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Roberts Gorden Corayvac CRV-B Series, Installation, Operation & Service Manual

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Roberts Gorden Corayvac CRV-B Series Installation, Operation & Service Manual Download Page 86

CRV-S

ERIES

 I

NSTALLATION

, O

PERATION

 

AND

 S

ERVICE

 M

ANUAL

78 of 85

SECTION 19: REPLACEMENT PARTS

See 

w

arnings and important information before remo

v

ing or replacing parts. After any maintenance or repair

w

ork, al

w

ays test fire the heater in accordance 

w

ith the start-

u

p instr

u

ctions 

on Page 63, Section 13

 to help

ens

u

re all safety systems are in 

w

orking order before lea

v

ing the heater to operate. Minor fa

u

lts may be

traced by 

u

sing the tro

u

bleshooting charts 

on Page 75, Section 18 through Page 77.

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

Summary of Contents for Corayvac CRV-B Series

Page 1: ...ur building 5 Extinguish any open flame 6 Leave the building 7 Immediately call your local gas supplier after leaving the building Follow the gas supplier s instructions 8 If you cannot reach your gas supplier call the Fire Department Fire Hazard Keep all flammable objects liquids and vapors the minimum required clear ances to combustibles away from heater Some objects will catch fire or explode w...

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Page 3: ... B 6 8 9 10 12 12A Only 52 12 3 CORAYVAC Modulating Thermostat 52 12 4 DPDT Transformer Relay P N 90436300 53 SECTION 13 Starting The System 63 13 1 Checking the Gas Line 63 13 2 Checking the Electrical System 63 13 3 Starting the System 63 13 4 Setting the Vacuum 64 SECTION 14 Variable Frequency Drive Programming For Use With CORAYVAC Modulating Heating Control 66 14 1 VFD Parameter Settings For ...

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Page 7: ...38 Figure 25 EP 200 Condensate Valve Assembly 39 Figure 26 Condensate Neutralization Tube 41 Figure 27 Vertical Venting Configuration 43 Figure 28 EP 100 and EP 200 Horizontal Venting Configurations 44 Figure 29 EP 300 Series Horizontal Venting Configurations 45 Figure 30 Duct Sizing 47 Figure 31 Outside Air Blower Internal Wiring Diagram 47 Figure 32 Filter Housing Assembly 48 Figure 33 Air Suppl...

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Page 9: ...ands to the surface of the reflector Before installation check that local distribution conditions nature of gas and pressure and adjustment of the appliance are compatible This heater must be applied and operated under the general concepts of reasonable use and installed using best building practices This appliance is not intended for use by persons including children with reduced physical sensory...

Page 10: ...lérant une témperature d au moins 105 C et 600 volts 2017 www robertsgordon com YELLOW Jaune YELLOW Jaune GREEN Vert BLACK Noir V2 GND Roberts Gordon TRANSFORMER Transformateur GAS VALVE Valve à gaz 120 V POWER SUPPLY Alimentation Électrique BROWN Marron GREEN Vert WHITE Blanc BLACK Noir 3 4 1 5 BURNER Brûleur IGNITION MODULE Module d A llumage BLUE Bleu YELLOW Jaune S1 TH V1 Internal Wiring Diagr...

Page 11: ...SECTION 1 HEATER SAFETY 3 of 85 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 12: ...he CRV Series heater e g thermostat or controller A copy of the wall tag P N 91037912 is illustrated on the back cover For an immediate solution you may affix this copy on the wall near the heater Know your model number and installed configuration Model number and installed configuration are found on the burner and in the Installation Operation and Service Manual See Page 6 Figure 3 through Page 8...

Page 13: ...lity to assure that adjacent materials are protected from degradation Maintain clearances from heat sensitive equipment and workstations Maintain clearances from vehicles parked below the heater Maintain clearances from swinging and overhead doors overhead cranes vehicle lifts partitions storage racks hoists building construction etc In locations used for the storage of combustible materials signs...

Page 14: ... B 12 4 36 60 36 11 92 153 92 CRV B 12A 4 36 60 36 11 92 153 92 B C D A FIGURE 4 ONE SIDE REFLECTOR inches centimeters Model A B C D A B C D CRV B 2 4 12 56 20 11 31 143 51 CRV B 4 4 12 56 20 11 31 143 51 CRV B 6 4 12 56 20 11 31 143 51 CRV B 8 4 12 56 20 11 31 143 51 CRV B 9 4 12 60 42 11 31 153 107 CRV B 10 4 12 60 42 11 31 153 107 CRV B 12 4 12 60 42 11 31 153 107 CRV B 12A 4 12 60 42 11 31 153...

Page 15: ...1 46 CRV B 12A 8 18 24 18 21 46 61 46 C A B D FIGURE 7 UNIVERSAL SHIELD WITH AND WITHOUT HOLES POSITION 2 inches centimeters Model A B C D A B C D CRV B 2 4 24 48 24 11 61 122 61 CRV B 4 4 24 48 24 11 61 122 61 CRV B 6 4 24 48 24 11 61 122 61 CRV B 8 4 24 48 24 11 61 122 61 CRV B 9 4 36 48 36 11 92 122 92 CRV B 10 4 36 48 36 11 92 122 92 CRV B 12 4 36 48 36 11 92 122 92 CRV B 12A 4 36 48 36 11 92 ...

Page 16: ...6 143 46 CRV B 12 4 18 56 18 11 46 143 46 CRV B 12A 4 18 56 18 11 46 143 46 A B C D FIGURE 10 BARRIER SHIELD inches centimeters Model A B C D A B C D CRV B 2 4 12 12 12 11 31 31 31 CRV B 4 4 12 12 12 11 31 31 31 CRV B 6 4 12 12 12 11 31 31 31 CRV B 8 4 12 12 12 11 31 31 31 CRV B 9 UNAPPROVED UNAPPROVED CRV B 10 UNAPPROVED UNAPPROVED CRV B 12 UNAPPROVED UNAPPROVED CRV B 12A UNAPPROVED UNAPPROVED C ...

Page 17: ...ovisions shall be made to assure accessibility to suspended heaters for recurrent maintenance purposes 4 3 Public Garages Installation in garages must be in accordance with the following codes United States Refer to Standard for Parking Structures NFPA 88A latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 30A latest revision Canada Refer to Natural Gas and Pr...

Page 18: ...pension hardware beam clamps chain or rod at predetermined locations Adjustments of chain length will provide uniform pitch FIGURE 12 Major Component Descriptions Standard Reflector Burner Tube Hot rolled heat treated or coated aluminized tube supplied in 10 3 m lengths 45 Elbow 90 Elbow End Vent Coupling Assembly with Lock Flex Gas Line with shut off cock Combustion Chamber Tee Standard Reflector...

Page 19: ...inless Steel Punch out center section to accommodate tube S Hook Turnbuckle Tube and Reflector Hanger Suspend system from these hangers Reflector Support Strap Wire Form Tube Schedule 40 steel pipe supplied by others Schedule 40 Tube and Reflector Hanger Suspend system from these hangers Schedule 40 Reflector Support Strap Wire Form Schedule 40 Adapter Cast Iron Combustion Chamber Schedule 40 Damp...

Page 20: ...d in 10 3 m lengths 45 Elbow 90 Elbow End Vent Coupling Assembly with Lock Flex Gas Line with shut off cock Combustion Chamber Tee High Efficiency Reflector with Hole Aluminum only Alternate overlap as shown on Page 27 Section 7 3 3 Minimum overlap is 6 16 cm Tube Adapter Cross High Efficiency Reflector Aluminum only Alternate overlap as shown on Page 27 Section 7 3 3 Minimum overlap is 6 16 cm ...

Page 21: ...escriptions High Efficiency Reflector Continued Reflector Joint EF Reflector End Cap EF Aluminum only Punch out center section to accommodate tube S Hook Turnbuckle Tube and Reflector Hanger EF Suspend system from these hangers Reflector Support Strap Wire Form EF ...

Page 22: ...E MANUAL 14 of 85 FIGURE 17 Optional Heater Accessories Universal Shield with Holes Reflector Side Extension Bracket Barrier Shield Reflector Side Extension Condensate Valve Assembly Deco Grille Protective Grille Universal Shield Bracket Assembly ...

Page 23: ...ormation refer to the EP 200 Series Installation Operation and Service Manual P N 127200NA EP 301 Pump Package 4 dia EP 301 Pump Package 6 dia EP 303 Pump Package 4 dia EP 303 Pump Package 6 dia For more information refer to the EP 300 Series Installation Operation and Service Manual P N 127202NA CORAYVAC Heating Control CORAYVAC Modulating Heating Control Models CRV B 6 B 8 B 9 B 10 or B 12 Only ...

Page 24: ...ted Aluminized 6 15 cm dia 10 3 m Part No Description 91418200 Tube Adapter Aluminized 6 15 cm dia x 4 10 cm dia 02722100 Adapter 4 10 cm Cast Iron 91240010 Tube Hanger 6 15 cm 91308001 High Temperature Pipe Compound 1lb can Part No Description Venting Accessories 01324401 Outside Air Supply Takeoff 4 10 cm 01326801 Outside Air Filter Housing 90707501 Air Supply Blower Power Venter 91409601 Outsid...

Page 25: ...tat Marked 1 5 90424300 Thermostat Guard Part No Description 90425104 Thermostat Modulating LonWorks 90425105 Thermostat Modulating 10001501 Water Resistant Sensor Part No Description Deco Grille 2 x 4 6 m x 1 2 m 01365900 Shield Frame 01370408 Reflector Side Extension 8 x 48 20 3 cm x 122 cm 01370412 Reflector Side Extension 12 x 48 30 5 cm x 122 cm 01370416 Reflector Side Extension 16 x 48 40 6 ...

Page 26: ...o the system operation and performance required by the building being heated Every effort should be made to follow the dimensions on the layout drawing If deviations are necessary either contact the company responsible for the layout design your ROBERTS GORDON independent distributor or consult the CRV Series Design Manual P N 127500NA ...

Page 27: ...SECTION 6 DESIGN REQUIREMENTS 19 of 85 FIGURE 19 Heater Assembly Overview Standard Coupling CORAYVAC Heating Control Modulating Thermostat or CORAYVAC Modulating Heating Control Standard Coupling ...

Page 28: ...20 Expansion and contraction of the tube dictates that the minimum suspension lengths must be maintained See table on Page 21 Figure 20 WARNING Severe Injury Hazard Standard CORAYVAC Systems Secure burner to combustion chamber with nuts and lockwashers Hang heater with materials with a minimum working load of 75 lbs 33 kg Failure to follow these instructions can result in death injury or property ...

Page 29: ...ement Description Part Number Turnbuckle 91903201 S Hook 91907302 Tube Reflector Hanger 0309010X 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 30: ...Spring Hook 3 8 91903301 Tube Reflector Hanger Schedule 40 Pipe 02790300 Tube and Reflector Hanger EF Schedule 40 Pipe 03090103 Cast Iron Combustion Chamber 02721200 1P Cast Iron Adapter 02722100 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 31: ...flector Hanger 0309010X A Close coupling and slide opposite end into tab Position tab underneath guide rail B Insert wide end of slide bar coupling lock into guide rail on opposite end of tabs Slide the slide bar coupling lock up the guide rail until snug approximately 3 8 cm to 4 10 cm C Insert tubes into coupling until end of each tube rests against internal pins D Strike slide bar coupling lock...

Page 32: ...tailpipe All tailpipe must be connected with lined couplings P N 0131270I Lined couplings can be identified by the thin layer of sheet metal attached to the inner portion of the coupling Tighten slide bar as shown below Description Part Number Elbow Package 0271870X 90 Elbow 01335801 Coupling 01312700 Reflector End Cap 0275080X Reflector Joint Piece 0275090XS U Clip Package 91107720 Minimum Distan...

Page 33: ... 2 3 Elbow Installation Step 7 3 Reflector Installation WARNING Fire Hazard Support reflector with reflector hanger and support strap Reflector must not touch tube Failure to follow these instructions can result in death injury or property damage ...

Page 34: ...er Tube Reflector Hanger 0309010X Tube 91409XXX Reflector with Hole 96 244 cm 027503XX Description Part Number Reflector Support Package 030500XX U Clip Package 91107720 Reflector End Cap 027508XX NOTE Reflectors must be supported using hangers reflector supports or positioning reflectors on top of a supported reflector Do not use U clips to support reflectors ...

Page 35: ... 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 Support Pac...

Page 36: ...CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 28 of 85 Step 7 4 Burner Installation Description Part Number Bolt 94273914 Burner 0270XXXX Lock Washer 96411600 Gasket 01367800 End Vent 013676XX ...

Page 37: ...r positioning reflectors on top of a supported reflector Do not use U clips to support reflectors The heater must be properly supported at all locations See Page 30 Figure 22 NOTE Minimum distance required between burner and U tube 5 1 5 m on CRV B 2 4 10 3 M on CRV B 6 8 9 15 4 5 m on CRV B 10 12A 12 WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are...

Page 38: ...TALLATION OPERATION AND SERVICE MANUAL 30 of 85 FIGURE 22 U Tube Heater Assembly Overview Step 8 2 Tee Installation Description Part Number Tee 01330XXX Tube Reflector Hanger 0309010X Tube 91409XXX Coupling 01312700 ...

Page 39: ...SECTION 8 OPTIONAL HEATER ACCESSORIES 31 of 85 Step 8 3 Reflector Joint Step 8 3 1 Reflector Joint Installation Step 8 3 2 Reflector Joint Installation ...

Page 40: ...CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 32 of 85 Step 8 3 3 Reflector Joint Detail FIGURE 23 Reflector Joint Detail ...

Page 41: ...4 1 Bracket Installation Step 8 4 2 Side Reflector Installation Description Part Number Reflector Side Extension Package 027127XX Reflector Side Extension 96 244 cm 0136800X Retainer Clips 02751200 Sheet Metal Screws 94118106 Order Separately Reflector Side Extension Bracket 01329911 ...

Page 42: ...sembly 02721400 Stud 02790900 Hex Nut 92114800 Universal shields are adjustable aluminum reflectors whose angle and height can be adjusted to direct heat to or away from a desired area See Page 7 Figure 6 through Page 7 Figure 8 for positions Description Part Number Barrier Shield Standard Reflector 96 244 cm 027503XX U Clip Package 91107720 Do not install barrier shield less than 20 6 m downstrea...

Page 43: ...85 8 7 Two Foot Decorative Grille Installation Step 8 7 1 Grille Installation Step 8 7 2 Frame Shield Installation Description Part Number Aluminum Grille 2 x 4 60 cm x 120 cm 91407000 Description Part Number Deco Grille Shield 24 61 cm 01365900 ...

Page 44: ...ector Side Extension Installation for Decorative Grilles Distance A Extension Minimum Maximum Part No Width 2 4 cm 6 15 cm 013704XX 8 20 cm 6 15 cm 10 26 cm 013704XX 12 30 cm 10 26 cm 14 37 cm 013704XX 16 40 cm Description Part Number Reflector Side Extension 48 122 cm 013704XX ...

Page 45: ... Grille Finger Description Part Number Grille Section Side Reflector 08050001 Grille End Cap Side Reflector 08050002 Silicone Cap 91915951 6P Grille Section EF Reflector 08050003 Grille End Cap EF Reflector 08050004 NOTE Protective grille NOT APPROVED for use with 45 tilted reflectors Bend up 90 Pull outward Grille Grille End Cap A B C D Grille Grille End Cap Reflector Final Grille Section 40 101 ...

Page 46: ...Condensate Valve Assembly EP 100 and EP 300 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 ...

Page 47: ...he total condensate gal h using the follow calculation Total condensate gal h Total Input Btu h 100 000 Btu h x condensate flow gal h Step 3 Choose the condensate neutralization tube Choose the condensate neutralization tube which is closest to and higher than the calculated gal h value Description Part Number Condensate Valve Assembly 01327001 Radiant Tube Length average distance between burners ...

Page 48: ...tion 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 Tailpipe Length per Flow Unit Minimum Recommended 1 7 ft flow unit Maximum Minimum N A 0 1 0 3 0 6 Recommended 0 1 0 3 0 6 0 8 Maximum 0 3 0 6 0 8 0 8 Calculated gal h Descript...

Page 49: ...zation Tube Calculated gal h Description Part Number Less than 2 Condensate Neutralization Tube 200 01327002 Less than 6 Condensate Neutralization Tube 600 01327003 Less than 10 Condensate Neutralization Tube 1000 01327004 Less than 20 Condensate Neutralization Tube 2000 01327005 ...

Page 50: ...uilding The vent shall not terminate within 3 0 9 m of a window or door that can be opened in any building any non mechanical air supply inlet to any building or of the combustion air inlet of any other appliance 9 2 3 Vertical Venting See Page 43 Figure 27 for recommended vertical venting options 9 2 4 Horizontal Venting See Page 44 Figure 28 through Page 46 Figure 10 for recommended horizontal v...

Page 51: ... cm Aluminized 91412802 Flexible Boot 6 15 cm 01335801 Elbow 4 10 cm Aluminized 90 91901300 Boot Clamp 4 10 cm 02718851 Drain Cap 4 10 cm 91913703 Boot Clamp 6 15 cm 02718852 Drain Cap Assembly 6 15 cm T0100320 Elbow 6 15 cm Aluminized 90 01327002 Condensate Neutralization Tube 200 01365400 Bird Screen 4 10 cm 01327003 Condensate Neutralization Tube 600 01397400 Bird Screen 6 15 cm 01327004 Conden...

Page 52: ...ube 1000 01331900 Damper Coupling 4 10 cm 01327005 Condensate Neutralization Tube 2000 01335801 Elbow 4 10 cm Aluminized 90 91409403 Tube Aluminized 4 10 cm dia 10 3 m 01365400 Bird Screen 4 10 cm 91412801 Flexible Boot 4 5 11 cm 02537801 1P Vent Terminal Non Combustible Wall 91901300 Boot Clamp 4 10 cm 02718851 Drain Cap 4 10 cm 91906900 Silicone Ring 01327002 Condensate Neutralization Tube 200 0...

Page 53: ...inized 6 15 cm dia 10 3 m 01335801 Elbow 4 10 cm Aluminized 90 91412801 Flexible Boot 4 5 11 cm 01365400 Bird Screen 4 10 cm 91418200 Tube Adapter 6 15 2 cm dia x 4 10 cm dia 01397400 Bird Screen 6 15 cm 91901300 Boot Clamp 4 10 cm 02718851 4 Drain Cap 91906900 Silicone Ring 01327002 Condensate Neutralization Tube 200 91412802 Flexible Boot 6 13cm 01327003 Condensate Neutralization Tube 600 013270...

Page 54: ... supplies the outside air blower motor has a pressure switch that must be used Wire this switch in series with the pump pressure switch When using an outside air blower with a CORAYVAC Heating Control or CORAYVAC Modulating Heating 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 separ...

Page 55: ...ents 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 3...

Page 56: ... 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 Outside Air 90707501K 5 12 7 cm Vent Cap 90502302 6 15 cm Bird Screen 01397400 6 15 cm Band Clamp 91913703 ...

Page 57: ...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 58: ...rop of 1 2 wc When 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 Appli ances ANSI Z21 24 CSA 6 10 latest revision Canada The Rubber Type 1 Gas Hose Can...

Page 59: ...le 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 81 Section 20 Description Part Number High Pressure Regulator 2 psi 90207600 High Pressure Regulator 5 psi 90207601 ...

Page 60: ...condition monitoring System status and settings are viewed and altered from a touchscreen For complete installation details please refer to the CORAYVAC Modulating Heating Control Installation Operation and Service Manual P N 1006101NA latest revision Special design requirements apply for CRV Series systems using the CORAYVAC Modulating Heating Control Controller Buildings today demand all sorts o...

Page 61: ...pump speed to a maximum frequency and burner s ON at maximum firing rate As the space temperature gets closer to the set point the thermostat program will slow the pump speed and burner s firing rate down until the room temperature reaches the thermostat set point NOTE To obtain Analog 0 10VDC signal connect as shown on Page 69 Section 15 2 and set standard speed source parameter 05 inside VFD men...

Page 62: ...CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 54 of 85 FIGURE 37 One Zone Operation without Control Panel optional Description Part Number DPDT Transformer Relay 90436300 ...

Page 63: ...ECTION 12 CONTROL METHODS 55 of 85 FIGURE 38 One Zone Operation with Outside Air Blower without Control Panel optional Description Part Number DPDT Transformer Relay 90436300 Blower Outside Air 90707501K ...

Page 64: ...CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 56 of 85 FIGURE 39 Two Zone Operation without Control Panel optional Description Part Number DPDT Transformer Relay 90436300 ...

Page 65: ...SECTION 12 CONTROL METHODS 57 of 85 FIGURE 40 General System Wiring FIGURE 41 External Wiring Diagram EP 100 and EP 201 120 V 1 Ø Pump Note External wiring done by others ...

Page 66: ... 42 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 Note External wiring done by others ...

Page 67: ...RE 43 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 68: ...AYVAC Modulating Wiring Diagram LonWorks 2 10 Vdc with 500 ohm resistor optional Description Part Number DPDT Transformer Relay 90436300 Thermostat Modulating LonWorks 90425104 Thermostat Modulating 90425105 Sensor Remote Modulating 10081520 Sensor Outdoor Modulating 10081521 ...

Page 69: ...YVAC Modulating Wiring Diagram LonWorks 4 20 mA optional Description Part Number DPDT Transformer Relay 90436300 Thermostat Modulating LonWorks 90425104 Thermostat Modulating 90425105 Sensor Remote Modulating 10081520 Sensor Outdoor Modulating 10081521 ...

Page 70: ...eplaced with wiring material having a temperature rating of at least 105 C and 600 volts FIGURE 47 Burner Internal Ladder Diagram 120 V YEL BRN GRN GRN WHT BLK YEL 3 1 4 5 S1 BLK V2 GND TH V1 BLUE YEL TRANSFORMER VALVE GAS MODULE IGNITION BURNER HEAD White Rodgers Gap TRANSFORMER L1 L2 Black White Blue Yellow Brown ELECTRODE GAS VALVE V2 Gnd S1 V1 TH Black Yellow IGNITION MODULE ...

Page 71: ...a preliminary vacuum check at burners in branches that have an adjustable damper coupling See Page 65 Figure 48 for manome ter hookup to check vacuum This check is to insure that all dampers are open before the system is fired Vacuum as measured at the end vents should be approximately 3 5 wc or slightly above cold 13 3 Starting the System NOTE During the initial firing the protective oil on the t...

Page 72: ...t Vacuum adjustments are made by means of the damper in the pump inlet and the adjustable damper coupling s in the system Check the vacuum at all end vents and then adjust the damper coupling to obtain equal vacuum readings of 2 5 wc to 3 0 wc If end vent vacuum exceeds 3 0 wc adjust the pump inlet damper until vacuum readings are 2 5 wc to 3 0 wc With systems designed to operate at maximum vacuum...

Page 73: ...SECTION 13 STARTING THE SYSTEM 65 of 85 FIGURE 48 Vacuum Reading ...

Page 74: ...ons to scroll to P14 the factory set password is 0 0 Press OK to enter password 101 Once the correct password value is entered the dis play will read P14 which indicates that the PROGRAM mode has been accessed at the begin ning of the parameter menu P01 is the first parameter 14 1 3 Use the arrow buttons to scroll to the desired parameter number For new parameter settings See Page 67 Section 14 2 ...

Page 75: ...101 unlocks parameters P15 P53 Parameter Number Parameter Name Factory Default New Setting P01 Maximum Frequency Hz 50 0 60 0 P02 Minimum Frequency Hz 0 0 40 0 P03 Accel Time sec 5 10 P04 Decel Time sec 5 10 P07 Nominal Motor Voltage V 230 Motor Voltage P08 Rated Motor Current A 4 8 Rated Motor Current from Motor Data Plate P09 Rated Motor Frequency Hz 50 0 Rated Motor Frequency from Motor Data Pl...

Page 76: ... value is entered the dis play 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 67 Section 1...

Page 77: ...AC Teck Lenze AC Teck Lenze AC Teck Lenze AC Teck Lenze P01 P107 Line Voltage 01 01 01 01 P03 P110 Start Method 01 0 05 05 P05 P101 Standard Speed Source 01 0 0 03 0 10 VDC 04 4 20 mA 01 for0 10VDC 02 for 4 20 mA P44 P194 Password 225 0 0 Any 000 999 Any 0000 9999 P45 P102 Speed at Minimum Signal 0 0 0 0 Frequency Setting Noted on Page 70 Section 16 Frequency Setting Noted on Page 70 Section 16 P4...

Page 78: ...tely 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 71 Figure 49 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 longest branch of the system Use the down arrow button on the VFD to reduce the frequency of the output signal to the p...

Page 79: ...Locations Damper Coupling Damper NOTE Damper setting will vary Zone 1 Zone 2 Zone 3 Zone 1 End Vent Zone 3 End Vent Zone 2 End Vent Zone 1 Damper Coupling Zone 2 Damper Coupling Zone 3 Damper Coupling Pump Damper Description Part Number Damper Coupling 4 10 cm 01331900 Damper Coupling 6 15 cm E0009356 ...

Page 80: ...Set thermostat 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 Insp...

Page 81: ...ely remove these items if they are present See Page 5 Section 3 Vehicles and Other Objects Maintain the clearances to combustibles Do not hang anything from or place anything on the heater Make sure nothing is lodged underneath the reflector in between the tubes or in the decorative or protective grilles included with select models Immediately remove objects in violation of the clearances to combu...

Page 82: ...ed correctly and secured in place if necessary Decorative grille only See Page 35 Section 8 7 2 Pump With pump operating check for excessive vibration or noise Vibration is usu ally a sign that the impeller is out of balance Turn off the system insure power is shut off and remove the inlet plate Check the shaft seal and replace it if worn or missing With the Power off Check the inlet and outlet of...

Page 83: ...re Hazard Keep all flammable objects liquids and vapors the minimum required clearances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp WARNING Failure to follow these instructions can result in death injury or property damage Burn Hazard Allow heater...

Page 84: ...CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 76 of 85 18 1 Troubleshooting Flow Chart ...

Page 85: ...SECTION18 TROUBLESHOOTING 77 of 85 Troubleshooting Flow Chart ...

Page 86: ...tion 13 to help 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 75 Section 18 through Page 77 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 s...

Page 87: ...90400 Transformer 90436900K Regulator Replacement Kit 02725300 Gasket Combustion Chamber 01367800 Electrode Replacement Kit includes electrode electrode gasket and mounting screws 02713200 Ignition Module 90439500K Ignition Cable 90427706 Filter Cartridge with Gasket not shown 01312401 Ignition Module Regulator Gas Valve rotated to side Combustion Chamber Gasket Electrode Gasket Electrode Ignition...

Page 88: ... VFD Using procedure described on Page 66 Section 14 1 1 through Page 66 Section 14 1 5 alter parame ter according to VFD model and make as shown on on Page 67 or 69 19 1 2 Variable Frequency Drive 25 A or 10 A Fuse VFD For Modulating Thermostat Only To replace a fuse turn off input power to the variable frequency drive assembly at the breaker or disconnect switch Inside the VFD assembly open the ...

Page 89: ...eaters are as follows See Page 5 Section 3 for clearances to combustibles PIPE CONNECTION 1 2 NPT DIMENSIONS Vent Connection Size 4 10 cm or 6 15 cm Outside Air Connection Size 4 10 cm Refer to figure above for dimensional information GAS INLET PRESSURE Natural Gas 4 5 wc Minimum 14 0 wc Maximum LP Gas 10 5 wc Minimum 14 0 wc Maximum ELECTRICAL RATING 120 V 60 Hz 0 3 A Standard Reflector Heat Inpu...

Page 90: ...ump Specifications 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 TEFC TEFC TEFC TEFC TEFC Noise Level 5 DBA 70 70 Inlet Outlet In 4 ...

Page 91: ...OID IF The ROBERTS GORDON CORAYVAC 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 is moved or transferred This warranty is nontra...

Page 92: ...CRV SERIES INSTALLATION OPERATION AND SERVICE MANUAL 84 of 85 ...

Page 93: ...SECTION 21 THE ROBERTS GORDON CORAYVAC LIMITED WARRANTY 85 of 85 2017 ...

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