Auto-Zone Control Systems Auto-Zone CV User Manual

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.

Copyright 2009 WattMaster Controls, Inc.

All rights reserved.

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

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

#1

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

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

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

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

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

s

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

g

g

g

CV Controller Wiring

Connect To

Next Controller

MiniLink On

Local Loop

Room Sensor

NORMAL

OVR

Mount In HVAC

Tem p. Sens or

And/Or

W

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

T

T

SH

SH

R

R

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

T

SH

SH

R

R

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

1

2
4

8

16

32
TOKEN

NETWORK

Line Voltage

RELAY

OUTPUTS

COM1-3

R1

R2

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

4

8

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

1

6

11

16

21

2

SW1 SW1 SW1 SW1

7

12

17

22

3

8

13

18

23

4

9

14

19

24

Address Switch Setting Chart For CV Controllers

5

10

15

20

25

26

SW1 SW1 SW1 SW1 SW1

27

28

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

V

A

A

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

12

IN
1

2
3

4
IN
5

GND
GND

OUT

YS

OVR

W

A
R
M
E
R

C
O
O
L
E

R

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

C

g

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

10

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