For Down Discharge

For Down Discharge
ICP
INSTALLATION INSTRUCTIONS
for Economizer NPECOMZR004A00
ICP's economizer is convertible-it will work in either a down discharge or horizontal discharge application. Read these instructions completely and carefully before beginning installation.
ILL. 1
For Down Discharge
Compressor
Compartment
(for Horizontal Application go to page 4)
1. Unpack top and bottom filter racks and filters.
Remove the side panel from the HVAC unit,
ILL 1. Discard panel.
2. Install bottom rack. Slide rack over to right side
(when facing coil) of HVAC unit. Set rack in
front of coil and screw rack to coil frame
through pre-punched hole. Maximum screw
length 1/2".
3. Install top rack. Slide rack over to right side of
HVAC unit. Set rack in front of coil and screw
rack to coil frame. Maximum screw length
1/2". Blank-off should fit between top and
bottom racks to the far left of HVAC unit.
(If using 1" filters, spacer may need to be
removed to position blank-off. Once blank-off
is in position, re-install spacer.)
Side Panel shipped
with HVAC unit.
Remove and discard.
Rack Detail
Blank-off
ILL. 2
Top filter
rack
Evaporator
Coil
4. If using 2" wide filter, remove spacer from top
and bottom filter racks. (ILL. 3.)
5. To change filter:
• Open hinged door.
• Remove middle filter first. Slide remaining
filters to middle of rack for removal.
• To install filters, reverse above operation.
HVAC unit
screws
Bottom filter
Spacer for
1" filter
ILL. 3
Bottom filter rack
Screw
Manufacturer reserves the right to discontinue, or change at any time, specifications, designs and prices without notice and without incurring obligations.
Form No. 5056-1P
Copyright MicroMetl Corporation 2005. All rights reserved.
519 06 1201 00
Down
Discharge
ILL.5
Install additional screw
through HVAC unit flange into
replacement panel.
13
Replacement panel.
Shipped with
economizer
7 / 6"
1
23 9/16"
Coil
Install 3/4" x 1/8"
gasket along
divider flange
Divider
Divider w/HVAC unit
Gasket
Top View
3/8"
flange
Alignment
holes
Horizontal filter
access door
23 7/16"
Relief
Blade
Detail
Damper
actuator
1/2" flange
MicroMetl
economizer
Install 3/4" x 1/8"
gasket along
economizer bottom
flange
Economizer
Add 3/4" x 1/8"
cover panel
gasket here
28 ½"
5. Install the replacement panel (shipped with the economizer) over the compressor compartment of the
HVAC unit. Screw in place through the prepunched holes.
6. Slide the economizer into the return air chamber, ILL. 5. Slide the economizer as far to the left as possible. The economizer's right side will slightly overlap the bottom filter rack and divider, see details. Be
sure economizer is flat.
7. Route the economizer wiring harness through the grommet in the economizer side and through the
HVAC units provided hole located in the upper part of the HVAC unit divider. (Install provided grommet in
divider hole of HVAC unit.) Follow the included harness routing diagram. (see page 9)
8. Install 3/4" x 1/8" gasket along economizers bottom flange. Install cover panel over the economizer. Slide
panel underneath HVAC unit flange. Screw in place to the divider, in the HVAC unit, base and top. Also,
align economizers 3/8" flange to the outside of 1/2" flange as shown and secure economizer cover panel
to economizer using provided pre-punched alignment holes with 1" long tek screw.
2
519 06 1201 00
Down
Discharge
9. Screw the rainhood to the economizer panel
through prepunched holes. Caulk the mating
flanges of the rainhood. The top flange of the
hood slips underneath the HVAC unit flange.
After adjusting the minimum position setting on
the actuator, install the 24 3/8" x 19 3/8" aluminum
filter in the rain hood.
ILL. 6
Filters
11. Remove the cover panel shipped over the
horizontal return opening. Locate the filter access panel and door latch angle. Install door
latch angle. Screw the hinge to the HVAC unit
over the horizontal return opening. Adjust the
closure handles for a tight seal.
12. Install the provided filter access sticker on the
hinged door.
Horizontal supply
air cover panel.
Shipped on HVAC
unit.
Aluminum water
entrainment
filter
ILL. 7
*Barometric relief
damper
SIDE VIEW
Down Discharge
*Barometric damper
Replacement
panel
relieves approximately
25% of total system
air. Actual relief will
vary depending on job
site conditions.
"
Rainhood
Door latch
angle
13. Be sure the seams are all water tight. Seal as
required.
22 1/16"
Filter access
door - hinged
Install filter
access door
sticker
Aluminum
Filter
14. Follow the wiring instructions enclosed.
(see page 7, 8)
TOP VIEW ILL. 8
Filter
Coil
Screw
Unit panel
Compressor
Door latch
angle
Hinge
0"
DOOR LATCH ANGLE
DETAIL
Economizer
Hood
3
519 06 1201 00
Replacement
Panel
Horizontal
Discharge
For Horizontal Discharge
(for Down Discharge Application go to page 1)
1. Unpack top and bottom filter racks and filters.
Remove the side panel from the HVAC unit,
ILL. 1, discard the panel.
Compressor
Compartment
2. Install bottom rack. Slide rack over to right
side (when facing coil) of HVAC unit. Set rack
in front of coil and screw rack to coil frame
through pre-punched hole. Maximum screw
length 1/2".
3. Install top rack. Slide rack over to right side of
HVAC unit. Set rack in front of coil and screw
rack to coil frame. Maximum screw length
1/2". Blank-off should fit between top and
bottom racks to the far left of HVAC unit. (If
using 1" filters, spacer may need to be removed to position blank-off. Once blank-off is
in position, re-install spacer.)
Side Panel shipped
with HVAC unit.
Remove and discard
Blank-off
Top filter
rack
4. If using 2" wide filter, remove spacer from top
and bottom filter racks. (ILL. 3.)
5. To change filter:
• Remove horizontal filter access door on
economizer cover panel.
• Remove middle filter first. Slide remaining
filters to middle of rack for removal.
• To install filters, reverse above operation.
HVAC unit
screws
Bottom filter
Rack Detail
ILL. 2
Spacer for
1" filter
ILL. 3
Bottom filter rack
Screw
4
519 06 1201 00
Evaporator
Coil
Horizontal
Discharge
ILL. 6
Install provided grommet in
HVAC unit divider.
Replacement panel
Shipped with economizer
Install additional screw
through unit flange into
replacement panel.
13 7/16"
Divider w/HVAC unit
9
23 /16"
23 7/16"
Divider
Gasket
Horizontal filter
access door
Install 3/4" x 1/8"
gasket along
HVAC bottom Install
3/4" x 5/8"
Gasketing,
Economizer
3 Sides.
Economizer
Blank-off
blank-off
Detail
(see detail)
Economizer
blank-off
Coil
Install 3/4" x 1/8"
gasket along HVAC
divider flange.
Alignment
holes
Economizer
cover panel
Screw
into base
Caulk these corners
after economizer is
installed
Remove molded gasket
from economizer for
horizontal application.
6. Install the replacement panel over the compressor compartment. Screw in place through the
prepunched holes.
7. Install provided economizer blank-off to bottom of economizer. Screw in place through the prepunched holes.
8. Install the 3/4 x 5/8" gasketing on the bottom flanges of the economizer (shaded area), ILL. 6.,
(economizer is shown in rotated position.)
9. Rotate the economizer on its side as shown, ILL. 6. Slide the economizer into the cabinet and as
far to the left as possible. The economizer will set against the left side of the HVAC unit. Caulk as
required.
10. Install the economizer cover panel over the economizer. Slide panel underneath HVAC unit flange.
Screw in place to the divider in the HVAC unit, base and top.
11. Align the economizer to the cover panel with 1" long tek screw using the provided pre-punched
alignment holes.
NOTE: The relief damper must be sealed shut for the horizontal discharge application.
5
519 06 1201 00
Horizontal
Discharge
HVAC Unit
ILL. 7
Replacement panel
shipped with economizer
Filter access door for
horizontal application
Install filter access
door sticker.
22 1/16"
Rainhood with
water entrainment
filter
The side hinged panel and
horizontal cover panel will not
be used in the horizontal
application.
11. Route the economizer wiring harness through
the grommet in the economizer side and
through the HVAC unit's provided hole located in the upper part of the HVAC unit
divider. (Intall provided grommet in divider
hole.) Follow the harness routing diagram.
(see page 9)
14 1/8"
12. Screw the rainhood to the economizer panel
through the prepunched holes. Caulk the
mating flanges of the rainhood. The top
flange of the hood slips underneath the
HVAC unit flange. An extended socket will be
required for the left side of the hood. After
adjusting the minimum position setting on the
actuator, install the aluminum filter in the
rainhood. Install the provided filter access
sticker on the horizontal filter door.
16"
ILL. 8
13. Follow the wiring instructions, see page 7,8.
6
519 06 1201 00
Wiring Diagram for Economizers (not Heat Pump) - NPECOMZR003A00 & NPECOMZR004A00
Gray
Discharge
Sensor 4
Equipment
Transformer
Orange
s
+
Green
Yellow
Main 24V
Splice Box
Dry Bulb
outside air
sensor
(or optional
enthalpy)
ACTUATOR
Yel.
TR
2
Brn.
L1
L2
3
Gray
SO
Resistor
SR
9
Brown
TR1 Economizer
+
+
TR
24 VAC
TR1
8
resistor
6
1S
1K
1
Red
Blue
White
7
Red
1
2
3
4
5
3
4
T
T1
P
P1
2K
1S1
T1
Min.
Pos
P1
P
5
1
NOTES:
T
2
WIRING LEGEND
OPTIONAL LOW AMBIENT CONTROL
TRANSFORMER IN HVAC UNIT.
Terminals
Wire nut of equivalent connection
POWER SUPPLY. DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
MUST BE INSTALLED ON SUPPLY AIR FAN. 3000 OHM AT
25 C, 77 F
REMOVE JUMPER WHEN OPTIONAL REMOTE
POTENTIOMETER IS USED
1S IS AN ELECTRONIC SWITCH WHICH CLOSES WHEN
POWERED BY A 24 VAC INPUT.
RELAY 1K & 2K ACTUATE WHEN THE OUTSIDE AIR
7 SENSED BY THE ENTHALPY OR DRY BULB IS LOWER
THAN THE SET POINT A-D.
FACTORY INSTALLED 620 OHM, 1 WATT, 5% RESISTOR
8 SHOULD BE REMOVED ONLY IF A SENSOR IS ADDED TO
SR AND + FOR DIFFERENTIAL CHANGEOVER.
9 RESISTER ONLY REQUIRED FOR FIXED DRY BULB.
Discharge
Sensor
Grn.
7
Minimum
Position
Green
5
MMC wiring harness
Optional Remote
Potentiometer
Field supplied low voltage wire
L
R
W1 G
Y1 Y2
Field supplied high voltage wire
Other low voltage wire
6
2- STAGE
THERMOSTAT
CAUTION
1. Disconnect power supply before
connecting writing to prevent
electrical shock or equipment damage
Form No. 2387-6PW
519 06 1201 00
Wiring Diagram For Economizers with Heat Pump
Gray
Gray
Discharge
Sensor 4
3
Main 24V
Splice Box
ACTUATOR
YEL.
L2
2
R1
ORANGE
resistor
11
R1
N.O.
BROWN
9
11
TR
TR1
SO
+
SR
+
Economizer
1
BLUE
WHITE
8
R1 11
1
TR1
8
6
1S
1K
RED
RED
Dry Bulb Outside
Air Sensor
(or optional enthalpy)
resistor
620
7
VOILET
TR
24 VAC
5
GREEN
NOTES:
s
+
2
3
4
T
T1
P
P1
T
2K
1S1
T1
Min.
Pos
P1
P
Discharge
Sensor
YELLOW
L1
Orange
Green
Minimum
Position
Equipment
Transformer
WIRING LEGEND
5
Terminals
1
OPTIONAL LOW AMBIENT CONTROL.
EQUIPMENT TRANSFORMER MUST BE SIZED TO ACCOMMO2 DATE AN ADDITIONAL 12VA. IF NOT, AN ADDITIONAL
OPTIONAL TRANSFORMER IS REQUIRED.
POWER SUPPLY. DISCONNECT MEANS AND OVERLOAD
3 PROTECTION AS REQUIRED.
MUST BE INSTALLED IN SUPPLY AIR STREAM. 3000 OHMS
4 AT 25ºC, 77ºF
REMOVE JUMPER WHEN OPTIONAL REMOTE POTENTIOM5
ETER IS USED
1S IS AN ELECTRONIC SWITCH WHICH CLOSES WHEN
6
POWERED BY A 24 VAC INPUT.
RELAY 1K & 2K ACTUATE WHEN THE OUTSIDE AIR SENSED
7 BY THE ENTHALPY OR DRY BULB IS LOWER THAN THE SET
POINT A-D.
FACTORY INSTALLED 620 OHM, 1 WATT, 5% RESISTOR
SHOULD BE REMOVED ONLY IF AN ENTHALPY OR ADJUST8
ABLE DRY BULB SENSOR IS ADDED TO SR AND + FOR
DIFFERENTIAL.
9 RESISTOR ONLY REQUIRED FOR FIXED DRY BULB.
R1- RELAY IS FIELD SUPPLIED AND FIELD INSTALLED. MOUNT
11
RELAY IN CONTROL BOX, ABOVE INDOOR FAN RELAY.
Wire nut or equivalent connection
Optional Remote
Potentiometer
MMC wiring harness
Field supplied low voltage wire
L
Field supplied high voltage wire
Other low voltage wire
R
W2 W1 G
O Y1
THERMOSTAT
Form No. 2387-6PW2
519 06 1201 00
Y2
CAUTION
1. Disconnect power supply before
connecting wiring to prevent electrical
shock or equipment damage
ECONOMIZER CONTROLS INSTALLATION
A
Routing
Wiring
Harness
Main 24V
splice box
Supply
fan
Discharge
sensor. Field
install.
Coil
Filter
Top View
Wiring harness. Factory
attached to economizer
actuator. Factory run to
splice box.
Economizer
Replacement panel
shipped with economizer
Damper
actuator
Dry bulb or
enthalpy
(optional)
Damper logic
module
Economizer
rainhood
A
Economizer
Water
entrainment
filter in hood
ACCESSORY SLIDE-IN
ECONOMIZER CONTROL
INSTALLATION.
1.
Unpackage economizer.
2.
Install accessory in unit per
installation instructions provided.
3.
Remove parts bag and instructions from inside of accessory.
4.
Install the discharge sensor in the
supply fan section. The sensor
must protrude into the supply air
stream. It should not interfere with
blower, etc.
5.
Uncoil the wiring harness.
Connect the two gray wires of the
harness to the discharge sensor
leads using the two wire nuts
provided.
6.
Route the remainder of the wire
harness through the unit to the
main 24V splice box.
7.
Mount thermostat downstairs per
the manufacturer’s instructions.
Run proper wire from the thermostat to the unit control panel.
8.
Review the wiring diagram from
this booklet . Connect unit , wire
from the thermostat and harness
from the economizer, together to
match the diagram.
9.
Follow start-up instructions below.
Economizer harness
from actuator
Economizer
rainhood
Main 24V
splice box
Supply
fan
Economizer
harness
10. Adjust change over setpoint on
logic module.
Damper actuator
and dry bulb or
enthalpy
Compressor
Discharge
sensor. Field
install.
"A-A" Side View
START-UP INSTRUCTIONS
1. After unit is wired begin start-up procedures.
2. Set thermostat functions to OFF. Set comfort levels to
minimum cool and minimum heat.
3. Turn unit power on following manufacturer's start up
instructions.
4. Turn thermostat fan function to ON. Unit indoor blower
should start and damper motor will drive to minimum vent
position. Minimum vent position should be adjusted on
the economizer logic for the proper percentage of outdoor
air.
5. Switch the thermostat function from OFF to HEAT or AUTO.
Bring the comfort setpoint for heat up to engage first stage
heating. Follow manufacturer’s procedures to check
heating cycle. Bring the comfort setpoint for heat up to
engage second stage heating if available. Check this
heating cycle also.
6. Under no circumstance should the economizer operate in
a heating mode except for minium vent position.
9
11. Adjust minimum position set point
on logic module.
7. Change the thermostat function from HEAT to COOL or
leave in AUTO. Drop the comfort setpoint down to engage
first stage call for cooling. The first stage cooling call
travels to the economizer. If the outdoor air is above the A
through D setpoint, (see chart on next page), the first
stage mechanical cooling is brought on. As the comfort
setpoint is reduced more there will be a second call for
cooling which will bring on second stage mechanical
cooling if available.
8. In the cooling mode if the outdoor air is below the setpoint,
the first stage call for cooling will open the economizer. As
the comfort setpoint is reduced more there will be a
second call for cooling. This call will bring on the first
stage mechanical cooling to back up the economizer.
9. Once all stages have been cycled, and all adjustments
made return thermostat to its proper operating mode,
replace all doors, panels and hoods.
10. Leave a copy of these instructions with the customer.
519 06 1201 00
System Description
These instructions are for fully modulating electronically controlled economizers utilizing solid
state logic throughout. A standard single or
(recommended) two stage thermostat is all that is
needed to complete the control and economizer
system for the HVAC equipment.
2
1
5
4
6
3
8
9
10
7
Component Description
6. Dry bulb...9901-0183 senses temperature of outside air
and provides signal to the economizer logic. Opens
outside air at 60°, closes outside air at 70° (enthalpy
optional).
1. Damper actuator ... 9901-0083 provides 24v modulating
control of economizer dampers, 25 in. lb. of torque.
(Honeywell M7415A-1006)
2. Ball joint for linkage connection.
7. 5/8" grommet fits 5/8" hole that wires may pass through to
keep from chaffing.
3. Discharge sensor ... 9901-0001 provides a signal (3000
Ohms at 25°C or 77°F) to the actuator during free cooling
or economizer mode. The signal opens the economizer
damper until the discharge temperature drops below 55°.
At this time the signal causes the motor to modulate the
damper and mix outside air with return air to maintain a
50° F. to 56° F. discharge temperature.
8. Wire clamps to secure wires to base, dividers, etc..
9. Wire harness color coded and pre-wired to actuator and
economizer logic... 9962-0087.
10. 1/2" hex head screws to secure wire clamps.
4. Wire nuts to connect discharge sensor to the harness.
5. Economizer logic ... 9901-0017 accepts input from
discharge sensor and outside air sensor. Analyzes input
to control actuator modulation and economizer switching.
Logic also houses minimum position adjustment and
enthalpy or adjustable dry bulb adjustment. When used
with optional differential sensors in the return air, the logic
is capable of selecting the most economical air available
for cooling. (Honeywell W7459A-1001)
10
519 06 1201 00
INTEGRATED ECONOMIZERS
The purpose of an economizer is to use outdoor air
for cooling , whenever possible, to reduce compressor operation.
The economizer system initially responds to a signal
from the cooling thermostat and functions as a true
first stage for cooling, while providing maximum fuel
economy. The economizer is automatically locked
out during the heating mode and holds the outdoor
air damper at the minimum position settings.
During the occupied period, on a call for cooling,
when outdoor air temperature or enthalpy (optional)
conditions are low, the economizer actuator will
proportion to maintain between 50º F and 56º F at
thermistor discharge sensor.
If the fully open actuator cannot satisfy the space
demand, mechanical cooling is sequenced on.
During the unoccupied period, the actuator will
override minimum position setting and drive fully
closed. On a loss of power, the actuator will spring
return fully closed.
When in heating operation, or when outdoor air
temperature or enthalpy (optional) conditions are
high, economizer operation is locked out, and
actuator is held at minimum position.
The staging relay is used when the first stage
compressors must provide mechanical cooling
when assisting the economizer.
If the mixed or discharge temperature is above 56º F,
actuator will open to admit additional outdoor air until
the temperature returns to the 50º to 56º F range. If
the mixed or discharge air temperature is below 50º
F, the actuator will proportion closed, shutting the
outdoor air damper until the temperature returns to
the 50º to 56º F range. During the occupied period,
the actuator will not close past the minimum
position.
11
The staging relay can be omitted when the second
stage compressors can be used to assist the
economizer with mechanical cooling.
519 06 1201 00
Minimum Position Adjustment
The minimum position potentiometer keeps the outdoor air
damper from closing completely during system operation
to provide ventilation.
2. If remote control of dampers is desired, connect the
remote potentiometer to P and P1 and turn it fully
clockwise before adjusting the minimum position.
1. Make sure the factory installed jumper is in place
across terminals P and P1.
3. Connect 24V AC to system and adjust the potentiometer on the face of the logic module with a screwdriver
for desired minimum position.
Enthalpy Changeover Setpoint (optional)
D
e
ampl
ex
C
B
A
DETERMINE MAXIMUM DRY BULB
TEMPERATURE FOR
ECONOMIZER CHANGEOVER
DETERMINE MAXIMUM RELATIVE
HUMIDITY FOR ECONOMIZER
CHANGOVER
Single enthalpy: The enthalpy changeover setpoints is set to
return the outdoor air damper to minimum position when the
enthalpy rises above its set point. The enthalpy setpoint
scale markings, located on W7459 are A,B,C,D as shown
below. The factory-installed 620-ohm jumper must be in
place across terminals + and SR unless using differential
enthalpy.
EXAMPLE FOR DETERMINING
ENTHALPY CONTROL SETTING
(1008-0100)
Differential Changeover Setting (optional)
Differential enthalpy control (optional) utilizes two enthalpy
sensors connected to one W7459 Economizer Control.
The enthalpy setpoint scale markings, located on the W7459,
are A,B,C,D. Turn the setpoint potentiometer fully clockwise
past the D setting. The economizer will select the air with
lower enthalpy for cooling; i.e., if outdoor air has lower
enthalpy than return air, then the outdoor air damper will be
opened to bring in outdoor air for free cooling. The differential
enthalpy connects to SR and + on the W7959 logic.
CAUTION
Exercise care when adjusting the changeover
set point and minimum position setting.
EXCESSIVE FORCE MAY DAMAGE THE
CONTROLS
Enthalpy Changeover Set
Point
Minimum Damper
Position Setting
Note: The C7650A adjustable dry bulb can also be used for
differential change over. Only the temperature of the outdoor
air and return air will be compared and the best selected for
free cooling.
LED Lights up to
indicate Outdoor Air is
Suitable for Free
Cooling
W7459 Logic Module
Manufacturerreservestherighttodiscontinue,orchangeatanytime,specifications,designsandpriceswithoutnoticeandwithoutincurringobligations.
Form No. 5056-1P
Copyright MicroMetl Corporation 2005. All rights reserved.
12
519 06 1201 00
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