8733 800-259 KIT IOM Replacement Kit: 641-176 641-187 641-225 641-244 1
Table of Contents 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 2
The UPM Controller The Unit Protection Module (UPM) board, shown in Figure 1, is used in all configure-toorder 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: Physical: Environmental Operating Range: 24VAC ± 10%, 50-60Hz, 1.4 VA of standby power consumption (Single Class II 70VA or 100VA option available) Printed Circuit Board and plastic stand offs. -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: Inputs: 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) 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: Protection: Visual (LED) status of power and alarms status indication. Surge and transient protection circuitry. Weight: Overall Dimensions: Listed By: 0.14 lbs. (0.07 Kg). 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). 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
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. 5
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. 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. Figure 2 - Plastic Stand-Off 6
CONTROLS IMPORTANT: Ground Do not forget to ground the board. If a connection is not available, ground the terminal by: 1. Adding a new screw to the electrical box. 2. Using an existing screw that secures an existing component. Avoid sharp edges on unit cabinet during installation Figure 3 - UPM Location 7
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. 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 4 - Freeze Sensor's Previous Location, Older Versions Figure 5 - Freeze Sensor's New Location 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. 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. 8
Figure 6 - Sensor with Wire Ties Figure 7 - Wire Tied Sensor with Cork Tape Figure 8 - Final Sensor Installation with Insulating Tape 9
Final Procedures 4 LOCKOUT 4 2 3 RESET R Y 2 ALARM CONT PULSE 1 TEST YES NO 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 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. 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. 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 10
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Figure 9 - UPM Typical Wiring Components 12
Figure 10 - UPM Operation Flow Chart 13
6720220404 REV. 8-12 14