Engineered air base User manual

A
EIOM73 February 2021
User Manual
Manual Revision 1.00
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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.
mWARNING:
Indicates a hazardous situation that, if not
avoided, could result in death or serious injury.
mCAUTION:
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate injury.
mNOTICE:
Indicates information considered important but not
hazard related.
mWARNING:
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.
mcWARNING:
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.
mCAUTION:
All the remote wiring must be complete and
functional before attempting to start the
appliance.
mCAUTION:
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.
mCAUTION:
Adding a variable air volume system to
equipment originally designed with constant air
flow will void warranty, unless approved and
recorded by Engineered Air.
mCAUTION:
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 .......................................8
APPLIANCE TYPES .....................................................9
DJ STYLE INDIRECT FIRED......................................9
DG STYLE INDIRECT FIRED ....................................9
HE DIRECT FIRED.................................................10
STAGED COOLING...............................................10
SH(X) HUMIDIFIER ..............................................10
ALARMS ..................................................................11

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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 –150°F (65°C)
Temperature Sensor
10k Type 2 NTC
Terminations
#14 awg max.
mNOTICE:
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
mNotice:
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
Communication
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
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.
mCAUTION:
Do not blow onto the pressure ports. Excessive
pressure and moisture will damage it. The ports are
fragile and should not be tampered with.
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

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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 Full 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
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

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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
attempt 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.
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.

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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 30s
with the supply fan output
off.
03
Shorted Air
Proving
Air SA Proving switch
shorted on start up.
04
Low airflow
Air Proving switch opens
during operation for 30s
or the VFD feedback drops
below the minimum speed
for 30 seconds.
05
Discharge Air
Sensor Failure
Discharge Air sensor is
outside of its range for
10s.
06
Ambient Air
Sensor Failure
Outdoor Ambient sensor
is outside of range for 10s.
07
Damper End
Switch Short
The 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
feedback is greater or less
than 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 is open
for more than 1 minute.
90
60 Hz
Combustion blower
frequency has exceeded
60 Hz ( 3590 RPM)
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.

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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
Measuring elevated drain
temperature when not
draining.
62
Water Foaming
Erratic water level probe
sensing .
63
Failed Water
Supply
Expected time to fill to
water level probes not
achieved.
64
Failure to Drain
Expected time to clear
water level probes not
achieved.
65
Water Probe
Sequence
On fill, probe sensing is
reversed.
66
Duct High Limit
Trip
Duct humidity high limit
open.
67
Drain Sensor
Failure
NTC Type 2 drain sensor
outside of range.
68
Fill Valve Stuck
Open
Expected time to clear Full
Water Probe not
achieved.