RenewAire EV450 Enhanced Commercial Controls

Product Information

Specifications:

• Product Name: Enhanced Commercial Controls
• Model: EV450, HE-Series, and LE-Series Units
• Brand: Carel
• Controller Model: c.pCO Mini
• Version: 3.xx.xx

Product Usage Instructions

Installation:

1. Ensure that all electric power supplies are disconnected before accessing the controller.
2. Verify that electric power is OFF using a voltmeter.
3. Wear protective equipment as per NFPA 70E guidelines when working within the electric enclosure.
4. To ensure no voltage is present inside the unit, install and open a remote disconnect switch and verify power is off with a voltmeter.
5. Refer to the unit electrical schematic for further instructions.
6. Follow all local codes and regulations.

Maintenance

It is important to perform regular maintenance to ensure optimal performance and longevity of the Enhanced Commercial Controls.

• Do not expose the controller to extreme weather conditions or temperature variations.
• Properly adjust unit setpoints to prevent inefficient operation of the ERV.
• Select input offsets carefully to avoid incorrect or inefficient operation of the ERV.
• Only trained and authorized personnel should access the ERV control panel and make changes to the controller settings.
• All changes to the controller settings must be documented in the Controller Maintenance Records section of the manual.
• Periodically check for firmware updates and ensure you have the most recent User Manual. Contact RenewAire Support for assistance.

FAQ (Frequently Asked Questions)

Q: Can the Enhanced Commercial Controls be exposed to extreme weather conditions?
A: No, the controller should not be exposed to extreme weather conditions or temperature variations. It is designed for use in protected environments only.

Q: Who is authorized to access the ERV control panel and make changes to the controller settings?
A: Only persons who have been properly trained and authorized are allowed to access the ERV control panel and make changes to the controller settings.

Q: How can I ensure the optimal efficiency of the ERV?
A: Make sure to properly adjust unit setpoints and select input offsets carefully to prevent inefficient operation of the ERV.

Q: How often should I check for firmware updates and User Manual revisions?
A: It is recommended to periodically check for firmware updates and contact RenewAire Support to ensure you have the most recent User Manual.

ENHANCED COMMERCIAL CONTROLS

Installation, Operation and Maintenance Manual
FOR EV450, HE-Series, and LE-Series Units
Carel c.pCO Mini

ERV Enhanced Commercial Controls This manual applies to energy recovery ventilator (ERV) units with enhanced controls version 3.xx.xx. For previous versions refer to the older manual. The version number can be seen on the splash screen when the unit power is cycled. Newer units also have this version information in the Unit Status screens.
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Enhanced Commercial Controls ERV

WARNING
ARC FLASH AND ELECTRIC SHOCK HAZARD
Microprocessor controllers as discussed in this manual are typically installed in a control panel where high voltages are present. Whenever accessing any controller, disconnect all electric power supplies, verify with a voltmeter that electric power is OFF and wear protective equipment per NFPA 70E when working within the electric enclosure. Failure to comply can cause serious injury or death.
The line side of the disconnect switch contains live high-voltage.
The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch and verify that power is off with a voltmeter. Refer to unit electrical schematic.
Follow all local codes.

CAUTION
RISK OF ELECTRIC SHOCK OR EQUIPMENT DAMAGE Whenever electrical wiring is connected, disconnected or changed, the power supply to the ERV and its controls must be disconnected. Lock and tag the disconnect switch or circuit breaker to prevent accidental reconnection of electric power.
CAUTION
RISK OF COMPUTER SECURITY BREACH This controller is capable of being connected to a network. Any device that is connected to a network is susceptible to unauthorized access and hostile activities. It is the owner’s responsibility to determine acceptable risks and to safeguard the security of the controller and all connected devices.

IMPORTANT
This controller is only for use in protected environments. It is not to be exposed to the weather or exposed to extremes in temperature.

IMPORTANT
Risk of degraded unit efficiency. Improper adjustment of unit setpoints may result in the ERV operating inefficiently. Improper selection of Input Offsets may cause incorrect or inefficient operation of the ERV.

IMPORTANT
Only persons who have been properly trained and authorized are to access the ERV control panel and the controller. Changes to the controller settings are to be made only by trained and authorized personnel. All changes to the controller settings are to be documented in the Controller Maintenance Records section in this manual.

IMPORTANT
This control system is subject to periodic updates in firmware and the User Manual itself. Please contact RenewAire Support at RenewAireSupport@RenewAire.com to determine if you have the most recent manual and firmware.

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OWNER INFORMATION ERV

Enhanced Commercial Controls

NOTE: This page is to be completed by the installing contractor. The completed document is to be turned over to the owner after start up.

READ AND SAVE THIS MANUAL/LIRE ET CONSERVER CE MANUEL

NOTICE

This manual contains space for maintaining written records of settings and changes. See Section 14, Maintenance Records. At the time the ERV is commissioned, a complete record (an operating parameter file) should be made of all settings, to include setpoints and offsets. Whenever changes are made to the controller data points, those changes should be recorded, along with the reason for the change.
Information that is recorded is specific to just one ERV or controller. If additional controllers are being documented, please make copies of these pages and identify each copy by its unit tag.

UNIT INFORMATION
Record information as shown below.
In the unlikely event that factory assistance is ever required, information located on the unit label will be needed.
Locate the RenewAire unit label found on the outside of the unit.
NOTE: This information is for purposes of identifying the unit-specific option data from the Configuration Code.

Configuration Code:
J

–

—

Serial Number:

SO #:
NOTE: When the ERV is first connected to electric power, the unit is to be started only for purposes of testing correct wiring and to verify correct operation of the fans and dampers.

UNIT INFORMATION

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UNIT LABEL (TYPICAL)
NOTICE
Whenever an operating parameter file is created in the controller internal memory, a backup file should be created on an external memory device and stored in some convenient place.

Enhanced Commercial Controls

OWNER INFORMATION ERV

CONFIGURATION CODE
Refer to Section 15, Reference in this manual for the full interpretation of the various configuration codes.

MODEL NUMBER

J

DIGIT NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

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OVERVIEW ERV

Enhanced Commercial Controls

NOTE: This unit has a microprocessor controller. It is commonly referred to as a “controller.”
NOTE: Many of these control features require the use of optional sensors. The unit configuration will determine the availability of some functions.

OVERVIEW

CONTROL SEQUENCE OVERVIEW
The Renewaire ERV with enhanced controls provides outdoor air while saving energy by passing the Exhaust Air through the energy recovery core to exchange energy with the incoming air, with energy being passed to the incoming air in the winter and energy being passed to the outgoing air in the summer. Pairing this with the factory-programmed enhanced controller provides an excellent turn-key solution with the following control options.
1. Turning the unit off and on based on u A digital input (smoke detector, occupancy sensor, etc) u The controller keypad u Schedule u A BMS system, if the feature is enabled
2. Isolation damper control (if option is included)
3. Supply and exhaust fan control u On/Off fan control for constant speed fans u Variable speed fan control for variable speed and ECM fans (set as a percentage) u Exhaust fan tracking u Single fan operation with digital input or BMS command
4. Supply and Exhaust Fan status via current sensors
5. Monitoring of these values u Outdoor Air (OA) Temperature u Outdoor Air (OA) Relative Humidity u Return Air (RA) Temperature u Return Air (RA) Relative Humidity u Supply Temperature (SA) before tempering u Exhaust Temperature (EA)
6. Monitoring of pressure across filter for filter status
7. Bypass control (with external bypass option) for frost control/economizer control
8. Alarm alerts and logging
1.2 ENERGY RECOVERY BASICS
IMPORTANT
It is important to understand and use the equipment airstream terminology as it is used in this manual. The airstreams are defined as:
u Outside Air (OA): Air taken from the external atmosphere and, therefore, not previously circulated through the system. Each ERV unit has an OA air inlet.
u Supply Air (SA): Air that is downstream of the enthalpic cores and is ready for conditioning.
u Conditioned Air (CA): Air that is supplied to an occupied space.
u Return Air (RA): Air that is returned to a heating or cooling appliance from a conditioned space. When the ERV unit operates in recirculation mode, RA is conditioned and returned to the occupied space in the form of CA. Each ERV unit has an RA inlet.
u Exhaust Air (EA): Air that is removed from a heating or cooling appliance and discharged. Each ERV unit has an EA outlet.

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OVERVIEW ERV

RenewAire energy recovery ventilators use static-plate, enthalpy-core heat exchangers that have no moving parts.
u During summer months, the hot and humid OA passes by the cooler, drier RA, lowing its temperature and humidity.
u During winter months, the cold and dry OA passes by the warmer, moister RA, raising its temperature and humidity.

EA

OA

SA

RA

1.3 TEMPERATURE SENSORS
There are four temperature sensors installed in each ERV. These are NTC sensors that have a Carel curve. The curve characteristics can be found in the Reference section. They are located at: u One at the inlet side of the EA Fan cone u One at the inlet side of the SA Fan cone u One at the entrance of the air intake to measure outdoor air (OA) temperature u One at the entering RA duct of the unit

FIGURE 1.3.0 DUCT TEMPERATURE SENSOR

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OVERVIEW ERV

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1.4 COMBINATION TEMPERATURE AND HUMIDITY SENSORS
Humidity transducers are mounted in the OA and RA compartments and provide an output from 0­10VDC that is proportional to 0­100% Relative Humidity.

FIGURE 1.4.0 TEMPERATURE AND HUMIDITY SENSOR
1.5 SENSOR LOCATIONS

VFD AUTO/ MANUAL CONTROL

EA FAN

ERV CORE

MERV 13 FILTER (OPTIONAL)

FILTER PRESSURE SENSORS

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SA FAN

MICROPROCESSOR

EA FAN AND SA TEMPERATURE

FAN CURRENT

SENSORS

SWITCHES

(SA AND EA)

TEMPERATURE AND HUMIDITY SENSORS

FIGURE 1.5.0 SENSOR LOCATIONS IN ERV UNITS, HE2XINH SHOWN

Enhanced Commercial Controls

CONTROLLER OVERVIEW ERV

2.0 CONTROLLER OVERVIEW
The control utilizes the Carel c.pco (pronounced see-pee-ko) controller.
34 7 10

1 2 3 65 4
1 Up Button 2 Enter Button 3 Down Button 4 Escape Button 5 Program Button 6 Alarm Button
FIGURE 2.0.0 C.PCO CONTROLLER BUTTONS

5

C.pCO n° (03)
75.5°F
Time 12:33
date: 07.06.2017
11
6
8 9

1

2

1 24VAC Power 2 Universal inputs/outputs 3 Power for RUT remote display 4 Remote display or
BMS connection 5 Relay digital outputs 6 +5V power supply 7 FBUS connection (not used) 8 Analog outputs 9 Digital inputs 10 Ethernet port 11 Micro USB port
FIGURE 2.0.1 CONTROLLER EXTERNAL CONNECTIONS

ALARM BUTTON PROGRAM BUTTON
ESCAPE BUTTON

UP BUTTON ENTER BUTTON DOWN BUTTON

FIGURE 2.0.2 OPTIONAL REMOTE USER TERMINAL (RUT) BUTTON LOCATIONS

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CONTROLLER OVERVIEW ERV

Enhanced Commercial Controls

NOTE: When an alarm is first detected, the Alarm button will be flashing and an audible alarm will sound. After the alarm has been viewed, the light will remain on and the audible alarm will stop.

Pressing the PRG (program) button accesses the Service Menu or Login screen from any location in the user interface screens. The options that are available dynamically change depending on the configuration of the unit and the options installed on the unit.
The ESC button is used to go one level back from the screen the user is currently on. If the user is finished setting variables in a sub-menu, the ESC button takes them back to the previous menu. If the user is editing a variable and decides to not make a change, the ESC button takes them back to the top of that screen. Pressing the ESC button from the Main Menu takes the user back to the Main Status screen.
When on a screen with the cursor in the upper left-hand corner,the UP or DOWN hard buttons move the user from one screen to the next. While editing a variable, the UP or DOWN hard buttons allow the user to set the desired value of the variable. When viewing a view only variable, the UP or DOWN hard buttons scroll through the values available to the user.
When a menu or menu item has been highlighted, press the “ENTER” hard button to enter the highlighted selection. When a writable entry has been changed, press the hard button to enter the new value and then press it again to confirm the change.
Pressing the ALARM button displays any alarms that are currently active. There may be multiple screens of alarms. Pressing and holding the Alarm button for three seconds resets the alarms.

2.1 CONTROLLER ACCESS METHODS
The controller has a built-in display that can be used to set up the system and view the status of the system as well as address alarms. Two other options for accessing these are through the remote RUT and through the embedded web pages. All three methods use similar keys for the same purpose.

2.1.1 Using the Remote User Terminal (RUT)
The Remote User Terminal (RUT) allows you to plug into a controller and see the screens from that controller. RUTs are connected to the controller by means of a 10′ cable and then used as hand-held devices. They can alternately be installed on a wall in some convenient location. The push buttons on the face of the RUT have the same functions as the push buttons on the controller.

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FIGURE 2.1.0 OPTIONAL REMOTE USER TERMINAL (RUT)

Enhanced Commercial Controls

CONTROLLER OVERVIEW ERV

The RUT (optional accessory, field-installed) plugs into the controller by means of a six wire cable with RJ12 jacks on each end. The six-wire cable is inserted in the RJ12 jack on the back of the RUT and the other end of the cable is inserted into the RJ12 adapter, found in the low voltage electrical compartment. The controller uses a pre-configured cable that plugs into the J3 jack on the controller and the other end is plugged into the RJ12 adapter. The cable looks similar to a standard phone cable but has a different pin out. The cable from the controller to the low voltage electrical box is factory- installed.

BACK OF RUT

NOTE: Common telephone wiring is 4 conductor and uses RJ11 terminals. It is different from the six-wire cable with RJ12 terminals needed for this accessory.

LOW VOLTAGE ELECTRICAL COMPARTMENT

NOTE: If the controller was ordered for use with a serial BMS and an RUT is also desired, contact the factory for further information.

FIGURE 2.1.1 CONNECTING A RUT
2.1.2 Connecting Using Internal Web Pages
The controller has embedded web pages and when they are accessed, an interactive screen appears that allows the user to move through all the controller menus. The IP address of the controller is factory-set at 10.10.1.2. The subnet address (needed for setting up a LAN) is set at 255.255.255.0. These can be changed in the General Settings menu.
In order to connect to the controller with your pc you will need: u An ethernet cable between the PC and the controller u The PC connection must be on the same subnet as the controller. For example, if using the
defaults, you would set the IP address of the PC connection to 10.10.1.xx where xx is not equal to 2, and the subnet to 255.255.255.0. (See directions for setting the PC IP address if you are not familiar with this.)

NOTE: For direct connection from RUT to J3 Terminal, use the following wiring: Green & Black = +Vterm Brown & Blue = GND Red = Negative (-) White = Positive (+)
NOTE: The controller will only support private IP addresses which start with 192, 172, or 10.

u Using a browser such as Chrome, put the controller IP address into the address bar.

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CONTROLLER OVERVIEW ERV

Enhanced Commercial Controls

You should see this web page. To get to the menu screens, click on RUT on the Menu Bar.

2.1.3 Setting the PC IP Address For those that are not familiar with changing their PC adapter settings, go into Network Setting in the Control Panel and Change Adapter Settings.
Choose the adapter you are using to connect to the controller.
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CONTROLLER OVERVIEW ERV

Select Internet Protocol 4 and click on Properties.

NOTE: When you are finished viewing the controller on your computer, remember to restore the original settings.

Enter the IP address you want to use. It should not be identical to the controller IP address. The last octet of the IP address should be different. Click OK.
2.1.4 Using the Multikey Function of the Web Pages When you want to press multiple keys or press a key longer for a function you can use the keys below the Menu Screens to do this.
Two common uses are: u Set the two keys to Alarm and Alarm and press Simulate long press to acknowledge alarms. u Set the two keys to Alarm and Enter and press Simulate long press to get to system menus.
2.2 CONTROLLER MENU STRUCTURE
Any screen will have the name of the menu to which it belongs on the top line of the screen.
2.2.1 User Menu Structure The user menu can be reached but pressing the ESC (back) button. The menus contain the following areas: u Unit Status–Contains the status values of the sensors, fans, and heating and cooling,
if applicable u Control Settings–Contains the control settings for the fans and heating and cooling,
if applicable u General Settings–Contains the clock settings, Unit of Measures, IP Address, BMS settings,
and the scheduler u Alarm Settings–Contains the alarm settings u Unit On/Off–Allows the user to turn the unit on and off via the keypad
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GENERAL FLOW ERV

Enhanced Commercial Controls

2.2.2 Password Protected Menu Structure
The password protected menu can be reached but pressing the PROG button and entering the password. The menus contain the following areas: u Back Up and Restore–Contains the screens to back up your settings or return to
factory defaults u Unit Configuration–Main Unit Configuration Settings that determine which screens show up
in other areas u I/O Configuration–Secondary configuration settings for functions u I/O Calibration–Allows sensors to be adjusted for accuracy u Sensor Overrides–Allows a sensor value to be temporarily overwritten for testing u Test End Devices–Allows outputs to be manually manipulated for troubleshooting u Advanced Service–Advanced Service Information and Settings

2.2.3 Password Entry
To access the password protected service screens, press the program (bullseye) button to get to the screen and enter the user password “1000.”

3.0 GENERAL FLOW FOR SETUP AND RUNNING UNIT
Depending upon features selected for the unit, the general flow for setup and running the unit is as follows:

GENERAL SETTING:
CLOCK, UNIT OF MEASURE, IP ADDRESS, SCHEDULE
FAN CONFIGURATION:
SET SUPPLY AND EXHAUST FAN CONTROL TYPES

UNIT CONFIGURATION:
FAN TYPE, DEFROST…
START UNIT:
PROVE FAN RUNNING

I/O CONFIGURATION:
ENABLE SPECIAL FEATURES
TEST FROST CONTROL:
SET CONTROL AND TEST

TEST SINGLE FAN MODE:
IF DESIRED

BMS INTEGRATION:
CHOOSE TYPE AND TEST

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UNIT CONFIGURATION ERV

4.0 UNIT CONFIGURATION
4.1 CONFIGURE GENERAL SETTING
There are several general settings that are need for correct operation of the controller.
4.1.1 Setting the Time and Date It is important to have the correct time and date for alarm time stamps and logging. u Set Refresh to YES, It will turn back to NO after changing the display to the current controller
time and date. u Change the Time ad Date accordingly. (Day is automatically generated.)

4.1.2 Setting the Unit of Measure
The controller supports the following settings: u SI (bar, Celsius) u USA (psi, Fahrenheit) u UK (bar, Celsius) u CAN (psi, Celsius)
Set the Unit of Measure to the desired units for the display.

4.1.3 Setting the IP Address of the Controller
The controller IP address may be used for the BMS, networking, or local access.
u Set the DHCP to OFF if using a static IP u Set the IP address and Mask u Set Update to YES u Cycle power to the controller

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UNIT CONFIGURATION ERV

Enhanced Commercial Controls

4.1.4 Scheduler
Enable the scheduler, if desired. If you enable the scheduler, it will have to be set for “ON” for the unit to run along with all other “ON” conditions.
u Enable the scheduler by setting to YES. u Set the schedule for each day. You can use the copy feature to copy days. Save data
after each. u Set vacation periods. u Set Special Days.

4.2 VERIFY UNIT CONFIGURATION
4.2.1 Main Unit Configuration It is important to verify the configuration as the settings on these screens will also determine which screens show up in the user settings screens. u Unit Type is Enhanced or Enhanced RD (for RD units). u Choose whether an EV450 unit (one fan motor). u Will you be adding an external bypass? u Was the unit ordered with isolation dampers? u If bypass is added, will you have frost protection? u Are the supply and exhaust fans variable speed (VFD or ECM)?
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UNIT OPERATION ERV

NOTE: If you choose EV450 you will only see information for the supply fan as both fans are run from one motor.

UNIT OPERATION AND FAN CONTROL

The primary purpose of the ERV unit is to provide 100% OA. The amount of air that it provides is based on the configuration of the supply and exhaust fans and whether the unit is running or not.
Fans are either controlled with variable speed drives or ECM motors.
5.1 SEQUENCE OF OPERATION FOR UNIT START
The unit will start when all of the following conditions are true: u There are no serious alarms. u The Digital Input for start/stop (terminals 17 and 18) are closed. u The unit is turned on at the keypad. u The time is within the scheduler “ON” time, if scheduler enabled. u The BMS has written the unit on signal, if BMS control is enabled.

Upon starting, the isolation dampers will open. The end switches of these dampers will complete the Fan Enable signal to the ECM or VFD fans.
Once the fan enable signal is complete, the fan command signal will be sent to the fan after the start up delay time. Each fan is paired with a current sensor. If within the alarm delay time, default 90s, the current sensor does not detect the fan running, the unit will shut down and an alarm will occur.
The setting SF Alarm Unit Run? setting tells whether the unit, and thus the exhaust fan, will continue to run if there is an alarm with the supply fan.

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UNIT OPERATION ERV

Enhanced Commercial Controls

The Unit status is shown on the bottom of this screen. More than one of these statuses may be valid at one time

STATUS SHOWN Unit on Off by alarm Off by BMS Off by Time Band Off by Schedule Off by Keypad EF Only Mode SF Only Mode In Device Test Input Overwritten Off by CO2 Level Flush Mode Frost Control on

UNIT STATUS CONDITIONS
MEANING The unit is on and running. The unit is off by a serious alarm. The unit is off by command from the BMS. The unit is off by the scheduler. The unit is off by the ID1 digital input. The unit is off by the setting on the local interface. The unit is in single fan mode with exhaust fan running. The unit is in single fan mode with supply fan running. The system is in device test mode. There is a sensor input that is overwritten. The CO2 level is below the limit for running. The unit is running in FLUSH mode. The unit is running in Frost Control Mode.

5.1.1 Digital Input (ID1) Unit On/Off
The digital input across terminals 17 and 18 must be closed to turn the unit on. It can be jumpered if not used. Some of the uses are a remote switch, a smoke detector or a motion/ occupancy sensor.

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UNIT OPERATION ERV

5.1.1.1 Optional Smoke Detector Normally field-installed on the discharge duct, near the furnace.

FIGURE 5.1.0 SMOKE DETECTOR
5.1.1.2 Optional Motion Sensor Used for occupancy-based ventilation, hardwired to the low-voltage terminal strip.

FIGURE 5.1.1 MOTION SENSOR (CEILING MOUNT)

FIGURE 5.1.2 MOTION SENSOR (WALL MOUNT)

5.1.2 Optional Dampers
The ERV unit has optional isolation dampers with end switches. For more information consult the unit specific IOM.

5.1.3 Fans
The variable speed fans may be driven by VFDs or may be ECM fans. The VFD fans get an enable signal and both types of fans get a 0­10VDC signal which is proportional to 0­100% fan command.
Factory VFD settings should not be changed. The settings are available in the Reference section of this manual.

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UNIT OPERATION ERV

Enhanced Commercial Controls

NOTE: Current sensors are calibrated for reduced fan speed at time of shipment from the factory. Immediately after entering new operating parameters for the fans (done during the start up process), current sensors are to be re- calibrated for minimum current draw. The fan should be running at its minimum speed.

5.1.4 Current Sensors Current sensors are installed on high voltage supply wires to sense current going to a fan motor. They are used to prove the ON/OFF state of fan motors.
FIGURE 5.1.3 CURRENT SWITCH
When the unit starts, this screen will show when the fans are enabled. There is a slight delay of a few seconds, and then the second line, supply (or exhaust) fan on shows the status of the current sensor.

The current sensors are factory adjusted and may need to be field-adjusted for the application. This will be evidenced by getting a supply fan alarm (AL10) or exhaust fan alarm (AL11). The instructions are in the Alarms and Troubleshooting section of this manual.
5.1.5 Filter Monitoring There is a pressure transducer across the filters on the outdoor air and RA streams to monitor the filter status. The scaling is factory set in this screen.

The alarm level can be set pressure can be set such that if the pressure reaches the alarm level, the unit will alarm but keep running.

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UNIT OPERATION ERV

You can also see the pressure in this screen so that if it gets close to the alarm level you can change it at your convenience.

5.2 OPTIONS FOR SUPPLY FAN CONTROL
Units with a VFD or ECM for the supply fan can control the fan for constant speed.
5.2.1 Constant Fan Speed Option The analog voltage command to the supply fan VFD or ECM can be set from the unit controller display or by the BMS. The adjustable range of 0% to 100% correspond to the minimum and maximum fan operating speed.

NOTE: It is possible to have the BMS control the fan directly. Refer to the BMS section for more information.

This supply fan operation mode can be used to field balance the SA flow rate.

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UNIT OPERATION ERV

Enhanced Commercial Controls

NOTE: It is possible to have the BMS control the fan directly. Refer to the BMS section for more information.

5.3 OPTIONS FOR EXHAUST FAN CONTROL
Units with a VFD or ECM for the exhaust fan can control the fan for fixed speed, or supply fan command tracking control.
5.3.1 Constant Fan Speed Option The analog voltage command to the exhaust fan VFD or ECM can be set from the unit controller display or by the BMS.

The adjustable range of 0% to 100% correspond to the minimum and maximum fan operating speed. This exhaust fan operation mode can be used to field balance the EA flow rate.

5.3.2 Supply Fan Command Tracking Control Option The controller will adjust the exhaust fan VFD or ECM command to track the supply fan VFD or ECM command.
The minimum (50%) and maximum (200%) tracking rates are adjustable. This exhaust fan operation mode can be used to maintain proportional supply and exhaust fan commands as the supply fan modulates.

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SPECIAL FEATURES ERV

6.0 SPECIAL FEATURES
These features are not common but are available in the ERV controller.
6.1 FROST CONTROL
ERV units utilize the optional bypass damper to bypass the core when it is very cold outside. This is usually used in northern states and Canada. To enable the frost control functionality for these units the Enable Frost Cntl must be set to YES in the Unit Configuration (password protected) screen.

The frost control function disables the supply fan and closes the OA damper when the following conditions are met: u The OA temperature is less than the OA Below set point u The EA temperature (sensed at the inlet to the EA fan–average exhaust air temperature) is
below the EA Below set point.
For variable speed fans, an additional setting is required for the exhaust fan operation. While the supply fan is off, a variable speed exhaust fan (ECM or VFD) will operate at the command set by the FC Exh Command set point. This command allows the user to minimize the negative space pressure that will be generated with the EF on and the SF off during frost control.
For fans that are not variable speed, the exhaust fan will run at the normal speed and this setting will not be shown.

The frost control mode ends (OA damper is opened and the supply fan is enabled) when the EA temperature increases to the EA Above set point. The unit then resumes the selected normal operating mode. If the EA temperature then falls below the OA Below set point frost control mode is enabled again.
There is a Unit Status screen that will appear if frost control function is enabled.

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SPECIAL FEATURES ERV

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6.2 SINGLE FAN MODE
In some cases the application may require that only one fan run. The single fan mode is initiated by either closing the ID2 contact (terminals and 19) or a BMS command to BMSEFOnly variable. It is BV11 for BACnet and Coil 1 for Modbus, where 0 = No and 1 = Yes. The default is Exhaust Fan but it can be changed to Supply Fan here. If tracking the supply fan, also set a value for exhaust fan in single fan mode.

6.3 USE ROOM TEMP AND HUMIDITY RATHER THAN RETURN
The system allows you to use a room temperature and humidity sensor in place of the return air temperature and humidity sensor. One use for this is when you have unoccupied operation when the fans are off, you will be able to get a temperature indicative of the actual room temperature. This feature is useful when feeding a single zone. It requires the removal of the return sensors and replace them with the room sensor. The setting here will change the word “return” to “room” on the main screen to eliminate confusion.

The Room Temperature and Humidity Sensor is P/N 102397 Wall Mount, RTH-W.

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SPECIAL FEATURES ERV

6.4 FLUSH FEATURE
The flush feature is used in conjunction with the scheduler function that allows you to set the unit into flush mode for specific time periods where the exhaust fan and supply fan will run at a % during this period.
It is enabled in the I/O Configuration screen.

This screen to allow you to define how the fans will run while in flush mode.

Once these setting are done, you will now have a third type of mode for the scheduler called FLUSH, as shown. In this example the unit will go into flush mode at 6:45 until 7:00 when it will turn on and run normally. During flush mode the OA and RA dampers (if included) will be open as in normal operation.

6.5 COLD WEATHER OPERATION
The ERV has a built-in feature for detecting low temperatures to avoid dumping cold air into the space. The settings are shown in the following screen.
In versions 3.00.30 and higher, the low temperature allowed was decreased. Be sure to make sure these settings are appropriate for your application.
u If the SA Temperature falls below the low warning temperature for the delay time while the supply fan is running, the warning will sound but the unit will remain running.
u If the SA Temperature falls below the low alarm temperature for the delay time while the supply fan is running, the alarm will sound but the unit will shut down and require a manual reset to start again.

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7.0 VERIFYING I/O AND UNIT WIRING
All of the I/O values should be verified and calibrated, if necessary.
7.1 VERIFYING ALL I/O THROUGH UNIT STATUS SCREENS
All of the individual I/O are able to be viewed in one place by pressing “ENTER” when on this screen, which is located toward the and of Unit Status.

There will be individual screens for each input and output. Several examples are shown.

7.2 CALIBRATING I/O
For a temperature sensor that may have run a long distance or a humidity sensor with a reading that may have drifted over time, a calibration may be necessary. There is a screen such as the one shown for each sensor and transducer. The current value at the top will reflect the change with the offset that is set in this screen.
7.3 GENERAL UNIT CONTROL WIRING
The following tables and diagrams show the general unit control wiring for the ERV units. A unit-specific electrical schematic is found inside the access door to the core module.
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7.3.1 Sensor Inputs

SENSOR

TYPE

OA Temperature OA Humidity

Combined CAREL NTC/0­
10VDC

RA Temperature RA Humidity

Combined CAREL NTC/0­
10VDC

SA Temperature CAREL NTC EA Temperature CAREL NTC

OA Filter Pressure

0­10VDC

RA Filter Pressure

0­10VDC

SENSOR TERMINALS Far Left (Red) 2 (Black)
3 (Red) 4 (Black) 5 (White) Far Left (Red) 2 (Black) 3 (Red) 4 (Black) 5 (White) (Red or White) (Red or White) (Red or White) (Red or White) Vin (Red) GND (Black) Vo (White) Vin (Red) GND (Black) Vo (White)

INTERMEDIATE TERMINALS X4-39 GND X4-38 X4-39 GND X4-36 X4-39 GND X4-38 X4-39 GND X4-37 –

CONTROLLER TERMINALS U1 (Main) GND TS2 24VAC TS1 GND TS2 U2 (Main) U3 (Main) GND TS2 24VAC TS1 GND TS2 U4 (Main) U5 (Main) GND (Main) U6 (Main) GND (Main) 24VAC TS1 GND TS2 U7 (Main) 24VAC TS1 GND TS2 U8 (Main)

7.3.2 Digital Inputs Inputs in Grey are optional, and field-installed.

INPUT

TYPE

INPUT TERMINALS

INTERMEDIATE TERMINALS

CONTROLLER TERMINALS

Smoke Detector Dry Contact

X2-15 X2-16

C1/2** 24VDC

ID1 Unit Enable* Dry Contact

X2-17

ID1

X2-18

GND

ID2 Single Fan Mode

Dry Contact

X2-19

ID2

X2-18

GND

SF Current Switch (SF Status)

Dry Contact

(Black) (Red)

–

GND TS2

–

U9 (Main)

EF Current Switch (EF Status)

Dry Contact

(Black) (Red)

–

GND TS2

–

U10 (Main)

*Overflow switch is wired into here if unit was ordered with one. ** Smoke alarm will interrupt the enable signal to the fans. This will cause a fan alarm.

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7.3.3 Digital Outputs
Outputs in Grey are optional, and field-installed. Heating and cooling may be factory-installed or field-installed, depending upon the unit.

OUTPUT SF Enable

TYPE Dry Contact

EF Enable

Dry Contact

Bypass Damper Dry Contact

OA Damper

Dry Contact

RA Damper
Serious Alarm Output

Dry Contact Dry Contact*

OUTPUT TERMINALS
(See wiring diagram)
(See wiring diagram)
HOT COM HOT COM HOT COM

INTERMEDIATE TERMINALS X2-13 X2-14 X2-11 X2-12 X2-07 (Red)
X2-06 (Black) X2-03 (Red) X2-02 (Black) X2-05 (Red) X2-04 (Black)
–

CONTROLLER TERMINALS NO1 (Main)
NO2 (Main)
NO3 (Main) Accy COM NO4(Main) Accy COM NO5 (Main) Accy COM NO6/NC6 (Main) C6 (Main)

7.3.4 Analog Outputs

OUTPUT SF Signal EF Signal

TYPE 0­10VDC 0­10VDC

OUTPUT TERMINALS

INTERMEDIATE TERMINALS 01-6-D 01-2-D 01-4-D 01-2-D

CONTROLLER TERMINALS Y1 (Main)
GND Y2 (Main)
GND

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1.800.627.4499 33

1 2 3 4 5 6 7 8 9 10 11 12 13

7.3.5 Sample Power Wiring Schematic

A

B

C

D

E

Input Power
208-230 VAC, 3 Phase 460 VAC, 3 Phase
L1 L2 L3 GND

Exhaust

Contactor

Overload

1L1

2T1

Exhaust Fan

3L2

4T2

M

5L3

6T3

F1

24 VAC

A1 A2

95 96

X2 12

Supply

Contactor

Overload

1L1

2T1

3L2

4T2

5L3
24 VAC A1 A2 X2 14

6T3 95 96

M

Supply Fan

REV.

DATE

NAME

Transformer

X2 20

X3 21

F2 2.5 AT

COM 24V Transformer

G0

Accy 24 VAC

X1 1

X2 16

COM 24V CHANGES

Accy COM

X1 2 X1 4

X1 6

2

7/31/2018

austine

1

10/19/2017

austine

0

10/19/2017

austine

Updated Damper Colors Updated G0 Connections New

02-5-A 02-9-A 02-8-C

RenewAire

HE-2_HE-8XJxxx-x34,35xx–xAx1,3x-xx_002

Power

SCHEME
1

NOTE: This wiring schematic is TYPICAL control wiring for a three phase, 208-230VAC and 460VAC input for models HE-2X, HE3X, HE-4X, HE6X, and HE-8X. A unit-specific electrical schematic is found inside the access door to the core module. For more information on VFD wiring, refer to the reference section at the end of this manual.

I/O AND UNIT WIRING ERV

Enhanced Commercial Controls

34 1.800.627.4499

A 1

2
TS1
3

4

5

G 24 VAC Hot

Accy 24 VAC 01-10-D

6

7
TS2
8

9
01-11-D

10

G0 Common

11

12

13

B

TH1

T

–

T

OA TempRed

O

OA HumidWht

OA Temp & Hum

TH2

T

RA TempRed

–

T

O

RA HumidWht

RA Temp & Hum

NTC1
SA Temp NTC2
EA Temp PS1
Vin Vout GND
OA Filter Press

G

G0

U1

U2

U3

GND

U4

SA TempRed EA TempRed

U5 U6

GND

OA 2″ FilterWht RA 2″ FilterWht

U7 U8

SF CurrentRed U9

EF CurrentRed U10

GND

ID1

ID2

GND

N1 Carel C.pCO Mini High End (Ethernet)

PS2
Vin Vout
GND
RA Filter Press

CS1

SF CurrentRed

X2 18
X2 19
ID1/2/GNDWht X2 17 ID1/2/GNDRed

SF Current Switch

CS2

EF CurrentRed

EF Current Switch

C

N1 Carel
C.pCO Mini High End (Ethernet)

+Vterm J3 Tx/Rx J3 Tx/Rx +
GND J4 Tx/RxJ4 Tx/Rx+
GND Ethernet
Y1 Y2 GND NO1 C1/2 NO2 NO3 C3/4/5 NO4 C3/4/5 NO5 NO6 NC6 C6

01-12-D

NO1/2/CRed X2 13 NO1/2/CBlk X2 15 NO1/2/CWht X2 11 NO3/4/5Red X1 7 NO3/4/5Blk X1 3 NO3/4/5Wht X1 5
Accy 24 VAC

REV.

DATE

NAME

CHANGES

2

7/31/2018

austine

1

10/19/2017

austine

0

10/19/2017

austine

Updated Damper Colors Updated G0 Connections New

NOTE: This wiring schematic is TYPICAL control wiring for a three phase, 208-230VAC and 460VAC input for models HE-2X, HE3X, HE-4X, HE6X, and HE-8X. A unit-specific electrical schematic is found inside the access door to the core module.

D

E

Not Used

N1 Carel C.pCO Mini High End (Ethernet)

V bat CAN L CAN H
GND J7 1 J7 2 J7 3 J7 4 J7 5 J7 6 +5VREF GND +V dc

RenewAire

HE-2_HE-8XJxxx-x34,35xx–xAx1,3x-xx_002

Control

SCHEME
2

7.3.6 Sample Control Wiring Schematic

Enhanced Commercial Controls

I/O AND UNIT WIRING ERV

1.800.627.4499 35

1 2 3 4 5 6 7 8 9 10 11 12 13

A

B

Accy 24 VAC X1 1

Accy COM NO 4

X1 2 X1 3

Accy COM NO 5

X1 4 X1 5

Accy COM NO 3

X1 6 X1 7

EXP C1/2 EXP NO 1 EXP NO 2

X1 8 X1 9 X1 10

NO 2

X2 11

EF En NO 1

X2 12 X2 13

SF En C1/2

X2 14 X2 15

Accy 24 VAC Unit Enable Sensor COM

X2 16 X2 17 X2 18

EF Only Enable X2 19

Sensor 24 VAC X2 20

BLK

COM OA/FA

BL

RED

DAMPER1 HOT

ORG

BLK/PK COM EA/RA

BL

RED/BR

DAMPER2 HOT

YEL

PUR

COM Bypass

YEL

ORG

DAMPER3 HOT

BL

Factory Jumper – remove if damper end switch is used

Factory Jumper – remove if damper end switch is used

Factory Jumper Factory Jumper

SD1

Smoke Detector

UE1 EFEN1

Unit Enable Exh Fan Only Enable

C
Sensor 24 VAC X3 21
X3 22 X3 23 X3 24 X3 25 X3 26 X3 27 X3 28 X3 29 X3 30

REV.

DATE

NAME

CHANGES

2

7/31/2018

austine

1

10/19/2017

austine

0

10/19/2017

austine

Updated Damper Colors Updated G0 Connections New

NOTE: This wiring schematic is TYPICAL control wiring for a three phase, 208-230VAC and 460VAC input for models HE-2X, HE3X, HE-4X, HE6X, and HE-8X. A unit-specific electrical schematic is found inside the access door to the core module.

D

E

RenewAire

HE-2_HE-8XJxxx-x34,35xx–xAx1,3x-xx_002

Accy Wiring

SCHEME
3

7.3.7 Sample Field Wiring Schematic

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ALARMS AND TROUBLESHOOTING

If the problem is caused by an alarm, the first step in troubleshooting is to view the Alarm screens. Press the Alarm button on the face of the controller to see all current alarms and what function or component is causing the alarm. In some cases, the Alarm pre-set may need to be adjusted or an offset may need to be changed. Before making any changes to the controller programming, be certain to have an updated Backup file so that current settings can be easily restored, if needed. See the following Alarms section for these.
Problems with an air handler are sometimes strictly mechanical, in which a fan or damper or some other component simply stops working. Mechanical problems are easily traced to specific components by using the Test End Device feature in the service level. See the following Test End Devices section for this.
In other cases, problems may be caused by the air handler trying to overcome a pre-set or operating parameter that has been set by the user. In these cases, view the controller screens to trace the problem. See Other Common Problems section for these.
8.1 ALARMS
The alarms are viewed through the controller screen or through the BMS.
8.1.1 Acknowledging Alarms
When an alarm occurs, you will hear a buzzer sound and the alarm light will flash. Press the alarm button to acknowledge the alarm and quiet the buzzer.
8.1.2 Viewing Alarms and Alarm Log
If there are active alarms the alarm button will be red. To view the active alarms, press the alarm button. Each alarm has an alarm number (AL*11, in this case), a time stamp, and a message to show which alarm occurred.

Continue to press the button to cycle through all active alarms. At the end you will see this screen. Here you can press “ENTER” to see the past alarms.

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An alarm log screen looks like this. If the event is Stop, it shows the time that the alarm went away. If the event is Start, it shows the time that the alarm first occurred. There may be up to 50 entries.

If no alarms are active, the screen will say No Alarms but you can still press “ENTER” to view the last 50 alarm occurrences.

8.1.3 Resetting Alarms
If you cycle through the alarms, you will see this screen. At this time, you can hold the alarm button down to reset the “User Reset” alarms. (The auto reset alarms reset themselves.)

8.1.4 Alarm Digital Outputs
The controller includes a digital output for remote indication of an alarm condition.
This is AlarmOut.val and it closes the contact if there is an alarm that will shut down the unit. These include: u Low Supply Temperature Alarm u High Supply Temperature Alarm u Loss of communication between the controller and the expansion module u Exhaust Fan Alarm (Failure to start) u Supply Fan Alarm (Failure to start) ONLY IF the SF Alarm Unit Run? is set to No. If yes, the
unit will not shut down and the exhaust fan will be allowed to continue to run.

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The physical connection is made at the controller, it is terminated at J12, located in the upper right corner. There is both a normally open (NO6 to C6) and normally closed (NC6 to C6) option.

8.1.5 Specific Alarms and Their Meaning The alarms are identified by number. The are grouped by type. Alarms 50­57, alarms 66­68.
8.1.5.1 General Alarms

NUMBER 0
1 2
3 4

NAME Al_retain

STATUS SHOWN User reset

Al_Err_retain_write User reset

Al_Device_Test

Auto reset

Al_BMS_Offline

Auto reset

OfflineAlrm_CPCOE_1 Auto reset

MEANING Error in the number of retain memory writings Error in retain memory writings Device Test is Running– Outputs Disabled! Device offline alarm to BMS Device offline alarm CPCOE

NOTE: The green LED indicates communication status on the BMS port. If there is communication on the BMS port (online) the green LED flashes, if there is no communication (offline) the LED stays on steady.

Alarm Number 0: Error in the number of retain memory writings This usually means indicates that the BMS is writing to a retained setpoint too often. Retained values are stored in a special memory so that they are kept on power loss. Failure to correct this could result in damage to the controller.
Alarm Number 1: Error in retain memory writings This usually means indicates that the BMS is writing to a retained setpoint too often. Retained values are stored in a special memory so that they are kept on power loss. Failure to correct this could result in damage to the controller.
Alarm Number 2: Device Test is Running–Outputs Disabled! This alarm occurs if someone had the unit in device test mode and the time limit has passed, usually an hour. Either cycle power to the unit or go into the Device Test section in the password protected menus and turn it off.
Alarm Number 3: Device offline alarm to BMS This alarm occurs if the BMS is enabled, and it is offline.
Alarm Number 4: Device offline alarm CPCOE This alarm occurs if the controller is not set to Enhanced. Go to the Unit Configuration and change this setting.

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8.1.5.2 Supply and Exhaust Alarms

NUMBER 10 11

NAME Al_SupplyFan Al_ExhaustFan

STATUS SHOWN User reset User reset

MEANING Supply Fan Alarm Exhaust Fan Alarm

Alarm Number 10: Supply Fan Alarm
This indicates that either the supply fan did not start, or that the current switch did not register the supply fan as running. Refer to the Supply or Exhaust Fan Alarm Troubleshooting section in the Test End Devices.
The delay for this alarm is set here. The setting is shared with the exhaust fan. Whether the unit shuts down if this alarm occurs is also set here.

Alarm Number 11: Exhaust Fan Alarm
This indicates that either the exhaust fan did not start, or that the current switch did not register the exhaust fan as running. Refer to the Supply or Exhaust Fan Alarm Troubleshooting section in the Test End Devices.
The delay for this alarm is set here. The setting is shared with the supply fan. This alarm will shut the unit down.

8.1.5.3 Airflow Condition Alarms

NUMBER 16
17

NAME
Al_SupAirLow Temp_Warn
Al_SupAirLow Temp_ A larm

STATUS SHOWN

MEANING

User reset

Low SA Temp Warning

User reset

Low SA Temp Shutdown

Alarm Numbers 16 and 17: Low SA Temp Warning and Low SA Temp Shutdown
The alarm applies to the supply temperature (SA).
First, view the sensor value in Unit Status. If it seems OK, then check the alarm levels set here. The difference in the two is that the warning will just show as an alarm while the shutdown will shut down the unit. You can use the warning as a warning set at higher temperature for the purposes of warning. You can also just use one or the other by setting the limits of the one you do not want to use very low.

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8.1.5.4 Sensor Alarms

NUMBER 30 31 32 33 34 35 36
37

NAME

STATUS SHOWN

Al_OA_Temp_Prb Auto reset

Al_OA_Hum_Prb

Auto reset

Al_RA_Temp_Prb Auto reset

Al_RA_Hum_Prb

Auto reset

Al_SA_Temp_Prb Auto reset

Al_EA_Temp_Prb Auto reset

Al_OA_Flt_Press_Prb Auto reset

Al_RA_Flt_Press_Prb Auto reset

MEANING OA Temperature Sensor Error OA Humidity Transducer Error RA Temperature Sensor Error RA Humidity Transducer Error SA Temperature Sensor Error EA Temperature Sensor Error OA Filter Pressure Transducer Alarm RA Filter Pressure Transducer Alarm

Alarm Numbers 30­37: Sensor Alarms
These alarms occur when the controller detects that sensor is not reading in the expected range. Passive sensors such as temperature sensors show an error when the controller detects a short circuit or open circuit. Active sensors (0­10V) are in alarm when they value read is slightly above 10V.
To resolve the alarms, check the wiring to see if there is a loose wire or missing sensor.

Filter Alarms

NUMBER 60 61

NAME Al_OA_Flt_Press Al_RA_Flt_Press

STATUS SHOWN Auto reset Auto reset

MEANING OA Filter Pressure Alarm RA Filter Pressure Alarm

Alarm Numbers 60­61: Filter Alarms
These alarms occur when the pressure exceeds the OA Level or the RA Level as set in the Alarm Settings.
For more information refer to Pressure Drop Charts in the unit specific IOM.

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To resolve the alarms, change the filter. If the alarm is still active, verify that the reading is as expected in the Unit Status. If not, check that someone has not changed the pressure transducer range in the I/O Configuration. Also check the offset or override for the sensors.

Enhanced Commercial Controls

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Maintenance Alarms

NUMBER

NAME

62

Al_UnitLife

64

Al_SupplyFanLife

65

Al_ExhaustFanLife

STATUS SHOWN Auto reset
Auto reset
Auto reset

MEANING
Unit Service Threshold Reached
Supply Fan Service Threshold Reached
Exhaust Fan Service Threshold Reached

Alarm Numbers 62­65: Maintenance Alarms
These alarms occur when the number of run hours reaches the thresholds set in the Advanced Service. A typical screen is shown here.

Refer to the Advanced Service for more information on these settings.
8.2 TEST END DEVICES
The Test End Devices allows you to manually control outputs for testing. The unit must be off for this feature to be enabled. An alarm will occur in one hour (default) if you forget to take the device out of test mode.
Once done. Make sure you cycle power to end test mode and put all values back to zero.

8.2.1 Supply or Exhaust Fan Alarm Troubleshooting
These alarms, 10 and 11, mean that either the fan did not start or that the current switch did not detect that the fan is running. To troubleshoot this: u Turn the unit off through the keypad. u In the password protected menus, go to the Test End Devices and enable. As shown, an alarm
will sound if you leave the unit in device test mode for more than an hour (default).

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u Open both dampers.

u Enable both fans.

u For the fan that has the alarm (supply or exhaust), command the fan to run at 35% or so. If you see the flow increase but don’t see the feedback (current switch) to yes, then the problem is with the current switch. If you don’t see the flow increase the fan did not start and the problem is either with the wiring or the VFD parameters.

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u If you think the problem is with the current switch, try adjusting the fan % up until you see the feedback go to YES. During this time, you should also see the flow to continue to increase. Once you see the feedback turn to yes you know the current switch needs adjustment. If it gets to 100% and you do not see it turn to yes, it may be wiring or a bad current switch. You can try to adjust it below.
Adjusting the Current Switch
With the dampers open and the fans enabled as described in the Test End Devices mode above, set the fan for which you want to calibrate to the minimum speed (%) at which you expect it to operate.
On the top of the sensor, there are an adjusting screw and two LED lights, one red and one blue. The adjusting screw will turn 15 turns. To set the sensor for any fixed-speed fan: u Verify that the blue LED is on. u Slowly adjust the potentiometer screw clockwise until the RED LED just turns on. This sets
the trip point at the normal operating load current u If the RED LED is on after initial power-up, slowly adjust the potentiometer counter-clockwise
until the BLUE LED turns on and then slowly adjust the potentiometer clockwise until the RED LED just turns on.
IMPORTANT
Cycle power to the unit after you are done testing. This will take the unit out of Device Test Mode and reset all of the test values to off or 0%.

Enhanced Commercial Controls

TROUBLESHOOTING ERV

8.3 OTHER COMMON PROBLEMS
Listed are some other common problems you may encounter.
8.3.1 Unit Not On
If the unit will not run, go to this screen in Unit Status and the bottom line will tell you why. Multiple items may be true. Possible messages and their meaning: u Unit On: Unit is running u Off by Alarm: A serious alarm is present; usually a fan alarm or supply temp alarm. u Off by BMS: The BMS has set Enable BMS Control to yes and is not sending an On command. u Off by DI: The terminals 17 and 18 need to be closed or jumped. u Off by Keyboard: The menu screen Unit On/Off is set to off. u Exhaust Fan Only Mode: The terminals 18 and 19 are closed indicating single fan mode. The
setting for which fan will run is in I/O Configuration. u Supply Fan Only Mode: The terminals 18 and 19 are closed indicating single fan mode. The
setting for which fan will run is in I/O Configuration. u In Device Test: Mode in Test End Devices is enabled. Cycle power to get it out of this mode. u Input Overwritten: There is a sensor that is overwritten in Sensor Overrides. This occurs after
24 hours as a reminder.

8.3.2 Sensor Reading #### or Has Extreme Value This normally means that the sensor is not connected, or it has faulty wiring.
8.3.3 BMS Loss of Comm after Param Change or Restore Most BMS setting changes require a power cycle. This applies to a parameter restore, which is basically the same thing.
8.3.4 Can Not See Device via IP Connection If you are connected locally with a PC: u Make sure your PC is on the same subnet but not the exact same IP address. The last octet
has to differ. u If you have just changed the IP address, make sure you said “update” on that screen and
cycle power. u Make sure the cable “snaps in” on both sides. u Microsoft Edge browser does not work as well. Use Chrome, if possible. u Make sure you don’t have anything in the USB connection in the front of the controller. If you are connected remotely, check all of the above but also note that the connection has to be on the same subnet. An IP tunnel may also work.

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8.4 TESTING FUNCTIONS IN GENERAL
When testing in general, the Sensor Overrides is a handy tool. These allow you to temporarily override a sensor to see if a function is working correctly. For example, if you want to test your cooling but it is cool outside, you can override your outdoor sensor to exceed the cool lockout temperature. This is handier than having to change all of your settings and then set them back.
To override a sensor, first set the value of the sensor and then enable. If you enable before setting the value, the value shown will be set right away. In this case, it will most likely turn on your heat.

If you leave a sensor overwritten, an alarm will occur after 24 hours. All overwritten values are lost on power cycle and the statuses go back to disabled.
8.5 RESTORE PARAMETERS (SETTING)
There are several levels of settings in the controller. Some are set by the factory, and some are set be users. These parameters include all configuration settings, fan settings, heat/cool settings, and BMS settings.

NOTE: RenewAire highly recommends that a USB thumb drive be installed in the USB port and a system backup (external) be made immediately after start up or commissioning.

8.5.1 User Commissioning Settings (Service)
At the end of the I/O Configuration, the user is prompted to save their settings. It is probably best to save these values after setting all of the values in the Control Variables as well. This is password protected as every time you save the settings, the file will overwrite. The file name is “SERVICE.txt,” and it will be save to either the internal memory location, or the external USB drive that is attached in front.
To perform this operation, the unit must be OFF. u Choose the location: internal or USB u Set Confirm to YES

If you choose USB and you get “Cannot access disk,” there is something wrong with the connection or disk.

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If you do the operation correctly, it will say “Operation Done.”

To restore user settings, the screen is in Backup and Restore. The steps are: u Choose the location: internal or USB u Set Confirm to Yes You should see “Operation done.”
If the unit does not confirm that the operation was done, the controller may have been older and upgraded in the field. Older version saved factory parameters in EXPORT_76. See the General Save and Restore for information on how to get those settings back into the controller.
8.5.2 Restore Factory Settings This operation is used to go back to factory settings that were set in the factory while they tested the unit. These are somewhat specific settings but going back to these settings will require you to perform start up and commissioning again. To return to factory defaults: u Choose internal u Set Confirm to YES

If the unit does not confirm that the operation was done, the controller may have been older and upgraded in the field. Older version saved factory parameters in EXPORT_76. See the General Save and Restore for information on how to get those settings back into the controller.

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8.5.3 General Save and Restore
There is a general save and restore function that allows you to save different versions of your parameters and save them under slightly different names.
Both saving and restoring use the same screen so care should be taken to make sure you have the screen set correctly so you do not lose all of your settings.
u Choose IMPORT (for restoring) or EXPORT (for saving) u Choose memory type: INTERNAL or USB
If the unit does not confirm that the operation was done, the controller may have been older and u Choose File ID: EXPORT_xx, where xx is any number from 00 to 99, If you are saving a set of
parameters remember the number. u Set Confirm to YES

NOTE: Do not use the other two lines unless directed to do so by TSS.

8.5.4 Code List for Save and Restore Use these codes to troubleshoot the Save and Restore Feature.

MESSAGE

MEANING

Operation Done

Save or Restore was successful.

Cannot Access Disk

This usually happens when you choose USB and the USB is not inserted or detected. If inserted, the connector may be too short.

Cannot access file

This usually happens when you are importing and the file you are importing does not exist.

Memory buffer is too small

You may have to erase some data from the drive or USB before you can perform the operation.

Time parameters are not correct The clock needs to be set in General Settings.

Module is currently busy–retry Another operation was running. Retry. is required

Log exporting failed

It is possible the connection was interrupted.

Input parameter value is not valid The file may not be compatible with the program.

8.5.5 Return to Program Defaults
A more drastic approach may be needed to get internal settings out of the controller. Once done, you can restore a set of parameters by using any of the previously described methods. The process is called “Wipe Retain” for anyone familiar with the Carel controller. Most likely you will not use this operation unless you are directed to do so by RenewAire Technical Sales Support (TSS).
To perform this operation, choose YES on the top line Wipe retain mem.

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The unit will take a minute to get back. Then you can resume entering your parameters by any method.
9.0 ACCESSING FILES FROM AND PERFORMING UPDATES TO THE CONTROLLER
The controller has a total of about 92 MB of internal memory. There are several types of files that use the internal 92 MB of mass storage that are available on the controller. u Logs–exported automatically in the root u Alarm List–exported on demand u Parameter sets –see Restore Parameters (Settings) u Program and OS Upgrade packages–Reside in an UPGRADE folder u Web pages–Reside in an HTTP folder u User storage, such as documents

These files can be accessed through one of two methods: u Connection via FTP through the Ethernet port u Connection with a micro USB cable
It is also possible to export directly alarms, current log, and parameter sets to a USB drive that has either a micro USB connector or uses an adapter.
9.1 CONNECTIONS USING THE MICRO USB PORT
The controller has a built-in USB port where an external memory device such as a USB thumb drive can be plugged in. The external memory device may be used for backing up all settings and reported conditions such as Alarm History and presets. Backing-up is user-commanded and is done through the menu screens.
Note that the USB port is a Micro USB Type “B.” Thumb drives with a Micro USB Type B are difficult to find in some areas and it may be necessary to purchase an adapter to go from a more common Type A connector to the newer Micro Type B.
Make sure that the longer side of the USB connection is to the bottom of the controller. Do not force the connector in or you could damage the controller.
The controller requires that you use a cable or adapter with a longer end for the Micro USB side. One adapter we have found that works is the UGreen, purchased on Amazon.

NOTE: You cannot be connected by both methods at the same time. If you are viewing the web pages and then connect with USB, the web page will go blank until you disconnect.

MICRO USB TYPE “B” PORT

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9.2 ALARMS AND DATA LOGS
Two types of files that are exported on demand are logs and alarm lists. They can be exported to the internal memory or the USB drive.
The export of the logs will show “In Progress” while exporting. It may take a while depending upon the size.

NOTE: There will be several log files on the internal drive. This is because the log is exported every night at midnight. The files are listed by day of week, where 1 = Monday. The file that starts with 9 is the file that is exported on demand.
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9.2.1 Example of Alarm Log
This is the file as opened in Excel. It includes a timestamp, alarm number, alarm name, and whether the event was the start of the alarm or the end (stop).

TIME

ID NAME

EVENT VAR1 VAR2

2022-01-28T16:11:22+00:00 39 Al_EA_Flow_Rate_Prb.Active Start

2022-01-28T16:11:22+00:00 38 Al_OA_Flow_Rate_Prb.Active Start

2022-01-28T16:11:21+00:00 42 Al_Supply_Temp_Prb.Active

Start

2022-01-27T17:48:22+00:00 39 Al_EA_Flow_Rate_Prb.Active Start

2022-01-27T17:48:22+00:00 38 Al_OA_Flow_Rate_Prb.Active Start

2022-01-27T17:48:20+00:00 42 Al_Supply_Temp_Prb.Active

Start

2022-01-27T15:48:02+00:00 39 Al_EA_Flow_Rate_Prb.Active Start

2022-01-27T15:48:02+00:00 38 Al_OA_Flow_Rate_Prb.Active Start

2022-01-27T15:48:01+00:00 42 Al_Supply_Temp_Prb.Active

Start

9.2.2 Exa-mp-le of Data Log

This is th-e fi-le as opened in Excel. It includes a timestamp and values of all of the factory

preconfig-ure-d log values.

—

—

OA_Temp. OA_Hum. RA_Hum. SA_Temp. EA_Temp. Cooling_C Heating_C RA_Temp.

T2I0M22E-0-2-06-ETV00E:N0T0:03+Val 22.079 Val

Val 23.14

Val

Val

ommand. ommand. Val

20.73 20.111 21.768

0

0 22.134

2022-0-2-06-T00:00:08+ 22.079

23.14

20.74 20.134 21.756

0

0 22.134

2022-0-2-06-T00:00:13+ 22.079 23.13 20.69 20.154 21.756

0

0 22.134

2022-0-2-06-T00:00:18+ 22.067

23.15

20.71 20.166 21.756

0

0 22.134

22002222–00-22–0066-TT0000::0000::2238++

22.067 22.067

23.15 20.725 20.166 21.756 23.14 20.695 20.178 21.756

0 0

0 22.123 0 22.123

2022-0-2-06-T00:00:33+ 22.067

23.14

20.71 20.189 21.756

0

0 22.123

2022-0-2-06-T00:00:38+ 22.067 23.14 20.705 20.199 21.745

0

0 22.123

2022-0-2-06-T00:00:43+ 22.067

23.14

20.69 20.209 21.745

0

0 22.123

2022–0-2–06-T00:00:48+ 22.067

23.14 20.735 20.209 21.745

0

0 22.123

– — –

– — –

– — –

– –

–

– –

–

– — –

—

—

—

—

—

—

—

—

—

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The variables that are logged are as listed here.

VARIABLE

VARIABLE

VARIABLE

OA Temp.Val OA Hum.Val R A _ Hum.Val S A _Temp.Val

E A _Temp.Val R A _Temp.Val OA_Enthalpy Bypass_Command.Val

A ny_ A larm _Out.Val

9.3 VIEWING PARAMETER FILES
You can view the parameter files that were created in Restore Parameters (Settings). You can also share them between controllers. An excerpt of a file is shown below. #Ver.1.0 cpCO Family Exported Configuration file

VARIABLE

DESCRIPTION DATA TYPE DEFAULT VALUE

BACnet_Mapping

UINT

BMSMng.BACnetPort

UDINT

BMSMng.BMS_Address_RS485

UINT

BMSMng.BMS_BACnetDeviceInstance

UDINT

BMSMng.BMS_BACnetMSTP_MaxInfoFrames UINT

BMSMng.BMS_BACnetMSTP_MaxMaster UINT

BMSMng.BMS_BACnet_CmdTimeout

UINT

BMSMng.BMS_BACnet_Timout

UINT

BMSMng.BMS_Baud_Msk

UINT

BMSMng.BMS_Baud_RS485

UDINT

BMSMng.BMS_Modbus_Timeout

UINT

BMSMng.BMS_Parity_MSK

USINT

0 47808 4 5002 20 127 1500 3000 2 19200 3000 0

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NOTE: It is advised that you delete this file once you are done. Every upgrade file is named the same, regardless of version.

9.4 PERFORMING UPDATES TO THE CONTROLLER
If directed by TSS, you may need to perform an upgrade to the controller program. A very similar process is also used to field-install BACnet licenses into the controller. Refer to the BMS Access for that process.
There are three different methods to update a program, depending upon which way you connect to the controller. All three require that you have a file called “autorun.ap1,” given to you by TSS.
1. Connect via USB. This requires that you have a micro USB cable to go from your PC to the controller micro USB connection and can see the files in Windows Explorer.
2. Connect with a USB thumb drive to the micro USB connection.
3. Connect via Ethernet. This requires a PC and the ability to connect to the embedded web pages inside the controller.
9.4.1 Upgrade Type: Connect via USB
1. Save the parameters using the General Save and Restore method. Make sure you choose EXPORT! Remember the Export_XX number you chose.
2. Carefully connect the micro USB cable to the front connection of the controller (long side to the bottom) and to your PC. Verify that you can see the files in Windows Explorer. It shows up as a USB drive. If you cannot see these files you will need to use another method.

3. Put the autorun.ap1 file in the folder called “UPGRADE.” You should not have other files in the root of that folder. You can have other folders in this folder, if needed.
4. You will be prompted to press “ENTER” to proceed.

5. Once it is done you will be prompted to press “ENTER” to restart the controller.

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6. Restore the parameters using the General Save and Restore method. Make sure you choose IMPORT! Use the Export_XX number you chose in step 1.
7. Cycle power.
9.4.2 Upgrade Type: Connect with a USB Thumb Drive Connect with a USB thumb drive to the micro USB connection. 1. Save the parameters using the General Save and Restore method. Make sure you choose
EXPORT! Remember the Export_XX number you chose. 2. Put the autorun.ap1 file in a folder in the root of the thumb drive called “UPGRADE.” 3. Carefully connect the micro USB drive to the front connection of the controller (long side to
the bottom). 4. You will be prompted to press “ENTER” to proceed.

5. Once it is done you will be prompted to press “ENTER” to restart the controller.

6. Restore the parameters using the General Save and Restore method. Make sure you choose IMPORT! Use the Export_XX number you chose in step 1.
7. Cycle power.
9.4.3 Upgrade Type: Connect via Ethernet This requires a PC and the ability to connect to the embedded web pages inside the controller. 1. Save the parameters using the General Save and Restore method. Make sure you choose
EXPORT! Remember the Export_XX number you chose. 2. Go to the Upgrade Tab in the web pages.

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3. Click on “CHOOSE FILE” and locate the autorun.ap1 file on your PC that corresponds to the controller. Click “OPEN.” You should now see that file name next to “CHOOSE FILE.”
4. Click “Upload AP1 to c.pco.” You will see the file upload.
5. Once 100% on the upload, switch back to the RUT screen to see the upgrade taking place.
6. On the controller the program will see the file and require you to push “ENTER.” You can see that on the front of the controller itself or on the RUT page of the web pages.
7. Restore the parameters using the General Save and Restore method. Make sure you choose IMPORT! Use the Export_XX number you chose in step 1.
8. Cycle power.
10.0 GENERAL SYSTEM MONITORING
This section describes the general system monitoring. It is here only to provide a general sense of how to monitor the system. Specific screens and information appear depending upon the features you have selected. Refer to the documentation on the specific function for the information on specific monitoring screens.
The unit is monitored through Unit Status.
10.1 MAIN SCREEN
The main screen shows either the SA temperature coming off the core, or the CA temperature, depending upon whether the unit has tempering or not. It also shows the other four temperatures near the core.

10.2 OTHER STANDARD SCREENS
These screens also show standard values.
10.3 FAN AND UNIT STATUS SCREENS
The first screen is helpful on starting the unit. It shows whether the fan is being asked to turn on (enabled), and whether the current sensor is detecting that it has turned on. It also shows the Unit Status conditions, described in the chart below. The seconds screen shows the speed of the fans.

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STATUS SHOWN Unit on Off by alarm Off by BMS Off by Time Band Off by Schedule Off by Keypad EF Only Mode SF Only Mode In Device Test Input Overwritten Off by CO2 Level Flush Mode Frost Control on

UNIT STATUS CONDITIONS
MEANING The unit is on and running. The unit is off by a serious alarm. The unit is off by command from the BMS. The unit is off by the scheduler. The unit is off by the ID1 digital input. The unit is off by the setting on the local interface. The unit is in single fan mode with exhaust fan running. The unit is in single fan mode with supply fan running. The system is in device test mode. There is a sensor input that is overwritten. The CO2 level is below the limit for running. The unit is running in FLUSH mode. The unit is running in Frost Control Mode.

The third screen shows: u Whether the unit is enabled. (See Unit Status Conditions in the first screen to assess why the
unit is not on). u Whether the OA and RA dampers are open–they should be open if the unit is ON and in
occupied mode, if applicable. u The status of the bypass damper which is used for economizer and frost control, if the
features are enabled.

10.4 FROST CONTROL INFORMATION
This screen contains all frost control information.

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10.5 ENTRY TO THE I/O INFORMATION SCREEN
This screen is described in Verifying all I/O through Unit Status Screens.

10.6 VERSION INFORMATION SCREEN
This screen contains: u Type of application u Version of program (SW) and operating system (OS) u Unique controller identifier

11.0 BMS ACCESS
The BMS settings are located in the General Settings after the scheduler. To get to that menu press the back button until it shows up.
11.1 SETTING CONTROL LEVEL
The first screen sets whether the unit will get an on/off command from the BMS. If you set this to Yes right away, the unit will not start until the BMS command is sent. Therefore, do not set this to Yes until you are ready to operate the unit.
Background: The unit will not turn on unless are all of the following are true. As a result, any one can turn the unit off. u There are no serious alarms. u The Digital Input for start/stop (terminals 17 and 18) are closed. u The unit is turned on at the keypad. u The time is within the scheduler “ON” time, if scheduler enabled. u The BMS has written the unit on signal, if BMS control is enabled.

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11.2 SETTING BMS TYPE
There are either three or five setting for BMS Type. The BACnet options will not show up unless a BACnet license has been installed. u None u BACnet MS/TP u BACnet IP u Modbus RTU u Modbus IP

The license status can be viewed in a later screen. Refer to Adding a BACnet License for more information.

Once a protocol has been selected, additional BMS programming screens will appear. Change settings as needed. After the BMS protocol has been selected and protocol options have been selected, cycle power to the controller.
11.3 BACNET
RenewAire units Are BTL listed by CAREL. They allow the BMS to write to the present value by default. This means that if the BMS writes to a setpoint that setpoint can be changed by the local HMI display. (Last one in wins). Priority array is not supported.
Setpoints, in general, are saved in EEPROM memory and maintained on power loss. These are referred to as RETAINED. For retained values, DO NOT write to these values constantly. Doing so will flag an alarm and can damage the controller. If you have a need to write to a value constantly, contact TSS to discuss options.
Older units wrote to the priority array. This was cumbersome to support. They also had limited mapping. If upgrading from an older version and you want to keep that mapping, change the setting below to “Pri Array legacy.” The mapping is quite different and is supported in the older documentation. Also note that priority array setpoints were not kept on power loss.

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11.3.1 BACnet IP Connection Connection of BACnet IP requires a physical cable connection to the RJ45 jack on the controller. Prior to making the wiring connections, the controller is to be tested to verify proper control of the unit under local control.
ETHERNET CONNECTION

NOTE: The controller will only support private IP addresses which start with 192, 172, or 10.

11.3.2 BACnet IP Settings
First, set the IP address of the controller in the same General Settings area. u Set DHCP to Off if static. u If Static, set the IP, mask, and gateway if required. u Set Update? To Yes (power will need to be cycled. This can be done after all of the
other settings.)

Next, set the BACnet Device ID. This screen allows you to set the ID digit by digit.

Last, set the BACnet port if different from the 47808 (BAC0). This screen allows you to set the BACnet Device ID scrolling up or down.

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If you need to set the timing values, you can do that here.

11.3.3 BACnet MSTP Settings First, set the BACnet Device ID. This screen allows you to set the ID digit by digit.

NOTE: Whenever the BMS type is changed, power to the controller must be cycled.

Next, set the BACnet MSTP Address, Baud rate, Max Master and Max Info frames as needed.

If you need to set the timing values, you can do that here.

11.3.4 BACnet MSTP Wiring
The BACnet MSTP network is wired into the four-pin connector named J3 Disp. In the upper left-hand corner of the controller. This is also used for a RUT display so the two cannot be used at the same time. For MSTP, use the plus (+) and minus (-), as well as the GND for reference if desired.
DO NOT use the +Vterm terminal. If you happen to plus a three-pin block in here and use the wrong three pins you might damage the port.

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11.4 BACNET OBJECT LIST

TYPE Analog Input

INSTANCE

VARIABLE NAME

0

OA _Temp.Val

DESCRIPTION OA Temperature

VALUE RANGE
F

READ/WRITE (RET)
Read_NoWrite

Analog Input

1

OA _ Hum.Val

OA Relative Humidity

%

Read_NoWrite

Analog Input

2

R A _Temp.Val

RA Temperature

F

Read_NoWrite

Analog Input

3

R A _ Hum.Val

RA Relative Humidity

%

Read_NoWrite

Analog Input

4

E A _Temp.Val

EA Temperature

F

Read_NoWrite

Analog Input Analog Input

5

S A _Temp.Val

24

R A Flt Press.Val

SA Temperature (before tempering)
RA Filter Pressure

F

Read_NoWrite

iwc

Read_NoWrite

Analog Input

25

OA Flt Press.Val

OA Filter Pressure

iwc

Read_NoWrite

Analog Input Analog Input Analog Value Analog Value

26

SF_Command.Val

Supply Fan Command % (actual)

27

EF_Command.Val

Exhaust Fan Command % (actual)

34

HeatingCommand_BMS Heating Command from %

BMS

35

RA_Flt_AlarmHigh

RA Filter Alarm Level

iwc

Read_NoWrite Read_NoWrite Read_Writeable Read_Writeable (X)

Analog Value

36

OA_Flt_AlarmHigh

OA Filter Alarm Level

iwc

Read_Writeable (X)

Analog Value

37

SF_ConstSpeedSetP.Val SF Const Speed Setpoint %

Read_Writeable (X)

Analog Value Analog Value

43

EF_ConstSpeedSetP.Val EF Constant Speed

%

Setpoint

45

EF_SF_TrackingSetP.Val EF SF Tracking Setpoint %

Read_Writeable (X) Read_Writeable (X)

Analog Value Analog Value Analog Value Binary Input Binary Input Binary Input

77

Defrost_OA_SetP.Val Frost control OA Setpoint F

Low Limit

Read_Writeable (X)

78

Defrost_EA_Low_SetP. Frost control EA Setpoint F

Val

Low Limit

Read_Writeable (X)

79

Defrost_EA_High_SetP. Frost control EA High

F

Val

Limit Setpoint

Read_Writeable (X)

8

OA _ Damp.Val

OA Damper Command

Closed/ Read_NoWrite Open

9

R A _ Damp.Val

RA Damper Command

Closed/ Read_NoWrite Open

14

AlarmMng.AlrmRes

Alarm Reset Status

No/Yes Read_NoWrite

Binary Input Binary Input Binary Input Binary Input

15

SF_Status.Val

16

EF_Status.Val

17

Alarm_Out.Val

21

UnitOn

SF Status from Current Sensor
EF Status from Current Sensor
Serious Alarm (Also a physical output)
Unit On Status

Off/On Read_NoWrite Off/On Read_NoWrite OK/Alarm Read_NoWrite Off/On Read_NoWrite

Binary Input

22

Al_SupplyFan.Active Supply Fan Start Alarm OK/Alarm Read_NoWrite

Binary Input

23

Al_ExhaustFan.Active Exhaust Fan Start Alarm OK/Alarm Read_NoWrite

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TYPE Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Input Binary Value Binary Value

INSTANCE

VARIABLE NAME

49

Bypass_Damper.Val

72

A ny_ A larm _Out.Val

DESCRIPTION
Bypass Damper Command Any Alarm is True Status

VALUE RANGE
Close/ Open
OK /Alarm

READ/WRITE (RET)
Read_NoWrite
Read_NoWrite

500

Al_retain.Active

Too Many Writes to Retained Memory

OK/Alarm Read_NoWrite

501

Al_Err_retain_write. Too Many Writes to

Active

Retained Memory

OK/Alarm Read_NoWrite

502

Al_Device_Test.Active Unit Was Left In Device OK/Alarm Read_NoWrite

Test Mode

503

Al_BMS_Offline.Active BMS Is Offline

OK/Alarm Read_NoWrite

504

OfflineAlrm_CPCOE_1. Offline Alarm Expansion OK/Alarm Read_NoWrite

Active

Module

510

Al_SupplyFan.Active Supply Fan Start Alarm OK/Alarm Read_NoWrite

511

Al_ExhaustFan.Active Exhaust Fan Start Alarm OK/Alarm Read_NoWrite

516

Al_SupAir_LowTemp Supply Air Low

OK/Alarm Read_NoWrite

Warn.Active

Temperature Warning

517

Al_SupAir_LowTemp Supply Air Low

Alarm.Active

Temperature Alarm

OK/Alarm Read_NoWrite

530

A l _OA Temp Prb.

Active

OA Temperature Sensor OK/Alarm Read_NoWrite Open or Short

531

Al_OA_Hum_Prb.Active OA Relative Humidity

OK/Alarm Read_NoWrite

Transmitter Out of Range

532

A l _ R A Temp Prb.

Active

RA Temperature Sensor OK/Alarm Read_NoWrite Open or Short

533

Al_RA_Hum_Prb.Active RA Relative Humidity

OK/Alarm Read_NoWrite

Transmitter Out of Range

534

A l _ S A Temp Prb.

Active

SA Temperature Sensor OK/Alarm Read_NoWrite Open or Short

535

A l _ E A Temp Prb.

Active

EA Temperature Sensor OK/Alarm Read_NoWrite Open or Short

536

Al_OA_Flt_Press_Prb. OA Filter Pressure

OK/Alarm Read_NoWrite

Active

Transmitter Out of Range

537

Al_RA_Flt_Press_Prb. RA Filter Pressure

OK/Alarm Read_NoWrite

Active

Transmitter Out of Range

560

Al_OA_Flt_Press.

Active

OA Filter Needs Change OK/Alarm Read_NoWrite

561

Al_RA_Flt_Press.

Active

RA Filter Needs Change OK/Alarm Read_NoWrite

562

Al_UnitLife.Active

Unit Service Request

OK/Alarm Read_NoWrite

564

Al_SupplyFanLife.

Active

Supply Fan Service Request

OK/Alarm Read_NoWrite

565

Al_ExhaustFanLife.

Exhaust Fan Service

Active

Request

OK/Alarm Read_NoWrite

10

OnOffUnitMng.

BmsOnOff

BMS On/Off Command Off/On Read_Writeable

11

OnOffUnitMng.

BmsEfOnly

BMS Exhaust Fan Only Command

Off/On

Read_Writeable

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TYPE
Binary Value
MultiState Input MultiState Input Multistate Input

INSTANCE

VARIABLE NAME

12

AlarmMng.

AlrmResByBms

2

SF_ControlType_BN

3

EF_ControlType_BN

7

UnitStatus_BN

DESCRIPTION Alarm Reset BMS Command SF_ControlType_BN
EF_ControlType_BN
UnitStatus_BN

VALUE RANGE

READ/WRITE (RET)

OK/Reset Read_Writeable

(See Notes)
(See Notes)
(See Notes)

Read_NoWrite Read_NoWrite Read_NoWrite

11.5 BACNET APPLICATION NOTES
11.5.1 Turning the Unit On and Off
If you plan to use the BMS to turn the unit on and off, make sure you have the control enabled through the keypad. Use Binary Value 10 “OnOffUnitMng.BmsOnOff.” The status can be read at “UnitOn” at Binary Input 21.
All of the following have to be true in order for the unit to be on: u There are no serious alarms. u The Digital Input for start/stop (terminals 17 and 18) are closed. u The unit is turned on at the keypad. u The time is within the scheduler “ON” time, if scheduler enabled. u The BMS has written the unit on signal, if BMS control is enabled

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VALUE 1 2
3 4
5
6
8
9 13
14
15 16

UNITSTATUS_BN: MULTISTATE INPUT 7

STATUS

MEANING

Unit on

The unit is on and running.

Unit switched off due to The unit is off by a serious alarm. alarm

Unit switched off by BMS The unit is off by command from the BMS.

Unit switched off by time The unit is off by the scheduler. band

Unit switched off by digital The unit is off due to contacts across 17 and 18 open. input

Unit switched off from the The unit is off by the setting on the menu screen. local keypad

Exhaust Fan Only Mode

The unit is in single fan mode with exhaust fan running.

Supply Fan Only Mode The unit is in single fan mode with supply fan running.

Device Test

The system is in device test mode for more than an hour.

Sens Ovrd Active

The system has a sensor overwritten for more than 24 hours.

Off by CO2 Level

Off by CO2 Level.

Frost Control On

Frost Control Mode Active.

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11.5.2 Alarms
Individual alarms are mapped to Binary Inputs 500 and above. Two general alarms are available: u Serious Alarm: Located at Binary Input 17, “Alarm_Out.val” indicates whether there is a
serious alarm that stops the unit. u Any Alarm: Located at Binary Input 72, “Any_Alarm_Out.val” indicates whether there is any
alarm present.
To reset the User Reset type alarms, set Binary Value 12 “AlarmMng.AlrmResByBMS” to true. The program will set it back to false. You can view the status change through Binary Input 14 “AlarmMng.AlrmRes.”

11.5.3 Temperature and Humidity Around the ERV

The following are available: u Analog Input 0 “OA_Temp.Val” u Analog Input 1 “OA_Hum.Val” u Analog Input 2 “RA_Temp.Val” u Analog Input 3 “RA_Hum.Val” u Analog Input 4 “EA_Temp.Val” u Analog Input 5 “SA_Temp.Val”

EA

OA

SA

RA

11.5.4 Fan Control
The supply fan control type method can be viewed at Multistate Input 2 “SF_ControlType_BN.” The valid values are 0 = Constant Speed.
The corresponding settings is as follows: u Constant Speed setpoint is Analog Value 37 “SF_ConstantSpeedSetP.Val”
The command to the fan is read at Analog Input 26 “SF_Command.Val.” The feedback from the current sensor is read at Binary Input 15 “SF_Status.Val.”
The exhaust fan control type method can be viewed at Multistate Input 3 “EF_ControlType_BN.” The valid values are 1 = Constant Speed and 3 = SF Command Tracking.
The corresponding settings are as follows: u Constant Speed setpoint is Analog Value 43 “EF_ConstantSpeedSetP.Val” u Exhaust Fan Tracking setpoint is Analog Value 45 “EF_SF_TrackingSetP.Val”
The command to the fan is read at Analog Input 27 “EF_Command.Val.” The feedback from the current sensor is read at Binary Input 16 “EF_Status.Val.”
The cooling output statuses are the following: u Binary Input 19 “Cooling_Enable_1.Val” for stage one or modulating types where the demand
is greater than 0 u Binary Input 20 “Cooling_Enable_2.Val” for stage two u Analog Input 33 “Cooling_Command.Val” shows a percentage for the 0­10V output.

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11.5.5 BMS Direct Fan Control
Available in ERV versions 03_00_26 ERV and higher.
Normally we use the setpoints below for constant speed fan control. These are retained variables that are kept on power loss and should not be written to constantly. You will get an alarm error and/or damage the controller by doing so.
Normal setpoint objects for constant speed fan control: u SF_ConstSpeedSetP.Val AV37 u EF_ConstSpeedSetP.Val AV43
The newer versions allow a BMS system to command directly to the speed control with a non-retained variable. This is done with systems where the BMS is writing to the value every program cycle. One example would be when they use their own pressure control loop and only write the output to the fan.
The fan settings for supply and exhaust fan are independent. The user must set the control for that fan to constant speed control.
The objects used for writing the fan control type are: u SF_ControlType_BN MV2 u EF_ControlType_BN MV2
They can also be set on these screens.

In order to use this feature, the settings must be set in this screen, located in the General Settings near the other BMS settings. The user must set the corresponding fan to “YES.”

The objects used for direct writing the percentages are:

u BMS_SupplyFanCommand

AV80 expressed as 0-100%

u BMS_ExhaustFanCommand

AV81 expressed as 0-100%

In the screen above you will be able to see the value of these objects under “Current Value” for troubleshooting purposes.

The Control Setting Screen will no longer be available. Instead, the following screen(s) will be shown accordingly, with the current command shown being read-only on the screen.

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11.5.6 Economizer Control The economizer will be enabled when there is a call for cooling and the outdoor is more favorable than the return air. In this case it will open the bypass damper to bypass the enthalpic core and thus inhibit the exchange of energy. During this time the unit still uses 100% OA. Economizing is allowed when both of the following Are below their limit: u Analog Value 52 “Economizer.Econ_Low_OA_Temp_Limit” u Analog Value 58 “Economizer.Econ_Low_RA_Temp_Limit”
11.5.7 Frost Control The frost control function is enabled, when the OA is lower than Analog Value 77 “DefrostOA SetP.Val” minus Analog Value 78 “Defrost_OA_SetP.DBright,” and turns off again when the OA exceeds the AV77. During this time, the supply fan is off and the OA damper is closed.
11.5.8 Filter Monitoring Filter pressures are read through Analog Input 24 “RA_FltPress.Val” and Analog Input 25 “OA Flt _ Press.Val.” Filter alarm levels are set at Analog Value 35 “RA_FltAlarmHigh” and Analog Value 36 “OA Flt _ A larmHigh.”
11.5.9 Exhaust Fan Only Mode If BMS control is enabled, the unit can also be put in exhaust fan only mode in occupied operation using Binary Value 74 “UnitOnOffMng.BMSEFOnly.”

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11.6 ADDING A BACNET LICENSE
11.6.1 Obtaining a BACnet License
If your controller does not have a BACnet license, contact whoever provided the unit to obtain one. You will need the Hardware ID number on this screen when ordering. Be sure to copy it carefully or the license will not work.

The license will be delivered as a file with extension “.ap1.”
11.6.2 Installing the BACnet License via Web Page
Prerequisites u Have ap1 BACnet upgrade file(s) located on your PC u Ethernet connection from the PC to the controller and view the web page
Steps 1. Go to the Upgrade Tab in the web pages.

2. Click on “CHOOSE FILE” and locate the file on your PC that corresponds to the controller. HINT: The ending character in the UID of the controller should match the character of the ap1 file. Click “OPEN.”
3. You should now see that file name next to “CHOOSE FILE.” Click “Upload AP1 to c.pco.” You will see the file upload.
4. On the controller the program will see the file and require you to push “ENTER.” You can see that on the front of the controller itself or on the RUT page of the web pages.
5. Once the upgrade is finished the controller will ask you to reboot.
You can then verify that the license is installed by going to the RUT page.

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11.6.3 Installing the BACnet License via USB Drive
Prerequisites u Micro USB Adapter. u USB Stick with the file in a folder in the root called “UPGRADE.” The file you received should
be in that folder.
Steps 1. Carefully insert the micro USB end into the controller front under the door with the wide side
to the bottom. 2. You should now see a prompt telling you press the enter key. 3. Once finished you will be prompted to press “ENTER” again.
You should now see the license is installed in the controller screen.
11.6.4 Installing the BACnet License via USB Connection
Prerequisites: u PC u Micro USB cable with the ability to plug in with a PC and have the controller appear as a USB
drive in your Windows Explorer
Steps 1. Carefully insert the micro USB end into the controller front under the door with the wide side
to the bottom. 2. You should see a folder called “UPGRADE” in the controller. Put the file in that folder. 3. Once finished you will be prompted to press “ENTER” again.
You should now see the license is installed in the controller screen.

11.7 MODBUS

The Modbus utilizes the standard registers and references them as an offset. For example, an offset of Input Register 0 is Register 30,001 and an offset for Holding Register 0 is register 40,001. All values are shown in decimal format. The implementation also uses Coils and Discrete Inputs in a similar manner.

11.7.1 Modbus TCP Connection

Connection of Modbus TCP requires a physical cable connection to the RJ45 jack on the controller. Prior to making the wiring connections, the controller is to be tested to verify proper control of the ERV unit under local control.

FIGURE 11.2.0 ETHERNET CONNECTION

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NOTE: The controller will only support private IP addresses which start with 192, 172, or 10.

11.7.2 Modbus TCP Settings
First, set the IP address of the controller in the same General Settings area.
u Set DHCP to Off if static u If Static, set the IP, mask, and gateway if required. u Set Update? To Yes (Power will need to be cycled. This can be done after all of the
other settings.)

Then set the timeout parameter, if needed.

11.7.3 Modbus RTU Settings First, set the address, baud rate, stop bits and parity.

Then set the timeout parameter if needed.
11.7.4 Modbus RTU Wiring The Modbus RTU network is wired into the four-pin connector named J3 Disp. In the upper left-hand corner of the controller. This is also used for a RUT display so the two cannot be used at the same time. For Modbus RTU, use the plus (+) and minus (-), as well as the GND for reference if desired. DO NOT use the +Vterm terminal. If you happen to plus a three-pin block in here and use the wrong three pins you might damage the port.
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11.8 MODBUS REGISTER LIST
Modbus Registers with an offset of 0 have been duplicated at register 98 to accommodate Automated Logic Systems and other systems that cannot map 0.

TYPE Coil

VARIABLE

0 OnOffUnitMng.BmsOnOff

DESCRIPTION BMS On/Off Command

RANGE Off/On

READ/WRITE MODE (RET)
Read_Writeable

Coil

1 OnOffUnitMng.BmsEfOnly BMS Exhaust Fan Only Command Off/On

Read_Writeable

Coil

2 AlarmMng.AlrmResByBms Alarm Reset BMS Command

OK/Reset Read_Writeable

Coil

7 Heating_Enable_1.Val

Heating Stage 1 BMS Enable

Off/On

Read_Writeable

Coil

98 OnOffUnitMng.BmsOnOff BMS On/Off Command

Off/On

Read_NoWrite

DiscreteInput 0 OA_Damp.Val

OA Damper Command

Closed/Open Read_NoWrite

DiscreteInput 1 RA_Damp.Val

RA Damper Command

Closed/Open Read_NoWrite

DiscreteInput 2 AlarmMng.AlrmRes

Alarm Reset Status

No/ Yes

Read_NoWrite

DiscreteInput 3 SF_Status.Val

SF Status from Current Sensor

Off/On

Read_NoWrite

DiscreteInput 4 EF_Status.Val

EF Status from Current Sensor

Off/On

Read_NoWrite

DiscreteInput DiscreteInput

5 Alarm_Out.Val 9 UnitOn

Serious Alarm (Also a physical output)
Unit On Status

OK /Alarm Off/On

Read_NoWrite Read_NoWrite

DiscreteInput 21 Al_SupplyFan.Active

Supply Fan Start Alarm

OK/Alarm Read_NoWrite

DiscreteInput 22 Al_ExhaustFan.Active

Exhaust Fan Start Alarm

OK/Alarm Read_NoWrite

DiscreteInput 12 Bypass_Damp.Val

Bypass Damper Command

Close/Open Read_NoWrite

DiscreteInput 20 Any_Alarm_Out.Val

Any Alarm is True Status

OK/Alarm Read_NoWrite

DiscreteInput 98 OA_Damp.Val

OA Damper Command

Closed/Open Read_NoWrite

HoldingRegister 0 RA_Flt_AlarmHigh

RA Filter Alarm Level

iwc

Read_Writeable (X)

HoldingRegister 2 OA_Flt_AlarmHigh

OA Filter Alarm Level

iwc

Read_Writeable (X)

HoldingRegister 4 SF_ConstSpeedSetP.Val

SF Const Speed Setpoint

%

Read_Writeable (X)

HoldingRegister 16 EF_ConstSpeedSetP.Val

EF Constant Speed Setpoint

%

Read_Writeable (X)

HoldingRegister 20 EF_SF_TrackingSetP.Val EF SF Tracking Setpoint

%

Read_Writeable (X)

HoldingRegister 98 RA_Flt_AlarmHigh

RA Filter Alarm Level

iwc

Read_Writeable (X)

InputRegister 0 OA_Temp.Val

OA Temperature

F

Read_NoWrite

InputRegister 2 OA_Hum.Val

OA Relative Humidity

%

Read_NoWrite

InputRegister 4 RA_Temp.Val

RA Temperature

F

Read_NoWrite

InputRegister 6 RA_Hum.Val

RA Relative Humidity

%

Read_NoWrite

InputRegister 8 EA_Temp.Val

EA Temperature

F

Read_NoWrite

InputRegister 10 SA_Temp.Val

SA Temperature (before tempering) F

Read_NoWrite

InputRegister 16 RA_Flt_Press.Val

RA Filter Pressure

iwc

Read_NoWrite

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TYPE InputRegister InputRegister InputRegister InputRegister InputRegister InputRegister InputRegister

VARIABLE

18 OA_Flt_Press.Val

20 SF_Command.Val

22 EF_Command.Val

98 OA_Temp.Val

42 SF_ControlType_BN

43 EF_ControlType_BN

50 UnitStatus_BN

DESCRIPTION OA Filter Pressure Supply Fan Command (actual) Exhaust Fan Command (actual) OA Temperature SF_ControlType_BN EF_ControlType_BN UnitStatus_BN

RANGE iwc % % F (See Notes) (See Notes) (See Notes)

READ/WRITE MODE (RET) Read_NoWrite Read_NoWrite Read_NoWrite Read_NoWrite Read_NoWrite Read_NoWrite Read_NoWrite

11.9 MODBUS APPLICATION NOTES
11.9.1 Turning the Unit On and OFF
If you plan to use the BMS to turn the unit on and off, make sure you have the control enabled through the keypad. Use Modbus Coil “OnOffUnitMng.BmsOnOff” at Coil 0. The status can be read at “UnitOn” at Discrete Input 9.

All of the following have to be true in order for the unit to be on: u There are no serious alarms. u The Digital Input for start/stop (terminals 17 and 18) are closed. u The unit is turned on at the keypad. u The time is within the scheduler “ON” time, if scheduler enabled. u The BMS has written the unit on signal, if BMS control is enabled.

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VALUE 1 2
3 4
5
6
8
9 13
14
15 16

UNITSTATUS_BN: INPUT REGISTER 50

STATUS

MEANING

Unit on

The unit is on and running.

Unit switched off due to The unit is off by a serious alarm. alarm

Unit switched off by BMS The unit is off by command from the BMS.

Unit switched off by time The unit is off by the scheduler. band

Unit switched off by digital The unit is off due to contacts across 17 and 18 open. input

Unit switched off from the The unit is off by the setting on the menu screen. local keypad

Exhaust Fan Only Mode

The unit is in single fan mode with exhaust fan running.

Supply Fan Only Mode The unit is in single fan mode with supply fan running.

Device Test

The system is in device test mode for more than an hour.

Sens Ovrd Active

The system has a sensor overwritten for more than 24 hours.

Off by CO2 Level

Off by CO2 Level.

Frost Control On

Frost Control Mode Active.

11.9.2 Alarms
Two general alarms are available: u Serious Alarm: Located at Discrete Input 5, “Alarm_Out.val” indicates whether there is a
serious alarm that stops the unit. u Any Alarm: Located at Discrete Input 20, “Any_Alarm_Out.val” indicates whether there is any
alarm present.
To reset the User Reset type alarms, set Coil 0 (or 98) “AlarmMng.AlrmResByBMS” to true. The program will set it back to false. You can view the status change through Discrete Input 2 “AlarmMng.AlrmRes.”

11.9.3 Temperature and Humidity Around the ERV

The following are available: u Input Register 0 “OA_Temp.Val” u Input Register 2 “OA_Hum.Val” u Input Register 4 “RA_Temp.Vall” u Input Register 6 “RA_Hum.Vall” u Input Register 8 “EA_Temp.Val” u Input Register 10 “SA_Temp.Vall”

EA

OA

SA

RA

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11.9.4 Fan Control The supply fan control type method can be viewed at Input Register 42 “SF_ControlType_BN.” The valid values are 0 = Constant Speed. The corresponding setting is as follows: u Constant Speed setpoint is Holding Register 4 “SF_ConstantSpeedSetP.Val The command to the fan is read at Input Register 20 “SF_Command.Val.” The feedback from the current sensor is read at Discrete Input 3 “SF_Status.Val.” The exhaust fan control type method can be viewed at Input Register 43 “EF_ControlType_BN.” The valid values are 1 = Constant Speed, 3 = SF Command Tracking, . The corresponding settings are as follows: u Constant Speed setpoint is Holding Register 16 “EF_ConstantSpeedSetP.Val” u Exhaust Fan Tracking setpoint is Holding Register 20 “EF_SF_TrackingSetP.Val” The command to the fan is read at Input Register 22 “EF_Command.Val.” The feedback from the current sensor is read at Discrete Input 4 “EF_Status.Val.” 11.9.5 BMS Direct Fan Control Available in ERV versions 03_00_26 ERV and higher. Normally we use the setpoints below for constant speed fan control. These are retained variables that are kept on power loss and should not be written to constantly. You will get an alarm error and/or damage the controller by doing so. Normal setpoint registers for constant speed fan control: u SF_ConstSpeedSetP.Val HR4 u EF_ConstSpeedSetP.Val HR16 The newer versions allow a BMS system to command directly to the speed control with a non-retained variable. This is done with systems where the BMS is writing to the value every program cycle. One example would be when they use their own pressure control loop and only write the output to the fan. The fan settings for supply and exhaust fan are independent. The user must set the control for that fan to constant speed control. The registers used for writing the fan control type are: u SF_ControlType_BN IR42 u EF_ControlType_BN IR43 They can also be set on these screens.
In order to use this feature, the settings must be set in this screen, located in the General Settings near the other BMS settings. The user must set the corresponding fan to “YES.”
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The registers used for direct writing the percentages are:

u BMS_SupplyFanCommand

HR70 expressed as 0-100%

u BMS_ExhaustFanCommand

HR72 expressed as 0-100%

In the screen above you will be able to see the value of these objects under “Current Value” for troubleshooting purposes.

The Control Setting Screen will no longer be available. Instead, the following screen(s) will be shown accordingly, with the current command shown being read-only on the screen.

11.9.6 Frost Control The frost control function is enabled when the OA is lower than Holding Register 64 “Defrost_ OA_SetP.Val” minus Holding Register 66 “Defrost_OA_SetP.DBright,” and turns off again when the OA exceeds the HR66. During this time the supply fan is off and the OA damper is closed.
11.9.7 Filter Monitoring Filter pressures are read through Input Register 16 “RA_FltPress.Val” and Input Register 18 “OA Flt _ Press.Val.” Filter alarm levels are set at Holding Register 0 (or 98) “RA_Flt_AlarmHigh” and Holding Register 2 “OA_Flt_AlarmHigh.”
11.9.8 Exhaust Fan Only Mode If BMS control is enabled, the unit can also be put in exhaust fan only mode in occupied operation using Coil 1 “UnitOnOffMng.BMSEFOnly.”

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12.0 ADVANCED SERVICE
This area gives advanced service information, as described. These screens are used infrequently.
12.1 RUN HOURS AND STARTS
For the ERV unit as well as each fan and compressor, if applicable, there is a screen that shows the run hours as well as the number of starts. This screen also lets you specify a threshold for alarm to alert that service is required and the ability to reset those numbers once service is performed.

12.2 LAST POWER LOSS
This screen gives information on the last time the unit was powered down as well as the length of time the unit was powered down for troubleshooting.

12.3 INTERNAL MEMORY WRITES
This screen gives information memory writes and the cycle speed of the applications. This would normally be used to give information to TSS, if requested.

12.4 ALARM INITIALIZATION
This screen will allow you to delete the alarm logs.

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12.5 MEMORY WIPE
This screen will allow to wipe retained values (most setpoints) and/or NVRAM (clock and IP settings). You should only use this screen if directed to do so by TSS.

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13.0 MAINTENANCE RECORDS
13.1 UNIT START UP CONDITIONS
This page is to be used to record all settings on the controller at the time of unit start up.

UNIT ID OR TAG:
13.1.1 Setpoints

NAME OF SETPOINT

VALUE

13.1.2 Offsets
NAME OF OFFSET

VALUE

13.1.3 IP Addresses
NAME OF COMPONENT
Controller

IP ADDRESS

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13.2 CHANGES MADE TO UNIT AFTER START UP
This page is to be used to record all user changes made to controller settings and indicate the reason for the change. In some cases, the reason for the change may be self-evident.
UNIT ID OR TAG:
13.2.1 Setpoints

NAME OF SETPOINT

NEW VALUE

13.2.2 Offsets
NAME OF OFFSET
13.2.3 I/O Configuration Changes

NEW VALUE

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13.3 CONTROLLER UPDATES
Anytime an updated controller program is provided by the factory and installed by the user, it should be recorded here:
DATE

13.4 SETTINGS BACKUP FILE
Use this space to record whether or not a backup has been performed to an external memory device (USB stick) and indicate where the USB stick is to be found.

Controller System Backup has been performed:

Yes

Type/ID of memory device:

Storage location of external memory device:

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REFERENCE ERV

14.0 REFERENCE
14.1 TUNING PI CONTROL LOOPS
For any heating or cooling device that has a variable output and uses a variable control signal (including HGRH), the desired action is for the heating/cooling device to reach the setpoint quickly and smoothly. The controller monitors a selected temperature sensor and any variation from the setpoint is considered “ERROR.” The controller senses the Error and sends a control signal (call for heat or call for cooling) to the heating/cooling device. This control signal is referred to as a “command.” For most variable output hardware, the command will be an analog 0­10VDC signal.
This controller uses PI programming to control the response to Error. PI programming uses two different types of settings to control the command; KP and Ti
KP = proportional gain u Responds directly to difference between setpoint and actual u Larger KP values will cause a greater output response and eventually will oscillate.
Ti = integral band u Responds to the accumulated difference between setpoint and actual u Larger Ti values will cause a slower output response, very small values eventually
will oscillate.

14.1.1 Proportional Constant (KP)
The Proportional Constant (KP) determines the strength of the command for any given error.
Example: the setpoint in a heating system is 72°F. The actual temperature is 71°F so the Error is 10°F, which requires very little heat from the heater. The controller sees there is an error and immediately sends a call for heat that starts at 0.1% strength and ramps up as needed, but the rate of increase tapers off as the Error decreases. The rate of increase is proportional to the amount of Error. When the controller senses that the Error is decreasing, it will slow the rate of increase of the command.
u When the Error is small, the rate of increase of the command is slow.
u When the Error is large, the rate of increase is greater (the command responds proportionally to the amount of Error).
The factory default KP setting for most heating and cooling devices is 1, which produces a low and slow response. If the response is too slow, the KP setting can be increased so that the command will be stronger and faster.
Example: when the KP setting is 1 and Ti is set for 30 (the factory defaults) and there is a 1°F Error, it takes about 50 seconds for the command to change by 10%. If the KP setpoint is changed to 10, it takes about 5 seconds for the command to change by 10%. For most installations, the KP value will have to be increased to speed up changes in the command signal to an acceptable level. Setting the KP value too high will result in the heater/cooler overshooting the setpoint constantly.
u If the KP value is too low, the command will change too slowly and the setpoint may take too long to reach.
u If the KP value is too high, the command will change to 100% too quickly and the setpoint will be over-shot. This results in the heating/cooling device switching “ON” and “OFF” constantly.

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14.1.2 Time Integral (Ti)
If the KP setting did not have some means of control, the resulting command signals would constantly over-shoot the setpoint. The Time Integral causes the controller to re-examine the amount of error at specific time intervals to see the amount of error remaining. Ti produces a damping effect on the KP value to reduce over-shooting the setpoint. Ti is an actual measure of time so that when the value is reduced, the frequency of sampling increases.
Example: the default Ti value is 30. If the value were changed to 15, sampling would occur twice as often. If the value were changed from 30 to 60, sampling would occur only half as often. If Ti were changed to 500, the result is that the sampling value would be insignificant and corrections to KP would not be happening. u If the Ti value is set too low (meaning that sampling is occurring too often), the increase
in the command signal will immediately begin to slow and keep getting slower because Ti is damping the KP value too much. u If Ti is set too high (sampling is not occurring often enough), the Command signal will overshoot the setpoint in both a negative and positive direction, causing short-cycling of the heating device.
DESIRED TEMPERATURE (SETPOINT)

“ERROR” EXISTING TEMPERATURE

When KP and Ti are both properly tuned, the controller Command signal will produce heat output that quickly and smoothly reaches the desired setpoint.
DESIRED TEMPERATURE (SETPOINT)

“ERROR” EXISTING TEMPERATURE

When KP is set too high, the controller Command signal responds too aggressively, causing the the heat output to overshoot the desired setpoint.
DESIRED TEMPERATURE (SETPOINT)

“ERROR” EXISTING TEMPERATURE

When KP is set too low, the controller Command signal is not aggressive enough and the heat output rises too slowly.

FIGURE 14.1.0 KP SETPOINT CHARTS

The process of adjusting KP and Ti to provide the most satisfactory controller output is known as tuning the controller. There are some sophisticated math equations that can be done to predict where the KP and Ti settings should be, but in the field, adjustment is normally done by a trial-and-error method. The KP setting is first adjusted and then the Ti setting is adjusted to manage the KP setting.
Tools needed: u Laptop computer to view the Heating screens and make adjustments to KP and Ti. u A stopwatch or watch with a second hand to monitor times. u Connect the laptop to the controller via ethernet.

Enhanced Commercial Controls

REFERENCE ERV

14.1.3 Establish a KP Setting
Use the KP Adjustment Chart to track and log test trials of different controller settings. Make copies of the adjustment charts, as needed. u Go to Main Menu > Unit Status > Heating. Note the temperature here. u Go to Main Menu > Control Settings> Heating. u Set the KP value at 5. u Set the Ti value at 500. This will make the sampling frequency so low that it is essentially of
no consequence and permits adjustment of KP without being affected by Ti.
u Set the setpoint for 20°F warmer than the current temperature as noted above. (Change the setpoint last because the controller will immediately respond to the setpoint change, using the KP and Ti settings that it currently has.)
u Click the “ENTER” button and then immediately go back to Main Menu > Unit Status > Heating.
View the Command and Temperature lines on the screen and enter the data at each time interval that was selected.
When the trial is complete, view the Command line on the chart to see how quickly it ramps up to 100%. If the Command percentage is rising too slowly, increase the KP value and run the trial again. The Command percentage should reach 100% (or very nearly) within 2­4 minutes.
Repeat the process, but move the heating setpoint 20°F lower than the current temperature and change the KP value to a larger value, possibly 10 or 15 larger than the previous trial.
Make data entries on the KP Adjustment Chart (following page) to help track changes to the KP settings. Select the most appropriate KP setting.
14.1.4 Establish a Ti Setting
u Leave the KP value as found above. u Set the Ti value at the default value of 30. For each trial, increase the Ti setting. u Follow the same process as described above. Repeat the trials until the smoothest response
is found that does not cause over-shooting or oscillation of the heating command.
14.1.5 Verify the Combined KP and Ti Settings
When both KP and Ti have been set, run one final trial with the KP and Ti settings at their new values and record the results in the final chart. This ensures that the results are repeatable. Temperature and Command readings are obtained from Main Menu > Unit Status > Heating
For Elapsed Time, select a convenient amount of time to allow between readings (example: 30 seconds).
In the first column of each trial, fill in the starting data for the trial.

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DEVICES BEING ADJUSTED

KP SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

KP Adjustment Trial 1

KP SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

KP Adjustment Trial 2

KP SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

KP Adjustment Trial 3

KP SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

KP Adjustment Trial 4

FIGURE 14.1.1 KP ADJUSTMENT WORKSHEET

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DEVICES BEING ADJUSTED

Ti SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

Ti Adjustment Trial 1 KP Setting for all Trials

Ti SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

Ti Adjustment Trial 2

Ti SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

Ti Adjustment Trial 3

Ti SETTING HEATING SETPOINT
T EMP ER AT U R E COMMAND PERCENTAGE
ELAPSED TIME 0

Ti Adjustment Trial 4

FIGURE 14.1.2 TI ADJUSTMENT WORKSHEET

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°C
-50.0 -49.0 -48.0 -47.0 -46.0 -45.0 -44.0 -43.0 -42.0 -41.0 -40.0 -39.0 -38.0 -37.0 -36.0 -35.0 -34.0 -33.0 -32.0 -31.0 -30.0 -29.0 -28.0 -27.0 -26.0 -25.0 -24.0 -23.0 -22.0 -21.0 -20.0 -19.0 -18.0 -17.0 -16.0 -15.0 -14.0 -13.0 -12.0 -11.0 -10.0

°F
-58.0 -56.2 -54.4 -52.6 -46.0 -49.0 -47.2 -45.4 -43.6 -41.8 -40.0 -38.2 -36.4 -34.6 -32.8 -31.0 -29.2 -27.4 -25.6 -23.8 -22.0 -20.2 -18.4 -16.6 -14.8 -13.0 -11.2 -9.4 -7.6 -5.8 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0

K
329.20 310.70 293.30 277.00 261.80 247.50 234.10 221.60 209.80 198.70 188.40 178.30 168.90 160.10 151.80 144.00 136.60 129.70 123.20 117.10 111.30 105.70 100.40 95.47 90.80 86.39 82.22 78.29 74.58 71.07 67.74 64.54 61.52 58.66 55.93 53.39 50.96 48.65 46.48 44.41 42.25

14.2 TEMPERATURE SENSOR CURVE
Only sensors with this Carel curve should be used with this system.

°C
-9.0 -8.0 -7.0 -6.0 -5.0 -4.0 -3.0 -2.0 -1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0

°F
15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.0 80.6 82.4 84.2 86.0 87.8

K
40.56 38.76 37.05 35.43 33.89 32.43 31.04 29.72 28.47 27.23 26.13 25.

References

• ABB Drives
• Lenze in the Americas

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