EngA Base User manual

IOM73 February 2021
User Manual
Manual Revision 1.01
mc
gk
These instructions are intended as an aid to qualified, licensed installers and service personnel for proper
installation, adjustment and operation of this unit. Read and understand these instructions thoroughly
before attempting installation or operation. Failure to follow these instructions may result in improper
installation, adjustment, service or maintenance possibly resulting in fire, electrical shock, carbon monoxide
poisoning, explosion, personal injury or property damage.
www.engineeredair.com

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INTRODUCTION
Read this manual thoroughly before operating or
servicing this unit.
The Engineered Air base and CD-XM expansion
module have been certified by Intertek (ETL) as a
recognized component for use with Engineered Air
appliances only, evaluated to CSA 22.2 No. 24
Temperature Indicating and Regulating Equipment
and UL873 Standard for Safety Temperature
Indicating and Regulating Equipment. This is a User
Operation Manual and therefore not subject to
evaluation.
If any errors or omissions are noted please contact
the nearest Engineered Air Technical Service
Department.
To ensure warranty is honored, only qualified
personnel should be employed for service or
troubleshooting. If further information is required
please contact the nearest Engineered Air sales
office.
There are two sets of electrical drawings and
function sheets provided with the appliance. One
set is in an envelope which also contains the
Operation, Installation and Maintenance manual(s).
This package is for copying, then should either be
returned to the appliance or stored in a safe place.
The other set is attached to the control panel door
and should never be removed.
Copyright
This document and the information in it are the
property of Engineered Air, and may not be used or
reproduced in whole or in part without written
permission. Engineered Air reserves the right to
revise this publication at any time, and to make
changes to its content without obligation to notify
any person of such revision or change.
CONTACT INFORMATION
Canadian Head Office and Factory
1401 Hastings Cres. SE
Calgary, Alberta, Canada
T2G 4C8
PH: [phone]
FX: 1 888 364 2727
USA Head Office and Factory
32050 W. 83rd Street
De Soto, Kansas, USA
66018
PH: [phone]
FX: [phone]
Canadian Eastern Factory
1175 Twinney Drive
Newmarket, Ontario, Canada
L3Y 5V7
PH: [phone]
FX: [phone]

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WARNINGS, CAUTIONS AND
NOTICES
Warning, Caution and Notice statements are used
throughout this manual to emphasize important and
critical information. You must read these
statements to help ensure safety and to prevent
damage.
m
WARNING:
Indicates a hazardous situation that, if not
avoided, could result in death or serious injury.
m
CAUTION:
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate injury.
m
NOTICE:
Indicates information considered important but not
hazard related.
m
WARNING:
Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, injury or death. Read the installation,
operation and maintenance instructions
thoroughly before installing or servicing this
equipment.
m
c
WARNING:
This unit is connected to high voltages. Electrical
shock could occur if instructions are not
followed. This equipment contains moving parts
that can start unexpectedly. Injury or death
could occur if instructions are not followed. All
work must be performed by a qualified
technician. Always disconnect and lock out
power before servicing. DO NOT bypass any
interlock or safety switches under any
circumstances.
m
CAUTION:
All the remote wiring must be complete and
functional before attempting to start the
appliance.
m
CAUTION:
It is important that the service technician
understands the base is a configurable
controller. Its operation on one appliance of
equipment may not mimic another.
m
CAUTION:
Adding a variable air volume system to
equipment originally designed with constant air
flow will void warranty, unless approved and
recorded by Engineered Air.
m
CAUTION:
The base is specifically programmed for this
specific appliance. Do not replace with another
controller without confirming its program
suitability with Engineered Air.

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TABLE OF CONTENTS
OVERVIEW ................................................................ 5
HARDWARE INFORMATION ...................................... 5
COMMUNICATION .................................................... 5
COMPUTER CONNECTION ........................................ 5
ALARM RESET ....................................................... 6
LED LIGHTS............................................................ 6
SEVEN SEGMENT DISPLAY .................................... 6
CD-XM EXPANSION MODULE ............................... 8
PRESSURE PORTS .................................................. 8
TERMINAL DESIGNATIONS ....................................... 9
APPLIANCE TYPES ................................................... 10
DJ STYLE INDIRECT FIRED .................................... 10
DG STYLE INDIRECT FIRED .................................. 10
HE DIRECT FIRED ................................................. 10
STAGED COOLING ............................................... 10
SH(X) HUMIDIFIER .............................................. 11
ALARMS .................................................................. 12

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OVERVIEW
The Engineered Air base controller is the primary
operational component of Engineered Air heating
equipment, with and without cooling. Functions
include:
 Outdoor, discharge and room temperature
monitoring.
 Single and variable speed fan control.
 Analog heating and cooling outputs.
 Damper and economizer control.
 Alarm annunciation.
 Freeze protection.
Each base controller is factory programmed
specifically for the equipment installed. Refer to
the appliance function description for additional
details.
HARDWARE INFORMATION
Control Voltage
24Vac
60Hz
Digital Output
Rating
120V 10A
Analog Output
0
-
10Vdc
Analog Input
0
-
10Vdc or 4
-
20mA
Temperature Rating
-
40
–
15
0°F
(65
°C)
Temperature Sensor
10k
Type 2 NTC
Terminations
#14 awg max.
m
NOTICE
:
Digital inputs connections to the base or any of the
expansion modules cannot use mosfet solid state
switches. Input switching must be mechanical.
COMMUNICATION
Direct connection may be made to a laptop
computer using a Cat.5 cable. Once connected and
correctly configured, a web page will appear
showing the various operational conditions and
settings.
COMPUTER CONNECTION
m
Notice:
The base requires a connection to a computer for
detailed information beyond what is indicated on
the LED displays.
Direct connection may be made to a Windows 10 OS
computer or tablet. To gain access to the base
display interface connect using a Cat.5 Ethernet
cable to the base, near the top right of the
controller. Tablets may require a USB to Ethernet
adapter. Any Windows based web browser should
work.
To set the correct IP address, click the Start
button, then Settings, then Network and Internet.
Then, click Ethernet (on the left side), then Change
Adapter Options. Click the Ethernet icon and a
status page should open. Press Properties, then
Ethernet, then select Internet Protocol Version,
and then Properties.
Set a static IP address on the computer with the
following settings:

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Click OK to accept, and then open a web browser
and type in the following address to gain access to
the display interface:
192.168.0.10:8080/webvisu.htm
To simplify connections, make this a bookmark in
the web browser for future connections.
The display interface should appear, similar to the
following. Note the tabs along the top for access
to additional information screens.
Changes made to adjustable values are ‘live’.
Pressing ENTER or SAVE is not required.
Heating and Cooling Display Sequence Definitions
The display screens specific to gas fired heating
and mechanical cooling have a number sequence
included to describe the current operating mode.
ALARM RESET
Alarms may be reset either from the laptop
computer alarm screen or the red reset button near
the top left.
LED LIGHTS
Light
Description
Function
Green
Power
ON=Powered
OFF=No Power to H&N
Yellow
Comm
unication
BLINK=Comm to CD
-
XM
ON=Internal Comm.
OFF=Failure
Red
Alarm
ON=Alarm Condition
OFF=No alarm present
SEVEN SEGMENT DISPLAY
Left is mode indication
4: Cooling
3: Heating
2: Economizer
1: Ventilation
Right 2 Displays: Alarm value
See ALARMS
m
NOTICE
:
The mode indication is indicative of the current
mode and not what the mode was when an alarm
occurred.
Burner sequence
Compressor Stages
①
Move to purge
➊
Stage #1 On
②
Purge
➋
Stage #2 On
③
Move to ignition
➌
Stage #3 On
④
Ignition / pilot
④
Stage #4 Off
➎
Main valve
⑤
Stage #5 Off
⑥
Post purge
⑦
Shutdown

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Standard Version
Humidifier Version

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CD-XM EXPANSION MODULE
A TRIAC driver slave connected via Modbus
communication to the base, this module controls
the combustion motor speed on DJ indirect fired
heaters. A 3 wire feedback signal is returned to
the module to confirm the blower speed.
PRESSURE PORTS
Marked as H (high side) and L (low side) for use on
direct fired appliances.
Pressure ports may not be included on appliances
that do not require them.
m
CAUTION:
Do not blow onto the pressure ports. Excessive
pressure and moisture will damage it. The ports are
fragile and should not be tampered with.

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TERMINAL DESIGNATIONS
Terminals indicated change on the humidifier
version.
H N Power Supply
GND Ground
LmA,B Local Modbus
ECO AI EC Motor Common
PWM AI EC Motor Running Speed
ECM AO EC Motor Demand
MHW AO Modulating Heating
MCW AO Modulating Cooling
MEc AO Modulating economizer
MPP AO Profile Plate Actuator
AL DO Alarm
SA DO Supply air
DM DO Damper actuator enable
CMa DO Relay ‘a’ Common
CMb DO Relay ‘b’ Common
STG1 DO Cooling Stage 1
STG2 DO Cooling Stage 2
STG3 DO Cooling Stage 3
STG4 DO Cooling Stage 4
STG5 DO Cooling Stage 5
HiS DO High Speed Exhaust Fan Start
Exl DO Low Speed Exhaust Fan Start
CMc DO Relay ‘c’ Common
MBV AO Modulating Ball Valve
MCA AO Modulating Air Actuator
FbG AI Modulating Gas Valve Feedback
FbA AI Modulating Air Feedback
CP AI Condensate Probe
PV1,2 DO Pilot Valve
SR1,2 DO Safety Relay
FR1,2 DO Flame Relay
FbV DI Feedback Gas Valve
VN DI Feedback Gas Valve Neutral
HL DI High Limit
EnH DI Enable Heat
BFS DI Blocked Flue Switch
CAS DI Combustion Air Switch
CMd DO Relay ‘d’ Common
SDO DO (HE) Dual Flame Rod
SDO DO (DG) Combustion Blower Start
WPu DO Water Pump
FbD AI Feedback Economizer Damper
ASP AI Remote VFD setpoint
RPM AI VFD Feedback Speed
W+/- AI Modulating heating thermostat
AA1,2 AI Ambient / Outside temperature
DA1,2 AI Discharge temperature
Y+- AI Modulating cooling thermostat
HiE DI High Speed Enable
ENC DI Enable Cooling
OCC DI Occupied / unoccupied mode
EnF DI Enable Fan
DES DI Damper end switch
FbB DI Air proving switch
BYP DI VFD Bypass
MX1,2 AO Maxitrol Modulating Valve
Humidifier Version Terminals
FV DO Fill Valve
MV DO Mixing Valve
DV DO Drain Valve
FVS DO Second Fill Valve
LWP CI Low Water Probe
FWP CI Fill Water Probe
DN1,2 AI Drain Water Temperature
CD-XM Terminals
H N 24Vac Power Supply
GND Ground
LmA,B Internal Modbus
OS AI Tachometer +
YS AI Tachometer -
GS AI Tachometer reference
CB AO TRIAC output
120 120Vac input
SR1,2 DO Safety relay

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APPLIANCE TYPES
DJ STYLE INDIRECT FIRED
For indirect fired equipment with DJ (E, S, X) style
burners up to size 140.
On a call for heating the combustion blower will be
enabled to full speed to prepurge the heat
exchanger. Once the prepurge time has elapsed
the combustion blower speed will reduce to ignition
speed and then enable the ignition control to start
and prove pilot flame, then open the main safety
valve (SSOV). After a time delay the pilot valve IS
disabled. The burner is allowed to operate from
low fire to high fire at a 15:1 turndown ratio to
maintain the requested discharge air temperature
by modulating the control valve and the
combustion blower speed. If heating is not
required the burner will be disabled and the
combustion blower will enter a post purge time,
and then shut down.
The base can control either a Maxitrol magnetic
style modulating valve or an actuator and ball valve
combination.
Combustion air blower modulation is controlled by
either the CD-XM expansion module. If using an
electronically commutated motor (ECM) modulation
is directly controlled from the base.
DG STYLE INDIRECT FIRED
For indirect fired equipment, DJX sizes 200 and
300, and all DG sizes. These use actuator
controlled air flow control damper and gas ball
valves.
On a call for heating the combustion blower will be
enabled and the air actuator will open to the
prepurge setpoint to purge the heat exchanger.
Once the prepurge time has elapsed the gas and air
actuators will move to ignition position and then
enable the ignition control to start and prove pilot
flame, then open the main safety valve (SSOV).
Once the pilot flame has proven and the main
flame is established, the base will then disable the
pilot valve. The burner is allowed to operate from
high fire to low fire at a 20:1 turndown ratio to
maintain the requested discharge air temperature
by modulating the gas and air actuators. If heating
is not required the burner will be disabled and the
combustion blower will enter a post purge time,
and then shut down.
HE DIRECT FIRED
For direct fired HE style direct fired heaters.
On a call for heating, and with the supply blower
enabled, the ignition control will be enabled to
start and prove pilot flame, then open the main
safety valve (SSOV). Once the pilot flame has
proven and the main flame is established, the M-XM
will then disable the pilot valve. The burner is
allowed to operate from low fire to high fire to
maintain the requested discharge air temperature
by modulating the fuel control valve. The heating
will remain on as long as the heating enable circuit
is energized.
The base can control either a Maxitrol magnetic
style modulating valve or an actuator and ball valve
combination.
Variable air volume systems include a burner
bypass damper which modulates to maintain the
correct burner profile pressure drop.
STAGED COOLING
For staged compressor operation the base will
sequence on and off up to 5 compressor stages to
maintain the discharge temperature setpoint. As
with all staged systems, expect the discharge
temperature to fluctuate from setpoint as
compressors are turned on and off.

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SH(X) HUMIDIFIER
SH and SHX series gas fired humidifiers are
controllable using the humidifier version of the
base controller.
SHX models use a second fill valve for the side
tank.
On a call for humidification the tank first fills with
water, then the burner gas-fired heat is enabled to
produce steam. Water level is controlled by the
water level probes. Water quality dictates the
minimum tank drain cycle times. Drain
temperature is monitored and cooled with the
supply water if required.
Drain cycle times are preprogrammed based on
water quality, or may be initiated by a time clock
contact.
Large SH(X) sizes (120-650) use DJ style burner for
the gas fired portion.

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ALARMS
LED
Name
Description
General Alarms
01 Low limit
The low limit setpoint is the lower of 40°F or 15°F below the discharge air
setpoint. 4 minute bypass time.
02 Air Proving Fault
VFD
Feedback is greater than the minimum VFD speed for more than 30
s
with the supply fan output off.
03
Shorted Air Proving
Air SA Proving switch shorted on start
up.
04 Low airflow
Air Proving switch open
s during operation for 30
s or the VFD feedback
drops below the minimum speed for 30 seconds.
05
Discharge Air Sensor
Failure
Discharge Air sensor is outsi
de of its range
for
10
s.
06
Ambient Air Sensor
Failure
Outdoor Ambient sensor is o
utside of range for 10s
.
07
Damper End
Switch
Short
T
he damper end
switch is made before energizing the damper output.
08
Damper End
Switch
Open
Indication damper end switch not made after actuator is energized.
09
Communication
Loss of communication
to
CD
-
XM
(if used).
Heating
Alarms
80 Gas Valve Wiring
Gas valve
feedback has power before the FR and SR contact are
energized.
81 Gas Valve out of range
Gas valve actuator
feed
b
ack
is greater or less tha
n the demand.
Timed event.
86
High Limit
High limit safety tripped due to excessively high temperature.
87 Flame Relay Wiring
Received a gas valve feedback within 500ms of activating the Flame relay
output.
88 Flame Failure
Gas valve feedback has no power after 1 minute of enabling the Flame
relay output.
DJ
/SH(X)
Alarms
82 RPM out of range
Combustion blower
motor RPM
is greater or less then the demand.
Timed event.
83
Open Air Proving
Combustion blower does not exceed 3000 rpm during purge.
84 Combustion Air Proving
Combustion rpm speed sensor has a value greater than 500 rpm for 60
seconds before the combustion blower has been commanded on.
85
Plugged Condensate
Blocked condensate sensor reads less then 7kΩ for more than 5 minutes.
89
Blocked Flue
Blocked flue input i
s
open
for
more than 1 minute
.
90 60 Hz
Combustion blower frequency has exceeded 60
Hz ( 3590 RPM)

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DG Alarms
82
Air Actuator Out of
range
Air Actuator Feedback Is greater or less then the demand. Tolerances and
timing vary depending on mode of operation.
83 Open Air Proving
Combustion blower air switch input
(CB)
has no power for 60
seconds
after commanding the combustion blower on / Combustion blower air
switch input has no power for 2 seconds during main flame.
84 Shorted CB Air Proving
Combustion blower air switch input has power for 10 seconds before the
combustion blower has been commanded on.
85 Plugged Condensate
Blocked condensate sensor reads less than 7kohms for more than 5
minutes.
86
High Limit
High limit safety tripped due to excessively high temperature.
89
Blocked Flue
Blocked flue input has opened for more than 1
minute.
HE Alarms
91 Low Velocity Air Switch
Occurs if the pressure drops below the low pressure setpoint during
modulation for more than 40 seconds
92 High Velocity Air Switch
Occurs if the pressure goes above the High pressure setpoint during
modulation for more than 90 seconds
94
Low Pressure
Air flow too low to enable heating.
95 Low Pressure Sensor
Unable to zero the pressure before the damper has opened.
96 Very Low Pressure
Occurs if the pressure drops below the very low pressure
setpoint after
the purge has been completed.
97
Far Sensor Flame
Failure
Occurs if a secondary
flame rod is enabled and
flame sensing
is lost
in less
than 20 seconds after the pilot valve drops out on consecutive attempts.
SH(X)
Water
Alarms
61
Tank
High Pressure
Overflow
SH is in normal operating mode and the drain temperature is greater than
110 deg F for longer than 10 seconds.
62 Water Foaming
Low water probe made and fill valve open for less than 2 minutes during
normal operation.
63 Failed Water Supply
The fill valve stay open longer than the required time (varies on current
mode: Normal operation: 5m; Complete fill: 1hr).
64
Failure to Drain
Low water probe covered and drain valve open for longer than 1 hour
.
65
Water Probe Sequence
Fill
water probe is covered before the low water probe.
66
Duct High Limit Trip
Duct humidity has tripped the mechanical high limit
.
67 Drain Sensor Failure
Drain sensor is out of range (less than 30° or greater than 212°F) for 10
seconds.
68 Fill Valve Stuck Open
Fill water probe and low water probes are covered
and the drain
temperature is greater than 110°F for longer than 10 seconds when the
SH is off and no drain is required.