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MUA Controls
Industrial Direct-Fired Heaters - Non-Recirculating and Recirculating Systems
Installation, Operation, and Maintenance Manual
FOR YOUR SAFETY
IF YOU SMELL GAS: OPEN WINDOWS, DO NOT TOUCH ELECTRICAL SWITCHES, EXTINGUISH
ANY OPEN FLAMES, IMMEDIATELY CALL YOUR GAS SUPPLIER.
FOR YOUR SAFETY
THE USE AND STORAGE OF GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN
OPEN CONTAINERS IN THE VICINITY OF THIS APPLIANCE IS HAZARDOUS!
RECEIVING AND INSPECTION
Upon receiving unit, check for any interior and exterior damage. If damage is found, report it immediately to the carrier. Check that all accessory items are accounted for and are not damaged.
WARNING!!
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment. ALWAYS disconnect power and gas prior to working on heater.
Note To Installer: This manual should be reviewed with the customer and left with the equipment user.
Please complete and return the Start-Up Checklist on the back of this manual to validate warranty.
Save these instructions . This document is the property of the owner of this equipment and is required for future maintenance. Leave this document with the owner when installation or service is complete.
A0033038
June 2022 Rev. 8
2
Table of Contents
WARRANTY ........................................................ 4
GENERAL INFORMATION ................................. 4
Listings .............................................................. 4
Patents .............................................................. 4
INSTALLATION ................................................... 5
Inspection on Arrival ......................................... 5
Mechanical ........................................................ 5
Site Preparation .............................................. 5
Unit Location ..................................................... 6
Rigging .............................................................. 7
Horizontal Split Units ......................................... 8
Vertical Split Units ............................................. 8
Discharge Air Sensor ........................................ 9
Loose Shipped Intake or Discharge Dampers .. 9
Curb and Ductwork ......................................... 10
Recommended Ductwork Sizing ..................... 11
Curbs ............................................................ 12
Z-Clip Installation .......................................... 12
Accessories ..................................................... 13
Installation Examples ...................................... 14
Horizontal Roof Top Installation ................... 14
Vertical Outdoor Ground Installation ............ 14
Gas ................................................................. 15
Strainer ......................................................... 16
HMI and Remote Room Sensor Installation . 17
Electrical ......................................................... 18
Make-up Air (MUA) Board Connectors ........... 19
Variable Frequency Drive (VFD) ..................... 29
VFD Installation ............................................ 30
Input AC Power ............................................ 30
VFD Output Power ....................................... 30
VFD Programming ........................................ 31
ACTECH SMV VFD ...................................... 32
Temperature Control .................................... 33
Thermistor Connected to HMI ...................... 33
OPERATION ..................................................... 34
Accessing Menu Configurations ..................... 34
Remote (HMI) Control Panel ........................ 34
HMI Notification Letters ................................ 34
HMI Configuration Menu ................................. 35
Communication ............................................ 35
Advanced Options ........................................ 35
Status ........................................................... 35
About ............................................................ 35
Scheduling ...................................................... 36
Unit Options .................................................... 37
Building Signal Damper Control ................... 37
Electric Cabinet Heater ................................ 37
Motorized Intake Damper ............................. 37
Recirculating Control Unit Options .................. 37
Menu Descriptions .......................................... 38
Start-Up Procedure ......................................... 50
Gas Train Start-Up Procedure .........................51
Setting High Fire ..............................................52
Setting Low Fire ...............................................53
Design Manifold Gas Pressure .....................53
Final Start-up Procedure ...............................54
Start-up Procedure Variable Air Volume .........54
Pulley Adjustment ............................................55
Pulley Alignment/Proper Belt Tension .............55
100% Profile Adjustments & Test/Balance ......56
Test and Balance ..........................................56
Single-Speed Profile .....................................56
Variable Air Volume Profile ...........................56
80/20% Air Balancing ......................................57
Airflow Sensor .................................................58
Modulating Gas System ..................................59
High Temperature Limit ...................................59
Pilot Adjustment ...............................................59
Sequence of Operation ....................................60
Flame Safety Control ....................................60
Static Pressure Sensor Installation ...............62
Component Check/Testing ...........................62
Network ...........................................................64
BACnet ..........................................................64
Device Instance, MAC Address, Baud Rate .65
Changing the IP Address ..............................66
LonWorks ......................................................67
DDC Control Points .........................................68
DDC Fault List .................................................73
TROUBLESHOOTING .......................................74
Airflow Troubleshooting Chart .........................74
Burner Troubleshooting ...................................75
Flame Safety Service ......................................76
HMI Fault Codes ..............................................78
VFD Fault List ..................................................81
Resetting Unit ..................................................81
MAINTENANCE .................................................82
General Maintenance ......................................82
2 Weeks After Start-up ....................................82
Every 3 Months ................................................82
Yearly ..............................................................82
Burner Maintenance ........................................83
Prolonged Shutdown of Unit ............................83
Start-Up and Maintenance Documentation .....84
3
WARRANTY
This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 2-years from date of shipment. This warranty shall not apply if:
1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation instructions shipped with the product.
2. The equipment is not installed in accordance with Federal, State, and Local codes/regulations.
3. The equipment is misused or neglected, or not maintained per the MANUFACTURER’S maintenance instructions.
4. The equipment is not installed and operated within the limitations set forth in this manual.
5. The invoice is not paid within the terms of the sales agreement.
The MANUFACTURER shall not be liable for incidental and consequential losses and damages potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be defective in material or workmanship within the 2-year warranty period, upon examination by the MANUFACTURER, such part will be repaired or replaced by MANUFACTURER at no charge. The BUYER shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall not be returned without
MANUFACTURER’S prior authorization, and all returned equipment shall be shipped by the BUYER, freight prepaid to a destination determined by the MANUFACTURER.
NOTE: To receive warranty coverage for this product, copy and print out the “Start-Up and
Maintenance Documentation” on page 84. Fill in all required information. Fax the page to 1-919-
516-8710 or call 1-866-784-6900 for email information within thirty (30) days of purchase.
GENERAL INFORMATION
Listings
This unit is ETL-listed to the American National Standard/CSA Standard for Gas Unit Heaters And Gas-
Fired Duct Furnaces ANSI Z83.4, CSA 3.7.
The Safety Control Board is ETL-listed to standard UL 60730-2-9, UL 60730-1, CSA E60730-1, CSA
E60730-2-9.
Patents
The Direct Gas Fired Make-Up Air Profile Plates is covered under the following patent: Heated Make-Up
Air System: United States Patent No. 6629523 B2.
4
INSTALLATION
It is imperative that this unit is installed and operated with the designed airflow and electrical supply in accordance with this manual. If there are any questions about any items, please call the service department at 1-866-784-6900 for warranty and technical support issues.
Inspection on Arrival
1. Inspect the unit on delivery. Photograph any visible damage. Report any damage to the delivery carrier.
2. Request written inspection report from the Claims Inspector to substantiate a claim. File claim with delivery carrier
3. Check unit’s rating plate to verify proper electric and fuel type meet job requirements. Compare unit received to description of product ordered.
Mechanical
WARNING: DO NOT RAISE UNIT BY THE INTAKE HOOD, BLOWER, MOTOR SHAFT, OR
BEARINGS. USE ALL LIFTING LUGS PROVIDED WITH A SPREADER BAR OR SLING UNDER THE
UNIT.
For clearances and unit location, refer to “Unit Location” on page 6
.
For rigging and lifting units, refer to
Site Preparation
1. Recirculation of room air may be hazardous in the presence of:
• Flammable solids, liquids, and gases.
• Explosive materials (e.g., grain dust, coal dust, gunpowder, etc.).
• Substances which may become toxic when exposed to heat (e.g., refrigerants, aerosols, etc.).
2. Recirculation is not recommended in uninsulated buildings where outside temperatures fall below 32 ° F
(0°C).
3. Excessive recirculation or insufficient ventilation air, which results in inadequate dilution of the combustion products generated by the heater, may create hazardous concentrations of carbon dioxide, carbon monoxide, nitrogen dioxide, and other combustion products in the heated space.
4. If gas fork trucks or other fossil fuel-powered equipment are utilized in the conditioned area, additional ventilation requirements for the facility must be addressed separately.
5. If the heater utilizes room sensors for limiting room CO2 concentration:
• The CO2 control set-point shall be no greater than the maximum allowable room concentration of
5000 ppm less the sensor’s published accuracy tolerance. The control shall prevent the CO2 concentration in room air from exceeding 5000 ppm.
• A minimum of one sensor shall be installed per room served by the heater.
• When a room area, served by a single heater, does not exceed 10,000 ft2 (929 m2), and height does not exceed 20 ft. (6 m), a duct sensor may be installed in the return air opening of the heater.
• Sensors shall be calibrated per the sensor manufacturer’s recommended procedure and frequency or annually, whichever is more frequent.
• Each heater shall require its own CO2 sensor(s).
• Sensors shall not be placed near sources of CO2.
• If using part number A/CO2-R2, 10V DC = 2000 PPM. Voltage reading can be found in HMI under
Service Menu > Variable Values > Inputs > AQ .
5
Unit Location
1. Do not locate any gas-fired equipment near corrosive or explosive vapors such as chlorinated or acid vapors. Refer to
for unit clearance spacing.
2. Avoid overhead power lines or other utility access to prevent accidental contact or damage.
3. Provide clearance around the installation site to safely rig and lift the equipment into its final position onto adequate supports. Refer to the manufacturer’s estimated weights.
4. Consider general service and installation space when locating the unit. Locate the unit close to the space it will serve to reduce long, twisted duct runs.
5. Do not allow the air intake to face prevailing winds. The airflow sensor may trip in high winds.
6. Situate the unit above ground or at roof level high enough to prevent precipitation from being drawn into its inlet. The inlet must also be located at least 10 feet away from any exhaust vents.
7. The heater inlet must be located in accordance with the applicable building code provisions for ventilation air.
8. All air to the heater must be ducted from the outdoors.
9. Recirculation of room air is not permitted. If in doubt regarding the application, consult the manufacturer.
10. The unit must have adequate structural support, or the equipment or building could be damaged.
11. Do not alter or otherwise restrict combustion or ventilation openings.
12. Direct-fired units should not be installed downstream from cooling systems that use refrigerants for cooling.
Figure 1 - Unit Clearances
6” Clearance to
Combustibles
24” Clearance for Servicing
48” Clearance for Servicing
COMBUSTIBLE CLEARANCES
The top, back, and front surfaces of this heater may not be installed less than 6 inches from combustible materials. The heater base may be installed on combustible surfaces.
SERVICE CLEARANCES
Allow 24 inches or greater minimum service clearance on all sides of this heater. Allow 48 inches or greater on the vestibule and blower door side.
6
Rigging
1.
shows the proper methods for lifting the unit and accessories.
2. Lift the unit and accessories separately, attach the accessories to the unit once the unit is in place.
3. Size 10, 12, 15, and 18 units are supplied with lifting eyes on the top corners of the casing.
4. Horizontal units are supplied with four lifting lugs on the bottom corners of the casing.
5. Vertical units are supplied with four lifting lugs at the top corners of the casings.
6. The main load should be on these lugs.
7. Always use spreader bars to prevent damage to the unit casing.
Size 10, 12, 15, 18
Figure 2 - Rigging
No Spreader Bar
With Spreader Bar Accessories
CAUTION!
THESE ARE UNBALANCED LOADS. LIFT EQUIPMENT GENTLY. DO NOT MAKE SUDDEN
MOVEMENTS.
WARNING!
Spreader bars must be used and should extend past the edges of the equipment to avoid damage to the casing. Not using spreader bars may cause damage to the casing.
WARNING!
Damage will result if the equipment is raised by the intake hood, blower, motor shaft, or bearings.
Use the provided lifting eyes and brackets on the unit.
7
Horizontal Split Units
1. Apply weather-proof gasketing to the seam of the horizontal unit, if not present.
).
Horizontal units have internal channels and a formed frame.
3. Apply silicone to the outside edge of the seam.
4. Field wire the discharge air sensor using a minimum 18 gauge thermistor wire.
Figure 3 - Horizontal Split Assembly
Vertical Split Units
1. Position vertical stand. Lower unit sections onto vertical stand and bolt together. Use brackets
2. Secure and seal ductwork connections to unit.
3. Secure mounting stand to equipment pad.
Figure 4 - Vertical Split Assembly
10-20 INCH BLOWERS (1 SECTION)
ALL OTHER UNITS (2 SECTIONS)
2 SECTION UNITS TO BE BOLTED
TOGETHER WITH BRACKETS PROVIDED
(SEE DETAIL B)
.75
.75
DETAIL A
TRUE .63
6.00
A
6.00
B
DETAIL B ( 4 PLACES)
(8 PLACES FOR TWO PIECE
UNITS) FIELD INSTALLED
(HARDWARE PROVIDED)
FILTER SECTION
VERTICAL STAND
GASKET IS
MOUNTED
BETWEEN
SECTIONS
* STANDS ARE SHIPPED
FULLY ASSEMBLED W/
VBANK INSTALLED IF ORDERED
* ALL HARDWARE INCLUDED
(NUTS, BOLTS, WASHERS, GASKET)
8
Discharge Air Sensor
Figure 5 - Sensor Field Assembly
DISCHARGE AIR
SENSOR
Loose Shipped Intake or Discharge Dampers
In some cases, an intake or discharge damper may be shipped loose. This may be requested by the customer or can be required because of larger units shipping size restrictions. Follow these instructions to attach and wire the loose shipped damper. Factory mounted dampers may be attached to the unit and will
not require assembly or field wiring. Refer to Figure 6 .
1. Attach the damper to the intake or discharge using gasketing, caulk, and #10 sheet metal screws.
2. Up discharge units should have a damper installed at building wall.
3. Field wire the damper using the as-built wiring schematic for the specific unit. Wiring may be different depending on the model and options selected.
4. Refer to the factory-supplied wiring print to verify the field wiring terminals.
Figure 6 - Discharge Damper Location (Top Mount shown)
9
Curb and Ductwork
This fan was specified for a specific CFM and static pressure. The ductwork attached to this unit will significantly affect airflow performance. When using rectangular ductwork, elbows must be radius throat, radius back with turning vanes. Flexible ductwork and square elbows should not be used. Any transitions and/or turns in the ductwork near the fan outlet will cause system effect. System effect will drastically increase the static pressure and reduce airflow. Units with twin blowers must have a common discharge plenum.
fan performance. Refer to
for return duct sizing.
• Do not use the unit to support ductwork in any way. This may cause damage to the unit.
• Follow SMACNA guides and manufacturer's requirements for the remaining duct run. Fans designed for rooftop installation should be installed on a prefabricated or factory-built roof curb.
• Follow curb manufacturer’s instructions for proper curb installation.
• The unit should be installed on a curb and/or rail that meets local code height requirements.
• Make sure the duct connection and fan outlet are properly aligned and sealed.
• Verify all fasteners are secure.
• Adequate building relief shall be provided so as not to over pressurize the building when the heating system is operating at its rated capacity. This can be accomplished by taking into account, through standard engineering methods, the structure’s designed infiltration rate; by providing properly-sized relief openings; or by interlocking a powered exhaust system; or by a combination of these methods.
• Heaters installed with intake ductwork must be purged to replace at least four air changes of the volume of the intake duct.
• If the failure or malfunction of this heater creates a hazard to other fuel-burning equipment in the building
(e.g., when the heater is providing makeup air to a boiler room), the unit is to be interlocked to open inlet air dampers or other such devices.
• On outdoor installations, it is recommended that the discharge duct be insulated to prevent condensation during the “OFF” cycle in cold weather.
• Flexible connectors should be used on all ductwork connections. Vibration isolators are optional and can be supplied in the loose parts package.
• Units that are installed in airplane hangars should be installed in accordance with the Standard for
Aircraft Hangars, ANSI/NFPA 409. Units that are to be installed in public garages should be installed in accordance with the Standard for Parking Structures, ANSI/NFPA 88A, or the Standard for Repair
Garages, ANSI/NFPA 88B, and with CAN/CGA B149 Installation Codes.
10
Recommended Ductwork Sizing
Blower Size (Inches)
10
12
15
18
20
22
25
27
30
33
36
Table 1 - Supply Ductwork
Supply Ductwork Sizing Single Blower
Duct Size (Inches)
14 x 14
16 x 16
20 x 20
24 x 24
26 x 26
30 x 30
32 x 32
36 x 36
38 x 38
44 x 44
44 x 44
Straight Duct Length* (Inches)
54
54
54
78
102
114
156
162
174
174
198
Blower Size (Inches)
222
225
227
230
233
236
Supply Ductwork Sizing Dual Blower
Duct Size (Inches)
77 x 28
88 x 32
96 x 36
104 x 38
116 x 44
122 x 44
Straight Duct Length (Inches)
156
168
180
198
204
222
Table 2 - Return Ductwork
Return Ductwork Sizing Single Blower
Blower Size (Inches)
10
12
15
18
20
22
25
27
30
33
36
Duct Size (Inches)
-
12 x 30
12 x 30
13 x 42
13 x 42
14 x 58
14 x 58
16 x 66
16 x 66
22 x 76
22 x 76
Return Ductwork Sizing Double Blower
Blower Size (Inches)
222
225
227
230
233
236
Duct Size (Inches)
14 x 124
14 x 124
15 x134
15 x 134
-
-
WARNING!!
Failure to properly size ductwork may cause system effects and reduce the performance of the equipment.
11
Curbs
WARNING!
The unit must have adequate structural support or the equipment or building could be damaged.
The curb and unit must be leveled or the unit may leak or damage may occur.
Use gasketing and caulk between the curb and unit. If necessary, use shims to level the unit. Screw or
weld the unit’s base to the curb to avoid damage to the equipment. Refer to Figure 7 .
Figure 7 - Curb
Z-Clip Installation
Refer to
for details on Z-Clip installation. Z-Clip brackets can be used to secure the equipment’s base to the curb. Z-Clip brackets should be installed on the curb prior to placing equipment in place. Install clips 12” from the edge of the curb on every side. Use two clips per side on single blower units. An additional clip is added to each side on twin blower units.
Figure 8 - Z-Clip Installation Details
Z-Clip Bracket
U se two clips per side for single blower units - Qty: 8
Use three clips per side for twin blower units - Qty 12
Roof Curb
Unit Base
12”
Curb Gasket
Z-Clip Bracket
Fasteners
Roof Curb
12
Accessories
Intake and discharge accessories are shipped loose and unassembled. When attaching accessories to the unit, use gasketing, caulk, and #10 sheet metal screws on all seams. All accessories must be level. Refer to
Figure 9 - Accessories Installation
13
Installation Examples
Horizontal Roof Top Installation
• Down discharge reduces ductwork
• Hood weight supported by support legs
• Union, regulator, and shut-off
• Roof curb supports unit
• Intake facing away from prevailing winds
Figure 10 - Horizontal Roof Top Installation
Vertical Outdoor Ground Installation
• Side discharge reduces ductwork
• Support stand on concrete pad
• Union, regulator, and shut-off
• Filter section inside support stand
• Ease of serviceability on ground
Figure 11 - Vertical Outdoor Ground Installation
14
Gas
Installation of gas piping must conform with local building codes, or in the absence of local codes to the
National Fuel Gas Code, ANSI Z223.1 (NFPA 54) – latest edition. In Canada, installation must be in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane units.
WARNING: INLET GAS PRESSURE MUST NOT EXCEED PRESSURE INDICATED ON NAMEPLATE.
SEE UNIT NAMEPLATE FOR PROPER GAS SUPPLY PRESSURE AND GAS TYPE.
1. Always disconnect power before working on or near a heater. Lock and tag the disconnect switch or breaker to prevent accidental power-up.
2. Piping to the unit should conform to local and national requirements for type and volume of gas handled, and pressure drop allowed in the line. Refer to the Gas Engineer’s Handbook for gas line capacities.
3. The incoming pipe near the heater should be sized to match the connection on the outside of the unit.
Avoid multiple taps in the gas supply line.
4. Install a ground joint union with brass seat and a manual shut-off valve external to the unit casing.
Install shut-off valve adjacent to the unit for emergency shut-off and easy servicing of controls. Refer to
.
5. Provide a sediment trap, as shown in
Figure 12 on page 16 , before each unit and where low spots in
the pipeline cannot be avoided.
6. Clean out the gas line to remove debris before making connections. Purge gas line to remove air before attempting to start unit. Purging air from gas lines should be performed as described in ANSI
Z223.1-latest edition “National Fuel Gas Code,” or in Canada as described in CAN/CGA-B149.
7. All field gas piping must be pressure/leak tested before unit operation. Use a non-corrosive bubble forming solution or equivalent for leak testing. The heater and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi.
8. This unit requires the gas pressure to be within the unit’s minimum and maximum gas pressure ratings. If the pressure is greater than the maximum, the internal valve components will be damaged. If the pressure is below the minimum, the heater will not perform to specifications.
9. If installing on a paint booth application, a manual shutoff should be located for access in case of a fire or explosion at the heater.
This unit may be supplied with a regulator, located upstream of all valves and switches. The regulator is sized based on the incoming gas pressure and gas supply rate. The outlet pressure of this regulator is sized to safely deliver gas to this equipment.
NOTICE
Refer to the heater’s rating plate for determining gas supply pressures and requirements.
15
Strainer
The strainer is used to prevent debris from entering the gas train. New piping must be used. Properly ream and clean metal burrs. Proper care is needed to ensure that the gas flow is in the same direction as indicated on the strainer. Do not over-tighten pipe connections. Use pipe dope on male threads only. Install a drip leg in the gas line in accordance with the Authority Having Jurisdiction (AHJ) guidelines.
Figure 12 - Gas Connection Diagram
1
1
2 B
4
To Unit
Gas Manifold
3
A
5
6
7
1. Gas Supply Line Connection
2. Manual Gas Shut-off Valve
3. Plugged 1/8” NPT Test Gauge Connection
4. Ground Joint Union with Brass Seat
5. Sediment Trap
6. Strainer
7. Unit
A. Minimum Depth = 6”
B. Maximum Length = 12”
Proper clearance must be provided in order to service the strainer. A minimum of a 4” clearance distance must be provided at the base of the strainer.
Table 3 - Gas Strainer Details
Strainer
4417K64
4417K65
4417K66
4417K67
4417K68
4417K69
4417K71
Size
3/4”
1”
1-1/4”
1-1/2”
2”
2-1/2”
3”
16
HMI and Remote Room Sensor Installation
Remote HMI faceplates (
), remote room sensors (
), and smart controls may be ordered and shipped separately. These components measure temperature and assist in controlling the unit. These components should be installed in a safe location, free of influence from external heat sources.
Install sensors in areas indicative of the average room temperature. Keep sensor away from heatproducing appliances. HMIs and remote room sensors can be installed directly to industry-standard junction boxes, either surface mounted or recessed mounted. HMIs have a built-in temperature/relative humidity (RH) sensor, which is typically used to help control the automatic function of the unit.
The HMI can also be configured to control the unit from a remote location manually. They can be configured not to use the internal temperature/relative humidity sensor. In this configuration, the sensor in the HMI is ignored in automatic operation. Multiple HMIs can be connected to one unit for temperature and
R/H averaging. All combination temperature/humidity HMIs will use a vented standoff. Mount the static pressure tube close to the HMI to obtain proper room conditions.
A max of 4 additional HMIs can be daisy-chained together. Place an End-of-Line (EOL) device in the last
HMI connected.
Figure 13 - HMI with Standoff
HMI Standoff
J-Box
Static Pressure Tube
Connected to the High Pressure
Port on Pressure Sensor
Route the provided 1/4” nylon tubing close to the HMI in the space.
5-1/2”
Cat 5 Connection
J1 on HMI-1 to J2 on HMI-2
HMI with Built-in
Temperature/Humidity
Sensor
5-1/2”
The room temperature sensor is a 10K ohm thermistor. The sensor provides constant room temperature to the controller.
It should be installed on a wall somewhere in the room, but not directly in the HVAC diffuser’s path or close to heatproducing appliances so that the reading is not affected by heat.
Room sensors are not required for proper control operation, but still can be configured as remote sensors or averaging sensors.
Do not install the room sensor on the ceiling
.
Figure 14 - Remote Room Sensor
17
Electrical
WARNING!
Disconnect power before installing or servicing unit. High voltage electrical input is needed for this equipment. A qualified electrician should perform this work.
Before connecting power to the heater, read and understand the entire section of this document. As-built wiring diagrams are furnished with each unit by the factory and are attached to the control module’s door or provided with paperwork packet.
National Electric Code, ANSI/NFPA 70. Verify the voltage and phase of the power supply. Confirm the wire amperage capacity is in accordance with the unit nameplate. For additional safety information, refer to
AMCA publication 410-96, Recommended Safety Practices for Users and Installers of Industrial and
Commercial Fans.
1.
Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch and/or breaker to prevent accidental power-up .
2. A dedicated branch circuit(s) should supply the motor/control circuits with adequate short circuit protection as required by the national electric code. Every branch circuit should include a properly sized ground connection.
3. Verify that the power source is compatible with the requirements of your equipment. The nameplate identifies the proper phase and voltage of the equipment.
4. Units shipped with a remote HMI will require a second drop through the base of the unit. It is important to route the motor wires in a separate conduit from the HMI wiring.
5. Before connecting the unit to the building’s power source, verify that the power source wiring is deenergized. Refer to schematics.
6. Secure the power cable to prevent contact with sharp objects. Verify ground connection is secure.
7. Do not kink power cable and never allow the cable to encounter the burner airstream, oil, grease, hot surfaces, or chemicals.
8. Before powering up the unit, make sure that the fan rotates freely. Make sure that the interior of the unit is free of loose debris or shipping materials.
9. If any of the original wire supplied with the unit must be replaced, it must be replaced with type THHN wire or equivalent.
Table 4 - Copper Wire Ampacity
Wire Size AWG
6
4
3
2
1
14
12
10
8
Maximum Amps
65
85
100
115
130
15
20
30
50
18
IT
OT
DT
DT
ST
ST
IT
RT
RT
OT
SL
SL
LLT
LLT
ICT
ICT
OCT
OCT
CDT
CDT
Make-up Air (MUA) Board Connectors
The Make-up Air (MUA) Board (
) is located in the main control cabinet.
Figure 15 - Make-up Air Board
24V
AC
24V
AC
IN
COM
24V
AC
0-10
VIN
COM
COM
24V
DC
0-10
VIN
COM
COM
24V
DC
0-10
VIN
COM
COM
24V
AC
24V
AC
IN
COM
24V
AC
0-10
VIN
COM
COM
J39
PS1
J20 J21
Power Vent
Neutral
J19 J17
Power
Vent
Hot
Power
Vent
Hot
1
CASLink BMS Slave
Pilot
Gas
Spark
Main
Gas
Alarm
Blower
Burn
Temp
Aux
1 J11 8 1 J16 8 1 J25 3
R C DDC
C
HMI VFD Master
Y G BAS/STAT
19
Note: Some connections may not be used dependent on system configurations.
RJ45 connectors.
Connector J1 and J2 are associated with BMS.
Connector J3 through J6 are interchangeable and may be used to connect to an HMI or VFD.
J1 - CASLink/Slave
J2 - CASLink/Slave
J3 - HMI/VFD/Master
J6
J4 - HMI/VFD/Master
J5 - HMI/VFD/Master
J6 - HMI/VFD/Master
J2
J5
J1
J4 J3
Connector J7 N/A
9
18
1
10
Connector J8 N/A
9
18
1
10
Connector J9 contains 120V AC connections 1 8
Pin 1 - 120VAC Main Input
Pin 2 - 120VAC Input from Discharge Damper End
Switch
Pin 3 - 120VAC Input from Fire Micro-Switch
Pin 4 - 120VAC Output to Intake/Discharge Damper
Actuator
Pin 5 - 120VAC Input from Intake Damper End
Switch
Pin 6 - N/A
Pin 7 - 120VAC Output to Cabinet Heater
Pin 8 - 120VAC Neutral
20
Connector J10 contains 120V AC connections
1 8
Pin 1 through Pin 4 - N/A
Pin 5 - 120VAC Input from Supply Overload
Pin 6 - 120VAC Output to Supply Starter Coil
Pin 7 - 120VAC Output to Exhaust Starter Coil
Pin 8 - 120VAC Input from Exhaust Overload
1 8
Connector J11 contains low voltage screw terminal connections
W Y G BAS/STAT
Pin 1 - 24VAC Auxiliary Input
Pin 2 - 24VAC Auxiliary Input
Pin 3 - 24VAC Auxiliary Input/Dry Mode
Pin 4 - 24VAC Call for Heat Input/Burner Interlock
Pin 5 - 24VAC Call for Cooling Input/AC Interlock
Pin 6 - 24VAC Call for Blower Input
Pin 7 - 24VAC Occupied Override Input
Pin 8 - 24VAC Isolated Common
1 8
Connector J12 contains low voltage screw terminal connections
Pin 1
Pin 2
Pin 3
Pin 4
- 24VAC Output to Smoke Detector
- 24VAC Output to Smoke Detector
- 24VAC Digital Input from Smoke Detector
- 24VAC Common to Smoke Detector
24V AC 24V AC
DI-1
24V AC
AI-1
Pin 5 - 24VAC Output to Air Quality Sensor
Pin 6 - 0-10V Analog Input from Air Quality Sensor
Pin 7 - 24VAC Common to Air Quality Sensor
Pin 8 - 24VAC Common to Air Quality Sensor
21
Connector J13 contains low voltage connections
7
14
1
8
Pin 1 - N/A
Pin 2 - N/A
Pin 3 - 24VAC Output for Low Gas Pressure Switch
Pin 4 - 24VAC Output for High Gas Pressure Switch
Pin 5 - 24VAC Output for Clogged Filter Switch
Pin 6 - 24VAC Output for Low Airflow
Pin 7 - 24VAC Input for Board Power
Pin 8 - N/A
Pin 9 - N/A
Pin 10 - 24VAC Input from Low Gas Pressure
Switch
Pin 11 - 24VAC Input from High Gas Pressure
Switch
Pin 12 - 24VAC Input from Clogged Filter Switch
Pin 13 - 24VAC Input from Low Air Pressure Switch
Pin 14 - 24VAC for Board Power
1 8
Connector J14 contains screw terminal connections
24V DC
AI-2
24V DC
AI-3
Pin 1 - 24VAC Output to Humidity Sensor
Pin 2 - 0-10VDC Analog Input from Humidity Sensor
Pin 3 - 24VAC Common to Humidity Sensor
Pin 4 - 24VAC Common to Humidity Sensor
Pin 5 - 24VAC Output to Humidity Sensor
Pin 6 - 0-10VDC Analog Input Humidity Sensor
Pin 7 - 24VAC Common Humidity Sensor
Pin 8 - 24VAC Common to Humidity Sensor
1 10
Connector J15 contains low voltage connections
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
- Intake Temperature Thermistor Input
- Intake Temperature Thermistor Input
- Return Temperature Thermistor Input
- Return Temperature Thermistor Input
- Outdoor Temperature Thermistor Input
THERMISTORS
Pin 6 - Outdoor Temperature Thermistor Input
Pin 7 - Discharge Temperature Thermistor Input
Pin 8 - Discharge Temperature Thermistor Input
Pin 9 - Space Temperature Thermistor Input
Pin 10 - Space Temperature Thermistor Input
22
1 8
Connector J16 contains low voltage screw terminal connections
BAS/STAT
R C
Pin 1 - 0-10VDC Analog Input for Heat Modulation
Pin 2 - 4-20 mA Analog Input for Heat Modulation
Pin 3 - Common
Pin 4 - Common
Pin 5 - 24VAC Unit Interlock Input/Dry Mode Input
Pin 6 - 24VAC Output (Stat)
Pin 7 - 24VAC Output (R)
Pin 8 - Common
NOTE: Connector J17 is grouped with connectors J-19 through J-21
Connector J18 contains low voltage connections
7
14
1
8
Pin 1 - 24VDC + Output
Pin 2 - 0-10VDC Analog Output for Recirc Actuator
Pin 3 - 0-10VDC Analog Output for Bypass Damper
Pin 4 - 24VAC Output for DX Float Switch
Pin 5 - 24VAC Output for Door Interlock
Pin 6 - N/A
Pin 7 - 24VAC for Damper Actuator
Pin 8 - 24VDC - Common
Pin 9 - Common for Recirc Actuator
Pin 10 - Common for Bypass Damper
Pin 11 - 24VAC Input from DX Float Switch
Pin 12 - 24VAC Input from Door Interlock
Pin 13 - N/A
Pin 14 - 24VAC for Damper Actuator
J20 J21
Connector J17 N/A
Connector J19 N/A
Connector J20 N/A
Connector J21 N/A
J19 J17
23
Connector J22 N/A
Connector J23 N/A
Connector J24 N/A
2 1
2 1
2 1
J22
J23
J24
1
Connector J25 contains low voltage screw terminal connections for DDC Communications Isolated
Pin 1 RS-485 +
Pin 2 RS-485 -
+ -
DDC
C
Pin 3 RS-485 Common
3
Connector J26 Programming Port0
1
2
USB
Connector J27 USB Programming Port
24
1 8
Connector J28 contains low voltage screw terminal connections
24V AC 24V AC
DI-2
24V AC
AI-4
Pin 1 - 24VAC Start Command for 3rd-Party VFD
Pin 2 - 24VAC Output
Pin 3 - 24VAC Trouble Input
Pin 4 - 24VAC Common for 3rd-Party VFD
Pin 5 - 24VAC Constant Output
Pin 6 - 0-10VDC Analog Input VFD Speed
Reference
Pin 7 - 24VAC Common
Pin 8 - 24VAC Common
Connector J29 contains 120V AC connections
Pin 1 - 120VAC Blower Service Switch Input
Pin 2 - 120VAC Burner Service Switch Input
Pin 3 - 120VAC High Temp Limit Input
Pin 4 - 120VAC Output to FSC (6)
1
Pin 5 - 120VAC Output to FSC (7)
Pin 6 - N/A
Pin 7 - Purge/Dry Contacts Output
Pin 8 - 120VAC Neutral
8
Connector J30 contains 120V AC connections
Pin 1 - 120VAC Input from Pilot Gas FSC (3)
Pin 2 - 120VAC Pilot Gas Output
Pin 3 - 120VAC Input from Spark FSC (4)
Pin 4 - 120VAC Spark Output
1 8
Pin 5 - 120VAC Input from Main Gas FSC (5)
Pin 6 - 120VAC Main Gas Output
Pin 7 - 120VAC Alarm Input from FSC (A)
Pin 8 - 120VAC Alarm Output
25
Connector J31 - Contains inputs and outputs for components
9
18
1
10
Pin 1 - 24VDC + Output to Profile / Main Airflow
Pressure Sensor
Pin 2 - 0-10VDC Analog Input from Profile / Main
Airflow Pressure Sensor
Pin 3 - 24VDC/0-10VDC Common from Profile /
Main Airflow Pressure Sensor
Pin 4 - N/A
Pin 5 - N/A
Pin 6 - N/A
Pin 7 - 24VDC + Output to Manifold Gas Pressure 1
Sensor
Pin 8 - 0-10VDC Analog Input from Manifold Gas
Pressure 1 Sensor
Pin 9 - 24VDC/0-10VDC Common from Manifold
Gas Pressure 1 Sensor
Pin 10 - 24VDC + Output to Manifold Gas Pressure
2 Sensor
Pin 11 - 0-10VDC Analog Input from Manifold Gas
Pressure 2 Sensor
Pin 12 - 24VDC/0-10VDC Common from Manifold
Gas Pressure 2 Sensor
Pin 13 - 24VDC + output to Clogged Filter Pressure
Sensor
Pin 14 - 0-10VDC Analog Input from Clogged Filter
Pressure Sensor
Pin 15 - 24VDC/0-10VDC Common from Clogged
Filter Pressure Sensor
Pin 16 - 24VDC + Output for Analog or Static
Pressure Control for Blower/Damper
Pin 17 - 0-10VDC Analog Input for Analog or Static
Pressure Control for Blower/Damper
Pin 18 - 24VDC/0-10VDC Common for Analog or
Static Pressure Control for Blower/Damper
Connector J32 contains inputs and outputs for components
9
18
1
10
Pin 1 - N/A
Pin 2 - N/A
Pin 3 - 24VAC Output for Proof Of Closure
Pin 4 - N/A
Pin 5 - 24VAC Output To CO Alarm
Pin 6 - 0-24VDC + Analog Input from Flame Sensor
Pin 7 - 24VDC Powered PWM to Modulating Gas
Valve, Full Wave, 16 kHz
Pin 8 - 0-10VDC Out for VFD
Pin 9 - N/A
Pin 10 - N/A
Pin 11 - N/A
Pin 12 - 24VAC Input from Proof of Closure
Pin 13 - N/A
Pin 14 - 24VAC From CO Alarm
Pin 15 - 24VDC Common From Flame Sensor
Pin 16 - 24VDC Powered PWM to Modulating Gas
Valve, Full Wave, 16 kHz
Pin 17 - 0-10VDC Common for VFD
Pin 18 - N/A
26
Connector J33 contains inputs and outputs for components
Pin 1 through Pin 9 - N/A
9
18
Pin 10 through Pin 18 - N/A
Connector J34 N/A
2 1
4 3
1
10
1 10
Connector J35 N/A
THERMISTORS
Connector J36 N/A
9
18
1
10
Connector J37 N/A
Connector J38 Modbus
Pin 1 (A) Modbus (-)
Pin 2 (B) Modbus (+)
27
2 1
4 3
MODBUS
C B A
3
Pin 3 (C) Modbus Ground
1
ON
Dip Switch S1
1 2 3 4
Switch 1, 2, 3 always OFF. Switch 4 Always ON. If Switch 4 is OFF, BAS terminals disabled.
Dip Switch S2
Programming - Service Only
Dip Switch S3
End of line termination
Dip Switch S4
Programming - Service Only
ON
28
Variable Frequency Drive (VFD)
WARNING!
- Before installing the VFD drive, ensure the input power supply to the drive is OFF.
- The power supply and motor wiring of the VFD must be completed by a qualified electrician.
- The VFD is factory programmed, only change if replaced or ordered separately.
Consult the VFD manual and all documentation shipped with the unit for proper installation and wiring of
the VFD. The VFD has been programmed by the factory with ordered specific parameters. Use Table 5 as
a guide during installation.
Table 5 - VFD Installation Check List
Check
Off
Description
The installation environment conforms to the VFD manual.
The drive is mounted securely.
Space around the drive meets the drive’s specification for cooling.
The motor and driven equipment are ready to start.
The drive is properly grounded.
The input power voltage matches the drive’s nominal input voltage.
The input power connections at L1, L2, and L3 are connected and tight. Verify correct size crimp fitting is used.
The input power protection is installed.
The motor’s power connection at U, V, and W are connected and tight. Verify correct size crimp fitting is used.
The input, motor, and control wiring are run in separate conduit runs.
The control wiring is connected and tight.
NO tools or foreign objects (such as drill shavings) are in the drive.
NO alternative power source for the motor (such as a bypass connection) is connected - NO voltage is applied to the output of the drive.
29
VFD Installation
Input AC Power
• Circuit breakers feeding the VFDs are recommended to be thermal-magnetic and fast-acting. They
should be sized based on the VFD amperage. Refer to Table 6 on page 32
. See installation schematic for exact breaker sizing.
• Every VFD should receive power from its own breaker. If multiple VFDs are to be combined on the same breaker, each drive should have its own protection measure (fuses or miniature circuit breaker) downstream from the breaker.
• Input AC line wires should be routed in conduit from the breaker panel to the drives. AC input power to multiple VFDs can be run in a single conduit if needed. Do not combine input and output power cables in the same conduit.
• The VFD should be grounded on the terminal marked PE. A separate insulated ground wire must be provided to each VFD from the electrical panel. This will reduce the noise being radiated in other equipment.
ATTENTION: Do not connect incoming AC power to output terminals U, V, W. Severe damage to the drive will result. Input power must always be wired to the input L terminal connections (L1, L2, L3).
VFD Output Power
• Motor wires from each VFD to its respective motor MUST be routed in a separate steel conduit away from control wiring and incoming AC power wiring. This is to avoid noise and crosstalk between drives.
An insulated ground must be run from each VFD to its respective motor. Do not run different fan output power cables in the same conduit.
• VFD mounted in ECP: A load reactor should be used and sized accordingly when the distance between the VFD and motor is greater than specified below. The load reactor should be installed within 10 feet of the VFD output:
208/230V - Load reactor should be used when distance exceeds 250 feet.
460/480V - Load reactor should be used when distance exceeds 50 feet.
575/600V - Load reactor should be used when distance exceeds 25 feet.
• VFD mounted in fan: The load reactor should be sized accordingly when the VFD is mounted in the fan.
208/230V - Load reactor is optional but recommended for 15 HP and above motors.
460/480V - Load reactor is optional but recommended for 7.5 HP and above motors.
575/600V - Load reactors are required for all HP motors.
• If the distance between the VFD and the motor is extremely long, up to 1000 FT, a dV/dT filter should be used, and the VFD should be increased by 1 HP or to the next size VFD. The dV/dT filter should be sized accordingly and installed within 10 feet of the output of the VFD.
208/230V – dV/dT filter should be used when distance exceeds 400 feet.
460/480V – dV/dT filter should be used when distance exceeds 250 feet.
575/600V – dV/dT filter should be used when distance exceeds 150 feet.
• Do not install a contactor between the drive and the motor. Operating such a device while the drive is running can potentially cause damage to the power components of the drive.
• When a disconnect switch is installed between the drive and motor, the disconnect should only be operated when the drive is in a STOP state.
30
VFD Programming
Programming
1. The Drive should be programmed for the proper motor voltage. P107 is set to 0 (Low) if motor voltage is 120V AC, 208V AC or 400V AC. P107 is set to 1 (High) if the motor voltage is 230V AC, 480V AC, or
575V AC.
2. The Drive should be programmed for the proper motor overload value. P108 is calculated as Motor
FLA x 100 / Drive Output Rating (refer to Table 6 on page 32 ).
To enter the PROGRAM mode to access the parameters:
This will activate the password prompt (PASS).
2. Use the Up and Down buttons to scroll to the password value (the factory default password is “0225”) and press the Mode (M) button. Once the correct password is entered, the display will read “P100”, which indicates that the PROGRAM mode has been accessed at the beginning of the parameter menu.
3. Use the Up and Down buttons to scroll to the desired parameter number.
4. Once the desired parameter is found, press the Mode (M) button to display the present parameter setting. The parameter value will begin blinking, indicating that the present parameter setting is being displayed. The value of the parameter can be changed by using the Up and Down buttons.
5. Pressing the Mode (M) button will store the new setting and exit the PROGRAM mode. To change another parameter, press the Mode (M) button again to re-enter the PROGRAM mode. If the Mode button is pressed within 1 minute of exiting the PROGRAM mode, the password is not required to access the parameters. After one minute, the password must be re-entered to access the parameters again.
P500 parameter provides a history of the last 8 faults on the drive. It can be accessed without entering
PROGRAM mode.
Figure 16 - VFD Screen
AUTO FWD
RUN
REV
M
R F
STOP
NOTE: When a parameter is changed in the drive, the drive should be de-energized. Wait for the display to go completely dark. Once the display is completely dark, the drive can be re-energized.
31
ACTECH SMV VFD
Table 6 - Cross-Reference
HP Part Number
20
25
30
40
50
60
0.5
ESV371N02YXB571
1 ESV751N02YXB571
1.5
ESV112N02YXB571
2 ESV152N02YXB571
3
5
ESV222N02YXB571
ESV402N02TXB571
7.5
ESV552N02TXB571
10
15
20
1
ESV752N02TXB571
ESV113N02TXB571
ESV153N02TXB571
ESV751N04TXB571
1.5
ESV112N04TXB571
2 ESV152N04TXB571
3
5
ESV222N04TXB571
ESV402N04TXB571
25
30
40
50
7.5
ESV552N04TXB571
10 ESV752N04TXB571
15
20
ESV113N04TXB571
ESV153N04TXB571
ESV183N04TXB571
ESV223N04TXB571
ESV303N04TXB571
ESV373N04TXB571
60
1
2
3
ESV453N04TXB571
ESV751N06TXB571
ESV152N06TXB571
ESV222N06TXB571
5 ESV402N06TXB571
7.5
ESV552N06TXB571
10
15
ESV752N06TXB571
ESV113N06TXB571
ESV153N06TXB571
ESV183N06TXB571
ESV223N06TXB571
ESV303N06TXB571
ESV373N06TXB571
ESV453N06TXB571
Volts
480V
600V
600V
600V
600V
600V
600V
600V
480V
480V
480V
480V
480V
480V
480V
480V
600V
600V
600V
600V
600V
600V
240V
240V
240V
480V
480V
480V
480V
480V
240V
240V
240V
240V
240V
240V
240V
HP Part Number Volts
0.5
ESV371N01SXB571 120/240V
1 ESV751N01SXB571 120/240V
1.5
ESV112N01SXB571 120/240V
1Ø
Input
X
X
X
3Ø
Input
-
-
-
Input Amps 1Ø
120V AC
9.2
16.6
20
Input Amps 1Ø
240V AC
4.6
8.3
10
Output
Amps
2.4
4.2
6
Breaker 1Ø
120V AC
15
25
30
Breaker 1Ø
240V AC
15
15
20
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1Ø
Input
X
X
X
X
X
- X
- X
X
X
3Ø
Input
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Input Amps 1Ø Input Amps 3Ø
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
5.1
8.8
12
13.3
17.1
-
-
6.8
10.2
12.4
19.7
87
2
3.2
4.4
38
45
59
74
12.4
15.8
24
31
25
31
36
47
59
71
3.6
4.1
5.4
9.3
33
48
59
2.5
2.9
5
6.9
8.1
10.8
18.6
26
Breaker 1Ø
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
15
15
20
25
30
-
-
Breaker 3Ø
15
20
20
30
150
15
15
15
70
80
100
125
20
25
40
50
40
50
60
70
90
110
15
15
15
15
50
80
90
15
20
30
40
15
15
15
15
6.1
9
11
17
77
1.7
2.7
3.9
34
40
52
65
11
14
21
27
22
27
32
41
52
62
3
3.5
4.8
8.2
29
42
54
2.1
Output
Amps
2.4
4.2
6
7
9.6
16.5
23
32
Temperature Control
Discharge Control : When used in discharge control, the MUA board receives a call to heat from the intake sensor. The MUA board will modulate the discharge temperature until the desired set point is reached. The user can choose whether discharge heating/cooling is activated based on intake temperature, space temperature, either, or both.
Space Control : When selected, an HMI with an internal temperature sensor or a temperature sensor wired to ST terminals on the MUA board can be used to sense space temperature. The user can choose whether the space heating/cooling is activated based on intake temperature, space temperature, either, or both.
Analog Control : If Analog Control is utilized, DIP switch #4 on the MUA board should be set On. Blower/
Heating/Cooling will be controlled by a 0-10V DC or 0-20mA signal based on input source.
Direct Digital Control (DDC) : A 0-10V DC or 0-20mA signal is sent to the MUA board from the building control system to regulate the blower/heating output of the unit.
In all cases, the MUA board controls the amount of gas to the burner based on the signal from the temperature control components.
The operation of the modulating gas valve with regard to voltage is as follows: from 0 volts to approximately 5 volts, the modulating gas valve should be on bypass flow with the heater operating on low or minimum fire. From approximately 5 volts to 15 volts DC, the valve should be performing its modulating function, and the heater should be firing at a modulated flow rate between low and high fire, depending upon the voltage. Above approximately 15 volts DC, the valve should be delivering full flow to the heater and the unit should be on high fire.
control board.
Figure 17 - Temperature Sensor
Thermistor Connected to HMI
Thermistors connected to connector J5 on the HMI may be averaged or used as a standalone for space temperature readings.
33
OPERATION
Accessing Menu Configurations
General Overview
The HMI allows the user to change parameters and options. The user may use the HMI to view operating information regarding sensors, temperatures, pressures, and fault history on the HMI screen
(
There are four buttons to navigate through the HMI screens.
NOTE: Buttons change functions during certain options and tests.
Verify the screen and buttons throughout the menu display.
Figure 18 - HMI Screen
SPACE
OCCUPIED
70°F
IDLE
Figure 19 - Save Screen
The user can access the Top Menu HMI configurations by pressing the top two buttons simultaneously. To exit this screen, simply press the
‘BACK’ button. When setting certain options or functions, pressing the
‘BACK’ button multiple times will bring up the save screen (
).
The user may select ‘YES’ to save the changes, select ‘NO’ to return to factory settings, or select ‘CANCEL.’ When selecting ‘CANCEL,’ any changes made will not be saved, and the screen will return to the top menu.
The HMI menu system allows full access to every configurable parameter in the HMI. The parameters are factory configured to the specific application. Parameters may need to be modified to fine-tune automatic operation after the original setup.
UP
SAVE CHANGES?
CONFIRM YES
BACK
DOWN ENTER
Remote (HMI) Control Panel
On units shipped with a space HMI, a Cat 5 cable will need to be run from J4, J5, or J6 (refer to schematics) on the main MUA Board to J2 on the HMI. If additional space HMIs have been added, they can be daisy-chained from the first HMI. In the event there is a slave MUA board, HMIs can also be powered from J1 or J2 of the slave board. An end of line resistor should be added to the last HMI in the chain.
HMI Notification Letters
The HMI will display notification letters (
Figure 20 ) when the unit is in a
specific status.
• B = Blower Start or Blower Stop Delay Active
• C = Condenser Min On or Min Off Timer Active. Displayed when any of the condensers are in a Min On/Off Time.
• D = Min or Max Discharge Temp Reached
• M = Max Temp Rise Reached
• R = OA Reset
• Δ = Dynamic SP Applied
Figure 20 - Notification Letters
B
OFF
01/01
FRI
B
OFF
HEAT
TEMP +
09:49
AM
SPACE
70°F
TEMP -
Notification
Letter Location
34
HMI Configuration Menu
To enter the configuration menu (
), press the bottom two buttons simultaneously on the HMI faceplate. In this menu screen, you may adjust Communication and Advanced Options, check Status, and
About information.
Figure 21 - Configuration Menu
UP MENU
Configuration
Communication
Advanced Options
Status
DOWN ENTER
Communication
Under the communication menu, the user may adjust the following settings:
• Modbus Address - Default is 55 for the first HMI. For every additional HMI, increase the address by one. For example, if a second HMI is used, the Modbus Address should be 56. For a third HMI, the
Modbus Address should be 57.
• Baud - The baud rate address is 115200.
• Parity - Do not adjust this setting. The default setting should always be set to ‘EVEN.’
Advanced Options
Under advanced options, the user may adjust the following settings:
• Contrast - The user may adjust the setting from 0 to 10. Setting the contrast to 0 is the lowest setting available, and 10 is the highest contrast setting available. The factory default contrast setting is 5.
• Audio Enable - User may set the audio to off.
• Dimming Enable - Default is set to Off. If set to On, the ‘HMI Dimming Timer’ option will be available.
• Set Time - The user may adjust dimming setting from 10-60 seconds. The default time is 30 seconds.
Status
User may monitor board temperature status, Uptime (how long the board has been active since last restart), HW RH (HMI hardware humidity sensor), HW Temp (HMI hardware temperature sensor).
About
User may view SCADA HMI Software Version, Modbus Address (assigned to HMI), Baud (115200).
35
Scheduling
To set a schedule on the HMI (
Figure 22 ), you must first enable scheduling:
Factory Settings >
Occupied Scheduling > On
Set your sensor temperature set points for occupied and unoccupied schedules: User Settings > Temp
Set Points > (Varies)
Once scheduling is enabled and the temperature set points are configured, you may enter your scheduled days and times: User Settings > Scheduling
Schedule A Default
• Monday - Friday
8:00AM to 6:00PM
• Saturday and Sunday
Unocc
Schedule B Default
• Monday - Friday
Unocc
• Saturday and Sunday
Unocc
Figure 22 - Scheduling Screen
Schedule C Default
• Monday - Friday
Unocc
• Saturday and Sunday
Unocc
UP BACK
A
B
OCCUPIED SCHEDULING
MONDAY
8:00AM TO 6:00PM
6:00PM TO 6:00PM
DOWN ENTER
To adjust the settings, highlight the parameter and press ENTER .
• The first parameter to be highlighted will be the day. Press UP or DOWN to select the day an occupied time schedule is required.
• Press ENTER to continue to set a start time. Press UP or DOWN to set start time.
• Press ENTER to set an end time. Press UP or DOWN to set end time.
The system will run between these days, time, and desired temperature settings. When in the
UNOCCUPIED setting, the system will run at the unoccupied temperature setting.
36
Unit Options
Building Signal Damper Control
When this option is ordered, the outdoor air (supply) and return dampers will modulate based on a 0-10V
DC signal from the Building automation system. 0V = max outside air, 10V = max return air. Direct fired units cannot go below 20% outside air, maximum output voltage may differ.
Electric Cabinet Heater
Units can be shipped with an optional 120V electric cabinet heater powered from the MUA board. There is a temperature sensor built onto the MUA board that will regulate when the cabinet heater activates. To enable this option go to Factory Settings > Unit Options > Cabinet Heater > Enable . Temperature readings and adjustments can be made through the HMI. Go to User Settings > Temp Set Points >
Option Set Points > Cab Heat Set Points .
Motorized Intake Damper
On units shipped with the optional motorized intake damper, a power transformer is supplied with the unit if the main incoming voltage is greater than 120V. No external wiring to the damper motor is required.
Recirculating Control Unit Options
Manual Control - The dampers can be controlled from the HMI in the unit or from a space HMI if one is provided to any position from 20% to 100% fresh air. This is a 0-10V setting, which is available under user settings, 100% Outdoor Air (0 volts), 80% Return Air (equivalent voltage). This will allow to manually set the dampers to match the building ventilation requirements. On a power failure, the return air damper will close by spring return.
Two Position Control - The dampers can be controlled by a two-position switch (a field-supplied switching device) to open the fresh air to 100%. The MUA board sends out a constant voltage. The field supplied switch will cut or allow the signal from the MUA board to the recirculating damper. On opening of the circuit, power failure, or if the unit is shut off, the return air damper will close by spring return. If the circuit is closed, the MUA board will allow the return air damper to open per the set point.
Outdoor Air % - The dampers can be controlled from the HMI in the unit or from a space HMI if one is provided to any position from 20% to 100% fresh air. There is an outdoor air percentage setting that is available under user settings. This will allow the user to manually set the dampers to match the building ventilation requirements.
• When preset OA is On, the unit will use preset values for recirculating OA% by directly associating
OA voltage to OA percentages. A calibration can be run from the service menu to store and use real-world results rather than provided defaults.
• When preset OA is Off, the MUA board utilizes an internal algorithm to alter its 0-10V output to the recirculating damper in order to maintain an exact outdoor air percentage. When this recirculating option is selected, a recirculating dead-band comes into play. This setting checks the delta T between outdoor and return air. If the difference between these two temperatures is less than or equal to the recirculating dead-band setting, the MUA board will not alter its output to the recirculating damper (default setting is 5 degrees). On a power failure, or if the unit is turned off, the return air damper will close by spring return.
Analog Control - When this is set to ON, a 0-10V input will drive the damper output to modulate linearly between the min and max OA voltage for both occupied and unoccupied modes.
Static Pressure Control - Damper position will modulate to maintain building pressure. Building pressure below the set point will increase the amount of outdoor air supplied to increase pressure. Building pressure above the set point will decrease the amount of outdoor air supplied to decrease pressure.
CO2 Control - When the unit senses the CO2 input to be above the threshold setting, the unit will decrease recirculating output until the CO2 falls below threshold setting.
37
Menu Descriptions
User settings: Allows the user to change or set certain temperatures and configurations on the unit.
Factory settings: Requires a password (1111) to enter this menu. These will be set job-specific from the plant. Any changes to the factory settings will require the user to save the updated changes.
Service settings: Requires a password (1234) to enter this menu. Allows a certified technician to monitor the unit and test components in the system.
About: Unit type and software revision information.
User Settings
Temp Set Points
- Some or all of these set points may not be available based on settings. If scheduling is enabled, there will be occupied and unoccupied values for each set point.
The user will be allowed to check or adjust the set points/limits.
• Intake Set Points - User adjustable set points for intake activation.
•
Heat
- Activate Based On must be set to Intake, Both,
Either, or Stat. Heating stage must = 1.
•
Cool
- Activate Based On must be set to Intake, Both,
Either, or Stat. Cooling type set to DX or both.
•
Evap
- Activate Based On must be set to Intake, Both,
Either, or Stat. Cooling type set to Evap or both.
•
Discharge Set Points
- User adjustable set points for heat discharge activation.
• Heat - Tempering mode must be set to discharge.
Heating stage must = 1.
• Space Set Points - User adjustable set points for heat, and cool space activation.
•
Heat
- Activate Based On must be set to Space, Both, or Either. Heating stage must = 1
•
Cool
- Activate Based On must be set to Space, Both,
Either, or Stat. Cooling type set to DX, Evap or both.
•
Discharge Limits
- User adjustable set points for discharge limits.
• Min - Cannot be greater than maximum discharge heat set point.
• Max - Cannot be less than minimum discharge heat set point.
• Differentials - User adjustable space heat and cool differential set points.
•
Intake
- Activate Based On must be set to Intake. Cool tempering mode set to Intake.
•
Space
- Activate Based On must be set to Space.
Cool tempering mode set to Space.
•
Option Set Points
- Adjustable set points for options that are enabled to “ON” in Factory Settings.
• Room Override, Firestat Set Points, Freezestat Set
Points, Cab Heat Set Point, Evap Drain Set Point, OA
Reset Low, OA Reset High, Reset Heat Discharge,
Reset Heat Space, Reset Cool Space.
USER SETTINGS
TEMP SET POINTS
INTAKE SET POINTS
HEAT (OCC/UNOCC)
COOL (OCC/UNOCC)
RANGE: 0-110°F/(-18)-43°C
DEFAULT: 45°F/7°C
RANGE: 55-120°F/13-50°C
DEFAULT: 85°F/29°C
EVAP (OCC/UNOCC)
DISCHARGE SET POINTS HEAT
RANGE: 55-100°F/13-38 °C
DEFAULT: 85°F/29°C
RANGE: 30-160°F/1-71°C
DEFAULT: 55°F/13°C
SPACE SET POINTS
HEAT (OCC/UNOCC)
COOL (OCC/UNOCC)
DISCHARGE LIMITS
DIFFERENTIALS
MIN (OCC/UNOCC)
MAX (OCC/UNOCC)
INTAKE (OCC/UNOCC)
SPACE (OCC/UNOCC)
OPTION SET POINTS
ROOM OVERRIDE
FIRESTAT SET POINTS
RANGE: 35-110°F/2-43°C
DEFAULT: 70°F/21°C
RANGE: 55-120°F/10-32°C
DEFAULT: 74°F/23°C
RANGE: 30-160°F/1-71°C
DEFAULT: 50°F/10°C
RANGE: 30-160°F/1-71°C
DEFAULT: 160°F/71°C
RANGE: 0-20°F/0-13°C
DEFAULT: 10°F/6°C
RANGE: 0-20°F/0-13°C
DEFAULT: 2°F/2°C
RANGE: 40-150°F/4-66°C
DEFAULT: 90°F/31°C
INTAKE
DISCHARGE
FREEZESTAT SET POINTS
RANGE: 100-300°F/38-149°C
DEFAULT: 135°F/57°C
RANGE: 100-300°F/38-149°C
DEFAULT: 240°F/101°C
FREEZESTAT
RANGE: (-40)-75°F/(-40)-24°C
DEFAULT: 35°F/2°C
CAB HEAT SET POINT
EVAP DRAIN SET POINT
OA RESET LOW
OA RESET HIGH
RESET HEAT DISCHARGE
RESET HEAT SPACE
RESET COOL SPACE
CAB HEAT
EVAP DRAIN
RESET LOW
RESET HIGH
HEAT DISCH
HEAT SPACE
COOL SPACE
RANGE: 0-40°F/(-18)-4°C
DEFAULT: 0°F/-18°C
RANGE: 35-50°F/2-10°C
DEFAULT: 40°F/4°C
RANGE: 35-110°F/7-43°C
DEFAULT: 45°F/7°C
RANGE: 35-110°F/7-43°C
DEFAULT: 75°F/24°C
RANGE: 40-150°F/4-65°C
DEFAULT: 90°F/32°C
RANGE: (-10)-10°F/(-6)-6°C
DEFAULT: 2°F/1°C
RANGE: (-10)-10°F/(-6)-6°C
DEFAULT: 2°F/1°C
38
Dry Mode Config - The user will be allowed to view or adjust dry mode set points/limits when the option is enabled.
Scheduling
- This menu will only show when the scheduling option is set to On.
•
Scheduling Times
- Each day contains the option for three occupied time periods. Time periods cannot overlap.
•
Schedule Copy
- This will allow the user to copy an existing schedule from one day of the week to individual days in the week, to Week Days, or All.
Fan Speed - Enabled when the supply fan is controlled by a
VFD or ECM. The range of this menu is limited by the min and max set points under factory settings.
When the fan is set to VFD, the settings will be displayed in
Hertz. When the fan is set to ECM, the PWM percentage will be displayed. When occupied scheduling is set to On, occupied and unoccupied settings are available.
Recirc Setting
- Recirc will allow outdoor air in vs. return air.
0V out is equal to 100% OA and 0% RA.
Pressure Config
- Adjustable pressure set points for static pressure control.
Single Zone VAV
- When single zone VAV is enabled to the blower, damper, or both, depending on settings, will modulate linearly between min and max discharge.
• Blower Speed Heat - Min/Max stage settings for blower speed in heating mode.
•
Damper Pos Heat
- Min/Max settings for damper position in heating mode.
• Blower Speed Cool - Min/Max stage settings for blower speed in cooling mode.
•
Damper Pos Cool
- Min/Max settings for damper position in cooling mode.
Active Faults Contains the current faults on the board.
Fault History
Displays time-stamped history of the last 20 faults. The most recent fault will show first.
Reset Lockouts
- Reset lockout faults.
Dynamic SP Diff - Temperature differential for dynamic set point change.
Dynamic SP Offset
- Temperature amount that will change per differential.
Dynamic Heat OA - Outdoor air dynamic heat set point.
Dynamic Cool OA
- Outdoor air dynamic cool set point.
CO2 Control Config
- CO2 Parts Per Million (PPM) set points and sensor settings.
• PPM Low/High - CO2 PPM threshold set points for the space, used in CO2 Override.
•
PPM Limit
- CO2 PPM threshold limit set point.
•
Sensor Min/Max
- Set minimum and maximum range setting for CO2 sensor.
USER SETTINGS
DRY MODE CONFIG
DISCHARGE TEMP
OUTDOOR AIR %
MIN TEMP
DB TEMP OFFSET
DEW POINT OFFSET
RANGE: 40-150°F/4-66°C
DEFAULT: 90°F/13°C
RANGE: MIN OA - MAX OA
DEFAULT: 100%
RANGE: 50-120°F/10-49°C
DEFAULT: 60°F/16°C
RANGE: 0-20°F/0-11°C
DEFAULT: 10°F/6°C
RANGE: 0-30°F/0-17°C
DEFAULT: 5°F/3°C
SCHEDULING
SCHEDULING TIMES
COPY SCHEDULE
MONDAY-SUNDAY
COPY FROM “DAY”
COPY TO “DAY”/WEEKDAYS/ALL
FAN SPEED (VFD)
FREQ (OCC/UNOCC)
RANGE: MIN-MAX FREQ
DEFAULT: 60 HZ
FAN SPEED (ECM)
RATE (OCC/UNOCC)
RANGE: 0-100%
DEFAULT: 100%
RECIRC SETTING
OA (OCC/UNOCC)
RANGE: 0-100% or 0-10V
DEFAULT: 0% or 0V
PRESSURE CONFIG
LOW (OCC/UNOCC)
HIGH (OCC/UNOCC)
RANGE: (-15.0) - HIGH
DEFAULT: 0.00 "W.C.
RANGE: LOW - 15.0
DEFAULT: 0.10 "W.C.
SINGLE ZONE VAV
BLOWER SPEED HEAT
ACTIVE FAULTS
FAULT HISTORY
DAMPER POS HEAT
BLOWER SPEED COOL
DAMPER POS COOL
RESET LOCKOUTS
DYNAMIC SP DIFF
DYNAMIC SP OFFSET
DYNAMIC HEAT OA
DYNAMIC COOL OA
RANGE: MIN-MAX Hz
DEFAULT: 0 Hz/60 Hz
RANGE: MIN-MAX%
DEFAULT: 20%/100%
RANGE: STG 1/2/3 0-60 Hz
DEFAULT: 0 Hz
RANGE: STG 1/2/3 0-100%
DEFAULT: 20%
DISPLAYS ACTIVE FAULTS
DISPLAYS UP TO
20 FAULTS
RESETS ACTIVE
LOCKOUTS
RANGE: 0-50°F/0-25°C
DEFAULT: 10°F/5°C
RANGE: (-20)-20°F/(-11)-11°C
DEFAULT: 1°F/1°C
RANGE: 0-110°F/(-18)-43°C
DEFAULT: 30°F/-1°C
RANGE: 35-110°F/2-43°C
DEFAULT: 80°F/27°C
CO2 CONTROL CONFIG
PPM LOW (OCC/UNOCC)
PPM HIGH (OCC/UNOCC)
PPM LIMIT
SENSOR MIN
SENSOR MAX
RANGE: 0 PPM-PPM HIGH
DEFAULT: 500 PPM
RANGE: PPM LOW-2,000 PPM
DEFAULT: 1,000
RANGE: 1-2,499 PPM
DEFAULT: 1,000
SET RANGE TO CO2
SENSOR MIN SETTING
SET RANGE TO CO2
SENSOR MAX SETTING
START A/B/C - UNOCC/TIME
END A/B/C - UNOCC/TIME
39
Factory Settings Factory Menu Password = 1111
Heating Type - User may select heating unit type.
Temperature Control - The MUA board monitors temperature control set points (SP) and components.
• Tempering Mode - The options for controlling the output of the tempering mode in heat/cool (if equipped).
Available options are Intake/Discharge/Space/Analog
Control/Direct Digital Control (DDC).
• Activate Based On - Select how the unit will activate based on temperature readings: Intake/Space/Both/
Either/Stat (field installed thermostat). These settings can be altered for occupied and unoccupied preferences.
- When Activate Based On is set to Stat, thermostat inputs and intake temperatures are monitored to activate heating/cooling.
•
Activation Sensor
- Allows selection of intake or outdoor sensor for unit to activate.
•
Construction Mode
- Configurable option for units used in construction settings. When construction mode is enabled on, the following factory settings will be overridden: HMI, Discharge Control, 100% Outside Air,
Activate Based on Intake, Blower Mode set to Manual.
Heating Config - Various heating configurations.
•
# of Heat Stages
- Default is set to 0 for units without gas heat. If the unit is equipped with gas heat, select 1.
•
Gas Type
- Gas type selection: natural gas or propane.
•
Gas Valve Limits
- Adjustment for unit’s gas valve range.
Adjustable Min or Max percentage range.
•
Low Fire Config
- Sets low fire time and valve position settings.
•
Time
- The amount of time the low fire setting is applied before modulation will occur.
•
Valve Pos
- Gas valve position before modulation occurs.
•
Heat Hyst
- Intake/Space tempering sensor must go this amount of degrees above the SP before heating turns off.
•
Input Source
- Informs board what signal (volts/ milliamps) to expect from the analog control system.
Only valid for analog tempering mode.
•
2nd Disch Sensor
- When an additional thermistor is added, the two thermistor readings will be averaged together.
• Average High Temp - When the “2nd Disch Sensor” is
On, this menu will be available. When “Average High
Temp” is Off, if either discharge sensor goes above high temp limit, the unit will go into high temp lockout. When
“Average High Temp” is On, both thermistors readings will be used to determine high temp lockout.
•
Pre Purge Config
- When On, this option will purge any gas that may not have combusted in the unit before the unit lighting off. You may set the amount of time the purge cycle will operate.
• Cabinet Hyst - The cabinet temp must reach this many degrees above the activation SP to turn off.
• Freezestat Timer - If the discharge temperature is below the freezestat SP for half the duration of the freezestat timer, the heat will shut off momentarily. If the freezestat trips for a second time, the heat will shutdown immediately. Reset the lockout manually on the HMI.
• Construction Heater - When On, overrides any other airflow proving values and high-temperature settings.
• Paint Booth - When On, current high limit SPs canceled.
•
Max Temp Rise Limit
- Compares max rise limit to calculated max temp rise. Software will always utilize the lower of the two values.
•
Blwr Off Flame Fail
- When On, the blower will shut down if a flame lockout occurs. The blower may go back into operation after the fault is cleared.
FACTORY SETTINGS
HEATING TYPE MOD DF/D76/IND DF
TEMPERATURE CONTROL
TEMPERING MODE
HEAT (OCC/UNOCC)
COOL (OCC/UNOCC)
ACTIVATE BASED ON
DISCHARGE, SPACE,
ANALOG, DDC
INTAKE, SPACE,
ANALOG, DDC
ACT (OCC/UNOCC)
INTAKE/SPACE/
BOTH/EITHER/STAT
ACTIVATION SENSOR
CONSTRUCTION MODE
SENSOR
ENABLE
INTAKE/OUTDOOR
DEFAULT: OUTDOOR
ON/OFF
DEFAULT: OFF
HEATING CONFIG
# OF HEAT STAGES
GAS TYPE
RANGE: 0-1
DEFAULT: WITH HEAT = 1
DEFAULT: WITHOUT HEAT = 0
NAT GAS/PROPANE
GAS VALVE LIMITS
MIN
MAX
RANGE: 0-100%
DEFAULT: 0%
RANGE: MIN- 100%
DEFAULT: 75%
LOW FIRE CONFIG
TIME
VALVE POS
RANGE: 0 - 600 S
DEFAULT: 15 S
RANGE: MIN- MAX
DEFAULT: 0%
HEAT HYST
INPUT SOURCE
2ND DISCH SENSOR
AVERAGE HIGH TEMP
SPACE
RANGE: 0-2°F/0-1°C
DEFAULT: 1°F/1°C
INTAKE
RANGE: 0-10°F/0-6°C
DEFAULT: 3°F/2°C
0-10VDC, 2-10VDC,
0-20mA, 4-20mA
JOB SPECIFIC
ENABLE
ENABLE
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
PRE PURGE CONFIG
CABINET HYST
FREEZESTAT TIMER
CONSTRUCTION HEATER
PAINT BOOTH
MAX TEMP RISE LIMIT
BLWR OFF FLAME FAIL
ENABLE
SECONDS
HYST
MINUTES
ENABLE
ENABLE
DELTA
ENABLE
ON/OFF
DEFAULT: OFF
RANGE: 0-120 S
DEFAULT: 30 S
RANGE: 1-10°F/0-6°C
DEFAULT: 1°F/1°C
RANGE: 1-10 M
DEFAULT: 10 M
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
RANGE: 40°F/22°C to
MAX VALUE SETTING
DEFAULT: VARIES BY UNIT
ON/OFF
DEFAULT: OFF
40
Cooling Config - Allows the user to set various cooling configurations and set points (SP).
•
Cooling Type
- Selections are None, DX, Evap, Both. If
“None” is selected, all cooling options under user settings are hidden.
•
Min Cool OA Temp
- When the space temperature is calling for cooling, and the outdoor air temperature is below the SP, the unit will shut the condensers off. The blower will start and use outdoor air to cool the space.
•
Condenser Staging
- Selections None, 1, 2, or 3 condensers. Within the 2 and 3 condenser selection, there is another sub-menu that allows for 2 or 3 stages.
For 2 condenser units, 3 stages should only be selected when the condensers are of unequal tonnages.
• Cool Hyst - Intake or Space tempering sensor must fall this many degrees below the SP before cooling turns off.
• Condenser Min Times - Minimum time each condensing stage must remain on after becoming activated. This is to prevent stage cycling.
A “C” will be present in the lower-left corner of the home screen when any of the condensers are in a MIN ON/OFF TIME.
•
Evap Config
•
Sprayer Times
•
Time On
- Time the evaporative cooler will spray in the cycle.
•
Time Off
- Time the evaporative cooler will be idle in the cycle.
•
Evap Drain
- Units that use evap drain should be set to On.
•
Drain Hyst
- Temperature differential setting before the drain shuts off.
•
Evap Hyst
- Temperature differential before the evap cooling shuts off.
Occupancy Config -
Allows access to setting scheduling and/or override On or Off.
•
Scheduling
- This menu is where the scheduling can be turned On or Off. Default is Off.
•
Override
- This menu is where the occupancy override can be turned On or Off.
FACTORY SETTINGS
COOLING CONFIG
COOLING TYPE
MIN COOL OA TEMP
CONDENSER STAGING
COOL HYST
NONE, DX, EVAP, BOTH
RANGE: 40-90°F/4-32°C
DEFAULT: 55°F/13°C
NONE (DEFAULT), 1 COND 1 STAGES, 2 COND 2 STAGES,
2 COND 3 STAGES, 3 COND 2 STAGES, 3 COND 3 STAGES
SPACE
INTAKE
RANGE: 0-2°F/0-1°C
DEFAULT: 1°F/1°C
RANGE: 0-10°F/0-6°C
DEFAULT: 3°F/2°C
CONDENSER MIN TIMES
MIN ON
MIN OFF
RANGE: 1-15 M
DEFAULT: 2 M
RANGE: 1-15 M
DEFAULT: 1 M
EVAP CONFIG
SPRAYER TIMES
TIME ON
TIME OFF
RANGE: 0-60 S
DEFAULT: 15 S
RANGE: 0-500 S
DEFAULT: 60 S
EVAP DRAIN
EVAP HYST
ENABLE
DRAIN HYST
HYST
ON/OFF
DEFAULT: OFF
RANGE: 1-5°F/1-3°C
DEFAULT: 2°F/1°C
RANGE: 0-10°F/0-6°C
DEFAULT: 1°F/1°C
OCCUPANCY CONFIG
SCHEDULING
OVERRIDE
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: ON
41
Unit Options - Allows user access to various options included with the unit.
• Board Config
•
Unit Address
- Modbus address of the MUA Board.
•
Startup Timer
- Time upon power-up where the board will sit idle.
•
Temp Readings
- Allows user to set temperature readings between Fahrenheit or Celsius. Changing between the two will reset all set points.
•
HMI Config
- Allows access to adjust HMI settings and options.
•
Number
- Set the number of HMIs connected to the MUA board.
•
Screensaver
- Default is set to On. If set to Off, the home screen will not time out to the screensaver.
•
Average HMI
- If there are multiple space HMIs connected, this menu allows you to select which will be included in the space temperature and relative humidity averaging. If a thermistor or relative humidity sensor is connected into the ST screw terminals, it will automatically be averaged into any HMIs included. When in Space Tempering
Mode, a minimum of one HMI must have “Average
HMI” set to On, or a separate remote sensor must be used that is wired back to the MUA board.
•
Lock Screen
- If the option is set to On, a password (9999) will be required; when the screensaver option is enabled or if any button functions are not pressed for 5 minutes.
•
Scnsvr Disp
- Displays date, time, and/or temperature when screensaver is active.
•
DDC Main Config
• Baud - The baud rate of the Modbus communications.
• Word Bits - The amount of data bits over Modbus communications.
• Parity - The parity selection for Modbus communications.
• Stop Bits - The stop bits selection for Modbus communications.
FACTORY SETTINGS
UNIT OPTIONS
BOARD CONFIG
UNIT ADDRESS
STARTUP TIMER
TEMP READINGS
HMI CONFIG
NUMBER
SCREENSAVER
AVERAGE HMI
LOCK SCREEN
SCNSVR DISP MODE
DDC MAIN CONFIG
BAUD
RANGE: 75-89
DEFAULT: 85
TIME
MODE
WORD BITS
PARITY
STOP BITS
RANGE: 5-240 S
DEFAULT: 5 S
FAHRENHEIT/CELSIUS
DEFAULT: FAHRENHEIT
RANGE: 1-5
DEFAULT: 1
ON/OFF
DEFAULT: ON
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
DATE/TIME
TEMP/DATE/TIME TEMP
9600, 19200 (DEFAULT),
38400, 57600, 115200
8/9
DEFAULT: 8
NONE, ODD, EVEN
DEFAULT: EVEN
1/2
DEFAULT: 1
42
• Blower Config
•
Blower Control
- Select one of the following:
•
120V Contactor
- 120V output on the MUA board to energize the coil of a contactor. This option should be selected when the MUA is used in conjunction with a DCV package.
•
VFD Manual
- HMI selectable VFD frequency.
•
VFD Jog
- For use with VFD using photohelic control. Aux pins are used to control the VFD.
Powering aux 1 will speed the fan up, powering aux 2 will slow the fan down. When aux 1 or aux 2 are not powered, the VFD will hold current speed.
• VFD 0-10V - For use when an external 0-10V signal is being provided to control the speed of the
VFD. 0 Volts will equal VFD min, 10V will equal
VFD max, and all voltages in between will be scaled linearly. This option will utilize 0-10V J28-
(6) and 0-10V common J28-(7) screw terminals, and will require field wiring.
•
VFD Pressure
- For use with VFDs that use a pressure transducer (0-10V output).
• Electronically Commutated Motor (ECM) - HMI selectable PWM rate.
•
ECM 0-10V
- For use when an external 0-10V signal is being provided to modulate the ECM supply output between min and max speed.
•
ECM Pressure
- For use with ECMs that use a pressure transducer (0-10V output).
• ECP - For use when the unit is controlled by an
Electrical Control Package (ECP). MUA board will still energize 120V supply contactor when there is a call for blower. Power to FSC cuts out at shutdown for 30 seconds.
•
Blower Mode
:
- If “Occ” is set to On, the menu screen for the blower mode will allow you to choose ON/AUTO OFF for
Occupied or Unoccupied.
- If “Occ” is set to Off, the menu screen for the blower mode will allow you to choose MANUAL/AUTO/
INTERLOCK. In blower auto mode, the blower will only run when it gets a call for heating/cooling.
- In blower manual/on mode, the blower will run as long as the fan button is enabled regardless of whether the unit is heating/cooling. In blower off mode, closing contacts J16-5 (unit intlk) and J16-6 (24V AC) will cause the blower to run.
• Air Profile Limits - Low PS cannot be adjusted below min setting, and High PS cannot be adjusted above max setting. Adjusting limit settings between min/max values may affect unit operation.
• Blower Presets - Blower preset option On/Off.
•
Post Purge Config
- When enabled, this option will run the blower for the set time after heating shutdown.
•
Door Interlock
- When enabled, if the door is open, the supply fan will shut down immediately.
FACTORY SETTINGS
UNIT OPTIONS
BLOWER CONFIG
BLOWER CONTROL
BLOWER MODE
AIR PROFILE LIMITS
120V CONTACTOR (DEFAULT)
VFD MANUAL
VFD JOG
VFD 0-10V
VFD PRESSURE
ECM
ECM 0-10V
ECM PRESSURE
ECP
OCC/UNOCC
LOW PS
(NON VAV BYPASS DAMPER*)
HIGH PS
(NON VAV BYPASS DAMPER*)
Presets
Normal Operation
(Selected Blower Mode)
Fan Speed/Damper Position 1
Fan Speed/Damper Position 2
Fan Speed/Damper Position 3
Fan Speed/Damper Position 4
Fan Speed/Damper Position 5
Fan Speed/Damper Position 6
Fan Speed/Damper Position 7
LOW PS
(VAV BYPASS DAMPER*)
HIGH PS
(VAV BYPASS DAMPER*)
LOW PS
(CONSTRUCTION HEATER*)
HIGH PS
(CONSTRUCTION HEATER*)
BLOWER PRESETS
POST PURGE CONFIG
DOOR INTERLOCK
ENABLE
PURGE TIME
Aux 1
X
X
X
X
ENABLE
ENABLE
RANGE: 0.15”-0.95”
DEFAULT: 0.15”
RANGE: 0.15”-0.95”
DEFAULT: 0.95”
RANGE: 0.15”-0.65”
DEFAULT: 0.15”
RANGE: 0.15”-0.65”
DEFAULT: 0.65”
RANGE: 0.25”-1.2”
DEFAULT: 0.25”
RANGE: 0.25”-1.2”
DEFAULT: 1.2”
ON/OFF
DEFAULT: ON
RANGE: 0-600 S
DEFAULT: 30 S
ON/OFF
DEFAULT: OFF
outlines the aux pins on Connector J11 for preset settings associated with fan speed and damper position found in
Factory Settings > Unit Options
.
Table 7 - Aux Presets
Aux 2
X
X
X
X
AUTO, OFF, ON
DEFAULT: AUTO
ON/OFF
DEFAULT: OFF
Aux 3
X
X
X
X
43
• Fan Proving Config - The exhaust contactor must be set to Before Airflow or After Airflow. When enabled, the user may set the number of contactors used.
Contactor 1 = Aux 2. Contactor 2 = Aux 3.
• VFD Direction - Sends a command to the VFD to run in forward or reverse.
•
VFD Freq Limits
- Min/Max settings for fan speed.
•
VFD Volt Limits
- Min/Max settings for 3rd-party
VFDs.
• PWM Rate Limits - Min/Max settings for fan speed.
•
Occ Fan Presets
- After the blower has started, the blower setting will use the aux pins to drive the preset occupied value.
•
Unocc Fan Presets
- After the blower has started, the blower setting will use the aux pins to drive the preset unoccupied value.
- Fan Preset Default: 1 = 40Hz, 2 = 50Hz, 3 = 0Hz, 4 =
60Hz, 5 = 0Hz, 6 = 0Hz, 7 = 0Hz.
• Occ PWM Presets - After the blower has started, the blower setting will use the aux pins to drive the preset unoccupied value.
•
Unocc PWM Presets
- Allows user to set unoccupied preset blower speed value.
- PWM Preset Default: 1 = 80%, 2 = 90%, 3 = 0%, 4 =
100%, 5 = 0%, 6 = 0%, 7 = 0%.
•
VFD By Others
- This option will be used when a factory provided Modbus control VFD is not utilized. A start command, as well as a 0-10 V output will be provided to the VFD.
• Pressure Config
• Sensor Range - Menu is available when any blower pressure or recirculating pressure option is selected.
• Static PS KP - Proportionally constant value for static pressure measured in V/sec.
• Cycle Time - Cycle time is the time between two consecutive readings.
• PS Hysteresis - The percentage band between high and low static set points. This will reduce cycling of blower or damper. Increase this value if the blower speed or damper does not settle into a SP.
•
Airflow Proving
- User can set unit to prove with airflow sensor located on the board.
FACTORY SETTINGS
UNIT OPTIONS
FAN PROVING CONFIG
VFD DIRECTION
ENABLE
# OF CONTACTORS
DIRECTION
OFF/PROVING
DEFAULT: OFF
1/2
DEFAULT: 1
FORWARD/REVERSE
DEFAULT: FORWARD
VFD FREQ LIMITS
OCC/UNOCC MIN
OCC/UNOCC MAX
RANGE: 0-MAX FREQ
DEFAULT: 0.0 HZ
RANGE: MIN FREQ- 80
DEFAULT: 80 HZ
VFD VOLT LIMITS
OCC/UNOCC MIN
OCC/UNOCC MAX
RANGE: 0-10 V
DEFAULT: 0 V
RANGE: 0-10 V
DEFAULT: 10 V
PWM RATE LIMITS
OCC FAN PRESETS
UNOCC FAN PRESETS
OCC PWM PRESETS
UNOCC PWM PRESETS
VFD BY OTHERS
OCC/UNOCC MIN
OCC/UNOCC MAX
PRESET (1-7)
PRESET (1-7)
PRESET (1-7)
PRESET (1-7)
ENABLE
RANGE: 0-100%
DEFAULT: 0%
RANGE: 0-100%
DEFAULT: 100%
RANGE: 0-80 HZ
DEFAULT: VARIES
RANGE: 0-80 HZ
DEFAULT: VARIES
RANGE: 0-100%
DEFAULT: VARIES
RANGE: 0-100%
DEFAULT: VARIES
ON/OFF
DEFAULT: OFF
PRESSURE CONFIG
SENSOR RANGE
AIRFLOW PROVING
STATIC PS KP
CYCLE TIME
PS HYSTERESIS
RANGE: +/- .25" W.C. or +/- .15" W.C.
DEFAULT: +/- .25" W.C.
RANGE: 0.10 V/S - 0.50 V/S
DEFAULT: 0.15 V/S
RANGE: 5-60 S
DEFAULT: 5 S
RANGE: 15-35%
DEFAULT: 25%
CONTROL
ONBOARD/REMOTE
DEFAULT: ONBOARD
44
• Purge Config
•
Purge Button
- When the purge button is pressed, the damper will open to max outdoor air and turn on the exhaust contactor, if enabled. Purge Button must be enabled for Dry Mode operation.
•
Purge Time
- This is the amount of time that the unit will run the purge process if the user does not stop the purge manually.
• Purge Speed - Adjustable between VFD or ECM. Min and Max frequency the fan will run during the purge cycle.
• Dry Mode Config - When this option is set to On, there are three separate ways to initiate dry mode.
Through the HMI home screen, through a hardwired input (contact closure between connector J11-3 and
J16-5), or automatic activation. Dry mode can use the
HMI’s Temp/RH sensor or a remote space temp/RH sensor to activate. When dry mode is activated:
- Dry mode activation may operate off of the HMI temp/
RH sensor or a remote temp/RH sensor.
- The unit will go to Dry Mode Discharge when there is a call for heat.
- Space dewpoint is the average of the Space RH input with any additional HMI inputs.
- If OA dewpoint < Space dewpoint, the mixing box should go to outdoor air setting. This should override any other mixing box functionality.
- If OA dewpoint > Space dewpoint, the mixing box should go to min OA%.
- Purge should run until the purge timer expires or the user cancels the purge.
• Exhaust
- Enables/disables exhaust contactor during dry mode.
•
Space DP SP
- Dew point threshold for automatic dry mode activation.
•
Enth Mode
- Dew point activation will be replaced with enthalpy activation when set to On.
•
Monitoring Sensors
- Smoke Detector, Filter Monitor,
Intake Firestat, Discharge Firestat, Freezestat,
Freezestat RA, Low Gas Switch, High Gas Switch, CO
Shutdown.
FACTORY SETTINGS
UNIT OPTIONS
PURGE CONFIG
PURGE BUTTON
PURGE TIME
PURGE SPEED
ENABLE
DURATION
ON/OFF
DEFAULT: OFF
RANGE: 1-120 M
DEFAULT: 60 M
VFD
ECM
DRY MODE CONFIG
ENABLE
EXHAUST
SPACE DP SP
ENTH MODE
MONITORING SENSORS
SMOKE DETECTOR
FILTER MONITOR
INTAKE FIRESTAT
DSCHRG FIRESTAT
FREEZESTAT
FREEZESTAT RA
LOW GAS SWITCH
HIGH GAS SWITCH
CO SHUTDOWN
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
HEAT/UNIT
DEFAULT: UNIT
RANGE: 0-80 HZ
DEFAULT: 60.0 HZ
RANGE: 0-100%
DEFAULT: 100%
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
RANGE: 40-80°F/4-27°C
DEFAULT: 60°F/16°C
ON/OFF
DEFAULT: OFF
45
• Recirc Config
•
Recirc
- Off, Manual, 2 Position, Outdoor Air %,
Analog Control, Pressure, CO2.
•
Recirc Deadband
- If the temperature difference between the outdoor and return sensor is less than or equal to this SP, the MUA board will not attempt to adjust the output voltage until it matches the outdoor air percentage SP. This setting only takes effect when either outdoor air % or schedule is selected.
• Return As Space - Setting this to On will not require a space sensor or HMI. This setting will use the return air thermistor (RT) in place of the space sensor.
• Off Position - Allows user to select how the dampers will be positioned when the supply fan is off. Standard
(default), Max Outdoor Air %, or Min Outdoor Air %.
•
Recirc Limits
- Minimum and maximum settings for recirc. Percentage or voltage based on recirc selection.
•
Edit OA% Table
- User may edit voltages for equivalent to outdoor air percent table (% of movement of recirc damper. No value may be the same.
•
Damper Presets
- This allows the user to set damper preset option On or Off.
• Preset Volts - Uses aux pins to control damper actuator.
• Occ/Unocc Preset Volts - When scheduling is On,
Occ Preset Volts and Unocc Preset Volts with be available.
•
Intake Damper
- User can adjust intake damper to be On or Off.
•
Discharge Damper
- User can adjust discharge damper to be On or Off.
•
Room Override
- Uses room override SP rather than
Discharge SP. This setting will only have an effect when the heat tempering mode setting is discharge and activate based on is not set to intake.
•
Exhaust Contactor
- This allows the user to assign a contactor for an interlocked exhaust fan. There are occupied and unoccupied settings.
• None
•
Before airflow
- Exhaust fan will start before the airflow proving switch has been activated.
•
After airflow
- Exhaust fan will start after the airflow proving switch has proved there is airflow.
•
Exhaust On Smoke
- When the input is enabled, if it receives a 24V signal from a fire system, this will shut down the supply fan and enable the exhaust contactor.
The 24VAC signal must originate from the MUA Board.
•
Cabinet Heater
- This allows the user to enable the cabinet heater, if applicable. If enabled, the temperature sensor on MUA board controls the cabinet heater.
FACTORY SETTINGS
UNIT OPTIONS
RECIRC CONFIG
RECIRC
RECIRC DEADBAND
RETURN AS SPACE
OFF POSITION
MODE
DEADBAND
ENABLE
OFF
OFF, MANUAL, 2 POSITION,
OUTDOOR AIR %, ANALOG
CTRL, PRESSURE, CO2
RANGE: 0-10°F/0-6°C
DEFAULT: 5°F/3°C
ON/OFF
DEFAULT: OFF
MAX OUTDOOR AIR% (DEFAULT),
MIN OUTDOOR AIR%,
STANDARD
RECIRC LIMITS
MIN OA OCC/UNOCC
RANGE: MIN-MAX %
DEFAULT: 20%
MAX OA OCC/UNOCC
PRESET OA VALUES ENABLE
RANGE: MIN-MAX %
DEFAULT: 100%
ON/OFF
DEFAULT: OFF
EDIT OA% TABLE
Adjustable percent values from 0-10V.
DAMPER PRESETS
PRESET VOLTS
OCC PRESET VOLTS
UNOCC PRESET VOLTS
ENABLE
ENABLE
PRESET 1-7
PRESET 1-7
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
RANGE: 0.0-7.45 V
DEFAULT: 0.0 V
RANGE: 0.0-7.45 V
DEFAULT: 0.0 V
INTAKE DAMPER
DISCHARGE DAMPER
ROOM OVERRIDE
EXHAUST CONTACTOR
EXHAUST ON SMOKE
CABINET HEATER
ENABLE
ENABLE
ENABLE
MODE
ENABLE
ENABLE
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
NONE,
BEFORE AIRFLOW (DEFAULT),
AFTER AIRFLOW
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
46
• VAV Bypass Config - When enabled On, the settings available will maintain burner profile pressure for proper combustion. Required for industrials with VAV option.
•
PS
- Profile pressure setting for VAV bypass damper.
• KP - Kp value will determine the rate of change for the
VAV damper output.
•
Deadband
- VAV Bypass damper deadband setting.
•
Blower Throttle
- The throttle function is to maintain profile pressure across the burner.
•
Throttle Volt Step
- Increases/decreases fan speed when a third party VFD is used.
•
Proof of Closure
- For gas valves that contain a proof of closure switch, the user may set this option On. Before heating occurs, a 24V AC input must be present at connector J32 pin 12.
•
No FSC Reset
- When this option is set to On, the flame safety control will not reset on a failure to prove flame. If the flame fails, a manual reset is required immediately via the push button or HMI.
•
Trouble Input
• Mode - If connector J28 pin 3 receives 24 volts, the unit will act based on mode setting:
-
Unit Off
- Shuts down blower (heating/cooling will also shutdown). Bypass any timers.
- Both Off - Turns off/lockout heating and cooling.
Bypass min on/off timers.
-
Heat Off
- Turns off/lockout heating.
-
Cool Off
- Turns off/lockout cooling. Bypass min on/off timers.
-
Set Back
- Forces unit to unoccupied state.
•
Time
- Setting for off/lockout time.
•
DD Wheel Size
- Direct drive wheel size selection.
• CO2 Control Config - Monitors CO2. Will adjust blower speed/damper position depending on CO2 SP.
• Override The unit will try to maintain space CO2
Parts Per Million (PPM) levels based on min/max threshold set points set by the user. The unit will modulate the blower/damper linearly between their corresponding min/max settings.
•
Threshold
CO2 Parts Per Million (PPM) maximum threshold set points for the space. When the space
CO2 PPM reading exceeds the threshold setting, the blower/damper will go to their max setting.
•
Outdoor Reset
- Functions for outdoor reset:
- Discharge Heat Tempering: If outside air is below OA
Reset Low SP, heat will discharge to Reset Heat
Discharge setting.
- Space Heat Tempering: If outside air is below OA Reset
Low SP, the space SP will adjust to Reset Heat Space setting.
- Intake Cool Tempering: If outside air is above OA Reset
High SP, cooling will go to max staging. If both evap and dx are present, unit will run all.
- Intake Space Cool Tempering: If outside air is below OA
Reset Low SP, the space SP will adjust to Reset Cool
Space setting.
FACTORY SETTINGS
UNIT OPTIONS
VAV BYPASS CONFIG
BLOWER THROTTLE
THROTTLE VOLT STEP
PROOF OF CLOSURE
NO FSC RESET
ENABLE
PS
KP
DEADBAND
ENABLE
STEP
ON/OFF
DEFAULT: OFF
RANGE:(-0.25) to 0.55
DEFAULT:(-0.45)
RANGE: 0.05V/sec to 2V/sec
DEFAULT: 0.10V/sec
RANGE: 0.01 to 0.2
DEFAULT: 0.1
ENABLE
ENABLE
ON/OFF
DEFAULT: OFF
RANGE: 0.10-2.0 V
DEFAULT: 0.5V
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
TROUBLE INPUT
DD WHEEL SIZE
MODE
TIME
UNIT OFF, BOTH OFF, COOL OFF,
HEAT OFF, SET BACK
RANGE: 0-600 S
DEFAULT: 0 S
MODELS: 11,13, 15, 18, 20, 24, 30, 36,
16Z,18Z, 20Z, 22Z, 25Z, 28Z.
CO2 CONTROL CONFIG
OUTDOOR RESET
OVERRIDE
THRESHOLD
OFF (DEFAULT), BLOWER,
DAMPER
OFF (DEFAULT), BLOWER,
DAMPER
ON/OFF
DEFAULT: OFF
47
• Dynamic Set Point - below are scenarios for dynamic functionality.
- When heating: If the measured outside air temperature is below the Dynamic Heat OA set point (SP) minus the differential SP, the space or discharge SP will increase/ decrease by the offset setting.
• Extra Cooling Input - When the DX cooling stage is set to 2 or greater, the cooling input will utilize all stages of cooling.
•
Single Zone VAV
- The single zone VAV option can be set to Off, Blower, Damper, or Both.
• Blower Speed Heat/Cool - Unit may be set to Blower or Both (Heating/Cooling).
- For heating in blower setting, blower to modulate with the discharge temp min discharge, min blower speed.
Max discharge, max blower speed. Scaled linearly between min/max discharge to min/max blower speed.
- For cooling in blower setting, blower speed will change depending on how many cooling stages are active.
Evap counts as 1st stage of cooling.
• Damper Pos Heat/Cool - Unit may be set to Blower or
Both (Heating/Cooling).
- For heating in damper setting, damper to modulate with the discharge temp min discharge, min damper position. Max discharge, max damper speed. Scaled linearly between min/max discharge to min/max damper position.
- For cooling in damper position setting, damper position will change depending on how many cooling stages are active. Evap counts as 1st stage of cooling.
• Alarm Output - User may set to All or Fireye. If All is selected, output will energize when any fault occurs. If
Fireye is selected, output will energize when Fireye faults occur. Connector J30 pin 8 will be energized.
Occ Ovrd Duration - Length of override timer. If override is active, it can be manually stopped by pressing the end override button on the HMI.
Limit SP Adjust
- This allows the user to change the current temperature SP through the home screen. The range adjustment is 0-100 degrees. Default is 5°F. When the SP is set to 0°F, the adjustment buttons (+/-) will not be visible.
Temp Ovrd Duration
- Length of temperature override timer.
PID Parameters
- (DO NOT CHANGE THESE
PARAMETERS)
Sensor Offsets
- Offset adjustment setting displayed for
Discharge and Space heating hysteresis.
FACTORY SETTINGS
UNIT OPTIONS
DYNAMIC SET POINT
EXTRA COOLING INPUT
LIMIT SP ADJUST
PID PARAMETERS
SENSOR OFFSETS
SINGLE ZONE VAV
ALARM OUTPUT
OCC OVRD DURATION
TEMP OVRD DURATION
DURATION
LIMIT
DURATION
DSCHRG DISP
SPACE DISP
INTAKE RH
SPACE RH
ON/OFF
DEFAULT: OFF
ON/OFF
DEFAULT: OFF
OFF (DEFAULT), BLOWER,
DAMPER, BOTH
ALL, FIREYE
DEFAULT: ALL
RANGE: 1-16 H
DEFAULT: 1 H
RANGE: 0-100°F/0-55°C
DEFAULT: 5°F/3°C
DO NOT ADJUST THESE
SETTINGS
RANGE: 1-16 H
DEFAULT: 1 H
RANGE: (-20)-20°F/(-11)-11°C
DEFAULT: 0°F/0°C
RANGE: (-20)-20°F/(-11)-11°C
DEFAULT: 0°F/0°C
RANGE: (-30)-30%
DEFAULT: 0%
RANGE: (-30)-30%
DEFAULT: 0%
NOTE: For heating, every multiple of Dynamic Set Point
Differential would multiply the effect of the Dynamic
Offset setting.
48
Service Settings
Service Menu Password = 1234
Temperatures
- Monitors various temperature values.
Relative Humidity
- Current humidity readings per HMI.
Open/Closed Status - Menu to view the open/closed status of all inputs.
Variable Values
- Allows the user to monitor all of the variable input and output values.
VFD Status
- Allows the user to monitor VFD parameters.
High Temp Limit
- Displays the high temp limit.
Airflow Limits - Displays the high/low airflow limits.
Recirc Values
- Allows the user to monitor recirc values.
Test Menu
•
Test Fans
- All, Supply, Exhaust.
•
Test Heating
- Contains high and low fire tests for stages. If “Heating Config” is set to 0, then “No Heat
Stage Set” will display.
- In test mode, the high limit setting will be based on intake temp + max temp rise + 10 degrees or the unit’s high limit setting (170°F), whichever is higher.
- If recirc is On, set to 0V or 100% OA.
- Exiting test mode should reset the PID.
•
Test High Temp Limit
- Test menu allows user to set a limit to simulate a high temp fault.
•
Test Options
•
Test Cabinet Heater
- Beginning this test will activate the cabinet heater on.
•
Test Drain Heater
- Beginning this test will activate the drain heater on.
•
Test Recirc
- Beginning this test will create an output to the outdoor air control. The test will begin at 0 volts.
The up and down buttons allow for modulation of the output.
•
Test Freezestat
- Test menu will allow user access to adjust set points to verify freezestat operation in various types of ambient conditions.
Clear Fault History
- This will clear the entire fault history. If there is an active fault when cleared, that fault will show up until it is fixed.
Set Clock
- Set day and time. This allows the user to set their time zone.
Factory Reset
- Confirming will reset to the last time the unit was commissioned, or when an update factory defaults was performed.
Update Factory Defaults (DFLTS) - This allows the original factory default settings to be overridden. When confirming the updated settings, these settings will now be used when
“Factory Reset” is used.
Calibrate Recirc
Calibration process to update factory default values to building site conditions.
Reset Recirc Values
- Resets recirc back to default values.
Calibrate Static PS
- Static pressure sensor calibration.
Disconnect all pressure tubes prior to calibration.
Calibrate CFM
- Calibrates pressure differential in the venturi to calculate approximate fan CFM. Must disconnect all pressure tubes prior to calibration.
CFM
- Displays measured CFM readings. This readout is only valid for units with direct-drive wheels.
SERVICE SETTINGS
TEMPERATURES
MONITOR TEMPERATURE
SENSOR READINGS
RELATIVE HUMIDITY
HMI (1-5)
CURRENT HMI HUMIDITY
READINGS
OPEN/CLOSED STATUS
INPUTS
OUTPUTS
COMPONENTS INPUT
READINGS
COMPONENTS OUTPUT
READINGS
VARIABLE VALUES
VFD STATUS
HIGH LIMIT SET POINT
AIRFLOW LIMITS
RECIRC VALUES
INPUTS
OUTPUTS
COMPONENTS INPUT
VARIABLE READINGS
COMPONENTS OUTPUT
VARIABLE READINGS
VFD PARAMETER
READINGS
DISPLAYS HIGH TEMP
LIMIT READINGS
HIGH/LOW AIRFLOW
READINGS
DISPLAYS MIXING BOX
VALUES
TEST MENU
TEST FANS STATE
TEST HEATING
TEST COOLING
TEST HIGH TEMP LIMIT
STATE
STATE
STATE
CLEAR FAULT HISTORY
SET CLOCK
FACTORY RESET
UPDATE FACTORY DFLTS
CALIBRATE RECIRC
RESET RECIRC VALUES
TEST OPTIONS
TEST CABINET HEATER
TEST DRAIN HEATER
TEST RECIRC
TEST FREEZESTAT
CONFIRM
CURRENT DATE AND TIME
CONFIRM
CONFIRM
CALIBRATE STATIC PS
CALIBRATE CFM
CFM
START
RESET
ENTER
ENTER
CFM READINGS
INLET PS READINGS
STATE
STATE
STATE
STATE
OFF, ALL, SUPPLY,
EXHAUST
OFF, LOW FIRE,
HIGH FIRE, ANALOG
OFF, ALL, STAGE 1,
STAGE 2, EVAP
OFF, HTL
OFF, CAB HEAT
OFF, DRAIN HEAT
OFF, RECIRC
OFF, FREEZESTAT
49
Start-Up Procedure
1. Check for signs of damage. Do not operate if damage exists and contact your manufacturer sales representative. Units are easier to fix before the equipment is installed.
2. Check all installation clearances.
Clearance from Combustibles
Top: 6” Sides: 6” Base: 0”
Clearance for Serviceability
Unit: 24” Service Accesses: 48”
3. Check that the unit has been set level and secured.
• Unit must have adequate structural support, or the equipment or building may be damaged.
• Curb and unit must be leveled, or the unit may leak or be damaged.
• Gasket and caulk the seam between the curb and unit base.
• Screw or weld the unit’s base to the curb to avoid damage to the equipment.
4. Check that the accessories are set level and secured.
• Accessories must have adequate structural support, or the equipment or building may be damaged.
• Gasket, caulk, and screw each accessory to unit seam.
5. Check that the unit’s intake and discharge are free of debris.
6. Check that the filters are installed in the (optional) filter section or intake hood in accordance with the airflow direction.
8. Check that all field wiring has been completed in accordance with the factory-supplied wiring diagram.
Field wires are shown as dashed lines on the wiring prints.
9. Check that all terminal screws are tight and that wires are in place.
.
Correct if necessary.
11. Check that the power supply matches the nameplate voltage, phase, and amperage. Record the voltage on the Start-up Sheet.
Figure 23 - Gas Pressure Type
12. Check that the gas type and pressure match the
nameplate type and pressure ( Figure 23
).
13. Contact the service department if the power or gas supply needs to be changed in the field. Different parts might be necessary for the change.
14. Turn the unit ON.
• Bump the blower motor starter to check the blower wheel rotation.
• The decal is located on the blower housing
).
• If the rotation is backwards, turn off the power and correct the wiring.
• The rotation can be corrected by interchanging two legs of
3-phase (must be between VFD and motor on
VAV units).
Directional
Arrow
Figure 24 - Fan Direction
50
15. Use the HMI to turn the fan ON. The (optional) intake or discharge damper motor will start to open.
Once the damper is 90% open, the damper motor internal end switch will close and energize the blower motor starter.
16. Check the motor’s amp draw (
Figure 25 - Amp Draw Check
• The motor’s amp draw should be less than the FLA (full load amps) of the blower motor.
• The fan RPM may need to be reduced to decrease motor amps.
• Opening the motor pulley decreases RPM and motor amps.
• Closing the motor pulley increases RPM and motor amps.
• Record the motor amps on the Start-up Sheet.
17. If the RPM was adjusted in the field, use a tachometer to record the new RPM on the Start-up Sheet.
18. If applicable, check the belt tension after any RPM adjustments.
Refer to
“Pulley Alignment/Proper Belt Tension” on page 55
.
Gas Train Start-Up Procedure
1. Use the HMI to verify profile pressure differential, go to Service > Variable Values > Inputs > Onbd
Prof PS .
• The airflow sensor on single-speed units is a low airflow sensor only and opens below 0.15 in w.c
.
• The target pressure drop range for the single-speed unit is 0.40 – 0.50 in w.c
.
• Do not adjust airflow.
• Use the profile plates or blower RPM to increase or decrease the pressure drop. If adjusting by blower RPM, you will need to adjust the blower pulley or VFD, if equipped.
• Record the pressure drop on the Start-Up Sheet.
2. Close the burner gas shut-off valve. This will allow the unit to fire the pilot only and will be opened at a later time.
3. Turn the fan ON.
4. Use the HMI to test heating, go to Service > Test Menu > Test Heating > State > High Fire .
5. The Fireye Flame Safety Control energizes the ignition transformer and pilot gas valve.
6. After the pilot flame is established, the main gas valves will open. At this time, the pilot will be the only flame in the burner.
7. The pilot regulator should be adjusted so the pilot flame signal is stable at 6-18 VDC. Use the HMI to read the flame signal located under Service > Test Menu > Test Heating .
8. Record the flame signal in the start-up sheet.
Figure 26 - Gas Train
PILOT PRESSURE
REGULATOR
PILOT PRESSURE
REGULATOR
GAS
VALVE
ON
GAS
VALVE
OFF
51
Setting High Fire
Figure 27 - Gas Nameplate
1. Open the Burner Gas Shut Off Valve. Refer to
2. Measure the intake air temperature.
3. Add the intake air temperature to the units nameplate design temperature rise. This result will be the desired high fire discharge temperature.
GAS TYPE: NATURAL
MAX. TEMP. RISE: 125°F
DESIGN TEMP. RISE: 72°F
MAX. DISCHARGE TEMP.: 160°F
Refer to Figure 27 for an example: Intake Temp (70°F) + Design Temp Rise (72°F) = Discharge
Temp (142°F)
4. Use the service test menu to lock the unit in high fire: Service > Test Menu > Test Heating > State >
High Fire . Press Enter.
5. Adjust the manifold gas pressure to achieve the desired discharge air temperature.
6. Measure the discharge temperature using a thermometer. Laser thermometers are not as accurate as a thermocouple type.
7. If the discharge ductwork outlet is hard to reach, you may feed a thermocouple into the mixing tube inside the blower discharge.
8. Use the regulator pressure adjusting screw, adjust the high fire manifold pressure to 5 inches wc maximum for natural gas, and 2.5 inches wc maximum for propane gas. High fire should be set to generate the design temperature rise. If the high fire screw is at the end of its adjustment and more pressure is needed, then adjust the main building gas pressure regulator spring (located external to the unit) to achieve the proper manifold pressure. Turning the regulator screw clockwise will increase pressure, and counter-clockwise will decrease pressure.
NOTE: When the unit is locked into high fire via test menu, the voltage should read 24V DC. The normal operation value reading is 15V-24V DC.
Figure 28 - High Fire/Low Fire Bypass Screw Setting
Modulating Valve
Adjustment Screw Location #1
Modulating Valve
Adjustment Screw Location #2
Regulator
Adjusting Screw
(High Fire)
Bypass Adjustment
(Low Fire)
Firing Mode: Low Fire = 0-5V DC, Modulation = 5-15V DC, High Fire = 15-24V DC
52
Setting Low Fire
1. Use the service test menu to lock the unit in low fire: Service > Test Menu > Test Heating > State >
Low Fire . Press Enter.
2. Check the DC voltage across the terminals on the modulating valve to verify 0V DC. This will confirm the unit is in the low fire.
3. Use the bypass screw (located on the side of the M511 and M611 valves, or under the cap of the
MR212 valve). Adjust the low fire manifold pressure until there is a very thin flame along the entire length of the burner. No dark spots should be seen in the burner. The burner may be observed through the view-port located on the external wall of the heater. Replace the cap to the valve and restore all of the original wiring and gas components.
4. A final gas leak check shall be performed to verify the gas-tightness of the heater’s components and piping under normal operating conditions. This can be done by measuring the gas pressure at the
1/4” gas plug just downstream of the modulating valve.
Design Manifold Gas Pressure
Figure 29 - Pressure vs. Firing Rating
Natural
Gas
Propane
Gas
2.00
1.00
0.00
-1.00
0
6.00
5.00
4.00
3.00
8.00
7.00
Average Manifold Pressure vs. Firing Rate/Ft. of Burner
100000 200000 300000 400000 500000
Firing Rate (BTU/Hr/Ft. of Burner)
600000 700000
53
Final Start-up Procedure
1. With the air and burner systems in full operation and all ducts attached, measure the system airflow.
The motor sheave (pulley) is variable pitch, and allows for an increase or decrease of the fan RPM. If
an adjustment is needed, refer to “Pulley Adjustment” on page 55
.
2. Once the proper airflow is achieved, measure and record the fan speed with a reliable tachometer.
Caution - Excessive speed will result in motor overloading and/or bearing failure. Do not set fan RPMs higher than specified in the maximum RPM chart. Refer to
“TROUBLESHOOTING” on page 74 .
3. Measure and record the voltage and amperage to the motor and compare with the motor nameplate to determine if the motor is operating under safe load conditions.
4. Once the rpm of the ventilator has been properly set, disconnect power and recheck belt tension and
pulley alignment, refer to Figure 31 .
Start-up Procedure Variable Air Volume
The Start-Up procedure for variable air volume units is the same as the single-speed unit, except there are additional steps for checking the burner pressure drop and setting high/low fire. Use the single-speed procedure along with these additional steps for the VAV start-up procedure.
• Use the HMI to verify profile pressure differential, go to Service > Variable Values > Inputs >
Onbd Prof PS . Check the pressure drop through the entire airflow range.
• The airflow sensor on VAV units is a low (0.15) and (0.65) high switch.
• Do not adjust airflow sensor.
• Use the profile plates or blower RPM to increase or decrease the pressure drop. Blower RPM can be adjusted in the HMI under User Setting > Fan Speed .
• Record the pressure drops on the Start-up Sheet.
• Verify the flame limiting device is functioning properly in low speed on units with a VFD.
• Verify the low fire setting at minimum flow rate as well.
54
Pulley Adjustment
The adjustable motor pulley is factory set for the RPM specified. Speed can be increased by closing or decreased by opening the adjustable motor sheave. Two groove variable pitch pulleys must be adjusted an equal number of turns open or closed. Any increase in speed represents a substantial increase in horsepower required by the unit. Motor amperage should always be checked to avoid serious damage to the motor when the speed is varied. Always torque set screws according to the torque specifications
Figure 30 - Adjustable Pulley
Decrease Amperage and
Blower RPM
Setscrew Thread Size Torque (in-lbs)
No. 10 (bushing)
1/4” (bushing)
5/16”
32
72
130
Pulley Alignment/Proper Belt Tension
1. Belts tend to stretch and settle into pulleys after an initial start-up sequence. Do not tension belts by changing the setting of the motor pulley , this will change the fan speed and may damage the motor.
• To re-tension belts, turn OFF power to the fan motor.
• Loosen all fasteners that hold the blower motor plate to the blower housing.
• Rotate the motor to the left or right to adjust the belt tension. Belt tension should be adjusted to allow 1/64” of deflection per inch of belt span. Use extreme care when adjusting V-belts as not to misalign pulleys. Any misalignment will cause a sharp reduction in belt life and produce squeaky noises. Over-tightening will cause excessive belt and bearing wear as well as noise. Too little tension will cause slippage at startup and uneven wear.
• Whenever belts are removed or installed, never force belts over pulleys without loosening motor first to relieve belt tension. When replacing belts, use the same type as supplied by the manufacturer. On units shipped with double groove pulleys, matched belts should always be used.
2. All fasteners should be checked for tightness each time maintenance checks are performed prior to restarting unit.
Belt tension examples:
• Belt span 12” = 3/16” deflection
• Belt span 32” = 1/2” deflection
Figure 31 - Pulley Alignment/Belt Tension
Correct Incorrect
A. Belt Span Length
B. Deflection
C. Center Distance
B
A
Incorrect Incorrect
C
55
100% Profile Adjustments & Test/Balance
Test and Balance
The burner profile area has been set according to the design conditions submitted with the order. At the design SCFM, the profile pressure drop will be 0.45 in w.c. Any variations of the design conditions will lead to a variance of the unit’s CFMs. Increase or decrease the RPMs as needed to achieve the design burner profile pressure drop, or follow the below profile adjustments. An accurate duct traverse is not possible without an adequate length of straight ductwork available.
WARNING!
Disconnect power and close all gas valves before and while making burner profile adjustments.
Single-Speed Profile
The pressure drop should be checked with the burner OFF if ambient temperature is greater than 60 degrees Fahrenheit. If the ambient temperature is lower than 60 degrees Fahrenheit, the burner should be operating and discharging approximately 70 degrees Fahrenheit. Use the HMI to check profile pressure differential. Use the HMI to verify profile pressure differential, go to Service > Variable Values > Inputs >
Onbd Prof PS .
Figure 32 - Single-Speed Profile
• If the pressure drop is too low, adjust the profile opening to be smaller, which will increase the pressure drop.
• If the pressure drop is too high, adjust the profile opening to be larger, which will decrease the pressure drop
Variable Air Volume Profile
The direct-fired gas make-up heater requires the correct airflow velocity across the burner. The airflow sensor monitors the profile pressure differential and will open the burner circuit if the pressure difference is not within the allowed range. The airflow sensor has low and high pressure settings for variable air volume units. The pressure drop should not be near the minimum and maximum of the airflow sensor. Profile adjustment may be required to fine-tune the burner profile pressure drop. See the specifications and instructions below on air balancing a 100% fresh air heater.
Figure 33 - VAV Profile
• In low speed, adjust the burner profile opening smaller to increase pressure drop or larger to lower pressure drop.
• In high speed, adjust the bypass damper opening larger to decrease the pressure drop and smaller to increase the pressure drop.
56
80/20% Air Balancing
The direct-fired gas make-up heater requires the correct airflow velocity across the burner. The burner profile opening creates a pressure drop, which increases the air velocity across the burner. The airflow sensor monitors the pressure difference, and will open the burner circuit if the pressure difference is not correct. The airflow sensor has low and high pressure settings. The pressure drop should not be near the minimum and maximum of the airflow sensor. Balancing may be required to fine-tune the burner profile pressure drop. The airflow pressure drop should be checked in fresh and return air modes on the recirculating heaters. Refer to
for airflow specifications.
Airflow Sensor
P/N
Table 8 - Recirculating Airflow Sensor
Low Setting
Inches W.C.
0.15”
High Setting
Inches W.C.
0.95”
Target Pressure
Drop Inches W.C.
Natural Gas
0.45”-0.65”
Target Pressure
Drop Inches W.C.
Propane Gas
0.45”-0.65” HIH8131-000-001
The pressure drop should be checked with the burner off or operating at 70-degree discharge if ambient temperature is less than 65 degrees. With the blower On, use the HMI to verify profile pressure differential.
Go to Service > Variable Values > Inputs > Onbd Prof PS . This should be repeated in fresh and return air modes.
WARNING!
Disconnect power and close all gas valves before and while making burner profile adjustments.
Figure 34 - Blank-Off Plates
The heater’s profile and damper openings are sized to the unit’s designed airflow.
While balancing the unit to jobsite static pressures the profile and damper blank-off plates may need to be moved to achieve the correct airflow pressure drop. Refer to
If the pressure drop is too high in fresh and return air mode, remove or adjust the bypass fresh air and return air damper blank-off panels. This will decrease the pressure drop.
If the correct airflow pressure drop is still not achieved, adjust the blower drives to decrease blower RPM.
Unit without Blank-Off Plates
Return Air
Damper
Burner
Profile
Bypass
Fresh Air
Damper
Blank-Off
Plates
Blank-Off
Plates
Blank-Off
Plates
If the pressure drop is too low in fresh and return air mode, add more blank-off panels to the burner profile opening and bypass fresh air and return air damper, which will increase the pressure drop. There must be at least 2 inches of area minimum around the burner. If the correct airflow pressure drop is still not achieved, adjust the blower speed to increase the blower’s RPM.
If the pressure drop is too high in fresh mode only, remove or adjust the bypass damper blank-off panels, which will decrease the pressure drop. The return air damper opening may need to be adjusted to maintain the correct airflow pressure drop when switching back to return air mode.
57
Airflow Sensor
Figure 35 - Board Airflow Sensor
The MUA board contains an onboard pressure sensor
(
Figure 35 ) for airflow monitoring. There are both high and
low airflow tubing connections connected to a sensor, measuring the pressure drop across the burner. This is to verify that there is proper airflow across the burner and proper combustion at all times. For units with VAV Bypass
Damper airflow 0.15 to 0.65 inch wc. For units without VAV
Bypass Damper airflow 0.15 to 0.95 inch wc.
H1
PS1
L2
There are two airflow tubes in the heater, located near the burner and profile plate assembly (profile plates surround the burner and control air into the burner section).
AIRFLOW
In the case of clogged filters, blocked intake, excessive duct static pressure, or a broken belt, the correct burner differential pressure may not be achieved, not allowing the low airflow sensor to close. The airflow sensor protects against profile plate failures that cause excessive airflow through the burner. In the event that the pressure drop across the burner is not in the range of the airflow sensor, gas flow to the burner is stopped by the Flame Safety
Control. NOTE: With the blower running, verify the airflow
AIRFLOW pressure reading is a positive value. Reverse the airflow tubes if the reading is negative.
AIRFLOW
AIRFLOW
To view burner profile pressure on the HMI, go to Service > Variable Values > Inputs > Onbd Prof PS .
58
Modulating Gas System
The Modulating Gas System is directly controlled from the MUA Board at connector J32 pin 7(+) and 16(-).
A modulating 0-24V DC signal is utilized to modulate the gas valve signal. The signal is a 16 kHz full-wave rectified signal.
The Modulating Gas System consists of an Intake Temp Sensor, a Discharge Temp Sensor, a Space
Temp Sensor (only on space temperature control options), and modulating gas valve(s). The intake air sensor, the space sensor, or a combination of the two can be used to give a call for heat signal to the MUA board.
The MUA board uses a PID loop and checks the difference between the temperature sensor readings in order to modulate the heat appropriately.
• For kitchen MUA heating applications, intake air set point should be set at 45°F, whereas the discharge set point should be set at 55°F. The defaults may be adjusted per field conditions.
• For all other applications, the set point should be set appropriately based on end-user preferences and on-site conditions.
High Temperature Limit
One of the backup safety devices is the high-temperature limit lockout. This temperature sensor measures the temperature inside the unit, downstream of the burner. If the factory-set temperature of 175°F/150°F
(Recirc) is exceeded, it will signal the FSC to turn off the burner. This requires a manual reset of the high-
temperature limit. Refer to “Resetting Unit” on page 81 .
Pilot Adjustment
Figure 36 - Pilot Assembly
1. Restart the fan and check the gas supply pressure at the inlet gas gauge upstream of all electronic valves. The inlet pressure should be 7 inches wc - 5 psi . If the inlet pressure is too high, install an additional pressure regulator external to the unit.
2. Open the field-installed manual gas shut-off valve.
3. Close the ball valve located inside the cabinet.
Pilot Tube
Connection
Spark Connection
Flame Rod
Connection
4. Call for heat using the HMI Service > Test Menu > Test
Heating > High Fire.
If the pilot does not light, purge the pilot line. If air purging is required, disconnect the pilot line at the outlet of the pilot valve.
5. Check the pilot flame voltage on the HMI. The voltage reading should be 12V-15V DC .
The Flame LED on the
Flame Safety Controller should be illuminated too. A weak pilot flame can be caused by low gas pressure or a dirty pilot orifice.
Flame Rod
Clearance = 2.96”
6. To adjust the pilot flame, remove the cap from the pilot adjustment screw on the combination gas valve, refer to
Figure 27 . Increase the pilot gas flow by turning the screw counter-clockwise. Decrease the pilot gas flow by turning the screw clockwise. The flame signal voltage should read 12V-15V DC on the HMI under Service > Test Menu > Test Heating .
7. Once the pilot has been established, open the main manual gas shut-off valve downstream of the electronic valves. Check to make sure that the main gas valve opens and gas flows to the burner.
59
Sequence of Operation
To better understand the heater, it is easier to break the unit out into smaller individual systems. There are two main systems, a make-up air fan and a heater. The make-up air fan consists of a blower and motor.
The heater may be further broken down into two control systems, the Flame Safety Control (FSC) and the
Modulating Gas System (MGS). The burner mixes air with the gas (Natural or LP), which heats the air.
Flame Safety Control
The first system to understand is the Flame Safety
). The FSC is there only to monitor the flame, NOT to control the temperature. The FSC uses a flame rectification sensor mounted on the pilot assembly to detect the presence of flame in the burner.
Flame strength and presence can be measured at the FSC by reading the rectified flame signal. Use a DC voltage meter, attach meter leads to the test jacks (TP1 and TP2) on the top edge of the FSC. Flame is present when DC voltage reads between 6 and 18V DC. Ideal flame intensity produces a signal of 12V DC or higher. Flame signal may also be read on the HMI by entering Service > Variable Values > Inputs >
Flame Sensor .
The board monitors the flame signal voltage at connector J32 pin 6 (+) and 15 (-). The FSC receives an airflow signal from the MUA Board, which tells it whether there is proper airflow through the unit (not just any airflow, but proper airflow). Proper airflow occurs; for units with VAV Bypass Damper: airflow 0.15” wc to 0.65” wc. For units without VAV Bypass Damper: airflow 0.15” wc to 0.95” wc.
When the airflow through the heater produces differential pressure in this range, the FSC indicates so by illuminating the AIRFLOW LED. The FSC controls the opening of the redundant solenoid gas valves and the operation of the spark igniter to initiate a pilot flame upon start-up.
Figure 37 - Flame Safety Controller
TP1 TP2
OPR CTRL
AIR FLOW
PTFI
FLAME
ALARM
DC Voltage Flame Status
0 to 5V DC
6 to 11V DC
No Flame
Weak Flame
12 to 18V DC Strong Flame
4 5 3 6 7 8 A 2 S1 S2
60
The OPR CTRL LED indicates that there is power to the FSC. Next, the AIRFLOW LED will come on if there is proper airflow through the unit. Third, the unit will pause to purge any gases or combustible vapors before attempting flame ignition. Then, there is a Pilot Trial For Ignition (PTFI), and the PTFI LED comes on. During PTFI, the FSC opens the pilot gas valve and allows gas to flow to the pilot assembly. At the same moment, the spark igniter is started, causing the spark to ignite the pilot gas. When the flame rod sensor detects the flame, it turns on the FLAME LED, turns off the PTFI LED, and powers the modulating gas system. This is the system’s normal operating mode. The FSC continues to monitor the flame and airflow. Once this occurs, the unit is in the main flame cycle and thus powers the main gas valve and the modulating gas system. This is the normal operating mode. The FSC continues to monitor the flame and airflow.
The last LED on the FSC is the ALARM LED. The alarm will turn on when the FSC determines an unsafe condition has occurred and will not allow the unit to recycle for heat until it has properly been reset.
Anytime the FSC goes into “Alarm” mode, the issue must be diagnosed and corrected to avoid further lockouts after resetting. If the unit fails to light the first time, the unit will try one more time before locking out. This retry will not occur if the No FSC reset option is enabled. To begin troubleshooting, or to reset the
FSC, refer to “Resetting Unit” on page 81
.
Figure 38 - Proper Spark Gap
1/8” to 3/16”
Proper Spark
Gap
61
Static Pressure Sensor Installation
For indoor mounted units using pressure control, the A-306 kit (
Figure 39 ) should be used for sensing
outside pressure. Use the installation instructions shipped with the sensor kit for installation guidance.
Figure 39 - A-306 Sensor
Item Number
029
163
164
165
1
3
4
028
168
290
Description
10-32 x 1/2” Machine Screw (2)
10-32 Nut (4)
10-32 x 1-3/4” Machine Screw (2)
Antenna Clamp
Mounting Bracket
Pick Up Body
Static Pressure Plates
“O” Ring Seal
Hole Plug
Tubing - 50’
Component Check/Testing
Clogged Filter Switch (PS-10)
1. The vent tube should be connected to the low side port ( Figure 40
). A fault will occur when the switch senses a negative pressure.
2. If the “Clogged Filters” fault is active:
• Check the filters. If the filters are clogged or damaged, replace as needed. Check for any other obstructions in the unit.
• Verify the electrical connections are secure and tight. Verify vent tube is not pinched or damaged.
• When the unit is powered ON:
- There should be 24-28V AC at connector J13 pin 5 to ground. If the voltage reading is incorrect, check the wiring harness and voltage at the circuit board.
- There should be 0V AC at connector J13 pin 12 to ground. If there is voltage at pin 12, check the adjustment of the switch.
Clogged Filter Switch Field Adjustment
Follow these steps if performing a part replacement, or to calibrate the switch.
• Install the switch. Install the vent tube on the low side port.
• Install the electrical connections. Power the unit ON. Set dampers to 100% open for outdoor air.
Monitor the HMI screen.
• Use a screwdriver to turn the adjustment screw clockwise until it is completely seated in the switch.
Use material suitable to block 50-75% of the intake from the outside of the unit.
Turn the adjustment screw counter-clockwise in one turn increments (waiting 3 seconds per adjustment) until the “Clogged Filters” fault is active. Turn the adjustment screw a 1/4 to 1/2 turn clockwise until the fault is no longer active.
Figure 40 - Clogged Filter Switch
Low Side
(Front)
Normally Closed
Normally Open
Common
Adjustment Screw
NO
PS-10
C
BR
J13
5
PR
12
62
High Gas Pressure Switch (PS-03)
1. Turn the unit ON. Reset the lever on the switch. Gas pressure must be lower in the chamber for the reset latch to be set properly. Verify the high gas pressure switch is set to 12 in. w.c.
3. Verify the ON/OFF gas valve, and modulating valve are set properly. Refer to
.
4. Check for voltage:
• Back probe connector J13 pin 4 to ground. There should be 24-28V AC .
• Back probe connector J13 pin 11 to ground. There should be 24-28V AC .
- If the voltage reading is incorrect, check the wiring for an open or short circuit. If the wiring is correct, the switch has failed. Replace the switch.
- If the voltage reading is correct, and the switch reset corrected the fault, there may have been an intermittent fault.
Figure 41 - High Gas Pressure Switch
C
NO
NC
NC
PS-03
C
BL
4
Connector J13
11
Low Gas Pressure Switch (PS-04)
1. Turn the unit ON. Verify the inlet pressure gauge is reading the correct pressure.
• Natural gas - 7 in. w.c. – 14 in. w.c
.
• Propane - 11 in. w.c. – 14 in. w.c.
NOTE: If the reading is incorrect, contact the gas supply company .
2. Reset the lever on the switch. Gas pressure must be higher in the chamber for the reset latch to be set properly. If the reset did not work, continue with the next step.
3. Remove the cover. Make sure the wiring is set up for Normally Open (N.O.) contact (
).
4. Check for voltage:
• Back probe connector J13 pin 3 to ground. There should be 24-28V AC .
• Back probe connector J13 pin 10 to ground. There should be 0V AC .
- If the voltage reading is incorrect, check the wiring for an open or short circuit. If the wiring is correct, the switch has failed. Replace the switch.
- If the voltage reading is correct, and the switch reset corrected the fault, there may have been an intermittent fault.
Figure 42 - Low Gas Pressure Switch
C
NO
NC
C
PS-04
NO
BL
3
Connector J13
10
63
Network
NOTE: The board will reboot when altering certain factory settings.
Communication Module (Optional)
The Communication Module, PN: SCADA , is included in all CASlink equipped panels. It obtains operational data from various connected components. This communication wiring is either RS-485 shielded twisted pair wiring or RJ45 Cat 5 Ethernet wiring.
BACnet
BACnet IP or BACnet MS/TP (
) compatibility can be implemented with this package through a
Protocessor, which is a BTL listed embedded Gateway configured to give a Building Management System access to monitor and/or control a list of BACnet objects. The Protocessor is mounted and factory prewired inside the Electrical Control Panel (ECP). Field connections to the Building Management System
(BMS) are shown on wiring schematics.
The Protocessor is preconfigured at the factory to use the field protocol of the Building Management
System in the specific jobsite. BACnet objects can only be accessed through the specified port and protocol.
Figure 43 - BACnet
5
1
2
3
1. Status LEDs
• Green - Data Out
• Yellow - Data In
• Red - Power On
2. Power Supply 24V AC/DC
4
3. Cat 5 Cable to MUA Board.
4. Field RS485 Connection for BACnet MS/TP
5. Field Ethernet Connection for BACnet IP
64
Device Instance, MAC Address, Baud Rate
Some applications may require that the Protocessor have a specific Device Instance, the default device instance is 50,000. To change the Device Instance, you must access the Web Configurator by connecting a computer to the Ethernet port of the Protocessor. The computer used must be assigned a static IP address of 192.168.1.xxx and a subnet mask of 255.255.255.0.
To access the Web Configurator, type the IP address of the Protocessor in the URL of any web browser.
The default IP address of the Protocessor is 192.168.1.24. Once the landing page has loaded, if required, log in using “admin” for the username and password. If the default “admin” password does not work, the gateway should have a printed password on the module’s Ethernet port.
Go to the main configuration page, select “Configure” from the left-hand menu. Select “Profile
Configuration,” the following window shown in Figure 44
should appear.
The MAC address and Baud Rate, used by BACnet MTSP, are editable. The MAC address default is 127, and the Baud Rate default is 38400.
If any changes are made, click on the submit button for each individual change.
Each individual change will require the system to restart.
Figure 44 - Configuration Parameters Page
Configuration Parameters
Parameter Name Parameter Description
bac_device_id bac_mac_addr
BACnet Device Instance
This sets the BACnet device instance.
(1 - 4194303)
BACnet MSTP Mac Address
This sets the BACnet MSTP MAC address.
(1 - 127)
Value
50177
7
Submit
Submit bac_baud_rate
BACnet MSTP Baud Rate
This sets the BACnet MSTP baud rate.
(9600/19200/38400/76800)
76800
Submit bac_max_master
BACnet MSTP Max Master
This sets the BACnet MSTP max master.
(1 - 27)
127
Submit
65
Changing the IP Address
Some BACnet IP applications may require changing the IP address of the Protocessor. To change the IP address, go to the internal server by typing the default IP address of the Protocessor, 192.168.1.24, in the
URL field of any web browser. The computer used must have a static IP address of 192.168.1.xxx. The
appears. Click on the “Diagnostics and Debugging” button in the lower right corner.
Click on “Setup” from the left-hand side menu and select “Network Settings.” The window shown in
will appear. You can now modify the IP address to whatever is required in the application. Once the IP address has been modified, click on “Update IP Settings.”
Figure 45 - Network Settings Page
SMC sierra monitor
Navigation
CN0861 CaptiveAire v1.00a
About
Setup
File Transfer
Network Settings
Passwords
View
User Messages
Network Settings
IP Settings
Note
Updated settings only take effect after a System Restart. If the IP Address is changed you will need to direct your browser to the new IP Address after the System Restart.
N1 IP Address
N1 Netmask
N1 DHCP Client State
N1 DHCP Server State
Default Gateway
Domain Name Server1
Domain Name Server2
Cancel
192.168.1.24
255.255.255.0
DISABLED
DISABLED
192.168.1.1
0.0.0.0
0.0.0.0
Update IP Settings
MAC Address
N1 MAC Address: 00:50:4E:10:07:27
Home Help (F1) Contact Us System Restart
66
LonWorks
LonWorks compatibility ( Figure 46 ) can be implemented on control packages through the ProtoNode, a
LonMark certified external Gateway configured to give a Building Management System access to monitor and/or control a list of Network Variables. The ProtoNode is mounted and factory pre-wired inside the
Electrical Control Panel. Refer to schematics connections to the Building Management System are shown.
Figure 46 - LonWorks
Commissioning on a LonWorks Network
During the commissioning process by the LonWorks administrator (using a LonWorks Network
Management Tool), the user will be prompted to hit the Service Pin in the ProtoNode. This pin is located in the front face, and it can be pressed by inserting a small screwdriver and tilting it towards the LonWorks
Port. Refer to Figure 47 for location of the “Service Pin.”
If an XIF file is required, it can be obtained by following these steps:
1. Set your computer’s static IP address to 192.168.1.xxx with a subnet mask of 255.255.255.0.
2. Run a Cat 5 connection from the ProtoNode’s Ethernet port to your computer.
3. On any web browser’s URL field, type 192.168.1.24/fserver.xif.
The web browser should automatically download the fserver.xif file or let you save it on your computer.
Save it as fserver.xif.
Figure 47 - LonWorks Service Pin
SE
RVI
CE PIN
NOTE : Insert Small Screwdriver.
Tilt Toward LonWorks Port To
Activate Service Pin.
A0
A1
A2
67
DDC Control Points
Refer to
for DDC Notes - 1-5.
BACNET OBJECT NAME ID BACNET TYPE
DDCHeatCommand (1)
DDCCoolCommand1 (1)
DDCCoolCommand2 (1)
DDCCoolCommand3 (1)
DDCBlowerCommand (1)
DDCHeatModulation (1)
DDCOccupiedOverride (4)
SchedulingEnabled (4)
HeatTemperModeOcc (2)
HeatTemperModeUnocc (2)
CoolTemperModeOcc (2)
CoolTemperModeUnocc (2)
ActivateOnOcc (2)
ActivateOnUnocc (2)
SpaceHeatHyst (2)
IntakeHeatHyst (2)
SpaceCoolHyst (2)
IntakeCoolHyst (2)
EvapHyst (2)
BlowerModeOcc (2)
BlowerModeUnocc (2)
MixingBoxMode (2)
MixingBoxMinOAPercentOcc (2)
MixingBoxMinOAPercentUnocc (2)
MixingBoxMaxOAPercentOcc (2)
3
4
5
1 Binary Value (BV)
2 BV
6
24
25
7
12
13
18
19
20
21
22
14
15
16
17
10
11
8
9
23
BV
BV
BV
Analog Value
(AV)
BV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
BV
AV
AV
AV
AV nviDDCBlow/nvoDDCBlow nviDDCModHeat/nvoDDCModHeat nviDDCOccOvrrd/nvoDDCOccOvrrd nviSchedEnabled/nvoSchedEnabled nviHeatModeOcc/nvoHeatModeOcc nviHeatModeUnocc/nvoHeatModeUnocc nviCoolModeOcc/nvoCoolModeOcc nviCoolModeUnocc/nvoCoolModeUnocc nviActOnOcc/nvoActOnOcc nviActOnUnoc/nvoActOnUnoc nviSpaceHeatHyst/nvoSpaceHeatHyst nviInHeatHyst/nvoInHeatHyst nviSpaceCoolHyst/nvoSpaceCoolHyst nviInCoolHyst/nvoInCoolHyst nviEvapHyst/nvoEvapHyst nviBlowModeOcc/nvoBlowModeOcc nviBlowModeUnoc/nvoBlowModeUnoc nviMixingBoxMode/nvoMixingBoxMode nviMBMinOAPerOcc/nvoMBMinOAPOcc
AV
AV
AV
AV
LON SNVT NAME nviDDCHeat/nvoDDCHeat nviDDCCool1/nvoDDCCool1 nviDDCCool2/nvoDDCCool2 nviDDCCool3/nvoDDCCool3 nviMBMinOAPerUn/nvoMBMinOAPUnoc nviMBMaxOAPerOcc/nvoMBMaxOAPOcc nviMBMaxOAPerUn/nvoMBMaxOAPUnoc nviMBMinVoltsOcc/nvoMBMinOAVOcc
MixingBoxMaxOAPercentUnocc (2)
MixingBoxMinVoltsOcc (2)
MixingBoxMinVoltsUnocc (2)
MixingBoxMaxVoltsOcc (2)
MixingBoxMaxVoltsUnocc (2)
BlowerVFDMinFreqOcc (2)
BlowerVFDMinFreqUnocc (2)
BlowerVFDMaxFreqOcc (2)
BlowerVFDMaxFreqUnocc (2)
BlowerPWMMinOcc (2)
BlowerPWMMinUnocc (2)
BlowerPWMMaxOcc (2)
BlowerPWMMaxUnocc (2)
IntakeHeatOccSP (3)
IntakeHeatUnoccSP (3)
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
28
29
30
35
36
37
38
31
32
33
34
39
40
26
27 nviMBMinVoltsUn/nvoMBMinOAVUnoc nviMBMaxVoltsOcc/nvoMBMaxOAVOcc nviMBMaxVoltsUn/nvoMBMaxOAVUnoc nviVFDMinFreqOcc/nvoVFDMinFreqOcc nviVFDMinFUnocc/nvoVFDMinFUnocc nviVFDMaxFreqOcc/nvoVFDMaxFreqOcc nviVFDMaxFUnocc/nvoVFDMaxFUnocc nviPWMMinOcc/nvoPWMMinOcc nviPWMMinUnocc/nvoPWMMinUnocc nviPWMMaxOcc/nvoPWMMaxOcc nviPWMMaxUnocc/nvoPWMMaxUnocc nviInHeatOccSP/nvoInHeatOccSP nviInHeatUnocSP/nvoInHeatUnocSP
FUNCTION
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Modbus DESCRIPTION
10000
10001
10002
10003
10004
10005
10006
Heating command, requires heat tempering mode = DDC
Cooling stage 1 command, requires cool tempering mode = DDC
Cooling stage 2 command, requires cool tempering mode = DDC
Cooling stage 3 command, requires cool tempering mode = DDC
Blower command, requires both heat and cool tempering modes = DDC
Heat modulation signal, 0-10V. 0V = low fire and 10V = high fire.
Requires heat tempering mode = DDC
Occupied override command, requires
SchedulingEnabled = ON (1)
Enable scheduling 15016
15055 Heat tempering mode during occupied time
15056 Heat tempering mode during unoccupied time
15057 Cool tempering mode during occupied time
15058 Cool tempering mode during unoccupied time
15059 "Activate based on" during occupied time
15060
15064
15065
15072
15073
15074
15081
15082
15096
15099
15100
15101
15102
15156
15157
15158
"Activate based on" during unoccupied time
Space Heating Hysteresis
Intake Heating Hysteresis
Space Cooling Hysteresis
Intake Cooling Hysteresis
Evap Cooling Hysteresis
Blower mode during occupied times
Blower mode during unoccupied times
Mixing box mode
Min occupied outdoor air percent when mixing box mode = outdoor air percent
Min unoccupied outdoor air percent when mixing box mode = outdoor air percent
Max occupied outdoor air percent when mixing box mode = outdoor air percent
Max unoccupied outdoor air percent when mixing box mode = outdoor air percent
Min occupied mixing box voltage when mixing box mode = manual
Min unoccupied mixing box voltage when mixing box mode = manual
Max occupied mixing box voltage when mixing box mode = manual
15159
Max unoccupied mixing box voltage when mixing box mode = manual
15085 Min blower VFD Frequency when occupied
15086 Min blower VFD Frequency when unoccupied
15087 Max blower VFD Frequency when occupied
15088 Max blower VFD Frequency when unoccupied
15089
15090
Min blower ECM speed when occupied
Min blower ECM speed when unoccupied
15091
15092
16000
16001
Max blower ECM speed when occupied
Max blower ECM speed when unoccupied
Intake Heating Occupied Setpoint
Intake Heating Unoccupied Setpoint
68
BACNET OBJECT NAME
SpaceHeatOccSP (3)
SpaceHeatUnoccSP (3)
MinDischargeHeatOccSP (3)
MinDischargeHeatUnoccSP (3)
DischargeHeatOccSP (3)
DischargeHeatUnoccSP (3)
MaxDischargeHeatOccSP (3)
MaxDischargeHeatUnoccSP (3)
IntakeCoolOccSP (3)
IntakeCoolUnoccSP (3)
SpaceCoolOccSP (3)
SpaceCoolUnoccSP (3)
IntakeCoolStagingDiffOcc (3)
IntakeCoolStagingDiffUnocc (3)
SpaceCoolStagingDiffOcc (3)
SpaceCoolStagingDiffUnocc (3)
RoomOverrideOccSP (3)
RoomOverrideUnoccSP (3)
OAEvapCoolOccSP (3)
OAEvapCoolUnoccSP (3)
ScheduleSundayAStart (4)
ScheduleSundayAEnd (4)
ScheduleSundayBStart (4)
ScheduleSundayBEnd (4)
ScheduleSundayCStart (4)
ScheduleSundayCEnd (4)
ScheduleMondayAStart (4)
ScheduleMondayAEnd (4)
ScheduleMondayBStart (4)
ScheduleMondayBEnd (4)
ScheduleMondayCStart (4)
ScheduleMondayCEnd (4)
ScheduleTuesdayAStart (4)
ScheduleTuesdayAEnd (4)
ScheduleTuesdayBStart (4)
ScheduleTuesdayBEnd (4)
ScheduleTuesdayCStart (4)
ScheduleTuesdayCEnd (4)
ScheduleWednesdayAStart (4)
ScheduleWednesdayAEnd (4)
ScheduleWednesdayBStart (4)
ScheduleWednesdayBEnd (4)
ScheduleWednesdayCStart (4)
ScheduleWednesdayCEnd (4)
ScheduleThursdayAStart (4)
ScheduleThursdayAEnd (4)
47
48
49
50
51
52
53
54
45
46
55
56
81
82
83
84
85
86
77
78
79
80
73
74
75
76
69
70
71
72
65
66
67
68
61
62
63
64
57
58
59
60
ID
41
42
43
BACNET TYPE
AV
AV
AV
LON SNVT NAME nviSpHeatOccSP/nvoSpHeatOccSP nviSpHeatUnocSP/nvoSpHeatUnocSP nviMinDHeatOccSP/nvoMinDHeatOccSP
44 AV nviMinDHeatUnoSP/nvoMinDHeatUnoSP
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV nviDisHeatOccSP/nvoDisHeatOccSP nviDisHeatUnocSP/nvoDisHeatUnocSP nviMaxDHeatOccSP/nvoMaxDHeatOccSP nviMaxDHeatUnoSP/nvoMaxDHeatUnoSP nviInCoolOccSP/nvoInCoolOccSP nviInCoolUnocSP/nvoInCoolUnocSP nviSpCoolOccSP/nvoSpCoolOccSP nviSpCoolUnocSP/nvoSpCoolUnocSP nviInCoolStDifOc/nvoInCoolStDifOc nviInCoolStDifUn/nvoInCoolStDifUn nviSpCoolStDifOc/nvoSpCoolStDifOc nviSpCoolStDifUn/nvoSpCoolStDifUn nviRoomOvOccSP/nvoRoomOvOccSP nviRoomOvUnocSP/nvoRoomOvUnocSP nviOAEvaCoolOCSP/nvoOAEvaCoolOCSP nviOAEvaCoolUnSP/nvoOAEvaCoolUnSP nviSundayAStart/nvoSundayAStart nviSundayAEnd/nvoSundayAEnd nviSundayBStart/nvoSundayBStart nviSundayBEnd/nvoSundayBEnd nviSundayCStart/nvoSundayCStart nviSundayCEnd/nvoSundayCEnd nviMondayAStart/nvoMondayAStart nviMondayAEnd/nvoMondayAEnd nviMondayBStart/nvoMondayBStart nviMondayBEnd/nvoMondayBEnd nviMondayCStart/nvoMondayCStart nviMondayCEnd/nvoMondayCEnd nviTuesdayAStart/nvoTuesdayAStart nviTuesdayAEnd/nvoTuesdayAEnd nviTuesdayBStart/nvoTuesdayBStart nviTuesdayBEnd/nvoTuesdayBEnd nviTuesdayCStart/nvoTuesdayCStart nviTuesdayCEnd/nvoTuesdayCEnd nviWedAStart/nvoWedAStart nviWedAEnd/nvoWedAEnd nviWedBStart/nvoWedBStart nviWedBEnd/nvoWedBEnd nviWedCStart/nvoWedCStart nviWedCEnd/nvoWedCEnd nviThursAStart/nvoThursAStart nviThursAEnd/nvoThursAEnd
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
FUNCTION
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
16057
16058
16059
16060
16061
16062
16049
16050
16051
16052
16053
16054
16055
16056
16041
16042
16043
16044
16045
16046
16047
16048
16024
16025
16026
16027
16037
16038
16039
16040
Modbus
16002
16003
16004
16005
16006
16007
16008
16009
16010
16011
16012
16013
16020
16021
16022
16023
DESCRIPTION
Space Heating Occupied Setpoint
Space Heating Unoccupied Setpoint
Min Discharge Heating when occupied, relevant only if heat tempering mode = space
Min Discharge Heating when unoccupied, relevant only if heat tempering mode = space
Discharge heating setpoint when occupied, requires heat tempering mode = discharge
Discharge heating setpoint when unoccupied, requires heat tempering mode = discharge
Max Discharge Heating when occupied, relevant only if heat tempering mode = space
Max Discharge Heating when unoccupied, relevant only if heat tempering mode = space
Intake Cooling Occupied Setpoint
Intake Cooling Unoccupied Setpoint
Space Cooling Occupied Setpoint
Space Cooling Unoccupied Setpoint
Intake Cooling Stage Differential Setpoint when occupied
Intake Cooling Stage Differential Setpoint when unoccupied
Space Cooling Stage Differential Setpoint when occupied
Space Cooling Stage Differential Setpoint when unoccupied
Room Override Occupied Setpoint
Room Override Unoccupied Setpoint
Outdoor air evap cooling occupied setpoint
Outdoor air evap cooling unoccupied setpoint
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
69
BACNET OBJECT NAME
ScheduleThursdayBStart (4)
ScheduleThursdayBEnd (4)
ScheduleThursdayCStart (4)
ScheduleThursdayCEnd (4)
ScheduleFridayAStart (4)
ScheduleFridayAEnd (4)
ScheduleFridayBStart (4)
ScheduleFridayBEnd
ScheduleFridayCStart (4)
ScheduleFridayCEnd (4)
ScheduleSaturdayAStart (4)
ScheduleSaturdayAEnd (4)
ScheduleSaturdayBStart (4)
ScheduleSaturdayBEnd (4)
ScheduleSaturdayCStart (4)
ScheduleSaturdayCEnd (4)
BlowerManualFreqOcc (2)
BlowerManualFreqUnocc (2)
BlowerManualPwmRateOcc (2)
BlowerManualPwmRateUnocc (2)
MixingBoxManualOAOcc (2)
MixingBoxManualOAUnocc (2)
MixingBoxManualVoltsOcc (2)
MixingBoxManualVoltsUnocc (2)
DryModeDischTempSpOcc (3)
DryModeDischTempSpUnocc (3)
DryModeDewPointSP
DryModeOAPercent
StaticPressureLowOcc (2)
StaticPressureLowUnocc (2)
StaticPressureHighOcc (2)
StaticPressureHighUnocc (2)
OutdoorStatTemp (5)
ReturnStatTemp (5)
DischargeStatTemp (5)
IntakeStatTemp (5)
SpaceStatTemp (5)
Hmi0Temp (5)
Hmi1Temp (5)
Hmi2Temp (5)
Hmi3Temp (5)
Hmi4Temp (5)
IntakeRh (5)
SpaceRh (5)
108
109
110
111
112
113
114
115
116
117
118
123
124
125
126
119
120
121
122
127
128
129
130
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
BACNET TYPE
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
AV
ID
99
100
101
102
95
96
97
98
91
92
93
94
87
88
89
90
103
LON SNVT NAME nviThursBStart/nvoThursBStart nviThursBEnd/nvoThursBEnd nviThursCStart/nvoThursCStart nviThursCEnd/nvoThursCEnd nviFridayAStart/nvoFridayAStart nviFridayAEnd/nvoFridayAEnd nviFridayBStart/nvoFridayBStart nviFridayBEnd/nvoFridayBEnd nviFridayCStart/nvoFridayCStart nviFridayCEnd/nvoFridayCEnd nviSatAStart/nvoSatAStart nviSatAEnd/nvoSatAEnd nviSatBStart/nvoSatBStart nviSatBEnd/nvoSatBEnd nviSatCStart/nvoSatCStart nviSatCEnd/nvoSatCEnd nviBlowManFreqOc/nvoBlowManFreqOc
104 AV nviBlowManFreqUn/nvoBlowManFreqUn
105
106
AV
AV nviBlowManPwmOc/nvoBlowManPwmOc nviBlowManPwmUn/nvoBlowManPwmUn
107 AV nviMixBoxManOAOc/nvoMixBoxManOAOc nviMixBoxManOAUn/nvoMixBoxManOAUn nviMixBoxManVOc/nvoMixBoxManVOc nviMixBoxManVUn/nvoMixBoxManVUn nviDryDischTSpOc/nvoDryDischTSpOc nviDryDischTSpUn/nvoDryDischTSpUn nviDryDewSp/nvoDryDewSp nviDryOAPer/nviDryOAPer nviStatPLowOcc/nviStatPLowOcc nviStatPLowUnoc/nviStatPLowUnoc nviStatPHighOcc/nviStatPHighOcc nviStatPHighUnoc/nviStatPHighUnoc nvoOutdoorTemp nvoReturnTemp nvoDischargeTemp nvoIntakeTemp nvoSpaceTemp nvoHmi0Temp nvoHmi1Temp nvoHmi2Temp nvoHmi3Temp nvoHmi4Temp nvoIntakeRh nvoSpaceRh
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
FUNCTION
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
16096
16097
9057
9058
9059
9060
9061
9063
9064
9065
9066
9067
9078
9079
Modbus
16071
16072
16073
16074
16075
16076
16077
16078
16063
16064
16065
16066
16067
16068
16069
16070
16079
16080
16081
16082
16084
16085
16093
16094
16101
16102
15249
16122
16095
16098
DESCRIPTION
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
Daily schedule start/end time in minutes
VFD frequency when occupied, requires blower control = VFD manual
VFD frequency when unoccupied, requires blower control = VFD manual
ECM speed when occupied, requires blower control = ECM manual
ECM speed when unoccupied, requires blower control = ECM manual
Mixing Box Outdoor Air Percent during occupied times, requires mixing box mode = outdoor air percent
Mixing Box Outdoor Air Percent during unoccupied times, requires mixing box mode = outdoor air percent
Mixing Box damper voltage during occupied times, requires mixing box mode = manual
Mixing Box damper voltage during unoccupied times, requires mixing box mode = manual
Dry mode discharge temperature setpoint when occupied
Dry mode discharge temperature setpoint when unoccupied
Dry mode dew point setpoint
Dry mode outdoor air percentage
Static Pressure Low setpoint when occupied
Static Pressure Low setpoint when unoccupied
Static Pressure High setpoint when occupied
Static Pressure High setpoint when unoccupied
Outdoor temperature
Return temperature
Discharge temperature
Intake temperature
Space temperature (thermistor)
Unit HMI temperature
Remote HMI 1 temperature
Remote HMI 2 temperature
Remote HMI 3 temperature
Remote HMI 4 temperature
Intake relative humidity
Space relative humidity
70
BACNET OBJECT NAME
AdjustableDamperPosition (2)
Hmi0Rh (5)
Hmi1Rh (5)
Hmi2Rh (5)
Hmi3Rh (5)
Hmi4Rh (5)
ActiveFault0Id (5)
ActiveFault1Id (5)
ActiveFault2Id (5)
ActiveFault3Id (5)
ActiveFault4Id (5)
ActiveFault5Id (5)
CurrentHvacState (5)
OccupiedbySchedule (4)
OccupiedbyInput (5)
OccupiedbyDDC (5)
OccupiedbyHMIOverride (5)
CurrentOccupiedStatus (5)
CalculatedAverageSpaceTemp (5)
BlowerVFDFrequency (5)
BlowerVFDCurrent (5)
BlowerVFDPower (5)
CalculatedAverageRh (5)
GasValveOutput (5)
CFMReading (5)
StaticPressure (5)
BACNET TYPE
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
ID
135
136
137
138
131
132
133
134
139
140
141
142
143
144
145
146
147
148
154
155
156
149
150
151
152
153
LON SNVT NAME nvoDampPosition nvoHmi0Rh nvoHmi1Rh nvoHmi2Rh nvoHmi3Rh nvoHmi4Rh nvoActiveFault0 nvoActiveFault1 nvoActiveFault2 nvoActiveFault3 nvoActiveFault4 nvoActiveFault5 nvoCurrentState nvoOccbySchedule nvoOccbyInput nvoOccbyDDC nvoOccbyHMI nvoOccStatus nvoAvgSpaceTemp nvoBlowVFDFreq nvoBlowVFDAmps nvoBlowVFDPower nvoAvgRh nvoGasOutput nvoCFMReading nvoStaticPress
FUNCTION
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
2083
2125
2132
2133
2134
2140
Modbus
9085
9097
9098
9099
9100
9101
30501
30502
30503
30504
30505
30506
2144
2146
2150
2152
2190
1045
2207
2224
DESCRIPTION
Mixing Box Damper signal
Unit HMI relative humidity
Remote HMI 1 relative humidity
Remote HMI 2 relative humidity
Remote HMI 3 relative humidity
Remote HMI 4 relative humidity
Active Fault Code (see fault code table)
Active Fault Code (see fault code table)
Active Fault Code (see fault code table)
Active Fault Code (see fault code table)
Active Fault Code (see fault code table)
Active Fault Code (see fault code table)
HVAC State (Idle = 0, Blower = 1,
Heating = 2, Cooling = 3)
Occupied due to the schedule
Occupied due to hardware input
Occupied due to DDC command
Occupied due to HMI command
Occupancy status, occupied = 1, unoccupied = 0
Average space temperature
Blower VFD frequency
Blower VFD current
Blower VFD power
Average space relative humidity
Controller output to the modulating gas valve.
0% = Low Fire, 100% = High Fire
Fan CFM Reading
Static Pressure
71
DDC Notes
(1) Full Control Points
• Use only if Heating and/or Cooling tempering mode has been set to “DDC” through the unit’s HMI.
• Setting the Heating and Cooling modes to “DDC” disables temperature based activation of these functions. The preferred heating and cooling activation method are to use space and/or intake temperatures along with unit set points.
• Heating and Cooling cannot be called for at the same time.
• The Fan Control point will only work if the heating or cooling mode is set to DDC.
(2) Factory Setting Points
• Avoid writing to these on a regular basis.
• The Allow Schedule point tells the unit whether scheduling is allowed or not. It is NOT an occupancy command.
• Unit Status: 0 = Idle, 1 = Blower, 2 = Heating, 3 = Cooling
• OA Mode: 0 = Off, 1 = Manual, 2 = 2 Position, 3 = OA Percent, 4 = Analog Ctrl, 5 = PS, 6 = 100% OA, 7 = Modes
• Occupancy Status: 0 = OFF, 1 = ON
• Heat Tempering Mode Occ: 0 = Discharge, 1 = Space, 2 = BAS, 3 = DDC
• Activate Based ON Occ: 0 = Intake, 1 = Space, 2 = Both, 3 = Either, 4 = Stat
• Cool Tempering Mode Occ: 0 = Intake, 1 = Space, 2 = BAS, 3 = DDC
• Heat Tempering Mode Unocc: 0 = Discharge, 1 = Space, 2 = BAS, 3 = DDC
• Activate Based ON Unocc: 0 = Intake, 1 = Space, 2 = Both, 3 = Either, 4 = Stat
• Cool Tempering Mode Unocc: 0 = Intake, 1 = Space, 2 = BAS, 3 = DDC
• Blower Mode Occ: 0 = Auto, 1 = OFF, 2 = ON
• Blower Mode Unocc: 0 = Auto, 1 = OFF, 2 = ON
(3) Temperature Set Points
• The preferred method for DDC control is through set point manipulation. Use the set points shown above along with the
“DDC Occupied Override” point in the Runtime settings section to control the blower and to determine when to heat or cool.
• Temperatures can be in degrees F or degrees C, depending on the “Temp Units” point in the factory settings.
(4) On-Board Scheduling
• Values are based on minutes in a day. 1439 minutes = 11:59 PM, 0 = 12:00AM.
• The end value of the A set or B set must be greater than or equal to the start value in that set (A start <= A end, B start
<= B end).
• The B set must be greater than the A set and cannot overlap it (A end <= B start).
• The value 1440 is a special value meaning that there is no scheduling for that set. Both the start and end value of a set must have the value for it to be valid. If the A set has this value, the B set must also have this value (no scheduling for the entire day).
NOTE: The preferred method for a BMS to control occupancy is through the “DDC Occupied Override” binary point. The “On-Board Schedule” points should all be set to unoccupied (1440) if the “DDC Occupied Override” is used.
(5) Sensor Values and Alerts
• For Alert Codes 0-5, refer to “DDC Fault List” on page 73 .
72
DDC Fault List
Fault
Description
None
FireDetect
SmokeDetect
SupplyOverload
ExhaustOverload
MasterRomCrc
AuxRomCrc
FlameProving
IntakeFirestat
DischargeFirestat
Freezestat
HighTempLimit
FireEyeAlarm
GasHighPs
GasLowPs
AuxGasHighPs
AuxGasLowPs
CoAlarm
EvapWaterPs
EvapFloat
DxFloat
FurnaceFloat
BlowerVfdMbComm
DoorInterlock
MuaToAuxMbComm
IntakeDamperEnd
DischargeDamperEnd
BlowerAirProving
CloggedFilter
MissingSensorIntake
BrokenSensorIntake
MissingSensorDischarge
BrokenSensorDischarge
MissingSensorSpace
BrokenSensorSpace
MissingSensorOutsideAir
BrokenSensorOutsideAir
MissingSensorReturn
26
27
28
29
22
23
24
18
19
20
21
14
15
16
17
34
35
36
30
31
32
33
9
10
12
13
7
8
5
6
Fault
Number
0
1
2
3
4
37
38
39
Fault
Description
BrokenSensorReturn
RtcTempSensor
AuxRtcTempSensor
Hmi0TempInvalid
Hmi1TempInvalid
Hmi2TempInvalid
Hmi3TempInvalid
Hmi4TempInvalid
ProofOfClosure
LowFlameVoltage
SpPressureLowLimit
SpPressureHighLimit
SpaceRh
IntakeRh
DischargeRh
HmiMbComm0
HmiMbComm1
HmiMbComm2
HmiMbComm3
HmiMbComm4
Co2ShutdownRequired
Co2Override
Vfd571IgbtTemp
Vfd571Output
Vfd571Ground
Vfd571Temp
Vfd571FlyingStart
Vfd571HighDcBus
Vfd571LowDcBus
Vfd571Overload
Vfd571Oem
Vfd571IllegalSetup
Vfd571DynamicBrake
Vfd571PhaseLost
Vfd571External
Vfd571Control
Vfd571Start
Vfd571IncompatParamSet
122
127
128
129
130
131
132
94
95
96
121
87
88
92
93
133
134
135
136
137
138
139
57
58
59
86
53
54
55
56
Fault
Number
40
49
50
51
52
140
141
142
Fault
Description
Vfd571EpmHw
Vfd571Internal1
Vfd571Internal2
Vfd571Internal3
Vfd571Internal4
Vfd571Internal5
Vfd571Internal6
Vfd571Internal7
Vfd571Internal8
Vfd571Personality
Vfd571Internal10
Vfd571RemoteKeypadLost
Vfd571AssertionLevel
Vfd571Internal11
Vfd571Internal12
Vfd571Internal13
Vfd571Internal14
Vfd571CommModuleFail
Vfd571Network
Vfd571Network1
Vfd571Network2
Vfd571Network3
Vfd571Network4
Vfd571Network5
Vfd571Network6
Vfd571Network7
Vfd571Network8
Vfd571Network9
ReturnRh
OutsideRh
Co2Threshold
ErvDoorInterlock
ExternalInterlockActive
ExhFanContactor1Prv
ExhFanContactor2Prv
164
165
166
167
168
169
170
160
161
162
163
156
157
158
159
171
173
174
175
176
182
183
152
153
154
155
148
149
150
151
Fault
Number
143
144
145
146
147
73
TROUBLESHOOTING
The following table lists causes and corrective actions for possible problems with the fan units. Review this list prior to consulting manufacturer. The following table lists causes and corrective actions for possible problems with the fan units. Review this list before consulting manufacturer.
Airflow Troubleshooting Chart
Problem Potential Cause Corrective Action
Fan Inoperative
Motor Overload
Insufficient Airflow
Blown fuse/Open circuit breaker
Disconnect switch in “OFF” position
Incorrect wiring to motor
Broken fan belt
Motor starter overloaded
Incorrect fan rotation
Fan speed is too high
Incorrect wiring to motor
Overload in starter set too low
Motor HP too low
Duct static pressure lower than design
Incorrect fan rotation
Poor outlet conditions
Intake damper not fully open
Duct static pressure higher than design
Blower speed too low
Supply grills or registers closed
Dirty/clogged filters
Check amperage.
Check fuse, replace if needed.
Check circuit breaker.
Place switch to the “ON” position.
Inspect motor wiring. Verify connections with wiring diagram located on fan motor.
Replace belt.
Check amperage.
Reset starter.
Verify that the fan is rotating in the direction shown on rotation label.
Reduce fan RPM.
Inspect motor wiring. Verify connections with wiring diagram located on fan motor.
Set overload to motor’s FLA value.
Determine if HP is sufficient for job.
Reduce fan RPM.
Verify that the fan is rotating in the direction shown on rotation label.
Check duct and connections. There should be a straight duct connection to the outlet.
Inspect damper linkage. If the linkage is damaged, replace damper motor.
Check ductwork. Adjust/resize to eliminate or reduce duct losses.
Increase fan RPM. Do not overload motor.
Open/Adjust.
Clean filters. Replace filters if they cannot be cleaned or are damaged.
Adjust belt tension.
Reduce fan RPM.
Install filters.
Reduce fan RPM.
Excessive Airflow
Belt slippage
Blower speed too high
Filters not installed
Duct static pressure lower than design
Excessive Vibration and
Noise
Damaged/Unbalanced wheel Replace wheel.
Misaligned pulleys
Fan is operating in unstable region of fan curve
Align pulleys.
Refer to performance curve for fan.
Bearings need lubrication/Damaged bearing Lubricate bearings, replace if damaged.
Fan speed is too high
Dirty/oily belt(s)
Belt(s) too loose
Worn belt(s)
Reduce fan RPM.
Clean belt(s).
Adjust, replace if necessary.
Replace belt(s).
74
Burner Troubleshooting
Problem
Pilot Does Not Light/Stay Lit
Main Burner Does Not Light
(Pilot is lit)
Not Enough Heat
Too much heat
Potential Cause Corrective Action
Main gas is off
Air in gas line
Dirt in pilot orifice
Gas pressure out of range
Pilot valve is off
Leak at pilot orifice
Excessive drafts
Safety device has cut power
Dirty flame sensor
Defective flame rod
No call for heat
No spark at igniter
Open main gas valve.
Purge gas line.
Clean orifice with compressed air.
Adjust to proper gas pressure.
Turn pilot valve on.
Tighten pilot orifice.
Redirect draft away from unit.
Check limits and airflow sensor.
Clean flame sensor.
Replace flame rod.
Adjust heat set point.
Check wiring, sensor, and ignition controller. Check spark gap, refer
.
Defective valve
Loose valve wiring
Replace combination valve.
Check wiring to valve.
Shut-off valve closed Open shut-off valve.
Defective flame safety controller Replace flame safety controller.
Pilot fails as main gas valve opens, and main gas flows.
Main gas pressure too low
Plug the first burner port next to the pilot gas tube with burner cement.
Increase main gas pressure - do not exceed 5 PSI.
Too much airflow
Burner undersized
Decrease airflow if possible.
Check design conditions.
Gas controls not wired properly Check wiring.
Heat set point too low Increase heat set point.
Faulty HMI Sensor Replace HMI.
Faulty Discharge Sensor
Unit locked into low fire
Check wiring. Replace sensor.
Check wiring.
Defective modulating gas valve Check/replace modulating valve.
Heat set point too high
Unit locked into high fire
Faulty HMI Sensor
Faulty Discharge Sensor
Decrease heat set point.
Check wiring.
Replace HMI.
Check wiring. Replace sensor.
75
Flame Safety Service
Troubleshooting Tips
• Verify that there is a solid earth ground wire brought to the panel that the Fireye base is mounted to.
• In a rectification system, verify that terminal S1 is connected to an earth ground connection. Confirm that the flame rod is aligned so it does not droop near the ignition spark.
• Confirm that there is no measurable voltage present between the ground screw and terminal 2
(neutral).
• Confirm that the 120 volt AC supply has its neutral leg earth grounded at the supply, (floating isolation transformers can cause problems).
• Confirm that the ignition transformer’s secondary winding is connected to an earth ground connection.
The grounding method is usually through the transformer case. Dirt, paint, loose mounting hardware, etc., can all be factors.
• There may be a problem with transients in the main power supply. If you think this may be the problem, you may want to run a ground wire directly from the pilot assembly back to the electrical panel where the Fireye control is mounted.
Situation #1 - Normal Lockout - If there is NO HEAT. Check OPR CTRL (Operator Control) and ALARM
LED are on. Use the HMI to check flame voltage, there should be 6-18V. Shut the gas supply valve off.
Wait 5 minutes. Reset control.
1. Is there a call for heat? If there is a call for heat, go to step 2. If there is not a call for heat, adjust set points to make the unit call for heat.
2. Did the OPR CTRL LED come on? If the LED did come on, go to step 3. If the LED did not come on, go to Situation #2.
3. Did the airflow LED come on? If the LED did come on, go to step 4. If the LED did not come on, go to
Situation #3.
4. Did the PTFI (Pilot Trial For Ignition Period) LED come on after a suitable delay? If the LED comes on after a suitable delay, go to step 5. If the LED did not come on after a suitable delay, replace the FSC-
01 board.
5. Did the FLAME LED come on? If the flame LED did come on, go to step 6. If the LED does not come on, go to step 8.
6. Did the PTFI LED go off after a suitable delay? If the LED did go off after a suitable delay, go to step 7.
If the LED did not go off after a suitable delay, replace the FSC-01 board.
7. Is the system running? If the system is running, the reset was successful. If the system is not running, repeat Situation #1.
8. Check for a 120V AC across the following pins:
• Pins 2 and 3 (Pilot voltage)
• Pins 2 and 4 (Ignition voltage)
• Pins 2 and 5 (Main voltage)
If the voltage is incorrect, check wiring and connections to the FSC-01 board. If the connections and wiring are correct, replace the FSC-01 board. If the voltage is correct, go to step 9.
9. Check the flame on the burner. If the flame is weak, make proper burner adjustment. If the flame is strong, go to step 10.
CAUTION: When powered on, depending on voltage connection, there may be 260V AC across S1, S2;
560V AC across S1, S2.
10. Verify that the S1 and S2 wiring connections are secure and tight. Check for AC voltage across pins S1 and S2. If the voltage is correct, replace the FR-01 (Flame Rod). If the voltage is incorrect, replace
FSC-01 board.
76
Situation #2 - No Heat, no LED’s on.
1. Check for 120V AC across the following pins:
• Pins 1 and 2
• Pins 2 and 7
If the voltage reading is correct, go to step 2. If the voltage reading is incorrect, go to step 3.
2. Check wiring to the FSC-01 board. Check for loose or broken wires. If damaged wiring or loose connections are found, repair or replace. If the wiring and connections are okay, replace the FSC-01 board.
3. Check breaker or FSC-01 board fuse. If the breaker tripped, reset breaker. If the fuse is blown, replace the FSC-01 board. If there are no faults found with the breaker or fuse, check system wiring.
Situation #3 - No Heat, check OPR CTRL (Operator Control) LED is on.
1. Check for 120V AC across the following pins: Pins 2 and 8
If the voltage reading is correct, go to step 2. If the voltage reading is incorrect, replace the FSC-01 board.
2. Is the blower on? If the blower is on, go to step 3. If the blower is not on, check the blower system.
3. Check for 120V AC across the following pins: Pins 2 and 6
If the voltage reading is correct, replace the FSC-01 board. If the voltage reading is incorrect, check the airflow sensor and tubing.
Situation #4 - No Heat, check OPR CTRL (Operator Control), FLAME ON and ALARM LED are on.
1. Is the flame present in the burner? If the flame is not present, go to step 2. If the flame is present, check the burner’s wiring, and check the gas valves.
2. Is the flame LED on? If the flame LED is not on, refer to Situation #1. If the flame LED is on, replace the FSC-01 board.
77
HMI Fault Codes
Fault
Fire Detect
Smoke Detect
Supply Overload
Exhaust Overload
Master ROM CRC
Flame Lockout
Potential Cause
The board is receiving an input from the fire detector.
The board is receiving an input from the smoke detector.
Motor overload has tripped.
Software mismatch.
The Flame Safety Control (FSC) verifies that airflow is sensed by the airflow sensor.
Corrective Action
Possible fire present.
Check wiring. Repair broken or loose wiring connections.
Faulty fire detector, replace fire detector.
Verify the smoke detector functionality.
Check wiring. Repair broken or loose wiring connections.
Faulty smoke detector, replace smoke detector.
Check motor for debris.
Check contactor/motor wiring connections.
Check overload reset button.
Check overload amperage setting.
Check motor bearings.
Contact technical support.
Verify spark gap, refer to Figure 38 on page 61 .
Faulty flame rod.
Max FSC Cycles Fault FSC cycles on and off greater than 20 times
Intake Firestat
Discharge Firestat
Freezestat in 60 minutes.
Intake temperature exceeds the firestat set point.
The discharge temperature was below the freezestat temperature set point for the duration of the freezestat timer set point.
Faulty FSC, replace FSC.
Verify heating activation, check for faulty
Space/Intake/Discharge sensor.
Inspect intake area of the unit for unexpected heat source.
Reset fault with HMI.
Discharge temperature exceed the firestat set point.
Check for faulty regulators or modulating valves.
Reset fault with HMI.
Inspect discharge area of the unit for unexpected heat source.
Check gas pressure.
Check for proper burner firing.
Check discharge sensor values. Go to
Service Settings > Temperatures>
Discharge
.
High Temp Limit
Fire Eye Alarm
Unit discharge temperature exceeds maximum limit.
Fireye detected improper burner operation.
Reset fault with HMI.
Check for proper airflow.
Measure discharge sensor (ohm reading should be 10k @ 77°F).
Gas is off, turn gas on.
Faulty ignition transformer, replace transformer.
Faulty Fireye, replace Fireye.
Improper flame/lighting, refer to
78
Fault
Gas High PS
Gas Low PS
CO Alarm
Supply VFD Comm
Door Interlock
Intake Damper
End
Discharge Damper
End
Supply (Blower) Air
Proving
Low PS Fault
High PS Fault
Potential Cause
The board is receiving an input from the CO detector.
Corrective Action
The board lost input on the gas pressure high terminal. There should be an input when gas pressure is at the proper level.
Adjust regulator or add regulator.
Check wiring. Repair broken or loose wiring connections.
The board lost input on the gas pressure low terminal. There should be an input when gas pressure is at the proper level.
Faulty high pressure gas switch, replace the switch.
Check wiring. Repair broken or loose wiring connections.
Faulty low pressure gas switch, replace the switch.
Check for proper exhaust ventilation.
Check wiring. Repair broken or loose wiring connections.
Faulty CO detector, replace CO detector.
Check Modbus wiring and connections.
Modbus communication fault.
Safety feature that will shut down supply fan when door signal lost.
End limit input not received.
Verify Modbus address.
Verify Min and Max settings of the VFD to the
MUA board settings. Go to
Factory Settings
> Unit Options > Blower Config > VFD Freq
Limits
.
Verify door is closed.
Check wiring. Repair broken or loose wiring connections.
Faulty door switch, replace the switch.
Check wiring. Repair broken or loose wiring connections.
Board damper output/input failed.
Faulty damper, Replace damper.
Airflow proving pressure value is less than
0.05” w.c.
Kinked/blocked/damaged hose.
Blockage in duct.
Confirm proper CFM.
Faulty airflow sensor, replace sensor.
Burner profile pressure out of range.
Adjust profile pressure.
Factory Settings
> Unit Options > Blower Config > Air
Profile Limits
. Profile pressure is less than low profile pressure setpoint, but greater than lower pressure limit (0.05” w.c.).
Increase blower speed.
Restrict airflow by adjusting blank off plates.
Profile pressure is greater than high profile pressure setpoint.
Adjust profile pressure.
Factory Settings
> Unit Options > Blower Config > Air
Profile Limits
.
Decrease blower speed.
Open airflow by adjusting blank off plates.
79
Fault
Clogged Filter
Missing Sensor Intake/
Discharge/Space/
Outside Air/Return
When a sensor is not wired or there is an open circuit.
Potential Cause
Input for clogged filters activated.
Corrective Action
Clean or replace filters.
Check clogged filter switch adjustment.
Faulty switch, replace switch.
Check wiring. Repair broken or loose wiring connections.
Install missing sensor.
Replace faulty sensor.
Check wiring. Repair grounded wiring.
Broken Sensor Intake/
Discharge/Space/
Outside Air/Return
Sensor or wiring shorted to ground.
Faulty sensor, replace sensor.
Broken Pressure
Sensor
RTC 1 Temp Sensor
HMI Temp Invalid
Proof of Closure
Pinched/missing airflow tubing. Faulty airflow sensor.
Real-Time Clock (RTC) temperature sensor located on MUA board.
HMI internal temperature sensor readings incorrect.
Check tubing at the airflow pressure sensor
.
Verify there is no damage to the MUA board or the wiring to the MUA board.
Replace HMI.
Input not received when there is a call for heat.
Check wiring. Repair broken or loose wiring connections.
Faulty gas valve, replace gas valve.
Low Flame Voltage
The board is receiving poor flame voltage signal.
Check wiring. Repair broken or loose wiring connections.
Improper flame. Adjust pilot and low fire settings.
Faulty Fireye, replace Fireye.
Communication Fault -
Check Configuration
HMI communication fault or software setting.
HMI MB Comm
CO2 Override
Improper software setting. If more than one
HMI is installed, check all HMIs.
Faulty Cat 5 cable, replace cable.
Faulty HMI, replace the HMI.
High source of CO2, above PPM threshold.
Check for proper exhaust ventilation.
80
VFD Fault List
Refer to VFD manufacturer manual for further details.
Fault Number
12
13
14
15
8
9
10
11
6
7
4
5
2
3
0
1
16
17
18 - 27
28
29
30 - 33
34
35 - 44
Description
No Fault
IGBT Temperature Fault
Output Fault
Ground Fault
Temperature Fault
Flying Start Fault
High DC BUS
Low DC BUS
Overload Fault
OEM Fault
Illegal Setup Fault
Dynamic Brake Fault
Phase Lost
External Fault
Control Fault
Start Fault
Incompatible Parameter Set
EPM Hardware Fault
Internal Fault
Remote Keypad Lost
Assertion Level Fault
Internal Fault
Comm. Module Failure
Network Fault
Resetting Unit
If the flame safety control is locked out (alarm light on), reset the unit by:
2. Turn OFF power to the unit.
3. Turn power to the unit back ON.
Figure 48 - Reset Buttons (MUA Board)
HI TEMP
LIM
FSC
RESET
!
81
MAINTENANCE
To guarantee trouble-free operation of this heater, the manufacturer suggests following these guidelines.
Most problems associated with fan failures are directly related to poor service and maintenance.
Please record any maintenance or service performed on this fan in the documentation section located at the end of this manual.
WARNING: DO NOT ATTEMPT MAINTENANCE ON THE HEATER UNTIL THE ELECTRICAL SUPPLY
HAS BEEN COMPLETELY DISCONNECTED AND THE MAIN GAS SUPPLY VALVE HAS BEEN SHUT
OFF.
General Maintenance
1. Fan inlet and approaches to ventilator should be kept clean and free from any obstruction.
2. All fasteners and electrical connections should be checked for tightness each time maintenance checks are performed before restarting unit.
3. These units require very little attention when moving clean air. Occasionally oil and dust may accumulate, causing imbalance. If the fan is installed in a corrosive or dirty atmosphere, periodically inspect and clean the wheel, inlet, and other moving parts to ensure smooth and safe operation.
4. Motors are normally permanently lubricated. Caution: Use care when touching the exterior of an operating motor. Components may be hot enough to burn or cause injury.
5. If bearings require lubrication, very little is needed. A general rule is one-half pump from a grease gun for 1/2” to 1-7/16” shaft diameters and one full pump for 1-11/16” and large diameter shafts for every
1500 to 3000 hours of operation. A lithium-based grease should be used. Bearings should be rotated as they are lubricated to evenly distribute the grease, either by hand or via extended grease lines. Do not attempt to grease bearings from inside the enclosure while the motor is energized. Caution:
Bearings are sealed, over-greasing can cause damage to the bearings. Do not grease until grease comes out of seals. Only add the appropriate amount of grease.
2 Weeks After Start-up
1. Belt tension should be checked after the first 2 weeks of fan operation.
2. All fasteners should be checked for tightness each time maintenance checks are performed before restarting unit.
Every 3 Months
1. Belt tension should be checked quarterly. Over-tightening will cause excessive bearing wear and noise. Too little tension will cause slippage at start-up and uneven wear.
2. Filters need to be cleaned and/or replaced quarterly, and more often in severe conditions. Washable filters can be washed in warm soapy water. When re-installing filters, be sure to install with the airflow in the correct direction as indicated on the filter.
Yearly
1. Inspect bearings for wear and deterioration. Replace if necessary.
2. Inspect belt wear and replace torn or worn belts.
3. Inspect bolts and set screws for tightness. Tighten as necessary.
4. Inspect motor for cleanliness. Clean exterior surfaces only. Remove dust and grease from the motor housing to ensure proper motor cooling. Remove dirt from the wheel and housing to prevent imbalance and damage.
5. Check for gas leak and repair if present.
6. Clean flame sensor by rubbing with steel wool to remove any rust build-up.
7. For heating season, inspect the burner assembly. Refer to
“Burner Maintenance” on page 83
. For cooling season, inspect the cooling module. Refer to cooling manufacturer’s recommendations.
82
Burner Maintenance
Burner maintenance should be performed annually when entering heating season.
1. Verify the unit is off.
2. Inspect the pilot assembly, refer to “Pilot Adjustment” on page 59
. Replace if required.
3. Inspect the burner plates.
4. Clean the burner plates. Make sure the baffles are secure and attached to the burner.
5. Clean burner with wire brush and make sure the burner ports are free of debris. Refer to Table 9
for drill size(s) to clear ports. Wipe the burner with a clean rag.
6. After cleaning the system, turn the system. Visually inspect the flame.
Table 9 - Burner Orifice Drill Size
Orifice
Gas Port
Air Port
Drill Size
1/8”
42
Emergency Shutdown of Unit
To shut down the unit in the event of an emergency, do the following:
1. Turn power OFF to the unit from main building disconnect.
2. Turn the external disconnect switch to the OFF position.
3. CLOSE the inlet gas valve located on the heater.
Prolonged Shutdown of Unit
For prolonged shutdown, the following steps should be done:
1. Turn the external disconnect switch to the OFF position.
2. CLOSE the inlet gas valve located on the heater.
To re-start the unit, the following steps should be done:
1. Turn the external disconnect switch to the ON position.
2. OPEN the inlet gas valve located on the heater.
83
Start-Up and Maintenance Documentation
START-UP AND MEASUREMENTS SHOULD BE PERFORMED AFTER THE SYSTEM HAS BEEN AIR
BALANCED AND WITH THE HEAT ON (Warranty will be void without completion of this form)
Job Information
Job Name
Address
City
State
Service Company
Address
City
State
Zip
Phone Number
Zip
Phone Number
Fax Number Fax Number
Contact Contact
Purchase Date Start-up Date
Heater Information
Refer to the start-up procedure in this manual to complete this section.
Name Plate and Unit Information
Model Number
Serial Number
Hardware Rev.
Software Rev.
Motor Volts
Motor Hertz
Motor Phase
Motor FLA
Motor HP
Blower Pulley
Motor Pulley
Belt Number
Min. Btu/Hr
Max. Btu/Hr
Gas Type
Field Measure Information
Motor Voltage
Motor Amperage*
RPM
Burner Differential Pressure
Pilot Flame Signal
Low Fire Flame Signal
High Fire Flame Signal
High Fire Inlet Gas Pressure
Inches WC
VDC
VDC
VDC
Inches WC
Low Fire Manifold Gas Pressure Inches WC
High Fire Manifold Gas Pressure Inches WC
Thermostat Set Point
Gas Type
Low Speed RPM**
High Speed RPM
Low Speed Differential Pressure**
High Speed Differential Pressure**
Temperature Control Discharge
Space
Airflow Direction Correct
Incorrect
*
If measured amps exceed the FLA rating on the nameplate, fan RPM must be reduced to decrease the measured amps below the nameplate FLA rating.
**Low speed readings used on variable air volume units.
Factory Service Department | Phone: 1-866-784-6900 | Fax: 1-919-516-8710
84
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