Atlas Metal DDC Installation Manual

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Installation, Operation and Maintenance Manual

MANEUVERING THROUGH THE CONTROLLER

The DDC controller is located in the control panel on the energy recovery unit. The face of the DDC controller has six buttons allowing the user to perform various tasks such as viewing conditions or changing set points. A brief description of the six buttons is provided. For additional details, refer to the page references included. Prior to accessing the controller, confirm the functions that were provided with

the unit by referencing the DDC Code shown

Greenheck Fan Corp.

ER DDC v3.##

Code: GY2X000B

on the controller Start-Up screen.

The Start-Up screen appears when power is applied to the controller. The program version and code are shown on this screen. The code shows the user what components and functionality were provided with the unit and also dicates how the program operates. Below is a description of the code.

PART #469690

DDC CONTROLLER

for ENERGY RECOVERY

Name Heat Cool HGRH Frost Economizer

GY 2 X 0 0 0 B

GFC G None – Disable X None – Disable X None – Disable X None – Disable 0 None – Disable 0 None – Unit Off 0 None X

Enable Y CW C On/Off A Timed Off 1 On/Off 1 Cycle on Room 1 Modbus M

PDx 1 stg 1 Mod B Preheat 2 Modulating 2 LON L

PDx 2 stg 2 Modulating 3 BACNet B

GFC Enable PDx 2 stg None – Disable None – Disable None – Disable None – Unit Off BACNet

Description Reference

Alarm

Up Arrow

Down Arrow

Enter

Escape

Indicates both visually on the controller (the button lights up) and to the Building Management Systems (BMS) (field-wired) that something is not functioning normally.

The arrow keys allow the user to scroll through different screens and adjust parameters.

A. In screens with adjustable parameters, pressing the Enter key moves the cursor

from the upper left corner of the screen to the parameter. The arrow keys can

then be used to adjust the parameter. B. To move to the next parameter on the same screen, press the Enter button. C. To save the change, press the Enter button until the cursor moves back to the

upper left corner of the screen.

Allows the user access to the Main Menu. The following adjustments can be made:

• Unit Status

• Set Points

• Manual Overrides

• Analog & Digital Input/Output Setup

• Time Clock Setup

• Miscellaneous Information

• Unit On/Off

UnOccupied

Mode

Communications

Page 3

Page 4

Program Allows the user access to the Program Menu

NOTE: If this controller needs to be interfaced with a BMS (ie: Lonworks, BACnet or Modbus), please refer to page 23 for an integration points list.

Page 17

24 VAC to Controller

DDC Controller for Energy Recovery

Outdoor Air Intake Temperature Sensor

Supply Discharge Temperature Sensor

Cold-Coil Temperature Sensor

Sensor B1, B2, B3 Commons

Room Temperature Sensor

or Digital Call for Cool

Humidistat

24 VAC for Analog Outputs

Analog Output to Energy Wheel

Analog Heating Output (HW or Electric)

Analog Cooling Output (CW)

Hot Gas Reheat Analog Output

Supply Fan Proving

Wheel Pressure

Wheel Rotation Alarm

Unit On/Off

Exhaust Fan Proving

Occupied/Unoccupied Input

Dirty Filter

Compressor Limit

Analog Sensor Inputs Analog Outputs Digital Inputs

Digital Outputs

24 VAC When Unit On

Frost Control Enable

Output to Supply Fan

Output to Exhaust Fan

24 VAC from Supply Fan Proving

Heating Enable (IG or Electric)

Call For Cooling

24 VAC

Output to Dampers

Alarm

Dry Contact

UNIT SET POINTS

Example of parameter adjustment

The cursor always begins in the upper left corner of the display.

__Supply air low limit alarm when supply is less than:

35.0°F Alarm delay: 030s

Supply air low limit alarm when supply is less than:

32.0°F Alarm delay: 030s

__Supply air low limit alarm when supply is less than:

32.0°F Alarm delay: 030s

If an alarm occurs, the controller (if enabled).

**ALARM** B1 SENSOR ERROR OUTSIDE TEMPERATURE ALARMED@-hr:min.mm/dd

…ALARM OPTIONS… Press UP to review. Press Esc to exit. Press ALARM to RESET

Use the up and down buttons to scroll through the display screens. The cursor must be in the upper left corner of the display to scroll through the screens.

Press

Use the cursor to the next parameter, or to the upper left corner.

When finished, make certain the cursor is in the upper left corner. If the cursor is not in the upper left corner, the changes made will not be saved. (The cursor must be in the upper left corner to enable screen advancement).

to move the cursor down for parameter adjustment.

keys to adjust the parameter up or down. Press to move the

Example of alarms

buttom will glow red, and a buzzer will sound if a remote display panel is connected to the

Step 1: Press the Alarm button once. This will disable the buzzer and

display which alarms have occurred.

Step 2: Scroll down through the alarm screens if more than one has occurred.

Use the arrow buttons or alarm button to scroll through the alarms. Step 3: Note which alarms occurred and at what time. Step 4: Scroll down until the “Alarm Options” screen is displayed.

Step 5: Press the Esc button to exit without resetting the alarms.

In this mode the unit will remain operational, as long as the alarm is

non-fatal. Non-fatal alarms = dirty filters, sensor failure…

Fatal alarms = airflow loss…

Step 6: Press the Alarm button to reset the alarms. If the alarm button

stops glowing red, the alarm has been cleared. No action is required.

(Sometimes a sensor can jump out of range for a short period of time,

causing an alarm. The sensor is probably OK, as long as the sensor

does not continually alarm and the displayed value looks reasonable). Step 7: If the alarm signals again, the problem still exists and action needs to

be taken. Fix the condition that has caused the alarm.

List of possible alarms

SUPPLY AIR AL: Indicates a loss of airflow in the supply fan Alarm & Shutdown

EXHAUST AIR AL: Indicates a loss of airflow in the exhaust fan Alarm & Shutdown

DIRTY WHEEL AL: Indicates a buildup of pressure across the energy recovery wheel Alarm

WHEEL ROTATION AL: Indicates a wheel rotation failure Alarm DIRTY FILTER AL: Indicates a buildup of pressure across the filters Alarm COMPRESSOR TRIP AL: Indicates a high or low refrigerant pressure Alarm & Compressor Shutdown AC LOCKOUT AL: Indicates either the low pressure or high pressure switch are open Alarm & Compressor Shutdown

SUPPLY LOW LIMIT AL:

MB1 FAIL: Indicates a failure of the outside air temperature sensor Alarm MB2 FAIL: Indicates a failure of the supply air temperature sensor Alarm

MB3 FAIL: Indicates a failure of the after cooling coil air temperature sensor Alarm

Indicates a discharge temperature lower than the supply low limit set point

Alarm & Shutdown

MAIN MENU / ESC BUTTON

Access the Main Menu by pressing the key. Scroll through the menu screens using the keys. All controller menus are accessed through the Main Menu. See below for description of each menu. Refer to the page

references for additional details about each menu. For details on the Program Menu, see page 17.

SCREEN DESCRIPTION ADDITIONAL INFORMATION

Press (ENTER) to go to *UNIT STATUS* menu. Press (down) for more menu options.

Press (ENTER) to go to *SET POINTS* menu. Press (up or down) for more menu options.

Press (ENTER) to go to *OVERRIDES* menu. Press (up or down) for more menu options.

Press (ENTER) to go to *I/O SETUP* menu. Press (up or down) for more menu options.

The UNIT STATUS menu allows the user to view real time conditions of the unit. Conditions that are displayed include:

• Temperature Sensors • Reheat • Compressors

• Fan Operation • Heating • Preheater

• Energy Recovery Wheel Operation • Cooling

For additional information, please refer to page 5

The SET POINTS menu allows the user to make adjustments to set points. The adjustable set points relate to:

• Heating • Economizer Mode

• Cooling • Supply Air Low Limit

• Dehumidification • Wheel Defrost

The factory programmed default settings may need to be adjusted to achieve optimum performance for the specific application.

For additional information, please refer to page 7

The OVERRIDES menu is for start-up/commissioning and troubleshooting the unit. Components that can be overriden within the system are:

• Frost Control Preheater • Energy Wheel

• Heating • Hot Gas Reheat

• Cooling

For additional information, please refer to page 10

The I/O SETUP menu allows the user to view the status of the digital and analog inputs and outputs of the DDC controller. In addition, adjustments can be made to recalibrate sensors and change input and output parameters.

For additional information, please refer to page 12

Press (ENTER) to go to *CLOCK SETUP* menu. Press (up or down) for more menu options.

Press (ENTER) to go to *MISC INFO* menu. Press (up or down) for more menu options.

Press (ENTER) to go to *UNIT ON/OFF* menu. Press (up or down) for more menu options.

- - End of MAIN MENU - -

Hrs:min:sec

month/day/year

The CLOCK SETUP menu shows the settings for the internal time clock. The Clock Setup menu is capable of:

• Setting up occupied / unoccupied modes

• Adjusting the time and date For additional information, please refer to page 15

The MISC INFO menu displays the version of the program and the DDC Code programmed. The DDC Code provides details of how the unit was ordered and intended to operate. Both the program version and the DDC Code are required when contacting the factory for assistance.

For additional information, please refer to page 16

The UNIT ON/OFF menu allows the user to turn the unit on and off from the controller.

For additional information, please refer to page 16

UNIT STATUS MENU

Access the UNIT STATUS menu through the Main Menu. Scroll through the menu screens using the keys. Screens with a dashed line border are dependent upon an optional accessory and may not

always appear.

“STATUS LINE”

System Status hr:min:sec mm/dd/yyyy

“STATUS LINE” Outside: 000. 0º F Supply: 000. 0º F Cold Coil: 000. 0º F

“STATUS LINE” Room: 000. 0º F

“STATUS LINE”

Supply Fan:On Exhaust Fan:On

THE STATUS LINE DISPLAYS WHICH MODE THE UNIT IS IN.

Possible modes include: A. Initial Delay J. Sys On-Dehumidifying B. Opening Dampers K. Sys On-Dehum & Reheat C. Exhaust Fan Starting L. Unoccupied-Unit Off D. Supply Fan Starting M. Unoccupied-Heating E. System On N. Unoccupied-Cooling F. Defrost Mode Active O. Manual Override!! G. Sys On-Economizer P. Remote Off H. Sys On-Heating Q. Press Alarm Button! I. Sys On-Cooling

THE TEMPERATURES ON THIS SCREEN DISPLAY REAL-TIME CONDITIONS FROM THE

SENSORS IN THE UNIT.

After a period of inactivity (approximately 3 minutes), the controller will revert to this screen.

THE TEMPERATURE ON THIS SCREEN REPRESENTS THE REAL-TIME CONDITIONS

BASED ON THE SENSOR IN THE ROOM.

This screen only appears if the room supply temp reset sensor is wired into B4 and BC4 on the controller.

THE CONTROLLER DISPLAYS THE RETURN SIGNAL THAT IS BEING RECEIVED FROM

THE SUPPLY AND EXHAUST FAN S.

On indicates the fan is running. In most modes of operation, both fans will be On. There are three modes in which one fan may be Off while the other is On. 1) Start-up of the unit, 2) Timed exhaust frost control, and 3) Unoccupied, 100% return air mode. Other than these three modes, if one fan is Off and the other is On, there may be a problem.

“STATUS LINE” Energy Recovery Wheel: 000% Speed

“STATUS LINE” Cooling Control:000%

Compressor: ##

ENERGY RECOVERY WHEEL OPERATION IS DISPLAYED AS A PERCENT.

If the unit does not contain a VFD on the wheel motor, then 0% = OFF; 100% = ON. If the unit contains a VFD to modulate the wheel speed for frost control or economizer operation, this screen will display the percentage directly proportional to the 0-10 VDC signal being sent to the wheel VFD 0 VDC = 000%, 10 VDC = 100% To override: ‘MANUAL OVERRIDE’ menu >Energy Recovery Wheel Override

THIS SCREEN DISPLAYS THE COOLING CONTROL AS A PERCENTAGE.

This screen only appears if a cooling option is provided.

Chilled Water Coil: The Loop Output % is directly proportional to a 0-10 VDC signal 000% = 0 VDC - Full Closed; 100% = 10 VDC - Full Open 000% = 2 VDC - Full Closed; 100% = 10 VDC - Full Open

The cooling control valve can either be 0-10 VDC or 2-10 VDC depending upon the valve installed. The user may need to adjust the I/O SETUP menu so that 0-100% cooling correlates with a 2-10 VDC signal (0-10 VDC is default).

To adjust: ‘I/O SETUP’ menu> Analog Output Y3

DX Coil: Cooling Control displays compressor engagement as a percent

• 000% Compressors OFF (1 or 2 compressor system)

• 050% First compressor ON (2 compressor system)

• 100% First & second compressor ON (2 compressor system) First compressor ON (1 compressor system)

UNIT STATUS MENU - continued

“STATUS LINE” Cooling Control:000%

Compressor: ##

“STATUS LINE” Hot Gas Reheat:000% Heater Control:000%

THIS SCREEN DISPLAYS THE COOLING CONTROL AS A PERCENTAGE (CONTINUED)

The Compressor line indicates which compressor is ON 1 First compressor 2 Second compressor 1 2 Both compressors To override: ‘MANUAL OVERRIDE’ menu >Cooling Loop Override

THIS SCREEN DISPLAYS THE CURRENT REHEAT AND HEAT OPERATION OF THE UNIT.

Hot Gas Reheat only appears if provided with unit.

Hot Gas Reheat operation is on/off control displayed as a percent. 100% is ON and 000% is OFF To override: ‘MANUAL OVERRIDE’ menu >Hot Gas Reheat Override

For Modulating Hot Gas Reheat Control: 000% is OFF and 001% HGRH is ON and the airflow damper is modulating between 4 VDC and 10 VDC.

Heater Control displays the real-time percent heater output and is directly proportional to a 0-10 VDC signal provided by the discharge temperature sensor. To override: ‘MANUAL OVERRIDE’ menu >Heating Loop Override

Electric Heater: The Heater Control % is directly proportional to a 0-10 VDC signal being sent to the SCR controller in the electric heater’s control center. 000% = 0 VDC = 0 kW output 100% = 10 VDC = Maximum kW output

Indirect Gas Furnace: The Heater Control % is directly proportional to a 0-10 VDC signal being sent to the indirect gas furnace control board. The first stage is full ON at a 1% Heater Control. Once the Heater Control reaches 50%, the second stage modulates between 50% and 100% output. 001 – 049% First stage: ON, Second stage: OFF 050 – 100% First stage: ON, Second stage: Modulating between 50% and 100% output

Hot Water Heater: The heating control valve (supplied by others) can either be 0-10 VDC or 2-10 VDC depending upon what valve is installed. The user may have to adjust the ‘I/O SETUP’ menu so that a 0-100% heating correlates with a 2-10 VDC signal (0-10 VDC is default).

“STATUS LINE” Energy recovery wheel differential pressure is: Normal

“STATUS LINE” Preheat heater: OFF

End of status menu

To adjust: ‘I/O SETUP’ menu >Analog Output Y2

THE UNIT CONTAINS A WHEEL PRESSURE DROP SENSOR TO INDICATE WHETHER

THE PRESSURE ACROSS THE WHEEL IS NORMAL OR HIGH.

This screen only appears if a frost control method was provided.

A status of High is an indication of frost accumulation. The pressure set point is adjustable on the wheel pressure switch.

THIS SCREEN INDICATES WHETHER THE ELECTRIC PREHEAT FROST CONTROL IS ON

OR OFF.

This screen only appears if Electric Preheat frost control was provided.

To override: ‘MANUAL OVERRIDE’ menu >Energy Recover y Wheel Preheater

Outdoor Air Reset Function

55°

57°

59°

61°

63°

65°

67°

69°

71°

73°

55° 60° 6 5° 70° 75°

Outside Air Temperature (°F)

Discharge Temperature (°F)

SET POINTS MENU

Access the SET POINTS menu through the Main Menu. Scroll through the menu screens using the keys.

***ACCESS DENIED***

Enter Password:0000 WRONG PASSWORD

Unit Set Points

Supply set pt is currently=###.#ºF This set pt is reset up/down by the DDC.

THIS SCREEN CAN BE LOCKED TO PREVENT TAMP ERI NG WITH THE SETTINGS. FROM THE FACTORY, ACCESS IS NOT PASSWORD PROTECTED TO ALLOW QUICKER

START-UP.

To set the password, go to the ‘PROGRAM’ menu by pressing the button. Once there, scroll down until you arrive at the Change Password screen. The ‘Level 1’ password protects the ‘SET POINTS’ menu.

THIS SCREEN DISPLAYS THE CURRENT DISCHARGE SET POINT FOR THE UNIT,

WHICH IS THE TEMPERATURE THE UNIT IS TRYING TO DISCHARGE.

If there is no room temperature sensor (nothing wired to terminals B4 and BC4 on controller), the controller changes the supply air discharge temperature of the unit based on the outdoor air temperature (refer to outdoor air reset function below). With no room temperature sensor, a BMS can override the controller and input directly the desired supply temperature for the unit. If a room temperature sensor is connected to terminals B4 and BC4 on the DDC controller, then the supply temperature of the unit is adjusted based on the difference between the actual room temperature (reading from the room temperature sensor) and the desired room temperature which is programmed into the controller (refer to Room Set Point screen below). With a room temperature sensor connected to the controller, a BMS can override the controller and input directly the desired room set point. This new desired room set point will be used for comparing with the actual room temperature. To activate the BMS override temperatures, refer to the Program Menu and change the Set Point Source screen to BMS Interface.

Supply Air Reset

Outside Supply

060.0ºF ---> 072.0ºF

070.0ºF ---> 060.0ºF

THESE PA RAMETERS DICTATE THE OPERATION OF THE OUTDOOR AIR RESET

FUNCTION IN THE CONTROLLER.

This screen does not appear when the room supply temp sensor is wired into terminals B4 and BC4 on the controller.

The unit monitors the outdoor air temperature and adjusts the desired supply temperature accordingly. For example, when the outdoor air is below 60.0ºF, the controller will change the Supply set pt to 72.0ºF. If the outdoor air is above 70.0ºF, the controller would change the Supply set pt to 60.0ºF. If the outdoor air temperature is between 60.0ºF and 70.0ºF, the Supply discharge temperature changes according to the outdoor air reset function. A visual representation of the outdoor air reset function is shown.

Desired Supply Temperature

72.0°F

Desired Supply Temperature

60.0°F

SET POINTS MENU - continued

Room Set Point

Local set pt:72.0ºF

Supply Reset Limits Supply Min:055.0ºF Supply Max:090.0ºF

Cold coil set point Normal Mode:55.0ºF Dehumidify:50.0ºF Active set pt:55.0ºF

THIS SCREEN DISPLAYS THE SPACE TEMPERATURE SET POINT.

This screen only appears if the room supply temp sensor is wired into terminals B4 and BC4 on the controller.

The unit will reset the unit discharge temperature up and down to maintain the local set point. If a BMS is interfaced with the controller, the user has the capability to dictate the desired Room set point through the BMS. The screen will show a BMS set point and an Active set point. The Active set point is the room temperature the controller is currently tr ying to maintain.

THIS SCREEN DISPLAYS THE MINIMUM AND MAXIMUM SUPPLY AIR TEMPERATURE.

This screen only appears if the room supply temp sensor is wired into terminals B4 and BC4 on the controller.

The supply air temp will integrate SLOWLY down (Pl loop) towards this minimum set point to maintain room temperature. The supply air temp will integrate SLOWLY up (PI loop) towards this maximum set point to maintain room temperature.

THIS SCREEN DISPLAYS THE TEMPERATURE SET POINTS FOR THE COOLING COILS.

This screen only appears if a Cooling option was provided with the unit.

The Normal Mode set point is the after coil temperature the unit will maintain under standard operation. If a Humidistat was provided with the unit, the Dehumidify set point is the temperature the cooling coil will discharge on a call for dehumidification from a humidistat.

The Active set pt is the temperature that the unit is currently trying to maintain off the coil.

Unit will energize to maintain unocc room set points. Differential:5.0ºF

Unoccupied room set point Heating:65.0ºF Cooling:85.0ºF

THIS SCREEN DISPLAYS THE DIFFERENTIAL SET POINT FOR THE HEATING AND

COOLING MODES.

This screen only appears if the 7th character in the DDC Code is set to 1, meaning the “Cycle on Room” unoccupied mode was chosen. Operation in “Cycle on Room” unoccupied mode requires the room sensor be wired into terminals B4 and BC4 , and a night setback damper in the unit.

This differential acts as a hysteresis to keep the heating and cooling from cycling too often. For example, on a call for heating (room temp. set point - differential, 65.0ºF-

5.0ºF=60.0ºF) supply fan cycles on. Unit cycles off when the room temperature reaches the Unoccupied room set point (65.0ºF, adjustable). For cooling, the differential is added to the Unoccupied room set point (85.0ºF+5.0ºF=90.0ºF) to cycle supply fan on. Unit cycles off when the room temperature reaches Unoccupied room set point (85.0ºF).

THIS SCREEN DISPLAYS THE ROOM SET POINTS WHICH DICTATE THE UNIT HEATING

AND COOLING OPERATION DURING UNOCCUPIED MODE.

This screen only appears if the “Cycle on Room” unoccupied mode was chosen for the unit. A room sensor temp. must be wired into terminals B4 and BC4 on the controller, and the unit must have a night setback damper.

In Unoccupied Mode when the temperature falls below the room Heating set point (hysteresis = 5ºF), the supply fan and unit heating will turn on. Unit will discharge the Supply Max temperature per the ‘Supply Reset Limits’ screen above until the room set point is satisfied. Unit will then shut down. In Unoccupied Mode when the temperature rises above the Cooling set point (hysteresis = 5ºF), the supply fan and unit cooling will turn on. Unit will discharge the Supply Min temperature per the ‘Supply Reset Limits’ screen above until the room temperature set point is satisfied. Unit will then shut down.

Heater Lockout Lockout heater when outside air >:70.0ºF Hysteresis=02.0ºF

THIS CONTROLLER WILL LOCK THE HEATING SECTION OFF WHEN THE OUTDOOR AIR

TEMPERATURE IS ABOVE THE SET POINT (FACTORY DEFAULT = 70ºF).

This screen only appears if a Heating option was provided with the unit.

A Hysteresis of 2ºF helps to avoid short cycling of the heater. The hysteresis is similar to a deadband above and below the Lockout heater set point. (Example: If Lockout = 70ºF, heating is locked out for outside air conditions above 72ºF and enabled below 68ºF).

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