Carrier CRDMNDGW001A00, CRDMNDGW002A00 Installation Instructions Manual

CRDMNDGW001A00
CRDMNDGW002A00
Energy Demand Gateway
Rooftop Unit Accessory

Installation Instructions

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NOTE: Read the entire instruction manual before starting the
installation, and follow instructions carefully. Failure to do so may
damage equipment, void warranties, or even cause serious injuries.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury or property
damage. Consult a qualified installer, service agency or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings and cautions
included in literature and attached to the unit. Consult local
building codes and the current edition of the National Electrical
Code (NEC) NFPA 70.

In Canada, refer to the current editions of the Canadian Electrical
Code CSA C22.1.

Recognize safety information. When you see this symbol
the unit and in instructions or manuals, be alert to the potential for
personal injury. Understand the signal words DANGER,
WARNING,andCAUTION. These words are used with the
safety--alert symbol. DANGER identifies the most serious hazards,
which will result in severe personal injury or death. WARNING
signifies hazards, which could result in personal injury or death.
CAUTION is used to identify unsafe practices, which may result
in minor personal injury or product and property damage. NOTE
is used to highlight suggestions which will result in enhanced
installation, reliability, or operation.

on

INTRODUCTION

Carrierr’s Energy Demand System provides reliable and
automated processes to manage the costs of energy consumption.
Carrier’s Energy Demand System uses wireless devices
incorporating patented Swarm Energy Management algorithms to
create a network of coordinated rooftop units to reduce and
optimize their energy usage. This system creates a wireless
network of rooftop units with Energy Demand Load Controllers
communicating through the Energy Demand Gateway.

Each individual Load Controller can independently decide whether
it should allow its unit to run by a relay that can break the
connection between the rooftop unit and the thermostat. By
communicating energy information through the Gateway, units are
prevented from running simultaneously when it is not necessary,
thereby smoothing out peak demand over time. This method
provides the ability to accomplish Demand Management, Demand
Response, and energy trending over time.

Carrier offers two accessories that, when combined, make up the
Energy Demand System. This technology utilizes Swarm Energy
Managementt methodology as a basis for the operating sequence:

S Energy Management Gateway (Coordinator)

(Model Nos. CRDMNDGW001A00, CRDMNDGW002A00):

This model is packaged with a cellular modem and modem
enclosure, and is the first controller to be attached to a packaged
rooftop unit and powered up. This controller will both
monitor/control the attached rooftop unit, as well as act as a
communicationsgateway back to the Swarm Energy
Management Web Portal, a service provided by REGEN Energy,
Inc..

Table 1 – Kit Voltage Requirements

Kit No. Unit Voltage

CRDMNDGW001A00 208/230/460V
CRDMNDGW002A00 575V

S Energy Demand Load Controller

(Model Nos. CRDMNDMD001A00, CRDMNDMD002A00):

This load controller is installed on the remaining packaged
rooftop units that are to be monitored and controlled.

NOTE: Please ensure you have the correct Installation
Instructions for the given type of controller before continuing.

INSTALLATION CONSIDERATIONS

RTU Checklist

Toward the end of this document, there is a RTU checklist that
must be filled out for every Gateway (Coordinator) installed. The
RTU checklist must be legible. The RTU checklists need to be

scanned and emailed to [e-mail] within 48
hours of the completion of the installation. Providing this

checklist is vital to completing device set--up for operation.

Wiring Diagram

A diagram noting all components and their proper wiring is
provided. (See Fig. 11)

Installation Report

An Installation Report is provided at the end of this document,
where you should record installation notes for each Gateway
(Coordinator), and issues encountered.

Recommended Order of Operation To Install the
Gateway (Coordinator):

1. Determine where to mount each component.

2. Mount the components.

3. Wire all components.

4. Power up and test the Gateway (Coordinator).

5. Fill out the required RTU Installation Checklist.

6. Fill out the Installation Report.

7. Scan and email “RTU Checklist” and “Installation Report”
to [e-mail] within 48 hours of complet­ing device setup.

Preferred Location

(Please note the central location on the rooftop)

Equipment Location:

The first step is to decide which rooftop unit should have the
Gateway (Coordinator). This device should be mounted preferably
in the middle of the rooftop or on a rooftop unit where other
controllers have line of sight access to this rooftop unit. (See Fig.

1.)

Overview Schematic

The components listed below must be installed. Refer to the
diagram in Fig. 2. when deciding where to mount each component
in relation to the rooftop unit.

Component Installation Location

Energy Demand Gateway

(Coordinator)

Transformer Inside cabinet

4--Pole Relay Inside cabinet

Modem Enclosure Exterior of cabinet

Antenna and Mounting Base Exterior of cabinet, on top

Inside cabinet

Supplied

Transformer

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Fig. 1 -- Preferred Equipment Installation Locations

Supplied

4-Pole Relay

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Fig. 2 -- Component Installation Schematic

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INSTALLATION

Basic list of tools and materials recommended to
complete installation:

Material

S Small blue wire nuts
S 9/16--in. Rubber grommet
S #18 THHN standard wire
S #18--22 fork connectors
S #18--22 female connectors
S #10 tek screws (3/4--in. long)
S 5--1/2--in. And 7--1/2--in. zip ties
S Tube of clear silicone

Tools

S Cordless drill
S Control screw drivers
S 1/4--in. Pilot bit
S Nut drivers
S Crimp tool
S Wire strippers

Relay

Transformer

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Fig. 3 -- Transformer and Relay Mounting Examples

Suggested Installation Sequence

1. Disable all power to the rooftop unit.

WARNING

!

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury
or death.

Disconnect power before opening unit.

WARNING

!

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury
or death.

Before installing, modifying, or servicing system, the main
electrical disconnect switch must be in the OFF position. There
may be more than one disconnect switch. Lock out and tag
switch with a suitable warning label.

2. Open the main cabinet and control board cover

!

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and

wear appropriate protective clothing and gloves when handling
parts.

3. Determine where each component will be mounted:
S Modem Enclosure: Mounted vertically, on a side of the

cabinet’s exterior

S Gateway (Coordinator): Mounted inside the cabinet,

such that allows access to the keypad and display.
Mounting location examples include, mounting within
the unit control box, on a side wall within the unit, or
any available panel. Ensure the selected mounting loca­tion does not cause damage to coils or existing compo­nents.

S Antenna & Mounting Base: Mounted on top of the cabi-

net

S Relay: Located inside the cabinet such that it reaches

cooling and heating control lines

S Transformer: Located inside the cabinet such that it can

reach:

a. Transformer primary--side wires will be attached to the

rooftop unit’s load--side leads

b. Transformer secondary--side wires will be attached to

the Gateway (Coordinator) power wires (1 & 2) and
modem power lines (24 & 25). See wiring diagram.

Mount Modem Enclosure:

S Modem enclosure should be mounted vertically on an exterior

fixed panel as close to the top of the cabinet as possible
position that allows the cover to be opened.

S DO NOT MOUNT THE MODEM ENCLOSURE ON ANY

REMOVABLE DOORS

!

CAUTION

ACCESSORY RELIABILITY HAZARD

Failure to follow this caution may result in accessory
component damage.

Installation of Modem Enclosure on moveable doors may
make it difficult or impossible to remove doors. This may
also result in dropping the door and damaging the attached
component or severing wires.

S Choose a side of the cabinet with the least exposure to the sun if

possible.

S Ensure the enclosure’s cables can reach the Gateway

(Coordinator)’s cable inside the cabinet.

S Pass the cables to the cabinet inside the rooftop unit using

existing holes if available, or drill one so the cables can reach the
control panel.

S Secure the cables using the black plastic gland (Hand--tighten).

,ina

Mount Gateway (Coordinator):

S Ensure the selected location for the Gateway (Coordinator)

allows access to see the display & use the keypad. (See Fig.4 )

S Ensure extension wire from the Antenna Mounting Base can

reach the top of the Gateway (Coordinator).

S Securely mount the Gateway (Coordinator) using four of the

Mounting Screws

3

Coordinator

V

S Plug the Molex connector pair from a CT to one of the matching

connectors on the Gateway (Coordinator) cable.

Connect Data Cables

Attach the 3--wire Molex connector from the Modem Enclosure to
the 3--wire Molex connector from the Gateway (Coordinator)
(wires 3, 4, 11, 12).

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Fig. 4 -- Gateway (Coordinator) Mounting Examples

Mount Transformer

Securely mount the transformer using 4 of the supplied mounting
screws.(SeeFig.5)

Primary Side

Fig. 5 -- Transformer

Secondary Side, 24

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Mount 4--Pole Relay

S Securely mount the 4--pole relay using the 2 supplied mounting

screws.

S The 4--pole relay has a set of pre--kitted wires to simplify

installation.

S When the coil is energized, this will allow the control signals to

pass on to the control board.

S The rooftop unit’s Y1 and Y2, W1 and W2 control lines should

be connected through the relays’ Normally Open control points
(See Fig. 11) using the pre--kitted wires.

4-Pole Relay

Transformer

Coordinator

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Fig. 7 -- Data Cable Connection

Install Antenna and Mounting Base

Antenna attached
to magnetic mount

Magnetic mount with
extension wire passed
inside cabinet, attached
to top of controller

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Fig. 8 -- Antenna and Mounting Base

S Locate a smooth surface on the top of the cabinet to secure the

Antenna and Antenna Mounting Base. Ensure there is sufficient
slack on the extension cable to reach the Gateway (Coordinator)
(mounted inside the cabinet). (See Fig. 8)

S Locate a small hole through which the antenna wire can pass

into the cabinet (or drill a hole small enough for the wire).
Ensure a 1/2--in. grommet is used to protect wiring from any
sharp edges.

S Hand--tightened the Antenna to the Mounting Base.
S Hand--tighten the Mounting Base’s extension cable to the

antenna mount on the top of the Gateway (Coordinator). Do not
attach the antenna directly to the top of a Gateway
(Coordinator).

Fig. 6 -- 4--Pole Relay Mounting Example

Connect Current Sensors (CTS)

S The two current sensors should be carefully clamped around

different legs of the load--side leads, preferably L1 & L2 (L1 is
often the leg powering single--phase fan motors; confirm via
reading current with a clamp--on meter). (See Fig. 9)

S Ensure the locking tabs are fully secured.

!

CAUTION

ACCESSORY RELIABILITY HAZARD

Failure to follow this caution may result in accessory

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component malfunction.
The antenna must be installed outside of the rooftop unit

cabinet to ensure signal broadcast and reception.

S Glue the Antenna Mounting Base to the top of the rooftop unit

using silicone to ensure it remains fixed even under heavy
winds.

S Use silicone to seal the hole where the antenna cable exits the

cabinet.

4

2 Legs of Load-Side Leads

Locking Tab

CT Molex Connector
mated to one of the

Controller Molex

Connectors

CTs

CT secured around

the load-side leads

Fig. 9 -- Connecting Current Sensors

Connect Power Lines

1. Connect the following wires in parallel to the 24V side of
the transformer:

a. Modem Enclosure Power (wires 24, 25)

b. Gateway (Coordinator) Power – RED Pair, (wires 1 &

2) (See Fig. 11)

2. Connect the primary side of the transformer to the load--side
leads. If a wire extension is required, use stranded 18 AWG
wire.

3. When you power up the Gateway the green WAN light &
green power light should be solid within one minute of
power up. If these lights do not come on please contact RE­GEN Energy’s Operations Center at 949--258--4415, Option
#2.

Fig. 10 -- Modem WAN and Power lights

Test Control Line Integration

1. Jumper the control lines to force the blower and compres­sors on.

2. Restore power to the rooftop unit.

3. Press the Gateway (Coordinator)’s ON button to power up
the Gateway (Coordinator).

4. Wait until you see the indicators on the left of the display
light up in a vertical row.

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6. After the screen displays “rly”, it will then show “1 2”,
where: “1” indicates that Relay 1 (blower control line) is
closed (Applies only for Energy Demand Load Controller
Accessory) and “2” indicates that Relay 2 (cooling and heat­ing control lines) is closed.

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7. Press B to open Relay 2 and confirm that the compressor(s)
turn off (after waiting for any minimum startup runtime de­lays). The display will show “1 –“, indicating that Relay 1 is
still closed, yet Relay 2 is now open.

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8. Wait 20 minutes and then press B to close Relay 2, and
confirm that the compressor(s) resume operation. The dis­play will show“1 2”, indicating that Relay 1 and Relay 2 are
both closed.

NOTE: Some control systems may have up startup delays

5. Press the unlock sequence: Y,B, ENTER. Confirm that the
OVERRIDE indicator flashes and the screen displays “rly”,
indicating that the Gateway (Coordinator) is in Relay Test
Mode.

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NOTE: The selected relay test settings will remain in place for up
to 20 minutes, and up to 10 changes can be made to relay settings
during each Relay Test, after which the Gateway (Coordinator)

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automatically exits the Relay Test Mode and commences regular

r

operation.
After finished the relay test, leave the jumpers connected for at

least five more minutes in order to capture the readings for the
maximum load of the unit.

Do not proceed to the next step until the Relay Test completes
successfully. The Gateway (Coordinator) can be restarted in Test

mode as many times as desired.

Test Gateway (Coordinator) Signal Strength

1. Disconnect all power to the rooftop unit.

2. Remove jumper wires from control lines.

3. Restore all power to the rooftop unit.

4. Turn the Gateway (Coordinator) on, and wait approximate­ly 20 seconds until the TRAFFIC indicator turns on, indi­cating that the Gateway (Coordinator) is attempting to boot
up in regular operation mode

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5. Confirm that the READY indicator turns on, and at least
two bars of signal strength are visible. Contact REGEN En­ergy’s Operation Center (949--258--4415, Option No. 2) for
assistance if fewer than two signal strength bars are dis­played.

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6. Close the rooftop unit’s control panel and all cabinet doors.

7. Contact REGEN Energy’s Operation Center
(949--258--4415, Option No. 2) to notify that the Gateway
(Coordinator) has been successfully commissioned (This
step does not need to be repeated for each Energy Demand
Load Controller).

Load-Side Powe

7

8

Molex

connector

CT Clamp

Sensor 1

CT

Clamp

Sensor 2

Controls

Terminal Board

W1

W2

Y1

18

19

20

21

Modem

Enclosure

9

10

GATEWAY

PWR RS232

GND

Molex

5

6

7

8

connector

Four pole Relay

Omron LY4

Transformer

24VAC-

12VDC

Fig. 11 -- Standard Wiring Schematic for Thermostat Controls (2--Stage Unit)

(COORDINATOR)

12
11

4
3

9

10

11

12

6

13

14

2

5

WIRE NUT CONNECTION

1

24
25

14

15

16

17

FIELD INSTALLED WIRE

Stepdown

Trasformer

FIELD INSTALLED WIRE

From

Thermostat

W1

W2

Y1

Y2

575V
480V

24V

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Parts List

The following equipment is shipped with each Gateway
(Coordinator) Accessory.

1. Gateway (Coordinator) Controller

2. Magnetic antenna base

3. Antenna

4. Modem enclosure (with modem inside)

5. (2) Current Transformers

6. 4--Pole Relay (pre--wired with extension wires)

7. Mounting screws (supplied in a plastic bag, not displayed
below

1. Gateway (Coordinator) Controller

4. Modem Enclosure

5. (2) Current Transformers

(with modem inside)

Fig. 12 -- Supplied Parts included with Each Gateway (Coordinator) Accessory

2. Magnetic antenna base

3. Antenna

6. 4-Pole Relay
(pre-wired with extension wires)

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Site Installation Report

Section 1.- Site Summary

Customer Name

Site Address

Customer Phone Number

Customer Email

Installation Contractor

Section 2.- Installation Details

Qty. of Modems/Gateways (Coordinators) Shipped Installed

Qty. of Load Controllers Shipped Installed

Qty. of 4-Pole Relays Shipped Installed

Qty. of Transformers Shipped Installed

Qty. of Antennas Shipped Installed

Section 3.- Installation Issues

Facility Roof Access Delays: (Ex.: Security, Escort. Clearances, etc.)

List of any RTU #s not operational/disrepair:

(Ex.: RTUs shut down, locked out for service, obvious mechanical problems, etc.)

Customer Name (Print Name) Installer Name (Print Name)

Signature Signature

Date Date

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Gateway (Coordinator) RTU Checklist

Gateway (Coordinator) Installation Checklist

Site

RTU #, Zone Name

Controller ID

Tod a y ’ s D a t e

Installer Name

REGEN Energy Operations Center/Support- [phone], Option #2

Step Notes 

1 Power off RTU

2 Install Gateway (Coordinator) and components, incl.

wiring. Install Modem Enclosure, wire to Gateway (Coordi­nator) inside cabinet.

3 Connect test jumper wires: R to lines on relay that will be

connected to original G, Y1, Y2 lines.

4 Glue antenna base, caulk any drilled openings

5 Pause if need to return to previous RTU after

waiting for portal test, note time

6 Power up RTU

7 Confirm modem WAN light is on within one min. After

power up

8 Wait until blower and all stages of cooling are

energized, note any startup

9 Once all stages of cooling energized, measure

amperage on lines where CTs are clamped,
measure incoming voltage

10 Perform relay test

UP, DOWN, ENTER

Factor in any blower/compressor min. run times and start
delays, note any shutdown delays

111 Exit the relay test to start regular operation

12 Confirm READY indicator and at least two bars of signal

strength. Change Zigbee channel if directed by REGEN
support.

UP, DOWN, UP, UP, ENTER

Note time

13 Move to next RTU, waiting at least 20 min. to

return

14  When you return, power off RTU

15 Remove jumper wires and dress wiring (e.g. tie wraps,

sticky backs)

16

Power up RTU & confirm controller connects to net­work (Confirm READY indicator and at least two

bars of signal strength)

delays

Time Paused:
Time Resumed:

Blower Delay

st

stage Delay

1

nd

stage Delay

2

Incoming Voltage: 277/480/120/208
CT1 Amps:
CT2 Amps:

Blower Delay:

Channel (default of 11 or new value):
#ofbars:

9

Copyright 2013 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Edition Date: 05/13

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Catalog No: CRDMNDGW001--- 01IIK

Replaces: NEW

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