MODINE CONTROLS SYSTEM MANUAL standard control for water source heat pump systems models GA/EA, GF/EF, GH/EH, GP/EP, and GS/ES

Transcription

1 5H March, 2017 MODINE CONTROLS SYSTEM MANUAL standard control for water source heat pump systems models GA/EA, GF/EF, GH/EH, GP/EP, and GS/ES WARNING 1. 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. 2. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage. 3. Improper control adjustments and manual mode control can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before making adjustments. IMPORTANT 1. The use of this manual is specifically intended for a qualified installation and service agency. All installation and service of this unit must be performed by a qualified installation and service agency. 2. These instructions must also be used in conjunction with the Installation and Service Manual originally shipped with the appliance, in addition to any other accompanying component supplier literature. 3. This manual applies to Modine Controls System program version series 2. For any other version, please contact Modine. The program version that resides in the unit controller can be found in the Information section of the Installer Sub Menu. Refer to the manual for instructions on accessing this screen. THIS MANUAL IS THE PROPERTY OF THE OWNER. PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

2 General Information Controls are one of the most important components of specialized HVAC equipment. The Modine Controls System is designed and engineered for the Modine geothermal units to ensure that they will operate safely, reliably, with optimized performance, and maintain maximum energy efficiency. Table of Contents Acronyms Commonly Used In Controller...2 Controller Overview...3 Description and Features...3 Model Nomenclature...4 pco1 Controller Layout...5 Connections / Field Wiring...6 Sequence of Operations...7 Loop Freeze Protection...7 Controller Process Flow Diagram...8 Alarms...9 Accessory Display/Keypad Functions...10 Standard Buttons...10 Menu Navigation...11 Navigation Sub Menus...11 Example Navigation to Clock/Timers Sub Menus..11 Password Protection...12 Adjusting Customer Control Settings...12 Main Menu Tree of Functions...12 Main Status Screen...13 Main Status Screen Parameters...13 Alarm Log Sub Menu...14 Clock/Timers Sub Menu...15 Installer Sub Menu...16 Information...16 BMS Configuration...17 Input / Output...18 Probe Calibration...19 Unit Configuration...19 Unit Alarms...20 Troubleshooting...21 Main Unit Controller Inputs/Outputs...22 pco1 Input and Output Terminals...22 Typical BMS EMS BAS System Variables...23 Table 2.1 Acronyms Used Acronym BMS BPS CCS CFM Comp Diff Elec hr Ht LL min Mod Phrase Building Management System Bits Per Second Capacity Control Solenoid Cubic Feet per Minute Compressor Difference Electric Hour Heat Liquid Line "Minutes" or "Minimum" Mode Perc Percentage "%" psig RA Rev Vl RH s SA SetPt Sp Stby Str Temp Vlv Pounds per Square Inch Gauge Return Air Reversing Valve Relative Humidity Seconds Supply Air Setpoint Speed Standby Start Temperature Valve 2 GEO

3 Controller Overview Description and Features The Modine Controls System utilizes a Carel pco1 programmable microprocessor controller. Highly advanced with a powerful microprocessor and fast processing speed, the controller features a number of I/O s for complex HVAC/R applications. The main controller board is housed in a plastic case that ensures a high index of protection and reduces the risk of electrostatic discharges due to incorrect handling. The controller offers greater safety due to the optical isolation of the serial plan, protection of the analog inputs in the event of incorrect connections, and an extended range of operating temperatures. Some of the features of the Carel pco1 programmable microprocessor controller are listed here. pco1 Main Features: 6 Analogue Inputs Uses 10K NTC temperature sensors, 01VDC, 05VDC, 020mA, or 420mA signals 4 Analog Outputs 2x 010vdc for easy fault finding 2x 5V PWM signals 8 Digital inputs Used to monitor all aspects of the unit 8 Digital Outputs True relayed outputs for reliability Real Time Clock with battery backup plan Communication To allow connectivity to optional controllers Run Hours Logging with maintenance setpoints Password Protection Installer password protection Simple Interface (with accessory display) Easy to understand menus and settings Remote Display Accessory Alarm Logging with a timestamp Not required for unit commissioning Provides visual confirmation of multimeter readings from terminals in control panel for troubleshooting Can be 100ft from unit Connects to controller with standard RJ12 cable GEO

4 Model Nomenclature ,5, , UA MT UC MBH DS CC SV CT AC SM HM HWG MT SA RA Digit 1 Unit Application (UA) G Residential E Commercial Digit 2 Model Type (MT) P GeoSync Premium Efficiency Forced Air Unit F Forced Air Unit H WatertoWater Unit A Air Handler Unit S Split Unit Digit 3 Unit Configuration (UC) V Vertical H Horizontal R Reversible W Non Reversible I Indoor Split Unit Digits 4, 5, 6 Nominal Capacity (MBH) XXX XXX,000 Btu/hr Digit 7 Development Sequence Designation (DS) A P Series Units D F, H, A, & S Series Units Digit 8 Compressor Configuration (CC) 0 None 1 Single Stage 2 Two Stage 3 Single Stage with Sure Start 4 Two Stage with Sure Start Digits 9, 10 Supply Voltage (SV) /60/ /60/ /60/ /60/ /60/ /60/3 Digit 11 Controls Type (CT) 4 Modine Controls System Digit 12 Air Coil (AC) N None C CF TM 2Row Microchannel R Round Tube Plate Fin (RTPF) R410A Digit 13 Source Coaxial Coil Material (SM) X None C Copper N Cupronickel Digit 14 Hydronic (Load) Coaxial Coil Material (HM) X None C Copper N Cupronickel Digit 15 Hot Water Generator or Desuperheater (HWG) 0 None 1 HWG with Factory Installed Pump Digit 16 Motor Type (MT) N None D DecStar ECM E ECM Digit 17 Supply Air Configuration (SA) N None T Top B Bottom S Side E End Digit 18 Return Air Configuration (RA) N None L Left R Right B Bottom T Top 4 GEO

5 Figure 5.1 pco 1 Controller Layout Table 5.1 pco 1 Controller Layout Descriptions Reference Description 1 Power supply connector [G (+), G0 ()] VAC, 2 A slowblow fuse (T2 A) 3 Universal analogue inputs 4 Passive analogue inputs 5 Passive analogue inputs 6 Yellow power LED and 3 status LEDs 7 Analogue outputs 8 24VAC/VDC Digital inputs 9 230VAC or 24VAC/VDC Digital inputs 10 +Vdc: power to active probes ; +5VR power to radiometric probes 11 plan telephone connector for remote terminal/downloading application program 12 plan plugin connector 13 Programming key connector 14 Relay digital outputs 15 Port for selecting analogue input types 16 BMS1 optional card cover 17 Clock card cover GEO

6 Connections / Field Wiring Terminal Strip Connections The terminal strip connections are designed to clamp down on the wires. To properly connect the wires to the terminal strip as shown in Figure 6.2: 1. Push a small flathead screwdriver into the SQUARE hole on the terminal. Press firmly until the screwdriver hits the back stop and opens the terminal. 2. Remove approximately 3/8" of insulation from the end of the wire and push the stripped wire into the OVAL hole in the terminal. Verify that the terminal clamp is in contact with bare wire (insulation removed). 3. Remove the screwdriver. Pull on the wire to make sure that it is securely clamped in the terminal. Thermostat Wiring for Forced Air and Split Units Modine Forced Air and Split units require a 4 Heat / 2 Cool heat pump thermostat for proper operation. Any commercially available 4 Heat / 2 Cool heat pump thermostat should properly operate these units. The following thermostats and zone controller have been tested and are recommended for use with Modine Forced Air and Split units: Honeywell Prestige (YTHX9421R5051) Honeywell Prestige IAQ (THX9421R5021 with THM5421R1021 Equipment Interface Module) Honeywell FocusPRO (TH6320R1004 with THM5421R1021 Equipment Interface Module) Honeywell Heat Pump Zone Panel (HZ432) White Rodgers Big Blue (1F951291) White Rodgers Inspire (1HDEZ1521) White Rodgers Blue (1F981421) Wire thermostat to unit control panel as shown on the wiring diagram included with the unit. Figure 6.1 Sample Thermostat Connections TE: Terminal numbers shown are for reference only, refer to unit wiring diagram for actual terminal numbers. Figure 6.2 Terminal Strip Connections Aquastat Wiring for Single WatertoWater Units WatertoWater systems require the use of aquastats or normally open () contacts to call for conditioning. NonReversible WatertoWater systems require a heating aquastat or contact, while Reversible WatertoWater systems need both heating and cooling aquastats or contacts as shown in Figure 6.3. Figure 6.3 Sample Aquastat Connections TE: Terminal numbers shown are for reference only, refer to unit wiring diagram for actual terminal numbers. Aquastat Wiring for Stacked WatertoWater Units Stacked WatertoWater systems require the use of two staged aquastats or normally open () contacts to call for conditioning. NonReversible WatertoWater systems require two heating aquastats or contacts with a minimum differential of 5 F between the first and second stage, while Reversible WatertoWater systems need both heating and cooling aquastats or contacts with a minimum differential of 5 F between the first and second stage. See Figure 6.3 for an example of aquastat wiring connections. Care must be taken to not allow heating and cooling setpoint overlap on Reversible WatertoWater units. 6

7 Sequence of Operations / Loop Freeze Protection Forced Air / Split Units The GP/EP GeoSync Forced Air, GF/EF Forced Air, and GS/ES Split systems work off of control signals from a heat pump thermostat or zone panel. These signals determine the type of conditioning and conditioning stage of the equipment. The unit s controller will monitor calls for heat or cooling by the thermostat. See Figure 8.1 for a flow chart that describes the Sequence of Operation. Blower The blower will cycle with a call for cooling or heating. Cool Upon receiving a G, Y1, and O signal from the thermostat, the compressor and reversing valve will be energized. On two stage units with ECM, the first stage of the compressor will be energized and the blower will provide the first stage airflow. The compressor will be limited by a 5 minute timer that will provide short cycle protection. When a subsequent Y2 signal is received, the second stage of the compressor will be energized and the blower will provide the second stage airflow (two stage units with ECM only). Heat Upon receiving a G and Y1 signal from the thermostat, the compressor will be energized and the reversing valve deenergized. On two stage units with ECM, the first stage of the compressor will be energized and the blower will provide the first stage airflow. The compressor will be limited by a 5 minute timer that will provide shortcycle protection. When a subsequent Y2 signal is received, the second stage of the compressor will be energized and the blower will provide the second stage airflow (two stage units with ECM only). Hydronic Units The GH/EH WatertoWater unit s controller will monitor calls for heat or cooling by aquastat(s) or normally open contact(s). See Figure 8.1 for a flow chart that describes the Sequence of Operation. Cool (Reversible Units Only) When the temperature increases above the cooling aquastat's set point, the compressor and reversing valve will be energized. The compressor will be limited by a 5 minute timer that will provide short cycle protection. Heat When the temperature falls below the heating aquastat's set point, the compressor will be energized and the and the reversing valve deenergized. The compressor will be limited by a 5 minute timer that will provide short cycle protection. Freeze Protection All Units Modine Geothermal systems use a robust, easy to set automatically resetting freeze protection temperature sensor that is attached to the Ground Water Out pipe inside of the heat pump. Care must be taken to adjust the setpoint on the control module to adequately protect the ground heat exchanger (GHEX) from freezing and damaging the ground loop and equipment. The system is set to 35 F at the factory to protect pure water from freezing. To enable the lower antifreeze setpoint of 10 F, remove the entire 4pin controller plug J3 with a resistor installed, as shown in Figure 7.1. Figure 7.1 Freeze Protection Resistor Plug Supplemental Electric Heat Upon receiving a G and W1 signal from the thermostat, the first stage of the auxiliary electric heat is energized and the blower will provide Emergency Heat Airflow. Upon receiving a W2/E signal from the thermostat, the second stage of auxiliary electric heat is energized. 7

8 Figure 8.1 Controller Process Flow Diagram CHECK UNIT DISCONNECT ENERGIZE REV VALVE OUTPUT FOR COOLING 24VAC ON TERM 563 HIGH SPEED FAN COMP LOW AND COMP HIGH OUTPUTS ON 24VAC ON TERM 537/550 START VOLTAGE ON CONTACTOR L1 & L2 YES ALARM LIGHT FLASHING? YES G INPUT? 24VAC ON TERM 520 YES YES O INPUT? 24VAC ON TERM 523 Y1 INPUT? 24VAC ON TERM 521 YES HAS COMP LOW BEEN OFF FOR 5 MINS? 0VAC ON TERM 537 YES Y2 INPUT? 24VAC ON TERM YES 525 AFTER ALARM CONDITION CLEARS, WAIT FOR COMPRESSOR TIMER, THEN: HIGH OR LOW PRESSURE ALARM? LOW FAN SPEED WAIT UNTIL 5 MINS HAS ELAPSED, THEN: MED SPEED FAN COMP LOW OUTPUT ON 24VAC ON TERM 537 YES UNIT LOCKED OUT ENERGIZE REV VALVE OUTPUT FOR COOLING 24VAC ON TERM 563 COMP LOW, COMP HIGH, AND HYDRONIC PUMP OUTPUTS ON 24VAC ON TERM 537/550/562 AQUASTAT INPUT? 24VAC ON TERM 540/541 YES O INPUT? 24VAC ON TERM 523 Y1 INPUT? 24VAC ON TERM 521 YES HAS COMP LOW BEEN OFF FOR 5 MINS? 0VAC ON TERM 537 YES Y2 INPUT? 24VAC ON TERM YES 525 STANDBY STANDBY WAIT UNTIL 5 MINS HAS ELAPSED, THEN: COMP LOW AND HYDRONIC PUMP OUTPUTS ON 24VAC ON TERM 537/562 8

9 Heat Pump Alarms Alarm Detection When the controller detects an alarm an output is generated to the relevant alarm relay which sends a 24VAC signal to the alarm terminals in the unit, see unit wiring diagram for more information. Alarm Notification The unit has an alarm indicator in the control panel. If an alarm is present, the indicator will flash an alarm code that corresponds to the fault present on the unit. The alarm light will flash a number of times, then will pause for 15 seconds, then repeat the flash code until the alarm is reset. There is a label near the light on the front of the control panel that provides a list of alarm codes. If there are multiple alarms present on a unit, only the highest priority alarm will be shown, with the highest priority alarm only flashing once. Table 9.1 Alarm Flash Codes Number of Flashes Alarm 1 High Pressure Switch (HPS) Tripped 2 Low Pressure Switch (LPS) Tripped 3 Freeze Protection Alarm 4 Condensate Overflow Switch (COS) Tripped 5 Water Outlet Temperature Sensor 1 Fault 6 Water Outlet Temperature Sensor 2 Fault (Stacked WatertoWater units only) Resetting the Alarm Some safety devices in the unit (Freeze Stat, COS, etc.) will automatically reset once the conditions are within the set parameters and the unit will resume normal operation. Low and High Refrigerant Pressure Switch alarms will lock the unit out for safety and require the alarm to be reset manually. To clear an alarm, cycle power to the unit (if an accessory display is present, see page 14 for information on how to reset the alarm without cycling power to the unit). If an accessory display is present, see page 20 for more information on accessing the Alarm Log. See the Troubleshooting guide on page 21 to diagnose the root cause of the alarm. 9

10 Accessory Display / Keypad Functions Figure 10.1 pgd1 Remote Display Keypad (Accessory) Display is not used for system commissioning, only for installer troubleshooting and/or remote system status display. Display is connected to unit controller with standard RJ12 cable. Table 10.1 pgd1 Remote Display Keypad Standard Buttons pgd1 Remote Display Function ALARM Description When one or more alarms are active the ALARM button will blink/flash red. Pressing the ALARM button once will indicate information regarding any active alarms. Pressing and holding the ALARM button a second time will reset any active manualreset alarms. PRG Pressing the PRG button will select the main navigation menu. ESC Pressing the ESC button will return the user to the main display screen showing unit status. UP Pressing the UP button can either: Scroll through the various display screens, providing the cursor is in the top left position. Increase the value of a setpoint adjustment. ENTER Pressing the ENTER button will confirm any set point adjustments and move the cursor to the next available setpoint. DOWN Pressing the DOWN button can either: Scroll through the various display screens, providing the cursor is in the top left position. Decrease the value of a setpoint adjustment. 10

11 Menu Navigation The following instructions refer to using the remote keypad for navigating the menu and changing settings. The Main Status Screen is displayed when the unit is first turned on or after five minutes of keypad inactivity. From this Main Status Screen, sub menus can be accessed by pressing the PRG button and using the UP or DOWN arrow buttons to move to the desired menu. The selected menu will be shown in ALL CAPITAL LETTERS. Press the ENTER button to enter the selected menu. Details on the Main Status Screen and each sub menu will be covered in the following sections of this manual. Example Navigation to Clock/Timers Sub Menus (Similar for all other sub menus): From the Main Status Screen, press the PRG key to access the Sub Menu selection screen. Use the UP or DOWN arrow buttons to navigate to the Clock/Timers sub menu as shown in Figure Figure 11.1 Program Menu Table 11.1 Navigation Sub Menus Sub Menu Description Alarm Log View the alarm log. Clock/Timers Installer Manufacturer Enable the clock card, view and set the current time and date, view and reset fan and compressor run timers. View maintenance related parameters, such as hours run, sensor calibration and manual overrides. This area is reserved for factory settings. There are no installer configurable parameters in this area. Press the ENTER button to access the Clock/Timers sub menu screen as shown in Figure Figure 11.2 Clock/Timers Sub Menu Press the ENTER button to navigate to the parameter to change, then use the UP or DOWN arrow button to change the value. Press the ENTER button again to confirm the setting. Press the ESC button to exit the sub menu screen and to return to the Main Status Screen. 11

12 Password Protection WARNING Improper control adjustments and manual mode control can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before making adjustments. To prevent unauthorized adjustments, a password is required to gain access to certain menus. When a password is requested use the UP or DOWN arrow keys to enter the number and the ENTER button to access the page. The passwords for the sub menus are as follows: Table 12.1 Menu Passwords Menu Alarm Log Clock/Timers Password None None PW1: Installer 1500 Adjusting Customer Control Settings The following procedure is used to access and adjust control parameters (refer to Parameters Lists on pages 1319). 4. After entering the correct password the cursor will appear at the top left corner (Home location). 5. Use the UP or DOWN arrow keys to move to the desired menu. 6. To move the flashing cursor to the required adjustable fields press the ENTER key. 7. Use the UP or DOWN arrow keys to change the values and press the ENTER key to move the cursor to the next field or Home location. 8. When the cursor is Home either use the UP or DOWN arrow keys to scroll to the next submenu or the ENTER key to exit and return to the Main Menu page. Main Menu Tree of Functions Regardless of the current screen displayed, pressing the PRG key accesses the main menu, as shown below: Unit Status A. Alarm Log B. Clock/Timers Time Clock Board Fitted Run Hours Timers Run Hours Reset Timers C. Installer Information BMS Configuration Input/Output (Read Only Values) a. Analog inputs b. Digital inputs c. Analog outputs To access the d. Digital outputs branches in this area, enter password PW1 Probe Calibration a. Geo Water Outlet Temp. 1 b. Geo Water Outlet Temp. 2 Unit Configuration a. Enable Air Filter Alarm b. Installer Override c. Installer Override Timers D. Manufacturer The branches in this area are reserved for factory use, no field configurable settings are available in this section. 12

13 Main Status Screen The Main Status Screen is displayed when the unit is first turned on or after five minutes of keypad inactivity. The following information is displayed on the Main Status Screen: Time/date Fan Speed Compressor Speed Hydronic Pump Status Unit Status Figure 13.1 Main Status Screen Once this screen is displayed, the user can navigate up and down through the list of Main Status Screen Parameters by using the UP or DOWN arrow buttons. These screens are described in further detail in the next section. Table 13.1 Main Status Screen Parameter Descriptions SCREEN NAME PARAMETER DESCRIPTION FACTORY VALUE RANGE UNITS Main Screen Compressor Status Time and Date: Current time and date Fan Speed: Actual value 0100 % Compressor Speed: Hydronic Pump Status: Unit Status: Compressor Safety Timers: Compressor Speed Actual Value Current Status of Unit Active Timers Off Low Speed High Speed Off On Unit On OFF by Alarm OFF by plan OFF by BMS OFF by Clock OFF by Input OFF by Keypad OFF by Manual Alarm Unit No Yes Minimum On Time: Actual Value 0300 Sec Minimum Off TIme: Actual Value 0300 Sec 13

14 Alarm Log Sub Menu Main Status Screen ð Alarm Log Figure 14.1 Alarm Log Display Alarm Log The alarm page offers a log of the last 100 alarm messages in a scrolling log, pressing the alarm button will enter the alarm page. Consequently the most recent alarm has the lowest log number (001) and will be displayed upon entering the alarm page. As another alarm occurs, the alarm number increases until 100 alarms have occurred. From this point on, alarm 001 moves to 002 and any new alarm will reside in position 001. As new alarms are generated and cleared, the highest number logs (100) in the scroll will be lost. Viewing the Alarm Log By using the arrow keys, the last 100 alarms generated can be reviewed in chronological order. The display provides the alarm type information and the time and date of each alarm occurrence. Alarm Detection When the controller detects an alarm an output is generated to the relevant alarm relay which in turn illuminates the ALARM button and sends a 24VAC signal to the alarm terminals in the unit, see unit wiring diagram for more information. To see the alarm message press the ALARM button and the most recent alarm will be displayed. If the alarm light is on, the alarm page can be viewed to identify which alarm is active. Resetting the Alarm The auto reset alarms will automatically reset once the conditions are within the set parameters. To clear a manual alarm either cycle power to the unit (if no display is present) or press the ALARM button, then press and hold the ALARM button, then follow the prompts and the red LED will disappear. 14

15 Clock / Timers Sub Menu Main Status Screen ð Clock/Timers The following table describes the menu parameters (Note: Change in shading indicates change to next screen by using the UP or DOWN arrow buttons): Table 15.1 Clock / TImers Screen Parameter Descriptions SCREEN NAME PARAMETER DESCRIPTION FACTORY VALUE RANGE UNITS Clock Board Present Time Clock Board Fitted Yes No Yes Set Time / Date Hour: 00:00 23:59 Hrs:Min Date: MM/DD/YY Day: Run Timers Fan Run Hours: Actual Value 0 999,999 Hrs Compressor Run Hours: Actual Value 0 999,999 Hrs Run Timer Reset Reset Fan Run Hours: No No Yes Reset Compressor Run Hours: No No Yes 15

16 Installer Sub Menu Main Status Screen ð Installer ð Information ( requires password PW1) The following table describes the menu parameters (Note: Change in shading indicates change to next screen by using the UP or DOWN arrow buttons): Table 16.1 Installer Screen Parameter Descriptions SCREEN NAME PARAMETER DESCRIPTION FACTORY VALUE RANGE UNITS Information Information Page 2 Code (Name of Program) Actual Value Version: Actual Value Date: Actual Value MM/DD/YY Bios Version & Date Actual Value MM/DD/YY Boot Version & Date Actual Value MM/DD/YY 16

17 Installer Sub Menu (continued) Main Status Screen ð Installer ð BMS Configuration ( requires password PW1) The following table describes the menu parameters (Note: Change in shading indicates change to next screen by using the UP or DOWN arrow buttons): Table 17.1 Installer Screen Parameter Descriptions SCREEN NAME BMS Configuration (Modine Controls System Supports the Following Protocols: Lon, BACnet IP/Eth, BACnet MSTP) PARAMETER DESCRIPTION BMS Card Protocol: FACTORY VALUE RANGE UNITS BACnet MSTP Lon BACnet IP\Eth BACnet MSTP PCOLOAD MODBUS EXT MODBUS MODEM CAREL BMS Configuration (Page 2) (Select "YES" to Change BACnet IP/Eth and BACnet MSTP Settings) BMS Configuration (Page 3) (Screen only visible when Modbus, Modbus Ext, Modem, Carel is selected) BMS Configuration (Page 4) BMS Configuration (Page 5) MSTP SETUP (Screen only Visible When BACnet MSTP is Selected and Termconf Plugin is Enabled.) TCP/IP Setup (Screen Only Visible when BACnet IP/Eth is Selected and Termconf Plugin is Enabled.) TCP/IP Setup (Page 2) Screen Only Visible when BACnet IP/Eth is Selected and Termconf Plugin is Enabled.) BACnet Read/Write Enable Unit On/Off By BMS: Termconf PlugIn? No No No Yes No Yes Address: Baud Rate: Enable heartbeat: No No Yes Thresholds: Timeout: 300s sec Period: Actual Value Sec If BMS offline, turn unit: Off Off On Instance Actual Value Baud rate N/A N/A MAC Address: Actual Value 0127 MaxMasters: Actual Value 0127 MaxInfoFrames: Actual Value 099 Instance: Actual Value 099,000 Static IP: SubNet: Gatewy: DNS DNS Type Function: IP Read IP Ethernet Read Write Update? No No bps bps 17

18 Installer Sub Menu (continued) Main Status Screen ð Installer ð Input/Output ( requires password PW1) The following table describes the menu parameters (Note: Change in shading indicates change to next screen by using the UP or DOWN arrow buttons): Table 18.1 Input/Output Screen Parameter Descriptions SCREEN NAME PARAMETER DESCRIPTION INPUT / OUTPUT FACTORY VALUE RANGE UNITS a. Analogue Inputs Not Used B1 Geo Water Outlet (Freeze Protect) Temperature 1 Geo Water Outlet (Freeze Protect) Temperature 2 j B2 Actual Value F B3 Actual Value F Not Used B4 Not Used B5 Freeze Setpoint Selection B6 Water Water (35.0 F) Antifreeze (10.0 F) b. Digital Inputs Fan On Request from Stat: ID1 Actual Value Closed or Open c. Analogue Outputs Compressor Low Stage Request from Stat: Compressor High Stage Request from Stat: Reversing Valve Request from Stat: ID2 Actual Value Closed or Open ID3 Actual Value Closed or Open ID4 Actual Value Closed or Open Condensate Overflow Switch: ID5 Actual Value Closed or Open Aquastat Status: ID6 Actual Value Closed or Open Low Pressure Switch: ID7 Actual Value Closed or Open High Pressure Switch ID8 Actual Value Closed or Open d. Digital Outputs Alarms Active: 1 Actual Value ON/OFF Compressor Low: 2 Actual Value ON/OFF Hydronic Pump: 3 Actual Value ON/OFF Alarm Flash Code: 6 Actual Value ON/OFF Compressor High: 7 Actual Value ON/OFF Reversing Valve: 8 Actual Value ON/OFF j Found on Stacked WatertoWater units (model sizes 096, 120, or 132) only. 18

19 Installer Sub Menu (continued) Main Status Screen ð Installer ð Probe Calibration ( requires password PW1) The following table describes the menu parameters (Note: Change in shading indicates change to next screen by using the UP or DOWN arrow buttons): Table 19.1 Probe Calibration Screen Parameter Descriptions SCREEN NAME PARAMETER DESCRIPTION FACTORY VALUE RANGE UNITS Geo Water Outlet Temperature 1 Geo Water Outlet Temperature 2 j Actual: Actual Value F Offset k: to 2.0 Actual: Actual Value F Offset k: 0.0 j Found on Stacked WatertoWater units (model sizes 096, 120, or 132) only. 2.0 to 2.0 k Offset can be used to calibrate a sensor that is reading slighly off when compared to a known temperature source. If the offset is not large enough to bring the sensor back into calibration, replace the sensor. Main Status Screen ð Installer ð Unit Configuration ( requires password PW1) The following table describes the menu parameters (Note: Change in shading indicates change to next screen by using the UP or DOWN arrow buttons): Table 19.2 Unit Configuration Screen Parameter Descriptions SCREEN NAME PARAMETER DESCRIPTION FACTORY VALUE RANGE UNITS Enable Air Filter Alarm Enable Air Filter Alarm j No Installer Override Installer Overide (Page 2) Enable: No No Yes No Yes Override Time: minutes Status: Reset: j Must be enabled for Energy Star Most Efficient installations. k Defines the minimum time between compressor starts. Actual Value No Active Inactive No Yes Min Time Off: seconds Min. Time Starts k: seconds F F 19

20 Unit Alarms All electrical safety devices have individual terminals in the control panel for easy unit troubleshooting with a multimeter and the wiring diagram included with the unit. In addition to the LED flash codes shown on page 9, the accessory display will provide the following alarm messages with a timestamp of when the alarm occurred: Table 20.1 Alarm List and Descriptions ALARM Unit in Manual Mode High Pressure Alarm Low Pressure Alarm Check Air Filter AUTO RESET UNIT DISABLED COMPONENT DISABLED CAUSE Unit set to operate manually. High Pressure Switch (HPS) tripped three times in one hour, unit is locked out. Low Pressure Switch (LPS) tripped three times in one hour, unit is locked out. Dirty Air Filter ACTION Alarm is generated No action taken. All outputs will be locked out, unit must be reset manually. Fan and emergency heat will energize when called for by thermostat. All outputs will be locked out, unit must be reset manually. Fan and emergency heat will energize when called for by thermostat. Check Air Filter, clean or replace as necessary. Alarm is generated No action taken. Clock Error Issue with clock board. Alarm is generated No action taken. BMS Offline Condensate Float Switch Alarm Freeze Protection Alarm Geo Water Outlet Temp. 1 Sensor Failure Geo Water Outlet Temp. 2 Sensor Failure No BMS heartbeat signal present. Condensate Overflow Switch (COS) tripped for more than 20 seconds.. Temperature sensed by Freeze Protection Sensor is below setpoint for more than 60 seconds. Temperature being read by sensor is out of normal limits, unit is locked out. Temperature being read by sensor is out of normal limits, unit is locked out. Verify BMS system is operating properly. Unit will be locked out until blockage is cleared and switch automatically resets itself. Unit will be locked out until temperature sensed by Freeze Protection Sensor rises to 5 F above setpoint. All outputs will be locked out. Fan and emergency heat will energize when called for by thermostat. All outputs will be locked out. Fan and emergency heat will energize when called for by thermostat. 20

21 Troubleshooting A brief listing of controllerspecific symptoms and remedies is shown below. For a comprehensive troubleshooting guide for general unit issues, please consult the Troubleshooting section of the unit Installation & Service manual included in the literature packet. Table 21.1 Troubleshooting Symptoms SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION No Power to Controller, Yellow Controller Power Indicator Light Not On High Pressure Alarm Low Pressure Alarm Freeze Protection Alarm Auxiliary Heat Won t Energize All Other Symptoms Not Listed Here 1. Controller fuse blown Replace fuse. Ensure corect power is connected to unit and secondary transformer voltage is not greater than 28 VAC. 2. Transformer trip Reset transformer switch (White Rodgers transformer only). See Unit Installation & Service Manual for possible causes and remedies. See Unit Installation & Service Manual for possible causes and remedies. 1. Freeze protection setpoint set incorrectly 2. Low flow through source coil Set correctly for type and percentage of antifreeze used. Verify correct flow through the coil. 1. Improper thermostat Install thermostat that supports 4 stages of heat. 2. Improper thermostat wiring Verify thermostat connections to the unit terminal strip. 3. AUX heat control harness not connected Connect Aux heat control harness according to wiring diagram. See Unit Installation & Service Manual for possible causes and remedies. Replacement Parts When servicing, repairing or replacing parts on these units, locate the serial plate of the unit and always give the complete Model Number and Serial Number from the serial plate. For a complete description of the model number, see Model Identification. Service parts can be ordered from the local Modine representative or by ing technicalservice@na.modine.com or calling (4GEO). 21

22 Main Unit Controller Inputs / Outputs The inputs and outputs of the controller are listed below: Table 22.1 pco 1 Input / Output Terminals I/O TYPE Analogue Input Digital Input INPUT / OUTPUT VOLTAGE DESCRIPTION TES STANDARD B1 Universal Not Used B2 Universal Geo Water Outlet (Freeze Protect) Temperature 1 B3 Universal Geo Water Outlet (Freeze Protect) Temperature 2 B4 Universal Not Used B5 Universal Not Used Stacked Waterto Water Only B6 Universal Freeze Protection Setpoint Selection ID1 24Vac G Fan Call Normally Open ID2 24Vac Y1 Compressor Low Speed Call Normally Open ID3 24Vac Y2 Compressor High Speed Call Normally Open ID4 24Vac O Reversing Valve Call Normally Open ID5 24Vac Condensate Float Switch Normally Closed ID6 24Vac Aquastat Call Normally Open ID7 24Vac Low Pressure Switch Normally Closed ID8 24Vac High Pressure Switch Normally Closed Y1 010V Not Used Analog Output Y2 010V Not Used Y3 010V Not Used Y4 010V Not Used 1 24Vac L Alarm Output Normally Open 2 24Vac Compressor Low Speed Output Normally Open 3 24Vac Hydronic Pump Output Normally Open Digital Output 4 24Vac Not Used 5 24Vac Not Used 6 24Vac Alarm Flash Code Normally Open 7 24Vac Compressor High Speed Output Normally Open 8 24Vac Reversing Valve Output Normally Open 22

23 Typical BMS EMS BAS System Variables Table 23.1 Typical BMS EMS BAS System Variables CAREL INDEX 1 2 DESCRIPTION VARIABLE NAME READ / WRITE DATA TYPE LON TYPE Geo Water Outlet Freeze Protection Temperature CCT1 (B2) Geo_H2O_Out_Temp_1 R Analog SNVT_temp 1 Geo Water Outlet Freeze Protection Temperature CCT2 (B3) Geo_H2O_Out_Temp_2 R Analog SNVT_temp 1 1 Fan Running Hours Low Component Fan_Hours_L R Integer SNVT_count 1 2 Fan Running Hours High Component Fan_Hours_H R Integer SNVT_count 1 3 Compressor Running Hours Low Component Comp_Hours_L R Integer SNVT_count 1 4 Compressor Running Hours High Component Comp_Hours_H R Integer SNVT_count 1 80 Current Day CURRENT_DAY R Integer NotSet 1 81 Current Month CURRENT_MONTH R Integer NotSet 1 82 Current Year CURRENT_YEAR R Integer NotSet 1 83 Current Hour CURRENT_HOUR R Integer NotSet 1 84 Current Minute CURRENT_MINUTE R Integer NotSet 1 1 Unit On/Off by BMS Command SUPERV_OFF R/W Digital SNVT_switch 1 2 Unit On/Off State System_ON R Digital SNVT_switch 1 3 General Alarm Alarms_on R Digital SNVT_switch 1 4 Unit Operating in Manual Override Mode Manual_ON_OFF R Digital SNVT_switch 1 7 Check Air Filter Alarm Al_Maintenance_Fan R Digital SNVT_switch 1 8 Clock Error Alarm AL_CLOCK32 R Digital SNVT_switch 1 9 Alarm Reset alarms_reset R/W Digital SNVT_switch 1 10 Fan Input (G) Din_Value_1 R Digital SNVT_switch 1 11 Compressor Low Input (Y1) Din_Value_2 R Digital SNVT_switch 1 12 Compressor High Input (Y2) Din_Value_3 R Digital SNVT_switch 1 13 Reversing Valve Input (O) Din_Value_4 R Digital SNVT_switch 1 14 Condensate Float Switch Input Din_Value_5 R Digital SNVT_switch 1 15 Aquastat Input Din_Value_6 R Digital SNVT_switch 1 16 Low Pressure Switch Input Din_Value_7 R Digital SNVT_switch 1 17 Alarm Active Dout_1 R Digital SNVT_switch 1 18 Compressor Low Speed Output Dout_2 R Digital SNVT_switch 1 19 Hydronic Pump Output Dout_3 R Digital SNVT_switch 1 22 Alarm Flash Code Dout_6 R Digital SNVT_count 1 23 Compressor High Speed Output Dout_7 R Digital SNVT_switch 1 24 Reversing Valve Output Dout_8 R Digital SNVT_switch 1 25 Heartbeat Signal from BMS heartbeat R/W Digital SNVT_switch 1 26 High Pressure Switch Input Din_Value_8 R Digital SNVT_switch 1 27 Critical Alarm Relay Output Critical_Alarm_DOUT R Digital SNVT_switch 1 28 High Pressure Alarm AL_High_Pressure R Digital SNVT_switch 1 29 Low Pressure Alarm AL_Low_Pressure R Digital SNVT_switch 1 30 Condensate Float Switch Alarm AL_Cond_Float_Switch R Digital SNVT_switch 1 31 Freeze Protection Alarm AL_Low_Freeze_Temp R Digital SNVT_switch 1 32 Geo Water Outlet 1 Sensor Failure Alarm AL_Geo_H2O_Out_Temp_1_Pr R Digital SNVT_switch 1 33 Geo Water Outlet 2 Sensor Failure Alarm AL_Geo_H2O_Out_Temp_2_Pr R Digital SNVT_switch 1 LON FACTOR 23

24 Modine Manufacturing Company 2017 Modine Manufacturing Company 1500 DeKoven Avenue Racine, WI Phone: (4GEO)