Roberts Gorden CRV-B-6 User Manual

WARNING

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

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

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

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

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

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.

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

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

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.

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.

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

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

FIGURE 3: STANDARD REFLECTOR

Model 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)

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

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 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

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 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

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.

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.

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)

DANGER

P/N 910080

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

w.rg-inc.com

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:

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

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:

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®.

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).

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

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

-in

rim

ats

-U

DANGER

Electrical Shock Hazard

Disconnect electrical

power before servicing.

This appliance must be

nnected to a properly

groun

ded electrical source.

Failure to follow

these

instructions can res

ult

in de

ath or electrical shock.

anger de Choc Électrique

Débran

cher le courant

électrique avant toute

révision

Cet appareil doit être

connecter à une source de

urant avec m

ise á terre

Faute de suivre ces

instructions peut entraîner la

ort ou

les choc éle

ctriqu

es.

-G

. B

-0

: 80

s-G

6 M

Stre

et W

est

nit

10 G

rim

by, O

nta

o L3

Tele

: 9

.54

Fax: 90

5.9

45.0

/Im

-U

ROBERTS GORDON

UltraVac



Controller

t N

iè

l N

. d

: I

, 3

(

)

SECTION 6: DESIGN REQUIREMENTS

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.

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

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

Orient coupling so that

the impact block is in the

2:00 or 10:00 oclock

positions.

Closed

Open

Tab

3" (8 cm) to 4" (10 cm)

Slide Bar/Coupling Lock

Coupling

Wide End

Coupling

Tube

Slide Bar/Coupling Lock

Close coupling with tab.

Start slide bar/coupling lock onto coupling.

Insert tubes into coupling.

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

Step 7.2.1 Coupling and Tube Assembly (Continued)

Incorrect slide bar

position

Correct slide bar

dimensions

± 2" (5 cm)

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

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

Tighten slide bar as shown below.

Tube

90° Elbow

Coupling

Description Part Number Elbow Package 02718702

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

Minimum Distance Required Between 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)

Tube

Coupling

7.3 Elbow Package Configuration Step 7.3.1 Elbow Installation

SECTION 7: HEATER I NSTALLATION

Step 7.3.2 Elbow Installation

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Tube

Hanger

Combustion

Chamber

Slide Reflector

with hole

through hanger. Unhook combustion chamber from chain

and insert through hole.

Reconnect chain.

Reflector with Hole

Description Part Number

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

Step 7.4 Reflector Installation

WARNING

Fire Hazard

Support reflector with reflector hanger and support strap.

Reflector must not touch tube.

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

Step 7.4.1 Reflector Installation with Hole

Step 7.4.2 Reflector Installation

Reflector

Wire Form

Tube

Reflector Support

Strap

Sheet Metal

Screw

U-Clip

(2 Clips per

Alternate Overlaps

per Side)

Description Part Number

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

SECTION 7: HEATER I NSTALLATION

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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.

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.

Reflector End Cap

U-Clips

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

(16 cm)

Overlap must be a

minimum of 6" (16 cm)

First Reflector

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

2 A

Slip Overlap

Reflector

Support

2 B

Slip Overlap

Reflector

Tight

Screws

3 B

Non-Slip Overlap

U-Clip

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

Reflector

3 A

Non-Slip Overlap

Wire Form

Reflector Support

Strap

Tight

Sheet Metal

Screw

Description Part Number Reflector Support Package 03050 010

Wire Form 91908004 Reflector Support Strap 03050000

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

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

Step 7.5 Burner Installation

Gasket

Burner

Combustion

Chamber

End

Vent

NOTE:

Install end vent at end combustion chamber position only.

Burner

Combustion

Chamber

End Vent

End

Vent

Clips

Rating

Number

Description Part Number

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

SECTION 7: HEATER I NSTALLATION

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

Failure to follow these instructions can result in injury.

Tee

Tube

Coupling

Description Part Number

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

SECTION 8: OPTIONAL HEATER ACCESSORIES

Step 8.1 Tee Installation

Step 8.2 Reflector Joint

Reflector

Joint

Flatten Edge

1" (2.5 cm) Maximum

Scribe Contour

Cut away contour with tin snips.

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

Step 8.2.1 Reflector Joint Installation

SECTION 8: OPTIONAL H EATER ACCESSORIES

Step 8.2.2 Reflector Joint Installation

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Install reflector end cap.

Attach reflector joint with six #8 sheet metal screws.

Reflector

Reflector Joint

Step 8.2.3 Reflector Joint Detail

FIGURE 15: Reflector Joint Detail

8.3 Reflector Side Extension

Reflector Side

Extension Bracket

(2 per reflector)

Use additional supports

in high air movement

applications.

Tube and Reflector Hanger

Reflector

Tube

Reflector Support

Description Part Number Reflector Side Extension Package 02712700

Reflector Side Extension 01368000 Retainer Clips 02751200 Sheet Metal Screws 9 4118106

Order Separately

Reflector Side Extension Bracket 01329910

Retainer Clip (2 per Side)

Cut relief notches for supports and hangers.

Reflector Side Extension

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

Step 8.3.1 Bracket Installation

SECTION 8: OPTIONAL H EATER ACCESSORIES

Step 8.3.2 Side Reflector Installation

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Tube

Universal Shield

Bracket Assembly*

Hex Nut*

Shield Support Bracket*

Stud*

Tube and Reflector Support Assembly*

Flattened

Section

Standard Reflector

* Included in universal shield

support package.

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

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 6, Figure 6 through Page 6, Figure 8 for positions.

Reflector Support Strap Cut Relief Notch

Flatten Reflector Edges

Attach U-Clips

Tube and Reflector Hanger

Standard Reflector

Barrier Shield

Description Part Number

Barrier Shield 02750303 U-Clip Package 91107720

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.

8.4 Universal Shield

8.5 Barrier Shield

8.6 Two-Foot Decorative Grille Installation

Suspended Ceiling Frame

Heat Exchanger Tube

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

Reflector

Tube and Reflector Hanger

Description Part Number

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

Shield

Description Part Number

Deco Grille Shield 01365900

Step 8.6.1 Grille Installation

SECTION 8: OPTIONAL H EATER ACCESSORIES

Step 8.6.2 Frame Shield Installation

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Reflector Side Extension

Cut relief notches for tube and reflector hangers.

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.

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

6" (15 cm) Minimum

Insert screw here (see note).

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)

Description Part Number

Reflector Side Extension 01370412

Step 8.6.3 Reflector Side Extension Installation for Decorative Grilles

8.7 Protective Grille Installation

Silicone Cap

Grille Finger

Description Part Number

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

Pull outward

Grille

Grille End Cap

Grille

Grille End Cap

Reflector

Final Grille Section

40"

(101 cm)

Step 8.7.1 Silicone Cap Installation

Step 8.7.2 Grille End Cap Installation

SECTION 8: OPTIONAL H EATER ACCESSORIES

Step 8.7.3 Grille Installation

Bend up 90°

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Schedule 40 Steel Pipe

Cast-Iron Combustion

Chamber

Cast-Iron Adapter

End Vent Plate for

End Burner Only

Cast-Iron Adapter

Coupling

4" Tube

7' (2.13 m) Maximum

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.

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.

ROBERTS-GORDON

End Vent Plate for

End Burner Only

End Vent

Clips

Special Tube and Reflector Hanger

ROBERTS-GORDON

End Vent

Clips

CORAYVAC® Classic

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

WARNING

Severe Injury Hazard

Hang heater with materials with a minimum working load of 750 lbs. (340 kg).

Use special tube and reflector hangers when suspending the schedule 40 steel pipe system.

Schedule 40 steel pipe is heavy and will fall if not supported properly.

Distance between supports must be 7' (2.13 m) or less.

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

Description Part Number

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

Step 8.8 Classic Cast-Iron Components

SECTION 9: PUMP I NSTALLATION AND VEN TING

WARNING

Carbon Monoxide Hazard

Heaters installed unvented must be interlocked with sufficient building exhaust.

Heaters must be installed according to the installation manual.

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

WARNING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

Failure to follow these instructions can result in injury.

Wall

1" NPT threaded hole.

Use 1" x ¾" reducer.

(not supplied)

Must be connected to a drain system in accordance with local codes.

flow

Condensate

Valve

Assembly

3/4" female

36" (0.9 m)

Minimum

vertical drop

between pump

and condensate

valve assembly.

Copper or

galvanized pipe

between pump

and condensate

valve.

Description Part Number

Condensate Valve Assembly 01327001

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 16: EP-200 Condensate Valve Assembly

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

Combustion by-products contain a chemical known to the State of California to cause cancer and birth defects or other reproductive harm.

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

This heater must be vented in accordance with the rules contained in this manual and with the following national codes and any state, provincial or local codes which may apply:

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

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

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

Vent pipe must be sloped downward away from the pump ¼'' every 10' (3 m).

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

The vent shall not terminate less than 7

' (0.3 m) above grade level.

' (2.1 m)

above grade where located adjacent to public walkways.

9.2.3 Vertical Venting

See Page 35, Figure 17 for recommended vertical venting options.

9.2.4 Horizontal Venting

See Page 36, Figure 18 through Page 38, Figure 20 for recommended horizontal venting options.

9.2.5 Length Requirements

See Page 35, Figure 17 through Page 38, Figure 20 for recommended vent lengths and sizes.

Seal all pipe joints with high temperature silicone sealant in the vent pipe. Insulation and additional sealing measures will be required.

Optional heat exchanger lengths are considered as vent length for length determination.

Subtract 15' (4.6 m) of maximum allowed vent or outside air duct length per vent elbow if more than three are used.

Vent terminal must be installed at a height sufficient to prevent blockage by snow, and building materials protected from degradation by flue gases.

Secure all joints with #8 x 3/8 sheet metal screws.

Seal all joints with high temperature silicone sealant.

Vent terminal must be beyond any combustible overhang.

9.2.1 United States Requirements

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

Vent must terminate at least 4

' (1.2 m) horizontally from, or 1' (0.3 m) above any

' (0.9 m) above any

' (3.1 m).

' (1.2 m) below,

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

9.2.2 Canadian Requirements

The vent shall not terminate within 6

' (1.8 m) of a

mechanical air supply inlet to any building.

The vent shall not terminate within 3

' (0.9 m) of a

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

FIGURE 17: Vertical Venting Configuration

Approved

Vent Cap

Approved

Thimble

2' (0.6 m)

Minimum

Aluminized Tee

1" (2.5 cm)

P. V.C to drain

system in

accordance

with local

codes.

Drain Cap

Clamps

Flexible Boot

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

SECTION 9: PUMP I NSTALLATION AND VEN TING

Part Number Description Part Number Description

01330203 Tee, 4" (10 cm) Aluminized

01330204 Tee, 6" (15 cm) Aluminized

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

90505600 Wall Thimble, 4" (10 cm) T0100320 Elbow, 6" (15 cm) Aluminized 90°

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

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

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)

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

25' (8 m) and 3 Elbows Maximum

50' (15 m) and 3 Elbows Maximum

Bird

Screen

4" (10 cm) Single Wall Pipe

5" (12.5 cm) Single Wall Pipe

Vent Terminal Tjernlund VH1-4

Vent Terminal Tjernlund VH1-6

Approved Thimbles

5" to 4" Reducer

(12.5 cm to 10 cm)

6" to 5" Reducer

(15 cm to 12.5 cm)

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

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

4" (10 cm) Band Clamp

9.3 Horizontal Venting 4" (10 cm) Pipe FIGURE 18: EP-100 Horizontal Venting Configurations

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 19: EP-200 Series Horizontal Venting Configurations

10' (3 m) Maximum and No Elbows

25' (8 m) and 3 Elbows Maximum

50' (15 m) and 3 Elbows Maximum

4" (10 cm) Single Wall Pipe

5" (12.5 cm) Single Wall Pipe

6" (15 cm) Single Wall Pipe

Bird

Screen

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

Vent Terminal Tjernlund VH1-6

Approved Thimbles

Vent Terminal Tjernlund VH1-4

4" (10 cm) Vent Terminal

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

5" to 4" Reducer

(12.5 cm to 10 cm)

6" to 5" Reducer

(15 cm to 12.5 cm)

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

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

4" (10 cm) Band Clamp

SECTION 9: PUMP I NSTALLATION AND VEN TING

Part Number Description Part Number Description

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

01331900 Damper Coupling, 4" (10 cm) 91409420 Tube, Aluminized 6" (15 cm) dia. 10' (3 m)

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

01365400 Bird Screen, 4" (10 cm)

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

02718851 4" Drain Cap

90502100 Vent Terminal, 4" (10 cm) (Combustible Wall) Not Supplied Tube, Aluminized 5" (12.7 cm) dia. 10' (3 m)

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

90505600 Wall Thimble, 4" (10 cm)

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 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.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

10' (3 m) Maximum and 1 Elbow

Approved

Thimble

Vent Terminal

Tjernlund VH1-

6" (15 cm)

or Equivalent

(Not Included)

6" (15 cm)

Bird Screen

(Included)

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

10' (3 m) Maximum and 1 Elbow

6" (15 cm)

Band Clamp

Single Wall Pipe/Tube 6" (15 cm)

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

FIGURE 20: EP-300 Series Horizontal Venting Configurations

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

CAUTION

Product Damage Hazard

Do not use heater in area containing corrosive chemicals.

Refer to appropriate Material Safety Data Sheets (MSDS).

Failure to follow these instructions can result in product damage.

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

10.1 Pressurized

See Page 42, Figure 25 for a typical layout of a pressurized air supply system. For pressurized outside air supplies, the outside air blower motor has a pressure switch that must be

sed. Wire this switch in series with the pump

pressure switch. When using an outside air blower

with a ROBERTS GORDON

ROBERTS GORDON

ULTRAVAC™ control or relay transformer, a separate load relay package is required. Wire the control for the relay in parallel with the pump. The outside air blower must have a separate 20 A, 120 V power supply. See Page 41, Figure 23 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 21. To prevent condensation, insulate the outside air duct.

System Control or

SECTION 10: OUTSIDE A IR SUPPLY

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Outside Air System Design Requirements:

Blower Performance (90707501): 112 F low Uni ts

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)

- Elbo

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

MOTOR

BLK

WHT

T1 T3T2

BLU BLU

BLOWER

PRESSURE

SWITCH

The outside air blower is shipped with the blower manufacturer’s standard internal wiring. For use with ROBERTS GORDON

heaters, the outside air blower must be rewired with existing wires by the electrical contractor. See diagram.

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

FIGURE 21: Duct Sizing

10.3 Outside Air Blower Internal Wiring FIGURE 22: Outside Air Blower Internal Wiring Diagram

FIGURE 23: Filter Housing Assembly

4" (10 cm)

Air Flex Duct

Wing Nut

Filter Housing

Filter

Top Gasket

and Disk

Bottom Gasket

Door-Control

Housing

Filter

Support

Clamp

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

Wall

Outside

Air Supply

Blower

Outside

Wall

5" (12.5 cm)

Inlet Pipe

5" (12.5 cm)

Outlet Pipe

Bird

Screen

Vent

Cap

Description Part Number

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

SECTION 10: OUTSIDE A IR SUPPLY

FIGURE 24: Air Supply Blower Support

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Outside

Wall

Burner

Sheet Metal

or PVC

Outside

Air Supply

Blower

Clamp

4" (10 cm)

Take Off

4" (10 cm)

Air Flex Duct

Filter

Housing

Vent Cap or

Bird Screen

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

Vent Cap

Outside Wall

7/16" (11.1 mm) Diameter Hole

Pressure Switch

Lock Nuts

6' (1.8 m)

Maximum

Bird Screen

Description Part Number

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

FIGURE 25: Pressurized Outside Air Supply

FIGURE 26: Non-Pressurized Outside Air Supply

SECTION 11: GAS PIPING

WARNING

Explosion Hazard

Leak test all components of gas piping before operation.

Gas can leak if piping is not installed properly.

Do not high pressure test gas piping with equipment connected.

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

WARNING

Fire Hazard

Tighten gas hose fittings to connect gas supply according to Figure 27.

SECTION 11: GAS P IPING

There is an expansion of the tube with each firing cycle. This will cause the burner to move with respect to the gas hose. This can cause a gas leak resulting in an unsafe condition if the gas connection is not made in strict accordance with Figure 27. Meter and service must be large enough to handle all the burners being installed plus any other connected load. The gas hose which feeds the system must be large enough to supply the required gas with a maximum pressure drop of 1/2" wc. When gas piping is not included in the layout drawing, the local gas supplier will u

sually help in planning the gas piping.

Gas hose can crack when twisted.

Gas hose moves during normal operation.

Use only 36" (91 cm) long connector of 1/2" or 3/4" nominal ID.

Connector supplied with heater for U.S. models (not with Canadian models).

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

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

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

Install the gas hose as shown on Page 44, Figure 27. The gas hose accommodates expansion of the heating system and allows for easy installation and service of the burner. Before connecting the burners to the supply system, verify that all high pressure testing of the gas piping has been completed.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Shut-Off Valve (included with gas hose) must be parallel to burner gas inlet. The 3" (8 cm)

displacement shown is for the cold condition. This displacement may reduce when the system is fired.

CORRECT POSITIONS

Horizontal

45°

End View

Vertical

(as shown left)

Alternate positions okay

Flexible Gas Hose

36" (91 cm) length

3" (8 cm) max. displacement

Side View

Heater Movement

12"

(30 cm)

CAUTION

Product Damage Hazard

Hold gas nipple securely with pipe wrench when attaching gas hose.

Failure to follow these instructions can result in product damage.

Description Part Number

1/2" Flexible Stainless Steel Gas Hose (US Models) 91412200 3/4" Flexible Stainless Steel Gas Hose (US Models) 91412204 1/2" Rubber (Type 1) Gas Hose (Canadian Models) 91412206 3/4" Rubber (Type 1) Gas Hose (Canadian Models) 91412207

INCORRECT POSITIONS (WRONG INSTALLATION)

Heater Movement

Heater Movement Heater Movement

FIGURE 27: Gas Connection with Flexible Gas Hose

SECTION 12: CONTROL METHODS

DANGER

Electrical Shock Hazard

Disconnect electric before service or maintenance.

More than one disconnect switch may be required to disconnect electric to the unit.

Control must be properly grounded to an electrical source.

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

WARNING

Explosion Hazard

Turn off gas supply to heater before service.

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

SECTION 12: CONTROL METHODS

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

System Control

designed to control CRV-Series heating systems. The System Control wiring is shown on Page 50, Figure 31 through Page 52, Figure 34 and in the System Control Installation Manual (P/N 10091601NA). The System Control can be used to control an EP100 or EP-201 pump from the control panel. Other pumps such as the EP-301 and 3 Ø models may be controlled in conjunction with a relay or motor starter. The System Control can control up to four zones of burners. The electrical circuit is a 120 Vac (20 A) supply. The output for the thermostat is 24 Vac. A System Control operated system has two minutes

post purge pump operation to completely exhaust products of combustion from the system. A system control provides indication of power to the pump and zones and indicates the status of the pressure switch with lights. The System Control is ETL listed in accordance with UL873 – Standard for Temperature Indicating and Regulating Equipment.

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.

Buildings today demand all sorts of control options based on the user’s preference. ULTRAVAC™ controls offer a host of communication options for integration with controls’ networks to best serve individual needs:

BACnet

: Interface ULTRAVAC™ with other building

management control platforms with our BACnet option. TCP/IP (LAN): Connect to ULTRAVAC™ via your local area network of computers. Load ULTRAVAC™ software onto any computer on the network and control and view your heating system from your computer. MODEM: Dial into ULTRAVAC™ from anywhere in the world via modem. Supplied as standard on all central controllers! RS-485: Hard wire ULTRAVAC™ directly to your computer.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

12.3 SPST Transformer Relay (P/N 90417600K)

The transformer relay wiring diagram is shown on Page 47, Figure 28. The transformer relay can be

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

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

12.4 DPST Transformer Relay (P/N 90436300)

The transformer relay wiring diagram is shown on Page 49, Figure 30. The transformer relay can be

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

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

FIGURE 28: One Zone Operation without Control Panel

COIL COIL

Thermostat

Pump Motor

Pressure

Switch

(Pump)

SPST (12A) Transformer

Relay

Zone 1

Burners

Nine Burners Maximum

Black

White

Red

Black

120 V

1 Ø

60 Hz

Ground

Description Part Number

SPST Transformer Relay 90417600K

SECTION 12: CONTROL METHODS

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

COIL COIL

Thermostat

Pump Motor

Pressure

Switch

(Pump)

SPST (12 A) Transformer

Relay

Zone 1

Burners

Nine Burners Maximum

Black

White

Red

Black

120 V

1 Ø

60 Hz

Ground

Pressure Switch

(Outside Air Blower)

Outside Air

Blower

FIGURE 29: One Zone Operation (with Outside Air Blower) without Control Panel

FIGURE 30: Two Zone Operation without Control Panel

COIL

Pump Motor

Pressure

Switch

(Pump)

Transformer

Relay

Zone 1

Burners

Zone 2

Burners

LNLN

Nine Burners Total

Maximum Between Zones

DPST (12 A) Transformer

Relay

Zone 1

Thermostat

Zone 2

Thermostat

Purple Red

Red

Black

Black Black

Black

Red/Yellow

Red/YellowWhite

White

DPST (12 A)

120 V

1 Ø

60 Hz

Purple

Description Part Number

DPST Transformer Relay 90436300

SECTION 12: CONTROL METHODS

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Burner Receptacles 4 Zone Max

120 Vac

Maximum 20 Amps Total

Thermostats

Pump Motor 115 Vac Operation (230 Vac Operation separate power circuit required for EP-203 or EP-300 series pumps)

Pressure Switch

Dotted Line Optional

Motor Starter

Pump 2

Pressure Switch 2

120 V

1 Ø

60 Hz

System Control

R R R R PS 2PS 124 VAC

COM

24 VAC COM

PS 1 PS 2WWWW

24 VAC

120 V 1 Ø 60 Hz

Ground

GLN

120 V 1 Ø 60 Hz

PUMP 2PUMP 1POWER

SUPPLY

Z3 Z4

NLL

All burners must be connected to Ground (Not shown)

Zone 1

Zone 2 Zone 3 Zone 4

EP-100 or

EP-201 Pump

EP-100 or

EP-201 Pump

TWO PUMP SYSTEM (optional) Pump 1 may be used for all zones. Pump 2 may be used to control zone 3 and/or zone 4.

Low voltage thermostats

located in heated zone

Zone1Zone

Zone

Pressure switch located at Pump 2

Pressure switch located at Pump 1

FIGURE 31: General System Wiring

FIGURE 32: External Wiring Diagram EP-100 and EP-201 120 V 1 Ø Pump

FIGURE 33: External Wiring Diagram EP-100, EP-201 or EP-301 230 V 1 Ø Pump

System Control

R R R R PS 2PS 124 VAC

COM

24 VAC COM

PS 1 PS 2WWWW

24 VAC

120 V 1 Ø 60 Hz

Ground

GLN

120 V 1 Ø 60 Hz

PUMP 2PUMP 1

POWER SUPPLY

Z3 Z4

NLL

All burners must be connected to Ground (Not shown)

Zone 1

Zone 2 Zone 3 Zone 4

TWO PUMP SYSTEM (optional) Pump 1 may be used for all zones. Pump 2 may be used to control zone 3 and/or zone 4. Refer to Pump 1 for configuration.

Low voltage thermostats

located in heated zone

Zone1Zone

Zone

Pressure switch located at Pump 2

Pressure switch located at Pump 1

208 - 230 V 1 Ø 60 Hz

Individual supply for pump rated for total full load current. See Pump Specifications Section for details.

EP-100, EP-201 or EP-301Pump

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

Motor Contactors P/N 10050011 P/N 10050012

EP-100, EP-201 or EP-301Pump

CAUTION

Product Damage Hazard

Do not directly connect control relay terminals to pump motor

Failure to follow these instructions can result in product damage.

SECTION 12: CONTROL METHODS

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

System Control

R R R R PS 2PS 124 VAC

COM

24 VAC COM

PS 1 PS 2WWWW

24 VAC

120 V 1 Ø 60 Hz

Ground

GLN

120 V 1 Ø 60 Hz

PUMP 2PUMP 1

POWER SUPPLY

Z3 Z4

NLL

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

208 - 230 V (or 460 V) 3 Ø 60 Hz

Individual supply for pump rated for total full load current. See Pump Specification Section for details.

EP-203 or

EP- 303 3 Ø Pump

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

TWO PUMP SYSTEM (optional) Pump 1 may be used for all zones. Pump 2 may be used to control zone 3 and/or zone 4. Refer to Pump 1 for configuration.

Motor Contactors P/N 10050011 P/N 10050012

Low voltage thermostats

located in heated zone

Zone1Zone

Zone

Pressure switch located at Pump 2

Pressure switch located at Pump 1

FIGURE 34: External Wiring Diagram EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø Pump

CAUTION

Product Damage Hazard

Do not directly connect control relay terminals to pump motor

Failure to follow these instructions can result in product damage.

FIGURE 35: Burner Internal Wiring

TRANSFORMER

VALVE

GAS

120 V

Power Supply

Yellow

Brown

Green

White

Black

BURNER

IGNITION

MODULE

Black

Blue

Yellow

V2/GND

Green

Gap

TRANSFORMER

Black

White

Blue

Yellow

Brown

ELECTRODE

GAS VALVE

Gnd

S1 V1

Black

Yellow

IGNITION MODULE

SECTION 12: CONTROL METHODS

FIGURE 36: Burner Internal Ladder Diagram

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.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

WARNING

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

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

Explosion Hazard

Leak test all components of gas piping before operation.

Gas can leak if piping is not installed properly.

Do not high pressure test gas piping with equipment connected.

DANGER

Electrical Shock Hazard

Disconnect electric before service.

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

Heater must be connected to a properly grounded electrical source.

Carbon Monoxide Hazard

Heaters installed unvented must be interlocked with sufficient building exhaust.

Heaters must be installed according to the installation manual.

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'' wc (1/2 PSIG).

4. Close the main gas valve.

13.2 Checking the Electrical System

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

2. Turn on power supply to system controls.

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

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

mp immediately.

5. Make a preliminary vacuum check at burners in branches that have an adjustable damper coupling. See Page 56, Figure 37 for manome- ter hookup to check vacuum. This check is to insure that all dampers are open before the system is fired. Vacuum, as measured at the end vents, should be approximately 3.5'' wc or slightly above (cold).

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

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

1. S t ar t with all temperature setpoints below room temperature.

2. Open main gas valve.

3. T

urn up temperature setpoints one zone at a time, waiting to see that all burners in a zone start. When the burner ignites, a blue flame will be observed through the viewer window.

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

13.4 Setting the Vacuum

1. Se t te m p e r at ure setpoints above room temperature. See that all burners are operating properly.

2. Allow at least ½ hour operation for temperature to normalize, then check system vacuum bal- ance. Vacuum can be measured by inserting a manometer hose into the end vent as shown on Page 56, Figure 37. Normal end vent vacuum should

be set at approximately 2.5'' wc to 3.0'' wc (hot). Vacuum adjustments are made by means of the damper in the pump inlet and the adjustable damper coupling(s) in the system. Check the vacuum at all end vents and then adjust the damper coupling to obtain equal vacuum readings of

2.5'' wc to 3.0'' wc

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

2.5'' wc to

3.0'' wc With systems designed to operate at maximum

vacuum, it may not be possible to obtain vacuum differential readings at or slightly above

2.5'' 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.

SECTION 13: STARTING THE S YSTEM

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Insert tubing

about 6" (15 cm).

Combustion Chamber

at end position

End Vent

Manometer

Approximate reading after

adjusting damper couplings and

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

FIGURE 37: Vacuum Reading

SECTION 14: OPERATION AND MAINTENANCE

SECTION 14: OPERATION AND M AINTENANCE

DANGER

Electrical Shock Hazard

Disconnect electric before service.

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

Heater must be connected to a properly grounded electrical source.

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

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

Explosion Hazard

Turn off gas supply to heater before service.

WARNING

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

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

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

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 continue operation for a post-purge period of two minutes.

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

5. A reset is accomplished by removing power from the module for at least 5 seconds

System Control, or ROBERTS

ULTRAVACTM, the pump will

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 u Turn ON main gas valve. Turn ON electric power. Set thermostat to desired temperature. Burner should light automatically.

14.4 Pre-Season Maintenance and Annual Inspection

To e n sure your safety and years of trouble-free operation of the heating system, service and annual inspections must be done by a contractor qualified in the installation and service of gas-fired heating equipment. Turn off gas and electric supplies before performing service or maintenance. Allow heater to cool before servicing. Before every heating season, a contractor qualified in the installation and service of gas-fired heating equipment must perform a thorough safety

nburned gases to vent from heater.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

inspection of the heater. For best performance, the gas, electrical, thermostat connections, tubing, venting, suspensions and overall heater condition should be thoroughly inspected. NOTE: Gas flow and burner ignition are among the first things that should be inspected. Please see Page 58, Section 14.5 for suggested items to inspect.

14.5 Maintenance Checklist Installation Code and Annual Inspections:

All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts-Gordon 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 conduct, at a minimum, annual inspections of your ROBERTS GORDON

equipment and perform service where necessary, using only replacement parts sold and supplied by Roberts-Gordon.

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 4, 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 4, Section 3.

Reflector Support reflector with reflector hanger and support strap.

Reflector must not touch tube.

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

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

Make sure reflectors are correctly overlapped. See Page 22, Figure 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 d

ust.

Remove any carbon deposits or scale using a wire brush. See Page 33, Section 9.

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

sealed areas or corrosion.

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

Tubes Make sure there are no cracks.

Make sure tubes are connected and suspended securely.

See Page 17, Figure 14 through Page 19, Section 7.2.1.

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

Clean or replace as required.

SECTION 14: OPERATION AND M AINTENANCE

Gas Line Check for gas leaks. See Page 44, Figure 27. Combustion Chamber

Window

Blower Scroll, Wheel and

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

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

Motor Burner Head and Orifice Clear of obstructions. (Even spider webs will cause problems).

Carefully remove any dust and debris from the burner.

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

of the electrode.

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

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

See Page 45, Section 12.

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

or ceiling.

See Page 17, Figure 14.

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 29, Section 8.6.1 through Page 31, Section 8.7.3

Make sure shield is installed correctly and secured in place if necessary. (Decorative grille only.) See Page 29, Section 8.6.2

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

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

With the Power off:

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

Check boots for cracking or deterioration and replace if necessary.

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

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

Check the condition and operation of the pressure switch.

Wall Tag If wall tag is present, make sure it is legible and accurate. Please contact

Roberts-Gordon LLC or your ROBERTS GORDON

independent distributor,

if you need a wall tag. See Page 3, Section 2.1.

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

DANGER

Electrical Shock Hazard

Disconnect electric before service.

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

Heater must be properly grounded to an electrical source.

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

Fire Hazard

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

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

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

WARNING

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

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

Explosion Hazard

Turn off gas supply to heater before service.

SECTION 15: TROUBLESHOOTING

15.1 Troubleshooting Flow Chart

Wrong end vent plate may

be installed. Make sure plate

and burner match.

Is the vacuum setting

too high?

Ye s

Adjust system for proper

vacuum at the end vent.

Is the pump impeller

obstructed?

Motor bearings may have

failed. Replace motor.

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

minutes for automatic reset.

Disconnect power to the

motor. Does the motor

turn freely?

Is the motor hot?

Ye s

Replace burner transformer.

Replace ignition module.

Is there 24 V at the burner

transformer secondary (blue

and yellow wires)?

Ye s

Tro u bleshoot Ends

Pre-purge. Wait 45 seconds.

Do the burners light?

Check LED on module and

refer to LED codes below.

Ye s

Correct gas problem.

Check wiring to the burner.

Make sure the burner is

plugged in.

Check thermostat wiring and

replace thermostat if

necessary.

Do all the burners

ignite smoothly?

Ye s

Check circuit breaker and/or

fuse on panel supply circuit.

Refer to control

panels listed below.

Does pump turn on?

Ye s

Is there power (120 V)

to the control?

(panel or relay)

Ye s

START

Check for proper vacuum

at end vent.

Unplug the burner, wait 10

seconds, then plug it in

again. Does the ignition

module begin ignition

sequence by sparking?

Is there proper gas pressure

and flow to the burners?

Ye s

Is there power (120 V) at

the burner receptacle?

Ye s

Refer to control

panel list.

Ye s

Refer to control panel

manuals list.

Is there power to the zone?

After 45 seconds pre-purge

period, do the burners

light?

Turn up thermostat.

Does the pump turn on?

Ye s

Module Diagnostic Codes:

LED Problem Solution

4 second steady

flash at start of cycle Normal Wait for valve to open

Steady on Microprocessor failure Replace module

within module

Three flashes Ignition lockout Recycle unit: check for

Lockout of module spark and valve opening and

after 3 tries replace:if none, replace module

SECTION 15: TROUBLESHOOTING

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Replace filters as necessary.

Replace the electrodes.

Adjust the gap or

replace the electrode.

Ignition module may have

failed. Replace module.

Electrode gap should be

1/8". Is the gap too small?

Yes

Inspect the electrodes on the

affected burners. Are they

burned or damaged?

Yes

Couplings may be installed

improperly. Lined couplings

should be used for tailpipe.

Refer to control

panel manuals

listed below.

Make sure that all

thermostats or internal

sensors are satisfied.

Do burners shut off after the

call for heat is satisfied?

Check for blockage in the

outside air supply or for

leaks in the system.

Replace filters as necessary.

Are the filters on the

burners dirty?

Consult wiring instructions in

pump manuals listed below

for reversal instructions.

Is the rotation of the

pump motor correct?

Adjust system for proper

vacuum at the end vent.

Is the vacuum setting

too low?

Is the flame low?

Are the filters on the

burners dirty?

Is the rotation of the

pump motor correct?

Adjust system for proper

vacuum at the end vent.

Follow burner check

procedure given above.

Are there any "dead"

burners in a branch?

Is the vacuum setting

too low?

Is the system leaking water?

Do the burners lockout

intermittently?

Yes

Make sure that all

thermostats or internal

sensors are satisfied.

Does the pump shut down

after a 2 minute post-purge

period?

TROUBLESHOOT ENDS.

If problems persist, contact

your

ROBERTS GORDON

Independent Distributor.

Refer to control

panel manuals

listed below.

Contact

Roberts-Gordon LLC

at www.rg-inc.com

Consult wiring instructions in

pump manuals listed below

for reversal instructions.

Control Panel IOS Manuals:

- System Control P/N: 10091601NA

- ROBERTS GORDON

ULTRAVAC™ P/N: 10081601NA

- For systems with no control panel, refer

to appropriate control manufacturers instructions.

Pump IOS Manuals:

- EP-100 P/N: 127201NA

- EP-200 P/N: 127200NA

- EP-300 P/N: 127202NA

Yes

YesYes

Yes

Troubleshooting Flow Chart

SECTION 16: REPLACEMENT PARTS

Carbon Monoxide Hazard

WARNING

Use only genuine ROBERTS GORDON® replacement parts per this installation, operation and service manual.

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

Explosion Hazard

DANGER

Electrical Shock Hazard

Fire Hazard

SECTION 16: REPLACEMENT P ARTS

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Gasket (Burner to Mixing Chamber)

Ignition Module

Mixing Chamber

Burner Head

Regulator

Electrode

Electrode Gasket

Combustion

Chamber

Gasket

Gas Valve

Transformer

Ignition Cable

Description Part Number

Gas Valve (All Burners) 90032502 Gasket (Burner to Mixing Chamber) 01351100 Burner Head Assembly Replacement Package (includes electrode and gasket installed) 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 90439500K Ignition Cable 90427706 Filter Cartridge with Gasket (not shown) 01312401

SECTION 17: GENERAL SPECIFICATIONS

Reflector

Length "A"

20"

(51 cm)

10"

(24.4 cm)

6 1/2"

(16 cm)

10 3/4"

(27 cm)

(10 cm)

6 7/8"

(17 cm)

3 1/2"

(9 cm)

7 5/8"

(19 cm)

14 1/4"

(36 cm)

9 1/2"

(24 cm)

5/32"

(.4 cm)

Heat Input Rate 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)

17.1 Material Specifications

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 17, Figure 14.

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:

SECTION 17: GENERAL S PECIFICATIONS

*See Page 4, 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" wc Minimum 14.0" wc Maximum LP Gas: 10.5

ELECTRICAL RATING:

120 V - 60 Hz, 0.3 A

" wc Minimum 14.0" wc Maximum

CRV-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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

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

General Specifications for pumps are as follows:

* 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

SECTION 18: THE ROBERTS GORDON® CORAYVAC® LIMITED W ARRANTY

SECTION 18: THE ROBERTS GORDON

CORAYVAC® LIMITED WARRANTY

ROBERTS-GORDON LLC WILL PAY FOR:

Within 36 months from date of purchase by buyer or 42 months from date of shipment by Roberts-Gordon LLC (whichever occurs first), replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect.

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

ROBERTS GORDON chamber of the ROBERTS GORDON

warrants the cast iron combustion

CORAYVAC® Classic System will be free from defects in material and workmanship. This warranty is limited to twenty-five (25) years from the date of shipment by Roberts-Gordon LLC. All other components of the ROBERTS GORDON

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

ROBERTS GORDON

Replacement Parts are warranted for a period of 12 months from date of shipment from Roberts-Gordon LLC or the remaining ROBERTS GORDON

CORAYVAC® warranty.

ROBERTS-GORDON LLC WILL NOT PAY FOR:

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

been paid. Damage due to:

• Improper installation, operation or maintenance.

• Misuse, abuse, neglect, or modification of the

ROBERTS GORDON

• Use of the ROBERTS GORDON

CORAYVAC® in any way.

CORAYVAC®

for other than its intended purpose.

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

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

• Failure to install or maintain the ROBERTS

GORDON

CORAYVAC® as directed in the

Installation, Operation and Service Manual.

• Relocation of the ROBERTS GORDON

CORAYVAC

after initial installation

• The use of the ROBERTS GORDON

CORAYVAC

in a corrosive atmosphere

containing contaminants.

• The use of the ROBERTS GORDON

CORAYVAC

in the vicinity of a combustible or

explosive material.

• Any defect in the ROBERTS GORDON

CORAYVAC

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

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

WARRANTY IS VOID IF:

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

Yo u cannot prove original purchase date and required annual maintenance history.

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

The ownership of the ROBERTS GORDON

CORAYVAC®

is moved or transferred. This warranty is nontransferable. Roberts-Gordon LLC is not permitted to inspect the

damaged equipment and/or component parts.

READ YOUR INSTALLATION, OPERATION AND SERVICE MANUAL

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

Roberts-Gordon LLC

1250 William Street P. O . B o x 4 4 Buffalo, New York 14240-0044

716.852.4400

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

Roberts-Gordon LLC's liability, and your exclusive remedy, under this warranty or any implied warranty (including the implied warranties of merchantability and fitness for a particular purpose) is limited to providing replacement parts during the term of this warranty. Some jurisdictions do not allow limitations on

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

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

CORAYVAC®. Some

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

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

LIMITATIONS ON AUTHORITY OF REPRESENTATIVES:

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

OWNER WARRANTY REGISTRATION CARD

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):

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______________

Mail or Fax to:

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

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

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

contractor qualiﬁed in the installation and service of equipment sold and supplied by Roberts-Gordon LLC and conform to all requirements set forth in the ROBERTS GORDON

manuals and all applicable governmental authorities pertaining to the

installation, service and operation of the equipment.

To help facilitate optimum performance and safety, Roberts-Gordon LLC recommends that a qualiﬁed contractor conduct, at a minimum, annual inspections of your ROBERTS GORDON

equipment and perform service where necessary, using only

replacement parts sold and supplied by Roberts-Gordon LLC.

These products are not for residential use.

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

herein my be reproduced or copied in any form or by any means – graphic, electronic, or mechanical, including photcopying, recording, taping, or information storage and retrieval systems – without written permission of Roberts Gordon LLC. Printed in

the U.S.A.

Infrared Heating

Maintain clearance

to the side and

clearance below

the heater from vehicles

and combustible materials.

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

Attach this information to a wall near the ROBERTS GORDON

heater.

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.

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.

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

FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER

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.

TO TURN OFF THE HEATER

Service Telephone: +44 (0)121 506 7709 Service Fax: +44 (0)121 506 7702 E-mail: uksales@rg-inc.com E-mail: export@rg-inc.com

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

WARNING

Roberts-Gordon Europe Limited

Unit A, Kings Hill Business Park Darlaston Road, Wednesbury West Midlands WS10 7SH UK Telephone: +44 (0)121 506 7700 Fax: +44 (0)121 506 7701

Installation Code and Annual Inspections:

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

manuals and all applicable governmental authorities pertaining to the installation, service and operation of the equipment. To help

facilitate optimum performance and safety, Roberts-Gordon recommends that a qualiﬁed contractor conduct, at a minimum, annual inspections of your ROBERTS GORDON

equipment and

perform service where necessary, using only replacement parts sold and supplied by Roberts-Gordon.

Further Information: Applications, engineering and detailed guidance on systems design, installation and equipment performance is available through ROBERTS GORDON® representatives. Please contact us for any further information you may require, including the Installation, Operation and Service Manual.

This product is not for residential use.

© 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 s

ystems – without written permission of Roberts-Gordon LLC.

Roberts Gorden CRV-B-6 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual