Roberts Gorden 10081601NA User Manual

Page 1

WARNING

Installation must be done by an electrician qualified in the installation and service of control systems for heating equipment.

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.

ROBERTS GORDON

UltraVac

PAT E NT E D

™

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 . B o x 4 4 Buffalo, New York 14240-0044 Telephone: +1.716.852.4400 Fax: +1.716.852.0854 Toll Free: 800.828.7450

www.rg-inc.com www.radiantheaters.com www.corayvac.com www.greenhouse-heater.com

P/N 10081601NA Rev H 12/11

Page 2

Page 3

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.

TABLE OF CONTENTS

SECTION 1: Introduction........................................................ 2

1.1 Safety ...........................................................................2

1.2 What is ROBERTS GORDON

ULTRAVAC™?............ 2

1.3 General Requirements .................................................2

1.4 CORAYVAC® Design Requirements.............................2

1.5 Example Site Layout.....................................................3

1.6 Check Installation Materials ......................................... 3

1.7 Safety Labels and Their Placement ............................. 3

1.8 Carton Contents ......................................................... 10

1.9 Standard Parts List ..................................................... 13

SECTION 2: Specifications ..................................................16

2.1 ROBERTS GORDON

ULTRAVAC™ Controller ....... 16

2.2 ULTRAVAC™ BMS Link Controller ............................ 16

2.3 NEMA 4 Enclosure (P/N 10080302) .......................... 16

2.4 Repeater....................................................................16

2.5 Temperature Sensors.................................................16

2.6 Line Reactor 480 V / 4 A Output................................ 17

2.7 Variable Frequency Drive (VFD) ................................ 19

SECTION 3: Installation........................................................ 21

3.1 Preparation ................................................................21

3.2 Positioning the ROBERTS GORDON

ULTRAVAC™

Controller and Variable Frequency Drive ...................21

3.3 Cable Requirements: .................................................22

3.4 Electrical Installation Requirements of ULTRAVAC™

Controller................................................................... 22

3.5 Pump Requirements ..................................................23

3.6 Variable Frequency Drive Requirements.................... 23

3.7 Indoor Sensor Placement .......................................... 24

3.8 Outdoor Sensor Placement .......................................24

3.9 Outside Air Supply.....................................................24

SECTION 4: Typical External Diagrams.............................. 25

SECTION 5: Communications..............................................30

5.1 Dedicated Phone Line for Central Controller Modem 30

5.2 RS-485 Converter for Central Controller....................31

5.3 TCP/IP Communication Module ................................32

5.4 Direct Connect...........................................................33

5.5 Communications Between Multiple ROBERTS

GORDON

ULTRAVAC™ Controllers........................35

SECTION 6: ULTRAVAC™ BMS Link Controller................. 38

6.1 ULTRAVAC™ BMS Link Controller Overview ............38

6.2 ULTRAVAC™ BMS Link Controller Requirements.....39

6.3 Technical Data ...........................................................40

6.4 ULTRAVAC™ BMS Link Controller Programming...... 40

There are references in this manual to various trademarks. All trademarks mentioned herein, whether registered or not, are the property of their respective owners. Roberts-Gordon LLC is not sponsored by or affiliated with any of the trademark or registered trademark owners, and make no representations about them, their owners, their products or services. Roberts-Gordon LLC is not sponsored by or affiliated with BACnet

or MODBUS®.

SECTION 7: Variable Frequency Drive Programming ........ 42

7.1 VFD Parameter Settings For Use With ROBERTS

GORDON

ULTRAVAC™.......................................... 42

7.2 Altering VFD Parameters............................................ 43

SECTION 8: Commissioning The CORAYVAC® System .... 44

8.1 Setting The CORAYVAC

End Burner Vacuum......... 44

SECTION 9: Troubleshooting .............................................. 48

SECTION 10: Replacement Parts ........................................ 55

10.1 ROBERTS GORDON

ULTRAVAC™ Controller

Replacement Parts.................................................. 56

10.2 Variable Frequency Drive Replacement Parts ......... 57

10.3 ULTRAVAC™ BMS Link Controller Replacement

Parts........................................................................ 58

10.4 Repeater Replacement Parts .................................. 59

10.5 Replacement Parts Instructions............................... 60

SECTION 11: The ROBERTS GORDON

ULTRAVAC™ Limited

Warranty.......................................................... 62

Prin ted in U.S.A.

Page 4

Page 5

TABLE OF FIGURES

Figure 1: ULTRAVAC™ Controller Label Placement.................4

Figure 2: ULTRAVAC™ BMS Link Controller Label Placement 5

Figure 3: VFD Label Placement................................................6

Figure 4: Repeater Label Placement ........................................7

Figure 5: Connected Components ............................................ 8

Figure 6: Example Site Layout ................................................ 15

Figure 7: ROBERTS GORDON

Specifications .......................................................... 18

Figure 8: Variable Frequency Drive Components

(Factory pre-wiring shown) ......................................20

Figure 9: Controller Mounting.................................................. 21

Figure 10: Variable Frequency Drive Mounting........................23

Figure 11: Indoor Sensor Mounting .........................................24

Figure 12: Outdoor Sensor Placement.................................... 24

Figure 13: ROBERTS GORDON

Controller External Wiring ......................................26

Figure 14: ROBERTS GORDON

Controller External Wiring ......................................28

Figure 15: Modem Location ....................................................30

Figure 16: RS-485 PC Connection.......................................... 31

Figure 17: TCP/IP Communication Module Mounting .............32

Figure 18: TCP/IP Communication Module Wiring..................33

Figure 19: 9 Pin Adapter for PC ..............................................34

Figure 20: Communications Between Multiple Controllers ..... 35

Figure 21: Repeater External Wiring ......................................36

Figure 22: Repeater Communication Wiring Between Multiple

Controllers..............................................................37

Figure 23: Standard ULTRAVAC™ BMS Link Architecture ..... 38

Figure 24: ULTRAVAC™ BMS Link Controller Schematic ...... 39

Figure 25: Communication Between ULTRAVAC™ BMS Link

Controller and Multiple ULTRAVAC™ Controllers.. 41

Figure 26: End Vent Vacuum .................................................. 45

Figure 27: Possible Damper Couplings’ Locations..................46

Figure 28: Troubleshooting Flow Chart ................................... 49

Figure 29: Troubleshooting Flow Chart - Repeater .................53

Figure 30: Trou

bleshooting Flow Chart - BACnet®..................54

Figure 31: ROBERTS GORDON® ULTRAVAC™ Controller

Components Diagram............................................56

Figure 32: Variable Frequency Drive Components Diagram ... 57 Figure 33: ULTRAVAC™ BMS Link Controller Components

Diagram ................................................................. 58

Figure 34: Repeater Components Diagram ............................ 59

ULTRAVAC™ Controller

ULTRAVAC™ Central

ULTRAVAC™ Satellite

Page 6

Page 7

1 of 62

Page 8

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Controller must be properly grounded to an electrical source.

Failure to follow these instructions can result in death or electrical shock.

SECTION 1: INTRODUCTION

1. 1 S a f e t y

Yo ur 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 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.

ROBERTS GORDON

ULTRAVAC™, see Page 8,

Figure 5. System status and settings are viewed and altered

from a PC (not supplied) running ROBERTS GOR-

ULTRAVAC™ Software.

DON

1. 3 G e n e ra l R e quirements

The heater must be applied and operated under the general concepts of reasonable use.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowl- edge, unless they have been given super instruction concerning use of the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the appliance.

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, contact your ROBERTS GORDON

independent distributor or Roberts-Gordon at (716) 852-4400, (800) 828-7450 or at www.rg-inc.com.

1.2 What is ROBERTS GORDON

The ROBERTS GORDON

ULTRAVAC™ is a micro-

ULTRAVAC™?

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.

For the overall view of connected components for

vision or

The ROBERTS GORDON

ULTRAVAC™ series of controllers are supplied pre-configured for use with ROBERTS GORDON

CORAYVAC® infrared heating equipment only. Failure to comply with the installation instructions and configuration may invalidate the

ROBERTS GORDON

ULTRAVAC™ limited war- ranty. See Page 62, Section 11.

ROBERTS GORDON requires a PC (not supplied) running Windows higher, with a Pentium

ULTRAVAC™ Software

95 or

class processor and at least

64k of RAM. The controller, variable frequency drive, burners,

repeater, 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 controller, it will be necessary to check that the following points have been considered:

1. 4 C O R AY VA C

CORAYVAC

Design Requirements

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.

2 of 62

Page 9

SECTION 1: INTRODUCTION

-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.

1.5 Example Site Layout

Page 15, Figure 6 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™.

1.6 Check Installation Materials

1.6.1 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.

ERTS GORDON

independent distributor to obtain replacement signs or labels. See Page 4, Figure 1 through Page 7, Figure 4.

1.6.2 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 pair of stranded 22 AWG minimum wire) is required for RS-485 communications between controllers.

1.6.3 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 board.

1. 6 . 4 P r o gramming 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.

1.7 Safety Labels and Their Placement

Product safety signs or labels should be replaced by the product user when they are no longer legible. Please contact Roberts-Gordon LLC or your ROB-

3 of 62

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Electrical Shock Hazard Label

Logo Label

Light Label

Front Door Panel (outside)

Front Door Panel (inside)

Control Board Wiring Label

External Wiring Label

Rating Plate Label

+-1+-2+-4+-3+-5+-6+-7+-

+- +-

REF

24VAC

NONC C

NONC CNONC CNONCCNONCC

NONC CNONC CNONC C

RS485 COMM

REF

+-1+-2+-3+-

METER INPUTS

UNIVERSAL INPUTS

INOUT

ADDRESS

RESET

10VDC

499 OHM

OFF ON

OUT IN

GINOUT G G G

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

OUTPUT 1

L1L2GRD

GRDL2L1

OUTPUT 2

GRDL2L1

OUTPUT 3

GRDL2L1

OUTPUT 4

GRDL2L1

OUTPUT 5

GRDL2L1

OUTPUT 6

GRDL2L1

OUTPUT 7

GRDL2L1

OUTPUT 8

GRDL2L1

POWER

Description Part Number

Logo Label 91013207 Rating Plate Label 91008005 Light Label 91008007 Control Board Wiring Label 91008004 External Wiring Label 91008003 Shock Hazard label 91008001

FIGURE 1: ULTRAVAC™ Controller Label Placement

4 of 62

Page 11

FIGURE 2: ULTRAVAC™ BMS Link Controller Label Placement

Description Part Number

Logo Label 91008017 Rating Plate Label 91008016 Light Label 91008015 Control Board Wiring Label 91008014 Shock Hazard label 91008001

SECTION 1: INTRODUCTION

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Page 12

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

M16/12.P

125611

13A

13B

13E2516

PEPEWVU

L2/NL1 B-PE

B+

Wiring Diagram Label

Variable Frequency Driver

1 Ø Input Model Shown

Relay 120 V

Input Fuse Holder

Power Input

Rotary Disconnect

Front Door Panel (inside)

Rating Plate Label

Side Panel (outside)

Electrical Shock Hazard Label

Front Door Panel (outside)

Description Part Number

Rating Plate Label 91008006 Wiring Label (230 V) 91008004 Wiring Label (460 V) 91008003 Shock Hazard label 91008001

FIGURE 3: VFD Label Placement

6 of 62

Page 13

FIGURE 4: Repeater Label Placement

Description Part Number

Wiring Diagram Label 91008020 Logo Label 91008021 Rating Plate Label 91008022 Shock Hazard Label 91008001

SECTION 1: INTRODUCTION

7 of 62

Page 14

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

FIGURE 5: Connected Components

8 of 62

Page 15

Connected Components (continued)

SECTION 1: INTRODUCTION

9 of 62

Page 16

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Line Voltage 120 V Wiring

Low Voltage 24 V Wiring

POWER

L1 L2 GRD

OUTPUT 1

L1 L2 GRD

OUTPUT 2

L1 L2 GRD

OUTPUT 3

L1 L2 GRD

OUTPUT 4

L1 L2 GRD

OUTPUT 5

L1 L2 GRD

OUTPUT 6

L1 L2 GRD

OUTPUT 7

L1 L2 GRD

OUTPUT 8

L1 L2 GRD

+-1+-2+-4+-3+-5+-6+-7+-

+- +-

REF

24VAC

NONCC

NONCCNONCCNONCCNONC C

NONCCNONC CNONCC

RS485 COMM

REF

+-1+-2+-3+-

METER INPUTS

UNIVERSAL INPUTS

INOUT

ADDRESS

RESET

10VDC

499 OHM

OFF ON

OUT IN

GINOUT G GG

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

ULTRAVAC™ Controller

ULTRAVAC™ Installation Manual (P/N 10081601NA)

Inside View

Kit, TCP/IP (LAN) Communication Module with PC Connection Cable Package (P/N 10080440K)

Outdoor Sensor (P/N 10081501)

+-1+-2+-3+

METER INPUTS

RESET

499 OHM

CDOH

ULTRAVAC™ Controller

with Modem Installed

Repeater (optional) Supplied w/24 VAC transformer inside NEMA 1 enclosure (P/N URVRP)

Inside View

ULTRAVAC™ Software (P/N 100816CDNA) contains: ULTRAVAC™ Software, ULTRAVAC™ Software Manual. (P/N 10081600NA) ULTRAVAC™ Installation Manual (P/N 10081601NA), BACnet

Software and Ruinet Manual.

Indoor Sensor (P/N 10081502)

1.8 Carton Contents

URVSC: ULTRAVAC™ Satellite Controller

URVCCL: ULTRAVAC™ Central Controller with TCP/IP Communication Module

Line Voltage 120 V Wiring

L1 L2 GRD

OUTPUT 5

OUTPUT 6

OUTPUT 7

OUTPUT 8

POWER

OUTPUT 1

OUTPUT 2

OUTPUT 3

OUTPUT 4

Modem Chip

Low Voltage 24 V Wiring

+- +-

GINOUT GGG

UNIVERSAL INPUTS

+-1+-2+-3+-

REF

+32

INOUT

RS485 COMM

METER INPUTS

AUX POWER

RESET

CDOH

ADDRESS

CPU

+-1+-2+-4+-3+-5+-6+-7+-

OUT

499 OHM

OFF

10VDC

PWR

NONC CNONC CNONCCNONC C

24VAC

RS232 DIRECT

NONC C

NONC CNONC CNONCC

10 of 62

Page 17

URVCCM: ULTRAVAC™ Central Controller with Modem

Outdoor Sensor (P/N 10081501)

PC Connection Cable Package (P/N 10080410)

ULTRAVAC™ Controller

with Modem Installed

Line Voltage 120 V Wiring

Low Voltage 24 V Wiring

POWER

L1 L2 GRD

OUTPUT 1

L1 L2 GRD

OUTPUT 2

L1 L2 GRD

OUTPUT 3

L1 L2 GRD

OUTPUT 4

L1 L2 GRD

OUTPUT 5

L1 L2 GRD

OUTPUT 6

L1 L2 GRD

OUTPUT 7

L1 L2 GRD

OUTPUT 8

L1 L2 GRD

+-1+-2+-4+-3+-5+-6+-7+-

+- +-

REF

24VAC

NONC C

NONC CNONC CNONCCNONC C

NONC CNONC CNONCC

RS485 COMM

REF

+-1+-2+-3+-

METER INPUTS

UNIVERSAL INPUTS

INOUT

ADDRESS

RESET

10VDC

499 OHM

OFF ON

OUT IN

GINOUT GGG

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

+-1+-2+-3+

METER INPUTS

RESET

499 OHM

CDOH

Modem Chip

Inside View

Repeater (optional) Supplied w/24 VAC transformer inside NEMA 1 enclosure (P/N URVRP)

Inside View

ULTRAVAC™ Software (P/N 100816CDNA) contains: ULTRAVAC™ Software, ULTRAVAC™ Software Manual. (P/N 10081600NA), ULTRAVAC™ Installation Manual (P/N 10081601NA), BACnet

Software and Ruinet Manual.

Indoor Sensor (P/N 10081502)

SECTION 1: INTRODUCTION

11 o f 6 2

Page 18

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

RS-485 Converter Package (P/N 10080430)

Power Supply

Outdoor Sensor (P/N 10081501)

PC Connection Cable Package (P/N 10080410)

ULTRAVAC™ Controller

with Modem Installed

Line Voltage 120 V Wiring

Low Voltage 24 V Wiring

POWER

L1 L2 GRD

OUTPUT 1

L1 L2 GRD

OUTPUT 2

L1 L2 GRD

OUTPUT 3

L1 L2 GRD

OUTPUT 4

L1 L2 GRD

OUTPUT 5

L1 L2 GRD

OUTPUT 6

L1 L2 GRD

OUTPUT 7

L1 L2 GRD

OUTPUT 8

L1 L2 GRD

+-1+-2+-4+-3+-5+-6+-7+-

+- +-

REF

24VAC

NONC C

NONC CNONC CNONCCNONC C

NONC CNONC CNONCC

RS485 COMM

REF

+-1+-2+-3+-

METER INPUTS

UNIVERSAL INPUTS

INOUT

ADDRESS

RESET

10VDC

499 OHM

OFF ON

OUT IN

GINOUT GGG

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

+-1+-2+-3+

METER INPUTS

RESET

499 OHM

CDOH

Modem Chip

Inside View

RS-485 Converter

Repeater (optional) Supplied w/24 VAC transformer inside NEMA 1 enclosure (P/N URVRP)

Inside View

ULTRAVAC™ Software (P/N 100816CDNA) contains: ULTRAVAC™ Software, ULTRAVAC™ Software Manual. (P/N 10081600NA), ULTRAVAC™ Installation Manual (P/N 10081601NA), BACnet

Software and Ruinet Manual.

Indoor Sensor (P/N 10081502)

URVCCR: ULTRAVAC™ Central Controller with RS-485 Converter

12 of 62

Page 19

SECTION 1: INTRODUCTION

ULTRAVAC™ Software (P/N 100816CDNA) contains:

ULTRAVAC™ Software, ULTRAVAC™ Software Manual. (P/N 10081600NA) ULTRAVAC™ Installation Manual (P/N 10081601NA),BACnet

MODBUS

Software

ULTRAVAC™ BMS Link

Controller

Inside View

URVBNC: ULTRAVAC™ BMS Link Controller

1.9 Standard Parts List

Table 1: Contents of ULTRAVAC™ Controller and Accessories

Part No. Description URVCCL ULTRAVAC™ Central Controller (with TCP/IP Communication Module, Software & Manual), Including:

URVSC Controller, ULTRAVAC™, 1 Pump 3 Zones (Satellite Control & Manual) 10080142 Modem Chip 10080440 TCP/IP Communication Module 10081501 Outdoor Sensor 10080410 PC Connection Cable Package 10081502 Indoor Sensor (sold separately)

URVCCM ULTRAVAC™ Central Controller (with Modem Chip, Software & Manual), Including:

URVSC Controller, ULTRAVAC™, 1 Pump 3 Zones (Satellite Control & Manual) 10080142 Modem Chip

1008150 Outdoor Sensor 10080410 PC Connection Cable Package 10081502 Indoor Sensor (sold separately)

URVCCR ULTRAVAC™ Central Controller (with RS-485 Converter, Software & Manual), Including:

URVSC Controller, ULTRAVAC™, 1 Pump 3 Zones (Satellite Control & Manual) 10080142 Modem Chip 10080430 RS-485 Converter with 9V Power Supply

1008150 Outdoor Sensor 10080410 PC Connection Cable Package 10081502 Indoor Sensor (sold separately)

URVBNC ULTRAVAC™ ULTRAVAC™ BMS Link Controller (with Software CD & Manual, IOS Manual)

URVSC Controller, ULTRAVAC™, 1 Pump 3 Zones (Satellite Control & Manual)

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Table 2: Common Components of ROBERTS GORDON® ULTRAVAC™ Controls

Part No. Description

Variable Frequency Drives*

VFD75115 Variable Frequency Drive Assembly, .75 HP 115 V 1 Ø Input VFD75230 Variable Frequency Drive Assembly, .75 HP 230 V 1 Ø Input VFD20230 Variable Frequency Drive Assembly, 2 HP 230 V 1 Ø Input

VFD75115N4 Variable Frequency Drive Assembly, .75 HP 115 V 1 Ø Input, NEMA 4

VFD75230N4 Variable Frequency Drive Assembly, .75 HP 230 V 1 Ø Input, NEMA 4

VFD75460 Variable Frequency Drive Assembly, .75 HP 480 V 3 Ø Input

VFD75460N4 Variable Frequency Drive Assembly, .75 HP 480 V 3 Ø Input, NEMA 4 VFD20230N4 Variable Frequency Drive Assembly, 2 HP 230 V 1 Ø Input, NEMA 4

VFD20460 Variable Frequency Drive Assembly, 2 HP 480 V 3 Ø Input

VFD20460N4 Variable Frequency Drive Assembly, 2 HP 480 V 3 Ø Input, NEMA 4

*NEMA 4 VFDs are special order items. Call for availablity.

NEMA4 Enclosures**

10080302 Enclosure, NEMA 4 for URV Controller

10081510 Enclosure, NEMA 4 for URV Sensor

**Enclosures only. Controller and/or Sensor must be purchased separately.

Related Accessories

10080142 Modem, Plug-In Chip

10080410 Cable Package, PC Connection 10080430 RS-485 Converter with 9 V Po 10080440 TCP/IP Communication Module 10080600 Telephone Sharing Device, 4-Port

10081500 Sensor, Adjustable Indoor, °F, URV

10081501 Sensor, Outdoor, URV

10081502 Sensor, Adjustable Indoor, °C, URV 90602450 Voltage Surge Supresser 90602460 Load Reactor 180 V / 4 A Output 90602470 Line Reactor 180 V / 4 A Input

URVRP Repeater, URV Communication

wer Supply

14 of 62

Page 21

FIGURE 6: Example Site Layout

Zone 1

Zone 2

Zone 3

Zone 2

Sensor

Zone 1

Sensor

Zone 3

Sensor

Variable

Frequency

Drive

North Wall

Outside

Sensor

Pump

ROBERTS GORDON

ULTRAVAC

Controller

SECTION 1: INTRODUCTION

NOTE: Conceptual drawing, not to scale. Venting not shown.

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

SECTION 2: SPECIFICATIONS

2.1 ROBERTS GORDON

ULTRAVAC™ Controller

2.1.1 Standard Enclosure

Construction: 16 gauge painted steel, hinged

door, removable knockouts provided.

Dimensions: W x H x D

(in): 14.7 x 17.7 x 3.5 (cm): 37.3 x 45.0 x 8.9

2.1.2 Electrical

Power Supply: 120 V (+/- 10%) 1 Ø, 60 Hz UL Standard: UL 916 / C22.2 No. 205-M1983

Universal Inputs:

Eight Universal Inputs

Thermistor 0-10 Vdc 4-20m A Resistance Dry contact

Analog Output:

One Analog Output 0-10 Vdc

Digital Inputs:

Digital Inputs: Timed, dry contact

Digital Outputs:

Eight Digital Output: Single Pole 3 A 120 Vac

Ports:

RS-485 Communications Bus RS-232 Direct Connect Bus RS-232 Modem Socket

2.2 ULTRAVAC™ BMS Link Controller

2.2.1 Standard Enclosure

Construction: 16 gauge painted steel, hinged

door, removable knockouts provided.

Dimensions: W x H x D

(in):14.7 x 17.7 x 3.5 (cm): 37.3 x 45.0 x 8.9

2.2.2 Electrical

Power Supply: 120V (+/-10%) 1 Ø, 60 Hz

Ports:

RS-485 Communications Bus Ethernet/IP

2.3 NEMA 4 Enclosure (P/N 10080302)

Description: NEMA 4 enclosu

re is sold separately as an option, for ULTRAVAC™ Controller and ULTRAVAC™ BMS

Link Controller. Standard enclosures are field mounted inside the NEMA 4 enclosure.

Construction: 14 gauge painted steel, hinged door

with 19" (48.3 cm) x (40.6 cm) 16" window.

Dimensions: W x H x D

(in): 24 x 24 x 9 (cm): 61.0 x 61.0 x 22.9

Protection Rating: NEMA 4, 12

2.4 Repeater

2.4.1 Standard Enclosure

Construction: Fabricated in accordance with UL

specifications from code gauge steel, NEMA 1.

Finish: Austin screw cover boxes standard

construction galvanized steel with ANSI 61 gray polyester powder coating.

Dimensions: W x H x D

(in): 12 x 12 x 4 (cm): 30.5 x 30.5 x 10.5

2.4.2 Electrical

Power Supply: 120 V (+/- 10%) 1 Ø, 60 Hz

Ports:

RS-485 Communications Bus RS-232 Direct Connect Bus

2.5 Temperature Sensors

Indoor Sensor

Dimensions: W x H x D

(in): 2.75 x 4.5 x 1.15

(cm): 7.0 x 11.4 x 2.9 Power: 32 V DC Operating Temperature Range:

32° to 158° F (0° to 70° C) Features: LCD temperature display, setpoint

adjustment, override button

Outdoor Sensor (P/N 10081501)

Dimensions: W x H x D

(in): 1.4 x 5.3 x 2

(cm): 3.6 x 13.5 x 5.1 Operating Temperature Range:

-40° to 221° F (-40° to 5° C)

16 of 62

Page 23

SECTION 2: SPECIFICATIONS

Enclosure: NEMA 4 gasketed aluminum LB

housing, ½" threaded connection

NEMA 4 Enclosure for Indoor Sensor (P/N 10081510)

Description: 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.

Dimensions: W x H x D

(in): 6.3 x 3.6 x 1.8 (cm): 16.0 x 9.1 x 4.6

Construction: Polycarbonate enclosure with clear

front cover, 4 screw cover closure. 16 gauge galvanized subpanel.

Protection Rating: NEMA 4, 4X

Flammability Rating: UL-94-5V

Volta ge Surge Suppressor 277 / 480 V

Construction: NEMA 2X Enclosure

Volts: 277 / 480 V Frequency: 50/60 Hz Wiring Size: #12 AWG Standard Wire

2.6 Line Reactor 480 V / 4 A Output

Construction: Fabricated in accordance with UL

specifications from code gauge steel, NEMA 1.

Dimensions: W x H x D

(in): 10 x 8 x 8 (cm): 25 x 20 x 20

Rated Current: 4 A

Volts: 480 V / 3 Ø

Line Reactor 480 V / 4 A Input

Construction: Fabricated in accordance with UL

specifications from code gauge steel, NEMA 1.

Dimensions: W x H x D

(in): 10 x 8 x 8 (cm): 25 x 20 x 20

Rated Current: 4 A

Volts: 480 V / 3 Ø

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Note: To e n s ure robust control signaling:

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.

FIGURE 7: ROBERTS GORDON

ULTRAVAC™ Controller Specifications

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Page 25

2.7 Variable Frequency Drive (VFD)

2.7.1 Enclosure

Standard Models

Construction: 14 gauge painted steel, mounting

panel included, left-hinged door, vented.

Dimensions: W x H x D

(in): 12 x 14.375 x 8 (cm): 30.5 x 36.5 x 20.3

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.

Construction: 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.

Dimensions: W x H x D

VFD75115N4 (in): 20 x 16 x 10

(cm): 50.8 x 40.6 x 25.4

VFD75230N4 (in): 14 x 12 x 8

(cm): 35.6 x 30.5 x 20.3

VFD20230N4 (in): 20 x 16 x 10

(cm): 50.8 x 40.6 x 25.4

VFD75460N4 (in): 16 x 14 x 10

(cm): 40.6 x 35.6 x 25.4

VFD20460N4 (in): 20 x 16 x 10

(cm): 50.8 x 40.6 x 25.4

Protection: NEMA 3R, 4, 12, 13

2.7.2 Electrical

Power Output: 230 V, 3 Ø, 0-60 Hz

(for 115 V and 230 V models) 480 V, 3 Ø, 0-60 Hz

(for 480 V models)

Speed Reference Follower: 0-10 Vdc or 4-20 mA

SECTION 2: SPECIFICATIONS

.75 HP, 230 V Drive (used with EP-203 pump)

(P/N VFD75230 or VFD75230N4) Power Input: 208/230 V, 1 Ø, 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 Ø, 50-60 Hz Input Voltage Tolerance: +/- 10% Amps: 16.6 A

2 HP, 230 V Drive (used with EP-303 pump)

(P/N VFD20230 or VFD20230N4) Power Input: 208/230 V, 1 Ø, 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 Ø, 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 Ø, 50-60 Hz Input Voltage Tolerance: +/- 10% Amps: 4.8/4.0 A

UL Standard: Industrial Controls Equipment Ambient Operating Temp.:

32° F - 104° F (0° C - 40° C)

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

FIGURE 8: Variable Frequency Drive Components (Factory pre-wiring shown)

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Page 27

SECTION 3: INSTALLATION

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Controller must be properly grounded to an electrical source.

Failure to follow these instructions can result in death or electrical shock.

SECTION 3: INSTALLATION

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 locations. See Page 18, Figure 7 and Page 20, Figure 8.

maximum ambient temperature does not exceed 104°F (40°C). Avoid installing the VFD in mezzanines, direct sunlight, or near external heat 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) without the use of a repeater. A repeater is available for wire length greater than 4000' (1219 m). See Page 36, Section 5.5.1. Wiring between the RS-485 converter to the controller should not be more than 400' (122 m) in length. See Page 31, Section 5.2.

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. If the VFD is more than 100' (150 m) from the pump a load reactor (P/N 90602460) must be used.

FIGURE 9: Controller Mounting

(Standard enclosure only, NEMA 4 enclosure mount- ing varies)

3.2 Positioning the ROBERTS GORDON ULTRAVAC™ Controller and Variable Frequency Drive

3.2.1 Choose a mounting location for the controller.

For serviceability, it is convenient to mount the controller and variable frequency drive at occupant level in the vicinity of the pump. The variable frequency drive should not be more than 50' (15 m) from the pump.

Do not mount controller or VFD outdoors. VFD must not be installed where subjected to adverse conditions such as: combustible, oily, or hazardous 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

16.25"

(41.3 cm)

13" (33 cm)

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

3.3 Cable Requirements:

As per individual building specification for class of cable to be used. Use copper conductors only.

3.3.1 ULTRAVAC™ Controller

Below is the recommended cable for the various connections for ULTRAVAC™ Controller:

• Line Power Supply The power connection should be made with cable, size 14 AWG.

• Eight Digital Output (Relays) The control connection for load of each individual relay should be made with cable, size 16 AWG.

• Digital Input The wiring connection for the pressure switch should be unshielded cable, size 18 AWG.

• Indoor Sensor Cable a) Shielded cable - Four twisted pairs of stranded,

24 AWG minimum or equivalent Madison Cable #08CFJ00004; Belden #9681.

b) Unshielded cable - Four twisted pairs of stranded,

24 AWG minimum or equivalent AMP#219538, #219513; Belden#1585, #1583A.

• Outdoor Sensor Cable Shielded cable - One twisted pair of 22 AWG minimum or equivalent Belden #8451, #1503A; General Cable #C2514.

• Communications between Multiple Controllers

(RS-485)

One twisted pairs of 18 AWG minimum or equiva- lent shield cable; Belden #1902, General Cable #C1670A.

VFD75230 or VFD75230N4 14 AWG VFD20230 or VFD20230N4 12 AWG VFD75460 or VFD75460N4 14 AWG VFD20460 or VFD20460N4 14 AWG

• VFD(0-10 Vdc) Speed Reference Control Wiring Shielded cable - one twisted pair of 22 AWG minimum or equivalent Belden #8451, #1503A; General Cable #C2514.

3.3.4 Repeater

Below is the recommended cable for the various connections for the repeater:

• Line Power Supply The power connection should be made with cable, size 18 AWG.

• RS485 Communications Multiple repeaters may be installed on the main loop and all communications cable should be made with shielded cable one twisted pair of 18-22 AWG.

3.4 Electrical Installation Requirements of ULTRAVAC™ Controller

DANGER

Electrical Shock Hazard

Disconnect electric before service.

3.3.2 ULTRAVAC™ BMS Link Controller

Below is the recommended cable for the various connections for ULTRAVAC™ BMS Link Controller:

• Line Power Supply The power connection should be made with cable, size 18 AWG.

• Communications between ULTRAVAC™ BMS

Link and Multiple Controllers

One twisted pair of 22 AWG minimum or equivalent shield cable; Belden #1902, General Cable #C1670A.

3.3.3 Variable Frequency Drive (VFD)

Below is the recommended cable for the various connections for VFD:

• Line Power Supply

Input Wire Size Requirements VFD P/N Wire Size

VFD75115 or VFD75115N4 12 AWG

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Controller must be properly grounded to an electrical source.

Failure to follow these instructions can result in death or electrical shock.

• ULTRAVAC™ Controller must be feeding from a local fused isolator for a total amperage not exceeding 25 A.

• Eight digital outputs for each individual relay must not exceed 3 A.

NOTES:

• 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.

Page 29

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 control enclosure. The 230 V drive power supply must be 230 V, 50-60 Hz, 1 Ø. The 120V drive power supply must be 120 V, 50-60 Hz, 1 Ø. The 480 drive power supply must be 480 V, 50-60 Hz, 3 Ø. See Page 19, Section 2.7 for additional details. The VFD on/off switching is done by an output on the relay board. The 0-10 V signal from the ULTRAVAC™ controller enclosure wired into VFD input relays 5 and 2 (see Page 26, Figure 13 through Page 28, Figure

14) will dictate the speed of the pump. The VFD output supply to the p

ump is 230 V 3 Ø 0-60 Hz for 115 V and 230 V models and is 480 V, 3 Ø, 0-60 Hz for 480 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 21, Sec- tion 3.2 for additional installation requirements.

SECTION 3: INSTALLATION

FIGURE 10: Variable Frequency Drive Mounting

(Standard enclosures only, NEMA 4 enclosure mounting varies by model)

14 .75" (37.5 cm)

10" (25.4 cm)

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

SEN SET O/R

Mounting

Hole

Plug-in LCD

Display

(grasp here

to unplug)

Mounting

Hole

Setback

Override

Button

Setpoint

Adjustment

Slide bar

North

Outside

Sensor

Sensor Module

facing down

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 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" (10.2 cm) x

2.13" (5.4 cm) junction box mounting.

FIGURE 11: Indoor Sensor Mounting

or control board damage. Refer to Page 26, Figure 13 and Page 28, Figure 14 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 mount the sensor on the north facing wall will result in artificially high temperature readings. If possible, locate the sensor high under an e

ve to prevent incorrect readings from direct sunlight

and damage due to the elements.

FIGURE 12: Outdoor Sensor Placement

3.7.1 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 24, Figure 11. 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

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 26, Figure 13 for external wiring diagrams. See Page 22, Section 3.4 for current load.

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Page 31

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Controller must be properly grounded to an electrical source.

Failure to follow these instructions can result in death or electrical shock.

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

FIGURE 13: ROBERTS GORDON

ULTRAVAC™ Central Controller External Wiring

26 of 62

Page 33

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

ROBERTS GORDON

ULTRAVAC™ Central Controller External Wiring (continued)

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

FIGURE 14: ROBERTS GORDON

ULTRAVAC™ Satellite Controller External Wiring

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Page 35

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

ROBERTS GORDON

ULTRAVAC™ Satellite Controller External Wiring (continued)

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Dip Switch #1

Set to ON

Installed

Modem Chip

Modem

Chip

1 2 3 4 5 6 7 8

Description Part Number

Modem Chip 10080142

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 30, Section 5.1. If only remote on-site control and system status

viewing is required, 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 15: Modem Location

shielded twisted pair communication wiring. See Page 31, Figure 16.

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 32, 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 electrical 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 35, Section

5.5.

Control Board of the

Central Controller

PWR

NONC CNONC CNONC CNONC C

24VAC

NONC C

NONC CNONC CNONC C

RS232 DIRECT

GINOUT G G G

+32

AUX POWER

UNIVERSAL INPUTS

+-4+-

Phone Cable Connection

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 30, Figure 15. 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 GOR-

DON

independent distributor for details.

REF

RS485 COMM

+- +-

REF

INOUT

METER INPUTS

RESET

ADDRESS

CPU

1+-2

OUT IN

OFF ON

1+-2

CDOH

499 OHM

10VDC

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.

Section 5.5

This allows multiple controllers to be

See Page 35,

controlled from a PC through a single communication package at the central controller.

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Page 37

5.2 RS-485 Converter for Central Controller

Description Part Number

RS-485 Converter Package with Power Supply

10080430

For remote on-site viewing of system status and settings of any controller, use the RS-485 converter to connect a single PC (9 pin serial port) to the RS485 terminals on the Central Controller. This will allow communication between one PC and any of the ULTRAVAC™ controllers on the network. For RS-485 converter wiring details see Page 31, Figure 16 and see Page 35, Section 5.5. Wiring between the RS- 485 converter to the controller should not be more than 400' (122 m) in length.

FIGURE 16: RS-485 PC Connection

SECTION 5: COMMUNICATIONS

For communication cable requirements see Page 22, Section 3.3.

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.

Section 5.5

This allows multiple controllers to be

See Page 35,

controlled from a PC through a single communication package at the central controller.

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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™ software 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 fou the ROBERTS GORDON 10081600NA).

For TCP/IP communication module wiring details,

Page 33, Figure 18

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.

Section 5.5

controlled from a PC through a single communication package at the central controller.

FIGURE 17: TCP/IP Communication Module Mounting

Software Manual (P/N

See Page 35,

This allows multiple controllers to be

nd in

see

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Page 39

FIGURE 18: TCP/IP Communication Module Wiring

Description Part Number

Kit, TCP/IP Communication 10080440K

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.

SECTION 5: COMMUNICATIONS

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 34, Figure 19), you may connect 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 18, Figure

7. This can be useful when a PC is in close proximity to any ROBERTS GORDON ler or while troubleshooting at the controller using a laptop PC. This type of connector should not be used if the phone cable is more than 50’ (15 m) in length.

ULTRAVAC™ Control-

Plug one end of the phone cable into the RS-232 direct port, plug the other end into the adapter shown in on Page 34, Figure 19. Plug the adapter into a 9- pin serial port on your computer.

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.

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Description Part Number

PC Connection Cable Package 10080410

FIGURE 19: 9 Pin Adapter for PC

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Page 41

SECTION 5: COMMUNICATIONS

Controller/Address

Number

Dip Switch Order (1,2,3,4,5,6,7,8)

Values (1=ON, 0=OFF)

11 110 10 00 0 12 00110000 13 10110000 14 01110000 15 11110 0 0 0 16 00001000 17 10 001000 18 01001000 19 11001000 20 00101000

Controller/Address

Number

Dip Switch Order (1,2,3,4,5,6,7,8)

Values (1=ON, 0=OFF)

1 (Central Controller) 10000000

2 01000000 3 11000000 4 00100000 5 10100000 6 01100000 7 11100000 800010000 910010000

10 0101000 0

5.5 Communications Between Multiple ROBERTS GORDON

If more than one ROBERTS GORDON ULTRAVAC™ Controller is installed in a building, the controllers’ RS-485 communications must be wired in series. See Page 35, Figure 20. Connect the RS-485 terminal on controller

terminal on controller

2 and so on in a daisy chain

1 to the RS-485

fashion. For communication cable requirements, See Page 22, Section 3.3

From a PC, by dialing into the modem on controller

or by connecting to controller

1 via RS-485

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 Controller. See Page 35, Figure 20 for dip switch settings. Contact Roberts-Gordon or your ROBERTS GORDON more than 20 controllers are connected.

converter or TCP/IP communication module, the

FIGURE 20: Communications Between Multiple Controllers

ULTRAVAC™ Controllers

independent distributor, if

ULTRAVAC™

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Description Part Number

Repeater URVRP

5.5.1 Repeater

If the RS-485 communications wire length is above 4000' (1219 m), a repeater must be used to extend the signal. The repeater can also be used to install in different methods:

• To extend communications beyond the standard 4000' (1219 m) limitation. See Page 36, Figure 21.

• To add parallel branches of ROBERTS GORDON

ULTRAVAC™ controller communications bus wiring.

See Page 37, Figure 22.

NOTE: The maximum number of ROBERTS GORDON

ULTRAVAC™ Controllers that can be installed is

242.

FIGURE 21: Repeater External Wiring

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Page 43

FIGURE 22: Repeater Communication Wiring Between Multiple Controllers

Description Part Number

Repeater URVRP

SECTION 5: COMMUNICATIONS

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

SECTION 6: ULTRAVAC™ BMS LINK CONTROLLER

6.1 ULTRAVAC™ BMS Link Controller Overview

Many customers have building management control systems that manage multiple mechanical systems in the building such as heating, ventilation, lighting, etc. ULTRAVAC™ Controls run a stand-alone proprietary program. With the addition of an ULTRAVAC™ BMS LINK Controller, the ULTRAVAC™ system can communicate with third party building management con-

trol systems using BACnet

or MODBUS® protocol.

Communication of data points from the ULTRAVAC™ system to the building controls system help allow building managers and end users to easily integrate ULTRAVAC™ into a single controls solution shared between multiple mechanical systems in the building. ULTRAVAC™ BMS Link has an option of communicating to the building control system via BACnet BACnet ULTRAVAC™ BMS Link architecture is detailed on Page 38, Figure 23.

FIGURE 23: Standard ULTRAVAC™ BMS Link Architecture

/IP,

MSTP or MODBUS® protocol. The standard

38 of 62

Page 45

FIGURE 24: ULTRAVAC™ BMS Link Controller Schematic

SECTION 6: ULTRAVAC™ BMS LINK CONTROLLER

6.2 ULTRAVAC™ BMS Link Controller Requirements

The purpose of the ULTRAVAC™ BMS Link Controller is to integrate with a third party building control system. This building control system is provided by others and must be capable of communicating via one of the ULTRAVAC™ BMS Link communication protocols.

For interface capability, one ULTRAVAC™ BMS Link Controller is needed for each ULTRAVAC™ network

of controllers. The ULTRAVAC™ BMS Link Controller is connected via communication wiring on the RS- 485 communication bus to the ULTRAVAC™ central controller.

The ULTRAVAC™ BMS Link Controller requires a 115 V, 20 A dedicated power circuit. The control board identification dip switch must be set on each ULTRAVAC™ controller. See Page 41, Figure 25. This enables ULTRAVAC™ Controls to communicate with a variety of controls.

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

6.3 Technical Data

• Power Supply: 120 VAC.

• Frequency: 50/ 60 Hz.

• Network Cable: Standard Ethernet Cables.

• Communication Ports: RS-485 Communication Bus

• Memory: Memory Card, SD 1GB.

6.4 ULTRAVAC™ BMS Link Controller Programming

Each ULTRAVAC™ BMS Link Controller is custom programmed before it is shipped. The custom program allows the controller to interface with the proper total number of ULTRAVAC™ Controls installed at the jobsite. The total number of ULTRAVAC™ Con- trols (including the central controller and all satellite controllers, but not including the ULTRAVAC™ BMS Link Controller) and the job name and location are submitted to Roberts-Gordon upon placing the order for the ULTRAVAC™ BMS Link Controller.

Each ULTRAVAC™ BMS Link Controller is supplied with a printed report listing all of the available points. The information in the report must be communicated to the controls manager for use in configuring the third party building controls software. This documen- tation is intended for the contractor to leave with the controls manager or end user upon commissioning of the ULTRAVAC™ system. Refer to the ULTRAVAC™ BMS Link Controller User Manual included on our ULTRAVAC™ Software CD for onsite programming instructions.

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Page 47

SECTION 6: ULTRAVAC™ BMS LINK CONTROLLER

Controller

Number

Dip Switch Order (1,2,3,4,5,6,7,8)

Values (1=ON, 0=OFF)

Address

Number

1 (Central

Controller)

01000000 2

2 11000000 3 3 00100000 4 4 10100000 5 5 01100000 6 6 11100000 7 7 00010000 8 8 10010000 9 9 01010000 10

10 11010000 11

Controller

Number

Dip Switch Order (1,2,3,4,5,6,7,8)

Values (1=ON, 0=OFF)

Address

Number

11 00110000 12 12 10110000 13 13 0 1110 00 0 1 4 14 1111 000 0 1 5 15 00001000 16 16 10001000 17 17 01001000 18 18 11001000 19 19 00101000 20 20 1010100 0 21

FIGURE 25: Communication Between ULTRAVAC™ BMS Link Controller and Multiple ULTRAVAC™ Controllers

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

DANGER

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.

225

P01

SECTION 7: VARIABLE FREQUENCY DRIVE PROGRAMMING

7. 1 V F D Pa r a m e t e r S e tt i n gs For Use With ROBERTS GORDON

The VFD parameters come with factory default set- tings. The following parameter settings must be changed for ROBERTS GORDON 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 no power to the 24 V power switch on the relay board of the ROBERTS GORDON ULTRAVAC™.

ULTRAVAC™

ULTRAVAC™.

7. 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 "P01", which indicates that the PROGRAM mode has been accessed at the beginning of the parameter menu (P01 is the first parameter).

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.

7. 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

NOTE: If the display flashes "Er", the password was incorrect, and the process to enter the password must be repeated.

7. 1 . 3 Use the arrow buttons to scroll to the desired parameter number. For new parameter settings, See Page 43, Section 7.2.

7. 1 . 4

Once the desired parameter number is found:

Press Mode to display present parameter setting (example setting 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.

7.1.5 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 exiting the PROGRAM mode, the password is not required to access the parameters. After two minutes,

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Page 49

the password must be entered in order to access the parameters again.

7. 2 A l t e r i n g VFD Parameters

Using the procedure described on Page 42, Section

7.1.1 through Section 7.1.5, alter the following parame-

ters:

SECTION 7: VARIABLE FREQUENCY DRIVE PROGRAMMING

Parameter Number

Parameter

Name

Factory Default

New

Setting

P01 Line Voltage 01 01 P03 Start Method 01 05 P05 Standard

Speed

01 (03) (0-10) Vdc

(04) (4-20) mA

Source

P44 Password 225 Any #

000-999

P45 Speed at

Minimum

Signal

0.0Hz Frequency Setting noted

on Page 44,

Section 8.1.2

P46 Speed at

Maximum

Signal

60.0Hz Frequency Setting noted

on Page 44,

Section 8.1.2

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Record Frequency Setting Here:

SECTION 8: COMMISSIONING THE CORAYVAC 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 commissioning procedure.

8.1 Setting The CORAYVAC

End Burner Vacuum

It is important to understand that the frequency that the VFD runs the motor at, determines the speed of the impeller in the pump. Variation of the impeller speed will increase or decrease vacuum in the system. The following procedure will help you set mini- mum and maximum VFD frequency settings to achieve proper vacuum in the system.

Step 8.1.1 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

ULTRAVAC™ 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 8.1.2 The pump should be running and the

burners 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 but- ton on the VFD until the number reads 60.0 Let the burners 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 45, Figure 26. 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 reduce the frequency until the end vent vacuum read- ing is between 2.5" - 3.0" wc. Make note of this frequency setting below. The frequency is found on the VFD’s LCD screen.

2.5" wc - 3.0" wc VFD Frequency Setting

SYSTEM

vacuum readings in the remaining branches are proper. If necessary, adjust the proper damper cou- pling to achieve an end vent v

acuum of 2.5" - 3.0" wc. See Page 45, Figure 26. 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 46, Fig- ure 27.

To avoid damage to the pump motor, do not adjust the frequency above 60.0 Hz. Verify that the end vent

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FIGURE 26: End Vent Vacuum

Manometer

Insert tubing

about 6" (15cm)

into end vent.

Combustion Chamber at end burner position

End Vent

Approximate reading after adjusting

VFD frequency setting and/or

damper couplings. ( 2.5"-3" wc)

SECTION 8: COMMISSIONING THE CORAYVAC® SYSTEM

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Damper Coupling

Damper

NOTE: Damper setting

will vary

Zone 1

Zone 2

Zone 3

Zone 1

End Vent

Zone 3

End Vent

Zone 2

End Vent

Zone 1

Damper

Coupling

Zone 2

Damper

Coupling

Zone 3

Damper

Coupling

Pump

Damper

FIGURE 27: Possible Damper Couplings’ Locations

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Step 8.1.3 After setting end vent vacuums between

Record Frequency Setting Here:

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

Step 8.1.4 Return to the PC and click the pump and

zones to "OFF".

Step 8.1.5 Using the procedure described on Page 42, Section 7.1.1 through Section 7.1.5, alter the fol-

lowing parameters on the VFD:Return to the PC and click the vacuum pump and three zones to "AUTO", then click exit.

SECTION 8: COMMISSIONING THE CORAYVAC® SYSTEM

Parameter Number

Parameter

Name

Factory Default

New

Setting

P01 Line Voltage 01 01 P03 Start Method 01 05 P05 Standard

Speed

01 (03) (0-10) Vdc

(04) (4-20) mA

Source

P44 Password 225 Any #

000-999

P45 Speed at

Minimum

Signal

0.0Hz Frequency Setting noted

on Page 44,

Section 8.1.2

P46 Speed at

Maximum

Signal

60.0Hz Frequency Setting noted

on Page 44,

Section 8.1.2

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

WARNING

Explosion Hazard

Turn off gas supply to heater before service.

Failure to follow these instructions can result in death, injury or property damage.

SECTION 9: TROUBLESHOOTING

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.

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FIGURE 28: Troubleshooting Flow Chart

SECTION 9: TROUBLESHOOTING

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Troubleshooting Flow Chart (continued)

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Troubleshooting Flow Chart (continued)

SECTION 9: TROUBLESHOOTING

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Troubleshooting Flow Chart (continued)

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FIGURE 29: Troubleshooting Flow Chart - Repeater

SECTION 9: TROUBLESHOOTING

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

FIGURE 30: Troubleshooting Flow Chart - BACnet

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SECTION 10: REPLACEMENT PARTS

DANGER

Electrical Shock 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.

Explosion Hazard

WARNING

Fire Hazard

Carbon Monoxide Hazard

55 of 62

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

1+-2

+-4+-

+- +-

REF

24VAC

NONC C

NONC CNONC CNONC CNONC C

NONC CNONC CNONC C

RS485 COMM

REF

1+-2

METER INPUTS

UNIVERSAL INPUTS

INOUT

ADDRESS

RESET

10VDC

499 OHM

OFF ON

OUT IN

GINOUT G G G

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

POWER

L1 L2 GRD

OUTPUT 1

L1 L2 GRD

OUTPUT 2

L1 L2 GRD

OUTPUT 3

L1 L2 GRD

OUTPUT 4

L1 L2 GRD

OUTPUT 5

L1 L2 GRD

OUTPUT 6

L1 L2 GRD

OUTPUT 7

L1 L2 GRD

OUTPUT 8

L1 L2 GRD

Plug-In Relays

Control

Board

Analog Output

Board

Relay Board

24 V

Power

1 A Fuse

Modem Chip

(only located on

Central Controller)

24 V

Power

Switch

Reset

Button

10.1 ROBERTS GORDON

ULTRAVAC™ Controller Replacement Parts

Caution: Use only genuine ROBERTS GORDON

Roberts-Gordon voids warranty.

FIGURE 31: ROBERTS GORDON

ULTRAVAC™ Controller Components Diagram

replacement parts. Use of parts not specified by

Description

Control Board (150 style) Relay Board Analog Output Board URV Eprom Chip (150 Style, current version) Plug-In Relay Modem Chip (located only on central controller) 1 A Fuse (Relay Board)

ROBERTS GORDON® ULTRAVAC™ Indoor Sensor °F (not shown) ROBERTS GORDON® ULTRAVAC™ Outdoor Sensor (not shown) ROBERTS GORDON® ULTRAVAC™ Indoor Sensor °C (not shown)

PC Connection Cable Package (not shown) RS-485 Converter Package (not shown) Kit, TCP/IP Communication Module (not shown) Telephone Sharing Device, 4 port

56 of 62

Part Number

10080102 10080200 10080141 10080122 10080212 10080142 10080211 10081500 10081501 10081502 10080410 10080430

10080440K

10080600

Page 63

SECTION 10: REPLACEMENT PARTS

M16/12.P

Description

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

10.2 Variable Frequency Drive Replacement Parts

Caution: Use only genuine ROBERTS GORDON

replacement parts. Use of parts not specified by

Roberts-Gordon voids warranty.

FIGURE 32: Variable Frequency Drive Components Diagram

Variable

Frequency Drive

(1 Ø input model shown)

L2/NL1 B-PE

B+

Part Number

07100

91321614 91321615 91321616

Power Input

Rotary

Dissconnect

Base Block

Relay 120 V

125611

13A

13B

13E2516

PEPEWVU

Input Fuse Holder

(1 Ø input model shown, 3 Ø input models have an additional input fuse holder and VFD power input.)

Description

Variable Frequency Drive, 1 HP, 120 V, 1 Ø Input (for use with EP-203) Variable Frequency Drive, 3/4 HP, 230 V, 1 Ø Inpu t (for use with EP-203) Variable Frequency Drive, 2 HP, 230 V, 1 Ø Input (for use with EP-303) Variable Frequency Drive, 1 HP, 480 V, 3 Ø Input (for use with EP-203) Variable Frequency Drive, 2 HP, 480 V, 3 Ø Input (for use with EP-303) Relay, 120 V Fuse 10 A (for.75 HP 230 V VFD, 1 HP 480 V VFD and 2 HP 480 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 Rotary Disconnect Handle (not shown) Rotary Disconnect Rod (not shown)

Fuse Holder Levers

M16/12.P

Grounding

Block

Part Number

10081201 10081202 10081203 10081204 10081205

90429100

91321410 91321425 91321300 91321400 91321550 91321551 91321552

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

10.3 ULTRAVAC™ BMS Link Controller Replacement Parts FIGURE 33: ULTRAVAC™ BMS Link Controller Components Diagram

Description

Communication Module Supervisor Board Module NetBurner Circuit Breaker 5A Transformer 100VA001 Memory Card, SD, 16 GB Fuse Micro, 125 V, 1/4A

Part Number

10081610 10081630 10081640 10081650 10081660 10081680 10081690

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10.4 Repeater Replacement Parts FIGURE 34: Repeater Components Diagram

SECTION 10: REPLACEMENT PARTS

Description

Repeater Circuit Breaker 5A Transformer Micro Fuse, 125 V, 1/4A

Part Number

10080445

10081650 10081661 10081690

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Controller must be properly grounded to an electrical source.

Failure to follow these instructions can result in death or electrical shock.

10.5 Replacement Parts Instructions

10.5.1 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 and turn on the 24 V power switch on the relay board. Press the reset button on the control board and close the doors.

10.5.2 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 control board and the 24 V power 1 A fuse.

10.5.3 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 scre 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.

10.5.4 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. Replace 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.

urn 120 V power to the relay board and turn on

Ret the 24 V power switch on the relay board. Press the reset button on the control board and close the doors.

10.5.5 Variable Frequency Drive (VFD)

To replace the Variable Frequency Drive, turn off all power to the 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.

Mark all wires connected to the VFD, noting the terminals 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 terminals. If possible, it may be easier to partially rewire 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.

10.5.6 Variable Frequency Drive 25 A or 10 A Fuse

To replace a fuse, turn off inpu

t 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

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Page 67

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 480 V VFD and 2 HP 480 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 120 V 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.

SECTION 10: REPLACEMENT PARTS

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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

SECTION 11: THE ROBERTS GORDON

ULTRAVAC™ LIMITED WARRANTY

Within 36 months from date of purchase by buyer or 42 months from date of shipment by Roberts-Gordon (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 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 for a period of 12 months from date of shipment from Roberts-Gordon or the remaining ROBERTS GORDON

Replacement Parts are warranted

System Control 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:

• Improper installation, operation or maintenance.

• Misuse, abuse, neglect, or modification of the ROBERTS GORDON

• Use of the ROBERTS GORDON

ULTRAVAC™ in any way.

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 GORDON ULTRAVAC™ as directed in the Installation, Operation and Service Manual.

• Relocation of the ROBERTS GORDON

ULTRAVAC™

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 material.

• Any defect in the ROBERTS GORDON

ULTRAVAC™ arising from a drawing, design, or specification sup- plied 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.

Yo u 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 control, contact your installing professional. Should you need Replacement Parts or have additional questions, call or write:

Roberts-Gordon

1250 William Street P. O . B o x 4 4 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 warranty lasts, so this limitation may not apply to you. There are no rights, warranties or conditions, expressed or implied, statutory or otherwise, other than those contained in this warranty.

Roberts-Gordon shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for

the ROBERTS GORDON

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.

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