Series R48 Single Zone Load Sequenced Economizer System: Installation & Troubleshooting

FANs 216, 121 Technical Bulletin R48 Issue Date 0695 Series R48 Single Zone Load Sequenced Economizer System: Installation & Troubleshooting Table of Contents Mounting... 1 Output Control... 2 Wiring... 2 Programming the Relays... 6 Adjustments... 8 Checkout Procedure... 8 R48DAF Stage Adder... 9 Repairs and Replacement... 9 Troubleshooting... 9 The R48 series consists of the Master Controller, Slave Controller and Stage Adder. The R48 Master Conroller is available in both 4- and 6-stage relay models. When an R48 Stage Adder is added to a Master Controller, up to four additional stages of heating or cooling can be handled by the relays on the Stage Adder. The R48 Slave Controller is only used when a single set of sensors will control more than one air handling unit. Each Slave Controller has a separate set of staging and damper control functions. The R48 Master Controller supplies the heating and cooling signals and the 21 VDC operating power. Refer to the R48 Product Data Bulletin for specifications, operational characteristics, system accessories and application information. Mounting Built into the R48 enclosure are four mounting holes. Fig. 1 shows the location of the holes and the mounting dimensions. Mount the unit on a flat surface and in an environment which meets the following conditions: Operating humidity: 20 to 90% RH Operating temperature: -40 to 150 F (-40 to 66 C).50 13.50 13 3.09 79.86 22 2.75 70 6.75 172 6.25 159 5.84 148.20 5.28 7 3.59 91 4.09 104.188 4.76.36 9.218 x 5.56 4 Places r48dm Fig. 1: Mounting Dimensions in./mm 1995 Johnson Controls, Inc. 1 Part No. 24-4235-0, Rev. B Code No. LIT-216080X

Output Control The R48 relay outputs can be programmed to actuate on either the heating ramp or the cooling ramp. The graph in Fig. 3 shows the proportional outputs for the R48. Voltage output can be measured on the following terminals referenced to common Terminals 3, 5 or 6: Cooling ramp output can be measured at Terminals 13, 15, 24 and 25. Damper signal can be measured at Terminal 14. Heating ramp output can be measured at Terminals 16, 23 and 26. Refer to Fig. 5 for location and designation of terminals. Wiring Cautions Disconnect motor actuator from power supply before making any wiring connections. Carefully check all wiring connections before applying power. The R48 is shipped with insulators which must be used to prevent possible electrical shock when switching line voltage. One insulator is factory installed on the NC contact of each relay stage. Two additional insulators per relay stage must be field installed on uninsulated male quick connect terminals. Do not run low voltage cables parallel or close to high voltage cables. To avoid electrical shock or equipment damage, observe all local and national electrical codes. To avoid damaging either the pins or the jumpers, use a needle-nosed pliers to gently lift the programming jumpers off the pins. Wiring Examples Several wiring examples are included in this bulletin. Table A identifies the examples and their figure numbers. Relay Identification Before programming the relays,you must know the location of each relay and the location of the programming pins associated with that relay. Fig. 2 shows the pins and relays of the 4-stage relay. The simplified schematics for both the 4- and 6-stage Master Controllers are shown in Fig. 4. Terminal Identification Refer to Fig. 5 for designation and description of the terminals. Installing the Control Wiring Select control wiring cable(s) from Table B. The length of the run and presence of other cables will determine the type of cable to use. Installing the Power Wiring To avoid potential miswiring, use a separate transformer to power the R48. When more than one R48 is powered from the same 24 VAC power source, maintain polarity by connecting the input terminals (Terminals 1 and 2) to the same side of the power supply. Refer to Fig. 5 for location of Terminals 1 and 2. Table A: Wiring Examples Figure No. Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig. 22 Fig. 23 Example Single Zone Operation with Sensible Outdoor Air Changeover and Mixed Air Low Limit Changeover Control When Used Without A80 Mixed Air Low Limit Single Zone Operation with Total Heat (Enthalpy) Changeover, Including Night Setback Return Air Sensing with Night Setup/Setback of Steam Heat and Chilled Water Cooling R48DAF Stage Adder Remote, Minimum Damper Position Adjustment Table B: Cable Selection Cable Length Recommendations 50 ft. (15 m) or less Use copper conductors. Shielding not required unless the cable is run in a common conduit with other low voltage cables near inductive loads. In that case, use cable recommended below for runs greater than 50 ft. (15 m). 50 to 250 ft. (15 to 76 m) Use shielded, 22-gauge copper cable, such as Beldfoil 8761 or equivalent. 250 ft. (76 m) or more Use shielded, 18-gauge copper cable, such as Beldfoil 8760 or equivalent. 2 R48 Technical Bulletin

g Relay A Heating/Cooling Selection r48rely1 Relay B Heating/Cooling Selection Relay B Function Selection Relay A Function Selection Fig. 2: Location of Relays and Programming Pins Volts 20 18 16 14 12 10 8 6 4 2 0 N-3ºF Minimum Postion Adjustable 0 to 100% N-2ºF N-1ºF N Setpoint N N+1ºF N+2ºF N+3ºF Adjustable No Load N= No-Load in ºF 2 r483 Fig. 3: Proportional Outputs R48 Technical Bulletin 3

Top Board: Relays A & B Heating 21 VDC 4-Stage Relay Model R48BBN Cooling Common A B D K H J H A Ca C K M L P Q Ra H B Cb C K M L P Q Rb Pin H C K L P M Q Signal Heating Cooling Heating or Cooling To Relay Coil To Relay Coil Common (H Wire) Common (Q Wire) Middle Board: Relays C & D H A Ca C K M L P Q Ra H B Cb C K M L P Q Rb 6-Stage Relay Model R48BBP Heating 21 VDC Cooling Common A B D K H J Top Board: Relays A & B H A Ca C K M L P Q Ra H B Cb C K M L P Q Rb Middle Board: Relays C & D H A Ca C K M L P Q Ra H B Cb C K M L P Q Rb Lower Board: Relays E & F H A Ca C K M L P Q Ra H B Cb C K M L P Q Rb r48schm1 Fig. 4: Simplified Relay Schematics for 4- and 6-Stage Models 4 R48 Technical Bulletin

Master Controller 4-Stage Master R48BBN* 6-Stage Master R48BBP 1 2 3 4 Slave Controller 4-Stage Slave R48CAP* 6-Stage Slave R48CAN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 16 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 16 Stage A A B C Stage B D E F Stage A A B C Stage B D E F Stage C G H J Stage D K L M Stage C G H J Stage D K L M Stage E N M O Stage F R S T Stage E N M O Stage F R S T r481 *Note: 4-Stage Controllers do not include Stage C and Stage D. r482 No. Abbreviation Designation Max. Current Output 1 24 VAC 24VAC Power Input - 2 24 VAC 24VAC Power Input - 3 COM Common - 4 +21 VDC +21VDC Regulated Output 200 ma, Total 5 COM Common - 6 COM Common - 7 +21 VDC +21VDC Regulated Output 200 ma, Total 8 +21 VDC +21VDC Regulated Output 200 ma, Total 9 OA C/O Outdoor Air Changeover Input - 10 REM MIN Remote Minimum Position Potentiometer Input - 11 MA LL Mixed Air Low Limit Input - 12 DA HTG Direct Acting Heating Ramp Output 8 ma, Total 13 CLG Direct Acting Cooling Ramp Output 8 ma, Total 14 DPR SIG Outside Air Damper (Natural Cooling Ramp Output) 8 ma, Total 15 CLG Direct Acting Cooling Ramp Output 8 ma, Total 16 RA HTG Reverse Acting Heating Ramp Output 8 ma, Total 17 COM Common - 18 SEN COM Space Sensor Common Terminal - 19 +21 VDC +21VDC Regulated Output 200 ma, Total 20 SETUP/SETBACK Night Setup/Setback Program Clock Connections - 21 SETUP/SETBACK Night Setup/Setback Program Clock Connections - 22 SEN Space Sensor Input Terminal - 23 DA HTG Direct Acting Heating Ramp Output 8 ma, Total 24 CLG Direct Acting Cooling Ramp Output 8 ma, Total 25 CLG Direct Acting Cooling Ramp Output 8 ma, Total 26 RA HTG Reverse Acting Heating Ramp Output 8 ma, Total Fig. 5: R48 Terminals: Location and Description R48 Technical Bulletin 5

Programming the Relays Programming directions are provided for the following systems and applications: A. Non-heat pump systems B. Heat pump systems C. Multiple relay outputs in parallel D. Simultaneously operating relays A. Non-Heat Pump Systems Refer to Fig. 2 for the location of relays and pins and Fig. 4 for the wiring schematics. 1. Remove the back panel of the R48. 2. Move the programming jumpers to the correct locations, depending on whether the relay will be used for heating or cooling. Refer to Table C for jumper settings for the 4-stage relay and Table D for the 6-stage relay. Fig. 6 shows the location of the jumpers. Programming Jumpers B. Heat Pump Systems Refer to Fig. 2 for the location of relays and pins and Fig. 4 for the wiring schematics. 1. Remove back panel of the R48. 2. On the left side of the board, set programming jumpers on pins A H and B C. With the jumpers at these locations, the board is set for one heating signal (A H jumper for relay A) and one cooling signal (B C jumper for relay B). Fig. 7 shows the location and setting of the jumpers. Install on Pins A-H and B-C r48rely3 Fig. 7: Heat Pump Application-- Jumper Settings for Staged Heating and Cooling 3. On the right side of the same board, are two additional sets of pins. Set jumpers on pins K L and M P of the relay which will be used. Set another jumper on pins K M of the other relay. In Fig. 8, relay B, the cooling relay, will be used. Relay B (Used) Jumpers M-Pand K-L Relay A (Unused) Jumpers K-M r48rely4 Fig. 8: Heat Pump Application-- Jumper Settings for Relay B r48rely2 Fig. 6: Non-Heat Pump Application--Jumper Settings for Staged Heating and Cooling Table C: 4-Stage Relay (R48BBN) Setting the Programming Jumpers Pull-In Drop-Out Jumper Location: Relay (VDC) (VDC) Cooling Heating A 12 4 A C A H B 13 5 B C B H C 14 6 A C A H D 15 7 B C B H Table D: 6-Stage Relay (R48BBP) Setting the Programming Jumpers Pull-In Drop-Out Jumper Location: Relay (VDC) (VDC) Cooling Heating A 12 4 A C A H B 13 5 B C B H C 14 6 A C A H D 15 7 B C B H E 16 8 A C A H F 17 9 B C B H 6 R48 Technical Bulletin

4. If several stages of heating/cooling are required, cut and remove a section of the H wire which runs between the boards. With the H wire cut, the heat pump operation is confined to the relays on the same board. Fig. 9 shows the location of the H wire. r48rely3 H Wire r48rely6 Fig. 10: Multiple Relay Outputs in Parallel--Jumper Settings for Staged Heating and Cooling 3. Determine which relay will be used to provide simultaneous relay outputs. On the right side of the board, set the jumpers on pins K L and P Q for that relay. For example, to program both relays for heating operation, relay B, the relay set for heating in the previous step, has jumpers set on pins K L and P Q. Fig. 11 shows this. Jumpers On Pins P-Q Of Relays A and C Fig. 12: Jumper Settings for Parallel Outputs r48rely7 D. Simultaneously Operating Relays If several sets of simultaneously operating relays are required, cut the J wire between the boards to isolate the relay drive signal to each board. Fig. 13 shows the location of the wire. If necessary, refer to Fig. 4 for the wiring schematic. Fig. 9: Location of H Wire r48rely5 C. Multiple Relay Outputs in Parallel The following procedure describes how a single comparator can be used to generate two isolated, parallel relay outputs. Refer to Fig. 2 for the location of the relays and pins and Fig. 4 for the wiring schematic. 1. Remove back panel of the R48. 2. On the left side of the board, for one heating stage and one cooling stage, set programming jumpers on pins A H (to use relay A for heating) and B C (to use relay B for cooling). These heating and cooling signals are now present on the K pins for each relay. Fig. 10 shows the location and setting of the programming jumpers. Fig. 11: Multiple Relay Outputs in Parallel Applications--Jumper Settings for Relay B 4. Set programming jumpers on pins P Q of all relays which are to operate in parallel. This relay does not have to be on the same board. In the example shown in Fig. 12, relay A on the top board and relay C on the bottom board will be triggered in parallel by relay B. J Wire r48rely8 Fig. 13: Location of J Wire R48 Technical Bulletin 7

Adjustments On the front of the R48 are the adjustments which control the following: 1) setup/setback range, 2) no-load range and 3) minimum damper position. Setup/setback range. Use SETUP/SETBACK to automatically setup or setback the temperature of a zone at night or during the weekends. You establish a range from 0 to 15 F (0 to 8.3 C) using SETUP/SETBACK, which is marked in 1 F (0.55 C) increments. Connect the building s program clock to Terminals 20 and 21. Refer to Fig. 5 for location of the terminals. Note: SETUP/SETBACK is factory set at 0 F (0 C) increments. No-load range. Define two temperature setpoints, up to 30 F (16.7 C) apart for a comfort range where no mechanical heating or cooling will occur. Example: with the LOAD BAND at 10 F (5.6 C) and the thermostat set to 70 F (21 C), the following occurs: Below 65 F (18 C), mechanical heating cycles Above 75 F (24 C), mechanical cooling cycles Note: LOAD BAND is factory set at 0 F (0 C) increments. Minimum damper position. Set MIN POS between 0 100% of outdoor air. For remote control, connect the Remote Damper Positioner (AQ-6001-8) to Terminals 10 and 6. Refer to Fig. 5 for location of the terminals. Also refer to Fig. 23 for a wiring example. Note: MIN POS is factory set for 0%. Checkout Procedure The ambient temperature must be -40 to 150 F (-40 to 66 C) and relative humidity must be 20 to 90%. Check the system and supply voltage wiring before applying power. Observe at least one complete operating cycle to see that all components are functioning correctly. Note: Refer to Fig. 5 for location of the terminals referenced in the following procedures. Checkout procedures are provided for the following conditions: A. Zone and discharge sensor checkout B. Simulating a high temperature C. Simulating a low temperature D. Simulating a high outdoor air temperature (high enthalpy) E. Simulating a low outdoor air temperature (low enthalpy) F. Simulating a high mixed air temperature G. Simulating a low mixed air temperature H. Minimum position potentiometer checkout A. Zone and Discharge Sensor Checkout 1. Disconnect the zone and discharge sensors from Terminals 18 and 22. 2. Check the sensors simultaneously or individually. Refer to Table E for correct resistance readings for both 1000 and 50 ohm sensors. Note: An infinite resistance across a sensor indicates an open sensor. Zero resistance indicates a shorted sensor. In either case, replace the faulty sensor and perform this checkout procedure again. 3. If the resistance readings are correct, reconnect the sensors to Terminals 18 and 22 and proceed to simulating a high temperature in the zone. B. Simulating a High Temperature 1. Disconnect the space (zone) sensor from Terminals 18 and 22. 2. Place a jumper wire between Terminals 8 and 9. 3. Verify that all cooling relays are now energized. 4. Connect a voltmeter, set to read up to 20 VDC, between Terminals 3 and 15. The meter should read 18 VDC or greater. 5. Remove the jumper wire and reconnect the sensor to Terminals 18 and 22. Table E: Temperature vs. Resistance Nominal Sensor Resistance: F C 1000 ohms 50 ohms -40-40 699 33.7-30 -34 725 36.3-20 -29 751 37.6-10 -23 777 38.9 0-18 803 40.2 10-12 830 41.5 20-7 858 42.9 30-1 885 44.3 40 4 914 45.7 50 10 942 47.1 60 16 971 48.6 70 21 1000 50.0 80 27 1030 51.5 90 32 1060 53.0 100 38 1090 54.5 110 43 1121 56.1 120 49 1152 57.6 130 54 1184 59.2 140 60 1216 60.8 150 66 1248 62.4 160 71 1281 64.1 170 77 1314 65.7 180 82 1348 67.4 190 88 1382 69.1 200 93 1417 70.9 210 99 1452 72.6 220 104 1487 74.4 230 110 1524 76.2 240 116 1560 78.0 8 R48 Technical Bulletin

C. Simulating a Low Temperature 1. Place a jumper wire between Terminals 18 and 22. 2. Verify that all heating relays are now energized. 3. Connect a voltmeter, set to read up to 20 VDC, between Terminals 3 and 16. The meter should read 18 VDC or greater. 4. Remove the jumper wire and reconnect the wires to Terminals 18 and 22. D. Simulating a High Outdoor Air Temperature (High Enthalpy) Follow this procedure if a W84 Enthalpy Control is being used. 1. Disconnect the changeover control from Terminal 9. 2. Place a jumper wire between Terminals 6 and 9. 3. Verify that the outdoor air damper has returned to its minimum position. 4. Disconnect the sensor from Terminals 18 and 22 to simulate a high cooling demand in the zone. All cooling relays should now be energized. 5. Remove the jumper wire and reconnect the wires to Terminals 9, 18 and 22. E. Simulating a Low Outdoor Air Temperature (Low Enthalpy) Follow this procedure if a W84 Enthalpy Control is being used. 1. Place a jumper wire between Terminals 8 and 9. 2. Disconnect the mixed air low limit control, if used, from Terminal 11. 3. Disconnect the sensor from Terminals 18 and 22 to simulate a high cooling demand in the zone. 4. Verify that the outdoor air damper is now fully opened and all cooling relays are energized. 5. Remove the jumper wire and reconnect the wires to Terminals 11, 18 and 22. F. Simulating a High Mixed Air Temperature 1. Disconnect the mixed air low limit control from Terminal 11. 2. Verify that the system has not been affected. Note: If the outside air temperature is very low and the mixed air temperature is below the mixed air low limit control setting, the outside air damper signal at Terminal 14 will be below the minimum position setting. Disconnecting Terminal 11 may increase the signal and open the outdoor air damper. 3. Reconnect the mixed air low limit control to Terminal 11. G. Simulating a Low Mixed Air Temperature 1. Place a jumper wire between Terminals 6 and 11. 2. Verify that the outside air damper has now returned to the fully closed position. 3. Remove the jumper wire. H. Minimum Position Potentiometer Checkout 1. Place a jumper wire between Terminals 6 and 10. 2. Disconnect the wire from Terminal 11. 3. Place a jumper wire between Terminals 8 and 9. 4. Connect a voltmeter to Terminals 3 and 14. 5. On the front of the R48, adjust MIN POS until it is fully CCW. The voltmeter reading should be less than 3 VDC. 6. Turn MIN POS fully CW. The voltmeter reading should be greater than 18 VDC. 7. Return MIN POS to its original setting. Refer to Adjustments on page 8 for more information on how to set the minimum damper position. 8. Remove the jumper wire and reconnect the wire to Terminal 11. R48DAF Stage Adder Use the R48DAF-1 Stage Adder with the R48 economizer panels for four additional stages of heating or cooling. Refer to the R48 Product Data Bulletin for Stage Adder specifications. Mounting Built into the R48DAF-1 are four mounting holes. Fig.1 shows the location of the holes and the mounting dimensions. Mount the unit on a flat surface and in an environment which meets the specifications listed in the R48 Product Data Bulletin. Wiring See wiring diagram, Fig. 22, for typical system hookup. When installing the Stage Adder, observe the precautions listed under Wiring, Page 2. Repairs and Replacement The R48 Master Controllers, Slave Controllers and Stage Adders are not field repairable. For a replacement, contact the nearest Johnson Controls branch office or the wholesale distributor. Troubleshooting Refer to Fig. 14, 15, 16, and 17 for troubleshooting guidelines. R48 Technical Bulletin 9

Check input voltage at terminals T 1 and T 2 on the M100G Motor Actuator. Is the Voltage between 20.4-26.4 VAC? Check: 1) Fuses 2) Circuit breakers 3) Power distribution lines 4) Transform er Check voltage between terminals T 1 and 10 on the M100G. Is the Voltage -11.5 to -12.5 VDC? Check voltage between terminals 9 and 10 on the M100G. Is the Voltage -2 VDC? Disconnect the R48 Controller from the M 100G. Place a jumper between Terminals 8 and 9 on the M100G Motor Actuator. Is M100G driven clockwise? Defective R81 circuit board in Motor Actuator. Replace with R81 GAA-3. N ote: If M o tor Actuator does n ot operate after installing R81G, replace the entire M otor Actuator. Disconnect the R48 Controller from the M 100G. Place a jumper between Terminals 8 and 10 on the M 100G Motor Actuator. Is M100G driven counterclockwise? Check Terminals 3 and 14 on the R48 Controller. Is the total cu rrent output 8 ma or less? Remove any resistors between DC input and Terminal(s) T1 of Motor Actuator(s). r48flow1 Fig. 14: Troubleshooting the M100G Motor Actuator 10 R48 Technical Bulletin

Check input voltage at Terminals 1 and 2 on the R48 Controller. Is the Voltage between 20.4-26.4 VAC? Check output voltage at Terminals 3 and 4 on the R48 Controller. Is the Voltage between 20.79-21.21 VDC? Check the following: 1) Fuses 2) Circuit breakers 3) Power distribution lines 4) Transformer Does a short circuit exist in the wiring of the auxiliary devices? 1) Disconnect the Series A80 Mixed Air Low Limit Control from terminal 11 on the R48 Controller. 2) Place a jumper between terminals 8 and 9 on the R48 Controller. 3) Disconnect the Series TE-6000 Zone and Discharge Sensor from terminal 18 on the R48 Controller. 4) Rotate clockwise the adjustment screw "MIN POS" on the front of the R48 Controller. Did the dam per open as the screw was turned? 1) Series A80 Mixed Air Low Limit Control 2) Series A19 Outdoor Air Changeover Control 3) Series TE-6000 Zone and Discharge Sensors Correct the cause of the short circuit. Replace R48 Controller. Check the MIN POS adjustment screw on the front of the R48 Controller. If the integral M inimum Dam per Positioner is being used, MIN POS must be set to a number other than 0%. Is MIN POS being used (not set 0%)? If the integral Minimum Damper Positioner is being used, a jumper m ust be installed between Terminals 6 and 10 on the R48 Controller. Is the jumper present? Measure the voltage between Terminals 3 and 14 on the R48. Does the voltage vary between 3-18 VDC as the "MIN POS" screw is turned clockwise? Install jum pe r between Terminals 6 and 10. Replace R48 Controller. Refer to Fig. 14, "Troubleshooting the M100G Motor Actuator. " r4 8flow2 Fig. 15: Troubleshooting the R48 with No Damper Modulation R48 Technical Bulletin 11

Check output voltage between terminals 3 and 4 on the R48 Controller. Is the Voltage between 20.79-21.21 VDC? Check input voltage at T erminals 1 and 2 on the R48 Controller. Is the Voltage between 20.4-26.4 VAC? Check the following: 1) Fuses 2) Circuit breakers 3) Power distribution lines 4) Transform er s Recheck the voltage at Terminals 3 and 4 Is the Voltage between 20.79-21.21 VDC? Does a short circuit exit in the wiring of the auxiliary devices? 1) Simulate a zone heating demand by placing a jumper between T erminals 18 and 22 on the R48 Controller. 2) Measure the voltage between T erminals 3 and 16. Is the voltage 18 VDC? Correct the cause of the short circuit. Replace R48 Controller. Replace R48 Controller. Gas Fixed/Electric Heat Are the relays programmed correctly? Hot Water/Steam Heat Is the M100G Motor actuator operating correctly? Check wiring to heating equipment. Refer to Programming the Relays, Page 6. Check for defect(s) in hot water/steam supply. Refer to Fig. 14, "Troubleshooting the M100G Motor Actuator." r48flow3 Fig. 16: Troubleshooting the R48 with No Heat Output 12 R48 Technical Bulletin

Check input voltage at Terminals 1 and 2 on the R48 Controller. Is the Voltage between 20.4-26.4 VAC? Check the following: 1) Fuses 2) Circuit breakers 3) Power distribution lines 4) Transformer s Check the voltage at T erminals 3 and 4. Is the Voltage between 20.79-21.21 VDC? Does a short circuit exit in the wiring of the auxiliary devices? 1) Simulate a zone heating demand by placing a jumper between terminals 18 and 22 on the R48 Controller. 2) Measure the voltage between terminals 3 and 16. Is the voltage 18 VDC? Correct the cause of the short circuit. Replace R48 Controller. Replace R48 Controller. DX Cooling Are the relays programmed correctly? Chilled Water Cooling Is the M 100G Motor actuator operating correctly? Check wiring to cooling equipment. Refer to Programming the Relays, Page 6. Check for defect(s) in hot water/steam supply. Refer to Fig. 14, "Troubleshooting the M100G Motor Actuator." r4 8flow4 Fig. 17: Troubleshooting the R48 with No Cooling Output R48 Technical Bulletin 13

Series A80 Mixed Air Low Limit Control To Term 3 To Term 14 Increase Temp Y B R 10 9 8 Increase Temp 1 2 3 4 Power Supply 24 VAC 20 VA Transformer* Transformer* 24 VAC Power Supply T1 T2 X 9 DC (+) Input 8 10 X M100G Motor Actuator * A Separate transformer is required for M100G actuator. ** A 50 Ohm Discharge Air Sensor is required. *** Jumper required between terminals 6 and 10 when using integral minimum position adjustment. Series A19 Sensible Outside Air Changeover Control 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 16 TE-600 0-5 & TE-6001-1** (50 Ohm s) Z one Discharge Sensor Stage A A B C Stage B D E F TE-6100-8 & Cover (With Set Point) Room Sensor Stage C G H J Stage D K L M Stage E N M O Stage F R S T Increase Temp. Y B R Series A19 Outside Air Refrigeration Lockout L 2 L 2 Heating 1 Heating Heating 2 3 Cooling C oo ling 3 2 Cooling 1 L 1 L 1 CAUTION When switching line voltage, the insulators provided with the R48 must be used to prevent possible electrical shock at relay stage terminals. r48wire1 Fig. 18: Single Zone Operation with Sensible Outdoor Air Changeover and Mixed Air Low Limit 14 R48 Technical Bulletin

A19 Temperature Control Y Increase Temp. 1 2 3 4 B R If Sensible Changeover Is U se d 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 2526 Stage A A B C Stage B D E F 16 CAUTION: When switching line voltage, the insulators provided with the R48 must be used to prevent possible electrical shock at relay stage terminals. * Jumper required between terminals 20 and 21 when not using night setback. Stage C G H J Stage D K L M * * Jumper required between terminals 6 and 10 when using integral minimum position adjustment. Stage E N M O Stage F R S T r48wire2 Fig. 19: Changeover Control When Used Without A80 Mixed Air Low Limit R48 Technical Bulletin 15

Series A80 Mixed Air Low Limit Control 10 Increase Temp 9 Increase Temp Y 8 Power Supply 24 VAC Transformer* T1 T2 X 9 DC (+) Inpu t 8 10 X M100G Motor Actuator R Series A19 Sensible Outside Air Changeover Control B N3 N3 Provides Night Setback Function 5 1 2 3 4 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 Stage A A B C Stage C G H J Stage B D E F Stage D K L M 16 Cooling 1 Cooling 2 * A separate transformer is required for M 100G actuator. * * N4 is required only when mechanical cooling is to be locked out in the unoccupied mode. * * * Jumper required between terminals 6 and 10 when using integral minimum position adjustment. Cooling 3 Stage E N M O Stage F R S T Cooling 4 L 1 CAUTION: When switching line voltage, the insulators provided with the R48 must be used to prevent possible electrical shock at relay stage terminals. TE: All "N" program clock contacts are shown in the occupied mode. Increase Temp. Y B R N4** Series A19 Outside Air Refrigeration Lockout Control L 2 r48wire3 Fig. 20: Single Zone Operation Changeover, Including Night Setback 16 R48 Technical Bulletin

Series A80 Mixed Air Low Limit Control 10 Increase Temp Increase Temp Y B R Series A19 Sensible Outside Air Changeover Control 9 8 1 2 3 4 Power Supply Transformer* (-) 24 VAC T1 T2 X 9 DC (+) Input 8 10 X Heating Coil Valve (Stem Up, N.O. to C oil) M100G Motor Actuator N3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Stage A A B C Stage B D E F TE-6000-5 & TE-6001-1 (50 ohms) Zone Discharge Sensor Stage C G H J Stage D K L M (-) Stage E N M O Stage F R S T Power Supply 24 VAC T1 T2 X 9 DC (+) Input 8 10 X M100G Motor Actuator TE-6000-1 (1000 ohms) R e tu rn Air Sensor C oolin g C o il Va lve (N.C. to Coil) CW AQ-6001-2 Ad justable R em ote Set Point 1 3 2 4 CAUTION: When switching line voltage, the insulators provid ed with the R 48 m ust be used to prevent possible electrical shock at relay stage terminals. TE: All "N" program clock contacts are shown in the occupied mode. * A separate transformer is required for M100G actuator. * * Jumper required between Terminals 6 and 10 when using integral minimum position adjustment. r48wire4 Fig. 21: Return Air Sensing with Night Setup/Setback of Steam Heat and Chilled Water Cooling R48 Technical Bulletin 17

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 4 5 6 8 Stage A A B C Stage B D E F Stage A Stage B A B C D E F Stage C G H J Stage D K L M Stage E N M O Stage F R S T Stage C G H J Stage D K L M r48wire5 R48 Master R48 DAF Wiring the R48DAF-1 into an R41 or R48 System Control Number R48DAF-1 R48 Control Signal Input 6 (Heating) 16, 26 (Heating) 5 (Cooling) 13, 15, 24, 25 (Cooling) +21 VDC Supply 3, 4 4, 7, 8 Common 1, 2 3, 5, 6, 7 Fig. 22: R48DAF Stage Adder 18 R48 Technical Bulletin

AQ -6 001-8 Remote Minimum Position Adjustor (-) CW 1 2 4 Power Supply 24 VAC T1 T2 X 9 DC (+) Input 8 10 X M100G Motor Actuator 5 1 2 3 4 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 16 M100J Motor Actuator 10 8 T1 9 X T2 24 VAC Power Supply Stage A A B C Stage B D E F M100J Motor Actuator 10 8 T1 24 VAC Power Supply 9 X T2 Stage C G H J Stage D K L M Stage E N M O Stage F R S T CAUTION: When switching line voltage, the insulators provided with the R48 must be used to prevent possible electrical shock at relay stage terminals. r48wire6 Fig. 23: Remote, Minimum Damper Position Adjustment R48 Technical Bulletin 19

Notes Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI 53202 Printed in U.S.A. 20 R48 Technical Bulletin