International Comfort Products CPECOMZR011A00, CPECOMZR012A00 Installation Manual
Part Number:
INCLUDING 3 TON 14 SEER HP AND DUAL FUEL MODELS
CPECOMZR011A00 & CPECOMZR012A00
Installation Instructions
SMALL PACKAGED PRODUCT (3-5 TON UNITS)
HORIZONTAL ECONOMIZER ACCESSORY
Read these instructions completely before attempting to install the
Horizontal Economizer Accessory.
CONTENTS
SAFETY CONSIDERATIONS................................1
GENERAL..............................................................1,2
ACCESSORIES LIST...............................................2
INSTALLATION...................................................2-6
CONFIGURATION.............................................6-10
ECONOMIZER CONTROL MODES....................6
OPERATION ...........................................................10
SEQUENCE OF OPERATION..............................10
PERFORMANCE DATA........................................11
TROUBLESHOOTING....................................11-12
WIRING DIAGRAMS .....................................13-14
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only
trained and qualied service personnel should install, repair, or service
air-conditioning equipment.
Untrained personnel can perform the basic maintenance functions of
replacing lters. All other operations should be performed by trained
service personnel. When working on air-conditioning equipment,
observe precautions in the literature, tags, and labels attached to the unit,
and other safety precautions that may apply.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the unit and in instructions or manuals, be
alert to the potential for personal injury. Understand these signal words;
DANGER, WARNING, and CAUTION. These words are used with the
safety-alert symbol. DANGER identies the most serious hazards which
will result in severe personal injury or death. WARNING signies haz-
ards 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.
Follow all safety codes. Wear safety glasses, protective clothing, and
work gloves. Use quenching cloth for brazing operations. Have a re
extinguisher available. Read these instructions thoroughly and follow
all warnings or cautions included in literature and attached to the
unit. Consult local building codes and current editions of the National
Electrical Code (NEC) NFPA 70. In Canada, refer to current editions of
the Canadian electrical code CSA 22.1.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing, modifying, or servicing system, main electrical
disconnect switch must be in the OFF position and install a lockout
tag. There may be more than 1 disconnect switch. Lock out and tag
switch with suitable warning label.
!
CAUTION
!
UNIT PERFORMANCE AND COMPONENT HAZARD
Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airow is 350 to 450 cfm
for each 12,000 Btuh of rated cooling capacity. For heating operation, the airow must produce a temperature rise that falls within the
range stamped on the unit rating plate.
GENERAL
Economizers are recommended for use with only commercial packaged
products that have ECM motors. The Economizer system utilizes the
latest technology available for integrating the use of free cooling with
mechanical cooling for rooftop units. The solid state control system
optimizes energy consumption, zone comfort, and equipment cycling
by operating the compressors when the outdoor-air temperature is too
warm, integrating the compressor with outdoor air when free cooling is
available, and locking out the compressor when outdoor-air temperature
is too cold. Demand ventilation is supported.
The Economizer system utilizes gear-drive technology with a directmount spring return actuator that will close upon loss of power. The
Economizer system comes standard with an outdoor air temperature
sensor, a supply air temperature sensor, and low temperature compressor
lockout switch. Indoor enthalpy sensor, outdoor enthalpy sensors and
CO2 sensors are available for eld installation.
See Table 2 for package contents. See Table 3 for sensor usage.
Table 1 - Filter Sizes
Economizer PN 1-IN. Filter Size 2-IN. Filter Size
CPECOMZR011A00
CPECOMZR012A00†
* Unscrew two brackets on the top lter rack to t 2-in. (50.8mm) lters.
† Place 14 x 24 x 2 in. (254.0 x 609.6 x 50.8mm) lter at the right side of
the coil and 10 x 24 x 2 in. (254.0 x 609.6 x 50.8mm) lters at the left side
in this order.
PART NUMBER QTY DESCRIPTIONS
CPECOMZR011A00
&
CPECOMZR012A00
1 - 14 x 24 (355.6 x 609.6mm)
1 - 16 x 24 (406.4 x 609.6mm)
1 - 16 x 24 (406.4 x 609.6mm)
1 - 18 x 24 (457.2 x 609.6mm)
Table 2 - Package Contents
1 Hood Top and Sides
1 Aluminum Filter
11 #10 Self-Drilling Screw and Washers
4 #10 x 1/2” Blunt End Screws
2 #10 x 1” Self-Drilling Screws
1 Economizer Assembly
1 Supply Air Temperature Sensor with Bracket
2 1” (25.4mm) Throw Away Filters
1 Top Filter Rack
1 Bottom Filter Rack
1 Replacement Return Chamber Panel
1 Compressor Cover Panel
1 Extension Harness w/ Plug
2 Wiring Diagram Labels
1 Installation Instruction
1
1 - 14 x 24 (355.6 x 609.6mm)
1 - 16 x 24 (406.4 x 609.6mm)
2 - 10 x 24 (254.0 x 609.6mm)
1 - 14 x 24 (355.6 x 609.6mm)
Table 3 - Economizer Sensor Usage
ECONOMIZER WITH OUTDOOR AIR
APPLICATION
Outdoor Air
Dry Bulb
Single
Enthalpy
Differential
Enthalpy
CO2 for
DCV Control
Using a
Wall-Mounted
CO2 Sensor
CO2 for
DCV Control
Using a
Duct-Mounted
CO2 Sensor
*CRENTDIF004A00 accessory is used on many different base units. As such, these kits may
contain parts that will not be needed for installation.
†33ZCSENCO2 and CGCDXSEN004A00 are accessory CO2 sensors.
**33ZCASPCO2 and CGCDXASP00100 are accessory aspirator boxes required for duct-mounted
applications.
††CRCBDIOX005A00 is an accessory that contains both 33ZCSENCO2 and 33ZVASPCO2
accessories.
33ZCSENCO2 or
CGCDXASP00100†
33ZCASPCO2 or
CGCDXASP00100**
DRY BULB SENSOR
Accessories Required
None. The outdoor air dry bulb sensor
and
is factory installed
HH57AC078
HH57AC078
and
CRENTDIF004A00*
33ZCSENCO2
CGCDXSEN004A00
or
CRCBDIOX005A00††
OR
ACCESSORIES LIST
The economizer has several eld-installed accessories available to
optimize performance. Refer to Table 4 for authorized parts.
4. Install the top lter rack in the HVAC unit next to the indoor coil. Lift
rack to the very top of the chamber, and screw into both the left and
right side of the coil FRAME, using #10 x 1/2” Blunt End screws. Be
careful not to insert screws where coil damage could occur. If using 2”
(50.8mm) lters, the lter spacer must be removed. See Fig. 1.
5. Install the bottom lter in the HVAC unit next to the indoor coil. Filter
rack will rest on the HVAC base and screw into both the left and right
sides of coil FRAME, using #10 x 1/2” Blunt End screws. Be careful not
to insert screws where coil damage could occur.
Top lter rack
Evaporator Coil
Bottom lter rack
Fig. 1A - Filter Rack Installation (Bent Coil)
Table 4 - Economizer Field-Installed Accessories
DESCRIPTION PART NUMBER
Outdoor Air Enthalpy Sensor HH57AC078
Indoor Air Enthalpy Sensor CRENTDIF004A00
Return Air CO2 Sensor (4-20mA) CRCBDIOX005A00
CO2 Room Sensor (4-20mA)
Aspirator Box for Duct Mount
CO2 Sensor (4-20mA)
Space Temperature and CO2 Room Sensor
with Override (4-20mA)
Space Temperature and CO2 Room Sensor
with Override and Set Point (4-20mA)
Heat Pump Relay Package CPRLYKIT001A00
33ZCSENXO2 or
CGCDXSEN004A00
33ZCASPCO2 or
CGCDXASP001A00
33ZCT55CO2
33ZCT56CO2
INSTALLATION
Economizer - See Fig. 2 for Economizer component locations. To install
the horizontal Economizer perform the following procedure:
1. Turn off unit power supply and install lockout tag.
WARNING
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing or servicing system, always turn off main power
to system and tag. There may be more than one disconnect switch.
Turn off accessory heater power switch if applicable.
2. Remove the compressor access panel and unit side panel. See Fig. 3.
3. Remove the return air duct cover to aid in the installation.
Top lter rack
Evaporator
Coil
Bottom lter rack
Fig. 1B - Filter Rack Installation (Straight Coil)
6. Most new Phase HVAC units will have an economizer plug in the
return air chamber, which runs back to the control box. If the unit has the
economizer harness / plug, rst remove the jumper plug from the end of
the harness to allow the plug from the economizer to be connected.
NOTE: The jumper plug should be saved for future use in the event that
the economizer is removed from the unit. The jumper plug is not needed
as long as the economizer is installed.
In the event that your HVAC unit does not have a factory installed harness
for the economizer, the extension harness shipped with the economizer
must be installed in the unit. Route the extension harness through the
HVAC unit as shown in Fig. 9. The plug end of the harness extension
will connect to the economizer plug in the return chamber and the other
end will be routed to and connect in the control box.
2
HH63AW001
Economizer
Controller
Economizer
Actuator
HH18HA286
Low ambient
Compressor
Lockout switch
HH57AC080
Adjustable Dry
Bulb Outside
Air Sensor
Economizer Plug
Fig. 2 - Component Locations
Compressor
Compartment
Outside Air
Damper
Hood Top
Outside Air
Cleanable
Aluminum Filter
Fig. 5 - Filter Installation
Divider in
HVAC Unit
Filter Clip
21 9/16”
(547mm)
Replacement
Panel Shipped
with Economizer
Economizer
Cover Panel
Side Panel shipped with HVAC
unit. Remove and Discard
NOTE: Units with base rails will
have a 2 piece panel. Discard the
panel covering the return air
chamber and reuse the panel
covering the compressor section.
Fig. 3 - Panel Removal
19 5/8”
(498mm)
28 1/4”
(718mm)
1 1/2 in. (38.1mm)
above the
top of the left side
of the return duct
opening use 1” self
drilling to screw
thru unit back panel
and into the top
rear corner of
economizer
assembly
Indoor
Blower
Panel
Compressor
Panel
Fig. 6A
Gasketing
3 Sides
Caulk these corners
after economizer
is installed
Screw
into base
(572mm)
Fig. 6 - Economizer Installation
HVAC Unit
21 9/16”
(547mm)
Filter
Door
22 1/2”
Replacement
Panel
Economizer
Panel
Filter
Panel
22”
(559mm)
22”
Aluminum
Filter
Remove Screw from base pan. Install
economizer then re-insert screw through
slot in economizer into basepan.
(559mm)
Fig. 4 - Hood Assembly Fig. 7 - Economizer Installed in HVAC Unit
3
Economizer
Economizer Harness from
Actuator and controller
Economizer
Rainhood
Indoor
Blower
Compressor
Fig. 8 - Routing Harness Extension and
Mounting SAT Sensor
Supply Air Temperature
Sensor (SAT)
Indoor
Blower
Main 24V
Splice Box
Economizer
Harness
Supply Air Temperature
(See Fig. 8A)
Economizer
Plug
Economizer
Harness
Self-Drilling
Screw
SAT Sensor
on Bracket
Indoor
Blower
Panel
Indoor
Blower
Fig. 8A - SAT Mounting for Units with
Upper Block Off Panel
Economizer
Economizer
Hood
Filter
Indoor Fan
Control
Box
Fig. 8B - SAT Location for Units without
Block Off Panel
Indoor
Blower Panel
Fig. 10 - Indoor Blower Panel
Compressor
4
To SAT Sensor
Fig. 9 - Routing Harness (Top View)
Economizer
Harness
7. Remove the panel on the HVAC unit covering the indoor blower. See
Fig. 11. The (provided) Supply Air Temperature (SAT) sensor, which
looks like and eyelet terminal, must be installed in the blower section.
Attach the (2) pink wires from the economizer harness (or extension
harness) to the SAT.
The SAT sensor is shipped attached to a small bracket. If the HVAC unit
has an upper block off panel, attach the sensor / bracket as shown in
Fig. 8A using a #10 x 5/8” self-drilling screw. If the unit does not have
an upper block off panel, remove the bracket from the SAT and screw
the SAT to the side of the indoor blower, using a #10 x 5/8”self-drilling
screw, as shown in Fig. 8B.
8. Replace the panel covering the indoor blower.
NOTE: For heat pump units, an additional relay package, Factory kit part
number CPRLYKIT001A00, or eld provided relays must be installed in
the blower section. See heat pump diagram for details.
Upper Block-off
panel (some units)
SEE
NOTE 1
Installation of Heat Pump Relays
When this economizer is used on heat pump HVAC units, relays must
be added for proper operation.
The relays, which are shown on the attached diagrams, can be eld
supplied, or relay kit CPRLYKIT001A00 can be ordered. Field provided
relays must be:
•SPDT, one pole normally open and one normally closed. Same
polarity.
•Minimum 124 VA inrush.
Acceptable relays include:
•Honeywell: R8222B117
•Honeywell: R422B1124
•White Rodgers: 91-103001-13002
•White Rodgers: 91-102006-13302
Relay Installation:
A. If the optional relay kit CPRLYKIT001A00 is used, it will mount
underneath the indoor blower as shown in Fig. 11 & 12. Follow
instructions sent with the package.
B. If relays are eld provided and installed, they can be mounted above
the upper block off panel, as shown in Fig. 11. Use caution to ensure
screws do not interfere with blower operation, Blunt end screws are
recommended.
C. If no upper block off panel is present mount relays on compressor
partition below indoor blower on left as shown in Fig. 11.
D. Wire the relays per diagram in this instruction.
INDOOR
BLOWER
COMPRESSOR
NOTE 1: Field provided
relays can be mounted
on upper block off
panel, if applicable
Location for heat
pump relay package
number
CPRLYKIT001A00
Fig. 11 - Relay Package Location
INDOOR
BLOWER
CONTROL
SECTION
9. This step applies to units without base rails only. If the unit does not
have a wrap around compressor access panel install the supplied.
10. Install the 5/8” gasketing on the duct side anges of the economizer,
see Fig. 6. Turn the economizer on its side (Fig. 6.) Slide economizer
into cabinet and as far to the left as possible. The economizer will set
against the left side of the unit and will cover the horizontal return air
opening. Caulk as required.
11. Install the replacement return chamber panel over the economizer
assembly and underneath the drip ange on the HVAC unit. Line up
the bottom left hole on the panel with the hole in the bottom of the
economizer and the mating hole in the base of the HVAC unit. Insert
screw, which will hold all parts in place. Insert screws on bottom and
right of panel as well. See Fig. 6.
12. At a location 1 1/2 in. (38.1mm) above the top of the left side of the
return duct opening use 1” self drilling to screw thru unit back panel and
into the top rear corner of economizer assembly (Fig. 6).
Screw
CPRLYKIT001A00
relay kit
Fig. 12 - Relay Package Installation
5
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