Engineered air EngA G-TRAC2 Installation, Operation And Maintenance Manual Download Page 1

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IOM-25

Mar 99 R7

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

FOR

G-TRAC2

INDIRECT FIRED HEATING CONTROLLER

UNIT MODEL NO. _________________

UNIT SERIAL NO. _________________

SERVICED BY: ___________________

TEL. NO: ________________________

CANADIAN

HEAD OFFICE

AND FACTORY

USA

HEAD OFFICE

AND FACTORY

CANADIAN

EASTERN FACTORY

1401 HASTINGS CRES. SE

CALGARY, ALBERTA

T2G 4C8

Ph: (403) 287-4774

Fx: 888-364-2727

32050 W. 83

STREET

DESOTO, KANSAS

66018

Ph: (913) 583-3181

Fx: (913) 583-1406

1175 TWINNEY DRIVE

NEWMARKET, ONTARIO

L3Y 5V7

Ph: (905) 898-1114

Fx: (905) 898-7244

SALES OFFICES ACROSS CANADA AND USA

Retain instructions with unit and maintain in a legible condition.

Please give model number and serial number when contacting

factory for information and/or parts.

www.engineeredair.com

Summary of Contents for EngA G-TRAC2

Page 1: ...ICE AND FACTORY CANADIAN EASTERN FACTORY 1401 HASTINGS CRES SE CALGARY ALBERTA T2G 4C8 Ph 403 287 4774 Fx 888 364 2727 32050 W 83rd STREET DESOTO KANSAS 66018 Ph 913 583 3181 Fx 913 583 1406 1175 TWINNEY DRIVE NEWMARKET ONTARIO L3Y 5V7 Ph 905 898 1114 Fx 905 898 7244 SALES OFFICES ACROSS CANADA AND USA Retain instructions with unit and maintain in a legible condition Please give model number and s...

Page 2: ...ED 11 LED 3 LOCKOUT FLAME FAILURE OR LOW LIMIT 11 LED 4 BURNER 11 XI AUTO BYPASS LOW LIMIT 12 XII DAY AND NIGHT OPERATING STRATEGIES 12 SUPPLY FAN DAMPER AND HEAT OPERATION 12 Standard G TRAC2 Supply Fan Function Temperature Priority Program 12 Day Night General Description of Fan Damper Operation 12 Fan Damper During Day Terminal K No Power Dipswitch A 4 12 Fan Damper at Night Terminal K Powered ...

Page 3: ...XXI DISCHARGE SENSOR READOUTS CALIBRATION ETC 29 TE6100 RESISTANCE S 29 TE6000 DISCHARGE SENSOR SELF TEST 30 SENSOR RESISTANCE CHART FOR TE 6100 960 AND TE 6000 960 30 DISCHARGE SENSOR CALIBRATION 30 DISCHARGE SET POINT CALIBRATION 30 Johnson Set Point 31 Built In Set Point 31 ROOM SENSOR CALIBRATION 31 BMS CALIBRATION AND SET UP 31 XXII G TRAC2 SET UP SHEET 32 XXIII BURNER SET UP 33 OPERATOR CONT...

Page 4: ...A G TRAC2 IOM 25 4 of 42 Mar 99 R7 PREPURGE LIGHT STAYS AT DAMPER MOVING STATUS 40 REPLACING A G TRAC2 IN THE FIELD 40 CHANGING GAS OR AIR OPERATOR ON G TRAC2 42 XXV MISCELLANEOUS NOTES 42 ...

Page 5: ...A G TRAC2 IOM 25 5 of 42 Mar 99 R7 ...

Page 6: ...s that can reset discharge air temperature Refer to the unit wiring diagram and GTRAC 2 label to determine if room thermostats return thermostats remote set points ambient resets building management resets BMS etc are in use If used refer to appropriate reset information in this guide IV GENERAL DESCRIPTION The G TRAC2 is a programmed logic controller designed for use with the Engineered Air DG se...

Page 7: ...trolled E g AS 3 Feedback pots 8 Intermittent night blower and optional damper operation Unit discharges at an adjustable elevated discharge temperature whenever the room calls GTRAC 2 has no night setback set point therefore a second night stat is required for a lower set point 9 Compatible with 0 10 VDC direct control signal Optical isolation on the digital and BMS inputs and V WIRING Power supp...

Page 8: ...e This allows the G TRAC2 to maintain an accurate set up throughout the complete combustion range Refer to Section XXII for set up procedures and Section XXIII for information changing operators or G TRAC2 s in the field VIII DIP SWITCHES The G TRAC2 has three dip switch blocks each block has 5 switches The individual switches are numbered from 1 through 5 and are used for the following purposes D...

Page 9: ...is dilutes the concentration and lowers the dew point temperature Note however that increasing the amount of excess air too much will reduce the burner efficiency slightly Following are curve guides for setting up air fuel mixtures Dipswitches 1 and 4 set gas valve curves Dipswitches 2 and 5 set air damper curves GAS CURVES Gas Curve Dip switch 1 Dip switch 4 Characteristics 1 OFF OFF Undersized v...

Page 10: ... Reset Voltage or current input calibration This pot is also used for direct 0 10 VDC control calibration 23 Reset Ratio Reset ratio for ambient and room reset 19 ROOM CAL Room thermostat calibration NIGHT SP Night operation discharge set point Service Burner manual firing service pot 33 Low Fire Burner minimum firing rate 35 High Fire Air High fire combustion air setting 35 Low Fire Air Low fire ...

Page 11: ...scharge temperature is below 40ºF but the low limit bypass timer is still operating Irregular Flash Blower is being delayed The supply fan will start once the damper open delay and or the heat exchanger warm up delay is complete Also indicates heat exchanger cool down timer active Fast Flash The discharge sensor resistance is greater than 4000 ohms or is open circuited On Low limit failure flame f...

Page 12: ...ut of night function This will reactivate the six minute low limit bypass thus allowing the heat to catch up to falling discharge air temperatures if cold outside air has been introduced into the system XII DAY AND NIGHT OPERATING STRATEGIES Supply Fan Damper and Heat Operation Standard G TRAC2 Supply Fan Function Temperature Priority Program In normal operation dipswitch A 4 is off The supply fan...

Page 13: ... or off GENERAL DETAIL OF ABOVE TABLE Note 1 Unit is off on low limit Note 2 In day operation when the unit starts up if the discharge sensor is warm the supply air fan will start in 64 seconds unless dipswitch A 4 is closed Note 3 If the heat switch is on and there is an immediate heat call or a heat call within the first two minutes of the blower starting the blower will shut off or remain off u...

Page 14: ...lame failure remove power from terminals HS and FS at the same time and remove power from T1 and T2 Turning off switch at remote control panel can usually do this NOTE On some applications with large amounts of outside air being switched while unit is in day time operation terminal K may be switched to simulate coming out of night function This will reactive the six minute low limit bypass thus al...

Page 15: ...ish the flame Trial for ign light flashing NO YES Do a controlled shut down If the combustion blower is on turn off the heat and do a heat exchanger cool down then shut off the combustion blower and reset the pre purge timer Is the pilot flame on NO YES Lock out the burner if reset will try cycle again Modulate the gas and air If the flame relay is in the lock out mode or will not establish the fl...

Page 16: ...heat exchanger is warming up NOTE If at any time the combustion air proving switch opens while the burner is firing the burner is shut off and the G TRAC2 will go to flame failure lockout Combustion fan will stop in a few minutes The Flame Failure light will flash and a signal will be on terminal LK The same voltage will be at terminal C as what is input at terminal A If the main flame lit about 1...

Page 17: ...ications unless resistance from long wiring runs or induced voltage on the remote wiring cause it to be out of calibration To check for induced voltages disconnect the entire field wiring in question from the G TRAC2 while the unit is operating and check for AC volts across each questionable wire and ground XVII NIGHT HEAT THERMOSTATS The GTRAC 2 control can be activated to control room heat at ni...

Page 18: ...stat increases or decreases the calculated discharge air set point NOTE If the room temperature is calling for a temperature adjustment the calculated discharge temperature set point will vary from the setting of master set point The room reset feature is activated by dipswitch A 3 Room sensor calibration pot is labelled ROOM CAL Reset ratio pot adjusts the reset authority bandwidth between 20 F a...

Page 19: ...unt of its authority 18 to 88ºF If room only cooled to 70ºF 2 degrees the new discharge temperature would be 18 12 Therefore 12 65ºF set point 77º discharge If the room had warmed above the temperature of the room thermostat a similar reset action would occur except the discharge temperature would be reduced Diagram A Discharge Operating Range Absolute lowest allowed discharge set point Lower rese...

Page 20: ...set point 120 F 48 F Discharge Operating Range Same as Diagram C except set point set low enough with wide reset range so bottom end of reset is cut off by absolute lowest limit Discharge Operating Range Diagram D Absolute lowest allowed discharge set point Lower reset limit Manual Set point Ex 55 F Upper reset limit Absolute highest allowed discharge set point 120 F 48 F Lower reset limit same as...

Page 21: ...5 78 11 5 53 23 5 74 5 12 53 5 21 4 28 5 83 5 10 5 51 5 35 5 96 9 48 26 79 11 52 27 21ºC 70ºF 1 28 82 5 17 62 5 26 5 79 5 18 64 5 15 2 29 5 85 16 61 3 31 88 15 59 28 82 5 16 5 62 20 5 4 34 93 13 55 5 5 41 106 9 48 29 84 5 15 5 59 5 25 30ºC 86ºF 1 35 95 24 75 34 93 26 78 5 14 5 2 36 97 22 5 72 5 3 37 98 5 21 71 35 95 23 5 74 5 20 5 4 39 5 103 17 5 63 5 5 44 111 13 5 56 37 99 21 5 71 28 NOTE These a...

Page 22: ...E The direction of reset is up only The maximum amount of reset is adjustable from 15ºF to 60ºF The maximum discharge temperature dial set point plus reset is limited to 120ºF The BMS reset option is activated by dipswitch A 1 Reset ratio pot is labelled BMS Reset Pot NOTE As a standard the G TRAC2 is designed to operate with 4 20 ma or 2 10 VDC into a 500 OHM load Some BMS devices do not have eno...

Page 23: ...he new G TRAC2 calculated set point DC voltage again and adjust the BMS Reset pot until the voltage is equal to the number of ºC maximum reset desired 6 Return the dip switches to their normal position Ambient Reset Day mode only requires dipswitch A 2 to be on This option requires an ambient sensor Johnson TE 6000 960 wired to terminals X and Z The discharge air set point will change based on the...

Page 24: ...point dial either the G TRAC mounted dial or the optional remote dial This set up is designed for a daytime override where you have the fan operating continuously It does not respond to terminal K for night heat operation If you attempt to operate this as a night time override the heat cannot start because the supply fan is not operating Additional steps must be taken for night operation You can t...

Page 25: ...ward reset During night discharge as set on night set point pot 100 120 F The amount of reset is determined by pot 5 Refer to the table in the section on Modulating Room Reset Section XVII page 17 Note that the table shows a minimum temperature and a maximum temperature for the discharge set point and pot 5 settings Reset amount is not linear When using this reset system the discharge temperature ...

Page 26: ...urant in its busy hours the desire is to discharge air at about 56ºF into the space When the restaurant is not crowded the space may cool down depending on solar load etc When the room thermostat calls for heat the space temperature has fallen below the desired 72ºF set point of the room thermostat It is now necessary to discharge at a higher temperature then 72ºF to satisfy the room s needs For t...

Page 27: ... Control 0 10 VDC CTRAC Metasys This section discusses direct control of the G TRAC2 The G TRAC2 must be configured to operate as a slave to another temperature controller while retaining its burner management roll If your wiring is for the more common BMS Reset Mode refer to the BMS Reset in section XVII above Y S SP Connect S to SP if required to use set point dial 24 V SUPPLY POWER COMBUSTION M...

Page 28: ... the voltage reads between 6 5 and 7 5 volts 5 Restore Block 1 switches to their initial positions When using a C TRAC Set C TRAC cooling deadband pot 3 to 4 degrees higher than normal value Set C TRAC heat envelope pot to position 1 5 pot 11 Heat may stay on due to G TRAC2 integral timing if the G TRAC2 heat switch is left on when the C TRAC switches to mechanical cooling Stage 1 mechanical cooli...

Page 29: ...35 95 4 40 104 NOTE The readable range is 0 to 55ºC At higher temperatures the reading accuracy is reduced Typically at 50ºC the reading will indicate 2 3ºC lower than actual NOTE The readout is designed to be accurate from 10 to 30ºC If checking discharge air temperature with another thermometer ensure it is located immediately next to the G TRAC2 sensor See Calibration Section XX page 29 XXI DIS...

Page 30: ...ion is not necessary The discharge sensor is used for both temperature control and low limit safety control For that reason it is VERY important that this calibration step be PROPERLY done The G TRAC2 has two calibration pots DSEN CAL is used to calibrate the discharge sensor and DSP CAL is used to calibrate the discharge set point 1 Accurately measure the discharge air temperature at the temperat...

Page 31: ...r normal position Room Sensor Calibration 1 Measure the room or return air temperature and set the room set point dial to the measured value 2 Record the settings of dipswitches 1 2 and 3 Turn off dipswitches 1 2 and 3 3 Measure the G TRAC2 calculated set point DC voltage from spade connector terminals DTEMP to COMMON 4 Turn dip switch 3 on 5 Measure the G TRAC2 calculated set point DC voltage aga...

Page 32: ...LTAGE or CURRENT RESET YES __________ NO ____________ dipswitch A 1 Reset Amount specify amount 15 F 8 3 C to 60 F 33 3 C _________ degrees F NOTE Voltage Current reset is in the up direction only GTRAC 2 DIP SWITCH BLOCK C SETTING Non Direct Control Direct Control GTRAC 2 Slaved to other controllers Including BMS Reset Stand Alone______ or BMS or Metasys______ or CTRAC3______ C2 on only C1 C3 C4 ...

Page 33: ... the service dipswitch A 5 and the fan switch are on the G TRAC2 is placed into the manual service mode In this mode the burner will cycle on and can be held at any firing rate set with the manual service pot The supply air fan will start 64 seconds after the flame starts The G TRAC2 will not lock the unit out on flame failure The low limit is still active in the manual service mode The operation ...

Page 34: ...el TT005 does not have a stem to adjust the resistance Step 2 below only applies to the older model TTB3005A gas actuators NOTE When using model TT005 gas actuator and BT405 air actuator change the resistance value in step 3 below to 100 Place the probe of the combustion analyzer directly into the heat exchanger outlet not to the flue If the probe is not inserted far enough flue gas may be diluted...

Page 35: ...lay will be energized In the service mode the G TRAC will not lock out on flame failure D After the flame starts the unit will go to high fire Adjust the unit gas pressure regulator to obtain the correct clocked high fire rate This has been factory pre set and should not require field adjustment E Adjust the high fire air pot until the high fire O2 reading is between 3 5 and 4 2 The high fire air ...

Page 36: ...roper O2 readings cannot be attained a new air and or fuel ratio curve must be selected Do not change setting while in the field Contact the factory Once a different curve is selected you must repeat the factory set up procedures NOTE Do not change air or fuel curves without contacting the factory If the air or fuel curves are changed both the high and low fire must be rechecked and the voltages r...

Page 37: ...If there is an intermittent problem with the discharge sensor a false low limit lock out code may be generated This happens if the discharge sensor generated an initial lockout and then the reason for the sensor lock out disappeared Refer to Section X for more detail on the low limit To reset remove power from FS and HS simultaneously and resume power to them or turn off main power If the discharg...

Page 38: ...r set incorrect For further information refer to the section for combustion set up If you have been having problems lighting the burner check the following items 1 If the combustion has been set up the ignition should be checked Whenever the total air slider has been adjusted it affects how much air flows into the pilot air tube 2 Occasionally some ignition control devices have the power to throw ...

Page 39: ...or units the vent orifice fitting on the RV appliance regulator is to be vented to atmosphere The field installed vent line should be sized adequately especially on longer runs If there is more than one regulator connected to a common run which includes the main regulator and the line is not adequately sized changes in pressure on the RV diaphragms are applied to all regulators This includes the m...

Page 40: ...cord the result Next check to see if there is power on G TRAC2 terminals 2 and neutral Record the result Next check to see if there is power to G TRAC2 terminals T1 and T2 Record the result If there is no power to any of the above terminals and if all wiring is as per the original diagram there should not be any power to the pilot or main gas blocking valve Very gently turn off the manual valve fo...

Page 41: ...set through the slot under the set point knob there is another set and on the latest revision there is a set of dip switches on the back near the top 2 Set dipswitch A 5 on the top set of switches ON to place the G TRAC2 into the service mode 3 Measure and record the following values to at least 1 10 volt accuracy 4 Take the burner to high fire record feedback DC voltage across PL and PA Also reco...

Page 42: ...ped with rotation switch 4 Now that the motor is at the beginning of its stroke when you unbolt the existing one and install the replacement tighten up the linkage at this same spot so that the marks are properly aligned 5 Having done the above when you restart the unit the stroke of the new motor should be the same as the old one thus the combustion set up should be the same and not need adjustme...

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