Page 3 - TABLE OF CONTENTS; SECTION 7: Commissioning The CORAYVAC
© 200 8 Ro b erts-Gordon LLC All rights reser v ed. N o part of this w ork co v ered b y the copyrights herein may b e reprod u ced or copied in any form or b y any means - graphic, electronic, or mechanical, incl u ding photocopying, recording, taping or information storage and retrie v al systems ...
Page 5 - TABLE OF FIGURES
TABLE OF FIGURES Figure 1: Example Site Layout .................................................. 6Figure 2: ROBERTS GORDON ® ULTRAVAC™ Controller Specifications ............................................................ 8 Figure 3: Variable Frequency Drive Components (Factory pre-wiring shown) .....
Page 7 - Design Requirements
SECTION 1: I NTRODUCTION 1 SECTION 1: INTRODUCTION1.1 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 outpu...
Page 8 - URVSC: ULTRAVACTM Satellite Controller; ULTRAVACTM Controller
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 2 1.5 Carton Contents URVSC: ULTRAVAC™ Satellite Controller URVCCL: ULTRAVAC™ Central Controller with TCP/IP Communication Module Line V oltage 120 V W iring Lo w V oltage 24 V W iring POWER L1 L2 GRD OUTPUT 1 L1 L2 GRD OUTPUT 2 L1 L2 GRD ...
Page 9 - URVCCM: ULTRAVACTM Central Controller with Modem; Inside View
SECTION 1: I NTRODUCTION 3 URVCCM: ULTRAVAC™ Central Controller with Modem ULTRAVAC™ Software (P/N 10080421)ULTRAVAC™ Software Manual (P/N 10081600NA)ULTRAVAC™ Installation Manual (P/N 10081601NA) Comms Equalization Cable(P/N 10080450) Outdoor Sensor(P/N 10081501) PC Connection Cable Package(P/N 100...
Page 10 - URVCCR: ULTRAVACTM Central Controller with RS-485 Converter; Power Supply
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 4 URVCCR: ULTRAVAC™ Central Controller with RS-485 Converter RS-485 Conver ter Package (P/N 10080430) Power Supply ULTRAVAC™ Software (P/N 10080421)ULTRAVAC™ Software Manual (P/N 10081600NA)ULTRAVAC™ Installation Manual (P/N 10081601NA) Co...
Page 11 - independent distrib-; Example Site Layout; is an example layout for a building
SECTION 1: I NTRODUCTION 5 1.6 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 atten-tion when reading and following the warnings in these sections. Installation, service and annual inspect...
Page 12 - FIGURE 1: Example Site Layout
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 6 FIGURE 1: Example Site Layout NOTE: Conceptual drawing, not to scale. Venting not shown. Zone 1 Zone 2 Zone 3 Zone 2 Sensor Zone 1 Sensor Zone 3 Sensor Va riab le Frequency Dr iv e Nor th W all Outside Sensor Pump R OBER TS GORDON ® UL T...
Page 14 - FIGURE 2: ROBERTS GORDON; Relay Board; Line Voltage 120 V wiring
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 8 FIGURE 2: ROBERTS GORDON ® ULTRAVAC™ Controller Specifications + - 1 + - 2 + - 4 + - 3 + - 5 + - 6 + - 7 + - 8 + - + - REF 24VAC L2 NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C RS485 COMM REF + - 1 + - 2 + - 3 + - 4 ME...
Page 15 - Standard Models; Construction: 14 gauge painted steel, mounting; NEMA 4 Models; Vdc
SECTION 2: S PECIFICATIONS 9 2.3 Variable Frequency Drive (VFD) 2.3.1 Enclosure Standard Models Construction: 14 gauge painted steel, mounting panel included, left-hinged door,vented. Dimensions: 12" w x 14 3/8" h x 8" d Protection: UL 50 Type 1, NEMA Type 1 NEMA 4 Models Description: Dr...
Page 16 - Po; qu; Input Fuse Holder
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 10 FIGURE 3: Variable Frequency Drive Components (Factory pre-wiring shown) M16/12.P M16/12.P Po w er Inp u t 1 2 5 6 11 13A 13B 13E 25 16 17 PE PE W V U L2/N L1 B- PE B+ V aria b le Fre qu ency Dri v e (1 Ø inp u t model sho w n) Terminal...
Page 17 - SECTION 3: INSTALLATION; Installation of the ROBERTS GORDON; Positioning the ROBERTS GORDON; Choose a mounting location for the controller.; FIGURE 4: Controller Mounting; WARNING; Severe Injury Hazard
SECTION 3: I NSTALLATION 11 SECTION 3: INSTALLATION Installation of the ROBERTS GORDON ® ULTRAVAC™ Controller and the associated external electrical wiring must be done by an electrician qualified in the installation of control systems for heating equipment. 3.1 Preparation Before installing the con...
Page 18 - See Page 12, Figure 5; FIGURE 5: Indoor Sensor Cable Detail; See Page 12, Figure 6; Shield Wire
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 12 3.3 Cable Requirements: 3.3.1 Line Power Supply: As per individual building specification for class of cable to be used. Use copper conductors only. To size the cable, use the amperages of the burners given on Page 13, Section 3.4.1 , f...
Page 19 - Electrical Installation Requirements; see; FIGURE 7: Variable Frequency Drive Mounting; DANGER; Electrical Shock Hazard
SECTION 3: I NSTALLATION 13 3.4 Electrical Installation Requirements 3.4.1 The enclosure must be supplied from a local fused isolator rated for a total amperage not exceeding 25 A. The method for calculating the current loading is as follows: CORAYVAC ® Burner 0.3 A/burner Multiply the current for t...
Page 20 - Indoor Sensor Placement; See Page 14, Figure 8; Outdoor Sensor Placement; If an outside air blower is to be used,
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 14 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 mounte...
Page 21 - Description
SECTION 4: T YPICAL E XTERNAL D IAGRAMS 15 SECTION 4: TYPICAL EXTERNAL DIAGRAMSFIGURE 10: Central Controller Communication Equalization Wiring + - 1 + - 2 + - 4 + - 3 + - 5 + - 6 + - 7 + - 8 + - + - REF RS485 COMM REF + - 1 + - 2 + - 3 + - 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESET 10VDC 4...
Page 22 - FIGURE 11: ROBERTS GORDON
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 16 FIGURE 11: ROBERTS GORDON ® ULTRAVAC™ Central Controller External Wiring + - 1 2 4 3 5 6 7 8 + - +-REF 24V AC L2 RS485 COMM REF +- 1 +- 2 +- 3 +- 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESET 10VDC 499 OHM OFF ON OUT IN G IN OUT ...
Page 23 - ROBERTS GORDON; VFD Power; Continued; Motor Power Supply
SECTION 4: T YPICAL E XTERNAL D IAGRAMS 17 ROBERTS GORDON ® ULTRAVAC™ Central Controller External Wiring (continued) for 115 V and 230 V inp u t V FD models. VFD Power Supply (1 Ø input VFD model shown, see NOTE 3) L1 L2 T 1 P u mp V FD Assem b ly ( 1 Ø inp u t V FD model sho w n) L1 L2 L1 L2 L1 L2 ...
Page 24 - FIGURE 12: ROBERTS GORDON; ot Gr
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 18 FIGURE 12: ROBERTS GORDON ® ULTRAVAC™ Satellite Controller External Wiring ADDRESS RESET 10VDC 499 OHM OFF ON OUT IN RI CD OH CPU BMS Ena b le (optional) N C C N O To Satellite Controller RS-4 8 5 (See N OTE 2) 120 V 1 Ø 60 Hz POWER L1 ...
Page 26 - SECTION 5: COMMUNICATIONS; See Page 25, Section; FIGURE 13: Modem Location; Modem
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 20 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 conve...
Page 27 - RS-485 Converter for Central Controller; and; nd Shield
SECTION 5: C OMMUNICATIONS 21 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 b...
Page 28 - For TCP/IP communication module wiring details,; FIGURE 15: TCP/IP Communication Module Mounting
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 22 5.3 TCP/IP Communication Module For remote on-site viewing of system status and settings of any controller, use the TCP/IP communi-cation module to connect the controllers to a Local Area Network (LAN) via Ethernet cable. Any computer o...
Page 29 - FIGURE 16: TCP/IP Communication Module Wiring
SECTION 5: C OMMUNICATIONS 23 FIGURE 16: TCP/IP Communication Module Wiring + - 1 + - 2 + - 4 + - 3 + - 5 + - 6 + - 7 + - 8 + - + - REF RS485 COMM REF + - 1 + - 2 + - 3 + - 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESET 10VDC 499 OHM OFFON OUTIN G IN OUT G G G +5 +32 AUX POWER RS232 DIRECT RI ...
Page 30 - FIGURE 17: 9 Pin Adapter for PC; Pin Adapter
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 24 5.4 Direct Connect For local viewing of system status and settings of any controller, a portable PC can be connected. Using the 9 pin adapter provided, ( See Page 24, Figure 17 ), you may wire from your computer serial port to the RS-23...
Page 31 - Communications Between Multiple ROBERTS GORDON; Gro; Controller
SECTION 5: C OMMUNICATIONS 25 5.5 Communications Between Multiple ROBERTS GORDON ® ULTRAVAC™ Controllers If more than one ROBERTS GORDON ® ULTRA- VAC™ Controller is installed in a building, the controllers’ RS-485 communications must be wired in series. See Page 25, Figure 18 . Connect the RS-485 te...
Page 32 - ULTRAVACTM controller; FIGURE 19: Repeater Wiring
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 26 5.5.1 Repeater If the RS-485 communications wire length is above 4000', a repeater must be used to extend the signal. The repeater can also be used to create parallel branches of ROBERTS GORDON ® ULTRAVAC™ controller communications bus ...
Page 33 - ULTRAVACTM; See
SECTION 6: V ARIABLE F REQUENCY D RIVE P ROGRAMMING 27 SECTION 6: VARIABLE FREQUENCY DRIVE PROGRAMMING6.1 VFD Parameter Settings For Use With ROBERTS GORDON ® ULTRAVAC™ The VFD parameters come with factory default set-tings. The following parameter settings must be changed for ROBERTS GORDON ® ULTRA...
Page 34 - Using the procedure described in
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 28 the password must be entered in order to access the parameters again. 6.2 Altering VFD Parameters Using the procedure described in Section 6.1.1 through Section 6.1.5 , alter the following parameters: Parameter Number Parameter Name Fac...
Page 35 - SECTION 7: COMMISSIONING THE CORAYVAC; Record Frequency Setting Here:
SECTION 7: C OMMISSIONING T HE CORAYVAC ® S YSTEM 29 SECTION 7: COMMISSIONING THE CORAYVAC ® SYSTEM NOTE: The ROBERTS GORDON ® ULTRAVAC™ software must be installed on the PC, the communi-cation connection must be made to the controller and all wiring of the ROBERTS GORDON ® ULTRAVAC™ control boards,...
Page 36 - FIGURE 20: End Vent Vacuum
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 30 FIGURE 20: End Vent Vacuum 65 4321 0 1234 56 Manometer Insert tubin g about 6" ( 1 5 cm ) into end vent . Combustion Chamber at end burner position End Vent Appro x imate readin g a f ter ad j ustin g VFD f requency settin g and / o...
Page 37 - FIGURE 21: Possible Damper Couplings’ Locations
SECTION 7: C OMMISSIONING T HE CORAYVAC ® S YSTEM 31 FIGURE 21: Possible Damper Couplings’ Locations Damper Couplin g Damper NOTE: Damper settin g w ill vary Zone 1 Zone 2 Zone 3 Zone 1 End Vent Zone 3 End Vent Zone 2 End Vent Zone 1 Damper Couplin g Zone 2 Damper Couplin g Zone 3 Damper Couplin g P...
Page 38 - on Page
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 32 Step 7.1.3 After setting end vent vacuums between 2.5" wc and 3.0" wc, while all the burners are still operating, use the down arrow button on the VFD to reduce the frequency of the output signal to the pump. Reduce the frequenc...
Page 39 - ULTRAVACTM Controller Replacement Parts; Use only genuine ROBERTS GORDON; FIGURE 22: ROBERTS GORDON; Part Number
SECTION 8: R EPLACEMENT P ARTS 33 SECTION 8: REPLACEMENT PARTS8.1 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 22: ROBERTS GORDON ® ULTRAVAC™ Controller Compon...
Page 40 - Variable Frequency Drive Replacement Parts; FIGURE 23: Variable Frequency Drive Components Diagram
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 34 8.2 Variable Frequency Drive Replacement Parts Caution: Use only genuine ROBERTS GORDON ® replacement parts. Use of parts not specified by Roberts-Gordon voids warranty. FIGURE 23: Variable Frequency Drive Components Diagram Comms Equal...
Page 41 - Replacement Parts Instructions
SECTION 8: R EPLACEMENT P ARTS 35 8.3 Replacement Parts Instructions 8.3.1 Plug-In Relay To replace the plug-in relay, turn off 120 V power to the relay board. Turn off the 24 V power switch on the relay board. Locate the malfunctioning relay and pull the relay from its socket. Fit a new relay in th...
Page 42 - Variable Frequency Drive 25 A or 10 A Fuse; ULTRAVACTM Controller. Turn
ROBERTS GORDON ® ULTRAVAC™ C ONTROLLER I NSTALLATION M ANUAL 36 8.3.6 Variable Frequency Drive 25 A or 10 A Fuse To replace a fuse, turn off input power to the variable frequency drive assembly at the breaker or disconnect switch. Turn off 120 V power to the relay board inside the ROBERTS GORDON ® U...
Page 45 - Ignition Module Diagnostic Codes:; un
SECTION 9: T ROUBLESHOOTING 39 Troubleshooting Flow Chart (continued) Ad j u st s y st em f or pr oper v ac uu m at the end v ent. See C ommissioning of the CR V S y st em f or det ails . W rong end v ent plat e ma y b e inst alled. Mak e s u re plat e and bu rner match. Is the end v ent v ac uu m s...
Page 47 - SECTION 10: THE ROBERTS GORDON
SECTION 10: T HE ROBERTS GORDON ® ULTRAVAC™ LIMITED W ARRANTY 41 SECTION 10: THE ROBERTS GORDON ® ULTRAVAC™ LIMITED WARRANTY ROBERTS-GORDON WILL PAY FOR: Within 42 months from date of shipment from Roberts- Gordon, replacement parts will be provided free of charge for any part of the controller whic...
