Bell & Gossett S14333 User Manual
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
Installation, Operation and Maintenance Instructions
SAFETY
INSTRUCTIONS
This safety alert symbol will be used in this manual and on the
ZoneSav Safety Instruction decal to draw attention to safety
related instructions. When used, the safety alert symbol means
ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED! FAILURE TO FOLLOW THE INSTRUCTION
MAY RESULT IN A SAFETY HAZARD!
Technologic
™
5500 Series
ZoneSav Controller
WARNING LABEL PART #S11550
INSTALLED IN THIS LOCATION.
IF MISSING IT MUST BE REPLACED.
DESCRIPTION
Microprocessor based valve controller for HVAC systems.
The control panel consists of the following components:
microprocessor, operator interface with 4 line display and
membrane key pad, and 24 VDC power supply.
OPERATIONAL LIMITS
See the control panel nameplate for operating voltage, current
draw, as well as information on the equipment to be connected to the control panel.
VARIABLE SPEED PUMPING SYSTEMS
INSTRUCTION MANUAL
Bell & Gossett
Instruction Manual S14333
2
Preface
The following manual describes the microprocessor
based ZoneSav Controller. This unit is in the tradition
of the other members of the Technologic Control
Panels as it incorporates many original, novel, and
proprietary features that may only be found on B&G
controllers. Some of these features require special
emphasis here.
The controller is best described as a specific purpose
programmable valve controller. This means that the
hardware and software have been created for the control and diagnostics of valves with consideration for
their inherent characteristics. This results in an optimum valve controller without the cost of general purpose control hardware. Software is dedicated and
established for the unit only after extensive testing.
Changes to this software are not taken lightly and
must pass rigid version control.
The controller has the unique analog input protection
of other members of the control family. In the event of
a short circuit condition the current limit circuitry prevents failure of the analog input components.
3
SECTION 1 - GENERAL Page
1.1 Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2.1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2.2 Safety Instruction Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2.3 Valve Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2.4 Closed System Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.5 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.6 Temperature and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.7 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.8 Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.9 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.10 Analog Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.11 Field Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.11.1 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.11.2 Analog Inputs with External Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.11.3 User Configurable I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.11.4 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.11.5 Local-Off-Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SECTION 2 - OPERATION INTERFACE
2.1 Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 ZoneSav Controller Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 Key Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.4 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SECTION 3 - SETUP SELECTION
3.1 Sensor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.1.1 Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.1.1.1 Sensor Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.1.1.2 Sensor Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.1.1.3 Sensor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1.1.4 Sensor Span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1.1.5 Sensor Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1.1.6 Sensor Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1.1.7 Do Another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1.2 Sensor Log Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 Valve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.1 Valve Position Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.2 Valve Log Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.3 Valve Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3 System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3.1 System Temperature Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.3.2 PID Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.3.2.1 PID Gains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.3.2.2 Setpoint Indexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.3.2.3 Heat/Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3.2.4 Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3.2.5 Optimize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3.3 Alarms Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3.4 Flow Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3.5 System Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3.6 Reset Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3.7 Date/Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3.8 Password Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3.9 I/O Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.3.9.1 DI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.3.9.2 DO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.3.9.3 AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.3.10 Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.3.10.1 BACnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.3.10.2 Metasys N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3.10.3 Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3.10.4 BACnet/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3.11 Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.3.11.1 Summer/Winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.3.12 Save to Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.3.13 Load to Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.3.14 Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Index
4
INDEX (continued)
3.4 Test Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.4.1 DI Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.2 DO Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.3 AI Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.4 AO Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.5 LED Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.6 Key Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.7 Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.8 Comm Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.5 Default Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SECTION 4 - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.1 Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.1.1 ZoneSav Controller Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.1.2 Temperature Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.1.3 Flow Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.1.4 Valve Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.2 Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.2.1 Manual Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.2.2 Auto Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3 Setpoint Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.4 Process Variable Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.5 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.6 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.7 Log Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.7.1 Averages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.7.2 Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.7.3 Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.7.4 Valve Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.7.5 Data Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.7.6 Operation Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.7.7 Power Logl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.7.8 Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.7.8.1 System Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.7.8.2 Operating Hours Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.7.9 Auto-Tune Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
SECTION 5 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.1 Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.3 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.4 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.5 Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.6 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.7 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.8 Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.9 Instruments and their Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.9.1 AC/DC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.9.2 Ohmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.9.3 Milliamp Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.9.4 Signal Generator (analyzer) – recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.10 Field Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.11 Special Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.12 Program Updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.13 Controller Information Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.14 Maintenance (Physical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.14.1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.14.2 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
APPENDIX A System Piping and Unit Installation – Final Check List . . . . . . . . . . . . . . . . . . . . . . . . . . .27
APPENDIX B Electrical Wiring and Control Settings – Final Check List . . . . . . . . . . . . . . . . . . . . . . . . . .27
APPENDIX C Valid I/O Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
APPENDIX D BACnet Protocol Implementation Conformance Statement for BACnet IP . . . . . . . . . . . .29
APPENDIX E BACnet Protocol Implementation Conformance Statement for BACnet MS/TP . . . . . . . . .30
APPENDIX F BACnet Communications Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
APPENDIX G LonWorks Communication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
APPENDIX H Metasys N2 Communications Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
APPENDIX I Modbus Communications Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
APPENDIX J Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35-37
NOTE: The information contained in this manual is intended to assist operating personnel by providing information on the char-
acteristics of the purchased equipment.
It does not relieve the user of the responsibility to adhere to local codes and ordinances and the use of accepted practices in
the installation, operation and maintenance of this equipment.
Further information pertaining to the installation, operation, and maintenance of your ZoneSave Controller can be found in the
I.O.M.s for the associated equipment provided see Section 5, Maintenance, for a list of relevant manuals.
1.1
Purpose of Manual
This manual is furnished to acquaint you with some
of the practical ways to install, operate, and maintain
this unit. Read it carefully before doing any work on
your unit and keep it handy for future reference.
Equipment cannot operate well without proper care.
To keep this unit at top efficiency, follow the recommended installation and servicing procedures outlined in this manual.
1.2 Safety
1.2.1 Safety Alert Symbol
SAFETY INSTRUCTION
This safely alert symbol will be used in this manual
and on the unit safety instruction to draw attention to
safety related instructions. When used the safety alert
symbol means
ATTENTION BECOME ALERT!
YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN A
SAFETY HAZARD.
1.2.2 Safety Instruction Decal
Your ZoneSav Controller should have a safety
instruction decal (part # S11550). If the decal is
missing or illegible contact your local B&G representative for a replacement.
1.2.3 Valve Safety
Ground fault protection should be sized properly.
Refer to local electrical codes for sizing and
selection.
Refer to the valve manufacturer's I.O.M. for specific
installation information.
Even when the valve is stopped, it should be considered alive as long as its controller is energized. Keep
hands away from the valve until the power is disconnected from the valve controller.
1.2.4
Closed System Safety Measures
Important:
Do not install and operate the ITT Bell &
Gossett ZoneSav Controller in a closed system
unless the system is constructed with properly sized
safety and control devices. Such devices include the
use of properly sized and located pressure relief
valves, compression tanks, pressure controls, temperature controls and flow controls as appropriate. If
the system does not include these devices, consult
the responsible engineer or architect before making
pumps operational.
1.3
Location
Install the ZoneSav Controller appropriately for ease of
inspection, maintenance and service. Observe local
electrical codes concerning control panel spacing.
5
Section 1 - General
Glossary of Terms
I.O.M. – Installation Operation Manual
LED – Light emitting diode, located on OIP and controller
OIP – Operator Interface Panel
PID – Proportional Integral Derivative; 3 variables required
for error control
Process Variable – Signal generated by a sensor that is set
up to control the system
Proof timer – Minimum time period before controller acknowledges an input; time period for which a signal must be stable
before it is accepted by the controller as a sustained and
valid signal
RTC – Real time clock
RTD – Resistive temperature device used to supply tempera-
ture signals to the PLC
BAS – Building Automation System
DANGER: The heating of water and other fluids causes
volumetric expansion. The associated forces may
cause failure of system components and releases of high
temperature fluids. This will be prevented by installing properly sized and located pressure relief valves and compression
tanks.
FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN SERIOUS PROPERTY DAMAGE AND
SERIOUS PERSONAL INJURY OR DEATH.
DANGER: Heavy load, may drop if not lifted properly.
Do not lift the entire unit by the motor eyebolts. Lift the
unit with slings placed under the unit base rails.
FAILURE
TO FOLLOW THESE INSTRUCTIONS COULD RESULT
IN SERIOUS PERSONAL INJURY, DEATH, AND/OR
PROPERTY DAMAGE.
6
1.4
Storage
For long periods of storage, the unit should be
covered to prevent corrosion and contamination from
dirt. It should be STORED in a clean, dry location
between -20 and +60ºC. The relative humidity should
not exceed 85%. The unit should be checked periodically to ensure that no condensation has formed.
After storage, check that it is dry before applying
power.
1.5
Handling
Care should be taken to prevent damage due to
dropping or jolting when moving the ZoneSav
Controller. Transportation damage should be brought
to the carrier's attention immediately upon receipt.
1.6 Temperature and Ventilation
All electrical equipment is susceptible to failure if
operated in ambient temperatures outside of its rating. The OPERATING temperature range for this unit
is 0 to 40°C. The relative humidity should not exceed
95% non-condensing. The unit should not be operated outside these extremes.
1.7
Input Voltage
The ZoneSav Controller can be set up to operate
across a broad range of voltages. It was factory set
to operate on the voltage shown on the nameplate.
The voltage tolerance is +10/-5% and phase to
phase voltage must not have an imbalance greater
than 5 VAC.
1.8
Ground Connections
A grounding terminal is provided for a dedicated
ground wire connection. All provisions of the
National Electrical Code and local codes must be
followed.
1.9
Power Wiring
Power wire types and sizes must be selected based
upon conformance with the National Electrical Code
and all local codes and restrictions. In addition, only
copper (Cu) wire rated for 75°C (minimum) may be
used for the power connections. Refer to the input
current as listed on the nameplate on the enclosure
door when sizing wire.
1.10
Analog Signal Wiring
Shielded cable (#22 AWG, Belden type 8762, Alpha
#2411, or equal) should be installed for all D.C. control wiring. The shield must be terminated in the
Technologic Valve Controller panel.
Do not connect
the shield at the other end of the cable! Insulate
the shield so that no electrical connection is made
at the other end of the cable.
A twisted pair of #22
AWG conductors (Belden 8442 or equal) can be used
in place of shielded cable. The cable length must be
limited to 5,000 feet for #22 AWG wire.
1.11 Field Connection Diagrams
Refer to the valve I.O.M. for specific details unique
to the valve. Refer to the flow sensor/transmitter
I.O.M. for specific details unique to the flow sensor/
transmitter.
The Wiring Diagram(s), Dimensional Drawings and
Field Connection Diagram should be reviewed prior
to unit installation and operation.
The following sections are based on the installation of
standard ZoneSav product. Because customized
software and hardware is available, the installing contractor should base all wiring connections on the
wiring diagrams that accompany each controller.
These sections are meant to complement, not
replace, those wiring diagrams.
1.11.1
Analog Inputs
The ZoneSav Controller may be provided with the
capability to accept many analog inputs. Typically,
all analog inputs must be 4-20mA and powered by
the 24VDC power supply in the ZoneSav Controller.
1.11.2 Analog Inputs with External Power
The following steps describe the general procedure
for rewiring an analog input sensor when the sensor's
power source is not the ZoneSav Controller.
1) Turn off all power to the ZoneSav Controller.
2) Refer to the appropriate controller wiring diagram
that was shipped with unit. Locate the analog
input sensors on the wiring diagram that will be
rewired. They are labeled AI X.
3) Remove the 24 VDC positive (+) wire from TB 40
for the respective analog input sensor connection.
This wire needs to be removed completely or terminated if used as a jumper. This will prevent any
accidental contact with a negative (-) voltage
source (i.e. control panel) and avoid becoming a
short circuit. Care should be taken to ensure that
24 VDC positive (+) voltage is still provided to any
remaining sensors that will be powered by the
ZoneSav Controller.
4) Remove the 24 VDC negative (-) wire from TB 41
for the respective analog input sensor connection.
This wire needs to be removed completely or terminated if used as a jumper. This will prevent any
accidental contact with a positive (+) voltage
source and avoid becoming a short circuit. Care
should be taken to ensure that 24 VDC (-) negative
voltage is still provided to any remaining sensors
that will still be powered by the ZoneSav Controller.
WARNING: Prevent electrical shocks. Disconnect
the power supply before beginning installation.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
WARNING: Conduit grounds are not adequate. A
separate ground wire must be attached to the ground
lug provided in the enclosure to avoid potential safety hazards.
FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS PERSONAL INJURY,
DEATH, AND/OR PROPERTY DAMAGE.
WARNING: Prevent electrical shocks. Disconnect
the power supply before beginning installation.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
7
5) Terminate the negative (-) wire of the sensor to TB
41 of the respective analog input sensor connection. Terminate the positive (+) wire of the sensor
to the terminal block which is connected to the
positive (+) terminal shown on the Analog input
card.
Note: Be certain that the power supplied to other terminal blocks has not been interrupted! The wires that
were removed in the preceding steps may have been
used as jumpers.
1.11.3 User Configurable I/O
The ZoneSav Controller comes equipped with the
capability to define the operation of any unused input
or output. Table 1 below shows the amount of each
type that is available for user setup on the standard
ZoneSav Controller. This does not include optional
I/O modules or the signals that are required for correct operation. Refer to Section 3.3.9 for detailed
information on the I/O Setup Menu.
I/O Type Amount Available
Digital Input (24V) 9
Digital Output (24V) 8 + 1 relay
Analog Output 1
Table 1: User Configuration I/O
1.11.4 Valve
The ZoneSav Controller sends a 4 - 20mA or 0 - 10V
signal to the valve. This signal can also be reversed.
See section 3.2.3, Valve Signal, for instructions on
how to change the signal sent to the valve. The Valve
must be configured to accept a 4 - 20mA or 0 - 10V
signal. All shields must be grounded, only in the
ZoneSav Controller, to prevent ground loops and
improper signals.
1.11.5
Local-Off-Remote Switch
In the LOCAL position, the panel is always energized.
With the LOCAL-OFF-REMOTE switch in REMOTE, a
contact closure from a remote source will energize
the panel. This signal can be supplied through any of
the communications protocols used or through a 24V
digital input.
Section 2 - Operator Interface
2.1 Power-Up
Put LOCAL-REMOTE-OFF (LRO) switch in the
LOCAL position.
Turn main disconnect on.
2.2
ZoneSav Controller Screen
Upon powering up the controller, the display will light
and show the ZoneSav Controller default screen
shown below. See section 4.1 for more description
of this screen and the neighboring status screens.
ZoneSav Controller
Version: #.#
MM/DD/YY HH:MM:SS A/P
Stop Man Heat Manual
2.3 Key Functionality
The names of the keys on the Operator Interface
Panel (OIP) are shown as CAPITAL LETTERS in this
manual. Table 2, on the next page, shows the functionality of the keys on the OIP.
2.4
LEDs
Table 3, shown on the next page, gives the meaning
of the LED states.
WARNING: Electrical shock hazard. Inspect all elec-
trical connections prior to powering the unit. Wiring
connections must be made by a qualified electrician in
accordance with all applicable codes, ordinances, and
good practices.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
WARNING: Electrical shock hazard. Multiple power
sources. The off position of the LOCAL-REMOTEOFF switch does not disconnect all of the power sources in
the technologic panel. All power sources must be disconnected prior to entering the control panel.
FAILURE TO
FOLLOW THESE INSTRUCTIONS COULD RESULT IN
SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
8
From the ZoneSav Controller screen, shown in section 2.2, press the SETUP key to get to the Setup
Selection screen shown below.
Setup Selection: 0
1 = Sensors 4 = Test
2 = Valve 5 = Default
3 = System 0 = Exit
Press the numeric key corresponding to the desired
Setup Selection submenu, and press ENTER.
3.1
Sensor Setup
From the Setup Selection Menu, shown in section 3,
press 1 and ENTER to get to the Sensor Setup
screen shown below.
Sensor Setup: #
1=Sensor Settings
2=Sensor Log Rate
0=Exit
Press the numeric key corresponding to the desired
Sensor Setup submenu and press ENTER.
3.1.1
Sensor Settings
3.1.1.1 Sensor Number
From the Sensor Setup screen, shown in section 3.1,
Press 1 and ENTER to get to the Sensor Number
screen shown below.
SENSOR NO: ##
Input the analog input number that will be modified,
and press ENTER.
3.1.1.2
Sensor Edit
After the analog input number is entered section
3.1.1.1, the Sensor Edit screen, shown below, will be
displayed.
Sensor# ## Type: (Type)
Span = 0 Zero = 0
Override:Y/N
Ok ? (Y/N)
Press YES and ENTER at the Ok prompt to accept
these values, and proceed to section 3.1.1.7. Press
NO and ENTER to modify these values, and go to
section 3.1.1.3.
Section 3 - Setup Selection
Key Name Functionality
START/STOP Starts and Stops System
AUTO/MANUAL Toggles operation mode
MANUAL VALVE Brings up the manual valve position screen. See section 4.2.1.
WARNING Brings up the active warnings if a warning exists (LED will blink when active)
PREV. SCREEN Navigates to neighboring screens (LED will blink when active)
NEXT SCREEN Navigates to neighboring screens (LED will blink when active)
HELP Brings up alarms. See section 4.5. If no alarm exists, help is available in every screen.
PROCESS VARIABLE/1 Brings up the Process Variable screen, shown in section 4.4, or used as a numeric key
SET POINT/2 Brings up the Set Point screen, shown in section 4.3, or used as a numeric key
SETUP/3 Brings up the Setup screen, shown in section 3, or used as a numeric key
F1/LOG/5 Brings up the Log Menu, shown in section 4.7, or used as a numeric key
F2/6 Used as a numeric key or an up arrow
YES/7 Used as a numeric key or YES
F3/INFO/8 Shows controller information screen, shown in section 5.13, or used as a numeric key
F4/9 Used as a numeric key or a down arrow
NO/0 Used as a numeric key or NO
ENTER Used to confirm entries and to advance to the next item if there are multiple fields
CLEAR Used to clear entries and to exit some screens
Table 2: Key Functionality
LED Description
START/STOP On = Start, Blinking = Stop
AUTO/MANUAL On = Auto, Blinking = Manual
MANUAL VALVE Blinks when system is on and in manual and in status screens to indicate it is active
WARNING Blinks when a warning exists and in status screens to indicate it is active
PREV. SCREEN Blinks when button is active
NEXT SCREEN Blinks when button is active
HELP Off = Brings up Help screen when pressed, Blinking = Brings up alarms when pressed.
Table 3
9
3.1.1.3
Sensor Type
If NO was selected in the Sensor Edit screen, shown
in section 3.1.1.2, the following will be displayed.
Sensor # ## Type: (Type)
1 = SysT 2 = ZST 3 = ZRT
4 = Flw 5 = Tmp 6 = VFbk
0 = None
Table 4, shown below, gives a description and the
units of each sensor type.
Selection Description Units
1=SysT System Temperature ˚F
2=ZST Zone Supply Temperature ˚F
3=ZRT Zone Return Temperature ˚F
4=Flw *Flow GPM
5=Temp Temperature (for display only) °F
6=VFbk Valve Feedback (for display only) %
0=None No Sensor N/A
Table 4: Sensor Types
Enter the numeric key corresponding to the type of
sensor you are setting up. The abbreviation for the
sensor type will appear in the upper right corner of
the display in the following screens. The ZoneSav
controller does not allow more than one sensor to
have types 1, 2, 3, 5, or 6.
*Note: A total of three flowmeters can be set up. The
smallest analog input number that has type "Flw" will
be the Zone Flow. It will be used for flow limit operation. See section 3.3.4 to set up a flow limit. The
other two flows will not be used in control algorithms.
They are for display only.
3.1.1.4
Sensor Span
After entering the sensor type in section 3.1.1.3, the
display will prompt the user for the sensor span as
shown below.
Sensor No ## Type: (Type)
Span = #####
Enter the span by pressing the appropriate numeric
keys and ENTER. Obtain the span of the sensor from
the nameplate on the sensor. The span is the numeric
value that corresponds to a 20mA signal.
3.1.1.5 Sensor Zero
After entering the sensor span in section 3.1.1.4, the
display will prompt the user for the zero of the sensor
as shown below.
Sensor No ## Type: (Type)
Span = ##### Zero = #####
Enter the desired zero value by pressing the appropriate numeric keys and ENTER. The Zero corresponds to the numeric value of the sensor at 4mA.
3.1.1.6
Sensor Override
After entering the sensor zero in section 3.1.1.5, the
display will prompt the user for Override (Yes/No) as
shown below.
Sensor No ## Type: (Type)
Span = # Zero = #
Override: Y/N
The controller is capable of accepting sensor input
either through a 4-20mA analog input or through the
communication port. See section 3.3.10 for available
protocols. The communication port must be set up
properly and connected to an external building
automation system (BAS).
Press YES and ENTER to receive the sensor signals
via the communication port. Press NO and ENTER to
receive the sensor signals via the analog input card.
After the selection is made, the controller will return
to the Sensor Edit screen shown in section 3.1.1.2.
3.1.1.7
Do Another
If YES was selected in the Sensor Edit screen, shown
in section 3.1.1.2, the display will show the following.
DO ANOTHER ? (Y/N)
Press YES and ENTER to set up another sensor, or
press NO and ENTER to return to the Sensor Setup
screen shown in section 3.1.
3.1.2
Sensor Log Rate
From the Sensor Setup screen, shown in section 3.1,
Press 2 and ENTER to get to the Sensor Log Rate
screen shown below.
Sensor Log Rate: #
0=None 2=Hr 4=Week
1=Min 3=Day 5=Month
OK ? (Y/N)
Press YES and ENTER to accept the current Sensor
Log Rate, or press NO and ENTER to edit the Sensor
Log Rate. See section 4.7.5 for more information on
the Data Log. See Table 5 for a description of the
Sensor Log Rate.
3.2
Valve Setup
From the Setup Selection screen, shown in section 3,
press 2 and ENTER to get to the Valve Setup screen
shown below.
SELECTION: # 0 = EXIT
1 = Valve Pos. Limit
2 = Valve Log Rate
3 = Valve Signal
Push the numeric key corresponding to the desired
Valve Setup submenu, and press ENTER to proceed.
Variable Description Default Value Range Field Value
Sensor Log Rate One data point is taken at the end of the interval 0 0-5
Table 5: Sensor Log Rate Variable
10
3.2.1
Valve Position Limit
From the Valve Setup screen, shown in section 3.2,
Press 1 and ENTER to get to the Valve Position Limit
screen shown below.
Valve Pos. Limit
Minimum: ###%
Maximum: ###%
0% = Closed OK ? (Y/N)
Press YES and ENTER to accept the values and
return to the Valve Setup screen, shown in section
3.2, or press NO and ENTER to edit the fields. See
Table 6 for a description of the Valve Position Limit
variables.
Note: The minimum and maximum valve position limits are ignored in manual operation mode.
3.2.2
Valve Log Rate
From the Valve Setup screen, shown in section 3.2,
Press 2 and ENTER to get to the Valve Log Rate
screen shown below.
Valve Log Rate: #
0=None 2=Hr 4=Week
1=Min 3=Day 5=Month
OK: ? (Y/N)
Press YES and ENTER to accept the current Valve
Log Rate, or press NO and ENTER to edit the Valve
Log Rate. See section 4.7.4 for more information on
the Valve Log. See Table 7 for a description of the
Valve Log Rate variables.
3.2.3
Valve Signal
From the Valve Setup screen, shown in section 3.2,
Press 3 and ENTER to get to the Valve Signal screen
shown below.
Valve Signal Type: #
1=4-20mA 2=0-10V
Signal Reversed: Y/N
OK: ? (Y/N)
Press YES and ENTER to accept the configuration
and return to the Valve Setup screen shown in section 3.2. Press NO and ENTER to edit the fields. See
Table 8 for a description of the Valve Signal variables.
3.3 System Setup
From the Setup Selection screen, shown in section 3,
press the 3 and ENTER to get to the System Setup
screens shown below.
Selection: # 0 = Exit
1 = System Temp Limit
2 = PID
3 = Alarms
Press NEXT SCREEN key or PREV. SCREEN to view
neighboring screens. There are five screens in this
menu. The remaining screens are shown below.
Selection: # 0 = Exit
4 = Flow Limit
5 = System Purge
6 = Reset Totals
Selection: # 0 = Exit
7 = Date, Time
8 = Password
9 = I/O Setup
Selection: # 0 = Exit
10 = Communication
11 = Special Function
12 = Save to Flash
Selection: # 0 = Exit
13 = Load From Flash
14 = Set Contrast
Press the numeric key corresponding to the desired
System Setup sub-menu, and press ENTER.
Variable Unit Description Default Value Range Field Value
Minimum % Minimum valve position in automatic operation mode 0 0-100
Maximum % Maximum valve position in automatic operation mode 100 0-100
Table 6: Valve Position Limit Variables
Variable Description Default Value Range Field Value
Valve Log Rate One data point is taken at the end of the interval 0 0-5
Table 7: Valve Log Rate Variables
Variable Description Default Value Range Field Value
Valve Signal Select 1 if the valve accepts a 4-20mA signal or select 1 1-2
Type 2 if it accepts a 0-10V signal
Signal Reversed Select N if the valve is closed at 4mA or 0V. Select Y if N Y/N
the valve is open at 4mA or 0V
Table 8: Valve Signal Variables
11
3.3.1
System Temperature Limit
From the System Setup Menu, shown in section 3.3,
press 1 and ENTER to get to the System Temperature Limit screen shown below.
System Temp Limit
Temp Limit = ###
Valve Opening = ###%
Timer = ###m OK ? (Y/N)
Press NO and ENTER to modify the fields, or press
YES and ENTER to exit back to accept the current
values and return to the System Setup screen, shown
in section 3.3. See Table 9 for a description of the
System Temperature Limit variables.
3.3.2
PID Setup
From the System Setup Menu, shown in section 3.3,
press 2 and ENTER to get to the PID Setup screen
shown below.
PID Selection: #
1 = Values 4 = AutoTune
2 = Index 5 = Optimize
3 = Heat/Cool 0 = Exit
Press the numeric key corresponding to the desired
PID Setup sub-menu, and press ENTER. Press 0 and
ENTER to return to the System Setup screen shown
in section 3.3.
3.3.2.1 PID Values
From the PID Setup screen, shown in section 3.3.2,
press 1 and ENTER to get to the PID Values screen
shown below.
(Type) PID VALUES
P = ###
I = ###
D = ### Ok ? (Y/N)
There is a different set of values for the zone supply
temperature, zone return temperature and flow.
Press NEXT SCREEN or PREV. SCREEN to change
the type of analog input.
The user should contact B&G if assistance is needed
in tuning the ZoneSav Controller's gains. Also see
section 3.3.2.4 for Auto-Tuning. To edit the fields,
press NO and ENTER. Press YES and ENTER to
accept the values. See Table 10 for a description of
the PID values variables.
3.3.2.2
Setpoint Indexing
From the PID Setup screen, shown in section 3.3.2,
press 2 and ENTER to get to the Setpoint Indexing
screen shown below.
Setpoint Indexing
Sup Idx = # ZSTmr = ## s
Ret Idx = # ZRTmr = ## s
Ok ? (Y/N)
Variable Unit Description Default Value Range Field Value
Temp °F If heating system, this is the low system temperature limit 55 0-999
Limit If cooling system, this is the high system temperature limit
Valve % Valve opens to this position when system temperature 50 0-100
Opening limit is exceeded
Timer minutes Valve will remain at the Valve Opening for the duration 1 0-99
of the timer
Table 9: System Temperature Limit Variables
Variable Description Default Default Default Field Field Field Range
Value Value Value Value Value Value
(ZS) (ZR) (FL) (ZS) (ZR) (FL)
Type ZS = zone supply N/A N/A N/A N/A N/A N/A N/A
ZR = zone return
FL = flow
PID-P Proportional value 400 400 20 1-999
PID-I Integral value 100 100 20 0-999
PID-D Derivative value 0 0 0 0-999
Table 10: PID Values
12
Setpoint Indexing is implemented when the system
supply temperature degrades to the point where it is
impossible to meet the setpoints in the system. In
this condition, the valve would normally go to the
wide open position to try to meet the setpoints.
However, if setpoint indexing is used, the ZoneSav
Controller can modify the setpoints in order to remain
in control. A warning is generated while the controller
is in this mode of operation.
To edit the fields, press NO and ENTER. Press YES
and ENTER to accept the values. See Table 11 for a
description of the Setpoint Indexing variables.
3.3.2.3
Heat/Cool
From the PID Setup Menu, shown in section 3.3.2,
press 3 and ENTER to get to the Heat/Cool screen
shown below.
Application Type: #
1:Heating
2:Cooling
Ok ? (Y/N)
Press YES and ENTER to accept the values and
return to the PID Setup Menu shown in section 3.3.2,
or press NO and ENTER to edit the field.
3.3.2.4
Auto Tune
From the PID Setup Menu, shown in section 3.3.2,
press 4 and ENTER to get to the Auto Tune screen
shown below.
Auto-Tune Select: #
ZS: (Message) 1=Start
ZR: (Message) 0=Stop
FL: (Message) Ok ? (Y/N)
Press YES and ENTER to return to the PID Setup
Menu shown in section 3.3.2. Press NO and ENTER
to edit the field. See Table 13 for a description of the
Auto Tune variables.
Auto-Tuning is used to find the optimal P, I, and D
values for the system being tuned. When the
process is started, the valve will be forced wide open.
It will remain there until the zone supply setpoint is
met. Then the valve will be forced closed. It will
remain there until the setpoint is no longer met. This
cycle will repeat 5 times. The message will change
from "Tune" to either "Comp" or "Err" indicating completion. Tuning of the zone return and flow values will
then commence. If an error occurs, auto tuning will
be aborted. The valve position and process variables
can be viewed in other screens during auto tuning.
The optimal P, I, and D will automatically be used.
These gains can be viewed or modified from the PID
Gains screen shown in section 3.3.2.1.
The controller must be stopped and in manual operation mode to begin the auto tuning process. Also,
make sure the zone return and zone supply setpoints
are set up and that they are realistic values. See section 4.3 for more information on modifying the setpoints. The setpoint used for flow will be 90% of the
flow limit value. Make sure that the flow limit value is
set up and realistic. See section 3.3.4 for more information on setting up a flow limit.
If a flowmeter is not used, the Auto-Tuning process
should be stopped manually. Wait for the message
for "FL" to be "Tune". Then enter a zero in the AutoTune Select field to stop the process. The gains for
zone supply and zone return will still be optimized
and used.
Variable Unit Description Default Value Range Field Value
Sup Idx °F Zone supply index: the difference between the system 0 0-20
supply temperature and the zone supply setpoint that will
be maintained. 0 will disable this mode of operation.
ZSTmr min Zone supply index timer: controlle will remain in zone 0 0-99
supply index mode for the duration of this timer
Ret Idx °F Zone return index: the difference between the system 0 0-20
supply temperature and the zone return setpoint that will
be maintained. 0 will disable this mode of operation.
ZRTmr min Zone return timer: controller will remain in zone supply 0 0-99
index mode for the duration of this timer
Table 11: Setpoint Indexing Variables
Variable Description Default Value Range Field Value
Application Select 1 if system is for heating, or select 2 if system 2 1-2
Type is for cooling
Table 12: Heat/Cool Variable
Variable Description Default Value Range
Auto-Tune Select 1 = Start Auto Tune Process 0 0-1
0 = End Auto Tune Process
Message Stop = Stopped, Tune = Tuning, Err = complete with error, N/A N/A
Comp = complete
Table 13: Auto Tune Variables
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