Installation, Start-Up and Service Instructions

Transcription

1 Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS... 1 PRE-INSTALLATION General... 1 Warranty...10 Unit/Ceiling Coordination...10 Unit-to-Unit Connections...10 Unit Suspension...10 INSTALLATION Step 1 Install Terminal...10 T-BAR CEILING TEGULAR CEILING Step 2 Mount Control (If Required)...15 Step 3 Install Sensor and Make Field Wiring Connections...15 GENERAL POWER WIRING SPACE TEMPERATURE SENSOR INSTALLATION AND WIRING CARRIER COMFORT NETWORK (CCN) INTERFACE CONTROL ADJUSTMENTS System Calibration of the TCU/Velocity Sensor Combination...22 Individual Zone Balancing and Calibration...22 BALANCING 37HC MODULINE TERMINALS Variation in Maximum Airflow...24 START-UP...26 General...26 Primary System Check...26 Control System Check...26 System Start-Up...26 MAINTENANCE...26 TROUBLESHOOTING...27 SAFETY CONSIDERATIONS 37HC Moduline VAV Air Terminals With Product Integrated Controls (PIC) If it is necessary to remove and dispose of mercury contactors in electric heat section, follow all local, state, and federal laws regarding disposal of equipment containing hazardous materials. PRE-INSTALLATION General Moduline units are integral diffuser air terminals. They are available with various control devices for constant volume and variable volume heating and cooling applications. The 37HC Moduline air terminal is equipped with Product Integrated Controls (PIC) providing pressure-independent variable air volume (VAV) control as part of the Carrier Comfort Network (CCN). All units consist of a plenum, valve assembly, and diffuser. A typical unit is shown in Fig. 1. The plenum is thermally and acoustically insulated and contains a distribution baffle to provide well-distributed flow to the valve assembly. Figure 2 shows a cross section of a typical 37HC unit. SAFETY NOTE Air-handling equipment will provide safe and reliable service when operated within design specifications. The equipment should be operated and serviced only by authorized personnel who have a thorough knowledge of system operation, safety devices, and emergency procedures. Good judgement should be used in applying any manufacturer s instructions to avoid injury to personnel or damage to equipment and property. Fig. 1 37HC Moduline Air Terminal Disconnect all power to the unit before performing maintenance or service. Unit may automatically start if power is not disconnected. Electrical shock and personal injury could result. Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 3 PC 201 Catalog No Printed in U.S.A. Form 37HC-1SI Pg 1 Replaces: New Tab 6a

2 The valve assembly includes the bellows, which is inflated in proportion to the duct pressure to regulate airflow to the space. The bellows is constructed of durable polyurethane. The assembly is connected at either end to 1/4-in. OD control tubing. The diffuser assembly is available in a 2-slot, one- or 2-way blow configuration. A 3-slot director diffuser is available for use in cooling/heating applications. The standard diffuser assembly is not removable. Control access is made through a ceiling opening (e.g., a removable ceiling tile) or nearby light fixture. Figures 3-5 show unit dimensions for 37HC1, 37HC2, and 37HC4. Figures 6 and 7 show dimensions of optional diffusers. The 37HC Moduline units are designed for installation in standard, narrow, and tegular T-bar ceilings. They are also available for custom ceilings where access to controls will be provided. All 37HC Moduline units can be installed as single units or in an air series. Layout guidelines for proper installations can be found in the 37HS Application Data book. It is important that these directions be read before attempting an installation. CONTROLS The 37HC Terminal PIC system consists of a terminal system manager (TSM), a terminal control unit (TCU), and a space temperature sensor (SPT). The TSM and SPT are sold separately. The TSM is remote mounted on the control network. The TCU, also called the PIC control box, is mounted on the air terminal unit. The 37HC terminal is shipped with all tubing factory installed between the terminal and the TCU. The TCU includes the following factory-supplied hardware: terminal control module two solenoid valves for bellows control airflow transducer (velocity sensor) wiring harness and terminal board filter The SPT must be mounted on a wall in the conditioned space. The SPT contains a communication port and an override button. The terminal control module monitors a differential velocity pressure signal across the baffle inside the Moduline terminal. This differential signal is compared to a set point to provide pressure-independent control of the air passing through the terminal. A wall-mounted SPT monitors room temperature changes and sends a signal to the terminal control module to satisfy zone demand. Figure 8 shows a typical installation of a 37HC Moduline control system. STORAGE AND HANDLING Inspect for damage upon receipt. Shipping damage claims should be filed with a shipper at time of delivery. Store in a clean, dry, and covered location. When unpacking units, care should be taken that the inlet collars and externally mounted components do not become damaged. Do not lift using collars, sensors, or externally mounted tubing as handles. Do not lay unpacked units on end or sides. Do not manhandle. Do not handle control boxes by tubing connections or other external attachments. INITIAL INSPECTION Once items have been removed from the carton, check carefully for damage. File claim immediately with transportation agency and notify Carrier. UNIT IDENTIFICATION Units are factory shipped, one per carton. Each carton contains a shipping label with the model number, and each unit contains a nameplate with the model number and other significant information. Figure 9 shows 37HC model number nomenclature; Fig. 10 shows the unit identification label. Fig.2 Typical 37HC Moduline Unit Cross Section 2

3 DIMENSIONS (in.) PLENUM SIZE B 1 B 2 C D E G H J PIC Product Integrated Control STANDARD DIFFUSER LENGTHS AVAILABLE (IN INCHES) A F A F Fig. 3 37HC1 Unit Dimensions 3

4 DIMENSIONS (in.) PLENUM SIZE (SQUARE) C D E G H J B PIC Product Integrated Control STANDARD DIFFUSER LENGTHS AVAILABLE (IN INCHES) A F Fig. 4 37HC2 Unit Dimensions 4

5 DIMENSIONS (in.) PLENUM SIZE (SQUARE) C D E G H J B PIC Product Integrated Control STANDARD DIFFUSER LENGTHS AVAILABLE (IN INCHES) A F Fig. 5 37HC4 Unit Dimensions 5

6 37HC1 (100 Cfm) CEILING T-BAR STYLE AND WIDTH STANDARD T-BAR TEGULAR T-BAR CONTINUOUS RUN T-BAR NARROW 9 16 T-BAR DIFFUSER LENGTH (in.) HC2 (200 Cfm) CEILING T-BAR STYLE AND WIDTH STANDARD T-BAR TEGULAR T-BAR CONTINUOUS RUN T-BAR NARROW 9 16 T-BAR DIFFUSER LENGTH (in.) Fig. 6 Optional Diffusers for 37HC1, HC2 37HC4 (400 Cfm) CEILING T-BAR STYLE AND WIDTH STANDARD T-BAR TEGULAR T-BAR CONTINUOUS RUN T-BAR NARROW 9 16 T-BAR DIFFUSER LENGTH (in.) Fig. 7 Optional Diffusers for 37HC4 6

7 SPT Space Temperature Sensor TCU Terminal Control Unit TSM Terminal System Manager Fig. 8 Basic Elements of CCN System With 37HC Moduline Terminal 7

8 Example: Model No. 37HC2A3862LNC describes a 200 cfm unit with a 120 v transformer for control package, 9-in. x 9-in. plenum, inlet diameter of 8 in., outlet diameter of 6 in., and a 2-way blow, 2-slot, in. long diffuser. The unit is standard order and is shipped in a single carton. Fig. 9 37HC Model Number Nomenclature 8

9 NOTES FOR FIG. 9 * AVAILABLE COMBINATIONS OF PLENUM AND COLLAR SIZES UNIT SIZE 37HS PLENUM SIZE (in.) INLET DIAM (in.) OUTLET DIAM (in.) 5x x x (100 Cfm) 9x x x x x x x (200 Cfm) 9x x x x x x (400 Cfm) 11x11 11x x x See Options, Fig. 6 and 7, and Unit Dimensions, Fig. 3-5, for available diffuser lengths by unit size. **For E-Z Sell Units, bracket option must be specified in position 14. NOTES: 1. A 37HC is a 37HS Moduline terminal with a factory-installed terminal control unit (TCU). A field-installed control is available using standard 37HS slave units with a separate TCU control package: 37HC (120 v, 1 ph) 37HC (208 v, 1 ph) 37HC (277 v, 1 ph) 37HC (no transformer) Installation of slave units is covered in 37HS Installation Instructions. 2. Space temperature sensor control packages for the 37HC are: 37HC T55 with override 37HC T56 with set point adjustment and override Fig. 10 Unit Identification Label 9

10 Electronic Control Location Each 37HC has a control address which identifies for the TSM the location of the TCU. Before installation, each Moduline unit should be checked for the proper address. Job drawings should identify each unit by number. The DIP (dual in-line package) switch in each unit control box should be compared to the job drawings and to Table 1 to verify that the unit is properly addressed. The DIP switches can be set in the factory or in the field. CODES Install units in compliance with all applicable code requirements. SERVICE ACCESS Provide service clearance for unit access. Refer to dimension drawings, Fig. 3-5, to determine clearance required to service the unit control box. Accessibility through the ceiling (by use of removable ceiling tile or access door) is required to reach the clearance space. Warranty All Carrier-furnished items carry the standard Carrier warranty. Unit/Ceiling Coordination Set up a ceiling mock-up to familiarize all trades with their functions during installation. Coordinate unit installation with ceiling construction. This is particularly important in custom installations with special mounting considerations. Unit-to-Unit Connections Use field-fabricated round duct or flex duct as required. Unit Suspension T-BAR SUPPORT Units are held in place by 2 accessory T-bar mounting brackets and are locked in place with factorysupplied wedges. The mounting brackets fit over the main T-bars, allowing the T-bars to carry unit weight. Install T-bar support wires close to each end of T-bar mounting brackets. Make sure that only wire-hung, main T-bars are used to support unit weight. Figure 11 shows a 37HC unit suspended in a T-bar ceiling. OTHER SUPPORTS When installed in accessible ceilings that require wire-hung units, the 37HC is held in place by field-installed accessory hanger mounting brackets. The brackets are wire-hung from the building structure and are adjustable for proper unit alignment. Figure 12 shows a 37HC unit wire-hung from the building structure. When units are wire-hung in accessible ceilings, T-bar mounting brackets can be used for ceiling alignment. INSTALLATION Step 1 Install Air Terminal Installation accessories are shown in Table 2. Table 1 Configuration of DIP Switches for Unit Address DIP ADDRESSES (*INDICATES SWITCHES TO BE SET TO ON ) SWITCH NO * * * * * * * * * * * * * * * * 2 * * * * * * * * * * * * * * * * 3 * * * * * * * * * * * * * * * * 4 * * * * * * * * * * * * * * * * 5 * * * * * * * * * * * * * * * * 6 * * * * * * * * * * * * * * * * * 2 * * * * * * * * * * * * * * * * 3 * * * * * * * * * * * * * * * * 4 * * * * * * * * * * * * * * * * 5 * * * * * * * * * * * * * * * * 6 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 7 * 8 DIP Dual In-Line Package 10

11 Table 2 Installation Accessories for 37HC Units ADAPTER CAP, Qty 12 Adapter Package No. For 6-in. round adapter 37AH For 8-in. round adapter 37AH For 10-in. round adapter 37AH DIFFUSER BAFFLE, Qty 50 Length (in.) Used On Package No. 37HC1, HC2 8 37AH HC CN T-BAR MOUNTING BRACKETS, Qty 24 (with wedges) Used On 37HC1, HC2 Package No. T-Bar 37CM Slot Tegular (in.) CM CM CM CM CM T-Bar 37CM Slot Tegular (in.) CM CM CM CM CM Used On 37HC4 Package No. T-Bar 37CN Slot Tegular (in.) CN CN CN CN CN T-Bar 37CN Slot Tegular (in.) CN CN CN CN CN T-Bar Tegular MOUNTING BRACKETS FOR RETURN AIR AND DUMMY DIFFUSERS Unit Package No. Qty One-Piece Mounting Bracket 37HC1, HC2 2-Slot T-Bar 35BD HC1, HC2 3-Slot T-Bar 37CM HC4 2-Slot T-Bar 37CN Piece Mounting Bracket 37HC4 3-Slot T-Bar 37CN FILLER TRIM PIECE, Qty 100 Used On Diffuser Pkg. No. 37HC1, HC2 2-Slot, One- or 2-Way Blow 37HS Slot 37HS Used On Diffuser Pkg. No. 37HC4 2-Slot, One- or 37HS Way Blow 3-Slot 37HS NOTE: For use with wire-hung units and continuous run units in accessible ceilings. Do not use with removable diffusers. END TRIM, Qty 50 Used On 37HC1, HC2 Color Package No. T-Bar* White 37CM Slot Tegular White 37CM Black 37CM Black & 37CM White 3-Slot T-Bar* White 37CM Tegular White 37CM Black 37CM Black & 37CM White Used On 37HC4 Color Package No. T-Bar* White 37CN Slot Tegular White 37CN Black 37CN Black & White 37CN Slot T-Bar* White 37CN Tegular White 37CN Black 37CN Black & White 37CN T-Bar Tegular *Used in continuous run units in nonaccessible ceilings (to fill space between units) and in concealed spline and plaster ceilings to finish off end of diffuser. Used to finish the exposed end of diffuser. ALIGNMENT PLATE, Qty 100 Used On Diffuser Pkg No. 37HC1, 37HC2 37HC4 2-Slot, One- or 2-Way Blow and 3-Slot 2-Slot, One- or 2-Way Blow and 3-Slot 37HS HS NOTE: For use with wire-hung units and continuous run units in accessible ceilings. Two plates required per connection. TUBING PACKAGES Usage Type Qty Pkg No. Wall Thermostat & Interconnecting Units Miscellaneous Connections 1 4-in. OD FR (Fire Retardant) Tubing 3 16-in. ID EPDM (Synthetic Rubber) Tubing 250- ft roll 100- ft roll HANGER MOUNTING BRACKET Package No. 37AE BB AE

12 T-BAR CEILING NOTE: Moduline systems are normally designed with multiple unit and control arrangements within a single system. Proper system operation is dependent on careful adherence to the specified job layout. Become familiar with and check the various control arrangements required on a particular job before installing the terminals. 1. Move units in cartons to installation area. 2. Remove units from cartons and discard packaging material. Do not remove protective tape from diffuser. When handling units, take care not to damage diffusers and adapters. 3. Arrange units on floor per design layout, diffuser side up. Check unit identification. 4. Wherever a unit is to be installed directly to another unit, attach field-supplied connecting duct (flex or metal duct) to one unit with screws or other mechanical fasteners before installing the next unit. Seal joint. 5. Install T-bar mounting bracket in each end of unit as shown in Fig. 13. Insert bracket in unit side diffusers and push evenly until bracket seats against diffuser end. 6. Raise unit above ceiling and lower into position. Engage T-bar mounting bracket tabs securely over main T-bars. Do not rest unit diffusers on T-bar flanges. Install 2 locking wedges on each bracket between bracket and T-bar. See Fig. 14. It may be desirable to crimp the bracket wedge assembly with pliers to ensure tightness. 7. On single-unit applications, make supply air connection directly to adapter on end of unit. 8. If other units are to be connected to the first unit, install T-bar mounting brackets on each end of the adjoining units. 9. Raise each unit above ceiling and lower into position. Engage mounting brackets over main T-bar. Reposition locking wedges at mounting bracket so that they also secure the mounting bracket of the adjoining unit. 10. Connect interconnecting duct between units, and seal. Installation of Return-Air Diffusers Install one-piece mounting brackets onto diffuser ends using screws provided. See Fig. 15. (For 37HC 3-slot director diffuser, use 2-piece mounting bracket.) Raise unit to ceiling and set in position with the tabs of the mounting bracket placed securely over the T-bar upright. Fig. 13 Installing T-Bar Mounting Bracket T-BAR SUPPORT WIRE (MAIN T-BAR MEMBER) WEDGE Fig HC Unit Installed in a T-Bar Ceiling WEDGE MOUNT BRACKET Fig. 14 T-Bar Mounting Details Fig HC Unit Wire-Hung in a T-Bar Ceiling 12

13 Wire-Hung Installations (With T-Bar Mounting Brackets Used for Alignment) Install accessory hanger mounting brackets, 2 on each end of the 37HC unit, and attach eyebolts as illustrated in Fig. 16. Install T-bar mounting brackets in end of diffuser; then raise units above ceiling and lower to previously installed hanger wires. Be sure to engage tabs of T-bar mounting brackets over T-bar. Adjust eyebolts to permit T-bar mounting brackets to just sit on the ceiling T-bars. All unit weight must be supported by the hanger wires on the unit. Continuous Run Installations Continuous run units have diffuser lengths equal to the full length of the ceiling module; for 2-, 4-, and 5-ft modules, the diffusers measure 24, 48, and 60 in., respectively. Units are wire-hung as described in Wire-Hung Installations section, except that no T-bar mounting brackets are used, not even for alignment. Instead, accessory alignment plates are used in the side diffusers of adjoining units to ensure alignment of the diffuser assemblies from unit to unit. As shown in Fig. 17 and 18, a plate is inserted first into a unit that has already been installed, and then into the next unit as the unit is being positioned in the ceiling structure. After alignment plates have been installed, filler trim piece can be installed with 2 pop rivets. See Fig. 19. Fig. 17 Inserting Alignment Plate into Unit ALIGNMENT PLATE FILLER TRIM PIECE Fig. 18 Installed Alignment Plate and Filler Trim Piece Fig. 15 One-Piece Mounting Bracket Installed on Diffuser End Fig. 19 Installation of Filler Trim Piece Fig. 16 Installed Hanger Mounting Brackets 13

14 TEGULAR CEILING A tegular (recessed T-bar) ceiling is constructed the same as a standard T-bar type ceiling, except that each lay-in ceiling panel is rabbeted. This means that the panel is notched to fit over the T-bar. When installed in the T-bar frame, the panel hangs below the grid. From inside the room, the ceiling effect is that of a recessed grid. This variation of the standard T-bar concept provides all the T-bar ceiling advantages (simplicity, ease of installation, low first-cost, and accessibility) with an architecturally more attractive appearance. Tegular (recessed T-bar) ceilings are provided by many ceiling manufacturers under various trade names, but are basically of the same design. All models of 37HC Moduline air terminals are adaptable to the recessed T-bar ceiling. They are applied in a manner similar to the standard T-bar ceiling. The system usually consists of a in. grid member suspended by wires to form a 4-ft x 4-ft module. These support wires should be located very near to the terminals and lights to avoid twisting of the grid. The module is further subdivided using cross T-bar members creating sub-modules. Each sub-module may be filled with a light fixture or a tile. The 37HC Moduline terminal may be used in the center of a 2-ft x 4-ft ceiling tile, or to replace a recessed T-bar member. In either case, the tile is cut and rests directly on the unit side diffuser, so that the unit is flush with the ceiling tile plane. The recessed T-bar may be painted (sometimes black with white tiles) to create an interesting grid pattern. The 37HC unit center diffuser (when installed on the grid line) may be painted to match. The depth of the notch or rabbet (dimension from grid face to tile face) varies from manufacturer to manufacturer but is normally between 3 16 in. and 5 8 inches. The mounting package for recessed grid (tegular) installation differs from the standard T-bar mounting package. The proper mounting package for the 37HC Moduline air terminal must drop the unit to the level of the tile face (below the T-bar grid face). The mounting bracket slides into the ends of the diffuser and engages the T-bar. Wedges are used to secure the units in place. It may be desirable to crimp the bracket wedge assembly with pliers to ensure tightness and unit alignment. Figure 20 shows a 37HC Moduline air terminal unit in a typical 2-ft x 4-ft recessed T-bar ceiling. For this application, the overall diffuser length of the unit is inches. For 5-ft x 5-ft ceiling module, the diffuser length used is inches. This shorter diffuser is used to allow room for 2 end trim pieces which finish the exposed end of the installed unit. This length is also used for dummy diffusers and return-air diffusers when used in recessed T-bar ceilings. The end trim piece is installed between the unit diffuser ends and the T-bar and is held in place by bending the end piece over the unit mounting bracket as shown in Fig. 20. Fig. 20 Typical Tegular (Recessed T-Bar) Ceiling Installation Using 37HC Air Terminals 14

15 Step 2 Mount Control (If Required) The 37HC is shipped with all tubing factory-installed between the control module (TCU) and the Moduline unit, including fittings and end piece. A separately ordered terminal control module is available for field mounting on standard 37HS slave units; the fittings and end piece are furnished with this module as part of the tubing. Figure 21 shows the locations of the tubing from the control box and the corresponding connection points at the unit. Figure 22 shows the fittings and end piece for each of the 4 tubes. Figure 23 shows the tubing at the unit end. Figure 24 shows the control tubing connections for master and slave units. HIGH O-RING FITTING LOW O-RING FITTING EPDM BELLOWS TUBE FR FEED TUBE Step 3 Install Sensor and Make Field Wiring Connections GENERAL The 37HC is shipped completely wired except for connections between the SPT and the TCU; the power wiring; and the CCN connections between the unit and the TSM. These wiring connections must be made in the field. Table 3 shows controller specifications. Refer to Fig. 25 for control box component locations. FR Fire Retardant Fig. 22 Tubing End Connections HIGH LOW FEED Disconnect electrical power before wiring inside the TCU or electrical shock and personal injury could result. BELLOWS Fig. 23 Tubing Connections to Unit Fig. 21 Tubing Connections 15

16 SINGLE MASTER UNIT INSTALLATION MASTER UNIT WITH ONE SLAVE FR Fire Retardant MASTER UNIT WITH 3 SLAVES Fig. 24 Control Arrangements Master Units with Slaves Table 3 Controller Specifications SOLENOID VALVES FEED FILTER TERMINAL BLOCK VOLTAGE FREQUENCY OPERATING TEMPERATURE OF UNITS Fire Rated Tubing THERMOSTAT RANGE TRANSFORMER Cooling Only Baseboard Heating CONDITION LIMITS Shipping and Storage Temperature Humidity Operating Temperature Humidity *Special order. 24 vac ( 6, 4) 50/60 Hz 32 to 130 F 0.25 in. OD 32 to 120 F 15 va 30 va* 40 to 185 F 10 to 95% Noncondensing 32 to 130 F 10 to 90% Noncondensing 16 TRANSFORMER TERMINAL CONTROL MODULE BELLOWS TRANSDUCER Fig HC Control Box

17 Factory Piping Provided Factory Wiring Provided Wiring by Others Fig. 26 Piping and Wiring Connections on the 37HC Moduline Unit (Schematic Only All Components Are Mounted in Control Box) 17

18 POWER WIRING 37HC Cooling Only The 37HC is furnished with a 24-vac transformer wired into the control box. For cooling applications the transformer will be 15 va. The 37HC can also be furnished without transformer, with 24-v power supplied in the field. Power should be connected to the control terminal block as show in Fig HC Cooling With Separate System Heating The transformer furnished will be 30 va. (Available by special order only; contact factory.) SPACE TEMPERATURE SENSOR INSTALLATION AND WIRING The SPT sensor is packaged and sold separately. It is installed on interior walls to measure room space air temperature. The wall plate accommodates both the NEMA (National Electrical Manufacturing Association) standard and the European 1 4 DIN standard. The use of a junction box to accommodate the wiring is recommended for installation. The sensor may be mounted directly on the wall, if acceptable by local codes. DO NOT mount the sensor in drafty areas such as near heating or air-conditioning ducts, open windows, fans, or over heat sources such as baseboard heaters or radiators. Sensors mounted in those areas will produce inaccurate readings. Avoid corner locations. Allow at least 3 ft between the sensor and any corner. Air in corners tends to be stagnant resulting in inaccurate sensor readings. Sensor should be mounted approximately 5 ft up from the floor, in an area that best represents the average temperature found in the space (zone). The space temperature sensor cover includes terminal block TB1, a jumper between Pin E1 and Pin E3, and an RJ11 plug. If wiring connection is made to the RJ11 plug, the RJ11 female connector can then be used to connect a network service tool with the Carrier Comfort Network. Before installing space temperature sensor, decide whether or not the RJ11 plug wiring connection will be made. If RJ11 plug wiring connection is desired, the CCN communication cable should be available at time of sensor installation, for convenient wiring connections. The cable selected must meet the requirements for the entire network. See Table 4 for CCN communication cable specifications. DO NOT run sensor or relay wires in the same conduit or raceway with Class 1 AC or DC service wiring. DO NOT abrade or nick the outer jacket of cable. DO NOT pull or draw cable with a force that may harm the physical or electrical properties. DO NOT bend a cable through a radius sharper than that recommended by its manufacturer. AVOID splices in any control wiring. Jumper must be in place between pin E1 and pin E3 or inaccurate temperature readings will result. See Table 5 for Thermistor Resistance vs Temperature values. NOTE: Space temperature sensor will be identified as T-55 or T-56. (The difference between T-55 and T-56 is that T-56 includes set point adjustment capability.) Wire used for T-55 is shown in Table 6; wire used for T-56 is shown in Table Table 4 Recommended Cables for Communication Bus Wiring and SPT Sensor T-56 MANUFACTURER CABLE NO. Alpha 2413 or 5463 American A22503 Belden 8772 Columbia *3-Conductor, 20 AWG (American Wire Gage). Table 5 Thermistor Resistance vs Temperature Values for Space Temperature Sensor RESISTANCE (Ohms) TEMP (F) RESISTANCE (Ohms) TEMP (F) Table 6 Recommended Wiring for SPT Sensor T-55 MANUFACTURER PART NUMBER Regular* Plenum Belden Columbia D6451 American A21501 A48301 Quabik 6130 Alpha 1895 Manhattan M13402 M64430 *Regular Wiring jacketed or non-jacketed wire. Plenum Wiring The jacketed wire approved by UL (Underwriter s Laboratories) for plenum spaces above dropped ceilings. NOTE: Wiring is 20 AWG, 2 conductor twisted cable.

19 Install and wire the space temperature sensor as follows: 1. Refer to Fig. 27. Remove sensor cover. Using a small blade screwdriver, insert blade into sensor cover latch slot on bottom of slat. Gently push upward on the screwdriver to release the cover latch. Rotate the cover forward as the screwdriver is removed. 2. Snap off the wall plate from the base assembly. 3. If the RJ11 plug connections will not be made, proceed to Step 4. If the RJ11 plug will be connected for communication with the CCN network, follow Step a or b below to prepare communication cable for connection to RJ11 plug; then continue with Step 4. a. If the distance between the TCU and the RJ11 plug is 100 feet or less, the RJ11 connectors may be connected to the secondary communication bus as a T-tap at the TCU. To prepare cable, strip about 4 to 6 in. of jacket from cable end and feed the wires from the electrical box through the opening in sensor base assembly near the terminal block wire openings. Cut drain wire from the end of the cable. b. If the distance between the TCU and the RJ11 plug is greater than 100 ft, connectors must be connected in a daisy chain arrangement with the TCU s on the secondary communication bus. To prepare cables, strip about 4 to 6 in. of jacket from each of the two cable ends. Twist the drain wires together and secure with a field-supplied wire nut. Feed the loose wires from the electrical box through the opening in sensor base assembly near the terminal block wire openings. Be sure the drain wire does not protrude through the sensor base assembly. 4. Using 2 field-supplied 6-32 x 5 8-in. screws, mount the sensor base assembly to the electrical box. 5. Dress the wires down and inside the perimeter of the sensor base. 6. Make temperature sensor wiring connections: (See Fig. 28.) If control package uses T-55 space temperature sensor: a. Use a 20-AWG twisted pair conductor cable rated for the application. (See Table 6.) b. Connect one wire of the twisted pair to terminal T1 and connect the other wire to terminal T2 of terminal block TB1 in the T-55 space temperature sensor cover. c. Connect the other ends of the wires to the terminals labeled LID on the wiring harness terminal board in the TCU. (See Fig. 26.) Connect wire from TB1, T1 to terminal 1 on the wiring harness; connect wire from TB1, T2 to terminal 2 on wiring harness. If control package uses T-56 space temperature sensor: a. Use 3-conductor cable of type used for communication bus wiring. See recommended cables in Table 4. b. Connect one wire of the 3 conductor cable to TH, COM, and SW respectively in the T-56 space temperature sensor cover. c. Connect the other ends of the wires to terminals on the wiring harness terminal board in the TCU. (See Fig. 26.) Connect wire from TH to terminal 1; connect wire from COM to terminal 2; connect wire from SW to terminal 3. Fig. 27 Space Temperature Sensor Installation 19 NEMA National Electrical Manufacturing Association

20 7. Make RJ11 plug wiring connections. When distance between the space sensor with RJ11 plug and the TCU is 100 ft or less:as described in Step 3 above, in this case, the RJ11 connectors may be connected to the secondary communication bus as a T-tap in the TCU. (See Fig. 29A.) a. Strip the ends of the RED, WHITE, and BLACK conductors of the communication cable. Refer to Fig. 28 and make connections to terminals in space temperature sensor cover. For T-55: Insert and secure the RED ( ) wire to pin J2 of terminal strip TB1. Insert and secure the WHITE (ground) wire to pin J3 of terminal strip TB1. Insert and secure the BLACK ( ) wire to pin J5 of terminal strip TB1. For T-56: Insert and secure the RED ( ) wire to terminal marked CCN ( ). Insert and secure the WHITE (ground) wire to terminal marked CCNG. Insert and secure the BLACK (-) wire to terminal marked CCN (-). b. The other end of the communication bus cable must be connected to the terminals labeled COMM located on the wiring harness terminal board in the TCU as follows (see Fig. 26): Connect the RED ( ) wire to terminal 1 of the terminal block COMM. Connect the WHITE (ground) wire to terminal 2 of the terminal block COMM. Connect the BLACK ( ) wire to terminal 3 of the terminal block COMM. Twist drain wire conductors together and connect with field-supplied wire nut. When the distance between the space sensor with RJ11 plug and the TCU is greater than 100 ft: As described in Step 3 above, in this case, the CCN communication wiring of the RJ11 plug must be connected in a daisy chain arrangement with the TCUs on the secondary communication bus. (See Fig. 29B.) Strip the ends of the RED, WHITE, and BLACK conductors of the secondary communication bus cables and make connections to terminal block TB1 in the space temperature sensor cover. For T-55: Connect the 2 RED ( ) wires to terminal J2 of terminal block TB1. Connect the 2 WHITE (ground) wires to terminal J3 of terminal block TB1. Connect the 2 BLACK ( ) wires to terminal J5 of terminal block TB1. Carefully push the wire back through the openings in the base assembly. For T-56: Connect the 2 RED ( ) wires to terminal marked CCN ( ). Connect the 2 WHITE (ground) wires to terminal marked CCNG. Connect the 2 BLACK (-) wires to terminal marked CCN (-). Carefully push the wire back through the openings in the base assembly. LEGEND CCN Carrier Comfort Network LID Space Temperature Sensor TCU Terminal Control Unit Fig. 28 Space Temperature Sensor Wiring 20

21 A. WIRING WHEN DISTANCE BETWEEN TCU AND SPT IS 100 FT MAX. B. WIRING WHEN DISTANCE BETWEEN TCU AND SPT IS GREATER THAN 100 FT. LEGEND CCN Carrier Comfort Network PIC Product Integrated Control SPT Space Temperature Sensor TCU Terminal Control Unit TSM Terminal System Manager Fig. 29 Wiring RJ11 Plug on Space Sensor to TCU (PIC Control Box) 8. Label no. 35CG is located on the PIC control box cover. The TCU# and BUS# shown on the label are marked at the factory, according to the numbers on the job order. (See Fig. 30.) Peel off the corner of this label and apply it to the gray base plate located behind the space temperature wall sensor cover. NOTE: It is important to label the sensor at installation; if the sensor is not labeled now, it will be difficult later on to identify the TCU to which the sensor and plug have been connected. 9. Replace the cover by inserting the top inside edge of the cover over the tab on top of the sensor base assembly and rotating the cover down. Snap cover on. Fig. 30 Sensor Label CARRIER COMFORT NETWORK (CCN) INTERFACE Specifications The CCN communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain (ground) wire. The cable selected must be identical to the CCN communication bus wire used for the entire network. 21 The system elements (TCUs) are connected to the secondary communication bus in a daisy chain arrangement. (Refer to space temperature sensor installation for information regarding RJ11 plug connections.) The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it; the negative pins must be wired to negative pins; the signal ground pins (drain wires) must be wired to signal ground pins and connected to chassis ground at one place only. NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of 20 C to 60 C is required. See Table 4 for cables that meet the requirements. When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. The following color code is recommended SIGNAL TYPE CCN BUS CONDUCTOR INSULATION COLOR COMM PLUG PIN NO. Red 1 Ground White 2 Black 3 If a cable with a different color scheme is selected, a similar color code should be adopted for the entire network.

22 Wiring Connection (See Fig. 31.) At each system element (TCU), the shields of its communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to ground at only one single point. If the communication bus cable exits from one building and enters another, the shields must be connected to ground at a lightning suppressor in each building where the cable enters or exits the building (one point only). The TSM is connected to the primary CCN bus. The 37HC TCU is connected to the CCN network via the TSM. The TSM provides a secondary bus from the CCN bus. The TSM will support up to 64 air terminals on a secondary bus up to 1000 feet in length. Refer to the TSM Overview and Configuration Manual for further information. To connect the first 37HC TCU to the TSM, proceed as follows: 1. Strip the ends of the RED, WHITE, and BLACK conductors of the communication bus cable. 2. One end of the communication bus cable must be connected to the TSM communication port labeled COMM 2: a. Connect the RED ( ) wire to pin 1 of the connector. b. Connect the WHITE (ground) wire to pin 2 of the connector. c. Connect the BLACK ( ) wire to pin 3 of the connector. 3. The other end of the communication bus cable must be connected to the terminal block labeled COMM in the TCU of the first air terminal. a. Connect the RED ( ) wire to terminal 1 of the terminal block COMM. b. Connect the WHITE (ground) wire to terminal 2 of the terminal block COMM. c. Connect the BLACK ( ) wire to terminal 3 of the terminal block COMM. 4. Connect additional air terminals in a daisy chain following the color coded wiring in Step 3 above. CONTROL ADJUSTMENTS The DAV (Digital Air Volume) system consists of a TSM and associated TCUs. There are 2 calibrations which will make commissioning of the DAV system as easy as possible: 1. Calibration of the flow probe/velocity sensor combination with the TCU. 2. Adjustment of each unit as part of a zone-by-zone balancing operation. The first calibration must be made in order for the system to function efficiently. If all systems have been installed properly, the second step may not be necessary. System Calibration of the TCU/Velocity Sensor Combination Efficient operation of the DAV system requires that the TSM receive accurate airflow data from the TCU (control zones). For that reason, it is suggested that the pressure characteristics of the velocity sensor and terminal box be calibrated to the TSM controller. This will ensure that airflow calibration will be accurate for all terminals at system start-up. System calibration is accomplished by calculating a flow coefficient that adjusts the pressure fpm characteristics. Individual Zone Balancing and Calibration Before individual zones can be balanced, the DAV system must be configured and operating (refer to the Terminal System Manager II Overview and Configuration Manual). The following checks must be made: 1. Check to be sure that the supply air pressure is stable and the TCU is operating normally. 2. Check to be sure that the last unit on the chain has sufficient pressure (0.75 in. wg). If the unit is fully open and design airflow (cfm) is not observed, the pressure must be increased. 3. Calibrate the airflow verification equipment in accordance with AABCC or NEBB recommendations. 4. Perform visual inspection and sound check for disconnected ducts, damaged linkage, or disconnected wires. If a hood is to be used, all diffusers connected to a unit should be checked for proper connection. LEGEND PIC Product Integrated Control TCU Terminal Control Unit TSM Terminal System Manager Fig. 31 CCN Communication Wiring 22

23 BALANCING 37HC MODULINE TERMINALS The following information will be used for the balancing procedure: TCU # (Control Zone Address) This number is recorded at the factory on the sensor label, which should be attached to the gray base plate located behind the SPT cover. The label should have been attached to the SPT at the time of installation. (See Space Temperature Sensor Installation and Wiring section, page 18.) If the label is not present, locate the terminal to which the sensor is connected and find the TCU # (Control Zone Address) located on the TCU cover. If more than one TCU is receiving temperature data from a single SPT, be sure to note the TCU # of each unit connected to the SPT. If a hood is used for flow verification, also note which diffusers are connected to each unit. Inlet Size (and Nominal Rated Cfm) Inlet size is determined from the unit identification label (Fig. 10) or from the submittal drawings. The box size should be verified visually if possible. 1. Record this information on a performance sheet (see sample, Fig. 32). This will provide a permanent record of the balancing information. terminal size heating maximum airflow (cfm) limit heating minimum airflow (cfm) limit cooling maximum airflow (cfm) limit temperature zone # cooling minimum airflow (cfm) limit TCU # (control zone address) TCU phase # number of terminals 2. Verify unit flow rate. This is accomplished by one of the following means: Direct flow measurement using a flow hood: Flow hoods are subject to several variables which affect the accuracy of the reading with Moduline units. Measuring the discharge velocity and converting this value to cfm using a supplied area factor: Insert an Alnor velometer (with the specified tip) into the slot at several locations along the length of the unit. Record and then average the discharge velocity. The average discharge velocity is converted to cfm either by multiplying by the area factor (Table 7) or using the supplied calibrations (also shown in Table 7). As an additional check, the pressure signal across the distribution baffle may be checked directly. This cannot be done while the unit is operating, however, as the controller will respond when the tubes are disconnected. Tapping into the sensing lines is not recommended as the bleed rate of the transducer is high enough that a high and unpredictable error will be read. Slave units, which have no transducer connected, may be monitored in this manner. Airflow (cfm) at measured differential pressure is shown in Table 8. Table 7 Airflow (Cfm) At Average Discharge Velocity* 37HS1 37HS2 37HS4 Area Factor Discharge Velocity Cfm Discharge Velocity Cfm Discharge Velocity Cfm *Velocity based on Alnor 6000 velometer, 6070 probe tip; measured at Moduline terminal slot discharge. Table 8 37HC Box Flow Data DIFFERENTIAL AIRFLOW (Cfm) PRESSURE* (in. wg) 37HC1 37HC2 37HC *Pressure signal sensed by transducer (measured across distribution baffle). 23

24 3. Access the TSM by means of the Building Supervisor III or Network Service Tool III. The service tool can be connected to the phone jack located on the side of the space sensor if the jack has been connected to the CCN bus. NOTE: The following procedures assume that the DAV system has been configured and is operating properly. The TSM II Overview and Configuration Manual should be referenced for configuration decisions. 4. Access the CONTROL ZONE CONFIGURATION TABLE associated with this temperature zone and the TCU #. Upload this table to obtain the TSM s current values for this zone. 5. Enter the cfm limits from the performance sheet into the corresponding cfm limits specified in this table. Download this information to the TSM II. 6. Set the 37HC Moduline unit for minimum cooling by configuring the space temperature set point to a value higher than the current space temperature in that zone. 7. Compare Flows Compare the measured value to that displayed by the monitoring program. This value is shown in the TSM s Temperature Zone Display table as Primary Cfm. Make sure that the data in the table corresponds to the unit being measured. This can be verified by comparing addresses or monitoring changes forced by the thermostat or by forcing the commanded position. NOTE: Make sure all slave units are accounted for by selecting a zone configuration under Modify Controller for that zone and entering the correct value for Number of Boxes. 8. Calculate the Cfm Calibration Multiplier as follows. a. If the measured value is greater than the displayed value: Cfm Calibration Multiplier = (Measured Value - Displayed Value) +1 Design Terminal Flow Example using 37HC4: Measured Value = 450 Cfm Displayed Value = 400 Cfm Design Terminal Flow = 400 Cfm Calibration Multiplier = ( ) = 1.13 b. If the measured value is less than the displayed value: Cfm Calibration Multiplier = (Displayed Value Measured Value) 1- Design Box Flow Example using 37HC4: Measured Value = 350 Cfm Displayed Value = 400 Cfm Design Terminal Flow = 400 Cfm ( ) Cfm calibration multiplier = = Enter the Cfm Calibration Multiplier in the CONTROL ZONE CONFIGURATION TABLE. Make sure the table corresponds to the unit being calibrated. This can be verified by checking that the displayed address matches the recorded TCU #. 10. Allow at least 3 minutes for the control algorithm to adjust to the new settings. If the airflow requires additional adjustments, modify the Cfm Calibration Multiplier in small increments. NOTE: Proper airflow measurements require reasonable inlet configurations. Sharp bends in inlet duct may result in significant corrections being required for accurate data displayed. Three diameters of straight duct is required. 11. Reset the unit to deliver maximum cooling airflow by configuring the space temperature set point to a value lower than the current space temperature in that zone. 12. Repeat Steps 7 through 10. Variation in Maximum Airflow Moduline units in air series can be controlled individually with a volume controller at each unit, or with a master/slave combination, where one controller is used with multiple units. All the units on one controller must be of the same model (capacity). In master/slave combinations, some variation in maximum airflow among the terminals in air series will occur. The variation in maximum airflow is a function of the unit plenum size, the model, and the number of units in an air series on one controller. Table 9 shows the expected variation from the unit with the smallest airflow to the unit with the largest airflow. For single units with controller, the cfm variation is 10%. UNIT Table 9 Multiple Unit Airflow Variation PLENUM SIZE (in.) APPROXIMATE AIRFLOW VARIATION (Cfm) LOWEST UNIT TO HIGHEST UNIT IN AIR SERIES* Number of Units in Air Series On One Controller x HC1 9 x x x HC2 9 x x x HC4 11x x *Values shown are based on a typical short, straight duct run between units. Variation shown may be affected if there are excessive duct pressure losses between units. NOTE: The variation value shown in Table 9 for a given number of units of a certain model size (capacity) is the same for all size plenums used in an air series of recommended combinations for that model size. Thus, 3 units of model size 37HC2, plenum size 9x9, will have a maximum variation of 30 cfm; 3 units, plenum sizes 9x9 (2) and 7x 7 (1) will also have a maximum variation of 30 cfm. A dash indicates that the quantity of a particular plenum size is not recommended in air series for that unit size. 24

25 AIR TERMINAL PERFORMANCE SHEET PAGE OF JOB NAME JOB LOCATION CUSTOMER ENGINEER BUILDING LOCATION/FLOOR BUS ADDRESS TSM ADDRESS No. of Terminals Tag Number Zone Address # Temp Zone # CONTROL TCU Phase # Terminal Size (in./cfm) SET POINTS Cooling Heating (cfm) (cfm) Heat Type kw/ Occupied Unoccupied Cfm Cal Btu Mult min max min max min max min max Fig. 32 Air Terminal Performance Sheet 25

26 START-UP General Air volume delivery to the conditioned space is controlled by the modulating of the primary air damper and the sequencing of the air source supply fan. The PIC controller positions the damper by way of an electric actuator and turns the fan on and off through relay contactors. Primary System Check 1. Check that all controls, control box, and ductwork have been properly installed and set according to installation instructions and job requirements. 2. If units are to be used with a central air source that is not equipped with PIC controls, check to be sure air source interface has been installed. 3. Check that final filters have been installed in the airhandling apparatus. Dust and debris can adversely affect system operation. 4. Check fan and system controls for proper operation. 5. Check that all air duct connections are tight. Control System Check 1. Check interconnections between thermostats and unit controls. 2. Force all dampers to 100% (of maximum cooling cfm) using the Building Supervisor III or Network Service Tool III. 3. Set supply-duct balancing dampers, if used, in fully open position. 4. Check that static pressure available at each box is at least 0.75 in. wg and below the maximum safe operating limit. 5. Set air source supply fan speed and duct static pressure regulator to obtain satisfactory static pressure at design airflow. 6. While at peak system load, check system operation and pressures. 7. Hook up system volume control and test system. With the Building Supervisor III or Network Service Tool III, force enough control boxes to 0% to affect air supply delivery. Check duct pressure at the ends of runs. If system static pressure probe has been properly located, pressure at last units of all branch headers should remain essentially the same. If pressure has changed considerably, recheck the supply air static pressure controller or relocate the probe to better sense system pressure changes. 8. Remove all forces and balance each control box zone through the balancing procedure described on page 22. System Start-Up The Building Supervisor III and the Network Service Tool III can aid in system start-up and troubleshooting. All set-up and set point configurations are factory set and field adjustable. Changes are made by using either Building Supervisor III or the Network Service Tool III. The Network Service Tool III can be used as a portable device to change system set-up and set points from a zone sensor or terminal control module. During start-up, the Building Supervisor III or the Network Service Tool III can also be used to verify communication with each TCU and TSM. For specific operating instructions, refer to the Network Service Tool Manual and to the TSM Overview and Configuration Manual. MAINTENANCE It is recommended that periodical preventive maintenance be performed to minimize possible equipment failure and inefficient unit operation. The minimum maintenance to be performed on the TCU is as follows: Check small filter located in the TCU for excessive dust deposited on filter surface. If entire filter surface is covered with dust, replace the filter. 26