Johnson Controls P66AAB-1, P66AAB-4, P66AAB-6, P66AAB-9, P66AAB-10 User Guide

...

Download

Page 1

Installation Instructions Issue Date September 30, 2009

P66 Series Electronic Fan Speed Controls

Application

IMPORTANT: Use this P66 Series Electronic Fan

Speed Control only as an operating control. Where failure or malfunction of the P66 control could lead to personal injury or property damage to the controlled equipment or other property, additional precautions must be designed into the control system. Incorporate and maintain other devices, such as supervisory or alarm systems or safety or limit controls, intended to warn of or protect against failure or malfunction of the P66 control.

The P66 Series Electronic Fan Speed Controls are pressure-actuated electronic motor-speed controllers designed primarily to control condenser fan motors on Heating, Ventilating, Air Conditioning, and Refrigeration (HVAC/R) applications (Figure 1). These controls vary the supply voltage to the fan motor in response to the sensed refrigerant pressure, providing direct response to changes in condenser pressure, regardless of the variations in air delivery curves.

P66 controls are available with one or two pressure sensor inputs. In dual sensor models, the control selects the input with the greatest demand.

P66 control models are also available with NEMA 3R (Rainproof) enclosures for outdoor applications (Figure 1). These models come with a plastic enclosure, appropriate gaskets, and low voltage wire leads for 24 VAC power. In addition, the critical high voltage components are encapsulated in a potting compound.

Note: NEMA 1 models cannot be retrofitted in the field to obtain the NEMA 3R (Rainproof) rating.

A P66 and speed controlled motor can replace On/Off fan cycling controls, multiple speed motors, condenser flood-back systems, temperature fan-speed controls, and modulating louver systems.

Typical applications include:

• computer roo m air conditioning

• commercial a i r conditioning

• commercial refrigeration

The P66 Series controls must be applied only to single-phase motors intended for use with a solid-state motor speed control. An applicable motor must be a single-phase, permanent split-capacitor motor and must be:

• ball-bearing constructio n only (Sleeve-bearing motors are not acceptable for use with P66 controls.)

• designe d to handle non-sinusoidal waveforms generated by solid-state motor speed controls

• designe d to dissipate the motor heat generated at reduced speed operation

CAUTION: Risk of Property Damage

Use only single-phase Permanent Split-Capacitor (PSC) motors approved by the manufacturer for speed control applications with the P66 control. Failure to use a single-phase PSC motor may damage the motor and other property.

Installation

WARNING: Risk of Personal Injury

Do not install the P66 Electronic Fan Speed Control in any application using corrosive or flammable refrigerants. The P66 control is not designed or intended for use with those refrigerants. Use of the P66 control with corrosive or flammable refrigerants may lead to release of refrigerant, which could cause property damage, fire, severe personal injury or death.

Part No. 24-7664-1482, Rev. D

Page 2

Dimensions

Depressor

Valve

1/4 in. Flare

0.093

2.36 Diameter Capillary

7/16 in.

20 UNF-2B

0.218

Diameter Mounting Holes

5.54

for No. 10 Screw

3.38 86

4.56 116

5.26

0.27 7

1.28 33

134

6.00 152

6.75 172

0.875

22.23

Two 0.250 Spade Ter m in als for 24 VAC Power Supply Inside Plug (NEMA 1 Enclosure)

Diameter Conduit Hole (2 places)

NEMA 3R Enclosure

5.33 135

4.20 107

4.72 120

Two 22 AWG W ire Leads for 24 VAC Power Supply (NEMA 3R Enclosure)

Figure 1: P66 Control and NEMA 3R Enclosure Dimensions, in./mm

Mounting

Observe the following guidelines when mounting a P66 control and routing the control’s capillary tube:

CAUTION: Risk of Environmental and

Property Damage

Coil and secure excess capillary tubing away from contact with sharp or abrasive objects or surfaces. Vibration or sharp or abrasive objects in contact with capillary tubes can cause damage that may result in refrigerant leaks or loss of element charge which may result in damage to the environment or property.

CAUTION: Risk of Environmental and

Property Damage

Avoid sharp bends in the capillary tubes. Sharp bends can weaken or kink capillary tubes which may result in refrigerant leaks or restrictions of flow.

3.34 85

4.12 105

P66_DIMS_ENCLOSURE

• Maintain operating pre s sures and temperatures within the listed product ratings to assure reliable operation. See Technical Specifications table.

• Mount the P66 control away from sources of excessive heat.

• Mount the P66 control with the cooling fins in a vertical position with no obstruction preventing airflow through the fins.

• Locate the P66 control wh ere fan air passes through the cooling fins to maximize heat dissipation.

• Locate the P66 control so the pressure elements inside the base are above the refrigerant liquid level of the controlled equipment.

• Mount the control wh ere it can be conveniently wired to the power supply and the motor.

• Provide the recommended pressure connection in the high-pressure vapor line near the condenser inlet. (A 60 in. capillary is standard.)

2 P66 Series Electronic Fan Speed Controls Installation Instructions

Page 3

• Evacuate all tubing and lines before connecting the P66 control.

Note: A Schrader® valve depressor is provided with the female flare fitting on standard P66 control models.

Wiring

WARNING: Risk of Electric Shock

Disconnect power supply before making electrical connections. Contact with components carrying hazardous voltage can cause electric shock and may result in severe personal injury or death.

Correct

WARNING: Risk of Electric Shock

Ground the P66 Series Electronic Fan Speed Control according to local, national, and regional regulations. Failure to ground the P66 control may result in electric shock and severe personal injury or death.

IMPORTANT: Use copper conductors only. Make all wiring connections in accordance with the National Electrical Code and local regulations. Do not exceed the P66 Series Electronic Fan Speed Control’s electrical ratings.

The P66 control must be supplied with 24 VAC (1 VA) from an external transformer powered from the same phase as the motor circuit (Figure 2, Figure 3, and Figure 4). The low voltage input connections are 1/4 in. quick-connect terminals on the NEMA 1 models and two 6 in. 22 AWG wires on the NEMA 3R models. The line voltage connections are 10-32 screw terminals.

Incorrect

VAC

Capacitor

P66

Main

Aux

Motor

VAC

Capacitor

Figure 2: Permanent Split-Capacitor Motor Connections to the P66 Fan Speed Control

(The 24 VAC power supply must be connected in-phase with the motor power supply.)

P66

Main

Aux

Motor

P66_IN-PHASE_WIRRING

P66 Series Electronic Fan Speed Controls Installation Instructions 3

Page 4

VAC

Capacitor

P66

Main

Aux

Motor

P66_WIRING

Figure 3: Permanent Split-Capacitor Motor

Connections to the P66 Fan Speed Control

Setup and Adjustments

The P66 control’s throttling range is fixed and cannot be adjusted. The operating range pressure is adjustable within the control pressure range. See the Technical Specifications table for P66 model pressure ratings.

To adjust the operating range pressure:

1. Apply a reliable pressure gauge to the controlled system to monitor the pressure adjustments.

VAC

P66

Motor

Capacitor

Main

Aux

P66_WIRING_OPT

Figure 4: Optional Wiring Diagram for Permanent

Split-Capacitor Motor Connections to the P66

Fan Speed Control

CAUTION: Risk of Property Damage

Limit any adjustments to two full turns in either direction. Over-adjustment may prohibit modulation of the motor resulting in high head pressures. All pressure adjustments should be verified with the use of refrigerant pressure gauges.

2. Access the operating range adjustment screw for the P66 pressure transducer through the opening in the upper left-hand corner of the P66 control base (Figure 5).

Note: On dual pressure models, access to the second adjustment screw is located in the lower righthand corner of the control base.

3. Turn the adjustment screw 1/2 turn (or less) clockwise to increase the operating range pressure or 1/2 turn (or less) counterclockwise to decrease the operating range pressure.

• Low Pressure Models (80 to 200 psig): 1/2 turn = approximately ± 9 psig (62 kPa)

• Medium Pressure Models (140 to 350 psig): 1/2 turn = approximately ± 18 psig (124 kPa)

• High Pressure Models (300 to 500 psig): 1/2 turn = approximately ± 35 psig (241 kPa)

IMPORTANT: Do not adjust the operating range screw more than 1/2 turn before allowing the system pressure to stabilize.

4. Check system pressure and repeat Step 3 until the desired operating range pressure is attained.

Figure 5: Operating Range Adjustment Screw

Location

Checkout

Before leaving the installation, observe working application for correct operation. See the Operation section for a typical operational sequence.

4 P66 Series Electronic Fan Speed Controls Installation Instructions

Page 5

Operation

Condensing unit installation, operation, and maintenance determine the overall capability of maintaining a satisfactory pressure by means of fan speed control. Within the operating range, the P66 control provides air delivery in direct proportion to heat rejection requirements. This allows the refrigeration system to perform efficiently in very low ambient temperatures.

97%

90%

Motor Voltage

10% to 40%

of Line

(model sp ecific)

No fan operation

in this

pressure range.

psig

Operating Range (190/250 psig)

The P66 pressure transducer provides direct response to changes in condenser pressure, regardless of the variations in fan delivery curves. The dual input models select the pressure input from the transducer sensing the highest pressure.

See Figure 6 for a typical operational sequence for a P66 control.

Operating Range

Plus 20 or 30 psi*

Pressure In pu t

350 psig

*20 psi for 30 psi Effective Throttling Range (ETR)

30 psi for 60 psi Effective Throttling Range (ETR)

Figure 6: Operation Chart for the P66 Fan Speed Control

Table 1: P66 Control Operation

Pressure Input Motor Voltage (VAC, true RMS)

Pressure is between 0 psig and the low end of the operating range.

Pressure is at the low end of the operating range. Pressure is in the operating range.

Pressure is above the operating range.

0 to 5 volts

Start voltage (10% to 40% of line - model specific) Motor voltage varies directly with system pressure from start

voltage to 90% of line voltage. A further pressure increase of 20 to 30 psi will increase

motor voltage to 97% of the applied voltage.

P66_OP_CHART

P66 Series Electronic Fan Speed Controls Installation Instructions 5

Page 6

Troubleshooting

Refer to the Operation section for proper operation.

Table 2: Troubleshooting Chart

Problem Possible Cause Possible Solution

No Fan Operation

Fan stops when pressure reaches the high end of the operating range.

No Fan Modulation (On-Off Operation)

Fan Starts at Full Speed.

Erratic Fan Operation

Fan motor is cycling thermal overload.

Input pressure is below operating range.

No 24 volt control voltage Check for 24 VAC at control. No input pressure to control Alignment. Schrader valve depressor

Bad fan motor Disconnect power. Place a jumper from L1

Pressure transducer problem See Pressure Transducer

Control is not wired correctly. See wiring diagrams. Ensure that the

Pressure transducer problem See Pressure Transducer

Control is not wired correctly. See wiring diagrams. Ensure that the

Pressure transducer problem See Pressure Transducer

Control is not wired correctly. Check to see if control voltage (24 VAC) is

Dirty or blocked condenser coil Clean condenser coil. Pressure transducer problem See Pressure Transducer

Dirty or blocked condenser coil Clean condenser coil. Wrong motor for fan speed control

application

No problem, normal operation.

must depress Schrader valve enough to allow pressure into capillary.

and connect power. If fan does not

to M

start, motor is bad and should be replaced.

Troubleshooting section.

24 VAC power supply is connected in-phase with the motor power supply.

Troubleshooting.

24 VAC power supply is connected in-phase with the motor power supply.

Troubleshooting.

on same phase as motor.

Troubleshooting.

Replace with motor approved for fan speed control application.

Pressure Transducer Troubleshooting

1. Disconnect 6-pin connector from right side of control.

Repairs and Replacement

Field repairs must not be made. For a replacement control, contact the Original Equipment Manufacturer or your local Johnson Controls/PENN distributor.

2. Place a jumper wire between third pin from the top and the bottom pin on the control, not the cable.

a. If fan goes to full speed, check for input

pressure.

b. If there is adequate pressure, the transducer

is bad and the control must be replaced.

6 P66 Series Electronic Fan Speed Controls Installation Instructions

Page 7

Ordering Information

Table 3: P66 Control Specific Model Information

Product Code Number

P66AAB-1 P66AAB-4 P66AAB-6 P66AAB-9 P66AAB-10 P66AAB-11 P66AAB-14 P66AAB-15 P66AAD-1* P66ABB-21+ P66AAB-34

P66BAB-1 P66BAB-3 P66BAB-4 P66BAB-5 P66BAD-1*

All models are rated for 208-240/277/480 volt; 60Hz except those with Product Code Numbers followed by an asterisk. * 50 Hz Models

Models with NEMA 3R Enclosure

Operating Range

(psig)

Single Input Sensor Models

190/250 10 60 135/165 10 60 170/230 16 60 170/230 40 60 190/250 16 120 140/200 16 60 220/280 40 120 190/250 40 60 160/220 25 60 220/280 16 120 320/410 40 60

Dual Input Sensor Models

190/250 10 60 170/230 16 60 190/250 16 120 190/250 40 60 160/220 25 60

Start Voltage

(% of Supply Voltage)

Capillary Length (in.)

For further information on model specifications and options, please contact Johnson Control s Application Engineering at 1-800-275-5676.

P66 Series Electronic Fan Speed Controls Installation Instructions 7

Page 8

Technical Specifications

Product Pressure Ratings Low Pressure Models Medium Pressure Models High Pressure Models Control Range

Effective Throttling Range Maximum Working

Pressure Maximum Overpressure Control Voltage Line Voltage Range Start Voltage Electrical Ratings 208 VAC 240 VAC 277 VAC 480 VAC Full Load Amperes Locked Rotor Amperes Ambient Temperature

Maximum Ambient Temperature

Minimum Ambient Storage

Temperature Construction Control Case Base and Sensors Plastic Enclosure Enclosure Wiring Connections Low Voltage Line Voltage Pressure Connections

Mounting Agency Listings

The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications, contact Johnson Controls Application Engineering at 1-800-275-5676. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products.

P66 Series Electronic Fan Speed Controls

80 to 200 psig (552 to 1379 kPa)

30 psi (207 kPa) 60 psi (414 kPa) 90 psi (621 kPa) 200 psig (1379 kPa) 350 psig (2413 kPa) 500 psig (3447 kPa)

250 psig (1724 kPa) 400 psig (2758 kPa) 695 psig (4792 kPa) 24 VAC, 1VA 208 to 480 VAC 10% to 40% of line (OEM specified - model specific)

8.0 8.0 6.9 4.0

16.5 16.5 14.3 10.5 130°F/54°C 130°F/54°C 130°F/54°C 150°F/66°C

-40°F/-40°C (at all Voltages)

-40°F/-40°C to 185°F/85°C

Galvanized steel case and cover Galvanized steel UV stabilized polycarbonate with closed cell foam gasket (NEMA 3R models only) NEMA 1 or NEMA 3R (Rainproof)

1/4 in. quick connects (NEMA 1); Two 6 in. 22 AWG Wire Leads (NEMA 3R) 10-32 Screw Terminals 60 in./1524 mm or 120 in./3048 mm copper capillary with 1/4 in./6 mm flare nut and

Schrader valve depressor Vertical only; two holes for No. 10 screws at the top and bottom UL Recognized (U.S.): File SA516, Guide SDFY2 UL Recognized (Canada): File SA516, Guide SDFY8 CSA Certified: File LR 948, Class 1222 01 - Specific models only. Contact Johnson

Controls Application Engineering at 1-800-275-5676 for specific model information.

140 to 350 psig (965 to 2413 kPa)

300 to 500 psig (2048 to 3447 kPa)

Metasys® and Johnson Controls® are registered trademarks of Johnson Controls, Inc.

8 P66 Series Electronic Fan Speed Controls Installation Instructions

Building Efficiency

507 E. Michigan Street, Milwaukee, WI 53202