AAON Pioneer Gold 3.0, Technical Manual

Page 1: ...sion 2 09 and up Bootloader Version 1 04 and up I O Board Version 1 01 and up Pioneer Gold Touchscreen Temp and Humidity Sensor Version 2 03 and up Prism 2 Software Version 5 04 and up Electric Heat E...

Page 2: ...field installed wiring must be completed by qualified personnel FieldinstalledwiringmustcomplywithNEC CEC local and state electrical code requirements Failure to follow code requirements could result...

Page 3: ...3 Pioneer Gold 1 10 Controller replaced by ASM02780 V94730 V94731 Pioneer Gold Electric Heat Board V98550 Pioneer Gold Touchscreen Space Temp and RH Sensor G000181 Wall Mount Space Temperature Sensor...

Page 4: ...de accurate and current product information However in the interest of product improvement AAON reserves the right to change pricing specifications and or design of its product without notice obligati...

Page 5: ...Chapter 1 Pioneer Gold Controller...

Page 6: ...Dehumidification 1 18 Thermostat Controlled Random Start Supply Fan 1 19 Thermostat Controlled Compressor Reversing Valve and Electric Heat 1 20 Thermostat Controlled Waterside Economizer and Dehumid...

Page 7: ...gure 1 5 H5 Standard Output Harness Wiring 1 8 Figure 1 6 H7 Variable Capacity Harness Wiring 1 8 Figure 1 7 H8 Reheat and Water Valve Pump Harness Wiring 1 8 Figure 1 8 H10 WSHP Harness Wiring 1 9 Fi...

Page 8: ...nsducers 1 27 Table 1 10 Temperature Resistance for Type III 10K ohm Thermistor Sensors 1 28 Table 1 11 Factory Set Default Setpoints for LLT Sensor Glycol 1 29 Table 1 12 Factory Set Default Setpoint...

Page 9: ...INTERFACE 2 8 Touchscreen LCD Color Interface with Two Levels of Security Prism 2 Computer Software Interface SERVICE AND RELIABILITY FEATURES Firmware Update via USB Port Fault and Status Indicator L...

Page 10: ...ive WIRING Important Wiring Considerations Control Device Voltage VA Load Operating Temperature Humidity Non Condensing Pioneer Gold Controller 18 30 VAC 25 15 Class 2 75 32 F to 158 F 0 C to 70 C 0 9...

Page 11: ...d touch adjoining terminals which could potentially cause a short circuit 7 When communication wiring is to be used to connect to other communication devices all wiring must be plenum rated minimum 18...

Page 12: ...ttComm MODBUS RTU or BACnet MS TP Connection To External BAS Network Selectable Expansion MODBUS Terminal Connection Touchscreen Space and Humidity Temperature Sensor Connection Micro USB Connection U...

Page 13: ...4 M2904 B L T B t L A B O R T I E S A R O T E S T R I G N A C n e 2019WXX H6 Field Wire Terminal H2 Line Pressure Terminal H9 Field Wire Terminal H12 T STAT Terminal H14 Spare Terminal H13 Standard In...

Page 14: ...ure UI2 Spare UI3 Spare UI4 Spare Input Output Map See Table 1 4 through 1 7 this page for Pioneer Gold Controller Inputs Outputs Future items are grayed out Table 1 4 Pioneer Gold Inputs DIGITAL OUTP...

Page 15: ...I2 UNIVERSAL INPUT 3 UNIVERSAL INPUT 4 SPARE ANALOG OUT 1 SPARE ANALOG OUT 2 SPARE DIGITAL OUT NOTE GREEN pins are GND RED pins are 24 VAC G Y1 COOLING CALL DEHUM CALL HEAT STG 1 CALL COMP STG 2 CALL...

Page 16: ...8 GND 4 WHT BLK GRN RED ORN GRN GRN ORN NOTE represented by a dotted line Multicolored wires are 5 1 6 2 7 3 8 4 CT 2 8 4 7 3 6 2 5 1 HOT WATER VALVE 8 GROUND 4 GROUND 3 GROUND 2 GROUND 1 ENTERING HOT...

Page 17: ...7 14 6 13 5 12 4 11 3 10 2 9 1 NOTE represented by a dotted line Multicolored wires are GROUND 7 24 VAC INPUT 14 HIGH PRESSURE SWITCH 6 24 VAC 13 LOW PRESSURE SWITCH 5 GROUND 12 GROUND 11 GROUND 9 GR...

Page 18: ...S B SW1 HEAT1 HEAT2 POWER STATUS J4 J6 A S B J1 J3 J2 J7 J5 S A J5 B Heat Relay 1 Heat Relay 2 18 30 VAC GND Line Voltage Size transformer for correct total load Electric Heat Expansion Module 20 VA...

Page 19: ...1 All wiring to be in accordance with local and national electrical codes and specifications 2 All communication wiring to be 18 gauge minimum two conductor twisted pair with shield Use Belden 82760 o...

Page 20: ...this input is energized the Auxiliary Fault Alarm will occur Once the compressor completes its Minimum Run Time it will be de energized and the fan will continue to run This can either be a 24 VAC we...

Page 21: ...ng position FAN Supply Fan Low Speed This 24 VAC relay output signal is used to engage the fan to run at low speed Y1 Compressor Stage 1 This 24 VAC relay output signal is used to energize the compres...

Page 22: ...eaving Water Temperature LWT drops to a dangerous level the Low Leaving Water Temperature Alarm will be generated and the compressors will be disabled When the LWT rises above the safe limit again thi...

Page 23: ...stages off The Supply Fan can be configured for three modes Auto Default Cycles on with Cooling Heating and Dehumidification Modes On To run continuously Off Unit will not run with Cooling Heating and...

Page 24: ...l or Rotary In Cooling or Heating Mode the compressor will be enabled There is no Supply Air Temperature Control Multiple Stage Compressors Stage Up Sequence In Cooling Mode as the SupplyAir Temperatu...

Page 25: ...sor heating is locked out and there is a demand for heating Emergency heat will not operate in addition to compressor heating There is no supply air control Waterside Economizer Operation On Off Water...

Page 26: ...according to the selected setpoints Hot Gas Reheat Dehumidification During Hot Gas Reheat Dehumidification the compressor is enabled at full capacity Y2 when Dehumidification Mode is enabled The supp...

Page 27: ...e controller will respond to the normal thermostat signals Supply Fan Operation The Supply Fan will enable upon receiving a 24VAC input on the G terminal or upon a call for compressor operation unless...

Page 28: ...Heat Operation External Duct Heater s The W1 Heat Output is designed to be used with duct heaters The W1 heat output will be enabled whenever the W1 input has 24VAC applied to it The duct heaters wil...

Page 29: ...Entering Water Temperature falls below the Cooling Entering Water Temperature Setpoint default 45 F range 45 60 F the WSE coil will be enabled and operate as described in the Waterside Economizer Ope...

Page 30: ...low 30 F or becomes out of range The alarm will release when the coil temperature increases to 45 F This alarm will disable the compressor but allow operation of the supply fan Space Sensor Alarm The...

Page 31: ...er Temperature Alarm The Leaving Water Temperature Alarm will trigger if the leaving water temperature drops below the freeze protection temperature The glycol percentage will be configured through th...

Page 32: ...port It will then turn off After inserting a USB flash drive with a firmware update and cycling power to the controller the LED should turn solid green once the board detects the update and then shoul...

Page 33: ...ATERSIDE ECONOMIZER LED MOTORIZED WATER VALVE PUMP LED HOT GAS REHEAT VALVE LED COMPRESSOR STAGE 2 LED COMPRESSOR STAGE 1 LED REVERSING VALVE LED SUPPLY FAN HIGH SPEED LED LM2904 M2904 B L T B t L A B...

Page 34: ...ety is closed If the LED turns red the Limit Switch input safety is open MODBUS LEDs D2 This yellow LED will light up and blink continuously to indicate there is MODBUS communications D3 This orange L...

Page 35: ...the positive lead from the meter on the DPT input terminal located on the controller Place the negative lead from the meter on the ground COM terminal located adjacent to the DPT terminal on the cont...

Page 36: ...r wiring is open If the voltage is less than 0 18 VDC then the sensor or wiring is shorted Temperature Resistance Voltage for Type III 10K ohm Thermistor Sensors Temp F Temp C Resistance Ohms Voltage...

Page 37: ...r Glycol Activation Temp Setpoint F Alarm Release Setpoint F 5 F offset 0 35 F 40 F 10 28 F 33 F 15 24 F 29 F 20 19 F 24 F 25 14 F 19 F 30 8 F 13 F 35 1 F 6 F 40 6 F 1 F Glycol Freeze Protection Setpo...

Page 38: ...Wiring Notes 1 All wiring to be in accordance with local and national electrical codes and specifications 2 All communication wiring to be 18 gauge minimum two conductor twisted pair with shield Use...

Page 39: ...the controller No Units AV 17 900 500 1500 CO2 Setpoint CO2 setpoint to control the damper override output PPM AV 18 74 55 85 Occupied Cooling Setpoint Cooling mode enable setpoint when space is occu...

Page 40: ...imum Percentage Not Used Percent AV 46 N A N A Not Used Not Used GPM AV 47 0 0 10 Space Sensor Maximum Setpoint Offset Maximum allowed user setpoint adjustment on the Touchscreen Temperature Humidity...

Page 41: ...versing Valve relay output BV 18 N A Water Valve Pump Status of the Water Valve or Pump relay output BV 19 N A HGRH Status of the Hot Gas Reheat relay output BV 20 N A Alarm Status of the alarm relay...

Page 42: ...control while in Heating Mode BV 44 N A Digital Input 1 Status Status of DI1 input BV 45 N A Occupancy Sensor Status of occupancy sensor which will force the unit into occupancy BV 46 False Unit Locko...

Page 43: ...onnection To BACnet Network Programming Note Use the Network Menu in the Touchscreen LCD Display to program the BACnet MS TP setting Wiring Notes 1 All wiring to be in accordance with local and nation...

Page 44: ...on Pressure Pressure reading from the suction pressure transducer PSI AI 12 Water Valve Pump Percentage Percentage output to an analog water valve or pump Percent AI 13 Hot Water Valve Percentage Perc...

Page 45: ...renheit AV 13 70 55 85 Occupied Heating Setpoint Heating Mode Enable Setpoint when space is occupied Fahrenheit AV 14 65 55 85 Unoccupied Heating Setpoint Heating Mode Enable Setpoint when space is un...

Page 46: ...fore going into compressor cooling Minutes AV 31 10 10 255 Waterside Econo Heating Failure Time Amount of time unit stays in economizer mode before going into compressor heating Minutes AV 32 70 55 12...

Page 47: ...or pump relay output BI 20 HGRH Status of the hot gas reheat relay output BI 21 Alarm Status of the alarm relay output and indicates if any alarm is present BI 22 Occupancy Status Indication of space...

Page 48: ...set Enable Enables space supply setpoint reset control while in heating mode BV 6 Unit Lockout Remote Reset Allows building management system to remotely release a unit from an alarm lockout BV 7 Pass...

Page 49: ...setting Wiring Notes 1 All wiring to be in accordance with local and national electrical codes and specifications 2 All communication wiring to be 18 gauge minimum two conductor twisted pair with shi...

Page 50: ...e input terminal Night Setback Override Discrete Input 0x02 Read 10204 Boolean Status of the night setback override input terminal Night Setback Tstat Discrete Input 0x02 Read 10205 Boolean Status of...

Page 51: ...y alarm Condensate Overflow Alarm Discrete Input 0x02 Read 10228 Boolean Status of the condensate overflow alarm Low Control Voltage Alarm Discrete Input 0x02 Read 10229 Boolean Status of the low cont...

Page 52: ...the hot water heat coil valve Supply Fan Percentage Input Register 0x04 Read 30225 Float Percent Percentage output for a variable speed supply fan Damper Override Percentage Input Register 0x04 Read 3...

Page 53: ...Register 0x03 Read 0x06 Write 40209 Integer 75 55 85 Fahrenheit High Space Temperature Setpoint when using space supply reset control in Cooling Mode Space Cooling Lo Reset Holding Register 0x03 Read...

Page 54: ...n Supply Fan Minimum Percentage Holding Register 0x03 Read 0x06 Write 40223 Integer 35 35 100 Percent Minimum allowed output for a variable speed supply fan Space Temp Offset Holding Register 0x03 Rea...

Page 55: ...Chapter 2 Pioneer Gold Touchscreen Operator Interface...

Page 56: ...5 SETUP GUIDE 2 6 Overview 2 6 Logging In and Passwords 2 7 Changing the Date 2 8 Changing the Time 2 9 Schedules 2 10 Configuration 2 12 SETPOINTS 2 14 Overview 2 14 Values 2 15 USB FUNCTION 2 17 Upd...

Page 57: ...e 2 11 Configuration Menu Screens 2 12 Figure 2 12 Application Selection screen 2 12 Figure 2 13 Setpoint Screens 2 14 Figure 2 14 Cooling Setpoints Screen 2 14 Figure 2 15 Setpoint Data Entry Screen...

Page 58: ...uthorized users through integral two level password authorization programming Multiple built in alarms enhance system monitoring USB port provides the ability to update firmware and upload and downloa...

Page 59: ...the Main Screen It will display a flame for Heating Mode a snowflake for Cooling Mode a fan for Vent Mode or a no water droplet for Dehumidification Mode It will display the word OFF when the unit is...

Page 60: ...ows you to do three things set the current date and time and configure Daylight Saving Time Alarms This icon takes you to the Alarms Screens The Alarm Screens display the status of all possible alarms...

Page 61: ...ms Screens display the status of all possible alarms Inputs This icon takes you to the Inputs Screens The Inputs Screens display the status of all possible inputs connected to the board Outputs This i...

Page 62: ...saving changes Use the OK button to save the data you just selected or entered Use the Back button on the number keypad to delete data Use the Apply Settings button to save your changes Use the Enter...

Page 63: ...he Manager Password Step 3 Set the Correct Date Time From the Administrator Settings Screen Press Clock to change the date and time Step 4 Set the Schedules From the Administrator Settings Screen Pres...

Page 64: ...also change the system date and time but no changes to any controller configurations can be made They can also update firmware download setpoints to USB and upload setpoints from USB Administrator Lev...

Page 65: ...See Figure 2 5 this page This screen displays the current settings for the date month and year Use the arrow keys at the top right and left of the calendar to change the month and year When you have a...

Page 66: ...Screen Select the option you are using Select one option Press OK to save The available selections are as follows Disable Default Select this option if your system is installed in an area of the worl...

Page 67: ...cupancy is caused by the remote occupancy input You can set separate schedules for weekdays and weekends set schedules for the entire week set a 24 7 schedule or create a custom schedule You can also...

Page 68: ...lection box blank When you have finished your selection Press OK to return to the Schedule Options Screen Custom Schedule Press Custom The screen contains each day of the week Select a day of the week...

Page 69: ...ontrol On Board Space Sensor or AAON Touchscreen Space and Humidity Sensor Fan Control Factory Set Select the fan control you are using Press OK to save Single Speed Single speed permanent split capac...

Page 70: ...uns compressor at full capacity and fan at low speed while in Dehumidification mode Unit must be equipped with a two speed fan to use this feature Hot Gas Reheat Reheat will operate Cooling Heating an...

Page 71: ...for an example Press Back to return to the Setpoints Screen The name of the setpoint will be displayed at the top of the screen Press the UP and or Down arrows to change the value Press OK to save the...

Page 72: ...zer can be used for Free Cooling Default 45 F Range 45 60 F Economizer Heating Enable If the Entering Water Temperature isAbove this value the Economizer can be used for Free Heating Default 85 F Rang...

Page 73: ...ow the Room Sensor temperature Default 0 F Range 10 F Sensor Calibrations Space Temperature Supply Temperature and Space Humidity Sensor Calibrations You can adjust the offset temperature when the sen...

Page 74: ...ments should flash green to indicate the download is in process When the download is complete the LED will turn off 4 Once complete the controller should be running the new version Verify the firmware...

Page 75: ...U WattComm BACnet MS TP NOTE BACnet MS TPand BACnet IPcannot be used simultaneously and neither can BACnet MS TP and WattComm Select the additional option Legacy BACnet Points This option will allow y...

Page 76: ...ign Device Configuration Foreign Device Enable Disable The default is Disabled Time to Live This is the device s time to live in seconds Selection is in 30 second increments from zero to 600 Default i...

Page 77: ...eturn to the Main Screen Figure 2 18 Inputs Screens Inputs 1 Space Temperature Space Humidity Supply Temperature Entering Water Temp Liquid Line Temp Leaving Water Temp Evap Coil Temp Entering Hot Wat...

Page 78: ...ess the second screen Press the Back button to access the first screen Press the Menu button to return to the Main Screen Figure 2 19 Outputs Screens Outputs 1 Supply Fan Lo Speed Supply Fan Hi Speed...

Page 79: ...e being affected by the particular alarm Continue scrolling through the Alarms pages until you see the item that shows Alarm to identify which item is in an alarm state that is causing associated item...

Page 80: ...recorded as 0000 one minute past midnight is 0001 1 a m is 0100 1 p m is 1300 and so on When converting from standard to 24 hour time and vice versa the minutes and seconds do not change Standard time...

Page 81: ...Chapter 3 Prism 2 Operator Interface Overview...

Page 82: ...ller Status Screen 3 3 Controller Setpoint Screens 3 4 Administrative Functions Changing Setpoints and Force Occupied 3 6 Setting Schedules and Holidays 3 7 Alarms and Trend Logs 3 9 TREND LOGS 3 10 P...

Page 83: ...Figure 3 10 Setpoints Help Window 3 6 Figure 3 11 Forced Occupied Option 3 6 Figure 3 12 Status Screen Schedules 3 7 Figure 3 13 Schedules Menu 3 7 Figure 3 14 Schedules Screen 3 7 Figure 3 15 Holiday...

Page 84: ...e following requirements Operating System Microsoft Windows 10 NOTE Prism 2 is not intended for a server client environment or any version of Windows Server Minimum Hardware Windows compatible compute...

Page 85: ...creen designation Step 3 Configuring Prism 2 This section describes how to have Prism 2 automatically restart after a power failure and broadcast time to all controllers It also explains how to set up...

Page 86: ...peration Active Cooling Setpoint Space Temp Leaving Water Temp 1 Supply Air Temp Leaving Water Temp 2 Indoor Humidity Entering Hot Water Temp CO2 Level Reversing Valve Status Evap Coil Pressure Occupa...

Page 87: ...will display See Figure 3 3 this page At the bottom of any Setpoints Screen you can access all other Setpoint Screens by clicking the icons Temperatures Staging Delays Miscellaneous Calibration Confi...

Page 88: ...er Technical Guide PRISM 2 OVERVIEW Controller Setpoint Screens Figure 3 5 Configurations Screen Figure 3 6 Miscellaneous Settings Screen Figure 3 7 Compressor Staging Delays Positions Screen Figure 3...

Page 89: ...e in that field When you enter a value you must press Enter to have Prism 2 save the value Saving and Restoring Setpoints At the top of each setpoint screen you can select Save or Restore These two fu...

Page 90: ...this page Click on the date to highlight it and tag it as a holiday Days selected as holidays are indicated with a green background and white text There are 14 holiday periods available for each year...

Page 91: ...completely erase the holidays appearing in the window See Figure 3 17 this page Saving all schedules from the controller to a file on your computer for use in restoring the schedules or for copying t...

Page 92: ...8 this page Each individual ALARM button will be bright red if an alarm exists and will be gray if no alarm exists Click the blue Reset Lockout button at the bottom right of the screen to immediately...

Page 93: ...Wtr Entering Hot Water Temp CO2 Space CO2 Level WtrFlw Water Flow Rate CtrlVolt Control Supply Voltage Fan Supply Fan Speed Pump Pump Speed DmprOvr Damper Position HtWtrVlv Hot Water Valve Position HG...

Page 94: ...Switch So the High Pressure Switch binary input is also currently active There is no remainder 2 2 0 so there are no more inputs that are active From the one value of 22 you are able to determine tha...

Page 95: ...G To S G T To A S A B Pioneer Gold CommLink 5 Wiring Should Be R To R SH G To Shld G T To T MiniLink PD 5 CommLink 5 NETWORK T SH R CommLink 5 COMM USB NETWORK L O O P T X U S B R X U S B C O M P A C...

Page 96: ...VAC GND LOOP SOFTWARE BACNET Wiring To Be R To B SHLD G To S G T To A S A B Pioneer Gold CommLink 5 Wiring Should Be R To R SH G To SHLD G T To T MiniLink PD 5 CommLink 5 NETWORK T SH R T SHLD R T SHL...

Page 97: ...etwork depending on the installation Mini DIN cable supplied with USB Link STAND ALONE NETWORK Communication speed switch must be set to High Speed Pioneer Gold Controller S A B SH T R Use the adapter...

Page 98: ...Chapter 4 Touchscreen Sensor SAT 7 03 55 4 HUM 74 Heat SPT Occupied OFF 75 3 F 4 11 PM 75 3 F MAIN MENU MAIN MENU...

Page 99: ...EENS 4 2 Home Screen Navigation 4 2 Setpoints 4 3 Viewing Alarms 4 6 Setting Schedules 4 7 Holidays 4 8 OVERRIDE OPTIONS 4 9 Occupancy and Setpoint Overrides 4 9 TROUBLESHOOTING 4 10 Touchscreen Senso...

Page 100: ...Economizer 4 4 Figure 4 10 Setpoints Compressor 4 4 Figure 4 11 Setpoints Supply Fan 4 5 Figure 4 12 Setpoints Glycol 4 5 Figure 4 13 Setpoints CO2 4 5 Figure 4 14 General Alarms Screens 4 6 Figure 4...

Page 101: ...See Figure 4 1 this page The Touchscreen Sensor has many features including the following User friendly high contrast touchscreen interface Graphic programming screens provide easy setup and operation...

Page 102: ...perature and space relative humidity are displayed Space Temperature Press the temperature to access the Setpoint Override Screen NOTE The Space Sensor Max Setpoint Offset can only be modified from th...

Page 103: ...F Supply Air Heating Setpoint Default 90 F Range 55 120 F Auxiliary Heat Deadband Space Temp has to be this far below setpoint before Aux Heat can energize Default 5 F Range 1 10 F Setpoints MAIN MEN...

Page 104: ...e value to 255 will disable the timer so the Waterside Economizer will run indefinitely in that mode and never timeout Default 10 minutes Range 10 255 minutes Compressor Setpoints MinimumOnTime Compre...

Page 105: ...Glycol mixed in the loop water It is needed to calculate Lockout setpoints Default 0 Range 0 40 CO2 Setpoints CO2 Override If CO2 is above this value the OA damper will be opened Default 900ppm Range...

Page 106: ...larms active and any item that shows L O is conveying that this particular item s is are being affected by the particular alarm Continue scrolling through the Alarms pages until you see the item that...

Page 107: ...ts are 0 in all fields You can select two events per day Select an hour and minute start time for Occupy 1 and an hour and minute stop time for Unoccupy 1 Repeat this for Occupy 2 and Unoccupy 2 All t...

Page 108: ...U MAIN MENU Occupancy Period 7 Period 6 Period 5 Period 4 Period 3 Period 2 Period 1 NEXT Schedule Occupancy Period 7 Period 6 Period 5 Period 4 Period 3 Period 2 Period 1 NEXT Schedule Holidays Page...

Page 109: ...ve seconds later it will display Occupancy Override and the silhouette will turn black To reset the override before the configured time period ends press the silhouette again for one second and the sc...

Page 110: ...pears on the screen 5 After touching this blue circle three times the Home Screen will appear 6 Test the calibration to see if the buttons etc are working properly 7 If not repeat steps 1 6 If yes rem...

Page 111: ...the resistor installed before they are shipped On the Touchscreen Sensor install the resistor between terminals A and B See Figure 4 20 this page On the PG Controller s main board install the resisto...

Page 112: ...eserved AAON Controls Support 866 918 1100 Monday through Friday 7 00 AM to 5 00 PM Central Standard Time Controls Support website www aaon com controlstechsupport AAON Factory Technical Support 918 3...