Hoffman Controls 816-10DH Manual

• Install the controller in a weatherproof control panel or
use HCC’s
NEMA 3R Weatherproof Kit (Part Number
545-0202-007)
.
Note:
Controller must be protected from
moisture and condensation.
WARNING
Disconnect power from the unit and electrically
disable the compressor prior to installation.
• Setting Minimum Speed Adjust: An adjustment,
Min Speed
,
is provided to accommodate the slowest allowable speed for ball
bearing or sleeve bearing type motors.
Recommended Minimum Speed
Ball Bearing Motors 200 RPM 7–9 o’clock
Sleeve Bearing Motors 400 RPM 3–5 o’clock
IMPORTANT
• Do not install the Controller in an airtight compart-
ment, or near heat generating sources.
• Do
not
attempt
to
set
Minimum
Speed
Adjust
to
obtain
a
desired
head
pressure.
This
adjustment
is
only
provided
to
compensate
for
fan
bearing
type
and
must
not
be
used
otherwise.
Improper
operation
will
result.
• Single sensor application must use the control's “S1” &
“COM” terminals. (Motor will run at full speed if sensor
is not connected to “S1” & “COM”).
Heat Pump Mode Jumper
Heat Pump Applications
For Heat Pump System applications, the lower "
H P
"
jumper tab
position is as follows: (See
Figure 1
)
Jumper position "RA"
is used when the Heat Pump reversing
(changeover) valve is activated (Heat Mode) by the
absence of 24
VAC
at the Heat Pump input terminals of the Control.
Jumper position "DA"
is used when the Heat Pump reversing
(changeover) valve is activated (Heat Mode) by the
presence of 24
presence of 24
VAC
at the Heat Pump input terminals of the Control.
Note:
The Condenser Fan Motor should run at full speed when in the
heating mode. The applicable RA or DA method of operation varies by
manufacturer and must be verified by the Installer/Service Technician.
General
CAUTION
Failure to read and understand the accompa-
nying instructions and diagrams or failure to
complete the “Checkout Procedure” prior to
energizing the Control may result in permanent
damage to the Control.
The 816-10DH Controller requires the installation of an
addi-
tional line voltage to 24
V
AC transformer (
VAC transformer (V
10VA mi
nimum)
. This
additional transformer's primary wires
must
be connected to the
must be connected to the must
exact same contactor terminals that supply power to the condenser
fan motor(s). Refer to Figures 3 & 4.
Pre-Installation Information/
Instruction
1.
For use with Single Phase, direct drive, open frame permanent
split capacitor, or shaded pole motors. Motors are to be select-
ed or designed for variable speed drive applications.
2.
Line Voltage Range: 115
V
AC, 208-230 VAC, 460
VAC, 208-230 VAC, 460 V
V
AC, or
VAC, or V
600 VAC.
3.
Wiring
must
comply
with
Local
and
National
Electrical
Codes.
4.
One Controller may control more than one motor.
a.
Maximum running amps, under all conditions, not to
exceed 10 amps.
b.
Locked Rotor Amps (LRA) not to exceed 30 Amps for 1
second.
5.
Do not mount the Controller in an airtight cabinet or
compartment.
6.
Application
Limitation:
Speed
regulation
and
performance
characteristics
will
vary
with
motor
design
and
motor
ventilating
capability.
Motors
used
should
be
designed
for
variable speed
operation
and
should
be
evaluated
for
suitability
and
acceptabil-
ity.
TEC
(totally
enclosed
types)
are
not
recommended
or
not
generally
suitable.
Installation
• Select
the
appropriate
line
voltage
wiring
diagram
for
either a
single capacitor (
Figure 3
) or dual capacitor (
Figure 4
) configu-
ration.
• Disconnect all factory wiring connecting the motor to the line.
Hoffma
n
|
Controls
Installation & Operating
Instructions
�
816-10DH Microprocessor Based
Electronic Head Pressure Control




1

2
Mode Jumper Diagram Figure 1
NON-Heat Pump Applications
For
NON
-Heat Pump System applications, the jumper tab
should be in the
"DA"
position as shown in Figure 1 for proper
operation.
NOTE:
If the jumper tab is in the "RA" position for NON-
Heat Pump applications, the condenser fan motor will operate at
full speed and will not modulate.
A selectable span of 25ºF or 30ºF is available (see
Figure 1
).
The 25ºF span is recommended for high efficiency units while the
30ºF span is recommended for older lower efficiency units.
The Range Adjust potentiometer provides 50ºF-80ºF up to 70ºF-
100ºF for the 30ºF span. The 25ºF span provides for adjustments
from 55ºF-80ºF up to 75ºF-100ºF. Markings are in 5ºF increments.
Typically TXV devices should be set at full CCW or at the second
mark. Orifice or Cap Tube devices should be set at the 4th or full
CW markings. These positions should provide adequate control of
head pressure for the specific device being used. The lower range
adjust positions will allow control to a lower ambient. Conversely,
the higher range adjust positions will provide control only to a higher
ambient. Factory Range Adjustment is set at 50ºF-80ºF.
CAUTION: It is not recommended that the range adjust be set
to satisfy a selected head pressure. These various range adjustments
are provided to ensure proper ambient control when the system is
properly charged (no vapor in the sight glass), filters and coils are
clean, and an air flow of 400 cfm/ton is available for delivery in the
HVAC system. In refrigeration application, consult factory or see
Engineering Bulletin for “Low Ambient Refrigeration Applications.”
Liquid Line Sensor
• Install Sensor(s) to the top of liquid line where the line exits the
condenser coil (refer to
Figure 2
). If two compressors (circuits)
are used, a second Sensor is required for the second refrigerant
circuit. (Part Number 100-0017-001.)
• Use the special tape provided to secure the Sensor to the liquid
line. Stretch the tape slightly, as you wrap the tape around the
sensor and liquid line. Use all the tape, lapping the Sensor.
•
Firm, mechanically clean, contact is required between the metal
tab of the Sensor and the liquid line. When using one sensor,
always use the control's
S1
and
COM
terminals.
•
D
O NOT
use t
ie wraps or hose clamps to secure sensor to
liquid line. Sensor element will b
reak.
• Connect the Sensor(s) wires to the Sensor input terminals.
• Additional
insulation
of
the
taped
sensor
and
adjacent
refrigerant
line
back to condenser header
is
required
in
extremely
cold
ambients
(+20º F).





Sensor Diagram Figure 2
1
Checkout Procedure
Step 1
With power disconnected and the Controller wired:
1.
Measure the ohms across the Control's terminals “#1” and
“#2” using an ohm meter.
2.
For single condenser applications; if you read 1 ohm or less
(115
V
AC operating voltage), or 5 ohms or less (208
V
AC or
greater operating voltage), the controller is improperly wired.
CAUTION
Correct
wiring
error(s).
Do
not
apply
power
if
incorrect
ohm
values
were
measured
during
para-
graph 2,
above
.
(The
load
is
shorted;
applying
power
will
destroy
the
c
ontroller.)
Step 2
With the compressor disabled, set thermostat for cooling
demand and apply voltage to the unit. Condenser fan will
start if liquid line temperature is 3º above the low ºF value
selected
using
selected usingselected
the Span jumper and Range Adjuat pot.
using the Span jumper and Range Adjuat pot. using
1.
Monitor liquid line temperature (°F) and condenser motor
voltage and current.
2.
Verify
that
the motor is
operating
properly for temperature
sensed. Depending on the Range Adjust position, when the
sensor temperature at “start up” is:
a.
Below
S
elected Span and Range
Minimum
,
depending on where the range adjust is set, the
motor(s)
will
not
start.
b.
Within Selected Span and Range
,
t
he
motor(s)
will
start
at
full
speed
for
a
few
seconds
and
immediately
modulate
to
a
reduced
speed
proportional
to
the
tempera-
ture
sensed when the temperature is 3
°
F
above the low end
of the
range adjust.
........................................................................ .
Continued on page 4
�
 


 
816-10DH Span
Range Adjust Pot
Sensor Installation




















 
 
 
 
 
 








 
 
 

50|55º- 80°
70|75º-100°
Range
Adjust
Min
Speed
LOAD LINE 24VAC
Faster (Sleeve)
Slower (Ball)
HPGND
Span
H P
Model 816-10DH
Featuring Range & Span Adjust
30º 25º
DA RA
HP24V
www.hoffmancontrols.com
C
®
10 Amps 115 | 208-230 | 460 | 600 VAC 50 | 60 Hz
Hoffman | Controls
#1 #2 #3 #4
MOTOR
GND
#4 IF
REQ
LINE
Microprocessor Controller
S2S1 COM
 

Wiring Diagram for the 816-10DH
Figure 4
3


 













 
 
 
 
 








 
 
 

50|55º- 80°
70|75º-100°
Range
Adjust
Min
Speed
LOAD LINE 24VAC
Faster (Sleeve)
Slower (Ball)
HPGND
Span
H P
Model 816-10DH
Featuring Range & Span Adjust
30º 25º
DA RA
HP24V
www.hoffmancontrols.com
C
®
10 Amps 115 | 208-230 | 460 | 600 VAC 50 | 60 Hz
Hoffman | Controls
#1 #2 #3 #4
MOTOR
GND
#4 IF
REQ
LINE
Microprocessor Controller
S2S1 COM

Wiring Diagram for the 816-10DH
Figure 3

Hoffman
|
Controls
2463 Merrell Road, Dallas, Texas 75229 • Phone: [phone] • Fax: [phone] • Toll Free: 1-888-HCC-1190
www.hoffmancontrols.com Form: 173-0229-001 Rev B
Temperature to Resistance Table - Key Point Values
Table 1
Temp
ºF
Sensor
(Ohms)
Temp
ºF
Sensor
(Ohms)
Temp
ºF
Sensor
(Ohms)
40.0 26,109 64.0 13,823 88.0 7,685
42.0 24,712 66.0 13,139 90.0 7,332
44.0 23,398 68.0 12,492 92.0 6,997
46.0 22,160 70.0 11,881 94.0 6,679
48.0 20,996 72.0 11,3033 96.0 6,378
50.0 19,899 74.0 10,8509 98.0 6,092
52.0 18,872 76.0 10,2095 100.0 5,820
54.0 17,903 78.0 9,750 102.0 5,561
56.0 16,990 80.0 9,287 104.0 5,316
58.0 16,128 82.0 8,848 106.0 5,094
60.0 15,315 84.0 8,433 108.0 4,873
62.0 14,547 86.0 8,056 110.0 4,662
40.0 26,109 64.0 13,823 88.0 7,685
42.0 24,712 66.0 13,139 90.0 7,332
44.0 23,398 68.0 12,492 92.0 6,997
46.0 22,160 70.0 11,881 94.0 6,679
48.0 20,996 72.0 11,3033 96.0 6,378
50.0 19,899 74.0 10,8509 98.0 6,092
52.0 18,872 76.0 10,2095 100.0 5,820
54.0 17,903 78.0 9,750 102.0 5,561
56.0 16,990 80.0 9,287 104.0 5,316
58.0 16,128 82.0 8,848 106.0 5,094
60.0 15,315 84.0 8,433 108.0 4,873
62.0 14,547 86.0 8,056 110.0 4,662
40.0 26,109 64.0 13,823 88.0 7,685
42.0 24,712 66.0 13,139 90.0 7,332
44.0 23,398 68.0 12,492 92.0 6,997
46.0 22,160 70.0 11,881 94.0 6,679
48.0 20,996 72.0 11,3033 96.0 6,378
50.0 19,899 74.0 10,8509 98.0 6,092
52.0 18,872 76.0 10,2095 100.0 5,820
54.0 17,903 78.0 9,750 102.0 5,561
56.0 16,990 80.0 9,287 104.0 5,316
58.0 16,128 82.0 8,848 106.0 5,094
60.0 15,315 84.0 8,433 108.0 4,873
62.0 14,547 86.0 8,056 110.0 4,662
c.
Above Selected Span and Range,
The
motor(s)
will
start
and
remain
at
full
speed when temperatures are above the
high end of the range
adjust
.
d.
Simple Test:
If Sensor 1 is not connected, motor runs at full speed.
Important:
Always use Sensor 1 input.
Step 3
Making unit ready for normal operation.
1.
Disconnect power to the unit & reconnect the disabled com-
pressor.
2.
Reconnect power to the unit & observe operation.
3.
Verify operation as described above by monitoring liquid line
temperature and observing motor speed.
Troubleshooting Guide
1.
Check wiring, review instructions.
2.
Additional 24 VAC transformer needed.
See "
GENERAL
" section instructions
3.
Normal operation.
4.
Motor protected.
5.
Check Heat Pump Mode Jumpers “DA”
and “RA”.
1.
Check wiring, review instructions.
2.
Replace control.
3.
Charge system.
4.
Replace Sensor.
5.
Normal operation.
6.
Switch DA/RA jumper position.
1.
Raise Min. RPM speed.
2.
Replace motor.
1
.
Additional 24 VAC transformer needed.
See "
GENERAL
" section instructions
2
.
Relocate per instructions.
3
.
Compare FLA rating to measured FLA.
4
.
Replace Sensor.
5
.
Replace Motor.
6
.
Recharge system. Add or remove refrig-
erant. (Liquid line must not indicate
vapor/gas.)
7
.
Adjust or replace expansion valve, cap
tube or orifice to provide proper control
of lowside.
8
.
Reset Range Adjust up (CW) to provide
evaporator temperature above 32°F.
Motor Will
Not Run
Motor Runs
at Full Speed
Only
Motor
Overheats
1.
Improper installation. Motor not wired correctly.
2.
24 VAC not in phase with motor line voltage.
3.
Sensor below 50°F up to 70°F.
4.
Motor “OFF” on internal overload.
5.
Heat Pump applications; control not providing full speed during
defrost cycle.
1.
Motor not wired correctly.
2.
Motor not wired correctly. Control damaged.
3.
Low refrigerant. (Hot gas in liquid line.)
4.
Sensor opened. (Verify Ohms vs. Temp.)
5.
Sensor above 80°F up to 100°F.
6.
Heat Pump Mode improperly programmed.
1.
Minimum speed set too low.
2.
Motor design not applicable for variable speed operation.
1
.
24 VAC not in phase with motor line voltage.
2
.
Sensor not properly located or attached to liquid line.
3
.
Fan blade does not load motor at full RPM (speed).
4
.
Sensor Ohms vs. Temperature measured not in compliance with
values in Table 1.
5
.
Motor design not applicable for
variable
speed
operation
.
6
.
System not properly charged.
7
.
Expansion
valve
is
not
properly
metering
refrigerant;
cap
tube
or
orifice
not
properly
sized
for
low
ambient
operation.
8
.
Low evaporation and head pressure.
Motor Will
Not Modulate
Properly
Condition
Cause
Solution
Condition
Checkout Procedure Con't