Roberts Gorden EP-203, EP-200 User Manual

EP-200 Series

Pump

Installation,
Operation &

Service Manual

WARNING

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

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

Quality in Any Language™

© Copyright 2004 Roberts-Gordon

Installer

Please take the time to read and understand

these instructions prior to any installation.

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

Owner

Keep this manual in a safe place in order to provide

your serviceman with necessary information.

Roberts-Gordon

1250 William Street
P. O . Bo x 4 4
Buffalo, New York 14240-0044
Telephone: [phone]
Fax: [phone]
Toll Free: 800.828.7450

www.rg-inc.com

Roberts-Gordon

76 Main Street West, Unit 10
Grimsby, Ontario, L3M 1R6
Canada
Telephone: [phone]
Fax: [phone]

P/N 127200NA Rev. F 12/04

TABLE OF CONTENTS

SECTION 1: Heating System Safety ............................1

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

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

2.1 Corrosive Chemicals...........................................2

2.2 National Standards and Applicable Codes .........2

SECTION 3: Unpacking the Pump ...............................2

3.1 Open Shipping Cartons ......................................2

SECTION 4: Major Components ..................................3

4.1 Standard Parts List .............................................4

SECTION 5: Pump Installation .....................................6

5.1 Pump Assembly Instructions ..............................6

5.2 Pump Suspension ..............................................9

5.3 Condensate Trap and Condensate Tee ............11

SECTION 6: Motor Wiring...........................................12

6.1 Prior to Operation .............................................12

SECTION 7: Venting....................................................13

7.1 General Venting Requirements.........................13

7.2 Venting the Pump .............................................13

7.3 Horizontal Venting ............................................13

7.4 Vertical Venting.................................................15

SECTION 8: Servicing Instructions ...........................16

8.1 Pre-Season Maintenance and

Annual Inspection .............................................16

8.2 To Change the Motor and/or the Impeller.........16

8.3 Maintenance Checklist .....................................17

SECTION 9: Replacement Parts and Accessories...18

9.1 Replacement Parts ...........................................18

9.2 Accessories ......................................................18

SECTION 10: Specifications.......................................19

SECTION 11: The ROBERTS GORDON

SERIES PUMP Limited Warranty .......21

®

EP-200

© 2004

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.

Printed in U.S.A.

TABLE OF FIGURES

Figure 1: Major Component Descriptions .......................3

Figure 2: Pump Discharge Orientation /

Impeller Rotation Direction ..............................6

Figure 3: Pump Assembly ...............................................7

Figure 4: Motor Shaft Seal Assembly..............................8

Figure 5: Wall Bracket Assembly ....................................9

Figure 6: Wall Mounting Angle Assembly........................9

Figure 7: Wall Mounting ................................................10

Figure 8: Mounting Platform Assembly .........................10

Figure 9: Condensate Check Valve...............................11

Figure 10: Condensate Tee - Discharge Side ...............11

Figure 11: EP-201 Motor Wiring ...................................12

Figure 12: EP-203 Motor Wiring ...................................12

Figure 13: Side Wall Venting .........................................14

Figure 14: Vertical Venting ............................................15

SECTION 1: HEATING SYSTEM SAFETY

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

ing the warnings in these sections.
Installation, Service and Annual Inspection of heater
and pump 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 heating system 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 electrical wiring, venting, etc., must be thor­oughly understood before proceeding with the instal­lation.

SECTION 1: HEATING SYSTEM S AFETY

Thin sheet metal parts, such as the various venting
components, have sharp edges. To prevent injury,
the use of work gloves is recommended.

Do not attempt to operate the pump until all steps of
the installation have been accomplished.

1.1 Manpower Requirements

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

1

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 2: INSTALLER RESPONSIBILITY

The installer is responsible for the following:

• To install the pump and electrical supplies, in
accordance with applicable specifications and
codes. Roberts-Gordon recommends the installer
contact a local building inspector or Fire Marshal
for guidance.

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

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

• To plan location of supports.

• To provide access to pump for servicing on all
sides and for pump removal.

• To provide the owner with a copy of this installa­tion, operation and service manual.

• To never use pump or pump platform as support

for ladder or other access equipment and never
hang or suspend anything from pump or pump
platform.

• To safely and adequately install pump using

materials with a minimal working load of 400 lb
(181 kg).

2.1 Corrosive Chemicals

of these compounds is suspected. Warranty will be invalid if the
heater is exposed to halogenated hydrocarbons.

2.2 National Standards and Applicable Codes

All Appliances must be installed in accordance with
the latest revision of the applicable standards and
national codes. This refers also to the electric, gas
and venting installation. Note: Additional standards
for installations in Public Garages, Aircraft Hangars,
etc. may be applicable.

SECTION 3: UNPACKING THE PUMP

3.1 Open Shipping Cartons

Open cartons and remove packing inserts. Carefully
remove pump components from the cartons. Lift
assembly by gripping metal pump frame. Two people
are required (weight 112 lb, 51 kg). This pump has
been tested prior to packing. The impeller was
dynamically balanced before assembly and requires
care in handling to avoid damage.

WARNING

CAUTION

Do not use heater and pump in an area containing

corrosive chemicals.

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

Failure to follow these instructions can result in
property damage.

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

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

Severe Injury Hazard

Install pump scr oll and inlet assembly before operating
high speed rotating impeller.

Keep hands, fingers and clothing away from inlet and
outlet.

Install and operate equipment according to installation
manual.

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

2

SECTION 4: MAJOR COMPONENTS

SECTION 4: MAJOR COMPONENTS
FIGURE 1: Major Component Descriptions

EP-201 Pump Assembly - 01312001
EP-203 Pump Assembly - 01312002

Inlet Plate Assembly - 01327400

Pump Scroll Assembly - 01394400

Pump Boot 4" (10 cm) - 91412800

Band Clamp 4" (10 cm) - 91901300

Mounting Angle - 01365000

Bird Screen 4" (10 cm) - 01365400

Pressure Switch - 90430600

3

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

4.1 Standard Parts List
Table 1: EP-201 Pump Package (P/N 02716305)

Part No. Description Quantity

Box 1 of 2

01312001 EP-201 Pump Assembly 1

127102NA

CORAYVAC

Box 2 of 2

01311700 EP-200 Series Accessory Package 1

91901300 Band Clamp, 4" 4

92113900 Hex Nut 6

93413912 Bolt (5/16" -18" x 3/4") 6

94273914 Bolt (5/16" -18" x 7/8") 16

95211600 Flat Washer (5/16") 28

96411600 Lockwasher (5/16") 6

01327400 Inlet Plate Assembly 1

01365400 Bird Screen, 4" 1

01365000 Mounting Angle 6

01394400 Pump Scroll 1

02757500 Motor Shaft Seal 1

90430600 Pressure Switch 1

91406940 Pump Gaskets 4

91412801 Pump Boot 2

91906900 Silicone Rubber Ring 2

127200NA EP-200 Series Installation, Operation and Service Manual 1

®

Installation, Operation and Service Manual

1

4

SECTION 4: MAJOR C OMPONENTS

Table 2: EP-203 Pump Package (P/N 02712034)

Part No. Description Quantity

Box 1 of 2

01312002 EP-203 Pump Assembly 1

127102NA

CORAYVAC

Box 2 of 2

01311700 EP-200 Series Accessory Package 1

91901300 Band Clamp, 4" 4

92113900 Hex Nut 6

93413912 Bolt (5/16" -18" x 3/4") 6

94273914 Bolt (5/16" -18" x 7/8") 16

95211600 Flat Washer (5/16") 28

96411600 Lockwasher (5/16") 6

01327400 Inlet Plate Assembly 1

01365400 Bird Screen, 4" 1

01365000 Mounting Angle 6

01394400 Pump Scroll 1

02757500 Motor Shaft Seal 1

90430600 Pressure Switch 1

91406940 Pump Gaskets 4

91412801 Pump Boot 2

91906900 Silicone Rubber Ring 2

127200NA EP-200 Series Installation, Operation and Service Manual 1

®

Installation, Operation and Service Manual

1

5

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 5: PUMP INSTALLATION

5.1 Pump Assembly Instructions

5.1.1 Determine Orientation of Pump Discharge

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

The pump must be installed in a location that it is
readily accessible for servicing.

5.1.2 Attaching Pump Scroll

After determining the correct orientation of the pump
scroll outlet, attach the pump scroll to the pump
frame as follows:

• Place Flat Washer (P/N 95211600), on the 5/16"
x 7/8" Screw (P/N 94273914).

An arrow is affixed to the outside of the pump scroll
to indicate the direction of rotation of the impeller.
The standard rotation of the impeller is in the coun­terclockwise direction.

Pump discharge orientation and impeller rotation
direction is viewed from the rear of the motor as
shown in on Page 6, Figure 2. Note that the pump
scroll outlet must always be positioned at the bottom
horizontal position.

FIGURE 2: Pump Discharge Orientation /
Impeller Rotation Direction

Counterclockwise Rotation

(Standard)

OUTLET

• From the motor side of the vertical mounting plate
of the pump frame, insert the 5/16" x 7/8" screws.

• Install two pieces of the gasket material on the
exposed thread ends of the mounting screws.
Make sure the ends of the opposing gasket seg­ments interlock to form a complete circular
gasket.

• Carefully position the pump scroll against the ver­tical mounting plate of the pump frame; align and
loosely install the 5/16" x 7/8" screws into the cor­responding mounting holes in the pump scroll.

• While tightening the screws that secure the pump
scroll to the motor frame, periodically spin the
impeller to be sure that adequete clearance is
maintained between the impeller blades and the
body of the pump scroll.

6

Arrow showing direction of rotation
(located on front of scroll housing)

Clockwise Rotation

OUTLET

FIGURE 3: Pump Assembly

SECTION 5: PUMP INSTALLATION

5/16 x 7/8" Screws (w/flat washers) - 16 Req'd.

Pump Scroll

Rubber
Mounts

Impeller

Description Part Number

Pressure Switch 90430600
Pump Scroll 01394400
Rubber Mounts 91906100
Impeller 01394602

Pressure Switch

1/8 NPT

Inlet Plate Assembly

Gasket (2 pieces)

Description Part Number

Inlet Plate Assembly Kit 01327400

Gaskets (2) 91406940
Inlet Plate 01327400
Accessory Bag (8 bolts, 8 flat washers) 01311702

1" NPT

Partial End View

5.1.3 Attaching the Inlet Plate Assembly

Following installation of the pump scroll to the pump
frame, attach the inlet plate assembly to the pump
scroll as follows:

• Place flat washer on the 5/16" x 7/8" screw.

• Position a single section of the gasket against the
face of the pump scroll; align the clearance holes
of the gasket with the mounting holes of the pump
scroll. Loosely install one 5/16" x 7/8" screw
through the gasket segment and into the top cen­ter mounting hole of the pump scroll to support
the gasket.

• Interlock the remaining gasket segment to the
previously installed gasket segment to complete
the circular gasket.

• Orient the inlet plate assembly as shown. The
1/8" NPT plug should face directly up, and the 1"
NPT plug should face directly downward. Care­fully position the top center mounting notch of the
inlet plate assembly to engage the mounting
screw positioned
previously.

and into the corresponding mounting holes in the
pump scroll.

• Tighten screws to complete installation of the inlet
plate assembly.

• Install pressure switch in 1/8" NPT hole in top of
outlet.

• Install the seven remaining 5/16" x 7/8" screws
through the notches in the inlet plate assembly

7

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 4: Motor Shaft Seal Assembly

Motor Shaft Seal

Pump Frame

EP-201 Motor

or

EP-203 Motor

Description Part Number

EP-201 Motor 90604500
EP-203 Motor 90604501
Motor Shaft Seal 02757500
Pump Scroll 01394400
Impeller 01394602
Inlet Plate Assembly 01327400
Pressure Switch 90430600

5.1.4 Install Motor Shaft Seal

• Separate the motor shaft seal at the pre-cut score
line.

Pump Scroll

Impeller

Pressure Switch

Inlet Plate Assembly

Motor Shaft Hub

• Wrap the shaft seal around the motor shaft hub
as shown on Page 8, Figure 4.

• Secure the shaft seal in position with the adhe­sive strip provided.

8

5.2 Pump Suspension

WARNING

Suspension Hazard

Mount pump with materials
with a minimum working
load of 400 lbs (181 kg).

Failure of the supports can

result in death, injury
or property damage.

5.2.1 Wall Mounting Angle Assembly

FIGURE 5: Wall Bracket Assembly

NOTE: Typical assembly shown.

Two (2) assemblies per
each pump required.

SECTION 5: PUMP INSTALLATION

The standard method of mounting the EP-200 pump
is on an outside wall and venting directly through the
wall.

The pump may be mounted by using mounting
angles as shown in Figure 5. The two mounting
angles form a mounting platform to which the pump
will be attached.

Attach the mounting frame to the wall using anchors.
Select an anchor that will give equal to or greater
than 2000 lb ultimate pull-out strength.

Lockwasher

Flat Washer

Hex Nut

Mounting
Angle

Description Part Number

Mounting Angle 01365000
Hex Bolt 5/16" x 3/4" 93413912
Flat Washer 95211600
Lockwasher 96411600
Hex Nut 92113900

FIGURE 6: Wall Mounting Angle Assembly

11.5"

(292 mm)

Flat Washer

Hex Bolt

7"

(178 mm)

9

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 7: Wall Mounting

5/8" (16 mm)

Diameter

Mounting Holes

7"

(178 mm)

10" (254mm)

3.9" (99 mm)

7"

(178 mm)

4.5" x 8" (114 x 203mm)
Boot with Spacer

4" (102 mm)

8.5"

(216mm)

Pressure

Switch

5-6"

(127-152 mm)

Silicone Rubber Ring

(Install on 4" (102 mm) Tube)

Tube

Thimble

(if applicable)

5.2.2 Mounting Platform (Optional Platform Assembly)

If mounting on an outside wall is not practical, it may
be mounted on a platform suspended from the
ceiling, or for noise reduction, in an enclosure.

FIGURE 8: Mounting Platform Assembly

4.5" X 8" (114 x 203mm)
Boot with Spacer

5-6"

(127-152mm)

3.25" (83mm)

11.5"

(292mm)

7"- 8"

(178-203mm)

Mounting

Angle

Assembly

(Standard)

Mounting
Angle (4)

11.5" or 7"

(292 mm or

178 mm)

Flat Washer

Lockwasher

Hex Head Bolt

Hex Nut

Flat Washer

10

FIGURE 9: Condensate Check Valve

SECTION 5: PUMP INSTALLATION

1" NPT threaded hole.

Use 1" x ¾" reducer.

3/4" female

Condensate

Valve

Assembly

3/4" female

(not supplied)

Copper or

galvanized pipe

between pump

and condensate

valve.

flow

Wall

Description Part Number

Condensate Valve Assembly 01327001

36" Minimum

vertical drop

between pump

and condensate

valve assembly.

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

FIGURE 10: Condensate Tee - Discharge Side

Flex Boot

5.3 Condensate Trap and Condensate Tee

The condensate trap assembly (optional) (P/N

01327001), should be installed on the inlet side of
the EP-200 Series pump assembly, See Page 11,
Figure 9.

It is possible to eliminate the condensate trap assem­bly on the pump if the one-inch threaded hole is
plugged. This arrangement will permit drainage of
condensate through the pump and outside via hori­zontal (pitched) discharge line.

4"(100 mm)

Minimum

Tee

Approved

Drain Cap

Thimble

(if applicable)

1"(25 mm)

P.V.C

The condensate trap assembly in the discharge line
can be eliminated if the discharge line is horizontal
through the wall and pitched down at least one inch
per foot. A condensate trap on the discharge side is
required if there is a vertical rise in the discharge
line.

11

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 6: MOTOR WIRING

WARNING

Electrical Shock Hazard

Disconnect electrical power and gas supply before
servicing.

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

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

All wiring must comply with current wiring regulations
and any local regulations which may apply. Always
switch off the supply and disconnect before servicing.

FIGURE 11: EP-201 Motor Wiring

6.1 Prior to Operation

Prior to operation of the pump in the heating system,
operation and proper rotation of the impeller must be
verified.

IMPORTANT: Improper rotation of the impeller will
not produce the vacuum required for proper system
operation.

The EP-201 motor must be wired for clockwise or

counterclockwise rotation as shown on Page 12, Fig-
ure 11.

The EP-201 motor is wired for 1 Ø, 120 V, 60 Hz
operation. The EP-201 motor can be rewired for 230 V
operation by changing the motor connections as
indicated by the diagram on the motor connection box
cover.

Wire the pressure switch per the CORAYVAC
127102NA), VANTAGE

®

EV (P/N 151100NA) or appro-

®

(P/N

piate controller installation manual.

EP-201 Motor

115V Power Supply

To reverse rotation,
interchange black
and red leads.

O

r

a

n

g

e

R

e

B

d

r

o

w

n

Motor Junction Box

Y

Ground

Screw

c

a

l

B

/

w

o

l

l

e

c

a

k

l

B

Y

e

l

l

o

w

W

h

i

t

e

B

r

o

w

n

/

W

B

r

o

w

n

/

W

h

(Control Panel or Relay)

k

h

i

t

e

i

t

e

Line

Neutral

Motor

Interlock

(Not Used)

The EP-203 motor can be wired for 3 Ø, 208 V - 230 V, 60 Hz or 3 Ø, 460 V, 60 Hz operation.
The EP-203 motor rotation direction can be changed by interchanging any two leads.
Wire the pressure switch per the CORAYVAC

®

(P/N 127102NA), VANTAGE

®

EV (P/N 151100NA) or appropiate

controller installation manual.

FIGURE 12: EP-203 Motor Wiring

12

SECTION 7: VENTING

WARNING

Carbon Monoxide Hazard

Pump must be vented to the

outside.

Heaters must be installed
according to the installation
manual.

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

7.1 General Venting Requirements

Install the venting in accordance with the require­ments within this manual and the National Fuel Gas
Code, ANSI Z223.1/NFPA-54 - latest revision and
CSA 22.1 - latest revision. This section provides par­tial information about this specification with regard to
size and configuration for venting requirements (see
following figures). However, to provide assurance of
proper and safe operation, it is the responsibility of
the installer to make sure the installation is in strict
accordance with all local and national codes.

7.2 Venting the Pump

• The exhaust connection from the pump is 4.5"
(11 cm) diameter.

• Connect one of the flexible isolation boots pro­vided to the 4" (10 cm) flue pipe, using the sili­cone rubber ring provided.

• Connections to flue pipe larger than 4" (10 cm)
require use of an appropriate "taper pattern
reducer" (not supplied).

• Venting from the pump may discharge either hori­zontally or vertically. Horizontal discharge is
preferred. See Page 14, Figure 13. Vertical dis-
charge must be arranged as shown on Page 15,
Figure 14. Corrosion resistant pipe is required.

• Both horizontal and vertical venting must be sup­ported by suitable hangers.

• Vent lengths are allowed as follows:

VENT LENGTH VENT SIZE

Up To 10' (3 m) 4" (10 cm) vent - 1 elbow

Up To 25' (8 m) 5" (12.5 cm) vent - 3 elbow

Up To 50' (15 m) 6" (15 cm) vent - 3 elbow

SECTION 7: VENTING

7.3 Horizontal Venting

The vent material must be either porcelain coated
tubing 4" (10 cm) O.D. (P/N 9141030D), heat treated
aluminized tubing 4" (10 cm) O.D. (P/N 91409408),
heat treated aluminized tubing 6"(15 cm) O.D. (P/N
E0009105) or single wall flue pipe minimum 26 Ga.
Vent length be limited to less than 30' (9 m). If using
vent lengths greater than 30' (9 m), condensation will
form in the vent pipe. Insulation and additional seal­ing measures will be required.

7.3.1 Horizontal Venting Guidelines

• Vent must exit building not less than 7' (2 m)
above grade when located adjacent to public
walkways.

• Vent must terminate at least 3' (1 m) above any
forced air inlet located within 10' (3 m).

• Vent must terminate at least 4' (1.2 m) below 4'
(1.2 m) horizontally from or 12" (30 cm) above
any door, window or gravity air inlet into building.

• Locate vent terminal at least 12" (30 cm) from any
opening through which vent gases could enter a
building.

• Use only corrosion resistant materials for the
discharge line from the pump to the point of
discharge.

• Vent terminal opening must extend beyond any
combustible overhang.

• Install vent terminal at a height sufficient to pre­vent blockage by snow.

• Protect building materials from degradation by
flue gases.

• Any portion of flue pipe passing through a com­bustible wall must be dual insulated and an
approved thimble must be used.

7.3.2 Side Wall Venting

Vent recommendations in order of preferred use:

1. Porcelain coated tubing 4" (10 cm) O.D. (P/N

9141030D)

2. Heat treated aluminized tubing 4" (10 cm) O.D.

(P/N 91409408)
Heat treated aluminized tubing 6" (15 cm) O.D.
(P/N E0009105)

3. Single wall flue pipe - minimum 26 ga.

13

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 13: Side Wall Venting

18" min.-40" max

46 cm min.-

101 cm max

Maximum and No Elbows

10' (3 m)

4" (10 cm) Single Wall Pipe/Tube

Approved Thimble

5" to 4" (12.7 to 10 cm) Reducer

5" (12.7 cm) Single Wall Pipe

25' (7.5 m) and 3 Elbows Maximum

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

6" (152mm) Single Wall Pipe

(If Applicable)

Bird Screen
(included w/

Pump

Package)

18" min.-40" max

46 cm min.-

101 cm max

4" (10 cm)

Vent Terminal

Tjernlund VH1-6"

(15 cm)

Vent Terminal

Tjernlund VH1-6"

(15 cm)

Vent Terminal

Tjernlund VH1-6"

(15 cm)

Vent Terminal

50' (15 m) and 3 Elbows Maximum

Description Part Number

4" (10 cm) Vent Terminal 02537801
Tjernlund VH1-6" (15 cm) Vent Terminal 90502100
Band Clamp 6" (15 cm) 91913703
Thimble 90505600

14

7.4 Vertical Venting

The vent material must be either porcelain coated
tubing 4" (10 cm) O.D. (P/N 9141030D), heat treated
aluminized tubing 4" (10 cm) O.D. (P/N 91409408),
heat treated aluminized tubing 6" (15 cm) O.D. (P/N
E0009105) or single wall flue pipe minimum 26 Ga.

FIGURE 14: Vertical Venting

Approved

Thimble

Silicone

Rubber Ring

(if applicable)

SECTION 7: VENTING

Condensation will form in the vent pipe. Insulation
and additional sealing measures may be required.
Length of flue pipe is equal to total of vertical and
horizontal length.

Approved
Vent Cap

2 feet

Minimum

Description Part Number

Tee 4" (10 cm) 01330203
Vent Cap 4" (10 cm) 90502300
Drain Cap 4" (10 cm) 02718851

Drain Cap

Tee

Approved

Thimble

(if applicable)

1"(2.5 cm)

P. V . C

15

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 8: SERVICING INSTRUCTIONS

WARNING

Severe Injury Hazard

Install pump scr oll and inlet assembly before operating
high speed rotating impeller.

Keep hands, fingers and clothing away from inlet and
outlet.

Install and operate equipment according to installation
manual.

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

WARNING

Before every heating season, a contractor qualified
in the installation and service of gas-fired heating
equipment must perform a thorough safety inspec­tion of the pump.

For safety and best performance, the electrical, vent­ing, suspensions and overall pump condition are
some of the areas requiring inspection.

Please see Page 17, Section 8.3 for suggested items
to inspect.

8.2 To Change the Motor and/or the Impeller

1. To remove the motor or impeller, the scroll must
be opened. Remove the (8) nuts/bolts and insert
a knife blade between the scroll halves to cut
through the factory applied sealant. Separate
the two halves.

2. The impeller can be removed by loosening the
(2) 3/8-24 set screws, removing the 10-32 screw
and retainer assembly. With an appropriate
wheel puller, remove the impeller.

Electrical Shock Hazard

Disconnect electrical power and gas supply before

servicing.

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

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

Disassembly and removal or replacement of any
pump components must be done by a service con­tractor or electrician qualified in the installation and
service of gas-fired heating equipment.

Overtorquing can result in a failure of components.

Failure to follow these instructions can compromise
pump operation and void warranty.

8.1 Pre-Season Maintenance and Annual
Inspection

3. The motor can now be removed, if necessary,
by loosening the attachment hardware.

4. Re-assembly of motor/impeller combination
require proper alignment. Make sure the impel­ler has a 1/4" (6 mm) clearance off the inside
wall of the scroll. Verify proper motor alignment
and free rotation.

5. The (2) impeller set screws should be removed
and reinstalled with a drop of thread locking
sealant and remain unseated during initial re­assembly.

6. Slide the impeller onto the motor shaft end.
Apply a drop of thread locking sealant to the
threads of the retainer screw/washer assembly.
Insert the retainer screw into the shaft so that it
bottoms on the end of the shaft and hub of the
impeller. Torque to 30 in/lb.

7. Seat the (2) impeller set screws. Torque to 100
in/lbs.

To ensure your safety and years of trouble-free oper­ation of the pump, service and annual inspections
must be done by a contractor qualified in the installa­tion and service of gas-fired heating equipment.

Disconnect electric and gas supplies before perform­ing service or maintenance.

16

8. Re-attach the scroll halves. Apply a bead of high
temperature silicone sealant (600°F) to the
scroll halves. Secure with all (7) nuts/bolts.
Torque to 150 in/lb.

8.3 Maintenance Checklist

SECTION 8: SERVICING I NSTRUCTIONS

Installation, Service and Annual Inspection of the pump must be done
by a contractor qualified in the installation and service of gas-fired heat­ing equipment.

Turn off the system and ensure power and gas supply is shut off before
servicing equipment.

Read this manual carefully before installation, operation, or service of
this equipment.

System Tubing and Vent
Pipe

Venting must be intact. Using a flashlight, look for obstructions, cracks on the
pipe, gaps in the sealed areas or corrosion.

The area must be free of dirt and dust or blockage.

Remove any carbon deposits or scale using a wire brush.

Replace pipe if there are any holes due to corrosion. Seal any gaps in venting
to prevent condensate leakage.

Pump Scroll, Impeller and
Motor

Compressed air or a vacuum cleaner may be used to clean dust and dirt.

Check for corrosion, if any parts have corroded through, replace as neces­sary.

Ensure all hex nuts are tight for proper seal.

Suspension Points Make sure the pump is hanging securely.

Look for signs of wear on the mounting angles, wall mounting points or ceiling
mounting points.

Pump Boot Inspect pump boot at pump inlet and outlet for cracking or deterioration.

Replace if cracks are found.

Ensure band clamps are tight at all connection points.

Condensate Trap, Drain
Cap

Check connection of tee to drain cap and between tee and condensate trap.

Seal connections between tee and drain cap to prevent condensate leakage.

Screw condensate trap tightly into drain cap or pump inlet assembly to pre­vent leakage.

Condensate trap should be filled with water.

Pressure Switch Ensure that wiring is intact.

17

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 9: REPLACEMENT PARTS AND ACCESSORIES
Use only genuine ROBERTS GORDON

®

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

Pump Scroll

Pressure Switch

Band Clamp

Pump Boot 4"

Inlet Plate Assembly

9.1 Replacement Parts

Description Part Number Description Part Number

EP-201 Motor 3/4 HP, 115 V, 1 Ø 90604500 Rubber Mounts 91906100
EP-203 Motor 3/4 HP
208 V - 230 V/ 460 V, 3 Ø
Impeller 01394602 4" (10 cm) Pump Boot 91412800
Boot Replacement Package 02771000 Mounting Angle 01365000
Pressure Switch 90430600 Inlet Plate Assembly Kit 01327401
Bird Screen w/ clamp 01312200 Gaskets (2) 91406940
Shaft Seal 02757500 Inlet Plate 01327400
Damper Assembly 01331900 Accessory Bag (8 bolts, 8 flat washers) 01311702

90604501 Pump Scroll 01394400

9.2 Accessories

Description Part Number Description Part Number

4" Plain Coupling 01312700 4" Aluminized 90° Elbow 01335801
6" Plain Coupling 01312706
4" Lined Coupling
4" Damper Coupling 01331900
4" Aluminized Tee 01330203 4" Aluminized Non Heat Treated 10’ Tube 91409403
6" Aluminized Tee 01330204
4" Coated Tee 0133022D 4" Coated 10’ Tube 9141030D
6" Coated Tee 0133025D
4" Aluminized Cross 01330903 6" Tube Hanger 91240010
4" Coated Cross 0133092D
4" (10 cm) Band Clamp 91901300 6" Drain Cap 02718852
6" (15 cm) Band Clamp 91913703 Condensate Trap 01327001

0131270I

6" Aluminized 90° Elbow T0100320
4" Coated 90° Elbow 0133580D
6" Coated 90° Elbow 0133660D

6" Aluminized Non Heat Treated 10’ Tube 91409420

Aluminized Tube adapter (6" dia. x 4" dia.) 91418200

4" Drain Cap 02718851

18

SECTION 10: SPECIFICATIONS

General Specifications

Pump Dimensional Data (in.)
Model ABCDEFG
EP-201
EP-203

17.75 17 20.25 3.25 10 4.5 4.5

SECTION 10: SPECIFICATIONS

A

G

D

B

C

F

dia.

E

Pump Specifications

Model EP-201 EP-203

Horsepower (Hp) 3/4 3/4

Phase (Ø)13

Hertz (Hz) 60 60

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

Full Load Amp (A) 6.6/3.3 2.4 - 2.2 / 1.1

R.P.M. 3450 3450

Motor Frame 56 56

Motor Enclosure TENV TEFC

Noise Level @ 5' (DBA) 70 N/A

Inlet/Outlet (In.) 4.5/4.5 4.5/4.5

Weight (lbs.) 112 112

19

EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL

20

SECTION 11: THE ROBERTS GORDON® EP-200 SERIES PUMP LIMITED WARRANTY

SECTION 11: THE ROBERTS GORDON

®

EP-200

SERIES PUMP LIMITED WARRANTY
ROBERTS-GORDON WILL PAY FOR:

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

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

®

ROBERTS GORDON

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

®

EP-200 Series Pump warranty.

ROBERTS-GORDON WILL NOT PAY FOR:

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

been paid.

Damage due to:

• Improper installation, operation or maintenance.

• Misuse, abuse, neglect, or modification of the
ROBERTS GORDON

®

EP-200 Series Pump in

any way.

®

• Use of the ROBERTS GORDON

EP-200 Series

Pump 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 GOR-

®

DON

EP-200 Series Pump as directed in the

Installation, Operation and Service manual.

®

• Relocation of the ROBERTS GORDON

EP-200

Series Pump after initial installation

®

• The use of the ROBERTS GORDON

EP-200
Series Pump in a corrosive atmosphere containing
contaminants.

®

• The use of the ROBERTS GORDON

EP-200
Series Pump in the vicinity of a combustible or
explosive material.

®

• Any defect in the ROBERTS GORDON

EP-200
Series Pump 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
installed by an contractor qualified in the installation and
service of gas-fired heating equipment.

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

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

®

EP-200 Series Pump is not

The ownership of the

ROBERTS GORDON

®

EP-200
Series Pump is moved or transferred. This warranty is
nontransferable.

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

READ YOUR INSTALLATION, OPERATION AND
SERVICE MANUAL

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

U.S.A.

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

716.852.4400

Canada

76 Main Street West, Unit 10
Grimsby, Ontario L3M 1R6

905.945.5403

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

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

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

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

ROBERTS GORDON

®

EP-200 Series Pump. Some

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

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

LIMITATIONS ON AUTHORITY OF
REPRESENTATIVES:

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

21