Van Air Systems FP-3 Kit User Manual

November 2008

P/N 32-0227

Rev. C

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

FOR

FP-3 FREEZE PROTECTION KIT

P/N 83-0762

FOR TURBO-COOL AFTERCOOLERS MODELS

(115-1-60 & 230-1-60 VOLTAGES)

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.

SECTION 1 INTRODUCTION

AC50-2&3 THRU AC130-2&3

WARNING

1.1 DESCRIPTION OF OPERATION

The FP-3 Freeze Protection Kit is designed to prevent aftercooler freeze up when the ambient temperature is near or below freezing, 32oF (0°C).

The FP-3 has a electronic temperature controller with a NEMA 4X rating. The temperature sensor and thermowell mount into the piping on the outlet side of the aftercooler. When the temperature of the compressed air system falls to 35oF, the controller will automatically turn OFF the fan(s). The controller is set for a 5oF dead band to prevent rapid fan cycling (fan will turn off at 35°F and on at 40°F).

A 6 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 provide additional freeze-up protection.

1.2 THIS KIT INCLUDES:

1. Electronic temperature controller

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

3. Two (2) cord grip connectors

4. 6' long heat tape, w/ thermostat

5. 3/8" conduit straight connector

6. Junction box cover plate with a 7/8" DIA hole

7. Six (6) feet of 3/8" flexible conduit

8. Four (4) #8-18 x 3/4" self tapping screws

9. Four (4) Seal fittings for connectors

10. 30' long roll of insulation wrap

11. Seven (7) wire nuts (yellow)

12. 3/8" 90 Degree elbow connector

13. Temperature sensor

14. Heat conductive compound

FIGURE 1-A ITEMS INCLUDED WITH THIS KIT

1.3 ADDITIONAL ITEMS REQ'D (not supplied):

Wire Pipe sealant

Models AC-50 & AC-60

One (1) 1" NPT tee One (1) 1" NPT close nipple One (1) reducer 1" x 1/2" NPT

Models AC-70 thru AC-100

One (1) 1-1/2" NPT tee One (1) 1-1/2" x 1/2" NPT bushing

Models AC-110 thru AC-130

One (1) 2" NPT tee One (1) 2" x 1/2" NPT bushing

PAGE 1

SECTION 2 INSTALLATION

2.1 MOUNTING THE CONTROLLER

The controller should be mounted on the side panel near the outlet of the aftercooler. Drill the pilot holes into the panel using a 1/8" drill. Reference Figure 2-A for dimensions. Fasten the controller in place using the four (4) #8-18 x 3/4" long self-tapping screws supplied with the kit.

FIGURE 2-A MOUNTING THE CONTROLLER

2.2 INSTALLING THE THERMOWELL AND SENSOR

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 installing the thermowell.

If a connection is not available, a tee fitting of the same size as the piping MUST be installed between the aftercooler and the separator. Use pipe sealant on all threaded pipe connections.

AC-50 & AC-60 Models only - Install a 1" NPT close nipple into the tee fitting. Attach a 1" x 1/2" NPT reducer to the nipple.

AC-70 thru AC-130 Models only - Install a bushing into the side branch of the tee fitting to reduce the connection size to 1/2" NPT.

Thread the thermowell into the bushing or reducer. Place some heat sink 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.

Remove the rubber plug from the hole in the controller and Install the cord grip connector as shown in Figure 2-B. Push the sensor cable through the connector. Twist the two (2) red wires together and wire the sensor cable to the controller circuit board terminals labeled SENSOR A as shown in Figures 2-E thru 2-H. Note that the sensor wires are NOT polarity sensitive. Tighten the grip nut on the connector.

FIGURE 2-B MOUNTING THE THERMOWELL

PAGE 2

SECTION 2 INSTALLATION

2.3 INSTALLING THE HEAT TAPE AND INSULATION

Remove the rubber plug from the hole in the bottom of the controller and install the cord grip as shown in Figure 2-C.

Cut the plug end off the heat tape. Remove 4" to 6" of the outer jacket. 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 as shown in FIGURES 2-E thru 2-H. Tighten the grip nut on the connector.

Run the heat tape to the separator. Wrap the heat tape around the separator as shown in Figure 2-C. DO NOT OVERLAP

THE HEAT TAPE.

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

2.4 INSTALLING THE CONDUIT AND COVER

FIGURE 2-C INSTALLING THE HEAT TAPE AND INSULATION

Install the straight conduit connector on the junction box cover. The cover with the connector will be used to replace the cover shipped on the aftercooler.

Remove the rubber plug from the hole in the control box and install the 90 degree elbow connector as shown in Figure 2-D.

The supplied conduit will be used to run wires between the aftercooler junction box and the controller. Trim the conduit to the length needed. Make sure that the conduit is long enough so that when it is installed it does not cross the fan guard(s). Install the conduit.

2.5 ELECTRICAL CONNECTIONS

WARNING

BEFORE STARTING INSTALLATION OR MAINTENANCE PROCEDURES, 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.

FIGURE 2-D INSTALLING THE CONDUIT AND COVER

The 7/8" hole on the Right side of the controller is to be used for incoming power. Remove the rubber plug from the hole and install appropriate conduit fitting (not supplied).

The controller is rated for 120/240V-1PH-50/60Hz. Make the necesssary wiring runs through the conduit from the aftercooler to

the controller. Make the wire connections at the junction box on the aftercooler and fasten the cover to the aftercooler using the screws from the old cover.

Complete the wire connections inside the controller as shown in FIGURES 2-E thru 2-H.

PAGE 3

SECTION 2 INSTALLATION

FIGURE 2-E AC-50-2 thru AC-110-2 WIRING DIAGRAM

FIGURE 2-F AC-50-3 thru AC-110-3 WIRING DIAGRAM

PAGE 4

SECTION 2 INSTALLATION

FIGURE 2-G AC-120-2 & AC-130-2 WIRING DIAGRAM

FIGURE 2-H AC-120-3 & AC-130-3 WIRING DIAGRAM

PAGE 5

SECTION 2 INSTALLATION

2.7 SETTING THE CONTROLLER

The factory settings for the controller are as follows:

RELAY 1 RELAY 2 SET POINT 35°F 35°F DIFFERENTIAL 5°F 5°F MODE COOLING COOLING

Turn on the main power to the FP-3 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 to set up relay #1.

2. Use the UP and DOWN arrow to select the SETPOINT. Press the RIGHT arrow to store the setpoint in memory.

3. 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.

4. Press the RIGHT arrow key to set the HEATING / COOLING mode. Use the UP or DOWN arrow to select the desired mode. Press the RIGHT arrow to store the mode in memory.

5. Press the right arrow three times and repeat steps 2 through 4 to set up relay #2.

FIGURE 2-J CONTROLLER FRONT COVER

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

SECTION 3 OPERATION

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

The controller will turn off the aftercooler fan(s) when the temperature of the system air at the outlet of the aftercooler falls to 35°F. The fan will turn on when the system tempterature rises above 40°F.

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 an LCD display.

During normal operation when the fan is operating, (temperature above set points) the sensor temperature and RELAYS 12 ON will be displayed on the controller.

SECTION 4 TROUBLESHOOTING

4.1 TROUBLESHOOTING

PROBLEM

1. Aftercooler fan motor(s) not operating, system temperature above 40OF.

POSSIBLE CAUSES

No power to the controller

Controller not set properly.

Controller failure.

Sensor failure

Check electrical power source. If power supply is okay, check the controller and sensor. Replace if necessary.

Check the controller settings as shown in SECTION 2.7.

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

Check electrical power source and controller. If the controller and power source are ok, the sensor may be faulty.

SOLUTIONS

PAGE 6

To check the sensor, remove it from the thermowell. Adjust the setpoint on the controller to 50 container of ice water. The controller should turn off the power to fans in several minutes.

Replace the sensor if faulty.

F and place the sensor in a

SECTION 4 TROUBLESHOOTING

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.

SECTION 5 PARTS

ITEM NO.

1 2 3 4 5 6 7 8

9 10 11 12 13 14

DESCRIPTION

CONTROLLER

THERMOWELL

CORD GRIP CONNECTOR

6' LONG HEAT TAPE

3/8" CONDUIT STRAIGHT CONECTOR

JUNCTION BOX COVER

3/8" FLEXIBLE CONDUIT

#8-18 x 3/4" SELF TAPPING SCREW

SEAL FITTING FOR CONNECTOR

30' ROLL OF INSULATION WRAP

WIRE NUT (yellow)

3/8" 90O ELBOW CONDUIT CONNECTOR

TEMPERATURE SENSOR

HEAT CONDUCTIVE COMPOUND

QTY

1 1 2 1 1 1

4 4 1 7 1 1 1

PART NO.

26-7284 29-0325

510-00001

26-0609 26-1068 46-2251 26-0875 28-1283 26-0883 26-0712 26-3383 26-1078 26-7186 26-7189

PAGE 7

YOUR VAN AIR REPRESENTATIVE IS:

NAME:

COMPANY:

ADDRESS:

CITY: STATE: ZIP:

PHONE: FAX:

ATTACH BUSINESS CARD HERE

PAGE 8

2950 Mechanic Street

Lake City, PA 16423 USA

Phone: 800-840-9906

Fax: 814-774-3482

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

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

22N/A

Floating

Outputs

Sensor

Inputs

Nbr of

Sensors

Included Enclosure

1 NEMA 4X

1 NEMA 1

E4436

62-0254-03

T775A/B/M SERIES 2000 CONTROLLER PRODUCT DESCRIPTION

Temperature Sensors

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

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)

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

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

SENSOR A AND SENSOR B TERMINAL WIRING IS POLARITY INSENSITIVE.

SENSOR A

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.

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).

NO HIGH VOLTAGE. CLASS 2 WIRING ONLY.

EARTH GROUND TERMINAL MUST BE CONNECTED TO CONDUIT CLAMP LOCALLY.

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

KNOCKOUT E

T T

120

MOD 1

MOD 2

DIGITAL

INPUT

KNOCKOUT B

POWER

24 VAC

OUTPUT RELAY 4

OUTPUT RELAY 1

KNOCKOUT C

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

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

SOURCE (24, 120, OR 240 VAC).

–

– +

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

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

120 or 240 Vac Power

120 Vac 120 120 Vac Power

Common COM Common

240 Vac 240 240 Vac Power

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.

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

(HOT)

24 VAC

LOAD 1

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

LOAD 2

COM

24 Vac load.

COM

M24475A

+ 30 hidden pages