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February 2008  
P/N 32-0228  
REV . B  
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS  
FOR  
FP-4 FREEZE PROTECTION KIT  
P/N 83-0763  
FOR TURBO-COOL AFTERCOOLERS  
MODELS AC-140-7 thru AC-220-7  
(230V-3PH-60Hz & 460V-3PH-60Hz)  
WARNING  
BEFORE STARTING INSTALLATION OR MAINTENANCE PROCEDURES, TURN OFF ELECTRICAL POWER AND  
COMPLETELY DEPRESSURIZE THE AFTERCOOLER. FAILURE TO HEED THIS WARNING MAY RESULT IN SERIOUS  
PERSONAL INJURY AND/OR DAMAGE TO THE UNIT.  
NEVER REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE AFTERCOOLER WHILE IT IS PRESSURIZED.  
WHEN INSTALLING THIS KIT, ALWAYS COMPLY WITH THE NATIONAL ELECTRICAL CODE AND ALL OTHER  
APPLICABLE FEDERAL, STATE AND LOCAL CODES.  
SECTION 1  
INTRODUCTION  
1.1DESCRIPTIONOFOPERATION  
The FP-4 freeze protection kit is designed to prevent aftercooler freeze up when the ambient temperature is near or below  
o
o
freezing, 32 F (0 C).  
The FP-4 has a two stage solid state temperature controller. The controller is mounted inside a Nema 4 enclosure. The  
controller is used to energize a control relay which is rated to handle the load of the aftercooler fan at the various voltages.  
The linear platinum temperature sensor and  
thermowell mount into the piping between the  
outlet manifold of the aftercooler and the  
FIGURE 1-A ITEMS INCLUDED WITH THIS KIT  
separator. When the temperature of the com-  
pressed air system at the aftercooler outlet falls  
O
to 35 F, the controller will automatically turn off of  
o
the fan. The controller is set for a 10 F dead  
band to prevent rapid cycling (fan will turn off at  
O o  
5 F and on at 45 F).  
3
A 12 foot heat tape and 30 feet of insulation wrap  
are provided to wrap around the separator. The  
heat tape is equipped with its own internal  
temperature control. The heat tape and insula-  
tion will provide additional freeze up protection.  
1
.2 THIS KIT INCLUDES:  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
Control box  
12'long heat tape, w/ thermostat  
30'long roll of insulation wrap  
Copper 1/2" NPT thermowell w/clip  
Cord grip connector  
Linear platinum sensor  
2'of 3/8" flexible conduit  
Three (3) seal fittings for connectors  
3/8" conduit straight connector  
1
0. 3/8" 90 degree elbow connector  
1. 1" x 1/2" NPT bushing  
2. Four (4) #12-14 x 1" self tapping screws  
3. Heat Condictive Compound  
1
1
1
PAGE 1  
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SECTION 2  
INSTALLATION  
2
.1MOUNTINGTHECONTROLBOX  
The control box should be mounted near the  
outlet manifold of the aftercooler. Make sure  
that the control box is close enough so that all  
components can reach the box when in-  
stalled.  
FIGURE 2-A MOUNTING THE CONTROL BOX  
Drill the four pilot holes in the mounting  
surface using a 1/8" drill. Reference Figure 2-  
A for dimensions.  
The control box will be mounted with the  
hinged side of the enclosure on the bottom.  
Fasten the controller in place using the four  
(4) #12-14 x 1" long self-tapping screws  
supplied with the kit.  
2.2 INSTALLING THE SENSOR AND  
THERMOWELL  
A 1/2" NPT or larger connection in the system  
piping between the outlet of the aftercooler  
and the inlet of the separator is required for  
the thermowell and sensor.  
FIGURE 2-B MOUNTING THE THERMOWELL  
Thread the thermowell and the 1" x 1/2"  
bushing (if required) into a connection  
between the aftercooler outlet and the  
separator.  
Place some heat conductive compound into  
the thermowell. Place the sensor into the  
thermowell and fasten it in place using the  
clip supplied with the thermowell. Reference  
Figure 2-B.  
Install the cord grip connector into the control  
box as shown in Figure 2-B. Push the sensor  
cable through the connector. Wire the sensor  
cable to the controller circuit board terminals  
as shown in Figure 2-F. Tighten the grip nut  
on the connector.  
2.3 INSTALLING THE HEAT TAPE AND  
INSULATION  
Install the cord grip on the control box as  
FIGURE 2-C INSTALLING THE HEAT TAPE AND INSULATION  
shown in Figure 2-C.  
Cut the plug end off the heat tape. Strip back  
the wires.  
Push the wire end of the heat tape through  
the connector. Allow enough cord inside the  
box for wiring. Connect the heat tape to the  
proper terminals in the control box as shown  
in FIGURES 2-F. Tighten the grip nut on the  
connector.  
Run the heat tape to the separator. Wrap the  
heat tape around the separator as shown in  
Figure 2-C. Do not overlap the tape.  
Wrap the insulation around the piping and  
heat tape as shown in Figure 2-C.  
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SECTION 2  
INSTALLATION  
2
.4 INSTALLING THE CONDUIT  
Install the straight conduit connector  
on the control box. Reference Figure  
FIGURE 2-D INSTALLING THE CONDUIT  
2
-D.  
The supplied conduit will be used to  
run between the aftercooler and the  
control box. Connect the conduit to  
the straight connector.  
Install the 90 degree elbow connector  
on the aftercooler. Reference Figure  
2
-D.  
2.5 INSTALLING THE TRANSFORMER JUMPERS  
WARNING  
FIGURE 2-E INSTALLING THE TRANSFORMER JUMPERS  
BEFORE STARTING THIS PROCEDURE, TURN OFF  
ELECTRICAL POWER. FAILURE TO HEED THIS  
WARNING MAY RESULT IN SERIOUS PERSONAL  
INJURY AND/OR DAMAGE TO THE UNIT.  
This kit was designed to operate at 230V-3PH-60Hz or  
460V-3PH-60Hz. Two jumpers were shipped inside the  
control box. They must be installed on the transformer  
before connecting the power to the control box. Install the  
jumper(s) as shown in Figure 2-E for the desired voltage.  
CAUTION  
It is important that this procedure be properly  
completed before continuing with installation.  
This kit will not operate without the jumpers.  
Damage to the control box will occur if the jumpers  
are improperly installed.  
2.6 ELECTRICALCONNECTIONS  
conduit to the connector on the aftercooler. Reference  
FIGURE 2-D.  
WARNING  
BEFORE STARTING INSTALLATION PROCEDURES  
OR ATTEMPTING TO MAKE ANY WIRING CHANGES,  
TURN OFF ELECTRICAL POWER. FAILURE TO HEED  
THIS WARNING MAY RESULT IN SERIOUS  
Make the wire connections at the junction box on the  
aftercooler. Reference FIGURE 2-F. Fasten the junction box  
cover to the aftercooler.  
PERSONAL INJURY AND/OR DAMAGE TO THE UNIT.  
Complete the wire connections inside the controller as  
shown in FIGURE 2-F.  
WHEN INSTALLING THIS KIT ALWAYS COMPLY WITH  
THE NATIONAL ELECTRICAL CODE AND ALL OTHER  
APPLICABLE FEDERAL, STATE AND LOCAL CODES.  
Once all wiring connections have been properly made, the  
rotation of the fan should be checked. The fan must rotate in  
the proper direction for maximum performance. Reference  
the operator's manual supplied with the aftercooler for the  
correct rotation direction. Also, check the aftercooler for a  
rotation direction label.  
A 7/8" hole in the top right side of the control box is provided  
for incoming power conduit. The hole can be enlarged if  
necessary.  
The control box is designed for 230V-3PH-60Hz or 460V-  
3
PH-60Hz operation. The transformer jumpers must be  
To check the rotation, turn on the power supply to the  
aftercooler. If the fan does not rotate in the proper direction,  
any two of the power leads to the motor can be switched.  
installed as outlined in Section 2.5 for the desired voltage.  
Make the necessary wiring runs and connections for the  
main power supply.  
Remove the junction box cover on the aftercooler for access  
to the junction box. Make the necessary wiring runs through  
the conduit from the aftercooler to the control box. Fasten the  
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SECTION 2  
INSTALLATION  
FIGURE 2-F CONTROL BOX COMPONENT LAYOUT and WIRING DIAGRAM  
IMPORTANT  
THE FAN MOTOR MUST ROTATE IN THE CORRECT DIRECTION. REFERENCE THE AFTERCOOLER  
OPERATOR'S MANUAL FOR PROPER ROATION DIRECTION. IF IT DOES NOT, THE ROTATION CAN BE  
CORRECTED BY SWITCHING TWO OF THE POWER LEADS TO THE MOTOR.  
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SECTION 2  
INSTALLATION  
2
.7 SETTING THE CONTROLLER  
The controller was factory set for normal operation. The  
FIGURE 2-G CONTROLLER DISPLAY  
factory settings are as follows:  
RELAY 1  
O
SET POINT  
DIFFERENTIAL  
MODE  
35 F  
O
10 F  
COOLING  
Turn on the main power to the FP-4 control.  
If the settings have been changed, set them to the factory  
settings following the procedures below . The controller will  
retain the setting if the power is disconnected.  
PROGRAMMING PROCEDURES  
1. Press MENU key, then press RIGHT arrow key three  
times. Use the UP and DOWN arrow to select the  
SETPOINT. Press the RIGHT arrow to store the setpoint in  
memory.  
2. Press the RIGHT arrow to set the DIFFERENTIAL. Use  
the UP and DOWN arrow to set the differential. Press the  
RIGHT arrow to store the differential in memory.  
3. Press the RIGHT arrow key to set the HEATING / COOL-  
ING mode. Use the UP or DOWN arrow to select the  
desired mode. Press the RIGHT arrow to store the mode in  
memory.  
4. Press RIGHT arrow three times to exit the program mode.  
SECTION 3  
OPERATION  
3
.1 OPERATION  
FIGURE 3-A OPERATION SEQUENCE  
Once the kit is installed and set properly, just energize the  
controller and it will operate automatically.  
The controller will turn off half of the aftercooler fan when the  
temperature of system air at the outlet of the aftercooler falls  
O
to 35 F. The fan will turn on when the system temperature  
o
rises to 45 F. Reference chart in Figure 3-A .  
The heat tape is controlled by its own internal thermostat.  
Power is supplied to the heat tape as long as the control box  
is energized.  
The temperature controller is equipped with a LCD display.  
During normal operation when the fan are operating,  
(temperature above set points) the sensor temperature and  
RELAYS 1 ON will be displayed on the controller.  
NOTE: The cover on the control box must be opened to view  
the temperature controller display.  
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SECTION 4  
TROUBLESHOOTING  
4.1 TROUBLESHOOTING PROCEDURES  
SOLUTIONS  
PROBLEM  
. Aftercooler fan motor  
POSSIBLE CAUSES  
1
Controller not set properly  
Check the controller settings as outlined in Section 2.7. The  
controller may be set in the heat mode or the set points set too  
low. Set the controller to the recommended settings.  
continues to operate,  
system temperature  
O
below 35 F.  
Control relay faulty  
Check the control relay. Replace if faulty.  
Check main electrical power source.  
2. Aftercooler fan motor  
No power to the control box  
No power to the controller  
not operating, system  
temperature above  
Check the transformer. Make sure that the jumpers on the  
transformer are properly installed. Reference Section 2.5.  
Check the fuses on the transformer.  
O
4
5 F.  
Controller not set properly  
Controller failure  
Check the controller settings as outlined in Section 2.7. The  
controller may be set in the heat mode or the set points set too  
high. Set the controller to the recommended settings.  
Check the controller settings. If the controller is properly set, check  
the main power source.  
Check the controller display for error codes. Section 4.2 outlines  
what the error codes indicate and the necessary steps.  
Sensor failure  
If the sensor is faulty a "--" will be displayed for the temperature on the  
controller display. Refer to Section 4.2 for further details. If the  
sensor is faulty, it must be replaced.  
Control relay faulty  
Check the control power at the relay coil. Check the relay for proper  
operation. Replace if faulty.  
4.2 CONTROLLER ERROR CODES  
The controller display panel is used to display error codes in the event of problems with the controller. The four error codes  
are listed below.  
-
- -SENSOR FAILURE  
The "--" displayed for the temperature indicates that there is a problem with the sensor. The sensor is open or shorted.  
All relays will be de-energized in the event of a sensor failure. If the sensor is damaged, it must be replaced.  
EE-EEPROM FAILURE  
The "EE" error code indicates that there is a problem with EEPROM. The values read back from the EEPROM are not  
the same as what was written into the EEPROM. This error cannot be field repaired. The controller must be replaced.  
-
60°F or 270°F (-51°C or 132°C) Blinking - TEMPERATURE OUT OF RANGE  
The temperature display blinks when the sensed temperature is outside of the display range, below -60°F (-51°C) or  
above 270°F (132°C). The displayed value remains at the display limit and the controller continues to function unless  
an open or shorted condition is detected.  
BLINKINGRELAYSTATUS  
This occurs when the Relay Minimum Off Time is active. The (ñ ) blinks while the relay's minimum off time is active.  
PAGE 6  
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SECTION 5  
REPLACEMENT PARTS  
5.1 REPLACEMENT PARTS  
ITEM NO.  
DESCRIPTION  
QTY  
PART NO.  
1
2
3
4
5
6
7
8
9
12'LONG HEAT TAPE  
30'ROLL OF INSULATION WRAP  
1/2" NPT THERMOWELL w/CLIP  
CORD GRIP CONNECTOR  
SENSOR  
1
1
1
2
1
2 FT  
3
1
1
1
4
1
1
1
1
2
2
2
26-8151  
26-0712  
29-0325  
26-5618  
26-7186  
26-0875  
26-0883  
26-1068  
26-1078  
14-0402  
28-1286  
26-7185  
26-0919  
26-5637  
26-5336  
26-5638  
26-0380  
26-0382  
26-0384  
26-0388  
26-0686  
26-5663  
3/8" FLEXIBLE CONDUIT  
SEAL FITTING FOR CONNECTOR  
3/8" CONDUIT STRAIGHT CONNECTOR  
O
3/8" 90 ELBOW CONDUIT CONNECTOR  
1
1
1
1
1
1
1
1
1
2
2
2
2
1
2
3
4
5
6
7
8
9
0
1
2
3
1" X 1/2" NPT BUSHING  
#12-14 x 1" SELF TAPPING SCREW  
TEMPERATURE CONTROLLER  
MOTOR RELAY  
TRANSFORMER  
1 AMP FUSE  
.6 AMP FUSE  
GRAY TERMINAL  
YELLOW TERMINAL  
GREEN TERMINAL  
END CLAMP TERMINAL  
JUMPER FOR TERMINAL  
JUMPER FOR TRANSFORMER  
2
2
2
2
PAGE 7  
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SECTION 6  
WARRANTY  
PER VAN AIR TERMS AND CONDITIONS OF SALE  
YOUR VAN AIR REPRESENTATIVE IS:  
NAME:  
COMPANY:  
ADDRESS:  
CITY:  
STATE:  
FAX:  
ZIP:  
PHONE:  
ATTACH BUSINESS CARD HERE  
2950 Mechanic Street  
Lake City, PA 16423 USA  
Phone: 800/840-9906  
Service Fax: 814/774-0778  
Order Entry Fax: 814/774-3482  
www.vanairsystems.com  
MAKING COMPRESSED AIR AND GAS WORK BETTER SINCE 1944.  
PAGE 8  
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T775A/B/M Series 2000 Electronic  
Stand-Alone Controllers  
INSTALLATION INSTRUCTIONS  
PRODUCT DESCRIPTION  
The T775 electronic stand-alone controllers are the next  
generation of commercial and agricultural controls  
capable of remote sensing of temperature and providing  
switched and/or proportional outputs to various types of  
loads.  
Five models have analog (modulating) outputs for  
actuator and motor control, and NEMA-4 weatherproof  
enclosures are available for wet environments.  
IMPORTANT  
Each T775A/B/M controller is an operating  
control, not a limit or safety control. If used in  
applications requiring safety or limit controls, a  
separate safety or limit control device is  
required.  
Table 1. T775A/B/M Controller Configurations.  
Analog  
(Mod)  
SPDT  
Relay  
Outputs Outputsb Outputsc Inputs Included Enclosure  
Nbr of  
Sensor Sensors  
Controller  
Modela Description  
Floating  
Replaces  
T775A1001  
T775A2009 Standard  
T775B2016 Standard  
T775B2024 Standard  
T775B2032 Standard  
T775B2040 Standard  
1
2
4
2
4
None  
None  
None  
None  
None  
None  
1
2
2
2
2
1
1
1
1
1
NEMA 1  
NEMA 4X  
NEMA 4X  
NEMA 1  
NEMA 1  
N/A  
1
2
1
2
T775C1009 T775D1008  
T775A1019 T775B1000  
T775A1027 T775A1035  
T775B1018 T775B1026  
T775B1042  
T775M2006 Modulating  
N/A  
None  
4
2
2
N/A  
N/A  
2
1
1
NEMA 1  
T775M2014 Modulating T775G1005 T775G1013  
T775G1021 T775G1039  
2d  
NEMA 4X  
T775M2022 Modulating  
N/A  
2
4
2
2
N/A  
N/A  
2d  
2d  
1
1
NEMA 4X  
NEMA 1  
T775M2030 Modulating T775E1114 T775F1022  
T775F1055 T775F1089  
T775M2048 Modulating T775E1015 T775E1023  
T775E1056 T775E1064  
T775E1098  
2
2
N/A  
2d  
1
NEMA 1  
a
b
c
d
All models include a digital input for use with the disable or setback option.  
The modulating (analog) outputs are 4-20 mA, 0-10 Vdc, 2-10 Vdc, or Series 90 selectable.  
Each floating output eliminates two SPDT relays.  
These models can support a high/low modulating limit at Sensor B for temperature control at Sensor A.  
E4436  
6
2-0254-03  
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T775A/B/M SERIES 2000 CONTROLLER  
PRODUCT DESCRIPTION  
Temperature Sensorsa  
The controller accepts 1,097 Ohms PTC at 77°F (25°C):  
Accessories  
•
•
•
107324A – Bulb Holder, duct insertion  
107408 – Heat Conductive Compound, 4 ounce  
50001774-001 – Immersion Well, stainless steel 304,  
/2 in. threading  
•
50021579-001 – Standard sensor (included with all  
models except NEMA 4X models)  
1
•
T775-SENS-WR – Water resistant with 5 foot leads  
(included with NEMA 4X models)  
•
•
•
T775-SENS-WT – Watertight with 6 foot lead  
T775-SENS-OAT – Outdoor air temperature sensor  
C7031D2003 – 5 inch immersion sensor with wiring  
box (use immersion well; P/N 50001774-001)  
C7031J2009 – 12 foot duct averaging sensor with  
wiring box  
•
•
•
C7046D1008 – 8 inch duct probe with mounting flange  
C7100D1001 – 12 inch fast response, duct averaging  
sensor with flange  
•
C7130B1009 – Room mount sensor  
a
See form 62-0265 – Tempera