Auto-Zone Control Systems Auto-Zone CV User Manual

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CV & CV-EX System

Design, Installation

and Operations Manual

Revision 01C

Auto-Zone CV & CV-EX

Design, Installation & Operations Manual

Section 1..............................................................................System Overview

Section 2...................................................................Installation and Wiring

Section 3....................................................................................Programming

Section 4....................................................... Start-Up and Troubleshooting

This document is subject to change without notice.

WattMaster Controls, Inc. assumes no responsibility

for errors or omissions herein.

Auto-Zone CV & CV-EX Design Installation & Operations Manual - Form WM-AZC-IO-01C

Auto-Zone is a registered trademark of WattMaster Controls, Inc.

Section 1

Table of Contents

Conventions ..................................................................... 1

Introduction ..................................................................... 2

CV System Overview.......................................................................................................2

CV System Features.........................................................................................................3

CV-EX System Overview................................................................................................4

CV-EX System Features ..................................................................................................5

Table of Figures

Figure 1-1: Typical Building for CV System.................................... 2

Figure 1-2: Typical CV System........................................................ 3

Figure 1-3: Typical Building for CV-EX System .............................. 4

Figure 1-4: Typical CV-EX System ..................................................5

System Overview

Auto-Zone CV & CV-EX Section 1

Conventions

This document uses the following definitions throughout as a guide to the user in determining the nature of information presented:

Note: Additional information which may be helpful.

Tip: Suggestion to make installation, set-up, and troubleshooting easier.

Caution: Items which may cause the equipment not to function correctly but will

not otherwise damage components.

Warning: Errors which can result in damage to equipment and void warranties.

System Overview 1-1

Section 1 Auto-Zone CV & CV-EX

Introduction

CV System Overview

The Auto-Zone CV system is used in buildings which have multiple rooftop units and is an excellent alternative over programmable thermostats. The CV system provides one central location to monitor and program the controllers instead of having to program each thermostat individually. The system has many features typically not found with programmable thermostats such as: central operators interface, heating/cooling failure alarm, change filter alarm, full energy saving economizer control, and holiday scheduling. This gives the end user a very versatile constant volume control system at a price well below a building automation system.

Below are a few of the typical building applications the CV system is commonly used for.

• Office Buildings • Retail Stores • Theaters

• Warehouses • Restaurants • Supermarkets

• Schools • Manufacturing • Houses of Worship

Figure 1-1: Typical Building for CV System

1-2 System Overview

Auto-Zone CV & CV-EX Section 1

CV System Features

NOTE: * Only One Outside Air Sensor is Required per CV Syste m

USB Cable To Computer

Optional Remote Link II

Connects to CommLink IV

And Provides Alarm Call-Outs

A Second Remote Link Is Required

If Connection To Job Site

Is Desired From Remote Computer

Remote Link II

(Option al)

CommLink IV

The CommLink IV Is

Required For All Systems.

The IP Module, Remote

Link II, And Computer Are

Optional On All Systems.

All Computers Require

Installation of Prism

Graphical User Interface

Software

Phone Cable To Telephone Wall Outlet Jack

CommLink IV

Single Loop

Computer

(Optional)

Ethernet Router

(By Others)

When IP Module

Option Is Used

Typical Constant Volume Unit

Supply

Air

Sensor

Outside

Air

Sensor

RS-485

Comm Loop

24VAC

RS-485

9600 Baud

Optional IP Module

Installs Into CommLink IV

And Provides

LAN And Internet Communications

With The Control System

Ethernet Cable To Router

Generic Al arm

Dirty F ilter Alarm

Shown

Economizer

(Actuator By Others)

Room Sensor

with Optional

Override & Adj.

24 VAC

24VAC

System Manager

CV Controllers

Up to 30 Units with Standard CV System

24VAC

System Manager

#30

Local Loop

24VAC

Figure 1-2: Typical CV System

Below is a list of some of the many features available with the CV system.

• CV system supports up to thirty constant volume units. For systems with more than thirty constant volume units, use the CV-EX system.

• System Manager is housed in an attractive, plastic enclosure suitable for wall mounting in the space and can be connected anywhere in the communications network.

• Complete modulating economizer control functions.

• CommLink IV interface included with the system. Provides connections for computer and Remote Link II (modem) for on-site or remote communications or connection for TCP/IP communications using the IP Module. Remote Link II, IP Module & personal computer are optional.

• Trend Logging capability if connected to a personal computer with free

Prism™ Windows

-based software installed.

System Overview 1-3

Section 1 Auto-Zone CV & CV-EX

CV-EX System Overview

The Auto-Zone CV-EX system is used in buildings that because of their size or design requirements have more than thirty rooftop units. Standard CV-EX systems can facilitate up to sixty constant volume units. With the addition of a CV-EX Loop Expansion Kit, an additional thirty units may be added to the CV-EX system. Two loop expansion kits can be added to the CV-EX system bringing the maximum total system capability up to 120 units. The versatile CV-EX system provides one central location to monitor and program the controllers instead of having to program individual thermostats. The system has many features typically not found with programmable thermostats such as: central operators interface, heating/cooling failure alarm, change filter alarm, full energy saving economizer control, and holiday scheduling.

Below are a few of the typical applications the CV-EX system is commonly used for.

• Office Buildings • Retail Stores • Theaters

• Warehouses • Restaurants • Supermarkets

• Schools • Manufacturing • Houses of Worship

Figure 1-3: Typical Building for CV-EX System

1-4 System Overview

Auto-Zone CV & CV-EX Section 1

CV-EX System Features

NOTE: * Only One Outside Air Sensor

is Required per CV-EX System

Phone Cable To Tel epho ne

Optional Remote Link II

Connects to CommLink IV

And Provides Alarm Call-Outs

A Second Remote Link Is Required

If Connection To Job Site

Is Desired From Remote Computer

CommLink IV

The CommLink IV Is

Required For All Systems.

The IP Module, Remote

Link II, And Computer Are

Optional On All System s.

All Computers Require

Installation of Prism

Graphical User Interface

Software

Wall Outlet Jack

Optional IP Module

Installs Into CommLink IV

And Provides LAN And Internet Comm unications With The Con trol System

Figure 1-4: Typical CV-EX System

Below is a list of some of the many features available with the CV-EX system.

• CV-EX system supports from thirty-one to one hundred twenty constant volume units. For systems with thirty or less constant volume units, use the CV system.

• System Manager is housed in an attractive, plastic enclosure suitable for wall mounting in the space and can be connected anywhere in the communications network.

• Complete modulating economizer control functions.

• CommLink IV interface included with the system. Provides connections for computer and Remote Link II (modem) for on site or remote communications or connection for TCP/IP network communications using IP Module. Remote Link II, IP Module, & personal computer are optional.

• Trend Logging capability if connected to a personal computer with free Prism™ Windows®-based software installed.

System Overview 1-5

Section 1 Auto-Zone CV & CV-EX

Index

120 Units............................................... 4

CommLink IV

Described ...................................... 3, 5

Conventions .......................................... 1

CV System

Features ............................................. 3

Overview........................................... 2

CV Units

< 30 ................................................... 3

> 30 ................................................... 4

60....................................................... 4

CV-EX Loop Expansion Kit................. 4

CV-EX System...................................... 3

Features ............................................. 5

Overview........................................... 4

Features

CV System ........................................ 3

CV-EX System.................................. 5

IP Module.......................................... 3, 5

Modem

Described ...................................... 3, 5

Network Communications ................ 3, 5

Overview

CV System ........................................ 2

CV-EX System.................................. 4

Prism ................................................. 3, 5

Remote Link II

Described ...................................... 3, 5

Rooftop Units

< 30 ................................................... 3

> 30 ................................................... 4

System Manager

Described ...................................... 3, 5

Trend Logging................................... 3, 5

Void Warranties .................................... 1

Warranties ............................................. 1

1-6 System Overview

Section 2

Table of Contents

Tips Before Beginning Installation.................................. 1

Systems Overview ........................................................... 2

CV System .......................................................................................................................2

CV-EX System.................................................................................................................3

Communications Loop ..................................................... 4

CV & CV-EX Communications Loops ...........................................................................4

Communications Loop Wiring Overview........................................................................5

CV Controller ...................................................................8

CV Controller Wiring ......................................................................................................9

CV Controller Addressing .............................................................................................11

CV System Sensors........................................................ 12

Room Sensor..................................................................................................................12

Supply Air Temperature Sensor.....................................................................................14

Outside Air Temperature Sensor ...................................................................................15

CommLink IV Interface.................................................. 16

Optional IP Module Kit .................................................................................................16

Optional Remote Link II................................................................................................17

CommLink IV Wiring....................................................................................................18

CommLink IV DIP Switch Setting ................................................................................19

Installing the CommLink IV ..........................................................................................21

System Manager ............................................................ 22

System Manager Wiring ................................................................................................23

MiniLink Interface.......................................................... 24

MiniLink Interface Wiring.............................................................................................25

CV & CV-EX Worksheet ..............................................................................................26

Index .............................................................................. 27

Installation and Wiring

Section 2

Table of Figures

Figure 2-1: CV System Overview .................................................................................2

Figure 2-2: CV-EX System Overview...........................................................................3

Figure 2-3: CV Communication Loop Wiring, Daisy-Chain Configuration.................5

Figure 2-4: CV-EX Communication Loop Wiring, Daisy-Chain Configuration ..........6

Figure 2-5: CV Controller with Backplate - Components.............................................8

Figure 2-6: Constant Volume Controller Wiring...........................................................9

Figure 2-7: CV Controller Address Switch Setting.....................................................11

Figure 2-8: Room Sensor Installation..........................................................................12

Figure 2-9: Room Sensor Wiring ................................................................................13

Figure 2-10: Supply Air Temperature Sensor Installation ..........................................14

Figure 2-11: Outside Air Temperature Sensor............................................................15

Figure 2-12: CommLink IV Interface Wiring & Jumper Setting................................18

Figure 2-13: CommLink IV DIP Switch Setting ........................................................19

Figure 2-14: CommLink IV to MiniLink Wiring .......................................................20

Figure 2-15: CommLink IV to CV Controller Wiring................................................20

Figure 2-16: System Manager Dimensional Data.......................................................22

Figure 2-17: System Manager Wiring.........................................................................23

Figure 2-18: MiniLink Interface Overview.................................................................24

Figure 2-19: MiniLink Interface Wiring.....................................................................25

Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Tips Before Beginning Installation

Take a few moments to review the following before beginning installation of the AutoZone CV and CV-EX systems.

• Familiarize yourself with all system components and review all documentation. Pay

special attention to “Cautions” and “Warnings” since these may keep you from experiencing unnecessary problems.

• Before installing each controller, be sure to tag it with its appropriate location. It is

also best to set the controller address switches before mounting. Use the CV and CVEX Address Worksheet included at the end of this section and in the CV and CV-EX submittal package to list all CV unit locations. This will assist you greatly when setting up the system and later for any necessary system troubleshooting.

• Be sure and install all wiring according to local, state, and national codes.

• Pay close attention to communication wiring since the most common mistakes are

made in this area. Polarity is the most important rule. Make notes on your wiring diagrams as to which color wire you will be using on each terminal.

• When in doubt - ask! Contact your local Auto-Zone distributor if you have any

questions. The only dumb questions are the ones you don’t ask.

• Remember - each electronic device contains only one puff of smoke. If you release it,

you have voided the warranty! So please be careful and pay attention.

Installation and Wiring 2-1

Section 2 Auto-Zone CV & CV-EX

Systems Overview

CV System

Figure 2-1: CV System Overview

2-2 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

CV-EX System

Figure 2-2: CV-EX System Overview

Installation and Wiring 2-3

Section 2 Auto-Zone CV & CV-EX

Communications Loop

The Communications Loop for both the CV and CV-EX systems is two-wire shielded RS-485. The loop is best connected in daisy-chain configuration, meaning the loop is connected from one controller to another. It is not necessary to sequentially address the CV Controllers in relation to their location on the loop. Cable must be Belden No. 82760 or equivalent.

Tip: Incorrect wiring of the communications loop is the most common mistake made

during installation. Before beginning installation, write down the wire color used on each terminal connection and consistently maintain that color code. It is recommended that a continuous wire run be made between devices. Anytime a splice is made in the cable, you increase your chance of problems.

Caution: Make sure when you are inserting wires into the terminal blocks that

strands of wire do not stick out and touch the next terminal. This could cause a short or erratic operation.

CV & CV-EX Communications Loops

The CV and CV-EX communications loops are different in one respect. The CV has only one communication loop while the CV-EX has two. On the CV system, all of the CV controllers are daisy-chained together and tied into the CommLink on one end of the loop. Each controller is assigned a numbered address by setting the DIP switch on each one. See Figure 2-3 for the CV system communication wiring diagram. This is the only communications loop required on the CV system.

For the CV-EX system communications wiring, see Figure 2-4. As is shown in the diagram, all of the CV Controllers are daisy-chained together just like the CV system. This is referred to as the “Local Loop.” This local communications loop is then tied into the MiniLink communication interface to the terminals marked Local Loop instead of the CommLink. On the CV-EX system, all of the MiniLinks terminals marked “Network Loop” are then daisy-chained to each other and on one end to the CommLink communication terminals. Each MiniLink is then addressed with a different number by setting its DIP switch in similar fashion to the CV controllers.

2-4 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Communications Loop Wiring Overview

The daisy-chain is the best method for running a communications loop since there is only one starting point and one ending point for each of the communications loops. See Figure 2-3 and Figure 2-4. The general concept is the same for both the CV and the CV-EX.

CV ControllerCV Controller

System Manager

The System Manager Can Be

Connected Anywhere

On The Loop

CV Controller

CommLink IV

The CommLink IV Is Required For

All Systems. The IP Module,

Remote Link II, And Computer Are

Optional On All Systems. All

Computers Require Installation of

Prism Graphical User Interface

Software

Ethernet Cable To Router

All Components Shown Inside This Box Are Optional

End Of Loop

The Comm Loop

Routing Does Not

Have To Follow

The Board Address Sequence

USB Cable To Computer

Loop Start

Optional IP Module

Installs Into CommLink IV

And Provides LAN And Internet

Communications

With The Control System

Ethernet Router

(By Others)

When IP Module

Option Is Used

Computer

(Optional)

Comm Loop

RS-485

9600 Baud

Serial Cable To Remote Link

Phone Cable To Telephone Wall Outlet Jack

Optional Re mote Link I I

Connects to CommLink IV And

Provides Alarm Call-Outs. A

Second Remote Link Is Required If

Connection To Job Site Is Desired

From Remote Computer.

CV Controller

Figure 2-3: CV Communication Loop Wiring, Daisy-Chain Configuration

Installation and Wiring 2-5

Section 2 Auto-Zone CV & CV-EX

CV ControllerCV Controller

System Manager

The System Manager Can Be

Connected Anywhere

On The Local Loop

End Of Local Loop

The Comm Loop

Routing Does Not

Have To Follow

The Board Address Sequence

CV Controller

CommLink IV

The CommLink IV Is Required For

All Systems. The IP Module,

Remote Link II, And Computer Are

Optional On All Systems. All

Computers Require Installation of

Prism Graphical User Interface

Software

Ethernet Cable To Router

All Components Shown Inside This Box Are Optional

USB Cable To Computer

Ethernet Router

(By Others)

When IP Module

Option Is Used

Network Loop Start

Optional IP Module

Installs Into CommLink IV And

Provides LAN And Internet

Communications

With The Control System

Remote Link Is Required If Connection To

Job Site Is Desired From Remote Computer.

Computer

(Optional)

Serial Cable To Remote Link

Phone Cable To Telephone Wall Outlet Jack

Optional Remote Link II

Connects to CommLink IV And

Provides Alarm Call-Outs. A Second

Connect To Network Loop Connection On Next MiniLink

Network Loop

RS-485

19200 Baud

Local Loop

RS-485

9600 Baud

MiniLink

Local Loop Start

CV Controller

Figure 2-4: CV-EX Communication Loop Wiring, Daisy-Chain Configuration

2-6 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Even though the daisy-chain configuration is preferred, the star configuration can also be used for the CV or CV-EX systems. If required, a combination of the two can also be used. Remember, the best communications loop wiring scheme is the one that utilizes the minimum number of ends while using the shortest wiring path.

Note: The communication loops do not have to follow the controller or MiniLink

address sequence.

Caution: If the communications loop is not installed in conduit, be careful to

position the cable away from high noise devices like fluorescent lights, transformers, variable frequency drives, radio or TV transmitting equipment, furnace ignition system wires, etc. Conduit is not required for communication loop wiring unless required by local codes.

Installation and Wiring 2-7

Section 2 Auto-Zone CV & CV-EX

Typical

CV Controller

The CV Controller (Constant Volume Controller) may be installed in any convenient protected location. Observe the recommended environmental limitations for the CV Controller. It should not be mounted in locations subject to extreme low or high temperatures (below 20° F or above 140° F) or in damp or wet environments (maximum of 90% RH). If it is to be mounted outdoors, it must be enclosed in a weather-tight enclosure.

The CV Controller may be mounted without removing the controller from the mounting plate. The unit is mounted by securing four (4) screws through the mounting holes in the mounting backplate. Select the correct screws or other fasteners for the type of mounting material being utilized.

CPU Chip

Pin 1 Indicator

RAM Chip

EPROM Chip

PAL Chip

RS-485 Communications Terminal Block

RS-485 Communications Driver Chip

Communications LED

Power LED

Diagnostic Blink Code LED 1

Diagnostic Blink Code LED 2

Relay Output Ter mi nal s

Address Switch

Real Time Clock Chip

24 VAC Power Input Termi nal

Figure 2-5: CV Controller with Backplate - Components

2-8 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

CV Controller Wiring

Connect To

Next Controller

MiniLink On

Local Loop

Room Sensor

NORMAL

OVR

Mount In HVAC

Tem p. Sens or

And/Or

A R M E R C O O L E R

Discharge Air Temp.

Sensor

Unit Supply

Air Duct

Switch Supplied

By Others

Auxiliary Alarm

Outside Air

(See Note 4)

All Comm Loop Wiring Is

Straight Thru

Local Loop

RS-485

9600 Baud

TMP

GND

AUX

Connection To AUX Terminal is Reqd Only When Sensor Is Specified With Slide Adjust Option

Input

Y 3 + 2

COM 1

Economizer

Actuator

(Belimo Shown)

Consult Factory For

Other Manufacturers

Wiring Connections

T SHLD R

+VDC

AIN 1 AIN 2 AIN 3 AIN 4 AIN 5 GND GND AOUT

TB3

EXPANSION T'STAT

Caution: When Wiring The CV Controller Be Sure To Disconnect All Communication Loop Wiring From The CV Controller Before Removing Power From The CV Controller. Reconnect Power And Then Reconnect Communication Loop Wiring.

24VAC

GND

See Note 1 & 2

Notes:

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

3.)All Communication Wiring To Be 2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

CV Controller

2 4

32 TOKEN

NETWORK

Line Voltage

RELAY

OUTPUTS

COM1-3

R3 R4 R5

COM4-5

GND

24VAC

4.)Only One Outside Air Sensor Is Required Per System. It May Be Connected To Any CV Controller On The System. If The Wetbulb Module Is Used, The OA Sensor Must Be Connected To The Wetbulb Module.

Constant Volume Unit Connections

R (24VAC) G (Fan-On/Off) Wx or Yx (Htg or Clg Stage x) Wx or Yx (Ht Wx or Yx (Ht

Wx or Yx (Ht

TB2

Note: Up To 4 Stages Of Heating Or Cooling Or Any Combination Of Each Is Allow ed And Programma ble Via The System Manager or Computer Front End Software. If The Unit Has Heat, Heating Stages Must Be Connected To The First Outputs in Consecutive Order And Cooling Stages To The Remaining Outputs In Consecutive Order.

Required VA For Transforme r

Each CV Controller = 20VA Min.

TB1

GND

24VAC

See Note 1 & 2

or Clg Stage x) or Clg Stage x)

or Clg Stage x)

Line Voltage

Figure 2-6: Constant Volume Controller Wiring

Installation and Wiring 2-9

Section 2 Auto-Zone CV & CV-EX

Warning: Polarity is very important when connecting power to the controllers!

The grounded side of the control transformer must be connected to the terminal labeled GND on the CV Controller. If a single transformer is used to power more than one CV Controller, you must connect GND-to-GND and 24VAC-to-24VAC on each CV controller. Failure to observe polarity will result in damage to one or more components in your system.

Warning: Use extreme care not to damage any of the electronic components

while mounting the backplate. Mark the holes and then remove the CV Controller from the backplate before drilling.

Do not allow metal shavings to fall onto the circuit boards.

The Constant Volume Controller requires the following electrical connections:

18-Gauge minimum unless otherwise noted.

-24 VAC Supply Voltage.......................................................................... 2 Conductors

-Communications Loop ...................................... 2 Conductor twisted pair with shield

(Belden #82760 or equivalent)

-Supply Air Temperature Sensor ........................................ (24 ga. Min.) 2 Conductors

-Room Air Temperature Sensor...........(24 ga. Min.) 2 Conductors for standard sensor

3 Conductors for sensors with setpoint adjustment

-Outside Air Temperature Sensor ....................................... (24 ga. Min.) 2 Conductors

-HVAC Unit Control Wiring .....................................................................R - Common

G - Fan Heat/Cool Stage 1 Heat/Cool Stage 2 Heat/Cool Stage 3 Heat/Cool Stage 4

Tip: After making all electrical connections, we recommend that you unplug all

terminal blocks on the CV Controller until you are ready to begin the checkout procedure. This may help to prevent damage if wiring errors occur elsewhere in the system during installation or start-up.

2-10 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

CV Controller Addressing

CV Controller Address Switch SettingCV Controller Address Switch Values

Switch Shown Is

Set For Address 5

ADDRESS ADD

Note:

1.) Ignore Any Markings On The Switch Body.

2.) Use The Address Charts Below Or Address Switch

3.) Power To Controller Must Be Turned Off And

SW1

Value Table Above To Determine Correct Switch Setting.

Back On In Order For Switch Settings To Take Effect.

Address Switch Values Are Not Labeled On The CV Controller Use The Table Below

Address Switch Values

1 2

16 32 (Always OFF- Not Used) TOKEN (Always OFF) NETWORK (Always ON)

SW1

Address Switch Shown Is

Set For Address 9

Address Switch Values Are Added Together When The Rocker Is Pushed Down In The Direction Of The “ADDRESS ADD” Arrow Marked On The CV Controller Circuit Board

ADDRESS ADD

Controller Address Switch

ADDRESS ADD

SW1

Address Switch Shown Is

Set For Address 30

ADDRESS ADD

SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1

Address Switch Setting Chart For CV Controllers

SW1 SW1 SW1 SW1 SW1

29 30

Figure 2-7: CV Controller Address Switch Setting

Installation and Wiring 2-11

Section 2 Auto-Zone CV & CV-EX

CV System Sensors

Room Sensor

The Room Sensor uses a patented flush-mount design to isolate the temperature sensing element from the housing which mounts flush with the wall surface.

Room Sensors should be located on an inside wall away from direct sunlight or heat producing equipment such as computers, copiers, etc. Such devices can adversely affect the accuracy of the sensor. Although the sensor eliminates most of the effects of thermal coupling to the walls, try to avoid walls which retain large amounts of thermal energy (such as marble or steel). Walls containing either cold or warm air currents should also be avoided whenever possible. Avoid locating the sensor in dead air areas of a room. This will result in slow response to temperature changes in the space.

Figure 2-8: Room Sensor Installation

Mount the sensor approximately 50-60 inches from the floor for best results. The Room Sensor is designed to mount vertically in a standard 2-by-4-inch electrical box. The sensor may be mounted directly into the drywall where electrical codes do not require low-voltage wiring to be enclosed in conduit. A template is supplied with the sensor to facilitate cutting a hole of the correct size.

2-12 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

AINAINAINA

Tip: Be careful when cutting the hole for the sensor or the plastic bezel of the sensor

may not completely cover the opening.

Tip: If sensors must be installed on walls that are solid and cannot be penetrated,

surface-mounted boxes and raceway can be purchased from your local electrical distributor.

ROOM SENSOR

CV CONTROLLER

PRESSURE

SENSOR

IN 1

2 3

4 IN 5

GND GND

OUT

OVR

A R M E R

C O O L E

TMP

GND AUX

Connect To AUX Terminal Required Only When Sensor Is Specified With Slide Adjust Option

Figure 2-9: Room Sensor Wiring

Connect the terminal labeled GND on the room sensor to the terminal labeled GND on the CV Controller terminal block TB3. Connect the terminal labeled TMP on the room sensor to the terminal labeled AIN1 on the CV Controller terminal block. If the room sensor has a setpoint adjust slider, connect the sensor terminal labeled AUX to the CV Controller AIN2 terminal block.

Installation and Wiring 2-13

Section 2 Auto-Zone CV & CV-EX

Supply Air Temperature Sensor

The Supply Air Temperature Sensor should be located as close to the rooftop unit discharge as possible for the best response. Locate the sensor in the center of the widest part of the duct. Use the supplied template and a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mount securely to the duct using the supplied sheet metal screws. Be sure the gasket is compressed to provide an air-tight seal. For best accuracy, apply insulation on the outside of the duct, over the sensor. This will help prevent thermal gradients from affecting the sensor.

Leads Are Non-polarized. Butt Splice Leads To24Gauge Wire Minimum. Connect Leads

To "AnalogIn"And "Ground" At Controller.

4.0"

Thread Together

5-1/2" (OE230) 11-1/2" (OE231)

3/4"

Mounting Plate

1/4" HexHead Sheet MetalScrews

Mounting Plate

Gasket

AdhesiveBacked Drill Guide MountingTemplate

Duct Work

Drill 5/16"Hole In Ductwork For Probe

Figure 2-10: Supply Air Temperature Sensor Installation

2-14 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Outside Air Temperature Sensor

The Outside Air Temperature Sensor must be located where it will not be affected by direct sun or heat-producing equipment. Mounting under the eave of a roof is often a good choice.

Caution: Complaints of inaccurate outside sensor readings are very common and

can almost always be shown to be the result of poor sensor location.

Note: All sensors utilize the same type thermistor sensor element. For troubleshooting

sensor problems, refer to temperature sensor resetting instructions in Section 3 of this manual.

Gasketed Cover

CAUTION! See Note3

3.00”

Cover Mounting Screw - Typ.

2.30”

2.70”

Closure Plug

CAUTION! See Note 2

0.21" Dia. x 0.73 Lg. Slot - Typ.

Incorrect

Postion

Mounting Tab & Screws - Typ.

Correct

4.50”

3.00”

Front View Side View

Notes:

1.)The Outside Air Sensor Must Be Mounted In A Vertical Position As Shown (Sensor Tube Pointing

Water Must Not Be

Down).

Allowed To Stand In Sensor Tube. Rainwater Will Damage Sensor.

Sensor Must Be Located Where It Will Not Be Affected By Direct Sunlight Or Heat Producing Equipment. If Possible Mount Under Roof Eave Or Similar Protected Location. If Sensor Is Not Located As Specified, Erroneous Outside Air Tem perature Readings Will Result.

2.25”

1.13”

Sensor Tube

CAUTION! See Note 1

2.)Unused Conduit Opening(s) Must Have Closure Plugs Installed And Must Be Coated with Sealing Compound To Provide Raintight Seal. Water Can

Damage Sensor!

3.)Gasket Must Be Installed Under Cover

Plate To Provide Raintight Seal.

Rainwater Can Damage Sensor!

4.)All Wiring To Be In Accordance With

Local And National Electrical Codes And Specifications.

Mounting Tab & Screw - Typ.

Closure Plug

CAUTION! See Note 2

Back View

See Note #1

Incorrect

Sensor Mounting

Figure 2-11: Outside Air Temperature Sensor

Installation and Wiring 2-15

Section 2 Auto-Zone CV & CV-EX

CommLink IV Interface

The CommLink IV Interface is used to transfer communications between controllers on your control system loops. It can also be used as an interface for connection of a computer to your system. The CommLink IV provides communication with any controller on the control system through a computer that is running Prism software, or it can be used to communicate with most controllers by using only the System Manager. For remote communications, an IP Module Kit can be installed for LAN and Internet connections, or a Remote Link II can be connected for dial-up connections.

STATUS

Optional IP Module Kit

The IP Module Kit, when installed and configured in the CommLink IV, provides TCP/IP Internet and/or intranet connection for Ethernet networked computer systems allowing them to communicate with your control system.

The OE415-02 IP Module Kit consists of the IP Module and a 10-foot-long CAT5 Ethernet crossover cable. Using standard TCP/IP Protocol, with WattMaster’s Prism software, you are able to monitor and configure your controllers without a modem or a direct connection from a PC. Utilizing existing routers, proxies, or firewalls allows a PC running Prism to connect to a controller in a remote accessible location or building. Several IP connection profiles can be created to facilitate monitoring several CommLink IVs with IP Module Kits installed on individual sites. See the IP-Module Technical Guide —WM-IPM-TGD for complete product details and installation instructions.

2-16 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Optional Remote Link II

The Remote Link II is a 14,400 baud modem that can be used with a CommLink IV or a computer. It is used to provide remote dial-up communications with the CommLink IV. When it is used as a computer modem (at the remote computer location), it connects to the remote computer.

Note: WattMaster will not support any other internal or external modems by other

manufacturers.

The OE419-06 Remote Link II connects to the CommLink IV communications interface at the control system location via a DB9 serial cable. A telephone line connects the Remote Link to the local phone service. Using another Remote Link modem connected to a computer and phone service at a remote location, you can monitor and control the system using the Prism computer front-end software. Connection is made by dialing the telephone number of the job site where the Remote Link is located. See the Remote Link II Technical Guide—WM-RLII-TGD for complete product details and installation instructions.

Installation and Wiring 2-17

Section 2 Auto-Zone CV & CV-EX

CommLink IV Wiring

USB Switch Should Be Set To N o r m al

MODEM

RS-232

Female

TGR

485 LOOP

9Pin

Optional Items Not Required For

DIAG

10/100

ETHERNET

ACT LNK

USB

Normal

Config

COMPUTER

USB

CommLink Only Installations

Optional - Prefabricated Ft. Long CAT5 Ethernet Cable (Included With Optional OE41502 IP Module Kit). Ethernet Router On Your LAN. Ethernet Cable Is Required, You Will Need To Obtain (From Others) And Install An Ethernet Cable Of The Required Length For Your Installation.

Notes:

1) Use 18-Gauge Minimum, 2-Conductor Twisted Pair With Shield Cable Belden #82760 Or Equivalent (Not Included) To Connect The CommLink IV To The MiniLink On Network Loop Or Controller Or System Manager On Local Loop.

2) For Direct Connection Via USB, Your Computer Must Have An Unused USB Port Available. Drivers For Your USB Port Are Provided On A CD Supplied With The CommLink IV And Will Need To Be Installed On Your Computer In Order For It To Function Correctly. Please Refer to the CommLink IV

Installation Technical Guide Form: WM-CLIV-TGD

3) The CommLink IV Cannot Communicate With The Control System Through Its Ethernet Port And USB Port At The Same Time.

4) All Wirin

USB Cable (Included). Connect This Cable To Your Computer USB Port For Directly Connecting To CommLink IV. Also Used For Advanced Configuration of CommLink IV.

Molded Modem Cable. Part #HZ000098 Supplied With RemoteLink II

Connect To A 10/100 Base-T

Must Conform To Applicable Federal, State & Local Electrical Wiring Codes.

If A Longer

When An Optional Remote Link Is Used, Connect This Cable To CommLink IV And Remote Link As Shown. Cable Is Included With Remote Link.

Which Is Supplied With The CommLink IV.

25 Pin

Male

ommLink IV

Communications Interface

Serial #

GND

24V

POWER

WARNI NG!

24 VAC Power

18-Gauge, 2-Conductor With Shield (Not Included)

Connect To The Controller Or System Manager On Local Loop Or MiniLink On Network Loop. See Note 1.

120 to 24 VAC Power Pack (Included) Connect To 120/1/60 Duplex Receptacle (By Others)

If Desired A 24 VAC Transformer Included)

Rated At 12 VA Minimum May Be Used Instead Of The Supplied Power Pack. Use 18 Gauge Minimum 2 Conductor Wire Between The Transformer & CommLink IV Terminals.

If You Are Using The IP Module

With Your CommLink, Do Not Have Your Ethernet Connection And USB Connection Connected At The Same Time. This Could Cause Unreliable Communications.

Figure 2-12: CommLink IV Interface Wiring

(Not

2-18 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

CommLink IV DIP Switch Setting

CommLink IV Communication Settings

The SW1 DIP Switch Located On The Circuit Board Inside The CommLink IV Housing Must Be Set Correctly For Your Specific Application In Order To Function Properly. The CommLink IV Is Factory Set For Multiple Loop Applications.

To Check And/Or Set The SW1 Dip Switch, First Remove The (2) Enclosure Screws That Hold The Top And Bottom Of The CommLink IV Enclosure Together. Remove The Top Half Of The Enclosure To Access The Circuit Board And Dip Switches.

SW1

The DIP Switch Setting Should Be Set To “Multiple” For The Auto-Zone System

Replace The CommLink IV Cover And Secure The Enclosure Halves Back Together With The (2) Enclosure Screws That Were Previously Removed.

CV-EX .

WattMaster Controls Inc. COMMLINK IV YS102074

REV6

MADE IN USA

ALTERA EPM3032

DIP Switch 1 & 2 Off = Multiple Loop Communications Re

uired Setting For Auto-Zone CV-EX System

Figure 2-13: CommLink IV DIP Switch Setting

Installation and Wiring 2-19

Section 2 Auto-Zone CV & CV-EX

USB

MODEM

RS-232

TGR

485 LOOP POWER

DIAG

Comm Loop

10/100

ETHERNET

ACT LNK

Local

Config

USB

COMPUTER

Normal

Figure 2-14: CommLink IV Wiring for CV System

Serial #

GND

24V

SHIELD

DIAG

Comm Loop

10/100

ETHERNET

ACT LNK

Network

Local

Comm Loo

Config

USB

MODEM

RS-232

COMPUTER

Normal

MiniLink Communications Interface

ADD

NETWORK

16 32

OFF >

LOOP

TGR

485 LOOP

Local Communications Loo p

To CV Controllers

And System Manager

Serial #

GND

24V

POWER

SHIELD

24VAC

GND

Figure 2-15: CommLink IV to MiniLink Wiring for CV-EX System

2-20 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Installing the CommLink IV

When you are using the CommLink IV with the Auto-Zone CV or CV-EX System and are not going to use a Computer, Remote Link II, or IP Module, you only need to perform three steps to install your CommLink IV.

Step #1:

Multiple if using the CV-EX system. See Figure 2-13 for details on setting the DIP Switch on the CommLink IV.

Step #2:

with shield) from the CommLink IV to a CV Controller (CV system) or MiniLink (CVEX system).

For the CV system, the communication wiring should connect from the T, G, & R terminals on the CommLink IV to the T, SHLD, & R terminals on the CV Controller. See Figure 2-14. Be sure that you wire the CommLink “T” terminal to the CV Controller “T” terminal, The CommLink “G” Terminal to the CV Controller “SHLD” terminal, and the CommLink “R” terminal to the CV Controller “R” terminal as shown.

For the CV-EX system, the communication wiring should connect from the T, G, & R terminals on the CommLink IV to the network T, SH, & R terminals on the MiniLink. See Figure 2-15. Be sure that you wire the CommLink “T” terminal to the MiniLink “T” terminal, The CommLink “G” Terminal to the MiniLink “SH” terminal, and the CommLink “R” terminal to the MiniLink “R” terminal as shown.

Step #3:

terminals on the CommLink IV. Plug the power pack into a standard 120 VAC duplex outlet.

If you intend to use a Computer, Remote Link II, or IP Module in addition to the steps just performed, you will need to perform additional installation procedures. Please refer to the CommLink IV Technical Guide—WM-CLIV-TGD which is supplied with the CommLink IV. It will instruct you regarding installation and troubleshooting of the CommLink when an optional personal computer and/or other communication devices are used. This manual is also available from any of the WattMaster websites for downloading as are the USB drivers and Prism Software. These are required for installation when using the optional personal computer or other communication devices.

Check and make sure your CommLink’s communication switch is set to

Install communications wiring (18-gauge minimum, 2-conductor twisted pair

Wire the supplied 120/24 VAC power pack to the 24 VAC and GND

Installation and Wiring 2-21

Section 2 Auto-Zone CV & CV-EX

System Manager

The microprocessor-based System Manager is a device which allows the CV Controller or any add-on device connected to the system to be programmed and monitored from a central location. The System Manager is connected via the RS-485 communication network.

The System Manager is mounted in an attractive, white, plastic housing, suitable for wall mounting. A four-line-by-twenty-character, backlighted, LCD display and membrane keypad provide a user-friendly interface. All system variables, setpoints, and values can be viewed and modified from the System Manager. Menu-driven programming makes the System Manager easy to set up your system and operate it without the need for specialized training.

6.25

1.90

9.00

Membrane Keypad

Four Line by 20 Character Backlighted Display

Figure 2-16: System Manager Dimensional Data

2-22 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

System Manager Wiring

The System Manager can be connected anywhere on the CV or CV-EX system local communications loop. Do Not Connect the System Manager to the CV-EX System Network Loop! The system will not function if the System Manager is connected to the network loop. The System Manager must also be connected to 24 VAC in order to operate. See Figure 2-17 for System Manager wiring.

03/20/09 06:38PM FRI

OCCUPIED

NO ALARMS

System Manager

Top

Required VA For Transformer

System Manager = 25VA Max.

Line Voltage

See Note 1

System Manager

Base

LD1

GND

24VAC

LD2

LD3

LD4

LD5

LD6

RN1

LD7

LD8

The Ideal Recommended Location For The System Manager Is As The First Device On The Local Loop. The System Manager May Be Connected To The Local Loop At Any Point On The Local Loop.

YS101806 REV. 1

74HC259

PCB80C552-5-16WP

DfD9722V7Y

442860=2/5

PHILIPS

C2C1

RN2

74HC573

CX13

74HC573

CX7

CX9

V62C518256L-70P

SS0017 vx.xx 1234

U13

UNIVERSAL SMART DISP. UNIT

DSPY1

EWDOG

CX4

CX8

CX5

24C128

CX6

8583

24VAC

SC1

RAM

TB1

CX12

EPROM

R10

RS-485 COMM

CX3

GND

U12

75176

82B715

PJ1

R12

SHLD

VAR1

TB2

C11

MADE IN THE USA

SERIAL #

CX1

SYSTEM MANAGER

Notes:

1.) 24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.) All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

3.) All Communication Wiring To Be

2-Conductor Twisted Pair With

Shield. Use Belden #82760 Or Equivalent.

470uF50v

DSPY1

SERIAL # :

1000uF10v

RV1

See Note 3

U10

74HC923

MC34064A

U11

9936

R11

1000uF10v

For CV Systems, Connect To Any CV Controller On The Local Loop Or To The CommLink. For The CV-EX System, Connect To Any Controller On The Local Loop Or To The Local Loop Terminal On The MiniLink.

Do Not Connect To The Network Loop On CV-EX Systems!

CX10

470uF50v

Figure 2-17: System Manager Wiring

Installation and Wiring 2-23

Section 2 Auto-Zone CV & CV-EX

MiniLink Interface

The MiniLink Interface is only required and used with the CV-EX system. It is not required for the CV system. It functions as the loop master for each CV-EX system local loop. With the CV-EX system, each local loop of CV controllers (maximum of 30) is connected to a MiniLink. Two MiniLinks are supplied with the standard CV-EX system. This allows up to 60 CV controllers (30 maximum per local loop) to be tied together to form an integrated system. A CV-EX expansion kit is available which provides another MiniLink to allow an additional 30 CV controllers to be connected to the system. A maximum of two expansion kits can be used on the CV-EX system to provide integration of up to 120 CV controllers. See Figure 2-18 for an overview of the MiniLink.

Network Loop

Communications

Driver Chip

Network Loop

Communications

LED

( Each Board Must Be Addressed Uniquely )

Address Switch

Switch Shown Set For Address 1

( 1,2,3,4)

ADD

Network Loop

Connector

Local Loop

Communications

LED

Local Loop

Connector

NETWORK

4.50"

16 32

OFF >

LOOP

Local Loop

Communications

Driver Chi

Figure 2-18: MiniLink Interface Overview

24 VAC

Power

24VAC

GND

7.50”

2-24 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

MiniLink Interface Wiring

All MiniLinks on the CV-EX system must be wired to each other with a Network communications loop, daisy-chaining the Network loop terminals together. One end of the CV-EX system Network loop must be connected to the CommLink IV interface. Each MiniLink on the CV-EX system is then wired from its Local loop terminals to the CV Controllers on that Local loop. The MiniLink also requires 24 VAC power to operate. Each MiniLink must be addressed from 1 to 4 with a unique address. The addresses are set with the address switch at each MiniLink board. See Figure 2-18 for the address switch location. See Figure 2-19 for wiring information.

Connect To Next

MiniLink And/Or

CommLink On

Network Loop

RS-485

19200 Baud

(See Note 3).

All Communication Loop

Wiring Is Straight Through

Local Loop

RS-485

9600 Baud

(See Note 3).

MiniLink Communications Interface

ADD

NETWORK

16 32

OFF >

LOOP

24VAC

GND

24VAC

GND

Required VA For Transformer

MiniLink = 10VA Max.

See Note 1.

Line Voltage

Connect To CV

Controller or

System Manager

On Local Loop

Notes:

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

Figure 2-19: MiniLink Interface Wiring

3.) All Communication Wiring To Be 2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

Installation and Wiring 2-25

Section 2 Auto-Zone CV & CV-EX

CV & CV-EX Worksheet

Project: ___________________________ Location ___________________________

Stages of Cool: ___ Stages of Heat: ___ Gas Electric Economizer Yes No 

Loop: 1 2 3 4 Remote Link Installed Yes  No  Phone No. ___________

Unit

Unit Description or Location Sensor Type

Address

1 2

[S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint Adj.

S  SO  SA  SOA  S  SO  SA  SOA 

S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA 

S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA  S  SO  SA  SOA 

2-26 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Index

< 30 Controllers .................................. 24

> 30 Controllers .................................. 24

120 CV controllers.............................. 24

14,400 Baud Modem........................... 17

24VAC-to-24VAC.............................. 10

90% RH................................................. 8

Above 140° F ........................................ 8

Addresses

CV Worksheet................................... 1

CV-EX Worksheet ............................ 1

List .................................................. 26

Address Switch Setting

CV Controller.................................. 11

Addressing

Controllers......................................... 1

CV Controller.................................. 11

MiniLinks........................................ 24

AIN1.................................................... 13

AIN2.................................................... 13

AUX.................................................... 13

Belden No. 82760 ................................. 4

Below 20° F .......................................... 8

Cable

Belden 82760 .................................... 4

DB9................................................. 17

Serial ............................................... 17

Telephone Line ............................... 17

Two Wire Shielded ........................... 4

Codes, Standard

Wiring ............................................... 1

CommLink IV

Connecting to MiniLink.................. 20

Dip Switch Setting .......................... 19

Installing.......................................... 21

Jumper Setting ................................ 19

Overview......................................... 16

Technical Guide .............................. 21

Wiring ............................................. 18

Communication Loop

Wiring Diagram, CV EX System...... 6

Communication Loop Wiring

CV System ........................................ 5

Communications Loops

CV System ........................................ 4

CV System Wiring Diagram............. 5

CV-EX System.................................. 4

Local Loop ........................................ 4

Network Loop ................................... 4

Overview........................................... 4

Wiring Overview .............................. 5

Conduit.................................................. 7

Configuration

Daisy Chain....................................... 4

Star .................................................... 7

Controllers

< 30 ................................................. 24

> 30 ................................................. 24

Addressing ........................................ 1

Damage ........................................... 10

List .................................................. 26

CV Address Worksheet......................... 1

CV Controller

Address Switch Setting................... 11

Addressing ...................................... 11

Backplate Components ..................... 8

Electrical Connections .................... 10

Installing............................................ 8

Mounting........................................... 8

Wiring ............................................... 9

Wiring Diagram ................................ 9

CV System

Communications Loops .................... 4

Diagram............................................. 2

Overview........................................... 2

Sensors ............................................ 12

Wiring Diagram ................................ 5

CV Worksheet..................................... 26

CV-EX Address Worksheet.................. 1

Installation and Wiring 2-27

Section 2 Auto-Zone CV & CV-EX

CV-EX System

Communication Loop Wiring........... 6

Communications Loops .................... 4

Diagram............................................. 3

Expansion Kit ................................. 24

Overview........................................... 3

Worksheet ....................................... 26

Daisy Chain..................................... 4, 25

Configuration .................................... 4

Daisy-Chain Configuration

CV-EX System Wiring Diagram ...... 6

Diagram............................................. 5

Damage

Controller ........................................ 10

Damp Environments ............................. 8

DB9 Serial Cable ................................ 17

Diagram

CV System ........................................ 2

CV-EX System.................................. 3

Dial-up Communications.................... 17

Dial-up Connections ........................... 16

Dimensions

System Manager.............................. 22

DIP Switch............................................ 4

Electrical

Short.................................................. 4

Electrical Connections

CV Controller.................................. 10

Enclosure

Weathertight...................................... 8

Environmental Limitations

Installation......................................... 8

Environments

Damp................................................. 8

Wet.................................................... 8

Expansion Kit ..................................... 24

Extreme High Temperatures ................. 8

Extreme Low Temperatures.................. 8

Firewall ............................................... 16

Fluorescent Lights................................. 7

Furnace Ignition System Wires............. 7

GND-to-GND ..................................... 10

Humidity

90% RH............................................. 8

Installation

CommLink IV................................. 21

CV Controller.................................... 8

CV System ........................................ 1

CV-EX System.................................. 1

Environmental Limitations ............... 8

Outside Air Sensor.......................... 15

Room Sensors ................................. 12

Supply Air Temperature Sensor...... 14

System Manager.............................. 22

Tips ................................................... 1

Intranet Connection............................. 16

IP Module

Overview......................................... 16

IP-Module Technical Guide................ 16

Jumper Setting

CommLink IV................................. 18

LAN and Internet Connections ........... 16

LCD Display

System Manager.............................. 22

Local Codes........................................... 7

Local Loop ............................................ 4

Marble Walls....................................... 12

Metal Shavings.................................... 10

MiniLink ............................................... 4

Address Location ............................ 24

Overview......................................... 24

Wiring ............................................. 25

Modem

Internal ............................................ 17

Other Manufacturers’...................... 17

Remote Link II................................ 17

Mounting

Room Sensors ................................. 12

Mounting Backplate.............................. 8

Multiple Setting .................................. 21

Network Loop ....................................... 4

OE415-02 IP Module Kit.................... 16

OE419-06 Remote Link II .................. 17

Outside Air Sensor

Inaccurate Readings ........................ 15

Installing.......................................... 15

Outside Air Temperature Sensor......... 15

2-28 Installation and Wiring

Auto-Zone CV & CV-EX Section 2

Overview

CommLink IV................................. 16

Communications Loops .................... 4

CV System ........................................ 2

CV-EX System.................................. 3

IP Module........................................ 16

MiniLink ......................................... 24

Remote Link II................................ 17

System Manager.............................. 22

Systems ............................................. 2

Plastic Bezel........................................ 13

Polarity............................................ 1, 10

Prism ....................................... 16, 17, 21

Radio Transmitting Equipment............. 7

Remote Link II.................................... 16

Described ........................................ 17

Overview......................................... 17

Requirements

Electrical, CV Controller ................ 10

Rooftop Unit Discharge ...................... 14

Room Sensors ..................................... 12

Installing.......................................... 12

Mounting......................................... 12

Wiring ............................................. 13

Router.................................................. 16

RS-485 ............................................ 4, 22

Sensors

CV System ...................................... 12

Outside Air Temperature ................ 15

Room............................................... 12

Supply Air Temperature.................. 14

Short

Electrical ........................................... 4

Splice..................................................... 4

Star Configuration

Wiring ............................................... 7

Steel Walls .......................................... 12

Supply Air Temperature Sensor

Installing.......................................... 14

Location .......................................... 14

System Manager

Dimensions ..................................... 22

Installling ........................................ 22

Overview......................................... 22

Wiring ............................................. 23

Systems

Overview........................................... 2

TB3 ..................................................... 13

TCP/IP Internet ................................... 16

Telephone Line ................................... 17

Temperatures

Above 140° F .................................... 8

Below 20° F ...................................... 8

Extreme High .................................... 8

Extreme Low..................................... 8

Humid ............................................... 8

Terminals

AIN1................................................ 13

AIN2................................................ 13

TB3 ................................................. 13

TMP ................................................ 13

TMP .................................................... 13

Transformers ......................................... 7

TV Transmitting Equipment................. 7

Two Wire Shielded ............................... 4

USB Drivers........................................ 21

Variable Frequency Drives ................... 7

Voiding, Warranty ................................ 1

Warranty, Voiding ................................ 1

Weathertight Enclosure......................... 8

Wet Environments ................................ 8

Wiring ................................................... 1

24VAC-to-24VAC.......................... 10

Color ................................................. 4

CommLink IV................................. 18

Communication Loops...................... 5

Conduit.............................................. 7

Continuous ........................................ 4

CV Communication Loop................. 5

CV Controller.................................... 9

CV Controller, Diagram.................... 9

CV-EX System.................................. 6

Diagram, CV System ........................ 5

GND-to-GND ................................. 10

Incorrect ............................................ 4

Local Codes....................................... 7

Mapping ............................................ 1

MiniLink ......................................... 25

Path ................................................... 7

Polarity........................................ 1, 10

Installation and Wiring 2-29

Section 2 Auto-Zone CV & CV-EX

Room Sensor................................... 13

Shortest Path ..................................... 7

Splice................................................. 4

Star Configuration............................. 7

System Manager.............................. 23

System Manager

LCD Display ................................... 22

2-30 Installation and Wiring

Section 3

Table of Contents

LCD/Keypad Operations................................................... 1

Keypad Functions ............................................................................................................1

System Manager LED Indicators .....................................................................................2

Screen Menus ..................................................................2

View Alarms Screen ........................................................5

Full System Access .........................................................6

Set Time & Date ..............................................................6

New Passcodes................................................................ 8

Rebuild Alarm Map........................................................... 9

Read/Reset Units ........................................................... 10

CV Controller Force Modes ...........................................11

CV Controller Read/Reset Operations........................... 12

CV Controller Status...................................................... 13

CV Controller Setpoints................................................. 16

CV Controller Scheduling and Holidays ........................ 22

Week Schedules .............................................................................................................22

Holidays .........................................................................................................................23

Economizer Module (Wetbulb) Read/Reset Operations 24

System Manager Keypad Operations Summary............ 26

Index .............................................................................. 27

Programming

Section 3 Auto-Zone CV & CV-EX

Programming

Auto-Zone CV & CV-EX Section 3

LCD/Keypad Operations

Keypad Functions

The System Manager keypad is labeled either numerically or as to actual function for that key. Below is a summary of the labeled keys and their functions.

03/20/09 06:38PM FRI

OCCUPIED

NO ALARMS

MENU This key is used to gain access to the first menu, and you will be

notified on the LCD if any subsequent use of the key will be required for further access.

ESC The ESCape key allows you to abort what you are doing or exit back

to previous menus. Also, anytime you want to leave the system unattended, you should press the ESC key until the Main Screen appears.

CLEAR If you make a mistake while entering setpoint data, you can clear the

bad data from the display by pressing the Clear key.

ENTER Use the Enter key to close out a data entry. The Enter key can also be

used to advance to the next field or screen.

DEC If entering a setpoint that requires a decimal point, press this key

where the decimal is located while entering the value.

MINUS If you need to enter a negative value, you must press the Minus key

before entering the digits for that value. UP/DOWN Arrows LEFT/RIGHT Arrows

Use these keys to step forward or backward through Status Screens or

Setpoint Data Fields.

If the screen prompts you to use these keys, it is used normally to

toggle modes of operation. In some cases, they may be used for other

functions and you will be prompted as to what these might be.

Programming 3-1

Section 3 Auto-Zone CV & CV-EX

System Manager LED Indicators

There are two LED indicators located on the right-hand side of the System Manager.

The top LED indicates an Alarm condition if the Manager detects an alarm condition while polling the system.

The bottom LED is active during actual communications or packet transfers. This LED will normally "flicker" and not remain on constantly.

Screen Menus

Main Screen

vX.XX Friday Operations 03/20/09 09:46 AM Outdoor Air 78.0°F

The Auto-Zone System Manager is your direct link to the status and setpoints of any Auto-Zone component on your communications loop. With the System Manager, you can view any temperature or output condition and change any setpoint to fine-tune the operations of the total system. All keypad operations are simple and straight-forward, utilizing non-cryptic plain English messages. The System Manager automatically detects the type of unit that has been selected and displays the appropriate status and setpoint screens. The attractive plastic case of the System Manager allows for placement in any area of your building.

The remainder of this section will lead you through the system menus and keypad operations.

All user functions are accessed by pressing the Menu button. Once the button is pressed, the Main User Menu is displayed.

3-2 Programming

Auto-Zone CV & CV-EX Section 3

Main User Menu

1) View/Change Zone

2) View Alarms MENU) Full Access ESC) Main Screen

1) View/Change Zone

2) View Alarms

MENU) Full Access

ESC) Main Screen

For quick access to an individual zone, select this menu item. Any Constant Volume unit can be selected. You can view the room temperature and change the current cooling and heating setpoints. You must be at least a Level 1 user to change the setpoints.

If the System Manager has been configured for Alarm Polling, you can select this item to get a list of unit addresses that are currently in alarm. If an alarm exists, the Alarm LED will be active on the right side of the panel.

If you are a Level 2 user, the full system Read/Reset capabilities are available to you. These capabilites are accessed via this Menu button.

When you have finished viewing the system, you can exit this menu and return to the Main Screen by pressing the ESC button.

View/Change Zone

View/Change [ Enter Unit ID# ] Selected Unit: 101

Programming 3-3

If you have selected the View/Change Zone menu item, you will be allowed to view any selected zone temperature and its current cooling and heating setpoints. If you are at least a Level 1 user, you can also change the cooling and heating setpoints from this screen. The first screen that appears prompts you for the Unit ID you wish to view. For the CV system, the Unit ID is actually the address of the CV controller you assigned to each board with the Address Switch—a number between 1 and 30. For the CV-EX system, it would also be the same CV controller address you assigned, but it would be preceded by the network loop address, which is the address number (between 1 and 4) you set for the MiniLink whose loop the particular CV controller resides on. For example, the CV controller address is 28 and it is on the loop with the MiniLink addressed 2. The ID number you would enter would be 228.

Section 3 Auto-Zone CV & CV-EX

Constant Volume Status

Constant Volume Unit Temperature: 75.4°F Cooling SP.: 75°F Heating SP.: 72°F

If the selected Unit ID is correct, and the unit responds, the following screen will appear. If you are a Level 1 user, you can select either the Cooling or the Heating setpoint with the Up/Down Arrow keys. To change the setpoint, use the Left/Right Arrow keys. The setpoints are fully adjustable between their normal limits of 50 to 90 degrees. When you are finished viewing this screen, simply press the ESC button to exit. The Heating Setpoint is never allowed to get any closer than one degree of the Cooling setpoint. If you are lowering the Cooling setpoint or raising the Heating setpoint, both values will be kept apart automatically by the correct amount.

Entering Passcodes

THIS ACTION REQUIRES PASSCODE CLEARANCE Enter Passcode: xxxx

Anytime you are prompted to enter a passcode, the following screen will appear. No reference is made as to the level of passcode to enter, but if you attempt to access a Level 2 function with a Level 1 passcode, the system will prompt you to enter the correct passcode again.

3-4 Programming

Auto-Zone CV & CV-EX Section 3

View Alarms Screen

Alarm Address Locations

SYSTEM ALARM STATUS Alarm @ Unit ID 118

Alarm Clearing

SYSTEM ALARM STATUS Clear Alarms? YES To Change Response Use Left/Right Arrow

The System Manager can be programmed to poll all Auto-Zone units on your system for alarm information. This allows the centrally located System Manager to display an Alarm Indicator whenever an alarm condition exists anywhere on your system. The actual alarms are not displayed on this screen; only the Unit ID where the alarm is located is displayed. The example shows that a unit at location 118 has experienced an alarm condition. This alarm may or may not be current, as the System Manager latches the alarm condition. This makes it possible to determine if any intermittent alarm conditions have occured. If you have Level 2 access, you can enter the full system access mode, select that unit for display, and determine the exact alarm condition for that unit. The alarm conditions are always displayed on the Status Screens.

If all the alarm conditions have been corrected at the individual units, you can clear these alarms from the System Manager on the following screen. Use the Left/Right arrow keys to select the YES/NO response desired. If you clear the alarms, but some still exist, the System Manager will show an alarm indication when the affected unit is polled again.

Programming 3-5

Section 3 Auto-Zone CV & CV-EX

Full System Access

Full Access Menu

1) Set Time & Date

2) Read/Reset Units

3) New Passcodes

4) Rebuild Alarm Map

If you selected the MENU key from the first menu screen, you can gain full system access. However, you must be a Level 2 user. If you haven't already been asked to enter the passcode, you will be asked before the Full Access Menu is displayed. This prevents a Level 1 user from being overwhelmed with the full amount of data and setpoints available to the Level 2 user.

Set Time & Date

The System Manager has its own built-in Real Time Clock. It broadcasts this time once a day at midnight to synchronize all of the other units on your Auto-Zone system. Although the times are displayed on the Main Screen in a standard 12-hour format, they are programmed using the 24-hour Military format. Once the time has been entered, it is also broadcast immediately to all other units on the system. That means that you only need to program the System Manager time to set the Real Time Clocks for all units on your communications loop.

Programming Time

Program Time/Date Day (Sunday=0): 1 Enter Hr. (0-23): 9 Enter Minutes : 53

Day

Hours (Hr)

Minutes

- Enter the Day of the Week (0 to 6) with Sunday = 0

- Enter Hours in 24-Hour Military Format (1700 = 5:00 PM)

Enter the Minutes (0 to 59)

3-6 Programming

Auto-Zone CV & CV-EX Section 3

Programming Date

Program Time/Date Month (1-12): 3 Day (1-31): 20 Year (00-99): 09

Month

Day

Year

Daylight Savings Adjustments

Daylight Savings Adjustments Enabled

Use Left/Right Arrow

If your area of the country requires Daylight Savings changes, you can enable the System Manager to automatically reset its own clock during the Daylight Savings changeover. However, if you enable this operation, be aware it will changeover the first Sunday in April and then switch back the last Sunday in October. These used to be the standard dates every year that were constant from year to year.

The U.S. government has seen fit recently to arbitrarily determine the switch over dates each year so it is recommended that you disable this function and manually change the schedules from year to year.

- Enter the Month (1 to 12)

Enter the Day of the Month

(1 to 31)

Enter the current Year with 2 digits (00 to 99)

Use the Left or Right arrow keys to toggle the second line of the display between Adjustments Enabled and Adjustments Disabled.

Programming 3-7

Section 3 Auto-Zone CV & CV-EX

New Passcodes

Programming Passcodes

Enter New Passcode

Level 1.....: XXXX

Level 2.....: XXXX

[Must Be 4 Digits]

Caution: If you change the Level 2 passcode and cannot remember what it is, you

will be locked out of your system!

The System Manager has two levels of user access.

Level 1 users are limited to viewing or changing Zone Temperatures and their Heating and Cooling Setpoints and to viewing Unit ID numbers for those in alarm conditions.

Level 2 users have complete system access. Any status or setpoint field can be read or reset from the Auto-Zone system.

These two levels of passcodes are programmable by any Level 2 user. The default Level 1 passcode is 1111, and the default Level 2 passcode is 2222.

The actual digits in your passcodes are never displayed. An "X" is used as a place holder for each digit entered. Passcodes must always be four digits in length, so the useable range of numbers is 1000 to 9999.

3-8 Programming

Auto-Zone CV & CV-EX Section 3

Rebuild Alarm Map

Rebuilding Screens

Clearing Old Map

....................

................

Building New Map Loop: 1 Unit: 1 FOUND

Alarm Unit Map Built Press Any Key To Continue

If you would like the LED Alarm Indicator to function on the front of your System Manager, you must enable Alarm Polling by building an Alarm Map. This map keeps track of which units exist on your communications loop so that the System Manager will poll only those units. That means you will need to rebuild this map anytime units are added or removed from your system. It also means you can disable alarm polling. To do this, disconnect the RS-485 communications plug from the back of your CommLink IV. Then select the Rebuild Alarm Map menu. The System Manager will not find any units to poll for alarms since none are connected. This is useful during building startup, when you don't want nuisance alarms bothering you.

The screen will display each address it is testing if a unit is FOUND at that address. If you have a CV system, you don't have to wait for the System Manager to check for all 30 loops; rather, you can press the ESC key as soon as the first loop has been checked since the CV system only has one loop. All units found up to that point will be saved in memory. The CV system

volume configuration only contains one loop, but the System Manager will always attempt to determine if more than one loop really exists. The CV-EX system will have 2 to 4 loops. Be sure to allow time for the System Manager to find all the local loops.

The System Manager does not rebuild this map automatically on powerup! You must do this manually. This rebuild should

only be performed one time, when all units are up and running. It is not a regular requirement. As mentioned above, only when the number of units connected changes should the alarm map be rebuilt.

Programming 3-9

Section 3 Auto-Zone CV & CV-EX

Read/Reset Units

Read/Reset Address Entry

Read/Reset [ Enter Unit ID# ] Selected Unit: 101

You must know the Unit ID of the controller you wish to view. This number is created by combining the network loop address with the CV Controller board address on CV-EX systems. On CV systems, the Unit ID is simply the CV controller board address. The CV Controllers should always be addressed starting with number 1 and continuing up to 30. The CV-EX MiniLinks (network loop address) should be numbered starting with 1 and continuing up to 4 (assuming you have 4 loops). Don’t skip numbers.

Once you have finished the Read/Reset function, you can exit this mode by pressing the ESC key. This will return you to the Full Access Menu.

3-10 Programming

Auto-Zone CV & CV-EX Section 3

CV Controller Force Modes

OPERATING MODE

0) Auto 1) Occupied

2) Night 3) Fan Only Enter Clock Mode: 0

The Constant Volume Units default to the Auto Mode of operation when first powered up. Any force modes entered will be retained in non-volatile memory. The unit will resume the force mode of operation anytime the power is cycled.

0) Auto

1) Occupied

2) Night

3) Fan Only

- Use internal schedules for Day/Night Mode

- Forced to Continuous Day or Occupied Mode

- Forced to Continuous Night or Unoccupied Mode.

- This mode disables any heating or cooling and operates the Fan only. You can use this mode anytime you want to manually purge your building.

Programming 3-11

Section 3 Auto-Zone CV & CV-EX

CV Controller Read/Reset Operations

If the Unit ID you entered found a Constant Volume AHU, the following menus will appear. Any references in this section to CVAHU are referring to the Constant Volume Air Handling Unit or its controller.

CV Controller Menu #1

1) CVAHU Status

2) CVAHU Setpoints MENU) Next Menu ESC) To Exit

1) CVAHU Status

2) CVAHU Setpoints

MENU) Next Menu

CV Controller Menu #2

1) Schedules

2) Force Modes

MENU) Previous Menu

1) Schedules

2) Force Modes

MENU) Previous Menu

View the current temperatures and operating modes for this Constant Volume AHU.

View or change any of the available setpoints for this Constant Volume AHU.

Access the next Menu Page for the Constant Volume AHU.

View or change any of the Week Schedules or Holidays for this Constant Volume AHU.

Select this menu to override the currently scheduled operating mode.

Return to the previous menu shown above.

3-12 Programming

Auto-Zone CV & CV-EX Section 3

CV Controller Status

Line 1 displays the currently selected CVAHU and its current operating software version on all Status Screens shown below.

Status Screen #1

CVAHU # 18 vl.xx Occupied Mode Neutral Mode

Line 2 -

Line 3 -

Line 4 - (Reserved for Future Use)

Status Screen #2

CVAHU # 18 vl.xx Temperature: 78.6ºF CSP 75.0 HSP 72.0º Slide Adjust.: 0.0°

Line 2 - Displays the current Zone Temperature.

Line 3 - Displays the currently active Cooling

Line 4 - Displays the current effect the optional

Unoccupied Mode Occupied Mode Holiday Active Push-button Override Forced Occupied Forced Unoccupied Forced Fan Only Mode

Neutral Mode Cooling Mode Heating Mode

This Line is Blank

Setpoint (CSP) and Heating Setpoint (HSP).

Sensor Slide Adjust has on the Heating and Cooling Setpoints.

Programming 3-13

Section 3 Auto-Zone CV & CV-EX

Status Screen #3

CVAHU # 18 vl.xx Supply Air.: 65.0° Outdoor Air.: 70.2° Wetbulb Temp: 0.0°

Line 2 - Displays the current Supply Air Temperature.

Line 3 - Displays the current Outdoor Air Temperature.

Line 4 - Displays the current Wetbulb Temperature if

Status Screen #4

CVAHU # 18 vl.xx Economizer...: 10% Heating Locked Out Fan On

Line 2 - Shows the current Economizer Damper position if

Line 3 -

Line 4 -

Status Screen #5

available.

the CVAHU has been configured to control the Economizer. (This line is blank if the CVAHU does not control the Economizer.)

No Lockouts Active Cooling Locked Out Heating Locked Out

Fan Off Fan On

Heating Stage #1 OFF Heating Stage #2 OFF Cooling Stage #1 OFF Cooling Stage #2 OFF

This screen shows how the relays were configured, either for Heating or Cooling. The first line shows the status of Relay #2, the second line shows the status of Relay #3, etc.

The message will show ON/OFF status for that relay.

3-14 Programming

Auto-Zone CV & CV-EX Section 3

Status Screen #6

CVAHU # 18 vl.xx

Zone Cooling ALARM

Line 2 -

Line 3 -

Zone Sensor O.K. Bad Zone Sensor! Zone Cooling ALARM Zone Heating ALARM

The line will show Zone Sensor OK if none of the above alarm conditions exist.

Binary Input ALARM

This line will remain blank if the contact has not closed. This input is normally used for Dirty Filter Alarms.

If no alarm conditions exist, then line 3 will display the words No Alarms!

Note: If no alarm conditions exist, then line 3 will display the words No Alarms!

Line 4 -

Mech Cooling ALARM Mech Heating ALARM

This line remains blank if no alarm condition exists.

These alarms are generated when the Supply Temperature does not change more than five degrees after a stage of heating or cooling has been activated for 30 minutes.

Programming 3-15

Section 3 Auto-Zone CV & CV-EX

CV Controller Setpoints

Line 1 displays CVAHU Setpoints message for identification only.

Setpoint Screen #1

CVAHU Setpoints Occupied Setpoints Cooling Setpt: 75°F Heating Setpt: 72°F

The Occupied Heating and Cooling Setpoints are entered on this screen. The Heating Setpoint should always be at least one degree below the Cooling Setpoint, or the CVAHU will not accept the new values.

Cooling Setpoint 50°F 75°F 90°F Heating Setpoint 50°F 72°F 90°F

Setpoint Screen #2

CVAHU Setpoints Unoccupied Setpoints Cool Setup...: 10°F Heat Setback.: -10°F

The Unoccupied Heating and Cooling Setup values are entered on this screen. The Occupied Cooling Setpoint will be increased by the Cooling Setup during Unoccupied Mode, and the Heating Setpoint will be decreased by the Heating Setback.

Cooling Setup 0°F 10°F 30°F Heating Setback 0°F -10°F -30°F

Minimum

Default

Maximum

3-16 Programming

Auto-Zone CV & CV-EX Section 3

Setpoint Screen #3

CVAHU Setpoints Slide Effect.: 3°F SP Deadband..: 1°F

If the Zone Temperature Sensor has the optional Sensor Slide Adjustment, the maximum effect it can have on the Heating

and Cooling Setpoints is programmed here.

The SP Deadband is divided in half across the current heating or cooling setpoint and is used in staging the heating or cooling on or off.

Slide Effect 0°F 3°F 5°F SP Deadband 0°F 1°F 10°F

Setpoint Screen #4

CVAHU Setpoints Cooling Stages: 2 Heating Stages: 2

The CVAHU can support a total of four stages of heating and cooling, configured to best match your system. As long as the total number of heating and cooling stages does not exceed four, you can specify any quantity between zero and four for each mode.

EXAMPLE:

The heating stages are always allocated first, starting with Relay #2 (Fan is Relay #1), and assigned sequentially up to a maximum of four heating and/or cooling stages.

Minimum

Default

3 Heating Stages (Relays #2 to #4)

1 Cooling Stage (Relay #5)

0 Heating Stages (No Relays)

4 Cooling Stages (Relays #2 to #5)

Maximum

Programming 3-17

Section 3 Auto-Zone CV & CV-EX

Setpoint Screen #5

CVAHU Setpoints Minimum On/Off Times Cool Staging: 4 Min Cooling Off : 5 Min

The cooling stages must have been off for a minimum amount of time before they can be activated or re-activated. As each additional stage of cooling is added, a minimum Staging Delay period must be satisfied between each additional stage required.

Cool Staging 1 Min 2 Min 30 Min Cooling Off 1 Min 5 Min 30 Min

Setpoint Screen #6

CVAHU Setpoints Minimum On/Off Times Heat Staging: 4 Min Heating Off : 5 Min

The heating stages must have been off for a minimum amount of time before they can be activated or re-activated. As each additional stage of heating is added, a minimum Staging Delay period must be satisfied between each additional stage required.

Heat Staging 1 Min 2 Min 30 Min Heating Off 1 Min 5 Min 30 Min

Minimum

Default

Maximum

Default Maximum

Setpoint Screen #7

CVAHU Setpoints Changeover Delay Between Heat/Cool

Modes......: 15 Min.

3-18 Programming

To prevent rapid cycling back and forth between the heating and cooling modes, the CVAHU has a programmable Changeover Delay Timer. This timer prevents a change in mode from bringing on any heating or cooling (based on last mode) until this delay is satisfied.

Normally, you do not want to change modes more than four or five times per hour.

Changeover

Minimum

Default

Maximum

1 Min 10 Min 30 Min

Delay

Auto-Zone CV & CV-EX Section 3

Setpoint Screen #8

CVAHU Setpoints Fan Mode.: Constant Economizer: Enabled Use Left/Right Arrow

Line 2 - The CVAHU can operate the fan in one of two

Line 3 - The CVAHU has the ability to control the

Setpoint Screen #9

modes:

Continuous or Constant running during occupied hours.

Cycle with heating or cooling during occupied hours.

The fan always cycles with heating or cooling during unoccupied hours. The Left/Right Arrow keys will toggle the current setting to the opposite mode.

Economizer operation. If you require this feature, select Enabled; otherwise, select Disabled.

Constant Volume Unit Uses Schedule #: 0 0 = Internal Clock 1-8 = External Clock

The CVAHU normally uses its own Real Time Clock and an Internal Week Schedule to determine the Occupied/

Unoccupied mode of operation. The CVAHU does have the ability to use a Global Broadcast from another scheduling device on the communications loop if a different schedule is required. If an external schedule is used, the range of schedule numbers is one to eight.

Programming 3-19

Section 3 Auto-Zone CV & CV-EX

Setpoint Screen #10

CVAHU Setpoints Cool Lockout.: 50°F Heat Lockout.: 65°F

The mechanical heating and cooling can be locked out from operating based on the Outdoor Air Temperature. If the Outdoor Air Temperature is above the Heating Lockout, no heating stages are allowed to activate or remain on if they are already ON. If the Outdoor Air drops below the Cooling Lockout, no cooling stages are allowed to activate or remain on if they are already ON.

Cool Lockout -40°F 50°F 90°F Heat Lockout 30°F 65°F 99°F

Setpoint Screen #11

CVAHU Setpoints Economizer Setpoints Enable Setpt.: 50°F Supply Setpt.: 55°F

If the CVAHU has been configured for Economizer Control, this screen will appear.

The Econo Enable setpoint is the Outdoor Air or Wetbulb Temperature that enables the Economizer to open past its minimum position setpoint to control Supply Air Temperature.

The Supply Setpt is the Supply Air Temperature the Economizer tries to maintain.

Enable Setpt -40°F 50°F 99°F Supply Setpt 50°F 55°F 90°F

Minimum

Default

Maximum

Setpoint Screen #12

CVAHU Setpoints Economizer Setpoints Min Position: 10 % Control Rate:. 50

3-20 Programming

The Min Econo % is the position the economizer holds during occupied mode when it is not enabled for operation due to Outdoor Air or Wetbulb Temperature.

During economizer control, the economizer damper is allowed to move open or closed, as required, at a rate controlled by this value. Use this to speed up or slow down the operation of your economizer. The larger the number, the slower the damper moves.

Minimum

Default

Maximum

Min Position 0 % 10 % 100 % Control Rate 1 50 90

Auto-Zone CV & CV-EX Section 3

Setpoint Screen #13

CVAHU Setpoints Economizer Setpoints Min Voltage: 0.0 v Max Voltage: 10.0 v

You can set the voltages required to open and close the damper. Some actuators use a 2-10 VDC signal instead of 0-10 VDC.

If the system is not configured for Economizer Control, no economizer setpoint screens will appear.

Min Voltage 0.0 VDC 0.0 VDC 10.0 VDC Max Voltage 0.0 VDC 10.0 VDC 10.0 VDC

Setpoint Screen #14

CVAHU Setpoints Fan Starting Delay Multiplier...: 10

If there are several air handling units on a system and you don’t want them to all start at the same time when going into the occupied mode or after a power outage, you can input a Fan Starting Delay Multiplier. The multiplier is multiplied times the address number of the unit and this becomes the number of seconds this unit waits before starting the fan. For example, if the Multiplier is 5 and this unit is at address #18, then the time delay will be 90 seconds.

Multiplier 0 0 30

Minimum

Minimum Default Maximum

Default

Maximum

Setpoint Screen #15

Sensor Rdg Offset ZNT.: 73.6 0.0 SAT.: 76.5 0.0 OAT.: 70.2 0.0

Programming 3-21

The Thermister Type III Sensor readings can be calibrated. Enter Positive values to increase the reading or Negative values to decrease the reading. The Outdoor Air calibration offset only applies to the CVAHU that has the sensor installed. It has no effect on the Global Broadcast value of Outdoor Air.

Minimum Default Maximum

Zone Sensor ZNT -100.0°F 0.0°F +100.0°F Supply Sensor SAT -100.0°F 0.0°F +100.0°F Outdoor Sensor OAT -100.0°F 0.0°F +100.0°F

Section 3 Auto-Zone CV & CV-EX

CV Controller Scheduling and Holidays

The Constant Volume AHU controllers contain their own built-in scheduling capability for calculating Occupied/Unoccupied periods. All schedules are entered in 24-Hour Military Format.

See the Constant Volume Menu Operations Screen for information on how to access these programming functions.

Scheduling/Holiday Menu

Constant Volume Unit

1) Week Schedules

2) Holidays MENU) Previous Menu

This menu appears whenever you access the Scheduling functions. It allows you to choose between schedules or

holidays.

Week Schedules

Start Time

WEEK SCHEDULES Sunday Start Time Value Hrs/Mins: 0 (MILITARY FORMAT)

Stop Time

WEEK SCHEDULES Sunday Stop Time Value Hrs/Mins: 0 (MILITARY FORMAT)

The screens will step through the Start Time and then the Stop Time for each day of the week. You can quit at any point in the

process by pressing the "A" key.

All times are in 24-hour format, so 5:00 PM would be entered as 1700.

If both the Start and Stop Times are ZERO, the schedule is in a Continuous OFF mode.

If both the Start and Stop Times are 2359, the schedule is in a Continuous ON mode.

Note: The second line displays which day of the week is currently being

programmed. This automatically increments as you finish the Stop Time and continues to the next Start Time screen.

3-22 Programming

Auto-Zone CV & CV-EX Section 3

Holidays

Holiday Day Selection

Program Holidays Holiday # 1 Start Mon/Day: 101 (EX: 101 = Jan. 1)

The screens will step through the eleven possible holidays one at a time. Line 2 shows which holiday is currently being programmed.

Remember to combine the month and day into a single fourdigit value.

EXAMPLE: 0704 = July 4th

1225 = December 25th

Holiday Start / Stop Times

Program Holidays Holiday Schedule Starting Time: 0 Stopping Time: 0

The eleven holidays all use the same Start and Stop time which you enter on this screen. You enter it in 24-hour military format, the same as a regular week schedule.

Programming 3-23

Section 3 Auto-Zone CV & CV-EX

Economizer Module (Wetbulb) Read/Reset Operations

If the Unit ID you entered was for the Economizer Module, the following menu will appear. Any references in this section to wetbulb are referring to the Economizer Module.

Wetbulb Menu

1) Wetbulb Status

2) Setpoints

ESC) To Exit

1) Wetbulb Status

2) Setpoints

View the current Outdoor Air Temperature, Humidity, and calculated Wetbulb Temperature.

View or change any of the available setpoints for this Economizer Module.

Wetbulb Status

WB # xx vl.xx Outdoor Air: 76.9°F Humidity...: 75 %

Wetbulb....: 71.3°F

Line 2 - Current Outdoor Air Temperature reading. The

Outdoor Air Sensor must be installed on this unit. It will not read a Global Broadcast of the Outdoor Air Temperature from another controller.

Line 3 - Current Outdoor Relative Humidity.

Line 4 - Current calculation of the Wetbulb Temperature.

3-24 Programming

Auto-Zone CV & CV-EX Section 3

Wetbulb Setpoints

WB Setpoints Calibration Offset Outdoor Air..: 77.1 Cal. Offset..: 0.0

The only setpoint available for this unit is the Calibration Offset for the Thermistor Outdoor Air Temperature Sensor. If

location or other factors are causing the Outdoor Air Temperature reading to be incorrect, you can adjust the reading up or down with this offset. Line 2 shows the current temperature when you first enter this screen, but it is not dynamically updated after the offset is changed. You will need to exit this screen and then return to this screen to see the effect of the entered offset.

Minimum

Default

Maximum

Cal. Offset -100.0°F 0.0°F 100.0°F

Programming 3-25

Section 3 Auto-Zone CV & CV-EX

System Manager Keypad Operations Summary

vX.XX 1 Friday Operations 03/20/09 09:46 AM Outdoor Air 78.0°F

1) View/Change Zone

2) View Alarms MENU) Full Access ESC) Main Screen

SYSTEM ALARM STATUS Clear Alarms? YES To Change Response Use Left/Right Arrow

SYSTEM ALARM STATUS Alarm @ Unit ID 118

1) Set Time & Date

2) Read/Reset Units

3) New Passcodes

4) Rebuild Alarm Map

Program Time/Date Day (Sunday=0): 1 Enter Hr. (0-23): 9 Enter Minutes : 53

Program Time/Date Month (1-12): 9 Day (1-31): 18 Year (00-99): 09

Enter New Passcode

Level 1.....: XXXX

Clearing Old Map

....................

................

Level 2.....: XXXX

[Must Be 4 Digits]

View/Change [ Enter Unit ID# ] Selected Unit: 101

Constant Volume Unit Temperature: 75.4°F Cooling SP.: 75°F Heating SP.: 72°F

Read/Reset [ Enter Unit ID# ] Selected Unit: 101

1) CVAHU Status

2) CVAHU Setpoints MENU) Next Menu ESC) To Exit

1) Wetbulb Status

2) Setpoints

ESC) To Exit

Daylight Savings Adjustments Enabled

Use Left/Right Arrow

Building New Map Loop: 1 Unit: 1 FOUND

Alarm Unit Map Built Press Any Key To Continue

1) Schedules

2) Force Modes

MENU) Previous Menu

3-26 Programming

Auto-Zone CV & CV-EX Section 3

Index

12-Hour Format .................................... 6

2359

Start and Stop Times....................... 22

24-Hour Format .................................. 22

24-Hour Military Format ................ 6, 22

50 to 90 Degrees ................................... 4

Address Entry

Read/Reset ...................................... 10

Addresses

Entering............................................. 3

Addressing

MiniLinks........................................ 10

Adjustments Disabled ........................... 7

Adjustments Enabled ............................ 7

AHU.................................................... 12

Alarm

Mech Cooling Alarm ...................... 15

Zone Heating Alarm........................ 15

Alarm

Address Locations............................. 5

Clearing............................................. 5

Condition .......................................... 2

Indicator ............................................ 9

LED................................................... 2

Map ................................................... 9

Polling............................................... 9

Alarms

Bad Zone Sensor ............................. 15

Binary Input Alarm ......................... 15

Clearing............................................. 5

Dirty Filter Alarm ........................... 15

Mech Heating Alarm....................... 15

Zone Cooling Alarm ....................... 15

Auto Mode .......................................... 11

Bad Zone Sensor!................................ 15

Binary Input ALARM ......................... 15

Building New Map................................ 9

Calibration Offset................................ 25

Changeover Delay Timer.................... 18

Clearing Old Map ................................. 9

Communications

LED................................................... 2

Constant Volume AHU

Operating Modes, View .................. 12

Setpoints, View or Change ............. 12

Temperatures, View........................ 12

Continuous Day Mode ........................ 11

Continuous Night................................ 11

Continuous OFF Mode ....................... 22

Continuous ON Mode......................... 22

Continuous or Constant

Fan Mode ........................................ 19

Control Rate........................................ 20

Cool Lockout ...................................... 20

Cool Staging........................................ 18

Cooling Locked Out............................ 14

Cooling Mode

CV Controller.................................. 13

Cooling Off ......................................... 18

Cooling Setpoint

CV Controller.................................. 13

Cooling Setpoints.................................. 3

Cooling Stages Setpoints .................... 17

Current Outdoor Air Temperature ...... 24

Current Outdoor Relative Humidity ... 24

Current Year.......................................... 7

CV Controller

Address ............................................. 3

Force Modes.................................... 11

Holidays .......................................... 22

Read/Reset Operations.................... 12

Scheduling....................................... 22

Setpoints.......................................... 16

Software Version ............................ 13

Status............................................... 13

CVAHU .............................................. 12

Economizer Damper ....................... 14

Force Modes.................................... 12

Schedules ........................................ 12

Setpoints.......................................... 12

Status............................................... 12

Programming 3-27

Section 3 Auto-Zone CV & CV-EX

Cycle with Heating or Cooling

Fan Mode ........................................ 19

Date

Programming..................................... 7

Day of the Month .................................. 7

Day/Night Mode ................................. 11

Daylight Savings Adjustments.............. 7

DEC....................................................... 1

Default Level 1 Passcode...................... 8

Default Level 2 Passcode...................... 8

Dirty Filter Alarm ............................... 15

Econo Enable Setpoint........................ 20

Economizer

Control Rate.................................... 20

Min Position.................................... 20

Economizer Control ............................ 20

Economizer Damper

CVAHU .......................................... 14

Economizer Module

Read/Reset Operations.................... 24

Economizer Operation

Setpoint ........................................... 19

Economizer Setpoint

Max Voltage.................................... 21

Min Voltage .................................... 21

ENTER.................................................. 1

Entering Passcodes................................ 4

External Clock .................................... 19

Fan Off ................................................ 14

Fan On................................................. 14

Fan Only Mode ................................... 11

Fan Starting Multiplier........................ 21

Force Modes

CV Controller.................................. 11

CVAHU .......................................... 12

Forced Fan Only Mode

CV Controller.................................. 13

Forced Occupied

CV Controller.................................. 13

Forced Unoccupied

CV Controller.................................. 13

Full Access............................................ 3

Full Access Menu ................................. 6

Full System Access

Menu ................................................. 6

Function

LCD/Keypad ..................................... 1

Global Broadcast................................. 19

Heat Lockout....................................... 20

Heat Staging........................................ 18

Heating Locked Out............................ 14

Heating Mode

CV Controller.................................. 13

Heating Off ......................................... 18

Heating Setpoint

CV Controller.................................. 13

Heating Setpoints.................................. 3

Heating Stages..................................... 17

Setpoints.......................................... 17

Holiday Active

CV Controller.................................. 13

Holiday Day Selection ........................ 23

Holiday Start and Stop Time............... 23

Holidays

CV Controller.................................. 23

Internal Clock...................................... 19

Internal Schedules............................... 11

Internal Week Schedule ...................... 19

Keypad Functions ................................. 1

Keypad Operations Summary ............. 26

LCD/Keypad Operations....................... 1

LED Alarm Indicator ............................ 9

LED Indicators...................................... 2

LEDs

Alarm Condition ............................... 2

Communications ............................... 2

Transfers ........................................... 2

LEFT/RIGHT........................................ 1

Level 1 User...................................... 3, 8

Level 2 User...................................... 3, 8

Main Screen ...................................... 2, 3

Main User Menu ............................... 2, 3

Max Voltage........................................ 21

Mech Cooling ALARM ...................... 15

Mech Heating ALARM ...................... 15

MENU................................................... 1

Menu Items

Full Access........................................ 3

Main Screen ...................................... 3

View Alarms ..................................... 3

3-28 Programming

Auto-Zone CV & CV-EX Section 3

View/Change..................................... 3

View/Change Zone ........................... 3

Menus

Full System Access ........................... 6

Holiday Day Selection .................... 23

Scheduling/Holiday......................... 22

Week Schedules .............................. 22

Wetbulb........................................... 24

Min Econo % ...................................... 20

Min Position........................................ 20

Min Voltage ........................................ 21

MiniLinks

Addressing ...................................... 10

MINUS.................................................. 1

Month.................................................... 7

Neutral Mode

CV Controller.................................. 13

New Passcodes...................................... 8

No Alarms........................................... 15

No Lockouts Active ............................ 14

Occupied Cooling

Setpoints.......................................... 16

Occupied Heating

Setpoint ........................................... 16

Occupied Mode................................... 11

Operating Modes................................. 11

Outdoor Air Calibration Offset........... 21

Outdoor Air Sensor ............................. 24

Outdoor Air Temperature.................... 25

CV Controller.................................. 14

Outdoor Relative Humidity................. 24

Outdoor Sensor OAT .......................... 21

Passcodes

Entering............................................. 4

Entering New .................................... 8

Polling

for Units ............................................ 9

Powerup ................................................ 9

Programming

Passcodes .......................................... 8

Programming Date ................................ 7

Programming Time ............................... 6

Push-button Override

CV Controller.................................. 13

Read/Reset

Address Entry.................................. 10

Read/Reset Capabilities ........................ 3

Read/Reset Operations

CV Controller.................................. 12

Economizer Module........................ 24

Wetbulb........................................... 24

Read/Reset Units................................. 10

Real Time Clock ................................. 19

Real Time Clocks.................................. 6

Rebuild Alarm Map .............................. 9

RS-485 Communications Plug.............. 9

Schedules

CVAHU .......................................... 12

Start Time........................................ 22

Stop Time........................................ 22

Scheduling

CV Controller.................................. 22

Scheduling/Holiday Menu .................. 22

Screens

Alarm Address Locations.................. 5

Clear Alarms ..................................... 5

Constant Volume Status.................... 4

CV Controller Force Modes............ 11

Entering Passcodes............................ 4

Full System Access ........................... 6

Holiday Day Selection .................... 23

Main .................................................. 2

New Passcodes.................................. 8

Read/Reset Units............................. 10

Rebuild Alarm Map .......................... 9

Scheduling/Holiday......................... 22

Set Time & Date ............................... 6

View Alarms ..................................... 5

View/Change Zone ........................... 3

Week Schedules .............................. 22

Wetbulb........................................... 24

Sensor Slide Adjust

CV Controller.................................. 13

Sensor Slide Adjustment..................... 17

Set Time & Date ................................... 6

Programming 3-29

Section 3 Auto-Zone CV & CV-EX

Setpoints................................................ 2

Cooling.............................................. 3

CV Controller.................................. 16

Heating.............................................. 3

Wetbulb..................................... 24, 25

Setpoints, Entering

Changeover Delay Timer................ 18

Cooling Lockout ............................. 20

Cooling Stages ................................ 17

Economizer Control ........................ 20

Economizer Operation .................... 19

Fan Mode ........................................ 18

Fan Starting Multiplier.................... 21

Heating Lockout.............................. 20

Heating Stages................................. 17

Min Econo % .................................. 20

Occupied Cooling ........................... 16

Occupied Heating............................ 16

Sensor Slide Adjustment................. 17

Slide Effect...................................... 17

SP Deadband................................... 17

Staging Delay Period....................... 18

Staging Delay Period, Heating........ 18

Unoccupied Cooling Setup ............. 16

Unoccupied Heating Setback.......... 16

Slide Effect Setpoint ........................... 17

Software Version

CV Controller.................................. 13

SP Deadband Setpoint......................... 17

Staging Delay Period

Cooling............................................ 18

Heating Stages................................. 18

Start and Stop Times

2359................................................. 22

Zero ................................................. 22

Start Time............................................ 22

Status..................................................... 2

Wetbulb........................................... 24

Stop Time............................................ 22

Summary

Keypad Operations.......................... 26

Supply Air Temperature

CV Controller.................................. 14

Supply Sensor SAT............................. 21

Supply Setpt........................................ 20

System Manager

Keypad .............................................. 1

Keypad Operations Summary ......... 26

Temperature

50 to 90 Degrees ............................... 4

Setpoints............................................ 4

Wetbulb........................................... 24

Thermister Type III Sensor ................. 21

Thermistor Outdoor Air Temperature

Sensor.............................................. 25

Time

12-Hour Format ................................ 6

24-Hour Military Format ............ 6, 22

Continuous OFF Mode ................... 22

Continuous ON Mode..................... 22

Daylight Savings............................... 7

Programming..................................... 6

Real Time Clocks.............................. 6

Transfers

LED................................................... 2

Unit

Polling............................................... 9

Unit ID .................................................. 3

Unoccupied Cooling Setup Setpoint... 16 Unoccupied Heating

Setback Setpoint.............................. 16

Unoccupied Mode

CV Controller.................................. 13

Unoccupied Mode............................... 11

UP/DOWN............................................ 1

View Alarms ......................................... 3

View Alarms Screen ............................. 5

View/Change......................................... 3

View/Change Zone ............................... 3

Week Schedules .................................. 22

Wetbulb

Read/Reset Operations.................... 24

Menu ............................................... 24

Setpoints.................................... 24, 25

Status............................................... 24

Wetbulb Temperature ......................... 24

CV Controller.................................. 14

Zero

Start and Stop Times....................... 22

Zone Cooling ALARM....................... 15

3-30 Programming

Auto-Zone CV & CV-EX Section 3

Zone Heating ALARM ....................... 15

Zone Sensor O.K................................. 15

Zone Sensor ZNT................................ 21

Zone Temperature................................. 3

CV Controller.................................. 13

Programming 3-31

Section 3 Auto-Zone CV & CV-EX

Notes

3-32 Programming

Section 4

Table of Contents

Communications Overview.............................................. 1

How It Works...................................................................................................................1

CV System .......................................................................................................................2

CV-EX System.................................................................................................................3

CommLink IV..................................................................................................................4

CommLink IV DIP Switch Setting ..................................................................................5

MiniLink ..........................................................................................................................6

System Manager...............................................................................................................7

CV Controller Communications ......................................................................................8

CV Controller Address Switches ....................................................................................9

CV and CV-EX System Communications Checklist.....................................................10

CV Controller Overview ................................................. 11

How It Works.................................................................................................................11

CV Controller Inputs & Outputs....................................................................................12

CV Controller Wiring ....................................................................................................14

Startup & Commissioning.............................................. 15

Procedures......................................................................................................................15

CV & CV-EX Worksheet ..............................................................................................17

Troubleshooting............................................................. 18

General Communications...............................................................................................18

Blink Codes....................................................................................................................19

Communications Loops .................................................................................................20

CV Controller.................................................................................................................32

Room Sensor..................................................................................................................33

Driver Chip Replacement ..............................................................................................35

Index .............................................................................. 37

Start-Up & Troubleshooting

Section 4

Table of Figures & Tables

Figure 4-1: CV System Communications Wiring .........................................................2

Figure 4-2: CV-EX System Communications Wiring...................................................3

Figure 4-3: CommLink IV Wiring.................................................................................4

Figure 4-4: CommLink IV DIP Switch Setting .............................................................5

Figure 4-5: MiniLink Wiring and Addressing...............................................................6

Figure 4-6: System Manager Component Location & Wiring ......................................7

Figure 4-7: CV Controller Component Locations.........................................................8

Figure 4-8: CV Controller Addressing..........................................................................9

Figure 4-9: Typical CV Controller Wiring Diagram...................................................14

Table 4-1: Diagnostic LED Blink Codes.....................................................................19

Table 4-2: Temperature Sensor Resistance .................................................................34

Figure 4-10: Driver Chip Locations............................................................................35

Figure 4-11: General Chip Replacement Procedures .................................................36

Start-Up & Troubleshooting

Auto-Zone CV & CV-EX Section 4

Communications Overview

Perhaps no other portion of the system seems as difficult to diagnose as the communications loop, yet it really can be quite simple if you understand how it works. In fact, much of the troubleshooting can be done by simple observation. We will lead you through the system functions and then provide you with detailed instructions for checking each piece of equipment.

How It Works

Auto-Zone uses a token-passing loop architecture, which means in simple terms that an “electronic message” called a token is passed from controller to controller in a roundrobin fashion. A controller must wait to receive the token before it can send or request any data. Only one device on each loop is capable of sending the token, and this device is considered the loop master. The loop master varies depending on the type of system and the installed options. For the CV system, the loop master is the CommLink. The CommLink must be connected to the system or the communications will not function. For the CV-EX system, the Local Loop master for the CV controllers is the MiniLink, and the Network Loop master is the CommLink.

Note: It is very important to know which device is the loop master on the loop you are

troubleshooting.

In order for the loop master to communicate with the various devices on that loop, each must have a unique address. With the CV or CV-EX system, each CV controller on the local loop must have its own address from 1 to 30. For the CV system, this is all that is required. For the CV-EX system, in addition to each CV controller being addressed, the MiniLink on each local loop must have its own unique address between 1 and 4. Please see Figure 4-5 for address switch setting information.

Start-Up and Troubleshooting 4-1

Section 4 Auto-Zone CV & CV-EX

CV System

The standard CV system has only one communications loop. If you are using the CV-EX System (for systems with more than 30 CV Controllers), please see the next page - CV- EX System. The CommLink IV is always the master on the CV system loop. You must be sure the CommLink IV is connected and functioning if you are troubleshooting the communications loop. The CommLink IV jumper switch must be set for single loop operation when used with the CV system. See Figure 4-1 for communications wiring connections and Figure 4-4 for jumper switch settings.

CV ControllerCV Controller

System Manager

The System Manager Can Be

Connected Anywhere

On The Loop

CV Controller

CommLink IV

The CommLin k IV Is R equired Fo r

All Systems. The IP Module,

Remote Link II, And Computer Are

Optional On All Systems. All

Computers Require Installation of

Prism Graphical User Interface

Software

Ethernet Cable To Router

All Components Shown Inside This Box Are Optional

End Of Loop

The Comm Loop

Routing Does Not

Have To Follow

The Board Address Sequence

USB Cable To Computer

Loop Start

Optional IP Module

Installs Into CommLink IV

And Provides LAN And Internet

Communicati ons

With The Control System

Ethernet Rout er

(By Others)

When IP Module

Option Is Used

Computer

(Optional)

Comm Loop

RS-485

9600 Baud

Serial Cable To Remote Link

Phone Cable To Telephone Wall Outlet Jack

Optional Remote Link II

Connects to CommLink IV And

Provides Alarm Call-Outs. A

Second Remote Link Is Required If

Connection To Job Site Is Desired

From Remote Computer.

CV Controller

Figure 4-1: CV System Communications Wiring

4-2 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

CV-EX System

See Figure 4-2. The CV-EX system has two types of communications loops. The loops which the CV controllers are connected to are called the Local Loops. The MiniLink is always the loop master on the CV-EX local loop. You must be sure the MiniLink is connected, powered up, and functioning if you are troubleshooting a Local communications loop. The other type of loop on the CV-EX system is called the Network Loop. This loop connects all the MiniLinks together and then ties into the CommLink IV which is the Network Loop Master. The CommLink IV jumper switch must be set for multiple loop operation when used with the CV-EX system. See Figure 4-4 for the correct jumper switch setting.

CV ControllerCV Controller

System Manager

The System Manager Can Be

Connected Anywhere

On The Local Loop

CV Controller

CommLink IV

The CommLink I V Is Required For

All Systems. The IP Module,

Remote Link II , And Computer Are

Optional On All Systems. All

Computers Require Installation of

Prism Graphica l User Interface

Software

Ethernet Cable To Router

All Components Shown Inside This Box Are Optional

USB Cable To Computer

Ethernet Router

(By Others)

When IP Module

Option Is Used

Network Loop Start

Optional IP Module

Installs Into CommLink IV And

Provides LAN And Inter net

Communications

With The Control System

Remote Link Is Requi red If Connection To

Job Site Is Desired From Remote Computer.

End Of Local Loop

The Comm Loop

Routing Does Not

Have To Follow

The Board Address Sequence

Computer

(Optional)

Serial Cable To Remote Link

Phone Cable To Telephone Wall Outlet Jack

Optional Remote Link II

Connects to CommLink IV And

Provides Alarm Call-Outs. A Second

Connect To Network Loop Connection On Next MiniLink

Network Loop

RS-485

19200 Baud

Local Loop

RS-485

9600 Baud

MiniLink

Local Loop Start

CV Controller

Figure 4-2: CV-EX System Communications Wiring

Start-Up and Troubleshooting 4-3

Section 4 Auto-Zone CV & CV-EX

CommLink IV

As previously described, the CommLink is the Local Loop Master for the CV system and the Network Loop Master for the CV-EX system. For both systems to function, the CommLink must be set to the correct operation mode by setting the correct jumper position on the CommLink board. Also, the CommLink communications must be wired correctly to the system and connected correctly to the computer (if used) and Remote Link II. It must also be powered up in order for either system to communicate. See Figure 4-3 for information.

USB Switch Should Be Set To No rm al

ommLink IV

Communications Interface

10/100

ETHERNET

DIAG

ACT LNK

Optional Items Not Required For CommLink Only Installations

Notes:

1) Use 18-Gauge Minimum, 2-Conductor Twisted Pair With Shield Cable Belden #82760 Or Equivalent (Not Included) To Connect The CommLink IV To The MiniLink On Network Loop Or Controller Or System Mana

Installation Technical Guide Form: WM-CLIV-TGD

3) The CommLink IV Cannot Communicate With The Control System Through Its Ethernet Port And USB Port At The Same Time.

4) All Wiring Must Conform To Applicable Federal, State & Local Electrical Wiring Codes.

USB Cable (Included). Connect This Cable To Your Computer USB Port For Directly Connecting To CommLink IV. Also Used For Advanced Configuration of CommLink IV.

Molded Modem Cable. Part #HZ000098 Supplied With RemoteLink II

Connect To A 10/100 Base-T

If A Longer

COMPUTER

Normal

Config

USB

When An Optional Remote Link Is Used, Connect This Cable To CommLink IV And Remote Link As Shown. Cable Is Included With Remote Link.

Which Is Supplied With The CommLink IV.

USB

MODEM

RS-232

Female

25 Pin

Male

TGR

485 LOOP

9Pin

Serial #

GND

24V

POWER

24 VAC Power

18-Gauge, 2-Conductor With Shield (Not Included)

Connect To The Controller Or System Manager On Local Loop Or MiniLink On Network Loop. See Note 1.

120 to 24 VAC Power Pack (Included) Connect To 120/1/60 Duplex Receptacle (By Others)

If Desired A 24 VAC Transformer Included)

Rated At 12 VA Minimum May Be Used Instead Of The Supplied Power Pack. Use 18 Gauge Minimum 2 Conductor Wire Between The Transformer & CommLink IV Terminals.

WARNING!

With Your CommLink, Do Not Have Your Ethernet Connection And USB Connection Connected At The Same Time. This Could Cause Unreliable Communications.

If You Are Using The IP Module

(Not

er On Local Loop.

Figure 4-3: CommLink IV Wiring

4-4 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

CommLink IV DIP Switch Setting

CommLink IV Communication Settings

The DIP Switch Setting Should Be Set To “Multiple”

SW1

For The Auto-Zone System

Replace The CommLink IV Cover And Secure The Enclosure Halves Back Together With The (2) Enclosure Screws That Were Previously Removed.

CV-EX .

WattMaster Controls Inc. COMMLINK IV YS102074 REV6

MADE IN USA

ALTERA EPM3032

DIP Switch 1 & 2 Off = Multiple Loop Communications Required Setting For Auto-Zone CV-EX System

Figure 4-4: CommLink IV DIP Switch Setting

Start-Up and Troubleshooting 4-5

Section 4 Auto-Zone CV & CV-EX

MiniLink

The MiniLink communications interface is only required when you are installing a CVEX system. It is not required for the CV system. Its address switch must be set correctly, it must be correctly wired into the system, and it must be powered up in order for the CVEX system to operate correctly. The address switches must be set and the power cycled in order for the address to be recognized by the system. See Figure 4-5 for MiniLink wiring and addressing.

onnect To Next

MiniLink And/Or

CommLink On

Network Loop

RS-485

19200 Baud

(See Note 3).

All Communication Loop

Wiring Is Straight Through

Local Loop

RS-485

9600 Baud

(See Note 3).

MiniLink Communications Interface

ADD

NETWORK

OFF >

24VAC

LOOP

GND

24VAC

GND

Required VA For Transformer

MiniLink = 10VA Max.

See Note 1.

Line Voltage

Connect To CV

Controller or

System Manager

On Local Loop

Notes:

1.) 24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.) All Wiring To Be In Accordance

With Local And National Electrical Codes And Specifications.

3.) All Communication Wiring To Be

2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

Caution!

The MiniLinks Must Have Address Switc hes Set Between 1 And 4 (Up To 4 MiniLinks Are Allowed Per CV-EX System). The MiniLinks Should Be Addressed In C onsecutive Order Starting With Address #1. Address #1 Must Be Present On The Loop For The System To Function.

Note:

The Power To The MiniLink Must Be Removed And Reconnected After C hanging The Address Switch.

Caution:

Disconnect All Communication Loop W iring From The MiniLin k Before Removing Power From The MiniLink. Reconnect Power And Then Reconnect Communicat ion Loop Wiring.

Address Switch Shown Is

Set For Address 1

Must Be Unique To The Other MiniLinks

On The Network Loop. Loop #1 MiniLink

Loop #2 MiniLink Should Be Addressed

ADD

1 2 4

8 16 32

MiniLink Address Switch

The Address For Each MiniLink

Should Be Addressed As #1

As #2 Etc.

These Switches Must Be In The OFF Position As Shown

Address Switch Shown Is

Set For Address 4

Figure 4-5: MiniLink Wiring and Addressing

4-6 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

System Manager

The System Manager is the central operator interface for the CV or CV-EX system. It must also be connected correctly to the communications loop in order to view the system status and configure or change setpoints. It must be supplied with 24 VAC power in order to operate. The System Manager does not require addressing. The System Manager is always connected to the “Local” loop. For the CV system, this is the only loop on the system. The System Manager can be connected anywhere on the CV communications loop. In contrast, the CV-EX has two types of loops—the “Network” and “Local” loops.

The System Manager must be connected to the local loop on the CV-EX system. It will not function correctly if connected to the network loop! See Figure 4-6 for wiring and

component location information for the System Manager.

03/20/09 06:38PM FRI

OCCUPIED

NO ALARMS

System Manager

Required VA For Transformer

System Manager = 25VA Max.

Line Voltage

See Note 1

System Manager

Base

Top

CX1

SYSTEM MANAGER

LD1

YS101806 REV. 1

74HC259

GND

24VAC

LD2

LD3

LD4

LD5

LD6

RN1

LD7

LD8

The Ideal Recommended Locat ion For The System Manager Is As The First Device On The Local Loop. The System Manager May Be Connected To The Local Loop At Any Point On The Local Loop.

Notes:

1.) 24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.) All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

PCB80C552-5-16WP

DfD9722V7Y

442860=2/5

C2C1

74HC573

CX7

CX9

V62C518256L-70P

CX13

SS0017 vx.xx 1234

U13

UNIVERSAL SMART DISP. UNIT

DSPY1

EWDOG

PHILIPS

CX4

RN2

CX8

74HC573

CX5

24C128

CX6

8583

SC1

RAM

TB1

EPROM

R10

CX3

82B715

PJ1

R12

24VAC

CX12

SHLD

GND

TB2

U12

C11

75176

RS-485

MADE IN

COMM

THE USA

SERIAL #

3.) All Communication Wiring To Be

2-Conductor Twisted Pair With Shield. Use Be lden #82760 Or Equivale nt.

DSPY1

SERIAL # :

RV1

See Note 3

VAR1

470uF50v

U10

MC34064A

U11

9936

R11

1000uF10v

CX10

74HC923

For CV Systems, Connect To Any CV Controller On The Local Loop Or To The CommLink. For The CV-EX System, Connect To Any Controller On The Local Loop Or To The Local Loop Terminal On The MiniLink.

Do Not Connect To The Network Loop On CV-EX Systems!

Figure 4-6: System Manager Component Location & Wiring

Start-Up and Troubleshooting 4-7

Section 4 Auto-Zone CV & CV-EX

Typical

CV Controller Communications

One CV controller is required for each Constant Volume AHU unit to be connected to the system. As with the communications devices on the system described previously, it must be wired correctly, and it must be connected to 24 VAC power for the system to function. Each controller must also be addressed correctly. Improper addressing is one of the most common mistakes made when installing a CV or CV-EX system. If duplicate addresses are assigned on the same loop, fluctuating readings will occur. First, one controller’s setpoints and status will be passed and then the other. This can be a very frustrating error to find. Another common mistake is flipping (reversing) of the T and R wires on the communication loop between controllers or other communications devices. Always be sure to double-check all communication wiring and addressing before initial commissioning of the system. It is much easier to set the address switch on a controller prior to installation than after it is installed in a ceiling or rooftop unit control panel. The address switches must be set and the power cycled in order for the address to be recognized by the system. Please see Figure 4-7 and Figure 4-8 for CV Controller component location and addressing information.

CPU Chip

RS-485 Communications Ter mi na l B loc k

Pin 1 Indicator

RAM Chip

EPROM Chip

PAL Chip

RS-485 Communications Driver Chip

Communications LED

Power LED

Diagnostic Blink Code LED 1

Diagnostic Blin k Code LED 2

Relay Output Ter min als

Address Switch

Real Time Clock Chip

24 VAC Power Input Ter min al

Figure 4-7: CV Controller Component Locations

4-8 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

CV Controller Address Switches

CV Controller Address Switch SettingCV Controller Address Switch Values

Switch Shown Is

Set For Address 5

ADDRESS ADD

Note:

1.) Ignore Any Markings On The Switch Body.

2.) Use The Address Charts Below Or Address Switch

3.) Power To Controller Must Be Turned Off And

SW1

Value Table Above To Determine Correct Switch Setting.

Back On In Order For Switch Settings To Take Effect.

Address Switch Values Are Not Labeled On The CV Controller Use The Table Below

Address Switch Values

1 2

16 32 (Always OFF- Not Used) TOKEN (Always OFF) NETWORK (Always ON)

Address Switch Setting Chart For CV Controllers

ADDRESS ADD

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1

Address Switch Shown Is

Set For Address 9

Address Switch Values Are Added Together When The Rocker Is Pushed Down In The Direction Of The “ADDRESS ADD” Arrow Marked On The CV Controller Circuit Board

ADDRESS

ADD

Controller Address Switch

ADDRESS

SW1

Address Switch Shown Is

Set For Address 30

ADD

SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1

29 30

SW1 SW1 SW1 SW1 SW1

Figure 4-8: CV Controller Addressing

Start-Up and Troubleshooting 4-9

Section 4 Auto-Zone CV & CV-EX

CV and CV-EX System Communications Checklist

CV & CV-EX Systems

 CV Units on each loop are correctly addressed from 1 to 30  Power has been cycled after changing addresses  There are no duplicate addresses on the loop  CommLink is connected to the communications loop  All CV Controllers are connected to the communication loop  System Manager is connected to the communications loop  All communication wiring is landed correctly, T to T, R to R, and SHLD to SHLD  CommLink is set for single loop operation (on CV System)  CommLink is set for multiple loop operation (on CV-EX System)  CV Controllers are wired to 24 Volt AC power supply  CommLink is wired to 24 Volt AC power supply  All 24 VAC power wiring is landed correctly—24VAC to 24VAC and GND to GND  CommLink is powered up  CV Units are powered up  System Manager is powered up

Additional Checks for the CV-EX System

 MiniLinks are correctly addressed from 1 to 4  MiniLink Power has been cycled after changing addresses  There are no duplicate addresses on the loop  All CV Controllers are connected to a Local communications loop  CommLink is connected to the Network communications loop only  System Manager is connected to one of the Local communications loops

Optional Equipment

 Personal computer is correctly connected to the CommLink  Prism™ software installed on personal computer  Remote Link II is correctly connected to the CommLink  Remote Link II connected to a working phone line  IP Module is correctly installed in the CommLink  IP Module’s Ethernet cable is connected to router

4-10 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

CV Controller Overview

How It Works

Initialization

On system power-up, the COMM LED remains extinguished for five seconds. After this delay, the COMM LED will blink out the address of the controller (Address Switch Setting). The COMM LED will then extinguish for another five seconds and then begin to blink for a twenty second startup delay. At the conclusion of this twenty second period, the COMM LED will begin blinking a diagnostic code every ten seconds. See the Blink Code section of this manual. The duration of a power-up initialization sequence is roughly one minute.

During this initialization period, the controller retrieves all operating setpoints from its non-volatile EEPROM memory and initializes all outputs to an OFF condition.

Operating Summary

At all times, after the conclusion of the initialization sequence, the CV controller performs a specific set of operating instructions in the following order: (1-7 repeat continuously)

1. Reads Analog Inputs for Temperatures and Overrides.

2. Checks the RS-485 communications port for any new setpoints from the System Manager and keeps the status updated for the System Manager.

3. If the push-button override is active, it checks the timer to see if the override is finished.

4. Calculates the current occupied/unoccupied mode from its internal week scheduling.

5. Calculates what state the output relays and analog output should be set to.

6. Updates the diagnostic COMM LED blinking.

7. Stores data in the internal trend log if ready for another log.

Start-Up and Troubleshooting 4-11

Section 4 Auto-Zone CV & CV-EX

CV Controller Inputs & Outputs

24 VAC Power Connector

This connector provides power to the CV Controller.

24VAC - The “hot” side of the control transformer.

GND - The grounded side of the control transformer. If the secondary of the con-

trol transformer is not grounded, you must still observe polarity if the transformer powers any other device!

Warning: Connect only the GND terminal to the grounded side of a transformer.

Failure to properly observe polarity will result in damage to the system.

Observe polarity at all points in the system.

Analog Input Descriptions

Input #1 - Space temperature is read on this input. If the room sensor with override is installed, the input is also monitored for push-button override commands. The pushbutton is only active during unoccupied hours, so a push during occupied hours has no effect.

Input #2 - This input is only used if a space temperature sensor that has the slide adjust option is installed. The slide adjust can be used to offset the current heating and cooling setpoints.

Input #3 - Supply air temperature is read on this input. The supply air reading is used to detect equipment failure. Once a heating or cooling stage has activated, the supply air has thirty minutes to change by 5°F or the controller assumes a mechanical failure has occurred. The supply air also prevents cooling stages from activating if the temperature is 45°F or lower in the cooling mode and prevents heating stages from activating if the temperature is 140°F or higher in the heating mode.

Input #4 - Outdoor air temperature is read on this input. If you have more than one CV controller installed on the RS-485 communication loop, only one controller needs this sensor. The unit that has this sensor will automatically broadcast the outdoor air temperature to all other controllers on the loop.

Input #5 - This input can be used to monitor an alarm contact closure. If the contact is closed, the alarm is active.

4-12 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

Note: All temperature sensors must be Thermistor Type III which provides 77°F @

10K Ohms Resistance.

Analog Output Description

Analog Output - This output is used to control the Outdoor Air Damper if you configure the unit for Economizer control. The output voltage range is user-programmable to cover all types of proportional actuators. 0 - 10 VDC, 2 - 10 VDC outputs are possible.

Relay Output Descriptions

Output #1 - Main Fan ON/OFF Control

Output #2 - Mechanical Heating / Cooling Stage #1

Output #3 - Mechanical Heating / Cooling Stage #2

Output #4 - Mechanical Heating / Cooling Stage #3

Output #5 - Mechanical Heating / Cooling Stage #4

Any combination of heating and cooling stages may be configured during setup as long as the required number of outputs does not exceed four.

RS-485 Communications Connector

This connector provides the connection point for the Local Loop RS-485 communications loop. The wiring consists of a twisted pair of wires with a shield.

T - RS485 (+) Communications terminal

SHLD - Common return wire, this point is internally tied to GND on the

CV Controller.

R - RS485 (-) Communications terminal

Start-Up and Troubleshooting 4-13

Section 4 Auto-Zone CV & CV-EX

CV Controller Wiring

CV Controller

2 4

32 TOKEN

NETWORK

Line Voltage

RELAY

OUTPUTS

COM1-3

COM4-5

GND

24VAC

4.) Only One Outside Air Sensor Is Required Per System. It May Be Connected To Any CV Controller On The System. If The Wetbulb Module Is Used, The OA Sensor Must Be Connected To The Wetbulb Module.

Constant Volume Unit Connections

R (24VAC) G (Fan-On/Off) Wx or Yx (Htg or Clg Stage x) Wx or Yx (Htg or Clg Stage x) Wx or Yx (Htg or Clg Stage x) Wx or Yx (Htg or Clg Stage x)

TB2

Required VA For Transforme r

Each CV Controller = 20VA Min.

TB1

GND

24VAC

See Note 1 & 2

Line Voltage

Connect To

Next Controller

MiniLink On

Local Loop

Room Sensor

NORMAL

OVR

Mount In HVAC

Unit Supply

Tem p. Sens or

And/Or

A R M E R C O O L E R

Discharge Air Temp.

Sensor

Air Duct

Switch Supplied

By Others

Auxiliary Alarm

Outside Air

(See Note 4)

All Comm Loop Wiring Is

Straight Thru

Local Loop

RS-485

9600 Baud

TMP

GND

AUX

Connection To AUX Terminal is Reqd Only When Sensor Is Specified With Slide Adjust Option

Input

Y 3 + 2

COM 1

Economizer

Actuator

(Belimo Shown)

Consult Factory For

Other Manufacturers

Wiring Connections

T SHLD R

+VDC

AIN 1 AIN 2 AIN 3 AIN 4 AIN 5 GND GND AOUT

TB3

EXPANSION T'STAT

24VAC

GND

See Note 1 & 2

Notes:

1.) 24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.) All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

3.) All Communication Wiring To Be 2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

Figure 4-9: Typical CV Controller Wiring Diagram

4-14 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

Startup & Commissioning

Commissioning the system correctly is one of the most important steps in getting a system installed and functioning with the least amount of problems and in the shortest length of time.

Procedures

The following is a list of items and reminders that are essential to the successful commissioning of your system. Some of these items have already been discussed in this manual and are repeated to confirm correct procedures. Familiarize yourself with this installation manual and the system wiring diagrams before installing!

1) Check to see if you have all of the correct components for your installation.

2) Establish the location for the CommLink Interface first. This is where your

communication cable will begin for the CV & CV-EX systems.

3) Lay out your communication wiring per the instructions in the previous

portion of this manual. For CV Systems, it is only one loop. For CV-EX Systems, there are two communication loops:

4) The Network Loop - This loop originates at the CommLink and interconnects

MiniLinks together.

5) The Local Loop – This loop originates at the MiniLink. All controllers and the

System Manager are connected to this loop.

6) Tip: Using the Auto-Zone color-coded and labeled Communication Cable

ensures a quality installation. It also makes your installation much easier and makes it less likely that your system will have communications wiring errors!

7) Always refer to the CV and CV-EX Wiring Diagrams for specific wiring

details. Communication cable must always be shielded – no exceptions!

8) Mount controllers in appropriate locations according to their operating

specification.

9) Use the CV and CV-EX Worksheets included in the back of this section or the

ones included with the submittal package to document unit location, descriptions, addressing, and setup. Address controllers according to location and addressing instructions located in this system manual.

Start-Up and Troubleshooting 4-15

Section 4 Auto-Zone CV & CV-EX

Procedures (Continued)

10) With no power connected, wire controller according to wiring diagrams and

in accordance with local codes. Never apply power until you have completed these procedures in accordance to all system instructions.

11) After completing all wiring connections, unplug the terminals for power and

communications. Always unplug the communications loop first and then the power. When reconnecting the wiring, connect the power first and then the communication loop.

12) Repeat Steps 8 through 11 until all devices have been wired and the power

and communication terminals have been unplugged.

13) Install the CommLink and power it up. At this point, you are ready to begin

commissioning of the system. It is preferred, though not necessary, to use a PC with Prism™ software installed to assist in the commissioning process. If you are not using a PC, the System Manager is required to be connected and powered up in order to communicate with the system.

14) For the CV system, start with the first CV controller on the communication

loop. Plug in the Communication terminal and then plug in the Power terminal. With the CV-EX multiple loop system, start with the MiniLink. Plug in the Communication terminal and then plug in the Power terminal. With the CV-EX system, confirm correct addressing of the MiniLink by verifying its blink code. Then connect the first CV controller on that local loop and proceed to the next step.

15) Check the CV Controllers for correct communications and addressing by

observing the LED indicator for the blink codes as outlined in the trouble shooting section of the manual. The blink code will first verify the address and then the operation. If the address is incorrect, reset the address switch, and then reapply power to the controller.

16) After each controller is connected and completes its initialization sequence,

use the PC or System Manager to verify communication to that device. If you cannot communicate, verify wiring, voltages, etc. in accordance with the trouble-shooting section in the system manual. Do not proceed to the next device until you are properly communicating with the current device.

17) Continue this process for each CV Controller on the loop and repeat the

process on each loop for the CV-EX system until all controllers are connected and properly communicating.

Remember that each controller only contains one puff of smoke. Making sure that all wiring terminations and voltages are correct prior to applying power to a controller will ensure that you don’t use that one puff up.

4-16 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

CV & CV-EX Worksheet

Project: ___________________________ Location ___________________________

Stages of Cool: ___ Stages of Heat: ___ Gas Electric Economizer Yes No 

Loop: 1 2 3 4 Remote Link Installed Yes  No  Phone No. ___________

Unit

Unit Description or Location Sensor Type

Address

1 2

[S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint Adj.

S  SO  SA  SOA  S  SO  SA  SOA 

Start-Up and Troubleshooting 4-17

Section 4 Auto-Zone CV & CV-EX

Troubleshooting

The following is a guide to assist in troubleshooting the CV and CV-EX systems. It is provided as a systematic approach to determining and resolving common system problems.

General Communications

No CV Units are communicating

 Is the CommLink connected and plugged in?

 For the CV System, is the CommLink jumper set for single loop operation? See

Figure 4-4.

 For the CV-EX System, is the CommLink jumper set for multiple loop operation?

See Figure 4-4.

 Are Comm Loop voltages correct? See the Comm Loop troubleshooting section.

 Is the Comm Loop open or shorted?

 Are the CV Controller address switches set correctly? See Figure 4-8.

 Are the CV Controllers powered? Check 24 VAC to the controllers. The PWR

LED should be lit.

 Is the Communications Loop shorted? Check Comm Loop voltages.

 Is the System Manager connected to the Communications Loop?

Some CV Units are communicating, but others are not

 Are the CV Controller address switches set correctly? See the addressing chart

(Figure 4-8.)

 Are the CV Controllers powered? Check 24 VAC to the controllers. The PWR

LED should be lit.

 Is the COMM LED on the missing CV Controller “flickering”? See Figure 4-7

for location of the COMM LED.

 Is the LED2 on the CV Controller blinking an error code? See the Blink Code

chart on the next page.

 Are Comm Loop voltages correct at the missing unit? See the Comm Loop

troubleshooting section.

4-18 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

Blink Codes

The CV Controller uses LED2 to indicate various diagnostic conditions during powerup and operation. Starting with power up, the LED blink codes are as follows:

• Off for five seconds

• LED2 blinks the board address (Address 14 = 14 blinks)

• Five second pause

• Twenty second time delay – LED2 blinks twenty times

• Status code is repeatedly blinked every ten seconds to indicate controller

status:

Priority No. of Blinks Status

Lowest 1 Normal Operation

- 2 Override Active

- 3 Bad Zone Sensor

N/A 4 Not Used for this System

Highest 5 Communication Failure

Table 4-1: Diagnostic LED Blink Codes

Only the highest priority failure code will be shown. You must correct the highest priority alarm before other problems will be indicated.

Start-Up and Troubleshooting 4-19

Section 4 Auto-Zone CV & CV-EX

Communications Loops

Checking CommLink Local Loop – CV

Diagram

CommLink IV

DIAG

T-To-G

+2.0 VDC

+4.0 VDC

Set Your Meter

To Read DC Volts

R-To-G

+2.0 VDC

+4.0 VDC

10/100

ETHERNET

ACT LNK

Config

USB

COMPUTER

USB

Normal

MODEM

RS-232

485 LOOP POWER

TGR

Serial #

24V

GND

To 2 4 VA C

Power Supply

To Zone Manager Network Loop

The CommLink IV Must Be

Powered Up For These Tests

Overview

This test checks for proper loop voltages at the CommLink IV.

Tip:

The Loop LED (located on the front panel) should “flicker” when the CommLink IV

is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the Loop LED does not flicker, the unit is defective.

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations at this point on the CommLink IV. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 10-15 sec- onds as the unit attempts to communicate.

Measurements

Network Loop Acceptable Range

T - G (SHLD) 2.0 - 4.0 Volts DC

R - G (SHLD) 2.0 - 4.0 Volts DC

Action

Condition Action

If voltages are too high or too low on either side.

1. Unplug the Comm loop from the CommLink IV and Check for proper loop voltages. If a problem exists, disconnect each CV Unit from the loop until the problem is isolated.

2. Replace the CommLink IV. The driver chip is not field-replaceable. See Page 4-22.

4-20 Start-Up and Troubleshooting

Auto-Zone CV & CV-EX Section 4

Checking the CV Local Loop

Diagram

CommLink IV

T-To-G

+2.4 VDC

+3.3 VDC

R-To-G

+2.4 VDC

+3.3 VDC

10/100

ETHERNET

DIAG

ACT LNK

To Read DC Volts

MODEM

COMPUTER

RS-232

USB

Normal

Config

USB

Set Your Meter

Serial #

TGR

24V

GND

485 LOOP POWER

Communications

Loop

Disconnected

The CommLink IV Must Be

Powered Up For These Tests

Communications

Loop

Disconnected

To 24 VAC

Power Supply

The indicated values are typical of a normal system; actual readings may deviate slightly due to the number of units connected and other system specific factors.

Note:

All of the connected CV Controllers should be powered up for this test.

Overview

This is a “quick check” to determine if any of the driver chips on the attached CV Controllers are damaged. Since all units will “float” both of their communications connections at about 2.45 Volts, you can quickly check the entire communications loop by unplugging it at the CommLink IV.

Note: Tip:

Be sure that the loop you are testing does not have a short circuit from T to R.

The Loop LED (located on the front panel) should “flicker” when the CommLink IV

is attempting to communicate with the CV Controllers. There is a noticeable change in the flicker when the loop is disconnected if you observe a normal functioning unit. When the loop is reconnected, it may take up to 60 seconds before the CommLink IV re-establishes communications with the CV Controllers.

Measurements

Network Loop Acceptable Range

T - G (SHLD) 2.4 - 3.3 Volts DC

R - G (SHLD) 2.4 - 3.3 Volts DC

Action

Condition Action

If voltages are too high or too low on either side.

One or more of the CV Controllers has a damaged Comm driver chip. Disconnect CV Controllers one at a time to isolate the problem.

Start-Up and Troubleshooting 4-21

Section 4 Auto-Zone CV & CV-EX

Checking CommLink Driver – CV

Diagram

CommLink IV

+3.1 VDC

+3.2 VDC

R-To-G

+3.4 VDC

+3.6 VDC

DIAG

T-To-G

10/100

COMPUTER

ETHERNET

USB

Normal

Config

USB

ACT LNK

Set Your Meter

To Read DC Volts

MODEM RS-232

485 LOOP

Serial #

TTGGR

GND

24V

485 LOOP

POWER

The CommLink IV Must Be

Powered Up For These Tests

To 24 VA C

Power Supply

Communications

Loop

Disconnected

Overview

This test checks for proper Communications Loop voltages coming from the CommLink IV.

Tip:

The Loop LED (located on the front panel) should “flicker” when the CommLink IV

is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the LED does not flicker, the unit is not functioning.

Measurements

Local Loop Acceptable Range

T - G (SHLD) 3.1 - 3.2 Volts DC

R - G (SHLD) 3.4 - 3.6 Volts DC

Action

Condition Action

If voltages are too high or too low on either side.

1. The CommLink IV has a damaged comm driver chip.

Replace the CommLink IV. The driver chip is not field-replaceable.

4-22 Start-Up and Troubleshooting

Auto-Zone Control Systems Auto-Zone CV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual