Download Western Premium Economizer Checkout Procedures

EWEB EMS
Western Premium Economizer
Checkout Procedures
General Outline; Tests for Honeywell W7459A Economizer Controller; Abbreviated Logic Checks
Advanced Tests: (Modules W7412, W7413, W7414, W7415 & W7340) Low Ambient Compressor Lockout;
Heat Pump Relay; Demand Controlled Ventilation (DCV); Relief or Exhaust Fan; Post Purge Relay; Anti-Cycle Relay
05/03/2004
Hookup Diagram Index
Hookup Unit Type
Diagram
1
Gas/Cool
2
3
Gas/Cool
Heat Pump
Thermostat Economizer Other Controls
Controller
Mech/Pgm
W7459
Fan Delay & Post Purge &
Anti-cycle
Mech/Pgm
W7459
Mechanical W7459
Anti-cycle & Post Purge
4
Heat Pump
Mech/Pgm
W7459
Post Purge
5
Heat Pump
Mech/Pgm
W7459
Post Purge
6
Heat Pump
Mech/Pgm
W7214
Post Purge
7
Heat Pump
Mech/Pgm
Post Purge
8
Gas/Cool
Mech/Pgm
9
Heat Pump
Mech/Pgm
W7212
(W7215)
W7212
(W7215)
W7340
10
11
Anti-cycle & Post Purge
Post Purge
Min OSA Activation
Actuator Comments
Tstat Ocp Sch A1/A2
(T7200/7300)
With Fan
Zone Occupancy
Sensor(s)
Demand Controlled
Ventilation (DCV)
Tstat Ocp Sch Aux
(T7350)
Demand Controlled
Ventilation (DCV)
Tstat Ocp Sch Aux
(T7350)
Demand Controlled
Ventilation (DCV)
Demand Controlled
Ventilation (DCV)
M7415
M7415
M7415
M7415
M7415
M7215
M7415
M7215
M7215
Testing/Sensor Simulator
Hydronic
cooling
Pneumatic
Pneumatic
Timer
Pneu
Please contact EWEB EMS to find out more about our Western Premium Outside Air Economizer Program.
For questions or comments regarding these hookup diagrams contact Dan Morehouse or Reid Hart, PE.
Eugene Water & Electric Board
Energy Management Services
500 E 4th Ave
PO Box 10148
Eugene OR 97440
Phone 541-484-1125
Fax 541-334-4614
Program Contacts:
Dan Morehouse x 3074
Reid Hart x 3079
Need two
transformers
Critical zone
warning light
Exhaust/ Relief
Fan
Need two
transformers
Exhaust/ Relief
Fan
Trane Reliatel
Economizer Check-Out Procedure
Developed by Ecotope in Fall 2002
Modified by EWEB in Spring 2004
Manufacturer-Specific Economizer Testing.
The economizer function should be tested to determine that it is functioning correctly. In
addition to the functionality of the components, this can include whether or not components are
set to preferred settings. In general, manufacturer’s checkout procedures should be used to
evaluate the functionality of the components. The data collected in this step is recorded in the
“Supplemental Economizer Information” form.
A knowledgeable technician can streamline the process but must be vigilant and account for
environment and thermostatic conditions. The manufacturer procedures have the advantage of
generally completing a checkout the same way, no matter the conditions. In following the
manufacturers economizer checkout procedures, there are several conditions to verify that will
not be elucidated in the checkout but are critical to the efficient operation of the economizer.
They should be noted and repaired as appropriate. The following general instructions are a guide
to checkout. See the specific “Supplemental Economizer Information” form instructions for
specific assistance.
·
Verify that the damper is fully closed when the unit is off, and that the minimum air
position is set with potentiometer or micro-switch rather than the linkage. On older units
without minimum air potentiometers or minimum position switches, the minimum
position will necessarily be set with the linkage.
·
Describe the minimum air setting and verify that the return dampers are completely open
in this state. If minimum airflow is very high, then the return dampers should be
somewhat closed.
·
Measure total and outdoor air flow at minimum position. To do this use flow grids or
delta-T method. At a minimum, check the cooling coil split temperature with the
compressor operating. If it is higher than 25oF it indicates that total air flow is
excessively low. If it is lower than 12 or 10oF it indicates that refrigerant charge may be
low and should be checked.
·
Verify that the damper opens completely, and when open, that the return dampers are
closed completely. Ideal economizer operation requires the return damper to be
completely closed. Typically this is not how they are installed. Linkage should be
adjusted to close the return dampers as much as possible without creating building
pressurization problems.
·
Measure total and outdoor air flow at full-open position. Do this by repeating process
described previously for minimum position, except first do measurement with flow plates
in place and then re-install filters and measure supply pressure for correction.
Economizer Checkout
1
April 2004
·
Verify that the wiring between the economizer and unit controls is correct with regard to
the number of compressor and thermostat stages. Often there is a particular way the
economizer should be wired depending upon the staging. This will require familiarity
with both the unit and economizer controls, or the ability to quickly read wiring
diagrams. Determine the number of cooling thermostat stages, and if the economizer has
a dedicated cooling stage. Review Thermostat setpoints and programming.
·
Verify that the logic controller is okay and that economizer is enabled at the correct
conditions. This requires that the logic board is checked and the sensors calibration
checked.
·
Determining the Economizer Logic. Most modern economizers support change over and
differential control with dry bulb and enthalpy sensors. Determining the logic used will
be unique to each unit. This may involve looking at product literature for unusual set-ups.
Items of interest are:
·
Changeover or differential. Generally, controllers have a terminal for a return air
sensor. If the terminal is wired to a sensor then the unit runs in differential mode. If
a wire is not connected or the terminals are jumped, then the unit is in changeover. In
older units with relay control, you will need to decipher the wiring diagrams and
locate the sensors to determine this.
·
Changeover setting. If a unit uses changeover logic, determine what temperature or
setting is used for changeover. On Honeywell controllers with solid state sensors
record the A-D setting. If the unit uses a snap disk for outdoor air temperature this
setting will not adjust the changeover but record it anyway. On Trane Voyager units
there is a switch block that determines the setting. Record the switch settings.
·
Changeover sensor types. Determine if outside air and return air sensors are drybulb, enthalpy, or dry-bulb with humidity.
·
Primary control sensor location. Determine if the primary control sensor (low-limit
sensor) is in the mixed air position (before the cooling coil) or the discharge air
position (after the cooling coil, in the fan scroll, or in the supply air).
Economizer Checkout
2
April 2004
Honeywell W7459A Economizer Control Module
Publications: Honeywell 63-2141, Honeywell 63-2484, Honeywell 63-2140-2, Honeywell 632499-1.
The Honeywell 7459A is the most common economizer controller and comes in a wide variety
of configurations. It attaches directly to the actuator, and it can be identified by appearance, in
particular the number and pattern of the terminals is deterministic. Publication 63-2484
highlights many, but by no means all, of the common wiring configurations. If the controller is a
model 7459B,C or D do not use these procedures. Refer to the above literature for guidance.
·
Check the SR/+ terminals to determine whether a return air sensor is connected. If so
then the controller will use differential logic. If not, a resistor must be jumpered between
the terminals and the controller will use change over logic.
·
Check terminal 1 for wire. This should be the stage 1 cooling wire from the unit control.
·
Check terminal 3 for stage two wire. Most, but not all, units are wired with Y2 going to
3. The unit wiring diagram will need to be consulted to determine if things are correct.
The following tables outline the standard check out procedures recommended by Honeywell.
Use non-conducting pliers whenever power is applied to the logic board, and be careful to not
yank on wires. This is tricky, as the spades can be quite tight. A lever action works best, using
the tips of the pliers to press into the case.
Minimum Position Check (Video Test #4)
a. Start with all wiring in original
position. Disconnect one leg of
T/T1.
Note: (the C7046A and C1750 sensors have
negative temperature coefficients. That means
high resistance = low temperature and low
resistance = high temperature).
b. Characterize found damper positions
and measure flows if desired.
c. Measure outside, return, and mixed
air temperatures. Calculate desired
mixed air temperature for desired %.
d. Adjust minimum position dial until
desired mixed air temp is achieved.
c. Restore T/T1.
Economizer Checkout
3
This simulates very cold mixed air or supply air
The outside air damper should be in or move to
minimum position and be adjustable with the
minimum air potentiometer unless an external
sensor is installed. Note that different units respond
differently to the minimum position potentiometer. Trane
units with Honeywell controls do not respond until the
potentiometer is turned half way and may limit minimum
position to 50% or so, while most other units respond
immediately.
Use formulas or nomograph on pages 16 to 21 of
Design & Application Guide for Honeywell
Economizer Controls.
Verify desired mixed air temperature and position.
April 2004
Logic Checkout – Step 1 (Video Test #1a)
a. Turn unit power off or disconnect
wire from terminal TR1 (common)
or TR
b. Disconnect one leg of jumper or wire
between from P and P1.
c. Jumper TR to 1.
d. Jumper T1 to T (mixed air sensor)
e. If connected remove one leg of the
sensor between SO to +.
f. Verify 620W resistor or sensor
between SR and +.
g. Turn power on or restore TR
Actuator Closed
If pulling wire from TR/TR1, be careful to not
ground the wire to other terminals or to any metal.
The damper should go completely closed.
Removes outside air minimum position signal;
minimum is fully closed
simulates call for cooling
simulates warm mixed air temperature so damper
will open all the way when it opens
simulates very warm outdoor air temperature
simulates mid-range return temperature
LED should be off (indicates Economizer is off)
and motor should go to or be in closed position.
If motor opens verify the resistor or sensor across
SR /+ has continuity.
Logic Checkout – Step 2 (Video Test #1b) Actuator Open
This puts the controller in differential control
a. Disconnect factory installed resistor
comparing two very warm temperatures. The
or sensor lead from SR or +
return is interpreted as the higher temperature so
the LED should go on (indicates Economizer is
enabled) and Motor should drive fully open. If
LED goes on but motor doesn’t move, do actuator
checkout. If LED is not on then controller is
probably bad. Go through the system check out
sequence.
b. Characterize damper positions and
measure flow.
Logic Checkout – Step 3 (Video Test #2) Outside Temperature/Enthalpy
a. Reconnect resistor or sensor leads to This simulates a mid-range outdoor temperature or
SR and +. Connect 1.2K ohm
enthalpy.
resistor between SO and +. If there is
a return air sensor, disconnect and
place 620 ohm resistor between SR
and +.
b. Turn changeover setpoint
Sets an aggressive change over setpoint.
potentiometer to “A”
LED should come on and motor drive open.
c. Turn changeover setpoint to “D”
Sets a conservative change over setpoint.
LED should be off and motor driven closed.
d. Disconnect 1.2K ohm resistor and
restore system.
If the unit does not pass the above test follow the system checkout procedures in publication 632484-1 pages 17-19 to determine the exact cause.
Economizer Checkout
4
April 2004
Sensor Check out (multi-meter must be able to read tenths of a milliamp DC).
Mixed Air / Supply Air Sensor Checkout
a. Disconnect mixed/supply air sensor
lead wires from T/T1.
b. With ohmmeter, check the resistance
across the sensor by connecting meter
leads to sensor leads. Measure
temperature at mixed air or supply air
sensor.
Honeywell Pub 60-2350-5.
Resistance should correspond to the current
mixed air temperature for the installed sensor.
The controller typically expects 3.0Kohms at 77F
with a 70ohm per degree sensitivity. (3.5Kohms at
70F, 4.0Kohms at 65F, 4.7Kohms at 60F. If
measurement deviates from target values, clean all
contacts and retest.
Outdoor Air Sensor Checkout (Video Test #3) Outside Sensor
a. Determine sensor type.
Honeywell Pub 63-2140-2 and 63-2499-1
b. If solid state, connect a DC
Reading should be between 3-25 mA.
milliammeter between terminal SO of
If meter indicates 0 check to see if sensor is wired
the controller and the S terminal of the backwards. If not then sensor is probably bad.
sensor lead (this should be the wire that Detail: Check amp readings with tables in relevant
publications to determine that sensor is reading
was hooked up to SO. It is also
possible to do this at the sensor. The
within 5 degrees of the correct temp. If
positive meter lead should be on the
measurement deviates from target values, clean all
sensor lead, negative on the controller
contacts and retest.
terminal.)
c1. If sensor is a snap disk, determine
Typically outdoor air snap disks are set to 60F.
state of switch with ohmmeter.
Above 60F the switch should be open below it
should be closed. Note temperature and state of
switch. If switch is in wrong position for
temperature (within 5 degrees), clean all contacts
and retest. If it still switches at the wrong
temperature then replace.
c2. If snap disk is closed, warm it with Switch should open. If not replace.
hand.
c3. If snap disk is open, cool it with
Switch should close. If not replace.
water or ice.
Return Air Sensor Checkout
b. If return air sensor connected to
Reading should be between 3-25 mA.
SR/+, connect a DC milliammeter
If meter indicates 0 check to see if sensor is wired
between terminal SR of the controller
back wards. If not then sensor is probably bad.
and the S terminal of the sensor lead
Detail: Check amp readings with tables in relevant
(this should be the wire that was
publications to determine that sensor is reading
hooked up to SR. It is also possible to
within 5 degrees of the correct temp. If
do this at the sensor. The positive
measurement deviates from target values, clean all
meter lead should be on the sensor
contacts and retest.
lead, negative on the controller
terminal.)
Economizer Checkout
5
April 2004
Abbreviated Logic Checks
Under many conditions all logic functions can be checked using tests that do not require wires to
be attached and detached to the controller. Because of the number of control variables extreme
care must be exercised to insure valid test results.
Test Method 1
Requirements
No Heating or Stage two cooling calls present.
Outside air conditions between ~55F and 80F
Changeover logic
Solid State sensor or adjustable electro-mechanical switch (not snap disk)
Test
Conditions must be such that the “A” setting turns the controller LED on and the “D” setting
turns the controller LED off. Or if electromechanical outdoor air sensor is present, conditions
must fall in the range of the adjustable setpoint. Simulate a call for cooling (jumper TR to 1).
Set the potentiometer to “A” or the changeover temperature to a warm enough temperature to
trigger the economizer. At these air conditions the damper should open fully. Set the
potentiometer to “D” or the changeover temperature to a cold enough setting to end economizer
action. The damper should move to the minimum position.
Advanced Module Logic Checks
Advanced modules (W7212, W7213, W7214, W7215 or W7340) use the same changeover logic
as the basic W7459. Follow the checkout procedures included in the literature supplied with
each module. If missing, the literature is available online at http://hbctechlit.honeywell.com/
for Honeywell products and specific manufacturer’s web sites for other products. The basic
logic checks are very similar to the W7459 tests previously reviewed. They should verify:
· Full physical actuator and damper operation
· Actuator closes damper fully
· Actuator opens damper fully
· Outside temperature changeover checkout
· Check sensor current for both outside and return sensors to verify correct connection
In addition to the basic logic checks advanced checks for DCV and exhaust fan setting require
either a variable 0-10 volt source (see schematic 10 in the hookup diagrams) or at a minimum an
9-volt battery with test leads and a volt meter. Follow the checkout procedures in the literature
for the specific module and test:
· DCV (ISI for W7215) maximum and minimum
· DCV setpoint
· Exhaust setpoint if relief fan being used
· For CO2 sensors, increased voltage output should be observed when exhaling at the
sensor. Remember it may take up to one minute to ramp voltage up or down.
Economizer Checkout
6
April 2004
Low Ambient Lockout Checkout
For all premium economizers, verify the operation of the low ambient lockout function.
· Measure outside air temperature
· Set lockout 10oF or more below outside temperature.
· Remove one of the leads from the outside sensor (SO or +O) to simulate high outside
temperature; the economizer should close to minimum and the free cooling light go out.
· Jumper from Red (24V hot) to Y1 and Y2 at the thermostat.
· Verify that Y1 (and Y2 for 2- stage cooling) on the system board do NOT have voltage
and the compressor is not running.
· Reconnect outside sensor (SO and +O) and reset low-ambient lockout to 55oF.
Heat Pump Relay Checkout
For heat pumps with economizers with normally-heating reversing valves (O terminal), verify
the operation of the heat pump function.
· If free cooling light is not on: place 620 ohm resistor across SO and +O and 1.2k ohm
resistor across SR and +R so that free cooling light is on.
· Jumper from Red (24V hot) to G, Y1 and verify no voltage at O at the thermostat or
thermostat leads; this simulates a call for heating.
· Economizer should not activate and voltage should be present at Y1 system connection;
compressor should operate in heating mode.
· Jumper from Red (24V hot) to G, Y1 and to O at the thermostat or thermostat leads; this
simulates a call for cooling.
· Economizer should activate and no voltage should be present at O system connection or
Y1; compressor should not operate.
· Remove one of the leads (or the resistor) from the outside sensor (SO or +O) to simulate
high outside temperature; the economizer should close to minimum and the free cooling
light will turn off.
· If outside temperature is below ambient lockout, jumper around lockout sensor.
· Verify that Y1 (and Y2 for 2- stage cooling) on the system board DO have voltage and
the compressor is running in cooling.
· Reconnect any sensors and remove jumpers.
For heat pumps with economizers with normally-cooling reversing valves (B terminal), verify
the operation of the heat pump function.
· If free cooling light is not on: place 620 ohm resistor across SO and +O and 1.2k ohm
resistor across SR and +R so that free cooling light is on.
· Jumper from Red (24V hot) to G, Y1, and B at the thermostat or thermostat leads; this
simulates a call for heating.
· Economizer should not activate and voltage should be present at Y1 and B system
connection; compressor should operate in heating mode.
· Jumper from Red (24V hot) to G and Y1 at the thermostat or thermostat leads and make
sure there is no voltage at B; this simulates a call for cooling.
Economizer Checkout
7
April 2004
·
·
·
·
·
Economizer should activate and no voltage should be present at Y1 system connection;
compressor should not operate.
Remove one of the leads (or the resistor) from the outside sensor (SO or +O) to simulate
high outside temperature; the economizer should close to minimum and the free cooling
light will turn off.
If outside temperature is below ambient lockout, jumper around lockout sensor.
Verify that Y1 (and Y2 for 2- stage cooling) on the system board DO have voltage and
the compressor is running in cooling.
Reconnect any sensors and remove jumpers.
Demand Controlled Ventilation (DCV) Setting
For W7215/W7212/W7213/W7214; confirm with specific module instructions.
· Set any jumpers on CO2 Sensor and calibrate.
o Take outside or ventilate area without occupancy and use 400 ppm reference and
adjust sensor following manufacturers procedures to read 400 ppm
o Calibrate to zero with argon/nitrogen or other non- CO2 atmosphere
o Automatic calibrating sensors go to 400 ppm at low point on regular schedule
· Determine CO2 Sensor voltage output at 1000 ppm setpoint
· Set Minimum position to 0% (full left or counter clockwise) and verify jumper on P/P1
· Set DCV Max high (full right or clockwise)
· Remove one of the leads from the outside sensor (SO or +O) to simulate high outside
temperature; the economizer should close to minimum and the free cooling light go out.
· Adjust DCV setpoint so DCV mode is just activated at desired setpoint
o Provide setpoint voltage to input or
o set by dial gradations
· Verify operation one of 3 ways:
o Adjust variable voltage sensor simulator to increase voltage above setpoint;
damper should open; Adjust variable voltage sensor simulator to reduce voltage
below setpoint; damper should close.
o Apply 9 volt battery to sensor terminals and damper should open to about 90%;
Remove battery from sensor terminals and damper should close.
o Exhale on CO2 Sensor a few times and damper should open after about a minute;
Ventilate area near sensor and remove people from sensor location and damper
should close.
· If desired, set minimum. This is not required in most occupancies.
o Remove CO2 sensor leads from controller, jumper P/P1, and verify power to
controller.
o Adjust to desired minimum outside air position.
o Determine percentage outside air with temperature or airflow measurement.
· For severe climates, it may be desirable to set a maximum setting.
o Remove CO2 sensor leads from controller, jumper P/P1, and verify power to
controller.
o Apply 9 volt battery to sensor terminals and damper should open to about 90%;
o Adjust to desired maximum outside air position.
Economizer Checkout
8
April 2004
o Determine maximum percentage outside air with temperature or airflow
measurement.
An existing W7459 controller can be retrofit for demand controlled ventilation as shown in
hookup diagram 4. For new installations, it may be better to start with DCV equipped controller
like W7212 or W7215. The W7459 requires the following setup procedure:
· Must have CO2 sensor with 500 to 2000 ppm range for 0-10 volts (for Honeywell: C7242
programmable or C7232 jumper; AirTest and other manufacturers apply)
· Install SEPARATE 24VAC TRANSFORMER for CO2 sensor to avoid confused
electronic signals
· Connect Q769C converter to P/P1 and to CO2 sensor, watch polarity on sensor and P/P1
connections.
Set up the controller as follows:
· Jumper P/P1 and adjust the min dial until the outside air damper is full open. In this
configuration, the minimum dial becomes the maximum. Watch the full clockwise spot
on the dial which sometimes reverts to closing the damper.
· Verify desired sensor voltage: 3.3 VDC = 1000 ppm on 0-10 VDC CO2 sensor with
range of 500 to 2000 ppm
· Connect Q769C to P/P1 and apply desired volts DC (3.3)
· Turn Calibration potentiometer on Q769C for DCV almost full clockwise to begin
opening at 3.3 VDC.
· Adjust Q769C calibration screw counter clockwise until dampers are closed
· Connect Sensor
Relief or Exhaust Fan Setting
Connect exhaust fan relay coil to dry contacts (EF and EF1) on economizer controller. Set to
turn on the exhaust fan when dampers are between 60% and 80% open.
Post-purge relay
·
·
·
Set thermostat fan switch to “Auto” or disconnect fan lead from thermostat.
Jumper G terminal at thermostat so fan is operating.
Turn off and observe that fan operation continues for one to two minutes.
Anti-cycle relay
·
·
·
·
·
Activate cooling at thermostat or jumper R to Y1.
Cycle cooling off (or remove jumper) for 5 seconds and cycle back on.
Compressor should remain off for three to five minutes before restarting.
With cooling activated, cut power to unit for 5 seconds and restore.
Compressor should remain off for three to five minutes before restarting.
Economizer Checkout
9
April 2004
Western
Premium
Economizer
Outside
Air
R
TR
C
SO
Dry-Bulb
Sensor S
C7650A +
SR
Dry-Bulb
Sensor S
C7650A +
Return
Air
TR
TR1
3
Discharge
Air Sensor
C7150B or
C7046A
T
P
D
Set changeover dial to
"D" for differential
Honeywell
W7459A
Economizer
Controller
Honeywell
M7415
Actuator
2
Measure RA/OA/MA temp
to set min. ventilation %
4
T
T1
T1
P
P1
P1
If A1/A2 not available
then jumper P and P1
A1
C
A2
Y1
C
TR1
SR+
1
Thermostat
Occupancy Dry
Contact
B
SO+
5
Locate Sensor
downstream of
DX cooling coil
A
Low OSA Lockout
Y1
Anticycle
Cool
Y2
W1
Close on Rise at 55 deg F
W1
Heat
W2
G
G
RH
R
Fan Delay
Relay
Post
Purge
RC
Thermostat
Terminals
Unit
Terminals
Hookup Diagram 1: One-Stage Cooling; Gas Heat
W7459A Economizer Controller with
2-stage Cooling Thermostat,
Low-Ambient Compressor Lockout, and
Dry-bulb Differential Changeover
Fan
24 VAC
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
4/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
R
TR
C
Outside
Air
SO
Dry-Bulb
Sensor S
C7650A +
SR
Dry-Bulb
Sensor S
C7650A +
Return
Air
TR
TR1
B
C
D
SO+
TR1
Set changeover dial to
"D" for differential
SR+
Honeywell
W7459A
Economizer
Controller
5
1
3
Locate Sensor
downstream of
DX cooling coil
A
T
Discharge
Air Sensor
C7150B or
C7046A
P
Honeywell
M7415
Actuator
2
Measure RA/OA/MA temp
to set min. ventilation %
4
T
T1
T1
P
P1
P1
Jumper P
and P1
Unit
Terminals
Thermostat
Terminals
Y1
C
Low OSA Lockout
Y1
Cool
Y2
W1
W2
G
RH
Close on Rise at 55 deg F
Connect to "G"
if electric heat
W1
Heat
G
Fan
Delay
Relay
R
RC
Fan
24 VAC
Hookup Diagram 2: One-Stage Cooling; Gas Heat
W7459A Economizer Controller with
2-stage Cooling Thermostat,
Low-Ambient Compressor Lockout, and
Dry-bulb Differential Changeover
Simplified Wiring; Compressor always on Y2
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
4/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
Outside
Air
TR
R
C
SO
Dry-Bulb
Sensor S
C7650A +
SR
Return
Air
Dry-Bulb
Sensor S
C7650A +
TR
TR1
5
1
Occupancy Sensor in
each room served,
auxilliary dry contacts
close on occupancy.
3
T
Discharge
Air Sensor
C7150B or
C7046A
P
B
C
D
TR1
SO+
SR+
Locate Sensor
downstream of
DX cooling coil
A
Set changeover dial to
"D" for differential
Honeywell
W7459A
Economizer
Controller
2
Honeywell
M7415
Actuator
Measure RA/OA/MA temp
to set min. ventilation %
4
T
T1
T1
P
P1
P1
Thermostat
Terminals
Unit
Terminals
X
Y
W2
E
C
Low OSA
Lockout
Anticycle
Y
Close on Rise at 55 o F
Compressor
W2
Resistance Heat lockout:
Open on Rise at 30oF OSA
Aux. Heat
E
G
G
O
O
RH
R
Em. Heat
Post Purge
Fan
Rev Valve
24 VAC
RC
3PDT relay
24VAC coil
Hookup 3: One-Stage Heat Pump
W7459A Economizer Controller with
2-stage Mechanical Thermostat,
Low-Ambient Compressor Lockout, and
Dry-bulb Differential Changeover,
Occupancy sensor ventilation.
Note: for electro/mechanical
thermostats only where first
stage cooling contact activates
"normally heating" reversing
valve. 3PDT relay starts fan
and economizer witn "O" and
maintains "Y" for heat.
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
5/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
Outside
Air
R
C
Dry-Bulb
Sensor S
C7650A +
TR
SO
SR
Dry-Bulb
Sensor S
C7650A +
Return
Air
TR
TR1
5
1
24 VAC
Provide separate
sensor transformer
with Q769C
CO2 Sensor C7242 or
C7232
+
Locate CO2 sensor in
space or return air
3
T
Discharge
Air Sensor
C7150B or
C7046A
P
B
C
D
TR1
SO+
SR+
Locate Sensor
downstream of DX
cooling coil
A
Set changeover dial to
"D" for differential
Honeywell
W7459A
Economizer
Controller
2
Honeywell
M7415
Actuator
While P/P1 jumpered, set "min." dial
to allow MAXIMUM OSA desired
4
T
T1
T1
P
P1
P1
- Adaptor
+ Q769C
Low OSA
Lockout
Close on Rise
at 55oF
Unit
Terminals
DPDT relay
24VAC coil
Y1
Y1
Y2
Y2
W2
W2
Heat lockout: Open on
Rise at 30oF OSA
E
Compressor
Compr. 2
Aux. Heat
E
G
G
O
O
RH
R
RC
C
Em. Heat
Post Purge
Fan
Rev Valve
24 VAC
X
Thermostat
Terminals
Hookup 4: One- or Two-Stage Heat Pump
Retrofit Demand Ventilation (DCV) on W7459A
Economizer Controller with 2-stage Thermostat,
Low-Ambient Compressor Lockout, and
Dry-Bulb Differential Changeover
Requires 2-stage HP
thermostat. "Normally
heating" reversing valve
shown. For "B"
(normally-cooling
reversing valve), reverse
contact positions shown
in relay.
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
5/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
Outside
Air
TR
R
C
SO
Dry-Bulb
Sensor S
C7650A +
SR
Dry-Bulb
Sensor S
C7650A +
Return
Air
TR
TR1
5
1
Locate Sensor
downstream of
DX cooling coil
Discharge
Air Sensor
C7150B or
C7046A
T
T
T1
P
B
C
D
SO+
SR+
3
A
TR1
Set changeover dial to
"D" for differential
Honeywell
W7459A
Economizer
Controller
2
Honeywell
M7415
Actuator
Measure RA/OA/MA temp
to set min. ventilation %
4
T
T1
T1
P
P1
P1
Thermostat
Occupancy
Contact
Thermostat
Terminals
A1
A2
Y1
End Switch: Close when damper opens 15%
more than minimum ventilation position.
With pre-approval by
EWEB, in critical zones
(servers, equipment,
medical diagnostic) failure
indicator may be used in
place of low ambient
compressor lock-out.
Unit
Terminals
Y1
Cool
Y2
W1
W1
Heat
W2
G
Fan Delay
Relay
RH
R
Post
Purge
C
C
G
RC
L1
L2
Open on Rise at
55 deg F OSA
Fan
24 VAC
L3
Schematic 5: Critical Zone One-Stage Cooling
Three possible indicator lights:
W7459A Economizer Controller with
L1: Red LED indicates "Failed
2-stage Cooling Thermostat,
Economizer in Cooling" (required)
L2: Red LED indicates "Failed
Low-Ambient Failure Warning, and
Economizer in Heating" (optional)
Dry-Bulb Differential Changeover
L3: Green LED indicates "Free
Economizer Cooling" (optional)
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
4/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
C
O
P
Discharge
Air Sensor
C7150B or
C7046A
T
R
TR
N
P1
T1
See Hookup Diagram 7
for M7415 connection
TR1
24 VAC Hot
Com
24 VAC Hot
24 VAC Com
+ Ctrl
2-10 VDC
Control Signal
- Ctrl
Honeywell
M7215
Actuator
Honeywell W7214A
Economizer Controller
1
AQ1
Outside Air
2
AQ+
4
Dry-Bulb
Sensor S
C7650A +
SO
3
SO+
5
SR
SR+
Return Air
Dry-Bulb
Sensor S
C7650A +
EF
EF1
L1
Exhaust
Fan
Locate CO2
sensor in space
or return air
CO2 Sensor
C7242
L2
+
DPDT relay
24VAC coil
Low OSA Close on Rise
Lockout at 55 deg F
Thermostat
Terminals
Unit
Terminals
Y1
Y1
Y2
Y2
W2
Heat lockout: Open on
Rise at 30oF OSA
Compressor
Compr. 2
W2
E
E
G
G
O
O
RH
R
RC
C
Aux. Heat
Em. Heat
Post Purge
Fan
Rev Valve
24 VAC
X
Hookup 6: One- or Two-Stage Heat Pump
W7214A Economizer Controller with
2-stage Thermostat, Demand Ventilation (DCV)
Low-Ambient Compressor Lockout, and
Dry-Bulb Differential Changeover
Requires 2-stage HP
thermostat. "Normally
heating" reversing valve
shown. For "B"
(normally-cooling
reversing valve), reverse
contact positions shown
in relay.
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
5/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
C
N1
P
Discharge
Air Sensor
C7150B or
C7046A
T
R
24 VAC
TR
N
P1
TR1
Provide separate
actuator transformer
with Q769C
24 VAC Hot
T1
Com
+ Ctrl
- Ctrl
TR
TR1
Honeywell W7212A
Economizer Controller
1
AQ1
Outside Air
2
AQ+
4
Dry-Bulb
Sensor S
C7650A +
SO
3
SO+
SR
SR+
Return Air
Dry-Bulb
Sensor S
C7650A +
Thermostat
Occupancy Dry
Contact or Hot "Aux"
Terminal.
Thermostat
Terminals
5
EF
Adaptor
Q769C
Honeywell
M7415
Actuator
EF1
L1
Exhaust
Fan
DPDT relay
24VAC coil
Low OSA
Lockout
L2
Close on Rise
at 55 deg F
Unit
Terminals
A1
Y1
Y1
Y2
Y2
E
+
Note: Connection of W7215A
or W7460 is similar, although
layout is different and Q/Q1
are jumpered.
A2/
Aux
W2
-
T
T1
P1
P
Heat lockout:
Open on Rise
at 30oF OSA
Compressor
Compr. 2
W2
Aux. Heat
E
G
G
O
O
RH
R
RC
C
Em. Heat
Post Purge
Fan
Rev Valve
24 VAC
X
Hookup 7: One- or Two-Stage Heat Pump
W7212A Economizer Controller/M7415 with
2-stage Thermostat with Occupancy contact
Low-Ambient Compressor Lockout, and
Dry-Bulb Differential Changeover
Requires 2-stage HP
thermostat. "Normally
heating" reversing valve
shown. For "B"
(normally-cooling
reversing valve), reverse
contact positions shown
in relay.
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
4/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
Discharge
Air Sensor
C7150B or
C7046A
C
N1
P
T
R
P1
T1
24 VAC Hot
Com
24 VAC Hot
24 VAC Com
+ Ctrl
2-10 VDC
Control Signal
- Ctrl
Honeywell
M7215
Actuator
1
2
AQ+
Outside Air
4
SO
S
+
3
SO+
SR
SR+
Return Air
Dry-Bulb
Sensor
C7650A
See Hookup Diagram 7
for M7415 connection
Honeywell W7212A
Economizer Controller
AQ1
Dry-Bulb
Sensor
C7650A
TR1
TR
N
5
EF
EF1
L1
S
+
Locate CO2
sensor in space
or return air
Exhaust
Fan
CO2 Sensor
C7242
L2
+
Thermostat
Terminals
Y1
Close on Rise
at 55 deg F
Low OSA
Lockout
Unit
Terminals
Y1
Y2
Y2
W1
W1
W2
W2
G
G
RC
RH
R
X
C
Anticycle
Cool
Compr. 2
Heat
Heat 2
Fan Delay
Relay
Post
Purge
Fan
24 VAC
Hookup 8: One- or Two-Stage Heating/Cooling
W7212A Economizer Controller with
2-stage Thermostat, Demand Ventilation (DCV)
Low-Ambient Compressor Lockout, and
Dry-Bulb Differential Changeover
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
4/2004
EWEB EMS 541-484-1125
Western
Premium
Economizer
ExF
MAT
Discharge
Air Sensor
10k NTC
Thermistor
See Hookup Diagram 7
for M7415 connection
2-10 VDC +
Feedback 2-10 Ctrl +
2-10 Ctrl -
24 VAC Hot
24 VAC Com
+ OAH
- /OAE
OAT
Outside Air
RAT
Dry-Bulb
+
Sensor
C7650A S
2-10 VDC
Control Signal
Honeywell
M7215
Actuator
Honeywell W7340
Economizer
Controller
+ RAH
- /RAE
+ DCV
-
Return Air
Dry-Bulb
+
Sensor
C7650A S
P
L1
Configure economizer module for
"Enthalpy Sensors" using control
configuration procedure in Honeywell
document 63-2569.
Locate CO2
sensor in space
or return air
CO2 Sensor
C7242
P1
MBUS MBUS +
TR1 24V COM
TR 24V AC
+
Close on Rise
at 55 deg F
-
Low OSA
Lockout
Thermostat
Terminals
DPDT relay
24VAC coil
Exhaust
Fan
MBUSMBUS+
L2
Demand Limit
Compressor lockout
Jumper on Reliatel
LTB Block
Unit
Terminals
Y1
Y1
Y2
Y2
W2
W2
E
Heat lockout: Open
on Rise at 30oF OSA
Compressor
Compr. 2
Aux. Heat
E
G
G
O
O
RH
R
RC
C
Em. Heat
Post Purge
Fan
Rev Valve
24 VAC
X
Hookup 9: One- or Two-Stage Heat Pump
W7340 Econo. Controller (Trane Reliatel)
2-stage Thermostat, Demand Ventilation (DCV)
Low-Ambient Compressor Lockout, and
Dry-Bulb Differential Changeover
Requires 2-stage HP
thermostat. "Normally
heating" reversing valve
shown. For "B"
(normally-cooling
reversing valve), reverse
contact positions shown
in relay.
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
5/2004
EWEB EMS 541-484-1125
Sensor
Simulator
& Tester
Black
mA Meter
set > 50 mA
before energizing
Red
Volt
Meter
Parts List
Sensor Simulator
Potentiometers, 1 watt:
500 ohm, 1k ohm, 50k ohm
2A Fuse and fuseholder
(2) Resistors 220 ohm, 1/2 watt
Resistor 5.6k ohm, 1/4 watt
Resistor 33 ohm, 1/4 watt
LED, green
SPDT ON-OFF-ON switch
(2) 9V batteries & connectors
(3) leads; alligator clips both ends
Box, crimp connectors
Circuit Protector
leads; alligator clips, insulated
spades, 3A circuit breaker
Red
Red
0-10+ V DC output or
4-20+ mA output when
connected to control input
device.
Black
Red
White
-
+
220 ohm
1k ohm
"Fine"
500 ohm
"V/mA"
5.6k ohm
Turn off when not in use, as
voltage divider uses power
even when there are no
external connections.
Alkaline 9V batteries will
provide 8-12 hours of "on"
use depending on external
loading.
50k ohm
"Rough"
LED
220 ohm
33 ohm
Red
9V
9V Battery
Snap
connectors
Low Battery setting will
provide more voltage or
current, but will consume
battery faster.
Remote minimum
damper position
For Honeywell
economizer
connect white leads
to P/P1; 240 ohms
for closed OSA
damper to 0 ohms
for open OSA
damper
9V
Blk
Circuit Protector
Use a lead with in-line circuit breaker for transformer
common connection to protect economizer controller
and transformer until correct connections are verified.
Schematic 10: Testing Unit
Test box with:
0-10 VDC or 4-20 mA adjustable output
Battery Powered (2-9V)
Variable Resistor 0 ohms to 50k ohms
with "Rough" and "Fine" dials
White
Thermistor
Simulator
Set minimum of
330 ohms for
12 V max.
Set minimum of
1200 ohms for
24V max.
ON
OFF
Lo Bat
2A
Green
3A
Green
EWEB provides suggested wiring for
education only. Installer and customer
to determine suitability for specific
products and application.
5/2004
EWEB EMS 541-484-1125
Hookup Diagram 11: Pneumatic OSA Economizer
Western Premium Economizer
Pneumatic controllers and actuators.
Dry-bulb differential changeover; interlocked
control; sequenced actuators.
Suggested configuration; consult with EWEB
for other existing conditions.
Parts List (Added Parts Only, shown dark)
(Honeywell part numbers shown, equivalents may be used)
(2-3) Ratio Relays 3:10 input:output (H'ny'l RP971A1007)
Lockout Relay (H'ny'l RP470B) and bleed restrictor
Snap Relay (H'ny'l RP471A)
Low Ambient cooling lockout and E/P or snap acting relay
(2) Direct-Acting Temperature controllers for OA/RA
Minimum outside air setting
pneumatic potentiometer with
unoccupied period outside air
lockout.
M
E/P
Relay
Lockout and Snap Relays are
connected to outside and
return air dry-bulb
temperature controllers.
Whenever return air is
warmer than outside air,
dampers return to minimum
outside air setting .
Min OSA
Setting
High
Selector
Low
Selector
Snap
Relay
(pilot type shown; bleed-type controllers may be used)
Control Signal Table (Typical Values)
Item Actuator Ratio Relays Ratio/Setting Operation Example
Heat 3-8 psi NO
RR 3:10; set 3
Vent 3-13 psi NC RR 3:10; set 7
Ratio Relays allow the existing actuator spring ranges to be
used. Depending on spring ranges, all 3 may not be needed.
Set ratio relays so heating valve closes fully before outside air
opens above minimum and outside air is fully open before
cooling valve begins to open (unless the changeover has
locked out the economizer).
Alternate method: If at least a 2 psi gap between heating and
cooling valve ranges: activate mixed air controlled economizer
when heating valve is closed before cooling valve opens.
M
Ratio
Relay
Provide chilled water or chiller
ambient lockout when outside
air is below 55oF.
Ratio
Relay
Return
Air
Ratio
Relay
E/P
Relay
M
Exhaust
Air
M
HWS
CHWS
DA
Controller
M
M
EWEB EMS
541-484-1125
Closed at 7; Open at 10
Cool 9-13 psi NC RR 3:10; set 10 Closed at 11.8; Open at 13
Lockout
Relay
Outside
Air
Open at 3; Closed at 4.5
Mixed
Air
Optional direct-acting low-limit mixed air controller,
set 55F with associated low selector relay.
Discharge
Air
Existing Sensor
and receiver
controller,
discharge
controller, or
room thermostat
EWEB provides suggested connections for
education only. Installer and customer to
determine suitability for specific products
and application.
5/2004