System Control Installation, Operation & Service Manual WARNING Improper installation, adjustment, alteration, service or maintenance can result in death, injury or property damage. Read the Installation, Operation and Service Manual thoroughly before installing or servicing this equipment. Installation must be done by an electrician qualified in the installation and service of control systems for heating equipment.
TABLE OF CONTENTS SECTION 1: Introduction........................................................ 2 1.1 Safety ........................................................................... 2 1.2 What is a ROBERTS GORDON® System Control? ...... 2 1.3 Electrical Requirements ............................................... 2 1.4 Check Installation Materials ......................................... 2 SECTION 2: Specifications .................................................... 4 2.1 Material Specifications ....
TABLE OF FIGURES Figure 1: Panel Layout .............................................................. 4 Figure 2: Terminal Block Guide ................................................. 5 Figure 3: Mounting Hole Layout................................................ 6 Figure 4: System Configuration ................................................. 7 Figure 5: External Wiring Diagram ROBERTS GORDON® Airflow 83 BWLG, Airflow 90 BWTL 230 V 1 Ø Pump...............................................................
Product Approval ROBERTS GORDON® appliances have been tested and CE certified as complying with the essential requirements of the Gas Appliance Directive, the Low Voltage Directive, the Electromagnetic Compatibility Directive and the Machinery Directive for use on natural gas and LPG when installed, commissioned and maintained in accordance with these instructions. These instructions refer to appliances designed to operate in the European Union.
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 1: INTRODUCTION 1.1 Safety Your Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings. Installation, service and annual inspection of controller must be done by an electrician qualified in the installation and service of control systems for heating equipment.
SECTION 1: INTRODUCTION powered from an additional power supply circuit by the use of a load relay package. 1.4.3 Pressure Switch For CORAYVAC® and BLACKHEAT® multiburner systems, a pressure switch (P/N E0007074, included with the pump assembly) 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.
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 2: SPECIFICATIONS FIGURE 1: Panel Layout 2.2 Electrical Specifications 2.1 Material Specifications Supply: 230 V, 50 Hz, 1 Ø, 20 A Enclosure Material: Metal Zone Relay: Single pole 20 A, 230 Vac (resistive) Weight: 6.8 lbs (3.08 kg) Dimensions: 10.2" x 11.4" x 2.8" (25.4 x 29.0 x 7.
SECTION 2: SPECIFICATIONS 2.4 Burner Electrical Ratings CORAYVAC® burners: 230 V, 50 Hz, 1 Ø 0.1 A BLACKHEAT® (multiburner only) burners: 230 V, 50 Hz, 1 Ø 0.3 A 2.5 Indicator Lights See Page 4, 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.
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 3: INSTALLATION DANGER Electrical Shock Hazard 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.
SECTION 3: INSTALLATION Pump Model Full Load Current Overload Range RG30-1 4.5 4 to 6 RG30-3 1.77 1.6 to 2.4 RG45-1 6.4 4 to 6 RG45-3 2.51 2.4 to 4 Description Fan Starter Kit Overload ZE6 Contactor DILM- 10 4KW,240 V Coil Enclosure QEWISS GW44207 Fan Starter Kit Overload ZE2.
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 4: TYPICAL EXTERNAL WIRING DIAGRAMS DANGER Electrical Shock Hazard Disconnect electric before service. More than one disconnect switch may be required to disconnect electric to the unit. Failure to follow these instructions can result in death or electrical shock. 4.1 Airflow 83 BWLG, Airflow 90 BWTL External Wiring Diagram The external wiring diagram below shows the connections for four zones of BLACKHEAT® multiburner burners.
SECTION 4: TYPICAL EXTERNAL WIRING DIAGRAMS FIGURE 6: External Wiring Diagram ROBERTS GORDON® RG30-1 or RG45-1 230 V 1Ø Pump CAUTION Product Damage Hazard RG30-1 or RG45-1 Pump Motor Contactor Kit P/N S7445K Do not directly connect control relay terminals to pump motor. Failure to follow these instructions can result in product damage.
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 7: External Wiring Diagram ROBERTS GORDON® RG30-3 or RG45-3 400 V 3 Ø Pump CAUTION Product Damage Hazard Do not directly connect control relay terminals to pump motor. RG30-3 or RG45-3 Pump Failure to follow these instructions can result in product damage.
SECTION 4: TYPICAL EXTERNAL WIRING DIAGRAMS 4.5 Thermostat Wiring Some applications may call for zones to operate off of a single thermostat. Zones 1 and 3 may share a thermostat and zones 2 and 4 may share a thermostat. At no time should either zone 1 or 3 be connected to zone 2 or 4. Doing so will result in damage to the control board.
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 5: TROUBLESHOOTING WARNING DANGER Explosion Hazard Electrical Shock Hazard Disconnect electric before service. Turn off gas supply to heater before service. More than one disconnect switch may be required to disconnect electric to the unit. Failure to follow these instructions can result in death, injury or property damage. Failure to follow these instructions can result in death or electrical shock. 5.
SECTION 5: TROUBLESHOOTING FIGURE 8: System Control Troubleshooting Chart If control is not working properly, disconnect power to control and check for signs of physical damage to the front and back of the circuit board, water damage (corrosion) or scorching. If damage is found, identify and rectify source of damage. Replace circuit board (P/N 10090102), if it has permanent damage.
SYSTEM CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 6: REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide Hazard Use only genuine ROBERTS GORDON® replacement parts per this installation, operation and service manual. Failure to follow these instructions can result in death, electric shock, injury or property damage.
SECTION 6: REPLACEMENT PARTS 6.1 Replacement Parts Instructions DANGER Electrical Shock Hazard Disconnect electric before service. More than one disconnect switch may be required to disconnect electric to the unit. Failure to follow these instructions can result in death or electrical shock. WARNING Explosion Hazard Turn off gas supply to heater before service. Failure to follow these instructions can result in death, injury or property damage. 6.1.
