AE-1275 - Sentronic and Sentronic+ Electronic Oil Pressure Control

AE-1275 - Sentronic and Sentronic+ Electronic Oil Pressure Control
AE8-1275 R9
AE8-1275 R8
November 1999
Reformatted November 2010
Sentronic® and Sentronic+™
Electronic Oil Pressure Control
must successfully pass a life test with a minimum of
200,000 cycles. Controls must be of the non-adjustable,
manual reset type with a 120 second nominal time delay
at rated voltage, have a cut-out pressure setting of 7
to 9 PSID (Pounds per Square Inch Differential, the
difference between crankcase pressure and oil-pump
outlet pressure) and a cut-in (timer delay off) pressure
of 12-14 PSID.
The current Copeland® Sentronic® electronic oil
pressure safety control (see Figure 1) replaces two
older Sentronics; the four terminal, triac output style,
and the five terminal, relay output style (see Figure
2). The current Sentronic has all the features of
previous Sentronics, with valuable additions.
All Sentronics utilize a pressure sensor and an
electronic control module to precisely measure oil pump
differential pressure. The main advantage of Sentronic
is the elimination of the traditional capillary tubes,
bellows, and pressure connections that mechanical
pressure switches require to measure differential oil
pressure. These require careful handling, and are
known to be a source of leaks in refrigeration systems.
BASIC CONTROL OPERATION
The Sentronic Sensor
The same oil pressure sensor is used for all Sentronics.
It mounts directly into the oil pump. The Sentronic
sensor measures oil pump differential pressure. It
has an internal contact that opens on low oil pressure
and signals the Sentronic electronic control module to
begin time out. The same contact closes when proper
oil pressure is present and stops the module time out.
A second advantage of Sentronic is in the use of a
precise electronic clock for the two minute time out
circuit. Traditional mechanical controls use resistance
heaters to provide the time to trip in the event of low oil
pressure. 208 volt systems, low ambient temperatures
or brown-out type conditions cause the heater output to
be reduced, thus increasing the time out period from two
minutes to three or four minutes when low oil pressure
conditions exist. With the electronic clock, the time out
will always be the same.
Should oil pressure fall below 7-9 PSID for a period of
two minutes, the Sentronic module will open the control
circuit, using its Normally-Closed (N.C.) contact, and
shut the compressor off.
Approximate oil pressure can be measured in the
field. Oil pumps are furnished with a Schrader valve
mounted on the oil pump discharge port. To measure oil
pressure, subtract crankcase pressure from discharge
oil pressure.
As a result of the elimination of the capillary tube
measuring system and a more precise timing circuit,
Sentronic will improve the overall reliability of the
refrigeration system.
Tripping of the oil pressure safety switch is a warning
that the system has been without proper lubrication
for too long a time. Repeated trips of the oil pressure
safety control are a clear indication that something in
the system requires immediate remedial action. On a
well designed system there should be no trips of the oil
pressure safety control, and repeated trips should never
be accepted as a normal part of the system operation.
Any Copeland compressor with the new oil pump
design (see AE4-1166) can utilize Sentronic. Any
Sentronic can replace existing capillary tube controls
in the field.
®
As in the past, all new and replacement Copelametic®
compressors equipped with oil pumps require the use
of an Emerson approved oil pressure safety switch.
Failure to use an approved oil pressure safety switch
will be considered as misuse of the compressor, and can
adversely affect warranty replacement of the compressor
should a lubrication connected failure occur.
Caution: An electronic timer may be placed in
series with the compressor contactor to force
a delay before each start and prevent possible
short cycling. The timer must be located so it also
prevents the Sentronic from energizing during the
timing period. SOME INEXPENSIVE TIMERS MAY
“LEAK” ENOUGH POWER, WHILE “TIMING OUT”,
TO ENERGIZE THE SENTRONIC EVEN THOUGH
THERE MAY NOT BE ENOUGH “LEAKAGE” TO
CLOSE THE COMPRESSOR CONTACTOR. THIS
To meet Emerson specifications, an oil pressure
safety switch must meet many requirements. These
include maintaining its pressure setting and time
delay calibration within close limits over the widest
variation in operating conditions to be expected, and
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CAN CAUSE A PREMATURE SENTRONIC TRIP.
To Install The Module, Figure 1:
If there is doubt, the circuit should be checked
before placing it in operation.
4. When using the bracket above the oil pump
use two 10-32 pan head slotted screws with
washers. The maximum screw length is .265
plus bracket thickness. Longer screws could
damage the circuit board.
The Sentronic Module
The Sentronic has in addition to the (N.C.) contact,
used for compressor shutdown, a Normally Open
(N.O.) contact that can be used in an alarm circuit (See
Diagram 4A).
5. Plug the cable from the module into the end
of the sensor. Care should be taken not to
wrap the cable around a current carrying
conductor.
The Single Pole Double Throw (S.P.D.T.) contact of
Sentronic can be electrically isolated from the control
circuit power supply, and used to control a circuit with
a different voltage (See Diagram 6).
Hi-Potting: Excessive hi-potting can cause damage to
the Sentronic module. Emerson hi-pots the module as
part of final processing. If hi-potting is required, we
recommend it to be limited to single time.
Sentronic has a timing circuit that actually compares
the amount of time with good oil pressure to that with
insufficient oil pressure and has a memory that will shut
the compressor down after a period of more than two
minutes if the compressor has a “history” of oil pressure
fluctuations with more unacceptable than acceptable
pressures.
Electrostatic Painting: Static electricity discharges from
electrostatic painting can damage the Sentronic module.
We recommend that the module not be mounted until
such painting is completed.
Remote Mounting the Sentronic Module
Sentronic also has a memory that retains the compressor
oil pressure “history” for up to one minute in the event
of a power loss.
The Sentronic sensor sends a low voltage signal to
the Sentronic module. When the Sentronic module is
mounted on the compressor the sensor will normally
experience no disturbance from nearby electrical
sources. The radiating power sources that can cause
problems are almost always in grounded metallic
enclosures. However, if the Module is located remotely
from the compressor, and the sensor leads are extended,
and/or routed along with other wiring, provisions must
be made to prevent interference with the sensor signal
which can cause nuisance trips or even damage to the
module itself. Observe these precautions:
Sentronic uses a permanent magnet integral with
the reset button to reset its output control relay in the
event of a trip. When the reset button is depressed, it
magnetically pulls the Sentronic relay's armature to its
original, reset position. Sentronic needs no voltage
present to reset.
INSTALLING SENTRONIC
All OEM Copeland® compressors with oil pumps shipped
after September, 1986, have a plug fitting in the oil pump
for mounting the sensor. The oil pump is designed to
accept either the Sentronic sensor or a capillary tube
for the traditional mechanical oil pressure control.
1. Sensor leads must be replaced with a
shielded cable. The shield should extend from
the Sentronic module to the female sensor
connector and should be grounded only at the
module end.
To Install The Sensor, Figure 1:
1. Remove the plug fitting from the oil pump
housing. Discard the copper washer from under
the head of the plug fitting.
2. The Sentronic module has a good grounding
source when mounted to the compressor.
When it is remote mounted, it must have
sufficient grounding area to minimize the
effects of high level electrical transients and
secondary lightning effects. A metal enclosure
with minimum mounting surface area of 75 sq.
in. is required.
2. Install a new O ring into the groove on the
sensor. Use refrigeration oil to pre-lube the O
ring before installation. Use care not to cut the
O ring.
3. Install a new copper washer under the hex
flange of the sensor. Do not reuse the copper
washer removed with the plug fitting.
3. Emerson makes available an optional 10' shielded
cable designed especially for the Sentronic. The
cable is grounded per instruction 1.
Screw the sensor into the pump body.
Torque the sensor to 60-65 Ft./lb.
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Figure 1
Figure 2
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FIELD INSTALLATION CHECKS
SENTRONIC SPECIFICATIONS
Before installing Sentronic, determine if the existing oil
pump is equipped with the plug fitting for mounting the
sensor. If not, order the Sentronic Oil Pump Kit.
Cut-Out Cut-In Time Delay Max Control All Sentronics can be used to replace conventional
capillary tube style oil pressure controls in the field.
ELECTRICAL CONNECTION INSTRUCTIONS
Earlier four and five terminal Sentronics (see Fig. 2)
were electrically reset oil pressure switches. They
were wired to have power to reset! The current
Sentronic requires no power to reset and may be
directly mechanically and electrically interchanged
with any mechanical oil pressure switch.
CAUTION!! Damage to the Sentronic module
will result if the “M” terminal of the Sentronic is
connected to ground or directly to line voltage!
When changing components or making any kind of
electrical alterations to any installation, existing or
new, all ground connections must be specifically
checked to make sure they are secure. If there is
any doubt about component or system grounding,
the local electrical inspector should be consulted.
If the Sentronic module is to be remote mounted from
the compressor and/or its sensor leads are to be routed
along with other voltage lines, the Sentronic Remote
Mount Instructions must be followed.
The electrical connection diagrams included in this
bulletin are intended to represent the most common
Sentronic application control circuits. The system
manufacturer should be consulted when more complex
circuits are encountered.
Wiring differences exist from one system manufacturer’s
unit to another. If wiring modifications are unclear,
consult a certified electrician. No wiring modifications
are required for compressors using solid state motor
protectors.
Standard Control Circuits
START-UP QUICK CHECKS
Both Diagrams 3A (new Sentronic) and 3B (previous
Sentronic) show typical wiring connections and the
similarity of Sentronic and Sentronic oil pressure
switches used on three-phase motor compressors.
Checking The Sensor
Unplug the sensor and start the compressor.
Simultaneously measure the oil pump differential
pressure. Monitor the two terminals at the back of the
sensor with an ohmmeter or continuity measuring set.
If the differential pressure is below the range of 7 to 9
PSID, the sensor circuit should be open (no continuity,
infinite resistance). If the pressure is above 12-14 PSID,
the sensor circuit should be closed.
Sentronics are energized when they are connected to
a voltage source. In both diagrams 3A and 3B, if the
compressor controlling and overload devices are closed,
the compressor starts and at the same time, a circuit
is made from one side of the power two incoming lines
to the “L” terminal. The “L” terminal is one side of the
“L”-“M”, N.C. contact of the Sentronic module. The "M"
side of the N.C. contact is usually connected to the
compressor contactor coil. The circuit for the electronic
module power is completed by the connection of the
230/ 240 (or 115/120) volt terminal to the other side of
the incoming power line.
Checking the Installed Sentronic Module*
Shut off the compressor. Unplug the sensor. Verify the
module is powered by reading control voltage between
the 208-230/240 (or 115/120) terminal and the L (or 2 if
separate control is used) terminal.
Start the compressor with the sensor unplugged.
Recheck to make sure the module voltage is still
present. After 120 seconds ±15 seconds, the L-M
contact should open and shut off the compressor.
The electronic two minute timing circuit operates
whenever voltage is applied to a Sentronic, and it
has not tripped. The timing will be interrupted when
oil pressure rises above 12-14 PSID and closes the
Sentronic sensor. Should oil pressure not build up
sufficiently for 120 seconds, the electronic delay will
time out, open its L-M contact, break the control circuit,
and de-energize the compressor contactor to stop
compressor operation.
With the module off on oil pressure, wait 2 minutes and
press the reset button. Module power is required to reset
the 4 and 5 terminal Sentronics. The contactor should
close and start the compressor.
*NOTE: More complete step-by-step procedures for
bench and system Sentronic checks are included on
pages 7 and 8 of this bulletin.
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7-9 PSID
12-14 PSID
120 Seconds ±15 Seconds
720 VA; 120/240V
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Copeland
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While the compressor is running, if the compressor net
oil pressure falls below the cut-out setting of the sensor
while operating, and does not re-establish sufficient
pressure within an acceptable time, the time delay
circuit will open the L-M contacts, stopping compressor
operation. Once the oil pressure switch has tripped,
it must be manually reset to restore the system to
operation.
safety switch will trip. Even though the compressor
motor cools sufficiently for the internal inherent protector
to automatically reset, the compressor cannot start until
the oil pressure safety control is manually reset.
This is normally not a problem, since the compressor, if
properly applied, will seldom if ever trip on the internal
inherent protector. If it should happen to do so, the
fact that a protector trip has occurred, indicates that
the system operation should be reviewed. However,
on frozen food or other critical applications where a
product loss may occur, if a compressor shutdown
should occur during the night, or over the weekend when
the equipment in unattended, it may be desirable to
prevent a possible nuisance trip by means of a current
sensing relay.
IMPORTANT: If a power interruption occurs after an oil
pressure safety trip, wait two minutes before resetting
after power is restored.
Control With Alarm
Diagrams 4A (new Sentronic) and 4B (previous
Sentronic) use an added alarm circuit. To contrast the
4 and 5 terminal Sentronics with the new Sentronic.
The new Sentronic does not require an extra relay or
auxiliary contact for an alarm circuit.
The Penn R10A (Johnson Controls) current sensing
relay has been developed for this purpose. It is mounted
on the load side of the contactor, senses by induction
the full operating current of one phase of the motor,
closes on a rise in current above 14 amps, and opens
if the load current falls below 4 amps.
The Current Sensing Relay Used With
Compressor Inherent Motor Protectors:
Compressors equipped with internal inherent protection
and oil pressure safety controls, will trip the oil pressure
safety control if the internal inherent protector should
open due to motor overheating or a temporary motor
overload.
The use of the current sensing relay allows the
compressor to cycle on the internal inherent protector
without affecting the operation of the oil pressure safety
control.
After an overload trip of a compressor with an
inherent protector the control circuit will still be
closed, and the Sentronic energized, although the
compressor motor is not operating. The two minute
timing circuit will activate due to a lack of oil pressure,
and after the 120 second time delay, the oil pressure
Both Diagrams 5A and 5B use a current relay (C.S.).
When the current relay is not energized by motor
current, its Normally Open (N.O.) contact opens the
circuit that powers the Sentronic to avoid a nuisance trip.
Diagram 5B shows the circuit used with the older model
Sentronic. An external control relay, "R", is required
to maintain power to the module in the event of an oil
pressure safety trip since the module requires power to
reset. When the module is tripped on low oil pressure,
relay "R" is not energized, and the relay "R" Normally
Closed (N.C.) contact provides a voltage path to the
module.
The circuit of Diagram 5A uses the new Sentronic.
The current relay operates in the same manner as in
Diagram 5B, but the oil pressure switch requires no
power to reset, so it needs no external relay to provide
a reset power path.
NOTE: On some 550 volt motor-compressors, it may
be necessary to loop the current carrying wire so that
it passes through the current sensing relay twice in
order to increase the metered amperage to close the
relay contacts.
Diagram 6
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Using a Separate Control Voltage With
the New Sentronic:
between the “M” terminal and the “120” terminal. It
should be the same as the electrical outlet voltage
- about 120VAC.
Diagram 6 shows how the current Sentronic might
be used with a voltage on its S.P.D.T. contact that is
different from the voltage that supplies its power. Any
A.C. voltage up to and including 240V might be used.
4. Since there is no connection made to the pressure
sensor, the module sees this as a no-oil pressure
condition. After two minutes (plus or minus 15 seconds - dependent on 50 or 60 cycle frequency) the
Sentronic internal timer will “time-out”. The module
will trip; the circuit between “L” and “M” will open,
and it will no longer pass current to the load.
To use the Sentronic contact (S.P.D.T.) for a separate
voltage, remove the jumper between terminals "2"
and "M". In this diagram, the separate control voltage
is supplied by "LL1" and "LL2". The separate voltage
powers the compressor contactor (CC), by means of a
Remote Relay. When the Remote Relay is energized,
requesting the compressor to run, its contact, (RR),
closes to deliver "LL1" voltage to the operating and limit
contacts. If the contacts in the operating and limit circuit
are closed, "LL1" voltage energizes the compressors
contactor coil (CC). When the compressor contactor
closes, it provides the power, through a control circuit
transformer (XFMR), to energize the Sentronic. If the
Sentronic trips, it contact ("L" to "M") in the "LL1-LL2"
control circuit opens to deenergize the compressor
contactor and stop the compressor. The Sentronic
contact ("L" to "A") closes to energize an Alarm Relay
(AR).
5. With the voltmeter connected to terminals “M”
and “120”, the voltage should now read zero volts
because the circuit between “L” and “M” has been
opened through the action of the electronic circuit.
ELECTRICAL BENCH CHECKOUT PROCEDURE
6. Reset the Sentronic, then remove voltage from
terminals “120” and “L”. With a small piece of wire,
jumper the female sensor connections at the end of
the black sensor cord attached to the module. Reapply power to terminals “120” and “L” and wait two
minutes. The module should not “time-out” after two
minutes because jumpering the sensor connections
makes the timing circuit “see” good oil pressure.
The jumper imitates the action of a small pressure
switch located in the sensor. This switch opens on
low oil pressure and closes on good oil pressure.
This instruction sheet describes how the sentronic may
be easily bench-checked using only a voltmeter and a
120VAC electrical extension cord.
7. Measure between the “120” terminal and the “M” terminal with the voltmeter. The meter should read full
line voltage showing that the circuit has not opened.
CAUTION!
8. To check if the module will operate on 208/240 volts
as well as on 120 volts, change the scale of the voltmeter (if necessary), to read up to 250VAC. Without
removing power, measure the voltage between the
“M” terminal and the “240” terminal. You should read
nearly twice the voltage as that read between the
“M” terminal and the 120“ terminal. This is because
Sentronic has a small control transformer connected
so that it can accept either 120V or 208/240V. It’s
self-transforming action actually enables it to step
up its own voltage. By making this voltage check,
the transformer is being checked.
Damage to the Sentronic module may result if
the “M” terminal of the Sentronic is connected to
ground or directly to a voltage line!
This test is conducted with 120VAC. A shock will
result if the Sentronic terminals are touched when
the Sentronic module is energized.
Use care whenever working with any voltage! Make
sure your electrical outlet is grounded, the electrical
extension cord used has a ground wire, and the
ground wire is connected to the grounding screw
of the Sentronic.
9. If the module successfully passes the above test
sequence it is fully functional. If the module fails
any of the above steps, it is faulty and should be
replaced.
1. Apply 120VAC power to the Sentronic module
terminals marked “120” and “L”. The Sentronic
should have a jumper in place between terminals
“M” and “2”.
2. Wait two minutes, then push the Sentronic reset button to reset the module and start the timing circuit.
3. With a voltmeter, measure line voltage (120VAC)
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AE8-1275 R9
How to Check a Sentronic Installed in a System
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AE8-1275 R9
Diagram (3A)
The Sentronic+TM oil pressure safety control replaces
the current Sentronic. The Sentronic+TM is a direct
replacement for mechanical devices and the current
Sentronic. The Sentronic+TM control offers the following
features:
Diagram (4A)
Cap Tube Elimination
Standard control with added alarm circuit
Diagram (5A)
Sentronic+TM continues to add system reliability by
removing the traditional cap tube oil pressure controls
that are prone to refrigerant leaks.
Standard control with alarm and current sensing relay circuit
Diagram (6)
Precise Timing
Identical to the current Sentronic the Sentronic+TM
uses a precise timing circuit that is not susceptible to
low voltage or brown out conditions. The memory in
the timing circuit remains the same, comparing low vs.
sufficient oil pressure time.
Checking the Sensor
Unplug the sensor and start the compressor. The
Sentronic module LED should be red. Simultaneously
measure the oil pump pressure vs. crankcase pressure.
Monitor the two terminals at the back of the sensor with
an ohmmeter. If the differential pressure is below the
range of 7 to 9 PSID, the sensor circuit should be open.
If the pressure is above 12 to 14 PSID, the sensor circuit
should be closed.
The Sentronic+TM has added an electronic noise
suppression feature that no longer requires the use of
shielded cables.
LED Diagnostics
Additional diagnostic capabilities have been added to
provide instant status of oil control.
Checking the Installed Sentronic+TM Module
• LED GREEN
Compressor has sufficient oil pressure
Shut off the compressor. Unplug the sensor. Verify the
module is powered by reading control voltage between
the 240V (or 115V) terminal and the L (or 2 if separate
control is used) terminal.
• LED RED
Compressor has experienced insufficient oil
pressure for longer than two minutes
Compressor is off on oil control
Start the compressor with the sensor unplugged.
Recheck to make sure the module voltage is still present.
After 120 seconds +/- 15 seconds, the L-M contact
should open and shut off the compressor.
• RED/GREEN FLASHING
Compressor is experiencing erratic oil pressure indicating a possible system issue
INTERCHANGEABILITY OF SENTRONIC™ AND
SENTRONIC+™ MODULES AND SENSORS
• NO LIGHT
Control circuit is not energized
The new Sentronic+™ oil pressure control uses both
a new module and a new sensor. The sensors and
module can be made compatible with older generation
components if the following steps are taken:
Sentronic+™ Specifications
7-9 PSID
12-14 PSID
120 Seconds+/-15 Seconds
500 VA; 120/240V
60-65 Ft./lb.
To use a Sentronic+ module with an older Sentronic™
sensor, the original Sentronic sensor cable must be
wired to the new Sentronic+ module.
Wiring
To use an older Sentronic module with a Sentronic+
sensor, the new Sentronic+ cable must be wired to the
Sentronic module.
The Sentronic+TM wiring remains the same. There are
several wiring schemes depending on control circuit
components. They are shown on pages 5 and 6.
© 2010 Emerson Climate Technologies
Printed in the U.S.A.
Standard control with alarm, current sensing relay and separate control voltage
START-UP QUICK CHECKS
Electrical Noise Suppression
Cut-out
Cut-in
Time Delay
Max Control
Sensor Torque
Standard control circuit
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There is an older generation Sentronic module which
is fully compatible with the new Sentronic+ sensor. It is
supplied with the new (Sentronic+) cable which is gray
for identification purposes, see illustration below.
New Sentronic+
Removing the cable from the new Sentronic+ module:
Old Sentronic
•
Remove the cover from the Sentronic+ module
•
Pull the 2 cable quick connects from the circuit
board (these are labeled “Org” and “Red”)
•
Remove the wires from the strain relief (note
the routing of the wires for future reference) and
lift the wires out
•
Remove the wire cable from the module by
twisting the conduit counterclockwise and
gently pulling
Connecting the old cable to the Sentronic+ module:
Connecting the Sentronic+ module to an older Sentronic
sensor
•
Trim approximately 2” of cable sheathing from
the module end of the old cable, taking care not
to nick the wire insulation
•
Feed the wires into the module through the hole
in the bottom of the case
•
Leaving enough lead length to reach the quick
connects, push the wires into the strain relief.
•
Connect the 2 quick-connects to the “ORG”
and “RED” spades. (Note: the connections may
be interchanged; there is no polarity on these
wires). Refer to the figure below.
•
Install the module to the compressor and make
wiring and sensor connections per the general
instructions.
Removing the cable from the old Sentronic module:
•
Disconnect power to the old module
•
Disconnect the cable from the sensor
•
Remove the cover from the old module
•
Remove the two cable quick connections from
the circuit board
•
Using pliers, squeeze the strain relief slots and
pull to remove the cable from the module
•
Remove the old module from the compressor
STRAIN RELIEF
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Connecting the old Sentronic module to a newer
Sentronic+ sensor
• Connecting the new cable to the old Sentronic
module:
Removing the cable from the new Sentronic+ module:
• Position the strain relief on the new cable at the
termination of the conduit
• Disconnect power to the module
• Disconnect the cable from the sensor
• Feed the wires into the module through the hole
in the bottom of the case
• Remove the cover from the Sentronic+ module
• Push the strain relief into position to lock it
• Pull the 2 cable quick connects from the circuit
board (these are labeled “Org” and “Red”)
• Connect the two quick connects to the circuit
board. There is no polarity on the leads.
• Remove the wires from the strain relief by lifting
the wires out
• Install the module on the compressor and make
wiring and sensor connections per the general
instructions
• Remove the wire cable from the module by
twisting the conduit counterclockwise and
gently pulling
Sentronic+ Terminal Strip
• The Sentronic+ module terminal strip is
designed to accept a bare wire end instead of
a spade terminal
• Removing the cable from the old Sentronic
module:
• If a Sentronic+ module is being retrofitted to a
system with spade connections, the spade may
be clipped off and ¼” of the wire end stripped.
Or, one leg of the spade may be clipped off for
insertion into the terminal strip
• Remove the cover from the old module
• Remove the two cable quick connections from
the circuit board
• Using pliers, squeeze the strain relief slots and
pull to remove the cable from the module
• Retain the strain relief from the cable for use
on the Sentronic+ cable
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