Roberts Gorden Gas Heater HP 120 V 1 User Guide

System Control  
Installation, Operation &  
Service Manual  
Installer  
WARNING  
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.  
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.  
Owner  
Keep this manual in a safe place in order to provide  
your serviceman with necessary information.  
Installation must be done by a contractor qualified  
in the installation and service of gas-fired heating  
equipment or your gas supplier.  
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  
P/N 10091601NA Rev. H 04/09  
© 2009 Roberts-Gordon LLC  
 
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  
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  
Roberts-Gordon LLC  
© 2009  
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  
 
 
SECTION1:INTRODUCTION  
SECTION 1: INTRODUCTION  
1.1 Safety  
1.3 Electrical Requirements  
Your Safety is Important to Us! This  
DANGER  
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.  
Electrical Shock Hazard  
Disconnect electric before service or  
maintenance.  
Control must be connected to a properly  
grounded electrical source.  
Failure to follow these instructions can  
result in death or electrical shock.  
Read this manual carefully before installation,  
operation, or service of this equipment.  
Failure to comply with the installation instructions will  
invalidate the limited warranty set out on Page 17,  
Section 7.  
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, con-  
tact your ROBERTS GORDON independent distrib-  
utor or Roberts-Gordon LLC at (716) 852-4400, (800)  
828-7450 or online at www.rg-inc.com.  
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 ordi-  
®
1.2 What is a ROBERTS GORDON System  
nances and any special diagrams furnished.  
Control?  
Canada: Refer to Canadian Electrical Code, CSA  
C22.1 Part 1 - latest revision.  
®
The ROBERTS GORDON System Control is an  
electronic controller designed for the control of  
®
®
CORAYVAC and VANTAGE NP (multiburner only)  
1.4 Check Installation Materials  
systems.  
Before proceeding with the installation of the  
ROBERTS GORDON System Control, check the fol-  
lowing points:  
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.  
®
1.4.1 Thermostats  
Electronic 24 Vac thermostats and mechanical ther-  
mostats with heat anticipator can be used. The sys-  
tem 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 con-  
trol.  
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 con-  
trolled in parallel with the pump. The blower incorpo-  
rates 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
 
SECTION2:SPECIFICATIONS  
SECTION 2: SPECIFICATIONS  
FIGURE 1: Panel Layout  
2.1 Material Specifications  
Enclosure Material: Metal  
Weight: 6.8 lbs  
2.2 Electrical Specifications  
Supply: 120 V, 60 Hz, 1 Ø, 20 A  
Zone Relay: Single pole 20 A, 120 Vac  
(resistive)  
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  
EP-100  
HP  
1/3  
3/4  
3/4  
2
120 V 1 Ø  
208/230 V 1 Ø  
208/230 V 3 Ø  
460 V 3 Ø  
4.8 A  
6.6 A  
-
N/A / 2.4 A  
-
-
EP-201  
N/A / 3.3 A  
-
-
EP-203  
-
2.4 A / 2.2 A  
-
1.1 A  
-
EP-301  
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, indi-  
cates that the system is in lockout.  
5. PRESSURE SWITCH 2, when lit, indicates that  
pressure switch 2 is closed. When blinking, indi-  
cates 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  
POWER  
PUMP 1  
ZONE 1  
ZONE 2  
ZONE 3  
ZONE 4  
PUMP 2  
BURNERS BURNERS BURNERS BURNERS  
SUPPLY  
G
N
L
N
L
N
L
N
L
N
L
N
L
N
L
4
 
SECTION3:INSTALLATION  
SECTION 3: INSTALLATION  
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 sta-  
tus 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.  
DANGER  
Electrical Shock Hazard  
Disconnect electric before service or  
maintenance.  
FIGURE 3: Mounting Hole Layout  
Control must be connected to a properly  
grounded electrical source.  
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.  
4.5" (114 mm)  
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.  
10.0" (254 mm)  
3.1.2 Read Page 1, Section 1.4 carefully to ensure  
the correct installation materials are available.  
3.3 Select the External Wiring Diagram for the  
Installation  
3.2 Installing the System Control Panel  
3.3.1 Use Page 7, Section 4 for the external wiring of  
3.2.1 Choose a mounting location for the System  
Control. It is advisable to choose a visible location  
near the pump.  
the burners, thermostats and pressure switch.  
3.3.2 Use the table below to select the correct pump  
external wiring diagram.  
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.  
Pump  
EP-100  
EP-100  
EP-201  
EP-201  
EP-301  
Supply Voltage  
120 V 1 Ø  
208/230 V 1 Ø  
120 V 1 Ø  
208/230 V 1 Ø  
120/208 - 230 V 1 Ø  
Page Section Figure  
7
8
7
8
8
9
9
4
4
4
4
4
4
4
5
6
5
6
6
7
7
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.  
EP-203 208 - 230 V (or 460 V) 3 Ø  
EP-303 208 - 230 V (or 460 V) 3 Ø  
3.2.4 Position the mounting hole location of the Sys-  
tem Control per Figure 3.  
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.  
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°.  
5
 
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL  
For the EP-203 (3 Ø), EP-303 (3 Ø), EP-100, EP-201 3.4 System Configuration  
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 jump-  
ers. 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 thermo-  
stat for the associated zone does not use an antici-  
pator, 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  
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.  
Part No. Description  
10050011 Contactor Package 17A  
10001002  
90600200  
Enclosure IEC metal 8X6X6 NEMA 1  
CONT 208-600 17A (A16-30-10-84)  
10050012 Contactor Package 28A  
10001002  
90600205  
Enclosure IEC metal 8X6X6 NEMA 1  
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  
AC POWER IN  
PUMP 1  
ZONE 1  
ZONE 2  
ZONE 3  
ZONE 4 PUMP 2  
G
N
L
N
L
N
L
N
L
N
L
N
L
N
L
ANTICIPATOR  
LOAD ENABLE  
FEATURE  
ENABLED  
ZONE 1  
ZONE 2  
ZONE 3  
ZONE 4  
ZONE 3  
ZONE 4  
FEATURE  
DISABLED  
ANTICIPATOR  
LOAD ENABLE  
ZONE  
ZONE  
ZONE  
ZONE  
ZONE  
ZONE  
1
2
3
4
3
4
PUMP 2  
OPERATION  
ENABLE  
PUMP  
OPERATION  
ENABLE  
2
6
 
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 con-  
DANGER  
nections 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  
below shows connection to an EP-100 or EP-201 120  
V 1 Ø pump.  
Electrical Shock Hazard  
Disconnect electric before service or  
maintenance.  
4.1.1 External Wiring Connection Details  
More than one disconnect switch may be  
required to disconnect electric to the unit.  
The cable used for all the wiring must be rated for  
line voltage up to 600 Vac.  
Failure to follow these instructions can result  
in death or electrical shock.  
The low voltage circuit conforms with Class 2 separa-  
tion 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  
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.  
All burners must be  
connected to Ground  
(Not shown)  
Zone 1 Zone 2 Zone 3 Zone 4  
Low voltage thermostats  
located in heated zone  
Pressure  
Pressure  
switch  
located at  
Pump 2  
switch  
Zone  
4
Zone Zone Zone  
located at  
Pump 1  
1
2
3
120 V  
1 Ø  
120 V  
1 Ø  
60 Hz  
60 Hz  
24 VAC  
L
N
Ground  
24 VAC PS 1  
COM  
R
R
R
R
PS 2  
N L  
N L  
N L  
N L  
N L  
N L  
Z3  
Z4  
Z1  
Z2  
POWER  
SUPPLY  
PUMP 1  
PUMP 2  
24 VAC PS 1  
COM  
W
W
W
W
PS 2  
System Control  
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  
Do not directly connect control relay terminals  
P/N 10050011  
to pump motor  
P/N 10050012  
.
Failure to follow these instructions can result  
in product damage.  
6
5
4
3
2
1
The power supply for the  
pump must be separate  
M
from the controller supply  
208 - 230 V  
Individual supply for  
pump rated for total full  
load current. See Section  
2.3 for details.  
L1  
L2  
1 Ø  
60 Hz  
EP-100,  
EP-201 or  
EP-301 Pump  
TWO PUMP SYSTEM (optional)  
All burners must be  
connected to Ground  
(Not shown)  
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.  
Zone 1 Zone 2 Zone 3 Zone 4  
Low voltage thermostats  
located in heated zone  
Pressure  
switch  
located at  
pump 1  
Pressure  
switch  
located at  
pump 2  
Zone  
4
Zone Zone Zone  
1
2
3
120 V  
1 Ø  
60 Hz  
120 V  
1 Ø  
60 Hz  
24 VAC  
L
N
Ground  
24 VAC PS 1  
COM  
R
R
R
R
PS 2  
N L  
N L  
N L  
N L  
N L  
N L  
Z3  
Z4  
Z1  
Z2  
PUMP 1  
PUMP 2  
POWER  
SUPPLY  
24 VAC PS 1  
COM  
W
W
W
W
PS 2  
System Control  
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  
The cable used for all the wiring must be rated for  
line voltage up to 600 Vac.  
connections for four zones of system burners.  
®
System burners can be either CORAYVAC or VAN-  
The low voltage circuit conforms with Class 2 separa-  
tion of circuit requirements. National Electrical Codes  
for wiring class 2 low voltage circuits must be followed.  
®
TAGE 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  
above shows connection to an EP 301 or EP-201 1 Ø  
8
 
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  
EP-203 or  
EP- 303 3 Ø Pump  
to pump motor  
.
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  
208 - 230 V  
(or 460 V)  
3 Ø  
M
60 Hz  
Individual supply  
L3  
L2  
L1  
for pump rated for  
total full load current.  
See Section 2.3  
for details.  
All burners must be  
connected to Ground  
(Not shown)  
EP-203 or  
EP-303 3 Ø  
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.  
Zone 1 Zone 2 Zone 3 Zone 4  
Low voltage thermostats  
located in heated zone  
Pressure  
Pressure  
switch  
switch  
Zone  
4
Zone Zone Zone  
located at  
pump 1  
located at  
pump 2  
1
2
3
120 V  
1 Ø  
60 Hz  
120 V  
1 Ø  
60 Hz  
24 VAC  
L
N
Ground  
24 VAC PS 1  
COM  
R
R
R
R
PS 2  
N L  
N L  
N L  
N L  
N L  
N L  
Z3  
Z4  
Z1  
Z2  
PUMP 1  
PUMP 2  
POWER  
SUPPLY  
24 VAC PS 1  
COM  
W
W
W
W
PS 2  
System Control  
4.3 EP-203 or EP-303 208 - 230 V (or 460 V) 3 Ø  
above shows connection to an EP-203 or EP-303 3 Ø  
Pump External Wiring Diagram  
pump.  
4.3.1 External Wiring Connection Details  
The external wiring diagram above shows the  
connections for four zones of system burners.  
The cable used for all the wiring must be rated for  
line voltage up to 600 Vac.  
®
System burners can be either CORAYVAC or  
®
VANTAGE NP (multiburner only).  
The low voltage circuit conforms with Class 2 separa-  
tion of circuit requirements. National Electrical Codes  
for wiring class 2 low voltage circuits must be followed.  
®
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  
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 Out-  
side 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  
Control Panel  
blower  
Outside Air  
Blower  
Live in  
Outside Air  
Pump  
Blower  
Relay Receptacle  
Back Plate  
120 V  
CR  
1 Ø  
L
N
60 Hz  
TWO PUMP SYSTEM (optional)  
Pump 1 may be used for all zones.  
Pump  
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  
Pressure switch located  
at outside air blower  
All burners must be  
connected to Ground  
(Not shown)  
Zone 1 Zone 2 Zone 3 Zone 4  
Pressure switch  
Pressure switch  
located at pump 1 located at outside air  
blower  
Low voltage thermostats  
located in heated zone  
Zone  
4
Zone Zone Zone  
1
2
3
120 V  
1 Ø  
60 Hz  
120 V  
1 Ø  
60 Hz  
24 VAC  
L
N
Ground  
24 VAC PS 1  
COM  
R
R
R
R
PS 2  
N L  
N L  
N L  
N L  
N L  
PUMP 2  
N L  
Z3  
Z4  
Z1  
Z2  
PUMP 1  
POWER  
SUPPLY  
24 VAC PS 1  
COM  
W
W
W
W
PS 2  
System Control  
4.4 Outside Air Blower External Wiring Diagram  
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  
The external wiring diagram above shows the con-  
nections for four zones of system burners. System  
®
®
burners can be either CORAYVAC or VANTAGE NP  
(multiburner only).  
10  
 
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.  
11  
 
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL  
SECTION 5: TROUBLESHOOTING  
tinuous operation, the system control will shut  
off and re-start to verify no faults exist in the  
system.  
DANGER  
e. After the heating is turned off, the pump will  
continue operation for 2 minutes, post purge.  
Electrical Shock Hazard  
Disconnect electric before service or  
maintenance.  
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 equipment before  
service or maintenance.  
Failure to follow these instructions can result  
in death, injury or property damage.  
5.1 Sequence of Operation  
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 re-  
start.  
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 con-  
12  
 
SECTION5: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 (cor-  
rosion) or scorching. If damage is found, identify and rectify source of  
damage. Replace circuit board (P/N 10090101), if it has permanent damage.  
Contact  
Roberts-Gordon LLC  
Check the power supply  
to the system control  
panel. Is it on?  
Is the line power  
indicator on?  
Check the 250mA  
fuse. Is it OK?  
No  
Yes  
Yes  
No  
No  
Replace fuse with  
P/N 10000212.  
Rectify power supply  
problem.  
Yes  
Refer to burner trouble-  
shooting in either the  
CORAYVAC® or  
Is the correct contactor  
selected for the  
pump?  
Adjust thermostat set  
point to call for heat.  
Does the pump  
come on?  
Is external wiring to the  
pump OK?  
Yes  
No  
Yes  
VANTAGE® NP  
Installation, Operation and  
Service Manuals.  
No  
No  
Rectify.  
Fit the correct contactor.  
Yes  
Is the thermostat connected  
to the correct terminal at the  
system control.  
Does the zone light  
come on?  
Does the pressure switch  
light come on?  
No  
Rectify.  
Yes  
No  
Yes  
No  
Refer to burner trouble-  
shooting in either the  
CORAYVAC® or  
Contact  
Roberts-Gordon LLC  
Is external wiring to the  
pressure switch OK?  
Yes  
VANTAGE® NP  
Installation, Operation and  
Service Manuals.  
No  
Rectify.  
Yes  
Do the incorrect zone  
lights or all zone  
lights come on?  
Are the zone thermostats  
wired correctly?  
Turn off power and correct  
wiring.  
No  
Yes  
Yes  
Contact  
Roberts-Gordon LLC  
No  
Refer to the burner start up  
instructions in either the CORAYVAC®  
or VANTAGE® NP Installation, Operation  
and Service Manuals.  
Is external wiring to the  
zone OK?  
Do the burners in the  
zone come on?  
Has the system been  
commissioned?  
Yes  
No  
No  
Yes  
No  
Refer to burner trouble-  
shooting in either the  
CORAYVAC® or  
Rectify.  
VANTAGE® NP  
Installation, Operation and  
Service Manuals.  
Yes  
Contact  
Roberts-Gordon LLC  
Do the burners turn off  
when the thermostat is  
satisfied?  
No  
Yes  
Contact  
Roberts-Gordon LLC  
Does the pump turn off  
following post purge period?  
No  
Yes  
Troubleshoot ends.  
Contact  
Roberts-Gordon LLC  
13  
 
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL  
SECTION 6: 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.  
FIGURE 10: System Control Internal Components Diagram  
AC POWER IN  
PUMP 1  
ZONE 1  
ZONE 2  
ZONE 3  
ZONE 4 PUMP 2  
G
N
L
N
L
N
L
N
L
N
L
N
L
N
L
1
2
4
Item  
Description  
Fuse 250 mA  
Transformer  
Board Assembly  
Part Number  
10000212  
N/A  
1
2
4
10090101  
14  
 
SECTION6: REPLACEMENT PARTS  
6.1 Replacement Parts Instructions  
See Page 14, Figure 10, Item 2.  
6.1.3 Microprocessor Programing  
DANGER  
The microprocessor may be re-programed by a  
reprograming device.  
Should the microprocessor program become suspect  
during troubleshooting, consult Roberts-Gordon LLC.  
Electrical Shock Hazard  
Disconnect electric before service or  
maintenance.  
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 equipment before  
service or maintenance.  
Failure to follow these instructions can result  
in death, injury or property damage.  
6.1.1 Fuse 250 mA  
See Page 14, Figure 10, Item 1.  
This time delay fuse protects the System Control  
from power surges, lightning and incorrect wiring.  
If the fuse needs replacing, the following steps must  
be taken.  
Disconnect power to the System Control.  
Remove the screws from the cover and remove the  
cover of the System Control. See Page 5, Section  
3.2.2 for details.  
Locate the fuse, and remove the fuse with a fuse pull-  
ing tool. See Page 14, Figure 10, Item 1.  
Replace with a new fuse rated at 250 mA slow blow.  
6.1.2 Transformer  
The transformer on the board cannot be replaced.  
15  
 
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL  
16  
 
®
SECTION 7: THE ROBERTS GORDON SYSTEM CONTROL WARRANTY  
®
Roberts-Gordon LLC is not permitted to inspect the  
damaged controller and/or component parts.  
SECTION 7: THE ROBERTS GORDON SYSTEM  
CONTROL WARRANTY  
ROBERTS-GORDON LLC WILL PAY FOR:  
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:  
Within 24 months from date of purchase by buyer or 27  
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  
1250 William Street  
P. O. B ox 4 4  
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.  
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  
• Incorrect gas or electrical supply, accident, fire, floods,  
acts of God, war, terrorism, or other casualty.  
• Improper service, use of replacement parts or acces-  
sories not specified by Roberts-Gordon LLC.  
• Failure to install or maintain the ROBERTS GORDON®  
System Control as directed in the Installation, Opera-  
tion and Service Manual.  
®
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.  
• Relocation of the ROBERTS GORDON® System Con-  
trol 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.  
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.  
®
• Any defect in the ROBERTS GORDON System Con-  
trol 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.  
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 autho-  
rized Executive Officer.  
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.  
17  
 
 

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