang heater in accordance to the minimum  
• 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 to specify the  
maximum permissible stacking height to maintain  
suspension requirements on Page 10, Figure 12.  
• If the radiant tubes must pass through the building  
structure, be sure that adequate sleeving and fire  
stop is installed to prevent scorching and/or fire  
hazard.  
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.  
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 1: STANDARD REFLECTOR  
(inches)  
(centimeters)  
Model  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
A
5
5
5
5
5
5
8
8
B
20  
27  
30  
32  
35  
39  
44  
47  
C
41  
51  
58  
60  
65  
71  
74  
76  
D
20  
27  
30  
32  
35  
39  
44  
47  
A
13  
13  
13  
13  
13  
13  
20  
20  
B
51  
C
D
51  
104  
130  
147  
152  
165  
180  
188  
193  
69  
69  
76  
76  
81  
81  
89  
89  
99  
99  
112  
119  
112  
119  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.  
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 2: ONE SIDE REFLECTOR  
Model  
(inches)  
(centimeters)  
A
5
5
5
5
5
5
8
8
B
6
6
6
6
6
6
6
6
C
46  
55  
64  
66  
69  
75  
77  
79  
D
35  
44  
49  
51  
58  
60  
68  
70  
A
13  
13  
13  
13  
13  
13  
20  
20  
B
15  
15  
15  
15  
15  
15  
15  
15  
C
D
A
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
117  
140  
163  
168  
175  
191  
196  
201  
88  
110  
123  
128  
145  
150  
170  
175  
B
D
C
FIGURE 3: TWO SIDE REFLECTORS  
Model  
(inches)  
(centimeters)  
A
5
5
5
5
5
5
8
8
B
16  
18  
21  
23  
26  
30  
32  
33  
C
47  
56  
65  
68  
73  
76  
88  
90  
D
16  
18  
21  
23  
26  
30  
32  
33  
A
13  
13  
13  
13  
13  
13  
20  
20  
B
41  
46  
53  
58  
66  
76  
81  
84  
C
D
41  
46  
53  
58  
66  
76  
81  
84  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
119  
142  
165  
173  
185  
193  
224  
229  
A
B
D
C
FIGURE 4: 45° TILT REFLECTOR  
Model  
(inches)  
(centimeters)  
A
8
B
4
4
4
4
4
4
4
4
C
35  
45  
54  
57  
63  
66  
69  
73  
D
43  
45  
55  
56  
58  
61  
68  
71  
A
20  
20  
23  
25  
25  
25  
25  
25  
B
10  
10  
10  
10  
10  
10  
10  
10  
C
D
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
89  
109  
114  
140  
142  
147  
155  
173  
180  
8
114  
137  
145  
160  
168  
175  
185  
9
10  
10  
10  
10  
10  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 3: CRITICAL CONSIDERATIONS  
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.  
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 5: U-TUBE, STANDARD REFLECTOR  
(inches)  
(centimeters)  
Model  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
A
B
C
D
A
B
C
D
- UNAPPROVED -  
- UNAPPROVED -  
5
5
5
5
5
8
8
27  
30  
32  
35  
39  
44  
47  
56  
61  
63  
66  
73  
75  
76  
19  
20  
20  
20  
21  
26  
30  
13  
13  
13  
13  
13  
20  
20  
69  
76  
142  
155  
160  
168  
185  
191  
193  
48  
51  
51  
51  
53  
66  
76  
81  
89  
99  
112  
119  
FIGURE 6: U-TUBE, 45°  
(inches)  
(centimeters)  
Model  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
A
B
C
D
A
B
C
D
- UNAPPROVED -  
- UNAPPROVED -  
A
8
8
8
8
8
8
8
4
4
4
4
4
4
4
47  
54  
57  
63  
66  
69  
73  
40  
46  
48  
53  
56  
59  
63  
20  
20  
20  
20  
20  
20  
20  
10  
10  
10  
10  
10  
10  
10  
119  
137  
145  
160  
168  
175  
185  
102  
117  
122  
135  
142  
150  
160  
B
D
C
FIGURE 7: U-TUBE, OPPOSITE 45° REFLECTOR  
(inches)  
(centimeters)  
Model  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
A
B
C
D
A
B
C
D
- UNAPPROVED -  
- UNAPPROVED -  
A
C
8
45  
55  
56  
58  
61  
68  
71  
45  
54  
57  
63  
66  
69  
73  
10  
10  
10  
10  
20  
20  
20  
20  
23  
25  
25  
25  
25  
25  
114  
140  
142  
147  
155  
173  
180  
114  
137  
145  
160  
168  
175  
185  
25  
25  
25  
25  
51  
51  
51  
9
10  
10  
10  
10  
10  
D
B
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows.  
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 8: 2-FOOT DECO GRILLE, 1-FOOT DECO GRILLE AND PROTECTIVE GRILLE  
(inches)  
(centimeters)  
Model  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
A
5
5
5
5
5
5
8
8
B
20  
27  
30  
32  
35  
39  
44  
47  
C
41  
51  
58  
60  
65  
71  
74  
76  
D
20  
27  
30  
32  
35  
39  
44  
47  
A
13  
13  
13  
13  
13  
13  
20  
20  
B
51  
C
D
51  
A
C
104  
130  
147  
152  
165  
180  
188  
193  
69  
69  
76  
76  
81  
81  
B
D
89  
89  
99  
99  
112  
119  
112  
119  
FIGURE 9: LOWER CLEARANCE SHIELD*  
Model  
(inches)  
(centimeters)  
A
5
5
5
5
5
5
B
25  
30  
37  
39  
41  
43  
C
22  
27  
37  
39  
41  
50  
D
25  
30  
37  
39  
41  
43  
A
13  
13  
13  
13  
13  
13  
B
64  
C
56  
D
64  
A
CTHN-40  
CTHN-60  
CTHN-80  
76  
69  
76  
94  
94  
94  
B
D
C
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
99  
99  
99  
104  
109  
104  
127  
104  
109  
- UNAPPROVED -  
- UNAPPROVED -  
- UNAPPROVED -  
- UNAPPROVED -  
*When installed in the first 10' (3 m).  
FIGURE 10: VENTING  
(inches)  
E
(centimeters)  
E
Model  
A
F
A
F
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
14  
14  
20  
20  
20  
20  
20  
20  
18  
18  
24  
24  
24  
30  
30  
30  
18  
18  
18  
18  
18  
18  
18  
18  
36  
36  
51  
51  
51  
51  
51  
51  
46  
46  
61  
61  
61  
76  
76  
76  
46  
46  
46  
46  
46  
46  
46  
46  
A
E
Unvented  
Vent  
Pipes  
Radiant Tubes  
Vented  
F
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES  
SECTION 4: NATIONAL STANDARDS AND  
APPLICABLE CODES  
4.1 Gas Codes  
4.3 Public Garages  
The type of gas appearing on the nameplate  
must be the type of gas used. Installation must  
comply with national and local codes and  
requirements of the local gas company.  
Installation in garages must be in accordance  
with the following codes:  
United States: Standard for Parking Structures  
NFPA-88A - latest revision or the Code for Motor  
Fuel Dispensing Facilities and Repair Garages,  
NFPA-30A - latest revision. Canada: Refer to  
CAN/CGA B149.1 and B149.2: Installation  
Codes for Gas Burning Appliances.  
United States: Refer to National Fuel Gas Code,  
ANSI Z223.1 - latest revision (same as NFPA  
54).  
Canada: Refer to CAN/CGA B149.1 and B149.2:  
Installation Codes for Gas Burning Appliances.  
• Heaters must not be installed less than 8'  
(2.4 m) above the floor. Minimum clearances to  
combustibles must be maintained from vehicles  
parked below the heater.  
4.2 Aircraft Hangars  
Installation in aircraft hangars must be in  
accordance with the following codes:  
• When installed over hoists, minimum  
clearances to combustibles must be maintained  
from the upper most point of objects on the hoist.  
United States: Refer to Standard for Aircraft  
Hangars, ANSI/NFPA-409 - latest revision.  
Canada: Refer to Standard CAN/CGA B149.1  
and B149.2: Installation Codes for Gas Burning  
Appliances.  
4.4 Electrical  
The heater must be electrically grounded in  
accordance with the following codes:  
• In aircraft storage and servicing areas, heaters  
shall be installed at least 10' (3 m) above the  
upper surface of wings or of engine enclosures  
of the highest aircraft which may be housed in  
the hangar. The measurement shall be made  
from the wing or engine enclosure (whichever is  
higher from the floor) to the bottom of the heater.  
• In shops, offices and other sections of aircraft  
hangars communicating with aircraft storage or  
servicing areas, heaters shall be installed not  
less than 8' (2.4 m) above the floor.  
United States: Refer to National Electrical  
Code®, ANSI/NFPA-70 - latest revision. Wiring  
must conform to the most current National  
Electrical Code®, local ordinances, and any  
special diagrams furnished.  
Canada: Refer to Canadian Electrical Code,  
CSA C22.1 Part 1 - latest revision.  
4.5 Venting  
• Suspended or elevated heaters shall be so  
located in all spaces of aircraft hangars that they  
shall not be subject to injury by aircraft, cranes,  
movable scaffolding or other objects. Provisions  
shall be made to assure accessibility to  
suspended heaters for recurrent maintenance  
purposes.  
The venting must be installed in accordance with  
the requirements within this manual and the  
following codes:  
United States: Refer to NFPA-54/ANSI Z223.1 -  
latest revision, National Fuel Gas Code.  
Canada: Refer to CAN/CGA B149.1 and B149.2:  
Installation Codes for Gas Burning Appliances.  
4.6 High Altitude  
These heaters are approved for installations up  
to 2000' (610 m)(US), 4500' (1370 m)(Canada)  
without modification. Consult factory if US  
installation is above 2000' (610 m) or Canadian  
installation is above 4500' (1370 m).  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
SECTION 5: HEATER DESCRIPTIONS  
5.1 Unitary vs. Multiburner  
CTHN-Series burners may be used for unitary  
heaters or for multiburner systems.  
Unitary heaters consist of a single burner, a single  
run of radiant tubing and a single fan assembly. See  
Page 14, Figure 13 or See Page 17, Figure 16 for  
details.  
Multiburner systems consist of more than one burner  
and more than one run of radiant tubing. The runs of  
radiant tubing are connected together by manifold  
tubing. The manifold tubing connects to a single  
pump that exhausts the flue gases outdoors. See  
Page 32, Figure 19 through Page 35, Figure 23 for  
common multiburner system layouts.  
Since this manual addresses installation of both  
unitary heaters and multiburner systems, pay  
close attention to section and figure titles to  
verify relevance to unitary heaters or multiburner  
systems.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 6: MAJOR COMPONENTS  
SECTION 6: MAJOR COMPONENTS  
FIGURE 11: Major Component Descriptions  
Burner with  
Tube Gasket  
Turbulator  
Turbulator must be installed in the last standard section  
of tube.Turbulator is only required on the CTHN-40, 60  
and 80. For installation, See Page 21, Step 8.8.  
Must be installed  
with the flame  
observation window  
facing down.  
Flex Gas Line  
with Shut Off Cock  
Tube and Reflector Hanger  
with Clamp Package  
Position this hanger no more  
than 4'' (10 cm) away from  
the burner assembly.  
Reflector (Aluminum or Stainless Steel)  
Alternate overlap as shown on Page 15,  
Figure 14 or on Page 18, Figure 17.  
Minimum overlap is 6'' (16 cm).  
Tube and Reflector Hanger  
Suspend system from these  
hangers.  
Reflector Support  
Strap & Wire Form  
Burner Tube  
Supplied in 10' (3 m) lengths.  
Burner tube is always the first  
tube after the burner.  
Reflector End Cap  
Punch out center section to  
accommodate tube.  
Tube  
Hot rolled or heat treated aluminized  
tube supplied in 10' (3 m) lengths.  
Restrictor Plate  
Used at fan assembly inlet  
for unitary heaters only.  
See fan assembly below.  
Coupling Assembly  
with Lock  
Fan Assembly  
EP-100 Pump Package -  
For more information, refer to the  
EP-100 Installation, Operation and  
Service Manual  
EP-300 Series  
Pump Package -  
For more information,  
refer to the EP-300  
Series Installation,  
Operation and  
(P/N 127201NA).  
EP-201 Pump Package -  
For more information, refer to  
the EP-200 Series Installation,  
Operation and Service Manual  
(P/N 127200NA).  
Service Manual  
(P/N 127202NA).  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
SECTION 7: GENERAL SUSPENSION DETAILS  
The gas or the electrical supply lines must not be  
used to support the heater.  
WARNING  
Suspension Hazard  
Do not locate the gas or electric supply lines directly  
over the path of the flue products from the heater.  
Burner is secured to burner tube  
by bolts and lockwashers.  
The heater must be installed in a location that is  
readily accessible for servicing.  
Hang heater with materials  
with a minimum working  
load of 75 lbs (33 kg).  
The heaters must be installed in accordance with  
clearances to combustibles as indicated on the rating  
plate and in this instruction manual.  
Failure of the supports  
can result in death, injury  
or property damage.  
The minimum and maximum gas inlet pressures  
must be maintained as indicated on the rating  
plate.Typical installation configurations are shown in  
Figure 12.  
To ensure your safety and comply with the terms of  
the warranty, all units must be installed in  
accordance with these instructions.  
FIGURE 12: Critical Hanger Placement  
Typical Suspension Details  
Beam Clamp  
Concrete Beam  
Wood Beam  
Locknut  
Anchor  
Screw Hook  
3/8"  
Chain Size  
3/16"  
Washers  
Rod 3/8"  
Minimum  
24" min.*  
(61 cm)  
“X”*  
S-hooks  
Turnbuckle  
Not Included  
* Allows for thermal expansion of system  
S-hooks  
Hanger  
Side View  
Hanger  
Reflector  
Must Be Within 4" (10 cm)  
Front View  
45° Angle  
Run Length  
Typical Expansion Minimum “X” Length  
10' (3 m) - 50' (15 m)  
51' (15.5 m) - 60' (18 m)  
61' (18.6 m) - 80' (24 m)  
1" (3 cm)  
2" (5 cm)  
3" (8 cm)  
12" (30 cm)  
18" (46 cm)  
24" (61 cm)  
Description  
S-Hook  
Tube/Reflector Hanger  
Part Number  
91907302  
03090100  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
8.1 Standard Parts  
Table 1: Contents of CTHN Burner Carton  
Part No.  
Description  
CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200  
052XXXXX Burner (Rate and Fuel Varies)  
07730400 Restrictor Plate 1.25'' (3.2 cm) dia.  
07730100 Restrictor Plate 1.50'' (3.8 cm) dia.  
07730500 Restrictor Plate 2.25'' (5.7 cm) dia.  
07730600 Restrictor Plate 2.50'' (6.4 cm) dia.  
07730700 Restrictor Plate 2.75'' ( 7 cm) dia.  
03051503 Turbulator Adapter  
1
1
-
1
-
1
-
1
-
1
-
1
-
1
-
1
-
-
-
-
-
-
-
-
1
-
-
-
-
-
-
-
-
1
-
1
-
-
-
-
-
-
-
1
-
-
-
-
-
-
1
-
1
2
1
1
4
-
1
4
-
-
-
-
03051504 Turbulator Section  
-
-
-
-
03051505 Turbulator Section,  
Stainless Steel  
-
-
-
-
*91412200 Flexible Stainless Steel Gas Hose , 1/2'' NPT  
(US Models Only)  
1
-
1
-
1
-
1
-
1
-
-
-
-
*91412203 Flexible Stainless Steel Gas Hose , 3/4'' NPT  
(US Models Only)  
1
1
1
02568200 Gasket (Burner to Burner Tube)  
94273914 Hex Head Cap Screw 5/16'' -18 x 7/8''  
96411600 Split Lock Washer  
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
91201708 Pipe Nipple 1/2'' NPT x 4''  
152101NA Installation, Operation and Service Manual  
*Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory. See Page 69, Section 16.  
Table 2: Contents of Core and Extension Packages  
Core Packages  
Hot Rolled Aluminized  
Extension Packages  
Hot Rolled Aluminized  
Part No.  
Description  
20  
'
30  
'
40  
'
10  
'
20  
'
30  
'
40  
'
10  
'
20  
'
30  
'
40  
'
10  
'
20  
'
30  
'
40'  
(6m)  
(9m) (12m) (3m)  
(6m)  
(9m) (12m) (3m)  
(6m)  
(9m) (12m) (3m)  
(6m)  
(9m) (12m)  
91409300  
91409408  
03051101  
03051601  
1
2
-
3
-
-
-
-
-
-
1
-
2
3
-
4
-
-
1
-
-
-
3
-
-
4
-
Tube, Hot Rolled Steel, 10  
'
(3 m)  
-
1
-
2
1
-
3
1
-
-
-
2
-
Tube, HT Aluminized, 10  
'
(3 m)  
Burner Tube, ALUMI-THERM® Steel, 10  
Burner Tube, HT ALUMI-THERM® Steel, 10  
'
(3 m)  
-
1
-
1
-
-
-
-
-
1
1
3
2
3
3
2
1
-
1
1
3
2
3
3
2
-
-
-
-
-
-
-
-
'
(3 m)  
01312700 Coupling Assembly  
02750303  
2
4
2
4
4
3
3
6
2
5
5
5
2
4
2
4
4
3
3
6
2
5
5
5
1
2
-
2
3
-
3
4
-
4
6
-
1
2
-
2
3
-
3
4
-
4
6
-
2
2
2
2
1
Standard Reflector, 8  
'
(2.4 m)  
02750800 End Cap  
03090100 Tube and Reflector Hanger  
91907302 S-hook  
1
1
2
2
2
3
3
3
4
4
4
6
1
1
2
2
2
3
3
3
4
4
4
6
03050010 Reflector Support Package  
(Strap, Wire Form, Screws)  
91107720 U-clip Package  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
1
-
1
-
1
-
1
-
1
-
1
-
1
-
90502700 Vent Adapter (Not used on CTHN)  
01318901 Tube Clamp Package  
-
-
-
-
-
-
-
-
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Table 3: Component Package Guide  
Tubing Length  
Core Packages  
Model  
Minimum  
Standard  
CP10ALUM  
CP20HRS  
CP20HRS  
CP30HRS  
CP40HRS  
CP40HRS  
Aluminized  
CP10ALUM  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
10' (3 m)  
20' (6 m)  
20' (6 m)  
30' (9 m)  
40' (12 m)  
40' (12 m)  
50' (15 m)  
50' (15 m)  
CP20ALUM  
CP20ALUM  
CP30ALUM  
CP40ALUM  
CP40ALUM  
CP30HRS + EXP20HRS  
CP30HRS + EXP20HRS  
CP30ALUM + EXP20ALUM  
CP30ALUM + EXP20ALUM  
Additional tubing length may be added to heater.  
Any additional tubing lengths are considered as vent length for length determination.  
Maximum venting length for unitary heater is 45' (13.7 m).  
For manifold tubing on multiburner systems, heat-treated aluminized or porcelain coated tubing is required.  
Table 4: Common CTHN-Series Components  
Venting Accessories  
Part No.  
Description  
01324401 Air Supply Takeoff, 4" (10 cm) Outside  
90707501 Air Supply Blower/Power Venter  
91409601 Air Flex Duct, 4" (10 cm) Outside  
(Box of 8 - 8' (2.4 m) sections)  
Tubing and Related Accessories  
01312700 Coupling, 4" (10 cm) Plain  
01312706 Coupling, 6" (15 cm) Plain  
0131270I  
Coupling, 4" (10 cm) Lined  
01331900 Coupling, 4" (10 cm) Damper  
E0009356 Coupling, 6" (15 cm) Damper  
0133022D Tee, 4" (10 cm) Coated  
01330203 Tee, 4" (10 cm) Aluminized  
01330204 Tee, 6" (15 cm) Aluminized  
0133092D Cross, 4" (10 cm) Coated  
01330903 Cross, 4" (10 cm) Aluminized  
01330904 Cross, 6" (15 cm) Aluminized  
01335801 Elbow, 4" (10 cm) Aluminized 90°  
T0100320 Elbow, 6" (15 cm) Aluminized 90°  
0133580D Elbow, 4" (10 cm) Coated 90°  
01336101 Elbow, 4" (10 cm) Aluminized 45°  
0133610D Elbow, 4" (10 cm) Coated 45°  
91409300 Tube, 4" (10 cm) dia Hot Rolled Steel 10' (3 m)  
Reflectors and Related Accessories  
01329910 Reflector Side Extension Support  
03050010 Reflector Support Package (Tubing)  
02712700 Reflector Side Extension, 2 Clips, 2 Screws  
02750303 Reflector, Aluminum  
027503SS Reflector, Stainless Steel  
02750800 Reflector End Cap, Aluminum  
027508SS Reflector End Cap, Stainless Steel  
027508SH Reflector End Cap, Stainless Steel with Hole  
02750900 Reflector Joint  
027509SS Reflector Joint, Stainless Steel  
027127SS Reflector Side Extension, Stainless Steel  
03090100 Tube and Reflector Hanger  
91907302 S-hook  
91409403 Tube, 4" (10 cm) dia Non-Heat Treated Aluminized  
10' (3 m)  
91409408 Tube, 4" (10 cm) dia Heat Treated Aluminized  
10' (3 m)  
91903201 Turnbuckle  
91903300 Spring Hook  
91903202 Turnbuckle with Eyebolt  
91409420 Tube, 6" (15 cm) dia Non-Heat Treated Aluminized  
10' (3 m)  
Control Packages and Thermostats  
9141030D Tube, 4" (10 cm) dia Coated 10' (3 m)  
02770002 System Control  
E0009105 Tube, 6" (15 cm) dia 10' (3 m)  
Heat Treated Aluminized  
91418200 Tube Adapter, 6" (15 cm) dia x 4"(10 cm) dia  
Aluminized  
91240010 Tube Hanger, 6" (15 cm)  
91308001 Pipe Compound, High Temperature 1lb can  
05023000 Load Relay Package  
90417600 Transformer Relay - SPST (12 A)  
90436300 Transformer Relay - DPST (12 A)  
90423000 Thermostat, 24 V Low Voltage (Marked 1-5)  
90424300 Thermostat Guard  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
Deco Grille (1' x 8' [.3 m x 2.4 m])  
01363003 Bracket  
01317805  
Accessory Package  
02723014 EP-301 Pump Package 4" (10 cm)  
01365901 End Piece  
01326801 Reinforcement  
01365903 Joint Piece  
02730101  
02730104  
EP-301 Pump Assembly  
Accessory Package  
02723016 EP-301 Pump Package 6" (15 cm)  
91406700 1' x 8' (.3 m x 2.4 m) Protective Grille  
02730101  
02730106  
EP-301 Pump Assembly  
Accessory Package  
Deco Grille (2' x 4' [.6 m x 1.2 m])  
02723034 EP-303 Pump Package 4" (10 cm)  
01365900 Shield Frame  
02730103  
02730104  
EP-303 Pump Assembly  
Accessory Package  
01370408 Reflector Side Extension 8" x 48" (20 cm x 122 cm)  
01370412 Reflector Side Extension 12" x 48" (30 cm x 122 cm)  
01370416 Reflector Side Extension 16" x 48" (40 cm 122 cm)  
91407000 Grille, Aluminum 2' x 4' (.6 m x 1.2 m)  
02723036 EP-303 Pump Package 6" (15 cm)  
02730103  
02730106  
EP-303 Pump Assembly  
Accessory Package  
Protective Grille  
Pump Accessories  
08050001 Grille, 40" (102 cm) Protective  
08050002 Protective Grille End Cap  
90430600K Pressure Switch  
Starters and Contactors  
Fan and Pump Packages  
10050001 Starter, 120 Vac for EP-203, 3 Ø  
10050003 Starter, 120 Vac for EP-201, 1 Ø  
10050008 Starter, 120 Vac for EP-301, 1 Ø  
05220000 Fan Package 40-150  
05221000 Fan Package 175-200  
02719105 EP-100 Pump Package  
10050009 Contactor Package-  
120 Vac Coil for EP-301, 230 V, 2 HP  
10050010 Starter, 120 Vac for EP-303, 3 Ø  
02719100  
02724700  
EP-100 Pump  
Accessory Package  
02716305 EP-201 Pump Package  
01312001  
01317805  
EP-201 Pump  
Accessory Package  
02712034 EP-203 Pump Package  
01312002 EP-203 Pump  
8.2 Unitary Heater Requirements  
CTHN unitary heaters are typically shipped as a  
burner package, fan assembly and a tube and  
accessory package. The tube and accessory  
packages contain enough tube, reflector and hanging  
parts for one unitary CTHN heater. Elbows, u-tubes,  
controls, and any other parts must be purchased  
separately.  
See Page 14, Figure 13 for a general overview of a  
CTHN unitary heater. CTHN unitary heaters are  
controlled by thermostat.  
Table 5 summarizes the design requirements for a  
CTHN unitary heater.  
Table 5: Unitary Heater Design Requirements  
Burner Model:  
CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200  
Maximum Number of Burners Allowed  
per Fan Assembly (P/N 05220000)  
1
-
1
-
1
1
-
1
-
1
-
-
-
Maximum Number of Burners Allowed  
per Fan Assembly (P/N 05221000)  
-
1
1
Minimum Radiant Tube Length  
10' (3 m) 20' (6 m)  
10' (3 m) 10' (3 m)  
20' (6 m)  
30' (9 m) 40' (12 m) 40' (12 m) 50' (15 m) 50' (15 m)  
20' (6 m) 20' (6 m)  
Minimum Distance from Burner to Elbow or  
U-Tube  
10' (3 m) 15' (4.5 m) 15' (4.5 m) 20' (6 m)  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
8.3 Unitary Linear Heater Layouts  
FIGURE 13: Linear Heater Assembly Overview  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
FIGURE 14: Unitary Linear Layout Overviews  
b
c
g
d
LEGEND  
f
10' (3 m) Tube Length  
Burner  
b
b
c
Reflector  
g
d
e
Tube  
Tube/Reflector  
Hanger  
f
Coupling Assembly  
20' (6 m) Tube Length  
Fan Assembly  
b
b
c
g
d
e
e
a = 14" (36 cm)  
reflector width (not shown)  
b = 2" (5 cm)  
end cap to burner/fan  
f
c = 2" (5 cm)  
end cap to hanger  
30' (9 m) Tube Length  
d = 7'6" (229 cm)  
distance first hanger  
b
b
c
e = 10' (305 cm)  
distance between hangers  
g
d
e
e
e
f = 9.5" (24 cm)  
burner height  
g = 17.5" (44 cm)  
burner length  
f
40' (12 m) Tube Length  
b
b
c
g
d
e
e
e
e
f
50' (15 m) Tube Length  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
FIGURE 15: Unitary Linear Layout Overviews (Continued)  
b
b
c
g
d
e
e
e
e
e
f
60' (18 m) Tube Length  
b
b
c
g
d
e
e
e
e
e
e
f
70' (21 m) Tube Length  
b
b
c
g
d
e
e
e
e
e
e
e
f
80' (24 m) Tube Length  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
8.4 Unitary U-tube Heater Layouts  
CTHN-Series heaters (except CTHN-40) are  
approved for optional u-tube configurations.  
• A minimum of 10' (3 m) on CTHN-60/80, a  
minimum of 15' (4.5 m) on CTHN-100/125, and a  
minimum of 20' (6 m) on CTHN-150/175/200 is  
required between the burner and the u-tube.  
• For turbulator installation, See Page 21, Step 8.8.  
• The burner must never be operated  
in a tilted position.  
The u-tube may be installed in either a standard  
horizontal position, 45° position or in an opposite 45°  
position as shown on Page 5, Figure 5 through  
Figure 7. When using a u-tube configuration, the  
following additional rules must be adhered to:  
The heater must be properly supported at all  
locations. See Page 10, Figure 12.  
FIGURE 16: U-tube Assembly Overview  
U-tube  
Support Bracket  
Reflector  
Support  
Burner  
Turbulator  
(With Select  
Models)  
Reflector  
Tube Clamp  
Package  
Tube  
Burner  
Tube  
U-tube, Standard  
Couplings  
1
2
U-clips  
Reflector  
End Caps  
U-tube, Full 45°  
Tight U-bolt  
Loose U-bolt  
1
2
4" (10 cm) u-bolt,  
4" (10 cm) u-bolt,  
2
secured to burner tube  
with 1/4" (6 mm)  
lockwashers and  
1/4-20 hex nuts.  
secured to bracket with  
1/4" (6 mm) lockwashers  
and 1/4-20 hex nuts on  
top and bottom to  
allow for tube expansion  
and contraction.  
U-tube  
18" (457 mm)  
Center to Center  
1
U-tube, Opposite 45°  
U-bolt  
Nut  
Lock Washer  
Lock Washer  
Nut  
1
2
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
FIGURE 17: Unitary U-tube Layout Overviews  
b
c
LEGEND  
g
g
g
g
g
g
g
e
Burner  
Reflector  
Tube  
20' (6 m)*  
h
h
h
h
h
h
h
Tube Length  
b
c
d
d
d
d
d
d
f
Tube/Reflector  
Hanger  
Coupling Assembly  
U-tube  
30' (9 m)  
Tube Length  
b
c
Fan Assembly  
(not shown)  
e
e
e
e
e
a = 14" (36 cm)  
reflector width (not shown)  
b = 2" (5 cm)  
40' (12 m)  
Tube Length  
end cap to burner  
c = 2" (5 cm)  
b
end cap to hanger  
c
f
d = 7'6" (229 cm)  
distance first hanger  
e = 10' (305 cm)  
distance between hangers  
50' (15 m)*  
Tube Length  
f = 5' (153 cm)  
distance between last full tube  
hanger and half tube hanger  
b
c
e
e
e
g = 17.5" (44 cm) burner length  
h = 9.5" (24 cm) burner height  
*20' (6 m) & 50' (15 m) tube length  
heaters require the last reflector  
before the u-tube to be cut in  
half for use on both sides.  
60' (18 m)  
Tube Length  
b
c
f
70' (21 m)  
Tube Length  
b
c
e
80' (24 m)  
Tube Length  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
Step 8.5 Burner Tube Installation  
NOTE:  
Tubing requires a downward  
slope of 1/2" (1.3 cm)  
per 20' (6 m) away  
from burner.  
Offset mounting  
hole must be  
to the top.  
S-hook  
Hanger  
Burner Tube  
Weld seam  
must be to the  
bottom of the tube.  
7' 6" ± 1'  
(229 cm ± 25 cm)  
Description  
Burner Tube  
S-hook  
Part Number  
03051XXX  
91907302  
Tube/Reflector Hanger  
03090100  
Step 8.6 Tube Clamp Package Installation  
Description  
Tube Clamp Package  
Tube Clamp  
Bolt  
Flat Washer  
Nut  
Part Number  
01318901  
01396801  
97113940  
95211600  
92113900  
Bolt  
Tube Clamp  
Flat  
Washer  
Nut  
(Torque 120 in/lb  
13.56 Nm)  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Step 8.7 Coupling and Tube Assembly  
Close coupling  
Awith tab.  
Start slide bar/coupling lock  
B onto coupling.  
Tab  
Slide Bar/Coupling Lock  
Wide End  
Coupling  
Open  
3" (8 cm) to  
4" (10 cm)  
Closed  
Insert tubes into coupling.  
Tighten coupling to join tubes.  
C
D
Slide Bar/Coupling Lock  
Coupling  
Orient coupling so that  
the impact block is in the  
2:00 or 10:00 o’clock  
positions.  
Tube  
Tube  
Description  
Coupling  
Part Number  
01329600  
Tube  
Slide Bar/Coupling Lock  
Tube  
01329700  
91409XXX  
Step 8.7.1 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.  
± 2" (5 cm)  
Correct Slide Bar  
Dimensions  
Incorrect Slide Bar  
Position  
• Repeat Step 8.7, A - D until all tubes are assembled. See Page 21, Step 8.7.2.  
NOTE: If coupling is not tight, loss of vacuum can occur.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
Step 8.7.2 Coupling and Tube Assembly (Continued)  
Radiant  
Model  
Tube Length  
10' (4.5 m)  
20' (6 m)  
20' (6 m)  
30' (9 m)  
40' (12 m)  
40' (12 m)  
50' (18 m)  
50' (18 m)  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
2.3 m .25 m  
3 m .25 m  
Step 8.8 Turbulator Installation  
Turbulator must be installed in the last  
standard section of radiant tube.  
Turbulator is only required on the  
CTHN-40, CTHN-60 and CTHN-80.  
T
t
w
i
s
Turbulator  
Section  
Turbulator Installation  
Model  
Tube Section  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
1st 10' (3 m) Section  
2nd 10' (3 m) Section  
2nd 10' (3 m) Section  
Turbulator  
Tab  
Adapter  
N/A  
N/A  
N/A  
N/A  
N/A  
Turbulator section  
(stainless) used in  
CTHN-40 heaters must be in the  
section of tube nearest to the burner.  
Pull String  
Fold tab around outside  
of tube nearest to the vent to  
hold turbulator in place.  
Description  
Part Number  
03051503  
03051504  
03051505  
91409XXX  
Turbulator Adapter  
Turbulator Section  
Turbulator Section (Stainless)  
Tube  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Step 8.9 Reflector Installation  
NOTE: All radiant tube surfaces  
must be covered by a reflector,  
except for a u-tube. Manifold tube  
may or may not be covered.  
Hanger  
Burner Tube  
Reflector  
Description  
Tube/Reflector Hanger  
Burner Tube  
Part Number  
03090100  
03051XXX  
02750303  
Reflector  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
Step 8.9.1 Reflector, U-clip and Reflector Support Installation  
The pictorial drawings of the heater construction in  
Section 8 are schematic only and provide a general  
guideline of where hangers, reflector supports and  
u-clips are to be installed.  
reflector supports and u-clips depend on the  
individual installation. Use either pop rivets or sheet  
metal screws instead of u-clips when installing end  
caps and joint pieces in areas where impact and high  
wind may be a factor. The following rules must be  
To ensure proper expansion and contraction  
movement of the reflectors, a combination of u-clips observed.  
and reflector supports are used. The positioning of  
1. The first reflector after the burner must be affixed in  
the middle of the reflector with a reflector support and  
tight screws.  
Tight  
Sheet Metal  
Screw  
Wire Form  
Reflector  
End Cap  
First Reflector  
Reflector Support  
Strap  
U-clips  
2 B  
Slip Overlap  
Overlap must be a  
minimum of " (16 cm).  
6"  
(16 cm)  
Reflector  
Reflector  
Support  
6
2. The overlap at the first and second reflector is a slip overlap.  
Thereafter, every third reflector joint is a slip overlap. A slip  
overlap is achieved by either:  
Loose screws  
loosened 1/16"  
(.16 cm) to allow  
slippage.  
a.) both reflectors lay inside a hanger.  
(No reflector support needed.)  
b.) using a reflector support with  
loose screws at the reflector  
2 A  
Slip Overlap  
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.  
3 A  
Non-Slip Overlap  
Reflector  
This section of three reflectors joined together must  
be affixed to the tube with at least one reflector support  
with tight screws.  
Tight  
Screws  
3 B  
Non-Slip Overlap  
Description  
Reflector Support Package  
Wire Form  
Reflector Support Strap  
Screw #8 x 3/4  
U-clip Package  
Part Number  
03050010  
91908004  
03050000  
94320812  
91107720  
027508XX  
U-clip  
(2 Clips per  
Non-slip Overlap  
Inside a Hanger)  
Reflector End Cap  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Step 8.10 Burner Installation  
Burner  
Gasket  
S-hook  
Burner Tube  
Burner must be installed  
with the flame observation  
window facing down.  
Lock  
Washer  
Bolt  
(Torque 120 in/lb  
13.56 Nm)  
Description  
Bolt  
Burner  
Part Number  
94273914  
052XXXXX  
96411600  
Lock Washer  
Gasket  
02568200  
Step 8.11 Fan Inlet Plate and Warning Tag  
Remove the warning tag and inlet collar  
from fan inlet.  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 8: UNITARY LINEAR & U-TUBE HEATER INSTALLATION  
Step 8.12 Restrictor Plate Installation  
Attach restrictor plate (see chart below right) to  
fan inlet and replace inlet collar.  
Model  
Fan Assy. P/N Restrictor Plate P/N  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
05220000  
05220000  
05220000  
05220000  
05220000  
05220000  
05221000  
05221000  
07730400 1.25'' dia  
07730100 1.50'' dia  
NONE  
07730500 2.25'' dia  
07730500 2.25'' dia  
07730700 2.75'' dia  
07730600 2.50'' dia  
NONE  
Description  
Restrictor Plate  
Part Number  
07730XXX  
Step 8.13 Fan Installation  
Fold tab around outside  
of tube nearest to the  
vent to hold turbulator  
in place.  
Remove warning tag from fan inlet  
and install restrictor plate if required.  
See Step 8.12.  
Last Tube  
Turbulator not required  
for all models. (See Page 21,  
Step 8.8 for details.)  
Tighten securely  
until tube cannot  
be removed.  
Vent Adapter  
Fan Assembly  
Description  
Fan Assembly 40 -150  
Fan Assembly 175-200  
Part Number  
05220000  
05221000  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
9.1 Standard Parts  
Table 6: Contents of CTHN Burner Carton  
Part No.  
Description  
CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200  
052XXXXX Burner (Rate and Fuel Varies)  
07730400 Restrictor Plate 1.25'' (3.2 cm) dia.  
07730100 Restrictor Plate 1.50'' (3.8 cm) dia.  
07730500 Restrictor Plate 2.25'' (5.7 cm) dia.  
07730600 Restrictor Plate 2.50'' (6.4 cm) dia.  
07730700 Restrictor Plate 2.75'' ( 7 cm) dia.  
03051503 Turbulator Adapter  
1
1
-
1
-
1
-
1
-
1
-
1
-
1
-
1
-
-
-
-
-
-
-
-
-
1
-
-
-
-
-
-
-
-
1
-
1
-
-
-
-
-
-
-
1
-
-
-
-
-
-
1
-
1
2
1
1
1
4
-
1
4
-
-
-
-
03051504 Turbulator Section  
-
-
-
-
03051505 Turbulator Section, Stainless Steel  
-
-
-
-
*91412200 Flexible Stainless Steel Gas Hose , 1/2'' NPT  
(US Models Only)  
1
1
1
1
-
-
*91412203 Flexible Stainless Steel Gas Hose , 3/4'' NPT  
(US Models Only)  
-
-
-
-
-
1
1
1
02568200 Gasket (Burner to Burner Tube)  
94273914 Hex Head Cap Screw 5/16'' -18 x 7/8''  
96411600 Split Lock Washer  
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
1
4
4
1
1
91201708 Pipe Nipple 1/2'' NPT x 4''  
152101NA Installation, Operation and Service Manual  
*Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory. See Page 69, Section 16.  
Table 7: Contents of Core and Extension Packages  
Core Packages  
Hot Rolled Aluminized  
Extension Packages  
Hot Rolled Aluminized  
Part No.  
Description  
20  
'
30  
'
40  
'
10  
'
20  
'
30  
'
40  
'
10  
'
20  
'
30  
'
40  
'
10  
'
20  
'
30  
'
40'  
(6m)  
(9m) (12m) (3m)  
(6m)  
(9m) (12m) (3m)  
(6m)  
(9m) (12m) (3m)  
(6m)  
(9m) (12m)  
91409300  
91409408  
03051101  
03051601  
1
2
-
3
-
-
-
-
-
-
1
-
2
3
-
4
-
-
1
-
-
-
3
-
-
4
-
Tube, Hot Rolled Steel, 10  
'
(3 m)  
-
1
-
2
1
-
3
1
-
-
-
2
-
Tube, HT Aluminized, 10  
'
(3 m)  
Burner Tube, ALUMI-THERM® Steel, 10  
Burner Tube, HT ALUMI-THERM® Steel, 10  
'
(3 m)  
-
1
-
1
-
-
-
-
-
1
1
3
2
3
3
2
1
-
1
1
3
2
3
3
2
-
-
-
-
-
-
-
-
'
(3 m)  
01312700 Coupling Assembly  
02750303  
2
4
2
4
4
3
3
6
2
5
5
5
2
4
2
4
4
3
3
6
2
5
5
5
1
2
-
2
3
-
3
4
-
4
6
-
1
2
-
2
3
-
3
4
-
4
6
-
2
2
2
2
1
Standard Reflector, 8  
'
(2.4 m)  
02750800 End Cap  
03090100 Tube and Reflector Hanger  
91907302 S-hook  
1
1
2
2
2
3
3
3
4
4
4
6
1
1
2
2
2
3
3
3
4
4
4
6
03050010 Reflector Support Package  
(Strap, Wire Form, Screws)  
91107720 U-clip Package  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
1
-
1
-
1
-
1
-
1
-
1
-
1
-
90502700 Vent Adapter (Not used on CTHN)  
01318901 Tube Clamp Package  
-
-
-
-
-
-
-
-
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
Table 8: Component Package Guide  
Tubing Length  
Core Packages  
Model  
Minimum  
Standard  
CP20HRS  
Aluminized  
CP10ALUM  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
20' (6 m)  
30' (9 m)  
30' (9 m)  
40' (12 m)  
50' (15 m)  
50' (15 m)  
60' (18 m)  
60' (18 m)  
CP30HRS  
CP20ALUM  
CP30HRS  
CP20ALUM  
CP40HRS  
CP30ALUM  
CP30HRS + EXP20HRS  
CP30HRS + EXP20HRS  
CP30HRS + EXP30HRS  
CP30HRS + EXP30HRS  
CP40ALUM  
CP40ALUM  
CP30ALUM + EXP30ALUM  
CP30ALUM + EXP30ALUM  
Additional tubing length may be added to heater.  
Any additional tubing lengths are considered as manifold tube length for length determination, See Page 29,  
Section 9.2 through Page 31, Section 9.6, design requirements and allowed manifold tube lengths.  
For manifold tubing on multiburner systems, heat-treated aluminized or porcelain coated tubing is required.  
Table 9: Common CTHN-Series Components  
Venting Accessories  
01324401 Air Supply Takeoff, 4" (10 cm) Outside  
90707501 Air Supply Blower/Power Venter  
91409601 Air Flex Duct, 4" (10 cm) Outside  
(Box of 8 - 8' (2.4 m) sections)  
Part No.  
Description  
Tubing and Related Accessories  
01312700 Coupling, 4" (10 cm) Plain  
01312706 Coupling, 6" (15 cm) Plain  
Reflectors and Related Accessories  
0131270I  
Coupling, 4" (10 cm) Lined  
01329910 Reflector Side Extension Support  
03050010 Reflector Support Package (Tubing)  
02712700 Reflector Side Extension, 2 Clips, 2 Screws  
02750303 Reflector, Aluminum  
027503SS Reflector, Stainless Steel  
02750800 Reflector End Cap, Aluminum  
027508SS Reflector End Cap, Stainless Steel  
027508SH Reflector End Cap, Stainless Steel with Hole  
02750900 Reflector Joint  
027509SS Reflector Joint, Stainless Steel  
027127SS Reflector Side Extension, Stainless Steel  
03090100 Tube and Reflector Hanger  
91907302 S-hook  
01331900 Coupling, 4" (10 cm) Damper  
E0009356 Coupling, 6" (15 cm) Damper  
0133022D Tee, 4" (10 cm) Coated  
01330203 Tee, 4" (10 cm) Aluminized  
01330204 Tee, 6" (15 cm) Aluminized  
0133092D Cross, 4" (10 cm) Coated  
01330903 Cross, 4" (10 cm) Aluminized  
01330904 Cross, 6" (15 cm) Aluminized  
01335801 Elbow, 4" (10 cm) Aluminized 90°  
T0100320 Elbow, 6" (15 cm) Aluminized 90°  
0133580D Elbow, 4" (10 cm) Coated 90°  
01336101 Elbow, 4" (10 cm) Aluminized 45°  
0133610D Elbow, 4" (10 cm) Coated 45°  
91409300 Tube, 4" (10 cm) dia Hot Rolled Steel 10' (3 m)  
91903201 Turnbuckle  
91903300 Spring Hook  
91903202 Turnbuckle with Eyebolt  
91409403 Tube, 4" (10 cm) dia Non-Heat Treated Aluminized  
10' (3 m)  
91409408 Tube, 4" (10 cm) dia Heat Treated Aluminized  
10' (3 m)  
91409420 Tube, 6" (15 cm) dia Non-Heat Treated Aluminized  
10' (3 m)  
9141030D Tube, 4" (10 cm) dia Coated 10' (3 m)  
E0009105 Tube, 6" (15 cm) dia 10' (3 m)  
Heat Treated Aluminized  
Thermostats  
02770002 System Control  
05023000 Load Relay Package  
90417600 Transformer Relay - SPST (12 A)  
90436300 Transformer Relay - DPST (12 A)  
90423000 Thermostat, 24 V Low Voltage (Marked 1-5)  
90424300 Thermostat Guard  
91418200 Tube Adapter, 6" (15 cm) dia x 4"(10 cm) dia  
Aluminized  
91240010 Tube Hanger, 6" (15 cm)  
91308001 Pipe Compound, High Temperature 1lb can  
Deco Grille (1' x 8' [.3 m x 2.4 m])  
01363003 Bracket  
01365901 End Piece  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
01326801 Reinforcement  
01365903 Joint Piece  
91406700 1' x 8' (.3 m x 2.4 m) Protective Grille  
Deco Grille (2' x 4' [.6 m x 1.2 m])  
01365900 Shield Frame  
01370408 Reflector Side Extension 8" x 48" (20 cm x 122 cm)  
01370412 Reflector Side Extension 12" x 48" (30 cm x 122 cm)  
01370416 Reflector Side Extension 16" x 48" (40 cm 122 cm)  
91407000 Grille, Aluminum 2' x 4' (.6 m x 1.2 m)  
Protective Grille  
08050001 Grille, 40" (102 cm) Protective  
08050002 Protective Grille End Cap  
Fan and Pump Packages  
05220000 Fan Package 40-150  
05221000 Fan Package 175-200  
02719105 EP-100 Pump Package  
02719100  
02724700  
EP-100 Pump  
Accessory Package  
02716305 EP-201 Pump Package  
01312001  
01317805  
EP-201 Pump  
Accessory Package  
02712034 EP-203 Pump Package  
01312002  
01317805  
EP-203 Pump  
Accessory Package  
02723014 EP-301 Pump Package 4" (10 cm)  
02730101  
02730104  
EP-301 Pump Assembly  
Accessory Package  
02723016 EP-301 Pump Package 6" (15 cm)  
02730101  
02730106  
EP-301 Pump Assembly  
Accessory Package  
02723034 EP-303 Pump Package 4" (10 cm)  
02730103  
02730104  
EP-303 Pump Assembly  
Accessory Package  
02723036 EP-303 Pump Package 6" (15 cm)  
02730103  
02730106  
EP-303 Pump Assembly  
Accessory Package  
Pump Accessories  
90430600K Pressure Switch  
Starters and Contactors  
10050001 Starter, 120 Vac for EP-203, 3 Ø  
10050003 Starter, 120 Vac for EP-201, 1 Ø  
10050008 Starter, 120 Vac for EP-301, 1 Ø  
10050009 Contactor Package-  
120 Vac Coil for EP-301, 230 V, 2 HP  
10050010 Starter, 120 Vac for EP-303, 3 Ø  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
9.2 Multiburner System Design Requirements  
A CTHN multiburner system has a number of radiant CTHN multiburner heaters are typically shipped as  
tube sections interconnected by manifold tube to a  
pump to form a complete system. Reflectors can be  
used over the manifold tube but are not required.  
The system design parameters are such that the  
manifold sections are not subjected to condensate  
burner packages and tube and accessory packages.  
The tube and accessory packages contain enough  
tube, reflector and hanging parts for the radiant  
section of one CTHN heater. Elbows, tees, manifold  
tube, pumps, controls, damper couplings and any  
when the system is fully heated up. It is required that other parts used beyond the burner, radiant tube and  
heat-treated aluminized or coated tubing is used for reflector must be purchased separately. See Figure  
the manifold to increase system life and to handle  
initial condensation during start-up. Damper  
couplings may be necessary to balance system  
vacuum.  
18 for a general overview of a simple CTHN  
multiburner system. Depending on system  
requirements, CTHN multiburner systems may be  
controlled by either a ROBERTS GORDON® System  
Control (shown) or by a relay system.  
Design requirements for a CTHN multiburner system  
are summarized on Page 30, Table 10.  
FIGURE 18: Typical CTHN Multiburner System Installation  
Zone 1 Thermostat  
T
System Control (optional)  
Turbulator (if required)  
Cross  
Optional Reflector  
Manifold Tube  
Pressure Switch  
Pump  
Tee  
Exhaust to  
Outside  
Radiant Tube  
Burners  
T
Zone 2 Thermostat  
Drawing Not to Scale  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Table 10: Multiburner Design Requirements  
Burner Model:  
CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200  
Radiant Tube Length  
20' (6 m)  
30' (9 m)  
3' (1 m)  
30' (9 m) 40' (12 m)  
3' (1 m) 6' (2 m)  
50' (15 m)  
6' (2 m)  
50' (15 m)  
10' (3 m)  
60' (18 m)  
10' (3 m)  
60' (18 m)  
10' (3 m)  
Minimum Manifold Tube Length per Burner 3' (1 m)  
Maximum Manifold Tube Length per  
30' (9 m) 35' (10.5 m) 40' (12 m) 45' (13.5 m) 50' (15 m) 55' (16.5 m) 60' (18 m)  
60' (18 m)  
Burner  
Minimum Distance from Burner to Elbow  
or U-tube  
10' (3 m)  
2
10' (3 m)  
2
10' (3 m) 15' (4.5 m) 15' (4.5 m)  
20' (6 m)  
2
20' (6 m)  
2
20' (6 m)  
2
Elbows Allowed per Burner*  
2
2
2
* U-tube = 2 elbows  
9.3 Burners Per Pump  
1. The maximum number of burners per pump is  
b. EP-200 up to 750,000 Btu/h max, but not  
more than 6 burners.  
c. EP-300 up to 1,600,000 Btu/h max, number  
of burners is limited to the maximum  
number of burners listed in Table 11 for the  
largest input model used.  
shown in Table 11.  
2. When combining different burner inputs in a  
system, the number of burners per pump (0' -  
2,000' altitude) is given by the sum of their  
inputs:  
a. EP-100 up to 500,000 Btu/h max, but not  
more than 4 burners.  
Table 11: Number of Burners Allowed Per Pump  
Pump Model  
Altitude  
CTHN-40 CTHN-60 CTHN-80 CTHN-100 CTHN-125 CTHN-150 CTHN-175 CTHN-200  
0' - 2,000'  
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
3
3
4
3
3
3
3
3
3
2
3
3
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
2,001' - 3,000'  
3,001' - 4,000'  
4,001' - 5,000'  
5,001' - 6,000'  
6,001' - 7,000'  
7,001' - 8,000'  
8,001' - 9,000'  
EP-100  
0' - 2,000'  
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
5
5
5
5
5
5
5
5
4
4
4
4
4
4
4
4
4
4
3
3
3
3
4
3
3
3
3
3
3
3
2,001' - 3,000'  
3,001' - 4,000'  
4,001' - 5,000'  
5,001' - 6,000'  
6,001' - 7,000'  
7,001' - 8,000'  
8,001' - 9,000'  
EP-200 Series  
0' - 2,000'  
16  
16  
16  
16  
16  
16  
16  
16  
16  
16  
16  
16  
16  
16  
16  
16  
14  
14  
14  
14  
14  
14  
14  
14  
12  
12  
12  
12  
12  
12  
12  
12  
12  
12  
11  
10  
10  
10  
10  
10  
10  
9
8
8
8
7
7
7
6
6
8
7
7
6
6
6
6
6
2,001' - 3,000'  
3,001' - 4,000'  
4,001' - 5,000'  
5,001' - 6,000'  
6,001' - 7,000'  
7,001' - 8,000'  
8,001' - 9,000'  
9
9
EP-300 Series  
8
8
8
8
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
9.4 Radiant Tube Length  
9.6 Multiburner System Layouts and Manifold  
Tube Length Rules  
The radiant tube length fixed for each burner is  
Most CTHN multiburner layouts can be classified as  
one of the following five layout types:  
shown on Page 30, Table 10.  
Flag, Modified In-Series, T, Fork or Herringbone.  
Please refer to Page 31, Section 9.6.1 through Page  
35, Section 9.6.3 for explanation of manifold rules  
and basic diagrams of each layout type. The  
diagrams show very simple examples of each layout  
type. Actual layouts will vary in total number of  
burners in the system as well as the overall shape of  
the system. Additional pieces such as elbows may  
change the overall layout appearance but are usually  
considered a variant of one of the five multiburner  
layout types.  
9.5 Manifold Tube  
Any tube beyond the radiant tube length is  
considered manifold. Manifold tube can be used to  
lengthen tube runs beyond the radiant tube length; to  
connect multiple runs of tubing and connect the  
system to the pump. Minimum and maximum  
manifold tube lengths are shown on Page 30,  
Table 10. The table must be used in conjunction  
with the additional rules for the diameter and  
length of manifold in a system, as described on  
Page 31, Section 9.5.1 through Page 35, Section  
9.6.3.  
9.6.1 Flag and Modified In-Series Layouts and  
Manifold Tube Length Rules  
9.5.1 Manifold Diameter  
See Page 32, Figure 19 through Page 32, Figure 20  
for diagrams of Flag and Modified In-Series layouts.  
Minimum and maximum manifold tube length applies  
to all tubing between the end of a radiant tube run  
and a tee or cross; all tubing between any tees and/  
or crosses; and all tubing between the last tee or  
cross and the pump. See Page 30, Table 10.  
1. Manifold diameter for systems containing less  
than 320,000 Btu/h input can be 4" (10 cm) or  
6" (15 cm).  
2. Manifold diameter for systems containing  
320,000 Btu/h input and greater must be 6"  
(15 cm).  
Exception: If total manifold tube length is 70'  
(21 m) or less, 4" (10 cm) diameter manifold  
tube can be used for systems up to  
800,000 Btu/h.  
Example: Consider a Flag or Modified In-Series  
layout with five CTHN-100 burners. Page 30, Table 10  
shows a minimum of 6' (2 m) and a maximum of 45'  
(13.5 m) of manifold tube required per burner.  
Therefore the entire five-burner system must have  
between 30' (10 m) and 225' (69 m) of manifold  
tubing. The manifold tubing is in addition to the 40'  
(12 m) of radiant tube per burner. Radiant tube may  
end at a tee, or runs may be lengthened by adding  
some manifold tube between the end of the radiant  
tube and a tee. Each burner in the system (except for  
the burner furthest from the pump) must use a  
damper coupling to properly adjust the vacuum at  
each burner. The damper coupling may be placed  
anywhere between the end of the radiant pipe and  
the tee.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
FIGURE 19: Flag Layout  
FIGURE 20: Modified In-Series Layout  
Multiple rows of burners:  
Multiple burners:  
pump placed at the end of the manifold tube.  
pump placed at the end of the manifold tube.  
A variation on the flag layout.  
Burner furthest from pump  
does not need a damper coupling.  
First Tee  
First Tee  
Manifold tube  
between radiant  
tube ends.  
Last Tee  
Pump  
Burner  
Last Tee  
Burner  
Manifold tube  
between joining  
tee and pump.  
Pump  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
9.6.2 T and Fork Layouts and Manifold Tube  
Length Rules  
manifold tube length on the table for each burner in  
the system, this is the maximum manifold tube length  
for the entire system.  
See Page 33, Figure 21 through Page 34, Figure 22  
for diagrams of T and Fork layouts. The T and Fork  
layouts have a tee or cross (called the "last tee" or  
"last cross") where the combustion gases in the  
system enter the tee or cross with directly opposing  
flow directions, which creates an added source of  
pressure drop in the system. This additional source  
of pressure drop requires some difference in how the  
allowed manifold length is calculated. In this case,  
we have to differentiate manifold tube that is located  
between the radiant pipe and the last tee (or cross)  
from manifold tube that is located between the last  
tee (or cross) and the pump.  
To determine the maximum manifold tube allowed  
between the last tee (or cross) and the pump:  
Subtract the manifold tube length between the  
radiant tube and the last tee (or cross) from the  
maximum manifold length for the entire system, then  
divide that number by 1.5.  
Example: Consider a T layout with two CTHN-100  
burners. See Page 33, Figure 21. Assume that 15'  
(4.5 m) of manifold was used from each radiant tube  
end to the last tee. Page 30, Table 10 indicates that  
each CTHN-100 burner can have a maximum of 45'  
(13.5 m) of manifold tube. Therefore the maximum  
manifold tube length amount allowed between the  
last tee and the pump in this case is  
First determine the length of manifold tube between  
the radiant tube end and the last tee (or cross). Do  
not count any tube length twice. Now refer to Page  
30, Table 10 and find the maximum manifold tube  
length for each burner. Add together the maximum  
([45' + 45']-[15' x 2])/1.5 = 40' or in metric,  
([13.5 m + 13.5 m]-[4.5 m x 2])/1.5 = 12 m.  
FIGURE 21: T Layout  
One pair of burners.  
Burner  
Last Tee  
Manifold tube between joining tee  
and pump.  
Pump  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
FIGURE 22: Fork Layout  
Multiple rows of burners:  
Manifold tube between the last tee or cross and  
the pump is perpendicular to the manifold tube  
joining the rows. Pump is not required to be  
placed in the center of the system (as shown).  
Pump  
Manifold tube between  
joining cross and pump.  
Manifold tube between  
radiant tube ends.  
Tee (2)  
Last Cross  
Damper Couplings  
located at the end of  
the rows.  
Radiant Tube  
Burner  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
9.6.3 Herringbone Layout and Manifold Tube  
Length Rules  
the connecting tee or cross.  
According to Table 10 each burner must have at least  
40' (12m) of radiant tube, also each burner must  
have between 6' (2m) and 45' (13.5m) of manifold  
tube. Each burner has already met the minimum  
manifold pipe requirement due to the 10' (3m) of  
manifold tube before the connecting tees and  
crosses. The maximum manifold tube length for the  
entire system is 10 burners X 45' (13.5m) = 450'  
(135m). Subtract the 100' (30m) that has already  
been used before the connecting tees/crosses and  
350' (105m) remains.  
The herringbone layout is essentially several T  
layouts stacked together. Therefore, the same  
principle for manifold tube calculation as used for T  
layouts is used for herringbone layouts, with one  
exception. In a herringbone layout, the manifold  
tube length between tees (or crosses) as well as  
between the last tee (or cross) and the pump is  
calculated by dividing by 1.5 as shown in the T  
example on Page 33, Section 9.6.2. The only  
manifold tube length in a herringbone layout that is  
not divided by 1.5 is any manifold tube length located  
between the end of the radiant tube and a tee or  
cross.  
Since the remaining manifold is located either  
between or after connecting tees or crosses, the  
manifold length must be divided by 1.5. 350' (105m)/  
1.5 = 233' (70m). Therfore, up to 233' (70m) can be  
used between the branches and also between the  
last cross and the pump.  
Example: Consider a herringbone layout similar to  
the layout on the left in Figure 23, having ten CTHN-  
100 burners. Assume that each heater has 40' (12m)  
of radiant tube and 10'(3m) of manifold tube before  
FIGURE 23: Herringbone Layout  
Multiple opposing rows of burners: pump placed at the end of the manifold tube or somewhere between  
the burners.  
Tee  
Tee  
Manifold tube between  
radiant tube ends.  
Cross (3)  
Pump  
Last Tee  
Burner  
Last Cross  
Manifold tube  
between joining  
tee and pump.  
Pump  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Step 9.7 Burner Tube Installation  
NOTE:  
Tubing requires a downward  
slope of 1/2" (1.3 cm)  
per 20' (6 m) away  
from burner.  
Offset mounting  
hole must be  
to the top.  
S-hook  
Hanger  
Burner Tube  
Weld seam  
must be to the  
bottom of the tube.  
7' 6" ± 1'  
(229 cm ± 25 cm)  
Description  
Part Number  
Burner Tube  
S-Hook  
Tube/Reflector Hanger  
03051XXX  
91907302  
03090100  
Step 9.8 Tube Clamp Package Installation  
Description  
Tube Clamp Package  
Tube Clamp  
Bolt  
Flat Washer  
Nut  
Part Number  
01318901  
01396801  
97113940  
95211600  
92113900  
Bolt  
Tube Clamp  
Flat  
Washer  
Nut  
(Torque 120 in/lb  
13.56 Nm)  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
Step 9.9 Coupling and Tube Assembly  
Close coupling  
Awith tab.  
Start slide bar/coupling lock  
B onto coupling.  
Tab  
Slide Bar/Coupling Lock  
Wide End  
Coupling  
Open  
3" (8 cm) to  
4" (10 cm)  
Closed  
Insert tubes into coupling.  
Tighten coupling to join tubes.  
C
D
Slide Bar/Coupling Lock  
Coupling  
Orient coupling so that  
the impact block is in the  
2:00 or 10:00 o’clock  
positions.  
Tube  
Tube  
Description  
Coupling  
Part Number  
01329600  
Tube  
Slide Bar/Coupling Lock  
Tube  
01329700  
91409XXX  
Step 9.9.1 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.  
± 2" (5 cm)  
Correct Slide Bar  
Dimensions  
Incorrect Slide Bar  
Position  
• Repeat Step 9.9 on Page 37, A - D until all tubes are assembled. See Page 38, Step 9.9.2.  
NOTE: If coupling is not tight, loss of vacuum can occur.  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Step 9.9.2 Coupling and Tube Assembly (Continued)  
Radiant  
Tube Length  
10' (4.5 m)  
20' (6 m)  
20' (6 m)  
30' (9 m)  
40' (12 m)  
40' (12 m)  
50' (18 m)  
50' (18 m)  
Model  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
2.3 m .25 m  
3 m .25 m  
Step 9.10 Turbulator Installation  
Turbulator must be installed in the last  
standard section of radiant tube.  
Turbulator is only required on the  
CTHN-40, CTHN-60 and CTHN-80.  
T
t
w
i
s
Turbulator  
Section  
Turbulator Installation  
Model  
Tube Section  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
1st 10' (3 m) Section  
2nd 10' (3 m) Section  
2nd 10' (3 m) Section  
Turbulator  
Tab  
Adapter  
N/A  
N/A  
N/A  
N/A  
N/A  
Turbulator section  
(stainless) used in  
Pull String  
CTHN-40 heaters must be  
in the section of tube nearest  
to the burner.  
Fold tab around outside  
of tube nearest to the vent to  
hold turbulator in place.  
Description  
Part Number  
03051503  
03051504  
03051505  
91409XXX  
Turbulator Adapter  
Turbulator Section  
Turbulator Section (Stainless)  
Tube  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
Step 9.11 Reflector Installation  
NOTE: All radiant tube surfaces  
must be covered by a reflector,  
except for a u-tube. Manifold tube  
may or may not be covered.  
Hanger  
Burner Tube  
Reflector  
Description  
Tube/Reflector Hanger  
Burner Tube  
Part Number  
03090100  
03051XXX  
02750303  
Reflector  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
Step 9.11.1 Reflector, U-clip and Reflector Support Installation  
The pictorial drawings of the heater construction in  
Section 9 are schematic only and provide a general  
guideline of where hangers, reflector supports and  
u-clips are to be installed.  
reflector supports and u-clips depend on the  
individual installation. Use either pop rivets or sheet  
metal screws instead of u-clips when installing end  
caps and joint pieces in areas where impact and high  
wind may be a factor. The following rules must be  
To ensure proper expansion and contraction  
movement of the reflectors, a combination of u-clips observed.  
and reflector supports are used. The positioning of  
1. The first reflector after the burner must be affixed in  
the middle of the reflector with a reflector support and  
tight screws.  
Tight  
Sheet Metal  
Screw  
Wire Form  
Reflector  
End Cap  
First Reflector  
Reflector Support  
Strap  
U-clips  
2 B  
Slip Overlap  
Overlap must be a  
minimum of " (16 cm).  
6"  
(16 cm)  
Reflector  
Reflector  
Support  
6
2. The overlap at the first and second reflector is a slip overlap.  
Thereafter, every third reflector joint is a slip overlap. A slip  
overlap is achieved by either:  
Loose screws  
loosened 1/16"  
(.16 cm) to allow  
slippage.  
a.) both reflectors lay inside a hanger.  
(No reflector support needed.)  
b.) using a reflector support with  
loose screws at the reflector  
2 A  
Slip Overlap  
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.  
3 A  
Non-Slip Overlap  
Reflector  
This section of three reflectors joined together must  
be affixed to the tube with at least one reflector support  
with tight screws.  
Tight  
Screws  
3 B  
Non-Slip Overlap  
Description  
Reflector Support Package  
Wire Form  
Reflector Support Strap  
Screw #8 x 3/4  
U-clip Package  
Part Number  
03050010  
91908004  
03050000  
94320812  
91107720  
027508XX  
U-clip  
(2 Clips per  
Non-slip Overlap  
Inside a Hanger)  
Reflector End Cap  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SECTION 9: MULTIBURNER HEATER INSTALLATION  
Step 9.12 Burner Installation  
Burner  
Gasket  
S-hook  
Burner Tube  
Burner must be installed  
with the flame observation  
window facing down.  
Lock  
Washer  
Bolt  
(Torque 120 in/lb  
13.56 Nm)  
Description  
Bolt  
Burner  
Part Number  
94273914  
052XXXXX  
96411600  
Lock Washer  
Gasket  
02568200  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CTHN-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL  
SECTION 10: OPTIONAL HEATER ACCESSORIES  
10.1 Elbow Package Configuration  
Step 10.1.1 Elbow Installation  
Tube  
Coupling  
Minimum Distance Required Between  
Burner and Elbow  
Minimum  
Model  
Distance  
10' (3 m)  
10' (3 m)  
10' (3 m)  
15' (4.5 m)  
15' (4.5 m)  
20' (6 m)  
20' (6 m)  
20' (6 m)  
CTHN-40  
CTHN-60  
CTHN-80  
CTHN-100  
CTHN-125  
CTHN-150  
CTHN-175  
CTHN-200  
Description  
Elbow Package  
90° Elbow  
Part Number  
02718702  
01335801  
01312700  
02750800  
02750900  
91107720  
90° Elbow  
Coupling  
Reflector End Cap  
Reflector Joint Piece  
U-Clip Package  
Step 10.1.2 Elbow Installation  
Tube  
Coupling  
Step 10.1.3 Reflector Joint Installation  
Reflector  
Reflector  
Joint  
Flatten Edge  
Scribe  
Contour  
1" (2.5 cm)  
Maximum  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Raritan Computer Network Router KX2 116 User Guide
RCA Microwave Oven RMW1156 User Guide
RCA MP3 Player M63 User Guide
Regency Indoor Fireplace E21 User Guide
Roberts Radio Portable Radio R9914 User Guide
Roberts Radio Radio CRD 39 User Guide
Rosen Entertainment Systems Car Video System CV1005 User Guide
Samsung Cell Phone 9330 User Guide
Sealife Digital Camera DC 600 User Guide
Sears Lawn Mower 6 3041 User Guide