EngA ENGINEERED AIR base Technical Manual

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Technical Manual

Manual Revision 1.05

These instructions are intended as an aid to qualified, licensed installers and service personnel for

proper installation, adjustment, and operation of this unit. Read and understand these instructions

thoroughly before attempting installation or operation. Failure to follow these instructions may result in

improper installation, adjustment, service, or maintenance possibly resulting in fire, electrical shock,

carbon monoxide poisoning, explosion, personal injury, or property damage.

www.engineeredair.com

IOM74

November 2020 R105

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Page 1 base Technical Manual Manual Revision 1.05 These instructions are intended as an aid to qualified, licensed installers and service personnel for proper installation, adjustment, and operation of this unit. Read and understand these instructions thoroughly before attempting installation or operation. Failure to follow these instructions may result in improper installation, adjustment, service, or maintenance possibly resulting in fire, electrical shock, carbon monoxide poisoning, explosion, personal injury, or property damage.
Page 2 base INTRODUCTION CONTACT INFORMATION This technical manual is intended for technicians and factory personnel already familiar with the Canadian Head Office and Factory operation of Engineered Air equipment, control 1401 Hastings Cres. SE strategies and combustion setup. Calgary, Alberta, Canada T2G 4C8 The base and CD-XM expansion module have been PH: (403) 287 2590...
Page 3 base WARNINGS, CAUTIONS AND NOTICES WARNING: Improper installation, adjustment, alteration, Warning, Caution and Notice statements are used service, or maintenance can cause property throughout this manual to emphasize important and damage, injury or death. Read the critical information. You must read these installation, operation, and maintenance statements to help ensure safety and to prevent instructions thoroughly before installing or...
Page 4: Table Of Contents
base TABLE OF CONTENTS GENERAL OVERVIEW ........6 TEMPERATURE CONTROL ......17 UNIT TYPE ..........6 ROOM OR RETURN THERMOSTAT ....17 SELECTOR SWITCH ........ 6 2 STAGE ROOM THERMOSTAT ....17 HEATING AND COOLING – DJ, DG, HE ... 6 REMOTE SETPOINT ........
Page 5 base ALARMS ..........31 MANIFOLD PRESSURE ......38 Appendix A - Thermistor Output Table ..... 35 CUSTOMER INSTALLED SENSORS ....38 Appendix B - Maxitrol Valve Adjustments ..36 SPEED SENSOR – DJ ....... 39 Appendix C – Startup Checks ......37 TOP LOADING ........
Page 6: General Overview
base GENERAL OVERVIEW UNIT TYPE The base may be configured for use with a variety of heating appliances, with and without cooling. A second version specific to the Engineered Air SH(X) type humidifier has 2 distinct terminal sets that differ from the heating version.
Page 7: Humdifier Version - Sh
HUMDIFIER VERSION – SH The Engineered Air base controller is the primary operational component for custom manufactured Engineered Air HVAC equipment. Engineered Air DJ style burners on SH(X) sizes 120-650, use the CD-XM expansion module for burner motor speed control.
Page 8: Computer Connection
base COMPUTER CONNECTION Notice: The base requires a connection to a computer for detailed information beyond what is indicated on the LED displays. Direct connection may be made to a computer or tablet that has the ability to connect to a static IP address. To gain access to the Testing Interface connect using a Cat.5 Ethernet cable to the base, near the top right of the controller.
Page 9: Wifi Connection
base To simplify connections, make this a bookmark in the web browser for future connections. The interface display should appear, similar to the following. Note the tabs along the top: WiFi Connection A USB Wi-Fi adapter may be plugged into the base controller for temporary communication to a laptop, tablet or phone.
Page 10: Terminal Descriptions
base TERMINAL DESCRIPTIONS HEATING COOLING VERSION Terminal changes when using SH(X) humidifier version are indicated. Terminal Type Name Description Value Power Supply 24 Vac Ground Connect to chassis. LmA B Modbus Internal network. ECM Motor Output ECM motor output controls signal. 0-10 Vdc ECM Motor Feedback ECM motor speed feedback signal.
Page 11 base Compares the combustion air actuator Feedback Air 0-10 Vdc feedback signal to the demand signal. Condensate probe Condensate probe sensor input. Ohms (Ω) Disables the pilot flame once the main PV1, PV2 Pilot valve 24/120 Vac burner has been established. SR1, SR2 Safety relay Secondary safety lockout contacts...
Page 12: Sh(X) Humidifier Version
base SH(X) HUMIDIFIER VERSION Common to output set Common power relays ‘b’, below. 24/120 Vac ‘b’ Fill Valve Enable water fill valve. 24/120 Vac Mixing Valve Enable drain water tempering valve. 24/120 Vac Drain Valve Enable primary drain valve. 24/120 Vac Side Tank Fill Valve Enable side tank (SHX) fill valve.
Page 13: Operation
base OPERATION MODE SELECTION The base can operate up to 4 distinct modes; heating, economizer, ventilation and cooling. There is a delay between changing from one mode to another to prevent cycling of the equipment. Mode selection is determined by the demand call and the ambient temperature. The base must have an ambient sensor installed either within the appliance, or remotely located to measure the ambient temperature.
Page 14: Warmup/Cooldown
base the air switch close (prove) within 30 seconds. If the switch does not close, the low air flow alarm is triggered. If during normal operation, the flow proving opens, a 15 second low air flow lock out timer is started. During this time, compressors and heat exchanger style burners are allowed to stay running.
Page 15: Economizer
base ambient compensation package. This option requires a modulating damper actuator and opposed blade dampers. ECONOMIZER Economizer damper control will mix the return and outside air streams to achieve the required discharge air temperature. It is possible for the economizer to operate while in heating or cooling mode. While the display will show either heating or cooling, the analog output to the economizer will be active until there is a heating (or cooling) demand.
Page 16: Cooling
base COOLING The base may control simple fluid based cooling devices (chilled water or glycol) from the auxiliary cooling 0- 10Vdc output. Expansion module(s) for mechanical cooling are necessary for staged or modulating mechanical cooling. Refer to the C-XM cooling expansion module section. The MCW (Modulating Chilled Water) output is a 0-10Vdc signal, with 0V=no cool and 10V=max cool, typically associated with a chilled water coil.
Page 17: Temperature Control
base TEMPERATURE CONTROL The base is a discharge air temperature controller. Changing of either the setpoint or the setpoint range requires connection to a laptop or similar device. There are a number of methods to change, or ‘reset’ the discharge temperature to what the space requires. ROOM OR RETURN THERMOSTAT The thermostat can output the demand signal into terminals W+/-.
Page 18: Module Grounding
base MODULE GROUNDING The base and CD-XM have a black power connection termination that includes Hot (H), Neutral (N), and Ground (GND). The GND terminal must be connected to a short green wire securely fastened to unpainted metal directly below the termination of each and every expansion module. On the CD-XM, the DJ speed sensor wire shield drain wire must connect to the same unpainted ground connection used by the CD-XM input power.
Page 19: Dj/Large Sh(X) Indirect Fired
base DJ/LARGE SH(X) INDIRECT FIRED For indirect fired equipment with DJ (E, S, X) style burners up to size 140. Large sizes (120-650) of SH(X) use the DJ burner. BASIC OPERATION On a call for heating the combustion blower will be enabled to full speed to prepurge the heat exchanger. Once the prepurge time has elapsed the combustion blower speed will reduce to ignition speed and then enable the ignition control to start and prove pilot flame, then open the main safety valve (SSOV).
Page 20: Dj/Large Sh(X) Combustion Setup
base DJ/LARGE SH(X) COMBUSTION SETUP Combustion setup may only be done using a computer. Refer to the combustion values and setup sheets at the end of this manual. Refer to the tabs along the top of the service screens to access noted sections. NOTICE: Always allow the heat exchanger temperatures to stabilize before accepting combustion values.
Page 21: Small Sh(X) Burner Setup
base For initial testing, to avoid high levels of CO overloading the analyzer at high fire, increase the ‘PacMan’ opening to near fully open before starting. Press Service Mode and set Service Override to 100%. The burner will be enabled to prepurge and ignition. Allow the heat exchanger to warmup a few minutes. CAUTION: Be aware of high discharge temperatures.
Page 22 base Adjust the service regulator to achieve design manifold pressure. Clock the gas flow and adjust as necessary. Follow the combustion setup sequence noted in appendix G. Adjust high fire air with the combustion air blower inlet slider. Re-clock gas flow and screw the inlet slider in place.
Page 23: Dg Indirect Fired
base DG INDIRECT FIRED For indirect heating appliances with DG and DJX200/300. BASIC OPERATION On a call for heating the combustion blower will be enabled and the air actuator will open to the prepurge setpoint to purge the heat exchanger. Once the prepurge time has elapsed the gas and air actuators will move to ignition position and then enable the ignition control to start pilot flame.
Page 24: Dg Combustion Setup
base DG COMBUSTION SETUP Combustion setup may only be done using a computer. Refer to the combustion values and setup sheets at the end of this manual. Refer to the tabs along the top of the service screens to access noted sections. NOTICE: Always allow the heat exchanger temperature to stabilize before accepting combustion values.
Page 25 base Press Service Mode and set Service Override to 100%. The burner will be enabled to prepurge and ignition. Allow the heat exchanger to warm up a few minutes. From this point begin setup. CAUTION: Be aware of high discharge temperatures. High limit failure may occur. Adjust regulator to achieve design manifold pressure.
Page 26: He Direct Fired
base HE DIRECT FIRED For direct fired HE style direct fired heaters. On a call for heating, and with the supply blower enabled, the ignition control will be enabled to start and prove pilot flame, then open the main safety valve (SSOV). Once the pilot flame has proven and the main flame is established, the base will then disable the pilot valve.
Page 27: He Burner Setup
base HE BURNER SETUP Combustion setup may only be done using a computer. Refer to the combustion values and setup sheets at the end of this manual. Refer to the tabs along the top of the service screens to access noted sections. MAXITROL VALVE Power the base and enable the fan switch.
Page 28 base The gas actuator will move to a fully closed (90°) position and read 2V. Set the ball valve to fully closed mechanically and tighten linkage. The feedback must be at or very near 2V. Record the feedback in the space provided.
Page 29: Sh / Shx Humidifier
base SH / SHX HUMIDIFIER BASIC OPERATION The base SH(X) humidifier controller version controls the operation of SH and SHX series gas fired humidifiers. This includes tank water fill and drain and burner control. On a call for humidification the tank first fills with water, then the burner gas-fired heat is enabled to produce steam.
Page 30: Cd-Xm
base CD-XM TRIAC combustion motor speed drive. The 120V and CB terminals are separated to accept heavy insulation wire from the combustion blower motor. The CD-XM will be mounted in the electrical panel on ‘standard’ equipment. The CD-XM must always be mounted such that the speed sensor wire does not need to be extended, therefore it may be mounted inside the burner cabinet in equipment that has the burner control panel mounted farther away.
Page 31: Alarms
base ALARMS When an alarm condition exists, the base will flash the RED LED and show a number on the right 2 seven segment displays. The first (left) seven segment LED describes the current operating mode, as: 1 = Ventilation 2 = Economizer 3 = Heating 4 = Cooling...
Page 32 base Combustion blower does not exceed 3000 rpm during purge. Open Air Proving Combustion rpm speed sensor has a value greater than 500 rpm for 60 seconds Shorted Air before the combustion blower has been commanded on. Proving Plugged Blocked condensate sensor reads less then 7kΩ for more than 5 minutes. Condensate High limit safety tripped due to excessively high temperature.
Page 33 base HE Alarms Gas valve feedback has power before the FR and SR contact are energized. Gas Valve Wiring When ball valve is enabled, this alarm occurs if the gas actuator feedback is Gas Valve out of greater or less then the demand by 10% for more then 60 (Default is currently range variable) seconds.
Page 34 base Water Probe Fill water probe is covered before the low water probe Sequence Duct humidity has tripped the mechanical high limit. Duct High Limit Drain sensor is out of range (less than 30° or greater than 212°F) for 10 Drain Sensor seconds Failure...
Page 35: Appendix A - Thermistor Output Table
base Appendix A - Thermistor Output Table °F °C Ω °F °C Ω °F °C Ω -39.4 323839 28365 45.0 4367 -38.3 300974 26834 46.1 4182 -37.2 279880 25395 47.2 4006 -36.1 260410 24042 48.3 3838 -35.0 242427 22770 49.4 3679 -33.9 225809...
Page 36: Appendix B - Maxitrol Valve Adjustments
base Appendix B - Maxitrol Valve Adjustments The ES345D-L has a built-in regulator for high fire. For M and MR series, adjust high fire with the upstream main regulator. On DJ style burners, the top of the valve is piped into the burner box to provide a pressure to the top of the control valve regulator, extending its operating range and overcoming pressure differences due to the varying combustion blower speed.
Page 37: Appendix C - Startup Checks
base Appendix C – Startup Checks Check and confirm all hardware connections a. Terminal Plugs firmly attached. b. Wiring connections. Confirm ground bonding is correct and firmly fastened. Confirm shielded grounds are correct. Confirm internal Modbus wiring is correct (LmA and LmB). Check all field electrical connections are intact and correct.
Page 38: Combustion Analysis
base confirm the terminals are firmly embedded into the controller. In addition, check the tightness of all wiring connections. COMBUSTION ANALYSIS Indirect heaters should be annually checked for quality of combustion. POOR PILOT SENSING Check the condition of the pilot assembly. Check for damaged or dirty ceramics, and the condition of the gasket.
Page 39: Speed Sensor - Dj
base SPEED SENSOR – DJ Magnet Magnet Retainer Blower Hall Effect Sensor 1/16 - 1/8” Gap With a digital AC voltmeter, measure the AC volts present on terminals “YS to GS”. When the combustion blower is running there should be 4 to 6 Vac present. If the AC voltage is not present, check the tachometer sensor to magnet gap.
Page 40: Appendix F - Fuel Curve Development
base Appendix F – Fuel Curve Development Clocking notes: Correct values for Altitude.  Ensure inlet pressure is correct at each stage.  All clocked values should be within 5% of the calculated value.  Offset values are set by 0.1Vdc increments. If results at low fire are not exact, and either too little or ...
Page 41: Typical Combustion Values
base Typical Combustion Values Review the appliance nameplate for the model number of the heater, the fuel type, and the turndown (maximum input btuh / minimum input btuh). Values noted are approximate. CO values should be very low. The maximum acceptable quantity of CO is 200 ppm. Any unit that emits more CO than 200 ppm at any point in its combustion curve must be corrected.
Page 42: Dj(X,E,S)/Large Sh Series 15:1 Turndown
base DJ(X,E,S)/Large SH Series 15:1 turndown Caution: High fire gas and air offsets should be set to zero. Use the PacMan to set air and the appliance regulator to set gas. Serial and Tag# Date Model # Technician Job Name Location Sequence Near High...
Page 43: Dg-Ht Series 20:1 Turndown
base DG-HT Series 20:1 turndown Caution: High fire gas offset should be set to zero. Use the appliance regulator to set. Serial and Tag# Date Model # Technician Job Name Location Sequence Near High Near Low Medium Medium Name High Fire Low Fire Fire Fire...
Page 44: Dg Series With 4:1 Turndown
base DG Series with 4:1 turndown GP Burner Propane Caution: High fire gas offset should be set to zero. Use the appliance regulator to set. This series uses a modified program due to the limited turndown. Serial and Tag# Date Model # Technician Job Name...
Page 45: Small Sh (3:1) Series
base Small SH (3:1) Series This style equipment uses hot surface ignition with constant combustion air. Combustion setup is for high and low fire only. Caution: High fire gas and air offsets should be set to zero. Use the PacMan to set air and the appliance regulator to set gas.
Page 46: He Series
base HE Series Caution: High fire gas offset should be set to zero. Use the appliance regulator to set. Serial and Tag# Date Model # Technician Job Name Location 1. Set profile pressure drop to 0.7”wc by blocking the discharge. If unable, then evenly block off inlet.