Page 1 ROOFTOP DEDICATED OUTDOOR AIR SYSTEMS (DOAS) INSTALLATION AND OPERATION MANUAL GEN2 Series (AR-DR) Base Rooftop DOAS 500 to 18,000 CFM GEN2 Series (AR-DE) Energy Recovery Wheel Rooftop DOAS 1,000 to 18,000 CFM...
Page 2: General Safety Information
Installation, Operation and Maintenance Manual Please read and save these instructions for future reference. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with these instructions will result in voiding of the product warranty and may result in personal injury and/or property damage.
Page 3: Table Of Contents
Table of Contents General Safety Information------------------------------------------------------------------------------------------------2 Unit Nomenclature-----------------------------------------------------------------------------------------------------------8 General Data------------------------------------------------------------------------------------------------------------------9 Receiving, Handling, Storage---------------------------------------------------------------------------------------------16 Product Overview------------------------------------------------------------------------------------------------------------18 - Cooling - Heating - Airflow Arrangement - Safety Listing - Models and Capacities Subassemblies---------------------------------------------------------------------------------------------------------------19 Installation Typical Unit Weights and Dimensions----------------------------------------------------------------------------------21 Service Clearances ---------------------------------------------------------------------------------------------------------22 Additional Clearances for Packaged DX-------------------------------------------------------------------------------23 Handling Concerns for Units with Package DX ----------------------------------------------------------------------23 Lifting----------------------------------------------------------------------------------------------------------------------------23 Roof Curb Mounting---------------------------------------------------------------------------------------------------------24...
Page 4 - VFD Compressor - Frost Control - Rotation Sensor - Dirty Filter Sensor - Microprocessor Control - Unoccupied Recirculation Damper - Vapor Tight Lights - Hot Gas Bypass Valve - Hot Gas Reheat Valve Factory-Installed Refrigeration System Components----------------------------------------------------------------28 Start-Up – Unit-----------------------------------------------------------------------------------------------------------------29 - Model and Serial Number - Pre-Start-Up Checklist - Special Tools Required...
Page 5 Routine Maintenance-----------------------------------------------------------------------------------------------------------56 - Monthly - Semiannually - Annually - Units with Packaged DX, Semiannually Maintenance Procedure-------------------------------------------------------------------------------------------------------58 - Lubrication - Dampers - Gas Furnace - Fan Motors - Fan Wheel and Fasteners - Internal Filter Maintenance - External Filter Maintenance - Coil Maintenance Reference -------------------------------------------------------------------------------------------------------------------------60 - Venting Connection Locations - Rated Airflow...
Page 6 - Gas Supply Requirements - Connect the Supply Gas Line - Installation of Additional Regulator - Test the System for Leaks - Gas Pressure Test Ports Sequence of Operation----------------------------------------------------------------------------------------------------------76 - Start-Up / Standby - Heat Mode - Recovery from Lockout Performance Data-----------------------------------------------------------------------------------------------------------------76 Start-Up –...
Page 7 Sequence of Operation ---------------------------------------------------------------------------------------------------------------131 Large Controller Overview -----------------------------------------------------------------------------------------------------------136 Medium Controller Overview --------------------------------------------------------------------------------------------------------137 Expansion Board Overview ---------------------------------------------------------------------------------------------------------138 Furnace Overview 139 Controller Set-Points Data Tables ----------------------------------------------------------------------------------------------------------------140 Network Settings Data Tables -------------------------------------------------------------------------------------------------------147 Alarm Data --------------------------------------------------------------------------------------------------------------------------------151 BACnet and MODBUS Points -------------------------------------------------------------------------------------------------------155 Unit Status Modes ----------------------------------------------------------------------------------------------------------------------167 Lon Talk Points --------------------------------------------------------------------------------------------------------------------------168 Appendix A: Remote Display ---------------------------------------------------------------------------------------------------------171 Appendix B: I/O Expansion Board Quick Start -----------------------------------------------------------------------------------172...
Page 8: Unit Nomenclature
Unit Nomenclature Family AR = Air-Source Packaged Rooftop Unit, R410A Refrigerant Type D = Dedicated Outdoor Air System (DOAS) ERV Option R = Base Unit E = Energy Recovery Wheel Chassis Size 02 =12 12 = 112 22 = 212 311 = 311 35 = 352 Cooling Capacity...
Page 9: General Data
GENERAL DATA Base Rooftop DOAS Table 1: Base Rooftop DOAS Model No. AR-DR02-03A AR-DR02-04A AR-DR02-05A AR-DR02-06A AR-DR02-07A Design Airflow (CFM) 1,050 1,240 ESP (in. wg) Entering Air Summer 95/75 95/75 95/75 95/75 95/75 DB/WB (°F) Entering Air Winter DB (°F) Cooling Performance Coil LAT DB/WB (°F) 54.9/54.8...
Page 10 GENERAL DATA Base Rooftop DOAS Table 1: Base Rooftop DOAS Model No. AR-DR12-05A AR-DR12-07A AR-DR12-10A AR-DR12-12A AR-DR12-15A Design Airflow (CFM) 1500 1800 2250 2900 ESP (in. wg) Entering Air Summer 95/75 95/75 95/75 95/75 95/75 DB/WB (°F) Entering Air Winter DB (°F) Cooling Performance Coil LAT DB/WB (°F) 54.8/54.7...
Page 11 GENERAL DATA Base Rooftop DOAS Table 2: Base Rooftop DOAS, continued. Model No. AR-DR22-15A AR-DR22-17A AR-DR22-20A AR-DR22-25A AR-DR22-30A Design Airflow (CFM) 2900 3200 3700 4600 5100 ESP (in. wg) Entering Air Summer 95/75 95/75 95/75 95/75 95/75 DB/WB (°F) Entering Air Winter DB (°F) Cooling Performance Coil LAT DB/WB (°F) 54.8/54.6...
Page 12 GENERAL DATA Base Rooftop DOAS Table 3: Base Rooftop DOAS, continued. LG Model AR-DR31125A AR-DR31130A AR-DR31135A AR-DR31143A Design Airflow (CFM) 5,000 5,950 7,050 7,950 ESP (in. wg) Entering Air Summer DB/WB (°F) 95/75 95/75 95/75 95/75 Entering Air Winter DB (°F) Cooling Performance Coil LAT DB/WB (°F)
Page 13 GENERAL DATA Base Rooftop DOAS Table 4: Base Rooftop DOAS, continued. LG Model AR-DR35-30A AR-DR35-40A AR-DR35-50A AR-DR35-60A AR-DR35-70A Design Airflow (CFM) 5,200 6,700 8,500 9,800 12,000 ESP (in. wg) Entering Air Summer DB/WB (°F) 95/75 95/75 95/75 95/75 95/75 Entering Air Winter DB (°F) Cooling Performance Coil LAT DB/WB (°F)
Page 14 GENERAL DATA Energy Recovery Wheel Rooftop DOAS Table 5: Energy Recovery Wheel Rooftop DOAS. LG Model AR-DE12-05A AR-DE12-07A AR-DE12-10A AR-DE12-12A AR-DE12-15A Design Airflow (CFM) 1700 2600 2950 3700 4150 ESP (in. wg) Entering Air Summer DB/WB (°F) 95/75 95/75 95/75...
Page 15 GENERAL DATA Energy Recovery Wheel Rooftop DOAS Table 6: Energy Recovery Wheel Rooftop DOAS, continued. Model No. AR-DE22-15A AR-DE22-17A AR-DE22-20A AR-DE22-25A AR-DE22-30A Design Airflow (CFM) 5000 5510 6300 6750 7450 ESP (in. wg) Entering Air Summer DB/WB (°F) 95/75 95/75 95/75 95/75 95/75...
Page 16 GENERAL DATA Energy Recovery Wheel Rooftop DOAS Table 7: Energy Recovery Wheel Rooftop DOAS, continued. LG Model AR-DE31125A AR-DE31130A AR-DE31135A AR-DE31143A Design Airflow (CFM) 9,150 10,500 12,200 13,000 ESP (in. wg) Entering Air Summer DB/WB (°F) 95/75 95/75 95/75 95/75 Entering Air Winter DB (°F)
Page 17 GENERAL DATA Energy Recovery Wheel Rooftop DOAS Table 8: Energy Recovery Wheel Rooftop DOAS, continued. LG Model AR-DE35-30A AR-DE35-40A AR-DE35-50A AR-DE35-60A AR-DE35-70A Design Airflow (CFM) 9,400 11,600 13,500 16,000 17,500 ESP (in. wg) Entering Air Summer DB/WB (°F) 95/75 95/75...
Page 18 Receiving Outdoor This product may have been subject to road salt during The unit should be placed on a level surface to prevent transit. If so, immediately wash off all visible white water from leaking into the unit. The unit should be residues from all exterior surfaces.
Page 19: Product Overview
Product Overview A horizontally conﬁgured High Percentage Outdoor Air Airﬂow Arrangement unit designed for installation either indoors or The unit is capable of Constant Air Volume (CAV), outdoors. Each unit has multiple options for cooling Variable Air Volume (VAV), 100% Outdoor Air and have and/or heating.
Page 20: Subassemblies
Subassemblies Filters – Blower - Either one or two plenum-type fans. All units Supply All housings are available with a filter are equipped with a plenum fan for Supply Air and a bank depth of either 2 or 4-inch. second may be selected for Exhaust (Relief) Air. Indirect Gas-Fired Furnace - Furnace model PVG is Coils -...
Page 21 Open view of Model AR-DE showing optional condenser coil, fans and energy recovery wheel. Low Sound Condenser Fans (optional) Energy Wheel (AR- DE) (optional) Outdoor Air Filters (pre-wheel) Condenser Coils Weather-hood Filters (optional) (metal mesh) Outdoor-Air Damper Packaged DX Plenum-Type Compressors Exhaust Air Blower (optional)
Page 22: Installation
Installation Typical Unit Weights and Dimensions Component Access Optional Inverter Compressor Optional Compressor/Electrical Optional Gas Furnace/Optional Electric Heater Electrical Supply Blower Coil Filters Exhaust Blower/Optional Electric Preheat Powered Exhaust Blower Section * When a powered exhaust fan (or XVE) is selected, door 8 will be to the immediate right of door 7.
Page 23 Installation Typical Unit Weights and Dimensions Nominal Nominal Condensing Unit Height Width Length Intake Outdoor Supply Return Exhaust tonnage weight Section Size Intake Discharge Intake Discharge (tons) (lbs.) Bottom 58.1 44.0 22.3 1,180 82.2 DR02 or End 5-15 59.3 52.5 98.6 /149.5 22.1...
Page 24 Installation Typical Unit Weights and Dimensions NA from NA from Piping Control Cabinet End Outdoor Air Intake from Condensing Vestibule Unit Section (not Unit Size Access Indoor shown) Side Mounted Outdoor Indoor Other with IG Mounted Mounted Furnace AR-DR-02 AR-DR12 AR-DR22 AR-DR32 AR-DR35...
Page 25: Additional Clearances For Packaged
Installation Handling Concerns for Additional Clearances for Units with Packaged DX or Air-Source Heat Pump Packaged DX Units Units with PDX or ASHP have a system that is pressurized with Packaged DX units require additional clearance because refrigerant. If damage occurs, the refrigerant could leak into the they must have unrestricted air movement around the atmosphere or cause bodily harm due to the extreme cold condenser coil and condenser fans.
Page 26: Lifting
Installation Roof Curb Mounting Lifting Roof curb details, including duct locations and 1. Ensure that all shipping materials have been dimensions, are to be found in the roof curb assembly removed from unit. instructions. 2. To assist in determining rigging requirements, Rooftop units require curbs to be mounted ﬁrst.
Page 27: Optional Piping Vestibule
Installation Optional Piping Vestibule Rail Mounting and Layout If the unit was ordered with the vestibule, the NA (Non- Access side) clearance dimension must be measured from • The units may be installed on rails provided and the vestibule. installed by others. Ensure that rails are designed to handle the weight of the unit and provide proper load distribution on building supports.
Page 28: Gas Connections
Installation Optional Gas Piping Recommended Electrical and Gas Supply Units with indirect gas-fired furnaces require field- Entry Locations supplied and installed gas supply piping. Manufacturer recommends that electrical service and gas supply be brought into the cabinet through the end wall, as Housing Total Max Gas...
Page 29 Installation WARNING Never drill holes into the roof of the unit. There is high voltage wiring located between the inner and outer roof panels. Damage to the wiring could cause severe bodily harm or death. NOTE Housing size 35 gas furnaces are designed for gas pressure of 5-13.5 in.
Page 30: Piping Installation
Piping Installation Direct Expansion (DX) Coils (Split DX) Optional Coil Piping Factory-installed cooling and heating components are 1. Piping should be in accordance with accepted mounted in the coil section of the unit. The coil section is industry standards. Pipework should be supported downstream of the energy wheel on the supply air side independently of the coils.
Page 31: Electrical Information
Electrical Information Determine the Size of Electric Heater WARNING Wiring The roof lining contains high voltage wiring. To prevent An optional electric heater may require a separate electrocution, do not puncture the interior or exterior power supply. The power connection should be made panels of the roof.
Page 32 Control Center Components Main Control Center Components Image represents a typical installation for AR-DE12 or AR-DE22. Components and locations will vary based on housings 12, 32, 35. Electrical Cabinet 1. Power distribution block; high voltage supply is terminated here Electrical Cabinet 2.
Page 33: Phase Monitor
Component Operation Optional Component Operation Exhaust Fan VFD Sequence Phase Monitor Optional Building Static Pressure Sensor: The unit control circuitry includes a phase monitor that exhaust fan is modulated based upon the signal from constantly checks for phase reversal, phase imbalance, a building static pressure sensor.
Page 34 Optional Component Operation Electronically Commutated (EC) Airﬂow Monitor Condenser Fans with Standard Scroll or Digital Scroll Compressors The EC condenser fan(s) will modulate up and down to maintain the optimal liquid line pressure using built in control sequences within the factory controller. One pressure transducer is provided with each refrigeration circuit for monitoring and the factory controller will ramp condenser fan(s) up or down based on the condenser...
Page 35 Optional Component Operation VFD Compressor Needlepoint Bipolar Ionization (NPBI®) If the VFD compressor option is included, the Needlepoint bipolar ionizers are mounted on the fan compressor VFD is mounted in the end of the inlet cone(s) and provide air disinfection. The ionizers condensing section.
Page 36 Microprocessor Control Aluminum Energy Wheel The microprocessor controller is specifically designed Available options are: and programmed to optimize the performance of 1. Modulating wheel frost control the unit with supplemental heating and cooling. This 2. Modulating wheel with electric preheat frost option ensures that the outdoor air is conditioned to Control the desired discharge conditions.
Page 37: Hot Gas Reheat Valve
Factory-Installed Refrigeration System Components Packaged DX Cooling with Three Way Hot Gas Reheat and Hot Gas Bypass 12. Thermostatic Expansion Valve (TVX) 1. Compressor Each unit is equipped with a TVX on each refrigerant 2. High Limit Pressure Switch circuit. The valve controls the ﬂow of liquid refrigerant The switch opens when refrigerant pressure entering the evaporator coil by maintaining a constant, increases above the set point in the discharge line.
Page 38 Factory-Installed Refrigeration System Components Air-Source Heat Pump with Three Way Hot Gas Reheat...
Page 39 Factory-Installed Refrigeration System Component 1. Compressor 2. High Limit Pressure Switch The switch opens when refrigerant pressure increases above the set point in the discharge line. A manual reset is then required 3. Hot Gas Reheat Valve (optional) Units equipped with a reheat coil use a three-way valve with actuator to control the supply air discharge temperature of the unit during dehumidification mode.
Page 40: Start-Up Unit
Start-Up Unit DANGER WARNING Prior to starting up the unit, power must be energized Electric shock hazard. Can cause injury or death. Before attempting to perform any service or for 24 hours without a call for cool to allow the maintenance, turn the electrical power to unit to OFF compressor crankcase heaters time to boil off any at disconnect switch(es).
Page 41: Pre-Start-Up Checklist
Start-Up Unit IG Furnace Pre-Start-Up Checklist  If there is an indirect gas-fired furnace in this unit,  Remove any foreign objects that are located in the refer to the manual provided with this unit for Pre- unit. Start-Up information. ...
Page 42: Start-Up Checklist
Start-Up Checklist Line Voltage. Check at unit disconnect L1-L2 Volts L2-L3 L1-L3 Volts Amps Motor Amp Draw Supply Motor 1 Amps Amps Amps Supply Motor 2 Amps Amps Amps Amps Exhaust Motor 1 Amps Amps Amps Amps Exhaust Motor 2 Amps Amps Amps Amps...
Page 43 Start-Up Checklist – Packaged Direct Expansion (PDX) Compressor 1 Compressor 2 Compressor 3 Compressor 4 Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps Crankcase Heater Amps Amps Amps Amps Not present on inverter compressor Superheat (Housing 02, 12, 22, 32) Deg.
Page 44 Start-Up Checklist – Air-source Heat Pump (ASHP) Compressor 1 Compressor 2 Compressors Amps Amps Amps Amps Amps Amps Crankcase Heater Amps Cooling Superheat Deg. F Deg. F Should be between 10º and 20ºF (0% reheat) or Should be between 10º and 30ºF (100% reheat) Subcooling Deg.
Page 45: Start-Up Components
Start-Up Components The fan should be checked for free rotation. If any binding occurs, check for concealed damage and foreign Refer to the respective installation, Operation and objects in the fan housing. Maintenance Manual shipped with this unit for additional CAUTION start-up and maintenance information regarding the plenum fan.
Page 46: Discharge Air Temperature Sensor
Discharge Air Temperature Sensor Units are supplied with a discharge air temperature sensor that is to be field-installed prior to unit start-up. The sensor is to be installed at least three duct diameters downstream of the heat exchanger. The sensor must be connected directly to the microprocessor controller.
Page 47 Start-Up Components Airﬂow Monitoring Communication Setup For additional information on how to navigate through 1. Press the UP and DOWN keys at the same time for the airﬂow controller menus, refer to technical manuals 3 seconds from GreenTrol® Automation Inc. at www.greentrol.com. 2.
Page 48: Optional Dirty Filter Switch
Optional Dirty Filter Switch To adjust the switch, the unit must be running with all of the access doors in place, except for the compartment where the switch is located (exhaust intake compartment). The adjusting screw is located on the top of the switch. 1.
Page 49 Optional Polymer Energy Wheel Sequence of Operation Start-Up Optional Economizer - The economizer will be locked If selected, the energy wheel is installed in the unit’s out when: the outside air is below economizer lockout; airstream with one half of the wheel in the intake the unit is operating in dehumidiﬁcation mode;...
Page 50 Optional Polymer Energy Wheel Maintenance Whenever retaining clips are opened, they should be closed as soon as possible. If the wheel should rotate WARNING when a clip is open, the clip will jam against the bearing Whenever performing maintenance or inspections, support bar and could cause damage.
Page 51 Start-Up THIS SMELL WILL DISSIPATE QUICKLY. Optional Frost Control Wheel Belt The microprocessor controller will output a signal when Inspect belts each time filters are replaced. Belts wheel frosting is occurring which is determined by a that look chewed up or are leaving belt dust near the temperature set point (EA <...
Page 52: Optional Energy Wheel
– Optional Energy Wheel Troubleshooting Symptom Possible Cause Corrective Action Refer to Adjust the Air Seals in the Optional Energy Wheel Air seals are too tight. Energy wheel Start-Up section. does NOT Broken belt. Replace. turn No power to wheel motor. Make sure wheel drive is plugged in.
Page 53 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Blown fuse or open circuit breaker. Replace fuse or reset circuit breaker and check amps. Defective motor or capacitor. Replace. Blower fails Motor overloaded. Reset VFD and check amps. to operate Check for On/Off switches.
Page 54 Troubleshooting – Refrigeration Circuit TROUBLESHOOTING NOTE IMPORTANT Do not release refrigerant to the atmosphere! If required service procedures include the adding or Before any components are changed on the removing of refrigerant, the service technician must refrigeration system, the cause of the failure must be comply with all federal, state and local laws.
Page 55 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Refrigerant overcharge. Check pressures, charge by subcooling. Compressor Condenser fan motor defective. Check fan motor. starts but Condenser coil inlet obstructed or dirty. Check coil and clearances. Clean coil if necessary. cuts out on high Check high side equalized pressures, check thermal...
Page 56 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Check for high entering wet bulb temperature, check for Excessive load on evaporator coil. excessive air ﬂow. Compressor is unloaded. Check digital scroll controller signal and solenoid valve. (digital scroll) Check the thermal expansion valve, ensure bulb is insulated.
Page 57 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Check subcooling, check for leak. Repair leak and add Insufﬁcient refrigerant charge. refrigerant. Defective or improperly adjusted Check superheating and adjust thermal expansion valve. expansion valve. discharge pressure See “low suction pressure”. Low suction pressure.
Page 58 Annually DANGER It is recommended that the annual inspection and Electric shock hazard. Can cause injury or death. maintenance occur at the start of the cooling season. Before attempting to perform any service or After completing the checklist, follow the unit start-up maintenance, turn the electrical power to the unit to checklist provided in the manual to ensure the OFF at disconnect switch(es).
Page 59: Routine Maintenance
Routine Maintenance Maintenance Procedures: For coils with fragile ﬁns or high ﬁn density, foaming chemical sprays and washes are available. Many coil Lubrication - Check all moving components for cleaners use harsh chemicals, so they must be used proper lubrication. Apply lubricant where required. with caution by qualiﬁed personnel only.
Page 60 Routine Maintenance *Based upon a 30/36 in. energy wheel (16x25x2, quantity of 3 for 41 in. energy wheel) **Based upon a 52 in. energy wheel (16x16x2, quantity of 8 for 58 in. energy wheel) Outdoor Air Supply Final Filters Model Weatherhood Pre-Wheel Outdoor Exhaust Filters...
Page 61 Reference - Venting Connection Locations AR-DE12 200-300MBH 100-150MBH COMPRESSOR / CONTROL CENTER ACCESS COMBUSTION AIR INLET COMBUSTION AIR INLET EXHAUST OUTLET EXHAUST OUTLET IG FURNACE ACCESS AR-DE22 300-400MBH 500MBH COMPRESSOR CONTROL CENTER COMPRESSOR CONTROL CENTER ACCESS ACCESS ACCESS ACCESS COMBUSTION AIR INLET COMBUSTION AIR INLET EXHAUST OUTLET EXHAUST OUTLET...
Page 62 Model Airflow (SCFM) Model Airflow (SCFM) 6400 AR-DR22-20A AR-DR02-03A 1100 5750 AR-DR22-25I AR-DR02-04A 1450 5600 AR-DR22-25D AR-DR02-05A 1700 AR-DR22-25S 5600 AR-DR02-06A 1900 7200 AR-DR22-25A AR-DR02-07A 1900 AR-DR22-30I 6000 2325 AR-DR12-5I 6000 AR-DR22-30D 2325 AR-DR12-5D 5750 AR-DR22-30S AR-DR12-5S 2325 7000 AR-DR22-30A 3400 AR-DR12-5A 6500...
Page 63: General Safety Information
Gas Furnace PVF and PVG (for 112, 212, and 311 Chassis) WARNING Model PVG FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Be sure to read and understand the installation,operation and service instructions in this manual.
Page 64: Unit Identification
Burner Control Turndown NOTE Burner turndown ratio is used in many places and must be calculated. On the data label, locate the INPUT Models PVF and PVG are indirect gas-fired heat BTU/HR (the largest number on the label) and also modules that will be referred to in this manual as a the MINIMUM INPUT BTU/HR.
Page 65: Furnace Control Center
Furnace Control Center Each ventilating unit containing one or more furnaces will have a furnace control center located on the furnace vest plate. The control center receives high voltage AC from the main unit control center and in most cases, also receives low voltage control signals (call for heat) from the main unit control center.
Page 66: Typical Furnace, Electrical And Control Components
Typical Furnace, Electrical and Control Components Microprocessor Airflow Switch The microprocessor Airflow switches are used on both provides the call for heat furnaces and are found on the furnace to the ignition controller vest plate. If the combustion blower and also monitors the is multi-speed, there will be two discharge air temperature.
Page 67: Gas-Fired Burner Turndown
Gas-Fired Burner Turndown Furnaces are available in electronically modulated Combinations configurations. Electronically modulated furnaces Various combinations of the methods outlined may have continuously variable firing rates. Turndown is be used to accomplish the turndown required by the the capability of the furnace to operate at less than application.
Page 68: Installation Of Venting For Outdoor Units
Installation of Venting for Installation of Venting for Outdoor Units Indoor Units Follow Guidelines WARNING All of the following guidelines must be followed when The following guidelines must be followed for all indoor installing the unit. units: WARNING 1. Installation of venting must conform with local building codes.
Page 69: Venting Methods
Venting Methods A = 12 inch minimum There are three venting methods for indoor mounted Exterior Wall units. For each method, the units can be vented horizontally through an exterior wall or vertically through the roof. Specific venting instructions are Pitch vent pipe downward provided for each method and shown in the following...
Page 70: Installation Of Concentric Venting
Installation of Concentric Venting Concentric Venting – Horizontal Concentric venting allows the exhaust pipe and combustion air pipe to pass through a single hole in the Refer to the diagram below for venting on horizontal roof or wall of the building. A concentric venting adapter concentric systems.
Page 71 Concentric Venting – Vertical Install Exhaust Pipe Refer to the diagram below for venting on vertical Attach a field-supplied exhaust air pipe to the concentric concentric systems. Maintain at least 12 inches side of the CVA. Provide enough exhaust piping to pass between the top of the combustion air inlet terminals through the wall (or floor) and provide the minimum and the bottom of the exhaust terminal.
Page 72: Horizontal
Install Exhaust Pipe Attach a field-supplied exhaust air pipe to the concentric side of the CVA. Provide enough exhaust piping to pass through the roof and provide the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake.
Page 73: Vertical
Installation of Two Pipe Venting – Vertical Install Combustion Air Pipe Run a combustion air pipe from the unit’s combustion Refer to the diagram for venting vertical two pipe air intake through the roof to the outdoors. The systems. The combustion air pipe must terminate at combustion air pipe must terminate at least 12 inches least 12 inches above the roof.
Page 74: Installation Of Gas Piping
Installation of Gas Piping Connect the Supply Gas Line A manual shut off valve, a 1/8 inch plugged test port and IMPORTANT a drip leg must be installed between the gas supply pipe All gas piping must be installed in accordance with the and the start of the gas train.
Page 75 Gas Supply In Typical Split Burner Manifold...
Page 76: Sequence Of Operation
Sequence of Operation High Turndown Electronic Modulation - The Start-Up / Standby furnace controller will ignite the necessary Prior to start-up, verify that all field-installed sensors manifold(s) at 100% for 10 seconds. The main burner have been installed. This includes a room temperature gas valves will then modulate from 100% down to sensor (optional) and a discharge air temperature sensor a minimum of 25% as needed.
Page 77: Start-Up - Furnaces (All Units)
Start-Up - Furnaces (all units) With 4:1 Turndown Electronic Modulation IMPORTANT For the unit to function properly, ALL gas valves must have their high fire and low fire settings adjusted for Discharge Temperature Sensor field conditions. Furnace IMPORTANT Controller Confirm the discharge air sensor is installed at least three duct diameters downstream of the furnace.
Page 78: Modulating Valve High Fire Setting
Before making furnace adjustments, enter the Modulating Valve High Fire Setting Commissioning Menu on the unit or Furnace Controller. Conduct this step with the Commissioning Menu on the The Commissioning Menu is located under Service > High Fire Setting screen. Overrides >...
Page 79 High Turndown Electronic Modulation IMPORTANT *High turndown furnaces use a split burner manifold with a shutoff and a modulating valve on each manifold section. High and low fire manifold pressure must be checked and properly set on each manifold section *High turndown furnace patent pending.
Page 80: Ignition Controller
Troubleshooting - Ignition Controller Ignition lockout (1 red flash for start-up, 4 red NOTE flashes for during operation) The green LED light indicates NORMAL operation while the red LED light indicates an ERROR operation. Possible Cause Solution Manual gas valve Open manual valve.
Page 81 Troubleshooting - 4:1 Modulating Furnace 4:1 Modulating Furnace with Stand-Alone Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram. Line voltage across L1 & L2, Main incoming power not connected L2 & L3, and L1 & L3 on main Connect proper supply power to unit disconnect (DS1)? Line voltage across T1 &...
Page 82 Troubleshooting - 4:1 Modulating Furnace 4:1 Modulating Furnace with Stand-Alone Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram..continued from previous page Fuse (FU7) Blown Line voltage at primary side of furnace transformer (TR5)? Test and replace blown fuse(s) Fuse (FU9) Blown...
Page 83 Troubleshooting - 4:1 Modulating Furnace 4:1 Modulating Furnace with Stand-Alone Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram..continued from previous page Wait for discharge temperature to cool or increase supply temp setpoint sufficiently above inlet air temperature.
Page 84 Troubleshooting - 4:1 Modulating Furnace 4:1 Modulating Furnace with Stand-Alone Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram..continued from previous page Pressure switch tubing kinked, disconnected, plugged, or filled with water/ice. Straighten, connect, clear or replace pressure switch tubing Pressure switch (PS5) failure Furnace Controller Alarm:...
Page 85 Troubleshooting - 4:1 Modulating Furnace 4:1 Modulating Furnace with Stand-Alone Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram..continued from previous page Discharge temperature was above high limit control (HLC) Furnace Controller Alarm: Wait for high limit to cool and reset ‘High Temp.
Page 86 Troubleshooting - 4:1 or High Turndown Modulating Furnace 4:1 or High Turndown Modulating Furnace with Microprocessor Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram. Line voltage across L1 & L2, Main incoming power not connected L2 &...
Page 87 Troubleshooting - 4:1 or High Turndown Modulating Furnace 4:1 or High Turndown Modulating Furnace with Microprocessor Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram..continued from previous page pCOe not powered Power the pCOe Microprocessor Alarm: pCOe not connected to main controller...
Page 88 Troubleshooting - 4:1 or High Turndown Modulating Furnace 4:1 or High Turndown Modulating Furnace with Microprocessor Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram..continued from previous page Fuse (FU8) Blown 120 VAC at 120/240 terminal on Test and replace blown fuse Ignition Controller (IC#)?
Page 89 Troubleshooting - 4:1 or High Turndown Modulating Furnace 4:1 or High Turndown Modulating Furnace with Microprocessor Controller Will Not Light In all cases, verify correct terminals as shown on the unit-specific wiring diagram..continued from previous page Ignition Controller (IC#) red LED Manual supply gas valve off or combo valve (MV) switch turned off blinks 1 time, 2 times or 4 times Turn supply gas valve or combo valve on...
Page 90: Reference: Controls
Reference - Controls Furnace Control with Microprocessor Control If the unit is equipped with a microprocessor control, the expansion board acts as an interface between the microprocessor controller and the furnace. In this case, the pCOe has no logic built into it since the logic is already contained in the microprocessor controller.
Page 91: Maintenance
Maintenance Combustion Blower Motor Flue Collector Box Motor maintenance is generally limited to cleaning. The flue passageway and flue collector box should be Cleaning should be limited to exterior surfaces only. inspected prior to each heating season and cleared of Removing dust and grease build-up on the motor any debris.
Page 92: Maintenance Log
Maintenance Log Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date...
Page 93 Maintenance Log Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date Time AM/PM Date Time AM/PM Notes: Notes: Date...
Page 94 NOTE: For HMA gas furnace for 311 and 352 chassis, see separate IOM Manual...
Page 95: Controller Overview
Controller OVERVIEW FUNCTION The DOAS controller is responsible for unit operation. The controller monitors inputs and regulates outputs to maintain unit operation. The controller provides user feedback via a web interface or an optional handheld keypad/display or can be connected to building management system interface. CONTROLLER The DOAS controller receives 24 VAC power from a transformer on the main control panel and is energized when the main disconnect is on.
Page 96 HANDHELD KEYPAD/DISPLAY (OPTIONAL)
Page 97: Expansion Boards
The DOAS controller can be hardwired to an optional keypad/display that is handheld. EXPANSION BOARDS Some unit configurations require control expansion boards. Carel c.pCO2 or Carel EVD evolution are used as expansion boards. Expansion boards communicate with the controller via Modbus protocol. CONNECTING TO THE WEB UI To access the controller from a computer, tablet, or smart phone connected to the network on which the controller resides, enter the controller’s IP address into your device’s web browser.
Page 98: Expansion Board Addresses And Dip Switch Settings
 Altitude Go to the Main/Ctrl Variables/Advanced/Unit Settings screen  IP address Go to the Main/Ctrl Variables/Advanced/Network Settings screen  BMS/AC Smart communication Go to the Main/Ctrl Variables/Advanced/Network Settings screen to set up network communication. AC Smart should be set to “Modbus” protocol ADDRESSES pLAN ADDRESSES Control components are assigned the following pLAN addresses at the factory:...
Page 99: Ip Address
DIP SWITCH SETTINGS FOR CAREL c.cPOe EXPANSION BOARD Expansion Baud Board Address Offset Rate Protocol Address Baud Prot Exp 1 19.2K Modbus Exp 2 19.2K Modbus Exp 3 19.2K Modbus Exp 4 19.2K Modbus Exp 5 19.2K Modbus Exp 6 19.2K Modbus IP ADDRESS...
Page 100: Software Backup And Restore
SOFTWARE BACKUP AND RESTORE CONNECTING TO USB DRIVES The controller has built-in USB ports for connecting to USB drives. The USB drives can be used for backing up all settings and reported conditions such as alarm history and current values. CREATING A BACKUP FILE The controller can create a backup file of set-points and configuration variables on a USB drive or in the controller’s internal memory.
Page 101: Ac Smart Setup
7. Press Enter to highlight and then the Up or Down arrow buttons to fill the Restore checkbox. This action restores the backup file. If there is an error during the process, the specific error is displayed on this screen. 8.
Page 102 AC Smart Controller Setup: 1. Go to “Installing” in the AC Smart 5 “Settings” tab 2. Click on the “AC Smart[00]” tab to go to Registration Status, and Set CH1 Setting to “MODBUS_9600” 3. Press “Auto Search” 4. Press “Auto Search” to automatically search for devices connected to the controller. Once the search is complete, click “Send All”...
Page 103 5. You can add additional units by clicking “Add Unit”. Click “Apply” after making the selections. 6. Click “Send All” to finish adding your device 7. Go to “Control” tab, then select “Device control”...
Page 104 8. Go to “Installation” tab, then select “AC Smart” 9. Click on the device you wish to view. You will see a new section on the right side of the screen. Click “View Details” 10. You can now view a detailed picture of the unit. Click on “Info” to see other information on the unit, such as the model, address, mode, temperature, etc.
Page 106: Navigation
NAVIGATION MENU MAP The Menu map shows screen order when using either the handheld keypad/display or the virtual keypad/display on the web interface. See the Navigation section for instructions about moving through menu screens.
Page 130 Controls Sequence of Operation...

LG GEN2 Series Installation And Operation Manual

Quick Links

Related Manuals for LG GEN2 Series

Summary of Contents for LG GEN2 Series

This manual is also suitable for:

Table of Contents