TP970 Series CONVERTASTAT Kits

TP970 Series CONVERTASTAT Kits APPLICATION REPLACEMENT DATA Each CONVERTASTAT Kit includes a universal wall plate adapter, cover, and a TP970 Series Thermostat to replace various manufacturer s thermostats. The thermostat cover is universal, allowing horizontal or vertical mounting and provides windows with or without setpoint and thermostat displays. All components needed to create a cover to meet building requirements are included. GENERAL RC121 INSTALLATION This sheet gives procedures for removing each manufacturer s thermostat and installing the appropriate TP970 Series CONVERTASTAT Kit. When the old mounting plate is removed, retain the screws to use for mounting the adapter plate. Cut the existing tubes as close as possible to the thermostat. Do not remove the antikink springs from cut tubes. Do not allow tubes to slip inside the wall after removing the old thermostat. This sheet describes replacing existing Johnson, Powers, and Robertshaw thermostats with the TP970 Series CONVERTASTAT Kit ( CONVERTASTAT Kit ). The appropriate CONVERTASTAT Kit, selected from Table 1, replaces newer (small size) models of Johnson, Powers, or Robertshaw vertical or horizontal pneumatic thermostats used in two-pipe applications and mounted on hollow wall (drywall) construction with air connections made directly to the thermostat using 5/32 in. plastic tubing, without the use of a wall fitting. Copyright 1995 Honeywell Inc. All Rights Reserved 85-0210

Table 1. TP970 Series CONVERTASTAT Kit Cross-Reference. Robertshaw* Order No. Description Johnson Powers Original Uni-line TP970A2145 Direct acting, single-temp, two - pipe, 60 to 90F range TP970A2242 Same as TP970A2145 except with beige plastic cover TP970A2234 TP970B2077 TP970B2166 TP970B2150 TP971A2102 TP971A2183 TP972A2192 TP972A2200 Same as TP970A2145 except with 15 to 30 C range Same as TP970A2145 except reverse acting Same as TP970B2077 except with beige plastic cover Same as TP970B2077 except with 15 to 30 C range Two-temp, two-pipe, 60 to 90F (16 to 32C) range, DAY and NITE setpoint knobs, 13-18 psi (90/124 kpa) changeover, field adjustable to 16/21 psi (110/145 kpa) Same as TP971A2102 except with beige plastic cover Single-temp, two-pipe, proportioning, 60 to 90F (16 to 32C) range, RA Summer 13 psi (90 kpa) or 9 psi (62 kpa) unit vent, DA Winter 18 psi (124 kpa) changeover, field adjustable Same as TP972A2192 except RA Summer 19 psi (131 kpa), DA Winter 14 psi (97 kpa) changeover T4002-201 T4002-203 T4002-6201 T4002-6203 T4101-1 T4101-6001 T4101-3 T4101-6003 T4002-202 T4002-204 T4002-6202 T4002-6204 T4001-2 T4001-6002 T4001-4 T4001-6004 T4506-201 T4506-202 T4506-6201 T4506-6202 T4506-203 T4506-204 T4506-6203 T4506-6204 T4756-217 T4756-205 T4756-206 T4756-6217 T4756-6205 T4756-6206 T4756-216 T4756-201 T4756-207 T4756-6216 T4756-6201 T4756-6202 * For 2 x 2 Thermostat mounted without 3 x 3 wall plate. Kit can be used only if two-pipe wall fitting installed originally. Use kit if DAY/NITE lever feature is acceptable. ** Original thermostat was part of a kitt. Use kit if Fahrenheit scale is acceptable. TH192-202 TH192-200 T18-301 T18-3011 TH192-222 T12-301 T12-3011 2212-118 2212-128 2211-112 2211-512 ** 2211-012 TH192-220 2212-518 TH192-203 TH192-201 T19-301 T19-3011 TH192-223 T13-301 T13-3011 TH192-221 TH192-204 TH192-224 TH192-208 TH192-2082 TH192-228 T27-301 T27-3011 T23-301 T23-3011 T32-301 T32-3011 T32-501 2212-119 2212-129 2212-519** 2211-013 2211-113 2211-513** 2216-126 2216-136 2216-526** 2214-121 2214-131 2214-521** 2218-132 2218-142 2218-134 2218-532** TH194-2083 T33-301 2218-133 Installation requires the following tools: 1/16 in. Allen wrench 0.050 in. Allen wrench Thermostat Tool CCT735A Side cutters (diagonals) or knife to cut tubes Phillips screwdriver Standard screwdriver 5/32 in. tubing plug (optional), CCT1814 (plastic) or CCT1815 (aluminum) Honeywell Thermostat Tool Kit CCT3863 includes thermostat Tool, thermostat key, and gage adapter. 85-0210 2

Remove Johnson Thermostat Remove Robertshaw Thermostat Loosen (counterclockwise) top and bottom screws to remove cover. Remove thermostat mounting screws at top and bottom and remove thermostat from mounting plate. Cut tubes near air head and temporarily plug main line to conserve air. Remove mounting plate and retain screws. Proceed to the Install New Thermostat section. Turn cover screw on bottom inward (clockwise) to remove cover. Remove mounting screws and remove thermostat from mounting plate. Do not remove mounting plate. Cut tubes near fitting and temporarily plug main line to conserve air. Proceed to the Install New Thermostat section. 40 50 60 70 80 90 60 70 80 ROBERTSHAW 70 50 90 Fig. 1. Johnson Thermostat. Remove Powers Thermostat Loosen (counterclockwise) screws on each side to remove cover. Pull thermostat from the mounting plate. Cut tubes near connector and temporarily plug main line to conserve air. Remove old mounting plate and retain screws. Proceed to the Install New Thermostat section. 10 15 20 25 30 20 25 MCC POWERS C2314 Fig. 2. Powers Thermostat. C2313 Fig. 3. Robertshaw Thermostat. Install New Thermostat 70 C2315 Feed the tubes through the large hole in adapter plate (Fig. 4). Match holes of the adapter plate to the wall screw holes. Mount adapter plate using screws retained from removal of old mounting plate. Do not overtighten the screws. NOTE: If any wall screw holes coincide with the noncoded holes on the adapter plate (Fig. 4), proceed as follows (If not, continue with Step 3.): a. With adaptor plate away from the wall, ream out or strip the threaded holes by tightening the screws retained when removing the old mounting plate. Tighten with enough force so that the screws move freely. Remove and retain screws. If the wall screw holes are larger than #6, enlarge the adapter plate holes to allow enough clearance for the screws. b. After removing temporary plug, push tubes onto thermostat backplate (main tube has air blowing out and must be connected to the M barb connection on rear of backplate). c. To remove cover from thermostat, slowly drive the screws inwards (clockwise) until cover is free to remove. To remove thermostat from backplate, spread retaining clips (Fig. 5) and separate. 3 85-0210

NOTE: d. Align and attach the backplate and adapter plate to the mounting screw holes with screws retained from stripping the threads in adapter plate. e. Proceed to Step 6. When adapting to a Johnson thermostat, if the holes in the wall are out of alignment with the adapter plate holes, use any available hole for an additional wall anchor. AIR TUBING CONNECTIONS (3) UP B B SET SCREWS M RETAINING CLIPS PILOT HOLE FOR #6 SELF-TAPPING SCREW HOLES CODED PER MANUFACTURER (10) (EXAMPLE: J = JOHNSON) COVER MOUNTING EARS Fig. 5. Backplate. C182-1 TUBING NON-CODED HOLE (2) Fig. 4. Adapter Plate Installation. C2837 To remove cover from thermostat, drive the screws inwards (clockwise) until cover is free to remove. To remove thermostat from backplate, spread retaining clips (Fig. 4) and separate. After removing temporary plug, push tubes onto the thermostat backplate (mainline tube has air blowing out and must be connected to the M barb connection on rear of backplate). Attach backplate to adapter plate with thread-forming screws provided with the thermostat. Do not overtighten the screws. Press the thermostat onto the backplate until it is fully seated and the clips (Fig. 5) on the backplate have engaged. Remove shipping stops (Fig. 6). Mount cover (see the Thermostat Cover Mounting section). QUICK-MOUNT STAT SETSCREWS THROTTLING RANGE SETTING INDICATOR TEMPERATURE INDICATOR SETPOINT INDICATOR SHIPPING STOP (2) (REMOVE WHEN INSTALLING) Fig. 6. TP970 Series Thermostat with Cover Removed. Thermostat Cover Mounting CALIBRATION SCREW SETPOINT ADJUSTMENT SETPOINT LOCK SCREW STOPS-TEMPERATURE SETTING C7257 Remove caution card from cover. Select the correct window (vertical or horizontal/ single, dual, or blank). Peel the release liner from window back (Fig. 7). Be careful that the window is oriented correctly for the installation. When viewed from the front of the cover, the setpoint and Day/Auto openings are on the bottom for a vertical thermostat or on the right for a horizontal thermostat. The cover has slots which must mate with the mounting ears on the backplate (Fig. 5). 85-0210 4

CAUTION Before installing window, remove card. Check window selection and orientation to cover. The setpoint, Day/ Auto openings and/or inserts must be down or to the right. Once assembled, disassembly may damage the window. Mount the cover. Hook the two slots on the cover bottom (right end for horizontal mounting) to the ears on the backplate. Swing the cover into place and back out (counterclockwise) the setscrews with a thermostat tool or a 0.050-inch Allen wrench to secure. 6 0 7 0 6 0 7 0 SETSREW HOLES (4) (USE HOLES CLOSEST TO THE WALL) 8 0 9 0 8 0 9 0 WINDOW (DUAL SHOWN, PARTIALLY INSTALLED) Throttling Range Thermostat throttling range (TR) is factory set at 4 degrees F (2.2 degrees C) and should not require any change under normal operating conditions. If a change in throttling range is necessary, use the following procedures to reset the throttling range to the values specified on the job drawings. Recalibration is required if throttling range is changed. Remove cover and install 0 to 30 psi (0 to 210 kpa) gage (with gage adapter) in gage tap (Fig. 8). Slide the throttling range adjustment to the desired position on the throttling range scale. Mechanically check the TR by moving setpoint adjustment until the branch line pressure is 3 psi (21 kpa); note the setpoint indicator setting. Move the setpoint adjustment until the branch line pressure is 13 psi (90 kpa) and note the setpoint indicator setting. The difference in setpoint indicator settings is the actual throttling range. NOTE: The ambient temperature ±1/2 degree of the throttling range must not exceed the minimum or maximum setpoints of the thermostat. That is, with a throttling range of 6 degrees F (3.3 degrees C) and an ambient temperature of 62F (16C), this procedure will not work for a TP970A which has a minimum setpoint of 60F (15C). Recalibrate using procedures in the Recalibration section. C7256 Fig. 7. Assembly of Cover with Window Frame and Insert. CHECKOUT AND TESTING Equipment Required The following equipment is available from your Serviceline Supplier: Gage 305965 or 40002576-001, 0 to 30 psi (0-210 kpa) CCT729 Gage Adapter CCT735A Thermostat Tool NOTE: Before making adjustments, set the thermostat to the desired setpoint and let the system operate long enough to stabilize. Make certain that the system is stable before checking calibration. All thermostats are accurately factory calibrated and should require only a calibration check to ensure correct operation. 5 85-0210

THROTTLING RANGE SCALE (DAY/SUMMER) GAGE TAP THROTTLING PLATE (2) THERMOMETER CALIBRATION BOBBIN MAX MAX THROTTLING RANGE ADJUSTMENT (NITE/WINTER) SCALEPLATE SETPOINT INDICATOR 60 70 80 90 TEMPERATURE INDICATOR CALIBRATION SCREW (DAY/SUMMER) 5 7 5 6 5 SETPOINT INDICATOR (NITE/WINTER) SETPOINT LOCK SCREW DAY/AUTO LEVER (TP971 ONLY) SETPOINT DIAL (NITE/WINTER) CALIBRATION SCREW (NITE/WINTER) SETPOINT LIMIT STOPS SETPOINT ADJUSTMENT NOTE: NOT ALL ADJUSTMENTS ARE ON ALL THERMOSTATS. C5410 Fig. 8. TP971 and TP972 Controls and Indicators, Front View with Cover Removed. Setpoint Limit Adjustment To set minimum or maximum setpoint limits: Loosen the setpoint lockscrew (Fig. 8). Move each stop to the desired position. Tighten the setpoint lockscrew. Check the positioning of the stops by changing the setpoint. Changeover TP971 and TP972 thermostats have changeover features. The TP971 has day/night changeover and the TP972 has summer/winter changeover. TP971 controls direct acting at day setting with 13 psi (90 kpa) main air pressure and direct acting at the lower night setting with 18 psi (124 kpa) main air pressure. The TP972 controls reverse acting (RA) for summer cooling at 13 psi (90 kpa) main air pressure and direct acting (DA) for winter heating at 18 psi (124 kpa) main air pressure. Remove thermostat from backplate if mounted. Remove the changeover adjustment screw (Fig. 9) on back of thermostat. Replace the gold-colored spring with the silvercolored spring furnished in the TP971 kit. Order 14002373-001 Spring for TP972 conversion. Reinstall the changeover adjustment screw and set flush with the top of the spring chamber. Mount thermostat on backplate again. Follow procedures in the Changeover Calibration Check section and recalibrate if necessary. The branchline pressure (BLP) drops as the temperature drops when the thermostat is operating DA. The BLP drops as the temperature rises when the thermostat is operating RA. FILTER COVER MOUNTNG SCREWS (4) M B Changeover Conversion On some systems the lower main air pressure is higher (14 or 15 psi [97 or 103 kpa]) so the changeover point must be raised. On these systems turn the changeover adjustment screw (Fig. 9) one-half turn clockwise for each 1 psi (7 kpa) over 13 psi (90 kpa). THERMOSTAT MULTISTAGE FILTER CHANGEOVER ADJUSTMENT SCREW SPRING CHAMBER P TP971s or TP972s used on systems having 16/21 psi (110/ 145 kpa) or 13/16/21 psi (90/110/145 kpa) main air pressure require a different spring for proper changeover operation. Change the spring as follows: DAY/AUTO LEVER (TP971 ONLY) Fig. 9. TP970 Series Thermostat Back View. C5411 85-0210 6

Changeover Calibration Check Set main air pressure to the higher pressure setting (night for TP971, winter for TP972A2192, and summer for TP972A2200). Insert gage using gage adapter into the gage tap (Fig. 8). If the results in Steps 3 or 5 are not correct, go to the Changeover Calibration section. TP971: Turn day setpoint adjustment until the setpoint indicator reads approximately 10F (5.5C) degrees above the space temperature and set the night setpoint dial below space temperature. The gage should indicate main air pressure. Push the day/auto lever to the day (left) position; it should stay there and the BLP should go to 0 psi (0 kpa). TP972: Turn the setpoint adjustment until the setpoint indicator reads approximately 10F (5.5C) degrees above space temperature. BLP should go to 0 psi (0 kpa). Set main air pressure to lower pressure setting (day for TP971, summer for TP972A2192, and winter for TP972A2200). Use 16 psi (110 kpa) on 13/16/21 psi (90/110/145 kpa) systems. TP971: With day setpoint indicator and night setpoint dial set as in Step 3, BLP should go to zero. Push the day/ auto lever to the day (left) position, it should return to the auto position when released. TP972: With the setpoint indicator set as in Step 3, BLP should go to main air pressure. Changeover Calibration Remove thermostat from the wall. Loosen screws. Remove backplate from wall but do not disconnect tubes from backplate. Plug thermostat into backplate. Use following changeover procedures for calibration with or without a branch line pressure gage. With Branchline Pressure Gage If the thermostat changeover point was not correct at Step 3 of the Changeover Calibration Check procedure, use the screwdriver end of the thermostat tool to turn the changeover adjustment screw (Fig. 10) one-quarter turn counterclockwise. Make a calibration check. Continue with one-quarter turn adjustments followed by a calibration check until the changeover point is correct. If the thermostat changeover point was not correct at Step 5 of the Changeover Calibration Check procedure, use the TP970 Series thermostat tool to turn the changeover adjustment screw (Fig. 10) one-quarter turn clockwise. Make a calibration check. Continue with one-quarter turn adjustments followed by a calibration check until the changeover point is correct. Fig. 10. Location of Calibration Adjustment Screw with Backplate Attached. Without Branchline Pressure Gage (TP971 Only) CHANGEOVER ADJUSTMENT SCREW Set system pressure to 18 psi (124 kpa) (night pressure). Hold the day/auto lever in the day (left) position. Turn the changeover adjustment screw counterclockwise until the lever holds in place. Release the lever and slowly turn the changeover adjustment screw clockwise until the lever snaps back to the auto position. Turn the changeover adjustment screw an additional one-eighth to one-quarter turn clockwise. This places the changeover in calibration and allows for normal main air pressure fluctuations. Calibration Check Direct-Acting, Bimetal Elements Turn setpoint adjustment until the setpoint indicator reads 5 degrees F (2.8 degrees C) below actual space temperature as measured by a test thermometer and allow thermostat to build up branch line pressure. Turn setpoint adjustment (Fig. 8) up slowly. If thermostat begins to bleed off between 1 and 3 degrees F (0.5 and 1.5 degrees C) below space temperature, no recalibration is necessary. Reverse-Acting, Bimetal Elements C183-2 Turn setpoint adjustment until the setpoint indicator reads 5 degrees F (2.8 degrees C) above actual space temperature as measured by a test thermometer and allow thermostat to build up branch line pressure. Turn setpoint adjustment (Fig. 8) down slowly. If thermostat begins to bleed off between 1 and 3 degrees F (0.5 and 1.5 degrees C) above space temperature, no recalibration is necessary. 7 85-0210

Recalibration CAUTION The thermostat is very sensitive and should not be heated by excessive handling during calibration. NOTE: References in the following procedures to a 30 psi (210 kpa) gage mean the gage with gage adapter listed in Equipment Required section. TP972 day (left) calibration screw (Fig. 8) until the gage indicates 0 psi (0 kpa). Turn the calibration screw in the opposite direction until the gage indicates 8 ±1 psi (56 ±7 kpa). With 18 psi (126 kpa) night main air pressure, rotate the night setpoint dial until its setting agrees with the indicated temperature. Repeat Steps 3 and 4 using the night (right) calibration screw. The thermostat is now in calibration. Remove the gage and replace cover. TP970 TP971 Remove the cover and install a 30 psi (210 kpa) gage into the gage tap. Turn the setpoint adjustment until the setpoint indicator reads the space temperature. Turn the calibration screw (Fig. 5) until the gage indicates 0 psi (0 kpa). Turn the calibration screw in the opposite direction until the gage indicates 8 ±1 psi (56 ±7 kpa). The thermostat is now calibrated. Remove the gage and replace the cover. Remove the cover and install a 30 psi (210 kpa) gage into the gage tap. Turn the setpoint adjustment until the setpoint indicator reads the indicated temperature. With 13 psi (90 kpa) day main air pressure, turn the Remove the cover and install a 30 psi (210 kpa) gage into the gage tap. Turn the setpoint adjustment until the setpoint indicator reads the indicated temperature. With 13 psi (90 kpa) main air pressure, turn the left calibration screw (Fig. 8) until the gage indicates 0 psi (0 kpa). Turn the calibration screw in the opposite direction until the gage indicates 8 ±1 psi (56 ±7 kpa). With 18 psi (126 kpa) main air pressure, repeat Steps 3 and 4 using the right calibration screw. NOTE: If the thermostat has a second setpoint dial (Fig. 8), it must be set to the indicated temperature before returning to Steps 3 and 4. The thermostat is now in calibration. Remove the gage and replace the cover. Home and Building Control Honeywell Inc. Honeywell Plaza P.O. Box 524 Minneapolis, MN 55408-0524 Home and Building Control Honeywell Limited-Honeywell Limitée 740 Ellesmere Road Scarborough, Ontario M1P 2V9 Helping You Control Your World 85-0210 Rev. 1-95 8