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New Control Box - PowerPoint PPT Presentation

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New Control Box. (Cleaner) Design. Command Center Terminal Board. RTU-MP Controller (Opt). Gas Controller. Controls: Cooling. High Pressure Switch Low Pressure Switch Indoor Fan Motor Overloads: Linebreak Thermik (pilot-circuit) External circuit-breaker. Controls: Cooling.

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New control box l.jpg
New Control Box

(Cleaner) Design

Command Center Terminal Board

RTU-MP Controller (Opt)

Gas Controller

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Controls: Cooling

  • High Pressure Switch

  • Low Pressure Switch

  • Indoor Fan Motor Overloads:

    • Linebreak

    • Thermik (pilot-circuit)

    • External circuit-breaker

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Controls: Cooling

Control Transformer

  • 75 va

  • 3.2-A circuit breaker on transformer housing

    CLO -- Accy or FIOP

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IGC Inputs

Flame Sensor

Hall Effect

W1 Demand Speed Sensor

Rollout Switch

24-v Limit Switch

IGC Outputs

Diagnostic LED

Inducer Motor (CM)

Indoor Blower (BM)

IFO signal

Gas Valve


Controls: HeatingIntegrated Gas Controller (IGC)

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Hall Effect

Ref: Honeywell

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Hall Effect:Pulse Output Signal

Speed Sensor Logic Criteria

Speed > 2400 RPM: Inducer Motor OK

Speed < 2000 RPM: Combustion Terminated

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IGC Error Codes:From NSMM 2003 (SPP PPT) in HVACPartners

  • Fault 2 – Limit Switch Open

    • If limit opens:

      • Gas valve and ignitor will be disable

      • Indoor blower will immediately energized.

      • Inducer shall remain energized

      • The indoor blower will turn off after the fan off delay if “W” goes away.

      • If limit closes again the fault will clear. If you still have “W”, the gas valve still open and re-igniton will occur.

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IGC Service Reference Material

  • NSMM 2003 SPP PPT IGC Alarms

  • Technical Base / Hall Effect

  • Service Training GT54-01

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New PN: HK32EA005

Thermostat demands for

1 or 2 stage Cooling

2 stage Heating

Emergency Heating

Defrost Control in Heating Mode

Based on RES HK32EA003

Heat Pump Defrost Board

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Controls: Heat Pump

  • HPS High Pressure Switch

    • Opens 660PSI. Close 505PSI

  • LPS Low Pressure Switch (A/C’s)

    • Opens 54PSI. Close 117PSI

  • Liquid Line Loss-of-Charge (HP’s)

    • Opens 27PSI. Close 44PSI

  • Freeze Protection Thermostat (FPS)

    • Opens 30F. Close 45F

    • Connects to new defrost board

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Reversing Valve Operation

  • No O or B signal required

  • Energized in Cooling

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

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Heat Pump Compressor Seq

Cooling Stage 1:

Reversing Valve 1 + Compressor

Cooling Stage 2: (2-comp models only)

Rev Valves 1+2 + Compressors 1+2

Heating Stage 1:

Compressor(s), No Reversing Valve

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Heat Pump Electric Heat

Heating Stage 2

Concurrent with compressor(s)

Emergency Heat

Electric Heat WITHOUT compressors

Defrost Tempering

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Heat Pump Defrost

Time-Temperature Sequence

1. Heat Run Time (30,60,90 or 120 mins) Factory 60 mins

2. Initiate if tube temperature (DFT) low

3. Terminate when tube temperature (DFT) rises or defrost run period reaches 10 min

HH18SA261DFT Settings:

Open: 30F

Close: 80F

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Defrost Speed-Up

  • JMP17-JMP18 (flat/slot screwdriver)

  • 1-5 secs: Speed-Up (0.1 sec/min)

  • 5-20 secs: Forced Defrost

    Run to normal

    termination or

    30 secs minimum

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Controls: Electric Heat

Accessory installation

1 or 2 stages

Fan housing limit switch (pilot, manual)

Element line-break

(or secondary contactor)

Heater control contactor(s)

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Electric Heat: Single-Point Box

  • Required with all electric heater installations

  • Splice box with cover

  • Power terminal block

  • Tap conductors

  • If FLA > 48-A:

    Fuse blocks and 60-A fuses

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Installation InstructionsandService Manuals (SM)

The complete unit installation procedure (rig and position through start-up) will require reference to two (or more) technical manuals.

Mechanical Installation: SI (II)

Configure/Start-up/Troubleshoot: SM

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Service Manual: LP Gas Conversion

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Specific Topic Tech Support

Smoke Detectors: Application Tip Cat# HKRNKA-1XA

(integration with building alarm systems)

PremierLink: Form 33CS-58SI (configuration, t-s)

RTU-MP: Form 48-50H-T-2T (configuration, t-s)

RTU-MP 3rd Party Integration Guide

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Controls Terminal Board


Light Commercial Terminal Board (LCTB)

Command Center Terminal Board

Carrier PN HK50AA049

UTEC PN CEPL130904-01

Array of terminal strips, housings and QCs

Contains NO LOGIC, no software

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Controls Terminal Board

Gas Controller


- Clean connection points

- Insures positive connections

- Visual aid

Phase Monitor


Fire / Remote Shutdown


Smoke Alarm



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Controls Terminal Board

11 terminal strips:

J1-J2: Screw terminals (thermostat wires)

0.046-in square pin

18 quick-connect terminals

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CTB: Jumpers




  • JMP1 Phase Monitor

  • JMP2 Occupancy Control

  • JMP3 Smoke Detector Shutdown

  • JMP4 Remote Shutdown

  • JMP5, 6, 7 Heat Pump / Reheat





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2010 FIOPs

  • Convenience Outlets

  • Smoke Detectors

  • CO2 Sensor (new)

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Convenience Outlets

  • Non-Powered

  • Unit-Powered

  • Neither is connected as delivered

  • Hinged cover shipped loose

    (in control box)

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Duplex GFCI

Weatherproof box

Hinged cover


Duplex GFCI

Weatherproof box


15-A fuse/switch

Hinged cover

Convenience Outlets

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Non-Powered CO

  • Provide a separate 115-v 15-A power supply and circuit disconnect from the building

  • Connect to the duplex outlet in the unit’s splice box

  • Install the weatherproof hinged cover

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Powered CO

  • Check local codes to determine if connecting the convenience outlet transformer to the LINE side of the unit disconnect is acceptable.

  • If acceptable: Connect primary leads at the power transformer together as required for unit line voltage and connect to unit disconnect’s line side terminals.

  • If not acceptable: Connect primary leads at the power transformer together as required for unit line voltage and connect to unit disconnect’s load side terminals.

  • Install the weatherproof hinged cover.

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Powered CO:Transformer Primary Connections

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Smoke Detector FIOPs

  • Supply Air (on supply fan housing)

  • Return Air w/o Economizer

  • Return Air with Economizer

  • Combine S/A and R/A

    R/A Smoke Detector is for VERTICAL only

    “Some assembly required”

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Smoke Detector Hardware

  • Controller Module (one per unit)

  • Sensor Module (one or two required)

  • R/A application: Sensor tube

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Smoke Detector:Alarm Integration

  • Application Tip Cat# HKRNKA-1XA

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NEW FIOP:Unit-Mounted CO2 Sensor

  • Same control logic as on accessory CO2

  • No LCD display on sensor

  • Requires PC access to configure

  • Software and cable available thru RCD

  • Details to follow in full training program

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2010 SRT FIOPs

  • Economizers (15th digit)

  • CO2 sensors (9th digit)

  • Smoke Detectors (9th digit)

  • Louvered Hail Guard (11th digit)

  • 2-position Damper (15th digit)

  • Convenience Outlet (16th digit)

  • Thru-The-Base Connections (17th digit)

  • PremierLink (14th digit)

  • RTU-MP/Open (14th digit)

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2010 SRT Accessories

  • Economizers & Roofcurbs

  • CO2 & Enthalpy sensors

  • Power Exhaust

  • Motormasters (low ambient) and winter start

  • LP Conversions

  • High Altitude Kits

  • 2-pos damper / Man damper

  • Thru-The-Base

  • Louvered Hail Guards

  • Electric Heat / Single Point

  • Phase Monitor, Status switch, time guard

  • PremierLink

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Economizer Plugs

  • Command Center aka Low Voltage Terminal Board (LVTB)

    • ECON 10pin Plug

      • Used for all Economizers

    • SAT/OAT 4pin Plug

      • Used for Econ 2 only

    • OCCUPANCY Terminals

      • Used for Econ IV and 2-pos Damper

  • 12-Pin Plug (male) – Unit Side plug in Econ Section

    • Same plug and arrangement as old units

  • 12-Pin Plug (female) – Econ Side

    • Comes with specific FIOP or Accessory

    • Small change on the Econ IV plug

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Economizer Plugs

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

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Economizer IV

  • Electro-mechanical Unit Economizer

  • Stand alone operation with Honeywell W7212 controller.

  • Compressor control runs through the W7212

    • If no econ then jumpers must be in 12-pin plug for cooling to operate

  • Actuator is 2-10 vdc pre-programmed ready for W7212 output

  • SAT in 12-pin plug (PL6)

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Economizer IV

  • Added occupancy control

    • The “N” terminal tells the controller when occupied

    • R-22 units had W7212 main power fed from the IFC and jumper to the N terminal

    • 410a units have main power fed from transformer, and IFC feeds the N terminal trough the Occupancy terminals

    • So W7212 is powered up when the unit is, instead of only when the fan is on

  • Low Ambient Lockout

    • The “LA” switch is installed on the Y2 input to the controller

    • Part number HH18HA286, Contacts Open: 42°F ±5°F, and Contacts Close: 57°F. ±5°F.

    • Below 42°F the second compressor will not run, econ will be stage one and 1st comp is stage 2

  • Power exhaust wire

    • Tan wire that is connected to 24Vac HOT, move to EF1

    • Add jumper from 24Vac HOT to EF

    • Connect other end of the tan wire to the tan wire in the PE Kit harness

    • Connect the Grey wire in the PE kit harness to the 24Vac COM terminal

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Economizer IV

  • CO2 Sensor

    • IAQ install, uses 24Vac (TR & TR1), and 0-10Vdc signal (AQ & AQ1), TR1 & AQ1 are common

    • Demand Control Ventilation (DCV) is the only CO2 control available for Econ IV.

      • DCV SET (POT) tells the controller at what input vdc from the IAQ sensor do we want to start opening the damper

      • DCV MAX (POT) tells the controller at what damper position do you want us to stop opening for DCV

      • The damper will modulate between the MIN POS (POT) and DCV MAX (POT) settings proportional to the IAQ vdc input from DCV SET (POT) to 10Vdc

  • Enthalpy

    • The Single Enthalpy sensor uses the same terminals as dry bulb (SO+ & SO).

    • For Differential Enthalpy, 2 enthalpy sensors required. One installed per above and the other on terminals SR+ & SR (after removing the resistor). Set the cross over POT to “D”

      • Whichever is lower is the air used for cooling

      • Remember O for outdoor and R for Return

    • Enthalpy sensors are HH57AC078 and Dry bulb are HH57AC074

  • Power Exhaust (PE)

    • Terminals EF and EF1 are dry contacts and switch when the damper pos (in Vdc) gets above the EXH SET (POT) setting (in vdc)

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Economizer 2

  • Econ2

    • No controller, requires Plink or RTU-MP/open

    • Jumper wires in 12-pin plug for cooling operation

    • Actuator is 2-10vdc pre-programmed

      • 500 ohm resistor (pre-installed) required for 4-20 controller output

    • OAT in 12-pin plug (PL6)

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Economizer 2

  • CO2 Sensor

    • IAQ is installed on the specific controller via PL18 for FIOP and direct to controller when field installed

    • DCV is set in the specific controller with a user interface.

  • Enthalpy (only field installed)

    • Single or Differential control from the DDC controller

    • Uses the 2 loose Grey wires near unit’s 12 pin plug

    • Sensor wires run to the LVTB and then to DDC

  • PE

    • Wires provided with the PE accessory have to be run to the control box specifically to which ever DDC is installed

    • Switch one stage on and off based on damper position

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Economizer 2

  • Cooling jumpers must be in harness for cooling to work

  • Resistor must be between the White signal wire and Black actuator common

    • Actuator is 2-10v and controllers output 4-20mA

  • Enthalpy sensor power from Actuator power

    • Switch signal using 2 grey wires

  • When troubleshooting

    • Read vdc across resistor

      • Determine if it’s the actuator or the controller

    • Shorting the actuator signal to 24VAC will drive it 100%, but disconnect the actual signal first

    • Spring return Closed

    • Direction switch set to same direction as the spring return

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2-Position Damper

  • Opens to set position whenever the fan is running

  • To set position, set the screw on the actuator face near the shaft opening

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Low Ambient

  • Winter start Kit (CRWINSTR001A00)

    • 3 minute timer relay to bypass low pressure switch

    • Field supply wires to tie into the LVTB, contact across LPS and coil between HPS and compressor contactor

    • Current Literature – IIK-CRWNTRAN01-01

  • Motormaster I (32LT)

    • Wave Chopper, varies voltage to vary fan speed, single phase approved motors, clip on sensor

    • May need to replace motor and capacitor. Usage chart in literature.

    • Copper Coil Controller with sensor – 32LT900301 (230v), and 32LT900611 (460v)

    • MCHX coil controller with sensor – 32LT901247 (230v), and 32LT901647 (460v)

    • Tries to maintain 100 deg SCT, unit operation down to -20 deg

    • Current Literature – IIK-32LT903-01

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Low Ambient

  • Motormaster II (CPLOWAMB001A00)

    • Fan cycle switch, on/off only, single phase motors, clip on sensor

    • Tries to maintain 130-110 high and 70-50 low SCT, unit operation down to -20 deg

  • Motormaster V

    • Kits CRLOWAMB030A00, 031A00, and 032A00 for specific voltage

    • For use on three phase motors (48/50TC 14 and 50TCQ 12)

    • VFD, varies frequency (HZ) to vary fan speed, 3 phase approved motors

    • Pressure sensor on liquid line, unit operation down to -20 deg

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Gas Conversion Kits

Four kits for use with LP and/or high altitude applications. Each contain 25 spuds, 5 of 5 different sizes.

Manifold Pressure

Natural Gas still 3.5-in.wc.

LP now 10.5-in.wc.

  • High Altitude Conversion

    • Pick kit based on orifices needed

    • Use only spuds and High-Alt label in kit

    • Some spuds may have to be purchased separately

    • Literature contains conversion tables

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Gas Conversion Kits

  • LP Conversion

    • New, low pressure switch on supply side

      • Closes at 10.2-in.wc. and opens at 7.2-in.wc.

      • Gas piping included in kits

    • Kits include springs for gas valve to operate at higher pressure

    • Labels for LP and high alt (if needed)

    • Chose Kit based on orifices needed, some orifices may have to be purchased separately


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  • PremierLink

    • FIOP or Accessory. If field installed make sure the CRPREMLK001A01 kit was also purchased. It has the harness for LVTB and the TB to install other accessories to.

  • RTU-MP

    • FIOP only and only available through mid-2009

    • Overview training PES0810302 on partners

    • Controller training PES0803241 on Partners

    • Other information and tools on HVACpartners (CCN Support – Multi-Protocol Controls)

  • RTU-Open

    • Only FIOP until 3 Qtr 2009, then the retrofit should be available

    • Replaces the RTU-MP, direct replacement

    • Improved control and improved networking

    • Fixes battery memory with flash memory, otherwise hardware is the same

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RTU-Open Support

Open release – FIOP around June 2009

– Accy around July 2009

  • Contact Equipment Product support for:

    • Specific base unit operation or problems

    • Questions/problems with the Controller or how it controls the unit, if it was Factory installed (FIOP)

    • Questions/problems with how the FIOP was installed

    • Controller operation, start-up, configuration, and troubleshooting questions

  • Contact CCN support for:

    • Network Integration and Communication questions or problems

    • Questions/problems with the controller if it was field installed (accessory)

    • Questions/problems with the accessory installation

    • Controller operation, start-up, configuration, and troubleshooting questions

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What’s Next

  • Bynum Training program 4th Qtr