EP-200 Series 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 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 .......................
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 ..................................
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-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 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 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.
SECTION 4: MAJOR COMPONENTS SECTION 4: MAJOR COMPONENTS FIGURE 1: Major Component Descriptions EP-201 Pump Assembly - 01312001 EP-203 Pump Assembly - 01312002 Inlet Plate Assembly - 01327400 Band Clamp 4" (10 cm) - 91901300 Mounting Angle - 01365000 Pump Scroll Assembly - 01394400 Pump Boot 4" (10 cm) - 91412800 Bird Screen 4" (10 cm) - 01365400 Pressure Switch - 90430600 3
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.
SECTION 4: MAJOR COMPONENTS Table 2: EP-203 Pump Package (P/N 02712034) Part No.
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 the warranty, all units must be installed in accordance with these instructions.
SECTION 5: PUMP INSTALLATION FIGURE 3: Pump Assembly 5/16 x 7/8" Screws (w/flat washers) - 16 Req'd. Pressure Switch Pump Scroll 1/8 NPT Rubber Mounts Inlet Plate Assembly Impeller Description Pressure Switch Pump Scroll Rubber Mounts Impeller Part Number 90430600 01394400 91906100 01394602 1" NPT Partial End View Gasket (2 pieces) Description Inlet Plate Assembly Kit Gaskets (2) Inlet Plate Accessory Bag (8 bolts, 8 flat washers) 5.1.
EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 4: Motor Shaft Seal Assembly Motor Shaft Seal Pump Frame Impeller Pressure Switch Inlet Plate Assembly EP-201 Motor or EP-203 Motor Description EP-201 Motor EP-203 Motor Motor Shaft Seal Pump Scroll Impeller Inlet Plate Assembly Pressure Switch Part Number 90604500 90604501 02757500 01394400 01394602 01327400 90430600 Motor Shaft Hub 5.1.4 Install Motor Shaft Seal • Separate the motor shaft seal at the pre-cut score line.
SECTION 5: PUMP INSTALLATION 5.2 Pump Suspension WARNING Suspension Hazard 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. The standard method of mounting the EP-200 pump is on an outside wall and venting directly through the wall. 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.
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) 3.9" (99 mm) 7" (178 mm) 4.5" x 8" (114 x 203mm) Boot with Spacer 10" (254mm) 8.5" (216mm) Pressure Switch 5-6" (127-152 mm) 3.25" (83mm) Thimble (if applicable) 11.5" (292mm) 7"- 8" (178-203mm) Silicone Rubber Ring (Install on 4" (102 mm) Tube) 4" (102 mm) Tube Mounting Angle Assembly (Standard) 5.2.
SECTION 5: PUMP INSTALLATION FIGURE 9: Condensate Check Valve Wall Description Condensate Valve Assembly Part Number 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 Valve Assembly flow 3/4" female Must be connected to a drain system in accordance with local codes.
EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 6.1 Prior to Operation SECTION 6: MOTOR WIRING WARNING Prior to operation of the pump in the heating system, operation and proper rotation of the impeller must be verified. 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, Figure 11.
SECTION 7: VENTING SECTION 7: 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. 7.1 General Venting Requirements Install the venting in accordance with the requirements within this manual and the National Fuel Gas Code, ANSI Z223.1/NFPA-54 - latest revision and CSA 22.1 - latest revision.
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) Maximum and No Elbows 4" (10 cm) Single Wall Pipe/Tube Approved Thimble (If Applicable) Bird Screen (included w/ Pump Package) 18" min.-40" max 46 cm min.101 cm max 4" (10 cm) Vent Terminal Tjernlund VH1-6" (15 cm) Vent Terminal 5" to 4" (12.7 to 10 cm) Reducer 5" (12.7 cm) Single Wall Pipe Tjernlund VH1-6" (15 cm) Vent Terminal 25' (7.
SECTION 7: 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.
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 inspection of the pump. For safety and best performance, the electrical, venting, suspensions and overall pump condition are some of the areas requiring inspection.
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 heating 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 Pipe Venting must be intact.
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.
SECTION 10: SPECIFICATIONS SECTION 10: SPECIFICATIONS General Specifications Pump Dimensional Data (in.) Model A B C EP-201 17.75 17 20.25 EP-203 D E F G 3.25 10 4.5 4.5 G A E D B C F dia. Pump Specifications Model EP-201 EP-203 3/4 3/4 Phase (Ø) 1 3 Hertz (Hz) 60 60 Voltage (V) 115/230 208 -230 / 460 Full Load Amp (A) 6.6/3.3 2.4 - 2.2 / 1.1 3450 3450 56 56 TENV TEFC 70 N/A 4.5/4.5 4.5/4.5 112 112 Horsepower (Hp) R.P.M.
EP-200 SERIES PUMP INSTALLATION, OPERATION AND SERVICE MANUAL 20
SECTION 11: THE ROBERTS GORDON® EP-200 SERIES PUMP LIMITED WARRANTY SECTION 11: THE ROBERTS GORDON® EP-200 SERIES PUMP LIMITED WARRANTY ROBERTS-GORDON WILL PAY FOR: Within 42 months from date of shipment from RobertsGordon, replacement parts will be provided free of charge for any part of the controller which fails due to a manufacturing or material defect. Roberts-Gordon will require the part in question to be returned to the factory.