CRDMNDMD001A00CRDMNDMD002A00Energy Demand Load ControllerRooftop Unit Accessory

Installation Instructions

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NOTE: Read the entire instruction manual before starting theinstallation, and follow instructions carefully. Failure to do so maydamage equipment, void warranties, or even cause serious injuries.

SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service, maintenance,or use can cause explosion, fire, electrical shock, or otherconditions which may cause death, personal injury or propertydamage. Consult a qualified installer, service agency or yourdistributor or branch for information or assistance. The qualifiedinstaller or agency must use factory--authorized kits or accessorieswhen modifying this product. Refer to the individual instructionspackaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,and work gloves. Have a fire extinguisher available. Read theseinstructions thoroughly and follow all warnings and cautionsincluded in literature and attached to the unit. Consult localbuilding codes and the current edition of the National ElectricalCode (NEC) NFPA 70.

In Canada, refer to the current editions of the Canadian ElectricalCode CSA C22.1.

Recognize safety information. When you see this symbol onthe unit and in instructions or manuals, be alert to the potential forpersonal injury. Understand the signal words DANGER,WARNING, and CAUTION. These words are used with thesafety--alert symbol. DANGER identifies the most serious hazards,which will result in severe personal injury or death. WARNINGsignifies hazards, which could result in personal injury or death.CAUTION is used to identify unsafe practices, which may resultin minor personal injury or product and property damage. NOTEis used to highlight suggestions which will result in enhancedinstallation, reliability, or operation.

INTRODUCTIONCarrierr’s Energy Demand System provides reliable andautomated processes to manage the costs of energy consumption.Carrier’s Energy Demand System uses wireless devicesincorporating patented Swarm Energy Management algorithms tocreate a powerful network of coordinated rooftop units to reduceand optimize their energy usage. This system creates a wirelessnetwork of rooftop units with Energy Demand Load Controllerscommunicating through the Energy Demand Gateway.

Each individual Load Controller can independently decide whetherit should allow its unit to run by a relay that can break theconnection between the rooftop unit and the thermostat. Bycommunicating energy information through the Gateway, units areprevented from running simultaneously when it is not necessary,thereby smoothing out peak demand over time. This methodprovides the ability to accomplish Demand Management, DemandResponse, and energy trending over time.

Carrier offers two accessories that, when combined, make up theEnergy Demand System. This technology utilizes Swarm EnergyManagementt methodology as a basis for the operating sequence:S Energy Management Gateway (Coordinator)

(Model Nos. CRDMNDGW001A00, CRDMNDGW002A00):

This model is packaged with a cellular modem and modem

enclosure, and is the first controller to be attached to a packaged

rooftop unit and powered up. This controller will both

monitor/control the attached rooftop, as well as act as a

communications gateway back to the Swarm Energy

Management Web Portal, a service provided by REGEN Energy,

Inc..

Table 1 – Kit Voltage Requirements

Kit No. Unit VoltageCRDMNDMD001A00 208/230/460VCRDMNDMD002A00 575V

S Energy Demand Load Controller

(Model Nos. CRDMNDMD001A00, CRDMNDMD002A00):

This load controller is installed on the remaining packaged

rooftop units that are to be monitored and controlled.

NOTE: Please ensure you have the correct InstallationInstructions for the given type of controller before continuing.

INSTALLATION CONSIDERATIONSRTU ChecklistToward the end of this document, there is a RTU checklist thatmust be filled out for every Load Controller installed. The RTUchecklist must be legible. The RTU checklists need to be scannedand emailed to fieldops@regenenergy.com within 48 hours ofthe completion of the installation. Providing this checklist is vitalto completing device set--up for operation.

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Supplied4-Pole Relay

Supplied Transformer

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Fig. 1 -- Component Installation Schematic

Wiring DiagramA diagram noting all components and their proper wiring isprovided. (See Fig. 8)

Installation ReportAn Installation Report is provided at the end of this document,where you should record installation notes for each LoadController, and issues encountered.

Recommended Order of Operation To Install theLoad Controller

1. Determine where to mount each component inside of theRTU.

2. Mount the components (Load Controller. 4--Pole Relay,Transformer, Antenna).

3. Wire all components.

4. Power up and test the Load Controller.

5. Fill out the required RTU Installation Checklist.

6. Fill out the Installation Report.

7. Scan and email “RTU Checklist” and “Installation Report”to fieldops@regenenergy.com within 48 hours of complet-ing device setup.

Overview SchematicThe components listed below must be installed. Refer to thediagram in Fig. 1. when deciding where to mount each componentin relation to the RTU.

Component Installation Location

Energy DemandLoad Controller Inside cabinet

Transformer Inside cabinet

4--Pole Relay Inside cabinet

Antenna and Mounting Base Exterior of cabinet, on top

INSTALLATIONBasic list of tools and materials recommended tocomplete installation:

MaterialS Small blue wire nuts

S 9/16--in. Rubber grommet

S #18 THHN standard wire

S #18--22 fork connectors

S #18--22 female connectors

S #10 tek screws (3/4--in. long)

S 5--1/2--in. And 7--1/2--in. zip ties

S Tube of clear silicone

ToolsS Cordless drill

S Control screw drivers

S 1/4--in. Pilot bit

S Nut drivers

S Crimp tool

S Wire strippers

Relay

Transformer

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Fig. 2 -- Transformer and Relay Mounting Examples

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Suggested Installation Sequence1. Disable all power to the rooftop unit.

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injuryor death.

Disconnect power before opening unit.

! WARNING

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injuryor death.

Before installing, modifying, or servicing system, the mainelectrical disconnect switch must be in the OFF position. Theremay be more than one disconnect switch. Lock out and tagswitch with a suitable warning label.

! WARNING

2. Open the main cabinet and control board cover

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care andwear appropriate protective clothing and gloves when handlingparts.

CAUTION!

3. Determine where each component will be mounted:

S Load Controller: Mounted inside the cabinet, such thatallows access to the keypad and display

S Antenna & Mounting Base: Mounted on top of the cabi-net. Mounting location examples include, mountingwithin the unit control box, on a side wall within theunit, or any available panel. Ensure the selected mount-ing location does not cause damage to coils or existingcomponents.

S Relay: Located inside the cabinet such that it reachescooling and heating control lines

S Transformer: Located inside the cabinet such that it canreach:

a. Transformer primary--side wires will be attached to therooftop unit’s load--side leads

b. Transformer secondary--side wires will be attached tothe Load Controller power wires (1 & 2) and modempower lines (24 & 25). (See Fig. 8)

Mount Load Controller:S Ensure the selected location for the Load Controller allows

access to see the display & use the keypad. (See Fig. 3)

S Ensure extension wire from the Antenna Mounting Base can

reach the top of the Load Controller.

S Securely mount the Load Controller using four of the Mounting

Screws

Controller

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Fig. 3 -- Load Controller Mounting Examples

Mount TransformerSecurely mount the transformer using 4 of the supplied mountingscrews. (See Fig. 4)

Secondary Side, 24VPrimary Side

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Fig. 4 -- Transformer

Mount 4--Pole RelayS Securely mount the 4--pole relay using the 2 supplied mounting

screws.

S The 4--pole relay has a set of pre--kitted wires to simplify

installation.

S When the coil is energized, this will allow the control signals to

pass on to the control board.

S The rooftop unit’s Y1 and Y2, W1 and W2 control lines should

be connected through the relays’ Normally Open control points

(See Fig. 8) using the pre--kitted wires.

4-Pole Relay

Transformer

Controller

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Fig. 5 -- 4--Pole Relay Mounting Example

Connect Current Sensors (CTS)S The two current sensors should be carefully clamped around

different legs of the load--side leads, preferably L1 & L2 (L1 is

often the leg powering single--phase fan motors; confirm via

reading current with a clamp--on meter). (See Fig. 6)

S Ensure the locking tabs are fully secured.

S Plug the Molex connector pair from a CT to one of the matching

connectors on the Load Controller cable.

4

2 Legs of Load-Side Leads

CTs CT secured around the load-side leads

Locking Tab

CT Molex Connectormated to one of the

Controller MolexConnectors

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Fig. 6 -- Connecting Current Sensors

Install Antenna and Mounting Base

Magnetic mount with extension wire passed inside cabinet, attached to top of controller

Antenna attached to magnetic mount

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Fig. 7 -- Antenna and Mounting Base

S Locate a smooth surface on the top of the cabinet to secure the

supplied Antenna and Antenna Mounting Base. Ensure there is

sufficient slack on the extension cable to reach the Load

Controller (mounted inside the cabinet). (See Fig. 7)

S Locate a small hole through which the antenna wire can pass

into the cabinet (or drill a hole small enough for the wire).

Ensure a 1/2--in. grommet is used to protect wiring from any

sharp edges.

S Hand--tightened the Antenna to the Mounting Base.

S Hand--tighten the Mounting Base’s extension cable to the

antenna mount on the top of the Load Controller. Do not attach

the antenna directly to the top of a Load Controller.

ACCESSORY RELIABILITY HAZARD

Failure to follow this caution may result in accessorycomponent malfunction.

The antenna must be installed outside of the rooftop unitcabinet to ensure signal broadcast and reception.

CAUTION!

S Glue the Antenna Mounting Base to the top of the rooftop unit

using silicone to ensure it remains fixed even under heavy

winds.

S Use silicone to seal the hole where the antenna cable exits the

cabinet.

Connect Power Lines1. Connect the following wires in parallel to the 24V side of

the transformer:

a. Gateway (Coordinator) Power – RED Pair, (wires 1 &2) (See Fig. 8)

2. Connect the primary side of the transformer to the load--sideleads. If a wire extension is required, use stranded 18 AWGwire.

3. When you power up the Gateway the green WAN light &green power light should be solid within one minute ofpower up. If these lights do not come on please contact RE-GEN Energy’s Operations Center at 949--258--4415, Option#2.

Test Control Line Integration1. Jumper the control lines to force the blower and compres-

sors on.

2. Restore power to rooftop unit.

3. Press the Load Controller’s ON button to power up theLoad Controller.

4. Wait until you see the indicators on the left of the displaylight up in a vertical row.

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5. Press the unlock sequence: Y,B, ENTER. Confirm that theOVERRIDE indicator flashes and the screen displays “rly”,indicating that the Load Controller is in Relay Test Mode.

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6. After the screen displays “rly”, it will then show “1 2”,where: “1” indicates that Relay 1 (blower control line) isclosed and “2” indicates that Relay 2 (cooling and heatingcontrol lines) is closed.

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7. PressB to open Relay 2 and confirm that the compressor(s)turn off (after waiting for any minimum startup runtime de-lays). The display will show “1 –“, indicating that Relay 1 isstill closed, yet Relay 2 is now open.

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8. Press Y to open Relay 1 and confirm that the blower turnsoff. The display then shows “-- --“, indicating that Relay 1and Relay 2 are both open.

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At this point, both blower and compressor(s) should be off.9. Press Y to close Relay 1 and confirm that the blower re-

sumes operation. The display will show “1 –“, indicatingthat Relay 1 is closed, while Relay 2 is still open.

NOTE: Some blowers may have up startup delays.

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10. Wait 20 minutes and then press B to close Relay 2, andconfirm that the compressor(s) resume operation. The dis-play will show“1 2”, indicating that Relay 1 and Relay 2 areboth closed.

NOTE: Some control systems may have up startup delays

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NOTE: The selected relay test settings will remain in place for upto 20 minutes, and up to 10 changes can be made to relay settingsduring each Relay Test, after which the Load Controllerautomatically exits the Relay Test Mode and commences regularoperation.

Do not proceed to the next step until the Relay Test completessuccessfully. The Load Controller can be restarted in Test mode asmany times as desired.

Test Load Controller Signal Strength1. Disconnect all power to the rooftop unit.

2. Remove jumper wires from control lines.

3. Restore all power to the rooftop unit.

4. Turn the Load Controller on, and wait approximately 20seconds until the TRAFFIC indicator turns on, indicatingthat the Load Controller is attempting to boot up in regularoperation mode

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5. Confirm that the READY indicator turns on, and at leasttwo bars of signal strength are visible. Contact REGEN En-ergy’s Operation’s Center (949--258--4415, Option No. 2)for assistance if fewer than two signal strength bars are dis-played.

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LoadController

Y1

G

575V 480V

24V

Y2

Y1

G

5

2

Installation With2 stage unit

Load-Side Power

Stepdown Trasformer

ControlsTerminal Board From

Thermostat

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CT Clamp Sensor 1

CT Clamp

Sensor 2

Om

ron LY4

Four pole R

elayY1

G

W2

W1

W2

W113

14

12

11

10

9

8

7

6

5

FIELD INSTALLED WIRE

6

34

14

15

16

17

18

19

20

21

1

11 12

9

8

7

WIRE NUT CONNECTION

FIELD INSTALLED WIRE

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Fig. 8 -- Standard Wiring Schematic for Thermostat Controls (2--Stage Unit)

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Parts ListThe following equipment is shipped with each Load ControllerAccessory.

1. Load Controller

2. (2) Current Transformers

3. 4--Pole Relay (pre--wired with extension wires)

4. Magnetic antenna base

5. Antenna

6. Mounting screws (supplied in a plastic bag, not displayedbelow

1. Load Controller 2. (2) Current Transformers

3. 4-Pole Relay (pre-wired with extension wires)

4. Magnetic antenna base

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Fig. 9 -- Supplied Parts included with Each Load Controller Accessory

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Site Installation ReportSection 1.- Site Summary

Customer Name

Site Address

Customer Phone Number

Customer Email

Installation Contractor

Section 2.- Installation Details

Qty. of Modems/Gateways (Coordinators) Shipped Installed

Qty. of Load Controllers Shipped Installed

Qty. of 4-Pole Relays Shipped Installed

Qty. of Transformers Shipped Installed

Qty. of Antennas Shipped Installed

Section 3.- Installation Issues

Facility Roof Access Delays: (Ex.: Security, Escort. Clearances, etc.)

List of any RTU #s not operational/disrepair:

(Ex.: RTUs shut down, locked out for service, obvious mechanical problems, etc.)

Customer Name (Print Name) Installer Name (Print Name)

Signature Signature

Date Date

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Load controller RTU Checklist

Load Controller Installation ChecklistSite

RTU #, Zone NameController IDToday’s DateInstaller NameREGEN Energy Operations Center/Support- (949) 258-4415, Option #2

Step Notes

1 Power off RTU2 Install Load Controller and components, incl. wiring. (Re-

fer to wiring schematic)Circle: Standard or Large CTsMax Ampacity:

3 Connect test jumper wires: R to lines on relay that will beconnected to original G, Y1, Y2 lines.

4 Glue antenna base, caulk any drilled openings5 Pause if need to return to previous RTU after

waiting for portal test, note timeTime Paused:Time Resumed:

6 Power up RTU7 Wait until blower and all stages of cooling are

energized, note any startup delays8 Once all stages of cooling energized, measure

amperage on lines where CTs are clamped,measure incoming voltage

Incoming Voltage: 277/480/120/208CT1 Amps:CT2 Amps:

9 Perform relay testUP, DOWN, ENTERFactor in any blower/compressor min. run times and startdelays, note any shutdown delays

Blower Delay:

10 Exit the relay test to start regular operation (press theenter key on the controller. It should read 100)

11 Confirm READY indicator and at least two bars of signalstrength. Change Zigbee channel if directed by REGENsupport.UP, DOWN, UP, UP, ENTERNote time

Channel (default of 11 or new value):# of bars:

12 Move to next RTU, waiting at least 20 min. toreturn

13 When you return, power off RTU14 Remove jumper wires and dress wiring (e.g. tie wraps,

sticky backs)15 Power up RTU & confirm controller connects to net-

work (Confirm READY indicator and at least twobars of signal strength)

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Copyright 2013 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Edition Date: 05/13

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Catalog No: CRDMNDMD001---01IIK

Replaces: NEW