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
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.
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.
1
ROBERTS GORDON® ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
URVCCR: ULTRAVAC™ Central Controller with RS-485 Converter
4
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™ .
5
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.
6
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
7
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
GINOUTGGG
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1
PWR
+-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
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
8
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
9
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