Roberts Gorden nRG Control Setup guide

Roberts-Gordon Europe Limited
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands, WS10 7SH UK
Telephone: [phone]
Fax: [phone]
Service Telephone: [phone]
Service Fax: [phone]
E-mail: [e-mail]
E-mail: expor[email protected]
www.rg-inc.com
www.combat.co.uk
www.blackheatheaters.co.uk
WARNING
Installation must be done by an electrician qualified
in the installation and service of control systems
for heatingequipment.
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installingor
servicingthis equipment.
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Owner
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
© 2012 Roberts-Gordon Europe Limited
ROBERTS GORDON®
NRG Control
Installation, Operation and Service Manual
P/N X235 Rev F 06/12
Energy Saving Control for
ROBERTS GORDON®Infrared and
Warm Air Heating Equipment

© 2012
Roberts-Gordon Europe Limited
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 Europe Limited.
Printed in U.K.
TABLE OF CONTENTS
SECTION 1: Introduction........................................................ 2
1.1 Safety Labels and Their Placement .............................2
1.2 What is a ROBERTS GORDON®NRG Control? .......... 2
1.3 General Requirements ................................................. 2
1.4 Control Location ........................................................... 2
1. 5 N e t work Installation...................................................... 2
1.6 Installation Requirements............................................. 3
1.7 Programming Details ....................................................3
SECTION 2: Specifications .................................................... 4
2.1 Material Specifications .................................................4
2.2 Keypad Layout ............................................................. 4
SECTION 3: Installation.......................................................... 6
3.1 Installing the ROBERTS GORDON®NRG Control ...... 6
3.2 Electrical Installation Requirements............................. 7
SECTION 4: Wiring.................................................................. 9
4.1 Network Wiring ............................................................ 9
4.2 LowVoltage Wiring .................................................... 10
4.3 CTU Wiring ................................................................ 11
4.4 CTCU Wiring.............................................................. 11
4.5 Interface Relay Wiring for Multiple Warm Air
Heaters ...................................................................... 12
4.6 PGP/POP Range Wiring - 1 Ø Cabinet Heaters ........ 12
4.7 PGP/POP Range Wiring - 3 Ø Cabinet Heaters ........ 13
4.8 Cabinet Heater Remote Lockout Reset Wiring .......... 13
4.9 Unitary Radiant System Wiring .................................. 14
4.10 CORAYVAC®and Multiburner Systems Wiring ........ 15
SECTION 5: Programming and Operation .......................... 16
5.1 Stand Alone Unit........................................................ 16
5.2 Network Unit .............................................................. 16
5.3 System Language ...................................................... 16
5.4 Network Open Level User Functions ......................... 18
5.5 Manager Settings....................................................... 22
5.6 Engineer Settings ......................................................28
SECTION 6: Standard Screen Messages ............................ 36
6.1 Stand Alone Control Screen Messages ..................... 36
6.2 Network Control Screen Message ............................. 37
6.3 Fault Messages ......................................................... 37

TABLE OF FIGURES
Figure 1: Keypad Layout ........................................................... 4
Figure 2: Remote Sensors ........................................................ 5
Figure 3: Cover Detail ...............................................................6
Figure 4: Mounting Hole Layout ................................................ 6
Figure 5: Cable Entry ................................................................ 6
Figure 6: Control Terminals and Relay Use............................... 7
Figure 7: Ferrite EMC Filter.......................................................7
Figure 8: Sensor Mounting Plate - Warm Air ............................ 7
Figure 9: Remote Temperature Sensor - Radiant ..................... 8
Figure 10: Sports Hall Sensor ...................................................8

1
Product Approval
ROBERTS GORDON
®
appliances have been tested and CE certified as complying with the
essential requirements of the Gas Appliance Directive, the Low Voltage Directive, the
Electromagnetic Compatibility Directive and the Machinery Directive for use on natural gas, LPG
and fuel oil when installed, commissioned and maintained in accordance with these instructions.
These instructions refer to appliances designed to operate in the European Union.
Appliances designed for other countries (non European Union) are available on request.
This appliance must be installed in accordance with the local and national codes in force and used
only in a sufficiently ventilated space, as specified in these instructions.
Before installation, check that the local gas distribution systems, nature of gas and pressure, and
adjustment of the appliance are compatible.

ROBERTS GORDON®NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
2
SECTION 1: INTRODUCTION
Your Safety is Important to Us!
This symbol is used throughout
the manual to notify you of
possible fire, electrical or burn
hazards. Please pay special
attention when reading and fol-
lowing the warnings in these
sections.
Installation, service and annual inspection of
controller must be done by an electrician qualified in
the installation and service of control systems for
heating equipment.
Installation, service and annual inspection of heater
must be done by a contractor qualified in the
installation and service of gas or oil fired heating
equipment.
Read this manual carefully before installation,
operation, or service of this equipment.
The appliance must be applied and operated under
the general concepts of resonable use and installed
using best building practices.
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given
supervision or instruction concerning use of the
appliance by a person responsible for their safety.
Children should be supervised to ensure that they
do not play with the appliance.
For optimum heater performance and safe heating
conditions, inspect and maintain heater(s) before
every heating season and as necessary. Also, know
and maintain heater clearances to combustibles,
see heater Installation, Operation and Service
Manual for further details. If you require additional
manuals, contact Roberts-Gordon at [phone]
7700 or at www.rg-inc.com.
1.1 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.
1.2 What is a ROBERTS GORDON®NRG
Control?
The ROBERTS GORDON®NRG Control is a micro
processor based controller designed for efficient
control of ROBERTS GORDON®warm air and
radiant products. Each control is intended for the
operation of a single zone of heating but is designed
so that individual controls may be linked to form a
network that will allowinformation and settings to be
available at one or any of the units dependant upon
site configuration. The controls will operate the
following products:
• Warm air heaters On/Off operation
• Unitary BLACKHEAT®radiant systems
•BLACKHEAT
®multi burner systems on a single
zone*
•CORAYVAC
®systems on a single zone*
•Heaterswith two stage High/Lowoperation
•Heaterswith modulating burners requiring a 0-
10V DC input
*For safe use of multiburner and CORAYVAC®systems with up
to four zones operating with a single shared fan, the additional
use of the ROBERTS GORDON®System Control will be
required with a ROBERTS GORDON®NRG Control installed for
each zone.
1.2.1 Features of the ROBERTS GORDON®NRG
Control.
• Coded access to set up and network functions to
prevent unauthorised access.
• Built in temperature sensor.
• Remote temperature sensor option.
• Self learning optimum start.
• Automatic correction for daylight saving time
changes.
• Burner lockout indication and reset for suitable
heater systems.
• Pre programmed holiday functions.
• May be connected on a network to give access
to all controls from a single point.
• Programmed in 5 languages as standard.
• Data logging of hours run and temperatures.
1. 3 G e n e r a l R e quirements
The ROBERTS GORDON®NRG Control is only for
use with ROBERTS GORDON®heating products.
On site commissioning is required to ensure that the
temperature sensor is calibrated, and that the
options available are selected correctly. Before
proceeding with installation, it will be necessary to
check that the following points have been
considered.
1.4 Control Location
Each control is intended to operate a single zone of
heating. The built in sensor may be used for
temperature control. In this case, position the control
as in Section 1.6.1 through Section 1.6.3.
When remote temperature sensors are required, the
control may be fitted in any suitable location. If
required, two remote sensors may be installed. The
average of the two sensors will be calculated by the
control.
1.5 Network Installation
The ROBERTS GORDON®NRG Control may be
installed on a network so that all controls may be
accessed from a single control, selected controls or
all controls dependant upon howthey are configured
on site. To use the control on a network simply
requires the wiring of the COMS port on one control
to connect to the COMS port on each of the other
controls in a continuous loop.
It will then be possible to set program times and
temperatures for all controls from one location and
copy programs from one control to another.
It will also be possible to read the current status of
all controls from a single station.

SECTION 1: INTRODUCTION
3
1.6 Installation Requirements
1.6.1 Radiant Tube Heaters
The ROBERTS GORDON®NRG Control can
operate up to ten burners providing that the
electrical load on each relay does not exceed 7 A
inductive.
Mount the ROBERTS GORDON®NRG Control (or
remote sensor if fitted) on a wall or column at a
height of approximately 1.5 to 1.8 metres from the
floor.
The ROBERTS GORDON®NRG Control, or sensor,
should be in a position to monitor an average radiant
temperature. Keep clear of cold draughts, direct
sunlight, direct radiant field heaters and areas of
little air movement such as corners. For larger
systems, use two remote sensors to provide closer
temperature control.
1.6.2 Warm Air Heaters
The ROBERTS GORDON®NRG Control can
operate a single warm air heater. However up to four
heaters may be controlled from each control if each
heater is provided with interface relays See Page 12,
Section 4.5.
Mount the ROBERTS GORDON®NRG Control, or
remote sensor, on a wall or column at a height of
approximately 1.5 to 1.8 metres from the floor. The
ROBERTS GORDON®NRG Control, or sensor,
should be positioned where it will monitor an
average room temperature. Keep clear of cold
draughts, direct sunlight, path of warm air from the
heater and areas of little air movement such as
corners.
1.6.3 Multiple Unit Considerations
When using the control to operate more than one
radiant or warm air heater, careful consideration
should be given to the position of the control or
remote temperature sensor because the single
temperature monitoring point controls all of the
heaters that are connected. The use of two remote
sensors may provide closer temperature control.
For warm air heaters, the interface relay D 258 must
be installed, in accordance with Page 12, Section
4.5, adjacent to each heater to ensure that the
electrical supply at each heater is isolated for
maintenance.
For larger air heaters, it may not be practical to
operate more than one heater from a single control
due the larger area covered by these heaters.
Contact Roberts-Gordon Europe Limited for further
advice on control location and application.
1.6.4 Installation Materials
Shielded cable Belden 8451, General Cable C 2514,
or equivalent rated for up to 300 V must be used for
sensors, modulating 0-10 V output, 12 V DC inputs
and network bus connections. Maximum cable
length for each sensor is 100 m. Maximum cable
length for network is 1,000 m. Keep control cables
away from high current mains circuits to prevent
signal interference.
1.6.5 Electrical Requirements
The controller must have a 230 V 50 Hz
power supply wired with the Ferrite EMC filter See
Page 7, Section 7 in accordance with the relevant
wiring diagram from Page 9, Section 4.
1.7 Programming Details
Every control is programmed with default settings
and may be reconfigured to suit the needs of the
installation. See Page 30, Section 5.6.3 and Page
31, Table 1.
When supplied each ROBERTS GORDON®NRG
Control is configured as a stand alone unit.
Each unit must be configured to operate the heating
equipment it is controlling. See Page 30, Section
5.6.3 and Page 31, Table 1.
The programming for stand alone units and network
units is similar. However, for network units, they
must be network configured first. See Page 28,
Section 5.6.1.
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.

ROBERTS GORDON®NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
4
SECTION 2: SPECIFICATIONS
Figure 1: Keypad Layout
2.1 Material Specifications
2.1.1 Enclosure
Enclosure Material: ABS fire retardant
Weight: 1.6 kg
Dimensions: 158 mm x 62 mm x 220 mm
2.1.2 Electrical
Supply: 230 V ± 10% 50 Hz 1 Ø
Outputs: 3 single pole normally open
Rated at 10 A resistive or
7 A inductive.
Battery Back Up: 3 Months.
Built in Fuses
Main Fuse: FS1 800 mA anti-surge
PCB Protection FS2 315 mA quick blow
12 V Output FS3 315 mA quick blow
2.1.3 Sensors
Sensor: Built in as standard
Remote available as option
Remote Sensor:
Warm Air & Radiant 80 mm x 80 mm x 22 mm
Black Bulb Radiant 68 mm diameter x 50 mm
Sports Hall Sensor Flush Mounting
2.1.4 Program Features
Zones: One
Programs: 3 timed periods per day,
7 days per week.
Optimum Start: Selectable
Night Set Back: Selectable
Burner Modulation: Selectable (0-10 V DC output.
0 V=lowfire)
Two Stage Burner Selectable
Burner Lockout:
Indication & Reset: Available for use with suitable
heater types
Pressure Switch Connections for fan proving
for CORAYVAC®systems
Network Up to 32 units may be
connected together on a
network using Belden 8451
shielded cable
2.2 Keypad Layout
1. LCD Readout
2. Run button and fan button, returns to standard
screen from programming options, manual
operation of fan on warm air heaters.
3. Program button and copy button used to enter
program options areas and copy time program.
4. Override button and summer button, used to
allowoperating time to be extended and set
control in summer mode.
5. Information button and reset button shows
current setting and status plus burner lockout
reset.
6. Built in temperature sensor.
7. Delete button cancels input during
programming (move forward around network).
8. Numerical key pad for inputting information.
Quality in Any Language™
2
1
0
12
456
89
ENTER DELETE
INFO
RESET
3
7
OVER
SUMMER
PROG
COPY
RUN
FAN
UK • [phone]
USA • 1.716.852.4400
WEB • www.rg-inc.com
DANGER - 230 V50 Hz
DISCONNECT FROM ELECTRICALSUPPLY
BEFORE REMOVING THIS COVER
3
4
5
6
789
®
NRG Control
®
10

SECTION 2: SPECIFICATIONS
5
9. Enter key to confirm inputs (move backward
around network).
10.Temperature adjustment (optional, between
engineer defined limits) reverts to programmed
set point at next switch on.
Figure 2: Remote Sensors
Temperature Sensor Black BulbSensor Sports Hall Sensor
Description Part Number
Temperature Sensor (Warm Air & Radiant) D247
Black Bulb Sensor (Radiant) D269
Sports Hall Sensor D270
(Wire On Site)

ROBERTS GORDON®NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
6
SECTION 3: INSTALLATION
Installation of the ROBERTS GORDON®NRG
Control must be done by an electrician qualified in
the installation of control systems for heating
equipment.
3.1 Installing the ROBERTS GORDON®NRG
Control
Choose a mounting location for the control. See
Page 2, Section 1.4 and Section 1.6.
3.1.1 Remove the cover of the controller by removing
the four clips and screws. See Figure 3 for cover
detail.
Figure 3: Cover Detail
3.1.2 Disconnect the ribbon cable from the control
PCB board.
3.1.3 Position the controller. Figure 4 shows the
mounting hole locations.
Figure 4: Mounting Hole Layout
3.1.4 Remove the plastic cable entry plate and care-
fully cut suitable holes as required for the conduit
entry to the control. See Figure 5.
Do not use other entry routes or pass site wiring
over the circuit board.
3.1.5 Refit the cable entry plate into the slot at the
side of the panel.
Figure 5: Cable Entry
3.1.6 Install electrical wiring in accordance with the
correct wiring diagram in Section 4 to the wiring ter-
minals as shown in Figure 6.
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.
Clip Cover
Screw
Lid Assembly
Description Part Number
Clip Cover Plastic 10000701
Screw10000700
Lid Assembly 10010500
175 mm
140 mm
4 x 5 mm dia
Circuit Board
Cut suitable holes
Removable Plastic Entry Plate

SECTION 3: INSTALLATION
7
Figure 6: Control Terminals and Relay Use
3.1.7 Reconnect the ribbon cable to the PCB board
and replace the cover of the control by replacing the
4 screws and covers as removed on Page 6, Section
3.1.1.
3.2 Electrical Installation Requirements
3.2.1 The panel must have a 230 V 50 Hz supply in
accordance with the appropriate wiring diagram from
Section 4.
3.2.2 Ensure that the Live, Neutral and Earth cables
are looped three times through the ferrite EMC filter
as shown.
Figure 7: Ferrite EMC Filter
3.2.3 Ensure that the cables to any lowvoltage
equipment are Belden 8451 shielded cables with the
shield connected as shown in the wiring diagrams
on Page 9, Section 4.1 through Page 10, Section
4.2.
3.2.4 Lockout Reset
Facilities are available for systems that reset to Live
or reset to Neutral. Look at the wiring diagram on
each heater to determine the correct system to use
for the heater concerned.
Failure to comply will cause permanent damage
to the burner control on the appliance and the
ROBERTS GORDON®NRG Control.
3.2.5 Network Connections
Optionally the controls may linked together as
described on Page 2, Section 1.5. The site wiring is
to be connected and the DIP switches set as shown
on Page 9, Section 4.1.
3.2.6 Remote Sensors
All sensors are electrically connected in the same
way. The use of remote sensors is optional.
One remote temperature sensor will operate the
control. For larger heated areas, two remote
temperature sensors may be installed where the
control will automatically calculate the average of
the two readings. See Figure 8 and Figure 9.
Position the remote sensor/s in accordance with
Page 2, Section 1.4 and Page 3, Section 1.6.
See Page 5, Figure 2 for sensor detail.
Figure 8: Sensor Mounting Plate - Warm Air
12 V
Override
Press' switch
0 -10 VDC
MODULATING
OUTPUT
-
+
S
COMS
PORT
-
+
S
REMOTE
SENSORS
1
+
S
2
INPUTS
-
+
2
1
Lockout
Reset
C
N.O.
N.C.
Burner
Fan
CRV- Multi
Burner Radiant
Unitary
Radiant
Warm Air
Relay 3
Relay 2
Relay 1
Power Supply
230 V50 Hz
(From Ferrite Filter)
Lockout Signal
230 V50 Hz
L
N
Fan
Burner or
Low Fire
High
Fire
Burner
N
L
Live, Neutral and Earth supply cables must be
installed so that they pass through the ferrite core
three times as shown. NOTE: Only one wire shown
for clarity.
Supply cables
to be installed
through the
ferrite EMC Filter.
Remote sensors must be fastened using
countersunk screws. Dome headed screws
will short out the board and result in failure
of the sensor.

ROBERTS GORDON®NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
8
Figure 9: Remote Temperature Sensor - Radiant
Figure 10: Sports Hall Sensor
3.2.7 Pressure Switch
For CORAYVAC®systems only, a pressure switch is
required to prove the operation of the system fan.
This must be connected to the input terminals as
shown on Page 10, Section 4.2 and Page 15,
Section 4.10 to allowthe control to monitor the
correct operation of the fan. The control must also
be configured to monitor the pressure switch. See
Page 30, Section 5.6.3 and Page 31, Table 1.
Cover Screws
Circuit Board
Screws
Cable Entry
Cable
Connections
Cable
Connections
Wire
Jumper
As supplied
plastic jumper
covers only
one pin.
For the proper
operation with the
NRG control, move
the jumper so that
it is covering both
pins.

SECTION 4: WIRING
9
SECTION 4: WIRING
4.1 Network Wiring
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.
Network DIP switch settings.
Controls at the two ends of the system all ON.
All other controls all OFF
Switch settings
Final control
ID number
(highest number
maximum 32)
Second control
ID number 02.
and intermediate
controls ID as
required.
First control
ID number 01
Belden 8451
shielded cable or similar rated at 230 V
S = Shield.
Total length of network cable not to exceed
1,000,000 mm
Communication from
previous control
Communication to
next control
12 volt
Override
INPUTS
Pressure switch
REMOTE
SENSORS
0 -10VDC
MODULATING
OUTPUT
COMS
PORT
-
+
S
-
+
S
1
+
S
2
-
+
2
1
INPUTS
REMOTE
SENSORS
0 -10VDC
MODULATING
OUTPUT
COMS
PORT
-
+
S
-
+
S
1
+
S
2
-
+
2
1
INPUTS
Pressure switch
REMOTE
SENSORS
0 -10VDC
MODULATING
OUTPUT
COMS
PORT
-
+
S
-
+
S
1
+
S
2
-
+
2
1
OFF
ON
OFF
ON
OFF
ON
OFF
ON
Switch settings
OFF
ON
Switch settings
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
Pressure switch

ROBERTS GORDON®NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
10
4.2 Low Voltage Wiring

SECTION 4: WIRING
11
4.3 CTU Wiring
4.4 CTCU Wiring

ROBERTS GORDON®NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
12
4.5 Interface Relay Wiring for Multiple Warm Air Heaters
4.6 PGP/POP Range Wiring - 1 Ø Cabinet Heaters

SECTION 4: WIRING
13
4.7 PGP/POP Range Wiring - 3 Ø Cabinet Heaters
4.8Cabinet Heater Remote Lockout Reset Wiring

ROBERTS GORDON®NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
14
4.9 Unitary Radiant System Wiring