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Roberts Gorden UltraVac URVBNC, Installation Manual

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ROBERTS GORDON

®

 ULTRAVAC™ C

ONTROLLER 

I

NSTALLATION 

M

ANUAL

46 of 65

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 1.2" wc - 
1.5" wc, Make note of this frequency setting below. 

The frequency is found on the VFD’s LCD screen.

1.2" w.c. - 1.5" wc VFD Frequency Setting

Step 8.1.4 

Return to the PC and click the pump and 

zones to "OFF".

Record Frequency Setting Here:

Summary of Contents for UltraVac URVBNC

Page 1: ... 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 service technician 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 ...

Page 2: ......

Page 3: ... 11 Low Voltage Power 21 SECTION 4 Typical External Diagrams 22 SECTION 5 Communications 27 5 1 Dedicated Phone Line for Central Controller Modem 27 5 2 RS 485 Converter for Central Controller 28 5 3 TCP IP Communication Module 29 5 4 Direct Connect 30 5 5 Communications Between Multiple ROBERTS GORDON ULTRAVAC Controllers 32 SECTION 6 ULTRAVAC BMS Link Controller 35 6 1 ULTRAVAC BMS Link Controll...

Page 4: ......

Page 5: ...or at www robertsgordon com 1 2 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 ERTS GORDON independent distributor to obtain replacement signs or labels 1 3 California Proposition 65 In accordance with California Proposition 65 require ments a warning label must be...

Page 6: ...ORAYVAC 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 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 7 Examp...

Page 7: ...SECTION 1 INTRODUCTION 3 of 65 FIGURE 1 Connected Components ...

Page 8: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 4 of 65 Connected Components continued ...

Page 9: ... LAN Communication Module with PC Connection Cable Package P N 10080440K Outdoor Sensor P N 10081501 ULTRAVAC Controller with Modem Installed Repeater optional Supplied w 24 VAC transformer inside NEMA 1 enclosure P N 10060153 Inside View ULTRAVAC Software P N 100816CDNA contains ULTRAVAC Software ULTRAVAC Software Manual P N 10081601NA ULTRAVAC Installation Manual P N 10081600NA BACnet Software a...

Page 10: ...ckage P N 10080410 ULTRAVAC Controller with Modem Installed Inside View Repeater optional Supplied w 24 VAC transformer inside NEMA 1 enclosure P N 10060153 ULTRAVAC Software P N 100816CDNA contains ULTRAVAC Software ULTRAVAC Software Manual P N 10081601NA ULTRAVAC Installation Manual P N 10081600NA BACnet Software and Ruinet Manual Indoor Sensor P N 10081502 ...

Page 11: ...ble Package P N 10080410 ULTRAVAC Controller with Modem Installed Inside View RS 485 Converter Repeater optional Supplied w 24 VAC transformer inside NEMA 1 enclosure P N 10060153 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 Indoor Sensor P N 10081502 ...

Page 12: ...troller 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 ULTRAVAC BMS Link Controller VDC VDC 24VAC 24VAC POWER SUPPLY PS1 1 2 3 4 5 POWER 5 PORT ETHERNET HUB PORT 1 PORT 2 PORT 3 PORT 4 PORT 5 NETWORK ROUTER Inside View ...

Page 13: ...ely 10081601NA ULTRAVAC Installation and Operation Manual 10081600NA ULTRAVAC Software Manual URVU ULTRAVAC Unitary Controller with Software CD Manual IOS Manual URVBNC ULTRAVAC ULTRAVAC BMS Link Controller with Software CD Manual IOS Manual URVSC Controller ULTRAVAC 1 Pump 3 Zones Satellite Control Manual Part No Description Variable Frequency Drives VFD75115 Variable Frequency Drive Assembly 75 ...

Page 14: ... 10081501 Sensor Outdoor URV 10081502 Sensor Adjustable Indoor C URV 90602450 Voltage Surge Supresser 277 480 V 90602451 Voltage Surge Supresser 120 V 90602452 Voltage Surge Supresser 120 240 V 1Ø 60 Hz 90602460 Line Reactor 480 V 3Ø 60 Hz w Enclosure Output 90602461 Line Reactor 230 V 3Ø 60 Hz 3 4 HP Output 90602462 Line Reactor 230 V 3Ø 60 Hz 2 HP Output 90602470 Line Reactor 480 V 3Ø 60 Hz 4 A ...

Page 15: ...GURE 2 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 Variable Frequency Drive North Wall Outside Sensor Pump ROBERTS GORDON ULTRAVAC Controller ...

Page 16: ...45 0 x 8 9 2 2 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 Three Relay Outputs Normally Open Single Pole Rating 8 A 120 VAC Ports RS 485 Communications Bus RS 232 Di...

Page 17: ...emperature 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 galvanize...

Page 18: ...5 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 230 V 3 Ø Voltage Surge Suppressor 277 480 V Construction NEMA 2X Enclosure Volts 277 480 V Frequency 50 60 Hz Wiring Size 12 AWG Standard Wire ...

Page 19: ...LTRAVAC 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 ...

Page 20: ...6 x 10 cm 50 8 x 40 6 x 25 4 Protection NEMA 3R 4 12 13 2 8 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 In...

Page 21: ...SECTION 2 SPECIFICATIONS 17 of 65 FIGURE 4 Variable Frequency Drive Components Factory pre wiring shown ...

Page 22: ...4 rated enclosures will withstand exposure to dust dirt and water VFD should be mounted in locations where the 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 Note that the maximum distance from the controller to any sensor is 300 120 m F...

Page 23: ...or Cable Shielded cable One twisted pair of 18 AWG mini mum or equivalent Belden 8451 1503A General Cable C2514 Communications between Multiple Controllers RS 485 One twisted pairs of 22 AWG minimum or equiva lent shielded cable Belden 3105A 3 4 5 ULTRAVAC Unitary Controller Below is the recommended cable for the various connections for ULTRAVAC Unitary Controller Line Power Supply The power conne...

Page 24: ... output from the relay board switched through a designated relay 3 7 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 16 Section 2 8 for additional details The VFD on off swit...

Page 25: ...en screws Wiring from 32 V terminals on the controller to sensor power terminals and is polarity sensitive Reversing polarity may cause sensor or control board damage Refer to Page 23 Figure 9 and Page 25 Figure 10 for wiring details 3 9 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 buildi...

Page 26: ...UAL 22 of 65 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 ...

Page 27: ...SECTION 4 TYPICAL EXTERNAL DIAGRAMS 23 of 65 FIGURE 9 ROBERTS GORDON ULTRAVAC Central Controller External Wiring ...

Page 28: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 24 of 65 ROBERTS GORDON ULTRAVAC Central Controller External Wiring continued ...

Page 29: ...SECTION 4 TYPICAL EXTERNAL DIAGRAMS 25 of 65 FIGURE 10 ROBERTS GORDON ULTRAVAC Satellite Controller External Wiring ...

Page 30: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 26 of 65 ROBERTS GORDON ULTRAVAC Satellite Controller External Wiring continued ...

Page 31: ...the controllers Appropriate precautions must be taken to protect the Ethernet wiring from any possible electrical interference noise caused by surrounding machinery or equipment If multiple ULTRAVAC controllers are being used the additional controllers communicate to controller 1 through communication wiring arranged in series from one controller to the next See Page 32 Section 5 5 FIGURE 11 Modem...

Page 32: ... Figure 12 and see Page 32 Section 5 5 Wiring between the RS 485 converter to the controller should not be more than 400 122 m in length For communication cable requirements see Page 19 Section 3 3 If multiple ULTRAVAC controllers are being used the additional controllers communicate to controller 1 through RS 485 communication wiring arranged in series from one controller to the next See Page 32 ...

Page 33: ...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...

Page 34: ...o the RS 232 direct port plug the other end into the adapter shown in on Page 31 Figure 15 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 se...

Page 35: ...SECTION 5 COMMUNICATIONS 31 of 65 FIGURE 15 9 Pin Adapter for PC Description Part Number PC Connection Cable Package 10080410 ...

Page 36: ... module the 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 32 Figure 16 for dip switch settings Contact Roberts Gordon or your ROBERTS GORDON independent distributor if more than 20 controllers are connected FIGURE 16 Communications Between Multiple Contro...

Page 37: ...ROBERTS GORDON ULTRAVAC Controllers that can be installed is 242 FIGURE 17 Repeater External Wiring REP 485 ON OFF BT 485 CONNECTOR ERTH GROUND REP 485 POWER CONNECTOR NETWORK B NETWORK B POWER JUMPER CONNECTOR BT 485 CONNECTOR NETWORK A CONNECTOR NETWORK A LED1 LED2 24 Vac LINE LOAD 3 1 4 5 1 2 0 8 Amps Fuse From Controller L1 L2 120 vac 1 2 2 1 3 2 1 1 2 3 LED3 120V 60HZ 1 3 24V 20VA 4 5 TRANSFO...

Page 38: ... NETWORK B NETWORK B POWER JUMPER CONNECTOR BT 485 CONNECTOR NETWORK A CONNECTOR NETWORK A LED1 LED2 24 Vac LINE LOAD 3 1 4 5 1 2 0 8 Amps Fuse 1 2 2 1 3 2 1 1 2 3 LED3 120V 60HZ 1 3 24V 20VA 4 5 TRANSFORMER Terminal Block GREEN BLACK BLACK WHITE BLUE YELLOW GREEN REP 485 ON OFF BT 485 CONNECTOR ERTH GROUND POWER CONNECTOR NETWORK B NETWORK B POWER JUMPER CONNECTOR BT 485 CONNECTOR NETWORK A CONNE...

Page 39: ...tem can com municate with third party building management con trol 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 communi c...

Page 40: ...a 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 i...

Page 41: ...al 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 ...

Page 42: ...ues 1 ON 0 OFF Address Number 1 Central Controller 01000000 2 2 11000000 3 3 00100000 4 4 10100000 5 5 01100000 6 6 11100000 7 7 00010000 8 8 10010000 9 9 01010000 10 10 11010000 11 Controller Number Dip Switch Order 1 2 3 4 5 6 7 8 Values 1 ON 0 OFF Address Number 11 00110000 12 12 10110000 13 13 01110000 14 14 11110000 15 15 00001000 16 16 10001000 17 17 01001000 18 18 11001000 19 19 00101000 20...

Page 43: ...LTRAVAC Unitary Controller The ULTRAVAC Unitary Controller is for use with unitary heaters See wiring diagrams for installation FIGURE 22 ULTRAVAC Unitary Relay Board External Wiring Diagram FIGURE 23 ULTRAVAC Unitary Control Board External Wiring Diagram ...

Page 44: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 40 of 65 FIGURE 24 ULTRAVAC Unitary Internal Diagram ...

Page 45: ... 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 NOTE If the display flashes Er the password was incorrect and the process to enter the password must be repeated 7 1 3 Use the arrow buttons to scroll to the desired parameter number For new parame...

Page 46: ...ogramming the drive and to enter a changed parameter value UP AND DOWN BUTTONS Used for programming and can also be used as a reference for speed PID setpoint or torque setpoint When the UP and DOWN buttons are the active ref erence the middle LED on the left side of the display will be on To go to the PROGRAM mode and access the parameters press RUN button then follow the VFD parameter below and ...

Page 47: ...hould 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 See Page 44 Figure 25 If the lowest end vent vacuum read...

Page 48: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 44 of 65 FIGURE 25 End Vent Vacuum ...

Page 49: ...ons Damper Coupling Damper NOTE Damper setting will vary Zone 1 Zone 2 Zone 3 Zone 1 End Vent Zone 3 End Vent Zone 2 End Vent Zone 1 Damper Coupling Zone 2 Damper Coupling Zone 3 Damper Coupling Pump Damper Description Part Number Damper Coupling 4 10 cm 01331900 Damper Coupling 6 15 cm E0009356 ...

Page 50: ...w 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 2 wc 1 5 wc Make note of this frequency setting below The frequency is found on the VFD s LCD screen 1 2 w c 1 5 wc VFD Frequency Setting Step 8 1 4 Return to the PC and click the pump and zones to OFF Record Frequency Setting Here ...

Page 51: ...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 ...

Page 52: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 48 of 65 FIGURE 27 Troubleshooting Flow Chart ...

Page 53: ...SECTION 9 TROUBLESHOOTING 49 of 65 Troubleshooting Flow Chart continued ...

Page 54: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 50 of 65 Troubleshooting Flow Chart continued ...

Page 55: ...SECTION 9 TROUBLESHOOTING 51 of 65 Troubleshooting Flow Chart continued ...

Page 56: ...ROBERTS GORDON ULTRAVAC CONTROLLER INSTALLATION MANUAL 52 of 65 FIGURE 28 Troubleshooting Flow Chart Repeater ...

Page 57: ...SECTION 9 TROUBLESHOOTING 53 of 65 FIGURE 29 Troubleshooting Flow Chart BACnet ...

Page 58: ...current Installa tion Operation and Service manual to help ensure all safety systems are in working order before leaving the heater to operate Minor faults may be traced by using the troubleshooting charts Carbon Monoxide Hazard WARNING Use only genuine ROBERTS GORDON replacement parts per this installation operation and service manual Failure to follow these instructions can result in death elect...

Page 59: ...80201 URV Eprom Chip 150 Style current version 10080122 Plug In Relay 10080213 Modem Chip located only on central controller 10080142 7 A Fuse Relay Board 10080210 ROBERTS GORDON ULTRAVAC Indoor Sensor F not shown 10081500 ROBERTS GORDON ULTRAVAC Outdoor Sensor not shown 10081501 ROBERTS GORDON ULTRAVAC Indoor Sensor C not shown 10081502 PC Connection Cable Package not shown 10080410 RS 485 Conver...

Page 60: ... 230 V 1 Ø Input for use with EP 203 10081202 Variable Frequency Drive 3 4 HP 230 V 3 Ø Input for use with EP 203 10081211 Variable Frequency Drive 2 HP 230 V 1 Ø Input for use with EP 303 10081203 Variable Frequency Drive 1 HP 480 V 3 Ø Input for use with EP 203 10081204 Variable Frequency Drive 2 HP 480 V 3 Ø Input for use with EP 303 10081205 Relay 120 V 90429100K Fuse 10 A for 75 HP 230 V VFD ...

Page 61: ...omponents Diagram Description Part Number Communication Module 10081610 Supervisor Board 10081630 Module NetBurner 10081640 Circuit Breaker 5A 10081650 Transformer 100VA001 10081660 Memory Card SD 16 GB 10081680 Fuse Micro 125 V 1 4A 10081690 Power Supply 10081670 Router 10081620 ...

Page 62: ... 10060143 Fuse 0 8A 91319910 Transformer 90436900 REP 485 ON OFF BT 485 CONNECTOR ERTH GROUND REP 485 POWER CONNECTOR NETWORK B NETWORK B POWER JUMPER CONNECTOR BT 485 CONNECTOR NETWORK A CONNECTOR NETWORK A LED1 LED2 24 Vac LINE LOAD 3 1 4 5 1 2 0 8 Amps Fuse 1 2 2 1 3 2 1 1 2 3 LED3 120V 60HZ 1 3 24V 20VA 4 5 TRANSFORMER Terminal Block GREEN BLACK BLACK WHITE BLUE YELLOW GREEN ...

Page 63: ...t 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 10 5 5 Variable Frequency Drive VFD To replace the Variable Frequency Drive turn off all power to the d...

Page 64: ...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 120 V power switch on the relay board Press the reset but ton on the control board and close the doors ...

Page 65: ......

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Page 67: ...ual 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 LLC is not permitted to inspect the damaged controller and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your control c...

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