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CORAYVAC ® Installation, Operation and Service Manual

1. 1 ee Low voltage thermostats lee Pressure located in heated zone Pressure switch switch locatedat Zone Zone Zone Zone located at Pump 1 1 2 3 Pump2 120 V x x 120V 10 x 10 60 Hz x 60 Hz 24vAC x 9L lt N 9 ceu Ground e e es 24VAC PS 1 G N L NL NL NL NLI NL N COM J power PUMP1 21 2 Z8 Z4 PUMP2 e e SUPPLY 24VAC PS1 w w w PS 2 COM System Control 58 of 83 SECTION 12 CONTROL METHODS FIGURE 37 CORAYVAC Modulating Wiring Diagram LonWorks 2 10 Vdc with 500 ohm resistor optional D TR21 Remote Outdoor 500 OHM Sensor Air Sensor Resister optional optional CX 2 10 VDC Modulating Thermostat See Note 2 with LonWorks Power Input Variable Frequency Driver Rotary Disconnect o 1 Input Model Shown Lonwork Bus Lonwork Motion Bus Sensor optional For Non communicating Thermostat See Note 7 Transformer Relay 60 Hz 33 VA Ext Load Pressure Switch TN Zone 1 Burner VFD Power nib Outpot Terminal 230V 460 V 3 PH 3 PH 0 60 Hz pr 0
2. TEES Ru commen mos Infrared Hir Ser Rating Plate Label Control Side Panel inside Logo Label Transformer Transformateur re Layee em BLUEIBLEU sROWNMARRON Internal Ladder Diagram Diagramme de S quence Interne Electrode Gas Valve 1 Valve gaz 1 Ignition Module O TRE ______ 1 Module d allumage It any of the original vire as supplied with the appliance must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C and 600 volts Si une partie du c blage d origine fourni avec le radiateur doit tre remplac e elle doit par du mat riel de tol rant au moins 105 C de temp rature et 600 volis D Reberte Gordon LLC Internal Ladder Diagram Label Prose US ming ux ater Filter Side Panel inside TRANSFORMERITransformateur Internal Wiring Diagram Sch ma de C blage Interne ha WalrE Blane uow zi scr 120V GREENVert l POWER SUPPLY Alimentation Electrique Jeune BROWNMatton 51 V2 GN YELLOW GAS VALVE ELON Valve gaz IGNITION MODULE Module dAlluma
3. 7 Universal Shield Position 3 7 2 Foot Deco 8 Barrier Shield 1 nette ieee 8 Protective Grille 8 Major Component Descriptions 10 Heater Assembly Overview 17 Critical Hanger Placement 19 Reflector Joint Detail 28 EP 200 Condensate Valve Assembly 35 Condensate Neutralization Tube 37 Vertical Venting Configuration 39 EP 100 Horizontal Venting Configurations 40 EP 200 Series Horizontal Venting Configurations 41 EP 300 Series Horizontal Venting Configurations 42 Duct SIZING tiec tete ERREUR 44 Outside Air Blower Internal Wiring Diagram 44 Filter Housing Assembly 45 Air Supply Blower Support 45 Pressurized Outside Air Supply 46 Non Pressurized Outside Air Supply 46 Gas Connection with Flexible Gas Hose 48 Terminal 2 2 2 2 22441 51 One Zone Operation without Control Panel Optional au sasakuna cene het edet 53 One Zone Operation with Outside Air Blower without Control Panel optional 54
4. I3 8 42 max displacement 30 cm Side View x Gas Hose Heater Movement 36 91 cm length Heater Movement Description CORRECT POSITIONS A CAUTION Product Damage Hazard Hold gas nipple securely with pipe wrench when attaching gas hose Failure to follow these instructions can result in product damage Vertical as shown left S Alternate positions okay Horizontal End View INCORRECT POSITIONS WRONG INSTALLATION Heater Movement Heater Movement Heater Movement gt Part Number 1 2 Flexible Stainless Steel Gas Hose US Models 91412200 3 4 Flexible Stainless Steel Gas Hose US Models 91412204 1 2 Rubber Type 1 Gas Hose Canadian Models 91412206 3 4 Rubber Type 1 Gas Hose Canadian Models 91412207 48 of 83 SECTION 12 CONTROL METHODS A DANGER Electrical Shock Hazard Disconnect electric before service or maintenance More than one disconnect switch may be required to disconnect electric to the unit Control must be properly grounded to an electrical source Failure to follow these instructions can result in death or electrical shock A WARNING Explosion Hazard Turn off gas supply to heater
5. Clips ROBERTS GORDON N Schedule 40 Steel Pipe Cast Iron Combustion Chamber E Cast Iron Adapter End Vent Plate for with Schedule 40 Steel Pipe 1 4 End Burner Only The total weight of each burner and Chamber combustion chamber is 40 25 Ibs 18 kg 4 Schedule 40 pipe weighs 10 9 Ibs 5 kg per foot CoRau Vac Coupling End Vent Clips a s gt 4 Tube Cast Iron Combustion Chamber with End Vent Plate for Standard 4 O D Infrared Tubing Cast Iron Adapter End Burner Only The total weight of each burner and Description Part Number combustion chamber is 40 25 Ibs 18 kg Special Tube amp Reflector Hanger 02790300 4 O D 16 Ga tubing weighs 2 8 lbs Turnbuckle 91903201 1 3 kg per foot Cast Iron Combustion Chamber 02721200 1P Cast Iron Adapter 02722100 Coupling 01312700 34 of 83 SECTION 9 PUMP INSTALLATION AND VENTING SECTION 9 PUMP INSTALLATION AND AWARNING AWARNING VENTING Carbon Monoxide Hazard Cut Pinch Hazard Heaters installed unvented must be interlocked Wear protective gear during installation with sufficient building exhaust operation and service Heaters must be installed according to the Edges are sharp installation manual Failure to follow these instructions can result Failure to follow these instructions can result in injury in death or injury
6. 8 eqni gt Jequieu JOJO JOY Jopayey x 009 JM OVAVELIN 51 10 A jeisouueu p sinO d U91IMS eunsseJgd loquo 5 5 Tos 17 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 7 HEATER INSTALLATION Expansion and contraction of the tube dictates that WARN NG the minimum suspension lengths must be PN maintained See table on Page 19 Figure 14 Severe Injury Hazard Secure burner to combustion chamber with nuts and lockwashers Hang heater with materials with a minimum working load of 75 Ibs 33 kg Failure to follow these instructions can result in death injury or property damage A WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury To ensure your safety and comply with the terms of the warranty all units must be installed in accordance with these instructions The gas or the electrical supply lines must not be used to support the heater Do not locate the gas or electric supply lines directly over the path of the flue products from the heater The heater must be installed in a location that i
7. Jedweq euoz euoZ a LON 70 of 83 SECTION 16 OPERATION AND MAINTENANCE ADANGER Electrical Shock Hazard Explosion Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from heater Heater must be connected to a propery grounded electrica source Turn off gas supply to heater before service SECTION 16 OPERATION AND MAINTENANCE A WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Burn Hazard Allow heater to cool before service Tubing may still be hot after operation Edges are sharp Failure to follow these instructions can result in death electric shock injury or property damage The heater is equipped with a direct spark ignition system 16 1 Sequence of Operation 1 Turn the thermostat up When the thermostat calls for heat the pump will start immediately After a short period the burners will begin their ignition sequence Sparking will begin at the electrodes and the gas valve will be energized 45 seconds later 2 The flame will be sensed by the flame sensing rod and the electrode is de energized 3 If a flame is detected the gas valve remains open When the call for heat is satisfied the burner shuts off On CRV Series systems equipped with the optional ROBERTS GORDONS System Control
8. URVSC ROBERTS GORDON ULTRAVAC Controller 10080142 Modem Chip 10080450 Comms Equalization Cable 10080430 RS 485 Converter with 9 V Power Supply 10081501 Outdoor Sensor 10080410 PC Connection Cable Package ROBERTS GORDON ULTRAVAC Central Controller with TCP IP Communication Module amp Software Includes ROBERTS GORDON ULTRAVAC Controller 10080142 Modem Chip 10080450 Comms Equalization Cable 10080440 TCP IP Communication Module 10081501 Outdoor Sensor 10080410 PC Connection Cable Package URVBNC Controller ROBERTS GORDON ULTRAVAC BACnet URVSC Controller ROBERTS GORDON ULTRAVAC 1 Pump 3 Zones Satellite Control URVU Controller ROBERTS GORDON ULTRAVAC Unitary VFD75115 VFD Assembly 75 HP 115 V 1 Input VFD75230 VFD Assembly 75 HP 230 V 1 Input VFD20230 VFD Assembly 2 HP 230 V 1 Input VFD75115N4 VFD Assembly 75 HP 115 V 1 Input NEMA 4 VFD75230N4 VFD Assembly 75 HP 230 V 1 Input NEMA 4 VFD75460N4 VFD Assembly 75 HP 460 V 3 Input NEMA 4 VFD20230N4 VFD Assembly 2 HP 230 V 1 Input NEMA 4 VFD20460 VFD Assembly 2 HP 460 V 3 Input VFD20460N4 YVFD Assembly 2 HP 460 V 3 Input
9. Top Gasket i and Disk Ra e Description Part Number Filter Housing 01326801 Filter and Gaskets 01312401 Clamp Filter Support 91905500 Wing Nut 92511601 4 10 cm Air Flex Duct box of eight 8 2 4 m sections 91409601 FIGURE 25 Air Supply Blower Support Outside Wall gt 5 12 5 cm Outlet Pipe Vent Bir Cap 97 screen ata tt LEE AEE Outside Air Supply 5 12 5 cm Blower Inlet Pipe Description Part Number Blower 90707501K 5 12 7 cm Vent Cap 90502302 6 15 cm Bird Screen 01397400 6 15 cm Band Clamp 91913703 45 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 26 Pressurized Outside Air Supply Wall Vent Cap or Bird Screen Outside Air Supply Power A 4 10 cm Outside Air Flex Duct _ VN 4 10 Clamp Take Off LN 214 Sheet Metal or PVC Description Part Number Filter Housing 01326801 4 10 cm Take Off 01324401 Blower 90707501K 5 12 7 cm Vent Cap 90502301 6 15 cm Bird Screen 01365400 6 15 cm Band Clamp 91913703 FIGURE 27 Non Pressurized Outside Air Supply Vent Cap or Bird Screen Outside Wall 1222222222 2777 6 1 8 Pressure Switch ap ak Nuts 7 16 11 1 mm Diameter Hole
10. 9 1 Pump Installation For complete pump installation including wiring and venting please refer to the EP 100 EP 200 or EP 300 Series Installation Operation and Service Manuals latest edition FIGURE 16 EP 200 Condensate Valve Assembly Description Part Number Condensate Valve Assembly 01327001 W 1 NPT threaded hole Use 1 34 reducer not supplied 9 BT CPVC between gt pump and condensate valve in accordance with local codes 6400000000006 OOO 36 0 9 m Minimum 3 4 female vertical drop between pump and condensate valve assembly Condensate Valve Assembly Y Must be connected to a drain system in accordance with local codes 35 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 9 1 1 Condensate Neutralization Tube optional If a condensate neutralization tube is specified to be used with the heating system follow the steps below to choose the proper condensate neutralization tube See Page 37 Figure 17 Step 1 Condensate flow gal h per 100 000 Btu h installed You will need to know the tailpipe length per flow unit and the total input Btu h on the heating system Please refer to the following chart to determine the condensate flow gal h per 100 000 Btu h installed Radiant Tube Tai
11. Combustion S gt mn 229 cm Description Part Number Tube 91409XXX Turnbuckle 91903201 Tube Reflector Hanger 03090100 maximum NOTE Tubing requires a downward slope of 1 2 13 mm per 20 6 m away from burner Tailpipe tubing requires a downward slope of 1 26 mm per 20 6 m away from burner 3 m Step 7 2 Coupling and Tube Assembly A Close coupling with tab Start slide bar coupling lock onto coupling Slide Bar Coupling Lock 3 8 cm lt lt 4 10 cm Wide Coupling x T C 24 Orient coupling so that the impact block is in the 2 00 or 10 00 o clock positions Tube D Tighten coupling to join tubes 22 Um Slide Bar Coupling Lock xe N Description Part Number Coupling 01329600 Slide Bar Coupling Lock 01329700 Tube 91409XXX 20 of 83 SECTION 7 HEATER INSTALLATION Step 72 1 Coupling and Tube Assembly Continued Tighten slide bar as shown below Drive slide bar until tight End of slide bar should be 7 within tolerance listed below Correct slide bar dimensions Incorrect slide bar position Repeat Step 72 A D until all tubes are assembled NOTE If coupling is not tight loss of vacuum can occur 7 3 Elbow Package Configuration Step 7 3 1 Elbow
12. 02537801 1P Vent Terminal Non Combustible Wall 91412800 Flexible Boot 4 10 cm 02718851 Drain Cap 4 10 cm 91412802 Flexible Boot 6 15 cm 02718852 Drain Cap 6 15 cm 91418200 Tube Adapter 6 15 2 cm dia x 4 10 cm dia 01327002 Condensate Neutralization Tube 200 91901300 Boot Clamp 4 10 cm 01327003 Condensate Neutralization Tube 600 91913703 Boot Clamp 6 15 cm 01327004 Condensate Neutralization Tube 1000 E0009356 Damper Coupling 6 15 cm 01327005 Condensate Neutralization Tube 2000 T0100320 Elbow 6 15 cm Aluminized 90 42 of 83 SECTION 10 OUTSIDE AIR SUPPLY A CAUTION Product Damage Hazard Do not use heater in area containing corrosive chemicals Refer to appropriate Material Safety Data Sheets MSDS Failure to follow these instructions can result in product damage The CRV Series system is approved for use with an outside air system Halogenated hydrocarbons or other corrosive chemicals in the air can be drawn into the equipment and seriously damage the system components Avoid the use of such chemical compounds near the air inlet to the heaters IMPORTANT If the building has a slight negative pressure or corrosive contaminants are present in the air an outside combustion air supply to the heater is required All joints and seams in the air supply system must be airtight Attach the filter housing to the burner assembly using the wing nut provided
13. 40 SECTION 10 Outside Air Supply 43 10 1 43 10 2 Non Pressurized sene 43 10 3 Outside Air Blower Internal Wiring 44 SECTION 11 Gas Piping SECTION 12 Control Methods 2 2744 12 1 ROBERTS GORDON System Control 12 2 ROBERTS GORDON ULTRAVAC 12 3 CORAYVAC Modulating Controls 12 4 SPST Transformer Relay Kit P N 90417600K 12 5 SPDT Transformer Relay P N 90436300 SECTION 13 Starting The 13 1 Checking the Gas Line 13 2 Checking the Electrical System 13 3 Starting the System 13 4 Setting the SECTION 14 Variable Frequency Drive Programming 14 1 VFD Parameter Settings For Use With Modulating Thermostats 14 2 Altering VFD Parameters SECTION 15 Commissioning The CORAYVAC Modulating System 15 1 Setting The CORAYVAC End Burner Vacuum 15 2 Adjusting the Variable Frequency Drive 15 3 Programming Of Variable Frequency Drive SECTION 16 Operat
14. 6 1 5 cm 20 5 1 cm for EP 300 Part Number Description Part Number Description 01330203 4 10 cm Aluminized 90502302 Vent Cap 6 15 cm Metalbestos 01330204 6 15 cm Aluminized 91409403 Tube Aluminized 4 10 cm dia 10 3 m 01331900 Damper Coupling 4 10 cm 91409420 Tube Aluminized 6 15 cm dia 10 3 m 01335801 Elbow 4 10 cm Aluminized 90 91412800 Flexible Boot 4 10 cm 02718851 Drain Cap 4 10 cm 91412801 4 Flexible Boot 1 2 1 3 cm 02718852 Drain Cap Assembly 6 15 cm 91412802 Flexible Boot 6 15 cm 01327002 Condensate Neutralization Tube 200 91901300 Boot Clamp 4 10 cm 01327003 Condensate Neutralization Tube 600 91913703 Boot Clamp 6 15 cm 01327004 Condensate Neutralization Tube 1000 E0009356 Damper Coupling 6 15 cm 01327005 Condensate Neutralization Tube 2000 70100320 6 15 cm Aluminized 90 90502300 Vent Cap 4 10 cm Metalbestos 39 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 9 3 Horizontal Venting 4 10 cm Pipe FIGURE 19 EP 100 Horizontal Venting Configurations 18 46 cm Minimum 40 102 cm Maximum 4 10 cm Single Wall Pipe 25 8 m and Elbows Maximum Approved Thimbles 4 4 10 cm and Clamp 18 46 cm kin 40 102 cm Maximum Pitch single wall pipe downward away from pump 1 4 6 mm for ev
15. BACnet connections allow integral peer to peer BACnet MS TP LAN network communications with configurable baud rates and can easily integrate with a building automation system MS TP Wiring Connect the A terminal in parallel with all other A terminals on the network and the B terminal in parallel with other B terminals Connect the shield of cable Belden cable 82760 or equivalent Connect the cable shield to a good earth ground at one end only SECTION 12 CONTROL METHODS 12 3 4 Cable Requirement Table 3 on Page 57 lists wiring types sizes and distances for modulating thermostat communication Power Requirement Programmable thermostats requires 24 volt AC power Table 3 Modulating Thermostat Cable Requirements Recommended Wire Size Minimum Wire Function Specification or Requirement Distance Maximum Digital Outputs 18 AWG 0 75 sq mm Standard thermostat wire 1000 ft 304 m Modulating Outputs 18 AWG 0 75 sq mm 1 pair 500 ft 152 m Outdoor Air Temperature Sensor 18 AWG 0 75 sq mm 1 pair 500 ft 152 m Remote Sensor 18 to 22 AWG Twisted pair wire 1000 ft 304 m 0 75 to 0 34 sq mm Power Wiring 18 to 14 AWG NEC Class II 140 F 60 C Limited by line loss effects on power 0 75 2 0 sq mm consumption LonWorks P N 90424104 only 18 AWG 1 pair Refer to E bus Wiring Guide 74 2865 0 75 sq mm nonshielded for maximum length and generic cable specifications
16. Description Part Number Reflector Support Package 03050010 Wire Form 91908004 Reflector Support Strap 03050000 Screw 8 x 3 4 94320812 U Clip Package 91107720 Reflector End Cap 027508XX 2 The overlap at the first and second reflector is a slip overlap Thereafter every third reflector joint is a slip overlap A slip 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 observed Tight Sheet Metal Screw Reflector Support Strap Reflector Reflector J Support Loose screws loosened 1 16 1 6 mm SES to allow slippage 3A Non Slip Overlap i Reflector Screws U Clip 2 Clips per Non slip Overlap inside a Hanger 24 of 83 Step 7 5 Burner Installation SECTION 7 HEATER INSTALLATION Description Part Number Bolt 94273914 Burner 0270XXXX Lock Washer 96411600 Gasket 01367800 End Vent 013676XX Combustion End E Vent gt a Chamber Combustion Chamber NOTE Install end vent at end combustion chamber position only 25 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 8 OPTIONAL HEATER ACCESSORIES AWARNING Cut Pinch Hazard Wear protective gear durin
17. Maintain clearances from vehicles parked below the heater 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 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 Hang heater in accordance to the minimum suspension requirements on Page 19 Figure 14 If the radiant tubes must pass through the building structure be sure that adequate sleeving and fire SECTION 3 CLEARANCES TO COMBUSTIBLES stop is installed to prevent scorching and or fire hazard AWARNING Fire Hazard Keep all flammable objects liquids and vapors the minimum required clearances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage 5 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL NOTE 1 All dimensions are from the sur
18. seoq peisi sjaued J011uoo BUOM JOJOW U S uo au seoq SOA 1OUu y yeysouway dn yenuew eu ur pue uo surejBeip Ajsadoid peyoeuuoo 1 51 pue apin6 88S peijddns jenuew pue uonejejsul uu ls s eui S Auedoud jeisouueu 120uu02 Kjesseoeu JI periddns pin6 pue uoneljejsur 75 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Troubleshooting Flow Chart 1 ye aNOCHO S LH390H 9 guos 45 51990 LOOHSATENOYL YNZOZZZ 00 d3 22 00 VNLOZZEL 001 3 sjenuew joued 041009 0 peysnes sjosues euJejul 10 Sjejsouueu1 1841 ens IYEN ponad eBund 1sod 2 e Jaye umop inus y sjenuey 01 suolnmonulsui 1 ejeudoudde 1 J 1 Jeued OU YM suJej
19. 10 1 Pressurized See Page 46 Figure 26 for a typical layout of a pressurized air supply system For pressurized outside air supplies the outside air blower motor has a pressure switch that must be used Wire this switch in series with the pump pressure switch When using an outside air blower with a ROBERTS GORDON System Control or ROBERTS GORDON ULTRAVAC control or relay transformer a separate load relay package is required Wire the control for the relay in parallel with the pump The outside air blower must have a separate 20 A 120 V power supply See Page 44 Figure 23 for outside air blower internal wiring requirements The outside air blower has an adjustable internal damper that should be wide open On smaller systems about 3 burners this damper might need to be closed up to half way if the pressure switch does not make 10 2 Non Pressurized For a non pressurized outside air supply a 4 O D SECTION 10 OUTSIDE AIR SUPPLY single wall pipe duct may be attached to the burner and end vent For length and duct sizing requirements see duct design rules in Figure 22 To prevent condensation insulate the outside air duct 43 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 22 Duct Sizing Outside Air System Design Requirements Blower Performance 90707501 K 112 Flow Units One outside air blower is required per each EP 100 or EP 200 series pump and two outside air blowers may
20. Control Side Panel Clearances to Combustibles Label Description Part Number Logo Label 91007901 Rating Plate Label 91010401 Clearances to Combustibles Label 91009101 Internal Ladder Diagram Label 91017301 Wiring Label 91017300 2 of 83 CohayVac ous SNLETEAROBERTSGORDON New York USA fret HealerjRadiateur aible ents Serato Feline rrr ln anneal pac Ft reno brett atq Ane tue aes coon ee eggs ahd rg miw Sua Fa rn Itech lest saron t cde Maru Dese aid Aparte NER Di ue eon e Ve la co m is ek es le M CAN SA0 as Prese eec Sa ect 3 575074 MEM 1 ire enr Pour utage on Pour Bet Sa uuu 0 Far aang drs dot Ara cet eo dpe es pm fans anons IHR ail Des cuf d trys bat amar ru esses Salma IBN lie le hd fy ds hos teat sexu deers te Rowton M m cil aig Puissance lectrique derni re dition Les Wed utilis s dans ies poulaillers Sis nsns ZDMG For etre Es feiern ete ade ZO n an lvl ee tenuate de 4 pour chaque 1000 305m au dessus du niveau de ia mer
21. Input for use with EP 303 10081203 Variable Frequency Drive 1 HP 460 V 3 O Input for use with EP 203 10081204 Variable Frequency Drive 2 HP 460 V 3 Input for use with EP 303 10081205 Relay 120 V 90429100 Fuse 10 A for 75 HP 230 V VFD 1 HP 460 V VFD and 2 HP 460 V VFD 91321410 Fuse 25 A for 1 HP 120 V VFD and 2 HP 230 V VFD 91321425 Grounding Block 91321300 Fuse Holder 91321400 Rotary Disconnect Base Block 91321550 Rotary Disconnect Handle not shown 91321551 Rotary Disconnect Rod not shown 91321552 79 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 18 2 Replacement Parts Instructions A DANGER Electrical Shock Hazard Disconnect electric before service Controller must be properly grounded to an electrical source Failure to follow these instructions can result in death or electrical shock 18 2 1 Variable Frequency Drive VFD To replace the Variable Frequency Drive turn off all power to the drive assembly at the breaker or discon nect switch Turn off the 24 V power switch on the relay board Turn off 120 V power to the relay board inside the ROBERTS GORDON ULTRAVAC Con troller or the modulating thermostat Mark all wires connected to the VFD noting the ter minals that they are secured to Remove all wires from the VFD terminals Remove the VFD from its mounting plate by remov ing the four securing screws Verify that the input voltage noted on the rating plat
22. MS TP P N 90425109 18 AWG 0 75 sq mm Shield Belden cable 82760 or equivalent Refer to Thermostat Installation Guide 12 3 5 Sequence of Operation Depending on the space temperature the thermostat will control the heat output based on demand signal communicated from the thermostat program The thermostat will close contact on the transformer relay P N 90417600K The VFD run command is energized by the transformer relay When the VFD energizes the pump and the vacuum has been established the pressure switch will close and energize the burners At high heat a demand signal will turn the pump speed to a maximum frequency and burner s ON at maximum firing rate As the space temperature gets closer to the set point the thermostat program will slow the pump speed and burner s firing rate down until the room temperature reaches the thermostat set point NOTE To obtain Analog 0 10VDC signal connect as shown on Page 61 Figure 39 and set standard speed source parameter 05 inside VFD menu to 03 12 3 6 Analog Signal An Analog Signal 2 10 Vdc with 500 ohm resistor or 4 20 mA output from a modulating thermostat controls the ROBERTS GORDON VFD The VFD supplies a variable frequency output signal to the pump that will vary based on the signal from the modulating thermostat The ROBERTS GORDON CORAYVAC with modulating thermostat wiring diagram is shown on Page 59 Figure 37 When the temperature falls below the set
23. NO 00 so Jayem Bupjeo ueijs s eui s 99 Bel polno l ay def isnipy eui eoejdeu 10 sieuinq pejoeye uo eu 12edsu Knu niiuu lui 1n0390 eui oq ool sl 8 L deb ainpow eoejdeg p uo S A 76 of 83 SECTION 18 REPLACEMENT PARTS SECTION 18 REPLACEMENT PARTS ADANGER A WARNING Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide Hazard Use only genuine ROBERTS GORDON replacement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage 77 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Gasket Burner to Mixing Chamber Burner Head Mixing Chamber Ignition Module Ignition Cable Electrode Electrode Gasket Combustion Gas Valve Chamber Gasket Transformer Regulator Description Gas Valve All Burners Gasket Burner to Mixing Chamber Burner Head Assembly Replacement Package includes electrode and gasket installed Mixing Chamber Transformer Regulator Replacement Kit Gasket Combustion Chamber Electrode Replacement Kit includes electro
24. New York 14240 0044 Telephone 1 716 852 4400 Fax 1 716 852 0854 Toll Free 800 828 7450 WWW rg inc com www corayvac com www robertsgordon com www radiantheaters com Roberts Gordon LLC s liability and your exclusive remedy under this warranty or any implied warranty including the implied warranties of merchantability and fitness for a particular purpose is limited to providing replacement parts during the term of this warranty Some jurisdictions do not allow limitations on how long an implied warranty lasts so this limitation may not apply to you There are no rights warranties or conditions expressed or implied statutory or otherwise other than those contained in this warranty Roberts Gordon LLC shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for the ROBERTS GORDON CORAYVAC Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction Roberts Gordon LLC shall not be responsible for failure to perform under the terms of this warranty if caused by circumstances out of its control including but not limited to war fire flood strike government or court orders acts of God terrorism unavailability of supplies part
25. 10 26 cm 14 87 cm 01370416 16 40 cm 32 of 83 SECTION 8 OPTIONAL HEATER ACCESSORIES 8 7 Protective Grille Installation Step 8 7 1 Silicone Cap Installation o Agile AW 2 8g d s S AJM SS 5 in 4 WV NS 1 5262 W IE I ojo 2 8 iM 555 ru V A X N YA m 5 8 5 y UN D 4 c NN c p 9 2 215 o 5 5 E EN gt AM 7 Cir S NA 2 WA ANM T SMAA A 5 N N N 33 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 8 Classic Cast Iron Components AWARNING Severe Injury Hazard Hang heater with materials with a minimum working load of 750 Ibs 340 kg Use special tube and reflector hangers when suspending the schedule 40 steel pipe system Schedule 40 steel pipe is heavy and will fall if not supported properly Distance between supports must be 7 2 13 m or less Failure to follow these instructions can result in death injury or property damage Turnbuckle Hang cast iron combustion chamber with a turnbuckle Special Tube and Reflector Hanger Q spring clips will not fit around cast iron hanging loop CoRayVac VT T 2 13 m Maximum gt End Vent
26. 10081520 Refer to thermostat installation instructions for wiring 12 3 2 Analog Signal Modulating Thermostat with LonWorks Communication If LonWorks communication is required a modulating thermostat can be installed to supply an analog 4 20 mA or 2 10 Vdc signal to control the pump speed For thermostat wiring See Page 59 Figure 37 and Page 60 Figure 38 An optional room sensor P N 10081520 and outdoor air sensors P N 10081521 are available for this thermostat as well The modulating thermostat with LonWorks provides networking capability in a LonWorks system With communications port running at 78 kilobits per second kbs this thermostat can be configured to perform a variety of activities in which data is sent or received via LonWorks Information that can be shared viewed and modified with the network includes Current year month day hour minute second System Mode Space Temperature Outdoor air temperature Current setpoint Occupied Unoccupied schedule commands Space Temperature 50 of 83 12 3 3 Analog signal Modulating with BACnet Programmable Thermostat If BACnet communication is required a BACnet enabled modulating thermostat can be installed to supply an analog output 0 10VDC signal control to dictate the speed of the pump For thermostat wiring See Page 61 Figure 39 This thermostat is a flexible wall mounted stand alone control with combined controller sensor
27. 171 2 44 Telephone 44 0 121 506 7700 elephone 1 716 852 4400 Fax 44 0 121 506 7701 Fax 1 716 852 0854 Toll Free 800 828 7450 Installation Code and Annual Inspections All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts Gordon and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and safety Roberts Gordon recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform service where necessary using only replacement parts sold and supplied by Roberts Gordon Further Information Applications engineering and detailed guidance on systems design installation and equipment performance is available through ROBERTS GORDONS representatives Please contact us for any further information you may require including the Installation Operation and Service Manual This product is not for residential use 2012 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 w
28. 30 One Zone Operation without Control Panel optional Description SPST Transformer Relay Part Number 90417600K Thermostat Pressure Switch SPST 12A Transformer Relay Zone 1 Burners Nine Burners Maximum 53 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 31 One Zone Operation with Outside Air Blower without Control Panel optional SPST 12 A Transformer Thermostat Outside Air Ground Blower Pressure Switch Outside Air Blower Pressure Zone 1 Switch Burners Nine Burners Maximum 54 of 83 SECTION 12 CONTROL METHODS FIGURE 32 Two Zone Operation without Control Panel optional Zone 1 Thermostat GROUND N Description Part Number SPDT Transformer Relay 90436300 SPDT 12 A SPDT 12 A Transformer Transformer Relay Relay oF lt i Zone 2 Thermostat Zone 1 Zone 2 Pump Motor Burners Burners Nine Burners Total Pressure Maximum Between Zones Switch 55 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 33 General System Wiring Burner Receptacles Pressure switch located at ee ee E EE 4 Zone Max outside air blower optional Pressure S cl Switch Pressure L
29. 5 12 7 cm dia 10 3 m 01327004 Condensate Neutralization Tube 1000 Not Supplied Tube Adapter 5 12 7 cm dia x 4 10 cm dia 01327005 Condensate Neutralization Tube 2000 Not Supplied Tube Adapter 6 15 2 cm dia x 5 12 7 cm dia 90502100 Vent Terminal 4 10 cm Combustible Wall 41 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 21 EP 300 Series Horizontal Venting Configurations 10 3 Maximum 1 Elbow 18 46 cm Minimum 40 102 cm Maximum 1 1 Single Wall Pipe Tube 6 15 Pitch single wall pipe downward away from pump 1 4 6 mm for every 10 3 m Approved Thimble 6 15 cm Bird Screen Included 6 15 cm Band Clamp Vent Terminal Tjernlund VH1 m 6 15 cm or Equivalent 2 Not Included Part Number Description Part Number Description 01330203 Tee 4 10 cm Aluminized 90502100 Vent Terminal 4 10 cm Combustible Wall 01330204 Tee 6 15 cm Aluminized 90502101 Vent Terminal 6 15 cm Combustible Wall 01331900 Damper Coupling 4 10 cm 90502302 Vent Cap 6 15 cm Metalbestos 01335801 Elbow 4 10 cm Aluminized 90 91409403 Tube Aluminized 4 10 cm dia 10 3 m 01397400 Bird Screen 6 15 cm 91409420 Tube Aluminized 6 15 cm dia 10 3 m
30. 60 Hz For 115 V and 230 V input For 460 V input VFD Models VFD Models NOTES 1 For 2 10 VDC Speed Control Set standard speed source parameter 05 to 03 2 See VFD rating plate for required input A 120 V 1 60 Hz supply for 120 V VFD model B 230 V 1 60 Hz Supply for 230 V VFD model 3 Ground only one end of the shielded cable m 4 Control Wire lo be a minimum of 20 AWG type Beldon 5401 FE CMR 75 C shielded or equivalent Description Part Number 5 Wire over 24 VAC to be a minimum of 16 AWG flexing type MTW 105 C 600 V or equivalent SPST Transformer Relay 90417600K A 120 VAC colors Phase Red Neutral White Ground Green B 24 VAC colors Blue Thermostat Modulating LonWorks 90425104 6 All three power wires from terminals U V and W to the pump motor must be kept tightly bundled and run in a separate conduit away from all other power and control wiring mee Thermostat Modulating 90425105 7 For Non communicating thermostats without LonWorks bus thermostat terminals marked EB Sensor Remote Modulating 10081520 will be marked _ _ and no LonWorks bus communication wires are used Sensor Outdoor Modulating 10081521 59 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 38 CORAYVAC Modulating Wiring Diagram LonWorks 4 20 mA optional i TR21 Remote Outdoor FC See Note Sensor Sensor optional optional e Modulating Thermo
31. 65 Figure 42 Normal end vent vacuum should be set at approximately 2 5 wc to 3 0 wc hot Vacuum adjustments are made by means of the damper in the pump inlet and the adjustable damper coupling s in the system Check the vacuum at all end vents and then adjust the damper coupling to obtain equal vacuum readings of 2 5 wc to 3 0 wc If end vent vacuum exceeds 3 0 wc adjust the pump inlet damper until vacuum readings are 2 5 wc to 3 0 wc With systems designed to operate at maximum vacuum it may not be possible to obtain vacuum differential readings at or slightly above 2 5 wc If so adjust the damper couplings to maximum but equal vacuum reading Be sure to lock all dampers securely after adjustment 3 Reset temperature setpoints to desired room temperature 4 f heat is not required turn off main switch and close the main gas valve 64 of 83 SECTION 13 STARTING THE SYSTEM FIGURE 42 Vacuum Reading Combustion Chamber at end position Insert tubing about 6 15 cm Manometer N 6 5 4 3 2 1 0 1 2 3 4 5 6 g Approximate reading after adjusting damper couplings and pump inlet 2 5 3 0 wc 65 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 14 VARIABLE FREQUENCY DRIVE PROGRAMMING 14 1 VFD Parameter Settings For Use With Modulating Thermostats The VFD parameters come with factory default set tings The following parameter settings mu
32. Description Part Number Less than 2 Condensate Neutralization Tube 200 01327002 Less than 6 Condensate Neutralization Tube 600 01327003 Less than 10 Condensate Neutralization Tube 1000 01327004 Less than 20 Condensate Neutralization Tube 2000 01327005 1 NPT threaded hole Use 1 x 34 reducer not supplied CPVC between pump SO condensate ge valve 9 accordance with local codes Condensate Neutralization Tube 2 Condensate Valve Assembly 9 2 General Venting Requirements Model EP 100 EP 200 and EP 300 Series Pumps This heater must be vented in accordance with the rules contained in this manual and with the following OOOOGJSZ7OOOOOOOOOO9 36 0 9 Minimum vertical drop between pump and condensate valve assembly Y national codes and any state provincial or local codes which may apply United States Refer to National Fuel Gas Code NFPA 54 ANSI Z223 1 latest revision Canada Refer to Natural Gas and Propane Installation Code CSA B149 1 latest revision Any portion of vent pipe passing through a combustible wall must have an approved thimble to conform with the above listed codes Vent pipe must be sloped downward away from the pump 14 every 10 3 m The bottom of the vent or air intake terminal shall not be located les
33. Description Part Number Pressure Switch Kit 90434501 4 10 cm Bird Screen 01365400 4 10 cm Vent Cap 90502300 6 15 cm Vent Cap 90502302 46 of 83 SECTION 11 GAs PIPING SECTION 11 GAS PIPING There is an expansion of the tube with each firing A WAR N G cycle This will cause the burner to move with respect to the gas hose This can cause a gas leak resulting in an unsafe condition if the gas connection is not made in strict accordance with Figure 28 Meter and service must be large enough to handle all the burners being installed plus any other connected load The gas hose which feeds the system must be Fire Hazard large enough to supply the required gas with a maximum pressure drop of 1 2 wc When gas piping Tighten gas hose fittings to connect gas is not included in the layout drawing the local gas supply according to Figure 28 supplier will usually help in planning the gas piping Gas lines must meet applicable codes United States The Flexible Stainless Steel Gas Hose US models supplied with the heater is certi fied per the Standard for Connectors for Gas Appli Use only 36 91 cm long connector of 1 2 ances ANSI 221 24 6 10 latest revision Gas hose can crack when twisted Gas hose moves during normal operation 3 4 nominal ID Canada The Rubber Type 1 Gas Hose Canadian models optional with the heater is certified as being Connector supplied with heater for U S in com
34. GORDON ULTRAVAC Controller 10080142 Modem Chip Part No Description Tubing and Related Accessories 01312700 4 10 cm Plain 01312706 6 15 cm Plain 01312701 Coupling 4 10 cm Lined 01331900 4 10 cm Damper E0009356 6 15 cm Damper 0133022D Tee 4 10 cm Coated 01330203 Tee 4 10 cm Aluminized 01330204 Tee 6 15 cm Aluminized 0133092D 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 Hot Rolled Steel 4 10 cm dia 10 3 m 91409403 Tube Non Heat Treated Aluminized 4 10 cm dia 10 3 m 91409408 Heat Treated Aluminized 4 10 cm dia 10 3 m 91409420 Non Heat Treated Aluminized 6 15 cm dia 10 3 m 9141030D Tube Coated 4 10 cm dia 10 3 m E0009105 Tube Heat Treated Aluminized 6 15 cm dia 10 3 m 10080450 10081501 Comms Equalization Cable Outdoor Sensor 10080410 PC Connection Cable Package 13 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL ROBERTS GORDON ULTRAVAC Central Controller with RS 485 Converter amp Software Includes Description
35. Injury or property damage blessures ou le dommage mat riel CORRECT POSITIONS POSITION EXACT h oe nut in se Shu Ot ert be pero barner etal Robinet Sous tne he rcs Mere p AWARNING Esto equipo sus accesorios y los productos equip y los derivados de su op contienen produ Heater Movement deppar de Mouvement d apparat de otros da os r ete Pinte in U S A Impreso en EEUU 2009 Robert Gordon LLC Printed inthe US Almpen aux Etats Unis PIN 91018125 Proposition 65 Label Gas Connection Label A WARNING Improper installation adjustment alteration service or maintenance will result in death injury or property damage Read the Installation Operation and Service Manual thoroughly before installing or servicing this equipment This appliance can be installed in variable configurations as specified in the installation instructions provided This unit is convertible for alternate gases Propane or Natural gas see your factory representative for details TO SHUT OFF HEATER TO START HEATER 1 Set thermostat to the lowest 1 Turn gas valve and electric setting power OFF and wait five 2 Turn OFF electric power to minutes for unburned gases to heater vent from heater 3 Turn OFF manual gas valve 2 ON main
36. Installation Tube OS Pa Coupling LN Minimum Distance Required Between Burner and Elbow 90 Elbow Model Minimum Distance CRVB 2 5 1 5 m Description Part Number CRVB 4 5 1 5 m Elbow Package 02718702 CRVB 6 10 3 m 90 Elbow 01335801 CRVB 8 10 3m Coupling 01312700 CRVB 9 10 3 m Reflector End Cap 02750800 CRVB 10 15 4 5 m Reflector Joint Piece 02750900 CRVB 12A 15 4 5 m U Clip Package 91107720 CRVB 12 15 4 5 m Step 7 3 2 Elbow Installation XJ Ly AA Coupling 21 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 7 4 Reflector Installation A WARNING Fire Hazard Support reflector with reflector hanger and support strap Reflector must not touch tube Failure to follow these instructions can result in death injury or property damage Step 7 4 1 Reflector Installation with Hole Reflector with Hole Slide Reflector with hole SS through hanger Unhook combustion chamber from chain and insert through hole Reconnect chain Description Part Number Tube Reflector Hanger 03090100 Tube 91409XXX Reflector with Hole 02750304 22 of 83 SECTION 7 HEATER INSTALLATION Step 7 4 2 Reflector Installation Wire Form Reflector Sheet Metal Screw m Reflec
37. L ab Pump Motor E 115 Vac Operation Ss 230 Vac Operation separate power circuit dl required for EP 203 or E T EP 300 series pumps Thermostats LI Motor Starter i O Pump 2 Outside Air Blower 120 V 10 OD O aM a ooo 60 2 Dotted Line Optional L o o lt NI 120 Vac Maximum 20 Amps Total EP 100 or EP 100 or TWO PUMP SYSTEM optional EP 201 Pump All burners must be EP 201 Pump Pump 1 may be used for all zones connected to Ground Pump 2 may be used to control Not shown zone 3 and or zone 4 Refer to Pump 1 for 2 1 2 2 2 20 4 connguranon Low voltage thermostats 99 99 99 99 Pressure located in heated zone pressure i switch switch located at Zone Zone Zone Zone located at Pump 1 2 3 4 i Pump2 120 V UNE prec on proto roc on ooro 120V 10 x 10 60 2 ae ae e EIS 60 Hz 124 a e e mE 252 9 lt lt I lt 1122 m x Ground G N L N L NL NL NL NL NL POWER PUMP 1 21 22 23 Z4 PUMP 2 e e S
38. NEMA 4 ULTRAVAC Accessories 10080142 Modem Plug In Chip 10080410 Cable Package PC Connection 10080430 RS 485 Converter with Power Supply 10080440 TCP IP Communication Module 10081500 Adjustable Indoor Deg F ROBERTS GORDON ULTRAVAC Controller 10081501 Sensor Outdoor ULTRAVAC 10081502 Sensor Adjustable Indoor Deg C ULTRAVAC 90602450 Voltage Surge Suppressor 277 480 V 90602451 Voltage Surge Suppressor 120 V 90602452 Voltage Surge Suppressor 120 240 V 1 60 Hz 90602460 Line Reactor 480 V 3 0 60 Hz w Enclosure Output 90602461 Line Reactor 230 V 3 60 Hz 75 HP Output 90602462 Line Reactor 230 V 3 0 60 Hz 2 HP Output 90602470 Line Reactor 480 V 3 0 60 Hz 4 A w Enclosure Input Part No Description Thermostats 05023000 Load Relay Package 90417600K Transformer Relay SPST 12 A 90436300 Transformer Relay SPDT 12 14 of 83 90423000 24 Low Voltage Thermostat Marked 1 5 90424300 Thermostat Guard Part No Description 90425104 Thermostat Modulating LonWorks 90425105 Thermostat Modulating 90425109 Thermostat Modulating BACnet 90429107 Thermostat On Off BACnet 10081520 Sensor Remote Modulating 10081521 Sensor Outdoor Modulating Part No Description Deco Grille 2 x 4 6 m x 1 2 01365900 Shield Frame 01370408 Reflector Side Extension 8 x 48 20 3 cm x 122 cm 01370412 Reflector Side Extension 12 x 48 30 5 cm x 122 cm 01370416
39. Reflector Side Extension 16 x 48 40 6 122 cm 91407000 Grille Aluminum 2 x 4 6 m x 1 2 m Part No Description Protective Grille 08050001 Protective Grille 40 1 08050002 Protective Grille End Cap Part No Description Shields 02750303 Barrier Shield 02751801 Universal Shield 02751855 Universal Shield Stainless Steel 02751800 Universal Shield with Holes Part No Description Pump Packages and Accessories 02719105 100 Pump Package 02719100 EP 100 Pump 02724700 Accessory Package 02716305 201 Pump Package 01312001 EP 201 Pump 01317805 Accessory Package 02712034 EP 203 Pump Package 01312002 EP 203 Pump 01317805 Accessory Package 02723014 EP 301 Pump Package 4 02730101 EP 301 Pump Assembly 02730104 Accessory Package 02723016 EP 301 Pump Package 6 02730101 EP 301 Pump Assembly 02730106 Accessory Package 02723034 EP 303 Pump Package 4 02730103 EP 303 Pump Assembly 02730104 Accessory Package 02723036 EP 303 Pump Package 6 02730103 EP 303 Pump Assembly 02730106 Accessory Package Part No Description Pump Accessories 90430600K Pressure Switch 01327001 Condensate Check Valve Assembly 02718851 Drain Cap 4 10 cm 02718852 Drain Cap 6 15 cm 01327002 Condensate Neutralization Tube 200 01327003 Condensate Neutralization Tube 600 01327004 Condensate Neutralization Tube 1000 01327005 Condensate Neutralization Tube 2000 0132700
40. Two Zone Operation without Control Panel optional ete eun 55 General System Wiring 56 External Wiring Diagram EP 100 and EP 201 120 V 1 56 External Wiring Diagram EP 100 EP 201 or EP 301 230 V 1 Pump optional 57 External Wiring Diagram EP 203 or EP 303 208 230 V 460 V Pump optional 58 CORAYVAC Modulating Wiring Diagram LonWorks 2 10 Vdc with 500 ohm resistor 25 ritenere Ve Rind 59 CORAYVAC Modulating Wiring Diagram LonWorks 4 20 mA optional 60 Figure 39 CORAYVAC Modulating with BACnet Wiring Diagram 61 Figure 40 Burner Internal Wiring 62 Figure 41 Burner Internal Ladder Diagram 62 Figure 42 Vacuum Reading serene 65 Figure 43 Possible Damper Couplings Locations 70 Figure 44 Variable Frequency Drive Components Diagram 79 LIST OF TABLES Table 1 Contents of CRV Series Burner Carton 13 Table 2 Common CRV Series Components 13 Table 3 Modulating Thermostat Cable Requirements 51 SECTION 1 HEATER SAFETY Your Safety is Important to Us This symbol is used throughout the manual to notify you
41. be required for each EP 300 series pump Outside air blowers cannot be shared between two separate CRV Series systems Duct Design Rules System should be designed so that the blower is positioned closest to the highest flow requirements end vents When a duct is carrying more than 40 flow units it must be at least 6 15 cm diameter Pressurized Systems 6 15 cm diameter duct must not exceed 120 36 m total per system 4 10 cm diameter duct must not exceed 120 36 m per radiant branch Non Pressurized 6 15 cm diameter duct must not exceed 90 27 m maximum 100 flow units 4 10 cm diameter duct must not exceed 90 27 m Elbows are equivalent to 10 3 m of duct length 10 3 Outside Air Blower Internal Wiring FIGURE 23 Outside Air Blower Internal Wiring Diagram The outside air blower is shipped with the blower manufacturer s standard internal wiring For use with ROBERTS GORDON heaters the outside air blower must be rewired with existing wires by the electrical contractor See diagram NOTE The internal 24 V relay provided will not be used and can be discarded BLOWER PRESSURE SWITCH C NO MOTOR BLK BLU BLU WHT L N M T1 T2 TS e v v Y Y 44 of 83 SECTION 10 OUTSIDE AIR SUPPLY FIGURE 24 Filter Housing Assembly Door Control Housing Filter Support Bottom Gasket
42. before service Failure to follow these instructions can result in death injury or property damage There are several methods of controlling CRV Series systems The options are as follows 12 1 ROBERTS GORDON System Control The System Control is an electronic control panel designed to control CRV Series heating systems The System Control wiring is shown on Page 56 Figure 33 through Page 58 Figure 36 and in the System Control Installation Manual P N 10091601 NA The System Control can be used to control an EP 100 or EP 201 pump from the control panel Other pumps such as the EP 301 and 3 models may be controlled in conjunction with a relay or motor starter The System Control can control up to four zones of burners and up to two vacuum pumps The electrical circuit is a 120 Vac 20 A supply The output for the thermostat is 24 Vac A System Control operated system has two minutes post purge pump operation to completely exhaust products of combustion from the system A system SECTION 12 CONTROL METHODS control provides indication of power to the pump and zones and indicates the status of the pressure switch with lights The System Control is ETL listed in accordance with UL873 Standard for Temperature Indicating and Regulating Equipment 12 2 ROBERTS GORDON ULTRAVAC The ROBERTS GORDON ULTRAVAC is a micro processor based control package designed for modulating control of CRV Series heaters bas
43. crosses 2 Clearances B C and D can be reduced by 50 after 25 7 5 m of tubing downstream from where the combustion chamber and the tube connect FIGURE 9 2 FOOT DECO GRILLE inches centimeters Model A B D A B D CRV B 2 4 12 48 12 11 31 122 31 CRV B 4 4 12 48 12 11 31 122 31 CRV B 6 4 12 48 12 11 31 122 31 CRV B 8 4 12 48 12 11 31 122 31 CRV B 9 4 18 56 18 11 46 143 46 CRV B 10 4 18 56 18 11 46 143 46 CRV B 12 4 18 56 18 11 46 143 46 CRV B 12A 4 18 56 18 11 46 143 46 FIGURE 10 BARRIER SHIELD inches centimeters Model A B D A B D CRV B 2 4 12 12 12 11 31 31 31 CRV B 4 4 12 12 12 11 31 31 31 CRV B 6 4 12 12 12 11 31 31 31 CRV B 8 4 12 12 12 11 31 31 31 CRV B 9 UNAPPROVED UNAPPROVED CRV B 10 UNAPPROVED UNAPPROVED CRV B 12 UNAPPROVED UNAPPROVED CRV B 12A UNAPPROVED UNAPPROVED FIGURE 11 PROTECTIVE GRILLE inches centimeters Model A B D A B D CRV B 2 4 20 48 20 11 51 122 51 CRV B 4 4 20 48 20 11 51 122 51 CRV B 6 4 20 48 20 11 51 122 51 CRV B 8 4 20 48 20 11 51 122 51 CRV B 9 4 36 60 36 11 92 153 92 CRV B 10 4 36 60 36 11 92 153 92 CRV B 12 4 36 60 36 11 92 153 92 CRV B 12A 4 36 60 36 11 92 153 92 8 of 83 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 appea
44. notches for supports and hangers Retainer Clip 2 per Side Reflector Side Extension 29 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 8 4 Universal Shield Universal shields are adjustable aluminum reflectors whose angle and height can be adjusted to direct heat to or away from a desired area See Page 7 Figure 6 through Page 7 Figure 8 for positions Standard Reflector Flattened Tube and Reflector S tA bly Section ube and Reflector Support Assembly Stud 7 Shield Support Bracket Description Part Number Bracket Assembly m Universal Shield 02751801 ex Nut Universal Shield with Holes 02751800 Universal Shield Support Package 02712100 Tube and Reflector Support Assembly 01329802 Universal Shield Support 02751700 Shield Bracket Assembly 02721400 TER TT Gnd T nozanann _ nciudea in universal snie 9214800 support package 8 5 Barrier Shield Do not install barrier shield less than 20 6 m downstream of any burner Do not attach end caps to the ends of the barrier shields For lengths greater than 8 2 6 m use universal shields Do not use barrier shields for burner sizes larger than 80 000 Btu h Tube and Reflector Hanger Flatten Reflector Edges Reflector Support Strap Attach U Clips Cut Relief Notch Barrier Shield Description Part Number Barrier
45. 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 Protective gear is to be worn during installation operation and service Thin sheet metal parts the aluminum reflector portion of the heater 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 This heater must be applied and operated under the general concepts of reasonable use and installed using best building practices This appliance is not intended for use by persons including children with reduced physical sensory or mental ca
46. or ROBERTS GORDON ULTRAVAC the pump will continue operation for a post purge period of two minutes 4 If no flame is detected the module will close and a purge period begins If a flame is not established a second purge and warm up will take place and then a third trial cycle will begin After three trials the module will lockout for one hour or until reset 5 A reset is accomplished by removing power from the module for at least 5 seconds thermostat cycle is required or automatically after 1 hour 16 2 To Shut Off Heater Set thermostat to lowest setting Turn OFF electric power to heater Turn OFF manual gas valve in the heater supply line 16 3 To Start Heater Turn gas valve and electric power OFF and wait five minutes for unburned gases to vent from heater Turn ON main gas valve Turn ON electric power Set thermostat to desired temperature Burner should light automatically 16 4 Pre Season Maintenance and Annual Inspection To ensure your safety and years of trouble free operation of the heating system service and annual inspections must be done by a contractor qualified in the installation and service of gas fired heating equipment Turn off gas and electric supplies before performing service or maintenance Allow heater to cool before servicing Before every heating season a contractor qualified in the installation and service of gas fired heating equipment must perform a thorough safety 7
47. remove the inlet plate Check the shaft seal and replace it if worn or missing With the Power off Check the inlet and outlet of the pump for blockage or excessive soot and clean as necessary Check boots for cracking or deterioration and replace if necessary If a condensate trap is installed check the condition of the trap and the drain line attached Note the condensate trap should be filled with water at the beginning of each heating season Check the condition of the motor mounts Lift the motor from the rear look for breaks in the rubber and replace if necessary Check the condition and operation of the pressure switch If wall tag is present make sure it is legible and accurate Please contact Roberts Gordon LLC or your ROBERTS GORDON independent distributor if you need a wall tag See Page 4 Section 2 1 Safety Labels Product safety signs or labels should be replaced by the product user when they are no longer legible Please contact Roberts Gordon LLC or your ROB ERTS GORDON independent distributor to obtain replacement signs or labels See Page 2 Figure 1 through Page 3 Figure 2 73 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 17 TROUBLESHOOTING A DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from heater Heater must be properly grounded Failure to follow these instructio
48. 1 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL inspection of the heater For best performance the gas electrical thermostat connections tubing venting suspensions and overall heater condition should be thoroughly inspected NOTE Gas flow and burner ignition are among the first things that should be inspected Please see Page 72 Section 16 5 for suggested items to inspect 16 5 Maintenance Checklist Installation Code and Annual Inspections All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts Gordon LLC and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and safety Roberts Gordon LLC recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform service where necessary using only replacement parts sold and supplied by Roberts Gordon LLC The Vicinity of the Heater Do not store or use flammable objects liquids or vapors near the heating sys tem Immediately remove these items if they are present See Page 5 Section 3 Vehicles and Other Objects Maintain the clearances to combustibles Do not hang anything from or pl
49. 51 uoniuBi sepoo 131 pue uo 437 42949 sieuinq Sspuooes 28511 pued 101 U09 Spu3 SOA Aq eouenbes uous uoniuBi y seoq uay spuooes OL yem y 6nidun aybi eui op poued efund aid spuooes 29002 eui jewod 3194 51 SOA Jeued puo Jadoid 10 Y29949 SJauing eui oi pue jeuung eui eunsseid 1edoud S ye A a194 S SOK SOA eoe deu p lie ul SI JeUJnq au eins exei aunq y Buum y99uS 108105 Ajaouy uan ON 100w s oq iolouu y 12euuoosiq Ajddns jaued uo esnj Jo pue 1exeeJq y99uO p onnsqo Jejeduui y 51 10 joued 5 amp 04 U09 99 A 021 4amod S Jase 10 91 01 YMS Aew 1 uo
50. 7 Refill Condensate Neutralization Tube 600 01327008 Refill Condensate Neutralization Tube 1000 01327009 Refill Condensate Neutralization Tube 2000 Part No Description Contactors 10050011 Contactor 120 Vac for EP 203 EP 303 3 0 EP 100 EP 201 208 230 V 1 EP 301 208 230 V 1 10050012 Contactor 120 for EP 301 120 V 1 SECTION 5 MAJOR COMPONENTS 15 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 6 DESIGN REQUIREMENTS The CRV Series system s design is related to the system operation and performance required by the building being heated Every effort should be made to follow the dimensions on the layout drawing If deviations are necessary either contact the company responsible for the layout design your ROBERTS GORDON independent distributor or consult the CRV Series Design Manual P N 127500NA 16 of 83 SECTION 6 DESIGN REQUIREMENTS lew Heater Assembly Overvi FIGURE 13 slle p JO uomejejsur 49 041u09 eyeudo4dde y ees 1ueuudinbe euonippe pue siosu s euoz seJibei OVAVHLIN sSNOQHOO S1H380H sieisouueu S ND uu ls S S rejop JO 5 pue uoneJedo uonejeisu sJe ouoo eyeudoudde y ul pue eq jou uoddng JojoeyeH 4 IE SoUlJ8U 10 JOSUBS BUOZ S
51. 8 Combustion Chamber Window Make sure it is clean and free of cracks or holes Clean or replace as required Blower Scroll Wheel and Motor Compressed air or a vacuum cleaner may be used to clean dust and dirt Burner Head and Orifice Clear of obstructions Even spider webs will cause problems Carefully remove any dust and debris from the burner Electrode Replace if there are cracked ceramics excessive carbon residue or erosion of the electrode The electrode gap should be 1 8 3 mm Thermostat or Sensor There should be no exposed wire or damage to the thermostat or sensor See Page 49 Section 12 Suspension Points Make sure the heater is hanging securely Look for signs of wear on the chain or ceiling See Page 19 Figure 14 Filter Check for dirt or dust Clean or replace as required Decorative and Protective Grille optional The grille must be securely attached Check that side reflector extensions are installed correctly and secured in place if necessary Decorative grille only See Page 31 Section 8 6 1 through Page 33 Section 8 73 Make sure shield is installed correctly and secured in place if necessary Decorative grille only See Page 31 Section 8 6 2 Pump Wall Tag With pump operating check for excessive vibration or noise Vibration is usu ally a sign that the impeller is out of balance Turn off the system insure power is shut off and
52. FOR YOUR SAFETY If you smell gas Open windows DO NOT try to light any appliance DO NOT use electrical switches DO NOT use any telephone in your building Extinguish any open flame Leave the building Immediately call your local gas supplier after leaving the building Follow the gas supplier s instructions If you cannot reach your gas supplier call the Fire Department A WARNING Fire Hazard Keep all flammable objects liquids and vapors the minimum required clear ances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage WARNING Improper installation adjustment alteration service or maintenance can result in death injury or property damage Read the Installation Operation and Service Manual thoroughly before installing or servicing this equipment Installation must be done by a contractor qualified in the installation and service of gas fired heating equipment or your gas supplier 2012 Roberts Gordon LLC SS BERTS GORDON RX Y Custom Engineered Low Intensity Infrared Heating Systems Installation Operation amp Service Manual CRV B 2 CRV B 4 CRV B 6 CRV B 8 CRV B 9 CRV B 10 CRV B 12 CRV B 12A Installer Please take the time to read and understand these instructions prior to any installation Inst
53. ISSIONING THE CORAYVAC MODULATING SYSTEM NOTE Before starting the commissioning procedure all the wiring of the ROBERTS GORDON ULTRAVAC control boards relay boards modulat ing thermostats pumps and VFD must be com pleted The communication connection must be made to the controller modulating thermostat and burners The ROBERTS GORDON ULTRAVAC software must be installed on the PC It is important to understand that the frequency that the VFD runs the motor at determines the speed of the impeller in the pump Variation of the impeller speed will increase or decrease vacuum in the sys tem The following procedure will help you set mini mum and maximum VFD frequency settings to achieve proper vacuum in the system 15 1 Setting The CORAYVAC End Burner Vacuum 15 1 1 ROBERTS GORDON ULTRAVAC For complete ROBERTS GORDON ULTRAVAC installation please refer to the ROBERTS GORDON ULTRAVAC Installation Operation and Service Manual P N 10081601NA latest edition 15 1 2 Modulating Thermostat Turn on power to the VFD and transformer relay this should energize the modulating thermostat Set the thermostat to call for heat as described in the accompanying instructions for the modulating thermostat See Page 66 Section 14 for setting up the VFD 15 2 Adjusting the Variable Frequency Drive 15 2 1 Maximum Signal Speed The pump should be running and the burners should light within 60 seconds At the VFD veri
54. LLC and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and safety Roberts Gordon LLC recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform service where necessary using only replacement parts sold and supplied by Roberts Gordon LLC These products are not for residential use This product is intended to assist licensed professionals in the exercise of their professional judgment 2012 Roberts Gordon LLC All rights reserved No part of this work covered by the copyrights herein my be reproduced or copied in any form or by any means graphic electronic or mechanical including photcopying recording taping or information storage and retrieval systems without written permission of Roberts Gordon LLC Printed in the U S A Attach this information to a wall near the ROBERTS GORDON heater ROBERTS GORDON Infrared Heating Read the Installation Operation and Service Manual thoroughly before installation operation or service 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 Write the largest clearance dimensions with permanent ink according to your mo
55. ON 19 GENERAL SPECIFICATIONS SECTION 19 GENERAL SPECIFICATIONS 19 1 Material Specifications 19 3 Suspension Specifications 19 1 1 Reflectors Hang heater with materials with a minimum working 024 Aluminium Optional 024 Stainless Steel Type 304 load of 75 Ibs 33 kg See Page 19 Figure 14 19 2 Heater Specifications 19 4 Controls Specifications 19 2 1 Ignition Time switches thermostats etc can be wired into Fully Automatic Three Try Direct Spark Electronic a Supply suppli d sis Ignition Control 100 Safety Shut Off General Specifications for CRV Series heaters are as follows Length A 9 1 2 6 1 2 10 3 4 4 24 16 27 10 Reflector fs 14 1 4 36 Heat Input Rate Length A ane Btu h x 1000 Minimum Maximum Spot Heating CRV B 2 NG only 10 3 m 20 6 1 m 8 24 m CRV B 4 12 5 3 8 m 25 7 6 m 8 2 4 m CRV B 6 0 6 1 m 107 m 8 24 m CRV B 8 0 6 1 m 137 m 10 3 CRV B 9 5 7 6 m 15 2m 10 3m CRV B 10 0 91 CRV B 12A NG only 35 10 7 m CRV B 12 LP only 35 10 7 m See Page 5 Section 3 for clearances to combustibles 18 3m 15 4 5 m 15 4 5 m 15 4 5 m 5 5 0 0 0 0 21 3 m PIPE CONNECTION 1 2 NPT DIMENSIONS Vent Connection Size 4 10 cm or 6 15 cm Outside Air Connect
56. Shield 02750303 U Clip Package 91107720 30 of 83 SECTION 8 OPTIONAL HEATER ACCESSORIES 8 6 Two Foot Decorative Grille Installation Step 8 6 1 Grille Installation Tube and Reflector Hanger Reflector Heat Exchanger Tube Description 2 x 4 60 cm x 120 cm Aluminum Grille Part Number Aluminum Grille 2 x 4 60 cm x 120 cm 91407000 Step 8 6 2 Frame Shield Installation Shield Description Part Number Deco Grille Shield 01365900 31 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 6 3 Reflector Side Extension Installation for Decorative Grilles NOTE If the decorative grille system is to be installed in an area with considerable air movement it is recommended that one 8 x 3 8 sheet metal screw be installed per reflector extension to prevent it from blowing over Description Part Number Reflector Side Extension 01370412 Cut relief notches for tube and reflector hangers T0000 Insert screw here see note ae 6 15 cm Minimum Allow 6 15 cm minimum clearance between burner box and overhead obstructions for Reflector Side Extension service A Extension gt Minimum Maximum Part No Width 2 4 cm 6 15 cm 01370408 8 20 cm 6 15 cm 10 26 cm 01370412 12 30 cm
57. UPPLY 24VAC PS1 COM System Control 56 of 83 SECTION 12 CONTROL METHODS FIGURE 35 External Wiring Diagram EP 100 EP 201 or EP 301 230 V 1 Pump optional EP 100 EP 201 or EP 301Pump 6 14 The power supply for the 9 o o pump must be separate 5 65 o from the controller supply 3 1 5 208 230 V ELEME e Individual supply for pump 2 1 rated for total full load 429 gt 60 HZ current See Pump Specifications Section for details 100 EP 201 L e DI IND eec ace ce All burners must be or EP 301Pump TWO PUMP SYSTEM optional connected to Ground Not shown Zone 1 Zone 2 Zone 3 Zone 4 ACAUTION Product Damage Hazard Do not directly connect control relay terminals to pump motor Failure to follow these instructions can result in product damage Motor Contactors P N 10050011 P N 10050012 Pump 1 may be used for all zones Pump 2 may be used to control zone 3 and or zone 4 Refer to Pump 1 for configuration 4 ee Low voltage thermostats 4 99 Pressure located in heated zone Pressure switch i switch l
58. ace anything on the heater Make sure nothing is lodged underneath the reflector in between the tubes or in the decorative or protective grilles included with select models Immediately remove objects in violation of the clearances to combustibles See Page 5 Section 3 Support reflector with reflector hanger and support strap Reflector Reflector must not touch tube Make sure there is no dirt sagging cracking or distortion Do not operate if there is sagging cracking or distortion Make sure reflectors are correctly overlapped See Page 24 Figure 74 3 Clean outside surface with a damp cloth Vent Pipe Venting must be intact Using a flashlight look for obstructions cracks on the pipe or gaps in the sealed areas or corrosion The area must be free of dirt and dust Remove any carbon deposits or scale using a wire brush See Page 35 Section 9 Outside Air Inlet Inlet must be intact Look for obstructions cracks on the pipe or gaps in the sealed areas or corrosion The area must be free of dirt and dust Clean and reinstall as required Tubes Make sure there are no cracks Make sure tubes are connected and suspended securely See Page 19 Figure 14 through Page 21 Section 72 1 Make sure there is no dirt sagging bending or distortion Clean or replace as required 72 of 83 Gas Line SECTION 16 OPERATION AND MAINTENANCE Check for gas leaks See Page 48 Figure 2
59. aller must give a copy of this manual to the owner Owner Keep this manual in a safe place in order to provide your serviceman with necessary information Roberts Gordon LLC 1250 William Street Box 44 Buffalo New York 14240 0044 Telephone 1 716 852 4400 Fax 1 716 852 0854 Toll Free 800 828 7450 Www rg inc com WWW Ccorayvac com www radiantheaters com www greenhouse heater com www robertsgordon com P N 127102NA Rev L 06 12 TABLE OF CONTENTS SECTION 1 Heater Safety 1 1 1 Manpower Requirements 1 1 2 Safety Labels and Their Placement 1 1 3 California Proposition 65 1 SECTION 2 Installer Responsibility 4 4 2 2 Corrosive 4 2 3 National Standards and Applicable Codes 4 SECTION 3 Clearances to Combustibles 5 3 1 Required Clearances to Combustibles 5 SECTION 4 National Standards and Applicable Codes 9 4 1 Gas Codes u u m dedere 9 4 2 Aircraft 5 9 4 3 Public Garages 2 9 4 4 Electrical 9 zB ule 9 4 6 High Altitude ire ete 9 SECTION 5 Major Com
60. connect electric before service More than one disconnect switch may be required to disconnect electric from heater Gas can leak if piping is not installed properly Do not high pressure Heater must be test gas piping with connected to a properly equipment connected grounded electrical source SECTION 13 STARTING THE SYSTEM AWARNING Carbon Monoxide Hazard Burn Hazard Allow heater to cool before service Heaters installed unvented must be interlocked with sufficient building exhaust Tubing may still be hot after operation Heaters must be installed according to the installation manual Failure to follow these instructions can result in death electric shock injury or property damage Start with the main gas valve closed and the electric power off 13 1 Checking the Gas Line 1 Open the main valve and verify that no gas is flowing through the meter 2 Purge the line if this was not done following pressure testing with air 3 Verify that the gas pressure is not above 14 wc 1 2 PSIG 4 Close the main gas valve 13 2 Checking the Electrical System 1 See that all temperature setpoints are set below room temperature 2 Turn on power supply to system controls 3 Check to see that no part of the system i e burners pump or air supply blower is powered 4 Individually check each zone by raising the zone temperature set points separately Raising each zone temperature set point ab
61. cording to your model number and configuration in the open spaces on the tag 4 of 83 2 2 Corrosive Chemicals A CAUTION Product Damage Hazard Do not use heater in area containing corrosive chemicals Refer to appropriate Material Safety Data Sheets MSDS Failure to follow these instructions can result in product damage Roberts Gordon LLC 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 3 National Standards and Applicable Codes All appliances must be installed in accordance with the latest revision of the applicable standards and national codes This refers also to the electric
62. cuums between 2 5 wc and 3 0 wc while all the burners are still operating use the down arrow button on the VFD to reduce the frequency of the output signal to the pump Reduce the frequency of the VFD until the manometer at each of the end vents reads 1 2 wc 1 5 wc Make note of this frequency setting below The frequency is found on the VFD s LCD screen 1 0 w c 1 2 wc VFD Frequency Setting Record Frequency Setting Here 15 3 Programming Of Variable Frequency Drive Parameter Parameter Factory New Number Name Default Setting Line Voltage 01 01 Start Method 01 05 5 Standard 01 03 0 10 Speed 04 4 20 mA Source P44 Password 225 Any 000 999 P45 Speed at 0 0Hz Frequency Minimum Setting noted Signal on Page 68 Section 15 2 2 P46 Speed at 60 0Hz Frequency Maximum Setting noted Signal on Page 68 Section 15 2 1 15 3 1 Modulating Thermostat Turn OFF the power to the transformer relay Using the procedure described on Page 66 Section 14 alter the parameters above on the VFD Turn on the transformer relay and program the modulating thermostat to the customer s requirements SECTION 15 COMMISSIONING THE CORAYVAC MODULATING SYSTEM 69 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 43 Possible Damper Couplings Locations euoZ S 22 z 9 07
63. d Aluminized Steel Combustion Chamber 0272230D 1P Porcelain Coated Steel Combustion Chamber 02721200 1P Cast Iron Combustion Chamber 01329910 Reflector Side Extension Support 03050010 Reflector Support Package Tubing 02712700 Reflector Side Extension 2 Clips 2 Screws 02716400 Reflector Support Package Schedule 40 Pipe 02750303 Reflector Aluminum 02750355 Reflector Stainless Steel 02750304 Reflector Aluminum with Hole 027503SH Reflector Stainless Steel with Hole 02750800 Reflector End Cap Aluminum 02750855 Reflector End Cap Stainless Steel 027508SH Reflector End Cap Stainless Steel with Hole 02750900 Reflector Joint 02750955 Reflector Joint Stainless Steel 027127SS Reflector Side Extension Stainless Steel 03090100 Tube and Reflector Hanger 02790300 and Reflector Hanger Cast Iron 91907302 5 91903201 Turnbuckle 91903300 Spring Hook 91903202 Turnbuckle with Eyebolt 02712100 Universal Shield Support 02751800 Universal Shield with Holes 02751801 Universal Shield 02751855 Universal Shield Stainless Steel Part No Description Control Packages and Accessories 10001501 Water Resistant Sensor 02770002 System Control ULTRAVAC Control Packages URVCCM ROBERTS GORDON ULTRAVAC Central Controller with Modem Chip amp Software Includes URVSC ROBERTS
64. d horizontal venting options 9 2 5 Length Requirements See EP 100 EP 200 or EP 300 Pump Series Installation Operation and Service Manuals for complete venting options Vent lengths are allowed as follows Vent Length Bree vent 200 YARI ai Mun Size Size Size Up to 10 3 m ES opos Sebows debo Up to 50 15 m M e Seal all pipe joints with high temperature silicone sealant in the vent pipe Insulation and additional sealing measures will be required Optional heat exchanger lengths are considered as vent length for length determination Subtract 15 4 6 m of maximum allowed vent or outside air duct length per vent elbow if more than three are used 9 2 6 Vent Material Recomendations Vent recommendations in order of preferred use 1 Porcelain coated tubing 4 10 cm O D P N 9141030D 2 Heat treated aluminized tubing 4 10 cm O D P N 91409408 Heat treated aluminized tubing 6 15 cm O D P N E0009105 3 Single wall flue pipe minimum 26 ga Not suitable for modulating and condensing system designs 38 of 83 FIGURE 18 Vertical Venting Configuration SECTION 9 PUMP INSTALLATION AND VENTING Approved Thimble Flexible Boot A d ITI Vent Cap 2 0 6 m Minimum 1 2 5 cm CPVC to drain Aluminized Tee Drain Cap system in accordance with local codes
65. de electrode gasket and mounting screws Ignition Module Ignition Cable Filter Cartridge with Gasket not shown Part Number 90032502 01351100 02713000 02790400 90436900K 02725300 01367800 02713200 90439500K 90427706 01312401 78 of 83 SECTION 18 REPLACEMENT PARTS 18 1 Variable Frequency Drive Replacement Parts Caution Use only genuine ROBERTS GORDON replacement parts Use of parts not specified by Roberts Gordon voids warranty FIGURE 44 Variable Frequency Drive Components Diagram Variable Power Input Frequency Drive 1 input model shown _ Rotary Dissconnect Base Block ggg ononon 83 ee Fuse Holder Levers 1 B ag iai EN Block Input Fuse Holder 1 input model shown 3 Q input models have an additional input fuse holder and VFD power input Description Part Number Variable Frequency Drive 1 HP 120 V 1 Input for use with EP 203 10081201 Variable Frequency Drive 3 4 HP 230 V 1 Input for use with EP 203 10081202 Variable Frequency Drive 2 HP 230 V 1
66. del number and configuration in the open spaces below OPERATING INSTRUCTIONS 1 STOP Read all safety instructions on this information sheet 2 Open the manual gas valve in the heater supply line 3 Turn on electric power to the heater 4 Set the thermostat to desired setting TO TURN OFF THE HEATER 1 Set the thermostat to off or the lowest setting Fire Hazard IF THE HEATER WILL NOT OPERATE TO ENSURE YOUR SAFETY FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER Keep all flammable objects liquids and vapors the minimum required clearances to combustibles away from heater Set the thermostat to off or the lowest setting Some objects will catch fire or explode when placed close to Turn off electric power to the heater heater Turn off the manual gas valve in the heater supply line Call your registered installer contractor qualified in the Failure to follow these instructions can result in death injury installation and service of gas fired heating equipment or property damage Maintain clearance to the side and _ Clearance below the heater from vehicles and combustible materials Roberts Gordon LLC Roberts Gordon Europe Limited Service Telephone 44 0 121 506 7709 1250 William Street Unit A Kings Hill Business Park Service Fax 44 0 121 506 7702 P O Box 44 Darlaston Road Wednesbury E mail uksales rg inc com Buffalo NY 14240 0044 USA West Midlands WS10 7SH UK E mail export rg inc com Telephone
67. e downward away from pump 1 4 6 mm for every 10 3 m 4 10 cm Single Wall Pipe 40 102 cm Maximum P D Q Bird Screen Approved Thimbles 18 46 cm Minimum 4 10 cm Band Clamp E 4 10 cm Vent Terminal 5 to 4 Reducer 12 5 cm to 10 cm 6 to 5 Reducer 15 cm to 12 5 cm 6 to 4 dereud 15 cm to a cm ES 5 12 5 cm Single Wall Pipe Man 25 8 m and Elbows Maximum gt 50 15 m and Elbows Maximum gt m Vent Terminal Tjernlund VH1 4 Vent Terminal Tjernlund VH1 6 Vent Terminal Tjernlund VH1 6 Part Number Description Part Number Description 01330203 4 10 cm Aluminized 90502101 Vent Terminal 6 15 cm Combustible Wall 01331900 Damper Coupling 4 10 cm 91409403 Tube Aluminized 4 10 cm dia 10 3 m 01335801 Elbow 4 10 cm Aluminized 90 91409420 Tube Aluminized 6 15 cm dia 10 3 m 01365400 Bird Screen 4 10 cm 91412801 4 Flexible Boot 1 2 1 3 cm 02537801 1P Vent Terminal Non Combustible Wall 91418200 Tube Adapter 6 15 2 cm dia x 4 10 cm dia 02718851 4 Drain Cap 91901300 Boot Clamp 4 10 cm 01327002 Condensate Neutralization Tube 200 91906900 Silicone Ring 01327003 Condensate Neutralization Tube 600 Not Supplied Tube Aluminized
68. e of the VFD matches the input voltage of the old VFD Secure the new VFD to the mounting plate with the four screws Return all wires to the correct VFD ter minals If possible it may be easier to partially re wire the new VFD before mounting it to the mounting plate Close the door and return power to the VFD Return 120 V power to the relay board or modulating ther mostat Turn on the 24 V power switch on the relay board Press the reset button on the control board and close the doors 18 2 2 Variable Frequency Drive 25 A or 10 A Fuse To replace a fuse turn off input power to the variable frequency drive assembly at the breaker or disconnect switch Turn off 120 V power to the relay board inside the ROBERTS GORDON ULTRAVAC Controller or modulating thermostat Turn off the 24 V power 80 of 83 switch on the relay board Inside the VFD assembly open the fuse holder by pulling down the lever to expose the fuse Remove the old fuse and insert a new fuse Verify the correct fuse rating 25 A for 1 HP 120 V VFD or 2 HP 230 V VFD 10 A for the 75 HP 230 V 1 HP 460 V and 2 HP 460 V VFD Close the fuse holder Return power to the VFD assembly and verify that the VFD LCD screen is on dashes displayed Close the VFD assembly door Return 120V power to the relay board or modulating thermostat Turn on 24 V power switch on the relay board Press the reset button on the control board and close the doors SECTI
69. ed on outdoor temperatures The controls offer full modulation between 60 and 100 of system maximum rated input This controller is capable of giving control outputs to one pump and three heating zones The controller also features inputs which are used for indoor and outdoor signal condition monitoring System status and settings are viewed and altered from a PC not supplied running ROBERTS GORDON ULTRAVAC Software ROBERTS GORDON ULTRAVAC Software requires a PC not supplied running Windows 95 or higher with a Pentium class processor and at least 64k of RAM For complete installation details please refer to the ROBERTS GORDON ULTRAVAC Installation Operation and Service Manual P N 10081601NA latest revision Special design requirements apply for CRV Series systems using the ROBERTS GORDON ULTRAVAC Controller Buildings today demand all sorts of control options based on the user s preference ULTRAVAC controls offer a host of communication options for integration with controls networks to best serve individual needs ULTRAVAC BMS Link Interface ULTRAVAC with other building management control platforms using BACnet or MODBUS protocol which communicates via our ULTRAVAC BMS Link option TCP IP LAN Connect to ULTRAVAC via your local area network of computers Load ULTRAVAC software onto any computer on the network and control and view your heating system from your compute
70. ery 10 3 m Vent Terminal Tjernlund VH1 4 5 to 4 Reducer 6 to 5 Reducer 12 5 cm to 10 cm 15 cm to 12 5 cm Vent Terminal Tjernlund VH1 6 50 15 m and 3 Elbows Maximum gt Part Number Description Part Number Description 01330203 Tee 4 10 cm Aluminized 01327005 Condensate Neutralization Tube 2000 01331900 Damper Coupling 4 10 cm 90502100 Vent Terminal 4 10 cm Combustible Wall 01335801 Elbow 4 10 cm Aluminized 90 90502101 Vent Terminal 6 15 cm Combustible Wall 01365400 Bird Screen 4 10 cm 91409403 Tube Aluminized 4 10 cm dia 10 3 m 02537801 1P Vent Terminal Non Combustible Wall 91412800 Flexible Boot 4 10 cm 02718851 Drain Cap 4 10 cm 91901300 Boot Clamp 4 10 cm 01327002 Condensate Neutralization Tube 200 Not Supplied Tube Aluminized 5 12 7 cm dia 10 3 m 01327003 Condensate Neutralization Tube 600 Not Supplied Tube Adapter 5 12 7 cm dia x 4 10 cm dia 01327004 Condensate Neutralization Tube 1000 Not Supplied Tube Adapter 6 15 2 cm dia x 5 12 7 cm dia 40 of 83 FIGURE 20 EP 200 Series Horizontal Venting Configurations SECTION 9 PUMP INSTALLATION AND VENTING 18 46 cm Minimum 40 102 cm Maximum 10 3 m Maximum and No Elbows gt Pitch single wall pip
71. es for servicing or burner removal To provide the owner with a copy of this Installation Operation and Service Manual To never use heater as a support for ladder or other access equipment and to 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 Ib 33 kg To ensure the heater is placed in an approved application 2 1 Wall Tag 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 LLC 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 CRV Series heater e g thermostat or controller 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 6 Figure 3 through Page 8 Figure 11 Write the proper clearance dimensions in permanent ink ac
72. es must be in accordance with the following codes United States Refer to 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 Natural Gas and Propane Installation Code CSA B149 1 latest revision 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 When installed over hoists minimum clearances to combustibles must be maintained from the upper most point of objects on the hoist 4 4 Electrical The heater must be electrically grounded in accordance with the following codes United States Refer to National Electrical Code 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 The venting must be installed in accordance with the requirements within this manual and the following codes United States Refer to National Fuel Gas Code NFPA 54 ANSI Z223 1 latest revision Canada Refer to Natural Gas and Propane Installation Code CSA B149 1 latest revision 4 6 High Altitude These heaters are approved for installations up to 2000 610 m US 4500 1370 m Canada w
73. faces of all tubes couplings elbows tees and crosses 2 Clearances B C and D can be reduced by 50 after 25 7 5 m of tubing downstream from where the combustion chamber and the tube connect FIGURE 3 STANDARD REFLECTOR inches centimeters Model A B D A B D CRV B 2 4 20 48 20 11 51 122 51 n CRV B 4 4 20 48 20 11 51 122 51 z CRV B 6 4 20 48 20 11 51 122 51 CRV B 8 4 20 48 20 11 51 122 51 C lt e CRV B 9 4 36 60 36 11 92 153 92 CRV B 10 4 36 60 36 11 92 153 92 CRV B 12 4 36 60 36 11 92 153 92 CRV B 12A 4 36 60 36 11 92 153 92 FIGURE 4 ONE SIDE REFLECTOR inches centimeters Model A B D A B D CRV B 2 4 12 56 20 11 31 143 51 CRV B 4 4 12 56 20 11 31 143 51 CRV B 6 4 12 56 20 11 31 143 51 CRV B 8 4 12 56 20 11 31 143 51 CRV B 9 4 12 60 42 11 31 153 107 CRV B 10 4 12 60 42 11 31 153 107 CRV B 12 4 12 60 42 11 31 153 107 CRV B 12A 4 12 60 42 11 31 153 107 FIGURE 5 TWO SIDE REFLECTORS inches centimeters I Model A B C D A B C D A CRV B 2 4 12 56 12 11 31 143 31 CRV B 4 4 12 56 12 11 31 143 31 CRV B 6 4 12 56 12 11 31 143 31 CRV B 8 4 12 56 12 11 31 143 31 C lt B CRV B 9 4 12 60 12 11 31 153 31 CRV B 10 4 12 60 12 11 31 153 31 CRV B 12 4 12 60 12 11 31 153 31 CRV B 12A 4 12 60 12 11 31 153 31 6 of 83 SECTION 3 CLEARANCES TO COMBUSTIBLES NOTE 1 All dimensions are from the surfaces of all tubes coupling
74. fy the number displayed on the LCD screen is 60 0 If it is lower than 60 0 hit the up arrow button on the VFD until the number reads 60 0 Let the burners fire for approximately 20 30 minutes to warm up the system Using a manometer check the end vent vacuum in each zone each branch of burners See Page 70 Figure 43 If the lowest end vent vacuum reading is above 3 0 wc reduce the vacuum pump speed Generally the lowest end vent vacuum reading is on the longest branch of the system Use the down arrow button on the VFD to reduce the frequency of the output signal to the pump thus reducing the pump speed and lowering the end vent vacuum reading Continue to 68 of 83 reduce the frequency until the end vent vacuum reading is between 2 5 3 0 wc Make note of this frequency setting below The frequency is found on the VFD s LCD screen 2 5 wc 3 0 wc VFD Frequency Setting Record Frequency Setting Here NOTE To avoid damage to the pump motor do not adjust the frequency above 60 0 Hz Verify that the end vent vacuum readings in the remaining branches are proper If necessary adjust the proper damper coupling to achieve an end vent vacuum of 2 5 3 0 wc See Page 65 Figure 42 Damper couplings should be found near the end of the radiant portion of the pipe in each branch or where a branch connects to other branches at a cross or tee See Page 70 Figure 43 15 2 2 Minimum Signal Speed After setting end vent va
75. g installation operation and service Edges are sharp Failure to follow these instructions can result in injury Step 8 1 Tee Installation S Tube T Coupling Description Part Number Tee 01330XXX Tube Reflector Hanger 03090100 Tube 91409XXX Coupling 01312700 26 of 83 Step 8 2 Reflector Joint Step 8 2 1 Reflector Joint Installation SECTION 8 OPTIONAL HEATER ACCESSORIES Scribe Contour Step 8 2 2 Reflector Joint Installation 1 2 5 cm Reflector Joint Punch drill six 3 32 2 mm holes Cut away contour with tin snips 27 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 2 3 Reflector Joint Detail Install reflector end cap Attach reflector joint with six 8 sheet metal screws 28 of 83 SECTION 8 OPTIONAL HEATER ACCESSORIES 8 3 Reflector Side Extension Step 8 3 1 Bracket Installation Tube Reflector V T Tube and Reflector Hanger Reflector Support Reflector Side Extension Bracket 2 per reflector Use additional supports in high air movement applications Description Part Number Reflector Side Extension Package 02712700 Reflector Side Extension 01368000 Retainer Clips 02751200 Sheet Metal Screws 94118106 Order Separately Reflector Side Extension Bracket 01329910 Cut relief
76. gas and venting installation Note Additional standards for installations in public garages aircraft hangars etc may be applicable SECTION 3 CLEARANCES TO COMBUSTIBLES 3 1 Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the heater to prevent serious fire hazards Combustibles are materials that may catch fire and include common items such as wood paper rubber fabric etc Maintain clearances to combustibles at all times for safety Clearances for all heater models are located on the burner of the heater and on Page 6 Figure 3 through Page 8 Figure 11 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 Keep gasoline or other combustible materials including flammable objects liquids dust or vapors away from this heater or any other appliance The stated clearances to combustibles represents a surface temperature of 90 F 50 C above room temperature Building materials with a low heat tolerance such as plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installer s responsibility to assure that adjacent materials are protected from degradation Maintain clearances from heat sensitive equipment and workstations
77. gas valve the heater supply line 3 Turn ON electric power 4 Set thermostat to desired temperature burner should V light automatically CAUTION Hold gas nipple securely with pipe wrench when attaching the flex gas connector Failure to follow these instructions will result in product damage USA Roxas comon PN 31020000 a B Burner Box Combination Label Description Part Number Gas Connection Label 91018125 Burner Box Combination Label 91029600 Proposition 65 Label 91070016 3 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 2 INSTALLER RESPONSIBILITY The installer is responsible for the following To ensure the system is designed in accordance with the parameters of the CRV Series Design Manual P N 127500NA To install the heater as well as the gas and electrical supplies in accordance with applicable specifications and codes Roberts Gordon LLC 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 To plan location of supports To provide access to burners on all sid
78. ge BURNER Br leur 1t any of the original wire supplied with the heater must bo replaced must be replaced wih wring material having Temperature rating of at least 105 C and 600 vol 2005 ROBERTS GORDON S une partie du c blage d origine fourni avec radiateur doit re remplac e elle dat etre par du mat riel de c blage tolerant une temperature d au moins 105 C et 600 vol Printed in U S Alimprim aux Etats Unis Wiring Label werpine com PIN 91017200 Rev B SECTION 1 HEATER SAFETY FIGURE 2 Top and Back Panel Label Placement AWARNING AATTENTION AWARNING Fire Hazard Risque d incendie Tighten and install gas hose fitings to connect gas Serrez et installez es raccords supply according to example below Gas hose can crack when twisted Gas hose moves during normal operation Use only 36 81cm long connector of 1 2 nominal D Le ligne de gaz de peut se fissurer une fols tordue Le ligne de gaz se d place pendant l ex cution normale Utilisez seulement un connecteur de ou de i en diam tre inteme nominal et d une longeur de 36 91 cm AADVERTENCIA Connector supplied with heater for US models not with Le connecteur est fourni avec le chauffage pour les Canadian models mod les am ricains Pas avec les mod les canadiens Failure to follow these instructions can result n death Le nor respect de ces consignes peut causer la mort les
79. inum or Stainless Steel Punch out center section to accommodate tube Tube and Reflector Hanger Suspend system from these hangers Reflector Support Strap amp Wire Form S S Hook Protective Grille Reflector Side Condensate Extension Bracket Valve X Assembly Universal Shield Universal Shield with Holes Bracket Assembly 11 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 10 Major Component Descriptions Continued ROBERTS GORDON ULTRAVAC Controller aac Waq tem m var ROBERTS GORDON ULTRAVAC Variable Frequency Drive Outdoor Sensor P N 10081501 ROBERTS GORDON ULTRAVAC Adjustable Indoor Sensor EP 100 Pump Package 4 dia For more information refer to the EP 100 Installation Operation and Service Manual P N 127201NA EP 201 Pump Package 4 dia EP 203 Pump Package 4 dia For more information refer to the EP 200 Series Installation Operation and Service Manual P N 127200NA O v SS EP 301 Pump Package 4 dia EP 301 Pump Package 6 dia EP 303 Pump Package 4 dia EP 303 Pump Package 6 dia For more information refer to the EP 300 Series Installation Operation and Service Manual P N 127202NA 12 of 83 5 1 Standard Parts List Table 1 Contents of CRV Serie
80. ion Size 4 10 cm Refer to figure above for dimensional information GAS INLET PRESSURE Natural Gas 4 5 wc Minimum 14 0 wc Maximum LP Gas 10 5 wc Minimum 14 0 wc Maximum ELECTRICAL RATING 120 V 60 Hz 0 3 81 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL General Specifications for pumps are as follows Pump Dimensional Data in Model A B D E F EP 100 17 14 5 21 3 75 10 4 4 201 203 17 75 17 20 25 3 25 10 45 45 EP 301 303 25 6 24 8 22 7 48 15 2 6 6 Pump Specifications Model EP 100 EP 201 EP 203 EP 301 EP 303 Phase 0 1 1 3 1 3 Voltage V 115 230 115 230 208 230 460 208 230 208 230 460 R P M 3450 3450 3500 3450 3450 Motor Enclosure TENV TENV TEFC TEFC TEFC Inlet Outlet In 4 4 4 4 4 4 6 6 6 6 For starter see National Electric Code NEC requirement for motors 1 hp or higher Air Supply Blower Specifications Power W 167 Hertz Hz 60 Full Load Amp Amps 1 5 Motor Enclosure OPEN FC Weight Ibs 10 SECTION 20 THE ROBERTS GORDON CORAYVAC LIMITED WARRANTY SECTION 20 THE ROBERTS GORDON CORAYVAC LIMITED WARRANTY ROBERTS GORDON LLC WILL PAY FOR Within 36 months from date of purchase by buyer or 42 months from date of shipment by Roberts Gordon LLC whichever occurs first replacement parts will be provided free of charge for any part of the produc
81. ion and Maintenance 16 1 Sequence of 16 2 To Shut Off 16 3 To Start Heater sss 16 4 Pre Season Maintenance and Annual Inspection 16 5 Maintenance Checklist SECTION 17 Troubleshooting 17 1 Troubleshooting Flow Chart SECTION 18 Replacement Parts 18 1 Variable Frequency Drive Replacement Parts 18 2 Replacement Parts Instructions SECTION 19 General Specifications 19 1 Material Specifications 19 2 Heater Specifications 19 3 Suspension Specifications 19 4 Controls Specifications SECTION 20 The ROBERTS GORDON CORAYVAC Limited Warranty There are references in this manual to various trademarks All trademarks mentioned herein whether registered or not are the property of their respective owners Roberts Gordon LLC is not sponsored by or affiliated with any of the trademark or regis tered trademark owners and make no representations ab
82. ithout modification Consult factory if US installation is above 2000 610 m or Canadian installation is above 4500 1370 m 9 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 5 MAJOR COMPONENTS The figures in this section provide a general overview of component placement in a CRV Series system The location of some components such as supports and couplings is crucial for proper installation Assemble the heater components as shown on Page 17 Figure 13 FIGURE 12 Major Component Descriptions Optional reflector configurations are shown on Page 6 Figure 3 through Page 8 Figure 11 Install appropriate suspension hardware beam clamps chain or rod at predetermined locations Adjustments of chain length will provide uniform pitch Burner Reflector Aluminum or Stainless Steel Alternate overlap as shown on Page 24 Section 74 3 Minimum overlap is 6 16 cm Flex Gas Line Qo with shut off cock D Combustion Chamber Coupling Assembly with Lock 45 Elbow Tube Hot rolled heat treated or coated aluminized tube supplied in 10 3 m lengths Reflector with Hole Aluminum or Stainless Steel Alternate overlap as shown on Page 24 Section 74 3 Minimum overlap is 6 16 cm 10 of 83 SECTION 5 MAJOR COMPONENTS FIGURE 10 Major Component Descriptions Continued Reflector Joint SS w Reflector End Cap Alum
83. ithout written permission of Roberts Gordon LLC www rg inc com Printed in U S A P N 91037912 Rev J
84. lpipe Length per Flow Unit Length average distance Minimum Recommended L4 Maximum between burners unit Minimum N A 0 1 0 3 0 6 Recommended 0 1 0 3 0 6 0 8 Maximum 0 3 0 6 0 8 0 8 Step 2 Total condensate Determine the total condensate gal h using the follow calculation Total condensate gal h Total Input Btu h 100 000 Btu h x condensate flow gal h Step 3 Choose the condensate neutralization tube Choose the condensate neutralization tube which is closest to and higher than the calculated gal h value Step 3 Choose the condensate neutralization tube Choose the condensate neutralization tube which is closest to and higher than the calculated gal h value For this example the total condensate is 1 8 gal h the condensate neutralization tube which is closest to and higher than the calculated gal h value is P N 01327002 Calculated gal h Description Part Number Less than 2 Condensate Neutralization Tube 200 01327002 Less than 6 Condensate Neutralization Tube 600 01327003 Less than 10 Condensate Neutralization Tube 1000 01327004 Less than 20 Condensate Neutralization Tube 2000 01327005 NOTE Condensate neutralization tubes must be replaced yearly every 2000 operating hours or check condensate water pH level If it is below pH 6 replace tube To order replacement see the chart below Description Part Number Condensate Neut
85. nput i F ps t jb or OF 7 All three power wires from terminals U V and W to the pump motor must be kept tightly bundled VED Models VED Models and run a separate conduit away from all other Bowel and control wiring Description Part Number SPST Transformer Relay 90417600K Thermostat Modulating BACnet 90425109 61 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 40 Burner Internal Wiring TRANSFORMER ER White r Yellow Black 120 V Green 3 4 Power Suppl pply i Blue Yellow 9 Green lo 7 TH GAS Brown vi VALVE Yellow Em Black 9 IGNITION 5 MODULE SS BURNER If any of the original wire as supplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C and 600 volts FIGURE 41 Burner Internal Ladder Diagram Blue ELECTRODE GAS VALVE IGNITION MODULE 62 of 83 SECTION 13 STARTING THE SYSTEM ADANGER Electrical Shock Hazard Explosion Hazard Leak test all compo nents of gas piping before operation Dis
86. ns can result in death or electrical shock A WARNING Fire Hazard Explosion Hazard Burn Hazard Cut Pinch Hazard Keep all flammable Turn off gas supply to Allow heater to cool Wear protective gear objects liquids and heater before service before service during installation vapors the minimum operation and service required clearances to Tubing may still be hot combustibles away after operation Edges are sharp from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage 74 of 83 SECTION 17 TROUBLESHOOTING 171 Troubleshooting Flow Chart eoejdai auou Seu e pue Buiuedo eA eA pue Jo 1n04201 JO YOOYO ejoKoeH 1n0x90 uous seuse Uopeuu Jeuung pue eje d eins exe Paesu eq ejejd pue 10sseooJdoJo9 lA uo Apeays uedo JO JO ye ysel pe ls p uonnios ut lqoid lnpolN JUBA pue y ye Alyjoous Jadoid 10 wayshs jsnipy ay je oq uBiu ool unnoeA au S 2 pue aniq 1euuojsuej ON ay 18 A 8194
87. ocated at Zone Zone Zone Zone located at Pump 1 1 2 3 4 Pump2 120 V ee ooro ore oy 120V 10 aue pum x 1 60Hz Ir 60 Hz 24 VAC 9 L ME que eo LT lt fM Ground e e e e eo 00 24VAC PS1 R G N L N L NL NL NL NL NL 4 power PUMP1 Zi 22 Z8 74 PUMP2 e SUPPLY 24VAC PS1 w w w PS2 COM System Control 57 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 36 External Wiring Diagram EP 203 or EP 303 208 230 V or 460 V 3 Pump optional EP 203 or Motor Contactors P N 10050011 P N 10050012 EP 303 3 Pump o4Fo HH CAUTION Product Damage Hazard Do not directly connect control relay terminals to pump motor Failure to follow these instructions can result in product damage The power supply for the pump must be separate from the controller supply 208 230 V or 460 V 30 60 Hz Individual supply L3 _ for pump rated for L2 9 gt total full load current All burners must be connected to Ground Not shown L1 e e Zone 1 Zone 2 Zone 3 Zone 4 See Pump Specification Section for details EP 303 3 TWO PUMP SYSTEM optional Pump Pump 1 may be used for all zones Pump 2 may be used to control zone 3 and or zone 4 Refer to Pump 1 for configuration
88. out them their owners their products or services Roberts Gordon LLC is not sponsored by or affiliated with BACnet LonWorks or MODBUS 2012 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 71 TABLE OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Side Panel Label 2 and Back Panel Label Placement 3 Standard 6 One Side 6 Two Side Reflectors 6 Universal Shield Position 1 7 Universal Shield Position 2
89. ove room temperature should start the pump immediately After a 45 second delay the burners will begin their ignition sequence by sparking at the electrode visible through the burner window 5 Make a preliminary vacuum check at burners in branches that have an adjustable damper coupling See Page 65 Figure 42 for manome ter hookup to check vacuum This check is to insure that all dampers are open before the system is fired Vacuum as measured at the end vents should be approximately 3 5 wc or slightly above cold 13 3 Starting the System NOTE During the initial firing the protective oil on the tubing may smoke for 30 to 60 minutes and adequate ventilation should be provided 1 Start with all temperature setpoints below room temperature 2 Open main gas valve 3 Turn up temperature setpoints one zone ata time waiting to see that all burners in a zone start When the burner ignites a blue flame will be observed through the viewer window 4 If any abnormal operation occurs see the trou bleshooting section of the service instructions 13 4 Setting the Vacuum 1 Set temperature setpoints above room tempera ture See that all burners are operating properly 63 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 2 Allow at least hour operation for temperature to normalize then check system vacuum bal ance Vacuum can be measured by inserting a manometer hose into the end vent as shown on Page
90. pabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do no play with the appliance For additional copies of the Installation Operation and Service Manual please contact Roberts Gordon LLC 1 1 Manpower Requirements To prevent personal injury and damage to the heater two persons will be required for installation SECTION 1 HEATER SAFETY 1 2 Safety Labels and Their Placement Product safety signs or labels should be replaced by the product user when they are no longer legible Please contact Roberts Gordon LLC or your ROBERTS GORDON independent distributor to obtain replacement signs or labels See Page 2 Figure 1 through Page 3 Figure 2 1 3 California Proposition 65 In accordance with California Proposition 65 requirements a warning label must be placed in a highly visible location on the outside of the equipment i e near equipment s serial plate See label placement drawing on Page 3 Figure 2 for label location Avoid placing label on areas with extreme heat cold corrosive chemicals or other elements To order additional labels please contact Roberts Gordon LLC or your ROBERTS GORDON independent distributor 1 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 1 Side Panel Label Placement
91. parameter number For new parameter settings See Page 67 Section 14 2 14 1 4 Once the desired parameter number is found Press Mode to display present parameter setting example setting is 20 0 Upper right decimal point blinks Use arrow buttons to change setting Press Mode to store new setting and exit the program mode 14 1 5 To change another parameter press the Mode key again to re enter the PROGRAM mode the parameter menu will be accessed at the parameter that was last viewed or changed before exiting If the Mode key is pressed within two minutes of exit ing the PROGRAM mode the password is not required to access the parameters After two minutes the password must be entered in order to access the parameters again SECTION 14 VARIABLE FREQUENCY DRIVE PROGRAMMING 14 2 Altering VFD Parameters Using the procedure described on Page 66 Section 14 1 1 through Section 14 1 5 alter the following parameters Parameter Parameter Factory New Number Name Default Setting Line Voltage 01 01 Start Method 01 05 5 Standard 01 03 0 10 Speed 04 4 20 mA Source P44 Password 225 Any 000 999 P45 Speed at 0 0Hz Frequency Minimum Setting noted Signal on Page 68 Section 15 2 2 P46 Speed at 60 0Hz Frequency Maximum Setting noted Signal on Page 68 Section 15 2 1 67 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 15 COMM
92. pecified by Roberts Gordon Failure to install or maintain the ROBERTS GORDON CORAYVAC as directed in the Installation Operation and Service Manual e Relocation of the ROBERTS GORDON CORAYVAC after initial installation The use of the ROBERTS GORDON CORAYVAC in a corrosive atmosphere containing contaminants e The use of the ROBERTS GORDON CORAYVAC in the vicinity of a combustible or explosive material Any defect in the ROBERTS GORDON CORAYVAC arising from a drawing design or specification supplied by or on behalf of the consumer e Damage incurred during shipment Claim must be filed with carrier WARRANTY IS VOID IF The ROBERTS GORDON is not installed by a contractor qualified in the installation and service of gas fired heating equipment You cannot prove original purchase date and required annual maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the ROBERTS GORDON CORAYVAC is moved or transferred This warranty is nontransferable Roberts Gordon LLC is not permitted to inspect the damaged equipment and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your equipment contact your installing professional Should you need Replacement Parts or have additional questions call or write Roberts Gordon LLC 1250 William Street P O Box 44 Buffalo
93. pliance with the Standard for Elastomeric models not with Canadian models Composite Hose and Hose Couplings for Conducting Propane and Natural Gas CAN CGA 8 1 Latest Failure to follow these instructions can result revision in death injury or property damage Check the pipe and tubing ends for leaks before placing heating equipment into service When checking for gas leaks use a soap and water solution never use an open flame AWARNING Explosion Hazard Leak test all components of gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with heater connected Failure to follow these instructions can result in death injury or property damage Install the gas hose as shown on Page 48 Figure 28 The gas hose accommodates expansion of the heating system and allows for easy installation and service of the burner Before connecting the burners to the supply system verify that all high pressure testing of the gas piping has been completed 47 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 28 Gas Connection with Flexible Gas Hose Shut Off Valve included with gas hose must be parallel to burner gas inlet The 3 8 cm displacement shown is for the cold condition This displacement may reduce when the system is fired
94. point the modulating thermostat will generate a demand signal to the VFD The VFD will output a signal to the pump to run at the desired heater s firing rate There are two means to set up the analog signal from the modulating thermostat to the VFD See Page 51 Figure 29 1 To obtain 4 20 mA signal connect as shown on Page 60 Figure 38 and set standard speed source parameter 05 inside VFD menu to 04 2 To obtain 2 10 Vdc with 500 ohm resistor signal connect as shown on Page 59 Figure 37 and set standard speed source parameter 05 inside VFD menu to 03 FIGURE 29 VFD Terminal Strip gt SIGNAL COMMON gt 5 0 10VDC INPUT gt DIGITAL INPUT REFERENCE T 5 4 20 m A INPUT gt MAINTAINED RUN STOP CONTACT As the pump receives the analog signal from the the heater s modulate to the corresponding firing rate As sensed air temperature rises closer to 51 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL the temperature setpoint the modulating thermostat and the VFD will reduce the signal output in turn reducing the heater firing rate Upon satisfying temperature setpoint the modulating thermostat and the VFD will either 1 Turn off heater 2 Reduce the signal so that the minimum heating firing rate is maintained until the sensed temper ature rises above the setpoint
95. ponents 10 5 1 Standard Parts 13 SECTION 6 Design Requirements 16 SECTION 7 Heater Installation 18 7 1 Tube Installation 2 20 7 2 Coupling and Tube 20 7 3 Elbow Package Configuration 21 7 4 Reflector Installation 22 7 5 Burner Installation 25 SECTION 8 Optional Heater Accessories 26 8 1 Tee 0 444202 26 8 2 Reflector 27 8 3 Reflector Side 29 8 4 Universal 30 8 5 Barrier 30 8 6 Two Foot Decorative Grille Installation 31 8 7 Protective Grille Installation 33 8 8 Classic Cast Iron Components 34 SECTION 9 Pump Installation and Venting 35 9 1 Pump Installation esee 35 9 2 General Venting Requirements Model EP 100 EP 200 and EP 300 Series Pumps 37 9 3 Horizontal Venting 4 10 cm Pipe
96. power and control wiring 7 For Non communicating thermostats without LonWorks bus thermostat terminals marked EB will be marked _ _ and no LonWorks bus communication wires are used 60 of 83 SECTION 12 CONTROL METHODS FIGURE 39 CORAYVAC Modulating with BACnet Wiring Diagram optional Terminals A MS TP and B MS TP to connect the BACnet MS TP LAN See Note 6 by using the EIA 485 Signaling Standard Common C Phase R SSSSSSSOS o See Note2 Power Input Variable Frequency Driver p Di Jumper 1 Input Model Shown I 918011601 Ground Transformer Relay Black Sec 24V Soe 60 Hz 33 VA Black Ext Load Pressure PO5 3 Switch See Note 2 IN NOTES 1 A jumper is pre installed between Phase R 24 VAC and SC1 3 24 VAC Relay 2 For 0 10VDC Speed Control set standard speed source parameter 05 to 03 VED Power 3 See VFD Rating Plate for Required Input F A 120 V 1 PH 60 HZ Supply for 120V VFD Model Outpot Terminal B 230 V 1 PH 60 HZ Supply for 230V VFD Model 4 Ground only one end of the shielded cable 5 Control Wire To Be A Minimum of 20 AWG Type Belden 5401FE CMR 75 C Shielded or Equivalent 230V 460 V 6 Wire Over 24 VAC To Be A Minimum of 16 AWG Flexing Type MTW 105 C 600V or Equivalent 3 PH 3 PH A 120 VAC Colors Phase Red Neutral White Ground Green For 115 Vana 250 V i
97. r via static IP address MODEM Dial into ULTRAVAC from anywhere in the world via modem Supplied as standard on all central controllers RS 485 Hard wire ULTRAVAC directly to your computer 12 3 CORAYVAC Modulating Controls For a ROBERTS GORDON CORAYVAC Modulating system combine a modulating thermostat a thermostat relay P N 90417600K and any one of the existing ROBERTS GORDON VFD 49 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL assemblies The result will be a one pump one zone CORAYVAC Modulating system The system will modulate based on the temperature sensed at the modulating thermostat not outdoor temperature The modulating controls offer many features like 7 day programmability four time periods per day 2 occupied 2 unoccupied temporary temperature setpoint override keypad lockout security and more Remote sensors or outdoor sensors are optional not required Remote sensors will allow for zone temperature averaging if required 12 3 1 Analog Signal Modulating Thermostat A programmable 7 day programming modulating thermostat can be installed to supply an analog 4 20mA or 2 10Vdc with 500 Ohm resistor control signal to dictate the speed of the pump For thermostat wiring See Page 59 Figure 37 Optional room sensors P N 10081520 and outdoor air sensors P N 10081521 are available Room temperature averaging networks can be created with up to nine room sensors P N
98. ralization Tube 200 01327002 Condensate Neutralization Tube 600 01327003 Condensate Neutralization Tube 1000 01327004 Condensate Neutralization Tube 2000 01327005 Refill Condensate Neutralization Tube 600 01327007 Refill Condensate Neutralization Tube 1000 01327008 Refill Condensate Neutralization Tube 2000 01327009 Calculated gal h Description Part Number Less than 2 Condensate Neutralization Tube 200 01327002 Less than 6 Condensate Neutralization Tube 600 01327003 Less than 10 Condensate Neutralization Tube 1000 01327004 Less than 20 Condensate Neutralization Tube 2000 01327005 Example CORAYVAC system has a total input of 600 000 Btu h The radiant tube length and tailpipe are set up according to the RECOMMENDED specifications Step 1 Condensate flow gal h per 100 000 Btu h installed Select 0 3 from the Condensate flow chart Radiant Tube Tailpipe Length per Flow Unit Length average distance Minimum Recommended 7 flew Maximum between burners Minimum N A 0 1 0 3 0 6 Recommended 0 1 0 3 0 6 0 8 Maximum 0 3 0 6 0 8 0 8 Step 2 Total condensate Multiply the total input Btu h 100 000 by the condensate flow gal h per 100 000 Btu h 600 000 100 000 x 0 3 1 8 gal h 36 of 83 FIGURE 17 Condensate Neutralization Tube Wall SECTION 9 PUMP INSTALLATION AND VENTING Calculated gal h
99. ring 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 United States Refer to National Fuel Gas Code 54 ANSI Z223 1 latest revision Canada Refer to Natural Gas and Propane Installation Code CSA B149 1 latest revision 4 2 Aircraft Hangars Installation in aircraft hangars must be in accordance with the following codes United States Refer to Standard for Aircraft Hangars NFPA 409 latest revision Canada Refer to Natural Gas and Propane Installation Code CSA B149 1 latest revision 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 e 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 Installation in garag
100. s elbows tees and crosses 2 Clearances B C and D can be reduced by 50 after 25 7 5 m of tubing downstream from where the combustion chamber and the tube connect FIGURE 6 UNIVERSAL SHIELD POSITION 1 inches centimeters Model A B D A B D CRV B 2 4 12 12 12 11 31 31 31 CRV B 4 4 12 12 12 11 31 31 31 CRV B 6 4 12 12 12 11 31 31 31 CRV B 8 4 12 12 12 11 31 31 31 CRV B 9 8 18 24 18 21 46 61 46 CRV B 10 8 18 24 18 21 46 61 46 CRV B 12 8 18 24 18 21 46 61 46 CRV B 12A 8 18 24 18 21 46 61 46 FIGURE 7 UNIVERSAL SHIELD POSITION 2 inches centimeters Model A B D A B D CRV B 2 4 24 48 24 11 61 122 61 CRV B 4 4 24 48 24 11 61 122 61 CRV B 6 4 24 48 24 11 61 122 61 CRV B 8 4 24 48 24 11 61 122 61 CRV B 9 4 36 48 36 11 92 122 92 CRV B 10 4 36 48 36 11 92 122 92 CRV B 12 4 36 48 36 11 92 122 92 CRV B 12A 4 36 48 36 11 92 122 92 FIGURE 8 UNIVERSAL SHIELD POSITION 3 inches centimeters Model A B D A B D CRV B 2 4 12 56 30 11 31 143 77 CRV B 4 4 12 56 30 11 31 143 77 CRV B 6 4 12 56 30 11 31 143 77 CRV B 8 4 12 56 30 11 31 143 77 CRV B 9 8 12 60 42 21 31 153 107 CRV B 10 8 12 60 42 21 31 153 107 CRV B 12 8 12 60 42 21 31 153 107 CRV B 12A 8 12 60 42 21 31 153 107 7 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL NOTE 1 All dimensions are from the surfaces of all tubes couplings elbows tees and
101. s readily accessible for servicing The heaters must be installed in accordance with clearances to combustibles as indicated on the rating plate and in this instruction manual The minimum and maximum gas inlet pressures must be maintained as indicated on the rating plate Typical installation configurations are shown on Page 19 Figure 14 18 of 83 SECTION 7 HEATER INSTALLATION FIGURE 14 Critical Hanger Placement Typical Suspension Details Beam Clamp Concrete Beam Wood Beam PRENDE Ws Locknut 277 Screw Hook w 3 8 S cnisz D Y M g i 3 16 minimum Washers Rod 3 8 x 24 min 61 cm f X See Table 41 Y Turnbuckle Locknut Typical E S Hook rM CMM LC MM LI CP KE C A Turnbuckle Hanger Reflector Side View Towards Pump gt Front View Run Length Typical Expansion Minimum X Length 50 15 m 1 3 cm 12 30 cm Description Part Number 100 31 m 2 5 cm 24 61 cm Turnbuckle 91903201 150 46 m 3 8 cm 36 91 cm S Hook 91907302 200 61 m 4 10 cm 46 122 cm Tube Reflector Hanger 03090100 250 76 m 5 13 cm 57 145 cm 19 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 7 1 Tube Installation gt NS SA d S
102. s s 104 VNLI0OS9L800L wiOVWAVYLIN sNOQHOD S1H38OH 10916001 N d 1 ueis g SOI JGued jo1u02 15 jaued 011009 peysnes sjosues 10 Sjejsouueul ens aye si jeou eo ON jo 1nus sjeuunq oq SUOnonJjsul 10 MOJ9q peisi ui 1Insuoo ju8A pue y ye ressooeu se eoe deu Jol uu 1s s y ui Syed 10 10 Ajddns eBexoojg 10 YOOYD si uinq y UO eui ev 41094100 y jo BU SI 00 Humes y sI MOL SUED Sur 10 NO Q peisi ui Bum e oqe xoeuo 4 pue y Alessaoeu se sedaid waists 1sn py adidjre 10 pesn eq pjnous peur Alu doiduui aq Aew 5 y uo 1991109 y JO 9uj S youeig sjeuunq peep Aue
103. s Burner Carton SECTION 5 MAJOR COMPONENTS Part No Description 91418200 Adapter Aluminized 6 15 cm dia x 4 10 cm dia 02722100 Adapter 4 10 cm Cast Iron 02726000K Lower Tube Temperature Insert 91240010 Tube Hanger 6 15 cm 91308001 High Temperature Pipe Compound 11b can Part No Description Venting Accessories 01324401 Outside Air Supply Takeoff 4 10 cm 01326801 Outside Air Filter Housing 90707501 Air Supply Blower Power Venter 91409601 Outside Air Flex Duct 4 10 cm Box of 8 8 2 4 m sections Part No Description Part No Description 0270XXXX Burner Rate and Fuel Varies 91412200 Flexible Stainless Steel Gas Hose 1 2 NPT US models only 013676XX End Vent Plate 01397300 Accessory Package 01361200 Filter Support Disk 01367800 Combustion Chamber Gasket 02724901 Door Assembly w Hole 91115100 Screw 10 24 x 5 8 91119500 U Clip 91905500 Filter Support 92123900 Nut 5 16 18 92511601 Wing Nut 10 24 96411600 Lock Washer 5 16 01312401 Filter and Gasket Reflectors and Related Accessories Canadian Models Rubber Type 1 Gas Hoses available as an accessory See Page 48 Figure 28 Table 2 Common CRV Series Components Part No Description Combustion Chambers 02722300 1P Hot Rolled Steel Combustion Chamber 02722301 1P Heat Treate
104. s or power No person is authorized to assume for Roberts Gordon LLC any other warranty obligation or liability LIMITATIONS ON AUTHORITY OF REPRESENTATIVES No representative of Roberts Gordon LLC other than an Executive Officer has authority to change or extend these provisions Changes or extensions shall be binding only if confirmed in writing by Roberts Gordon LLC s duly authorized Executive Officer 83 of 83 ES S ROBERTS GORDON Sot Infrared Heating OWNER WARRANTY REGISTRATION CARD Mail or Fax to Roberts Gordon LLC 1250 William Street P O Box 44 e Buffalo NY 14240 0044 Phone 716 852 4400 Fax 716 852 0854 Toll Free 800 828 7450 www rg inc com About the Owner Name Address City State Zip Code Phone Fax E mail About the Installer Name Address City State Zip Code Phone Fax E mail Purchased From if different than installer Name Address City State Zip Code Phone Fax E mail About your Heater Model Serial Fuel Installation Date Type of Installation check one 0 Automotive o Manufacturing o Warehouse 0 Recreational o Aircraft o Public Building 0 Office o Retail 0 Agricultural 0 Other Installation Code and Annual Inspections All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts Gordon
105. s than 1 0 3 m above grade level The vent shall not terminate less than 7 2 1 m above grade where located adjacent to public walkways Must be connected to a drain system in accordance with local codes and manufacturers instructions Vent terminal must be installed at a height sufficient to prevent blockage by snow and building materials protected from degradation by flue gases Secure all joints with 8 x 3 8 sheet metal screws Seal all joints with high temperature silicone sealant Vent terminal must be beyond any combustible overhang 9 2 1 United States Requirements Vent must terminate at least 3 0 9 m above any forced air inlet located within 10 3 1 m Vent must terminate at least 4 1 2 m below 4 1 2 m horizontally from or 1 0 3 m above any door operable window or gravity air inlet into any building 9 2 2 Canadian Requirements The vent shall not terminate within 6 1 8 m of a mechanical air supply inlet to any building The vent shall not terminate within 3 0 9 m of a window or door that can be opened in any building any non mechanical air supply inlet to any building or of the combustion air inlet of any other appliance 37 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 9 2 3 Vertical Venting See Page 39 Figure 18 for recommended vertical venting options 9 2 4 Horizontal Venting See Page 40 Figure 19 through Page 42 Figure 21 for recommende
106. st be changed for modulating thermostats Settings can only be altered when the pump motor is stopped Verify that there is power to the VFD LCD display will be on and modulating thermostat is set to off ADANGER Electrical Shock Hazard Enclosure contains live electrical components Programming must be done by a trained technician only Replace cover before operating Failure to follow these instructions can result in death or electrical shock To override the rotary disconnect switch inside the VFD enclosure turn the square rod with a wrench to the ON position In order to be able to close the cover of the disconnect the rods need to be turned back to the OFF position 14 1 1 To enter the PROGRAM mode and access the parameters press the Mode button This will activate the PASSWORD prompt if the password has not been disabled Display reads 00 Upper right decimal point blinks 14 1 2 Use the arrow buttons to scroll to the password value 66 of 83 the factory set password is 225 Press Mode to enter password Once the correct password value is entered the dis play will read which indicates that the PROGRAM mode has been accessed at the begin ning of the parameter menu is the first parameter NOTE If the display flashes the password was incorrect and the process to enter the password must be repeated 14 1 3 Use the arrow buttons to scroll to the desired
107. stat See Note 2 with LonWorks Power Input Variable Frequency Driver Rotary Disconnect o 1 Input Model Shown Lonwork Bus Lonwork Motion Bus Sensor optional For Non communicating Thermostat See Note 7 Transformer Relay Sec 24V 60 Hz 33 VA Ext Load Black 1 Black 4 N PO5 4 See Note 1 b Pressure Switch 295 IN Zone 1 VFD Power Burners Outpot Terminal Pump For 115 V and 230 V input For 460 V input VFD Models VFD Models NOTES 1 For 4 20 mA Speed Control Set standard speed source parameter 05 to 04 Description Part Number 2 See VFD rating plate for required input 8 pM 1 d us suppy Tor 10V VED monel SPST Transformer Relay 90417600K z supply for model mre SA Da HETT a 3 Ground only one end of the shielded cable Thermostat Modulating LonWorks 90425104 4 Control wire to be a minimum of 20 AWG type Belden 5401 FE CMR 75 C shielded or equivalent 7 5 Wire over 24 to be a minimum of 16 AWG flexing type MTW 105 C 600 V or equivalent Thermostat Modulating 90425105 120 VAC colors Phase Red Neutral White Ground Green Sensor Remote Modulating 10081520 B 24 VAC colors Blue 6 All three power wires from terminals U V and W to the pump motor must be kept tightly bundled Sensor Outdoor Modulating 10081521 and run in a separate conduit away from all other
108. t which fails due to a manufacturing or material defect Roberts Gordon LLC will require the part in question to be returned to the factory Roberts Gordon LLC will at its sole discretion repair or replace after determining the nature of the defect and disposition of part in question ROBERTS GORDON warrants the cast iron combustion chamber of the ROBERTS GORDON CORAYVAC Classic System will be free from defects in material and workmanship This warranty is limited to twenty five 25 years from the date of shipment by Roberts Gordon LLC All other components of the ROBERTS GORDON CORAYVAC Classic System adhere to the standard warranty listed in the paragraph above ROBERTS GORDON Replacement Parts are warranted for a period of 12 months from date of shipment from Roberts Gordon LLC or the remaining ROBERTS GORDON warranty ROBERTS GORDON LLC WILL NOT PAY FOR Service trips service calls and labor charges Shipment of replacement parts Claims where the total price of the goods have not been paid Damage due to Improper installation operation or maintenance Misuse abuse neglect or modification of the ROBERTS GORDON CORAYVAC in any way Use of the ROBERTS GORDON CORAYVAC for other than its intended purpose Incorrect gas or electrical supply accident fire floods acts of God war terrorism or other casualty Improper service use of replacement parts or accessories not s
109. to a cut off limit temperature when the modulating thermostat turns off the heater 12 4 SPST Transformer Relay Kit P N 90417600K The transformer relay wiring diagram is shown on Page 53 Figure 30 The transformer relay can be used to control an EP 100 or EP 201 pump CORAYVAC system The single pole relay can only be used to control one zone of burners The electrical circuit is a 120 V AC 20 A supply The transformer 24 V AC output for the thermostat is rated at 40 V A Thermostats used with the transformer must not exceed this power requirement A transformer relay operated system will not give any post purge pump operation to completely exhaust products of combustion from the system or provide indication of operating conditions 12 5 SPDT Transformer Relay P N 90436300 The transformer relay wiring diagram is shown on Page 55 Figure 32 The transformer relay can be used to control an EP 100 or EP 201 pump CORAYVAC system The double pole relay can only be used to control two zones of burners The electrical circuit is a 120 V AC 20 A supply The transformer 24 V AC output for the thermostat is rated at 40 VA Thermostats used with the transformer must not exceed this power requirement A transformer relay operated system will not give any post purge pump operation to completely exhaust products of combustion from the system or provide indication of operating conditions 52 of 83 SECTION 12 CONTROL METHODS FIGURE
110. tor Support is p Description Part Number 2 Clips per Reflector Support Package 03050010 AOL U Clip Package 91107720 per Side Reflector End Cap 027508XX 23 of 83 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 7 4 3 Reflector U Clip and Reflector Support Installation The pictorial drawings of the heater construction in Section 7 are schematic only and provide a general guideline of where hangers reflector supports and U clips are to be installed To ensure proper expansion and contraction movement of the reflectors a combination of U clips 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 Reflector Overlap must be a minimum of 6 16 cm overlap is achieved by either a both reflectors lay inside a hanger No reflector support needed b using a reflector support with loose screws at the reflector 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 This section of three reflectors joined together must be affixed to the tube with at least one reflector support with tight screws

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CORAYVAC ® Installation, Operation and Service Manual