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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.
This heater is not certified to meet the requirements of NFPA30A-2012 Section 7.6.6. (maximum tube temperature of 750° F (399° C). Do not install this
heater in facilities where major repairs are conducted on compressed natural gas (CNG) or liquefied natural gas (LNG) fueled vehicles.
© 2019 Roberts-Gordon LLC
Model CRV-B
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.
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
CRV-B-2
CRV-B-4
CRV-B-6
CRV-B-8
CRV-B-9
CRV-B-10
CRV-B-12
CRV-B-12A
P/N 127102NA Rev. W 02/19
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Summary of Contents for Roberts Gorden Corayvac CRV-B 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 Model CRV-B your building. 5. Extinguish any open flame. 6.
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Page 3: Table Of Contents
TABLE OF CONTENTS ® SECTION 1: Heater Safety............1 12.3 CORAYVAC Modulating Thermostat ..... 52 1.1 Manpower Requirements ..........1 12.4 DPDT Transformer Relay (P/N 90436300) ....53 1.2 Safety Labels and Their Placement ......1 SECTION 13: Starting The System ........63 1.3 California Proposition 65 .......... - Page 7 TABLE OF FIGURES Figure 40: General System Wiring .......... 57 Figure 41: External Wiring Diagram EP-100 and EP-201 120 V 1 Figure 1: Side Panel Label Placement........2 Ø Pump ..............57 Figure 2: Top and Back Panel Label Placement ....... 3 Figure 42: External Wiring Diagram EP-100, EP-201 or EP-301 Figure 3: Level Reflector ............
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Page 9: Section 1: Heater Safety
SECTION 1: H EATER AFETY SECTION 1: HEATER SAFETY Your Safety is Important to Us! For additional copies of the Installation, Operation This symbol is used throughout and Service Manual, please contact Roberts-Gordon the manual to notify you of LLC. possible fire, electrical or burn hazards. -
Page 10: 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) TRANSFORMER/Transformateur Internal Wiring Diagram/ Schéma de Câblage Interne YELLOW/ Clearances to Combustibles Label Control Side Panel (inside) WHITE/Blanc Jaune... -
Page 11: 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 85... -
Page 12: Section 2: Installer Responsibility
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 2: INSTALLER RESPONSIBILITY The installer is responsible for the following: 2.2 Corrosive Chemicals • To ensure the system is designed in accordance CAUTION with the parameters of the CRV-Series Design Manual (P/N 127500NA). •... -
Page 13: 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 14: Figure 3: Level Reflector
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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 15: Figure 6: Universal Shield (With And Without Holes), Position 1
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 16: Figure 9: 2-Foot Deco Grille
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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 17: 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 18: 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 19: Figure 13: Major Component Descriptions - Standard Reflector (Continued)
SECTION 5: M AJOR OMPONENTS FIGURE 13: Major Component Descriptions - Standard Reflector (Continued) Reflector End Cap Reflector Joint (Aluminum or Stainless Steel) Punch out center section to accommodate tube. S-Hook Tube and Reflector Hanger Suspend system from these hangers. Turnbuckle Reflector Support Strap &... -
Page 20: Figure 15: Major Component Descriptions - High Efficiency Reflector
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 15: Major Component Descriptions - High Efficiency Reflector Tube Burner Hot rolled, heat treated or coated aluminized tube supplied in 10' (3 m) lengths. High Efficiency Reflector with Hole High Efficiency (Aluminum only) Reflector Alternate overlap as (Aluminum only) -
Page 21: Figure 16: Major Component Descriptions - High Efficiency Reflector (Continued)
SECTION 5: M AJOR OMPONENTS FIGURE 16: Major Component Descriptions - High Efficiency Reflector (Continued) Reflector End Cap-EF Reflector Joint-EF (Aluminum only) Punch out center section to accommodate tube. S-Hook Tube and Reflector Hanger-EF Suspend system from these hangers. Turnbuckle Reflector Support Strap &... -
Page 22: Figure 17: Optional Heater Accessories
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 17: Optional Heater Accessories Barrier Shield Reflector Side Extension Protective Grille Deco Grille Universal Shield with Holes Universal Shield Reflector Side Condensate Extension Bracket Valve Assembly Bracket Assembly 14 of 85... -
Page 23: Figure 18: Pumps And Controls Descriptions
SECTION 5: M AJOR OMPONENTS FIGURE 18: Pumps and Controls Descriptions EP-100 Pump Package - 4" dia For more information, refer to the EP-100 Installation, Operation and Service Manual (P/N 127201NA). CORAYVAC ® Modulating Heating Control (Models CRV-B-6, B-8, B-9, B-10 or B-12 Only EP-201 Pump Package - 4"... -
Page 24: Standard Parts List
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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) 91240010 Tube Hanger, 6"... - Page 25 SECTION 5: M AJOR OMPONENTS Part No. Description 460V3P Central Controller 90425104 Thermostat, Modulating LonWorks ® 10060001 1 - 3/4 hp, 460V 3Ø VFD 90425105 Thermostat, Modulating 10060002 2 - 3/4 hp, 460V 3Ø VFD’s 10001501 Water Resistant Sensor 10060003 1 - 3/4 hp, 1-2 hp, 460V 3Ø...
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Page 26: 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 27: Figure 19: Heater Assembly Overview
SECTION 6: D ESIGN EQUIREMENTS FIGURE 19: Heater Assembly Overview 19 of 85... -
Page 28: Section 7: Heater Installation
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: HEATER INSTALLATION WARNING WARNING Severe Injury Hazard Severe Injury Hazard CORAYVAC ® Classic Systems Standard CORAYVAC ® Systems Hang heater with materials with a minimum Secure burner to combustion chamber with working load of 750 lbs. -
Page 29: Figure 20: Critical Hanger Placement
SECTION 7: H EATER NSTALLATION FIGURE 20: Critical Hanger Placement Run Length Typical Expansion Minimum “X” Length 50' (15 m) ±1" (3 cm) 12" (30 cm) Description Part Number 100' (31 m) ±2" (5 cm) 24" (61 cm) Turnbuckle 91903201 150' (46 m) ±3"... - Page 30 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 21: Critical Hanger Placement (CORAYVAC ® Classic) 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"...
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Page 31: Tube Installation
SECTION 7: H EATER NSTALLATION Step 7.1 Tube Installation Distance of first hanger after burner Note: CORAYVAC® Classic systems require all hangers after the first hanger to be positioned a maximum of 7’ (2.1 m) apart. Description Part Number Tube 91409XXX Turnbuckle 91903201... - Page 32 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.2.1 Coupling and Tube Assembly (Continued) Tighten slide bar as shown below. Note: If coupling is not tight, loss of vacuum can occur. • Repeat Step 7.2 A - D until all tubes are assembled. See Page 25, Step 7.3. Note: Standard couplings (P/N 01312700) are used to connect radiant tubing, combustion chambers, and radiant tubing to tailpipe.
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Page 33: Reflector Installation
SECTION 7: H EATER NSTALLATION Step 7.2.3 Elbow Installation Step 7.3 Reflector Installation WARNING Fire Hazard Support reflector with reflector hanger and support strap. Reflector must not touch tube. Failure to follow these instructions can result in death, injury or property damage. 25 of 85... - Page 34 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.3.1 Reflector Installation with Hole Description Part Number Tube/Reflector Hanger 0309010X Tube 91409XXX Reflector with Hole, 96" (244 cm) 027503XX Step 7.3.2 Reflector Installation Description Part Number NOTE: Reflectors must be supported using hangers, reflector Reflector Support Package 030500XX supports, or positioning reflectors on top of a supported reflector.
- Page 35 SECTION 7: H EATER NSTALLATION Step 7.3.3 Reflector, U-Clip and Reflector Support Installation The pictorial drawings of the heater construction in reflector supports and U-clips depend on the Section 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.
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Page 36: Burner Installation
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.4 Burner Installation Description Part Number Bolt 94273914 Burner 0270XXXX Lock Washer 96411600 Gasket 01367800 End Vent 013676XX 28 of 85... -
Page 37: Section 8: Optional Heater Accessories
SECTION 8: O PTIONAL EATER CCESSORIES 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. 8.1 U-Tube Configuration When using a U-tube configuration, the following additional rules must be adhered to: Note: Reflectors must be supported using hangers, reflector supports, or positioning reflectors on top of a... -
Page 38: Tee Installation
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 22: U-Tube Heater Assembly Overview Step 8.2 Tee Installation Description Part Number 01330XXX Tube/Reflector Hanger 0309010X Tube 91409XXX Coupling 01312700 30 of 85... -
Page 39: Reflector Joint
SECTION 8: O PTIONAL EATER CCESSORIES Step 8.3 Reflector Joint Step 8.3.1 Reflector Joint Installation Step 8.3.2 Reflector Joint Installation 31 of 85... -
Page 40: Figure 23: Reflector Joint Detail
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 8.3.3 Reflector Joint Detail FIGURE 23: Reflector Joint Detail 32 of 85... -
Page 41: Reflector Side Extension
SECTION 8: O PTIONAL EATER CCESSORIES 8.4 Reflector Side Extension Step 8.4.1 Bracket Installation Description Part Number Reflector Side Extension Package 027127XX Reflector Side Extension, 96" (244 cm) 0136800X Retainer Clips 02751200 Sheet Metal Screws 94118106 Order Separately Reflector Side Extension Bracket 01329911 Step 8.4.2 Side Reflector Installation 33 of 85... -
Page 42: Universal Shield
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.5 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 43: Two-Foot Decorative Grille Installation
SECTION 8: O PTIONAL EATER CCESSORIES 8.7 Two-Foot Decorative Grille Installation Step 8.7.1 Grille Installation Description Part Number Aluminum Grille 2' x 4' (60 cm x 120 cm) 91407000 Step 8.7.2 Frame Shield Installation Description Part Number Deco Grille Shield, 24" (61 cm) 01365900 35 of 85... - Page 44 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 8.7.3 Reflector Side Extension Installation for Decorative Grilles Distance "A" Extension Minimum Maximum Part No. Width 2" (4 cm) 6" (15 cm) 013704XX 8" (20 cm) Description Part Number 6" (15 cm) 10"...
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Page 45: Protective Grille Installation
SECTION 8: O PTIONAL EATER CCESSORIES 8.8 Protective Grille Installation Step 8.8.1 Silicone Cap Installation Silicone Cap Grille Description Part Number Finger Grille Section - Side Reflector 08050001 Grille End Cap - Side Reflector 08050002 Silicone Cap 91915951-6P NOTE: Protective grille NOT APPROVED for use with 45° Grille Section - EF Reflector 08050003 tilted reflectors. -
Page 46: Section 9: Pump Installation And Venting
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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. Edges are sharp. Heaters must be installed according to the installation manual. -
Page 47: Figure 25: Ep-200 Condensate Valve Assembly
SECTION 9: P NSTALLATION AND ENTING FIGURE 25: EP-200 Condensate Valve Assembly Description Part Number Condensate Valve Assembly 01327001 9.1.1 Condensate Neutralization Tube (optional) 100,000 (Btu/h) x condensate flow (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 48 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Example: Step 3: Choose the condensate neutralization tube CORAYVAC ® system has a total input of 600,000 Btu/h. The radiant tube length and tailpipe are set-up Choose the condensate neutralization tube which is closest to and higher than the calculated gal/h value.
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Page 49: Figure 26: Condensate Neutralization Tube
SECTION 9: P NSTALLATION AND ENTING FIGURE 26: 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 50: General Venting Requirements Model Ep-100, Ep-200 And Ep-300 Series Pumps
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 9.2 General Venting Requirements Model EP-100, See Page 44, Figure 28 through Page 46, Figure 10 for recommended horizontal venting options. EP-200 and EP-300 Series Pumps This heater must be vented in accordance with the 9.2.5 Length Requirements rules contained in this manual and with the following See EP-100, EP-200 or EP-300 Pump Series... -
Page 51: Figure 27: Vertical Venting Configuration
SECTION 9: P NSTALLATION AND ENTING FIGURE 27: Vertical Venting Configuration NOTE: Vacuum loss Bird Screen may occur when Optional using vent caps. The use of bird screen to cover vent terminations is recommended. 6 (15 cm) for EP-100 and EP-200 20 (51 cm) for EP-300 Part Number Description... -
Page 52: Figure 28: Ep-100 And Ep-200 Horizontal Venting Configurations
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 28: EP-100 and EP-200 Horizontal Venting Configurations Part Number Description Part Number Description 01330203 Tee, 4" (10 cm) Aluminized 01327004 Condensate Neutralization Tube 1000 01331900 Damper Coupling, 4" (10 cm) 01327005 Condensate Neutralization Tube 2000 01335801 Elbow, 4"... -
Page 53: Figure 29: Ep-300 Series Horizontal Venting Configurations
SECTION 9: P NSTALLATION AND ENTING FIGURE 29: 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) 01331900 Damper Coupling, 4" (10 cm) 91409420 Tube, Aluminized 6"... -
Page 54: Section 10: Outside Air Supply
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: OUTSIDE AIR SUPPLY the pressure switch does not make. 10.2 Non-Pressurized CAUTION For a non-pressurized outside air supply, a 4" (O.D.) single wall pipe duct may be attached to the burner and end vent. -
Page 55: Outside Air Blower Internal Wiring
SECTION 10: O UTSIDE UPPLY FIGURE 30: 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 CRV- Series systems. -
Page 56: Figure 32: Filter Housing Assembly
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 32: 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 33: Air Supply Blower Support Description... -
Page 57: Figure 34: Pressurized Outside Air Supply
SECTION 10: O UTSIDE UPPLY FIGURE 34: 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 35: Non-Pressurized Outside Air Supply Description... -
Page 58: Section 11: Gas Piping
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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 36. -
Page 59: Figure 36: Gas Connection With Flexible Gas Hose
SECTION 11: G IPING FIGURE 36: Gas Connection with Flexible Gas Hose See Page 81, Section 20. Description Part Number High Pressure Regulator - 2 psi 90207600 High Pressure Regulator - 5 psi 90207601 Description Part Number 1/2" Flexible Stainless Steel Gas Hose (US Models) 91412200 1/2"... -
Page 60: Section 12: Control Methods
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 12: CONTROL METHODS completely exhaust products of combustion from the system. A CORAYVAC ® Heating Control provides DANGER indication of power to the pump and zones and indicates the status of the pressure switch with lights. The CORAYVAC ®... -
Page 61: Dpdt Transformer Relay (P/N 90436300)
SECTION 12: C ONTROL ETHODS temperature. The modulating controls offer many created with up to nine room sensors (P/N features like 7 day programmability, four time periods 10081520). Refer to thermostat installation per day (2 occupied, 2 unoccupied), temporary instructions for wiring. temperature setpoint override, keypad lockout security and more. -
Page 62: Figure 37: One Zone Operation Without Control Panel (Optional)
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 37: One Zone Operation without Control Panel (optional) Description Part Number DPDT Transformer Relay 90436300 54 of 85... -
Page 63: Figure 38: One Zone Operation (With Outside Air Blower) Without Control Panel (Optional)
SECTION 12: C ONTROL ETHODS FIGURE 38: One Zone Operation (with Outside Air Blower) without Control Panel (optional) Description Part Number DPDT Transformer Relay 90436300 Blower Outside Air 90707501K 55 of 85... -
Page 64: Figure 39: Two Zone Operation Without Control Panel (Optional)
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 39: Two Zone Operation without Control Panel (optional) Description Part Number DPDT Transformer Relay 90436300 56 of 85... -
Page 65: Figure 40: General System Wiring
SECTION 12: C ONTROL ETHODS FIGURE 40: General System Wiring FIGURE 41: External Wiring Diagram EP-100 and EP-201 120 V 1 Ø Pump Note: External wiring done by others 57 of 85... -
Page 66: Figure 42: External Wiring Diagram Ep-100, Ep-201 Or Ep-301 230 V 1 Ø Pump (Optional)
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 42: External Wiring Diagram EP-100, EP-201 or EP-301 230 V 1 Ø Pump (optional) CAUTION Product Damage Hazard Do not directly connect control relay terminals to pump motor. Failure to follow these instructions can result in product damage. -
Page 67: Figure 43: External Wiring Diagram Ep-203 Or Ep-303 208 - 230 V (Or 460 V) 3 Ø Pump (Optional)
SECTION 12: C ONTROL ETHODS FIGURE 43: External Wiring Diagram EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø Pump (optional) CAUTION Product Damage Hazard Do not directly connect control relay terminals to pump motor. Failure to follow these instructions can result in product damage. -
Page 68: Figure 44: Corayvac
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 44: CORAYVAC ® Modulating Wiring Diagram [LonWorks ® (2-10 Vdc with 500 ohm resistor) optional] Description Part Number DPDT Transformer Relay 90436300 Thermostat, Modulating LonWorks ® 90425104 Thermostat, Modulating 90425105 Sensor, Remote Modulating 10081520 Sensor, Outdoor Modulating 10081521... -
Page 69: Figure 45: Corayvac
SECTION 12: C ONTROL ETHODS FIGURE 45: CORAYVAC ® Modulating Wiring Diagram [LonWorks ® (4-20 mA) optional] Description Part Number DPDT Transformer Relay 90436300 Thermostat, Modulating LonWorks ® 90425104 Thermostat, Modulating 90425105 Sensor, Remote Modulating 10081520 Sensor, Outdoor Modulating 10081521 61 of 85... -
Page 70: Figure 46: Burner Internal Wiring
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 46: Burner Internal Wiring TRANSFORMER 120 V BLUE IGNITION MODULE V2/GND VALVE (White Rodgers) BURNER HEAD 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 71: 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 72: Setting The Vacuum
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 4. If any abnormal operation occurs, see the trou- bleshooting section of the service instructions. 13.4 Setting the Vacuum 1. Set temperature setpoints above room tempera- ture. See that all burners are operating properly. 2. -
Page 73: Figure 48: Vacuum Reading
SECTION 13: S TARTING YSTEM FIGURE 48: Vacuum Reading 65 of 85... -
Page 74: Section 14: Variable Frequency Drive Programming For Use With Corayvac Modulating Heating Control
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 14: VARIABLE FREQUENCY DRIVE PROGRAMMING FOR USE WITH CORAYVAC ® MODULATING HEATING CONTROL 14.1 VFD Parameter Settings For Use With parameter). CORAYVAC ® Modulating Heating Control The VFD parameters come with factory default set- 14.1.3 Use the arrow buttons to scroll to the desired tings. -
Page 75: Altering Vfd Parameters For Use With Corayvac
SECTION 14: V CORAY- ARIABLE REQUENCY RIVE ROGRAMMING 14.2 Altering VFD Parameters For Use With CORAYVAC ® Modulating Heating Control Using the procedure described on Page 66, Section 14.1.1 through Section 14.1.5, alter the following parameters: Parameter Parameter Name Factory Default New Setting Number Maximum Frequency (Hz) -
Page 76: Section 15: Variable Frequency Drive Programming For Use With Corayvac
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: VARIABLE FREQUENCY DRIVE PROGRAMMING FOR USE WITH CORAYVAC ® SYSTEM WITH MODULATING THERMOSTAT 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 77: Altering Vfd Parameters For Use With Corayvac
SECTION 15: V CORAY- ARIABLE REQUENCY RIVE ROGRAMMING 15.2 Altering VFD Parameters For Use With CORAYVAC ® System With Modulating Thermostat Using the procedure described on Page 66, Section 14.1.1 through Section 14.1.5, alter the following parameters: Parameter Parameter Name Factory Default Number Setting... -
Page 78: Modulating System
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 16: COMMISSIONING THE CORAYVAC ® MODULATING SYSTEM NOTE: Before starting the commissioning procedure, reduce the frequency until the end vent vacuum all the wiring of the CORAYVAC ® Modulating Heating reading is between 2.5" - 3.0" wc. Make note of this Control control boards, relay boards, modulating ther- frequency setting below. -
Page 79: Figure 49: Possible Damper Couplings' Locations
SECTION 16: C CORAYVAC ® OMMISSIONING ODULATING YSTEM FIGURE 49: Possible Damper Couplings’ Locations Description Part Number Damper Coupling 4" (10 cm) 01331900 Damper Coupling 6" (15 cm) E0009356 71 of 85... -
Page 80: Section 17: Operation And Maintenance
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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. -
Page 81: Maintenance Checklist
SECTION 17: O PERATION AND AINTENANCE 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 82 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Check for gas leaks. See Page 51, Figure 36. 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.
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Page 83: Section 18: Troubleshooting
SECTION 18: T ROUBLESHOOTING 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. WARNING Fire Hazard Explosion Hazard... -
Page 84: Troubleshooting Flow Chart
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 18.1 Troubleshooting Flow Chart 76 of 85... - Page 85 SECTION 18: T ROUBLESHOOTING Troubleshooting Flow Chart 77 of 85...
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Page 86: Section 19: Replacement Parts
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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 87 SECTION 19: R EPLACEMENT ARTS Ignition Module Ignition Cable SIDE VIEW Electrode Electrode Gasket TOP VIEW Transformer Gasket (Burner to Mixing Chamber) Burner Head Mixing Chamber Description Part Number Gas Valve LP or NG (White-Rodgers Gas Valve - For burners made after 1/1/2018) 90032512 Gasket (Burner to Mixing Chamber) 01351100...
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Page 88: Replacement Parts Instructions
CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.1 Replacement Parts Instructions power to the VFD assembly and verify that the VFD LCD screen is on. (dashes displayed). Close the DANGER VFD assembly door. Electrical Shock Hazard Disconnect electric before service. Controller must be properly grounded to an electrical source. -
Page 89: 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 75 lbs (33 kg). See Page 21, Figure 20. .024 024 Stainless Steel Aluminium (Optional- Type 304, 20.4 Controls Specifications... - Page 90 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)
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Page 91: Section 21: The Roberts Gordon Corayvac Limited Warranty
SECTION 21: T ROBERTS GORDON ® CORAYVAC ® IMITED ARRANTY SECTION 21: THE ROBERTS GORDON ® CORAYVAC ® LIMITED WARRANTY ROBERTS-GORDON LLC WILL PAY FOR: WARRANTY IS VOID IF: ® Within 36 months from date of purchase by buyer or 42 The ROBERTS GORDON CORAYVAC ®... - Page 92 CRV-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 84 of 85...
- Page 93 SECTION 21: T ROBERTS GORDON ® CORAYVAC ® IMITED ARRANTY 2017 85 of 85...
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