Installation Instructions

Issue Date January 15, 2003

®

A419 Series Electronic Temperature Controls with NEMA 1 or NEMA 4X Watertight Enclosures

Application

IMPORTANT: The A419 Series Electronic

Temperature Controls are intended to control equipment under normal operating conditions.

Where failure or malfunction of an A419 control could lead to an abnormal operating condition that could cause personal injury or damage to the equipment or other property, other devices (limit or safety controls) or systems (alarm or supervisory) intended to warn of or protect against failure or malfunction of the A419 control must be incorporated into and maintained as part of the control system.

The A419 Electronic Temperature Control is a single-stage, electronic temperature control with a

Single-Pole, Double-Throw (SPDT) output relay. The control features a lockable, three-button touchpad for setup and adjustment and a Liquid Crystal Display

(LCD) which displays the sensed temperature and other control functions. A front panel Light-Emitting

Diode (LED) indicates the output relay status. The control has a setpoint range of -30 to 212°F

(-34 to 100°C) and is available in 24 VAC or

120/240 VAC models. See the Technical

Specifications section.

The A419 control has heating and cooling modes with adjustable setpoint and differential, an adjustable anti-short cycle delay, and a temperature offset

(setback) function. The control provides remote sensing capability, and electronic accuracy in a

Type NEMA 1 high-impact plastic enclosure suitable for surface or DIN rail mounting or a surface mount

Type NEMA 4X watertight and corrosion resistant enclosure. The temperature sensor supplied with the control is interchangable with compatible

Johnson Controls/PENN® A99 temperature sensors.

Canadian Compliance Statement

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the

Canadian Department of Communications.

FCC Compliance

This device complies with Part 15 of the FCC Rules.

Operation is subject to the following two conditions:

(1) this device may not cause harmful interference, and (2) this device must accept any interference that may cause undesired operation.

© 2003 Johnson Controls, Inc.

Part No. 24-7664-1539, Rev. B

This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to

Part 15 of FCC rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his or her own expense.

Installation

Refer to the following guidelines, procedures and illustrations when installing an A419 control.

Parts Included

Each A419 control includes a Johnson Controls/PENN

A99 temperature sensor. The sensor may be removed and replaced with any compatible Johnson Controls

A99 temperature sensor, or the wire leads on the sensor may be extended. See the Mounting and

Wiring sections for additional guidelines and restrictions when mounting and wiring the control.

Dimensions

9/64

(3.7)

2-3/8

(61)

1/2

(13)

2-15/16

(75)

DIN

Rail

1-9/16

(40)

1/4

(6)

7/16

(11)

Sensor

2

(50)

MENU

2-3/8

(61)

5

(127)

4

(102)

2-3/8

(61)

7/8

(22)

7/8

(22)

(1/2 in. Trade Size)

Conduit Hole

Figure 1: Dimensions for A419 Temperature

Controls with NEMA 1 Enclosures, in./(mm)

1

2-1/4

56

A419

MENU

1-3/4

44

6-5/8

168

6-1/8

155

1-1/16

27

Wiring

!

WARNING: Risk of Electrical Shock.

To avoid the risk of electrical shock, disconnect all power sources to the control before wiring any connections. More than one disconnect may be required to completely de-energized the control and equipment.

2-13/16

71

2-13/16

71

Position the A99 sensor in bracket at bottom of

A419 NEMA 4X enclosure.

Figure 2: Dimensions for A419 Temperature

Controls with NEMA 4X Enclosures, in./(mm)

Mounting

An A419 control has either a standard high-impact plastic NEMA 1 or a NEMA 4X watertight enclosure.

The A419 control is not position sensitive but should be mounted for convenient wiring and adjustment. The

NEMA 4X models may be mounted to flat vertical surfaces using the four screw holes at the enclosure

corners. See Figure 2.

Note: When mounting the control to rigid conduit, attach the hub to the conduit before securing the hub to the control enclosure. For a NEMA 4X model, use a watertight fitting rated for the ambient environment.

On NEMA 4X models select the knockout to be removed. Place a screwdriver blade on the knockout near the edge. Apply a sharp blow to the screwdriver handle to loosen the knockout. Be careful not to damage the control’s interior components.

An additional low-voltage, two-wire cable is required to operate the A419 control’s temperature offset function.

On NEMA 4X enclosures you must install a suitable water-tight fitting in an available knockout to pass the two-wire cable through the enclosure wall.

IMPORTANT: The short-lead A99 sensor, included with A419 NEMA 4X controls, must be mounted on the bottom of the control in the bracket on the NEMA 4X housing. Mounting the sensor on top of the control may reduce the accuracy of the

displayed temperature. See Figure 2.

IMPORTANT: All wiring must conform to local, national, and regional regulations. Use copper conductors only for all wire connections. Do not exceed the electrical ratings for the A419 control or the equipment it is wired to.

Observe the following guidelines and refer to Figure 3

and Table 1 when wiring the A419 control to your

equipment.

• Use wire no larger than 12 AWG when connecting to the two lower terminal blocks (TB1 and TB2).

• Use wire no larger than 16 AWG when connecting to the upper sensor terminal block (TB3).

• Wire insulation rating must be 90°C, minimum.

• A99 temperature sensors are not polarity sensitive. Wire the leads to (+) SEN and (-) COM

on the sensor terminal block (TB3). See Figure 3.

• Keep the leads between the control and sensor as short as possible/practical in your application. The additional resistance in long sensor leads creates error between the actual temperature and the

displayed temperature. Refer to Table 1 when

extending sensor leads.

• Temperature sensor signals may be affected by electrical interference. When extending sensor cable beyond 50 ft (15.2 m) use a twisted-pair, shielded cable to reduce electrical interference.

Table 1: Maximum Recommended Sensor Cable

Lengths and Wire Sizes

Wire

Gauge

16 AWG

18 AWG

20 AWG

22 AWG

Maximum Sensor Cable Length* feet (meters)

500 (150)

300 (100)

200 (60)

125 (40)

* At the listed maximum cable lengths there is less than

1F° (0.6C°) error in the actual temperature vs.

displayed temperature.

2 A419 Electronic Temperature Control with NEMA 1 and NEMA 4X Watertight Enclosures Installation Instructions

(Optional)

Binary

Input

Switch

TB3

24 VAC Application

A419GBF-1

A419GEF-1

(+) BIN

(–)

(+)

COM

SEN

Cable

Shield

(if used)

A99

Sensor

TB1

TB2

(Optional)

Binary

Input

Switch

Cable

Shield

(if used)

A99

Sensor

120 VAC Application

A419ABC-1

A419AEC-1

(+) BIN

(–)

(+)

COM

SEN

TB3

TB1

TB2

(Optional)

Binary

Input

Switch

240 VAC Application

(–)

(+)

A419ABC-1

A419AEC-1

(+) BIN

COM

SEN

TB3

Cable

Shield

(if used)

A99

Sensor

TB1

TB2

24 VAC

Class 2

Transformer

Load

120 VAC

Neutral Load

240

VAC

L1

L2 Load

Figure 3: Typical Wiring for the A419 Series Temperature Controls: 24, 120 and 240 VAC Applications

Setup and Adjustments

!

WARNING: Risk of Electrical Shock.

To avoid the risk of electrical shock disconnect all power sources to the control before opening control cover and repositioning jumpers. More than one disconnect may be required to completely de-energized the control and equipment.

Jumper

=

Installed

(Jumper Positioned on Both Pins)

IMPORTANT: To ensure that the output relay operates as intended, verify that all three of the jumpers are positioned properly for the application before powering the A419 control.

=

Pins

Removed

(Jumper Positioned on One Pin)

Figure 4: Positioning the Jumpers

IMPORTANT: The touchpad cannot be unlocked without a jumper installed across the P5 jumper pins. Do not discard jumpers in case they are

required in the future. See Figure 4 and Figure 5.

Positioning the Jumpers

The P5 jumper position determines if the touchpad is locked or unlocked.

The P4 jumper pin block has two pairs of jumper pins.

The top pair of pins (JUMP1), determines if the control is set for Heating or Cooling mode. The bottom pair of pins, (JUMP2) establishes whether Setpoint is at cut-in

or at cutout. See Figure 4 and Figure 5.

To position a jumper in the Installed position, place the jumper on both pins, which closes the circuit between the pins. To position a jumper in the

Removed position, place the jumper on one pin only.

See Figure 4.

Touchpad

Locked

Heating Mode

Cut-in at Setpoint

P5

JUMP2

P4

Cooling Mode

Cut-in at Setpoint

Heating Mode

Cut-out at Setpoint

Cooling Mode

Cut-out at Setpoint

Figure 5: Jumper Positions and Control Settings

A419 Electronic Temperature Control with NEMA 1 and NEMA 4X Watertight Enclosures Installation Instructions 3

Table 2: Jumper Designations, Jumper Positions and Control Settings

Function

Jumper Pins Designation on Control

Setting

Jumper

Position

Cooling Mode Removed

Cooling/Heating

Operating Mode

JUMP1

(Top Pair of Pins on Block P4)

Heating Mode Installed

Setpoint at

Cut-in or Cutout

Touchpad Lock

JUMP2

Setpoint at Cut-in

(Bottom Pair of Pins on Block P4) Setpoint at Cutout

Locked

P5

Unlocked

Removed

Installed

Removed

Installed

The A419 Control Functions

Setpoint (SP) establishes the temperature value at which the equipment is switched on or off, depending on the user selected mode of operation. Setpoint range is -30 to 212°F or -34 to 100°C (in 1-degree increments).

If Setpoint mode is set to cut-in, setpoint is the temperature value at which the control closes the

Normally Open (N.O.) contacts. If Setpoint mode is set to cutout, setpoint is the temperature at which the N.O.

contacts open.

Differential (dIF) establishes the difference in temperature between the cut-in value and cutout value. The differential is set relative to Setpoint and may be set from 1 to 30 F° or C° (in 1-degree increments).

Anti-Short Cycle Delay (ASd) establishes the minimum time that the output relay remains de-engergized before the next on-cycle. The ASd does not allow the output relay to re-energize until the programmed time delay has elapsed. The delay is activated when the control is first turned on and every time an on-cycle ends. When the delay is activated, the LCD alternately flashes the sensor temperature and ASd. The Anti-short Cycle Delay range is

0 to 12 minutes (in 1-minute increments).

Sensor Failure Operation (SF) establishes how the

A419 control’s output-relay operates the equipment in the event of a sensor or sensor wiring failure. The user may select to run the equipment continuously or to shut it down. When the control detects a sensor circuit failure, the LCD flashes SF alternately with OP (if the sensor circuit is open), or SH (if the sensor circuit is shorted).

Before indicating a failure, the control implements a

1-minute delay, which allows verification of failure condition and avoids nuisance failure indications.

Factory Default Setting

(and Jumper Position)

Cooling Mode

(Jumper Removed)

Cut-in

(Jumper Removed)

Unlocked

(Jumper Installed)

Temperature Offset (OFS) establishes a set secondary Setpoint and Differential values that may be invoked to control an application when a circuit is closed between the binary input (BIN) and common

(COM) terminals (and BIN appears on the display).

See Figure 3. Offset range is 0 to 50F° or C° (in 1-

degree increments). A typical application might use a switching time clock to invoke night-setback temperature settings.

IMPORTANT: Make sure the Touchpad Lock jumper is installed (unlocked) before attempting to

adjust the A419 control functions. See Figure 5.

Changing the A419 Control Temperature Units

The A419 control is factory set to display Fahrenheit temperature. To change to Celsius, press Up and

Down (arrows) simultaneously. Press them again to display Fahrenheit units. Verify that the control is displaying the desired temperature units before setting the Setpoint.

Setting the A419 Control Setpoint Value

To view and adjust Setpoint, follow these steps:

1. Press and hold MENU (about 2 seconds) until the display flashes SP.

2. Press MENU again to display the existing setpoint value.

3. Press Up or Down (arrows) to change the setpoint value.

4. Press MENU again to save the new value. The display returns to the sensed temperature.

Note: If no setup entry is made for 30 seconds, the control reverts to the (normal) temperature display.

4 A419 Electronic Temperature Control with NEMA 1 and NEMA 4X Watertight Enclosures Installation Instructions

IMPORTANT: If MENU is not pressed after changing the setpoint value, the control reverts to the previously programmed setpoint value.

BIN

F

Temperature

Offset Indicator

Temperature

Units Indicator

Operating Mode

Indicator

3. Press MENU to display the function’s current value.

4. Press Up or Down (arrows) until the desired value is displayed.

5. Press MENU to save the new value. The display returns to the sensor temperature.

MENU

Liquid Crystal

Display

MENU Button

DOWN Arrow

Button

UP Arrow

Button

Output Relay

Status Indicator

LED

Figure 6: Liquid Crystal Display, Touchpad, and

LED Indicator

Setting the Other A419 Control Functions

To set the Differential, Anti-short Cycle Delay,

Temperature Offset, or Sensor Failure operation, use the following method.

1. Press and hold MENU until the display changes to flashing SP. (This takes about 2 seconds.)

2. Press Up or Down (arrows) repeatedly until the

desired function is displayed. (See Table 3.)

IMPORTANT: If MENU is not pressed after changing the settings, the new settings are not saved and the control reverts to the previously programmed setting values.

Note: If no setup entry is made for 30 seconds, the control reverts to the (normal) temperature display.

Note: Any saved A419 control settings are

non-volatile and remain in the control’s memory during power interruptions.

IMPORTANT: Do not set Setpoint and

Differential values which (when totaled) fall out of

A419 control’s Setpoint range (-30 to 212°F

[-34 to 100°C]). The control will not function properly if Cut-in or Cutout values are outside of the control’s

Setpoint range.

Checkout

Before applying power, make sure installation and wire connections are correct for your application. Then power, operate and observe the system and A419 control for at least three complete operating cycles before leaving the installation.

Table 3: Display Symbols, Control Function, Ranges, Units, Values, and Factory Settings

Display

Symbol

SP dIF

ASd

OFS

Control Function

Setpoint*

Differential*

Anti-short Cycle Delay

Temperature Offset

Range – Units/Value

-30 to 212 – °F (-34 to 100 – °C)

1 to 30 – (F° or C° in 1-degree increments)

SF

F or C

BIN

Sensor Failure Operation

Temperature Units

Temperature Offset Indicator

0 to 12 – (in 1-minute increments)

0 to 50 (F° or C° in 1-degree increments)

(No range)— 0 = output relay de-energized

1 = output relay energized

(No range) – F° or C°

(No range) – BIN is displayed and the A419 control operates on the secondary setpoints when the circuit between the BIN and COM terminals is closed.

5

1

0

Factory Set

Value

30

1

F°

N/A

or

Cooling or Heating Mode of

Operation

(No range) – (Cooling Mode) is displayed when the

Jump1 jumper is removed. (Heating Mode) is displayed when the Jump1 jumper is installed.

Cooling Mode

* The sum of the Setpoint and Differential values must be within the Setpoint range, or the control may not function properly.

A419 Electronic Temperature Control with NEMA 1 and NEMA 4X Watertight Enclosures Installation Instructions 5

Troubleshooting

!

WARNING: Risk of Electrical Shock.

Hazardous voltages may be present at electrical terminals and other exposed internal metal surfaces.

Do not touch any metal parts within the control when cover is removed. Any contact with metal parts, including with metal or conductive tools, may result in serious injury or death.

If the control system does not function properly, verify that the control is wired, and set up properly. If the problem persists, use the following procedures to determine the cause of the problem:

IMPORTANT: Follow these troubleshooting procedures in the order presented. Do not skip any of the steps in the procedures.

1. Check for proper voltage to the A419 control. a. Remove the cover by loosening the four captive cover screws.

b. Use a reliable AC voltmeter to check the voltage between the COM and 120V or 240V terminals on-line voltage models and the two

24V terminals on low-voltage models. Refer to

Figure 3.

c. The voltage must be between 20 and 30 VAC for 24 VAC applications, 102 and 132 VAC for

120 VAC applications, 177 and 264 VAC for

208/240 VAC applications.

d. If the voltage reading is not within the required range, check the power source and input power wires for problems.

2. Check for proper sensor operation. a. Disconnect all power sources to control.

b. Using an accurate thermometer, take a temperature reading at the sensor location,.

c. Disconnect the sensor from the control.

d. Using an ohmmeter, measure the resistance across the two sensor leads while the sensor is at the temperature taken in Step 2b.

e. Consult Figure 7 to verify that the measured

temperature and resistance conform to established temperature and resistance values.

f. If the measured values conform to the values

in Figure 7, proceed to Step 3.

g. If the sensor’s measured resistance value is substantially different from the expected value for that temperature, check the sensor wiring.

If sensor wiring is okay, replace the sensor.

Temperature (°F) Temperature (°C)

260

240

220

200

180

160

140

120

100

80

60

40

20

0

-20

-40

120

100

80

60

40

20

0

-20

-40

500 700 900 1100 1300 1500 1700 1900 2100

Resistance in Ohms

Figure 7: Temperature vs. Sensor Resistance

3. Check the A419 for proper operation.

Note: Perform Troubleshooting Steps 1 and 2 before performing this step.

a. Disconnect the load from the output relay terminals.

b. Ensure that the Touchpad Lock jumper is installed, so that the touchpad is unlocked.

c. Reconnect the sensor leads and supply power to the control.

d. Replace the cover.

e. Check the control settings for proper values.

f. Press and hold MENU until Setpoint appears

(This takes about 2 seconds).

the Setpoint temperature above and below the sensor temperature until the relay energizes

and de-energizes as shown in Table 5.

Note: If the anti-short cycle delay has a set delay-time value greater than 0 minutes when the control is powered On, the relay does not energize until the time delay has elapsed.

h. If the output relay does not perform as

indicated in Table 5, replace the A419 control.

i. If proper operation of the A419 control is verified, reconnect the load and consult the equipment manufacturer’s instructions for troubleshooting the controlled equipment.

6 A419 Electronic Temperature Control with NEMA 1 and NEMA 4X Watertight Enclosures Installation Instructions

Table 4: A419 Output Relay Operation in Different Operating modes

Setpoint

Mode

Cutout

Cut-in

Operating

Mode

Cooling

Heating

Cooling

Heating

Output Relay is Energized (closing the NO and COM contacts) at…

Setpoint plus differential

Setpoint minus differential

Setpoint

Setpoint

Output Relay is De-energized (opening the NO and COM contacts) at…

Setpoint

Setpoint

Setpoint minus differential

Setpoint plus differential

Fault Codes

If the LCD displays an alarm or fault code (SF or EE),

consult Table 5 for explanation.

Table 5: Fault Codes Defined

Fault Code Definition

SF flashing alternately with OP

Open temperature sensor or sensor wiring

SF flashing alternately with SH

EE

Shorted temperature sensor or sensor wiring

Program failure

Repairs and Replacement

Do not attempt to repair or recalibrate the

A419 temperature control. In case of a defective or improperly functioning control, contact your nearest

Authorized Johnson Controls/PENN Distributor or

Sales Representative.

When contacting your Johnson Controls/PENN

Distributor, have the model number of the control available. This number can be found on the label inside the cover of the control.

System Status

Output functions according to the selected sensor failure mode

(SF setting)

Output functions according to the selected sensor failure mode

(SF setting)

Output is off

Solution

See Troubleshooting section.

Cycle power to reset the control.

See Troubleshooting section.

Cycle power to reset the control.

Reset the control by pressing

MENU. If problems persist, replace the control.

Ordering Information

Refer to Table 6 to order sensors, mounting hardware

and other accessories used to install A419 controls.

Contact your nearest Johnson Controls/PENN

Distributor or Sales Representative to order these products.

Table 6: A419 Controls Accessories

Product Code Number Description

A99BB-200

A99BA-200

Temperature Sensor: PTC Sensor with 6-1/2 ft (2 m) Non-shielded 2-Wire Lead

Temperature Sensor: PTC Sensor with 6-1/2 ft (2 m) Shielded 2-Wire Lead

BKT287-1R

BKT287-2R

PLT344-1R

CLK350-2C

WEL11A-601C

DIN Rail: 12 in. (305 mm) long

DIN Rail: 36 in. (914 mm) long

End Clamps for DIN Rail Mounting

7-Day Programmable Digital Clock for activating Binary Offset

Immersion Well for Mounting Sensor in Liquid Applications

A419 Electronic Temperature Control with NEMA 1 and NEMA 4X Watertight Enclosures Installation Instructions 7

Technical Specifications

Product A419 Series Electronic Temperature Controls with NEMA 1 General Purpose

Enclosures and NEMA 4X Watertight Enclosures

Setpoint Range -30 to 212°F (-34 to 100°C)

Differential Range 1 to 30F° (1 to 30C°)

Supply Voltage 24 VAC, 60 Hz, Class 2:

120 or 240 VAC, 60 Hz:

A419GBF-1 (NEMA 1 Enclosure Model)

A419GEF-1 (NEMA 4X Watertight Enclosure Model)

A419ABC-1 (NEMA 1 Enclosure Model)

A419AEC-1 (NEMA 4X Watertight Enclosure Model)

Power Consumption 1.8 VA Maximum

Output Relay Contacts

Electrical Ratings

24 VAC models: A419GBF-1 (NEMA 1 Enclosure)

A419GEF-1 (NEMA 4X Watertight Enclosure)

100 VA, 30 VAC maximum, Class 2

120/240 VAC models:

Applied Voltage:

Horsepower N.O. (N.C.) :

Full Load Amperes N.O. (N.C.):

A419ABC-1 (NEMA 1 Enclosure)

A419AEC-1 (NEMA 4X Watertight Enclosure)

120 VAC

1 (0.25) hp

16 (5.8) A

Locked Rotor Amperes N.O. (N.C.):96 (34.8) A

208 VAC

1 (0.33) hp

9.2 (4.0) A

55.2 (24) A

240 VAC

1 (0.5) hp

8.0 (4.9) A

48 (29.4) A

Non-inductive Amperes N.O. (N.C.):15 (10) A 10 (10) A 10 (10) A

Pilot Duty: 125 VA (N.O. contacts) @ 24 to 240 VAC

125 VA (N.C. contacts) @ 120 to 240 VAC

50 VA (N.C. contacts) @ 24 VAC

Sensor Type A99 Series Temperature Sensors (Various Models and Wire Lead Lengths Available)

Control Ambient

Temperature

Operating:

Shipping:

-26 to 140°F (-32 to 60°C)

-40 to 185°F (-40 to 85°C)

Ambient Humidity 0 to 95% RH Non-condensing; Maximum Dew Point: 85°F (29°C)

Control Enclosure Material Case and Cover: NEMA 1 - High-Impact Thermoplastic

NEMA 4X - Watertight, High-Impact Noryl® Thermoplastic with

Polycarbonate Faceplate

Agency Listings UL: File E27734; CCN’s XAPX (US), XAPX7 (Canada)

FCC: CFR 47, Part 15, Class A. DOC, Class A

The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications, contact Application Engineering at 1-800-275-5676. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products.

Controls Group

507 E. Michigan Street

P.O. Box 423

Milwaukee, WI 53201

Published in U.S.A.

www.johnsoncontrols.com

8 A419 Electronic Temperature Control with NEMA 1 and NEMA 4X Watertight Enclosures Installation Instructions