EconoMi$er, Power Exhaust, and Sensor Installation Instructions

Transcription

1 Small Rooftop Units Gas Heating/Electric Cooling, Electric Cooling, and Heat Pump Units 3 to.5 Tons (50/60 Hz) EconoMi$er Package for Vertical and Horizontal Duct Systems Issue Date /0/0 EconoMi$er, Power Exhaust, and Sensor Installation Instructions Introduction Overview The EconoMi$er system utilizes the latest technology available for integrating the use of free cooling with mechanical cooling for 3 through.5 ton rooftops. The microprocessor-based system optimizes energy consumption, zone comfort, and equipment cycling by operating the compressors when the outdoor air is too warm, integrating the compressors with outdoor air when free cooling is available, and locking out the compressors when outdoor air is too cold. The values at which these actions take place are adjustable from the front of the control. The EconoMi$er system utilizes gear-drive technology, with a direct mount spring return actuator that closes upon loss of power. The EconoMi$er system comes standard with an outdoor air temperature sensor. Enthalpy and enthalpy comparison sensors are available for field installation. When free cooling is not available, the zone thermostat controls the compressors. When free cooling is available, the outdoor air damper is positioned through the use of a Proportional-Integral (PI) control process to supply 55 F supply air temperature into the zone. As the supply air temperature fluctuates above or below 55 F, the dampers modulate (open or close) to bring the supply air temperature back within control. If mechanical cooling is utilized with free cooling, the outdoor air damper will be locked into its current position at the time the compressor is started. If this increase in cooling capacity was to cause the supply air temperature to drop below 45 F, the outdoor air damper position will be decreased to the minimum position. If the supply air temperature continues to fall, the outdoor air damper will be closed. This process is known as the supply air low limit control. Barometric relief dampers provide natural building pressurization control. An optional two-stage power exhaust system is available for jobs requiring even greater relief. Each stage of exhaust is controlled by adjustable end switches. As the outdoor air damper opens and closes, the exhaust fans are energized and de-energized. Field installed CO sensors are available. When connected to the EconoMi$er control, a PI-controlled demand ventilation strategy begins to operate. As the CO level in the zone increases above the CO setpoint, the minimum position of the damper is increased proportionally. As the CO level decreases because of the increase in fresh air, the outdoor air damper will be proportionally closed. The heart of the EconoMi$er system is the onboard microprocessor based controller. Six key features on the front of the control are highlighted below:. Ventilation Control (CO ) Setpoint - Adjustable between 800 and,400 parts per million (ppm), the Minimum Position proportionally increases as the CO level in the zone rises above this setpoint. This feature does not function without a CO sensor installed, and the fan must be energized.. Mechanical Cooling Lockout Setpoint - Adjustable between 0 and 60 F, or disable this feature by turning full counterclockwise to the Off position. When the outdoor air temperature drops below this setpoint, both compressors are disabled. When the outdoor air temperature increases above this setpoint, plus F (differential), the compressors are enabled, and continue to cycle as required. 3. Economizer Changeover Setpoint - Adjustable between A, B, C, and D settings, this setpoint is used to determine the value at which the control uses free cooling before mechanical cooling. When differential temperature or differential enthalpy strategies are used, this setpoint is disabled, because their values are fixed. 4. Minimum Position Setpoint - Adjustable between 0 and 00%, this setpoint determines the minimum opening of the outdoor air damper when the fan is energized. The fan must be energized before the damper opens. 5. Diagnostics Indication - The STATUS light indicates when the system has power and is operating correctly, or when flashing, indicating faults within the system. 00 Part No , Rev. C

2 6. CONFIG Button - This button has three purposes: Pushing the button for 3 to 9 seconds initiates an AUTO TEST MODE in which the dampers will stroke fully open, and then close (approximately 3 minutes to complete). Pushing the button for 0 to 9 seconds cancels the AUTO TEST MODE and removes any noncritical sensors, clearing the flash code associated with the faulty sensor. Pushing the button for more than 30 seconds and releasing enables the enthalpy comparison strategy (with the outdoor air and return air enthalpy sensors installed). Systems and Accessories Refer to Table for descriptions and part numbers. Table : EconoMi$ers and Accessories Part Number Description CREZR004A0 CREZR006A0 CRPWREXH04A0 CRPWREXH06A0 CREZR005A0 CREZR007A0 CRPWREXH05A0 CRPWREXH07A0 CROUTENT00A00 CRRETTMP00A00 CRRETENT00A00 33ZCSENCO 33ZCASPCO CRCDXSEN004A00 CRCDXASP00A00 -HT-0AH-850 -HT-0AH HJ HJ to 6 Ton Vertical EconoMi$er 3 to 6 Ton Horizontal EconoMi$er 3 to 6 Ton Power Exhaust System 3 to 6 Ton Power Exhaust System with Vertical EconoMi$er 7.5 to.5 Ton Vertical EconoMi$er 7.5 to.5 Ton Horizontal EconoMi$er 7.5 to.5 Ton Power Exhaust System 7.5 to.5 Ton Power Exhaust System with Vertical EconoMi$er Enthalpy Sensor Return Air Temperature Sensor with Wiring Harness Return Air Enthalpy Sensor with Wiring Harness CO Sensor (Carrier) Aspiration Box (Carrier) CO Sensor (Bryant) Aspiration Box (Bryant) 460 VAC Step-down (to 30 VAC) Transformer for 575 VAC Power Exhaust Applications. Approved for outdoor applications. 575 VAC Step-down (to 30 VAC) Transformer for 575 VAC Power Exhaust Applications. Approved for outdoor applications. 3 to 6 Ton Lower Hinged Filter Panel Assembly 7.5 to.5 Ton Lower Hinged Filter Panel Note: The CRPWREXH04A0 can be used with either the CREZR004A0 (vertical) or the CREZR006A0 (horizontal) EconoMi$er. Note: The CRPWREXH05A0 can be used with either the CREZR005A0 (vertical) or the CREZR007A0 (horizontal) EconoMi$er. IMPORTANT: Before installing any EconoMi$er: Go to the Installation of Auxiliary Sensors section before proceeding if installing a single enthalpy, differential enthalpy, or differential temperature sensor. Go to the Installation of Power Exhaust Option, before proceeding if installing a damper position switch or to the Damper Switch Adjustment Procedure section if changes to the standard settings (30% and 70%) of the end switches are required. Installation of EconoMi$er Vertical EconoMi$er Contents CREZR004A0 (3 to 6 Ton Unit) CREZR005A0 (7.5 to.5 Ton Unit) Top Filler Panel w/insulation Block-off Plate Return Air Block-off Plate (7.5 to.5 Ton Only) Top Hood Panel Side Hood Panels w/insulation Bottom Hood Bracket Outdoor/Return Air Divider Panel Filter Retainer Air Filters Bag of No. 0 Sheet Metal Screws EconoMi$er Assembly Supply Air Sensor CRPWREXH06A0 (3 to 6 Ton Unit) CRPWREXH07A0 (7.5 to.5 Ton Unit) Contents outlined in the Power Exhaust Contents section EconoMi$er Assembly Supply Air Sensor Return Air Block-off Plate (7.5 to.5 Ton Only) See Figures and for vertical EconoMi$er component locations. EconoMi$er, Power Exhaust, and Sensor Installation Instructions

3 EconoMi$er Plug Temperature Sensor Controller Filter Access Panel Actuator Indoor Coil Access Panel Gear-driven Damper Barometric Relief Damper Figure : 3 to 6 Ton Vertical EconoMi$er Assembly EconoMi$er Plug Controller Gear-driven Damper Figure 3: Typical Access Panel Locations. Proceed to Step 4 for a 3 to 6 ton unit. 3. For a 7.5 to.5 ton unit, install the return air block-off plate over the return air duct opening. For a 7.5 and 8.5 ton unit, remove the factory-installed return air block-off plate. (See Figure 4.) Actuator Blower Temperature Sensor Return Air Block-off Plate Filter Barometric Relief Damper Figure : 7.5 to.5 Ton Vertical EconoMi$er Assembly IMPORTANT: Read these instructions completely before attempting to install any EconoMi$er accessory.! WARNING: Electrical Shock Hazard. Disconnect power supply and install lockout tag before wiring connections are made to avoid possible electrical shock or damage to the equipment. To remove the filter access panel, raise the panel and swing the bottom outward. The panel is now disengaged from the track and can be removed.. Remove the indoor coil access panel and discard. (See Figure 3.) Factory Installed Block-off Plate (Present on 7.5 and 8.5 Ton Units Only) Figure 4: Return Air Block-off Plate Installation in a 7.5 to.5 Ton Unit Only 4. Slide the EconoMi$er assembly into the rooftop unit. (See Figures 5, 6, and 7.) Note: Be sure to engage the rear EconoMi$er flange under the tags in the return air opening of the unit base. (See Figure 5.) Unit Filter Rack Unit Base EconoMi$er Clip on HVAC Unit EconoMi$er EconoMi$er Rear Flange Figure 5: Rear EconoMi$er Flange Installation 5. Install the outdoor air block-off plate, then secure the EconoMi$er to the unit with the screws provided. (See Figures 6 and 7.) EconoMi$er, Power Exhaust, and Sensor Installation Instructions 3

4 Horizontal EconoMi$er Contents Wiring Harness Shipping Tape Block-off Plate Figure 6: Vertical EconoMi$er Installed in a 3 to 6 Ton Unit Wiring Harness Block-off Plate Shipping Tape Figure 7: Vertical EconoMi$er Installed in a 7.5 to.5 Ton Unit 6. Remove and save the jumper plug (blue/yellow wire) from the unit wiring harness located in the upper left corner, and insert the EconoMi$er plug into the unit wiring harness. 7. Remove the shipping tape from the barometric relief dampers and ensure the dampers move freely. (See Figures 6 and 7.) 8. Remove the indoor fan motor access panel. 9. Mount the supply air temperature sensor to the lower left portion of the indoor blower housing with the screws provided. (See Figure 8.) CREZR006A0 (3 to 6 Ton Unit) CREZR007A0 (7.5 to.5 Ton Unit) Top Filler Panel w/insulation Block-off Plate Return Air Top Filler Plate, Side Seal Bracket and Clips (7.5 to.5 Ton Unit Only) Top Hood Panel Side Hood Panels w/insulation Bottom Hood Bracket /Return Air Divider Panel Filter Retainer Air Filters Bag of No. 0 Sheet Metal Screws EconoMi$er Assembly Supply Air Sensor See Figure 9 for horizontal EconoMi$er component locations. Controller Actuator Gear-driven Damper Supply Air Temperature Sensor Mounting Location Supply Air Temperature Sensor Outdoor Air Temperature Sensor Barometric Relief Dampers Figure 9: 3 to 6 Ton Horizontal EconoMi$er Assembly IMPORTANT: Read these instructions completely before attempting to install any EconoMi$er accessory. Figure 8: Supply Air Sensor Placement 0. Connect the violet and pink wires to the corresponding connections on the supply air temperature sensor. Replace the indoor fan motor access panel.. Proceed to the Standard Hood section to install a standard hood, or to the Installation of Power Exhaust Option section for a power exhaust hood. 4 EconoMi$er, Power Exhaust, and Sensor Installation Instructions! WARNING: Electrical Shock Hazard. Disconnect power supply and install lockout tag before wiring connections are made to avoid possible electrical shock or damage to the equipment. To remove the filter access panel, raise the panel and swing the bottom outward. The panel is now disengaged from the track and can be removed.

5 . Remove the indoor coil access panel and discard. (See Figure 0.) Filter Access Panel Figure : Return Air Duct Cover Installation Clip off both wire ties on the rooftop wiring harness, and slide the EconoMi$er assembly into the rooftop. (See Figure.) Indoor Coil Access Panel Figure 0: Typical Access Panel Locations Shipping Tape Block-off Plate. Remove the factory-installed horizontal return air duct cover, and place it foil side up over the vertical return air duct opening in the base pan of the unit. (See Figure.) Note: The outdoor air block-off plate is located on the left side of a 7.5 to.5 ton unit. Figure : Horizontal EconoMi$er Installed in a 3 to 6 Ton Unit Factory-installed Horizontal RA Duct Cover Blower Filter Vertical RA Duct Opening 4. Proceed to Step 6 for a 3 to 6 ton unit. 5. For a 7.5 to.5 ton unit, install the return air top filler plate and side seal bracket. Secure the bracket with the fastener clips. (See Figure 3.) For a 0.5 to.5 ton unit, install the return air top filler plate. (Discard the top filler plate for any other size unit.) 6. Install the outdoor air block-off plate. (See Figure.) Side Seal Bracket Four Fastener Clips Return Air Top Filler Plate (For 0.5 and.5 Ton Units Only) Return Air Block-off Plate Side Seal Bracket Holes to Secure Rooftop Wiring Harness (Wire Tie Not Included) Figure 3: Horizontal EconoMi$er Installed in a 7.5 to.5 Ton Unit EconoMi$er, Power Exhaust, and Sensor Installation Instructions 5

6 7. Secure the EconoMi$er to the unit with the screws provided. (See Figures and 3.) 8. Remove and save the jumper plug (blue/yellow wire) from the unit wiring harness located in the upper left corner, and insert the EconoMi$er plug into the unit wiring harness. 9. Remove the shipping tape from the barometric relief dampers and ensure the dampers move freely. (See Figure.) 0. Remove the indoor fan motor access panel.. Mount the supply air temperature sensor to the lower left portion of the indoor blower housing with the screws provided. (See Figure 8.). Connect the violet and pink wires to the corresponding connections on the supply air temperature sensor. Replace the indoor fan motor access panel. 3. Proceed to the Standard Hood section to install a standard hood, or to the Installation of Power Exhaust Option section for a power exhaust hood. Standard Hood To assemble the standard hood assembly to either the vertical or horizontal EconoMi$er, using the screws provided:. Remove the EconoMi$er hood from its packaging, locating the parts shown in Figure 4. Top Filler Panel Top Panel. Assemble the side panels to the roof top unit as shown in Figure 5. Bottom Bracket Top Panel /Return Air Divider Panel Figure 5: 3 to 6 Ton Partially Completed Outdoor Air Hood Assembly 3. Assemble the bottom bracket, divider panel and then the top panel as shown in Figure Slide the filters in place and secure using the filter retainer as shown in Figure Assemble the top filler bracket as shown in Figure 6. Top Filler Panel Filter Retainer Filter Retainer Left Side Panel Bottom Bracket Right Side Panel /Return Air Divider Panel Inlet Filters Figure 6: 3 to 6 Ton Completed Hood Assembly Figure 4: 3 to 6 Ton Hood Components Note: The 7.5 to.5 ton hood components are similar to those shown in Figure 4 (the filters and screws are not shown). 6 EconoMi$er, Power Exhaust, and Sensor Installation Instructions

7 Installation of Power Exhaust Option Power Exhaust Contents CRPWREXH04A0 (3 to 6 Ton Unit) CRPWREXH05A0 (7.5 to.5 Ton Unit) Power Exhaust Hood Top Power Exhaust Hood Bottom Power Exhaust Hood Sides Power Exhaust Fan Divider Plate Damper Block-off Plate with x 4 in. Junction Box Power Exhaust Hood Braces Power Exhaust Hood Filter Power Exhaust Fan Assembly 4 U-Clips Bag of No. 0 Sheet Metal Screws Seal Strip - /8 x 7/8 in. Seal Strip - 3/4 x 3/4 in. Panel Hood Top Panel Hood Sides Filters Filter Retainer Damper Position Switch Kit Note: The Power Exhaust Hood installation is the same for both a vertical and horizontal EconoMi$er. If the Power Exhaust Assembly is being added to an existing vertical or horizontal EconoMi$er:. Remove the existing hood assembly and discard.. Remove the outdoor air block-off plate located adjacent to the EconoMi$er damper and discard it. (See Figure ). Table : Power Requirements Power Exhaust Size Total Ampere 3 to 6 Ton.40 ampere at 60 Hz 7.5 to.5 Ton 3.04 ampere at 60 Hz MOCP 30 VAC 460 VAC 575 VAC 5.0 ampere 5.0 ampere 5.0 ampere IMPORTANT: Motors are rated for 30 VAC, Phase, and 50/60 Hz. For 460 applications, use an HT0AH850 transformer. For 575 VAC applications, us a HT0AH859 transformer. (See the Wiring section.) To assemble the power exhaust hood:. Install the 3/4 x 3/4 in. seal strip on the top panel of the power exhaust hood. Install the /8 x 7/8 in. seal strip on the power exhaust hood side panels and bottom panel. Assemble the power exhaust side panels, then the bottom panel as shown in Figure 7, to the outdoor air panel. Outdoor Air Panel Power Exhaust Hood Sides Power Exhaust Bottom Panel 3/4 x 3/4 in. Seal Strip /8 x 7/8 in. Seal Strip Power Exhaust Fan Assembly Power Exhaust Hood Top Exhaust Fan Divider Panel Power Exhaust Hood Filter Figure 7: Power Exhaust Hood Assembly. Attach the hood top panel to the side panels. 3. Assemble the outdoor air panels, then top panel, to the outdoor air panel. (See Figure 8.) Outdoor Air Panel Assembled Power Exhaust Hood Side Brace /8 x 7/8 in. Seal Strip /8 x 7/8 in. Seal Strip Hood Sides Hood Top Filter Retainer Inlet Filters Figure 8: Hood Assembly 4. Slide the outdoor air inlet filters into the screen track on the hood side panels. While holding the filters in place, fasten the filter retainer to the hood. (See Figure 8.) EconoMi$er, Power Exhaust, and Sensor Installation Instructions 7

8 5. Attach the exhaust hood side braces to the power exhaust side panels and outdoor air hood top. (See Figure 9.) 9. Locate the outdoor air block-off plate with the x 4 in. junction box attached. (See Figure.) Hood Top Field-supplied Wiring and Connector Side Brace Power Exhaust Side Panels Figure 9: Completed Hood Assembly 6. Slide the fan assembly into the power exhaust assembly, and secure to the side panel. (See Figures 7 and 0.) Exhaust Fan Divider Plate Power Exhaust Hood Side Brace Power Exhaust Hood Bottom Panel Power Exhaust Hood Top Panel U-Clips (4) Fan Assembly Power Exhaust Hood Filter Figure 0: Power Exhaust Hood Cross Section 7. Attach the U-Clips provided to the hood screen and then to the fan assembly. (See Figures 0 and.) U-Clip (4) Block-off Plate Junction Box 4-pin High-voltage Connector Plug Figure : Junction Box Termination 0. Terminate the field-supplied power wiring in the x 4 in. junction box, and reinstall the cover. (See Figure 46.). Install the 4-pin connector from the junction box through the hole in the outdoor air block-off plate. (See Figures and 3.) Wiring Harness * On 7.5 to.5 ton rooftop units, the connector plugs are located on the left side of the damper. 3 Block-off Plate Junction Box 4-pin High-voltage Connector Plug* 3-pin Low-voltage Connector Plug Figure 3: Connector Plug Location in a 3 to 6 Ton EconoMi$er Rooftop Assembly 3 4 Power Exhaust Hood Side No. 0 Sheet Metal Screw (4) Power Exhaust Hood Screen. Assemble the block-off plate to the damper. (See Figure 3.) 3. To install the hood assembly, tilt the hood assembly up to the rooftop. Connect the 3-pin and 4-pin connectors as shown in Figure 3. Figure : U-Clip Installation 8. Attach the exhaust fan divider plate to the hood bottom panel and then to the fan assembly. (See Figures 0 and 4.) 8 EconoMi$er, Power Exhaust, and Sensor Installation Instructions

9 Capacitor Capacitor Divider Plate Location Fan Fan Relay Relay 4-pin Connector Plug (High Voltage) 3-pin Connector Plug (Low Voltage) Figure 4: Fan Assembly Components 4. Secure the complete hood assembly to the rooftop using the screws provided. 5. Refer to Figure 46 for wiring information. Optional Damper Position Switch Installation! WARNING: Electrical Shock Hazard. Disconnect the power supply and install a lockout tag before wiring connections are made to avoid possible electrical shock or damage to the equipment. Perform the following procedure to install the switch module.. Verify that the outdoor air blade is fully closed.. Position the switch module near the hub of the gear as indicated in Figure 5 and 6 with the mounting holes aligned. 3. Rotate the shaft of the switch module clockwise until the pointer is at the bottom of the scale. 4. Slide the square end of the shaft into the square hole in the plastic gear. 5. Fasten the switch module to the damper frame using the two sheet metal screws provided. Optional Switch Kit Installation Figure 5: Switch Kit Installation on a Vertical EconoMi$er Figure 6: Switch Kit Installation on a Horizontal EconoMi$er Optional Switch Kit Installation EconoMi$er, Power Exhaust, and Sensor Installation Instructions 9

10 Damper Switch Adjustment Procedure Perform the following to adjust the switch. Note: The top switch is factory set to 30% (7 degrees) and the bottom switch is factory set to 70% (63 degrees) of the outdoor blade full open position. If these factory settings are acceptable for the application, move to the Electrical Connection section. If a setting other than the factory settings is desired, continue with the Damper Switch Adjustment Procedure.. Connect a continuity tester or ohmmeter to the common () and Normally Open (N.O.) terminals of the top switch (see Figure 7) or to the pins with the orange and brown wires.. With the unit power applied, and the indoor fan on, adjust the MINIMUM POSITION on the EconoMi$er control to the desired start point of the power exhaust fan. 3. After the outdoor air blade has reached this position, adjust the switch start point by using the teeth on the top switch cam. Rotate the cam until the tester indicates a change in the switch. 4. Repeat Steps through 3 for the bottom switch except check the continuity between the pins with the yellow and brown wires. Installation of Auxiliary Sensors Auxiliary Sensor Contents CROUTENT00A00 Enthalpy Sensor sensor CRRETTMP00A00 Return Air Temperature Sensor or CRRETENT00A00 Return Air Enthalpy Sensor Contents sensor with wiring harness and mounting bracket three tie wraps two No. 6-0 self-tapping screws (requires /4 in. nut drive) two No. 0-6 self-drilling screws (requires 5/6 in. nut drive) / in. bushing Replacing the Temperature Sensor with an Enthalpy Sensor The outdoor air temperature sensor is factory-installed in the EconoMi$er system. See Figure 9 to replace the outdoor air temperature sensor in a horizontal EconoMi$er and Figure 8 for a vertical EconoMi$er. 5. Remove the continuity tester or ohmmeter, and reset the MINIMUM POSITION to the original position. Existing Temperature Sensor* Controller Electrical Connection. Plug the two-pin connector into the mating connector in the EconoMi$er harness (red and brown wire leads).. Install the three pin connector into the rectangular hole in the EconoMi$er damper flange. 3. Use the anchor wire tie to secure the wire leads. Wire Tie Anchor Hole Top Switch Cam Position Indicator Top Switch * The sensor is located on the left side of the damper in a 7.5 to.5 ton rooftop unit. No. 6 Self-tapping Screws () Figure 8: Vertical EconoMi$er Assembly To replace the outdoor air temperature sensor:. Disconnect the two wires from the installed sensor.. Use a /4 in. nut driver to remove the two screws securing the sensor to the sheet metal. 3. Reuse the screws to mount the new sensor. Bottom Switch Figure 7: Switch Positions (Harness is Not Shown) 4. Reuse the original wiring harness, using all five wires to wire the sensor. (See Figures 9 and 30 for connections.) 0 EconoMi$er, Power Exhaust, and Sensor Installation Instructions

11 EconoMi$er Controller OAT OAH +5V RAT RAH +5V CO (+) CO DAT REM POT LED Brown White Red Pink Brown White Red Supply Air Temperature Sensor TEMP TEMP TEMP TEMP OUT PWR TEMP TEMP OUT PWR CO Sensor* V+ Outdoor Air Sensor* Return Air Sensor* 4 VAC * Field installed accessory. See Table for ordering information and Figure 44 for wiring information. Figure 9: Sensor Wiring Diagram UP Replacing the Return Air Temperature Sensor or the Return Air Enthalpy Sensor To install the mounting bracket using the No. 6 self-tapping screws provided. (The sensor must be mounted in the upright position. See Figure 3.) Note: The mounting bracket orientation varies, depending on the EconoMi$er assembly. (See Figures 3 and 3 to determine the proper bracket orientation for a vertical EconoMi$er and Figure 33 for a horizontal EconoMi$er. Mounting for a 3 to 6 Ton EconoMi$er Assembly Bracket Edge Sensor No. 6 Self-tapping Screws () Mounting for a 7.5 to.5 Ton EconoMi$er Assembly Figure 3: Mounting the Sensor to the Bracket in a Vertical EconoMi$er Assembly T C O O U M T PWR T Figure 30: Terminal Locations for or Return Air Enthalpy Sensors Sensor EconoMi$er Side Panel Mounting Bracket * On 7.5 to.5 ton rooftop units, the sensor is mounted on the left side of the EconoMi$er. No. 0 Self-drilling Screws () Figure 3: Mounting the Sensor and Bracket in a 3 to 6 Ton Vertical EconoMi$er Assembly EconoMi$er, Power Exhaust, and Sensor Installation Instructions

12 Knockout Plug Controller Actuator Gear-driven Damper Outdoor Air Temperature Sensor Barometric Relief Dampers Figure 33: Mounting the Sensor and Bracket in a Horizontal EconoMi$er Assembly To wire the Return Air Temperature Sensor or the Return Air Enthalpy Sensor:. Remove the knockout plug. (See Figure 33 or 34.). Feed the wires through the knockout opening and insert the bushing to secure the wires. 3. Route and attach the wiring harness to the original harness using tie wraps. 4. Refer to Figures 9 and 30 to wire the sensor. 5. Check to ensure the barometric relief dampers move freely. Knockout Plug and Bushing Table 3: EconoMi$er Sensor Switchover Control Strategy Dry Bulb Sensor Type Single Enthalpy Temperature Sensor EconoMi$or Controller Mounting Holes () for Return Air Sensor and Bracket Barometric Relief Dampers Figure 34: Location of the Return Air Sensor and Bracket Controller Sensor Inputs Enthalpy Sensor Return Air Temperature Sensor Differential Temperature Return Air Enthalpy Sensor Differential Enthalpy* *On certain EconoMi$er controller models, the differential enthalpy strategy must be selected manually. To enable differential enthalpy, refer to the Commissioning section. EconoMi$er, Power Exhaust, and Sensor Installation Instructions

13 Commissioning The EconoMi$er saves energy when it uses outdoor air to provide free cooling instead of mechanical air conditioning. The EconoMi$er controller switchover strategy determines if the outdoor air is suitable for free cooling. The controller chooses the switchover strategy with the most energy savings, provided the required sensors are connected and functioning normally. IMPORTANT: If a sensor stops functioning normally, the EconoMi$er controller switches to a strategy with reliable sensors. CO Control Setup If a CO sensor is not being used, proceed to the Mechanical Cooling Lockout section. If a CO sensor is being used:. Make sure the CO sensor is installed as indicated in Figure 45.. Determine the value at which you want the minimum position of the dampers to begin opening to allow a greater amount of outdoor air to enter. The range is 800 to,400 ppm. 3. Locate the CO SP (ppm) potentiometer and adjust to the desired setpoint. See Figure A B OFF D C CO SP MECH CLG ECON MIN (PPM) LOCKOUT SP POS (%) CONFIG STATUS Figure 35: EconoMi$er Control Adjustment Potentiometers (Factory Settings) Mechanical Cooling Lockout Determine the Temperature (OAT) at which mechanical cooling (compressor) is to be disabled. Note: Mechanical Cooling Lockout (MECH CLG LOCKOUT) may also be referred to as outdoor air lockout.. Locate the MECH CLG LOCKOUT potentiometer.. Disable this feature by turning the potentiometer full Counterclockwise (CCW) to the OFF position, or set the value between 0 and 60 F. Note: Mechanical cooling will not operate when the OAT is below this value. (See Figure 35.) Economizer Changeover Setup Determine the economizer changeover setpoint from Table 4. The settings are A, B, C, and D. Table 4: Changeover Setpoints Dry Bulb F ( C) Single Enthalpy* Btu/lb (KJ/kg) Sensor A B C D Differential Temperature* F (C ) Differential Enthalpy* Btu/lb (KJ/kg) 73 (.7) 7 (6.8) 69 (0.5) 5 (58.) 66 (8.9) 4 (55.8) FIXED AT (.) FIXED AT (.3) 63 (7.) (5.) *See Table for EconoMi$ers and accessories. Locate the ECON SP potentiometer, and set the economizer changeover setpoint. (See Figure 35.) Note: When the OAT is above this setpoint, the damper is limited to minimum position. IMPORTANT: On certain EconoMi$er controller models, the differential enthalpy strategy must be selected manually. Refer to the Startup section. EconoMi$er, Power Exhaust, and Sensor Installation Instructions 3

14 If a potentiometer fails, its setting defaults to the values in Table 5. Table 5: Default Potentiometer Settings Potentiometer Default Setting CO SP (ppm),000 MECH CLG LOCKOUT ( F) 47 ECON SP D MIN POS (%) 0 Ventilation Air Requirements (Minimum Position Setup) Turn on base unit power. The EconoMi$er begins operation 30 seconds after power up.! WARNING: Personal Injury Hazard. Avoid possible injury by keeping fingers away from damper blades. If there is no change required in the ventilation air, proceed to Startup section. To change the ventilation air requirement, perform the following: Make sure the indoor fan is on to set the ventilation air. Either put the thermostat in the continuous fan mode, or jumper the R and G terminals at the rooftop unit connection board. Locate the minimum position (MIN POS) potentiometer. Turn the potentiometer full CCW to fully close the OA damper. Turn the potentiometer gradually Clockwise (CW) to the desired position. (See Figure 35.) Replace the filter access panel. (See Figure 3.) Ensure the filter access panel slides along the tracks and is securely engaged. Calculate the minimum airflow across the EconoMi$er. To calculate the minimum airflow, the formulas in Option or Option may be used. Option : MAT = Mixed Air Temperature OAT = Temperature RAT = Return Air Temperature cfm = OA cubic feet per minute (cfm) or minimum OA across the EconoMi$er Note: To determine cfm, use this equation: (MAT RAT) x cfm3 / (OAT RAT) = cfm cfm = cfm3 cfm cfm3 = total cfm For example, to determine cfm using,400 for cfm3: (MAT RAT) x cfm3 / (OAT RAT) = cfm (77 75 ) x,400 / (95 75 ) x,400 / 0 = 4,800 / 0 = 40 for cfm Insert the data into the following equation: [(OAT x cfm) + (RAT x cfm)] / cfm3 = MAT [(95 x 40) + (75 x,60)] /,400 = MAT (, ,000) /,400 = MAT 84,800 /,400 = MAT 77 = MAT If cfm does not match the desired minimum airflow, readjust the minimum position (MIN POS) potentiometer. Remove the filter access panel to make the adjustment. Note: Be sure to replace the filter access panel before repeating the process. Option : MAT = Mixed Air Temperature OAT = Temperature RAT = Return Air Temperature Insert the data into the following equation: [(OAT RAT) x (OA% / 00)] + RAT = MAT For example: [(95-75 ) x (0% / 00)] + 75 = MAT (0 x 0.) + 75 = MAT + 75 = MAT 77 = MAT The installation is complete. 4 EconoMi$er, Power Exhaust, and Sensor Installation Instructions

15 Performance Data for the Vertical EconoMi$er See Figures 36, 37, and 38 for performance characteristics for vertical EconoMi$er systems. 0.5 Performance Data for the Horizontal EconoMi$er See Figures 39, 40, and 4 for performance characteristics for horizontal EconoMi$er systems. 0.5 Static Presure (W.C.) Static Presure (W.C.) Flow in cubic feet per minute (cfm) Flow in cubic feet per minute (cfm) 3 to 6 Ton 7-/ to -/ Ton 3 to 6 Ton 7-/ to -/ Ton Figure 36: Barometric Flow Capacity.cdr) Figure 39: Barometric Flow Capacity Flow in cubic feet per minute (cfm) Static Pressure (W.C.) 3 to 6 Ton 7-/ to -/ Ton Flow in cubic feet per minute (cfm) Static Pressure (W.C.) 3 to 6 Ton 7-/ to -/ Ton Figure 37: Leakage Figure 40: Leakage Static Pressure (W.C.) Flow in cubic feet per minute (cfm) 3 to 6 Ton 7-/ to -/ Ton Figure 38: Return Air Pressure Drop Static Pressure (W.C.) Flow in cubic feet per minute (cfm) 3 to 6 Ton 7-/ to -/ Ton Figure 4: Return Air Pressure Drop EconoMi$er, Power Exhaust, and Sensor Installation Instructions 5

16 Startup Sensor Characteristics The discharge air, outdoor air, and return air temperature sensors are Negative Temperature Coefficient (NTC) type. Their respective temperature vs. resistance values are shown in Table 6. Table 6: Temperature vs. Resistance Degrees F Degrees C Resistance(ohms) 0-8 9,08 0-4, , , , , ,450 70, , , ,33 The outdoor air and return air humidity sensors have an output signal of 0 to 5 VDC based upon a Relative Humidity (RH) value of 0 to 00%. (See Figure 4.) VDC % 0% 40% 60% 80% 00% Relative Humidity (RH) Figure 4: Output Signal vs. RH The CO input of to 0 VDC is based upon a 0 to 000 ppm and shown in Figure 43. Differential Enthalpy Switchover Strategy To enable differential enthalpy: Press and hold the CONFIG button for more than 30 seconds, then release. The Light-Emitting Diode (LED) flashes twice and the controller resumes normal operation. To return to single enthalpy mode, press and hold the CONFIG button for more than 30 seconds, then release. The LED flashes once and the controller resumes normal operation. Operating Sequence Cooling When the outdoor air is above the ECON SP setpoint and the room thermostat calls for Stage cooling (R to G + Y), the indoor fan motor is energized and the EconoMi$er damper modulates to minimum position. The compressors and outdoor fan motor contactors are energized to start the compressor and outdoor fan motor. After the thermostat is satisfied, the damper modulates to the fully closed position when the indoor fan motor is de-energized. When the outdoor air temperature is below the ECON SP setting and the room thermostat calls for Stage cooling (R to G + Y), the EconoMi$er modulates to the minimum position when the indoor fan motor is energized. The EconoMi$er provides Stage of cooling by modulating the return air and outdoor air dampers to maintain a 55 F supply air setpoint. If the supply air temperature is greater than 57 F, the EconoMi$er modulates open, allowing a greater amount of outdoor air to enter the unit. If the supply air temperature drops below 53 F, the outdoor air damper modulates closed to reduce the amount of outdoor air. When the supply air temperature is between 53 and 57 F, the EconoMi$er maintains its position. 0 8 VDC Parts per million (ppm) Figure 43: Output Signal vs. CO (ppm) 6 EconoMi$er, Power Exhaust, and Sensor Installation Instructions

17 If outdoor air alone cannot satisfy the cooling requirements of the conditioned space, and the outdoor air temperature is above the MECH CLG LOCKOUT setpoint, the EconoMi$er integrates free cooling with mechanical cooling. To accomplish, follow these strategies: Note: A two minute Minimum On, a one minute Minimum Off, and interstage delay timer resides within the EconoMi$er controller.. If Y is energized, and the room thermostat calls for Y (two-stage thermostat), the compressor and outdoor fan motor are energized. The EconoMi$er damper position is maintained at its current value.. If Y is energized for more than 0 minutes, and Y is not energized (whether or not a two-stage thermostat is used), the compressor and outdoor fan motor are energized. The position of the EconoMi$er damper is maintained at its current value. 3. If Y is energized, and Compressor is already energized (see Step ) and the room thermostat calls for Y, Compressor continues to operate. If Y remains energized for more than 0 minutes, Compressor is energized. Note: Compressor cannot be energized unless there is a signal for Y from the space thermostat. 4. If Compressor is energized, and the Y signal from the thermostat is satisfied, Compressor and Compressor are de-energized. Re-asserting Y will start Compressor and (after a 0-minute interstage delay) Compressor. 5. If Compressor is energized and the thermostat is satisfied, Compressor, the outdoor fan motor, and the indoor fan motor are de-energized and the EconoMi$er modulates closed. When the outdoor air temperature is below the MECH CLG LOCKOUT setpoint, the compressors remain off. Heating When the room thermostat calls for heat, the heating controls are energized as described in the Installation, Startup and Service Instructions provided with the rooftop unit. The indoor fan motor is energized and the EconoMi$er damper modulates to the minimum position. When the thermostat is satisfied, the damper modulates closed. Ventilation (Continuous Fan) When the room thermostat is set for continuous fan, the EconoMi$er damper remains at minimum position as long as the indoor fan motor is energized. When the indoor fan motor cycles off, the damper modulates closed. Ventilation Control If a CO sensor is connected to the EconoMi$er controller, and the indoor fan motor is energized, the EconoMi$er minimum position increases if the CO level is greater than the CO setpoint. The setpoint is adjustable between 800 and,400 ppm through the CO SP potentiometer located on the EconoMi$er control. The greater the difference between the actual CO level and the setpoint, the greater amount the damper modulates open. Supply Air Low Limit The supply air low limit control strategy is used to protect the mechanical equipment. The supply air low limit overrides the minimum position setpoint and the damper command from the ventilation control strategy, if supply air temperature drops below 45 F. The outdoor air damper is completely closed when the supply air temperature reaches 35 F. If mechanical cooling is energized, it stays energized. EconoMi$er, Power Exhaust, and Sensor Installation Instructions 7

18 Troubleshooting LED Indication The EconoMi$er controller features an onboard diagnostic LED that flashes to indicate its status. The controller also has terminal connections (REM LED) for remotely mounting an LED, if desired. Table 7: Flash Code Identification See Table 7 for flash codes, and Figure 45 for installation of a remote mounted LED. Flash Code Cause Action Taken by EconoMi$er Critical Fault Non- Critical Fault Constant On Normal operation Normal operation Constant Off No power No operation Continuous Flash CONFIG button pushed and held between 3 and 9 seconds Outdoor air damper is stroked fully open, then closed (automatic test procedure takes three minutes to complete). Flash One Control board fault System shutdown Flash Two Thermostat fault (i.e., Y without Y) System shutdown until corrected Flash Three Actuator fault Revert to mechanical cooling only. Flash Four Supply air temperature sensor fault Continue operation with damper at minimum position. Revert to mechanical cooling only. Flash Five OAT sensor fault Continue operation with damper at minimum position. Disable mechanical cooling lockout. Flash Six Outdoor air humidity sensor fault Continue operation with dry bulb or dry bulb differential switchover. Flash Seven Return air temperature sensor fault Continue operation with single enthalpy switchover or dry bulb switchover (without humidity sensor). Flash Eight Return air humidity sensor fault Continue operation with differential dry bulb. Flash Nine Carbon dioxide (CO ) sensor fault Continue operation without ventilation control. Flash Ten On-board adjustment potentiometer Continue operation with default potentiometer settings. fault The flash code priorities are as follows:. Flash Code One. Continuous Flash 3. Flash Codes through 0 If sensors are opened, shorted, or removed, the EconoMi$er controller flashes its LED and determines the criticality of the sensor. If a non-critical sensor fault occurs (i.e., outdoor air humidity), the EconoMi$er reconfigures its control strategy to a more appropriate mode. If a critical sensor fault occurs (i.e., supply air sensor), the EconoMi$er reverts to a safe mode of operation until the sensor problem is resolved. 8 EconoMi$er, Power Exhaust, and Sensor Installation Instructions

19 Table 8: Troubleshooting Problem Cause Remedy Damper Does Not Open Damper Position Limited to Minimum Position Continued on next page... Indoor (Evaporator) Fan Off No Power to EconoMi$er Controller No Power to G Terminal Controller Fault Thermostat Fault Actuator Fault Minimum Position Set Incorrectly EconoMi$er Changeover Setpoint Set Too High or Too Low Supply Air Temperature Sensor Faulty Check to ensure that 4 VAC is present at Terminal C (Common Power) on the Indoor Evaporator Fan Contactor (IFC) or that 4 VAC is present at the Indoor Evaporator Fan On (IFO) terminal. Check whether 4 VAC is present at Plug PL6- (red wire) and/or PL6-3 (black wire). If 4 VAC is not present, check wiring. (See unit label diagram.) Check proper thermostat connection to G on the connection board. Check to ensure that 4 VAC is present across Terminals 4 VAC and 4 VAC on the EconoMi$er control. If 4 VAC is not present, check wiring. (See rooftop unit label diagram.) If 4 VAC is present, STATUS light should be on constantly. If IFM is on, check to ensure 4 VAC is present on G Terminal of the EconoMi$er controller. If 4 VAC is not present, check wiring. (See unit label diagram.) If STATUS light is flashing one flash, the EconoMi$er controller is experiencing a fault condition. Cycle power to the controller. If condition continues, replace the EconoMi$er controller. If STATUS light is flashing two flashes, the EconoMi$er controller believes the thermostat is wired incorrectly. Check wiring between the thermostat and the connection board in the electrical panel. The fault condition is caused by Y being energized before Y. Check the wiring between the EconoMi$er controller and the actuator. Hold CONFIG button between three and ten seconds to verify actuator operation. (This process takes three minutes to complete.) STATUS light should flash continuously during test. Actuator will stroke open, then close. Check output signal at AO and on EconoMi$er controller. If 0 VDC is present, the actuator should be closed. If something between 0 to 0 VDC is present, the actuator should be open proportional to signal. At 0 VDC, the actuator should be full open. If actuator does not respond to the signal, check the wiring or possible bind in the damper. (See unit label diagram.) If wiring is correct, replace the actuator. Verify MIN POS (%) is set greater than zero. Adjust the MIN POS (%) to 00% to verify operation, and then set to correct setting. Set at correct value. See Table 4. If STATUS light is flashing four flashes, the supply air temperature sensor is faulty. Check the wiring from the sensor to the controller. Using Table 9, verify the temperature vs. resistance of the sensor is accurate at ambient conditions. Set the multi-meter in the resistance mode to 0 k ohms. Disconnect the wires from the sensor, and measure across the two terminals. If accurate, reconnect the wires. Disconnect the wires from DAT (violet) and (pink) at the controller. Using the same technique, measure the resistance between the wires. The values should be the same as the original test. If the temperature vs. resistance does not coincide with the appropriate value, replace the sensor. Make sure the violet and pink wires are connected on both ends, at the sensor and the controller. EconoMi$er, Power Exhaust, and Sensor Installation Instructions 9

20 Table 8: Troubleshooting (cont.) Problem Cause Remedy Damper Position Limited to Minimum Position (Cont.) Damper Position Less than Minimum Position Setpoint Damper Does Not Return to Minimum Position Damper Does Not Close on Power Loss Compressors Do Not Start Status Light Is Flashing Power Exhaust Does Not Start Temperature Sensor Faulty Supply Air Low Limit Strategy Controlling CO Ventilation Strategy Controlling Damper Travel Restricted No Input Signal from T-Stat Mechanical Cooling Lockout in Effect Minimum Off or Inter-stage Delay in Effect Fault Condition No Primary Power Supply If STATUS light is flashing five flashes, the outdoor air temperature sensor is faulty. Check the wiring from the sensor to the controller. Using Table 9, verify the temperature vs. resistance of the sensor is accurate at ambient conditions. Set the multi-meter in the resistance mode to 0 k ohms. Disconnect the wires from the sensor, and measure across the two terminals. If accurate, reconnect the wires. Disconnect the wires from OAT (tan) and (violet) at the controller. Using the same technique, measure the resistance between the wires. The values should be the same as the original test. If the temperature vs. resistance does not coincide with the appropriate value, replace the sensor. Make sure the tan and violet wires are connected on both ends, at the sensor and the controller. The supply air temperature is less than 45 F, causing the minimum position to decrease. Refer to the Startup section. Verify correct setting of the MIN POS (%). If correct, EconoMi$er is operating correctly. If a CO sensor is being used, and the damper position is greater than the minimum position, the ventilation control strategy is controlling. Refer to the Startup section. EconoMi$er is operating correctly. Check to ensure the damper is not blocked. Check for 4 VAC on G, Y and Y (if applicable) at TB. If not present, check the setpoint at the T-Stat, and the connections between the T-Stat and the rooftop. If present, check for 4 VAC at G, Y and Y on the EconoMi$er controller. The Outdoor air temperature is below Mechanical Cooling Lockout setpoint. Disable Mechanical Cooling Lockout by turning the setpoint to full counterclockwise position (off). Compressors should start. Adjust to the desired setpoint. Minimum off time of two minutes or interstage time of two minutes may be keeping compressor off. Wait for completion of the time delay before taking further action. Refer to Table 7 for a list of flash codes and the appropriate action. Reset the MIN POS (%) to 00%. The OA Damper should open, and both fans should energize. Reset MIN POS (%) to the correct setting. Make sure line voltage was correctly installed, and proper voltage is present. Verify the auxiliary switch settings are correct. Make sure -pin, 3-pin and 4-pin Molex connections are tight and properly installed. Manual Configuration Pushbutton The EconoMi$er controller also features a manual pushbutton (CONFIG) to help troubleshoot the system. It has three purposes:. Pressing this button for more than 3 seconds but less than 0 seconds, then releasing starts the automatic test procedure. The damper modulates fully open, wait, and modulate closed. This process takes 3 minutes to complete. Use this feature to determine if the actuator can be commanded.. If the CONFIG button is pressed and held for more than 0 seconds, but less than 30 seconds, then released, the EconoMi$er controller reconfigures its mode of operation based on the sensors that are connected and functioning normally, and cancels the automatic test procedure. If the EconoMi$er controller recognizes a non-critical sensor fault, and flashes a code (i.e., Flash 6, outdoor air humidity sensor fault), the flash code is cleared and normal operation begins. Make sure to disconnect the faulty sensors before using this feature. 0 EconoMi$er, Power Exhaust, and Sensor Installation Instructions

21 If the EconoMi$er controller recognizes a critical sensor fault and flashes a code (i.e., Flash 4, supply air sensor fault), the flash code will not be cleared, and the EconoMi$er remains in the safe operation mode. The sensor fault must be corrected to return to normal operation. Refer to the Troubleshooting section. 3. If the CONFIG button is pressed and held for more than 30 seconds and released, the EconoMi$er controller enables the enthalpy comparison strategy (with the outdoor air and return air enthalpy sensors installed). -pin Female Wiring! WARNING: Electrical Shock Hazard. Disconnect power supply and install lockout tag before wiring connections are made to avoid possible electrical shock or damage to the equipment. IMPORTANT: Make all wiring connections in accordance with the National Electrical Code and all local regulations. Figure 44 shows a wiring diagram for a factory installed EconoMi$er with an actuator and a sensor. Figure 45 shows a wiring diagram for field-installed sensors, and Figure 46 shows a power exhaust system. 50DK50834 OAT Actuator 50DK T T PL6 Red Blue Black 3 Brown 4 Gray 5 6 Pink 7 Yellow 8 Orange 9 White 0 Brown 9 5 Red Blue 3 Black 4 Brown 5 Gray 6 Pink 7 Yellow 8 Orange 9 0 Molex Connector (Rear of Plug) Red Brown Green Gray Orange Blue Yellow Black Red Brown Stepper Drive 4VAC 4 GND CLG CLG 50DK5083 B Y Y G AO CONFIG A B 0 0 OFF C D STATUS MIN POS (%) ECON SP MECH CLG LOCKOUT CO SP (ppm) OAT OAH +5V RAT RAH +5V CO (+) CO DAT REM POT LED Tan White Red Used for Enthalpy (See Figure 45.) Pink Connector Cable Figure 44: Wiring Diagram for EconoMi$er with Sensor, Actuator, andcontroller (Factory Installed) EconoMi$er, Power Exhaust, and Sensor Installation Instructions

22 - OAT OAH +5V RAT RAH +5V Enthalpy CROUTENT00A00 Tan White Red Tan White Red T C O O UT M T PW C O M T O UT T PW Unoccupied Control (Part number on the control must be AD-DME7-.) Unoccupied Contact 470 ohm 5 watt Resistor 4 VAC must be present on BI for the system to be unoccupied. Return Air Enthalpy CRRETENT00A00 BI Y Y G AO CO Sensors: 33ZCSENCO (Carrier) CRCDXSEN004A00 (Bryant) CO (+) CO DAT REM POT LED Remote Minimum Position k ohm Potentiometer NOT USED RELAY RELAY 4 VAC 0 VA to 0 VDC at 0 to 000 ppm Line Voltage 0 ma LED PWR Remote LED Field-supplied Wiring Wiring Included Figure 45: Wiring Diagram for Field-installed Sensors EconoMi$er, Power Exhaust, and Sensor Installation Instructions

23 Capacitor Capacitor Fan Fan To Fused Disconnect Relay Relay Red H Gray Red Yel BlueGray H H H3 H H4 HT0AH850 (460 VAC) 4-pin Connector Plug (High Voltage) 3-pin Connector Plug (Low Voltage) X4 X X3 X X X X3 X4 Secondary 30 VAC HT0AH859 (575 VAC) Or Secondary 30 VAC Compressor Contactor 30 VAC 3 3 Field Supplied Wiring C Brown Green/ Yellow Black Black Light Blue Fan Black B A R 4 VAC 3-pin Connector Plug x 4 in. Handy Box Black Blue Green L L GND VAC Phase L L GND 4-pin Connector Plug Green Black Blue C Brown Green/ Yellow Fan Blue Black Light Blue Black Blue B A R 4 VAC Orange Yellow Brown 3 Figure 46: Wiring Diagram for the Power Exhaust System (High Voltage) EconoMi$er, Power Exhaust, and Sensor Installation Instructions 3