A INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR G-TRAC2 GENERAL MANUAL MODEL 2.2 INDOOR AND OUTDOOR MODELS C LIST E D LIST E D R R UNIT MODEL NO. ______________________________ UNIT SERIAL NO. ______________________________ SERVICED BY: __________________________________ TEL. NO: ______________________________________ CANADIAN HEAD OFFICE AND FACTORY USA HEAD OFFICE AND FACTORY CANADIAN EASTERN FACTORY 1401-HASTINGS CRES. S.E. CALGARY, ALBERTA T2G-4C8 32050 W. 83rd ST.
A G-TRAC2 MANUAL TABLE OF CONTENTS TEMPERATURE CONVERSIONS.................................................................................................................................. 1 I. APPLICATION.......................................................................................................................................................... 1 II. SERVICE.......................................................................................................................................
A XVIII. G-TRAC2 MANUAL ROOM RESET THERMOSTAT OPTIONS ................................................................................................... 12 MODULATING ROOM RESET (CONTINUOUS BLOWER OPERATION ONLY) ............................................................................ 12 CALCULATED DISCHARGE T ABLE FOR ROOM AND AMBIENT RESET .................................................................................. 16 MULTIPLE ROOM SENSORS ....................................................
A G-TRAC2 MANUAL FIRE WITHOUT COMBUSTION FAN .................................................................................................................................... 35 HEAT LOCKED ON – G-TRAC2 SLAVE TO C-TRAC ........................................................................................................ 35 PREPURGE LIGHT STAYS AT “DAMPER MOVING” STATUS ................................................................................................
A G-TRAC2 MANUAL A G-TRAC2 Report any errors, omissions, etc. to Wade Pascoe at (403) 287-4775 or FAX (403) 287-4799. Warranty will only be honoured when a qualified HVAC service person, who has received training on the GTRAC2 is employed for service and troubleshooting. If further information is required please contact the nearest Engineered Air office. TEMPERATURE CONVERSIONS In this manual temperatures are listed in both degrees C (ºC) and degrees F (ºF).
A G-TRAC2 MANUAL Operation On start-up the G-TRAC2 opens the dampers and starts the blower after a time delay. If there were a call for heat the combustion blower would operate at full air to purge the heat exchanger. After the heat exchanger is purged, the air and gas operators move to “light off position”. The G-TRAC2 closes contacts to activate a flame supervision device. This device activates the ignition, supervises the pilot flame and main flame.
A VI. SYSTEM TIMINGS Pre-purge Maintained purge Supply fan start delay (damper open time) Heat exchanger warm up time Burner cool down time Heat exchanger cool down time Flame fail Flame fail light Auto Low limit Bypass (from blower start) VII.
A G-TRAC2 MANUAL Dip switch Block “B” – Fuel Curves/Air Curves The G-TRAC-2 has built in air to fuel ratio curves. The combination of these curves provides 16 possible settings. The curves are selected by turning dipswitches on or off. These dipswitches are located in a slot below the setpoint knob on the front of the control. Dipswitches 1 and 4, on block A and B, adjust the gas valve curve; dipswitches two and five adjust the combustion air curve.
A G-TRAC2 MANUAL SW1 XXX XXX SW2 XXX XXX SW3 XXX XXX SW4 XXX XXX SW5 ON OFF OFF ON OFF OFF XXX ON ON OFF OFF ON ON OFF ON *** *** ACTIONS Low limit active. * Low limit disabled. * NORMAL OPERATION (PI control). (No BMS on C-TRAC direct control but may be reset control) Direct C-TRAC control (reduced integral control). @ Direct BMS 0B10 VDC control (proportional control only). i i * Set-up sheet Section XX.
A G-TRAC2 MANUAL Irregular Flash The combustion blower is off but the combustion air-proving switch is closed or shorted. This indicates a wiring, set up, or part failure problem. Fast Flash The actuators controlling the air and gas are not in the correct position for pre-purge or ignition. The G-TRAC2 is attempting to reposition the motors. On The pre-purge timer is active and the heat changer is pre-purging. LED 2 Heat Required Off There is no heat call or both the fan and heat switch are off.
A XI. G-TRAC2 MANUAL AUTO BYPASS LOW LIMIT NOTE: Low limit can be disabled (Dipswitch C-5). The low limit set point is fixed at 40ºF. There are two low limit bypass timers, start-up and anti noise. The 6 minute start-up auto bypass low limit timer is started every time the night terminal energized status changes (on-off or offon transition) or when the "SA" (supply air blower) contactor is energized.
A G-TRAC2 MANUAL The values for “FS and HS”, service switch and flame supervision device are noted on the following table. Terminal “K” is OFF (not powered) for this “Daytime Operation Table”, thus the control is operating in day mode. Dipswitch A-4 determines supply fan configuration (as noted above). NOTE FS Fan SW HS SW Serv. SW 1 XX XX XX 2&3 ON OFF OFF 3, 4, & 5 3 3, 4, & 5 • ON XX OFF Term.
A • G-TRAC2 MANUAL NOTE FS Fan SW HS Heat SW Service SW Low Limit Flame Fail 1 ON ON OFF Lock Out N/A OFF OFF OFF Enabled XX 6 OFF ON OFF Enabled NO 6 ON XX ON Enabled Disabled Configure Dip Switch 1-4 OPEN Temperature Priority Unit locked off on L/L.* Unit switched off. Intermittent S/A fan delays on 64 sec. After main flame starts. Call is from room thermostat. Blower delays on after main flame (64 sec.).
A G-TRAC2 MANUAL The following is a flowchart covering many general operating/troubleshooting situations. If a more detailed manual is needed, contact the nearest EngA factory. BASIC BURNER OPERATION FLOW CHART Is there a heat required light on indicating a call for heat? NO YES There is no call for heat. G-TRA2 should move combustion air actuator to the max. pre-purge position. Control may still be setting the air and a gas operator to their light off positions after pre-purge is complete. Max.
A 2. G-TRAC2 MANUAL Heat Required LED ON Upon a call for heat, the “Heat Required” LED light will come on. 3. Pre-Purge Light PRE-PURGE LITE ON When the combustion air actuator is in the correct position, the air-proving switch will close and the “pre-purge” light and timer will start. When the burner is pre-purging, the “pre-purge” light will remain ‘on’.
A G-TRAC2 MANUAL XV. THE MASTER SET-POINT As a set point, the G-TRAC2 is designed to use either: • The set point mounted on the face of the G-TRAC2 (range of 12.7-37.8°C or 55-100°F). If the G-TRAC2 face mounted set point is used, terminals ‘SP and S’ must be jumped, or; • The Johnson TE 6100-960 set point (range of 50-85°F and usually remote mounted).
A G-TRAC2 MANUAL TE 6100 G-TRAC2 GREY wired to terminal V VIOLET wired to terminal X ORANGE wired to terminal Y BLUE wired to terminal Z As the room requires more or less heat, the modulating room thermostat increases or decreases the calculated discharge air set point.
A G-TRAC2 MANUAL • If room gradually cools so sensor is 3º colder (67ºF), discharge temperature resets up the full amount of its authority (+18) to 88ºF. • If room only cooled to 70ºF (2 degrees) the new discharge temperature would be + 65ºF set point = 77º discharge. • If the room had warmed above the temperature of the room thermostat, a similar reset action would occur except the discharge temperature would be reduced. b * 18 = 12°.
A G-TRAC2 MANUAL Diagram C Same as Diagram A but wider reset range because Pot 5 set at 5. Discharge Operating Range 48°F Absolute lowest allowed discharge set point 120°F Upper reset limit Manual Set point Ex 70°F Lower reset limit Absolute highest allowed discharge set point Diagram D Same as Diagram C except set point set low enough with wide reset range so bottom end of reset is cut off by absolute lowest limit.
A G-TRAC2 MANUAL Calculated Discharge Table for Room and Ambient Reset ROOM RESET Discharge Set-Point 15.5ºC 60ºF 21ºC 70ºF 30ºC 86ºF NOTE: General Manual AMBIENT RESET Max. Discharge Temp. (when room calls for heat) Min. Discharge Temp. (when room is too warm) ºC ºF ºC ºF ºC ºF ºC ºF 22.5 72.5 12.5 54.5 21.5 70.5 13 55 15.5 2 24 75 12 53.5 3 25.5 78 11.5 53 23.5 74.5 12 53.5 21 4 28.5 83.5 10.5 51 5 35.5 96 9 48 26 79 11 52 27 1 28 82.5 17 62.
A G-TRAC2 MANUAL X TE6000 TE6000 Grey V Orange Y Z TE6000 Blue Built in TE6100 Sensor Element Violet Multiple Room Sensors Four sensors can be wired to give an average reading of room temperatures to the TRAC control. They must be wired in a series/parallel arrangement. The drawing above drawing shows a circuit making use of the built in sensor in the TE6100 Johnson Sensor/Setpoint assembly and using TE6000 sensors for the other three.
A G-TRAC2 MANUAL BMS Reset from Voltage Applied to + and – Reset Voltage (VDC) 0 4 5 6 7 8 9 10 Calculated Set-Point ºC ºF 13 55 13.5 56 14.5 58 16 61 18 65 20 68 23 75 26 79 Approximate relationship between 0-10 VDC and 4-20 ma signal is: VDC 0 2 4 5 6 8 10 ma 0 3 8 10 12 16 20 Note: zero reset less than 2 VDC or less than 1 ma BMS Calibration 1. Apply 20 ma or 10 VDC signal to the G-TRAC2 ‘+ and B’ terminals. 2. Record the settings of dipswitches 1, 2, and 3. 3.
A G-TRAC2 MANUAL Ambient Based Discharged Air Set Point Reset Curves Maximum Up Reset Warmer Set Point Ambient Temperature No Reset 20°F 0°F -20°F 40°F 80°F 60°F Maximum Down Reset Cooler In order for the discharge air temperature to go from zero reset to maximum reset, (up or down) the ambient temperature has to change by 40°F. Make/Break Resets and Overrides 1. “OR” and “V” Override (Day Only) DAY OPERATION ONLY (Dipswitch A-3 should be on).
A • G-TRAC2 MANUAL Note that if this system is to be used as a night heat package with the room temperature being set back to a lower value then that used in the daytime, this system would require a separate night thermostat and a device switching between the day and night thermostats. See Diagram D1 below. HOT NEUTRAL E DM C FAN M DM SA DM C1 FS LL Air Flow Switch M N AS 2 HS 1 Q 3 IGN.
A NOTE: G-TRAC2 MANUAL When the room thermostat calls while operating in night mode, a modulating high limit feature built into the G-TRAC will not allow the discharge temperature to exceed the setting of the night SP pot (100° 120°F), if the unit’s heating capacity will allow temperatures to rise that high. During the night cycle when the G-TRAC's terminal K is powered the readouts for the calculated set point across "Dtemp" and common, will not be correct.
A G-TRAC2 MANUAL HOT 120 OR 24 NEUTRAL E C DM DM DM SA C1 FAN SW M M HOT 24v FS K NIGHT SIGNAL CONTACT Air Flow Switch M M LK N AS 2 HS 1 Q 3 24V PV IGN. CONTROL MV U M V M OR S PV PV SP HEAT OVERIDE CONTACT V X T1 24 V SUPPLY POWER Y T2 Z CB COMBUSTION MOTOR + - 3.
A G-TRAC2 MANUAL For Direct C-TRAC Control of the G-TRAC-2 The G-TRAC, model 2.2 gives better control than previous versions. • Set C-TRAC cooling deadband pot 3 to 4 degrees higher than normal value. • Set C-TRAC heat envelope pot to position 1.5 (pot 11) • Heat may stay on due to G-TRAC2 integral timing, if the G-TRAC2 heat switch is left on when the CTRAC switches to mechanical cooling. Stage 1 mechanical cooling call should turn power off to the GTRAC2 terminal “HS” by opening relay contacts.
A G-TRAC2 MANUAL SET-POINT READOUT AND DISCHARGE TEMPERATURE FROM VOLTAGE ON READOUT PINS Voltage (VDC) 1 1.5 2 2.5 3 3.5 4 ºC ºF 50 59 68 77 86 95 104 10 15 20 25 30 35 40 XX. DISCHARGE TEMPERATURE READOUT The discharge temperature at the temperature sensor can be obtained by measuring the voltage across spade connector terminals “DTEMP” to “COMMON”. The readings are based on 10ºC per volt. (Example: A reading of 2.15 volts = 21.5ºC.
A G-TRAC2 MANUAL TE6000 Discharge Sensor Self-Test If the discharge sensor resistance is greater than 4000-ohms or less than 880-ohms, the unit will lock out either on low limit or bad temperature sensor. The G-TRAC2 will not operate with a bad discharge sensor. If the GTRAC2 locks out due to an open discharge sensor LED 3 will flash rapidly. Sensor Resistance Chart for TE 6100-960 and TE 6000-960 °C -40 -34.4 -28.9 -23.3 -17.8 -12.2 -8.7 -1.1 4.4 10 12.
A G-TRAC2 MANUAL 4.1 Johnson Set-Point Adjust DSP CAL until the SPC voltage reading matches the dial set point value divided by 10° will give VDC. Return the dipswitches to their normal position. 4.2 Built In Set-Point Loosen the setscrew on the set-point knob and move the knob until the dial set point agrees with the measured set-point value. Tighten the setscrew and return the dipswitches to their normal position. Room Sensor Calibration 1.
A G-TRAC2 MANUAL XXII. G-TRAC2 SET UP SHEET Rev. OCT/08 Job #_________Tag #__________Designer________Model #______________Date_________ BASE SETPOINT LOCATION G-TRAC2 ________ or Remote ________ Base discharge set point *_____________ degrees F *Set point is not required when GTrac-2 is DIRECT controlled by other controllers. ROOM RESET [YES] __________ [NO] ___________ (dipswitch A-3) Reset Ratio Pot Setting _______________________________ NOTE: The room reset is bi-directional.
A G-TRAC2 MANUAL XXIII. BURNER SET UP Operator Control Rules The G-TRAC2 provides separate independent control loops for the gas and air operators. Each operator has a position feedback set point and deadband. The control deadband is the allowable operator position error (actual position versus set point) before the operator is repositioned. The calculated position set point is determined by a combination of pot settings and the current firing rate.
A G-TRAC2 MANUAL Combustion Set Up Pot Position Fine Tuning (Low Fire Rate, Low Fire Air) Adjusting the trim pots may, at times seem to have no effect, but turning the pot just a little more will move the operator a large step. For some applications this step may be too large. If this happens there is a method to get the G-TRAC2 to recognize small or partial step movements.
A G-TRAC2 MANUAL B. (Initial Operator Wiring Pre-Check) With power to the FS terminal "off", but power to the actuators "on": • Jumper “OG to G” (open gas) – the gas actuator should move towards open. The DC volts across terminals PG to PL should be increasing as the operator moves. • Jumper “CG and G” (close gas) – the gas actuator should move back to the closed position. (Only if required, interchanging wires “OG and CG” can reverse the above rotation.
A G-TRAC2 MANUAL The low fire air is meant to be set by an initial mechanical adjustment followed by fine-tuning on the low fire air pot. For the initial factory adjustment, place the low fire air pot to mid-scale. Mechanically adjust the damper blade until the O2 is between 15 and 18% then use the pot to fine tune the O2 readings. Record the DC volts across terminal PA (+) and PL. NOTE: At no time should the air damper operator be in the fully closed position.
A G-TRAC2 MANUAL pressure), temperature, and the correction factor for the meter are often overlooked, thus leading to an incorrect conclusion. Inlet gas pressures are recorded on the unit label. At high fire inlet gas pressure to the unit should not fall below 6.25" on units designed for 7" inlet pressure. If design is for 14" pressures should not fall below 12" and should not rise above 14” on 7” inlet and above 18” on 14” inlet.
A G-TRAC2 MANUAL To give a rough idea, assume a 10,000-CFM unit is located in an area that reached -30ºF in the winter was being air balanced on a 75ºF day with the heat off. The unit design temperature rise is 100ºF. It should be balanced to deliver about 8,200 CFM. On a day that is -30º, the fan is still delivering 8,200 CFM onto the heat exchanger, but as the air expands over the exchanger there is 10,000 CFM coming off of the unit.
A G-TRAC2 MANUAL 12. Due to the low capacities of some small units with standard (round) burners only, there may be too much air entering into the pilot air tube. It may be necessary to reduce this air quantity by placing a screw through the side of the combustion blower outlet in a manner that the screw also passes through the metal tube that the rubber hose connects to. This normally only occurs on units with an input of less then 300,000 BTUH.
A G-TRAC2 MANUAL Burner Pulsing, Backfiring, Exploding, Noisy An improper air/fuel mixture usually causes this condition. Do not attempt to do any combustion analysis until the inlet fuel pressure has been checked with the unit operating at high fire. (This should include other loads on the same gas system being on.) If the inlet pressure falls too low then the velocity of the air over the flame will be too great and tear the flame.
A G-TRAC2 MANUAL Before changing a G-TRAC2, if possible you should have the unit in operation and record the following information so that you may make the change quickly and avoid a time consuming combustion set up. If the information is already recorded on a label on the unit and the G-TRAC2 is operable it is advisable to recheck the values. If you follow the steps below using the recorded values, the burner set up should not change significantly from the existing G-TRAC2.
A G-TRAC2 MANUAL 3. Ensure that the switch for direction of rotation and the mounting are the same for the existing and replacement motors if equipped with rotation switch. 4. Now that the motor is at the beginning of its stroke, when you unbolt the existing one and install the replacement, tighten up the linkage at this same spot so that the marks are properly aligned. 5.
