Honeywell AC-140-7 User Manual

February 2008

P/N 32-0228

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

FOR

FP-4 FREEZE PROTECTION KIT

P/N 83-0763

FOR TURBO-COOL AFTERCOOLERS

MODELS

(230V-3PH-60Hz & 460V-3PH-60Hz)

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.

AC-140-7 thru AC-220-7

WARNING

REV . B

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, 32oF (0oC).

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 com­pressed air system at the aftercooler outlet falls
to 35OF, the controller will automatically turn off of
the fan. The controller is set for a 10oF dead
band to prevent rapid cycling (fan will turn off at
35OF and on at 45oF).

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 insula­tion will provide additional freeze up protection.

1.2 THIS KIT INCLUDES:

Control box

1.
12' long heat tape, w/ thermostat

2.
30' long roll of insulation wrap

3.
Copper 1/2" NPT thermowell w/clip

4.
Cord grip connector

5.
Linear platinum sensor

6.
2' of 3/8" flexible conduit

7.
Three (3) seal fittings for connectors

8.
3/8" conduit straight connector

9.
3/8" 90 degree elbow connector

10.
1" x 1/2" NPT bushing

11.
Four (4) #12-14 x 1" self tapping screws

12.
Heat Condictive Compound

13.

FIGURE 1-A ITEMS INCLUDED WITH THIS KIT

PAGE 1

SECTION 2 INSTALLATION

2.1 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 in­stalled.

Drill the four pilot holes in the mounting
surface using a 1/8" drill. Reference Figure 2­A for dimensions.

The control box will be mounted with the
hinged side of the enclosure on the bottom.

Fasten the controller in place using the four
(4) #12-14 x 1" long self-tapping screws
supplied with the kit.

2.2 INSTALLING THE SENSOR AND
THERMOWELL

A 1/2" NPT or larger connection in the system
piping between the outlet of the aftercooler
and the inlet of the separator is required for
the thermowell and sensor.

Thread the thermowell and the 1" x 1/2"
bushing (if required) into a connection
between the aftercooler outlet and the
separator.

FIGURE 2-A MOUNTING THE CONTROL BOX

FIGURE 2-B MOUNTING THE THERMOWELL

Place some heat conductive compound into
the thermowell. Place the sensor into the
thermowell and fasten it in place using the
clip supplied with the thermowell. Reference
Figure 2-B.

Install the cord grip connector into the control
box as shown in Figure 2-B. Push the sensor
cable through the connector. Wire the sensor
cable to the controller circuit board terminals
as shown in Figure 2-F. Tighten the grip nut
on the connector.

2.3 INSTALLING THE HEAT TAPE AND
INSULATION

Install the cord grip on the control box as
shown in Figure 2-C.

Cut the plug end off the heat tape. Strip back
the wires.

Push the wire end of the heat tape through
the connector. Allow enough cord inside the
box for wiring. Connect the heat tape to the
proper terminals in the control box as shown
in FIGURES 2-F. Tighten the grip nut on the
connector.

FIGURE 2-C INSTALLING THE HEAT TAPE AND INSULATION

Run the heat tape to the separator. Wrap the
heat tape around the separator as shown in
Figure 2-C. Do not overlap the tape.

Wrap the insulation around the piping and
heat tape as shown in Figure 2-C.

PAGE 2

SECTION 2 INSTALLATION

2.4 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.

Install the 90 degree elbow connector
on the aftercooler. Reference Figure
2-D.

FIGURE 2-D INSTALLING THE CONDUIT

2.5 INSTALLING THE TRANSFORMER JUMPERS

WARNING

BEFORE STARTING THIS PROCEDURE, TURN OFF
ELECTRICAL POWER. FAILURE TO HEED THIS
WARNING MAY RESULT IN SERIOUS PERSONAL
INJURY AND/OR DAMAGE TO THE UNIT.

This kit was designed to operate at 230V-3PH-60Hz or
460V-3PH-60Hz. Two jumpers were shipped inside the
control box. They must be installed on the transformer
before connecting the power to the control box. Install the
jumper(s) as shown in Figure 2-E for the desired voltage.

CAUTION

It is important that this procedure be properly
completed before continuing with installation.
This kit will not operate without the jumpers.
Damage to the control box will occur if the jumpers
are improperly installed.

FIGURE 2-E INSTALLING THE TRANSFORMER JUMPERS

2.6 ELECTRICAL CONNECTIONS

WARNING

BEFORE STARTING INSTALLATION PROCEDURES
OR ATTEMPTING TO MAKE ANY WIRING CHANGES,
TURN OFF ELECTRICAL POWER. FAILURE TO HEED
THIS WARNING MAY RESULT IN SERIOUS
PERSONAL INJURY AND/OR DAMAGE TO THE UNIT.

WHEN INSTALLING THIS KIT ALWAYS COMPLY WITH
THE NATIONAL ELECTRICAL CODE AND ALL OTHER
APPLICABLE FEDERAL, STATE AND LOCAL CODES.

A 7/8" hole in the top right side of the control box is provided
for incoming power conduit. The hole can be enlarged if
necessary.

The control box is designed for 230V-3PH-60Hz or 460V­3PH-60Hz operation. The transformer jumpers must be
installed as outlined in Section 2.5 for the desired voltage.

Make the necessary wiring runs and connections for the
main power supply.

Remove the junction box cover on the aftercooler for access
to the junction box. Make the necessary wiring runs through
the conduit from the aftercooler to the control box. Fasten the

conduit to the connector on the aftercooler. Reference
FIGURE 2-D.

Make the wire connections at the junction box on the
aftercooler. Reference FIGURE 2-F. Fasten the junction box
cover to the aftercooler.

Complete the wire connections inside the controller as
shown in FIGURE 2-F.

Once all wiring connections have been properly made, the
rotation of the fan should be checked. The fan must rotate in
the proper direction for maximum performance. Reference
the operator's manual supplied with the aftercooler for the
correct rotation direction. Also, check the aftercooler for a
rotation direction label.

To check the rotation, turn on the power supply to the
aftercooler. If the fan does not rotate in the proper direction,
any two of the power leads to the motor can be switched.

PAGE 3

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

SECTION 2 INSTALLATION

2.7 SETTING THE CONTROLLER

The controller was factory set for normal operation. The
factory settings are as follows:

RELAY 1

O

SET POINT 35
DIFFERENTIAL 10
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.

PROGRAMMING PROCEDURES

1. Press MENU key, then press RIGHT arrow key three
times. Use the UP and DOWN arrow to select the
SETPOINT. Press the RIGHT arrow to store the setpoint in
memory.

2. Press the RIGHT arrow to set the DIFFERENTIAL. Use
the UP and DOWN arrow to set the differential. Press the
RIGHT arrow to store the differential in memory.

3. Press the RIGHT arrow key to set the HEATING / COOL-
ING mode. Use the UP or DOWN arrow to select the
desired mode. Press the RIGHT arrow to store the mode in
memory.

F

O

F

FIGURE 2-G CONTROLLER DISPLAY

4. Press RIGHT arrow three times to exit the program mode.

SECTION 3 OPERATION

3.1 OPERATION

Once the kit is installed and set properly, just energize the
controller and it will operate automatically.

The controller will turn off half of the aftercooler fan when the
temperature of system air at the outlet of the aftercooler falls
to 35OF. The fan will turn on when the system temperature
rises to 45oF. Reference chart in Figure 3-A .

The heat tape is controlled by its own internal thermostat.
Power is supplied to the heat tape as long as the control box
is energized.

The temperature controller is equipped with a LCD display.
During normal operation when the fan are operating,
(temperature above set points) the sensor temperature and
RELAYS 1 ON will be displayed on the controller.

NOTE: The cover on the control box must be opened to view
the temperature controller display.

FIGURE 3-A OPERATION SEQUENCE

PAGE 5

SECTION 4 TROUBLESHOOTING

4.1 TROUBLESHOOTING PROCEDURES

PROBLEM POSSIBLE CAUSES

1. Aftercooler fan motor
continues to operate,
system temperature
below 35

O

F.

Controller not set properly

Control relay faulty

Check the controller settings as outlined in Section 2.7. The
controller may be set in the heat mode or the set points set too
low. Set the controller to the recommended settings.

Check the control relay. Replace if faulty.

SOLUTIONS

2. Aftercooler fan motor
not operating, system
temperature above
45OF.

No power to the control box

No power to the controller

Controller not set properly

Controller failure

Sensor failure

Control relay faulty

Check main electrical power source.

Check the transformer. Make sure that the jumpers on the
transformer are properly installed. Reference Section 2.5.
Check the fuses on the transformer.

Check the controller settings as outlined in Section 2.7. The
controller may be set in the heat mode or the set points set too
high. Set the controller to the recommended settings.

Check the controller settings. If the controller is properly set, check
the main power source.

Check the controller display for error codes. Section 4.2 outlines
what the error codes indicate and the necessary steps.

If the sensor is faulty a "--" will be displayed for the temperature on the
controller display. Refer to Section 4.2 for further details. If the
sensor is faulty, it must be replaced.

Check the control power at the relay coil. Check the relay for proper
operation. Replace if faulty.

4.2 CONTROLLER ERROR CODES

The controller display panel is used to display error codes in the event of problems with the controller. The four error codes
are listed below.

-- -SENSOR FAILURE

The "--" displayed for the temperature indicates that there is a problem with the sensor. The sensor is open or shorted.
All relays will be de-energized in the event of a sensor failure. If the sensor is damaged, it must be replaced.

EE-EEPROM FAILURE

The "EE" error code indicates that there is a problem with EEPROM. The values read back from the EEPROM are not
the same as what was written into the EEPROM. This error cannot be field repaired. The controller must be replaced.

-60°F or 270°F (-51°C or 132°C) Blinking - TEMPERATURE OUT OF RANGE

The temperature display blinks when the sensed temperature is outside of the display range, below -60°F (-51°C) or
above 270°F (132°C). The displayed value remains at the display limit and the controller continues to function unless
an open or shorted condition is detected.

BLINKING RELAY STATUS

This occurs when the Relay Minimum Off Time is active. The (ñ ) blinks while the relay's minimum off time is active.

PAGE 6

SECTION 5 REPLACEMENT PARTS

5.1 REPLACEMENT PARTS

ITEM NO.

1
2
3
4
5
6
7
8

9
11
12
13
14
15
16
17
18
19
20
21
22
23

DESCRIPTION

12' LONG HEAT TAPE

30' ROLL OF INSULATION WRAP

1/2" NPT THERMOWELL w/CLIP

CORD GRIP CONNECTOR

SENSOR

3/8" FLEXIBLE CONDUIT

SEAL FITTING FOR CONNECTOR

3/8" CONDUIT STRAIGHT CONNECTOR

3/8" 90O ELBOW CONDUIT CONNECTOR

1" X 1/2" NPT BUSHING

#12-14 x 1" SELF TAPPING SCREW

TEMPERATURE CONTROLLER

MOTOR RELAY

TRANSFORMER

1 AMP FUSE

.6 AMP FUSE

GRAY TERMINAL

YELLOW TERMINAL

GREEN TERMINAL

END CLAMP TERMINAL

JUMPER FOR TERMINAL

JUMPER FOR TRANSFORMER

QTY

1
1
1
2
1

2 FT

3
1
1
1
4
1
1
1
1
2
2
2
2
2
2
2

PART NO.

26-8151
26-0712
29-0325
26-5618
26-7186
26-0875
26-0883
26-1068
26-1078
14-0402
28-1286
26-7185
26-0919
26-5637
26-5336
26-5638
26-0380
26-0382
26-0384
26-0388
26-0686
26-5663

PAGE 7

SECTION 6 WARRANTY

PER VAN AIR TERMS AND CONDITIONS OF SALE

PAGE 8

YOUR VAN AIR REPRESENTATIVE IS:

NAME:

COMPANY:

ADDRESS:

CITY: STATE: ZIP:

PHONE: FAX:

ATTACH BUSINESS CARD HERE

MAKING COMPRESSED AIR AND GAS WORK BETTER SINCE 1944.

2950 Mechanic Street

Lake City, PA 16423 USA

Phone: [phone]

Service Fax: [phone]

Order Entry Fax: [phone]

www.vanairsystems.com

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.

Five models have analog (modulating) outputs for
actuator and motor control, and NEMA-4 weatherproof
enclosures are available for wet environments.

IMPORTANT

Each T775A/B/M controller is an operating
control, not a limit or safety control. If used in
applications requiring safety or limit controls, a
separate safety or limit control device is
required.

Table 1. T775A/B/M Controller Configurations.

Controller

T775A2009 Standard T775A1001 1 None None 1 1 NEMA 1

T775B2016 Standard N/A 2 None 1 2 1 NEMA 4X

T775B2024 Standard T775C1009 T775D1008 4 None 2 2 1 NEMA 4X

T775B2032 Standard T775A1019 T775B1000 2 None 1 2 1 NEMA 1

T775B2040 Standard T775A1027 T775A1035

T775M2006 Modulating N/A None 2 N/A 2 1 NEMA 1

T775M2014 Modulating T775G1005 T775G1013

T775M2022 Modulating N/A 2 2 N/A

T775M2030 Modulating T775E1114 T775F1022

T775M2048 Modulating T775E1015 T775E1023

a

b

c

d

a

Model

All models include a digital input for use with the disable or setback option.
The modulating (analog) outputs are 4-20 mA, 0-10 Vdc, 2-10 Vdc, or Series 90 selectable.
Each floating output eliminates two SPDT relays.
These models can support a high/low modulating limit at Sensor B for temperature control at Sensor A.

Description Replaces

T775B1018 T775B1026

T775B1042

T775G1021 T775G1039

T775F1055 T775F1089

T775E1056 T775E1064

T775E1098

SPDT
Relay

Outputs

Analog

(Mod)

Outputs

4None 2 2 1NEMA 1

42N/A

42N/A

22N/A

Floating

b

Outputs

Sensor

c

Inputs

Nbr of

Sensors

Included Enclosure

d

2

d

2

d

2

d

2

1 NEMA 4X

1 NEMA 4X

1 NEMA 1

1 NEMA 1

E4436

62-0254-03

T775A/B/M SERIES 2000 CONTROLLER PRODUCT DESCRIPTION

Temperature Sensors

a

The controller accepts 1,097 Ohms PTC at 77°F (25°C):

• 50021579-001 – Standard sensor (included with all
models except NEMA 4X models)

• T775-SENS-WR – Water resistant with 5 foot leads
(included with NEMA 4X models)

• T775-SENS-WT – Watertight with 6 foot lead

• T775-SENS-OAT – Outdoor air temperature sensor

• C7031D2003 – 5 inch immersion sensor with wiring
box (use immersion well; P/N 50001774-001)

• C7031J2009 – 12 foot duct averaging sensor with
wiring box

• C7046D1008 – 8 inch duct probe with mounting flange

• C7100D1001 – 12 inch fast response, duct averaging
sensor with flange

• C7130B1009 – Room mount sensor

a

See form 62-0265 – Temperature Sensors for the T775

Series 2000 Stand-alone Controller

Controller Dimensions

1 (25.5)

7/8 (22.5)

2 15/16 (74)

Accessories

• 107324A – Bulb Holder, duct insertion

• 107408 – Heat Conductive Compound, 4 ounce

• 50001774-001 – Immersion Well, stainless steel 304,
1/2 in. threading

TOP

4 1/16 (103.4)

4 1/16 (103.4)

7/8 (22.5)

1/64 (3.8)

2 11/16 (68.1)

4 13/32 (112.1)

LEFT RIGHT

8 5/32
(207.1)

7 23/32

(196)

7/8 (22.5)

1 (25.5)

3 31/32 (101)

FRONT VIEW

BOTTOM

1/2 (12.4)

Fig. 1. T775A/B/M dimensions in inches (mm).

2 13/16 (71.8)

7/8 (22.5)

M24279

62-0254–03 2

BEFORE INSTALLATION T775A/B/M SERIES 2000 CONTROLLER

BEFORE INSTALLATION

Review the “Specifications” on page 35 before
installing the controller.

When Installing This Product

1. Read these instructions carefully. Failure to follow

them could damage the product or cause a hazard­ous condition.

2. Check ratings given in instructions and on the prod-

uct to ensure the product is suitable for your appli­cation.

3. Installer must be a trained, experienced service

technician.

4. After installation is complete, check out product

operation as provided in these instructions.

INSTALLATION AND SETUP

The following installation procedures are typically
performed in the order listed:

1. Mounting — see “Mounting” below.

2. Wiring — see “Wiring” on this page.

3. Checkout — see page 10.

4. Programming — see page 13.

5. Scheduling (optional) — see page 30.

Additional topics are:

• Temperature sensor calibration begins on page 10.

• Interface overview begins on page 11.

• Setup (for advanced options) begins on page 17.

• Summary menu begins on page 34.

• Troubleshooting begins on page 34.

MOUNTING

This section describes the mounting procedures for the
controller and temperature sensor(s).

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
keypad.

NEMA 4 Enclosure Mounting

For models with NEMA 4 enclosures, ensure that
waterproof wire/conduit fittings are used at the knockouts
for all wiring attachments. See Fig. 7 on page 6 for
knockout locations.

IMPORTANT

For NEMA 4 enclosures, be sure to cover and
seal all unused open knockouts.

Temperature Sensor(s) Mounting and
Location

Temperature sensors may be located up to 1,000 feet
(304 m) from the T775A/B/M controller. See Table 3 on
page 10 for calibration guidelines.

The sensors may be mounted on a wall or panel for
sensing space temperature, strapped to a pipe or inserted
in an immersion well (see Fig. 2) for hot or cold water
sensing, or taped to a standard cap or bulb holder for duct
air sensing. To prevent moisture or condensation entering
the sensor through the lead wire holes, mount the sensor
with the lead wires exiting the bottom of the sensor.

NOTES:

1. The included sensor is not designed for very
wet applications. For immersion applications,
an immersion well is used.

2. Heat conductive compound must be used in
immersion wells.

3. See “Temperature Sensors” on page 2 for this
type of installation.

SENSOR

PLACED
IN WELL

USE HEAT

CONDUCTIVE

COMPOUND

Controller Mounting

IMPORTANT

Avoid mounting in areas where acid fumes or
other deteriorating vapors can attack the metal
parts of the controller circuit board, or in areas
where escaping gas or other explosive vapors
are present.

IMPORTANT

The controller must be mounted in a position that
allows clearance for wiring, servicing, and
removal.

Use a screwdriver to pry out only the knockouts that you
will use.

If mounting on DIN rail, be sure to remove the knockouts
before mounting. See “Controller Wiring” on page 5 and
Fig. 7 on page 6 for recommended knockout usage and
locations. If you do not use an opened knockout be sure
to cover it.

Mount the controller on any convenient interior location
using the four mounting holes provided on the back of the
enclosure using #6 or #8 screws (screws are not provided
and must be obtained separately). Use controller
dimensions in Fig. 1 on page 2 as a guide.

1/2 NPT

Fig. 2. Sensor inserted in immersion well.

NOTE: Multiple sensors may be parallel-series wired to

sense average temperatures in large spaces.
See Fig. 3 on page 4.

IMMERSION
WELL

M24470

WIRING

All wiring must comply with applicable electrical codes
and ordinances, or as specified on installation wiring
diagrams. Controller wiring is terminated to the screw
terminal blocks located inside the device.

The remainder of this section describes the temperature
sensor wiring and the T775A/B/M controller wiring.

3 62-0254–03

T775A/B/M SERIES 2000 CONTROLLER WIRING

Wiring Connections Access

To access the wiring connections, remove the two screws
on the left side of the enclosure and gently swing open the
top. Be careful to not stress the ribbon cables that
connect the keypad and LCD display to the controller
circuit board.

Temperature Sensor Wiring

CAUTION

Electrical Shock Hazard.
Can short equipment circuitry.

Make sure that metal tube of sensor does not
short against T terminals in wall-mounted case.

IMPORTANT

Poor wiring practices can cause erratic readings
from the sensor. Avoid the following to ensure
proper operation:

• Do not route the temperature sensor wiring with
building power wiring.

• Do not locate the temperature sensor wiring next
to control contactors.

• Do not locate the temperature sensor wiring near
electrical motors.

• Do not locate the temperature sensor wiring near
welding equipment.

• Make sure good mechanical connections are
made to both the sensor and the controller.

• Do not mount the sensor with the lead wire end
pointing up in an area where condensation can
occur.

If any of the above conditions cannot be
avoided, use shielded cable.

NOTE: Each T775 controller must be wired to its own

sensor(s). However, a benefit of the T775
controller’s accuracy is that there is no more
than a 2°F differential between any two T775
controllers.

Multiple Parallel Sensors

Multiple sensors can be parallel-series wired to sense
average temperatures in large spaces. To maintain
control accuracy, the number of sensors to be parallel­series wired must be of the n

2

power (for example, 4, 9,

16, etc.). See Fig. 3.

SENSORS

TO T775 CONNECTIONS (SENSOR A) OR (SENSOR B).

M24471

Fig. 3. Parallel-series wiring of sensors.

Temperature Sensor Wire Type and Size

Temperature sensors use standard AWG 18/2 unshielded
wire. For cable runs greater than 25 feet or where
electrical interference may be a problem, shielded cable
is recommended. See Fig. 4.

Refer to “Temperature Sensor Calibration” on page 10 for
wire size selection where cable runs are longer than 25
feet.

T
T

T
T

SENSOR A AND SENSOR B TERMINAL WIRING IS POLARITY INSENSITIVE.

1

SENSOR A

1

SENSOR B

SHIELDED
CABLE

Fig. 4. Sensor wiring — showing shielded cable connection to Sensor A.

SHIELDED
CABLE

NOTE: SHIELDED CABLE MUST BE
CONNECTED TO AN EARTH
GROUND.
HOWEVER, DO NOT GROUND
SHIELDED CABLE AT SENSOR END.

SENSOR

NOTE: TO MINIMIZE NOISE PICKUP,
MAKE SENSOR CONNECTION FROM
SHIELDED CABLE AS CLOSE AS
POSSIBLE TO SENSOR BODY.

M24472

62-0254–03 4

WIRING T775A/B/M SERIES 2000 CONTROLLER

Controller Wiring

WARNING

Electrical Shock Hazard.
Can cause severe injury, death or property
damage.

Disconnect power supply before beginning wiring,
or making wiring connections, to prevent electrical
shock or equipment damage.

CAUTION

Do not use 24 Vac power to power any external
loads if 120 Vac or 240 Vac is used to power
the T775A/B/M controller.

CAUTION

A separate earth ground is required.

Equipment damage can result if the earth ground
is not connected. See Fig. 5 and Table 2 on
page 6.

CAUTION

Equipment Damage Hazard.
Electrostatic discharge can short equipment
circuitry.

Ensure that you are properly grounded before
handling the unit.

See Fig. 7 on page 6 for locating the appropriate power
input, remote sensors input, low voltage, contact closure,
and load output terminals.

Access to the terminals can be gained through standard
conduit knockouts (A through E in Fig. 7 on page 6)
located around the perimeter of the enclosure:

• Knockouts A and B should be used only for sensor and
low-voltage wiring.

• Knockouts C, D, and E can be used to gain access to
the load relay output terminals and 120/240 Vac power
wiring.

Controller Wiring Method

Wire the sensors and outputs, then wire the power
connection.

Each terminal can accommodate the following gauges of
wire:

• Single wire – from 14 AWG to 22 AWG solid or
stranded

• Multiple wires – up to two 22 AWG stranded

For 24, 120, or 240 Vac power connections:

Single wire – from 14 to 18 AWG solid or stranded

Prepare wiring for the terminal blocks, as follows:

1. Strip 1/2 in. (13 mm) insulation from the conductor.

2. Cut a single wire to 3/16 in. (5 mm). Insert the wire

in the required terminal location and tighten the
screw.

3. If two or more wires are being inserted into one ter-

minal location, twist the wires together a minimum
of three turns before inserting them to ensure
proper electrical contact.

4. Cut the twisted end of the wires to 3/16 in. (5 mm)

before inserting them into the terminal and tighten­ing the screw.

5. Pull on each wire in all terminals to check for good

mechanical connection.

1

2

IMPORTANT

Poor wiring practices can cause erratic readings
from the sensor. To ensure proper operation,
ensure that good mechanical connections are
made to both the sensor and the controller.

IMPORTANT

When wiring the input power, only one source of
power can be applied to the T775A/B/M control­ler (24 Vac or 120 Vac or 240 Vac).

1

W

NO HIGH VOLTAGE. CLASS 2 WIRING ONLY.

EARTH GROUND TERMINAL MUST BE CONNECTED
TO CONDUIT CLAMP LOCALLY.

C

+

2

M24296

Fig. 5. Earth Ground.

1. STRIP 1/2 IN. (13 MM)

FROM WIRES TO
BE ATTACHED AT
ONE TERMINAL.

2. TWIST WIRES

TOGETHER WITH
PLIERS (A MINIMUM
OF THREE TURNS).

1/2 (13)

3. CUT TWISTED END OF WIRES

TO 3/16 IN. (5 MM) BEFORE INSERTING
INTO TERMINAL AND TIGHTENING SCREW.
THEN PULL ON EACH WIRE IN ALL
TERMINALS TO CHECK FOR
GOOD MECHANICAL CONNECTION.

M24473

Fig. 6. Attaching two or more wires at terminal blocks.

5 62-0254–03

T775A/B/M SERIES 2000 CONTROLLER WIRING APPLICATIONS (EXAMPLES)

Controller Wiring Details

The wiring connection terminals are shown in Fig. 7 and
are described in Table 2.

See Fig. 8 – Fig. 20 beginning on page 6 for typical
T775A/B/M wiring applications.

KNOCKOUT A

NO

C

NC

KNOCKOUT E

T
T

T
T

NC

C

NO

120

NO

C

NC

MOD 1

2

MOD 2

DIGITAL

INPUT

KNOCKOUT B

POWER

3

24 VAC

OUTPUT
RELAY 4

OUTPUT
RELAY 1

KNOCKOUT C

1

SENSORS A AND B USE THE TWO TT CONNECTIONS AND ARE
POLARITY INSENSITIVE.

2

FOR MOD 1 AND MOD 2 CURRENT (mA) OR VOLTAGE (VDC) OUTPUT,
USE SIGNAL (+) & COMMON (-).
FOR MOD 1 AND MOD 2 SERIES 90 OUTPUT, USE W, R, & B.

A SEPARATE EARTH GROUND IS REQUIRED FOR ANY POWER

3

SOURCE (24, 120, OR 240 VAC).

B

–

R

+

W

B

–

R

+

W

–
+

C

+

NC

C

NO

Fig. 7. T775A/B/M terminal and feature locations.

NOTE: Refer to Table 1 on page 1 for the specific con-

figuration of sensors and outputs supported by
the model you are installing.

NOTE: For NEMA 4 enclosures, use waterproof fittings

for wiring/conduit connections at knockouts.

COM

240

SENSOR A

1

SENSOR B

OUTPUT
RELAY 3

POWER
120/240 VAC

OUTPUT
RELAY 2

KNOCKOUT D

M24474

Table 2. Description of Wiring

Terminal Connections. (Continued)

Connection Terminal Label Description

Input

DI + - Digital Input (dry

contact)

24 Vac Power

24V + + 24 Vac Hot

Common C 24 Vac Common

Ground

Earth Ground

b

120 or 240 Vac Power

120 Vac 120 120 Vac Power

Common COM Common

240 Vac 240 240 Vac Power

a

For Series 90 connections, you must insert a 340 Ohm
resistor across terminals R and W. See Fig. 17 on
page 8. The resistor is included with the controller.

b

A separate earth ground is required for all installations
regardless of the power source (24, 120, or 240 Vac).
See Fig. 5 on page 5.

WIRING APPLICATIONS
(EXAMPLES)

Fig. 8 – 20 illustrate typical controller wiring for various
applications.

SENSOR A

T
T

L1

(HOT)

L2

24 VAC

LOAD 1

C

+

Table 2. Description of Wiring

Terminal Connections.

Connection Terminal Label Description

Sensors

Sensor A

Sensor B

T T

Outputs

Temperature Sensor;
polarity insensitive

Fig. 8. Wiring for two-stage control – 24 Vac input and

Relay 1
Relay 2
Relay 3
Relay 4

Mod 1

Mod 2

62-0254–03 6

NO
COM
NC

+ - (Vdc or mA)
W R B (Series 90)

120-240 Vac Relay
Output

Modulating Output

a

LOAD 2

NO

COM

24 Vac load.

NO

C

NC

NO

C

NC

COM

NO

M24475A