EngA G-TRAC 1.1 Bedienungsanleitung
A
IOM-24 March 1999 R1
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
FOR
G-TRAC
Model 1.1
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. 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 serial number when contacting
factory for information and/or parts.
www.engineeredair.com
A G-TRAC MANUAL
IOM-24 Page i March 1999 R1
TABLE OF CONTENTS
I. PURPOSE ................................................................................................................ 1
II. CAUTION ................................................................................................................. 1
III. SIMPLIFIED OPERATION ....................................................................................... 1
IV. TEMPERATURE CONTROL .................................................................................... 2
G-TRAC as a Slave to the CTRAC ...................................................................................................... 2
Suggested Settings Re Hunting Problems ........................................................................................ 2
G-TRAC as a “Stand Alone Device” ................................................................................................... 2
V. MASTER SET-POINT .............................................................................................. 3
TE 6100 Wiring Connections and Resistance Values ...................................................................... 3
Sensor Resistance Chart for TE 6100-960 and TE 6000-960 ............................................................ 4
Temperature Can Be Controlled By ................................................................................................... 4
VI. RESET CONTROL ................................................................................................... 4
Example 1 ............................................................................................................................................. 5
Example 2 ............................................................................................................................................. 5
Example 3 ............................................................................................................................................. 5
Multiple Room Sensors ....................................................................................................................... 6
Room Reset Authority Pot .................................................................................................................. 6
VII. TO TEMPORARILY DRIVE THE UNIT TO HIGH OR LOW FIRE ............................ 6
VIII. G-TRAC DISCHARGE TEMPERATURE SENSOR/SETPOINT CALIBRATION ..... 6
Method 1 ............................................................................................................................................... 6
Method 2 ............................................................................................................................................... 7
IX. ROOM RESET CONTROL CALIBRATION ............................................................. 7
Method 1 (Most accurate method) ............................................................................................................ 7
Method 2 (Does not correct for remote wire resistance) ............................................................................. 7
A G-TRAC MANUAL
IOM-24 Page ii March 1999 R1
Method 3 ............................................................................................................................................... 8
Method 4 (May correct minor electrical noise on remote wire) ................................................................... 8
X. BMS RESET OF THE DISCHARGE AIR TEMPERATURE ..................................... 8
XI. POTENTIOMETERS ON THE G-TRAC ................................................................. 10
XII. DIAGNOSTIC LIGHTS ........................................................................................... 10
Heat Call Light .................................................................................................................................... 10
Pre-Purge Timer Light ....................................................................................................................... 11
Burner Enabled Light ........................................................................................................................ 11
XIII. TROUBLE SHOOTING .......................................................................................... 11
Supply Blower Not Starting .............................................................................................................. 11
No Heat (Burner Not Firing) ................................................................................................................ 12
Low Heat (Burner Firing) .................................................................................................................... 12
Unit Short of Temperature Rise ........................................................................................................ 12
Over Delivering Air ............................................................................................................................ 13
Inlet Gas Pressure Low or Burner Rumbles.................................................................................... 13
Regulator/Manifold Pressure Low or Slow to Respond ................................................................. 13
Gas Valve Won’t Open Fully (G-TRAC Slave to CTRAC) ................................................................... 13
Water and Ice From Combustion ...................................................................................................... 13
Over Heating ....................................................................................................................................... 14
Rapid Cycling of SA Contacts on G-TRAC Connected to BMS Reset .......................................... 14
G-TRAC not responding to BMS signal ........................................................................................... 14
Flame Failure Lockouts ..................................................................................................................... 14
“B” and “C” BURNER ELECTRODE DETAIL............................................................................15
XIV. CHANGING A G-TRAC IN THE FIELD .................................................................. 15
TO SET PRE-PURGE TIME DELAY ................................................................................................... 15
TO SET THE MAINTAIN PURGE TIME DELAY ................................................................................ 16
A G-TRAC MANUAL
IOM-24 Page iii March 1999 R1
ESTIMATED POT SETTINGS (Use for situations where design values not available) .............................. 16
Combustion Set Up ............................................................................................................................ 17
High Fire Combustion Set Up ....................................................................................................17
Low Fire Combustion Set Up .....................................................................................................17
Mid-Fire Range Combustion Set Up ..........................................................................................17
CHECK OUT FOR G-TRAC-1 NORMAL OPERATION .................................................... 18
A G-TRAC MANUAL
IOM-24 Page 1 March 1999 R1
A
G-TRAC
CONTROL FOR MODULATING DG UNITS
If you note any errors, omissions, or items that require further clarification, please contact Wade Pascoe at
(403) 287-4775 or Fax (403) 287-4799 or (403) 243-5059.
To ensure warranty is honoured, only a qualified HVAC service person or gas fitter thathasreceivedtraining
ontheG-TRAC,should be employed for service andtroubleshooting.Ifinformationisrequired please contact
the nearest Engineered Air office.
If conversion of degrees F to C is wanted, refer to table on page 4.
I. PURPOSE
The G-TRAC is designed to provide an accurate method of temperature control by modulating the size of the
flame on the DG Series heaters. It has been designed to operate with a variety of discharge control devices
and has the ability to utilize a room sensor for set point override control. The usual controls being applied to
the G-TRAC are arranged to Johnson Controls TE 6000/TE 6100 series or the G-TRAC is being operated as
a slave to the CTRAC. It is often applied to Gordon Piatt or Maxon Burner Systems.
II. CAUTION
The G-TRAC has a number of internal potentiometers. These are set up at the factory. These potentiometers
should not be field adjusted unless consultation has been made with someone who is familiar with the control.
Tampering may misalign the control operation resulting in poor combustion and/or poor temperature control or
calibration.
III. SIMPLIFIED OPERATION
24 V power to terminals "H" and "N"
36 seconds later terminals "SA" and "SA" make to start supply fan if the heat switch is not “on”.
NOTE: If the heat switch is already "on" there may be a further delay before the supply
blower starts while the heat starts.
Closing the remote heat switch places 24 V power to "HS" (heat switch).
If there is a call for heat from the temperature control device attached to the G-TRAC:
- As a safety procedure, the G-TRAC checks if "AS" is closed before the combustion blower starts. If it
is, then "CB" contacts will not close to start the combustion blower due to a closed air switch.
- If “AS” is open then "CB" to "CB" will close to start the combustion burner motor. Pre-purge is factory
set between 1 and 8 minutes. The length of pre-purge time is determined by the size of the heat
exchanger. (Jumper selection listed in Section XIV about replacing the G-TRAC.)
- The combustion blower moves air into the combustion chamber and the airflow closes the air switch
putting 24 volts on G-TRAC terminal "AS" (air switch).
- After pre-purge is complete "FR" to "FR" (flame relay) closes to power the flame relay for an ignition
attempt.
- If the supply blower had been shut off, "SA" to "SA" will close again 36 seconds after the pre-purge is
done to re-start the supply air fan. This is to allow for heat exchanger warm-up.
A G-TRAC MANUAL
IOM-24 Page 2 March 1999 R1
The flame relay (external to the G-TRAC) energizes the ignition transformer and pilot solenoid valve.
When the pilot is established, the flame relay will power the main gas valve and shut off the spark.
The G-TRAC and its associated controls maintain the discharge air temperature.
If the rise in discharge air temperature at low fire is greater than that required to satisfy the set-point, it is
necessary to cycle the burner on and off. The normal G-TRAC will likely cycle at about one minute intervals
and at a 20ºF-temperature swing when a low temperature rise is required. At extra cost the G-TRAC can be
tuned to "high sensitivity" which causes more burner cycling but gives better discharge control during
conditions when only a small increase is needed in discharge temperatures.
When higher temperature rise is required the G-TRAC will modulate the size of the flame rather than cycle
the burner. Note that burner cycling may occur in temperatures where theory suggests modulation should be
possible. This is caused by the mass of the heat exchanger, the time heat transfers to the air and the time for
the discharge temperature control device to react.
After a heat call is complete the combustion blower will remain in a "maintain purge” mode for 7 to 15
minutes (depending on jumper selection noted later). If the combustion blower is running it will allow a heat
call to start immediately without going through pre-purge.
IV. TEMPERATURE CONTROL
G-TRAC as a Slave to the CTRAC
In this application there is no temperature control sensor or set point attached to the G-TRAC. The G-TRAC’s
ability to control the firing rate is done with a 0 to 10 VDC volt signal from a CTRAC2.1 terminals "HD and B",
(0 to 8.5 VDC on the CTRAC2 version terminal "HT and B"). The CTRAC2.1 is the master control of the system.
G-TRAC heat call light will be activated when about a 4.5 VDC signal is received from the CTRAC. Terminal
HT to B are connected to D and W of G-TRAC. Refer to C-TRAC manual also.
Suggested Settings Re Hunting Problems
C-TRAC2.1 with G-TRAC with TE 6000-960 discharge sensor – may modulate through 20 degrees.
Set C-TRAC Pots Set G-TRAC Pots
P3 = 6 min. as high as 9
P6 = 5 ***
P11 = 2
P5 = 2
P6 = 4
P8 = 4
C-TRAC2.1 with G-TRAC and hyper sensor – may modulate whtough 10 degrees.
Set C-TRAC Pots Set G-TRAC Pots
P3 = 6 min. as high as 9 P5 = 2
P6 = 5 *** P6 = 4
P11 = 2 P8 = 4
*** On C-TRAC2.1 pot 6 does not exist.
G-TRAC as a “Stand Alone Device”
Either the internal set point or an external set point will be used as the discharge set point. Most installations
will use an external set point.
The usual discharge set-point control is a Penn TE 6100-960 control (which is both a set point and sensor, but
only the set point half is wired). The TE 6100-960 set-point device requires a cover such as T4000-264S. The
discharge sensor is a Penn TE 6000-960 sensor located in the discharge air stream.
A G-TRAC MANUAL
IOM-24 Page 3 March 1999 R1
V. MASTER SET-POINT
TE 6100 Wiring Connections and Resistance Values
As a SET POINT, the G-TRAC is designed to use either:
The set point pot 4 (auxillary setpoint) (range of 12-35°C or 55-95°F). If the G-TRAC pot 4 auxillary set-point
is used, terminals “SP and S” must be jumped, or;
The Johnson TE 6100-960 set point (range of 50-85°F and often remote mounted). If the TE 6100-960 is
used as a set-point, “S to SP” must not be jumpered and the TE 6100 must be wired:
TE 6100 Wires CTRAC2.1 Terminals
Violet (not used, sensor)
Blue U
Orange S
Grey M
Red (not used) Q
(No jumper S-SP)
TE6100-960 Sensor/Set Point
SENSOR (purple and blue) Same resistance as TE 6000-960
Set-Point Dialled To
60 degrees 90 degrees
POT
(orange and grey) 2.725 K 3.272 K
(orange and blue) 3.184 K 2.702 K
(blue and grey) 970
OTHER (purple and orange) 4.19 K 3.71 K
(purple and grey) About 1.981 K (varies with element temp.)
TE 6000 Sensor
A G-TRAC MANUAL
IOM-24 Page 4 March 1999 R1
TE 6000 SENSOR
SENSOR (purple and blue) Resistance in table below
Sensor Resistance Chart for TE 6100-960 and TE 6000-960
°C °F Resistance °C °F Resistance °C °F Resistance
-40 -40 602-605 18.3 65 983 48.9 120 1234
-34.4 -30 633 20 68 996 54.4 130 1269
-28.9 -20 665 20.6 69 1000.7 60 140 1333
-23.3 -10 698 21.1 70 1005 65.5 150 1365
-17.8 0 732 23.9 75 1026.5 71.1 160 1437
-12.2 10 768 26.7 80 1048 76.7 170 1491
-8.7 20 804 29.4 85 1070 82.2 180 1546
-1.1 30 842 32.2 90 1092 87.7 190 1602
4.4 40 881 35.6 95 1116 93.3 200 1659
10 50 921 37.8 100 1139 98.8 210 1718
12.8 55 941.5 43.3 110 1186 100 212 1778
Reference resistance is 1035 ohms at 77°F. Resistance tolerances are ±0.05 to 0.15% at 77°F. Temperature range +32 to
+104°F. (TE 6100-960 pot is 53C3, 500R, 7/8 by ¼ shaft.)
NOTE: Engineered Air’s design discharge temperature range is 30 to 140ºF.
Temperature Can Be Controlled By
DISCHARGE AIR CONTROL Consists of TE6000-960 duct sensor and set point (often
TE 6000-960) wired as above (or use the internal set point pot
4 with a jumper on “S to SP”).
DISCHARGE CONTROL WITH ROOM RESET Consists of duct sensor and set point wiring as noted
above with room sensor/set-point also connected to the G-
TRAC. (To activate this feature there must be a jumper from
terminals “RR and +”.)
Seldom used is control from a Honeywell T991A or equivalent control wired to terminals “D, U, M and V”
(R=D, W=U, B=M and V).
NOTE: To determine your system, refer to the unit wiring diagrams.
VI. RESET CONTROL
TE 6100 WIRE COLOUR C-TRAC2.1 TERMINAL PURPOSE
Room reset sensor/set-point
Blue Z Room reset set point +
Grey V Room reset set point
Orange Y Room reset centre tap
Violet X Room sensor
In a stand-alone system the G-TRAC operates as a discharge air control. If a room-reset control is used,
the room set point and sensor will modify the set point. This is best explained by an example. The room
reset ratio authority (pot 2) setting determines high and low discharge points.
A G-TRAC MANUAL
IOM-24 Page 5 March 1999 R1
Example 1
Discharge Room Room Reset High Discharge Low Discharge
Set point Set-point Ratio (Pot 2) Room Call Max Room Call Min
70ºF 72°F Pos 3 = 14 84°F 56°F
As the room temperature deviates from 72ºF it can modify the discharge temperatures up to as high as
84ºF and as low as 56ºF.
Example 2
Discharge Room Room Reset High Discharge Low Discharge
Set point Set-point Ratio (pot 2) Room Call Max Room Call Min
55ºF 72°F Pos 3 = + 14 69°F 41°F
As the room temperature deviates from 72°F it can modify the discharge temperature up to as high as 69°F
and as low as 41°F. Note you cannot reach a 72° room temperature. Also note that the internal design of
the G-TRAC will resist dropping the discharge temperature below 52°F.
Example 3
Discharge Room Room Reset High Discharge Low Discharge
Set point Set-point Ratio (pot 2) Room Call Max Room Call Min
63ºF 72°F Pos 4 + 18 81°F 45°F
This will allow discharge temperature as high as 81°F. If the room set point were turned up to 76°F we
would reset discharge to 81°F until the space temperature was raised to about 76°F. Also note that the
internal design of the G-TRAC will resist dropping the discharge temperature below 52°F.
NOTE: When dealing with systems that are equipped with room reset controls be aware
that any room sensor must be located in an area where it is sensing a true
average space temperature. A room reset that is located in a hot or cool area that
does not represent the room temperature willcreate room comfort problems. Also
do not locate the reset sensor in an area that is affected by discharge air from any
duct or other device. The G-TRAC terminals "RR and +" need to be jumped when
when the room reset is used. Note that on some wiring diagrams this may be
jumped during one mode and inactive in another.
TE
6000
TE6000
Grey
X
V
Orange
Blue
Built in
TE6100
TE6000
Violet
A G-TRAC MANUAL
IOM-24 Page 6 March 1999 R1
Multiple Room Sensors
Four sensors can be wired to give an average reading of room temperatures to the Trac cntrol. They must
be wired in a series/parallel arrangement. The drawing shows a circuit making use of the built in sensor in
the T#6100 Johnson Sensor/set point assembly and using TE6000 sensors for the other three. (The other
three could also be TE6100, just using the sensor wires)
Room Reset Authority Pot
Position Reset Amount Position Reset Amount
1 ±9°F 4 ±18°F
2 ±11°F 4.5 ±23°F
3 ±14°F 5 ±32°F
VII. TO TEMPORARILY DRIVE THE UNIT TO HIGH OR LOW FIRE
To force a G-TRAC to full heat, short the discharge sensor "Q" and "U".
To force a G-TRAC to low fire substitute a 1000 ohm resistor for the discharge sensor and adjust the set-
point pot to a point that just turns the heat call light on.
VIII. G-TRAC DISCHARGE TEMPERATURE SENSOR/SETPOINT CALIBRATION
Calibration is best done with supply fan on.
Method 1
Bring the G-TRAC to a stable discharge temperature by the following steps after disconnecting any override
devices. If the room reset option is wired on the unit you are working on you must disconnect the jumper
between “RR and +”. Note that all other potentiometer settings should be finalized before continuing with
this procedure. Calibration may be affected if other pots are adjusted after this procedure is complete.
Pivot
Point
RESET CONTROL
Discharge Temperature
Warm Discharge
Discharge Air Set Point
Cool Discharge
Room Hot
Room Cold
Room Temperature
Room Set Point
Inhaltsverzeichnis
Andere EngA Controller Handbücher
