Page 1 ® For CORAYVAC and Unitary Infrared Heating Systems Installation Manual Installer WARNING Please take the time to read and understand Improper installation, adjustment, alteration, service these instructions prior to any installation. or maintenance can result in death, injury or Installer must give a copy of this manual to the owner.
Page 3: Table Of Contents
SECTION 12: Integration with Building Management Control Installation Materials........16 System (BMS) ..........89 ® 3.5 Electrical Installation Requirements of CORAYVAC 12.1 BACnet over ARC156 ..........89 Modulating Heating Control ........19 12.2 BACnet MS/TP ............91 3.6 Pump Requirements ..........19 12.3 BACnet PTP ............
Page 5: Section 1: Introduction
® COMPLETE™ and maintain heater clearances to combustibles, see Modulating Heating Control? heater Installation, Operation and Service Manual for Similar to the CORAYVAC ® Modulating Heating Con- further details. If you require additional manuals, con- trol, The ROBERTS GORDON ®...
Page 6: General Requirements
1.2 - 1.5’ per UO-2 Inputs: All UI-8 10V Max, 20mA Max UO-1 UI-9 Auto Off On 0-20mA Relay 0-10Vdc flow unit of tailpipe length. See the CORAYVAC ® UI-10 Set Pot Full CW UO-8 UI-11 Universal Input UO-7 UI-12 Mode Select Volts...
Page 7: Example Site Layout
SECTION 1: I NTRODUCTION 1.12 Example Site Layout heating systems shown. The layout consists of four zones of ROBERTS GORDON ® CORAYVAC ® Modu- Below is an example layout for a building where lating Heating Control. ROBERTS GORDON ® CORAYVAC ®...
Page 8 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 2: CORAYVAC ® Modulating Heating Control Label Placement Pump Operated Zones Zone 1 Zone 3 Zone 4 Zone 2 Modulating Heating Control Burners Burners Burners Burners External Wiring Diagram 1 schéma de câblage externe 1...
Page 9 SECTION 1: I NTRODUCTION FIGURE 3: COMPLETE™ Modulating Heating Control Label Placement Unitary Controller Wiring TERMINAL BLOCK 1 (Optional) TOUCH 120V 60HZ SCREEN 1 20A A B C D S1 S2 Power Without Keypad: 24Vac 26Vdc 24Vac, 50VA 2A, 50-60 Hz Port 1 Rx Port 1 Tx ONLY Use Copper...
Page 10 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 5: Connected Components Outdoor Air Temperature Sensor BMS Operator’s Workstation Indoor Sensor (one per zone) BACnet ® , Modbus ® N2, or LonWorks (requires separate LonWorks card) RS 485 Wiring...
Page 11 ® If combining a CORAYVAC system with VANTAGE CTH3/HEM unitary heaters on a single CORAYVAC Modulating ® ® Heating Control, users are restricted to a maximum of 2 zones between and a single CORAYVAC system and VANTAGE CTH3/HEM unitary heaters.
Page 12: Carton Contents
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 1.13 Carton Contents 100600XX: CORAYVAC ® Modulating Heating Control Central Controller Installation Manual VFD Manual CORAYVAC ® Modulating (P/N 1006101NA) Mounting Template Heating Control Controller (P/N 91702810) with Modem Installed 10060XXX: CORAYVAC ®...
Page 13 SECTION 1: I NTRODUCTION Accessories Outdoor Sensor Repeater (optional) (P/N 10081501) Supplied w/24 VAC Indoor Sensor transformer inside (P/N 10061003) NEMA 1 enclosure (P/N 10060156) LonWorks Card Load Reactor (P/N 10061019) (P/N 10060160) (P/N 10061020) (P/N 10061021) (P/N 10061022) Terminating Resistor, BT485 (P/N 10061018) USB-L Cable (P/N 10061017)
Page 14: Section 2: Specifications
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL SECTION 2: SPECIFICATIONS 2.1 ROBERTS GORDON ® CORAYVAC ® Communication Ports: Modulating Heating Control and COMPLETE™ Port 1: Configurable for ARC156 or EIA-485 (2-wire). Modulating Heating Control (Unitary Heaters)
Page 15: Load Reactor
2.7 Variable Frequency Drive (Located inside the pump overheating and noise emissions. Reactors CORAYVAC ® Modulating Heating Control) also minimize harmonic current levels within the drive 2.7.1 Electrical...
Page 16 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 1 HP, 460V 3 Ø Drive (used with EP-203 pump) (P/N 10061204) Power Input: 460 V, 3 Ø, 50-60 Hz Input Voltage Tolerance: +/- 10% Amps: 2.2 2 HP, 460V 3 Ø Drive (used with EP-303 pump) (P/N 10061205) Power Input: 460 V, 3 Ø, 50-60 Hz...
Page 17: Section 3: Installation
3.1.2 Familiarize yourself with the Controller and Vari- able Frequency Drive component names and loca- tions. See Page 14, Figure 6, Figure 6. Note: The VFD is located inside of the CORAYVAC ® Modulating Heating Control panel. Be sure to plan...
Page 18 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 6: ROBERTS GORDON ® CORAYVAC ® Modulating Heating Control Specifications Power Battery Status LED's BT485 Terminating Resistor Port Without Keypad: Power 24Vac 24Vac, 50VA Port 1 Tx 2A, 50-60 Hz...
Page 19: Positioning Corayvac Modulating Heating Control
SECTION 3: I NSTALLATION 3.2 Positioning CORAYVAC ® Modulating Heating FIGURE 7: Controller Mounting - CORAYVAC ® Control Modulating Heating Control 3.2.1 For serviceability, it is convenient to mount the (Dimensions shown in inches) controller at occupant level in the vicinity of the 19.00...
Page 20: Cable Requirements
Use copper conductors only. Below 3.4.2 Control Programming Details is the recommended cable for the various connec- Controllers are pre-programmed. Can be configured tions for CORAYVAC ® and COMPLETE™ Modulat- in the field to any combination of one/two pumps, ing Heating Control.
Page 21 SECTION 3: I NSTALLATION • Outdoor Sensor Cable • Communications between Multiple Controllers (MS/TP) Cable Shielded cable, One twisted pair of 18 AWG minimum or equivalent Belden Maximum network length, 4000’ (1219 m) at 19.2K #8451, #1503A; General Cable baud rate, and 2000’ (609.5 m) at 76.8K baud rate. #C2514.
Page 22 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 10: Hybrid Network Configuration Segment Segment Segment Segment C: Controller R: Repeater T: BT485 Terminating Resistor Recommended MS/TP cable specification Description Single twisted pair, low capacitance (12pF), CL2P, 22 AWG (7x30), TC foam FEP,...
Page 23: Electrical Installation Requirements Of Corayvac Modulating Heating Control
The power connection should be made with cable, Failure to follow these instructions can result in death or electrical shock. size 18 AWG. ® • CORAYVAC and COMPLETE™ Modulating Heat- • RS485 Repeater Communications ing Control Panel Note: Use the same polarity throughout the network Controller panel must be feeding from a local fused segment.
Page 24: Variable Frequency Drive Requirements
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL Note: Reading the number "99" on the system view 3.7 Variable Frequency Drive Requirements zone screen (or "Err" sign on the zone sensor dis- VFD Drive Drive Power Supply...
Page 25: Outdoor Sensor (P/N 10081500) Placement
SECTION 3: I NSTALLATION 3.10 Outdoor Sensor (P/N 10081500) 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 and failure to modulate as designed.
Page 26 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL THIS PAGE LEFT INTENTIONALLY BLANK...
Page 27: Section 4: Typical Wiring Diagrams
SECTION 4: T YPICAL IRING IAGRAMS SECTION 4: TYPICAL WIRING 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. Note: Systems must be electrically grounded in accordance with the following codes: United States: Refer to National Electrical Code...
Page 28 ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 13: CORAYVAC ® Modulating Central and Satellite Control Internal Wiring, 1Ø Pump Ground shield (on and only) indicated by; operated Connections indicated by; zones Separate line and low voltage circuits.
Page 29 SECTION 4: T YPICAL IRING IAGRAMS CORAYVAC ® Modulating Central and Satellite Control Internal Wiring, 1Ø (Continued) Single pole circuit breaker for 115V L1/L L2/N L3 L1/L L2/N L3 Indicator Lights POWER INPUT POWER INPUT VFD1 VFD2 VFD2 OPTIONAL 4 5 6 7 8 9...
Page 30 ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 14: CORAYVAC ® Modulating Central and Satellite Control Internal Wiring, 3Ø Ground shield (on and only) indicated by; Pump Connections indicated by; operated Separate line and low voltage circuits. zones Notes: - Do not run low voltage wiring through section of enclosure that houses VFD(s).
Page 31 SECTION 4: T YPICAL IRING IAGRAMS CORAYVAC ® Modulating Central and Satellite Control Internal Wiring, 3Ø (continued) L1/L L2/N L3 L1/L L2/N L3 Indicator Lights POWER INPUT POWER INPUT VFD1 VFD2 VFD2 OPTIONAL 4 5 6 7 8 9 4 5 6 7 8 9...
Page 32 EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 15: CORAYVAC ® Modulating Central and Satellite Control External Wiring, 3Ø Notes: - Do not run low voltage wiring through section of enclosure that houses VFD(s). - Do not run line and low voltage wiring in same conduit - Dashed lines indicate field wiring - Ground shield (on and only) indicated by;...
Page 33 SECTION 4: T YPICAL IRING IAGRAMS CORAYVAC ® Modulating Central and Satellite Control External Wiring, 3Ø (continued) Pump Operated Zones Zone 1 Zone 3 Zone 4 Zone 2 Burners Burners Burners Burners CONTROL PWR IN 120V 60HZ 1O 20A TO PS 2...
Page 34 EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 16: CORAYVAC ® Modulating Central and Satellite Control External Wiring, 1Ø Notes: - Do not run low voltage wiring through section of enclosure that houses VFD(s). - Do not run line and low voltage wiring in same conduit - Dashed lines indicate field wiring - Ground shield (on and only) indicated by;...
Page 35 SECTION 4: T YPICAL IRING IAGRAMS CORAYVAC ® Modulating Central and Satellite Control External Wiring, 1Ø (continued) Pump Operated Zones Zone 1 Zone 3 Zone 4 Zone 2 Burners Burners Burners Burners CONTROL PWR IN 120V 60HZ 1O 20A TO PS 2...
Page 36 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 17: COMPLETE™ Modulating Central and Satellite Control Wiring (Unitary Burners) Notes: - Do not run low voltage wiring through section of enclosure that houses VFD(s). - Do not run line and low voltage wiring in same conduit - Dashed lines indicate field wiring - Ground shield (on and only) indicated by;...
Page 37 SECTION 4: T YPICAL IRING IAGRAMS COMPLETE™ Modulating Central and Satellite Control Wiring (Unitary Burners) (continued) TERMINAL BLOCK 1 120V 60HZ 1O 20A ZONE 1 LOW VOLTAGE LOW VOLTAGE THERMOSTAT THERMOSTAT BURNER BURNER SPARE SPARE TO ADDITIONAL BURNERS ZONE 2 RELAY 1 RELAY 2 RELAY 3...
Page 38 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 18: COMPLETE™ Modulating Central and Satellite Control Wiring (CRV On/Off) Notes: - Do not run low voltage wiring through section of enclosure that houses VFD(s). - Do not run line and low voltage wiring in same conduit - Dashed lines indicate field wiring - Ground shield (on and only) indicated by;...
Page 39 SECTION 4: T YPICAL IRING IAGRAMS COMPLETE™ Modulating Central and Satellite Control Wiring (CRV On/Off) (continued) Pump Operated Zones TERMINAL BLOCK 1 Zone 1 Zone 2 Burners Burners 120V 60HZ 1O 20A RELAY 1 RELAY 2 RELAY 3 RELAY 4 RELAY 5 RELAY 6 PUMP 2...
Page 40 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 19: Repeater External Wiring...
Page 41 SECTION 4: T YPICAL IRING IAGRAMS FIGURE 20: Repeater Communication Wiring Between Multiple Controllers...
Page 42: Section 5: Communications
The central controller communicates with all satellite con- trollers, and COMPLETE™ unitary controllers when applicable. More than one "central" controller can be used, if desired. If multiple CORAYVAC ® Modulating Heating Control controllers are being used, the addi-...
Page 43: Integration Into Building Management System (Bms)
SECTION 5: C OMMUNICATIONS Custom IP Address Assign a custom IP address using the touchscreen located on the central control panel provided. Open the local Menu at the bottom right of the screen scroll to the bottom, and select IP. This opens the IP menu. IP can be reached on Menu ...
Page 44: Communications Between Multiple Corayvac Modulating Heating Controls
CORAYVAC Modulating Heating Controls upper rotary switch (1's) to "0". ® If more than one CORAYVAC Modulating Heating Control is installed in a building, the controllers' MS/ TP communications must be wired in series. See Note: All central controllers should be set to "1". All Page 34, Figure 18.
Page 45: Setting Baud Rate
SECTION 5: C OMMUNICATIONS FIGURE 21: Communications Between Multiple Controllers Without Keypad: Without Keypad: Power Power 24Vac 24Vac, 50VA 24Vac 24Vac, 50VA Port 1 Tx Port 1 Tx 2A, 50-60 Hz 2A, 50-60 Hz 26Vdc 26Vdc Port 1 Rx Port 1 Rx 26Vdc, 23W, 0.9A 26Vdc, 23W, 0.9A ONLY Use Copper...
Page 46: Control Board Setup
• Port 1 jumpers set to "485" • Port 2a jumpers configured for "EIA485, 2 WIRES" • The CORAYVAC ® On/Off system uses universal outputs 7 and 8 to control the pumps. In this case, the jumper for UO's 7 and 8 is set to Relay.
Page 47 SECTION 5: C OMMUNICATIONS 5.7.1 Module Status LED Error Code on Control Board Table 1: Module Status LED Error Code on Controller Board During normal operation, the controller Module Status LED is chasing. When a problem exists, the controller Module Status LED will indicate the number listed below. Error Indicates Possible Solution...
Page 48 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL Port 2a is used as a device port to communicate with the VFD(s). Port 2a has two jumpers used to set its configuration. These jumpers should be set to EIA- 485, 2-wire.
Page 49: Touchscreen
SECTION 5: C OMMUNICATIONS 5.8 Touchscreen Note: For detailed touchscreen navigation, reference the Touchscreen Navigation Tree, located on Page 104, Section 13. 5.8.1 Initial Touchscreen Setup Initial setup is required in order to communicate with all controllers within the network. Prior to initial touch- screen setup, ensure that the system(s) are properly installed and that all universal inputs and outputs, ports, rotary and DIP switches are properly config-...
Page 50 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL After logging in, you will be taken to the Setup <Create DB>. The System View screen will now screen. Select <Communications> show the new network of connected control panels.
Page 51: The Rep485 Repeater (P/N 10060156)
• To extend communications beyond the standard 4000' (1219 m) limitation. See Page 30, Figure • To add parallel branches of ROBERTS GOR- ® CORAYVAC ® Modulating Heating Control communications bus wiring. See Page 32, Figure • To add more than 31 controllers to the network...
Page 52: Section 6: Variable Frequency Drive Programming
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL SECTION 6: VARIABLE FREQUENCY DRIVE PROGRAMMING 6.1 VFD Parameter Settings For Use With 6.1.1 Program Mode ROBERTS GORDON ® CORAYVAC ® Modulating To enter the PROGRAM mode and access the Heating Control Parameters, hold "OK"...
Page 53: Altering Vfd Parameters
SECTION 6: V ARIABLE REQUENCY RIVE ROGRAMMING 6.2 Altering VFD Parameters Parameter Parameter Name Factory Default New Setting Number 60.0 (After setting the system, take right Fre- quency according to Page 57 , Step 7 .1.1 and Maximum Frequency (Hz) 50.0 input.) 40.0 (After setting the system, take right Fre-...
Page 54 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 6.2.1 Acknowledge error message (Reset) 6.2.2 Error Messages To acknowledge and reset the current error mes- The following table shows the Error messages list, sage, you can either switch off the supply voltage or the possible causes and indicates corrective mea- press the STOP button.
Page 55 SECTION 6: V ARIABLE REQUENCY RIVE ROGRAMMING • Check the wiring to the motor. • Check whether there is a short - circuit between the phases or an earth fault in a phase. P5-trF • Check the variable frequency Fault in power section •...
Page 56: Sequence Of Operation Corayvac Modulating Heating Control
System (Modulating)) compares outdoor air temperature with zone tem- 1. On a call for heat from zone sensor, controller will perature setpoint and will modulate the CORAYVAC ® verify that vacuum pump air pressure switch is open. system appropriately to meet zone temperature set- If switch is open, VFD 'Run' command will be issued point.
Page 57 COMPLETE™ Modulating Heating Control compares outdoor air temperature COMPLETE™ Modulating Heating Control with zone temperature setpoint and will modulate the (VANTAGE ® CTHN Multiburner or CORAYVAC ® ® VANTAGE Modulating burner appropriately to meet On/Off (Non-Modulating)) zone temperature setpoint.
Page 58 ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL Note: On/Off CORAYVAC ® system will not modulate. System will function as designed. 5. When the call for heat is satisfied, burners shut off, zone LED light on control panel turns off. 6. The pump will continue operation for a post-purge period of 2 minutes.
Page 59: Section 7: Commissioning The Corayvac
"OK" to store new setting. Press "START" button on 2.5" w.c. and 3.0" w.c., while all the burners are still VFD to turn on the CORAYVAC® vacuum pump. operating, use the down arrow button on the VFD to Pump should ramp up to value set in P-01. Verify reduce the frequency of the output signal to the pump rotation.
Page 60 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 24: End Vent Vacuum Note: System vacuum should be set by measuring vacuum pressure at end burner furthest away from vacuum pump. All other end burners on the other branches should have the same vacuum pressure reading.
Page 61 SECTION 7: C CORAYVAC ® OMMISSIONING YSTEM FIGURE 25: Possible Damper Coupling Locations Description Part Number Damper Coupling 4" (10 cm) 01331900 Damper Coupling 6" (15 cm) E0009356...
Page 62: Section 8: Programming And Troubleshooting The System
This section will provide details reached when occupancy begins. The feature is set on how to modify these settings. The program to not start more than 30 minutes before scheduled defaults to 4 CORAYVAC ® heating zones. The default occupancy.
Page 63: Home Screen And Programming The System
Initial Touchscreen Setup has been complete, see gramming instructions. For detailed instructions, Page 45, Section 5.8. please refer to the CORAYVAC ® /COMPLETE™ Mod- ulating Heating Control installation and operation manual.
Page 64: Zone Temperature Setpoints
Note: Setpoint displayed also reflects any adjust- wiring. Yellow and blue lines indicate which pump ments made at the zone sensor. This is the "Effective each CORAYVAC ® system is connected to within the Setpoint". For example: If the setpoint is at 68 °F and controller's logic.
Page 65 SECTION 8: P ROGRAMMING AND ROUBLESHOOTING THE YSTEM Select <Schedule Object #1>, to access the Calen- Note: 'Dated' will allow users to set a specific time dar View screen. Calendar View and date for the system to be active. The date can be set to a single day or a specific day each month or each year.
Page 66: Edit Existing Schedule
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 8.6 Edit Existing Schedule Edit schedule information by pressing the times to edit the 'Starts:' and 'Ends:' times. Select desired If at the Home screen, users can access the Calen- 'Days:' of the week schedule is to be active.
Page 67: Maintenance
SECTION 8: P ROGRAMMING AND ROUBLESHOOTING THE YSTEM pre-heat, bringing the temperature in the space up to • Use this screen to see which alarms are active, if any. Use the info button for occupied setpoint.) more information about the alarm •...
Page 68: Unit Configuration
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL • Use this screen to check for successful Modbus • The default times for startup and post purge in connection to the VFD. If the drives are communi- this section should not be altered.
Page 69 SECTION 8: P ROGRAMMING AND ROUBLESHOOTING THE YSTEM THIS PAGE LEFT INTENTIONALLY BLANK...
Page 70: Section 9: Troubleshooting
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL SECTION 9: TROUBLESHOOTING Table of Contents: Page 67 , Figure 26 - Vacuum pump does not turn on DANGER Page 68, Figure 27 - VFD Turns on, but the desired...
Page 71 SECTION 9: T ROUBLESHOOTING FIGURE 26: Vacuum pump does not turn on...
Page 72 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 27: VFD Turns on but the desired zone does not turn on...
Page 73 SECTION 9: T ROUBLESHOOTING FIGURE 28: VFD showing a fault sign FIGURE 29: VFD input power issue...
Page 74 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 30: Vacuum pump power issue...
Page 75 SECTION 9: T ROUBLESHOOTING FIGURE 31: Burner troubleshooting in manual mode...
Page 76 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 32: After 45 second prepurge, burners do not light...
Page 77 SECTION 9: T ROUBLESHOOTING After 45 second prepurge, burners do not light (continued)
Page 78 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 33: Burner intermittent lockout...
Page 79 SECTION 9: T ROUBLESHOOTING FIGURE 34: APS does not close within 60 seconds after VFD receives run command...
Page 80 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 35: Zone sensor issue...
Page 81 SECTION 9: T ROUBLESHOOTING FIGURE 36: Air Pressure Switch alarm...
Page 82 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 37: Modbus troubleshooting...
Page 83 SECTION 9: T ROUBLESHOOTING FIGURE 38: Repeater troubleshooting...
Page 84 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 39: BACnet MS/TP troubleshooting...
Page 85 SECTION 9: T ROUBLESHOOTING BACnet MS/TP troubleshooting (continued)
Page 86 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 40: Touch pad troubleshooting...
Page 87: Section 10: Controls Start-Up Checklist
SECTION 10: C ONTROLS TART HECKLIST SECTION 10: CONTROLS START-UP CHECKLIST Mechanical system installed properly All utilities hooked up and on Power is present at panel(s) Panels and pumps grounded properly Pump rotation is correct All switches are wired back to panel Wiring is run according to building layout drawings Is the correct communication wire used...
Page 88: Section 11: Replacement Parts
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL SECTION 11: 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.
Page 89: Corayvac
Modulating Heating Control Controller Replacement Parts Caution: Use only genuine ROBERTS GORDON ® replacement parts. Use of parts not specified by Roberts Gordon voids warranty. FIGURE 41: CORAYVAC ® Modulating Heating Control Controller Components L1/L L2/N L3 L1/L L2/N L3...
Page 90: Complete™ Modulating Heating Control Controller Replacement Parts
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 11.2 COMPLETE™ Modulating Heating Control Controller Replacement Parts Caution: Use only genuine ROBERTS GORDON ® replacement parts. Use of parts not specified by Roberts-Gordon voids warranty. FIGURE 42: COMPLETE™ Modulating Heating Control Controller Components...
Page 91: Repeater Replacement Parts
SECTION 11: R EPLACEMENT ARTS 11.3 Repeater Replacement Parts FIGURE 43: Repeater Components Diagram 0.8 Amps. Fuse Terminal Block BLACK BLACK WHITE GREEN LINE 120V 60HZ 1-3 TRANSFORMER 24V 20VA 4-5 LOAD GREEN BASE PLATE YELLOW BLUE POWER JUMPER POWER CONNECTOR 24 Vac ON OFF...
Page 92: Replacement Parts Instructions
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 11.4 Replacement Parts Instructions 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 93: Section 12: Integration With Building Management System (Bms)
To set up the Modulating Controller for ARC156 in death or electrical shock. 1. Turn off power to control board. The CORAYVAC® and COMPLETE™ Modulating 2. Using the rotary switches, set the controller's Heating Controls have built in BACnet/IP connection address.
Page 94 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 7. Set a unique Device Instance number. 4. Port 1 on the I/O Pro 812u control board is the only port that supports BACnet over ARC 156. Connect BACnet over ARC 156 communications wiring to Port 1 in the screw terminals labeled Net +, Net - and Gnd.
Page 95: Bacnet Ms/Tp
SECTION 12: I (BMS) NTEGRATION WITH UILDING ANAGEMENT YSTEM 12.2 BACnet MS/TP BACnet MS/TP network on the touch screen. BACnet MS/TP is a token passing protocol. MS stands for Master-Slave and the TP stands for Token Passing. Each controller on the network has the ability to hear the broadcast of any other device on the network.
Page 96 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL • Terminal connection for ELA-485 2 wire 7. Turn on power to control board. 8. Set the correct network number to the unique BACnet MS/TP network at the touch screen.
Page 97: Bacnet Ptp
SECTION 12: I (BMS) NTEGRATION WITH UILDING ANAGEMENT YSTEM • If RX LED is solid, then the terminations are incor- 6. Connect the communications wiring to Port 2a. rect. • If the network has greater than 32 devices or exceeds 2000’ (610 m) a Repeater should be installed.
Page 98: Bacnet Over Ip
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 9. Set the following DIP switch on the modem Note: The default address is an intranet address. 10. Turn on power to the control board. Data packets from this address is not routable to the Note: The most common communication problems Internet.
Page 99 SECTION 12: I (BMS) NTEGRATION WITH UILDING ANAGEMENT YSTEM 3. Connect Port E1, which is the only port that speaks BACnet over IP. 7. Connect Port E1, which is the only port that speaks BACnet over IP. Wiring Specifications • Maximum cable length 328’ (100 m). •...
Page 100: Bacnet Over Ethernet
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 7. Set a unique Device Instance number 2. Set Comm Selector DIP Switches 1 through 8 OFF. Verify accuracy of the following: Hardware settings for speaking BACnet over IP: Note: The default address is an intranet address.
Page 101: Modbus
SECTION 12: I (BMS) NTEGRATION WITH UILDING ANAGEMENT YSTEM 12.6.1 To set up the Modulating Controller for 5. Set the IP address on touch screen. Modbus RTU or ASCII on Port 1 1. Turn off power to control board. 2. Using the rotary switches, set the controller's address.
Page 102 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL 5.Set Comm Selector DIP Switch 3 OFF for BAS Port Note: Use the same polarity throughout the network segment. 7. Turn on power to control board. 12.6.2 To set up the Modulating Controller for Modbus RTU or ASCII on Port 2a 1.
Page 103 SECTION 12: I (BMS) NTEGRATION WITH UILDING ANAGEMENT YSTEM for 38.4k, Port 2, and Modbus. EIA-485, 4-wire 7. Connect the communications port and jumper wir- ing to Port 2a. Wiring specifications • A dedicated 24 AWG to 18 AWG twisted pair •...
Page 104: Port 1
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL grounds. 3. Connect Port E1 to the third-party device. Note: Port E1 will still be capable of BACnet communication. Wire Specifications 18–28 AWG; twisted pair preferable Wiring Specifications • Maximum wire length, 328’ (100 m) 50’...
Page 105: To Set Up The Modulating Controller For N2 On
SECTION 12: I (BMS) NTEGRATION WITH UILDING ANAGEMENT YSTEM address. Wiring specifications 3. Set the Comm Selector DIP Switches 1 - 8 for • A dedicated 24 AWG to 18 AWG twisted pair wire (EIA-485) baud rate, port number, wiring, and protocol. •...
Page 106: Lonworks
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL EIA-485, 2-wire NOTES: • If RX LED is solid, then the terminations are incor- rect. • If the network has greater than 32 devices or exceeds 2,000' (609.6 m), a Repeater should be installed.
Page 107 SECTION 12: I (BMS) NTEGRATION WITH UILDING ANAGEMENT YSTEM • Set the Comm Selector DIP Switches 6 through 8 5. Connect the LonWorks network to the LonWorks for LonWorks Option Card Option Card's 2-pin Net port. The following example shows the DIP Switches set NOTE: The 2-pin Net port provides TP/FT-10 for 38.4k baud, Port 1and LonWorks Option Card.
Page 108: Section 13: Touchscreen Tree
® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL SECTION 13: TOUCHSCREEN TREE FIGURE 44: Touchscreen Tree Overview System Status Page 106, Figure 45 Schedules Page 106, Figure 46 Maintenance-Unit Page 107 , Figure 47 Alarms Page 107 , Figure 48...
Page 109 SECTION 13: T OUCHSCREEN Touchscreen Tree Overview (continued)
Page 110 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 45: System Status FIGURE 46: Schedules...
Page 111 SECTION 13: T OUCHSCREEN FIGURE 47: Maintenance-Unit FIGURE 48: Alarms...
Page 112 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 49: VFD-Status FIGURE 50: Configuration-Service...
Page 113 SECTION 13: T OUCHSCREEN FIGURE 51: Configuration-Zones FIGURE 52: Configuration-Unit...
Page 114 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 53: Configuration-Alarm FIGURE 54: Hardware I/O Note: Settings in Hardware I/O screen are factory defaults and SHOULD NOT BE ADJUSTED.
Page 115 SECTION 13: T OUCHSCREEN FIGURE 55: Touchscreen System FIGURE 56: Touchscreen Setup...
Page 116 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL FIGURE 57: Trends FIGURE 58: Communication FIGURE 59: IP...
Page 117: Section 14: The Roberts Gordon
SECTION 14: T ROBERTS GORDON ® CORAYVAC ® /COMPLETE™ M ODULATING EATING ONTROL IMITED ARRANTY SECTION 14: THE ROBERTS GORDON ® CORAYVAC ® /COMPLETE™ Modulating Heating Control LIMITED WARRANTY Within 36 months from date of purchase by buyer or 42...
Page 118 ® ® ROBERTS GORDON CORAYVAC ODULATING EATING ONTROL ONTROLLER NSTALLATION ANUAL...
Page 119 SECTION 14: T ROBERTS GORDON ® CORAYVAC ® /COMPLETE™ M ODULATING EATING ONTROL IMITED ARRANTY...

Roberts Gorden CORAYVAC Installation Manual

Table of Contents

SECTION 1: Introduction

SECTION 2: Specifications

SECTION 3: Installation

SECTION 4: Typical Wiring Diagrams

SECTION 5: Communications

SECTION 6: Variable Frequency Drive Programming

SECTION 7: Commissioning the CORAYVAC

SECTION 8: Programming and Troubleshooting the System

SECTION 9: Troubleshooting

SECTION 10: Controls Start-Up Checklist

SECTION 11: Replacement Parts

SECTION 12: Integration with Building Management System (BMS)

SECTION 13: Touchscreen Tree

SECTION 14: the ROBERTS GORDON

Quick Links

Troubleshooting

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Summary of Contents for Roberts Gorden CORAYVAC

Table of Contents