Roberts Gorden NEMA 4 User Manual

WARNING

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

Improper installation, adjustment, alteration, service or maintenance can result in death, injury or property damage. Read the Installation and Operation Manual thoroughly before installing or servicing this equipment.

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

UltraVac

™

Controls for

Modulating

CORAYVAC

Infrared Heating

Systems

Installation Manual

Quality in Any Language™

Roberts-Gordon LLC

1250 William Street P.O . B o x 4 4 Buffalo, New York 14240-0044 Telephone: 716.852.4400 Fax: 716.852.0854 Toll Free: 800.828.7450

www.rg-inc.com

P/N 10081601NA Rev F 10/08

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........................................................1

1.1 What is ROBERTS GORDON

1. 2 CO R AY V A C

Design Requirements............................. 1

1.3 General Requirements .................................................1

1.4 Check Installation Materials .........................................1

1.5 Carton Contents ...........................................................2

1.6 Safety ...........................................................................5

1.7 Example Site Layout.....................................................5

SECTION 2: Specifications ....................................................7

2.1 ROBERTS GORDON

2.2 Temperature Sensors...................................................7

2.3 Variable Frequency Drive (VFD) ..................................9

SECTION 3: Installation........................................................ 11

3.1 Preparation ................................................................ 11

3.2 Positioning the ROBERTS GORDON

Controller and Variable Frequency Drive ................... 11

3.3 Cable Requirements: ................................................. 12

3.4 Electrical Installation Requirements........................... 13

3.5 Pump Requirements .................................................. 13

3.6 Variable Frequency Drive Requirements ................... 13

3.7 Indoor Sensor Placement .......................................... 14

3.8 Outdoor Sensor Placement ....................................... 14

3.9 Outside Air Supply ..................................................... 14

SECTION 4: Typical External Diagrams .............................. 15

SECTION 5: Communications..............................................20

5.1 Dedicated Phone Line for Central Controller Modem 20

5.2 RS-485 Converter for Central Controller....................21

5.3 TCP/IP Communication Module ................................22

5.4 Direct Connect ........................................................... 24

5.5 Communications Between Multiple ROBERTS

GORDON

ULTRAVAC™ Controllers ........................25

SECTION 6: Variable Frequency Drive Programming........27

6.1 VFD Parameter Settings For Use With ROBERTS

GORDON

ULTRAVAC™ ..........................................27

6.2 Altering VFD Parameters........................................... 28

SECTION 7: Commissioning The CORAYVAC® System ....29

7.1 Setting The CORAYVAC

SECTION 8: Replacement Parts .......................................... 33

8.1 ROBERTS GORDON® ULTRAVAC™ Controller

Replacement Parts ....................................................33

8.2 Variable Frequency Drive Replacement Parts ........... 34

8.3 Replacement Parts Instructions.................................35

SECTION 9: Troubleshooting............................................... 37

SECTION 10: The ROBERTS GORDON

LIMITED Warranty.......................................... 41

ULTRAVAC™?............1

ULTRAVAC™ Controller ......... 7

ULTRAVAC™

End Burner Vacuum ..........29

ULTRAVAC™

Printed in U.S.A.

TABLE OF FIGURES

Figure 1: Example Site Layout .................................................. 6

Figure 2: ROBERTS GORDON

Specifications ............................................................8

Figure 3: Variable Frequency Drive Components

(Factory pre-wiring shown) ...................................... 10

Figure 4: Controller Mounting.................................................. 11

Figure 5: Indoor Sensor Cable Detail ......................................12

Figure 6: Outdoor Sensor, VFD (0-10 V) Signal, RS-485

Communications Cable and

Pressure Switch Cable Detail................................... 12

Figure 7: Variable Frequency Drive Mounting.........................13

Figure 8: Indoor Sensor Mounting .......................................... 14

Figure 9: Outdoor Sensor Placement ..................................... 14

Figure 10: Central Controller Communication Equalization

Wiring.....................................................................15

Figure 11: ROBERTS GORDON

Controller External Wiring ...................................... 16

Figure 12: ROBERTS GORDON® ULTRAVAC™ Satellite

Controller External Wiring ...................................... 18

Figure 13: Modem Location ....................................................20

Figure 14: RS-485 PC Connection..........................................21

Figure 15: TCP/IP Communication Module Mounting............. 22

Figure 16: TCP/IP Communication Module Wiring.................. 23

Figure 17: 9 Pin Adapter for PC ..............................................24

Figure 18: Communications Between Multiple Controllers......25

Figure 19: Repeater Wiring..................................................... 26

Figure 20: End Vent Vacuum ..................................................30

Figure 21: Possible Damper Couplings’ Locations..................31

Figure 22: ROBERTS GORDON

Components Diagram ............................................33

Figure 23: Variable Frequency Drive Components Diagram ... 34

Figure 24: Troubleshooting Flow Chart ................................... 37

ULTRAVAC™ Controller

ULTRAVAC™ Central

ULTRAVAC™ Controller

SECTION 1: INTRODUCTION

1.1 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.

System status and settings are viewed and altered from a PC (not supplied) running ROBERTS GORDON

1.2 CORAYVAC

CORAYVAC

burners shall be CRV B-6, B-8, B-9,

ULTRAVAC™ Software.

Design Requirements

B-10 or B-12 burners.

CORAYVAC

systems designed shall have minimum radiant pipe length and 1.5 - 2.0 feet per flow unit of tailpipe length.

-OR-

CORAYVAC

systems designed shall have recommended radiant pipe length and 1.2 - 1.5 feet per flow unit of tailpipe length. See the CORAYVAC Design Manual (P/N 127500NA) for minimum and recommended radiant pipe length.

SECTION 1: INTRODUCTION

1.4 Check Installation Materials

1.4.1 Switchable Loads

The controller relays are rated for switching loads no greater than 3 A. The total added current load for all 8 relays must not exceed 25 A.

1.4.2 Control Wiring

Shielded cable (four twisted pairs of stranded 24 AWG minimum wire) is required for use with indoor sensors.

Shielded cable (one twisted pair of stranded 22 AWG minimum wire) is required for the outdoor air sensor, VFD signal wiring, pressure switch and wiring from controller

1 to the PC.

Shielded cable (one twisted triad of stranded 22 AWG minimum wire) is required for RS-485 communications between controllers.

1.4.3 Control Board and Sensor Power

The power supply for all sensors is from the “+32 V” terminal to be found on the board of the controller. Power for the control board is 24 V provided by the relay board.

1.4.4 Programming Details

Every controller is pre-programmed for one pump and up to three heating zones. Use a site layout drawing to identify the heating zones.

1.3 General Requirements

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 warranty. See Page 41, Section 10.

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, 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.

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

NONCCNONC CNONC CNONC C

NONCCNONC 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

ULTRAVAC™ Controller

ULTRAVAC™ Installation Manual (P/N 10081601NA)

Inside View

RS232

RS485

RS485 INRS485OUT

+5V

-+-+

PROGRAM

RUN

RS232

RS485

RS485 OUTREF

- +- +

PROGRAM

RUN

RS485 OUT

- +- +

RS485 OUTRS485 OUT

- +- +

RS485 OUT

1/4A

1/4A 1/4A

ULTRAVAC™ Software (P/N 10080421) ULTRAVAC™ Software Manual (P/N 10081600NA) ULTRAVAC™ Installation Manual (P/N 10081601NA)

TCP/IP (LAN) Communication Module (w/ 7’ phone wire) (P/N 10080440)

Comms Equalization Cable (P/N 10080450)

Outdoor Sensor (P/N 10081501)

PC Connection Cable Package (P/N 10080410)

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

NONCCNONC CNONC CNONC C

NONCCNONC 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

ULTRAVAC™ Controller

with Modem Installed

Repeater (optional) Supplied w/24 VAC transformer inside NEMA 1 enclosure (P/N 10080445)

Inside View

1.5 Carton Contents

URVSC: ULTRAVAC™ Satellite Controller

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

URVCCM: ULTRAVAC™ Central Controller with Modem

ULTRAVAC™ Software (P/N 10080421) ULTRAVAC™ Software Manual (P/N 10081600NA) ULTRAVAC™ Installation Manual (P/N 10081601NA)

Comms Equalization Cable (P/N 10080450)

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

NONCC

NONCCNONC CNONC CNONC C

NONCCNONC 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

RS232

RS485

RS485 OUTREF

- +- +

PROGRAM

RUN

RS485 OUT

- +- +

RS485 OUTRS485 OUT

- +- +

RS485 OUT

1/4A

1/4A 1/4A

Repeater (optional) Supplied w/24 VAC transformer inside NEMA 1 enclosure (P/N 10080445)

SECTION 1: INTRODUCTION

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

RS-485 Converter Package (P/N 10080430)

Power Supply

ULTRAVAC™ Software (P/N 10080421) ULTRAVAC™ Software Manual (P/N 10081600NA) ULTRAVAC™ Installation Manual (P/N 10081601NA)

Comms Equalization Cable (P/N 10080450)

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

NONCC

NONCCNONC CNONC CNONC C

NONCCNONC 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

RS232

RS485

RS485 OUTREF

- +- +

PROGRAM

RUN

RS485 OUT

- +- +

RS485 OUTRS485 OUT

- +- +

RS485 OUT

1/4A

1/4A 1/4A

Repeater (optional) Supplied w/24 VAC transformer inside NEMA 1 enclosure (P/N 10080445)

URVCCR: ULTRAVAC™ Central Controller with RS-485 Converter

1. 6 Sa fe t y

Your Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings in these sections.

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

Installation, service and annual inspection of heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment.

Read this manual carefully before installation, operation, or service of this equipment.

For optimum heater performance and safe heating conditions, inspect and maintain heater(s) before every heating season and as necessary. Also, know and maintain heater clearances to combustibles, see heater Installation, Operation and Service Manual for further details. If you require additional manuals, contact your ROBERTS GORDON

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

1.6.1 Manpower Requirements

SECTION 1: INTRODUCTION

To prevent personal injury and damage to the controls, two persons will be required for installation.

1.7 Example Site Layout

Page 6, Figure 1 is an example layout for a building where ROBERTS GORDON

ULTRAVAC™ will be used to control the infrared heating systems shown. The layout consists of three zones of ROBERTS

GORDON

ULTRAVAC™ .

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

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

FIGURE 1: Example Site Layout

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

SECTION 2: SPECIFICATIONS

2.1 ROBERTS GORDON

ULTRAVAC™ Controller

2.1.1 Enclosure

Standard Enclosure

Construction: 16 gauge painted steel, hinged

door, removable knockouts provided.

Dimensions: 14.7" w x 17.7" h x 3.5" d

NEMA 4 Enclosure (P/N 10080302)

Description: NEMA 4 enclosure is sold separately

as an option. ULTRAVAC™ Controller in standard enclosure is field mounted inside the NEMA 4 enclosure.

Construction: 14 gauge painted steel, hinged door

with 19" x 16" window.

Dimensions: 24" w x 24" h x 9" d Protection

Rating: NEMA 4/12

2.1.2 Electrical - Control Board

Power Supply: 24 V 60 Hz

(from relay board)

Analog Inputs: Sensor (thermistor), BMS enable

(dry contact)

Relay Outputs: 24 Vac Analog Outputs: 0-10 Vdc

SECTION 2: SPECIFICATIONS

Wiring: Shielded Cable, one twisted pair,

22 AWG min.

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: 6.3" x 3.6" x 1.8"

Construction: Polycarbonate enclosure with clear

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

Protection Rating: NEMA 4/4x/12/13

Flammability Rating: UL-94-5V

Digital Inputs: Timed, dry contact

Network Ports: RS-485, RS-232 UL Standard: UL 916 / C22.2 No. 205-M1983

2.1.3 Electrical - Relay Board

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

Inputs: 24V AC

Relay Outputs: Single Pole 3 A 120 Vac UL Standard: UL 916 / C22.2 No. 205-M1983

2.2 Temperature Sensors

Indoor Sensor

Dimensions: 2.75" w x 4.5" h x 1.15" d

Power: 32 V DC Features: LCD temperature display, setpoint

adjustment, override button

Wiring: Shielded Cable, four twisted pairs,

24 AWG min.

Outdoor Sensor (P/N 10081501)

Dimensions: 1.4" w x 5.3" h x 2" d Enclosure: NEMA 4 gasketed aluminum LB

housing, ½" threaded connection

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 GGG

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

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

+- +-

REF

24VAC

NONC C

NONC CNONC CNONC CNONC C

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

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

120 Vac Outputs

Plug-In

Relays

24 V

Power

Switch

Control Board

Transformer

Meter Inputs

Analog Output

Board

Modem

Phone Port

Analog Inputs

Eprom

Chip

Selector

Switch

Reset

Button

RS 485

Terminals

RS 232

Direct Connect

Por t

24 V Board

Power Input

24 V Control Board

Power Supply

Relay Board

24 V

Power

1 A Fuse

Sensor

Power

120 Vac Power Input

Modem Chip

(optional - only located

on Controller #1)

24 V

Outputs

24 V Outputs

24 V Input

Connections

Controller Enclosure

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

Line Voltage 120 V wiring

Relay Board

Low Voltage 24 V wiring

Control Board

5 V TCP/IP

Module

Power

Analog

Outputs

Note:

To ensure 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 2: ROBERTS GORDON

ULTRAVAC™ Controller Specifications

2.3 Variable Frequency Drive (VFD)

2.3.1 Enclosure

Standard Models

Construction: 14 gauge painted steel, mounting

panel included, left-hinged door, vented.

Dimensions: 12" w x 14 3/8" h x 8" d Protection: UL 50 Type 1, NEMA Type 1

NEMA 4 Models

Description: Drive assembly and components fully

factory assembled inside NEMA 4 enclosure. Enclosure dimensions and construction vary by model.

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: VFD75115N4 20" x 16" x 10"

VFD75230N4 14" x 12" x 8" VFD20230N4 20" x 16" x 10" VFD75460N4 16" x 14" x 10" VFD20460N4 20" x 16" x 10"

Protection: NEMA 3R/4/12/13

2.3.2 Electrical

Power Output: 230 V, 3 Ø, 0-60 Hz

(for 115 V and 230 V models) 460 V, 3 Ø, 0-60 Hz

(for 460 V models)

Speed Reference Follower: 0-10 Vdc

UL Standard: Industrial Controls Equipment

SECTION 2: SPECIFICATIONS

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

(P/N VFD20230 or VFD20230N4) Power Input: 208/240 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

Ambient Operating Temp.: 32°F - 104°F (0°C-40°C)

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

(P/N VFD75230 or VFD75230N4) Power Input: 208/240 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

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

M16/12.PM16/12.P

Power Input

125611

13A

13B

13E2516

PEPEWVU

L2/NL1 B-PE

B+

Variable

Frequency Drive

(1 Ø input model shown)

Terminal Inputs

230 V 3 Ø or

460 V 3 Ø outputs

Grounding

Block

120 V signal from relay board

output #8

Relay 120 V

Rotary

Disconnect

Input Fuse Holder

(1 Ø input model shown, 3 Ø input models have an

additional input fuse holder and VFD power input.)

VFD Enclosure

(Standard Enclosure Shown)

FIGURE 3: Variable Frequency Drive Components (Factory pre-wiring shown)

SECTION 3: INSTALLATION

WARNING

Severe Injury Hazard

Mount controls with materials with a minimum working load of 75 lbs (33 kg).

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

13" (33 cm)

16.25"

(41.3 cm)

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

sources because these locations usually have unpredictable temperature rises.

Note that the maximum distance from the controller to any sensor is 300' (120 m). For longer distances, larger gauge wire may be needed (Consult your local distributor). For multiple controllers, maximum length of communication wire from the first controller to the last is 4000' (1219 m).

3.2.2 Position the controller and VFD at occupant level for ease of service. To avoid electrical interferences with communications bus, do not mount VFD directly next to controller. Allow 2' (.6 m) minimum between controller and VFD.

FIGURE 4: Controller Mounting

(Standard enclosure only, NEMA 4 enclosure mounting varies)

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 Variable Frequency Drive component names and locations. See Page 8, Figure 2 and Page 10, Figure 3.

3.2 Positioning the ROBERTS GORDON

ULTRAVAC™ Controller and Variable Frequency Drive

3.2.1 Choose a mounting location for the controller.

Generally near the pump, a dedicated phone connection (optional) and the variable frequency drive. For serviceability, it is convenient to mount the controller and variable frequency drive at occupant level in the vicinity of the pump.

Do not mount controller or VFD outdoors. VFD must not be installed where subjected to adverse conditions such as: combustible, oily, or 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 maximum ambient temperature does not exceed 104°F (40°C). Avoid installing the VFD in mezzanines, direct sunlight, or near external heat

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Shield Wire

Foil Shield

Insulation

24 AWG

Minimum

Insulation

Foil Shield

22 AWG Minimum

conductor

22 AWG Minimum

conductor

Uninsulated Shield Wire

3.3 Cable Requirements:

3.3.1 Line Power Supply:

As per individual building specification for class of cable to be used. Use copper conductors only. To size the cable, use the amperages of the burners given on Page 13, Section 3.4.1, for each individual zone.

3.3.2 Control Wiring

All control wiring (sensor, VFD control (0 - 10 Vdc), pressure switch and RS-485 communication wiring) may be plenum or non-plenum rated depending on installation requirements, consult the National Electric Code

(NEC). Regardless of the code or its interpretation, the local Fire Marshall makes the final decision, contact the local Fire Marshall if you have questions.

Do not run control (low voltage) wiring together with power (line voltage) wiring in the same conduit. Electrical signal interference or induced current could occur and cause communication problems.

VFD (0-10 V) control wiring and all RS-485 communication wiring must be shielded. Shielded wire

provides noise and interference isolation and reduces the possibility of communication problems.

Pressure switch wiring is not required to be shielded. If electrical interference from machinery or

other sources cannot be avoided, shielded wire must be used. All control cable specification diagrams shown will refer to shielded cable.

3.3.3 Indoor Sensor Cable:

FIGURE 5: Indoor Sensor Cable Detail

3.3.4 Outdoor Air Sensor VFD (0-10 V) signal, Pressure Switch Cable and PC RS-485 converter wiring:

Shielded cable (one twisted pair of 22 AWG min. wire) is required for the outdoor air sensor, VFD signal wiring, pressure switch wiring and RS-485 converter wiring between controller #1 and PC (RS-485 converter wiring to PC is only used if controller is using an RS-485 Converter Communication Package). See Page 12, Figure 6 for an illustration of the cable specification to be used. Shielded Cable: Belden #8451, #1503A, #8760; General Cable #C2514 or equivalent.

FIGURE 6: Outdoor Sensor, VFD (0-10 V) Signal, RS-485 Communications Cable and Pressure Switch Cable Detail

Shielded cable (four twisted pairs of stranded 24 AWG min. wire) is required for use with indoor sensors. See Page 12, Figure 5 for an illustration of the shielded cable specification to be used. See Page 12, Section 3.3.2 to see if unshielded cable may be used.

Unshielded Cable:

AMP #57248, #219538, #219513; Belden # 1585A, #1583A; General Cable #C6015 or equivalent. Shielded Cable: Madison Cable #08CFJ10001, #08CFJ00004; Belden #9681; General Cable #2131673, #C1676 or equivalent.

3.3.5 RS-485 Communication Wire Between Controllers:

Shielded cable (one twisted triad or two twisted pairs of 22 AWG min. wire) is required for RS-485 communications between controllers. See Page 12, Figure 6 for an illustration of the shielded cable specification to be used. Shielded Cable: Belden #1902, #8770 General Cable #C1670 or equivalent.

SECTION 3: INSTALLATION

DANGER

Electrical Shock Hazard

Disconnect electrical before servicing.

This appliance must be connected to a properly grounded electrical source.

Replace cover before operating.

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

10" (25.4 cm)

14 .75" (37.5 cm)

3.4 Electrical Installation Requirements

3.4.1 The enclosure must be supplied from a local

fused isolator rated for a total amperage not exceeding 25 A.

The method for calculating the current loading is as follows:

CORAYVAC

Burner 0.3 A/burner

The 0-10 V signal from the ULTRAVAC™ controller enclosure wired into VFD input relays 5 and 2 (see Page 16, Figure 11 through Page 18, Figure 12) will dictate the speed of the pump. The VFD output supply to the pump is 230 V 3 Ø 0-60 Hz for 115 V and 230 V models and is 460 V, 3 Ø, 0-60 Hz for 460 V models. The frequency of the output supply signal to the pump will be varied based on the 0-10 V signal from the control enclosure. See Page 11, Section 3.2 for additional installation requirements.

FIGURE 7: Variable Frequency Drive Mounting

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

Multiply the current for the individual burners above by the number of burners supplied from the enclosure to give the total current required.

The full load amps for the optional outside air blower (P/N 90707500) are: 1.6 A

The total added current load for each individual relay must not exceed 3 A.

The total added current load for all 8 relays must not exceed 25 A.

3.5 Pump Requirements

The pump is powered directly from the Variable Frequency Drive (VFD). The VFD will be energized via an output from the relay board switched through a designated relay.

3.6 Variable Frequency Drive Requirements

The VFD must be powered separately from the 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 460 drive power supply must be 460 V, 50-60 Hz, 3 Ø. See Page 9, Section 2.3 for additional details. The VFD on/off switching is done by an output on the relay board.

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 suitable for direct surface mounting or 4" x 2 1/8" junction box mounting.

FIGURE 8: Indoor Sensor Mounting

Figure 12 for wiring details.

3.8 Outdoor Sensor Placement

The outdoor sensor measures air temperature outside 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 eve to prevent incorrect readings from direct sunlight and damage due to the elements.

FIGURE 9: 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 14, Figure 8. After removing the plug-in LCD display from its socket, secure the sensor to the wall or junction box using the screws provided. Replace the plug-in LCD display and secure the cover with the two 1/16" allen screws.

Wiring from 32 V terminals on the controller to sensor power terminals "+" and "-" is polarity sensitive. Reversing polarity may cause sensor damage. Refer to Page 16, Figure 11 and Page 18,

Mount the outside sensor with the sensor module facing down to prevent accumulation of dirt or water.

3.9 Outside Air Supply

If an outside air blower is to be used, See Page 16, Figure 11 for external wiring diagrams. See Page 13, Section 3.4.1 for current load.

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

+-4+-

+- +-

REF

RS485 COMM

REF

METER INPUTS

UNIVERSAL INPUTS

INOUT

ADDRESS

RESET

10VDC

499 OHM

OFF ON

OUT IN

GINOUT GGG

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

Communications Circuit Equalizer Wiring (included, must be field installed)

RED

BLACK

RED

BLACK

120 ohm resistor (included w/ P/N 100800450)

Shrinkwrap

All ULTRAVAC™ Central Controllers are shipped with a communication equalization cable (P/N 10080450). The cable is supplied to equalize and balance the circuitry of the communications on the controller network that may be experiencing noise or transient voltage levels. Connect the communication equalization cable as shown below to the first or the last controller on the data bus.

This connector will plug into the right set of RS-485 +/- terminals on this board as shown.

Description Part Number

Comms Equalization Cable 10080450

FIGURE 10: Central Controller Communication Equalization Wiring

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

REF

24VAC

RS485 COMM

REF

METER INPUTS

UNIVERSAL INPUTS

INOUT

ADDRESS

RESET

10VDC

499 OHM

OFF

OUT

GINOUT

GGG

+32

AUX POWER

RS232 DIRECT

RICDOH

CPU

L1 PWR

Separate line and low voltage circuits. Do not run line voltage wiring through bottom section of enclosure that houses the control board. Do not run low voltage wiring through top section of enclosure that houses the relay board. Do not run line and low voltage wiring in the same conduit.

NOTE 1: This diagram applies to the Central Controller (controller #1) only. For all Satellite Controllers see Satellite Controller External Wiring Diagram. Central Controller (controller #1) requires outdoor sensor wiring and either modem, RS-485 converter wiring, or TCP/IP module wiring.

NOTE 2: Twist shield wires for both RS-485 communication cables together and ground at central panel only. On controller #1 only, connect these twisted shield wires to ground. For VFD 0-10 V signal wiring, connect shield wire to ground at the controller only.

NOTE 3: 120 V 1 Ø 50-60 Hz supply for 120 V VFD model. 230V 1 Ø 50-60 Hz supply for 230 V VFD model. 460 V 3 Ø 50-60 Hz supply for 460 V

VFD model. See VFD rating plate for required input. Repetitive cycling of a disconnect or input contactor

(more than once every two minutes) may cause damage to the drive.

NOTE 4: Zone 3 Sensor(not shown) wiring is as follows: SEN output to analog input 3; SET output to analog input 6; O/R output to meter input 3; +/- outputs to +32 V/GND inputs.

NOTE 5: Internal pre-wiring not shown.

NOTE 6: Wiring from 32 V terminals on the controller to sensor power terminals "+" and "-" is polarity sensitive.

NOTE 7: All three power output wires from terminals U, V, and W to the pump motor must be kept tightly bundled and run in a separate conduit away from all other power and control

wiring.

Outdoor

Sensor

BMS Enable

(optional)

NC C NO

To Satellite Controller

RS-485

(see NOTE 2)

Zone 1 Sensor

(see NOTE 6)

120 V

1 Ø

60 Hz

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

Pressure Switch (Pump)

Phone Line

for Modem

(optional)

(see NOTE 1)

To RS-485 Converter at PC (optional) (see NOTE 1 & 2)

Pressure Switch (Optional Outside Air Blower)

Zone 2 Sensor

(see NOTE 6)

O/RSET

SEN

O/RSET

SEN

Electrical wiring connections indicated by a dot;

Ground Shield (one end only) indicated by;

(See

NOTE 2)

Continued

On Next

Page

+-1+-2+-3+-

NC C NO

FIGURE 11: ROBERTS GORDON

ULTRAVAC™ Central Controller External Wiring

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

for 115 V and

230 V input

VFD models.

VFD Power

Supply

(1 Ø input

VFD model shown,

see NOTE 3)

L1L2

Pump

VFD Assembly

( 1 Ø input

VFD model shown)

L1L2

230 V

3 Ø

0-60 Hz

Terminal 5

Terminal 2

L1L2

Zone 3

Burners

L1L2

Outside Air

Blower

(optional)

Zone 2

Burners

Zone 1

Burners

T2T

Continued

From

To Terminals

13 and 14

Motor Power Supply

(see NOTE 7)

460 V

3 Ø

0-60 Hz

for 460 V

input VFD

models.

M16/12.PM16/12.P

125611

13A

13B

13E2516

PEPEWVU

L2/NL1 B-PE

B+

ROBERTS GORDON

ULTRAVAC™ Central Controller External Wiring (continued)

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

ADDRESS

RESET

10VDC

499 OHM

OFF

OUT

RICDOH

CPU

BMS Enable

(optional)

NC C NO

To Satellite Controller

RS-485

(See NOTE 2)

120 V

1 Ø

60 Hz

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

Pressure Switch (Pump)

Join Shields - Do Not Ground

From previous controller RS-485 (See NOTE 2)

Pressure Switch (Optional Outside Air Blower)

Zone 1

Sensor

(see NOTE 6)

Zone 2 Sensor

(see NOTE 6)

O/RSETSEN O/RSETSEN

Electrical wiring connections indicated by a dot;

(See NOTE 2)

Continued

On Next

Page

NOTE 1: This diagram applies to the Satellite Controller only. The Satellite Controller does not require modem, RS-485 converter wiring to the PC, TCP/IP module wiring, or outdoor sensor wiring. For Central Controller see Central Controller External Wiring Diagram.

NOTE 3: 120 V 1 Ø 50-60 Hz supply for 120 V VFD model. 230V 1 Ø 50-60 Hz supply for 230 V VFD model. 460 V

3 Ø 50-60 Hz

supply for 460 V VFD model. See VFD rating plate for required input. Repetitive cycling of a disconnect or input contactor (more

than once every two minutes) may cause damage to the drive.

NOTE 4: Zone 3 Sensor(not shown) wiring is as follows: SEN output to analog input 3; SET output to analog input 6; O/R output to meter input 3; +/- outputs to +32 V/GND inputs.

NOTE 5: Internal pre-wiring not shown.

NOTE 6: Wiring from 32 V terminals on the controller to sensor power terminals "+" and "-" is polarity sensitive.

NOTE 7: All three power output wires from terminals U, V, and W to the pump motor must be kept tightly bundled and run in a

separate condu

it away from all other power and control wiring.

24VAC

L2 L1

PWR

NC C NO

+- +-

REF

RS485 COMM

REF

METER INPUTS

INOUT

GINOUT G G

+32

AUX POWER

RS232 DIRECT

UNIVERSAL INPUTS

Ground Shield (one end only) indicated by;

FIGURE 12: ROBERTS GORDON

ULTRAVAC™ Satellite Controller External Wiring

SECTION 4: TYPICAL EXTERNAL DIAGRAMS

L1L2

Zone 3

Burners

L1L2

Zone 2

Burners

Zone 1

Burners

To Terminals

13 and 14

T2T

Continued

From

Motor Power Supply

(See NOTE 7)

Pump

230 V

3 Ø

0-60 Hz

for 115 V and

230 V input

VFD models.

460 V

3 Ø

0-60 Hz

for 460 V

input VFD

models.

Outside Air

Blower

(optional)

VFD Power

Supply

(1 Ø input

VFD model shown,

see NOTE 3)

VFD Assembly

( 1 Ø input

VFD model shown)

Terminal 5

Terminal 2

M16/12.PM16/12.P

125611

13A

13B

13E2516

PEPEWVU

L2/NL1 B-PE

B+

ROBERTS GORDON

ULTRAVAC™ Satellite Controller External Wiring (continued)

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Control Board of the

Central Controller

Phone Cable Connection

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

GINOUT G G G

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

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 RS485 converter, or a TCP/IP communications module.

For remote on-site and off-site control and system status viewing the central controller (controller

1) is

fitted with a modem chip. See Page 20, Section 5.1. If only remote on-site control and system status

viewing, two controller communications interface devices are available: an RS-485 converter or a

TCP/IP communication module.

An RS-485 converter is installed at a single PC, this PC can interface with any controller on the network of ULTRAVAC™ controllers. The RS-485 converter at the PC is wired directly to controller #1 using

FIGURE 13: Modem Location

shielded twisted pair communication wiring. See Page 21, Figure 14.

To interface with ULTRAVAC™ controllers through a Local Area Network (LAN), a TCP/IP Communication module is installed at controller #1. Controller #1 is wired to the LAN by an Ethernet cable. See Page 22, Section 5.3. Any computer on the LAN that has ULTRAVAC™ software installed can communicate with the controllers. Appropriate precautions must be taken to protect the Ethernet wiring from any possible 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 25, Section

5.5.

5.1

Dedicated Phone Line for Central Controller

Modem

The Central Controller is fitted with a modem chip. To use the modem, the controller must have a phone line for modem communications. Install a phone line near the location of the Central Controller. The phone cable is plugged into the phone connection in the corner of the control board. See Page 20, Figure 13. If the modem option is not used for everyday communication to the controller(s), it can still be plugged into a phone line for troubleshooting or programming assistance. Contact your local Roberts-Gordon independent distributor for details.

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 25,

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

5.2 RS-485 Converter for Central Controller

Description Part Number

RS-485 Converter Package with Power Supply

10080430

SECTION 5: COMMUNICATIONS

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 21, Figure 14 and

see Page 25, Section 5.5

FIGURE 14: RS-485 PC Connection

To Controller #2

10VDC

UNIVERSAL INPUTS

OFF

OUT

499 OHM

CPU

ADDRESS

RESET

CDOH

RS232 DIRECT

GINOUT G G G

+32

AUX POWER

REF

RS485 COMM

REF

INOUT

+- +-

METER INPUTS

Ground Shield

Dip Switch #1 set to ON

For communication cable requirements see Page 12, Section 3.3.5.

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 25,

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

RS-485 adapter power supply (supplied with RS-485 adapter)

Wire with white stripe to positive terminal

RS-485 Adapter

25-pin male to 9-pin female adapter (supplied with RS-485 adapter)

9-Pin Female

gnd

shld

(+)

(-)

LED

single

+-1+-2+-3+-

Central Controller

Windows

Compatible PC

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Controller Enclosure

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

Line Voltage 120 V Wiring

Relay Board

Low Voltage 24 V Wiring

Mount TCP/IP module to enclosure here or other suitable location within the control board's compartment.

Do not mount module in relay board compartment.

PSC CONTROLLER

+-1+-

+-4+-

+-5+-6+-7+-

+- +-

REF

24VAC

NC C

NONC CNONCCNO

NC CNONC C

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 GGG

+32

AUX POWER

RS232 DIRECT

CDOH

CPU

PWR

Control Board

5.3 TCP/IP Communication Module

from the controller to computers on the LAN via Ethernet cable plugged into the RJ45 jack on the

For remote on-site viewing of system status and settings of any controller, use the TCP/IP communication 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

module. A setup procedure must be performed on the module upon installation to create its IP address on the LAN. The setup instructions can be found in the ROBERTS GORDON

For TCP/IP communication module wiring details,

Page 23, Figure 16

If multiple ULTRAVAC™ controllers are being used, the additional controllers communicate to controller #1 through RS-485 communication wiring arranged in-series from one controller to the next.

Section 5.5

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

the control board. The module will relay the data

FIGURE 15: TCP/IP Communication Module Mounting

Software Manual.

See Page 25,

This allows multiple controllers to be

see

FIGURE 16: TCP/IP Communication Module Wiring

+-4+-

+- +-

REF

RS485 COMM

REF

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

RED

BLACK

RED

BLACK

RED

BLACK

120 ohm resistor (included)

w/ P/N 10080440

Shrinkwrap

RS-232 Direct Port

Dip Switch #1 set to ON

Red +

Black -

RS-45

Jack

Ethernet

Cable

to LAN

RJ-11

Jack

Standard 4 Wire Phone Cord (included)

Communications Circuit Equalizer Wiring (included)

module power wire

Description Part Number

TCP/IP Communication Module 10080440

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

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

9 Pin Adapter

Phone Jack

Connect to RS-232

direct port

on control board

Description Part Number

PC Connection Cable Package 10080410

5.4 Direct Connect

For local viewing of system status and settings of any controller, a portable PC can be connected. Using the 9 pin adapter provided, (See Page 24, Figure 17), you may wire from your computer serial port to the RS-232 direct connect port on the control board via standard 4-wire phone cable. For identification of the RS-232 direct connect port, see Page 8, Figure 2. This can be useful when a PC is in close proximity to any ROBERTS GORDON

ULTRAVAC™ Controller or while troubleshooting at the controller using a laptop PC. This type of connector should not be used if the phone wire is more than 50’ (15m) in length.

Plug one end of the phone cable into the RS-232 direct port, plug the other end into the adapter shown in on Page 24, Figure 17. Plug the adapter into a 9- pin serial port on your computer.

FIGURE 17: 9 Pin Adapter for PC

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 conjunction 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.

SECTION 5: COMMUNICATIONS

Dip Switch #1

Set to ON

(controller

address

Modem

Chip

1 2 3 4 5 6 7 8

Controller

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 0 1110 000 15 11110 0 0 0 16 00001000 17 10001000 18 01001000 19 11001000 20 00101000

Controller

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 8 00010000 9 10010000

10 01010000

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 25, Figure 18. 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 12, Section 3.3.5

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 25, Figure 18 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 18: Communications Between Multiple Controllers

Dedicated

Outside

Phone Line

(optional)

℡

Central Controller

(controller #1)

NONC CNONC CNONC C

NONC C

UNIVERSAL INPUTS

OFF

OUT

499 OHM

10VDC

24VAC

RS232 DIRECT

AUX POWER

RS485 COMM

INOUT

CPU

ADDRESS

RESET

METER INPUTS

CDOH

NONC CNONC CNONC CNONC C

PWR

GINOUT G G G

+32

REF

+- +-

RS 485

Wiring

To RJ11

connection on

TCP/IP Module

(optional)

Ground Shield

Wiring

to RS 485

Converter

at PC

(optional)

Satellite Controller

(controller

NONC CNONC CNONC C

NONC C

UNIVERSAL INPUTS

OFF

OUT

499 OHM

10VDC

NONC CNONC CNONC CNONC C

24VAC

PWR

RS232 DIRECT

GINOUT G G G

+32

AUX POWER

REF

RS485 COMM

REF

INOUT

CPU

ADDRESS

RESET

METER INPUTS

CDOH

+- +-

Join Shields Do Not Ground

ULTRAVAC™ Controllers

independent distributor, if

Satellite Controller

(controller #3)

NONC CNONC CNONC C

ADDRESS

NONC CNONC CNONC CNONC C

24VAC

PWR

RS232 DIRECT

GINOUT G G G

+32

AUX POWER

REF

RS485 COMM

REF

INOUT

+- +-

RESET

METER INPUTS

CDOH

NONC C

UNIVERSAL INPUTS

OFF

OUT

CPU

499 OHM

10VDC

ULTRAVAC™

To Additional Controllers

Join Shields Do Not Ground

1 2 3 4 5 6 7 8

Dip Switch #2

Set to ON (controller

address

1 2 3 4 5 6 7 8

Dip Switch

1 and #2 Set to ON (controller

address

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

RS232

RS485

RS485 OUTREF

- +- +

PROGRAM

RUN

RS485 OUT

- + - +

RS485 OUT RS485 OUT

- + - +

RS485 OUT

1/4A

1/4A 1/4A

Red

Black

Red

Black

Red

Black

Drain

Red

Black

RS232

RS485

RS485 OUTREF

- +- +

PROGRAM

RUN

RS485 OUT

- + - +

RS485 OUT RS485 OUT

- + - +

RS485 OUT

1/4A

1/4A 1/4A

Red

Black

Red

Black

Red

Black

RS232

RS485

RS485 OUTREF

- +- +

PROGRAM

RUN

RS485 OUT

- + - +

RS485 OUT RS485 OUT

- + - +

RS485 OUT

1/4A

1/4A 1/4A

Red

Black

Red

Black

Red

Black

120 Vac

Central ULTRAVAC™ Controller

Satellite 1

Satellite 2

Red

Black

Drain

Satellite 3

Satellite 4

Red

Black

Drain

Satellite 5

Satellite 6

120 Vac

24Vac

120 Vac

24Vac

120 Vac

24Vac

Description Part Number

Repeater 10080445

5.5.1 Repeater

If the RS-485 communications wire length is above 4000', a repeater must be used to extend the signal. The

repeater can also be used to create parallel branches of ROBERTS GORDON

ULTRAVAC™ controller communications bus wiring. Each repeater is sold in a 12" x 12" NEMA 1 enclosure with a 120/24 Vac transformer.

There is no limit on the quantities of repeaters used in a system.

FIGURE 19: Repeater Wiring

SECTION 6: VARIABLE FREQUENCY DRIVE PROGRAMMING

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

200

6.1 VFD Parameter Settings For Use With ROBERTS GORDON

The VFD parameters come with factory default settings. 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 power to the 24 V power switch on the relay board of the ROBERTS GORDON VAC™ controller is off.

ULTRAVAC™

ULTRAVAC™.

ULTRA-

6.1.2

Use the arrow buttons to scroll to the password value (the factory set password is 225)

Press Mode to enter password

Once the correct password value is entered, the display will read "P01", which indicates that the PROGRAM mode has been accessed at the beginning of the parameter menu (P01 is the first parameter).

SECTION 6: VARIABLE FREQUENCY DRIVE PROGRAMMING

To override the rotary disconnect switch inside the VFD enclosure, turn the square rod with a wrench to the ON position. In order to be able to close the cover of the disconnect, the rods need to be turned back to the OFF position.

6.1.1

To enter the PROGRAM mode and access the parameters, press the Mode button. This will activate the PASSWORD prompt (if the password has not been disabled).

Display reads "00" Upper right decimal point blinks

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

6.1.3 Use the arrow buttons to scroll to the desired parameter number. For new parameter settings See Page 28, Section 6.2.

6.1.4 Once the desired parameter number is found:

Press Mode to display present parameter setting (example setting is 20.0).

Upper right decimal point blinks.

Use arrow buttons to change setting

Press Mode to store new setting and exit the program mode.

6.1.5 To change another parameter, press the Mode key again to re-enter the PROGRAM mode (the parameter menu will be accessed at the parameter that was last viewed or changed before exiting).

If the Mode key is pressed within two minutes of exiting the PROGRAM mode, the password is not required to access the parameters. After two minutes,

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

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

6.2 Altering VFD Parameters

Using the procedure described in Section 6.1.1 through Section 6.1.5, alter the following parameters:

Parameter Number

Parameter

Name

Factory

Default

New

Setting

P16 Units Ending 02 01 P44 Password 225 Any #

000-999

P03 Start Method 01 05

SECTION 7: COMMISSIONING THE CORAYVAC® SYSTEM

Record Frequency Setting Here:

SECTION 7: COMMISSIONING THE CORAYVAC NOTE: The ROBERTS GORDON

ULTRAVAC™

software must be installed on the PC, the communication 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.

7.1 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 minimum and maximum VFD frequency settings to achieve proper vacuum in the system.

Step 7.1.1 At the controller, turn on the 24 V power switch on the relay board. At the PC, "connect" to the controller (see the ROBERTS GORDON

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 7.1.2 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 button 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 30, Figure 20. If the lowest end vent vacuum reading is above 3.0" wc, reduce the vacuum pump speed. Generally, the lowest end vent vacuum reading is on the longest branch of the system. Use the down arrow button on the VFD to reduce the frequency of the output signal to the pump, thus reducing the pump speed and lowering the end vent vacuum reading. Continue to reduce the frequency until the end vent vacuum reading 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

proper. If necessary, adjust the proper damper coupling to achieve an end vent vacuum of 2.5" - 3.0" wc See Page 30, Figure 20. Damper couplings should be found near the end of the radiant portion of the pipe in each branch or where a branch connects to other branches at a cross or tee. See Page 31, Fig- ure 21.

To avoid damage to the pump motor, do not adjust the frequency above 60.0 Hz. Verify that the end vent vacuum readings in the remaining branches are

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

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)

FIGURE 20: End Vent Vacuum

FIGURE 21: Possible Damper Couplings’ Locations

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

SECTION 7: COMMISSIONING THE CORAYVAC® SYSTEM

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Record Frequency Setting Here:

Step 7.1.3 After setting end vent vacuums between

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 7.1.4 Return to the PC and click the pump and

zones to "OFF".

Step 7.1.5 Using the procedure described in on Page 27, Section 6.1.1 through Section 6.1.5, alter the fol-

lowing parameters on the VFD:

Parameter

Number

P05 Standard

Parameter

Name

Factory

Default

01 03

New

Setting

Speed

Source

P45 Speed at

Minimum

Signal

P46 Speed at

Maximum

Signal

0.0Hz Frequency Setting noted in

Section 7.1.3

60.0Hz Frequency Setting noted in

Section 7.1.2

Step 7.1.6 Return to the PC and click the vacuum pump and three zones to "AUTO", then click exit.

SECTION 8: REPLACEMENT PARTS

8.1 ROBERTS GORDON

ULTRAVAC™ Controller Replacement Parts

Caution: Use only genuine ROBERTS GORDON

Roberts-Gordon voids warranty.

L1 L2 GRD

OUTPUT 7

Plug-In

Relays

ULTRAVAC™ Controller Components Diagram

L1 L2 GRD

OUTPUT 6

L1 L2 GRD

OUTPUT 5

FIGURE 22: ROBERTS GORDON

L1 L2 GRD

OUTPUT 8

SECTION 8: REPLACEMENT PARTS

replacement parts. Use of parts not specified by

24 V

L1 L2 GRD

OUTPUT 4

L1 L2 GRD

OUTPUT 3

L1 L2 GRD

OUTPUT 2

L1 L2 GRD

OUTPUT 1

L1 L2 GRD

POWER

Power

1 A Fuse

24 V Power Switch

Relay

Board

Reset

Button

24VAC

PWR

RS232 DIRECT

GINOUT G G G

+32

AUX POWER

UNIVERSAL INPUTS

REF

+-4+-

RS485 COMM

NONC CNONC CNONC CNONC C

NONC C

NONC CNONC CNONC C

REF

1+-2

INOUT

+- +-

ADDRESS

CPU

OUT IN

OFF ON

RESET

METER INPUTS

499 OHM

10VDC

1+-2

Control

Board

CDOH

Analog

Output

Board

Modem Chip

(only located on

Central Controller)

Description Part Number

Control Board (150 style) Relay Board

10080102

10080200

Analog Output Board 10080141 URV Eprom Chip Plug-In Relay

10080122

10080212

Modem Chip (located only on central controller) 10080142 1 A Fuse (Relay Board) ROBERTS GORDON® ULTRAVAC™ Indoor Sensor °F (not shown) ROBERTS GORDON® ULTRAVAC™ Outdoor Sensor (not shown)

10080211

10081500

10081501

ROBERTS GORDON® ULTRAVAC™ Indoor Sensor °C (not shown) 10081502 PC Connection Cable Package (not shown)

10080410

RS-485 Converter Package (not shown) 10080430 TCP/IP Communication Module (not shown)

10080440

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

M16/12.PM16/12.P

Power Input

125611

13A

13B

13E2516

PEPEWVU

L2/NL1 B-PE

B+

Variable

Frequency Drive

(1 Ø input model shown)

Grounding

Block

Relay 120 V

Rotary

Dissconnect

Base Block

Input Fuse Holder

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

Fuse Holder Levers

Description Part Number

Comms Equalization Cable (not shown, located only on Central Controller) Telephone Sharing Device, 4 port

10080450 10080600

Relay 120 V Unitary 07100 Lights for 150 Style Control Board Lamp Green Enclosure Mount w/o Light

91321614

Lamp Red Enclosure Mount w/o Light 91321615 Light Diode 24 Vac

91321616

8.2 Variable Frequency Drive Replacement Parts

Caution: Use only genuine ROBERTS GORDON

replacement parts. Use of parts not specified by

Roberts-Gordon voids warranty.

FIGURE 23: Variable Frequency Drive Components Diagram

Description

Variable Frequency Drive, 1 HP, 120 V, 1 Ø Input (for use with EP-203) 10081201 Variable Frequency Drive, 3/4 HP, 230 V, 1 Ø Input (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, 460 V, 3 Ø Input (for use with EP-203) 10081204 Variable Frequency Drive, 2 HP, 460 V, 3 Ø Input (for use with EP-303) Relay, 120 V Fuse 10 A (for.75 HP 230 V VFD, 1 HP 460 V VFD and 2 HP 460 V VFD) Fuse 25 A (for 1 HP 120 V VFD and 2 HP 230 V VFD) Grounding Block Fuse Holder Rotary Disconnect Base Block

Part Number

10081202 10081203

10081205 90429100 91321410 91321425 91321300 91321400 91321550

SECTION 8: REPLACEMENT PARTS

DANGER

Electrical Shock Hazard

Disconnect electrical before servicing.

This appliance must be connected to a properly grounded electrical source.

Replace cover before operating.

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

Description Part Number

Rotary Disconnect Handle (not shown) Rotary Disconnect Rod (not shown)

91321551 91321552

8.3 Replacement Parts Instructions

8.3.1 Plug-In Relay

To replace the plug-in relay, turn off 120 V power to the relay board. Turn off the 24 V power switch on the relay board. Locate the malfunctioning relay and pull the relay from its socket.

Fit a new relay in the socket. Return 120 V power to the relay board and turn on the 24 V power switch on the relay board. Press the reset button on the control board and close the doors.

8.3.2 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.

8.3.3 10080122 Eprom Chip

The Eprom is where the controller's program (not settings) is stored. To take out the Eprom. The following steps must be taken:

Turn off the power to the control board by turning off the 24 V power switch on the relay board.

Locate the Eprom and with a small terminal screw driver placed underneath the device, pry the Eprom out of the socket.

To fit a new Eprom, look for the notch on one end of the Eprom.There is a notch on the socket and a notch on the Eprom. The Eprom should be fit so that the notch on the socket and the Eprom are aligned.

Turn on the 24 V power switch on the relay board, press the reset button on the control board and close the doors.

8.3.4 24V Power 1 A Fuse

To replace the 1 A fuse, turn off power to the relay board and turn off the 24 V power switch on the relay board.

Locate the 1A fuse and remove it from its socket using a flathead screwdriver. Twist the fuse a 1/4 turn counter-clockwise until the fuse pops out of the socket. 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.

Return 120 V power to the relay board and turn on the 24 V power switch on the relay board. Press the reset button on the control board and close the doors.

8.3.5 Variable Frequency Drive (VFD)

To replace the Variable Frequency Drive, turn off all power to the drive assembly at the breaker or 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 removing 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 button on the control board and close the doors.

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

8.3.6 Variable Frequency Drive 25 A or 10 A Fuse

To replace a fuse, turn off input power to the variable frequency drive assembly at the breaker or disconnect switch.

Turn off 120 V power to the relay board inside the ROBERTS GORDON

ULTRAVAC™ Controller. Turn

off the 24 V power switch on the relay board. Inside the VFD assembly, open the fuse holder by

pulling down the lever to expose the fuse. Remove the old fuse and insert a new fuse. Verify the correct fuse rating, 25 A for 1 HP 120 V VFD or 2 HP 230 V VFD, 10 A for the.75 HP 230 V VFD, 1 HP 460 V VFD and 2 HP 460 V VFD. Close the fuse holder. Return power to the VFD assembly and verify that the VFD LCD screen is on. (dashes displayed). Close the VFD assembly door.

Return 120V power to the relay board. Turn on 24 V power switch on the relay board. Press the reset button on the control board and close the doors.

SECTION 9: TROUBLESHOOTING

Contact your

ROBERTS GORDON

Independent Distributor.

On the Manual Override

screen (Alt+M), set the

pump status to ON. Does

the pump light on the

controller come on?

Ye s

Verify communication wiring

between PC and controller.

Verify wiring between sensor

and controller. Verify shield

wires are twisted and/or

grounded. Does the pump

light on the controller turn on?

Ye s

Are current conditions being

continually updated on the

Board Status screen?

Rectify wiring between 24

V control board power

supply and 24 V control

board power input.

Ye s

Is there 24 Vac at the 24 V

control board power input?

Check circuit breaker and

controller power supply.

Replace 24 V power 1 A fuse

on relay board. See Section 8.

Ye s

Is there 120 V at the relay

board power input terminals

L1 and L2?

Contact your

ROBERTS GORDON

Independent Distributor.

Are shield wires from RS-485

communication bus wiring and

VFD 0-10 V signal wiring

correctly twisted and/or

grounded?

Ye s

START

On the Manual Override

screen (Alt+M), set the pump

status to "Auto".

Does the pump go on?

Ye s

Press the reset button on

the control board. Is the

red "RUN" light blinking.

Is the bulb for the pump light

on the controller burnt out?

Yes

Is the red “RUN” LED on

the control board blinking?

Ye s

Is there 24 Vac across the

24 V control board power

supply terminals on the

relay board?

Ye s

Is the green power LED on

the control board lit?

Is the 24 Vac switch on the

relay board on?

Ye s

Is the power light bulb

burnt out?

Ye s

Is the pump light on the

controller lit?

Ye s

Are pump and/or burners

turning on and off erratically?

Ye s

Is the power light on the

control panel lit?

Ye s

Set the setpoint above the

zone temperature. Verify

scheduling times and adjust

the correct setpoint (occupied

or setback). Verify zone

temperature sensor reading

on the Board Status screen.

Does the pump turn ON?

Yes

Ye s

FIGURE 24: Troubleshooting Flow Chart

SECTION 9: TROUBLESHOOTING

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Replace rotary disconnect

base block.

Is there power (120 V or

230 V) between the rotary

disconnect outputs?

Turn rotary disconnect

switch to the ON position.

See Section 6.1.

Check circuit breaker and

power supply.

Motor bearings may have

failed. Repace motor.

Is the pump impeller

obstructed?

Disconnect power to the

motor. Does the motor

shaft turn freely?

Motor may have tripped

overload. Wait 10-15

minutes and reset.

Ye s

Is the pump motor hot?

Rectify wiring between

VFD and pump.

Ye s

Is there power between any

two input wires at the

pump?

Replace VFD. See

Replacement Parts

section.

Ye s

Is there 120 V (230 V for

460 V models) between any

two output (motor) terminals

(U,V or W)?

Refer to the VFD

manufacturer's Installation

and Operation Manual to

clear error.

Replace VFD. See

Replacement Parts

section.

Rectify wiring between fuse

holder outputs and VFD

power inputs L1 and L2/N

Replace fuse. See

Replacement Parts

section.

Is there power (120 V or

230 V) between the rotary

disconnect inputs?

Ye s

Is there power (120 V or

230 V) between fuse

holder inputs?

Ye s

Is there power (120 V or

230 V) between fuse

holder outputs?

Ye s

Is there power (120 V or

230 V) between L1 and

L2/N inputs on the VFD?

Ye s

Is the LCD display

of the VFD on?

Rectify wiring between

120 V relay and VFD

terminals 1 and 11.

Ye s

Is there continuity between

VFD terminals 1 and 11?

Ye s

Is there an error showing

on the LED display?

Replace 120 V relay.

See Replacement Parts

section.

Ye s

Is there continuity between

output terminals on 120 V

relay.

Rectify wiring between

controller and 120 V relay.

Ye s

Is there 120 V into 120 V

relay in the variable

frequency drive assembly.

Replace plug-in relay or

relay board. See

Replacement Parts section.

Ye s

Is there 120 V at output # 8

on the relay board?

Replace plug-in relay.

See Replacement Parts

section.

Secure wiring between 24 V

Output #8 on control board

and 24 V input connection

#8 on relay board.

Ye s

Is there 24 Vac across 24 V

input connection #8 on the

relay board?

Verify external wiring

diagrams, Does the pump

turn on?

Ye s

Is the red LED on plug-in

relay #8 on the relay board

lit?

Ye s

Troubleshooting Flow Chart (continued)

Adjust system for proper

vacuum at the end vent.

See Commissioning of the

CRV System for details.

Wrong end vent plate may

be installed. Make sure

plate and burner match.

Is the end vent vacuum

setting too high?

Ye s

Replace burner transformer.

Replace ignition module.

Is there 24 V at the burner

transformer secondary

(blue and yellow wires)?

Ye s

Tro ubleshoot Ends

Pre-purge. Wait 45 seconds.

Do the burners light?

Check LED on module and

refer to LED codes below.

Ye s

Check for proper vacuum

at end vent. See

Commissioning of the

CRV System for details.

Unplug burner, wait 10

seconds, then plug it in again.

Does the ignition module

begin ignition

sequence by sparking?

Ye s

Replace plug-in relay. See

Replacement Parts section.

Correct gas problem. See

gas piping section of

CORAYVAC

IOS manual

(P/N 127102NA)

Is there proper gas pressure

and flow to the burners?

Ye s

Verify wiring between

controller and burner.

Contact your

ROBERTS GORDON

Independent Distributor.

Is there 24 Vac across the

control board 24 V output

(#1-3) for that zone?

Ye s

Is there continuity across

meter input #4 (pressure

switch input) on the control

board?

Do all the burners

ignite smoothly?

On the relay board, is the

appropriate zone relay

(#1-3) LED lit?

After 45 seconds pre-purge

period, do the burners light?

Verify pressure switch wiring

and operation. Replace

pressure switch if necessary.

Is there power at the

burner recepticle?

Ye s

Is there 24 Vac across the

relay board's appropriate 24

V output connection (#1-3)?

Secure wiring between 24 V

output on the control board

and output connection on

the relay board.

Ye s

Contact your

ROBERTS GORDON

Independent Distributor.

Are shield wires from RS-485

communication wiring and

VFD 0-10 V signal wiring

correctly twisted and/or

grounded?

Ye s

Are pump and/or burners

turning on and off erratically?

Ye s

Ignition Module Diagnostic Codes:

LED Problem Solution

4 second steady

ﬂash at start of cycle Normal Wait for valve to open

Steady on Microprocessor failure Replace module

within module

Three ﬂashes Ignition lockout Recycle unit: check for

Lockout of module spark and valve opening and

after 3 tries replace:if none, replace module

Ye s

SECTION 9: TROUBLESHOOTING

ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL

Consult wiring instructions

in 200 Series Pump Manual

(P/N 127200NA) or EP-300

Series Pump Manual (P/N

127202NA) for reversal

instructions.

Replace filters as necessary.

Replace the electrodes.

Adjust the gap or

replace the electrode.

Ignition module may have

failed. Replace module.

Electrode gap should be

1/8". Is the gap too small?

Ye s

Inspect the electrodes on the

affected burners. Are they

burned or damaged?

Ye s

Couplings may be installed

improperly. Lined couplings

should be used for tailpipe.

All couplings should be

snug around tube.

Make sure that all

sensor set points are

satisfied.

Do burners shut off after the

call for heat is satisfied?

Ye s

Check for blockage in the

outside air supply or for

leaks in the system.

Replace filters as necessary.

Ye s

Are the filters on the

burners dirty?

Is the rotation of the

pump motor correct?

Ye s

Adjust system for proper

vacuum at the end vent.

See Commissioning of the

CRV System for details.

Is the vacuum setting

too low?

Yes

Is the flame low?

Ye s

Are the filters on the

burners dirty?

Ye s

Is the rotation of the

pump motor correct?

Follow burner check

procedure given above.

Ye s

Are there any "dead"

burners in a branch?

Is the vacuum setting

too low?

Ye s

Is the system leaking water?

Ye s

Do the burners lockout

intermittently?

Ye s

Make sure that all

sensor set points are

satisfied.

Does the pump shut down

after a 2 minute post-purge

period?

Ye s

TROUBLESHOOT ENDS.

If problems persist, contact

your

ROBERTS GORDON

Independent Distributor.

Contact

Roberts-Gordon at

www.rg-inc.com

Adjust system for proper

vacuum at the end vent.

See Commissioning of the

CRV System for details.

Ye s

Consult wiring instructions

in 200 Series Pump Manual

(P/N 127200NA) or EP-300

Series Pump Manual (P/N

127202NA) for reversal

instructions.

Troubleshooting Flow Chart (continued)

SECTION 10: THE ROBERTS GORDON® ULTRAVAC™ LIMITED WARRANTY

SECTION 10: THE ROBERTS GORDON

ULTRAVAC™ LIMITED WARRANTY

ROBERTS-GORDON WILL PAY FOR:

Within 42 months from date of shipment from RobertsGordon, replacement parts will be provided free of charge for any part of the controller which fails due to a manufacturing or material defect.

Roberts-Gordon will require the part in question to be returned to the factory. Roberts-Gordon will, at its sole discretion, repair or replace after determining the nature of the defect and disposition of part in question.

ROBERTS GORDON

Replacement Parts are warranted for a period of 18 months from date of shipment from Roberts-Gordon or the remaining ROBERTS GORDON

ULTRAVAC™ wa rra nty.

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 GOR-

DON

ULTRAVAC™ as directed in the Installation,

Operation and Service manual.

• Relocation of the ROBERTS GORDON

ULTRA-

VAC™ after initial installation

• The use of the ROBERTS GORDON

ULTRAVAC™

in a corrosive atmosphere containing contaminants.

• The use of the ROBERTS GORDON

ULTRAVAC™

in the vicinity of a combustible or explosive material.

• Any defect in the ROBERTS GORDON

ULTRAVAC™ arising from a drawing, design, or specification supplied by or on behalf of the consumer.

• Damage incurred during shipment. Claim must be filed with carrier.

WARRANTY IS VOID IF:

The ROBERTS GORDON® ULTRAVAC™ is not installed by an electrician qualified in the installation and service of control systems for heating equipment.

You cannot prove original purchase date and required annual maintenance history.

The data plate and/or serial number are removed, defaced, modified or altered in any way.

The ownership of the ROBERTS GORDON ULTRAVAC™ is moved or transferred. This warranty is nontransferable.

Roberts-Gordon is not permitted to inspect the damaged controller and/or component parts.

READ YOUR INSTALLATION, OPERATION AND SERVICE MANUAL

If you have questions about your controller, contact your installing professional. Should you need Replacement Parts or have additional questions, call or write Roberts-Gordon:

U.S.A.

1250 William Street P. O. B o x 44 Buffalo, New York 14240-0044

716.852.4400

On the web at: www.rg-inc.com

Roberts-Gordon's liability, and your exclusive remedy, under this warranty or any implied warranty (including the implied warranties of merchantability and fitness for a particular purpose) is limited to providing replacement parts during the term of this warranty. Some jurisdictions

do not allow limitations on how long an implied 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.

Roberts Gorden NEMA 4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual