LG AR-DE12-05A Installation And Operation Manual Download

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Summary of Contents for AR-DE12-05A

Page 1: ...OOFTOP DEDICATED OUTDOOR AIR SYSTEMS DOAS INSTALLATION AND OPERATION MANUAL GEN2 Series AR DR Base Rooftop DOAS 500 to 18 000 CFM GEN2 Series AR DE Energy Recovery Wheel Rooftop DOAS 1 000 to 18 000 CFM ...

Page 2: ...lectrical Code CEC in Canada 2 All moving parts must be free to rotate without striking or rubbing any stationary objects 3 Unit must be securely and adequately grounded 4 Do not spin wheel faster than maximum cataloged fan RPM Adjustments to fan speed signiﬁcantly affect motor load If the fan RPM is changed the motor current should be checked to make sure it is not exceeding the motor nameplate a...

Page 3: ...trical and Gas Supply Entry Locations 26 Gas Supply Piping Gas Connections Piping Installation 27 Optional Coil Piping Condensate Drain Trap Condensate Overflow Switch Electrical Information 28 Determine the Size of Main Power Lines Determine the Size of Electric Heater Wiring Provide the Opening s for the Electric Connections Connect the Power Supplies Wire the Optional Convenience Outlet Connect...

Page 4: ...p Components 36 Fan Supply Fan Plenum Type Fan Wheel Rotation Direction Supply Exhaust Fan Vibration Discharge Air Temperature Sensor Airflow Monitor Optional Dirty Filter Switch Optional Energy Wheel 37 Start Up Drive Belt Adjust the Air Seals Sequence of Operation Maintenance Inspection Wheel Disassembly Cleaning Reassembly Energy Recovery Wheel Belt Energy Recovery Wheel Bearings Energy Recover...

Page 5: ... 63 Furnace Serial Number 63 ETL Listing 63 Product Overview 63 Furnace Control Center 64 Furnace Control Center Components Typical Furnace Control Logic Typical Furnace Electrical and Control Components 65 Gas Fired Burner Turndown 66 Electronic Modulation Combinations Available Turndown Control Options Installation of Venting for Outdoor Units 67 Installation of Venting for Indoor Units 67 Venti...

Page 6: ...ller 4 1 Modulating with Stand Alone Controller 4 1 Modulating with Microprocessor Controller Reference Controls 90 Furnace Control with Microprocessor Maintenance 91 Combustion Blower Motor Burners and Orifices Heat Exchanger Flue Collector Box Electrical Wiring Gas Train Replacement Parts Maintenance Log 92 Controller Overview 95 Keypad Description 98 Expansion Boards 98 Connecting to the Web UI...

Page 7: ...nts Data Tables 140 Network Settings Data Tables 147 Alarm Data 151 BACnet and MODBUS Points 155 Unit Status Modes 167 Lon Talk Points 168 Appendix A Remote Display 171 Appendix B I O Expansion Board Quick Start 172 Appendix C Space Thermostat Quick Start 173 Appendix D Greentrol Airflow Monitoring Quick Start 175 Appendix F Factory Modbus Connections 176 ...

Page 8: ... Recovery Wheel Chassis Size 02 12 12 112 22 212 311 311 35 352 Cooling Capacity 03 3 Tons 15 15 Tons 04 4 Tons 17 17 5 Tons 05 5 Tons 20 20 Tons 60 60 Tons 70 70 Tons 06 6 Tons 25 25 Tons 07 7 7 5 Tons 30 30 Tons 10 10 Tons 40 40 Tons 12 12 5 Tons 50 50 Tons Series A First Series AR D R 12 05 A Rooftop Dedicated Outdoor Air System Engineering Manual ...

Page 9: ... Gas Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 75 75 100 100 150 Capacity Output MBH 60 60 80 80 120 LAT F 89 6 72 2 77 2 70 5 89 6 Turndown Type Modulating Modulating Modulating Modulating Modulating Turndown Ratio 4 1 4 1 4 1 4 1 4 1 Supply Fan Data Fan Quantity 1 1 1 1 1 Wheel Speed RPM 1900 1939 1991 2029 2113 Motor HP 3 4 3 4 1 1 1 5 Configuration Outdoor Air Intake E...

Page 10: ...oll Heating Fuel Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 100 200 200 250 300 Capacity Output MBH 80 160 160 200 240 LAT F 75 6 98 8 82 3 82 3 76 6 Turndown Type Modulating Modulating Modulating Modulating Modulating Turndown Ratio 4 1 4 1 4 1 4 1 4 1 Supply Fan Data Fan Quantity 1 1 1 1 1 Wheel Diameter in 14 14 14 14 18 Wheel Speed RPM 1809 1996 2133 2376 17...

Page 11: ...Digital scroll Standard scroll Heating Fuel Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 300 400 400 500 500 Capacity Output MBH 240 320 320 400 400 LAT F 76 6 92 6 80 1 80 5 72 6 Turndown Type Modulating Modulating Modulating Modulating Modulating Turndown Ratio 4 1 4 1 4 1 4 1 4 1 Supply Fan Data Fan Quantity 1 1 1 1 1 Wheel Diameter in 20 20 20 20 22 Wheel Spee...

Page 12: ... 6 Number of compressors 4 4 4 4 Compressor Type s Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Fuel Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 500 500 600 700 Capacity Output MBH 400 400 480 560 LAT F 74 1 74 1 63 65 2 Turndown Type Modulating Modulating Modulating Modulating Turndown Ratio 4 1 ...

Page 13: ...mpressor Type s Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Heating Fuel Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 600 600 800 800 1000 Capacity Output MBH 480 480 640 640 800 LAT F 85 5 85 5 69 7 69 7 61 7 Turndown Type Modulating Modulating Modulatin...

Page 14: ...l Digital scroll standard scroll Digital scroll standard scroll Digital scroll standard scroll Heating Fuel Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 100 100 150 200 200 Capacity Output MBH 80 80 120 160 160 LAT F 92 9 76 9 83 7 85 7 78 9 Turndown Type Modulating Modulating Modulating Modulating Modulating Turndown Ratio 4 1 4 1 4 1 4 1 4 1 Fan Data Supply Fan ...

Page 15: ...croll standard scroll Digital scroll standard scroll Digital scroll standard scroll Digital scroll standard scroll Heating Fuel Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 300 300 300 300 300 Capacity Output MBH 240 240 240 240 240 LAT F 94 6 88 9 81 3 81 1 76 1 Turndown Type Modulating Modulating Modulating Modulating Modulating Turndown Ratio 4 1 4 1 4 1 4 1 4 ...

Page 16: ...ressors 4 4 4 4 Compressor Type s Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Heating Fuel Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 250 300 350 400 Capacity Output MBH 200 240 280 320 LAT F 70 8 69 7 67 3 67 7 Turndown Type Modulating Modulating Modulating Modulating Turndown Ratio 4 1 4 1 4 1...

Page 17: ...ype s Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Digital Scroll Standard Scroll Heating Fuel Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas Capacity Input MBH 600 600 600 600 800 Capacity Output MBH 480 480 480 480 640 LAT F 99 4 87 5 79 7 68 1 77 4 Turndown Type Modulating Modulating Modulating Modulatin...

Page 18: ...ations of dirt water ice or snow and wipe dry before moving to indoor storage To avoid condensation allow cold parts to reach room temperature Leave coverings loose to permit air circulation and to allow for periodic inspection The unit should be stored at least 3 in 89 mm off the ﬂoor Clearance should be provided to permit air circulation and space for inspection Outdoor The unit should be placed...

Page 19: ...with packaged DX are shipped fully charged with refrigerant and are ready for operation upon arrival Heating There are three different optional heat sources that can be ordered for this unit Indirect gas ﬁred furnace with one or two sets of heat exchangers Electric heat with inﬁnitely variable SCR control Hot water coil Airﬂow Arrangement The unit is capable of Constant Air Volume CAV Variable Air...

Page 20: ...th of either 2 or 4 inch Indirect Gas Fired Furnace Furnace model PVG is available on AR DR02 AR DR12 AR DE12 AR DR22 and AR DE22 Models AR DR32 and AR DE32 use furnace model PVG 600 800 or model HMA 1000 1200 Models AR DR35 and AR DE35 use furnace model HMA 600 1200 Packaged DX System Any unit may be ordered with a packaged DX system Housing size 02 will include one compressor housing size 12 wil...

Page 21: ...nergy Wheel AR DE optional Outdoor Air Filters pre wheel Weather hood Filters metal mesh Outdoor Air Damper Packaged DX Compressors optional Furnace Vest Plate and Furnace Control Center optional Plenum Type Supply Air Blower Recirculating Damper Coils optional Plenum Type Exhaust Air Blower Main Control Center Indirect Gas Fired Furnace Optional ...

Page 22: ... 2 Optional Compressor Electrical 3 Optional Gas Furnace Optional Electric Heater 4 Electrical 5 Supply Blower 6 Coil 7 Filters 8 Exhaust Blower Optional Electric Preheat 9 Powered Exhaust Blower Section When a powered exhaust fan or XVE is selected door 8 will be to the immediate right of door 7 ...

Page 23: ...AR DE22 15 30 72 5 68 2 163 2 197 25 27 1 30 1 5 100 Bottom End AR DE32 25 50 101 3 98 199 66 228 55 47 5 NA 8 000 Bottom or Side Side AR DE35 30 70 99 5 96 2636 3075 45 3 N A 10 450 All dimensions are shown in inches Weight is shown in pounds and includes largest supply and exhaust fans PDX with reheat largest indirect gas ﬁred furnace and all dampers Actual weights will vary based on the unit co...

Page 24: ...door Mounted Indoor Mounted AR DR 02 50 42 NA 36 NA 24 NA NA AR DR12 40 42 72 42 18 24 18 30 AR DR22 36 58 72 42 18 24 18 30 AR DR32 48 48 N A 87 NA 48 NA NA AR DR35 48 48 N A 48 N A 48 N A N A AR DE12 40 42 72 42 18 24 18 30 AR DE22 36 58 72 42 18 24 18 30 AR DE32 48 48 N A 87 NA 48 NA NA AR DE35 48 48 N A 48 N A 48 N A N A All dimensions are shown in inches No condensing section or piping vestib...

Page 25: ...ized with refrigerant If damage occurs the refrigerant could leak into the atmosphere or cause bodily harm due to the extreme cold nature of expanding refrigerant Use protective equipment such as gloves and safety glasses to minimize or prevent injury in case of a system leak during installation Before Lifting Before lifting be sure that all shipping materials have been removed from the unit Vesti...

Page 26: ...ils including duct locations and dimensions are to be found in the roof curb assembly instructions Rooftop units require curbs to be mounted ﬁrst The duct connections must be located so they will be clear of structural members of the building 1 Factory Supplied Roof Curbs Roof curbs are shipped in a knockdown kit includes duct adapters and require ﬁeld assembly by others on all housing sizes excep...

Page 27: ... configuration and the area directly beneath the heat source must not have any openings such as louvers or grates Rail Mounting and Layout The units may be installed on rails provided and installed by others Ensure that rails are designed to handle the weight of the unit and provide proper load distribution on building supports Make sure that rail positioning does not interfere with the openings o...

Page 28: ...f the location and ensure the use of an alternate location does not interfere with unit wiring components or functionality Gas Connections If this unit is equipped with an indirect gas fired furnace connection to an appropriate gas supply line will be required For complete information on installation procedures for the optional gas furnace refer to the PVF PVG Indirect Gas Fired Heat Module Instal...

Page 29: ...cause severe bodily harm or death NOTE Housing size 35 gas furnaces are designed for gas pressure of 5 13 5 in w g for natural gas 6 in minimum on single 500 600 MBH furnaces and 11 13 5 in w g for LP If the gas pressure at the job location is greater than 13 5 in w g an additional regulator is required to reduce pressure For other models reference the PVF and PVG IOM ...

Page 30: ...ance with accepted industry standards Pipework should be supported independently of the coils Undue stress should not be applied at the connection to coil headers 2 The condensate drain pipe should be sized adequately to ensure the condensate drains properly Refer to Condensate Drain Trap section 3 When connecting suction and liquid connections make sure the coil is free from all foreign material ...

Page 31: ...mine the Size of the Main Power Lines The unit s nameplate states the voltage and the unit s MCA The main power lines to the unit should be sized accordingly The nameplate is located on the outside of the unit on the control panel side cause motor starters to chatter or not pull in which can cause contactor failures and or motor failures Field Provided Disconnect If ﬁeld installing an additional d...

Page 32: ... 13 Relays 11 14 Dirty ﬁlter switch 15 Wheel pressure switch 16 Outdoor airﬂow monitor 17 Exhaust airﬂow monitor 18 Digital scroll controller 18 8 12 13 Controls Cabinet 5 Accessible via compressor door Optional Indirect Gas Fired Furnace Note In some models two furnaces are installed to provide greater output When two furnaces are installed they are in parallel and both will operate at the same t...

Page 33: ... airﬂow delivered by the fan to maintain room air temp at a desired set point Optional 0 10 VDC by others to VFD Supply fan is modulated by a 0 10 VDC ﬁeld provided by others Exhaust Fan VFD Sequence Optional Building Static Pressure Sensor The exhaust fan is modulated based upon the signal from a building static pressure sensor The microprocessor will modulate the exhaust fan based upon a compari...

Page 34: ...inute CFM at factory controller or can be read by a building management system if communication is established Operation Outdoor and or exhaust airﬂow monitoring is accomplished using two thermal dispersion sensors that accurately measure airﬂow velocity down to zero feet per minute fpm The airﬂow controller takes the average measurement for two sensor conﬁgurations and determines the outdoor airﬂ...

Page 35: ...int bipolar ionizers are mounted on the fan inlet cone s and provide air disinfection The ionizers are factory powered and are on when there is power to the unit disconnect Frost Control Extremely cold outdoor air temperatures can cause moisture condensation and frosting on the energy recovery wheel Frost control is an optional feature that will prevent control wheel frosting Three options are ava...

Page 36: ...ss the filters exceeds the set point the sensor will close a set of contacts in the unit control center Field wiring of a light or other alarm to these contacts will notify maintenance personnel when filters need to be replaced The switch has not been set at the factory due to external system losses that will affect the switch This switch will need minor field adjustments after the unit has been i...

Page 37: ...r Drier 10 Sight Glass 11 Fan Cycle Switch es The switch es open or close based on liquid refrigerant pressure to control the condensing fans to maintain liquid pressure 12 Thermostatic Expansion Valve TVX Each unit is equipped with a TVX on each refrigerant circuit The valve controls the ﬂow of liquid refrigerant entering the evaporator coil by maintaining a constant factory set superheat of 10 F...

Page 38: ...Factory Installed Refrigeration System Components Air Source Heat Pump with Three Way Hot Gas Reheat ...

Page 39: ...sor circuit is equipped with a reversing valve to reverse the direction of refrigerant flow switching the unit between heating and cooling mode 12 Electronic Expansion Valve EXV or Thermostatic Expansion Valve TXV An expansion valve is provided on each refrigerant circuit This valve controls the flow of liquid refrigerant entering the indoor and outdoor coils by maintaining a constant superheat Th...

Page 40: ...e electrical power to unit to OFF at disconnect switch es Unit may have multiple power supplies CAUTION Use caution when removing access panels or other unit components especially while standing on a ladder or other potentially unsteady base Access panels and unit components can be heavy and serious injury may occur CAUTION Do not operate without the filters and birdscreens installed They prevent ...

Page 41: ...e heater for each compressor which needs power supplied to it 24 hours prior to start up If start up is scheduled in 24 hours unlock the disconnect power and energize unit Compressor shipping brackets are removed if provided IG Furnace If there is an indirect gas fired furnace in this unit refer to the manual provided with this unit for Pre Start Up information Gas piping is complete and gas lines...

Page 42: ...if equipped L1 Amps L2 Amps L3 Amps Condensing Fans PDX only Condensing Fan 1 L1 Amps L2 Amps L3 Amps Condensing Fan 2 L1 Amps L2 Amps L3 Amps Condensing Fan 3 L1 Amps L2 Amps L3 Amps Condensing Fan 4 L1 Amps L2 Amps L3 Amps Condensing Fan 5 L1 Amps L2 Amps L3 Amps Condensing Fan 6 L1 Amps L2 Amps L3 Amps Condensing Fan 7 L1 Amps L2 Amps L3 Amps Condensing Fan 8 L1 Amps L2 Amps L3 Amps Outdoor Fan...

Page 43: ...een 10 and 20 F 0 reheat or should be between 10 and 30 F 100 reheat Deg F Deg F Deg F Deg F Subcooling Housing 35 Should be between 10 and 15 F 0 reheat or should be between 2 and 10 F 100 reheat Deg F Deg F Deg F Deg F Discharge Pressure Should be between 300 and 500 PSIG PSIG PSIG PSIG PSIG Suction Line Pressure Should be between 100 and 135 PSIG PSIG PSIG PSIG PSIG Liquid Line Temp Deg F Deg F...

Page 44: ...Deg F Deg F Suction Line Temp Deg F Deg F Moisture Indicating Sight Glass Liquid Visible Liquid Visible Color of Center Dot Yes No Purple Pink Yes No Purple Pink Heating Superheat Should be between 10º and 20ºF Deg F Deg F Subcooling Should be between 10º and 20ºF Deg F Deg F Discharge Pressure Should be between 250 and 500 PSIG PSIG PSIG Suction Line Pressure Should be between 96 and 155 PSIG PSI...

Page 45: ...he drive side and should match the rotation decal affixed to the fan housing If the wheel is rotating the wrong way direction can be reversed by interchanging any two of the three electrical leads Check for unusual noise vibration or overheating of the bearings Refer to the Troubleshooting portion of this manual if a problem develops Supply Exhaust Fan The optional exhaust fan is a direct drive pl...

Page 46: ...ree duct diameters downstream of the heat exchanger The sensor must be connected directly to the microprocessor controller All other sensors and low voltage devices are to be connected to the low voltage terminal strip in the control center The discharge air sensor is shipped loose and can be found in the unit s control center See the unit specific wiring diagram for connection locations ...

Page 47: ...et ﬂow and press ENTER 9 Set ﬂow to actual CFM measured by Test and Balance and press ENTER 10 Wait for calibration before cycling power 11 Proceed to Communication Setup Communication Setup 1 Press the UP and DOWN keys at the same time for 3 seconds 2 When SETUP appears on the screen press ENTER 3 Scroll DOWN twice to the NETWORK menu and press ENTER 4 When NETOUT appears on the screen press ENTE...

Page 48: ...ch Senses pressure on the blower side of filters Positive pressure connection is toward the back or bottom of the switch Senses pressure at air inlet side of filters 2 Replace the ﬁlter compartment door 3 Check to see if there is power at the alert signal leads refer to electrical diagram 4 Whether there is power or not turn the adjustment screw on the dirty ﬁlter gauge clockwise if you did not ha...

Page 49: ...isconnect the wiring to the wheel module and pull the wheel cassette out of the cabinet on its tracks Large cassettes are not removable Then slowly rotate the wheel by hand to make sure there is no binding or misalignment There is a perimeter seal located around the outside of the wheel and a diameter seal across the face of the wheel on both sides Check to make sure that all air seals are secure ...

Page 50: ...ord and secure it so it cannot jam or otherwise get damaged Each wheel has removable segments that hold the coated layers of media and each segment is held can also be used Avoid aggressive organic solvents such as acetone Wheel segments can be soaked in the above solution overnight for removal of stubborn dirt or accumulations After cleaning is complete shake excess water from the wheel or segmen...

Page 51: ...leanliness of the air If air filters are not changed frequently the wheel will collect contaminants and will then have to be cleaned Cleaning Accumulation of dust or particles on the surface of the wheel can typically be vacuumed purged with compressed air or wiped from the surface In cases when a more thorough cleaning is required use the following procedure Liberally spray 409 cleaner onto a sma...

Page 52: ...ected It is located in the main control center Variable Frequency Drive VFD Variable frequency drives have a display screen that will show an alarm condition If a fault such as a voltage spike occurs the VFD will go into alarm and will not reset until a hard restart is performed See the unit speciﬁc manufacturer s manual supplied with the unit VFDs are located in the main control center Optional D...

Page 53: ... windings in motor Replace motor Low airﬂow cfm Unit damper not fully open Adjust damper linkage or replace damper motor System static pressure too high Improve ductwork to eliminate losses using good duct practices Blower speed too low Check maximum motor RPM and compare with catalog data Verify that external control wiring is in place if required Fan wheels are operating backwards For 3 phase se...

Page 54: ...ngs or burn out Compressor may be seized check refrigerant If necessary replace compressor High pressure switch open or defective If manual reset high pressure reset switch Switch opens at 610 psi and will not reset above 420 psi for R 410A Replace if defective Low pressure switch open or defective See switch label for set point Open room thermostat or control No cooling required Check room temper...

Page 55: ...tem Check air conditions and cfm Compressor cuts out on thermal Defective compressor overload If compressor is hot allow compressor to cool for two hours Recheck for open circuit Improper refrigerant charge Check subcooling overload Improperly wired Review wiring schematics Loose wiring Check all connections Defective start relay Replace relay Motor windings damaged Verify amp draw Compressor hums...

Page 56: ... for proper clearances and possible air recirculating Clean coil Condenser fan motor defective Check condenser fan motor Too much refrigerant Check subcooling Remove excess refrigerant Non condensable in system Remove non condensable from system Dirty condenser coil Clean condenser coil Condenser fan not running or running backwards Check electrical circuit and fuse Check fan cycling controls High...

Page 57: ...ck system for leaks Repair leaks and add refrigerant Short cycling Check low pressure control settings Refrigerant ﬂood back Check thermal expansion valve setting Check for refrigerant overcharge Check crankcase heater operation Reheat ﬂush cycle inadequate Contact factory Not enough cooling or lack of cooling Refrigeration undercharged Check subcooling Adjust charge if necessary Dirty ﬁlter or ev...

Page 58: ...noise Lubricate bearings in accordance with the motor manufacturer s recommendations 2 Condensate Drain if applicable Inspect and clean reﬁll with water 3 Condenser Coils Inspect for cleanliness clean as required 4 Outdoor Fan Blades and Motor If applicable Check for cleanliness Check all fasteners for tightness Check for fatigue corrosion wear Annually It is recommended that the annual inspection...

Page 59: ...nsteady base Access panels and unit components are heavy and serious injury may occur Internal Filter Maintenance The unit will typically be provided with 2 inch thick pleated paper ﬁlters in the airstream These ﬁlters should be checked according to a routine maintenance schedule and replaced as necessary to ensure proper airﬂow through the unit Replacement ﬁlters shall be of same performance and ...

Page 60: ...12 1 16x20x1 NA NA 1 12x24 1 24x24 AR DR22 4 20x20x2 NA NA 4 20x20 AR DR311 4 25x25x2 NA NA 8 16x25 AR DR311 8 16x20x2 NA NA 8 20x20 4 16x20 AR DR35 30 40 tons 8 20x25x1 NA NA 6 row DX coil 4 20x24 4 20x20 4 row DX coil 6 20x24 6 20x20 AR DR35 50 60 70 tons 8 20x25x1 NA NA 6 20x24 6 20x20 AR DE12 4 20x20x2 2 20x25x2 2 20x25x2 4 20x20 AR DE22 4 25x25x2 4 16x25x2 4 16x25x2 8 16x25 AR DE32 12 16x20x2...

Page 61: ...CESS CONTROL CENTER ACCESS COMBUSTION AIR INLET EXHAUST OUTLET IG FURNACE ACCESS B A IG FURNACE ACCESS B A COMBUSTION AIR INLET EXHAUST OUTLET C C D D IG Venting Location Model Furnace Size MBH A B C D Flue Connection Size diameter in inches Standard 2 Pipe Concentric Exhaust Exhaust Intake AR DR12 AR DE12 100 14 23 5 20 5 20 5 4 4 4 150 4 4 4 200 15 2 23 7 31 5 35 9 6 6 6 250 6 6 6 300 6 6 6 AR D...

Page 62: ...0 AR DR22 17 5S 4650 AR DR22 17 5A 5500 AR DR22 20I 5100 AR DR22 20D 5100 AR DR22 20S 5100 Model Airflow SCFM AR DR22 20A 6400 AR DR22 25I 5750 AR DR22 25D 5600 AR DR22 25S 5600 AR DR22 25A 7200 AR DR22 30I 6000 AR DR22 30D 6000 AR DR22 30S 5750 AR DR22 30A 7000 AR DR31125D 6500 AR DR31125S 6500 AR DR31130D 7000 AR DR31130S 7000 AR DR31135D 7000 AR DR31135S 7000 AR DR31143D 8100 AR DR31143S 8100 A...

Page 63: ... refrigeration units In these conditions condensate could form in the duct furnace and provision must be made to dispose of the condensate WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage Be sure to read and understand the installation operation and service instructions in this manual Improper installation adjustment...

Page 64: ...er Control Turndown Burner turndown ratio is used in many places and must be calculated On the data label locate the INPUT BTU HR the largest number on the label and also the MINIMUM INPUT BTU HR Calculate the burner turndown ratio and record it INPUT BTU HR Burner Control Turndown Ratio MINIMUM BTU HR Example 150 000 2 75 000 The turndown ratio is 2 1 in this example Burner Turndown Furnace Seria...

Page 65: ...the unit specific wiring diagram located on the unit control center door This illustration is only for a typical 4 1 turndown electronic modulation configuration Optional Microprocessor Controller Configuration Microprocessor Controller Located in unit main control center Expansion Board Activates and modulates Modulating Valve Furnace Controller Temperature Sensor If there is no Microprocessor Co...

Page 66: ...ferent pressure The switch is connected to the combustion blower by means of a vacuum tube and is used to sense operation of the combustion blower The internal switch is Normally Open NO If the blower fails to operate the open circuit will cause the ignition controller to disable the furnace Flame Igniter The igniter receives a high voltage input from the ignition controller to produce a spark bet...

Page 67: ...rnace Unit 4 1 uses modulating valve and furnace controller High turndown uses 4 1 modulating valve with split manifold and furnace controller Two Furnace Unit 4 1 uses two 4 1 modulating furnaces controlled in parallel High turndown furnaces in a parallel configuration use two high turndown furnaces controlled in parallel of its maximum capacity The electronically controlled gas valve will modula...

Page 68: ... exhaust pipe Exhaust transition and vent termination must be purchased from the factory for proper operation Exhaust pipe is by others Installation of Venting for Indoor Units WARNING The following guidelines must be followed for all indoor units 1 Installation of venting must conform with local building codes In the absence of local codes installation must conform with the National Fuel Gas Code...

Page 69: ...building Units must not be installed in a potentially explosive flammable or corrosive atmosphere To prevent premature heat exchanger failure do not locate unit where chlorinated halogenated or acid vapors are present When units are installed in tightly sealed buildings provisions should be made to supply an adequate amount of infiltration air from the outside The rule of thumb is that an opening ...

Page 70: ...ng instructions Mounting Bracket COMBUSTION AIR B A Exhaust Vent Termina l Mounting Bracket Combustion Air Inlet Guard Vent Connection Diameter Vent terminals must be used one vent terminal and inlet guard included with each furnace Construct the vent system as shown in the drawings and refer to the table for the correct vent connection diameters CVA 4 4 inch Concentric Venting Adapter Combustion ...

Page 71: ...Assembly to Unit Connect the unit s combustion exhaust to the exhaust connection on the CVA Connect the unit s combustion air supply intake to the combustion air connection on Roof Line A Mounting Bracket C C Combustion Air Inlet Terminal Mounting Bracket Tee with drip leg and clean out cap the CVA Install Combustion Air Inlet Guard and Exhaust Vent Terminal Slide the combustion air inlet guard ov...

Page 72: ...systems Maintain at least 12 inches of clearance between the exhaust pipe termination and the exterior surface of the exterior wall The combustion air pipe must be a minimum of 12 inches from the exhaust pipe and 2 inches from the exterior surface of the outside wall A maximum of 48 inches of building wall thickness is required for separated combustion vent pipe Vent Connection Diameter Vent termi...

Page 73: ... openings around the vent pipes Installation of Control Wiring Disconnect power supply before making any wiring connections to prevent electrical shock and equipment damage All appliances must be wired strictly in accordance with the wiring diagram furnished with the unit Any wiring different from the diagram could result in a hazard to persons and property Any original factory wiring that require...

Page 74: ...fer to a Gas Engineer s Handbook for gas pipe capacities NOTE Each furnace has a single 3 4 inch connection Determine the Gas Supply Requirements The data label located on the face of the furnace lists the requirements for the gas being supplied to the unit Connect the Supply Gas Line A manual shut off valve a 1 8 inch plugged test port and a drip leg must be installed between the gas supply pipe ...

Page 75: ...Gas Supply In Typical Split Burner Manifold ...

Page 76: ...ess heat is needed a manifold section will be turned off Each time a manifold section is initialized the manifold section will ignite at 100 6 The ignition control constantly monitors the call for heat the pressure switch and the burner flame to assure proper operation 7 When the unit or furnace controls are satisfied the main gas valve is then de energized and the combustion blower shuts off foll...

Page 77: ... the furnace manifold It has a built in digital controller that will accept user settings for High Fire and Low Fire During normal use the amount of combustion gas will vary constantly to regulate the heat output from the furnace The modulation is controlled by the microprocessor controller through the pCOe expansion board or by the furnace controller The controller sends a 0 10 VDC analog signal ...

Page 78: ...Low Fire Setting Conduct this step when the Commissioning Menu reaches the Low Fire Setting screen 1 With a manometer installed at the burner manifold test port press and hold down button Modulating Valve Adjustments At start up remove the cover from the circuit board housing by loosening the two Phillips head retaining screws Identify Button 1 and Button 2 and also locate the LED indicator light ...

Page 79: ...t modulates or changes the gas volume that is being supplied to the furnace manifold Its function is described in the 4 1 Turndown Electronic Modulation section When a manifold section is initiated the furnace controller will first provide a 10 VDC signal to the modulating valve so that it will always start in a high fire condition After ignition the controller will change its output signal causin...

Page 80: ...tect it and energize the combustion blower Should the main valve later close completely and remove the flame signal the combustion will be de energized Valve Circuit Error 3 red flashes Check that the valve is a 24 volt AC valve Check that the valve is wired correctly Internal Control Error 7 red flashes Check all ground connections including the entire unit Line Frequency Voltage Error solid red ...

Page 81: ... replace blown fuse s Fan Switch S2 open or not wired Close or wire fan switch If fan switch is not required place jumper from R to G Supply fan running No Yes 24 VAC across W1 and C No Yes Freeze protection tripped Cycle disconnect to reset Supply fan overload tripped Push reset button on overload or VFD to reset Check motor amp draw and correct as necessary Damper limit switch D1L not closed Dam...

Page 82: ...on furnace controller SC1 No Yes Blank screen on furnace controller Yes Furnace controller defective or not powered Replace or wire furnace controller No Furnace Controller Alarm Furn Alarm Check Log Yes New furnace alarm s have been logged Press the down arrow to scroll to the end of the alarms menu Press enter to go to the data logger and review alarms No Furnace Controller Alarm Supply Sensor U...

Page 83: ... 7 times or is on Yes No 120 VAC at 120 240 terminal on Ignition Controller IC No Fuse FU8 Blown Test and replace blown fuse Furnace Transformer TR5 fault Replace heating transformer Yes Ignition Controller IC red LED blinks 6 times or Furnace Controller Alarm Comb fan not proved Yes Pressure switch tubing kinked disconnected plugged or filled with water ice Straighten connect clear or replace pre...

Page 84: ...off or combo valve MV switch turned off Turn supply gas valve or combo valve on Inlet gas pressure incorrect Adjust inlet gas pressure to the range specified on the furnace label Improper manifold pressure Set high and low manifold pressure refer to 4 1 Electronic Modulation Start Up section Faulty spark rod or spark gap does not equal 1 8 inch Replace spark rod or adjust gap to 1 8 inch Spark wir...

Page 85: ...sure at combustion fan pressure tap with furnace running and compare reading to pressure setting of pressure switches 1 If Pressure switch trips at wrong pressure replace pressure switch 2 If the combustion fan does not generate enough pressure consult the factory No Furnace Controller Alarm IG furnace max retry Yes Furnace has reached its maximum number of automatic error resets 1 Review alarm hi...

Page 86: ... 24 VAC across G and C No Fan Switch S2 open or not wired Close or wire fan switch If fan switch is not required place jumper from R to G Yes Blank screen on microprocessor controller Yes Microprocessor controller defective or not powered Replace or wire furnace controller Unit Main No Furnace Board Line voltage at primary side of furnace transformer TR5 No Fuse FU7 Blown Test and replace blown fu...

Page 87: ...e Wire or replace outdoor temperature sensor U05 No Inlet air temperature above heating lockout setting Yes Increase heating lockout setting to above inlet air temperature Be sure to return this setting to the proper temperature after testing furnace No Wait for discharge temperature to cool or increase supply temp setpoint sufficiently above inlet air temperature Be sure to return this setting to...

Page 88: ...ition controller Check wiring to combustion fan and correct as necessary Ignition Controller IC BLWR relay fault relay stuck closed Replace ignition controller Pressure switch PS2 failure Repair or replace pressure switch PS2 Microprocessor Alarm Pressure Switch closed with combustion fan off Yes No Microprocessor Alarm IG furnace high pressure Yes Pressure switch tubing kinked disconnected plugge...

Page 89: ...p or remove debris One or more orifices fully or partially plugged Inspect and clean or replace orifices Flame lights but doesn t travel all the way across the burner manifold Yes No Flame flashes back during light off Yes Heat exchanger cracked Inspect and replace heat exchanger if necessary Combustion air inlet or discharge passageway restricted Inspect and remove restriction No Discharge temper...

Page 90: ...roprocessor controller Message codes that may appear include Alarm Descriptions IG furnace no flame after three trials Indicates a furnace failure to light or properly sense flame after 3 trials IG combustion fan high pressure switch failure Indicates a call for high speed combustion fan but high pressure switch did not close IG furnace ignition control Indicates an alarm from the ignition control...

Page 91: ...ices or burners a Remove any soot deposits from the burner with a wire brush b Clean the ports with an aerosol degreaser or compressed air c Wipe the inside of the burner clean Cleaning the burner with a degreaser will slow the future buildup of dirt Before reinstalling the burner assembly look down the heat exchanger tubes to make sure they are clear of any debris Reinstall manifold and burner as...

Page 92: ...ate Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes ...

Page 93: ...ate Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes Date Time AM PM Notes ...

Page 94: ...NOTE For HMA gas furnace for 311 and 352 chassis see separate IOM Manual ...

Page 95: ...er provides user feedback via a web interface or an optional handheld keypad display or can be connected to building management system interface CONTROLLER The DOAS controller receives 24 VAC power from a transformer on the main control panel and is energized when the main disconnect is on The size of the Carel cpCO board varies with unit configuration WEB UI USER INTERFACE ...

Page 96: ...HANDHELD KEYPAD DISPLAY OPTIONAL ...

Page 97: ...ry with IP address 192 68 1 101 Connect CAT5 cable to Ethernet Port 1 and your computer Open web browser Internet Explorer or Chrome browsers are supported and type in IP address SERVICE PASSWORD A service password is required to change or enter some settings To gain service level access go to Main Ctrl Variables Advanced Login Password Change password 0000 to 4800 the Advanced Menu should show F ...

Page 98: ...at the factory Carel c pCO main controller 01 Carel c pCOe expansion boards 02 03 04 05 06 07 Handheld keypad display 32 pLAN addresses are visible on the main controller and on c pCOe expansion boards as shown below EXPANSION BOARD ADDRESSES AND DIP SWITCH SETTINGS Our units use Carel c pCO and c pCOe expansion boards when additional inputs or outputs are required See the following pages for more...

Page 99: ...ess can be set manually at the Main Ctrl Variables Advanced Network Settings screen A service password is required to change this setting Expansion Board Address Offset Baud Rate Protocol Ext Prot Exp 1 2 No 19 2K Modbus Off Off ON Off Off Off Off Off Exp 2 3 No 19 2K Modbus Off Off ON ON Off Off Off Off Exp 3 4 No 19 2K Modbus Off ON Off Off Off Off Off Off Exp 4 5 No 19 2K Modbus Off ON Off ON O...

Page 100: ...Advanced Login screen Press the Enter and Up or Down arrow buttons to enter the service password 4800 2 Go the Main Menu Ctrl Variables Advanced Backup Restore screen 3 Press the Up or Down arrow buttons to navigate to the Backup Settings screen 4 Press the Enter and Up or Down arrow buttons to select the backup location internal memory or USB If creating a backup to a USB drive insert a USB drive...

Page 101: ...unit Carel controller and AC Smart 5 Channel 1 wiring is 18 AWG 2 conductor twisted stranded shielded and must comply with all applicable local and national codes 2 Note that AC Smart 5 or later version must be used with Carel controller AC Smart 4 is not compatible with Carel controller 3 Device ID on Carel controller under Network Settings should be set as follows a AR DE models Carel Device ID ...

Page 102: ...rt 5 Settings tab 2 Click on the AC Smart 00 tab to go to Registration Status and Set CH1 Setting to MODBUS_9600 3 Press Auto Search 4 Press Auto Search to automatically search for devices connected to the controller Once the search is complete click Send All ...

Page 103: ...5 You can add additional units by clicking Add Unit Click Apply after making the selections 6 Click Send All to finish adding your device 7 Go to Control tab then select Device control ...

Page 104: ...n the device you wish to view You will see a new section on the right side of the screen Click View Details 10 You can now view a detailed picture of the unit Click on Info to see other information on the unit such as the model address mode temperature etc ...

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Page 106: ...ENU MAP The Menu map shows screen order when using either the handheld keypad display or the virtual keypad display on the web interface See the Navigation section for instructions about moving through menu screens ...

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