NetworkAIR AFX Operation and Maintenance AFX65 AFX18
Contents Operation... 1 Display Interface.......................................... 1 Using the Display......................................... 3 Start-up screen...................................... 3 Handling alarms...................................... 3 Display return air conditions status....................... 4 Display component status.............................. 4 Display run hours.................................... 4 View alarm history.................................... 5 Clear alarm history................................... 5 General Setup............................................ 6 Display interface operation............................. 6 Change the temperature setpoint......................... 6 Change the high and low return temperature alarms.......... 6 Change the humidity setpoint........................... 7 Change the humidity high and low alarms.................. 7 Remote alarm setup................................... 8 Customizing System Settings............................... 9 System setup........................................ 9 Passwords.......................................... 9 Temperature units................................... 10 Communications.................................... 10 Temperature control................................. 11 Humidity control.................................... 12 Compressor setup................................... 13 Temperature sensor offset (calibrating AI1)................ 14 Sensor offsets for AI2 through AI4....................... 14 Humidity sensor offset (calibrating AI5)................... 15 Analog output setup (AO1)............................. 16 Analog output setup (AO2)............................. 16 Resetting the Microprocessor Controller..................... 17 Blower................................................. 18 Cooling Cycle........................................... 19 Compressor cooling................................. 19 Humidification...................................... 19 Heating cycle....................................... 20 NetworkAIR AFX Installation i
Electronic Controls Component Identification................ 21 Main board components...............................21 Interface diagram...................................22 Pinout of interface board..............................23 Memory...........................................24 RS485 serial connection card...........................24 Display cable.......................................25 Temperature/humidity sensor...........................25 DIP switch settings..................................26.................................................26 Gateway...........................................27 Redundant group connection box.......................27 Configuration Checklist................................... 28 Maintenance... 31 Component Control/Safety Adjustments..................... 31 Belt tension........................................31 Overload relay......................................32 Motor pulley........................................32 Clogged-filter switch.................................33 Low air pressure switch...............................33 Air filters..........................................34 Firestat...........................................35 Refrigeration system sight glass........................35 High pressure switch.................................36 Flow switch (optional)................................36 Humidifier Procedures.................................... 37 Humidifier operation.................................37 Areas with low water conductivity.......................37 Humidifier service...................................38 Remove the steam cylinder............................38 Remove the humidifier drain valve manifold................41 Remove and clean the humidifier drain solenoid............42 Remove and clean the humidifier fill valve assembly.........43 System Configurations................................... 44 Air cooled.........................................44 Water cooled.......................................44 Glycol system......................................45 ii NetworkAIR AFX Installation
System Maintenance Information...........................46 Glycol system...................................... 46 Glycol system and water cooled system.................. 46 Air cooled system................................... 46 Troubleshooting Tables...................................47 Monthly Preventive Maintenance............................51 Environment....................................... 51 Cleanliness........................................ 52 Mechanical........................................ 52 Electrical.......................................... 52 Seasonal Preventive Maintenance...........................53 Mechanical........................................ 53 Electrical.......................................... 53 Annual Preventive Maintenance............................54 Cleanliness........................................ 54 Warranty...55 Warranty Statement.......................................55 APC product covered................................ 55 Terms of warranty................................... 55 Non-transferable Warranty extends to first purchaser for use.. 55 Assignment of warranties............................. 55 Drawings, descriptions............................... 56 Warranty claims procedure............................ 56 Exclusions........................................ 56 NetworkAIR AFX Installation iii
Operation Display Interface Item Function Temp key Allows direct access to the cooling and reheating setpoints, and to their alarm thresholds. Humid key Allows direct access to the humidification and dehumidification setpoints, and to their alarm thresholds. Run Hours key Accesses run-hours information including accumulated run-hours on components, runhour intervals, and hours left before next run-hour alarm. Status key Displays incoming air conditions and operational status. Liquid Crystal Display (LCD) The 4-line by 20-character alphanumeric display shows unit operating conditions, any present alarms, and user-programmable configuration prompts. Alarm History key Accesses past (cue/number) alarms.3 Help key Provides information to navigate screens. Network key Displays the number of units on the redundant network and their addresses. Enter key Moves the cursor within the menu screen. Clears displayed alarms. After modifying a parameter, repeatedly pressing the Enter key will return the cursor to the upper left corner where it must be located to accept the change. Down Arrow key Turns to the previous page within a menu. Decreases a selected control parameter in small increments. When pressed and held, decreases the parameter in large increments. NetworkAIR AFX 1
Operation: Display Interface Item Function Up Arrow key Turns to the next page within a menu. Increases a selected control parameter in small increments. When pressed and held, increases the parameter in large increments. Alarm key Immediately displays the first alarm. An illuminated red LED in the center of the key indicates the presence of an alarm. On/Off key Starts the unit locally when it is in the System Off mode. Stops the unit locally when it is in the Fan On mode (indicated by an illuminated green LED in the center of the key). Blank key Returns the display screen to the home page. Config key Allows access to the following Technician menus: Custom Setup Remote Alarm Setup Special key Allows you to set the time and date. 2 NetworkAIR AFX
Using the Display Start-up screen When power is applied, the display momentarily shows the unit type and date of the program: Handling alarms After the start up screen has displayed, the red LED in the center of the alarm key illuminates if an alarm has been activated. If no action is taken, the display will cycle through the following screens: 1 2 3 To clear alarms: 1. Press the alarm key. 2. Press the key to scroll through the alarms. 3. Press Enter to clear the alarms. Note: If the alarm returns after clearing, the alarm condition still exists. 60 seconds of key inactivity will return the display to the default screen (screen 1). You may change the first line of the default screen to personalize the designation of the unit with up to 10 digits. See Communications on page 10 for more information. NetworkAIR AFX 3
Operation: Using the Display Note: You cannot change the following status screens. Display return air conditions status Press the Status key to display the default screen, which reports the temperature and humidity and indicates whether the system is ON or OFF. If the system is ON, the bottom line will display Fan ON after first showing Initial delay... If the system is in the dehumidification mode, the display will also show Dehumidify. Note: The screens shown are examples only. Your screens may be different, depending upon the system, options, and status. Display component status Press the Status Key, then press 1 time. Top line: As shown, the unit is OFF. Fan ON = the unit is running. Second line: C1-OFF = The compressor is OFF. C1-ON = The compressor is running. If the unit has two stages of cooling, the C2 status will be displayed as well. C1-PMDN = A compressor is pumping down. Last line: Heat and humidifier status. Display run hours 1. Press the Run Hours key. The digital output for the component is shown on the first line. The component name and run hours is shown on the second line. The alarm interval is shown on the third line. To modify Alarm set, press Enter 1 time. Use or to set the hours as desired (0000-9999). After modifying you must press Enter repeatedly until the cursor returns to the upper left corner and the changes are accepted. The remaining time left before the next alarm occurs is shown on the fourth line. 2. Press to display the next run time alarm and settings. 4 NetworkAIR AFX
Operation: Using the Display View alarm history The last twenty alarm occurrences are tracked and displayed as a list. Each list will store up to ten different simultaneous alarms. 1. Press the Alarm History key. 2. Press Enter to display the most recent alarm list. The first line shows the date, time in 24-hour format, and sequential list number. In this example, the alarm occurred on January 1 at 1:15 pm, and is the third list in the sequence (L:03). Note: As alarms occur, the list number is incremented until the maximum number of 20 is reached. After list number 20 is reached, the next alarm will overwrite the oldest list. The second line shows the return temperature and humidity level at which the alarm occurred. The third line displays the alarm type. 3. To view the next list, press Enter. Press or to loop through all the lists. Clear alarm history Caution: After the history is cleared from memory, it cannot be retrieved. You might want to clear the alarm history from the controller, for example, after you change or update the program, or overhaul your equipment. 1. Press the Alarm History key to display the alarm history screen. 2. Press (the blank key) to move the cursor above the word Key. 3. Press the Help key to reset the history. When the screen displays again, the history has been reset. NetworkAIR AFX 5
General Setup Display interface operation Note: Record any custom settings (settings that differ from the factory default settings) on the configuration checklist on page 28 of this manual. Changes are stored in nonvolatile memory and are not affected by power outages. Changes will NOT be accepted until you repeatedly press Enter, moving the cursor to the upper left corner of the screen. Once the cursor is located in the upper left corner of the screen, the setting can take effect. You may now press another key and perform a different programming function, or in 60 seconds, the display will revert to the default screen. When using or to change settings, a single press of the key will change the setting to the next value. Press and hold the key to scroll quickly. Change the temperature setpoint 1. Press the Temp key to display the temperature setpoint screen. 2. Press Enter until the cursor is under the setpoint value you want to change. 3. Press to raise the setpoint temperature or press to lower the setpoint temperature until the desired value is displayed. Press and hold the appropriate key to scroll rapidly through the temperature selections. 4. Repeat step 3 until you are finished changing settings. 5. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. Change the high and low return temperature alarms 1. Press the Temp key, then press to display the high and low return temperature alarms screen: 2. Press Enter until the cursor is under the setpoint value you want to change. 3. Press to raise the setpoint or press to lower the setpoint until the desired value is displayed. Press and hold the appropriate key to scroll rapidly through the selections. 4. Repeat step 3 until you are finished changing settings. 5. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. 6 NetworkAIR AFX
Operation: General Setup Change the humidity setpoint 1. Press the Humid key. 2. Press Enter until the cursor is under the value you want to change. 3. Press to raise the setpoint or press to lower the setpoint until the desired value is displayed. Press and hold the appropriate key to scroll rapidly through the setpoint selections. 4. Repeat step 3 until you are finished changing settings. 5. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. Change the humidity high and low alarms 1. Press the Humid key, then press to display the humidity alarms screen. 2. Press Enter until the cursor is under the value you want to change. 3. Press to raise the setpoint or press to lower the setpoint until the desired value is displayed. Press and hold the appropriate key to scroll rapidly through the setpoint selections. 4. Repeat step 3 until you are finished changing settings. 5. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. NetworkAIR AFX 7
Operation: General Setup Remote alarm setup 1. Press the Config key to display the technician menu. 2. Press Enter until the cursor is on the Remote alarm setup line. 3. Press to display the remote alarm setup screen. 4. Press or to scroll through the following alarms: EEPROM Fail Low Temp C2 High PSI C1 LP Airflow High Hum Water Detect Water Flow Ret Hi Temp Low Hum Humidifier Ret Low Temp C1 High PSI Smoke Detector Hi Temp C2 Low PSI Filter Note: Factory default setting on all alarms are: COM set to ON and XFR set to OFF. Each alarm may be set with its COM (Common Option) ON or OFF: COM set to ON: When an alarm occurs, the unit will display the alarm locally (at the unit) and change the state of the Common Alarm Dry Contacts (see unit wiring). COM set to OFF: When an alarm occurs, the unit will still display the alarm locally, but the Common Alarm Dry Contacts will not change state. Each alarm may be set with its XFR (Transfer Option) ON or OFF: XFR set to ON: When an alarm occurs, the unit will display the alarm locally, shut down, and transfer operation to a standby unit in the same Redundant Unit Group Network, if one exists. XFR set to OFF: When an alarm occurs, the unit will display the alarm locally and continue running. Fatal alarms, such as Fire or Smoke are the exception. The unit will shut down and will not attempt to transfer operation to any other unit. 5. Press Enter to select each alarm s COM or XFR setting and press or to set each to ON or OFF. 6. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. 8 NetworkAIR AFX
Customizing System Settings System setup 1. Press the Config key to display the Technician Menu. 2. Press Enter repeatedly until the cursor is on the Custom setup line. 3. Press to display the first page of the setup screen. The Fan delay and Mode delay allow a wide range of settings to stagger the startup of multiple units to prevent power overloads or allow external dampers to open. a. Fan delay is adjustable to 999 seconds and delays the amount of time before the blower runs when the on/off key is pressed from the Keypad OFF mode. The default is factory set to zero (no delay). b. Mode delay values are adjustable from 1 to 999 seconds. The factory set default is 11 seconds. This setting delays the first mode of operation after the blower starts. The Alarm buzzer is factory set to OFF. When set to OFF, the alarm sounds momentarily during startup, but not during an alarm condition. When set to ON, the alarm sounds whenever an alarm condition exists. 4. Press Enter repeatedly to move the cursor to the desired item. 5. Press or to change the setting. 6. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. Passwords The two levels of passwords are factory set to all zeros, allowing unlimited access to all programming functions without password prompts. The level 1 password allows access only to the temperature and humidity setpoints. The level 2 password allows access to the setpoints and the setup menus. 1. Press the Config key to display the technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the password screen is displayed. 4. Press Enter repeatedly until the cursor is below the desired password level. 5. Press or to change the password. NetworkAIR AFX 9
Operation: Customizing System Settings 6. When you finish your changes to the first password, press Enter repeatedly until the cursor is below the next password level. 7. Press or to change the password. 8. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen... Note: The level 1 password will not become effective until a password is entered for level 2. Note: Call the Customer Support telephone number for your region (located on the back of the manual) for technical support if you forget your passwords. Temperature units The temperature can be displayed and controlled in either Fahrenheit or Celsius. 1. Press the Config key to display the technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press until the temperature screen is displayed. 4. Press Enter repeatedly until the cursor is on the Units line. 5. Press or to change the temperature units. 6. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. Communications You can set the following values: Unit name (up to 10 digits) Network ID number (1-200) Communications baud rate (1200-19200) 1. Press the Config key to display the technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the communications screen is displayed. 4. Press Enter repeatedly until the cursor is under the specific digit of the setting you want to change. 5. Press or to change the digit. 6. Repeat steps 4 and 5 until all changes are made. 7. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. 10 NetworkAIR AFX
Operation: Customizing System Settings Temperature control Caution: The controller has been factory set for the best possible environmental control applications and should not be changed unless absolutely necessary. For guidance, call the Customer Support telephone number for your region (located on the back of the manual). Controller factory settings and options are: Field Default Setting Option or Range Control Type Proportional (P) P or P + I Deadbands ±2ºF (±1ºC) 1º - 99º F/C Integral Timer 600 seconds 1 to 99 seconds With proportional control type, the microprocessor operates within the selected deadband around the temperature setpoint. (See Change the temperature setpoint on page 6 of this manual.) The strength of the demand signal ranges proportionally from 0 to 100% from the setpoint to the end of the deadband. If the controller does not seem to be responding quickly enough, the control type setting can be changed to proportional and integral (P+I). In this case, operation occurs only after the selected integral time has elapsed (provided the target temperature was not achieved). At that point, the demand signal strength increases by 100% until the unit is operating at the target temperature. 1. Press the Config key to display the technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the temperature control screen is displayed. 4. Press Enter repeatedly until the cursor is under the parameter you want to change. 5. Press or to change the setting. 6. Repeat steps 4 and 5 until all changes are made. 7. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. NetworkAIR AFX 11
Operation: Customizing System Settings Humidity control Caution: The controller has been factory set for the best possible environmental control applications and should not be changed unless absolutely necessary. For guidance, call the Customer Support telephone number for your region (located on the back of the manual). Controller factory settings and options are: Field Default Setting Option or Range Control Type Proportional (P) P or P + I Deadbands ±5% RH 1% - 99% RH Integral Timer 600 seconds 1 to 99 seconds With proportional control type, the microprocessor operates within the selected deadband around the humidity setpoint. (See Change the humidity setpoint on page 7 of this manual.) The strength of the demand signal ranges proportionally from 0 to 100% from the setpoint to the end of the band. If the controller does not seem to be responding quickly enough, the control type setting can be changed to proportional and integral (P+I). In this case, operation occurs only after the selected integral time has elapsed (provided the target humidity was not achieved). At that point, the demand signal strength increases by 100% until the unit is operating at the target humidity. 1. Press the Config key to display the technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the humidity control screen is displayed. 4. Press Enter repeatedly until the cursor is under the parameter you want to change. 5. Press or to change to the desired setting. 6. Repeat steps 4 and 5 until all changes are made. 7. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. 12 NetworkAIR AFX
Operation: Customizing System Settings Compressor setup You can change the small-room delay time, compressor rotation, and rotation time. Field Default Setting Option or Range Small-room delay 0 seconds 0 to 999 seconds Rotation ON ON or OFF Rotation Time 10 hours 1 to 999 hours The microprocessor has an inter-mode delay of 300 seconds. Any additional small-room delay time is added to that delay to help prevent rapid cycling between heating and cooling modes. This additional time helps allow the room temperature to stabilize between modes. Note: The small-room delay feature cannot compensate for an environmental control unit that is improperly sized for the load. AFX65 Only: When rotation is set to ON, the microprocessor allows the LEAD compressor to become the LAG compressor. The rotation time is the runtime (in hours) that the LEAD compressor must run before becoming the LAG compressor. 1. Press the Config key to display the Technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the compressors screen is displayed. 4. Press Enter repeatedly until the cursor is under the parameter you want to change. 5. Press or to change the setting. 6. Repeat steps 4 and 5 until all changes are made. 7. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. NetworkAIR AFX 13
Operation: Customizing System Settings Temperature sensor offset (calibrating AI1) You can calibrate the temperature portion of the temperature and humidity sensor from the display without actually making adjustments to the physical sensors in the environmental control unit. The offset is factory set for 0.0º, but may be adjusted from -10º to +10º. Note: If this offset range is insufficient to correct the reading, the temperature and humidity sensor must be replaced. Use a calibrated, industrial-quality instrument to determine what (if any) offset is required. Place the bulb of the instrument as close as possible to the sensor to ensure that the instrument is sampling the same air as the sensor. 1. Press the Config key to display the Technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the sensor offset screen is displayed. 4. Press Enter repeatedly until the cursor is under the the CALIBRATION (offset) value. 5. Press or to change the offset to the desired setting. For example, in the sample display screen the ACTUAL line reads 72ºF. If the temperature as measured by the instrument is 75.0ºF (24º C), enter an offset value of +3º. Note: Properly calibrated, the temperature as shown on the ACTUAL line will change to agree with the measuring instrument. 6. Repeat step 5 until the temperature on the ACTUAL line agrees with the calibrated measuring instrument. 7. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. Sensor offsets for AI2 through AI4 These screens are factory configured according to options selected with the environmental control unit. They will not display unless the option is present on the unit. Adjust the offsets in the same way as the previous temperature and humidity sensor offsets. 14 NetworkAIR AFX
Operation: Customizing System Settings Humidity sensor offset (calibrating AI5) You can calibrate the humidity portion of the temperature and humidity sensor from the display without actually making adjustments to the physical sensors in the environmental control unit. The offset is factory set for 0.0%, but may be adjusted from -10% to +10%. Note: If this offset range is insufficient to correct the reading, the temperature and humidity sensor must be replaced. Use a calibrated, industrial quality instrument to determine what (if any) offset is required. Place the bulb of the instrument as close to the sensor as possible to ensure that the instrument is sampling the same air as the sensor in the environmental control unit. 1. Press the Config key to display the technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the sensor offset screen is displayed. 4. Press Enter repeatedly until the cursor is under the the CALIBRATION (offset) value. 5. Press or to change the offset to the desired setting. For example, in the sample display the ACTUAL relative humidity reads 45.0%. If the humidity as measured by the instrument is 41.0%, enter an offset value of -4%. Note: Properly claibrated, the humidity as shown on the ACTUAL line will change to agree with the measuring instrument. 6. Repeat step 5 until the temperature on the ACTUAL line agrees with the calibrated measuring instrument. 7. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. NetworkAIR AFX 15
Operation: Customizing System Settings Analog output setup (AO1) Note: If the display reads N/A and the system is utlilizing analog output at startup, call the Customer Support number for your region (see the back cover of this manual) for technical assistance. Some options of the environmental control unit use analog voltage outputs. You can configure the starting and ending voltages, and choose either the direct-acting or reverse-acting mode. Factory settings: Line 2 displays the name of the optional unit (CG Damper, Humidifier, COOL, or HEAT). If you have none of these options, NA is displayed. Field Default Setting Range or Option Low voltage 06.0 VDC 0.0 to 10.0 VDC High voltage 09.0 VDC 0.0 to 10.0 VDC Mode DIR DIR or REV 1. Press the Config key to display the technician menu. 2. Press Enter twice until the cursor is on the Custom setup line. 3. Press repeatedly until the sensor analog output screen is displayed. 4. Press Enter repeatedly until the cursor is under the the value you want to change. 5. Press or to change the value. 6. Repeat steps 4 and 5 until all values have been changed. 7. To save your changes, press Enter repeatedly to move the cursor to the upper left corner of the screen. Analog output setup (AO2) Note: If the display reads N/A and the system is utlilizing analog output at start-up, call the Customer Support number for your region (see the back cover of this manual) for technical assistance. See Analog output setup (A01) on page 15 of this manual for instructions on Analog output number 2 setup. 16 NetworkAIR AFX
Resetting the Microprocessor Controller The controller stores all setup information in non-volatile memory; factory defaults user-defined values information specific to any options supplied with the unit Caution: Before you change any setup values, see the configuration checklist on page 28 of this manual. Reset values from the Software Version screen 1, which is displayed upon intial power-up, or by pressing (the blank key) at any time. 1. Press Enter until the cursor is above the S as shown on screen 1. 2. Press the Temp key and the Run Hours key simultaneously. The cursor moves under the date (020599), which corresponds to this software version. 3. Press or to change the date to anything other than the original date. 4. Press Enter. The display shown in screen 2 appears. After a brief time, screen 3 appears, with the cursor under the temperature units of measurement. 5. Press or if you want to change units of measurement. 6. Press Enter to move the cursor under the Model selection. 7. Press or to select the type of unit. 8. Press Enter. Pause until Wait-Configuring displays. Ignore the alarm that sounds. 9. When the first page of the I/O menu is displayed. Press to scroll down all pages of the I/O menu. After page 13 of the menu, screen 4 is displayed. 10. Turn off power for 10 seconds, then reapply power. 11. Clear the power loss alarm that sounds. 1 2 3 4 NetworkAIR AFX 17
Blower The blower will run continuously under the following conditions: Correct current (24 volts) is present on DI 5 (Enable) The start-up delay timer is not running The unit is not in STANDBY No FIRE or SMOKE alarms exist The unit has not been placed in the STOP mode (either locally or remotely) Overloads are not tripped Caution: The blower will not run during an AIRFLOW ALARM condition. 18 NetworkAIR AFX
Cooling Cycle Compressor cooling AFX65: In cooling mode, compressors are engaged incrementally with increasing demand. The lead compressor stage activates when the return air temperature reaches the setpoint plus 50% of the deadband. For example, if the setpoint is 80º F and the deadband is 4º, the lead compressor is activated at 82ºF. As the return air temperature rises to the setpoint plus 99% of the deadband (84º F in the example), the lag compressor is activated. To set deadbands, see Temperature control on page 11 of this manual. When the return air temperature falls to the setpoint plus 20% of the deadband (approximately 81ºF, 27ºC), the lag compressor shuts off, provided its minimum-on timer has expired. If the return air temperature drops to the setpoint plus 1% of the deadband (80ºF, 26ºC), the lead compressor shuts off provided its minimum-on timer has expired. AFX18: In cooling mode, the compressor is engaged when the return air temperature reaches the setpoint plus 50% of the deadband. For example, if the setpoint is 80ºF (26ºC) and the deadband is 4º, the compressor is activated at 82ºF (28ºC). When the return air temperature falls to the setpoint plus 20% of the deadband (approximately 81ºF, 27ºC), the compressor shuts off. Humidification To set deadbands, see Temperature control on page 11 of this manual. To configure humidifier settings, see Humidity control on page 12 of this manual. When enabled, humidification occurs when the relative humidity is less than the humidity setpoint minus the humidity deadband. The digital humidity output turns on and remains on until the humidity reaches the humidity setpoint. If the analog humidifier control is enabled, the analog output can be used to control a proportional humidifier. The output is at the minimum voltage when the humidity is at or above the humidification setpoint. The output increases proportionally as the humidity drops from the humidity setpoint. NetworkAIR AFX 19
Operation: Cooling Cycle Heating cycle To set up dehumidification, see Change the humidity setpoint on page 7 of this manual. To configure the heating setpoint, see Change the temperature setpoint on page 6 of this manual. Electric heating occurs when the heaters are enabled and the return air temperature is below its heating setpoint minus the deadband. Three stages of heating are available to maintain the return air temperature above its heating setpoint. Stage 1 Stage 2 Percentage of total available heat output OFF ON 33% ON OFF 66% ON ON 100% The percentage of heating is shown in the center of the display. During either dehumidification mode, air is reheated after it is cooled in order to remove moisture. 20 NetworkAIR AFX
Electronic Controls Component Identification Main board components Item Description Replaceable fuse block Microprocessor containing the application program Building Management System (BMS) RS485/RS422 Connection Relays Addressing/clock card. This card is the location of the permanent memory microprocessor (page 24) and also DIP switches (page 26) Redundant Unit Grouping (RUG) connection Power supply connection NetworkAIR AFX 21
Operation: Electronic Controls Component Identification Interface diagram 22 NetworkAIR AFX
Operation: Electronic Controls Component Identification Pinout of interface board Pin Levels Default Signal Definition DI 1 Digital Input Low= Airflow Alarm DI 2 Digital Input High = Clogged Filter Alarm DI 3 Digital Input High = Water Detector Alarm DI 4 Digital Input Low = Compressor 1 L P, HWF Alarm DI 5 Digital Input High = System Enable DI 6 Digital Input Low = Compressor 2 L P, Door Alarm DI 7 Digital Input Low = Water F12, Water F13 Alarm DI 8 Digital Input High = Firestat Alarm DI 9 Digital Input High = Smoke Detector Alarm DI 10 Digital Input High = Humidifier Freeze, Compressor Lockout, Condensate Pump Alarm DI 11 Digital Input Low = Compressor 1 High Pressure Alarm DI 12 Digital Input Low = Compressor 2 High Pressure Alarm AI 1 NTC Input Return Temperature sensor AI 2 NTC Input Supply Temperature AI 3 NTC Input Not Used AI 4 NTC Input Temperature 2 AI 5* Analog Input 0 to 1 volt Return Humidity sensor AI 6* Analog Input Not Used AI 7** Analog Input Remote Temp AI 8** Analog Input Remote Humidity DO 1 Digital Output Blower DO 2 Digital Output Electric Heat Stage 1 or Heat Valve Open DO 3 Digital Output Electric Heat Stage 2 or Heat Valve Close DO 4 Digital Output Humidifer DO 5 Digital Output Compressor 1 Liquid Line DO 6 Digital Output Compressor 1 Contactor DO 7 Digital Output Compressor 2 Liquid Line, Fan low speed, Hot Gas bypass DO 8 Digital Output Compressor 2 Contactor DO 9 Digital Output Unloader 1, Hot Gas 1, CL Valve open DO 10 Digital Output DEH/HG2, CL valve close, Unloader 2 DO 11 Digital Output Common Alarm DO 12 Digital Output Not Used DO 13 Digital Output Not Used AO1 Analog Output Cool, Heat, Humidifier AO2 Analog Output Cool, Heat, Humidifier NOTE: * Analog inputs 5 and 6 (AI 5 and AI 6) are selectable for either 0-1 volt or 4-20 ma inputs. * Jumper 2 and 3 for 0-1 volt or 1 and 2 for 4-20 ma. See the Interface Board diagram on page 22. * J14 controls AI 5 * J15 controls AI 6 ** Analog inputs 7 and 8 (AI 7 and AI 8) are 4-20 ma inputs only. NetworkAIR AFX 23
Operation: Electronic Controls Component Identification Memory Location and removal. Item Description Main Board Microprocessor containing application program ) Addressing/clock card Microprocessor containing permanent memory RS485 serial connection card 24 NetworkAIR AFX
Operation: Electronic Controls Component Identification Display cable Item Description Item Description Wire, White Wire, Black Wire, Red Wire, Green Wire, Yellow Wire, Blue RJ11 modular plug, (Quantity of 2) Flat cable, 6-conductor, 24-guage, 500 ft maximum Temperature/humidity sensor NetworkAIR AFX 25
Operation: Electronic Controls Component Identification DIP switch settings 1. The location of the display board DIP switches. 2. The location of the DIP switches on addressing/clock card. The addressing/clock card is located on the main board. See Main Board on page 21. 26 NetworkAIR AFX
Operation: Electronic Controls Component Identification Gateway Redundant group connection box NetworkAIR AFX 27
Configuration Checklist Numbers in parentheses are Celsius Ranges for temperatures are scale independent (ºF or ºC). The given ranges do not imply that the unit will function properly over all of the values. PARAMETER DEFAULT RANGE SETTING Start Up Delay 000 seconds 0 to 600 seconds Fan Delay 11 seconds 0 to 600 seconds Cool Setpoint 72.0º F (22.0º) 12.0º to 95.0º (-11º to 35º) Cool Band 2.0º F (1.0º) 1.0º to 15.0º Return Temperature Offset 00.0º F (00.0º) -20.0º to + 20.0º DX Stages 2 0 to 2 Small Room Delay 000 seconds 0 to 999 seconds Pump Down OFF ON or OFF Minimum DX Off Time 300 seconds 180 to 999 seconds Minimum DX On Time 300 seconds 180 to 999 seconds Return Temperature Sensor Alarm Common ON ON or OFF Return Temperature Sensor Alarm Transfer ON ON or OFF DX Lead/Lag ON ON or OFF Lead/Lag Switch Time 10 hours 1 to 999 hours Heat Setpoint 70.0º F (21.0º) 0º to 85.0º (-17º to 29º) Heat Band 2.0º F (1.0º) 1.0º to 15.0º Heat Type ELECTRIC ELECTRIC or VALVE Electric Heat Stages 2 0-2 Humidifier Control ENABLED ENABLED or DISABLED Dehumidification Control ENABLED ENABLED or DISABLED Humidification Setpoint 45.0 % RH 10.0 to 85.0 % RH Dehumidification Setpoint 55.0 % RH 10.0 to 95.0 % RH Humidification Band 5.0 % RH 1.0 to 30.0 % RH Dehumidification Band 5.0 % RH 1.0 to 30.0 % RH Humidity Sensor Offset 00.0 % -20.0 % to +20.0 % Analog Humidity Start Voltage 00.0 V 0.0 to +10.0 V Analog Humidity Span Voltage 10.0 V -10.0 to +10.0 V Analog Humidity Offset Voltage 0.0 V -2.0 to +2.0 V Return Humidity Sensor Alarm Common ON ON or OFF Return Humidity Sensor Alarm Transfer OFF ON or OFF Airflow Alarm Common ON ON or OFF Airflow Alarm Transfer OFF ON or OFF Airflow Alarm Closure OFF ON or OFF Airflow Alarm Enable ON ON or OFF Airflow Alarm Delay 10 seconds 10-600 seconds Clogged Filter Alarm Common ON ON or OFF Clogged Filter Alarm Transfer OFF ON or OFF 28 NetworkAIR AFX
Operation: Configuration Checklist PARAMETER DEFAULT RANGE SETTING Clogged Filter Alarm Closure ON ON or OFF Clogged Filter Alarm Enable ON ON or OFF Water Detector Alarm Common ON ON or OFF Water Detector Alarm Transfer OFF ON or OFF Water Detector Alarm Closure ON ON or OFF Water Detector Alarm Enable ON ON or OFF Comp. 1 Low Pressure Alarm Common ON ON or OFF Comp. 1 Low Pressure Alarm Transfer OFF ON or OFF Comp. 1 Low Pressure Alarm Closure OFF ON or OFF Comp. 1 Low Pressure Alarm Enable ON ON or OFF Comp. 2 Low Pressure Alarm Common ON ON or OFF Comp. 2 Low Pressure Alarm Transfer OFF ON or OFF Comp. 2 Low Pressure Alarm Closure OFF ON or OFF Comp. 2 Low Pressure Alarm Enable ON ON or OFF Water Flow Alarm Common ON ON or OFF Water Flow Alarm Transfer OFF ON or OFF Water Flow Alarm Closure OFF ON or OFF Water Flow Alarm Enable ON ON or OFF FireStat Alarm Common ON ON or OFF FireStat Alarm Transfer OFF ON or OFF FireStat Alarm Closure ON ON or OFF FireStat Alarm Enable ON ON or OFF Smoke Detector Alarm Common ON ON or OFF Smoke Detector Alarm Transfer OFF ON or OFF Smoke Detector Alarm Closure ON ON or OFF Smoke Detector Alarm Enable ON ON or OFF Comp. 1 High Pressure Alarm Common ON ON or OFF Comp. 1 High Pressure Alarm Transfer OFF ON or OFF Comp. 1 High Pressure Alarm Closure OFF ON or OFF Comp. 1 High Pressure Alarm Enable ON ON or OFF Comp. 2 High Pressure Alarm Common ON ON or OFF Comp. 2 High Pressure Alarm Transfer OFF ON or OFF Comp. 2 High Pressure Alarm Closure OFF ON or OFF Comp. 2 High Pressure Alarm Enable ON ON or OFF Comp. 1 Pump Down Alarm Common ON ON or OFF Comp. 1 Pump Down Alarm Transfer OFF ON or OFF Comp. 2 Pump Down Alarm Common ON ON or OFF Comp. 2 Pump Down Alarm Transfer OFF ON or OFF High Return Temp. Alarm Common ON ON or OFF High Return Temp. Alarm Transfer OFF ON or OFF High Return Temp. Alarm Enable ON ON or OFF High Return Temp. Alarm At 85.0º F (30.0º) 0º to 100.0º High Return Temp. Alarm Delay 300 seconds 1 to 600 seconds Low Return Temp. Alarm Common ON ON or OFF Low Return Temp. Alarm Transfer OFF ON or OFF Low Return Temp. Alarm Enable ON ON or OFF NetworkAIR AFX 29
Operation: Configuration Checklist PARAMETER DEFAULT RANGE SETTING Low Return Temp. Alarm At 55.0º F (13º) 0.0º to 100.0º Low Return Temp. Alarm Delay 300 seconds 1 to 600 seconds High Humidity Alarm Common ON ON or OFF High Humidity Alarm Transfer OFF ON or OFF High Humidity Alarm Enable ON ON or OFF High Humidity Alarm At 85.0% RH 0 to 100.0% RH High Humidity Alarm Delay 300 seconds 1 to 600 seconds Low Humidity Alarm Common ON ON or OFF Low Humidity Alarm Transfer OFF ON or OFF Low Humidity Alarm Enable ON ON or OFF Low Humidity Alarm At 30.0% RH 0 to 100.0% RH Low Humidity Alarm Delay 300 seconds 1 to 600 seconds Power Loss Alarm ON ON or OFF Blower Run Time Alarm OFF ON or OFF Blower Run Time Alarm Every 1000 hours 0 to 9999 Comp. 1 Run Time Alarm OFF ON or OFF Comp. 1 Run Time Alarm Every 1000 hours 0 to 9999 Comp. 2 Run Time Alarm OFF ON or OFF Comp. 2 Run Time Alarm Every 1000 hours 0 to 9999 Humidifier Run Time Alarm OFF ON or OFF Humidifier Run Time Alarm Every 1000 hours 0 to 9999 Setpoint Password 0000 0000-9999 Service Password 0000 0000-9999 Supervisor Address 00 00-100 30 NetworkAIR AFX
Maintenance Component Control/Safety Adjustments Note: APC recommends using only trained APC service personnel when servicing this equipment. Belt tension Warning: Perform Lockout/Tagout procedures on the equipment being serviced. Failure to remove power before servicing this equipment could result in serious injury or death. The blower motor is mounted on an adjustable base. Increase or decrease belt tension by raising or lowering the base. A properly adjusted belt will deflect about 3/4 to 1 inch (19 to 25 mm) per foot (300 mm) of span between the blower and motor pulleys when firmly pressed. Lock the belt in position after making adjustments. Caution: Too much tension shortens bearing, shaft and belt life. NetworkAIR AFX 31
Maintenance: Component Control/Safety Adjustments For quiet operation, the belt should be as loose as possible without causing slippage. Slippage can cause belt noise, insufficient airflow, or both. If the smaller pulley is noticeably warmer than the larger pully, the likely cause is belt slippage. Tighten the belt slightly. Do not test temperature while pulleys are turning. Readjust belt tension if the variable-speed pulley setting is changed or if the belt is replaced. Overload relay The blower motor starter has an adjustable overload relay. Set the adjustment dial to correspond to the full load amperes (FLA) on the blower motor. The overload has a manual reset button to prevent the motor from cycling on the overload switch. Motor pulley Warning: Perform Lockout/Tagout procedures on the equipment being serviced. Failure to remove power before servicing this equipment could result in serious injury or death. The pulley on the blower motor has a variable pitch diameter to allow the blowers to be sped up or slowed down to compensate for higher or lower external static pressure, or in some cases, high altitude. Before it left the factory, the motor pulley was sized and the unit tested with the pitch in the middle of its adjustment range. To change blower speed: 1. Remove the belt from the larger, nonadjustable blower pulley first. 2. Loosen the set screw on both movable sheaves (pulley sections) a. To increase blower speed, turn the moveable sheaves inward toward the center stationary sheave to increase the effective pitch diameter. b. To decrease blower speed, turn the moveable sheaves outward away from the center stationary sheave to decrease the effective pitch diameter. Note: Turn both sheaves the same number of times to maintain uniform tension on both belts. 3. Tighten the set screws again, making sure that they are not on the threaded portion of the sheave, and put the belts back on. 4. Check for proper alignment between the driving and driven sheaves. Improper alignment will cause premature wear on the blower belts. 32 NetworkAIR AFX
Maintenance: Component Control/Safety Adjustments Clogged-filter switch Note: The following procedure can only be performed using new, clean filters. The clogged-filter switch senses the air pressure drop across the filters. When the pressure drop is too high because of dirty filters, the switch closes and causes an alarm. The clogged filter switch has been set at the factory for approximately 1.0 inch of Water Column pressure drop across the filters. Check the setting at unit start-up. Cover one-third of the filter area and increase or decrease the clogged filter switch sensitivity so that the switch closes when one third of the filter area is blocked. Low air pressure switch The unit uses an APD (air pressure differential) switch to sense airflow loss through the unit. The APD is factory set to close at 0.2 inches of Water Column. The pressure setting is adjustable by turning the adjustment screw clockwise to increase and counterclockwise to decrease the setting. NetworkAIR AFX 33
Maintenance: Component Control/Safety Adjustments Air filters Replace air filters as necessary to maintain efficient operation. Consider local environmental conditions when deciding how frequently to change filters. Model Flow Filter Size Quantity AFX18 Down flow 15 1/2 X 30 X 4 2 AFX18 Up flow 18 X 27 X 4 2 AFX65 Down flow 15 1/2 X 30 X 4 6 AFX65 Up flow 18 X 27 X 4 6 34 NetworkAIR AFX
Maintenance: Component Control/Safety Adjustments Firestat The firestat heat response device used in this unit has a manual reset and an adjustable temperature setting. The firestat is factory set prior to shipment to trip when temperatures above 125 F are detected. If the firestat is tripped, an alarm sounds and the unit is shut down. To reset the firestat, press the silver button on the device. The location of the firestat depends on the unit model and options. Refrigeration system sight glass The refrigeration sight glass indicates liquid refrigerant flow and the presence of moisture. Bubbles in the sight glass indicate a shortage of refrigerant or a restriction in the liquid line. The moisture indicator changes from green to yellow when moisture is present in the system. NetworkAIR AFX 35
Maintenance: Component Control/Safety Adjustments High pressure switch The high pressure switch is located on the discharge line coming from the compressor. An alarm will sound if pressure exceeds the default setting on the switch. To manually reset the switch, remove the cover and press the red button. Flow switch (optional) If the unit is equipped with a flow switch, adjust the switch sensitivity for the flow at initial start-up to prevent false alarms. 36 NetworkAIR AFX
Humidifier Procedures Humidifier operation When the humidistat is activated, the cylinder fills to 110% of the Full Load Amperage (F.L.A.) or to the top of the cylinder, whichever occurs first. If it reaches 110% F.L.A., the water heats and boils away to 90% F.L.A. The humidistat concentrates conductive minerals in the cylinder so that a smaller volume of water is required to produce the rated steam output. Achieving the correct concentration of minerals extends the life of the disposable cylinder by minimizing electrode coverage. A water level that is too high usually indicates that the concentration of minerals in the cyliinder needs to be reduced so the unit adjusts the fill and drain valves to dilute the water. When 90% F.L.A. is reached, the fill valve opens refilling the cylinder to 110% F.L.A. If the water level rises too high, the drain valve will also come on. 0321456013251 Item Description Steam hose Cylinder Electrodes Drain valve Drain pan Drain canal Strainer Fill valve Inlet chamber Fill cup Fill chamber Water overflow chamber Areas with low water conductivity You can accelerate the normalization process by artificially increasing water conductivity. Dissolve one-half teaspoon of salt in a cup of water. Add it to the humidifier at the fill cup during a fill cycle. NetworkAIR AFX 37
Maintenance: Humidifier Procedures Humidifier service Warning: Perform Lockout/Tagout procedures on the equipment being serviced. Failure to remove power before servicing this equipment could result in serious injury or death. Warning: Burn hazard. The humidifier cylinder and drain lines may contain hot water. Let the humidifier cool before servicing. 1. Toggle the humidifier switch to the DRAIN position. Note: Wait 30 seconds to allow the humidifier cylinder to drain completely. 2. Remove power from the equipment at the mains. 3. Open the equipment door. 4. Verify that power is off. Remove the steam cylinder Warning: Burn hazard. The cylinder may be hot. Let it cool before touching it, or use protective gloves. Note: Replace the disposable steam cylinder at the end of its cylinder life. Cylinder life depends on water condition and humidifier usage. 1. The power wires to the cylinder are attached to cylinder plugs to the electrode pins on top of the cylinder. Pull these plugs vertically off the pins. 38 NetworkAIR AFX