Page 3 - TABLE OF CONTENTS; ULTRAVAC; SECTION 18: The ROBERTS GORDON
© 2006 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 wri...
Page 5 - TABLE OF FIGURES; Figure 31: External Wiring Diagram EP-301
TABLE OF FIGURES Figure 1: Standard Reflector ..................................................... 4Figure 2: One Side Reflector ..................................................... 4Figure 3: Two Side Reflectors ................................................... 4Figure 4: Universal Shield, Posi...
Page 7 - SECTION 1: HEATER SAFETY
SECTION 1: H EATER S AFETY 1 SECTION 1: HEATER SAFETY Your Safety is Important to Us!This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings in these sections. Installation, service and...
Page 8 - SECTION 2: INSTALLER RESPONSIBILITY; through Page; Corrosive Chemicals; * Halogenated Hydrocarbons; National Standards and Applicable Codes; AUTION
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 2 SECTION 2: INSTALLER RESPONSIBILITY The installer is responsible for the following: • To ensure the system is designed in accordance with the parameters of the CRV-Series Design Manual (P/N 127500NA). • To install the heater, as well as t...
Page 9 - SECTION 3: CRITICAL CONSIDERATIONS; through; WARNING; Fire Hazard
SECTION 3: C RITICAL C ONSIDERATIONS 3 SECTION 3: CRITICAL CONSIDERATIONS 3.1 Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the heater to prevent serious fire hazards. Combustibles are materials that may catch fire and include co...
Page 11 - Model
SECTION 3: C RITICAL C ONSIDERATIONS 5 NOTE: 1. All dimensions are from the surfaces of all tubes, couplings, elbows, tees and crosses.2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the combustion chamber and the tube connect. FIGURE 4: UNIVERSAL SHI...
Page 13 - SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES; , local ordinances and any
SECTION 4: N ATIONAL S TANDARDS AND A PPLICABLE C ODES 7 SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Gas Codes The type of gas appearing on the nameplate must be the type of gas used. Installation must comply with national and local codes and requirements of the local gas company. United ...
Page 16 - System Control; ROBERTS GORDON
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 10 FIGURE 10: Major Component Descriptions (Continued) DANGER © P/N 91008001 www.rg - inc.com Printed in the U .S.A Imprimé aux E tats-Unis DANGER Electrical Shoc k Hazard Disconnect electrical power before servicing. This appliance must be...
Page 17 - Standard Parts List; Table 1: Contents of CRV-Series Burner Carton; Description
SECTION 5: M AJOR C OMPONENTS 11 5.1 Standard Parts List Table 1: Contents of CRV-Series Burner Carton * Canadian Models: Rubber (Type 1) Gas Hoses available as an accessory, see Page 41 . Table 2: Common CRV-Series Components Part No. Description 0270XXXX Burner (Rate and Fuel Varies) *91412200 Fle...
Page 18 - Starters
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 12 Control Packages and Accessories 10001501 Water Resistant Sensor 02770002 System Control URVCCM ROBERTS GORDON ® ULTRAVAC™ Central Controller (with Modem Chip & Software) Includes: URVSC ROBERTS GORDON ® ULTRAVAC™ Controller 10080142...
Page 19 - SECTION 6: DESIGN REQUIREMENTS; independent distributor,
SECTION 6: D ESIGN R EQUIREMENTS 13 SECTION 6: DESIGN REQUIREMENTS The CRV-Series system’s design is related to the system operation and performance required by the building being heated. Every effort should be made to follow the dimensions on the layout drawing. If deviations are necessary, either ...
Page 20 - FIGURE 11: Heater Assembly Overview
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 14 FIGURE 11: Heater Assembly Overview End Vent C omb ustion Chamber Tube & Re flect or Hanger Bur ner R ef lect or Tube C oupling R ef lect or End C ap R ef lect or Suppor t Fle xib le Boot R ef lect or w ith Hole Pump Exhaust to Outsi...
Page 21 - SECTION 7: HEATER INSTALLATION; Suspension Hazard; Hang heater with materials with a; Side View Towards Pump; Typical Suspension Details; Hanger; Run Length
SECTION 7: H EATER I NSTALLATION 15 SECTION 7: HEATER INSTALLATION To ensure your safety and comply with the terms of the warranty, all units must be installed in accordance with these instructions. The gas or the electrical supply lines must not be used to support the heater. Do not locate the gas ...
Page 22 - Tube; Closed; Coupling; Close coupling with tab.
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 16 Step 7.1 Tube Installation Step 7.2 Coupling and Tube Assembly Combustion Chamber 7' 6" (229 cm) Combustion Chamber NOTE: Tubing requires a downward slope of 1/2" (13 mm) per 20' (6 m) away from burner. Tailpipe tubing requires a...
Page 23 - Elbow Package Configuration; Incorrect Slide Bar; Drive slide bar until tight.; Repeat; lbow; up
SECTION 7: H EATER I NSTALLATION 17 Step 7.2.1 Coupling and Tube Assembly (Continued) 7.3 Elbow Package Configuration Step 7.3.1 Elbow Installation Step 7.3.2 Elbow Installation Incorrect Slide Bar Position Correct Slide Bar Dimensions ± 2" (5 cm) Drive slide bar until tight. End of slide bar sh...
Page 24 - ol
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 18 Step 7.4 Reflector Installation Step 7.4.1 Reflector Installation with Hole Step 7.4.2 Reflector Installation T u b e Han g er C o m b usti o n Cham b er S l ide Ref l ect o r w ith h ol e thr o u g h han g er. Unh oo k c o m b usti o n ...
Page 25 - The pictorial drawings of the heater construction in; slip overlap; Reflector
SECTION 7: H EATER I NSTALLATION 19 Step 7.4.3 Reflector, U-Clip and Reflector Support Installation The pictorial drawings of the heater construction in Section 7 are schematic only and provide a general guideline of where hangers, reflector supports and U-clips are to be installed. To ensure proper...
Page 26 - Step 7.5 Burner Installation
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 20 Step 7.5 Burner Installation Gasket Burner Combustion Chamber End Vent NOTE: Install end vent at end combustion chamber position only. Burner Combustion Chamber End Vent End Vent Clips Rating Number Description Part Number Bolt 94273914 ...
Page 27 - SECTION 8: OPTIONAL HEATER ACCESSORIES; ee
SECTION 8: O PTIONAL H EATER A CCESSORIES 21 SECTION 8: OPTIONAL HEATER ACCESSORIES Step 8.1 Tee Installation Step 8.2 Reflector Joint Step 8.2.1 Reflector Joint Installation T ee T u b e C o up l in g Description Part Number Tee 01330XXX Tube/Reflector Hanger 03090100 Tube 91409XXX Coupling 0131270...
Page 28 - FIGURE 13: Reflector Joint Detail
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 22 Step 8.2.2 Reflector Joint Installation Step 8.2.3 Reflector Joint Detail FIGURE 13: Reflector Joint Detail Cut awa y contour with tin snips. Punch/drill six 3 / 32" (2 mm ) holes. Install reflector end cap. Attach reflector j oint w...
Page 29 - Retainer Clip
SECTION 8: O PTIONAL H EATER A CCESSORIES 23 8.3 Reflector Side Extension Step 8.3.1 Bracket Installation Step 8.3.2 Side Reflector Installation Ref l ect o r Side Extensi o n Bracket (2 per ref l ect o r ) Use additi o na l supp o rts in hi g h air m o vement app l icati o ns. T u b e and Ref l ect...
Page 31 - Two-Foot Decorative Grille Installation; Shie
SECTION 8: O PTIONAL H EATER A CCESSORIES 25 8.6 Two-Foot Decorative Grille Installation Step 8.6.1 Grille Installation Step 8.6.2 Frame Shield Installation Suspended Ceiling Frame Heat Exchanger Tube 2' x 4' (60 cm x 120 cm) Aluminum Grille Reflector Tube and Reflector Hanger Description Part Numbe...
Page 32 - One-Foot Decorative Grille Installation
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 26 Step 8.6.3 Reflector Side Extension Installation for Decorative Grilles 8.7 One-Foot Decorative Grille Installation Step 8.7.1 One-Foot Decorative Grille Bracket Reflector Side Extension Cut relief notches for tube and reflector hangers....
Page 33 - Spread apart brackets
SECTION 8: O PTIONAL H EATER A CCESSORIES 27 Step 8.7.2 Decorative Grille Step 8.7.3 Joint Piece and Reinforcement Spread apart brackets and install decorative grille. Description Part Number Decorative Grille 8' x 1' (2.4 m x .3 m) 91406700 # 8 Sheet M etal Screws J oint Piece Reinforcement Slip j ...
Page 34 - Step 8.7.4 End Piece and Reflector End Cap
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 28 Step 8.7.4 End Piece and Reflector End Cap Step 8.7.5 90° Elbow F asten end piece to brackets using two # 8 sheet metal screws and replace reflector end cap. Insert end piece between grille and brackets. End Piece Reflector End Cap Descr...
Page 35 - Protective Grille Installation; Silicone Cap; ll
SECTION 8: O PTIONAL H EATER A CCESSORIES 29 8.8 Protective Grille Installation Step 8.8.1 Silicone Cap Installation Step 8.8.2 Grille End Cap Installation Step 8.8.3 Grille Installation Silicone Cap Grille Finger Description Part Number Grille Section 08050001 Grille End Cap 08050002 Silicone Cap 9...
Page 36 - Cast-Iron Combustion Chamber
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 30 Step 8.9 Classic Cast-Iron Components WARNING Suspension Hazard Hang heater with materials with a minimum wor k ing load of 750 lbs. (340 k g). Use special tube and reflector hangers when suspending the schedule 40 steel pipe system.Sche...
Page 37 - SECTION 9: PUMP INSTALLATION AND VENTING; flow
SECTION 9: P UMP I NSTALLATION AND V ENTING 31 SECTION 9: PUMP INSTALLATION AND VENTING 9.1 Pump Installation For complete pump installation, please refer to the EP-100, EP-200 or EP-300 Series Installation, Operation and Service Manuals. FIGURE 14: EP-20 0 Condensate Valve Assembly Wall 1" NPT ...
Page 38 - Length Requirements
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 32 9.2 General Venting Requirements Model EP-100, EP-200 and EP-300 Series Pumps This heater must be vented in accordance with the rules contained in this manual and with the following national codes and any state, provincial or local codes...
Page 39 - FIGURE 15: Vertical Venting Configuration; Part Number
SECTION 9: P UMP I NSTALLATION AND V ENTING 33 FIGURE 15: Vertical Venting Configuration Approved Vent Cap Approved Thimble 2' (.6 m) Minimum Aluminized Tee 1" (2.5 cm) P.V.C to drain system in accordance with local codes. Drain Cap Clamps Flexible Boot 6"(1.5 cm) 20"(5.1 cm) for EP-300 ...
Page 40 - FIGURE 16: EP-100 Horizontal Venting Configurations
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 34 9.3 Horizontal Venting 4" (10 cm) Pipe FIGURE 16: EP-100 Horizontal Venting Configurations 25' (8 m) and 3 Elbows Maximum 50' (15 m) and 3 Elbows Maximum Bird Screen 4" (10 cm) Single Wall Pipe 5" (12.5 cm) Single Wall Pipe V...
Page 41 - FIGURE 17: EP-20 0 Series Horizontal Venting Configurations
SECTION 9: P UMP I NSTALLATION AND V ENTING 35 FIGURE 17: EP-20 0 Series Horizontal Venting Configurations 10' (3 m) Maximum and No Elbows 25' (8 m) and 3 Elbows Maximum 50' (15 m) and 3 Elbows Maximum 4" (10 cm) Single Wall Pipe 5" (12.5 cm) Single Wall Pipe 6" (15 cm) Single Wall Pipe ...
Page 42 - FIGURE 18: EP-30 0 Series Horizontal Venting Configurations
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 36 FIGURE 18: EP-30 0 Series Horizontal Venting Configurations 10' (3 m) Maximum and 1 Elbow Approved Thimble Vent Terminal Tjernlund VH1- 6" (15 cm) or Equivalent (Not Included) 6" (15 cm) Bird Screen (Included) 18" (46 cm) Min...
Page 43 - SECTION 10: OUTSIDE AIR SUPPLY
SECTION 10: O UTSIDE A IR S UPPLY 37 SECTION 10: OUTSIDE AIR SUPPLY The CRV-Series system is approved for use with an outside air system. Halogenated hydrocarbons or other corrosive chemicals in the air can be drawn into the equipment and seriously damage the system components. Avoid the use of such...
Page 44 - oo
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 38 10.3 Outside Air Blower Internal Wiring FIGURE 20: Outside Air Blower Internal Wiring Diagram FIGURE 21: Filter Housing Assembly L MOTOR M N BLK WHT T1 T3 T2 C NO BLU BLU BLOWER PRESSURE SWITCH Outside air blower is shipped with the blow...
Page 45 - FIGURE 22: Air Supply Blower Support; Outside
SECTION 10: O UTSIDE A IR S UPPLY 39 FIGURE 22: Air Supply Blower Support FIGURE 23: Pressurized Outside Air Supply Wall Outside Air Supply Blower Outside Wall 5" (12.5 cm) Inlet Pipe 5" (12.5 cm) Outlet Pipe Bird Screen or Vent Cap Description Part Number Blower 90707501 5" (12.7 cm) Ve...
Page 46 - FIGURE 24: Non-Pressurized Outside Air Supply
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 40 FIGURE 24: Non-Pressurized Outside Air Supply Vent Cap Outside Wall 7/16" (11.1 mm) Diameter Hole Pressure Switch Lock Nuts 6' (1.8 m) Maximum Bird Screen or Description Part Number Pressure Switch Kit 90434501 4" (10 cm) Bird Sc...
Page 47 - SECTION 11: GAS PIPING; Install the gas hose as shown in; • Do not high pressure test the gas piping with
SECTION 11: G AS P IPING 41 SECTION 11: GAS PIPING Install the gas hose as shown in Figure 25 . The gas hose accommodates expansion of the heating system and allows for easy installation and service of the burner. Before connecting the burners to the supply system, verify that all high pressure test...
Page 48 - on; Electrical Shoc
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 42 SECTION 12: CONTROL METHODS There are several methods of controlling CRV-Series systems. The options are as follows: 12.1 ROBERTS GORDON ® System Control The System Control is an electronic control panel designed to control CRV-Series he...
Page 49 - FIGURE 26: One Zone Operation without Control Panel; Ground
SECTION 12: C ONTROL M ETHODS 43 FIGURE 26: One Zone Operation without Control Panel 1 2 3 4 5 6 COIL COIL R C W G Y Thermostat Pump Motor Pressure Switch (Pump) SPST (12A) Transformer Relay Zone 1 Burners N L L N Nine Burners Maximum Black White Red Black L 120 V 1 Ø 60 Hz N Ground Description Part...
Page 51 - FIGURE 28: Two Zone Operation without Control Panel
SECTION 12: C ONTROL M ETHODS 45 FIGURE 28: Two Zone Operation without Control Panel 1 2 3 4 5 6 COIL COIL R C W G Y 1 2 3 4 5 6 COIL COIL R C W G Y Pump Motor Pressure Switch (Pump) Transformer Relay Zone 1 Burners Zone 2 Burners N L L N L N Nine Burners Total Maximum Between Zones DPST (12 A) Tran...
Page 52 - FIGURE 29: General System Wiring; separate power circuit; System
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 46 FIGURE 29: General System Wiring FIGURE 30: External Wiring Diagram EP-100 and EP-201 120 V 1 Ø Pump Burner Receptacles 4 Zone Max 120 Vac Maximum 20 Amps Total Thermostats Outside Air Supply Blower Motor and Pressure Switch Pump Motor 1...
Page 55 - SECTION 13: STARTING THE SYSTEM
SECTION 13: S TARTING T HE S YSTEM 49 SECTION 13: STARTING THE SYSTEM Start with the main gas valve closed and the electric power off. 13.1 Checking the Gas Line 1. Open the main valve and verify that no gas is flowing through the meter. 2. Purge the line if this was not done following pressure test...
Page 56 - FIGURE 35: Vacuum Reading; Insert tubing; Approximate reading after
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 50 FIGURE 35: Vacuum Reading Insert tubing about 6" (15 cm). Combustion Chamber at end position End Vent Manometer 6543210123456 Approximate reading after adjusting damper couplings and pump inlet. ( 2.5"- 3.0" w.c.) ~~
Page 57 - SECTION 14: OPERATION AND MAINTENANCE; To Shut Off Heater
SECTION 14: O PERATION AND M AINTENANCE 51 SECTION 14: OPERATION AND MAINTENANCE The heater is equipped with a direct-spark ignition system. 14.1 Sequence of Operation 1. Turn the thermostat up. When the thermostat calls for heat, the pump will start immediately. After a short period, the burners wi...
Page 58 - See Page 3, Section 3
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 52 14.5 Maintenance Checklist Installation Code and Annual Inspections: All installations and service of ROBERTS GORDON ® products must be performed by a contractor qualified in the installation and service of products sold and supplied by ...
Page 60 - Pump; Check the condition and operation of the pressure switch.
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 54 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 replac...
Page 61 - SECTION 15: TROUBLESHOOTING
SECTION 15: T ROUBLESHOOTING 55 SECTION 15: TROUBLESHOOTING 15.1 Troubleshooting Flow Chart W rong end v ent plat e ma y be inst alled. Mak e sur e plat e and b ur ner match. Is the v acuum set ting too high? Ye s Adjust s ys tem f or pr oper vacuum at the end v ent. Is the pump impeller obstr uct e...
Page 62 - Troubleshooting Flow Chart; Control Panel IOS Manuals:; TS GORDON
CRV-S ERIES I NSTALLATION , O PERATION AND S ERVICE M ANUAL 56 Troubleshooting Flow Chart No Replace filters as necessar y. Replace the electrodes. Adjust the gap or replace the electrode. Ignition module may have failed. Replace module. Electrode gap should be 1/8". Is the gap too small? No Ye ...
Page 63 - SECTION 16: REPLACEMENT PARTS
SECTION 16: R EPLACEMENT P ARTS 57 SECTION 16: REPLACEMENT PARTS Use only genuine ROBERTS GORDON ® replacement parts. Use of parts not specified by Roberts-Gordon voids warranty.Failure to follow these instructions can result in property damage. Description Part Number Gas Valve (All Burners) 900325...
Page 65 - General Specifications for pumps are as follows:; Air Supply Blower Specifications
SECTION 17: G ENERAL S PECIFICATIONS 59 General Specifications for pumps are as follows: * For starter, see National Electric Code (NEC) requirement for motors 1 hp or higher. Air Supply Blower Specifications Capacity 240 CFM @ 0.75 in wc Power (W) 167 Phase 1 Hertz (Hz) 60 Voltage (V) 120 Full Load...
Page 67 - SECTION 18: THE ROBERTS GORDON
SECTION 18: T HE ROBERTS GORDON ® CORAYVAC ® LIMITED W ARRANTY 61 SECTION 18: THE ROBERTS GORDON ® CORAYVAC ® LIMITED WARRANTY ROBERTS-GORDON WILL PAY FOR: Within 42 months from date of shipment from Roberts-Gordon, replacement parts will be provided free of charge for any part of the product which ...
Page 69 - OWNER WARRANTY REGISTRATION CARD; Installation Code and Annual Inspections:
® OWNER WARRANTY REGISTRATION CARD About the Owner: Name:Address: City: State: Zip Code: Phone: Fax: E-mail: About the Installer: Name:Address: City: State: Zip Code: Phone: Fax: E-mail: Purchased From (if different than installer): Name:Address: City: State: Zip Code: Phone: Fax: E-mail: About your...
Page 72 - I n f r a r e d H e a t i n g; Attach this information to a wall near the ROBERTS GORDON
I n f r a r e d H e a t i n g Maintain ???? cm clearance to the side and ???? cm clearance below the heater from vehicles and combustible materials. www.rg-inc.com Printed in U.S.A. P/N 91037912 Rev. C Attach this information to a wall near the ROBERTS GORDON ® heater. Read the Installation, Operati...
