OAS 2.5 User Manual (Final).pdf

OAS

2.5 Version 2/19/2018

OAS

2.5

User’s Guide

OAS

2.5 User’s Manual

Table of Contents

General Information

Manufacturer

Definitions

Quick Reference

Installation

5.1 Physical Installation

5.2 Electrical Requirements

5.3 Connections

Operation

6.1 Introduction

6.2 User Inputs

6.3 System Status Lights

6.4

Operational States

6.5

Sequence of Operations

Troubleshooting

Parts List

Schematics

Appendixes

A Thermostat Setup

B

OAS

Functional Test

OAS

2.5 User’s Manual

Table of Contents

General Information

Manufacturer

Definitions

Quick Reference

Installation

5.1 Physical Installation

5.2 Electrical Requirements

5.3 Connections

Operation

6.1 Introduction

6.2 User Inputs

6.3 System Status Lights

6.4

Operational States

6.5

Sequence of Operations

Troubleshooting

Parts List

Schematics

Appendixes

A Thermostat Setup

B

OAS

Functional Test

OAS

2.5 User’s Manual

General Information:

This user manual is intended to accompany the

OAS

2.5

HVAC

Controller.

The

OAS

HVAC

controller is a

FAA

designed

HVAC

controller for use at critical

FAA

facilities that require reliable redundant

HVAC

control.

The

OAS

is a simple yet robust control system which captures specific operational criteria important to

NAS

equipment.

Some of these features are listed below:

1. Redundant control of

HVAC

Units

2. Primary Unit Selection

3. Adjustable Set Points

4. Automatic Unit Switch Over

5. System Status Lights

6. Audible and Visual Alarms

7. Audible Alarm Silence

8. Simplified Troubleshooting

9. Commercially Available Replacement Parts

10. Ease of Use and Reparability

11. ERMS

compatibility

Manufacturer Information:

The

OAS

2.5 was designed by

NDP

Infrastructure Engineering (Jonathan Salter, 202.744.1408) and manufactured by:

The

FAA

National Staging Area

(AJW-‐2C15P)

S.

Geospace Dr

Independence, MO

64056

Ph:

(816) 329-‐3970 http://stagingarea.faa.gov

OAS

2.5 User’s Manual

Definitions:

Dehumidify

The mechanical process of reducing the air humidity.

OAS

Overtemp Automated System

FAA

specific controller that provides control to a Unit, fully redundant

HVAC

system.

These systems are typically associated with unoccupied electrical equipment rooms.

Overtemp Condition where the room temperature becomes greater than what is considered acceptable for a normally operating

HVAC

Unit.

An Overtemp situation indicates that the selected

HVAC

Unit is not functioning properly.

Set Point

The manually inputted temperature setting for an associated thermostat.

Relay

Electronic device that when activated, allows current to pass through.

Room Temperature Actual Current Temperature of the Equipment Room as measured by the

OAS.

OAS

2.5 User’s Manual

OAS

Quick Reference:

Figure 1:

OAS

Quick Reference

Alarm:

Red Visual

Alarm Light and

Audible Alarm

System Status Lights

Indicate the presence of Control Power and a call for operation for both

HVAC

Units

Room Temperature

Control Thermostat

(T1) Provides Control to the Active

HVAC

Unit.

Setpoint input for the desired room temperature

Room Overtemp

Thermostat (T2)

Setpoint input for the overtemp switchover

Primary Unit Selector

Switch Manual control point for the selection of the desired primary Unit

Audible Alarm Silence

When the controller is in Alarm, this button silences the audible alarm tone.

Overtemp Reset

Button Resets the

Controller from an

Alarm

OAS

2.5 User’s Manual

Installation:

5.1 Physical Installation:

The

OAS

is contained within a 10”x16”x5” electrical box.

The box contains mounting holes for attaching the box to a supporting wall or stand.

The controller should be mounted at chest level in a central location where the ambient temperature is representative of the room.

Locating the unit on an uninsulated outside wall, near equipment exhaust, or in a stagnant air area may cause the system to operate inefficiently.

If space is not available for the

OAS

in a preferred location, a separate remote temperature sensor option can be added.

of these sensors are required, one for each thermostat on the

OAS.

The sensors must be setup within the thermostat settings.

Use of remote sensors should be limited to the greatest extent possible.

Buttons, thermostats and switches shall be accessible and warning light shall be generally visible within the associated room.

Allow for 3’ of clearance from the face of the control box per the latest revision of the

NEC.

5.2 Electrical Requirements:

All requirements of the most current revisions of

FAA-‐STD-‐19

and

FAA-‐C-‐1217

shall be followed.

All associated control wires run between the Controller and

HVAC

Units shall be contained within conduits.

Any outdoor conduit runs shall be rigid type with threaded connections or liquid-‐tite flexible conduit.

The

OAS

is powered by low voltage

24VAC,

supplied by the associated

HVAC

Units.

To fully isolate power from the controller, each

HVAC

must be electrically disconnected.

The

OAS

does not require a separate power circuit and the only energized power within the controller will be the

24VAC

provided from the

HVAC

Units.

Warning:

When attaching or changing wired connections within the

OAS,

ensure power is electrically isolated from

BOTH

HVAC

Units.

Failure to do so may cause sparks, damage to the

OAS,

damage to the

24VAC

Transformers in the

HVAC

units, and/or personal injury.

OAS

2.5 User’s Manual

Installation:

5.1 Physical Installation:

The

OAS

is contained within a 10”x16”x5” electrical box.

The box contains mounting holes for attaching the box to a supporting wall or stand.

The controller should be mounted at chest level in a central location where the ambient temperature is representative of the room.

Locating the unit on an uninsulated outside wall, near equipment exhaust, or in a stagnant air area may cause the system to operate inefficiently.

If space is not available for the

OAS

in a preferred location, a separate remote temperature sensor option can be added.

of these sensors are required, one for each thermostat on the

OAS.

The sensors must be setup within the thermostat settings.

Use of remote sensors should be limited to the greatest extent possible.

Buttons, thermostats and switches shall be accessible and warning light shall be generally visible within the associated room.

Allow for 3’ of clearance from the face of the control box per the latest revision of the

NEC.

5.2 Electrical Requirements:

All requirements of the most current revisions of

FAA-‐STD-‐19

and

FAA-‐C-‐1217

shall be followed.

All associated control wires run between the Controller and

HVAC

Units shall be contained within conduits.

Any outdoor conduit runs shall be rigid type with threaded connections or liquid-‐tite flexible conduit.

The

OAS

is powered by low voltage

24VAC,

supplied by the associated

HVAC

Units.

To fully isolate power from the controller, each

HVAC

must be electrically disconnected.

The

OAS

does not require a separate power circuit and the only energized power within the controller will be the

24VAC

provided from the

HVAC

Units.

Warning:

When attaching or changing wired connections within the

OAS,

ensure power is electrically isolated from

BOTH

HVAC

Units.

Failure to do so may cause sparks, damage to the

OAS,

damage to the

24VAC

Transformers in the

HVAC

units, and/or personal injury.

OAS

2.5 User’s Manual

5.3 Connections:

The

OAS

controller has connections identical to most modern thermostats, and therefore wiring the controller is similar.

Each installation may vary slightly, however the basic premise remains the same.

Inside the box, there are separate terminal strip areas, one for each unit.

They should appear similar to the picture below:

Figure 2:

OAS

Wiring Terminals

These connections are in accordance with industry standard, and are compatible with the vast majority of

HVAC

equipment.

The symbols are defined below for reference:

Symbol Description Standard Wire Color

R Control Power

(24VAC)

from associated

HVAC

Unit Red

Y1 Stage Cooling, control point Yellow

Y2 Stage Cooling, control point Blue

W Heat, control point White

G Fan (Supply Air Blower) Green

C Common or Neutral Brown

Wire colors and symbols may vary slightly depending on manufacturer

A single line diagram is shown on the next page for a simple packaged unit installation.

Each facility should be provided with a site specific control drawing that depicts the actual configuration.

The diagram contained in this manual shall be used for reference only.

Unit

Connections

Unit

Connections

OAS

2.5 User’s Manual

Figure 3:

Typical Control Wiring

OAS

2.5 User’s Manual

Operation:

6.1 Introduction:

The

OAS

is delivered configured, tested, and ready for the operation of a Unit, fully redundant, dual stage, cooling only, HVAC

System.

However, if a thermostat is replaced or for some other reason the thermostat needs to be reset, the required parameters are provided in “Appendix A” to assist in reprograming.

The

OAS

utilizes the Honeywell VisionPro Thermostat.

This model has a touch screen, and provides various capabilities that allow the

OAS

to be more robust and flexible while also providing a simple operational interface.

The diagram below explains the basic operation of this thermostat:

Figure 4:

Thermostat Quick Reference

Heating:

If the associated

HVAC

system includes heat, the

SYSTEM

setting on T1 (upper thermostat) only can be changed to “Auto”.

In this setting, the

OAS

will provide automatic switchover from cooling and heating as needed on the active unit.

The T2

(lower thermostat)

SYSTEM

setting must always be set to “Cool” regardless of the system configuration.

Current

Temperature

FAN

Menu Sets fan mode.

Set to

“On”

SYSTEM

Menu

Sets System

Setting.

Default is

“Cool”

Current System

Mode

Set Point

Adjusted with Up

Down Arrows

OAS

2.5 User’s Manual

6.2 User Inputs:

The

OAS

Controller has basic inputs:

Room Set Point The Desired Room Temperature To set, adjust the set point of the T1 (upper) thermostat.

This will be the temperature that the

OAS

will try to maintain the room at within a few degrees.

Recommended Set Point:

70°

Overtemp Set Point The Unit Failure Temperature To set, adjust the set point of the T2 (lower) thermostat.

This will be the temperature where the controller assumes the selected primary unit has failed, and will switch to the back-‐up unit.

Recommended Set Point:

80°

Primary Unit Selection The Unit that will operate as Primary To set, move the selector switch to the desired unit number.

Whichever unit is selected will be the operational unit unless the

OAS

is in Alarm.

To ensure similar run times on both

HVAC

Units, this selector switch should be toggled at regular intervals.

Recommended Interval:

Monthly

Care should be taken in selecting the Room and Overtemp Set Points.

Selecting a Room Temperature that is too low may result in Unit failure.

Additionally, selecting an Overtemp Temperature that is too close to the Room Temperature set point may cause the

OAS

to alarm during normal operation.

To prevent these issues, do no set the Room Temperature below 68°, and ensure the Overtemp Set Point is at least 6° higher than the Room Set Point.

6.3 System Status Lights:

There are status lights on the

OAS

which are intended to provide quick visual information to the user.

The lights are split up by

HVAC

Units so there are statuses shown per unit.

An illuminated power light indicates that the associated

HVAC

Unit is providing control voltage.

An illuminated Run Light indicates that the associated

HVAC

unit is active.

This light does not indicate that the unit is actually cooling, only that if cooling is called for, this is the unit that should cool.

Under normal operation, the Power lights for each unit should be illuminated, and the

Run light for the selected primary unit should be illuminated.

UNIT

UNIT

POWER

RUN

OAS

2.5 User’s Manual

6.4 Operational States:

Normal Operation:

The T1 (upper) thermostat will control the selected primary unit directly.

Only the primary unit will be allowed to run and maintain the room at the Room Set

Point.

Unit Failure:

If the primary unit fails for any reason, it will not be able to maintain the Room

Set Point.

Once the room temperature climbs above the Overtemp Set Point, the

OAS

will alarm.

During alarm, a red light will illuminate on top of the controller, the Alarm

Silence button will illuminate, and a loud alarm tone will sound from the controller.

When in alarm, the

OAS

will shutdown the selected primary unit, and T1 will begin controlling the back-‐up unit directly.

Only the back-‐up unit will be allowed to operate.

Since T1 is now controlling the back-‐up unit, the room temperature should return back to the Room Set Point.

Alarm Silence

To silence the audible alarm, press the Alarm Silence button once.

The red alarm light on the top of the controller and the light in the Alarm Silence button will remain illuminated.

Reset:

To reset the

OAS

controller from an alarm condition, press the Reset Button.

This will resume normal operation of the

OAS

controller.

If the room temperature is above the Overtemp Set Point, the Reset button will not function.

The room temperature must be below the Overtemp Set Point to reset.

Note:

The

OAS

does not monitor specific conditions in each

HVAC

unit and an alarm only indicates that the

Temperature in the room exceeded the Overtemp Set Point while the selected primary unit was active.

Upon an alarm, a technician should perform a deeper evaluation into why the selected unit was not able to maintain the Room Set Point.

OAS

2.5 User’s Manual

6.4 Operational States:

Normal Operation:

The T1 (upper) thermostat will control the selected primary unit directly.

Only the primary unit will be allowed to run and maintain the room at the Room Set

Point.

Unit Failure:

If the primary unit fails for any reason, it will not be able to maintain the Room

Set Point.

Once the room temperature climbs above the Overtemp Set Point, the

OAS

will alarm.

During alarm, a red light will illuminate on top of the controller, the Alarm

Silence button will illuminate, and a loud alarm tone will sound from the controller.

When in alarm, the

OAS

will shutdown the selected primary unit, and T1 will begin controlling the back-‐up unit directly.

Only the back-‐up unit will be allowed to operate.

Since T1 is now controlling the back-‐up unit, the room temperature should return back to the Room Set Point.

Alarm Silence

To silence the audible alarm, press the Alarm Silence button once.

The red alarm light on the top of the controller and the light in the Alarm Silence button will remain illuminated.

Reset:

To reset the

OAS

controller from an alarm condition, press the Reset Button.

This will resume normal operation of the

OAS

controller.

If the room temperature is above the Overtemp Set Point, the Reset button will not function.

The room temperature must be below the Overtemp Set Point to reset.

Note:

The

OAS

does not monitor specific conditions in each

HVAC

unit and an alarm only indicates that the

Temperature in the room exceeded the Overtemp Set Point while the selected primary unit was active.

Upon an alarm, a technician should perform a deeper evaluation into why the selected unit was not able to maintain the Room Set Point.

OAS

2.5 User’s Manual

6.5 Sequence of Operation:

OAS

2.5 User’s Manual

Troubleshooting:

Problem

Check Condition Potential Cause Corrective Action

Power light is not illuminated for a unit.

(If power light is not illuminated for the backup unit, make the backup unit the primary and perform these steps.

If the power light illuminates in only one mode, perform the

System Test in App B)

• 24VAC

present at the R terminal for the associated

Unit?

• 24VAC

is present at R terminal

• Lose Connection

Check

Connections within the

OAS

to ensure there are no loose wires or short circuits

• Tighten and/or secure loose connections as needed.

• Bad Relay

Perform System

Test in Appendix B to ensure all

Relays are operational

• Replace Defective

Relay (see parts list)

• Bad

LED

Check

LED

operation by applying

24VAC

across contacts.

• Replace

LED

bulb

(see parts list)

• 24VAC

is not present at R terminal

• Unit is electrically isolated.

• Check breakers and disconnects for the associated Unit.

• Check Associated

Unit Control

Power

24VAC

output

Measured between terminals R and C terminals in the

Unit.

• Check control transformer for a fuse or built in circuit breaker.

If no

CB

or fuse are present, and transformer is not outputting

24VAC,

Replacement of the transformer may be required.

Run light is not illuminated for the selected unit.

• Is

OAS

is in Alarm?

OAS

is in Alarm.

• When in Alarm, the “Run Light” should be illuminated for the back-‐up Unit and not the selected Unit.

• Reset

OAS

and troubleshoot the selected unit.

• Is the

FAN

setting on T1 set to “On”?

• FAN

Setting set to

“Auto”.

• The Run light is tied directly to the call for indoor fan.

In “Auto” setting, the Run light will only illuminate during a call for cooling.

• It is recommended that the fan be run continuously on the active Unit.

Change

T1

FAN

Setting to

“On”.

FAN

Setting set to

“On”

• Bad

LED

Check

LED

operation by applying

24VAC

across contacts.

• Replace

LED

bulb

(see parts list)

OAS

2.5 User’s Manual

Problem Check Condition Potential Cause Corrective Action

Sporadic clicking sounds while opening the

OAS

Panel

N/A

• Relays are engaging/disengaging randomly as

OAS

door is moving.

• Short or loose connection in

Wiring Bundle between panel door and relay board

• Inspect for loose connections and repair as needed.

• Request

Replacement

Controller from

Staging Area.

OAS

is in Alarm and will not reset

Is Room

Temperature above

Overtemp Setpoint

(T2)?

• Room Temperature is above Overtemp

Setpoint.

• OAS

Alarm cannot be reset when the conditions would immediately put it back into Alarm.

• Alternate Units, ventilate, and/or add temporary cooling to bring down the room temperature.

• Room Temperature is below Overtemp

Setpoint.

• T2 may be in a time delay function

• Allow some time for T2 to reset (5 minutes max) and retry.

Upper thermostat

(T1) isn’t functioning.

Is the Power Light illuminated for the selected unit?

• Power Light is On

• Bad Thermostat or other

OAS

Component

Perform System

Test in Appendix B to ensure all components are operational

• Replace Defective part (see parts list)

• Power Light is Off

• OAS

is not receiving control power from the selected unit.

• Perform troubleshooting steps for “Run light is not illuminated for the selected unit.”

above.

Lower thermostat

(T2) isn’t functioning.

Is the Power Light illuminated for the back-‐up unit?

• Power Light is On

• Bad Thermostat or other

OAS

Component

Perform System

Test in Appendix B to ensure all components are operational

• Replace Defective part (see parts list)

• Power Light is Off

• OAS

is not receiving control power from the backup unit.

• Perform troubleshooting steps for “Run light is not illuminated for the selected unit.”

above.

OAS

2.5 User’s Manual

Problem Check Condition Potential Cause Corrective Action

Sporadic clicking sounds while opening the

OAS

Panel

N/A

• Relays are engaging/disengaging randomly as

OAS

door is moving.

• Short or loose connection in

Wiring Bundle between panel door and relay board

• Inspect for loose connections and repair as needed.

• Request

Replacement

Controller from

Staging Area.

OAS

is in Alarm and will not reset

Is Room

Temperature above

Overtemp Setpoint

(T2)?

• Room Temperature is above Overtemp

Setpoint.

• OAS

Alarm cannot be reset when the conditions would immediately put it back into Alarm.

• Alternate Units, ventilate, and/or add temporary cooling to bring down the room temperature.

• Room Temperature is below Overtemp

Setpoint.

• T2 may be in a time delay function

• Allow some time for T2 to reset (5 minutes max) and retry.

Upper thermostat

(T1) isn’t functioning.

Is the Power Light illuminated for the selected unit?

• Power Light is On

• Bad Thermostat or other

OAS

Component

Perform System

Test in Appendix B to ensure all components are operational

• Replace Defective part (see parts list)

• Power Light is Off

• OAS

is not receiving control power from the selected unit.

• Perform troubleshooting steps for “Run light is not illuminated for the selected unit.”

above.

Lower thermostat

(T2) isn’t functioning.

Is the Power Light illuminated for the back-‐up unit?

• Power Light is On

• Bad Thermostat or other

OAS

Component

Perform System

Test in Appendix B to ensure all components are operational

• Replace Defective part (see parts list)

• Power Light is Off

• OAS

is not receiving control power from the backup unit.

• Perform troubleshooting steps for “Run light is not illuminated for the selected unit.”

above.

OAS

2.5 User’s Manual

Parts List:

QTY

Description Make/Model Part No

EA

Thermostat Honeywell VisionPro

HW-‐TH8321-‐R1001

AS

Selector Switch Eaton Switch

EA

10250T3011

Contact

EA

10250T1

EA

Indicator Lights Grainger 24M067

AS

Push Button (Alarm Silence)

ABB

Button

EA

MP1-‐31R

Contact

EA

MCBH-‐01

LED

EA

MLBL-‐01R

AS

Push Button (Reset)

ABB

Button

MP1-‐30R

Contact

MCBH-‐01

EA

Relay

IDEC

RH-‐4B-‐UL

AC24V

Optional Parts:

QTY

Description Make/Model Part No

EA

Wireless Remote Sensors Honeywell C7189R

OAS

2.5 User’s Manual

Schematics:

OAS

2.5 User’s Manual

OAS

2.5 User’s Manual

Appendix A

Appendix A

T1 (Top):

Installer Setup:

Application Commercial Thermostat Name Thermostat Zoned No Equipment Module No Connect Redlink No Installer Setup

NEXT

Thermostat Type Non-‐ Programmable Temperature Scale Fahrenheit Outdoor Air Sensor No Heating System None (Cool Only) Cooling Stages A-‐L/A Terminal None Control Options Basic Cool/Compressor

CPH

Stg Cool/Compressor

CPH

Stg Compressor Off time Off Extended Fan Run Time in Cool Off Min Cool Setpoint Keypad Lockout Unlocked Wired Sensor on S Terminal No Filter Type:

Media Number of Filters Air Filter Reminder Off Humidifier Type None Humidifier Pad Reminder Off Dehumidifier None Defumidifier Filter Reminder Off Ventilation Type None Ventilation Filter Reminder Off Number of

UV

Devices None Custom Reminder

NEXT

Backlighting On Demand Clock Format 12hr Daylight Savings Time Off Indoor Temp Offset Indoor Humidity Offset Alert Light Indicator On Dealer Name

NEXT

Dealer Phone

NEXT

Dealer Email

NEXT

Dealer Website

NEXT

Dealter Message

NEXT

DONE

Exit Installer Setup

YES

T2 (Bottom):

Installer Setup:

Application Commercial Thermostat Name Thermostat Zoned No Equipment Module No Connect Redlink No Installer Setup

NEXT

Thermostat Type Non-‐ Programmable Temperature Scale Fahrenheit Outdoor Air Sensor No Heating System None (Cool Only) Cooling Stages A/L/A Terminal Off Control Options Basic Cool/Compressor

CPH

Stg Compressor Off time Off Extended Fan Run Time in Cool Off Min Cool Setpoint Keypad Lockout Unlocked Wired Sensor on S Terminal No Filter Type:

Media Number of Filters Air Filter Reminder Off Humidifier Type None Humidifier Pad Reminder Off Dehumidifier None Defumidifier Filter Reminder Off Ventilation Type None Ventilation Filter Reminder Off Number of

UV

Devices None Custom Reminder

NEXT

Backlighting On Demand Clock Format 12hr Daylight Savings Time Off Indoor Temp Offset Indoor Humidity Offset Alert Light Indicator On Dealer Name

NEXT

Dealer Phone

NEXT

Dealer Email

NEXT

Dealer Website

NEXT

Dealter Message

NEXT

DONE

Exit Installer Setup

YES

Main Screen Settings:

SYSTEM:

COOL

FAN:

ON

OAS

2.5 User’s Manual

B

Appendix B

Relay Operation Check:

Note:

This test confirms the proper operation of the

OAS

controller.

This test is best performed using isolated

24VAC

power sources as shown below.

Test can be performed using control power from the

HVAC

Units, but this test will cause non-‐continuous operation of the units, so care must be taken to ensure the equipment space remains at a desirable temperature.

During Test, note any inconsistencies from the expected checks and utilize this information for troubleshooting faulty components or other issues.

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B

OAS

2.5 User’s Manual

B