Roberts Gorden CorayVac Classic SF Series Operation & Service Manual
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Roberts Gorden CorayVac Classic SF Series Operation & Service Manual

Heavy duty, high efficiency infrared heating for specialty fuel repair facilities
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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 Department.
WARNING
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
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installing or
servicing this equipment.
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
*Approved and certified by CSA to meet maximum tube temperature
of 750 °F (399 °C) in accordance with NFPA30A7.6.6.
© 2018 Roberts-Gordon LLC
Heavy Duty, High Efficiency
Infrared Heating for
Specialty Fuel Repair
Installation, Operation &
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.
Keep this manual in a safe place in order to provide
your service technician with necessary information.
Roberts-Gordon LLC
1250 William Street
P.O. Box 44
Buffalo, New York 14240-0044
Telephone: +1.716.852.4400
Fax: +1.716.852.0854
Toll Free: 800.828.7450
www.robertsgordon.com
Facilities*
Service Manual
CRVSF-2
CRVSF-4
CRVSF-6
CRVSF-8
Installer
Owner
P/N 127302NA Rev. A 11/18

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Summary of Contents for Roberts Gorden CorayVac Classic SF Series

  • Page 1 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS ® SECTION 1: Heater Safety............1 13.3 CORAYVAC Modulating Controls ......43 1.1 Manpower Requirements ..........1 13.4 SPST Transformer Relay Kit (P/N 90417600K) ..46 1.2 Safety Labels and Their Placement ......1 13.5 SPDT Transformer Relay (P/N 90436300) ....46 1.3 California Proposition 65 ..........
  • Page 5 TABLE OF FIGURES Figure 38: CORAYVAC ® CLASSIC SF Modulating with ® BACnet Wiring Diagram (optional) ....55 Figure 1: Side Panel Label Placement........2 Figure 39: Burner Internal Wiring..........56 Figure 2: Top and Back Panel Label Placement ....... 3 Figure 40: Burner Internal Ladder Diagram ......

  • Page 7: Section 1: Heater Safety

    SECTION 1: H EATER AFETY SECTION 1: HEATER SAFETY Your Safety is Important to Us! 1.1 Manpower Requirements This symbol is used throughout To prevent personal injury and damage to the heater, the manual to notify you of two persons or more will be required for installation. possible fire, electrical or burn hazards.

  • Page 8: Figure 1: Side Panel Label Placement

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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 2 of 83...

  • Page 9: Figure 2: Top And Back Panel Label Placement

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

  • Page 10: Section 2: Installer Responsibility

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 2: INSTALLER RESPONSIBILITY The installer is responsible for the following: • To install the outside air supply system to each burner and end vent. • To ensure the system is designed in accordance with the parameters of the CRVSF-Series Design •...

  • Page 11: National Standards And Applicable Codes

    SECTION 2: I NSTALLER ESPONSIBILITY chemicals or halogenated hydrocarbons* anywhere in the premises. * Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These compounds are frequently used in refrigerants, cleaning agents, solvents, etc.

  • Page 12: Section 3: Clearances To Combustibles

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 3: CLEARANCES TO COMBUSTIBLES 3.1 Required Clearances to Combustibles required clearances from the heater to the combustibles. Signs must be posted adjacent to Clearances are the required distances that the heater thermostat. In the absence of a combustible objects must be away from the heater to thermostat, signs must be posted in a prevent serious fire hazards.

  • Page 13: Figure 4: One Side Reflector

    SECTION 3: C LEARANCES TO OMBUSTIBLES 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.

  • Page 14: Section 4: National Standards And Applicable Codes

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.5 Venting 4.1 Gas Codes The venting must be installed in accordance with The type of gas appearing on the nameplate the requirements within this manual and the must be the type of gas used.

  • Page 15: Section 5: Major Components

    SECTION 5: M AJOR OMPONENTS SECTION 5: MAJOR COMPONENTS The figures in this section provide a general overview of component placement in a CRVSF-Series system. The location of some components such as supports and couplings is crucial for proper installation. Assemble the heater components as shown on Page 15, Figure 12.

  • Page 16: Figure 9: Major Component Descriptions (Continued)

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 9: Major Component Descriptions (Continued) ROBERTS GORDON ® ULTRAVAC™ Controller (Models CRVSF-6/-8 only) EP-100 Pump Package - 4" dia For more information, refer to the EP-100 Installation, Operation and Service Manual (P/N 127201NA). ®...

  • Page 17: Figure 10: Schedule 40 Black Steel Fittings

    SECTION 5: M AJOR OMPONENTS FIGURE 10: Schedule 40 Black Steel Fittings Cross Threaded Coupling 90° Elbow 45° Elbow (All Schedule 40 Black Steel Fittings are supplied by others.) FIGURE 11: Optional Heater Accessories Reflector Side Extension Bracket Barrier Shield Reflector Side Extension Protective Grille 11 of 83...

  • Page 18: Standard Parts List For In-Series Systems

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 5.1 Standard Parts List for In-Series Systems Part No. Description Control Packages and Accessories Table 1: Contents of CRVSF-Series Burner Carton 10001501 Water Resistant Sensor Part No. Description 02770002 System Control 0270XXXX-SF Burner (Rate and Fuel Varies) ULTRAVAC™...
  • Page 19 SECTION 5: M AJOR OMPONENTS Part No. Description Part No. Description 90602451 Voltage Surge Suppressor 120 V Pump Accessories 90602452 Voltage Surge Suppressor 120/240 V 1 Ø 60 Hz 90430600K Pressure Switch 90602460 Line Reactor 480 V 3 Ø 60 Hz w/Enclosure (Output) 01327001 Condensate Check Valve Assembly 90602461...

  • Page 20: Section 6: Design Requirements

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 6: DESIGN REQUIREMENTS The CRVSF-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 contact the company responsible for the layout design, your ROBERTS GORDON...

  • Page 21: Figure 12: Heater Assembly Overview

    SECTION 6: D ESIGN EQUIREMENTS FIGURE 12: Heater Assembly Overview 15 of 83...

  • Page 22: Section 7: Unitary Heaters

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: UNITARY HEATERS attention to section and figure titles to verify relevance to in-series systems and unitary 7.1 In-Series Systems vs. Unitary Heaters heaters. CRVSF-Series burners may be used as in-series NOTE: Quantities and items listed in Table 3 systems or unitary heaters.

  • Page 23: Section 8: Heater Installation

    SECTION 8: H EATER NSTALLATION SECTION 8: HEATER INSTALLATION WARNING WARNING Severe Injury Hazard Burn Hazard Pipe compound may drip during first start-up. Hang heater with materials with a minimum working load of 750 lbs. (340 kg). Protect personnel and surfaces below heater Use special tube and reflector hangers when prior to start-up.

  • Page 24: Figure 14: Critical Hanger Placement

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 14: Critical Hanger Placement Run Length Typical Expansion Minimum “X” Length Description Part Number 50' (15 m) ±1" (3 cm) 12" (30 cm) Eyebolt Turnbuckle 91903202 100' (31 m) ±2" (5 cm) 24"...

  • Page 25: Tube Installation

    SECTION 8: H EATER NSTALLATION Step 8.1 Tube Installation 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 8.2 Elbow Package Configuration Step 8.2.1 Elbow Installation Minimum Distance Required Between Burner and Elbow...

  • Page 26: Reflector Installation

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 8.3 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. Install all threaded components with a minimum thread engagement of three threads.
  • Page 27 SECTION 8: H EATER NSTALLATION Step 8.3.2 Reflector Installation Description Part Number Reflector Support Package 02716400 U-Clip Package 91107720 Reflector End Cap 02750800 21 of 83...
  • Page 28 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 8.3.3 Reflector, U-Clip and Reflector Support Installation The pictorial drawings of the heater construction in reflector supports and U-clips depend on the Section 8 are schematic only and provide a general individual installation. Use either pop rivets or sheet guideline of where hangers, reflector supports and metal screws instead of u-clips when installing end U-clips are to be installed.

  • Page 29: Burner Installation

    SECTION 8: H EATER NSTALLATION 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 23 of 83...

  • Page 30: Section 9: Optional Heater Accessories

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 9: OPTIONAL HEATER ACCESSORIES WARNING Cut/Pinch Hazard Wear protective gear during installation, operation and service. Edges are sharp. Failure to follow these instructions can result in injury. Step 9.1 Tee Installation Description Part Number Supplied by Others Schedule 40 Tube/Reflector Hanger...

  • Page 31: Reflector Joint

    SECTION 9: O PTIONAL EATER CCESSORIES Step 9.2 Reflector Joint Step 9.2.1 Reflector Joint Installation Description Part Number Reflector End Cap 02750800 Reflector Joint 02750900 U-clip Package 91107720 Step 9.2.2 Reflector Joint Installation 25 of 83...

  • Page 32: Figure 15: Reflector Joint Detail

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 9.2.3 Reflector Joint Detail FIGURE 15: Reflector Joint Detail 26 of 83...

  • Page 33: Reflector Side Extension

    SECTION 9: O PTIONAL EATER CCESSORIES 9.3 Reflector Side Extension Step 9.3.1 Bracket 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 Step 9.3.2 Side Reflector Installation 27 of 83...

  • Page 34: Barrier Shield

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 9.4 Barrier Shield 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: Protective Grille Installation

    SECTION 9: O PTIONAL EATER CCESSORIES 9.5 Protective Grille Installation Step 9.5.1 Silicone Cap Installation Silicone Cap Description Part Number Grille Grille Section 08050001 Finger Grille End Cap 08050002 Silicone Cap 91915951-6P Step 9.5.2 Grille End Cap Installation Grille Grille End Cap Bend up 90°...

  • Page 36: Section 10: Pump Installation And Venting

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: PUMP INSTALLATION AND VENTING WARNING WARNING Carbon Monoxide Hazard Cut/Pinch Hazard Wear protective gear during installation, Heaters installed unvented must be interlocked with sufficient building exhaust. operation and service. Edges are sharp. Heaters must be installed according to the installation manual.
  • Page 37 SECTION 10: P NSTALLATION AND ENTING 10.1.1 Condensate Neutralization Tube (optional) (600,000/100,000) x 0.3 = 1.8 (gal/h) If a condensate neutralization tube is specified to be Step 3: Choose the condensate neutralization used with the heating system, follow the steps below tube to choose the proper condensate neutralization tube.

  • Page 38: General Venting Requirements Model Ep-100, Ep-200 And Ep-300 Series Pumps

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 17: Condensate Neutralization 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...
  • Page 39 SECTION 10: P NSTALLATION AND ENTING 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 equipment. NOTE: Vertical venting (venting through roof) is not recommended.
  • Page 40 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 18: EP-100 & EP-200 Horizontal Venting Configurations Pump Maximum Length A Maximum Number of Elbows EP-100 25' (8 m) EP-200 10' (3 m) Part Number Description Part Number Description 01330203 Tee, 4" (10 cm) Porcelain 90502101 Vent Terminal, 6"...

  • Page 41: Figure 19: Ep-300 Series Horizontal Venting Configurations

    SECTION 10: P NSTALLATION AND ENTING FIGURE 19: EP-300 Series Horizontal Venting Configurations Part Number Description Part Number Description 01330203 Tee, 4" (10 cm) Aluminized 91409403 Tube, Aluminized 4" (10 cm) dia. 10' (3 m) 01330204 Tee, 6" (15 cm) Aluminized 91409420 Tube, Aluminized 6"...

  • Page 42: Section 11: Outside Air Supply

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 11: OUTSIDE AIR SUPPLY and end vent via flexible duct as system will expand and contract. For length and duct sizing CAUTION requirements, see duct design rules in Figure 20. To prevent condensation, insulate the outside air duct. Product Damage Hazard Do not use heater in area containing corrosive chemicals.

  • Page 43: Outside Air Blower Internal Wiring

    SECTION 11: O UTSIDE UPPLY FIGURE 20: Duct Sizing Outside Air System Design Requirements: Blower Performance (90707501K): 112 Flow Units One outside air blower is required per each EP-100 or EP-200 series pump and two outside air blowers may be required for each EP-300 series pump. Outside air blowers cannot be shared between two separate CRVSF-Series systems.

  • Page 44: Figure 22: Filter Housing Assembly

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 22: Filter Housing Assembly 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 FIGURE 23: Air Supply Blower Support Description...

  • Page 45: Figure 24: Pressurized Outside Air Supply

    SECTION 11: O UTSIDE UPPLY FIGURE 24: Pressurized Outside Air 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 FIGURE 25: Non-Pressurized Outside Air Supply Description...

  • Page 46: Figure 26: Filter Box

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 26: Filter Box 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. Description Part Number Fresh Air Filter Box 90740100K Filter Box 9074100...

  • Page 47: Section 12: Gas Piping

    SECTION 12: G IPING SECTION 12: GAS PIPING There is an expansion of the tube with each firing cycle. This will cause the burner to move with respect to the gas hose. This can cause a gas leak resulting in an unsafe condition if the gas connection is not made in strict accordance with Figure 27.

  • Page 48: Figure 27: Gas Connection With Flexible Gas Hose

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 27: Gas Connection with Flexible Gas Hose See Page 75, Section 20. Description Part Number High Pressure Regulator - 2 psi 90207600 High Pressure Regulator - 5 psi 90207601 Description Part Number 1/2"...

  • Page 49: Section 13: Control Methods

    SECTION 13: C ONTROL ETHODS SECTION 13: CONTROL METHODS control provides indication of power to the pump and zones and indicates the status of the pressure switch DANGER with lights. The System Control is ETL listed in accordance with UL873 – Standard for Temperature Indicating and Regulating Equipment.
  • Page 50 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL any one of the existing ROBERTS GORDON ® 13.3.3 Analog signal Modulating with BACnet ® assemblies. The result will be a one pump, one zone Programmable Thermostat ® CORAYVAC Modulating system. The system will If BACnet ®...

  • Page 51: Figure 28: Vfd Terminal Strip

    SECTION 13: C ONTROL ETHODS 13.3.4 Cable Requirement Table 5, on Page 45, lists wiring types, sizes and distances for modulating thermostat communication. Power Requirement Programmable thermostats requires 24 volt, AC power. Table 5: Modulating Thermostat Cable Requirements Wire Function Recommended Wire Size Specification or Distance (Maximum)

  • Page 52: Spst Transformer Relay Kit (P/N 90417600K)

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL the temperature setpoint, the modulating thermostat and the VFD will reduce the signal output, in turn reducing the heater firing rate. Upon satisfying temperature setpoint, the modulating thermostat and the VFD will either: 1.

  • Page 53: Figure 29: One Zone Operation Without Control Panel (Optional)

    SECTION 13: C ONTROL ETHODS FIGURE 29: One Zone Operation without Control Panel (optional) Description Part Number SPST Transformer Relay 90417600K 47 of 83...

  • Page 54: Figure 30: One Zone Operation (With Outside Air Blower) Without Control Panel (Optional)

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 30: One Zone Operation (with Outside Air Blower) without Control Panel (optional) 48 of 83...

  • Page 55: Figure 31: Two Zone Operation Without Control Panel (Optional)

    SECTION 13: C ONTROL ETHODS FIGURE 31: Two Zone Operation without Control Panel (optional) Description Part Number SPDT Transformer Relay 90436300 49 of 83...

  • Page 56: Figure 32: General System Wiring

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 32: General System Wiring FIGURE 33: External Wiring Diagram EP-100 and EP-201 120 V 1 Ø Pump 50 of 83...

  • Page 57: Figure 34: External Wiring Diagram Ep-100, Ep-201 Or Ep-301 230 V 1 Ø Pump (Optional)

    SECTION 13: C ONTROL ETHODS FIGURE 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: Figure 35: External Wiring Diagram Ep-203 Or Ep-303 208 - 230 V (Or 460 V) 3 Ø Pump (Optional)

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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: Figure 36: Corayvac Classic Sf Modulating Wiring Diagram [Lonworks (2-10 Vdc With 500 Ohm Resistor) Optional]

    SECTION 13: C ONTROL ETHODS FIGURE 36: CORAYVAC ® CLASSIC SF Modulating 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 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 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 54 of 83...

  • Page 61: Classic Sf Modulating With

    SECTION 13: C ONTROL ETHODS FIGURE 38: CORAYVAC ® CLASSIC SF Modulating with BACnet ® Wiring Diagram (optional) Description Part Number SPST Transformer Relay 90417600K ® 90425109 Thermostat, Modulating BACnet 55 of 83...

  • Page 62: Figure 39: Burner Internal Wiring

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 39: Burner Internal Wiring TRANSFORMER White Yellow Black 120 V Green Power Supply Blue Yellow Green Brown VALVE Yellow V2/GND Black IGNITION MODULE BURNER If any of the original wire as supplied with the heater must be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C and 600 volts.

  • Page 63: Section 14: Starting The System

    SECTION 14: S TARTING YSTEM SECTION 14: STARTING THE SYSTEM WARNING DANGER Explosion Hazard Carbon Monoxide Hazard Burn Hazard Electrical Shock Hazard Leak test all compo- Heaters installed Allow heater to cool Disconnect electric unvented must be nents of gas piping before service.

  • Page 64: Setting The Vacuum

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 14.4 Setting the Vacuum 1. Set temperature setpoints above room tempera- ture. See that all burners are operating properly. 2. Allow at least one hour operation for tempera- ture to normalize, then check system vacuum balance.

  • Page 65: Figure 41: Vacuum Reading

    SECTION 14: S TARTING YSTEM FIGURE 41: Vacuum Reading 59 of 83...

  • Page 66: Section 15: Variable Frequency Drive Programming

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: VARIABLE FREQUENCY DRIVE PROGRAMMING 15.1 VFD Parameter Settings For Use With (the factory set password is 225). Modulating Thermostats Press Mode to enter password. The VFD parameters come with factory default set- Once the correct password value is entered, the dis- tings.

  • Page 67: Altering Vfd Parameters

    SECTION 15: V ARIABLE REQUENCY RIVE ROGRAMMING 15.2 Altering VFD Parameters Using the procedure described on Page 60, Section 15.1.1 through Section 15.1.5, alter the following parameters: Parameter Parameter Factory Number Name Default Setting Line Voltage Start Method Standard (03) (0-10) Vdc Speed (04) (4-20) mA Source...

  • Page 68: Section 16: Commissioning The Corayvac

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 16: COMMISSIONING THE CORAYVAC ® CLASSIC SF MODULATING SYSTEM NOTE: Before starting the commissioning procedure, reduce the frequency until the end vent vacuum all the wiring of the ROBERTS GORDON ® reading is between 2.5" - 3.0" wc. Make note of this frequency setting below.

  • Page 69: Programming Of Variable Frequency Drive

    SECTION 16: C CORAYVAC ® CLASSIC SF M OMMISSIONING ODULATING YSTEM 16.3 Programming Of Variable Frequency Drive Parameter Parameter Factory Number Name Default Setting Line Voltage Start Method Standard (03) (0-10) Vdc Speed (04) (4-20) mA Source Password Any # 000-999 Speed at 0.0Hz...

  • Page 70: Figure 42: Possible Damper Nipples' Locations

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 42: Possible Damper Nipples’ Locations Description Part Number Schedule 40 Damper Nipple 01332000 64 of 83...

  • Page 71: Section 17: Operation And Maintenance

    SECTION 17: O PERATION AND AINTENANCE SECTION 17: OPERATION AND MAINTENANCE WARNING DANGER Electrical Shock Hazard Explosion Hazard Burn Hazard Cut/Pinch Hazard Turn off gas supply to Allow heater to cool Wear protective gear Disconnect electric heater before service. before service. during installation, before service.

  • Page 72: Maintenance Checklist

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL inspection of the heater. All installation and service of ROBERTS GORDON ® For best performance, the gas, electrical, thermostat equipment must be performed by a contractor connections, tubing, venting, suspensions and qualified in the installation and service of equipment overall heater condition should be thoroughly sold and supplied by Roberts-Gordon LLC and inspected.
  • Page 73 SECTION 17: O PERATION AND AINTENANCE Check for gas leaks. See Page 42, Figure 27. Gas Line Combustion Chamber Make sure it is clean and free of cracks or holes. Window Clean or replace as required. Blower Scroll, Wheel and Compressed air or a vacuum cleaner may be used to clean dust and dirt.

  • Page 74: Section 18: Troubleshooting

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 18: TROUBLESHOOTING DANGER Electrical Shock Hazard Disconnect electric before service. More than one disconnect switch may be required to disconnect electric from heater. Heater must be properly grounded. Failure to follow these instructions can result in death or electrical shock.

  • Page 75: Troubleshooting Flow Chart

    SECTION 18: T ROUBLESHOOTING 18.1 Troubleshooting Flow Chart 69 of 83...
  • Page 76 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Troubleshooting Flow Chart 70 of 83...

  • Page 77: Section 19: Replacement Parts

    SECTION 19: R EPLACEMENT ARTS SECTION 19: REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Carbon Monoxide Hazard Fire Hazard 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. See warnings and important information before removing or replacing parts.
  • Page 78 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Gasket (Burner to Mixing Chamber) Transformer Burner Head Mixing Chamber Ignition Module Ignition Cable Regulator Electrode Electrode Gasket Combustion Gas Valve Chamber Gasket NOTE: In the event that a manifold replacement part is needed (e.g. gas valve, regulator), please contact Roberts-Gordon LLC or your ROBERTS GORDON ®...

  • Page 79: Variable Frequency Drive Replacement Parts

    SECTION 19: R EPLACEMENT ARTS 19.1 Variable Frequency Drive Replacement Parts Caution: Use only genuine ROBERTS GORDON ® replacement parts. Use of parts not specified by Roberts-Gordon voids warranty. FIGURE 43: Variable Frequency Drive Components Diagram Description Part Number Variable Frequency Drive, 1 HP, 120 V, 1 Ø Input (for use with EP-203) 10081201 Variable Frequency Drive, 3/4 HP, 230 V, 1 Ø...

  • Page 80: Replacement Parts Instructions

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.2 Replacement Parts Instructions switch on the relay board. Inside the VFD assembly, open the fuse holder by DANGER pulling down the lever to expose the fuse. Remove the old fuse and insert a new fuse. Verify the correct fuse rating, 25 A for 1 HP 120 V VFD or 2 HP 230 V VFD, 10 A for the.75 HP 230 V VFD, 1 HP 460 V VFD and 2 HP 460 V VFD.

  • Page 81: Section 20: General Specifications

    SECTION 20: G ENERAL PECIFICATIONS SECTION 20: GENERAL SPECIFICATIONS 20.1 Material Specifications 20.3 Suspension Specifications 20.1.1 Reflectors Hang heater with materials with a minimum working load of 750 lbs (340 kg). See Page 18, Figure 14. .024 Aluminium. 20.4 Controls Specifications 20.2 Heater Specifications Time switches, thermostats, etc.

  • Page 82: Section 21: General Specifications For Pumps

    CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 21: GENERAL SPECIFICATIONS FOR PUMPS Pump Dimensional Data (in.) Model EP-100 14.5 3.75 EP-201/203 17.75 20.25 3.25 EP-301/303 25.6 24.8 22.7 15.2 dia. Model EP-100 EP-201 EP-203 EP-301 EP-303 Horsepower (Hp) Phase (Ø) Hertz (Hz) Voltage (V) 115/230...

  • Page 83: Section 23: General Specifications For Fresh Air Filter Box Specifications

    SECTION 23: G ENERAL PECIFICATIONS RESH ILTER PECIFICATIONS SECTION 23: GENERAL SPECIFICATIONS FOR FRESH AIR FILTER BOX SPECIFICATIONS Filter Box Dimensional Data 20" (51 cm) 15" (38 cm) 20" (51 cm) 8" (20 cm) 2" (5 cm) 20" (51 cm) 77 of 83...
  • Page 84 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 78 of 83...

  • Page 85: Section 24: Corayvac Classic Sf Start-Up And Installation Report

    SECTION 24: CORAYVAC ® CLASSIC SF S TART P AND NSTALLATION EPORT SECTION 24: CORAYVAC ® CLASSIC SF START-UP AND INSTALLATION REPORT ® CORAYVAC Classic SF Start-Up and Installation Report Date of Installation: Model # Serial # Installed at: Service Company: Name: Name: Address:...
  • Page 86 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL CORAYVAC ® CLASSIC SF START-UP AND INSTALLATION REPORT (Continued) ® CORAYVAC Classic SF Start-Up and Installation Report Fill out one report per system (1 pump). System defi ned as in-series burners connected to a single vacuum pump. 8.

  • Page 87: Figure 38: Corayvac

    SECTION 24: CORAYVAC ® CLASSIC SF S TART P AND NSTALLATION EPORT CORAYVAC ® CLASSIC SF START-UP AND INSTALLATION REPORT (Continued) 12. Units Installed Branch 1 Branch # Model Serial Number Tube Temperature* (See Drawing) 1(@ End Burner) Branch 2 Branch # Model Serial Number...
  • Page 88 CRVSF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 82 of 83...

  • Page 89: Section 25: The Roberts Gordon

    SECTION 25: T ROBERTS GORDON ® CORAYVAC ® CLASSIC SF L IMITED SECTION 25: THE ROBERTS GORDON ® CORAYVAC ® CLASSIC SF LIMITED WARRANTY ROBERTS-GORDON LLC WILL PAY FOR: You cannot prove original purchase date and required annual maintenance history. Within 36 months from date of purchase by buyer or 42 The data plate and/or serial number are removed, months from date of shipment by Roberts-Gordon LLC...

This manual is also suitable for:

Corayvac crvsf-8Corayvac crvsf-2Corayvac crvsf-4Corayvac crvsf-6

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