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Roberts Gorden CoRayVac CRV-B-2 Installation, Operation & Service Manual

Custom-engineered, low-intensity infrared heating systems
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If you smell gas:
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© Copyright 2002 Roberts-Gordon
CoRayVac
Custom-Engineered, Low-Intensity
Infrared Heating Systems
Installation, Operation &
Roberts-Gordon
1250 William Street
P.O. Box 44
Buffalo, New York 14240-0044
Telephone: 716.852.4400
Fax: 716.852.0854
Toll Free: 800.828.7450
www.rg-inc.com
Service Manual
CRV-B-2
CRV-B-4
CRV-B-6
CRV-B-8
CRV-B-9
CRV-B-10
CRV-B-12
CRV-B-12A
Roberts-Gordon Canada Inc.
76 Main Street West, Unit 10
Grimsby, Ontario L3M 1R6 Canada
Telephone: 905.945.5403
Fax: 905.945.0511
P/N 127102NA
Rev. C 04/02
®
®

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  • Page 1 ® If you smell gas: ® CoRayVac Custom-Engineered, Low-Intensity Infrared Heating Systems Installation, Operation & Service Manual CRV-B-2 CRV-B-4 CRV-B-6 CRV-B-8 CRV-B-9 CRV-B-10 CRV-B-12 CRV-B-12A Roberts-Gordon Roberts-Gordon Canada Inc. 1250 William Street 76 Main Street West, Unit 10 P.O. Box 44...

  • Page 3: Table Of Contents

    ! ! ! ! ! TABLE OF CONTENTS 1. Heater Safety ........... 1 11. Gas Piping ............. 40 Read this section carefully. Improper 12. Control Methods ........... 41 installation, adjustment, operation or maintenance will result in death, injury or 13. Operation and Maintenance ......47 property damage.
  • Page 4 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Figure 29 External Wiring Diagram EP 203 and EP 303 230V 3ph Pump ....46 Figure 30 CRV Burner Internal Wiring ....47 Figure 31 CRV Burner Internal Ladder ....47 Figure 32 Vacuum Reading ........

  • Page 5: Heater Safety

    1: H ECTION EATER AFETY ! ! ! ! ! SECTION 1: HEATER SAFETY Your Safety is Important to Us! 2.1 Halogenated Hydrocarbons 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.

  • Page 6: Critical Considerations

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ! ! ! ! ! SECTION 3: CRITICAL CONSIDERATIONS 3.1 Minimum Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the tube to prevent serious fire hazards. Combustibles are materials, which may catch on fire and include common items such as wood, paper, rubber, fabric, etc.

  • Page 7: Clearances To Combustibles

    2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from the burner. 3. “-” indicates an unapproved application. Roberts-Gordon does not allow the installation of unapproved applications. CLEARANCES TO COMBUSTIBLES STANDARD REFLECTOR (inches) (centimeters) Model CRV-B-2 CRV-B-4 CRV-B-6 CRV-B-8 CRV-B-9 CRV-B-10 CRV-B-12 CRV-B-12A...
  • Page 8 2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from the burner. 3. “-” indicates an unapproved application. Roberts-Gordon does not allow the installation of unapproved applications. CLEARANCES TO COMBUSTIBLES UNIVERSAL SHIELD (POSITION 1) (inches) (centimeters) Model CRV-B-2 CRV-B-4 CRV-B-6 CRV-B-8 CRV-B-9 CRV-B-10 CRV-B-12 CRV-B-12A...

  • Page 9: Barrier Shield

    2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from the burner. 3. “-” indicates an unapproved application. Roberts-Gordon does not allow the installation of unapproved applications. CLEARANCES TO COMBUSTIBLES 2 FOOT DECO GRILLE (inches) (centimeters) Model CRV-B-2 CRV-B-4 CRV-B-6 CRV-B-8 CRV-B-9 CRV-B-10 CRV-B-12 CRV-B-12A...

  • Page 10: National Standards And Applicable Codes

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ! ! ! ! ! SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Gas Codes 4.3 Public Garages The type of gas appearing on the nameplate must Installation in garages must be in accordance with be the type of gas used.

  • Page 11: Standard Parts List

    5: S ECTION TANDARD ARTS ISTS ! ! ! ! ! SECTION 5: STANDARD PARTS LIST ® Table 1. Contents of CORAYVAC Carton (CRV-B all models) Part No. Description Quantity 0270XXXX Burner 9141030D 16 Ga. Coated 4" dia. 10' Tube 013676XX End Vent Plate 9141060D...
  • Page 12 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ® BZC300 ROBERTS GORDON BZC 300 Controller 02719304 Accessory Package ® BZC700 ROBERTS GORDON BZC 700 Controller Accessories 10001500 Internal Sensor 90430600 Pressure Switch 02770002 System Control 01327000 Condensate Trap Assembly for EP-201 Pump 05023000 Load Relay Package 02718851...

  • Page 13: Design Requirements

    6: D ECTION ESIGN EQUIREMENTS ! ! ! ! ! SECTION 6: DESIGN REQUIREMENTS The CORAYVAC ® systems 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, ®...

  • Page 14: Assembly Overview

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ! ! ! ! ! SECTION 7: ASSEMBLY OVERVIEW The figures in this section provide a general overview of Optional reflector configurations are shown on Pages ® component placement in a CORAYVAC system. The 3-5, Section 3, Figures 1-9 .
  • Page 15 7: A ECTION SSEMBLY VERVIEW FIGURE 10 – Major Components’ Descriptions 90° Elbow: 4" Coated - 0133580D 4" Aluminized - 01335801 6" Coated - 0133660D 6" Aluminized - T0100320 45° Elbow: 4" Coated - 0133610D 4" Aluminized - 01336101 Cross: 4"...
  • Page 16 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL FIGURE 10 – Major Components’ Descriptions Reflector Joint - 02750900 Barrier Shield - 02750303 Reflector End Cap - 02750800 Stainless Steel Reflector End Cap - 027508SS Remove center section to accommodate heat exchanger tube when necessary.
  • Page 17 7: A ECTION SSEMBLY VERVIEW FIGURE 10 – Major Components’ Descriptions EP-101 Pump Package - 4" dia. - 02719105 ROBERTS GORDON ® BZC 700 For more information, refer to the EP-100 Controller - BZC700 Installation, Operation and Service Manual ROBERTS GORDON ®...

  • Page 18: Crv Assembly Overview

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL FIGURE 11 –CRV Assembly Overview...

  • Page 19: Heater Installation

    8: H ECTION EATER NSTALLATION ! ! ! ! ! SECTION 8: HEATER INSTALLATION Sections 8.1 - 8.13 show the logical sequence of heater installation, pictorially. Follow these steps in order and if any questions arise, refer to the assembly overview ( Page 14, Section 7, Figure 11 ) for guidance. If any step is unclear, please contact your ROBERTS GORDON ®...

  • Page 20: Tube Assembly

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 8.2 – Tube Assembly Description Part Number Tube 91409XXX Turnbuckle 91903201 Tube/Reflector Hanger 03090100 8.3 Coupling and Tube Step 8.3.1 – Coupling and Tube Assembly Close Coupling with tab Start Slidebar onto Coupling Open Closed Insert tubes into Coupling...

  • Page 21: Elbow Package

    8: H ECTION EATER NSTALLATION Step 8.3.2 – Coupling and Tube Assembly (Continued) Tighten slidebar as shown below. • Repeat steps 8.3.1 A-D until all tubes are assembled. 8.4 Elbow Package Configuration Step 8.4.1 – Elbow Package Description Part Number Tube 914XXXXX Elbow Package...

  • Page 22: Reflector

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 8.4.2 – Tee Description Part Number 01330XXX Tube/Reflector Hanger 03090100 Tube 91409XXX Coupling 01312700 8.5 Reflector Step 8.5.1 – Reflector with Hole Description Part Number Burner 027XXXXX Tube/Reflector Hanger 03090100 Tube 91409XXX Reflector with Hole 02750304...

  • Page 23: Figure 12 Reflector Overlap Detail

    8: H ECTION EATER NSTALLATION Step 8.5.2 – Reflector Description Part Number Reflector Support Package 03050010 U-Clip Package 91107720 Reflector End Cap 027508XX FIGURE 12 – Reflector Overlap Detail...

  • Page 24: Burner

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 8.6 – Burner Description Part Number Bolt 94273914 Lock Washer 96411600 Gasket 01367800 Burner 0270XXXX End Vent 013676XX 8.7 Reflector Joint Step 8.7.1 – Reflector Joint...
  • Page 25 8: H ECTION EATER NSTALLATION Step 8.7.2 – Reflector Joint Step 8.7.3 – Reflector Joint Description Part Number 90° Elbow Package 02718702 Reflector Joint 02750900 Reflector End Cap 02750800 U-Clip Package 91107720 Sheet Metal Screws (#8 x 3/8) 94118106 90° Elbow 01335801 Coupling 01312700...

  • Page 26: Reflector Side Extension

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL FIGURE 13 – Reflector Joint Detail 8.8 Reflector Side Extension Step 8.8.1 – Bracket Description Part Number Reflector Side Extension Bracket 01329910...

  • Page 27: Universal Shield

    8: H ECTION EATER NSTALLATION Step 8.8.2 – Reflector Side Description Part Number Reflector Side Extension Package 02712700 Reflector Side Extension 01368000 Retainer Clips 02751200 Sheet Metal Screws 94118106 8.9 Universal Shield Universal shields are adjustable aluminum reflectors that can be angled and height adjusted to direct heat to or away from a desired area.

  • Page 28: Barrier Shield

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 8.10 Barrier Shield Step 8.10.1 – Barrier Shield Do not install barrier shield less than 20' (6 m) downstream of any burner. Do not attach end caps to the ends of the barrier shields.

  • Page 29: Decorative Grille

    8: H ECTION EATER NSTALLATION 8.11 Decorative Grille Step 8.11.1 – Grille Description Part Number Aluminum Grille 91407000 Step 8.11.2 – Frame Shield Description Part Number Shield 01365900...

  • Page 30: 1-Foot Deco Grille

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 8.11.3 – Reflector Extension Distance "A" Extension Minimum Maximum Part No. Width 2" (4 cm) 6" (15 cm) 01370408 8" (20 cm) 6" (15 cm) 10" (26 cm) 01370412 12" (30 cm) 10 (26 cm) 14 (37 cm) 01370416...
  • Page 31 8: H ECTION EATER NSTALLATION Step 8.12.2 – Decorative Grille Description Part Number Decorative Grille 8' x 1' 91406700 Step 8.12.3 – Joint Piece and Reinforcement Description Part Number Joint Piece 01365903 Reinforcement 01365902...
  • Page 32 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 8.12.4 – End Piece and Reflector End Cap Description Part Number End Piece 01365901 Step 8.12.5 – 90° Elbow...

  • Page 33: Protective Grille

    8: H ECTION EATER NSTALLATION 8.13 Protective Grille Step 8.13.1 – Silicone Cap Silicone Cap Grille Finger Description Part Number Grille Section 08050001 Grille End Cap 08050002 Silicone Cap (6 pieces) 91915951-6P Step 8.13.2 – Grille End Cap...
  • Page 34 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Step 8.13.3 – Grille...

  • Page 35: Corayvac Classic Cast Iron Components

    8: H ECTION EATER NSTALLATION ® 8.14 CORAYVAC Classic Cast-Iron Components...

  • Page 36: Pump Installation And Venting

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ! ! ! ! ! SECTION 9: PUMP INSTALLATION AND VENTING Vertical Venting For complete pump installation, please refer to the EP- 100, EP-201 or EP-301 installation, operation and Refer to Page 33, Section 9.2, for recommended service manuals.

  • Page 37: Vertical Venting

    9: P ECTION NSTALLATION AND ENTING 9.2 Vertical Venting Configuration Part No. Description 91412800 4" Flexible Boot 91412801 4 - 1/2” Flexible Boot 91412802 6" Flexible Boot 91901300 4" Boot Clamp 91913703 6" Boot Clamp 90505600 4" Wall Thimble 01331900 4"...

  • Page 38: Horizontal Venting Configurations

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL 9.3 Horizontal Venting Configurations FIGURE 15 – EP-100 Horizontal Venting Configurations Part No. Description Part No. Description 91412800 4" Flexible Boot Not Supplied 16 Ga. Aluminized 5" dia. 10' Tube Not Supplied 5" dia. x 4" dia. Tube Adapter 91901300 4"...

  • Page 39: Figure 16 Ep-201/203 Horizontal Venting

    9: P ECTION NSTALLATION AND ENTING FIGURE 16 – EP-201/203 Horizontal Venting Configurations Part No. Description Part No. Description Not Supplied 16 Ga. Aluminized 5" dia. 10' Tube 91412801 4-1/2" Flexible Boot Not Supplied 5" dia. x 4" dia. Tube Adapter 91906900 Silicone Ring Not Supplied 6"...

  • Page 40: Figure 17 Ep-301/303 Horizontal Venting

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL FIGURE 17 – EP-301/303 Horizontal Venting Configurations Part No. Description Part No. Description 91412800 4" Flexible Boot 02718851 4" Drain Cap 91412802 6" Flexible Boot 02718852 6" Drain Cap 91901300 4" Boot Clamp 01397400 6”...

  • Page 41: Outside Air Supply

    10: O ECTION UTSIDE UPPLY ! ! ! ! ! SECTION 10: OUTSIDE AIR SUPPLY The CORAYVAC® system is approved for use with an Pressurized outside air system. Halogenated hydrocarbons or other See Page 39, Figure 21, for a typical layout of a corrosive chemicals in the air can be drawn into the pressurized air supply system.

  • Page 42: Figure 19 Filter Housing Assembly

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL Figure 19 – Filter Housing Assembly Description Part Number Filter Housing 01326801 Filter and Gaskets 01312401 Filter Support 91905500 Wing Nut 92511601 Figure 20 – Air Supply Blower Support Description Part Number Blower 90707500 Mounting Bracket 01316000...

  • Page 43: Figure 21 Outside Air Supply-Pressurized

    10: O ECTION UTSIDE UPPLY Figure 21 – Outside Air Supply - Pressurized Description Part Number Filter Housing 01326801 4" Take Off 01324401 4" Air Flex Duct (8' sections) 91409601 Blower 90707500 Figure 22 – Outside Air Supply - Non-Pressurized Description Part Number Pressure Switch Kit...

  • Page 44: Gas Piping

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ! ! ! ! ! SECTION 11: GAS PIPING There is an expansion of the heat exchanger tube with each firing cycle, this will cause the burner to move with respect to the gas line. This can cause a gas leak resulting in an unsafe condition if the gas connection is not made strictly in accordance with Figure 23 below.

  • Page 45: Control Methods

    12: C ECTION ONTROL ETHODS ! ! ! ! ! SECTION 12: Control Methods ® ROBERTS GORDON BZC100 ® The ROBERTS GORDON BZC100 wiring is shown ® in the ROBERTS GORDON BZC100 Installation ® manual P/N 10011601NA. The ROBERTS GORDON BZC100 can be used to control a CORAYVAC ®...
  • Page 46 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL A pressure switch is required to confirm pump operation on all pumps. A pressure switch (outside air) is also required on the inlet duct of a non-pressurized air supply. For pressurized outside air supplies, the outside air blower motor has a motor interlock that should be used.

  • Page 47: Figure 24 One Zone Operation

    12: C ECTION ONTROL ETHODS FIGURE 24 – One Zone Operation without Control Panel Description Part Number SPST Transformer Relay 90417600...

  • Page 48: Figure 25 Two Zone Operation

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL FIGURE 25 – Two Zone Operation without Control Panel Description Part Number DPST Transformer Relay 90436300...

  • Page 49: Figure 26 General System Wiring

    12: C ECTION ONTROL ETHODS FIGURE 26 – General System Wiring FIGURE 27 – External Wiring Diagram EP 100 and EP 201 120V 1ph Pump...

  • Page 50: V 1Ph Pump

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL FIGURE 28 – External Wiring Diagram EP 301 120V 1ph Pump FIGURE 29 – External Wiring Diagram EP 203 and EP 303 230V 3ph Pump...

  • Page 51: Figure 30 Crv Burner Internal Wiring

    12: C ECTION ONTROL ETHODS FIGURE 30 – CRV Burner Internal Wiring TRANSFORMER Yellow White Black 120 V Green Power Supply Blue Yellow Green Brown VALVE Yellow V2/GND Black BURNER IGNITION MODULE 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 52: Figure 32 Vacuum Reading

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL FIGURE 32 – Vacuum Reading...

  • Page 53: Operation And Maintenance

    13: O ECTION PERATION AND AINTENANCE ! ! ! ! ! SECTION 13: OPERATION AND MAINTENANCE 13.2 Start Up Procedure 13.1 Sequence of Operation Pre-Season Maintenance and Annual Inspection Turn the thermostat up. When the thermostat calls for To ensure your safety and years of trouble-free heat, the pump will start immediately.
  • Page 54 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL REMEMBER TO CHECK: Installation, Service and Annual Inspection of the heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment. Read this manual carefully before installation, operation, or service of this equipment.
  • Page 55 13: O ECTION PERATION AND AINTENANCE Thermostat or Internal There should be no exposed wire or damage to the thermostat or sensor. Sensor Suspension Points Make sure the heater is hanging securely. Look for signs of wear on the chain or ceiling. Contact a contractor qualified in the installation and service of gas-fired heating equipment for repair.

  • Page 56: Troubleshooting

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ! ! ! ! ! SECTION 14: TROUBLESHOOTING 14.1 Troubleshooting Flow Chart...
  • Page 57 14: T ECTION ROUBLESHOOTING...

  • Page 58: Replacement Parts

    CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL ! ! ! ! ! SECTION 15: 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 Description...

  • Page 59: General Specifications

    16: G ECTION ENERAL PECIFICATIONS ! ! ! ! ! SECTION 16: GENERAL SPECIFICATIONS General Specifications for CORAYVAC ® heaters are as follows Rate Length “A” Recommended Model (BTUH X1000) Minimum Maximum Minimum Mounting Height* CRV-2 10' (3 m) 20' (6 m) 8' (2.5 m) CRV-4 12.5' (3.7 m)
  • Page 60 CORAYVAC ® NSTALLATION PERATION AND ERVICE ANUAL General Specifications for CORAYVAC ® pumps are as follows: Pump Dimensional Data (in.) Model EP 100 14-1/2 3-3/4 EP 201/203 17-3/4 18-3/4 3-1/4 4-1/2 4-1/2 EP 301/303 25-1/2 21-3/4 27-1/2* 7-1/8 * with 8"x6" inlet adapter installed ** with 8"x6"...

  • Page 61: Limited Warranty

    ® ® ROBERTS GORDON CORAYVAC 17: THE ARRANTY ECTION ! ! ! ! ! SECTION 17: THE ROBERTS GORDON ® CORAYVAC ® WARRANTY. ROBERTS-GORDON WILL PAY FOR: You cannot prove original purchase date and required annual maintenance history. ® ROBERTS GORDON warrants to the original owner-user that this ROBERTS GORDON ®...

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