Roberts Gorden EP-203 Service Manual

CoRayVac®Installation, Operation &Service ManualCRV-B-2CRV-B-4CRV-B-6CRV-B-8CRV-B-9CRV-B-10CRV-B-12CRV-B-12AInstallerPlease take the time to read

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL!!!!!SECTION 4: NATIONAL STANDARDS ANDAPPLICABLE CODES4.1 Gas CodesThe type of gas appearing on th

Table 1. Contents of CORAYVAC® Carton(CRV-B all models)Part No. Description Quantity0270XXXX Burner 1013676XX End Vent Plate 101397300 Accessory Packa

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALBZC300 ROBERTS GORDON® BZC 300 ControllerBZC700 ROBERTS GORDON® BZC 700 Controller10001500 Interna

9!!!!!SECTION 6: DESIGN REQUIREMENTSThe CORAYVAC® systems design is related to the system operation and performance required by the building beingheat

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL20"(51 cm)!!!!!SECTION 7: ASSEMBLY OVERVIEWThe figures in this section provide a general over

16"(61 cm)10"(24.4 cm)20"(51 cm)11SECTION 7: ASSEMBLY OVERVIEW90° Elbow:4" Coated - 0133580D4" Aluminized - 013358016" C

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL12Reflector Side Extension (8')- 02712700Condensate Trap Assembly - 01327000Barrier Shield -

SECTION 7: ASSEMBLY OVERVIEW13FIGURE 10 – Major Components’ DescriptionsROBERTS GORDON® BZC 100Controller with Sensor - BZC100Sensor - 10001500System

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALFIGURE 11 –CRV Assembly Overview14EndVentCombustionChamberTube &ReflectorHangerBurnerReflector

Side View Towards PumpTypical Suspension DetailsTurnbuckleRod (3/8")Beam ClampConcrete BeamWood BeamWashersLocknutScrew Hoo

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALCombustionChamber7' 6"(229 cm)HangerTurnbucklesTubeCombustionChamberNOTE: Tubing require

SECTION 8: HEATER INSTALLATION17Step 8.3.2 – Coupling and Tube Assembly (Continued)• Repeat steps 8.3.1 A-D until all tubes are assembled.8.4 Elbow Pa

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALReflectorwith HoleTubeHangerCombustionChamberSlide Reflectorwith holethrough hanger.Unhook combust

U-Clip(2 clips peralternate overlapsper side)ReflectorWire FormTubeReflector SupportStrapSheet MetalScrewSECTION 8: HEATER INSTALLATION19FIGURE 12 – R

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALGasketBurnerCombustionChamberEndVentNOTE:Install End Ventat end combustionchamber position onlyCom

SECTION 8: HEATER INSTALLATION21Step 8.7.2 – Reflector JointCut away contourwith tin snips.Punch/Drill six 3/32" (2 mm) holesStep 8.7.3 – Reflect

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALFIGURE 13 – Reflector Joint DetailReflectorReflectorJoint228.8 Reflector Side ExtensionReflector S

TubeUniversal ShieldBracket Assembly*Hex Nut*Shield Support Bracket*Stud*Tube and Reflector Support Assembly*FlattenedSectionStandard Reflector* Inclu

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL248.10 Barrier ShieldReflector Support Strap Cut Relief NotchFlatten Reflector EdgesAttach U-Clips

SECTION 8: HEATER INSTALLATION25Shield8.11 Decorative GrilleStep 8.11.2 – Frame ShieldSuspended Ceiling FrameTube2' x 4' (60 x 120 cm) Alumi

1. Heater Safety ...1Read this section carefully. Improperinstallation, adjustment, operation ormainte

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALReflector Side ExtensionCut Relief Notches for Tubeand Reflector HangersANOTE: If the Decorative G

Spread apart bracketsand installDecorative Grille.SECTION 8: HEATER INSTALLATION27#8 Sheet Metal ScrewsJoint PieceReinforcementSlip joint piece intosu

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALFasten end pieceto brackets using two#8 sheet metal screwsand replace reflector end cap.Insert end

29SECTION 8: HEATER INSTALLATION8.13 Protective GrilleStep 8.13.2 – Grille End CapSilicone CapGrilleFingerGrilleGrille End CapPull outwardBend up 90°S

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALStep 8.13.3 – GrilleGrilleGrilleEnd CapReflectorFinal GrilleSection40 "(101 cm)30

SECTION 8: HEATER INSTALLATION31WARNINGSuspension HazardUse special tube and reflector hangers whensuspending the schedule 40 steel pipe system.Schedu

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALFor complete pump installation, please refer to the EP-100, EP-201 or EP-301 installation, operati

9.2 Vertical Venting ConfigurationSECTION 9: PUMP INSTALLATION AND V ENTING33ApprovedVent CapApprovedThimble2' (61 cm)MinimumAluminized Tee1"

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL9.3 Horizontal Venting Configurations3425' (8 m) and 3 Elbows Maximum50' (15 m) and 3 El

FIGURE 16 – EP-201/203 Horizontal Venting ConfigurationsSECTION 9: PUMP INSTALLATION AND V ENTING3510' (3 m) Maximum and No Elbows25' (8 m)

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALFigure 29 External Wiring Diagram EP 203and EP 303 230V 3ph Pump ...46Figure 30 CRV Bur

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL36FIGURE 17 – EP-301/303 Horizontal Venting Configurations10' (3 m) Maximum and 1 Elbow50&apo

SECTION 10: OUTSIDE AIR SUPPLY37The CORAYVAC® system is approved for use with anoutside air system. Halogenated hydrocarbons or othercorrosive chemica

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL38Wing NutFilter HousingFilterTop Gasketand DiskBottom GasketDoor-ControlHousingFilterSupportFigur

39OutsideWallMountingBracketBurnerSheet Metalor PVCOutsideAir SupplyBlowerClamp4" TakeOff4" AirFlex DuctFilterHousingOutside Wall7/16"

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALHorizontal45°Rear ViewBurner2" (5 cm)StainlessSteel FlexGas ConnectorShut-Off Valve(includedw

There are several methods of controlling CORAYVAC®systems. The options are as follows:1. ROBERTS GORDON® System ControlP/N 02770002The System Control

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL42A pressure switch is required to confirm pump operationon all pumps.A pressure switch (outside a

123456COIL COILRCWGYThermostatPumpMotorPressureSwitch(Pump)SPST (12A)TransformerRelayZone 1BurnersNLLNNine Burners MaximumBlackWhiteRedBlackL120V1ph60

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL44123456COILCOILRCWGY123456COILCOILRCWGYPumpMotorPressureSwitch(Pump)TransformerRelayZone 1Burners

Burner Recepticals4 Zone Max120VACMaximum 20 Amps TotalThermostatsOutsideAir SupplyBlower Motorand PressureSwitchPump Motor115 VAC Operation230 VAC Op

!!!!!SECTION 1: HEATER SAFETYYour Safety is Important to Us!This symbol is used throughout themanual to notify you of possible fire,electrical or burn

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALCT1CCCCT3T2T4PS120V1ph60 Hz120V1ph60 HzGround12V DCLNGLNPUMP Z1 Z2 Z3 Z4NNNNNLLLLLGroundSystem Con

47S1TRANSFORMERVALVEGAS120 VPower SupplyYellowYellowBrownGreenWhiteBlack3415BURNERIGNITION MODULEBlackBlueYellowV2/GNDTHV1GreenGapTRANSFORMERL1L2Black

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL48FIGURE 32 – Vacuum ReadingManometer65432101234566543210123456Insert tubingabout 6" (15cm).C

SECTION 13: OPERATION AND MAINTENANCE4913.1 Sequence of OperationTurn the thermostat up. When the thermostat calls forheat, the pump will start immedi

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL50Installation, Service and Annual Inspection of the heater mustbe done by a contractor qualified

51SECTION 13: OPERATION AND MAINTENANCEThermostat or Internal There should be no exposed wire or damage to the thermostat or sensor.SensorSuspension P

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALIs the pump impellerobstructed?NoMotor bearings may havefailed. Replace motor.Is the motor connect

NoReplace filters as necessary.Replace the electrodes.Adjust the gap orreplace the electrode.Ignition module may havefailed. Replace module.Electrode

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALGasket (Burner to Mixing Chamber)Ignition ModuleMixing ChamberBurner HeadRegulatorElectrodeElectro

!!!!!SECTION 16: GENERAL SPECIFICATIONSGeneral Specifications for CORAYVAC® heaters are as followsRate Length “A” RecommendedModel (BTUH X1000) Minim

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL!!!!!SECTION 3: CRITICAL CONSIDERATIONS3.1 Minimum Required Clearances toCombustiblesClearances ar

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUALPump SpecificationsModel EP 100 EP 201 EP 203 EP 301 EP 303Horsepower (Hp) 1/3 3/4 3/4 1-1/2 1-1/2

ROBERTS-GORDON WILL PAY FOR:ROBERTS GORDON® warrants to the original owner-user thatthis ROBERTS GORDON® product will be free from defects inmaterial

(inches)Model ABCDCRV-B-2 4 20 48 20CRV-B-4 4 20 48 20CRV-B-6 4 20 48 20CRV-B-8 4 20 48 20CRV-B-9 4 36 60 36CRV-B-10 4 36 60 36CRV-B-12 4 36 60 36CRV-

CORAYVAC® INSTALLATION, OPERATION AND SERVICE MANUAL(inches)Model ABCDCRV-B-2 4 12 12 12CRV-B-4 4 12 12 12CRV-B-6 4 12 12 12CRV-B-8 4 12 12 12CRV-B-9

ABCD(inches)Model ABCDCRV-B-2 4 12 48 12CRV-B-4 4 12 48 12CRV-B-6 4 12 48 12CRV-B-8 4 12 48 12CRV-B-9 4 18 56 18CRV-B-10 4 18 56 18CRV-B-12 4 18 56 18