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Roberts Gorden UltraVac NEMA 4 User's Manual

1. 13 33 cm 11 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 3 3 Cable Requirements 3 3 1 Line Power Supply As per individual building specification for class of cable to be used Use copper conductors only To size the cable use the amperages of the burners given on Page 13 Section 3 4 1 for each individual zone 3 3 2 Control Wiring All control wiring sensor VFD control 0 10 Vdc pressure switch and RS 485 communication wiring may be plenum or non plenum rated depending on installation requirements consult the National Elec tric Code NEC Regardless of the code or its inter pretation the local Fire Marshall makes the final decision contact the local Fire Marshall if you have questions Do not run control low voltage wiring together with power line voltage wiring in the same conduit Electrical signal interference or induced current could occur and cause communication problems VFD 0 10 V control wiring and all RS 485 com munication wiring must be shielded Shielded wire provides noise and interference isolation and reduces the possibility of communication problems Pressure switch wiring is not required to be shielded If electrical interference from machinery or other sources cannot be avoided shielded wire must be used All control cable specification diagrams shown will refer to shielded cable 3 3 3 Indoor Sensor Cable Shielded cable four twist
2. ULTRAVAC Controller with Modem Installed P N 10080450 Line Voltage 120 V Wiring Eum a Low Voltage 24 V Wiring Inside View ULTRAVAC Software P N 10080421 ULTRAVAC Software Manual P N 10081600NA ULTRAVAC Installation Manual P N 10081601NA Comms Equalization Cable Outdoor Sensor P N 10081501 ged Eseg all dk Em Repeater optional Supplied w 24 VAC transformer inside NEMA 1 enclosure P N 10080445 PC Connection Cable Package P N 10080410 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL URVCCR ULTRAVAC Central Controller with RS 485 Converter SEIS Line Voltage 120 V Wiring EHE en ss se E aie u B Modem Chip M jit n OH co m ka m MA Low Voltage 24 V Wiring aF so 1 e D Bad D so n u T BA 1 20 I 5j L EM SOM meli ue E a N We rnc I ff _ b C Peel 2 at o ojo o TA oo ULTRAVAC Controller Inside View Repeater optional with Modem Installed Supplied w 24 VAC transformer inside NEMA 1 enclosure P N 10080445 x ILLL uum KEETE ULTRAVAC Software P N 10080421 ULTRAVAC
3. Software Manual P N 10081600NA ULTRAVAC Installation Manual P N 10081601NA Comms Equalization Cable Outdoor Sensor PC Connection Cable Package P N 10080450 P N 10081501 P N 10080410 RS 485 Converter Package P N 10080430 RS 485 Converter Power Supply 1 6 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 atten tion when reading and following the warnings in these sections 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 fired heating equipment Read this manual carefully before installation operation or service of this equipment For optimum heater performance and safe heating conditions inspect and maintain heater s before every heating season and 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 at 716 852 4400 800 828 7450 or at www rg inc com 1 6 1 Manpower Requirements To prevent personal injury and damage to
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5. For serviceability it is convenient to mount the con troller and variable frequency drive at occupant level in the vicinity of the pump Do not mount controller or VFD outdoors VFD must not be installed where subjected to adverse conditions such as combustible oily or hazard ous vapors or dust excessive moisture or dirt vibration To avoid damage from possible drips do not mount controller or VFD directly beneath pump Models with NEMA 4 rated enclosures will withstand exposure to dust dirt and water VFD should be mounted in locations where the maximum ambient temperature does not exceed 104 F 40 C Avoid installing the VFD in mezza nines direct sunlight or near external heat SECTION 3 INSTALLATION sources because these locations usually have unpredictable temperature rises Note that the maximum distance from the controller to any sensor is 300 120 m For longer distances larger gauge wire may be needed Consult your local distributor For multiple controllers maximum length of communication wire from the first controller to the last is 4000 1219 m 3 2 2 Position the controller and VFD at occupant level for ease of service To avoid electrical interferences with communications bus do not mount VFD directly next to controller Allow 2 6 m minimum between controller and VFD FIGURE 4 Controller Mounting Standard enclosure only NEMA 4 enclosure mount ing varies 16 25 41 3 cm
6. ULTRAVAC Controller Components Diagram Variable Frequency Drive Components Diagram Troubleshooting Flow Chart SECTION 1 INTRODUCTION 1 1 What is ROBERTS GORDON ULTRAVAC The ROBERTS GORDON ULTRAVAC is a micro processor based control package designed for modulating control of CORAYVAC heaters based on outdoor temperatures This controller is capable of giving control outputs to one vacuum pump and three heating zones The controller also features inputs which are used for indoor and outdoor signal condition monitoring System status and settings are viewed and altered from a PC not supplied running ROBERTS GORDON ULTRAVAC Software 1 2 CORAYVAC Design Requirements CORAYVAC burners shall be CRV B 6 B 8 B 9 B 10 or B 12 burners CORAYVAC systems designed shall have minimum radiant pipe length and 1 5 2 0 feet per flow unit of tailpipe length OR CORAYVAC systems designed shall have recommended radiant pipe length and 1 2 1 5 feet per flow unit of tailpipe length See the CORAYVAC Design Manual P N 127500NA for minimum and recommended radiant pipe length 1 3 General Requirements The ROBERTS GORDON ULTRAVAC series of controllers are supplied pre configured for use with ROBERTS GORDON CORAY VAC infrared heating equipment only Failure to comply with the installation instructions and configura
7. Industrial Controls Equipment Ambient Operating Temp 32 F 1049F 09C 409C 75 HP 230 V Drive used with EP 203 pump P N VFD75230 or VFD75230N4 Power Input 208 240 V 1 50 60 Hz Input Voltage Tolerance 10 Amps 6 9 6 0 A 1 HP 120 V Drive used with EP 203 pump P N VFD75115 or VFD75115N4 Power Input 120 V 1 O 50 60 Hz Input Voltage Tolerance 10 Amps 16 6 A Construction Dimensions 2 HP 230 V Drive used with EP 303 pump P N VFD20230 or VFD20230N4 Power Input 208 240 V 1 50 60 Hz Input Voltage Tolerance 10 Amps 18 4 16 0 A 1 HP 460 V Drive used with EP 203 pump P N VFD75460 or VFD75460N4 Power Input 400 480 V 3 50 60 Hz Input Voltage Tolerance 10 Amps 3 0 2 5 A 2 HP 460 V Drive used with EP 303 pump P N VFD20460 or VFD20460N4 Power Input 400 480 V 3 50 60 Hz Input Voltage Tolerance 10 Amps 4 8 4 0 A ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL FIGURE 3 Variable Frequency Drive Components Factory pre wiring shown o Rotary Variable Disconnect Frequency Drive 1 O input model shown Power Input e lel le lel adr aa L2N PE B B auuunuaauuuuauaagaaB8uu Uu sum rnama Grounding Block solas goa O 7 HO BORO ex
8. 230 V 3 O or 460 V 3 outputs Relay Es 120 V 120 V signal from relay board output 8 Input Fuse Holder e L 1 input model shown 3 input models have an O additional input fuse holder and VFD power input VFD Enclosure Standard Enclosure Shown 10 SECTION 3 INSTALLATION A WARNING Severe Injurv Hazard Mount controls with materials with a minimum working load of 75 Ibs 33 kg Failure to follow these instructions can result in death injurv or propertv damage Installation of the ROBERTS GORDON ULTRAVAC Controller and the associated external electrical wiring must be done by an electrician qualified in the installation of control systems for heating equipment 3 1 Preparation Before installing the controller observe the following 3 1 1 Ensure that you have a copy of the site layout for the project that clearly identifies the separate zones 3 1 2 Familiarize yourself with the Controller and Vari able Frequency Drive component names and loca tions See Page 8 Figure 2 and Page 10 Figure 3 3 2 Positioning the ROBERTS GORDON ULTRAVAC Controller and Variable Frequency Drive 3 2 1 Choose a mounting location for the controller Generally near the pump a dedicated phone con nection optional and the variable frequency drive
9. 5 Cart n ContentS i nie deste ree 2 1 6 Safely i e amautamayqh lass 5 1 7 Example Site Layout 5 SECTION 2 Specifications 7 2 1 ROBERTS GORDON ULTRAVAC Controller 7 2 2 Temperature Sensors sse 7 2 3 Variable Frequency Drive VFD 9 SECTION 3 Installation u 11 3 1 Preparation utente e 11 3 2 Positioning the ROBERTS GORDON ULTRAVAC Controller and Variable Frequency Drive 11 3 3 Cable Requirements 12 3 4 Electrical Installation Requirements 13 3 5 Pump Requirements see 13 3 6 Variable Frequency Drive Requirements 13 3 7 Indoor Sensor Placement 14 3 8 Outdoor Sensor Placement 14 3 9 Outside Air Supply a 14 SECTION 4 Typical External Diagrams 15 SECTION 5 Communications 20 5 1 Dedicated Phone Line for Central Controller Modem 20 5 2 RS 485 Converter for Central Controller 21 5 3 TCP IP Communication Module 22 5 4 Direct Connect nn 24 5 5 C
10. Supply See NOTE 7 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL SECTION 5 COMMUNICATIONS One ROBERTS GORDON ULTRAVAC Controller per building called the central controller must have equipment for remote communications to a PC This equipment consists of either a modem chip an RS 485 converter or a TCP IP communications module For remote on site and off site control and system status viewing the central controller controller 1 is fitted with a modem chip See Page 20 Section 5 1 If only remote on site control and system status viewing two controller communications interface devices are available an RS 485 converter or a TCP IP communication module An RS 485 converter is installed at a single PC this PC can interface with any controller on the network of ULTRAVAC controllers The RS 485 converter at the PC is wired directly to controller 1 using FIGURE 13 Modem Location Control Board of the Central Controller shielded twisted pair communication wiring See Page 21 Figure 14 To interface with ULTRAVAC controllers through a Local Area Network LAN a TCP IP Communication module is installed at controller 1 Controller 1 is wired to the LAN by an Ethernet cable See Page 22 Section 5 3 Any computer on the LAN that has ULTRAVAC software installed can communicate with the controllers Appropriate precautions must be taken to protect the Ethernet wiring from any possible e
11. bottom section of enclosure that houses the control board Do not run low voltage wiring through top section a of enclosure that houses the relay board I p Switch Do not run line and low voltage wiring I ji TeSSUre witcl A in the same conduit Optional Outside Air Blower ll NOTE 1 This diagram applies to the Central Controller controller 1 only For all Satellite Controllers see Satellite Controller External Wiring Diagram Central Controller controller 1 requires outdoor sensor wiring and either modem RS 485 converter wiring or TCP IP module wiring NOTE 2 Twist shield wires for both RS 485 communication cables together and ground at central panel only On controller 1 only connect these twisted shield wires to ground For VFD 0 10 V signal wiring connect shield wire to ground at the controller only NOTE 3 120 V 1 50 60 Hz supply for 120 V VFD model 230V 1 50 60 Hz supply for 230 V VFD model 460 V 3 O 50 60 Hz supply for 460 V VFD model See VFD rating plate for required input Repetitive cycling of a disconnect or input contactor more than once every two minutes may cause damage to the drive NOTE 4 Zone 3 Sensor not shown wiring is as follows SEN output to analog input 3 SET output to analog input 6 O R output to meter input 3 outputs to 32 V GND inputs NOTE 5 Internal pre wiring not shown NOTE 6 Wiring from 32 V terminals on the controller to sensor power terminals and i
12. connector should not be used if the phone wire is more than 50 15m in length Plug one end of the phone cable into the RS 232 direct port plug the other end into the adapter shown in on Page 24 Figure 17 Plug the adapter into a 9 pin serial port on your computer FIGURE 17 9 Pin Adapter for PC Phone Jack If a PC does not have a serial port but does have a USB port purchase of a USB to Serial Converter is required A USB to 9 pin Serial Cable will allow connection between the RS 232 device ULTRAVAC Control Board and the USB port on the PC The USB to serial RS232 DB9 Cable Adapter will be used in con junction with the PC Connection Cable Package P N 10080410 USB to Serial RS232 DB9 Cable Adapters can be purchased at a local computer store or on the internet for 20 00 or less The converter should come with drivers and should draw power directly from USB requiring no additional power adapter WL LA 9 Pin Adapter Part Number 10080410 Description PC Connection Cable Package 24 Connect to RS 232 direct port on control board SECTION 5 COMMUNICATIONS 5 5 Communications Between Multiple ROBERTS GORDON ULTRAVAC Controllers If more than one ROBERTS GORDON ULTRA VAC Controller is installed in a building the controllers RS 485 communications must be wired in series See Page 25 Figure 18 Connect the RS 485 terminal on controller 1 to the RS 485 terminal on contr
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14. manufacturing or material defect 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 ROBERTS GORDON Replacement Parts are warranted for a period of 18 months from date of shipment from Roberts Gordon or the remaining ROBERTS GORDON ULTRAVAC warranty 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 e Improper installation operation or maintenance e Misuse abuse neglect or modification of the ROBERTS GORDON ULTRAVAC in any way Use of the ROBERTS GORDON ULTRAVAC 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 ULTRAVAC as directed in the Installation Operation and Service manual Relocation of the ROBERTS GORDON ULTRA VAC after initial installation The use of the ROBERTS GORDON ULTRAVAC in a corrosive atmosphere containing contaminants The use of the ROBERTS GORDON ULTRAVAC in the vicinity of a combustible or explosive materia
15. the controls two persons will be required for installation 1 7 Example Site Layout Page 6 Figure 1 is an example layout for a building where ROBERTS GORDON ULTRAVAC will be used to control the infrared heating systems shown The layout consists of three zones of ROBERTS GORDON ULTRAVAC M SECTION 1 INTRODUCTION ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL FIGURE 1 Example Site Layout e BA A An gt IEM YHON C Josuos episino Josueg z euoz 4 dung QQ 1 llonuoo ic im WLOVAVHLIN meNOGHOD S 1HHHOH oo nd gt Ne Aouenbol4 Y SS Josueg euoz lt not to scale Venting not shown NOTE Conceptual drawing SECTION 2 SPECIFICATIONS 2 1 ROBERTS GORDON ULTRAVAC Controller 2 1 1 Enclosure Standard Enclosure Construction 16 gauge painted steel hinged door removable knockouts provided Dimensions 14 7 w x 17 7 h x 3 5 d NEMA 4 Enclosure P N 10080302 Description NEMA 4 enclosure is sold separately as an option ULTRAVAC Controller in standard enclosure is field mounted inside the NEMA 4 enclosure Construction 14 gauge painted steel hinged door with 19 x 16 window Dimensions 24 w x 24 h x 9 d Protection Rating NEMA 4 12 2 1 2 Electrical Control Board Power Supply 24 V 60 Hz from relay board Analog Inputs Sensor thermistor BMS enable dry contact Relay Outputs 24 Vac Anal
16. twisted pairs of 22 AWG min wire is required for RS 485 commu nications between controllers See Page 12 Figure 6 for an illustration of the shielded cable specification to be used Shielded Cable Belden 1902 8770 General Cable C1670 or equivalent 3 4 Electrical Installation Requirements ADANGER Electrical Shock Hazard Disconnect electrical before servicing This appliance must be connected to a properly grounded electrical source Replace cover before operating Failure to follow these instructions can result in death or electrical shock 3 4 1 The enclosure must be supplied from a local fused isolator rated for a total amperage not exceeding 25 A The method for calculating the current loading is as follows CORAYVAC Burner 0 3 A burner Multiply the current for the individual burners above by the number of burners supplied from the enclosure to give the total current required The full load amps for the optional outside air blower P N 90707500 are 16A The total added current load for each individual relay must not exceed 3 A The total added current load for all 8 relays must not exceed 25 A 3 5 Pump Requirements The pump is powered directly from the Variable Frequency Drive VFD The VFD will be energized via an output from the relay board switched through a designated relay 3 6 Variable Frequency Drive Requirements The VFD must be powered separately from the con trol enclosure
17. under the first section of radiant tube first 10 3 m section of tube after the burner in direct sunlight or in the path of other sources of radiant heat The sensors are suit able for direct surface mounting or 4 x 2 1 8 junction box mounting FIGURE 8 Indoor Sensor Mounting Mounting Hole Plug in LCD Display grasp here to unplug Setback Override Button Setpoint Adjustment Slide bar Mounting Hole 3 71 Indoor Sensor Mounting Remove the cover of the sensor by the two 1 16 allen screws located in the lower corners of the cover To gain access to the top mounting hole remove the plug in LCD display To remove the LCD display grasp the green plug in board at the lower corners and gently pull the board away from the sensor back plate See Page 14 Figure 8 After removing the plug in LCD display from its socket secure the sensor to the wall or junction box using the screws provided Replace the plug in LCD dis play and secure the cover with the two 1 16 allen Screws Wiring from 32 V terminals on the controller to sensor power terminals and is polarity sensitive Reversing polarity may cause sensor damage Refer to Page 16 Figure 11 and Page 18 14 Figure 12 for wiring details 3 8 Outdoor Sensor Placement The outdoor sensor measures air temperature out side the building It is important that the sensor is located on the outside of the building on the north facing wall Failure to
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19. 6 00001000 11100000 17 10001000 00010000 18 01001000 10010000 19 11001000 01010000 00101000 20 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 5 5 1 Repeater If the RS 485 communications wire length is above 4000 a repeater must be used to extend the signal The repeater can also be used to create parallel branches of ROBERTS GORDON ULTRAVAC controller communications bus wiring Each repeater is sold in a 12 x 12 NEMA 1 enclosure with a 120 24 Vac transformer There is no limit on the quantities of repeaters used in a system FIGURE 19 Repeater Wiring Central ULTRAVAC Controller 120 Vac 120 Vac 120 Vac 120 Vac Satellit i Satellit Description Part Number Repeater 10080445 26 SECTION 6 VARIABLE FREQUENCY DRIVE PROGRAMMING SECTION 6 VARIABLE FREQUENCY DRIVE PROGRAMMING 6 1 VFD Parameter Settings For Use With ROBERTS GORDON ULTRAVAC The VFD parameters come with factory default set tings The following parameter settings must be changed for ROBERTS GORDON ULTRAVAC M Settings can only be altered when the pump motor is stopped Verify that there is power to the VFD LCD display will be on and power to the 24 V power switch on the relay board of the ROB
20. ERTS GORDON ULTRA VAC controller is off ADANGER Electrical Shock Hazard Enclosure contains live electrical components Programming must be done by a trained technician only Replace cover before operating Failure to follow these instructions can result in death or electrical shock To override the rotary disconnect switch inside the VFD enclosure turn the square rod with a wrench to the ON position In order to be able to close the cover of the disconnect the rods need to be turned back to the OFF position 6 1 1 To enter the PROGRAM mode and access the parameters press the Mode button This will activate the PASSWORD prompt if the password has not been disabled Display reads 00 Upper right decimal point blinks 6 1 2 Use the arrow buttons to scroll to the password value the factory set password is 225 Press Mode to enter password Once the correct password value is entered the dis play will read PO1 which indicates that the PROGRAM mode has been accessed at the begin ning of the parameter menu P01 is the first parameter NOTE If the display flashes Er the password was incorrect and the process to enter the password must be repeated 6 1 3 Use the arrow buttons to scroll to the desired parameter number For new parameter settings See Page 28 Section 6 2 6 1 4 Once the desired parameter number is found Press Mode to display present parameter setting example setting
21. FD model 230V 1 50 60 Hz supply for 230 V VFD model 460 V 3 50 60 Hz supply for 460 V VFD model See VFD rating plate for required input Repetitive cycling of a disconnect or input contactor more than once every two minutes may cause damage to the drive NOTE 4 Zone 3 Sensor not shown wiring is as follows SEN output to analog input 3 SET output to analog input 6 O R output to meter input 3 outputs to 32 V GND inputs NOTE 5 Internal pre wiring not shown NOTE 6 Wiring from 32 V terminals on the controller to sensor power terminals and is polarity sensitive NOTE 7 All three power output wires from terminals U V and W to the pump motor must be kept tightly bundled and run in a separate conduit away from all other power and control wiring SECTION 4 TYPICAL EXTERNAL DIAGRAMS ROBERTS GORDON ULTRAVAC Satellite Controller External Wiring continued Zone 3 Zone 2 Zone 1 Burners Burners Burners L2 L1 1 H i X H H x H L2 u L2 u L2 Ju H H 1 H X H x H Continued From Previous Page Outside Air Blower VFD Power I Supply optional 1 O input VFD model shown see NOTE 3 VFD Assembly 1 O input VFD model shown To Terminal 5 To Terminals 13 and 14 To Terminal 2 for 115 V and for 460 V 230 V input input VFD VFD models models gres Felt z Motor Power
22. GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL FIGURE 2 ROBERTS GORDON ULTRAVAC Controller Specifications 120 Vac Outputs 120 Vac P Input Relay Board 0 Vac Power Inpu Power Tus ai MD cl 1 A Fuse TANAL 11 0 quo cl 9 1NdLNO S10 uo cl MO ZI LI 8 INdLNO 1ndino 24V ALL 7 Plug In Relays eejee 24 V Input 24 V Control Board Transformer Connections Power Supply 24V 24 V Board Outputs Power Input RS 232 5 V TCP IP i Sensor RS 485 Control Direct Connect Module 3 Board Port Power Power Terminals Miter inpute eeeeeeeeeeee Jee eeeeeeeeeeoeeoeJ eeee6666e Reset 0 0j0 00 eeoooo oeeo eeeeeeeeceeeeeeceeeeee co Button NC c NO NC c No NC C NO NC C NO L1 PWR OUT IN G s3245 G G la e a oran ia RS232 DIRECT AUX POWER RS485 COMM METER INPUTS p Modem Chip optional only located Selector reser on Controller 1 Switch bones LI Lm Analog Eprom Outputs Chip 99999999 UNIVERSAL INPUTS Tf 6 5 4 B 2 l NC C NO Nc c NO NC c NO NC c NO l al l Ced 499 OHM eeeeeeeeeeee eeeeececeeeeoeoeoe N ee eeeeeeeeeeee 6666666666066 6906 66 s ET vec 24 V Outputs Analog Inputs Phone Port Controller Enclosure Note I To ensure robust control signaling ttir Do not run line voltage wiring thr
23. INJON 9 ON o o o O O O oo EC me ne ne ne mne nen W3MOdXnv LOFuId ZEZSU SLNANI NSN3AND pul o 9 9 G ze49 NIIN ino WINOQ S8 SH NI RI DJoin Shields Do Not Ground UTPUT 1 B R RDILI SINAN HALIN d E ah BMS Enable optional POWEI L2 From previous controller RS 485 See NOTE 2 Electrical wiring connections indicated by a dot e Pressure Ground Shield one end only indicated by Switch Pump Separate line and low voltage circuits Do not run line voltage wiring through bottom section of enclosure that houses the control board Do not run low voltage wiring through top section of enclosure that houses the relay board Pressure Switch Do not run line and low voltage wiring 1 Optional Outside Air Blower in the same conduit o NOTE 1 This diagram applies to the Satellite Controller only The Satellite Controller does not require modem RS 485 converter wiring to the PC TCP IP module wiring or outdoor sensor wiring For Central Controller see Central Controller External Wiring Diagram NOTE 2 Twist shield wires for both RS 485 communication cables together and ground at central panel only On controller 1 only connect these twisted shield wires to ground For VFD 0 10 V signal wiring connect shield wire to ground at the controller only NOTE 3 120 V 1 50 60 Hz Supply TOT 120 V V
24. The 230 V drive power supply must be 230 V 50 60 Hz 1 B The 120V drive power supply must be 120 V 50 60 Hz 1 O The 460 drive power supply must be 460 V 50 60 Hz 3 Q See Page 9 Section 2 3 for additional details The VFD on off switching is done by an output on the relay board SECTION 3 INSTALLATION The 0 10 V signal from the ULTRAVAC controller enclosure wired into VFD input relays 5 and 2 see Page 16 Figure 11 through Page 18 Figure 12 will dictate the speed of the pump The VFD output sup ply to the pump is 230 V 3 0 60 Hz for 115 V and 230 V models and is 460 V 3 0 60 Hz for 460 V models The frequency of the output supply signal to the pump will be varied based on the 0 10 V signal from the control enclosure See Page 11 Section 3 2 for additional installation requirements FIGURE 7 Variable Frequency Drive Mounting Standard enclosures only NEMA 4 enclosure mounting varies by model 14 75 875 cm 10 25 4 cm 13 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 3 7 Indoor Sensor Placement The sensor measures the air temperature in the building It is important that the sensor is located in an area within the heated zone at occupant level For the most accurate results sensors should be mounted on an inside wall away from any air vents or other sources of heat and cold In order to avoid short system cycles and inaccurate temperature readings do not mount sensors
25. age not shown 10080430 TCP IP Communication Module not shown 10080440 33 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL Description Part Number Comms Equalization Cable not shown located only on Central Controller Telephone Sharing Device 4 port Relay 120 V Unitary Lights for 150 Style Control Board Lamp Green Enclosure Mount w o Light Lamp Red Enclosure Mount w o Light Light Diode 24 Vac 10080450 10080600 07100 91321614 91321615 91321616 8 2 Variable Frequency Drive Replacement Parts Caution Use only genuine ROBERTS GORDON replacement parts Use of parts not specified by Roberts Gordon voids warranty FIGURE 23 Variable Frequency Drive Components Diagram Variable Power Input Frequency Drive 1 input model shown HIO amp u e Rotary Dissconnect Base Block O foo ooo gaa i ee ee A i B n Lj oee ser DAE nh Input Fuse Holder bd Fuse Holder Levers Grounding Block 1 O input model shown 3 Q input models have an additional input fuse holder and VFD power input Descripti
26. ay Pana Fate Pana Pant Sees ee ee eem qe eesem Power SSR SATE kl RS Ut CR CSS RS OR SN as y y gu c1 M049 C1 LIJGHD c LIJGHD ci LIJGHD ec 11 GMD ci rrg5 cl LIJGUD er jay ZI H 1 A Fuse 8 1Nd1NO L INALNO 9 1NdLNO S 1NdLNO y 1ndino Ind1no 1nd1no L 1ndino HIMOd 24V LLLLLLL lE Relay Board Plug In Relays eooo e ee eeee ee Reset Button ececeeoececeeecjoe eeeeeeeeeeeeeeeeeeeeee eeo0 0060j000 000 0 6 ceo0 j00000 000000 0009 NC c NO NC c No NC c NO NC C NO je aps OUT IN G 32 G G G REF REF HE 24VAC OUT IN 4 RS232 DIRECT AUX POWER RS485 COMM 3 LI UNIVERSAL INPUTS 6 5 4 2 1 Nc c No Nc c NO NC c No Nc c NO q jer Alle es eeeeeea eee eee eb eee eeeeeeeeeeee eeeeeeeeee Modem Chip only located on Central Controller Description Part Number Control Board 150 style 10080102 Relay Board 10080200 Analog Output Board 10080141 URV Eprom Chip 10080122 Plug In Relay 10080212 Modem Chip located only on central controller 10080142 1 A Fuse Relay Board 10080211 ROBERTS GORDON ULTRAVAC Indoor Sensor F not shown 10081500 ROBERTS GORDON ULTRAVAC Outdoor Sensor not shown 10081501 ROBERTS GORDON ULTRAVAC Indoor Sensor C not shown 10081502 PC Connection Cable Package not shown 10080410 RS 485 Converter Pack
27. being used the additional controllers communicate to controller 1 through RS 485 communication wiring arranged in series from one controller to the next See Page 25 Section 5 5 This allows multiple controllers to be controlled from a PC through a single communication package at the central controller SECTION 5 COMMUNICATIONS 5 2 RS 485 Converter for Central Controller For remote on site viewing of system status and For communication cable requirements see Page 12 settings of any controller use the RS 485 converter Section 3 3 5 to connect a single PC 9 pin serial port to the RS it multiple ULTRAVAC controllers are being used the 485 terminals on the Central Controller This will additional controllers communicate to controller 1 allow communication between one PC and any of the through RS 485 communication wiring arranged ULTRAVAC controllers on the network For RS 485 in series from one controller to the next See Page 25 converter wiring details see Page 21 Figure 14and Section 5 5 This allows multiple controllers to be see Page 25 Section 5 5 controlled from a PC through a single communication package at the central controller FIGURE 14 RS 485 PC Connection To Controller 2 h Ground Shield RS 485 adapter power supply supplied with RS 485 adapter 193410 c csu SLNdNI TWSYSAINN lt M3MOd XnV RS 485 Adapter WWO9 S8vSH s
28. doid euou SI 49Jondeoeu JBLINQ ON IUDIJ siouing y op poised eu 1 Jamod 3194 SI e und eud spuooes gy Jeyy pepunoi6 Jo pue PAJSIMI jJ994 09 Burm euis A 01 0 GHA pue fi uoneoiunuJuoo S8v SH WO SOJIM Palys eJ WNZOLZZL N d JENUBWI SOI DVAAVHOO Jo uonoes Buldid seb 988 Wajqojd seb 4291109 i uinq pue 4ejjonuoo ueemjeg unm JJJSA SOA Ayeoyese yo pue uo Buluin1 suauing 10 pue dund aly SO JOINUISIG 1uepuedepu eNOGHOD SLH44OH Jno JOBJUOQ 39 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL inued ing Flow Chart cont Troubleshoot eqni punoje Bnus eg pinous sBuidnoo jy adidjiej 40 pesn eg pjnoys sBuidnoo paun Auedoiduui payjeysul eq Aew sBuljdnog 1o nqiisiq 1uepuedepu UJ09 2UI B J MMM eNOQH09 DD T Mn i JOBJUO9 jsisied swajqosd J SaNa LOOHS318NOHL peysnes ale sjuiod jas Josues e yey euns ayen ponad ON e und jsod einuiu Z e 1 ye umop jnus dund y seog peljsnes eie sjulod jas Josues lle yey euns ayen ow _ amp Peusnes SI Yey 10 JE N y aaye yo nus sieuing og suononjjsul esie eu 10 VNZOZZZL N d enuen dung seues 00 d3 10 VNOOZZZL N d yenuey dund seues ooz ul SUOIJONJISUI Buum JINSUOQ Sjrejep 10 W8JSAS AYO ay JO Buiuoissiuulo ees JU9A pue y ye uinnoeA Jedoud 10 uiejsAs 1snfpy Amessooau se sey eoejdeu WAJSAS eu ui syee
29. e 1 a Dedicated Outside Phone Line optional San oo YD z ye 899999 6565656 co N to wo e N Dip Switch 1 Set to ON controller address 1 amp 2929999999099 o o o e o o o oo o o o YU SC n ew o anlon o onl ow o onl o o onl oe FFF 99999999999999 a 3 al ow o anlon o on on a ow 5552522552 ja ee ssesssissszsj 9999 99999999 99 999999999999 f P IE 9 1 8 Join Shields Do Not Ground n all inda wawan eee 9 555555555 IE pit call 5 EFJERERERERERERER ole ole ele cle clecieclce Join Shields Do Not Ground Ee een E oo ITO 6555656 12345678 Dip Switch 2 Set to ON controller address 2 Dip Switch and 2 Set to ON controller address 3 Dip Switch Order 1 2 3 4 5 6 78 Values 1 ON 0 OFF Controller Number Dip Switch Order 1 2 3 4 5 6 78 Values 1 ON 0 OFF Controller Number 1 Central Controller 10000000 11 11010000 01000000 12 00110000 11000000 13 10110000 00100000 14 01110000 10100000 15 11110000 01100000 1
30. ed pairs of stranded 24 AWG min wire is required for use with indoor sensors See Page 12 Figure 5 for an illustration of the shielded cable specification to be used See Page 12 Section 3 3 2 to see if unshielded cable may be used Unshielded Cable AMP 57248 219538 219513 Belden 1585A 1583A General Cable C6015 or equivalent Shielded Cable Madison Cable 08CFJ10001 08CFJO0004 Belden 9681 General Cable 2131673 C 1676 or equivalent 12 FIGURE 5 Indoor Sensor Cable Detail Insulation Shield Wire d Foil 24 AWG Shield Minimum 3 3 4 Outdoor Air Sensor VFD 0 10 V signal Pressure Switch Cable and PC RS 485 converter wiring Shielded cable one twisted pair of 22 AWG min wire is required for the outdoor air sensor VFD signal wiring pressure switch wiring and RS 485 con verter wiring between controller 1 and PC RS 485 converter wiring to PC is only used if controller is using an RS 485 Converter Communication Package See Page 12 Figure 6 for an illustration of the cable specification to be used Shielded Cable Belden 48451 1503A 8760 General Cable C2514 or equivalent FIGURE 6 Outdoor Sensor VFD 0 10 V Signal RS 485 Communications Cable and Pressure Switch Cable Detail Uninsulated Shield Wire Insulation 22 AWG Minimum conductor 22 AWG Minimum conductor 3 3 5 RS 485 Communication Wire Between Controllers Shielded cable one twisted triad or two
31. escription Part Number Comms Equalization Cable 10080450 15 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL FIGURE 11 ROBERTS GORDON ULTRAVAC Central Controller External Wiring To Satellite Controller RS 485 see NOTE 2 Zone 1 Zone 2 Sensor Sensor Outdoor see NOTE 6 see NOTE 6 Sensor SEN SET O R SEN SET O R JON D ONION 9 ONION 9 ONION 9 ON ee Tai ee 555553555555 Continued On Next UMd 17 ZILJON 3 ONJON 9 9NION 9 9NJON 9 ON AI L SANANI TYSYIANN WaModxnv 19331028S8 N In qe qe quts e agg E EEEE ooo MIET o O O O O O O O gt 9 En nr TID TIC TIC TID TICCI a OUTPUT2 OUTPUT 3 OUTPUT 4 f OUTPUT 5 f OUTPUT6 OUTPUT7 OUTPUT 8 WOO SSH L1 L2 GRDILI L2 GRDIL1 L2 GRDILI L2 GRDILI L2 GRDILI L2 GRDIL1 L2 GRDILI L2 GRDILI L2 GRD Ssauonv nao e NC C NO LA leo z BMS Enable i ech 2 optional u p w Phone Line THIER for Modem To RS 485 i optional See Converter at PC see NOTE 1 NOTE 2 optional see NOTE 1 amp 2 Electrical wiring connections indicated by a dot RAW 2X Pressure Ground Shield one end only indicated by Switch Pump Separate line and low voltage circuits Do not run line voltage wiring through
32. is 20 0 Upper right decimal point blinks Use arrow buttons to change setting Press Mode to store new setting and exit the program mode 6 1 5 To change another parameter press the Mode key again to re enter the PROGRAM mode the parameter menu will be accessed at the parameter that was last viewed or changed before exiting If the Mode key is pressed within two minutes of exit ing the PROGRAM mode the password is not required to access the parameters After two minutes 27 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL the password must be entered in order to access the parameters again 6 2 Altering VFD Parameters Using the procedure described in Section 6 1 1 through Section 6 1 5 alter the following parameters Parameter Parameter Factorv New Number Name Default Setting P16 Units Ending 02 01 P44 Password 225 Any 000 999 POS Start Method 01 05 28 SECTION 7 COMMISSIONING THE CORAYVAC SYSTEM SECTION 7 COMMISSIONING THE CORAYVAC SYSTEM NOTE The ROBERTS GORDON ULTRAVAC software must be installed on the PC the communi cation connection must be made to the controller and all wiring of the ROBERTS GORDON ULTRAVAC control boards relay boards burners pumps and VFD must be completed before starting the commis sioning procedure 7 1 Setting The CORAYVAC End Burner Vacuum It is important to understand that the frequency that the VFD ru
33. l Any defect in the ROBERTS GORDON ULTRA VAC arising from a drawing design or specifica tion supplied by or on behalf of the consumer Damage incurred during shipment Claim must be filed with carrier WARRANTY IS VOID IF The ROBERTS GORDON ULTRAVAC 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 ULTRAVAC is moved or transferred This warranty is nontransferable Roberts Gordon is not permitted to inspect the damaged controller and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL 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 U S A 1250 William Street P O Box 44 Buffalo New York 14240 0044 716 852 4400 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 warra
34. lace it with a new fuse Slide the fuse back into the socket press down and turn the fuse a 1 4 turn clockwise until secure Return 120 V power to the relay board and turn on the 24 V power switch on the relay board Press the reset button on the control board and close the doors 8 3 5 Variable Frequency Drive VFD To replace the Variable Frequency Drive turn off all power to the drive assembly at the breaker or discon nect switch Turn off 120 V power to the relay board inside the ROBERTS GORDON ULTRAVAC Con troller Turn off the 24 V power switch on the relay board Mark all wires connected to the VFD noting the ter minals that they are secured to Remove all wires from the VFD terminals Remove the VFD from its mounting plate by remov ing the four securing screws Verify that the input voltage noted on the rating plate of the VFD matches the input voltage of the old VFD Secure the new VFD to the mounting plate with the four screws Return all wires to the correct VFD ter minals If possible it may be easier to partially re wire the new VFD before mounting it to the mounting plate Close the door and return power to the VFD Return 120 V power to the relay board Turn on the 24 V power switch on the relay board Press the reset but ton on the control board and close the doors 35 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 8 3 6 Variable Frequency Drive 25 A or 10 A Fuse To replace a fu
35. lectrical interference noise caused by surrounding machinery or equipment If multiple ULTRAVAC controllers are being used the additional controllers communicate to controller 1 through communication wiring arranged in series from one controller to the next See Page 25 Section 5 5 Dip Switch 1 Setto ON 666660 666 666 696 eeej eeeee eeeoee 12345678 ja um QUT G 32 5 G G G REF REF 24VAC OUT RS232 DIRECT AUX POWER RS485 COMM eee ee 1 eeeeee eeee EXE rrr 66 summe a 1 a 1 1 a 1 1 Installed Modem Chip T as Phone Cable Connection Part Number 10080142 Description Modem Chip 5 1 Dedicated Phone Line for Central Controller Modem The Central Controller is fitted with a modem chip To use the modem the controller must have a phone line for modem communications Install a phone line near the location of the Central Controller The phone cable is plugged into the phone connection in the corner of the control board See Page 20 Figure 13 If the modem option is not used for everyday commu nication to the controller s it can still be plugged into a phone line for troubleshooting or programming assistance Contact your local Roberts Gordon inde pendent distributor for details 20 If multiple ULTRAVAC controllers are
36. mount the sensor on the north facing wall will result in artificially high temperature readings If possible locate the sensor high under an eve to prevent incorrect readings from direct sunlight and damage due to the elements FIGURE 9 Outdoor Sensor Placement Outside Sensor Sensor Module facing down Mount the outside sensor with the sensor module facing down to prevent accumulation of dirt or water 3 9 Outside Air Supply If an outside air blower is to be used See Page 16 Figure 11 for external wiring diagrams See Page 13 Section 3 4 1 for current load SECTION 4 TYPICAL EXTERNAL DIAGRAMS SECTION 4 TYPICAL EXTERNAL DIAGRAMS FIGURE 10 Central Controller Communication Equalization Wiring All ULTRAVAC Central Controllers are shipped with a communication equalization cable P N 10080450 The cable is supplied to equalize and balance the circuitry of the communications on the controller network that may be experiencing noise or transient voltage levels Connect the communi cation equalization cable as shown below to the first or the last controller on the data bus This connector will plug into the right set of RS 485 terminals on this board as shown BERHAN OUT IN G 32 5 G G REF OUT IN RS232 DIRECT AUX POWER RS485 COMM UNIVERSAL INPUTS 7 6 5 4 3 2 1 METER RESET ADDRESS aje epe ele ele eje ede l eejeej 06 00 006jJ0000 0 0 ooleoleoeoleooo oo D
37. n 2 5 wc and 3 0 wc while all the burners are still operating use the down arrow button on the VFD to reduce the frequency of the output signal to the pump Reduce the frequency of the VFD until the manometer at each of the end vents reads 1 0 wc 1 2 wc Make note of this frequency setting below The frequency is found on the VFD s LCD screen 1 0 w c 1 2 wc VFD Frequency Setting Record Frequency Setting Here Step 7 1 4 Return to the PC and click the pump and zones to OFF Step 7 1 5 Using the procedure described in on Page 27 Section 6 1 1 through Section 6 1 5 alter the fol lowing parameters on the VFD Parameter Parameter Factory New Number Name Default Setting PO5 Standard 01 03 Speed Source P45 Speed at 0 0Hz Frequency Minimum Setting noted in Signal Section 71 3 P46 Speed at 60 0Hz Frequency Maximum Setting noted in Signal Section 712 Step 7 1 6 Return to the PC and click the vacuum pump and three zones to AUTO then click exit 32 SECTION 8 REPLACEMENT PARTS SECTION 8 REPLACEMENT PARTS 8 1 ROBERTS GORDON ULTRAVAC Controller Replacement Parts Caution Use only genuine ROBERTS GORDON replacement parts Use of parts not specified by Roberts Gordon voids warranty FIGURE 22 ROBERTS GORDON ULTRAVAC Controller Components Diagram Tr 24V a wA nr WW re Vara Fara Fare Fara Fara Fara Fara Fara Fara Fara Fara Fara Fara Fara Fara Fara Fara Fara Fara F
38. nd turn on the 24 V power switch on the relay board Press the reset button on the control board and close the doors 8 3 2 Control Board Power LED The LED is linked to the 24 Vac input which supplies the control board with power If the LED is not lit there is no power to the board If this is the case check the 120 V power wiring to the relay board the 24 Vac power wiring from the relay board to the con trol board and the 24 V power 1 A fuse 8 3 3 10080122 Eprom Chip The Eprom is where the controller s program not settings is stored To take out the Eprom The following steps must be taken Turn off the power to the control board by turning off the 24 V power switch on the relay board Locate the Eprom and with a small terminal screw driver placed underneath the device pry the Eprom out of the socket To fit a new Eprom look for the notch on one end of the Eprom There is a notch on the socket and a notch on the Eprom The Eprom should be fit so that the notch on the socket and the Eprom are aligned Turn on the 24 V power switch on the relay board press the reset button on the control board and close the doors 8 3 4 24V Power 1 A Fuse To replace the 1 A fuse turn off power to the relay board and turn off the 24 V power switch on the relay board Locate the 1A fuse and remove it from its socket using a flathead screwdriver Twist the fuse a 1 4 turn counter clockwise until the fuse pops out of the socket Rep
39. ns the motor at determines the speed of the impeller in the pump Variation of the impeller speed will increase or decrease vacuum in the sys tem The following procedure will help you set mini mum and maximum VFD frequency settings to achieve proper vacuum in the system Step 7 1 1 At the controller turn on the 24 V power switch on the relay board At the PC connect to the controller see the ROBERTS GORDON ULTRA VAC Software Installation and Operation Manual P N 10081600NA for details and then open the manual override screen Alt M On the screen click the ON button for the vacuum pump Wait 30 seconds then click the ON button for zones 1 3 Step 7 1 2 The pump should be running and the burn ers should light within 60 seconds At the VFD verify that the number displayed on the LCD screen is 60 0 If it is lower than 60 0 hit the up arrow button on the VFD until the number reads 60 0 Let the burn ers fire for approximately 20 30 minutes to warm up the system Using a manometer check the end vent vacuum in each zone each branch of burners See Page 30 Figure 20 If the lowest end vent vacuum reading is above 3 0 wc reduce the vacuum pump speed Generally the lowest end vent vacuum reading is on the longest branch of the system Use the down arrow button on the VFD to reduce the frequency of the output signal to the pump thus reducing the pump speed and low ering the end vent vacuum reading Continue to red
40. nty 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 ULTRAVAC 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 LIMITATIONS ON AUTHORITY OF REPRESENTATIVES 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 41
41. oard 1 4 4 Programming Details Every controller is pre programmed for one pump and up to three heating zones Use a site layout drawing to identify the heating zones ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 1 5 Carton Contents URVSC ULTRAVAC Satellite Controller ULTRAVAC Controller Line Voltage 120 V Wiring mu jj kun denm Inside View ULTRAVAC Installation Manual P N 10081601NA URVCCL ULTRAVAC Central Controller with TCP IP Communication Module Line Voltage 120 V Wiring eren eure 29999999 s Inside View ULTRAVAC Controller with Modem Installed ULTRAVAC Software P N 10080421 Comms Equalization Cable P N 10080450 ULTRAVAC Software Manual P N 10081600NA ULTRAVAC Installation Manual P N 10081601NA Repeater optional Supplied w 24 VAC transformer inside NEMA 1 enclosure P N 10080445 RS232 RS485 e PROGRAM ri FI TCP IP LAN Communication Module w 7 phone wire P N 10080440 AL A lt PC Connection Cable Package Outdoor Sensor P N 10080410 P N 10081501 URVCCM ULTRAVAC Central Controller with Modem SECTION 1 INTRODUCTION
42. oftware Manual For TCP IP communication module wiring details see Page 23 Figure 16 If multiple ULTRAVAC controllers are being used the additional controllers communicate to controller 1 through RS 485 communication wiring arranged in series from one controller to the next See Page 25 Section 5 5 This allows multiple controllers to be controlled from a PC through a single communication package at the central controller FIGURE 15 TCP IP Communication Module Mounting Controller Enclosure Line Voltage 120 V Wiring cccccccbtteeccceeeett Relav Board 5 5 5 a 8 S J u IU IU IU 10 IU IU 10 oooo oo099 eo oo seeej esses ee ee Low Voltage 24 V Wiring eeeeeeeeeeee ee ml eooccoooolooooooococoocooe eeecceceeoeeo ee eee NC C NO wc C NO wc C wo uc c wo i v erw a erw a a aper Fe a I eT ur iN at 372 Control Board L1 09999999 Mount TCP IP module to enclosure here or other suitable location within the control board s compartment Do not mount module in
43. og Outputs 0 10 Vdc Digital Inputs Timed dry contact Network Ports RS 485 RS 232 UL Standard UL 916 C22 2 No 205 M1983 2 1 3 Electrical Relay Board Power Supply 120 V 10 1 60 Hz Inputs 24V AC Relay Outputs Single Pole 3 A 120 Vac UL Standard UL 916 C22 2 No 205 M1983 2 2 Temperature Sensors Indoor Sensor Dimensions 2 75 w x 4 5 h x 1 15 d Power 32 V DC Features LCD temperature display setpoint adjustment override button Wiring Shielded Cable four twisted pairs 24 AWG min Outdoor Sensor P N 10081501 Dimensions 14 wx5 3 hx2 d Enclosure NEMA 4 gasketed aluminum LB housing 1 2 threaded connection Wiring SECTION 2 SPECIFICATIONS Shielded Cable one twisted pair 22 AWG min NEMA 4 Enclosure for Indoor Sensor P N 10081510 Description Dimensions Construction Protection Rating Flammability Rating NEMA 4 Enclosure is sold separately as an option The indoor sensor is field mounted inside the NEMA 4 enclosure Temperature thermistor and LCD temperature display will not operate properly inside the enclosure LCD display feature should be disabled and use of the NEMA 4 sensor enclosure will require the use of an outdoor sensor P N 10081501 in the space to monitor zone temperature 6 3 x 3 6 x 1 8 Polycarbonate enclosure with clear front cover 4 screw cover closure 16 gauge galvanized subpanel NEMA 4 4x 12 13 UL 94 5V ROBERTS
44. oller 2 and so on in a daisy chain fashion For communication cable requirements See Page 12 Section 3 3 5 From a PC by dialing into the modem on controller 1 or by connecting to controller 1 via RS 485 converter or TCP IP communication module the system status and settings can be viewed for any of the controllers on the network The control board identification dip switch must be set on each ROBERTS GORDON ULTRAVAC Controller See Page 25 Figure 18 for dip switch settings Contact Roberts Gordon or your ROBERTS GORDON independent distributor if more than 20 controllers are connected FIGURE 18 Communications Between Multiple Controllers a gt Central Controller controller 1 4 RS 485 Satellite Controller controller 2 To Additiona Controllers Satellite Controller controller 3 ES Wiring To RJ11 connection on TCP IP Module optional 999 999 999 999 e ooo 999990929009 eo o o o o o o o o o dya TAT ONS SH CAD ERT ON 555552525525 poosooooooo999 oet awl i Bl soma 0084 ano eeseecejeoceocjeoe 8999 99999 999 Ground Shield l Wiring to RS 485 Converter at PC optional wa eojleojesjeolso oojso aa eejeejecjcejocoojcooe 9j99j99 9999 99 99 99 sooo HEES momi jLeslselsels o cele ol
45. ommunications Between Multiple ROBERTS GORDON ULTRAVAC Controllers 25 SECTION 6 Variable Frequency Drive Programming 27 6 1 VFD Parameter Settings For Use With ROBERTS GORDON ULTRAVACTV 27 6 2 Altering VFD Parameters a 28 SECTION 7 Commissioning The CORAYVAC System 29 7 1 Setting The CORAYVAC End Burner Vacuum 29 SECTION 8 Replacement Parts 33 8 1 ROBERTS GORDON ULTRAVAC Controller Replacement Parts en 33 8 2 Variable Frequency Drive Replacement Parts 34 8 3 Replacement Parts Instructions 35 SECTION 9 Troubleshooting 37 SECTION 10 The ROBERTS GORDON ULTRAVAC LIMITED Warranty 41 2008 Roberts Gordon LLC 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 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figu
46. on Part Number Variable Frequency Drive 1 HP 120 V 1 Input for use with EP 203 Variable Frequency Drive 3 4 HP 230 V 1 Input for use with EP 203 Variable Frequency Drive 2 HP 230 V 1 Q Input for use with EP 303 Variable Frequency Drive 1 HP 460 V 3 Q Input for use with EP 203 Variable Frequency Drive 2 HP 460 V 3 Q Input for use with EP 303 Relay 120 V Fuse 10 A for 75 HP 230 V VFD 1 HP 460 V VFD and 2 HP 460 V VFD Fuse 25 A for 1 HP 120 V VFD and 2 HP 230 V VFD Grounding Block Fuse Holder Rotary Disconnect Base Block 10081201 10081202 10081203 10081204 10081205 90429100 91321410 91321425 91321300 91321400 91321550 34 SECTION 8 REPLACEMENT PARTS Description Part Number Rotary Disconnect Handle not shown Rotary Disconnect Rod not shown 91321551 91321552 8 3 Replacement Parts Instructions ADANGER Electrical Shock Hazard Disconnect electrical before servicing This appliance must be connected to a properly grounded electrical source Replace cover before operating Failure to follow these instructions can result in death or electrical shock 8 3 1 Plug In Relay To replace the plug in relay turn off 120 V power to the relay board Turn off the 24 V power switch on the relay board Locate the malfunctioning relay and pull the relay from its socket Fit a new relay in the socket Return 120 V power to the relay board a
47. ough bottom section ard 7 of enclosure that houses the control board Do not run low voltage wiring through top section of enclosure that houses the relay board Line Voltage 120 V wiring EH H Relay Bo Low Voltage 24 V wiring Control Board SECTION 2 SPECIFICATIONS 2 3 Variable Frequency Drive VFD 2 3 1 Enclosure Standard Models Construction 14 gauge painted steel mounting panel included left hinged door vented Dimensions 12 wx 14 3 8 h x 8 d Protection UL 50 Type 1 NEMA Type 1 NEMA 4 Models Description Drive assembly and components fully factory assembled inside NEMA 4 enclosure Enclosure dimensions and construction vary by model VFD75115N4 VFD20230N4 and VFD20460N4 enclosures are 16 gauge painted steel left hinged door non vented VFD75230N4 and VFD75460N4 enclosures are 14 gauge steel left hinged door non vented VFD75115N4 20 x 16 x 10 VFD75230N4 14 x 12 x 8 VFD20230N4 20 x 16 x 10 VFD75460NA 16 x 14 x 10 VFD20460N4 20 x 16 x 10 Protection NEMA 3R 4 12 13 2 3 2 Electrical Power Output 230 V 3 0 60 Hz for 115 V and 230 V models 460 V 3 O 0 60 Hz for 460 V models Speed Reference Follower 0 10 Vdc UL Standard
48. re 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Example Site Layout ROBERTS GORDON ULTRAVAC Controller Specifications iieis iiiad Variable Frequency Drive Components Factory pre wiring shown Controller Mounting eene Indoor Sensor Cable Detall Outdoor Sensor VFD 0 10 V Signal RS 485 Communications Cable and Pressure Switch Cable Detail Variable Frequency Drive Mounting Indoor Sensor Mounting Outdoor Sensor Placement Central Controller Communication Equalization WING Fas toot HE te ROBERTS GORDON ULTRAVAC Central Controller External Wiring ROBERTS GORDON ULTRAVAC Satellite Controller External Wiring Modem Location nee RS 485 PC Connection TCP IP Communication Module Mounting TCP IP Communication Module Wiring 9 Pin Adapter for PC Communications Between Multiple Controllers Repeater Wiring L ent End Vent Vacuum a Possible Damper Couplings Locations ROBERTS GORDON
49. relay board compartment 22 SECTION 5 COMMUNICATIONS FIGURE 16 TCP IP Communication Module Wiring Standard 4 Wire Phone Cord included Communications Circuit a Shrinkwrap Ey Equalizer Wiring included 120 ohm resistor included Ti w P N 10080440 HEHH HERE OUT IN G 32 5 G G G REF FF N RS 232 RS232 DIRECT AUX POWER RS485 PES us he Direct Port RESET OH CD RI ADDRESS mu EN Dip Switch i set to ON CPU te UN Vee 5 Be je a eet Ol x c Cable to LAN It is important that the module power wire is connected as shown black 5 V red 5 V wire orientation Make sure to verify connection before connecting to the control board bas module power wire Description Part Number TCP IP Communication Module 10080440 23 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 5 4 Direct Connect For local viewing of system status and settings of any controller a portable PC can be connected Using the 9 pin adapter provided See Page 24 Figure 17 you may wire from your computer serial port to the RS 232 direct connect port on the control board via standard 4 wire phone cable For identification of the RS 232 direct connect port see Page 8 Figure 2 This can be useful when a PC is in close proximity to any ROBERTS GORDON ULTRAVAC Controller or while troubleshooting at the controller using a lap top PC This type of
50. ron oto al controller Wa AS 400810071 GA A WARNING Improper installation adjustment alteration service or maintenance can result in death injurv or propertv damage Read the Installation and Operation Manual thoroughiv before installing or servicing this equipment Installation must be done bv an electrician qualified in the installation of control svstems for heating equipment C UL US LISTED Quality in Any Language 2008 Roberts Gordon LLC AW TE ROBERTS GORDON ROBERTS GORDON Ulraac Controls for Modulating CORAYVAC Infrared Heating Systems Installation Manual Installer 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 Owner Keep this manual in a safe place in order to provide your serviceman with necessary information 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 www rg inc com P N 10081601NA Rev F 10 08 TABLE OF CONTENTS SECTION 1 Introduction 1 1 1 What is ROBERTS GORDON ULTRAVACTV 1 1 2 CORAYVAC Design Requirements 1 1 3 General Requirements 1 1 4 Check Installation Materials 1 1
51. s 10119 ue eueu SI LLL pue sjeu QA Kejdsip qO1 eui SI a usemjeq Ainunuoo eJeu SI JOJJ9 JB9JO o JENUBJAI uoneiedo pue uonejpe su Sseunyoejnuew GHA 9U1 0119 9H uono s syed Ueuieog dou ees e 8J A OZL eoejdeu uonoes sueg 1ueuleoe ded 988 pueog ejo1 Jo ejaJ ui Bnjd eoejdeu Rejei A OZL pue 18 J0 JU09 ueemjeq Buum Ajoeg lll se Peoq Rejei ou uo g Aejel ur Bnid uo G37 pe eui SI Alguiesse eAup Aouenbej ejqeueA eu ul Aejas A Oc OW A OS 9491 SI uono s syed JUBWBJBJASH ees ejou ui Bnjd eoejdeu pseog Aeje eu uo SSA g jndino ye A OZL eJeui SI SeA A OZL UO s euluu l jndjno ueemjeq Aununuoo eueu SI S A pieoq eja1 uo g uonoeuuoo jndui A pz pue p1eoq o41uoo uo g IndinO A ve ueoM eg um 94198 uo un dund ay seog sweep Buum jeusayxe Aya p1eog eJoJ ON 94 UO 8 uonoeuuoo Indu A YZ SSOJO 9BA HZ 3194 SI SO SO 38 TROUBLESHOOTING SECTION 9 Troubleshooting Flow Chart continued npoui o9ejdou auou Ji 92e daJ Sali Jaye pue uiuodo 9AJBA pue yJeds ojnpoui JO jn0y907 10 42949 3Iun 9 9 4994 JNOXJOJ uomiub S9USEJJ 994U AJNPOLU UUM ajnpow o9ejdou 9JnjIej J0Ss9204d049 A uo Apeays SOA uado 0 9A EA 10 JIEM JeuoN 9 9 9 JO Mejs 1 USEIJ Apeo s puo99s p uonnjos ua qo4d 31 sapo9 JISOUBEIg ajnpojy uoniub uojeuu JeuJnq pue eje d eJns G EJA PAJJEJSUI
52. s polarity sensitive NOTE 7 All three power output wires from terminals U V and W to the pump motor must be kept tightly bundled and run in a separate conduit away from all other power and control wiring 16 SECTION 4 TYPICAL EXTERNAL DIAGRAMS ROBERTS GORDON ULTRAVAC Central Controller External Wiring continued Continued From Previous Page To Terminal 5 Terminal 2 VFD Assembly VFD model shown G VFD Power Supply 1 O input VFD model shown see NOTE 3 OHIO I ON eed Fatt amp To Terminals 13 and 14 Motor Power Supply see NOTE 7 Zone 1 Burners Outside Air Blower optional Pump 230 V 30 or 0 60 Hz 0 60 Hz for115V and _ for 460 V 230 V input input VFD VFD models models 17 ROBERTS GORDON ULTRAVAC CoNTROLLER INSTALLATION MANUAL FIGURE 12 ROBERTS GORDON ULTRAVAC Satellite Controller External Wiring To Satellite Controller RS 485 Zone 1 Zone 2 See NOTE 2 Sensor Sensor see NOTE 6 see NOTE 6 SEN SET O R SEN SET O R sa 7 Eu 8 2 GRDILI L2 GRD 1 L2 GRDILU L OUTPUT 6 QUTPUT 2 OUTPUT 3 OUTPUT 4 OUTPUT5 D L1 L2 GRDJL1 L2 GRDILI L2 GRDJL L2 GRDIL sn eu yen 0n yd 0 Fu ybu A t AS ybu en Uu S DI FI o JON 9 INTON 9 ONION 9 ONION 9 ON UMdJET ZILJON 9 ONJON 9 9NJON 9
53. saqaqv 25 pin male to 9 pin female adapter supplied with RS 485 adapter Dip Switch uu 9 Pin Female SSS z 2 al s m e U c c a Em um um IM GO HO Central Controller eee 00000000 Description Part Number RS 485 Converter Package with Windows Power Supply 0089459 Compatible PC 21 ROBERTS GORDON ULTRAVAC CoNTROLLER INSTALLATION MANUAL 5 3 TCP IP Communication Module For remote on site viewing of system status and settings of any controller use the TCP IP communi cation module to connect the controllers to a Local Area Network LAN via Ethernet cable Any computer on the LAN that has ULTRAVAC soft ware installed can be used to communicate with the controllers The module must be mounted inside the ULTRAVAC central controller controller 1 enclosure next to the control board The power 5V for the module will come from the ULTRAVAC control board The module will communicate to the controller via regular phone wire from the RJ11 jack on the module to the RS 232 direct connect port on the control board The module will relay the data from the controller to computers on the LAN via Ethernet cable plugged into the RJ45 jack on the module A setup procedure must be performed on the module upon installation to create its IP address on the LAN The setup instructions can be found in the ROBERTS GORDONS S
54. se turn off input power to the variable frequency drive assembly at the breaker or disconnect switch Turn off 120 V power to the relay board inside the ROBERTS GORDON ULTRAVAC Controller Turn off the 24 V power switch on the relay board Inside the VFD assembly open the fuse holder by pulling down the lever to expose the fuse Remove the old fuse and insert a new fuse Verify the correct fuse rating 25 A for 1 HP 120 V VFD or 2 HP 230 V VFD 10 A for the 75 HP 230 V VFD 1 HP 460 V VFD and 2 HP 460 V VFD Close the fuse holder Return power to the VFD assembly and verify that the VFD LCD screen is on dashes displayed Close the VFD assembly door Return 120V power to the relay board Turn on 24 V power switch on the relay board Press the reset but ton on the control board and close the doors 36 TROUBLESHOOTING SECTION 9 TROUBLESHOOTING Troubleshooting Flow Chart SECTION 9 FIGURE 24 S A S A UO euloo 4ejjonuoo eui uo JU IJ dund ey seog NO 0 snjejs duind ay jas JAl HIV uoeuos BPIJJSAQ JBNUEJA eui uo indui eod pieog 041009 A pg pue Ajddns 1eMod pueog JO JU09 A pz ueemjeq unm Anoeu S A S A duund eu s oq pepunoi6 1o pue peisIM ae SOIM pieius Aya J9JJO1JU09 pue ON josues uaamjeq unm JU A 19 JO1JU09 pue 9d ueeMjeg Buyum uoneoiunuuuoo JU A 4oinquisiq uepuedepu eNOGHOD S 1HH8OH ANOA JOBJUOQ a INAUI JOMOA preog ouoo A Ve 9U e ILA yc BBY SI
55. shooting Flow Chart continued SINAJNO j0euuoosip Areyoi eu usemjeq A OFZ JO A OZL Jewod eJeuj SI Jojow eoedoM pe ley e eu Aew sBuueeq JOJOJA Xoo q eseq joeuuoosip Aie oi eoejdeu ON L 9 uonoes ees uonisod NO eu 0 YAMS joeuuoosip reos UINL pejonusqo Jejjedui dund eu SI SINAUI sapjoy esny usemjeq A oec JO A OZL Jewod 9181 SI N Ajeeu uan yeys JOJOW eu seog JO OW y 01 amod JOSUUONSIG uonoes Sed ueuoeoge deu eeg esn eoejdeu SINAUI 190uuoosip Krejoi eui ueeMjeq A OFZ JO A OZL 4amod 919U SI SINdjNO 1epjou asnj ueevMeg A OFS JO A OZL JeMod 9 9U SI jesal pue sejnuiu S L OL HEM PEOJJOAO peddiJ SABU Aew JOJOJN N Z1 pue 7 sindui samod GHA pue sindino Jepjou esn usemjeq Duu Ajjoeu SeA lou doloui duund y S S9A A ddns jewod pue 1eyee1g JINDJJO yoayD dund ON au e SelM 1ndui OM Aue ueeMjeq Jamod 3194 SI GHA eur uo sindui N Z1 so pue L1U98MISQ A OEZ JO A 0ZL JeMod 91911 SI LL pue SJELIWJS GHA pue el 1 A OZL uooM eg BuuiM Jll99H uono s syed 1ueujeoe deg 998 qdA eoejdeu duund pue GHA useMjaq Buum jHJ98H lM 40 AN ow jeune 10101 jndjno om N fue usemjeq sjepoui A 09r 10 A OEZ A OSL 8194 SI uonoes sued iueuieogjdeH 998 Q4A 99ejdoH kejdsip q31 eui uo ON uo GHA au Jo Bulmou
56. tion may invalidate the ROBERTS GORDON ULTRAVAC limited war ranty See Page 41 Section 10 ROBERTS GORDON ULTRAVAC Software requires a PC not supplied running Windows 95 or higher with a Pentium class processor and at least 64k of RAM The controller variable frequency drive burners pump and outside air blower must be electrically grounded in accordance with the National Electrical Code ANSI NFPA 70 latest revision Before proceeding with the installation of the control ler it will be necessary to check that the following points have been considered SECTION 1 INTRODUCTION 1 4 Check Installation Materials 1 4 1 Switchable Loads The controller relays are rated for switching loads no greater than 3 A The total added current load for all 8 relays must not exceed 25 A 1 4 2 Control Wiring Shielded cable four twisted pairs of stranded 24 AWG minimum wire is required for use with indoor sensors Shielded cable one twisted pair of stranded 22 AWG minimum wire is required for the outdoor air sensor VFD signal wiring pressure switch and wiring from controller 1 to the PC Shielded cable one twisted triad of stranded 22 AWG minimum wire is required for RS 485 communications between controllers 1 4 3 Control Board and Sensor Power The power supply for all sensors is from the 32 V terminal to be found on the board of the controller Power for the control board is 24 V provided by the relay b
57. uce the frequency until the end vent vacuum read ing is between 2 5 3 0 wc Make note of this fre quency setting below The frequency is found on the VFD s LCD screen 2 5 wc 3 0 wc VFD Frequency Setting Record Frequency Setting Here To avoid damage to the pump motor do not adjust the frequency above 60 0 Hz Verify that the end vent vacuum readings in the remaining branches are proper If necessary adjust the proper damper cou pling to achieve an end vent vacuum of 2 5 3 0 wc See Page 30 Figure 20 Damper couplings should be found near the end of the radiant portion of the pipe in each branch or where a branch connects to other branches at a cross or tee See Page 31 Fig ure 21 29 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL FIGURE 20 End Vent Vacuum Combustion Chamber at end burner position Insert tubing about 6 15cm into end vent Manometer Approximate reading after adjusting VFD frequency setting and or damper couplings 2 5 3 wc SECTION 7 COMMISSIONING THE CORAYVAC SYSTEM FIGURE 21 Possible Damper Couplings Locations JU9A pu43 euo7 Pw lt JU9A puy z euo7 Buiidnoo Jedureq Jadueq ouoz A d Buiidnoo Jedweq euoz d JU9A puy euoz KIA jjIM 6umes Jodweq 3 LON 31 ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL Step 7 1 3 After setting end vent vacuums betwee

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