Roberts Gorden CRV-B-12, CRV-B-12A, CRV-B-4, CRV-B-8, CRV-B-10 User Manual

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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. Leave the building.

6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions.

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

CoRayVac

Custom-Engineered,

Low-Intensity Infrared

WARNING

Fire Hazard

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

Some objects will catch fire or explode when placed close to heater.

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

Heating Systems

Installation, Operation &

Service Manual

CRV-B-2 CRV-B-4 CRV-B-6 CRV-B-8

CRV-B-9 CRV-B-10 CRV-B-12

CRV-B-12A

WARNING

Improper installation, adjustment, alteration, service or maintenance can result in death, injury or property damage. Read the Installation, Operation and Service Manual thoroughly before installing or servicing this equipment.

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

Quality in Any Language™

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

Keep this manual in a safe place in order to provide

your serviceman with necessary information.

Roberts-Gordon, LLC

1250 William Street P.O . B ox 44 Buffalo, New York 14240-0044 Telephone: 716.852.4400 Fax: 716.852.0854 Toll Free: 800.828.7450

www.rg-inc.com

P/N 127102NA Rev. F 05/06

TABLE OF CONTENTS

SECTION 1: Heater Safety...................................................... 1

1.1 Manpower Requirements .............................................1

SECTION 2: Installer Responsibility ..................................... 2

2.1 Wall Tag.......................................................................2

2.2 Corrosive Chemicals.................................................... 2

2.3 National Standards and Applicable Codes ..................2

SECTION 3: Critical Considerations......................................3

3.1 Required Clearances to Combustibles.........................3

SECTION 4: National Standards and Applicable Codes .....7

4.1 Gas Codes................................................................... 7

4.2 Aircraft Hangars ........................................................... 7

4.3 Public Garages ............................................................7

4.4 Electrical ......................................................................7

4.5 Venting.........................................................................7

4.6 High Altitude ................................................................ 7

SECTION 5: Major Components ............................................ 8

5.1 Standard Parts List .................................................... 11

SECTION 6: Design Requirements......................................13

SECTION 7: Heater Installation............................................ 15

7.1 Tube Installation ........................................................ 16

7.2 Coupling and Tube Assembly....................................16

7.3 Elbow Package Configuration..................................... 17

7.4 Reflector Installation .................................................. 18

7.5 Burner Installation...................................................... 20

SECTION 8: Optional Heater Accessories.......................... 21

8.1 Tee Installation .......................................................... 21

8.2 Reflector Joint............................................................ 21

8.3 Reflector Side Extension............................................23

8.4 Universal Shield.........................................................24

8.5 Barrier Shield............................................................. 24

8.6 Two-Foot Decorative Grille Installation....................... 25

8.7 One-Foot Decorative Grille Installation......................26

8.8 Protective Grille Installation........................................ 29

8.9 Classic Cast-Iron Components.................................30

SECTION 9: Pump Installation and Venting ....................... 31

9.1 Pump Installation .......................................................31

9.2 General Venting Requirements Model EP-100,

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

9.3 Horizontal Venting 4" (10 cm) Pipe ............................ 34

SECTION 10: Outside Air Supply.........................................37

10.1 Pressurized ..............................................................37

10.2 Non-Pressurized ...................................................... 37

10.3 Outside Air Blower Internal Wiring ........................... 38

SECTION 11: Gas Piping ......................................................41

SECTION 12: Control Methods ............................................ 42

12.1 ROBERTS GORDON

12.2 ROBERTS GORDON

12.3 SPST Transformer Relay (P/N 90417600)............... 42

12.4 DPST Transformer Relay (P/N 90436300)............... 42

SECTION 13: Starting The System ...................................... 49

13.1 Checking the Gas Line ............................................ 49

13.2 Checking the Electrical System ............................... 49

13.3 Starting the System ................................................. 49

13.4 Setting the Vacuum.................................................. 49

SECTION 14: Operation and Maintenance.......................... 51

14.1 Sequence of Operation............................................ 51

14.2 To Shut Off Heater................................................... 51

14.3 To Start Heater ........................................................ 51

14.4 Pre-Season Maintenance and Annual Inspection.... 51

14.5 Maintenance Checklist............................................. 52

SECTION 15: Troubleshooting............................................. 55

15.1 Troubleshooting Flow Chart..................................... 55

SECTION 16: Replacement Parts ........................................ 57

SECTION 17: General Specifications .................................. 58

17.1 Material Specification ............................................... 58

17.2 Heater Specifications ............................................... 58

17.3 Suspension Specifications ....................................... 58

17.4 Controls Specifications............................................. 58

SECTION 18: The ROBERTS GORDON

Limited Warranty............................................ 61

System Control ................... 42

ULTRAVACTM..................... 42

CORAYVAC®

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 te d in U.S.A.

TABLE OF FIGURES

Figure 1: Standard Reflector .....................................................4

Figure 2: One Side Reflector..................................................... 4

Figure 3: Two Side Reflectors ...................................................4

Figure 4: Universal Shield, Position 1 ....................................... 5

Figure 5: Universal Shield, Position 2 ....................................... 5

Figure 6: Universal Shield, Position 3 ....................................... 5

Figure 7: 2-Foot Deco Grille...................................................... 6

Figure 8: Barrier Shield ............................................................. 6

Figure 9: 1-Foot Deco Grille ...................................................... 6

Figure 10: Major Component Descriptions................................ 8

Figure 11: Heater Assembly Overview ...................................14

Figure 12: Critical Hanger Placement ..................................... 15

Figure 13: Reflector Joint Detail .............................................. 22

Figure 14: EP-200 Condensate Valve Assembly ..................... 31

Figure 15: Vertical Venting Configuration................................33

Figure 16: EP-100 Horizontal Venting Configurations ............. 34

Figure 17: EP-200 Series Horizontal

Venting Configurations...........................................35

Figure 18: EP-300 Series Horizontal

Venting Configurations...........................................36

Figure 19: Duct Sizing ............................................................ 37

Figure 20: Outside Air Blower Internal Wiring Diagram...........38

Figure 21: Filter Housing Assembly ........................................38

Figure 22: Air Supply Blower Support .....................................39

Figure 23: Pressurized Outside Air Supply..............................39

Figure 24: Non-Pressurized Outside Air Supply......................40

Figure 25: Gas Connection with Flexible Gas Hose................ 41

Figure 26: One Zone Operation without Control Panel ...........43

Figure 27: One Zone Operation (with Outside Air Blower)

without Control Panel.............................................44

Figure 28: Two Zone Operation without Control Panel............ 45

Figure 29: General System Wiring .......................................... 46

Figure 30: External Wiring Diagram EP-100 and EP-201

120 V 1 Ø Pump ....................................................46

Figure 31: External Wiring Diagram EP-301

120 V 1 Ø Pump ....................................................47

Figure 32: External Wiring Diagram EP-203 or

EP-303 208 V - 230 V (or 460 V) 3 Ø Pump .......... 47

Figure 33: Burner Internal Wiring ............................................48

Figure 34: Burner Internal Ladder Diagram ............................ 48

Figure 35: Vacuum Reading....................................................50

SECTION 1: HEATER SAFETY

Your Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings in these

sections. Installation, service and annual inspection of heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment. Read this manual carefully before installation, operation or service of this equipment. This heater is designed for heating nonresidential indoor spaces. Do not install in residential spaces. These instructions, the layout drawing, local codes and ordinances, and applicable standards that apply to gas piping, electrical wiring, venting, etc. must be thoroughly understood before proceeding with the installation. Thin sheet metal parts, the aluminum reflector portion of the heater and the various venting components, have sharp edges. To prevent injury, the use of work gloves is recommended. The use of gloves will also prevent the transfer of body oils from the hands to the surface of the reflector. Before installation, check that the local distribution conditions, nature of gas and pressure, and adjustment of the appliance are compatible.

1.1 Manpower Requirements

To prevent personal injury and damage to the heater, two persons will be required for installation.

SECTION 1: HEATER S AFETY

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 2: INSTALLER RESPONSIBILITY

The installer is responsible for the following:

• To ensure the system is designed in accordance with the parameters of the CRV-Series

Design

Manual (P/N 127500NA).

• To install the heater, as well as the gas and electrical supplies, in accordance with applicable specifications and codes. Roberts-Gordon recommends the installer contact a local Building Inspector or Fire Marshal for guidance.

• To use the information given in a layout drawing and in the manual together with the cited codes and regulations to perform the installation.

• To install the heater in accordance with the clearances to combustibles requirements.

• To furnish all needed materials not furnished as standard equipment.

• To plan location of supports.

• To provide access to burners on all sides for servicing or burner removal.

• To provide the owner with a copy of this Installation, Operation and Service Manual.

• To never use heater as a support for ladder or

other access equipment and to never hang or suspend anything from heater.

• To ensure there is adequate air circulation around

the heater and to supply air for combustion, ventilation and distribution in accordance with local codes.

• To safely and adequately install heater using

materials with a minimal working load of 75 lb (33 kg).

2.1 Wall Tag

A laminated wall tag is available for the heater as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles. Please contact Roberts-Gordon or your ROBERTS GORDON

independent distributor to obtain the wall tag. Affix the tag by peeling off the backing of the adhesive strips on the rear surface and position the tag on a wall near the CRV-Series heater (e.g. thermostat or controller). A copy of the wall tag (P/N 91037912) is illustrated on the back cover. For an immediate solution, you may affix this copy on the wall near the heater. Know your model number and installed configuration. Model number and installed configuration are found on the burner and in the Installation, Operation and

Service Manual. See Page 4, Figure 1 through Page 6, Figure 9. Write the proper clearance dimensions in permanent ink according to your model number and configuration in the open spaces on the tag.

2.2 Corrosive Chemicals

CAUTION

Do not use heater in an area containing corrosive chemicals.

Avoid the use of corrosive chemicals to ensure a longer life of the burner, tubing and other parts.

Failure to follow these instructions can result in property damage.

Roberts-Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation; this is entirely the responsibility of the installer. It is essential that the contractor, the sub-contractor, or the owner identifies the presence of combustible materials, corrosive chemicals or halogenated hydrocarbons* anywhere in the premises.

* Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These compounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the life span of the heater components will be greatly reduced. An outside air supply must be provided to the burners whenever the presence of these compounds is suspected. Warranty will be invalid if the heater is exposed to halogenated hydrocarbons.

2.3 National Standards and Applicable Codes

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

SECTION 3: CRITICAL CONSIDERATIONS

3.1 Required Clearances to Combustibles

Clearances are the required distances that combustible objects must be away from the heater to prevent serious fire hazards. Combustibles are materials that may catch fire and include common items such as wood, paper, rubber, fabric, etc.

Maintain clearances to combustibles at all times for safety.

Clearances for all heater models are located on the burner of the heater and on Page 4, Figure 1 through Page 6, Figure 9 in this manual. Check the clearances on each burner for the model heater being installed to make sure the product is suitable for your application and the clearances are maintained. Read and follow the safety guidelines below:

• Keep gasoline or other combustible materials including flammable objects, liquids, dust or vapors away from this heater or any other appliance.

• Maintain clearances from heat sensitive material, equipment and workstations.

• Maintain clearances from vehicles parked below the heater.

SECTION 3: CRITIC AL C ONSIDERATIONS

WARNING

Fire Hazard

Some objects will catch fire or explode when placed close to heater.

Keep all flammable objects, liquids and vapors the required clearances to combustibles away from heater.

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

• 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 15, Figure 12.

• If the radiant tubes must pass through the building structure, be sure that adequate sleeving and fire stop is installed to prevent scorching and/or fire hazard.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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

2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the combustion chamber and the tube connect.

* Protective Grille clearances are the same as Standard Reflector.

FIGURE 1: STANDARD REFLECTOR

Model ABCDABCD

CRV-B-2 4 20 48 20 11 51 122 51

CRV-B-4 4 20 48 20 11 51 122 51

CRV-B-6 4 20 48 20 11 51 122 51

CRV-B-8 4 20 48 20 11 51 122 51

CRV-B-9 4 36 60 36 11 92 153 92

CRV-B-10 4 366036119215392

CRV-B-12 4 36 60 36 11 92 153 92

CRV-B-12A 4 36 60 36 11 92 153 92

FIGURE 2: ONE SIDE REFLECTOR

Model ABCDABCD

CRV-B-2 4 12 56 20 11 31 143 51

CRV-B-4 4 12 56 20 11 31 143 51

CRV-B-6 4 12 56 20 11 31 143 51

CRV-B-8 4 12 56 20 11 31 143 51

CRV-B-9 4 12 60 42 11 31 153 107

CRV-B-10 4 12 60 42 11 31 153 107

CRV-B-12 4 12 60 42 11 31 153 107

CRV-B-12A 4 12 60 42 11 31 153 107

(inches) (centimeters)

FIGURE 3: TWO SIDE REFLECTORS

Model ABCDABCD

CRV-B-2 4 12 56 12 11 31 143 31

CRV-B-4 4 12 56 12 11 31 143 31

CRV-B-6 4 12 56 12 11 31 143 31

CRV-B-8 4 12 56 12 11 31 143 31

CRV-B-9 4 12 60 12 11 31 153 31

CRV-B-10 4 12 60 12 11 31 153 31

CRV-B-12 4 12 60 12 11 31 153 31

CRV-B-12A 4 12 60 12 11 31 153 31

(inches) (centimeters)

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

2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the combustion chamber and the tube connect.

FIGURE 4: UNIVERSAL SHIELD, POSITION 1

Model ABCDABCD

CRV-B-2 4 12 12 12 11 31 31 31

CRV-B-4 4 12 12 12 11 31 31 31

CRV-B-6 4 12 12 12 11 31 31 31

CRV-B-8 4 12 12 12 11 31 31 31

CRV-B-9 8 18 24 18 21 46 61 46

CRV-B-10 8 18241821466146

CRV-B-12 8 18 24 18 21 46 61 46

CRV-B-12A 8 18241821466146

SECTION 3: CRITIC AL C ONSIDERATIONS

(inches) (centimeters)

FIGURE 5: UNIVERSAL SHIELD, POSITION 2

Model ABCDABCD

CRV-B-2 4 24 48 24 11 61 122 61

CRV-B-4 4 24 48 24 11 61 122 61

CRV-B-6 4 24 48 24 11 61 122 61

CRV-B-8 4 24 48 24 11 61 122 61

CRV-B-9 4 36 48 36 11 92 122 92

CRV-B-10 4 36 48 36 11 92 122 92

CRV-B-12 4 36 48 36 11 92 122 92

CRV-B-12A 4 36 48 36 11 92 122 92

FIGURE 6: UNIVERSAL SHIELD, POSITION 3

Model ABCDABCD

CRV-B-2 4 12 56 30 11 31 143 77

CRV-B-4 4 12 56 30 11 31 143 77

CRV-B-6 4 12 56 30 11 31 143 77

CRV-B-8 4 12 56 30 11 31 143 77

CRV-B-9 8 12 60 42 21 31 153 107

CRV-B-10 8 12 60 42 21 31 153 107

CRV-B-12 8 12 60 42 21 31 153 107

CRV-B-12A 8 12 60 42 21 31 153 107

(inches) (centimeters)

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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

2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the combustion chamber and the tube connect.

FIGURE 7: 2-FOOT DECO GRILLE

Model ABCDABCD

CRV-B-2 4 12 48 12 11 31 122 31

CRV-B-4 4 12 48 12 11 31 122 31

CRV-B-6 4 12 48 12 11 31 122 31

CRV-B-8 4 12 48 12 11 31 122 31

CRV-B-9 4 18 56 18 11 46 143 46

CRV-B-10 4 18 56 18 11 46 143 46

CRV-B-12 4 18 56 18 11 46 143 46

CRV-B-12A 4 18 56 18 11 46 143 46

(inches) (centimeters)

FIGURE 8: BARRIER SHIELD

Model ABCDABCD

CRV-B-2 4 12 12 12 11 31 31 31

CRV-B-4 4 12 12 12 11 31 31 31

CRV-B-6 4 12 12 12 11 31 31 31

CRV-B-8 4 12 12 12 11 31 31 31

CRV-B-9 - UNAPPROVED - - UNAPPROVED -

CRV-B-10 - UNAPPROVED - - UNAPPROVED -

CRV-B-12 - UNAPPROVED - - UNAPPROVED -

CRV-B-12A - UNAPPROVED - - UNAPPROVED -

FIGURE 9: 1-FOOT DECO GRILLE

Model ABCDABCD

CRV-B-2 4 12 48 12 11 51 122 51

CRV-B-4 4 12 48 12 11 51 122 51

CRV-B-6 4 12 48 12 11 51 122 51

CRV-B-8 4 12 48 12 11 51 122 51

CRV-B-9 4 18 56 18 11 92 153 92

CRV-B-10 4 18 56 18 11 92 153 92

CRV-B-12 4 18 56 18 11 92 153 92

CRV-B-12A 4 18 56 18 11 92 153 92

(inches) (centimeters)

SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES

SECTION 4: NATIONAL STANDARDS AND APPLICABLE C ODES

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, ANSI Z223.1 - latest revision (same as NFPA

54).

Canada: Refer to CAN/CGA B149.1 and B149.2: Installation Codes for Gas Burning Appliances.

4.2 Aircraft Hangars

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

United States: Refer to Standard for Aircraft Hangars, ANSI/NFPA-409 - latest revision.

Canada: Refer to Standard CAN/CGA B149.1 and B149.2: Installation Codes for Gas Burning Appliances.

• In aircraft storage and servicing areas, heaters shall be installed at least 10' (3 m) above the upper surface of wings or of engine enclosures of the highest aircraft which may be housed in the hangar. The measurement shall be made from the wing or engine enclosure (whichever is higher from the floor) to the bottom of the heater.

• In shops, offices and other sections of aircraft hangars communicating with aircraft storage or servicing areas, heaters shall be installed not less than 8' (2.4 m) above the floor.

• Suspended or elevated heaters shall be so located in all spaces of aircraft hangars that they shall not be subject to injury by aircraft, cranes, movable scaffolding or other objects. Provisions shall be made to assure accessibility to suspended heaters for recurrent maintenance purposes.

4.3 Public Garages

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

United States: Standard for Parking Structures NFPA-88A - latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages, NFPA 30A - latest revision. Canada: Refer to CAN/CGA B149.1 and B149.2: Installation Codes for Gas Burning Appliances.

• Heaters must not be installed less than 8' (2.4 m) above the floor. Minimum clearances to combustibles must be maintained from vehicles parked below the heater.

• When installed over hoists, minimum clearances to combustibles must be maintained from the uppermost point of objects on the hoist.

4.4 Electrical

The heater must be electrically grounded in accordance with the following codes:

United States: Refer to National Electrical

Code

, ANSI/NFPA-70 - latest revision. Wiring must conform to the most current National Electrical Code

, local ordinances and any

special diagrams furnished.

Canada: Refer to Canadian Electrical Code, CSA C22.1 Part 1 - latest revision.

4.5 Venting

The venting must be installed in accordance with the requirements within this manual and the following codes:

United States: Refer to NFPA-54/ANSI Z223.1 latest revision, National Fuel Gas Code.

Canada: Refer to CAN/CGA B149.1 and B149.2: Installation Codes for Gas Burning Appliances.

4.6 High Altitude

These heaters are approved for installations up to 2000' (610 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).

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 5: MAJOR COMPONENTS

The figures in this section provide a general overview of component placement in a CRV-Series system. The location of some components such as supports and couplings is crucial for proper installation. Assemble the heater components as shown on Page 14, Figure 11.

FIGURE 10: Major Component Descriptions

Optional reflector configurations are shown on Page 4, Figure 1 through Page 6, Figure 9. Install

appropriate suspension hardware, beam clamps, chain or rod at predetermined locations. Adjustments of chain length will provide uniform pitch.

Burner

Reflector (Aluminum or Stainless Steel)

Alternate overlap as shown on overview. Minimum overlap is 6" (16 cm).

Tube

Hot rolled, heat treated or coated aluminized tube supplied in 10' (3 m) lengths.

Reflector with Hole (Aluminum or Stainless Steel)

Alternate overlap as shown on overview. Minimum overlap is 6" (16 cm).

Flex Gas Line with shut-off cock

Combustion Chamber

Coupling Assembly with Lock

45° Elbow

Tee

Tube Adapter

90° Elbow

Cross

End Vent

FIGURE 10: Major Component Descriptions (Continued)

Reflector Joint

SECTION 5: MAJOR COMPONENTS

Reflector End Cap (Aluminum or Stainless Steel)

Punch out center section to accommodate heat exchanger tube when necessary.

Tube and Reflector Hanger with Clamp Package

Position this hanger no more than 4" (10 cm) away from the burner.

Tube and Reflector Hanger

Suspend system from these hangers.

Reflector Support Strap & Wire Form

Barrier Shield

Reflector Side Extension

Deco Grille

S-Hook

Reflector Side Extension Bracket

Bracket Assembly

Turn buc kl e

Protective Grille

Condensate Valve Assembly

Universal Shield

Universal Shield with Holes

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 10: Major Component Descriptions (Continued)

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ULTRAVAC™ Controller

ROBERTS GORDON ULTRAVAC™ Variable Frequency Drive

EP-100 Pump Package - 4" dia For more information, refer to the EP-100 Installation, Operation and Service Manual (P/N 127201NA).

System Control

ROBERTS GORDON® ULTRAVAC™ Adjustable Indoor Sensor

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).

SECTION 5: MAJOR COMPONENTS

5.1 Standard Parts List

Table 1: Contents of CRV-Series Burner Carton

Part No. Description

0270XXXX Burner (Rate and Fuel Varies)

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

(US models only) 013676XX End Vent Plate 01397300 Accessory Package

01361200 Filter Support Disk 01367800 Combustion Chamber Gasket 02724901 Door Assembly w/ Hole 91115100 Screw #10 - 24 x 5/8 91119500 U-Clip 91905500 Filter Support 92123900 Nut 5/16 - 18 92511601 Wing Nut #10 - 24 96411600 Lock Washer 5/16" 01312401 Filter and Gasket

* Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory, see Page 41.

Table 2: Common CRV-Series Components

Part No. Description

Combustion Chamber: 02722300-1P Hot Rolled Steel Combustion Chamber 02722301-1P Heat-Treated Aluminized Steel Combustion Chamber

0272230D-1P Porcelain Coated Steel Combustion Chamber

02721200-1P Cast Iron Combustion Chamber

Tubing and Related Accessories

01312700 Coupling, 4" (10 cm) Plain 01312706 Coupling, 6" (15 cm) Plain

0131270I Coupling, 4" (10 cm) Lined 01331900 Coupling, 4" (10 cm) Damper E0009356 Coupling, 6" (15 cm) Damper

0133022D Tee, 4" (10 cm) Coated

01330203 Tee, 4" (10 cm) Aluminized 01330204 Tee, 6" (15 cm) Aluminized

0133092D Cross, 4" (10 cm) Coated

01330903 Cross, 4" (10 cm) Aluminized 01330904 Cross, 6" (15 cm) Aluminized 01335801 Elbow, 4" (10 cm) Aluminized 90° T0100320 Elbow, 6" (15 cm) Aluminized 90°

0133580D Elbow, 4" (10 cm) Coated 90°

01336101 Elbow, 4" (10 cm) Aluminized 45°

0133610D Elbow, 4" (10 cm) Coated 45°

91409300 Tube, Hot Rolled Steel 4" (10 cm) dia 10' (3 m) 91409403 Tube, Non-Heat Treated Aluminized 4" (10 cm)

dia 10' (3 m) 91409408 Tube, Heat Treated Aluminized 4" (10 cm) dia 10' (3 m) 91409420 Tube, Non-Heat Treated Aluminized 6" (15 cm)

dia 10' (3 m)

9141030D Tube, Coated 4" (10 cm) dia 10' (3 m)

E0009105 Tube, Heat Treated Aluminized 6" (15 cm) dia 10' (3 m) 91418200 Tube Adapter, Aluminized

6" (15 cm) dia x 4" (10 cm) dia

02722100 Adapter, 4" (10 cm) Cast Iron 91240010 Tube Hanger, 6" (15 cm) 91308001 High Temperature Pipe Compound, 1lb. can

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)

Reflectors and Related Accessories 01329910 Reflector Side Extension Support 03050010 Reflector Support Package (Tubing) 02712700 Reflector Side Extension, 2 Clips, 2 Screws 02716400 Reflector Support Package (Schedule 40 Pipe) 02750303 Reflector, Aluminum

027503SS Reflector, Stainless Steel 02750304 Reflector, Aluminum with Hole 027503SH Reflector, Stainless Steel with Hole 02750800 Reflector End Cap, Aluminum 027508SS Reflector End Cap, Stainless Steel 027508SH Reflector End Cap, Stainless Steel with Hole 02750900 Reflector Joint 027509SS Reflector Joint, Stainless Steel 027127SS Reflector Side Extension, Stainless Steel 03090100 Tube and Reflector Hanger 02790300 Tube and Reflector Hanger, Cast Iron 91907302 S-Hook 91903201 Turnbuckle 91903300 Spring Hook 91903202 Turnbuckle with Eyebolt 02712100 Universal Shield Support 02751800 Universal Shield with Holes 02751801 Universal Shield 027518SS Universal Shield, Stainless Steel

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Control Packages and Accessories

10001501 Water Resistant Sensor 02770002 System Control

URVCCM

ROBERTS GORDON® ULTRAVAC™ Central Controller (with Modem Chip & Software) Includes:

URVSC

ROBERTS GORDON

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

URVCCR

ROBERTS GORDON

ULTRAVAC™ Central Controller

(with RS-485 Converter & Software) Includes:

URVSC

ROBERTS GORDON

ULTRAVAC™ Controller 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 10080440 TCP/IP Communication Module 10081501 Outdoor Sensor 10080410 PC Connection Cable Package

URVSC

Controller, ROBERTS GORDON

ULTRAVAC™ , 1

Pump 3 Zones (Satellite Control) VFD75115 Variable Frequency Drive Assembly, 75 HP, 115 V Input VFD75230 Variable Frequency Drive Assembly, 75 HP, 230 V Input VFD20230 Variable Frequency Drive Assembly, 2 HP, 230 V Input 10080142 Modem, Plug-In Chip 10080410 Cable Package, PC Connection 10080430 RS-485 Converter with 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™

Thermostats

05023000 Load Relay Package 90417600 Transformer Relay - SPST (12 A) 90436300 Transformer Relay - DPST (12 A) 90423000 24 V Low Voltage Thermostat (Marked 1-5) 90424300 Thermostat Guard

Deco Grille (1' x 8' [.3 m x 2.4 m])

01363003 Bracket 01365901 End Piece 01326801 Reinforcement 01365903 Joint Piece 91406700 1' (.3 m) x 8' (2.4 m) Protective Grille

Protective Grille

08050001 Protective Grille, 40" (1 m) 08050002 Protective Grille End Cap

Shields

02750303 Barrier Shield 02751801 Universal Shield 027518SS Universal Shield, Stainless Steel 02751800 Universal Shield with Holes

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

Pump Accessories

90430600K Pressure Switch

01327001 Condensate Check Valve Assembly 02718851 Drain Cap, 4" (10 cm) 02718852 Drain Cap, 6" (15 cm)

Starters

10050001 Starter, 120 Vac for EP-203, 3 Ø 10050002 Starter, 12 Vdc for EP-201, 1Ø 10050003 Starter, 120 Vac for EP-201, 1 Ø 10050008 Starter, 120 Vac for EP-301, 1 Ø 10050009 Contactor Package-230 Vac Coil for EP-301, 2 HP 10050010 Starter, 120 Vac for EP-303, 3 Ø

Deco Grille (2' x 4' [.6 m x 1.2 m])

01365900 Shield Frame 01370408 Reflector Side Extension 8" x 48" (20.3 cm x 122 cm) 01370412 Reflector Side Extension 12" x 48" (30.5 cm x 122 cm) 01370416 Reflector Side Extension 16" x 48" (40.6 cm 122 cm) 91407000 Grille, Aluminum 2' x 4' (.6 m x 1.2 m)

SECTION 6: DESIGN REQUIREMENTS

The CRV-Series system’s design is related to the system operation and performance required by the building being heated. Every effort should be made to follow the dimensions on the layout drawing. If deviations are necessary, either contact the company responsible for the layout design, your ROBERTS GORDON

independent distributor, or consult the CRV-Series Design Manual (P/N 127500NA).

SECTION 6: DESIGN R EQUIREMENTS

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 11: Heater Assembly Overview

Controller



System Control

ULTRAVAC

or ROBERTS GORDON

Relay*

Exhaust

to Outside

Pressure Switch

Pump

Flexible

Boot

Tube &

Hanger

Reflector

with Hole

Support

Reflector

requires zone sensors



ULTRAVAC

U-Clips

Tube

Reflector

Burner

End

Vent

Coupling

Chamber

Combustion

End Cap

Reflector

Zone 1 Sensor or Thermostat**

controller's Installation, Operation and Service Manual for details.

* May not be needed with certain pumps and controllers. Refer to wiring diagram in the appropriate

**System Control requires thermostats. ROBERTS GORDON

and additional control equipment. See the appropriate controller installation manual for details.

SECTION 7: HEATER INSTALLATION

WARNING

Suspension Hazard

Hang heater with materials with a minimum working load of 75 lbs (33 kg).

Failure of the supports can result in death, injury or property

To ensure your safety and comply with the terms of the warranty, all units must be installed in accordance with these instructions.

The gas or the electrical supply lines must not be used to support the heater.

FIGURE 12: Critical Hanger Placement

Typical Suspension Details

Beam Clamp

damage.

SECTION 7: HEATER I NSTALLATION

Do not locate the gas or electric supply lines directly over the path of the flue products from the heater. The heater must be installed in a location that is readily accessible for servicing. The heaters must be installed in accordance with clearances to combustibles as indicated on the rating plate and in this instruction manual. The minimum and maximum gas inlet pressures must be maintained as indicated on the rating plate. Typical installation configurations are shown in Figure 12. Expansion and contraction of the tube dictates that the minimum suspension lengths in the table on Figure 12 be maintained.

Concrete Beam

Anchor

Screw Hook 3/8"

Locknut

Wood Beam

Rod 3/8"

24" min.

(61 cm)

"X" (See Table)

Side View Towards Pump

Chain size

3/16" minimum

Turnbuckle

Locknut (Typical)

7'6" (2.3 m)

Washers

S-Hook

Turnbuckle

Hanger

Reflector

Front View

Description Part Number

Turnbuckle 91903201 S-Hook 91907302 Tube/Reflector Hanger 03090100

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)

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 7.1 Tube Installation

Combustion

Chamber

NOTE: Tubing requires a downward slope of

1/2" (13 mm) per 20' (6 m) away from burner. Tailpipe tubing requires a downward slope of 1" (26 mm) per 20' (6 m) away from burner.

End View

Weld

Seam

Bottom of Tube

7' 6"

(229 cm)

Description Part Number

Tube 91409XXX Turnbuckle 91903201 Tube/Reflector Hanger 03090100

Step 7.2 Coupling and Tube Assembly

Close coupling with tab.

Open

maximum

Tab

Tube

10'

(3 m)

Hanger

Turnbuckles

Combustion

Chamber

Start slide bar/coupling lock

onto coupling.

3" (8 cm) to

4" (10 cm)

Slide Bar/Coupling Lock

Wide End

Coupling

Insert tubes into coupling.

Closed

Tube

Orient coupling so that

the impact block is in the

2:00 or 10:00 oclock

positions.

Tube

Tighten coupling to join tubes.

Tube

Description Part Number

Coupling 01329600 Slide Bar/Coupling Lock 01329700 Tube 91409XXX

Slide Bar/Coupling Lock

Coupling

Step 7.2.1 Coupling and Tube Assembly (Continued)

Tighten slide bar as shown below.

Drive slide bar until tight. End of slide bar should be within tolerance listed below.

± 2" (5 cm)

SECTION 7: HEATER I NSTALLATION

Correct Slide Bar

Dimensions

Repeat Step 7.2, A - D until all tubes are assembled. NOTE: If coupling is not tight, loss of vacuum can occur.

7.3 Elbow Package Configuration Step 7.3.1 Elbow Installation

Tube

Description Part Number Elbow Package 02718702

90° Elbow 01335801 Coupling 01312700 Reflector End Cap 02750800 Reflector Joint Piece 02750900 U-Clip Package 91107720

Coupling

Incorrect Slide Bar

Position

Minimum Distance Required Between

90° Elbow

Burner and Elbow Model Minimum Distance

CRVB-2 5' (1.5 m) CRVB-4 5' (1.5 m) CRVB-6 10' (3 m) CRVB-8 10' (3 m) CRVB-9 10' (3 m) CRVB-10 15' (4.5 m) CRVB-12A 15' (4.5 m) CRVB-12 15' (4.5 m)

Step 7.3.2 Elbow Installation

Tube

Coupling

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 7.4 Reflector Installation Step 7.4.1 Reflector Installation with Hole

Reflector with Hole

Slide Reflector

with hole

through hanger. Unhook combustion chamber from chain

and insert through hole.

Reconnect chain.

Hanger

Tube

Description Part Number

Tube/Reflector Hanger 03090100 Tube 91409XXX Reflector with Hole 02750304

Step 7.4.2 Reflector Installation

Wire Form

Reflector

Reflector Support

Strap

Description Part Number

Reflector Support Package 03050010 U-Clip Package 91107720 Reflector End Cap 027508XX

Sheet Metal

Screw

Tube

Combustion

Chamber

U-Clip

(2 Clips per

Alternate Overlaps

per Side)

Step 7.4.3 Reflector, U-Clip and Reflector Support Installation

The pictorial drawings of the heater construction in Section 7 are schematic only and provide a general guideline of where hangers, reflector supports and U-clips are to be installed. To ensure proper expansion and contraction movement of the reflectors, a combination of U-clips

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

SECTION 7: HEATER I NSTALLATION

1. The first reflector after the burner must be affixed in the middle of the reflector with a reflector support and tight screws.

Reflector End Cap

First Reflector

U-Clips

Overlap must be a

minimum of 6" (16 cm)

2. The overlap at the first and second reflector is a slip overlap. Thereafter, every third reflector joint is a slip overlap. A slip overlap is achieved by either: a.) both reflectors lay inside a hanger.

(No reflector support needed).

b.) using a reflector support with

loose screws at the reflector overlap.

(16 cm)

2 A

Slip Overlap

Wire Form

Reflector Support

2 B

Slip Overlap

Tight

Sheet Metal

Screw

Strap

Reflector Reflector

Support

Loose screws loosened 1/16" (1.6 mm) to allow slippage.

3. The remaining reflector overlaps require a non-slip overlap connection. To affix the reflectors together in a non-slip overlap either: a.) use reflector support and tight screws. b.) if both reflectors lay inside a hanger, u-clips or

sheet metal screws may be used.

This section of three reflectors joined together must be affixed to the tube with at least one reflector support with tight screws.

Description Part Number Reflector Support Package 03050010

Wire Form 91908004 Reflector Support Strap 03050000

Screw #8 x 3/4 94320812 U-Clip Package 91107720 Reflector End Cap 027508XX

3 A

Non-Slip Overlap

Reflector

Tight

Screws

3 B

Non-Slip Overlap

U-Clip

(2 Clips per Non-slip Overlap inside a Hanger)

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 7.5 Burner Installation

Burner

Description Part Number

Bolt 94273914 Burner 0270XXXX Lock Washer 96411600 Gasket 01367800 End Vent 013676XX

Combustion

End

Vent

Clips

End Vent

Burner

Combustion

Chamber

Gasket

End

Vent

Chamber

NOTE:

Install end vent at end combustion chamber position only.

Rating

Number

SECTION 8: OPTIONAL HEATER ACCESSORIES Step 8.1 Tee Installation

Description Part Number

Tee 01330XXX Tube/Reflector Hanger 03090100 Tube 91409XXX Coupling 01312700

SECTION 8: OPTIONAL H EATER A CCESSORIES

Tube

Coupling

Tee

Step 8.2 Reflector Joint Step 8.2.1 Reflector Joint Installation

Reflector

Scribe Contour

Reflector

Joint

Flatten Edge

1" (2.5 cm) Maximum

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 8.2.2 Reflector Joint Installation

Step 8.2.3 Reflector Joint Detail

Cut away contour with tin snips.

Punch/drill six 3/32" (2 mm) holes.

Install reflector end cap.

FIGURE 13: Reflector Joint Detail

Attach reflector joint with six #8 sheet metal screws.

Reflector

Reflector Joint

8.3 Reflector Side Extension Step 8.3.1 Bracket Installation

SECTION 8: OPTIONAL H EATER A CCESSORIES

Tube

Reflector

Tube and Reflector Hanger

Reflector Support

Reflector Side

Extension Bracket

(2 per reflector)

Use additional supports

in high air movement

applications.

Description Part Number Reflector Side Extension Package 02712700

Reflector Side Extension 01368000 Retainer Clips 02751200 Sheet Metal Screws 94118106

Order Separately

Reflector Side Extension Bracket 01329910

Step 8.3.2 Side Reflector Installation

#8 x 3/8 (3.9 x 9.5 mm) Sheet Metal Screw

Cut relief notches for supports and hangers.

Retainer Clip (2 per Side)

Reflector Side Extension

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

8.4 Universal Shield

Universal shields are adjustable aluminum reflectors whose angle and height can be adjusted to direct heat to or away from a desired area.

See Page 5, Figure 4 through Page 5, Figure 6 for positions.

Tube

Universal Shield

Description Part Number

Universal Shield 02751801 Universal Shield with Holes 02751800

Universal Shield Support Package 02712100

Tube and Reflector Support Assembly 01329802 Universal Shield Support 02751700 Shield Bracket Assembly 02721400 Stud 02790900 Hex Nut 92114800

Flattened

Section

Bracket Assembly*

Standard Reflector

Tube and Reflector Support Assembly*

Stud*

Shield Support Bracket*

Hex Nut*

* Included in universal shield

support package.

8.5 Barrier Shield

Do not install barrier shield less than 20' (6 m) downstream of any burner. Do not attach end caps to the ends of the barrier shields. For lengths greater than 8' (2.6 m), use universal shields. Do not use barrier shields for burner sizes larger than 80,000 Btu/h.

Tube and Reflector Hanger

Flatten Reflector Edges

Reflector Support Strap Cut Relief Notch

Attach U-Clips

Standard Reflector

Barrier Shield

Description Part Number

Barrier Shield 02750303 U-Clip Package 91107720

8.6 Two-Foot Decorative Grille Installation Step 8.6.1 Grille Installation

Reflector

Heat Exchanger Tube

SECTION 8: OPTIONAL H EATER A CCESSORIES

Tube and Reflector Hanger

2' x 4' (60 cm x 120 cm) Aluminum Grille

Suspended Ceiling Frame

Step 8.6.2 Frame Shield Installation

Shield

Description Part Number

Aluminum Grille 2' x 4' (60 cm x 120 cm) 91407000

Description Part Number

Deco Grille Shield 01365900

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 8.6.3 Reflector Side Extension Installation for Decorative Grilles

NOTE: If the decorative grille system is to be installed in an area with considerable air movement, it is recommended that one #8 x 3/8" sheet metal screw be installed per reflector extension to prevent it from blowing over.

Cut relief notches for tube and reflector hangers.

6" (15 cm) Minimum

Allow 6" (15 cm) minimum clearance between burner box and overhead obstructions for service.

Insert screw here (see note).

Reflector Side Extension

Description Part Number

Reflector Side Extension 01370412

8.7 One-Foot Decorative Grille Installation Step 8.7.1 One-Foot Decorative Grille Bracket

#8 Sheet Metal Screws

Decorative Grille Bracket

Cut relief notches for supports and hangers.

Distance "A" Extension

Minimum Maximum Part No. Width

2" (4 cm) 6" (15 cm) 01370408 8" (20 cm)

6" (15 cm) 10" (26 cm) 01370412 12" (30 cm)

10" (26 cm) 14" (37 cm) 01370416 16" (40 cm)

In order to maintain reflector shape, do not fasten brackets together. Do not fasten bracket to adjoining reflectors. Maintain same slipjoint position as reflectors.

2" (5 cm) Minimum Bracket Overlap

Description Part Number

Bracket 01363003

Step 8.7.2 Decorative Grille

Spread apart brackets and install decorative grille.

#8 Sheet Metal Screws

Joint Piece

Reinforcement

Slip joint piece into support bracket and fasten to bracket on one side of the joint only.

Joint Piece

Description Part Number

Decorative Grille 8' x 1' (2.4 m x .3 m) 91406700

SECTION 8: OPTIONAL H EATER A CCESSORIES

Step 8.7.3 Joint Piece and Reinforcement

Description Part Number

Joint Piece 01365903 Reinforcement 01365902

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Fasten end piece to brackets using two #8 sheet metal screws and replace reflector end cap.

Insert end piece between grille and brackets.

End Piece

Reflector End Cap

Step 8.7.4 End Piece and Reflector End Cap

Description Part Number

End Piece 01365901

Step 8.7.5 90° Elbow

Inside

Corner

Grille Brackets

Joint Piece

Insert end piece between grille and brackets.

Decorative Grille

Brackets

Cut grille bracket at

Joint Piece

reflector joint piece.

8.8 Protective Grille Installation Step 8.8.1 Silicone Cap Installation

Silicone Cap

SECTION 8: OPTIONAL H EATER A CCESSORIES

Grille Finger

Step 8.8.2 Grille End Cap Installation

Grille

Grille End Cap

Pull outward

Step 8.8.3 Grille Installation

Description Part Number

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

Bend up 90°

40"

(101 cm)

Reflector

Final Grille Section

Grille

Grille End Cap

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Step 8.9 Classic Cast-Iron Components

WARNING

Suspension 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.

Special Tube and Reflector Hanger

7' (2.13 m) Maximum

Schedule 40 Steel Pipe

Cast-Iron Combustion Chamber with Schedule 40 Steel Pipe

The total weight of each burner and combustion chamber is 40.25 lbs (18 kg). 4" Schedule 40 pipe weighs 10.9 lbs. (5 kg) per foot.

Coupling

4" Tube

ROBERTS-GORDON

CORAYVAC® Classic Cast-Iron Combustion

Chamber

ROBERTS-GORDON

Turnbuckle Hang cast-iron combustion chamber with a turnbuckle (spring clips will not fit around cast-iron hanging loop).

End Vent

Clips

Cast-Iron Adapter

End Vent Plate for

End Burner Only

End Vent

Clips

Cast-Iron Combustion Chamber with Standard 4" O.D. Infrared Tubing

The total weight of each burner and combustion chamber is 40.25 lbs (18 kg). 4" O.D. 16 Ga. tubing weighs 2.8 lbs. (1.3 kg) per foot.

Cast-Iron Adapter

End Vent Plate for

End Burner Only

Description Part Number

Special Tube & Reflector Hanger 02790300 Turnbuckle 91903201 Cast-Iron Combustion Chamber 02721200-1P Cast-Iron Adapter 02722100 Coupling 01312700

SECTION 9: PUMP INSTALLATION AND VENTING

9.1 Pump Installation

For complete pump installation, please refer to the EP-100, EP-200 or EP-300 Series Installation, Operation and Service Manuals.

FIGURE 14: EP-200 Condensate Valve Assembly

Description Part Number

Wall

1" NPT threaded hole.

Use 1" x ¾" reducer.

(not supplied)

Copper or

galvanized pipe

between pump

and condensate

valve.

Condensate Valve Assembly 01327001

3/4" female

Condensate

Valve

Assembly

3/4" female

36" (.9 m)

Minimum

vertical drop

between pump and condensate valve assembly.

flow

Must be connected

to a drain system

in accordance with

local codes.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

9.2 General Venting Requirements Model EP-100, EP-200 and EP-300 Series Pumps

WARNING

Carbon Monoxide Hazard

Heaters installed unvented must be interlocked with sufficient building exhaust.

Heaters must be installed according to the installation manual.

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

This heater must be vented in accordance with the rules contained in this manual and with the following national codes and any state, provincial or local codes which may apply: United States: Refer to ANSI Z223.1 (NFPA 54) - latest revision; Canada: Refer to CAN/CGA-B149.1 and B149.2 - latest revision.

Any portion of vent pipe passing through a combustible wall must have an approved thimble to conform with the above listed codes.

Vent pipe must be sloped downward away from the pump 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

' (.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.

9.2.2 Horizontal Venting

See Page 34, Figure 16 through Page 36, Figure 18 for recommended horizontal venting options.

9.2.3 United States Requirements

Vent must terminate at least 3 forced air inlet located within 10

Vent must terminate at least 4

' (1.2 m) horizontally from, or 1' (.3 m) above any

' (.9 m) above any

' (3.1 m).

' (1.2 m) below,

door, operable window, or gravity air inlet into any building.

9.2.4 Canadian Requirements

The vent shall not terminate within 6

' (1.8 m) of a

mechanical air supply inlet to any building.

The vent shall not terminate within 3

' (.9 m) of a

window or door that can be opened in any building, any non-mechanical air supply inlet to any building, or of the combustion air inlet of any other appliance.

Length Requirements

See Page 33, Figure 15 through Page 36, Figure 18 for recommended vent lengths and sizes.

Seal all joints with high temperature silicone sealant.

Vent terminal must be beyond any combustible overhang.

9.2.1 Vertical Venting

See Page 33, Figure 15 for recommended vertical venting options.

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 m) of maximum allowed vent or outside air duct length per vent elbow if more than three are used.

FIGURE 15: Vertical Venting Configuration

SECTION 9: PUMP INSTALLATION AND VENTING

Approved Vent Cap

2' (.6 m)

Minimum

Approved

Thimble

Flexible Boot

1" (2.5 cm)

P.V.C to drain

system in

accordance

with local

codes.

Clamps

Aluminized Tee

Drain Cap

6"(1.5 cm) 20"(5.1 cm) for EP-300

Part Number Description Part Number Description

01330203 Tee, 4" (10 cm) Aluminized

01330204 Tee, 6" (15 cm) Aluminized

01331900 Damper Coupling, 4" (10 cm)

01335801 Elbow, 4" (10 cm) Aluminized 90°

02718851 Drain Cap, 4" (10 cm)

02718852 Drain Cap Assembly, 6" (15 cm)

90502300 Vent Cap, 4" (10 cm) Metalbestos

90502302 Vent Cap, 6" (15 cm) Metalbestos

91409403 Tube, Aluminized 4" (10 cm) dia. 10' (3 m)

91409420 Tube, Aluminized 6" (15 cm) dia. 10' (3 m)

91412800 Flexible Boot, 4" (10 cm)

91412801 4 - Flexible Boot, 1/2" (1.3 cm)

91412802 Flexible Boot, 6" (15 cm)

91901300 Boot Clamp, 4" (10 cm)

91913703 Boot Clamp, 6" (15 cm)

E0009356 Damper Coupling, 6" (15 cm)

90505600 Wall Thimble, 4" (10 cm)

T0100320 Elbow, 6" (15 cm) Aluminized 90°

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

9.3 Horizontal Venting 4" (10 cm) Pipe FIGURE 16: EP-100 Horizontal Venting Configurations

18" (46 cm) Minimum 40" (102 cm) Maximum

4" (10 cm) Single Wall Pipe

25' (8 m) and 3 Elbows Maximum

Pitch single wall pipe downward away from pump 1/4" (6 mm) for every 10' (3 m).

5" to 4" Reducer

(12.5 cm to 10 cm)

5" (12.5 cm) Single Wall Pipe

50' (15 m) and 3 Elbows Maximum

6" to 5" Reducer

(15 cm to 12.5 cm)

Screen

Approved Thimbles

18" (46 cm) Minimum 40" (102 cm) Maximum

Vent Terminal Tjernlund VH1-4

Vent Terminal Tjernlund VH1-6

Bird

4" (10 cm) Band Clamp

Part Number Description Part Number Description

01330203 Tee, 4" (10 cm) Aluminized 90505600 Wall Thimble, 4" (10 cm)

01331900 Damper Coupling, 4" (10 cm) 91409403 Tube, Aluminized 4" (10 cm) dia. 10' (3 m)

01335801 Elbow, 4" (10 cm) Aluminized 90° 91412800 Flexible Boot, 4" (10 cm)

01365400 Bird Screen, 4" (10 cm) 91901300 Boot Clamp, 4" (10 cm)

02537801-1P Vent Terminal (Non-Combustible Wall) Not Supplied Tube, Aluminized 5" (12.7 cm) dia. 10' (3 m)

02718851 Drain Cap, 4" (10 cm) Not Supplied Tube Adapter, 5" (12.7 cm) dia. x 4" (10 cm) dia.

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

90502101 Vent Terminal, 6" (15 cm) (Combustible Wall)

FIGURE 17: EP-200 Series Horizontal Venting Configurations

SECTION 9: PUMP INSTALLATION AND VENTING

18" (46 cm) Minimum 40" (102 cm) Maximum

4" (10 cm) Single Wall Pipe

10' (3 m) Maximum and No Elbows

Pitch single wall pipe downward away from pump 1/4" (6 mm) for every 10' (3 m).

5" to 4" Reducer

(12.5 cm to 10 cm)

5" (12.5 cm) Single Wall Pipe

25' (8 m) and 3 Elbows Maximum

6" to 4" Reducer (15 cm to 10 cm)

6" to 5" Reducer

(15 cm to 12.5 cm)

Approved Thimbles

18" (46 cm) Minimum 40" (102 cm) Maximum

4" (10 cm) Vent Terminal

Vent Terminal Tjernlund VH1-4

Vent Terminal Tjernlund VH1-6

Bird

Screen

4" (10 cm) Band Cla

6" (15 cm) Single Wall Pipe

50' (15 m) and 3 Elbows Maximum

Part Number Description Part Number Description

01330203 Tee, 4" (10 cm) Aluminized 91409403 Tube, Aluminized 4" (10 cm) dia. 10' (3 m)

01331900 Damper Coupling, 4" (10 cm)

01335801 Elbow, 4" (10 cm) Aluminized 90° 91412801 4 - Flexible Boot, 1/2" (1.3 cm)

01365400 Bird Screen, 4" (10 cm)

02537801-1P Vent Terminal (Non-Combustible Wall)

02718851 4" Drain Cap

90502100 Vent Terminal, 4" (10 cm) (Combustible Wall)

90502101 Vent Terminal, 6" (15 cm) (Combustible Wall)

90505600 Wall Thimble, 4" (10 cm)

91409420 Tube, Aluminized 6" (15 cm) dia. 10' (3 m)

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

91901300 Boot Clamp, 4" (10 cm)

91906900 Silicone Ring

Not Supplied Tube, Aluminized 5" (12.7 cm) dia. 10' (3 m)

Not Supplied Tube Adapter, 5" (12.7 cm) dia. x 4" (10 cm) dia.

Not Supplied Tube Adapter, 6" (15.2 cm) dia. x 5" (12.7 cm) dia.

Vent Terminal Tjernlund VH1-6

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 18: EP-300 Series Horizontal Venting Configurations

10' (3 m) Maximum and 1 Elbow

18" (46 cm) Minimum 40" (102 cm) Maximum

10' (3 m) Maximum and 1 Elbow

6" (15 cm)

Bird Screen

(Included)

Single Wall Pipe/Tube 6" (15 cm)

6" (15 cm)

Band Clamp

Pitch single wall pipe downward away from pump 1/4" ( 6 mm) for

Approved

Thimble

every 10' (3 m).

Vent Terminal

Tjernlund VH1-

6" (15 cm)

or Equivalent

(Not Included)

Part Number Description Part Number Description

01330203 Tee, 4" (10 cm) Aluminized 91409403 Tube, Aluminized 4" (10 cm) dia. 10' (3 m)

01330204 Tee, 6" (15 cm) Aluminized 91409420 Tube, Aluminized 6" (15 cm) dia. 10' (3 m)

01331900 Damper Coupling, 4" (10 cm) 91412800 Flexible Boot, 4" (10 cm)

01335801 Elbow, 4" (10 cm) Aluminized 90° 91412802 Flexible Boot, 6" (15 cm)

01397400 Bird Screen, 6" (15 cm) 91418200 Tube Adapter, 6" (15.2 cm) dia. x 4" (10 cm) dia.

02537801-1P Vent Terminal (Non-Combustible Wall) 91901300 Boot Clamp, 4" (10 cm)

02718851 Drain Cap, 4" (10 cm) 91913703 Boot Clamp, 6" (15 cm)

02718852 Drain Cap, 6" (15 cm) E0009356 Damper Coupling, 6" (15 cm)

90502100 Vent Terminal, 4" (10 cm) (Combustible Wall) T0100320 Elbow, 6" (15 cm) Aluminized 90°

90502101 Vent Terminal, 6" (15 cm) (Combustible Wall)

90502302 Vent Cap, 6" (15 cm) Metalbestos

90505600 Wall Thimble, 4" (10 cm)

SECTION 10: OUTSIDE AIR SUPPLY

The CRV-Series system is approved for use with an outside air system. Halogenated hydrocarbons or other corrosive chemicals in the air can be drawn into the equipment and seriously damage the system components. Avoid the use of such chemical compounds near the air inlet to the heaters. IMPORTANT: If the building has a slight negative pressure or contaminants are present in the air, an outside combustion air supply to the heaters is strongly recommended. All joints and seams in the air supply system must be airtight. Attach the filter housing to the burner assembly using the wing nut provided.

10.1 Pressurized

See Page 39, Figure 23 for a typical layout of a pressurized air supply system. For pressurized outside air supplies, the outside air

FIGURE 19: Duct Sizing

SECTION 10: OUTSIDE AIR S UPPLY

blower motor has a pressure switch interlock that must be used. Wire this switch in series with the pump pressure switch. When using an outside air blower with a ROBERTS GORDON

or ROBERTS GORDON

ULTRAVAC™ control or

System Control

relay transformer, a separate load relay package is required. Wire the control for the relay in parallel with the pump. The outside air blower must have a separate 20A, 120V power supply. See Page 38, Figure 21 for outside air blower internal wiring requirements.

10.2 Non-Pressurized

For a non-pressurized outside air supply, a 4" (O.D.) single wall pipe duct may be attached to the burner and end vent. For length and duct sizing requirements, see duct design rules in Figure 19. To prevent condensation, insulate the outside air duct.

Outside Air System Design Requirements:

Blower Performance (90707501): 112 Flow Units

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 CRVSeries systems.

Duct Design Rules:

- System should be designed so that the blower is positioned closest to the highest flow requirements (end vents).

- When a duct is carrying more than 40 flow units, it must be at least 6" (15 cm) diameter.

Pressurized Systems

- 6" (15 cm) diameter duct must not exceed 120'

(36 m) total per system.

- 4" (10 cm) diameter duct must not exceed 120'

(36 m) per radiant branch.

Non Pressurized

- 6" (15 cm) diameter duct must not exceed 90'

(27 m) maximum 100 flow units

- 4" (10 cm) diameter duct must not exceed 90'

(27 m)

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

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

10.3 Outside Air Blower Internal Wiring FIGURE 20: Outside Air Blower Internal Wiring Diagram

Outside air blower is shipped with the blower manufacturer’s standard internal wiring. For use with Roberts-Gordon heaters, the outside air blower must be rewired with existing wires by the electrical contractor. See diagram.

Internal 24 V transformer provided will not be used and can be discarded.

MOTOR

BLOWER

PRESSURE

SWITCH

FIGURE 21: Filter Housing Assembly

Door-Control

Housing

Filter

BLK

WHT

Filter

Support

BLU BLU

T1 T3T2

4" (10 cm)

Air Flex Duct

Filter Housing

Wing Nut

Clamp

Bottom Gasket

Top Gasket

and Disk

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

FIGURE 22: Air Supply Blower Support

Outside

Air Supply

Blower

Wall

5" (12.5 cm)

Inlet Pipe

5" (12.5 cm)

Outlet Pipe

SECTION 10: OUTSIDE AIR S UPPLY

Vent

Bird

Screen

Outside

Wall

Description Part Number

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

Cap

FIGURE 23: Pressurized Outside Air Supply

Vent Cap or Bird Screen

Burner

Outside

Air Supply

Blower

Outside

Wall

4" (10 cm)

Air Flex Duct

4" (10 cm)

Take Off

Filter

Housing

Clamp

Sheet Metal

or PVC

Description Part Number

Filter Housing 01326801 4" (10 cm) Take Off 01324401 Blower 90707501 5" (12.7 cm) Vent Cap 90502301 6" (15 cm) Bird Screen 01365400 6" (15 cm) Band Clamp 91913703

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 24: Non-Pressurized Outside Air Supply

Vent Cap

Bird Screen

6' (1.8 m)

Maximum

Outside Wall

Description Part Number

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

Pressure Switch

Lock Nuts

7/16" (11.1 mm) Diameter Hole

SECTION 11: GAS P IPING

SECTION 11: GAS PIPING

WARNING

Fire Hazard

Tighten gas hose fittings to connect gas supply

according to Figure 25.

according to Figure 24.

Gas hose can crack when twisted.

Gas hose moves during normal operation.

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

Install the gas hose as shown in Figure 25. The gas hose accommodates expansion of the heating system and allows for easy installation and service of the burner. Before connecting the burners to the supply system, verify that all high pressure testing of the gas piping has been completed.

There is an expansion of the tube with each firing cycle. This will cause the burner to move with respect to the gas hose. This can cause a gas leak resulting in an unsafe condition if the gas connection is not made in strict accordance with Figure 25. Meter and service must be large enough to handle all the burners being installed plus any other connected load. The gas hose which feeds the system must be large enough to supply the required gas with a maximum pressure drop of 1/2" w.c. When gas piping is not included in the layout drawing, the local gas supplier will usually help in planning the gas piping.

• Do not high pressure test the gas piping with the burner connected. Failure to follow these instructions can result in property damage.

• Check the pipe and tubing ends for leaks before placing heating equipment into service. When checking for gas leaks, use a soap and water solution; never use an open flame.

FIGURE 25: Gas Connection with Flexible Gas Hose

Shut-Off Valve must be

3/4" NPT Pipe

Shut-Off Valve

(Included

With Gas Hose)

12"

2" (5 cm)

parallel to burner gas inlet. The 2" (50 mm) displacement shown is for the cold condition. This displacement may reduce when the system is fired.

(30 cm)

Flexible

Gas

Hose

Hold gas nipple securely with pipe wrench when attaching the gas hose. Failure to follow these instructions can result in product damage.

45°

Horizontal

Rear ViewBurner

Description Part Number

1/2" Flexible Stainless Steel Gas Hose (US Models) 91412200 3/4" Flexible Stainless Steel Gas Hose (US Models) 91412203 1/2" Rubber (Type 1) Gas Hose (Canadian Models) 91412206 3/4" Rubber (Type 1) Gas Hose (Canadian Models) 91412207

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 12: CONTROL METHODS

WARNING

Electrical Shock Hazard

Disconnect electrical power and gas supply before servicing.

This appliance must be connected to a properly grounded electrical source.

Failure to follow these instructions can result in death or electrical shock.

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

12.1 ROBERTS GORDON

The System Control is an electronic control panel designed to control CRV-Series heating systems. The System Control wiring is shown on Page 46, Figure 29 through Page 47, Figure 32 and in the System Control Installation Manual (P/N 10091601NA). The System Control can be used to control an EP-100 or EP-201 pump from the control panel. Other pumps such as the EP-301 and 3 phase models may be controlled by a relay or motor starter. The System Control can control up to four zones of burners. The electrical circuit is a 120V AC (20A) supply. The output for the thermostat is 12V DC. Do not use thermostats that draw power from the low voltage supply. A System Control operated system has two minutes post purge pump operation to completely exhaust products of combustion from the system. A system control provides indication of power to the pump and the zones as well as indicating the status of the pressure switch with lights. The System Control is UL listed in accordance with UL873 – Temperature Indicating and Regulating Equipment.

System Control

12.2 ROBERTS GORDON

ULTRAVAC

The ROBERTS GORDON® ULTRAVACTM is a micro processor based control package designed for modulating control of CRV-Series heaters based on outdoor temperatures. The controls offer full modulation between 60% and 100% of system maximum rated input. This controller is capable of giving control outputs to one pump and three heating zones. The controller also features inputs which are used for indoor and outdoor signal condition monitoring. System status and settings are viewed and altered from a PC (not supplied) running ROBERTS GORDON ROBERTS GORDON requires a PC (not supplied) running Windows higher, with a Pentium

ULTRAVACTM Software.

ULTRAVACTM Software

class processor and at least

95 or

64k of RAM.

Special design requirements apply for CRV-

Series systems using the ROBERTS GORDON ULTRAVAC

Controller.

12.3 SPST Transformer Relay (P/N 90417600)

The transformer relay wiring diagram is shown on Page 43, Figure 26. The transformer relay can be

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

system. The single pole relay can only be used to control one zone of burners. The electrical circuit is a 120V AC (20 A) supply. The transformer 24V AC output for the thermostat is rated at 40 V A. Thermostats used with the transformer must not exceed this power requirement. A transformer relay operated system will not give any post purge pump operation to completely exhaust products of combustion from the system or provide indication of operating conditions.

12.4 DPST Transformer Relay (P/N 90436300)

The transformer relay wiring diagram is shown on Page 45, Figure 28. The transformer relay can be

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

CORAYVAC

system. The double pole relay can only be used to control two zones of burners. The electrical circuit is a 120V AC (20A) supply. The transformer 24V AC output for the thermostat is rated at 40VA. Thermostats used with the transformer must not exceed this power requirement. A transformer relay operated system will not give any post purge pump operation to completely exhaust products of combustion from the system or provide indication of operating conditions.

FIGURE 26: One Zone Operation without Control Panel

SPST (12A)

Transformer

Thermostat

Relay

SECTION 12: CONTROL METHODS

120 V

1 Ø

60 Hz

Ground

Pump Motor

Black

White

COIL COIL

Red

Description Part Number

SPST Transformer Relay 90417600

Pressure

Switch

(Pump)

Zone 1

Burners

Nine Burners Maximum

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 27: One Zone Operation (with Outside Air Blower) without Control Panel

SPST (12 A)

Transformer

Relay

Thermostat

Outside Air

Blower

120 V

1 Ø

60 Hz

Ground

Pressure Switch

(Outside Air Blower)

Black

COIL COIL

Black

White

Red

Pressure

Switch

(Pump)

Pump Motor

Zone 1

Burners

Nine Burners Maximum

FIGURE 28: Two Zone Operation without Control Panel

SECTION 12: CONTROL METHODS

Zone 1

Thermostat

120 V

1 Ø

60 Hz

COIL

White

DPST (12 A)

Transformer

Relay

Purple Red

COIL

Red

Black

Black Black

Zone 2

Thermostat

Purple

Red/Yellow

Black

DPST (12 A) Transformer

Relay

COIL

Red/YellowWhite

Description Part Number

DPST Transformer Relay 90436300

Pump Motor

Pressure

Switch

(Pump)

LNLN

Zone 1

Burners

Nine Burners Total

Maximum Between Zones

Zone 2

Burners

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 29: General System Wiring

Burner Receptacles 4 Zone Max

Thermostats

120 V

1 Ø

60 Hz

120 Vac

Maximum 20 Amps Total

Pressure Switch

Pump Motor 115 Vac Operation

(230 Vac Operationseparate power circuit required for EP-203 or EP-300 series pumps)

Motor Starter

(Needed for EP-203 and EP-300 Series Pump)

Outside Air Supply Blower Motor and Pressure Switch

FIGURE 30: External Wiring Diagram EP-100 and EP-201 120 V 1 Ø Pump

All burners must be connected to Ground (Not shown)

Zone 1

Zone 2 Zone 3 Zone 4

Pump

Low voltage thermostats

located in heated zone

Zone1Zone

120 V 1 Ø 60 Hz

Ground

Zone

Pressure switch located at pump

12 Vdc

Ground

GLN

NLL

Z3 Z4

System Control

PUMP

CT1C

CCC

T3T2T4

FIGURE 31: External Wiring Diagram EP-301 120 V 1 Ø Pump

EP 301

Pump

Do not directly connect the controller relay terminals to the pump motor. Product damage will result.

All burners must be connected to Ground. (Not shown.)

Zone 1 Zone 2 Zone 3 Zone 4

120 V 1 Ø

120 V

60 Hz

1 Ø 60 Hz

Ground

IEC contactor (P/N

10050009) rated for the EP 301 pump motor

The power supply for the

pump must be separate from the controller supply.

Low voltage thermostats

located in heated zone.

Zone1Zone

Zone

230 V 1 Ø 60 Hz

Zone

SECTION 12: CONTROL METHODS

Individual supply for pump rated for total full load current.

Pressure switch located at pump.

12 Vdc

Ground

GLN

Z3 Z4

NLLLL

PUMP

T1T3T2

CCC

System Control

FIGURE 32: External Wiring Diagram EP-203 or EP-303 208 V - 230 V (or 460 V) 3 Ø Pump

Motor starter (P/N 10050001) rated for EP-203 pump motor; motor starter (P/N 10050010) rated for EP-303 pump motor.

All burners must be connected to Ground. (Not shown.)

Zone 1

Zone 2 Zone 3 Zone 4

EP-203 or

EP- 303 3 Ø Pump

The power supply for the pump must be separate from the controller supply.

Do not directly connect the controller relay terminals to the pump motor. Product damage will result.

208 - 230 V (or 460 V) 3 Ø 60 Hz

L2 L1

Zone

Individual supply for pump rated for total full load current.

Zone

Pressure switch located at pump.

120 V 1 Ø 60 Hz

Low voltage thermostats

located in heated zone.

Zone1Zone

Ground

GLN

Z3 Z4

NLL

System Control

PUMP

CT1C

CCC

T3T2T4

12 Vdc

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 33: Burner Internal Wiring

Black

120 V

Power Supply

Green

TRANSFORMER

White

Yellow

Blue

Green

GAS

VALVE

Yellow

Brown

Yellow

Black

V1 S1 V2/GND

IGNITION

MODULE

BURNER

If any of the original wire as supplied with the heater must be replaced, it must be replaced with

wiring material having a temperature rating of at least 105°C and 600 volts.

FIGURE 34: Burner Internal Ladder Diagram

TRANSFORMER

Black

White

Yellow

ELECTRODE

Gap

Black

Gnd

Blue

S1 V1

Yellow

Brown

GAS VALVE

IGNITION MODULE

SECTION 13: STARTING THE SYSTEM

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

13.1 Checking the Gas Line

1. Open the main valve and verify that no gas is flowing through the meter.

2. Purge the line if this was not done following pressure testing with air.

3. Verify that the gas pressure is not above 14'' w.c. (1/2 PSIG).

4. Close the main gas valve.

13.2 Checking the Electrical System

1. See that all temperature setpoints are set below room temperature.

2. Turn on power supply to system controls.

3. Check to see that no part of the system (i.e. burners, pump or air supply blower) is powered.

4. Individually check each zone by raising the zone temperature set points separately. Raising each zone temperature set point above room temperature should start the pump immediately. After a 45 second delay, the burners will begin their ignition sequence by sparking at the electrode (visible through the burner window).

5. Make a preliminary vacuum check at burners in branches that have an adjustable damper coupling. See Page 50, Figure 35 for manome- ter hookup to check vacuum. This check is to insure that all dampers are open before the system is fired. Vacuum, as measured at the end vents, should be approximately 3.5'' w.c. or slightly above (cold).

13.3 Starting the System NOTE: During the initial firing, the protective oil on

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

1. Start with all temperature setpoints below room temperature.

2. Open main gas valve.

3. Turn up temperature setpoints one zone 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 troubleshooting section of the service instructions.

13.4 Setting the Vacuum

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

SECTION 13: STARTING THE S YSTEM

2. Allow at least ½ 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 50, Figure 35. Normal end vent vacuum should w.c.

be set at approximately 2.5'' w.c. to 3.0''

(hot). Vacuum adjustments are made by means of the damper in the pump inlet and the adjustable damper coupling(s) in the system. Check the vacuum at all end vents and then adjust the damper coupling to obtain equal vacuum readings of

2.5'' w.c. to 3.0'' w.c.

If end vent vacuum exceeds 3.0" w.c., adjust the pump inlet damper until vacuum readings are

2.5'' w.c. to

3.0'' w.c. With systems designed to operate at maximum vacuum, it may not be possible to obtain vacuum differential readings at or slightly above

2.5'' w.c. If so, adjust the damper couplings to maximum but equal vacuum reading. Be sure to lock all dampers securely after adjustment.

3. Reset temperature setpoints to desired room temperature.

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

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 35: Vacuum Reading

Combustion Chamber

at end position

End Vent

Insert tubing

about 6" (15 cm).

Manometer

Approximate reading after

adjusting damper couplings and

pump inlet. ( 2.5"- 3.0" w.c.)

SECTION 14: OPERATION AND MAINTENANCE

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

14.1 Sequence of Operation

1. Turn the thermostat up. When the thermostat calls for heat, the pump will start immediately. After a short period, the burners will begin their ignition sequence. Sparking will begin at the electrodes and the gas valve will be energized 45 seconds later.

2. The flame will be sensed by the flame sensing rod and the electrode is de-energized.

3. If a flame is detected, the gas valve remains open. When the call for heat is satisfied, the burner shuts off. On CRV-Series systems equipped with the optional ROBERTS

GORDON GORDON

System Control, or ROBERTS

ULTRAVACTM, the pump will continue operation for a post-purge period of two minutes.

4. If no flame is detected, the module will close and a purge period begins. If a flame is not established, a second purge and warm-up will take place and then a third trial cycle will begin. After three trials, the module will lockout for one hour or until reset.

5. A reset is accomplished by removing power from the module for at least 5 seconds (thermostat cycle is required) or automatically after 1 hour.

14.2 To Shut Off Heater

Set thermostat to lowest setting. Turn OFF electric power to heater. Turn OFF manual gas valve in the heater supply line.

14.3 To Start Heater

Turn gas valve and electric power OFF and wait five minutes for unburned gases to vent from heater. Turn ON main gas valve. Turn ON electric power. Set thermostat to desired temperature. Burner should light automatically.

SECTION 14: OPERATION AND MAINTENANCE

14.4 Pre-Season Maintenance and Annual Inspection

WARNING

Explosion Hazard

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

Turn off gas and electrical supplies before performing service or maintenance.

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

To ensure your safety and years of trouble-free operation of the heating system, service and annual inspections must be done by a contractor qualified in the installation and service of gas-fired heating equipment. Turn off gas and electric supplies before performing service or maintenance. Allow heater to cool before servicing. Before every heating season, a contractor qualified in the installation and service of gas-fired heating equipment must perform a thorough safety inspection of the heater. For best performance, the gas, electrical, thermostat connections, tubing, venting, suspensions and overall heater condition should be thoroughly inspected. NOTE: Gas flow and burner ignition are among the first things that should be inspected. Please see Page 52, Section 14.5 for suggested items to inspect.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

14.5 Maintenance Checklist Installation Code and Annual Inspections:

WARNING

All installations and service of ROBERTS GORDON products must be performed by a contractor qualified in the installation and service of products sold and supplied by Roberts-Gordon and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation, service and operation of

Explosion Hazard

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

Turn off gas and electrical supplies before performing service or maintenance.

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

the equipment. To help facilitate optimum performance and safety, Roberts-Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON

products and

perform service where necessary, using only

ROBERTS GORDON

replacement parts.

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 3, Section 3.

Vehicles and Other Objects

Maintain the clearances to combustibles.

Do not hang anything from, or place anything on, the heater.

Make sure nothing is lodged underneath the reflector, in between the tubes or in the decorative or protective grilles (included with select models).

Immediately remove objects in violation of the clearances to combustibles.

See Page 3, Section 3.

Reflector Make sure there is no dirt, sagging, cracking or distortion.

Do not operate if there is sagging, cracking or distortion.

Make sure reflectors are correctly overlapped. See Page 19, Figure 7.4.3.

Clean outside surface with a damp cloth.

Vent Pipe Venting must be intact. Using a flashlight, look for obstructions, cracks on the

pipe or gaps in the sealed areas or corrosion.

The area must be free of dirt and dust.

Remove any carbon deposits or scale using a wire brush.

Outside Air Inlet Inlet must be intact. Look for obstructions, cracks on the pipe or gaps in the

sealed areas or corrosion.

The area must be free of dirt and dust. Clean and reinstall as required.

Tube s Make sure there are no cracks.

Make sure tubes are connected and suspended securely.

See Page 15, Figure 12 through Page 17, Section 7.2.1.

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

Clean or replace as required.

Gas Line Check for gas leaks. See Page 41, Figure 25.

SECTION 14: OPERATION AND MAINTENANCE

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 Make sure it is clear of obstructions. (Even spider webs will cause problems).

Carefully remove any dust and debris from the burner.

Electrode Replace if there are cracked ceramics, excessive carbon residue, or erosion

of the electrode.

The electrode gap should be 1/8" (3 mm).

Thermostat or Sensor There should be no exposed wire or damage to the thermostat or sensor.

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

or ceiling.

See Page 15, Figure 12.

Decorative and Protective Grille (optional)

The grille must be securely attached.

Check that side reflector extensions are installed correctly and secured in place if necessary. (Decorative grille only.)

See Page 25, Section 8.6.1 through Page 28, Section 8.7.5

Make sure shield is installed correctly and secured in place if necessary. (Decorative grille only.) See Page 25, Section 8.6.2.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Pump With pump operating, check for excessive vibration or noise. Vibration is usu-

ally a sign that the impeller is out of balance. Turn off the system, insure power is shut off and remove the inlet plate. Check the shaft seal and replace it if worn or missing.

With the Power off:

Check the inlet and outlet of the pump for blockage or excessive soot and clean as necessary.

Check boots for cracking or deterioration and replace if necessary.

If a condensate trap is installed, check the condition of the trap and the drain line attached. Note: the condensate trap should be filled with water at the beginning of each heating season.

Check the condition of the motor mounts. Lift the motor from the rear; look for breaks in the rubber and replace if necessary.

Check the condition and operation of the pressure switch.

SECTION 15: TROUBLESHOOTING

15.1 Troubleshooting Flow Chart

SECTION 15: TROUBLESHOOTING

Is the motor connected properly?

Refer to the wiring diagrams on the

motor and in the installation manual.

Motor may have tripped

overload switch. Wait 10-15

Ye s

Is the motor hot?

Ye s

minutes for automatic reset.

obstructed?

Is the pump impeller

turn freely?

motor. Does the motor

Disconnect power to the

at end vent.

Check for proper vacuum

Ye s

failed. Replace motor.

Motor bearings may have

Correct gas problem.

module begin ignition

seconds, then plug it in

sequence by sparking?

again. Does the ignition

Unplug the burner, wait 10

Ye s

and flow to the burners?

Is there proper gas pressure

Ye s

Troubleshoot Ends

Ye s

Do the burners light?

Check LED on module and

Pre-purge. Wait 45 seconds.

Replace ignition module.

Ye s

and yellow wires)?

refer to LED codes below.

Is there 24V at the burner

Replace burner transformer.

transformer secondary (blue

Module Diagnostic Codes:

within module

LED Problem Solution

4 second steady

flash at start of cycle Normal Wait for valve to open

Steady on Microprocessor failure Replace module

Lockout of module spark and valve opening and

after 3 tries replace:if none, replace module

Three flashes Ignition lockout Recycle unit: check for

replace thermostat if

Check thermostat wiring and

necessary.

Refer to control

panels listed below.

Does pump turn on?

Ye s

the control?

(panel or relay)

Is there power (120V) to

fuse on panel supply circuit.

Check circuit breaker and/or

START

Turn up thermostat.

Does the pump turn on?

Check wiring to the burner.

Make sure the burner is

plugged in.

Ye s

burner receptacle?

Is there power (120V) at the

Ye s

manuals list.

Refer to control panel

Is there power to the zone?

After 45 seconds pre-purge

period, do the burners light?

panel list.

Refer to control

vacuum at the end vent.

Adjust system for proper

Ye s

too high?

Is the vacuum setting

Ye s

smoothly?

Do all the burners ignite

Wrong end vent plate may

be installed. Make sure plate

and burner match.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Troubleshooting Flow Chart

Couplings may be installed

should be used for tailpipe.

improperly. Lined couplings

Yes

burners dirty?

failed. Replace module.

Ignition module may have

Are the filters on the

Yes

ULTRAVAC P/N: 10081601NA

Pump IOS Manuals:

- EP-100 P/N: 127201NA

- EP-200 P/N: 127200NA

- EP-300 P/N: 127202NA

leaks in the system.

outside air supply or for

Replace filters as necessary.

Check for blockage in the

Control Panel IOS Manuals:

- For systems with no control panel, refer

- System Control P/N: 10091601NA

to appropriate control manufacturers instructions.

- ROBERTS GORDON

Yes

Adjust the gap or

Electrode gap should be

1/8". Is the gap too small?

burned or damaged?

affected burners. Are they

Inspect the electrodes on the

Yes

replace the electrode.

Yes

Replace the electrodes.

Is the rotation of the

pump motor correct?

Yes

Are there any "dead"

burners in a branch?

Yes

too low?

Is the vacuum setting

Yes

burners dirty?

for reversal instructions.

pump manuals listed below

Consult wiring instructions in

Follow burner check

procedure given above.

vacuum at the end vent.

Adjust system for proper

Are the filters on the

Yes

Is the rotation of the

pump motor correct?

too low?

Is the vacuum setting

Yes

Replace filters as necessary.

for reversal instructions.

pump manuals listed below

Consult wiring instructions in

Yes

vacuum at the end vent.

Adjust system for proper

listed below.

panel manuals

Refer to control

Yes

Make sure that all

sensors are satisfied.

thermostats or internal

listed below.

panel manuals

Refer to control

Yes

Make sure that all

sensors are satisfied.

thermostats or internal

Contact

www.rg-inc.com

Roberts-Gordon at

Yes

intermittently?

Do the burners lockout

Is the system leaking water?

Is the flame low?

call for heat is satisfied?

Do burners shut off after the

Yes

period?

Does the pump shut down

after a 2 minute post-purge

Independent

Yes

your

TROUBLESHOOT ENDS.

If problems persist, contact

ROBERTS GORDON

Distributor.

SECTION 16: REPLACEMENT PARTS Use only genuine ROBERTS GORDON

replacement parts. Use of parts not specified by Roberts-Gordon voids warranty. Failure to follow these instructions can result in property damage.

Gasket (Burner to Mixing Chamber)

SECTION 16: REPLACEMENT PARTS

Burner Head

Ignition Cable

Electrode

Electrode Gasket

Mixing Chamber

Combustion

Chamber

Gasket

F OF

Gas Valve

Transformer

Ignition Module

Regulator

Description Part Number

Gas Valve (All Burners) 90032502 Gasket (Burner to Mixing Chamber) 01351100 Burner Head Assembly Replacement Package 02713000 Mixing Chamber 02790400 Transformer 90436900K Regulator 90207100 Gasket (Combustion Chamber) 01367800 Electrode Replacement Kit (includes electrode, electrode gasket and mounting screws) 02713200 Ignition Module 90439500 Ignition Cable 90427706 Filter Cartridge with Gasket (not shown) 01312401

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 17: GENERAL SPECIFICATIONS

17.1 Material Specification

17.1.1 Reflectors

.024

Aluminium (Optional - 024 Stainless Steel Type 304).

17.2 Heater Specifications

17.2.1 Ignition

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

17.3 Suspension Specifications

Hang heater with materials with a minimum working load of 75 lbs (33 kg). See Page 15, Figure 12.

17.4 Controls Specifications

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

General Specifications for CRV-Series heaters are as follows:

9 1/2"

(24 cm)

6 1/2"

(16 cm)

14 1/4"

(36 cm)

6 7/8"

(17 cm)

5/32"

(.4 cm)

10 3/4"

(27 cm)

(10 cm)

20"

(51 cm)

10"

(24.4 cm)

7 5/8"

(19 cm)

3 1/2"

(9 cm)

Reflector

Heat Input Rate Length “A”

Length "A"

Recommended Minimum

Mounting Height*

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

CRV-B-2 (NG only) 20 10' (3 m) 20' (6.1 m) 8' (2.4 m)

CRV-B-4 40 12.5' (3.8 m) 25' (7.6 m) 8' (2.4 m)

CRV-B-6 60 20' (6.1 m) 35' (10.7 m) 8' (2.4 m)

CRV-B-8 80 20' (6.1 m) 45' (13.7 m) 10' (3 m)

CRV-B-9 90 25' (7.6 m) 50' (15.2 m) 10' (3 m)

CRV-B-10 100 30' (9.1 m) 60' (18.3 m) 15' (4.5 m)

CRV-B-12A (NG only) 110 35' (10.7 m) 70' (21.3 m) 15' (4.5 m)

CRV-B-12 (LP only) 120 35' (10.7 m) 70' (21.3 m) 15' (4.5 m)

*See Page 3, Section 3 for clearances to combustibles.

PIPE CONNECTION:

1/2" NPT

DIMENSIONS:

Vent Connection Size: 4" (10 cm) or 6" (15 cm) Outside Air Connection Size: 4" (10 cm) Refer to figure above for dimensional information.

GAS INLET PRESSURE:

Natural Gas: 4.5" w.c. Minimum 14.0" w.c. Ma x imum LP Gas: 10.5

" w.c. Minimum 14.0" w.c. Maximum

ELECTRICAL RATING:

120 V - 60 Hz, 0.3 A

SECTION 17: GENERAL SPECIFICATIONS

General Specifications for pumps are as follows:

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

dia.

Pump Specifications

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

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

Air Supply Blower Specifications

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

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 18: THE ROBERTS GORDON® CORAYVAC® LIMITED WARRANTY

SECTION 18: THE ROBERTS GORDON

CORAYVAC® LIMITED WARRANTY

ROBERTS-GORDON WILL PAY FOR:

Within 42 months from date of shipment from RobertsGordon, replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect.

Roberts-Gordon will require the part in question to be returned to the factory. Roberts-Gordon will, at its sole discretion, repair or replace after determining the nature of the defect and disposition of part in question.

ROBERTS GORDON combustion chamber of the CORAYVAC

warrants the cast iron

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 RobertsGordon. All other components of the CORAYVAC

Classic System adhere to the standard warranty listed in the paragraph above.

ROBERTS GORDON

Replacement Parts are warranted for a period of 18 months from date of shipment from Roberts-Gordon or the remaining CORAYVAC

warranty.

ROBERTS-GORDON WILL NOT PAY FOR:

Service trips, service calls and labor charges. Shipment of replacement parts. Claims where the total price of the goods have not

been paid.

Damage due to:

• Improper installation, operation or maintenance.

• Misuse, abuse, neglect, or modification of the CORAYVAC

• Use of the CORAYVAC

in any way.

for other than its intended

purpose.

• Incorrect gas or electrical supply, accident, fire, floods, acts of God, war, terrorism, or other casualty.

• Improper service, use of replacement parts or accessories not specified by Roberts-Gordon.

• Failure to install or maintain the CORAYVAC

as directed in the Installation, Operation and Service Manual.

• Relocation of the CORAYVAC

after initial

installation

• The use of the CORAYVAC

in a corrosive

atmosphere containing contaminants.

• The use of the CORAYVAC

in the vicinity of a

combustible or explosive material.

• Any defect in the CORAYVAC

arising from a drawing, design, or specification supplied by or on behalf of the consumer.

• Damage incurred during shipment. Claim must be filed with carrier.

WARRANTY IS VOID IF:

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

You cannot prove original purchase date and required annual maintenance history.

The data plate and/or serial number are removed, defaced, modified or altered in any way.

The ownership of the CORAYVAC

is moved or

transferred. This warranty is nontransferable.

Roberts-Gordon is not permitted to inspect the damaged controller and/or component parts.

READ YOUR INSTALLATION, OPERATION AND SERVICE MANUAL

If you have questions about your controller, contact your installing professional. Should you need Replacement Parts or have additional questions, call or write RobertsGordon:

U.S.A.

1250 William Street P. O . B ox 44 Buffalo, New York 14240-0044

716.852.4400

On the web at: www.rg-inc.com

Roberts-Gordon's liability, and your exclusive remedy, under this warranty or any implied warranty (including the implied warranties of merchantability and fitness for a particular purpose) is limited to providing replacement parts during the term of this warranty.

Some jurisdictions do not allow limitations on how long an implied warranty lasts, so this limitation may not apply to you. There are no rights, warranties or conditions, expressed or implied, statutory or otherwise, other than those contained in this warranty.

Roberts-Gordon shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for the CORAYVAC

. Some jurisdictions do not allow the

exclusion or limitation of incidental or consequential damages, so this limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from jurisdiction to jurisdiction.

Roberts-Gordon shall not be responsible for failure to perform under the terms of this warranty if caused by circumstances out of its control, including but not limited to war, fire, flood, strike, government or court orders, acts of God, terrorism, unavailability of supplies, parts or power. No person is authorized to assume for Roberts-Gordon any other warranty, obligation or liability.

LIMITATIONS ON AUTHORITY OF REPRESENTATIVES:

No representative of Roberts-Gordon, other than an Executive Officer, has authority to change or extend these provisions. Changes or extensions shall be binding only if confirmed in writing by Roberts-Gordon's duly authorized Executive Officer.

OWNER WARRANTY REGISTRATION CARD

Roberts Gordon, LLC 1250 William Street, P.O. Box 44  Buffalo, NY 14240-0044  Phone: 716-852-4400  Fax: 716-852-0854

About the Owner:

Name: Address: City: State: Zip Code: Phone: Fax: E-mail:

About the Installer:

Name: Address: City: State: Zip Code: Phone: Fax: E-mail:

Purchased From (if different than installer):

Name: Address: City: State: Zip Code: Phone: Fax: E-mail:

About your Heater:

Model#: Serial #: Fuel: Installation Date:

Type of Installation (check one):

o Automotive o Manufacturing o Warehouse o Recreational o Aircraft o Public Building o Office o Retail o Agricultural o Other

Toll Free: 800-828-7450  www.rg-inc.com

Mail or Fax to:

Installation Code and Annual Inspections: All installations and service of ROBERTS GORDON® products must be performed by a

contractor qualified in the installation and service of products sold and supplied by Roberts-Gordon and conform to all requirements

set forth in the ROBERTS GORDON

manuals and all applicable governmental authorities pertaining to the installation, service and

operation of the equipment.

To help facilitate optimum performance and safety, Roberts-Gordon recommends that a qualified contractor annually inspect your

ROBERTS GORDON

products and perform service where necessary, using only ROBERTS GORDON® replacement parts.

This product is not for residential use.

This product is intended to assist licensed professionals in the exercise of their professional judgement.

in any form or by any means  graphic, electronic, or mechanical, including photcopying, recording, taping, or information storage and retrieval systems  without written permission of Roberts Gordon, LLC. Printed in the U.S.A.

Attach this information to a wall near the ROBERTS GORDON

heater.

Infrared Heating

Read the Installation, Operation, and Service Manual thoroughly before installation, operation, or service.

Know your model number and installed configuration.

Model number and installed configuration are found on the burner and in the Installation, Operation and Service Manual.

Write the largest clearance dimensions with permanent ink according to your model number and configuration in the open spaces below.

OPERATING INSTRUCTIONS

1. STOP! Read all safety instructions on this information sheet.

2. Open the manual gas valve in the heater supply line.

3. Turn on electric power to the heater.

4. Set the thermostat to desired setting.

TO TURN OFF THE HEATER

1. Set the thermostat to off or the lowest setting.

IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY,

FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER

1. Set the thermostat to off or the lowest setting.

2. Turn off electric power to the heater.

3. Turn off the manual gas valve in the heater supply line.

4. Call your registered installer/contractor qualified in the installation

and service of gas-fired heating equipment.

Some objects can catch fire or explode when placed close to heater.

Keep all flammable objects, liquids and vapors the required clearances to combustibles away from heater.

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

WARNING

Fire Hazard

Maintain ???? cm clearance

to the side and

???? cm clearance below

the heater from vehicles

and combustible materials.

Roberts-Gordon, LLC

1250 William Street P.O. Box 44 Buffalo, NY 14240-0044 USA Telephone: 716.852.4400 Fax: 716.852.0854 Toll Free: 800.828.7450

Installation Code and Annual Inspections:

All installations and service of ROBERTS GORDON in the ROBERTS GORDON recommends that a qualified contractor annually inspect your ROBERTS GORDON

© 2006 Roberts-Gordon, LLC All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means  graphic, electronic, or mechanical, including photocopying,

www.rg-inc.com Printed in U.S.A. P/N 91037912 Rev. C

manuals and all applicable governmental authorities pertaining to the installation, service and operation of the equipment. To help facilitate optimum performance and safety, Roberts-Gordon

recording, taping, or information storage and retrieval systems  without written permission of Roberts-Gordon, LLC.

Roberts-Gordon Europe Limited

Oxford Street Bilston, West Midlands WV14 7EG UK Telephone: +44(0) 1902 494425 Fax: +44(0) 1902 403200

products must be performed by a contractor qualified in the installation and service of products sold and supplied by Roberts-Gordon and conform to all requirements set forth

products and perform service where necessary, using only ROBERTS GORDON® replacement parts.

Service Telephone: +44(0) 1902 498733 Service Fax: +44(0) 1902 401464 E-mail: uksales@rg-inc.com E-mail: export@rg-inc.com

Roberts Gorden CRV-B-12, CRV-B-12A, CRV-B-4, CRV-B-8, CRV-B-10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual