(CONSISTING OF: C7046C DISCHARGE AIR SENSOR OR C7150B MIXED AIR SENSOR, C7232 OR C7632 CARBON DIOXIDE SENSOR, C7400 SOLID STATE ENTHALPY SENSOR OR C7660 SOLID STATE TEMPERATURE SENSOR, M7215
DAMPER ACTUATOR AND W7212, W7213 OR W7214 SOLID STATE ECONOMIZER LOGIC MODULE)
SYSTEM ENGINEERING GUIDE
FEATURES
C7046C Discharge Air Sensors have probe lengths of 8 in.
(203 mm) and nominal sensor resistance of 3000 ohms at
77°F (25°C).
• No setting or calibration required.
• Solid state components not affected by dust or dirt.
• Fast reacting.
• Rugged aluminum insertion probe.
C7150B Mixed Air Sensor is used with the M7215 Damper
Actuator to sense mixed or discharged air in rooftop packaged
air conditioning equipment.
• No setting or calibration required.
APPLICATION
The Solid State Economizer System provides an economical
method of providing cooling air by incorporating outdoor air in
the first stage of cooling in heating, ventilating and air
conditioning (HVAC) systems. The Solid State Economizer
System consists of the C7046 Discharge Air Sensor, C7150
Mixed Air Sensor, C7232 or C7632 Demand Control
Ventilation (DCV) Sensor, C7400 Enthalpy Sensor or C7660
Dry Bulb Temperature Sensor, M7215 Damper Actuator, and
W7212 Solid State Economizer Logic Module.
C7232 and C7632 DCV Sensors are stand-alone carbon dioxide (CO
with heating ventilation and air conditioning (HVAC) controllers. They measure the CO
space or duct. They are used in HVAC systems to control the
amount of fresh outdoor air supplied to maintain acceptable
levels of CO
• C7232 models available with LCD that provides sensor
• Non-Dispersion-Infrared (NDIR) technology used to
• C7632 has fixed 0 to 10 Vdc from 0 to 2000 ppm. No
) sensors for use in determining ventilation necessity
2
concentration in the ventilated
2
in the space.
2
readings and status information.
measure carbon dioxide gas.
stability.
levels.
2
based ventilation control.
2
based on long-term evaluation reduces required
typical zero-drift check maintenance.
adjustments are necessary.
(Continued)
63-2576—02
SOLID STATE ECONOMIZER SYSTEM
CAUTION
C7400 Solid State Enthalpy Sensor and C7660 Solid State
Temperature Sensors are used with the W7212 Solid State
Economizer Logic Module to allow using outdoor air as the
first stage of cooling in HVAC systems.
• C7400 senses and combines temperature and
humidity of outdoor air (heat index).
• C7660 senses dry bulb temperature only.
• Long-lasting, solid state sensing element is accurate
and stable over time.
• When enthalpy/temperature of outdoor air increases,
the outdoor air damper closes to a preset minimum
position.
• When enthalpy/temperature of outdoor air is low, the
outdoor air damper opens to reduce the building
cooling load.
• Provides 4 to 20 mA output signal to the Economizer
Logic Modules; setpoint is located on economizer
control.
• Maximum economizer savings is achieved with two
C7400 Enthalpy Sensors connected to one
Economizer Logic Modules for differential enthalpy
changeover control.
M7215 Damper Motors are 25 lb-in. spring return damper
actuators that provide modulating control of economizer systems, ventilation dampers and combustion air dampers used
in residential or commercial HVAC equipment.
• M7215 Damper Motors provide modulating control of
economizer dampers from a 2-10 Vdc controller.
• Quiet, high efficiency drive motor.
• High impact, glass-fiber reinforced plastic case is
rugged, lightweight and corrosion resistant.
• Provides 2-10 Vdc output signal proportional to the
shaft position.
W7212 Economizer Logic Modules are used with C7232
Demand Control Ventilation (DCV) Sensors, and solid state
C7400 Enthalpy Sensors or C7660 Dry Bulb Temperature
Sensors to proportion outdoor and return air dampers for control of free cooling in commercial HVAC equipment.
• Operates from thermostat and DCV sensor to provide a
totally integrated control system.
• Solid state control package provides accurate, reliable
and stable control.
• Mounts on M7215 Motor or duct work.
• Control can be tempered by DCV and fan cycling.
• Used with Honeywell actuators.
• Combines minimum and DCV maximum damper
position potentiometers with compressor staging.
• Relay functions with solid state enthalpy or dry bulb
changeover control.
• Terminals included for switching between Occupied
and Unoccupied operation.
• Terminals included for connecting optional S963B1128
Remote Potentiometer for remote minimum damper
position control.
• LED indicates when free cooling is available.
• LED indicates when module is in DCV mode.
• LED indicates when exhaust fan contact is closed.
• W7213 is used with heat pump B terminal.
• W7214 is used with heat pump O terminal.
IMPORTANT
Specifications given in this publication do not include
normal manufacturing tolerances. Therefore, this unit
may not exactly match the listed specifications. Also,
this product is tested and calibrated under closely
controlled conditions and some minor differences in
performance can be expected if those conditions are
changed.
When Installing this Product...
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on the
product to make sure 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.
Electrical Shock or Equipment Damage Hazard.
Can shock individuals or short equipment
circuitry.
Disconnect power supply before installation.
IMPORTANT
All wiring must agree with applicable codes,
ordinances and regulations.
63-2576—022
C7046C DISCHARGE AIR SENSORS
)
D
)
02
(25)
)
)
)
)
)
)8 (
)
GASKET
R
)
USH
)
C
BUS
G
SENSO
OBE
GE
)
S
(
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O
E
SYSTEM
COMPO
S
CO
W
O
W
S
(
)
3
SENSO
E
SYS
UM
GE
S
Y
CONDU
OX
CO
OR
CONDUIT
E
(
)
SYS
COMPO
S
CO
S
(
)
P
)
SOLID STATE ECONOMIZER SYSTEM
Specifications
Intended for use as a discharge sensor in rooftop applications.
Dimensions: See Fig. 1.
Mounting: Mounting flange requiring two No. 8 screws.
Operating Temperature Range: 40 to 150°F (4 to 66°C).
Wiring Connections: 6 in. (152 mm) leadwires.
Performance Characteristics:
Reaction Time Constant with Air Approach Velocity of
500 ft/min (2 m/sec): 60 seconds.
Resistance/Temperature (NTC):
Nominal Resistance: 3000 ohms at 77°F (25°C).
Nominal Sensitivity: 70 ohms per degree F (124 ohms per
degree C) at midrange.
2 (51
1-1/2 (38
3/4 (19
203
PLASTI
HIN
1 (25
6 (152
1/16 (2
4. Fasten the sensor to the duct or plenum surface
with two No. 8 sheet metal screws (not provided).
Mounting in a Junction Box (Fig. 3)
1. Cut a 3/8 in. (9.5 mm) hole in the duct or plenum
surface at the desired location.
2. Remove the center rear knockout from the junction box
and insert the sensing probe through the knockout with
the flange flat against the outlet box.
3. Using the flange as a template, mark and drill two holes
in the junction box and the duct or plenum surface for
No. 8 mounting screws.
4. Insert sensor probe through both the junction box
knockout and the 3/8 in. (9.5 mm) hole drilled in the duct
or plenum and fasten the junction box and sensor to the
duct or plenum surface.
SYSTEM DUCT
OR PLENUM
NO. 8 (4mm
MOUNTING SCREW
PR
R
NOT PROVIDED
FLAN
5/16 (9) DIAMETE
(BUSHING
LOCKING P
1/4 (6
NUTS (2
IAMETER (2 HOLES
NEOPRENE
M224
Fig. 1. C7046C Air Temperature Sensor dimensions
in in. (mm).
NOTE: Sensor probe diameter is 1/4 in. (6 mm).
Installation
The sensor assembly (see Fig. 1) consists of an aluminum
sensor probe (element housed internally) with attached flange
that can be mounted on a flat duct or plenum surface, or in
a 2 in. by 4 in. (51 by 102 mm) junction box using two No. 8
screws. Connections to the sensor are made through two 6 in.
(152 mm) leadwires.
LOCATION
The sensor should be located in the air duct or plenum where
it will sample an average air temperature. Avoid locations
where air stratification can cause sensing errors.
MOUNTING
Mounting on a Flat Duct or Plenum Surface (Fig. 2)
1. Cut a 3/8 in. (9.5 mm) hole in the duct or plenum
surface at the desired location.
2. Insert sensor probe into the duct or plenum until the
flange rests against the duct or plenum wall.
3. If necessary, use the flange as a template to mark
and drill two holes for No. 8 mounting screws.
T
APPROPRIAT
NENT
M2240
Fig. 2. Mounting C7046 Air Temperature
Sensor on a flat duct or plenum surface.
FLAN
TANDARD UTILIT
IT B
NNECT
LOCKNUT
TO APPROPRIATE
TEM
NENT
TEM
DUCT OR
PLEN
R
PROB
NNECT SENSOR WIRE
WITH TWO WIRENUT
CONNECTORS
Fig. 3. Mounting C7046 Air Temperature
Sensor in a junction box.
NNECT SENSOR
IRES WITH TW
IRENUT CONNECTOR
NOT PROVIDED
NO. 8 (4mm)
MOUNTING
SCREWS (NOT
ROVIDED
FACEPLAT
OPTIONAL
NOT PROVIDED
363-2576—02
SOLID STATE ECONOMIZER SYSTEM
CAUTION
CAUTION
Wiring
Electrical Shock or Equipment Damage Hazard.
Can shock individuals or short equipment
circuitry.
Disconnect power supply before installation.
Erratic System Operation Hazard.
Failure to follow proper wiring practices can
introduce disruptive electrical interference (noise).
Keep wiring at least one foot away from large inductive
loads such as motors line starters, lighting ballasts,
and large power distribution panels.
Shielded cable is required in installations where these
guidelines cannot be met.
Ground shield only to grounded controller case.
IMPORTANT
1. All wiring must agree with applicable codes,
ordinances and regulations.
2. Do not mount sensor in incorrect environment.
3. Wire according to the applicable controller
instructions.
4. Erratic temperature readings from a sensor can be
caused by improper wiring practices. These must
be avoided to assure proper operation:
•Avoid poor wiring connections.
•Avoid intermittent or missing building earth ground.
•Do not mount sensor in incorrect environment.
Connect low voltage wiring from the sensor to the appropriate
system component terminals using solderless connectors.
See Fig. 3.
Operation
The C7046C Air Temperature Sensors consist of a thermistor
sensing element mounted in a tubular probe. They are applied
at various locations throughout single zone and multizone
duct systems. The negative temperature coefficient (NTC)
characteristic of the thermistor element causes its resistance
to decrease as the sampled air temperature increases. This
resistance shift is balanced with other system sensor signals
by appropriate system logic panels to stabilize system control.
Checkout
Allow the C7046 Air Temperature Sensor to soak in the air
moving through the duct or plenum for a minimum of five
minutes before taking a resistance measurement.
1. Disconnect the sensor leadwires from the associated
system components.
2. Connect an ohmmeter across the leadwires.
3. Assure nominal resistance measurements are in
accordance with the resistance/temperature curves
shown in Fig. 4.
4. Reconnect sensor leadwires to associated system
components.
5. Check operation of the complete control system.
17000
16000
15000
14000
13000
12000
11000
10000
9000
8000
7000
6000
RESISTANCE (OHMS)
5000
4000
3000
2000
1000
60504070
0-10
5
TEMPERATURE (DEGREES)
2010
15
Fig. 4. C7046C Sensor resistance vs. temperature.
3,000 OHMS
AT 77 F (25 C)
8010203090 100
3035
25-5
F
C
M17969
63-2576—024
C7150B MIXED AIR SENSOR
3
R
)
1-1/2
(38)
(51)
3/4
(19)
3/4
(19)
2-3/8
(60)
2-1/4 (57)
M17992
C7150B1004C7150B1046
SOLID STATE ECONOMIZER SYSTEM
Specifications
Models: See Table 1.
Dimensions: See Fig. 5.
Mounting Arrangement:
Integral mounting flange that requires No. 8 screws.
NOTE: The C7150B1004 requires four No. 8 screws;
the C7150B1046 requires two No. 8 screws.
Ambient Temperature Ratings:
Maximum: 250°F (121°C).
Operating Range: -40 to 110°F (-40 to 43°C).
Shipping Range: -30 to 150°F (-34 to 66°C).
Wiring Connection: 1/4 in. (6 mm) quick-connects.
NOTE: The C7150B1046 includes 4 in. lead wires with
connector for W7340 compatibility.
Table 1. C7150B Models.
Nominal Resistance
Model
at 77°F (25°C)
C7150B1004 3000 ohms70 ohms per °F
C7150B1046 10K ohms234 ohms per °F
a
Negative Temperature Coefficient (NTC).
Nominal Sensitivity
at midrange
(124 ohms per °C)
(415 ohms per °C)
Installation
1. Install on a mounting bracket (not included) inside the
2. Wire using 1/4 in. (6 mm) female quick-connect
a
DUCT
mixed air or discharge air duct using No. 8 mounting
screws and nuts. (See Fig. 6).
NOTE: When mounting, ensure that terminals do not
touch metallic conductive surfaces.
terminated wires from C7150B to control inputs.
NOTE: For C7150B1046, splice additional wiring as
needed between sensor and connector.
NO. 8
MOUNTING
SCREW
2 (51)
3/8
(9)
TO APPROPRIATE
SYSTEM SENSOR
1/2 (13)
INPUT
M17938A
Fig. 6. Mounting C7150B [C7150B1004 shown].
/16 (5) DIAMETE
2-1/2 (64
Fig. 5. C7150B approximate dimensions in in. (mm).
NOTE: Fig. 6 displays bracket (not included) and suggested
bracket dimensions in in. (mm).
Operation
The C7150B Air Temperature Sensor consists of a thermistor
sensing element mounted on a phenolic board. It is applied in
ventilation duct systems. The thermistor element negative
temperature coefficient (NTC) characteristic causes its
resistance to decrease as the sampled air temperature
increases. This resistance change is used as a control system
sensor to regulate discharge air temperature in a W973 Single
Zone System or damper position of the M7215A Motor (either
directly, or through the Economizer Logic Module).
Checkout
Allow the C7150B Sensor to soak in the air moving through
the duct for a minimum of 5 minutes before taking a resistance
measurement:
1. Disconnect sensor leadwires from associated system
components.
2. Connect an ohmmeter across the leadwires.
3. Nominal resistance measurements should be in
accordance with the resistance/temperature curves
shown in Fig. 7 and Fig. 8.
4. Reconnect sensor leadwires to associated system
components.
5. Check operation of the M7215A Motor, W973 System,
or the Economizer Logic Module.
563-2576—02
SOLID STATE ECONOMIZER SYSTEM
17000
16000
15000
14000
13000
12000
11000
10000
9000
8000
7000
6000
RESISTANCE (OHMS)
5000
4000
3000
2000
1000
60504070
0-10
5
TEMPERATURE (DEGREES)
15
2010
3,000 OHMS
AT 77 F (25 C)
8010203090 100
3035
25-5
F
C
M17969
Fig. 7. C7150B1004 Sensor resistance temperature.
50000
45000
40000
35000
30000
25000
RESISTANCE (OHMS)
20000
15000
10000
5000
60504070
0
15
5
TEMPERATURE (DEGREES)
2010
10,000 OHMS
AT 77 F (25 C)
80203090 100
3035
25-5
F
C
M20071
Fig. 8. C7150B1046 Sensor resistance temperature.
63-2576—026
C7232 DCV SENSORS
CAUTION
CAUTION
CAUTION
SOLID STATE ECONOMIZER SYSTEM
Specifications
Models: C7232 Sensor and Controller. A stand-alone carbon
dioxide (CO
(one analog and one spst relay).
C7232A: Wall mount model.
C7232B: Duct mount model.
NOTE: Models are available with or without a 4-digit LCD
Dimensions:
C7232A: See Fig. 9.
C7232B: See Fig. 10.
Sensor Performance Ratings:
Response Time: 2 min.
Carbon Dioxide Sensor:
Operation: Non-dispersive infrared (NDIR).
Sampling: Diffusion.
Range: 0 to 2000 ppm ±5% and ±50 ppm.
Annual Drift: 20 ppm (nominal).
Electrical Ratings:
Power Supply: 24 Vac ±20%, 50/60 Hz (Class 2).
Maximum Power Consumption: 3W.
Peak Current (at 20 ms): 600 mA.
Relay:
Configuration: Shipped N.O. (reconfigure with software.)
Contact Rating: 1A at 50 Vac/24 Vdc.
Minimum Permissible Load: 1 mA at 5 Vdc.
Linear Analog Output:
Voltage: 0/2-10 Vdc (resistive load greater than
5000 ohms).
Current: 0/4-20 mA (resistive load less than 500 ohms).
Outputs (Jumper Adjustable, see Table 3):
Analog: 0-10 Vdc (Default: 2-10 Vdc, 500 to 1500 ppm).
Relay: Normally Open Spst (Default: Close at 800 ppm).
Storage: -4°F to +158°F (-20°C to +70°C).
Relative Humidity (non-condensing): 0 to 95 percent.
CO
Pressure Dependence: 1.4% change in reading per
2
1 kPa deviation from 100 kPa.
Connections:
Wiring:
C7232A: 20-gauge cable with six 8 in. leadwires.
C7232B: 20-gauge cable with six 6 in. leadwires.
Mounting:
C7232A: Vertical surface with standard single-gang junction
box.
C7232B: Sheet metal duct with a sampling tube.
Automatic Background Calibration (ABC) default: On.
Approvals:
CE.
Health Hazard.
Improper use can create dangerous situations.
Use in application for sensing carbon dioxide only.
For life-safety applications, this device can function
only as a secondary or lesser device.
Electrical Shock or Equipment Damage Hazard.
Can shock individuals or short equipment
circuitry.
Disconnect power supply before installation.
Equipment Damage Hazard.
Electrostatic discharge can short equipment
circuitry.
Ensure that you are properly grounded before
handling the unit.
763-2576—02
SOLID STATE ECONOMIZER SYSTEM
C7232A Cover Removal/Replacement
C7232A COVER REMOVAL (SEE FIG. 11)
1. Remove button head socket cap screw and set it aside.
2. Insert the head of a small screwdriver into the slot at the
center and near the top of the cover.
3. Gently pull the handle down toward the bottom of the
device until a small gap between the subbase and the
cover appears.
4. Remove the screwdriver and pull the cover straight
down until it meets a stop.
5. Pull the cover straight off the subbase.
C7232A COVER REPLACEMENT
1. Feed the wires through the opening in the subbase.
2. Place the cover, with a small gap at the top, flat on top
of the subbase.
3. When the cover rests flat on the subbase, slide it
straight up until it latches in place.
B
NOTE: When mounting on a junction box, see Fig. 12.
3. Replace the cover.
DUCT MOUNTING (SEE FIG. 13)
1. Place gasket on aspiration tube.
IMPORTANT
Ensure largest tab at tube control end is at the top.
2. Insert tube into duct; attach using screws and washers.
IMPORTANT
Leakage into the duct or the C7232 box cover from
the room will skew the sensor readings. Ensure the
box cover and duct seal completely.
3. Place o-ring on tube end; mount the control to the tube.
STANDARD UTILITY CONDUIT BOX
NO. 6 SCREW
FRONT
COVER
BUTTON HEAD
SOCKET CAP
SCREW
A
M17541
C
ALLEN TOOL
Fig. 11. C7232A cover removal.
Location and Mounting
C7232 Sensors mount directly on the wall, sheet metal duct,
or a panel. When planning the installation, allow enough
clearance for maintenance and service. Mount the sensor in a
well-ventilated area.
NOTES: Do not install the sensor where it can be affected by:
WALL MOUNTING
The C7232 Wall Mount models can be mounted using two or
four screws:
— drafts or dead spots behind doors and in corners.
— air from ducts.
1. Remove C7232 cover.
2. Mount the subbase to the wall using washers and two or
four screws (not supplied) appropriate for the wall
material.
BUTTON HEAD
SOCKET CAP
SCREW
NO. 6 SCREW
Fig. 12. Junction box mounting (C7232A).
FLOW
Fig. 13. Duct mounting (C7232B).
SUBBASE
M17542
M17591
63-2576—028
SOLID STATE ECONOMIZER SYSTEM
CAUTION
CAUTION
L1
(HOT)
L2
M17543
1
1 POWER SUPPLY. PROVIDE
DISCONNECT MEANS AND
OVERLOAD PROTECTION
AS REQUIRED.
C7232
24V
YELLOW
BLACK
RED
BROWN
ORANGE
GREEN
ANALOG
OUT
+
–
Wiring
The factory ships the device with the output default settings
shown in Table 3 and Table 4. Set the jumpers and wire the
device (see Table 2 and Fig. 14).
Electrical Shock or Equipment Damage Hazard.
Can shock individuals or short equipment
circuitry.
Disconnect power supply before installation.
Equipment Damage Hazard.
Electrostatic Discharge Can Short Equipment
Circuitry.
Ensure that you are properly grounded before
handling the unit.
IMPORTANT
1. All low voltage connections to this device must be
24 Vac Class 2.
2. All wiring must comply with applicable local codes,
ordinances and regulations.
Table 2. C7232 Wiring Connections (see Fig. 14).
Wire ColorDesignationFunction
RedG+24 Vac Hot
BlackG024 Vac Common
YellowOUT1Analog Output Signal
BrownMAnalog Output Common
OrangeNORelay Output Normally Open
GreenCOMRelay Output Common
Operation
Input Signal
The C7232 Sensors have an adjustable range. These ranges
are determined by the SW1 and SW2 jumper settings
(see Table 3).
Tab l e 3 . C O
SW1SW2AN (ppm)Relaya (ppm)
OnOn0 to 10001000
OnOff0 to 20001200
Off
b
On
b
OffOff500 to 20001200
a
When the level reaches this value, the contacts close;
when the level drops 100 ppm below this value, the contacts open.
b
Setting when shipped from the factory.
Output Signal
The output signal can be adjusted for 0/2-10Vdc or 0/4-20mA
(see Table 4).
Table 4. Output Signal Jumper Settings
AN
Voltage0-10Vdc2-10Vdc
Current0-20 mA4-20 mA
NOTES:
—On duct models, remove the screw holding the
board in place to view jumper settings on reverse.
(See Fig. 15.)
—The CO
are independent of each other. 0-100% and
20-100% are simply markings for the OUT jumper
settings on the sensor (to differentiate between
the two voltage and the two current ranges) and
do not refer to or alter the ppm range chosen.
Range Jumper Settings
2
500 to 1500800
OUT
0-100%20-100%
settings and the output signal settings
2
Fig. 14. Wiring the C7232.
SW2SW1 OUT
ON
OFF
ON
OFF
AN
20 – 100%
0 – 100%
Current
Voltage
M19424
Fig. 15. C7232 default jumper settings.
963-2576—02
SOLID STATE ECONOMIZER SYSTEM
Example
For a CO2 setting of 0-2000 ppm and a voltage output of 0-10 Vdc, the output would be as shown in Table 5 (arbitrary points
along the analog curve).
Table 5. 0-10 Vdc Output Example.
CO
Level (ppm)
2
0200400600800100012001400160018002000
Voltage Output (Vdc)012345678910
For a CO
along the analog curve).
setting of 0-2000 ppm and a voltage output of 2-10 Vdc, the output would be as shown in Table 6 (arbitrary points
2
Table 6. 2-10 Vdc Output Example.
CO
Level (ppm)
2
025050075010001250150017502000
Voltage Output (Vdc)2345678910
Calibration
Typically, calibration is unnecessary. No calibration kits are
available. However, if CO
chamber using a general gas purge device, the sensor can be
rezeroed:
gas can be purged from the sensor
2
Checkout
Perform a quick test of the unit with the unit powered:
1. Stand close to the unit and breathe air into the sensor.
2. Check the CO2 level registered by the controller to
ensure a strong rise.
3. When connected to a damper in a ventilation system,
IMPORTANT
Any CO
zero level resulting in incorrect CO
present during calibration skews the sensor
2
level reports.
2
the controller typically signals an increase in air flow.
1. Once the sensor stabilizes, use a screwdriver to
connect the two MENU soldering pads.
2. The display should indicate CAL.
3. Execute the zero calibration by connecting the two
ENTER soldering pads.
4. The display should return to providing the measured
CO
level.
2
63-2576—0210
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