Roberts Gorden CoRayVac CRV-B-2 Manual

CoRayVac®
Installation, Operation &
Service Manual
CRV-B-2
CRV-B-4
CRV-B-6
CRV-B-8
CRV-B-9
CRV-B-10
CRV-B-12
CRV-B-12A
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 to provide your
serviceman with information should it become
necessary.
WARNING
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier
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
®
© Copyright 2002 Roberts-Gordon P/N 127102NA Rev. C 04/02
Roberts-Gordon
1250 William Street
P.O. Box 44
Buffalo, New York 14240-0044
Telephone: [phone]
Fax: [phone]
Toll Free: 800.828.7450
www.rg-inc.com
Roberts-Gordon Canada Inc.
76 Main Street West, Unit 10
Grimsby, Ontario L3M 1R6 Canada
Telephone: [phone]
Fax: [phone]
WARNING
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 Leave the building
6 Immediately call your local gas
supplier after leaving the building
Follow the gas suppliers
instructions
7 If you cannot reach your gas
supplier, call the Fire Department
Fire Hazard
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance
Failure to follow these instructions can
result in death, injury or property
damage
Quality in Any Language™
Custom-Engineered, Low-Intensity
Infrared Heating Systems

1. Heater Safety ...................................................1
Read this section carefully. Improper
installation,adjustment, operationor
maintenance will result in death, injury or
property damage.
2. Installer Responsibility ...................................1
3. Critical Considerations...................................2
3.1 Minimum Required Clearances to
Combustibles .................................................2
4. National Standards and Applicable Codes...6
4.1 Gas Codes ...............................................6
4.2 Aircraft Hangars .......................................6
4.3 Public Garages.........................................6
4.4 Electrical...................................................6
4.5Venting ......................................................6
5. Standard Parts List .........................................7
6. Design Requirements .....................................9
7. Assembly Overview ......................................10
CRV Assembly Overview ............................14
8. Heater Installation .........................................15
8.1 Critical Hanger Placement ...................15
8.2 Tube Assembly.....................................16
8.3 Coupling andTube Assembly...............16
8.4 Elbow Package ....................................17
8.5 Reflector...............................................18
8.6 Burner ..................................................20
8.7 Reflector Joint ......................................20
8.8 Reflector Side Extension......................22
8.9 Universal Shield ...................................23
8.10 Barrier Shield........................................24
8.11 Decorative Grille...................................25
8.12 1-Foot Deco Grille................................26
8.13 Protective Grille....................................29
8.14 CORAYVAC®Classic Cast Iron
Components.........................................31
9. Pump Installation and Venting .....................32
9.1 GeneralVenting Requirements...............32
9.2VerticalVenting .......................................33
9.3 HorizontalVenting Configurations...........34
10. Outside Air Supply........................................37
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!!
!TABLE OF CONTENTS 11. Gas Piping .....................................................40
12. Control Methods ...........................................41
13. Operation and Maintenance .........................47
13.1 Sequence of Operation.........................47
13.2 Start Up Procedure ..............................47
14. Troubleshooting ............................................50
14.1Troubleshooting Flow Chart..................50
15. Replacement Parts ........................................54
16. General Specifications..................................55
18. LimitedWarranty ...........................................57
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!!
!TABLE OF FIGURES
Figure 1 Standard Reflector ...............................3
Figure 2 One Side Reflector ..............................3
Figure 3 Two Side Reflectors .............................3
Figure 4 Universal Shield (Position 1)................4
Figure 5 Universal Shield (Position 2)................4
Figure 6 Universal Shield (Position 3)................4
Figure 7 2-Foot Deco Grille................................5
Figure 8 Barrier Shield .......................................5
Figure 9 Protective Grille and 1-Foot Deco Grille .5
Figure 10 Major Components’ Descriptions .......10
Figure 11 Assembly Overview...........................14
Figure 12 Reflector Overlap Detail.....................19
Figure 13 Reflector Joint Detail..........................22
Figure 14 EP-201 CondensateTrap Installation.32
Figure 15 EP-100 HorizontalVenting .................34
Figure 16 EP-201/203 HorizontalVenting ..........35
Figure 17 EP-301/303 HorizontalVenting ..........36
Figure 18 Duct Sizing.........................................37
Figure 19 Filter Housing Assembly....................38
Figure 20 Air Supply Blower Support.................38
Figure 21 Outside Air Supply-Pressurized ........39
Figure 22 Outside Air Supply-Non-Pressurized 39
Figure 23 Gas Connection .................................40
Figure 24 One Zone Operation ..........................43
Figure 25 Two Zone Operation...........................44
Figure 26 General System Wiring ......................45
Figure 27 ExternalWiring Diagram EP 100
and EP 201 120V 1ph Pump..............45
Figure 28 ExternalWiring Diagram EP 301
120V 1ph Pump .................................46
Printed in the U.S.A.
© 2002
All rights reserved. o 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.

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
Figure 29 External Wiring Diagram EP 203
and EP 303 230V 3ph Pump..............46
Figure 30 CRV Burner Internal Wiring ................47
Figure 31 CRV Burner Internal Ladder...............47
Figure 32 Vacuum Reading................................48

!!
!!
!SECTION 1: HEATER 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 in these
sections.
Installation, Service and Annual Inspection of heater
mustbe donebyacontractor qualifiedinthe installation
and service of gas-fired heating equipment.
Readthismanual carefullybeforeinstallation,operation
or service of this equipment.
Thisheaterisdesigned forheating nonresidentialindoor
spaces. Do not install in residential spaces. These
instructions, the layout drawing, local codes and
ordinances,and applicablestandards thatapplyto gas
piping,electricalwiring,venting,etc.,mustbethoroughly
understood before proceeding with the installation.
1
SECTION 1:HEATER SAFETY
!!
!!
!SECTION 2: INSTALLER RESPONSIBILITY
The Installer is responsible for the following:
• To ensure the system is designed in accordance
with the parameters of the CORAYVAC® design
manual (P/N 127500US).
• To install the heating system, as well as the gas
and electricalsupplies, inaccordance withapplicable
specifications and codes. Roberts-Gordon
recommends the installer contact a local building
inspector or Fire Marshal for guidance.
• To use the information given in a layout drawing
and in the manual, together with the cited codes and
regulations, to perform the installation.
• To install the heating system in accordance with
the Clearances to Combustibles.
• To furnish all needed materials not furnished as
standardequipment.
• To plan location of supports.
• To provide access to burners for servicing on all
sides, for burner removal.
• To providethe owner with acopyofthis installation,
operation and service manual.
• To never use heater as support for ladder or other
access equipment and never hang or suspend
anything from the heater.
CAUTION
Do not use heater in an area containing corrosive
chemicals
Avoid the use of corrosive chemicals to ensure a
longer life of the burner, tubing and other parts
Failure to follow these instructions can result in
property damage
2.1 Halogenated Hydrocarbons
Roberts-Gordon cannot be responsible for ensuring
that all appropriate safety measures are undertaken
prior to installation; this is entirely the responsibility of
the installer.It is essential that the contractor, the
sub-contractor, or the owner identifies the presence
of combustible materials or halogenated
hydrocarbons* anywhere in the premises.
* Halogenated Hydrocarbons are a family of chemical
compounds characterized by the presence of halogen elements
(flourine, chlorine, bromine, etc.). These compounds are
frequently used in refrigerants, cleaning agents, solvents, etc. If
these compounds enter the air supply of the burner, the lifespan
of the heater components will be greatly reduced. An outside air
supply must be provided to the burners whenever the presence
of these compounds is suspected. Warranty will be invalid if the
heater is exposed to halogenated hydrocarbons.

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
!!
!!
!SECTION 3: CRITICAL CONSIDERATIONS
3.1 Minimum Required Clearances to
Combustibles
Clearancesare therequired distancesthat combustible
objects must be away from the tube to prevent serious
fire hazards. Combustibles are materials, which may
catchon fire and include common items suchaswood,
paper, rubber, fabric, etc. Maintain clearances to
combustibles at all times for your safety.
Clearances for all heater models are located on the
burner of the heater and on
Pages 3-5, Section 3,
Figures 1-9
in this manual. Check the clearances on
eachburnerforthemodelheaterbeinginstalled tomake
surethe product is suitable for your applicationandthe
clearances are maintained. Read and follow the safety
guidelinesbelow:
• Keep gasoline or other combustible materials
including flammable objects, liquids, dust or vapors
awayfromthis heatingsystem orany otherappliance.
• Maintain clearances from heat sensitive material,
equipment and workstations.
• Maintain clearances from vehicles parked below
theheater.
• Maintainclearancesfrom swingingdoors, overhead
cranes, vehicle lifts, partitions, storage racks, hoists,
etc.
• In locations used for the storage of combustible
materials, signs must be posted to specify the
maximum permissible stacking height to maintain
required clearances from the heater to the
combustibles. Signs must be posted adjacent to the
heater thermostat. In the absence of a thermostat,
signs must be posted in a conspicuous location.
• Consult local Fire Marshal, Fire Insurance Carrier
or other authorities for approval of proposed
installation when there is a possibility of exposure to
combustible airborne materials or vapors.
• Hang heating system in accordance to the
suspension requirements on
Page 15, Section 8,
Step 8.1 .
• If the radiant tubes must pass through the building
structure, be sure that adequate sleeving and fire
stop is installed to prevent scorching and/or fire
hazard.
2
WARNING
Fire Hazard
Some objects will catch fire or explode when placed
close to heater
Keep all flammable objects, liquids and vapors the
required clearances to combustibles away from heater
Failure to follow these instructions can result in death,
injury or property damage

(inches)
Model ABCD
CRV-B-2 4 20 48 20
CRV-B-4 4 20 48 20
CRV-B-6 4 20 48 20
CRV-B-8 4 20 48 20
CRV-B-9 4 36 60 36
CRV-B-10 4 36 60 36
CRV-B-12 4 36 60 36
CRV-B-12A 4 36 60 36
(inches)
Model ABCD
CRV-B-2 4 12 56 20
CRV-B-4 4 12 56 20
CRV-B-6 4 12 56 20
CRV-B-8 4 12 56 20
CRV-B-9 4 12 60 42
CRV-B-10 4 12 60 42
CRV-B-12 4 12 60 42
CRV-B-12A 4 12 60 42
(inches)
Model ABCD
CRV-B-2 4 12 56 12
CRV-B-4 4 12 56 12
CRV-B-6 4 12 56 12
CRV-B-8 4 12 56 12
CRV-B-9 4 12 60 12
CRV-B-10 4 12 60 12
CRV-B-12 4 12 60 12
CRV-B-12A 4 12 60 12
NOTE:1.All dimensions are from the surfaces of all tubes, combustion chambers, couplings, tees,
elbows and crosses.
2.Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from the burner.
3.“-” indicates an unapproved application. Roberts-Gordon does not allow the installation of
unapproved applications.
(centimeters)
ABCD
10 50 120 50
10 50 120 50
10 50 120 50
10 50 120 50
10 90 150 90
10 90 150 90
10 90 150 90
10 90 150 90
(centimeters)
ABCD
10 30 140 50
10 30 140 50
10 30 140 50
10 30 140 50
10 30 150 105
10 30 150 105
10 30 150 105
10 30 150 105
(centimeters)
ABCD
10 30 140 30
10 30 140 30
10 30 140 30
10 30 140 30
10 30 150 30
10 30 150 30
10 30 150 30
10 30 150 30
STANDARD REFLECTOR
ONE SIDE REFLECTOR
TWO SIDE REFLECTORS
FIGURE 1
FIGURE 2
FIGURE 3
3
SECTION 3:CRITICAL CONSIDERATIONS
A
B
C
D
A
B
C
D
A
B
CD
CLEARANCES TO COMBUSTIBLES

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
(inches)
Model ABCD
CRV-B-2 4 12 12 12
CRV-B-4 4 12 12 12
CRV-B-6 4 12 12 12
CRV-B-8 4 12 12 12
CRV-B-9 8 18 24 18
CRV-B-10 8 18 24 18
CRV-B-12 8 18 24 18
CRV-B-12A 8 18 24 18
(inches)
Model ABCD
CRV-B-2 4 20 48 20
CRV-B-4 4 20 48 20
CRV-B-6 4 20 48 20
CRV-B-8 4 20 48 20
CRV-B-9 4 36 48 36
CRV-B-10 4 36 48 36
CRV-B-12 4 36 48 36
CRV-B-12A 4 36 48 36
(inches)
Model ABCD
CRV-B-2 4 12 56 30
CRV-B-4 4 12 56 30
CRV-B-6 4 12 56 30
CRV-B-8 4 12 56 30
CRV-B-9 8 12 60 42
CRV-B-10 8 12 60 42
CRV-B-12 8 12 60 42
CRV-B-12A 8 12 60 42
(centimeters)
ABCD
10 30 30 30
10 30 30 30
10 30 30 30
10 30 30 30
20 45 60 45
20 45 60 45
20 45 60 45
20 45 60 45
(centimeters)
ABCD
10 60 120 60
10 60 120 60
10 60 120 60
10 60 120 60
10 90 120 90
10 90 120 90
10 90 120 90
10 90 120 90
(centimeters)
ABCD
10 30 140 75
10 30 140 75
10 30 140 75
10 30 140 75
20 30 150 105
20 30 150 105
20 30 150 105
20 30 150 105
UNIVERSAL SHIELD (POSITION 1)
UNIVERSAL SHIELD (POSITION 2)
UNIVERSAL SHIELD (POSITION 3)
FIGURE 4
FIGURE 5
FIGURE 6
4
A
B
C
D
A
B
CD
A
B
C
D
CLEARANCES TO COMBUSTIBLES
NOTE:1.All dimensions are from the surfaces of all tubes, combustion chambers, couplings, tees,
elbows and crosses.
2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from the burner.
3. “-” indicates an unapproved application. Roberts-Gordon does not allow the installation of
unapproved applications.

A
B
C
D
(inches)
Model ABCD
CRV-B-2 4 12 48 12
CRV-B-4 4 12 48 12
CRV-B-6 4 12 48 12
CRV-B-8 4 12 48 12
CRV-B-9 4 18 56 18
CRV-B-10 4 18 56 18
CRV-B-12 4 18 56 18
CRV-B-12A 4 18 56 18
(inches)
Model ABCD
CRV-B-2 4 12 12 12
CRV-B-4 4 12 12 12
CRV-B-6 4 12 12 12
CRV-B-8 4 12 12 12
CRV-B-9 ----
CRV-B-10 ----
CRV-B-12 ----
CRV-B-12A ----
(inches)
Model ABCD
CRV-B-2 4 20 48 20
CRV-B-4 4 20 48 20
CRV-B-6 4 20 48 20
CRV-B-8 4 20 48 20
CRV-B-9 4 36 60 36
CRV-B-10 4 36 60 36
CRV-B-12 4 36 60 36
CRV-B-12A 4 36 60 36
(centimeters)
ABCD
10 30 120 30
10 30 120 30
10 30 120 30
10 30 120 30
10 45 140 45
10 45 140 45
10 45 140 45
10 45 140 45
(centimeters)
ABCD
10 30 30 30
10 30 30 30
10 30 30 30
10 30 30 30
----
----
----
----
(centimeters)
ABCD
10 50 120 50
10 50 120 50
10 50 120 50
10 50 120 50
10 90 150 90
10 90 150 90
10 90 150 90
10 90 150 90
2 FOOT DECO GRILLE
BARRIER SHIELD
FIGURE 7
FIGURE 8
5
SECTION 3:CRITICAL CONSIDERATIONS
A
B
CD
PROTECTIVE GRILLE AND 1 FOOT DECO GRILLE
FIGURE 9
A
B
C
D
CLEARANCES TO COMBUSTIBLES
NOTE:1.All dimensions are from the surfaces of all tubes, combustion chambers, couplings, tees,
elbows and crosses.
2.Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from the burner.
3.“-” indicates an unapproved application. Roberts-Gordon does not allow the installation of
unapproved applications.

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
!!
!!
!SECTION 4: NATIONAL STANDARDS AND
APPLICABLE CODES
4.1 Gas Codes
The type of gas appearing on the nameplate must
be the type of gas used. Installation must comply
with national and local codes and requirements of
the local gas company.
United States: Refer to National Fuel Gas Code,
ANSI Z223.1 - latest revision, (same as NFPA
Bulletin54).
Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances.
4.2 Aircraft Hangars
Installation in aircraft hangars must be in
accordance with the following codes:
United States: Refer to Standard for Aircraft
Hangars, ANSI/NFPA-409 - latest revision.
Canada: Refer to Standard CAN/CGA B149.1 and
B149.2.
• In aircraft storage and servicing areas, heaters
shall be installed at least 10' (3 m) above the upper
surface of wings or of engine enclosures of the
highestaircraft which maybe housed inthe hangar.
The measurement shall be made from the wing or
engineenclosure whicheverishigherfrom thefloor,
to the bottom of the heaters.
• In shops, offices and other sections of aircraft
hangars communicating with aircraft storage or
servicing areas, heaters shall be installed not less
than 8' (2.6 m) above the floor.
•Suspendedor elevatedheaters shallbesolocated
in all spaces of aircraft hangars that they shall not
be subject to injury by aircraft, cranes, movable
scaffolding or other objects. Provisions shall be
madeto assure accessibility to suspended heaters
for recurrent maintenance purposes.
4.3 Public Garages
Installation in garages must be in accordance with
the following codes:
United States: Standard for Parking Structures
NFPA-88A - latest revision or the Standard for
Repair Garages, NFPA 88B - latest revision.
Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances.
• Heaters must not be installed less than 8' (2.6 m)
above the floor. Minimum clearances to
combustibles must be maintained from vehicles
parked below the heater.
• When installed over hoists, minimum clearances
tocombustibles mustbe maintained fromthe upper
most point of objects on the hoist.
4.4 Electrical
Entireheatingsystem mustbe wiredand electrically
grounded in accordance with the following codes:
United States: Refer to
National Electrical Code
®,
ANSI/NFPA-70 - latest revision. Wiring must
conform to the most current National Electrical
Code
®,local ordinances, and any specialdiagrams
furnished.
Canada: Refer to Canadian Electrical Code, CSA
C22.1 Part 1 - latest revision.
4.5Venting
The venting must be installed in accordance with
therequirementswithinthismanualandthefollowing
codes:
United States: Refer to NFPA-54/ANSI Z223.1 -
latest revision, National Fuel Gas Code.
Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances.
6

Table 1. Contents of CORAYVAC®Carton
(CRV-B all models)
Part No. Description Quantity
0270XXXX Burner 1
013676XX EndVent Plate 1
01397300 Accessory Package 1
01361200 Filter Support Disk 1
01367800 CombustionChamberGasket 1
02724901 Door Assembly w/ Hole 1
91115100 Screw#10-24x5/8 4
91119500 U Clip 4
91905500 FilterSupport 1
92123900 Nut 5/16 - 18 2
92511601 Wing Nut #10 - 24 1
96411600 Lockwasher5/16" 2
01312401 Filter and Gasket 1
!!
!!
!SECTION 5: STANDARD PARTS LIST
SECTION 5:STANDARD PARTS LISTS
7
Table 2. Common CORAYVAC®System Components
Tubing and Related Accessories
01312700 4" PlainCoupling
01312706 6" PlainCoupling
0131270I4" LinedCoupling
01331900 4" Damper Coupling
E0009356 6" Damper Coupling
0133022D 4" CoatedTee
0133025D 6" CoatedTee
01330203 4" AluminizedTee
01330204 6" AluminizedTee
0133092D 4" Coated Cross
0133095D 6" Coated Cross
01330903 4" Aluminized Cross
01330904 6" Aluminized Cross
01330800 4"Tube Plug
01335801 4" Aluminized 90° Elbow
T0100320 6" Aluminized 90° Elbow
0133580D 4" Coated90° Elbow
0133660D 6" Coated90° Elbow
01336101 4" Aluminized 45° Elbow
0133610D 4" Coated45° Elbow
91409300 16 Ga.Hot Rolled Steel 4" dia.10'Tube
91409403 16Ga.Non-heattreatedAluminized4"dia.10'Tube
91409408 16 Ga.HeatTreated Aluminized 4"dia.10'Tube
91409420 16Ga.Non-heattreatedAluminized6"dia.10'Tube
9141030D 16 Ga.Coated4"dia.10'Tube
9141060D 16 Ga.Coated6"dia.10'Tube
E0009105 16 Ga.HeatTreated Aluminized 6" dia.10'Tube
91418200 Aluminized Tube Adapter 6" dia.x 4" dia.
02722100 4" Cast Iron Adapter
91240010 6"TubeHanger
91308001 HighTemperature PipeCompound,1lb.can.
VentingAccessories
01316000 Outside Air Supply Blower Mounting Kit
01324401 4" Outside Air Supply Takeoff
01326801 OutsideAirFilter Housing
90707500 Air SupplyBlower/PowerVenter
91409601 4" Outside Air Flex Duct (Box of 8 - 8' sections)
90434501 Outside Air Pressure Switch
ReflectorsandRelated Accessories
01329910 ReflectorSideExtensionSupport
03050010 Reflector SupportPackage(Tubing)
02712700 Reflector Side Extension, 2 Clips ,2 Screws
02716400 Reflector Support Package (Sch 40 Pipe)
02750303 AluminumReflector
027503SS Stainless Steel Reflector
02750304 AluminumReflector with Hole
027503SH Stainless Steel Reflector with Hole
02750800 Aluminum Reflector End Cap
027508SS Stainless Steel Reflector End Cap
027508SH Stainless Steel Reflector End Cap with Hole
02750900 Reflector Joint
027509SS Stainless Steel Reflector Joint
03090100 Tubeand ReflectorHanger
02790300 TubeandReflector Hanger (Cast Iron)
91907302 “S”Hook
91903201 Turnbuckle
02712100 UniversalShield Support
02751800 Universal Shield with Holes
02751801 Universal Shield
Controls andThermostats
BZC100 ROBERTSGORDON®BZC100
ControllerwithSensor

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
BZC300 ROBERTSGORDON®BZC300Controller
BZC700 ROBERTSGORDON®BZC700Controller
10001500 InternalSensor
02770002 SystemControl
05023000 LoadRelayPackage
90417600 TransformerRelay-SPST(12A)
90436300 TransformerRelay- DPDT(12A)
90423000 24VLowVoltageThermostat (Marked1-5)
10050002 12V DC Starter for EP-201, 1PH*
10050003 120V AC Starter for EP-201, 1PH*
10050004 12V DC Starter for EP-301, 1PH*
10050005 120V AC Starter for EP-301, 1PH*
10050006 120VACContactorfor EP-301, 1PH**
10050007 12V DC Contactor for EP-301, 1PH**
90424300 ThermostatGuard
Deco Grille (1' x 8')
01363003 Bracket
01365901 End Piece
01365902 Reinforcement
01365903 Joint Piece
91406700 1' x 8' Protective Grille
Deco Grille (2' x 4')
01365900 Shield Frame
01370408 Reflector Side Extension 8" x 48"
01370412 Reflector Side Extension 12" x 48"
01370416 Reflector Side Extension 16" x 48"
91407000 Aluminum Grille 2' x 4'
Protective Grille
08050001 40" Protective Grille
08050002 Protective Grille End Cap
Pump Packages and Accessories
02719105 EP-100 Pump Package
02719100 EP-100Pump
02724700 Accessory Package
02716305 EP-201 Pump Package
01312001 EP-201Pump
01317805 Accessory Package
02713014 EP-301 Pump Package 4"
02719300 EP-301Pump
02719303 Accessory Package
02713016 EP-301 Pump Package 6"
02719300 EP-301Pump
*Optional for use with ROBERTS GORDON®BZC Controllers if
pump trip indication is desired.
**Required for use with the EP-301.
8
02719304 Accessory Package
Accessories
90430600 Pressure Switch
01327000 CondensateTrapAssemblyforEP-201Pump
02718851 4" DrainCap
91216001 6" DrainCap

9
!!
!!
!SECTION 6: DESIGN REQUIREMENTS
TheCORAYVAC®systemsdesignis related tothe systemoperationandperformancerequiredby thebuildingbeing
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®independent distributor,
or consult the CORAYVAC®Design Manual (P/N 127500US).
SECTION 6:DESIGN REQUIREMENTS

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
20"
(51 cm)
!!
!!
!SECTION 7: ASSEMBLY OVERVIEW
The figures in this section provide a general overview of
component placement in a CORAYVAC®system. The
location of some components such as supports and
couplings is crucial for proper installation. Assemble the
heater components as shown on
Page 14, Section 7,
Figure 11 .
Optional reflector configurations are shown on
Pages
3-5,Section3,Figures1-9
.Installappropriatesuspension
hardware, beam clamps, chain or rod at predetermined
locations.Adjustmentsofchainlengthwillprovideuniform
pitch.
FIGURE 10 – Major Components’ Descriptions
Coupling:
4" Plain - 01312700
4" Lined - 0131270I
4" Damper - 01331900
6" Plain - 01312706
6" Damper - E0009356
Burner - 0270XXXX
Tube:
(Suppliedin10'(3m)lengths.)
4" Hot Rolled Steel - 91409300
4" Aluminized - 91409403
4" Coated - 9141030D
4" HeatTreated Aluminized - 91409408
6" Aluminized - 91409420
6" Coated - 9141060D
6" HeatTreated Aluminized - E0009105
Combustion Chamber:
Hot Rolled Steel -02722300-1P
Aluminized - 02722301-1P
Double Coated - 0272230D-1P
Cast Iron - 02721200-1P
10
1/2" Flex Gas Line - 91412200
EndVent - 013676XX

16"
(61 cm)
10"
(24.4 cm)
20"
(51 cm)
11
SECTION 7:ASSEMBLY OVERVIEW
90° Elbow:
4" Coated - 0133580D
4" Aluminized - 01335801
6" Coated - 0133660D
6" Aluminized - T0100320
Tee:
4" Coated - 0133022D
4" Aluminized - 01330203
6" Coated - 0133025D
6" Aluminized - 01330204
Tube Adapter:
6" to 4" Aluminized 91418200
Cross:
4" Coated - 0133092D
4" Aluminized - 01330903
6" Coated - 0133095D
6" Aluminized - 01330904
6-1/4"
(16 cm)
9"(23 cm)
radius
15-1/4"
(38.7 cm)
20"
(51 cm) 20"
(51 cm)
Aluminum Reflector with Hole (8') - 02750304
Stainless Steel Reflector with Hole (8') - 027503SH
Aluminum Reflector (8') - 02750303
Stainless Steel Reflector (8') - 027503SS
FIGURE 10 – Major Components’ Descriptions
22 1/2"
(57 cm)
9-3/8"
(24 cm)
45° Elbow:
4" Coated - 0133610D
4" Aluminized - 01336101

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
12
Reflector Side Extension (8')
- 02712700
Condensate Trap Assembly
- 01327000
Barrier Shield - 02750303
Universal Shield (8') - 02751801
Stainless Steel Universal Shield
(8') - 027518SS
Universal Shield with Holes -
02751800
Deco Grille (2' x 4') - 91407000
(1' x 8') - 91406700
Protective Grille (40") - 08050001
FIGURE 10 – Major Components’ Descriptions
Reflector End Cap - 02750800
Stainless Steel Reflector End
Cap - 027508SS
Remove center section to
accommodate heat exchanger
tube when necessary.
Tube and Reflector Hanger
- 03090100
Reflector Support Package
- 03050010
Reflector Joint - 02750900
Reflector Side Extension
Bracket - 01329910
Turnbuckle - 91903201
“S” Hook - 91907302

SECTION 7:ASSEMBLY OVERVIEW
13
FIGURE 10 – Major Components’ Descriptions
ROBERTS GORDON® BZC 100
Controller with Sensor - BZC100
Sensor - 10001500
System Control - 02770002
EP-201 Pump Package - 4" dia. - 02716305
For more information, refer to the EP-201
Installation, Operation and Service Manual
P/N 127200NA.
EP-301 Pump Package - 4" dia. - 02713014
EP-301 Pump Package - 6" dia. - 02713016
For more information, refer to the EP-301
Installation, Operation and Service Manual
P/N 127202NA.
EP-101 Pump Package - 4" dia. - 02719105
For more information, refer to the EP-100
Installation, Operation and Service Manual
P/N 127201NA. ROBERTS GORDON® BZC 300
Controller - BZC300
ROBERTS GORDON® BZC 700
Controller - BZC700

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
FIGURE 11 –CRV Assembly Overview
14
End
Vent
Combustion
Chamber
Tube &
Reflector
Hanger
Burner
Reflector
Burner
Tube
Coupling
Reflector
End Cap
Reflector
Support
Flexible
Boot
Reflector
with Hole
Pump
Exhaust
to Outside
Pressure Switch
S
Zone 1 Sensor
Relay
System Control or
ROBERTS GORDO
®
BZC Controller
U-Clips

Side View Towards Pump
Typical Suspension Details
Turnbuckle
Rod (3/8")
Beam Clamp Concrete Beam
Wood Beam
Washers
Locknut
Screw Hook
(3/8")
24" min.
(61 cm) "X" (see table)
Locknut
(Typical)
Anchor
Hanger
Front View
S Hook
Straight Typical Minimum
Run Length Expansion X Length
50'( 5 m) ± "(3 cm) 2"(30 cm)
00'(3 m) ±2"(5 cm) 24"(6 cm)
50'(46 m) ±3"(8 cm) 36"(9 cm)
200'(6 m) ±4"( 0 cm) 46"( 22 cm)
250'(76 m) ±5"( 3 cm) 57"( 45 cm)
Turnbuckle
Reflector
7'6" (2.3 m)
Chain size
3/16" minimum
!!
!!
!SECTION 8: HEATER INSTALLATION
Sections 8.1 - 8.13 show the logical sequence of heater installation, pictorially. Follow these steps in order and
if any questions arise, refer to the assembly overview (
Page 14, Section 7, Figure 11 ) for guidance. If any step
is unclear, please contact your ROBERTS GORDON®independent distributor or Roberts-Gordon at (716) 852-
4400 or [phone] in the U.S., [phone] or [phone] in Canada or at www.rg-inc.com.
WARNING
Suspension Hazard
Hang heater with materials
with a minimum working
load of 175 lbs (80 kg)
Failure of the supports can
result in death, injury
or property damage
Step 8.1 – Determine Critical Hanger Placement
Description Part Number
Turnbuckle 91903201
“S” Hook 91907302
Tube/Reflector Hanger 03090100
SECTION 8:HEATER INSTALLATION
15

CORAYVAC®INSTALLATION,OPERATION AND SERVICE MANUAL
Combustion
Chamber
7' 6"
(229 cm)
Hanger
Turnbuckles
Tube
Combustion
Chamber
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" per 20' (6 m) away
from burner.
10'
maximum
(3 m)
End View
Weld
Seam Bottom
of Tube
Tube
Tube
Orient coupling so that
the impact block is in the
2:00 or 10:00 oclock
positions
Step 8.2 – Tube Assembly
8.3 Coupling andTube
Step 8.3.1 – Coupling andTube Assembly
Closed
Open
Tab
3" (8 cm) to
4" (10 cm)
Slide Bar/Coupling Lock
Coupling
Wide end
16
AB
CD
Close Coupling with tab Start Slidebar onto Coupling
Insert tubes into Coupling Tighten Coupling to join tubes
Description Part Number
Tube 91409XXX
Turnbuckle 91903201
Tube/Reflector Hanger 03090100
Coupling
Tube
Slide Bar/Coupling Lock
Description Part Number
Coupling & Lock Assy. 01312700
Coupling 01329600
Slidebar 01329700
Tube 914XXXXX