Roberts Gorden HP 120 V 1, HP 208 V 3, HP 230 V 1, HP 230 V 3, HP 460 V 3 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.
System Control
Installation, Operation &
Service Manual
© 2009 Roberts-Gordon LLC
Roberts-Gordon LLC
1250 William Street P.O . B o x 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
P/N 10091601NA Rev. H 04/09
© 2009
Roberts-Gordon LLC
All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping or information storage and retrieval systems - without the written permission of Roberts-Gordon LLC.
TABLE OF CONTENTS
SECTION 1: Introduction........................................................1
1.1 Safety ...........................................................................1
1.2 What is a ROBERTS GORDON
1.3 Electrical Requirements ............................................... 1
1.4 Check Installation Materials ......................................... 1
SECTION 2: Specifications ....................................................3
2.1 Material Specifications.................................................3
2.2 Electrical Specifications...............................................3
2.3 Pump Specifications ....................................................3
2.4 Burner Electrical Ratings .............................................4
2.5 Outside Air Supply Blower Electrical Ratings .............. 4
2.6 Indicator Lights ............................................................4
2.7 Terminal Block Guide................................................... 4
SECTION 3: Installation..........................................................5
3.1 Preparation .................................................................. 5
3.2 Installing the System Control Panel ............................. 5
3.3 Select the External Wiring Diagram for the
Installation.................................................................... 5
3.4 System Configuration...................................................6
SECTION 4: Typical External Wiring Diagrams .................... 7
4.1 EP-100 or EP-201 120 V 1 Ø Pump External
Wiring Diagram............................................................7
4.2 EP-201 or EP-301 230 V 1 Ø External
Wiring Diagram............................................................8
4.3 EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø Pump
External Wiring Diagram..............................................9
4.4 Outside Air Blower External Wiring Diagram ............. 10
SECTION 5: Troubleshooting............................................... 12
5.1 Sequence of Operation..............................................12
SECTION 6: Replacement Parts .......................................... 14
6.1 Replacement Parts Instructions................................. 15
SECTION 7: The ROBERTS GORDON
Warranty ........................................................... 17
®
System Control? ......1
®
System Control
Printed in U.S.A.
TABLE OF FIGURES
Figure 1: Panel Layout ..............................................................3
Figure 2: Terminal Block Guide.................................................4
Figure 3: Mounting Hole Layout ................................................5
Figure 4: System Configuration.................................................6
Figure 5: External Wiring Diagram ROBERTS GORDON
EP-100 and EP-201 120 V 1 Ø Pump ........................ 7
Figure 6: External Wiring Diagram ROBERTS GORDON®
EP-100, EP-201 or EP-301, 230 V 1 Ø Pump ............8
Figure 7: External Wiring Diagram ROBERTS GORDON
EP-203 or EP-303, 208 - 230 V (or 460 V)
3 Ø Pump...................................................................9
Figure 8: External Wiring Diagram ROBERTS GORDON
EP-100 or EP-201 120 V 1 Ø Pump with Outside
Air Blower ................................................................ 10
Figure 9: System Control Troubleshooting Chart .................... 13
Figure 10: System Control Internal Components Diagram...... 14
®
®
®
SECTION 1: INTRODUCTION
DANGER
Electrical Shock Hazard
Disconnect electric before service or maintenance.
Control must be connected to a properly grounded electrical source.
Failure to follow these instructions can result in death or electrical shock.
1. 1 S a f e ty
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.
Installation, service and annual inspection of controller must be done by an electrician qualified in the installation and service of control systems for heating equipment. Installation, service and annual inspection of heater must be done by a contractor qualified in the installation and service of gas or oil fired heating equipment.
Read this manual carefully before installation, operation, or service of this equipment.
For optimum heater performance and safe heating conditions, inspect and maintain heater(s) before every heating season as necessary. Also, know and maintain heater clearances to combustibles, see heater Installation, Operation and Service Manual for further details. If you require additional manuals, con­tact your ROBERTS GORDON
®
independent distrib­utor or Roberts-Gordon LLC at (716) 852-4400, (800) 828-7450 or online at www.rg-inc.com.
1.2 What is a ROBERTS GORDON Control?
The ROBERTS GORDON
®
System Control is an electronic controller designed for the control of CORAYVAC
®
and VANTAGE® NP (multiburner only)
systems.
The System Control is capable of giving four zones of burners' temperature control and power. The control will also give power output to as many as two pumps, provided that the load is not greater than 20 A and 1 Ø. For additional electrical specifications see Page 3, Section 2.2.
®
System
SECTION 1: INTRODUC TION
1.3 Electrical Requirements
Failure to comply with the installation instructions will invalidate the limited warranty set out on Page 17, Section 7.
The cable used for all wiring must be rated for 600 V.
The system control, burners, pump and outside air blower must be electrically grounded in accordance with the following:
United States: Refer to National Electrical Code
®
, NFPA 70 - latest revision. Wiring must conform to the most current National Electrical Code
®
, local ordi-
nances and any special diagrams furnished.
Canada: Refer to Canadian Electrical Code, CSA C22.1 Part 1 - latest revision.
1.4 Check Installation Materials
Before proceeding with the installation of the ROBERTS GORDON
®
System Control, check the fol-
lowing points:
1.4.1 Thermostats
Electronic 24 Vac thermostats and mechanical ther­mostats with heat anticipator can be used. The sys­tem control offers a 24 Vac power supply to power electronic thermostats. Roberts-Gordon offers a selection of low voltage thermostats approved for use with the system con- trol.
The thermostats measure the air temperature in the building. It is important that the thermostat is located in an area within the heated zone at occupant level. Do not place thermostat in an area shaded from the low-intensity, infrared heating system.
1
SYSTEM CONTROL INSTALLATI ON, OPERATION AND SERVICE MANUAL
CAUTION
Product Damage Hazard
Pressure switch must be installed on all ROBERTS GORDON
®
systems to ensure
safety and operation.
System will not operate without pressure switch.
Failure to follow these instructions can result in product damage.
1.4.2 Electrical Installation Materials
120 V, 60 Hz, 1 Ø, 20 A, power supply to the control panel must be installed in accordance with the most current National Electrical Code
®
, local codes and
any site specific diagrams.
Total load powered by the panel must not exceed 20 A. Loads totaling more than 20 A must be powered from an additional power supply circuit by the use of a load relay package.
1.4.3 Outside Air Supply Blower
If used, the optional outside air blower is to be con­trolled in parallel with the pump. The blower incorpo­rates a pressure switch which must be wired in series with the pressure switch on the pump. The load relay package may be required with the blower. See Page 10, Figure 8 for wiring detail.
1.4.4 Pressure Switch
A pressure switch (P/N 90430600K), is required for installation on the inlet of the pump. This switch is required to interlock the operation of the pump with the control panel.
2
SECTION 2: SPECIFICATIONS FIGURE 1: Panel Layout
SECTION 2: SPECIFICATIONS
2.1 Material Specifications
Enclosure Material: Metal
Weight: 6.8 lbs
Dimensions: 10.2" x 11.4" x 2.8"
(25.4 x 29.0 x 7.1 cm)
Protection: Rating IP20
2.2 Electrical Specifications
Supply: 120 V, 60 Hz, 1 Ø, 20 A
Zone Relay: Single pole 20 A, 120 Vac
(resistive)
Pump Relay: Single pole 20 A, 120 Vac
(resistive) 1 HP motor rated.
Thermostats: Low voltage 24 Vac
2.3 Pump Specifications
Full Load Current
Pump Model HP 120 V 1 Ø 208/230 V 1 Ø 208/230 V 3 Ø 460 V 3 Ø
EP-100 1/3 4.8 A N/A / 2.4 A - -
EP-201 3/4 6.6 A N/A / 3.3 A - -
EP-203 3/4 - - 2.4 A / 2.2 A 1.1 A
EP-301 2 23 A 12.8 A / 11.9 A - -
EP-303 2 - - 5.5 A / 5.2 A 2.6 A
3
SYSTEM CONTROL INSTALLATI ON, OPERATION AND SERVICE MANUAL
2.4 Burner Electrical Ratings
CORAYVAC
VANTAGE
®
burners: 120 V, 60 Hz, 1 Ø 0.3 A
®
NP (multiburner only) burners:120 V, 60
Hz, 1 Ø 0.2 A
2.5 Outside Air Supply Blower Electrical Ratings
Outside air supply blower (P/N 90707501) has a full load rating of 1.6 A when supplied by a 120 V, 60 Hz, 1 Ø power source.
2.6 Indicator Lights
See Page 3, Figure 1.
1. LINE POWER, when lit, indicates power is supplied to the panel.
2. PUMP POWER 1, when, lit, indicates the relay for power to pump 1 is energized.
3. PUMP POWER 2, when, lit, indicates the relay for power to pump 2 is energized.
4. PRESSURE SWITCH 1, when lit, indicates that pressure switch 1 is closed. When blinking, indi­cates that the system is in lockout.
5. PRESSURE SWITCH 2, when lit, indicates that pressure switch 2 is closed. When blinking, indi­cates that the system is in lockout.
6. ZONE, when lit, indicates which zone relay is energized.
2.7 Terminal Block Guide
Figure 2 is a guide to the terminal abbreviations.
FIGURE 2: Terminal Block Guide
POWER SUPPLY
NEUTRAL
GROUND
PUMP 1 ZONE 1
BURNERS
LINE
NEUTRAL
LINE
NEUTRAL
LINE
BURNERS
NEUTRAL
LINE
ZONE 3
BURNERS
NEUTRAL
ZONE 4
BURNERS
LINE
NEUTRAL
LINE
PUMP 2ZONE 2
NEUTRAL
ZONE 1 R
ZONE 2 R
ZONE 2 R
ZONE 2 R
AIR SW 2
COM
AIR SW 1
24 VAC
LINE
4
G
N L N L N L N L N L N L N L
COM
24 VAC
AIR SW 1
ZONE 1 W
ZONE 2 W
ZONE 2 W
ZONE 2 W
AIR SW 2
SECTION 3: INSTALLATION
DANGER
Electrical Shock Hazard
Disconnect electric before service or maintenance.
Control must be connected to a properly grounded electrical source.
Failure to follow these instructions can result in death or electrical shock.
10.0" (254 mm)
4.5" (114 mm)
4 x Ø 0.360" (9 mm)
SECTION 3: INSTALLATION
Installation of the System Control and the associated external electrical wiring must be completed by an electrician qualified in the installation of control systems for heating equipment.
3.1 Preparation
3.2.6 When the case is rotated 180°, the LED status
circuit card needs to be rotated so that the LED's match the upright cover panel. Remove the LED sta­tus circuit card by squeezing each standoff gently with pliers one at a time until it is loose. Rotate the circuit card so that it will line up with the upright cover and re-attach to the standoffs. The ribbon cable that connects the LED status circuit card to the circuit card assembly will have a twist in it. Use caution not to cause any creases or put any tension to the ribbon cable when rotating the circuit card.
FIGURE 3: Mounting Hole Layout
Before installing the System Control, observe the following:
3.1.1 Ensure that you have a copy of the site layout for the project that identifies clearly the separate zones.
3.1.2 Read Page 1, Section 1.4 carefully to ensure the correct installation materials are available.
3.2 Installing the System Control Panel
3.2.1 Choose a mounting location for the System
Control. It is advisable to choose a visible location near the pump.
Do not mount System Control outdoors or in an area with moisture spray, excessive moisture or humidity. To avoid damage from possible drips, do not mount controller directly beneath pump.
3.2.2 Remove the cover of the System Control by
removing the four securing screws.
3.2.3 Place the cover and the hardware in a safe place for refitting after the external wiring connections have been made.
3.2.4 Position the mounting hole location of the Sys- tem Control per Figure 3.
3.2.5 Remo entry into the System Control panel. The knockouts are on the top of the system control case. If the knockouts are required to be on the bottom the case can be rotated 180°.
ve the knockouts required for the conduit
3.3 Select the External Wiring Diagram for the Installation
3.3.1 Use Page 7, Section 4 for the external wiring of
the burners, thermostats and press
ure switch.
3.3.2 Use the table below to select the correct pump external wiring diagram.
Pump Supply VoltagePageSection Figure
EP-100 120 V 1 Ø 7 4 5 EP-100 208/230 V 1 Ø 8 4 6 EP-201 120 V 1 Ø 7 4 5 EP-201 208/230 V 1 Ø 8 4 6 EP-301 120/208 - 230 V 1 Ø 8 4 6 EP-203 208 - 230 V (or 460 V) 3 Ø 9 4 7 EP-303 208 - 230 V (or 460 V) 3 Ø 9 4 7
Roberts-Gordon LLC provides, at an additional cost, the following IEC contactor packages required for EP-100 and EP-201 208/230 V (1 Ø), EP-203 (3 Ø), EP-303 (3 Ø) and EP-301 (1 Ø) pumps.
5
SYSTEM CONTROL INSTALLATI ON, OPERATION AND SERVICE MANUAL
G N L N L N L N L N L N L N L
AC POWER IN
PUMP 1 ZONE 1 PUMP 2ZONE 2 ZONE 3 ZONE 4
24 VAC
COM
Z1W
Z2W
Z3W
Z4W
24 VAC
COM
Z1R
Z2R
Z3R
Z4R
AIR
SW1
AIR
SW2
AIR
SW1
AIR
SW2
ANTICIPATOR LOAD ENABLE
ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 3 ZONE 4
PUMP 2 OPERATION ENABLE
ANTICIPATOR LOAD ENABLE
ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 3 ZONE 4
PUMP 2 OPERATION ENABLE
FEATURE ENABLED
FEATURE DISABLED
For the EP-203 (3 Ø), EP-303 (3 Ø), EP-100, EP-201 and EP-301 208/230 V (1 Ø) pumps, use the 17 Amp contactor package (P/N 10050011).
For the EP-301 pumps that are operated with 120 V (1 Ø) use the 28 Amp contactor package (P/N
10050012). The contents are listed below:
Contactor Packages
Part No.
Description
10050011 Contactor Package 17A
10001002 Enclosure IEC metal 8X6X6 NEMA 1
90600200 CONT 208-600 17A (A16-30-10-84)
10050012 Contactor Package 28A
10001002 Enclosure IEC metal 8X6X6 NEMA 1
90600205 CONT 208-600 28A (A26-30-10-84)
All pump motors are equipped with thermal overloads.
3.3.3 If an outside air blower is to be used with any of the above options, See Page 10, Figure 8.
3.4 System Configuration
See Page 6, Figure 4 for details. Below the ribbon cable J2 connector, there are six configurable jump- ers. They indicate whether the thermostat for each zone uses an anticipator. If the thermostat for that associated zone has an anticipator, then use a jumper to cover both pins for that zone. If the thermo­stat for the associated zone does not use an antici­pator, then cover the right side pin only.
The bottom two jumpers are associated with Pump 2 operation. They indicate whether Pump 2 is active and which zones are associated with it. Pump 2 can only be associated w
ith Zone 3 and/or Zone 4. To enable Pump 2, use a jumper to cover both pins for the zone(s) that will operate on Pump 2. To disable Pump 2, cover only the right side of the pin of zone 3 and 4.
FIGURE 4: System Configuration
6
SECTION 4: TYPICAL EXTERNAL WIRI NG D IAGRAMS
DANGER
Electrical Shock Hazard
Disconnect electric before service or maintenance.
More than one disconnect switch may be required to disconnect electric to the unit.
Failure to follow these instructions can result in death or electrical shock.
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
N
L
Z1
Z2
Z3 Z4
N
N
N
NLL
L
L
All burners must be connected to Ground (Not shown)
Zone 1
Zone 2 Zone 3 Zone 4
EP-100 or
EP-201 Pump
N
L
EP-100 or
EP-201 Pump
L
N
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
2
Zone
4
Zone
3
Pressure switch located at Pump 2
Pressure switch located at Pump 1
SECTION 4: TYPICAL EXTERNAL WIRING DIAGRAMS
4.1 EP-100 or EP-201 120 V 1 Ø Pump External Wiring Diagram
The external wiring diagram above shows the con­nections for four zones of system burners. System burners can be either CORAYVAC (multiburner only).
The zones are connected to a single pump, unless zone 3 and/or zone 4 are selected to function with the optional pump 2. The external wiring diagram below shows connection to an EP-100 or EP-201 120 V 1 Ø pump.
4.1.1 External Wiring Connection Details
The cable used for all the wiring must be rated for line voltage up to 600 Vac.
The low voltage circuit conforms with Class 2 separa- tion of circuit requirements. National Electrical Codes for wiring class 2 low voltage circuits must be followed.
FIGURE 5: External Wiring Diagram ROBERTS GORDON
®
or VANTAGE® NP
®
EP-100 and EP-201 120 V 1 Ø Pump
®
7
SYSTEM CONTROL INSTALLATI ON, 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
N
L
Z1
Z2
Z3 Z4
N
N
N
NLL
L
L
All burners must be connected to Ground (Not shown)
Zone 1
Zone 2 Zone 3 Zone 4
EP-100,
EP-201 or
EP-301 Pump
N
L
L
N
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
2
Zone
4
Zone
3
Pressure switch located at pump 2
Pressure switch located at pump 1
208 - 230 V 1 Ø 60 Hz
L2
L1
M
1
5
3
2
64
Individual supply for pump rated for total full load current. See Section
2.3 for details.
EP-100, EP-201 or
EP-301 Pump
The power supply for the pump must be separate from the controller supply
Motor Contactors P/N 10050011 P/N 10050012
FIGURE 6: External Wiring Diagram ROBERTS GORDON
Do not directly connect control relay terminals to pump motor
Failure to follow these instructions can result in product damage.
®
EP-100, EP-201 or EP-301, 230 V 1 Ø Pump
CAUTION
Product Damage Hazard
.
4.2 EP-201 or EP-301 230 V 1 Ø External Wiring Diagram
The external wiring diagram above shows the connections for four zones of system burners. System burners can be either CORAYVAC TAG E
The zones are connected to a single pump, unless zone 3 and/or zone 4 are selected to function with the optional pump 2. The external wiring diagram above shows connection to an EP 301 or EP-201 1 Ø
8
®
NP (multiburner only).
®
or VAN-
pump.
4.2.1 External Wiring Connection Details
The cable used for all the wiring must be rated for line voltage up to 600 Vac.
The low voltage circuit conforms with Class 2 separa- tion of circuit requirements. National Electrical Codes for wiring class 2 low voltage circuits must be followed.
®
FIGURE 7: External Wiring Diagram ROBERTS GORDON
CAUTION
Product Damage Hazard
Do not directly connect control relay terminals to pump motor
.
Failure to follow these instructions can result in product damage.
3 Ø Pump
EP-203 or
Motor Contactors P/N 10050011 P/N 10050012
EP- 303 3 Ø Pump
The power supply for the pump must be separate from the controller supply
208 - 230 V (or 460 V)
M
3 Ø 60 Hz
L3
L2 L1
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
SECTION 4: TYPICAL EXTERNAL WIRI NG D IAGRAMS
®
EP-203 or EP-303, 208 - 230 V (or 460 V)
Individual supply for pump rated for total full load current. See Section 2.3 for details.
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.
120 V 120 V 1 Ø
1 Ø
60 Hz 60 Hz
L
N
Ground
L
GLN
POWER SUPPLY
N
4.3 EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø Pump External Wiring Diagram
The external wiring diagram above shows the connections for four zones of system burners. System burners can be either CORAYVAC
®
VANTAGE
The zones are connected to a single pump, unless zone 3 and/or zone 4 are selected to function with the optional pump 2. The external wiring diagram
NP (multiburner only).
N
N
Z1
Z2
System Control
N
L
Z3 Z4
®
or
Low voltage thermostats
Pressure switch located at pump 1
located in heated zone
Zone1Zone
2
Zone
3
Zone
4
Pressure switch located at pump 2
24 VAC
NLL
L
L
N
COM
PUMP 2PUMP 1
24 VAC COM
above shows connection to an EP-203 or EP-303 3 Ø pump.
4.3.1 External Wiring Connection Details
The cable used for all the wiring must be rated for line voltage up to 600 Vac.
The low voltage circuit conforms with Class 2 separa- tion of circuit requirements. National Electrical Codes for wiring class 2 low voltage circuits must be followed.
R R R R PS 2PS 124 VAC
PS 1 PS 2WWWW
®
9
SYSTEM CONTROL INSTALLATI ON, OPERATION AND SERVICE MANUAL
FIGURE 8: External Wiring Diagram ROBERTS GORDON side Air Blower
Optional power supply for Outside Air Blower
Typical wiring for Load Relay
Package (P/N 05023000)
Coil connections to Pump L & N Outputs from Control Panel
Coil
3
6
2
5
1
4
Coil
Relay Receptacle Back Plate
Outside Air
Blower
Pump
Outside Air
Blower
Live out to the outside air blower
Live in
®
EP-100 or EP-201 120 V 1 Ø Pump with Out-
120 V 1 Ø 60 Hz
L
N
120 V 1 Ø 60 Hz
CR
All burners must be connected to Ground (Not shown)
Zone 1
Zone 2 Zone 3 Zone 4
120 V
L
N
1 Ø 60 Hz
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. Refer to Pump 1 for configuration.
Pressure switch
located at pump 2
Pressure switch
located at pump 1
Pressure switch located
at outside air blower
Pressure switch
located at outside air
blower
Low voltage thermostats
located in heated zone
Zone1Zone
Zone
2
Zone
4
3
24 VAC
Ground
GLN
POWER SUPPLY
L
N
N
N
Z1
Z2
N
L
Z3 Z4
NLL
System Control
4.4 Outside Air Blower External Wiring Diagram
The external wiring diagram above shows the con­nections for four zones of system burners. System burners can be either CORAYVAC (multiburner only).
10
®
or VANTAGE® NP
L
L
N
COM
PUMP 2PUMP 1
24 VAC COM
R R R R PS 2PS 124 VAC
PS 1 PS 2WWWW
The zones are connected to a single pump, unless zone 3 and/or zone 4 are selected to function with the optional pump 2. The external wiring diagram above shows connection to an EP-100 or EP-201 1 Ø motor. The diagram also shows the connection via a
load relay to the optional outside air blower.
4.4.1 External Wiring Connection Details
The cable used for all the wiring must be rated for line voltage up to 600 V.
The low voltage circuit conforms with Class 2 separation of circuit requirements. National Electrical Codes
®
for wiring class 2 low voltage circuits
must be followed.
SECTION 4: TYPICAL EXTERNAL WIRI NG D IAGRAMS
11
SYSTEM CONTROL INSTALLATI ON, OPERATION AND SERVICE MANUAL
DANGER
Electrical Shock Hazard
Disconnect electric before service or maintenance.
More than one disconnect switch may be required to disconnect electric to the unit.
Failure to follow these instructions can result in death or electrical shock.
WARNING
Explosion Hazard
Turn off gas supply to equipment before service or maintenance.
Failure to follow these instructions can result in death, injury or property damage.
SECTION 5: TROUBLESHOOTING
tinuous operation, the system control will sh off and re-start to verify no faults exist in the system.
e. After the heating is turned off, the pump will
continue operation for 2 minutes, post purge.
ut
5.1 Sequence of Operation
a. On demand for heat from the thermostat, the
panel will send power to the pump. The pump will begin operation.
b. Once vacuum is established, the pressure
switch at the pump will close. If the vacuum is not established within 30 seconds the pump will go into lockout (pump LED is flashing). After one hour of lockout, the system will re­start.
c. The System Control panel sends power to the
burners. The burners will go through a 45 second purge and cycle time.
d. Once flame is established, the heater will
remain in operation until such time as either the heating is turned off by the thermostat, lockout conditions occur, or after 24 hours of continuous operation. After 24 hours of con-
12
FIGURE 9: System Control Troubleshooting Chart
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
Tro u bleshoot ends.
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
Does the pump turn off
following post purge period?
No
Ye s
Do the burners turn off when the thermostat is
satisfied?
No
Ye s
Rectify.
Do the burners in the
zone come on?
No
Has the system been
commissioned?
No
Ye s
Is external wiring to the
zone OK?
Ye s
No
Refer to burner trouble-
shooting in either the
CORAYVAC
®
or
VANTAG E
®
NP
Installation, Operation and
Service Manuals.
Refer to the burner start up
instructions in either the CORAYVAC
®
or VANTA GE
®
NP Installation, Operation
and Service Manuals.
Do the incorrect zone
lights or all zone lights come on?
Ye s
No
Are the zone thermostats
wired correctly?
No
Ye s
Rectify.
Is external wiring to the
pressure switch OK?
Ye s
No
Rectify.
Rectify.
Ye s
No
Is the correct contactor
selected for the
pump?
Adjust thermostat set
point to call for heat.
Does the pump
come on?
No
Ye s
Does the zone light
come on?
Ye s
No
No
Ye s
Ye s
No
Is external wiring to the
pump OK?
Fit the correct contactor.
Is the thermostat connected to the correct terminal at the
system control.
Ye s
Replace fuse with
P/N 10000212.
Is the line power
indicator on?
Check the power supply
to the system control
panel. Is it on?
Ye s
Ye s
Check the 250mA
fuse. Is it OK?
Ye s
No
No
Rectify power supply
problem.
No
No
Does the pressure switch
light come on?
Refer to burner trouble-
shooting in either the
CORAYVAC
®
or
VANTAG E
®
NP
Installation, Operation and
Service Manuals.
Refer to burner trouble-
shooting in either the
CORAYVAC
®
or
VANTAG E
®
NP
Installation, Operation and
Service Manuals.
Turn off power and correct
wiring.
Ye s
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
If control is not working properly, disconnect power to control and check for signs of physical damage to the front and back of the circuit board, water damage (cor­rosion) or scorching. If damage is found, identify and rectify source of damage. Replace circuit board (P/N 10090101), if it has permanent damage.
SECTION 5: TROUBLESHOOTING
13
SYSTEM CONTROL INSTALLATI ON, OPERATION AND SERVICE MANUAL
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
G N L N L N L N L N L N L N L
AC POWER IN
PUMP 1 ZONE 1 PUMP 2ZONE 2 ZONE 3 ZONE 4
24 VAC
COM
Z1W
Z2W
Z3W
Z4W
24 VAC
COM
Z1R
Z2R
Z3R
Z4R
AIR
SW1
AIR
SW2
AIR
SW1
AIR
SW2
1
2
4
SECTION 6: REPLACEMENT PARTS
FIGURE 10: System Control Internal Components Diagram
Item Description Part Number
1 Fuse 250 mA 10000212 2 Transformer N/A 4 Board Assembly 10090101
14
SECTION 6: REPLACEMENT P ARTS
DANGER
Electrical Shock Hazard
Disconnect electric before service or maintenance.
More than one disconnect switch may be required to disconnect electric to the unit.
Failure to follow these instructions can result in death or electrical shock.
WARNING
Explosion Hazard
Turn off gas supply to equipment before service or maintenance.
Failure to follow these instructions can result in death, injury or property damage.
6.1 Replacement Parts Instructions
See Page 14, Figure 10, Item 2.
6.1.3 Microprocessor Programing
The microprocessor may be re-programed by a reprograming device.
Should the microprocessor program become suspect during troubleshooting, consult Roberts-Gordon LLC.
6.1.1 Fuse 250 mA
See Page 14, Figure 10, Item 1.
This time delay fuse protects the System Control from power surges, lightning and incorrect wiring.
If the fuse needs replacing, the following steps must be taken.
Disconnect power to the System Control.
Remove the screws from the cover and remove the cover of the System Control. See Page 5, Section
3.2.2 for details.
Locate the fuse, and remove the fuse with a fuse pull- ing tool. See Page 14, Figure 10, Item 1.
Replace with a new fuse rated at 250 mA slow blow.
6.1.2 Transformer
The transformer on the board cannot be replaced.
15
SYSTEM CONTROL INSTALLATI ON, OPERATION AND SERVICE MANUAL
16
SECTION 7: THE ROBERTS GORDON® SYSTEM C ONTROL WARRANTY
®
SECTION 7: THE ROBERTS GORDON
SYSTEM
CONTROL WARRANTY ROBERTS-GORDON LLC WILL PAY FOR:
Within 24 months from date of purchase by buyer or 27 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
®
Replacement Parts are warranted for a period of 12 months from date of shipment from Roberts-Gordon LLC or the remaining ROBERTS GORDON
®
System Control warranty.
ROBERTS-GORDON 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
System Control in any way.
®
System Control 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 LLC.
• Failure to install or maintain the ROBERTS GORDON System Control as directed in the Installation, Opera­tion and Service Manual.
• Relocation of the ROBERTS GORDON
®
System Con-
trol after initial installation
• The use of the ROBERTS GORDON
®
System Control
in a corrosive atmosphere containing contaminants.
• The use of the ROBERTS GORDON
®
System Control
in the vicinity of a combustible or explosive material.
• Any defect in the ROBERTS GORDON
®
System Con­trol 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® System Control is not installed by an electrician qualified in the installation and service of control systems for 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 Control is moved or transferred. This warranty is nontransferable.
®
System
Roberts-Gordon LLC 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 control, 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
Some jurisdictions do not allow the exclusion or limitation
®
of incidental or consequential damages, so this limitation
®
System Control.
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 autho- rized Executive Officer.
17
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