Engineered air EngA W-TRAC User manual

IOM‐49 Mar99R4
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
FOR
W-TRAC
HEAT WHEEL CONTROLLER
UNIT MODEL NO. _________________
UNIT SERIAL NO. _________________
SERVICED BY: ___________________
TEL. NO: ________________________
CANADIAN
HEAD OFFICE
AND FACTORY
USA
HEAD OFFICE
AND FACTORY
CANADIAN
EASTERN FACTORY
1401 HASTINGS CRES.
SE
CALGARY, ALBERTA
T2G 4C8
Ph: [phone]
Fx: 888-364-2727
32050 W. 83r
d
STREET
DESOTO, KANSAS
66018
Ph: [phone]
Fx: [phone]
1175 TWINNEY DRIVE
NEWMARKET,
ONTARIO
L3Y 5V7
Ph: [phone]
Fx: [phone]
SALES OFFICES ACROSS CANADA AND USA
Retain instructions with unit and maintain in a legible condition.
Please give model number and serial number when contacting
Engineered Air for information and/or parts.

www.engineeredair.com
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A
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IOM‐49 2of12 Mar99R4
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W‐TRAC
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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and
troubleshooting.IffurtherinformationisrequiredpleasecontactthenearestEngineeredAiroffice.

Therearetwosetsofelectricaldrawingandunit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.

Pleasereportanyomissionstothenationalservicemanager.
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Warning:

Improperinstallation,adjustment,alteration,serviceormaintenancecancause
propertydamage,injuryordeath.Readtheinstallation,operatingand
maintenanceinstructionsthoroughlybeforeinstallingorservicingthisequipment.

Warning: Thisunitisconnectedtohighvoltages.Electricalshockordeathcouldoccurif
instructionsarenotfollowed.Thisequipmentcontainsmovingpartsthatcanstart
unexpectedly.Injuryordeathcouldoccurifinstructionsarenotfollowed.All
workshouldbeperformedbyaqualifiedtechnician.Alwaysdisconnectandlock
outpowerbeforeservicing.DONOTbypassanyinterlockorsafetyswitchesunder
anycircumstances.
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

AW-TRAC
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IOM‐49 3of12 Mar99R4
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


AW-TRAC
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
IOM‐49 4of12 Mar99R4
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TableofContents
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INTRODUCTION..................................................................................................................................................5
CONTROLLERRATINGS......................................................................................................................................5
CONTROLLERDESCRIPTION...............................................................................................................................6
TERMINALLIST...................................................................................................................................................6
DIPSWITCHES....................................................................................................................................................6
INDICATIONANDDIAGNOSTICLIGHTS..............................................................................................................7
ADJUSTMENTPOTS............................................................................................................................................7
TEMPERATURECONTROL..................................................................................................................................7
BASESETPOINT..................................................................................................................................................8
SETPOINTRESET.................................................................................................................................................8
FROSTCONTROL................................................................................................................................................8
EXHAUSTAIRRH%SENSOR...............................................................................................................................8
RETURNAIRRH%SENSOR.................................................................................................................................9
BDRHPREDICTEDRETURNAIRRELATIVEHUMIDITY........................................................................................9
WIRING...............................................................................................................................................................9
SENSORTABLE.................................................................................................................................................12
SERVICENOTES................................................................................................................................................10
ROTATION........................................................................................................................................................10
MOTORSPEEDCONTROL.................................................................................................................................10
KBVF/SIVF(R)..................................................................................................................................................10
WHEELROTATIONSPEED................................................................................................................................11
SENSORCALIBRATION.....................................................................................................................................11
DISCHARGETEMPERATURECALIBRATION......................................................................................................11
EXHAUSTTEMPERATURECALIBRATION..........................................................................................................11
HUMIDITYSENSORS.........................................................................................................................................12
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

AW-TRAC
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IOM‐49 5of12 Mar99R4
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INTRODUCTION

TheW‐TRACisasupervisorycontrollerforEngineeredAirHRWheatwheels,withbuiltindischargeair
temperaturecontrolandoptionalexhaustfrostcontrol.

Theinformationusedinthismanualshouldbeusedinconjunctionwiththeunitfunctionsheet(s)andthe
HRWseriesInstallation,Operation,andMaintenancemanual.

TheW‐TRACisdesignedtocontrolonlyEngineeredAirequipment.Variousupgradesandimprovements
havebeenmadeovertime.Alwaysincludeanysuffixlettersandnumbersfortroubleshootingand/or
replacement.AllW‐TRACmodelsarebackwardscompatible;howeversomeadditionalwiringmaybe
required.
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Note:Itisnecessarythatalloftheremotewiringandcontrolsbecompleteandoperationalbeforestarting
theappliance.
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
CONTROLLERRATINGS
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Powerrequirements:24VAC,40VA.
ContactRating:120V3Ainductive
0‐10Vdcinputimpedance:5k
Environment:‐40to120°F(‐40to50°C)non‐condensing.


AW-TRAC
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IOM‐49 6of12 Mar99R4
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CONTROLLERDESCRIPTION
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TERMINALLIST
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Terminal Description
C1 Sensorcommon,and0‐10Vdcresetcommon(‐).
S 0‐10Vdctemperatureresetinput(+).
D Supplyairtemperaturesensorinput.
E Exhaustairtemperaturesensorinput.
A Outsideairtemperaturesensorinput.
RMH 0‐10VdcreturnairRH%input.
EXH 0‐10VdcexhaustairRH%input.
MOD 0‐10Vdcheatwheelcontroloutput(+).
C2 0‐10Vdcheatwheelcontroloutput(‐).
+12 12Vdcoutputpower
+32 32Vdcoutputpower(RH%sensorhot)
T2(N) 24VacNeutralpowerinput.
T1 24VacHotpowerinput.
6 Outputcontactcommon
5 Outputcontactnormallyclosed(N.C.)
4 Outputcontactnormallyopen(N.O.).Startcontact.
P1 Lowoutputpotentiometer(legacy,foroldstyleDCdrivemotors).
P2 Wiperoutputpotentiometer(legacy,foroldstyleDCdrivemotors).
P3 Highoutputpotentiometer(legacy,foroldstyleDCdrivemotors).
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DIPSWITCHES
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W‐TRACconfigurationoptionsareconfiguredbyDIPswitchselection and/or wiring connections.  These
arefactorysetandshouldnotnormallyneedtobealtered.
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DIPSW Description
BDRHSPEN ‘ON’whenRH%sensingofthereturnairisnotused.W‐TRACwillcontrolbasedon
pre‐definedRH%values.Switchwillbe‘OFF’whensensingactualRH%.
EXRHCTRL ‘ON’whenusingexhaustairRH%sensing.
BDRHCTRL ‘ON’whenRH%sensingofthereturnairisnotused.Switchmustbeinthesame
positionasBDRHSPEN(above).
MANHISPEED* ‘ON’todrivetheoutputtomaximumwheelrotationspeed.
MANLOSPEED* ‘ON’todrivetheoutputtominimumwheelrotationspeed.
*Donotenablebothswitchesatthesametime,orleaveeitherswitch‘on’innormaloperation.
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AW-TRAC
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IOM‐49 7of12 Mar99R4
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INDICATIONANDDIAGNOSTICLIGHTS
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OnthefaceoftheW‐TRACare5redLEDindicationlights.

Light Description
LowExhaust
Temp
Indicatestheexhausttemperatureisbelowthecalculatedminimumallowable
temperature,whichisbasedontheamountofmoistureinthereturnair(measured
orestimated)andtheambienttemperature.
BadSensor Shortedoropensensorindication.
VentMode Wheelwillbestopped.Nocallforheatingorcooling.
DischargeTooHot Wheelisslowingdownduetoexcessiverecoveryofheat.
FrostMode Heatwheelrotationspeedisreducingtopreventfrostaccumulation.
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ADJUSTMENTPOTS
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Thereareanumberofsettingandcalibrationpotentiometers(POT’s)locatedonthefaceoftheW‐TRAC.
Modificationstotheseshouldonlybedonebyexperiencedandqualifiedpersonnel.

POT Description
DISCAL Dischargetemperaturesensorcalibration.
EXCAL Exhausttemperaturesensorcalibration.
AMBCAL Ambient/outdoortemperaturesensorcalibration.
BDRH PredicteddesignreturnairRH%scale(1‐4).

TEMPERATURECONTROL
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TheW‐TRAChas4modesofoperation;Heat,Defrost,VentandCool,thatcontrolsthewheelrotational
speedtoachievethedesiredtemperaturesetpointofsupplyairleavingthewheel.

Whentheoutsideairiscolderthantheexhaustair,theheatwheelwillrotatetocaptureheatfromthe
exhaustairsideandtransferittothesupplyairstream.Increasingtherotationspeedwillincreasethe
amountofheattransferred.

Iftoomuchheatisbeingremovedfromtheexhaustairstreamitispossibleforfrosttoaccumulateonthe
faceoftheheatwheel.TheW‐TRACwillautomaticallyreducetherotationspeedtopreventfrosting.

Ifnoheatingisrequired,theW‐TRACwillstopthewheelrotationandenter‘ventmode’.


AW-TRAC
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
IOM‐49 8of12 Mar99R4


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IftheoutsideairtemperatureiswarmerthantheexhaustairtheW‐TRACwillenter‘coolmode’and
rotatetheheatwheeltotransferheatfromtheoutsideairtotheexhaust.

BASESETPOINT
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TheW‐TRACisdesignedtobeadischargeairtemperaturecontroller.Thebasedischargeairtemperature
issetfromthesetpointcontrolknoblocatedonthefaceoftheW‐TRAC.

SETPOINTRESET

Thebasedischargeairtemperatureisoftenmodifiedfromaremotesignaltomaintainthedesired
temperatureofthesuppliedspace.Thisiscalledreset.TheW‐TRACdischargetemperaturecanbereset
fromavarietyofsourcesusinga0‐10VDCsignal.

AnoffsettotheBMSinputrangecanbeimplementedbyaddinga7.5kresistorinserieswithterminalS.
Thefollowingtabledescribesthechangeofdischargesetpointfromtheinputvoltage(toterminalsS+and
C1‐),withasetpointfixedat66°F.Refertotheequipmentfunctionpageforthedesignresetrange.

 InputVoltage
 0.0 2.0 4.0 6.0 8.0 10.0
Discharge
Setpoint(°F/°C)
NoResistor 30/‐1 40/4 45/7 52/11 60/15 66/19
7.5kResistor 48/9 53/12 56/13 59/15 63/17 66/19


FROSTCONTROL

Frostshouldnotbeallowedtobuilduponthewheel.Itisnecessarytoreducetheamountofheat
recoveredwhentheoutsidetemperatureisbelowthefreezingpoint(0°C/32°F)andtheexhaustleaving
temperaturefallstoapointthatfrostcanbegintoform.Frostmaydamagethewheelandreduceairflow.

Operatingtheheatwheelclosetothefrostthresholdtemperaturewillprovidemaximumenergyrecovery.
Thereare3differentmethodsofprovidingfrostcontrol,allofwhichreducetheheatwheelrotation
speed.

EXHAUSTAIRRH%SENSOR

ThismethodofcontrolrequiresahumiditysensorconnectedacrossterminalsEXHandC2.DIP1and3
mustbeOFF,DIP2mustbeON.Thesensorisinstalledintheexhaustairsection,justaftertheheat
wheel.
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AW-TRAC
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IOM‐49 9of12 Mar99R4
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Whentheoutdoorambienttemperatureisbelow15°F(‐10°C)thespeedoftheheatwheelwillbereduced
tomaintaintheleavingexhaustairhumiditybetween80–90%.Thisapplicationrequireshighaccuracy
humiditysensors.
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RETURNAIRRH%SENSOR
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ThismethodoffrostcontrolrequiresaRHsensorinstalledintheequipmentreturnairsection,justbefore
theheatwheel,wiredintoterminalsRMHandC2.DIP3mustbeON,DIP1and2mustbeOFF.
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UsingthevaluesoftheRHandambient(outsideair)sensor,theW‐TRACcalculatestheminimum
allowableexhaustairtemperaturethatwillkeepfrostfromformingonthewheel.
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BDRHPREDICTEDRETURNAIRRELATIVEHUMIDITY
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RH%sensingisnotusedinthismethodoffrostcontrol.DIP1and3mustbeON,whileDIP2isOFF.
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TheW‐TRACmayoperatewithouttheuseofhumiditysensinginsituationswheretheRH%valuesare
expectedtobereasonablyconstant.Inthesecases,theW‐TRACoperatesbysensibletemperatureonly.
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Whenenabled,theBDRHpot(BuildingDesignRelativeHumidity)issetaccordingtotheexpecteddesign
returnairconditions.RefertothetablebelowtosettheexpectedvaluesbasedontemperatureandRH%.
Table1
BDRHsetting ReturnAirConditions
70°F(21°C) 75°F(24°C) 80°F(27°C)
1 <25% <21% <18%
2 26–32% 22–27% 19–23%
3 33–39% 28–33% 24–27%
4 40–49% 34–42% 28–35%
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Tousethistable,firstselectthereturnairtemperature,thenselecttheRH%rangeinthecolumnbelow,
thenselecttheBDRHsettingtotheleft.
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WIRING
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TheW‐TRACterminalsHandNrequireaminimum24VAC,40VAclass2powersupplythatdoesnotneed
tobeisolatedfromtherestofthesystemscomponents.
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TerminalNshouldbewiredtothecommonofthesamesourcesupplyingpowertoterminalsE,A,andK.
Allremotewiringshouldbeinstalledinaclean(noelectricalnoise)environment.Wiresizeshouldbea
minimumof24ga.twistedpairtoreduceelectricalnoise(shieldedwireisrecommended).Forlongerruns

AW-TRAC
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IOM‐49 10of12 Mar99R4
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(over50ft.eq.length),theuseofaminimum20gauge‐shieldedwireisrecommended.Theshieldshould
begroundedatthecontrollerendonly,withtheotherendtaped.
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Itisimportanttoensurecorrectpolaritywhenwiringintothesystem.
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NOTE:Fieldanalogcontrolinputsrequiresignalisolationtopreventgroundloop
signalcorruptionand/ordamagetothecontroller(s).
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SERVICENOTES
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ROTATION
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Mostheatwheelshaveapurgesectiontopurgeexhaustairtrappedinthewheelflutesbeforetheyrotate
tothesupplyairside.Thecorrectwheelrotationdirectionisnotedonthefaceoftheheatwheel.Drive
motorrotationmaybechangedatthemotorwireconnectionsorontheinverterdrivefeedingthemotor
(ifused).
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MOTORSPEEDCONTROL
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Themodulating0‐10Vdcmotorspeedoutputmaybeconnectedtoavarietyofcontrollersand/or
inverters.Refertotheequipmentwiringdiagramforconnectiondetails.Thefollowingsetupparameters
aretypical.Alwaysrefertotheequipmentfunctionsheetforanychanges.Toensurepropersetup
operation,donothaveDIP4andDIP5onatthesametime.
KBVF/SIVF(R)
TheKBVFinverterdriveandSIVFsignalisolatoraremanufacturedbyKBElectronicsInc.Theinverterand
isolatorinstallationandoperationmanualsareincludedintheinformationpackage,originallylocatedin
themainequipmentelectricalpanel.The0‐10VdcW‐TRACcontroloutputfeedsintotheSIVFsignal
isolatorwhich,inturn,feedsanisolated0‐5VdcsignaltotheKBVFinverterdrive.
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HighSpeed
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TurnonW‐TRACDIP4toforcetheW‐TRACtomaximumoutput(near10Vdc).Notethatifthe
W‐TRACisoperatinginfrostmodeDIP4willnotallowthedrivetogotofullspeed.Measurethemotor
ampsandconfirmthereadingsarelessthanthemaximummotorampacity.Ifpossible,measureand
confirmtheoutputfrequencyis60Hz.
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TheKBVFisfactorysetto100%ofratedfrequency(60Hz)andshouldnotbeadjusted.
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AW-TRAC
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IOM‐49 11of12 Mar99R4
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LowSpeed
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TurnonDIP5todrivetheoutputtominimum(0Vdc).AdjusttheminimumspeedpotontheKBVF
inverterdriveuntiltheheatwheeljustbeginstoturn,usuallybetween0.5and2rpm.Turnthepoweroff,
andthenrestartthesystemtoconfirmthemotorhasenoughstartingtorquetoreliablystartrotatingthe
heatwheel.
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ReturnallDIPswitchestotheiroriginalposition.
WHEELROTATIONSPEED
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Maximumwheelrotationspeedwillbefactorysetintherangeof30‐40rpm,at60Hz,dependingonthe
sizeoftheheatwheel.
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Minimumwheelspeedisdependentonthestartingtorqueofthemotorandheatwheel,usuallybetween
0.5and2rpm.
SENSORCALIBRATION
DischargeTemperatureCalibration
Removethesupplyairtemperaturesensorandmeasureboththesensorresistanceandthetemperature
atthesensingelement.Comparethesereadingstothesensortablevalues.Iftheresistanceisoutby
morethan16ohms,replacethesensor.
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 Measuringasensortemperaturebetween60–70°F,slowlyrotatethetemperaturesetpointdial
counterclockwiseuntilthe‘DischargeTooHot’lightjustcomeson.
 Slowlyincreasethetemperaturesetpointdialuntilthelightgoesoff.
 Thesetpointshouldmatchthesensedtemperaturemeasurement.Ifnot,adjustthecalibrationpot
andrepeattest.
ExhaustTemperatureCalibration
Removetheexhaustairtemperaturesensorandmeasureboththesensorresistanceandthetemperature
atthesensingelement.Comparethesereadingstothesensortablevalues.Iftheresistanceisoutby
morethan16ohms,replacethesensor.The‘badsensor’LEDmayturnonandoffduringthisprocedure.
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 PlaceajumperwireacrossterminalsAandC1.
 Removetheexhausttemperaturesensorandreplacewitha909Ωresistor.
 NotethepositionoftheBDRHpot,andthenadjusttoposition2.

AW-TRAC
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IOM‐49 12of12 Mar99R4
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 Slowlyrotatepot#2counterclockwise(EXCAL))untilthelowexhausttemperaturelightcomeson.
 Slowlyrotatepot#2clockwiseuntilthelowexhausttemperaturelightjustturnsoff.
 ReconnectallsensorsandsetpotBDRHbacktoitsoriginalposition.
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Humiditysensors
AccuratelymeasuretherelativehumidityatthesensorlocationandcomparetothesensorVdcoutput.
The0‐10Vdcoutputisproportionalto0‐100%RH.
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SENSORTABLE
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SensorResistanceChartforTE6000EA3
Table2
°C °F Resistance°C °F Resistance°C °F Resistance
‐40 ‐40 602 18.3 65 983 48.9 120 1234
‐34.4 ‐30 633 20 68 996 54.4 130 1269
‐28.9 ‐20 665 20.6 69 1000.7 60 140 1333
‐23.3 ‐10 698 21.1 70 1005 65.5 150 1365
‐17.8 0 732 23.9 75 1026.5 71.1 160 1437
‐12.2 10 768 26.7 80 1048 76.7 170 1491
‐8.7 20 804 29.4 85 1070 82.2 180 1546
‐1.1 30 842 32.2 90 1092 87.7 190 1602
4.4 40 881 35.6 95 1116 93.3 200 1659
10 50 921 37.8 100 1139 98.8 210 1718
12.8 55 942 43.3 110 1186 100 212 1778
Referenceresistanceis1035ohmsat77°F.Resistancetolerancesare±0.05to0.15%at77°F.Temperature
range+32to+104°F.
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