new control box gas controllerrtu-mp controller (opt) command center terminal board (cleaner) design
TRANSCRIPT
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New Control Box
Gas ControllerRTU-MP Controller
(Opt)
Command Center Terminal Board
(Cleaner) Design
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Controls: Cooling
• High Pressure Switch
• Low Pressure Switch
• Indoor Fan Motor Overloads:LinebreakThermik (pilot-circuit)External circuit-breaker
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Controls: Cooling
Control Transformer75 va3.2-A circuit breaker on transformer housing
CLO -- Accy or FIOP
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CLO Connections
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Controls: HeatingIntegrated Gas Controller (IGC)
• IGC Inputs
Flame Sensor
Hall Effect
W1 Demand Speed Sensor
Rollout Switch
24-v Limit Switch
• IGC OutputsDiagnostic LED
Inducer Motor (CM)
Indoor Blower (BM)
IFO signal
Gas Valve
Sparker
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Hall Effect
Ref: Honeywell
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Hall Effect Sensor
Includes:
Current field
Integrated circuit
Transistor
Amplifier circuit
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Hall Effect:Pulse Output Signal
Speed Sensor Logic Criteria
Speed > 2400 RPM: Inducer Motor OK
Speed < 2000 RPM: Combustion Terminated
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IGC Alarms
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IGC Troubleshooting
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IGC Error Codes: From NSMM 2003 (SPP PPT) in HVACPartners
• Fault 2 – Limit Switch OpenIf limit opens:
• Gas valve and ignitor will be disable • Indoor blower will immediately energized.• Inducer shall remain energized• The indoor blower will turn off after the fan off
delay if “W” goes away.• If limit closes again the fault will clear. If you
still have “W”, the gas valve still open and re-igniton will occur.
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IGC Service Reference Material
• NSMM 2003 SPP PPT IGC Alarms
• Technical Base / Hall Effect
• Service Training GT54-01
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Heat Pump Defrost Board
New PN: HK32EA005
Thermostat demands for 1 or 2 stage Cooling 2 stage HeatingEmergency Heating
Defrost Control in Heating Mode
Based on RES HK32EA003
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Controls: Heat Pump
• HPS High Pressure SwitchOpens 660PSI. Close 505PSI
• LPS Low Pressure Switch (A/C’s) Opens 54PSI. Close 117PSI
• Liquid Line Loss-of-Charge (HP’s)Opens 27PSI. Close 44PSI
• Freeze Protection Thermostat (FPS)Opens 30F. Close 45FConnects to new defrost board
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Reversing Valve Operation
• No O or B signal required
• Energized in Cooling
• Reversing Valve does not shift mode in Off cycle (No Dump)
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Heat Pump Compressor Seq
Cooling Stage 1:Reversing Valve 1 + Compressor
Cooling Stage 2: (2-comp models only)Rev Valves 1+2 + Compressors 1+2
Heating Stage 1:Compressor(s), No Reversing Valve
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Heat Pump Electric Heat
Heating Stage 2
Concurrent with compressor(s)
Emergency Heat
Electric Heat WITHOUT compressors
Defrost Tempering
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Heat Pump Defrost
Time-Temperature Sequence
1. Heat Run Time (30,60,90 or 120 mins) Factory 60 mins
2. Initiate if tube temperature (DFT) low
3.Terminate when tube temperature (DFT) rises or defrost run period reaches 10 min
HH18SA261DFT Settings:Open: 30FClose: 80F
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Defrost Speed-Up
• JMP17-JMP18 (flat/slot screwdriver)
• 1-5 secs: Speed-Up (0.1 sec/min)
• 5-20 secs: Forced DefrostRun to normal termination or30 secs minimum
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Controls: Electric Heat
Accessory installation
1 or 2 stages
Fan housing limit switch (pilot, manual)
Element line-break
(or secondary contactor)
Heater control contactor(s)
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Electric Heat: Single-Point Box
• Required with all electric heater installations
• Splice box with cover
• Power terminal block
• Tap conductors
• If FLA > 48-A:
Fuse blocks and 60-A fuses
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SERVICE MANUAL
CONTROLS TERMINAL BOARD
CONVENIENCE OUTLETS
SMOKE DETECTORS
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Installation Instructionsand
Service Manuals (SM)
The complete unit installation procedure (rig and position through start-up) will require reference to two (or more) technical manuals.
Mechanical Installation: SI (II)
Configure/Start-up/Troubleshoot: SM
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Service Manual: LP Gas Conversion
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Service Manual: Heat Pump Piping
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Service Manual: Appendix
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Specific Topic Tech Support
Smoke Detectors: Application Tip Cat# HKRNKA-1XA
(integration with building alarm systems)
PremierLink: Form 33CS-58SI (configuration, t-s)
RTU-MP: Form 48-50H-T-2T (configuration, t-s)
RTU-MP 3rd Party Integration Guide
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Controls Terminal Board
akaLight Commercial Terminal Board (LCTB)Command Center Terminal Board
Carrier PN HK50AA049UTEC PN CEPL130904-01
Array of terminal strips, housings and QCsContains NO LOGIC, no software
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Controls Terminal Board
LPS HPS
OR
OR
Fire / Remote Shutdown
Smoke Alarm
Gas Controller
Phase Monitor
Provides:
- Clean connection points
- Insures positive connections
- Visual aid
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Controls Terminal Board
11 terminal strips:
J1-J2: Screw terminals (thermostat wires)
0.046-in square pin
18 quick-connect terminals
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CTB: Jumpers
• JMP1 Phase Monitor
• JMP2 Occupancy Control
• JMP3 Smoke Detector Shutdown
• JMP4 Remote Shutdown
• JMP5, 6, 7 Heat Pump / Reheat
JMP7 JMP5JMP6
JMP1
JMP4
JMP3
JMP2
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CTB: Actual vs Schematic View
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2010 FIOPs
• Convenience Outlets
• Smoke Detectors
• CO2 Sensor (new)
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Convenience Outlets
• Non-Powered• Unit-Powered
• Neither is connected as delivered
• Hinged cover shipped loose (in control box)
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Convenience Outlets
Non-Powered:
Duplex GFCI
Weatherproof box
Hinged cover
Powered:
Duplex GFCI
Weatherproof box
Transformer
15-A fuse/switch
Hinged cover
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Non-Powered CO
• Provide a separate 115-v 15-A power supply and circuit disconnect from the building
• Connect to the duplex outlet in the unit’s splice box
• Install the weatherproof hinged cover
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Powered CO
• Check local codes to determine if connecting the convenience outlet transformer to the LINE side of the unit disconnect is acceptable.
• If acceptable: Connect primary leads at the power transformer together as required for unit line voltage and connect to unit disconnect’s line side terminals.
• If not acceptable: Connect primary leads at the power transformer together as required for unit line voltage and connect to unit disconnect’s load side terminals.
• Install the weatherproof hinged cover.
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Powered CO: Label
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Powered CO:Transformer Primary Connections
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Weatherproof Hinged Cover
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Powered Convenience Outlet:Duty Cycle Limit
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Smoke Detector FIOPs
• Supply Air (on supply fan housing)• Return Air w/o Economizer• Return Air with Economizer• Combine S/A and R/A
R/A Smoke Detector is for VERTICAL only
“Some assembly required”
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Smoke Detector Hardware
• Controller Module (one per unit)
• Sensor Module (one or two required)
• R/A application: Sensor tube
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Smoke Detectors
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R/A Sensor: Site Installation
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Smoke Detector: LED
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Smoke Detector:Alarm Integration
• Application Tip Cat# HKRNKA-1XA
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NEW FIOP:Unit-Mounted CO2 Sensor
• Same control logic as on accessory CO2
• No LCD display on sensor
• Requires PC access to configure
• Software and cable available thru RCD
• Details to follow in full training program
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2010 SRT FIOPs
• Economizers (15th digit)
• CO2 sensors (9th digit)
• Smoke Detectors (9th digit)
• Louvered Hail Guard (11th digit)
• 2-position Damper (15th digit)
• Convenience Outlet (16th digit)
• Thru-The-Base Connections (17th digit)
• PremierLink (14th digit)
• RTU-MP/Open (14th digit)
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2010 SRT Accessories• Economizers & Roofcurbs• CO2 & Enthalpy sensors• Power Exhaust • Motormasters (low ambient) and winter start• LP Conversions• High Altitude Kits• 2-pos damper / Man damper• Thru-The-Base• Louvered Hail Guards• Electric Heat / Single Point• Phase Monitor, Status switch, time guard• PremierLink
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Economizer Plugs• Command Center aka Low
Voltage Terminal Board (LVTB) ECON 10pin Plug
• Used for all Economizers SAT/OAT 4pin Plug
• Used for Econ 2 only OCCUPANCY Terminals
• Used for Econ IV and 2-pos Damper
• 12-Pin Plug (male) – Unit Side plug in Econ Section Same plug and arrangement as old
units
• 12-Pin Plug (female) – Econ Side Comes with specific FIOP or
Accessory Small change on the Econ IV plug
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Economizer Plugs
• Table to help Troubleshoot Economizer wiring at the LVTB and the 12-pin plug
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Economizer IV
• Electro-mechanical Unit Economizer
• Stand alone operation with Honeywell W7212 controller.
• Compressor control runs through the W7212If no econ then jumpers must be in 12-pin plug
for cooling to operate
• Actuator is 2-10 vdc pre-programmed ready for W7212 output
• SAT in 12-pin plug (PL6)
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Economizer IV• Added occupancy control
The “N” terminal tells the controller when occupied R-22 units had W7212 main power fed from the IFC and jumper to the N
terminal 410a units have main power fed from transformer, and IFC feeds the N
terminal trough the Occupancy terminals So W7212 is powered up when the unit is, instead of only when the fan
is on• Low Ambient Lockout
The “LA” switch is installed on the Y2 input to the controller Part number HH18HA286, Contacts Open: 42°F ±5°F, and Contacts
Close: 57°F. ±5°F. Below 42°F the second compressor will not run, econ will be stage one
and 1st comp is stage 2• Power exhaust wire
Tan wire that is connected to 24Vac HOT, move to EF1 Add jumper from 24Vac HOT to EF Connect other end of the tan wire to the tan wire in the PE Kit harness Connect the Grey wire in the PE kit harness to the 24Vac COM terminal
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Economizer IV• CO2 Sensor
IAQ install, uses 24Vac (TR & TR1), and 0-10Vdc signal (AQ & AQ1), TR1 & AQ1 are common
Demand Control Ventilation (DCV) is the only CO2 control available for Econ IV. • DCV SET (POT) tells the controller at what input vdc from the IAQ sensor do we
want to start opening the damper• DCV MAX (POT) tells the controller at what damper position do you want us to
stop opening for DCV• The damper will modulate between the MIN POS (POT) and DCV MAX (POT) settings
proportional to the IAQ vdc input from DCV SET (POT) to 10Vdc• Enthalpy
The Single Enthalpy sensor uses the same terminals as dry bulb (SO+ & SO). For Differential Enthalpy, 2 enthalpy sensors required. One installed per
above and the other on terminals SR+ & SR (after removing the resistor). Set the cross over POT to “D”
• Whichever is lower is the air used for cooling• Remember O for outdoor and R for Return
Enthalpy sensors are HH57AC078 and Dry bulb are HH57AC074• Power Exhaust (PE)
Terminals EF and EF1 are dry contacts and switch when the damper pos (in Vdc) gets above the EXH SET (POT) setting (in vdc)
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Economizer IV
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Economizer 2
• Econ2No controller, requires Plink or RTU-MP/openJumper wires in 12-pin plug for cooling
operationActuator is 2-10vdc pre-programmed
• 500 ohm resistor (pre-installed) required for 4-20 controller output
OAT in 12-pin plug (PL6)
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Economizer 2
• CO2 Sensor IAQ is installed on the specific controller via PL18 for FIOP and
direct to controller when field installed
DCV is set in the specific controller with a user interface.
• Enthalpy (only field installed) Single or Differential control from the DDC controller
Uses the 2 loose Grey wires near unit’s 12 pin plug
Sensor wires run to the LVTB and then to DDC
• PE Wires provided with the PE accessory have to be run to the
control box specifically to which ever DDC is installed
Switch one stage on and off based on damper position
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Economizer 2
• Cooling jumpers must be in harness for cooling to work
• Resistor must be between the White signal wire and Black actuator common Actuator is 2-10v and
controllers output 4-20mA• Enthalpy sensor power from
Actuator power Switch signal using 2 grey
wires• When troubleshooting
Read vdc across resistor• Determine if it’s the actuator or
the controller Shorting the actuator signal to
24VAC will drive it 100%, but disconnect the actual signal first
Spring return Closed Direction switch set to same
direction as the spring return
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2-Position Damper• Opens to set position
whenever the fan is running• To set position, set the screw
on the actuator face near the shaft opening
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Low Ambient • Winter start Kit (CRWINSTR001A00)
3 minute timer relay to bypass low pressure switch Field supply wires to tie into the LVTB, contact
across LPS and coil between HPS and compressor contactor
Current Literature – IIK-CRWNTRAN01-01• Motormaster I (32LT)
Wave Chopper, varies voltage to vary fan speed, single phase approved motors, clip on sensor
May need to replace motor and capacitor. Usage chart in literature.
Copper Coil Controller with sensor – 32LT900301 (230v), and 32LT900611 (460v)
MCHX coil controller with sensor – 32LT901247 (230v), and 32LT901647 (460v)
Tries to maintain 100 deg SCT, unit operation down to -20 deg
Current Literature – IIK-32LT903-01
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Low Ambient
• Motormaster II (CPLOWAMB001A00) Fan cycle switch, on/off only, single phase motors, clip on sensor Tries to maintain 130-110 high and 70-50 low SCT, unit operation
down to -20 deg
• Motormaster V Kits CRLOWAMB030A00, 031A00, and 032A00 for specific
voltage For use on three phase motors (48/50TC 14 and 50TCQ 12) VFD, varies frequency (HZ) to vary fan speed, 3 phase approved
motors Pressure sensor on liquid line, unit operation down to -20 deg
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Gas Conversion Kits
• High Altitude ConversionPick kit based on orifices neededUse only spuds and High-Alt label in kitSome spuds may have to be purchased separatelyLiterature contains conversion tables
Four kits for use with LP and/or high altitude applications. Each contain 25 spuds, 5 of 5 different sizes.
Manifold PressureNatural Gas still 3.5-in.wc.LP now 10.5-in.wc.
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Gas Conversion Kits
LPS
• LP Conversion New, low pressure switch on supply side
• Closes at 10.2-in.wc. and opens at 7.2-in.wc.• Gas piping included in kits
Kits include springs for gas valve to operate at higher pressure Labels for LP and high alt (if needed) Chose Kit based on orifices needed, some orifices may have
to be purchased separately
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Controls• PremierLink
FIOP or Accessory. If field installed make sure the CRPREMLK001A01 kit was also purchased. It has the harness for LVTB and the TB to install other accessories to.
• RTU-MP FIOP only and only available through mid-2009 Overview training PES0810302 on partners Controller training PES0803241 on Partners Other information and tools on HVACpartners (CCN Support – Multi-
Protocol Controls)
• RTU-Open Only FIOP until 3 Qtr 2009, then the retrofit should be available Replaces the RTU-MP, direct replacement Improved control and improved networking Fixes battery memory with flash memory, otherwise hardware is the
same
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RTU-Open Support
• Contact Equipment Product support for: Specific base unit operation or problems Questions/problems with the Controller or how it controls the unit,
if it was Factory installed (FIOP) Questions/problems with how the FIOP was installed Controller operation, start-up, configuration, and troubleshooting
questions
• Contact CCN support for: Network Integration and Communication questions or problems Questions/problems with the controller if it was field installed
(accessory) Questions/problems with the accessory installation Controller operation, start-up, configuration, and troubleshooting
questions
Open release – FIOP around June 2009 – Accy around July 2009
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What’s Next
• Bynum Training program 4th Qtr
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Questions???