WARNING
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installing or
servicing this equipment.
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.
®
WARNING
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier’s
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
Fire Hazard
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Some objects can catch fire or explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
CoRayVac
Custom-Engineered,
Low-Intensity Infrared
Heating Systems
Installation, Operation &
Service Manual
CRV-B-2
CRV-B-4
CRV-B-6
© 2009 Roberts-Gordon LLC
CRV-B-8
CRV-B-9
CRV-B-10
CRV-B-12
CRV-B-12A
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
www.radiantheaters.com
www.corayvac.com
P/N 127102NA Rev. G 04/09
© 2009
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.
TABLE OF CONTENTS
SECTION 1: Heater Safety...................................................... 1
1. 1 M an p o wer Requirements ............................................. 1
1.2 Safety Labels and Their Placement ............................. 1
SECTION 2: Installer Responsibility ..................................... 3
2.1 Wall Tag ....................................................................... 3
2.2 Corrosive Chemicals....................................................3
2.3 National Standards and Applicable Codes ..................3
SECTION 3: Clearances to Combustibles............................. 4
3.1 Required Clearances to Combustibles......................... 4
SECTION 4: National Standards and Applicable Codes .....8
4.1 Gas Codes...................................................................8
4.2 Aircraft Hangars........................................................... 8
4.3 Public Garages ............................................................8
4.4 Electrical ......................................................................8
4.5 Venting.........................................................................8
4.6 High Altitude ................................................................8
SECTION 5: Major Components............................................9
5.1 Standard Parts List .................................................... 12
SECTION 6: Design Requirements...................................... 14
SECTION 7: Heater Installation............................................16
7.1 Tube Installation ........................................................ 18
7.2 Coupling and Tube Assembly....................................18
7.3 Elbow Package Configuration..................................... 19
7.4 Reflector Installation .................................................. 20
7.5 Burner Installation...................................................... 23
SECTION 8: Optional Heater Accessories..........................24
8.1 Tee Installation ..........................................................24
8.2 Reflector Joint............................................................25
8.3 Reflector Side Extension............................................27
8.4 Universal Shield.........................................................28
8.5 Barrier Shield............................................................. 28
8.6 Two-Foot Decorative Grille Installation ......................29
8.7 Protective Grille Installation........................................ 31
8.8 Classic Cast-Iron Components.................................32
SECTION 9: Pump Installation and Venting .......................33
9.1 Pump Installation .......................................................33
9.2 General Venting Requirements Model EP-100,
EP-200 and EP-300 Series Pumps ........................... 34
9.3 Horizontal Venting 4" (10 cm) Pipe ............................36
SECTION 10: Outside Air Supply......................................... 39
10.1 Pressurized .............................................................. 39
10.2 Non-Pressurized ......................................................39
10.3 Outside Air Blower Internal Wiring ...........................40
SECTION 11: Gas Piping ......................................................43
SECTION 12: Control Methods ............................................45
12.1 ROBERTS GORDON
12.2 ROBERTS GORDON
12.3 SPST Transformer Relay (P/N 90417600K)............. 46
12.4 DPST Transformer Relay (P/N 90436300)...............46
®
System Control ................... 45
®
ULTR AVA CTM......................45
SECTION 13: Starting The System...................................... 54
13.1 Checking the Gas Line ............................................ 54
13.2 Checking the Electrical System............................... 54
13.3 Starting the System ................................................. 54
13.4 Setting the Vacuum.................................................. 54
SECTION 14: Operation and Maintenance.......................... 57
14.1 Sequence of Operation............................................ 57
14.2 To Shut Off Heater................................................... 57
14.3 To Start Heater ........................................................ 57
14.4 Pre-Season Maintenance and Annual Inspection.... 57
14.5 Maintenance Checklist............................................. 58
SECTION 15: Troubleshooting............................................. 60
15.1 Troubleshooting Flow Chart ..................................... 61
SECTION 16: Replacement Parts ........................................ 63
SECTION 17: General Specifications.................................. 65
17.1 Material Specifications ............................................. 65
17.2 Heater Specifications ............................................... 65
17.3 Suspension Specifications ....................................... 65
17.4 Controls Specifications............................................. 65
SECTION 18: The ROBERTS GORDON
Warranty ......................................................... 67
®
CORAYVAC® Limited
Printed in U.S.A.
TABLE OF FIGURES
Figure 1: Side Panel Label Placement......................................1
Figure 2: Top and Back Panel Label Placement .......................2
Figure 3: Standard Reflector .....................................................5
Figure 4: One Side Reflector.....................................................5
Figure 5: Two Side Reflectors ................................................... 5
Figure 6: Universal Shield, Position 1 ....................................... 6
Figure 7: Universal Shield, Position 2 ....................................... 6
Figure 8: Universal Shield, Position 3 ....................................... 6
Figure 9: 2-Foot Deco Grille......................................................7
Figure 10: Barrier Shield ........................................................... 7
Figure 11: Protective Grille ........................................................7
Figure 12: Major Component Descriptions................................9
Figure 13: Heater Assembly Overview ................................... 15
Figure 14: Critical Hanger Placement .....................................17
Figure 15: Reflector Joint Detail.............................................. 26
Figure 16: EP-200 Condensate Valve Assembly.....................33
Figure 17: Vertical Venting Configuration................................35
Figure 18: EP-100 Horizontal Venting Configurations .............36
Figure 19: EP-200 Series Horizontal Venting Configurations.. 37
Figure 20: EP-300 Series Horizontal Venting Configurations.. 38
Figure 21: Duct Sizing ............................................................ 40
Figure 22: Outside Air Blower Internal Wiring Diagram...........40
Figure 23: Filter Ho
Figure 24: Air Supply Blower Support ..................................... 41
Figure 25: Pressurized Outside Air Supply ............................. 42
Figure 26: Non-Pressurized Outside Air Supply......................42
Figure 27: Gas Connection with Flexible Gas Hose................44
Figure 28: One Zone Operation without Control Panel ........... 47
Figure 29: One Zone Operation (with Outside Air Blower)
without Control Panel .............................................48
Figure 30: Two Zone Operation without Control Panel............ 49
Figure 31: General System Wiring ..........................................50
Figure 32: External Wiring Diagram EP-100 and EP-201
120 V 1 Ø Pump..................................................... 50
Figure 33: External Wiring Diagram EP-100, EP-201 or EP-301
230 V 1 Ø Pump .................................................... 51
Figure 34: External Wiring Diagram EP-203 or EP-303
208 - 230 V (or 460 V) 3 Ø Pump ..........................52
Figure 35: Burner Internal Wiring............................................ 53
Figure 36: Burner Internal Ladder Diagram ............................ 53
Figure 37: Vacuum Reading.................................................... 56
using Assembly ........................................41
LIST OF TABLES
Table 1: Contents of CRV-Series Burner Carton.................... 12
Table 2: Common CRV-Series Components .......................... 12
SECTION 1: HEATER SAFETY
Control Side Panel
Rating Plate Label
Logo Label
Clearances to Combustibles Label Control Side Panel (inside)
Filter Side Panel (inside)
Wiring Label
Internal Ladder Diagram Label
Description Part Number
Logo Label 91007901
Rating Plate Label 91010401
Clearances to Combustibles Label 91009101
Internal Ladder Diagram Label 91017301
Wiring Label 91017300
Yo ur Safety is Important to Us!
This symbol is used throughout
the manual to notify you of
possible fire, electrical or burn
hazards. Please pay special
attention when reading and
following the warnings in these
sections.
Installation, service and annual inspection of heater
must be done by a contractor qualified in the
installation and service of gas-fired heating
equipment.
Read this manual carefully before installation,
operation or service of this equipment.
This heater is designed for heating nonresidential
indoor spaces. Do not install in residential spaces.
These instructions, the layout drawing, local codes
and ordinances, and applicable standards that apply
to gas piping, electrical wiring, venting, etc. must be
thoroughly understood before proceeding with the
installation.
Protective gear is to be worn during installation,
operation and service. Thin sheet metal parts, the
aluminum reflector portion of the heater and the
various venting components, have sharp edges. To
FIGURE 1: Side Panel Label Placement
SECTION 1: HEATER S AFETY
prev
ent 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.
For additional copies of the Installation, Operation
and Service Manual, please contact Roberts-Gordon
LLC.
1.1 Manpower Requirements
To p r event personal injury and damage to the heater,
two persons will be required for installation.
1.2 Safety Labels and Their Placement
Product safety signs or labels should be replaced by
the product user when they are no longer legible.
Please contact Roberts-Gordon LLC or your
ROBERTS GORDON
®
independent distributor to
obtain replacement signs or labels. See Page 1,
Figure 1 through Page 2, Figure 2.
1
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Top Panel Gas Connection Label
Back
Panel
Burner Box
Combination Label
Description Part Number
Gas Connection Label 91018125
Burner Box Combination Label 91029600
FIGURE 2: Top and Back Panel Label Placement
2
SECTION 2: INSTALLER RESPONSIBILITY
CAUTION
Product Damage Hazard
Do not use heater in area containing
corrosive chemicals.
Refer to appropriate Material Safety Data
Sheets (MSDS).
Failure to follow these instructions can result
in product damage.
The installer is responsible for the following:
• To ensure the system is designed in accordance
with the parameters of the CRV-Series
Manual (P/N 127500NA).
• To install the heater, as well as the gas and
electrical supplies, in accordance with applicable
specifications and codes. Roberts-Gordon LLC
recommends the installer contact a local Building
Inspector or Fire Marshal for guidance.
• To use the information given in a layout drawing
and in the manual together with the cited codes
and regulations to perform the installation.
• To install the heater in accordance with the
clearances to combustibles requirements.
• To furnish all needed materials not furnished as
standard equipment.
• To plan location of supports.
• To provide access to burners on all 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 arou
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).
• To ensure the heater is placed in an approved
application.
2.1 Wall Tag
A laminated wall tag is available for the heater as a
permanent reminder of the safety instructions and
the importance of the required clearances to
combustibles. Please contact Roberts-Gordon LLC
or your ROBERTS GORDON
®
independent
distributor to obtain the wall tag. Affix the tag by
peeling off the backing of the adhesive strips on the
rear surface and position the tag on a wall near the
CRV-Series heater (e.g. thermostat or controller).
A copy of the wall tag (P/N 91037912) is illustrated on
the back cover. For an immediate solution, you may
affix this copy on the wall near the heater.
Know your model number and installed configuration.
Model number and installed configuration are found
on the burner and in the Installation, Operation and
Service Manual. See Page 5, Figure 3 through Page
7, Figure 11. Write the proper clearance dimensions
in permanent ink according to your model number
and configuration in the open spaces on the tag.
Design
SECTION 2: INSTALLER R ESPONSIBILITY
2.2 Corrosive Chemicals
Roberts-Gordon LLC cannot be responsible for
ensuring that all appropriate safety measures are
undertaken prior to installation; this is entirely the
responsibility of the installer. It is essential that the
contractor, the sub-contractor, or the owner identifies
nd
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 m
ust 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.
3
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clearances to
combustibles away from heater.
Some objects will catch fire or explode when
placed close to heater.
Failure to follow these instructions can result
in death, injury or property damage.
SECTION 3: CLEARANCES TO COMBUSTIBLES
3.1 Required Clearances to Combustibles
Clearances are the required distances that
combustible objects must be away from the heater to
prevent serious fire hazards. Combustibles are
materials that may catch fire and include common
items such as wood, paper, rubber, fabric, etc.
Maintain clearances to combustibles at all times
for safety.
Clearances for all heater models are located on the
burner of the heater and on Page 5, Figure 3 through
Page 7, Figure 11 in this manual. Check the
clearances on each burner for the model heater
being installed to make sure the product is suitable
for your application and the clearances are
maintained. Read and follow the safety guidelines
below:
• Keep gasoline or other combustible materials
including flammable objects, liquids, dust or
vapors away from this heater or any other
appliance.
• The stated clearances to combustibles represents
a surface temperature of 90° F (32°C) above room
temperature. Building materials with a low heat
tolerance (such as plastics, vinyl siding, canvas,
tri-ply, etc) may be subject to degradation at lower
temperatures. It is the installer’s responsibility to
assure that adjacent materials are protected from
degradation.
• Maintain clearances from heat sensitive
equipment and workstations.
• Maintain clearances from vehicles parked below
the heater.
• Maintain clearances from swinging and overhead
doors, overhead cranes, vehicle lifts, partitions,
storage racks, hoists, building construction, etc.
• In locations used for the storage of combustible
materials, signs must be posted to specify the
maximum permissible stacking height to maintain
required clearances from the heater to the
combustibles. Signs must be posted adjacent to
the heater thermostat. In the absence of a
thermostat, signs must be posted in a
conspicuous location.
• Consult local Fire Marshal, Fire Insurance Carrier
or other authorities for approval of proposed
installation when there is a possibility of exposure
to combustible airborne materials or vapors.
• Hang heater in accordance to the minimum
suspension requirements on Page 17, Figure 14.
• If the radiant tubes must pass through the building
structu
re, be sure that adequate sleeving and fire
stop is installed to prevent scorching and/or fire
hazard.
4
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, elbows, tees and crosses.
B
C
D
A
A
B
C
D
A
B
C
D
2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from
where the combustion chamber and the tube connect.
FIGURE 3: STANDARD REFLECTOR
Model A B C D A B C D
CRV-B-2 4 20 48 20 11 51 122 51
CRV-B-4 4 20 48 20 11 51 122 51
CRV-B-6 4 20 48 20 11 51 122 51
CRV-B-8 4 20 48 20 11 51 122 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 4: ONE SIDE REFLECTOR
Model A B CDABCD
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
SECTION 3: CLEARANCES TO C OMBUSTIBLES
(inches) (centimeters)
(inches) (centimeters)
FIGURE 5: TWO SIDE REFLECTORS
(inches) (centimeters)
Model A B CDABCD
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
5
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
C
A
B
D
C
A
B
D
C
A
B
D
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 6: UNIVERSAL SHIELD, POSITION 1
Model A B CDABCD
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 18 24 18 21 46 61 46
(inches) (centimeters)
FIGURE 7: UNIVERSAL SHIELD, POSITION 2
(inches) (centimeters)
Model A B CDABCD
CRV-B-2 4 24 48 24 11 61 122 61
CRV-B-4 4 24 48 24 11 61 122 61
CRV-B-6 4 24 48 24 11 61 122 61
CRV-B-8 4 24 48 24 11 61 122 61
CRV-B-9 4 36 48 36 11 92 122 92
CRV-B-10 4 36 48 36 11 92 122 92
CRV-B-12 4 36 48 36 11 92 122 92
CRV-B-12A 4 36 48 36 11 92 122 92
FIGURE 8: UNIVERSAL SHIELD, POSITION 3
(inches) (centimeters)
Model A B CDABCD
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
6
NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, elbows, tees and crosses.
A
B
C
D
C
A
B
D
A
B
C
D
2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from
where the combustion chamber and the tube connect.
FIGURE 9: 2-FOOT DECO GRILLE
Model A B CDABCD
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
SECTION 3: CLEARANCES TO C OMBUSTIBLES
(inches) (centimeters)
FIGURE 10: BARRIER SHIELD
(inches) (centimeters)
Model A B CDABCD
CRV-B-2 4 12 12 12 11 31 31 31
CRV-B-4 4 12 12 12 11 31 31 31
CRV-B-6 4 12 12 12 11 31 31 31
CRV-B-8 4 12 12 12 11 31 31 31
CRV-B-9 - UNAPPROVED - - UNAPPROVED -
CRV-B-10 - UNAPPROVED - - UNAPPROVED -
CRV-B-12 - UNAPPROVED - - UNAPPROVED -
CRV-B-12A - UNAPPROVED - - UNAPPROVED -
FIGURE 11: PROTECTIVE GRILLE
(inches) (centimeters)
Model A B CDABCD
CRV-B-2 4 20 48 20 11 51 122 51
CRV-B-4 4 20 48 20 11 51 122 51
CRV-B-6 4 20 48 20 11 51 122 51
CRV-B-8 4 20 48 20 11 51 122 51
CRV-B-9 4 36 60 36 11 92 153 92
CRV-B-10 4 36 60 36 11 92 153 92
CRV-B-12 4 36 60 36 11 92 153 92
CRV-B-12A 4 36 60 36 11 92 153 92
7
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 4: NATIONAL STANDARDS AND
APPLICABLE CODES
4.1 Gas Codes
The type of gas appearing on the nameplate
must be the type of gas used. Installation must
comply with national and local codes and
requirements of the local gas company.
United States: Refer to National Fuel Gas Code
NFPA 54/ANSI Z223.1 - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code CSA B149.1 - latest revision.
4.2 Aircraft Hangars
Installation in aircraft hangars must be in
accordance with the following codes:
United States: Refer to Standard for Aircraft
Hangars, NFPA 409 - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code CSA B149.1 - latest revision.
In aircraft storage and servicing areas, heaters
shall be installed at least 10' (3 m) above the
upper surface of wings or of engine enclosures
of the highest aircraft which may be housed in
the hangar. The measurement shall be made
from the wing or engine enclosure (whichever is
higher from the floor) to the bottom of the heater.
• In shops, offices and other sections of aircraft
hangars communicating with aircraft storage or
servicing areas, heaters shall be installed not
less than 8' (2.4 m) above the floor.
• 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: Refer to Standard for Parking
Structures NFPA 88A - latest revision or the
Code for Motor Fuel Dispensing Facilities and
Repair Garages, NFPA 30A - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code CSA B149.1 - latest revision.
• Heaters must not be installed less than 8'
(2.4 m) above the floor. Minimum clearances to
combustibles must be maintained from vehicles
parked below the heater.
• When installed over hoists, minimum
clearances to combustibles must be maintained
from the upper most point of objects on the hoist.
4.4 Electrical
The heater must be electrically grounded in
accordance with the following codes:
United States: Refer to National Electrical Code
NFPA 70 - latest revision. Wiring must conform
to the most current National Electrical Code
local ordinances and any special diagrams
furnished.
Canada: Refer to Canadian Electrical Code,
CSA C22.1 Part 1 - latest revision.
4.5 Venting
The venting must be installed in accordance with
the requirements within this manual and the
following codes:
United States: Refer to National Fuel Gas Code
NFPA 54/ANSI Z223.1 - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code CSA B149.1 - latest revision.
®
,
®
,
8
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).
SECTION 5: MAJOR COMPONENTS
Burner
Tube
Hot rolled, heat treated or
coated aluminized tube
supplied in 10' (3 m) lengths.
45° Elbow
90° Elbow
End Vent
Coupling Assembly
with Lock
Flex Gas Line
with shut-off cock
Combustion Chamber
Tee
Reflector
(Aluminum or
Stainless Steel)
Alternate overlap as
shown on Page 22,
Section 7.4.3. Minimum
overlap is 6" (16 cm).
Reflector with Hole
(Aluminum or
Stainless Steel)
Alternate overlap as
shown on Page 22,
Section 7.4.3. Minimum
overlap is 6" (16 cm).
Tube Adapter
Cross
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
15, Figure 13.
FIGURE 12: Major Component Descriptions
Optional reflector configurations are shown on Page
5, Figure 3 through Page 7, Figure 11. Install
appropriate suspension hardware, beam clamps,
chain or rod at predetermined locations. Adjustments
of chain length will provide uniform pitch.
9
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Universal Shield with Holes
Reflector Joint
Reflector Side
Extension Bracket
Barrier Shield
Reflector Side Extension
Condensate
Valve
Assembly
Reflector End Cap
(Aluminum or Stainless
Steel)
Punch out center section to
accommodate tube.
S-Hook
Deco Grille
Turn b uc kl e
Protective Grille
Universal Shield
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
Bracket Assembly
FIGURE 10: Major Component Descriptions (Continued)
10
FIGURE 10: Major Component Descriptions (Continued)
DANGER
©
P/N 910080
01
w
w
w.r
g-inc.com
Printed
in the U.
S.A
Imp
rimé
aux Etats-Unis
DANGER
Electrical Shock Hazard
Disconnect electrical
power before servicing.
This appliance must be
connected to a properly
grounded electrical source.
Failure to follow these
instructions can result
in death or electrical shock.
Danger de Choc Électrique
Débrancher le courant
électrique avant toute
révision.
Cet appareil doit être
connecter à une source de
courant avec mise á terre.
Faute de suivre ces
instructions peut entraîner la
mort ou les choc électriques.
Roberts-Gordon
P.O. B
ox 44
Buffalo, NY 14240-0044
T
elephone
: 716.852.4400
Fax: 716.852.0854
T
oll Fre
e: 800.828.7450
ww
w.rg-inc.com
R
oberts-Gordon
76 Main Street W
est
Unit 10
Grim
sby, Ontario L3M 1R6
Canada
Telephone: 905.945.5403
Fax: 905.945.0511
Printed in U.S.A/Imprimé aux Etats-Unis P/N 9100800
5 Rev B
ROBERTS GORDON
®
UltraVac
Controller
Part Num
ber:
Numéro de la P
ièce:
©
ENCLOSED ENERGY
MANAGEMENT EQUIPMENT
58SB
Serial Number:
N
o. de Série:
Ratings: Input 120V AC, 25A Outputs 120V AC, 3A (8 total)
EP-100 Pump Package - 4" dia
For more information, refer to the EP-100
Installation, Operation and Service Manual
(P/N 127201NA).
EP-201 Pump Package - 4" dia
EP-203 Pump Package - 4" dia
For more information, refer to the EP-200
Series Installation, Operation and Service
Manual (P/N 127200NA).
EP-301 Pump Package - 4" dia
EP-301 Pump Package - 6" dia
EP-303 Pump Package - 4" dia
EP-303 Pump Package - 6" dia
For more information, refer to the
EP-300 Series Installation, Operation and
Service Manual (P/N 127202NA).
System Control
ROBERTS GORDON
®
ULTRAVAC™ Controller
ROBERTS GORDON
®
ULTRAVAC™
Adjustable Indoor Sensor
ROBERTS GORDON
®
ULTRAVAC™
Variable Fre quency Drive
SECTION 5: MAJOR COMPONENTS
11
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
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 44, Figure 27.
Table 2: Common CRV-Series Components
Part No. Description
Combustion Chambers
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
Part No. Description
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)
Part No. Description
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
Part No. Description
Venting Accessories
01324401 Outside Air Supply Takeoff, 4" (10 cm)
01326801 Outside Air Filter Housing
90707501 Air Supply Blower/Power Venter
91409601 Outside Air Flex Duct, 4" (10 cm)
(Box of 8 - 8' [2.4 m] sections)
Part No. Description
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
Part No. Description
Control Packages and Accessories
10001501 Water Resistant Sensor
02770002 System Control
ULTRAVAC™ Control Packages
URVCCM
ROBERTS GORDON
®
ULTRAVAC™ Central Controller
(with Modem Chip & Software) Includes:
URVSC
ROBERTS GORDON
®
ULTRAVAC™ Controller
10080142 Modem Chip
10080450 Comms Equalization Cable
10081501 Outdoor Sensor
10080410 PC Connection Cable Package
URVCCR
ROBERTS GORDON
®
ULTRAVAC™ Central Controller
(with RS-485 Converter & Software) Includes:
12
SECTION 5: MAJOR COMPONENTS
Part No. Description
URVSC
ROBERTS GORDON® ULTRAVAC™ Controller
10080142 Modem Chip
10080450 Comms Equalization Cable
10080430 RS-485 Converter with 9 V Power Supply
10081501 Outdoor Sensor
10080410 PC Connection Cable Package
URVCCL
ROBERTS GORDON
®
ULTRAVAC™ Central Controller
(with TCP/IP Communication Module & Software)
Includes:
URVSC
ROBERTS GORDON
®
ULTRAVAC™ Controller
10080142 Modem Chip
10080450 Comms Equalization Cable
10080440 TCP/IP Communication Module
10081501 Outdoor Sensor
10080410 PC Connection Cable Package
URVBNC
URVSC
Controller, ROBERTS GORDON
®
BACnet
Controller, ROBERTS GORDON® ULTRAVAC™,
®
ULTRAVAC™
1 Pump 3 Zones (Satellite Control)
Variable Frequency Drive Assemblies
VFD75115 VFD Assembly, .75 HP, 115 V, 1 Ø Input
VFD75230 VFD Assembly, .75 HP, 230 V, 1 Ø Input
VFD20230
VFD75115N4
VFD75230N4
VFD75460
VFD75460N4
VFD20230N4
VFD20460
VFD20460N4
VFD Assembly,
VFD Assembly,
VFD Assembly,
VFD Assembly, .75 HP, 460 V, 3 Ø Input
VFD Assembly, .75 HP, 460 V, 3 Ø Input, NEMA 4
VFD Assembly,
VFD Assembly, 2 HP, 460 V, 3 Ø Input
VFD Assembly, 2 HP, 460 V, 3 Ø Input, NEMA 4
2 HP, 230 V, 1 Ø Input
.75 HP, 115 V, 1 Ø Input, NEMA 4
.75 HP, 230 V, 1 Ø Input, NEMA 4
2 HP, 230 V, 1 Ø Input, NEMA 4
ULTRAVAC™ Accessories
10080142 Modem, Plug-In Chip
10080410 Cable Package, PC Connection
10080430 RS-485 Converter with 9V Power Supply
10080440 TCP/IP Communication Module
10081500
Sensor, Adjustable Indoor, Deg F, ROBERTS GORDON
ULTRAVAC™ Controller
10081501 Sensor, Outdoor, ULTRAVAC™
10081502 Sensor, Adjustable Indoor, Deg C, ULTRAVAC™
Part No. Description
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
Part No. Description
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)
Part No. Description
Protective Grille
08050001 Protective Grille, 40" (1 m)
08050002 Protective Grille End Cap
Part No. Description
Shields
02750303 Barrier Shield
02751801 Universal Shield
027518SS Universal Shield, Stainless Steel
02751800 Universal Shield with Holes
Part No. Description
Pump Packages and Accessories
02719105 EP-100 Pump Package
02719100 EP-100 Pump
02724700 Accessory Package
02716305 EP-201 Pump Package
01312001 EP-201 Pump
01317805 Accessory Package
02712034 EP-203 Pump Package
01312002 EP-203 Pump
01317805 Accessory Package
02723014 EP-301 Pump Package 4"
02730101 EP-301 Pump Assembly
02730104 Accessory Package
02723016 EP-301 Pump Package 6"
02730101 EP-301 Pump Assembly
02730106 Accessory Package
02723034 EP-303 Pump Package 4"
02730103 EP-303 Pump Assembly
02730104 Accessory Package
02723036 EP-303 Pump Package 6"
02730103 EP-303 Pump Assembly
02730106 Accessory Package
®
Part No. Description
Pump Accessories
90430600K Pressure Switch
01327001 Condensate Check Valve Assembly
02718851 Drain Cap, 4" (10 cm)
02718852 Drain Cap, 6" (15 cm)
Part No. Description
Contactors
10050011 Contactor, 120 Vac for EP-203, EP-303, 3 Ø
EP-100, EP-201 208/230 V, 1 Ø
EP-301 208/230 V, 1 Ø
10050012 Contactor, 120 Vac for EP-301, 120 V, 1 Ø
There are references in this manual to various trademarks. All
trademarks mentioned herein, whether registered or not, are the
property of their respective owners. Roberts-Gordon is not
sponsored by or affiliated with any of the trademark or registered
trademark owners, and make no representations about them,
their owners, their products or services.
Roberts-Gordon LLC is not sponsored by or affiliated with
BACnet®.
13
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 6: DESIGN REQUIREMENTS
The CRV-Series system’s design is related to the
system operation and performance required by the
building being heated. Every effort should be made
to follow the dimensions on the layout drawing. If
deviations are necessary, either contact the
company responsible for the layout design, your
ROBERTS GORDON
®
independent distributor,
or consult the CRV-Series Design Manual
(P/N 127500NA).
14
FIGURE 13: Heater Assembly Overview
End
Vent
Combustion
Chamber
Tu be &
Reflector
Hanger
Burner
Reflector
Tu be
Coupling
Reflector
End Cap
Reflector
Support
Flexible
Boot
Reflector
with Hole
Pump
Exhaust
to Outside
Pressure Switch
S
Zone 1 Sensor or Thermostat**
Relay*
System Control
or ROBERTS GORDON
®
ULTRAVAC
™
Controller
U-Clips
* May not be needed with certain pumps and controllers. Refer to wiring diagram in the appropriate
controller's Installation, Operation and Service Manual for details.
**System Control requires thermostats. ROBERTS GORDON
®
ULTRAVAC
™
requires zone sensors
and additional control equipment. See the appropriate controller installation manual for details.
DANGER
©
P
/N
9
1
0
08
0
0
1
w
w
w
.
rg
-in
c
.c
o
m
P
r
in
te
d
in
th
e
U
.S
.A
I
m
p
rim
é
au
x
Et
ats
-U
n
is
DANGER
Electrical Shock Hazard
Disconnect electrical
power before servicing.
This appliance must be
co
nnected to a properly
groun
ded electrical source.
Failure to follow
these
instructions can res
ult
in de
ath or electrical shock.
D
anger de Choc Électrique
Débran
cher le courant
électrique avant toute
révision
.
Cet appareil doit être
connecter à une source de
co
urant avec m
ise á terre
.
Faute de suivre ces
instructions peut entraîner la
m
ort ou
les choc éle
ctriqu
es.
R
o
b
er
ts
-G
o
r
d
o
n
P
.O
. B
o
x
4
4
B
u
ff
a
lo
,
N
Y
1
4
2
4
0
-0
0
4
4
T
e
le
p
h
o
n
e
:
7
1
6
.8
5
2
.4
4
0
0
F
a
x
:
7
1
6
.8
5
2
.0
8
5
4
T
o
ll
F
r
e
e
: 80
0
.8
2
8
.
7
4
5
0
w
w
w
.r
g
-
in
c
.c
o
m
R
o
be
rt
s-G
or
do
n
7
6 M
a
in
Stre
et W
est
U
nit
10
G
rim
s
by, O
nta
ri
o L3
M
1
R
6
C
an
ad
a
Tele
ph
on
e
: 9
05
.9
45
.54
03
Fax: 90
5.9
45.0
51
1
P
ri
n
te
d
in
U
.S
.A
/Im
p
r
im
é
a
u
x
E
ta
ts
-U
n
is
P
/N
9
1
0
0
80
0
5
R
e
v
B
ROBERTS GORDON
®
UltraVac
Controller
P
a
r
t N
u
m
b
e
r
:
N
u
m
é
r
o
d
e
la
P
iè
c
e
:
©
E
N
C
L
O
S
E
D
E
N
E
R
G
Y
M
A
N
A
G
E
M
E
N
T
E
Q
U
I
P
M
E
N
T
5
8
S
B
S
e
r
ia
l N
u
m
be
r
:
N
o
. d
e
S
é
r
ie
:
R
a
t
in
g
s
: I
n
p
u
t
1
2
0
V
A
C
,
25
A
O
u
tp
u
t
s
1
2
0
V
A
C
, 3
A
(
8
to
ta
l
)
SECTION 6: DESIGN REQUIREMENTS
15
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Severe Injury Hazard
Secure burner to combustion chamber with
nuts and lockwashers.
Hang heater with materials with a minimum
working load of 75 lbs (33 kg).
Failure to follow these instructions can result
in death, injury or property damage.
WARNING
Cut/Pinch Hazard
Wear protective gear during installation,
operation and service.
Edges are sharp.
Failure to follow these instructions can result
in injury.
SECTION 7: HEATER INSTALLATION
Expansion and contraction of the tube dictates that
the minimum suspension lengths must be
maintained.See table on Page 17, Figure 14.
To ensure your safety and comply with the terms of
the warranty, all units must be installed in
accordance with these instructions.
The gas or the electrical supply lines must not be
used to support the heater.
Do not locate the gas or electric supply lines directly
over the path of the flue products from the heater.
The heater must be installed in a location that 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
on Page 17, Figure 14.
16
FIGURE 14: Critical Hanger Placement
Side View Towards Pump
Typical Suspension Details
Turnbuckle
Rod 3/8"
Beam Clamp
Concrete Beam
Wood Beam
Washers
Locknut
Screw Hook
3/8"
24" min.
(61 cm)
"X" (See Table)
Locknut
(Typical)
Anchor
Hanger
Front View
S-Hook
Turnbuckle
Reflector
7'6" (2.3 m)
Chain size
3/16" minimum
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)
SECTION 7: HEATER I NSTALLATION
17
CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Combustion
Chamber
7' 6"
(229 cm)
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.
10'
maximum
(3 m)
End View
Weld
Seam
Bottom
of Tube
Hanger
Turnbuckles
Tube
Description Part Number
Tube 91409XXX
Turnbuckle 91903201
Tube/Reflector Hanger 03090100
Tube
Tube
Orient coupling so that
the impact block is in the
2:00 or 10:00 oclock
positions.
Closed
Open
Tab
3" (8 cm) to
4" (10 cm)
Slide Bar/Coupling Lock
Coupling
Wide End
Coupling
Tube
Slide Bar/Coupling Lock
A
Close coupling with tab.
B
Start slide bar/coupling lock
onto coupling.
C
Insert tubes into coupling.
D
Tighten coupling to join tubes.
Description Part Number
Coupling 01329600
Slide Bar/Coupling Lock 01329700
Tube 91409XXX
Step 7.1 Tube Installation
Step 7.2 Coupling and Tube Assembly
18
Loading...