Roberts Gorden CorayVac Classic SF Series, CorayVac CRVSF-8, CorayVac CRVSF-2, CorayVac CRVSF-4, CorayVac CRVSF-6 Operation & Service Manual

WARNING

Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.

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.

WARNING

FOR YOUR SAFETY
If you smell gas:

1. Open windows.

2. DO NOT try to light any appliance.

3. DO NOT use electrical switches.

4. DO NOT use any telephone in
your building.

5. Extinguish any open flame.

6. Leave the building.

7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier’s
instructions.

8. If you cannot reach your gas
supplier, call the Fire Department.

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.

Heavy Duty, High Efficiency

Infrared Heating for

Specialty Fuel Repair

Facilities*

Installation, Operation &

Service Manual

CRVSF-2
CRVSF-4
CRVSF-6
CRVSF-8

Installer

Please take the time to read and understand

these instructions prior to any installation.

Installer must give a copy of this manual to the owner.

Owner

*Approved and certified by CSA to meet maximum tube temperature
of 750 °F (399 °C) in accordance with NFPA30A7.6.6.

© 2018 Roberts-Gordon LLC

Keep this manual in a safe place in order to provide

your service technician with necessary information.

Roberts-Gordon LLC

1250 William Street
P. O. Bo x 44
Buffalo, New York 14240-0044
Telephone: [phone]
Fax: [phone]
Toll Free: 800.828.7450

www.robertsgordon.com

P/N 127302NA Rev. A 11/18

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

2.1 Wall Tag .......................................................................4

2.2 Corrosive Chemicals.................................................... 4

2.3 National Standards and Applicable Codes ..................5

SECTION 3: Clearances to Combustibles............................. 6

3.1 Required Clearances to Combustibles.........................6

SECTION 4: National Standards and Applicable Codes .....8

4.1 Gas Codes................................................................... 8

4.2 Aircraft Hangars ........................................................... 8

4.3 Public Garages ............................................................8

4.4 Electrical ......................................................................8

4.5 Venting.........................................................................8

4.6 High Altitude ................................................................ 8

4.7 Compressed and Liquid Natural Gas Installations....... 8

SECTION 5: Major Components ............................................9

5.1 Standard Parts List for In-Series Systems .................12

SECTION 6: Design Requirements...................................... 14

SECTION 7: Unitary Heaters ................................................16

7.1 In-Series Systems vs. Unitary Heaters ....................... 16

SECTION 8: Heater Installation............................................ 17

8.1 Tube Installation ........................................................ 19

8.2 Elbow Package Configuration .................................... 19

8.3 Reflector Installation ..................................................20

8.4 Burner Installation...................................................... 23

SECTION 9: Optional Heater Accessories.......................... 24

9.1 Tee Installation .......................................................... 24

9.2 Reflector Joint............................................................ 25

9.3 Reflector Side Extension............................................27

9.4 Barrier Shield............................................................. 28

9.5 Protective Grille Installation........................................ 29

SECTION 10: Pump Installation and Venting...................... 30

10.1 Pump Installation .....................................................30

10.2 General Venting Requirements Model EP-100,

EP-200 and EP-300 Series Pumps...........................32

SECTION 11: Outside Air Supply.........................................36

11.1 Pressurized...............................................................36

11.2 Non-Pressurized .......................................................36

11.3 Outside Air Blower Internal Wiring ............................37

SECTION 12: Gas Piping...................................................... 41

SECTION 13: Control Methods ............................................ 43

13.1 ROBERTS GORDON® System Control ................... 43

13.2 ROBERTS GORDON

(CRVSF-6/-8 only) ...........................................................43

®

ULTRAVAC™

13.3 CORAYVAC® Modulating Controls .......................... 43

13.4 SPST Transformer Relay Kit (P/N 90417600K) ....... 46

13.5 SPDT Transformer Relay (P/N 90436300) .............. 46

SECTION 14: Starting The System ...................................... 57

14.1 Checking the Gas Line ............................................ 57

14.2 Checking the Electrical System ............................... 57

14.3 Starting the System ................................................. 57

14.4 Setting the Vacuum.................................................. 58

14.5 Record Start-Up Results.......................................... 58

SECTION 15: Variable Frequency Drive Programming ...... 60

15.1 VFD Parameter Settings For Use With Modulating

Thermostats............................................................................ 60

15.2 Altering VFD Parameters ......................................... 61

SECTION 16: Commissioning The CORAYVAC

CLASSIC SF Modulating System ................. 62

16.1 Setting The CORAYVAC® CLASSIC SF End

Burner Vacuum....................................................... 62

16.2 Adjusting the Variable Frequency Drive ................... 62

16.3 Programming Of Variable Frequency Drive.............. 63

SECTION 17: Operation and Maintenance.......................... 65

17.1 Sequence of Operation ............................................ 65

17.2 To Shut Off Heater.................................................... 65

17.3 To Start Heater ......................................................... 65

17.4 Pre-Season Maintenance and Annual Inspection .... 65

17.5 Maintenance Checklist ............................................. 66

SECTION 18: Troubleshooting............................................. 68

18.1 Troubleshooting Flow Chart ..................................... 69

SECTION 19: Replacement Parts ........................................ 71

19.1 Variable Frequency Drive Replacement Parts ......... 73

19.2 Replacement Parts Instructions................................74

SECTION 20: General Specifications.................................. 75

20.1 Material Specifications............................................. 75

20.2 Heater Specifications............................................... 75

20.3 Suspension Specifications....................................... 75

20.4 Controls Specifications ............................................ 75

SECTION 21: General Specifications for pumps ............... 76

SECTION 22: General Specifications For Air Supply

Blower ............................................................ 76

SECTION 23: General Specifications For Fresh Air

Filter Box Specifications............................... 77

SECTION 24: CORAYVAC

Installation Report......................................... 79

SECTION 25: The ROBERTS GORDON

CLASSIC SF Limited Warranty..................... 83

®

CLASSIC SF Start-Up and

®

®

CORAYVAC®

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 regis­tered trademark owners, and make no representations about them, their owners, their products or services. Roberts-Gordon
LLC is not sponsored by or affiliated with BACnet

© 2018

®

, LonWorks®or MODBUS®.

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.

Prin ted in U.S.A.

TABLE OF FIGURES

Figure 1: Side Panel Label Placement......................................2

Figure 2: Top and Back Panel Label Placement .......................3

Figure 3: Standard Reflector .....................................................6

Figure 4: One Side Reflector.....................................................7

Figure 5: Two Side Reflectors ................................................... 7

Figure 6: Barrier Shield (See Section 9.4 for application

restrictions) .............................................................. 7

Figure 7: Protective Grille.......................................................... 7

Figure 8: Major Component Descriptions..................................9

Figure 9: Major Component Descriptions (Continued)............ 10

Figure 10: Schedule 40 Black Steel Fittings............................ 11

Figure 11: Optional Heater Accessories .................................. 11

Figure 12: Heater Assembly Overview ................................... 15

Figure 13: CRVSF Unitary Heater Assembly Overview .......... 16

Figure 14: Critical Hanger Placement ..................................... 18

Figure 15: Reflector Joint Detail ..............................................26

Figure 16: EP-200 Condensate Valve Assembly.....................30

Figure 17: Condensate Neutralization Tube ............................32

Figure 18: EP-100 & EP-200 Horizontal Venting Configurations34
Figure 19: EP-300 Series Horizontal Venting Configurations ..35

re 20: Duct Sizing ............................................................ 37

Figu

Figure 21: Outside Air Blower Internal Wiring Diagram...........37

Figure 22: Filter Housing Assembly ........................................ 38

Figure 23: Air Supply Blower Support .....................................38

Figure 24: Pressurized Outside Air Supply.............................. 39

Figure 25: Non-Pressurized Outside Air Supply......................39

Figure 26: Filter Box................................................................ 40

Figure 27: Gas Connection with Flexible Gas Hose................42

Figure 28: VFD Terminal Strip.................................................45

Figure 29: One Zone Operation without Control Panel

(optional)............................................................... 47

Figure 30: One Zone Operation (with Outside Air Blower)

without Control Panel (optional) ............................ 48

Figure 31: Two Zone Operation without Control Panel

(optional)............................................................... 49

Figure 32: General System Wiring ..........................................50

Figure 33: External Wiring Diagram EP-100 and EP-201

120 V 1 Ø Pump....................................................50

Figure 34: External Wiring Diagram EP-100, EP-201 or

EP-301 230 V 1 Ø P
Figure 35: External Wiring Diagram EP-203 or EP-303

208 - 230 V (or 460 V) 3 Ø Pump (optional) ......... 52

Figure 36: CORAYVAC

®

Diagram [LonWorks

resistor) optional] ..................................................53

®

Figure 37: CORAYVAC

[LonWorks

CLASSIC SF Modulating Wiring Diagram

®

(4-20 mA) optional] ............................ 54

ump (optional).......................51

CLASSIC SF Modulating Wiring

®

(2-10 Vdc with 500 ohm

Figure 38: CORAYVAC

®

CLASSIC SF Modulating with

BACnet® Wiring Diagram (optional) .................... 55

Figure 39: Burner Internal Wiring............................................ 56

Figure 40: Burner Internal Ladder Diagram ............................ 56

Figure 41: Vacuum Reading ................................................... 59

Figure 42: Possible Damper Nipples’ Locations...................... 64

Figure 43: Variable Frequency Drive Components Diagram ... 73

LIST OF TABLES

Table 1: Contents of CRVSF-Series Burner Carton ............... 12

Table 2: Common CRVSF-Series Components ..................... 12

Table 3: Minimum Heat Exchanger Length ............................ 16

Table 4: Contents of CRVSF Unitary Packages..................... 16

Table 5: Modulating Thermostat Cable Requirements ........... 45

SECTION 1: HEATER SAFETY

Yo ur 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, where exposed surfaces of heating
equipment cannot exceed temperatures of 750 °F
(399 °C) in facilities where compressed natural gas
(CNG) or liquid natural gas (LNG) are present. 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.
Protecti

ve gear is to be worn during installation,
operation and service in accordance to the
Occupational Safety and Hazard Administration
(OSHA). Gear must be in accordance to NFPA 70E,
latest revision when working with electrical
components. Thin sheet metal parts 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 equipment are compatible.

This heater must be applied and operated under the
general concepts of reasonable use and installed
using best building practices.
This equipment is not intended for use by persons
(including children) with reduced physical, sensory or
mental capabilities, or lack of experience and
knowledge, unless they have been given supervision
or instruction concerning use of the equipment by a
person responsible for their safety. Children should
be supervised to ensure that they do not play with the
equipment.
For additional copies of the Installation, Operation
and Service Manual, please contact Roberts-Gordon
LLC.

SECTION 1: HEATER S AFETY

1.1 Manpower Requirements

To p re vent personal injury and damage to the heater,
two persons or more will be required for installation.

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

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Logo Label 91031110
Rating Plate Label 91010455
Clearances to Combustibles Label 91009106
Internal Ladder Diagram Label 91017301
Wiring Label 91017300

FIGURE 1: Side Panel Label Placement

2 of 83

FIGURE 2: Top and Back Panel Label Placement

Description Part Number

Gas Connection Label 91018125
Burner Box Combination Label 91029600
Proposition 65 Label 91070016

SECTION 1: HEATER S AFETY

3 of 83

CRVSF-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 CRVSF-Series

Design

Manual (P/N 127502NA).

• To provide schedule 40 heat exchanger radiant
pipe and fittings. Pipe: ASTM A53 (Latest edition)
grade B ERW black steel pipe TNC 4", both ends
threaded to 4" NPT conforming to ANSI/ASME
B1.20.1 (latest edition). Fittings: 150 lb malleable
black iron 4", both ends threaded to 4" NPT
conforming to ANSI/ASME B1.20.1 (latest
edition).

• 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 install all threaded components with a
minimum thread engagement of three threads.
Apply sufficient amount of high temperature, anti­seize pipe compound (P/N 91308001 or
equivalent) to threads prior to engagement. Hot
compound may drip from threads. Protect
surfaces underneath heater during first start-up.

• 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.

• 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 remo

val.

• 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 750 lb
(340 kg).

• To ensure the heater is placed in an approved

application.

• Expansion and contraction of the tube dictates

that the minimum suspension lengths must be
maintained. See table on Page 18, Figure 14.

• To install all components of the system with a

minimum of 18" (45 cm) ceiling clearance in
accordance to National Fire Protection
Association NFPA 30A 7.6.6 (2012 edition) latest
revision.

4 of 83

• To install the outside air supply system to each
burner and end vent.

• To coordinate with ROBERTS GORDON®
independent distributor the return of the
completed CORAYVAC

®

CLASSIC SF start up
and installation report within 24 hours of start-up.
See Page 79, Section 24.

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
CRVSF-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. 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

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 equipment must be installed in accordance with
the latest revision of the applicable standards and
national codes. This refers also to the electric, gas
and venting installation. Note: Additional standards
for installations in public garages, aircraft hangars,
etc. may be applicable.

SECTION 2: INSTALLER R ESPONSIBILITY

5 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

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.

B

C

D

A

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 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
equipment.

• 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.

• 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 18, Figure 14.

• If the radiant tubes must pass through the building
structure, be s

ure that adequate sleeving and fire
stop is installed to prevent scorching and/or fire
hazard.

NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, 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

Model ABCDABCD

CRVSF-2/-4/-6/-8 4 20 48 20 11 51 122 51

6 of 83

(inches) (centimeters)

NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, elbows, tees and crosses.

A

B

C

D

A

B

C

D

C

A

B

D

A

B

C

D

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: ONE SIDE REFLECTOR

Model ABCDABCD

CRVSF-2/-4/-6/-8 4 12 56 20 11 31 143 51

FIGURE 5: TWO SIDE REFLECTORS

Model ABCDABCD

SECTION 3: CLEARANCES TO COMBUSTIBLES

(inches) (centimeters)

(inches) (centimeters)

CRVSF-2/-4/-6/-8 4 12 56 12 11 31 143 31

FIGURE 6: BARRIER SHIELD (SEE SECTION 9.4 FOR APPLICATION RESTRICTIONS)

(inches) (centimeters)

Model ABCDABCD

CRVSF-2/-4/-6/-8 4 12 12 12 11 31 31 31

FIGURE 7: PROTECTIVE GRILLE

(inches) (centimeters)

Model ABCDABCD

CRVSF-2/-4/-6/-8

4 20 48 20 11 51 122 51

7 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES

4.1 Gas Codes

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
NFPA 54/ANSI Z223.1 - latest revision.

Canada: Refer to Natural Gas and Propane
Installation Code CSA B149.1 - 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

4.2 Aircraft Hangars

Installation in aircraft hangars must be in
accordance with the following codes:

United States: Refer to Standard on Aircraft
Hangars, NFPA 409 - latest revision.

Canada: Refer to Natural Gas and Propane
Installation Code, Standard CSA B149.1 - latest
revision.

4.3 Public Garages

Installation in garages must be in accordance
with the following codes:

United States: Refer to Standard for Parking
Structures NFPA 88A - latest revision or Code for
Motor Fuel Dispensing Facilities and Repair
Garages, NFPA 30A - latest revision.

Canada: Refer to Natural Gas and Propane
Installation Code, Standard CSA B149.1 - latest
revision.

These heaters are approved for installations up
to 2000' (610 m)(US), 4500' (1370 m)(Canada)
without modification. Consult factory if US
installation is above 2000' (610 m) or Canadian
installation is above 4500' (1370 m).

4.7 Compressed and Liquid Natural Gas Installations

Installation must comply with Code for Motor
Fuel Dispensing Facilities and Repair Garages
NFPA 30A – latest revision. Heaters are certified
by CSA to meet maximum tube temperature of
750 °F (399 °C) in accordance with NFPA 30A
(2012 Edition) section 7.6.6.

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.

8 of 83

SECTION 5: MAJOR COMPONENTS

Burner

Tube

Schedule 40 steel pipe
(supplied by others.)

End Vent

Reflector
(Aluminum)

Alternate overlap as
shown on Page 22,
Section 8.3.3. Minimum
overlap is 6" (16 cm).

Reflector
with Hole (Aluminum)

Alternate overlap as shown on
Page 22, Section 8.3.3.

Minimum overlap is 6" (16 cm).

Schedule 40

Adapter

Reflector Joint

Reflector End Cap
(Aluminum)

Punch out center
section to
accommodate tube.

Tube and Reflector
Hanger

Suspend system from
these hangers.

Reflector Support
Strap & Wire Form

Flex Gas Line
with shut-off cock

Cast-Iron Combustion

Chamber

Turnbu ck le

Condensate

Valve Assembly

Schedule 40

Damper Nipple

ROBERTS-GORDON

®

3/8" Spring Hook

The figures in this section provide a general overview
of component placement in a CRVSF-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
15, Figure 12.
Install appropriate suspension hardware, beam
clamps, chain or rod at predetermined locations.
Adjustments of chain or turnbuckle length will provide
uniform pitch. Thread pipe and fittings per ASTM.
See Page 4, Section 2.

FIGURE 8: Major Component Descriptions

SECTION 5: MAJOR COMPONENTS

9 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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DANGER

Electrical Shock Hazard

Disconnect electrical
power 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.

Danger de Choc Électrique

Débrancher le courant
électrique avant toute
révision.

Cet appareil doit être
connecter à une source de
courant avec mise á terre.

Faute de suivre ces
instructions peut entraîner la
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

Controller

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Numéro de la Pièce:

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R

atings: Input 120V AC

, 25A Outputs 120V

AC, 3A (8 total)

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).

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).

System Control

ROBERTS GORDON

®

ULTRAVAC™ Controller

(Models CRVSF-6/-8 only)

ROBERTS GORDON

®

ULTRAVAC™
Adjustable Indoor Sensor

ROBERTS GORDON

®

ULTRAVAC™
Variable Frequency Drive

Outdoor Sensor
(P/N 10081501)

FIGURE 9: Major Component Descriptions (Continued)

10 of 83

FIGURE 10: Schedule 40 Black Steel Fittings

45° Elbow

90° Elbow Tee

Cross

Threaded Coupling

(All Schedule 40 Black Steel Fittings are supplied by others.)

Reflector
Side
Extension
Bracket

Barrier Shield

Reflector Side Extension

Protective Grille

FIGURE 11: Optional Heater Accessories

SECTION 5: MAJOR COMPONENTS

11 o f 8 3

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

5.1 Standard Parts List for In-Series Systems

Table 1: Contents of CRVSF-Series Burner Carton

Part No. Description

0270XXXX-SF Burner (Rate and Fuel Varies)

*91412200 Flexible Stainless Steel Gas Hose, 1/2" NPT

(US models only)
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

* Canadian Models: Rubber (Type 1) Gas Hoses available as an
accessory. See Page 42, Figure 27.

Table 2: Common CRVSF-Series Components

Part No. Description

Combustion Chambers

02721200-1P Cast Iron Combustion Chamber

End Vent Components

E00094XX End Vent Plate Package

02722100 Schedule 40 Adapter

Tubing and Related Accessories

91308001 High Temperature Pipe Compound

01332000 Schedule 40 Damper Nipple

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)

Gas Components

90207600 High Pressure Regulator - 2 psi 90207601 High Pressure Regulator - 5 psi

Reflectors and Related Accessories

02716400 Reflector Support Package (Schedule 40 Pipe) 02750303 Reflector, Aluminum, 96" (244 cm) 02750304 Reflector, Aluminum with Hole, 96" (244 cm) 02750800 Reflector End Cap, Aluminum 02750900 Reflector Joint 02790300 Tube and Reflector Hanger (Schedule 40 Pipe) 91903301 Spring Hook 3/8" 91903202 Eyebolt Turnbuckle 01329910 Reflector Side Extension Support 02712700 Reflector Side Extension, 96" (244 cm)

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 & Software) Includes:

URVSC

ROBERTS GORDON

®

ULTRAVAC™ Controller
10080142 Modem Chip
10080450 Comms Equalization Cable
10081501 Outdoor Sensor
10080410 PC Connection Cable Package

URVCCR

ROBERTS GORDON® ULTRAVAC™ Central Controller
(with RS-485 Converter & Software) Includes:

Part No. Description

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

URVCCL

ROBERTS GORDON

®

ULTRAVAC™ Central Controller
(with TCP/IP Communication Module & Software)
Includes:

URVSC

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

URVSC

Controller, ROBERTS GORDON

®

BACnet
Controller, ROBERTS GORDON

®

ULTRAVAC™

®

ULTRAVAC™,

1 Pump 3 Zones (Satellite Control)

URVU

Controller, ROBERTS GORDON® ULTRAVAC™, Unitary

Variable Frequency Drive Assemblies

VFD75115 VFD Assembly, .75 HP, 115 V, 1 Ø Input VFD75230 VFD Assembly, .75 HP, 230 V, 1 Ø Input VFD20230

VFD75115N4
VFD75230N4

VFD75460

VFD75460N4
VFD20230N4

VFD20460

VFD20460N4

VFD Assembly,
VFD Assembly,
VFD Assembly,

2 HP, 230 V, 1 Ø Input
.75 HP, 115 V, 1 Ø Input, NEMA 4

.75 HP, 230 V, 1 Ø Input, NEMA 4
VFD Assembly, .75 HP, 460 V, 3 Ø Input
VFD Assembly, .75 HP, 460 V, 3 Ø Input, NEMA 4
VFD Assembly,

2 HP, 230 V, 1 Ø Input, NEMA 4
VFD Assembly, 2 HP, 460 V, 3 Ø Input
VFD Assembly, 2 HP, 460 V, 3 Ø Input, NEMA 4

ULTRAVAC™ Accessories

10080142 Modem, Plug-In Chip 10080410 Cable Package, PC Connection 10080430 RS-485 Converter with 9V Power Supply 10080440 TCP/IP Communication Module 10081500

Sensor, 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

®

12 of 83

SECTION 5: MAJOR COMPONENTS

Part No. Description

90602451 Voltage Surge Suppressor 120 V 90602452 Voltage Surge Suppressor 120/240 V 1 Ø 60 Hz 90602460 Line Reactor 480 V 3 Ø 60 Hz w/Enclosure (Output) 90602461 Line Reactor 230 V 3 Ø 60 Hz .75 HP (Output) 90602462 Line Reactor 230 V 3 Ø 60 Hz 2 HP (Output) 90602470 Line Reactor 480 V 3 Ø 60 Hz 4 A w/Enclosure (Input)

Thermostats

05023000 Load Relay Package

90417600K Transformer Relay - SPST (12 A)

90436300 Transformer Relay - SPDT (12 A) 90423000 24 V Low Voltage Thermostat (Marked 1-5) 90424300 Thermostat Guard 90425104

Thermostat, Modulating LonWorks

®

90425105 Thermostat, Modulating 90425109

Thermostat, Modulating BACnet

®

90425400 Thermostat, 24 V Programable 90429107

Thermostat, On/Off BACnet

®

10081520 Sensor, Remote Modulating 10081521 Sensor, Outdoor Modulating

Pump Packages and 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

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 01327007 Refill, Condensate Neutralization Tube 600 01327008 Refill, Condensate Neutralization Tube 1000 01327009 Refill, Condensate Neutralization Tube 2000

Contactors

10050011 Contactor, 120 Vac for EP-203, EP-303, 3 Ø

EP-100, EP-201 208/230 V, 1 Ø
EP-301 208/230 V, 1 Ø

10050012 Contactor, 120 Vac for EP-301, 120 V, 1 Ø

Protective Grille

08050001 Protective Grille, 40" (102 cm) 08050002 Protective Grille Cap

Shields

02750303 Barrier Shield

Fresh Air Filter Box

90740100K Fresh Air Filter Box 20628 Aluminum Mesh Filter 20" x 20" x 1"

(51 cm x 51 cm x 3 cm)

13 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 6: DESIGN REQUIREMENTS

The CRVSF-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 CRVSF-Series Design Manual
(P/N 127502NA).

14 of 83

FIGURE 12: Heater Assembly Overview

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SECTION 6: DESIGN R EQUIREMENTS

15 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 7: UNITARY HEATERS

7.1 In-Series Systems vs. Unitary Heaters

CRVSF-Series burners may be used as in-series
systems or unitary heaters.
Unitary heaters consist of a single burner, a single
run of radiant tubing and a vacuum pump. See Page
16, Figure 13 for details.
In-series systems consist of more than one burner
and more than one run of radiant tubing. The runs of
radiant tubing are connected together by manifold
tubing. The manifold tubing connects to a single
pump that exhausts the flue gases outdoors.

Since this manual addresses installation of both
unitary heaters and in-series systems, pay close

Table 4: Contents of CRVSF Unitary Packages

Part No. Description CRVSF60N CRVSF60P CRVSF80N CRVSF80P

02700XXX-SF Burner CRVSF 1 1 1 1

02790300 Tube and Reflector Hanger (Schedule 40 Pipe) 4 4 5 5 02716400 Reflector Support Package (Schedule 40 Pipe) 4 4 5 5 91903202 Eyebolt Turnbuckle 5 5 6 6 91903301 Spring Hook 3/8" (Schedule 40) 5 5 6 6

02721200-1P Cast Iron Combustion Chamber Pkg-1 1 1 1 1

02750800 Reflector End Cap, Aluminum 2 2 2 2 02750304 Reflector with Hole for CRV Burner, Aluminum - 96" (244 cm) 1 1 1 1 02750303 Reflector, Aluminum - 96" (244 cm) 4 4 5 5

E00094XX End Vent Package CRVSF 1 1 1 1

01326801 Housing Filter Assy - Outside Air 1 1 1 1 91308001 Pipe Joint Compound - High Temp 1lb (Never Seize) 1 1 1 1 91107720 U-Clips (20 Pkg) 1 1 1 1 02719105 Pump Package, EP-100 1 1 1 1

attention to section and figure titles to verify
relevance to in-series systems and unitary
heaters.

NOTE: Quantities and items listed in Ta b l e 3
represent components needed to complete a CRVSF
unitary heater at specified minimum heat exchanger
length.

Table 3: Minimum Heat Exchanger Length

Part Number Length

CRVSF60N 31.5' (9.6 m) CRVSF60P 31.5' (9.6 m) CRVSF80N 42" (12.8 m) CRVSF80P 42" (12.8 m)

NOTE: Scheduled 40 pipe and fittings are provided by others.

FIGURE 13:

CRVSF Unitary Heater Assembly Overview

16 of 83

SECTION 8: HEATER INSTALLATION

WARNING

Severe Injury Hazard

Hang heater with materials with a minimum
working load of 750 lbs. (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.

WARNING

Cut/Pinch Hazard

Wear protective gear during installation,
operation and service.

Edges are sharp.

Failure to follow these instructions can result
in injury.

WARNING

Burn Hazard

Pipe compound may drip during first start-up.

Protect personnel and surfaces below heater
prior to start-up.

Failure to follow these instructions can result
in injury or property damage.

SECTION 8: HEATER INSTALLATION

To e n sure 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 is
readily accessible for servicing.

The heaters must be installed in accordance with
clearances to combustibles as indicated on the
burner control side panel (inside) 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 18, Figure 14.

Expansion and contraction of the tube dictates that
the minimum suspension lengths must be
maintained.See table on Page 18, Figure 14.

Install all threaded components with a minimum
thread engagement of three threads. Apply sufficient
amount of high temperature anti-seize pipe
compound (P/N 91308001 or equivalent) to threads
prior to engagement. Hot compound may drip from
threads.

17 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Eyebolt Turnbuckle 91903202
Spring Hook 3/8" 91903301
Tube/Reflector Hanger 02790300
Cast-Iron Combustion Chamber 02721200-1P

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)
200' (61 m) ±4" (10 cm) 46" (122 cm)
250' (76 m) ±5" (13 cm) 57" (145 cm)

FIGURE 14: Critical Hanger Placement

18 of 83

Step 8.1 Tube Installation

Description Part Number

Schedule 40 Steel Pipe and Fittings Supplied by Others
Turnbuckle with Eyebolts 91903202
Spring Hook 3/8" 91903301
Tube/Reflector Hanger 02790300
High Temperature Pipe Compound 91308001

Minimum Distance Required Between
Burner and Elbow
Model Minimum Distance

CRVSF-2 5' (1.5 m)
CRVSF-4 5' (1.5 m)
CRVSF-6 10' (3 m)
CRVSF-8 10' (3 m)

SECTION 8: HEATER INSTALLATION

8.2 Elbow Package Configuration

Step 8.2.1 Elbow Installation

Step 8.2.2 Elbow Installation

19 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Schedule 40 Tube/Reflector Hanger 02790300
Schedule 40 Steel Pipe and Fittings Supplied by Others
Reflector with Hole,

96" (244 cm)

02750304

Step 8.3 Reflector Installation

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.

Install all threaded components with a minimum
thread engagement of three threads. Apply sufficient
amount of high temperature, anti-seize pipe
compound (P/N 91308001 or equivalent) to threads
prior to engagement.

Step 8.3.1 Reflector Installation with Hole

20 of 83

Step 8.3.2 Reflector Installation

Description Part Number

Reflector Support Package 02716400
U-Clip Package 91107720
Reflector End Cap 02750800

SECTION 8: HEATER INSTALLATION

21 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Reflector Support Package (Schedule 40 Pipe) 02716400

Wire Form (Schedule 40 Pipe) 91908001

Reflector Support Strap 03050000
U-Clip Package 91107720
Reflector End Cap 02750800

Step 8.3.3 Reflector, U-Clip and Reflector Support Installation

The pictorial drawings of the heater construction in
Section 8 are schematic only and provide a general
guideline of where hangers, reflector supports and
U-clips are to be installed.
To ensure proper expansion and contraction
movement of the reflectors, a combination of U-clips

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.

and reflector supports are used. The positioning of

22 of 83

Step 8.4 Burner Installation

Description Part Number

Bolt 94273914
Burner 0270XXXX-SF
Lock Washer 96411600
Gasket 01367800
End Vent E00097XX
Schedule 40 Adapter 02722100

SECTION 8: HEATER INSTALLATION

23 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

Cut/Pinch Hazard

Wear protective gear during installation,
operation and service.

Edges are sharp.

Failure to follow these instructions can result
in injury.

Description Part Number

Te e S upplied by Others
Schedule 40 Tube/Reflector Hanger 02790300
Schedule 40 Steel Pipe Supplied by Others

SECTION 9: OPTIONAL HEATER ACCESSORIES

Step 9.1 Tee Installation

24 of 83

Step 9.2 Reflector Joint

Description Part Number

Reflector End Cap 02750800
Reflector Joint 02750900
U-clip Package 91107720

Step 9.2.1 Reflector Joint Installation

SECTION 9: OPTIONAL H EATER ACCES SORIES

Step 9.2.2 Reflector Joint Installation

25 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 9.2.3 Reflector Joint Detail

FIGURE 15: Reflector Joint Detail

26 of 83

9.3 Reflector Side Extension

Description Part Number
Reflector Side Extension Package 02712700

Reflector Side Extension, 96" (244 cm) 01368000
Retainer Clips 02751200
Sheet Metal Screws 94118106

Order Separately

Reflector Side Extension Bracket 01329910

Step 9.3.1 Bracket Installation

SECTION 9: OPTIONAL H EATER ACCES SORIES

Step 9.3.2 Side Reflector Installation

27 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Barrier Shield 02750303
U-Clip Package 91107720

Barrier shields must be cut down to 4' (1.2 m) sections. Do not install barrier shield less than 5' (1.5 m)
downstream of any burner or within 1' (.3 m) of next in-series burner. Do not install more than 1 barrier
shield in between in-series burners.

9.4 Barrier Shield

28 of 83

9.5 Protective Grille Installation

Silicone Cap

Grille
Finger

Description Part Number

Grille Section 08050001
Grille End Cap 08050002
Silicone Cap 91915951-6P

Pull outward

Grille

Grille End Cap

A

B

C

D

Grille

Grille
End Cap

Reflector

Final Grille
Section

40"

(101 cm)

Step 9.5.1 Silicone Cap Installation

Step 9.5.2 Grille End Cap Installation

SECTION 9: OPTIONAL H EATER ACCES SORIES

Step 9.5.3 Grille Installation

Bend up 90°

29 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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.

WARNING

Cut/Pinch Hazard

Wear protective gear during installation,
operation and service.

Edges are sharp.

Failure to follow these instructions can result
in injury.

Description Part Number

Condensate Valve Assembly 01327001

SECTION 10: PUMP INSTALLATION AND VENTING

10.1 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

30 of 83

SECTION 10: PUMP INSTALLATION AND VENTING

10.1.1 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 32, Figure 17.

Step 1: Condensate flow (gal/h) per 100,000 Btu/h
installed

Yo u 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
Length

(average distance
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

Minimum Recommended

Tailpipe Length per Flow Unit

1.7 ft/flow
unit

Maximum

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.

(600,000/100,000) x 0.3 = 1.8 (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.
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 Neutralization 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

®

CLASSIC SF 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
Length

(average distance
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

Minimum Recommended

Tailpipe Length per Flow Unit

1.7 ft/flow
unit

Maximum

Step 2: Total condensate

Multiply the total input Btu/h / 100,000 by the
condensate flow (gal/h) per 100,000 (Btu/h)

31 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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

FIGURE 17: Condensate Neutralization Tube

10.2 General Venting Requirements Model EP­100, 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
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 ¼'' every 10' (3 m).

The bottom of the vent or air intake terminal shall not
be located less than 1

The vent shall not terminate less than 7

' (0.3 m) above grade level.

' (2.1 m)

above grade where located adjacent to public
walkways.

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.

10.2.1 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.

10.2.2 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

32 of 83

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 equipment.

NOTE: Vertical venting (venting through roof) is not
recommended.

10.2.3 Horizontal Venting

See Page 34, Figure 18 through Page 34, Figure 18
for recommended horizontal venting options.

10.2.4 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:

SECTION 10: PUMP INSTALLATION AND VENTING

Vent Length

Up to 10' (3 m)

Up to 25' (8 m)

Up to 50' (15 m)

EP-300 Vent

Size

6" (15 cm) -

1 elbow

7" (18 cm) -

3 elbow

8" (20 cm) -

3 elbow

EP-200 Vent

Size

4" (10 cm) -

1 elbow

5" (12.7 cm) -

3 elbows

6" (15 cm) -

3 elbows

EP-100 Vent

Size

4" (10 cm) -

3 elbows

4" (10 cm) -

3 elbows

5" (12.7 cm) -

3 elbows

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.

10.2.5 Vent Material Recommendations

Vent recommendations:

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. (Supplied by others - Not suitable for modulating and condensing system designs.)

4. Schedule 40 ASTM A53 (Latest Edition) grade B ERW black steel pipe.

33 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

.

Pump Maximum Length A Maximum Number of Elbows

EP-100 25' (8 m) 3
EP-200 10' (3 m) 1

FIGURE 18: EP-100 & EP-200 Horizontal Venting Configurations

Part Number Description Part Number Description

01330203 Tee, 4" (10 cm) Porcelain 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)

90502100 Vent Terminal, 4" (10 cm) (Combustible Wall) Not Supplied Tube Adapter, 6" (15.2 cm) dia. x 5" (12.7 cm) dia.

02771000 4.5" (11 cm) Flexible Boot Package

34 of 83

FIGURE 19: EP-300 Series Horizontal Venting Configurations

SECTION 10: PUMP INSTALLATION AND VENTING

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)

01397400 Bird Screen, 6" (15 cm) 91412800 Flexible Boot, 4" (10 cm)

02537801-1P Vent Terminal (Non-Combustible Wall) 91412802 Flexible Boot, 6" (15 cm)

02718851 Drain Cap, 4" (10 cm) 91418200 Tube Adapter, 6" (15.2 cm) dia. x 4" (10 cm) dia.

02718852 Drain Cap, 6" (15 cm) 91901300 Boot Clamp, 4" (10 cm)

90502100 Vent Terminal, 4" (10 cm) (Combustible Wall) 91913703 Boot Clamp, 6" (15 cm)

90502101 Vent Terminal, 6" (15 cm) (Combustible Wall) T0100320 Elbow, 6" (15 cm) Aluminized 90°

90502302 Vent Cap, 6" (15 cm) Metalbestos 02771000 4.5" (11 cm) Flexible Boot Package

35 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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.

SECTION 11: OUTSIDE AIR SUPPLY

The CRVSF-Series system must use 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.
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.
To p re vent condensation, insulate the outside air
duct.

11.1 Pressurized

See Page 39, Figure 24 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
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 37,
Figure 21 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.

11.2 Non-Pressurized

For a non-pressurized outside air supply, a 4" (O.D.)
single wall pipe duct may be attached to the burner

ULTRAVAC™ control or relay

and end vent via flexible duct as system will expand
and contract. For length and duct sizing
requirements, see duct design rules in Figure 20. To
prevent condensation, insu

late the outside air duct.

36 of 83

FIGURE 20: Duct Sizing

Outside Air System Design Requirements:

Blower Performance (90707501K):
112 Flow Units

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
CRVSF-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)

- Elbo

ws are equivalent to 10' (3 m) of duct length.

L

MOTOR

MN

BLK

WHT

T1 T3T2

C

NO

BLU

BLU

BLOWER

PRESSURE

SWITCH

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.

SECTION 11: OUTSIDE A IR SUPPLY

11.3 Outside Air Blower Internal Wiring FIGURE 21: Outside Air Blower Internal Wiring Diagram

37 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Filter Housing 01326801
Filter and Gaskets 01312401
Filter Support 91905500
Wing Nut 92511601
4" (10 cm) Air Flex Duct (box of eight 8' (2.4 m) sections) 91409601

Description Part Number

Blower 90707501K
5" (12.7 cm) Vent Cap 90502302
6" (15 cm) Bird Screen 01397400
6" (15 cm) Band Clamp 91913703

FIGURE 22: Filter Housing Assembly

FIGURE 23: Air Supply Blower Support

38 of 83

FIGURE 24: Pressurized Outside Air Supply

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

Description Part Number

Pres sure Switch Kit 90434501
4" (10 cm) Bird Screen 01365400
4" (10 cm) Vent Cap 90502300
6" (15 cm) Vent Cap 90502302

SECTION 11: OUTSIDE A IR SUPPLY

FIGURE 25: Non-Pressurized Outside Air Supply

39 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number
Fresh Air Filter Box 90740100K

Filter Box 9074100

Aluminum Mesh Filter, (washable)
20" x 20" x 1" (51 cm x 51 cm x 3 cm)

20628

Magnetic Strip (20 inches) 90740101

Double filtered outside air is
recommended. Mount Fresh Air
Filter box on exterior wall.
Connect duct work to 8” (20 cm)
diameter fresh air inlet.

FIGURE 26: Filter Box

40 of 83

SECTION 12: GAS PIPING

WARNING

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.

SECTION 12: 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 27.
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" wc. When gas piping
is not included in the layout drawing, the local gas
supplier will us

Gas lines must meet applicable codes:
United States: The Flexible Stainless Steel Gas
Hose (US models) supplied with the heater is certi­fied per the Standard for Connectors for Gas equip-
ments, ANSI Z21.24/CSA 6.10 - latest revision.
Canada: The Rubber Type 1 Gas Hose (Canadian
models) optional with the heater is certified as being
in compliance with the Standard for Elastomeric
Composite Hose and Hose Couplings for Conducting
Propane and Natural Gas, CAN/CGA 8.1 - Latest
revision.

• 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.

ually help in planning the gas piping.

Install the gas hose as shown on Page 42, Figure 27.
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.

41 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

1/2" Flexible Stainless Steel Gas Hose (US Models) 91412200
1/2" Rubber (Type 1) Gas Hose (Canadian Models) 91412206

See Page 75, Section 20.

Description Part Number

High Pressure Regulator - 2 psi 90207600
High Pressure Regulator - 5 psi 90207601

FIGURE 27: Gas Connection with Flexible Gas Hose

42 of 83

SECTION 13: CONTROL METHODS

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.

WARNING

Explosion Hazard

Turn off gas supply to heater before service.

Failure to follow these instructions can result
in death, injury or property damage.

SECTION 13: CONTROL METHODS

There are several methods of controlling CRVSF-
Series systems. The options are as follows:

®

13.1 ROBERTS GORDON

The System Control is an electronic control panel

System Control

designed to control CRVSF-Series heating systems.
The System Control wiring is shown on Page 50,
Figure 32 through Page 52, Figure 35 and in the
System Control Installation Manual
(P/N 10091601NA).
The System Control can be used to control an EP­100 or EP-201 pump from the control panel. Other
pumps such as the EP-301 and 3 Ø 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

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 Eq

13.2 ROBERTS GORDON

uipment.

®

ULTRAVAC™

(CRVSF-6/-8 only)

The ROBERTS GORDON

®

ULTRAVAC™ is a micro­processor based control package designed for
modulating control of CRVSF-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
ROBERTS GORDON
requires a PC (not supplied) running Windows
higher, with a Pentium

ULTRAVAC™ Software.

®

ULTRAVAC™ Software

®

class processor and at least

®

95 or

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 CRVSF-

®

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
computer 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.

®

13.3 CORAYVAC

For a ROBERTS GORDON

Modulating Controls

®

CORAYVAC®
Modulating system, combine a modulating
thermostat, a thermostat relay (P/N 90417600K) and

43 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

any one of the existing ROBERTS GORDON

®

VFD

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.

13.3.1 Analog Signal Modulating Thermostat

A programmable, 7-day programming, modulating
thermostat can be installed to supply an analog (4­20mA) or (2-10Vdc with 500 Ohm resistor) control
signal to dictate the speed of the pump. For
thermostat wiring, See Page 53, Figure 36. 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

10081520). Refer to thermostat installation
instructions for wiring.

13.3.3 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 55, Figure 38.

This thermostat is a flexible, wall-mounted stand-
alone control with combined controller/sensor.
BACnet
BACnet

®

connections allow integral peer to peer

®

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.

13.3.2 Analog Signal Modulating Thermostat with
LonWorks

If LonWorks

®

Communication

®

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 53,
Figure 36 and Page 54, Figure 37. 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
networking capability in a LonWorks

®

provides

®

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

44 of 83

13.3.4 Cable Requirement

Ta b l e 5 , on Page 45, lists wiring types, sizes and
distances for modulating thermostat communication.

Power Requirement

Programmable thermostats requires 24 volt, AC
power.

Table 5: Modulating Thermostat Cable Requirements

SECTION 13: CONTROL METHODS

Wire Function Recommended Wire Size

(Minimum)

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

(0.75 to 0.34 sq mm)

Power Wiring 18 to 14 AWG

( 0.75to 2.0 sq mm)

®

LonWorks

MS/TP (P/N 90425109) 18 AWG (0.75 sq mm) Shield Belden cable #82760 or equivalent Refer to Thermostat Installation Guide

(P/N 90424104 only)

18 AWG
(0.75 sq mm) nonshielded

Twisted pair wire 1000 ft (304 m)

NEC Class II 140ºF (60°C ) Limited by line-loss effects on power

1 pair Refer to E-bus Wiring Guide 74-2865

13.3.5 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

Specification or

Requirement

Distance (Maximum)

consumption.

for maximum length and generic cable
specifications.

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 45, Figure 28):

1. To obtain 4-20 mA signal, connect as shown on Page 54, Figure 37 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 53, Figure 36 and set standard speed source (parameter 05 inside VFD menu) to 03.

FIGURE 28: VFD Terminal Strip

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 55, Figure 38 and set standard speed
source (parameter 05 inside VFD menu) to 03.

13.3.6 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 53, Figure 36. When the temperature falls
below the setpoint, the modulating thermostat will

As the pump receives the analog signal from the
VFD, the heater(s) modulate to the corresponding
firing rate. As sensed air temperature rises closer to

45 of 83

CRVSF-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 tem­perature rises above the setpoint to a cut-off
limit temperature when the modulating thermo­stat turns off the heater.

13.4 SPST Transformer Relay Kit (P/N 90417600K)

The transformer relay wiring diagram is shown on
Page 47, Figure 29. The transformer relay can be

used to control an EP-100 or EP-201 pump

CORAYVAC

®

CLASSIC SF 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.

13.5 SPDT Transformer Relay (P/N 90436300)

The transformer relay wiring diagram is shown on
Page 49, Figure 31. 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.

46 of 83

FIGURE 29: One Zone Operation without Control Panel (optional)

Description Part Number

SPST Transformer Relay 90417600K

SECTION 13: CONTROL METHODS

47 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 30: One Zone Operation (with Outside Air Blower) without Control Panel (optional)

48 of 83

FIGURE 31: Two Zone Operation without Control Panel (optional)

Description Part Number

SPDT Transformer Relay 90436300

SECTION 13: CONTROL METHODS

49 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 32: General System Wiring

FIGURE 33: External Wiring Diagram EP-100 and EP-201 120 V 1 Ø Pump

50 of 83

SECTION 13: CONTROL METHODS

CAUTION

Product Damage Hazard

Do not directly connect control relay terminals
to pump motor

.

Failure to follow these instructions can result
in product damage.

FIGURE 34: External Wiring Diagram EP-100, EP-201 or EP-301 230 V 1 Ø Pump (optional)

51 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 35: External Wiring Diagram EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø Pump (optional)

CAUTION

Product Damage Hazard

Do not directly connect control relay terminals
to pump motor

Failure to follow these instructions can result
in product damage.

.

52 of 83

SECTION 13: CONTROL METHODS

Description Part Number

SPST Transformer Relay 90417600K
Thermostat, Modulating LonWorks

®

90425104
Thermostat, Modulating 90425105
Sensor, Remote Modulating 10081520
Sensor, Outdoor Modulating 10081521

FIGURE 36: CORAYVAC
ohm resistor) optional]

®

CLASSIC SF Modulating Wiring Diagram [LonWorks® (2-10 Vdc with 500

53 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

SPST Transformer Relay 90417600K
Thermostat, Modulating LonWorks

®

90425104
Thermostat, Modulating 90425105
Sensor, Remote Modulating 10081520
Sensor, Outdoor Modulating 10081521

FIGURE 37: CORAYVAC

®

CLASSIC SF Modulating Wiring Diagram [LonWorks® (4-20 mA) optional]

54 of 83

SECTION 13: CONTROL METHODS

Description Part Number

SPST Transformer Relay 90417600K
Thermostat, Modulating BACnet

®

90425109

FIGURE 38 : CORAYVAC

®

CLASSIC SF Modulating with BACnet® Wiring Diagram (optional)

55 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

S1

TRANSFORMER

VALVE

GAS

120 V

Power Supply

Yellow

Yellow

Brown

Green

White

Black

3

4

1

5

BURNER

IGNITION

MODULE

Black

Blue

Yellow

V2/GND

TH

V1

Green

Gap

TRANSFORMER

L1

L2

Black

White

Blue

Yellow

Brown

ELECTRODE

GAS VALVE

V2

Gnd

S1 V1

TH

Black

Yellow

IGNITION
MODULE

FIGURE 39: Burner Internal Wiring

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 40: Burner Internal Ladder Diagram

56 of 83

SECTION 14: STARTING THE SYSTEM

SECTION 14: STARTING THE S YSTEM

DANGER

Electrical Shock Hazard

Disconnect electric
before service.

More than one
disconnect switch may
be required to
disconnect electric from
heater.

Heater must be
connected to a properly
grounded electrical
source.

Failure to follow these instructions can result in death, electric shock, injury or property damage.

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
equipment connected.

WARNING

Carbon Monoxide Hazard

Heaters installed
unvented must be
interlocked with sufficient
building exhaust.

Heaters must be installed
according to the
installation manual.

Burn Hazard

Allow heater to cool
before service.

Tubing may still be
hot after operation.

Start with the main gas valve closed and the electric
power off.

14.1 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.

14.2 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 above room
temperature should start the pu
After a 45 second delay, the burners will begin
their ignition sequence by sparking at the
electrode (visible through the burner window).

mp immediately.

5. Vacuum pump motors can be wired to rotate the
impeller in either direction. A negative pressure
can still be measured when the impeller is run-
ning backwards. Ensure proper rotation of the
impeller prior to setting the vacuum pressure.

6. Make a preliminary vacuum check at burners in
branches that have an adjustable damper
coupling. See Page 59, Figure 41 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).

14.3 Starting the System NOTE: During the initial firing, the protectiv

the pipe may smoke for 30 to 60 minutes and
adequate ventilation should be provided.

1. S t a r t with all temperature setpoints below room temperature.

2. Open main gas valve.

3. 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.

4. If any abnormal operation occurs, see the trou-
bleshooting section of the service instructions.

e oil on

57 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

14.4 Setting the Vacuum

1. Set temperature setpoints above room tempera­ture. See that all burners are operating properly.

2. Allow at least one hour operation for tempera­ture to normalize, then check system vacuum
balance. Vacuum can be measured by inserting
a manometer hose into the end vent as shown

on Page 59, Figure 41. Normal end vent vac-
uum should

3.0'' wc

be set at approximately 2.5'' wc to

(hot).
Vacuum adjustments are made by means of the
damper in the pump inlet and the adjustable
damper nipple(s) in the system. Check the vac-
uum 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. After adjustment, seal all openings found in the damper nipple(s) with high temperature silicone sealant.

4. Reset temperature setpoints to desired room temperature.

5. If heat is not required, turn off main switch and close the main gas valve.

14.5 Record Start-Up Results

1. D uring the initial installation and start-u p of the
system, fill out the

CORAYVAC

®

CLASSIC SF
Start-Up and Installation Report in its entirety.
In locations where multiple

CORAYVAC

®

CLAS­SIC SF systems are installed, one report should
be completed for each pump system.

2. Submit each completed form to Roberts Gor­don. The warranty will be voided if the form is
not returned within 24 hours of start-up.

58 of 83

FIGURE 41: Vacuum Reading

SECTION 14: STARTING THE S YSTEM

59 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

DANGER

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.

00

225

P01

SECTION 15: VARIABLE FREQUENCY DRIVE PROGRAMMING

15.1 VFD Parameter Settings For Use With Modulating Thermostats

The VFD parameters come with factory default set-
tings. The following parameter settings must 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.

(the factory set password is 225).

Press Mode to enter password.

Once the correct password value is entered, the dis-
play will read "P01", w
PROGRAM mode has been accessed at the begin­ning of the parameter menu (P01 is the first
parameter).

hich indicates that the

To o verride 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.

15.1.1

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

15.1.2

Use the arrow buttons to scroll to the password value

NOTE: If the display flashes "Er", the password was
incorrect, and the process to enter the password
must be repeated.

15.1.3 Use the arrow buttons to scroll to the desired parameter number. For new parameter settings See Page 61, Section 15.2.

15.1.4 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.

15.1.5 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 exit­ing 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.

60 of 83

15.2 Altering VFD Parameters

Using the procedure described on Page 60, Section

15.1.1 through Section 15.1.5, alter the following

parameters:

SECTION 15: VARIABLE FREQUENCY DRIVE P ROGRAMMING

Parameter
Number

Parameter

Name

Factory
Default

New

Setting

P01 Line Voltage 01 01
P03 Start Method 01 05
P05 Standard

Speed

01 (03) (0-10) Vdc

(04) (4-20) mA

Source

P44 Password 225 Any #

000-999

P45 Speed at

Minimum

Signal

0.0Hz Frequency
Setting noted

on Page 62,

Section 16.2.2

P46 Speed at

Maximum

Signal

60.0Hz Frequency
Setting noted

on Page 62,

Section 16.2.1

61 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Record Frequency Setting Here:

Record Frequency Setting Here:

SECTION 16: COMMISSIONING THE CORAYVAC
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 com­pleted. 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 sys­tem. The following procedure will help you set mini-
mum and maximum VFD frequency settings to
achieve proper vacuum in the system.

16.1 Setting The CORAYVAC

®

CLASSIC SF End

Burner Vacuum

16.1.1 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.

16.1.2 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 60, Section 15 for setting up
the VFD.

®

CLASSIC SF MODULATING SYSTEM

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

NOTE: To avoid damage to the pump motor, do not

adjust the frequency abo

ve 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 59, Figure 41. 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 64,
Figure 42.

16.2.2 Minimum Signal Speed

®

After setting end vent vacuums 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 freq

uency is

found on the VFD's LCD screen.

1.0" w.c. - 1.2" wc VFD Frequency Setting

16.2 Adjusting the Variable Frequency Drive

16.2.1 Maximum Signal Speed

The pump should be running and the burners should
light within 60 seconds. At the VFD, verify 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 64,
Figure 42.
If the lowest end vent vacuu
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

62 of 83

m reading is above 3.0"

16.3 Programming Of Variable Frequency Drive

Parameter
Number

Parameter

Name

Factory

Default

New

Setting

P01 Line Voltage 01 01
P03 Start Method 01 05
P05 Standard

Speed

01 (03) (0-10) Vdc

(04) (4-20) mA

Source

P44 Password 225 Any #

000-999

P45 Speed at

Minimum

Signal

0.0Hz Frequency
Setting noted

on Page 62,

Section 16.2.2

P46 Speed at

Maximum

Signal

60.0Hz Frequency
Setting noted

on Page 62,

Section 16.2.1

16.3.1 Modulating Thermostat

Turn "OFF" the power to the transformer relay. Using
the procedure described on Page 60, Section 15,
alter the parameters above on the VFD. Turn on the
transformer relay and program the modulating
thermostat to the customer's requirements.

SECTION 16: COMMISSIONING THE CORAYVAC® CLASSIC SF MODULATING SYSTEM

63 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Description Part Number

Schedule 40 Damper Nipple 01332000

FIGURE 42: Possible Damper Nipples’ Locations

64 of 83

SECTION 17: OPERATION AND MAINTENANCE

Cut/Pinch Hazard

Wear protective gear
during installation,
operation and service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, electric shock, injury or property damage.

Burn Hazard

Allow heater to cool
before service.

Tubing may still be hot
after operation.

Explosion Hazard

Turn off gas supply to
heater before service.

DANGER

Electrical Shock Hazard

Disconnect electric
before service.

More than one
disconnect switch may
be required to
disconnect electric from
heater.

Heater must be
connected to a properly
earthed electrical
source.

SECTION 17: OPERATION AND MAINTENANCE

The heater is equipped with a direct-spark ignition
system.

17.1 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 CRVSF-Series
systems equipped with the optional ROBERTS
GORDON
GORDON
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

®

System Control, or ROBERTS

®

ULTRAVAC™, the pump will

(thermostat cycle is required) or automatically
after 1 hour.

17.2 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.

17.3 To Start Heater

Turn gas valve and electric power OFF and wait five
minutes for u
Turn ON main gas valve.
Turn ON electric power.
Set thermostat to desired temperature.
Burner should light automatically.

17.4 Pre-Season Maintenance and Annual Inspection

To e n sure 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

nburned gases to vent from heater.

65 of 83

CRVSF-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 66, Section 17.5 for suggested
items to inspect.

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.

17.5 Maintenance Checklist Installation Code and Annual Inspections:

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 6, 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 6, Section 3.

Reflector Support reflector with reflector hanger and support strap.

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 22, Figure 8.3.3.

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 du

st.

Remove any carbon deposits or scale using a wire brush.
See Page 30, Section 10.

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.

Tube s Make sure there are no cracks.

66 of 83

Make sure tubes are connected and suspended securely.

See Page 18, Figure 14 through Page 19, Section 8.2.

Make sure there is no dirt, sagging, bending or distortion.

Clean or replace as required.

SECTION 17: OPERATION AND MAINTENANCE

Gas Line Check for gas leaks. See Page 42, Figure 27.
Combustion Chamber

Window

Blower Scroll, Wheel and

Make sure it is clean and free of cracks or holes.

Clean or replace as required.
Compressed air or a vacuum cleaner may be used to clean dust and dirt.

Motor
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 43, Section 13.

Suspension Points Make sure the heater is hanging securely. Look for signs of wear on the chain

or ceiling.

See Page 18, Figure 14.

Filter Check for dirt or dust. Clean or replace as required.
Fresh Air Filter Box Change or clean filter as necessary. Heavy contaminated filter may warrant a

tighter maintenance schedule than the remaining of the heating system.

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.

Wall Tag 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 ROB­ERTS GORDON

®

independent distributor to obtain replacement signs or

labels. See Page 2, Figure 1 through Page 3, Figure 2.

67 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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.

Cut/Pinch Hazard

Wear protective gear
during installation,
operation and service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, injury or property damage.

Burn Hazard

Allow heater to cool
before service.

Tubing may still be hot
after operation.

Explosion Hazard

Turn off gas supply to
heater before service.

SECTION 18: TROUBLESHOOTING

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 instructions can
result in death or electrical shock.

68 of 83

18.1 Troubleshooting Flow Chart

SECTION 18: TROUBLESHOOTING

69 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Troubleshooting Flow Chart

70 of 83

SECTION 19: REPLACEMENT PARTS

Carbon Monoxide Hazard

WARNING

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.

Explosion Hazard

DANGER

Electrical Shock Hazard

Fire Hazard

SECTION 19: REPLACEMENT PARTS

See warnings and important information before removing or replacing parts. After any maintenance or repair
work, always test fire the heater in accordance with the start-up instructions on Page 57, Section 14 to help

ensure all safety systems are in working order before leaving the heater to operate. Minor faults may be
traced by using the troubleshooting charts on Page 68, Section 18 through Page 70.

71 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Gasket (Burner to Mixing Chamber)

Ignition Module

Mixing Chamber

Burner Head

Regulator

Electrode

Electrode Gasket

Combustion

Chamber

Gasket

Gas Valve

Transformer

OF

F

ON

Ignition Cable

NOTE: In the event that a manifold replacement part is needed (e.g. gas valve, regulator), please
contact Roberts-Gordon LLC or your ROBERTS GORDON

®

independent distributor.

Description Part Number

Gas Valve (All Burners) Contact Factory
Gasket (Burner to Mixing Chamber) 01351100
Burner Head Assembly Replacement Package (includes electrode and gasket installed) Contact Factory
Mixing Chamber Contact Factory
Transformer 90436900K
Regulator Replacement Kit Contact Factory
Gasket (Combustion Chamber) 01367800
Electrode Replacement Kit (includes electrode, electrode gasket and mounting screws) 02713200
Ignition Module 90439500K
Ignition Cable 90427706
Filter Cartridge with Gasket (not shown) 01312401

72 of 83

19.1 Variable Frequency Drive Replacement Parts

Caution: Use only genuine ROBERTS GORDON

®

replacement parts. Use of parts not specified by

Roberts-Gordon voids warranty.

FIGURE 43: Variable Frequency Drive Components Diagram

SECTION 19: REPLACEMENT PARTS

Description

Vari able Frequency Drive, 1 HP, 120 V, 1 Ø Input (for use with EP-203)
Vari able Frequency Drive, 3/4 HP, 230 V, 1 Ø Input (for use with EP-203)
Vari able Frequency Drive, 2 HP, 230 V, 1 Ø Input (for use with EP-303)
Vari able Frequency Drive, 1 HP, 460 V, 3 Ø Input (for use with EP-203)
Vari able Frequency Drive, 2 HP, 460 V, 3 Ø Input (for use with EP-303)
Relay, 120 V
Fuse 10 A (for.75 HP 230 V VFD, 1 HP 460 V VFD and 2 HP 460 V VFD)
Fuse 25 A (for 1 HP 120 V VFD and 2 HP 230 V VFD)
Grounding Block
Fuse Holder
Rotary Disconnect Base Block
Rotary Disconnect Handle (not shown)
Rotary Disconnect Rod (not shown)

Part Number

10081201
10081202
10081203
10081204
10081205
90429100
91321410
91321425
91321300
91321400
91321550
91321551
91321552

73 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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.

19.2 Replacement Parts Instructions

19.2.1 Variable Frequency Drive (VFD)

To replace the Variable Frequency Drive, turn off all
power to the drive assembly at the breaker or discon­nect 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 ter­minals to which they are secured. 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 plate
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 ter­minals. If possible, it may be easier to partially re­wire 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.

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 VFD, 1 HP 460 V VFD
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.

19.2.2 Variable Frequency Drive 25 A or 10 A Fuse

To replace a fuse, turn off inpu

t 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

74 o f 83

SECTION 20: GENERAL SPECIFICATIONS

Heat Input Rate Length “A” Recommended Minimum Mounting Height*

Model (Btu/h) x (1000) Minimum Maximum Spot Heating

CRVSF-2

(NG Only)

40 ** See Below 21' (6.4 m) 8' (2.4 m)

CRVSF-4 40 ** See Below 31.5' (9.6 m) 8' (2.4 m)

CRVSF-6 60 ** See Below 42' (12.8 m) 8' (2.4 m)

CRVSF-8 80 ** See Below 52.5' (16 m) 10' (3 m)

20.1 Material Specifications

20.1.1 Reflectors

.024

Aluminium.

20.2 Heater Specifications

20.2.1 Ignition

Fully Automatic, Three-Try, Direct Spark, Electronic
Ignition Control, 100% Safety Shut-Off.

SECTION 20: GENERAL SPECIFICATIONS

20.3 Suspension Specifications

Hang heater with materials with a minimum working
load of 750 lbs (340 kg). See Page 18, Figure 14.

20.4 Controls Specifications

Time switches, thermostats, etc. can be wired into
the electrical supply. External controls supplied as an
option.

*See Page 6, Section 3 for clearances to combustibles.
**Refer to the CRVSF-Series Design Manual (P/N 127502NA)

GAS INLET PRESSURE:

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.

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 A

75 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

C

B

G

A

E

D

F

dia.

Model EP-100 EP-201 EP-203 EP-301 EP-303

Horsepower (Hp) 1/3 3/4 3/4 2* 2*
Phase (Ø) 11313

Hertz (Hz) 60 60 60 60 60

Voltage (V) 115/230 115/230 208-230/460 208-230 208-230/460

Full Load Amp (Amps) 4.8/2.4 6.6/3.3 2.4-2.2/1.1 12.8-11.5 5.5-5.2/2.6

R.P.M. 3450 3450 3500 3450 3450

Motor Frame 56 56 56 90 90

Motor Enclosure TENV TENV TEFC TEFC TEFC

Noise Level @ 5' (DBA) - 70 70 - -

Inlet/Outlet (In.) 4/4 4/4 4/4 6/6 6/6

Weight (lbs.) 62 112 112 170 170

Pump Dimensional Data (in.)
Model A B C D E F G
EP-100 17 14.5 21 3.75 10 4 4
EP-201/203 17.75 17 20.25 3.25 10 4.5 4.5
EP-301/303 25.6 24.8 22.7 4.8 15.2 6 6

SECTION 21: GENERAL SPECIFICATIONS FOR PUMPS

* For starter, see National Electric Code (NEC) requirement for motors 1 hp or higher.

SECTION 22: GENERAL SPECIFICATIONS FOR AIR SUPPLY BLOWER

Capacity 240 CFM @ 0.75 in wc

Power (W) 167

Phase 1

Hertz (Hz) 60

Voltage (V) 120

Full Load Amp (Amps) 1.5

R.P.M. 3000

Motor Enclosure OPEN FC

Inlet/Outlet (In.) 5/5

Weight (lbs.) 10

76 of 83

SECTION 23: GENERAL SPECIFICATIONS FOR FRESH AIR FILTER BOX SPECIFICATIONS

Filter Box Dimensional Data

ABCDEF

20" (51 cm) 15" (38 cm) 20" (51 cm) 8" (20 cm) 2" (5 cm) 20" (51 cm)

SECTION 23: GENERAL SPECIFICATIONS FOR FRESH AIR FILTER BOX SPECIFICATIONS

77 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

78 of 83

SECTION 24: CORAYVAC® CLASSIC SF START-UP AND INSTALLATION REPOR T

CORAYVAC® Classic SF Start-Up and Installation Report

Form must be completed and returned within 24 hours of start-up or warranty is void.

Date of Installation: Model # Serial #

Installed at: Service Company:

Name: Name:

Address: Address:

Phone: Phone:

Fax: Fax:

E-mail: E-mail:

Cut/Pinch Hazard

Wear protective gear
during installation,
operation and service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, electric shock, injury or property damage.

Burn Hazard

Allow heater to cool
before service.

Tubing may still be hot
after operation.

Explosion Hazard

DANGER

Electrical Shock Hazard

Disconnect electric
before service.

More than one
disconnect switch may
be required to
disconnect electric from
heater.

Heater must be
connected to a properly
grounded electrical
source.

Leak test all compo­nents of equipment
gas piping before
operation.

Gas can leak if
piping is not
installed properly.

Do not high pressure
test gas piping with
equipment
connected.

WARNING

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.

WARNING

Falling Hazard

Use proper safety equipment and practices
to avoid falling.

Do not use any part of equipment as support.

Failure to follow these instructions can result
in death, injury or property damage.

SECTION 24: CORAYVAC

®

CLASSIC SF START-UP AND INSTALLATION REPORT

79 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

1. Turn system on. Run for one hour.

2. Gas Type Natural Gas  Liquid Propane 
A. Supply Pressure (measured at last burner of gas
supply line with entire building heat operating at full
capacity)
B. Flex Lines Installed Properly 
C. High Pressure Regulators Used 
Installed Upstream of the Flex Line  YES  NO
Model Number

3. Vacuum Pump
A. Model/Serial Number Installed
B. Motor Rotation Direction  CW  CCW
C. Damper Nipples  YES  NO
D. End Vent Vacuum

Branch # End Vent Vacuum End Vent Plate ID

Number Installed

4. Electrical
A. Pump Supply Voltage
B. Pump Amperage Draw
C. Thermostat(s)

Thermostat Location Thermostat Type

5. Flue Discharge
A. Flue Direction  Roof  Wall
B. Vent Material
C. Vent Diameter

6. Condensate Discharge  YES  NO

7. Tube Pitch  YES  NO

8. Re ectors
A. Proper Overlap at Joints 
B. Slip Joint every 3rd Re ector 
C. End Caps Installed 

9. Mandatory Fresh Air Supply  YES  NO
A. Blower Installed  YES  NO
Blower Model Number
B. Double  ltered air supply at occupant level
 YES  NO

10. Control Panel Installed 
A. URV 
B. System Controller 
C. Other 

11. Other Comments

Job Name

Address:

Phone Number:

Customer Name:

Installation Date:

Start-Up Date:

Room Temperature:

Outside Temperature:

Technician Name:

Technician E-mail:

CORAYVAC® Classic SF Start-Up and Installation Report

Fill out one report per system (1 pump). System de ned as in-series burners connected to a single vacuum pump.

CORAYVAC

®

CLASSIC SF START-UP AND INSTALLATION REPORT (Continued)

80 of 83

SECTION 24: CORAYVAC® CLASSIC SF START-UP AND INSTALLATION REPOR T

12. Units Installed
Branch 1

Branch # Model Serial Number Tube Temperature* (See Drawing)

1(@ End Burner)

2

3

4

Branch 2

Branch # Model Serial Number Tube Temperature* (See Drawing)

1(@ End Burner)

2

3

4

Branch 3

Branch # Model Serial Number Tube Temperature* (See Drawing)

1(@ End Burner)

2

3

4

Branch 4

Branch # Model Serial Number Tube Temperature* (See Drawing)

1(@ End Burner)

2

3

4

* Highest measured temperature after each burner. Measurement must be taken using a calibrated thermometer type K thermocouple
or its equivalent. Infrared temperature measuring devices are not acceptable.

CORAYVAC

®

CLASSIC SF START-UP AND INSTALLATION REPORT (Continued)

81 of 83

CRVSF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

82 of 83

SECTION 25: THE ROBERTS GORDON® CORAYVAC® CLASSIC SF LIMITED WAR-

SECTION 25: THE ROBERTS GORDON

®

CORAYVAC® CLASSIC SF 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 product 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 LLC warrants the cast iron combustion
chamber of the ROBERTS GORDON

®

CORAYVAC®
CLASSIC SF 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 SF
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

®

CORAYVAC® CLASSIC SF 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® CLASSIC SF in

any way.

• Use of the ROBERTS GORDON

®

CORAYVAC

®

CLASSIC SF 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 ROBERTS GORDON

®

CORAYVAC

CLASSIC SF as directed in the

Installation, Operation and Service Manual.

®

• Relocation of the ROBERTS GORDON

CORAYVAC®

CLASSIC SF after initial installation

®

• The use of the ROBERTS GORDON

CORAYVAC®
CLASSIC SF in a corrosive atmosphere containing
contaminants.

®

• The use of the ROBERTS GORDON

CORAYVAC®
CLASSIC SF in the vicinity of a combustible or
explosive material.

• Any defect in the ROBERTS GORDON

®

CORAYVAC®
CLASSIC SF 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 ROBERTS GORDON® CORAYVAC® CLASSIC SF is
not installed by a contractor qualified in the installation and
service of gas fired heating equipment.

Yo u 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®
CLASSIC SF 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 . B o x 4 4
Buffalo, New York 14240-0044
Telephone: [phone]
Fax: [phone] Toll Free: 800.828.7450

www.robertsgordon.com www.corayvac.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®

CLASSIC SF. 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, parts 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