EngA CRD C-TRAC3 Manuale utente

Jan 13 R5

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

FOR

C-TRAC3

COOLING 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

Engineered Air for information and/or parts.

www.engineeredair.com

2 of 21 Jan 13 R5

C-TRAC3

If any errors or omissions are noted please contact Engineered Air –Calgary Service at

(403) 287-2590 or Fax (403) 287-4799 or email [email protected].

To ensure warranty is honored, only a qualified HVAC service person, who has received training on the

C-TRAC3, should be employed for service and troubleshooting. If further information is required please

contact the nearest Engineered Air office.

Under no conditions (except for temporary copying) should the unit function description be removed from

the unit. There are two copies provided with the unit. One is in an envelope for copying, then return it to

the unit or store in a safe place. The other is attached to the control panel door and should never be

removed. If a copy of the function for a particular unit is needed, contact Engineered Air with the unit

serial number, C-TRAC3 model number (ex model C-TRAC3.3.1) and the C-TRAC3’s program number noted

near the top right corner of the controller. The program number should also be noted on the electrical

drawing.

Warning:

This unit is connected to high voltages. Electrical shock or death could occur if

instructions are not followed. This equipment contains moving parts that may start

unexpectedly. All work should be performed by a qualified technician. Always

disconnect and lock out power before servicing. DO NOT bypass any interlock or

safety switches under any circumstances.

AC-TRAC3

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Table of Contents

INTRODUCTION ................................................................................................................................................................ 5

STARTUP AND SHUT DOWN ............................................................................................................................................. 5

SERVICE SWITCH............................................................................................................................................................... 5

TEMPERATURE CONTROL ................................................................................................................................................. 6

BASE SETPOINT ................................................................................................................................................................. 6

SETPOINT RESET ............................................................................................................................................................... 6

SETPOINT LIMITS .............................................................................................................................................................. 6

MODES OF OPERATION .................................................................................................................................................... 6

SENSOR #2 ........................................................................................................................................................................ 7

MEASURING TEMPERATURE AND SETPOINT ................................................................................................................... 7

OPERATION....................................................................................................................................................................... 7

AMBIENT SENSING............................................................................................................................................................ 8

BLOWER CONTROL ........................................................................................................................................................... 8

ECONOMIZER MODE ........................................................................................................................................................ 8

MINIMUM POSITION ........................................................................................................................................................ 9

Ambient Compensation.................................................................................................................................................. 10

HEATING MODE.............................................................................................................................................................. 10

COOLING MODE.............................................................................................................................................................. 10

DUAL MODE.................................................................................................................................................................... 10

OCCUPIED/UNOCCUPIED................................................................................................................................................ 11

INDICATION AND DIAGNOSTIC LIGHTS........................................................................................................................... 11

LOW LIMIT ...................................................................................................................................................................... 13

VARIABLE AIR VOLUME .................................................................................................................................................. 13

WIRING ........................................................................................................................................................................... 14

EMS Wiring ..................................................................................................................................................................... 15

TROUBLE SHOOTING ...................................................................................................................................................... 15

BASIC (MULTIMETER) ..................................................................................................................................................... 15

DIP Switches (C-TRAC 3.2 and higher) ............................................................................................................................ 15

SIMULATING A HEAT/COOL CALL ................................................................................................................................... 16

ENCHANCED (COMPUTER) ............................................................................................................................................. 16

Calibration ...................................................................................................................................................................... 17

SENSOR TABLES .............................................................................................................................................................. 18

SERVICE NOTES............................................................................................................................................................... 19

AC-TRAC3

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AC-TRAC3

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INTRODUCTION

The CTRAC-3 is designed to control the cooling, heating, mixing economizer and fan(s). Additionally, it

allows for independent control of other types of equipment operations such as multi-zone and

dehumidification.

The CTRAC-3 requires a 24Vac grounded power supply. The fuse is located on the back of the control, and

has a rating of 800mA (slow blow). Fuse failure can be checked by having 24Vac across terminals H and N,

but the small green light on the face of the C-TRAC3 is not illuminated. There should also be no Vdc

reading across V and Z.

This information in this manual should be used in conjunction with the unit function sheet(s) and the

terminal designation list that accompanied the equipment.

The C-TRAC3 configuration program number is noted on the face of the C-TRAC3. This number is

important when contacting the factory about the unit operation, or for replacement parts. This number

should accompany the unit serial and tag number, and model number.

The C-TRAC3 is designed to control Engineered Air equipment only. It is not designed to simulate or

copy other controllers on the market today, nor can it be modified to do so.

CAUTION:

All of the remote wiring must be complete and functional before attempting to start

the unit.

CAUTION:

It is important that the service technician understands the C-TRAC3 is a configurable

controller. While the terminal designation remains the same, the operation of the

terminal is dependent on the required function, and may differ from unit to unit.

The C-TRAC3 is not field programmable. If the C-TRAC3 program becomes damaged or corrupted, it

must be replaced or returned to Engineered Air for re-programming.

STARTUP AND SHUT DOWN

Startup and shutdown should always be accomplished by the use of the remote start contacts and/or

switches, or the unit on/off switch or an EMS control signal. This will allow the C-TRAC3 to disable unit

operation in sequence, protecting the unit components from damage.

SERVICE SWITCH

The service switch, located in the main electrical control panel, is designed for service and maintenance

use only, and should not be used to regularly enable or disable normal operation. Once the unit has

AC-TRAC3

6 of 21 Jan 13 R5

completely shut down, turn the main disconnect switch off prior to attempting any service or

maintenance.

Additional details regarding startup and shutdown are noted in the unit function and in the Installation,

Operation and Maintenance manual.

TEMPERATURE CONTROL

BASE SETPOINT

The C-TRAC3 is designed to be a discharge air temperature controller. The base discharge air temperature

setpoint is typically set from the setpoint 1 control knob located on the face of the

C-TRAC3. Optionally, this setpoint may be replaced by a remote mounted potentiometer, directly set from

a remote BMS signal (0-10Vdc), preset from a computer, or commanded from an EMS signal. If not used,

set this knob to maximum (fully clockwise), as noted on the face of the C-TRAC3.

The C-TRAC3 has the ability to perform 2 independent operations at the same time, such as a

dehumidification system (pre-cool and reheat) or a multizone system (hot deck, and cold deck). These

types of systems normally incorporate both face-mounted setpoint dials, but the optional setpoints noted

above can still apply to both or either setpoint. As above, if setpoint 2 is not used, set to maximum, as

indicated on the face of the C-TRAC3.

SETPOINT RESET

The base discharge air temperature is normally modified from a remote signal to maintain the desired

temperature of the supplied space. This is called reset. The C-TRAC3 discharge temperature can be reset

from a variety of sources such as ambient air temperature, modulating or staged room thermostats, return

air temperature, or a BMS signal (0-10Vdc).

The resulting change in the discharge temperature setpoint from reset is the actual, or calculated,

discharge air temperature setpoint. This is normally referred to as the SPC.

SETPOINT LIMITS

The discharge air setpoint range is set, and limited to, a specified temperature range programmed prior to

shipment. For example, if the minimum discharge temperature is programmed at 60°F, then that is the

minimum possible temperature setting. Even though the setpoint dial may go as low as 50°F, the

calculated, or actual, setpoint can never go below 60°F.

MODES OF OPERATION

The C-TRAC3 has 3 distinct sequential modes of operation: heating, economizer and cooling. Depending

on ambient conditions the C-TRAC3 may start in any of the three modes. Mode change time is five

minutes (six minutes from heat to mechanical cooling if there is no economizer). If the C-TRAC3 is unable

AC-TRAC3

7 of 21 Jan 13 R5

to satisfy the SPC in its present mode and the discharge temperature slips outside of the discharge

temperature dead band then it will begin timing for a mode change. Once the timing is completed, it can

change modes. If the timer is active and the discharge temperature slides back into the dead band, the

mode change timer is reset. If the current operating mode becomes disabled the C-TRAC3 will immediately

move into the next mode. A preprogrammed option can disable the unit operation if no modes are

available. The table below indicates which 24Vac input terminal can enable or disable its corresponding

mode.

Table 1

Mode

Terminal

Operation

Heat

Heating is allowed with 24Vac at the terminal.

Economizer

Economizer is disabled to minimum with 24Vac.

Cool

Cooling is allowed with 24Vac at the terminal.

The C-TRAC3 will not always be able to exactly maintain the SPC. Enabling a cooling compressor, for

example, may cause the discharge temperature to fall below the SPC. When the compressor is disabled

the temperature may rise above the setpoint. On average, however, the discharge temperature will

closely match the SPC.

The C-TRAC3 controls to a +/-2°F dead band of the SPC when in heating and economizer mode. The

cooling dead band is based on the dry bulb temperature drop of each stage of mechanical cooling.

SENSOR #2

The C-TRAC3 is has the option of using, and controlling to, two sensors. Some equipment may incorporate

2 discharge air sensors for improved temperature control. Multi-zone equipment use sensor #1 for the

hot deck, and sensor #2 for the cold deck. Dehumidification equipment use sensor #1 for the reheat

(leaving) section, and sensor #2 for the pre-cool section.

MEASURING TEMPERATURE AND SETPOINT

The calculated setpoint (SPC) and the actual temperature can be monitored using a DC voltmeter and the

temperature test points and a DIP switch block mounted on the face of the C-TRAC3 (located near the

RS232 serial connection). Note that the calculated setpoint includes any resets to the setpoint. Refer to

Table 4 on page 14.

OPERATION

As the C-TRAC3 is configurable and will vary in its operation unit to unit, it is imperative that the unit

function, terminal designation sheet and wiring diagram be reviewed to understand how the control is

operating for each particular application.

CAUTION:

All of the remote wiring must be complete and functional before attempting to start

the unit.

AC-TRAC3

8 of 21 Jan 13 R5

AMBIENT SENSING

The C-TRAC3 constantly monitors the ambient temperature using an Engineered Air TE6000EA3 sensor. On

initial start up the C-TRAC3 pre-determines which mode to start in: heating, cooling, or economizer. The

load requirements, ambient temperature and digital inputs determine which mode the C-TRAC3 can start

in. Note that some applications will involve dual modes, such as dehumidification and multi-zone

equipment.

The C-TRAC3 must have an ambient sensor installed to operate, or it will lockout on ‘open sensor’ failure.

BLOWER CONTROL

When 24Vac is applied to terminal FS the C-TRAC3 is considered to be in occupied mode. After a time

delay, that allows the damper actuators to respond, the blower(s) will be enabled by closing the output

contact between terminals C and SA. The time delay is variable depending on the equipment and the

function.

Control of occupied and unoccupied time may be accomplished with an EMS controller. If used, and

enabled by the SMC programming software, the 24Vac input into terminal K is not required.

Fan start timing will vary depending on the unit configuration. Make up air equipment has a base delay

time of 90 seconds, while equipment with mixing dampers have a 10 second base delay time. Additionally,

there may be delays for morning warm up, cool down, and pump down, which may vary depending on the

ambient and discharge air temperature. Always refer to the unit function for specific application time

values. The fan delay off time can vary from 10s to 2.5 minutes.

ECONOMIZER MODE

When in economizer mode the C-TRAC3 will mix the warm return air with the cool outside air to try and

achieve the required discharge SPC. The C-TRAC3 will modulate the mixing dampers (return, outside and if

equipped, exhaust) from fully open to the minimum position setting (expressed as a percentage of outside

air).

The C-TRAC3 has 2 independent outputs for damper control. One is a 24Vac output from terminal DM for

on/off control or a 2 position damper actuator. The other is a modulating Vdc output from terminal ED for

modulating (economizer) actuator control. Flat mixing boxes are set to output a 0-7Vdc range, while angle

mixing boxes use a 0-10Vdc range.

The C-TRAC3 will drive the actuator to minimum position when in heating mode. Optionally, the

C-TRAC3 can be programmed to either drive the damper actuator to minimum position when in cooling

mode or continue to modulate to 100% outside air. If set to modulate, the dampers will decrease the

amount of outside air as the mechanical cooling is enabled to ensure that there is sufficient startup load to

avoid damaging the compressor. Once the compressor has started, the dampers will slowly modulate

open, as required.

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9 of 21 Jan 13 R5

If input terminal E is powered (24Vac), the modulating output signal will drop to the minimum outside air

position setting. An optional enthalpy control is normally connected to this terminal.

Unoccupied mode will disable the mixing dampers to 100% return air.

MINIMUM POSITION

The normal setting for the minimum amount of outside air is 15%, although there are many situations

where this number could vary substantially. Refer to the unit function sheet to determine the required

amount.

The mixed air minimum position setpoint is typically adjusted at the C-TRAC3 using the face mounted

minimum position potentiometer; however a variety of methods could be employed. Input terminal MP

may be used to set the minimum position from a remote 0-10Vdc signal (10Vdc = 100% outside air). The

minimum position can also be programmed into the C-TRAC3 through the RS232 communication port from

a computer or directly controlled from an EMS signal. If the minimum position potentiometer is not used

it should be set to zero (turned fully CCW) as it remains in the hardware control circuit.

The mixed air minimum position may overridden from another device, such as a building static pressure

sensor or CO sensor. Refer to the unit function and wiring diagram to clarify. If used, this is normally a

“flow through” device that would input to the MP terminal on the C-TRAC3 first. The C-TRAC3 would then

output the appropriate signal to the damper actuator(s), rather than the minimum position signal directly

feeding into the damper actuator.

Variable Frequency Drives

If the equipment is employing variable frequency drives to control the fan speed (and program options are

selected), a feedback signal of actual speed (10Vdc = 60Hz) is connected to the C-TRAC3. This is to ensure

the airflow is adequate to correctly operate and safeguard the equipment.

As the total air volume drops when the VFD speed decreases, the amount of minimum outside air also

decreases. To compensate for this, the C-TRAC3 will automatically increase the minimum outside air

signal to the damper actuator(s) to allow for more outside air.

Under low air volume conditions the C-TRAC3 will limit the maximum amount of heating and cooling

output for improved temperature control and to safeguard the equipment. This is referred to as ‘load

shedding’. This feature has been removed in versions 3.6 and later.

Refer to the variable air volume section of this manual for additional information.

Mixed Air Low Limit Override

To avoid low limit failure, if the discharge air temperature approaches the low limit setpoint (typically

40°F) the C-TRAC3 will try and keep the unit operational by decreasing the minimum outside air position

down to ½ of its setpoint.

AC-TRAC3

10 of 21 Jan 13 R5

Ambient Compensation

Makeup air equipment normally uses a 2 position damper actuator. Equipment can be ordered with an

Ambient Compensation Package. Among other things, this package uses a modulating outside air damper

actuator. The modulating economizer output (ED) will control the actuator and vary the output signal

depending on the ambient temperature. As the ambient temperature falls, the output will decrease

proportionally, adding static pressure drop across the dampers and effectively reducing the outside air

volume. This compensates for the thermal expansion of the air as it passes over the heat exchanger.

HEATING MODE

Heating is allowed to operate if terminal HS is powered (24Vac). The heating is only activated when the C-

TRAC3 is in heat or dual mode. The C-TRAC3 has a set of contacts (terminals HE1 and HE2) that will close

to enable a heating source, as well as a modulating (0-10Vdc typically) output from terminal HD to control

an independent heating controller, SCR, or water/steam valve. Typically this output will drive one of the

Engineered Air heating controllers (G-TRAC, DJM, H-TRAC etc). Refer to the appropriate manual for

additional information on these controls.

COOLING MODE

Cooling mode is allowed if terminal A is powered (24Vac) and the ambient temperature exceeds the

minimum, pre-programmed low ambient setpoint. The cooling is only activated when the C-TRAC3 is in

cool or dual mode. The C-TRAC3 has 5 output contacts (1 to 5) to enable mechanical cooling stages.

Additionally, a modulating (0-10Vdc typical) output is available from terminal CD for control of a

modulating style of compressor or cooling valve actuator.

Terminal CF is an ambient based cooling output (24Vac). If the first cooling stage is enabled, and the

ambient temperature is above the pre-programmed setpoint, this contact will close. Typical applications

for this would be for an ambient based condenser fan or compressor.

Compressor inter-stage, and minimum on/off times range from 4 to 8 minutes depending on operating

conditions. When the C-TRAC3 first enters cooling mode the first compressor minimum delay is 2 ½

minutes, with the second compressor capable of starting 20 seconds later. These short compressor start

times occur only once whenever the C-TRAC3 initially enters the cooling mode.

Terminal AMB is wired to an externally mounted ambient sensor (Engineered Air TE6000-EA3). The

C-TRAC3 uses this sensor to perform multiple functions, such as low ambient compressor lockout, high

ambient set back, and mode control.

DUAL MODE

Dual control mode allows the cooling or economizer to operate at the same time as the heating. These

are for dehumidification and multi-zone equipment applications.

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