Roberts Gorden EP-203 Service manual

System Control
Installation, Operation &
Service Manual
Installer
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.
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 serviceman with necessary information.
Roberts-Gordon LLC
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
© 2009 Roberts-Gordon LLC
www.rg-inc.com
www.radiantheaters.com
www.corayvac.com
P/N 10091601NA Rev. L 11/09
TABLE OF CONTENTS
SECTION 1: Introduction........................................................ 1
1.1 Safety ........................................................................... 1
1.2 What is a ROBERTS GORDON® System Control? ...... 1
1.3 Electrical Requirements ............................................... 1
1.4 Check Installation Materials ......................................... 1
SECTION 2: Specifications .................................................... 3
2.1 Material Specifications................................................. 3
2.2 Electrical Specifications ............................................... 3
2.3 Pump Specifications .................................................... 3
2.4 Burner Electrical Ratings ............................................. 4
2.5 Outside Air Supply Blower Electrical Ratings .............. 4
2.6 Indicator Lights ............................................................ 4
2.7 Terminal Block Guide................................................... 4
SECTION 3: Installation.......................................................... 5
3.1 Preparation .................................................................. 5
3.2 Installing the System Control Panel ............................. 5
3.3 Select the External Wiring Diagram for the
Installation.................................................................... 5
3.4 System Configuration................................................... 6
SECTION 4: Typical External Wiring Diagrams .................... 7
4.1 EP-100 or EP-201 120 V 1 Ø Pump External Wiring
Diagram ....................................................................... 7
4.2 EP-201 or EP-301 230 V 1 Ø External Wiring
Diagram ....................................................................... 8
4.3 EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø Pump
External Wiring Diagram.............................................. 9
4.4 Outside Air Blower External Wiring Diagram ............. 10
4.5 Thermostat Wire Lengths .......................................... 11
SECTION 5: Troubleshooting............................................... 12
5.1 Sequence of Operation.............................................. 12
SECTION 6: Replacement Parts .......................................... 14
6.1 Replacement Parts Instructions................................. 15
SECTION 7: The ROBERTS GORDON® System Control
Warranty ........................................................... 17
© 2009 Roberts-Gordon LLC
All rights reserved. No part of this work covered by the copyrights herein may be reproduced
or copied in any form or by any means - graphic, electronic, or mechanical, including
photocopying, recording, taping or information storage and retrieval systems - without the
written permission of Roberts-Gordon LLC.
Printed in U.S.A.
TABLE OF FIGURES
Figure 1: Panel Layout .............................................................. 3
Figure 2: Terminal Block Guide ................................................. 4
Figure 3: Mounting Hole Layout................................................ 5
Figure 4: System Configuration................................................. 6
Figure 5: External Wiring Diagram ROBERTS GORDON®
EP-100 and EP-201 120 V 1 Ø Pump......................... 7
Figure 6: External Wiring Diagram ROBERTS GORDON®
EP-100, EP-201 or EP-301, 230 V 1 Ø Pump ............. 8
Figure 7: External Wiring Diagram ROBERTS GORDON®
EP-203 or EP-303, 208 - 230 V (or 460 V)
3 Ø Pump ................................................................... 9
Figure 8: External Wiring Diagram ROBERTS GORDON®
EP-100 or EP-201 120 V 1 Ø Pump with Outside
Air Blower................................................................. 10
Figure 9: System Control Troubleshooting Chart .................... 13
Figure 10: System Control Internal Components Diagram ...... 14
SECTION 1: INTRODUCTION
SECTION 1: INTRODUCTION
1.1 Safety
Your Safety is Important to Us! 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.
Installation, service and annual inspection of
controller must be done by an electrician qualified in
the installation and service of control systems for
heating equipment.
Installation, service and annual inspection of heater
must be done by a contractor qualified in the
installation and service of gas or oil fired heating
equipment.
Read this manual carefully before installation,
operation, or service of this equipment.
For optimum heater performance and safe heating
conditions, inspect and maintain heater(s) before
every heating season as necessary. Also, know and
maintain heater clearances to combustibles, see
heater Installation, Operation and Service Manual for
further details. If you require additional manuals, contact your ROBERTS GORDON® independent distributor or Roberts-Gordon LLC at (716) 852-4400, (800)
828-7450 or online at www.rg-inc.com.
1.2 What is a ROBERTS GORDON® System
Control?
The ROBERTS GORDON System Control is an
electronic controller designed for the control of
CORAYVAC® and VANTAGE® NP (multiburner only)
systems.
®
The System Control is capable of giving four zones of
burners' temperature control and power. The control
will also give power output to as many as two pumps,
provided that the load is not greater than 20 A and 1
Ø. For additional electrical specifications see Page 3,
Section 2.2.
1.3 Electrical Requirements
DANGER
Electrical Shock Hazard
Disconnect electric before service.
Control must be properly grounded to an
electrical source.
Failure to follow these instructions can
result in death or electrical shock.
Failure to comply with the installation instructions will
invalidate the limited warranty set out on Page 17,
Section 7.
The cable used for all wiring must be rated for 600 V.
The system control, burners, pump and outside air
blower must be electrically grounded in accordance
with the following:
United States: Refer to National Electrical Code®,
NFPA 70 - latest revision. Wiring must conform to the
most current National Electrical Code®, local ordinances and any special diagrams furnished.
Canada: Refer to Canadian Electrical Code, CSA
C22.1 Part 1 - latest revision.
1.4 Check Installation Materials
Before proceeding with the installation of the
ROBERTS GORDON® System Control, check the following points:
1.4.1 Thermostats
Electronic 24 Vac thermostats and mechanical thermostats with heat anticipator can be used. The system control offers a 24 Vac power supply to power
electronic thermostats.
Roberts-Gordon offers a selection of low voltage
thermostats approved for use with the system control.
The thermostats measure the air temperature in the
building. It is important that the thermostat is located
in an area within the heated zone at occupant level.
Do not place thermostat in an area shaded from the
low-intensity, infrared heating system.
1
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
1.4.2 Electrical Installation Materials
120 V, 60 Hz, 1 Ø, 20 A, power supply to the control
panel must be installed in accordance with the most
current National Electrical Code®, local codes and
any site specific diagrams.
Total load powered by the panel must not exceed
20 A. Loads totaling more than 20 A must be
powered from an additional power supply circuit by
the use of a load relay package.
1.4.3 Outside Air Supply Blower
If used, the optional outside air blower is to be controlled in parallel with the pump. The blower incorporates a pressure switch which must be wired in series
with the pressure switch on the pump. The load relay
package may be required with the blower. See Page
10, Figure 8 for wiring detail.
1.4.4 Pressure Switch
A pressure switch (P/N 90430600K), is required for
installation on the inlet of the pump. This switch is
required to interlock the operation of the pump with
the control panel.
CAUTION
Product Damage Hazard
Pressure switch must be installed on all
ROBERTS GORDON® systems to ensure
safety and operation.
System will not operate without pressure
switch.
Failure to follow these instructions can result
in product damage.
2
SECTION 2: SPECIFICATIONS
SECTION 2: SPECIFICATIONS
FIGURE 1: Panel Layout
2.2 Electrical Specifications
2.1 Material Specifications
Supply: 120 V, 60 Hz, 1 Ø, 20 A
Enclosure Material: Metal
Zone Relay: Single pole 20 A, 120 Vac
(resistive)
Weight: 6.8 lbs (3.08 kg)
Dimensions: 10.2" x 11.4" x 2.8"
(25.4 x 29.0 x 7.1 cm)
Pump Relay: Single pole 20 A, 120 Vac
(resistive) 1 HP motor rated.
Protection: Rating IP20
Thermostats: Low voltage 24 Vac
2.3 Pump Specifications
Full Load Current
Pump Model
HP
120 V 1 Ø
208/230 V 1 Ø
208/230 V 3 Ø
460 V 3 Ø
EP-100
1/3
4.8 A
N/A / 2.4 A
-
-
EP-201
3/4
6.6 A
N/A / 3.3 A
-
-
EP-203
3/4
-
-
2.4 A / 2.2 A
1.1 A
EP-301
2
23 A
12.8 A / 11.9 A
-
-
EP-303
2
-
-
5.5 A / 5.2 A
2.6 A
3
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
2.4 Burner Electrical Ratings
CORAYVAC® burners: 120 V, 60 Hz, 1 Ø 0.3 A
VANTAGE® NP (multiburner only) burners:120 V, 60
Hz, 1 Ø 0.2 A
2.5 Outside Air Supply Blower Electrical Ratings
Outside air supply blower (P/N 90707501) has a full
load rating of 1.6 A when supplied by a 120 V, 60 Hz, 1
Ø power source.
2.6 Indicator Lights
See Page 3, Figure 1.
1. LINE POWER, when lit, indicates power is
supplied to the panel.
2. PUMP POWER 1, when, lit, indicates the relay
for power to pump 1 is energized.
3. PUMP POWER 2, when, lit, indicates the relay
for power to pump 2 is energized.
4. PRESSURE SWITCH 1, when lit, indicates that
pressure switch 1 is closed. When blinking, indicates that the system is in lockout.
5. PRESSURE SWITCH 2, when lit, indicates that
pressure switch 2 is closed. When blinking, indicates that the system is in lockout.
6. ZONE, when lit, indicates which zone relay is
energized.
2.7 Terminal Block Guide
Figure 2 is a guide to the terminal abbreviations.
FIGURE 2: Terminal Block Guide
N
L
N
L
N
L
N
LINE
NEUTRAL
LINE
NEUTRAL
LINE
NEUTRAL
LINE
NEUTRAL
NEUTRAL
LINE
NEUTRAL
LINE
NEUTRAL
LINE
L
L
AIR SW 2
ZONE 2 W
ZONE 2 W
ZONE 2 W
ZONE 1 W
AIR SW 1
24 VAC
COM
4
AIR SW 2
N
ZONE 2 R
L
ZONE 2 R
N
ZONE 2 R
L
ZONE 1 R
N
ZONE 1
ZONE 2
ZONE 3
ZONE 4
PUMP 2
BURNERS BURNERS BURNERS BURNERS
AIR SW 1
G
PUMP 1
24 VAC
COM
GROUND
POWER
SUPPLY
SECTION 3: INSTALLATION
SECTION 3: INSTALLATION
DANGER
Electrical Shock Hazard
Disconnect electric before service.
Control must be properly grounded to an
electrical source.
3.2.6 When the case is rotated 180°, the LED status
circuit card needs to be rotated so that the LED's
match the upright cover panel. Remove the LED status circuit card by squeezing each standoff gently
with pliers one at a time until it is loose. Rotate the
circuit card so that it will line up with the upright cover
and re-attach to the standoffs. The ribbon cable that
connects the LED status circuit card to the circuit
card assembly will have a twist in it. Use caution not
to cause any creases or put any tension to the ribbon
cable when rotating the circuit card.
FIGURE 3: Mounting Hole Layout
4 x Ø 0.360" (9 mm)
Failure to follow these instructions can
result in death or electrical shock.
Installation of the System Control and the associated
external electrical wiring must be completed by an
electrician qualified in the installation of control
systems for heating equipment.
3.1 Preparation
Before installing the System Control, observe the
following:
3.1.1 Ensure that you have a copy of the site layout
for the project that identifies clearly the separate
zones.
3.1.2 Read Page 1, Section 1.4 carefully to ensure
the correct installation materials are available.
3.2 Installing the System Control Panel
3.2.1 Choose a mounting location for the System
Control. It is advisable to choose a visible location
near the pump.
Do not mount System Control outdoors or in an
area with moisture spray, excessive moisture or
humidity. To avoid damage from possible drips,
do not mount controller directly beneath pump.
3.2.2 Remove the cover of the System Control by
removing the four securing screws.
3.2.3 Place the cover and the hardware in a safe
place for refitting after the external wiring connections
have been made.
3.2.4 Position the mounting hole location of the System Control per Figure 3.
3.2.5 Remove the knockouts required for the conduit
entry into the System Control panel. The knockouts
are on the top of the system control case. If the
knockouts are required to be on the bottom the case
can be rotated 180°.
4.5" (114 mm)
10.0" (254 mm)
3.3 Select the External Wiring Diagram for the
Installation
3.3.1 Use Page 7, Section 4 for the external wiring of
the burners, thermostats and pressure switch.
3.3.2 Use the table below to select the correct pump
external wiring diagram.
Pump
EP-100
EP-100
EP-201
EP-201
EP-301
EP-203
EP-303
Supply Voltage
Page Section Figure
120 V 1 Ø
7
4
5
208/230 V 1 Ø
8
4
6
120 V 1 Ø
7
4
5
208/230 V 1 Ø
8
4
6
120/208 - 230 V 1 Ø
8
4
6
208 - 230 V (or 460 V) 3 Ø
9
4
7
208 - 230 V (or 460 V) 3 Ø
9
4
7
Roberts-Gordon LLC provides, at an additional
cost, the following IEC contactor packages required
for EP-100 and EP-201 208/230 V (1 Ø), EP-203 (3
Ø), EP-303 (3 Ø) and EP-301 (1 Ø) pumps.
5
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
3.4 System Configuration
For the EP-203 (3 Ø), EP-303 (3 Ø), EP-100, EP-201
and EP-301 208/230 V (1 Ø) pumps, use the 17 Amp
contactor package (P/N 10050011).
See Page 6, Figure 4 for details. Below the ribbon
cable J2 connector, there are six configurable jumpers. They indicate whether the thermostat for each
zone uses an anticipator. If the thermostat for that
associated zone has an anticipator, then use a
jumper to cover both pins for that zone. If the thermostat for the associated zone does not use an anticipator, then cover the right side pin only.
For the EP-301 pumps that are operated with 120 V
(1 Ø) use the 28 Amp contactor package (P/N
10050012). The contents are listed below:
Contactor Packages
Part No.
The bottom two jumpers are associated with Pump 2
operation. They indicate whether Pump 2 is active
and which zones are associated with it. Pump 2 can
only be associated with Zone 3 and/or Zone 4. To
enable Pump 2, use a jumper to cover both pins for
the zone(s) that will operate on Pump 2. To disable
Pump 2, cover only the right side of the pin of zone 3
and 4.
Description
10050011 Contactor Package 17A
10001002
Enclosure IEC metal 8X6X6 NEMA 1
90600200
CONT 208-600 17A (A16-30-10-84)
10050012 Contactor Package 28A
10001002
Enclosure IEC metal 8X6X6 NEMA 1
90600205
CONT 208-600 28A (A26-30-10-84)
All pump motors are equipped with thermal
overloads.
3.3.3 If an outside air blower is to be used with any of
the above options, See Page 10, Figure 8.
FIGURE 4: System Configuration
PUMP 2
N
L
AIR
SW2
Z4W
6
Z3W
PUMP 2
OPERATION
ENABLE
Z2W
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 3
ZONE 4
Z1W
AIR
SW1
24 VAC
COM
ANTICIPATOR
LOAD ENABLE
Z4R
ZONE 4
N
L
AIR
SW2
ZONE 3
N
L
Z3R
ZONE 2
N
L
Z2R
ZONE 1
N
L
Z1R
PUMP 1
N
L
AIR
SW1
24 VAC
COM
AC POWER IN
G
N
L
ANTICIPATOR
LOAD ENABLE
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 3
ZONE 4
PUMP 2
OPERATION
ENABLE
FEATURE
ENABLED
FEATURE
DISABLED
SECTION 4: TYPICAL EXTERNAL WIRING DIAGRAMS
SECTION 4: TYPICAL EXTERNAL WIRING
DIAGRAMS
4.1 EP-100 or EP-201 120 V 1 Ø Pump External
Wiring Diagram
The external wiring diagram above shows the connections for four zones of system burners. System
burners can be either CORAYVAC® or VANTAGE® NP
(multiburner only).
DANGER
The zones are connected to a single pump, unless
zone 3 and/or zone 4 are selected to function with
the optional pump 2. The external wiring diagram
below shows connection to an EP-100 or EP-201 120
V 1 Ø pump.
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric to the unit.
4.1.1 External Wiring Connection Details
Failure to follow these instructions can result
in death or electrical shock.
The cable used for all the wiring must be rated for
line voltage up to 600 Vac.
The low voltage circuit conforms with Class 2 separation of circuit requirements. National Electrical Codes®
for wiring class 2 low voltage circuits must be followed.
FIGURE 5: External Wiring Diagram ROBERTS GORDON® EP-100 and EP-201 120 V 1 Ø Pump
EP-100 or
EP-201 Pump All burners must be
connected to Ground
(Not shown)
EP-100 or
EP-201 Pump
TWO PUMP SYSTEM (optional)
Pump 1 may be used for all zones.
Pump 2 may be used to control
zone 3 and/or zone 4.
Zone 1 Zone 2 Zone 3 Zone 4
Pressure
switch
located at
Pump 1
120 V
1Ø
60 Hz
120 V
1Ø
60 Hz
Low voltage thermostats
located in heated zone
Zone
1
Zone
2
Zone
3
Zone
4
Pressure
switch
located at
Pump 2
24 VAC
L
N
L
N
G
Ground
POWER
SUPPLY
N L
PUMP 1
N L
NL
NL
N L
Z1
Z2
Z3
Z4
System Control
N L
24 VAC PS 1
COM
R
R
R
R
PS 2
PUMP 2
24 VAC
COM
PS 1
W
W
W
W
PS 2
7
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 6: External Wiring Diagram ROBERTS GORDON® EP-100, EP-201 or EP-301, 230 V 1 Ø Pump
CAUTION
EP-100, EP-201 or
EP-301 Pump
Product Damage Hazard
Motor Contactors
P/N 10050011
P/N 10050012
Do not directly connect control relay terminals
to pump motor.
Failure to follow these instructions can result
in product damage.
6
4
2
The power supply for the
pump must be separate
from the controller supply
M
3
1
208 - 230 V
supply for
1 Ø Individual
pump rated for total full
60 Hz load current. See Section
5
L1
L2
2.3 for details.
EP-100,
TWO PUMP SYSTEM (optional)
EP-201 or
Pump 1 may be used for all zones.
EP-301 Pump Pump 2 may be used to control zone 3
and/or zone 4. Refer to Pump 1 for configuration.
All burners must be
connected to Ground
(Not shown)
Zone 1 Zone 2 Zone 3 Zone 4
Pressure
switch
located at
pump 1
120 V
1Ø
60 Hz
120 V
1Ø
60 Hz
Low voltage thermostats
located in heated zone
Zone
1
Zone
2
Zone
3
Zone
4
Pressure
switch
located at
pump 2
24 VAC
L
N
L
N
G
Ground
POWER
SUPPLY
N L
PUMP 1
N L
NL
NL
N L
Z1
Z2
Z3
Z4
System Control
N L
24 VAC PS 1
COM
R
R
R
R
PS 2
PUMP 2
24 VAC
COM
PS 1
W
W
W
W
PS 2
4.2 EP-201 or EP-301 230 V 1 Ø External Wiring
Diagram
pump.
4.2.1 External Wiring Connection Details
The external wiring diagram above shows the
connections for four zones of system burners.
System burners can be either CORAYVAC® or VANTAGE® NP (multiburner only).
The cable used for all the wiring must be rated for
line voltage up to 600 Vac.
The zones are connected to a single pump, unless
zone 3 and/or zone 4 are selected to function with
the optional pump 2. The external wiring diagram
above shows connection to an EP 301 or EP-201 1 Ø
8
The low voltage circuit conforms with Class 2 separation of circuit requirements. National Electrical Codes®
for wiring class 2 low voltage circuits must be followed.
SECTION 4: TYPICAL EXTERNAL WIRING DIAGRAMS
FIGURE 7: External Wiring Diagram ROBERTS GORDON® EP-203 or EP-303, 208 - 230 V (or 460 V)
3 Ø Pump
CAUTION
Product Damage Hazard
Do not directly connect control relay terminals
to pump motor.
EP-203 or
EP- 303 3 Ø Pump
Motor Contactors
P/N 10050011
P/N 10050012
Failure to follow these instructions can result
in product damage.
The power supply for the
pump must be separate
from the controller supply
M
L3
L2
L1
208 - 230 V
(or 460 V)
3Ø
60 Hz Individual supply
All burners must be
connected to Ground
(Not shown)
for pump rated for
total full load current.
See Section 2.3
for details.
EP-203 or
EP-303 3 Ø
Pump
Zone 1 Zone 2 Zone 3 Zone 4
Pressure
switch
located at
pump 1
120 V
1Ø
60 Hz
120 V
1Ø
60 Hz
TWO PUMP SYSTEM (optional)
Pump 1 may be used for all zones.
Pump 2 may be used to control zone 3
and/or zone 4. Refer to Pump 1 for configuration.
Low voltage thermostats
located in heated zone
Zone
1
Zone
2
Zone
3
Zone
4
Pressure
switch
located at
pump 2
24 VAC
L
N
L
N
G
Ground
POWER
SUPPLY
N L
PUMP 1
N L
NL
NL
N L
Z1
Z2
Z3
Z4
System Control
4.3 EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø
Pump External Wiring Diagram
The external wiring diagram above shows the
connections for four zones of system burners.
System burners can be either CORAYVAC® or
VANTAGE® NP (multiburner only).
The zones are connected to a single pump, unless
zone 3 and/or zone 4 are selected to function with
the optional pump 2. The external wiring diagram
N L
24 VAC PS 1
COM
R
R
R
R
PS 2
PUMP 2
24 VAC
COM
PS 1
W
W
W
W
PS 2
above shows connection to an EP-203 or EP-303 3 Ø
pump.
4.3.1 External Wiring Connection Details
The cable used for all the wiring must be rated for
line voltage up to 600 Vac.
The low voltage circuit conforms with Class 2 separation of circuit requirements. National Electrical Codes®
for wiring class 2 low voltage circuits must be followed.
9
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 8: External Wiring Diagram ROBERTS GORDON® EP-100 or EP-201 120 V 1 Ø Pump with Outside Air Blower
Optional power supply for Outside Air Blower
Typical wiring for Load Relay
Package (P/N 05023000)
Coil connections
Live out to the to Pump L & N
outside air
Outputs from
blower
Control Panel
3
6
5
2
1
4
Live in
Pump
Coil
Outside Air
Blower
Coil
Outside Air
Blower
Relay Receptacle
Back Plate
120 V
1Ø
60 Hz
CR
L
N
Pump
TWO PUMP SYSTEM (optional)
Pump 1 may be used for all zones.
Pump 2 may be used to control zone 3
and/or zone 4. Refer to Pump 1 for configuration.
Pressure switch
located at pump 2
All burners must be
connected to Ground
(Not shown)
Pressure switch located
at outside air blower
Zone 1 Zone 2 Zone 3 Zone 4
Pressure switch
located at pump 1
Pressure switch
located at outside air
blower
Low voltage thermostats
located in heated zone
Zone
1
120 V
1Ø
60 Hz
120 V
1Ø
60 Hz
Zone
2
Zone
3
Zone
4
24 VAC
L
N
L
N
G
Ground
POWER
SUPPLY
N L
PUMP 1
N L
NL
NL
N L
Z1
Z2
Z3
Z4
System Control
4.4 Outside Air Blower External Wiring Diagram
The external wiring diagram above shows the connections for four zones of system burners. System
burners can be either CORAYVAC® or VANTAGE® NP
(multiburner only).
10
N L
24 VAC PS 1
COM
R
R
R
R
PS 2
PUMP 2
24 VAC
COM
PS 1
W
W
W
W
PS 2
The zones are connected to a single pump, unless
zone 3 and/or zone 4 are selected to function with
the optional pump 2. The external wiring diagram
above shows connection to an EP-100 or EP-201 1 Ø
motor. The diagram also shows the connection via a
SECTION 4: TYPICAL EXTERNAL WIRING DIAGRAMS
load relay to the optional outside air blower.
4.4.1 External Wiring Connection Details
The cable used for all the wiring must be rated for
line voltage up to 600 V.
The low voltage circuit conforms with Class 2
separation of circuit requirements. National Electrical
Codes® for wiring class 2 low voltage circuits
must be followed.
4.5 Thermostat Wire Lengths
To ensure proper thermostat operation the
recommendations for wire guages as indicated below
must be used.
Distance (ft)
Up to 500
Up to 400
Up to 300
Up to 200
Up to 100
Guage
20
20
22
24
26
11
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 5: TROUBLESHOOTING
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric to the unit.
Failure to follow these instructions can result
in death or electrical shock.
WARNING
Explosion Hazard
Turn off gas supply to heater before service.
Failure to follow these instructions can result
in death, injury or property damage.
5.1 Sequence of Operation
12
a.
On demand for heat from the thermostat, the
panel will send power to the pump. The pump
will begin operation.
b.
Once vacuum is established, the pressure
switch at the pump will close. If the vacuum is
not established within 30 seconds the pump
will go into lockout (pump LED is flashing).
After one hour of lockout, the system will restart.
c.
The System Control panel sends power to the
burners. The burners will go through a 45
second purge and cycle time.
d.
Once flame is established, the heater will
remain in operation until such time as either
the heating is turned off by the thermostat,
lockout conditions occur, or after 24 hours of
continuous operation. After 24 hours of continuous operation, the system control will shut
off and re-start to verify no faults exist in the
system.
e.
After the heating is turned off, the pump will
continue operation for 2 minutes, post purge.
SECTION 5: TROUBLESHOOTING
FIGURE 9: System Control Troubleshooting Chart
If control is not working properly, disconnect power to control and check for signs
of physical damage to the front and back of the circuit board, water damage (corrosion) or scorching. If damage is found, identify and rectify source of
damage. Replace circuit board (P/N 10090101), if it has permanent damage.
Is the line power
indicator on?
No
Check the power supply
to the system control
panel. Is it on?
Yes
No
Check the 250mA
fuse. Is it OK?
Yes
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
No
Replace fuse with
P/N 10000212.
Rectify power supply
problem.
Yes
Adjust thermostat set
point to call for heat.
Does the pump
come on?
No
Is external wiring to the
pump OK?
Yes
Is the correct contactor
selected for the
pump?
No
No
Rectify.
Fit the correct contactor.
Yes
Refer to burner troubleshooting in either the
CORAYVAC® or
VANTAGE® NP
Installation, Operation and
Service Manuals.
Yes
Does the zone light
come on?
No
Is the thermostat connected
Yes to the correct terminal at the
system control.
Does the pressure switch
light come on?
No
Rectify.
Yes
No
Is external wiring to the
pressure switch OK?
No
Refer to burner troubleshooting in either the
Yes
CORAYVAC® or
VANTAGE® NP
Installation, Operation and
Service Manuals.
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
Rectify.
Yes
Do the incorrect zone
lights or all zone
lights come on?
Yes
Are the zone thermostats
wired correctly?
No Turn off power and correct
wiring.
Yes
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
No
Do the burners in the
zone come on?
No
Is external wiring to the
zone OK?
No
Rectify.
Yes
Has the system been
commissioned?
No
Refer to the burner start up
instructions in either the CORAYVAC®
or VANTAGE® NP Installation, Operation
and Service Manuals.
Yes
Refer to burner troubleshooting in either the
CORAYVAC® or
VANTAGE® NP
Installation, Operation and
Service Manuals.
Yes
Do the burners turn off
when the thermostat is
satisfied?
No
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
No
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
Yes
Does the pump turn off
following post purge period?
Yes
Troubleshoot ends.
Contact
Roberts-Gordon LLC
at www.rg-inc.com.
13
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 6: REPLACEMENT PARTS
WARNING
DANGER
Electrical Shock Hazard
Explosion Hazard
Fire Hazard
Carbon Monoxide 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.
FIGURE 10: System Control Internal Components Diagram
Item
1
2
14
Description
Transformer
Board Assembly
Part Number
N/A
10090101
SECTION 6: REPLACEMENT PARTS
6.1 Replacement Parts Instructions
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric to the unit.
Failure to follow these instructions can result
in death or electrical shock.
WARNING
Explosion Hazard
Turn off gas supply to heater before service.
Failure to follow these instructions can result
in death, injury or property damage.
6.1.1 Transformer
The transformer on the board cannot be replaced.
See Page 14, Figure 10, Item 1.
6.1.2 Microprocessor Programing
The microprocessor may be re-programed by a
reprograming device.
Should the microprocessor program become suspect
during troubleshooting, consult Roberts-Gordon LLC.
15
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
16
SECTION 7: THE ROBERTS GORDON® SYSTEM CONTROL WARRANTY
SECTION 7: THE ROBERTS GORDON® SYSTEM
CONTROL WARRANTY
ROBERTS-GORDON LLC WILL PAY FOR:
Within 36 months from date of purchase by buyer or 42
months from date of shipment by Roberts-Gordon LLC
(whichever occurs first), replacement parts will be
provided free of charge for any part of the product which
fails due to a manufacturing or material defect.
Roberts-Gordon LLC will require the part in question to be
returned to the factory. Roberts-Gordon LLC will, at its sole
discretion, repair or replace after determining the nature of
the defect and disposition of part in question.
ROBERTS GORDON® Replacement Parts are warranted
for a period of 12 months from date of shipment from
Roberts-Gordon LLC or the remaining ROBERTS
GORDON® System Control warranty.
Roberts-Gordon LLC is not permitted to inspect the
damaged controller and/or component parts.
READ YOUR INSTALLATION, OPERATION AND
SERVICE MANUAL.
If you have questions about your control, contact your
installing professional. Should you need Replacement
Parts or have additional questions, call or write:
Roberts-Gordon LLC
1250 William Street
P.O. Box 44
Buffalo, New York 14240-0044
716.852.4400
On the web at: www.rg-inc.com
ROBERTS-GORDON WILL NOT PAY FOR:
Service trips, service calls and labor charges.
Shipment of replacement parts.
Claims where the total price of the goods have not
been paid.
Damage due to:
• Improper installation, operation or maintenance.
• Misuse, abuse, neglect, or modification of the
ROBERTS GORDON® System Control in any way.
• Use of the ROBERTS GORDON® System Control for
other than its intended purpose.
• Incorrect gas or electrical supply, accident, fire, floods,
acts of God, war, terrorism, or other casualty.
• Improper service, use of replacement parts or accessories not specified by Roberts-Gordon LLC.
• Failure to install or maintain the ROBERTS GORDON®
System Control as directed in the Installation, Operation and Service Manual.
• Relocation of the ROBERTS GORDON® System Control after initial installation
• The use of the ROBERTS GORDON® System Control
in a corrosive atmosphere containing contaminants.
• The use of the ROBERTS GORDON® System Control
in the vicinity of a combustible or explosive material.
• Any defect in the ROBERTS GORDON® System Control arising from a drawing, design, or specification
supplied by or on behalf of the consumer.
• Damage incurred during shipment. Claim must be filed
with carrier.
WARRANTY IS VOID IF:
The ROBERTS GORDON® System Control is not installed
by an electrician qualified in the installation and service of
control systems for heating equipment.
You cannot prove original purchase date and required
annual maintenance history.
The data plate and/or serial number are removed,
defaced, modified or altered in any way.
The ownership of the ROBERTS GORDON® System
Control is moved or transferred. This warranty is
nontransferable.
Roberts-Gordon LLC's liability, and your exclusive
remedy, under this warranty or any implied warranty
(including the implied warranties of merchantability
and fitness for a particular purpose) is limited to
providing replacement parts during the term of this
warranty. Some jurisdictions do not allow limitations on
how long an implied warranty lasts, so this limitation may
not apply to you. There are no rights, warranties or
conditions, expressed or implied, statutory or otherwise,
other than those contained in this warranty.
Roberts-Gordon LLC shall in no event be responsible
for incidental or consequential damages or incur
liability for damages in excess of the amount paid by
you for the ROBERTS GORDON® System Control.
Some jurisdictions do not allow the exclusion or limitation
of incidental or consequential damages, so this limitation
or exclusion may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights
which vary from jurisdiction to jurisdiction.
Roberts-Gordon LLC shall not be responsible for failure to
perform under the terms of this warranty if caused by
circumstances out of its control, including but not limited to
war, fire, flood, strike, government or court orders, acts of
God, terrorism, unavailability of supplies, parts or power.
No person is authorized to assume for Roberts-Gordon
LLC any other warranty, obligation or liability.
LIMITATIONS ON AUTHORITY OF
REPRESENTATIVES:
No representative of Roberts-Gordon LLC, other than an
Executive Officer, has authority to change or extend these
provisions. Changes or extensions shall be binding only if
confirmed in writing by Roberts-Gordon LLC's duly authorized Executive Officer.
17