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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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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.
© 2012 Roberts-Gordon LLC
CoRayVac
Custom-Engineered,
Low-Intensity Infrared
Heating Systems
Installation, Operation &
Service Manual
Installer
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 serviceman 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.rg-inc.com
www.corayvac.com
www.radiantheaters.com
www.greenhouse-heater.com
www.robertsgordon.com
CRV-B-2
CRV-B-4
CRV-B-6
CRV-B-8
CRV-B-9
CRV-B-10
CRV-B-12
CRV-B-12A
Owner
P/N 127102NA Rev. L 06/12
®

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Summary of Contents for Roberts Gorden CoRayVac CRV-B-2

  • Page 1 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.rg-inc.com www.corayvac.com www.radiantheaters.com www.greenhouse-heater.com P/N 127102NA Rev. L 06/12 © 2012 Roberts-Gordon LLC www.robertsgordon.com...

  • Page 3: Table Of Contents

    There are references in this manual to various trademarks. All trademarks mentioned herein, whether registered or not, are the property of their respective owners. Roberts-Gordon LLC is not sponsored by or affiliated with any of the trademark or regis- tered trademark owners, and make no representations about them, their owners, their products or services. Roberts-Gordon LLC is not sponsored by or affiliated with BACnet ®...
  • Page 5 TABLE OF FIGURES Figure 39: CORAYVAC ® Modulating with BACnet ® Wiring Diagram (optional) ..........61 Figure 1: Side Panel Label Placement........2 Figure 40: Burner Internal Wiring..........62 Figure 2: Top and Back Panel Label Placement ....... 3 Figure 41: Burner Internal Ladder Diagram ......62 Figure 3: Standard Reflector .............

  • Page 7: Section 1: Heater Safety

    Product safety signs or labels should be replaced by the manual to notify you of the product user when they are no longer legible. possible fire, electrical or burn Please contact Roberts-Gordon LLC or your hazards. Please pay special ® ROBERTS GORDON...

  • Page 8: Figure 1: Side Panel Label Placement

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 1: Side Panel Label Placement Logo Label Control Side Panel Internal Ladder Diagram Label Rating Plate Label Filter Side Panel (inside) Clearances to Combustibles Label Control Side Panel (inside) Description Part Number Logo Label 91007901 Rating Plate Label...

  • 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

    • To provide the owner with a copy of this Roberts-Gordon LLC cannot be responsible for Installation, Operation and Service Manual. ensuring that all appropriate safety measures are • To never use heater as a support for ladder or undertaken prior to installation;...

  • Page 11: Section 3: Clearances To Combustibles

    SECTION 3: C LEARANCES TO OMBUSTIBLES SECTION 3: CLEARANCES TO COMBUSTIBLES 3.1 Required Clearances to Combustibles stop is installed to prevent scorching and/or fire hazard. Clearances are the required distances that combustible objects must be away from the heater to prevent serious fire hazards.

  • Page 12: Figure 3: Standard Reflector

    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 3: STANDARD REFLECTOR (inches) (centimeters) Model CRV-B-2 CRV-B-4 CRV-B-6 CRV-B-8 CRV-B-9 CRV-B-10...

  • Page 13: Figure 6: Universal Shield, Position 1

    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 6: 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...

  • Page 14: Figure 9: 2-Foot Deco Grille

    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 9: 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...

  • Page 15: Section 4: National Standards And Applicable Codes

    SECTION 4: N ATIONAL TANDARDS AND PPLICABLE ODES SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Gas Codes 4.3 Public Garages The type of gas appearing on the nameplate Installation in garages must be in accordance must be the type of gas used. Installation must with the following codes: comply with national and local codes and United States: Refer to Standard for Parking...

  • Page 16: Section 5: Major Components

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 5: MAJOR COMPONENTS Optional reflector configurations are shown on Page 6, Figure 3 through Page 8, Figure 11. Install The figures in this section provide a general overview appropriate suspension hardware, beam clamps, of component placement in a CRV-Series system.
  • Page 17 SECTION 5: M AJOR OMPONENTS FIGURE 10: Major Component Descriptions (Continued) Reflector Joint Reflector End Cap Barrier Shield (Aluminum or Stainless Steel) Punch out center section to accommodate tube. Tube and Reflector Hanger Reflector Side Extension Suspend system from these hangers.
  • Page 18 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 10: Major Component Descriptions (Continued) ROBERTS GORDON ® ULTRAVAC™ Controller EP-100 Pump Package - 4" dia For more information, refer to the EP-100 Installation, Operation and Service Manual (P/N 127201NA). ® ROBERTS GORDON ULTRAVAC™...

  • Page 19: Standard Parts List

    SECTION 5: M AJOR OMPONENTS 5.1 Standard Parts List Part No. Description 91418200 Tube Adapter, Aluminized Table 1: Contents of CRV-Series Burner Carton 6" (15 cm) dia x 4" (10 cm) dia Part No. Description 02722100 Adapter, 4" (10 cm) Cast Iron 0270XXXX Burner (Rate and Fuel Varies) 02726000K Lower Tube Temperature Insert...
  • Page 20 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL URVCCR ROBERTS GORDON ULTRAVAC Central Controller 90423000 24 V Low Voltage Thermostat (Marked 1-5) ® ™ (with RS-485 Converter & Software) Includes: 90424300 Thermostat Guard Part No. Description Part No. Description URVSC ROBERTS GORDON ®...
  • Page 21 SECTION 5: M AJOR OMPONENTS Part No. Description Pump Accessories 90430600K Pressure Switch 01327001 Condensate Check Valve Assembly 02718851 Drain Cap, 4" (10 cm) 02718852 Drain Cap, 6" (15 cm) 01327002 Condensate Neutralization Tube 200 01327003 Condensate Neutralization Tube 600 01327004 Condensate Neutralization Tube 1000 01327005...

  • Page 22: Section 6: Design Requirements

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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 contact the company responsible for the layout design, your ROBERTS GORDON...

  • Page 23: Figure 13: Heater Assembly Overview

    SECTION 6: D ESIGN EQUIREMENTS FIGURE 13: Heater Assembly Overview 17 of 83...

  • Page 24: Section 7: Heater Installation

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: HEATER INSTALLATION Expansion and contraction of the tube dictates that the minimum suspension lengths must be WARNING maintained.See table on Page 19, Figure 14. Severe Injury Hazard Secure burner to combustion chamber with nuts and lockwashers.

  • Page 25: Figure 14: Critical Hanger Placement

    SECTION 7: H EATER NSTALLATION FIGURE 14: Critical Hanger Placement Typical Suspension Details Concrete Beam Beam Clamp Wood Beam Anchor Locknut Screw Hook 3/8" Chain size 3/16" minimum Washers Rod 3/8" 24" min. (61 cm) "X" (See Table) Turnbuckle S-Hook Locknut (Typical) 7'6"...

  • Page 26: Tube Installation

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.1 Tube Installation NOTE: Tubing requires a downward slope of 1/2" (13 mm) per 20' (6 m) away from burner. Tailpipe tubing requires a downward slope of 1" (26 mm) per 20' (6 m) away from burner. End View Combustion Chamber...

  • Page 27: Elbow Package Configuration

    SECTION 7: H EATER NSTALLATION Step 7.2.1 Coupling and Tube Assembly (Continued) Tighten slide bar as shown below. Drive slide bar until tight. End of slide bar should be within tolerance listed below. ± 2" (5 cm) Correct slide bar Incorrect slide bar dimensions position...

  • Page 28: Reflector Installation

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.4 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. Step 7.4.1 Reflector Installation with Hole Reflector with Hole...
  • Page 29 SECTION 7: H EATER NSTALLATION Step 7.4.2 Reflector Installation Wire Form Sheet Metal Reflector Screw Tube Reflector Support Strap U-Clip (2 Clips per Description Part Number Alternate Overlaps Reflector Support Package 03050010 per Side) U-Clip Package 91107720 Reflector End Cap 027508XX 23 of 83...
  • Page 30 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.4.3 Reflector, U-Clip and Reflector Support Installation The pictorial drawings of the heater construction in reflector supports and U-clips depend on the Section 7 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 31: Burner Installation

    SECTION 7: H EATER NSTALLATION Step 7.5 Burner Installation Burner Burner Combustion Chamber Gasket Vent NOTE: Install end vent at end combustion Description Part Number chamber position only. Bolt 94273914 Burner 0270XXXX Lock Washer 96411600 Gasket 01367800 End Vent 013676XX 25 of 83...

  • Page 32: Section 8: Optional Heater Accessories

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 8: 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 8.1 Tee Installation Tube Coupling Description Part Number...

  • Page 33: Reflector Joint

    SECTION 8: O PTIONAL EATER CCESSORIES Step 8.2 Reflector Joint Step 8.2.1 Reflector Joint Installation Step 8.2.2 Reflector Joint Installation 27 of 83...

  • Page 34: Figure 15: Reflector Joint Detail

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 8.2.3 Reflector Joint Detail FIGURE 15: Reflector Joint Detail 28 of 83...

  • Page 35: Reflector Side Extension

    SECTION 8: O PTIONAL EATER CCESSORIES 8.3 Reflector Side Extension Step 8.3.1 Bracket Installation Tube Reflector Tube and Reflector Hanger Reflector Support Reflector Side Extension Bracket (2 per reflector) Use additional supports in high air movement applications. Description Part Number Reflector Side Extension Package 02712700 Reflector Side Extension...

  • Page 36: Universal Shield

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.4 Universal Shield Universal shields are adjustable Standard Reflector 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.

  • Page 37: Two-Foot Decorative Grille Installation

    SECTION 8: O PTIONAL EATER CCESSORIES 8.6 Two-Foot Decorative Grille Installation Step 8.6.1 Grille Installation Tube and Reflector Hanger Reflector Heat Exchanger Tube 2' x 4' (60 cm x 120 cm) Aluminum Grille Suspended Ceiling Frame Description Part Number Aluminum Grille 2' x 4' (60 cm x 120 cm) 91407000 Step 8.6.2 Frame Shield Installation Shield...
  • Page 38 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 8.6.3 Reflector Side Extension Installation for Decorative Grilles NOTE: If the decorative grille system is to be installed in an area with considerable air movement, it is recommended that one #8 x 3/8" sheet metal screw be installed per reflector extension to 6"...

  • Page 39: Protective Grille Installation

    SECTION 8: O PTIONAL EATER CCESSORIES 8.7 Protective Grille Installation Step 8.7.1 Silicone Cap Installation Silicone Cap Description Part Number Grille Grille Section 08050001 Finger Grille End Cap 08050002 Silicone Cap 91915951-6P Step 8.7.2 Grille End Cap Installation Grille Grille End Cap Bend up 90°...

  • Page 40: Classic Cast-Iron Components

    Hang cast-iron combustion chamber with a turnbuckle (spring clips will not fit around cast-iron hanging loop). Special Tube and Reflector Hanger 7' (2.13 m) Maximum End Vent Clips ROBERTS-GORDON ® Schedule 40 Steel Pipe End Vent Plate for Cast-Iron Adapter Cast-Iron Combustion Chamber CORAYVAC ®...

  • Page 41: Section 9: Pump Installation And Venting

    SECTION 9: P NSTALLATION AND ENTING SECTION 9: 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. Heaters must be installed according to the Edges are sharp.
  • Page 42 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 9.1.1 Condensate Neutralization Tube (optional) Step 3: Choose the condensate neutralization tube If a condensate neutralization tube is specified to be used with the heating system, follow the steps below Choose the condensate neutralization tube which is to choose the proper condensate neutralization tube.

  • Page 43: General Venting Requirements Model

    SECTION 9: P NSTALLATION AND ENTING 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 01327005...
  • Page 44 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 9.2.3 Vertical Venting See Page 39, Figure 18 for recommended vertical venting options. 9.2.4 Horizontal Venting See Page 40, Figure 19 through Page 42, Figure 21 for recommended horizontal venting options. 9.2.5 Length Requirements See EP-100, EP-200 or EP-300 Pump Series Installation, Operation and Service Manuals for complete venting options.

  • Page 45: Figure 18: Vertical Venting Configuration

    SECTION 9: P NSTALLATION AND ENTING FIGURE 18: Vertical Venting Configuration Part Number Description Part Number Description 01330203 Tee, 4" (10 cm) Aluminized 90502302 Vent Cap, 6" (15 cm) Metalbestos 01330204 Tee, 6" (15 cm) Aluminized 91409403 Tube, Aluminized 4" (10 cm) dia. 10' (3 m) 01331900 Damper Coupling, 4"...

  • Page 46: Horizontal Venting 4" (10 Cm) Pipe

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 9.3 Horizontal Venting 4" (10 cm) Pipe FIGURE 19: EP-100 Horizontal Venting Configurations 18" (46 cm) Minimum - 40" (102 cm) Maximum Bird 4" (10 cm) Single Wall Pipe Screen 4" (10 cm) 25' (8 m) and 3 Elbows Maximum Approved Thimbles Band Clamp...

  • Page 47: Figure 20: Ep-200 Series Horizontal Venting Configurations

    SECTION 9: P NSTALLATION AND ENTING FIGURE 20: EP-200 Series Horizontal Venting Configurations 18" (46 cm) Minimum - 40" (102 cm) Maximum Bird 4" (10 cm) Single Wall Pipe Screen Approved Thimbles 4" (10 cm) 10' (3 m) Maximum and No Elbows Band Clamp 18"...

  • Page 48: Figure 21: Ep-300 Series Horizontal Venting Configurations

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 21: EP-300 Series Horizontal Venting Configurations 18" (46 cm) Minimum - 40" (102 cm) Maximum 10' (3 m) Maximum and 1 Elbow 6" (15 cm) 10' (3 m) Maximum and 1 Elbow Bird Screen (Included) Single Wall Pipe/Tube 6"...

  • Page 49: Section 10: Outside Air Supply

    SECTION 10: O UTSIDE UPPLY SECTION 10: OUTSIDE AIR SUPPLY single wall pipe duct may be attached to the burner and end vent. For length and duct sizing CAUTION requirements, see duct design rules in Figure 22. To prevent condensation, insulate the outside air duct. Product Damage Hazard Do not use heater in area containing corrosive chemicals.

  • Page 50: Outside Air Blower Internal Wiring

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 22: 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.

  • Page 51: Figure 24: Filter Housing Assembly

    SECTION 10: O UTSIDE UPPLY FIGURE 24: Filter Housing Assembly Door-Control Housing Filter Filter Support Bottom Gasket Filter Housing Top Gasket Wing Nut and Disk 4" (10 cm) Description Part Number Air Flex Duct Filter Housing 01326801 Filter and Gaskets 01312401 Clamp Filter Support...

  • Page 52: Figure 26: Pressurized Outside Air Supply

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 26: 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 27: Non-Pressurized Outside Air Supply Description...

  • Page 53: Section 11: Gas Piping

    SECTION 11: G IPING SECTION 11: 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 28.

  • Page 54: Figure 28: Gas Connection With Flexible Gas Hose

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 28: Gas Connection with Flexible Gas Hose CORRECT POSITIONS CAUTION Product Damage Hazard Shut-Off Valve (included with gas hose) must be parallel to burner gas inlet. The 3" (8 cm) Hold gas nipple securely with pipe wrench displacement shown is for the cold condition.

  • Page 55: Section 12: Control Methods

    SECTION 12: C ONTROL ETHODS SECTION 12: 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 56 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL assemblies. The result will be a one pump, one zone 12.3.3 Analog signal Modulating with BACnet ® CORAYVAC ® Modulating system. The system will Programmable Thermostat modulate based on the temperature sensed at the If BACnet ®...

  • Page 57: Figure 29: Vfd Terminal Strip

    SECTION 12: C ONTROL ETHODS 12.3.4 Cable Requirement Table 3, on Page 51, lists wiring types, sizes and distances for modulating thermostat communication. Power Requirement Programmable thermostats requires 24 volt, AC power. Table 3: Modulating Thermostat Cable Requirements Wire Function Recommended Wire Size Specification or Distance (Maximum)

  • Page 58: Spst Transformer Relay Kit (P/N 90417600K)

    CRV-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 59: Figure 30: One Zone Operation Without Control Panel (Optional)

    SECTION 12: C ONTROL ETHODS FIGURE 30: One Zone Operation without Control Panel (optional) Description Part Number SPST Transformer Relay 90417600K 53 of 83...

  • Page 60: Figure 31: One Zone Operation (With Outside Air Blower) Without Control Panel (Optional)

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 31: One Zone Operation (with Outside Air Blower) without Control Panel (optional) 54 of 83...

  • Page 61: Figure 32: Two Zone Operation Without Control Panel (Optional)

    SECTION 12: C ONTROL ETHODS FIGURE 32: Two Zone Operation without Control Panel (optional) Description Part Number SPDT Transformer Relay 90436300 55 of 83...

  • Page 62: Figure 33: General System Wiring

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 33: General System Wiring FIGURE 34: External Wiring Diagram EP-100 and EP-201 120 V 1 Ø Pump 56 of 83...

  • Page 63: Figure 35: External Wiring Diagram Ep-100, Ep-201 Or Ep-301 230 V 1 Ø Pump (Optional)

    SECTION 12: C ONTROL ETHODS FIGURE 35: 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 64: Figure 36: External Wiring Diagram Ep-203 Or Ep-303 208 - 230 V (Or 460 V) 3 Ø Pump (Optional)

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 36: 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 65: Figure 37: Corayvac Modulating Wiring Diagram [Lonworks (2-10 Vdc With 500 Ohm Resistor) Optional]

    SECTION 12: C ONTROL ETHODS FIGURE 37: CORAYVAC ® 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 59 of 83...

  • Page 66: Figure 38: Corayvac ® Modulating Wiring Diagram

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 38: CORAYVAC ® 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 60 of 83...

  • Page 67: Figure 39: Corayvac

    SECTION 12: C ONTROL ETHODS FIGURE 39: CORAYVAC ® Modulating with BACnet ® Wiring Diagram (optional) Description Part Number SPST Transformer Relay 90417600K ® 90425109 Thermostat, Modulating BACnet 61 of 83...

  • Page 68: Figure 40: Burner Internal Wiring

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 40: 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 69: Section 13: Starting The System

    SECTION 13: S TARTING YSTEM SECTION 13: 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 70 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 2. Allow at least ½ hour operation for temperature to normalize, then check system vacuum bal- ance. Vacuum can be measured by inserting a manometer hose into the end vent as shown on Page 65, Figure 42.

  • Page 71: Figure 42: Vacuum Reading

    SECTION 13: S TARTING YSTEM FIGURE 42: Vacuum Reading 65 of 83...

  • Page 72: Section 14: Variable Frequency Drive Programming

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 14: VARIABLE FREQUENCY DRIVE PROGRAMMING 14.1 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 73: Altering Vfd Parameters

    SECTION 14: V ARIABLE REQUENCY RIVE ROGRAMMING 14.2 Altering VFD Parameters Using the procedure described on Page 66, Section 14.1.1 through Section 14.1.5, 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 74: Section 15: Commissioning The Corayvac Modulating System

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: COMMISSIONING THE CORAYVAC ® 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 75: Programming Of Variable Frequency Drive

    SECTION 15: C CORAYVAC ® OMMISSIONING ODULATING YSTEM 15.3 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 Frequency Minimum...

  • Page 76: Figure 43: Possible Damper Couplings' Locations

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 43: Possible Damper Couplings’ Locations 70 of 83...

  • Page 77: Section 16: Operation And Maintenance

    SECTION 16: O PERATION AND AINTENANCE SECTION 16: 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 78: Maintenance Checklist

    Roberts-Gordon LLC and inspected. conform to all requirements set forth in the NOTE: Gas flow and burner ignition are among the ®...
  • Page 79 See Page 4, Section 2.1. Safety Labels Product safety signs or labels should be replaced by the product user when they are no longer legible. Please contact Roberts-Gordon LLC or your ROB- ERTS GORDON ®...

  • Page 80: Section 17: Troubleshooting

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 17: 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 81: Troubleshooting Flow Chart

    SECTION 17: T ROUBLESHOOTING 17.1 Troubleshooting Flow Chart 75 of 83...
  • Page 82 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Troubleshooting Flow Chart 76 of 83...

  • Page 83: Section 18: Replacement Parts

    SECTION 18: R EPLACEMENT ARTS SECTION 18: 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. 77 of 83...
  • Page 84 CRV-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 Description Part Number Gas Valve (All Burners) 90032502 Gasket (Burner to Mixing Chamber) 01351100 Burner Head Assembly Replacement Package (includes electrode and gasket installed) 02713000...

  • Page 85: Variable Frequency Drive Replacement Parts

    ARTS 18.1 Variable Frequency Drive Replacement Parts Caution: Use only genuine ROBERTS GORDON ® replacement parts. Use of parts not specified by Roberts-Gordon voids warranty. FIGURE 44: Variable Frequency Drive Components Diagram Variable Power Input Frequency Drive (1 Ø input model shown)

  • Page 86: Replacement Parts Instructions

    CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 18.2 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 87: Section 19: General Specifications

    Recommended Minimum Heat Input Rate Length “A” Mounting Height* Model (Btu/h) x (1000) Minimum Maximum Spot Heating CRV-B-2 (NG only) 10' (3 m) 20' (6.1 m) 8' (2.4 m) CRV-B-4 12.5' (3.8 m) 25' (7.6 m) 8' (2.4 m) CRV-B-6 20' (6.1 m)
  • Page 88 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL General Specifications for pumps are as follows: 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. Pump Specifications Model EP-100 EP-201 EP-203 EP-301 EP-303 Horsepower (Hp) Phase (Ø) Hertz (Hz)

  • Page 89: Section 20: The Roberts Gordon Corayvac Limited Warranty

    You cannot prove original purchase date and required a manufacturing or material defect. annual maintenance history. Roberts-Gordon LLC will require the part in question to be The data plate and/or serial number are removed, returned to the factory. Roberts-Gordon LLC will, at its sole defaced, modified or altered in any way.

This manual is also suitable for:

Corayvac crv-b-4Corayvac crv-b-9Corayvac crv-b-6Corayvac crv-b-8Corayvac crv-b-10Corayvac crv-b-12 ... Show all

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