Roberts Gorden System Control HP 120 V 1 Installation manual

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Roberts Gorden System Control HP 120 V 1 Installation manual | Manualzz

ROBERTS GORDON

®

UltraVac ™

PATENTED

Controls for

Modulating

CORAYVAC

®

Infrared Heating

Systems

Installation Manual

WARNING

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.

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

© 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. Box 44

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

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

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

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®.

© 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.

Printed in U.S.A.

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

® ULTRAVAC™ Controller

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

® ULTRAVAC™ Central

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

Figure 14: ROBERTS GORDON

® ULTRAVAC™ Satellite

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: Troubleshooting 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

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

SECTION 1: INTRODUCTION

1.1 Safety

Your Safety is Important to Us!

This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special 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.

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 knowledge, unless they have been given supervision or 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 ® ULTRAVAC™?

The ROBERTS GORDON ® ULTRAVAC™ is a micro- processor based control package designed for modulating control of CORAYVAC ® heaters based on outdoor temperatures.

This controller is capable of giving control outputs to one vacuum pump and three heating zones. The controller also features inputs which are used for indoor and outdoor signal condition monitoring.

For the overall view of connected components for

ROBERTS GORDON

Figure 5.

®

ULTRAVAC™,

1.3 General Requirements

DANGER

see Page 8,

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

DON ® ULTRAVAC™ Software.

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.

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 62, Section 11.

ROBERTS GORDON ® ULTRAVAC™ Software requires a PC (not supplied) running Windows ® 95 or higher, with a Pentium ® class processor and at least

64k of RAM.

The controller, variable frequency drive, burners, 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 CORAYVAC ® Design Requirements

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

B-10 or B-12 burners.

CORAYVAC ® systems designed shall have

minimum radiant pipe length and 1.5 - 2.0 feet per flow unit of tailpipe length.

2 of 62

SECTION 1: I NTRODUCTION

-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.

ERTS GORDON ® independent distributor to obtain

replacement signs or labels. See Page 4, Figure 1

through Page 7, Figure 4.

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.

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 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.

1.7 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-

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

FIGURE 1: ULTRAVAC™ Controller Label Placement

Light Label

Rating Plate Label Front Door Panel (outside)

Electrical Shock Hazard Label

Logo Label

4 of 62

External Wiring Label

NC C NO NC C NO NC C NO NC C NO L2 L1 PWR

24VAC

OUT IN G +32 +5 G

RS232 DIRECT

G

AUX POWER

G REF

OUT

+

REF

IN

RS485 COMM

+

4

+ +

3 2

METER INPUTS

+

1

+

RESET

ADDRESS

OH CD RI

CPU

NC C NO NC C NO NC C NO NC C NO

- 8 + - 7 + - 6 +

UNIVERSAL INPUTS

- 5 + - 4 + - 3 + - 2 + - 1 +

OUT

IN

OFF

ON

499 OHM

10VDC

Front Door Panel (inside)

Control Board Wiring Label

Description

Logo Label

Rating Plate Label

Light Label

Control Board Wiring Label

External Wiring Label

Shock Hazard label

Part Number

91013207

91008005

91008007

91008004

91008003

91008001

FIGURE 2: ULTRAVAC™ BMS Link Controller Label Placement

SECTION 1: I NTRODUCTION

Description

Logo Label

Rating Plate Label

Light Label

Control Board Wiring Label

Shock Hazard label

Part Number

91008017

91008016

91008015

91008014

91008001

5 of 62

ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

FIGURE 3: VFD Label Placement

Front Door Panel (outside)

Electrical Shock Hazard Label

Side Panel (outside)

Wiring Diagram Label

Description

Rating Plate Label

Wiring Label (230 V)

Wiring Label (460 V)

Shock Hazard label

6 of 62

Front Door Panel (inside)

Part Number

91008006

91008004

91008003

91008001

Rating Plate Label

Variable Frequency Driver

1 Ø Input Model Shown

L1 L2/N PE BB+

Power Input

Rotary Disconnect

1 2 5 6 11 13A 13B 13E 25

U V W PE PE

Input Fuse Holder

M16/12.P

Relay 120 V

FIGURE 4: Repeater Label Placement

SECTION 1: I NTRODUCTION

Description

Wiring Diagram Label

Logo Label

Rating Plate Label

Shock Hazard Label

Part Number

91008020

91008021

91008022

91008001

7 of 62

ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

FIGURE 5: Connected Components

8 of 62

Connected Components (continued)

SECTION 1: I NTRODUCTION

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

1.8 Carton Contents

URVSC: ULTRAVAC™ Satellite Controller

ULTRAVAC™ Controller

Line Voltage 120 V Wiring

GRD

OUTPUT 8

GRD

OUTPUT 7

GRD

OUTPUT 6

GRD

OUTPUT 5

GRD

OUTPUT 4

GRD

OUTPUT 3

GRD

OUTPUT 2

GRD

OUTPUT 1

GRD

POWER

Low Voltage 24 V Wiring

NC C NO NC C NO NC C NO NC C NO L2 L1 PWR

24VAC

OUT IN G

RS232 DIRECT

+32 +5 G G

AUX POWER

G REF

OUT

+-

REF

RS485 COMM

IN

+-

4

++-

3 2

METER INPUTS

+-

RESET

ADDRESS

OH CD RI

1

+-

CPU

UNIVERSAL INPUTS

NC C NO NC C NO NC C NO NC C NO

OUT

IN

OFF

ON

499 OHM

10VDC

ULTRAVAC™ Installation Manual

(P/N 10081601NA)

Inside View

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

Line Voltage 120 V Wiring

GRD

OUTPUT 8

GRD

OUTPUT 7

GRD

OUTPUT 6

GRD

OUTPUT 5

GRD

OUTPUT 4

GRD

OUTPUT 3

GRD

OUTPUT 2

GRD

OUTPUT 1

GRD

POWER

ULTRAVAC™ Controller with Modem Installed

Low Voltage 24 V Wiring

NC C NO NC C NO NC C NO NC C NO L2 L1 PWR

24VAC

OUT IN G

RS232 DIRECT

+32 +5 G G

AUX POWER

G REF

OUT

+-

REF

IN

RS485 COMM

+-

4

++-

3 2

METER INPUTS

+-

RESET

ADDRESS

OH CD

1

+-

RI

CPU

UNIVERSAL INPUTS

NC C NO NC C NO NC C NO NC C NO

OFF

ON

499 OHM

10VDC

Inside View

4

+ + -

3 2

METER INPUTS

+ -

1

+

RESET

RESS

OH CD RI

Modem Chip

499 OHM

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.

Repeater (optional)

Supplied w/24 VAC transformer inside

NEMA 1 enclosure

(P/N URVRP)

Inside View Outdoor Sensor

(P/N 10081501)

Kit, TCP/IP (LAN) Communication Module with PC Connection Cable Package

(P/N 10080440K)

Indoor Sensor

(P/N 10081502)

10 of 62

SECTION 1: I NTRODUCTION

URVCCM: ULTRAVAC™ Central Controller with Modem

ULTRAVAC™ Controller with Modem Installed

Line Voltage 120 V Wiring

GRD

OUTPUT 8

GRD

OUTPUT 7

GRD

OUTPUT 6

GRD

OUTPUT 5

GRD

OUTPUT 4

GRD

OUTPUT 3

GRD

OUTPUT 2

GRD

OUTPUT 1

GRD

POWER

Low Voltage 24 V Wiring

NC C NO NC C NO NC C NO NC C NO L2 L1 PWR

24VAC

OUT IN G

RS232 DIRECT

+32 +5 G G

AUX POWER

G REF

OUT

+-

REF

RS485 COMM

IN

+-

4

++-

3 2

METER INPUTS

+-

1

+-

RESET

ADDRESS

OH CD RI

CPU

UNIVERSAL INPUTS

NC C NO NC C NO NC C NO NC C NO

OUT

IN

OFF

ON

499 OHM

10VDC

Inside View

4

+ + -

3 2

METER INPUTS

+ -

1

+

RESET

RESS

OH CD RI

Modem Chip

499 OHM

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.

Repeater (optional)

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

Inside View

Outdoor Sensor

(P/N 10081501)

Indoor Sensor

(P/N 10081502)

PC Connection Cable Package

(P/N 10080410)

11 of 62

ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

URVCCR: ULTRAVAC™ Central Controller with RS-485 Converter

Line Voltage 120 V Wiring

GRD

OUTPUT 8

GRD

OUTPUT 7

GRD

OUTPUT 6

GRD

OUTPUT 5

GRD

OUTPUT 4

GRD

OUTPUT 3

GRD

OUTPUT 2

GRD

OUTPUT 1

GRD

POWER

4

+ + -

3 2

METER INPUTS

+ -

1

+

RESET

RESS

OH CD RI

Modem Chip

ULTRAVAC™ Controller with Modem Installed

Low Voltage 24 V Wiring

NC C NO NC C NO NC C NO NC C NO L2 L1 PWR

24VAC

OUT IN

RS232 DIRECT

G +32 +5 G G

AUX POWER

G REF

OUT

+-

REF

IN

RS485 COMM

+-

4

++-

3 2

METER INPUTS

+-

1

+-

RESET

ADDRESS

OH CD RI

CPU

UNIVERSAL INPUTS

NC C NO NC C NO NC C NO NC C NO

OUT

IN

OFF

ON

499 OHM

10VDC

Inside View

499 OHM

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.

Repeater (optional)

Supplied w/24 VAC

Inside View transformer inside NEMA 1 enclosure (P/N URVRP)

Outdoor Sensor

(P/N 10081501)

RS-485 Converter Package (P/N 10080430)

PC Connection Cable Package

(P/N 10080410)

Indoor Sensor

(P/N 10081502)

12 of 62

RS-485 Converter Power Supply

SECTION 1: I NTRODUCTION

URVBNC: ULTRAVAC™ BMS Link Controller

ULTRAVAC™ BMS Link

Controller

Inside View

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

ULTRAVAC™ Software, ULTRAVAC™

Software Manual. (P/N 10081600NA)

ULTRAVAC™ Installation Manual

(P/N 10081601NA),BACnet ® or

MODBUS ® Software

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™ C ONTROLLER I NSTALLATION M ANUAL

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

Part No.

Variable Frequency Drives*

Description

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 Power Supply

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

14 of 62

FIGURE 6: Example Site Layout

Outside Sensor

Zone 3 Sensor

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

Zone 2 Sensor

Zone 1 Sensor

SECTION 1: I NTRODUCTION

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

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

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

2.2 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 enclosure is sold separately as an option, for ULTRAVAC™

Controller and ULTRAVAC™ BMS

2.5 Temperature Sensors

Indoor Sensor

Dimensions: W x H x D

(in): 2.75 x 4.5 x 1.15

Power:

(cm): 7.0 x 11.4 x 2.9

32 V DC

Operating Temperature Range:

32° to 158° F (0° to 70° C) 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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SECTION 2: S PECIFICATIONS

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:

Flammability

Rating:

NEMA 4, 4X

UL-94-5V

Voltage 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:

Volts:

4 A

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:

Volts:

4 A

480 V / 3 Ø

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FIGURE 7: ROBERTS GORDON ® ULTRAVAC™ Controller Specifications

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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.

SECTION 2: S PECIFICATIONS

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

UL Standard: Industrial Controls Equipment

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: 208/230 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

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

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SECTION 3: INSTALLATION

DANGER 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.

SECTION 3: I NSTALLATION 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

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.

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 Variable Frequency Drive component names and locations.

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

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 mounting 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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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 equivalent 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.

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.

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

VFD75115 or VFD75115N4

Wire Size

12 AWG

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.

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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 pump 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.

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)

SECTION 3: I NSTALLATION

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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" (10.2 cm) x

2.13" (5.4 cm) junction box 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 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 11: Indoor Sensor Mounting

FIGURE 12: Outdoor Sensor Placement

North

Mounting

Hole

Plug-in LCD

Display

(grasp here to unplug)

Outside

Sensor

SEN SET O/R +

Setback

Override

Button

Sensor

Module facing down

Setpoint

Adjustment

Slide bar

Mounting

Hole

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 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

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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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: T YPICAL E XTERNAL D IAGRAMS

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FIGURE 13: ROBERTS GORDON ® ULTRAVAC™ Central Controller External Wiring

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SECTION 4: T YPICAL E XTERNAL D IAGRAMS

ROBERTS GORDON ® ULTRAVAC™ Central Controller External Wiring (continued)

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FIGURE 14: ROBERTS GORDON ® ULTRAVAC™ Satellite Controller External Wiring

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SECTION 4: T YPICAL E XTERNAL D IAGRAMS

ROBERTS GORDON ® ULTRAVAC™ Satellite Controller External Wiring (continued)

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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 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.

FIGURE 15: Modem Location

Control Board of the

Central Controller

NC C NO NC C NO NC C NO NC C NO L2 L1 PWR

24VAC

OUT IN

RS232 DIRECT

G +32 +5 G G

AUX POWER

G

-

REF

OUT

+ -

REF

IN

RS485 COMM

+ -

4

+ + -

3 2

METER INPUTS

+ -

1

+

RESET

ADDRESS

OH CD RI

Dip Switch # 1

Set to ON

1 2 3 4 5 6 7 8

Modem

Chip

CPU

NC C NO NC C NO NC C NO NC C NO

- 8 + - 7 + - 6 +

UNIVERSAL INPUTS

- 5 + - 4 + - 3 + - 2 + - 1 +

OUT

IN

OFF

ON

499 OHM

10VDC

Installed

Modem Chip

Phone Cable Connection

Description

Modem Chip

Part Number

10080142

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 communication 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.

If multiple ULTRAVAC™ controllers are being used, the additional controllers communicate to controller #1 through RS-485 communication wiring arranged

in-series from one controller to the next. See Page 35,

Section 5.5. This allows multiple controllers to be

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

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SECTION 5: C OMMUNICATIONS

5.2 RS-485 Converter for Central Controller

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 RS-

485 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

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. See Page 35,

Section 5.5. This allows multiple controllers to be

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

Description

RS-485 Converter Package with

Power Supply

Part Number

10080430

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5.3 TCP/IP Communication Module

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 the control board. The module will relay the data from the controller to computers on the LAN via

Ethernet cable plugged into the RJ45 jack on the module. A setup procedure must be performed on the module upon installation to create its IP address on the LAN. The setup instructions can be found in the ROBERTS GORDON ® Software Manual (P/N

10081600NA).

For TCP/IP communication module wiring details, see

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. See Page 35,

Section 5.5. This allows multiple controllers to be

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

FIGURE 17: TCP/IP Communication Module Mounting

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FIGURE 18: TCP/IP Communication Module Wiring

SECTION 5: C OMMUNICATIONS

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.

Description Part Number

Kit, TCP/IP Communication 10080440K

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 ® ULTRAVAC™ Controller 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.

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 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.

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FIGURE 19: 9 Pin Adapter for PC

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Description

PC Connection Cable Package

Part Number

10080410

SECTION 5: C OMMUNICATIONS

5.5 Communications Between Multiple ROBERTS GORDON ® ULTRAVAC™ Controllers

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 #

See Page 22, Section 3.3

1 to the RS-485

2 and so on in a daisy chain fashion. For communication cable requirements, system status and settings can be viewed for any of the controllers on the network.

The control board identification dip switch must be set on each ROBERTS GORDON ® ULTRAVAC™

Controller. See Page 35, Figure 20 for dip switch

settings. Contact Roberts-Gordon or your

ROBERTS GORDON ® independent distributor, if more than 20 controllers are connected.

From a PC, by dialing into the modem on controller # 1 or by connecting to controller # 1 via RS-485 converter or TCP/IP communication module, the

FIGURE 20: Communications Between Multiple Controllers

Controller/Address

Number

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

Values (1=ON, 0=OFF)

1 (Central Controller)

2

3

4

5

6

7

8

9

10

10000000

01000000

11000000

00100000

10100000

01100000

11100000

00010000

10010000

01010000

Controller/Address

Number

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

Values (1=ON, 0=OFF)

15

16

17

18

11

12

13

14

19

20

11010000

00110000

10110000

01110000

11110000

00001000

10001000

01001000

11001000

00101000

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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

Description

Repeater

Part Number

URVRP

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FIGURE 22: Repeater Communication Wiring Between Multiple Controllers

SECTION 5: C OMMUNICATIONS

Description

Repeater

Part Number

URVRP

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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 control 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 ® /IP,

BACnet ® MSTP or MODBUS ® protocol. The standard

ULTRAVAC™ BMS Link architecture is detailed

on

Page 38, Figure 23.

FIGURE 23: Standard ULTRAVAC™ BMS Link Architecture

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FIGURE 24: ULTRAVAC™ BMS Link Controller Schematic

SECTION 6: ULTRAVAC™ BMS L INK C ONTROLLER

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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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™ Controls (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 documentation 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 L INK C ONTROLLER

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

Controllers

Controller

Number

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

Values (1=ON, 0=OFF)

Address

Number

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

11

12

00110000

10110000

12

13

2

3

11000000

00100000

3

4

13

14

01110000

11110000

14

15

4

5

10100000

01100000

5

6

15

16

00001000

10001000

16

17

6

7

11100000

00010000

7

8

17

18

01001000

11001000

18

19

8

9

10010000

01010000

9

10

19

20

00101000

10101000

20

21

10 11010000 11

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ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

SECTION 7: VARIABLE FREQUENCY DRIVE PROGRAMMING

7.1 VFD Parameter Settings For Use With

ROBERTS GORDON ® ULTRAVAC™

7.1.2

Use the arrow buttons to scroll to the password value

(the factory set password is 225).

The VFD parameters come with factory default settings. The following parameter settings must be changed for ROBERTS GORDON ® ULTRAVAC™.

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™.

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).

DANGER

Electrical Shock Hazard

Enclosure contains live electrical components.

2 2 5

P 0 1

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

Programming must be done by a trained technician only.

7.1.3 Use the arrow buttons to scroll to the desired parameter number. For new parameter settings,

See

Page 43, Section 7.2.

Replace cover before operating.

7.1.4 Once the desired parameter number is found:

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

Press Mode to display present parameter setting

(example setting is 20.0).

Upper right decimal point blinks.

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

0 0

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,

42 of 62

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

7.2 Altering VFD Parameters

Using the procedure described

on Page 42, Section

7.1.1 through Section 7.1.5, alter the following parame-

ters:

Parameter

Number

P01

P03

P05

Parameter

Name

Line Voltage

Start Method

P44

Standard

Speed

Source

Password

Factory

Default

01

01

New

Setting

01

05

01 (03) (0-10) Vdc

(04) (4-20) mA

P45

P46

Speed at

Minimum

Signal

Speed at

Maximum

Signal

225

0.0Hz

Any #

000-999

Frequency

Setting noted

on Page 44,

Section 8.1.2

60.0Hz

Frequency

Setting noted

on Page 44,

Section 8.1.2

SECTION 7: V ARIABLE F REQUENCY D RIVE P ROGRAMMING

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ROBERTS GORDON

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ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

SECTION 8: COMMISSIONING THE CORAYVAC ® SYSTEM

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.

8.1 Setting The CORAYVAC ® End Burner Vacuum vacuum readings in the remaining branches are proper. If necessary, adjust the proper damper coupling to achieve an end vent vacuum 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.

ure 27.

See Page 46, Fig-

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 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 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 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 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

Record Frequency Setting Here:

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

44 of 62

SECTION 8: C OMMISSIONING T HE CORAYVAC ® S YSTEM

FIGURE 26: End Vent Vacuum

Combustion Chamber at end burner position

End Vent

Insert tubing about 6" (15cm) into end vent.

0

1

2

1

4

3

6

5

4

5

2

3

6

Manometer

Approximate reading after adjusting

VFD frequency setting and/or damper couplings. ( 2.5"-3" wc)

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ROBERTS GORDON

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ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

FIGURE 27: Possible Damper Couplings’ Locations

Zone 3 End

Zone 2 End

Pump Damper

Zone 3 Damper Couplin

Zone 1 End

Zone 2 Damper Couplin

Zone 1 Damper Couplin

46 of 62

Step 8.1.3 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

Record Frequency Setting Here:

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.

Parameter

Number

P01

P03

P05

Parameter

Name

Line Voltage

Start Method

P44

Standard

Speed

Source

Password

Factory

Default

01

01

New

Setting

01

05

01 (03) (0-10) Vdc

(04) (4-20) mA

P45

P46

Speed at

Minimum

Signal

Speed at

Maximum

Signal

225

0.0Hz

Any #

000-999

Frequency

Setting noted

on Page 44,

Section 8.1.2

60.0Hz

Frequency

Setting noted

on Page 44,

Section 8.1.2

SECTION 8: C OMMISSIONING T HE CORAYVAC ® S YSTEM

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

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.

WARNING

Explosion Hazard

Turn off gas supply to heater before service.

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

48 of 62

FIGURE 28: Troubleshooting Flow Chart

SECTION 9: T ROUBLESHOOTING

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

Troubleshooting Flow Chart (continued)

50 of 62

Troubleshooting Flow Chart (continued)

SECTION 9: T ROUBLESHOOTING

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

Troubleshooting Flow Chart (continued)

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FIGURE 29: Troubleshooting Flow Chart - Repeater

SECTION 9: T ROUBLESHOOTING

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ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

FIGURE 30: Troubleshooting Flow Chart - BACnet ®

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WARNING

SECTION 10: R EPLACEMENT P ARTS

SECTION 10: REPLACEMENT PARTS

DANGER

Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide 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.

55 of 62

ROBERTS GORDON

®

ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

10.1 ROBERTS GORDON ® ULTRAVAC™ Controller Replacement Parts

Caution: Use only genuine ROBERTS GORDON ® replacement parts. Use of parts not specified by

Roberts-Gordon voids warranty.

FIGURE 31: ROBERTS GORDON ® ULTRAVAC™ Controller Components Diagram

GRD L2

OUTPUT 8

L1 GRD L2

OUTPUT 7

L1 GRD L2

OUTPUT 6

L1 GRD L2

OUTPUT 5

L1 GRD L2

OUTPUT 4

L1 GRD L2

OUTPUT 3

L1 GRD L2

OUTPUT 2

L1 GRD L2

OUTPUT 1

L1 GRD L2

POWER

L1

24 V

Power

1 A Fuse

24 V

Power

Switch

Relay

Board

Plug-In

Relays

Reset

Button

NC C NO NC C NO NC C NO NC C NO L2 L1 PWR

24VAC

OUT IN

RS232 DIRECT

G +32 +5 G G

AUX POWER

G

-

REF

OUT

+

RS485 COMM

-

REF

IN

+ -

4

+ + -

3 2

METER INPUTS

+ -

1

+

RESET

ADDRESS

OH CD RI

Control

Board

CPU

NC C NO NC C NO NC C NO NC C NO

- 8 + - 7 + - 6 +

UNIVERSAL INPUTS

- 5 + - 4 + - 3 + - 2 + - 1 +

OUT

IN

OFF

ON

499 OHM

10VDC

Modem Chip

(only located on

Central Controller)

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

Analog

Output

Board

Part Number

10080102

10080200

10080141

10080122

10080212

10080142

10080211

10081500

10081501

10081502

10080410

10080430

10080440K

10080600

56 of 62

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

SECTION 10: R EPLACEMENT P ARTS

Part Number

07100

91321614

91321615

91321616

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)

Power Input

L1 L2/N PE BB+

Rotary

Dissconnect

Base Block

Relay

120 V Fuse

Holder

Levers

1 2 5 6 11 13A 13B 13E 25

U V W PE PE

Grounding

Block

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 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, 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)

Part Number

10081201

10081202

10081203

10081204

10081205

90429100

91321410

91321425

91321300

91321400

91321550

91321551

91321552

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ROBERTS GORDON

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ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

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

58 of 62

Part Number

10081610

10081630

10081640

10081650

10081660

10081680

10081690

10.4 Repeater Replacement Parts

FIGURE 34: Repeater Components Diagram

SECTION 10: R EPLACEMENT P ARTS

Description

Repeater

Circuit Breaker 5A

Transformer

Micro Fuse, 125 V, 1/4A

Part Number

10080445

10081650

10081661

10081690

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ROBERTS GORDON

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ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

10.5 Replacement Parts Instructions the doors.

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Controller must be properly grounded to an electrical source.

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.

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.

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

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 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

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 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.

10.5.6 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

60 of 62

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 button on the control board and close the doors.

SECTION 10: R EPLACEMENT P ARTS

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ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL

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 ® Replacement Parts are warranted for a period of 12 months from date of shipment from

Roberts-Gordon or the remaining ROBERTS GORDON ®

System Control warranty.

ROBERTS-GORDON WILL NOT PAY FOR:

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. Box 44

Buffalo, New York 14240-0044

716.852.4400

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

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 ® ULTRAVAC™ in any way.

• Use of the ROBERTS GORDON ® ULTRAVAC™ for other than its intended purpose.

• Incorrect gas or electrical supply, accident, fire, floods, acts of God, war, terrorism, or other casualty.

• Improper service, use of replacement parts or accessories not specified by Roberts-Gordon.

• Failure to install or maintain the ROBERTS 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 supplied by or on behalf of the consumer.

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.

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

WARRANTY IS VOID IF:

LIMITATIONS ON AUTHORITY OF

REPRESENTATIVES:

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.

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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