EngA DJM3 Instructions de montage

IOM‐17WWW.ENGINEEREDAIR.COMMAR99R3

USER OPERATION

MANUAL

FOR

DJM3

INDIRECT FIRED HEATING CONTROLLER

UNIT MODEL NO. _________________

UNIT SERIAL NO. _________________

SERVICED BY: ___________________

TEL. NO: ________________________

CANADIAN

HEAD OFFICE

AND FACTORY

USA

HEAD OFFICE

AND FACTORY

CANADIAN

EASTERN FACTORY

1401 HASTINGS CRES.

CALGARY, ALBERTA

T2G 4C8

Ph: (403) 287-2590

Fax: 888-364-2727

32050 W. 83r

STREET

DESOTO, KANSAS

66018

Ph: (913) 583-3181

Fax: (913) 583-1406

1175 TWINNEY DRIVE

NEWMARKET,

ONTARIO

L3Y 5V7

Ph: (905) 898-1114

Fax: (905) 898-7244

SALES OFFICES ACROSS CANADA AND USA

Retain instructions with unit and maintain in a legible condition.

Please give model number and serial number when contacting

factory for information and/or parts.



A DJM3

IOM-17 2 of 27 Mar 99 R3



DJM3



TheDJM3hasbeencertifiedbyIntertek(ETL)forusewithEngineeredAirappliancesonly.Ithasbeen

evaluatedtoCSAC22.2No.24Temperature‐IndicatingandRegulatingEquipmentandUL873UL

StandardforSafetyTemperature‐IndicatingandRegulatingEquipment.ThisisaUserOperation

Manualandthereforenotsubjecttoevaluation.



IfanyerrorsoromissionsarenotedpleasecontactthenearestEngineeredAirTechnicalService

Department.



Toensurewarrantyishonored,onlyqualifiedpersonnelshouldbeemployedforserviceand

troubleshooting.IffurtherinformationisrequiredpleasecontactthenearestEngineeredAiroffice.



Therearetwosetsofelectricaldrawingsandunitfunctionsheetsprovidedwiththeappliance.Oneset

isinanenvelopewhichalsocontainstheOperation,InstallationandMaintenancemanual(s).This

packageisforcopying,thenshouldeitherbereturnedtotheapplianceorstoredinasafeplace.The

othersetisattachedtothecontrolpaneldoorandshouldneverberemoved.



Pleasereportanyomissionstothenationalservicemanager.



Warning:



Improperinstallation,adjustment,alteration,serviceormaintenancecancause

propertydamage,injuryordeath.Readtheinstallation,operatingand

maintenanceinstructionsthoroughlybeforeinstallingorservicingthisequipment.



Warning: Thisunitisconnectedtohighvoltages.Electricalshockordeathcouldoccurif

instructionsarenotfollowed.Thisequipmentcontainsmovingpartsthatcanstart

unexpectedly.Injuryordeathcouldoccurifinstructionsarenotfollowed.All

workshouldbeperformedbyaqualifiedtechnician.Alwaysdisconnectandlock

outpowerbeforeservicing.DONOTbypassanyinterlockorsafetyswitchesunder

anycircumstances.





A DJM3

IOM-17 3 of 27 Mar 99 R3

A DJM3

IOM-17 4 of 27 Mar 99 R3

TABLEOFCONTENTS



INTRODUCTION...............................................................................................................................................................5

CONTROLLERRATINGS.....................................................................................................................................................5

CONTROLLERDESCRIPTION..............................................................................................................................................6

TERMINALS..................................................................................................................................................................................6

DIPSWITCHES..............................................................................................................................................................................7

INDICATIONANDDIAGNOSTICLIGHTS........................................................................................................................................7

ADJUSTMENTPOTS......................................................................................................................................................................8

MULTIMETERTESTPOINTS..........................................................................................................................................................9

SYSTEMTIMINGS.........................................................................................................................................................................9

TEMPERATURECONTROL.................................................................................................................................................9

CALCULATEDSETPOINT(SPC)......................................................................................................................................................9

DISCHARGETEMPERATURESENSOR(DTEMP)..........................................................................................................................10

MODULATINGROOMRESET......................................................................................................................................................10

MultipleRoomSensors....................................................................................................................................................11

ROOMRESETAUTHORITYTABLE...............................................................................................................................................11

BMSRESET.................................................................................................................................................................................12

AMBIENTRESET(CONTINUOUSBLOWEROPERATIONONLY).................................................................................................................12

MAKE/BREAKRESETANDOVERRIDE...........................................................................................................................................13

“OR”and“V”Override(DayOperationonly)..................................................................................................................13

“X”and“Z”Override(DayandNightOperation).............................................................................................................13

OPERATION...................................................................................................................................................................14

DAY/NIGHTOPERATION...........................................................................................................................................................14

FANCONTROL............................................................................................................................................................................14

DAMPERCONTROL....................................................................................................................................................................14

BURNERCONTROL.....................................................................................................................................................................14

LOWLIMIT..................................................................................................................................................................................15

ResettingLowLimit..........................................................................................................................................................15

SERVICE.........................................................................................................................................................................15

SERVICEMODE...........................................................................................................................................................................15

BURNERSETUP..........................................................................................................................................................................15

TEMPERATURECONTROL..........................................................................................................................................................22

AIRBALANCING..........................................................................................................................................................................22

PRE‐PURGEPROBLEM................................................................................................................................................................22

INDUCEDVOLTAGEONREMOTECONTROLWIRING..................................................................................................................23

CALIBRATION.................................................................................................................................................................23

DISCHARGESENSOR........................................................................................................................................................................23

DISCHARGESETPOINTCALIBRATION...................................................................................................................................................23

ROOMSENSORCALIBRATION............................................................................................................................................................23

BMSSIGNALCALIBRATION...............................................................................................................................................................24

SENSORTABLE...........................................................................................................................................................................24

FANOPERATIONFLOWCHART........................................................................................................................................25

HEATOPERATIONFLOWCHART......................................................................................................................................26

UPGRADINGDJM3.2OR3.3TODJM3.4.........................................................................................................................26

A DJM3

IOM-17 5 of 27 Mar 99 R3

INTRODUCTION



TheDJM3isanindependentcontrollerforEngineeredAirDJstylegasfiredheatingequipment

designedtoprovidethemajorityofcontrolrequirements.TheDJM3modulatesavariablespeed

combustionblowerinconjunctionwithanmodulatinggasvalve.Thecombustionblowerspeedand

thegasvalveflowratearebothmodulatedtomaintaintherequireddischargeairtemperature.



Theinformationusedinthismanualshouldbeusedinconjunctionwiththeunitfunctionsheet(s)and

theDJ(E,S)&DGorDJXseriesInstallation,Operation,andMaintenancemanuals.



TheDJM3isdesignedtocontrolonlyEngineeredAirequipment.Variousupgradesandimprovements

havebeenmadeovertime.Alwaysincludeanysuffixlettersandnumbersfortroubleshootingand/or

replacement.



Note:Itisnecessarythatalloftheremotewiringandcontrolsbecompleteandoperationalbefore

startingtheappliance.



CONTROLLERRATINGS



Powerrequirements:24Vac,40VA.

ContactRating:120V5Ainductive

0‐10Vdcinputimpedance:2k

Environment:‐40to120°F(‐40to50°C)non‐condensing.

FuseRating:1.5GDCslow‐blow



A DJM3

IOM-17 6 of 27 Mar 99 R3

CONTROLLERDESCRIPTION



TERMINALS

TABLE1

Terminal Description

T1 Boardpowersupply.(HOT)24Vacisolated.

T2 Boardpowersupply.(NEUTRAL)24Vacisolated.

FS Fanswitch(orDaymode)enableinput(24Vac).

K Night(unoccupied)modeenableinput(24Vac).

HS Heatenableinput(24Vac).

N Grounded24Vacneutral(referencetoFS,K,HS).

DM1,DM2 Dampermotoroutputcontacts(dry).

FR,CFR Flamerelayoutputcontacts(dry).

AL Alarmoutput.

C Contactcommoninputpower(toALandSA).

SA Supplyairfanenableoutput.

CB1 Combustionblowermotorinput.

CB2 Combustionblowermotorspeedcontroloutput.

PV1,PV2 Pilotvalvedisablecontact(dry).

VFB120 Maingasvalvefeedback(SSOV)hotinputfor120Vvalves.

VFB24 Maingasvalvefeedback(SSOV)hotinputfor24Vvalves.

VN Maingasvalvefeedback(SSOV)neutralinput.

MX1,MX2 Modulatingvalveoutput.(DCvolts)

VS Legacyinput.Notused.

OS,GS,YS Combustionblowerspeedsensorinput.

Q,U Dischargeairtemperaturesensorinput.

SSPM Internal(jumpered)orexternaldischargesetpointinputs.

VXYZ Modulating(resistive)room/returnairthermostatinputs.

OR Singlestageheatthermostatinput.

+/‐ 0‐10Vdc(4‐20mA)temperatureresetinput.





A DJM3

IOM-17 7 of 27 Mar 99 R3

DIPSWITCHES

TheDJM3optionsareconfiguredbyDIPswitchselectionand/orwiringconnections.

TABLE2

DIPSW Description

1 EnableVdcormAtemperatureresetifON.

2 EnableambientresetifON.

3 Enableroom/returntemperatureresetifON.

4 Notused.

5 Servicemode(mustbeleftOFFfornormaloperation).

6 Notused.

7 ConstantcombustionairpurgemodeifON.

8 EnablelowlimitdischargetemperaturesensingifON



Note:TheDJM3willonlyacceptonetypetemperatureresetsignal.



INDICATIONANDDIAGNOSTICLIGHTS

Thereare4statuslightsontheDJM3labeled1to4.Theyoperatein4patterns:constanton,2second

flash(onfor1second,offfor1second),1secondflash(onfor½second,offfor½second)andan

irregularflash(flashestwice,thenoff,repeat).

TABLE3

LIGHT LEDON 2SECFLASH 1SECFLASH INTFLASH

1 LLLOCKOUT LLBYPASS DSENOPEN ‐‐‐‐‐‐‐‐‐‐

2 PREPURGE PPPROBLEM ‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐

3 HEATCALL HTSWOPEN ‐‐‐‐‐‐‐‐‐‐ SERVICEMODE

4 IGNENABLE ‐‐‐‐‐‐‐‐‐‐ FLAMEFAIL ‐‐‐‐‐‐‐‐‐‐



1 ON

Theappliancehasbeenshutdownduetolowlimitfailureandlockout.

(dischargetemperaturebelow4°C(40°F))Resetwiththeserviceswitch.

Normaloperatingstatus:OFF.

1 2SEC

Unithaslowdischargetemperatureandistimingout.Ifthetemperaturedoes

notrecovertoabove4°C(40°F)itwillshutdownandlockout.

Normaloperatingstatus:OFF,orwaitingforthedischargetemperaturetorise

above4°C(40°F).

1 1SEC

Thedischargesensorcircuitisopen(sensorrangemustbebetween880and

4000Ω).

Normaloperatingstatus:OFF.

2 ON

Thecombustionblowerispurgingtheexchangerasapreliminarytoignition.

Normaloperatingstatus:EITHERONorOFF.

2 2SEC

PrePurgeproblem.TheDJM3isnotreceivingacorrectsignalfromthehall

effecttachometersensor,intoterminalsYS,OS,GS.

Normaloperatingstatus:OFF.

A DJM3

IOM-17 8 of 27 Mar 99 R3

3 ON

Thedischargesensorisbelowcalculatedsetpoint(SPC)andtheDJM3has

initiatedtheheatingsequence.

Normaloperatingstatus:ONforheating.

3 2SEC

Thereisacallforheating,howevertheheatinghasbeendisabledfromno

inputintoterminalHS(24Vac).

Normaloperatingstatus:OFF.

3 INT

FLASH

Unitisinservicemode,allowingthetechniciantomanuallysettheheating

fromlowtohighfirewiththeservicepot.

Normaloperatingstatus:OFF.

4 ON

FRandCFRcontactshaveclosed,enablingtheignitioncontroltofirethe

burner.

Normaloperatingstatus:ONforheating.

4 1SEC

Burnerignitionwasunsuccessful.TheDJM3didnotreceiveamaingasvalve

(SSOV)feedbacksignalintoterminalsVFB24orVFB120.

Normaloperatingstatus:OFF.



ADJUSTMENTPOTS

Thereareanumberofsettingandcalibrationpotentiometers(POT’s)locatedonthefrontofthe

DJM3.Modificationstotheseshouldonlybedonebyexperiencedandqualifiedpersonnel.

TABLE4

POT Description

DSENCAL Dischargesensorcalibration.

DISSPCAL Dischargesetpointcalibration.

BMSCAL BMS(0‐10Vdcor4‐20mA)resetcalibration.

ROOMCAL Roomsensorcalibration.

SERVICE Servicemodepot.

RESETRATIO Temperatureresetrangeadjustment.

LOWFIRE* LowfirespeedRPMadjustmentpot(nearterminalPV1).

CURVEMATCHING* ValvecurvematchingRPMadjustmentpot(nearterminalCS).

SETPOINT Ifused,theon‐boarddischargesetpointdial.

*Thesepotsshouldonlybeadjustedwhenusedwithacombustionanalyzer.





A DJM3

IOM-17 9 of 27 Mar 99 R3

MULTIMETERTESTPOINTS

TheDJM3hasreadoutterminalsformeasuringthedischargesensortemperatureandthecalculated

dischargesetpoint.These3testpointsarelocatedneartheMandQterminals.



MeasurementsaremadeusingaVdcmultimeterusingascaleof1Vdc=10°C.Forexample,areading

of2.1Vdc=21°C(or70°F).RefertothetablebelowforCelsiustoFahrenheitconversion.



TABLE5

VoltageReading(Vdc) °C °F

1.0 10 50

1.5 15 59

2.0 20 68

2.5 25 77

3.0 30 86

3.5 35 95

4.0 40 104



SYSTEMTIMINGS

Thetimeslistedaregeneral,andmaybeaffectedbyexternaltimedelaydevices.

TABLE6

Pre‐purge 45seconds

Postpurge 4minutes(daymode)1minute(nightmode)

Fandelay 30seconds

Warmuptime 30seconds

Cooldowntime 60seconds

Lowlimitbypass 5minutes

FlameFailure 90seconds



TEMPERATURECONTROL



CALCULATEDSETPOINT(SPC)

TheDJM3isdesignedtobeadischargeairtemperaturecontrol.Thebasedischargeairtemperature

setpointistypicallysetfromthecontrolpotlocatedonthefaceoftheDJM3.Thebasedischargeair

temperatureisnormallymodifiedfromaremotesignaltomaintainthedesiredtemperatureofthe

suppliedspace.Thisiscalledreset.TheDJM3dischargesetpointcanberesetfromavarietyofsources

suchasambientairtemperature,modulatingorstagedroomthermostats,returnairtemperature,ora

BMSsignal(0‐10Vdcor4‐20mA).

Withoutanytemperatureresetmethodthebasesetpoint(eitherfacemountedorremotemounted)is

thecalculatedsetpointthattheDJM3willattempttomaintainthedischargetemperatureat.



SetpointCalculation(SPC)=DischargeSetpoint+Reset



A DJM3

IOM-17 10 of 27 Mar 99 R3

TheDJM3isdesignedtouseeitherofthefollowingasasetpoint:

 ThesetpointmountedonthefaceoftheDJM3(rangeof50‐95°F(10‐35°C)).IftheDJM3face

mountedset‐pointisused,terminals“SPandS”mustbejumpered;or

 TheJohnsonControlsTE6100‐960set‐point(rangeof50‐85°F(10‐29°C)).IftheTE6100‐960isused

asaset‐point,“StoSP”isnotjumperedandtheTE6100mustbewired:



TABLE7

TE6100Wires DJM3Terminals

Violet(notused) ‐

Red(notused) ‐

Grey WiredtoterminalU

Blue WiredtoterminalM

Orange WiredtoterminalS



DISCHARGETEMPERATURESENSOR(DTEMP)

TheDJM3usesthedischargesensorforbothtemperaturecontrolandlowlimit.Becauseofthis,the

DJM3willnotoperatewithafaultydischargesensor.Ifthedischargesensorresistanceisgreaterthan

4000‐ohmsorlessthan880‐ohms,theunitwilllockouteitheronlowlimitorbadtemperaturesensor.



MODULATINGROOMRESET(continuousbloweroperationonly)

DIPswitch3mustbe"on".ThisoptionalsorequiresaTE6100wired:

TABLE8

TE6100Wires DJM3Terminals

Red(notused) ‐

GREY WiredtoterminalV

VIOLET WiredtoterminalX

ORANGE WiredtoterminalY

BLUE WiredtoterminalZ



IfDIPswitch3isonandtheTE6100isnotwiredtothecorrectDJM3terminals,theDJM3willresetthe

dischargetemperaturedownasitthinksthattheroomsensorisverywarm.Theroomtemperature

requirementscanincreaseordecrease(reset)thecalculateddischargeairset‐point.



Note:Ifroomresetcalling,the“calculated”dischargetemperaturesetpointwillvaryfromthesetting

of“master”setpoint.

 Theroom‐resetfeatureisactivatedbyDIPswitch3.

 RoomsensorcalibrationpotisRoomCalPot.

 Roomresetbandis3°F(fixed).



The“roomresetband”meansaroomtemperatureerrorofjust3°Fwillresultinamaximumresetof

thedischargeairsetpoint.Theactualamountreset(indegrees)variesasperboththesettingofPot

ResetRatioandthedischargesetpoint.Thecalculateddischargeairsetpoint(dialsetting+reset)is

limitedbetween48and120°F.



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