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INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
BEFORE STARTING INSTALLATION OR MAINTENANCE PROCEDURES, TURN OFF ELECTRICAL POWER AND
COMPLETELY DEPRESSURIZE THE AFTERCOOLER. FAILURE TO HEED THIS WARNING MAY RESULT IN SERIOUS
PERSONAL INJURY AND/OR DAMAGE TO THE UNIT.
NEVER REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE AFTERCOOLER WHILE IT IS PRESSURIZED.
WHEN INSTALLING THIS KIT, ALWAYS COMPLY WITH THE NATIONAL ELECTRICAL CODE AND ALL OTHER
APPLICABLE FEDERAL, STATE AND LOCAL CODES.
SECTION 1
1.1 DESCRIPTION OF OPERATION
The FP-4 freeze protection kit is designed to prevent aftercooler freeze up when the ambient temperature is near or below
o
o
freezing, 32
F (0
C).
The FP-4 has a two stage solid state temperature controller. The controller is mounted inside a Nema 4 enclosure. The
controller is used to energize a control relay which is rated to handle the load of the aftercooler fan at the various voltages.
The linear platinum temperature sensor and
thermowell mount into the piping between the
outlet manifold of the aftercooler and the
separator. When the temperature of the com-
pressed air system at the aftercooler outlet falls
to 35
O
F, the controller will automatically turn off of
the fan. The controller is set for a 10
band to prevent rapid cycling (fan will turn off at
35
O
F and on at 45
o
F).
A 12 foot heat tape and 30 feet of insulation wrap
are provided to wrap around the separator. The
heat tape is equipped with its own internal
temperature control. The heat tape and insula-
tion will provide additional freeze up protection.
1.2 THIS KIT INCLUDES:
Control box
1.
2.
12 long heat tape, w/ thermostat
3.
30 long roll of insulation wrap
4.
Copper 1/2" NPT thermowell w/clip
Cord grip connector
5.
Linear platinum sensor
6.
2 of 3/8" flexible conduit
7.
8.
Three (3) seal fittings for connectors
9.
3/8" conduit straight connector
10.
3/8" 90 degree elbow connector
1" x 1/2" NPT bushing
11.
Four (4) #12-14 x 1" self tapping screws
12.
Heat Condictive Compound
13.
FP-4 FREEZE PROTECTION KIT
P/N
FOR TURBO-COOL AFTERCOOLERS
MODELS AC-140-7 thru AC-220-7
(230V-3PH-60Hz & 460V-3PH-60Hz)
WARNING
FIGURE 1-A ITEMS INCLUDED WITH THIS KIT
o
F dead
FOR
83-0763
February 2008
P/N 32-0228
REV . B
INTRODUCTION
PAGE 1
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Table of Contents
Troubleshooting
Summary of Contents for Van Air Systems FP-4
- Page 1 SECTION 1 INTRODUCTION 1.1 DESCRIPTION OF OPERATION The FP-4 freeze protection kit is designed to prevent aftercooler freeze up when the ambient temperature is near or below freezing, 32 F (0 The FP-4 has a two stage solid state temperature controller. The controller is mounted inside a Nema 4 enclosure. The controller is used to energize a control relay which is rated to handle the load of the aftercooler fan at the various voltages.
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Page 2: Installation
SECTION 2 INSTALLATION 2.1 MOUNTING THE CONTROL BOX FIGURE 2-A MOUNTING THE CONTROL BOX The control box should be mounted near the outlet manifold of the aftercooler. Make sure that the control box is close enough so that all components can reach the box when in- stalled. -
Page 3: Electrical Connections
SECTION 2 INSTALLATION 2.4 INSTALLING THE CONDUIT FIGURE 2-D INSTALLING THE CONDUIT Install the straight conduit connector on the control box. Reference Figure 2-D. The supplied conduit will be used to run between the aftercooler and the control box. Connect the conduit to the straight connector. - Page 4 SECTION 2 INSTALLATION FIGURE 2-F CONTROL BOX COMPONENT LAYOUT and WIRING DIAGRAM IMPORTANT THE FAN MOTOR MUST ROTATE IN THE CORRECT DIRECTION. REFERENCE THE AFTERCOOLER OPERATOR'S MANUAL FOR PROPER ROATION DIRECTION. IF IT DOES NOT, THE ROTATION CAN BE CORRECTED BY SWITCHING TWO OF THE POWER LEADS TO THE MOTOR. PAGE 4...
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Page 5: Setting The Controller
DIFFERENTIAL MODE COOLING Turn on the main power to the FP-4 control. If the settings have been changed, set them to the factory settings following the procedures below . The controller will retain the setting if the power is disconnected. -
Page 6: Troubleshooting Procedures
SECTION 4 TROUBLESHOOTING 4.1 TROUBLESHOOTING PROCEDURES SOLUTIONS PROBLEM POSSIBLE CAUSES Controller not set properly 1. Aftercooler fan motor Check the controller settings as outlined in Section 2.7. The continues to operate, controller may be set in the heat mode or the set points set too system temperature low. -
Page 7: Replacement Parts
SECTION 5 REPLACEMENT PARTS 5.1 REPLACEMENT PARTS ITEM NO. DESCRIPTION PART NO. 12 LONG HEAT TAPE 26-8151 30 ROLL OF INSULATION WRAP 26-0712 1/2" NPT THERMOWELL w/CLIP 29-0325 CORD GRIP CONNECTOR 26-5618 SENSOR 26-7186 3/8" FLEXIBLE CONDUIT 2 FT 26-0875 SEAL FITTING FOR CONNECTOR 26-0883 3/8"... -
Page 8: Warranty
SECTION 6 WARRANTY PER VAN AIR TERMS AND CONDITIONS OF SALE YOUR VAN AIR REPRESENTATIVE IS: NAME: COMPANY: ADDRESS: CITY: STATE: ZIP: PHONE: FAX: ATTACH BUSINESS CARD HERE 2950 Mechanic Street Lake City, PA 16423 USA Phone: 800/840-9906 Service Fax: 814/774-0778 Order Entry Fax: 814/774-3482 MAKING COMPRESSED AIR AND GAS WORK BETTER SINCE 1944. -
Page 9: Installation Instructions
T775A/B/M Series 2000 Electronic Stand-Alone Controllers INSTALLATION INSTRUCTIONS PRODUCT DESCRIPTION The T775 electronic stand-alone controllers are the next generation of commercial and agricultural controls capable of remote sensing of temperature and providing switched and/or proportional outputs to various types of loads. -
Page 10: Controller Dimensions
T775A/B/M SERIES 2000 CONTROLLER PRODUCT DESCRIPTION Temperature Sensors Accessories The controller accepts 1,097 Ohms PTC at 77°F (25°C): • 107324A – Bulb Holder, duct insertion • 50021579-001 – Standard sensor (included with all • 107408 – Heat Conductive Compound, 4 ounce models except NEMA 4X models) •... -
Page 11: Before Installation
BEFORE INSTALLATION T775A/B/M SERIES 2000 CONTROLLER BEFORE INSTALLATION The controller may be mounted in any orientation. However, mounting in the orientation shown in Fig. 1 permits proper viewing of the LCD display and use of the Review the “Specifications” on page 35 before keypad. -
Page 12: Wiring Connections Access
T775A/B/M SERIES 2000 CONTROLLER WIRING Wiring Connections Access NOTE: Each T775 controller must be wired to its own sensor(s). However, a benefit of the T775 To access the wiring connections, remove the two screws controller’s accuracy is that there is no more on the left side of the enclosure and gently swing open the than a 2°F differential between any two T775 top. -
Page 13: Controller Wiring
WIRING T775A/B/M SERIES 2000 CONTROLLER Controller Wiring See Fig. 7 on page 6 for locating the appropriate power input, remote sensors input, low voltage, contact closure, and load output terminals. WARNING Access to the terminals can be gained through standard conduit knockouts (A through E in Fig. - Page 14 T775A/B/M SERIES 2000 CONTROLLER WIRING APPLICATIONS (EXAMPLES) Controller Wiring Details Table 2. Description of Wiring Terminal Connections. (Continued) The wiring connection terminals are shown in Fig. 7 and are described in Table 2. Connection Terminal Label Description Input See Fig. 8 – Fig. 20 beginning on page 6 for typical Digital Input (dry T775A/B/M wiring applications.
- Page 15 WIRING APPLICATIONS (EXAMPLES) T775A/B/M SERIES 2000 CONTROLLER SENSOR A SENSOR A (HOT) 24 VAC 120V LOAD LOAD LOAD LOAD LOAD LOAD 1 LOAD 4 LOAD M24476A 1 FOR 240 VAC LOAD, CONNECT TO 240 TERMINAL. M24478A Fig. 9. Wiring for four-stage control – 24 Vac input Fig.
- Page 16 POTENTIOMETER (H205 OR H705) M24482 MODUTROL MOTOR (Q209) Fig. 14. Wiring for Digital Input (dry contact). W R B T1 T2 B HONEYWELL MODUTROL MOTOR WITH 4-20 mA MODULATING INPUT POWER – + T1 T2 OUTPUT – MODULATING OUTPUT POWER –...
- Page 17 WIRING APPLICATIONS (EXAMPLES) T775A/B/M SERIES 2000 CONTROLLER M9184 OR M9185 MODUTROL MOTOR (HOT) – M9184 OR M9185 MODUTROL MOTOR – M9184 OR M9185 MODUTROL MOTOR MODULATING OUTPUT TERMINAL (MOD 1) POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. USE A 1300 OHM RESISTOR FOR TWO MOTORS, 910 OHM RESISTOR FOR THREE MOTORS.
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Page 18: Power Loss
T775A/B/M SERIES 2000 CONTROLLER CHECKOUT CHECKOUT Table 3. Temperature Sensor Calibration for Resistance Loss due to Wire Length. Inspect all wiring connections at the controller terminals, Temperature Offset in and verify compliance with the installation wiring °F (Foot) diagrams. Rating mΩ/ft 200 ft 500 ft... -
Page 19: Interface Overview
INTERFACE OVERVIEW T775A/B/M SERIES 2000 CONTROLLER INTERFACE OVERVIEW Menu Button • Pressing the MENU button always displays the Program menu. If you are in Setup mode, you exit The T775A/B/M controllers use an LCD panel and setup and return to the Program menu. 6-button keypad to provide status information and permit •... -
Page 20: Accessing The Menus
T775A/B/M SERIES 2000 CONTROLLER INTERFACE OVERVIEW Accessing the Menus HOME Menus are used for programming, scheduling, viewing the RELAYS 1 2 3 4 summary settings, and setup of advanced options. SETUP SENSORS SENSORS SENSOR A Programming, Scheduling, and Summary Menus OUTPUTS EXIT To access these menus from the home screen, press the... - Page 21 1. PROGRAMMING T775A/B/M SERIES 2000 CONTROLLER 1. PROGRAMMING Setpoint High Limit You can set a single irreversible setpoint high limit maximum value, which is applied to all outputs. The controller must be programmed before being placed into service. Adjust the setpoint (at any output) to the desired IMPORTANT maximum setpoint.
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Page 22: Entering Program Mode
T775A/B/M SERIES 2000 CONTROLLER 1. PROGRAMMING Programming the T775A/B/M Controller When programming is complete, you may continue with “3. Scheduling” on page 30 or, for advanced options, continue with “2. Setup (Advanced Options)” on page 17. To program the controller, perform the following procedures in the order listed: 1. - Page 23 1. PROGRAMMING T775A/B/M SERIES 2000 CONTROLLER MENU 1.2.2. DIFFERENTIAL or THROTTLING RANGE PROGRAM PROGRAM RELAY 1 RELAY 1 Differential is used for Relay outputs and Throttling Range DIFFRNTL DIFFRNTL is used for Modulating outputs. 1. From the menu, use the buttons to high- light THROT RNG or DIFFERNTL.
- Page 24 T775A/B/M SERIES 2000 CONTROLLER 1. PROGRAMMING MENU 1.2.5. SETBACK PROGRAM PROGRAM RELAY 1 RELAY 1 The Setback temperature option displays if scheduling is SETBACK SETBACK enabled (see Fig. 55 on page 24) or the DI Option is set to Setback. (see Fig. 57 on page 25). This is the desired setpoint temperature that you want to use during setback mode for this output.
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Page 25: Setup Procedure
2. SETUP (ADVANCED OPTIONS) T775A/B/M SERIES 2000 CONTROLLER 2. SETUP (ADVANCED OPTIONS) Setup provides the ability to change the factory default Once in Setup mode, you use the — settings for the temperature sensors and outputs, to • Left arrow button( ) to scroll backward through the enable/disable reset control, and to enable/disable Setup menus scheduling. - Page 26 T775A/B/M SERIES 2000 CONTROLLER 2. SETUP (ADVANCED OPTIONS) 2.2.2. SENSOR A SETUP SETUP SENSORS SENSORS SENSOR A 1. From the Sensors menu, highlight SENSOR A. SENSOR A 2. Press the button to display the Sensor A selec- UNITS CALIBRATE tions. LABEL EXIT M24502...
- Page 27 2. SETUP (ADVANCED OPTIONS) T775A/B/M SERIES 2000 CONTROLLER 2.2.2.4. Exit Sensor A Setup SETUP SENSORS Press the button to exit Sensor A selections and return SENSOR A to the Sensors menu. UNITS CALIBRATE Use the buttons to highlight EXIT and press the LABEL EXIT button.
- Page 28 T775A/B/M SERIES 2000 CONTROLLER 2. SETUP (ADVANCED OPTIONS) SETUP SETUP 2.2.4. LIMIT SENSORS (Sensor B only) SENSORS SENSOR B SENSOR B For the T775M2030 and T775M2048 models only, the LIMIT LIMIT LIMIT item displays on the Sensor B menu. DISABLE HI LIMIT NOTE: The LIMIT option acts only on Modulating LOW LIMIT...
- Page 29 2. SETUP (ADVANCED OPTIONS) T775A/B/M SERIES 2000 CONTROLLER 2.2.4.2. THROTTLING RANGE SETUP (Sensor B only) SETUP SENSORS SENSORS The throttling range for the modulating high or low limit SENSOR B SENSOR B positions the setpoint at the end of the throttling range. UNITS For example, with a high (Heat) limit at Sensor B of 200°F CALIBRATE...
- Page 30 T775A/B/M SERIES 2000 CONTROLLER 2. SETUP (ADVANCED OPTIONS) SETUP SETUP 2.3.1.1. TYPE (of output signal) OUTPUTS OUTPUTS MOD 1 MOD 1 TYPE TYPE 1. From the Mod menu, use the buttons to highlight TYPE. 4 - 20 mA 0-10 V 2.
- Page 31 2. SETUP (ADVANCED OPTIONS) T775A/B/M SERIES 2000 CONTROLLER SETUP SETUP 2.3.1.4. DERIVATIVE OUTPUTS OUTPUTS MOD 1 MOD 1 The Derivative default value is factory set to zero (no DERIVATIV DERIVATIV derivative control). It is strongly recommended that the derivative remain at zero (0) unless you have a very good reason to adjust it.
- Page 32 T775A/B/M SERIES 2000 CONTROLLER 2. SETUP (ADVANCED OPTIONS) 2.3.2. NBR OF RELAYS SETUP SETUP OUTPUTS OUTPUTS # RELAYS # RELAYS 1. From the Outputs menu, use the buttons to highlight # RELAYS. 2. Press the button to display the number of relays. 3.
- Page 33 2. SETUP (ADVANCED OPTIONS) T775A/B/M SERIES 2000 CONTROLLER SETUP SETUP 2.3.3.2. MIN OFF (minimum off time for all relays) OUTPUTS OUTPUTS OPTIONS OPTIONS This is the minimum number of seconds of “off time” for MIN OFF MIN OFF all relays. 1.
- Page 34 T775A/B/M SERIES 2000 CONTROLLER 2. SETUP (ADVANCED OPTIONS) 2.3.3.5. Exit Options Setup SETUP OUTPUTS Press the button (or highlight EXIT and press the OPTIONS button) to exit and return to the Outputs menu. USE SCHED MIN OFF Continue with “2.3.4. Setting up the Relays” DI OPTION SHOW RT EXIT...
- Page 35 2. SETUP (ADVANCED OPTIONS) T775A/B/M SERIES 2000 CONTROLLER 2.3.4.1.1. Floating Relay Menu SETUP SETUP OUTPUTS OUTPUTS The Floating option is only available on the T775B2016, FLOAT 1 FLOAT 1 T775B2024, T775B2032, and T775B2040 models. TYPE ACTUATOR When Relay 1 or Relay 3 is setup as floating, relays are INTEGRAL DERIVATIV paired and the Float 1 or Float 2 menu displays with the...
- Page 36 T775A/B/M SERIES 2000 CONTROLLER 2. SETUP (ADVANCED OPTIONS) SETUP SETUP 2.3.4.1.1.3. DERIVATIVE (modulating/floating relay only) OUTPUTS OUTPUTS FLOAT 1 FLOAT 1 The Derivative option displays only on the T775B2016, DERIVATIV DERIVATIV T775B2024, T775B2032, and T775B2040 models when the Type option = Floating. 1.
- Page 37 2. SETUP (ADVANCED OPTIONS) T775A/B/M SERIES 2000 CONTROLLER 2.4. EXIT Setup Mode SETUP OUTPUTS Press the button to exit the selected relay set up and RELAY 1 return to the Outputs menu. RESET SCHEDULE To setup the next relay output go to “2.3.4. Setting up the RESET RT EXIT Relays”...
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Page 38: Creating A Schedule
T775A/B/M SERIES 2000 CONTROLLER 3. SCHEDULING 3. SCHEDULING Scheduling provides the ability to set daily temperature NOTES: settings for up to two events per day. Typically, these are If you press the HOME button or there is no the daytime (setpoint) and the nighttime (setback) keypad activity for four minutes, you exit settings. - Page 39 3. SCHEDULING T775A/B/M SERIES 2000 CONTROLLER MAIN MAIN 3.2.1. SET TIME SCHEDULE SCHEDULE OPTIONS OPTIONS Setting the system time is required to enable the SET TIME SET TIME controller to follow daylight saving time. IMPORTANT Set the Date before setting the Time. See “3.2.2.
- Page 40 T775A/B/M SERIES 2000 CONTROLLER 3. SCHEDULING 3.3. Setting Individual Schedules MENU MENU SCHEDULE SCHEDULE As shown in the Schedule menu (Fig. 69 on page 30), MON-FRI MON-FRI schedules can be set for the following time periods: E1 SETPT • Monday through Friday E1 TIME •...
- Page 41 3. SCHEDULING T775A/B/M SERIES 2000 CONTROLLER MAIN MAIN 3.3.2. E1 TIME (time for event 1) SCHEDULE SCHEDULE MON-FRI MON-FRI E1 TIME E1 TIME 1. From the selected time period menu, use the buttons to highlight E1 TIME. 2. Press the button to display the current time set- ting for event 1.
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Page 42: Summary Menu
T775A/B/M SERIES 2000 CONTROLLER SUMMARY MENU SUMMARY MENU TROUBLESHOOTING The Summary menu provides the ability to view the Power Loss schedule (E1 and E2 times) for each relay for each day of the week. The date and time settings are retained for 24 hours after a power outage. -
Page 43: Specifications
SPECIFICATIONS T775A/B/M SERIES 2000 CONTROLLER SPECIFICATIONS Power: 24, 120, or 240 Vac; 50/60 Hz; Emissions Compliance A separate earth ground is required for any power source. EN 55022: 2006 CISPR 22: 2006 Power Consumption: VCCI V-3/2006.04 • 8 VA maximum at 60 Hz ICES-003, Issue 4: 2004 •... - Page 44 T775A/B/M SERIES 2000 CONTROLLER Automation and Control Solutions Honeywell International Inc. Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9 customer.honeywell.com ® U.S. Registered Trademark © 2007 Honeywell International Inc. 62-0254–03 M.S. Rev. 09-07...