FAST-STAT. Wiring Extenders - PDF Free Download

FAST-STAT Wiring Extenders 1-800-775-4750 www.fast-stat.com 0

Contents General Information... 2 Basics 3 Model 1000..... 4 Wiring Diagrams... 6 How to Test.. 12 Model 3000.. 13 Wiring Diagrams... 15 How to Test.. 20 Model 5000.... 21 Wiring Diagrams.. 23 How to Test. 25 Model 7000.. 26 Wiring Diagrams... 28 How to Test.. 31 Model 9000.. 32 Wiring Diagrams 34 How to Test.. 37 Common Maker. 38 General Wiring Diagrams 40 Taco Zone Valve & Controller Diagrams.. 43 Fenwal, Weil-Mclain, Energy Kinetics Diagrams. 49 How to Test.. 52 Jan 2017 Edition Note: We reserve the right to make changes & corrections without notice. Every effort has been made to provide accurate technical & product information. The company disclaims responsibility for any error or omission regarding technical & product information published. Nordic Technology Ltd Tel: 1-800-775-4750 Fax: 236-420-0193 Website: www.fast-stat.com Email: info@fast-stat.com 1

General Information FAST-STAT wiring extenders electronically add more wires to a control cable. Saves significant time and expense as compared to repulling of new cables. Causes no damage to walls or ceilings as compared to access holes that are often needed when re-pulling cables. The Sender and Receiver communicate over the existing thermostat cable and/or outdoor unit cable. Not a wireless system and therefore avoids all the problems that wireless systems may have. No batteries required. All FAST-STAT models are powered by the existing 24 volt transformer. Compatible with all conventional wiring systems using R, C, W, W2, Y, Y2, G, O/B and other terminals. Works with old and new systems. Can be connected to older systems such as thermopile millivolt, standing pilot systems, intermittent pilot controllers, fan centers etc. Can be used with oil burners, zone controllers and other systems that require dry contact switching. Works over long cable lengths up to 500 ft and more. FAST-STAT Wiring Extenders do not produce interference with other electronic devices nor are they affected electronic devices that produce large amounts of interference. Many FAST-STAT Wiring Extenders can be used in the same building or complex without interference between units. Low power use. Most FAST-STAT models use less than 3 watts of power. 2

Basics Models 1000, 3000 & 5000 These are general purpose wiring extender kits that can be used for a wide range of applications. The FAST-STAT Models 1000, 3000 & 5000 come with a Sender and a Receiver. When adding wires from the thermostat to the indoor unit, the Sender is installed into the wall cavity behind the thermostat. This is achieved by increasing the size of the opening around the thermostat cable so that the Sender can be inserted into the wall cavity after the connections to the cable and thermostat are made. The Receiver is installed at the indoor unit near the other controls. If there is no room to mount the receiver inside the cabinet, it can be mounted in any suitable location on or near the indoor unit. When using the Models 1000, 3000 & 5000 to add wires from the indoor unit to the outdoor unit, the Receiver is installed inside the cabinet of the outdoor unit. The Sender is installed at the indoor unit. Models 7000 & 9000 The Model 7000 & 9000 are for air conditioner to heat pump conversions. The Model 7000 is a 3-part kit with a Sender, Indoor Unit Module and an Outdoor Unit Module. This kit requires a minimum of existing 4-wire thermostat cable and a 2-wire outdoor unit cable. The Model 9000 extends the wiring only from the indoor unit to the outdoor unit. It is a 2-part kit with an Indoor Unit Module and an Outdoor Unit Module. The Model 9000 requires a minimum of a 2-wire cable. Common Maker The Common Maker provides a C or common connection for Wi-Fi and other types of powered thermostats. It requires a minimum of a 2-wire thermostat cable. The Common Maker can be used with all types of heating and cooling systems including some types of oil burners and zone controllers that require dry contact switching. Some types of Wi-Fi thermostats require a common connection C in order to function at all while the performance of some types of power stealing battery equipped Wi-Fi thermostats can be greatly improved if they have a common connection. 3

Model 1000 Model 1000 It adds one wire to any system The Sender has three wires; Input A, Input B and a communication wire The Receiver has five wires; Output A, Output B, a Communication wire, Power R and a Common C Any combination of two functions such as W1, W2, Y1, Y2, G, O/B and others can be connected. Only transformer R and C cannot be connected to the Sender. 4

Model 1000 How It Works Input A and Input B are independent of each other in that either one can be on by itself or they can both be on at the same time. Any two functions such as W, Y, G, or O/B can share one wire between the thermostat and indoor unit or between the indoor and outdoor units. Application Examples 2-stage Air Conditioners A 2-wire air conditioner cable can be converted to provide R, C, Y1 & Y2 using the Model 1000. There are two wiring methods that can be used. Wi-Fi Thermostats If the thermostat cable has three or more wires, the Model 1000 can be used to add a common or C connection at the thermostat. This is achieved by having two existing functions share one wire which then frees up a wire that can then become a common wire. Many Wi-Fi thermostats have a self-configure option in which the thermostat automatically detects the wires connected to it in order to make easier for homeowners to install the thermostat. When using the Model 1000, do a Reset then select Pro Setup to manually configure the thermostat. There are diodes in the Model 1000 sender that often prevents the thermostat from properly autoconfiguring itself. Adding an Extra Function The Model 1000 can be used to add W2, Y2, G, etc to a thermostat cable. For example the existing W wire can become W1 & W2. Cable Repairs If a wire in a cable is broken (open circuit) or shorted to another wire or to ground, the Model 1000 can often be used to replace the damaged wire. 5

Model 1000 Testing Method 1. Measure the transformer voltage (often marked as R and C). The meter should read from 24 to 28 volts AC. For furnaces, make sure the door switch is in the on position. 2. Connect the Sender directly to the Receiver: PURPLE to PURPLE, and then connect the Receiver BLACK to transformer C, RED to transformer R. 3. Connect the Sender GREEN to the transformer R. The relay in the Receiver should switch on. With Sender GREEN still connected to the transformer R, measure the voltage between the Receiver GREEN wire and the transformer C. The meter should read 24 to 28 volts. 4. Connect the Sender YELLOW to the transformer R. The relay in the Receiver should switch on. With Sender YELLOW still connected to the transformer R, measure the voltage between the Receiver YELLOW wire and the transformer C. The meter should read 24 to 28 volts. 12

Model 3000 Model 3000 It adds two wires to a cable. For example, with a 2-wire cable, it can provide R, G, Y, W connections at a thermostat and indoor unit. With cables having more than two wires, the additional wires can be directly connected to the thermostat and indoor unit and used for any purpose. The Sender has six wires; Power In R, Power Out R, a Communication wire, Input A, Input B and Input C. The Receiver has seven wires; Power In R, Power Out R, a Communication wire, Output A, Output B, Output C and a Common C wire. 13

Model 3000 How It Works Output A (GREEN wire) and output B (YELLOW wire) are linked so that when output B is on it will also switch on output A. For typical installations output A (GREEN wire) is used for G and output B (YELLOW wire) is used for Y so does not create any problems as the fan will be on with the when the air conditioner is running. Output C (WHITE wire) is independent of outputs A & B. It can be on by itself or at the same time as either or both outputs A or B. It is often used for the W function but can be used for other functions as well. Application Examples Adding Air Conditioning A 2-wire thermostat cable can be converted to provide R, G, Y & W using the Model 3000. Wi-Fi Thermostats If the thermostat cable has three or more wires, the Model 3000 can be used to add a common or C connection at the thermostat. This is achieved by having two or three existing functions share one wire which then frees up a wire that can then become a common wire. Many Wi-Fi thermostats have a self-configure option in which the thermostat automatically detects the wires connected to it in order to make easier for homeowners to install the thermostat. When using the Model 3000, do a Reset then select Pro Setup to manually configure the thermostat. There are diodes in the Model 3000 sender that often prevents the thermostat from properly autoconfiguring itself. Adding an Extra Functions The Model 3000 can be used to add W2, Y2, G, etc to a thermostat cable. For example the existing W wire can become W1, W2 & Y2. Cable Repairs If a wire in a cable is broken (open circuit) or shorted to another wire or to ground, the Model 3000 can often be used to replace up to two damaged wires. 14

Model 3000 Testing Method 1. Measure the transformer voltage (often marked as R and C). The meter should read from 24 to 28 volts AC. For furnaces, make sure the door switch is in the on position. 2. Connect the Sender directly to the Receiver: PURPLE to PURPLE & RED to RED and then connect the Receiver BLACK to transformer C, RED to transformer R. 3. Connect the Sender GREEN to the RED. The relay in the Receiver should switch on. With Sender GREEN still connected to the RED, measure the voltage between the Receiver GREEN wire and the transformer C. The meter should read 24 to 28 volts. 4. Connect the Sender YELLOW to the RED. The relays in the Receiver should switch on. With Sender YELLOW still connected to the transformer R, measure the voltage between the Receiver YELLOW wire and the transformer C. The meter should read 24 to 28 volts. 5. Connect the Sender WHITE to the RED. The relay in the Receiver should switch on. With Sender WHITE still connected to the RED, measure the voltage between the Receiver WHITE wire and the transformer C. The meter should read 24 to 28 volts. 20

Model 5000 Model 5000 It adds four wires to a cable. For example, with a 2-wire cable, it can provide R, C, G, Y, W1 & W2 connections at a thermostat and indoor unit. With cables having more than two wires, the additional wires can be directly connected to the thermostat and indoor unit and used for any purpose. The Sender has eight wires; Power In R, Power Out R, a Communication wire, a Common wire, Input A, Input B, Input C & Input D. The Receiver has eight wires; Power In R, Power Out R, a Communication wire, Output A, Output B, Output C, Output D and a Common C wire. 21

Model 5000 How It Works Output A (GREEN wire) and output B (YELLOW wire) are linked so that when output B is on it will also switch on output A. For typical installations output A (GREEN wire) is used for G and output B (YELLOW wire) is used for Y so does not create any problems as the fan will be on with the when the air conditioner is running. Output C (WHITE wire) and output D (BLUE wire) are linked so that when output D is on it will also switch on output C. For typical installations output C (WHITE wire) is used for W1 and output D (BLUE wire) is used for W2 so does not create any problems as heat stage-1 will be on when heat stage-2 is on. When output C or output D is on, outputs A and B will shut off. If the fan is in manual on mode it will shut off the fan while the heat exchanger warms up and the furnace fan control/limit then switches on the fan. When the thermostat is in fan manual on mode, at the end of a heating cycle, the fan will continue to operate. Application Examples Adding Air Conditioning A 2-wire thermostat cable can be converted to provide R, C, G, Y, W1 & W2 using the Model 5000.. Wi-Fi Thermostats The Model 5000 can be used to add a common or C connection at the thermostat. Many Wi-Fi thermostats have a self-configure option in which the thermostat automatically detects the wires connected to it in order to make easier for homeowners to install the thermostat. When using the Model 5000, do a Reset then select Pro Setup to manually configure the thermostat. There are diodes in the Model 5000 sender that often prevents the thermostat from properly autoconfiguring itself. Adding an Extra Functions The Model 5000 can be used to add W2, Y2, G, etc to a thermostat cable. For example the existing W wire can become W1, W2, G & Y. Cable Repairs If a wire in a cable is broken (open circuit) or shorted to another wire or to ground, the Model 5000 can often be used to replace up to five damaged wires. 22

Model 5000 Testing Method 6. Measure the transformer voltage (often marked as R and C). The meter should read from 24 to 28 volts AC. For furnaces, make sure the door switch is in the on position. 7. Connect the Sender directly to the Receiver: PURPLE to PURPLE & RED to RED and then connect the Receiver BLACK to transformer C, RED to transformer R. 8. Connect the Sender GREEN to the RED. The relay in the Receiver should switch on. With Sender GREEN still connected to the RED, measure the voltage between the Receiver GREEN wire and the transformer C. The meter should read 24 to 28 volts. 9. Connect the Sender GREEN & YELLOW to the RED. The relays in the Receiver should switch on. With Sender GREEN & YELLOW still connected to the transformer R, measure the voltage between the Receiver YELLOW wire and the transformer C. The meter should read 24 to 28 volts. 10. Connect the Sender WHITE to the RED. The relay in the Receiver should switch on. With Sender WHITE still connected to the RED, measure the voltage between the Receiver WHITE wire and the transformer C. The meter should read 24 to 28 volts. 11. Connect the Sender WHITE & BLUE to the RED. The relay in the Receiver should switch on. With Sender WHITE & BLYE still connected to the RED, measure the voltage between the Receiver BLUE wire and the transformer C. The meter should read 24 to 28 volts. 25

Model 7000 Model 7000 The Model 7000 is used for air conditioner to heat pump conversions. It requires a minimum of a 4-thermostat cable and a 2-wire heat pump cable. It can operate single or 2-stage heat pumps. The Sender is installed into the wall cavity behind the thermostat. The Indoor Unit Module is installed at the furnace or air handler. The Heat Pump Module is installed at the heat pump. The Model 7000 also has an optional use built-in fossil fuel kit. 26

Model 7000 How It Works 1. When the thermostat calls for the heat pump compressor to run, it will apply power to the Sender Y1 wire which will energize the Y1 relay in the Outdoor Unit Module. This completes the circuit between R and Y1, which will start the compressor. 2. If the heat pump is a 2-stage unit, when power is applied to the Sender Y2 wire, the Y2 relay in the Outdoor Unit Module will energize and cause the compressor to run in high speed. The Y2 relay in Indoor Unit Module will also energize and its Y2 wire is used to switch the fan into high speed. 3. The Sender G wire operates the Indoor Unit fan. 4. The Sender W wire can be connected to thermostat as Aux Heat, Emergency Heat, W or W2 as may be required. It will start the Indoor Unit heating system when power is applied the Sender W wire. 5. The Sender OB wire is used to operate the reversing valve. 6. The Sender R and C wires supply 24 volt power to the thermostat. 7. The Heat Pump Module W wire is connected to the defrost control. When the heat pump is in defrost mode, the indoor unit heating system will start. 8. The Heat Pump Module has an optional use fossil fuel kit. When a thermostat (not included) is mounted at the heat pump, it can be set to a temperature that will shut off the compressor and start the Indoor Unit heating system when the temperature falls to the thermostat set point. On a call for heat, the outdoor thermostat will either run the compressor or start the Indoor Unit heating system based on the outdoor air temperature and the temperature setting of the heat pump located thermostat. 9. There are two wiring methods. One method is referred to as the two transformer method. For this method a transformer is installed at the heat pump. This transformer only provides power the heat pump. The other method is referred to as grounded commons. This method requires that the common wires on the Heat Pump Module are connected to chassis ground. A transformer is not required at the heat pump when using the grounded commons method. 27

Model 7000 - How to Test 1. Test for 24 volt power at the RED and BLACK wires at the Sender, Indoor Unit Module and the Heat Pump Module. If there is no power at any one or more locations check wiring and the control board fuse. If using the grounded commons wiring method, a BLACK wire at the Heat Pump Module must be connected to chassis ground. 2. At the indoor unit, disconnect the wire connected to Heat Pump Module ORANGE and connect this wire to indoor unit R terminal. When 24 volt power is applied to the ORANGE wire, Y1, Y2 & OB should switch on at the Heat Pump Module. Reconnect wiring after testing. 3. At the indoor unit, disconnect the thermostat cable wire connected to Indoor Unit Module PURPLE and connect the PURPLE wire to indoor unit R terminal. When 24 volt power is applied to the PURPLE wire, G & W should switch on at the Indoor Unit. Reconnect wiring after testing. 4. At the indoor unit, disconnect the thermostat cable wire connected to Indoor Unit Module GREY and connect the GREY wire to indoor unit R terminal. When 24 volt power is applied to the GREY wire, W should switch on at the Indoor Unit and Y1, Y2 & OB at the Heat Pump Module should also switch on. Reconnect wiring after testing. 5. At the thermostat, connect the RED to the GREEN then YELLOW, then BROWN, then WHITE, then BLUE. Each function should start when tested. 31

Model 9000 Model 9000 The Model 9000 is used for air conditioner to heat pump conversions. It requires a minimum of a 2-wire heat pump cable. It can operate single or 2-stage heat pumps. The Indoor Unit Module is installed at the furnace or air handler. The Heat Pump Module is installed at the heat pump. The Model 9000 also has an optional use built-in fossil fuel kit. 32

Model 9000 How It Works 1. When 24 volt power is applied to the Y1, Y2 or OB wires of the Indoor Unit Module, the same wires will be energized at the Heat Pump Module. 2. The Heat Pump Module W wire is connected to the defrost control. When the heat pump is in defrost mode, the indoor unit heating system will start. 3. The Heat Pump Module has an optional use fossil fuel kit. When a thermostat (not included) is mounted at the heat pump, it can be set to a temperature that will shut off the compressor and start the Indoor Unit heating system when the temperature falls to the thermostat set point. On a call for heat, the outdoor thermostat will either run the compressor or start the Indoor Unit heating system based on the outdoor air temperature and the temperature setting of the heat pump located thermostat. 4. There are two wiring methods. One method is referred to as the two transformer method. For this method a transformer is installed at the heat pump. This transformer only provides power the heat pump. The other method is referred to as grounded commons. This method requires that the common wires on the Heat Pump Module are connected to chassis ground. A transformer is not required at the heat pump when using the grounded commons method. 33

Model 9000 Grounded Commons Wiring Method DWG 9K-A 34

Model 9000 Two Transformers Wiring Method DWG 9K-B 35

Model 9000 Zone Panel Wiring Method DWG 9K-C 36

Model 9000 - How to Test 1. Test for 24 volt power at the RED and BLACK wires at the Indoor Unit Module and the Heat Pump Module. If there is no power at any one or more locations check wiring and the control board fuse. If using the grounded commons wiring method, a BLACK wire at the Heat Pump Module must be connected to chassis ground. 2. At the Indoor Unit or Zone Panel, disconnect the wire connected to Heat Pump Module ORANGE and connect this wire to indoor unit R terminal. When 24 volt power is applied to the ORANGE wire, Y1, Y2 & OB should switch on at the Heat Pump Module. Reconnect wiring after testing. 3. At the Zone Panel or Indoor Unit, connect the RED to the YELLOW (Y1), then BROWN (Y2), then BLUE (OB). Each function should start when tested. 37

Common Maker Common Maker It is used to add a common connection C at a thermostat. Having a C connection allows for a 24 volt power source which is required by some Wi-Fi thermostats and greatly improves the performance of other Wi-Fi thermostats. It works with all systems including those requiring dry contact switching such some oil burners and zone controllers. 38

Common Maker How It Works 1. The BLACK and WHITE Sender wires are connected to the C and W terminals of the thermostat. 2. The Sender PURPLE wire is connected to the thermostat cable and this same wire is connected to the Receiver PURPLE wire. Power then flows from the thermostat R terminal through to C terminal and back through the Sender and Receiver to the transformer. When the thermostat calls for heat, the relay in the Receiver is energized. 3. When the relay is energized, it takes power from the Indoor Unit R terminal and applies it to the W terminal (conventional wiring). Alternatively the Receiver RED and WHITE wires can be connected to an Indoor Unit that requires dry contact switching by connecting these wires to the T or T1/T2 terminals of the Indoor Unit or zone controller. 39

Common Maker Testing Method 1. Measure the transformer voltage (often marked as R and C). The meter should read from 24 to 28 volts AC. For furnaces, make sure the door switch is in the on position. 2. Connect the Sender directly to the Receiver: PURPLE to PURPLE, and then connect the Receiver BLACK to transformer C, RED to transformer R. 3. Measure the voltage between the Sender BLACK and the transformer R. The meter should read 21 to 28 volts. 4. Connect the Sender WHITE to the transformer R. The relay in the Receiver should switch on. 5. With Sender WHITE still connected to the transformer R, measure the voltage between the Receiver WHITE wire and the transformer C. The meter should read 24 to 28 volts. Notes If the wires between the Sender and Receiver are crossed during installation, the thermostat will power up but will not switch on the heating system. When in heating mode, the Sender produces about one watt of heat. 52