INSTALLATION MANUAL FOR BASE-RAY® CAST IRON BASEBOARD RADIATION TABLE OF CONTENTS PAGE 2 RATINGS 8 INSTALLATION DETAILS 9 INSTALLATION INSTRUCTIONS 4 ASSEMBLY CHART 5 SYSTEM TYPES 10 ASSEMBLY INSTRUCTIONS 6 SERIES LOOP SYSTEMS 14 SPECIAL APPLICATIONS 7 SERIES LOOP DESIGN 16 WARRANTY H e a ti ng C o ntr a c to r A d d re s s 103829-02 - 9/14 Ins t a lla ti o n D a te P h o ne N u m b e r Price - $2.
For Ratings at the following temperatures, multiply the 150° rating by the multiplier of the desired temperature. Temperature – Multiplier 150° - 1.0 140° - .82 130° - .68 120° - .54 110° - .42 100° - .32 90° - .22 No. 9A Base-Ray® Ratings – Steam and Hot Water (500 LBS/HR Flow Rate **) Length in Lineal Feet* Steam Rating Square Feet Steam Ratings BTU Per Hr. At 215°F HOT WATER RATINGS IN BTU PER HOUR AT 500 LBS./HR.
For Ratings at the following temperatures, multiply the 150° rating by the multiplier of the desired temperature. Temperature – Multiplier 150° - 1.0 140° - .82 130° - .68 120° - .54 110° - .42 100° - .32 90° - .22 No. 9A Base-Ray® Ratings – Steam and Hot Water (2000 LBS/HR Flow Rate **) Length in Lineal Feet* Steam Rating Square Feet Steam Ratings BTU Per Hr. At 215°F HOT WATER RATINGS IN BTU PER HOUR AT 500 LBS./HR.
Dimensions and Specifications BASE-RAY TAPPINGS- Tapped 3/4" top and bottom of end sections. A 3/4" x 1/8" vent bushing is furnished with each Base-Ray Assembly. Only one air vent location need be used. Use of PTFE (Teflon®) tape or paste containing PTFE is not recommended as overtightening is possible, causing cracking of the Base Ray tappings. Sub-Assembly Chart Copper tubing is not recommended for steam applications due to high heat loss through the tubing and thermal expansion noise.
BASE-RAY® HYDRONICS Types of Systems Hydronic Heating Systems are classified according to the piping arrangement and heating medium employed. BASE-RAY is very versatile in that it may be used in almost all types of systems as noted below: 1. Series Loop Forced Circulation Hot Water 2. One-Pipe Forced Circulation Hot Water 3. Two-Pipe Reverse Return Gravity or Forced Circulation Hot Water 4. Two-Pipe Steam or Vapor. It is not recommended that BASE-RAY be used in a One-Pipe Steam System. System Description 1.
SERIES LOOP SYSTEMS Installation Data This type of installation, in which the BASE-RAY® Assemblies serve as part of the main, is the most economical way BASE-RAY can be installed. Substantial savings in labor and material are realized in that one-pipe fittings, shut-off valves, balancing cocks and additional piping are eliminated. Quality is not sacrificed as tests have proven the ability of a Series Loop System to produce comfort conditions equal to those produced by other hydronic heating systems.
To Design Series-Loop Base-Ray® Installation – 1. Calculate the Heat Loss of each room using the procedure outlined in the I=B=R Heat Loss Calculation Guide No. H-21 or the ASHRAE Guide. 2. Using 210°F as design water temperature and 500 lbs/hr. as flow rate, select length of BASE-RAY Assembly for each room to produce desired output. (Design water temperature other than 210°F may be used but should not exceed 230°F.
Installation Details A BASE-RAY® heating system is extremely easy to install – no other heating system requires less labor. The same installation practices that are used in an ordinary radiator system are followed. Use conventional methods in selecting boiler and pipe sizes, including mains, risers and branches. Supply and return connections to BASE-RAY are made in the same way as with conventional radiators.
INSTALLATION INSTRUCTIONS 1. Wall Preparation: To prevent excessive heat loss through the walls in back of BASE-RAY®, it is recommended that the stud space behind the Assemblies be insulated to a height of at least 12” above the floor with 4” mineral wool batts (blanket or loose insulation may also be used) or other approved insulating materials. This is particularly essential if the BASE-RAY is recessed. Mark Stud locations. 2.
5. Assembling BASE-RAY® Press down on both cam handles simultaneously until castings are drawn together. Be sure clamp is not tilted, since this may break casting. If nipples do not draw up evenly during final tightening, strike end of assembly with wood block and hammer or mallet to bring the sections back in line. Do not strike BASE-RAY sections with metal hammer.
Spring Clip Bottom Center Support Top Center Support Stand Assemblies upright, place in position and fasten to the walls with Top Center Supports using the number shown in the table above. Insert Top Center Supports in Air Outlet opening of Sections opposite studs (stud locations determined in step 1). Use wood screw furnished with Top Center Support and screw into stud until tight, the longer dimension of the top center support is in a vertical position when installed.
8. Installation of Corner Plates INVERTED CORNER PLATES – for inside corners – furnished in two types, 4-5/8” standard plate is used when Assemblies on adjoining walls extend to within 4-3/8” of the corner. If this distance is greater than 4-3/8” but less than 10-3/8”, the 10-5/8” plate is used. Extended Plate may be cut to desired length with hacksaw. Set Inverted Corner Plate in place overlapping the end of the adjoining BASE-RAY® Assemblies. Secure to floor with wood screws furnished.
ADJUSTABLE END CAPS & FILLER PIECES – Adjustable End Caps are available in both left-hand and right-hand patterns and are used in the same locations as the standard end caps except the 9” length of the adjustable end caps makes it possible to fill in spaces of up to 7-1/2”. A knockout is also available in the ends for piping. Filler pieces are used where a 9” space or less exists between two sections of baseboard or between a section of baseboard and baseboard extension.
SPECIAL APPLICATIONS BASE-RAY® INSTALLED ON THREE WALLS OF ROOM – When BASE-RAY is installed on three walls, expansion noises are sometimes created by the middle assembly when rigid piping is used to connect all three assemblies together. Flexibility can be gained by connecting two of the adjoining assemblies with a flexible connector or swing joint such as illustrated. INSTALLATION WITH U.S.
All Base-Ray® Repair Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408.
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.
