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Variable Air Volume (VAV) Controller Technical Bulletin

1. C1 TE Y Plenum GO H Discharge Supply e T G DPT1 DA1 a I A S gt VA2 E B D vavi Figure 29 Mechanical System Flow Example 4 Pressure Independent w Parallel Fan VAV Controller Variable Air Volume VAV Controller 61 VAV111 1 ANALOG INPUTS Q a A 2 Lo Lu 1 51 51 51 51 315 Q a 5 5 8 ar x x at ate DPT1 DA1 Box Damper Actuator Incremental Box Heat Actuator VA2 Fan Proportional Relay Valve Actuato Baseboard vame6a Figure 30 Single Duct Fan Powered Box Wiring Example 4 Table 25 Fan Powered Box Wiring Example 4 Bill of Materials e VAVweBOsad2AOs ASVAVITMH PTET Temperature Sensor TEM0Sees DPT 1 DA 1 Delta P Transducer Damper ATP 2040 Actuator Valve Actuator Box Heat VA 8020 1 VA 2 Electro pneumatic Transducer EP 8000 2 Baseboard Heat Note Box OEM manufacturers typically supply fan relays and electric heat relays 62 VAV Controller Variable Air Volume Controller Dual Duct The following examples are created by answering configuration questions Applications using HVAC PRO for Windows to identify terminal locations of the inputs and outputs Refer to the HVAC PRO for Windows User s Manual FAN 637 5 the VAV Controller section for
2. ANALOG INPUTS v gt X X BINARY OUTPUTS OR alal al 5 5 ell lal al al al xl lt i lt i lt i lt k lt Voy of mim Sy 5 6 S 5 5 5 5 5112 5151 511 T ga at z 8586 8 DPT2 Flow Sensor DPT1 Flow Sensor Figure 34 Dual Duct Wiring Example 1 Table 28 Dual Duct Wiring Example 1 Bill of Materials Component Description DA1 and DPT1 Cold Deck ATP 2040 nn DA2 AND DPT2 Hot Deck ATP 2040 nn 68 VAV Controller Variable Air Volume Controller The following table illustrates the selections made through HVAC PRO for Windows for this example Note The examples contained in this technical bulletin do not reflect all of the possible questions and answers These examples are provided as a basic overview of wiring locations you might expect to see Table 29 Dual Duct Wiring Example 2 Questions and Configuration Selections Exhaust Box Required Lighting Integration DA2 Hot Deck e ig DPT2 Cold Deck gt 9 it TE DA1 DPT1 C1 R1 VAV5 Figure 35 Dual Duct Wiring Example 2 Mechanical Flow Diagram VAV Controller Variable Air Volume VAV Controller 69 120 24VA 120VAC Power 24VAC Transform 4 BINARY IN NE OR al ala
3. r3 T il B o BO2 L15VDC 15VDC COMMON BI1 24VAC DA1 Damper Actuator DPT2 DA2 Damper Actuator Figure 36 Dual Duct Wiring Example 2 Table 30 Dual Duct Wiring Example 2 Bill of Materials DPT1 and DA Cold Deck ATP 2040 nn DPT2 and DA2 Hot Deck ATP 2040 nn R1 Lighting Relay GE RR7 Lighting 70 VAV Controller Variable Air Volume Controller Via Zone Bus Via N2 Bus Downloading Commissioning We recommend that you connect the zone sensor prior to performing the initial configuration download Even if you do not permanently install the zone sensor at this time terminate the N2 Bus wiring and pull it back to the equipment room location of the NCM or Companion System Refer to HVAC PRO for Windows User s Manual FAN 637 5 for upload features Downloading and commissioning via the Zone Bus requires the use of the CBLPRO interface and a laptop or PC running the HVAC PRO for Windows software You can connect to the Metastat 6 pin connector or directly at the controller VAV140 141 models have a spare 6 pin connector making it unnecessary to disconnect the Metastat or zone sensor during download commissioning Communication rate is 1200 baud over the Zone Bus HVAC PRO for Windows allows you to perform downloading and commissioning over the N2 Bus Because the communication rate is 9600 baud perfo
4. Duct Wiring Example 1 Questions and Configuration Selections Box Heat Type 3 Stages Lighting Integration Note The OEM box manufacturer typically supplies the fan relays and electric heat relays Plenum _ a Supply ae Discharge DPT1 DA1 R OI vav1 Figure 23 Single Duct Wiring Example 1 Mechanical Flow Diagram VAV Controller Variable Air Volume VAV Controller 55 120 24VAC TE1 120VAC Power 24VAC Room Transformer Se y nsor ANALOG INPUTS 9 al al el al I al xl xl xl lt i xl SI SI 8 3 51 3 51 NE x al z z ZI e x gt a Damper Actuator OUT 1 COM 2 VDC 3 vawvela Figure 24 Single Duct Wiring Example 1 Pressure Independent Configuration Table 19 Single Duct Wiring Example 1 Bill of Materials R1 Lighting Relay GE RR7 DA1 and DPT1 Actuator Flow Sensor ATP 2040 Note Box OEM manufacturers typically supply fan relays and electric heat relays 56 VAV Controller Variable Air Volume Controller The following table illustrates the selections made through HVAC PRO for Windows for this example Note The examples contained in this technical bulletin do not reflect all of the possible questions and answers These examples are provided as a basic overview of wiring locations you might exp
5. VDC 15 Volts DC 15 VDC 15 Volts DC BICM Binary Input Binary Input 1 Common BICM Binary Input Common BICM Binary Input Common BICM Binary Input Common 24 VAC POWER Transformer High Side COMMON Transformer Low Side B04 LE 24 VAC AO CM 24 Volts AC AO BO 7 A0 1 Common 24 VAC AO CM 24 Volts AC AO BO 8 A0 2 Common Binary Input 2 Binary Input 3 Binary Input 4 Binary Output 1 Binary Output 2 Binary Output 3 Binary Output 4 Binary Output 5 Binary Output 6 Binary Output 7 Analog Output 1 Binary Output 8 Analog Output 2 VAV Controller Variable Air Volume VAV Controller 33 xe NSON CONTRELS METASYS VAV140 Aa A5 Ae 5 py p B2 BIS LR LL LL LL LL LL LL LL L L 4 555 807 Vic BO8 LLY Bl B4 Bot 3 Boe Bos VAVI41 415 415 voc voc A 15 415 AB Cou A4 A5 cou LL LL lp bp by lp LL vavterma Figure 12 VAV140 and VAV141 Terminal Strip Models 34 VAV Controller Variable Air Volume Controller Table 8 Series 140 141 Controller m Aui m JAM 4 o Ambghpi SSCS ma Ambghpid as Amos SSCS B ET Bh B
6. controllers follow these precautions e Ensure polarity is maintained at each 24 VAC connection e As per NEC code you must enclose 24 VAC power trunks with greater than 4 amperes 100 VA in conduit Note See NEC Article 725 Class 2 30 VRMS Max and 100 VA Max Any individual binary output triac can drive up to 800 mA when you limit the total 24 VAC power draw You must limit the power draw of a controller and its load to avoid heat dissipation problems You must limit the total 24 VAC power draw of a VAV Controller installed in an enclosure to a maximum of 40 VA You must limit the total 24 VAC power draw of a VAV Controller mounted in an open air environment to a maximum of 75 VA When you determine the system load consider all the actual loads as well as the basic load of the controller The following tables assist you in determining the total 24 VAC power draw of your system Table 4 VAV Power and Load Specifications System Loads VAV Controller with sensors transmitters 10 VA 400 mA BO Load Relay Contactor Solenoid Incremental Actuator Refer to specific product Maximum allowable load for any individual binary output documentation triac is 19 VA 800 mA at 24 VAC Minimum required load for each binary output triac used is 1 2 VA 50 mA at 24 VAC Note Relay loads less than 50 mA may cause triac relay chattering If necessary use a 1000 ohm 2W resistor across the binary output AO Load Refer to T
7. detailed information regarding controller configuration VAV Controller Variable Air Volume VAV Controller 63 Select VAV Control Strategy 1 Pressure Independent 2 Constant Volume 3 Single Duct Conversion 4 Ind Cold Deck with Dep Hot Deck DPT Locality ___1 Hot and Cold Deck __ 2 Hot Deck and Total How 3 Cold Deck and Total Flow Select Damper Output Select Damper Output 1 Incremental 1 Incremental 2 Proportional 2 Proportional Is Discharge Low Limit Required 1 No 2 Yes Is Discharge Low Limit Required 1 No 2 Yes 1 No 2 Yes Bumpless How Transfer Between Hot Cold Decks Bumpless How Transfer Between Hot Cold Decks 1 No 2 Yes Is There an Exhaust Box 1 No 2 Yes Select Baseboard Heat Type 1 None __ 2 Incremental __3 Normally Open Valve __4 Normally Closed Valve Is Lighting Required 1 No 2 Yes Power Fail Restart Logic 1 No 2 Yes 64 VAV Controller Variable Air Volume Controller Select Damper 1 Incremental 2 Proportional Is there an Exhaust Box 1 No 2 Yes Select Damper Type 1 Separate m 2 Linked Dampers Select Damper Output 1 Incremental 2 Proportional Is Discharge Low Limit Required 1 No 2 Yes Is Discharge Low Limit Required 1 No 2 Yes Select Damper Output 1 Incremental 2 Proportional Is The
8. disabled for 10 seconds minimum and then come on per Restart Configuration NM normal mode CM common mode CM Cap is a common mode capacitor connected from the I O point to a separate ground plane To interface to TTL outputs such as demand meters use an open collector output to drive the 15 VDC pull up resistor and contact cleaning current capacitor 90 VAV Controller Variable Air Volume Controller Table 47 Function Reso Sam Accu Range lution pling racy Time Al Voltage 14bit 1 5sec x20 mV 0 2 V or 470k ohm 0 5k ohm NM ResCap 0 10 VDC CM Cap IEEE 587 Al 14bit 1 5 sec 0 5 F 1000 ohm Si 3540 ohm 0 2k ohm NM ResCap a CM Ringwave Temperature CM Cap 1 5k V Al 15bit 1 5sec 0 7 F 1000 ohm Ni 3541 ohm 0 2k ohm NM ResCap b NM Bi Wave Temperature CM Cap 1 5k V 3k A Al 16 bit 1 5 sec 1 3 F 1000 ohm Pt 3542 ohm 0 2k ohm NM ResCap Temperature CM Cap IEEE 472 Al 17 bit 1 5 sec 0 2k ohm 3543 ohm 0 2k ohm NM ResCap a CM Ringwave Potentiometer Potentiometer CM Cap 1 5k V ACCUM DC 32 bit 10ms N A 0 15 VDC 47k ohm 0 5k ohm NM ResCap b NM Ringwave 100 Hz 2 5 V Trig CM Cap 500 V BI DC Sense 1 bit 10ms N A 0 15 VDC 47k ohm 0 5k ohm NM ResCap 2 5 V Trig CM Cap AO Voltage 8bit 1 5sec 0 10 VDC N A 1k 10M ohm No Special 10 mA maximum Parts BO AC Triac N A 1 5sec INA 24 VAC N A 48 480 ohm Cap 50 500 mA DC Supply N A N A N A 14 6 17 VDC N A 162
9. into DVM If you read 5 VAC or greater the transformer is earth grounded You need an isolation transformer in order to isolate the connections from earth ground and protect system components Wire a separate 24 VAC to 24 VAC isolation transformer such as the Y65GS to the VAV Ifyou read less than 5 VAC the circuit is properly isolated Usually a value less than 0 10 VAC indicates a completely isolated circuit Line NIE Voltage 24VAC 100K ohm lt Figure 39 Testing the Transformer Determine the polarity of the transformer s leads by using a DVM referenced to earth ground without the 100k ohm resistor Connect the transformer s secondary lead with the higher voltage potential to the 24 VAC terminal on the VAV Connect the transformer s secondary lead with the lower potential to the 24 VAC Common terminal on the VAV 78 VAV Controller Variable Air Volume Controller Load Isolation VAV100 101 If the field wires are not yet connected because you skipped the section called Field Device Wiring Isolation VAV100 101 disconnect one 24 VAC wire and terminate the field wires Reconnect the 24 VAC wire Note If you ground the contactor or solenoid coils to be driven by the VAV you must use a separate isolation relay for each load e Connect the leads of the DVM in parallel with the 100k ohm resistor from the DC power supply 15 VDC output terminal of the VAV to earth ground Figure 40 This t
10. into one ZT load file For example a single duct box with reheat might require the values shown in Table 33 Table 33 Parameters for Balancing a Single Duct Box with Reheat Parametername Function Purpose FOce Hig Min view amp adjust veiy amp corefowsepan Occ Hig Max view amp aduet verly amp conectfow setom OceSept view amp acust chanepresenconmipon Once you load the base configuration files into each controller the balancing contractor can use a Zone Terminal to officially set the CFM schedules VAV Controller Variable Air Volume VAV Controller 73 74 VAV Controller Variable Air Volume Controller Troubleshooting Hardware We recommend that once the mechanical contractor starts receiving Installation delivery of the VAV boxes with factory mounted controls arrangements Inspection are made to pull a sample of the shipment and bench test it by loading a job configuration before all the boxes are mounted in the ceiling It can also be advantageous to keep a box off to the side for use in training the balancing contractor on a bench setup rather than a live box mounted in the ceiling A conos Equipment Damage Hazard Before starting make sure power is switched off Tools Needed Tools needed for typical troubleshooting include for e ASC and N2 Bus Networking and Troubleshooting Guide Troubleshooting LIT 6363003 e Digital Multimeter DMM e 100k ohm resistor e double
11. on both the RS 232 and the Zone Bus is 1200 baud The connection to the RS 232 COM port of the computer is by means of a DB9 or DB25 connector supplied with the CBLPRO After connecting it make sure the CBLPRO is about a foot or more away from the computer monitor and system unit IMPORTANT In some cases a computer monitor or PC will give off electromagnetic noise that may disturb CBLPRO communications Therefore do not position the CBLPRO near the monitor or PC Zone Bus communications to the application specific controllers or ZT may also be monitored with a CBLCON AS CBLCON 0 This device has a red and green LED whose purposes are described in the following table Table 16 CBLCON LEDs Power UE a e o e Zone Bus wire shorted to Common or 24 VAC or CBLCON 0 switch in download position 50 VAV Controller Variable Air Volume Controller Application Examples Single Duct The following examples are created by answering configuration questions Applications using HVAC PRO for Windows to identify terminal locations of the inputs and outputs Refer to the HVAC PRO for Windows User s Manual FAN 637 5 the VAV Controller section for detailed information regarding controller configuration VAV Controller Variable Air Volume VAV Controller 51 Select the VAV Control Strategy 1 Pressure Independent Select the Damper Output Type 1 Binary Outputs Incremental Control 2 Analog Outputs Proportionall
12. proper polarity VAV cycles A read only point is defined in the Delete the AO or BO point and online and Companion data base as a read write read it as an Al or BI point to offline point AO or BO the Companion data base A Companion process is using an Delete the use of the unconfigured point i e not listed in unconfigured point in the HVACPRO SYM file Companion process VAV does not Two or more VAVs have the same Change each duplicate VAV come online address address to a unique number The address of the VAV was changed Cycle power on the VAV without its power being cycled afterward The ten second delay after downloading Wait until the delay expires or the VAV has not yet expired cycle power on the VAV HVAC PRO Revision 1 0 or earlier 82 VAV Controller Variable Air Volume Controller Zone Bus Table 36 lists and describes the errors that may occur while using the Troubleshooting HVAC PRO for Windows commissioning tool with the VAVs over the HVAC PRO Zone Bus The cause of the error is often a loose or improper connection for Windows between the CBLPRO AS CBLPRO laptop PC and the controller A defective COM port on the laptop could also be at fault Other times a defective controller can cause an error Note It takes ten seconds for a VAV Controller to reset and resume communication after being downloaded An effective troubleshooting technique is to use a CBLCON and observe its LEDs which will
13. still in reset mode Wait ten seconds for the reset Communication Resetting takes ten seconds aftera period to expire before trying to Error download commission the controller 17 Bad CRC The Cyclical Redundancy Check of Check for tight and proper the message received is incorrect connections between the laptop due to an error in transmission PC CBLPRO and the VAV Invalid The message received is not what response the HVAC PRO for Windows Load Utility expected VAV Controller Variable Air Volume VAV Controller 83 The green LED on the VAV110 111 and VAV140 141 Series Controllers may be used to troubleshoot problems with the Zone Bus Table 37 Zone Bus LED Indications LED Status Indication TweinopweiWeASo O ssid The Zone Bus is shorted to Common or 24 VAC Blinking Normal communication is taking place 84 VAV Controller Variable Air Volume Controller Ordering Information Johnson Controls Code Numbers Controllers Table 38 Controller Code Numbers Code Number Description AS VAV110 1 VAV Controller with eight Binary Outputs Quick Connects AS VAV111 1 VAV Controller with six Binary Outputs and two Analog Outputs Quick Connects AS VAV140 1 VAV Controller with screw terminals and eight BOs AS VAV141 1 VAV Controller with screw terminals six BOs and two AOs AS VAVDPT1 1 AS VAV110 1 Control and DPT 2015 1 for Trane Single Duct Applications AS VAVDPT2 1 AS VAV111 1 Co
14. the N2 Communications Bus and the Companion Companion PC Panel LTD 15 required to service N2 devices An MM CVT101 0 Communications Converter 1s required to network to the Companion See Figure 21 for terminal locations Refer to the Metasys Companion Technical Manual FAN 628 1 for information specific to the CVT101 or Companion Panel LTD Companion PC Version METASYS po ec 11 1 1111 eo n item d RS232 to N2Bug DITIT o MET TU I Converter LLLI LI DR ooo N2 Bus Terminal Vv Vv REF NS To N2 N2 RE Next N2 N2 2 N2 N2 REA Device n2wire2 Figure 21 Connecting the VAV Controller to Companion 48 VAV Controller Variable Air Volume Controller Zone Bus Communications Zone Bus Description The Zone Bus is a 2 wire communications bus that allows a computer to communicate with the VAV to download the VAV s data base and to communicate with Zone Terminals and M100 Actuators A third wire is used for 24 VAC power to the CBLPRO Zone Terminal and CBLCON The bus interface sustains no damage in presence of fault voltages of 24 VAC MIOOC Actuators must be powered with separate transformers therefore only the Zone Bus and Common wires need to be pulled The Zone Bus has the following specifications Table 15 Zone Bus Specifications Multidrop serial communications bus Recommended C
15. 10M CM Cap Out 90 mA ohm N A N A N A 5000 f 1500 m N A N A PTC Opto IEEE 587 Tranzorb CM Ringwave NM Ringwave Zone Bus N A N A N A 500 ft 150 m N A N A PTC IEEE 472 Tranzorb CM Ringwave NM Ringwave State of Outputs During PWR Fail Disables when 24 VAC PWR drops below 18 VAC State of Outputs After PAR is Restored Remain disabled for 10 seconds minimum and then come on per Restart Configuration NM normal mode CM common mode CM Cap is a common mode capacitor connected from the I O point to a separate ground plane To interface to TTL outputs such as demand meters use an open collector output to drive the 15 VDC pull up resistor and contact cleaning current capacitor VAV Controller Variable Air Volume VAV Controller 91 JAHNSON CONTRELS Controls Group 507 E Michigan Street Box 423 Milwaukee WI 53201 92 VAV Controller Variable Air Volume Controller Notes FAN 636 3 Application Specific Controllers Manual Printed in U S A
16. Air Temp Exhaust Delta P Unused Binary Inputs Bl 1 Unused Rename Occupied BI 2 Unused Rename Standby BI3 Unused Rename Shutdown Box Open BI 4 Unused Rename Shutdown Box Closed Unused Rename Temp Occupancy Momentary BI BI5 Boost Binary Outputs BO 1 Damper Open None BO2 Damper Close None Cold Deck Close BOS3 Heating Cooling Changeover None BO4 Unused Rename Hot Deck Close BO5 Unused Rename BO6 BO7 BO8 Unused Basebd Close Lights Off O Unused Exhaust Close K Unused Basebd Heat Basebd Open Lights On 5 66 VAV Controller Variable Air Volume Controller The following table illustrates the selections made through HVAC PRO for Windows for this example Note The examples contained in this technical bulletin do not reflect all of the possible questions and answers These examples are provided as a basic overview of wiring locations you might expect to see Table 27 Dual Duct Wiring Example 1 Questions and Configuration Selections Discharge Air Low Lim Exhaust Box Required Lighting Integration No 4 DA2 Hot Deck 9 H p DPT2 Cold Deck gt 9 DPT1 DA1 C1 VAV4 Figure 33 Dual Duct Wiring Example 1 Mechanical Flow Diagram VAV Controller Variable Air Volume VAV Controller 67 120 24VA 120VAC Power 24VAC Transform y
17. Application Specific Controllers Technical Manual 636 3 VAV Controller Section METASYS Teon sue Dale 0309 Variable Air Volume VAV Controller Introduction Page 5 e Description 5 e OEM Applications 8 e Standards Compliance 8 Coordination of Factory Mounted VAV Systems 8 Configuring the Controller 11 Using HVAC PRO for Windows Configuration Tool 11 Defining a VAV Control Device Object in Metasys Software 13 Installation Procedures 17 e Tools Needed 17 e Environmental Information 17 e Mounting the Controller 18 e Power Line Wiring Transient Noise Precautions 21 I O and Communication Lines Wiring Transient Noise Precautions 23 Indicates those sections where changes have occurred since the last printing 2009 Johnson Controls Inc 1 Code No LIT 6363040 Wiring Details Page Power Source and Loads e Grounding and Isolation I O and Communication Terminals Power Zone Bus and N2 Connections e Analog Inputs e Binary Inputs e Binary Outputs e Analog Outputs e Zone Bus e Wiring to RLY50 002 Relays e Wiring Sensors and Actuators Networking the Controller N2 Bus Overview Installing the N2 Bus e Zone Bus Communications Application Examples e Single Duct Applications Dual Duct Applications Downloading Commissioning Via Zone Bus Via N2 Bus Incremental Valve Actuator Stroke Time e Incremental Damper Actuator Stroke Time e Zone Terminal Setup for Balancing Con
18. C 15 Volts DC BICM Binary Input Binary Input 1 Common BICM Binary Input Binary Input 2 Common BICM Binary Input Binary Input 3 Common BICM Binary Input Binary Input 4 Common 24 VAC POWER Transformer High 24 VAC COMMON Transformer Low Side Side Zone Bus N2 Reference and ZBus Common 24 VAC 24 Volts AC Boi Binary Output 1 24 VAC 24 Volts AC BO2 Binary Output 2 24 VAC 24 Volts AC BO3 Binary Output 3 24 VAC 24 Volts AC BO 4 Binary Output 4 24 VAC 24 Volts AC BO5 Binary Output 5 24 VAC 24 Volts AC Binary Output 6 24 VAC AOCM 24 Volts AC BO 7 AO 1 Binary Output 7 AO Common Analog Output 1 24 VAC AOCM 24 Volts AC BO 8 AO 2 Binary Output 8 AO Common Analog Output 2 A VAV100 has eight BOs VAV101 has six BOs and two AOs VAV Controller Variable Air Volume VAV Controller 31 Figure 11 VAV110 VAV111 Terminal Designations 32 VAV Controller Variable Air Volume Controller Table 7 VAV 110 111 Terminal Identification Series 110 111 Controller AI CM Analog Input Analog Input 1 Common AI CM Analog Input Analog Input 2 Common AI CM Analog Input Analog Input 3 Common AI CM Analog Input Analog Input 4 Common AI CM Analog Input Analog Input 5 Common AI CM Analog Input Analog Input 6 Common 15
19. CM data base 9 Upload the NCM to make an archive copy of the new object following the instructions in the Operator Workstation User s Manual FAN 634 the Advanced User s Guide tab the Uploading and Downloading Data Bases chapter the Uploading from the NCM section Once you have defined the VAV object you can modify or monitor its attribute values online using the VAV object Focus window See the Operator Workstation User s Manual FAN 634 for more information on using Focus windows VAV Controller Variable Air Volume VAV Controller 15 16 VAV Controller Variable Air Volume Controller Tools Needed Environmental Information Installation Procedures Instructions for the installation of the VAV Controller and its accessory devices are detailed in this section The types and numbers of components sensors and actuators selected for use with the VAV vary according to application Analyze the proposed installation for logical places to locate these devices and draw up an inventory based on that study Information on types of accessory devices available is in the Ordering Information section of this technical bulletin Most VAV installation should be coordinated with the VAV box manufacturer for factory mounting The OEM Reference Manual FAN 638 describes the steps and pricing to coordinate a factory mount solution Tools needed for a typical installation include e HVAC PRO for Windows currently released softwar
20. Control Define Diagnostics 1 None 2 Actuator Runtime 3 Moving Avg Flow Error 4 Moving Avg Zone Temperature Error 5 Runtime and Moving Avg Flow Error 6 Runtime and Moving Avg Zone Temp Error 7 Moving Avg Fllow and Zone Temp Error 8 of the Above Select Fan Type None 2 Series On Off 3 Series Proportional 4 Parallel Temperature 5 Parallel Flow A Is there an exhaust box 1 No 2 Yes Type of Heating 1 None 2 Baseboard Heat Only 3 Box Heat Only 4 Both Baseboard and Box Heat Select Type of Baseboard Heat 1 Incremental 2 Normally Open Valve 3 Normally Closed Valve Select Type of Box Heat 1 Incremental 2 Proportional 3 Normally Open Valve 4 Normally Closed Valve Single Stage 5 2 Stages 6 3 Stages Is lighting required 2 Pressure Dependent without Feedback 3 Pressure Dependent with Feedback 4 Pressure Independent User Defined Flow Select the Damper Output Type 1 Binary Outputs Incremental Control 2 Analog Outputs Proportionall Control Define Setpoint Type 1 Separate Heating and Cooling Setpoints 2 Single Setpoint with Bias Define Remote Al points 1 None 2 Remote Setpoint 3 Wermer Cooler Adjust Define Remote Al Points 1 None 2 Cooling Heating Setpoints 3 Warmer Cooler Adjust Define Occupied Mode 1 Software N2 Command 2 Hardware BI P
21. EF N2 N2 The N2 screw terminal block is removable to allow you to disconnect the communication trunk without disrupting the N2 that is daisy chained to other controllers Analog Inputs The six analog input terminals their power supply and their common points occupy the terminal strip These inputs may be of two types resistive or voltage The VAV Controller processes and controls the configured control strategy It reads the analog inputs through the analog input DIP switches located directly above the analog input terminals You use these switches and HVAC PRO for Windows to select the type of analog input Use T for all RTD temperature sensors and setpoint potentiometers Use 10V for DPT 2015 differential pressure transmitters For 3 wire voltage transmitters such as the DPT 2015 Series use the 15 VDC power supply terminals next to the inputs for AL 6 You can source 90 mA from 15V supply The following table shows each configuration Table 9 Analog Input Configurations Switch Position Set Al Type Range SW1 SW2 Voltage V 0to 2 VDC Voltage V 0 to 10 VDC Resistance T 1000 ohm Nickel T 2 Platinum Silicon 2k Potentiometer T 1000 ohm Nickel V 2V Platinum Silicon 2k Potentiometer 36 VAV Controller Variable Air Volume Controller The VAV Controller has two sets of DIP switches One set is for configuring the analog input points and the other for setting the address of the controller Use Tables 9 and 10 to se
22. N 636 3 for more information The switches located in the upper right corner of the VAV are set to the same number as was assigned to the module through software The Metasys or Companion Facility Management System FMS uses this address for polling and commanding The numbers are in binary format and vertically arranged with the least significant digit to the right For example if the controller address is 17 decimal the binary representation is 00010001 Switches 1 and 16 must be set to the On position 1 16 17 as shown in Figure 19 5 ras O 123456 12 33333353 Address Switches dipswtch Figure 19 Setting the N2 Address DIP Switches IMPORTANT When setting the N2 Address do not use address 0 46 VAV Controller Variable Air Volume Controller N2 Wiring to the Network Control Module Device Note Since the VAV Controller is a self terminating device end of line termination for the N2 Bus is not required Figure 20 Connecting the VAV Controller to an NCM Table 14 Terminal Locations TB1 Terminal Function Number VAVConnection ChassisGround Soft Ground 58 fne NA Ref Ground 4 fae O O Oo y o smamma 3 fe N2B Connection 2 N2Bus N2 N2B Connection N2Bus N2 VAV Controller Variable Air Volume VAV Controller 47 N2 Wiring to A hardware connection between
23. VAC 277 VAC 347 VAC Minimum Continuous 130 to 135 VRMS 250 to 280 VRMS 300 to 320 VRMS 385 VRMS Voltage Rating Only 250V types listed Minimum Energy Rating 30 Joules 55 Joules 80 Joules 85 Joules Minimum Peak Current 4 000 Amperes 4 000 Amperes 4 000 Amperes 4 000 Amperes 8 x 20 second pulse V130LA10A V250LA20A None None V130LA20A V250LA40A V130LA20B V250LA40B V130K14 V250K14 V300K14 V385K14 V130K20 V250K20 V300K20 V385K20 D6321Z0V131RA15 D6321ZOV251RA90 D6321ZOV301RA105 D6521Z0V131RA20 D6521ZOV251RA130 D6521ZOV301RA150 D6921Z0V131RA09 D6921ZOV251RA72 D6921ZOV301RA80 Mallory VSAC14DK201U VSAC14DK391U VSAC14DK471U VSAC14DK621U VSAC20DK201U VSAC20DK391U VSAC20DK471U VSAC20DK621U TNR15G211KM TNR15G391KM TNR15G471K TNR23G201KM TNR23G391JM TNR23G471K TNR23G211KM TNR23G391KM Oneida CKE OZ130LA10A OZ250LA20A OZ21L471 None OZ130LA20A OZ250LA40A OZ130LA20B OZ250LA40B 0z21L221 0216NR14 3 0216NR20 4 Panasonic ERZ C14DK201U ERZ C14DK391U ERZ C14DK471U ERZ C14DK621U ree Jerome erom nr rent ercmenr Phlps zszzsossis 202250552516 232250553016 202250553816 S14K130 S14K250 S14K300 S14K385 pem eur ou meo 0216NR14 3 0390NR14 3 0620NR14 3 0620NR14 3 0216NR20 4 0390NR20 4 0620NR20 4 0620NR20 4 0216NR20DB 0416NR14 3 0416NR20 4 Thomson VE17M00131K VE17M00251K VE17M00301K None VD24M00131K VD24M00251K VD24M00301K Indicates the preferred model if several a
24. VAV Controller in an Enclosure Kit Mount the VAV in any convenient location using the predrilled mounting holes The controller must be mounted on a wall or panel where it can be easily wired through the enclosure cover Mount the VAV vertically for best DPT differential pressure transmitter performance The same instruction applies to remote location packages Refer to Figure 7 when installing a VAV Controller 1 Secure the VAV inside the enclosure kit 3 using three screws through the mounting tabs on the sides of the controller board base 2 Position the VAV and enclosure so that it rests firmly against the mounting surface 3 Using a flat blade screwdriver and pliers remove the necessary wire passage knockouts amp Note Do not use knockouts on the opposite sides of enclosure as you will not be able to remove the VAV board 4 Attach the enclosure cover after installing wiring 20 VAV Controller Variable Air Volume Controller Power Line Wiring Transient Noise Precautions Surge Levels The standard VAV Controller when powered by any typical separate isolation transformer or step down transformer operates reliably in an electrical environment defined as Location Category A by the IEEE 587 Standard that is when installed more than 30 feet 9 meters from electrical distribution panels or major bus and feeder systems in industrial plants IEEE 587 Location Category A power line surge noise le
25. able 5 Actuator Maximum allowable load for each AO is 10 mA witha minimum load resistance of 1000 ohm Zone Terminal or CBLPRO 1 2 VA 50 mA Actuator VA requirements are found in Table 5 With total controller power draw limited as described previously 26 VAV OController Variable Air Volume Controller Table 5 Actuator VA Requirements pa TE for 24 VAC Supply Volage 010 10 VDO Grounding and On unit mounted controls OEMs typically minimize Isolation wiring between digital controls and equipment interface relays by using one leg of the stepdown transformer VAV100 101 as common Isolation C Transformer NE N L 4 l Power Transformer 24 24 5 N o 8 Be a T t Pi 6 See th AUTION Z below Figure 9 ak Load POR Contactor Isolation Relay visoxfmr VAV100 101 Figure 8 Transformer and Relay Isolation Wiring Diagram for Series 100 101 VAV Controllers VAV Controller Variable Air Volume VAV Controller 27 N2 Bus Isolation VAV 100 101 Power Transformer Isolation VAV100 101 Load Isolation VAV100 101 VAV110 111 and VAV140 141 All VAV100 101 connections must be isolated from earth ground to protect the CBLPRO laptop PC or other system components from damage Due to OEM system designs and or electrical codes the VAV may become earth grounded unless you take isolation measures Typical
26. able Type 18 AWG 1 5 mm with shield Beldon 8760 or 24 AWG 0 6 mm diameter with no shield unshielded telephone cable Maximum Bus Length 500 feet 150 meters with 18 AWG 1 5 mm cable or 50 feet 15 meters with 24 AWG 0 6 mm diameter cable Range of Addresses 0 to 63 Voltages Logic High Voltage 4 VDC minimum approximately Logic Low Voltage 1 VDC maximum approximately Data Transmission 1 Start Bit low level 8 Data Bits least significant bit first 1 Stop Bit high level The VAV110 111 and VAV140 141 Series Controllers contain an LED that blinks to indicate Zone Bus activity with or without external connection When a PC via CBLPRO communicates with the controller the blink rate may appear to be more steady See Table 37 Zone Bus LED Indications in the Troubleshooting section of this document for more information VAV Controller Variable Air Volume VAV Controller 49 CBLPRO Description CBLPRO AS CBLPRO is an interface device for use between a computer running HVAC PRO for Windows and application specific controllers such as the VAV Controller It is used for data base downloading uploading or commissioning via the Zone Bus communication port When used with a Zone Bus device such as the VAV or ZT the CBLPRO 15 strictly an electrical interface between the serial RS 232 port of the computer and the Zone Bus CBLPRO operates on 24 VAC drawn from a VAV over the wire used to make the Zone Bus connections The data rate
27. ary push 1 Momentary push 1 Momentary push button from zone button from zone button from zone sensor for temporary sensor for temporary sensor for temporary occupancy mode occupancy mode occupancy mode BI 4 may be used as BI 4 may be used as BI 4 may be used as an accumulator input an accumulator input an accumulator input for frequencies less for frequencies less for frequencies less than 100 Hz than 100 Hz than 100 Hz Analog 0 2 0 2 0 2 Outputs 0 to 10 VDC 0 to 10 VDC 0 to 10 VDC 10mA 10mA 10mA Binary 8 6 8 6 8 6 Outputs 24 VAC Triacs 24 VAC Triacs 24 VAC Triacs 0 5 amperes 0 5 amperes or 0 5 amperes or 0 8 amperes if total 0 8 amperes if total power is limited power is limited N2Bus Not Isolated Isolated Isolated Zone Bus Discrete connections Discrete connections Discrete connections at controller at controller at controller 8 pin phone jack on 8 pin phone jack on 8 pin and 6 pin phone controller controller jack on controller 6 pin phone jack at 6 pin phone jack at 6 pin phone jack at zone sensor zone sensor zone sensor LED Indication LED Indication 24 VAC Power Quick Connects Removable Screw Removable Screw Terminations Spade Lugs Terminal Block Terminal Block Quick Connects Quick Connects Fixed Screw Terminal Terminations Spade Lugs Spade Lugs Block N2 Fixed Screw Terminal Removable Screw Removable Screw Terminations Block Terminal Block Terminal Block VAV Contro
28. ate isolation relay for each load see Figure 8 28 VAV OController Variable Air Volume Controller Power Transformer Isolation VAV110 111 and VAV140 141 Load Isolation VAV110 111 and VAV140 141 VO and Communication Terminals m L Power Transformer N v SeeCAUTIONbelow To E AL Contactor Figure 9 Transformer Wiring Diagram for Series 110 111 VAV Controllers CAUTION Some local electric codes require the secondary common of stepdown transformers be connected to earth ground typically on units powered by more than 150 VAC You may have a maximum of one single earth ground connection which must be at the transformer secondary common whether one or multiple controllers are powered by the same transformer You may connect the Series VAV110 111 and VAV 140 141 power transformer secondary directly to earth ground If you elect to do so the grounded side must connect to the Common power input terminal of the controller You do not need a separate isolation transformer for these controllers If VAV output loads such as contactor or solenoid coils are grounded you must use a separate isolation relay for each load The VAV terminal designations which identify sensor actuator and power connection points are illustrated in Figures 10 through 12 and Tables 6 through 8 Use the HVAC PRO for Windows Configuration Tool to assign
29. banana plug optional shown in Figure 37 available from local electronics store or ITT Pomona Stock No 34F856 or 3F845 1 4 watt for earth ground voltage tests 100k ohm 1 4 watt CED gr Poi Use double banana plug for all tests that require a 100k ohm resistor placed in parallel with DIMM Steps M 1 Connect 100k ohm resistor under plug s prongs zi 2 Insert banana plug into DVM 3 Connect leads of DMM into banana plug banana Figure 37 Double Banana Plug Used with 100k ohm Resistor VAV Controller Variable Air Volume VAV Controller 75 Installation Inspect the mounted VAV to ensure proper installation Refer to the Checkout appropriate illustrations in the section of this technical bulletin titled Installation Procedures and to the engineering drawings 1 Check that the mounting screws holding the subassembly onto the base frame are secure Verify that accessory equipment is connected and labeled correctly Ensure that the controller terminal connections are secure Verify that the N2 connections are secure and labeled correctly Verify that the VAV switches are appropriately positioned Refer to the Wiring Details and Networking the Controller sections of this technical bulletin 6 Verify that there are no unwanted earth ground connections to the controller following the procedures below No earth ground connections are allowed when wiring a Series VAV100 101 Controller A
30. cessary wiring terminations between the VAV Controller and the TE 6410 Series Metastat use phone cable that has preterminated 8 pin RJ 45 connectors These cables are available from Anixter Refer to the Vendor Code Numbers in the Ordering Information section of this technical bulletin for specific information regarding cables Connect one end of the cable to the Zone Bus connector on the controller and the other end to the 8 pin connector on the back of the sensor as shown in Figure 15 In addition to the 8 pin RJ 45 connection the TE 6410 Metastat also has a 6 pin RJ 12 connection under its cover This allows remote connection of the CBLPRO used during commissioning or the Zone Terminal used for system monitoring For VAV140 141 Series Controller there is an additional 6 pin jack for Zone Bus communication You may permanently connect a Metastat to the 8 pin jack of the controller and simultaneously connect a laptop PC CBLPRO or Zone Terminal to the Zone Bus via the 6 pin jack VAV Controller Variable Air Volume VAV Controller 41 Phone Jack Figure 16 illustrates the polarization of the 6 pin and 8 pin phone jacks on Polarization the VAV Controller or Metastat Terminal is to the extreme left as you face the jack opening tab notch down ANS 12345678 PHONEJKS 8 pin ns euin Figure 16 Phone Jack Polarization The following table defines the pin usage for each jack Table 13 Phone Jack Pin Identification 6 Pin Ja
31. ck VAV140 141 Controller 8 Pin Jack to CBLPRO or ZT and CBLPRO or VAV Controller to Metastat Zone Terminal to Metastat 3 Heating Setpoint 2 Warmer Cooler or Cooling Setpoint Not used 24 VAC Not used 7 Note Refer to the Vendor Code Numbers in the Ordering Information section of this technical bulletin for information on cables Zone Bus Not Used Pin C pes s 42 VAV Controller Variable Air Volume Controller Fabricating an You must construct any fabricated interconnection cable so the same color Interconnection wire on both ends of the cable align with Pin 1 in the plug This provides a Cable consistent field assembly of the cable Figure 17 illustrates the interconnection cable 8 ZBUS 7 Al2 3 COM 6 COM 24VAC Metastat 5 Phone Plug 4 7 3 Alt 1 2 Al2 5 1 AI3 i 87654321 Controller Phone Plug CBLFAE Figure 17 Interconnection Cable Note This is not typical of pre assembled phone cable purchased in retail stores A telephone system cable is wired opposite the zone sensor requirements VAV Controller Variable Air Volume VAV Controller 43 Sharing a Sensor You may use one sensor as a master input to multiple VAV Controllers instead of mounting and wiring separate zone sensors for each controller This application is especially beneficial when you have a mechanical system that uses more than one ter
32. control system at most of the key box manufacturers If the job cannot be factory mounted check with the VAV box manufacturer to determine if a control enclosure for the VAV Controller and Actuator Velocity Pressure Transducer combination is already available on the VAV box If there is not an available enclosure the common packaging for the VAV Controller is an enclosure provided by the contractor or the Johnson Controls EN EWC10 EN EWC15 BZ1000 or AS ENC enclosure The controller requires a flat mounting surface area to match its dimensions e 6 5 x 6 4 x 2 2 in 165 x 163 x 56 mm H x W x D without enclosure e 6 8 x 7 3 x 4 7 in 173 x 185 x 119 mm H x W x D with the AS ENC100 0 enclosure e 7x 13x 6in 180 x 330 x 150 mm H x W x D with the EN EWC10 0 and EN EWC15 0 enclosure Make sure you allow enough room to install the enclosure and conduit for wiring terminations to the controller Figure 7 shows a common packaging configuration for the VAV Controller 18 VAV Controller Variable Air Volume Controller Mounting the into a Universal Packaging Module Field Mounting Low Voltage Wiring Trough vavpwer Figure 6 EWC10 Enclosure with VAV Controller and 50 VA Transformer The VAV can be directly mounted into an EWC10 15 enclosure You may also purchase the VAV premounted in a EWC10 enclosure with a 50 VA transformer Refer to the Application Specific Controllers Tech
33. ctors readings or flow readings are not repeatable No change in the CFM value while you are manually overriding the damper by changing the temperature setpoint or issuing a direct override to the damper command The damper actuator cycles excessively Series fan is not running Velocity Pressure Transducer out of calibration by more than 20 percent Damper does not seal Box Multiplier Constant and or Box Area parameters are not set correctly One or both airflow pickup to DPT tubing connections are crossed plugged or open The ductwork configuration upstream of the airflow pickup is disturbing the air flow across the pickup Damper linkage is slipping or linked incorrectly Main system is not supplying enough air The Supply Deadband and or Heating Cooling Prop Bands are too narrow Electrical noise is present on zone temperature signal Unit is not in Occupied mode Unit in initial startup Command Auto Zero mode using HVAC PRO for Windows and read the offset value for the DPT sensor If the value is greater than 20 percent of the sensor range you need to replace or manually calibrate the transducer Override damper closed and verify Verify the numbers displayed in the HVAC PRO for Windows parameters screen against the information on the box or check the OEM Reference Manual FAN 638 for the recommended numbers per box type Check that the high or upstream side of the pickup conne
34. cts to the DPT high side and the downstream side of the pickup connects to the DPT low side Check that the tubing is not plugged and that the test taps are capped Turns transitions and flex duct should be no closer than one duct diameter upstream from the airflow pickup The takeoff should be at least three duct diameters upstream from the pickup Inspect the linkage while the actuator is being commanded to ensure tight connection If the VAV box actuator is linked correctly and you cannot obtain the maximum CFM setpoint check the Central System Static Pressure to ensure enough primary air is being provided to properly balance the system Check the Supply Deadband value to ensure that it is greater than 48 box inlet area ft 4 5 box inlet area m If the cycling persists after changing the supply deadbands check the heating and cooling prop bands to see if they are greater than 4 F 15 5 C If not increase the prop band values to at least 4 F 15 5 C and add an integration timer of 400 Diagnose with HVAC PRO for Windows data graphing If present reroute wire or use twisted pair and or shielded cable Check HVAC PRO for Windows parameter table to ensure occupied status shows on Before the series fan is commanded on the damper fully closes to ensure the fan does not turn backwards VAV Controller Variable Air Volume VAV Controller 84 Troubleshooting You need to troubleshoot the N2 Bus if the Metasys syst
35. e e IBM PC compatible laptop computer e Windows 3 x or Windows 95 e two screwdrivers 1 8 in and 1 4 in flat blade e AS CBLPRO 2 Zone Bus communication tool e MM CVT101 0 N2 Bus communication tool AS ZTUIOO 1 Zone Bus interface to application specific controllers The installation site of the VAV Controller must meet the following environmental standards e The atmosphere must be free of explosive vapors or escaping gases e The atmosphere must be free of exposure to corrosive chemical or salt vapors which might damage electrical equipment The temperature must be maintained between 32 to 122 F 0 to 50 C with the relative humidity non condensing maintained between 10 and 90 e The power line must be clean without electrical noise transients that are often present in industrial environments Commercial and residential buildings typically have clean power but may not depending on the location nearby equipment etc Follow the power line wiring transient noise precautions VAV Controller Variable Air Volume VAV Controller 17 Mounting the Controller Factory Mounting Typically the most cost effective and highest quality installation of the VAV Controller EDA 2040 Damper Operator and DPT 2015 Velocity Pressure Transducer can be accomplished by the box manufacturer The OEM Reference Manual FAN 638 describes the relationship pricing and process to accomplish factory mounting of the VAV
36. earth ground and then to each output to ground For the DVM test connect the DVM from each input to earth ground and then to each output to ground Figure 38 If the LED turns On or you read a value less than 1 Megohm at any input or output the circuit is improperly isolated Replace or repair the wiring or the field device or for a binary output add an isolation relay Repeat the DVM test only If the LED does not turn On or you read a value greater than 1 Megohm the circuit may be properly isolated It will not be isolated if there are earth grounds that exist at higher voltages A value of infinite ohms indicates a completely isolated circuit at approximately zero volts Connect this wire to the appropriate VAV terminal and check the next wire Field Device VAV or LED Test Circuit Preferred Method Ecce eC E eo Figure 38 Testing for an Isolated Circuit VAV Controller Variable Air Volume VAV Controller 77 Power e Transformer Isolation VAV100 101 Before connecting the transformer to the VAV connect the input power to the primary leads of the 24 VAC transformer Note If you ground the secondary of the power transformer you must use a separate 24 VAC to 24 VAC isolation transformer such as the Y65GS Measure the voltage of each secondary transformer lead to earth ground with the DVM in parallel with a 100k ohm 1 4 watt resistor Figure 39 if using double banana plug insert plug
37. ect to see Table 20 Single Duct Wiring Example 2 Questions and Configuration Selections Box Heat Type Proportional Lighting Integration Not Available H o T LE G DPT1 DA1 VA1 C1 DA2 DPT2 E 9 a Exhaust Box VAV2 Figure 25 Single Duct Wiring Example 2 Mechanical Flow Diagram VAV Controller Variable Air Volume VAV Controller 57 120 24VA 120VAC Power 24VAC Transform 4 ANALOG INPUTS lt BINARY IN COMMON BI4 EN x CSN COMMON BI2 AICM AI6 COMMON 1 COMMON BI3 DPT2 DA2 EXH Actuator VA Figure 26 Single Duct Wiring Example 2 Table 21 Single Duct Wiring Example 2 Bill of Materials Component Descri ption Part Number 9 Number CE O me est TEO Seres DA1 and DPT1 Actuator AP Sensor ATP 2040 Valve Actuator VA 8022 Series DA2 and DPT2 Actuator DP Sensor ATP 2040 58 VAV Controller Variable Air Volume Controller The following table illustrates the selections made through HVAC PRO for Windows for this example Note The examples contained in this technical bulletin do not reflect all of the possible questions and answers These examples are provided as a basic overview of wiring locations you might expect to see Table 22 Single Duct Wiring Example 3 Questions and C
38. ed e Zone sensor cables are pulled The use of phone cable for terminating zone sensor wiring allows basically anyone to terminate zone sensors in certain locales e If desired the N2 address switches can be set by the electrical contractor Initial loading of the HVAC PRO for Windows configuration files is done once the electrical contractor s functions are completed in preparation for the final system balancing Training of the balancing contractor to ensure the balancing contractor knows how to use the Zone Terminal ZT or HVAC PRO for Windows Commissioning mode so they can perform the final system balancing Mounting and terminating the cable connections for the zone temperature sensor Set the N2 address switch if the electrical contractor was not contracted to perform this function Configuring downloading and commissioning the controller VAV Controller Variable Air Volume VAV Controller 9 10 VAV Controller Variable Air Volume Controller Configuring the Controller Using Use HVAC PRO for Windows to configure the VAV VAV110 111 and HVAC PRO VAV140 141 models require HVAC PRO for Windows HVAC PRO for for Windows Windows also works with the VAV100 101 models This easy to use Configuration software tool configures commissions and downloads the VAV Tool Controller s data base Figure 2 illustrates the HVAC PRO for Windows configuration process Refer to the HVAC PRO for Windows User s Manual FAN 637 5 f
39. em is not the N2 Bus and properly communicating with the VAVs This section first presents a Networked VAV troubleshooting table Table 35 covers VAV or N2 communication Controller problems and suggests which actions to take Second specific troubleshooting tests are given Before trying one of these tests you may be able to determine the cause of the problem by asking yourself the following questions e Are the N2 Bus wires securely terminated to each VAV e Is the N2 polarity correct e Is the VAV powered and ready to respond e Are the end of line device settings correct e Have you cycled power on a VAV after changing its N2 address e Is the W3 loop back jumper on the Companion Panel LTD fully pushed down on Pins 1 and 2 e Are the VAVs configured properly with the correct number of points A CAUTION Electrical Shock Hazard To avoid electrical shocks when troubleshooting always measure the REF to earth ground voltage with the DMM If line voltage is measured have a qualified electrician locate the fault Table 35 N2 Bus Troubleshooting Symptoms and Corrective Action Symptom Possible Cause Action N2 Bus is EOL jumpers and or W3 jumper on Install EOL jumpers and W3 offline MM CVT101 or Companion Panel LTD jumper properly are not installed MM CVT101 is not plugged into PC or Plug MM CVT101 into PC or 9 VDC source plug it into a 9 VDC source N2 Bus polarity is incorrect Rewire N2 Bus wires for
40. essure Dependent with Feedback and Independent Path Rename Unused Rename BI2 Unused Rename pees INN BI3 Unused Rename pees Sumo O Bl4 Unused Rename CS BI Boost Mode Continued on next page VAV Controller Variable Air Volume VAV Controller 53 HVAC PRO for Windows HVAC PRO for Windows Configuration Configuration Options Assignments and Defaults Binary BO 1 Supply Damper Open Outputs 802 Supply Damper Close BOS Parallel and Series On Off Fans None Exhaust Box Open Unused Exhaust Box Close Baseboard Heat On Off First Stage Box Heat Unused Baseboard Incremental Open Box Heat Incremental Open First Stage Box Heat Second Stage Box Hea Lights On for VAV101 Unused kkk Baseboard Incremental Close Box Heat Incremental Close On Off Single Stage Box Heat Second Stage Box Heat Third Stage Box Heat Lights Off for VAV101 Unused Baseboard Incremental Open on VAV100 Lights On for VAV100 Unused Baseboard Incremental Close on VAV100 Lights Off for VAV100 Unused Analog S66 Output for None Outputs Proportional Series Fan 2 Proportional Box Heat None 2 Stages Box Heat 3 Stages Box Heat kk kkk 54 VAV Controller Variable Air Volume Controller Note The examples contained in this technical bulletin do not reflect all of the possible questions and answers These examples are provided as a basic overview of wiring locations you might expect to see Table 18 Single
41. ests whether the field devices the VAV and the transformer assembly are properly isolated VAV 24 VAG line C Voltage 24VAC 24 VAC COM Field Wring 100k ohm gt DVM lt 5 VDO VAC CK Isolated 1 4 watt gt DVM gt 5 VDC VAC Earth Grounded 9 AICOM BICOM ZBUS COM AOCOM BOCOM VT GRDLOCP Figure 40 Testing for Ground Loops e If you read 5 VDC VAC or greater the circuit is improperly isolated Follow these steps 1 Remove all the field wires and N2 Bus wires from the VAV but leave the transformer wires attached With the DVM still connected reconnect each set of field wires one at a time until you read 5 VDC V AC or greater At this point you have discovered one cause of the ground loop Correct the problem 2 Continue to reconnect each set of field wires until all ground loops are found and corrected You ll know that all grounds are corrected when you read less than 5 VDC VAC on the DVM 3 However if you check all the field wires and you still read greater than 5 VDC VAC the transformer secondary is earth grounded In this case wire a 24 VAC to 24 VAC isolation transformer to the VAV and measure again If the value is still 5 VDC VAC or greater replace the VAV Note Binary outputs are often the cause of ground loops Therefore we recommend that you test the binary outputs of the VAV before testing other points VAV Controller Variable Air Volume VAV Controller 79 e Ifyou
42. finition window Figure 5 Definition Item Edit View Action GoTo Accessory Tower Hoor 1 System Name Object Name Expanded ID NC Name Graphic Symbol Cperating Instr Hardware N2 Trunk Number N2 Device Address Poll Priority Comm Disabled windob Figure 5 VAV Control Device Object Definition Window Note that some of the fields in the window are blank and some are already filled in You must fill in the blank attribute fields of required attributes An N2 device address from 1 to 255 must also be specified Attribute fields that are already filled in contain default values that may be accepted or changed 14 VAV Controller Variable Air Volume Controller Modifying and Monitoring the VAV Object Table 2 explains the blank attributes The Operator Workstation User s Manual FAN 634 describes the general procedures for entering and modifying data Table 2 Blank VAV Object Attributes Attribute Description Entry Values Object Name Identifies the object 1 to 8 alphanumeric i e ILC The object name characters cannot be duplicated in the system Expanded ID Further identifies the object 0 to 24 alphanumeric i e LC Device 1 characters Optional 8 To save the new VAV object select Save from the Item pull down menu The object is added to the N
43. iameter 8 Conductor Solid Wire 8 position Non keyed Plugs for Solid Cable 074683 Stewart Bag of 25 Hand Tool with 8 position Die Set for 060612 24 AWG 0 6 mm diameter Solid Wire 88 VAV Controller Variable Air Volume Controller Specifications Table 45 General Specifications Product Name Product Code Numbers Power Input Power Draw Ambient Operating Conditions Ambient Storage Conditions Dimensions H x W x D Shipping Weight Processor Word Size EEPROM Size ROM EPROM Size RAM Size Interfaces Inputs Outputs Standard Compliance Agency Listings Variable Air Volume VAV Controller AS VAV100 0 AS VAV101 0 AS VAV110 1 AS VAV111 1 AS VAV140 1 AS VAV141 1 20 30 VAC 10 VA VAV with sensors transmitters 10 VA 400 mA 32 to 122 F 0 to 50 C 10 to 90 RH 40 to 158 F 40 to 70 C 10 to 90 RH 6 5 x 6 4 x 2 2 in 165 x 163 x 56 mm without enclosure 6 8 x 7 3 x 4 7 in 173 x 185 x 119 mm with the AS ENC100 0 enclosure 1 4 1b 0 64 kg 80C652 11 MHz 8 bit 8k byte 2k byte for VAV 100 101 64k byte 8k byte N2 and Zone Bus 8 Analog Inputs 0 10 VDC 4 Binary Inputs 0 2 Analog Outputs 0 10 VDC 8 6 Binary Outputs 24 VAC Triacs IEEE 472 IEEE 518 IEEE 587 Category A FCC Part 15 Subpart J Class A UL 916 Energy Management Listed Class PAZX VDE 0871 Class B UL 916 Listed and CSA Certified as part of the Metasys Network VAV Controller Variable Ai
44. indicate the problem You may also try exchanging the component that you believe is defective with a working component of the same type A noisy wire adjacent to the Zone Bus can also cause communication errors Noise can be periodically induced into the Zone Bus thereby causing sporadic communication failures between the laptop and the VAV Most often noisy lines cause intermittent disruption not total loss of communication For more information on the HVAC PRO for Windows refer to the HVAC PRO for Windows User s Manual FAN 637 5 Table 36 Communication Errors on Download Error Number or Description Cause Description Undefined The device is being sent a message command that contains an invalid command Invalid The size of the message sent does Check for tight and proper message size not correspond to the type of connections between the laptop message sent PC CBLPRO and the VAV Invalid The command issued is not valid for command the data type Not ready The VAV cannot process this Cycle power on the VAV If message at this time For example problem persists return VAV for the EEPROM is not functioning repair or replacement properly Bad E Write A problem with the EEPROM exists Return the VAV for repair or replacement Some hardware problem exists Check for tight and proper eee such as a loose connection or a connections between the laptop failed component PC CBLPRO and the VAV Hardware Controller is
45. ion use proportional control or actuators with position feedback 72 VAV Controller Variable Air Volume Controller Incremental Damper Actuator Stroke Time Zone Terminal Setup for Balancing Contractors The position accuracy of the VAV box damper is dependent upon the actuator stroke time entered It is important that the true damper actuator stroke time be entered The listed actuator times of 1 2 or 5 5 minutes are for 90 degrees of rotational travel If a VAV box has 45 or 60 degrees of travel the stroke time must be adjusted Multiply the listed stroke time by 0 5 for 45 degrees of travel by 0 667 for 60 degrees of rotation Drive times that are inaccurate cause the controller to calculate a software damper position that 15 not synchronous to the actual damper position This error is particularly noticeable at the very end of the travel when the controller thinks the damper is fully closed but is physically open If a box has 45 or 60 degree travel it is highly recommended that the entered stroke time used in HVAC PRO for Windows be tested under field conditions to verify that the box can be driven fully closed and open For simplicity program a Zone Terminal to access only those values required for testing and balancing processes For each box configuration style determine which parameters the test and balance will require Build a controller display file for each configuration Up to three display files can be combined
46. ion the controller either locally with the AS CBLPRO 2 interface at the zone sensor Figure 15 or from a central location where the N2 has been pulled controller s field hardware addressed and an MM CVT101 1 interfaced to the laptop Using a Metasys Network system you need to define a VAV Controller device object by entering data into the Attribute menu as seen on the Operator Workstation 1 Goto the Network Map 2 Double click the system name in which you want to add the new VAV object Click New in the Item pull down menu 4 Click on Type N2 devices in the Item New dialog box VAV Item New Type gt Accumulator Analog data Analog input Analog output digital Analog output setpoint Binary data Binary input Binary output MS data MS input gt MS output Control system gt DL LR group LC group PID loop Fire Zone L2 devices N2 devices S2 devices Card Reader Hardware system name Hardware object name Copy of System Object ITEM NEW Figure 3 Item New Dialog Box Note The Hardware System and Hardware Object text fields are not used for this object type 5 Click OK to display the Add N2 Device dialog box VAV Controller Variable Air Volume VAV Controller 13 6 Highlight VAV Hardware Add N2 Device n2dvc Figure 4 Add N2 Device Dialog Box 7 Click OK to display the VAV De
47. ioned from the sensor connection 44 VAV Controller Variable Air Volume Controller N2 Bus Overview Wiring the Controller to an NCU N2 Bus Characteristics Networking the Controller If you are familiar with the N2 Bus go to the next section of this technical bulletin Installing the N2 Bus hardware connection between the N2 Communications Bus and the NCM of the Network Control Unit NCU is required if the NCM is to service N2 devices Refer to Table 14 for terminal locations and to the N2 Communications Bus Technical Bulletin for termination resistor values When installed in a Metasys Network the VAV Controller receives commands from the Network Control Module NCM or Companion on the N2 Bus and transmits status reports in return The maximum electrical limitation on the N2 Bus is 255 devices However the number of controllers on the N2 Bus is a data base memory issue at the NCU or Companion Refer to the N2 Communications Bus Technical Bulletin FAN 636 and either the Metasys Companion Technical Manual FAN 628 1 or the Metasys Technical Manual FAN 636 to determine practical limitations to the number of controllers on the N2 Bus The N2 Bus connections are electrically isolated from other series VAV110 111 and VAV 140 141 Controller circuitry by optical and magnetic coupling For runs of up to 5 000 feet 1 500 meters use 22 AWG 0 6 mm diameter or higher twisted pair wire Electrically 26 AWG wire works but
48. irect Mount Actuators Proportional Voltage or Current M9200 G Series Direct Mount Actuators Proportional Voltage or Current M9200 H Series Direct Mount Actuators Proportional Voltage or Current Valve Actuator Assemblies Table 41 Valve Actuator Code Numbers Code Number VA 715x Series Valve Actuator Incremental or 0 10 VDC Proportional VA 7200 Series Valve Actuator Incremental or 0 10 VDC Proportional VA 8020 Series Valve Actuator Assemblies 1 2 in 24 VAC Triac Incremental VA 8022 Series Valve Actuator Assemblies 1 2 in 0 10 VDC VA 8050 Series Valve Actuator Assemblies i 24 VAC 1 2 in 3 4 in 1 in and 1 1 2 in Triac Incremental VA 8051 Series Valve Actuator Assemblies 24 VAC 1 2 in 3 4 in 1 in and 1 1 2 in Triac Incremental with Feedback VA 8052 Series Valve Actuator Assemblies 0 10 VDC 1 2 in 3 4 in 1 in and 1 1 2 in VG 5000 Series Valve Actuator Assemblies 24 VAC On Off 1 2 in 3 4 in and 1 in Incremental 0 10 VDC EP 8000 1 Electric to Pneumatic Transducer 0 to 10 VDC to and 2 for Pneumatic Valves Pneumatic High or Low Volume 86 VAV Controller Variable Air Volume Controller Accessories Table 42 Accessories Code Numbers MM CVT101 0 RS 232 RS 485 Converter for N2 Download Commissioning with HVAC PRO for Windows P32 Series Air Flow Switch TE 6001 961 Momentary Button Kit for Temporary Occupancy or Boost Modes for TE 6100 11 12 only WS WINPRO 0 Configuration T
49. it is too fragile and prone to nicks and breaks Runs longer than 5 000 feet 1 500 meters require use of a bus repeater An N2 network may be extended to a maximum length of 15 000 feet 4 500 meters using two repeaters The N2 Bus is a daisy chain communications line Essentially it consists of three wires which carry three signals N2 N2 and REF The N2 and N2 lines carry the actual data signals The REF line provides a common reference so that each connected device is capable of electrically receiving and transmitting data by creating a common voltage reference among all the devices connected together by the N2 lines Three lines are required for optimum reliability It is important that the N2 and N2 lines must be twisted pair lines which allows most induced noise common mode noise from external sources to affect both lines equally thereby canceling the noise Note Do not run N2 Bus wiring in the same conduits as line voltage wiring above 30 VAC or wiring that switches power to highly inductive loads such as contactors coils motors or generators VAV Controller Variable Air Volume VAV Controller 45 Installing the N2 Bus Setting the N2 Address Set the N2 address and test for N2 voltage polarity and isolation before actually wiring the VAV Controller for operation Refer to the ASC and N2 Bus Networking and Troubleshooting Guide LIT 6363003 in the Application Specific Controllers Technical Manual FA
50. l of which are covered in the HVAC PRO for Windows User s Manual FAN 637 5 VAV Controller Variable Air Volume VAV Controller 5 IHNSON LS CONTRE SYS MY MET ova EI ove DO OVV Do ovrve et Ore So Nz Ta ove TT TT OVALS BINARY OUTPUTS DSI Bim HNSON CONTRELS SYS MET N a Zv o tr da Z a QUAS OQASL BINARY OUTPUTS DSI Figure 1 VAV110 top and VAV111 bottom Controller 6 VAV Controller Variable Air Volume VAV Controller Table 1 VAV Controller Model Features Feature VAV100 101 VAV110 111 VAV140 141 Discontinued F F F Ambient 32 to 122 32 to 122 32 to 122 Temperature 0 to 50 C 0 to 50 C 0 to 50 C Rating Analog Inputs 6 6 6 RTD temperature RTD temperature RTD temperature elements 1000 ohm elements 1000 ohm elements 1000 ohm nickel platinum or nickel platinum or nickel platinum or silicon silicon silicon 2k ohm setpoint 2k ohm setpoint 2k ohm setpoint potentiometers potentiometers potentiometers 0 to 10 VDC or 0 to 10 VDC or 0 to 10 VDC or 0 to 2 VDC 0 to 2 VDC 0 to 2 VDC transmitters transmitters transmitters Binary Inputs 4 4 4 4 Dry contacts 4 Dry contacts 4 Dry contacts 1 Moment
51. ll open positions If possible measure the actual stroke time of the incremental actuator with water flow through the valve Some valves have 1 2 5 16 or 3 4 inch strokes which require different stroke times If you do not measure the actual stroke time you at least need to know the approximate stroke time of the valve and enter that in the HVAC PRO for Windows configuration tool Conservatively you can add up to 20 to the nominal time Always add to the stroke time never subtract The controller modulates the valve based on a calculated stroke time of 150 of the stroke time you specify This is done to compensate for variations in water system pressure actuator wear and manufacturing tolerances The VAV controller has a built in overdrive algorithm that drives the actuator closed for an additional 50 of the entered stroke time when a 0 or 100 open command is issued This ensures that the valve is fully closed or open This fully opens or closes the valve but does not correct the mid stroke position errors due to a grossly incorrect valve stroke time Refer to the following table for approximate stroke times Table 32 Approximate Stroke Times Incremental Valve Actuators Stroke Time VA 8050 1 1 2 in stroke 65 sec 1 1 min VA 8051 1 1 2 in stroke 65 sec 1 1 min VA 8050 1 3 4 in stroke 90 sec 1 5 min Note There may be no correlation between valve position and controller output 0 to 100 If you require correlat
52. ller model feature differences VAV Controller Variable Air Volume VAV Controller 7 OEM Applications Standards Compliance Coordination of Factory Mounted VAV Systems When providing VAVs for projects which use Trane or TITUS terminal boxes consider using the AS VAVDPTx 1 product refer to Building VAVDPT Applications Application Note LIT 6363042 in the Application Specific Controllers Technical Manual FAN 636 3 Trane and TITUS are both Original Equipment Manufacturers OEMs who provide VAV terminal boxes for projects Trane typically provides the damper actuator with their terminal box and TITUS provides the damper actuator with their QFPC Series Fan Powered Box The VAVDPT comes in two models which include a VAV Controller and a DPT 2015 Velocity Pressure Transducer The DPT is mounted and prewired to the cover of the VAV Refer to the OEM Reference Manual FAN 638 The VAV Controller complies with the following standards e FCC Part 15 Subpart J Class A UL 916 Listed e IEEE 472 IEEE 518 e VDE 0871 Class B e IEEE 587 Category A A factory mounted VAV box control system requires close coordination between a variety of different disciplines Refer to the OEM Reference Manual FAN 636 for factory manufacturer s details Although the responsibilities may differ per city or region the following parties are usually involved on the job e controls contractor e mechanical contractor e local VAV box ma
53. lthough a single earth ground connection to the common terminal of Series VAV110 111 and VAV140 141 Controller is allowed you may not want to use one The same procedure as described in the following text for VAV100 101 may be used when no earth ground connections to VAV are intended Isolation and This section will help you ensure proper isolation within your system Grounding These procedures are not required but are recommended to reduce VAV100 101 installation errors Use the following procedures to ensure proper isolation Test the field device wiring for proper isolation e transformer for isolation and correct polarity termination e connected field devices transformer and VAV for proper isolation e transformer and VAV for proper VA load requirements 76 VAV Controller Variable Air Volume Controller Field Device Wiring Isolation VAV100 101 This section assists you in measuring field wiring terminated to the VAV If you are confident that the field wiring has no earth grounds you may go to the following section called Power Transformer Isolation VAV100 101 A field device that is earth grounded becomes apparent when you test the entire controller Before you terminate the field wires to the VAV measure the resistance of each wire to earth ground using an LED test circuit preferred or a DVM For the LED test circuit assemble the test circuit 1llustrated in Figure 38 Then connect the circuit from each input to
54. ly the VAV box manufacturer supplies a step down isolation transformer as part of their mounting service Poe Potential Equipment Damage and Improper Functioning Do not earth ground the 24 VAC high side of the VAV s transformer or any of the VAV s BO terminals If you do the VAV s N2 Bus communications will cycle online and offline You will also damage all of the interface components that are connected including the CBLPRO laptop PC Companion PC and MM CVTIOI Depending on the primary voltage of the power transformer and the prevailing electrical code the 24 VAC secondary might be earth grounded Earth ground on one side of the secondary destroys hardware by creating a short circuit path through the CBLPRO and laptop PC serial card during a download Earth ground on either side of the secondary can disrupt the isolation required for N2 communication integrity The box manufacturer supplies fan or electric heat relays that might also be earth grounded This also disrupts the isolation required for N2 communication integrity Note The Troubleshooting section of this technical bulletin contains a detailed process that will reduce installation errors by ensuring proper isolation If the secondary of the power transformer is grounded you must use a separate 24 VAC to 24 VAC isolation transformer such as the Y65GS see Figure 8 If VAV output loads are grounded such as a driven contactor or solenoid coil you must use a separ
55. ly inductive loads such as contactors coils motors or generators Table 11 Sensor Wire Sizes and Lengths Sensor Type RunLlengh Wire Size Teet Meters Aawe s00 BI Voltage Contact 24 to 18 NEM 6 mm diameter to 1 5 mm SingleBO at0 1 ampere 500 150 18 s phone cable phone cable Note lf an AS CBLPRO 1 and a Zone Terminal are used the cable length must be limited to 50 feet 15 meters Input and Load Impedances Table 12 Input and Load Impedances DC Input Sensor or Range Impedance Load Impedance Al Voltage 0 2 VDC 470k ohm 0 5k ohm Voltage 0 10 VDC 128k ohm 0 5k ohm or 0 2k ohm potentiometer 40 VAV Controller Variable Air Volume Controller Temperature Sensors DC Supply Out 14 6 17 VDC 90 mA N A 162 10M ohm With total controller power draw limited as described previously JANSON CONTR LS METASYS 111 1 1 1111 AS 55 TETE TI III TE 11111111 Hu zm gee i B ANALOG INPUTS INARY IN BINARY OUTPUTS CBLPRO LELEII TI 9 pin or 25 pin IIIi III ogoogo Adapter N Laptop PC Zone Bus 6 pin to 8 pin or CBLPRO 9 pin or 25 pin j 8 pin Adapter amp a or to 8 pin Laptop PC Zone Bus Metastat 6 pin to 6 pin ues Figure 15 VAV Interconnection To make all of the ne
56. minal unit to serve the same area for example a large conference room or open office space Note The practical limitation to this application is four VAV Controllers to one sensor Set for Set for 2 VDC and 2 VDC and Voltage Temperature Metastat 8 pin Connectioi on Back Sensor Sensor sensors2 Note Route sensor wiring and N2 wiring together Since the VAV Controller is a self terminating device end of line termination for the N2 Bus is not required Figure 18 Example of Sharing a Sensor Among VAV Controllers Figure 18 shows the wiring and analog input switch settings for two controllers that use one zone sensor To ensure the noise immunity of the VAV Controllers pull the N2 Bus wiring with the sensor wiring between controllers that share the same zone sensor Notes This configuration shifts the AI value by one degree for each added controller Compensate for this temperature shift by entering an offset of 1 F for each added controller through the AI Offset Table You can find this table in the Commissioning mode of HVAC PRO for Windows On the HVAC PRO for Windows Analog Input Modify screen verify that both controllers are set to the same temperature sensor type If the master zone sensor uses the Zone Bus connection only the master controller can be loaded and commiss
57. mon The maximum load for each output is 10 mA with a minimum load resistance of 1000 ohm 38 VAV OController Variable Air Volume Controller Zone Bus Wiring to RLY50 002 Relays The Zone Bus allows you to connect CBLPRO or the Zone Terminal to the VAV Controller With CBLPRO connected use HVAC PRO for Windows for commissioning downloading and uploading The Zone Bus is available for connection at Metastat or a zone temperature sensor Connect power to the relay module and the transformer through the conduit knockouts in each box Wire the module according to the following diagram an example of a VAV140 141 wired to an RLY50 002 All BOs must be isolated from earth ground VAV110 111 connections are similar VAV Note 1 Low Voltag gt High Voltage BO t 0 A CON 24 V 02 4 t NC Bo 2 1 Oc 4 2 ALO AV x Z St 7s s A I B A B A CON COILS AA Ic TRIAC 1 ATE NG BI3 HAND AS J J BICOM o 0 Z TZ 4 es h COM l i Note2 AS RLY50 0 AS RLYOO2 I vavrelay Note 3 Note 1 Separate low voltage and line wiring with line voltage on the right Note 2 Hand operation using the H O A Hand Off Auto switch requires 24 VAC to the COILS terminal and COM to the TRIAC terminal to energize the relay Note 3 The Hand or Off position signals the binary input connected to th
58. myhpia Bs Bmymus fea Bmyhu4 o O BmayOmui Boo evom BmayOWu3 Boa evoa O sos BmwOuus 4 COM Common Transformer Low Side zBus Zoos BO E REF N2 Reference VAV Controller Variable Air Volume VAV Controller 35 Power Zone The 24 VAC power connection to VAV100 101 is at the quick connects Bus and N2 identified as 24 VAC Power and Common The 24 VAC power connection Connections to VAV110 111 or VAV140 141 is at the far left two positions of the 3 position screw terminal block The removable terminal block also allows you to disconnect power to the VAV without disrupting the 24 VAC that is daisy chained to other controllers Zone Bus may be hard wired to the VAV Controller instead of using the phone jack as described later in this technical bulletin The Zone Bus connection to VAV 100 101 is at the far left position of the 4 position terminal block identified as ZBUS COM N2 REF N N2 The Zone Bus connection to VAV110 111 or VAV 140 141 is at the far right position of the 3 position screw terminal block identified as 24 VAC COM ZBUS For all VAVs the other side of the two wire Zone Bus the common side may be connected to any available Common terminal The N2 connection to VAV100 101 is at the 4 position screw terminal block identified as ZBUS COM N2 REF N2 N2 The N2 connection to VAV110 111 or VAV140 141 is at the 3 position screw terminal block identified as R
59. nical Manual FAN 636 3 for instructions on mounting the enclosure to a wall To mount the VAV in the EWC10 1 Orient the VAV so that its terminals face the low voltage wiring trough Figure 6 2 Align the three mounting holes in the base of the controller with the holes in the back of the enclosure On the side with four mounting holes use the two outside holes for mounting in the EWC See the Universal Packaging Module Technical Bulletin FAN 636 3 for a more detailed explanation 3 Secure the controller with three No 8 x 1 in screws For best results use a plastite type thread A thread forming or sheet metal thread type may also be used Position the controller or controller s enclosure on the mounting surface before installation to ensure the calculated mounting area is correct You can make precise measurements for distance between controller terminals and sensor actuator mounting points on the VAV terminal Confirm electrical power source and conduit requirements prior to mounting VAV Controller Variable Air Volume VAV Controller 19 You can install a VAV Controller into a control panel or an AS ENC100 0 enclosure Do not use this knockout Otherwise controller wil be in the way of wiring PADS W we m Top Bottom SLAP Side VAV Controlle vavencl2 VAV Enclosure Cover Figure 7 Installing the
60. ntrol and DPT 2015 1 for Trane Single Duct Applications Refer to Building VAVDPT Applications Application Note LIT 6363042 in the Application Specific Controllers Technical Manual FAN 636 3 Sensors Table 39 Sensor Transmitters Code Numbers Transmitters Code Number _ Description Type DPT 2015 1 Velocity Pressure Transducer 1 to 5 VDC with 15 VDC Supply 1 5 in W C Wall Mount Humidity Sensor 0 to 5 VDC with 12 to 30 VDC Supply Duct Mount Humidity 0 to 5 VDC with 12 to 30 VDC Supply TE 6000 Series Temperature Sensor RTD Resistance TE 6100 11 Zone Temperature Sensor Nickel 1000 ohm with Phone TE 6100 12 Series for T 4000 Cover Jack TE 6300 Series Temperature Sensor Nickel Platinum Silicon TE 6400 Series Metastat Zone Temperature Resistance Sensor Series DPT Transmitters are typically supplied as part of the actuator assembly ATP Series or a controller assembly VAV DPT Series VAV Controller Variable Air Volume VAV Controller 85 Damper Actuator Table 40 Damper Actuator Code Numbers Assemblies ATP 2040 212 EDA 2040 1 and DPT 2015 1 with 24 VAC Incremental ATP 2040 612 EDA 2040 2 and DPT 2015 1 with 24 VAC Incremental Cable 1 to 5 VDC Transmitter M100C Series Zone Bus Damper Actuators Zone Bus Addressable M9000 500 Series Valve Linkage Assembly for M9100 and M9200 Direct Mount Actuators M9100 G Series Direct Mount Actuators Proportional Voltage or Current M9100 H Series D
61. nufacturer s representative e balancing contractor e electrical contractor Typically the mechanical contractor is the focal point for coordinating the entire process The basic responsibilities under the domain of the mechanical contractor are 1 Purchasing the VAV box system Most specifications include the OEM mounting fees and enclosures for the control system in the mechanical contractor s price Mounting fees vary per box manufacturer but ranges can be found in the OEM Reference Manual FAN 638 2 Providing the release schedule for the VAV boxes to the job Contracting or working closely with the balancing contractor to ensure the system is set up per the mechanical prints Note The owner often directly hires the balancing contractor This ensures neutrality in dealing with other contractors involved in the project 8 VAV Controller Variable Air Volume VAV Controller In conjunction with the mechanical contractor the controls contractor s responsibilities include 1 Coordination of the control system release schedule to the box manufacturer to ensure the mechanical system delivery schedule can be met Coordination with the local box manufacturer representative is normally required Coordination with the electrical contractor to ensure the following steps are covered e 24 VAC power is provided at each VAV Controller e N2 Bus wiring is pulled and terminated e Valve actuator wiring is pulled and terminat
62. o BI Common 15 applied BI 4 may be used as an accumulator input for frequencies less than 100 Hz Binary Outputs There are six or eight binary outputs depending on the selected model on the controller Binary outputs are triacs on the controller hardware These outputs switch the transformer s low side or common to the output Each binary output must be connected between the BO terminal and 24 VAC terminal since it is low side switching IMPORTANT Chattering Relays Driven by Binary Outputs Chattering may occasionally occur in relays from manufacturers other than Johnson Controls due to a low load condition across the binary output triac The chattering relays are audible and arcing may be visible at the contacts The minimum holding current for the triac is 50 mA To eliminate chattering use a 360 ohm 5W resistor across the binary output or use the AS RLY 100 1 Relay Kit There have been a few instances where loads have met the 50 mA current requirement but still chattered To date the exceptions are Honeywell damper actuator Model ML6161 and Finder relay Model 60 12 In these instances we recommend a 1000 ohm 2W resistor in parallel across the load Analog Outputs There are two analog outputs on the VAVIOI VAVIII and VAV141 Controller The load is connected between the analog output and analog output common terminals Each output is controlled to generate a proportional voltage output of 0 to 10 VDC to com
63. oint L 3 Both with BI Backup L 4 Both can Activate Define Standby Mode 1 Software N2 Command __ 2 Hardware BI Point 3 Both with BI Backup 4 Both can Activate Define Shutdown Mode 1 Software N2 Command 2 Hardware BI Point L 3 Both with BI Backup 4 Both can Activate 1 No Do you want the Temporary Occupied feature 1 No Power fail restart logic r 2 Yes 1 No 2 Yes Do you want Boost mode __ 1 No Use box supply temperature for Warmup Cooldown L 2 Yes during unoccupied mode aos Check Parameters and IO Points then save the Configuration File charta Figure 22 HVAC PRO for Windows Single Duct Configuration 52 VAV Controller Variable Air Volume Controller Hardware Point The following table shows the HVAC PRO for Windows hardware point Assignment assignments and options for single duct configurations Table Table 17 Single Duct Point Assi HVAC PRO for Windows HVAC PRO for Windows Name Configuration Configuration Options Assignments and Defaults 1 Zone Temperature Unused Rename Warmer Cooler Adjust Potentiometer Cooling Setpoint Potentiometer AI3 Unused Heating Setpoint Potentiometer Rename AI 4 Actuator Feedback on Pressure None Dependent CFM on Pressure Independent Unused Proportional Series Fan CFM 16 BI 1 Exhaust Box CFM Unused A Unused Box Supply Temperature for Standalone Warmup in Pr
64. om power wiring to the maximum extent possible To establish tight reliable electrical connections use the correct wire sizes for the terminals e Make all wiring connections to the VAV Controller using only copper conductors e The N2 must be daisy chained The use of Y or T connections without a repeater installed in the T tap may cause loss of communications e Do not run N2 Bus Zone Bus Analog Input AI Binary Input BI or Binary Output BO wiring in the same conduit as line voltage wiring above 30 VAC or with wiring that switches power to highly inductive loads such as contactors coils motors or generators e Do not run non shielded N2 Bus wiring in the same conduit or bundle as 24 VAC power wiring e You may run Zone Bus Analog Input Analog Output and Binary Input wiring in the same bundle or conduit where convenient If the Binary Output wiring is not wired through other switches or contacts you may also bundle it with the other I O wiring where convenient VAV Controller Variable Air Volume VAV Controller 25 Power Source Use a separate isolation transformer or step down transformer for each and Loads VAV Controller Refer to Standards Compliance in the Introduction section of this technical bulletin The power transformer used must comply with e CSA 22 2 No 205 e NEMA ICS 2 Part 2 230 Limit the power to each VAV to 3 amperes or less However if you use one low voltage power trunk to power multiple
65. onfiguration Selections Lighting Integration 9 a G DAI VA2 B A VM C1 B D R1 VAV3 Figure 27 Single Duct Wiring Example 3 Mechanical Flow Diagram VAV Controller Variable Air Volume VAV Controller 59 120 24VAC 120VAC Power 24VAC Transformer 4 ANALOG INPUTS BINARY IN OUTPUTS rp ap o x Q Q z a 8 s 8 R1 5 aly 3 3l H Lighting i VO 8 8 Relay 24VAC Hi 24vac B06 HM 24vac IE Damper Actuator VA2 Basbd Box Heat Heat vavwe3a Figure 28 Single Duct Wiring Example 3 Table 23 Single Duct Wiring Example 3 Bill of Materials Component Description Box Heat Valve Actuator VA 8020 DAI sd Damper Actuator EDA 2040 nn Ri Lighting Relay GE RR7 60 VAV Controller Variable Air Volume Controller The following table illustrates the selections made through HVAC PRO for Windows for this example Note The examples contained in this technical bulletin do not reflect all of the possible questions and answers These examples are provided as a basic overview of wiring locations you might expect to see Table 24 Example 4 Pressure Independent with Parallel Fan Exhaust Box Required NO Baseboard Heat Type Analog Output Lighting Integration END O
66. ools Software includes HVAC PRO for Windows WS WINPRO 6 Configuration Tools Software Upgrade includes HVAC PRO for Windows Y65XX X Series Transformer Option 24 120 220 277 480 VAC to 24 VAC Note The AS ZTU100 1 supports both AS VAVxxx 0 and AS VAVxxx 1 models The AS ZTU100 0 supports AS VAVxxx 0 models only Vendor Code The following tables list code numbers and descriptions for VAV Numbers Controller equipment requirements This equipment is available from Anixter 4701 W Schroeder Drive Brown Deer WI 53223 414 355 0222 in Milwaukee 1 800 242 5575 structure wiring 1 800 447 8565 wire and cable Use the following table to order preconfigured cables from the factory Table 43 Preconfigured Cables Description Cable Eze Meera Part Number RJ45 Straight through Cable Assembly Non plenum Feet Meters 889158 Non keyed plugs 50 15 889161 24 Gauge 0 6 mm diameter 100 30 889166 8 Conductor Solid Wire RJ45 Straight through Cable Assembly Plenum 889315 Non keyed plugs 889318 24 Gauge 0 6 mm diameter 100 30 889324 8 Conductor Solid Wire VAV Controller Variable Air Volume VAV Controller 87 Use the following table to order cable components for creating your own cables Table 44 Cable Components Description PartNumber O 1000 ft 300 m Roll of Non plenum Rated CM 00424BAG 3 24 Gauge 0 6 mm diameter 8 Conductor Solid Wire 1000 ft 300 m Roll of Plenum Rated CMP 0042EAC 3 24 Gauge 0 6 mm d
67. or specific information when configuring the VAV Controller VAV Controller Variable Air Volume VAV Controller 11 Start PRO for Windows Select File New 1 Select VAV Applications 2 Select Single or Dual Duct Complete Q A Session Complete Configuration Process 1 Fill in job information 2 Review and change inputs outputs Option Job Information 3 Review and change default parameters Save Configuration 1 File Save As 3 Enter file name for configuration file 2 Select device type Download Controller 1 Attach MM CVT101 1 Converter 3 Select Bus type comm port and or AS CBLPRO 2 N2 address if N2 Bus 2 Select Download Current Configuration 4 Select OK Commission Controller 1 Attach MV CVT101 1 Converter 6 Review controller information or AS CBLPRO 2 7 Exit Commissioning 2 Select Commission Current Configuration 8 If adjustments were made save 3 Select Bus type comm port and changes to controller and to file N2 address if N2 Bus 9 Unplug MM CVT101 1 or AS CBLPRO 2 4 Select OK 5 View Adjust parameter values PROFLO40 Exit HVAC PRO for Windows Figure 2 Steps in Configuring a VAV Controller Using HVAC PRO for Windows 12 VAV Controller Variable Air Volume Controller Defining a VAV Control Device Object in Metasys Software Note You can load and commiss
68. ose terminals These switches can be hardwire DR ed and connected to one BI This switch uses the HOA COM terminal which is isolated from the relays Note 4 Choose Bls desired for H O A feedback Figure 14 VAV140 141 Wired to RLY50 002 caution Possible Equipment Damage or Electrical Shock Disconnect power circuit before wiring Relay Kit You can obtain a DPDT Double Pull Double Throw relay configuration by connecting the BO signal to two terminals on the Relay Kit terminal block e g B and C If you require a phone jack at a remote RLY kit add an AS CBLCON O0 For additional information refer to the Grounding and Isolation section of this technical bulletin VAV Controller Variable Air Volume VAV Controller 39 Wiring Sensors Use 18 AWG 1 5 mm twisted pair wire for all sensor and output wiring and Actuators Shielding is not required but if used earth ground the shield at the transformer or the controller You may use 24 AWG 0 6 mm diameter wire in some applications However the length of wire is reduced due to the resistance To minimize sensor error caused by field wiring the total resistance of all resistive sensor wiring should be less than 3 ohm A Potential Controller Malfunctioning Do not run AI BI AO BO ZBus or N2 Bus wiring in the same conduit as wiring carrying 30 VAC or more Do not run AL BI AO BO ZBus or N2 Bus wiring in the same conduit as wiring that switches power to high
69. r Volume VAV Controller 89 Table 46 Input Output Specifications for VAV 100 101 Reso jSam Accu Range lution pling racy Time Al Voltage 14bit 1 5sec 420 mV10 2 V or 470k ohm 0 5k ohm NM ResCap 0 10 VDC CM Cap IEEE 587 Al 14bit 1 5sec 0 5 F 1000 ohm Si 3540 ohm 0 2k ohm NM ResCap a CM Ringwave Temperature CM Cap 1 5k V Al 15bit 1 5sec 0 7 F 1000 ohm Ni 3540 ohm 0 2k ohm NM ResCap b NM Bi Wave Temperature CM Cap 1 5k V 3k A Al 16bit 1 5 sec 1 3 F 1000 ohm Pt 3540 ohm 0 2k ohm NM ResCap Temperature CM Cap IEEE 472 Al 17 bit 1 5sec 40 1 F 0 2k ohm 3540 ohm 0 2k ohm NM ResCap a CM Ringwave Potentiometer Potentiometer CM Cap 1 5k V ACCUM DC 32 bit 10ms N A 0 15 VDC 47k ohm 0 5k ohm NM ResCap b NM Ringwave 100 Hz 2 5 V Trig CM Cap 500V BI DC Sense 1 bit 10ms N A 0 15 VDC 47k ohm 0 5k ohm NM ResCap 2 5 V Trig CM Cap AO Voltage 8bit 1 5sec N A 10 10 VDC N A 1k 10M ohm No Special 10 mA maximum Parts BO AC Triac INA 15sec N A 24 VAC N A 48 480 ohm Opto 50 500 mA CM Cap DC Supply N A N A N A 14 6 17 VDC N A 162 10M ohm Opto Out 90 mA CM Cap N A N A N A 5000 ft N A N A PTC IEEE 587 1500 m Tranzorb CM Ringwave NM Ringwave Zone Bus N A N A N A 500 150 m N A N A PTC IEEE 472 Tranzorb CM Ringwave NM Ringwave State of Outputs During PWR Fail Disables when 24 VAC PWR drops below 18 VAC State of Outputs After PWR is Restored Remain
70. re an Exhaust Box 1 No 2 Yes Select Baseboard Heat Type 1 None 2 Incremental 3 Normally Open Valve 4 Normally Closed Valve Is Lighting Required 1 No pe Yes Power Fail Restart Logic 1 No 2 Yes chart b Figure 31 HVAC PRO for Windows Dual Duct Configuration Flowchart Part One of Two Define Remote Points 1 None __ 2 Cooling Heating Setpoints __3 Warmer Cooler Adjust Define Occupied Mode 1 Software N2 Command __2 Hardware BI point __3 Both with BI Backup __4 Both can Activate Define Standby Mode __1 Software N2 Command __2 Hardware BI point __3 Both with BI Backup 4 Both can Activate Define Shutdown Mode 1 Software N2 Command 2 Hardware BI point __3 Both with BI Backup 4 Both can Activate Do You Want the Temporary Occupied Feature 1 No 2 Yes Do You Want Boost Mode __1 No _2 Yes Go Check Parameters and Points Then Save the Configuration File charta Figure 32 HVAC PRO for Windows Dual Duct Configuration Flowchart Part Two of Two VAV Controller Variable Air Volume VAV Controller 65 Table 26 Dual Duct Hardware Point Assignments and Options Name Assignments and Defaults Configuration Options Analog Inputs 2 Unused Rename Cooling Setpoint Warmer Cooler Adjust Al3 Unused Rename Ce e Al 4 Cold Deck Delta P None 5 Hot Deck Delta P None 6 Discharge
71. re listed 22 VAV Controller Variable Air Volume Controller VO and The I O wiring and N2 Bus must be clean without electrical noise Communication transients from nearby lightning heavy equipment switching or inductive Lines Wiring loads being driven Transient Noise For the N2 Bus the Transient Eliminator model TE JCO4C12 made by Precautions Advanced Protection Technologies APT is recommended Refer to the Metasys Network Technical Manual FAN 636 the N2 Communications Bus Technical Bulletin LIT 636018 for more information VAV Controller Variable Air Volume VAV Controller 23 24 VAV Controller Variable Air Volume Controller Wiring Details Take special precautions and follow certain grounding procedures when installing the VAV Controller A CAUTION Possible Equipment Damage or Electrical Shock To avoid damaging equipment or possible electrical shock ensure that all power supplies to the system have been disconnected prior to wiring installation The CMOS Complimentary Metal Oxide Semiconductor circuits used in the controller are static sensitive Use static protection anti static mats and or grounding straps when working on or near internal circuitry Follow these precautions e Make all wiring connections in accordance with the National Electrical Code NEC as well as within local regulations e Locate equipment and route the wiring so that signal wiring is twisted pair and separated fr
72. read a value less than 5 VDC VAC the circuit is properly isolated A value of less than 0 10 VDC V AC indicates a completely isolated circuit e Connect the DVM across the 24 VAC and the 24 VAC Common terminal of the VAV Read the voltage with all typical loads energized A reading of 24 VAC is required when the line voltage is nominal If you read a value less than 20 VAC make sure the primary voltage matches the transformer s voltage rating For details refer to the Power Source and Loads section of this technical bulletin and recalculate the VA requirements for the VAV Controller You have completed the VAV isolation tests If you plan to connect this VAV to the N2 Bus for communication to other devices refer to the Application Specific Controllers Technical Manual FAN 636 3 the Introduction tab the ASC and N2 Bus Networking and Troubleshooting Guide Technical Bulletin 80 VAV Controller Variable Air Volume Controller Troubleshooting the VAV Controller with HVAC PRO for Windows Table 34 VAV Controller Troubleshooting The following table indicates symptoms and corrections for typical control system malfunctions primarily in pressure independent applications We recommend that you use HVAC PRO for Windows Commissioning mode during all troubleshooting procedures Symptoms and Corrective Actions Symptom Possible Cause Corrective Action VAV Controller CFM readings are not within 10 percent of balancing contra
73. rming downloading and commissioning over the N2 Bus saves a great deal of time in loading the initial controller configuration files and parameters into the controller prior to the balancing contractor s final testing To perform the downloading and commissioning process over the N2 Bus we recommend that you create a job file spreadsheet similar to the one illustrated in the following table Table 31 Example File per N2 Trunk for Pressure Independent Job N2 Cooling Cooling Heating Heating Damper Filename Address Min CFM Max CFM Min CFM Max CFM Deadband Ses 1 sw 9 Sue 2 30 mo 3o 3 19 You should develop a separate filename for each size box with a different configuration style For example if the inlet is 8 inches in diameter Size 8 would be a logical filename Table 31 This allows you to have your base set of requirements in place before you adjust the CFM setpoint schedule per the mechanical prints VAV Controller Variable Air Volume VAV Controller 71 Incremental The stroke time of an incremental valve actuator is important because the Valve Actuator controller uses it to position the actuator in reference to an analog 0 100 Stroke Time open position command If the stroke time is grossly inaccurate the controller drives the actuator under an incorrect assumption of total stroke time and causes inaccurate positioning particularly at the near closed or near fu
74. t the SW1 and SW2 analog input DIP switches Refer to the Networking the Controller section of this technical bulletin for instructions on setting the N2 address DIP switches Analog Input Switches Figure 13 Setting the Analog Input DIP Switches The switches are factory set with 1 2 and 3 as resistive inputs and AI 4 5 and 6 as 0 to 10 VDC inputs However you may configure them to any combination Use the following table to set the switches For example if you connect a 10 VDC input to AI 4 set SW1 4 to Off and SW2 4 to On Table 10 Analog Input DIP Switch Settings Temperature 2 VDC 10 VDC Hardware Resistive 0 to 2 VDC 0 to 10 VDC Point Input Input Input fat Swi swer ov or or Orr or ov uz Swrz swez ov or orr orr on ma sw swoa on orr or or or ow as swra swoa ON orr or or or ow ns swrs swos on or or or or ow ue swis sws on orr or or VAV Controller Variable Air Volume VAV Controller 37 Binary Inputs There are four dry contact binary inputs on the controller They are located in the center of the terminal strip The VAV Controllers have an available momentary binary input option This input 15 connected at the zone sensor input to initiate a temporary occupancy or boost mode of operation The binary inputs on the VAV Controllers are inactive when open They are active when a contact closure t
75. the inputs and outputs for a specific application The filename PRN file identifies these connections after you assemble the configuration You may make connections to the VAV by connecting single wires to the individual screw or spade terminals VAV Controller Variable Air Volume VAV Controller 29 A SON CONTR LS METASYS ANALOGINPUTS dua 4 56 TITI 11111 ANALOG INPUTS A mn 150 Bli 16 H15VDC 15VDC AICM Ali AICM Al2 AICM ZBUS COM N2 REF Je HNSON CONTRELS METASYS VAV101 RE f BNARYN 4 24VAC 5 2 AICM AI6 BO1 24VAC BO6 AICM Ali AICM Al2 AICM 8 AICM Al4 AICM AI5 24VAC BO3 24VAC 24VAC ZBUS COM N2 REF N2A N2A VAVterm3 Figure 10 VAV100 VAV101 Terminal Designations 30 VAV Controller Variable Air Volume Controller Table 6 VAV100 101 Terminal Identification Series 100 101 Controller AI COM Analog Input Analog Input 1 Common AI COM Analog Input Analog Input 2 Common COM Analog Input Analog Input 3 Common AI COM Analog Input Analog Input 4 Common AI COM Analog Input Analog Input 5 Common AI COM Analog Input Analog Input 6 Common 15 VDC 15 Volts DC 15 VD
76. tractors Indicates those sections where changes have occurred since the last printing 2 VAV Controller Variable Air Volume VAV Controller 25 26 27 29 36 36 38 38 38 39 39 40 45 45 46 49 51 51 63 71 71 71 72 73 73 Troubleshooting Page 75 Hardware Installation Inspection 75 Tools Needed for Troubleshooting 75 e Installation Checkout 76 e Troubleshooting the VAV Controller with HVAC PRO for Windows 81 e Troubleshooting the N2 Bus and Networked VAV Controller 82 e Zone Bus Troubleshooting HVAC PRO for Windows 83 Ordering Information 85 e Johnson Controls Code Numbers 85 e Vendor Code Numbers 87 Specifications 89 Indicates sections where changes occurred since the last printing VAV Controller Variable Air Volume VAV Controller 3 4 VAV Controller Variable Air Volume VAV Controller Description Introduction The Variable Air Volume VAV Controller is an electronic device for digital control of single duct dual duct fan powered and supply exhaust VAV box configurations See Figure 1 You may use the VAV as a standalone controller or connected to the Metasys network through a Network Control Module NCM or Companion system When connected to the Metasys Network the VAV provides all point and control information to the rest of the network The devices communicate through an N2 Bus Each VAV Controller application uses a different sequence of operation al
77. vel is specified at 6 kV 500A Normal Mode Ringwave In addition the VAV Controller actually exceeds this category specification by meeting these surge levels as well IEEE 587 style Common Mode Pulse 1 5 kV 3 kA IEEE 587 style Normal Mode Pulse 3kV 3kA IEEE 472 style Common Mode Ringwave 1 5 kV IEEE 472 style Normal Mode Ringwave 500V You must take further precautions to prevent unwanted Binary Output cycling or other possible controller malfunctions such as resetting when the controller is installed within 30 feet 9 meters of electrical distribution panels or major bus and feeder systems in industrial plants This electrical environment is defined as Location Category B by the IEEE 587 Standard To prevent electrical noise from adversely affecting the controller 1 Connect an MOV Metal Oxide Varistor across the VAV supply transformer primary The MOV must be rated appropriately for the line voltage 2 Usethe list in Table 3 to select the correct MOV sold through your electronics parts distributor The VAV Controller meets the following power line surge noise standards when you correctly apply the MOV as described IEEE 577 Common Mode Pulse 1 5 kV 3 kA Normal Mode Pulse 6 kV 3 kA Normal Mode Ringwave 6 kV 500A TEEE 472 Common Mode Ringwave 1 5 KV Normal Mode Ringwave 500V VAV Controller Variable Air Volume VAV Controller 21 Table 3 MOV Selection Power Transformer Primary Voltage Ji20ovac 208 to 240

Variable Air Volume (VAV) Controller Technical Bulletin

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