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
© 2011 Roberts-Gordon LLC
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
© 2011
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
Page 10
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+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONCCNONCC
NONC CNONC CNONC C
RS485 COMM
REF
+-1+-2+-3+-
4
METER INPUTS
UNIVERSAL INPUTS
INOUT
ADDRESS
RESET
10VDC
499 OHM
OFF ON
OUT IN
GINOUT G G G
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1
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
5 of 62
Page 12
ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
M16/12.P
125611
13A
13B
13E2516
17
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+-
8
+- +-
REF
24VAC
L2
NONCC
NONCCNONCCNONCCNONC C
NONCCNONC CNONCC
RS485 COMM
REF
+-1+-2+-3+-
4
METER INPUTS
UNIVERSAL INPUTS
INOUT
ADDRESS
RESET
10VDC
499 OHM
OFF ON
OUT IN
GINOUT G GG
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1
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
RI
CDOH
ULTRAVAC™ Controller
with Modem Installed
Repeater (optional) Supplied w/24 VAC transformer inside NEMA 1 enclosure (P/N URVRP)
Inside View
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
L1 L2 GRD
L1 L2 GRD
L1 L2 GRD
L1 L2 GRD
L1 L2 GRD
L1 L2 GRD
L1 L2 GRD
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
REF
+32
+5
4
INOUT
RS485 COMM
METER INPUTS
AUX POWER
RESET
CDOH
RI
ADDRESS
CPU
+-1+-2+-4+-3+-5+-6+-7+-
OUT
499 OHM
IN
OFF
10VDC
ON
PWR
NONC CNONC CNONCCNONC C
L2
L1
24VAC
RS232 DIRECT
8
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+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONCCNONC C
NONC CNONC CNONCC
RS485 COMM
REF
+-1+-2+-3+-
4
METER INPUTS
UNIVERSAL INPUTS
INOUT
ADDRESS
RESET
10VDC
499 OHM
OFF ON
OUT IN
GINOUT GGG
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1
PWR
+-1+-2+-3+
METER INPUTS
RESET
499 OHM
RI
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+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONCCNONC C
NONC CNONC CNONCC
RS485 COMM
REF
+-1+-2+-3+-
4
METER INPUTS
UNIVERSAL INPUTS
INOUT
ADDRESS
RESET
10VDC
499 OHM
OFF ON
OUT IN
GINOUT GGG
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1
PWR
+-1+-2+-3+
METER INPUTS
RESET
499 OHM
RI
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
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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
®
or
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)
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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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Page 24
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
18 of 62
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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Page 34
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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Page 36
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
L2
L1
24VAC
NONC C
NONC CNONC CNONC C
8
RS232 DIRECT
7
+-
+-
6
GINOUT G G G
+32
+5
AUX POWER
UNIVERSAL INPUTS
5
+-
+-
3
+-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
4
INOUT
METER INPUTS
RESET
ADDRESS
CPU
1+-2
+-
OUT IN
OFF ON
+-
+-
1+-2
3
CDOH
RI
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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Page 38
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.
33 of 62
Page 40
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.
#
1
converter or TCP/IP communication module, the
FIGURE 20: Communications Between Multiple Controllers
®
ULTRAVAC™ Controllers
®
independent distributor, if
®
ULTRAVAC™
35 of 62
Page 42
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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Page 46
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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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.
00
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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Page 51
FIGURE 26: End Vent Vacuum
6
5
4
3
2
1
0
1
2
3
4
5
6
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
45 of 62
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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
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
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ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
+-
1+-2
+-4+-
3
+-
5
+-
6
+-
7
+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONC CNONC C
NONC CNONC CNONC C
RS485 COMM
REF
+-
1+-2
+-
3
+-
4
METER INPUTS
UNIVERSAL INPUTS
INOUT
ADDRESS
RESET
10VDC
499 OHM
OFF ON
OUT IN
GINOUT G G G
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1
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
17
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
w
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
60 of 62
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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