Installation - Smartcool Systems
Contents
1. 20 CN 1 0 P 2 l Lebe si 0052 L duy 9 jo wnwpew y HUN 4 093 NSI pesn asry peiunow 55 e yey st il s asna aunsopua WS nuo M 1 PIOA eq 5003 andu jemod Page 5 of 18 All Rights Reserved Smartcool Systems Inc Copyright 1986 2006 TRAINING MANUAL ECO INSTALLATION 5SMARTCOLULU ECO Dual Channel d ki Gooidiayem si Japjoy ens eq episino 3 e oqe euo y esnj ssejb yun jouueu jeng uonoeuuoo deus ue Jo sesnj 55216 u NSA Jo esn s J Hu Ww a 5 oi 2 gales 79 77 _ pases 9 C dwy G jo pasn eq sny jeuspa unsopua qup w HUN 811 QyAggz dwy asn WWS32. No le Control Voltag gt Legend ___ Contactor Compressor CLO Compressor Lockout COMP Compressor Motor cs Control Stage e GND Ground 59 HPS High Pressure Switch A E eer E epee 4 IFC indoor Fan Contactor Indoor Fan Motor ne IFMOVL Indoor Fan Overload Switch LPS Low Pressure Swich B LS Limit Swich OFA Oi Faiure Alarm OFC Outdoor Fan Contactor et 90 Sch E OPS Oil Pressure Switch 4 PDS Pump Down Solenoid pr gt 7 SIN ECO SIM In Contact Ge n SN ECO Neutral SNC ECO SIM Out NC Contact B SNO ECO SIM Out NO Contact Thermostat L le Control Voltage gt GND Control Volt A gt Legend Contactor Compressor commen COMP Compressor Motor CS Control Stage GND Ground High Pressure Switch IDM Induced Draft Motor IFC Indoor Fan Contactor IFM Fan Motor IFMOVL Indoor Fan Overload Switch LPS Low Pressure Switch LS Z Limit Swich OFA OllFalure Alarm cedes OL Overload Swich OPS Pressure Switch PDS Pump Down Solenoid SN ECO SIM In Contact SN ECO Neural SNC ECO SIM Out NC Contact SNO ECO SIM Out NO Contact Thermostat I ontrol Voltage Fooling Must match output from Compressor Cal GND VOLTAGE BACK FEED On some
3. GND Page 10 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved 5SMARTCUDL TRAINING MANUAL ECO INSTALLATION One option to solve the issue is to put the ECO TM into manual priority of 2 1 In this method savings will always be applied to stage 2 when itis running The danger in this method is if the control quickly satisfies during the save then you will also lose some of your savings The preferred method would be to ensure that the fan continues to get signal even when the ECO M has put stage 1 into save le Control Voltage gt Legend m Contactor Compressor CLO Compressor Lackout 63 4 COMP Compressor Motor 2 CS Control Stage GND Ground HPS High Pressure Switch IDM Induced Draft Motor T IFC Indoor Fan Contactor IFM Indoor Fan Motor IFMOVL Indoor Fan Overload Switch 082 tewe OFA Ol ature Outdoor Fan Contactor 010 Overoed Such s HEG Ors 2 O1 Pressure Switch Ez ae a 4 08 Pump Down seenod PN M SIN EGO In Contact SN T Ecom Newt 4 SNo ECO SIMOUNC Contact e SNO ECO SIM OUt NO Contact Conte gt PUMP DOWN SOLENOIDS Some compressors are not immediately stopped or started by a coil In some cases a thermostat is wired to the liquid line solenoid valve On a call for
4. PIOA 9 6 oun ILON peuog 298015 WSI Aiddns Abe 008 NSI Page 6 of 18 Smartcool Systems Inc All Rights Reserved Copyright 1986 2006 SMARTCOOL TRAINING MANUAL ECO INSTALLATION To enable servicing a switch fuse or circuit breaker with a minimum current rating of 1Amp should be installed in the mains supply 240VAC 110VAC to the 24 VAC step down transformer The wiring installation of the ECO must be carried out at all times by qualified technicians and must comply with all statutory and advisory codes relevant to the locality and environment The unique circuitry of ECO enables it to control and switch loads with supply voltages ranging from 24 volts to 240 volts by utilizing interface relays to switch loads Warning The inputs to a ECO must be the same voltage and the same phase The maximum permissible voltage to be applied to the terminals is 240Vac The ECO is connected into the control circuits of the refrigeration and air conditioning systems and therefore only low current Amperage capacity wiring minimum of 1 5 mm cable is required The installation of the ECO should be treated as the installation of an additional switch connected into the control circuit in series with and after the primary controller eithe
5. cooling the thermostat contacts close This causes the solenoid coil to be energized opening the valve Liquid refrigerant flows into the evaporator and the suction pressure rises above the low pressure control set point The contacts on the low pressure control close and the compressor begins to run When the thermostat is satisfied its contacts open causing the solenoid valve to close This stops refrigerant flow into the evaporator As the compressor continues to run refrigerant is pumped out of the evaporator coil and suction pressure falls When the suction pressure reaches the cut out setting on the low pressure control its contacts open stopping the compressor This removes all refrigerant from the low side of the system during the off cycle Page 11 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTLCOOL TRAINING MANUAL ECO INSTALLATION In these circumstances the is wired to the solenoid rather than to the compressor coil In Voltage gt 6 Contactor Compressor CLO Compressor Lockout COMP Compressor Motor CS Control Stage GND Ground HPS High Pressure Switch 4 4 IDM Induced Draft Motor IFC Indoor Fan Contactor 2 A IFM Indoor Fan Motor t p 1 Indoor Fan Overload Switch LPS Low Pressure Swich m ue LS Limit
6. SMARTCOOL TRAINING MANUAL ECO INSTALLATION Training Manual ECO Installation In this module we will be discussing the following topics EQUIPMENT OTHER MATERIALS ADDITIONAL EQUIPMENT 3 INSTALLATION nee E ER RE anes 3 WIRING THE 4 Single Channel Dual Channel WIRING AN EXTERNAL OVERRIDE RELAY 8 Single Channel ECO Dual Channel WIRING NOTES ineno etienne eerie etin er EEE 9 SAFETY SWITCHES CONDENSOR FAN RUN FROM STAGE 1 10 PUMP DOWN SOLENOIDS COMPRESSOR PROOFING RELAYS 12 VOLTAGE BACK FEED 13 INSTALLATION CHECKLIST sels REMOVING THE ECO 16 MANUAL amp INSTALLATION STICKER 17 REVIEW Mor 18 Page 1 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION WHAT YOU NEED TOOLS List of tools that will be required are EQUIPMENT OTHER MATERIALS Cordless Drill Measuring Tape Small Level Wire Cutters Wire Strippers Crimper Screw Drivers Pliers Needle Nose Pliers ECO3 s Transformer s Fuse Holders Fuses There are a number of additional material pieces that will be required f
7. Switch OFC Outdoor Fan Contactor 0 Overload Switch OHO OPS Oil Pressure Switch E m p pos ay 4 SIM Out NC Contact T SIM Out NO Contact us Thermostat e ontrol Voltage gt COMPRESSOR PROOFING RELAYS Many manufacturers have now added proofing relays so their controller knows whether or not the compressor or compressor capacity controller they called for actually started running This is so that their control can react immediately to compressors or capacity that is not operating rather than waiting for suction pressure to be impacted enough to bring on more capacity In many cases these relays will then lock out the impacted unit so it will be ignored in their algorithm until repairs are done The ECO will turn off not allow starting a compressor or compressor capacity controller that the primary controller thinks should be running When a proofing relay exists the primary control would now lock out that channel until it was informed of repairs As such we need to fool the proofing relay into seeing a signal during the off times This requires the addition of a fooling coil to match the signal that would come from the regular coil Page 12 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved 5SMARTCUDL TRAINING MANUAL ECO INSTALLATION
8. ems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION INSTALLATION CHECKLIST The following installation checklist will assist in ensuring that the installation of the ECO TM was successful 1 Ensure the unit has 24 power to it and the unit display shows ON Press the Enter button once and make sure the RUN LED lights up Press the Enter button again and make sure the Save LED lights up Press the Enter button again and make sure the Bypass LED lights up Press the Enter button again and make sure the Bypass LED light flashes Using a multi meter when the compressor is running on the channel being tested verify that there is control voltage between N and IN and N and NC 7 Using a multi meter when the channel is in save verify there is control voltage between and IN and and NO and no voltage between and If you don t want to wait for a save cycle disconnect the wire from NC feeding the compressor contactor or pump down solenoid and verify there is control voltage from N to IN and no control voltage between N and the wire removed from the NC terminal CAUTION dangerous voltage may be present at the terminals and wires These tests will verify that power is being fed from the control device Thermostat or Pressure Switch through the IN terminal and out the NC terminal to the compres
9. h the two screws 1 2 Slide metal ruler or thin metal strip up the back of the unit to release the locking mechanism Page 16 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved 5SMARTCUDL TRAINING MANUAL ECO INSTALLATION Once released the unit should push down and then come off of the mounting bracket MANUAL amp INSTALLATION STICKER Be sure to install the installation sticker close to the ECO TM and leave a copy of the user manual with the Customer SMARTCOOL SYSTEMS INC ESM ENTER SMARTCOOL dti E e de User Page 17 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION REVIEW Page 18 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved
10. or the installation These are Wire 3 wire insulated minimum 20AWG 7mm Wire 2 wire insulated minimum 20AWG 6mm Wire markers Wire Ends Self tapping metal screws Cable Ties Conduit if required Relays if required Page 2 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION ADDITIONAL EQUIPMENT A certified 24VAC power supply not supplied is required for the unit It is recommended to put an in line fuse 250V 1A from the power supply to the see wiring diagrams It is also recommended to place an in line fuse 250 5 onto each of the incoming controls voltages to protect the ECO from power surges that might harm its internal circuitry see wiring diagrams Damage due to power surges is not covered by the manufacturer warranty INSTALLATION Safety Warning Installation and maintenance of the ECO must be carried out at all times by suitably qualified persons The ECO must be installed in strict compliance with the national wiring rules The 24 VAC power supply to the ECO must protected by a suitable switch fuse or circuit breaker The back plate of the ECO is attached to a flat surface via four screws The unit is then inserted onto the back plate and pushed up until it clicks into place If theft is not a concern the locking mechanism can be bent to make it easie
11. r the thermostatic or pressure control Three connections are required for each channel A control input control output and a reference wire connected to the system neutral or return side of the control circuit as outlined in the previous page diagram Three wires per control circuit are required as shown in the above drawing It is advisable to use three different colours Connect one wire from the control thermostat or low pressure control to the IN terminal on the ECO channel Connect one wire from the N C terminal on the ECO Channel to the oil safety switch or directly to the motor starter if an oil safety switch is not fitted Page 7 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION Finally connect the reference wire from the N terminal on the ECO Channel to the return Neutral side of the contactor coil Be sure to reinstall the wiring cover to preserve the IP rating and to have the certification label with the product at all times WIRING AN EXTERNAL OVERRIDE RELAY To add an extra level of safety into an ECO3 installation a normally closed relay actuated by a thermostat can be inserted between the power supply and the ECO3 with the thermostat situated in the controlled space see below drawings The thermostat is set to an appropriate temperature Once this temperature is exceeded power to the ECO3 will be c
12. r to remove once installed or the backplate can be installed upside down The unit may then be wired into the system via the cable housing on the bottom of the ECO see wiring instructions later in this manual Page 3 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION WIRING THE ECO Safety Warning For USA and Canada the ECO M must be connected to a class 2 power supply or class 2 transformer If installed outside the transformer must also have an IP65 rating The requires a 24 VAC power supply to operate It is recommended to fuse it with a 1 Amp fuse This supply is via a 24 VAC isolation transformer and is powered from the control circuit in the air conditioning or refrigeration system The power supply should be connected to the 24 VAC terminals as shown below Page 4 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved TRAINING MANUAL ECO INSTALLATION le Channel ing ECO Si x i SMARTCOOL Gooidiayem 5 Japjoy au euns eq episino pejoidep euo y asny 55216 ouueup ajguis uonoeuuoo deus aulju ue 10 sasny ssejb uj 153 40 esn s 3 LON Um abes N 3
13. rent systems manufacturers and types of units can be significantly different Knowing where and how to insert the ECO3 into the control circuit correctly is important for the success of the project In this module we will look at a number of scenarios for where and how the ECO should be wired into the control circuit It is important to remember that The ECO must know at all times when capacity is being utilized by the primary controller If power to a channel drops off as additional capacity is added a relay can be used to ensure the ECO3 sees all the capacity that is being used The ECO looks for a constant signal If the existing controller uses a pulse signal then timers and or relays must be used to ensure it sees a constant signal Page 9 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved TRAINING MANUAL ECO INSTALLATION If the existing controller has a feedback loop to ensure compressors are running when it has told them to then relays must be used to ensure it still sees a signal when the ECO has put a unit into save Also remember that the Normally Closed contact on the ECO is the preferred contact as it helps ensure that the unit fails to safe should there be a malfunction of power issue to the ECO TM SAFETY SWITCHES Within the control circuit there will be a number of safety switches that are there to en
14. sor contactor or pump down solenoid If there is voltage between the wire removed from the and the N terminal or voltage between N and NC during a save and no voltage between the N terminals and IN then the wires are reversed in the circuit and the ECO3 will not work properly Correct wiring and restart the system 8 Repeat steps 7 and 8 if the installation is an ECO TM Dual 9 Verify all DIP switches are in the proper position for the site conditions 10 Verify that any ECO3 installed outdoors has the wiring openings facing down to maintain IP65 integrity Seal any unused holes with RTV silicone sealant Install bottom wiring cover and make sure there are no exposed wires outside the wiring terminals UA amp a Page 15 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION 11 Verify that the 24 VAC supply is fused with a minimum of a 1 Amp fuse 12 Verify that the control feed to the IN terminal has an in line fuse of 5 amps 250V installed REMOVING THE ECO WARNING When the ECO is being used to switch mains voltages these voltages are present on exposed metal on the PCB Ensure that incoming voltages are switched off before the enclosure is opened To remove the ECO be sure that power to the unit and main voltages are turned off Remove the wiring tray wit
15. ssor 4 CLO Compressor Lockout COMP Compressor Motor cS ContolSlage A GND Ground ft ep 9 4 High Pressure Switch VY IDM Induced Draft Motor es les IFC Indoor Fan Contactor IFM Indoor Fan Motor IFMOVL Indoor Fan Overicad Switch LPS Low Pressure Switch LS Limit Swich OFA Oi Failure Alam OFC Outdoor Fan Contactor s i 4 OL Overload Switch 5 OPS Oil Pressure Switch irs PDS Pump Down Solenoid SIN ECO SIM In Contact SN ECO Neural ECO SIM Out NC Contact SNO ECO SIM Out NO Contact Thermostat ke Control Voltage gt GND Control Legend C Contactor Compressor GLO Compressor Lockout 4 COMP Compressor Motor cs Control Stage GND Ground JEN HPS High Pressure Switch A p IDM Induced Draft Motor IA IFC indoor Fan Contaclor is IFM Indoor Fan Motor IFMOVL Indoor Fan Overicad Switch LPS Low Pressure Switch 0 RT OFA Oi Failure Alam OFC Outdoor Fan Contactor p pu Xs OL Overload Swich DKA OPS Oil Pressure Switch Ts Ar pt Pump Down Solenoid re e is SIN ECO SIM In Contact SN ECO Neutral 4 SNC ECO SIM Out NC Contact SNO ECO SIM Out NO Contact 4 T Thermostat Control Voltag gt Page 14 of 18 Copyright 1986 2006 Smartcool Syst
16. sure that the system is operating properly and that the expensive pieces of equipment like the compressors are not damaged should an issue arise Typically the ECO TM should be wired before these safety circuits to ensure they continue to operate as expected Some that you will see are high pressure switches low pressure switches oil pressure switches and compressor proofing relays CONDENSOR FAN RUN FROM STAGE 1 On some units the condenser fan for a two stage unit will be run from the same circuit as stage 1 of cooling Therefore if the turns off stage 1 while stage 2 is running the condenser fan will not be running This will cause the unit to shut down on a high pressure failure le Control Voltage gt Legend Z Contactor Compressor A 1 CLO Compressor Lackout X o Come Compressor Motor CS Control Stage GND Ground 4 HPS High Pressure Switch IDM Induced Draf Motor IFC IndoorFan Contactor Indoor Fan Motor IFMOVL Indoor Fan Overload Switch LPS Low Pressure Switch LS Limit Switch OFA Oil Failure Alarm OFC Outdoor Fan Contactor 2 OL Overload Switch pp 1 OPS 2 Oil Pressure Switch PDS Pump Down Solenoid SIN ECO SIM In Contact SN ECO Neutral ECO SIM Out NC Contact SNO ECO SIM Out NO Contact T Thermostat Control Voltage
17. systems a back feed of voltage will be present This usually will occur in one of two ways The first is a voltage less than the normal control voltage Because the ECO3 is designed to handle voltages from 24 240V AC it is possible for a voltage to be detected that will not activate the compressor contactor This can be identified by seeing the Run LED on when the compressor is not actually running The second is a back feed voltage that appears only when the ECO3 internal relay activates for a save period When the circuit is broken Page 13 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION the back feed voltage now appears This can be identified by the Save LED lighting up even though the compressor was not running when the system went into a save This can also be identified if a large amount of save hours are being recorded with a lower amount of Run hours The easiest way to determine if there is a problem is to force the unit off via the thermostat Pull the Y1 wire coming from the thermostat from the terminal at the unit Measure the voltage between the wire and common If there is voltage there when there is no call from the thermostat either install a relay or go further down the circuit until no voltage is found le Control Voltage gt Legend C Contactor Compre
18. ut off and all control reverts to the primary controller until the temperature returns below the temperature again This then acts like the Y2 Override function on an ESM or one of the override terminals available on a SIM ECO Single Channel ESMECO stage1 p sy input px T wOTE I the fuses are not installed all warranties will be void FeseSampOSM tis madatory that a glase Mounted External to ESMECO unt Sape Neutral to ger e THis suggested you use Din rail mounte Installation of BEM EC In line glass fuses or an inline snap connection Single Channel unit ath Dude glass fuse holder like the one depicted above if outside be sure the holder is waterproo Page 8 of 18 Copyright 1986 2006 Smartcool Systems Inc All Rights Reserved SMARTCOOL TRAINING MANUAL ECO INSTALLATION ECO Dual Channel ESM ECO stage 1 24 Power supply input ESM ECO stage Contact Contact NOTE If the tuses are not installed all pvarranties will be void Fuse SAmp 250 o Mounted Extemaly to ESM ECO unt Stage 1 Stage 2 NOTE Iris suggested you use Din rail mounted In line glass fuses or an inline snap connection glass fuse holder like the one depicted above if outside be sure the holder is waterproof WIRING NOTES The wiring between diffe
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