Orion SA Controller User Manual

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Factory Packaged Controls

SA Controller

Technical Guide

SA Controller Code: Y200921

Requires System Manager Code: Y200921SM Version 1.0 and up

Requires Service Tool Code: Y200921HH Version 1.0 and up

Table of Contents

OVERVIEW ....................................................................................................................................... 4

Part Number Cross Reference ..................................................................................................................................................4

Features and Applications ........................................................................................................................................................5

SA Controller Dimensions ........................................................................................................................................................6

SA Expansion Module Dimensions ..........................................................................................................................................7

12-Relay Expansion Module Dimensions ................................................................................................................................8

SA Controller Component Locations .......................................................................................................................................9

INSTALLATION AND WIRING ........................................................................................................10

Important Wiring Considerations ...........................................................................................................................................10

SA Controller Wiring ...............................................................................................................................................................11

Digital Room Sensor ..........................................................................................................................................................12

Space Temperature Sensor ...............................................................................................................................................13

Remote SAT Reset Signal .................................................................................................................................................13

Supply Air Temperature Sensor ................................................................................................. ........................................14

Entering Water Temperature Sensor .................................................................................................................................15

Entering Air Temperature Sensor .......................................................................................................................................16

Water Side Economizer Valve ...........................................................................................................................................17

Water Side Economizer Bypass Valve ..............................................................................................................................17

Supply Fan VFD Signal or Zoning Bypass Damper Actuator Signal .................................................................................18

SA Expansion Module Input Wiring ........................................................................................................................................20

SA Expansion Module Output Wiring .....................................................................................................................................21

Suction Pressure Transducer ............................................................................................................................................22

SA Expansion Module Binary Inputs ................................................................................................................................23

Entering Air Humidity Sensor .............................................................................................................................................24

Indoor Wall-Mounted Humidity Sensor ..............................................................................................................................25

Modulating Heating Device ................................................................................................................................................26

Modulating Cooling Signal(s) .............................................................................................................................................27

12-Relay Expansion Module .............................................................................................................................................30

Two Condenser Head Pressure Module ............................................................................................................................32

Water Source Heat Pump Protection Module ....................................................................................................................33

START-UP AND COMMISSIONING

Addressing & Powering Up .....................................................................................................................................................34

Before Applying Power ......................................................................................................................................................34

Controller Addressing ........................................................................................................................................................34

Power Wiring ....................................................................................................................................................................34

Initialization ........................................................................................................................................................................35

Operating Summary ..........................................................................................................................................................35

Programming the Controller ...................................................................................................................................................35

www.aaon.com

WattMaster Controls Inc. 8500 NW River Park Drive · Parkville , MO 64152 Toll Free Phone: 866-918-1100 PH: (816) 505-1100 · FAX: (816) 505-1101 · E-mail: mail@wattmaster.com Visit our web site at www.orioncontrols.com WattMaster Form : AA-SA-TGD-01C Copyright August 2012 WattMaster Controls, Inc.

AAON Part Number: R97490

AAON

is a registered trademark of AAON, Inc., Tulsa, OK. Copeland Digital Scroll™ is a registered trademark of Copeland Corporation, Sidney, OH EBTRON® is a registered trademark of Ebtron, Inc., Loris, SC.

Neither WattMaster Controls, Inc. nor AAON assumes any responsibility for errors or omissions in this document. This document is subject to change without notice.

Table of Contents

INPUTS AND OUTPUTS

SA Controller Inputs and Outputs ..........................................................................................................................................36

SA Expansion Module Inputs and Outputs ............................................................................................................................37

SEQUENCE OF OPERATION ..........................................................................................................38

Operation Modes ......................................................................................................................................................................38

Occupied/Unoccupied Mode of Operation .........................................................................................................................38

HVAC Modes of Operation ................................................................................................................................................38

Vent Mode Operation .........................................................................................................................................................38

Cooling Mode Operation ....................................................................................................................................................38

Stage Control Window .......................................................................................................................................................40

Modulating Cooling ............................................................................................................................................................40

DX Cooling .......................................................................................................................................................................40

Air Cooled Condenser Fan Operation ...............................................................................................................................41

Water Side Economizer Operation (Valves 1 & 2) .............................................................................................................41

Water Cooled Condenser (Valve 3) ...................................................................................................................................41

Chilled Water Cooling ........................................................................................................................................................41

External Cooling ................................................................................................................................................................41

Dehumidiﬁ cation Mode ......................................................................................................................................................42

Coil Temperature Reset .....................................................................................................................................................42

Reheat Control ..................................................................................................................................................................43

Coil Temperature Offset .....................................................................................................................................................43

Heating Mode ...................................................................................................................................................................43

Stage Control Window .......................................................................................................................................................43

Hot Water or Modulating Steam Heating ...........................................................................................................................44

External Heat .....................................................................................................................................................................44

Air to Air Heat Pump Operation .........................................................................................................................................44

Water Source Heat Pump Operation .................................................................................................................................44

Morning Warm-Up Mode ...................................................................................................................................................44

Off Mode ............................................................................................................................................................................45

Supply Air Temperature Setpoint Reset .............................................................................................................................45

Supply Fan Control ............................................................................................................................................................45

Duct Static Pressure Control .............................................................................................................................................45

Pre-Heater Operation ........................................................................................................................................................46

Entering Air Lockouts ......................................................................................................... ................................................46

Supply Air Cutoffs ..............................................................................................................................................................47

SA Controller Alarms .........................................................................................................................................................48

VAV/Zone Controller Alarms ..............................................................................................................................................49

Scheduling .........................................................................................................................................................................50

Internal Trend Logging .......................................................................................................................................................50

Force Modes or Overrides .................................................................................................................................................51

VAV Terminal Unit Controller Compatibility ........................................................................................................................51

VAV/Zone System ..............................................................................................................................................................51

TROUBLESHOOTING ..................................................................................................................... 52

LED Diagnostics .......................................................................................................................................................................52

Diagnostic LED Operation .......................................................................................................................................................53

APPENDIX

System Conﬁ gurations ............................................................................................................................................................54

Stand-Alone System Layout ..............................................................................................................................................55

Interconnected System Layout ..........................................................................................................................................56

Networked System Layout .................................................................................................................................................57

Temperature Sensor Testing ...................................................................................................................................................58

OE265 Series RH Sensor Testing .....................................................................................................................................59

OE271 Pressure Sensor Testing .......................................................................................................................................60

OE275-01 Suction Pressure Transducer Testing for R410A Refrigerant ...........................................................................61

INDEX ............................................................................................................................................ 62

SA Controller Technical Guide 3

Overview

Part Number Cross Reference

PART DESCRIPTION

SA Controller OE332-23-SA-A R96070 SA Expansion Module OE333-23-SA-A R96180 12-Relay Expansion Module OE358-23-12R R69180 E-BUS Distribution Module OE365-23-EBD-A R82930 Two Condenser Head Pressure Module OE370-23-HP2C R90230 Water Source Heat Pump Protection Module - 410A OE334-23-WPM-A R88350 Water Source Heat Pump Protection Module - 410A - 20% Glycol OE334-23-WPM-A20 R99750 Water Source Heat Pump Protection Module - 410A - 40% Glycol OE334-23-WPM-A40 R99760 Bypass & Slave Interface Card PL101824 N/A Bypass Damper Actuator OE281-04 N/A CommLink IV Communications Interface OE361-12 R66760 Digital Room Sensor - Temp & Humidity OE217-01 R83870 Digital Room Sensor - Temp. Only OE217-00 R83860 Duct Static Pressure Sensor OE271 P87100 Duct Temperature Sensor - 12" Probe OE231 R44940 / P87140 Duct Temperature Sensor - 6" Probe OE230 R36340 IP Module Kit OE415-02 R66770 MiniLink Polling Device OE364-22 N/A Modular Service Tool - Operator Interface OE391-08 V09280 Modular System Manager - Operator Interface OE392-08 V09270 Entering Air RH Sensor - 3% - 0-5 VDC Output OE265-14 R34700 Entering Air Temperature Sensor OE250 R34650 Remote Link II Modem Kit OE419-06 R69760 Room Mounted RH Sensor - 3% - 0-5 VDC Output OE265-11 R34690 Standard Room Sensor - Plain OE210 R31480 Standard Room Sensor - w/ Override OE211 P87040 Standard Room Sensor - w/ Override & Slide Adjust OE213 P94320 Standard Room Sensor - w/ Slide Adjust OE212 P94100 Static Pressure Pickup Tube OE290 S18780 Suction Pressure Transducer OE275-01 R28390 USB-Link Kit OE366 R71870

ORION

PART NO:

AAON TULSA

PART NO:

Revised 10/18/10

SA Controller Technical Guide

Overview

Features and Applications

Features

The Series A Controller (OE332-23-SA)—SA Controller—is designed with 6 analog inputs, 2 analog outputs, and 5 relay outputs. Most common HVAC unit control applications can be conﬁ gured using only the SA Controller; however , if needed, the SA Controller’s input and output capabilities can be expanded with the SA Expansion Module ( OE33323-SA) or 12-Relay Expansion Module (OE358-23-12R) by means of a modular cable. The SA Expansion Module provides an additional 4 analog inputs, 5 analog outputs, 8 binary inputs, and 4 conﬁ gurable relays. The 12-Relay Expansion Module provides an additional 12 conﬁ gurable relays.

The SA Controller can also use the Two Condenser Head Pressure Module ( OE370-23-HP2C) connected to the E-BUS Distribution Module ( OE365-23-EBD-A) for those applications requiring Head Pressure Control. The SA Controller can also use the WSHP Protection Module (OE334-23-WPM-A) connected to the E-BUS Distribution Module for Water Source Heat Pump applications.

Each SA Controller can be conﬁ gured for control of VAV Units (with or without VAV/Zone Controllers), Constant Volume Units, and Make-Up Air Units. Features include the following:

• Modulating Cooling Output ( Copeland Digital

Scroll™ Compressor or Chilled Water Valve Control)

• Modulating Heating Output ( Hot Water Valve,

Steam Valve, SCR Electric Heat Control)

• Full Integration with the AAON

Hot Gas Reheat Valve Controller

MHGRV Modulating

• Conﬁ gurable for Air to Air and Water Source Heat Pump

Applications

• Advanced Dehumidiﬁ cation Capabilities

• Adaptive Supply Air Reset

• Selectable Control Sensor

• Fan Proving Interlock

• Dirty Filter Alarm

• Emergency Shutdown Input (Smoke Detector/Firestat or

other Shutdown Conditions)

• Water Side Economizer Option

• Remote Occupied Capabilities

• 7-Day, 2-Event-per-Day Scheduling

• 14 Holiday Event Scheduling

• Optimal Start Scheduling

• Trend Logging Capability

• Static Pressure Control for Filter Loading Applications

• Head Pressure Control (with optional Two Condenser Head

Pressure Module)

• Additional Water Safeties (with optional Water

Source Heat Pump Protection Module)

Applications

Variable Air Volume Unit

The SA Controller can be conﬁ gured to control a VFD Supply Fan for Duct Static Pressure control. If the unit is not equipped with a VFD, but Duct Static Pressure control is needed, a modulating Zoning Bypass Damper can be controlled by the SA Controller.

VAV units are typically designed for occupied Cooling with Morning W arm-up Heating. This option is available with the SA Controller. The SA Controller can also be used for a Zoning System that needs Duct Static Pressure control and Occupied Cooling and Heating. The SA Controller also has the ability to be conﬁ gured for Duct Static Pressure Control by controlling the Supply Fan VFD for the purpose of maintaining proper Duct Static Pressure in response to varying ﬁ lter loading conditions.

The SA Controller allows Dehumidiﬁ cation Priority on a VAV unit. This could be useful on a building with a very low internal sensible load, but which has a high internal and/or external latent load. During VAV Dehumidiﬁ cation, the SA Controller activates Cooling based on the Evaporator Coil Temperature and activates Gas Reheat to warm the Supply Air Temperature to the Active Supply Air Temperature Setpoint.

Constant Air Volume Unit

The SA Controller can be conﬁ gured to activate a Constant Volume Supply Fan. In most cases, this is a very basic unit with Space Temperature control.

Make-Up Air Unit

The SA Controller can be conﬁ gured for 100% Outdoor Air control for Make-Up Air. All HVAC Modes are determined from the Outdoor Air Sensors. The Outdoor Air Volume must always be at least 50% or higher to be conﬁ gured for Outdoor Air control.

Single or Dual Cabinet Unit

The SA Controller can control an SA Series Single Cabinet Unit or an SA Series Dual Cabinet Unit. Wiring for Dual Cabinet Units is shown and noted on applicable Single Cabinet Unit diagrams.

AAON® Modulating Hot

SA Controller Technical Guide

Overview

SA Controller Dimensions

Figure 1: OE332-23-SA Controller – SA Controller Dimensions

SA Controller Technical Guide

Overview

SA Expansion Module Dimensions

Figure 2: OE333-23-SA – SA Expansion Module Dimensions

SA Controller Technical Guide

Overview

12-Relay Expansion Module Dimensions

Figure 3: OE358-23-12R – 12-Relay Expansion Module Dimensions

SA Controller Technical Guide

Overview

SA Controller Component Locations

Figure 4: OE332-23-SA – SA Controller Component Locations

SA Controller Technical Guide

Installation & Wiring

Important Wiring Considerations

Zone

General

Correct wiring of the SA Controller is the most important factor in the overall success of the controller installation process. In general, most SA Controllers are factory installed and wired at the AAON

factory.

Controller Mounting

When the controller is to be ﬁ eld mounted, it is important to mount the controller in a location that is free from extreme high or low temperatures, moisture, dust, and dirt. See Table 1 for a list of the required operating conditions for the SA Controller and associated modules.

The SA Controller is housed in a plastic enclosure. It is designed to be mounted by using the 3 mounting holes in the enclosure base. The SA Controller needs to be installed in an environment which can maintain a temperature range between -30°F and 150°F not to exceed 90% RH levels (non-condensing). It is important to mount the controller in a location that is free from extreme high or low temperatures, moisture, dust, and dirt. Be careful not to damage the electronic components when mounting the controller.

Considerations

The SA Controller and associated modules must be connected to a 24 VAC power source of the proper size for the calculated VA load requirements. All transformer sizing should be based on the VA rating listed in Table 1.

Device

Control

OE332-23-SA Controller

SA Controller

OE333-23-SA

SA Expansion Module

OE358-23-12R

12-Relay Expansion

Module

OE370-23-HP2C

Two Condenser Head

Pressure Module

OE334-23-WPM-A

Water Source Heat Pump

Protection Module

OE365-23-EBD

E-BUS Distribution

Module

Voltage

24VAC 8

24VAC 10

24VAC 15

24VAC 5

24VAC 8

24VAC 50

VA Load

Temperature

-30°F to 150°F

(Non-

Humidity

Condensing)

90% RH

Warning: When using a single transformer to power more than one controller or expansion module, the correct polarity must always be maintained between the boards. Failure to observe correct polarity will result in damage to the SA Controller and associated modules.

Please carefully read and apply the following information when wiring the SA Controller or its associated modules. See Figure 5 on page 12 for the SA Controller wiring diagram. See Figur es 16 and 17 on pages 20 and 21 for SA Expansion Module wiring. And see Figure 24 on page 28 for 12-Relay Expansion Module wiring.

1. All wiring is to be in accordance with local and national electrical codes and speciﬁ cations.

2. Minimum wire size for 24 VAC wiring should be 18-gauge.

3. Minimum wire size for all sensors should be 24-gauge. Some sensors require 2-conductor wire and some require 3-or 4-conductor wire.

4. Be sure that all wiring connections are properly inserted and tightened into the terminal blocks. Do not allow wire strands to stick out and touch adjoining terminals which could potentially cause a short circuit.

5. When communication wiring is to be used to interconnect SA Controllers together or to connect to other communication devices, all wiring must be plenum-rated, minimum 18-gauge, 2-conductor, twisted pair with shield. WattMaster can supply communication wire that meets this speciﬁ cation and is color coded for the network or local loop. Please consult your WattMaster distributor for information. If desired, Belden #82760 or equivalent wire may also be used.

6. Before applying power to the SA Controller, be sure to recheck all wiring connections and terminations thoroughly.

Table 1: Voltage and Environment Requirements

SA Controller Technical Guide

Installation & Wiring

SA Controller Wiring

SA Controller

NOTE: Only one SA Controller is required whether the SA Unit is a Single Cabinet or Dual Cabinet Unit. Additional wiring for Dual Cabinet Units is shown and noted as such on the applicable Single Cabinet Unit Diagrams.

Figure 5: OE332-23-SA Controller – SA Controller Wiring

SA Controller Technical Guide

Installation & Wiring

Digital Room Sensor Wiring

Digital Room Sensor

The OE217-00 Digital Room Sensor is used to sense Space Temperature and the OE217-01 Digital Room Sensor is used to sense Space Temperature and Space Humidity. The Sensor connects to the SA Controller with the TSDRSC modular cable. It should be mounted at approximately 5 ft. above the ﬂ oor on the wall in an area that does not have drafts or is exposed to direct sunlight. See Figure 6 for wiring details.

Zone

Figure 6: OE217-00 & OE217-01 – Digital Room Sensor Wiring

SA Controller Technical Guide

Installation & Wiring

SAT & Remote SAT Reset Signal Wiring

Space Temperature Sensor

The OE210, OE211, OE212, OE213 Space Temperature Sensor is typically used for constant volume HVAC unit applications controlling one zone. The Space T emperature Sensor is a 10K T ype III thermistor sensor and should be mounted approximately 5 feet above the ﬂ oor in the space that is to be controlled. The Space Temperature Sensor is available as a sensor only, sensor with override button, sensor with slide adjust, and sensor with slide adjust and override conﬁ gurations.

When the Remote Supply Air T emperature Reset Signal option is needed, the Slide Offset option on the Room Sensor cannot be used. Only one of these options may be used on the SA Controller.

See Figure 7 below for complete Space Temperature Sensor wiring details.

Remote SAT Reset Signal

A Remote Supply Air T emperature Reset Signal can be connected to AI7 for applications requiring remote reset of the Supply Air Temperature Setpoint.

When the Slide Offset option on the Room Sensor is used, the Remote Supply Air Temperature Reset Signal cannot be used. Only one of these options may be used on the SA Controller.

The SA Controller can accept either a 0-5 VDC signal or a 0-10 VDC signal on this input.

See Figure 8 below for complete Remote SAT Reset Signal wiring details.

Figure 7: OE210, OE211, OE212, OE213 – Space Temperature Sensor Wiring

Figure 8: Remote Supply Air Temperature Reset Signal Wiring

SA Controller Technical Guide

Installation & Wiring

SAT Sensor Wiring

Zone

Supply Air Temperature Sensor

The OE231 Supply Air Temperature Sensor must be wired as shown in Figure 9 below for proper operation. The Supply Air Temperature Sensor is a 10K Type III thermistor sensor. The Supply Air Temperature Sensor should be mounted in the unit discharge plenum or in the supply air duct.

NOTE: For Dual Cabinet Units, mount the Supply Air Temperature Sensor in a Supply Air Ducting area that is common to both SA Units.

Figure 9: OE231 – Supply Air Temperature Sensor Wiring

SA Controller Technical Guide

Installation & Wiring

Entering Water Temperature Sensor Wiring

Entering Water Temperature Sensor

The OE233 Entering W ater T emperature Sensor must be wired as shown in Figure 10 below for proper operation. The Entering Water Tempera- ture Sensor is a 10K Type III thermistor sensor. The Entering Water Temperature Sensor should be mounted in the entering water piping.

NOTE: For Dual Cabinet Units, mount the Entering Water Temperature Sensor in an Entering Water Piping area that is common to both SA Units.

Figure 10: OE233 – Entering Water Temperature Sensor Installation & Wiring

SA Controller Technical Guide

Zone

Installation & Wiring

Entering Air Temperature Sensor Wiring

Zone

Entering Air Temperature Sensor

The OE231 Entering Air Temperature Sensor must be wired as shown in Figure 11 below for proper operation of the SA Controller. The Entering Air Temperature Sensor is a 10K Type III thermistor sensor. The sensor should be mounted as shown in an area that is protected from the elements and direct sunlight.

NOTE: For Dual Cabinet Units, mount the Entering Air Temperature Sensor in an Entering Air Duct area that is common to both SA Units.

Figure 11: OE231 – Entering Air Temperature Sensor Wiring

SA Controller Technical Guide

Installation & Wiring

Water Side Economizer Wiring

Water Side Economizer (WSE) Valve(s)

The Water Side Economizer Valve(s) must be wired as shown in Figure 12 below for proper operation of the SA Controller. The Water Side

Economizer Valve(s) connects to AO1 on the SA Controller.

NOTE: For Dual Cabinet Units, wire the Second Cabinet’s WSE Valve Actuator in parallel with the First Cabinet’s WSE Valve Actuator.

Water Side Economizer (WSE) Bypass Valve

The W ater Side Economizer Bypass Valve(s) must be wired as shown in Figure 13 below for proper operation of the SA Controller. The Water Side Economizer Bypass Valve(s) are wired to AO4 and AO5 on the SA Expansion Module.

NOTE: For Dual Cabinet Units, wire the Second Cabinet’s WSE Bypass Valve Actuator to AO5 on the SA Expansion Module.

Figure 12: Water Side Economizer Valve Wiring

Figure 13: Water Side Economizer Bypass Valve Wiring

SA Controller Technical Guide

Installation & Wiring

Supply Fan VFD Signal

Supply Fan VFD Signal or Zoning Bypass Damper Actuator Signal

The Supply Fan VFD or Zoning Bypass Damper Actuator Signal is a 0-10 VDC output from AO2 on the SA Controller . This signal output can be connected to the Supply Fan Variable Frequency Drive to modulate the Supply Fan speed and control Duct Static Pressure utilizing the Duct Static Pressure Sensor connected to the SA Controller. Alternatively, it can be connected to a Zoning Bypass Damper Actuator that will modulate the Zoning Bypass Damper Actuator to control Duct Static Pressure utilizing the Duct Static Pressure Sensor connected to the SA Controller. A Duct Static Pressure Sensor must be connected in order for the VFD or Zoning Bypass Damper Actuator to operate. See Figures 14 and 15 for detailed wiring.

Zone

Caution: Variable Frequency Drive units can cause large transient noise spikes which can cause interference to be propagated on other electronic equipment. Use shielded wire wherever possible and route all sensor and controller wiring away from the Variable Frequency Drive and the HVAC Unit electrical wiring.

NOTE: For Dual Cabinet Units, VFD #2 must be wired in parallel to VFD #1 as shown in Figure 14 below.

Figure 14: Supply Fan VFD Wiring

SA Controller Technical Guide

Supply Fan VFD Signal or Zoning Bypass Damper Actuator Signal

When the Bypass Damper is used (Zoning applications), be sure the Bypass Duct and Damper are designed so that Supply Air will bypass to the Entering Air Duct, ensuring equal airﬂ ow to both cabinets.

Installation & Wiring

Zoning Bypass Damper Actuator

Figure 15: Zoning Bypass Damper Actuator Wiring

SA Controller Technical Guide

Installation & Wiring

SA Expansion Module Input Wiring

Zone

SA Expansion Module

Two different Expansion Modules are available for use with the SA

The 12-Relay Expansion Module ( OE358-23-12R) provides for 12 Dry Contact Conﬁ gurable Relay Outputs. See Figure 25 for complete

wiring details. Controller to provide additional inputs and outputs beyond those found on the SA Controller.

The expansion modules can be used individually or together to provide

the required inputs and outputs for your speciﬁ c applications. The SA Expansion Module ( OE333-23-SA Controller) provides 8 Binary Inputs, 4 Analog Inputs, 5 Analog Outputs, and 4 Conﬁ gurable Relay Outputs. See Figures 16 and 17 for complete wiring details.

WARNING!!

Observe Polarity! All boards must be wired with GND-to-GND and 24VAC-to-24VAC. Failure to observe polarity will result in damage to one or more of the boards. Expansion Module must be wired in such a way that the expansion module and the controller are always powered together. Loss of power to the expansion module will cause the controller to become inoperative until power is restored to the expansion module.

10 VA Minimum Power Required

For SA Expansion Module

24 VAC

GND

Additional Suction Pressure Sensor Required On Dual Units Only.

Modular Cable

Connect To SA Controller

Modular Cable

Connect To E-BUS Distribution

Module (When Used)

See Suction Pressure Transducer Wiring Details For Complete Wiring Information.

See Humidity Sensor Wiring Details For Complete Wiring Information.

Entering Air

Humidity Sensor

VAC OR DC

GND

0-5V

Indoor Air

Humidity Sensor

VIN

GND

VOUT (0-5V)

Suction Pressure

Transducer #2

Suction Pressure

Transducer #1

Splice Wire As Required To Reach From Transducer Location To Expansion Module Location

Water Proof of Flow A- N.O. Input

Water Proof of Flow B - N.O. Input

Air Proof Of Flow - N.O. Input

Remote Forced Occupied - N.O. Input

Emergency Shutdown - N.C. Input

Drain Pan Overflow A - N.O. Input

Drain Pan Overflow B - N.O. Input

Dirty Filter - N.O. Input

RD WH

GND

B 1I

B 2I

B 3I

B 4I

B 5I

B 6I

B 7I

BI8

AI1

AI2

AI3

AI4

SA Expansion Module

Figure 16: OE333-23-SA – SA Expansion Module Input Wiring

Revised 6/21/11

SA Controller Technical Guide

Installation & Wiring

SA Expansion Module Output Wiring

The SA Expansion Module must be connected to 24 VAC as shown in the wiring diagram below. Please see Table 1 on page 10 for correct VA requirements to use when sizing the transformer(s) used for powering the expansion module.

Also please note that when wiring the SA Expansion Module, its contacts must be wired as wet contacts (connected to 24 VAC).

Figure 17: OE333-23-SA – SA Expansion Module Output Wiring

SA Controller Technical Guide

Installation & Wiring

Suction Pressure Transducer Wiring

Zone

Suction Pressure Transducer

The OE275-01 Suction Pressure Transducer always wires directly to the Digital Scroll Compressor Controller. See Figure 18 below for wiring details.

The Suction Pressure Transducer is used to measure suction pressure at the HVAC unit’s DX evaporator coil suction line. This suction line pressure is converted to saturated refrigerant temperature by the SA Controller. This temperature is used by the SA Controller to accurately control the compressors and reheat cycle components to provide optimum performance from the system during Dehumidiﬁ cation operation.

Figure 18: OE275-01 – Suction Pressure Transducer Wiring

SA Controller Technical Guide

Installation & Wiring

SA Expansion Module Binary Inputs Wiring

SA Expansion Module Binary Inputs

The SA Expansion Module provides 8 Binary Inputs. See Figure 19 below for detailed wiring.

The transformer used for powering the SA Expansion Module must also be used to power the binary inputs.

WARNING!!

10 VA Minimum Power Required

For SA Expansion Module

24 VAC

GND

Warning: Do not apply any voltage greater than 24 VAC to the binary inputs. Higher voltages will damage the expansion module and possibly other components on the system.

Modular Cable

Connect To SA Controller

Modular Cable Connect To E-BUS Distribution Module

(When Used)

Water Proof of Flow A- N.O. Input Water Proof of Flow B - N.O. Input

Air Proof Of Flow - N.O. Input Remote Forced Occupied - N.O. Input Emergency Shutdown - N.C. Input

Drain Pan Overflow A - N.O. Input

Drain Pan Overflow B - N.O. Input Dirty Filter - N.O. Input

BI1

BI2

BI3

BI4

BI5

BI6

BI7

BI8

SA Expansion Module

Figure 19: OE333-23-SA – SA Expansion Module 8 Binary Inputs Wiring

SA Controller Technical Guide

Revised 6/21/11

Installation & Wiring

Entering Air Humidity Sensor Wiring

Zone

Entering Air Humidity Sensor

The OE265-14 Entering Air Humidity Sensor is connected to the system by wiring it to the AI1 input on the SA Expansion Module. It must be wired as shown in Figure 20 below for proper controller operation.

Warning: It is very important to be certain that all wiring is correct as shown in the wiring diagram below. Failure to observe the correct polarity will result in damage to the Entering Air Humidity Sensor or SA Expansion Module.

Figure 20: OE265-14 – Entering Air Humidity Sensor Wiring

SA Controller Technical Guide

Installation & Wiring

Indoor Wall-Mounted Humidity Sensor Wiring

Indoor Wall-Mounted Humidity Sensor

When used, the OE265-11 Indoor Wall-Mounted Humidity Sensor is connected to the system by wiring it to the AI2 input on the SA Expansion Module. It must be wired as shown in Figure 21 below for proper controller operation.

Warning: It is very important to be certain that all wiring is correct as shown in the wiring diagram below. Failure to observe the correct polarity will result in damage to the Space Humidity Sensor or SA Expansion Module.

Figure 21: OE265-11 – Indoor Wall-Mounted Humidity Sensor Wiring

SA Controller Technical Guide

Installation & Wiring

Modulating Heating Device Wiring

Zone

Modulating Heating Device

The Modulating Heating Device signal can be conﬁ gured for either a 0-10 VDC or 2-10 VDC output signal when programming the controller . The output signal can be conﬁ gured for either Direct Acting or Reverse Acting operation as required.

The Output signal is normally used to control a Modulating Hot Water Valve or Modulating Steam Valve or is used for SCR Control of an Electric Heating Coil.

See Figure 22 below for detailed wiring of the Modulating Heating Device.

Warning: It is very important to be certain that all wiring is correct as shown in the wiring diagram below. Failure to observe the correct polarity could result in damage to the Modulating Heating Device or the SA Expansion Module.

Figure 22: Modulating Heating Device Wiring

SA Controller Technical Guide

Installation & Wiring

Modulating Cooling Device Wiring

Chilled Water Valve

For Chilled Water Applications, the Modulating Cooling Signal(s) can be conﬁ gured for either a 0-10 VDC or 2-10 VDC output signal when programming the controller. The output signal can also be conﬁ gured for either Direct Acting or Reverse Acting operation as required by your application. This signal output would be connected to a Modulating Chilled Water Valve.

See Figure 23 below for detailed wiring of a Chilled Water Valve.

Figure 23: Chilled Water Valve Wiring

SA Controller Technical Guide

Installation & Wiring

Modulating Cooling Device Wiring

Zone

Digital Scroll Compressor Wiring

For Digital Scroll Applications, the Modulating Cooling Signal(s) must be conﬁ gured for a 1.5-5.0 VDC output signal when programming the controller. This signal output would be connected to a Digital Scroll Compressor Controller.

For Digital Scroll Compressor wiring details, see Figure 24 below.

Figure 24: Digital Scroll Compressor Wiring

SA Controller Technical Guide

Warning: It is very important to be certain that all wiring is

correct as shown in the wiring diagram below. Failure to observe the correct polarity could result in damage to the Modulating Cooling Device or the SA Expansion Module.

Installation & Wiring

Modulating Cooling Device Wiring

Figure 24: Digital Scroll Compressor Wiring, continued

SA Controller Technical Guide

Zone

Installation & Wiring

Zone

12-Relay Expansion Module Overview and Wiring

12-Relay Expansion Module

Two different Expansion Modules are available for use with the SA Controller to provide additional inputs and outputs beyond those found on the SA Controller.

The SA Expansion Module ( OE333-23-SA) is provided with 8 Binary Inputs, 4 Analog Inputs, 4 Relay Outputs, and 5 Analog Outputs. See Figures 16 and 17 on page 20 and 21 for complete wiring details.

The 12-Relay Expansion Module ( OE358-23-12R) provides for 12 Dry Contact Conﬁ gurable Relay Outputs. See Figure 25 below for complete wiring details.

The expansion modules can be used individually or together to provide the required inputs and outputs for your speciﬁ c applications.

When using the 12-Relay Expansion Module, you must correctly conﬁ g- ure a set of jumpers on the board depending on whether it will be used by itself or in addition to the SA Expansion Module.

The jumpers are located on the edge of the 12-Relay Expansion Module on the same side of the module as the power connection. See Figure 25 below for details regarding setting the switch correctly for your application.

Figure 25: OE358-23-12R – 12-Relay Expansion Module Wiring and Jumper Settings

SA Controller Technical Guide

Installation & Wiring

E-BUS Distribution Module Overview and Wiring

E-BUS Distribution Module

The E-BUS Distribution Module ( OE365-23-EBD-A) is a communications device that allows WattMaster-approved E-BUS Modules to be connected to the SA Controller with I

The E-BUS Distribution Module allows the following E-BUS Modules to be connected to the SA Controller:

• Two Condenser Head Pressure Module ( OE370-23-HP2C)

• Water Source Heat Pump Protection Module ( OE334-23-WPM-A)

The E-BUS Modules are connected to the E-BUS Distribution Module by HSSC Series Modular Cables that can be ordered in various lengths. See Figure 26 for the E-BUS Distribution Module wiring and HSSC cable length options.

C communications.

All E-BUS Modules require a 24 VAC power connection with an appropriate VA rating. The E-BUS Distribution Module can provide limited power for E-BUS Communicating Sensors (limited to 400 mA total).

The E-BUS Distribution Module also provides terminal block connections for applications that require pulling multi-conductor wire through conduit for applications requiring longer wire runs.

NOTE: The E-BUS Distribution Module contains no userserviceable parts. Contact qualiﬁ ed technical personnel if your module is not operating correctly.

Figure 26: E-BUS Distribution Module Wiring Diagram

SA Controller Technical Guide

Zone

3 (Y)

5 (U)

2 (+)

1 (-)

Installation & Wiring

Zone

Two Condenser Head Pressure Module Overview and Wiring

Two Condenser Head Pressure Module

The T wo Condenser Head Pressure Module ( OE370-23-HP2C) monitors four individual head pressure transducers and controls two Condenser Fans or Water Valves on units with two physically separate condenser sections. The highest reading of head pressure transducers 1 & 2 controls Condenser Signal A. The highest reading of head pressure transducers 3 & 4 controls Condenser Signal B.

signal is used to control the Condenser Fans. A 0-10 volt output signal is used to control the valves.

Head Pressure Transducers

0 - 667 PSI

(One Per Refrigerant Circuit)

RD WH

Use For Dual

Applications Only

This Dip Switch Is Not

Used For This Application

A pulse width modulation (PWM)

OE370-23-HP2C

SIG

GND

SIG

GND

SIG

GND

SIG

GND

Two Condenser Head Pressure Module

+5V

SIG 1

GND

+5V

SIG 2

GND

+5V

SIG 3

GND

+5V

SIG 4

GND

BIN 1

BIN 2

COM

ADDRESS

PWR

The Two Condenser Head Pressure Module is connected to the SA Controller ( OE332-23-SA) using the E-BUS Distribution Module (OE365-23-EBD-A). This allows the Two Condenser Head Pressure Module to receive setpoints from the SA Controller. See Figure 27 below for wiring diagram.

The Two Condenser Head Pressure Module requires a 24 VAC power connection with an appropriate VA rating.

NOTE: For complete information, including the sequence of operation, refer to the Two Condenser Head Pressure Module Technical Guide.

Head Pressure Control

Valve Actuator - A For Water Cooled

Condenser Applications

Head Pressure Control

Valve Actuator - B For Water Cooled

Condenser Applications

ECM Motor

COM

ECM Motor

COM

Use For

Dual

Applications

Only

Use For

Dual

Applications

Only

RELAYS

ANALOG

AO1

AO2

GND

PWM1-

PWM1+

PWM2-

PWM2+

VFD Condenser A Signal

Condenser Applications

VFD Condenser B Signal

Condenser Applications

OPTIONS

Setting Of OPTIONS

Not Required When

ALARM

STAT

Used With SA Controller

COMM

For Air Cooled

COM

For Air Cooled

COM

Condenser Fan A

Condenser Fan B

Dip Switch

Connect To E-BUS Distribution Module

HSSC Cable

GND

HSSC Cable

24 VAC

24 VAC Transformer

3 VA Minimum

E-BUS Expansion Module(s)

Line Voltage

Connect To Other

WattMaster-Approved

WARNING!!

Observe Polarity! All Boards Must Be Wired With GND-to-GND And 24 VAC-To-24 VAC. Failure To Observe Polarity Could Result In Damage To The Boards.

Figure 27: Two Condenser Head Pressure Module to E-BUS Distribution Module Wiring Diagram

Revised 1/21/11

SA Controller Technical Guide

Installation & Wiring

Water Source Heat Pump Protection Module Overview and Wiring

Water Source Heat Pump Protection Module

The W ater Source Heat Pump Protection Module (OE-334-23-WPM-A) protects the compressors on an AAON Water Source Heat Pump unit from damage by monitoring Suction Pressure, Leaving W ater T emperature, and Water Proof of Flow. It also utilizes a Delay Timer to prevent the compressors from turning on at the same time.

There is one water-only version of the W ater Source Heat Pump Protection Module—the OE-334-23-WPM-A which uses R-410A refrigerant. There are also two 410-A glycol versions—the OE-334-23-WPM-A20 which uses 20% glycol and the OE334-23-WPM-A40 which uses 40% glycol.

NOTE: When using the WSHP Protection Module, the

compressors are wired to this module instead of the SA Controller and SA Expansion Module.

The Water Source Heat Pump Protection Module connects to the SA Controller ( OE332-23-SA) using the E-BUS Distribution Module ( OE365-23-EBD-A). This allows the W ater Source Heat Pump Protection Module to receive control data and alarms from the SA Controller. See Figure 28 below for wiring diagram.

The Water Source Heat Pump Protection Module requires a 24 VAC power connection with an appropriate VA rating.

NOTE: For complete information, including the sequence of operation, refer to AAON Tulsa’s Water Source Heat Pump Protection Module Technical Guide.

Figure 28: Water Source Heat Pump Protection Module to E-BUS Distribution Module Wiring Diagram

SA Controller Technical Guide

Revised 10/18/10

Zone

Start-Up & Commissioning

Addressing & Powering Up

Before Applying Power

In order to have a trouble free start-up, it is important to follow a few simple procedures. Before applying power for the ﬁ rst time, it is very important to correctly address the controller and run through a few simple checks.

Controller Addressing

All SA Controllers are equipped with address switches. If the SA Controller is to operate as a stand-alone system (not connected to any other HVAC unit or VAV/Zone Controllers), the controller address switch should be set for address 1. When using the Modular Service Tool or System Manager to program and conﬁ gure the SA Controller, you would enter this address to communicate with the controller. When the system is to be connected to other HVAC unit controllers on a communication loop, each controller’s address switch must be set with a unique address between 1 and 59. When the SA Controller will be used with

Zone

VAV/Zone Controllers, the SA Controller’s address switch must be set as address 59, no exceptions. See Figure 29 below for address switch setting information.

Power Wiring

One of the most important checks to make before powering up the system for the ﬁ rst time is to conﬁ rm proper voltage and transformer sizing for each controller. Each SA Controller requires 8 VA of power delivered to it at 24 VAC and each of the modules require different VA loads (see Table 1 on page 10 for details). You may use separate transformers for each device (preferred) or power several devices from a common transformer. If several devices are to be powered from a single transformer, correct polarity must be followed.

Figure 29: SA Controller Address Switch Setting

SA Controller Technical Guide

Start-Up & Commissioning

Programming the Controller

Warning: Observe Polarity! All boards must be wired with GND-

to-GND and 24 VAC-to-24 VAC. Failure to observe polarity will result in damage to one or more of the boards. The Expansion Module must be wired in such a way that the Expansion Module and the SA Controller are always powered together. Loss of power to the Expansion Module will cause it to become inoperative until power is restored to the Expansion Module.

Check all wiring leads at the terminal block for tightness. Be sure that wire strands do not stick out and touch adjacent terminals. Conﬁ rm that all sensors required for your system are mounted in the appropriate location and wired into the correct terminals on the SA Controller . Be sure any Expansion Module connected to the SA Controller is also correctly wired just as you did for the SA Controller.

After all the above wiring checks are complete, apply power to the SA Controller and any Expansion Module connected to it.

Initialization

On system power up, a 30-second startup delay is performed where all default setpoints are initialized, LED’s are initialized, and all outputs are turned off.

When power is ﬁ rst applied, LED1 and LED2 will ﬂ ash out the controller address. LED1 will ﬂ ash to represent the tens position. LED2 will ﬂ ash to represent the ones position. After the controller address is complete, there will be a short pause and then 60 fast ﬂ ashes to represent controller initialization. There will be no controller operation or communications during initialization. After initialization, LED1 and LED2 will continuously ﬂ ash the status code.

Example of a controller address of 59:

LED1 will ﬂ ash 5 times. LED2 will ﬂ ash 9 times.

Programming the Controller

The next step is programming the controller for your speciﬁ c require- ments. In order to conﬁ gure and program the SA Controller, you must use an operator interface. Three different operator interfaces are available for programming and monitoring of the SA Controller. These are as follows:

• Modular Service Tool

• Modular System Manager

• Notebook or Desktop Computer with

Prism Computer Front-End Software Installed

Any of these devices or a combination of them can be used to access the status, conﬁ guration, and setpoints of any controller on your com- munications loop.

If using the Modular Service Tool or Modular System Manager with your system, refer to the SA Controller Operator Interfaces Technical Guide for complete SA Controller programming instructions.

If using a Notebook or Desktop computer and the Prism Computer Front End Software, refer to the Orion Prism Computer Front-End Technical Guide.

No matter which operator interface you use, we recommend that you proceed with the programming and setup of the SA Controller in the order that follows:

1. Conﬁ gure the Controller for your application.

2. Program the Controller setpoints.

3. Program the Controller operation schedules.

4. Set the Controller current time and date.

5. Review Controller status screens to verify system operation and correct Controller conﬁ guration.

See Table 3 on page 53 in the Troubleshooting Section of this manual for detailed diagnostic blink code information.

Operating Summary

There is a standard set of operating instructions that are continuously repeated during normal operations. They are listed below.

1. Read Analog Inputs for Temperatures, Pressures, and Binary Contact Closures.

2. Calculate Occupied/Unoccupied Mode of Operation.

3. Calculate HVAC Mode of Operation.

4. Set all outputs to match calculations for Heating or Cooling or Vent Mode.

5. Broadcast information to other controllers if conﬁ gured.

6. Log all temperatures and output conditions.

7. Repeat steps 1 through 6 continuously.

SA Controller Technical Guide

Selection

STATUS

SETPOINTS

SCHEDULES

OVERRIDES

ALARMS

CONFIGURATION

BALANCE- TEST

DOWN

CLEAR

ESC

ENTER

708

DEC

MINUS

708

DEC

MINUS

System Manager

CLEAR

ESC

DOWN

ENTER

STATUS

SETPOINTS

SCHEDULES

OVERRIDES

ALARMS

Mode

Figure 30: Modular Service Tool and Modular System Manager Operator Interfaces

Inputs & Outputs

SA Controller Inputs

Zone

SA Controller Inputs

AI1 - Space Temperature Sensor Input

If you want to generate Occupied or Unoccupied Heating and Cooling demands based on Space Temperature, select this Sensor for the HVAC Mode enable. The Space Temperature Sensor can be used for Night Setback control regardless of the HVAC Mode Sensor selected. If the Space Temperature Sensor used is equipped with the optional Push-Button Override Feature, this input will detect user overrides from Unoccupied back to Occupied operation for a user-adjustable amount of time. This Sensor is only required for Space Temperature Control or Night Setback. The Space Temperature Sensor can also be conﬁ gured to reset the Supply Air Temperature Setpoint. The Space Temperature Sensor is the only Sensor that can be used for Night Setback operation during the Unoccupied Mode.

AI2 - Supply Air Temperature Sensor Input

The Supply Air Temperature Sensor is the default HVAC Mode Enable Sensor. For typical VAV units that are Cooling Only with Morning W arm-up, this Sensor should be conﬁ gured as the HVAC Mode Enable Sensor. For all applications, the Supply Air Temperature Sensor is the sensor used for Staging Control. The HVAC unit must always have a Supply Air Temperature Sensor installed.

AI3 - Entering Water Temperature Sensor Input

The Entering Water Temperature is used to determine when to initiate Water Side Economizer operation. If the unit is in Cooling Mode and the Entering W ater T emperature drops 10˚F (adj.) below the Entering Air Temperature, the unit will begin to modulate the W ater Side Economizer Valve as part of the cooling operation. See Water Side Economizer in the Sequence of Operation Section of this manual for a full description of this operation.

AI4 - Entering Air Temperature Sensor Input

The Entering Air Temperature Sensor can be used as the controlling sensor for 100% Entering Air units. The Entering Air Temperature is used to lock out Heating or Cooling to conserve energy at whatever temperature you deem appropriate for each Mode of Operation. The Entering Air Temperature Sensor can also be used to provide Low Ambient Temperature Protection in the building. If the Entering Air T emperature is below the Low Ambient Temperature Setpoint, the Preheat Relay Output will be maintained during Occupied operation and will not be allowed to stage off unless the Supply Fan is turned off. The Entering Air Temperature Sensor is also used in combination with the Entering Air Humidity Sensor for Dewpoint calculations.

AI6 - Duct Static Pressure Sensor Input

This special phone jack-style input connection accepts a Duct Static Pressure Sensor input modular cable. The Duct Static Pressure Sensor reading is used to determine current Duct Static Pressure. This Static Pressure reading is used to control the output signal supplied to the Supply Fan VFD or Zoning Bypass Damper Actuator . If you have conﬁ gured the HVAC unit for Constant Volume operation, this Sensor is optional. If it is installed on a Constant Volume unit, it will not affect operation, but rather will be used as a status-only reading.

AI7 - Space Temperature Sensor Slide Adjust or Remote SAT Reset Signal Input

AI7 on the SA Controller is a dual-purpose input. It can be used for the Space Sensor Slide Adjust option or for connection of the Remote Supply Air Setpoint Reset Signal option. Only one or the other can be used, not both.

Space Temperature Sensor Slide Adjust

If the Space Temperature Sensor being used has the optional Slide Adjust feature, its AUX output is connected to this input. The Slide Adjust control is used to vary the HVAC Mode Heating and Cooling Setpoints by a user-conﬁ gured maximum amount. The Slide Adjust- ment adjusts whichever Temperature Sensor has been conﬁ gured as the HVAC Mode Enable Sensor, even if that Sensor is not the installed Space Temperature Sensor.

If Space Temperature or Entering Air Temperature is conﬁ gured as the SAT/Reset Source, the Slide Adjustment adjusts both the HVAC Mode Enable Heating and Cooling setpoints and the SA T/Reset Source Heating and Cooling setpoints simultaneously by a user-conﬁ gurable maximum amount.

Remote Supply Air Temperature Reset Signal

When a 0-5 or 0-10 VDC Remote Supply Air T emperature Reset Signal is to be used, the controller must be conﬁ gured for it, and the Room Sensor Slide Offset setpoint must be set to zero for this option. If the slide offset is not set to zero, the Supply Air Temperature Reset will not function.

The Remote Supply Air Temperature Reset signal must be conﬁ gured so that its setpoint will be at the coldest Supply Air Temperature at 0 VDC, and so that its setpoint will be at the warmest Supply Air Temperature at 5 or 10 VDC, depending on the voltage signal required.

The jumper AI7 must be set to 0-10V regardless of whether the controller is conﬁ gured for 0-5 or 0-10VDC operation. See the wiring diagram on page 13 for details.

AI5 - Not Utilized At This Time

SA Controller Technical Guide

Inputs & Outputs

SA Controller Outputs and SA Expansion Module Inputs & Outputs

SA Controller Outputs

AO1 - Water Side Economizer Valve Signal

This 2-10 VDC signal is used to modulate the Water Side Economizer valve(s) of either a single SA Unit or a dual SA Unit during Water Side Economizer operation.

AO2 - Supply Fan VFD

This voltage signal (0-10 VDC) can be connected to a Supply Fan VFD or to Proportional Inlet Vanes to control the Duct Static Pressure. This signal can also be connected to a 0-10 VDC Modulating Zoning Bypass Damper Actuator to control Duct Static Pressure. When this signal is used to control a Zoning Bypass Damper Actuator, the Zoning Bypass Damper Actuator needs to be mechanically conﬁ gured to close the Zon- ing Bypass Damper on an increase of the 0-10 VDC output signal. This is necessary because the signal is Direct Acting and is not conﬁ gurable as a Reverse Acting Signal on the SA Controller.

R1 - Supply Fan (Enable)

This is reserved for the Supply Fan and cannot be conﬁ gured for any other option.

R2-R5 - User-Conﬁ gurable Relays

These relays are conﬁ gurable by the user. For all the available conﬁ gura- tion options, see Table 2 on page 38.

By using all (4) of the available relay outputs on the SA Controller, all (4) of the relay outputs on the SA Expansion Module, and all 12 of the relay outputs on the 12 Relay Expansion Module, you have the ability to conﬁ gure up to a combined total of (20) relay outputs for Heating Stages, Cooling Stages, and options 3 through 10 listed in Table 2.

SA Expansion Module Inputs and Outputs

AI1 - Entering Air Humidity Sensor Input

This input is used to connect an Entering Air Humidity Sensor that when combined with the Entering Air Temperature Sensor reading is used to calculate a Dewpoint T emperature. The Entering Air Dewpoint Temperature is used to activate the Dehumidiﬁ cation Mode on Entering Air conﬁ gured units.

AI2 - Indoor Air Humidity Sensor Input

The Indoor Air Humidity Sensor is used to activate Dehumidiﬁ cation Mode when the unit is conﬁ gured for Supply Air Control or Space Temperature Control on a VAV or CAV unit. This sensor can be used as a reset sensor for Entering Air Controlled units.

AI3 - Suction Pressure A Input

The Suction Pressure Transducer (0-5 VDC input) is used to measure the suction pressure at the HV AC Unit’ s DX evaporator coil suction line. This suction line pressure is converted to saturated refrigerant temperature by the SA Controller. This temperature is used by the SA Controller to accurately control the compressor’s cycle to provide optimum performance from the system during Dehumidiﬁ cation operation.

AI4 - Suction Pressure B Input

The Suction Pressure Transducer (0-5 VDC input) is used to measure the suction pressure at the HV AC Unit’ s DX evaporator coil suction line. This suction line pressure is converted to saturated refrigerant temperature by the SA Controller. This temperature is used by the SA Controller to accurately control the compressor’s components to provide optimum performance from the system during Dehumidiﬁ cation operation.

NOTE: The Binary Inputs require wet contacts (24 VAC only) to recognize an active input. If you provide dry contacts, the contact closure will not be recognized.

AO1 - Modulating Heating Signal

This output signal can be conﬁ gured for either a 0-10 VDC or 2-10 VDC output signal. This signal can be conﬁ gured for either Direct Act- ing or Reverse Acting operation. This output signal is used to operate a AAON Air Temperature Setpoint.

Modulating Heating Device to maintain the Heating Supply

AO2 - Modulating Cooling Stage 1 Signal

This output is used to control either a Copeland Digital Scroll Compressor™ or a Modulating Chilled Water Valve to maintain the Cooling Supply Air Temperature Setpoint. If used for a Copeland Digital Scroll Compressor, the output is conﬁ gured for a 1.5-5.0 VDC operation. If used for a Modulating Chilled Water Valve, the output is conﬁ gured for either 0-10 VDC or 2-10 VDC operation and can be conﬁ gured for direct acting or reverse acting operation.

AO3 - Modulating Cooling Stage 2 Signal

This output signal must be conﬁ gured for a 1.5-5.0 VDC output signal. This output signal is used to operate a Copeland Digital Scroll™ Compressor to maintain the Cooling Supply Air Temperature Setpoint.

SA Controller Technical Guide

Inputs & Outputs

SA Expansion Module Binary Inputs

Zone

AO4 - Water Side Economizer Bypass Actuator

Valve A

This output signal is a Direct Acting 2-10 VDC output signal that is used to modulate the Water Side Economizer Bypass Actuator on a Single SA Unit or Unit A of a Dual SA Unit.

AO5 - Water Side Economizer Bypass Actuator Valve B

This output signal is a Direct Acting 2-10 VDC output signal that is used to modulate the Water Side Economizer Bypass Actuator of Unit B of a Dual SA Unit.

R1-R4 - User-Conﬁ gurable Relay Outputs

Conﬁ gure relays as indicated by the factory wiring diagram when mounted controls are used. The options are listed in Table 2 below.

BI1 - Water Proof of Flow Input A

This input is for the W ater Proof of Flow Switch for a single SA Unit or for Unit A of a Dual SA Unit. If the W ater Proof of Flow Switch contact opens while the Condenser Valve is operating, the Unit will enter W ater Proof of Flow Failure mode. In this mode, the mechanical cooling will deactivate and the Condenser Valve will be forced to 100%. The Unit will exit this mode when the Water ﬂ ow Switch is closed again and Water Flow is proven.

BI2 - Water Proof of Flow Input B

This input is for the Water Proof of Flow Switch for Unit B of a Dual SA Unit. If the Water Proof of Flow Switch contact opens while the Condenser Valve is operating, the Unit will enter Water Proof of Flow Failure mode. In this mode, the mechanical cooling will deactivate and the Condenser V alve will be forced to 100%. The Unit will exit this mode when the Water ﬂ ow Switch is closed again and Water Flow is proven.

BI3 - Air Proof of Flow Input

An Air Proof of Flow Switch that provides a wet contact closure whenever the HVAC Unit Supply Fan is operating can be connected to this input. If the Air Proof of Flow Switch contact opens while the Supply Fan is operating, all Heating and Cooling is suspended or disabled. The Air Proof of Flow Switch is an optional input. This means that you must conﬁ gure the SA Controller to recognize this input signal.

BI4 - Remote Forced Occupied Mode Input

When this wet contact input closes, it will force the SA Controller into the Occupied Mode. When the Remote Forced Occupied Signal is removed, the controller will revert to the Unoccupied Mode of operation if no internal or external schedule has been conﬁ gured or is in effect when this occurs.

BI5 - Emergency Shutdown Input

This wet contact input is used to initiate shutdown of the HVAC Unit when an N.C. Smoke Detector (by others), Firestat (by others), or other shutdown condition (by others) contact is opened. The controller remains active and can initiate alarm relays.

BI6 - Drain Pan Overﬂ ow Input A

This input is for the Drain Pan Overﬂ ow Switch for a single SA Unit or for Unit A of a Dual SA Unit. When the drain pan is in an overﬂ ow condition, a Drain Pan Overﬂ ow Switch will provide a 24 VAC wet contact closure to this input. When this contact closure is initiated, the controller will enter Drain Pan Overﬂ ow Failure Mode and deactivate mechanical cooling.

BI7 - Drain Pan Overﬂ ow Input B

This input is for the Drain Pan Overﬂ ow Switch for Unit B of a Dual SA Unit. When the drain pan is in an overﬂ ow condition, a Drain Pan Overﬂ ow Switch will provide a 24 VAC wet contact closure to this input. When this contact closure is initiated, the controller will enter Drain Pan Overﬂ ow Failure Mode and deactivate mechanical cooling.

BI8 - Dirty Filter Contact Closure Input

This wet contact input is required for Filter Status Indication and requires a Differential Pressure Switch to initiate “Dirty Filter” indication.

No. Relay Description Details

1 Heating Stages Conﬁ gure (1) Relay for each stage of heat. Conﬁ gure (1) Relay for Mod heat. 2 Cooling Stages Conﬁ gure (1) Relay for each stage of cooling. For Chilled Water, conﬁ gure (1) Relay for cooling. 3 Warm-Up Mode (VAV Boxes) Conﬁ gure (1) Relay for Warm-Up Mode when Non-Orion VAV/Zone Controllers are used. 4 Reversing Valve (Heat Pumps) Conﬁ gure (1) Relay for Reversing Valve operation. Can be conﬁ gured for heating or cooling. 5 Reheat (Dehumidiﬁ cation) Conﬁ gure (1) Relay for On/Off reheat when used.

Pre-Heater

(low ambient protection) 7 Alarm Conﬁ gure (1) Relay to initiate an alarm output when any SA Controller alarm occurs. 8 Override Conﬁ gure (1) Relay to initiate an output signal when Space Temperature override button is pushed. 9 Occupied Conﬁ gure (1) Relay to initiate an output signal any time the SA Controller is in Occupied Mode. 10 Water Side Economizer Conﬁ gure (1) Relay to initiate an output signal any time the SA Controller is in Economizer Mode.

Conﬁ gure (1) Relay for pre-heat coil when required. Activated when the Entering Air Temperature drops below the Ambient Protection Setpoint.

Table 2: User-Conﬁ gurable Relay Outputs

Revised 7/11/11

SA Controller Technical Guide

Sequence of Operations

Mode of Operation Overview

Occupied/ Unoccupied Mode of Operation

The SA Controller can utilize several methods for determining the Occupied Mode of Operation. These are as follows:

• Forced Schedule

• Remote Forced Occupied Signal

• Internal Week Schedule

• Push-Button Override Signal

Forced Schedule

The SA Controller can be forced into the Occupied Mode by inputting a Forced Schedule from any operator interface.

Remote Forced Occupied Signal

When this wet contact input closes, it will force the SA Controller into the Occupied Mode. When the Remote Forced Occupied Signal is removed, the controller will revert to the Unoccupied Mode of operation if no Internal or External Schedule has been conﬁ gured or is in effect when this occurs.

NOTE: When using Remote Forced Occupied Mode, set all the Internal Week Schedules to ‘0’ so that the Internal Schedule always commands the Unoccupied Mode.

HVAC Modes of Operation

There are 8 possible HVAC Modes of Operation. They are as follows:

• Vent Mode

• Cooling Mode

• Dehumidiﬁ cation Mode

• Heating Mode

• Heat Pump

• Water Side Economizer

• Warm-Up Mode

• Off Mode

Vent Mode Operation

This Mode only applies to the Occupied Mode of Operation. The Vent Mode is deﬁ ned as the Supply Fan running with no Heating, Cooling, or Dehumidiﬁ cation demand.

V ent Mode can occur during the Occupied Mode if the Space or Entering Air Temperature Sensor is selected as the HVAC Mode Enable Sensor.

NOTE: During Vent Mode, all Cooling and Heating Stages are deactivated. The Static Pressure is still maintained by the Supply Fan VFD or Zoning Bypass Damper Signal since the Supply Fan is still operating in this Mode.

Internal Week Schedule

An Internal Week Schedule, which supports up to two start/stop events per day, is available for determining Occupied and Unoccupied Schedules. If you are using the Internal Schedule, an Optimal Start calculation is also available. See the Scheduling Section on page 50 for more information on the Optimal Start feature.

Push-Button Override Signal

During Unoccupied hours, you can force the SA Controller back to Occupied operation by pressing the Override Button on the Space T emperature Sensor for a period of less than 3 seconds. This initiates the Override or resets the Override Timer back to zero during Unoccupied hours of operation.

During Override operations, you can cancel the Override by pressing the Override Button for a period of time between 3 seconds and 10 seconds. This restores the SA Controller to Normal Unoccupied Operation.

If the Override Button is held for more than 10 seconds, it causes a Space Sensor Failure Alarm. This is due to the fact that the Override Button actually shorts the Space Temperature Sensor input to ground. If this input is shorted to ground or left ﬂ oating with no Space Temperature Sensor detected for more than 10 seconds, it is considered a Space Temperature Sensor failure.

You can still use the Space Temperature Sensor input for an Override Command even when a Space Temperature Sensor is not connected. Simply provide a Momentary Push-Button connected between AI1 and the Ground T erminal on the same terminal block. Follow the same procedure for initiating Overrides, even on Supply Air Temperature Controlled Cooling-Only HVAC units.

Cooling Mode Operation

Occupied Cooling Mode occurs whenever the HVAC Mode Enable

Temperature rises one deadband above the HV AC Cooling Mode Enable Setpoint. The unit will leave the Cooling Mode when the HVAC Mode Enable T emperature falls one deadband below the HVAC Mode Enable Cooling Setpoint. Unoccupied Cooling Mode only occurs if a Space Temperature Sensor is connected to the SA Controller or a broadcast of Space T emperature is being received from a General Broadcast Controller and if the Space Temperature is above the Cooling Setpoint.

The Mechanical Cooling will be disabled if the Entering Air Temperature is below the Cooling Lockout Setpoint by 1°F. This gives a 2°F hysteresis around the Cooling Lockout Setpoint to prevent unwanted cycling in and out of Mechanical Cooling Mode. If the Entering Air Temperature disables the Mechanical Cooling while it is currently operating, the Mechanical Cooling will stage off if all staging and run times are satisﬁ ed.

If the Water Side Economizer has been enabled for operation, it is used as the ﬁ rst stage of Cooling, and the Mechanical Cooling will be activated if necessary. See the Water Side Economizer Operation section on page 41 for a more detailed operating sequence.

No matter which Sensor is conﬁ gured for the HVAC Mode Enable, the Supply Air Temperature is always controlled to the Active Supply Air Temperature Setpoint while in the Cooling Mode.

SA Controller Technical Guide

Sequence of Operations

Cooling Mode

Zone

Stage Control Window

The Cooling Stage Control Window Setpoint determines when the compressors start to stage down. In the Cooling Mode, as the Supply Air Temperature rises above the Active Supply Air Temperature Setpoint, the Cooling Stages will begin to stage on based on the Cooling Stage Up Delay setting. The Cooling Stages will continue to run until the Supply Air Temperature drops below the Active Supply Air Temperature Setpoint minus the Cooling Stage Control Window. For example, if the Supply Air Temperature Setpoint is 55° and the Cooling Stage Control Window is 5°, as the Supply Air T emperature drops below 50°, the Cooling Stages will begin to stage off based on the Cooling Stage Down Delay setting.

Cooling Staging Delay

Minimum Off Time A Cooling Stage cannot be activated unless it has been off for this amount of time. Minimum Run Time After a Cooling Stage has been activated, it must remain on for this amount of time. Staging Up Delay After the ﬁ rst Cooling Stage has been activated, this delay pre- vents additional stages from activating too quickly before they are needed to achieve the Active Supply Air Temperature Setpoint.

Staging Down Delay

After a Cooling Stage has met its Minimum Run Time and is not needed, this delay prevents additional stages from deactivating too quickly in case they are needed to maintain the Active Supply Air Temperature Setpoint Temperature.

Modulating Cooling

The SA Controller can control one of two Modulating Cooling sources. This can either be a Chilled Water Valve or a Copeland Digital Scroll™ Compressor(s). A Copeland Digital Scroll™ Compressor is a Variable Capacity Compressor that has a 10-to-1 turn down ratio. Whichever source is used, the SA Controller will control the Modulating Cooling source to maintain the Active Supply Air Temperature Setpoint.

The Modulating Cooling Proportional Window is used to determine the signal to the Modulating Cooling Source and is user-adjustable. The Modulating Cooling signal is calculated based on the differential between the Supply Air T emperature and the Active Supply Air T emperature Setpoint based on the Modulating Cooling Proportional Window.

The Maximum Signal Adjustment per Time Period is 10% and is not user-adjustable. The Minimum Signal Adjustment per Time Period is based on the Modulating Cooling Proportional Window. The larger the Modulating Cooling Proportional Window, the smaller the signal adjustment will be per Time Period. The Time Period is the delay between another increase or decrease in the Modulating Cooling Source Signal and is user-adjustable. For example, if the Modulating Cooling Proportional Window is 5F, the signal would adjust 2% per F each Time Period above or below the Active Supply Air T emperature Setpoint. When the Supply Air Temperature is above or below the Active Supply Air T emperature Setpoint by 5F or more, the signal would adjust 10% each Time Period.

DX Cooling

If the unit is in the Cooling Mode and the Supply Air Temperature is above the Active Supply Air Cooling Setpoint, the following staging sequences will occur.

Units with 2 Digital Compressors

Two Stages of Cooling need to be conﬁ gured for the two Compressors. If the Water Side Economizer is active, the Economizer valve needs to reach 100% before activating mechanical cooling. When mechanical cooling is active, the Compressors will modulate to maintain the Active Supply Air Cooling Temperature Setpoint.

The First Stage of Cooling will modulate as required. If the ﬁ rst stage rises above 60% and remains there for the Stage Up Delay and the Supply Air Temperature (SAT) is above the Active Supply Air Cooling Temperature Setpoint, then the Second Stage of Cooling will activate. The two Compressors will go to half the position of the ﬁ rst Compressor and will modulate together to maintain the Active Supply Air Cooling Temperature Setpoint.

If both Compressors fall below 30% and remain there for the Stage Down Delay and the Supply Air Temperature Setpoint is below the SAT Setpoint minus the Cooling Stage Control Window, then the Second Stage will deactivate. The ﬁ rst Compressor will go to 60% and it will modulate to maintain the Active Supply Air Cooling Temperature Setpoint.

Units with 4 Digital Compressors (Dual Unit)

The Compressors will Stage Up and Stage Down the same as 2 Digital Compressors. Number 1 Compressors from both units will modulate together and number 2 Compressors from both units will modulate together.

Units with 1 Digital Compressor and 1 ON/OFF Compressor

Two Stages of Cooling need to be conﬁ gured for the two Compres- sors. If the Economizer is active, the Economizer valve needs to reach 100% before activating mechanical cooling. When mechanical cooling is active, the Digital Compressor will modulate to maintain the Active Supply Air Cooling Temperature Setpoint.

The First Stage of Cooling will modulate up. If the First Stage stays at 100% for the Stage Up Delay and the Supply Air Temperature is above the Supply Air Temperature Setpoint, then the Second Stage (ON/OFF) will activate while the First Stage is allowed to modulate.

If the Digital Compressor falls below 20% and remains there for the Stage Down Delay and the Supply Air Temperature is below the Supply Air Temperature Setpoint minus the Cooling Stage Control Window, then the Second Stage (ON/OFF) will deactivate.

Units with 2 Digital Compressors and 2 ON/ OFF Compressors (Dual Unit)

The Compressors will Stage Up and Stage Down similar to 1 Digital Compressor and 1 ON/OFF Compressor. The two Digital Compressors modulate together as Stage One. The two ON/OFF Compressors are considered the 2nd and 3rd Stage of Cooling.

The ﬁ rst Stage ( 2 Digital Compressors) will modulate up. If the First Stage stays at 100% for the Stage Up Delay and the Supply Air Temperature is above the Supply Air Temperature Setpoint, then the Second Stage will activate while the First Stage is allowed to modulate. This sequence will repeat for the Third Cooling Stage.

If the two Digital Compressors fall below 20% and remain there for the Stage Down Delay and the Supply Air Temperature is below the Supply Air Temperature Setpoint minus the Cooling Stage Control Window,

SA Controller Technical Guide

Sequence of Operations

Cooling Mode

then the Second Stage will deactivate. This sequence will repeat for the Third Cooling Stage.

Air Cooled Condenser Fan Operation

If this is an Air Cooled SA Unit that has an installed Two Condenser Head Pressure Module, whenever the compressor(s) are ﬁ rst activated the signal to the condenser fan will go to 50% for 30 seconds. After this 30 second period, the unit will then monitor the Head Pressure Transducer(s) and modulate the Condenser Fan(s) to maintain the Head Pressure Setpoint (275 psi adjustable). The SA Controller can monitor up to two Head Pressure Transducers on a Single SA Unit or up to two Head Pressure Transducers in each unit of a Dual SA Unit. The highest of the two readings in each unit will be used to control the Condenser Fan in that unit.

During Heat Pump Defrost, the Condenser Fan signal will go to 0%. When compressors are not active the Condenser Fan signal will go to 100%.

Water Side Economizer Operation (Valves 1 & 2)

The Water Side Economizer (WSE) is only available if using a Water Cooled Condenser. The WSE is only active in the Cooling Mode and is activated when the Entering W ater T emperature drops 10°F (Adjustable) below the Entering Air Temperature.

If the Compressors are Active:

The WSE (V alve 1) will open to 100% and the WSE Bypass (V alve

2) will close to 0%.

If the Compressors are not Active:

If the unit is conﬁ gured for Constant Flow, the WSE (Valve 1) will modulate to maintain the

Setpoint and the WSE Bypass (Valve 2) will modulate opposite.

If the unit is conﬁ gured for Variable Flow, the WSE (Valve 1) will modulate to maintain the

Setpoint and the WSE Bypass (Valve 2) will close.

The Economizer Deactivates as follows:

When the Entering W ater T emperature rises to 8°F below the Entering Air Temperature, the WSE will deactivate.

If the unit is conﬁ gured for Constant Flow, the WSE (Valve 1) will close to 0% and the Economizer Bypass (Valve 2) will open to 100%.

If the unit is conﬁ gured for Variable Flow, the WSE (Valve 1) will close to 0% and the WSE Bypass (Valve 2) will modulate to maintain Head Pressure (275 psi adjustable). A Two Condenser Head Pressure Module is required.

Active Supply Air Cooling Temperature

Water Cooled Condenser (Valve 3)

If the SA Unit has a Water Cooled Condenser and an installed Two Condenser Head Pressure Module, the SA Controller can monitor up to two Head Pressure Transducers on a Single SA Unit or up to two Head Pressure Transducers in each unit of a Dual SA Unit. The highest of the two readings in each unit will be used to control the Condenser Valve in that unit.

If the unit is conﬁ gured for Constant Flow:

When the compressor(s) are ﬁ rst called to activate for Cooling, Dehumidiﬁ cation, or Heat Pump Heating Mode, the signal to the condenser valve will go to 75% for 3 minutes in order to prove water ﬂ ow. After this 3 minute period, the compressor(s) will ener gize and the Condenser Valve will modulate to maintain the Head Pressure Setpoint (275 PSI adjustable).

During Heat Pump Heating, the Condenser Valve signal will go to 100%. When compressors are not active, the Condenser Valve signal will go to 100%.

Once Water Flow has been initially proven, the compressors are energized for Cooling, Dehumidiﬁ cation, or Heat Pump Heating. Once the compressor(s) are energized, the only time a loss of water ﬂ ow will be recognized during Cooling or Dehumidiﬁ cation is if the Condenser Valve is above 70%. If this happens, an alarm will be generated and the compressors(s) will be de-energized. During Heat Pump Heating, anytime there is a loss of water ﬂ ow, an alarm will be generated and the compressors(s) will be de-energized.

If the unit is conﬁ gured for Variable Flow and has no Water Side Economizer (WSE):

When compressor(s) are ﬁ rst called to activate, the signal to the Condenser Valve will go to 75% for 3 minutes in order to prove water ﬂ ow . After this 3 minute period, compressor(s) will ener gize and the Condenser Valve will modulate to maintain the Head Pressure Setpoint (275 PSI adjustable). During Heat Pump Heating, the Condenser Valve signal will go to 100%.

Water Flow must always be initially proven for the compressors to energize for Cooling, Dehumidiﬁ cation, or Heat Pump Heating. Once the compressor(s) are energized, the only time a loss of water ﬂ ow will be recognized during Cooling or Dehumidiﬁ cation is if the Condenser Valve is above 70%. If this happens, an alarm will be generated and the compressors(s) will be de-energized. During Heat Pump Heating, anytime there is a loss of water ﬂ ow, an alarm will be generated and the compressors(s) will be de-energized.

When compressors are not active, the Condenser Fan signal will go to 0%.

If the unit is conﬁ gured for Variable Flow and has a Water Side Economizer (WSE):

When compressor(s) are ﬁ rst called to activate, the signal to the Condenser Valve will go to 75% for 3 minutes in order to prove water ﬂ ow . During this period, the WSE Bypass Valve signal will go to 100%. After this 3 minute period, the compressor(s) will energize, the Condenser Valve signal will go to 100%, and the WSE Bypass Valve will modulate to maintain the Head Pressure Setpoint (275 PSI adjustable). During Heat Pump Heating, the WSE Bypass Valve signal will go to 100%.

Water Flow must always be initially proven for the compressors to energize for Cooling, Dehumidiﬁ cation, or Heat Pump Heating. Once the compressor(s) are energized, the only time a loss of water ﬂ ow will be recognized during Cooling or Dehumidiﬁ cation is if the WSE Bypass Valve is above 70%. If this happens, an alarm will be generated and the compressors(s) will be de-energized. During Heat Pump Heating, anytime there is a loss of water ﬂ ow, an alarm will be generated and the compressors(s) will be de-energized.

When compressors are not active, the WSE Bypass Valve signal will go to 100%. When the unit is off, the Economizer (WSE) Valve and WSE Bypass Valve will be closed.

SA Controller Technical Guide

Revised 7/11/11

Sequence of Operations

Dehumidiﬁ cation Mode

Zone

Economizer Flush Cycle

If the Economizer has been closed for 72 hours, a Flush Cycle will be initiated the next time the compressor is activated or at the next 6:00 AM time slot, whichever happens ﬁ rst. During the Flush Cycle, the Econo- mizer Valve will open for 5 minutes and then close again. The 72 hour timer will restart once the Flush Cycle is completed or the Economizer has been activated and has closed again.

Chilled Water Cooling

One Stage of Cooling needs to be conﬁ gured for the Chilled Water Valve. If the Water Side Economizer is active, the Economizer valve needs to reach 100%, before activating the Chilled Water Valve. When the Chilled Water Valve is active, the valve will modulate to maintain the Active Supply Air Cooling Temperature Setpoint.

External Cooling

The SA Controller can be conﬁ gured to control stages of cooling that are external to the SA Unit.

Dehumidiﬁ cation Mode

On VAV or CAV applications, the Indoor Air Humidity initiates Dehumidiﬁ cation when the Indoor Air Humidity rises 5% above the Indoor Air Humidity Setpoint during the Occupied Mode of operation and likewise stops Dehumidiﬁ cation when the Indoor Air Humidity drops more than 5% below the Indoor Air Humidity Setpoint during the Occupied Mode of operation.

On 100% Entering Air applications, the Entering Air Dewpoint initiates the Dehumidiﬁ cation Mode when the Entering Air Dewpoint rises 2F above the Entering Air Dewpoint Setpoint during the Occupied Mode of operation and likewise stops Dehumidiﬁ cation when the Entering Air Dewpoint drops more than 2F below the Entering Air Dewpoint Setpoint during the Occupied Mode of operation. The Entering Air Dewpoint is calculated by using an Entering Air Temperature Sensor and an Entering Air Humidity Sensor.

For Chilled Water units, the SA Controller opens the Chilled Water V alve to a ﬁ xed 100% position to provide full moisture removal capabilities.

For DX Cooling Units, the SA Controller will modulate the Copeland Digital Scroll™ Compressor(s) and activate the Fixed Stages as necessary to maintain the Evaporator Coil Temperature Setpoint. The Evaporator Coil T emperature is calculated by using the Suction Pressure Transducer and converting the pressure to temperature.

Coil Temperature Reset

Any time an Indoor Humidity Sensor is used, the Coil Temperature Setpoint will be automatically reset as the humidity rises above or drops below the Indoor Humidity Setpoint. It can reset the Coil Temperature Setpoint by a maximum of 5ºF. For example, if the Coil Temperature Setpoint is 45ºF and the Indoor Humidity Setpoint is 50% with an actual humidity reading of 55%, the new Coil Temperature Setpoint will be 40ºF. If the humidity is below the Indoor Humidity Setpoint, then the Coil Temperature Setpoint will be increased by a maximum of 5ºF.

Units with 2 Digital Compressors

This application requires 2 Suction Pressure Transducers. The lowest Coil Temperature is used for the Compressor control. Two Stages of Cooling need to be conﬁ gured for the 2 Compressors. When mechanical cooling is active, the Compressors will modulate to maintain the Coil Temperature Setpoint.

The First Stage of Cooling will modulate up. If the First Stage reaches 100% for the Stage Up Delay and the Coil T emperature is above the Coil Temperature Setpoint, then the Second Stage of Cooling will activate. The First Stage of Cooling will Lock at 100% and modulate the Second Stage of Cooling.

If the second compressor reaches 0% for the Stage Down Delay and the Coil T emperature is below the Coil Temperature Setpoint minus the Cooling Stage Control Window, then the Second Stage of Cooling will deactivate. The ﬁ rst Compressor will then modulate to maintain the Coil Temperature Setpoint.

Units with 4 Digital Compressors (Dual Unit)

This application requires 2 Suction Pressure Transducers. The lowest Coil Temperature is used for the Compressor control.

Units with 1 Digital Compressor and 1 ON/OFF Compressor

This application requires 2 Suction Pressure Transducers. The lowest Coil Temperature is used for the Compressor control. Two Stages of Cooling need to be conﬁ gured for the 2 Compressors. When mechanical cooling is active, the Digital Compressor will modulate to maintain the Coil Temperature Setpoint.

The First Stage (Digital Compressor) will modulate up. If the First Stage stays above 100% for the Stage Up Delay and the Coil Temperature is above the Coil Temperature Setpoint, then the Second Stage (ON/OFF Compressor) will activate. The First Compressor will modulate between 70-100% to provide energy in the Reheat Coil.

If the Digital Compressor stays at 70% for the Stage Down Delay and the Coil T emperature is below the Coil Temperature Setpoint minus the Cooling Stage Control Window, then the Second Stage will deactivate.

Units with 2 Digital Compressors and 2 ON/ OFF Compressors (Dual Unit)

This application requires 2 Suction Pressure Transducers. The lowest Coil Temperature is used for the Compressor control.

The ﬁ rst Stage (2 Digital Compressors) will modulate up. If the First Stage stays above 100% for the Stage Up Delay and the Coil Temperature is above the Coil T emperature Setpoint, then the Second Stage will activate. The First Compressor will modulate between 70-100% to provide energy in the Reheat Coil. This sequence will repeat for the Third Cooling Stage.

Revised 7/11/11

SA Controller Technical Guide

Sequence of Operations

Heating Mode

If the two Digital Compressors stay at 70% for the Stage Down Delay and the Coil T emperature is below the Coil T emperature Setpoint minus the Cooling Stage Control Window, then the Second Stage will deactivate. This sequence will repeat for the Third Cooling Stage.

Dehumidiﬁ cation Conﬁ guration Options

The SA Controller can be conﬁ gured to have Dehumidiﬁ cation Priority. If conﬁ gured, the SA Controller will enter the Dehumidiﬁ cation Mode when the Dewpoint or Humidity is above the Setpoint regardless of the current Heating or Cooling demands. The Reheat is always controlled to the Active Supply Air Cooling Temperature Setpoint. The Active Supply Air Cooling Temperature Setpoint will change during Heating, Cooling, or Vent Modes. During the Vent Mode, the Supply Air Temperature Setpoint will be a Calculated Setpoint that is halfway between the HVAC Mode Setpoints.

If Dehumidiﬁ cation Priority has not been conﬁ gured, the SA Controller will only enter the Dehumidiﬁ cation Mode during the Vent Mode. The Reheat will be controlled to a Calculated Supply Air Temperature Setpoint that is halfway between the HVAC Mode Setpoints.

Night Dehumidiﬁ cation can also be conﬁ gured and is used primarily for CAV units that require an Unoccupied Mode of Dehumidiﬁ cation. Night Dehumidiﬁ cation is only activated when the Indoor Air Humidity is above the Indoor Air Humidity Setpoint during the Unoccupied Mode.

NOTE: Compressor Lockout Setpoints are ignored during dehumidiﬁ cation as the compressors are controlled by coil temperature.

Air Temperature than what Hot Gas Reheat can provide. When Heating is used in conjunction with Reheat, the SA Controller restricts the Heating to one form of Modulating Heat or one stage of External Heat.

Coil Temperature Offset

On systems that have the condensing unit mounted a considerable distance from the air handling unit, the actual Evaporator Coil T emperature can be quite a bit different than the Calculated Coil T emperature based on the Suction Pressure Transducer reading in the condensing unit. Y ou can put in a temperature offset to the Calculated Coil T emperature reading so that it will more closely match the actual Evaporator Coil T emperature. For example, the Suction Pressure Transducer in the condensing unit may give you a Calculated Coil Temperature reading of 30ºF, but the actual temperature of the Evaporator Coil in the air handler may be 45ºF . To compensate, you can put in a 15ºF of fset so that the Calculated Coil Temperature reading will read 45ºF. This of fset prevents the unit from shutting off compressors prematurely based on the ﬁ xed 32ºF Suction Temperature Low Limit Safety Cutoff Temperature. The maximum amount of offset allowed is ± 30ºF.

Heating Mode

Occupied Heating Mode occurs whenever the HVAC Mode Enable Temperature falls one deadband below the HVAC Heating Mode Enable Setpoint. The unit will leave the Heating Mode when the HVAC Mode Enable T emperature rises one deadband above the HVAC Heating Mode Enable Setpoint. Unoccupied Heating Mode only occurs if a Space Temperature Sensor is connected to the SA Controller or a broadcast of Space Temperature is being received from an General Broadcast Device (GBD-X).

Reheat Control

This application requires that at least one Cooling Stage is active. The Modulating Hot Gas Reheat Valve Controller (MHGR V) will modulate the Reheat Valve to maintain the Supply Air Setpoint.

During the Dehumidiﬁ cation Mode, the SA Controller activates Cooling to extract moisture from the Supply Air and utilizes either Modulating Hot Gas Reheat, On/Off Hot Gas Reheat, or Heating to warm the Supply Air before entering the building. Modulating Hot Gas Reheat is the standard form of Reheat. The HVAC unit’ s Heat Source or a Heat Source located in the Supply Air Duct can be used for Reheat if the unit is not equipped with Hot Gas Reheat.

If the unit is equipped with a Modulating Hot Gas Reheat Controller, it is automatically detected by the SA Controller. In Dehumidiﬁ cation Mode, as the Cooling causes the Supply Air Temperature to drop, the MHGRV will bypass Hot Gas to the Hot Gas Reheat Coil, raising the Supply Air Temperature back up to the Active Supply Air Temperature Setpoint.

If the unit is equipped with an On/Off Hot Gas Valve, then one of the relays will be conﬁ gured for Reheat. The Reheat Relay will be activated if the Supply Air Temperature is less than the HVAC Mode Enable Heating Setpoint. The Hot Gas Reheat Relay will remain on during the Dehumidiﬁ cation Mode regardless of the Supply Air T emperature. This is to ensure a steady Supply Air Temperature.

When Heating is used for Reheat instead of Hot Gas Reheat, the SA Controller can activate the Heat Source(s) discussed in the Heating Mode section. Heating can also be used in conjunction with Hot Gas Reheat to add additional Reheat for applications that require a higher Supply

The Mechanical Heating will be disabled if the Entering Air T emperature is above the Heating Lockout Setpoint by 1°F . This gives a 2°F hysteresis around the Heating Lockout Setpoint to prevent unwanted cycling in and out of Mechanical Heating Mode. If the Entering Air Temperature disables the Mechanical Heating while it is currently operating, the Mechanical Heating will stage off if all staging and run times are satisﬁ ed.

No matter which Sensor is conﬁ gured for the HVAC Mode Enable, the Supply Air Temperature is always controlled to the Active Supply Air Temperature Setpoint while in Heating Mode.

Stage Control Window

In the Heating Mode, as the Supply Air Temperature falls below the Active Supply Air Temperature Setpoint, the Heating Stages will begin to stage on based on the Heating Stage Up Delay. The Heating Stages will continue to run until the Supply Air Temperature rises above the Active Supply Air Temperature Setpoint plus the Heating Stage Control Window. For example, if the Supply Air Temperature Setpoint is 140°F and the Heating Stage Control Window is 5F, as the Supply Air Temperature rises above 145F, the Heating Stages will begin to stage off based on the Heating Stage Down Delay.

Heating Staging Delay

Minimum Off Time

A Heating Stage cannot be activated unless it has been off for this amount of time.

Minimum Run Time

After a Heating Stage has been activated, it must remain on for this amount of time.

SA Controller Technical Guide

Sequence of Operations

Heating Mode

Zone

Staging Up Delay After the ﬁ rst Heating Stage has been activated, this delay pre- vents additional stages from activating too quickly before they are needed to achieve the Active Supply Air Temperature Setpoint.

Staging Down Delay

After a Heating Stage has met its Minimum Run Time and is not needed, this delay prevents additional stages from deactivating too quickly in case they are needed to maintain the Active Supply Air Temperature Setpoint.

The SA Controller supports various forms of Modulating Heat such

as SCR Electric Heat, Modulating Hot Water Heat, and Modulating Steam Heat. Whichever form of Modulating Heating is used, the SA Controller will modulate the Heat Source to achieve the Active Supply Air Temperature Setpoint.

Modulating Hot Water or Steam Heating

One Stage of Heating needs to be conﬁ gured for the Modulating Hot W ater or Modulating Steam Valve. When the Hot Water or Steam Valve is active, the V alve will modulate to maintain the Active Heating Supply Air Temperature Setpoint.

The Modulating Heating Proportional Window is used to determine the signal to the Modulating Heating Source and is user-adjustable. The Modulating Heating Signal is calculated by the differential between the Supply Air Temperature and the Active Supply Air Temperature Setpoint based on the Modulating Heating Proportional Window. The maximum signal adjustment per Time Period is 10% and is not useradjustable. The minimum signal adjustment per Time Period is based on the Modulating Heating Proportional Window . The lar ger the Modulating Heating Proportional Window , the smaller the signal adjustment will be per Time Period. The Time Period is the delay between another increase or decrease in the Modulating Heating source signal and is user-adjustable. For example, if the Modulating Heating Proportional Window is 5°F, the signal will be adjusted 2% per °F each Time Period above or below the Active Supply Air Temperature Setpoint. When the Supply Air Temperature is above or below the Active Supply Air Temperature Setpoint by 5°F or more, the signal will adjust 10% each Time Period. The SA Controller can activate two forms of Heating that are classiﬁ ed as Primary and Secondary Heat Sources. The Primary Heat Source used can be SCR Electric Heat, Modulating Hot Water Heat, or Modulating

Steam Heat.

ured in order for the unit to provide Heating. Auxiliary Heating can also be Modulating Heat in the form of SCR Electric, Hot Water, or Steam.

The Cooling and Dehumidiﬁ cation Modes operate in the same manner as described under the Cooling and Dehumidiﬁ cation titled sections on pages 39 through 43 of this manual. In the Heating Mode, the SA Controller activates the Reversing Valve and stages compressors to provide Heating if the Entering Air T emperature (EAT) is above the EAT Cooling Lockout Setpoint. The compressor heating stages are activated as needed to achieve the Active Supply Air Heating Setpoint. Staged or Modulating Auxiliary Heat can be activated to supplement Compressor Heating in order to achieve the Active Supply Air Heating Setpoint if the EAT is below the EA T Heating Lockout Setpoint. If the EAT is below the EAT Cooling Lockout Setpoint, only Auxiliary Heating will occur . If the EAT is above the EA T Heating Lockout, only Compressor Heating will occur .

For SA applications with an installed Suction Pressure Transducer, a Head Pressure Module and a Head Pressure Transducer(s), a Defrost Mode is available during the Heat Pump Heating operation. The SA Controller converts the Suction Pressure to a Suction Temperature. A user-adjustable Suction Temperature Setpoint determines when the unit will go into Defrost Mode during Heat Pump Heating. The unit will operate in Defrost Mode for 10 minutes or until the Head Pressure reaches 450 PSIG.

An Adaptive Defrost Adjustment conﬁ guration is available that will automatically adjust the length of the Defrost Timer (interval between Defrost Modes) depending on if the unit stays in Defrost Mode for the full 10 minutes or leaves the Defrost Mode early because of reaching a Head Pressure of 450 PSIG. If Adaptive Defrost is conﬁ gured and the Defrost Mode is terminated because the 10 minute timer has elapsed, this could indicate that the unit needs more defrost time. In this case, the Adaptive Defrost Adjustment value will be subtracted from the original Defrost Timer to shorten the interval between defrost cycles. If the Defrost Cycle is terminated between the 8th and 9th minute, the Defrost Timer value will not be changed. If the Defrost Cycle is terminated before the 8th minute, this could indicate that the Defrost Timer is too short. In this case the Adaptive Defrost Adjustment value will be inversely proportionally added to the original Defrost Timer as the termination time shortens from 8 minutes to 0 minutes.

Water Source Heat Pump Operation

External Heat

The SA Controller can be conﬁ gured to control heat sources that are external to the SA Unit. Contact WattMaster Controls for options that can be used in your application.

Air to Air Heat Pump Operation

The SA Controller can be conﬁ gured for Heat Pump applications. The compressors are used for both Heating and Cooling. With the SA Controller, the Reversing Valve is activated during Heating operation as the default because operation. The Reversing Valve can be conﬁ gured to activate during Cooling operation for equipment that is built to fail to Heating operation.

Auxiliary Heating Stages are conﬁ gured as Heat Relays and are used to supplement the Compressor Heating Stages. If the unit is not equipped with Auxiliary Heating Stages, Heating Relays do not need to be conﬁ g-

AAON® units are typically built to fail to Cooling

For Water Source Heat Pump applications, the SA Controller is used in conjunction with the Water Source Heat Pump Protection Module. Heating, Cooling, and Dehumidiﬁ cation would operate in the same man- ner as described in Air to Air Heat Pump Operation; however, defrost operation would not apply.

The Water Source Heat Pump Protection Module provides safeties for Proof of Flow, Low/Unsafe Suction Pressure, and Low Leaving Water Temperature. An E-BUS Distribution Module is used to provide communication from the SA Controller to the Water Source Heat Pump Protection Module.

For more detailed sequence and wiring information, see the AAON T ulsa version of the Water Source Heat Pump Protection Module Technical Guide.

SA Controller Technical Guide

Sequence of Operations

SAT Setpoint Reset

Morning Warm-Up Mode

For Morning Warm-Up application, the unit must be conﬁ gured as a VAV unit (Supply Air Temperature control). When the SA Controller switches to the Occupied Mode of Operation (not Override Mode), the unit compares the Entering Air Temperature to a Morning Warm-Up Target Temperature. If the Entering Air Temperature is below this Setpoint, the W arm-Up Mode is initiated. This Mode remains in effect until the Entering Air Temperature rises above the Target Temperature or a user-adjustable Time Period expires. W arm-Up Mode is not initiated by Push-Button Overrides or Unoccupied Heating demands.

Once the Warm-Up Mode has been terminated, it cannot resume until the unit has been through a subsequent Unoccupied Mode. Only one Warm-Up Mode is allowed per Occupied cycle.

If you have stand-alone VAV boxes that need to be forced wide open during the Warm-Up Mode, you can conﬁ gure one of the relay outputs to be used during this Mode. If the Warm-Up Mode is active, the relay is activated. This relay then becomes the Force Open Command for all VAV boxes to which it is wired.

Off Mode

If the schedule has set the Unoccupied Mode and no Heating, Cooling, or Dehumidiﬁ cation demands exist, the SA Controller enters the Off Mode. During the Off Mode, the Supply Fan is off.

Supply Air Temperature Setpoint R eset

The SA Controller incorporates a dynamic Supply Air T emperature Reset function based on a selected Reset Source. The available Reset Source options are Space Temperature, Entering Air Temperature, Supply Fan VFD Signal, or a Remote Reset Signal. In each case, for the heating mode and the cooling mode, a Low and a High Reset Source Setpoint must be entered that will correspond to a Low and High Supply Air Setpoint. Since the Supply Air Setpoints are not ﬁ xed during reset, we refer to them as the “Active Supply Air Temperature Setpoints.” The SA Controller uses the HVAC Mode Enable Setpoints to determine the mode of operation. Once the HV AC Mode has been determined, the SA Controller will proportionally reset the Supply Air Temperature Setpoint based on the Reset Source condition relative to the Reset Source Low and High Setpoints. For each of the Reset Source options discussed below there is an example of how to set it up in the SA Controller Operator Interfaces T echnical Guide in the Supply Air Reset conﬁ guration screens #4 & #5 and setpoint screens #4 through #7.

If you conﬁ gure Space Temperature or Entering Air Temperature as the Reset Source, then separately, for the heating mode and the cooling mode you will need to enter a Low and High Reset Source Setpoint and a Low and High Supply Air Temperature Setpoint. This creates a range of Reset Source T emperature Setpoints and a range of Supply Air Temperature Setpoints. As the Reset Source Temperature varies within its range, it will proportionally reset the Supply Air T emperature Setpoint within its reset range. When the temperature at the Reset Source is at the Reset Source Low Setpoint, the Supply Air Temperature Setpoint would be reset to the Supply Air High Setpoint. When the temperature at the Reset Source is at the Reset Source High Setpoint, the Supply Air Temperature Setpoint would be reset to the Supply Air Low Setpoint.

When the temperature at the Reset Source is in between its Low and High Setpoints, the Supply Air Setpoint will be proportionally reset between its High and Low Setpoints. When the unit is in the Vent Mode or Vent Dehumidiﬁ cation Mode, the Supply Air Temperature Setpoint will be calculated to be halfway between the HV AC Mode Enable Setpoints. If Dehumidiﬁ cation Priority has been conﬁ gured and the unit is in Heating Dehumidiﬁ cation or Cooling Dehumidiﬁ cation Mode, the Supply Air Temperature Setpoint is proportionally reset in the same way as in the Heating and Cooling Modes described above in this paragraph.

If the Supply Fan VFD Signal is conﬁ gured as the Reset Source, then separately, for the heating mode and the cooling mode, you will need to enter a Low and High VFD Signal Setpoint and a Low and a High Supply Air Setpoint. This creates a range of VFD Signal Setpoints and a range of Supply Air Temperature Setpoints. As the VFD Signal varies within its range, it will proportionally reset the Supply Air Temperature Setpoint within its range. For example, in the Cooling Mode, when the Supply Fan VFD Signal is at its low setpoint, the Supply Air Cooling Setpoint will be reset to its high setpoint; when the Supply Fan VFD signal is at its high setpoint, the Supply Air Cooling Setpoint will be reset to its low setpoint. In the heating mode, the Supply Air Heating Setpoint reset would react in the opposite fashion with the VFD signal at its highest setpoint the Supply Air Heating Setpoint is reset to its highest setpoint, and with the VFD signal at its lowest setpoint the Supply Air Heating Setpoint is reset to its lowest setpoint. In either mode, if the VFD signal is halfway (for instance) between the Low Signal Setpoint and the High Signal Setpoint, the Supply Air Setpoint would be reset to halfway between its High and Low Setpoint. If Dehumidiﬁ cation Priority has been conﬁ gured and the unit is in Heating Dehumidiﬁ ca- tion or Cooling Dehumidiﬁ cation Mode, the Supply Air Temperature Setpoint is proportionally reset in the same way as in the Heating and Cooling Modes described above in this paragraph. When the unit is in the Vent Mode or Vent Dehumidiﬁ cation Mode, the Supply Air Tem- perature Setpoint will be calculated to be halfway between the HVAC Mode Enable Setpoints.

If a Remote Reset Signal is conﬁ gured as the Reset Source, a 0-5 or 0-10 VDC signal can be used to reset the Supply Air Temperature Setpoint. Separately, for the Heating Mode and the Cooling Mode you will need to enter a Low and a High Supply Air Setpoint.

As an example when using a 0-5 VDC signal, when the Reset Signal is at 0 VDC, the Supply Air Setpoint will be at its lowest setpoint for both Heating and Cooling. When the Reset Signal is at 5 VDC, the Supply Air Setpoint will be at it highest setpoint for both Heating and Cooling. As the voltage signal changes between 0 VDC and 5 VDC, the Supply Air Setpoint will be proportionally reset between the Low and High Supply Air Temperature Setpoint for both Heating and Cooling. If Dehumidiﬁ cation Priority has been conﬁ gured and the unit is in Heating Dehumidiﬁ cation or Cooling Dehumidiﬁ cation Mode, the Supply Air Temperature Setpoint is proportionally reset in the same way as in the Heating and Cooling Modes described above in this paragraph. When the unit is in the V ent Mode or V ent Dehumidiﬁ cation Mode, the Supply Air Temperature Setpoint will be calculated to be halfway between the HVAC Mode Enable Setpoints.

SA Controller Technical Guide

Sequence of Operations

Duct Static Pressure Control

Zone

Supply Fan Control

Any time the Supply Fan is requested to start, a timer is checked to make sure the Supply Fan has been off for at least 1 minute. This 1-minute delay is a protection against rapid cycling of the Supply Fan. Once the 1-minute delay has been satisﬁ ed, the Supply Fan relay is activated and all other outputs are veriﬁ ed to be in the off condition for a period of 1 to 2 minutes. This short period of Supply Fan-Only Operation serves to purge the stagnant air from the duct before any Heating or Cooling occurs.

Normally, the Supply Fan runs continuously during the Occupied Mode of operation. If the fan is only required to run in the Occupied Mode during Heating, Cooling, or Dehumidiﬁ cation Modes, the SA Controller can be conﬁ gured for Fan Cycle Mode. This means the Fan will only run during Heating, Cooling, or Dehumidiﬁ cation and will be off the rest of the time.

Duct Static Pressure Control

The SA Controller reads and controls Static Pressure in the duct system if the Supply Fan has been conﬁ gured for Duct Static Pressure Control. Any time the Supply Fan is operating, the SA Controller is controlling Duct Static Pressure. The Duct Static Pressure Setpoint and Deadband limits are user-adjustable along with a Control Interval. This Control Interval is the amount of time that elapses between each adjustment to the Duct Static Pressure Control Output Signal. The default period is 10 seconds and should not be changed unless close observation reveals that the Supply Fan is hunting and not maintaining a stable pressure reading. The Static Pressure Control Output Signal can be used to control a Supply Fan VFD or a Zoning Bypass Damper Actuator.

The Duct Static Pressure Control Output Signal is a non-conﬁ gurable Direct Acting Signal (0-10 VDC). This Output Signal can be used to directly connect to a Supply Fan VFD. The Output Signal increases (increases VFD Speed) if the Duct Static Pressure is below the Duct Static Pressure Setpoint by the Deadband amount, and the Output Signal decreases (decreases VFD Speed) if the Static Pressure is above the Setpoint by the Deadband amount.

Any time the Supply Fan is off, the Duct Static Pressure Control Output Signal will remain at zero volts. If the Supply Fan control is not conﬁ gured for Duct Static Pressure Control, you can still monitor the Duct Static Pressure if the Duct Static Pressure Sensor is installed; however, no control will occur.

Duct Static Pressure Control for Filter Loading

In order to maintain a constant CFM through the supply air ducts on a mixed air CA V unit, the SA Controller can utilize a Duct Static Pressure Sensor (used to monitor the discharge pressure) in conjunction with a Supply Fan VFD. If the ﬁ lters are getting dirty, the SA Controller will ramp up the VFD to compensate for the decrease in airﬂ ow. To utilize this feature, the unit must be conﬁ gured to use VFD Fan Control. This feature cannot be used if this is a VAV or Zoning application with typical Duct Static Pressure Control.

Pre-Heater Operation

In colder climates where freezing temperatures are sometimes experienced, it is desirable to preheat the Entering Air being drawn into the HVAC unit before it reaches the Water Coils to prevent freezing. The Pre-Heater control option is available by setting a Low Ambient Protection Setpoint and by conﬁ guring one of the relay outputs as a Pre-Heater. Only one relay can be conﬁ gured for this option, and therefore, staging of Pre-heater relays is not available. The Pre-Heater operation will only operate in the Occupied Mode.

The Pre-Heater sequence operates so that any time during the Occupied mode, if the Entering Air T emperature is below the Low Ambient Protection Setpoint and the Supply Fan is running, the Pre-heater Relay will activate. It will remain on until the Entering Air Temperature rises 1°F above the Setpoint or until the Supply Fan shuts down. If the Proof of Flow option is installed and conﬁ gured, its signal must also be active for the Pre-Heater Relay to activate.

Since the Duct Static Pressure Control Output Signal is a non-conﬁ g- urable Direct Acting Signal (0-10 VDC), when you are using a Zoning Bypass Damper Actuator to control the Duct Static Pressure, you must set up the Zoning Bypass Damper Actuator on the Zoning Bypass Damper so that it is Reverse Acting in operation. The Output Signal increases (closes Zoning Bypass Damper) if the Duct Static Pressure is below the Duct Static Pressure Setpoint by the Deadband amount, and the Output Signal decreases (opens Zoning Bypass Damper) if the Static Pressure is above the Setpoint by the Deadband amount.

If the Static Pressure ever rises 0.5” above the Duct Static Pressure Setpoint, the Duct Static Pressure Control Output Signal will be cut in half every control period until the Static Pressure is brought under control. This is to prevent damage to the ductwork if all the VAV boxes are closed or some other blockage occurs in the ductwork.

Warning: The manufacturer does not assume responsibility for protecting the equipment from over-pressurization! You should always install mechanical high static protection cutoffs to protect your system!

Entering Air Lockouts

The Entering Air Cooling and Heating Lockouts Setpoints are designed to prevent unwanted Mechanical Heating or Cooling operation during certain Entering Air Temperature conditions.

When the Entering Air Temperature is below the Cooling Lockout Setpoint, no Mechanical Cooling can operate. However, if the unit is equipped with a W ater Side Economizer (WSE) and the SA Controller is conﬁ gured to use the WSE, it can be used to provide free Cooling when the Mechanical Cooling is locked out. For Heat Pumps, the Cooling Lockout also applies to Compressor Heating, which means it usually will be a lower setting than on Cooling units that are not Heat Pumps.

The Entering Air Heating Lockout operates so that when the Entering Air Temperature is above the Entering Air Heating Lockout Setpoints, no Mechanical Heating can operate. This applies to any type of Heating except Compressor Heating as used on Heat Pumps. The lockout for Compressor Heating is explained in the previous paragraph regarding Cooling Lockout Setpoints.

SA Controller Technical Guide

Supply Air Cutoffs

The Supply Air Temperature Cutoffs are designed to prevent extremely High and Low Temperature Supply Air from entering the building.

High Supply Air Temperature Cutoff

High Supply Air Temperature Cutoff is initiated when the Supply Air Temperature rises above the HI SAT Cutoff Setpoint. When this occurs, Heating stages will be deactivated until the Supply Air Temperature falls 5°F below the HI SAT Cutoff Setpoint.

Low Supply Air Temperature Cutoff

Low Supply Air Temperature Cutoff is initiated when the Supply Air Temperature falls below the LO SAT Cutoff Setpoint. If the SA Controller is in WSE Operation, Vent Mode, or Heating Mode and the Supply Air Temperature falls below the LO SAT Cutoff Setpoint for 10 minutes, it is assumed a Mechanical Failure has occurred and all Heating will be deactivated and the Supply Air Fan will shut off. If the SA Controller is in the Cooling or Dehumidiﬁ cation Mode and the Supply Air T emperature falls below the LO SAT Cutoff Setpoint, the Cooling Signal or Cooling Stages will immediately begin deactivating.

Sequence of Operations

Supply Air Cutoffs

To restore normal operation, one of the following three things must occur:

1. The Supply Air Temperature rises above the LO SAT Cutoff Setpoint by 5°F.

2. The SA Controller goes from Occupied to Unoccupied or from Unoccupied to Occupied Mode.

3. The SA Controller’s power is cycled.

SA Controller Technical Guide

Sequence of Operations

SA Controller Alarms

Zone

SA Controller Alarms

Sensor Failure Alarms

Supply Air Temperature Sensor Failure Alarm

The Supply Air Temperature Sensor Failure Alarm is generated when the controller detects an open or short circuit on the Supply Air Temperature Sensor input. Once the alarm is generated, the unit will be completely shut down. If a sensor is properly detected after the unit has alarmed, the alarm will be cleared and the unit will restart operations.

Entering Air Temperature Sensor Failure Alarm

The Entering Air Temperature Sensor Failure Alarm is generated when the controller detects an open or short circuit on the Outdoor Air Temperature Sensor input.

Space Temperature Sensor Failure Alarm

If the Space Sensor is conﬁ gured as the Controlling Sensor (Mode En- able Sensor) or as the Reset Sensor, and if the controller detects an open or short circuit on the Space Sensor input, then a Space Temperature Sensor Failure Alarm is generated. If the Space Sensor is conﬁ gured as the Controlling Sensor and the Failure Alarm is generated, the unit will shut down. If the Space Sensor is only conﬁ gured as a Reset Sensor and the Failure Alarm is generated, the Space Temperature will default to a value half way between the Heating and Cooling Mode Enable Setpoints, and the unit will continue to run.

Mechanical Failure Alarms

Mechanical Cooling Failure

The Mechanical Cooling Failure Alarm is generated if the Supply Air Temperature fails to drop 5 degrees (within a user-adjustable time period) from the temperature the supply air was at when the cooling was activated. The alarm will be cleared when the Supply Air Temperature drops the 5 degrees and sets the failure timer back to zero. This alarm does not apply for Modulating Cooling.

Mechanical Heating Failure

The Mechanical Heating Failure Alarm is generated if the Supply Air Temperature fails to rise 5 degrees (within a user-adjustable time period) from the temperature the supply air was at when the heating was activated. The alarm will be cleared when the Supply Air Temperature rises the 5 degrees and sets the failure timer back to zero. This alarm does not apply for Modulating Heating.

Proof of Air Flow Alarm

A Proof of Flow switch (by others) provides a 24 VAC wet contact closure when the Supply Fan is operating. If this contact opens while the fan is being called to run, all heating and cooling is disabled, and a Fan Proving Alarm is generated. Fan Proving needs to be conﬁ gured for this alarm to occur.

Dirty Filter Alarm

A differential pressure switch (by others) is used to provide a 24 VAC wet contact closure to indicate a dirty ﬁ lter status. A Dirty Filter Alarm is then generated. Dirty Filter needs to be conﬁ gured for this alarm to occur.

Emergency Shutdown (Smoke) Alarm

A 24 VAC wet contact input is available to be used when a N.C. Smoke Detector, Firestat, or other shutdown condition occurs. If this contact opens, it will initiate shutdown of the SA and will generate an alarm condition. This contact closure does not produce an instantaneous shutdown. Emergency Shutdown needs to be conﬁ gured for this alarm to occur.

For instantaneous shutdown, the device initiating the open condition on this contact should also be wired to cut the 24 V common to the SA relay outputs.

Proof of Water Flow Failure

A Proof of Water Flow Switch, that provides a wet contact closure whenever the Condenser Water Valve is operating, can be connected to this unit.

If the Proof of Flow Switch contact opens while the Condenser Water Valve is operating, the unit will enter the Water Proof of Flow Failure mode. In this mode, the mechanical cooling will be deactivated and the Condenser Water Valve will be forced to 100%.

The unit will exit this mode when the Water Proof of Flow Switch is closed again and water ﬂ ow is proven.

Drain Pan Overﬂ ow Failure

A Drain Pan Overﬂ ow Switch provides a wet contact closure whenever the Supply Fan is operating and the Drain Pan is not in an overﬂ ow condition. If this contact opens while the Supply Fan is operating, the controller will enter Drain Pan Overﬂ ow Failure Mode and deactivate mechanical cooling.

Revised 6/28/12

SA Controller Technical Guide

Sequence of Operations

VAV/Zone Controller Alarms

Failure Mode Alarms

High and Low Supply Temp Alarm

These alarms are activated when the Supply Air Temperature (SAT) rises above the High Cutoff T emperature Setpoint (immediate) or drops below the Low Cutoff Temperature Setpoint (for 10 minutes). Both cutoff setpoints are user-adjustable. This mode shuts off the unit (with a 3 minute fan off delay) until the mode is cancelled.

This mode is cancelled when the SAT drops 5 degrees below the High Cutoff Temperature Setpoint or rises 5 degrees above the Low Temp Cutoff Temperature Setpoint, or when the unit changes back into Occupied Operation.

High and Low Control Temp Failure

When the Controlling Sensor T emperature rises above the Cooling Mode Enable Setpoint plus the Control Mode High Alarm Offset setpoint, the controller will generate a High Control Temp Failure Alarm.

When the Controlling Sensor Temperature drops below the Heating Mode Enable Setpoint minus the Control Mode Low Alarm Offset setpoint, the controller will generate a Low Control Temp Failure Alarm.

Both offset setpoints are user-adjustable.

Module Alarm

This alarm applies to any E-BUS Module communicating with the SA Controller. The E-BUS modules include the Two Condenser Head Pressure Module and W ater Source Heat Pump Module. If any of these modules stop communicating with the SA E-BUS Controller or if there is an alarm on one of these modules, this Module Alarm will be generated.

VAV/Zone Controller Alarms

Space Sensor Failure Alarm

If the controller detects an open or short on the Space Sensor input, this alarm will be generated.

CFM Sensor Failure Alarm

If the Air Flow Constant (K Factor) is set to any value other than zero, and the controller does not detect the Airﬂ ow Sensor, this alarm will be generated.

Damper Opening Alarm

After initial calibration, if the damper is called to be fully open and cannot reach that position within approximately 2 minutes, this alarm will be generated.

Damper Closing Alarm

After initial calibration, if the damper is called to be fully closed and cannot reach that position within approximately 2 minutes, this alarm will be generated.

High Space Temp Alarm

If the zone temperature is above the Cooling Setpoint by the Hi Zone Alarm Offset (user adj.) for the Zone Alarm Delay Period (user adj.), this alarm will be generated.

Low Space Temp Alarm

If the zone temperature is below the Heating Setpoint by the Lo Zone Alarm Offset (user adj.) for the Zone Alarm Delay Period (user adj.), this alarm will be generated.

Damper Feedback Failure Alarm

If the controller fails to detect the actuator feedback signal, this alarm will be generated.

SA Controller Technical Guide

Revised 6/28/12

Sequence of Operations

Internal Trend Logging

Zone

Scheduling

The SA Controller has an internal power source for the Real T ime Clock (RTC) that allows the controller to keep the time and accurately control scheduling. It can also broadcast the time to the VAV/Zone Controllers if that option is conﬁ gured.

The SA Controller has an internal 7-day Schedule with 2 Start/Stop Events per day. You can also have 1 Holiday Schedule with 2 Start/ Stop Events per day. This Holiday Schedule can be used for 14 different Holiday periods.

You can change the time on the SA Controller through the Modular Service Tool, Modular System Manager, or the System Manager TS. Y ou can also broadcast the time and date to all SA Controllers by using a Personal Computer and the Prism Computer Front-End Software.

The Internal Scheduling in the SA Controller also includes a SelfTeaching Optimal Start Routine that can be activated by entering a value of 1.0 or greater for the Soak Multiplier Setpoint. The Optimal Start function can only be used if your SA Controller has a Space Temperature Sensor installed and it is being used as the Controlling Sensor or if you are using WattMaster VAV/Zone controllers with the SA Controller.

No adjustments other than the Soak Multiplier are required because the SA Controller monitors how long it takes to reach the T ar get T emperature each day and adjusts the Starting Time accordingly . That means the ﬁ rst day you operate your HVAC unit, it will not be able to Optimally Start because it does not have a history of previous Starts and their results. After the ﬁ rst day, the SA Controller will begin adjusting the Start Time, and after six Normally Scheduled Starts have occurred, the Optimal Start Routine will have gathered enough data to provide an accurate Pre-Start based on the learned conditions. This is an ongoing learning process of the six previous starts, so the unit automatically adjusts for the changing seasons. If you don’t need this feature, but you are using the Space Temperature Sensor as the Controlling Sensor, you can set the Soak Multiplier to zero to eliminate the Optimal Start Routines.

Internal Trend Logging

The SA Controller continuously maintains an Internal T rend Log, which records a ﬁ xed set of values at a user-programmed interval. These values can be retrieved only with the Prism Computer Front-End Software. If you do not have a computer with Prism Software installed and connected to the system communications loop, you do not have access to these logs.

There are 120 log positions available. Once the last (120th) position has been recorded, the log jumps back to the ﬁ rst position and begins overwriting the old data. This means the you will need to retrieve the logs at an interval that is shorter than the duration of the last 120 logs

Shown below are some log intervals and the duration of 120 logs.

1 minute interval = 2 hours 12 minute interval = 24 hours 15 minute interval = 30 hours 30 minute interval = 60 hours 60 minute interval = 120 hours

The ﬁ xed items in the log are listed below:

Date Time Space Temperature Entering Water Temperature Entering Air Temperature Cooling Setpoint Heating Setpoint Supply Air Temperature Supply Air Temperature Setpoint Entering Humidity Space Humidity Water Side Economizer Position (Analog Output #1) VFD Fan (Analog Output #2) Modulating Heating (Analog Output #1) Modulating Cooling Stage 1 (Analog Output #2) Digital Compressor Stage 2 (Analog Output #3) Modulating Reheat Position Coil A Suction Pressure Coil B Suction Pressure Circuit A Head Pressure Circuit B Head Pressure Condenser Signal A Condenser Signal B WSE Bypass A WSE Bypass B On Board Relay Status (Bit Pattern) Expansion Module Relay Status (Bit Pattern)

These items and values are explained in greater detail in the Prism Computer Front-End Software Technical Guide.

SA Controller Technical Guide

Force Modes or Overrides

Warning: No equipment protection is available during the

Force Mode of operation. That means you could start a compressor without running the Supply Fan or could create other conditions that WILL damage the equipment. WattMaster Controls assumes no responsibility or liability for the misuse of Overrides that cause damage to the equipment!

Sequence of Operations

VAV Applications

If you are using another manufacturer’s VAV Terminal Unit Controllers, the SA Controller can activate a relay to inform the VAV/Zone Controllers that the SA Controller is operating in Warm-up Mode. No other information can be passed between the SA Controller and the other manufacturer’s VAV Terminal Unit Controllers. This means that Overrides or Unoccupied Heating and Cooling calls cannot activate the SA Controller. If you need any of these capabilities, you must use only Orion VAV/Zone Controllers for controlling all of your VAV Terminal Units.

VAV/Zone System

The SA Controller relay and analog outputs can be user-overridden if the Modular Service Tool or the Prism Computer Front-End Software is used. The System Manager cannot be used for these Force Modes. The Modes of operation for the relays are as follows:

0 = Normal Operation 1 = Forced ON 2 = Forced OFF

The Analog Outputs are Forced when you specify a value between 0.0 and 10.0 VDC. To cancel the Force Mode, you must enter a value less than zero, such as -1.0 VDC.

When the Analog Outputs are Forced, the display on the Modular Service Tool or Prism program can be interpreted as the actual voltage. During normal operation, the display indicates the percentage signal applied based on the user-deﬁ ned voltage limits. For example, if you deﬁ ne a

2.0 VDC to 10.0 VDC range, then 50% would be 6.0 VDC instead of the 5.0 VDC applied when the range is 0.0 VDC to 10.0 VDC.

As previously mentioned, Force Modes can only be activated when using either the Modular Service Tool or the Prism Computer FrontEnd Software. Furthermore, the Override condition can only remain in effect as long as one of these Operator Interface devices is connected and communicating with the SA Controller . That means that you cannot Force an Override condition and then walk away from the equipment with the Override still active. The loss of communications, removal, or shutdown of the Operator Interface will automatically terminate the Override within 10 minutes. This protects the equipment and prevents an Override condition from remaining active indeﬁ nitely, resulting in inefﬁ cient or dangerous operation of the equipment.

VAV Terminal Unit Controller Compatibility

The SA Controller is designed to communicate with Orion VAV/Zone Controllers. The SA Controller can be conﬁ gured to broadcast its Internal Schedule, Time, and Date, Fan and Heat Status, and Supply Air Temperature. The SA Controller can also broadcast Force to Max or Force to Fixed Position during Morning Warm-up. The Orion VAV/ Zone Controllers broadcast Push-Button Overrides from Unoccupied to Occupied. The controllers can also generate Unoccupied Heating and Cooling calls to the SA Controller based on Setbacks.

When the SA Controller goes into the Occupied Mode, it initiates Morning Warm-up if the Entering Air Temperature is below the Morning W arm-up Target Temperature Setpoint. During Morning Warm-Up, the VAV/Zone Controllers will modulate open if the Space Temperatures are too cold. They can also move to their Maximum Airﬂ ow or Fixed Airﬂ ow Position Setpoint if they receive this broadcast from the SA Controller. Once Morning Warm-up has been satisﬁ ed, the SA Controller enters the Cooling Mode and the VAV/Zone Controllers will modulate to satisfy their Space Temperature Setpoints. If the Space Temperature falls below the Heating Setpoint, staged or modulating Reheat can be activated to warm the space.

Communications between the SA Controller and the VA V/Zone Controllers are handled by the MiniLink Polling Device. Alarm Polling and Tenant Overrides are also monitored by the MiniLink Polling Device. Tenant Overrides are overrides generated by the Space T emperature Sensor’s push button. The MiniLink Polling Device records the start and stop times and total run times of the overrides on a daily and monthly basis. A computer running Prism Computer Front-End Software is required to retrieve all data acquired by the MiniLink Polling Device.

Zoning System

The SA Controller automatically conﬁ gures itself for Voting Control when the MiniLink Polling Device is installed and is conﬁ gured as a Voting System. The SA Controller sets the HVAC Mode Enable to the Entering Air Temperature Sensor as soon as communication is acquired with the MiniLink Polling Device. If the VAV/Zone controllers are conﬁ gured for Voting, the MiniLink Polling Device totals the Heating and Cooling demands and determines which HV AC Mode the SA Controller should be in. The MiniLink Polling Device broadcasts a forced Heating, Cooling, or Vent Mode of operation to the SA Controller. Once the SA Controller receives the broadcast to set the HVAC Mode, it operates as previously described in the SA Controller Sequence of Operations. If communications are lost, the SA Controller returns to its own control and will maintain the HVAC Mode Enable Setpoints by using the Entering Air Temperature Sensor as the Controlling Sensor.

SA Controller Technical Guide

Troubleshooting

LED Diagnostics

Zone

Using LEDs To Verify Operation

The SA Controller is equipped with 4 LEDs that can be used as very powerful troubleshooting tools. See Figure 30 below for the LED locations. The LEDs and their uses are as follows:

REC - This LED will light up to indicate system communications.

POWER - This LED will light up to indicate that 24 VAC power has been applied to the controller.

STATUS 1 - This is the diagnostic blink code LED. It will light up

and blink out diagnostic codes. ST ATUS 1 LED also represents the tens column in the address blink code.

STATUS 2 - This is the diagnostic blink code LED. It will light up and

blink out diagnostic codes. STATUS 2 LED also represents the ones column in the address blink code.

POWER LED Operations

When the SA Controller is powered up, the POWER LED should light up and stay on continuously. If it does not light up, check to be sure that you have 24 VAC connected to the controller , that the wiring connections are tight, and that they are wired for the correct polarity. The 24 VAC power must be connected so that all ground wires remain common. If after making all these checks, the POWER LED does not light up, please contact WattMaster Controls Technical Support for assistance.

REC LED Operations

When power is applied to the controller, the REC LED will also light up. If this is a Stand Alone System (one controller only on the loop) or an Interconnected System (several SA Controllers tied together without a CommLink), the REC LED will glow continuously. The REC LED will ﬂ icker when you are connected to the SA Controller and you are entering setpoints with the Modular Service Tool or one of the System Managers. It will also ﬂ icker if this is a Networked System. If this is a Networked System (the system has a CommLink installed), the REC

LED should ﬂ icker rapidly, indicating that the system is communicat- ing. A “ﬂ icker” is deﬁ ned as a brief moment when the LED turns off and then back on. It may be easier to see this “ﬂ icker” if you cup your hand around the LED.

If the REC LED does not operate as indicated above, ﬁ rst check the address switch setting. Verify the address switch as outlined in the Diagnostic LEDs Operations section on page 53. See Figure 29 on page 34 for complete address switch setting instructions.

NOTE: ST ATUS 1 LED represents the tens position and STATUS 2 LED represents the ones position of the controller address. If the address of the controller is set to 59 with the address switch, ﬁ rst STATUS 1 LED will blink 5 times, and then STATUS 2 LED will blink 9 times.

If the address switch setting is correct and the REC LED still does not behave as indicated above, check to be sure the operator’s interface is connected correctly. If you are using the Modular Service Tool, verify that it is plugged in securely to the DIN connection on the SA Controller . If you are using one of the System Manager Operator’s Interfaces, see the SA Controller Operator Interfaces Technical Guide or the System Manager TS Operator Interfaces Technical Guide for a connection diagram.

If the REC LED still does not behave correctly, check the voltages at the communications terminal block. Be sure the Controller is powered up for this test. Unplug the communications terminal block from the controller and check the DC voltage between T and SHLD and between R and SHLD. Check the voltage with a digital multimeter set to DC volts. The voltage should be between 3.0 to 3.2 VDC between SHLD and either T or R. If the voltage is not in this range, you probably have a damaged driver chip that must be replaced.

For driver chip replacement instructions, please see the Orion Controls SA Controller Component & System Wiring Technical Guide for more information or contact the factory for further assistance.

Figure 31: SA Controller Diagnostic LED Locations

SA Controller Technical Guide

Troubleshooting

Blink Code Description

LED Diagnostics

Diagnostic LED Operation

When power is ﬁ rst applied, the STATUS 1 and STATUS 2 LEDs will be off for 1 second. At this time, both LEDs will blink to indicate the setting of the address switch and then will extinguish for 5 seconds. Verify that the address switch setting is correct by counting the number of blinks.

If the address switch is not correct, ﬁ rst remove the communication loop terminal plug from the controller and then from the power terminal plug. Set the address dip switches correctly. See Figure 29 on page 34 for correct address switch setting instructions. After you are sure the address switch setting is correct, ﬁ rst reconnect the power connection and then reconnect the communication loop connection to the controller.

NOTE: You must always cycle power to the Controller being addressed after changing address switch settings in order for the changes to take effect.

Reapply power to the controller and observe the blink code to verify the address is set correctly. If the STATUS 1 and ST ATUS 2 LEDs now blink the correct address, your controller is addressed correctly. If they don’t light up at all, the controller is not operating correctly and could be defective. Once the controller is done blinking the address, STATUS 2 LED will blink continuously for 30 seconds while the controller calibrates. Once the controller is done calibrating, the LEDs will blink a code every 10 seconds to indicate controller status. See Table 3 for a list of the various blink codes and their meanings.

STATUS 1

Blink Code Description

Normal Operation 0 1 Supply Air Temp Sensor Fail 1 2 Entering Air Temp Sensor Fail 2 2 Space Sensor Failure 3 2 Module Alarm 4 2 Mechanical Cooling Failure 1 3 Mechanical Heating Failure 2 3 Fan Proving Failure 3 3 Dirty Filter Alarm 4 3 Emergency Shutdown 5 3 Water Flow Alarm 6 3 Drain Pan Alarm 7 3 Low Supply Air Temp Alarm 1 4 High Supply Air Temp Alarm 2 4 Control Temp Cooling Failure 3 4 Control Temp Heating Failure 4 4 Push Button Override 1 5 Zone Override 2 5 Output Force Active 0 6

LED

Blinks

STATUS 2

LED

Blinks

If all of these tests are made and the controller still doesn’t operate, please contact WattMaster Controls Technical Support at 866-918-1100.

Table 3: Diagnostic LED Blink Code Interpretation

SA Controller Technical Guide

Appendix

System Conﬁ gurations

Zone

System Conﬁ guration Options

The SA Controller can be used as a Stand-Alone System (one SA Controller only), connected together on an Interconnected System (multiple SA Controllers only) or connected together on a Network System (multiple SA Controllers, VA V/Zone Controllers, or Add-On Controllers) to form a complete Orion Controls System that can be programmed and monitored with one or more of the available Orion Operator Interfaces.

For detailed information about the various Orion Controls Systems that are available and their related wiring requirements and options, please see the Orion Systems Technical Guide.

Operator Interfaces

The Orion Operator Interfaces are designed to provide for programming and monitoring of SA Controller(s) and/or any VAV/Zone or Add-on Controller(s) connected to your Orion System. The Operator Interfaces available for use with the Orion Systems are as follows:

• Modular Service Tool

• Modular System Manager

• Personal Computer with Prism Computer Front End

Software Installed

You can use any one of these interfaces or all of them on the same Orion System.

Stand-Alone System

The Stand-Alone System is used when you have a single SA Controller only. Programming and status monitoring are accomplished by selecting and installing one or more of the Operator Interfaces.

Interconnected System

The Interconnected System is used when you have multiple SA Controllers on your job. With this system, you simply connect the controllers together using W attMaster communications wire or 18-gauge, 2-conductor twisted pair with shield wire (Belden #82760 or equivalent). This allows for all controllers that are connected on the communications loop to be programmed and monitored from one or more of the available Operator Interfaces connected on the communications loop.

See Figure 34 on page 56 for a Typical Interconnected System Layout diagram.

Networked System

If you have 1 to 59 SA Controllers that require information sharing, simply connect the controllers together using WattMaster communications wire or 18-gauge, 2-conductor twisted pair with shield wire (Belden #82760 or equivalent). The Networked Single Loop System requires that either a MiniLink PD communication interface and/or CommLink communication interface are purchased and wired into the communications loop in a similar manner to the SA Controllers.

The Networked Multiple Loop system is used when you have more than 59 SA Controllers and/or are using multiple SA Controllers that are connected to VAV/Zone controllers. These groups of controllers are broken up into multiple “Local Loops” that connect to each other via the “Network Loop.” Each individual MiniLink PD handles its speciﬁ c local loop’s communications requirements. The CommLink communications interface handles all the communications between the individual MiniLink PDs to form the network loop. Up to 60 local loops can be connected together with this conﬁ guration. This provides the capability for over 3500 controllers to be networked together.

See Figure 33 on page 55 for a Typical Stand-Alone System Layout diagram.

Operator

Interfaces

Modular Service Tool

Personal Computer & CommLink

See Figure 35 on page 57 for a Typical Networked System Layout diagram.

Modular System Manager

Figure 32: Available Operator Interfaces

SA Controller Technical Guide

Appendix

Stand-Alone System Layout

Operator

Interfaces

Figure 33: Typical Stand-Alone System Layout

SA Controller Technical Guide

Appendix

Interconnected System Layout

Zone

Figure 34: Typical Interconnected System Layout

SA Controller Technical Guide

Appendix

Networked System Layout

Operator

Interfaces

Interface

Operator

Figure 35: Typical Networked System Layout

SA Controller Technical Guide

Appendix

Temperature Sensor Testing

Zone

Temperature Sensor Testing

The following sensor voltage and resistance tables are provided to aid in checking sensors that appear to be operating incorrectly. Many system operating problems can be traced to incorrect sensor wiring. Be sure all sensors are wired per the wiring diagrams in this manual.

If the sensors still do not appear to be operating or reading correctly, check voltage and/or resistance to conﬁ rm that the sensor is operating correctly per the tables. Please follow the notes and instructions below each chart when checking sensors.

Temperature – Resistance – Voltage for

Type III 10 K Ohm Thermistor Sensors

Temp

(ºF)

-10 93333 4.620

-5 80531 4.550 0 69822 4.474 5 60552 4.390

10 52500 4.297 15 45902 4.200 20 40147 4.095 25 35165 3.982 30 30805 3.862 35 27140 3.737 40 23874 3.605 45 21094 3.470 50 18655 3.330 52 17799 3.275 54 16956 3.217 56 16164 3.160 58 15385 3.100 60 14681 3.042 62 14014 2.985 64 13382 2.927 66 12758 2.867 68 12191 2.810 69 11906 2.780 70 11652 2.752 71 11379 2.722 72 11136 2.695 73 10878 2.665

Table 4: Temperature/Resistance for Type III 10K Ohm Thermistor Sensors

Resistance

(Ohms)

Voltage @

Input (VDC)

Temperature – Resistance – Voltage for

Type III 10 K Ohm Thermistor Sensors

Temp

(ºF)

74 10625 2.635 75 10398 2.607 76 10158 2.577 78 9711 2.520 80 9302 2.465 82 8893 2.407 84 8514 2.352 86 8153 2.297 88 7805 2.242 90 7472 2.187

95 6716 2.055 100 6047 1.927 105 5453 1.805 110 4923 1.687 115 4449 1.575 120 4030 1.469 125 3656 1.369 130 3317 1.274 135 3015 1.185 140 2743 1.101 145 2502 1.024 150 2288 0.952

Resistance

(Ohms)

Voltage @

Input (VDC)

Table 4, cont.: Temperature/Resistance for Type III 10K Ohm Thermistor Sensors

Thermistor Sensor Testing Instructions

Use the resistance column to check the thermistor sensor while disconnected from the controllers (not powered).

Use the voltage column to check sensors while connected to powered controllers. Read voltage with meter set on DC volts. Place the “-” (minus) lead on GND terminal and the “+” (plus) lead on the sensor input terminal being investigated.

If the voltage is above 5.08 VDC, then the sensor or wiring is “open.” If the voltage is less than 0.05 VDC, then the sensor or wiring is shorted.

SA Controller Technical Guide

Appendix

OE265-11 and -14 RH Sensors

OE265 Series RH Sensor Testing

The chart below is used to troubleshoot the OE265-11 and OE265-14 Relative Humidity Sensors.

OE265-11 & OE265-14 Relative Humidity Transmitters –

Humidity vs. Voltage for 0-5 VDC Sensors

Humidity

Percentage

(RH)

0% 0.00 52% 2.60 2% 0.10 54% 2.70 4% 0.20 56% 2.80 6% 0.30 58% 2.90

8% 0.40 60% 3.00 10% 0.50 62% 3.10 12% 0.60 64% 3.20 14% 0.70 66% 3.30 16% 0.80 68% 3.40 18% 0.90 70% 3.50 20% 1.00 72% 3.60 22% 1.10 74% 3.70 24% 1.20 76% 3.80 26% 1.30 78% 3.90 28% 1.40 80% 4.00 30% 1.50 82% 4.10 32% 1.60 84% 4.20 34% 1.70 86% 4.30 36% 1.80 88% 4.40 38% 1.90 90% 4.50 40% 2.00 92% 4.60 42% 2.10 94% 4.70 44% 2.20 96% 4.80 46% 2.30 98% 4.90 48% 2.40 100% 5.00 50% 2.50

Voltage

Input

(VDC)

Humidity

Percentage

(RH)

Voltage

Input

(VDC)

OE265-11 & OE265-14 Rela tive Humidity Sensor T esting Instructions

Use the voltage column to check the Humidity Sensor while connected to a powered expansion module. Read voltage with meter set on DC volts.

Place the “-” (minus) lead on the terminal labeled GND and the “+” lead on the AIN terminal that the Humidity sensor is connected to on the Analog Input/Output Expansion Module.

Table 5: Humidity/Voltage for OE265-11 & -14 Humidity Sensors

SA Controller Technical Guide

Appendix

OE271 Pressure Sensor Testing

Zone

OE271 Pressure Sensor Testing

The table below is used to troubleshoot the OE271 Duct Static Pressure Sensors.

OE271 Duct Static Pressure Sensor

Pressure

Sensor

(“ W.C.)

0.00 0.25 2.60 2.33

0.10 0.33 2.70 2.41

0.20 0.41 2.80 2.49

0.30 0.49 2.90 2.57

0.40 0.57 3.00 2.65

0.50 0.65 3.10 2.73

0.60 0.73 3.20 2.81

0.70 0.81 3.30 2.89

0.80 0.89 3.40 2.97

0.90 0.97 3.50 3.05

1.00 1.05 3.60 3.13

1.10 1.13 3.70 3.21

1.20 1.21 3.80 3.29

1.30 1.29 3.90 3.37

1.40 1.37 4.00 3.45

1.50 1.45 4.10 3.53

1.60 1.53 4.20 3.61

1.70 1.61 4.30 3.69

1.80 1.69 4.40 3.77

1.90 1.77 4.50 3.85

2.00 1.85 4.60 3.93

2.10 1.93 4.70 4.01

2.20 2.01 4.80 4.09

2.30 2.09 4.90 4.17

2.40 2.17 5.00 4.25

2.50 2.25

Voltage

Input

(VDC)

Pressure

Sensor

(“ W.C.)

Voltage

Input

(VDC)

OE271 Pressure Sensor Testing Instructions

Use the voltage column to check the Duct Static Pressure Sensor while connected to powered controllers. Read voltage with meter set on DC volts. Place the “-” (minus) lead on the GND terminal and the “+” (plus) lead on the 0-5 pin terminal on (TP) with the jumper removed. Be sure to replace the jumper after checking.

Table 6: Duct Static Pressure/Voltage for OE271 Duct Static Pressure Sensors

SA Controller Technical Guide

Appendix

OE275-01 Suction Pressure Transducer Testing

OE275-01 Suction Pressure Transducer Testing for R410A Refrigerant

The Evaporator Coil Temperature is calculated by converting the Suction Pressure to T emperature. The Suction Pressure is obtained by using the OE275-01 Suction Pressure Transducer , which is connected into the Suction Line of the Compressor.

Use the voltage column to check the Suction Pressure Transducer while connected to the SA Expansion Module. The SA Controller and the SA Expansion Module must be powered for this test. Read voltage with a meter set on DC volts. Place the positive lead from the meter on the PR OUT terminal located on the SA Expansion Module terminal block. Place the negative lead from the meter on the ground (GND) terminal located adjacent to the PR OUT terminal on the SA Expansion Module terminal block. Use a refrigerant gauge set and/or an accurate electronic thermometer to measure the temperature or suction line pressure near where the Suction Pressure Transducer is connected to the suction line. Measure the Voltage at the terminals PR OUT and GND terminals and compare it to the appropriate chart depending on the refrigerant you are using. If the temperature/voltage or pressure/voltage readings do not align closely with the chart, your Suction Pressure Transducer is probably defective and will need to be replaced.

See the OE275-01 Suction Pressure Transducer , Pressure, T emperature, and Voltage Chart for R410A Refrigerant testing (Table 7). The chart show a temperature range from 20°F to 80°F. For troubleshooting purposes, the DC Voltage readings are also listed with their corresponding temperatures and pressures.

OE275-01 Suction Pressure Transducer Coil Pressure

– Temperature – Voltage Chart for R410A Refrigerant

°F

Temperature

21.19 80.94 1.8 59.03 168.10 3.2

24.49 87.16 1.9 61.17 174.32 3.3

27.80 93.39 2.0 63.19 180.55 3.4

30.99 99.62 2.1 65.21 186.78 3.5

33.89 105.84 2.2 67.23 193.00 3.6

36.80 112.07 2.3 69.24 199.23 3.7

39.71 118.29 2.4 71.15 205.46 3.8

42.30 124.52 2.5 72.95 211.68 3.9

44.85 130.75 2.6 74.76 217.91 4.0

47.39 136.97 2.7 76.57 224.14 4.1

49.94 143.2 2.8 78.37 230.36 4.2

52.23 149.42 2.9 80.18 236.59 4.3

54.50 155.65 3.0

56.76 161.88 3.1

PSI

Pressure

Signal

DC Volts

°F

Temperature

PSI

Pressure

Signal

DC Volts

Table 7: Coil Pressure/Voltage/Temp for OE275-01 Suction Pressure Transducers - R410A Refrigerant

SA Controller Technical Guide

Index

A-B

Zone

2-Conductor Wire.........10

2 Digital Compressors.........40

3- or 4-Conductor Wire.........10

7-Day, 2-Event-per

10K T ype III Thermistor Sensors.........14,15

12 Relay Expansion Module

Voltage and Environment Requirements.........10

12-Relay Expansion Module.........11

Dimensions.........8

Wiring.........30

12-Relay Expansion Module Jumper Settings.........30

14 Holiday Event Scheduling.........5

18-Gauge.........10

24-Gauge.........10

24 VAC-to-24 VAC.........35

-Day

Scheduling.........5

AAON® MHGRV Modulating Hot Gas Reheat

Controller.........5

AAON

Actuators

Address 1.........34

Address 59.........34

Addressing

AI1.........37

AI1- AI7.........36

AI1 Wiring

AI2.........36,37

AI2 Wiring

AI3.........36,37

AI3 Wiring

AI4.........36,37

AI5.........36

AI6.........36

AI7.........36

AI7 Wiring

Air Proof of Flow Input.........38

Air to Air Heat Pump Operation.........44

Tulsa

WSHP Protection Module.........33

Zoning Bypass Damper.........18,19

Controllers.........34

Instructions.........34

SA Expansion Module.........24

SA Controller.........13

SA Expansion Module.........25

SA Controller.........14

SA Expansion Module.........22,28

SA Controller.........15

SA Controller.........16

SA Expansion Module.........22,28

SA Controller.........13

Alarm

Low Space Temp Alarm.........49

Alarm Deﬁ nitions.........48

Alarms.........50

CFM Sensor Failure.........49

Damper Closing Alarm.........49

Damper Feedback Failure Alarm.........49

Damper Opening Alarm.........49

Dirty Filter Alarm.........48

Drain Pan Overﬂ ow Failure.........48

Emergency Shutdown Alarm.........48

Entering Air Temperature Sensor Failure Alarm.........48

High and Low Supply Temp Alarm.........49

High Space Temp Alarm.........49

Mechanical Cooling Failure.........48

Mechanical Heating Failure.........48

Module Alarm.........49

SA Controller.........48

Space Sensor Failure.........49

VAV/Zone Controller.........49

Water Proof of Flow Failure.........48

Analog Inputs.........36

AO1.........37

SA Expansion Module.........26

AO1 Wiring

SA Controller.........17

AO2.........37

SA Controller.........19

SA Expansion Module.........27,28

AO2 Wiring

SA Controller.........18

AO3.........37

SA Expansion Module.........27,28

AO4.........38

AO4 Wiring

SA Expansion Module.........17

AO5.........38

AO5 Wiring

SA Expansion Module.........17

Applications

Overview.........5

Applying Power.........34

Automatic Supply Air Reset.........5

Auxiliary Heating Stages Overview.........44

Belden #82760 Wire.........10

BI1 - B8........38

Binary Inputs.........38

SA Expansion Module.........23

Blink Code Interpretation

LEDs.........53

SA Controller Technical Guide

Index

C-D

CFM Sensor Failure Alarm.........49

Chilled W ater units.........42

Chilled W ater Valve.........27,37,40,42

Control.........5

Coil 1 Suction Pressure.........50

Coil 2 Suction Pressure.........50

Coil Pressure/Voltage/Temp for OE275-01 Suction Pressure

Transducers.........61

Coil T emperature Offset.........43

Coil T emperature Reset.........43

Component Locations

SA Controller.........9

Compressor Lockout Setpoints.........43

Condenser Fan Speed 1.........50

Condenser Fan Speed 2.........50

Conﬁ gurations

Interconnected System.........54

Interconnected System Layout.........56

Networked System Layout.........57

Network System.........54

Stand-Alone System.........54

Stand-Alone System Layout.........55

Conﬁ guring

SA Controller.........35

Constant Air V olume Unit

Overview.........5

Constant Volume Supply Fan.........5

Controller

Addressing.........34

Programming.........35

Control Temp Cooling Failure

LED Blinks.........53

Control Temp Heating Failure

LED Blinks.........53

Cooling and Heating Lockouts Setpoints.........46

Cooling Mode.........39

Cooling Staging Delay.........40

Minimum Off Time.........40

Minimum Run Time.........40

Operation.........39

Stage Control Window.........40

Staging Down Delay.........40

Staging Up Delay.........40

Cooling Only with Morning Warm-up.........36

Cooling Setpoint.........50

Cooling Stage Control Window Setpoint.........40

Cooling Staging Delay.........40

Copeland Digital Scroll Compressor.........22,40

Damage to Equipment.........51

Damper Closing Alarm.........49

Damper Feedback Failure Alarm.........49

Damper Opening Alarm.........49

Dehumidiﬁ cation Capabilities.........5

Dehumidiﬁ cation Conﬁ guration Options.........43

Dehumidiﬁ cation Mode.........39,42

Reheat Control.........43

Dehumidiﬁ cation Priority.........5

Diagnostic LED Operation.........53

Diagnostics

LED.........52

Diagram

E-BUS Distribution Module Wiring.........31

Water Side Economizer Bypass Valve.........17

Diagrams

12-Relay Expansion Module Dimensions.........8

12-Relay Expansion Module Jumper Settings.........30

Digital Room Sensor Wiring.........12

Digital Scroll Compressor Wiring.........28,29

Entering Air Humidity Sensor Wiring.........24

Entering Air Temperature Sensor.........16

Entering W ater Temperature Sensor .........15

Indoor Wall-Mounted Humidity Sensor Wiring.........25

Interconnected System Layout.........56

Modular Service Tool & Modular System Manager

Operator Interfaces.........35

Modulating Cooling Device Wiring.........27

Modulating Heating Device Wiring.........26

Networked System Layout.........57

Outdoor Air Temperature Sensor Wiring.........17

Remote Supply Air Temperature Reset Signal

Wiring.........13

SA Controller

Diagnostic LED Locations.........52

Operator Interfaces.........54

SA Controller Components.........9

SA Controller Dimensions.........6

SA Controller Wiring.........11

SA Expansion Module

Input Wiring.........20

Output Wiring.........21

SA Expansion Module Dimensions.........7

SA Expansion Modules Binary Inputs Wiring.........23

SA Expansion Module Wiring.........20

Space T emperature Sensor W iring.........13

Stand-Alone System Layout.........55

Suction Pressure Transducer Wiring.........22

Suction Pressure Transducer Wiring (Units W ith Digital

Compressors).........22

SA Controller Technical Guide

Index

D-H

Zone

DIAGRAMS, CONTINUED

Supply Air and Return Air Temperature Sensor Wiring -

Units Without MODGAS or MHGRV.........15

Supply Air Temperature Sensor Wiring - Units Without

MODGAS or MHGRV.........14

Supply Fan VFD Wiring.........18

Water Side Economizer Valve.........17

Water Side Economizer Wiring.........17

Water Source Heat Pump Protection Module.........33

Zoning Bypass Damper Actuator Wiring.........19

Digital Compressor Stage 2.........50

Digital Room Sensor

Wiring.........12

Digital Scroll Compressor.........5

Wiring.........28,29

Dimensions

12-Relay Expansion Module.........8

SA Controller.........6

SA Expansion Module.........7

Dirty Filter Alarm.........5,48

LED Blinks.........53

Dirty Filter Contact Closure Input.........38

Drain Pan Overﬂ ow Failure.........48

Drain Pan Overﬂ ow Input A.........38

Drain Pan Overﬂ ow Input B.........38

Dual Cabinet Units.........11

EAT Sensor.........15

SAT Sensor.........14

Supply Fan VFD.........18

Duct Static Pressure.........18

Control.........5,46

Sensor.........18

Sensor Input.........36

Voltage Chart.........60

Duct Static Pressure Control.........46

DX Evaporator Coil.........22

Entering Air Humidity Sensor Input.........37

Entering Air Lockouts.........46

Entering Air Sensor Failure

LED Blinks.........53

Entering Air Temperature.........45,50

Entering Air Temperature Sensor.........16

Input.........36

Entering Air Temperature Sensor Failure Alarm.........48

Entering Humidity.........50

Entering W ater Temperature.........50

Entering W ater Temperature Sensor .........15

Dual Cabinet Units.........15

Input.........36

Entering W ater Temperature Sensor Installation.........15

Entering W ater Temperature Sensor Wiring.........15

Evaporator Coil Temperature.........5

Expansion Module

12-Relay Dimensions.........8

12-Relay Expansion Jumper Settings.........30

Expansion Module Relay Status (Bit Pattern).........50

External Heat.........44

Fan Proving Failure

LED Blinks.........53

Fan Proving Interlock.........5

Filter Loading.........46

Filter Loading Applications.........5

First Circuit Head Pressure.........50

Forced Schedule.........39

Force Modes.........51

Force Outputs Override

LED Blinks.........53

EAT Cooling Lockout Setpoint.........44

EAT Heating Lockout Setpoint.........44

E-BUS Distribution Module.........31,33

Voltage and Environment Requirements.........10

E-BUS Distribution Module Wiring.........31

Economizer Flush Cycle.........42

Electrical Codes.........10

Electric Heating Coil.........26

Emergency Shutdown Alarm.........48

Emergency Shutdown Input.........38

Entering Air Applications.........42

Entering Air Dewpoint.........42

Entering Air Humidity Sensor.........24

Testing.........59

GND-to-GND.........35

Head Pressure Control.........5

Heating Mode.........43

Heating Mode Operation.........39

Heating Staging Delay.........43

Minimum Off Time.........43

Minimum Run Time.........43

Modulating Heating.........44

Stage Control Window.........43

Staging Down Delay.........44

Staging Up Delay.........44

Heating Setpoint.........50

SA Controller Technical Guide

Index

H-N

Heating Staging Delay.........43

Heat Pump Applications.........5

Heat Pump Operation.........39

High and Low Supply Temp Alarm.........49

High Space Temp Alarm.........49

High Supply Air Temperature Cutoff.........47

High Supply Temp Alarm

LED Blinks.........53

Hot W ater Valve.........5

HSSC Series Modular Cables.........31

Humidity/Voltage

Chart.........59

HVAC Cooling Mode Enable Setpoint.........39

HVAC Mode

Sensor Selection.........36

HVAC Mode Enable Temperature.........39

HVAC Mode Operation

Types of.........39

Indoor Air Humidity Sensor Input.........37

Indoor Wall-Mounted Humidity Sensor.........25

Testing.........59

Wiring.........25

Initialization

System.........35

Input Wiring

SA Expansion Module.........20

Instructions

Addressing.........34

Interconnected System.........54

Interconnected System Layout.........56

Internal Trend Logging.........50

Internal W eek Schedule.........39

Jumper Settings

12-Relay Expansion Module.........30

LED

Blink Codes.........53

Diagnostics.........52

Troubleshooting.........53

LEDs.........52

POWER.........52

REC.........52

STATUS 1.........52,53

STATUS 2.........52,53

Low Space Temp Alarm.........49

Low Supply Air Temperature Cutoff.........47

Low Supply Temp Alarm

LED Blinks.........53

Make-Up Air Unit

Overview.........5

Mechanical Cooling Failure.........48

LED Blinks.........53

Mechanical Heating Failure.........48

LED Blinks.........53

Minimum Off Time.........40,43

Minimum Run Time.........40,43

Minimum Wire Size

For 24 VAC.........10

For Sensors.........10

Modes of Operation

Dehumidiﬁ cation Mode.........42

Modular Service Tool.........35,54

Modular System Manager.........35,54

Modulating Chilled Water Valve.........27,28,37

Modulating Cooling.........40

Device.........27,28

Output.........5

Proportional Window.........40

Wiring.........27,28

Modulating Cooling Stage 1.........50

Modulating Cooling Stage 1 Signal.........37

Modulating Cooling Stage 2 Signal.........37

Modulating Heating.........44,50

Device.........26

Wiring.........26

Modulating Heating Device Wiring.........26

Modulating Heating Proportional Window.........44

Modulating Heating Signal.........37

Modulating Hot Gas Reheat.........5

Modulating Hot Water.........44

Modulating Hot Water Heat.........44

Modulating Hot Water Valve.........26

Modulating Reheat Position.........50

Modulating Steam Heat.........44

Modulating Steam Valve.........26

Module Alarm.........49

Morning W arm-up Heating.........5

Morning Warm-Up Mode Operation.........45

SA Controller Technical Guide

Index

O-P

Zone

Networked System.........54

Networked System Layout.........57

Network System.........54

Night Setback Control.........36

Normal Operation LED Blinks.........53

Occupied Cooling Mode.........39

Occupied Mode of Operation.........39

OE210.........13

OE211.........13

OE212.........13

OE213.........13

OE213 Space Temperature Sensor.........13

OE217-00 Digital Room Sensor.........12

OE217-01 Digital Room Sensor.........12

OE231 Wiring.........15

OE231 Entering Air Temperature Sensor.........16

OE231 Supply Air & Return Air Temperature Sensors.........14

OE233.........15

OE250 Wiring.........17

OE265-11 W iring.........25

OE265-11 Indoor Wall-Mounted Humidity Sensor.........25,59

OE265-14 Wiring.........24

OE265-14 Entering Air Humidity Sensor.........59

OE265 RH Sensor Testing.........59

OE271 Pressure Sensor Testing.........60

OE275-01 Wiring.........22

OE275-01 Suction Pressure Transducer

R410A Refrigerant Testing.........61

OE332-23-SA.........32,33

Components.........9

Dimensions.........6

Requirements.........10

Wiring.........11

OE332-23-SA SA Controller.........5,11

OE333-23-EM.........10

OE333-23-SA.........5,11,20,30

Dimensions.........7

Input Wiring.........20

Output Wiring.........21

Requirements.........10

OE333-23-SA SA Expansion Module.........30

OE334-23-WPM-A.........31

OE356-00-BI.........10

OE358-23-12R.........10,11,30

Dimensions.........8

Jumper Settings.........30

Wiring.........30

OE358-23-12R 12-Relay Expansion Module.........20,30

OE365-23-EBD.........5,33

Requirements.........10

OE365-23-EBD-A.........31

OE370-23-HP2C.........5,31,32

Requirements.........10

Off Mode.........39

On Board Relay Status (Bit Pattern).........50

Operating Summary.........35

Operation Modes

Cooling Mode.........39

Dehumidiﬁ cation Mode.........39

Duct Static Pressure Control.........46

Forced Schedule.........39

Heating Mode.........39,43

Heat Pump.........39

HVAC Modes.........39

Internal W eek Schedule.........39

Morning W arm-Up Mode.........45

Off Mode.........39,45

Pre-Heater Operation.........46

Push-Button Override Signal.........39

Remote Forced Occupied Signal.........39

Supply Fan Control.........46

Vent Mode.........39

Warm-Up Mode.........39

Water Side Economizer.........39

Operator Interfaces.........35,54

Optimal Start Scheduling.........5

Outdoor Air V olume.........5

Output Wiring

SA Expansion Module.........21

Overrides.........51

Polarity

Correct.........10,34

Observing.........35

Warning.........35

POWER LED Operations.........52

Power Requirements

Before Applying.........34

SA Controller.........34

Power Wiring.........34

Pre-Heater Operation.........46

Pressure Sensor Testing.........60

Prism Computer Front End Software.........54

Prism Computer Front-End Software.........35

Programming Controllers.........35

Proportional Inlet Vanes.........37

Push-Button Override

Feature.........36

LED Blinks.........53

Signal.........39

SA Controller Technical Guide

Index

R-S

R1 - R4.........38

R1 - R5.........37

R410A Refrigerant.........61

REC LED.........52

Relative Humidity Sensor

Testing Instructions.........59

Remote Forced

Occupied Signal.........39

Remote Forced Occupied Mode Input.........38

Remote Override Capabilities.........5

Remote SAT Reset Signal

Diagram.........13

Input.........36

Overview.........13

Wiring.........13

Remote Supply Air Temperature Reset Signal.........13

Reset Source.........45

RH Sensor Testing.........59

Room Sensor

Slide Offset Option.........13

SA Controller.........33

Addressing.........34

AI1 Wiring.........13

AI2 Wiring.........14

AI3 Wiring.........15

AI4.........16

Alarms.........48

AO1 Wiring.........17

AO2.........19

AO2 Wiring.........18

Component Locations.........9

Conﬁ guring.........35

Digital Room Sensor Wiring.........12

Dimensions.........6

Duct Static Pressure Sensor Input.........36

Entering Air Temperature Sensor Input.........36

Entering Water Temperature Sensor Input.........36

Features.........5,11

LEDs.........52

Mounting Requirements.........10

Overview.........5,11

Power Requirements.........34

Programming.........35

Remote SAT Reset Signal Input.........36

Scheduling.........50

Space Temperature Sensor Input.........36

Space Temperature Sensor Slide Adjust.........36

Supply Air Temperature Sensor Input.........36

Supply Fan (Enable).........37

Supply Fan VFD.........37

Supply Fan VFD Signal Wiring.........18

User-Conﬁ gurable Relays.........37

VAV Terminal Unit Compatibility.........51

Voltage and Environment Requirements.........10

Water Side Economizer Valve Signal.........37

Wiring Diagram.........11

Zoning Bypass Damper Actuator Signal Wiring.........18,19

SA Controller Inputs.........36

SA Controller Outputs.........37

SA Controller Wiring

AI7.........13

SA Expansion Module.........5,11

AI1.........24

AI2.........25

AI3.........22,28

AI4.........22,28

Air Proof of Flow Input.........38

AO1.........26

AO2.........27,28

AO3.........27,28

AO4 Wiring.........17

AO5 Wiring.........17

Binary Inputs.........23

Dimensions.........7

Dirty Filter Contact Closure Input.........38

Drain Pan Overﬂ ow Input A.........38

Drain Pan Overﬂ ow Input B.........38

Emergency Shutdown Input.........38

Entering Air Humidity Sensor Input.........37

Indoor Air Humidity Sensor Input.........37

Input Wiring.........20

Modulating Cooling Signal.........37

Modulating Heating Signal.........37

Remote Forced Occupied Mode Input.........38

Suction Pressure A Input.........37

Suction Pressure B Input.........37

User-Conﬁ gurable Relay Outputs.........38

Voltage and Environment Requirements.........10

Water Proof of Flow Input A.........38

Water Proof of Flow Input B.........38

Water Side Economizer Bypass Actuator Valve A.........38

Water Side Economizer Bypass Actuator Valve B.........38

SA Expansion Module Inputs and Outputs.........37

SA Expansion Module Wiring

Diagram.........20

Scheduling.........50

SCR Control.........26

SCR Electric Heat.........44

SCR Electric Heat Control.........5

Second Circuit Head Pressure.........50

Selectable Control Sensor.........5

SA Controller Technical Guide

Index

S-T

Zone

Sensors

10K T ype III Thermistor.........14,15

Entering Air Humidity.........24

Entering Air Temperature Sensor.........16

Entering W ater Temperature.........15

Indoor W all-Mounted Humidity.........25

Pressure Sensor Testing.........60

Relative Humidity Sensor Humidity/Voltage.........59

RH Sensor Testing.........59

Space T emperature.........13

Supply Air.........14

Supply Air Temperature.........14

Temperature Sensor Testing.........58

Thermistor Sensor Testing Instructions.........58

Type III 10K Ohm Thermistor Sensors.........58

Service T ool.........35

Setpoints

Cooling and Heating Lockouts.........46

Sizing

Transformer.........34

Slide Offset Option.........13

Smoke Detector Input.........5

Space Humidity.........50

Space Sensor Failure

LED Blinks.........53

Space Sensor Failure Alarm.........49

Space T emperature.........45,50

Space T emperature Sensor

Diagram.........13

Input.........36

Overview.........13

Slide Adjust.........36

Wiring.........13

SS1027.........1

SS1028.........1

Stage Control Window.........40,43

Staging Down Delay.........40,44

Staging Up Delay.........40,44

Stand-Alone System.........54

Addressing.........34

Layout.........55

Static Pressure Control.........5

STATUS1 LED.........52,53

STATUS2 LED.........52,53

Steam Heating.........44

Steam Valve.........5

Suction Pressure A Input.........37

Suction Pressure B Input.........37

Suction Pressure Transducer

Diagram.........22

Wiring.........22

Suction Pressure Transducer Testing.........61

Supply Air Cutoffs.........47

High Supply Air Temperature Cutoff.........47

Low Supply Air Temperature Cutoff.........47

Supply Air Sensor Failure

LED Blinks.........53

Supply Air Temperature.........50

Supply Air Temperature Sensor.........14

Diagram.........14

Dual Cabinet Units.........14

Input.........36

Wiring.........14,15

Supply Air Temperature Sensor Failure Alarm.........48,49

Supply Air Temperature Setpoint.........50

Supply Air Temperature Setpoint Reset.........45

Supply Fan Enable.........37

Supply Fan Control.........46

Supply Fan VFD.........37

Diagram.........18

Dual Cabinet Units.........18

Signal.........18

Wiring.........18

Supply Fan VFD Signal.........45

System

Applications.........5

Features.........5

Initialization.........35

Powering-Up.........34

System Conﬁ guration.........54

System Manager.........35

Temperature/Resistance Chart.........58

Temperature Sensor Testing.........58

Testing

OE271 Pressure Sensor.........60

OE275-01 Suction Pressure Transducer - R410A

Refrigerant.........61

Pressure Sensor.........60

Relative Humidity Sensor.........59

RH Sensors.........59

Thermistor Sensor Testing Instructions.........58

Transformer Sizing.........10,34

Trend Logging.........50

Capability.........5

Troubleshooting

LED Diagnostics.........52

Two Condenser Head Pressure Module.........5,32

Voltage and Environment Requirements.........10

Wiring.........32

Type III 10K Ohm Thermistor Sensors.........58

SA Controller Technical Guide

Index

U-Z

Units with 1 Digital Compressor and 1 ON/OFF

Compressor.........40

Units with 2 Digital Compressors.........42

Units with 2 Digital Compressors and 2 ON/OFF

Compressors (Dual Unit).........40,42

Units with 4 Digital Compressors (Dual Unit).........40,42

Unoccupied Cooling Mode.........39

Unoccupied Mode of Operation.........39

User-Conﬁ gurable Relays.........37

VA Load Requirements.........10

VA Rating.........10

V ariable Air Volume Unit

Overview.........5

Variable Frequency Drive Units.........18

VAVAV Terminal Box Compatibility.........51

VAV Dehumidiﬁ cation.........5

VAV/Zone Controller

Alarms.........49

VAV/Zone System.........51

Vent Mode Operation.........39

VFD Fan.........50

VFD Signal.........18,19

VFD Supply Fan.........5

Voltage

Proper.........34

Voltage and Environment Requirements.........10

Warm-Up Mode.........39

Water Cooled Compressor Condenser.........41

Water Proof of Flow Failure.........48

Water Proof of Flow Input A.........38

Water Proof of Flow Input B.........38

Water Safeties.........5

Water Side Economizer.........39

Water Side Economizer Bypass Actuator Valve A.........38

Water Side Economizer Bypass Actuator Valve B.........38

Water Side Economizer Bypass Valve.........17

Water Side Economizer Operation.........5,39

Water Side Economizer Position.........50

Water Side Economizer Valve.........17

Water Side Economizer Valve Signal.........37

Water Side Economizer Wiring.........17

Water Side Economizer (WSE).........41

Water Source Heat Pump Applications.........44

Water Source Heat Pump Protection Module.........33

WattMaster Controls Technical Support.........53

Wet Contacts.........21

Wire

Belden #82760.........10

Wire Size

18-gauge.........10

Minimum for 24 VAC.........10

Wiring

12-Relay Expansion Module.........30

18-gauge.........10

24-gauge.........10

24 VAC-to-24 VAC.........35

Digital Room Sensor.........12

Entering Air Humidity Sensor.........24

Entering Air Temperature Sensor.........16

Entering W ater Temperature Sensor .........15

GND-to-GND.........35

Important Considerations.........10

Indoor Wall-Mounted Humidity Sensor.........25

Modulating Cooling Device.........27,28

Modulating Heating Device.........26

Remote Supply Air Temperature Reset Signal.........13

SA Expansion Module.........20

Space T emperature Sensor.........13

Suction Pressure Transducer.........22

Supply Air Temperature Sensor.........14,15

Supply Fan VFD Signal.........18

Water Side Economizer.........17

Water Side Economizer Bypass Valve.........17

Water Side Economizer Valve.........17

Zoning Bypass Damper Actuator Signal.........18,19

Wiring Diagram

SA Controller.........11

Two Condenser Head Pressure Module.........32

Water Source Heat Pump Protection Module.........33

Wiring Diagrams

Two Condenser Head Pressure Module.........32

WSE Bypass A.........50

WSE Bypass B.........50

WSHP Protection Module.........5,33

Requirements.........10

Zone Override

LED Blinks.........53

Zoning Bypass Damper.........5

Zoning Bypass Damper Actuator.........37

Diagram.........18,19

Zoning Bypass Damper Actuator Signal

Wiring.........18,19

Zoning System.........51

SA Controller Technical Guide

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AAON® Manual Part No. R97490

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Orion SA Controller User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual