Roberts Gorden UltraVac NEMA 4 User manual

WARNING
Installation must be done by an electrician qualified
in the installation of control systems for heating
equipment.
Improper installation, adjustment, alteration, ser ice
or maintenance can result in death, injury or property
damage. Read the Installation and Operation Manual
thoroughly before installing or ser icing this
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.
Roberts-Gordon LLC
1250 William Street
P. O . B o x 4 4
Buffalo, New York 14240-0044
Telephone: [phone]
Fax: [phone]
Toll Free: 800.828.7450
www.rg-inc.com
© 2008 Roberts-Gordon LLC
Quality in Any Language™
ROBERTS GORDON®
UltraVac™
Controls for
Modulating
CORAYVAC®
Infrared Heating
Systems
Installation Manual
P/N 10081601NA Rev F 10/08

© 2008Roberts-Gordon LLC
All rights reserved. No part of this work covered by the copyrights herein may be reproduced
or copied in any form or by any means - graphic, electronic, or mechanical, including
photocopying, recording, taping or information storage and retrieval systems - without the
written permission of Roberts-Gordon LLC.
TABLE OF CONTENTS
SECTION 1: Introduction........................................................ 1
1.1 What is ROBERTS GORDON®ULTRAVAC™?............1
1. 2 C O R AY VA C ®Design Requirements.............................1
1.3 General Requirements .................................................1
1.4 Check Installation Materials .........................................1
1.5 Carton Contents ...........................................................2
1.6 Safety ...........................................................................5
1.7 Example Site Layout.....................................................5
SECTION 2: Specifications ....................................................7
2.1 ROBERTS GORDON®ULTRAVAC™ Controller ......... 7
2.2 Temperature Sensors...................................................7
2.3 Variable Frequency Drive (VFD) ..................................9
SECTION 3: Installation........................................................ 11
3.1 Preparation ................................................................ 11
3.2 Positioning the ROBERTS GORDON®ULTRAVAC™
Controller and Variable Frequency Drive ................... 11
3.3 Cable Requirements: ................................................. 12
3.4 Electrical Installation Requirements........................... 13
3.5 Pump Requirements .................................................. 13
3.6 Variable Frequency Drive Requirements ................... 13
3.7 Indoor Sensor Placement .......................................... 14
3.8 Outdoor Sensor Placement ....................................... 14
3.9 Outside Air Supply..................................................... 14
SECTION 4: Typical External Diagrams .............................. 15
SECTION 5: Communications.............................................. 20
5.1 Dedicated Phone Line for Central Controller Modem 20
5.2 RS-485 Converter for Central Controller....................21
5.3 TCP/IP Communication Module ................................22
5.4 Direct Connect ........................................................... 24
5.5 Communications Between Multiple ROBERTS
GORDON®ULTRAVAC™ Controllers ........................ 25
SECTION 6: Variable Frequency Drive Programming ........ 27
6.1 VFD Parameter Settings For Use With ROBERTS
GORDON®ULTRAVAC™ .......................................... 27
6.2 Altering VFD Parameters ...........................................28
SECTION 7: Commissioning The CORAYVAC®System ....29
7.1 Setting The CORAYVAC®End Burner Vacuum..........29
SECTION 8: Replacement Parts .......................................... 33
8.1 ROBERTS GORDON®ULTRAVAC™ Controller
Replacement Parts .................................................... 33
8.2 Variable Frequency Drive Replacement Parts ........... 34
8.3 Replacement Parts Instructions................................. 35
SECTION 9: Troubleshooting............................................... 37
SECTION 10: The ROBERTS GORDON®ULTRAVAC™
LIMITED Warranty.......................................... 41
Printed in U.S.A.

TABLE OF FIGURES
Figure 1: Example Site Layout ..................................................6
Figure 2: ROBERTS GORDON®ULTRAVAC™ Controller
Specifications ............................................................8
Figure 3: Variable Frequency Drive Components
(Factory pre-wiring shown) ...................................... 10
Figure 4: Controller Mounting.................................................. 11
Figure 5: Indoor Sensor Cable Detail...................................... 12
Figure 6: Outdoor Sensor, VFD (0-10 V) Signal, RS-485
Communications Cable and
Pressure Switch Cable Detail................................... 12
Figure 7: Variable Frequency Drive Mounting ......................... 13
Figure 8: Indoor Sensor Mounting .......................................... 14
Figure 9: Outdoor Sensor Placement ..................................... 14
Figure 10: Central Controller Communication Equalization
Wiring..................................................................... 15
Figure 11: ROBERTS GORDON®ULTRAVAC™ Central
Controller External Wiring ...................................... 16
Figure 12: ROBERTS GORDON®ULTRAVAC™ Satellite
Controller External Wiring ...................................... 18
Figure 13: Modem Location .................................................... 20
Figure 14: RS-485 PC Connection.......................................... 21
Figure 15: TCP/IP Communication Module Mounting............. 22
Figure 16: TCP/IP Communication Module Wiring.................. 23
Figure 17: 9 Pin Adapter for PC ..............................................24
Figure 18: Communications Between Multiple Controllers...... 25
Figure 19: Repeater Wiring ..................................................... 26
Figure 20: End Vent Vacuum .................................................. 30
Figure 21: Possible Damper Couplings’ Locations..................31
Figure 22: ROBERTS GORDON®ULTRAVAC™ Controller
Components Diagram ............................................ 33
Figure 23: Variable Frequency Drive Components Diagram... 34
Figure 24: Troubleshooting Flow Chart ...................................37

SECTION 1: INTRODUCTION
1
SECTION 1: INTRODUCTION
1.1 What is ROBERTS GORDON®ULTRAVAC™?
The ROBERTS GORDON®ULTRAVAC™ is a micro-
processor based control package designed for
modulating control of CORAYVAC®heaters based on
outdoor temperatures.
This controller is capable of giving control outputs to
one vacuum pump and three heating zones. The
controller also features inputs which are used for
indoor and outdoor signal condition monitoring.
System status and settings are viewed and altered
from a PC (not supplied) running
ROBERTS GORDON®ULTRAVAC™ Software.
1.2 CORAYVAC®Design Requirements
CORAYVAC®burners shall be CRV B-6, B-8, B-9,
B-10 or B-12 burners.
CORAYVAC®systems designed shall have
minimum radiant pipe length and 1.5 - 2.0 feet per
flow unit of tailpipe length.
-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.
1.3 General Requirements
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-
ranty. See Page 41, Section 10.
ROBERTS GORDON®ULTRAVAC™ Software
requires a PC (not supplied) running Windows®95 or
higher, with a Pentium®class processor and at least
64k of RAM.
The controller, variable frequency drive, burners,
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.
1.4 Check Installation Materials
1.4.1 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.
1.4.2 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 triad of stranded 22
AWG minimum wire) is required for RS-485
communications between controllers.
1.4.3 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.
1.4.4 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.

ROBERTS GORDON®ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
2
1.5 Carton Contents
URVSC: ULTRAVAC™ Satellite Controller
URVCCL: ULTRAVAC™ Central Controller with TCP/IP Communication Module
Line Voltage 120 VWiring
LowVoltage 24 VWiring
POWER
L1 L2 GRD
OUTPUT1
L1 L2 GRD
OUTPUT2
L1 L2 GRD
OUTPUT3
L1 L2 GRD
OUTPUT4
L1 L2 GRD
OUTPUT5
L1 L2 GRD
OUTPUT6
L1 L2 GRD
OUTPUT7
L1 L2 GRD
OUTPUT8
L1 L2 GRD
+-
1
+-
2
+-
4
+-
3
+-
5
+-
6
+-
7
+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONC CNONC C
NONC CNONC CNONC C
RS485COMM
REF
+-
1
+-
2
+-
3
+-
4
METERINPUTS
UNIVERSALINPUTS
INOUT
ADDRESS
RESET
10VDC
499OHM
OFF
ON
OUT
IN
GINOUT GGG
+5
+32
AUXPOWER
RS232DIRECT
RI
CDOH
CPU
L1 PWR
ULTRAVAC™ Controller
ULTRAVAC™ Installation Manual
(P/N 10081601NA)
Inside View
RS232
RS485
RS485 INRS485 OUT
+5V
-+-+
-+
PROGRAM
RUN
RS232
RS485
RS485 OUTREF
- +- +
PROGRAM
RUN
RS485 OUT
- +- +
RS485 OUTRS485 OUT
- +- +
RS485 OUT
1/4A 1/4A
1/4A 1/4A
ULTRAVAC™ Software (P/N 10080421)
ULTRAVAC™ Software Manual (P/N 10081600NA)
ULTRAVAC™ Installation Manual (P/N 10081601NA)
TCP/IP (LAN) Communication Module
(w/ 7’ phone wire) (P/N 10080440)
Comms Equalization Cable
(P/N 10080450)
Outdoor Sensor
(P/N 10081501)
PC Connection Cable Package
(P/N 10080410)
Line Voltage 120 VWiring
LowVoltage 24 VWiring
POWER
L1 L2 GRD
OUTPUT1
L1 L2 GRD
OUTPUT2
L1 L2 GRD
OUTPUT3
L1 L2 GRD
OUTPUT4
L1 L2 GRD
OUTPUT5
L1 L2 GRD
OUTPUT6
L1 L2 GRD
OUTPUT7
L1 L2 GRD
OUTPUT8
L1 L2 GRD
+-
1
+-
2
+-
4
+-
3
+-
5
+-
6
+-
7
+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONC CNONC C
NONC CNONC CNONC C
RS485COMM
REF
+-
1
+-
2
+-
3
+-
4
METERINPUTS
UNIVERSALINPUTS
INOUT
ADDRESS
RESET
10VDC
499OHM
OFF
ON
OUT
IN
GINOUT GGG
+5
+32
AUXPOWER
RS232DIRECT
RI
CDOH
CPU
L1 PWR
+-
1
+-
2
+-
3
+
4
METER INPUTS
RESS
RESET
499 OHM
RI
CDOH
Modem Chip
ULTRAVAC™ Controller
with Modem Installed
Repeater (optional)
Supplied w/24 VAC
transformer inside NEMA 1
enclosure (P/N 10080445)
Inside View

SECTION 1: INTRODUCTION
3
URVCCM: ULTRAVAC™ Central Controller with Modem
ULTRAVAC™ Software (P/N 10080421)
ULTRAVAC™ Software Manual (P/N 10081600NA)
ULTRAVAC™ Installation Manual (P/N 10081601NA)
Comms Equalization Cable
(P/N 10080450)
Outdoor Sensor
(P/N 10081501)
PC Connection Cable Package
(P/N 10080410)
ULTRAVAC™ Controller
with Modem Installed
Line Voltage 120 VWiring
LowVoltage 24 VWiring
POWER
L1 L2 GRD
OUTPUT1
L1 L2 GRD
OUTPUT2
L1 L2 GRD
OUTPUT3
L1 L2 GRD
OUTPUT4
L1 L2 GRD
OUTPUT5
L1 L2 GRD
OUTPUT6
L1 L2 GRD
OUTPUT7
L1 L2 GRD
OUTPUT8
L1 L2 GRD
+-
1
+-
2
+-
4
+-
3
+-
5
+-
6
+-
7
+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONC CNONC C
NONC CNONC CNONC C
RS485COMM
REF
+-
1
+-
2
+-
3
+-
4
METERINPUTS
UNIVERSALINPUTS
INOUT
ADDRESS
RESET
10VDC
499OHM
OFF
ON
OUT
IN
GINOUT GGG
+5
+32
AUXPOWER
RS232DIRECT
RI
CDOH
CPU
L1 PWR
+-
1
+-
2
+-
3
+
4
METER INPUTS
RESS
RESET
499 OHM
RI
CDOH
Modem Chip
Inside View
RS232
RS485
RS485 OUTREF
- +- +
PROGRAM
RUN
RS485 OUT
- +- +
RS485 OUTRS485 OUT
- +- +
RS485 OUT
1/4A 1/4A
1/4A 1/4A
Repeater (optional)
Supplied w/24 VAC
transformer inside NEMA 1
enclosure (P/N 10080445)

ROBERTS GORDON®ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
4
URVCCR: ULTRAVAC™ Central Controller with RS-485 Converter
RS-485 Converter Package (P/N 10080430)
Power Supply
ULTRAVAC™ Software (P/N 10080421)
ULTRAVAC™ Software Manual (P/N 10081600NA)
ULTRAVAC™ Installation Manual (P/N 10081601NA)
Comms Equalization Cable
(P/N 10080450)
Outdoor Sensor
(P/N 10081501)
PC Connection Cable Package
(P/N 10080410)
ULTRAVAC™ Controller
with Modem Installed
Line Voltage 120 VWiring
LowVoltage 24 VWiring
POWER
L1 L2 GRD
OUTPUT1
L1 L2 GRD
OUTPUT2
L1 L2 GRD
OUTPUT3
L1 L2 GRD
OUTPUT4
L1 L2 GRD
OUTPUT5
L1 L2 GRD
OUTPUT6
L1 L2 GRD
OUTPUT7
L1 L2 GRD
OUTPUT8
L1 L2 GRD
+-
1
+-
2
+-
4
+-
3
+-
5
+-
6
+-
7
+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONC CNONC C
NONC CNONC CNONC C
RS485COMM
REF
+-
1
+-
2
+-
3
+-
4
METERINPUTS
UNIVERSALINPUTS
INOUT
ADDRESS
RESET
10VDC
499OHM
OFF
ON
OUT
IN
GINOUT GGG
+5
+32
AUXPOWER
RS232DIRECT
RI
CDOH
CPU
L1 PWR
+-
1
+-
2
+-
3
+
4
METER INPUTS
RESS
RESET
499 OHM
RI
CDOH
Modem Chip
Inside View
RS-485 Converter
RS232
RS485
RS485 OUTREF
- +- +
PROGRAM
RUN
RS485 OUT
- +- +
RS485 OUTRS485 OUT
- +- +
RS485 OUT
1/4A 1/4A
1/4A 1/4A
Repeater (optional)
Supplied w/24 VAC
transformer inside NEMA 1
enclosure (P/N 10080445)

SECTION 1: INTRODUCTION
5
1. 6 S a f et y
Your Safety is Important to Us!
This symbol is used throughout
the manual to notify you of
possible fire, electrical or burn
hazards. Please pay special atten-
tion when reading and following
the warnings in these sections.
Installation, service and annual inspection of
controller must be done by an electrician qualified in
the installation and service of control systems for
heating equipment.
Installation, service and annual inspection of heater
must be done by a contractor qualified in the
installation and service of gas-fired heating
equipment.
Read this manual carefully before installation,
operation, or service of this equipment.
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 [phone], (800)
828-7450 or at www.rg-inc.com.
1.6.1 Manpower Requirements
To prevent personal injury and damage to the
controls, two persons will be required for installation.
1.7 Example Site Layout
Page 6, Figure 1 is an example layout for a building
where ROBERTS GORDON®ULTRAVAC™ will be
used to control the infrared heating systems shown.
The layout consists of three zones of ROBERTS
GORDON®ULTRAVAC™.

ROBERTS GORDON®ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
6
FIGURE 1: Example Site Layout
NOTE: Conceptual drawing, not to scale. Venting not shown.
Zone 1
Zone 2
Zone 3
Zone 2 Sensor
Zone 1 Sensor
Zone 3 Sensor
Variable
Frequency
Drive
North Wall
Outside
Sensor
Pu p
ROBERTS GORDON
®
ULTRAVAC
Controller

SECTION 2: SPECIFICATIONS
7
SECTION 2: SPECIFICATIONS
2.1 ROBERTS GORDON®ULTRAVAC™ Controller
2.1.1 Enclosure
Standard Enclosure
Construction: 16 gauge painted steel, hinged
door, removable knockouts
provided.
Dimensions: 14.7" w x 17.7" h x 3.5" d
NEMA 4 Enclosure (P/N 10080302)
Description: NEMA 4 enclosure is sold separately
as an option. ULTRAVAC™ Controller
in standard enclosure is field mounted
inside the NEMA 4 enclosure.
Construction: 14 gauge painted steel, hinged door
with 19" x 16" window.
Dimensions: 24" w x 24" h x 9" d
Protection
Rating: NEMA 4/12
2.1.2 Electrical - Control Board
Power Supply: 24 V 60 Hz
(from relay board)
Analog Inputs: Sensor (thermistor), BMS enable
(dry contact)
Relay Outputs: 24 Vac
Analog Outputs: 0-10 Vdc
Digital Inputs: Timed, dry contact
Network Ports: RS-485, RS-232
UL Standard: UL 916 / C22.2 No. 205-M1983
2.1.3 Electrical - Relay Board
Power Supply: 120 V (+/- 10%) 1 Ø, 60 Hz
Inputs: 24V AC
Relay Outputs: Single Pole 3 A 120 Vac
UL Standard: UL 916 / C22.2 No. 205-M1983
2.2 Temperature Sensors
Indoor Sensor
Dimensions: 2.75" w x 4.5" h x 1.15" d
Power: 32 V DC
Features: LCD temperature display, setpoint
adjustment, override button
Wiring: Shielded Cable, four twisted pairs,
24 AWG min.
Outdoor Sensor (P/N 10081501)
Dimensions: 1.4" w x 5.3" h x 2" d
Enclosure: NEMA 4 gasketed aluminum LB
housing, ½" threaded connection
Wiring: Shielded Cable, one twisted pair,
22 AWG min.
NEMA 4 Enclosure for Indoor Sensor (P/N
10081510)
Description: NEMA 4 Enclosure is sold separately
as an option. The indoor sensor is
field mounted inside the NEMA 4
enclosure. Temperature thermistor
and LCD temperature display will not
operate properly inside the
enclosure. LCD display feature should
be disabled and use of the NEMA 4
sensor enclosure will require the use
of an outdoor sensor (P/N 10081501)
in the space to monitor zone
temperature.
Dimensions: 6.3" x 3.6" x 1.8"
Construction: Polycarbonate enclosure with clear
front cover, 4 screw cover closure. 16
gauge galvanized subpanel.
Protection
Rating: NEMA 4/4x/12/13
Flammability
Rating: UL-94-5V

ROBERTS GORDON®ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
8
FIGURE 2: ROBERTS GORDON®ULTRAVAC™ Controller Specifications
+-
1
+-
2
+-
4
+-
3
+-
5
+-
6
+-
7
+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONC CNONC C
NONC CNONC CNONC C
RS485 COMM
REF
+-
1
+-
2
+-
3
+-
4
METER INPUTS
UNIVERSAL INPUTS
INOUT
ADDRESS
RESET
10VDC
499 OHM
OFF
ON
OUT
IN
GINOUT GGG
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1 PWR
+-
1
+-
2
+-
4
+-
3
+-
5
+-
6
+-
7
+-
8
+- +-
REF
24VAC
L2
NONC C
NONC CNONC CNONC CNONC C
NONC CNONC CNONC C
RS485 COMM
REF
+-
1
+-
2
+-
3
+-
4
METER INPUTS
UNIVERSAL INPUTS
INOUT
ADDRESS
RESET
10VDC
499 OHM
OFF
ON
OUT
IN
GINOUT G G G
+5
+32
AUX POWER
RS232 DIRECT
RI
CDOH
CPU
L1 PWR
POWER
L1 L2 GRD
OUTPUT 1
L1 L2 GRD
OUTPUT 2
L1 L2 GRD
OUTPUT 3
L1 L2 GRD
OUTPUT 4
L1 L2 GRD
OUTPUT 5
L1 L2 GRD
OUTPUT 6
L1 L2 GRD
OUTPUT 7
L1 L2 GRD
OUTPUT 8
L1 L2 GRD
120 Vac Outputs
Plug-In
Relays
24 V
Power
Switch
Control
Board
Transformer
Meter Inputs
Analog
Output
Board
Modem
Phone Port
Analog Inputs
Eprom
Chip
Selector
Switch
Reset
Button
RS 485
Terminals
RS 232
Direct Connect
Port
24 VBoard
Power Input
24 VControl Board
Power Supply
Relay Board
24 V
Power
1 A Fuse
Sensor
Power
120 Vac Power Input
Modem Chip
(optional - only located
on Controller #1)
24 V
Outputs
24 VOutputs
24 VInput
Connections
Controller Enclosure
OUTPUT 1
L1 L2 GRD GRD L2 L1
OUTPUT 2
GRD L2 L1
OUTPUT 3
GRD L2 L1
OUTPUT 4
GRD L2 L1
OUTPUT 5
GRD L2 L1
OUTPUT 6
GRD L2 L1
OUTPUT 7
GRD L2 L1
OUTPUT 8
GRD L2 L1
POWER
Line Voltage 120 V wiring
Relay Board
Low Voltage 24 V wiring
Control Board
5 VTCP/IP
Module
Power
Analog
Outputs
Note:
To ensure robust control signaling:
Do not run line voltage wiring through bottom section
of enclosure that houses the control board.
Do not run low voltage wiring through top section
of enclosure that houses the relay board.

SECTION 2: SPECIFICATIONS
9
2.3 Variable Frequency Drive (VFD)
2.3.1 Enclosure
Standard Models
Construction: 14 gauge painted steel, mounting
panel included, left-hinged door,
vented.
Dimensions: 12" w x 14 3/8" h x 8" d
Protection: UL 50 Type 1, NEMA Type 1
NEMA 4 Models
Description: Drive assembly and components fully
factory assembled inside NEMA 4
enclosure. Enclosure dimensions and
construction vary by model.
Construction: VFD75115N4, VFD20230N4 and
VFD20460N4 enclosures are
16 gauge painted steel, left hinged
door, non-vented.
VFD75230N4 and VFD75460N4
enclosures are 14 gauge steel, left
hinged door, non-vented.
Dimensions: VFD75115N4 20" x 16" x 10"
VFD75230N4 14" x 12" x 8"
VFD20230N4 20" x 16" x 10"
VFD75460N4 16" x 14" x 10"
VFD20460N4 20" x 16" x 10"
Protection: NEMA 3R/4/12/13
2.3.2 Electrical
Power Output: 230 V, 3 Ø, 0-60 Hz
(for 115 V and 230 V models)
460 V, 3 Ø, 0-60 Hz
(for 460 V models)
Speed Reference
Follower: 0-10 Vdc
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: 208/240 V, 1 Ø, 50-60 Hz
Input Voltage Tolerance: +/- 10%
Amps: 6.9/6.0 A
1 HP, 120 V Drive (used with EP-203 pump)
(P/N VFD75115 or VFD75115N4)
Power Input: 120 V, 1 Ø, 50-60 Hz
Input Voltage Tolerance: +/- 10%
Amps: 16.6 A
2 HP, 230 V Drive (used with EP-303 pump)
(P/N VFD20230 or VFD20230N4)
Power Input: 208/240 V, 1 Ø, 50-60 Hz
Input Voltage Tolerance: +/- 10%
Amps: 18.4/16.0 A
1 HP, 460 V Drive (used with EP-203 pump)
(P/N VFD75460 or VFD75460N4)
Power Input: 400/480 V, 3 Ø, 50-60 Hz
Input Voltage Tolerance: +/- 10%
Amps: 3.0/2.5 A
2 HP, 460 V Drive (used with EP-303 pump)
(P/N VFD20460 or VFD20460N4)
Power Input: 400/480 V, 3 Ø, 50-60 Hz
Input Voltage Tolerance: +/- 10%
Amps: 4.8/4.0 A

ROBERTS GORDON®ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
10
FIGURE 3: Variable Frequency Drive Components (Factory pre-wiring shown)
M16/12.PM16/12.P
Power Input
1 2 5 6 11 13A 13B 13E 25 16 17
PEPEWVU
L2/NL1 B-PE
B+
Variable
Frequency Drive
(1 Ø input model shown)
Terminal Inputs
230 V3 Ø or
460 V3 Ø outputs
Grounding
Block
120 Vsignal from relay board
output #8
Relay
120 V
Rotary
Disconnect
Input Fuse Holder
(1 Ø input model shown, 3 Ø input models have an
additional input fuse holder and VFD power input.)
VFD Enclosure
(Standard Enclosure Shown)

SECTION 3: INSTALLATION
11
SECTION 3: INSTALLATION
Installation of the ROBERTS GORDON®
ULTRAVAC™ Controller and the associated external
electrical wiring must be done by an electrician
qualified in the installation of control systems for
heating equipment.
3.1 Preparation
Before installing the controller, observe the following:
3.1.1 Ensure that you have a copy of the site layout
for the project that clearly identifies the separate
zones.
3.1.2 Familiarize yourself with the Controller and Vari-
able Frequency Drive component names and loca-
tions. See Page 8, Figure 2 and Page 10, Figure 3.
3.2 Positioning the ROBERTS GORDON®
ULTRAVAC™ Controller and Variable Frequency
Drive
3.2.1 Choose a mounting location for the controller.
Generally near the pump, a dedicated phone con-
nection (optional) and the variable frequency drive.
For serviceability, it is convenient to mount the con-
troller and variable frequency drive at occupant level
in the vicinity of 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.
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). 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).
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.
FIGURE 4: Controller Mounting
(Standard enclosure only, NEMA 4 enclosure mount-
ing varies)
WARNING
Severe Injury Hazard
Mount controls with
materials with a minimum
workingload of 75 lbs
(33 kg).
Failure to follow these
instructions can result in
death, injury or property
damage.
13" (33 cm)
16.25"
(41.3 cm)

ROBERTS GORDON®ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
12
3.3 Cable Requirements:
3.3.1 Line Power Supply:
As per individual building specification for class of
cable to be used. Use copper conductors only. To
size the cable, use the amperages of the burners
given on Page 13, Section 3.4.1, for each individual
zone.
3.3.2 Control Wiring
All control wiring (sensor, VFD control (0 - 10 Vdc),
pressure switch and RS-485 communication wiring)
may be plenum or non-plenum rated depending on
installation requirements, consult the National Elec-
tric Code®(NEC). Regardless of the code or its inter-
pretation, the local Fire Marshall makes the final
decision, contact the local Fire Marshall if you have
questions.
Do not run control (low voltage) wiring together
with power (line voltage) wiring in the same
conduit. Electrical signal interference or induced
current could occur and cause communication
problems.
VFD (0-10 V) control wiring and all RS-485 com-
munication wiring must be shielded. Shielded wire
provides noise and interference isolation and
reduces the possibility of communication problems.
Pressure switch wiring is not required to be
shielded. If electrical interference from machinery or
other sources cannot be avoided, shielded wire must
be used. All control cable specification diagrams
shown will refer to shielded cable.
3.3.3 Indoor Sensor Cable:
Shielded cable (four twisted pairs of stranded 24
AWG min. wire) is required for use with indoor
sensors. See Page 12, Figure 5 for an illustration of
the shielded cable specification to be used. See
Page 12, Section 3.3.2 to see if unshielded cable
may be used.
Unshielded Cable: AMP #57248, #219538, #219513;
Belden # 1585A, #1583A;
General Cable #C6015 or equivalent.
Shielded Cable:
Madison Cable #08CFJ10001, #08CFJ00004;
Belden #9681;
General Cable #2131673, #C1676 or equivalent.
FIGURE 5: Indoor Sensor Cable Detail
3.3.4 Outdoor Air Sensor VFD (0-10 V) signal,
Pressure Switch Cable and PC RS-485 converter
wiring:
Shielded cable (one twisted pair of 22 AWG min.
wire) is required for the outdoor air sensor, VFD
signal wiring, pressure switch wiring and RS-485 con-
verter wiring between controller #1 and PC
(RS-485 converter wiring to PC is only used if
controller is using an RS-485 Converter
Communication Package). See Page 12, Figure 6 for
an illustration of the cable specification to be used.
Shielded Cable: Belden #8451, #1503A, #8760;
General Cable #C2514 or equivalent.
FIGURE 6: Outdoor Sensor, VFD (0-10 V) Signal,
RS-485 Communications Cable and
Pressure Switch Cable Detail
3.3.5 RS-485 Communication Wire Between
Controllers:
Shielded cable (one twisted triad or two twisted pairs
of 22 AWG min. wire) is required for RS-485 commu-
nications between controllers. See Page 12, Figure 6
for an illustration of the shielded cable specification
to be used. Shielded Cable: Belden #1902, #8770
General Cable #C1670 or equivalent.
Shield Wire
Foil
Shield
Insulation
24 AWG
Mini u
Insulation
Foil
Shield
22 AWG Minimum
conductor
22 AWG Minimum
conductor
Uninsulated
Shield Wire

SECTION 3: INSTALLATION
13
3.4 Electrical Installation Requirements
3.4.1 The enclosure must be supplied from a local
fused isolator rated for a total amperage not
exceeding 25 A.
The method for calculating the current loading is as
follows:
CORAYVAC®Burner 0.3 A/burner
Multiply the current for the individual burners above
by the number of burners supplied from the
enclosure to give the total current required.
The full load amps for the optional outside air blower
(P/N 90707500) are: 1.6 A
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.
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 con-
trol 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 460 drive power
supply must be 460 V, 50-60 Hz, 3 Ø. See Page 9,
Section 2.3 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 2 (see
Page 16, Figure 11 through Page 18, Figure 12) will
dictate the speed of the pump. The VFD output sup-
ply to the pump is 230 V 3 Ø 0-60 Hz for 115 V and
230 V models and is 460 V, 3 Ø, 0-60 Hz for 460 V
models. The frequency of the output supply signal to
the pump will be varied based on the 0-10 V signal
from the control
enclosure. See Page 11, Section 3.2 for additional
installation requirements.
FIGURE 7: Variable Frequency Drive Mounting
(Standard enclosures only, NEMA 4 enclosure
mounting varies by model)
DANGER
Electrical Shock Hazard
Disconnect electrical before servicing.
This appliance must be connected to a
properly grounded electrical source.
Replace cover before operating.
Failure to follow these instructions can result
in death or electrical shock.
10" (25.4 cm)
14 .75"
(37.5 cm)

ROBERTS GORDON®ULTRAVAC™ CONTROLLER INSTALLATION MANUAL
14
3.7 Indoor Sensor Placement
The sensor measures the air temperature in the
building. It is important that the sensor is located in
an area within the heated zone at occupant level. For
the most accurate results, sensors should be
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" x 2 1/8" junction
box mounting.
FIGURE 8: Indoor Sensor Mounting
3.7.1 Indoor Sensor Mounting
Remove the cover of the sensor by the two 1/16"
allen screws, located in the lower corners of the
cover. To gain access to the top mounting hole,
remove the plug-in LCD display. To remove the LCD
display, grasp the green plug-in board at the lower
corners and gently pull the board away from the
sensor back plate. See Page 14, Figure 8. After
removing the plug-in LCD display from its socket,
secure the sensor to the wall or junction box using
the screws provided. Replace the plug-in LCD 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
damage. Refer to Page 16, Figure 11 and Page 18,
Figure 12 for wiring details.
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 9: Outdoor Sensor Placement
Mount the outside sensor with the sensor module
facing down to prevent accumulation of dirt or water.
3.9 Outside Air Supply
If an outside air blower is to be used, See Page 16,
Figure 11 for external wiring diagrams. See Page 13,
Section 3.4.1 for current load.
SEN SET O/R -+
Mounting
Hole
Plug-in LCD
Display
(grasp here
to unplug)
Mounting
Hole
Setback
Override
Button
Setpoint
Adjustment
Slide bar
North
Outside
Sensor
Sensor
Module
facing down