Home

Roberts Gorden CoRayVac CRV-B-2 User's Manual

Contents

1. 13 SECTION 7 Heater Installation 15 7 1 Tube Installation mmm nene nenea nana 16 7 2 Coupling and Tube 16 7 3 Elbow Package Configuration 17 7 4 Reflector Installation 18 7 5 Burner 20 SECTION 8 Optional Heater Accessories 21 8 1 Tee Installation sess 21 8 2 Reflector Joint mmm nana 21 8 3 Reflector Side 23 8 4 Universal Shield nenea 24 8 5 Barrier Shield 8 6 Two Foot Decorative Grille Installation 25 8 7 One Foot Decorative Grille Installation 26 8 8 Protective Grille Installation 8 9 Classic Cast lron Components SECTION 9 Pump Installation and Venting 31 9 1 Pump Installation esiri 31 9 2 General Venting Requirements Model EP 100 EP 200 and EP 300 Series Pumps 32 9 3 Horizontal Venting 4 10 cm 34 SECTION 10 Outside Air 37 10 1 Pressurized rnrvnnnnnonnnvvnnnnonnnnrnnnnnnnnnnrnnnnnnnnnrnnnnnnnn 37 10 2 Non Pressurized 37 10
2. 5 Universal Shield Position 2 5 Universal Shield Position 3 5 2 Foot Deco Grille anaron 6 Bartier Shield 2 re 6 1 Foot Deco Grille 6 Major Component Descriptions 8 Heater Assembly Overview 14 Critical Hanger 15 Reflector Joint 22 EP 200 Condensate Valve Assembly 31 Vertical Venting Configuration 33 EP 100 Horizontal Venting Configurations 34 EP 200 Series Horizontal Venting 35 EP 300 Series Horizontal Venting Configurations eene 36 Duct Sizing i eoi a Pes ies 37 Outside Air Blower Internal Wiring Diagram 38 Filter Housing Assembly 38 Air Supply Blower 39 Pressurized Outside Air Supply 39 Non Pressurized Outside Air Supply 40 Gas Connection with Flexible Gas 41 One Zone Operation without Control Panel 43 One Zone Operation with Outside Air Blower without Control
3. 44 Two Zone Operation without Control Panel 45 General System Wiring 46 External Wiring Diagram EP 100 and EP 201 120 V 1 9 Pump s i ci tem P 46 External Wiring Diagram EP 301 120 V 10 Pump uinea het 47 External Wiring Diagram EP 203 or EP 303 208 V 230 V or 460 V 3 Pump 47 Burner Internal 48 Burner Internal Ladder Diagram 48 Vacuum Reading eene 50 SECTION 1 HEATER SAFETY Your Safety is Important to Us This symbol is used throughout the manual to notify you of possible fire electrical or burn hazards Please pay special attention when reading and following the warnings in these sections Installation service and annual inspection of heater must be done by a contractor qualified in the installation and service of gas fired heating equipment Read this manual carefully before installation operation or service of this equipment This heater is designed for heating nonresidential indoor spaces Do not install in residential spaces These instructions the layout drawing local codes and ordinances and applicable standards that apply to gas piping electrical wiring venting etc must be thoroughly understood before proceeding with the installation Thin sheet metal parts the aluminum reflector portion of the heater and the v
4. sBuueeq amp A991 ON JOJOW BY Seoq y je vod joeuuoosiq yno Ajddns jeued uo esnj Jo pue 19Xe21q payoniyjsqo Jejjeduui y 51 Jo jaued SOA amp 104U09 eui S uo seoq peisi sjaued 011009 19J9H jesei sejnuiui 91 01 HEM YMS poddiuy e eu uo eui seoq dn UINL SOA 10y S Asessaoeu JI pue Buum 2940 yenuew UONR EJSU eui pue 94 uo Buum y peyoeuuoo 51 55 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Troubleshooting Flow Chart 2011914511 juapuadapu NOQHOS 5153909 W09 2UI BI MMM Jno 18 U0pJ05 sueqoy 7 YNZOCZCL N d 008 d3 1061000 15158190 SWa qoAd si SONA LOOHSITANOUL VN002Z2c I N d 006 d3 VNLO2ZcL N d 001 d3 01 dung MO 8q pasi sjenueuu jaued 104000 0 19jay 5 SJOSUAS 809101 JO SJEISOUWISU yey ans exe ponad abind jsod z e Jaye umop inus ay 5900 SUONDNJISUI sJeJnj9ejnueui 041u09 3udoIdde 19491 Jaued 01002 OU
5. Step 8 6 2 Frame Shield Installation Shield Description Part Number Deco Grille Shield 01365900 25 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 6 3 Reflector Side Extension Installation for Decorative Grilles 6 15 cm Minimum 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 Cut relief notches for tube and reflector hangers Allow 6 15 cm minimum clearance between burner box and overhead obstructions for service a Insert screw here see note Reflector Side Extension Distance A Extension Minimum Maximum Part No Width 2 4 cm 6 15 cm 01370408 8 20 cm Description Part Number 6 15 cm 10 26 cm 01370412 12 30 cm Reflector Side Extension 01370412 10 26 cm 14 37 cm 01370416 16 40 cm 8 7 One Foot Decorative Grille Installation Step 8 71 One Foot Decorative Grille Bracket In order to maintain reflector shape do not fasten brackets together 8 Sheet Metal Screws Do not fasten bracket to adjoining reflectors Maintain same slipjoint Decorative Grille Bracket 5 cm Cut relief notches for supports and hanger
6. Zone 1 Zone 2 Zone 3Zone 4 Je 7 The power supply for the 9 pump must be separate 3 S from the controller supply 3 1 o5 Individual supply for BE 230 V pump rated for total Fry SE NO 1 2 full load current 60 2 120V 10 120 V 60 Hz Low voltage thermostats 1 eo located in heated zone Pi itch 60 Hz Zone Zope Zone Zone Presse sen lt oe N4 BIENE EEE ME 2 vae A Ground ee jee e e e e e Ground o Zz NLI NL INL NL INL o of of o o 21 22 73 74 PUMP N wn F F H F a System Control FIGURE 32 External Wiring Diagram EP 203 or EP 303 208 V 230 V or 460 V 3 8 Pump EP 203 or Do not directly connect the Motor starter P N 10050001 EP 303 3 Pump controller relay terminals to the rated for EP 203 pump motor pump motor Product damage will motor starter P N 10050010 result rated for EP 303 pump motor The power supply for the pump must be separate All burners must be connected o Ground x from the controller supply
7. When installed over hoists minimum clearances to combustibles must be maintained from the uppermost 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 ANSI NFPA 70 latest revision Wiring must conform to the most current National Electrical Code local ordinances and any special diagrams furnished Canada Refer to Canadian Electrical Code CSA C22 1 Part 1 latest revision 4 5 Venting The venting must be installed in accordance with the requirements within this manual and the following codes United States Refer to NFPA 54 ANSI Z223 1 latest revision National Fuel Gas Code Canada Refer to CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances 4 6 High Altitude These heaters are approved for installations up to 2000 610 US 4500 1370 Canada without modification Consult factory if US installation is above 2000 610 m or Canadian installation is above 4500 1370 m 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 14 Fi
8. Not shown oL Zone 1 Zone 2 Zone 3 Zone 4 208 230 V or 460 V ee ee 9 9 9 3 6 60 Hz Individual supply for pump rated for 2 total full load current n ee eo trr e e gt 120V 120 V 1 Low voltage thermostats 1 6 Pel located heated zone 60 Hz Zone Zone Zone Zone 60 Hz 1 2 3 4 lt e_e61 o Pressure switch 0 5 located at pump ee EJ P 2 II T De Ground 12 dd do bb ss 6 Ground 2 4 NL NL NL INL NL Zi 22 23 24 PUMP asl N 0 F F F a System Control 47 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 33 Burner Internal Wiring TRANSFORMER 1 A 5 White Yellow Black Bauer Sanai Green 3 Blue F Ir Yellow Green GAS Brown H 1 VALVE Yellow T Black IGNITION S MODULE 7 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 34 Burner Internal
9. Vent Terminal 4 10 cm Combustible Wall Not Supplied Tube Aluminized 5 12 7 cm dia 10 3 m 90502101 Vent Terminal 6 15 cm Combustible Wall Not Supplied Tube Adapter 5 12 7 cm dia x 4 10 cm dia 90505600 Wall Thimble 4 10 cm Not Supplied Tube Adapter 6 15 2 cm dia x 5 12 7 cm dia 35 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 18 EP 300 Series Horizontal Venting Configurations 10 3 Maximum 1 Elbow 18 46 cm Minimum 40 102 i 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 36 A Vil Vent Terminal Tjernlund VH1 2m 6 15 cm Wet Included Part Number Description Part Number Description 01330203 Tee 4 10 cm Aluminized 91409403 Tube Aluminized 4 10 cm dia 10 3 m 01330204 Tee 6 15 cm Aluminized 91409420 Tube Aluminized 6 15 cm dia 10 3 m 01331900 Damper Coupling 4 10 cm 91412800 Flexible Boot 4 10 cm 01335801 Elbow 4 10 cm Aluminized 90 91412802 Flexible Boot 6 15 cm 01397400 Bird Screen 6 15 91418200 Tube Adapter 6 15 2 cm dia x 4 10 cm dia 02537801 1P Vent Termina
10. 50 mm displacement shown is for the cold condition This displacement may reduce when th tem is fired i 2 5 e system is fired 30 cm Flexible O Gas pper meee Horizontal Burner Rear View Description Part Number 1 2 Flexible Stainless Steel Gas Hose US Models 91412200 3 4 Flexible Stainless Steel Gas Hose US Models 91412203 1 2 Rubber Type 1 Gas Hose Canadian Models 91412206 3 4 Rubber Type 1 Gas Hose Canadian Models 91412207 41 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 12 CONTROL METHODS A WARNING Electrical Shock Hazard Disconnect electrical power and gas supply before servicing This appliance must be connected to a properly grounded electrical source Failure to follow these instructions can result in death or electrical shock 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 46 Figure 29 through Page 47 Figure 32 and in the System Control Installation Manual P N 10091601NA 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 phase models may be controlled by relay or motor starter The System C
11. 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 15 Figure 12 If the radiant tubes must pass through the building structure be sure that adequate sleeving and fire stop is installed to prevent scorching and or fire hazard SECTION 3 CRITICAL CONSIDERATIONS A WARNING amp Fire Hazard Some objects will catch fire or explode when placed close to heater Keep all flammable objects liquids and vapors the required clearances to combustibles away from heater Failure to follow these instructions can result in death injury or property damage CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL NOTE 1 All dimensions are from the surfaces 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 Protective Grille clearances are the same as Standard Reflector FIGURE 1 STANDARD REFLECTOR inches centimeters Model A B C D B C 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 1
12. 12 8 18 24 18 21 46 61 46 CRV B 12A 8 18 24 18 21 46 61 46 FIGURE 5 UNIVERSAL SHIELD POSITION 2 inches centimeters Model A B C D C 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 6 UNIVERSAL SHIELD POSITION 3 inches centimeters Model A B C 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 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL NOTE 1 All dimensions are from the surfaces of all tubes couplings elbows tees and crosses 2 Clearances and can be reduced by 50 after 25 7 5 of tubing downstream from where the combustion chamber and the tube connect FIGURE 7 2 FOOT DECO GRILLE inches centimeters Model A B C D B C 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 1
13. 15 cm dia 10 3 m 9141030D Coated 4 10 cm dia 10 3 m E0009105 Tube Heat Treated Aluminized 6 15 cm dia 10 3 m 91418200 Tube Adapter Aluminized 6 15 cm dia x 4 10 cm dia 11 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Control Packages and Accessories Protective Grille 10001501 Water Resistant Sensor 08050001 Protective Grille 40 1 m 02770002 System Control 08050002 Protective Grille End Cap URVCCM ROBERTS GORDON ULTRAVAC Central Controller with Modem Chip amp Software Includes Shields URVSC ROBERTS GORDON ULTRAVAC Controller 02750303 Barrier Shield 10080142 Modem Chip 02751801 Universal Shield 10081501 Outdoor Sensor 02751855 Universal Shield Stainless Steel 10080410 PC Connection Cable Package 02751800 Universal Shield with Holes ROBERTS GORDON ULTRAVAC Central Controller with RS 485 Converter amp Software Includes ROBERTS GORDON ULTRAVAC Controller 10080430 RS 485 Converter with 9 V Power Supply 10081501 Outdoor Sensor 10080410 URVCCL PC Connection Cable Package ROBERTS GORDON ULTRAVAC Central Controller with TCP IP Communication Module amp Software Includes URVSC ROBERTS GORDON ULTRAVAC Controller 10080440 TCP IP Communication Module 10081501 Outdoor Sensor 10080410 PC Connection Cable Package Pump Packages an
14. 300 Series Pump El Ge 4 mt ye 2 Outside Air Supply Blower Motor and Pressure Switch FIGURE 30 External Wiring Diagram EP 100 and EP 201 120 V 1 Pump Pump All burners must be connected to Ground Not shown Zone 1 Zone 2 Zone 3 Zone 4 eoe 1 ee Low voltage thermostats ee le le located in heated zone Zone Zone Zone Zone 1 2 3 4 120 V Pressure switch 160 lee 601 le located at pump 60 Hz Se e 12 Vdc MN 120 V 1 ev e 60 Hz Ground a n e Ground NL NL NL NL 4 Zi Z2 Z3 74 PUMP PB System Control 46 SECTION 12 CONTROL METHODS FIGURE 31 External Wiring Diagram EP 301 120 V 1 Pump EP 301 Pump Do not directly connect the controller relay terminals to the pump motor Product damage will result IEC contactor P N 10050009 rated for All burners must be connected aoe e 4 the EP 301 pump to Ground Not shown motor
15. GORDON independent distributor or consult the CRV Series Design Manual P N 127500NA SECTION 6 DESIGN REQUIREMENTS CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 11 lew Heater Assembly Overvi JO UONP E SUI eyeudoudde eui ees jeuonippe pue SJOSUSS euoz saJmbei OVAVHLIN eBNOGHOD SLHAGOH SJeIsouLIauy seunbai S rejep JO enuey pue uonejeisu sJe ouoo eyeudoudde y ul 0 49JeH s18J 041U09 pue jou uoddns 10199 jeY JO JOSUBS euoz 1099 JOH Guydno9 JOojoo jeH Jequieu5 10199 JOH ES 1009 DS P qxejd 19 1044u09 OVAVHLTN AC gNOQHOD 51 990 10 1 jsneux3 1 14 SECTION 7 HEATER INSTALLATION A WARNING Suspension Hazard Hang heater with materials with a minimum working load of 75 Ibs 33 kg Failure of the supports can result in death injury or property damage To ensure your safety and comply with the terms of the warranty all units must be installed in accordance with t
16. Minimum 40 102 cm Maximum PI Pitch single wall pipe downward away from pump 1 4 6 mm for every 10 3 m 5 to 4 Reducer 12 5 cm to 10 cm 4 10 cm Single Wall Pipe 10 3 m Maximum and No Elbows gt 6 to 5 Reducer 15 cm to 12 5 cm 5 12 5 Single Wall Pipe 6 to 4 oc 15 cm to 10 cm 25 8 m and 3 Elbows Maximum Bird Screen Approved Thimbles gt 18 46 cm Minimum 40 102 cm Maximum 4 10 cm Band Clan 4 10 cm Vent Terminal Vent Terminal Tjernlund VH1 4 h m Vent Terminal Tjernlund VH1 6 al 6 15 cm Single Wall Pipe 50 15 m and 3 Elbows Maximum gt Vent Terminal Fine Tjernlund VH1 6 A Part Number Description Part Number Description 01330203 Tee 4 10 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 91412801 4 Flexible Boot 1 2 1 3 cm 01365400 Bird Screen 4 10 cm 91418200 Tube Adapter 6 15 2 cm dia x 4 10 cm dia 02537801 1P Vent Terminal Non Combustible Wall 91901300 Boot Clamp 4 10 cm 02718851 4 Drain Cap 91906900 Silicone Ring 90502100
17. can be adjusted to direct heat to or away from a desired area See Page 5 Figure 4 through Page 5 Figure 6 for positions Flattened gt Tub d Reflector Support Assembl Section T PP y Stud Description Part Number Universal Shield 02751801 Universal Shield with Holes 02751800 Universal Shield Support Package 02712100 Tube and Reflector Support Assembly 01329802 Universal Shield Support 02751700 Shield Bracket Assembly 02721400 Sud r 2790900 Included in universal shield Hex Nut 92114800 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 Shield 02750303 U Clip Package 91107720 24 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 eee ES 2 x 4 60 cm x 120 cm Aluminum Grille Description Part Number Aluminum Grille 2 x 4 60 cm x 120 cm 91407000
18. expressed or implied statutory or otherwise other than those contained in this warranty Roberts Gordon 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 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 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 parts or power No person is authorized to assume for Roberts Gordon any other warranty obligation or liability LIMITATIONS ON AUTHORITY OF REPRESENTATIVES No representative of Roberts Gordon 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 s duly authorized Executive Officer 61 B BERTS GORDON Infrared Heating OWNER WARRANTY REGISTRATION CARD Mail or Fax to Roberts Gordon LLC 1250 William Street P 0 Box 44 e Buffalo NY 14240 0044 e Phone 716 852 4400 Fax 716 852 0854 Tol
19. not exceed 120 Elbows are equivalent to 10 3 m of duct length 37 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 10 3 Outside Air Blower Internal Wiring FIGURE 20 Outside Air Blower Internal Wiring Diagram Outside air blower is shipped with the blower manufacturer s standard internal wiring BLOWER For use with Roberts Gordon heaters the PRESSURE outside air blower must be rewired with existing SWITCH wires by the electrical contractor See diagram Internal 24 V transformer provided will not be NO used and can be discarded MOTOR BLK BLU BLU WHT LN M 1 T2 T3 v v M FIGURE 21 Filter Housing Assembly Door Control Housing Bottom Gasket Filter Housing Wing Nut Top Gasket a and Disk at SS 27 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 38 FIGURE 22 Air Supply Blower Support SECTION 10 OUTSIDE AIR SUPPLY Outside Air Supply Blower 5 12 5 cm Inlet Pipe 5 12 5 cm Wall Outlet Pipe Description Part Number Blower 90707501 5 12 7 cm Vent Cap 90502302 6 15 cm Bird Screen 01397400 6 15 cm Band Clamp 91913703 FIGURE 23 Pressurized O
20. 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 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 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 2 Service Manual See Page 4 Figure 1 through Page 6 Figure 9 Write the proper clearance dimensions in permanent ink according to your model number and configuration in the open spaces on the tag 2 2 Corrosive Chemicals A CAUTION Do not use he
21. 00 61 m 4 10 cm 46 122 cm 250 76 m 5 13 cm 57 145 cm 15 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 7 1 Tube Installation re Combustion gt e 7 6 Description Part Number Tube 91409XXX Turnbuckle 91903201 Tube Reflector Hanger 03090100 maximum 3 m SS NOTE Tubing requires downward slope of 1 2 13 mm per 20 6 m away from burner Tailpipe tubing requires downward slope of 1 26 mm per 20 6 m away from burner Step 7 2 Coupling and Tube Assembly A Close coupling with tab B Start slide bar coupling lock onto coupling Slide Bar Coupling Lock 3 8 cm IR 4 10 cm Wide End Coupling 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 Ne Slide Bar Coupling Lock 4 ide Bar Coupling Loc Coupling x e Description Part Number Coupling 01329600 Slide Bar Coupling Lock 01329700 Tube 91409XXX 16 SECTION 7 HEATER INSTALLATION Step 7 2 1 Coupling and Tube Assembly Continued Tighten slide bar as shown below Drive slide bar until tight End of slide bar should be within tolerance listed below 2 5 cm Correct Slide Bar x Dimensions C Incorrect Slide B
22. 1 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 8 BARRIER SHIELD inches centimeters Model A B C D A B C 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 9 1 FOOT DECO GRILLE inches centimeters Model A B C D A B C D CRV B 2 4 12 48 12 11 51 122 51 CRV B 4 4 12 48 12 11 51 122 51 CRV B 6 4 12 48 12 11 51 122 51 CRV B 8 4 12 48 12 11 51 122 51 CRV B 9 4 18 56 18 11 92 153 92 CRV B 10 4 18 56 18 11 92 153 92 CRV B 12 4 18 56 18 11 92 153 92 CRV B 12A 4 18 56 18 11 92 153 92 SECTION 4 NATIONAL STANDARDS AND APPLICABLE CODES SECTION 4 NATIONAL STANDARDS AND APPLICABLE CODES 4 1 Gas Codes 4 3 Public Garages The type of gas appearing on the nameplate must be the type of gas used Installation must comply with national and local codes and requirements of the local gas company United States Refer to National Fuel Gas Code ANSI 2223 1 latest revision same as NFPA 54 Canada Refer to CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances 4 2 Aircraft Hangars Installation in aircraft hangars must be in accordance with the following codes United States Refer to Standard for Aircraft Ha
23. 2 A 90436300 Transformer Relay DPST 12 A 90423000 24V Low Voltage Thermostat Marked 1 5 90424300 Thermostat Guard Deco Grille 1 x 8 3 m x 2 4 m 90430600K Pressure Switch 01327001 Condensate Check Valve Assembly 02718851 Drain Cap 4 10 cm 02718852 Drain Cap 6 15 cm Starters 10050001 Starter 120 Vac for EP 203 3 10050002 Starter 12 Vdc for EP 201 10 10050003 Starter 120 Vac for EP 201 1 10050008 Starter 120 Vac for EP 301 1 10050009 Contactor Package 230 Vac Coil for EP 301 2 HP 10050010 Starter 120 Vac for EP 303 3 01363003 Bracket 01365901 Piece 01326801 Reinforcement 01365903 Joint Piece 91406700 1 3 m x 8 2 4 m Protective Grille Deco Grille 2 x 4 6 m x 1 2 ml 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 Reflector Side Extension 16 x 48 40 6 cm 122 cm 91407000 Grille Aluminum 2 x 4 6 m x 1 2 m 12 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
24. 22 51 NN CRV B 9 4 36 60 36 11 92 153 92 Y 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 2 ONE SIDE REFLECTOR inches centimeters Model A B C D A B C 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 3 TWO SIDE REFLECTORS inches centimeters A Model A B C D B C D A GRV B 2 4 12 56 12 11 31 143 31 Y 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 DER 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 SECTION 3 CRITICAL CONSIDERATIONS NOTE 1 All dimensions are from the surfaces 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 4 UNIVERSAL SHIELD POSITION 1 inches centimeters Model A B C D A B C 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
25. 3 Outside Air Blower Internal Wiring 38 SECTION 11 Gas Piping eene 41 SECTION 12 Control 5 42 12 1 ROBERTS GORDON System Control 42 12 2 ROBERTS GORDON ULTRAVAC 42 12 3 SPST Transformer Relay P N 90417600 42 12 4 DPST Transformer Relay P N 90436300 42 SECTION 13 Starting The 49 13 1 Checking the Gas Line 49 13 2 Checking the Electrical System 49 13 3 Starting the 49 13 4 Setting the Vacuum 49 SECTION 14 Operation and Maintenance 51 14 1 Sequence of 51 14 2 To Shut Off Heater sse 51 14 3 To Start Heater men 51 14 4 Pre Season Maintenance and Annual Inspection 51 14 5 Maintenance 52 SECTION 15 Troubleshooting eere 55 15 1 Troubleshooting Flow 55 SECTION 16 Replacement Parts 57 SECTION 17 General Specifications 58 17 1 Material Sp
26. C 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 written permission of Roberts Gordon LLC www rg inc com Printed in U S A P N 91037912 Rev C
27. C arising from a drawing design or specification supplied by or on behalf of the consumer Damage incurred during shipment Claim must be filed with carrier WARRANTY IS VOID IF The CORAYVAC 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 CORAYVAC is moved or transferred This warranty is nontransferable Roberts Gordon is not permitted to inspect the damaged controller and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your controller contact your installing professional Should you need Replacement EE or have additional questions call or write Roberts ordon U S A 1250 William Street Box 44 Buffalo New York 14240 0044 716 852 4400 On the web at www rg inc com Roberts Gordon 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
28. 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 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 Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Some objects will catch fire or explode when placed 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 Quality in Any Language Copyright 2006 Roberts Gordon SW RG Q ROBERTS GORDON XX 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 installati
29. Jo pausing ON Aau 5 payoaye uo sapoJj99 a y 1290 Aue Wau 110320 s1auJnq ay OG 00 def ay S 8 ag deb epouj99 3 aoejday pales uoniub SOA 56 SECTION 16 REPLACEMENT PARTS SECTION 16 REPLACEMENT PARTS Use only genuine ROBERTS GORDON replacement parts Use of parts not specified by Roberts Gordon voids warranty Failure to follow these instructions can result in property damage Gasket Burner to Mixing Chamber Mixing Chamber Ignition Module Ignition Cable Regulator Electrode Electrode Gasket Combustion Gas Valve Chamber Gasket Description Part Number Gas Valve All Burners 90032502 Gasket Burner to Mixing Chamber 01351100 Burner Head Assembly Replacement Package 02713000 Mixing Chamber 02790400 Transformer 90436900K Regulator 90207100 Gasket Combustion Chamber 01367800 Electrode Replacement Kit includes electrode electrode gasket and mounting screws 02713200 Ignition Module 90439500 Ignition Cable 90427706 Filter Cartridge with Gasket not shown 01312401 57 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL SECTION 17 GENERAL SPECIFICATIONS 17 1 Material Specification 17 3 Suspension Spec
30. Ladder Diagram L1 L2 TRANSFORMER Black White Blue ELECTRODE Yellow GAS VALVE FE 101 IGNITION V2 S1 Vi TH Gnd i MODULE 48 SECTION 13 STARTING THE SYSTEM Start with the main gas valve closed and the electric power off 13 1 Checking the Gas Line 1 3 4 Open the main valve and verify that no gas is flowing through the meter Purge the line if this was not done following pressure testing with air Verify that the gas pressure is not above 14 w c 1 2 PSIG Close the main gas valve 13 2 Checking the Electrical System 1 See that all temperature setpoints are set below room temperature Turn on power supply to system controls Check to see that no part of the system i e burners pump or air supply blower is powered Individually check each zone by raising the zone temperature set points separately Raising each zone temperature set point above 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 Make a preliminary vacuum check at burners in branches that have an adjustable damper coupling See Page 50 Figure 35 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 w c o
31. N 17 GENERAL SPECIFICATIONS General Specifications for pumps are as follows Pump Dimensional Data in Model A B D E F EP 100 17 145 21 375 10 4 4 EP 201 203 1775 17 2025 325 10 45 45 EP 301 303 25 6 24 8 22 7 4 8 15 2 6 6 F dia Pump Specifications Model EP 100 EP 201 EP 203 EP 301 EP 303 Phase 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 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 60 SECTION 18 THE ROBERTS GORDON CORAYVAC LIMITED WARRANTY SECTION 18 THE ROBERTS GORDON CORAYVAC LIMITED WARRANTY ROBERTS GORDON WILL PAY FOR Within 42 months from date of shipment from Roberts Gordon replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect Roberts Gordon will require the part in question to be returned to the factory Roberts Gordon will at its sole discretion repair or replace after determining the nature of the defect and disposition of part in question ROBE
32. RTS GORDON warrants the cast iron combustion chamber of the CORAYVAC Classic System will be free from defects in material and workmanship This warranty is limited to twenty five 25 eae from the date of shipment by Roberts ordon All other components of the CORAYVAC Classic System adhere to the standard warranty listed in the paragraph above ROBERTS GORDON Replacement Parts are warranted for a period of 18 months from date of shipment from Roberts Gordon or the remaining CORAYVAC warranty ROBERTS GORDON 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 CORAYVAC any way Use of the 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 specified by Roberts Gordon Failure to install or maintain the CORAYVAC as directed in the Installation Operation and Service Manual Relocation of the CORAYVAC after initial installation The use of the CORAYVAC in a corrosive atmosphere containing contaminants e The use of the CORAYVAC in the vicinity of a combustible or explosive material Any defect in the CORAYVA
33. ULM SW JS S 104 VNL0918001 mOVAVYLIN eNOQuOS SLYIEOU VNL0916001 N d 10 300 5 sjenueN 01 2 5 syenuew jaued 0 3002 0 Jajay aie 5105195 Jeu19jul 10 Syejsouuaui ye 184 ans aye 5 SI ea 10 ED au Jaye 40 Mys sjeuing oq SUONONJJSUI ES49A91 10 Mo aq pajsi ui suomnonugsul 3jnsuo JUBA pua 3U WNNILA KJESS9JAU se 5191 eoe dau Pr pe pina 180 Dd 5 5 ay ui SYEA 10 10 Ajddns apisjno y 10 X98u9 sawing 1991109 1070uu y UO 51911 94 Y JO ay SI MOJ 00 18s WNNIA au S MOJ S SUONDNJISUI eS19A81 10 5 SUONINJISU JNSUOJ UNG e1npaoo4d yoayo Jung MoJ 04 JUBA pua y JE uinnoeA Ayessaoau se 19111 99 day 190010 10 waists ysnipy adidje 10 pasn aq pjnous peur Apadouduui paesu Aew shuljdno9 susuing y uo y 41981109 duind JO uoneio1 aui S GUDULIG e ui sieunq Peep Aue 9194 amp MO 00 i i918 5 au S ay 922109 Jo def ay 1sn py S9poJ129 8 99 da4 pabewep
34. anre 10sseooJdoJo lA JO NEM JEWION Jo es ye peaijs puooes y uonnjios sapo9 onsouBeig aINPOIN JUBA pue y Jedoud 104 ujejs s 1sn py Ajyjoows y je OG 00 Bunes 99 ON amp S9JIM Moj o pue SeA enjq Ajepuooes Jeuuojsuen ON JeuJng eui JE Apz 9194 51 ejnpouu uoniufi eoejdou JeulJoJsueJ eoejdeu 1311 pue uo 37 42840 oq spuooes gy 3511 pued 011009 19JeH Spu3 100usejqnoJ So amp Bupueds Aq souanbas uoniufi y seoq uiri uay spuooes OL eui amp 8U0Z y 19MOd eJeui S SOA ISI jaued amp SJeuJnq SU pue ainssaid sef adoud S ybi y op ponad spuooes Gp pue 40 yooyD SOA SoA amp e oejdeoei a eui SI SOK ul SI SU ANS YEN euunq eui Buum 45 ulejqoud se 1991109 JOJOW
35. ar Position Repeat Step 7 2 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 Installation SS Ne Coupling AN C wa gt gt Minimum Distance Required Between arent 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 i15 45m U Clip Package 91107720 CRVB 12 15 4 5 m Step 7 3 2 Elbow Installation SS we Tube N SE CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 7 4 Reflector Installation Step 7 4 1 Reflector Installation with Hole Slide Reflector chamber from cha and insert through h Reconnect chain with hole RE through hanger Unhook combustion in ole Description Part Number Tube Reflector Hanger 03090100 Tube 91409XXX Reflector with Hole 02750304 Combustion Chamber Step 7 4 2 Reflector Installation 2 Clips per Alternate Overlaps per Side 18 Description Part Number Reflector Support Package 03050010 U Clip Package 91107720 Reflector E
36. arious venting components have sharp edges To prevent injury the use of work gloves is recommended The use of gloves will also prevent the transfer of body oils from the hands to the surface of the reflector Before installation check that the local distribution conditions nature of gas and pressure and adjustment of the appliance are compatible 1 1 Manpower Requirements To prevent personal injury and damage to the heater two persons will be required for installation SECTION 1 HEATER SAFETY 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 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 sides for servicing or burner removal To provide the owner with a copy of
37. ater in an area containing corrosive chemicals Avoid the use of corrosive chemicals to ensure a longer life of the burner tubing and other parts Failure to follow these instructions can result in property damage Roberts Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation this is entirely the responsibility of the installer It is essential that the contractor the sub contractor or the owner identifies the presence of combustible materials corrosive chemicals or halogenated hydrocarbons anywhere in the premises Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements fluorine chlorine bromine etc These compounds are frequently used in refrigerants cleaning agents solvents etc If these compounds enter the air supply of the burner the life span of the heater components will be greatly reduced An outside air supply must be provided to the burners whenever the presence of these compounds is suspected Warranty will be invalid if the heater is exposed to halogenated hydrocarbons 2 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 gas and venting installation Note Additional standards for installations in public garages aircraft hangars etc may be app
38. ation Subtract 15 4 m of maximum allowed vent or outside air duct length per vent elbow if more than three are used FIGURE 15 Vertical Venting Configuration SECTION 9 PUMP INSTALLATION AND VENTING Approved Thimble ET Aluminized Tee Drain Cap Approved gt Vent Cap 2 6 m Minimum 1 2 5 cm P V C to drain system in accordance with local 6 1 5 cm 20 5 1 cm for EP 300 Part Number Description Part Number Description 01330203 Tee 4 10 cm Aluminized 91409403 Tube Aluminized 4 10 cm dia 10 3 m 01330204 Tee 6 15 cm Aluminized 91409420 Tube Aluminized 6 15 cm dia 10 3 m 01331900 Damper Coupling 4 10 cm 91412800 Flexible Boot 4 10 cm 01335801 Elbow 4 10 cm Aluminized 90 91412801 4 Flexible Boot 1 2 1 3 cm 02718851 Drain Cap 4 10 91412802 Flexible Boot 6 15 cm 02718852 Drain Cap Assembly 6 15 cm 91901300 Boot Clamp 4 10 cm 90502300 Vent Cap 4 10 cm Metalbestos 91913703 Boot Clamp 6 15 cm 90502302 Cap 6 15 cm Metalbestos E0009356 Damper Coupling 6 15 cm 90505600 Wall Thimble 4 10 cm 70100320 Elbow 6 15 cm Aluminized 90 33 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 9 3 Horizontal Venting 4 10 cm Pipe FIGURE 16 EP 100 Horizontal Venting Configuratio
39. combustion chamber is 40 25 Ibs 18 kg 4 Schedule 40 pipe weighs 10 9 Ibs 5 kg per foot Coupling Cast lron Adapter CORAYVAC Classic Cast Iron Combustion Chamber Coraulac Cast Iron Combustion Chamber with Standard 4 O D Infrared Tubing The total weight of each burner and combustion chamber is 40 25 lbs 18 kg 4 16 Ga tubing weighs 2 8 Ibs 1 3 kg per foot Cast lron Adapter End Vent Clips N gt gt gt gt End Vent Plate for End Burner Only End Vent Clips gt p gt gt gt End Vent Plate for End Burner Only Description Part Number Special Tube amp Reflector Hanger 02790300 Turnbuckle 91903201 Cast lron Combustion Chamber 02721200 1P Cast Iron Adapter 02722100 Coupling 01312700 30 SECTION 9 PUMP INSTALLATION AND VENTING SECTION 9 PUMP INSTALLATION AND VENTING 9 1 Pump Installation For complete pump installation please refer to the EP 100 EP 200 or EP 300 Series Installation Operation and Service Manuals FIGURE 14 EP 200 Condensate Valve Assembly Description Part Number Condensate Valve Assembly 01327001 wd br 1 NPT threaded hole a Use 1 x 34 reducer 555 not supplied Copper or galvanized pipe between pum
40. d Accessories 02719105 EP 100 Pump Package 02719100 EP 100 Pump 02724700 Accessory Package 02716305 EP 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 Pump Accessories URVSC Controller ROBERTS GORDON ULTRAVAC 1 Pump 3 Zones Satellite Control VFD75115 Variable Frequency Drive Assembly 75 HP 115 V Input VFD75230 Variable Frequency Drive Assembly 75 HP 230 V Input VFD20230 Variable Frequency Drive Assembly 2 HP 230 V Input 10080142 Modem Plug In Chip 10080410 Cable Package PC Connection 10080430 RS 485 Converter with Power Supply 10080440 Communication Module 10081500 Sensor Adjustable Indoor Deg F ROBERTS GORDON ULTRAVAC Controller 10081501 Sensor Outdoor ULTRAVAC 10081502 Sensor Adjustable Indoor Deg C ULTRAVAC Thermostats 05023000 Load Relay Package 90417600 Transformer Relay SPST 1
41. e 28 Section 8 75 Make sure shield is installed correctly and secured in place if necessary Decorative grille only See Page 25 Section 8 6 2 53 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Pump 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 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 54 SECTION 15 TROUBLESHOOTING TROUBLESHOOTING SECTION 15 ing Flow Chart 15 1 Troubleshoot 99e dai auou Ji e2e doJ Sou e Jaye pue eA eA pue Jo 1nox90 JO 49840 8 0 08H uous seuse eeJu L Jeuung pue eje d eins ayeyy pejjeisur eq ajd pue BuoJM eoejded
42. ecification 58 172 Heater Specifications 58 17 3 Suspension Specifications 58 174 Controls 5 58 SECTION 18 The ROBERTS GORDON CORAYVAC Limited Warranty cere 61 2006 ROBERTS GORDON LLC All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Roberts Gordon LLC Printed in U S A 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 Standard Reflector 4 One Side 4 Two Side Reflectors 4 Universal Shield Position 1
43. ector is a slip overlap Thereafter every third reflector joint is a slip overlap A slip be affixed to the tube with at least one reflector support 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 Support Loose screws loosened 1 16 1 6 mm to allow slippage Reflector Tight Screws 2 Clips per Non slip Overlap inside a Hanger 19 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 7 5 Burner Installation Description Part Number Bolt 94273914 Burner 0270XXXX Lock Washer 96411600 Gasket 01367800 End Vent 013676XX Combustion Chamber End Vent gt Combustion gt Chamber NOTE Install end vent at end combustion chamber position only 20 SECTION 8 OPTIONAL HEATER ACCESSORIES SECTION 8 OPTIONAL HEATER ACCESSORIES Step 8 1 Tee Installation Ss Tube s 5 PP Description Part Number Tee 01330XXX Tube Reflector Hanger 03090100 Tube 91409XXX Coupling 01312700 Step 8 2 Reflector Joint Step 8 2 1 Reflector Joi
44. ent to prevent blockage by snow and building materials protected from degradation by flue gases Secure all joints with 48 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 Vertical Venting See Page 33 Figure 15 for recommended vertical venting options 32 9 2 2 Horizontal Venting See Page 34 Figure 16 through Page 36 Figure 18 for recommended horizontal venting options 9 2 3 United States Requirements Vent must terminate at least 3 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 3 m above any door operable window or gravity air inlet into any building 9 2 4 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 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 Length Requirements See Page 33 Figure 15 through Page 36 Figure 18 for recommended vent lengths and sizes 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 determin
45. 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 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 52 Section 14 5 for suggested items to inspect 51 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 14 5 Maintenance Checklist A WARNING Explosion Hazard Service and annual inspection must be done by contractor qualified in the installation and service of gas fired heating equipment or your gas supplier Turn off gas and electrical supplies before performing service or maintenance Failure to follow these instructions can result in death injury or property damage The Vicinity of the Heater Installation Code and Annual Inspections All installations and service of ROBERTS GORDON products must be performed by contractor qualified in the installation and service of products 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 instal
46. erature Pipe Compound 11b can 0270XXXX Burner Rate and Fuel Varies 91412200 Flexible Stainless Steel Gas Hose 1 2 NPT Venting Accessories US models only 01324401 Outside Air Supply Takeoff 4 10 cm 013676XX End Vent Plate 01326801 Outside Air Filter Housing 01397300 Accessory Package 90707501 Air Supply Blower Power Venter 01361200 Filter Support Disk 91409601 Outside Air Flex Duct 4 10 cm 01367800 Combustion Chamber Gasket Box of 8 8 2 4 m sections 02724901 Door Assembly w Hole 91115100 Screw 10 24 x 5 8 Reflectors and Related Accessories 91119500 U Clip 01329910 Reflector Side Extension Support 91905500 Filter Support 03050010 Reflector Support Package Tubing 92123900 Nut 5 16 18 02712700 Reflector Side Extension 2 Clips 2 Screws 92511601 Wing Nut 10 24 02716400 Reflector Support Package Schedule 40 Pipe 96411600 Lock Washer 5 16 02750303 Reflector Aluminum 01312401 Filter and Gasket 02750355 Reflector Stainless Steel Canadian Models Rubber Type 1 Gas Hoses 02750304 Reflector Aluminum with Hole available as an accessory see Page 41 0275035 Reflector Stainless Steel with Hole 02750800 Reflector End Cap Aluminum Table 2 Common CRV Series Components 027508SS Reflector End Cap Stainless Steel Part No Description 027508SH Reflector End Cap Stainless Steel with Hole Combustion Chamber 02750900 Reflector Joint 02722300 1P Hot Rolled Steel Combustion Chamber 02750958 Reflector Joint S
47. es away from heater Turn off the manual gas valve in the heater supply line Failure to follow these instructions can result in death Call your registered installer contractor qualified in the installation injury or property damage and service of gas fired heating equipment 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 1902 498733 1250 William Street Oxford Street Service Fax 44 0 1902 401464 P O Box 44 Bilston West Midlands WV14 7EG UK E mail uksales rg inc com Buffalo NY 14240 0044 USA Telephone 44 0 1902 494425 E mail export rg inc com Telephone 716 852 4400 Fax 44 0 1902 403200 Fax 716 852 0854 Toll Free 800 828 7450 Installation Code and Annual Inspections All installations and service of ROBERTS GORDON products must be performed by a contractor qualified in the installation and service of products 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 and operation of the equipment To help facilitate optimum performance and safety Roberts Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON products and perform service where necessary using only ROBERTS GORDON replacement parts 2006 Roberts Gordon LL
48. gure 11 FIGURE 10 Major Component Descriptions Optional reflector configurations are shown on Page 4 Figure 1 through Page 6 Figure 9 Install appropriate suspension hardware beam clamps chain or rod at predetermined locations Adjustments of chain length will provide uniform pitch Burner Reflector CN Aluminum or x Stainless Steel Alternate overlap as shown on overview Minimum overlap is 6 16 cm e Flex Gas Line Xm with shut off cock Tee Coupling Assembly SN with Lock 45 Elbow Tube Adapter 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 overview Minimum overlap is 6 16 cm End Vent SECTION 5 MAJOR COMPONENTS FIGURE 10 Major Component Descriptions Continued c Reflector Joint Reflector End Cap a Aluminum or Stainless tk Steel Punch out center section to accommodate heat exchanger tube when necessary Tube and Reflector Hanger a with Clamp Package A Reflector Side Extension Position this hanger no more than 4 10 cm away from the burner Tube and Reflector Hanger Suspend system from these hangers gt Reflector Support Strap amp Wire Form Q Turnbuckle Protective Grille Reflector Side Condensate Extension Bracket Valve Assembl
49. hese instructions The gas or the electrical supply lines must not be used to support the heater FIGURE 12 Critical Hanger Placement SECTION 7 HEATER INSTALLATION 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 is 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 in Figure 12 Expansion and contraction of the tube dictates that the minimum suspension lengths in the table on Figure 12 be maintained Typical Suspension Details Beam Clamp Rod 3 8 24 min 61 cm Side View Description Part Number Turnbuckle 91903201 S Hook 91907302 Tube Reflector Hanger 03090100 Anchor 3 8 Concrete Beam Locknut X See Table Chain size 3 16 minimum Locknut i ae Typical S Hook Washers Towards Pump gt Wood Beam Turnbuckle Front View Run Length Typical Expansion Minimum X Length 50 15 m 1 3 cm 12 30 cm 100 31 m 2 5 cm 24 61 cm 150 46 m 3 8 cm 36 91 cm 2
50. ifications 17 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 15 Figure 12 17 2 Heater Specifications 17 4 Controls Specifications 17 2 1 Ignition Time switches thermostats etc can be wired into Fully Automatic Three Try Direct Spark Electronic a Suppe EXIOTRAL cons supplied Ignition Control 100 Safety Shut Off General Specifications for CRV Series heaters are as follows Length A 91 2 sje 6 1 2 lt 10 3 4 J JO Reflector pr zs Heat Input Rate Length A s cung ean Btu h x 1000 Minimum Maximum Spot Heating CRV B 2 NG only 10 3 m 20 6 1 m CRV B 4 12 5 3 8 m 25 7 6 m CRV B 6 0 61 m 10 7 m CRV B 8 0 6 1m 13 7m GRV B 9 5 7 6 m 15 2 m CRV B 10 0 9 1 m 18 3 CRV B 12A NG only 35 10 7 CRV B 12 LP only 35 10 7 m See Page 3 Section 3 for clearances to combustibles 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 Connection Size 4 10 cm Refer to figure above for dimensional information GAS INLET PRESSURE Natural Gas 4 5 w c Minimum 14 0 w c Maximum LP Gas 10 5 w c Minimum 14 0 w c Maximum ELECTRICAL RATING 120 V 60 Hz 0 3 A 58 SECTIO
51. l Non Combustible Wall 91901300 Boot Clamp 4 10 cm 02718851 Drain Cap 4 10 cm 91913703 Boot Clamp 6 15 cm 02718852 Drain Cap 6 15 cm E0009356 Damper Coupling 6 15 cm 90502100 Vent Terminal 4 10 cm Combustible Wall 10100320 Elbow 6 15 cm Aluminized 90 90502101 Vent Terminal 6 15 cm Combustible Wall 90502302 Vent Cap 6 15 cm Metalbestos 90505600 Wall Thimble 4 10 cm SECTION 10 OUTSIDE AIR SUPPLY 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 contaminants are present in the air an outside combustion air supply to the heaters is strongly recommended 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 10 1 Pressurized See Page 39 Figure 23 for a typical layout of a pressurized air supply system For pressurized outside air supplies the outside air FIGURE 19 Duct Sizing SECTION 10 OUTSIDE AIR SUPPLY blower motor has a pressure switch interlock that must be used Wire this switch in series with the pump pressure switch When using an outside air blower with a ROBERTS GORDON Sy
52. l 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 Aircraft o Public Building 0 Office Retail o Agricultural o Other Installation Code and Annual Inspections installations and service of ROBERTS GORDON products must be performed by a contractor qualified in the installation and service of products 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 and operation of the equipment To help facilitate optimum performance and safety Roberts Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON products and perform service where necessary using only ROBERTS GORDONS replacement parts This product is not for residential use This product is intended to assist licensed professionals in the exercise of their professional judgement 2006 Roberts Gordon LLC All rights reserved No part of this work covered by the copyrights herei
53. lation service and operation of the equipment To help facilitate optimum performance and safety Roberts Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON products and perform service where necessary using only ROBERTS GORDON replacement parts 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 3 Section 3 Vehicles and Other Objects Maintain the clearances to combustibles Do not hang anything from or place 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 3 Section 3 Reflector 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 19 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 Outside Air Inlet Inlet must be intact Look for obstructions cracks on the pipe or gaps in the sealed areas or corro
54. licable SECTION 3 CRITICAL CONSIDERATIONS 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 4 Figure 1 through Page 6 Figure 9 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 Maintain clearances from heat sensitive material equipment and workstations 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
55. m it may not be possible to obtain vacuum differential readings at or slightly above 2 5 w c If so adjust the damper couplings to maximum but equal vacuum reading Be sure to lock all dampers securely after adjustment Reset temperature setpoints to desired room temperature If heat is not required turn off main switch and close the main gas valve 49 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 35 Vacuum Reading Combustion Chamber at end position CoRauVac Insert tubing about 6 15 cm Manometer Approximate reading after adjusting damper couplings and pump inlet 2 5 3 0 w c 50 SECTION 14 OPERATION AND MAINTENANCE The heater is equipped with a direct spark ignition system 14 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 GORDON System Control or ROBERTS GORDON ULTRAVAC the pump will continue operation for post purge period of two minutes 4 If no fla
56. me 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 thermo stat cycle is required or automatically after 1 hour 14 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 14 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 SECTION 14 OPERATION AND MAINTENANCE 14 4 Pre Season Maintenance and Annual Inspection A WARNING Explosion Hazard Service and annual inspection must be done by a contractor qualified in the installation and service of gas fired heating equipment or your gas supplier Turn off gas and electrical supplies before performing service or maintenance Failure to follow these instructions can result in death injury or property damage 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
57. n 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 model 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 i i FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER cem cen CEN fire or explode when oltor ihelowest setin Keep all flammable objects liquids and vapors the required ermos O OTT O Ow setting Turn off electric power to the heater clearances to combustibl
58. nd Cap 027508XX SECTION 7 HEATER INSTALLATION 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 with tight screws 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 refl
59. ngars ANSI NFPA 409 latest revision Canada Refer to Standard CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances 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 above the floor 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 garages must be in accordance with the following codes United States Standard for Parking Structures NFPA 88A latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 30A latest revision Canada Refer to CAN CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances 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
60. ns 18 46 cm Minimum 40 102 cm Maximum 4 10 cm Single Wall Pipe Se A d Thimbl 10 Imbles and Clamp 18 46 cm iiniu 40 102 cm Maximum Pitch single wall pipe downward away from pump 1 4 6 mm for every 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 and 3 Elbows Maximum Part Number Description Part Number Description 01330203 Tee 4 10 cm Aluminized 90505600 Wall Thimble 4 10 cm 01331900 Damper Coupling 4 10 cm 91409403 Tube Aluminized 4 10 cm dia 10 3 m 01335801 Elbow 4 10 cm Aluminized 90 91412800 Flexible Boot 4 10 cm 01365400 Bird Screen 4 10 cm 91901300 Boot Clamp 4 10 cm 02537801 1P Vent Terminal Non Combustible Wall Not Supplied Tube Aluminized 5 12 7 cm dia 10 3 m 02718851 Drain Cap 4 10 cm Not Supplied Tube Adapter 5 12 7 cm dia x 4 10 cm dia 90502100 Vent Terminal 4 10 cm Combustible Wall Not Supplied Tube Adapter 6 15 2 cm dia x 5 12 7 cm dia 90502101 Vent Terminal 6 15 cm Combustible Wall 34 FIGURE 17 200 Series Horizontal Venting Configurations SECTION 9 PUMP INSTALLATION AND VENTING 18 46 cm
61. nt Installation Scribe Contour Pp Flatten Edge 1 2 5 cm Maximum 21 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 2 2 Reflector Joint Installation Cut away contour with tin snips Punch drill six 3 32 2 mm holes Step 8 2 3 Reflector Joint Detail Install reflector end cap gt Attach reflector joint with six 8 sheet metal screws FIGURE 13 Reflector Joint Detail Reflector lt Reflector Joint 22 SECTION 8 OPTIONAL HEATER ACCESSORIES 8 3 Reflector Side Extension Step 8 3 1 Bracket Installation Tube Reflector V JE Tube and Reflector Hanger ng 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 Step 8 3 2 Side Reflector Installation 8 x 3 8 3 9 x 9 5 mm Sheet Metal Screw Cut relief notches for supports and hangers Retainer Clip 2 per Side Reflector Side Extension 23 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 8 4 Universal Shield Universal shields are adjustable aluminum reflectors whose angle and height
62. on Installer 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 P O Box 44 Buffalo New York 14240 0044 Telephone 716 852 4400 Fax 716 852 0854 Toll Free 800 828 7450 www rg inc com P N 127102NA Rev F 05 06 TABLE OF CONTENTS SECTION 1 Heater Safety eene 1 1 1 Manpower Requirements 1 SECTION 2 Installer Responsibility 2 2 1 Wall Tag rene ren e tek Cate Re RR 2 2 2 Corrosive Chemicals men nenea nana 2 2 3 National Standards and Applicable Codes 2 SECTION 3 Critical 3 3 1 Required Clearances to Combustibles 3 SECTION 4 National Standards and Applicable Codes 7 4 1 Gas 7 4 2 Aircraft Hangars near 7 4 3 Public Garages tg cus 7 4 4 Electrical eir a ia oa sala Ea ina ale 7 4 5 Venting tbe MEE 7 4 6 High Altitude 7 SECTION 5 Major Components 8 5 1 Standard Parts 11 SECTION 6 Design
63. ontrol can control up to four zones of burners The electrical circuit is a 120V AC 20A supply The output for the thermostat is 12V DC Do not use thermostats that draw power from the low voltage supply A System Control operated system has two minutes post purge pump operation to completely exhaust products of combustion from the system A system control provides indication of power to the pump and the zones as well as indicating the status of the pressure switch with lights The System Control is UL listed in accordance with UL873 Temperature Indicating and Regulating Equipment 42 12 2 ROBERTS GORDON ULTRAVAC The ROBERTS GORDON ULTRAVAC is a micro processor based control package designed for modulating control of CRV Series heaters based 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 Special design requirements apply for CRV Series systems using the ROBERTS GORDON ULTRAVAC Cont
64. orative Grille Cut grille bracket at Joint Piece Brackets reflector joint piece SECTION 8 OPTIONAL HEATER ACCESSORIES 8 8 Protective Grille Installation Part Number 08050001 08050002 91915951 6P Description Grille Section Grille End Cap Silicone Cap Step 8 8 1 Silicone Cap Installation Finger Step 8 8 2 Grille End Cap Installation Pull outward Step 8 8 3 Grille Installation gt o CC Final Grille Section 29 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 9 Classic Cast Iron Components Special Tube and Reflector Hanger A WARNING Suspension 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 spring clips will not fit around cast iron hanging loop 7 2 18 m Maximum gt Cohaylac Schedule 40 Steel Pipe Cast Iron Combustion Chamber with Schedule 40 Steel Pipe The total weight of each burner and
65. p and condensate valve Z00000000000 ooo 36 9 m Minimum 3 4 female vertical drop between pump and condensate valve assembly Condensate Valve Assembly Must connected to a drain system in accordance with local codes 31 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 9 2 General Venting Requirements Model EP 100 EP 200 and EP 300 Series Pumps WARNING Carbon Monoxide Hazard Heaters installed unvented must be interlocked with sufficient building exhaust Heaters must be installed according to the installation manual Failure to follow these instructions can result in death or injury This heater must be vented in accordance with the rules contained in this manual and with the following national codes and any state provincial or local codes which may apply United States Refer to ANSI Z223 1 NFPA 54 latest revision Canada Refer to CAN CGA B149 1 and B149 2 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 less than 1 3 m above grade level The vent shall not terminate less than 7 2 1 m above grade where located adjacent to public walkways Vent terminal must be installed at a height suffici
66. r 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 2 4 Start with all temperature setpoints below room temperature Open main gas valve Turn up temperature setpoints one zone at a 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 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 ture See that all burners are operating properly SECTION 13 STARTING THE SYSTEM 2 Allow at least 7 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 50 Figure 35 Normal end vent vacuum should be set at approximately 2 5 w c to 3 0 w c 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 w c to 3 0 w c If end vent vacuum exceeds 3 0 w c adjust the pump inlet damper until vacuum readings are 2 5 w c to 3 0 w c With systems designed to operate at maximum vacuu
67. roller 12 3 SPST Transformer Relay P N 90417600 The transformer relay wiring diagram is shown on Page 43 Figure 26 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 120V AC 20 A supply The transformer 24V 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 4 DPST Transformer Relay P N 90436300 The transformer relay wiring diagram is shown on Page 45 Figure 28 The transformer relay can be used to control an EP 100 or EP 201 pump CORAY VAC system The double pole relay can only be used to control two zones of burners The electrical circuit is a 120V AC 20A supply The transformer 24V AC output for the thermostat is rated at 40VA 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 SECTION 12 CONTROL METHODS FIGURE 26 One Zone Operation without Control Panel SPST 12A Transformer Relay Thermosta
68. s Minimum E 5 Description Part Number Bracket 01363003 26 SECTION 8 OPTIONAL HEATER ACCESSORIES Step 8 7 2 Decorative Grille Ay n SIS Ny M iy i Me M MV IN ua f i Y M Ny Spread apart brackets and install decorative grille Description Part Number Decorative Grille 8 x 1 2 4 m x 3 m 91406700 Step 8 73 Joint Piece and Reinforcement Joint Piece AVA iy A V Ny gt m A 0 jut NY i i vs Vut V iy AV f 7 M i A w M V f f WW Wi M i NAN Slip joint piece into support bracket and fasten to bracket on one side of the joint only Description Part Number Joint Piece 01365903 Reinforcement 01365902 27 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL Step 8 7 4 End Piece and Reflector End Cap _ RN Reflector End Cap End Piece Insert end piece between grille and brackets Fasten end piece to brackets using two 8 sheet metal screws and replace reflector end cap Description Part Number End Piece 01365901 Step 8 75 90 Elbow Insert end piece between grille and brackets Dec
69. sion The area must be free of dirt and dust Clean and reinstall as required 52 Tubes SECTION 14 OPERATION AND MAINTENANCE Make sure there are no cracks Make sure tubes are connected and suspended securely See Page 15 Figure 12 through Page 17 Section 72 1 Make sure there is no dirt sagging bending or distortion Clean or replace as required Gas Line Check for gas leaks See Page 41 Figure 25 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 Make sure it is 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 Suspension Points Make sure the heater is hanging securely Look for signs of wear on the chain or ceiling See Page 15 Figure 12 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 25 Section 8 6 1 through Pag
70. stem 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 20A 120V power supply See Page 38 Figure 21 for outside air blower internal wiring requirements 10 2 Non Pressurized For a non pressurized outside air supply a 4 O D 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 19 To prevent condensation insulate the outside air duct Outside Air System Design Requirements Blower Performance 90707501 112 Flow Units Series systems Duct Design Rules positioned closest to the highest flow requirements end vents must be at least 6 15 cm diameter Pressurized Systems 36 m total per system 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 One outside air blower is required per each EP 100 or EP 200 series pump and two outside air blowers may be required for each EP 300 series pump Outside air blowers cannot be shared between two separate CRV System should be designed so that the blower is When a duct is carrying more than 40 flow units it 6 15 cm diameter duct must not exceed 120 4 10 cm diameter duct must
71. t Zone 1 Burners Pressure Switch Pump Nine Burners Maximum Description Part Number SPST Transformer Relay 90417600 43 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 27 One Zone Operation with Outside Air Blower without Control Panel SPST 12 A Transformer Thermostat N Outside Air Ground Blower Pressure Switch Outside Air Blower Pressure Zone 1 Switch E Burners Pump Nine Burners Maximum 44 FIGURE 28 Two Zone Operation without Control Panel SECTION 12 CONTROL METHODS DPST 12 A Transformer Zone 2 Thermostat Zone 1 Thermostat 120 V 10 60 Hz 4 0 N Motor Pressure Switch Pump Description Part Number DPST Transformer Relay 90436300 DPST 12 A Transformer Relay pee Red Yellow Zone 2 Burners Zone 1 Burners Nine Burners Total Maximum Between Zones 45 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 29 General System Wiring Burner Receptacles 4 Zone Max 10 pu Thermostats 120 Vac Maximum 20 Amps Total e Pressure Switch Pump Motor 115 Vac Operation 230 Vac Operation Separate power circuit required for EP 203 or EP 300 series pumps NE Motor Starter 1 Needed for EP 203 and EP
72. tainless Steel 02722301 1P Heat Treated Aluminized Steel Combustion Chamber 02712758 Reflector Side Extension Stainless Steel 0272230D 1P Porcelain Coated Steel Combustion Chamber 03090100 _ and Reflector Hanger 02721200 1P Cast Iron Combustion Chamber 02790300 and Reflector Hanger Cast Iron 91907302 S Hook Tubing and Related Accessories 91903201 Turnbuckle 01312700 Coupling 4 10 cm Plain 91903300 Spring Hook 01312706 Coupling 6 15 cm Plain 91903202 Turnbuckle with Eyebolt 01312701 Coupling 4 10 cm Lined 02712100 Universal Shield Support 01331900 Coupling 4 10 cm Damper 02751800 Universal Shield with Holes E0009356 Coupling 6 15 cm Damper 02751801 JUniversal Shield 0133022D Tee 4 10 cm Coated 02751855 Universal Shield Stainless Steel 01330203 Tee 4 10 cm Aluminized 01330204 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 70100320 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 Non Heat Treated Aluminized 4 10 cm dia 10 3 m 91409408 Tube Heat Treated Aluminized 4 10 cm dia 10 3 m 91409420 Non Heat Treated Aluminized 6
73. utside Air Supply S a Vent Cap or at Bird Screen Burner Outside Air ona Blower Wa DJ EY 4 10 cm Air Flex Duc 4 10 cm Take Off Sheet Metal QQ or PVC Description Part Number Filter Housing 01326801 4 10 cm Take Off 01324401 Blower 90707501 5 12 7 cm Vent Cap 90502301 6 15 cm Bird Screen 01365400 6 15 cm Band Clamp 91913703 39 CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 24 Non Pressurized Outside Air Supply Vent Cap or D Bird Screen 6 1 8 m Maximum Outside Wall 2222222222222222 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 Pressure Switch Lock Nuts 7 16 11 1 Diameter Hole 40 SECTION 11 GAS PIPING A WARNING Fire Hazard Tighten gas hose fittings to connect gas supply according to Figure 25 Gas hose can crack when twisted Gas hose moves during normal operation Failure to follow these instructions can result in death injury or property damage Install the gas hose as shown in Figure 25 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 s
74. y Universal Shield Universal Shield with Holes Bracket Assembly CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL FIGURE 10 Major Component Descriptions Continued ROBERTS GORDON ULTRAVAC Variable Frequency Drive Vac Cota bn ee EP 100 Pump Package 4 dia For more information refer to the EP 100 Installation Operation and Service Manual P N 127201NA ROBERTS GORDON ULTRAVAC Controller Ill Jil UG A MN 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 ROBERTS GORDON ULTRAVACT Adjustable Indoor Sensor 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 10 SECTION 5 MAJOR COMPONENTS 5 1 Standard Parts List 02722100 Adapter 4 10 cm Cast Iron Table 1 Contents of CRV Series Burner Carton 91240010 Tube Hanger 6 15 cm Part No Description 91308001 High Temp
75. ystem verify that all high pressure testing of the gas piping has been completed SECTION 11 GAs PIPING There is an expansion of the tube with each firing 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 25 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 large enough to supply the required gas with a maximum pressure drop of 1 2 w c When gas piping is not included in the layout drawing the local gas supplier will usually help in planning the gas piping Do not high pressure test the gas piping with the burner connected Failure to follow these instructions can result in property damage Check the pipe and tubing ends for leaks before placing heating equipment into service When checking for gas leaks use a soap and water solution never use an open flame FIGURE 25 Gas Connection with Flexible Gas Hose 3 4 NPT Pipe Shut Off Valve Included With Gas Hose Hold gas nipple securely with pipe wrench when attaching the gas hose Failure to follow these instructions can result in product damage z Shut Off Valve must be parallel to burner gas inlet The 2

Download Pdf Manuals

Related Search

Related Contents

Samsung GT-S5233A راهنمای محصول  11 No. 2 2004 ESTIMACION DE VALOR GENETICO DE CERDOS  Manual  マルチパワーハーネス 取扱説明書  Arobas Music Guitar Pro - 6 User's Guide  経緯度レベルのディファレンシャルGPS測位に関する研究  Ergotron StyleView  Nokia 6700 2.2" 113g Pink  HRDP Funzionamenti manuali  

Copyright © All rights reserved. Failed to retrieve file