EP-100 Pump 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 a contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier.
TABLE OF CONTENTS SECTION 1: Heating System Safety ............................1 1.1 Manpower Requirements ....................................1 1.2 Safety Labels and Their Placement ....................1 1.3 California Proposition 65 .....................................1 SECTION 2: Installer Responsibility............................3 2.1 Corrosive Chemicals...........................................3 2.2 National Standards and Applicable Codes .........3 SECTION 3: Unpacking the Pump ....................
TABLE OF FIGURES Figure 1: Label Placement ..............................................2 Figure 2: Major Component Descriptions........................5 Figure 3: Pump Discharge Orientation............................8 Figure 4: Pump Assembly ...............................................9 Figure 5: Damper Assembly..........................................10 Figure 6: Motor Shaft Seal Installation .......................... 11 Figure 7: Pressure Switch Mounting Holes ...................
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 following 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.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 1: Label Placement Description Severe Injury Label Rating Plate Label Logo Label 2 of 29 Part Number 91012100 91010401 91017200
SECTION 2: INSTALLER RESPONSIBILITY SECTION 2: INSTALLER RESPONSIBILITY The installer is responsible for the following: • To install the pump and electrical supplies, in accordance with applicable specifications and codes. Roberts-Gordon LLC 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.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 3: UNPACKING THE PUMP 3.1 Open Shipping Cartons WARNING Cut/Pinch Hazard Wear protective gear during installation, operation and service. Edges are sharp. Failure to follow these instructions can result in injury. 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 62 lbs, 28.1 kg). This pump has been tested prior to packing.
SECTION 4: MAJOR COMPONENTS SECTION 4: MAJOR COMPONENTS FIGURE 2: Major Component Descriptions EP-100 Pump Assembly - P/N 02719100 Pump Scroll - P/N 02757001 Pump Inlet Assembly - P/N 02724200 Pump Boot - P/N 91412800 Band Clamp 4" (10 cm) - P/N 91901300 2 1/2'' S-Hook - P/N 91907302 Pressure Switch - P/N 90430600K Bird Screen 4" (10 cm) P/N 01365400 5 of 29
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 4.1 Standard Parts List Table 1: EP-100 Pump Package 4" (10 cm) (P/N 02719105) Part No.
SECTION 5: PUMP INSTALLATION SECTION 5: PUMP INSTALLATION WARNING Cut/Pinch Hazard Wear protective gear during installation, operation and service. Edges are sharp. Failure to follow these instructions can result in injury. WARNING Severe Injury Hazard Secure pump to tube. Hang pump with materials with a minimum working load of 750 lbs (340 kg). 5.1 Pump Assembly Instructions 5.1.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 3: Pump Discharge Orientation Counterclockwise Rotation (Standard) OUTLET Arrow showing direction of rotation (located on front of scroll housing) Clockwise Rotation OUTLET 5.1.2 Attaching Pump Scroll After determining the correct orientation of the pump scroll outlet, attach the pump scroll to the pump frame using the #10 - 24 Keps locknuts provided.
SECTION 5: PUMP INSTALLATION 5.1.3 Attaching the Pump Inlet Assembly From the scroll assembly side of the pump, orient the inlet assembly so the threaded pipe coupling is on the top. See partial end view on Page 9, Figure 4. • Attach inlet assembly onto the scroll assembly by using the #10 - 24 Keps locknuts provided.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 5.1.4 Damper Assembly The pump is equipped with a damper assembly which is used as a means of setting the system vacuum. See the appropriate Installation, Operation and Service Manual for additional vacuum setting information. 1. When the pump is installed, be certain to lock the damper in the full open position with the (1/4"- 20) Hex Head bolt. See Page 10, Figure 5.
SECTION 5: PUMP INSTALLATION 5.1.5 Installing the Motor Shaft Seal The motor shaft seal (P/N 02757500) eliminates air leakage around the motor shaft and reduces the associated noise. Install the shaft seal as follows: 1. Separate the motor shaft seal at the pre-cut score line. 2. Wrap the shaft seal around the motor shaft hub as shown. 3. Secure the shaft seal in position with the adhesive strip provided.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 6: PRESSURE SWITCH MOUNTING AND WIRING FIGURE 9: Pump Pressure Switch For connection to a pump, locate the two pressure switch mounting holes on the pump frame. If Common Terminal replacing an old pressure switch, you may need to Ground drill two holes in the pump frame (7/32" dia. approximately 13/16" apart).
SECTION 7: PUMP MOUNTING INSTRUCTIONS SECTION 7: PUMP MOUNTING INSTRUCTIONS 7.1 Chain Suspension The standard method of mounting the EP-100 pump is suspending it from a chain and venting through the roof.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 7.2 Wall Mounting 7.2.1 Wall Mounting Platform The alternative method of mounting the pump is on an outside wall and venting directly through the wall. The optional mounting angle package (P/N 01312102) must be ordered if this method is used. The pump may be mounted by using mounting angles as shown on Page 14, Figure 11 and Page 15, Figure 12. The two mounting angles form a mounting platform to which the pump will be attached.
SECTION 7: PUMP MOUNTING INSTRUCTIONS 7.2.2 Mounting Platform (Angle Assembly) Pump may be mounted by using mounting angles as shown on Page 15, Figure 12. FIGURE 12: Wall Mounting Angle Assembly 11.5" (29 cm) 7" (18 cm) FIGURE 13: Wall Mounting 4" x 8" (11 x 20 cm) Boot 5/8" Diameter Mounting Holes 5-6" (13-15 cm) 7" (18 cm) 4" (10 cm) 10.25" (26 cm) 10" (25 cm) 7.5" (19 cm) 3.75" (9.5 cm) Thimble (if applicable) 5-6" (13-15 cm) 4" x 8" (10 x 20 cm) Boot 4" (10 cm) Tube 11.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 7.2.3 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 14: Optional Platform Assembly Mounting Flat Washer Lockwasher Hex Nut Mounting Angle (4) 11.
SECTION 8: MOTOR WIRING SECTION 8: MOTOR WIRING the pump scroll for the correct rotation direction. The motor must be wired for clockwise or counterclockwise rotation. IMPORTANT: Improper rotation of the impeller can produce only half of the vacuum required for proper system operation. DANGER 8.2 EP-100 Wiring The EP-100 motor is wired for 1 Ø, 115 V, 60 Hz operation. However, the motor can be rewired for Disconnect electric before service.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 9: VENTING WARNING 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. WARNING Cut/Pinch Hazard Wear protective gear during installation, operation and service. Edges are sharp. Failure to follow these instructions can result in injury. 9.
SECTION 9: VENTING • 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. • Use only corrosion resistant materials for the discharge line from the pump to the point of discharge. • Vent terminal opening must extend beyond any combustible overhang.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 9.5 Vertical Venting Vent length should 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 sealing measures will be required. Length of flue pipe is equal to total of vertical and horizontal length. FIGURE 17: Vertical Venting Approved Vent Cap 2' (.
SECTION 9: VENTING FIGURE 18: Condensate Check Valve Description Condensate Valve Assembly Part Number 01327001 FIGURE 19: Condensate Tee - Discharge Side 9.6 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 21, Figure 18. condensate through the pump and outside via horizontal (pitched) discharge line.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 9.6.1 Condensate Neutralization Tube (optional) If a condensate neutralization tube is specified to be used with the heating system, follow the steps below to choose the proper condensate neutralization tube. See Page 23, Figure 20. Step 1: Condensate flow (gal/h) per 100,000 Btu/h installed You will need to know the tailpipe length per flow unit and the total input (Btu/h) on the heating system.
SECTION 9: VENTING FIGURE 20: Condensate Neutralization Tube Calculated gal/h Less than 2 Less than 6 Less than 10 Less than 20 Description Part Number Condensate Neutralization Tube 200 01327002 Condensate Neutralization Tube 600 01327003 Condensate Neutralization Tube 1000 01327004 Condensate Neutralization Tube 2000 01327005 23 of 29
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 10: SERVICING INSTRUCTIONS WARNING DANGER Electrical Shock Hazard Disconnect electric before service. Explosion Hazard Turn off gas supply to heater before service. Heater and pump must be connected to a properly grounded electrical source. Burn Hazard Allow heater and pump to cool before service. Cut/Pinch Hazard Wear protective gear during installation, operation and service. Tubing may still be hot Edges are sharp. after operation.
SECTION 10: SERVICING INSTRUCTIONS 6. The motor can now be detached, if necessary, by removing the attachment hardware. 7. Re-assembly of motor/impeller combination requires proper alignment. Make sure the impeller has a 1/4" (6 mm) clearance off the inside wall of the scroll. Be certain of the proper motor alignment and free rotation. 10.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 11: REPLACEMENT PARTS AND ACCESSORIES 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. 11.1 Replacement Parts Call Out # 1 2 3 4 5 5 5 6 7 8 26 of 29 Description Motor (1/3 H.P.
SECTION 11: REPLACEMENT PARTS AND ACCESSORIES 11.
EP-100 PUMP INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 12: SPECIFICATIONS 12.1 Material Specifications 12.1.1 Pump Frame, Inlet, Scroll and Impeller 12 Gauge Stamped Steel Construction 12.1.2 Impeller Materials 12.3 Controls Specifications Time switches, thermostats, etc. can be wired into the electrical supply. External controls supplied as an optional extra. See the heaters’ Installation, Operation and Service Manual for details. 319 Cast Aluminum 12.
SECTION 13: THE ROBERTS GORDON® EP-100 SERIES PUMP WARRANTY SECTION 13: THE ROBERTS GORDON® EP-100 SERIES PUMP WARRANTY ROBERTS-GORDON LLC WILL PAY FOR: Within 36 months from date of purchase by buyer or 42 months from date of shipment by Roberts-Gordon LLC (whichever occurs first), replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect. Roberts-Gordon LLC will require the part in question to be returned to the factory.
