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- 10081601NA Rev H 12/11
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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
ULTRAVAC™?............ 2
1.3 General Requirements ................................................. 2
® 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
® 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
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
® ULTRAVAC™.......................................... 42
7.2 Altering VFD Parameters............................................ 43
SECTION 8: Commissioning The CORAYVAC ®
System .... 44
End Burner Vacuum ......... 44
SECTION 9: Troubleshooting .............................................. 48
SECTION 10: Replacement Parts ........................................ 55
® 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
® 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
® ULTRAVAC™ Central
Controller External Wiring ...................................... 26
® 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
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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®
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
®
1.3 General Requirements
DANGER
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.
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.
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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
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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®
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
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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
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®
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
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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
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®
ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL
FIGURE 5: Connected Components
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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)
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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)
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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)
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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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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
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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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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.
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
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
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,
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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.
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.
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.
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.
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 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,
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
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, (
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,
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 #
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.
• To add parallel branches of ROBERTS GORDON ® ULTRAVAC™ controller communications bus wiring.
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
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,
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
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
60.0Hz
Frequency
Setting noted
SECTION 7: V ARIABLE F REQUENCY D RIVE P ROGRAMMING
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ROBERTS GORDON
®
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.
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).
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
60.0Hz
Frequency
Setting noted
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.
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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
®
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
®
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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ROBERTS GORDON
®
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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Table of contents
- 8 SECTION 1: Introduction
- 8 1.1 Safety
- 8 ULTRAVAC™?
- 8 1.3 General Requirements
- 8 Design Requirements
- 9 1.5 Example Site Layout
- 9 1.6 Check Installation Materials
- 9 1.7 Safety Labels and Their Placement
- 16 1.8 Carton Contents
- 19 1.9 Standard Parts List
- 22 SECTION 2: Specifications
- 22 ULTRAVAC™ Controller
- 22 2.2 ULTRAVAC™ BMS Link Controller
- 22 2.3 NEMA 4 Enclosure (P/N 10080302)
- 22 2.4 Repeater
- 22 2.5 Temperature Sensors
- 23 2.6 Line Reactor 480 V / 4 A Output
- 25 2.7 Variable Frequency Drive (VFD)
- 27 SECTION 3: Installation
- 27 3.1 Preparation
- 27 Controller and Variable Frequency Drive
- 28 3.3 Cable Requirements
- 28 Controller
- 29 3.5 Pump Requirements
- 29 3.6 Variable Frequency Drive Requirements
- 30 3.7 Indoor Sensor Placement
- 30 3.8 Outdoor Sensor Placement
- 30 3.9 Outside Air Supply
- 31 SECTION 4: Typical External Diagrams
- 36 SECTION 5: Communications
- 37 5.2 RS-485 Converter for Central Controller
- 38 5.3 TCP/IP Communication Module
- 39 5.4 Direct Connect
- 41 ULTRAVAC™ Controllers
- 44 SECTION 6: ULTRAVAC™ BMS Link Controller
- 44 6.1 ULTRAVAC™ BMS Link Controller Overview
- 45 6.2 ULTRAVAC™ BMS Link Controller Requirements
- 46 6.3 Technical Data
- 46 6.4 ULTRAVAC™ BMS Link Controller Programming
- 48 SECTION 7: Variable Frequency Drive Programming
- 48 ULTRAVAC
- 49 7.2 Altering VFD Parameters
- 50 System
- 50 End Burner Vacuum
- 54 SECTION 9: Troubleshooting
- 61 SECTION 10: Replacement Parts
- 62 Replacement Parts
- 63 10.2 Variable Frequency Drive Replacement Parts
- 64 Parts
- 65 10.4 Repeater Replacement Parts
- 66 10.5 Replacement Parts Instructions
- 68 Warranty