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February 2008
P/N 32-0228
REV . B
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
FOR
FP-4 FREEZE PROTECTION KIT
P/N 83-0763
FOR TURBO-COOL AFTERCOOLERS
MODELS AC-140-7 thru AC-220-7
(230V-3PH-60Hz & 460V-3PH-60Hz)
WARNING
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
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SECTION 2 INSTALLATION 2.1 MOUNTING THE CONTROL BOX FIGURE 2-A 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 in- stalled. Drill the four pilot holes in the mounting surface using a 1/8" drill. Reference Figure 2- A for dimensions. The control box will be mounted with the hinged side of the enclosure on the bottom. Fasten the controller in place
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SECTION 2 INSTALLATION 2.4 INSTALLING THE CONDUIT FIGURE 2-D 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. 2.5 INSTALLING THE TRANSFORMER JUMPERS FIGURE 2-E INSTALLING THE TRANSFORMER JUMPERS WARNING BEFORE STARTING THIS PR
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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
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SECTION 2 INSTALLATION 2.7 SETTING THE CONTROLLER FIGURE 2-G CONTROLLER DISPLAY The controller was factory set for normal operation. The factory settings are as follows: RELAY 1 O SET POINT 35 F O DIFFERENTIAL 10 F 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 RI
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SECTION 4 TROUBLESHOOTING 4.1 TROUBLESHOOTING PROCEDURES SOLUTIONS PROBLEM POSSIBLE CAUSES 1. Aftercooler fan motor Controller not set properly Check the controller settings as outlined in Section 2.7. The continues to operate, controller may be set in the heat mode or the set points set too system temperature low. Set the controller to the recommended settings. O below 35 F. Control relay faulty Check the control relay. Replace if faulty. 2. Aftercooler fan motor No power to the control box
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SECTION 5 REPLACEMENT PARTS 5.1 REPLACEMENT PARTS ITEM NO. DESCRIPTION QTY PART NO. 1 12' LONG HEAT TAPE 1 26-8151 2 30' ROLL OF INSULATION WRAP 1 26-0712 3 1/2" NPT THERMOWELL w/CLIP 1 29-0325 4 CORD GRIP CONNECTOR 2 26-5618 5 SENSOR 1 26-7186 6 3/8" FLEXIBLE CONDUIT 2 FT 26-0875 7 SEAL FITTING FOR CONNECTOR 3 26-0883 8 3/8" CONDUIT STRAIGHT CONNECTOR 1 26-1068 O 9 3/8" 90 ELBOW CONDUIT CONNECTOR 1 26-1078 11 1" X 1/2" NPT BUSHING 1 14-0402 12 #12-14 x 1" SELF TAPPING SCREW 4 28-1286 13 TEMPERA
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SECTION 6 WARRANTY PER VAN AIR TERMS AND CONDITIONS OF SALE YOUR VAN AIR REPRESENTATIVE IS: NAME: COMPANY: ADDRESS: CITY: STATE: ZIP: PHONE: FAX: ATTACH BUSINESS CARD HERE 2950 Mechanic Street Lake City, PA 16423 USA Phone: 800/840-9906 Service Fax: 814/774-0778 Order Entry Fax: 814/774-3482 MAKING COMPRESSED AIR AND GAS WORK BETTER SINCE 1944. www.vanairsystems.com PAGE 8
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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
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T775A/B/M SERIES 2000 CONTROLLER PRODUCT DESCRIPTION a Temperature Sensors Accessories The controller accepts 1,097 Ohms PTC at 77°F (25°C): • 107324A – Bulb Holder, duct insertion • 50021579-001 – Standard sensor (included with all • 107408 – Heat Conductive Compound, 4 ounce models except NEMA 4X models) • 50001774-001 – Immersion Well, stainless steel 304, 1/2 in. threading • T775-SENS-WR – Water resistant with 5 foot leads (included with NEMA 4X models) • T775-SENS-WT – Watertight with 6
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BEFORE INSTALLATION T775A/B/M SERIES 2000 CONTROLLER The controller may be mounted in any orientation. BEFORE INSTALLATION However, mounting in the orientation shown in Fig. 1 permits proper viewing of the LCD display and use of the Review the “Specifications” on page 35 before keypad. installing the controller. NEMA 4 Enclosure Mounting When Installing This Product For models with NEMA 4 enclosures, ensure that waterproof wire/conduit fittings are used at the knockouts 1. Read these inst
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T775A/B/M SERIES 2000 CONTROLLER WIRING NOTE: Each T775 controller must be wired to its own Wiring Connections Access sensor(s). However, a benefit of the T775 To access the wiring connections, remove the two screws controller’s accuracy is that there is no more on the left side of the enclosure and gently swing open the than a 2°F differential between any two T775 top. Be careful to not stress the ribbon cables that controllers. connect the keypad and LCD display to the controller circu
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WIRING T775A/B/M SERIES 2000 CONTROLLER See Fig. 7 on page 6 for locating the appropriate power Controller Wiring input, remote sensors input, low voltage, contact closure, and load output terminals. WARNING Access to the terminals can be gained through standard conduit knockouts (A through E in Fig. 7 on page 6) Electrical Shock Hazard. located around the perimeter of the enclosure: Can cause severe injury, death or property • Knockouts A and B should be used only for sensor and damage.
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T775A/B/M SERIES 2000 CONTROLLER WIRING APPLICATIONS (EXAMPLES) Table 2. Description of Wiring Controller Wiring Details Terminal Connections. (Continued) The wiring connection terminals are shown in Fig. 7 and are described in Table 2. Connection Terminal Label Description Input See Fig. 8 – Fig. 20 beginning on page 6 for typical DI + - Digital Input (dry T775A/B/M wiring applications. contact) 24 Vac Power KNOCKOUT A 24V + + 24 Vac Hot Common C 24 Vac Common T SENSOR A B T MOD 1 b Ground
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WIRING APPLICATIONS (EXAMPLES) T775A/B/M SERIES 2000 CONTROLLER SENSOR A SENSOR A T T T T L1 (HOT) 24 VAC L2 C + 120V C + COM 1 NC LOAD NC NC COM NC LOAD COM C C 4 C C NO 3 NO NO NO NO NO NO NO LOAD NO NO LOAD NO COM NO C C 1 COM 2 C C NC NC NC NC COM LOAD LOAD 1 NO 2 LOAD 4 COM LOAD NO 3 M24476A 1 FOR 240 VAC LOAD, CONNECT TO 240 TERMINAL. M24478A Fig. 9. Wiring for four-stage control – 24 Vac input Fig. 11. Wiring for four-stage control with 120 or 240 and 24 Vac load. Vac (120 Vac inp
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T775A/B/M SERIES 2000 CONTROLLER WIRING APPLICATIONS (EXAMPLES) ML7984 ACTUATOR HONEYWELL ELECTRONIC SERIES 90 MODUTROL MOTOR T1 T2 B R W 1 T1 T2 B R W POWER OUTPUT 2 POWER B 1 OUTPUT R – 2 W + B MODULATING OUTPUT B R TERMINAL (MOD 1) R – – 3 W + W + MODULATING B OUTPUT R – TERMINAL W 1 USE SEPARATE TRANSFORMER FOR T775R WHEN USING 24 VAC. (MOD 1) + 2 250 OHM RESISTOR M24480 Fig. 13. Wiring for ML7984 valve actuator. 1 TO VERIFY OUTPUT, TEST OPEN CIRCUIT VOLTAGE BETWEEN THE MOD 1 TERMINALS W AND
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WIRING APPLICATIONS (EXAMPLES) T775A/B/M SERIES 2000 CONTROLLER 1 M9184 OR M9185 L1 L2 MODUTROL MOTOR (HOT) R TR W TR B B 2 – M9184 OR M9185 R 3 W + MODUTROL MOTOR B R R – TR W + W TR B M9184 OR M9185 MODUTROL MOTOR MODULATING OUTPUT TERMINAL (MOD 1) R TR W TR B 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. USE A 1300 OHM RESISTOR FOR TWO MOTORS, 910 OHM RESISTOR FOR THREE MOTORS. 2 THE 407EAU RESISTOR KIT, WHICH IS SHIPPED WITH THE M9184 AND M9185 MOTORS, INC
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T775A/B/M SERIES 2000 CONTROLLER CHECKOUT CHECKOUT Table 3. Temperature Sensor Calibration for Resistance Loss due to Wire Length. Inspect all wiring connections at the controller terminals, Temperature Offset in and verify compliance with the installation wiring a diagrams. °F (Foot) AWG Rating mΩ /ft 200 ft 500 ft 1,000 ft 14 2.5 0.46 1.14 2.28 WARNING 16 4.0 0.72 1.82 3.64 Electrical Shock Hazard. 18 6.4 1.16 2.90 5.82 Can cause severe injury, death or property damage. 20 10.2 1.86 4.64
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INTERFACE OVERVIEW T775A/B/M SERIES 2000 CONTROLLER Menu Button INTERFACE OVERVIEW •Pressing the MENU button always displays the Program menu. If you are in Setup mode, you exit The T775A/B/M controllers use an LCD panel and setup and return to the Program menu. 6-button keypad to provide status information and permit • Pressing and holding the MENU button for five user input of the programming, setup, and scheduling seconds leaves the current screen and displays parameters. the Setup me
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T775A/B/M SERIES 2000 CONTROLLER INTERFACE OVERVIEW Accessing the Menus HOME Menus are used for programming, scheduling, viewing the RELAYS 1 2 3 4 summary settings, and setup of advanced options. ON SETUP SENSORS SENSORS SENSOR A OUTPUTS Programming, Scheduling, and Summary Menus o F 78 EXIT To access these menus from the home screen, press the SENSOR B o MENU button. See Fig. 24. 84 F MOD1 40% MOD2 60% MENU DISPLAY WHEN MENU DISPLAY
