Installation and Maintenance Manual
Accessories for Maverick I™
Commercial Packaged Rooftop Systems
IM 921
Group: Applied Systems
Part Number: IM 921
Date: April 2008
Models MPS003A – 020A
3 to 20 Tons
Note: This manual is a collection of various installation manuals for accessories that may be purchased separately. To print this manual with
page numbers showing, choose “Documents and Markups” from the Adobe® Reader® print option settings.
© 2008 McQuay International
Page 1
Contents
Carbon Dioxide Sensor. . . . . . . . . . . . . . . . . . . . . . 3
Damper (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Damper (Motorized). . . . . . . . . . . . . . . . . . . . . . . . . 13
Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dual Enthalpy Sensor . . . . . . . . . . . . . . . . . . . . . . . 17
Economizer (Convertible) . . . . . . . . . . . . . . . . . . . . 20
Economizer (Vertical) . . . . . . . . . . . . . . . . . . . . . . . 35
Electric Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
GFCI Convenience Outlet . . . . . . . . . . . . . . . . . . . . 48
LP Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Power Exhaust (BFF02) . . . . . . . . . . . . . . . . . . . . . 54
Power Exhaust ((BGF03 & 04) . . . . . . . . . . . . . . . . 58
Roof Curbs (CAD) . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Roof Curbs (CAE) . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Roof Curbs (CAF) . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Smoke Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Smoke Detector (Ionization) . . . . . . . . . . . . . . . . . 76
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Thermostat Guard. . . . . . . . . . . . . . . . . . . . . . . . . . 84
Thermostat Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 85
Page 2
Page 3
C7232A,B SENSOR AND CONTROLLER
SPECIFICATIONS
Models: C7232 Sensor and Controller. A stand-alone carbon
dioxide (CO2) sensor with two jumper-adjustable outputs
(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
that indicates the current CO2 concentration.
Wiring Connections:
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.
Calibration: This product is factory calibrated. No field calibration is necessary for the life of this product.
Dimensions:
C7232A: See Fig. 1.
C7232B: See Fig. 2.
Approvals:
CE
Underwriters Laboratories Inc. Listed, File No. E4436
cUL
C7232B: Flammability Rating, UL94-5V
C7232A: NEMA1
C7232B: NEMA3
Sensor Performance Ratings:
Response Time: 2 min.
Carbon Dioxide Sensor:
Operation: Non-dispersive infrared (NDIR).
Sampling: Diffusion.
Range: 0 to 2000 ppm
Accuracy: ± (30 ppm +2% of reading)*.
1
(25)
* This product complies with Title 24 Part 6, CEC Standard
for Residential and Non-Residential Buildings— 2005,
when installed according to instructions.
KNOCKOUTS
FOR
EUROPEAN
APPLICATIONS
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.
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).
2-3/8 (60)
STANDARD
UTILITY
CONDUIT
2-3/8
BOX
(60)
(2X4)
MOUNTING
HOLES
5-1/16
(128)
3-5/32 (80)
M17540A
Fig. 1. C7232A dimensions in inches (mm).
3-5/16 (84)
Outputs (Jumper Adjustable, see Table 2):
Analog: 0-10 Vdc (Default: 2-10 Vdc, 500 to 1500 ppm).
Relay: Normally Open SPST (Default: Close at 800 ppm).
1-13/16
(46)
5-5/8
(142)
Ambient Ratings:
Temperature:
Operating: +32°F to +122°F (0°C to +50°C).
Storage: -4°F to +158°F (-20°C to +70°C).
Relative Humidity (non-condensing): 0 to 95 percent.
1-5/8
(41)
8 (203)
M17592
Fig. 2. C7232B dimensions in inches (mm).
CO2 Pressure Dependence: 1.4% change in reading per
1 kPa deviation from 100 kPa.
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the
TRADELINE® Catalog or price sheets for complete ordering number.
If you have additional questions, need further information, or would like to comment on our products or services, please write or
phone:
1. Your local Honeywell Automation and Control Products Sales Office (check white pages of your phone directory).
2. Honeywell Customer Care
1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386
In Canada—Honeywell Limited/Honeywell Limitée, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9.
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,
Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
63-2571—7
2
Page 4
C7232A,B SENSOR AND CONTROLLER
INSTALLATION
4.
When Installing this Product...
5.
1.
2.
3.
4.
Remove the screwdriver and pull the cover straight down
until it meets a stop.
Pull the cover straight off the subbase.
Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous
condition.
Check the ratings given in the instructions and on the
product to make sure the product is suitable for your
application.
Installer must be a trained, experienced service
technician.
After installation is complete, check out product
operation as provided in these instructions.
B
IMPORTANT
All wiring must agree with applicable codes,
ordinances and regulations.
BUTTON HEAD
SOCKET CAP
SCREW
CAUTION
A
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.
C7232A Cover Replacement
3.
Feed the wires through the opening in the subbase.
Place the cover, with a small gap at the top, flat on top of
the subbase.
When the cover rests flat on the subbase, slide it straight
up until it latches in place.
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.
CAUTION
Equipment Damage Hazard.
Electrostatic discharge can short equipment
circuitry.
Ensure that you are properly grounded before
handling the unit.
NOTES:
C7232A Cover Removal/Replacement
C7232A Cover Removal (see Fig. 3)
3.
Fig. 3. C7232A cover removal.
1.
2.
CAUTION
1.
2.
M17541
C
ALLEN TOOL
Remove button head socket cap screw and set it aside.
Insert the head of a small screwdriver into the slot at the
center and near the top of the cover.
Gently pull the handle down toward the bottom of the
device until a small gap between the subbase and the
cover appears.
3
Page
5
Do not install the sensor where it can be affected by:
— drafts or dead spots behind doors and in corners.
— air from ducts.
Sensor must be mounted in a location which sees at
lease one 4-hour unoccupied period per week so that
the CO2 level drops to outdoor levels. Automatic
Background Calibration will not work properly in locations without four hours of unoccupied time per week,
or where there are sources of CO2 other than people
(breweries, mushroom farms, etc).
IMPORTANT
This sensor is not for use in highly corrosive environments.
63-2571—7
C7232A,B SENSOR AND CONTROLLER
Wall Mounting
The C7232 Wall Mount models can be mounted using two or
four screws:
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.
WIRING
The factory ships the device with the output default settings
shown in Tables 2 and 3. Set the jumpers and wire the device
(see Table 1 and Fig. 6).
CAUTION
NOTE: When mounting on a junction box, see Fig. 4.
3.
Electrical Shock or Equipment Damage Hazard.
Can shock individuals or short equipment
circuitry.
Disconnect power supply before installation.
Replace the cover.
STANDARD UTILITY CONDUIT BOX
CAUTION
NO. 6 SCREW
Equipment Damage Hazard.
Electrostatic Discharge Can Short Equipment
Circuitry.
Ensure that you are properly grounded before
handling the unit.
FRONT
COVER
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.
SUBBASE
BUTTON HEAD
SOCKET CAP
SCREW
NO. 6 SCREW
M17542
Fig. 4. Junction box mounting (C7232A).
Table 1. C7232 Wiring Connections (see Fig. 6).
Duct Mounting (see Fig. 5)
1.
Wire Color
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.
Designation
Function
Red
G+
24 Vac Hot
Black
G0
24 Vac Common
Yellow
OUT1
Analog Output Signal
Brown
M
Analog Output Common
Orange
NO
Relay Output Normally Open
Green
COM
Relay Output Common
C7232
RED
Place O-ring on tube end; mount the control to the tube.
24V
BLACK
+
ANALOG
OUT
W
YELLOW
BROWN
–
ORANGE
O
FL
L1
(HOT)
L2
1
GREEN
1
POWER SUPPLY. PROVIDE
DISCONNECT MEANS AND
OVERLOAD PROTECTION
AS REQUIRED.
M17543A
Fig. 6. Wiring the C7232.
M17591
Fig. 5. Duct mounting (C7232B).
63-2571—7
4
Page 6
C7232A,B SENSOR AND CONTROLLER
Input Signal
NOTES:
—
The C7232 Sensors have an adjustable range. These ranges
are determined by the SW1 and SW2 jumper settings (see
Table 2).
On duct models, remove the screw holding the
board in place to view jumper settings on reverse.
(See Fig. 7.)
The CO2 settings and the output signal settings
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.
—
Table 2. CO2 Range Jumper Settings
SW2
Relaya (ppm)
AN (ppm)
On
On
0 to 1000
1000
On
Off
0 to 2000
1200
Offb
Onb
500 to 1500
800
Off
Off
500 to 2000
1200
SW2SW1 OUT
a
OFF
ON
OFF
ON
0 – 100%
20 – 100%
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
AN
Voltage
Current
SW1
The output signal can be adjusted for 0/2-10 Vdc or 0/4-20 mA
(see Table 3).
Table 3. Output Signal Jumper Settings
M19424
OUT
AN
0-100%
Fig. 7. C7232 default jumper settings.
20-100%
Voltage
0-10Vdc
2-10Vdc
Current
0-20 mA
4-20 mA
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 4 (arbitrary points along
the analog curve).
Table 4. 0-10 Vdc Output Example.
CO2 Level (ppm)
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Voltage Output (Vdc)
0
1
2
3
4
5
6
7
8
9
10
For a CO2 setting of 0-2000 ppm and a voltage output of 2-10 Vdc, the output would be as shown in Table 5 (arbitrary points along
the analog curve).
Table 5. 2-10 Vdc Output Example.
CO2 Level (ppm)
Voltage Output (Vdc)
0
250
500
750
1000
1250
1500
1750
2000
2
3
4
5
6
7
8
9
10
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, the
controller typically signals an increase in air flow.
5
Page
7
63-2571—7
C7232A,B SENSOR AND CONTROLLER
APPENDIX
IMPORTANT
This page is only for models with date code prior to 0309.
Pre 0309 Date Code Jumper Settings
Input Signal
The C7232 Sensors have an adjustable range. These ranges
are determined by the SW2 and OUT1 jumper settings (see
Table 6).
NOTE: When choosing analog output, be sure to set the
SW1 jumper to the On position.
Table 6. CO2 Range Jumper Settings for models
with date code prior to 0309.
Jumper SW1
Jumper
OUT1b
Setting
Ona
Off
—c
0 to 1000
AN2a
X
—c
500 to 1500 500 to 2000
Relay Switchingb
X
800d
X
20-100%
0-10Vdc
2-10Vdc
Current
0-20 mA
4-20 mA
—
X
0-100%
Voltage
Off
AN1
OUT
AN1 and AN2 (set
both the same)
NOTES:
—
Jumper SW2
Ona
Table 7. Output Signal Jumper Settings for models
with date code prior to 0309.
0 to 2000
1200d
On duct models with date code prior to 0309,
remove the screw holding the board in place to
view jumper settings on reverse. (See Fig. 8.)
The CO2 settings and the output signal settings
are independent of each other. 0-100% and 20100% 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.
1000d
a
Setting when shipped from the factory.
OUT1 jumper setting does not affect the Relay Switching.
c The analog output will not work properly when SW1 is Off.
d When the level reaches this value, the contacts close; when
the level drops 100 ppm below this value, the contacts
open.
b
OUT1
Select
AN1
AN2
The output signal can be adjusted for 0/2-10 Vdc or 0/4-20 mA
(see Table 7).
AN1
Voltage
Current
Output Signal
AN2
Voltage
Current
OFF
ON
OFF
ON
0 – 100%
20 – 100%
SW2SW1 OUT
M20494
Fig. 8. C7232 default jumper settings for models
with date code prior to 0309.
63-2571—7
6
Page 8
INSTRUCTIONS FOR
(-)XRF-HEA1 MANUAL FRESH AIR DAMPER
(-)XRX-AT01 MOTORIZED AND
FRESH AIR DAMPER KIT
Recognize this symbol as an indication of Important Safety Information!
WARNING
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR
PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS
THOROUGHLY BEFORE ATTEMPTING ADJUSTMENT OR OPERATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN IMPROPER INSTALLATION, ADJUSTMENT; SERVICE OR MAINTENANCE,
POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WARNING
TURN OFF ELECTRIC POWER TO THE UNIT BEFORE
ATTEMPTING ANY MAINTENANCE. FAILURE TO DO
SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN
PERSONAL lNJURY OR DEATH.
1. Remove (4) screws from each side of the unit top
cover.
2. Remove all screws from top left panel (retain screws
and top left panel for later use).
3. Lift top cover high enough to replace top left panel with
damper panel assembly.
4. Replace top left panel with (A) damper panel
assembly.
5. Secure the (B) hood sides to the edges of the (A)
damper panel assembly with (6) screws removed in
step 2.
6. Adjust damper slide to appropriate opening now.
7. Trap (C) filters between (C) front filter support and filter
support on the (A) damper assembly while attaching to
the (B) hood side with (3) screws provided.
8. Attach (D) rain hood (previously the top left panel) to
the (B) hood side with (4) screws each side, (6) screws
between rain hood and front filter support.
9. Attach (E) rain hood top to the same location as upper
edge of (A) damper panel assembly with (6) screws
that were removed in step 2.
10. Secure (E) rain hood top to rain hood and hood side
with (8) screws provided.
11. Secure all remaining screws, making sure that all
weather exposed screw holes use the screws.
—
RAIN HOOD TOP
NOTE:
CIRCLED LETTERS EQUAL
ORDER OF INSTALLATION
E
RAIN HOOD
(PREVIOUSLY TOP LEFT PANEL)
DAMPER PANEL ASSEMBLY
DAMPER SLIDE
A
D
FILTER SUPPORT
B
C
C
B
FRONT FILTER SUPPORT
HOOD SIDES
FILTER - PERMANENT
(2) REQ'D
Page 9
IF UNIT HAS AN EXISTING MANUAL FRESH
AIR DAMPER
Refer to page 1. Reverse assembly procedure until
damper panel assembly is removed. Assemble motorized
damper assembly (see (F) below). Then reassemble fresh
air damper using motorized damper assembly.
IF UNIT HAS NO EXISTING MANUAL FRESH
AIR DAMPER
1. Assemble motorized damper panel assembly by
removing the damper slide from damper panel
assembly, then attaching the (F) motorized damper to
the opposite side. Use (6) of the screws from the
damper slide to attach the motorized damper.
2. Remove (4) screws from top cover sides.
3. Remove all screws from top left panel (retain screws
and top left panel for later use).
MOTORIZED DAMPER
4. Lift top cover and remove top left panel. Plug power
cord for motorized damper into polarized wire harness
connector.
5. Apply power to unit and set minimum damper position
with adjustment wheel on damper motor.
6. Secure the (B) hood sides to the edges of the (A)
motorized damper panel assembly with (6) screws
removed in step 3.
7. Trap (C) filters between (C) front filter support and filter
support on the (A) damper assembly while attaching to
the (B) hood side with (3) screws provided.
8. Attach (D) rain hood (previously the top left panel) to
the (B) hood side with (4) screws each side, (6) screws
between rain hood and front filter support.
9. Attach (E) rain hood top to the same location as upper
edge of (A) damper panel assembly with (6) screws
that were removed in step 3.
10. Secure (E) rain hood top to rain hood and hood side
with (8) screws provided.
11. Secure all remaining screws, making sure that all
weather exposed screw holes use the screws.
DAMPER PANEL
ASSEMBLY
F
A
DAMPER
SLIDE
(DISCARD)
MOTORIZED DAMPER PANEL ASSEMBLY
NOTE:
CIRCLED LETTER EQUAL
ORDER OF INSTALLATION
—
E
RAIN HOOD TOP
RAIN HOOD
(PREVIOUSLY TOP LEFT PANEL)
TOP COVER
(REF.)
MOTORIZED DAMPER
PANEL ASSEMBLY
D
A
HOOD SIDES
B
C
FRONT FILTER SUPPORT
C
B
FILTER - PERMANENT
(2) REQ'D
HOOD SIDES
2
Page 10
DAMPER MOTOR
TO ADJUST DAMPER MINIMUM POSITION
1.
2.
3.
4.
Remove return air cover.
Apply power to unit.
Supply fan must be on.
Turn potentiometer wheel on damper motor to adjust
damper minimum position,
5. After successfully adjusting damper position, replace
return air cover.
WITH UNIT POWER ON,
TURN WHEEL ON DAMPER
MOTOR TO ADJUST
MINIMUM POSITION
RETURN AIR
COVER
FOR HORIZONTAL AIR FLOW INSTALLATIONS
1. Installer must provide opening in return air duct with
removable cover for access to minimum position
adjustment on motorized damper.
2. Remove cover on return air duct.
3. Apply power to unit.
4. Supply fan must be on.
5. Turn potentiometer wheel on damper motor to adjust
damper minimum position.
6. After successfully adjusting damper position, replace
cover on return air duct.
APRIL 26, 2006
DRIP RAIL
12"
REMOVABLE COVER
8"
RMIOAD15
3
Page 11
HARNESS DETAIL
E# = WIRE END DESIGNATION
E2 STUD #6 18 Ga. Wire
E3 Female ¼ Quick Disc.
E4 Male ¼ Quick Disc. Insul
E6 Wire Nut Size 73B
COMPONENT CODE
Economizer
M8405A
Damper Actuator 24v
PL7
Female Damper Plug
PL6
Male A/C Unit Plug
BLK
BRN
ORG
WHT
WIRE COLOR CODE
Black
BLU Blue
Brown
GRY Gray
Orange
RED Red
White
YEL Yellow
HARNESS ENDS AT PL7
CONNECTOR & CONTACT CONFIGURATION
PL7 (303917) CAP - (303902) SOCKET
0-35% Motorized Outside Air
RXRX-AT01
Notes:
1. Unit wiring shown as reference only. Check unit wiring for actual unit wiring.
Rooftop Systems, Inc.
2405 McIver Lane
Carrollton, Texas 75006
Phone (972) 247-7447
Fax
(972) 243-0940
Page 12
Date: August 29, 2000
Supercedes: 02-23-00
Drawn by:
Unit # 60-287-15B
Diagram# 28715W
INSTALLATION INSTRUCTIONS
MODEL RXRF - FBB1
0-35% MOTORIZED OUTSIDE AIR
The 0-35% manual outside air system is designed to replace the unit duct cover. No drilling on the unit or field assembly is
required. A 2-position control motor opens the intake damper when the blower is energized. The amount of air is
controlled by the a slide damper on damper motor. The intake panel is fully insulated..
SUPPLY DUCT
COVER
A/C UNIT
OUTSIDE AIR
ASSEMBLY
RETURN DUCT COVER (REMOVED)
OUTSIDE AIR HOOD
ADJUSTABLE SLIDE DAMPER
2-POSITION MOTOR
FIGURE 1
STEP 1:
Check for correct number of parts. See list below:
1 ea. - Outside Air Intake damper assembly with hood and slide damper.
STEP 2:
Remove return air duct cover from unit, and save the screws.
STEP 3:
Remove filter access panel. Plug the “PL5" connector to ”PL2" connector in return section.
STEP 4:
Install outside air assembly as shown in Figure 1 over duct opening with the screws removed in Step 2.
STEP 5:
Adjust the slide damper to the desired position.
MARCH 2, 1998
RM35MAD20B
Page 13
HAR NESS DE TAIL
E# = WIRE END DES IG NA TION
E2
STUD #6 18 Ga. Wire
E3
Fe male 14 Quick Disc.
E4
Male 14 Quick Disc. In sul
E6
Wire Nut Size 73B
HAR NESS STOPS AT PL5
Notes:
1.
COM PO NENT CODE
Economizer
M847A1080
PL5
Plug
PL2
Unit Plug
WIRE COLOR CODE
Damper Ac tua tor 24v
Male Damper
Fe male A/C
RED
BLU
GRY
BRN
Red
Blue
Gray
Brown
0-35% MO TOR IZED DAMPER
RKKA/RJKA/RLKA 036- 072
Unit wir ing shown as ref er ence only.
Rheem Manu fac tur ing
5600 Old Green wood Rd
Ft. Smith, AR 72917- 7010
Date: Feb ru ary 27, 1998
Drawn by:
Unit # RXRF- FBB1
Page 14
Form# 35MAD20BW
Dia gram# 6028220BW
Installation Manual
Disconnect Switch for Maverick I™ Units
IM 904
Group: MPS
Part Number: IM 904
MPS 007 to 020 ton
Date: January 2008
Installation
Procedure (also see diagram next
page)
WARNING
1. Connect the three black wires to terminals T1, T2,
and T3 located on the disconnect switch.
Failure to follow these instructions can result in improper
installation, adjustment, service, or maintenance, and can
result in fire, electrical shock, property damage, personal
injury, or death. These instructions are intended as an aid to
qualified service personnel for proper installation, adjustment,
and operation of this kit. Read carefully and thoroughly before
attempting installation, adjustment, or operation.
2. Remove the disconnect switch mounting hole cover
plate (with gasket) and discard.
3. Place the actuator shaft through the weather gasket.
4. Insert the actuator shaft and weather gasket assembly
onto the disconnect switch.
Parts List
Description
Part Number
Quantity
Disconnect switch assembly
42-42559-02
1
Wire (black)
AE-72749-17
3
Label (On/Off)
92-42563-01
1
DANGER
Electrical shock hazard. Can cause property damage,
personal injury or death. Before beginning any modification,
be sure the main disconnect switch is in the “Off” position and
tagged with a suitable warning label.
5. Place the cover plate over the actuator shaft and on
top of the weather gasket.
6. Position the assembly adjacent to the panel with the
actuator shaft through the large hole.
7. Through the panel, insert and tighten four screws
(63-42109-05) into the disconnect switch.
8. Place the label over the four screws.
9. Position the handle on the actuator shaft.
10. Tighten the set screw.
11. Connect the three black wires to L1, L2, and L3
located on terminal block TB1.
© 2008 McQuay International
Page 15
Page 16
INSTRUCTIONS FOR
DUAL ENTHALPY SENSOR UPGRADE KIT
Installation
Upgrade single enthalpy economizers (outdoor air
enthalpy) to dual enthalpy by adding a return air enthalpy
sensor and wiring it to the Honeywell model W7213A1016
Logic Module.
Parts Included
The sensor upgrade kit contains the following:
• (1) Sensor
• (1) Wiring harness
• (2) No. 8-16 x ¾” PHI/PAN - TEC screws
• (1) Strain relief bushing
(Required for 7.5 to 25 ton units only)
• (1) Sensor mounting bracket
(Required for the 3 to 6 and 7.5 Ton units only)
• (2) No. 10 self-drilling screws (½ - inch long)
• (3) Tie wraps
Mounting
3 to 6 and 7.5 Ton Vertical
To mount the sensor:
1. Remove four screws holding barometric damper.
2. Mount the bracket to the Economizer damper using
the two No. 10 self-drilling screws provided.
SENSOR MOUNTING BRACKET
ENTHALPY SENSOR
WARNING: Risk of Electrical Shock.
Disconnect the power supply and install a lockout
tag before wiring connections are made to avoid
possible electrical shock or damage to the
equipment.
(2) 8-16 x ¾” PHI/PAN - TEC SCREWS
Figure 1: Mounting the Sensor to the Bracket
Mounting for 3 to 6 and 7.5 Ton Economizer
3. Mount the sensor to the mounting bracket (refer to
Figure 1 for the proper bracket orientation) using the
two No. 6-20 thread-forming screws (provided).
MOUNTING BRACKET
(2) #10 x ½" SELFDRILLING SCREWS
ECONOMIZER SIDE
PANEL
REMOVE TO PULL
BAROMETRIC DAMPER
ENTHALPY SENSOR
Figure 2: Mounting the Sensor and Bracket in a 3 to 6 and 7.5 Ton Economizer Assembly
1 - DUAL ENTHALPY SENSOR UPGRADE KIT INSTALLATION INSTRUCTION
Page 17
7.5 to 25 Ton Vertical and Horizontal
To mount the sensor:
1. Remove the four screws holding the return air sensor
mounting plate to the damper (see Figure 3).
2. Mount the sensor to the mounting plate using the two
No. 6-20 thread-forming screws (provided).
WIRE
HARNES
ENTHALPY
SENSOR
MOUNTED INSIDE
THE DAMPER
RETURN AIR
SENSOR
MOUNTING
PLATE
Wiring
3 to 6 and 7.5 Ton Vertical
To wire the sensor to the Logic Module:
1. Remove the strain relief from the damper.
2. Feed the wiring Enthalpy harness wires through the
opening with the existing control harness and replace
the strain relief furnished with the damper originally.
3. Route and attach the wiring harness with the other
harnesses on the damper using the tie wraps
provided.
4. Wire the sensor and Logic Module (see Figure 5 for
wiring).
5. Ensure the barometric relief dampers move freely.
6. Reconnect the electrical power supply.
Figure 3: 7.5 to 12.5 and 15 to 25 Ton Vertical
Economizer with Enthalpy Sensor Installed
7 to 25 Ton Vertical and Horizontal
To wire the sensor to the Logic Module:
1. Remove the knockout plug from the mounting plate
(see Figure 4).
2. Feed the wiring harness wires through the knockout
opening and insert the strain relief provided to secure
the wires.
3. Route and attach the wiring harness with the other
harnesses on the damper using the tie wraps
provided.
4. Wire the sensor and Logic Module (see Figure 5 for
wiring).
5. Mount the sensor to the mounting plate using (2) 6-20
x 78” screws. Secure mounting plate back to the
damper using the four screws removed in Step 1 of the
7 to 25 Ton Vertical and Horizontal section.
6. Reconnect the electrical power supply.
STANDARD
OUTDOOR AIR
ENTHALPY SENSOR
SENSOR
MOUNTING PLATE
KNOCKOUT PLUG
Note: The sensor mounting plate gets installed so
that the sensor resides in the return RA air
stream.
Figure 4: 7.5 to 12.5 and 15 to 25 Ton Horizontal Economizer
Showing the Sensor Mounting Position
2 - DUAL ENTHALPY SENSOR UPGRADE KIT INSTALLATION INSTRUCTION
Page 18
620 OHM
RESISTOR
OR
C7400A1004
DUAL ENTHALPY
FIELD INSTALLED
OPTION
Figure 5: Enthalpy Sensor Wiring Diagram
MAY 24, 2006
RMIDE02
Page 19
INSTALLATION INSTRUCTIONS
MODELS RXRD-MCCM3 & RXRD-MECM3
CONVERTIBLE AIRFLOW ECONOMIZERS
WARNING
THIS ACCESSORY IS TO BE INSTALLED BY A QUALIFIED, LICENSED SERVICE PERSON. TO AVOID
UNSATISFACTORY OPERATION OR DAMAGE TO THE PRODUCT AND POSSIBLE UNSAFE CONDITIONS,
INCLUDING ELECTRICAL SHOCK, REFRIGERANT LEAKAGE AND FIRE, THE INSTALLATION INSTRUCTIONS
PROVIDED WITH THIS ACCESSORY MUST BE STRICTLY FOLLOWED AND THE PARTS SUPPLIED USED
WITHOUT SUBSTITUTION. DAMAGE TO THE PRODUCT RESULTING FROM NOT FOLLOWING THE
INSTRUCTIONS OR USING UNAUTHORIZED PARTS MAY BE EXCLUDED FROM THE MANUFACTURER’S
WARRANTY COVERAGE.
WARNING
DISCONNECT ELECTRICAL POWER TO THE UNIT. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL INJURY OR DEATH.
TOOLS REQUIRED FOR INSTALLATION:
3
" electric drill with 516" socket
Small flat blade (0.125" wide) screwdriver
" diameter drill bit for sheet metal.
Sheet metal tools (e.g. shears)
8
1
8
RXRD-MECM3
economizer with
controller, actuator,
and outside enthalpy
sensor attached
PACKAGE CONTENTS
ITEM
DESCRIPTION
RXRD-MCCM3
economizer with
controller, actuator, and
outside enthalpy sensor
attached
PART No.
PART No.
1
Discharge Air Sensor (Hardware Bag)
6036420 / 3112
6036408 / 3112
2
Permanent Filter
6036420 / 8569
15 ½ x 21 3 8
6036408 / 8570
15 ½ x 27 3 8
3
Bird Screen
6036420 / PERF
6036408 / PERF
4
OA Rainhood – Filter Access
6036420 / FAP
6036408 / FAP
5
OA Rainhood Assy – Left Side
6036420 / EHSL
6036408 / EHSL
6
OA Rainhood Assy – Right Side
6036420 / EHSR
6036408 / EHSR
7
OA Rainhood Assy – Bottom
6036420 / EHB
6036408 / EHB
8
OA Rainhood – Top
6036420 / EHT
6036408 / EHT
9
OA Rainhood – Filter Retainer
6036420 / FCH
6036408 / FCH
10
BR Rainhood Assy – Left Side
6036420 / EHS2L
6036408 / EHS2L
11
BR Rainhood Assy – Right Side
6036420 / EHS2R
6036408 / EHS2R
12
BR Rainhood Assy – Bottom
6036420 / EHB2
6036408 / EHB2
13
BR Rainhood – Top
6036420 / EHT2
6036408 / EHT2
14
BR Rainhood – Bird Screen
6036420 / FCH2
6036408 / FCH2
15
Hardware Bag
6036420 / HDW
6036408 / HDW
Page 20
FIGURE 1
RXRD-MECM3 Shown
RRDX-MCCM3 Similar
COIL / FILTER ACCESS
31 316
BLOWER ACCESS
3 1316
5 1132
SUPPLY COVER
82 ¼
48
24
RETURN COVER
1
16
1
32
CONDENSATE DRAIN
¾" NPT FEMALE
A0801-12
STEP 1:
Immediately upon receipt, all cartons and contents should
be inspected for transit damage. Units with damaged
cartons should be opened immediately. If damage is
found, it should be noted on the delivery papers and a
damage claim filed with the last carrier. Compare carton(s)
contents to PACKAGE CONTENTS List (TABLE 1) above
to note any missing items.
FIGURE 2
SIDEFLOW APPLICATIONS ONLY
STEP 2:
Remove RETURN COVER, COIL/FILTER ACCESS
PANEL and BLOWER ACCESS PANEL from the unit and
retain for reuse (SEE FIGURE 1). Retain screws.
STEP 3:
Remove the RETURN AIR FILLER and carefully cut
insulation attached to fully expose return air opening.
Discard the RETURN AIR FILLER.
STEP 4:
For sideflow applications, install the RETURN COVER in
the bottom return opening. Discard the RETURN COVER
for downflow applications.
STEP 5:
For sideflow applications, remove the barometric relief
damper from economizer prior to installation in unit. This
component will be relocated to the sideflow return air duct
along with the barometric relief hood (SEE FIGURE 2).
2
Page 21
PLACE RETURN AIR
COVER W/ INSULATION UP
(NO SCREWS REQUIRED)
REMOVE BAROMETRIC
DAMPER AS INDICATED
A0818-04-01
NOTE:
Units produced after August 20, 1999, have economizer connections relocated. For units produced before this date, go to
STEP 6. For units produced after this date, go to STEP 7.
STEP 6:
These units will require an EXTENSION HARNESS (not provided) to connect the economizer to the ECONOMIZER
PLUG provided on the unit. Remove jumper plugs, connect EXTENSION HARNESS to unit ECONOMIZER PLUG, and
slide economizer into unit return air section being careful not to tear the insulation on the rear panel (SEE FIGURE 3). After
the economizer is installed, snap the EXTENSION HARNESS plugs into the openings in the economizer top and connect
mating economizer plug. Save the jumper plugs in this compartment for diagnostic purposes.
STEP 7:
Remove jumper plugs and slide economizer into unit return air section being careful not to tear the insulation on the rear
panel (SEE FIGURE 3). After the economizer is installed, snap the unit ECONOMIZER PLUGS into the openings in the
economizer top and connect mating economizer plug. Save the jumper plugs in this compartment for diagnostic purposes.
FIGURE 3
UNIT ECONOMIZER CONNECTOR CONNECT ECONOMIZER MATCHING PLUGS
A0818-04-01
3
Page 22
STEP 8:
Using the holes located above the return air opening on the unit attach the economizer to the REAR PANEL using the
screws removed in STEP 2 (SEE FIGURE 4).
FIGURE 4
WIRE TIES
(3) SCREWS
ECONOMIZER RAIN HOOD (FRESH AIR) ASSEMBLY
STEP 9:
Fasten (7) OA RAINHOOD ASSY – BOTTOM to the (5) OA RAINHOOD ASSY – LEFT SIDE and the (6) OA RAINHOOD
ASSY - RIGHT SIDE.
STEP 10:
Attach the two (9) OA RAINHOOD – FILTER RETAINERS to the (5) OA RAINHOOD ASSY – LEFT SIDE and the (6) OA
RAINHOOD ASSY – RIGHT SIDE from STEP 9 above. Please notice that the flange on the (9) OA RAINHOOD – FILTER
RETAINERS must be as shown in (SEE FIGURE 5) to retain the (2) PERMANENT FILTER.
STEP 11:
Fasten (8) OA RAINHOOD – TOP to the (5) OA RAINHOOD ASSY – LEFT SIDE and the (6) OA RAINHOOD ASSY –
RIGHT SIDE.
STEP 12:
Slide (2) PERMANENT FILTER between (9) OA RAINHOOD – FILTER RETAINERS and back into the (7) OA
RAINHOOD ASSY – BOTTOM. Attach (4) OA RAINHOOD – FILTER ACCESS to the front/top of (5) OA RAINHOOD
ASSY – LEFT SIDE and the (6) OA RAINHOOD ASSY – RIGHT SIDE.
4
Page 23
FIGURE 5
RXRD-MECM3 Shown
RRDX-MCCM3 Similar
ˆ
‰
13
„
†
11
14
‰
‚
ƒ
…
12
14
Š
‡
ECONOMIZER RAIN HOOD - BOTTOM
(BAROMETRIC DAMPER - BR)
ECONOMIZER RAIN HOOD - TOP
(FRESH AIR - OA)
ECONOMIZER RAIN HOOD (BAROMETRIC DAMPER) ASSEMBLY
STEP 13:
Fasten (12) BR RAINHOOD ASSY – BOTTOM to the remaining (10) BR RAINHOOD ASSY – LEFT SIDE and the
remaining (11) BR RAINHOOD ASSY – RIGHT SIDE.
STEP 14:
Attach the two (14) BR RAINHOOD – FILTER RETAINERS to the (10) BR RAINHOOD ASSY - LEFT SIDE and the (11)
BR RAINHOOD ASSY – RIGHT SIDE from STEP 13 above. Please notice that the flange on the (14) BR RAINHOOD –
FILTER RETAINERS must be as shown in (SEE FIGURE 5) to retain the (3) BIRD SCREEN.
STEP 15:
Slide (3) BIRD SCREEN between (14) BR RAINHOOD – FILTER RETAINERS and back into the (12) BR RAINHOOD
ASSY – BOTTOM.
STEP 16:
Fasten (13) BR RAINHOOD – TOP to the (10) BR RAINHOOD ASSY - LEFT SIDE and the (11) BR RAINHOOD ASSY –
RIGHT SIDE.
STEP 17:
Fasten HOOD EXTENSION SIDES to the outside of HOOD EXTENSION BOTTOM and HOOD EXTENSION DIVIDER
with screws provided with economizer. Fasten HOOD EXTENSION TOP to the OUTSIDE OF HOOD EXTENSION
SIDES. (SEE FIGURE 6.)
STEP 18:
Install HOOD EXTENSION ASSEMBLY and economizer with remaining screws removed in STEP 2. (SEE FIGURE 6.)
5
Page 24
NOTE:
COIL NOT SHOWN
FOR CLARITY
HOOD EXTENSION TOP
HOOD EXTENSION DIVIDER
HOOD EXTENSION SIDE
(10) SCREWS
HOOD EXTENSION ASSEMBLY
FIGURE 6
MODEL
"A"
3 - 6 TON
21.750 REF
7 ½ TON
27.750 REF.
A
14
SUPPLY
DUCT
RETURN DUCT TO BE
PROPERLY SIZED FOR
AIRFLOW OF SPECIFIC
INSTALLATION
A
12 3 8
BAROMETRIC RELIEF DAMPER &
HOOD TO BE RELOCATED FROM
ECONOMIZER TO RETURN DUCT
AS SHOWN
FIGURE 7
6
Page 25
FIGURE 8
NOTE:
COIL NOT SHOWN
FOR CLARITY
STEP 19:
On downflow applications, the barometric relief hood mounts directly to the lower part of the HOOD EXTENSION opening
using holes provided. On sideflow applications the barometric relief hood is attached to the return air duct.
STEP 20:
Mount the fresh air (upper) hood ((2) PERMANENT FILTER, (5) OA RAINHOOD ASSY – LEFT SIDE, (6) OA RAINHOOD
ASSY – RIGHT SIDE, (7) OA RAINHOOD ASSY – BOTTOM, (8) OA RAINHOOD – TOP, (9) OA RAINHOOD – FILTER
RETAINERS). Slide the fresh air hood flange under the HOOD EXTENSION top panel flange, align holes and secure with
screw(s) provided (SEE FIGURE 6).
STEP 21:
Connect the (1) DISCHARGE AIR SENSOR to wires located on the blower support leg in the blower motor compartment
(SEE FIGURE 4).
STEP 22:
Replace the BLOWER ACCESS PANEL with screws removed in STEP 2.
STEP 23:
Upon start-up check the economizer sequence of operation using the steps provided in these instructions. After testing
unit operation and setting outside air damper minimum position, replace COIL/FILTER ACCESS panel with remaining
screws.
7
Page 26
DIRECT MOUNT ECONOMIZER SEQUENCE OF OPERATION
GENERAL
This accessory economizer package is designed to save energy costs by using outdoor air for cooling and ventilation in
place of mechanical cooling whenever possible. The economizer continuously monitors indoor and outdoor air conditions
and compares them to a user-selected setpoint to determine if free cooling is available.
ACCESSORIES
RXRX-AV02 — Dual Enthalpy Upgrade Kit
For maximum energy savings, this upgrade kit will allow the economizer to compare the outdoor air enthalpy to the return
air enthalpy, instead of a user-selected setpoint to determine if "free cooling" is available.
RXRX-AR02 — Wall-Mounted Carbon Dioxide Sensor
For installations requiring Demand Control Ventilation (DCV) based upon indoor air levels of carbon dioxide (CO2). When
the unit supply fan is running, the CO2 sensor modulates the outside air damper to maintain a user-selected CO2 level
inside the occupied space. Energy savings are achieved by not bringing in excessive amounts of outdoor air when the
indoor air conditions are suitable. Energy savings can be substantial on buildings with highly variable occupancy rates.
Wall-Mounted Remote Potentiometer
For installations requiring remote adjustment of damper minimum position by the occupants, a remote potentiometer,
such as the Honeywell S963B1128 can be used.
RXRX-BFG03/4C, RXRX-BGF03/4D, RXRX-BGF03/4Y — Power Exhaust Kit
For installations requiring more space static pressure relief than can be obtained with the standard barometric relief
damper included with the economizer, a power exhaust kit can be added.
STARTUP
Attach connector from Economizer Controller to Rooftop Control Panel Connector and install discharge/mixed air
temperature sensor per installation guide.
ADJUSTMENTS
5 potentiometers with screwdriver
adjustment slots, starting from top
of controller
1. EXH Set — Adjustments for (optional) power
exhaust
A. The outside air damper position at which
the power exhaust fan(s) will engage. The
L E D l a b e l e d E XH b e l o w t h e
potentiometer adjustment will indicate
when power exhaust is available. When
the power exhaust call is made, the
controller provides a 60 ±30 second delay
before exhaust fan activation to allow the
damper to reach the appropriate position.
B. Range of adjustment is from 0-100%
(2-10V); in most applications the power
exhaust is set to engage at about 70%
outside air.
2. Min Pos — Outside Air Damper minimum position
A. A d j u s t t h e mi n i m u m p o s i t io n
potentiometer to allow the minimum
amount of outdoor air, as required by local
codes, to enter the building.
8
Page 27
B. Range of adjustment is from 0-100% (2-10V); in most applications the minimum position is adjusted to allow
10% to 25% outside air to enter the system.
C. The Outside Air Damper Minimum Position potentiometer can be adjusted at any time.
D. Whenever the "G" (supply fan) signal is present, the damper will open to this minimum position unless:
a. It may modulate to a greater position if overridden by the CO2 sensor (DCV).
b. It may not open if overridden by the discharge air temperature sensor (Freeze Protect Mode).
3. DCV Max — Demand Control Ventilation (DCV) Maximum Setpoint
A. The DCV maximum position potentiometer allows the installer to limit the amount of outdoor air flow into the
building when the DCV overrides the mixed air sensor.
B. Setting the DCV maximum position of the damper prevents the introduction of large amounts of hot or cold air
into the space.
C. Note: If the DCV maximum position is set below the outside air damper minimum position, the minimum
position overrides the DCV maximum position (negating the function of the DCV).
4. DCV Set — Demand Control Ventilation (DCV) Setpoint
A. The DCV can be any sensor that provides a 2-10Vdc output. The DCV modulates the outdoor damper to
provide ventilation based on occupancy. Typically, a carbon dioxide (CO2) sensor is used to indirectly monitor
occupancy level.
B. No cooling signal (e.g.Y1, Y2) is required for the DCV to override the outdoor air damper when ventilation
requires outdoor air.
C. The controller must receive a "G" (supply fan) signal to open the damper.
D. Range of adjustment is from 2 Volts to 10 Volts.
E. The DCV setpoint can be adjusted at any time.
F. The controller compares the CO2 sensor input to the setpoint setting to determine the damper minimum
position.
a. If the actual CO2 level is below the setpoint, then the damper minimum position is determined by the
damper minimum position potentiometer setting.
b. If the actual CO2 level rises above the setpoint, then the damper minimum position is overridden
proportionally more open.
c. If the discharge air temperature drops below 48°F (Freeze Protect Mode), the DCV input will be
overridden and the damper may not open.
G. Compatible CO2 sensors will have a 2-10Vdc output for a 0-1500 ppm CO2 input.
H. Ensure proper polarity of the sensor wires when connecting to the economizer controller. Incorrect polarity
negates the sensor signal.
5. Economizer Setpoint
A. Only the coolest, driest outside air is used for economizer operation when the potentiometer is on setting "D".
For greatest energy savings, the potentiometer is on setting "A".
B. Adjustment range is A, B, C, or D
a. Setting "A" = 73F db or 27
Btu/lbm @ 50% RH
b. Setting "B" = 70F db or 25
Btu/lbm @ 50% RH
c. Setting "C" = 67F db or 23
Btu/lbm @ 50% RH
d. Setting "D" = 63F db or 22
Btu/lbm @ 50% RH
9
Page 28
C. Economizer Setpoint potentiometer can be adjusted at any time.
D. The controller compares the enthalpy sensor input with the economizer setpoint to determine if free cooling is
available.
a. Single enthalpy strategy: If outdoor air enthalpy is lower than the setpoint, then free cooling is
available. Note: The factory-installed 620-ohm resistor must be in place across terminals SR and
SR+.
b. Dual enthalpy strategy: If outdoor air enthalpy is lower than return air enthalpy, then free cooling is
available.
1. Note: If using dual enthalpy, the Economizer Setpoint must be at the "D" setting.
2. The factory-installed 620-ohm jumper must be removed to install the dual enthalpy
upgrade kit.
NORMAL OPERATION
1. Fan Only (G)
A. Damper will go to minimum position (in 90 seconds or less) whenever the "G" (supply fan) signal is present.
B. When "G" signal is removed, the outside air damper closes against blade seals for tight shutoff of outside air.
C. If the discharge air temperature drops below 48ºF, then the control will override the minimum position setting
and will modulate the outside air damper closed.
2. Call for First Stage of Cooling (Y1)
A. Economizer Unavailable (warm outdoor air). Compressor 1 is commanded on without delay.
B. Economizer Available (free cooling). The controller tries to maintain a discharge air temperature of 53ºF ± 5
by modulating the outside air damper position.
3. Call for Second Stage of Cooling (Y2)
A. Economizer Unavailable (warm outdoor air). Compressor 2 is commanded on without delay.
B. Economizer Available (free cooling). Compressor 1 is commanded on without delay. The controller tries to
maintain a discharge air temperature of 53ºF ± 5 by modulating the outside air damper position. Compressor
2 is not activated in the economizer mode.
4. Call for Heat
A. Standard Air Conditioner with electric or gas heat. (W1 & W2)
a. The Thermostat controls the stages of heating directly.
b. If the control detects that the supply fan is on (through its "G" input), then the control will open the
damper to minimum position.
c. If the discharge air temperature drops below 48ºF, then the control will override the minimum position
setting and will modulate the outdoor damper closed.
B. Heat Pump Operation (B)
a. The "B" signal from the Thermostat allows operation of the compressors to provide heating without
delay.
b If the control detects that the supply fan is on (through its "G" input), then the control can open the
damper to minimum position.
c. If the discharge air temperature drops below 48ºF, then the control will override the minimum position
setting and will modulate the outdoor damper closed.
5. Low Ambient Compressor Lockout – None present.
10
Page 29
TROUBLESHOOTING
1. Checkout requires a handheld multimeter, 9V battery, a 5.6k ohm ¼ watt resistor, a 1.2k ohm ¼ watt resistor, a jumper
wire with ¼" quick connect terminals, and the 620 ohm resistor that is factory-installed across terminals SR+ and SR.
The terminal names below reference the economizer controller. Use the following flowcharts for to diagnose unit.
2.
a. Disconnect power to the unit.
b. Jumper P to P1 (factory installed jumper is normally present).
c. Remove outdoor air enthalpy sensor from terminals SO+ and SO and install the 1.2k ohm resistor.
d. Put 620 ohm resistor across terminals SR+ and SR (factory installed 620 ohm resistor is normally present and
can be used).
e. Put 5.6k ohm resistor across T and T1.
3.
a. Turn (EXH Set) Exhaust fan Setpoint potentiometer fully CCW.
b. Turn (Min Pos) Minimum Outside Air Damper potentiometer fully CCW.
c. Turn (DCV Max) Demand Control Ventilation Maximum potentiometer fully CW.
d. Turn (DCV Set) Demand Control Ventilation Setpoint potentiometer fully CCW.
e. Turn enthalpy potentiometer to "D".
11
Page 30
BASIC ECONOMIZER OPERATION
START
Perform STEP 2
Reapply Power to the Unit
Put thermostat fan setting to "CONTINUOUS FAN"
Set thermostat so neither heating or cooling is called
Perform STEP 3
Connect Economizer Wire Harness to Unit
Check Thermostat Connections
Check for 24 VAC at Unit Transformer
Check Unit Wire Harness
NO
24 VAC power
available between terminal TR and TR1?
YES
Check Economizer Controller Model Number
(W7213A1016)
Perform STEP 2 & STEP 3 again.
If problem continues, replace controller
NO
Are all LED's off &
outside air damper fully closed?
YES
Turn down thermostat setting so that a call for cooling is present.
Unplug Economizer Wire Harness from Unit Wire harness and Install
Jumper Plug (Jumpers Y1 Thermostat to Y1 Compressor and Jumpers
Y2 Thermostat to Y2 Compressor)
If one
stage of cooling
is called by the
thermostat, do first stage
compressor(s) run? If both stages
YES
are called, do both stages
of compressors
run?
Check Economizer Wiring
Harness. Check Unit wiring
NO
harness at economizer
connection for proper terminal
Check Thermostat Wiring
location
Check Unit Wiring Harness
NO
If one
stage of cooling
is called by the
thermostat, do first stage
compressor(s) run? If both stages
are called, do both stages
of compressors
run?
YES
Set enthalpy potentiometer on economizer controller to A (fully CCW).
The "Free Cooling" LED turns on & the EXH LED turns on.
If only one stage of cooling is called by the thermostat, then that stage
will turn off. If two stages are called by the thermostat, then only the
second stage will turn off. The power exhaust (optional) contacts will
close after 60 +/- 30 seconds. The outside air damper opens
approximately 50% (this position is determined by the actual resistance
of the 5.6k ohm resistor placed across terminals T and T1).
NO
Recheck STEP 2 and STEP 3. If LED’s turn on and damper motor
does not operate, measure voltage between terminals 24V COM and
(+ (white wire)). If approximately 6 VDC is present, replace damper
actuator. If voltage not present, or LED’s do not light replace controller.
YES
Set enthalpy potentiometer to D (fully CW).
The "Free Cooling" LED turns off & the EXH LED turns off.
If only one stage of cooling is called by the thermostat, then that stage
will turn back on. If two stages are called by the thermostat, then both
stages will turn on. The power exhaust (optional) contacts open & the
outside air damper fully closes.
NO
YES
Set enthalpy potentiometer back to A (fully CCW).
Remove 5.6k ohm resistor and jumper terminals T to T1.
The "Free Cooling" LED turns on & the EXH LED turns on. If only one
stage of cooling is called by the thermostat, then that stage will turn off.
If two stages of cooling are called by the thermostat, then only the
second stage will turn off. The power exhaust (optional) contacts will
close after 60 +/- 30 seconds. The outside air damper fully opens
Recheck STEP 2 and STEP 3.
If problem continues replace controller
NO
YES
Remove jumper from terminals T to T1 and leave open (simulates the
Freeze Protect mode).
The "Free Cooling" LED remains on & the EXH LED turns off.
If only one stage of cooling is called by the thermostat, then that stage
will remain off. If two stages of cooling are called by the thermostat,
then only the second stage will remain off. The power exhaust
(optional) contacts opens & the outside air damper fully closes
NO
YES
Economizer Controller, Actuator, Wiring are correct.
Remove resistors, reconnect wires, and set up
potentiometers per jobsite requirements.
12
Page 31
HEAT PUMP OPERATION
(Perform BASIC ECONOMIZER OPERATION check first)
START
Perform STEP 2
Perform STEP 3
Reapply Power to the Unit
Put thermostat fan setting to "CONTINUOUS FAN"
Turn down thermostat setting so that a call for cooling is present.
Set enthalpy potentiometer on economizer controller to A (fully CCW).
The "Free Cooling" LED turns on & the EXH LED turns on.
If only one stage of cooling is called by the thermostat, then that stage will turn off.
If two stages are called by the thermostat, then only the second stage will turn off.
The power exhaust (optional) contacts will close after 60 +/- 30 seconds.
The outside air damper opens approximately 50% (this position is determined by
the actual resistance of the 5.6k ohm resistor placed across terminals T and T1).
NO
YES
Reset the thermostat setting so that a call for heating is present.
The "Free Cooling" LED turns off & the EXH LED turns off.
If only one stage of heating is called by the thermostat, then that stage will turn on.
If two stages are called by the thermostat, then both stages will turn on.
The power exhaust (optional) contacts will open The outside air damper fully
closes.
Perform Basic Economizer Operation
check first. Recheck STEP 2 and
STEP 3
NO
YES
Turn Min Pos potentiometer fully CW.
Check for 24 VAC at B terminal.
Check for B signal at thermostat.
Check Unit wire harness.
Check Economizer Wire harness.
The outside air damper drives fully open.
The EXH LED turns on.
The power exhaust (optional) contacts will close after
approximately 60 +/- 30 seconds.
NO
YES
Heat Pump Operation is Correct.
Remove resistors, reconnect wires, and set up
potentiometers per jobsite requirements.
Replace controller.
13
Page 32
Use the following graph and the multimeter to
verify proper operation of the mixed air / discharge
air temperature sensor.
Measure the resistance (ohms) of the mixed air /
discharge air temperature sensor with the
multimeter. Look up the equivalent temperature
on the graph. This should be the same as
temperature the mixed air / discharge air sensor is
detecting. If it is not, replace the mixed air
/discharge air sensor.
NOTES
1. The mist eliminator (Permanent Outdoor Air Filter), is of aluminum mesh construction and should be cleaned by
flushing regularly with warm soapy water. The replacement mist eliminator size is listed on the first page of these
instructions.
2. When diagnosing the system, the best results are obtained by first putting the fan setting on the Thermostat to the
"Continuous Fan" mode.
3. Operation of the optional power exhaust only depends upon the supply fan running and the damper position (it is
possible to set the minimum position high enough to engage the power exhaust in the heating mode).
4. This economizer requires a two-stage thermostat.
5. Upon loss of power to the unit or economizer, the outside air damper will spring close shut in about 5 seconds.
6. Compressor Time Delays, Compressor Interstage Delays, Compressor Low Ambient Lockouts, etc. are not provided
by the economizer controller.
14
Page 33
HARNESS ENDS AT PL5
COMPONENT CODE
9RT1H
Mixed Air Sensor
C7400A
Fresh Air Sensor
J2
Power Exhaust Cap
MS7106K
Damper Actuator 24v
PL2
Female A/C Unit Plug
PL5
Male Economizer Plug
W7213A
Logic Module
Revision
WIRE COLOR CODE
BLK Black
BLU Blue
BRN Brown
GRN Green
GRY Gray
ORG Orange
RED Red
TAN Tan
VIO Violet
WHT White
YEL Yellow
A
Change
Changed Mixed Air Sensor
Date
02-23-06
CONNECTOR & CONTACT CONFIGURATION
PL5 (303903) PLUG - (303901) PIN
J2 (303909) CAP - (303902) SOCKET
Notes:
1. Unit wiring shown as reference only. Check unit wiring for actual unit wiring.
2. Relays 1K and 2K actuate when the Outdoor Air Enthalpy is lower than the Return Air Enthalpy.
3. 1S is an electronic switch which closes when powered by a 24 VAC input.
4. Factory installed resistor should be removed only if C7400 Differential Enthalpy Sensor is added.
Page 34
Modulating Gear Economizer
RKKA / RJKA / RLKA 036-090
RKMA / RJMA / RLMA 036-090
Rooftop Systems, Inc.
2405 McIver Lane
Carrollton, Texas 75006
Phone (972) 247-7447
Fax
(972) 243-0940
Date: March 1, 2006
Supercedes: 01-16-06
Drawn by:
Unit # 60-364-08/20
Diagram# 6036420W
INSTALLATION INSTRUCTIONS
MODELS RXRD-MDCM3 & RXRD-MFCM3
VERTICAL AIRFLOW ECONOMIZERS
WARNING
THIS ACCESSORY IS TO BE INSTALLED BY A QUALIFIED, LICENSED SERVICE PERSON. TO AVOID
UNSATISFACTORY OPERATION OR DAMAGE TO THE PRODUCT AND POSSIBLE UNSAFE CONDITIONS,
INCLUDING ELECTRICAL SHOCK, REFRIGERANT LEAKAGE AND FIRE, THE INSTALLATION
INSTRUCTIONS PROVIDED WITH THIS ACCESSORY MUST BE STRICTLY FOLLOWED AND THE PARTS
SUPPLIED USED WITHOUT SUBSTITUTION. DAMAGE TO THE PRODUCT RESULTING FROM NOT
FOLLOWING THE INSTRUCTIONS OR USING UNAUTHORIZED PARTS MAY BE EXCLUDED FROM THE
MANUFACTURER’S WARRANTY COVERAGE.
WARNING
DISCONNECT ELECTRICAL POWER TO THE UNIT. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL INJURY OR DEATH.
TOOLS REQUIRED FOR INSTALLATION:
3
5
8" electric drill with 16" socket
Small flat blade (0.125" wide) screwdriver
TABLE 1
PACKAGE CONTENTS
ITEM
PART No.
RXRD-MFCM3
economizer with
controller, actuator, and
outside enthalpy sensor
attached
PART No.
6036413 / 3112
6036415 / 3112
6036413 / 8567
(11.875" X 23.875")
6036415 / 8568
(23.875" X 23.875")
RXRD-MDCM3
economizer with controller,
actuator, and outside
enthalpy sensor attached
DESCRIPTION
1
Discharge Air Sensor (Hardware Bag)
2
(2) Permanent Filters
3
Spotweld Assy - Bird Screen
6036413 / BSWA
6036415 / BSWA
4
Exhaust Air Rainhood Assy – Birdscreen
Front Support
6036413 / EHB2
6036415 / EHB2
5
OA Rainhood Assy - Left Side
6036413 / EHSL
6036415 / EHSL
6
OA Rainhood Assy - Right Side
6036413 / EHSR
6036415 / EHSR
7
Exhaust Air Rainhood - Left Side
6036413 / EHS2L
6036415 / EHS2L
8
Exhaust Air Rainhood – Right Side
6036413 / EHS2R
6036415 / EHS2R
9
OA Filter Rail Assy
6036413 / EHT2
6036415 / EHT2
10
OA Rainhood Assy – Top
6036413 / EHT
6036415 / EHT
11
OA Rainhood - Front Filter Support
6036413 / EHB
6036415 / EHB
12
Hardware Bag
6036413 / HDW
6036415 / HDW
Page 35
FIGURE 1
RXRD-MDCM3 Shown - RRDX-MFCM3 Similar
LEAVE THESE
SCREWS ENGAGED
FRONT SIDE
ROOF PANEL REMOVE
SCREWS FROM THREE
SIDES (FRONT, LEFT AND
BACK) EXCEPT AS NOTED
FILTERS
LEFT PANEL - UPPER
(REMOVE TO BE REUSED
IN RAIN HOOD ASSEMBLY
LEFT PANEL - LOWER
(REMOVE TO BE REUSED
IN RAIN HOOD ASSEMBLY
RETURN COVER
DOWNFLOW RETURN OPENING
A1010-01
STEP 1:
Immediately upon receipt, all cartons and contents
should be inspected for transit damage. Units with
damaged cartons should be opened immediately.
If damage is found, it should be noted on the
delivery papers and a damage claim filed with the
last carrier. Compare carton(s) contents to
PACKAGE CONTENTS List (TABLE 1) above to
note any missing items.
FIGURE 2
ROOF PANEL
FRONT SIDE
PLUG
STEP 2:
Remove RETURN COVER, PANEL – TOP LEFT,
and PANEL – LEFT BOTTOM SECTION from the
unit and retain for reuse (SEE FIGURE 1). Retain
screws.
FILTERS
NOTE 1
STEP 3:
Remove screws from 3 sides of ROOF PANEL so
that it can be raised during economizer insertion.
NOTE 1:
Remove shipping bracket, ‚ PERMANENT
FILTERS, … OA RAINHOOD - LEFT SIDE, † OA
RAINHOOD - RIGHT SIDE, ‡ EXHAUST AIR
RAINHOOD - LEFT SIDE and ˆ EXHAUST AIR
RAINHOOD – RIGHT SIDE from fresh air opening.
(SEE FIGURE 2).
RETURN COVER
DOWNFLOW RETURN OPENING
WIRE HARNESS
ACTUATOR
CONTROLLER
ECONOMIZER ASSEMBLY
STEP 4:
Remove jumper plug and slide economizer into unit
return air section (SEE FIGURE 2). After the
economizer is installed, connect unit
ECONOMIZER PLUG to economizer mating plug.
Save the jumper plug in this compartment for
diagnostic purposes.
ƒ
A1011-01
2
Page 36
STEP 5:
Secure economizer and ƒ SPOTWELD ASSY - BIRD
SCREEN along bottom with six screws as shown (SEE
FIGURE 2). See TABLE 1 for identification.
STEP 6:
Fasten ‡ EXHAUST AIR RAINHOOD - LEFT SIDE and ˆ
EXHAUST AIR RAINHOOD – RIGHT SIDE to barometric
relief opening (lower opening) on the economizer (SEE
FIGURE 3). Fasten with six screws. See FIGURE 4 for
identification of EXHAUST AIR RAINHOODS.
STEP 7:
F a s t e n „ EXHAUST AIR RAIN HOO D ASSY –
BIRDSCREEN FRONT SUPPORT under edge of LEFT
PANEL – LOWER using six screws. Do not install a screw
in the rightmost hole in the panels at this time.
STEP 8:
Fasten LEFT PANEL – LOWER and „ EXHAUST AIR
RAINHOOD ASSY – BIRDSCREEN FRONT SUPPORT
to the top of the ‡ EXHAUST AIR RAINHOOD - LEFT
SIDE and ˆ EXHAUST AIR RAINHOOD – RIGHT SIDE
which was previously installed on the unit (SEE STEP 7).
STEP 9:
Attach ‰ OA FILTER RAIL ASSY to economizer center
support, ‡ EXHAUST AIR RAINHOOD - LEFT SIDE and
ˆ EXHAUST AIR RAINHOOD – RIGHT SIDE and LEFT
PANEL – LOWER using screws provided.
STEP 10:
Position the Š OA RAINHOOD ASSY – TOP under edge
of ROOF PANEL. Do not install screws at this time.
STEP 11:
Fasten … OA RAINHOOD - LEFT SIDE and † OA
RAINHOOD - RIGHT SIDE to unit using screws provided
(2 each on RXRD-MDCM3, 3 each on RXRD-MFCM3).
STEP 12:
Slide ‚ PERMANENT FILTERS between … OA
RAINHOOD - LEFT SIDE and † OA RAINHOOD - RIGHT
SIDE back into the ‰ OA FILTER RAIL ASSY.
STEP 13:
Fasten 11 OA RAINHOOD - FRONT FILTER SUPPORT to
PANEL – TOP LEFT with six screws. The bottom lip should
support the ‚ PERMANENT FILTERS. Do not install a
screw in the rightmost hole in the panels at this time.
STEP 14:
Fasten PANEL – TOP LEFT to … OA RAINHOOD - LEFT
SIDE and † OA RAINHOOD - RIGHT SIDE and 11 OA
RAINHOOD - FRONT FILTER SUPPORT using screws
(12 on RXRD-MDCM3, 16 on RXRD-MFCM3).
STEP 15:
Re-secure ROOF PANEL using the washer head screws
that were removed in STEP 3 from the ROOF PANEL.
FIGURE 3
RXRD-MDCM3 Shown - RRDX-MFCM3 Similar
(See Table 1 for identification of parts)
ROOF PANEL (REF.)
Š
†
‰
ˆ
11
ƒ
…
ECON. CENTER
SUPPORT (REF.)
‡
LEFT PANEL - UPPER
LEFT PANEL - LOWER
‚
„
A1012-01
3
Page 37
FIGURE 4
EXHAUST AIR RAIN HOOD
(LOWER LEFT SIDE)
OUTSIDE AIR RAIN HOOD
(UPPER LEFT SIDE)
SEAL STRIP
EXHAUST AIR RAIN HOOD ASSEMBLY
(BIRDSCREEN FRONT SUPPORT)
END VIEW
A1005-01
STEP 16:
Remove the BLOWER MOTOR ACCESS PANEL (SEE
FIGURE 5).
FIGURE 5
STEP 17:
Connect the j DISCHARGE AIR SENSOR to wires 51
and 52 located in the blower motor compartment.
NOTE:
Mixed air sensor should be secured with the included wire
tie to avoid entanglement with the blower and direct
contact with any sheet metal surfaces.
WIRE TIE

STEP 18:
Replace the BLOWER MOTOR ACCESS PANEL.
STEP 19:
Upon start-up check the economizer sequence of
operation using the steps provided in these instructions.
After testing unit operation and setting outside air damper
minimum position, replace RETURN COVER with
remaining screws.
INDOOR MOTOR
A1006-01
4
Page 38
DIRECT MOUNT ECONOMIZER SEQUENCE OF OPERATION
GENERAL
This accessory economizer package is designed to save
energy costs by using outdoor air for cooling and
ventilation in place of mechanical cooling whenever
possible. The economizer continuously monitors indoor
and outdoor air conditions and compares them to a
user-selected setpoint to determine if free cooling is
available.
ACCESSORIES
RXRX-AV02 — Dual Enthalpy Upgrade Kit
For maximum energy savings, this upgrade kit will allow
the economizer to compare the outdoor air enthalpy to the
return air enthalpy, instead of a user-selected setpoint to
determine if "free cooling" is available.
RXRX-AR02 - Wall-Mounted Carbon Dioxide Sensor
For installations requiring Demand Control Ventilation
(DCV) based upon indoor air levels of carbon dioxide
(CO2). When the unit supply fan is running, the CO2 sensor
modulates the outside air damper to maintain a
user-selected CO2 level inside the occupied space.
Energy savings are achieved by not bringing in excessive
amounts of outdoor air when the indoor air conditions are
suitable. Energy savings can be substantial on buildings
with highly variable occupancy rates.
Wall-Mounted Remote Potentiometer
For installations requiring remote adjustment of damper
minimum position by the occupants, a remote
potentiometer, such as the Honeywell S963B1128 can be
used.
RXRX-BFF02C, RXRX-BFF02D, RXRX-BFF02Y —
Power Exhaust Kit
For installations requiring more space static pressure relief
than can be obtained with the standard barometric relief
damper included with the economizer, a power exhaust kit
can be added.
B. Range of adjustment is from 0-100% (2-10V); in
most applications the minimum position is
adjusted to allow 10% to 25% outside air to enter
the system.
C. The Outside Air Damper Minimum Position
potentiometer can be adjusted at any time.
D. Whenever the "G" (supply fan) signal is present,
the damper will open to this minimum position
unless:
a. It may modulate to a greater position if
overridden by the CO2 sensor (DCV).
b. It may not open if overridden by the discharge
air temperature sensor (Freeze Protect
Mode).
3. DCV Max — Demand Control Ventilation (DCV)
Maximum Setpoint
A. The DCV maximum position potentiometer allows
the installer to limit the amount of outdoor air flow
into the building when the DCV overrides the
mixed air sensor.
B. Setting the DCV maximum position of the damper
prevents the introduction of large amounts of hot
or cold air into the space.
C. Note: If the DCV maximum position is set below
the outside air damper minimum position, the
minimum position overrides the DCV maximum
position (negating the function of the DCV).
4. DCV Set — Demand Control Ventilation (DCV)
Setpoint
A. The DCV can be any sensor that provides a
2-10Vdc output. The DCV modulates the outdoor
damper to provide ventilation based on
occupancy. Typically, a carbon dioxide (CO2)
sensor is used to indirectly monitor occupancy
level.
B. No cooling signal (e.g.Y1, Y2) is required for the
DCV to override the outdoor air damper when
ventilation requires outdoor air.
C. The controller must receive a "G" (supply fan)
signal to open the damper.
D. Range of adjustment is from 2 Volts to 10 Volts.
E. The DCV setpoint can be adjusted at any time.
FIGURE 6
STARTUP
Attach connector from Economizer Controller to Rooftop
Control Panel Connector and install discharge/mixed air
temperature sensor per installation guide.
ADJUSTMENTS
5 potentiometers with screwdriver adjustment slots,
starting from top of controller
1. EXH Set — Adjustments for (optional) power exhaust
A. The outside air damper position at which the
power exhaust fan(s) will engage. The LED
labeled EXH below the potentiometer adjustment
will indicate when power exhaust is available.
When the power exhaust call is made, the
controller provides a 60 ±30 second delay before
exhaust fan activation to allow the damper to
reach the appropriate position.
B. Range of adjustment is from 0-100% (2-10V); in
most applications the power exhaust is set to
engage at about 70% outside air.
9
Page 39
F. The controller compares the CO2 sensor input to
the setpoint setting to determine the damper
minimum position.
a. If the actual CO2 level is below the setpoint,
then the damper minimum position is
determined by the damper minimum position
potentiometer setting.
b. If the actual CO 2 level rises above the
setpoint, then the damper minimum position is
overridden proportionally more open.
c. If the discharge air temperature drops below
48°F (Freeze Protect Mode), the DCV input
will be overridden and the damper may not
open.
G. Compatible CO2 sensors will have a 2-10Vdc
output for a 0-1500 ppm CO2 input.
H. Ensure proper polarity of the sensor wires when
connecting to the economizer controller. Incorrect
polarity negates the sensor signal.
5. Economizer Setpoint
A. Only the coolest, driest outside air is used for
economizer operation when the potentiometer is
on setting "D". For greatest energy savings, the
potentiometer is on setting "A".
B. Adjustment range is A, B, C, or D
a. Setting "A" = 73F db or 27 Btu/lbm @ 50% RH
b. Setting "B" = 70F db or 25 Btu/lbm @ 50% RH
c. Setting "C" = 67F db or 23 Btu/lbm @ 50% RH
d. Setting "D" = 63F db or 22 Btu/lbm @ 50% RH
C. Economizer Setpoint potentiometer can be
adjusted at any time.
D. The controller compares the enthalpy sensor input
with the economizer setpoint to determine if free
cooling is available.
a. Single enthalpy strategy: If outdoor air
enthalpy is lower than the setpoint, then free
cooling is available. Note: The
factory-installed 620-ohm resistor must be in
place across terminals SR and SR+.
b. Dual enthalpy strategy: If outdoor air enthalpy
is lower than return air enthalpy, then free
cooling is available.
1. Note: If using dual enthalpy, the Economizer
Setpoint must be at the "D" setting.
2. The factory-installed 620-ohm jumper must
be removed to install the dual enthalpy
upgrade kit.
NORMAL OPERATION
1. Fan Only (G)
A. Damper will go to minimum position (in 90
seconds or less) whenever the "G" (supply fan)
signal is present.
B. When "G" signal is removed, the outside air
damper closes against blade seals for tight shutoff
of outside air.
C. If the discharge air temperature drops below 48ºF,
then the control will override the minimum position
setting and will modulate the outside air damper
closed.
2. Call for First Stage of Cooling (Y1)
A. Economizer Unavailable (warm outdoor air).
Compressor 1 is commanded on without delay.
B. Economizer Available (free cooling). The
controller tries to maintain a discharge air
temperature of 53ºF ± 5 by modulating the outside
air damper position.
FIGURE 7
3. Call for Second Stage of Cooling (Y2)
A. Economizer Unavailable (warm outdoor air).
Compressor 2 is commanded on without delay.
B. Economizer Available (free cooling). Compressor
1 is commanded on without delay. The controller
tries to maintain a discharge air temperature of
53ºF ± 5 by modulating the outside air damper
position. Compressor 2 is not activated in the
economizer mode.
4. Call for Heat
A. Standard Air Conditioner with electric or gas heat.
(W1 & W2)
a. The Thermostat controls the stages of heating
directly.
b. If the control detects that the supply fan is on
(through its "G" input), then the control will
open the damper to minimum position.
c. If the discharge air temperature drops below
48ºF, then the control will override the
minimum position setting and will modulate
the outdoor damper closed.
B. Heat Pump Operation (B)
a. The "B" signal from the Thermostat allows
operation of the compressors to provide
heating without delay.
b If the control detects that the supply fan is on
(through its "G" input), then the control can
open the damper to minimum position.
c. If the discharge air temperature drops below
48ºF, then the control will override the
minimum position setting and will modulate
the outdoor damper closed.
5. Low Ambient Compressor Lockout – None present.
6
Page 40
TROUBLESHOOTING
1. Checkout requires a handheld multimeter, 9V battery,
a 5.6k ohm .25 watt resistor, a 1.2k ohm .25 watt
resistor, a jumper wire with .25" quick connect
terminals, and the 620 ohm resistor that is
factory-installed across terminals SR+ and SR. The
terminal names below reference the economizer
controller. Use the following flowcharts for to diagnose
unit.
2.
a. Disconnect power to the unit.
b. Jumper P to P1 (factory installed jumper is
normally present).
c. Remove outdoor air enthalpy sensor from
terminals SO+ and SO and install the 1.2k ohm
resistor.
d. Put 620 ohm resistor across terminals SR+ and
SR (factory installed 620 ohm resistor is normally
present and can be used).
e. Put 5.6k ohm resistor across T and T1.
3.
a . T u r n ( EXH Set ) E x h a u s t fa n S e t p o i n t
potentiometer fully CCW.
b. Turn (Min Pos) Minimum Outside Air Damper
potentiometer fully CCW.
c. Turn (DCV Max) Demand Control Ventilation
Maximum potentiometer fully CW.
d. Turn (DCV Set) Demand Control Ventilation
Setpoint potentiometer fully CCW.
e. Turn enthalpy potentiometer to "D".
7
Page 41
BASIC ECONOMIZER OPERATION
START
Perform STEP 2
Reapply Power to the Unit
Put thermostat fan setting to "CONTINUOUS FAN"
Set thermostat so neither heating or cooling is called
Perform STEP 3
Connect Economizer Wire Harness to Unit
Check Thermostat Connections
Check for 24 VAC at Unit Transformer
Check Unit Wire Harness
NO
24 VAC power
available between terminal TR and TR1?
YES
Check Economizer Controller Model Number
(W7213A1016)
Perform STEP 2 & STEP 3 again.
If problem continues, replace controller
NO
Are all LED's off &
outside air damper fully closed?
YES
Turn down thermostat setting so that a call for cooling is present.
Unplug Economizer Wire Harness from Unit Wire harness and Install
Jumper Plug (Jumpers Y1 Thermostat to Y1 Compressor and Jumpers
Y2 Thermostat to Y2 Compressor)
If one
stage of cooling
is called by the
thermostat, do first stage
compressor(s) run? If both stages
YES
are called, do both stages
of compressors
run?
Check Economizer Wiring
Harness. Check Unit wiring
NO
harness at economizer
connection for proper terminal
Check Thermostat Wiring
location
Check Unit Wiring Harness
NO
If one
stage of cooling
is called by the
thermostat, do first stage
compressor(s) run? If both stages
are called, do both stages
of compressors
run?
YES
Set enthalpy potentiometer on economizer controller to A (fully CCW).
The "Free Cooling" LED turns on & the EXH LED turns on.
If only one stage of cooling is called by the thermostat, then that stage
will turn off. If two stages are called by the thermostat, then only the
second stage will turn off. The power exhaust (optional) contacts will
close after 60 +/- 30 seconds. The outside air damper opens
approximately 50% (this position is determined by the actual resistance
of the 5.6k ohm resistor placed across terminals T and T1).
NO
Recheck STEP 2 and STEP 3. If LED’s turn on and damper motor
does not operate, measure voltage between terminals 24V COM and
(+ (white wire)). If approximately 6 VDC is present, replace damper
actuator. If voltage not present, or LED’s do not light replace controller.
YES
Set enthalpy potentiometer to D (fully CW).
The "Free Cooling" LED turns off & the EXH LED turns off.
If only one stage of cooling is called by the thermostat, then that stage
will turn back on. If two stages are called by the thermostat, then both
stages will turn on. The power exhaust (optional) contacts open & the
outside air damper fully closes.
NO
YES
Set enthalpy potentiometer back to A (fully CCW).
Remove 5.6k ohm resistor and jumper terminals T to T1.
The "Free Cooling" LED turns on & the EXH LED turns on. If only one
stage of cooling is called by the thermostat, then that stage will turn off.
If two stages of cooling are called by the thermostat, then only the
second stage will turn off. The power exhaust (optional) contacts will
close after 60 +/- 30 seconds. The outside air damper fully opens
Recheck STEP 2 and STEP 3.
If problem continues replace controller
NO
YES
Remove jumper from terminals T to T1 and leave open (simulates the
Freeze Protect mode).
The "Free Cooling" LED remains on & the EXH LED turns off.
If only one stage of cooling is called by the thermostat, then that stage
will remain off. If two stages of cooling are called by the thermostat,
then only the second stage will remain off. The power exhaust
(optional) contacts opens & the outside air damper fully closes
NO
YES
Economizer Controller, Actuator, Wiring are correct.
Remove resistors, reconnect wires, and set up
potentiometers per jobsite requirements.
8
Page 42
HEAT PUMP OPERATION
(Perform BASIC ECONOMIZER OPERATION check first)
START
Perform STEP 2
Perform STEP 3
Reapply Power to the Unit
Put thermostat fan setting to "CONTINUOUS FAN"
Turn down thermostat setting so that a call for cooling is present.
Set enthalpy potentiometer on economizer controller to A (fully CCW).
The "Free Cooling" LED turns on & the EXH LED turns on.
If only one stage of cooling is called by the thermostat, then that stage will turn off.
If two stages are called by the thermostat, then only the second stage will turn off.
The power exhaust (optional) contacts will close after 60 +/- 30 seconds.
The outside air damper opens approximately 50% (this position is determined by
the actual resistance of the 5.6k ohm resistor placed across terminals T and T1).
NO
YES
Reset the thermostat setting so that a call for heating is present.
The "Free Cooling" LED turns off & the EXH LED turns off.
If only one stage of heating is called by the thermostat, then that stage will turn on.
If two stages are called by the thermostat, then both stages will turn on.
The power exhaust (optional) contacts will open The outside air damper fully
closes.
Perform Basic Economizer Operation
check first. Recheck STEP 2 and
STEP 3
NO
YES
Turn Min Pos potentiometer fully CW.
Check for 24 VAC at B terminal.
Check for B signal at thermostat.
Check Unit wire harness.
Check Economizer Wire harness.
The outside air damper drives fully open.
The EXH LED turns on.
The power exhaust (optional) contacts will close after
approximately 60 +/- 30 seconds.
NO
YES
Heat Pump Operation is Correct.
Remove resistors, reconnect wires, and set up
potentiometers per jobsite requirements.
Replace controller.
9
Page 43
Use the following graph and the multimeter to verify proper
operation of the mixed air / discharge air temperature
sensor.
Measure the resistance (ohms) of the mixed air / discharge
air temperature sensor with the multimeter. Look up the
equivalent temperature on the graph. This should be the
same as temperature the mixed air / discharge air sensor is
detecting. If it is not, replace the mixed air /discharge air
sensor.
NOTES
1. The mist eliminator (Permanent Outdoor Air Filter), is
of aluminum mesh construction and should be
cleaned by flushing regularly with warm soapy water.
The replacement mist eliminator size is listed on the
first page of these instructions.
2. When diagnosing the system, the best results are
obtained by first putting the fan setting on the
Thermostat to the "Continuous Fan" mode.
3. Operation of the optional power exhaust only depends
upon the supply fan running and the damper position
(it is possible to set the minimum position high enough
to engage the power exhaust in the heating mode).
4. This economizer requires a two-stage thermostat.
5. Upon loss of power to the unit or economizer, the
outside air damper will spring close shut in about 5
seconds.
6. Compressor Time Delays, Compressor Interstage
Delays, Compressor Low Ambient Lockouts, etc. are
not provided by the economizer controller.
10
Page 44
HARNESS ENDS AT PL7
COMPONENT CODE
C7400A
Fresh Air Sensor
9RT1H
Mixed Air Sensor
J2
Power Exhaust Cap
MS7106K
Damper Actuator 24v
PL6
Male A/C Unit Plug
PL7
Female Economizer Cap
W7213A
Logic Module
Revision
WIRE COLOR CODE
BLK Black
BLU Blue
BRN Brown
GRN Green
GRY Gray
ORG Orange
RED Red
TAN Tan
VIO Violet
WHT White
YEL Yellow
Change
Date
A
Changed Mixed Air Sensor
02-23-06
B
Exchanged wire 3 & 4
03-29-06
CONNECTOR & CONTACT CONFIGURATION
PL7 (303917) CAP - (303902) SOCKET
J2 (303909) CAP - (303902) SOCKET
Notes:
1. Unit wiring shown as reference only. Check unit wiring for actual unit wiring.
2. Relays 1K and 2K actuate when the Outdoor Air Enthalpy is lower than the Return Air Enthalpy.
3. 1S is an electronic switch which closes when powered by a 24 VAC input.
4. Factory installed resistor should be removed only if C7400 Differential Enthalpy Sensor is added.
5. Y2 must be energized for the compressor to operate.
Page 45
Modulating Gear Economizer
RKKB / RLKB 090-240
Rooftop Systems, Inc.
2405 McIver Lane
Carrollton, Texas 75006
Phone (972) 247-7447
Fax
(972) 243-0940
Date: March 29, 2006
Supercedes: 03-01-06
Drawn by:
Unit # 60-364-13/15
Diagram# 6036413BW
--- -.-------
INSTALLATION INSTRUCTIONS
FOR
AUXILIARY ELECTRIC HEATER KITS
.
A. Recognizethis symbolas an indicationof ImportantSafety Informationl
IMPORTANT: TO ENSUREPROPBRINSTALLAnON ANDOPBRATION,PLBASEREADALL INSTRUCTIONSPRIOR TO
ASSBMBLY, INSTALLATION,OPERATION,MAINTENANCBOR REPAIROF nus PRODUCT. AFTERUNPACKING11IB
HEATERKIT, INSPECTALL PARTSFOR DAMAGBPRIORTO INSTALLATIONAND STARTUP.
.
INDOOR BLOWER SPEED
INTRODUCfION
The information contained in these instructions has been prepared
to assist in the proper installation and operation of the auxiliary
electric heaters. Improper installation can result in unsatisfactory
opezation or dangerous conditions not covered I>ythe unit wammty
and may invalidate the Underwriters Laboratories recognition.
\
CHECKING
PRODUCT
RECEIVED
Upon receiving the heater kit, inspect it for any shipping damage.
Claims for damage should be tiled immediately with the shipping
company.
IChcclcheater kit model number to determine that it is the correct
series for the unit, as shown on the unit rating plate. and is of the
desired voltage and KW size.
APPLICATION
Refer to the blower airflow tables in the unit installation
instructionsto set the proper blower speed for your airflow and
static pressure requirements.
.
A WARNING
DISCONN~CT ALL POWER BEFORE STARTING
REATER KIT INSTAL~ TION. FAILURE TO DO SO CAN
RESULT IN SEVER ELECTRICAL SHOCK OR DEATIL
ELECTRICAL WIRING
Field wiring must comply with the National Electrical Code (CBC
in Canada) and any local ordinances that may apply.
POWER WIRING
"'.
These-auxiliary-e1ectrie-resistance heater kits ar.e desi
insbiIIation in the discharge air compartment of the indoor blower.
Improper usage can cause results which may be dangecous. Do not
use heater kits other than those referenced on the unit rating plate.
e unit has been in operation without an elec::tricheater kit
installed, it may be necessary to change the field installed
power wiring. The added current of the electric heater kit may
require larger gauge wiring than that required for the unit
alone. Refer to the unit rating plate or instaUation instructions
for the required supply circuit sim and overcurrent protection.
A wire sizing table follows for reference .
Clearance to combustible material for the unit and fIrSt three (3)
feet of duct is "0" inches.
OPERATION
2.
The heater elements are wired through controllers operated by the
24 volt thermostat circuit To insure blower operation, the blower
is also controlled by the heater controllers. The heater controllers
will turn the blower and first stage heater "on" first and will turn
the beater and blower "off" last when the thermostat is satisfied.
It is important that proper electrical power is available at the
heater kit terminals. Voltage should Dot vary more than 10%
from that marked on the unit rating plate. Phase voltages must
be balancedwithin3%.
.
3. A properly sized disconnect switch shall be located within
sight of the unit or as required by local codes.
.
TOOLS NEEDED
4. Power wiring must be run in grounded, rain-tight conduit.
The following tools can be helpful in installing the kits:
1. Slottedscrewdriversand 5/16" nut driver.
2. Some kits will require the use of alien wrenches.
3. Needle-nose pliers.
4. Wire cutters and strippers.
5. Referto the unit installationinstructionsfor power entry
location.The highvoltagefield installedpowersupplycircuit
should be connected to the line side of the tenninal block
located on the heater kit. Consult the heater kit wiring
diagram.
Page 46
------.
.ror
1I1::1U WSUUlauUU
Ul 11I1 C:JCC\OC nc:aacr
au"
LUI1UW we
instructions below:
I. AU lOWvOltage wanng mUStoe roUted mto the lOWvOltage
connection area and not into the power wiring or heater conCroI
area.
a.
Removing screws as required, open heater access door
and detach adjacent power entry panel.
2. For thermostat low voltage connections, see unit installation
Instructions.
b. Remove wires to unit contactor (Ill, 11.2, lL3) ftom the
unit terminal block on the left side of the electric heat
compartment Remove and discard the terminal block
3. Thennostat heat anticipator should be adjustable for a
minimumrangeof .10 - 1.20. Typicalsettingsare as follows:
. and the adjacent ground l';1g.
c.
Remove the heater kit block-off panel and install the
heaterkit in itspla~ using9 of the 12screwspreviously
removed.
d.
Connect the unit contactor wires (Ill, IL2, IL3) to the
compressor fuse block on the heater kit
e.
Re-install the power entty panel & ~n con(Juit and the
proper size field w.iringthrough
the opening in the panel.
\
f.
ColUlect field wiring to the power tenninal block located
on the electric heater kit Connect ground wire to the
adjacent ground lug.
THERMOSTAT HEAT ANTICIPATORSETTlNG*
NUMBER OF STAGES
I
Z
SE'ITlNG
.7
.7&."
*NOTES
I. Nonnally.1hc first stage heat has a fixed $CUing.
2.
Some chcrmostaIs
have DOll!iustable
second
setting
indicator.
Follow the instnlctions
lhennostaU
10 get proper operation.
3.
stage heat antidpator
in these
spc:cific
RqJlace the control box cover and control compartmentacccss
after all wiring is complctccl.
panel
4. Chcclcunit for properopcwlon.
g.
Connect heater kit control plug to the receptacleon the
control wiringharness.
h.
Check all electrical connections including factory wiring
within the unit and make sure all connections are tigh
and properly located.
WIRE SIZE -7SOC INSULA110N FOR 1% VOLTAGE DROP
i. -- Close heater access door and secure. With tbe screws
previously removed.
t
AffiHeatel'-kit-wiring4iagmm-m-inside-()k6ntro1--1filtcr
access door.
Page 47
.
COPPERWIRE-AWG'MCM
SUPPLY
CIRCUIT
SUPPLYWIRE LENG1H FEET
AMPACITY
100
ISO
200
250
300
6
..
3
2
I
15
:20
25
30
35
10
I
8
6
6
8
6
6
4
4
..
4
3
6
..
4
3
2
40
45
SO
60
70
6
4
4
4
3
4
3
3
2
2
3
2
2'
I
110
2
I
I
I/O
210
I
VO
I/O
210
310
80
90
100
110
12S
3
2
2
I
I
1
110
I/O
210
210
110
210
210
310
3/0
210
3/0
3/0
...,0
3/0
.c/O
.uo
250
250
150
175
200
225
110
2/0
3/0
'I/O
310
410
410
250
410
250
300
350
250
300
350
450
300
350
400
500
"
..
<C/O
Installation Manual
GFCI Convenience Outlet for
Maverick I™ Units
IM 905
Group: MPS
Part Number: IM 905
Date: January 2008
MPS007 to 020 ton
Installation
Procedure (also see diagram next
page)
WARNING
Failure to follow these instructions can result in improper
installation, adjustment, service, or maintenance, and can
result in fire, electrical shock, property damage, personal
injury, or death. These instructions are intended as an aid to
qualified service personnel for proper installation, adjustment,
and operation of this kit. Read carefully and thoroughly before
attempting installation, adjustment, or operation.
1. Connect the three wires to the receptacle.
2. Remove the convenience outlet mounting hole cover
plate (with gasket) and discard.
3. Use two setscrews to attach the convenience outlet
outdoor cover, gasket, GFCI convenience outlet with
wires, and convenience outlet box.
4. Connect the three wires to an external 110 V power
source.
Parts List
Description
Part Number
Quantity
Receptacle/Ground Fault
45-41954-01
1
Cover
45-41953-02
1
Outlet Box
45-41952-02
1
Wire
AS-50217-25-AH
1
Wire
AS-50221-25-AH
1
Wire
AS-50519-25-AH
1
Strain Relief
45-18753-01
1
Wire Tie
64-17606-01
2
DANGER
Electrical shock hazard. Can cause property damage,
personal injury or death. Before beginning any modification,
be sure the main disconnect switch is in the “Off” position and
tagged with a suitable warning label.
© 2008 McQuay International
Page 48
Page 49
CONVERSION KIT INDEX
NATURAL GAS TO PROPANE GAS,
CANADIAN HIGH ALTITUDE, AND
MAIN BURNER ORIFICE CHART
(-)RNL/(-)RPL/(-)KNL/(-)KPL/(-)RKA/(-)RMA/(-)RNA/(-)KKA/(-)KMA/(-)QPW
(-)KNA/(-)KKB/(-)KMB/(-)KNB ROOFTOP UNITS
(50 AND 60Hz MODELS)
!
Recognize this symbol as an indication of Important Safety Information!
!
WARNING
FURNACES USED ON LP GAS MUST BE EQUIPPED WITH 100% SAFETY SHUT-OFF CONTROLS. CONVERSION
WITH THE CORRECT KIT WILL MEET THIS SAFETY REQUIREMENT. CONVERSION WITH THE WRONG KIT CAN
LEAD TO A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
The conversion of Air Conditioning Division furnaces must be made by a qualified service professional using factory specified or approved parts. The following conversion kits must only be used on the furnace models and gas control systems
for which they are shown. If you do not find your exact furnace model number in the kit selection chart, contact your distributor or manufacturer for help in verifying the correct kit selection for your equipment. Do not substitute kits or kit components in order to avoid risk of dangerous conditions that may result in personal injury or property damage.
IMPORTANT NOTE FOR INSTALLATIONS AT ELEVATIONS ABOVE 2,000 FEET (610 METERS): The main burner orifices in your furnace and in Natural Gas to LP Gas (Propane) Conversion Kits are sized for the nameplate input and intended for installations at elevations up to 2,000 feet only. For elevations above 2,000 feet (610 meters), the burner orifices
must be sized to reduce the input as follows:
In the USA: Reduce the input 4% for each 1,000 feet (305 meters) above sea level.
See Chart III in this Conversion Kit Index for proper orifice sizes for the elevation at which the specific unit is
to be installed. The Conversion Kit Index is shipped with each unit and with the Natural Gas to LP Gas
(Propane) Conversion Kits.
In Canada: A high altitude conversion kit available from the manufacturer must be used for operation on natural gas at elevations of 2,000 - 4,500 feet (610 - 1373 meters) above sea level. See Chart II in this Conversion Kit Index for
the Canadian High Altitude Kit model number.
The proper high altitude orifices and instructions are included with the standard Natural Gas to LP Gas
(Propane) Conversion Kits for operation on LP Gas (Propane) at elevations of 2,000 - 4,500 feet (610 - 1373
meters) above sea level in Canada. A special high altitude kit is not required in this case. Simply use the proper orifice size specified in Chart III in this Conversion Kit Index for elevations of 2,000 - 4,500 feet (610 - 1373
meters) in Canada.
NOTICE:
THE CONVERSION SHALL BE CARRIED OUT BY A MANUFACTURER'S AUTHORIZED REPRESENTATIVE, IN ACCORDANCE WITH THE REQUIREMENTS OF THE MANUFACTURER, AND STATE, PROVINCIAL, OR TERRITORIAL AUTHORITIES HAVING JURISDICTION AND IN ACCORDANCE WITH THE
REQUIREMENTS OF ALL LOCAL CODES, THE NATIONAL FUEL GAS CODE, ANSI Z223.1, CAN/CGAB149.1, OR CAN/CGA-B149.2 INSTALLATION CODES.
HOW TO IDENTIFY THE CONTROL SYSTEM
ON THE FURNACE TO BE CONVERTED
The model number and the first two letters of the serial number on the furnace to be converted are required to select the
proper conversion kit. This information is located on the rating plate of the furnace. The first two characters of the serial
number designate the control system as applied by the manufacturer and the type gas it was manufactured to burn.
STEP 1. Locate the first two letters of the serial number in Chart I. This is the control system on the furnace. All furnaces
are manufactured to burn natural gas.
STEP 2. Determine the altitude at which the furnace is to be installed.
Page 50
92-21519-47-16
SUPERSEDES 92-21519-47-15
EXAMPLE
Serial number on furnace rating plate: 1AD1234AAAAF12340001
CONTROL SYSTEM
The first two characters in the serial number are “1A.” When the “1A” is located in Chart I, the control system in the furnace
is a Honeywell VR8205 gas valve with United Tech. 1016-452 direct spark ignition control, manufactured to burn natural
gas.
With the model number from the rating plate, the control system from Chart I, and the type gas it presently burns, the proper conversion kit can now be selected.
CHART I
CONTROL SYSTEMS
1A = HONEYWELL VR8205M GAS VALVE WITH UNITED TECH. 1016-452 DIRECT SPARK IGNITION CONTROL
1B = HONEYWELL VR8205M GAS VALVE WITH FENWALL 05-29DSI DIRECT SPARK IGNITION CONTROL
1C = HONEYWELL VR8205M GAS VALVE WITH JOHNSON CONTROLS G766BCA DIRECT SPARK IGNITION
CONTROL
1D = WHITE RODGERS 36E36 GAS VALVE WITH UNITED TECH. 1016-452 DIRECT SPARK IGNITION CONTROL
1E = WHITE RODGERS 36E36 GAS VALVE WITH FENWALL 05-29DSI DIRECT SPARK IGNITION CONTROL
1F = WHITE RODGERS 36E36 GAS VALVE WITH JOHNSON CONTROLS G766BCA DIRECT SPARK IGNITION
CONTROL
1G = ROBERTSHAW 7200DER GAS VALVE WITH UNITED TECH. 1016-452 DIRECT SPARK IGNITION CONTROL
1H = ROBERTSHAW 7200DER GAS VALVE WITH FENWALL 05-29DSI DIRECT SPARK IGNITION CONTROL
1J = ROBERTSHAW 7200DER GAS VALVE WITH JOHNSON CONTROLS G766BCA DIRECT SPARK IGNITION
CONTROL
1K = WHITE RODGERS 36E96 GAS VALVE WITH UNITED TECH. 1016-452 DIRECT SPARK IGNITION CONTROL
1L = WHITE RODGERS 36E96 GAS VALVE WITH FENWALL 05-29DSI DIRECT SPARK IGNITION CONTROL
1M = WHITE RODGERS 36E96 GAS VALVE WITH JOHNSON CONTROLS G766BCA DIRECT SPARK IGNITON
CONTROL
1N = ROBERTSHAW 7200DER2-5 GAS VALVE WITH UNITED TECH. 1016-452 DIRECT SPARK IGNITION CONTROL
1P = ROBERTSHAW 7200DER2-5 GAS VALVE WITH FENWALL 05-29DSI DIRECT SPARK IGNITION CONTROL
1Q = ROBERTSHAW 7200DER2-5 GAS VALVE WITH JOHNSON CONTROLS G766BCA DIRECT SPARK IGNITION
CONTROL
1R = HONEYWELL VR8205 WITH UNITED TECH. 1068-300 OR 1068-301 INTEGRATED FURNACE CONTROL
1S = WHITE RODGERS 36-36 WITH UNITED TECH. 1068-300 OR 1068-301 INTEGRATED FURNACE CONTROL
1T = WHITE RODGERS 36E37 WITH UNITED TECH. 1016-452 DIRECT SPARK
1U = WHITE RODGERS 36E37 WITH JOHNSON CONTROLS G766BCA DIRECT SPARK
1V = HONEYWELL VR8205H WITH UNITED TECH. 1016-452 DIRECT SPARK
1W = HONEYWELL VR8205H WITH JOHNSON CONTROLS G7766BCA DIRECT SPARK
1X = WHITE RODGERS 36E37 WITH UNITED TECH. 1068-300 OR 1068-301 INTEGRATED FURNACE CONTROL
1Y = HONEYWELL VR8205H WITH UNITED TECH. 1068-300 OR 1068-301 INTEGRATED FURNACE CONTROL
1Z = WHITE RODGERS FAST OPEN (36C76) WITH UNITED TECHNOLOGIES 1068-210 INTEGRATED FURNACE
CONTROL
2A = WHITE RODGERS SLOW OPEN (36E23) WITH UNITED TECHNOLOGIES 1068-300 OR 1068-301 INTEGRATED
FURNACE CONTROL
2B = WHITE RODGERS SNAP OPEN (36E99) WITH UNITED TECHNOLOGIES 1068-210 INTEGRATED FURNACE
CONTROL
2C = WHITE RODGERS SNAP OPEN (36E99) WITH UNITED TECHNOLOGIES 1068-300 INTEGRATED FURNACE
CONTROL
2D = HONEYWELL SNAP OPEN (VR8305Q) WITH UNITED TECHNOLOGIES 1068-210 INTEGRATED FURNACE
CONTROL
2E = WHITE RODGERS SLOW OPEN (36F23) WITH UNITED TECHNOLOGIES 1068-300 OR 1068-301 INTEGRATED
FURNACE CONTROL
2F = WHITE-RODGERS SNAP OPEN (36E55) AND UNITED TECHNOLOGIES INTEGRATED FURNACE CONTROL
(1068-300)
2G = HONEYWELL SLOW OPEN (VR8205S) AND UNITED TECHNOLOGIES INTEGRATED FURNACE CONTROL
(1068-300/301)
2H = WHITE-RODGERS SNAP OPEN (36E55) AND UNITED TECHNOLOGIES INTEGRATED FURNACE CONTROL
(1068-210)
Page 51
USING CONVERSION KIT CHART II
STEP 1) Find the appropriate control system by serial number code letters in line 2 of Chart II.
STEP 2) Verify the control system listed in line 3 of Chart II by name. Also verify that the furnace actually has this type
control system.
STEP 3) Identify the furnace model number in lines 4 or 5 in Chart II and move across this line until it intersects the
proper serial number column found in step 1. This space shows the proper conversion kit model number.
EXAMPLE
You wish to convert a Rooftop natural gas furnace model (-)RKA from Natural Gas to Propane Gas. Using the information
from the first example, the first two letters of the serial number were “1A.” From Chart I the “1A” signifies this furnace was
manufactured with a Honeywell VR8205 gas valve with United Technologies direct spark ignition control. Locate the serial
number coded letters “1A” in line 2 of Chart II and then look below this space to verify the type control system by name as
shown on line 3 (Honeywell VR8205 gas valve with direct spark ignition). Then verify that the furnace actually has this type
control system. Locate the model number of the unit in lines 4 and 5 of the first column. Then move across this line until it
intersects the column under the proper serial number code. The proper conversion kit model number is RXGJ-EP85H.
CHART II
CONVERSION KITS - NATURAL GAS TO PROPANE GAS
1
TYPE KIT,
ALTITUDE AND COUNTRY
NAT. GAS TO
PROPANE
ALL ALTITUDES (USA & CANADA)
2
SERIAL NO. CODE LETTER
1A, 1B, 1C, 1R, 1V,
1W, 1Y or 2G
3
TYPE CONTROL SYSTEM
4
KIT NUMBER FOR FURNACE
MODELS:
ALL RRKA MODELS
ALL RRMA MODELS
ALL RRNA MODELS
ALL RRNL MODELS
ALL RRPL MODELS
ALL RQPW MODELS
ALL SINGLE STAGE RKKA
MODELS
ALL SINGLE STAGE RKMA
MODELS
ALL RKNA MODELS
ALL RKNL MODELS
ALL RKPL MODELS
KIT NUMBER FOR FURNACE
MODELS:
5
TWO STAGE
RKKB/RKKA/RKMB/RKMA
MODELS
NAT. GAS TO
PROPANE
ALL ALTITUDES (USA & CANADA)
NAT. GAS TO
PROPANE
ALL ALTITUDES (USA & CANADA)
1D, 1E, 1F, 1S, 1T, 1U, 1K, 1L, 1M, 2B, 2C,
1X, 2A or 2E
2F OR 2H
NAT. GAS TO
NAT. GAS TO
NAT. GAS TO NAT. GAS
PROPANE
PROPANE
2,000-4,500 FT.
ALL ALTITUDES - ALL ALTITUDES (610-1373M)
(USA & CANADA) (USA & CANADA)
(CANADA ONLY)
1Z
WHITE RODGERS
WHITE RODGERS WHITE RODGERS
HONEYWELL VR8205
36E23, 36E36, 36F23 36E55, 36E96 OR 36C76 GAS VALVE
GAS VALVE WITH
OR 36E37 GAS VALVE 36E99 GAS VALVE
WITH DIRECT
DIRECT SPARK
WITH DIRECT
WITH DIRECT
SPARK
IGNITION
SPARK IGNITION
SPARK IGNITION
IGNITION
USE KIT NO.
RXGJ-EP85H
2D
ALL
HONEYWELL
VR8305Q GAS
VALVE WITH
DIRECT SPARK
IGNITION
ALL
USE KIT NO.
RXGJ-EP84W
USE KIT NO.
RXRX-AH01
USE KIT NO.
RXGJ-EP86W
Page 52
USE KIT NO.
RXGJ-EP87W
USE KIT NO.
RXGJ-FP14
USE KIT NO.
RXRX-AH02
USING CONVERSION KIT CHART III
The following chart should be used to verify the size of all main burner orifices for high altitude derating and natural gas to
propane gas conversions.
Use the furnace nameplate gas INPUT rating, the number of main burners and the altitude of the installation to select the
correct natural gas or propane gas orifice size.
The table is based on manifold pressures of 3.5” W.C. for natural gas and 10” W.C. for propane gas.
IMPORTANT:
NEVER ATTEMPT TO INCREASE THE GAS FURNACE FIRING RATE BY USING LARGER ORIFICES THAN SPECIFIED. ALTHOUGH FURNACE DIMENSIONS MAY APPEAR SIMILAR,
INTERNAL DIFFERENCES CAN CAUSE POOR COMBUSTION, UNSAFE OPERATING
CONDITIONS, AND PREMATURE EQUIPMENT FAILURE.
CHART III
MAIN BURNER ORIFICE SIZES
TOTAL
FURNACE
RATING PLATE
INPUT
(BTU/HR)
CANADIAN
HIGH
ALTITUDE
DERATED
INPUT
(BTU/HR)
NUMBER
OF
BURNERS
NATURAL GAS
PROPANE GAS
HEATING VALUE 1075 BUT/CU. FT.
HEATING VALUE 2500 BTU/CU. FT.
SPECIFIC GRAVITY 0.65/MANIFOLD PRESSURE @ 3.5” W.C.
SPECIFIC GRAVITY 1.53/MANIFOLD PRESSURE @ 10.0” W.C.
ELEVATION
0 - 2000’
(USA/
CANADA)
ELEVATION
4000’
(USA ONLY)
ELEVATION
6000’
(USA ONLY)
ELEVATION
8000’
(USA ONLY)
ELEVATION
2000 - 4500’
(CANADA)
ELEVATION
0 - 2000’
(USA/
CANADA)
ELEVATION
4000’
(USA ONLY)
ELEVATION
6000’
(USA ONLY)
ELEVATION
8000’
(USA ONLY)
ELEVATION
2000 - 4500’
(CANADA)
40,000
36,000
2
45
47
48
49
5/64
55
55
56
56
3/64
60,000
54,000
3
45
47
48
49
5/64
55
55
56
56
3/64
72,000
(50 Hz Model)
N/A
4
5/64
49
50
51
N/A
3/64
57
57
59
N/A
80,000
72,000
4
45
47
48
49
5/64
55
55
56
56
3/64
90,000
(50 Hz Model)
N/A
5
5/64
49
50
51
N/A
3/64
57
57
59
N/A
100,000
90,000
5
45
47
48
49
5/64
55
55
56
56
3/64
120,000
(50 and 60 Hz)
108,000
6
45
47
48
49
5/64
55
55
56
56
3/64
135,000
121,500
6
44
45
47
48
45
54
55
55
56
55
150,000
135,000
6
42
43
44
45
44
54
55
55
56
54
180,000
(50 Hz Model)
N/A
9
45
47
48
49
N/A
55
55
56
56
N/A
210,000
(50 Hz Model)
N/A
9
43
44
45
47
N/A
54
55
55
56
N/A
210,000
(50 Hz Model)
N/A
10
45
47
48
49
N/A
55
55
56
56
N/A
225,000
202,500
9
42
43
44
45
44
54
55
55
56
54
250,000
225,000
10
42
43
44
45
44
54
55
55
56
54
252,000
225,000
9
40
42
43
44
42
53
54
54
55
54
252,000
(50 Hz Model)
N/A
12
45
47
48
49
N/A
55
55
56
56
N/A
290,000
(50 Hz Model)
N/A
14
45
47
48
49
N/A
55
55
56
56
N/A
270,000
12
42
43
44
45
44
54
55
55
56
54
N/A
14
43
44
45
47
N/A
54
55
55
56
N/A
350,000
315,000
14
42
43
44
45
44
54
55
55
56
54
400,000
360,000
14
40
42
43
44
42
53
54
54
55
54
300,000
330,000
(50 Hz Model)
N/A = Not Applicable
CM 1206
Page 53
Page 54
Page 55
Page 56
Page 57
INSTALLATION INSTRUCTIONS
MODELS RXRX-BGF03 & RXRX-BGF04
ECONOMIZER POWER EXHAUST
WARNING
This installation shall be carried out by a manufacturer's authorized representative, in accordance with the
requirements of the manufacturer. Failure to follow instructions can result in fire or explosion, causing property
damage, severe personal injury, or death. The qualified service personnel performing this work assumes
responsibility for this installation.
IMPORTANT
Damage to the product, resulting from failure to follow instructions or use of unauthorized parts, may be exclude from
the manufacturer's product warranty coverage.
WARNING
Turn off electrical power and turn off main gas supply before beginning modification. Failure to do so can
cause electrical shock, explosion, or fire, resulting in property damage, personal injury, or death.
TOOLS REQUIRED FOR INSTALLATION:
3
1
" electric drill with 516" socket
8
" diameter drill bit for sheet metal.
8
PACKAGE CONTENTS
ITEM
DESCRIPTION
RXRX-BGF03
Power Exhaust
C, D, Y Voltage
RXRX-BGF04
Power Exhaust
C, D, Y Voltage
PART No.
PART No.
1
Power Exhaust Assembly
6046520 / PEA
6046508 / PEA
2
Fan Blade
6046520 / 3464
6046508 / 3464
3
Fan Motor 208-230 volt / 1 phase (C)
6046520 / 3675
6046508 / 3675
4
Fan Motor 208-230 volt / 1 phase (D)
6046520 / 3675
6046508 / 3675
5
Fan Motor 208-230 volt / 1 phase (Y)
6046520 / 3698
6046508 / 3968
6
Relay (R1)
6046520 / 3400
6046508 / 3400
7
Fuse Block
6046520 / 3370
6046508 / 3370
8
Barometric Relief Adaptor
6046520 / ADP
6046508 / ADP
Page 58
Step 1:
Remove lower barometric relief hood. Remove relief damper section from economizer or duct work.
Step 2:
Place relief damper section onto barometric relief damper adapter and secure with screws provided with power exhaust.
Step 3:
Place relief damper assembly into lower hood assembly where prepunched holes are in hood sides with screws from Step
1.
Horizontal Application:
Step 4:
Place power exhaust over hole in duct work and secure to duct work. Adjust support legs to level power exhaust. See
Figure 1.
Vertical Application:
Step 5:
Place over hole where hood was located and secure. See Figure 2.
MODEL
"A"
3 - 6 TON
23.750 REF
7 ½ TON
29.750 REF.
RETURN DUCT TO BE
PROPERLY SIZED FOR
AIRFLOW OF SPECIFIC
INSTALLATION
A
SECURE TO DUCT WORK
FIGURE1
BAROMETRIC RELIEF DAMPER &
HOOD TO BE RELOCATED FROM
ECONOM IZER
TO
POW ER
EXHAUST
PREPUNCHED HOLE FOR
RELIEF DAMPER
2
Page 59
NOTE:
COIL NOT SHOWN
FOR CLARITY
SECURE TO HOOD EXTENSION
PREPUNCHED HOLE FOR RELIEF DAMPER
FIGURE 2
COMPONENT CODE
HARNESS DETAIL
WIRE COLOR CODE
BLK
BRN
GRY
RED
YEL
Black
Brown
Gray
Red
Yellow
BLU
GRN
ORG
VIO
Blue
Green
Orange
Violet
230 Volt 1-Phase Power Exhaust for
RXRX-BGF03C / RXRX-BGF04C
RKKA / JKA / LKA-MA 036-090
Notes:
Rooftop Systems, Inc.
2405 McIver Lane
Carrollton, Texas 75006
Phone(972) 247-7447
Fax (972) 243-0940
Date: May 17, 2006
Supercedes:
Drawn by:
Unit # 60-465-20/08-21
Diagram# 4652021w
3
Page 60
HARNESS DETAIL
COMPONENT CODE
WIRE COLOR CODE
BLK
BRN
GRY
RED
WHT
Black
Brown
Gray
Red
White
BLU
GRN
ORG
VIO
YEL
Blue
Green
Orange
Violet
Yellow
460 Volt 1-Phase Power Exhaust for
RXRX-BGF03D / RXRX-BGF04D
RKKA / JKA / LKA-MA 036-090
Notes:
Rooftop Systems, Inc.
2405 McIver Lane
Carrollton, Texas 75006
Phone(972) 247-7447
Fax (972) 243-0940
HARNESS DETAIL
COMPONENT CODE
Date: May 23, 2006
Supercedes: 05-17-06
Drawn by:
Unit # 60-465-20/08-31
Diagram# 4652031w
WIRE COLOR CODE
BLK
BRN
GRY
RED
WHT
Black
Brown
Gray
Red
White
BLU
GRN
ORG
VIO
YEL
Blue
Green
Orange
Violet
Yellow
575 Volt 1-Phase Power Exhaust for
RXRX-BGF03Y / RXRX-BGF04Y
RKKA / JKA / LKA-MA 036-090
Notes:
Rooftop Systems, Inc.
2405 McIver Lane
Carrollton, Texas 75006
Phone(972) 247-7447
Fax (972) 243-0940
SUPERCEDES 05-17-06
MAY 24, 2006
Date: May 23, 2006
Supercedes: 05-17-06
Drawn by:
Unit # 60-465-20/08-41
Diagram# 4652041w
RMIPE20
Page 61
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
This Roof Curb is built to NRCA specifications and is constructed of 18 gauge galvanized steel with a full perimeter 1" X 4"
wood nailer strip. Curb height is determined by the part number as listed below.
(-)XKG-CAD14 = 14 inches high
(-)XKG-CAD24 = 24 inches high
Step 1:
Check for the correct number of parts. See list below.
Figure 1
Parts List For (-)XKG-CAD14
Description
Part #
Tie Down Brackets
7 ½ Ton Duct Support - 43 ½ Long (F)
602012014/TDB
602012014/VER2
3-6 Ton Duct Support - 38 Long (E)
602012014/VER1
Duct Support - 20 3 8 Long (D)
602012014/HOR1
Duct Support 39 Long (C)
602012014/HOR2
Insulated Panels w/ Cutouts (H)
602012014/PAN1
Insulated Panels (G)
602012014/PAN2
Curb Long Side - 71" Long (B)
602012014/CLS
Curb Short Side - 42 5 8" long (A)
602012014/CSS
¾" x 1 ¼" x 14' Gasket
602012014/4102
" x 13 ½" Hinge Pins
3
16
602012014/4451
Hardware Bag
602012014/HDW
I & O Manual
RMICRB20
Screw (Hex Head) #10-16 x ½"
Qty
4
1
1
1
1
2
2
2
2
2
4
1
1
14
Parts List For (-)XKG-CAD24
Description
Part #
Tie Down Brackets
602012024/TDB
7 ½ Ton Duct Support - 43 ½ Long (F)
3-6 Ton Duct Support - 38 Long (E)
602012024/VER1
Duct Support - 20 3 8 Long (D)
602012024/HOR1
Duct Support 39 Long (C)
602012024/HOR2
Insulated Panels w/ Cutouts (H)
602012024/PAN1
Insulated Panels (G)
602012024/PAN2
Curb Long Side - 71" Long (B)
602012024/CLS
Curb Short Side - 42 5 8" long (A)
602012024/CSS
¾" x 1 ¼" x 14' Gasket
602012024/4102
" x 23 ½" Hinge Pins
3
16
602012024/4452
Hardware Bag
602012024/HDW
I & O Manual
RMICRB20
Screw (Hex Head) #10-16 x ½"
(A)
(B)
(G)
(H)
(H)
602012024/VER2
(C)
(G)
(E)
(F)
(B)
(D)
(A)
Figure 2
Step 2:
Layout the curb pieces before assembly to insure that all the necessary pieces are included.
U.S. PATENT 5148647
Page 62
Qty
1
1
1
1
1
2
2
2
2
2
4
1
1
14
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
HINGE PIN
TAPERED END
HINGE
CURB SIDE
Figure 4
Figure 3
Step 3:
Corner Assembly: Align each curb side as shown in Figure 3. Using a hammer, drive the curb "hinge" pin down until the
top of the pin is below the top of the curb as shown in Figure 4.
82 1316
82 1316
+ 1
- 8
+ 1
- 8
Figure 5
Step 4:
After the four corners are assembled; the curb should be checked to be sure it is in "square". Do this by measuring
diagonally from each opposite corner. The two measurements should be the same for each direction as shown in Figure 5.
Page 63
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
DETAILS
1.
Duct support
inter-locks with
curb.
The duct support flange goes in
the slot on the curb. Screw the
duct support to the curb.
The (-)XKG can now have the duct
support and the insulated pans installed,
unless a transition (RXMC-CB03 or
CB04) is to be installed. If this is the case
follow transition instruction from this
point.
Step 5:
Place the duct support (C) on the curb,
making sure that it is in the right location.
See "DETAIL #1".
Step 6:
Place duct support (E or F) on the curb and
duct support (C), making sure that it is in the
right location. See "DETAIL #1 and #2".
Step 7:
Place duct support (D) on the curb and duct
support (E or F) making sure that it is in the
right location.
Step 8:
Install the insulated pans (G and H) on the
curb as shown with the roof opening over
the desired duct location.
Step 9:
If the curb is being assembled & moved to
another location, attach the brace & pans to
the curb as shown in the "DETAILS".
Duct
support
inter-locks with pan
or other duct
support.
2.
The duct support flange goes in the
slot on the pan. Screw the duct
support and pan the together.
TOP VIEW
71
B
PLACE GASKET HERE
DETAIL "1"
(C)
16 5 8
DETAIL "1"
DETAIL "2"
(G)
(H)
(H)
(G)
42 5 8
(E or F)
SUPPLY
RETURN
13 ¾
20 ¼
(D)
OMIT ONE (G) ON THE "085" UNIT
UNIT
036-072
085
A
22
1
8
27 5 8
DUCT SIZE
B
ROOF
OPENING
37
38 x 20 ½
21
5
8
x 19 ¾
13 ¼ x 19 ¾
43 ½ x 20 ½
27
1
8
x 19 ¾
13 ¼ x 19 ¾
7
8
43 3 8
ROOF OPENING
(SHADED AREA)
2
RETURN
SUPPLY
Page 64
A
Figure 6
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
TYPICAL INSTALLATION
(4) CORNERS OF UNIT
UNIT BASEPAN
INSTALLATION
REQUIRES
FIELD DRILLING
TIE DOWN BRACKET
Step 10:
To secure unit to curb, position unit on curb. Using four of the #10 x ½"
self drilling screws, attach the tie down bracket furnished, as shown in
detail. Recheck all joints to assure watertightness.
UNIT BASERAIL
ROOF CURB
ROOF INSTRUCTIONS
WOOD NAILER
COUNTER FLASHING
(FIELD SUPPLIED)
CURB FRAME
ROOFING FELT
(FIELD SUPPLIED)
RIGID INSULATION
(FIELD SUPPLIED)
CANT STRIP
(FIELD SUPPLIED)
AUGUST 2, 2006
RMICRB20R
Page 65
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
This Roof Curb is built to NRCA specifications and is constructed of 18 gauge galvanized steel with a full perimeter 1" X 4"
wood nailer strip. Curb height is determined by the part number as listed below.
(-)XKG-CAE14 = 14 inches high
(-)XKG-CAE24 = 24 inches high
Step 1:
Check for the correct number of parts. See list below.
Figure 1
Parts List For (-)XKG-CAE14
Description
Part #
Tie Down Brackets
602011314/TDB
Duct Support - 49 916" Long (D)
602011314/VER
Duct Support - 20 8" Long (C)
602011314/HOR1
Duct Support 29 ¾" Long (E)
602011314/HOR2
3
Curb Long Side - 88 916" Long (B)
602011314/CLS
Curb Short Side - 53 3 8" long (A)
602011314/CSS
¾" x 1 ¼" x 14' Gasket
602011314/4102
3
16
" x 13 ½" Hinge Pins
602011314/4451
Hardware Bag
602011314/HDW
I & O Manual
RMICRB13R
Screw (Hex Head) #10-16 x ½"
Qty
4
2
1
1
2
2
3
4
1
1
14
Parts List For (-)XKG-CAE24
Description
Part #
Tie Down Brackets
602011324/TDB
Duct Support - 49 916" Long (D)
602011324/VER1
Duct Support - 20 8" Long (C)
602011324/HOR1
Duct Support 29 ¾" Long (E)
602011324/HOR2
3
Curb Long Side - 88 916" Long (B)
602011324/CLS
Curb Short Side - 53 3 8" long (A)
602011324/CSS
¾" x 1 ¼" x 14' Gasket
602011324/4102
" x 23 ½" Hinge Pins
3
16
602011324/4452
Hardware Bag
602011324/HDW
I & O Manual
RMICRB13R
Screw (Hex Head) #10-16 x ½"
(A)
(D)
(B)
(E)
(D)
(C)
(B)
(A)
Figure 2
Step 2:
Layout the curb pieces before assembly to insure that all the necessary pieces are included.
U.S. PATENT 5148647
Page 66
Qty
1
1
1
1
2
2
3
4
1
1
14
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
HINGE PIN
TAPERED END
HINGE
CURB SIDE
Figure 4
Figure 3
Step 3:
Corner Assembly: Align each curb side as shown in Figure 3. Using a hammer, drive the curb "hinge" pin down until the
top of the pin is below the top of the curb as shown in Figure 4.
103 716
103 716
+ 1
- 8
+ 1
- 8
Figure 5
Step 4:
After the four corners are assembled; the curb should be checked to be sure it is in "square". Do this by measuring
diagonally from each opposite corner. The two measurements should be the same for each direction as shown in Figure 5.
Page 67
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
DETAILS
1.
Duct support interlocks with curb.
The duct support flange goes in
the slot on the curb. Screw the
duct support to the curb.
The RXKG can now have the duct support
installed, if a transition (RXMC-C***) is to
be installed. If this is the case follow
transition instruction from this point.
Step 5:
Place both duct supports (D) on the curb,
making sure that it is in the right location. See
"DETAIL #1".
Step 6:
Place duct support (C) on the curb and duct
support (D), making sure that it is in the right
location. See "DETAIL #1 and #2".
Step 7:
Install duct support (E) on the duct supports
(D) as shown with the roof opening over the
desired duct location. See "DETAIL #2".
Step 8:
If the curb is being assembled & moved to
another location, attach the duct supports to
the curb as shown in the "DETAILS".
2.
Duct support interlocks with pan or
other duct support.
The duct support flange goes in
the slot on the pan. Screw the duct
support and pan the together.
TOP VIEW
88
9
16
84 13 16
4
4
29 ¾
20 13 16
PLACE GASKET HERE
DETAIL "2"
(D)
(D)
2
DETAIL "2"
(C)
2
DETAIL "1"
(E)
49 5 8
RETURN
20 ¼ x 40 ¾
24
SUPPLY
29 ¼ x 23 ½
DETAIL "1"
ROOF OPENING
54 ¾" x 49 5 8"
Figure 6
Page 68
41 116
53 3 8
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
TYPICAL INSTALLATION
(4) CORNERS OF UNIT
UNIT BASEPAN
INSTALLATION
REQUIRES
FIELD DRILLING
TIE DOWN BRACKET
Step 9:
To secure unit to curb, position unit on curb. Using four of the #10 x ½"
self drilling screws, attach the tie down bracket furnished, as shown in
detail. Recheck all joints to assure watertightness.
UNIT BASERAIL
ROOF CURB
ROOF INSTRUCTIONS
WOOD NAILER
COUNTER FLASHING
(FIELD SUPPLIED)
CURB FRAME
ROOFING FELT
(FIELD SUPPLIED)
RIGID INSULATION
(FIELD SUPPLIED)
CANT STRIP
(FIELD SUPPLIED)
RMICRB13R
AUGUST 2, 2006
Page 69
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
This Roof Curb is built to NRCA specifications and is constructed of 16 gauge galvanized steel with a full perimeter 1" X 4"
wood nailer strip. Curb height is determined by the part number as listed below.
(-)XKG-CAF14 = 14 inches high
Figure 1
Step 1:
Check for the correct number of parts. See list below.
Parts List For (-)XKG-CAF14
Description
Part #
Tie Down Brackets
602011514/TDB
Splice Bracket (G)
602011514/SBR
Duct Support - 49
" Long (E)
9
16
602011514/HOR
Duct Support - 42" Long (F)
602011514/VER1
Duct Support - 22" Long (D)
602011514/VER2
602011514/CLS
Curb Long Side - 70 ½" Long (C)
Curb Long Side - 70 ½" Long (B)
602011514/CLS
Curb Short Side - 53 3 8" Long (A)
602011514/CSS
¾" x 1 ¼" x 14' Gasket
602011514/4102
3
16
" x 13 ½" Hinge Pins
602011514/4451
Hardware Bag
602011514/HDW
I & O Manual
RMICRB15R
Screw (Hex Head) #10-16 x ½"
(A)
Qty
4
2
3
1
1
2
2
2
4
6
1
1
26
(B)
(G)
(E)
(E)
(F)
(B)
(C)
(E)
(G)
(D)
(C)
(A)
Figure 2
Step 2:
Layout the curb pieces before assembly to insure that all the necessary pieces are included.
U.S. PATENT 5148647
Page 70
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
HINGE PIN
TAPERED END
HINGE
CURB SIDE
Figure 4
Figure 3
Step 3:
Corner Assembly: Align each curb side as shown in Figure 3. Using a hammer, drive the curb "hinge" pin down until the
top of the pin is below the top of the curb as shown in Figure 4.
150 1116
150 1116
+ 1
- 8
+ 1
- 8
Figure 5
Step 4:
After the four corners and middle hinges are assembled; the curb should be checked to be sure it is in "square". Do this by
measuring diagonally from each opposite corner. The two measurements should be the same for each direction as shown
in Figure 5. Then take the splice bracket (G) and secure to outside of the middle hinges.
Page 71
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
DETAILS
1.
The RXKG can now have the duct support
installed, if a transition (RXMC-C***) is to
be installed. If this is the case follow
transition instruction from this point.
Duct support interlocks with curb.
2.
Duct support interlocks with pan or
other duct support.
Step 5:
Place all three duct supports (E) on the curb,
making sure that it is in the right location. See
"DETAIL #1".
Step 6:
Place duct support (D) on the curb and duct
support (E), making sure that it is in the right
location. See "DETAIL #1 and #2".
Step 7:
Install duct support (F) on the duct supports
(E) as shown with the roof opening over the
desired duct location. See "DETAIL #2".
The duct support flange goes in
the slot on the curb. Screw the
duct support to the curb.
The duct support flange goes in
the slot on the pan. Screw the duct
support and pan the together.
Step 8:
If the curb is being assembled & moved to
another location, attach the duct supports to
the curb as shown in the "DETAILS".
TOP VIEW
140 15 16
137 3 16
4
4
4
22
42
8 116
PLACE GASKET HERE
2
DETAIL "2"
(E)
(D)
DETAIL "1"
2
DETAIL "2"
(E)
49 5 8
(E)
24
SUPPLY
41 ½ x 23 ½
DETAIL "1"
ROOF OPENING
69" x 49 5 8"
Figure 6
Page 72
RETURN
21 ½ x 40 ¾
41
1
16
53 3 8
INSTALLATION INSTRUCTIONS
MODEL# (-)XKG SERIES
ROOF CURBS
TYPICAL INSTALLATION
(4) CORNERS OF UNIT
UNIT BASEPAN
INSTALLATION
REQUIRES
FIELD DRILLING
TIE DOWN BRACKET
Step 9:
To secure unit to curb, position unit on curb. Using four of the #10 x ½"
self drilling screws, attach the tie down bracket furnished, as shown in
detail. Recheck all joints to assure watertightness.
UNIT BASERAIL
ROOF CURB
ROOF INSTRUCTIONS
WOOD NAILER
COUNTER FLASHING
(FIELD SUPPLIED)
CURB FRAME
ROOFING FELT
(FIELD SUPPLIED)
RIGID INSULATION
(FIELD SUPPLIED)
CANT STRIP
(FIELD SUPPLIED)
AUGUST 2, 2006
RMICRB15R
Page 73
Installation Manual
Smoke Detector
IM: 908
Group: MPS
Date: January 2008
Supersedes: None
The MQuay smoke detector is designed specifically for applications where standard external
mount detectors cannot be utilized, such as air shafts, plenum spaces, or applications requiring
extremely low, or no air velocity. The detector provides early detection of smoke and
combustion present in the air of a duct supply, return, or both, in commercial, residential, and
industrial applications.
Contents
• Specifications.............................................................................................................. page 2
• Terminal Connections ................................................................................................. page 2
• Installation .................................................................................................................. page 2
© 2008 McQuay International
Page 74
Specifications
1 The smoke detector can be mounted in the duct or in the
Table 1: Unit Specifications
Power Requirements
60 Hz Alarm Current
24 V (ac) – 139 mA
24 V (dc) – 48 mA
115 V (ac) – 34 mA
230 V (ac) – 20 mA
Unit Ratings
Alarm Contacts:
1 set form “C” rated at 10 A @ 115 V
(ac) resistive
1 form “A” rated at 2 A
Trouble Contact:
1 set form “B” rated at 10 A @ 115 V
(ac) resistive
Air Velocity
0 to 3000 ft/min.
Ambient Temperature:
32° to 140°F (0° to 60°C)
Humidity:
0% to 85% RH non-condensing/nonfreezing
Material:
White platic base/housing and detector
Dimensions:
6" diameter, 4" H overall/2.6" front to
back
Max. Weight:
1.0 lb
Radioactive element:
Americum 241, 0.9 micro curie
Mounting:
Standard 4" square back box
Standby Current
24 V (ac) – 54.4 mA
24 V (dc) – 15 mA
115 V (ac) – 31 mA
230 V (ac) – 18 mA
Terminal Connections
Prior to connecting input power to the duct unit, determine the
correct input voltage/current availability and connect to the
correct terminals.
return air section of the unit. If installing inside the unit,
locate an area where there is a uniform, non-turbulent
airflow of between 500 and 3000 ft/min (example shown in
Figure 2). Other possible installation locations are inside
the economizer and inside the curb.
Figure 2. Non-Turbulant Airflow Area for Mounting
2 Mount a 4 x 4 junction box in this non-turbulant airflow
area. Twist the smoke detector onto the screws on the top
of the junction box (Figure 3) to form a complete installed
unit (Figure 4).
Figure 3. Mounting the Smoke Detector to Junction Box
ALM - N.O.
ALM - COM
ALM - N.C.
Figure 1. Dry Contact Outputs Alarm
8
9
10
MPS TERMINAL
R
°
T-STAT TERMINAL
R
°
Figure 4. Junction Box and Smoke Detector Installed
15 A @ 124 V (ac)
10 A @ 277 V (ac)
7 A @ 30 V (dc)
1/4 HP @ 125/250 V (ac) (N.C.)
1/3 HP @ 125/250 V (ac) (N.O.)
Installation
DANGER
Moving machinery and electrical power hazards. Will
cause severe personal injury or death.
Disconnect and lock off all power before servicing equipment.
CAUTION
Sharp edges on sheet metal and fasteners can cause
personal injury. This equipment must be installed, operated,
and serviced only by an experienced installation company and
fully trained personnel.
2
3 Run the wires for the 24 VAC and NC contacts back to the
control panel.
Note: For Maverick units, the wires may be run with the
existing exhaust fan wiring or economizer wiring.
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McQuay IM 908
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Engineering Data
ED: 9043
Group: MPS
Date: January 2008
Supersedes: None
3 Heat, 2 Cool Thermostat for Maverick I™ Units
Single Stage, Multi-Stage, and Heat Pump Applications
The commercial setback digital thermostat uses microcomputer technology to provide precise
time and temperature control. This thermostat offers the flexibility to design heating and cooling
programs that fit building needs. This thermostat is adaptable to most residential 24 volt forced
air multi-stage systems with electric or fossil fuel auxiliary and is the ulitmate for comfort,
convenience, and performance.
Contents
• Features ..................................................................................................................... page 2
• Terminals (typical connection to MPS I) ..................................................................... page 2
• Specifications.............................................................................................................. page 2
© 2008 McQuay International
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Features
Specifications
The T170 thermostat can enhance your HVAC system by
offering you the following performance features.
Table 1: Thermostat specifications
Electrical Rating Single
Stage:
mV to 30 V (ac), NEC Class II, 50/60
Hz or DC
Electrical Rating Staging:
20 to 30 V (ac), NEC Class II
Terminal Load:
5 A per terminal, 2.5 A max. combined
Setpoint Range:
45° to 99°F (7° to 37°C)
• Permanent program memory
Anticipation, Heating:
Adjustable
• Configuration menu allows keypad selection of options, no
additional sub-bases required
Anticipation, Cooling:
Adjustable
Rated Differential Single
Stage:
Heat 0.5° to .5°F, Cool 0.8° to 2.2°F
Rated Differential Staging:
Heat 0.5° to .5°F, Cool 0.5° to 2.2°F
Operating Ambient:
32° to +0°F (0° to +43°C)
• Single stage models accept remote indoor sensor
Operating Humidity
90% non-condensing max.
• Staging models accept up to three indoor sensors and offer
temperature averaging or weighted average by sensor
location and program time
Shipping Temperature Range: -4° to 50°F (-20° to 65°C)
• Automatic heat/cool system changeover
• Fossil fuel or electric heat compatible
• Large luminescent display and industry first lighted keypad
• Selectable energy management recovery
• Onboard system and thermostat diagnostics
Dimensions (H x W x D):
4 1/8" x 6 7/8" x 1 3/8"
Terminals (typical connection to MPS I)
Use the terminal output information below to help you wire the
thermostat properly for your multi-stage system.
L
Malfunction Light
Thermostat Terminals (Upper)
PH
D
SA
SB
X-10 Module Input Not Used
Remote
Remote
Sense A
Sense B
System
E
Multi-Stage No Function
Br
R
C
24 Volt
(Common)
R
24 Volt
(Hot)
SC
Remote
Sense C
OT
Outdoor
Sensor
Thermostat Terminals (Lower)
W3/A1
W2
E2/P
W1
Y2
Y1
B
O
G
Blower/Fan
Heat Mode Heat Mode No Function Heat Mode Cool Mode Cool Mode Energized Energized
3rd Stage 2nd Stage
1st Stage 2nd Stage 1st Stage in Heat and in Cool Energized on call
for Cool (and heat
Mode
Off Mode
if configureed to
Electric Heat
O
Bk
Bl
°
°
°
°
°
°
°
C
R
W1
W2
Terminal Block
G
Y1
Y2
Y
G
1 On 3 - 6 ton units, a terminal block is not supplied. Use a
wirenut to extend from the leads provided in the unit to the
thermostat.
2 W1, W2, and Y2 are optional depending upon the size and
selected options of the unit.
3 Colors shown above are typical for the MPS I.
2
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McQuay ED 9043
Engineering Data
ED: 9045
Group: MPS
Date: January 2008
Supersedes: None
Thermostat Guard for Maverick I™ Units
All Thermostat Types
Features
The thermostat guard can enhance your HVAC system by offering you the following features:
• Accepts all thermostat types
• Each model is furnished with one key and can be mounted vertically or horizontally
• Clear plastic models for applications that need the thermostat visible
• Furnished with a ring and/or solid wall mounting plate
© 2008 McQuay International
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Engineering Data
ED: 9044
Group: MPS
Date: January 2008
Supersedes: None
Remote Sensor for Maverick I™ Units
Indoor and Outdoor Sensor for Digital Thermostats
Features
The remote sensor can enhance your HVAC system by offering you the following performance features:
• Digital signal output provides superior temperature control, even over long wire runs
• No temperature variance caused by wire resistance
• Choice of styling, indoor models are interchangeable
• Perfect for securing the thermostat in on are or room while sensing temperature in the conditioned space
Specifications
Table 1: Sensor operating range specifications
Indoor Models:
40° to 99°F
Outdoor Models:
-40° to 40°F
Terminal Load:
5 A per terminal, 2.5 A max. combined
Operating Humidity Range:
0% to 90% RH (non-condensing)
Max. Distance from T-stat
300’
Recommended Wire
20 gauge, 3 conductor shielded cable
© 2008 McQuay International
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McQuay Training and Development
Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority.
For training information on all McQuay HVAC products, please visit us at www.mcquay.com and click on training, or
call 540-248-9646 and ask for the Training Department.
Warranty
All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product
Warranty. Consult your local McQuay Representative for warranty details. Refer to Form 933-43285Y. To find your
local McQuay Representative, go to www.mcquay.com.
This document contains the most current product information as of this printing. For the most up-to-date product
information, please go to www.mcquay.com.
© 2008 McQuay International • www.mcquay.com • 800-432-1342
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