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AirTrak Digital Control System User Manual

1. DISCONNECT SWITCH ace BEFORE SERVICING STARTER EQUIPMENT OP TONAL CONTACTS y 208 230 460 575 VOLT 9 a OL T2 ELECTRONIC RELAY 5 lt VAL 3 T3 iso 24 VAC 12 OO OG 60 HERTZ Teala zs H MODULATING 3 WRE MOTOR CIRCUIT A Do Not Ground A 2 x TRANSFORMER Transformer Use Only 34 08 p To Adaptaire Control MODULATING 210244 Shielded Signal Conductors VALVE as c 58 1 TRANSFORMER FUSING SUPPLY AIR RETURN AIR ACF FIRESTAT FIRESTAT DOOR OPTIONAL OPTIONAL SWITCH 24 VAC AL Od Ta 03 FR 0 rod CONTROL 25 TRANSFORMER JUMPER 103 104 JUMPER 101 103 S o7 IF NOT USED F NOT USED UNIT SHALL BE GROUNDED ACCORDING THE LATEST PROVISIONS OF NEC LOW AND HIGH GAS STARTER 104 AND HIGH VELOCITY HIGH PRESSURE SWITCHES VALVE RELAY INTERLOCK AIRFLOW SWITCHES LIMIT OPTIONAL CONTACT AUX GAS VALVE af e t l sa ta ge ts s 20 k 121 XL MAIN GAS VALVE JUMPER 119 120 IF NOT USED 4 17 SAFETY CIRCUIT
2. COOLING ENABLE CONTACT ALARM STATIS CONTACT CONTROL MODULE bad 24 Fe 34 fac m F LL SHIELDED CABLE Key sadD she n Port OUTSIDE AIR TEMPERATURE u 15 SENSOR 4 2 a r 1 SPACE TEMPERATURE 34 SEE UNIT SENSOR 04 2 0 WIRING DISCHARGE AIR TEMPERATURE M DIAGRAM SENSOR C4 A020 u A 60 A DENOTES BY OTHERS FAN STATUS 228 3 DIM ao O lend 227 AUXILARY UNIT SAFETY STATUS 226 NS B UNIT ENABLE RELAY 10K OHM ENABLE SWTCH 7 dr BURNER ENABLE RELAY CLOGGED FILTER BURNER STATUS 224 NS pos Qe 20K OHM SWITCH 6 5 T oo LA COOLING ENABLE RELAY 5 Das C ALARM STATUS RELAY bral FLAME FAILURE FLAME SUPERVISION 20K OHM CONTACT poz 1 1 SWITCHING RELAY b ay gl HO TO 21 ON UNIT RING DIAGRAM C000575 bo LOW VOLTAGE TRANSFORMER 10 Networkin e AirTrak operates on BACnet network architecture at 38 4K or 9600 baud BACnet Modbus and N2 network systems do not require special communication interfacing The AirTrak system can be connected to most existing building automation systems using special controllers and network communication devices See Appendix I for Device Parameters and Cache Setup information AirTrak Default Setti
3. 33 ena bone easet dus ed 33 SIATUSMENU ed Ded ut agus P TH 34 a EEUU KREBS RUD REIR Ba ae 34 domo E eben e mordet qot RCN E ER dn 35 SCHEDULE S Oria l alta bald 35 CLOCKSE T SERE bn rep 35 Appendix LS ia 36 A E pem C 36 Device Parameters oed RRS 36 E SM SR lg E 36 Modbus Device Parameters oe os aee e dct eausa atem aedis 37 N2 Device LARA A 37 Cache Setup for Modbus and 2 a 37 Cache Table for Modbus and eese a race Eta Rs 39 Appendix cutter 40 Thermistor Output Curve e bi LC keen Sta dM Reo cd 40 Overview Applied Air s Digital Control System AirTrak is designed to give the user the ultimate in heater performance and operational flexibility Combined with the patent applied for airflow station used with recirculating heaters AirTrak provides flexibility adaptability and reliability in a user friendly package Non recir
4. 1 lisa Em ALARM STATUS RELAY 15 n NS 002 le 1 T ing M DO2 e La 19 2 0 7532 20 B 004 i oS TO LINE ELOCK Power Ground OR OPTIONAL gd2t Vac DISCONNECT SWITCH i 201 TURA LOW VOLTAGE TRANSFORMER C000574 RECIRCULATING SDFW and SDFI MODEL DIAGRAM CAUTION OPEN MAIN DISCONNECT SWITCH TO CIRCUIT BREAKER BEFORE SERVICING DISCONNECT EQUIPMENT OPTIONAL hon 208 230 460 575 VOLT H Fe e OL 12 3 PHASE 9 OL T3 60 HERTZ 1 a bea v STARTER FAN 3 CONTACTS MOTOR TO MAIN SUPPLY AR FETU AR CIRCUIT BREAKER DISCONNECT JS SWITCH UNIT SHALL BE GROUNDED ACCORDING OPTIONAL 5 OPTIONAL PA To THE LATEST PROVISIONS OF T CONTROL TRANSFORMER II CUSTOMER EXHAUST JUMPER 1B 1 JUMPER 1 1 DAMPER MOTOR ae FAN INTERLOCK NOT USED PETNI DAMPER 1 3 v TRANSFORMER IF NOT USED 1 UNIT ENABLE RELAY yr C 3 H le 5 X 1 4 T 24v 3 D 11
5. Pu 19K OHM pr RE 215 20K OHM CONTACT 214 1 uL 213 al b 212 e AIRFLOW STATION PRESSURE TRANSDUCER T 49 000552 BUILDING PRESSURE TRANSDUCER c e Eg Gr AOAO le a EE 2 k SEE_UNIT A030 se Ha WIRING fe DIAGRAM A02 s e use _ AO O m UNIT ENABLE RELAY DOS e dr e BURNER ENABLE RELAY DOS pt 206 4 BR u e COOLING ENABLE RELAY 004 22 5 le or ALARM STATUS RELAY ge lt ti FLAME SUPERVISION DO2 4 4 le ON le SWITCHING RELAY D01 2 O ja Pore Ground TO 2 1 ON UNIT cO 9124 WIRING DIAGRAM r 4 po 1201 LOW VOLTAGE TRANSFORMER NON RECIRCULATING SDFW SDFI MODEL DIAGRAM CAUTION OPEN MAIN CIRCUIT BREAKER DISCONNECT SWITCH BEFORE SERMCING DISCONNECT EQUIPMENT oP ORAL ol 208 230 480 575 VOLT L T2 3 PHASE
6. Diagnostics Won Criti al Fault Codes This section should assist the user in troubleshooting non critical fault codes messages which have been displayed on the local user interface FAULT CODE Check Airflow Switches PROBLEM The controller has activated DO6 to start the fan and detected that the fan is running from a signal at the fan status input IN4 Subsequently the controller has detected a momentary opening of the fan status input IN4 The momentary opening must occur within two seconds of the previous closure for this fault to occur SOLUTION If high airflow switch is opening Do not adjust the switch setpoints 1 Are all of the filters in place a No Install filters and continue b Yes Continue 2 Does the external static pressure match that listed on the rating plate a No Verify all associated ductwork is installed and continue b Yes Continue 3 Does the fan RPM match that listed on the Spec Sheet a No Correct to reduced fan speed and continue b Yes Continue 4 Are the airflow switches sensing tubes obstructed 26 a Yes Clear and continue b No Continue 5 Contact factory SOLUTION If low airflow switch is opening Do not adjust the switch setpoints 1 Does low airflow switch open when the burner is off a No Disconnect both pressure sensing tubes from one of the airflow switches and measure the differential pressure by connecting the high sensing port of a manometer to one of the airflo
7. STERLING w Rev 11 19 03 Table of Contents UR cae enn 5 Controller SpeelfiCatiolls RR RO Mentes eique 6 Typical Wiring Schematic iu petet tee ta ads Untere lale 7 RECIRCULATING SDR MODEL DIAGRAM ie ei it ertt etes tad oa eb odes i to nd 7 NON RECIRCULATING SDR MODEL DIAGRAM eee eene RECIRCULATING SDFW and SDFI MODEL DIAGRAM err 9 NON RECIRCULATING SDFW and SDFI MODEL DIAGRAM err 10 Networkin el cael eles 11 AirTrak Default Setti nos 11 Unit Operating Modes noe ned en Ea eu echte ts 11 OFF MODE uic astundst tuin rasta ha ied Gs ected SARS 12 sR RSS a s 12 ATG MODE Tr 12 Time Clock 12 Heating Night Setback ed aue den D E al r tette e RUD t dete RE 12 Cooling Night Setback sm oes aues rate REN eed e Ge E QURE MAR Fee dite Re OR EN ente dta 13 Auxiliary Unit Enable s cea ae RGR GEOR PARR Batis e e edet ie e E 13 Heating Cooling Operating 2 2 2 13 HFATING MODE a i a di tis a Galba odia a Nd ds vibe ote A a 13 General Burner Conttol sop e ree Gi Dee Dri ce ian ial HU ded ies 13 Energy Savings Mode 1 Recirculating 14 Energy Savings Mode 1 1 2 41 001121202 44 0 0 4400000 00000
8. AO BACnet Analog Output microblock AV BACnet Analog Value Parameter or Status microblock BI BACnet Binary Input microblock BO BACnet Binary Output microblock BV BACnet Binary Value Parameter or Status microblock ID The BACnet Object ID assigned to the BACnet microblock This must be a decimal value in the range 1 to 999 999 Description Optional text describing the cache point Action This determines how the cache line is processed Valid actions depend on whether the module is configured as a Master or Slave device Use to disable the cache line Mod Fmt This describes the Modbus format for the object Valid Modbus formats are UINT 16 bit unsigned integer SINT 16 bit signed integer FLOAT 32 floating point number in two adjacent registers BITn where n 0 15 BITO being the least significant DO discrete output DI discrete input ES exception status DEV device type COMERR communication error 37 Mod Obj This is the data address on the Modbus device N2 Fmt The Network Point type Valid Modbus formats are AI Exposed as an Analog Input BI Exposed as an Binary Input AO Exposed as an Analog Output BO Exposed as an Binary Output ADF Exposed as an Analog Data Float ADI Exposed as an Analog Data Integer BYT Exposed as a Data Byte N2 Obj The N2 Network Point address 1 255 38 Cache Table for Modbus and N2 Non Recirc amp ID Recirc or Recirc POINT INSTANCE MOD MOD
9. Connect an ohmmeter to the sensor If it is shorted replace the sensor At 70 F the resistance should be 10 See thermistor output curve for other temperatures If it is not shorted there is a short in the wiring between the sensor and the input plug Determine cause and rectify Refer to Appendix II for a typical 10 thermistor output curve b No Continue 3 Is the discharge air temperature DAt displayed on the BACview remote reading 40 F or less a Yes The discharge air temperature sensor circuit or the sensor itself is open Jumper the input for the sensor Did the display change to 150 F or more 1 2 No There is an open in the controller input Replace the controller Yes Disconnect the discharge air temperature sensor wiring at the sensor Connect an ohmmeter to the sensor If it is open replace the sensor At 70 F the resistance should be 10KQ See thermistor output curve for other temperatures If it is not open there is a break in the wiring between the sensor and the input plug Determine cause and rectify b No Continue 4 Reset the alarm Check and note the DC voltage at AO 3 Set the Heating Setpoint for 90 F Set the MAX DAT and MIN DAT Setpoints for 130 F Did the Burner VDC displayed on the BACview remote increase a No Unless the outside air temperature is extremely warm the Burner VDC should have increased to 7 5VDC or more Close the manual main gas valve closest to the burner and
10. Determine cause and rectify b Yes Continue 5 Isthe fan status relay s normally open auxiliary contact closed a No Replace relay b Yes Continue 19 6 Is there continuity between both IN 4 terminals 7 and 8 a No There is an open in the wiring between these terminals Determine cause and rectify b Yes Replace controller SOLUTION If fan motor is not running 1 Is the BACview remote indicating an alarm a Yes Check previous alarms and continue b No Continue 2 Is controller output LED for DO 6 lit a No There is a problem with the controller Replace controller b Yes Continue 3 Is the unit enable relay energized a No There is an open in the wiring between these terminals Determine cause and rectify b Yes Continue 4 Is the unit enable relay s normally open contact closed a No Replace relay b Yes Continue 5 Is the motor overload relay tripped a Yes Determine cause rectify and reset b No Continue 6 Is the motor starter energized a No There is an open or break in the wiring Determine cause and rectify b Yes Check motor and motor wiring FAULT CODE Low Discharge Temperature PROBLEM The controller has detected a low temperature at the fan outlet and has shut off the unit See Freezestat section of this manual SOLUTION If burner was operating prior to shutdown check prior alarm log 1 Is the outside air OAt room air RoomT or discharge air temperature DAt dis
11. OL 60 HERTZ 1 al boa ie STARTER FAN 3 WIRE CONTACTS MOTOR TO MAIN SUPPE DAR FETU AE CIRCUIT BREAKER DISCONNECT JS 9 SWITCH UNIT SHALL BE GROUNDED ACCORDING OPTIONAL 5 OPTIONAL 28 TO THE LATEST PROVISIONS OF T CONTROL TRANSFORMER CARER NORCO puc CUSTOMER EXHAUST JUMPER 18 1 JUMPER 1A 1B FAN INTERLOCK IF NOT USED IF NOT USED 1 Q JUMPER 1 B In NOTRUSED UNIT ENABLE RELAY EAE 3 4 15 2 LOW AND HIGH VELOCITY STARTER BURNER ENABLE RELAY AIRFLOW SWITCHES CONTACT M FAN STARTER 19 e oc 16 15 N FAN STATUS MODULATING VALVE TRANSFORMER he ELECTRONIC RELAY 24v DOOOE L208 m TO ADAPTAIRE CONTROL 0 10 vDC 12 209 m INPUT MODULATING GAS VALVE BURNER STATUS 50 BURNER RELAY HIGH LOW AND HIGH GAS RED Rue AUXILIARY GAS VALVE TEMPERATURE PRESSURE SWITCHES VOCATION Ba LIMIT SWITCH OP TIONAL El ers teg sa T 3 25 2 FLAME SUPERVISION 42 IGNITION TRANSFORMER M RM SWITCHING CONTACT 5 qa 7 s Iz zs FLOT GAS VALVE PILOT MAIN ME FAILURE RELAY FLAME S FLAME FAILURE REL Bog Ton CIRCUIT STATUS COOLING MODE ENABLE REMOTE ALARM INDICATION KEYPAD DISPLAY MODULE REMOTE MOUNTED
12. digital output DO4 will be activated To place the unit in Cooling Mode scroll through the Unit Modes menu tree locate the HTG CLG OFF branch and select Cooling This will place the unit in the Cooling mode To change the desired cooling operational temperature scroll through the Setpoints menu tree locate the Cooling Setpoint and enter a new temperature The allowable temperature range is 55 F 90 F The cooling will be disabled when the room temperature drops 3 F below the Cooling Setpoint Damper Control Modes There are four different modes which control the heater damper operation Manual Mixed Air Temperature Building Pressure and 100 Outside Air Except for the 100 Outside Air mode these operating modes are selected through the menu tree of the local user interface or PC MANUAL MODE Manual Mode is the default damper operational mode This will set the outside air damper to a fixed position To place the damper operation in Manual Mode scroll through the menu tree locate the Damper Mode branch and select Manual Pos Next scroll through the menu tree locate the Setpoints branch select Man Vent SP and enter the desired damper position The allowable range is 0 to 100 Any setting below 20 will cause the burner to automatically cycle off MIXED AIR TEMPERATURE MODE The Mixed Air Temperature mode varies the percentages of outside air and return air to maintain a constant mixed air temperature The AirTrak controller co
13. holiday and override Each of these schedules can be programmed for up to nine separate On Off events with any combination of days The normal schedule sets the typical On Off times for the heater The holiday schedule sets the Off times for holidays and other shutdown periods The override schedule sets the On times that will override the holiday schedule This scheduling system allows the user to program a diverse array of On Off operations An example of a typical schedule would be to have the heater On Monday through Friday from 6 00 AM to 5 00 PM except during the weeks of Thanksgiving and Christmas when the heaters will be Off However they will run each weekday during the Thanksgiving shutdown from 8 00 AM until noon while a maintenance crew is in the building AirTrak has no preset operational schedule To set the operational times of the heater scroll through the SCHEDULES menu tree and locate the desired Normal Holiday or Override branch Enter the days and times for the heater to operate In the Normal or Override section these times should correspond to the desired times for the heater s operation In the Holiday section these times should correspond to the desired off times for the heater s operation See the CLOCK SET section of this manual for setting the time date and Daylight Savings function Heating Night Setback The Heating Night Setback function automatically cycles the heater if the room temperatu
14. HIGH GAS STARTER LOW AND HIGH VELOCITY PRESSURE SWITCHES VALVE RELAY INTERLOCK AIRFLOW SWITCHES LIMIT OPTIONAL CONTACT AUX GAS VALVE H e a 8 Sca Fe 34121 a uh a 1 MAIN GAS VALVE JUMPER 119 120 IF NOT USED 17 SAFETY CIRCUIT STATUS RELAY FAN STATUS RELAY Cx DAMPER MOTOR UNIT ENABLE RELAY ERE 05 07 10 zl 4 LI TE SW 18 FAN BURNER ENABLE RELAY OLOLOL STARTER 12 11 re nio oj Rad FIELD PURGE TIMER LOCATION BURNER HEAT BURNER STATUS ae n 4 C 6969 GAS VALVE INSTALLED JUMPER E T 42 1 FLAME SENSOR p KEYPAD DISPLAY MODULE COOLING MODE ENABLE REMOTE ALARM INDICATION 1 REMOTE MOUNTED COOLING ENABLE CONTACT ALARM STATIS CONTACT CONTROL MODULE 7 a sd of fp pni SHIELDED CABLE 4 Keypa Display OUTSIDE AIR TEMPERATURE m TA Pot we 8 ow SENSOR O e 2 pitt AO4 O fe e coe eH w SPACE TEMPERATURE E 208 SEE UNIT SENSOR Cj 5 QN Q oX WIRING DISCHARGE AIR TEMPERATURE Ex pen DIAGRAM SENSOR Cj 1 1230 E o20 3 j Ll e 7 le A DENOTES BY OTHERS STATIS 228 s m RESISTORS AUXILARY UNIT SAFETY STATIS 227 a AINE 207 A d 10K OHM ENABLE SWITCH 28 1 6 004 Sat e X 221 ss 1 225 BURNER ENABLE RELAY CLOGGED FILTER 1 BURNER STATUS 224 EINS pos 10 le 206 1 20K OHN SWITCH iF us ow I p23 i e ls COOLING ENABLE RELAY bed a bo 004 Og 6
15. N2 N2 Onl NUMBER DESCRIPTION ACTION FMT OBJ zu E N amp R Space Temp N amp R A OA Temp N amp R Al DA Temp Al Flow Stn Prs Al Bldg Prs x 100 IVDC Dampers Gas Valve Htg Nite SP 16001 UINT 16002 Unit Enable A O M UINT 16003 Freeze Stat SP UINT 16004 Flow Stn Avg Prs FLOAT 16005 Return Air 96 UINT 16006 Outside Air 96 UINT R AV 16007 EQ Temp Rise Expose to FLOAT 39 R AV 16008 Max EQ Temp Rise Expose to FLOAT 38 N amp R AV 16009 Max Disch Temp Expose to FLOAT 44 R AV 16010 Mixed Air Temp Expose to FLOAT 43 N amp R AV 16011 Fan Cycles Expose to UINT 45 N amp R AV 16012 Fan Hours Expose to UINT 46 R AV 16013 Mix Air Temp SP Expose to UINT 31 R AV 16014 Bldg Press SP Expose to FLOAT 28 R AV 16015 Manual Damper SP Expose to UINT 30 R AV 16016 Recirc Mode Select Expose to UINT 36 N amp R AV 16019 Bnr Cycles Expose to UINT 47 N amp R AV 16020 Bnr Hours Expose to UINT 48 N amp R AV 16021 Inlet Duct SP Expose to UINT 24 R AV 16022 Min Vent SP Expose to UINT 25 N amp R AV 16023 Heating SP Expose to UINT 23 N amp R AV 16024 Gas Open Expose to FLOAT 37 N amp R AV 16025 Min DAT SP Expose to UINT 26 N amp R AV 16027 Cooling Cycles Expose to UINT 49 N amp R AV 16028 Cooling Hours Expose to UINT 50 N amp R AV 16029 Cooling SP Expose to UINT 27 N amp R AV
16. normally open contact closed a No Replace relay 24 b Yes Continue 4 Is there a pilot flame present a No Refer to the nstallation Operation and Maintenance Manual for guidance in troubleshooting the flame relay or ignition module b Yes Continue 5 Isthe flame relay or ignition module main valve terminal energized a No Refer to the nstallation Operation and Maintenance Manual for guidance in troubleshooting the flame relay or ignition module b Yes Continue 6 Is the gas valve burner status relay energized a No There is an open in the main valve control circuit Determine cause and rectify b Yes Continue 7 Isthe gas valve burner status relay s normally open contact closed a No Replace relay b Yes Continue 8 Isthere continuity across both IN 6 terminals 11 and 12 a No There is an open in the wiring between these terminals Determine cause and rectify b Yes Replace controller FAULT CODE Burner Hand PROBLEM The controller has not activated DO 5 to start the burner but the burner status input IN6 is receiving a signal that the burner is on SOLUTION Inspect burner control circuit This fault has the potential to be a very serious problem Close the manual gas valves immediately if the fan is not running 1 Is the controller output DO 5 LED lit a Yes Close manual gas valves There is a problem with the controller program Contact factory b No Continue 2
17. 00000000000000000000000000443 14 Energy Savings Mode 2 cust Ro ie RR I DR duele Avie EE kvi 14 Energy 3 sei sedi eie bei te oet ec tue Gt Ee UH CRT OS GRE D UR UI ERE Leg 15 GOOEING MO itc Ng a tovt dodi 13 Damper Control 2 1 02020 15 MANOA Te a Ee sales 15 MIXED AIR TEMPERATURE MODBE sess eene enne enne 15 BOILDING PRESSURE MODE 45 sss Ses 16 TOU OUTSIDE 16 Minimum Ventilation assa sta ist li aaa 16 DTC OSU Arion ei indu 16 INLET Saisie R 16 Clock SECs la a aa e Saa 17 Multiplexed Inputs SERS ga 17 MN 17 ALARM RS PARI UU 17 CADIBRATE nr RR 17 TON COUNT oo ANE a eee Ute os AA uu OI uds 18 HEATING EN a a tentatus a o as 18 COOLING COUN Drs asa 18 Diagnostics Critical Fault Codes ees 18 FAULT CODES Of ene piod tie Hes ra a a 18 SOLUTION Tifa tS runnin eR SER edu ER fe ati tuere es ede ies 18 SOLUTION Tf
18. 16030 Max DAT SP Expose to UINT 29 AV 16031 Clg Nite SP Expose to UINT 16032 Bldg Press Expose to 16033 Calb Time secs 16034 Calb Time min 12001 Blower Status Expose to 10001 12002 Burner Status Expose to 10002 12003 Safety Limits Expose to 10003 Unit Enable Burner Enable FSG Alarm Enable Cooling Enable N amp R 11005 Flame Rod Switch Expose to 10005 Fan Fault Status Bnr Cntr Clear Cool Cntr Clear Aux On Filter Dirty All Vent FSG Alarm H C Mode Select Fuel Select Force Calibrate Network Enable 39 10 Thermistor Output Curve Resistance Ohms Typical 10 000 Ohm Thermistor Output Curve 180000 170000 160000 150000 140000 32 41 50 59 68 77 86 95 104 113 122 131 140 149 Temperature in Degrees Resistance Ohms Typical 10 000 Ohm Thermistor Output Curve 30000 25000 20000 15000 10000 5000 32 41 50 59 68 77 86 95 Temperature in Degrees 104 40
19. 4 LOW AND HIGH VELOCITY STARTER BURNER ENABLE RELAY AIRFLOW SWITCHES CONTACT ds FAN STARTER 19 lt H ke 18 e EID 13 M FAN STATUS MODULATING VALVE TRANSFORMER 1 ELECTRONIC RELAY 24 MOODS ou TO ADAPTAIRE CONTROL Q m 209 INPUT MODULATING GAS VALVE BURNER STATUS 12 HIGH LOW AND HGH GAS FELD PURGE AUXILIARY GAS VALVE TEMPERATURE PRESSURE SWITCHES Locanon CE 7 LIMIT SWITCH OPTIONAL MAIN GAS VALVE 21 zp 7 03 e A FLAME SUPERMSION r IGNITION TRANSFORMER diu ELE SWMICHING CONTACT OS i 27 5 s Ne BHA LOT GAS VALVE PILOT FLAME FAILURE REL LI AY FLAME FLAME 2a Qv ROD ROD camem CIRCUIT STATUS KEYPAD DISPLAY MODULE COOLING MODE ENABLE REMOTE ALARM INDICATION 1 REMOTE MOUNTED COOUNG ENABLE CONTACT ALARM STATIS CONTACT CONTROL MODULE Ee MH Be He A s SHIELDED CABLE lt eypad Display OUTSIDE AIR TEMPERATURE a SENSOR 5 SPACE TEMPERATURE SENSOR DISCHARGE AIR TEMPERATURE SENSOR Cj A DENOTES BY OTHERS STATUS oe ii 227 AUXILARY UNIT SAFETY STATUS 228 10K OHM ENABLE SWITCH 221 2 225 CLOGGED FILTER BURNER STATUS 224 20K OHN SWITCH
20. 5 Is the fan status relay energized a Yes There is a short or jumper in the wiring Determine cause and rectify b No Continue 6 Is the fan status relay s normally open contact closed a Yes Replace relay b No Continue 7 Isthere continuity between both IN 4 terminals 7 and 8 a Yes There is a short in the wiring between these terminals Determine cause and rectify b No Replace controller SOLUTION If fan is not running 1 Is the fan status relay s normally open contact closed a Yes Replace relay b No Continue 2 Is there approximately 5VDC at both IN 4 terminals 7 and 8 a Yes There is a short in the wiring between these terminals Determine cause and rectify b No Replace controller FAULT CODE Unit on Fan off PROBLEM The controller has activated DO6 to start the fan but the fan status input IN4 is not receiving a signal that the fan is running SOLUTION If fan motor is running 1 Is BACview remote indicating an alarm a Yes Check previous alarms and continue b No Continue 2 Is the motor starter s normally open auxiliary contact closed a No Replace contact b Yes Continue 3 Are the high and low velocity airflow switch contacts closed a No Are the belts on and is the fan motor 1 Yes Contact factory Do not adjust the switches setpoints 2 No Determine cause and rectify b Yes Continue 4 Isthe fan status relay energized a No There is an open or break in the wiring
21. Are the main automatic gas shutoff valves energized a No The main automatic gas shutoff valves are leaking Turn off unit and close manual gas valves Determine cause of valve failure and rectify b Yes Continue 3 Is the flame relay energized a No There is a short in the wiring of the gas valves Close manual gas valves Determine cause of short and rectify b Yes Continue 4 Is the burner enable relay energized 25 a Yes There is a short in the wiring of the flame relay Close manual gas valves Determine cause of short and rectify b No Continue 5 Is the burner enable relay s normally open contact closed a Yes Close manual gas valves Replace the relay b No Continue 6 Unplug the input terminals from the input jack Is there continuity between IN 6 terminals 11 and 12 a No Close manual gas valves There is a short in the wiring between the burner status relay and IN 6 Determine cause and rectify b Yes Close manual gas valves Replace the controller FAULT CODE Flame Failure PROBLEM SDFW and SDFI Models Only The controller has received a signal from the flame relay at input IN8 indicating a flame failure SOLUTION Investigate flame relay 1 Is there a prior alarm such as Unit On Fan Off Airflow Sw or Safety Circuit a Yes See the Diagnostic section for the previous alarm b No Continue 2 See flame relay troubleshooting information in unit Installation Operation and Maintenance Manual
22. COUNT Cooling Count records each cooling start To reset a cooling count scroll through the menu tree locate the Resets branch and select Cooling Count Press the Enter key The word OFF should flash Now press the INC key and the word ON should flash on the display Press the Enter key again and ON should stop flashing Repeat this process so the word OFF is displayed and not flashing The cooling count has now been cleared and the Cooling Count function has been rearmed Diagnostics Critical Fault Codes This section should assist the user in troubleshooting critical fault codes messages which have been displayed on the local user interface FAULT CODE Unit off Fan on PROBLEM The controller has not activated DO6 to start the fan but the fan status input IN4 is receiving a signal that the fan is running SOLUTION If fan is running 1 Is controller output LED for DO 6 lit a Yes There is a problem with the controller program Call factory b No Continue 2 Is controller output contact for DO 6 closed a Yes Turn off the power to the controller and recheck If contact is still closed the controller output is shorted Replace the controller b No Continue 3 Is the unit enable relay energized a Yes There is a short or jumper in the wiring Determine cause and rectify 18 b No Continue 4 Is motor starter energized a Yes There is a short or jumper in the wiring Determine cause and rectify b No Continue
23. DE AIR The 10096 Outside Air function automatically opens the outside air dampers and closes the return air dampers This function is activated whenever a 10 000Q or 6 6670 resistance is connected across Universal Input 8 See the Typical Wiring Schematic and Multiplexed Input sections of this manual for more information The 100 Outside Air function overrides all other damper control functions Minimum Ventilation The Minimum Ventilation function defines the minimum outside air percentage and automatically prevents the dampers from modulating below this point This function can be used in heating or cooling mode In the heating mode the AirTrak controller will attempt to maintain a minimum of 20 outside air by overriding other damper controls as necessary Anytime the outside air drops below 20 the burner will automatically cycle off To specify the Minimum Ventilation scroll through the menu tree locate the Setpoints branch and select Min Vent and enter the desired outside air percentage The allowable range is 0 100 outside air Freezestat The Freezestat function automatically cycles the heater off if the supply air temperature drops below the Freezestat setpoint for 3 continuous minutes The Freezestat function prevents digital output DOI from activating and keeps the heater from starting The default for this setpoint is 45 F To change the Freezestat setpoint scroll through the menu tree locate the Setpoints branch select Freezest
24. LTIME CLOCK Battery backed to keep time in event of power failure TEMPERATURE OPERATING RANGE 20 F to 150 F 10 to 95 RH non condensing INPUTS OUTPUTS 10 Universal Inputs e 0 5 VDC or 0 20 mA 6 Digital Outputs Relay contacts rated at 3A Resistive 24VAC Hand Off Auto switches e LED indication 4 Analog Outputs e 0 10 VDC or0 20 mA e LED indication OUTPUT ASSIGNMENTS ANALOG AOI Unassigned AO2 RA or Mixing Damper Control 0 10VDC AO3 Burner firing rate to Maxitrol A200 0 10 VDC AO4 Unassigned OUTPUT ASSIGNMENTS DIGITAL DO1 Unassigned DO2 Pilot to Main Flame Sensor Changeover Switch DO3 Alarm DO4 Cooling Enable DOS Burner Enable DO6 Unit Enable INPUT ASSIGNMENTS UNIVERSAL IN1 Outside Air sensor IN2 Room Air sensor no limit on distance from controller IN3 Discharge Air sensor INA Fan Status INS Safety Circuit Status IN6 Burner Status IN7 Multiplexed A Auxiliary Unit Enable B Clogged Filter IN8 Multiplexed 100 Outside Air Switch B Flame Failure from flame IN9 Pressure Transducer for Building Pressure Control IN10 Unavailable RECIRCULATING SDR MODEL DIAGRAM CAUTION OPEN MAIN
25. Owners Manual for more information b Yes Continue 3 Is the high gas pressure switch closed a No Verify the firing rate pressure at full input is as specified on the unit rating plate The high gas pressure switch setpoint should not be adjusted The firing rate pressure must remain as specified when unit fires at full input Correct gas pressure and reset switch If the switch cannot be reset replace it See nstallation Operation and Maintenance Manual for more information b Yes Continue 4 Is the safety circuit relay energized a No Check for loose wiring and rectify b Yes Continue 5 Is the safety circuit relay s normally open contact closed a No Replace the relay b Yes Continue 8 Is there continuity across both IN 5 terminals 9 and 10 a No There is an open in the wiring between these terminals Determine cause and rectify b Yes Replace controller FAULT CODE Burner Status PROBLEM The controller has activated DOS to start the burner but the burner status input IN6 is not receiving a signal that the burner is on SOLUTION Inspect burner control circuit and burner 1 Is there a prior alarm such as Unit On Fan Off Airflow Sw or Safety Circuit a Yes See the Diagnostic section for the previous alarm b No Continue 2 Is the burner enable relay energized a No There is an open in the 24VAC circuit Determine cause and rectify b Yes Continue 3 Is the burner enable relay s
26. STATUS RELAY FAN STATUS RELAY Tx UNIT ENABLE RELAY lads gt dus 0 e Fe E a io7 10 3 AdaptAire s I Control t FAN BURNER ENABLE RELAY OLOLOL STARTER 112 111 ho ho 2 FIELD PURGE TMER LOCATION BOG En u GAS VALVE FACTORY RELAY INSTALLED JUMPER 115 2 i FLAME SENSOR T KEYPAD DISPLAY MODULE COOLING MODE ENABLE REMOTE ALARM INDICATION i REMOTE MOUNTED COOLING ENABLE CONTACT ALARM STATIS CONTACT CONTROL MODULE E gf f kpa f SHIELDED CABLE prp vive Keypad Dip OUTSIDE AIR TEMPERATURE TA SENSOR H 3 SPACE TEMPERATURE aA SEE_UNIT SENSOR NL WIRING DISCHARGE AIR TEMPERATURE Bl gq ER DIAGRAM SENSOR INS i es 229 DENOTES BY OTHERS FAN STATUS m um C d 227 UNIT ENABLE RELAY RESISTORS AUXILARY UNIT SAFETY STATUS _926 4 B 3 10K OHM ENABLE SWITCH i LS og 57 TTE 225 TA BURNER ENABLE RELAY CLOGGED FILTER BURNER STATUS 224 INS 55 E 1 20K OHM SWITCH 12 B oy lI BA E COOLING ENABLE RELAY g 3 004 4 100 OUTSIDE e Alis 7 ALARM STATUS RELAY 10K OHM AIR SWITCH 15 6 5 4 peas ss 219 215 3 or ey i 214 INS em OK IR f 00 2 a 20K OHM or mo e NT 001 q AIRFLOW STATION 1 PRESSURE_TRANSDUCER E BUILDING PRESSURE Power Sara TRANSDUCER 426 Vac DISCONNECT SWITCH a Eg C000546 20 LOW
27. VOLTAGE TRANSFORMER NON RECIRCULATING SDR MODEL DIAGRAM CAUTION OPEN MAIN DISCONNECT SWITCH eds BEFORE SERVICING EQUIPMENT OPTIONAL STARTER V CONTACTS g 0 208 230 480 575 VOLT 2 OL ELECTRONIC RELAY 3 PHASE 0 ek eel 3 24 3 13 60 HERTZ at ODO e MODULATING 32 3 WRE MOTOR CIRCUIT Fr Do Not Ground 208 ir TRANSFORMER Transformer Use Only 54 m AdaptAire Control 1 MODULATING 0 10 vde Shielded Signal Conductors VALVE iac 36 o Input TRANSFORMER FUSING SUPPLY AIR RETURN AIR 4L FIRESTAT FIRESTAT DOOR OPTIONAL OPTIONAL SWITCH 24 VAC 4 1 TS 1103 7 cr CONTROL rm TRANSFORMER JUMPER 103 104 JUMPER 101 103 Sr 02 IF NOT USED IF NOT USED SHALL BE GROUNDED ACCORDING TO THE LATEST PROVISIONS OF NEC LOW AND
28. at SP and enter a new temperature The allowable temperature range is 35 F 50 F Clogged Filter An optional clogged filter switch is required for this function The Clogged Filter function automatically notifies the user of a dirty filter condition A Clogged Filter indication will appear on the local user interface This function is activated whenever a 16 20 0000 6 6670 resistance is connected across Universal Input 7 See the Typical Wiring Schematic and Multiplexed Input sections of this manual for more information Clock Set The Clock Set function is used to set the current time and date as well as enabling Daylight Saving Time To set the clock scroll through the menu tree locate the Clockset branch select Date and enter a new date and time Select DST to enable Daylight Saving Time Daylight Saving Time is the default If the unit is installed in the southern hemisphere Sou Hem must be enabled The default is not Sou Hem For you convenience Daylight Saving Time has been preprogrammed for the next several years To reset the starting and ending DST dates scroll through the DST menu tree locate the desired year and enter a new date Multiplexed Inputs The I O 6104 Automated Logic controller has 6 digital outputs 10 universal inputs and 4 analog outputs thus the name I O 6104 Connecting two switching devices each to input 7 and to input 8 has expanded the functionality of this controller These two switches effe
29. ctively share their respective input To allow the controller to identify which switch has closed the switches are connected to the input through different size resistors These resistors have values of 10K ohms and 20K ohms When a single switch is closed either the 10K or 20K resistor is connected to the input When both switches are closed the effective resistance at the input is 6 667 ohms The controller is programmed to associate each different resistance with a specific function For example a 20K ohm resistor is connected to input 7 when the optional clogged filter switch is closed This tells the controller that the filters are clogged and it notifies the user through the local user interface See the Typical Wiring Schematic section of this manual for more information Resets This section should assist the user in resetting alarms and cycle counters which have been displayed on the local user interface ALARM RS Alarm RS is the alarm reset To reset an alarm scroll through the menu tree locate the Resets branch and select Alarm RS Press the Enter key The word OFF should flash Now press the INC key and the word ON should flash on the display Press the Enter key again and ON should stop flashing Repeat this process so the word OFF is displayed and not flashing The alarm has now been cleared and the Alarm RS function has been rearmed CALIBRATE The Calibrate function forces the controller to recalibrate the return air flow stati
30. culating heaters equipped with the AirTrak system do not have return air capabilities and all functions related to recirculating heaters are not relevant Where a function is similar but different between recirculating and non recirculating heaters the function is explained separately AirTrak accepts single or multiple heaters on the system network Each heater is provided with a local user interface The operating parameters for individual heaters may be input through the local interface A PC may also be connected to the network This allows the user to configure each heater separately or all heaters can be configured simultaneously A controls contractor can provide assistance in networking Operational modes include time scheduling filter monitoring and multiple damper control and temperature control schemes of these modes provide the maximum heater operational flexibility The patent applied for airflow station imparts unparalleled adaptability into the operation of each heater A daily self calibration enables AirTrak to detect the total air volume and the exact ratio of outside and return air entering the heater Then AirTrak daily fine tunes the heater s operation based on these new parameters Air volume can vary because of changes in static pressure conditions due to loading filters VAV boxes and building dynamics These varying conditions influence the ventilation air provided by the heater which in turn impacts the allo
31. e OA setpoint The dampers utilized on the heater are not linear with respect to airflow and openness and as such the proportion of outside air damper movement will not be exactly equal to the OA setpoint However at 20 OA the dampers should be approximately 1 2 open a Yes Continue b No Check the damper motor and linkage connections When 24VAC is powering the damper actuator and the control signal is OVDC the outside air damper should be close to a rattle tight position and the return air damper should be open If the 24VAC power is removed the actuator will draw the outside air damper tightly closed and the return air damper tightly open When 24VAC is powering the damper actuator and the control signal is 10VDC the outside air damper should be fully open and the return air damper should be closed 29 6 Is there approximately 24V AC at the COM and EXC terminals on the airflow station pressure transducer a Yes Continue b No Is there 120VAC on the primary side of the low voltage transformer and 24V AC volt at the transformer secondary 1 Yes There is an open in the wiring between the transformer and the transducer Locate the wiring problem and rectify 2 No If there is 120VAC on the primary and on the secondary replace the transformer If there is on the primary there is an open in the wiring supplying power to the transformer Locate the wiring problem and rectify 7 Remove both of th
32. e RT ER ED AER DERE und 26 SOLUTION If high airflow switch is opening Do not adjust the switch setpoints 26 SOLUTION If low airflow switch is opening Do not adjust the switch setpoints 27 FAULT CODE Clogged Filter BW ates Ede e Cu REL 27 SOLUTION If clogged filter switch is closing essere 27 FAULT CODE Energy Save Mode T o co ooo ot oon 28 SOLUTION be ea i o o Rees 28 SOLUTION If setpoints not 2 eene 28 FAULT CODE Energy Save Mode 22s er tese 29 SOLUTION If OAT RoomT or DAT are such that heat is required 29 FAULT CODE Energy Save Mode ven pde 30 SOLUTION If OAT RoomT or DAT are such that heat is 30 SOLUTION If 51 eren enne 30 FAULT CODE Insufficient ose edi 31 SOLUTION It heatas OCEAN ORR AOS d ess 31 SOLUTION It less Outside desired eget eet eus 32 GIOSSAFV 32 Memi Selection 33 UNIF MODES bea edet dug
33. e plastic tubes from the airflow station pressure transducer and gently blow into the HIGH side port Is there approximately 5VDC across the COM and OUT terminals of the pressure transducer a Yes Continue b No The pressure transducer is defective Replace it 8 Remove both of the plastic tubes from the airflow station pressure transducer and gently blow into the HIGH side port Is there approximately 5VDC across the IN 9 terminals 17 and 18 terminals a Yes There is a problem with the controller Replace it b No There is an open in the wiring between these pressure transducer and the AirTrak controller terminals Locate and rectify FAULT CODE Energy Save Mode 3 PROBLEM The controller has turned off DOS because it determined the inlet air temperature exceeds the Economizer setpoint See the Energy Savings Mode 3 section of this manual for more information SOLUTION If OAT RoomT or DAT are such that heat is required 1 Is the outside air temperature OAT displayed on the BACview remote reading 150 F or more a Yes The outside air sensor circuit or the sensor itself is shorted Unplug the input jack from the AirTrak controller Did the display change to 40 F or less 1 No There is a short in the controller input Replace the controller b Yes Disconnect the sensor wiring at the sensor Connect an ohmmeter to the sensor If it is shorted replace the sensor At 70 F the resistance should be 10 See thermistor ou
34. e wiring supplying power to the transformer Locate the wiring problem and rectify 31 6 Remove both of the plastic tubes from the airflow station pressure transducer and gently blow into the HIGH side port Is there approximately 5VDC across the COM and OUT terminals of the pressure transducer a Yes Continue b No The pressure transducer is defective Replace it 7 Remove both of the plastic tubes from the airflow station pressure transducer and gently blow into the HIGH side port Is there approximately 5VDC across the IN 9 terminals 17 and 18 terminals a Yes There is a problem with the controller Replace it b No There is an open in the wiring between these pressure transducer and the AirTrak controller terminals Locate and rectify SOLUTION If less outside air is desired 1 Is heat required a Yes The AirTrak control system must be in the Heating mode In this mode the smallest allowable amount of outside air is 20 Verify the system is in the Heating mode and the MIN VENT SP is set for 20 See Heating Cooling Mode and Minimum Ventilation Sections of this manual b No Continue 2 Is cooling or ventilation required a Yes The AirTrak control system must be in the Cooling mode In this mode the smallest allowable amount of outside air is 0 Verify the system is in the Cooling mode and the MIN VENT SP is set for the desired percent of outside air See Heating Cooling Mode and Minimum Ventilation Sections of t
35. fans NOt runnifig hee eo e ad eee av hh see 19 EAULITCODES Unit on Par ettet si sagan a 19 SOLUTION If fan motor is running sess entretenir nennen nnns 19 SOLUTION If fan motor is not running nennen nnne 20 FAULT CODE Low Discharge TOmperature isses Tease uiae o de 20 SOLUTION If burner was operating prior to shutdown check prior alarm 0 20 SOLUTION If burner was not operating prior to shutdown check prior alarm l108 22 FAULT CODE Safety Circuit ODOW ca RE ERROR DU ER LUN RA IDE 23 SOLUTION If fan is not running check prior alarm 23 SOLUTION If fan is running check prior alarm log 24 FAGIT CODES i k 24 SOLUTION Inspect burner control circuit and assesses 24 FAULT CODE Bumer fa ORO SS ali eod OR E SS RODA 25 SOLUTION Inspect burner control circuit This fault has the potential to be a very serious problem Close the manual gas valves immediately if the fan is not running rr 25 FAULT CODE Flame Falluke i cete eee icti e eer eta eo laste bes 26 SOLUTION Investigate flamerelay iintoes oio etoile ee NO 26 Diagnostics Non Critical Fault Codes sss 26 FAULT CODE Check Airflow Switches ue tet tr caer te
36. his manual b No Contact factory Glossary Equivalent temperature rise Simply stated this value is the actual temperature rise generated by the heater at any given time More precisely stated it is the quantity of outside air raised to the discharge air temperature plus the quantity of return air raised to the discharge air temperature It is equivalent to the heat actually delivered to the space The purpose for this in the burner control scheme is to limit the burner s firing rate based on the percentage of outside air and thus the carbon monoxide generated by the heater Expressed mathematically it is Teg OA Taa Toa Tra Local User Interface The BACview two line by sixteen character display used to change setpoints and monitor the unit s operation 32 Menu Selection Tree UNIT MODES Auto Off Man o Auto o Off o Man e Htg Clg o Heating o Cooling e Damper Mode o MA Temp Ctrl o Bldg Prs Ctrl o Manual Pos e Fuel Select o Natural Gas o Propane Gas e Home e Previous SETPOINTS e Roomt SP o F range 55 90 o Home o Previous Htg Setback SP o F range 40 80 o Home o Previous e Clg Setback SP o F range 75 130 o Home o Previous e Max DAt SP o F range 55 130 o Home o Previous e Min DAt SP o F range 40 130 o Home o Previous e Mixed Air SP o F range 30 80 o Home o Previous 33 e Bldg Prs SP o WC range 0 05 0 05 o Home Previou
37. ing tubes obstructed a Yes Clear and continue b No Continue 3 Is the airflow switch setpoint properly adjusted a No Adjust setpoint b Yes Continue 4 Are the wires connected to the air pressure switch s normally open contact 27 a No Rewire switch and continue b Yes Continue 5 Is the air pressure switch s normally open contact open a No Disconnect the sensing tubes and recheck Replace the switch if contacts do not open b Yes Continue 6 Disconnect the wire from terminal 13 of IN7 Does this clear the alarm a Yes There is short in the wiring Determine cause and rectify b No There is an internal short in the controller Replace the controller FAULT CODE Energy Save Mode 1 PROBLEM The controller has turned off DOS because it determined the mixed air temperature is equal to or greater than the minimum discharge air temperature setpoint and the room air temperature is 5 F above the room air temperature setpoint See the Energy Savings Mode 1 section of this manual for more information SOLUTION If setpoints are misadjusted 1 Is the mixed air temperature MAt displayed on the BACview remote greater than or equal to the minimum discharge air temperature setpoint a Yes Increase the MIN DAT setpoint See Heating Mode General Burner Control section of this manual for more information b No Continue 2 Is the room temperature more than 5 F above the room air temperature setpoint a Ye
38. ital output DOS is deactivated This function is intended to restrain the room temperature from rising uncontrollably in buildings with internal heat gain In certain conditions it may be necessary to readjust the minimum discharge air or room temperature setpoint upward or adjust the outside return air ratio to provide a warmer supply air temperature Energy Savings Mode 2 Energy Savings Mode 2 will automatically disable the burner if the burner s minimum firing rate exceeds the allowable equivalent temperature rise When the burner is disabled digital output DOS is deactivated This condition is unlikely to occur unless the 14 burner s minimum firing rate is misadjusted and set too high or the inlet air opening is restricted Energy Savings Mode 3 Energy Savings Mode 3 will automatically disable the burner if the outside air temperature is above the Outside Air Economizer setpoint When the burner is disabled digital output DOS 1s deactivated This function is similar to an inlet duct thermostat The burner will cycle back on if the supply air temperature drops 3 F below the Outside Air Economizer setpoint To change the desired outside air economizer temperature scroll through the SETPOINTS menu tree locate the ECONOMIZER Setpoint and enter a new temperature The default for this setpoint is 65 F The allowable temperature range is 40 F 80 F COOLING MODE Cooling Mode allows the cooling to operate as needed When cooling is required
39. livered to the space a No Follow the instructions in this manual for placing the heater in Manual Pos damper control Adjust the Man Vent setpoint to 20 outside air Is there sufficient temperature rise for the amount of outside air that is being delivered to the space 1 No Contact the factory 2 Yes Continue b Yes Continue 9 Verify there is sufficient inlet gas pressure Verify the modulating valve is properly adjusted Verify the burner orifices are clear of obstruction Contact the factory FAULT CODE Safety Circuit Open PROBLEM The controller has detected a failure in the safety circuit SOLUTION If fan is not running check prior alarm log 1 Is there a prior alarm such as Unit On Fan Off or Airflow Sw a Yes See the Diagnostic section for the previous alarm b No Continue 2 Set Unit Mode to Manual Did fan start 23 a No See the Diagnostic section for Unit On Fan Off b Yes Continue SOLUTION If fan is running check prior alarm log 1 Isthe high temperature limit tripped a Yes Determine cause and rectify b No Continue 2 Isthe low gas pressure switch closed a No Verify the inlet gas pressure is as specified on the gas piping diagram The low gas pressure switch setpoint should not be adjusted The inlet gas pressure must remain as specified when unit fires at full input Correct gas pressure and reset switch If the switch cannot be reset replace it See Installation Operation and
40. measure the discharge air temperature Is it less than 130 F 22 1 Yes There is a problem with the controller program or controller itself Contact the factory 2 No The outside air temperature is too hot to determine the actual cause of the problem Reset the alarm and recheck when the outside air temperature is much cooler b Yes This signal is fed to the Maxitrol A200 signal conditioner Disconnect the wires from terminals 5 and 6 on the A200 and measure the voltage on the wires Is it the same as the voltage coming from the controller 1 No There is an open in the wiring from the controller output Correct wiring and reconnect the wires to the terminals on the A200 Be sure the wire from AO 3 terminal number 6 is connected to the A200 s terminal number 5 2 Yes Continue 5 Is there 24 on the A200 terminals 1 and 2 a No Determine cause and rectify b Yes Continue 6 Is there twice the DC voltage on the A200 terminals 3 and 4 as there is on terminals 5 and 6 a No Replace the A200 b Yes Continue c Yes Continue 7 Is the DC voltage on the Maxitrol modulating valve terminals the same as the DC voltage on the A200 terminals 3 and 4 a No There is a break in the wiring between the A200 and the modulating valve terminals Determine cause and rectify b Yes The electronics are working to this point Continue 8 Is there sufficient temperature rise for the amount of outside air that is being de
41. mputes the mixed air temperature using the outside air and return air temperatures and the ratio of their respective airflows To place the damper operation in Mixed Air Temperature Mode scroll through the menu tree locate the Damper Mode branch and select MA Temp Ctrl Next scroll through the menu tree locate the Setpoints branch select Mixed Air SP and enter the desired temperature The allowable range is 30 F 80 F Anytime the outside 15 air drops below 20 the burner will automatically cycle off See Minimum Ventilation BUILDING PRESSURE MODE The Building Pressure mode varies the percentages of outside air and return air to maintain a constant pressure within the space A pressure transducer compares the pressure outside the space to the pressure inside the space and transmits a corresponding signal to the AirTrak controller The controller compares this signal to the desired building pressure setpoint and uses a PID loop to modulate the outside air and return air dampers to maintain the specified building pressure To place the damper operation in Building Pressure Mode scroll through the menu tree locate the Damper Mode branch and select Bldg Prs Ctrl Next scroll through the menu tree locate the Setpoints branch select Bldg Prs SP and enter the desired pressure The allowable range is 0 05 wc to 0 05 wc Anytime the outside air drops below 20 the burner will automatically cycle off See Minimum Ventilation 10076 OUTSI
42. nes the maximum and minimum discharge temperatures To change the desired minimum supply or discharge air temperature scroll through the SETPOINTS menu tree locate the MIN DAT Setpoint and enter a new temperature This temperature must not be greater than the MAX DAT Setpoint The allowable temperature range is 40 F 90 F This sets the lowest discharge air temperature which will leave the heater 13 To change the desired maximum supply or discharge air temperature scroll through the SETPOINTS menu tree locate the MAX DAT Setpoint and enter a new temperature This temperature must not be less than the MIN DAT Setpoint The allowable temperature range is 55 F 130 F This sets the highest discharge air temperature which will leave the heater If the maximum and minimum discharge temperature setpoints are set for the same temperature the supply air temperature will be the same as the setpoint regardless of the room temperature setpoint or actual room temperature Direct fired heaters deliver all of their products of combustion directly to the heated air space For this reason it is extremely important that the proper ventilation rate be maintained to dilute these emissions The AirTrak system accurately measures the ratio of outside and return air calculates the allowable equivalent temperature rise and automatically limits the burners firing rate This insures the products of combustion delivered to the space by the heater are held a
43. ngs The following is a list of AirTrak DDC controller defaults These are the default operating parameters set at the factory prior to shipment ITEM DEFAULT RANGE RELATED Unit Network Address 000 binary dips 000 255 binary dips Unit Operating Mode OFF OFF MANUAL AUTO DO6 Time Clock Schedule None 16 Normal 16 Holiday 8 DO6 Override schedules Heating Cooling Heating HEATING COOLING DOS Operating Mode Damper Operating Manual MANUAL BUILDING AO2 Mode PRESS MIXED AIR TEMP Fuel Selection Natural Gas NATURAL PROPANE AO3 Heating Night Setback 55 F 40 F 80 F DOS DO6 Cooling Night Setback 100 F 75 F 120 F DO4 DO6 Room Temperature 65 F 55 F 90 F AO2 DO6 Setpoint Freezestat 45 F 35 F 50 F DO6 Outside Air 65 F 40 F 80 F DOS Economizer Setpoint Minimum Discharge 55 F 40 F 130 F AO3 Temperature Setpoint Maximum Discharge 100 F 55 F 130 F AO3 Temperature Setpoint Mixed Air 50 F 30 F 90 F AO2 Temperature Setpoint Building Pressure 0 W 0 05 0 05 W C IN10 AO2 Setpoint Manual Damper 20 Outside 0 100 AO2 Position Setpoint Air Minimum Ventilation 20 Outside 0 100 AO2 Setpoint Air Unit O time Modes There are three different modes which control the supply fan and unit operation Off Manual and Auto These operating modes are selected through the UNJT MODES menu
44. nit to recalibrate See Calibrate in the Resets Section of this manual Do the dampers track with a change in the OA setpoint The dampers utilized on the heater are not linear with respect to airflow and openness and as such the proportion of outside air damper movement will not be exactly equal to the OA setpoint However at 20 OA the dampers should be approximately 1 2 open a Yes Continue b No Check the damper motor and linkage connections When 24VAC is powering the damper actuator and the control signal is OVDC the outside air damper should be close to a rattle tight position and the return air damper should be open If the 24VAC power is removed the actuator will draw the outside air damper tightly closed and the return air damper tightly open When 24VAC is powering the damper actuator and the control signal is 10VDC the outside air damper should be fully open and the return air damper should be closed Is there approximately 24V AC at the COM and EXC terminals on the airflow station pressure transducer a Yes Continue b No Is there 120VAC on the primary side of the low voltage transformer and 24V AC volt at the transformer secondary 1 Yes There is an open in the wiring between the transformer and the transducer Locate the wiring problem and rectify 2 No If there is 120VAC on the primary and on the secondary replace the transformer If there is on the primary there is an open in th
45. oltage on the A200 terminals 3 and 4 a No There is a break in the wiring between the A200 and the modulating valve terminals Determine cause and rectify b Yes The electronics are working to this point Continue 7 Is there sufficient temperature rise for the amount of outside air that is being delivered to the space a No Follow the instructions in this manual for placing the heater in Manual Pos damper control Adjust the Man Vent setpoint to 20 21 outside air Is there sufficient temperature rise for the amount of outside air that is being delivered to the space 1 No Contact the factory 2 Yes Continue b Yes Continue 8 Verify there is sufficient inlet gas pressure Verify the modulating valve is properly adjusted Verify the burner orifices are clear of obstruction Contact the factory SOLUTION If burner was not operating prior to shutdown check prior alarm log 1 Is there a prior alarm such as Safety Ckt Airflow Sw or Flame Failure a Yes See the Diagnostic section for the previous alarm b No Continue 2 Is the room air RoomT or discharge air temperature DAt displayed on the BACview remote reading 150 F or more a Yes That sensor circuit or the sensor itself is shorted Unplug the input jack from the AirTrak controller Did the display change to 40 F or less 1 No There is a short in the controller input Replace the controller 2 Yes Disconnect the sensor wiring at the sensor
46. omatically cycles the heater into operation This function is activated whenever a 10 000Q or 6 6670 resistance is connected across Universal Input 7 See the Typical Wiring Schematic and Multiplexed Input sections of this manual for more information This function can be used with a twist timer toggle switch door switch exhaust fan interlock or any other dry contact to override the time clock schedule Heating Cooling Operating Modes There are two different modes which control the heating and cooling operation Heating and Cooling These operating modes are selected through the UNIT MODES menu tree of the local user interface or PC HEATING MODE Heating Mode allows the burner to operate as needed When heating is required digital output DOS will be activated To place the unit in Heating Mode scroll through the Unit Modes menu tree locate the HTG CLG OFF branch and select Heating This will place the unit in the Heating mode General Burner Control In the Heating Mode the burner will modulate to maintain a constant room temperature To change the desired heating room temperature scroll through the SETPOINTS menu tree locate the Heating Setpoint and enter a new temperature The allowable temperature range is 55 F 90 F The burner will modulate using a PID loop to maintain this temperature Additionally the control system modulates the burner to maintain the supply air temperature within a user defined operating window This window defi
47. on The recalibration will occur immediately if the fan is running or at the next fan start To recalibrate scroll through the menu tree locate the Resets branch and select Calibrate Press the Enter key The word OFF should flash Now press the INC key and the word ON should flash on the display Press the Enter key again and ON should stop flashing 17 Repeat this process so the word OFF is displayed and not flashing The calibration has now been initiated and the Calibration function has been rearmed FAN COUNT Fan Count records each fan start To reset a fan count scroll through the menu tree locate the Resets branch and select Fan Count Press the Enter key The word OFF should flash Now press the INC key and the word ON should flash on the display Press the Enter key again and ON should stop flashing Repeat this process so the word OFF is displayed and not flashing The fan count has now been cleared and the Fan Count function has been rearmed HEATING COUNT Heating Count records each burner start To reset a heating count scroll through the menu tree locate the Resets branch and select Heating Count Press the Enter key The word OFF should flash Now press the INC key and the word ON should flash on the display Press the Enter key again and ON should stop flashing Repeat this process so the word OFF is displayed and not flashing The heating count has now been cleared and the Heating Count function has been rearmed COOLING
48. played on the BACview remote reading 150 F or more a Yes That sensor circuit or the sensor itself is shorted Unplug the input jack from the AirTrak controller Did the display change to 40 F or less 1 No There is a short in the controller input Replace the controller 2 Yes Disconnect the sensor wiring at the sensor Connect an ohmmeter to the sensor If it is shorted replace the sensor At 70 F the resistance should be 10KQ See thermistor output curve for other temperatures If it is not shorted there is a short in the wiring between the sensor and the input plug Determine cause and rectify Refer to Appendix II for a typical 10KQ thermistor output curve b No Continue 2 Is the outside air OAt room air RoomT or discharge air temperature DAt displayed on the BACview remote reading 40 F or less 20 a Yes That sensor circuit or the sensor itself is open Jumper the input for the sensor Did the display change to 150 F or more 1 No There is an open in the controller input Replace the controller 2 Yes Disconnect the sensor wiring at the sensor Connect an ohmmeter to the sensor If it is open replace the sensor At 70 F the resistance should be 10 See thermistor output curve for other temperatures If it is not open there is a break in the wiring between the sensor and the input plug Determine cause and rectify b No Continue 3 Reset the alarm Check and note the DC voltage at AO 3 Set
49. re falls below the Heating Night Setback temperature setpoint and the heater is scheduled to be off If the heater is scheduled to be off and the Heating Night Setback function turns the heater the heater will be cycled off once the room air temperature has risen 3 above the Heating Night Setback setpoint This function toggles 12 digital output DOI The default for this setpoint is 55 F To change the Heating Night Setback setpoint scroll through the SETPOINTS menu tree locate the Heating Night Setback setpoint and enter a new temperature The allowable temperature range is 40 F 80 F Cooling Night Setback The Cooling Night Setback function automatically cycles the heater if the room temperature rises above the Cooling Night Setback temperature setpoint and the heater is scheduled to be off If the heater is scheduled to be off and the Cooling Night Setback function turns the heater the heater will be cycled off once the room air temperature has fallen 3 below the Cooling Night Setback setpoint This function toggles digital output DO1 The default for this setpoint is 100 F To change the Cooling Night Setback setpoint scroll through the SETPOINTS menu tree locate the Cooling Night Setback setpoint and enter a new temperature The allowable temperature range is 75 F 125 Auxiliary Unit Enable The Auxiliary Unit Enable function overrides all other Auto Mode functions and aut
50. rt Setup Network Port Owner BACnet use B for BACnet M for Modbus or N for N2 Network Port Type EIA 485 use 2 or 4 Network communications set for 8 data bits No parity 1 stop bit BACnet Device Parameters Use default device object name Y Device Name see status screen Use default device object ID Y Device Name see status screen APDU Timeout 3000 milliseconds Number of APDU retries 0 Vendor Name Automated Logic Vendor Identifier 24 BACnet MS TP Parameters Station ID set by module s rotary address switches see status screen 36 Master node Y Max masters 127 1 127 BACnet default 127 Max info frames 50 BACnet default 1 Should not be 0 Modbus Device Parameters Modbus address for this device is 1 Slave use 0 for master The transmission mode is RTU use A for ASCII Reverse order of high and low words for FLOAT data type NO Master response timeout 1 x 100ms default 100ms N2 Device Parameters The slave address for this N2 device 1s 255 use 1 255 Cache Setup for Modbus and N2 The cache allows you to configure up to 200 points for Modbus or N2 communications The protocol assigned to the I O 6104 s Network Port determines which cache parameters Modbus or N2 will be used to process the cache point Type The BACnet object type of thie internal BACnet microblock that will send data to or receive data from an external device Valid object types include AI BACnet Analog Input microblock
51. s e Man Vent SP o 9 range 0 100 o Home Previous e Min Vent SP o 9 range 0 100 o Home Previous e Econmzr SP o F range 40 80 o Home Previous e Freeze SP o F range 35 80 o Home o Previous e Home e Previous STATUS MENU Roomt F OAt DAt ActEQ Bldg P WC Dmprs VDC Burner VDC Fan Hrs Fan Cyc Htg Hrs Htg Cyc Clg Cyc Clg Hrs Home Previous ALARM e Alarm History o Critical 34 o Non Critical o Return Normal Previous RESETS Alarm RS Calibrate Fan Count Htg Count Clg Count Previous SCHEDULES Normal o Schedulel typical 1 through 16 Start hr min Stop gt DAYS SUN MON TUE WED THU FRI SAT Prev Next V V Holiday o Holidayl typical 1 through 16 MM DD month day Start hr min Stop hr min Prev Next VVVVV e Override o Override typical 1 through 8 MM DD month day Start hr min Stop Prev Next VVVVV CLOCKSET e Date dd mm yy e Time hh mm ss e Prev e DST o Enable gt N no gt Y yes o Sou Hem gt N no gt Y yes 03Beg 35 gt 06 o 03End gt Oct 26 o 04Beg Apr 04 o 04 gt Oct 31 o 05 gt Apr 03 o 05 gt Oct 30 o 06Beg Apr 02 o 06End gt Oct 29 o 07 gt 01 o 07 gt Oct 28 O8Beg gt 06 o O8End gt Oct 26 09 gt 05 Network Po
52. s Increase the Roomt SP setpoint See Heating Mode General Burner Control section of this manual for more information b No Continue SOLUTION If setpoints are not misadjusted 1 Is there a prior alarm such as Insufficient OA a Yes See the Diagnostic section for the previous alarm b No Continue 2 Is the discharge air temperature DAT displayed on the BACview remote reading 150 F or more a Yes That sensor circuit or the sensor itself is shorted Unplug the input jack from the AirTrak controller Did the display change to 40 F or less 1 No There is a short in the controller input Replace the controller 2 Yes Disconnect the sensor wiring at the sensor Connect an ohmmeter to the sensor If it is shorted replace the sensor At 70 F the resistance should be 10 See thermistor output curve for other temperatures If it is not shorted there is a short in the wiring between the sensor and the input plug Determine cause and rectify Refer to Appendix II for a typical 10KQ thermistor output curve b No Contact factory 28 FAULT CODE Energy Save Mode 2 PROBLEM The controller has turned off DOS because it determined the burner s minimum firing rate exceeds the allowable equivalent temperature rise See the Energy Savings Mode 2 section of this manual for more information SOLUTION If OAT RoomT or DAT are such that heat is required 1 Are the outside air hood filters or bird screen or any associated ou
53. t or below allowable OSHA thresholds The outside air percentage is the driving parameter for this function A greater percentage of outside air or dilution air enables the heater to generate a higher allowable equivalent temperature rise In order of lowest to greatest priority the burner modulation parameters are room temperature discharge or supply air temperature and equivalent temperature rise There are three Energy Savings modes which could disable the burner Energy Savings Mode 1 Recirculating Heaters Energy Savings Mode 1 will automatically disable the burner if the mixed air temperature is equal to or greater than the minimum discharge air temperature setpoint and the room air temperature is 5 F above the room air temperature setpoint When the burner is disabled digital output DOS is deactivated This function is intended to restrain the room temperature from rising uncontrollably in buildings with internal heat gain In certain conditions it may be necessary to readjust the minimum discharge air or room temperature setpoint upward or adjust the outside return air ratio to provide a warmer supply air temperature Energy Savings Mode 1 Non Recirculating Heaters Energy Savings Mode 1 will automatically disable the burner if the outside air temperature is equal to or greater than the minimum discharge air temperature setpoint and the room air temperature is 5 F above the room air temperature setpoint When the burner is disabled dig
54. the Heating Setpoint for 90 F Set the MAX DAT and MIN DAT Setpoints for 130 F Did the Burner VDC displayed on the BACview remote increase a No Unless the outside air temperature is extremely warm the Burner VDC should have increased to 7 5VDC or more Close the manual main gas valve closest to the burner and measure the discharge air temperature Is it less than 130 F 1 Yes There is a problem with the controller program or controller itself Contact the factory 2 No The outside air temperature is too hot to determine the actual cause of the problem Reset the alarm and recheck when the outside air temperature is much cooler b Yes This signal is fed to the Maxitrol A200 signal conditioner Disconnect the wires from terminals 5 and 6 on the A200 and measure the voltage on the wires Is it the same as the voltage coming from the controller 1 No There is an open in the wiring from the controller output Correct wiring and reconnect the wires to the terminals on the A200 Be sure the wire from AO 3 terminal number 6 is connected to the A200 s terminal number 5 2 Yes Continue 4 Is there 24VAC on the A200 terminals 1 and 2 a No Determine cause and rectify b Yes Continue 5 Is there twice the DC voltage on the A200 terminals 3 and 4 as there is on terminals 5 and 6 a No Replace the A200 b Yes Continue c Yes Continue 6 Is the DC voltage on the Maxitrol modulating valve terminals the same as the DC v
55. tput curve for other temperatures If it is not shorted there is a short in the wiring between the sensor and the input plug Determine cause and rectify Refer to Appendix II for a typical 1OKQ thermistor output curve 2 Is the outside air sensor in the direct sunlight a Yes Provide shade for the sensor so it is not affected by the direct sun b No Contact factory SOLUTION If setpoints are misadjusted 1 Is the Econmzr Setpoint set for 80 F 30 a Yes The outside air temperature is over 80 F and there should be no need for heat If this is not the case contact factory b No Increase the ECONMZR SP setpoint See Heating Mode Energy Savings Mode 3 section of this manual for more information FAULT CODE Insufficient OA PROBLEM The controller has turned off DOS because the percentage of outside air has dropped below 20 for more than five minutes and the unit is in the Heating mode SOLUTION If heat is desired 1 Are the outside air hood filters or bird screen or any associated outside air ductwork obstructed a Yes Clear obstruction or change filters b No Continue Are the outside air and return air dampers and actuators working properly a Yes Continue b No Make necessary adjustments and force the unit to recalibrate See Calibrate in the Resets Section of this manual Are the AirTrak flow measuring station pitot tubes and pressure tubing clear a Yes Continue b No Clean and force the u
56. tree of the local user interface or PC 11 OFF MODE Off Mode is the default heater operational mode To place the unit in Off Mode scroll through the Unit Modes menu tree locate the AUTO OFF MAN branch and select OFF This will place the unit in the OFF mode The OFF mode prevents the fan and burner from starting This mode will override the Time Clock and Night Setback functions The Off mode prevents digital output DOI from activating and keeps the heater from starting MANUAL MODE Manual Mode allows the supply fan to turn on regardless of the Time Clock or Night Setback functions To place the unit in Manual Mode scroll through the Unit Modes menu tree locate the AUTO OFF MAN branch and select MANUAL This will place the unit in the MANUAL mode This function activates digital output DOI AUTO MODE Auto Mode has four different functions which control the supply fan and unit operation They are a time clock function heating and cooling night setbacks and a signal from an external source to an auxiliary digital input To place the unit in Auto Mode scroll through the Unit Modes menu tree locate the AUTO OFF MAN branch and select AUTO This will place the unit in the AUTO mode This activates the four Auto mode functions Time Clock The primary Auto Mode function is the Time Clock Schedule The Time Clock function allows the user to schedule the operational times of the heater There are three different schedules available normal
57. tside air ductwork obstructed a Yes Clear obstruction or change filters b No Continue 2 Are the outside air and return air dampers and actuators working properly a Yes Continue b No Make necessary adjustments and force the unit to recalibrate See Calibrate in the Resets Section of this manual 3 Are the AirTrak flow measuring station pitot tubes and pressure tubing clear a Yes Continue b No Clean and force the unit to recalibrate See Calibrate in the Resets Section of this manual 4 Do the dampers track with a change in the OA setpoint The dampers utilized on the heater are not linear with respect to airflow and openness and as such the proportion of outside air damper movement will not be exactly equal to the OA setpoint However at 20 OA the dampers should be approximately 1 2 open a Yes Continue b No Check the damper motor and linkage connections When 24VAC is powering the damper actuator and the control signal is OVDC the outside air damper should be close to a rattle tight position and the return air damper should be open If the 24VAC power is removed the actuator will draw the outside air damper tightly closed and the return air damper tightly open When 24VAC is powering the damper actuator and the control signal is 10VDC the outside air damper should be fully open and the return air damper should be closed 1 c No Contact factory 5 Do the dampers track with a change in th
58. w sensing tubes and the low sensing port to the other Is the differential pressure approximately the midpoint between the high and low airflow switch setpoints 1 No Close the profile opening until the differential pressure is approximately the midpoint between the high and low airflow switch setpoints Reconnect the sensing tubes restart the burner and verify the airflow switch remains closed when the burner is at the maximum rated input Continue 2 Yes Continue 2 Are all of the filters dirty a Yes Install clean filters and continue b No Continue 3 Does the external static pressure match that listed on the rating plate a No Verify all associated ductwork is installed as designed and there are no obstructions Continue b Yes Continue 4 Does the fan RPM match that listed on the Spec Sheet a No Correct to increased fan speed and continue b Yes Continue 5 Are the airflow switches sensing tubes obstructed a Yes Clear and continue b No Continue 6 Contact factory FAULT CODE Clogged Filter Switch PROBLEM The filter air pressure switch has closed and connected a 20 000Q or 6 667Q resistance at controller input IN7 See the Typical Wiring Schematic Multiplexed Input and Clogged Filter sections of this manual for more information SOLUTION If clogged filter switch is closing 1 Are the filters dirty a Yes Install clean filters and continue b No Continue 2 Are the airflow switch sens
59. wable equivalent temperature rise of the heater Systems which do not measure the outside air return air ratio and recalibrate themselves accordingly may cause the burner to shut off when it is need the most AirTrak diagnostic capabilities insure swift response to abnormal heater conditions A fault is generated anytime the operational parameters and actual heater operation are at odds An indication of trouble is displayed at the local user interface and system PC in text format In the Diagnostics section of this manual is a list of all faults and possible causes and solutions of the features of the AirTrak system are designed to provide the user with real time information At any time the user can display all of the operational parameters make changes if necessary and observe the various temperature pressure and damper readings The system s diagnostic capabilities provide the user with up to the minute status reporting son troller Specifications POWER REQUIREMENTS 24VAC 10 20VA NETWORK COMMUNICATION BACnet Modbus or N2 bus at 38 4K or 9600 baud LonWorks using gateway LOCAL USER INTERFACE BACview 2 line 16 character display connected to controller via CAT5 cable and RJ45 connectors BACview 4 line 40 character display required for Modbus or N2 bus Either BACview can be located up to 1000 away from the controller MEMORY 512K bytes of flash memory and 512K bytes of non volatile battery backed RAM REA

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