new control box gas controllerrtu-mp controller (opt) command center terminal board (cleaner) design

New Control Box

Gas ControllerRTU-MP Controller

(Opt)

Command Center Terminal Board

(Cleaner) Design

Controls: Cooling

• High Pressure Switch

• Low Pressure Switch

• Indoor Fan Motor Overloads:LinebreakThermik (pilot-circuit)External circuit-breaker

Controls: Cooling

Control Transformer75 va3.2-A circuit breaker on transformer housing

CLO -- Accy or FIOP

CLO Connections

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

Hall Effect

Ref: Honeywell

Hall Effect Sensor

Includes:

Current field

Integrated circuit

Transistor

Amplifier circuit

Hall Effect:Pulse Output Signal

Speed Sensor Logic Criteria

Speed > 2400 RPM: Inducer Motor OK

Speed < 2000 RPM: Combustion Terminated

IGC Alarms

IGC Troubleshooting

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.

IGC Service Reference Material

• NSMM 2003 SPP PPT IGC Alarms

• Technical Base / Hall Effect

• Service Training GT54-01

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

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

Reversing Valve Operation

• No O or B signal required

• Energized in Cooling

• Reversing Valve does not shift mode in Off cycle (No Dump)

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

Heat Pump Electric Heat

Heating Stage 2

Concurrent with compressor(s)

Emergency Heat

Electric Heat WITHOUT compressors

Defrost Tempering

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

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

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)

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

SERVICE MANUAL

CONTROLS TERMINAL BOARD

CONVENIENCE OUTLETS

SMOKE DETECTORS

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

Service Manual: LP Gas Conversion

Service Manual: Heat Pump Piping

Service Manual: Appendix

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

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

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

Controls Terminal Board

11 terminal strips:

J1-J2: Screw terminals (thermostat wires)

0.046-in square pin

18 quick-connect terminals

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

CTB: Actual vs Schematic View

2010 FIOPs

• Convenience Outlets

• Smoke Detectors

• CO2 Sensor (new)

Convenience Outlets

• Non-Powered• Unit-Powered

• Neither is connected as delivered

• Hinged cover shipped loose (in control box)

Convenience Outlets

Non-Powered:

Duplex GFCI

Weatherproof box

Hinged cover

Powered:

Duplex GFCI

Weatherproof box

Transformer

15-A fuse/switch

Hinged cover

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

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.

Powered CO: Label

Powered CO:Transformer Primary Connections

Weatherproof Hinged Cover

Powered Convenience Outlet:Duty Cycle Limit

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”

Smoke Detector Hardware

• Controller Module (one per unit)

• Sensor Module (one or two required)

• R/A application: Sensor tube

Smoke Detectors

R/A Sensor: Site Installation

Smoke Detector: LED

Smoke Detector:Alarm Integration

• Application Tip Cat# HKRNKA-1XA

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

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)

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

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

Economizer Plugs

• Table to help Troubleshoot Economizer wiring at the LVTB and the 12-pin plug

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)

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

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)

Economizer IV

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)

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

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

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

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

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

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.

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

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

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

What’s Next

• Bynum Training program 4th Qtr

Questions???