EP-200 Series
Pump
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
Roberts-Gordon
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
76 Main Street West, Unit 10
Grimsby, Ontario, L3M 1R6
Canada
Telephone: 905.945.5403
Fax: 905.945.0511
Quality in Any Language™
P/N 127200NA Rev. F 12/04
© Copyright 2004 Roberts-Gordon
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TABLE OF CONTENTS
SECTION 1: Heating System Safety ............................1
1.1 Manpower Requirements ...................................1
SECTION 2: Installer Responsibility............................2
2.1 Corrosive Chemicals...........................................2
2.2 National Standards and Applicable Codes.........2
SECTION 3: Unpacking the Pump ...............................2
3.1 Open Shipping Cartons......................................2
SECTION 4: Major Components ..................................3
4.1 Standard Parts List.............................................4
SECTION 5: Pump Installation.....................................6
5.1 Pump Assembly Instructions ..............................6
5.2 Pump Suspension ..............................................9
5.3 Condensate Trap and Condensate Tee ............11
SECTION 6: Motor Wiring...........................................12
6.1 Prior to Operation .............................................12
SECTION 7: Venting....................................................13
7.1 General Venting Requirements.........................13
7.2 Venting the Pump .............................................13
7.3 Horizontal Venting ............................................13
7.4 Vertical Venting.................................................15
SECTION 8: Servicing Instructions...........................16
8.1 Pre-Season Maintenance and
Annual Inspection .............................................16
8.2 To Change the Motor and/or the Impeller.........16
8.3 Maintenance Checklist .....................................17
SECTION 9: Replacement Parts and Accessories...18
9.1 Replacement Parts...........................................18
9.2 Accessories ......................................................18
SECTION 10: Specifications.......................................19
SECTION 11: The ROBERTS GORDON® EP-200
SERIES PUMP Limited Warranty .......21
© 2004
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.
Printed in U.S.A.
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TABLE OF FIGURES
Figure 1: Major Component Descriptions .......................3
Figure 2: Pump Discharge Orientation /
Impeller Rotation Direction ..............................6
Figure 3: Pump Assembly...............................................7
Figure 4: Motor Shaft Seal Assembly..............................8
Figure 5: Wall Bracket Assembly ....................................9
Figure 6: Wall Mounting Angle Assembly........................9
Figure 7: Wall Mounting ................................................10
Figure 8: Mounting Platform Assembly .........................10
Figure 9: Condensate Check Valve...............................11
Figure 10: Condensate Tee - Discharge Side ...............11
Figure 11: EP-201 Motor Wiring ...................................12
Figure 12: EP-203 Motor Wiring ...................................12
Figure 13: Side Wall Venting.........................................14
Figure 14: Vertical Venting ............................................15
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SECTION 1: HEATING SYSTEM SAFETY
SECTION 1: HEATING SYSTEM 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 follow-
ing the warnings in these sections.
Installation, Service and Annual Inspection of heater
and pump must be done by a contractor qualified in
the installation and service of gas-fired heating
equipment.
Read this manual carefully before installation, opera-
tion or service of this equipment.
This heating system is designed for heating nonresi-
dential indoor spaces. Do not install in residential
spaces. These instructions, the layout drawing, local
codes and ordinances, and applicable standards that
apply to electrical wiring, venting, etc., must be thor-
oughly understood before proceeding with the instal-
lation.
Thin sheet metal parts, such as the various venting
components, have sharp edges. To prevent injury,
the use of work gloves is recommended.
Do not attempt to operate the pump until all steps of
the installation have been accomplished.
1.1 Manpower Requirements
To prevent personal injury and damage to the pump,
two persons will be required for installation.
1
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
of these compounds is suspected. Warranty will be invalid if the
heater is exposed to halogenated hydrocarbons.
SECTION 2: INSTALLER RESPONSIBILITY
The installer is responsible for the following:
2.2 National Standards and Applicable Codes
• To install the pump and electrical supplies, in
accordance with applicable specifications and
All Appliances must be installed in accordance with
codes. Roberts-Gordon recommends the installer the latest revision of the applicable standards and
contact a local building inspector or Fire Marshal national codes. This refers also to the electric, gas
for guidance.
and venting installation. Note: Additional standards
for installations in Public Garages, Aircraft Hangars,
etc. may be applicable.
• 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 furnish all needed materials not furnished as
standard equipment.
SECTION 3: UNPACKING THE PUMP
3.1 Open Shipping Cartons
• To plan location of supports.
Open cartons and remove packing inserts. Carefully
remove pump components from the cartons. Lift
assembly by gripping metal pump frame. Two people
are required (weight 112 lb, 51 kg). This pump has
been tested prior to packing. The impeller was
dynamically balanced before assembly and requires
care in handling to avoid damage.
• To provide access to pump for servicing on all
sides and for pump removal.
• To provide the owner with a copy of this installa-
tion, operation and service manual.
• To never use pump or pump platform as support
for ladder or other access equipment and never
hang or suspend anything from pump or pump
platform.
WARNING
• To safely and adequately install pump using
materials with a minimal working load of 400 lb
(181 kg).
2.1 Corrosive Chemicals
CAUTION
Severe Injury Hazard
Do not use heater and pump in an area containing
Install pump scroll and inlet assembly before operating
high speed rotating impeller.
corrosive chemicals.
Avoid the use of corrosive chemicals to ensure a
longer life of the pump, burner, tubing and other
parts.
Keep hands, fingers and clothing away from inlet and
outlet.
Failure to follow these instructions can result in
property damage.
Install and operate equipment according to installation
manual.
Failure to follow these instructions can result in death
or severe injury.
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, corrosive chemicals or
halogenated hydrocarbons* anywhere in the
premises.
* Halogenated Hydrocarbons are a family of chemical com-
pounds characterized by the presence of halogen elements (flu-
orine, 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 life span
of the heater components will be greatly reduced. An outside air
supply must be provided to the burners whenever the presence
2
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SECTION 4: MAJOR COMPONENTS
SECTION 4: MAJOR COMPONENTS
FIGURE 1: Major Component Descriptions
EP-201 Pump Assembly - 01312001
EP-203 Pump Assembly - 01312002
Pump Scroll Assembly - 01394400
Inlet Plate Assembly - 01327400
Pump Boot 4" (10 cm) - 91412800
Bird Screen 4" (10 cm) - 01365400
Band Clamp 4" (10 cm) - 91901300
Pressure Switch - 90430600
Mounting Angle - 01365000
3
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
4.1 Standard Parts List
Table 1: EP-201 Pump Package (P/N 02716305)
Part No.
Description
Quantity
Box 1 of 2
01312001 EP-201 Pump Assembly
1
1
CORAYVAC® Installation, Operation and Service Manual
Box 2 of 2
127102NA
01311700
91901300
92113900
93413912
94273914
95211600
96411600
01327400
01365400
01365000
01394400
02757500
90430600
91406940
91412801
91906900
127200NA
EP-200 Series Accessory Package
Band Clamp, 4"
1
4
Hex Nut
6
Bolt (5/16" -18" x 3/4")
Bolt (5/16" -18" x 7/8")
Flat Washer (5/16")
6
16
28
6
Lockwasher (5/16")
Inlet Plate Assembly
Bird Screen, 4"
1
1
Mounting Angle
6
Pump Scroll
1
Motor Shaft Seal
1
Pressure Switch
1
Pump Gaskets
4
Pump Boot
2
Silicone Rubber Ring
EP-200 Series Installation, Operation and Service Manual
2
1
4
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SECTION 4: MAJOR COMPONENTS
Table 2: EP-203 Pump Package (P/N 02712034)
Part No. Description
Quantity
Box 1 of 2
01312002 EP-203 Pump Assembly
1
1
CORAYVAC® Installation, Operation and Service Manual
Box 2 of 2
127102NA
01311700 EP-200 Series Accessory Package
1
4
91901300
92113900
93413912
94273914
95211600
96411600
01327400
01365400
01365000
01394400
02757500
90430600
91406940
91412801
91906900
127200NA
Band Clamp, 4"
Hex Nut
6
Bolt (5/16" -18" x 3/4")
Bolt (5/16" -18" x 7/8")
Flat Washer (5/16")
Lockwasher (5/16")
Inlet Plate Assembly
Bird Screen, 4"
6
16
28
6
1
1
Mounting Angle
6
Pump Scroll
1
Motor Shaft Seal
1
Pressure Switch
1
Pump Gaskets
4
Pump Boot
2
Silicone Rubber Ring
EP-200 Series Installation, Operation and Service Manual
2
1
5
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 5: PUMP INSTALLATION
5.1 Pump Assembly Instructions
5.1.1 Determine Orientation of Pump Discharge
5.1.2 Attaching Pump Scroll
To ensure your safety, and comply with the terms of After determining the correct orientation of the pump
the warranty, all units must be installed in accor-
dance with these instructions.
scroll outlet, attach the pump scroll to the pump
frame as follows:
• Place Flat Washer (P/N 95211600), on the 5/16"
x 7/8" Screw (P/N 94273914).
The pump must be installed in a location that it is
readily accessible for servicing.
An arrow is affixed to the outside of the pump scroll
to indicate the direction of rotation of the impeller.
The standard rotation of the impeller is in the coun-
terclockwise direction.
• From the motor side of the vertical mounting plate
of the pump frame, insert the 5/16" x 7/8" screws.
• Install two pieces of the gasket material on the
exposed thread ends of the mounting screws.
Make sure the ends of the opposing gasket seg-
ments interlock to form a complete circular
gasket.
Pump discharge orientation and impeller rotation
direction is viewed from the rear of the motor as
shown in on Page 6, Figure 2. Note that the pump
scroll outlet must always be positioned at the bottom
horizontal position.
• Carefully position the pump scroll against the ver-
tical mounting plate of the pump frame; align and
loosely install the 5/16" x 7/8" screws into the cor-
responding mounting holes in the pump scroll.
FIGURE 2: Pump Discharge Orientation /
Impeller Rotation Direction
• While tightening the screws that secure the pump
scroll to the motor frame, periodically spin the
impeller to be sure that adequete clearance is
maintained between the impeller blades and the
body of the pump scroll.
Counterclockwise Rotation
(Standard)
OUTLET
Arrow showing direction of rotation
(located on front of scroll housing)
Clockwise Rotation
OUTLET
6
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SECTION 5: PUMP INSTALLATION
FIGURE 3: Pump Assembly
5/16 x 7/8" Screws (w/flat washers) - 16 Req'd.
Pressure Switch
1/8” NPT
Pump Scroll
1" NPT
Rubber
Mounts
Inlet Plate Assembly
Gasket (2 pieces)
Partial End View
Impeller
Description
Pressure Switch
Pump Scroll
Rubber Mounts
Impeller
Part Number
Description
Inlet Plate Assembly Kit
Gaskets (2)
Inlet Plate
Accessory Bag (8 bolts, 8 flat washers)
Part Number
01327400
91406940
01327400
90430600
01394400
91906100
01394602
01311702
5.1.3 Attaching the Inlet Plate Assembly
and into the corresponding mounting holes in the
pump scroll.
Following installation of the pump scroll to the pump
frame, attach the inlet plate assembly to the pump
scroll as follows:
• Tighten screws to complete installation of the inlet
plate assembly.
• Place flat washer on the 5/16" x 7/8" screw.
• Install pressure switch in 1/8" NPT hole in top of
outlet.
• Position a single section of the gasket against the
face of the pump scroll; align the clearance holes
of the gasket with the mounting holes of the pump
scroll. Loosely install one 5/16" x 7/8" screw
through the gasket segment and into the top cen-
ter mounting hole of the pump scroll to support
the gasket.
• Interlock the remaining gasket segment to the
previously installed gasket segment to complete
the circular gasket.
• Orient the inlet plate assembly as shown. The
1/8" NPT plug should face directly up, and the 1"
NPT plug should face directly downward. Care-
fully position the top center mounting notch of the
inlet plate assembly to engage the mounting
screw positioned
previously.
• Install the seven remaining 5/16" x 7/8" screws
through the notches in the inlet plate assembly
7
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 4: Motor Shaft Seal Assembly
Pump Scroll
Impeller
Motor Shaft Seal
Pump Frame
Pressure Switch
Inlet Plate Assembly
EP-201 Motor
or
EP-203 Motor
Description
Part Number
90604500
90604501
02757500
01394400
01394602
01327400
90430600
EP-201 Motor
EP-203 Motor
Motor Shaft Seal
Pump Scroll
Impeller
Inlet Plate Assembly
Pressure Switch
Motor Shaft Hub
5.1.4 Install Motor Shaft Seal
• Separate the motor shaft seal at the pre-cut score
line.
• Wrap the shaft seal around the motor shaft hub
as shown on Page 8, Figure 4.
• Secure the shaft seal in position with the adhe-
sive strip provided.
8
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SECTION 5: PUMP INSTALLATION
5.2 Pump Suspension
The standard method of mounting the EP-200 pump
is on an outside wall and venting directly through the
wall.
WARNING
Suspension Hazard
The pump may be mounted by using mounting
angles as shown in Figure 5. The two mounting
angles form a mounting platform to which the pump
will be attached.
Mount pump with materials
with a minimum working
load of 400 lbs (181 kg).
Failure of the supports can
result in death, injury
or property damage.
Attach the mounting frame to the wall using anchors.
Select an anchor that will give equal to or greater
than 2000 lb ultimate pull-out strength.
5.2.1 Wall Mounting Angle Assembly
FIGURE 5: Wall Bracket Assembly
Lockwasher
NOTE: Typical assembly shown.
Two (2) assemblies per
Flat Washer
each pump required.
Hex Nut
Mounting
Angle
Description
Mounting Angle
Hex Bolt 5/16" x 3/4"
Flat Washer
Lockwasher
Hex Nut
Part Number
01365000
93413912
95211600
96411600
92113900
Flat Washer
Hex Bolt
FIGURE 6: Wall Mounting Angle Assembly
7"
11.5"
(292 mm)
(178 mm)
9
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 7: Wall Mounting
4.5" X 8" (114 x 203mm)
Boot with Spacer
5/8" (16 mm)
Diameter
Mounting Holes
5-6"
(127-152mm)
7"
(178 mm)
10" (254mm)
3.9" (99 mm)
8.5"
3.25" (83mm)
(216mm)
7"
(178 mm)
Pressure
Thimble
(if applicable)
11.5"
Switch
5-6"
(292mm)
(127-152 mm)
7"- 8"
(178-203mm)
4.5" x 8" (114 x 203mm)
Boot with Spacer
Silicone Rubber Ring
Mounting
(Install on 4" (102 mm) Tube)
Angle
Assembly
(Standard)
4" (102 mm)
Tube
5.2.2 Mounting Platform (Optional Platform Assembly)
If mounting on an outside wall is not practical, it may
be mounted on a platform suspended from the
ceiling, or for noise reduction, in an enclosure.
FIGURE 8: Mounting Platform Assembly
Lockwasher
Hex Nut
Flat Washer
Mounting
Angle (4)
11.5" or 7"
(292 mm or
178 mm)
Flat Washer
Hex Head Bolt
10
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SECTION 5: PUMP INSTALLATION
FIGURE 9: Condensate Check Valve
Wall
Description
Part Number
Condensate Valve Assembly
01327001
1" NPT threaded hole.
Use 1" x ¾" reducer.
(not supplied)
Copper or
galvanized pipe
between pump
and condensate
valve.
36" Minimum
vertical drop
between pump
and condensate
valve assembly.
3/4" female
Condensate
flow
Valve
Assembly
Must be connected
to a drain system
in accordance with
local codes.
3/4" female
FIGURE 10: Condensate Tee - Discharge Side
4"(100 mm)
Minimum
Flex Boot
Tee
Approved
Thimble
(if applicable)
Drain Cap
1"(25 mm)
P.V.C
5.3 Condensate Trap and Condensate Tee
The condensate trap assembly (optional) (P/N
01327001), should be installed on the inlet side of
the EP-200 Series pump assembly, See Page 11,
Figure 9.
The condensate trap assembly in the discharge line
can be eliminated if the discharge line is horizontal
through the wall and pitched down at least one inch
per foot. A condensate trap on the discharge side is
required if there is a vertical rise in the discharge
line.
It is possible to eliminate the condensate trap assem-
bly on the pump if the one-inch threaded hole is
plugged. This arrangement will permit drainage of
condensate through the pump and outside via hori-
zontal (pitched) discharge line.
11
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 6: MOTOR WIRING
6.1 Prior to Operation
Prior to operation of the pump in the heating system,
operation and proper rotation of the impeller must be
verified.
WARNING
IMPORTANT: Improper rotation of the impeller will
not produce the vacuum required for proper system
operation.
The EP-201 motor must be wired for clockwise or
counterclockwise rotation as shown on Page 12, Fig-
ure 11.
Electrical Shock Hazard
Disconnect electrical power and gas supply before
servicing.
This appliance must be connected
The EP-201 motor is wired for 1 Ø, 120 V, 60 Hz
operation. The EP-201 motor can be rewired for 230 V
operation by changing the motor connections as
indicated by the diagram on the motor connection box
cover.
Wire the pressure switch per the CORAYVAC® (P/N
127102NA), VANTAGE® EV (P/N 151100NA) or appro-
piate controller installation manual.
to a properly grounded electrical source.
Failure to follow these instructions can result in
death or electrical shock.
All wiring must comply with current wiring regulations
and any local regulations which may apply. Always
switch off the supply and disconnect before servicing.
FIGURE 11: EP-201 Motor Wiring
EP-201 Motor
115V Power Supply
(Control Panel or Relay)
To reverse rotation,
interchange black
and red leads.
O
n
c
a
l
B
/
e
w
o
B
l
d
e
Y
Line
w
n
ac
Yello
w
Neutral
h
i
t
e
B
n
Motor
Interlock
(Not Used)
te
B
r
o
w
n
/
W
i
e
Ground
Screw
Motor Junction Box
The EP-203 motor can be wired for 3 Ø, 208 V - 230 V, 60 Hz or 3 Ø, 460 V, 60 Hz operation.
The EP-203 motor rotation direction can be changed by interchanging any two leads.
Wire the pressure switch per the CORAYVAC® (P/N 127102NA), VANTAGE® EV (P/N 151100NA) or appropiate
controller installation manual.
FIGURE 12: EP-203 Motor Wiring
12
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SECTION7:VENTING
SECTION 7: VENTING
7.3 Horizontal Venting
WARNING
The vent material must be either porcelain coated
tubing 4" (10 cm) O.D. (P/N 9141030D), heat treated
aluminized tubing 4" (10 cm) O.D. (P/N 91409408),
heat treated aluminized tubing 6"(15 cm) O.D. (P/N
E0009105) or single wall flue pipe minimum 26 Ga.
Vent length be limited to less than 30' (9 m). If using
vent lengths greater than 30' (9 m), condensation will
form in the vent pipe. Insulation and additional seal-
ing measures will be required.
Carbon Monoxide Hazard
Pump must be vented to the
outside.
Heaters must be installed
according to the installation
manual.
Failure to follow these
instructions can result in death
or injury.
7.3.1 Horizontal Venting Guidelines
• Vent must exit building not less than 7' (2 m)
above grade when located adjacent to public
walkways.
7.1 General Venting Requirements
Install the venting in accordance with the require-
ments within this manual and the National Fuel Gas
Code, ANSI Z223.1/NFPA-54 - latest revision and
CSA 22.1 - latest revision. This section provides par-
tial information about this specification with regard to
size and configuration for venting requirements (see
following figures). However, to provide assurance of
proper and safe operation, it is the responsibility of
the installer to make sure the installation is in strict
accordance with all local and national codes.
• Vent must terminate at least 3' (1 m) above any
forced air inlet located within 10' (3 m).
• Vent must terminate at least 4' (1.2 m) below 4'
(1.2 m) horizontally from or 12" (30 cm) above
any door, window or gravity air inlet into building.
• Locate vent terminal at least 12" (30 cm) from any
opening through which vent gases could enter a
building.
7.2 Venting the Pump
• The exhaust connection from the pump is 4.5"
(11 cm) diameter.
• Use only corrosion resistant materials for the
discharge line from the pump to the point of
discharge.
• Connect one of the flexible isolation boots pro-
vided to the 4" (10 cm) flue pipe, using the sili-
cone rubber ring provided.
• Vent terminal opening must extend beyond any
combustible overhang.
• Connections to flue pipe larger than 4" (10 cm)
require use of an appropriate "taper pattern
reducer" (not supplied).
• Install vent terminal at a height sufficient to pre-
vent blockage by snow.
• Protect building materials from degradation by
flue gases.
• Venting from the pump may discharge either hori-
zontally or vertically. Horizontal discharge is
preferred. See Page 14, Figure 13. Vertical dis-
charge must be arranged as shown on Page 15,
Figure 14. Corrosion resistant pipe is required.
• Any portion of flue pipe passing through a com-
bustible wall must be dual insulated and an
approved thimble must be used.
7.3.2 Side Wall Venting
• Both horizontal and vertical venting must be sup-
ported by suitable hangers.
Vent recommendations in order of preferred use:
1. Porcelain coated tubing 4" (10 cm) O.D. (P/N
9141030D)
• Vent lengths are allowed as follows:
VENT LENGTH
Up To 10' (3 m)
Up To 25' (8 m)
Up To 50' (15 m)
VENT SIZE
2. Heat treated aluminized tubing 4" (10 cm) O.D.
(P/N 91409408)
4" (10 cm) vent - 1 elbow
5" (12.5 cm) vent - 3 elbow
6" (15 cm) vent - 3 elbow
Heat treated aluminized tubing 6" (15 cm) O.D.
(P/N E0009105)
3. Single wall flue pipe - minimum 26 ga.
13
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
FIGURE 13: Side Wall Venting
18" min.-40" max
46 cm min.-
101 cm max
10' (3 m)
Bird Screen
(included w/
Pump
Maximum and No Elbows
Package)
4" (10 cm) Single Wall Pipe/Tube
18" min.-40" max
46 cm min.-
101 cm max
Approved Thimble
(If Applicable)
4" (10 cm)
Vent Terminal
Tjernlund VH1-6"
(15 cm)
Vent Terminal
5" to 4" (12.7 to 10 cm) Reducer
Tjernlund VH1-6"
(15 cm)
Vent Terminal
5" (12.7 cm) Single Wall Pipe
25' (7.5 m) and 3 Elbows Maximum
6" to 4" (15 to 10 cm) Reducer
Tjernlund VH1-6"
(15 cm)
Vent Terminal
50' (15 m) and 3 Elbows Maximum
Description
Part Number
02537801
90502100
91913703
90505600
4" (10 cm) Vent Terminal
Tjernlund VH1-6" (15 cm) Vent Terminal
Band Clamp 6" (15 cm)
Thimble
14
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SECTION7:VENTING
7.4 Vertical Venting
The vent material must be either porcelain coated
tubing 4" (10 cm) O.D. (P/N 9141030D), heat treated
aluminized tubing 4" (10 cm) O.D. (P/N 91409408),
heat treated aluminized tubing 6" (15 cm) O.D. (P/N
E0009105) or single wall flue pipe minimum 26 Ga.
Condensation will form in the vent pipe. Insulation
and additional sealing measures may be required.
Length of flue pipe is equal to total of vertical and
horizontal length.
FIGURE 14: Vertical Venting
Approved
Vent Cap
2 feet
Minimum
Approved
Thimble
(if applicable)
Silicone
Rubber Ring
Tee
Approved
Thimble
(if applicable)
Drain Cap
1"(2.5 cm)
P. V. C
Description
Tee 4" (10 cm)
Vent Cap 4" (10 cm)
Drain Cap 4" (10 cm)
Part Number
01330203
90502300
02718851
15
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 8: SERVICING INSTRUCTIONS
WARNING
Before every heating season, a contractor qualified
in the installation and service of gas-fired heating
equipment must perform a thorough safety inspec-
tion of the pump.
For safety and best performance, the electrical, vent-
ing, suspensions and overall pump condition are
some of the areas requiring inspection.
Please see Page 17, Section 8.3 for suggested items
to inspect.
Severe Injury Hazard
Install pump scroll and inlet assembly before operating
high speed rotating impeller.
8.2 To Change the Motor and/or the Impeller
1. To remove the motor or impeller, the scroll must
be opened. Remove the (8) nuts/bolts and insert
a knife blade between the scroll halves to cut
through the factory applied sealant. Separate
the two halves.
Keep hands, fingers and clothing away from inlet and
outlet.
Install and operate equipment according to installation
manual.
Failure to follow these instructions can result in death
or severe injury.
2. The impeller can be removed by loosening the
(2) 3/8-24 set screws, removing the 10-32 screw
and retainer assembly. With an appropriate
wheel puller, remove the impeller.
WARNING
3. The motor can now be removed, if necessary,
by loosening the attachment hardware.
4. Re-assembly of motor/impeller combination
require proper alignment. Make sure the impel-
ler has a 1/4" (6 mm) clearance off the inside
wall of the scroll. Verify proper motor alignment
and free rotation.
Electrical Shock Hazard
Disconnect electrical power and gas supply before
servicing.
This appliance must be connected
to a properly grounded electrical source.
5. The (2) impeller set screws should be removed
and reinstalled with a drop of thread locking
sealant and remain unseated during initial re-
assembly.
Failure to follow these instructions can result in
death or electrical shock.
Disassembly and removal or replacement of any
pump components must be done by a service con-
tractor or electrician qualified in the installation and
service of gas-fired heating equipment.
6. Slide the impeller onto the motor shaft end.
Apply a drop of thread locking sealant to the
threads of the retainer screw/washer assembly.
Insert the retainer screw into the shaft so that it
bottoms on the end of the shaft and hub of the
impeller. Torque to 30 in/lb.
Overtorquing can result in a failure of components.
Failure to follow these instructions can compromise
pump operation and void warranty.
7. Seat the (2) impeller set screws. Torque to 100
in/lbs.
8.1 Pre-Season Maintenance and Annual
Inspection
To ensure your safety and years of trouble-free oper-
ation of the pump, service and annual inspections
must be done by a contractor qualified in the installa-
tion and service of gas-fired heating equipment.
8. Re-attach the scroll halves. Apply a bead of high
temperature silicone sealant (600°F) to the
scroll halves. Secure with all (7) nuts/bolts.
Torque to 150 in/lb.
Disconnect electric and gas supplies before perform-
ing service or maintenance.
16
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SECTION 8: SERVICING INSTRUCTIONS
8.3 Maintenance Checklist
Installation, Service and Annual Inspection of the pump must be done
by a contractor qualified in the installation and service of gas-fired heat-
ing equipment.
Turn off the system and ensure power and gas supply is shut off before
servicing equipment.
Read this manual carefully before installation, operation, or service of
this equipment.
System Tubing and Vent Venting must be intact. Using a flashlight, look for obstructions, cracks on the
Pipe
pipe, gaps in the sealed areas or corrosion.
The area must be free of dirt and dust or blockage.
Remove any carbon deposits or scale using a wire brush.
Replace pipe if there are any holes due to corrosion. Seal any gaps in venting
to prevent condensate leakage.
Pump Scroll, Impeller and Compressed air or a vacuum cleaner may be used to clean dust and dirt.
Motor
Check for corrosion, if any parts have corroded through, replace as neces-
sary.
Ensure all hex nuts are tight for proper seal.
Suspension Points
Pump Boot
Make sure the pump is hanging securely.
Look for signs of wear on the mounting angles, wall mounting points or ceiling
mounting points.
Inspect pump boot at pump inlet and outlet for cracking or deterioration.
Replace if cracks are found.
Ensure band clamps are tight at all connection points.
Condensate Trap, Drain
Cap
Check connection of tee to drain cap and between tee and condensate trap.
Seal connections between tee and drain cap to prevent condensate leakage.
Screw condensate trap tightly into drain cap or pump inlet assembly to pre-
vent leakage.
Condensate trap should be filled with water.
Pressure Switch
Ensure that wiring is intact.
17
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
SECTION 9: REPLACEMENT PARTS AND ACCESSORIES
Use only genuine ROBERTS GORDON® replacement parts.
Use of parts not specified by Roberts-Gordon voids warranty.
Failure to follow these instructions can result in property damage.
Pump Scroll
Pressure Switch
Band Clamp
Pump Boot 4"
Inlet Plate Assembly
9.1 Replacement Parts
Description
Part Number Description
Part Number
EP-201 Motor 3/4 HP, 115 V, 1 Ø
EP-203 Motor 3/4 HP
208 V - 230 V/ 460 V, 3 Ø
Impeller
Boot Replacement Package
Pressure Switch
Bird Screen w/ clamp
Shaft Seal
Damper Assembly
90604500
Rubber Mounts
91906100
90604501
Pump Scroll
01394400
01394602
02771000
90430600
01312200
02757500
01331900
4" (10 cm) Pump Boot
Mounting Angle
Inlet Plate Assembly Kit
Gaskets (2)
Inlet Plate
Accessory Bag (8 bolts, 8 flat washers)
91412800
01365000
01327401
91406940
01327400
01311702
9.2 Accessories
Description
Part Number
01312700
01312706
0131270I
01331900
01330203
01330204
0133022D
0133025D
01330903
0133092D
91901300
91913703
Description
Part Number
01335801
T0100320
0133580D
0133660D
91409403
91409420
9141030D
91418200
91240010
02718851
02718852
01327001
4" Plain Coupling
6" Plain Coupling
4" Lined Coupling
4" Damper Coupling
4" Aluminized Tee
6" Aluminized Tee
4" Coated Tee
4" Aluminized 90° Elbow
6" Aluminized 90° Elbow
4" Coated 90° Elbow
6" Coated 90° Elbow
4" Aluminized Non Heat Treated 10’ Tube
6" Aluminized Non Heat Treated 10’ Tube
4" Coated 10’ Tube
Aluminized Tube adapter (6" dia. x 4" dia.)
6" Tube Hanger
4" Drain Cap
6" Drain Cap
Condensate Trap
6" Coated Tee
4" Aluminized Cross
4" Coated Cross
4" (10 cm) Band Clamp
6" (15 cm) Band Clamp
18
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SECTION10:SPECIFICATIONS
SECTION 10: SPECIFICATIONS
General Specifications
Pump Dimensional Data (in.)
Model
A
B
C
D
E
F
G
EP-201
EP-203
17.75
17
20.25
3.25
10
4.5
4.5
G
A
E
D
B
C
F
dia.
Pump Specifications
Model
EP-201
3/4
EP-203
Horsepower (Hp)
Phase (Ø)
3/4
3
1
Hertz (Hz)
60
60
Voltage (V)
115/230
6.6/3.3
3450
56
208 -230 / 460
2.4 - 2.2 / 1.1
3450
Full Load Amp (A)
R.P.M.
Motor Frame
56
Motor Enclosure
Noise Level @ 5' (DBA)
Inlet/Outlet (In.)
Weight (lbs.)
TENV
70
TEFC
N/A
4.5/4.5
112
4.5/4.5
112
19
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EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL
20
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SECTION 11: THE ROBERTS GORDON® EP-200 SERIES PUMP LIMITED WARRANTY
The ownership of the ROBERTS GORDON® EP-200
Series Pump is moved or transferred. This warranty is
nontransferable.
SECTION 11: THE ROBERTS GORDON® EP-200
SERIES PUMP LIMITED WARRANTY
ROBERTS-GORDON WILL PAY FOR:
Roberts-Gordon is not permitted to inspect the damaged
controller and/or component parts.
Within 42 months from date of shipment from Roberts-
Gordon, replacement parts will be provided free of
charge for any part of the controller which fails due to a
manufacturing or material defect.
READ YOUR INSTALLATION, OPERATION AND
SERVICE MANUAL
Roberts-Gordon will require the part in question to be
returned to the factory. Roberts-Gordon will, at its sole
discretion, repair or replace after determining the
nature of the defect and disposition of part in question.
If you have questions about your controller, contact your
installing professional. Should you need Replacement
Parts or have additional questions, call or write Roberts-
Gordon:
ROBERTS GORDON® Replacement Parts are
warranted for a period of 18 months from date of
shipment from Roberts-Gordon or the remaining
ROBERTS GORDON® EP-200 Series Pump warranty.
U.S.A.
1250 William Street
P. O. B ox 4 4
Buffalo, New York 14240-0044
716.852.4400
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
Canada
been paid.
76 Main Street West, Unit 10
Grimsby, Ontario L3M 1R6
905.945.5403
Damage due to:
• Improper installation, operation or maintenance.
• Misuse, abuse, neglect, or modification of the
ROBERTS GORDON® EP-200 Series Pump in
any way.
• Use of the ROBERTS GORDON® EP-200 Series
Pump 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.
• Failure to install or maintain the ROBERTS GOR-
DON® EP-200 Series Pump as directed in the
Installation, Operation and Service manual.
• Relocation of the ROBERTS GORDON® EP-200
Series Pump after initial installation
• The use of the ROBERTS GORDON® EP-200
Series Pump in a corrosive atmosphere containing
contaminants.
• The use of the ROBERTS GORDON® EP-200
Series Pump in the vicinity of a combustible or
explosive material.
On the web at: www.rg-inc.com
Roberts-Gordon'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 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® EP-200 Series Pump. 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 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
any other warranty, obligation or liability.
• Any defect in the ROBERTS GORDON® EP-200
Series Pump 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:
WARRANTY IS VOID IF:
The ROBERTS GORDON® EP-200 Series Pump is not
installed by an contractor qualified in the installation and
service of gas-fired heating equipment.
No representative of Roberts-Gordon, 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's duly authorized
Executive Officer.
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.
21
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