Vortex Combo-pac CP30 User manual

Controls User Manual
Combo-pac™
hot water air handler
with iStat6 electronic controller
Vortex Source Systems
Cambridge, Ontario
Phone: [phone]
Fax: [phone]
[e-mail]
www.vortexsource.com

Controls User Manual – Combo-pac
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Table of Contents
Controller Basics .................................................................................................. 3
Table Status Messages .................................................................................... 3
Table 2 Display Icons .......................................................................................... 3
Controller Keypad ................................................................................................. 4
USER MODE ........................................................................................................ 4
ADMIN MODE ............................................................................................... 4
Initial Controls Setup ............................................................................................. 5
Cycle Timer (Pump Exerciser) ............................................................................. 6
Cooling Control Mode .................................................................................... 6
Two-Stage Air-Conditioning ................................................................................. 7
Freeze Protection .......................................................................................... 7
Troubleshooting .................................................................................................... 8
Table 3 User Mode .............................................................................................. 0
Table 4 Admin Mode ...........................................................................................

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This document describes proper setup and use of the electronic controller for the Vortex
Combo-pacTM air handler with the iStat6 controller. Although the system will function
when left at factory default settings, it is recommended that the installer read through
this short manual in order to ensure the system has been setup to match the required
heating and cooling loads and air-conditioning equipment installed, and to take
advantage of the various features available.
Controller Basics
The controller automatically adjusts blower motor speeds and engages relays for
control of the system components. Through its LCD display and keypad, important
system parameters may be configured and operating conditions may be monitored.
When the controller keypad has not been pressed for a few minutes, the backlight will turn
off and the display may go blank. Simply press any one of the buttons to wake up the
controller. By default, the controller will display a short message describing the operating
status of the system. Table 1 provides a list of the different possible status messages and
their meaning. There are also a number of small icons that may appear around the edges
of the display according to the current operating status. Table 2 gives an explanation of the
different icons.
Table 1 - status messages
Message
Meaning
NO CALL System is not currently receiving a call, all functions are off.
HEATING There is currently a call for heating
COOLING There is currently a call for cooling
FanOnly There is currently a call for continuous fan only and no heating or cooling
TST ERR Thermostat error (simultaneous heating & cooling calls). Check wiring & ensure
heat/cool thermostats are used
FROZEN Supply air is too cold, freeze protection has been activated. Compressor calls
will be suspended until temperature rises and time delays are satisfied
TEST Pressing the button on the bottom of the control will operate the fan and pump for
20 seconds to verify operation. After 20 seconds, it returns to normal.
Table 2 - display icons
Icon
Meaning
Flame
system is in heating mode
Snowflake
system is in cooling mode
4
-
blade fan
blower is running
at or
below 50%
8
-
blade fan
blower is running above 50%

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Controller Keypad
By using the option and setting keys, different parameters and their current settings
may be displayed and modified. Use the outer option keys to scroll through the
available parameters, and use the inner setting keys to modify the parameter’s current
setting (if available). By default, the control will remain in ‘user’ mode, in which a
limited selection of parameters may be accessed. By entering ‘admin’ mode, additional
parameters may be made available. Please exercise caution while in ‘admin’ mode, as
these settings are meant to be accessed by the experienced user or installing
contractor. A description of each of the modes is found below.
USER MODE
This is the basic display and operating mode, in which only a limited selection of parameters
may be displayed. Refer to Table 3 for a description of each item displayed.
ADMIN MODE
This is the advanced display and configuration mode. It is intended only for the properly
trained contractor. To enter ‘admin’ mode, press any button to illuminate the display
backlight, then press and hold the two option (outer) buttons at the same time (‘user’ will
be displayed at first, hold until ‘admin’ is displayed). You can now scroll through the
display items by using the outer two option buttons, and adjust certain values using the
inner two setting buttons. To return the control to ‘user’ mode simply wait a few minutes
or press and hold both option buttons.
Use Table 4 as a quick reference on the items available in this mode. Detailed descriptions
on important parameters are found below.

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Initial Controls Setup
When first powering up the Combo-pac air handler during commissioning, enter
‘admin’ mode on the controller and adjust the following settings to match the
installed equipment.
MODEL – the model number of the Combo-pac air handler. Options are CP30,
CP63, CP70, CP80 and CP 00. This is used to set maximum airflow based on fan
and motor capacity. This will be preset in the factory but should be verified by the
installer. Refer to the table below.
Model Max. Tonnage Max. Airflow
(cfm)
CP30 2 800
CP63 3 200
CP70 3 /2 400
CP80, CP 00 5 800
AC_Size – the capacity (in tons) of the air-conditioning equipment. This setting impacts
the amount of airflow when the system is in cooling mode. If a two-stage air-conditioner
is installed, use the nominal (full capacity) tonnage. If air-conditioning is not installed, it
is recommended to set this to match the maximum capacity of the Combo-pac air
handler (i.e. CP30 = 2 tons, CP80 = 5 tons). Refer to the table above. Caution!: An
improper setting may result in coil freeze, excess noise or poor performance.
ContFan – the amount of airflow used for a continuous fan call, as a
percentage of the maximum system airflow. The default setting is 50%.
HeatS d – Heating speed control mode, options are “fixed” and “auto”. In fixed
mode, heating calls will always run at HeatMax. In auto mode, heating will vary
between HeatMin and HeatMax depending upon the previous heating call speed
and time to satisfy the heating call.
HeatTim – Target length of time of a heating cycle. The default is 5 minutes.
Longer time will reduce fan speed for typical heating calls.
HeatMAX – maximum heating airflow, as a percentage of the maximum system
airflow. Lower settings will mean longer heating cycles and improved air
distribution throughout the home but reduces total heating capacity. Default
setting is 00%.
HeatMIN – minimum heating airflow, as a percentage of the maximum system
airflow. Default is 25%. Used only when heating is in automatic mode. Note that

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a low value can improve comfort and reduce noise but may cause insufficient
heating at the farthest duct runs.
PreHeat – Length of time in seconds that the fan will run at half speed at the start of each
heating cycle. Default is 30 seconds. This can improve comfort by pre-heating the coil with
hot water.
PstHeat – Length of time in seconds that the fan will run at half speed at the end of each
heating cycle. Default is 30 seconds. This can improve efficiency by delivering residual heat
in the water coil to the rooms.
Cycle Timer (Pump Exerciser)
The Combo-pac includes an optional cycle timer or pump exerciser feature which may
need to be enabled depending on the hot water source and local regulations. When
enabled, the cycle timer will run the heating circulating pump for 30 seconds every 24
hours.
Pum Exr – Pump Exerciser (Cycle timer) mode. Set to to enable, 0 to disable.
Pump exerciser is disabled by default.
Cooling Control Mode
There are two modes of operation available for controlling cooling airflow: “fixed” and
“auto”. Descriptions for each mode are found below.
CoolS d – Cooling speed control mode, options are “fixed” and “auto”. Controls are
in “fixed” mode by default.
In “fixed” mode, the cooling airflow will operate at 420cfm per ton for single stage
AC.
In “auto” mode, the airflow will adjust to maintain the supply air temperature at the
chosen cooling setpoint (CoolTm ). This mode can provide better control of indoor
comfort, helping to ensure adequate dehumidification is taking place. Caution: for
proper operation, the supply air temperature sensor must be installed downstream of
the cooling coil and measuring well-mixed air. Note that the cooling airflow will
always be maintained between 270 and 420 cfm per ton of air-conditioner capacity
(AC_Size).
CoolTm – The cooling setpoint temperature for auto cooling mode. Default setting
is oC (52oF). Lower setpoint temperatures will lead to lower airflow, increased
dehumidification and comfort, but may decrease overall cooling capacity and
efficiency.
PreCool – Length of time in seconds that the fan will run at half speed at the start of each

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cooling cycle. Default is 0 seconds. This can improve comfort by pre-cooling the AC coil.
Caution - excessive time may cause coil freeze-up.
PstCool – Length of time in seconds that the fan will run at half speed at the end of each
cooling cycle. Default is 30 seconds. This can improve efficiency by using residual cooling in
the AC coil.
PID_PROP, PID_INT, PID_DB, PID_RAMP – These settings are the proportional,
integral, deadband, and ramp rate used for the P.I.D. cooling speed control when in
auto mode. It is recommended that these settings only be changed by someone who
has a firm understanding of P.I.D. control schemes and only if the response rate of the
fan is unsatisfactory. Contact Vortex if you believe there’s an issue with these settings.
Two-Stage Air-Conditioning
An output is available on the low-voltage terminal strip for the control of a two-stage
air-conditioner. When a cooling call is present, the air conditioning compressor will
initially be activated in first stage (low). If the cooling call continues beyond time
AC2Time, second stage will be activated for the remainder of the cooling call. Note
that maximum and minimum airflows are automatically reduced to 2/3 during first
stage operation whether cooling is in fixed or auto mode.
AC_2STG – Turn ON if a 2-stage air conditioner is present.
AC2Time – The time, in minutes, in which 2nd stage is activated, set by default to
20 minutes. Decreasing this value will cause 2nd stage to be activated sooner,
leading to full capacity.
Freeze Protection
In order to prevent the heat exchanger coils from freezing during cooling, the air
handler includes a freeze protection feature. If the measured supply air temperature
drops below the freeze protection temperature FRZ_TMP, the signal to the air-
conditioner contactor is interrupted. In order to prevent short-cycling of the
compressor, this feature includes two settable delay intervals: FrzDly1 sets the amount
of time the supply air temperature has to remain below FRZ_TMP before the alarm is
triggered; and FrzDly2 sets the amount of time until the compressor is allowed to come
back on, once the supply air temperature has returned to above FRZ_TMP. Note: This
feature will only turn off the AC compressor signal. It will not protect the home or air
handler from freezing house temperatures or improper fresh air connections such as
from a heat recovery ventilator.
FRZ_TMP – The freeze protection setpoint temperature. Default value is 3 °C.
Lowering this value will decrease sensitivity of the freeze protection feature.
FrzDly1 – Amount of time (in minutes) to wait before acknowledging a freeze
protection condition. Default setting is 3 minutes. Increasing this value will decrease

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sensitivity of the freeze protection feature.
FrzDly2 – Amount of time in minutes to wait before bringing the A/C compressor back
on, once the measured supply air temperature has returned to a safe value. Default
setting is 2 minutes.
Troubles ooting
Warning: The homeowner can diagnose many issues from the main controller on the front of
the air handler but any diagnostics or servicing inside the air handler (blower compartment)
should only be performed by a qualified service person. High voltages are resent.
No Dis lay – If pushing one of the four front buttons does not refresh the display, there may
be no power to the air handler, or the transformer has failed or the controller has failed.
Thermostat calls – The status screen (default) will show heating, cooling or continuous fan
calls detected from the thermostat (Table ). Using the outer keys, the user can scroll
through the screens to see individual thermostat calls and fan speed (Table 3).
If a thermostat is calling but not detected by the control:
. Check the thermostat and its connections
2. Check thermostat wiring at the thermostat and air handler.
3. Check the 4/8gang relay indicator lights.
W , Y and G are connected directly from
the thermostat terminal strip. The 4/8 gang
relay converts 24vac thermostat signals to
digital signals for input to the iStat6 controller.
If the lights are on but the controller does not
respond, the problem is the wiring to the
control or the control has failed.
No Heating – Try Test Mode first – pushing the button on
the bottom (underneath) of the control will run the pump and
fan for 20 seconds. Pipes should get warm and fan should
run. No pump – check the pump relay for a 24vac signal from the control, wiring and pump.
No Cooling - Check for 24vac at the terminal strip Y -OUT. If not, check wiring to and from
control and control.
No Blower - The fan can be tested from 0- 00% by placing the primary thermostat in FAN
ON (or jumper R to G) with no heat or cool call. Then, adjust ContFan up and down within
ADMIN mode. It should modulate smoothly from % to 00% and off completely at 0%. If it

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fails to run, check wiring from controller to motor speed control, motor speed control, wiring to
motor and motor.
Blower motor never fully sto s, even with no demand signal
Ensure control displays NO CALL. If not, check thermostat settings and
thermostat wiring.
Ensure the blower motor speed control board has a jumper installed across the
terminals labeled “P”. The motor speed control board and the jumpers are shown
below.
Note: The green signal light of the EVO motor control flashes according to its speed
output to the motor. Ex. 5 long 3 short blinks = 53%
Note: Newer combo-pac models do not use the EVO control (p/n XELK7 0 + harness
XELK7 2). The new wire harness (p/n XECM77) is sealed, no lights and not
serviceable.
Too much airflow, causing noise
This can occur due to undersized ductwork, dirty filter or improper setup of the air
handler heating/cooling loads. Note that Model, HeatMAX and AC_Size determine
airflows. Installing a 2-stage air conditioner will reduce the cooling airflow most of the
time.
Alarm message “TST ERR”
There is a simultaneous call for heating and cooling, indicating an error with
thermostat wiring or setup. Ensure that the thermostat is wired as per the Installation
Instructions, and configured for heat / cool systems. Combo-pac air handlers that
will run on 2 heat/ 2 cool thermostats are available by special order.

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Not enough humidity removal in cooling mode
The air handler controls humidity during cooling through use of the “auto” cooling
speed mode (set CoolS d to “auto”). See the Cooling Control Mode section above.
Su ly or return air tem erature (SA_TMP or RA_TMP) reads -50 °C
This indicates the supply air temperature sensor is not properly connected to the
controller. Ensure that the sensor is connected as per the wiring diagram found in the
Installation Instructions and that no wires have become loose. RA_TMP is not used
and can be ignored. A failed supply air temperature sensor will put the system into
freeze protection.
Freeze rotection errors (alarm message “FROZEN”)
This usually occurs when there is inadequate airflow for a given air-conditioner.
 Ensure that the air filter is not plugged and all ductwork is open
 Ensure the setting Model matches the air handler model and AC_Size has
been selected to match the installed air-conditioner capacity
 Ensure supply air temperature sensor is located after cooling coil and in the
supply air stream, not touching the coil, heat source, plumbing, etc.
 Ensure the cooling setpoint temperature CoolTm is not set too high
 Decrease sensitivity of the freeze protection feature (see Freeze Protection above)
Table 3 User Mode (default)
Line Line 2 Set. Type Description Default
ComboPac #### D Display Display status of system NO CALL
W _Heat (0)Off/( )On D Input Thermostat heating input (ON/OFF)
Y _Cool (0)Off/( )On D Input Thermostat cooling input (ON/OFF)
SA_TMP ###.# C D Input Supply air temperature
RA_TMP ###.# C D Input
Return air temperature (display only, not used in
calcs.)
FAN_Spd #### % D calc Fan speed as a percentage
ComboPac ##.## REV D Display Program name and revision number . 0
* note: "D" in set. indicates variable is for display only and is not
settable

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Table 4 Admin Mode
Line Line 2 Set. Type Description Default
ComboPac #### D Display Display status of system NO CALL
W _Heat (0)Off/( )On D Input Thermostat heating input first stage (ON/OFF)
Y _Cool (0)Off/( )On D Input Thermostat cooling input first stage (ON/OFF)
MODEL #### Setting Set air handler model. Select from list. CP30
AC_SIZE ####
Text
Setting
Capacity of air-conditioner in tons, select from available
choices.
SA_TMP ###.# C D Input Supply air temperature
RA_TMP ###.# C D Input Return air temperature (display only, not used in calcs.)
FAN_Spd #### % D calc Fan speed as a percentage
ContFan #### % Setting Continuous Fan airflow as a percent of maximum. 50
HeatSpd #### Setting Set heating fan speed as fixed or automatic FIXED
HeatTim #### min. Setting Ideal heating cycle time in minutes 5
HeatMAX #### % Setting Maximum heating airflow as a % of blower maximum 00
HeatMIN #### % Setting Minimum heating airflow as a % of blower maximum 25
PreHeat #### sec Setting
Time fan runs at half speed at beginning of heating call
in seconds 30
PstHeat #### sec Setting
Time fan runs at half speed at the end of a heating call
in seconds 30
PumpExr (0)Off/( )On Input Daily pump exerciser ON/OFF OFF
CoolSpd #### Setting Set cooling fan speed as fixed or automatic FIXED
CoolTmp #### C Setting
Supply air temperature setting for automatic cooling
mode
PreCool #### sec Setting
Time fan runs at half speed at beginning of cooling call
in seconds 0
PstCool #### sec Setting
Time fan runs at half speed at the end of a cooling call in
seconds 30
AC_2STG (0)Off/( )On
Text
Setting Is the air conditioner condenser 2 stage? 0
AC2Time #### min Setting Time to activate 2nd stage cooling. 20
FRZ_TMP #### C Setting Freeze alarm setpoint temperature 2
FrzDly #### min Setting Freeze Delay - wait time to activate freeze alarm 3
FrzDly2 #### min Setting
Freeze Delay 2 - wait time to restore operation after a
freeze alarm 2
PID_PROP ###.# %/C Setting Cooling PID Proportional value 3
PID_INT
##.##
%/sec/C Setting Cooling PID Integral value 0.2
PID_DB ###.# C Setting Cooling PID Deadband value 0.5
PID_RAMP ###.# %/sec Display Cooling PID Ramp Rate value 5
ComboPac ##.## REV D Input Program name and revision number . 0
Modbus #### Setting Modbus address 36