Auto-Zone Control Systems Auto-Zone Plus User Manual

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Design, Installation

Plus System

and Operations Manual

Revision 03A

Auto-Zone Plus

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 Plus Design, Installation & Operations Manual - Form WM-AZP-IO-03A

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

Section 1

Table of Contents

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

General Information .....................................................................................3

Description of System Components.................................................................................5

Design Considerations.................................................................................10

Zone Diversity................................................................................................................10

Cooling - Partial Load Conditions .................................................................................10

Heating - Partial Load Conditions .................................................................................13

Override Conditions.......................................................................................................13

Building Pressurization..................................................................................................14

Design Guide ................................................................................................15

Step #1 - Zoning.............................................................................................................15

Step #2 - Sizing the Central Unit ...................................................................................18

Step #3 - Duct Design Considerations ...........................................................................18

Step #4 - Room Air Motion/Diffuser Selection.............................................................19

Step #5 - Bypass Damper Sizing....................................................................................19

Step #6 - VFD Considerations .......................................................................................20

Step #7 - Sizing Zone Dampers .....................................................................................22

Auxiliary Heat Control Options.................................................................25

Index: ............................................................................................................27

Table of Figures

Figure 1-1: Auto-Zone Plus System ..............................................................................2

Figure 1-2: Typical HVAC Unit Installation.................................................................3

Figure 1-3: Incorrect Zoning of Typical Building .......................................................16

Figure 1-4: Correct Zoning of Typical Building..........................................................17

Figure 1-5: Locating the Static Pressure Sensor..........................................................21

Table 1-1: Round Damper Sizing Chart ......................................................................22

Table 1-2: Round Damper Dimensional Data .............................................................23

Table 1-3: Pressure Independent “K” Factors..............................................................23

Table 1-4: Rectangular Damper Sizing Information....................................................24

Design Guide

Auto-Zone Plus 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.

Design Guide 1-1

Section 1 Auto-Zone Plus

Figure 1-1: Auto-Zone Plus System

1-2 Design Guide

Auto-Zone Plus Section 1

General Information

The Auto-Zone Plus control system converts single-zone Constant Volume HVAC units into variable air volume/variable temperature multiple zone systems. The microprocessor based Zone Manager calculates the heating and cooling requirements for each zone based on real time information received from each Zone Controller. The Zone Manager then directs the HVAC unit to provide the appropriate amount of heating, cooling, and ventilation to satisfy each zone's requirements. A static air pressure sensor located in the supply duct measures air pressure and the Zone Manager controller sends a signal to modulate a bypass damper to maintain the static pressure setpoint. The Zone Manager has been updated with a new feature so that it can instead be configured to provide a 0-10 VDC signal output to control a Variable Frequency Drive (VFD) which in turn varies the HVAC units supply air fan motor speed to maintain the static pressure setpoint.

Typical HVAC Unit

(Packaged or Split System)

LOCAL COMM LOOP

ZONE CONTROLLER

Above Corridor

( Preferred Location )

Zone Sensor

(4-1/2' to 5'; Shoulder Height)

TWISTED PAIR

WITH SHIELD TO

LOCAL COMM LOOP

TWISTED PAIR WITH

SHIELD TO OTHER

ZONE CONTROLLERS

OR CV CONTROLLERS

Static Pressure Pickup

(2/3 Of The Way Down Main Duct)

Supply Duct

Supply Temp Sensor

(Ahead of Bypass Takeoff)

Zone Damper and Control

( Over Corridor for Easy Service )

LOCAL COMM LOOP

ZONE CONTROLLER

TWISTED PAIR

WITH SHIELD TO

Diffuser at Perimeter Wall

(Direct Airflow Inward Towards Center of Area)

Bypass Damper

( Locate Where Easily Accessible )

Duct to Return

(Preferred)

Outdoor Air Sensor

(Mount Away From Direct Sunlight))

Zone Manager

NETWORK COMM LOOP

WITH SHIE LD TO

NEXT ZONE MANAGER

TWISTED PAIR

Return Duct

Return Temp Sensor

(Avoid Mixed Air Area)

Figure 1-2: Typical HVAC Unit Installation

Design Guide 1-3

Section 1 Auto-Zone Plus

Other new features provided with the Zone Manager controller include the ability to control a modulating chilled water valve for cooling and/or a modulating hot water valve or SCR electric heater for heating. This modulating cooling and/or heating requires the addition of the OE352 2 Slot Expansion Base Board with an OE355 4 Analog Output Board mounted on it. The base board/expansion board assembly connects to the Zone Manager via a modular cable. The Zone Manager has the ability to control up to 2 stages of cooling and 2 stages of heating. When more stages are required the same OE352 2 Slot Expansion Base Board can be populated with up to (2) OE357 4 Relay Output Expansion Boards to provide up to 4 additional stages of heating and/or cooling.

This new version also has Optimal Start capabilities. A target zone can be selected as a control point and the Zone Manager will start the system at the correct time to make sure the zone setpoint temperature is reached according to the scheduled start time based on the soak time that the user configures. The new Zone Manager can now also be configured to allow control of your HVAC unit based on the heating or cooling Supply Air Temperature.

The Auto-Zone Plus System Manager allows multiple Zone Managers to be programmed and monitored from a central operator's panel. Single-zone constant volume rooftop HVAC units can also be connected to the Auto-Zone Plus communication network, allowing for both multizone and single-zone equipment to be controlled from the same system.

Substantial savings can be realized using the Auto-Zone Plus system instead of having to install multiple single zone Constant Volume rooftop units to accommodate multiple zone requirements. The Auto-Zone Plus system is versatile and can be used with any packaged roof top or indoor HVAC unit or any split system HVAC unit. It controls a variety of terminal unit functions including pressure dependent or pressure independent single duct terminals and series or parallel flow fan terminals.

The optional Prism color graphics software package is available to provide for on site or remote monitoring via a personal computer.

1-4 Design Guide

Auto-Zone Plus Section 1

Description of System Components

A typical Auto-Zone Plus system is comprised of the following basic components.

System Manager The microprocessor based System Manager allows multiple Zone Managers and any single-zone constant volume HVAC units to be programmed and monitored from a central operator's panel. The System Manager is connected to the Auto-Zone Plus communication network and can be wired to any local loop connection on the system.

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 Auto-Zone Plus easy to set up and operate without the need for specialized training.

CommLink IV

The OE361-12 CommLink IV Communications Interface allows computer access into the Auto-Zone controls system and also provides communications across multiple local communications loops on the control system.

The CommLink IV comes packaged in an attractive beige colored plastic enclosure. The CommLink IV is powered by a small plug-in transformer that is included. Locally, an optional on-site personal computer with Prism software installed may be connected to the CommLink IV to provide direct access to system control parameters. A USB cable (6 ft. long) is provided with the CommLink IV for connection to your computer.

Design Guide 1-5

Section 1 Auto-Zone Plus

Remote telephone access to the control system can be obtained by purchasing the optional OE419-06 Remote Link II modem. With the optional Remote Link II modem installed, the control system can be accessed remotely by using another Remote Link II modem (purchased separately) connected to a personal computer with Prism software installed at the remote location. With the Remote Link installed at the job site, the CommLink IV can be configured to call a pager or cell phone number if an alarm condition occurs.

An optional OE415-02 IP Module Kit is also available that provides an Ethernet connection to the controls system from any computer connected to your building’s LAN. It can also be configured to allow access to the control system from the Internet if your Ethernet firewall is configured for this option.

Zone Manager

The Zone Manager is a microprocessor based controller which monitors up to sixteen zones in the system. The zone manager controls the zoned HVAC unit to satisfy the requirements of each individual zone while maintaining efficient operation and comfort. The Zone Manager operates the fan, heating, cooling, duct static pressure, and economizer functions. Each Zone Manager also features time scheduling, night set back, trend logging of sensor values, and automatic changeover.

1-6 Design Guide

Auto-Zone Plus Section 1

Bypass Damper or VFD Control

A Bypass damper or Variable Frequency Drive (VFD) is used to control the duct static pressure. When using bypass damper control, the Zone Manager sends a signal to the bypass damper actuator to maintain duct static pressure by opening and closing a damper in order to bypass a portion of the discharge air stream back into the return air duct of the HVAC unit in response to the duct static pressure.

When a VFD is used, the Zone Manager sends a 0–10 VDC signal to the VFD to maintain duct static pressure by causing the VFD to change the Supply Fan motor speed thereby increasing or decreasing the air flow in response to the duct static pressure. Minimum airflow requirements of the heat exchanger must be considered when using a VFD on units that have heating. See the design section of this manual for specific recommendations and information.

Design Guide 1-7

Section 1 Auto-Zone Plus

Zone Controller

The Zone Controller monitors space temperature and positions a damper to maintain proper air flow to the assigned zone in order to achieve desired comfort and ventilation levels.

If the current supply air temperature in the duct will benefit the local zone temperature setpoint, the zone damper will modulate the air flow across the damper as needed to in order to satisfy the setpoint temperature. If the supply air will not benefit the zone (such as hot air in the duct when the space is calling for cooling), the controller will direct the damper actuator to a minimum position and wait for a change in the supply air temperature to occur that will help achieve the heating or cooling setpoint.

Constant Volume Controller

The Constant Volume (CV) Controller is a microprocessor based controller designed to operate packaged roof top HVAC units. Up to thirteen stand alone CV controllers can be connected to each Zone Manager's local communications loop to provide a fully integrated multizone/single-zone control system. The CV controller operates the fan, heating, cooling, and economizer functions. Each CV controller also features time scheduling, night set back, trend logging of sensor values, and automatic changeover.

1-8 Design Guide

Auto-Zone Plus Section 1

A /

V A

T A

V A

T A

V A

T A

V A

T A

A /

Zone Sensor

The patented zone sensor is of a flush, wall mounted design. A special plate on the face of the sensor accurately senses space conditions. As a result of its unique design, the zone sensor rejects the influence of internal wall temperature effects. The sensor comes in four different configurations:

• Sensor only

• Sensor w/push-button override (Override time fixed at 2 hours)

• Sensor w/setpoint adjustment

• Sensor w/override & setpoint adjustment

Any combination of these sensor configurations can be used with the system.

Expansion Boards

The Zone Manager is designed to utilize expansion boards to provide additional versatility to the control system. The OE352 2 Slot Expansion Base Board connects to the Zone Manager via a modular cable and with the OE355 4 Analog Output Expansion Board mounted on it can provide for 2 additional analog outputs to control a modulating hot water heating valve or SCR electric heater and/or modulating chilled water valve. The OE357 4 Relay Output Board can also be mounted on the 2 Slot Expansion Base Board and provides for up to 6 total stages of heating and/or cooling combined when two OE357 Boards are used.

RV1

PJ1

CX1

D2D1 R8

R11

PJ2

LM358

CX2

+24VDC-OUT

Q2R3Q4

GND

LD1

TB1

R13

PWR

D1R6D2R7D4D3R8

24VAC-IN

GND

TB2

Design Guide 1-9

CX3

7824CT

AOUT1

AOUT2

TB1

VR2

VR3

CX3

AOUT3

CX1

P82B715P

LM358

C2 C3

7805ACT

GND

AOUT4

CX1

U L

2 8 0 3

U L 5

5 0

YS101786

U L 5

2 5 0

7812CT

4 AOUT MOD. I/O BD.

HAANI

S P I L I H P

2 4

O N

C C :

C4 C5

O N

C C :

VR5

P2JP2

CX2

1 U

L M 3 5 8 N

- 1

- P S

1 1

- P S

7824CT

3 X C

2 U

P C

R4R

5 7

CX2

R10

1 N R

K2K

R12

P S

L R 4

7824CT

Section 1 Auto-Zone Plus

Design Considerations

Consider the following items when designing an Auto-Zone Plus system.

Zone Diversity

An Auto-Zone Plus system is designed to improve tenant comfort by dynamically rebalancing the air distribution when used with a typical constant volume rooftop heating/cooling unit. If zones with extremely different load conditions are serviced by a single rooftop unit, the result will be poor control and excessive wear due to cycling of the equipment.

It is especially important to avoid mixing interior zones (which require cooling all year) with exterior zones (which may require constant heat during winter months). If you must mix zones under these conditions, consider using either VAV boxes with heat or separate baseboard heat on exterior zones. Auto-Zone Plus systems offer a variety of methods to control additional zone heat to help you avoid problems.

Group similar loads on an individual unit and use more than one zoned unit if required. Any special loads can be handled by using separate constant volume units.

The Auto-Zone Plus system offers the designer considerable flexibility by allowing both multiple-zoned units and single-zone units to be connected within a single simple system.

Cooling - Partial Load Conditions

The engineer must be aware of several potential problems when applying an Auto-Zone Plus system during cold weather operation.

Low Ambient Temperature Lockout

During very cold weather it is common for mechanical systems to have “low temp lockouts” which protect equipment from damage if operated under these conditions. Auto-Zone Plus also provides user programmed lockouts for protection purposes,

although mechanical safeties should always be used as the final stage of protection.

If the rooftop unit services interior zones with thermal loads which require cooling when outside temperatures are below the safe operating limits for your equipment, you should seriously consider installing an economizer on your rooftop unit. The Auto-Zone Plus control system is designed to take advantage of an economizer if it is installed. The use of an economizer will save money on utilities and provide comfort under conditions when it is not possible to operate the mechanical cooling system.

1-10 Design Guide

Auto-Zone Plus Section 1

Low Supply Air Temperatures

Under lightly loaded conditions much of the supply air may be bypassed back into the return air side of the system. This bypassing will result in the lowering of the supply air temperature, which may result in the supply air temperature reaching the low temp safety limit. If the supply air low temp safety limit is exceeded, the control system will “cut-off” the mechanical cooling to protect it from damage. Excessive cycling of the mechanical system will result if this condition persists. Comfort may also suffer if the system cannot run long enough to satisfy cooling demands.

A number of things can be done to reduce this problem. Some of these things depend upon the type of installation.

• Avoid oversizing the unit. Do your load calculations carefully. Since Auto-Zone Plus

directs the heating or cooling to the zones which require it, you may find that you can use a smaller unit in many cases. Oversizing is the number one cause of excessive low supply air temperature cycling.

• Increase your cooling minimum airflow or damper position settings to allow more air

during cooling operation. Be careful to avoid settings which are so high you cause over cooling of the spaces. Find a compromise position.

• Bypass the air into the plenum instead of into the return air intake. Be careful if you

use this method since you may get “dumping” of cold air from your return air grilles. This method works best with plenum returns, do not use this method with ducted returns unless you have carefully considered the consequences.

• Increase your static pressure setpoint to help reduce the amount of air being bypassed.

Be aware of increased noise levels and the cost of operation if you use excessive static pressures. This will not work if you are using pressure independent zone controllers, since they will maintain a constant flow of air to the zones regardless of duct static pressure. This technique will likely cause over cooling of the spaces due to increased airflows at minimum positions.

Design Guide 1-11

Section 1 Auto-Zone Plus

Warning: If the fan system has the capability of producing static pressures which

could damage ductwork you must provide a manual reset, high pressure limit switch to cut-off the fan system in the event of high duct static. Do not use your Auto-Zone Plus system as

a safety device!

• Use an Economizer. Although this is not a cure-all, it greatly improves operation

during cool weather when cooling loads are minimal. Using an Economizer also improves ventilation and lowers operating costs.

1-12 Design Guide

Auto-Zone Plus Section 1

Heating - Partial Load Conditions

Heating difficulties are less common than cooling difficulties. They are similar in nature, however, and the cures are generally the same.

• Increase the Heating minimum setpoints on as many zones as possible.

• Increase the static pressure setting as high as is practical. Increasing static pressure

does not help if you are using pressure independent operation.

• Bypass to plenum instead of the return air intake if acceptable.

• Do not oversize your equipment.

• Use auxiliary heat in either your VAV boxes or baseboard.

Caution: When using a VFD for duct static pressure control, the VFD control

must have its minimum speed setting configured to meet the minimum airflow requirements of the installed heating equipment. This is especially critical when using indirect fired gas heating since the heat exchanger could be damaged if the heating airflow falls below the minimum airflow recommended for the heat exchanger. If the unit is equipped with electric heat, failure to meet minimum airflow requirements of the electric heater could cause nuisance tripping of the electric heaters safety devices. The minimum heating airflow required for your HVAC unit should be available from your HVAC unit manufacturer. See your VFD installation manual for information on setting the minimum airflow.

Auto-Zone Plus has a number of auxiliary heat control options which provide solutions to most problems. Refer to the Auxiliary Heat Control Options topic near the end of this section.

Override Conditions

After-hours overrides can produce aggravated partial load conditions in both the heating and cooling modes. The problem is most commonly caused by a single zone being overridden for after-hours use. This causes the rooftop equipment to operate for only one zone. The Auto-Zone Plus system offers an improved solution to this common problem by allowing a single override to trigger a group of zones via a “global” override. This allows the system to operate with sufficient load to reduce cycling caused by light load conditions.

Design Guide 1-13

Section 1 Auto-Zone Plus

Building Pressurization

If you are using an economizer, building pressurization must be addressed. Failure to properly handle building pressurization may result in doors remaining open when the economizer is operating. Pressurization problems can render economizer operation useless. The following suggestions will help to avoid potential problems.

• Use powered exhaust when the system uses ducted returns. The return duct pressure

drop will cause most barometric relief dampers to function poorly or not at all. AutoZone Plus has the ability to control a powered exhaust whenever the economizer is operating.

• Use a separate building pressure control which operates a relief fan or dampers.

1-14 Design Guide

Auto-Zone Plus Section 1

Design Guide

There are seven basic steps to designing an Auto-Zone Plus system:

1. Zoning

2. Sizing the Central Unit

3. Duct Design Considerations

4. Room Air Motion / Diffuser Selection

5. Bypass Damper Sizing

6. VFD Considerations

7. Sizing Zone Dampers

Step #1 - Zoning

Determine the number of zones. A single air handler unit can have no more than sixteen zones. If the number of zones exceeds sixteen then more than one Zone Manager will be required.

The primary precaution to be taken in applying the Auto-Zone Plus System is to select the zoning so that no zone will be at maximum (design) heating (or cooling) load when any other zone requires the opposite temperature air to satisfy its load. For example, depending on the wall, ceiling and floor material and location within the building (e.g. top or middle floor), a typical floor of a building usually has a minimum of nine distinct temperature or control zones that are affected uniquely by the outdoor load. These zones are depicted in Figure 1-3 & Figure 1-4.

Depending on the size of the building and partition layout, some of these zones may overlap or be insignificant from a zoning standpoint. For example, Zone 9 could be multiple conference or computer rooms where additional zoning would be required, or it could be as small as a corridor where no zoning is required. Similarly, zones 7 and 8 could have no external windows and no partitions between them and could be considered a single zone. Zone 6 could be divided into multiple offices with full partitions between them, thus requiring separate Zone Controllers because of different internal loads, but the same external load.

Generally speaking, the greater the number of individual Zone Controllers, the greater the comfort. The designer will have to look at the specific building, balancing the costs of multiple zones with the added comfort and energy savings possible with multiple zones, to match the building owner's requirements.

Design Guide 1-15

Section 1 Auto-Zone Plus

It is important to recognize that all buildings have some purely internal zones, such as Zone 10, which may contain separate offices/conference/computer rooms. These internal zones will normally have high cooling requirements year around while external zones (1,2,3, etc.) could be at or near design heating load requirements during the winter months. This diversity can be used (if properly zoned with multiple HVAC units serving similar loads and zones) to save energy. However, a single HVAC unit is used to serve zones with opposed cooling and heating demands as shown in Figure 1-3 the resulting system will be very energy inefficient and comfort levels in the building will not be satisfactory.

Figure 1-3: Incorrect Zoning of Typical Building

As previously mentioned, Figure 1-3 shows a misapplication of an Auto-Zone Plus (or any heating/cooling changeover) system. Supplemental heat could be added to the perimeter zones and controlled with the auxiliary heat control board from the Zone Controller which would improve the performance of the system but still would not be ideal. System performance would still generally be compromised and frequent changeover from the heating to the cooling mode will occur during the heating season if purely internal zones are combined on the same air-conditioning unit serving perimeter zones.

1-16 Design Guide

Auto-Zone Plus Section 1

The best approach would be to serve the interior zones with cooling only loads with a separate constant volume HVAC unit (that could be zoned if desired between multiple rooms with a similar load profile) instead of zoned with perimeter zones. Also perimeter zones with South and West exposures typically have a higher cooling load than North and East exposures. It is best to group the South and West perimeter zones together on the same HVAC unit and the North and East perimeter zone together on another HVAC unit. This will provide the best energy savings, prevent the HVAC units from changing over from heating to cooling frequently and provide the best comfort for the occupants. This recommended ideal system is depicted in Figure 1-4. If you use this approach you will have the best flexibility and energy saving system design that is possible.

Figure 1-4: Correct Zoning of Typical Building

Design Guide 1-17

Section 1 Auto-Zone Plus

Step #2 - Sizing the Central Unit

Because the zones are controlled with variable air volume, it is unlikely that all zones will be at design load at the same time. The zoning allows for the diversity of loads to be taken into account and will often provide better comfort with a smaller HVAC unit.

In sizing the system, the individual zone loads should be calculated using any dependable load estimating program. Because of diversity, the central unit should be selected for the instantaneous peak load, not the sum of the peak loads, as would be done with a constant volume single zone system. Consider the following when sizing the central unit.

• Size the peak cooling load based on the month and hour of the greatest total

building/system load.

• Heating should be sized for the lowest design temperature with an additional margin

for morning "pickup". This margin is generally recommended to be 20 to 25 percent of base design.

Step #3 - Duct Design Considerations

The AZ Plus system uses a typical low pressure duct design. To reduce noise problems duct pressures should not exceed 1 inch W.C.

Primary trunk ducts should not be "undersized." This is especially true for "pressure dependent" systems. Pressure dependent refers to the typical Auto-Zone, Zone Controller without the air flow sensor. With larger trunk ducts, it is easier to assure relatively constant pressure to each zone. Runs should be as short as possible, and the trunk duct system kept as symmetrical as possible to facilitate system balancing. Wherever possible, run the trunk ducts above corridors and locate the zone dampers above corridors to reduce the noise in the space and facilitate service of the units. Trunk ducts should be sized for no more than 0.1 inch W.C. drop per 100 feet., and a maximum duct velocity of 2000 FPM.

Note: For pressure independent terminal units with velocity sensors and

conventional "VAV" boxes properly selected for "quiet" operation, this 2000 FPM rule can be exceeded by up to 50 percent. The designer, however, should be very experienced in VAV system design before considering modification of this general rule

Typical VAV systems with pressure independent terminals use the static regain method for sizing ducts. The typical Auto-Zone Plus system is a low-pressure, pressure dependent system that utilizes conventional unitary air-conditioning units. These systems should use the equal-friction method of sizing the ducts, and use the maximum loss of 0.1 inch per 100 feet as described above.

1-18 Design Guide

Auto-Zone Plus Section 1

Step #4 - Room Air Motion/Diffuser Selection

Air motion is a consideration for occupant comfort. The selection of diffusers for an Auto-Zone Plus system requires more care than a constant volume system due to varying flow of air into the zones. Slot diffusers are recommended due to their superior performance at low air flows. Because the zone air flow is variable volume, lower cost round or rectangular diffusers that were satisfactory for constant volume may prove unsatisfactory with an Auto-Zone Plus system. These diffusers may result in "dumping" of the cold air at low flows in the cooling mode, and insufficient room air motion at low air flows in the heating mode. Although high air motion in the heating mode can be undesirable, a slot diffuser with a high induction ratio generally helps to reduce room air "stratification" when the heating comes from a ceiling diffuser. Linear slot diffusers should be properly selected for the air flow and "throw" suited to the specific installation or zone.

Additional factors to consider in diffuser selection are sound level and throw at design flow. Generally, multiple diffusers will result in lower sound levels in the space, but this must be balanced with the additional hardware and installation costs. It is commonly recommended that slot diffusers be located near the perimeter or outside wall with the airflow directed into the room. Consult your diffuser supplier or catalog for proper diffuser sizing and location.

Series fan boxes may be used instead of zone dampers where higher induction rates are desirable. If the heat loss on perimeter walls is high, such as large areas of glass, the use of Series Fan Boxes may be indicated to maintain higher induction rates to offset “downdrafts.” If the heat loss is greater than 275 BTUH/LINEAR FOOT, you should use high quality slot diffusers next to the outer wall with the airflow directed inward to counteract downdrafts during heating. Serious downdraft problems occur when heat losses exceed 400 BTUH/LINEAR FOOT and both high induction diffusers and series fan boxes are recommended.

Step #5 - Bypass Damper Sizing

Using a load calculation program, the bypass damper should be sized to give you the maximum CFM of air to be bypassed, typically 60 to 70 percent of the HVAC units rated capacity.

To size the damper, select a damper from the table based on calculated bypass CFM and a maximum velocity between 1750-2250 FPM. When determining the bypass duct size, be sure to take into account any transition fittings and associated pressure drops. (See Table 1-1: Damper Sizing Chart)

Design Guide 1-19

Section 1 Auto-Zone Plus

Whenever possible, use a single bypass damper and round duct for the bypass. If space limitations or total airflow requires it, multiple bypass dampers can be controlled in parallel.

For proper control of the Bypass Damper the static pressure sensor location is very important. See Figure 1-5: Locating the Static Pressure Sensor for proper mounting locations.

Step #6 - VFD Considerations

When using a VFD instead of a bypass damper for static pressure control, it is important to consider the minimum fan speed that will still allow for proper airflow across the electric heating element or gas fired heat exchanger. You should consult the HVAC unit’s selection and design information regarding the minimum airflow that is allowed to prevent damage to the heat exchanger in the case of gas fired equipment and prevent nuisance tripping of the thermal safety devices when you are using an electric heater.

The VFD Controller on your HVAC unit must be configured so that the airflow never falls below the minimum required by the heat exchanger. The WattMaster controller will only modulate the VFD to control the fan speed in response to the static pressure setpoint that you have set.

Also the wiring supplying the 0-10 VDC signal between the Zone Manager and the VFD should be 18 gauge minimum 2 conductor twisted pair with shield to help prevent signal feedback to the Zone Manager. This wire is available from WattMaster as part number WR-LL-WG-18 or you can use Belden #82760 or equivalent wire.

For proper control of the VFD, the Static Pressure Sensor location is very important. See Figure 1-5: Locating the Static Pressure Sensor for proper mounting locations.

1-20 Design Guide

Auto-Zone Plus Section 1

Preferred Location

If the trunk ducts are properly sized for minimum pressure drop, the location of the static pickup probe is not particularly critical. It should ideally be located at right angles to the airflow in a straight section of the supply duct approximately 2/3 the distance of the total length of the supply duct. Also the probe should be located not less than 3 duct diameters downstream and 2 duct diameters upstream of any elbow or takeoff.

Less Than Ideal, But Acceptable

Since the "ideal" location is often difficult to find in an installation, a location in the main trunk where the tip is not in a "negative pressure area" (e.g. just downstream of the inside curve of an elbow) or an area where the tube opening is directly impacted by the velocity of the supply air. Another option is to use (2) Static Pressure Probes and tie them together with a tee. Use equal lengths of tubing for each sensor and run the third leg of the tee back to the Static Pressure Sensor. This will average the pressure readings of the two duct runs.

Least Desirable, But Acceptable

If the supply duct comes directly from the unit and immediately splits in opposite directions without a curved duct split, the pressure pickup should be located ahead of the split, or as close to it as possible to it, even if the bypass damper(s) are located downstream of the split.

Supply Air

Temp. Sensor

Supply Air

Duct

Supply Air

Duct

Supply Air

Temp. Sensor

Static Pressure

Sensor

Supply

Duct

Tee

Tubing To Be Equal Length And Size

Fan

Bypass Damper

Supply

Fan

Static Pressure

Probes

Picku

Supply

Fan

Static Pressure

Pickup Probe

Static Pressure

Pickup Probe

Bypass Damper

Supply Air

Temp. Sensor

Static Pressure

Sensor

Bypass Damper

Return Air Duc t

3D Min.2DMin.

Return Air Duct

Static Pressure

Return Air Duct

Return Air Tem p. Se ns or

Sensor

Return Air Tem p. S en sor

Return Air Temp. Sensor

Figure 1-5: Locating the Static Pressure Sensor

Design Guide 1-21

Section 1 Auto-Zone Plus

Step #7 - Sizing Zone Dampers

Use a load program to determine the peak load for each zone. These calculations will be used in selecting the appropriate zone damper sizes. WattMaster can provide either round zone dampers or rectangular zone dampers for your zones

Using the maximum acceptable velocity for a branch duct (typically 1000-1500 FPM for minimal noise), find the smallest damper that will deliver the required CFM as determined by the load program.

Round Zone Damper Selection

Locate the branch velocity used in the duct design program on the left hand column of the damper sizing chart (Table 1-1). Move across the chart and find the damper which will provide the acceptable CFM to meet zone requirements.

Note: Compare the damper size selected against the duct size to determine if the

next size up or down will provide acceptable performance without requiring a transition fitting.

One additional damper may be slaved together for large zones. See zone wiring diagram for details. This should be reserved for situations when it is not practical to use a single large damper.

Air Damper Round Duct Size

Velocity through Round Air

( Area Ft

Damper

750 - P.I. or P.D. Zone

1000 - P.I. or P.D. Zone

Maximum CFM For P.I. Zone

1250 – P.D. Zone Only

1500 – P.D. Zone Only

1750 - Bypass Only

2000 - Bypass Only

2250 - Bypass Only

(FPM)

Damper

)

Round Air Damper Selection

6″

(0.188)

141 254 399 577 788 1031

188 338 532 769 1050 1375

206 413 634 921 1264 1608

235 423 665 961 1313 1718

282 507 798 1154 1575 2062

329 592 931 1346 1838 2405

376 676 1064 1538 2100 2749

423 761 1197 1730 2363 3094

8″

(0.338)

Volume through Round Air Damper

10″

(0.532)

(CFM)

12″

(0.769)

14″

(1.050)

16″

(1.375)

Table 1-1: Round Damper Sizing Chart

1-22 Design Guide

Auto-Zone Plus Section 1

Round Damper Blade Assembly

Zone Controller

1/2" Foil Faced Insulation

R L F

L R I

Actuator

Control Enclosure (Cover Removed)

VAV/Zone Round Damper Dimensional

Data

Duct Diameter A B C

6″

8″

10″

12″

14″

16″

19.00 5.88 9.38

19.00 7.88 11.38

19.00 9.88 13.38

22.00 11.88 15.38

22.00 13.88 17.38

22.00 15.88 19.38

Table 1-2: Round Damper Dimensional Data

Pressure Independent Round Damper “K” Factor

Pressure Independent Round Air Dampers utilize “K” factors to correctly measure and read CFM values. These “K” factors represent the airflow that will pass through a given size damper at 1” of velocity pressure. These “K” factors must be programmed into the control system for all pressure independent dampers. See Table 1-3 for a list of “K” factors by round damper diameter used.

Flow Probe “K” Factor Chart

K Factor = CFM Flow @ 1” Velocity Pressure

Damper Diameter Flow Probe “K” Factor

6″

8″

10″

12″

14″

16″

474

950

1417

2120

2908

3700

Table 1-3: Pressure Independent “K” Factors

Design Guide 1-23

Section 1 Auto-Zone Plus

Rectangular Zone Dampers

The Rectangular Damper is used in applications where rectangular ducts are specified or required because of space limitations or job requirements. The Rectangular Damper utilizes opposed blades for improved air flow control. See Table 1-4 for sizing info.

Dimensional Data Typical Installation

Height

(B)

Width

(A)

10″ 510 590 690 800 910 1030 1150 1260 1380 1500 1610 1730 1840 2000 2080

12″ 560 650 730 850 970 1090 1210 1330 1460 1580 1700 1820 1940 2060 2190

14″ 660 770 880 1030 1180 1330 1480 1630 1760 1910 2060 2210 2360 2510 2640

16″ 750 890 1030 1200 1370 1540 1710 1880 2060 2230 2400 2570 2740 2910 3090

18″ 770 980 1180 1380 1580 1780 1980 2180 2350 2550 2750 2950 3150 3350 3540

20″ 850 1090 1330 1550 1770 1990 2210 2430 2650 2870 3090 3310 3530 3750 3990

22″ 930 1210 1480 1730 1980 2230 2480 2730 2950 3200 3450 3700 3950 4200 4440

24″ 950 1290 1630 1900 2170 2440 2710 2980 3250 3520 3790 4060 4330 4600 4880

26″ 990 1390 1780 2080 2380 2680 2980 3280 3550 3850 4150 4450 4750 NA NA

28″ 1070 1500 1930 2250 2570 2890 3210 3530 3850 4170 4500 4820 NA NA NA

30″ 1020 1550 2080 2430 2780 3130 3480 3830 4150 4500 4850 NA NA NA NA

32″ 1090 1660 2230 2600 2970 3340 3710 4080 4450 4820 NA NA NA NA NA

34″ 1150 1770 2380 2780 3180 3580 3980 4370 4750 NA NA NA NA NA NA

36″

″

10″ 12″ 14″ 16″ 18″ 20″ 22″ 24″ 26″ 28″ 30″ 32″ 34″ 36″

8″ 410 530 640 740 850 970 1080 1190 1300 1410 1520 1630 1740 1850 1970

1060 1790 2520 2670 3090 3510 3930 4350 5040 NA NA NA NA NA NA

Rectangular Damper Selection Data

Airflow Through Rectangular Damper

CFM @ 1000 FPM Velocity

Notes:

1.) Zone Dampers should be sized based on the required zone CFM. The table above is calculated based on 1000 FPM velocity through

the Rectangular Damper. Zone Damper recommended velocity is 1000 - 1500 FPM. Select 1000 FPM or less for quiet operation. For

other velocities, use the following multipliers to obtain the correct CFM: 500 FPM = 0.5, 750 FPM = 0.75, 1250 FPM = 1.25, 1500 FPM =

1.5, 2000 FPM = 2.0, 2250 FPM = 2.25.

2.) Bypass Dampers should be selected for 60% to 70% of the HVAC units rated CFM capacity. Recommended Bypass Damper velocity

Table 1-4: Rectangular Damper Sizing Information

1-24 Design Guide

Auto-Zone Plus Section 1

Auxiliary Heat Control Options

The Auto-Zone Plus system offers the user a variety of methods to deal with zone heating requirements. When deciding how to handle zone heating requirements the user should consider the following:

• Does the rooftop unit have heat?

• Are you using fan powered boxes?

• Is auxiliary heat used such as baseboard or radiant ceiling panels?

If the zone has some type of heat, the user must consider how the heat is to be used. Typical questions that should be asked:

Q: Should the zone heat be used as a first stage where it will become active before a

heating demand is created at the rooftop unit?

A: This mode is useful if you expect to have both heating and cooling demands at the

same time. The zone will use it’s own heat and allow the rooftop unit to continue to provide cooling for other zones. This mode is also useful if the rooftop unit does not have any heating capabilities.

Q: Is the zone heat only to be used as a second stage, where it will be activated only if

the rooftop unit cannot maintain the space temperature, such as during very cold weather?

A: In this mode of operation the rooftop will examine the heating and cooling demands

and try to satisfy all of the zones by switching between heating and cooling as required. The zone heat will only be activated if the zone temperature falls below a selected limit.

Q: Should the zone heat be locked out if the rooftop unit is supplying warm air?

A: In many instances it is desirable to use the rooftop heating whenever possible and

only use zone heat when the rooftop unit is in cooling or vent mode. This often provides the most cost effective operation since zone heat is typically electric. This mode of operation will lockout zone heat if the rooftop is delivering heated air.

Design Guide 1-25

Section 1 Auto-Zone Plus

The following paragraphs describe the operation of each of the relays on the optional relay expansion board. The user can choose the appropriate relays for any given application.

Relay #1 - Parallel Fan

If the Zone is in cooling mode or vent mode, the parallel fan can activate anytime the zone temperature drops 0.5°F below the heating setpoint. It de-activates when the temperature rises above the heating setpoint. The space temperature must be below the Aux Heat Setpoint in the occupied mode, before the Parallel Fan relay can be energized.

Relay #2 - Box Heat

If the Zone Manager is in cooling mode or vent mode then the box heat can activate anytime the zone temperature drops 1.5°F below the heating setpoint. It de-activates when the temperature rises to within 1.0°F of the heating setpoint. Box Heat is not allowed to activate in the heating mode when there is hot air being supplied by the air handling unit. This output was intended to allow zone re-heat while the Zone Manager is satisfying cooling demands in other zones. The space temperature must be below the Aux Heat Setpoint in the occupied mode, before the Box Heat relay can be energized.

Relay #3 - Aux Heat

In the occupied mode, the Aux Heat can activate anytime the zone temperature is 0.5°F below the Aux Heat Setpoint. It de-activates when the temperature rises 0.5°F above the Aux Heat Setpoint. In the Unoccupied Mode, the Aux Heat uses the Unoccupied Heating Setpoint with the same deadband values mentioned above. This prevents the zone from maintaining the same Aux Heat Setpoint at night that it does during the daytime.

This output was intended to allow zone heating to augment the normal Heating Mode and also to allow a zone an attempt to satisfy its own heating needs before creating a Heating Demand at the Zone Manager.

Relay #4 - Series Fan

The series fan runs anytime the main fan is running. This includes Occupied and Unoccupied Modes. The fan can only start running when the Zone Damper is closed, so it determines that the damper is closed before starting the fan.

Modulating Box Heat Available

Modulating Heat is available by using the OE322 Expansion Board but requires special consideration. The OE322 board can provide a 0-10 VDC modulating signal for a Modulating Hot Water Valve or an SCR Electric Heating Coil Controller. Please contact WattMaster for more information.

1-26 Design Guide

Auto-Zone Plus Section 1

Index:

“K” Factor........................................... 23

1000-1500 FPM .................................. 22

1750-2250 FPM .................................. 19

2000 FPM rule .................................... 18

275 BTUH/LINEAR FOOT................ 19

4 Relay Output Expansion Board.......... 4

400 BTUH/LINEAR FOOT................ 19

Air Motion .......................................... 19

Analog Output Board............................ 4

Auto-Zone Plus System

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

Aux Heat ............................................. 26

AUX HEAT setpoint........................... 26

Auxiliary Heat..................................... 13

Auxiliary Heat Control Options.......... 25

Baseboard Heat ................................... 25

Box Heat ............................................. 26

Building Pressurization....................... 14

Bypass CFM........................................ 19

Bypass Damper

Defined.............................................. 7

Bypass Damper Sizing........................ 19

Ceiling Diffuser .................................. 19

Central Unit

Sizing ........................................ 17, 18

CommLink IV

Described .......................................... 5

Constant Volume Controller

Defined.............................................. 8

Constant Volume Rooftop Units........... 4

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

Cooling

Partial Load Conditions .................. 10

Damper

Sizing .............................................. 19

Design Considerations ........................ 10

Design Guide ...................................... 15

Diffuser ............................................... 19

Downdrafts.......................................... 19

Duct Design ........................................ 18

Duct Static Pressure .............................. 7

Ducted Returns.................................... 11

East Exposures .................................... 17

Economizer ............................. 10, 12, 14

Ethernet Connection.............................. 6

Expansion Boards

Defined.............................................. 9

Exposures

East.................................................. 17

North ............................................... 17

South ............................................... 17

West ................................................ 17

Fan Powered Boxes............................. 25

First Stage Heat................................... 25

Heating

Sizing .............................................. 18

Heating - Partial Load Conditions ...... 13

Heating Difficulties............................. 13

Heating Requirements......................... 25

High Duct Static.................................. 12

HVAC Unit Installation

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

Incorrect Zoning

Diagram........................................... 16

Installation

HVAC Unit ....................................... 3

Internet .................................................. 6

IP Module Kit

Defined.............................................. 6

Linear Slot Diffusers........................... 19

Load Program...................................... 22

Low Ambient Temperature Lockout... 10

Low Supply Air Temperatures............ 11

Low Temp Lockouts ........................... 10

Modulating Box Heat.......................... 26

Modulating Chilled Water Valve.......... 4

Modulating Hot Water Valve................ 4

Noise Levels........................................ 11

Noise Problems ................................... 18

North Exposures.................................. 17

Optimal Start......................................... 4

Override Conditions............................ 13

Design Guide 1-27

Section 1 Auto-Zone Plus

Oversizing

Unit ................................................. 11

Parallel Fan ......................................... 26

Partial Load Conditions

Cooling............................................ 10

Heating............................................ 13

Peak Cooling Load

Sizing .............................................. 18

Peak Load

Determining .................................... 22

Plenum Returns................................... 11

Powered Exhaust................................. 14

Pressure Eependent ............................. 18

Pressure Independent Round Damper

“K” Factor....................................... 23

Pressure Independent Zone

Controllers....................................... 11

Prism ................................................. 4, 5

Radiant Ceiling Panels........................ 25

Rectangular Damper Sizing ................ 24

Rectangular Zone Dampers................. 24

Relay #1 - Parallel Fan........................ 26

Relay #2 - Box Heat............................ 26

Relay #3 - Aux Heat............................ 26

Relay #4 - Series Fan .......................... 26

Remote Link II

Described .......................................... 6

Requirements

for Heating ...................................... 25

Rooftop HVAC Units ........................... 4

Rooftop Unit ....................................... 25

Room Air Motion................................ 19

Round Damper Sizing Chart............... 22

Round Zone Damper Selection........... 22

SCR Electric Heater.............................. 4

SCR Electric Heating Coil.................. 26

Second Stage Heat .............................. 25

Selection

Round Zone Damper....................... 22

Sensors

Described .......................................... 9

Series Fan............................................ 26

Series Fan Boxes................................. 19

Sizing

Central Unit..................................... 17

Rectangular Dampers...................... 24

Zone Dampers................................. 22

Slaved Dampers .................................. 22

Slot Diffusers ...................................... 19

Slot Expansion Base Board................... 4

South Exposures ................................. 17

Static Pressure Sensor

Locations......................................... 21

Static Pressure Sensor Location.......... 20

Static Pressure Setpoint....................... 11

Stratification........................................ 19

System Components.............................. 5

System Manager.................................... 4

Defined.............................................. 5

Temperatures

Low Supply Air............................... 11

Variable Frequency Drive (VFD) ......... 7

VFD................................................. 7, 13

VFD Control

Defined.............................................. 7

West Exposures................................... 17

Zone Controller

Defined.............................................. 8

Zone Controllers

Pressure Independent ...................... 11

Zone Dampers

Rectangular ..................................... 24

Sizing .............................................. 22

Zone Diversity..................................... 10

Zone Manager

Defined.............................................. 6

Requirements for............................. 15

Zone Sensor

Defined.............................................. 9

Zoning................................................. 15

Incorrectly ....................................... 16

1-28 Design Guide

Auto-Zone Plus Section 2

Table of Contents

Installation Tips............................................................... 5

Zone Manager ..................................................................8

General.............................................................................................................................8

Zone Manager Components.............................................................................................9

Zone Manager Wiring....................................................................................................10

Zone Manager Addressing.............................................................................................11

Expansion Board Wiring................................................................................................12

Communications Loops .................................................14

Bypass Dampers ............................................................16

Bypass Damper Wiring..................................................................................................18

Zone Dampers................................................................ 19

Zone Controllers ............................................................20

Zone Controller Components.........................................................................................21

Zone Controller Wiring & Addressing ..........................................................................23

Slaved Zone Controller Wiring......................................................................................24

Auxiliary Relay Board for Zone Controllers .................. 25

General...........................................................................................................................25

Auxiliary Relay Board Wiring .......................................................................................26

Auxiliary Relay Sequence of Operation.........................................................................27

Relay #1 - Parallel Fan...............................................................................................27

Relay #2 - Box Heat...................................................................................................27

Relay #3 - Aux Heat...................................................................................................27

Relay #4 - Series Fan .................................................................................................27

Modulating Box Heat.................................................................................................27

CV Controller .................................................................28

General...........................................................................................................................28

CV Controller Components ...........................................................................................29

CV Controller Wiring ....................................................................................................30

CV Controller.................................................................................................................32

CV-C Controller .............................................................. 33

General...........................................................................................................................33

CV-C Controller Wiring ................................................................................................34

CV-C Expansion Board Wiring .....................................................................................35

CV-C Controller.............................................................................................................37

Design Guide 2-1

Section 2 Auto-Zone Plus

Sensors .......................................................................... 38

Room Sensors ................................................................................................................38

Supply Air Temperature Sensor.....................................................................................40

Return Air Temperature Sensor .....................................................................................40

Outside Air Temperature Sensor....................................................................................41

Duct Static Pressure Sensor ...........................................................................................42

CommLink IV ................................................................. 44

General...........................................................................................................................44

Optional IP Module Kit .................................................................................................44

Optional Remote Link II................................................................................................45

CommLink IV Wiring....................................................................................................46

CommLink IV DIP Switch Setting ................................................................................47

Installing the CommLink IV ..........................................................................................48

System Manager............................................................ 49

System Manager Wiring ................................................................................................50

Table of Figures

Figure 2-1: Plus System Overview.................................................................................6

Figure 2-2: Typical System Component Location ..........................................................7

Figure 2-3: Remote Communication Options.................................................................7

Figure 2-4: Auto-Zone Plus Zone Manager Dimensions................................................8

Figure 2-5: Auto-Zone Plus Zone Manager Components ..............................................9

Figure 2-6: Zone Manager Wiring..................................................................................10

Figure 2-7: Zone Manager Address Switch Setting........................................................11

Figure 2-8: Expansion Board Wiring and Jumper Settings ............................................12

Figure 2-9: Communication Loop Wiring, Daisy-Chain Configuration ........................15

Figure 2-10: Round And Rectangular Bypass Dampers................................................16

Figure 2-11: Bypass Damper Wiring..............................................................................18

Figure 2-12: Round And Rectangular Zone Dampers ...................................................19

Figure 2-13: Zone Controller Components....................................................................21

Figure 2-14: Zone Controller Wiring & Addressing......................................................23

Figure 2-15: Slaved Zone Controller Wiring.................................................................24

Figure 2-16: Auxiliary Relay Board Layout ..................................................................25

Figure 2-17: Zone Controller Auxiliary Relay Board Wiring Examples.......................26

Figure 2-18: CV Controller Dimensions........................................................................28

Figure 2-19: CV Controller - Components ....................................................................29

Figure 2-20: CV Controller Wiring ...............................................................................30

Figure 2-21: CV Controller Address Switch Setting .....................................................32

2-2 Design Guide

Auto-Zone Plus Section 2

Figure 2-22: CV-C Controller Dimensions.................................................................33

Figure 2-23: CV-C Controller Wiring ........................................................................34

Figure 2-24: CV-C Expansion Board Wiring .............................................................35

Figure 2-25: CV-C Controller Address Switch Setting ..............................................37

Figure 2-26: Room Sensor Installation .......................................................................38

Figure 2-27: Room Sensor to Zone Controller Wiring...............................................39

Figure 2-28: Room Sensor to CV Controller Wiring..................................................39

Figure 2-29: Supply or Return Air Sensor Installation...............................................40

Figure 2-30: Outside Air Temperature Sensor............................................................41

Figure 2-31: Duct Static Pressure Sensor Dimensions ...............................................42

Figure 2-32: Static Pressure Sensor Wiring................................................................43

Figure 2-33: CommLink IV Wiring............................................................................46

Figure 2-34: CommLink IV DIP Switch Setting ........................................................47

Figure 2-35: CommLink IV to Zone Manager Wiring ...............................................47

Figure 2-36: System Manager Dimensional Data.......................................................49

Figure 2-37: System Manager Wiring.........................................................................50

Design Guide 2-3

Section 2 Auto-Zone Plus

2-4 Design Guide

Auto-Zone Plus Section 2

Installation Tips

Take a few moments to review the following before beginning installation of the AutoZone Plus System.

• 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 zone dampers, be sure to tag each damper with its appropriate

location. A set of labels is included with this manual. It is also best to set the zone controller address switches before mounting in drop ceilings. Use the Zone Address Worksheet to list all zone locations. This will assist you greatly when setting up the system.

• 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.

Note: Auto-Zone Plus systems use two separate types of communications loops. The

Network Loop connects only to the Zone Managers and the CommLink IV. The Local Loops connect between the Zone Manager and the Zone Controllers for that HVAC unit. Each Zone Manager has its own Local Loop for connection to associated Zone Controllers and any additional Constant Volume units and the System Manager.

Do not connect Zone Controllers, Constant Volume Units or the System Manager to the Network Loop!

• 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.

Design Guide 2-5

Section 2 Auto-Zone Plus

Typical Rooftop HVAC Unit

Control Cable

Supply Fan

Mixed Air

Heating Coil

Cooling Coi l

Filter Bank

Outdoor Air

Exhaust Air

Connect To Other Zone Managers

Avoid Direct

Sunlight

Network Comm Loop

Vol tage

120/24 VAC Transfomer

Ethernet Cable To Router

Temperature Sensor

2 Conductor

24 GA.

Outdoor Air Temp. Sensor

24 VAC

Ground

Supply Air

2 Conductor

24 GA.

3 Conductor

24 GA.

Modulating Zone

Damper

Controller

Zone Manager

Local Comm Loop

Space Temperature Sensor

System Manager

CommLink IV

Use Of The CommLink IV Is Required For All Multiple Loop Networked Systems. The IP Module, Remote Link II And Computer Are Optional. All Computers Used Require The Graphical User Interface Software

Ethernet Router

(By Others)

When IP Module

Option Is Used

Be Installed.

Optional IP Module

Installs Into CommLin k IV

And Provides

LAN And Internet Com munications

With The Cont rol System

Prism

USB Cable To Computer

Serial Cable To Remote Link

All Components Shown Inside This Box Are Optional

Modulating Bypass

Damper

Static Pressure Sensor

& Pickup Tube

Supply Air Duct

Zone

Zone 1

Plain

UP TO 16 ZONES

Optional Personal Computer

Phone Cable To Telephone Wall Outlet Jack

Optional Remote Link II

Connects to CommLink IV

And Provides Dial-up Modem

Communications

With The Control System

2 Conductor

24 GA.

Return Air

Temperature Sensor

Connect To Other

Zone Controllers Or

CV Units

Zone

Controller

Space Temperature Sensor

W/ Override & Setpoint Adjustment

WARMER

NORMAL

COOLER

OVR

Zone 2

Modulating Zone

Damper

Figure 2-1: Plus System Overview

2-6 Design Guide

Auto-Zone Plus Section 2

Typical HVAC Unit

(Packaged or Split System)

Supply Temp Sensor

(Ahead of Bypass Takeoff)

Bypass Damper

( Locate Where Easily Accessible )

Return Duct

LOCAL COMM LOOP

TWISTED PAIR

WITH SHIELD TO

ZONE CONTROLLER

Above Corridor

( Preferred Location )

Static Pressure Pickup

(2/3 Of The Way Down Main Duct)

LOCAL COMM LOOP

TWISTED PAIR WITH

ZONE CONTROLLERS

OR CV CONTROLLERS

Zone Sensor

(4-1/2' to 5'; Shoulder Height)

SHIELD TO OTHER

Supply Duct

Zone Damper and Control

( Over Corridor for Easy Service )

W A R M

N O

V R

O L E R

LOCAL COMM LOOP

TWISTED PAIR

WITH SHIELD TO

ZONE CONTROLLER

Diffuser at Perimeter Wall

(Direct Airflow Inward Towards Center of Area)

Duct to Return

(Preferred)

Outdoor Air Sensor

(Mount Away From Direct Sunlight))

Zone Manager

NETWORK COMM LOOP

TWISTED PAIR

WITH SHIELD TO

NEXT ZONE MANAGER

Return Temp Sensor

(Avoid Mixed Air Area)

Figure 2-2: Typical System Component Location

Communications Cable Network Loop:

Connects To Zone Managers(s

CommLink IV

The CommLink IV Is Required For All Auto-Zone Plus Systems. The IP Module, Remote Link II, And Computer Are Optional On All Systems, But They Require A CommLink IV. All Computers Require Installation of Prism Graphical User Interface Soft ware.

Ethernet Cable To Router

)

USB Cable To Computer

Optional IP Module

Installs Into CommLink IV

And Provid es

LAN And Internet Communications

With The Control System

Serial Cable To Remote Link

Ethernet Router

(By Others)

When IP Module

Option Is Used

All Components Shown Inside This Box Are Optional

Optional Personal Computer

Phone Cable To Telephone Wall Outlet Jack

Optional Remote Link II

Connects to CommLink IV

And Provides Alarm Ca ll-Outs

A Second Remote Link II Is Required

If Connection To Job Site

Is Desired From Remote Computer

Figure 2-3: Remote Communication Options

Design Guide 2-7

Section 2 Auto-Zone Plus

Zone Manager

General

The Zone Manager may be installed in any convenient protected location. Observe the recommended environmental limitations for the Zone Manager (see Technical Data section of the product data sheet) when choosing a location.

The Zone Manager may be mounted without removing the controller from the mounting plate. The unit is mounted by four (4) screws in the corners. Select the correct screws or other fasteners for the type of mounting material being utilized.

7.13

9.00

7.63

Figure 2-4: Auto-Zone Plus Zone Manager Dimensions

2-8 Design Guide

8.25

2.38

Auto-Zone Plus Section 2

Zone Manager Components

COMMUNICATIONS

LOCAL

COMMUNICATIONS

LOOP

ZONE MANAGER

ADDRESS

SWITCH

SET TO ADDRESS 17

NETWORK

LOOP

CLUSTER

ADDRESS

SWITCH

SET SEQUENTIAL

ADDRESSES 1,2,3, ETC

24VA

POWER

ECONOMIZER

CONTROL

STATIC

PRESSURE

SENSOR

RELIEF

FAN

CONTACT

ANALOG

INPUTS

Figure 2-5: Auto-Zone Plus Zone Manager Components

Design Guide 2-9

Section 2 Auto-Zone Plus

Zone Manager Wiring

Expansion Board For Modulating Heating & 6

e Cooling Configuration.

Sta Shown. Other Configuration Options Are Available.

Figure 2-4

See

Bypass/Slave

Actuator

(Optional)

Bypass Interface

(Optional)

Network

Comm Loop

Board

PJ1

GND

OPEN

PJ2

LD2

LD1

FDBK

GND OPEN

TB1 TB2

Y2 W1 W2

HVAC Unit

rminals

24 VAC Only

Line

Voltage

Note

Wired So That All Ground Wires Remain Common

OE352 Expansion Base Board

W/ OE355 4 Analog Output &

OE357 4 Relay Expansion Board

Auto-Zone Plus Zone Manager

24VAC

PWR

GND

NE5090

REC

K 1

OPEN

FDBK GND

K 2

OPEN

SHIELD

NETWORK

SHIELD

R FAN

COOL1

COOL2

HEAT1

HEAT2

LOOP

LOCAL

LOOP

R G

24VAC

GND

: 24 VAC Power Connection Must Be

(Optional)

V R 3

7824

2 7

1 2 4 8

S W 1

V R 2

7812

2 6

R 4 0

5.11V ADJUST

Local Communications Loop

PJ1

A D D

To Zone Controllers

And System Manager

Note: See Specific Manufacturer’s Wiring Diagrams

For Other Models Or Brands Of Actuators If Used. (Actuator Must Be Capable of Acceptin VDC Signal)

Splice As Required

Static Pressure

Sensor

LO HI

FRP

Tubing

(By Others)

S E N

P R

S O

E S

ANALOG

INPUTS

+12V

SAT

R10

RAT

OAT

AUX1 AUX2

AUX3

GND GND

EXHAUST

CONTACTS

N.O.

Output Signal (0-10 VDC)

ANALOG OUTPUTS

A1 A2 G

TB2

Static Pressure

Pick-up Probe

Supply Air Temperature

Sensor

Return Air Temperature

Sensor

Outdoor Air Temperatur

Sensor

AUX1 Heat/Cool

Disable Or Fan

Proving

AUX2

Filter

Alarm

AUX3

Forced

Occupied

Mode

VFD

(Optional)

Economizer Actuator

BELIMO

AF24-SR

COMM

5 U

4 Y2

3 Y1

133 IN-LB

2 + 1 COM

TB3

0-10 or 2-10

Figure 2-6: Zone Manager Wiring

2-10 Design Guide

Auto-Zone Plus Section 2

Zone Manager Addressing

Figure 2-7: Zone Manager Address Switch Setting

Design Guide 2-11

Section 2 Auto-Zone Plus

Expansion Board Wiring

The OE352 Expansion Base Board can be populated with (1) or (2) OE357 Relay Output Expansion Boards or (1) OE357 Relay Output Expansion Board and (1) OE355 4 Analog Output Expansion Board or (1) OE355 4 Analog Output Expansion Board by itself. The number and type of expansion board(s) required depend on your HVAC unit configuration and requirements. See Figure 2-8 for details.

OE352 Expansion Base Board

With OE355 4 Analog Output &

OE357 4 Relay Expansion Board

Connect To Zone Manager

Connect To 24 VAC Transformer

OUT1

OUT2

OUT3

OUT4

4RLY IO BD.

(Optional)

24VAC

GND

YS101790

Jumpers Must Be Set As Shown

Modulating Cooling Device

Cooling

Heating

Modulating Heating Device

OE352 Expansion Base Board

With OE355 4 Analog Output Board

Connect To Zone Manager

Connect To 24 VAC Trans former

(Optional)

24 VAC 24 VAC

GND GND

24VAC

GND

AOUT1

AOUT2

AOUT3

AOUT4

GND GND

4 AOUT MOD I/O BD 4 AOUT MOD I/O BD

Jumpers Must Be Set As Shown

Modulating Heating Device

Heating

YS101786 YS101786

Cooling Stage 3 Cooling Stage 4 Cooling Stage 5 Cooling Stage 6

Expansion Board Wiring For HVAC Units With

Modulating Hot Water Heating & Modulating

Modulating Cooling Device

Cooling

Heating Stage 3

Heating Stage 4 Heating Stage 5 Heating Stage 6

Expansion Board Wiring For HVAC Units With

Modulating Chilled Water Cooling &

Chilled Water Cooling

OE352 Expansion Base Board With OE355 4 Analog Output &

OE357 4 Relay Expansion Board

Connect To Zone Manager

Connect To 24 VAC Trans former

Than 2 Stages Of ing

(Optional)

24 VAC 24 VAC

GND GND

24VAC

GND

AOUT1

AOUT2

AOUT3

AOUT4

GND

4 AOUT MOD I/O BD

YS101790

4RLY IO BD.

Heat

Jumpers Must Be Set As Shown

YS101786

Requiring More

Expansion Board Wiring For HVAC Units With

Modulating Hot Water Heating & Requiring More

Cooling Stage 3

Cooling Stage 4 Cooling Stage 5 Cooling Stage 6

Heating Stage 3

Heating Stage 4 Heating Stage 5 Heating Stage 6

Expansion Board Wiring For HVAC Units Requiring More

Than 2 Stages of Heating & Also Requiring More

Than 2 Stages Of Cooling

OE352 Expansion Base Board

With (2) sOE357 4 Relay Expansion Board

Connect To Zon e Manager

Connect To 24 VAC Transformer

Than 2 Stages Of Cooling

Figure 2-8: Expansion Board Wiring and Jumper Settings

(Optional)

4RLY IO BD.

Jumpers Must Be Set As Shown

24VAC

GND

YS101790

2-12 Design Guide

Auto-Zone Plus Section 2

The Expansion board(s) plugs into the OE352 Expansion Base Board and the Base Board connects to the Zone Manager via a modular cable. There are jumpers located on the base board that must be set depending on the board and application it is being used for. Refer to Figure 2-8 for wiring and jumper settings for the various configurations available.

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

while mounting the backplate. Mark the holes then remove the Zone Manager before drilling. Do not allow metal shavings to

fall onto the circuit boards.

The Zone Manager requires the following electrical connections:

18 gauge minimum unless otherwise noted.

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

-Communications Loop .................. (18 ga. min.) 2 conductor twisted pair with shield

WattMaster wire, Belden #82760 wire or equivalent

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

-Return Air Temperature Sensor......................................... (24 ga. min.) 2 Conductors

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

-Supply Static Pressure Sensor ........................................... (24 ga. min.) 3 Conductors

-Bypass Damper.................................................4 Conductors, twisted pair with shield

-VFD ..................................................................2 Conductors, twisted pair with shield

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

G - Fan Y1 - Cool 1 Y2 - Cool 2 W1 - Heat 1 W2 - Heat 2

The Following Outputs Require The OE352 Expansion Base Board and 1 or more of the following expansion boards:

OE357 4 Relay Expansion Board -Y3 through Y6 OE357 4 Relay Expansion Board - W3 through W6

OE355 4 Analog Output Expansion Board – Modulating Cooling

OE355 4 Analog Output Expansion Board – Modulating Heating

Tip: After making all electrical connections, it is advised to unplug all terminal

blocks on the Zone Manager 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.

Design Guide 2-13

Section 2 Auto-Zone Plus

Communications Loops

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 2-9.

Note: Auto-Zone Plus systems use two separate types of communications loops. The

Network Loop connects only to the Zone Managers and the CommLink. The Local Loops connect between the Zone Manager and the Zone Controllers for that HVAC unit. Each Zone Manager has its own Local Loop for connection to its associated Zone Controllers, any additional CV or CV-C units or Add-on Controllers and the System Manager.

Do not connect Zone Controllers, CV Controllers, Add-on Controllers or

the System Manager to the Network Loop!

Both the network communications loop and the local communications loops utilize 18 gauge minimum 2 conductor twisted pair with shield communication cable to interconnect the various controllers and interfaces on the system. The loops are best connected in daisy chain configuration, meaning the loops are connected from one controller to another. It is not necessary to sequentially address the zone controllers or other controllers in relation to their location on the loop. However zone controllers should be numbered from 1 to 16 and any CV, CV-C or Add-on Controllers should be numbered from 18 to 30.

WattMaster offers communications cable that is color coded with red or green candy striping to distinguish the Network and Local Loop wiring runs. The network loop wire has red striping while the local loop wire has green striping. This can really help you on large jobs by keeping your network and local loop wiring runs visually distinguishable from each other and helps prevent potential network and local loop cross connections. If you do not use the WattMaster communications cable you must use Belden #82760 cable or its 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. Any time a splice is made in the cable you increase your chance of problems.

2-14 Design Guide

Auto-Zone Plus Section 2

|b0|i0|c0|

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.

Constant Volume

Controller

(Addresses Start At 18)

Computer

(Optional)

Set MiniLink

Address

Switch To 1

Network Loop

24VAC

HVAC Unit #1 Zone Manager

Zone

Controller #1

RAM

R34

R18

32K

FLOW

CX4

CX3

CX8

U3 RN1 1

9936

MS6264L-70PC

AZZONE

V4.00F C094

74HC573N

B31920PS

R27

CX9

C13

LMC662

RAM

EPROM

C14

80C55

R22

VREF

ADJ

P.U.

C10

R32

R23

T'STA

R28

R24

U11

C2C1

R19

PHILIPS

C11

R20

C15

PHILIPS

PCB80C55 2- 5 -1 6WP

500650=1/ 3

DFD9940SM

CX5

EWDOG

R25

ADDRE

SS ADD

CX10

93C46

PJ1

COMM

75176

SW1

CX6

U10

16 32

LD3

POWER

TOKEN

R100

PJ2

NET

R13

R26

R14

250

LD2

LD1

R21

YS101

562 REV. 2

REC

SCAN

R12C6R11

R10

fTimes New

Roman|b0|i0|

Roman

c0|p18;OMRON

G5L-114P-PS 24VDC CONTACT:

MDL

VR1

UL / CSA 5A250VAC

fTimes New

7824

7824C

R15

fTimes New

24VAC

Roman|b0|i0|

9936

Roman

64A

c0|p18;OMRON

G5L-114P-PS

MC340

24VDC CONTACT:

Q3Q2

R16

UL / CSA 5A250VAC

R17

GND

CX1

TCU32K2V

16L8

CX2

74HC259

B31920PS

EXPAN

SION

ACTUA

TOR

p18;

Zone

Controller #16

RAM

R34

R18

32K

FLOW

CX4

CX3

CX1

CX8

RN1

TCU32K2V

9936

MS6264L-70PC

AZZONE

V4.00F C094

74HC573N

B31920PS

R27

16L8

CX9

C13

LMC662

RAM

EPROM

C14

80C55

R22

CX2

VREF

ADJ

P.U.

C10

R32

R23

74HC259

B31920PS

T'STA

R28

R24

U11

C2C1

R19

PHILIPS

C11

R20

C15

PHILIPS

PCB80C55 2- 5 -1 6WP

500650=1/ 3

DFD9940SM

CX5

EWDOG

R25

ADDRE

SS ADD

CX10

93C46

PJ1

COMM

75176

SW1

CX6

U10

16 32

LD3

POWER

TOKEN

R100

PJ2

NET

R13

R26

R14

250

LD2

LD1

R21

YS101

562 REV. 2

REC

SCAN

R12C6R11

R10

fTimes New

Roman|b0|i0|

p18;

Roman

c0|p18;OMRON

G5L-114P- PS 24VDC CONTACT:

MDL

VR1

UL / CSA 5A 25 0V AC

fTimes New

7824

7824C

R15

fTimes New

24VAC

Roman|b0|i0|

p18;

9936

Roman

64A

c0|p18;OMRON

G5L-114P- PS

MC340

24VDC CONTACT:

Q3Q2

R16

UL / CSA 5A 25 0V AC

R17

GND

EXPAN

SION

ACTUA

TOR

USB Cable To C omp ut er

CommLink IV

Set MiniLink

Address

Switch To 2

Set Board To

Address 17

24VAC

Set Board To

Address 17

Local Loop #1

HVAC Unit #2 Zone Manager

Local Loop #2

24VAC

The Loop Does Not Have To Follow The Board Address Sequence

Zone

Controller #1

RAM

R34

R18

32K

FLOW

CX4

CX3

CX1

CX8

RN1

TCU32K2V

MS6264L-70PC

V4.00F

74HC573N

B31920PS

AZZONE

9936

C094

R27

16L8

CX9

C13

LMC662

RAM

EPROM

C14

80C55

R22

CX2

VREF

ADJ

P.U.

C10

R32

R23

74HC259

B31920PS

T'STA

R28

U11

R24

C2C1

R19

PHILIPS

C11

R20

C15

PHILIPS

PCB80C552-5-16WP

500650=1/3

DFD9940SM

CX5

EWDOG

R25

ADDRE

SS ADD

CX10

93C46

PJ1

EXPAN

SION

COMM

75176

SW1

CX6

U10

8 16 32

LD3

POWER

TOKEN

R100

PJ2

NET

R13

R26

ACTUA

TOR

R14

250

LD2

LD1

R21

YS101

562 REV.

REC

SCAN

R12C6R11

R10

fTimes New

Roman|b0|i0|

p18;

Roman

c0|p18;OMRON

G5L-114P-PS 24VDC CONTACT:

MDL

VR1

UL / CSA 5A250VAC

fTimes New

7824

7824C

R15

fTimes New

24VAC

Roman|b0|i0|

p18;

9936

Roman

64A

c0|p18;OMRON

G5L-114P-PS

MC340

24VDC CONTACT:

Q3Q2

R16

UL / CSA 5A250VAC

R17

GND

24VAC

Zone

Controller #16

RAM

R34

R18

32K

FLOW

CX4

CX3

CX8

RN1 1

MS6264L-70PC

V4.00F

74HC573N

B31920PS

AZZONE

9936

C094

R27

CX9

C13

LMC662

RAM

EPROM

C14

80C55

R22

VREF

ADJ

P.U.

C10

R32

R23

T'STA

R28

U11

R24

C2C1

R19

PHILIPS

C11

R20

C15

PHILIPS

PCB80C552-5-16WP

500650=1/3

DFD9940SM

CX5

EWDOG

R25

ADDRE

SS ADD

CX10

93C46

PJ1

COMM

75176

SW1

CX6

U10

8 16 32

LD3

POWER

TOKEN

R100

PJ2

NET

R13

R26

R14

250

LD2

LD1

R21

YS101

562 REV.

REC

SCAN

R12C6R11

R10

fTimes New

Roman|b0|i0|

Roman

c0|p18;OMRON

G5L-114P- PS 24VDC CONTACT:

MDL

VR1

UL / CSA 5A 25 0V AC

fTimes New

7824

7824C

R15

fTimes New

24VAC

Roman|b0|i0|

9936

Roman

64A

c0|p18;OMRON

G5L-114P- PS

MC340

24VDC CONTACT:

Q3Q2

R16

UL / CSA 5A 25 0V AC

R17

GND

24VAC

Or Add On Devices

(Addresses Start At 18)

CX1

TCU32K2V

16L8

CX2

74HC259

B31920PS

EXPAN

SION

ACTUA

TOR

p18;

24VAC

To A ny Ot her

CV Controllers

Constant Volume

Controller

24VAC

To Ot he r

CV, CV-C or Add-On Controllers

Figure 2-9: Communication Loop Wiring, Daisy-Chain Configuration

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

Note: The loop does not have to follow the controller address sequence.

Caution: If comm loop is not installed in conduit be careful to position the cable

away from high noise devices like fluorescent lights, transformers, VFD’s, etc. Conduit is not required for comm loop wiring unless required by local codes.

Design Guide 2-15

Section 2 Auto-Zone Plus

Bypass Dampers

The Bypass Damper can be either round or rectangular. The Round Bypass Damper is supplied with the Damper Actuator and Bypass Wiring Interface Board factory mounted in a sheet metal enclosure attached to a Round Air Damper assembly. This Round Bypass Damper Package is field connected to the appropriate size round duct. Rectangular Bypass Dampers mount directly in the rectangular ductwork using flanged connections field formed in the rectangular ductwork. A Rectangular Bypass Damper Kit is required to complete the Rectangular Bypass Damper package. The Rectangular Bypass Damper

Figure 2-10: Round And Rectangular Bypass Dampers

Kit is supplied with the Damper Actuator and Bypass Wiring Interface Board factory mounted in a sheet metal enclosure. This assembly is then field mounted over the Rectangular Damper shaft and secured to the ductwork with sheet metal screws.

Up to two additional Rectangular Bypass or Round Bypass Dampers can be slaved together when it is not practical to use a single large damper. See Figure 2-11. The bypass damper(s) should be installed as close as possible to the rooftop unit.

Round and Rectangular Bypass Dampers should be securely hung using either wire cradles or metal strapping. While the dampers may be hung in any position, avoid sharp kinks in flexible duct to prevent airflow restrictions. The Round Bypass Dampers are insulated for use in non-conditioned spaces to avoid sweating and to improve energy efficiency.

2-16 Design Guide

Auto-Zone Plus Section 2

See Figure 2-2 for a typical bypass damper mounting location. See Figure 2-11 for typical Bypass Wiring Interface Board wiring instructions.

Warning: If sheet metal screws are used to mount the dampers, be certain that

they do not interfere with the movement of the damper blade.

Warning: Never depress the actuator clutch with power applied. Unplug the

actuator cable before depressing the clutch and attempting to rotate the damper blade. Do not force the damper blade as this can damage the gears in the damper actuator.

Design Guide 2-17

Section 2 Auto-Zone Plus

Bypass Damper Wiring

BYPASS ACTUATOR #1

(MASTER)

MODULARCABLE

BYPASS ACTUATOR #3 (SLAVE)

(WHEN USED)

1 10 0

NOT USED FOR THIS APPLICATI ON

OPEN

TB1

GND

FDBK

OPEN

GND

BYPASS &

SLAVE INTERFACE CARD

LD1

LD2

PJ2

FRO

ONE

LLE

TB2

PJ1

BYP

SLAVEINTE

TO ACTUA

101824

ASSAN

TOR

ACE

BYPASS ACTUATOR #2 (SLAVE)

ZONE MANAGERBOARD

NE5090

REC

K1K1

OPEN

FDBK

GND

K2K2

OPEN

NET

WOR

BYPASS &

SLAVE INTERFACE CARD

ACE

TOR

ASSAN

101824

TO ACTUA

BYP

SLAVEINTE

PJ1

TB2

LLE

ONE

FRO

PJ2

LD2

LD1

TB1

GND

OPEN

FDBK

GND

OPEN

MODULAR

CABLE

NOT USED FOR THIS APPLICATI ON

BYPASS &

SLAVE INTERFACE CARD

ACE

TOR

ASSAN

101824

TO ACTUA

BYP

SLAVEINTE

PJ1

GND

OPEN

TB2

LLE

ONE

FRO

PJ2

LD2

LD1

FDBK

GND

TB1

OPEN

MODULAR

CABLE

NOT USED FOR THIS APPLICATI ON

Figure 2-11: Bypass Damper Wiring

Warning: If the fan system has the capability of producing static pressures which

could damage ductwork, you must provide a manual reset, high pressure limit switch to cut-off the fan system in the event of high duct static. Do not use your Auto-Zone System as a

safety device!

2-18 Design Guide

Auto-Zone Plus Section 2

Zone Dampers

The Zone Damper can also be either round or rectangular. The Round Zone Damper is supplied with the damper actuator and Zone Controller factory mounted in a sheet metal enclosure attached to a Round Air Damper assembly. This Round Zone Damper Package is field connected to the appropriate size round duct. Rectangular Zone Dampers mount directly in the rectangular ductwork using flanged connections field formed in the rectangular ductwork. A Rectangular Zone Damper Kit is required to complete the Rectangular Zone Damper package. The Rectangular Zone Damper Kit is supplied with the Damper Actuator and Zone Controller factory mounted in a sheet metal enclosure. This assembly is then field mounted over the Rectangular Damper shaft and secured to the ductwork with sheet metal screws.

Figure 2-12: Round And Rectangular Zone Dampers

Up to two additional Rectangular Zone or Round Zone Dampers can be slaved together when it is not practical to use a single damper. See Figure 2-15. Generally this is not required.

Round and Rectangular Zone dampers should be securely hung using either wire cradles or metal strapping. While the dampers may be hung in any position, avoid sharp kinks in flexible duct to prevent airflow restrictions. The Round Zone Dampers are insulated for use in non-conditioned spaces to avoid sweating and to improve energy efficiency.

See Figure 2-2 for typical Round Zone Damper mounting locations. See Figure 2-14 for Zone Controller wiring instructions.

Design Guide 2-19

Section 2 Auto-Zone Plus

Zone Controllers

The Zone Controllers are mounted in snap-track which is typically located in the control enclosure on each zone damper. Orient the board in the snap-track so that the actuator, flow sensor (optional), and auxiliary relay board (optional) cables will reach their respective connectors on the Zone Controller, if they are used. Press the board into the snap-track carefully to avoid damaging any of the electronic components on the circuit board. To remove a board from the snap-track, carefully pull one edge of the snap-track away from the board with your fingers and remove the board.

Caution: Do not use any tools to pry the board loose. This will damage the

board and/or the snap-track.

Warning: When mounting the snap-track, be sure the heads of the screws do not

protrude far enough to touch the bottom of the Zone Controller circuit board.

Consider serviceability of the location when mounting the Zone Controllers. They should be easily accessible to facilitate servicing.

Tip: Use small stickers on the ceiling grid or tiles to help future service personnel

locate system components. If you use small stickers from an office supply store, you can get different colors to code the location of various components.

2-20 Design Guide

Auto-Zone Plus Section 2

Zone Controller Components

Air Flow Sensor Modular Connector

Auxiliary Input

Terminals

Space Sensor Terminals

RS-485 Communications Loop Connection

PowerLED

Fuse

DiagnosticBlink Code LED

Typ ical Pin 1 Indicator

FLOW

RN1

R27

R32

T'STAT

R28

COMM

R26

250

REV. 2

562

YS101

MDL

24VAC

C13

R25

C14

ADJ

C15

CX9

VREF

U11

CX10

75176

R22

P.U .

R23

R24

CX8

C11

R20

LD3

VR1

RAM Chip

R34

EWDOG

U10

POWER

R21

7824

C10

R19

ADDRESS

SW1

SCAN

R18

ADD

LD2

REC

RAM Size Select Jumper

CX4

RAM

80C55 2

2 4 8

16 32 TOKEN

NET

R13

R14

LD1

R15

RAM

R12C6R11

EPROM Chip

32K

EPROM

CX6

R100

R10

PAL Chip

CX3

CX1

16L8

R1 R2 R3

CX2

CX5

R5 R6 R7

PJ1

C2C1

Address Switch

(Set Between 1 & 16)

EXPANSION

Expansion Board Modular Connector

PJ2

ACTUATOR

DamperActuator Modular Connector

GND

R17

R16

24 VAC PowerInput

Figure 2-13: Zone Controller Components

Design Guide 2-21

Section 2 Auto-Zone Plus

The Zone Controller requires the following electrical connections:

18 Gauge minimum unless otherwise noted.

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

-Communications Loop .................. (18 ga. min.) 2 conductor twisted pair with shield

WattMaster wire, Belden #82760 wire or equivalent

-Room Temperature Sensor..................................... 2 Conductors for standard sensors

3 Conductors for sensors with setpoint adjustment

-Fan Terminal units / Auxiliary Heat.............. 2-4 Conductors see wiring diagrams for

(Optional) Auxilary Relay board

Tip: After making all electrical connections, it is suggested that all terminal blocks on

the Zone Controller be unplugged until you are ready to begin the checkout procedure. This may help prevent damage if wiring errors occur elsewhere in the system during installation or start-up. This is particularly important with the Zone Controllers since an error on one unit may prevent any of the others from working until the problem is found and corrected.

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 Zone Controller. If a single transformer is used to power more than one Zone Controller you must connect GND-to-GND and 24VAC-to-24VAC on each zone controller. Failure to observe polarity will result in damage to one or more components in your system.

2-22 Design Guide

Auto-Zone Plus Section 2

ging

Zone Controller Wiring & Addressing

Airflow Sensor (Optional) Only Used For Pressure Independent Applic ations

Airflow

Room Sensor

A R M E R

NORMAL

C O O

OVR

L E R

All Comm Loop Wiring Is

TMP

GND

AUX

Straight Thru

Connection To AUX Terminal Required Only When Sensor Is Spec ified With Slide Adjust Option

Local Loop

RS-485

9600 Baud

Connect To

Next Controller

And/Or Zone

Manager On

Local Loop

24VAC

Required VA For Transformer

Each Zone Controller = 10 VA Max.

(Includes Actuator)

Diagnostic Blink Code LED

Caution!

Zone Controllers Must Have Address Switches Set Between 1 And 16 ( Up To 16 Zone Controllers Per Local Loop ).

Note:

The Power To The Zone Controller M ust Be Removed And Reconnected After Chan Address Switch Set tin To Ta ke Eff ec t.

Caution:

Disconnect All Communic ation Loop Wiring From The Zone Contr oller Before Removing Power From The Zone Control ler. Reconnect Power And Then Reconnect Com munication Loop Wiring.

Notes:

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

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

s In Order For Any Changes

3.)AllCommunication Wirin g To Be 2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

GND

The

SHIELD

Zone Controller

AIRFLOW

RN1

PJ3

P.U.

R27

C13

C14

P.U.

VREF

ADJ

R32

R28

T'STAT

C15

R33

R25

COMM

CX10

485

R26

YS101562 REV. 3

R35

24VAC

GND

C16

Address Switch Sh own Is

Set For Address 9

CX8

R34

R18

CX9

R22

P.U.

C10

R23

R24

U11

R19

R20

C11

EWDOG

ADDRESS

OFF

U10

SW1

POWER

R21

VR1

7824

R17

This Switch Must Be In The ON Position As Shown

CX4

CX3

EPROM

ADD

SCAN

R16

2 4

CX6

8 16 32

R100

NET

R14

R13

REC

R12

R11

R15

Controller Address Switch

The Address For Each Controller

Must Be Between 1 And 16 And Be

Unique To The Other Controllers

CX1

PAL

R1 R2

CX2

CX5

R5 R6 R7

PJ1

EXPANSION

PJ2

ACTUATOR

ADDRESS ADD

1 2 4

8 16 32 TOKEN NET

On The Local Loop

Zone Actuator

Switches Labele d 32 And Token Should Be In The OFF Position As Shown

Address Switch S hown Is

Set For Address 13

Figure 2-14: Zone Controller Wiring & Addressing

Set the Zone Controller Address Switch following the following addressing instructions.

Caution: Incorrect addressing is the number one cause of communication

problems. Check the addressing carefully. Remember, the Zone Controller only reads the switch during a power-up. If the address switch is changed, the unit must be turned OFF then ON before the new setting will be recognized.

Note: Ignore any markings or numbers on the switch. Use this chart!

Design Guide 2-23

Section 2 Auto-Zone Plus

Slaved Zone Controller Wiring

EXPANSION

ACTUATOR

PJ2PJ1

ZONECONTROLLER BOARD

SLAVED-ZONE ACTUATOR #2

(WHEN USED)

ZONE ACTUATOR #1

(MASTER)

MODULARCABLE

SLAVED-ZONE ACTUATOR #1

1 10 0

MODULARCABLE

BYPASS &

SLAVE INTERFA CE CARD

OPEN

TB1

GND

FDBK

OPEN

GND

LD1

LD2

PJ2

FRO

ONE

LLE

TB2

PJ1

BYP

SLAVEINTE

TO ACTUA

101824

ASS AN

TOR

ACE

BYPASS &

SLAVE INTERFA CE CARD

ACE

TOR

ASS AN

101824

TO ACTUA

BYP

SLAVEINTE

PJ1

GND

OPEN

TB2

LLE

ONE

FRO

PJ2

LD2

LD1

FDBK

GND

TB1

OPEN

MODULAR

CABLE

NOT USED FOR THIS APPLICATI ON

BYPASS &

SLAVE INTERFA CE CARD

ACE

TOR

ASS AN

101824

TO ACTUA

BYP

SLAVEINTE

PJ1

GND

OPEN

TB2

LLE

ONE

FRO

PJ2

LD2

LD1

FDBK

GND

TB1

OPEN

MODULAR

CABLE

NOT USED FOR THIS APPLICATI ON

Figure 2-15: Slaved Zone Controller Wiring

2-24 Design Guide

Auto-Zone Plus Section 2

Auxiliary Relay Board for Zone Controllers

General

An optional auxiliary relay board is available for the Zone Controllers. This board provides additional outputs for the following applications:

• Parallel Fan

• Box Heat

• Auxiliary Heat (typically perimeter type)

• Series Fan The board comes shipped with a modular cable which plugs directly into the Zone Controller connector marked “Expansion.” After connecting the board, the system will need to be powered OFF then ON for the system to recognize the presence of the relay board.

Figure 2-16: Auxiliary Relay Board Layout

Warning: Relay contacts are rated for 24VAC pilot duty only! Do not apply

voltages higher than 24VAC.

Design Guide 2-25

Section 2 Auto-Zone Plus

Auxiliary Relay Board Wiring

24VAC

GND

OE320 Zone Controller

24VAC

8 2

34063

B 4

GND

Fan Relay

(By Others)

U 7

OE320 Zone Controller

24VAC

K 2

GND

8 2

34063

B 4

GND

Fan Relay

(By Others)

U 7

K 2

Heat

Contactor

(By Others)

EXPANSION

24VAC

GND

OE321 Relay Expansion Board

Expansion Board Wiring For Series Flow Fan Terminal Without Heat

OE320 Zone Controller

24VAC

8 2

34063

B 4

GND

Fan Relay

(By Others)

U 7

K 2

24VAC

GND

OE321 Relay Expansion Board

Expansion Board Wiring For Series Flow Fan Terminal With Electric Heat

OE320 Zone Controller

24VAC

8 2

34063

B 4

GND

Fan Relay

(By Others)

U 7

K 2

EXPANSION

Heat

Contactor

(By Others)

EXPANSION

OE321 Relay Expansion Board

Expansion Board Wiring For Parallel Flow Fan Terminal Without Heat

OE320 Zone Controller

24VAC

GND

24VAC

8 2

2 4

B 4

GND

Aux. Heat Contactor

(By Others)

34063

U 7

K 2

OE321 Relay Expansion Board

Expansion Board Wiring For Parallel Flow Fan Terminal With Electric Heat

EXPANSION

OE321 Relay Expansion Board

Expansion Board Wiring For Auxiliary Heat

Figure 2-17: Zone Controller Auxiliary Relay Board Wiring Examples

2-26 Design Guide

Auto-Zone Plus Section 2

Auxiliary Relay Sequence of Operation

Relay #1 - Parallel Fan

Relay #2 - Box Heat

If the Zone Manager is in cooling mode or vent mode then the box heat can activate anytime the zone temperature drops 1.5°F below the heating setpoint. It de-activates when the temperature rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate in the Heating Mode when there is hot air being supplied by the air handling unit. This output was intended to allow zone re-heat while the Zone Manager is satisfying cooling demands in other zones. The space temperature must be below the Aux Heat Setpoint in the occupied mode, before the Box Heat relay can be energized.

Relay #3 - Aux Heat

Relay #4 - Series Fan

The Series Fan runs anytime the Main Fan is running. This includes Occupied and Unoccupied Modes. The fan can only start running when the Zone Damper is closed, so it determines that the damper is closed before starting the fan.

Modulating Box Heat Available

Design Guide 2-27

Section 2 Auto-Zone Plus

CV Controller

General

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 weathertight enclosure.

The CV Controller may be mounted without removing the controller from the mounting plate. The unit is mounted by securing with 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.

.20 Dia. Typ. of 4

7.3”

6.2“

6.6”

1.1”

Figure 2-18: CV Controller Dimensions

2-28 Design Guide

Auto-Zone Plus Section 2

Typical

CV Controller Components

PAL Chip

Relay Output Ter mi nals

Address Switch

RS-485 Communications Terminal Block

RS-485 Communications Driver Chip

Communications LED

Power LED

Diagnostic Blink Code LED 1

Diagnostic Blink Code LED 2

CPU Chip

Pin 1 Indicator

RAM Chip

EPROM Chip

Figure 2-19: CV Controller - Components

Real Time Clock Chip

24 VAC Power Input Ter minal

Design Guide 2-29

Section 2 Auto-Zone Plus

CV Controller Wiring

Figure 2-20: CV Controller Wiring

2-30 Design Guide

Auto-Zone Plus Section 2

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 GNDto-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 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.

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

-Communications Loop .................. (18 ga. min.) 2 conductor twisted pair with shield

WattMaster wire, Belden #82760 wire 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

-Outdoor 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 it is advised to 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.

Design Guide 2-31

Section 2 Auto-Zone Plus

CV Controller Addressing

CV ControllerAddress Switch SettingCV ControllerAddress SwitchValues

Switch Shown Is

Set ForAddress 5

ADDRESS ADD

Note:

1.) Ignore AnyMarkingsOnThe Switch Body.

2.) Use The Address Charts Below OrAddress Switch

3.) PowerTo ControllerMust Be Turned Off And

SW1

Value Table Above To Determine Correct Switch Setting.

Back On InOrderFo

Address Switch Values Are Not Labeled On The CV Controller Use The TableBelow

Address SwitchValues

1 2

16 32 (AlwaysOFF- Not Used) TOKEN (AlwaysOFF) NETWORK (AlwaysON)

rSwitch Settings To Take Effect.

Address Switch Shown Is

Set ForAddress 9

Address Switch Values Are Added Together When The RockerIs Pushed Down In The Direction OfThe “ADDRESS ADD” Arrow Marked On The CV Controller Circu

ADDR

ESS

ADD

Controller Address Switch

it Board

Address Switch Shown Is

Set ForAddress 30

RESS

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 A

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

DDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

SW1 SW1 SW1 SW1

Address Switch SettingChart For CV Controllers

SW1 SW1 SW1 SW1 SW1

29 30

Figure 2-21: CV Controller Address Switch Setting

2-32 Design Guide

Auto-Zone Plus Section 2

CV-C Controller

General

The CV-C Controller is very similar to the CV controller except the OE331 CV-C Controller is a configurable controller that allows for user configurable inputs and outputs. CV-C Controllers also have provisions for mounting a Relay Expansion Board to provide additional heating or cooling staging capability. It cannot be programmed

Caution: The CV-C controller requires the use of a personal computer with Prism

software installed for programming and monitoring of the controller. Unlike the CV controller the System Manager cannot communicate with the CV-C Controller.

The CV-C Controller may be installed in any convenient protected location. Observe the recommended environmental limitations for the CV-C 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 weathertight enclosure.

The CV-C Controller may be mounted without removing the controller from the mounting plate. The unit is mounted by securing with 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.

.20 Dia. Typ. of 4

6.2“

7.3”

TB1

COMM

SHLD

LD6

COMM

LD7 PWR

LD8 LED1

LD9 LED2

INPUTS

AOUT2

TB3

PRESSURE SENSOR

C21

CX5

TEST POINT

RV1 VREF ADJ

+VDC

AIN1 AIN2 AIN3 AIN4

AIN5

GND GND AOUT1

AIN7 GND

PJ1

EXPANSION

CX1

RN1

RS-485

COMM

RN3

+VREF

5.11V

EWDOG

R28

RN5

C10

C12

D15

C17

C20

R26

CX2

EPROM

RAM

TUC-5R PLUS

YS101816 REV. 2

PHILIPS

ADD

ADDRESS

1 2 4

PU1

PU2

D7 PU3

D8 PU4

D9 PU5

D11 PU7

D14

U13

PJ2

CX10

32 TOKEN NETWORK

U10

SW1

C11

0-5

0-1

VDC

JP1

R15

U12

CX14

C14

R19

U14

CX13

U15

C15

R22

R24

R25

D17

CX15

PJ3

T'STAT

6.7”

CX3

CX4

RLY1

RLY2RLY3RLY4RLY5

PAL

(1 MEG)

RN2

CX6

RN4

D10

CX12

D12

R13

SC1

D19

D18

C19

C18

VR1

VR2

D2D3D4D5

COM1-3

R1 R2 R3

R4 R5

COM4-5

TB2

NE5090NPB3192 0PS

CX8

R10

D13

9936

R11

U11

MC34064A

C13

C16

TB4

GND

R27

D16

POWER

7824CT

24VAC

6.6”

1.1”

Figure 2-22: CV-C Controller Dimensions

Design Guide 2-33

Section 2 Auto-Zone Plus

CV-C Controller Wiring

Figure 2-23: CV-C Controller Wiring

2-34 Design Guide

Auto-Zone Plus Section 2

CV-C Expansion Board Wiring

Required VA For Transformer

Relay Expansion Board = 20VA Max.

Relay Outputs R6 Thru R13 May Be User Configured For The Following:

0 - Not Used (Nothing connected to this output ) 1 - Heating Stage 2 - Cooling Stage 3 - Humidifier Enable 4 - Reheat Enable 5 - Scheduled Relay from Internal Schedule 6 - Scheduled Relay from External Schedule

(Only 1 Available!)

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.

PRESSURE SENSOR

Connect Expansion Board to CV-C Controller with Modular Cable

24VAC

GND

COM

POWER

N.O. CONTACTS

1 - 8

RELAY COMMONS 9,10

CV- C Controller

EXPANSION

RELAY 1

RELAY 2

RELAY 3

RELAY 4

RELAY 5

RELAY 6

RELAY 7

RELAY 8

T'STAT

IN OUT

EXPANSION PORT

Relay Expansion Board

Required VA For Transformer

Each CV-C Controller = 20VA Min.

GND

24VAC

Warnin g:

If One Transformer Is Used To Power The CV-C Controller And The Relay Expansion Board, Polarity Must Be Strictly Observed. If The Polarity Is Reversed, Serious Damage To Both Boards Will Result.

Not Used

Caution!

Relay Expansion Board Must Have Address Switches Set As Shown Or The Board Will Not Function.

ADDRESS

Caution:

Disconnect The Modular Cable Between The CV-C Controller And The

U4 U5

Relay Expansion Board Before Removing Power From The Relay Expansion Board. Reconnect Power And Then Reconnect The Modular Cable Between The CV-C Controller And The Relay Expansion Board.

Note: Set-up, Programming And Monitoring Of The CV-C Controller Requires The Use Of A Personal Computer And Prism Software.

Figure 2-24: CV-C Expansion Board Wiring

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-C Controller. If a single transformer is used to power more than one CV-C 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.

Design Guide 2-35

Section 2 Auto-Zone Plus

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

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

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

The CV-C Controller requires the following electrical connections: 18 Gauge minimum unless otherwise noted.

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

-Communications Loop .................. (18 ga. min.) 2 conductor twisted pair with shield

WattMaster wire, Belden #82760 wire or equivalent

-SA, OA, RA, MA Temperature Sensors (optional)........... (24 ga. min.) 2 Conductors

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

3 Conductors for sensors with setpoint adjustment

-All other Sensors ......................................... See wiring diagram included with sensor

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

R1-G - Fan R2 – configurable

R3 – configurable

R4 – configurable

R5 – configurable

-AOUT1.................................................................................................... Configurable

-AOUT2.................................................................................................... Configurable

The Following Outputs Require The OE351 Relay Expansion Board:

R6, R7, R8, R9, R10, R11, R12, R13 ...................................................... Configurable

Tip: After making all electrical connections it is advised to unplug all terminal blocks

on the CV-C 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.

2-36 Design Guide

Auto-Zone Plus Section 2

CV-C Controller Addressing

CV-C Controller Address Switch SettingCV-C 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 Value Table Above To Determine Correct Switch Setting.

3.) Power To Controller Must Be Turned Off And Back On In Order For Switch Settings To Take Effect.

SW1

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

Address Switch Values

1 2

(Always OFF- Not Used)

32 TOKEN

(Always OFF)

NETWORK

(Always ON)

Address Switch Setting Chart For CV-C Controllers

ADDRESS ADD

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD

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-C Controller Circuit Board

Controller Address Switch

Address Swit ch Shown Is

Set For Address 30

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

SW1 SW1 SW1 SW1 SW1

29 30

Figure 2-25: CV-C Controller Address Switch Setting

Design Guide 2-37

Section 2 Auto-Zone Plus

Sensors

Room Sensors

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 2-26: 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.

2-38 Design Guide

Auto-Zone Plus Section 2

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 which are solid and cannot be penetrated,

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

Connect the terminal labeled GND on the room sensor to the terminal labeled GND on the Zone Controller terminal block for the TEMP SENSOR. See Figure 2-27. Connect the terminal labeled TMP on the room sensor to the terminal labeled TEMP on the Zone Controller terminal block for the TEMP SENSOR. If the room sensor has a setpoint adjust slider, connect the sensor terminal labeled AUX to the Zone Controller AUX terminal block labeled AUX1.

ZoneController

Room Sensor

M E

R C O O

OVR

L E

TMP

GND

AUX

Connection To AUX Terminal Required Only

When SensorIs Specified With Slide Adjust Option

AUX

+VS

AUX1

AUX2

GND

TEMP

GND

TB1TB1

TB2

Figure 2-27: Room Sensor to Zone Controller Wiring

Connect the terminal labeled GND on the room sensor to the terminal labeled GND on the CV Controller terminal block for the TEMP SENSOR. See Figure 2-28. Connect the terminal labeled TMP on the room sensor to the terminal labeled AIN1 on the CV Controller terminal block for the TEMP SENSOR. If the room sensor has a setpoint adjust slider, connect the sensor terminal labeled AUX to the CV Controller AUX terminal block labeled AIN2.

Figure 2-28: Room Sensor to CV Controller Wiring

Design Guide 2-39

Section 2 Auto-Zone Plus

Supply Air Temperature Sensor

The supply air temperature sensor should be located as close to the rooftop unit discharge as possible for best response. It should also be mounted upstream of the bypass damper for best results. 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 To 24 Gauge Wire Minimum. Connect Leads To "Analog In" And "Ground" At Controller.

4.0"

Thread Together

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

3/4"

Mounting Plate

1/4" Hex Head Sheet Metal Screws

Mounting Plate

Gasket

Adhesive Backed Drill Guide Mounting Template

Duct Work

Drill 5/16" Hole In Ductwork For Probe

Figure 2-29: Supply or Return Air Sensor Installation

Return Air Temperature Sensor

The return air temperature sensor should be located as close to the rooftop unit return air intake as possible. Avoid locations which will be exposed to extreme outside temperatures. 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.

Caution: Do not mount the return air sensor in the mixed air section. This will

cause an error in the reading.

2-40 Design Guide

Auto-Zone Plus Section 2

Outside Air Temperature Sensor

The outside air sensor must be located where it will not be affected by direct sun or heat producing equipment. Mounting under the eve 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”

ClosurePlug

CAUTION! See Note 2

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

4.50”

3.00”

Front View Side View

Notes:

1.)The Outside Air SensorMust Be Mounted In AVertical Position As Shown (SensorTube Pointing Down).

Water Must Not Be Allowed To Stand In Sensor Tube. Rainwater Will Damage Sensor.

SensorMust Be Located Where ItWill Not Be Affected By Direct Sunlig Equipment.IfPossible Mount Under RoofEaveOr Similar Protected

Location.IfSensorIs Not Located As Specified, Erroneous Outside Air Temperature ReadingsWill Result.

ht OrHeat Producing

2.25”

1.13”

SensorTube

CAUTION! See Note 1

2.)Unused Conduit Opening(s) Must HaveClosurePlugs

Be Coated with Sealing Compound To Provide Raintight Seal. Water Can

Damage Sensor!

3.)Gasket Must Be Installed Under Cover

Plate ToProvide Raintight Seal.

Rainwater Can Damage Sensor!

4.)All WiringToBeIn Accordance With

LocalAnd NationalElectrical Codes And Specifications.

MountingTab &Screw -Typ.

Installed And Must

ClosurePlug

CAUTION! See Note 2

BackView

Incorrect

See Note #1

Incorrect

SensorMounting

Correct

Postion

MountingTab &Screws -Typ.

Figure 2-30: Outside Air Temperature Sensor

Design Guide 2-41

Section 2 Auto-Zone Plus

Duct Static Pressure Sensor

The duct static pressure sensor is designed to be mounted at the controller, or on the ductwork near the pickup tube, and may be connected via its modular plug. If the sensor is mounted on the ductwork, the modular plug must be cut off and 3-conductor wire spliced onto the sensor leads. If the trunk ducts are properly sized for minimum pressure drop, the location of the static pickup probe is not particularly critical. It should ideally be located at right angles to the airflow in a straight section of the supply duct approximately 2/3 the distance of the total length of the supply duct. Also the probe should be located not less than 3 duct diameters downstream and 2 duct diameters upstream of any elbow or takeoff. See Figure 1-3 in Section 1 of this manual for general mounting location information.

" 0 0

1 5 5

. 0

1.95"

OE271

0.60"

0.200" (3/16" Tubing Conn.)

0.125" (1/8" Tubing Conn.)

(-)LO

S.P. Sensor

0.15" DIA.

12.0" APPROX

OUT (Black)

GND (Green)

OUT

GND

2.20"

2.50"

IN (Red)

0.15"

1.29"

2.94"

0.35"

Figure 2-31: Duct Static Pressure Sensor Dimensions

Caution: Mount the static pressure sensor on a vertical surface with the tube tips

pointing downward. Avoid any kinks or sharp bends in the tubing which runs from the pickup tube to the sensor.

Warning: The plastic housing on the sensor is electrically conductive. Avoid

contact with any electrical components. It is acceptable to mount the sensor on grounded sheet metal such as ductwork, electrical panels, etc.

2-42 Design Guide

Auto-Zone Plus Section 2

Warning: Use extreme care when mounting the sensor to avoid damage to the

plastic housing. Do not over tighten the mounting screws! Do not use mounting screws which are too large for the holes!

Tip: Having at least 10-20 feet of tubing between the pick-up tube and the pressure

sensor will improve control performance by acting as a “filter” to remove pressure fluctuations caused by turbulence in the duct.

Figure 2-32: Static Pressure Sensor Wiring

Note: Refer to Figure 1-4 in section 1 of this manual for instructions concerning

proper location of the static pressure sensor.

Design Guide 2-43

Section 2 Auto-Zone Plus

CommLink IV

General

The CommLink IV 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 OE415-02 IP Module Kit, when installed and configured in the CommLink IV communication interface, 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 ft. 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 Form: WM-IPM-TGD for complete product details and installation instructions.

2-44 Design Guide

Auto-Zone Plus Section 2

Optional Remote Link II

The OE419-06 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 Remote Link 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 Form: WM-RLII-TGD for complete product details and installation instructions.

Design Guide 2-45

Section 2 Auto-Zone Plus

CommLink IV Wiring

ommLink IV

Communications Interface

Serial #

GND

24V

POWER

Optional Items Not Required For

DIAG

10/100

ETHERNET

ACT LNK

USB Switch Should Be Set To Normal

COMPUTER

USB

Normal

Config

USB

MODEM

RS-232

Female

TGR

485 LOOP

9 Pin

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.

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

25 Pin

Male

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

Connect To The Zone Manager MiniLink 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) Used Instead Of The Supplied Power Pack. Use 18 Gauge Minimum 2 Conductor Wire Between The Transformer & CommLink IV Te rm in a ls

WARNING!

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

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 Zone Manager MiniLink.

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 Follow The Directions In The CommLink IV USB Driver Installation Section (Included) To Install And Configure The USB Drivers.

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.

24 VAC Power

18 Gauge 2 Conductor With Shield (Not Included) See Note 1

Rated At 12 VA Minimum May Be

(Not

If You Are Using The IP Module

Figure 2-33: CommLink IV Wiring

2-46 Design Guide

Auto-Zone Plus 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.

The DIP Switch Setting Should Be Set To “Multiple”

SW1

For The Auto-Zone Plus System

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

WattMaster Controls Inc. COMMLINK IV YS102074 REV6

MADE IN USA

ALTERA EPM3032

DIP Switch 1 & 2 Off = Multiple Loop Communications

uired Setting For Auto-Zone Plus System

Figure 2-34: CommLink IV DIP Switch Setting

USB

LOOP

LOCAL

LOOP

MODEM

RS-232

1 2 4 8 16

S W 1

DIAG

10/100

ETHERNET

USB

ACT LNK

Network

Comm Loop

FDBK

GND OPEN

SHIELD

R FAN

COOL1

COOL2

HEAT1

HEAT2

SHIELD

Local

Comm Loo

COMPUTER

Normal

Config

K 2

R NETWORK

TGR

485 LOOP

A D D

Local Communications Loop

To Zone Controllers

And System Manager

Serial #

GND

24V

POWER

SHIELD

ANALOG OUTPUTS

A1 A2 G

TB2

COMM

TB3

Figure 2-35: CommLink IV to Zone Manager Wiring

Design Guide 2-47

Section 2 Auto-Zone Plus

Installing the CommLink IV

When you are using the CommLink IV with the Auto-Zone Plus 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: Check and make sure your CommLink’s communication switch is set to Multiple. See Figure 2-34 for details on setting the DIP Switch on the CommLink IV.

Step #2: Install communications wiring (18 ga. minimum 2 conductor twisted pair with shield) from the CommLink IV to a Zone Manager on your controls system. The communication wiring should connect from the T, G & R terminals on the CommLink IV to the network T, SH & R terminals of the MiniLink mounted on top of one of the Zone Managers on your controls system. See Figure 2-35. Be sure that you wire the CommLink “T” terminal to the MiniLink “T” terminal, The CommLink “G” Terminal to the MiniLink “SH” terminal and from the CommLink “R” terminal to the MiniLink “R” terminal as shown.

Step #3: Wire the supplied 120/24 VAC power pack to the 24 VAC and GND 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 Installation Technical Guide Form: 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 which are required for installation when using the optional personal computer or other communication devices.

2-48 Design Guide

Auto-Zone Plus Section 2

System Manager

The OE392 System Manager System Operator Interface provides a direct link to enable the system operator to view the status and to adjust the setpoints of any Zone Manager, Zone Controller or CV Controller on the Auto-Zone Plus system communications loop. The System Manager is housed in an attractive beige colored plastic enclosure with white and green accents. The System Manager is equipped with a four line by 20 character backlighted display panel and a 20 key membrane keypad for data selection and entry. All keypad operations are simple and straight forward, utilizing non-cryptic plain English language messages. Menu driven programming allows for easy setup and operation without the need for specialized training. The System Manager also has two integral LED’s for user notification of system communication and alarm conditions. Protection from unauthorized users is provided by the System Manager’s integral multi-level passcode authorization programming.

The System Manager is designed for wall mounting. It is recommended that the System Manager be mounted at approximately eye level to allow for ease of programming and reading of the display. The System Manager is typically mounted in the building manager or superintendent’s office or in an equipment room. The enclosure is quite suitable for mounting in any location or with most decor.

9.00

6.25

Membrane Keypad

Four Line by 20 Character Backlighted Display

Figure 2-36: System Manager Dimensional Data

1.90

Design Guide 2-49

Section 2 Auto-Zone Plus

System Manager Wiring

The System Manager can be connected anywhere on the Plus system local communications loop. Do Not Connect the System Manager to the Plus 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 2-37 for System Manager wiring.

Figure 2-37: System Manager Wiring

2-50 Design Guide

Auto-Zone Plus Section 2

Index:

14,400 Baud Modem........................... 45

24VAC-to-24VAC.................. 22, 31, 35

90% RH............................................... 33

Above 140° F ...................................... 33

Actuator Cable .................................... 17

Actuator Clutch................................... 17

Add-on Controllers

Addressing ...................................... 14

Address Switch

Zone Controller............................... 23

Address Switch Setting

CV Controller.................................. 32

CV-C Controller.............................. 37

Addressing

Add-on Controllers ......................... 14

CV Controllers.......................... 14, 32

CV-C Controllers...................... 14, 37

MiniLink ......................................... 11

Zone Controllers ....................... 14, 23

Zone Manager ................................. 11

AUX.................................................... 39

Aux Heat Relay................................... 27

AUX1.................................................. 39

Auxiliary Heat..................................... 25

Auxiliary Relay

Operation Sequence ........................ 27

Auxiliary Relay Board

Layout ............................................. 25

Wiring ............................................. 26

Zone Controllers ............................. 25

Backplate

Mounting......................................... 13

Belden #82760 cable........................... 14

Below 20° F ........................................ 33

Box Heat ............................................. 25

Box Heat Relay ................................... 27

Bypass Damper

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

Bypass Dampers

Installing.......................................... 16

Mounting......................................... 16

Bypass Wiring Interface Board ........... 16

Wiring ............................................. 17

Cable

Belden #82760 ................................ 14

WattMaster...................................... 14

CommLink IV

Connecting to Zone Manager.......... 47

Description...................................... 44

Dip Switch Setting .......................... 47

Installation....................................... 48

Installing.......................................... 46

Wiring ............................................. 46

Communication Problems

Incorrect Addressing....................... 23

Communications Loops ...................... 14

Components

CV Controller.................................. 29

Zone Controller............................... 21

Conductors

Voltage............................................ 13

Conduit................................................ 15

CV Controller

Addressing ................................ 14, 32

Components .................................... 29

Dimensions ..................................... 28

Electrical Connections .................... 31

Environmental Limitations ............. 28

Installing.......................................... 28

Mounting......................................... 28

Wiring ............................................. 30

CV-C Controller

Addressing ................................ 14, 37

Dimensions ..................................... 33

Electrical Connections .................... 36

Environmental limitations............... 33

Installing.......................................... 33

Mounting......................................... 33

Prism requirement........................... 33

Wiring ............................................. 34

CV-C Expansion Board

Wiring ............................................. 35

Daisy Chain......................................... 14

Design Guide 2-51

Section 2 Auto-Zone Plus

Damp or Wet Environments ............... 33

Damper Actuator........................... 16, 17

Damper Blade ..................................... 17

DB9 Serial Cable ................................ 45

Dial-up Communications.................... 45

Dial-up Connections ........................... 44

Dimensions

CV Controller.................................. 28

CV-C Controller.............................. 33

Duct Static Pressure Sensor ............ 42

System Manager.............................. 49

Drywall................................................ 38

Duct Static Pressure Sensor ................ 42

Dimensions ..................................... 42

Installing.......................................... 42

Mounting......................................... 42

Electrical Connections

CV Controller.................................. 31

CV-C Controller.............................. 36

Zone Controller............................... 22

Zone Manager ................................. 13

Electrical Short.................................... 15

Energy Efficiency

Improving........................................ 16

Environmental Limitations

CV-C Controller.............................. 33

Expansion Board

Jumper Settings............................... 12

Wiring ............................................. 12

Extreme High Temperatures ............... 33

Extreme Low Temperatures................ 33

GND.................................................... 39

GND-to-GND ......................... 22, 31, 35

Inaccurate Outside Sensor Readings... 41

Incorrect Addressing........................... 23

Incorrect Wiring.................................. 14

Installation Tips .................................... 5

Intranet Connection............................. 44

IP Module Kit ..................................... 44

Desribed .......................................... 44

LAN and Internet Connections ........... 44

Local Loops..................................... 5, 14

Metal Shavings.............................. 31, 36

MiniLink

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

Modulating Box Heat.......................... 27

Modulating Hot Water Valve.............. 27

Network Loop ................................. 5, 14

OE322 Expansion Board..................... 27

OE351 Relay Expansion Board .......... 36

OE352 Expansion Base Board............ 12

OE355 4 Analog Output

Expansion Board....................... 12, 13

OE357 4 Relay Expansion Board ....... 13

OE357 Relay Output Expansion

Board............................................... 12

OE392 System Manager ..................... 49

OE415-02 IP Module Kit.................... 44

OE419-06 Remote Link II .................. 45

Outside Air Temperature Sensor......... 41

Installing.......................................... 41

Mounting......................................... 41

Parallel Fan ......................................... 25

Parallel Fan Relay ............................... 27

Plastic Bezel........................................ 39

Plastic Housing ................................... 43

Plus System Overview

Diagram............................................. 6

Polarity................................ 5, 22, 31, 35

Power

Recycling .................................. 23, 25

Prism ................................................... 44

Rectangular Damper shaft................... 16

Recycling Power ........................... 23, 25

Relay #1 - Parallel Fan........................ 27

Relay #2 - Box Heat............................ 27

Relay #3 - Aux Heat............................ 27

Relay #4 - Series Fan .......................... 27

Relay Contacts .................................... 25

Remote Link II.................................... 44

Described ........................................ 45

Requirements

Electrical, CV Controller ................ 31

Return Air Temperature Sensor

Installing.......................................... 40

Mounting......................................... 40

Rooftop Unit

Discharge ........................................ 40

Return Air Intake ............................ 40

2-52 Design Guide

Auto-Zone Plus Section 2

Room Sensor

Wiring ............................................. 39

Room Sensors

Installing.......................................... 38

Mounting......................................... 38

Round Zone Damper........................... 19

SAT

Sensor.............................................. 40

SCR Electric Heating Coil.................. 27

Sensors

OAT ................................................ 41

RAT................................................. 40

SAT................................................. 40

Sequence of Operation

Auxiliary Relay............................... 27

Series Fan............................................ 25

Series Fan Relay.................................. 27

Setpoint Adjust Slider......................... 39

Slaved Dampers ............................ 16, 19

Slaved Zone Controller

Wiring ............................................. 24

Star Configuration............................... 15

Static Pressure Sensor

Wiring ............................................. 43

Supply Air Temperature Sensor.......... 40

Installing.......................................... 40

Mounting......................................... 40

Sweating

Prevention ................................. 16, 19

System Manager

Described ........................................ 49

Dimensions ..................................... 49

Wiring ............................................. 50

TCP/IP Internet ................................... 44

TEMP SENSOR ................................. 39

Temperatures

Extreme High .................................. 33

Extreme Low................................... 33

Terminal Blocks

Unplugging...................................... 22

Thermistor Sensor............................... 41

TMP .................................................... 39

WattMaster

Communication Cable .................... 14

Weathertight Enclosure

CV Controller.................................. 28

Wire

Requirements .................................. 13

Wiring

Incorrect .......................................... 14

Wiring

Auxiliary Relay Board .................... 26

Bypass Damper ............................... 18

Bypass Wiring Interface Board ....... 17

CommLink IV................................. 46

CV Controller.................................. 30

CV-C Controller.............................. 34

CV-C Expansion Board .................. 35

Expansion Board............................. 12

Room Sensor................................... 39

Slaved Zone Controllers ................. 24

System Manager.............................. 50

Zone Controller............................... 23

Zone Manager ................................. 10

Zone Controller

Address Switch ............................... 23

Addressing ................................ 14, 23

Auxiliary Relay Board .................... 25

Components .................................... 21

Electrical connections ..................... 22

Installing.......................................... 20

Mounting......................................... 20

Serviceability .................................. 20

Slaved.............................................. 24

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

Zone Controller Address Switches

When to Set....................................... 5

Zone Dampers

Installing.......................................... 19

Mounting......................................... 19

Zone Manager

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

Components ...................................... 9

Dimensions ....................................... 8

Electrical Connection Requirements13

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

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

Wiring ............................................. 10

Design Guide 2-53

Section 2 Auto-Zone Plus

2-54 Design Guide

Auto-Zone Plus Section 3

Table of Contents

LCD/Keypad Operations................................................... 3

System Manager Layout...................................................................................................4

View Alarms Screen ........................................................ 6

Full System Access ......................................................... 7

Keypad Functions ............................................................................................................7

System Manager LED Indicators .....................................................................................8

Set Time & Date ..............................................................8

New Passcodes................................................................ 9

Rebuild Alarm Map......................................................... 10

Read / Reset Units .........................................................11

Zone Manager Read/Reset Operations ......................... 12

Zone Manager Status .................................................... 13

Zone Manager Configuration ......................................... 16

Zone Manager Setpoints ............................................... 21

Control Setpoints ...........................................................................................................21

Zone Manager & CV AHU Force Modes......................... 28

Zone Controller Read/Reset Operations ....................... 30

Individual Zone Status Screens .................................... 30

Zone Controller Setpoints ............................................. 33

Zone Controller Force Modes ........................................ 37

CV Read/Reset Operations ............................................38

Constant Volume AHU Status ....................................... 39

Constant Volume AHU Setpoints .................................. 42

Zone Manager Scheduling, Holidays and Optimal Start49

Week Schedules .............................................................................................................49

Holidays .........................................................................................................................50

Optimal Start..................................................................................................................51

CV AHU Scheduling and Holidays ................................. 52

Week Schedules .............................................................................................................52

Holidays .........................................................................................................................53

Wetbulb Module Read/Reset Operations...................... 54

LCD/Keypad Operations Summary ................................ 56

Programming 3-1

Section 3 Auto-Zone Plus

3-2 Programming

Auto-Zone Plus Section 3

LCD/Keypad Operations

Main Screen

v1.xx Monday Operations 03/24/02 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 document will lead the user through the system menus and keypad operation.

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

Programming 3-3

Section 3 Auto-Zone Plus

System Manager Layout

1.90

9.00

6.25

Main User Menu

1) View/Change Zone

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

Four Line by 20 Character Backlighted Display

1) View/Change Zone

2) View Alarms

MENU) Full Access

ESC) Main Screen

Membrane Keypad

For quick access to an individual zone, select this menu item. Any Zone or Constant Volume unit can be selected. The user 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, the user 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.

3-4 Programming

Auto-Zone Plus Section 3

View/Change Zone

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

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. The Unit ID is actually two separate numbers, combined into one value. The first part of the number contains the Loop Address at which the zone is located. The second part of the number contains the actual Board Address.

EXAMPLE: You would like to view the 3rd zone on the

You would like to view the 12th zone on the

Zone Controller Status

Zone Controller Temperature: 75.4°F Cooling SP.: 75°F Heating SP.: 72°F

If the selected Unit ID is correct, and the unit responds, one of the following screens 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.

5th loop. Enter 503 as the Unit ID

24th loop. Enter 2412 as the Unit ID

Constant Volume Unit

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

Programming 3-5

The Heating Setpoint is never allowed to get any closer than two degrees of the Cooling setpoint on Zone Controllers and one degree on Constant Volume Units. If you are lowering the Cooling setpoint or raising the Heating setpoint, both values will be kept apart automatically by the correct amount.

Section 3 Auto-Zone Plus

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.

View Alarms Screen

Alarm Address Locations

SYSTEM ALARM STATUS Alarm @ Unit ID 118

The System Manager can be programmed to poll all the AutoZone 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. 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 what the exact alarm condition is for that unit. The alarm conditions are always displayed on the Status Screens.

Alarm Clearing

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

3-6 Programming

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.

Auto-Zone Plus Section 3

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 the casual user from being overwhelmed with the full amount of data and setpoints available to the Level 2 user.

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.

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

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

ESC The ESCape key allows the user to abort what he/she is 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. It 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 the user will be prompted as to what these might be.

Programming 3-7

Section 3 Auto-Zone Plus

System Manager LED Indicators

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

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

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

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 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

Programming Date

Program Time/Date Month (1-12): 9 Day (1-31): 18 Year (00-99): 95

Month

Day

Year

- 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)

- 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)

3-8 Programming

Auto-Zone Plus Section 3

Daylight Savings Adjustments

Daylight Savings Auto Adjustments: YES

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.

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

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.

Programming 3-9

Section 3 Auto-Zone Plus

Rebuild Alarm Map

Rebuilding Screens

Clearing Old Map

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

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

Build New Map?

[ESC = NO]

Building New Map Loop: 1 Unit: 1 Dec) Go To Next Loop ESC) Abort Process

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 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 Comm Link 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 and if a unit has been found at that address. If you know you only have two loops on your system and you don't want to wait for it to test the remaining twenty-eight loops, you can press the ESC key as soon as Loop 3 is displayed and the test will conclude. All units found up to that point will be saved in memory.

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.

3-10 Programming

Auto-Zone Plus Section 3

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 Loop Address with the controller Board Address. The Zone Controllers are always addressed starting at one and continuing up to sixteen. The Zone Manager is always at address seventeen and any Constant Volume units would start at eighteen and continue to thirty. If this is a Constant Volume only system, the address range of the controllers would simply be one to thirty.

Example Unit ID Numbers:

Controller @ Loop 3, Board Address 1

Controller @ Loop 12, Board Address 14

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.

Unit ID = 301

Unit ID = 1214

Programming 3-11

Section 3 Auto-Zone Plus

Zone Manager Read/Reset Operations

If the Unit ID you entered was for a Zone Manager, the following menus will appear.

Zone Manager Menu #1

1) Manager Status

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

1) Manager Status

2) Change Setpoints

MENU) Next Menu

Zone Manager Menu #2

1) Schedules

2) Configuration

3) Force Modes MENU) Previous Menu

1) Schedules

2) Configuration

3) Force Modes

MENU) Previous Menu

View the current temperatures and operating modes for this Zone Manager.

View or change any of the available setpoints for this Zone Manager.

Access the next Menu Page for the Zone Manager.

View or change any of the Week Schedules or Holidays for this Zone Manager.

View or change the operating configuration of the Zone Manager. These setpoints are normally set one time and never changed again. They include parameters such as the number of zones, or heating and cooling stages, etc..

Select this menu to override the currently scheduled operating mode.

Return to the previous menu shown above.

3-12 Programming

Auto-Zone Plus Section 3

Zone Manager Status

Line 1 Displays the currently selected Zone Manager and its current operating software version on all Status Screens shown below.

Status Screen #1

Manager # 1 vl.xx Occupied Mode Vent Mode

Line 2 -

Line 3 -

Line 4 -

Status Screen #2

Manager # 1 vl.xx Supply Air: 78.6°F Return Air: 77.3°F Outdoor Air: 70.2°F

The Supply Air Temperature, Return Air Temperature and Outdoor Air Temperature are displayed on this screen.

The Outdoor Air Temperature is either the onboard sensor reading, or it can be the Global Broadcast value received from another unit. Only one unit per system needs to have the Outdoor Air Sensor installed.

Unoccupied Mode Return Control Occupied Mode Push Button Override Forced Occupied Forced Unoccupied Forced Fan Only Mode Purge Mode

Neutral Mode Vent Mode Cooling Mode Heating Mode

Binary Contact Alarm

Blank Line if no Alarm

Programming 3-13

Section 3 Auto-Zone Plus

Status Screen #3

Manager # 1 vl.xx Static Pr..: 0.49" Bypass Dmpr: 18 % Economizer.: 50 %

The Static Pressure, measured in Inches of Water Column, is displayed along with the Bypass Damper or VFD Percentage position currently being used to maintain that amount of static.

The last line shows the Economizer Damper position if your system is configured for Economizer Control.

Status Screen #4

Manager # 1 vl.xx Active Cool Stage: 0 Active Heat Stage: 0

Manager # 1 vl.xx

CW Valve ...: 0% HW Valve ...: 0%

If you configured the Zone Manager for DX cooling the active number of cooling stages will be displayed. If you also configured the Zone Manager for Staged Heating the active number of heating stages will be displayed also. There are a maximum of six stages of heating and six stages of cooling available, if the optional relay expansion board is used. If you configured your Zone Manager for a Cooling Valve the percent open position of the CW valve will be displayed. If you configured the Zone Manager for HW valve the percent open position of the HW valve will be displayed.

Status Screen #5

Manager # 1 vl.xx Cool Total.: 0.0°F Heat Total.: 0.0°F Mavericks..: 0

As the Zone Manager polls its Zone Controllers, it totals up the heating and cooling demand so it can make an HVAC decision. The Cooling Total and Heating Total are displayed on this screen.

The Zone Manager also knows if any units have had more than a four degree demand for at least one hour. It totals them up and displays this value as the total number of Mavericks.

Mavericks occur when Zone Controller has had more than a four degree demand for one hour. It will move out of Maverick Mode if demand falls within two degrees or less.

3-14 Programming

Auto-Zone Control Systems Auto-Zone Plus User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual