Full Text Searchable PDF User Manual
1
8733 800-259 KIT
Replacement Kit:
641-176
641-187
641-225
641-244
IOM
THE UPM CONTROLLER .......................3
SPECIFICATIONS ................................4
KIT INCLUDES .....................................5
INSTALLATION PROCEDURE ...............5
Remove Old Board ........................................................5
Mounting holes..............................................................5
Wiring Installation.........................................................6
Sensor Installation .........................................................8
FINAL PROCEDURES .........................10
Table of Contents
2
The UPM Controller
The Unit Protection Module (UPM) board,
shown in
Figure 1
, is used in all ‘configure-to-
order’ applications.
The controller provides short cycling and
refrigerant circuit protection. The controller is
a plug and play device which also has
options for freeze and condensate overflow
protection if sensors are installed.
The controller is programmed and it is
backwards compatible for most functions of
its earlier versions. This controller can be
used as replacement for the following part
numbers:
1.
641-176
2.
641-187
3.
641-225
4.
641-244
User settings such as reset on power versus
“Y call” and the number of faults prior to
lockout among others can be adjusted by a
qualified technician when replacing previous
revisions.
Figure 1 - UPM Controller
3
Specifications
Power:
24VAC ± 10%, 50-60Hz, 1.4 VA of standby power consumption
(Single Class II 70VA or 100VA option available)
Physical:
Printed Circuit Board and plastic stand offs.
Environmental
Operating Range
:
-40° to 176°F (-40 °C to 80°C); 10 to 90% relative humidity, non-condensing
All
controls
are
conformal
coated for environmental protection.
Digital Outputs:
Two digital outputs relay contacts rated at 10A resistive @ 125 VAC; One dedicated for the
compressor contactor 24VAC when “ON” and one dedicated for alarm purposes dry
contact Normally Open (NO)
Inputs:
Four (4) inputs. Dedicated inputs for:
High Pressure Switch (HPC)
Low Pressure Switch (LPC)
Freeze Sensor (FREEZE) 10 K @ 77F Thermistor
Condensate Overflow Sensor (CON) 230 K +/- 15%
Compressor Call (Y) Signal
Status Indication:
Visual (LED) status of power and alarms status indication.
Protection:
Surge and transient protection circuitry.
Weight:
0.14 lbs. (0.07 Kg).
Overall
Dimensions:
4-1/4” (width) by 3-3/4” (height) by 1-3/4” (recommended panel depth).
108mm (width) by 95mm (height) by 32mm (recommended panel depth).
Listed By:
UL
Mounting Hole
Dimensions:
Four mounting holes in rectangular pattern with dimensions between them as follows:
3-3/4” (width) by 3-1/4” (height).
95mm (width) by 83 mm (height).
4
5
Kit Includes
The UPM replacement kit includes the following components required for the replacement from
all previous board versions.
Included in this kit
Description Qty
Screws 1"
4
UPM I Replacement Instructions
1
UPM I IOM
1
Nylon Tubular Sleeves
4
Unit Protection Module, UPM-I
1
Freeze sensor jumper Assembly
1
Ground harness Assembly
1
Needs to be updated
Installation Procedure
Controller shall be installed inside the unit
electrical box; mounting holes are available
on the location of the previous board. The
plastic stand-offs from the UPM board match
the pilot holes on the electrical box.
Remove Old Board
1.
Locate existing UPM in unit electrical
box.
2.
Verify old part number on the old board
as one of the four listed on page 3.
3.
Take a picture or LABEL all wires
currently present and according to the
terminal designations on the UPM
board.
4.
Disconnect all the previously labeled
wires.
5.
Remove existing circuit board.
Mounting Holes
If existing UPM has plastic stand-offs, pinch
the tab on the stand-off from the top side
and push downward to release it from the
circuit board as shown in
Figure 2
. The snap
the new board onto the stand-offs.
If existing UPM does NOT have plastic
stand-offs, choose one of the following:
A.
If drilling is possible bigger pilot holes
will need to be made.
1.
Use a unit bit or a 3/16” (0.187”)
drill bit to enlarge the existing pilot
hole of the electrical box.
2.
Align the plastic stand-offs with
the new pilot holes and push in
firmly until the stand-offs snap in
and do not pull out.
B.
If drilling is not possible due to space
constraints screws will be used to
fasten the board.
1.
Remove plastic stand-offs from
the new controller. Pinch the tab
on the stand-off from the top side
and push downward to release it
from the circuit board as shown in
Figure 2
.
2.
Secure controller to unit by using
four 1” long #6 screws along with
the tubular sleeves.
Figure 2 - Plastic Stand-Off
Wiring Installation
Reconnect the wires using the labels or
picture from old board removal process.
IMPORTANT: Freeze Protection
A.
If the unit is not equipped with
Freeze Protection, use the
supplied jumper to short the
FREEZE
terminals.
Open
connections will result in faults
and lockouts.
B.
If unit has an existing Freeze
Protection or if it will be
installed proceed to Sensor
Installation section on page 8.
6
7
1.
Adding a new screw to the
electrical box.
2.
Using an existing screw that
secures an existing component.
IMPORTANT: Ground
Do not forget to ground the board. If a
connection is not available, ground the
terminal by:
Avoid sharp edges on unit
cabinet during installation
C O N T R O L S
Figure 3 - UPM Location
Sensor Installation
If the unit is equipped with freeze sensor, it
can be found attached to the leaving water
pipe as shown in
Figure 4
.
Figure 4 - Freeze Sensor's Previous Location, Older
Versions
The new controller has a different trip point
for sensing freeze condition, and therefore
the freeze sensor must be relocated to the
refrigerant line as shown in
Figure 5
.
Figure 5 - Freeze Sensor's New Location
Once the sensor has been relocated use
wire ties and cork tape to secure and
insulate sensor as shown below in
Figure 6
,
Figure 7
, and
Figure 8
.
If this is a new install (no previous sensor)
the wires must be led into the electrical box
and connected to the UPM across the
FREEZE connections as shown in
Figure 9
.
IMPORTANT:
If unit is equipped with factory installed
DDC, two sensors can be found. Make
sure that the DDC leaving water sensor
remains in place as it may cause
nuisance alarms in the building
automation system.
8
Figure 6 - Sensor with Wire Ties
Figure 7 - Wire Tied Sensor with Cork Tape
Figure 8 - Final Sensor Installation with Insulating Tape
9
10
Final Procedures
1.
Check the blue dip switch with the
white rockers. The table above shows
the switch functionality.
2.
If the STATUS LED is blinking, count
the number of blinks in an interval.
The number of blinks will indicate the
fault.
Figure 10
shows the operation
flow and consequences of each fault.
Use the flow chart to back track the
connection error. To the right of the
POWER and STATUS LEDs, a list of
number
of
blinks
and
their
corresponding faults are shown.
1= High Pressure Switch
2= Low Pressure Switch
3= Freeze Protection
4= Condensate Sensor
5= Brownout Protection
A COND error will result in a hard lockout
requiring a restart. All other errors must be
tripped four times to reach a hard lockout, as
set on the dip switch #4 ON, setting #4 OFF
will require only two error trips for a hard
lockout.
4 LOCKOUT
4
2
3
RESET
R
Y
2 ALARM CONT
PULSE
1
TEST
YES
NO
IMPORTANT: Freeze Protection Faults
If the unit is not equipped with Freeze
Protection, use the supplied jumper to
short the FREEZE terminals. Open
connections will result in faults and
lockouts.
11
12
Figure 9 - UPM Typical Wiring Components
13
Figure 10 - UPM Operation Flow Chart
14
6720220404
REV. 8-12