Roberts Gorden CorayVac Classic SF Series Operation & Service Manual Download Page 19

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SECTION 5: M

AJOR

OMPONENTS

13 of 83

Part No.

Description

90602451

Voltage Surge Suppressor 120 V

90602452

Voltage Surge Suppressor 120/240 V 1 Ø 60 Hz

90602460

Line Reactor 480 V 3 Ø 60 Hz w/Enclosure (Output)

90602461

Line Reactor 230 V 3 Ø 60 Hz .75 HP (Output)

90602462

Line Reactor 230 V 3 Ø 60 Hz 2 HP (Output)

90602470

Line Reactor 480 V 3 Ø 60 Hz 4 A w/Enclosure (Input)

Thermostats

05023000

Load Relay Package

90417600K

Transformer Relay - SPST (12 A)

90436300

Transformer Relay - SPDT (12 A)

90423000

24 V Low Voltage Thermostat (Marked 1-5)

90424300

Thermostat Guard

90425104

Thermostat, Modulating LonWorks

90425105

Thermostat, Modulating

90425109

Thermostat, Modulating BACnet

90425400

Thermostat, 24 V Programable

90429107

Thermostat, On/Off BACnet

10081520

Sensor, Remote Modulating

10081521

Sensor, Outdoor Modulating

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)

01327002

Condensate Neutralization Tube 200

01327003

Condensate Neutralization Tube 600

01327004

Condensate Neutralization Tube 1000

01327005

Condensate Neutralization Tube 2000

01327007

Refill, Condensate Neutralization Tube 600

01327008

Refill, Condensate Neutralization Tube 1000

01327009

Refill, Condensate Neutralization Tube 2000

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

Protective Grille

08050001

Protective Grille, 40" (102 cm)

08050002

Protective Grille Cap

Shields

02750303

Barrier Shield

Fresh Air Filter Box

90740100K

Fresh Air Filter Box

20628

Aluminum Mesh Filter 20" x 20" x 1"
(51 cm x 51 cm x 3 cm)

Summary of Contents for CorayVac Classic SF Series

Page 1: ...tion Service Manual 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...

Page 2: ......

Page 3: ...13 3 CORAYVAC Modulating Controls 43 13 4 SPST Transformer Relay Kit P N 90417600K 46 13 5 SPDT Transformer Relay P N 90436300 46 SECTION 14 Starting The System 57 14 1 Checking the Gas Line 57 14 2 Checking the Electrical System 57 14 3 Starting the System 57 14 4 Setting the Vacuum 58 14 5 Record Start Up Results 58 SECTION 15 Variable Frequency Drive Programming 60 15 1 VFD Parameter Settings F...

Page 4: ......

Page 5: ...Box 40 Figure 27 Gas Connection with Flexible Gas Hose 42 Figure 28 VFD Terminal Strip 45 Figure 29 One Zone Operation without Control Panel optional 47 Figure 30 One Zone Operation with Outside Air Blower without Control Panel optional 48 Figure 31 Two Zone Operation without Control Panel optional 49 Figure 32 General System Wiring 50 Figure 33 External Wiring Diagram EP 100 and EP 201 120 V 1 Ø ...

Page 6: ......

Page 7: ...fore installation check that the local distribution conditions nature of gas and pressure and adjustment of the equipment are compatible This heater must be applied and operated under the general concepts of reasonable use and installed using best building practices This equipment is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of ...

Page 8: ...AND SERVICE MANUAL 2 of 83 FIGURE 1 Side Panel Label Placement Description Part Number Logo Label 91031110 Rating Plate Label 91010455 Clearances to Combustibles Label 91009106 Internal Ladder Diagram Label 91017301 Wiring Label 91017300 ...

Page 9: ...SECTION 1 HEATER SAFETY 3 of 83 FIGURE 2 Top and Back Panel Label Placement Description Part Number Gas Connection Label 91018125 Burner Box Combination Label 91029600 Proposition 65 Label 91070016 ...

Page 10: ...working load of 750 lb 340 kg To ensure the heater is placed in an approved application Expansion and contraction of the tube dictates that the minimum suspension lengths must be maintained See table on Page 18 Figure 14 To install all components of the system with a minimum of 18 45 cm ceiling clearance in accordance to National Fire Protection Association NFPA 30A 7 6 6 2012 edition latest revis...

Page 11: ...rner 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 equipment must be installed in accordance with the latest revision of the applicable standards and...

Page 12: ...ked 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 he...

Page 13: ...SIDE REFLECTOR inches centimeters Model A B C D A B C D CRVSF 2 4 6 8 4 12 56 20 11 31 143 51 A B C D FIGURE 5 TWO SIDE REFLECTORS inches centimeters Model A B C D A B C D CRVSF 2 4 6 8 4 12 56 12 11 31 143 31 A B C D FIGURE 6 BARRIER SHIELD SEE SECTION 9 4 FOR APPLICATION RESTRICTIONS inches centimeters Model A B C D A B C D CRVSF 2 4 6 8 4 12 12 12 11 31 31 31 C A B D FIGURE 7 PROTECTIVE GRILLE ...

Page 14: ...opane Installation Code Standard CSA B149 1 latest revision 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 ...

Page 15: ...fittings per ASTM See Page 4 Section 2 FIGURE 8 Major Component Descriptions Burner Tube Schedule 40 steel pipe supplied by others End Vent Reflector Aluminum Alternate overlap as shown on Page 22 Section 8 3 3 Minimum overlap is 6 16 cm Reflector with Hole Aluminum Alternate overlap as shown on Page 22 Section 8 3 3 Minimum overlap is 6 16 cm Schedule 40 Adapter Reflector Joint Reflector End Cap ...

Page 16: ... Unit 10 Grims by Ontario L3M 1R6 Canad a Telephone 905 945 5403 Fax 905 945 0511 Printe d in U S A Impri mé aux Etats Unis P N 91008 005 Rev B ROBERTSGORDON UltraVac Controller Part Number Numéro de la Pièce ENCLO SED ENERG Y MANAG EMENT EQUIP MENT 58SB Serial Number No 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...

Page 17: ...0 Black Steel Fittings FIGURE 11 Optional Heater Accessories 45 Elbow 90 Elbow Tee Cross Threaded Coupling All Schedule 40 Black Steel Fittings are supplied by others Reflector Side Extension Bracket Barrier Shield Reflector Side Extension Protective Grille ...

Page 18: ...t 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 Part No Des...

Page 19: ...5 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 Acc...

Page 20: ...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 CRVSF Series Design Manual P N 127502NA ...

Page 21: ...ion 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 G ordon P O Box 44 Buffalo NY 14240 004 4 Telephone 716 852 4 400 Fax 716 852 0 854 Toll Free 800 828 7 450 www rg in c com Roberts G ordon 76 Main Street West Unit 10 Grimsby Ontario L3M 1R6 Canada Telephone 905 945 54 03 Fax 905 94...

Page 22: ...tary heater at specified minimum heat exchanger length Table 3 Minimum Heat Exchanger Length Table 4 Contents of CRVSF Unitary Packages NOTE Scheduled 40 pipe and fittings are provided by others FIGURE 13 CRVSF Unitary Heater Assembly Overview Part Number Length CRVSF60N 31 5 9 6 m CRVSF60P 31 5 9 6 m CRVSF80N 42 12 8 m CRVSF80P 42 12 8 m Part No Description CRVSF60N CRVSF60P CRVSF80N CRVSF80P 027...

Page 23: ...n lengths must be maintained See table on Page 18 Figure 14 Install all threaded components with a minimum thread engagement of three threads Apply sufficient amount of high temperature anti seize pipe compound P N 91308001 or equivalent to threads prior to engagement Hot compound may drip from threads WARNING Severe Injury Hazard Hang heater with materials with a minimum working load of 750 lbs 3...

Page 24: ...n Part Number Eyebolt Turnbuckle 91903202 Spring Hook 3 8 91903301 Tube Reflector Hanger 02790300 Cast Iron Combustion Chamber 02721200 1P 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 ...

Page 25: ...llation Description Part Number Schedule 40 Steel Pipe and Fittings Supplied by Others Turnbuckle with Eyebolts 91903202 Spring Hook 3 8 91903301 Tube Reflector Hanger 02790300 High Temperature Pipe Compound 91308001 Minimum Distance Required Between Burner and Elbow Model MinimumDistance CRVSF 2 5 1 5 m CRVSF 4 5 1 5 m CRVSF 6 10 3 m CRVSF 8 10 3 m ...

Page 26: ...N 91308001 or equivalent to threads prior to engagement Step 8 3 1 Reflector Installation with Hole 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 Description Part Number Schedule 40 Tube Reflector Hanger 02790300 Schedule 40 Steel Pipe and Fittings Suppli...

Page 27: ...SECTION 8 HEATER INSTALLATION 21 of 83 Step 8 3 2 Reflector Installation Description Part Number Reflector Support Package 02716400 U Clip Package 91107720 Reflector End Cap 02750800 ...

Page 28: ...ment of the reflectors a combination of U clips and reflector supports are used The positioning of 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 Description Part Number Reflector Supp...

Page 29: ...TION 8 HEATER INSTALLATION 23 of 83 Step 8 4 Burner Installation Description Part Number Bolt 94273914 Burner 0270XXXX SF Lock Washer 96411600 Gasket 01367800 End Vent E00097XX Schedule 40 Adapter 02722100 ...

Page 30: ... Tee Installation WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury Description Part Number Tee Supplied by Others Schedule 40 Tube Reflector Hanger 02790300 Schedule 40 Steel Pipe Supplied by Others ...

Page 31: ... ACCESSORIES 25 of 83 Step 9 2 Reflector Joint Step 9 2 1 Reflector Joint Installation Step 9 2 2 Reflector Joint Installation Description Part Number Reflector End Cap 02750800 Reflector Joint 02750900 U clip Package 91107720 ...

Page 32: ...CRVSF SERIES INSTALLATION OPERATION AND SERVICE MANUAL 26 of 83 Step 9 2 3 Reflector Joint Detail FIGURE 15 Reflector Joint Detail ...

Page 33: ...3 1 Bracket Installation Step 9 3 2 Side Reflector Installation Description Part Number Reflector Side Extension Package 02712700 Reflector Side Extension 96 244 cm 01368000 Retainer Clips 02751200 Sheet Metal Screws 94118106 Order Separately Reflector Side Extension Bracket 01329910 ...

Page 34: ...Part Number Barrier Shield 02750303 U Clip Package 91107720 Barrier shields must be cut down to 4 1 2 m sections Do not install barrier shield less than 5 1 5 m downstream of any burner or within 1 3 m of next in series burner Do not install more than 1 barrier shield in between in series burners ...

Page 35: ...tion Step 9 5 2 Grille End Cap Installation Step 9 5 3 Grille Installation Silicone Cap Grille Finger Description Part Number Grille Section 08050001 Grille End Cap 08050002 Silicone Cap 91915951 6P Bend up 90 Pull outward Grille Grille End Cap A B C D Grille Grille End Cap Reflector Final Grille Section 40 101 cm ...

Page 36: ...URE 16 EP 200 Condensate Valve Assembly 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 foll...

Page 37: ... total condensate is 1 8 gal h the condensate neutralization tube which is closest to and higher than the calculated gal h value is P N 01327002 NOTE Condensate neutralization tubes must be replaced yearly every 2000 operating hours or check condensate water pH level If it is below pH 6 replace tube To order replacement see the chart below Radiant Tube Length average distance between burners Tailp...

Page 38: ...above grade where located adjacent to public walkways Vent terminal must be installed at a height sufficient to prevent blockage by snow and building materials protected from degradation by flue gases Secure all joints with 8 x 3 8 sheet metal screws Seal all joints with high temperature silicone sealant Vent terminal must be beyond any combustible overhang 10 2 1 United States Requirements Vent m...

Page 39: ...es 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 10 2 5 Vent Material Recommendations Vent recommendations 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 a...

Page 40: ...escription 01330203 Tee 4 10 cm Porcelain 90502101 Vent Terminal 6 15 cm Combustible Wall 01365400 Bird Screen 4 10 cm 91409403 Tube Aluminized 4 10 cm dia 10 3 m 02537801 1P Vent Terminal Non Combustible Wall 91412800 Flexible Boot 4 10 cm 02718851 Drain Cap 4 10 cm 91901300 Boot Clamp 4 10 cm 90502100 Vent Terminal 4 10 cm Combustible Wall Not Supplied Tube Adapter 6 15 2 cm dia x 5 12 7 cm dia ...

Page 41: ...01397400 Bird Screen 6 15 cm 91412800 Flexible Boot 4 10 cm 02537801 1P Vent Terminal Non Combustible Wall 91412802 Flexible Boot 6 15 cm 02718851 Drain Cap 4 10 cm 91418200 Tube Adapter 6 15 2 cm dia x 4 10 cm dia 02718852 Drain Cap 6 15 cm 91901300 Boot Clamp 4 10 cm 90502100 Vent Terminal 4 10 cm Combustible Wall 91913703 Boot Clamp 6 15 cm 90502101 Vent Terminal 6 15 cm Combustible Wall T01003...

Page 42: ... ROBERTS GORDON System Control or 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 37 Figure 21 for outside air blower internal wiring requirements The outside air blower has an adjustable internal damper that should be ...

Page 43: ...vents When a duct is carrying more than 40 flow units it must be at least 6 15 cm diameter Pressurized Systems 6 15 cm diameter duct must not exceed 120 36 m total per system 4 10 cm diameter duct must not exceed 120 36 m per radiant branch Non Pressurized 6 15 cm diameter duct must not exceed 90 27 m maximum 100 flow units 4 10 cm diameter duct must not exceed 90 27 m Elbows are equivalent to 10 ...

Page 44: ... Blower Support 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 Description Part Number Blower 90707501K 5 12 7 cm Vent Cap 90502302 6 15 cm Bird Screen 01397400 6 15 cm Band Clamp 91913703 ...

Page 45: ...r Supply Description Part Number Filter Housing 01326801 4 10 cm Take Off 01324401 Blower 90707501K 5 12 7 cm Vent Cap 90502301 6 15 cm Bird Screen 01365400 6 15 cm Band Clamp 91913703 Description Part Number Pressure Switch Kit 90434501 4 10 cm Bird Screen 01365400 4 10 cm Vent Cap 90502300 6 15 cm Vent Cap 90502302 ...

Page 46: ...t Number Fresh Air Filter Box 90740100K Filter Box 9074100 Aluminum Mesh Filter washable 20 x 20 x 1 51 cm x 51 cm x 3 cm 20628 Magnetic Strip 20 inches 90740101 Double filtered outside air is recommended Mount Fresh Air Filter box on exterior wall Connect duct work to 8 20 cm diameter fresh air inlet ...

Page 47: ...hen gas piping is not included in the layout drawing the local gas supplier will usually help in planning the gas piping 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 equip ments ANSI Z21 24 CSA 6 10 latest revision Canada The Rubber Type 1 Gas Hose Canadian models op...

Page 48: ...tion with Flexible Gas Hose Description Part Number 1 2 Flexible Stainless Steel Gas Hose US Models 91412200 1 2 Rubber Type 1 Gas Hose Canadian Models 91412206 See Page 75 Section 20 Description Part Number High Pressure Regulator 2 psi 90207600 High Pressure Regulator 5 psi 90207601 ...

Page 49: ...stem status and settings are viewed and altered from a PC not supplied running ROBERTS GORDON ULTRAVAC Software ROBERTS GORDON ULTRAVAC Software requires a PC not supplied running Windows 95 or higher with a Pentium class processor and at least 64k of RAM For complete installation details please refer to the ROBERTS GORDON ULTRAVAC Installation Operation and Service Manual P N 10081601NA latest re...

Page 50: ...ump speed For thermostat wiring See Page 53 Figure 36 and Page 54 Figure 37 An optional room sensor P N 10081520 and outdoor air sensors P N 10081521 are available for this thermostat as well The modulating thermostat with LonWorks provides networking capability in a LonWorks system With communications port running at 78 kilobits per second kbs this thermostat can be configured to perform a variet...

Page 51: ...thermostat wiring diagram is shown on Page 53 Figure 36 When the temperature falls below the setpoint the modulating thermostat will generate a demand signal to the VFD The VFD will output a signal to the pump to run at the desired heater s firing rate There are two means to set up the analog signal from the modulating thermostat to the VFD See Page 45 Figure 28 1 To obtain 4 20 mA signal connect ...

Page 52: ...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 13 5 SPDT Transformer Relay P N 9...

Page 53: ...SECTION 13 CONTROL METHODS 47 of 83 FIGURE 29 One Zone Operation without Control Panel optional Description Part Number SPST Transformer Relay 90417600K ...

Page 54: ...CRVSF SERIES INSTALLATION OPERATION AND SERVICE MANUAL 48 of 83 FIGURE 30 One Zone Operation with Outside Air Blower without Control Panel optional ...

Page 55: ...SECTION 13 CONTROL METHODS 49 of 83 FIGURE 31 Two Zone Operation without Control Panel optional Description Part Number SPDT Transformer Relay 90436300 ...

Page 56: ...CRVSF SERIES INSTALLATION OPERATION AND SERVICE MANUAL 50 of 83 FIGURE 32 General System Wiring FIGURE 33 External Wiring Diagram EP 100 and EP 201 120 V 1 Ø Pump ...

Page 57: ...IGURE 34 External Wiring Diagram EP 100 EP 201 or EP 301 230 V 1 Ø Pump optional CAUTION Product Damage Hazard Do not directly connect control relay terminals to pump motor Failure to follow these instructions can result in product damage ...

Page 58: ... 52 of 83 FIGURE 35 External Wiring Diagram EP 203 or EP 303 208 230 V or 460 V 3 Ø Pump optional CAUTION Product Damage Hazard Do not directly connect control relay terminals to pump motor Failure to follow these instructions can result in product damage ...

Page 59: ...dulating Wiring Diagram LonWorks 2 10 Vdc with 500 ohm resistor optional Description Part Number SPST Transformer Relay 90417600K Thermostat Modulating LonWorks 90425104 Thermostat Modulating 90425105 Sensor Remote Modulating 10081520 Sensor Outdoor Modulating 10081521 ...

Page 60: ... 37 CORAYVAC CLASSIC SF Modulating Wiring Diagram LonWorks 4 20 mA optional Description Part Number SPST Transformer Relay 90417600K Thermostat Modulating LonWorks 90425104 Thermostat Modulating 90425105 Sensor Remote Modulating 10081520 Sensor Outdoor Modulating 10081521 ...

Page 61: ...TION 13 CONTROL METHODS 55 of 83 FIGURE 38 CORAYVAC CLASSIC SF Modulating with BACnet Wiring Diagram optional Description Part Number SPST Transformer Relay 90417600K Thermostat Modulating BACnet 90425109 ...

Page 62: ...d with wiring material having a temperature rating of at least 105 C and 600 volts FIGURE 40 Burner Internal Ladder Diagram S1 TRANSFORMER VALVE GAS 120 V Power Supply Yellow Yellow Brown Green White Black 3 4 1 5 BURNER IGNITION MODULE Black Blue Yellow V2 GND TH V1 Green Gap TRANSFORMER L1 L2 Black White Blue Yellow Brown ELECTRODE GAS VALVE V2 Gnd S1 V1 TH Black Yellow IGNITION MODULE ...

Page 63: ...Figure 41 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 14 3 Starting the System NOTE During the initial firing the protective oil on the pipe may smoke for 30 to 60 minutes and adequate ventilation should be provided 1 Start with all temper...

Page 64: ...l 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 wc If so adjust the damper couplings to maximum but equal vacuum reading Be sure to lock all dampers securely after adjustment 3 After adjustment seal all openings found in the damper nipple s with high temperature silicone...

Page 65: ...SECTION 14 STARTING THE SYSTEM 59 of 83 FIGURE 41 Vacuum Reading ...

Page 66: ...lay will read P01 which indicates that the PROGRAM mode has been accessed at the begin ning of the parameter menu P01 is the first parameter NOTE If the display flashes Er the password was incorrect and the process to enter the password must be repeated 15 1 3 Use the arrow buttons to scroll to the desired parameter number For new parameter settings See Page 61 Section 15 2 15 1 4 Once the desired...

Page 67: ...following parameters Parameter Number Parameter Name Factory Default New Setting P01 Line Voltage 01 01 P03 Start Method 01 05 P05 Standard Speed Source 01 03 0 10 Vdc 04 4 20 mA P44 Password 225 Any 000 999 P45 Speed at Minimum Signal 0 0Hz Frequency Setting noted on Page 62 Section 16 2 2 P46 Speed at Maximum Signal 60 0Hz Frequency Setting noted on Page 62 Section 16 2 1 ...

Page 68: ... lower than 60 0 hit the up arrow button on the VFD until the number reads 60 0 Let the burners fire for approximately 20 30 minutes to warm up the system Using a manometer check the end vent vacuum in each zone each branch of burners See Page 64 Figure 42 If the lowest end vent vacuum reading is above 3 0 wc reduce the vacuum pump speed Generally the lowest end vent vacuum reading is on the longe...

Page 69: ...bove on the VFD Turn on the transformer relay and program the modulating thermostat to the customer s requirements Parameter Number Parameter Name Factory Default New Setting P01 Line Voltage 01 01 P03 Start Method 01 05 P05 Standard Speed Source 01 03 0 10 Vdc 04 4 20 mA P44 Password 225 Any 000 999 P45 Speed at Minimum Signal 0 0Hz Frequency Setting noted on Page 62 Section 16 2 2 P46 Speed at M...

Page 70: ...CRVSF SERIES INSTALLATION OPERATION AND SERVICE MANUAL 64 of 83 FIGURE 42 Possible Damper Nipples Locations Description Part Number Schedule 40 Damper Nipple 01332000 ...

Page 71: ...at to lowest setting Turn OFF electric power to heater Turn OFF manual gas valve in the heater supply line 17 3 To Start Heater Turn gas valve and electric power OFF and wait five minutes for unburned gases to vent from heater Turn ON main gas valve Turn ON electric power Set thermostat to desired temperature Burner should light automatically 17 4 Pre Season Maintenance and Annual Inspection To en...

Page 72: ...m Immediately remove these items if they are present See Page 6 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 clearance...

Page 73: ...perating 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 re...

Page 74: ...rical 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 Hazar...

Page 75: ...SECTION18 TROUBLESHOOTING 69 of 83 18 1 Troubleshooting Flow Chart ...

Page 76: ...CRVSF SERIES INSTALLATION OPERATION AND SERVICE MANUAL 70 of 83 Troubleshooting Flow Chart ...

Page 77: ...elp ensure all safety systems are in working order before leaving the heater to operate Minor faults may be traced by using the troubleshooting charts on Page 68 Section 18 through Page 70 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 ...

Page 78: ... 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 Gasket Burner to Mixing Chamber Ignition Module Mixing Chamber Burner Head Regulator Electrode Electrode Gasket Combustion Chamber Gasket Gas Valve Transformer OF F ON Ignition Cable...

Page 79: ... 230 V 1 Ø Input for use with EP 203 10081202 Variable Frequency Drive 2 HP 230 V 1 Ø Input for use with EP 303 10081203 Variable Frequency Drive 1 HP 460 V 3 Ø Input for use with EP 203 10081204 Variable Frequency Drive 2 HP 460 V 3 Ø Input for use with EP 303 10081205 Relay 120 V 90429100 Fuse 10 A for 75 HP 230 V VFD 1 HP 460 V VFD and 2 HP 460 V VFD 91321410 Fuse 25 A for 1 HP 120 V VFD and 2 ...

Page 80: ... ther mostat Turn on the 24 V power switch on the relay board Press the reset button on the control board and close the doors 19 2 2 Variable Frequency Drive 25 A or 10 A Fuse To replace a fuse turn off input power to the variable frequency drive assembly at the breaker or disconnect switch Turn off 120 V power to the relay board inside the ROBERTS GORDON ULTRAVAC Controller or modulating thermost...

Page 81: ...ontrols supplied as an option See Page 6 Section 3 for clearances to combustibles Refer to the CRVSF Series Design Manual P N 127502NA 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 wc Minimum 14 0 wc Maximum ELE...

Page 82: ...s 10 C B G A E D F dia Model EP 100 EP 201 EP 203 EP 301 EP 303 Horsepower Hp 1 3 3 4 3 4 2 2 Phase Ø 1 1 3 1 3 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 I...

Page 83: ...IFICATIONS FOR FRESH AIR FILTER BOX SPECIFICATIONS 77 of 83 SECTION 23 GENERAL SPECIFICATIONS FOR FRESH AIR FILTER BOX SPECIFICATIONS Filter Box Dimensional Data A B C D E F 20 51 cm 15 38 cm 20 51 cm 8 20 cm 2 5 cm 20 51 cm ...

Page 84: ...CRVSF SERIES INSTALLATION OPERATION AND SERVICE MANUAL 78 of 83 ...

Page 85: ...ion Hazard 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 Leak test all compo nents of equipment gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with equipment connec...

Page 86: ...mp Supply Voltage B Pump Amperage Draw C Thermostat s Thermostat Location Thermostat Type 5 Flue Discharge A Flue Direction Roof Wall B Vent Material C Vent Diameter 6 Condensate Discharge YES NO 7 Tube Pitch YES NO 8 Reflectors A Proper Overlap at Joints B Slip Joint every 3rd Reflector C End Caps Installed 9 Mandatory Fresh Air Supply YES NO A Blower Installed YES NO Blower Model Number B Double...

Page 87: ...h 2 Branch Model Serial Number Tube Temperature See Drawing 1 End Burner 2 3 4 Branch 3 Branch Model Serial Number Tube Temperature See Drawing 1 End Burner 2 3 4 Branch 4 Branch Model Serial Number Tube Temperature See Drawing 1 End Burner 2 3 4 Highest measured temperature after each burner Measurement must be taken using a calibrated thermometer type K thermocouple or its equivalent Infrared te...

Page 88: ...CRVSF SERIES INSTALLATION OPERATION AND SERVICE MANUAL 82 of 83 ...

Page 89: ... be filed with carrier WARRANTY IS VOID IF The ROBERTS GORDON CORAYVAC CLASSIC SF is not installed by a contractor qualified in the installation and service of gas fired heating equipment You cannot prove original purchase date and required annual maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the ROBERTS GORDON CORAYVAC ...

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Roberts Gorden CorayVac Classic SF Series, Operation & Service Manual

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Summary of Contents for CorayVac Classic SF Series

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