Engineered air EngA G-TRAC2 Bedienungsanleitung

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. 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

AG-TRAC2

IOM-25 2 of 42 Mar 99 R7

TABLE OF CONTENTS

I. APPLICATION.......................................................................................................................................................................6

II. SERVICE............................................................................................................................................................................6

III. RESET DISCHARGE AIR TEMPERATURE...........................................................................................................................6

IV. GENERAL DESCRIPTION...................................................................................................................................................6

OPERATION .................................................................................................................................................................................6

BASIC FEATURES...........................................................................................................................................................................7

V. WIRING ............................................................................................................................................................................7

VI. SYSTEM TIMINGS.............................................................................................................................................................8

VII. BLOWER AIR AND GAS MODULATION............................................................................................................................8

VIII. DIP SWITCHES..................................................................................................................................................................8

DIP SWITCH BLOCK A....................................................................................................................................................................8

DIP SWITCH BLOCK “B” –FUEL CURVES/AIR CURVES ..........................................................................................................................9

GAS CURVES.........................................................................................................................................................................9

AIR CURVES ..........................................................................................................................................................................9

DIPSWITCH BLOCK “C” –LOW LIMIT,PI, CTRAC, 010 VDC CONTROL ...............................................................................................9

IX. POTS...............................................................................................................................................................................10

X. STATUS LIGHTS ..............................................................................................................................................................10

LED 1BURNER PRE-PURGE..........................................................................................................................................................10

LED 2HEAT REQUIRED................................................................................................................................................................11

LED 3LOCKOUT FLAME FAILURE OR LOW LIMIT...............................................................................................................................11

LED 4BURNER ..........................................................................................................................................................................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)...................................................................................................................13

XIII. BASIC BURNER OPERATION ..........................................................................................................................................14

1. THE BASIC BURNER-OPERATING SCHEME IS AS FOLLOWS:............................................................................................................14

2. HEAT REQUIRED LED ON ....................................................................................................................................................16

3. PRE-PURGE LIGHT...............................................................................................................................................................16

XIV. TEMPERATURE CONTROL –GENERAL OVERVIEW .......................................................................................................17

XV. THE MASTER SET-POINT................................................................................................................................................17

XVI. INDUCED VOLTAGE ON REMOTE CONTROL WIRING ...................................................................................................17

XVII. NIGHT HEAT THERMOSTATS .....................................................................................................................................17

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XVIII. ROOM RESET THERMOSTAT OPTIONS......................................................................................................................17

MODULATING ROOM RESET (CONTINUOUS BLOWER OPERATION ONLY).................................................................................................18

CALCULATED DISCHARGE TABLE FOR ROOM AND AMBIENT RESET........................................................................................................21

MULTIPLE ROOM SENSORS...........................................................................................................................................................22

BMS RESET (CONTINUOUS BLOWER ONLY)......................................................................................................................................22

BMS RESET FROM VOLTAGE APPLIED TO +AND –............................................................................................................................23

BMS CALIBRATION .....................................................................................................................................................................23

AMBIENT RESET (DAY MODE ONLY –REQUIRES DIPSWITCH A-2 TO BE ON)............................................................................................23

MAKE/BREAK RESETS AND OVERRIDES ...........................................................................................................................................24

1. “OR” and “V” Override (Day Only) .............................................................................................................................24

2. "X" and "Z" Override (Day and night operation) ...........................................................................................................25

3. Linear Ambient Reset (During day and night) –Room Control with Intermittent Blower (During night) ......................27

DIRECT CONTROL 0–10 VDC –(CTRAC, METASYS).......................................................................................................................27

FOR DIRECT C-TRAC CONTROL OF THE GTRAC-2......................................................................ERROR!BOOKMARK NOT DEFINED.

FOR DIRECT 0–10 VDC CONTROL................................................................................................................................................28

XIX. CALCULATED SET-POINT READOUT (BASE PLUS CALCULATED)....................................................................................28

XX. DISCHARGE TEMPERATURE READOUT .........................................................................................................................29

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 CONTROL RULES .........................................................................................................................................................33

MANUAL SERVICE MODE .............................................................................................................................................................33

COMBUSTION SET UP..................................................................................................................................................................34

PROPANE GAS......................................................................................................................ERROR!BOOKMARK NOT DEFINED.

INLET/MANIFOLD PRESSURE SETTINGS ...........................................................................................................................................36

XIV. SPECIAL SERVICE NOTES................................................................................................................................................37

ON BOARD FUSE ........................................................................................................................................................................37

LOW LIMIT LOCKOUTS .................................................................................................................................................................37

FAILED OPERATION OR SOLID STATE CONTROL CONTACTS BY OTHERS...................................................................................................37

AIR BALANCING (REFER TO NEXT ITEM). ..........................................................................................................................................38

COLD DISCHARGE TEMPERATURE IN COLD WEATHER.........................................................................................................................38

IGNITION PROBLEMS ...................................................................................................................................................................38

REGULATOR GAS PRESSURE RESPONSES..........................................................................................................................................39

PILOT SENSING PROBLEMS ...........................................................................................................................................................39

SMELL FROM FLUE (PRODUCTS OF COMBUSTION).............................................................................................................................39

WATER AND ICE FROM COMBUSTION.............................................................................................................................................39

BURNER PULSING,BACKFIRING,EXPLODING,NOISY ..........................................................................................................................40

FIRE WITHOUT COMBUSTION FAN..................................................................................................................................................40

HEAT LOCKED ON –G-TRAC2 SLAVE TO C-TRAC ...........................................................................................................................40

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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

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IOM-25 5 of 42 Mar 99 R7

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IOM-25 6 of 42 Mar 99 R7

G-TRAC2

Report any errors, omissions, etc. to Engineered Air –Calgary Service at (403) 287-4775 or FAX (403) 287-4799.

Warranty will only be honored when a qualified HVAC service person, who has received training on the G-TRAC2 is

employed for service and troubleshooting. If further information is required please contact the nearest Engineered Air

office.

I. APPLICATION

The G-TRAC2 is designed to control larger capacity high turndown “DG” indirect fired burners applied to heating, vent

and/or MUA applications.

II. SERVICE

Do not adjust pots or dip switches unless you are familiar with operation, effect, and how to return to correct setting. Just

noting settings will not allow return to the exact position on some pots, which require special instruments to set.

Before servicing, the technician should be familiar with the following points in this guide:

The GTRAC-2 internal fuse should be checked if the control is dead when 24 VAC is on "T1 and T2". (Section XXIII)

System Timings (Section V)

Basic Operation (Section IV)

Status Lights (Section IX)

Temperature Readout (Section XIX)

Calculated Set-Point (Section XVIII)

Auto Bypass Low Limit (Section X)

III. RESET DISCHARGE AIR TEMPERATURE

Some G-TRAC2's accept reset signals from other devices 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 series heaters. This control

package provides temperature, supply blower, and burner control. The G-TRAC2 eliminates the mechanical linkages

between the combustion air and gas actuator by using direct drive floating point. The G-TRAC2 is not intended to be

retrofitted on jobs with the older G-TRAC/V9055 gas valve combination.

Operation

On start-up the G-TRAC2 opens the dampers and starts the blower after a time delay. If there were a call for heat the

combustion blower would operate at full air to purge the heat exchanger. After the heat exchanger is purged, the air and

gas operators move to “light off position”. The G-TRAC2 closes contacts to activate a flame supervision device. This device

activates the ignition, supervises the pilot flame and main flame. After the main flame is activated a “feedback” signal to G-

TRAC2 terminal 3 allows the G-TRAC2 to modulate the heat as required maintaining the discharge temperature set point. If

there is an optional reset device attached, it electronically modifies the discharge air set point. The “calculated set point”

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IOM-25 7 of 42 Mar 99 R7

value can be read at the terminals provided (See Section XVIII). The G-TRAC2 will modulate/cycle the burner as needed to

maintain discharge air temperatures.

Basic Features

1. Standard service and testing features such as status indicating LED’s, service pot, and temperature test points.

2. Proportional and Integral (PI) discharge air temperature control.

3. Built in discharge set point with a 55 to 100ºF setting range (or optional remote set point).

4. Supports one of the optional resets (discharge set point reset) from the following list:

Room Sensing (resistive)

Ambient Sensing (resistive)

0-10 Vdc

4-20 mA

5. Built in auto bypass low limit (can be switched off, Section X).

6. Alarm output contacts (AL). The contacts provide low limit and flame failure annunciation. (Note the Low Limit bypass

can be switched off, Section X.)

7. Has input terminals for the fan switch, heat switch, and time clock contact, usually remote controlled by a remote

panel, DDC controls etc. Other input terminals are internally controlled. (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 supply = 24 VAC @ 0.9 amps.

The G-TRAC2 terminals T1 and T2 require a separate 24 VAC, 20 VA class 2 ungrounded isolation transformer supplying

power to only T1 and T2.

Terminal N should be wired to the neutral which is common to the same grounded power source supplying power to

terminals HS, FS, K, and AS. All remote wiring less than 50 feet long installed in clean electrical environments and attached

to terminals “M, P, Q, U, X, Y, V, Z” and “OR” should be a minimum of 22 ga twisted pair wire. For longer runs and

electrically noisy installations, the use of a minimum 20 gauge-shielded wire is recommended. (Shield to be grounded at

GTRAC-2 end only.)

The main digital outputs (damper, supply blower, combustion blower, flame relay, pilot valve, and lockout alarm) are rated

at 4 amps. Digital outputs CA, CG, OA and OG are rated at 1 amp at 24 VAC.

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IOM-25 8 of 42 Mar 99 R7

VI. SYSTEM TIMINGS

Pre-purge

75 seconds at 85% opening

Maintained purge

5 minutes

Supply fan start delay (damper open time)

64 seconds

Heat exchanger warm up time

64 seconds

Burner cool down time

60 seconds

Heat exchanger cool down time

1 min (except on low limit failure)

Flame fail

Usually 15 seconds (it is set by flame relay)

Flame fail light

90 seconds from ignition command

Auto Low limit Bypass (from blower start)

5 minutes 30 second anti-cycle timer

VII. BLOWER AIR AND GAS MODULATION

As a gas valve or damper opens or closes, the flow through the device changes in a non-linear fashion. This varying flow rate

normally creates set up and operating problems. Advanced technology in the G-TRAC2 corrects these issues.

The G-TRAC2 monitors both the gas and air operator positions and calculates the corrected flow rates. Modulating

adjustments of the gas and air are based on flow rates through gas valves and dampers, not on degrees of control rotation

that other systems use. 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:

Dip Switch Block A

Is accessible from the large opening on the G-TRAC label. Switch 1 of Block A is located on the right hand side. The switches

are used to activate the following functions:

A-1 BMS reset (0-10 VDC, 0-10 VDC, 4-20 ma).

A-2 Ambient reset.

A-3 Room reset.

A-4 Supply Fan configuration switch. (At start-up and during operation "ON" maintains airflow as a priority, to

pressurize space. "OFF” the discharge temperature has priority).

NOTE:If the airflow has priority then the supply fan doesn’t shut down if the discharge temperature is too cold.

(Often selected as per day/night configuration chart.) This statement applies to the GTRAC-2 control

starting up from a cold start.

A-5 Service mode - If this switch is ‘on’ the ‘Heat Required’ light will be flashing, erratically, indicating the control is in a

service mode.

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Dip switch Block B –Fuel Curves/Air Curves

The GTRAC-2 has built in air to fuel ratio curves. The combination of these curves provides 16 possible settings. The curves

are selected by turning dipswitches on or off. These dipswitches are located in a slot below the set-point knob on the front

of the control. Dipswitches 1 and 4, on block A and B, adjust the gas valve curve; dipswitches two and five adjust the

combustion air curve. There is a label attached to the unit indicating the factory dipswitch settings.

The correct curves for a particular burner will vary based on the gas valve, air shutter, and combustion air blower and unit

size. If there are problems with condensate forming in the flue, the burner can be set up to reduce the amount of

condensate formed. This will require the burner to operate with extra combustion air (higher O2) in the mid-to-low fire

range. Increasing the amount of combustion air distributes the water vapor, formed during combustion, over a larger

volume of flue gases. This 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

OFF

Undersized valve or high efficiency application. Lower O2 in

mid-range.

OFF

Normal Setting

OFF

Oversized gas valve or condensate reduction. More O2in mid-

range.

Even more O2in low and mid-range. *

* On versions manufactured after May 12, 1998.

AIR CURVES

Air Curve

Dipswitch 2

Dipswitch 5

Characteristics

OFF

Rich (Lower O2 in mid-range).

OFF

Normal Setting

OFF

Lean (More O2 in mid-range).

Lean “S” curve

Dipswitch Block “C” – Low Limit, PI, CTRAC, 010 VDC Control

This dip switch block is located:

G-TRAC 2.1 - near the top on the back of the board.

G-TRAC 2.2 –through the small slot at the very top of the panel front.

The controller must be turned over to access these switches. This dipswitch block provides low limit enable or disable, and

control choices of “Normal PI”, “CTRAC PI” or “Direct 0-10 VDC Control” (such as from a BMS).

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IOM-25 10 of 42 Mar 99 R7

NOTE: XXX Switch position does not affect description in “ACTION” box.

SW1

SW2

SW3

SW4

SW5

ACTIONS

XXX

Low limit active. *

XXX

OFF

Low limit disabled. *

OFF

XXX

NORMAL OPERATION (PI control). (No BMS on C-TRAC direct

control but may be reset control)

OFF

***

Direct C-TRAC3 control (reduced integral control).

OFF

***

@ Direct BMS 010 VDC control (proportional control only).

* Set-up sheet Section XX.

If the low limit is required a discharge sensor must be connected to terminals Q and U and jumper U to S. If the low limit is not required jumper

terminals Q to U.

When using direct control, by C-TRAC on BMS terminal S must be connected to terminal U. Dipswitch A-1 must be in the off position (BMS reset

disabled).

IX. POTS

The G-TRAC2 has 10 adjustable trim pots.

POT NAME

APPLICATION

PAGE #

DSEN CAL

Discharge sensor calibration.

DSP CAL

Discharge set-point calibration.

BMS Reset

Voltage or current input calibration. This pot is also used for direct 010 VDC

control calibration.

Reset Ratio

Reset ratio for ambient and room reset.

ROOM CAL

Room thermostat calibration.

NIGHT SP

Night operation discharge set point.

Service

Burner manual firing service pot.

Low Fire

Burner minimum firing rate.

High Fire Air

High fire combustion air setting.

Low Fire Air

Low fire combustion air setting.

NOTE: Do not adjust any pot without fully reading and understanding the correct adjustment procedure for that

pot.

X. STATUS LIGHTS

There are 4 LED lights, which can indicate 20 various operation modes, status and/or fault codes. These lights have different

meanings based on their rate of flashing.

Slow Flash (1 second on, 1 second off)

Fast Flash (¼ second on, ¼ second off)

Irregular (2 short ‘on’ flashes followed by a long ‘off’)

The GTRAC-2 faceplate has a reference chart to indicate it.

LED 1 Burner Pre-Purge

Off The heat exchanger ignition pre-purge is completed or the combustion blower is not required to run.

Slow Flash The combustion blower is on and at pre-purge position, but the combustion air-proving switch is open.

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