®
ROBERTS GORDON
™
UltraVac
PATENTED
Controls for
Modulating
®
CORAYVAC
Infrared Heating
Systems
Installation Manual
Installer
WARNING
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.
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.
Owner
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Installation must be done by an electrician
qualified in the installation and service of control
systems for heating equipment.
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
© 2011 Roberts-Gordon LLC
P/N 10081601NA Rev H 12/11
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TABLE OF CONTENTS
SECTION 1: Introduction........................................................2 SECTION 7: Variable Frequency Drive Programming........ 42
1.4 CORAYVAC® Design Requirements.............................2 SECTION 8: Commissioning The CORAYVAC® System .... 44
1.6 Check Installation Materials .........................................3 SECTION 9: Troubleshooting .............................................. 48
1.7 Safety Labels and Their Placement .............................3 SECTION 10: Replacement Parts ........................................ 55
Replacement Parts.................................................. 56
10.3 ULTRAVAC™ BMS Link Controller Replacement
2.5 Temperature Sensors................................................. 16 SECTION 11: The ROBERTS GORDON® ULTRAVAC™ Limited
Warranty.......................................................... 62
Controller and Variable Frequency Drive ...................21
3.4 Electrical Installation Requirements of ULTRAVAC™
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 regis-
tered 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®.
Roberts-Gordon LLC
© 2011
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.
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TABLE OF FIGURES
Specifications .......................................................... 18
Figure 8: Variable Frequency Drive Components
Controller External Wiring ......................................26
Controller External Wiring ......................................28
Figure 22: Repeater Communication Wiring Between Multiple
Figure 25: Communication Between ULTRAVAC™ BMS Link
Components Diagram............................................56
Figure 33: ULTRAVAC™ BMS Link Controller Components
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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 atten-
tion when reading and following
the warnings in these sections.
System status and settings are viewed and altered
from a PC (not supplied) running ROBERTS GOR-
DON® ULTRAVAC™ Software.
1.3 General Requirements
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.
DANGER
Installation, service and annual inspection of heater
must be done by a contractor qualified in the
installation and service of gas-fired heating
equipment.
Electrical Shock Hazard
Read this manual carefully before installation,
operation, or service of this equipment.
Disconnect electric before service.
Controller must be properly grounded to an
electrical source.
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 knowl-
edge, unless they have been given supervision or
instruction concerning use of the appliance by a per-
son responsible for their safety.
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 war-
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.
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, con-
tact your ROBERTS GORDON® independent distrib-
utor or Roberts-Gordon at (716) 852-4400, (800)
828-7450 or at www.rg-inc.com.
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 control-
ler, it will be necessary to check that the following
points have been considered:
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.
1.4 CORAYVAC® Design Requirements
CORAYVAC® burners shall be CRV B-6, B-8, B-9,
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.
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.
For the overall view of connected components for
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SECTION 1: INTRODUCTION
ERTS GORDON® independent distributor to obtain
replacement signs or labels. See Page 4, Figure 1
-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.
1.5 Example Site Layout
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™ CONTROLLER INSTALLATION MANUAL
FIGURE 1: ULTRAVAC™ Controller Label Placement
Light Label
Electrical Shock Hazard Label
Logo Label
Rating Plate Label
Front Door Panel (outside)
External Wiring Label
+
-
+
-
+
-
+
-
+
-
+
-
PWR
NC
C
N
O
N
C
C
N
O
N
C
C
NO NC
C
NO
L2 L1
24VAC
OUT IN
G
+32 +5
G
G
G
REF
OUT REF IN
4
3
2
1
RS232 DIRECT
AUX POWER
RS485 COMM
METER INPUTS
RESET
ADDRESS
OH CD RI
CPU
UNIVERSAL INPUTS
8
7
6
5
4
3
2
1
-
+
-
+
-
+
-
+
-
+
-
+
-
+
+
-
IN
NC
C NO NC C NO NC C NO NC C NO
OUT
499 OHM
10VDC
OFF
ON
Front Door Panel (inside)
Description
Logo Label
Part Number
91013207
91008005
91008007
91008004
91008003
91008001
Rating Plate Label
Light Label
Control Board Wiring Label
External Wiring Label
Shock Hazard label
Control Board Wiring Label
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SECTION 1: INTRODUCTION
FIGURE 2: ULTRAVAC™ BMS Link Controller Label Placement
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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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
FIGURE 3: VFD Label Placement
Electrical Shock Hazard Label
Side Panel (outside)
Front Door Panel (outside)
Rating Plate Label
Power Input
Rotary Disconnect
Variable Frequency Driver
1 Ø Input Model Shown
L1
L2/N
PE
B-
B+
Input Fuse Holder
Wiring Diagram Label
U
V
W
PE
PE
M16/12.P
Relay 120 V
Front Door Panel (inside)
Description
Part Number
Rating Plate Label
Wiring Label (230 V)
Wiring Label (460 V)
Shock Hazard label
91008006
91008004
91008003
91008001
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SECTION 1: INTRODUCTION
Connected Components (continued)
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I
9
+
+
-
+
-
+
-
4
3
2
1
Modem Chip
METER INPUTS
RESET
RESS
OH CD RI
-
ULTRAVAC™ Software
P
NC
C
N
O
N
C
C
N
O
N
C
C
N
O
N
C
C
NO
L2 L1
24VAC
O
U
T
I
N
G
+
3
2
+
5
G
G
G
REFOUT REF IN
RS485 COMM
4
3
2
1
RS232 DIRECT
AUX POWER
METER INPUTS
RESET
ADDRESS
O
H
C
D
R
I
CPU
(P/N 100816CDNA) contains:
ULTRAVAC™ Software,
UNIVERSAL INPUTS
8
7
6
5
4
3
2
1
-
+
-
+
-
+
-
+
-
+
-
+
-
+
+
-
IN
NC
C NO NC C NO NC C NO NC C NO
OUT
499 OHM
10VDC
499 OHM
OFF
ON
ULTRAVAC™ Software Manual.
(P/N 10081600NA)
Inside View
ULTRAVAC™ Controller
ULTRAVAC™ Installation Manual
(P/N 10081601NA), BACnet®
Software and Ruinet Manual.
with Modem Installed
Repeater (optional)
Supplied w/24 VAC
transformer inside
NEMA 1 enclosure
(P/N URVRP)
Inside View
Indoor Sensor
(P/N 10081502)
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SECTION 1: INTRODUCTION
URVCCM: ULTRAVAC™ Central Controller with Modem
+
+
-
+
-
+
-
4
3
2
1
Modem Chip
METER INPUTS
RESET
RESS
OH CD RI
+
-
+
-
+
-
+
-
+
-
+
-
PWR
NC
C
N
O
N
C
C
N
O
N
C
C
N
O
N
C
C
NO
L2 L1
24VAC
O
U
T
I
N
G
+
3
2
+
5
G
G
G
REFOUT REF IN
RS485 COMM
4
3
2
1
RS232 DIRECT
AUX POWER
METER INPUTS
RESET
ADDRESS
O
H
C
D
R
I
C
UNIVERSAL INPUTS
8
7
6
5
4
3
2
1
-
+
-
+
-
+
-
+
-
+
-
+
-
+
+
-
IN
NC
C NO NC C NO NC C NO NC C NO
OUT
499 OHM
10VDC
499 OHM
OFF
ON
Inside View
ULTRAVAC™ Controller
with Modem Installed
Repeater (optional)
Supplied w/24 VAC
transformer inside NEMA 1
enclosure (P/N URVRP)
Inside View
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.
PC Connection Cable Package
(P/N 10080410)
Outdoor Sensor
(P/N 10081501)
Indoor Sensor
(P/N 10081502)
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+
+
-
+
-
+
-
4
3
2
1
Modem Chip
METER INPUTS
RESET
RESS
OH CD RI
-
PWR
NC
C
N
O
N
C
C
N
O
N
C
C
N
O
N
C
C
NO
L2 L1
24VAC
O
U
T
I
N
G
+
3
2
+
5
G
G
G
REFOUT REF IN
RS485 COMM
4
3
2
1
RS232 DIRECT
AUX POWER
METER INPUTS
RESET
ADDRESS
O
H
C
D
R
I
CPU
UNIVERSAL INPUTS
8
7
6
5
4
3
2
1
-
+
-
+
-
+
-
+
-
+
-
+
-
+
+
-
IN
NC
C NO NC C NO NC C NO NC C NO
OUT
499 OHM
10VDC
499 OHM
OFF
ON
Inside View
ULTRAVAC™ Controller
with Modem Installed
Inside View
Repeater (optional)
Supplied w/24 VAC
transformer inside NEMA 1
enclosure (P/N URVRP)
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.
Outdoor Sensor
(P/N 10081501)
PC Connection Cable Package
(P/N 10080410)
RS-485 Converter Package (P/N 10080430)
Indoor Sensor
(P/N 10081502)
Power Supply
RS-485 Converter
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SECTION 1: INTRODUCTION
URVBNC: ULTRAVAC™ BMS Link Controller
ULTRAVAC™ Software (P/N 100816CDNA) contains:
ULTRAVAC™ Software, ULTRAVAC™
Software Manual. (P/N 10081600NA)
ULTRAVAC™ Installation Manual
(P/N 10081601NA),BACnet® or
ULTRAVAC™ BMS Link
Controller
Inside View
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™ CONTROLLER INSTALLATION MANUAL
Table 2: Common Components of ROBERTS GORDON® ULTRAVAC™ Controls
Part No.
Description
Variable Frequency Drives*
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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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
SECTION 2: SPECIFICATIONS
Link Controller.
2.1 ROBERTS GORDON® ULTRAVAC™ Controller
Standard enclosures are field
mounted inside the NEMA 4
enclosure.
2.1.1 Standard Enclosure
Construction: 16 gauge painted steel, hinged
door, removable knockouts
provided.
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): 14.7 x 17.7 x 3.5
(cm): 37.3 x 45.0 x 8.9
Dimensions: W x H x D
(in): 24 x 24 x 9
(cm): 61.0 x 61.0 x 22.9
2.1.2 Electrical
Protection
Rating:
Power Supply: 120 V (+/- 10%) 1 Ø, 60 Hz
UL Standard: UL 916 / C22.2 No. 205-M1983
NEMA 4, 12
Universal Inputs:
Eight Universal Inputs
Thermistor
2.4 Repeater
2.4.1 Standard Enclosure
0-10 Vdc
4-20m A
Resistance
Dry contact
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.
Analog Output:
One Analog Output 0-10 Vdc
Digital Inputs:
Digital Inputs: Timed, dry contact
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
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
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
2.5 Temperature Sensors
Indoor Sensor
Construction: 16 gauge painted steel, hinged
door, removable knockouts provided.
Dimensions: W x H x D
(in): 2.75 x 4.5 x 1.15
(cm): 7.0 x 11.4 x 2.9
Dimensions: W x H x D
(in):14.7 x 17.7 x 3.5
(cm): 37.3 x 45.0 x 8.9
Power:
Operating Temperature Range:
32° to 158° F (0° to 70° C)
32 V DC
2.2.2 Electrical
Power Supply: 120V (+/-10%) 1 Ø, 60 Hz
Ports:
Features:
LCD temperature display, setpoint
adjustment, override button
RS-485 Communications Bus
Ethernet/IP
Outdoor Sensor (P/N 10081501)
Dimensions: W x H x D
(in): 1.4 x 5.3 x 2
2.3 NEMA 4 Enclosure (P/N 10080302)
(cm): 3.6 x 13.5 x 5.1
Description: NEMA 4 enclosure is sold separately
as an option, for ULTRAVAC™
Operating Temperature Range:
Controller and ULTRAVAC™ BMS
-40° to 221° F (-40° to 5° C)
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SECTION 2: SPECIFICATIONS
Enclosure:
NEMA 4 gasketed aluminum LB
housing, ½" threaded connection
Voltage Surge Suppressor 277 / 480 V
Construction: NEMA 2X Enclosure
NEMA 4 Enclosure for Indoor Sensor
(P/N 10081510)
Volts:
277 / 480 V
50/60 Hz
Frequency:
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
Wiring Size: #12 AWG Standard Wire
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:
NEMA 4, 4X
UL-94-5V
Flammability
Rating:
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:
4 A
Volts:
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:
4 A
Volts:
480 V / 3 Ø
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
FIGURE 7: ROBERTS GORDON® ULTRAVAC™ Controller Specifications
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.
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SECTION 2: SPECIFICATIONS
2.7 Variable Frequency Drive (VFD)
2.7.1 Enclosure
.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%
Standard Models
Construction: 14 gauge painted steel, mounting
panel included, left-hinged door,
vented.
Amps:
6.9/6.0 A
Dimensions: W x H x D
(in): 12 x 14.375 x 8
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%
(cm): 30.5 x 36.5 x 20.3
Protection:
UL 50 Type 1, NEMA Type 1
NEMA 4 Models
Amps:
16.6 A
Description: Drive assembly and components fully
factory assembled inside NEMA 4
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%
enclosure. Enclosure dimensions and
construction vary by model.
Construction: VFD75115N4, VFD20230N4 and
VFD20460N4 enclosures are
Amps:
18.4/16.0 A
16 gauge painted steel, left hinged
door, non-vented.
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%
VFD75230N4 and VFD75460N4
enclosures are 14 gauge steel, left
hinged door, non-vented.
Amps:
3.0/2.5 A
Dimensions: W x H x D
VFD75115N4 (in): 20 x 16 x 10
(cm): 50.8 x 40.6 x 25.4
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%
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
Amps:
4.8/4.0 A
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)
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SECTION 3: INSTALLATION
SECTION 3: INSTALLATION
maximum ambient temperature does not exceed
104°F (40°C). Avoid installing the VFD in mezza-
nines, direct sunlight, or near external heat
sources because these locations usually have
unpredictable temperature rises.
DANGER
Note that the maximum distance from the controller
to any sensor is 300' (120 m). For longer distances,
larger gauge wire may be needed (Consult your local
distributor). For multiple controllers, maximum length
of communication wire from the first controller to the
last is 4000' (1219 m) without the use of a repeater. A
repeater is available for wire length greater than
between the RS-485 converter to the controller
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.
3.2.2 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.
3.1 Preparation
FIGURE 9: Controller Mounting
Before installing the controller, observe the following:
(Standard enclosure only, NEMA 4 enclosure mount-
ing varies)
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 Vari-
able Frequency Drive component names and loca-
3.2 Positioning the ROBERTS GORDON®
ULTRAVAC™ Controller and Variable Frequency
Drive
16.25"
(41.3 cm)
3.2.1 Choose a mounting location for the controller.
For serviceability, it is convenient to mount the con-
troller 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 hazard-
ous 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.
13" (33 cm)
VFD should be mounted in locations where the
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
VFD75230 or VFD75230N4
VFD20230 or VFD20230N4
VFD75460 or VFD75460N4
VFD20460 or VFD20460N4
14 AWG
12 AWG
14 AWG
14 AWG
3.3 Cable Requirements:
As per individual building specification for class of
cable to be used. Use copper conductors only.
• VFD(0-10 Vdc) Speed Reference Control Wiring
Shielded cable - one twisted pair of 22 AWG mini-
mum or equivalent Belden #8451, #1503A; General
Cable #C2514.
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.
3.3.4 Repeater
Below is the recommended cable for the various
connections for the repeater:
• Eight Digital Output (Relays)
The control connection for load of each individual
relay should be made with cable, size 16 AWG.
• Digital Input
• Line Power Supply
The power connection should be made with cable,
size 18 AWG.
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.
• 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
• Outdoor Sensor Cable
Shielded cable - One twisted pair of 22 AWG mini-
mum or equivalent Belden #8451, #1503A; General
Cable #C2514.
• Communications between Multiple Controllers
(RS-485)
One twisted pairs of 18 AWG minimum or equiva-
lent shield cable; Belden #1902, General Cable
#C1670A.
Electrical Shock Hazard
Disconnect electric before service.
3.3.2 ULTRAVAC™ BMS Link Controller
Controller must be properly grounded to an
electrical source.
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
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.
One twisted pair of 22 AWG minimum or equivalent
shield cable; Belden #1902, General Cable
#C1670A.
• Eight digital outputs for each individual relay must
not exceed 3 A.
NOTES:
3.3.3 Variable Frequency Drive (VFD)
• 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.
Below is the recommended cable for the various
connections for VFD:
• Line Power Supply
Input Wire Size Requirements
VFD P/N
Wire Size
VFD75115 or VFD75115N4
12 AWG
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SECTION 3: INSTALLATION
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
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
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)
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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 suit-
able for direct surface mounting or 4" (10.2 cm) x
2.13" (5.4 cm) junction box mounting.
3.8 Outdoor Sensor Placement
The outdoor sensor measures air temperature out-
side 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 12: Outdoor Sensor Placement
North
FIGURE 11: Indoor Sensor Mounting
Mounting
Hole
Plug-in LCD
Display
(grasp here
to unplug)
Outside
Sensor
Setback
Override
Button
Sensor
Module
facing down
SEN SET
O/R
-
+
Setpoint
Adjustment
Slide bar
Mount the outside sensor with the sensor module
facing down to prevent accumulation of dirt or water.
Mounting
Hole
3.9 Outside Air Supply
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
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 dis-
play 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
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SECTION 4: TYPICAL EXTERNAL DIAGRAMS
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.
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SECTION 4: TYPICAL EXTERNAL DIAGRAMS
ROBERTS GORDON® ULTRAVAC™ Central Controller External Wiring (continued)
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SECTION 4: TYPICAL EXTERNAL DIAGRAMS
ROBERTS GORDON® ULTRAVAC™ Satellite Controller External Wiring (continued)
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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.
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
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.
For remote on-site and off-site control and system
status viewing, the central controller (controller #1) is
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.
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.
An RS-485 converter is installed at a single PC, this
PC can interface with any controller on the network
of ULTRAVAC™ controllers. The RS-485 converter at
the PC is wired directly to controller #1 using
FIGURE 15: Modem Location
Dip Switch #1
Set to ON
Control Board of the
Central Controller
1 2 3 4 5 6 7 8
+
-
+
-
+
-
+
-
+
-
+
-
PWR
NC
C
NO NC
C
NO NC
C
NO NC
C
NO
L2 L1
24VAC
OUT IN
G
+32 +5
G
G
G
REF
OUT REF IN
4
3
2
1
RS232 DIRECT
AUX POWER
RS485 COMM
METER INPUTS
Modem
Chip
RESET
ADDRESS
OH CD RI
CPU
Installed
Modem Chip
UNIVERSAL INPUTS
8
7
6
5
4
3
2
1
-
+
-
+
-
+
-
+
-
+
-
+
-
+
+
-
IN
NC
C NO NC C NO NC C NO NC C NO
OUT
499 OHM
10VDC
OFF
ON
Phone Cable Connection
Description
Modem Chip
Part Number
10080142
5.1 Dedicated Phone Line for Central Controller
Modem
If multiple ULTRAVAC™ controllers are being used, the
The Central Controller is fitted with a modem chip. To additional controllers communicate to controller #1
use the modem, the controller must have a phone through RS-485 communication wiring arranged
line for modem communications. Install a phone line in-series from one controller to the next. See Page 35,
near the location of the Central Controller. The phone Section 5.5 This allows multiple controllers to be
cable is plugged into the phone connection in the controlled from a PC through a single communication
.
If the modem option is not used for everyday commu-
nication 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.
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SECTION 5: COMMUNICATIONS
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
485 converter to the controller should not be more
than 400' (122 m) in length.
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,
.
controlled from a PC through a single communication
package at the central controller.
FIGURE 16: RS-485 PC Connection
Description
Part Number
RS-485 Converter Package with
Power Supply
10080430
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
5.3 TCP/IP Communication Module
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 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 on the LAN that has ULTRAVAC™ soft-
ware installed can be used to communicate with the
controllers.
For TCP/IP communication module wiring details, see
.
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
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,
.
controlled from a PC through a single communication
package at the central controller.
FIGURE 17: TCP/IP Communication Module Mounting
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SECTION 5: COMMUNICATIONS
FIGURE 18: TCP/IP Communication Module Wiring
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 If a PC does not have a serial port, but does
controller, a portable PC can be connected. Using have a USB port, purchase of a USB to Serial
you may connect from your computer serial port to
A USB to 9-pin Serial Cable will allow connection
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
to any ROBERTS GORDON® ULTRAVAC™ Control-
ler 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.
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 con-
junction 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.
Plug one end of the phone cable into the RS-232
direct port, plug the other end into the adapter shown
pin serial port on your computer.
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SECTION 5: COMMUNICATIONS
5.5 Communications Between Multiple ROBERTS GORDON® ULTRAVAC™ Controllers
If more than one ROBERTS GORDON®
system status and settings can be viewed for any of
the controllers on the network.
ULTRAVAC™ Controller is installed in a building, the
controllers’ RS-485 communications must be wired in
RS-485 terminal on controller #1 to the RS-485
terminal on controller #2 and so on in a daisy chain
fashion. For communication cable requirements,
The control board identification dip switch must be
set on each ROBERTS GORDON® ULTRAVAC™
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 Dip Switch Order (1,2,3,4,5,6,7,8)
Controller/Address Dip Switch Order (1,2,3,4,5,6,7,8)
Number
Values (1=ON, 0=OFF)
Number
Values (1=ON, 0=OFF)
1 (Central Controller)
10000000
11
12
13
14
15
16
17
18
19
20
11010000
2
3
01000000
00110000
11000000
10110000
4
00100000
01110000
5
10100000
11110000
6
01100000
00001000
7
11100000
10001000
8
00010000
01001000
9
10010000
11001000
10
01010000
00101000
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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 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
Part Number
Repeater
URVRP
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
SECTION 6: ULTRAVAC™ BMS LINK CONTROLLER
6.1 ULTRAVAC™ BMS Link Controller Overview
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 communi-
cating to the building control system via BACnet®/IP,
BACnet® MSTP or MODBUS® protocol. The standard
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 com-
municate with third party building management con-
trol systems using BACnet® or MODBUS® protocol.
FIGURE 23: Standard ULTRAVAC™ BMS Link Architecture
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SECTION 6: ULTRAVAC™ BMS LINK CONTROLLER
FIGURE 24: ULTRAVAC™ BMS Link Controller Schematic
6.2 ULTRAVAC™ BMS Link Controller
Requirements
of controllers. The ULTRAVAC™ BMS Link Controller
is connected via communication wiring on the RS-
485 communication bus to the ULTRAVAC™ central
controller.
The purpose of the ULTRAVAC™ BMS Link Control-
ler 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.
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
This enables ULTRAVAC™ Controls to communicate
with a variety of controls.
For interface capability, one ULTRAVAC™ BMS Link
Controller is needed for each ULTRAVAC™ network
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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 pro-
gram allows the controller to interface with the proper
total number of ULTRAVAC™ Controls installed at
the jobsite. The total number of ULTRAVAC™ Con-
trols (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 documen-
tation 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 LINK CONTROLLER
FIGURE 25: Communication Between ULTRAVAC™ BMS Link Controller and Multiple ULTRAVAC™
Controllers
Controller Dip Switch Order (1,2,3,4,5,6,7,8) Address
Controller Dip Switch Order (1,2,3,4,5,6,7,8) Address
Number
Values (1=ON, 0=OFF)
Number
Number
Values (1=ON, 0=OFF)
Number
1 (Central
Controller)
11
12
13
14
15
16
17
18
19
20
00110000
12
13
14
15
16
17
18
19
20
21
01000000
2
10110000
2
3
11000000
00100000
10100000
01100000
11100000
00010000
10010000
01010000
11010000
3
4
01110000
11110000
4
5
00001000
5
6
10001000
6
7
01001000
7
8
11001000
8
9
00101000
9
10
11
10101000
10
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
SECTION 7: VARIABLE FREQUENCY DRIVE PROGRAMMING
7. 1 V F D Pa r a m e t e r S e tt i n gs For Use With
7. 1. 2
ROBERTS GORDON® ULTRAVAC™
Use the arrow buttons to scroll to the password value
(the factory set password is 225).
The VFD parameters come with factory default set-
tings. The following parameter settings must be
changed for ROBERTS GORDON® ULTRAVAC™.
Settings can only be altered when the pump motor is
stopped.
Press Mode to enter password.
Once the correct password value is entered, the dis-
play will read "P01", which indicates that the
PROGRAM mode has been accessed at the begin-
ning of the parameter menu (P01 is the first
parameter).
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™.
DANGER
Electrical Shock Hazard
NOTE: If the display flashes "Er", the password was
incorrect, and the process to enter the password
must be repeated.
Enclosure contains live electrical
components.
Programming must be done by a trained
technician only.
7. 1. 3 Use the arrow buttons to scroll to the desired
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.
Use arrow buttons to change setting.
7. 1. 1
Press Mode to store new setting and exit the
program mode.
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).
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).
Display reads "00"
Upper right decimal point blinks
If the Mode key is pressed within two minutes of exit-
ing the PROGRAM mode, the password is not
required to access the parameters. After two minutes,
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SECTION 7: VARIABLE FREQUENCY DRIVE PROGRAMMING
the password must be entered in order to access the
parameters again.
7. 2 A l t e r i n g VFD Parameters
ters:
Parameter Parameter Factory
New
Setting
Number
Name
Default
P01
Line Voltage
Start Method
01
01
05
P03
01
P05
Standard
Speed
01
(03) (0-10) Vdc
(04) (4-20) mA
Source
P44
P45
Password
225
Any #
000-999
Speed at
Minimum
Signal
0.0Hz
Frequency
Setting noted
P46
Speed at
Maximum
Signal
60.0Hz
Frequency
Setting noted
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
SECTION 8: 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, relay boards, burners, pumps and
VFD must be completed before starting the commis-
sioning procedure.
vacuum readings in the remaining branches are
proper. If necessary, adjust the proper damper cou-
pling to achieve an end vent vacuum of 2.5" - 3.0" wc.
be found near the end of the radiant portion of the
pipe in each branch or where a branch connects to
other branches at a cross or tee. See Page 46, Fig-
8.1 Setting The CORAYVAC® End Burner Vacuum
It is important to understand that the frequency that
the VFD runs the motor at, determines the speed of
the impeller in the pump. Variation of the impeller
speed will increase or decrease vacuum in the sys-
tem. The following procedure will help you set mini-
mum 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 but-
ton 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 low-
ering the end vent vacuum reading. Continue to
reduce the frequency until the end vent vacuum read-
ing is between 2.5" - 3.0" wc. Make note of this fre-
quency 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
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SECTION 8: COMMISSIONING THE CORAYVAC® SYSTEM
FIGURE 26: End Vent Vacuum
Combustion Chamber
at end burner position
End Vent
Insert tubing
about 6" (15cm)
into end vent.
6
5
4
3
2
1
0
1
2
3
4
5
6
Manometer
Approximate reading after adjusting
VFD frequency setting and/or
~
damper couplings. ( 2.5"-3" wc)
~
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SECTION 8: COMMISSIONING THE CORAYVAC® SYSTEM
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".
lowing parameters on the VFD:Return to the PC and
click the vacuum pump and three zones to "AUTO",
then click exit.
Parameter Parameter Factory
New
Setting
Number
Name
Default
P01
Line Voltage
Start Method
01
01
05
P03
01
P05
Standard
Speed
01
(03) (0-10) Vdc
(04) (4-20) mA
Source
P44
P45
Password
225
Any #
000-999
Speed at
Minimum
Signal
0.0Hz
Frequency
Setting noted
P46
Speed at
Maximum
Signal
60.0Hz
Frequency
Setting noted
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
Troubleshooting Flow Chart (continued)
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SECTION 9: TROUBLESHOOTING
Troubleshooting Flow Chart (continued)
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
Troubleshooting Flow Chart (continued)
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SECTION 10: REPLACEMENT PARTS
SECTION 10: REPLACEMENT PARTS
WARNING
DANGER
Electrical Shock Hazard
Explosion Hazard
Carbon Monoxide Hazard
Fire 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.
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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
24 V
Power
1 A Fuse
24 V
Power
Switch
Relay
Board
Plug-In
Relays
Reset
Button
Control
Board
Analog
Output
Board
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
Part Number
10080102
10080200
10080141
10080122
10080212
10080142
10080211
10081500
10081501
10081502
10080410
10080430
10080440K
10080600
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SECTION 10: REPLACEMENT PARTS
Description
Part Number
Relay 120 V Unitary
07100
Lights for 150 Style Control Board
Lamp Green Enclosure Mount w/o Light
Lamp Red Enclosure Mount w/o Light
Light Diode 24 Vac
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
Power Input
Frequency Drive
(1 Ø input model shown)
L1
L2/N
PE
B-
B+
Rotary
Dissconnect
Base Block
Relay
120 V
Fuse
Holder
Levers
M16/12.P
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
Part Number
10081201
10081202
10081203
10081204
10081205
90429100
91321410
91321425
91321300
91321400
91321550
91321551
91321552
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)
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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
Part Number
10081610
10081630
10081640
10081650
10081660
10081680
10081690
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
10.5 Replacement Parts Instructions
the doors.
DANGER
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.
Electrical Shock Hazard
Disconnect electric before service.
Slide the fuse back into the socket, press down and
turn the fuse a 1/4 turn clockwise until secure.
Controller must be properly grounded to an
electrical source.
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
10.5.5 Variable Frequency Drive (VFD)
To replace the plug-in relay, turn off 120 V power to
the relay board. Turn off the 24 V power switch on the To replace the Variable Frequency Drive, turn off all
relay board. Locate the malfunctioning relay and pull power to the drive assembly at the breaker or discon-
the relay from its socket.
nect switch. Turn off 120 V power to the relay board
inside the ROBERTS GORDON® ULTRAVAC™ Con-
troller. Turn off the 24 V power switch on the relay
board.
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.
Mark all wires connected to the VFD, noting the ter-
minals that they are secured to. Remove all wires
from the VFD terminals.
10.5.2 Control Board Power LED
Remove the VFD from its mounting plate by remov-
ing the four securing screws.
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 con-
trol board and the 24 V power 1 A fuse.
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 ter-
minals. If possible, it may be easier to partially re-
wire the new VFD before mounting it to the mounting
plate.
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:
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 but-
ton on the control board and close the doors.
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.
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.
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 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.
Turn on the 24 V power switch on the relay board,
press the reset button on the control board and close
Inside the VFD assembly, open the fuse holder by
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SECTION 10: REPLACEMENT PARTS
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 but-
ton on the control board and close the doors.
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ROBERTS GORDON ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
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
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:
(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
ROBERTS GORDON® Replacement Parts are warranted 1250 William Street
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:
Service trips, service calls and labor charges.
P. O. B ox 4 4
Buffalo, New York 14240-0044
716.852.4400
On the web at: www.rg-inc.com
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.
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.
• Incorrect gas or electrical supply, accident, fire, floods,
acts of God, war, terrorism, or other casualty.
• Improper service, use of replacement parts or acces-
sories 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
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.
a corrosive atmosphere containing contaminants.
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.
• 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 sup-
plied by or on behalf of the consumer.
• Damage incurred during shipment. Claim must be filed
with carrier.
LIMITATIONS ON AUTHORITY OF
REPRESENTATIVES:
No representative of Roberts-Gordon, other than an
Executive Officer, has authority to change or extend these
provisions. Changes or extensions shall be binding only if
confirmed in writing by Roberts-Gordon's duly authorized
Executive Officer.
WARRANTY IS VOID IF:
The ROBERTS GORDON® ULTRAVAC™ is not installed
by an electrician qualified in the installation and service of
control systems for heating equipment.
You cannot prove original purchase date and required
annual maintenance history.
The data plate and/or serial number are removed,
defaced, modified or altered in any way.
The ownership of the ROBERTS GORDON®
ULTRAVAC™ is moved or transferred. This warranty is
nontransferable.
Roberts-Gordon is not permitted to inspect the damaged
controller and/or component parts.
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