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

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.

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

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.

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.

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.

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.

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

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

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

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

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

Table 14: Optimize Variables

If a "Tune" message does not change to "Comp" or "Err" within 10 minutes, enter 0 to manually stop the Auto-Tuning process. If the "Err" message is displayed in any of the fields, repeat the Auto-Tune process. If the error persists, check the Auto-Tune Log shown in section 4.7.9, record the information, and contact B&G for assistance.

3.3.2.5

Optimize

From the PID Setup Menu, shown in section 3.3.2, press 5 and ENTER to get to the Optimize screen shown below.

PID Opti.: ? (Y/N) Floating Range: ###% Holding Time: ###s

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 fields. See Table 14 for a description of the Optimize Variables.

PID optimization is used to close the valve as much as possible while still meeting the zone supply and zone return setpoints.

3.3.3

Alarms Setup

From the System Setup Menu, shown in section 3.3, press 3 and ENTER to get to the Alarms Setup screen shown below.

AI Fail Pr. Tm = ##s

Ok ? (Y/N)

Press YES and ENTER to accept the value and return to the System Setup Menu, shown in section 3.3, or press NO and ENTER to edit the field. See Table 15 for a description of the Alarms Variables.

3.3.4 Flow Limit

From the System Setup screen, shown in section 3.3, press 4 and ENTER to get to the Flow Limit screen shown below.

Flow Limit Pr. Tmr = ### sec LimTm = # AvgTmr = # Ok ? YN

To return to the System Setup Menu, shown in section 3.3, press YES and ENTER. To edit the fields, press NO and ENTER. See Table 16 for a description of the Flow Limit variables. See Table 31 for more information on flow limit operation.

3.3.5

System Purge

From the System Setup Menu, shown in section 3.3, press 5 and ENTER to get to the System Purge screen shown below.

Purge Timer = ###m Valve Position = ###%

Ok ? (Y/N)

To return to the System Setup screen, shown in section 3.3, press YES and ENTER.

To edit the fields, press NO and ENTER. See Table 17 for a description of the Bypass Setup variables.

Variable Unit Description Default Value Range Field Value

PID Opti N/A Select Y to enable PID optimization or N to disable N Y/N Floating % The percentage by which the valve position will be 3 0-20 Range decreased Holding s Proof timer prior to decreasing valve position by the 20 0-999 Time floating range

Variable Unit Description Default Value Range Field Value

AI Fail Seconds Proof timer prior to setting an analog input failure alarm 10 0-999 Pr. Tm

Table 15: Alarm Variables

Variable Unit Description Default Value Range Field Value

Pr. Tmr Seconds Proof timer prior to starting flow limit operation 30 0-999 Lim Tmr Minutes The controller will remain in flow limit operation for the 0 0-999

duration of the timer, 0 will disable flow limit

Limit GPM Maximum flow before entering flow limit operation 40 0-65535

Table 16: Flow Limit Variables

Variable Description Default Value Range Field Value

Purge Timer The valve will remain at the Valve Position for the duration 0 0-30

of the Purge Timer. 0 min will disable purging.

Valve Position Valve will go to this position during purging. 100 0-100

Table 17: System Purge Variables

Purging is used to give the system time to react to changing water temperatures on startup. If purging is enabled, purging will occur every time the system is started in automatic mode. Stopping and then starting the system while in automatic operation mode will start the purging process. A command to purge the system can also be initiated through a communications port. See Appendices F through I for the relevant communications point. When the system is purging, "Purge" will be displayed in the Valve Status screen shown in section 4.1.4.

3.3.6

Reset Totals

From the System Setup Menu, shown in section 3.3, press 6 and ENTER to get to the Reset Totals screen shown below.

Reset Total Values Op Hours: Y/N Gallons: Y/N BTU: Y/N Ok ? (Y/N)

To return to the System Setup Menu, shown in section 3.3, press YES and ENTER. To edit the field, press NO and ENTER. Table 18 gives a description of the Reset Totals variables.

3.3.7 Date/Time Setup

From the System Setup Menu, shown in section 3.3,

press 7 and ENTER to get to the Date/Time Setup screen shown below.

MM/DD/YYYY HH:MM:SS Display 24 Hr Fmt: ? (Y/N) Daylite Saving Tm: ? (Y/N)

Ok ? (Y/N)

To return to the System Setup Menu, shown in section 3.3, press YES/7 and ENTER. To edit the fields, press NO and ENTER. See Table 19 for a description of the Date/Time Setup variables.

3.3.8 Password Setup

From the System Setup Menu, shown in section 3.3, press 8 and ENTER to get to the Password Setup screen shown below.

Enable Password To: Setup Menu ? (Y/N) Set Point ? (Y/N)

Ok ? (Y/N)

To return to the System Setup Menu, shown in section 3.3, press YES and ENTER. To edit the fields, press NO and ENTER. See Table 20 for a description of the Password Setup variables.

Variable Description Default Value Range Field Value

Op Hours Set this to Y to reset the operating hours and N Y/N

commissioning date and time (see section 4.7.8.2)

GAL Set GAL to Y to reset the total gallons and Avg GPM N Y/N

(see sections 4.7.1 and 4.7.2)

BTU Set BTU to Y to reset the Avg TON, Avg MBH, and N Y/N

Tot KBTU (see sections 4.7.1 and 4.7.2)

Table 18: Reset Totals Variables

Variable Description Default Value Range Field Value

Setup Menu Enter YES for password protection of the entire setup N Y / N

Set Point Enter YES for password protection of set point N Y / N

modification

Table 20: Password Variables

Variable Description Default Value Range Field Value

MM Current month (two digits), example: Jan. should be

created as 01

DD Current date (two digits), example: the 6th should be

entered as 06 YYYY Current year using all 4 digits HH Hours (24 hour format), example: 9:00 p.m. should be

entered as 21 MM Minutes (two digits) Display Enter YES to display the time in the 24 hour format. N Y/N 24 Hr Fmt Enter NO to display the time in AM/PM format. Daylite Enter YES for automatic setback during daylight N Y/N Saving TM saving time. Enter NO to disable the automatic setback

during daylight saving time.

Table 19: Date/Time Variables

If either of the above are set to YES the screen, shown below, prompts the user to define the password.

ENTER NEW PASSWORD

>_______________<

Enter a password from 0-999999. Record it here or somewhere else!

After entering a password the Verify Password screen requires the user to confirm the password. If the confirmed number does not agree with the first number, the Enter New Password screen is repeated to allow the user to get both input screens to agree.

VERIFY THE PASSWORD

>_______________<

3.3.9 I/O Setup

From the System Setup Menu, shown in section 3.3, press 9 and ENTER to get to the I/O Setup screen shown below.

I/O Setup Select: # 1 = DI 2 = DO 3 = AO 0 = EXIT

Note:

The total available number of I/O to be config-

ured is dependent on the system setup. Complete all

previous setup screens, specifically sensors, prior to completing the following.

3.3.9.1

From the I/O Setup Menu, shown in section 3.3.9, press 1 and ENTER to get to the DI screen shown below.

Opt. DI = # Avail: = # Code = # Delay = ##s (Functionality)

Exit: ? (Y/N)

To return to the I/O Setup Menu, shown in section

3.3.9, press YES and ENTER. To edit the fields, press NO and ENTER. See Table 21 for a description of the DI variables.

3.3.9.2

From the I/O Setup Menu, shown in section 3.3.9, press 2 and ENTER to get to the DO screen shown below.

Available DOs = ## Opt. DO# = #### Code = ### (Functionality)

Exit: ? (Y/N)

To return to the I/O Setup Menu, shown in section

3.3.9, press YES and ENTER. To edit the fields, press NO/0 and ENTER. See Table 22 for a description of the DO variables.

Note: DO#1-8 are 24V transistor outputs. DO#9 is a relay.

Variable Unit Description Default Value Range Field Value

Opt. DI N/A Enter the DI # that will assume the desired functionality N/A 0-10 Avail N/A This variable is not modifiable. It is here to advise the N/A 0-9

user of how many digital inputs can be customized Code N/A Defines the desired functionality of the input, valid codes 0 0-3

are defined in Appendix C of this manual Delay Seconds Proof timer 0 0-999 Function- N/A This message will show the functionality of the code N/A N/A ality that was entered

Table 21: DI Variables

Variable Description Default Value Range Field Value

Available DOs This screen can not be modified. It is here to advise the 9 0-9

user of how many digital outputs can be customized Opt. DO# Enter the DO# that will assume the desired functionality N/A 0-9 Code Enter the code to defines the desired functionality of the 0 0-6

output. Valid codes are defined in Appendix C of this

manual Functionality This message will show the functionality of the code N/A N/A

that was entered

Table 22: DO Variables

3.3.9.3

From the I/O Setup Menu, shown in section 3.3.9, press 3 and ENTER to get to the AO screen shown below.

Total Avail. AO = # Opt. AO = # Code = # (Functionality)

Exit: ? (Y/N)

To return to the I/O Setup Menu, shown in section

3.3.9, press YES and ENTER. To edit the fields, press NO and ENTER. See Table 23 for a description of the AO variables.

3.3.10 Communication Setup

From the System Setup screen, shown in section 3.3, press 10 and ENTER to get to the Communication Setup screen shown below.

Comm. Setting 1 = BACnet 2 = JC N2 3 = Modbus 4 = BACnet/IP 0 = Exit Select: #

Press the numeric key corresponding to the desired Communication Setup sub-menu, and press ENTER.

3.3.10.1

BACnet

From the Communication Setup screen, shown in section 3.3.10, press 1 and ENTER to get to the BACnet screen shown below.

BACnet MS/TP Baud, 8, 1, 1, N Slave MAC = ### Inst = #### SP Ovrd: ? Y/N Exit ? Y/N

The first line confirms setup for the BACnet protocol. The second line defines the baud rate, 8 bit data packets, 1 stop bit, 1 start bit and no parity. The ZoneSav Controller is a slave device only. To return to the Communication Setup Menu, shown in section

3.3.10, press YES and ENTER. To edit the fields, press NO and ENTER. Table 24 gives a description of the BACnet variables.

Variable Description Default Value Range Field Value

Total Available AOs This screen can not be modified. It is here to advise the N/A 0-8

user of how many analog outputs can be customized Opt. AO Enter the output to be configured as it appears on the N/A 0-8

wiring diagram. The analog output card can be configured

for 0-10VDC or 4-20mA signals. Remove the card from

the rack. There are two switches below the pin

connector on the back of the card. The bottom switch

#1 configures the first analog output. The top switch #2

configures the second analog output. Select position U

for 0-10VDC and position I for 4-20mA output signals. Code Defines the desired functionality of the output. Valid 0 0-9

codes are defined in Appendix C of this manual Functionality This message will show the functionality of the code N/A N/A

that was entered

Table 23: AO Variables

Variable Description Default Value Range Field Value

Baud The baud rate is user adjustable 9600 9600,

19200,

38400

MAC Address Obtain the node number from the manufacturer that 128 1-255

supplied the device that will communicate with the

Technologic Controller Inst Unique instance numbers are needed only if multiple 100 0-9999

TECHNOLOGIC panels are connected to the same

network. Some BACnet devices do not require this

number to communicate with the ZonSav controller SP Ovrd Select “Y” to allow the setpoints to be overwritten N Y/N

through the communications port

Table 24: BACnet Variables

3.3.10.2

Metasys N2

From the Communication Setup Menu, shown in section 3.3.10, press 2 and ENTER to get to the Metasys N2 screen shown below.

Metasys N2 9600, 8, 1, 1, N. VND Node = # SP Ovrd: ? Y/N

Exit ? Y/N

The first line confirms setup for the Johnson Controls N2 protocol. The second line defines the 9600 bps baud rate, 8 bit data packets, 1 stop bit, 1 start bit and no parity. To return to the Communications Setup Menu, shown in section 3.3.10, press YES and ENTER. To edit the fields, press NO and ENTER. Table 25 gives a description of the Metasys N2 variables.

3.3.10.3

Modbus

From the Communication Setup Menu, shown in section 3.3.10, press 3 and ENTER to get to the Modbus screen shown below.

Modbus 9600, 8, 1, 1, N RTU Node = # SP Ovrd: ? Y/N

Exit ? Y/N

The first line confirms setup for Modbus protocol. The second line defines the 9600 bps baud rate, 1 stop bit, 1 start bit, and no parity. To return to the Communications Setup Menu, shown in section

3.3.10, press YES and ENTER. To edit the fields, press NO/0 and ENTER. Table 26 gives a description of the Modbus variables.

3.3.10.4

BACnet/IP

From the Communication Setup Menu, shown in section 3.3.10, press 4 and ENTER to get to the BACnet/IP screen shown below.

IP Address: ###. ###. ###. ### Subnet: ###. ###. ###. ###

The BACnet device IP address and Subnet Mask are provided by building management system. Press NEXT SCREEN and the display will show:

Start Delay = ## Sec Setpoint Ovrd: ?(Y/N) Save IPAdd: ?(Y/N) OK: ? (Y/N)

To return to the Communications Setup Menu, shown in section 3.3.10, press YES and ENTER. To edit the fields, press NO and ENTER. Table 27 gives a description of the BACnet/IP variables.

For additional information concerning the above protocols, consult the Bell & Gossett Tech 500 Serial Communications instruction manual (part number S13654).

There may have been additional protocols added to the communication setup menu, contact your Bell & Gossett representative concerning additional protocols and setups.

Variable Description Default Value Range Field Value

Node Obtain the node number from the manufacturer that 1 0-255

supplied the device that will communicate with the

Technologic Controller SP Ovrd Select “Y” to allow the setpoints to be overwritten N Y/N

through the communications port

Table 25: Metasys N2 Variables

Variable Description Default Value Range Field Value

Node Obtain the node number from the manufacturer that 1 255

supplied the device that will communicate with the

Technologic Controller SP Ovrd Select “Y” to allow the setpoints to be overwritten N Y/N

through the communications port

Table 26: Modbus Variables

Variable Unit Description Default Value Range Field Value

Start Delay Seconds Time delay to start the BACnet interface 10 0-999 Set Point N/A Select YES for the external device to override the local N Y/N Ovrd setpoint data Save IP N/A Select YES to save IP address (restarts) N Y/N Add

Table 27: BACnet/IP Variables

3.3.11

Special Functions

From the System Setup Menu, shown in section 3.3, press 11 and ENTER to get to the Special Functions Menu shown below.

Selection: # 1 = Summ/Wint Setting

0 = Exit

Press the numeric keys corresponding to the desired Special Functions sub menu, and press ENTER.

3.3.11.1

Summer/Winter

From the Special Functions screen, shown in section

3.3.11, press 1 and ENTER to get to the Summer/ Winter screen shown below.

Select Sum/Wint Op: # 1 = DI 2 = Serial Com 0 = Disable

OK ? (Y/N)

Table 28, shown below, gives a description of the Summer/Winter variables.

When Summer/Winter mode is enabled by selecting 1 or 2 above, two different sets of setpoints can be defined. The default season is summer. When a high signal on the digital input or serial communication point is received, the season will change to winter. See section 4.3 for more information.

3.3.12 Save to Flash

From the System Setup Menu, shown in section 3.3, press 12 and ENTER to get to the Save to Flash screen shown below.

Current Settings Will Be Saved to the flash ROM. PROCEED? # (Y/N)

To return to the System Setup Menu, shown in section 3.3, press NO and ENTER. To save all of the user setup data to the ROM in the controller, press YES and ENTER.

3.3.13

Load from Flash

From the System Setup Menu, shown in section 3.3, press 13 and ENTER to get to the Save to Flash screen shown below.

**WARNING**

PRIOR SETTINGS TO BE

LOADED FROM FLASH.

PROCEED? # (Y/N)

To return to the System Setup Menu, shown in section 3.3, press NO and ENTER. To load the user setup data, which was previously saved, press YES and ENTER.

3.3.14 Contrast

From the System Setup Menu, shown in section 3.3, press 14 and ENTER to get to the Brightness/ Contrast screen shown below.

Contrast is: ### Change is: ###

Ok ? (Y/N)

To return to the System Setup Menu, shown in section 3.3, press YES and ENTER. To edit the field, press NO and ENTER. Table 27 gives a description of the Contrast variables.

3.4 Test Selection

From the Setup Selection menu, shown in section 3, press 4 and ENTER to get to the Test Selection screen shown below.

Test Selection: # 1 = DI 4 = AO 7 = Disp 2 = DO 5 = LED 8 = Comm 3 = AI 6 = Key 0 = Exit

Press the numeric key corresponding to the desired Test Selection sub-menu, and press ENTER.

Variable Description Default Value Range Field Value

Select Select 1 to switch summer/winter setpoints based on a 0 0-2 Sum/Wint Op. digital input. Select 2 to switch summer/winter setpoints

based on a serial communications port. Select 0 to disable

Table 28: Summer/Winter Variables

Variable Description Default Value Range Field Value

Contrast is: Current contrast setting is not modifiable (40 = Light 75 40-100

Characters, 100 = Darkest Characters) Change to: Desired Contrast Setting (Setting of 100 will reduce the 75 40-100

life of the screen)

Table 29: Brightness/Contrast Variables

3.4.1

DI Test

From the Test Selection Menu, shown in section 3.4, press 1 and ENTER to get to the DI Test screen shown below.

Digital Inputs

1234567890 0000000000

Press Clear to Exit

The zero below each corresponding input will change to a one upon receiving a digital input. Press CLEAR to exit the test.

3.4.2

DO Test

From the Test Selection Menu, shown in section 3.4, press 2 and ENTER to get to the DO Test screen shown below.

Digital Inputs

1234567890 0000000000

Enter DO # 0 (0=Exit)

Press any numeric key, numbered 1-9, corresponding to the digital output for which the state is to be changed. Press ENTER to change the state of the digital output. Pressing ENTER multiple times will toggle between 0 and 1. To exit, press 0 followed by the ENTER key.

3.4.3

AI Test

From the Test Selection Menu, shown in section 3.4, press 3 and ENTER to get to the AI Test Screen shown below.

Analog Inputs 1 = ###% 3 = ###% 2 = ###% 4 = ###% Press Clear to Exit

The current % of the signal will be indicated next to each input. 4mA = 0%, and 20mA = 100%. Press CLEAR to exit the test, or press NEXT/PREV SCREEN to view more inputs.

3.4.4 AO Test

From the Test Selection Menu, shown in section 3.4, press 4 and ENTER to get to the AO Test Screen shown below.

Analog Output Test AO1 = ###% AO3 = ###% AO2 = ###% AO4 = ###%

OK = ? (Y/N)

Press YES and ENTER to return to the Test Selection Menu shown in section 3.4.

Press NO and ENTER to modify the analog outputs. The signal is shown next to each analog output. 0% = 0mA or 0V, and 100% = 20mA or 10V depending on the position of the switch on the analog output card. Enter an alternate value by using the numeric keys and press ENTER to output the new value, or press ENTER to move to the next channel. A03 - A06 may not be modified unless the corresponding output cards are attached to the system.

3.4.5

LED Test

From the Test Selection screen, shown in section 3.4, press 5 and ENTER to get to the LED Test Screen shown below.

LED TEST

**** LED ON ****

**** LED OFF ****

**** LED BLINK ****

All of the LED's on the left key set turn on, then turn off, then flash. The entire test takes 5 seconds to complete prior to returning to the Test Selection screen shown in section 3.4. Press the CLEAR key at any time to terminate the test and return to the Test Selection menu.

3.4.6

Key Test

From the Test Selection Menu, shown in section 3.4, press 6 and ENTER to get to the Key Test Screen shown below.

Key Test

Press a key to test Press Clear to Exit

Press any key except for the CLEAR key, and the display will confirm that the key is working by displaying the key name. Press the CLEAR key to return to the Test Selection menu shown in section 3.4.

3.4.7 Display Test

From the Test Selection Menu, shown in section 3.4, press YES/7 and ENTER to get to the Display Test Screen shown below.

Press Clear to Exit >>> 0 1 2 3 4 5 6 7 8 9>>> >>> 0 1 2 3 4 5 6 7 8 9>>> >>> 0 1 2 3 4 5 6 7 8 9>>> >>> 0 1 2 3 4 5 6 7 8 9>>>

The display will scroll ASCII characters from right to left. All four lines will be tested at the same time. Press CLEAR to return to the Test Selection screen shown in section 3.4.

3.4.8 Comm Test

From the Test Selection Menu, shown in section 3.4, press 8 and ENTER to get to the Comm Test Screen shown below.

Test Communication

B & G Read #

B & G Write #

Press Clear to Exit

If the controller is communicating properly with the building automation system, the numbers will continue increasing in value. For Modbus protocol, the read and write numbers will be equal. For BACnet and Johnson N2 protocols, the numbers will not be equal. If the numbers are not increasing in value, the controller is not communicating properly. If it is not communicating, check the wiring at the terminal blocks and the RS communication card mounted on the controller. Consult the Tech 5500 Serial Communication Manual for further assistance. Press CLEAR to exit this test.

3.5

Default Setup

From the Setup Selection Menu, shown in section 3, press 5 and ENTER to get to the Default screen shown below.

*** WARNING ***

All Setup Data Will

Be Overwritten.

Proceed: ? (Y/N)

Prior to reverting to the default values, it is strongly recommended that all factory/field variables be recorded for future reference. Use the 'Field Value' location in the tables to record your current data. Also record your sensor and valve setup information on the wiring diagram that was included with the unit.

Press NO to return to the Setup Selection Menu, shown in section 3, without loading the default values. Press YES to load all of the pre-defined default variables defined in the tables in this manual. Once the default values are loaded, the controller will return to the Setup Selection screen shown in section 3.

4.1

Status Screens

There are at least 3 status screens that can be navigated by pressing NEXT SCREEN or PREV. SCREEN. Many screens can only be accessed from the status screens including: the Alarm screen, Warning screen, Process Variable screen, Setpoint screen, Setup Selection screen, Log screen, Info screen, and the Manual Valve screen.

4.1.1

ZoneSav Controller Screen

The ZoneSav Controller screen, shown below, is one of at least 3 status screens. It displays the date, time, and the version number. It also displays a status bar on the bottom line. See Table 30 below for a description of the status messages.

ZoneSav Controller

Version: #:##

MM/DD/YY HH:MM:SS

Status1 Status2 Status3 Status4

During normal operation, PREV. SCREEN and NEXT SCREEN can be pressed to scroll through the status screens shown below.

Section 4 - Operation

Possible States Description

Status 1 STOP/START STOP: The valve will close.

START: The valve can be controlled in auto or manual mode. Press the START/STOP button to toggle.

Status 2 MAN/AUTO MAN: The user can manually set the valve position by first pressing the

MANUAL VALVE key. AUTO: The control algorithms will determine the position of the valve. Press the AUTO/MANUAL key to toggle.

Status 3 HEAT/COOL HEAT: The system is intended for heating.

COOL: The system is intended for cooling. See section 3.3.2.3.

Status 4 ALRM/WARN/NORM NORM: no alarms or warnings

WARN: warning but no alarm ALRM: alarm See section 4.5

Table 30: Status Bar

4.1.2

Temperature Status

Pressing NEXT SCREEN, the controller will display the Temperature Status screen shown below.

Temperatures

Sys= ### Zn Sup= ###

*Tmp= ### Zn Ret= ###

Status1 Status2 Status3 Status4

The Temperature Status screen displays all of the temperatures in the system and the status bar on the bottom line. It shows the system supply temperature, the zone supply temperature and the zone return temperature.

*The fourth temperature, "Tmp", will only be visible if an analog input is set up with type "Temp".

4.1.3

Flow Status

Pressing NEXT SCREEN, the controller will display the Flow Status screen shown below.

Sys Flow= ##### GPM Flow #1= ##### Flow #2= ##### Status1 Status2 Status3 Status4

The Flow Status screen displays all of the flows in the system and the status bar on the bottom line. This screen is only available if at least one analog input has type "Flw". If more than one analog input is set up to have a type "Flow", then the lowest analog input number will be the system flow, the next highest will be flow #1 and the next highest will be flow #2. Flow #1 and Flow #2 are only visible if the sensors are set up.

4.1.4

Valve Status

Pressing NEXT SCREEN, the controller will display the Valve Status screen shown below.

Signal to Vlv = ###% *Signal from Vlv: ###% Control: (Control Mode) Status1 Status2 Status3 Status4

The first line shows the signal to the valve. 0% should always indicate closed, and 100% should always indicate open. If this is not correct, see section 3.2.3.

The second line shows the signal from valve and will only be visible if an analog input is set up with type "VFbk".

The third line shows the control mode. See Table 31 below for a description of the different control modes.

4.2

Valve Operation

The valve position can be controlled manually or automatically. See the following sections for instructions on both types of operation.

4.2.1

Manual Valve Operation

To manually control the Valve with the controller, the operation mode must be set to Manual by pressing the AUTO/MANUAL key. The system must also be started by pressing the START/STOP key. The controller must also be in one of the status screens shown in section 4.1.

The LED on the MANUAL VALVE key will be flashing if all of the above is true. Press it to go to the Manual Valve Position Screen shown below.

Valve Position = ###% 0%=Closed 100%=Open Press Clear to Exit

Input the desired valve position, and press ENTER. The controller will return to the previous status screen. The actual output signal to the valve will vary depending on the valve signal type. See section

3.2.3.

4.2.2

Auto Valve Operation

To automatically control the valve with the controller, the operation mode must be set to Auto by pressing the AUTO/MANUAL key. The system must also be started by pressing the START/STOP key.

4.3 Setpoint Modification

To modify any of the setpoints, press the SETPOINT key while in one of the status screens shown in section 4.1. The following will be displayed.

(Season) Setpoint Sply SP= ### Ret. SP= ### Ok ? (Y/N)

Control Mode Description None No control algorithm is being executed. Flow Limit 90% of the flow limit value is the setpoint for a user adjustable timer. Sys Temp System Temperature is beyond the limit. Valve goes to a predefined position for the duration of a user

adjustable timer ZR Temp The zone return temperature is being controlled. ZS Temp The zone supply temperature is being controlled. Purge The valve goes to a fixed position for a user adjustable timer. ZR Index The zone return setpoint is being modified. ZS Index The zone supply setpoint is being modified. PID Opt PID optimization control is closing the valve. Auto-Tune PID Auto-Tuning is in process.

Table 31: Control Modes

If Summer/Winter mode is enabled, the season for which the setpoints will be modified will be shown in the upper left corner. Switch to the other season by pressing PREV. SCREEN or NEXT SCREEN. See section 3.3.11.

To modify the setpoints, press NO and ENTER at the OK prompt. Input the desired setpoints and press ENTER. To accept the current setpoints, press YES and ENTER at the OK prompt. The controller will then return to the previous Status screen.

4.4

Process Variable Monitoring

To view the process variables and their setpoints, press the PROCESS VARIABLE key while in one of the status screens shown in section 4.1. The controller will go to the System Parameters screen shown below.

System Parameters Temp= ### Lim = ### Flow= ##### Lim = ##### START AUTO COOL S/W

The System Parameters screen shows the system supply temperature on the second line along with its limit. If at least one analog input has type "Flw", the system flow will be shown on the third line along with its limit.

Press NEXT SCREEN to view the Zone Parameters screen shown below.

Zone Parameters Supply= ### SP = ### Return= ##### SP = ##### START AUTO COOL S/W

The second line shows the zone supply temperature along with its setpoint. The third line shows the zone return temperature along with its setpoint.

Press NEXT SCREEN to view the Active Inputs screen shown below.

Active (PID) Inputs PV= ##### SP= ### Index Sply/Ret= ###/### START AUTO COOL S/W

The PV field will show the active process variable. The SP field will show the active setpoint. Both of these fields will be zero if flow limit control or system supply temperature limit control is active. If the SP was modified through a communications port or with Summer/Winter operation, the current setpoint will be shown here. If Summer/Winter mode is enabled, an

S or W will be displayed in the lower right corner to indicate the current season mode. The indices of the supply and return setpoints are also shown.

From any of the above Process Variable screens, press CLEAR to return to the status screens.

4.5

Alarms

When the controller detects an alarm condition, the display will flash ALRM in the lower right corner of all of the status screens shown in section 4.1. If the current screen is one of the status screens, the LED on the HELP key will be flashing. Press the HELP key for additional information on the alarm(s). To view possible causes for alarms press the HELP key again after the alarm is displayed. Refer to Table 32 below for an overview of the possible alarms and their respective causes. If more than four alarms exist simultaneously, press NEXT SCREEN or PREV. SCREEN to view the remaining alarms.

The controller logs alarms as they occur to aid in troubleshooting unobserved alarms. Refer to Section

4.7.3 for alarm logging information. Press CLEAR to return to the previous screen.

4.6

Warnings

When the controller detects a warning condition, the display will flash "Warn" in the lower right corner of all of the status screens shown in section 4.1. If the current screen is one of the status screens, the LED on the WARNING key will be flashing. Press the WARNING key for additional information. Refer to Table 33 on next page for an overview of the possible warnings and their respective causes. If more than four warnings exist simultaneously, press NEXT SCREEN or PREV. SCREEN to view the remaining warnings.

Press CLEAR to return to the previous screen.

4.7

Log Selection

Press the LOG key, while in one of the status screens shown in section 4.1, to get to the Log Selection screen shown below.

Log Selection: # 0 1 = Averages 4 = Valve 2 = Totals 5 = Data 3 = Alarm 0 = Exit

Select the log to view, and press ENTER. Press PREV. SCREEN or NEXT SCREEN to view the neighboring screen shown below.

Log Selection: # 0 6 = Operat. 9 = AutoTune 7 = Power 8 = Service 0 = Exit

HELP HELP/HELP DETAILED DESCRIPTION SCREEN SCREEN DISPLAY ALARM

Battery! Check battery's voltage Check for less then a 3V charge on the battery. Check the battery connection.

and its continuity AI #1-8 Fail Check wiring, piping, AI failure occurs when signal is less than 2.5mA or greater than 19.8mA for the

polarity, continuity duration of the proof timer.

Table 32: Alarm Messages

4.7.1

Averages

From the Log Selection screen, shown in section 4.7, press 1 and ENTER to get to the Averages screen shown below.

Avg TON = ##### Avg MBH = ############ Avg GPM = ##### Press Clear to Exit

The average heat transfer rate and flow rate are shown here. 1 MBH = 1000 btu/hr. 1 TON = 12 MBH. These values are only calculated while system is started and in auto operation mode. They can be reset from the setup menu. See section 0.

4.7.2

Totals

From the Log Selection screen, shown in section 4.7, press 2 and ENTER to get to the Totals screen shown below.

Tot Gal = ##### Tot KBTU = ############

Press Clear to Exit

The total number of gallons and BTUs are shown here. 1KBTU = 1000 btu. These values are only calculated while system is started and in auto operation mode. They can be reset from the setup menu. See section 0.

4.7.3

Alarm Log

From the Log Selection screen, shown in section 4.7, press 3 and ENTER to get to the Alarm Log screen shown below.

DATE TIME ALARM MMDD HHMM ALARM

"" ""

The four digit date is displayed in the MMDD format. The four digit time is displayed in the 24 hour HHMM format. Press NEXT SCREEN or PREV. SCREEN to view more events. The most recent alarm is shown first. Press the CLEAR key to exit this screen.

4.7.4

Valve Log

From the Log Selection screen, shown in section 4.7, press 4 and ENTER to get to the Valve Log screen shown below.

Rate: (Valve Log Rate) DATE Maximum = ###% TIME Minimum = ###% Average = ###% Scrn# 1

The four digit date is displayed in the MMDD format. The four digit time is displayed in the 24 hour HHMM format. The current logging interval is shown. See section 3.2.2 to change the log rate. The maximum and minimum valve positions that were observed during the specified logging interval will be logged. The average valve position over the interval is also shown.

Press NEXT SCREEN or PREV. SCREEN to view more events. The most recent event is shown first. Press the CLEAR key to exit this screen.

4.7.5

Data Log

From the Log Selection screen, shown in section 4.7, press 5 and ENTER to get to the Data Log screen shown below.

(Sensor Type) Max = ##### DATE Min = ##### TIME Avg = ##### Scrn#

The Data Log screen will show the minimum and maximum values for the system supply temperature, zone supply temperature, zone return temperature, and flow. It will save the sixty most recent entries. The type is shown in the upper left corner. Pressing the UP ARROW and DOWN ARROW will change the sensor type.

The four digit date is displayed in the MMDD format. The four digit time is displayed in the 24 hour HHMM format. The maximum and minimum values that were observed during the specified logging interval will be logged. The average sensor value over the interval is also shown. See section 3.1.2 to change the log rate.

Warning Message Detailed Description

2.5mA < AI # < 3.9mA The specified AI # is greater than 2.5mA but less than 3.9mA AI # > 19.8mA The specified analog input is greater than 19.8mA Unusual Temps (COOL) The zone supply temperature is less than the system supply temperature, or the zone

return temperature is less than the zone supply temperature

Unusual Temps (HEAT) The zone supply temperature is greater than the system supply temperature, or the zone

return temperature is greater than the zone supply temperature System Temp Limit The controller is in System Temperature Limit operation Flow Limit The controller is in Flow Limit operation mode Zone Supply SP Index The controller is in zone supply setpoint indexing mode Zone Return SP Index The controller is in zone return setpoint indexing mode

Table 33: Warning Messages

Press NEXT SCREEN or PREV. SCREEN to view more events. The most recent event is shown first. Press the CLEAR key to exit this screen.

4.7.6

Operation Log

From the Log Selection screen, shown in section 4.7, press 6 and ENTER to get to the Operation Log screen shown below.

Operation Mode

DATE

STOP/MAN TIME

Scr #

The four digit date is displayed in the MMDD format. The four digit time is displayed in the 24 hour HHMM format. Every time the START/STOP key or the AUTO/MANUAL key is pressed, the event will be logged by showing the state of both variables immediately after the change. Press NEXT SCREEN or PREV. SCREEN to see more events. The most recent event will be shown first. Press the CLEAR key to exit this screen.

4.7.7

Power Log

From the Log Selection screen, shown in section 4.7, press 7 and ENTER to get to the Power Log screen shown below.

MMDDYY HHMM (up/down) MMDDYY HHMM (up/down) MMDDYY HHMM (up/down) MMDDYY HHMM (up/down)

The four digit date is displayed in the MMDD format. The four digit time is displayed in the 24 hour HHMM format. "Up" will be shown if powered up, and "Down" will be shown if powered down. Press NEXT SCREEN or PREV. SCREEN to view more events. The most recent event will be shown first. Press the CLEAR key to exit this screen.

4.7.8

Service Log

From the Log Selection screen, shown in section 4.7, press 8 and ENTER to get to the Service Log screen shown below.

Selection: # 1 = System Log 2 = Operating Hours Exit = 0

Press the numeric key corresponding to the desired Service Log sub-menu, and press ENTER.

4.7.8.1 System Log

From the Service Log screen, shown in section 4.7.8, press 1 and ENTER to get to the Error Log screen shown below.

MMDDYY HHMM #### MMDDYY HHMM #### MMDDYY HHMM #### MMDDYY HHMM ####

The four digit date is displayed in the MMDD format. The four digit time is displayed in the 24 hour HHMM format. The third column shows system error code for the error that occurred at the given time. Press NEXT SCREEN or PREV. SCREEN to view more events. Press the CLEAR key to exit this screen.

4.7.8.2

Operating Hours Log

From the Service Log screen, shown in section 4.7.8, press 2 and ENTER to get to the Operating Hours Log screen shown below.

Operating Since

MM/DD/YY HH:MM

Total Hours = ####

The Operating Hours screen shows the date and time when the controller was configured. Total Hours shows how long the controller has had power applied. See section 0 to reset these values. Press the CLEAR key to exit this screen.

4.7.9

Auto-Tune Log

From the Log Selection screen, shown in section 4.7, press 9 and ENTER to get to the Auto-Tune Log screen shown below.

Auto-Tune MM/DD status: ##### HH:MM addInfo: ##### (type) Scr# ##

The date and time are shown in the upper right corner. The screen number is shown in the lower right. The type of sensor for which the error occurred is shown in the lower left. The status and addInfo codes are also shown. Press CLEAR to exit.

The following is a description of the hardware, diagnostics, and corrective action to maintain a process being controlled by the ZoneSav controller.

Note: The following should not be interpreted as the maximum configuration of this controller; rather this describes its application as a ZoneSav controller only.

5.1

Technical Overview

The ZoneSav Controller is a micro-processor based valve controller unique to and exclusively manufactured by ITT Bell & Gossett. All aspects of this unit are strictly proprietary to ITT Bell & Gossett.

5.2 Digital Inputs

The controller has provision for digital inputs with an operating voltage of 24 VDC. This signal voltage must be obtained from the 24 VDC power supply mounted to the subpanel. It is not recommended that other power sources be used without factory approval. Customer connections are made directly to the terminal blocks tied to the digital input module.

5.3

Digital Outputs

The controller has provision for relay outputs to control 120 V 50/60 HZ devices. The relays are not removable. If defective, the digital output module must be returned to the factory for repair. All relays operate as single pole single throw. Components are provided to reduce contact arc and extend electrical life. Customer connections are made directly to the terminals mounted on the digital output module.

5.4

Analog Inputs

Analog inputs are provided for process variables and optional transmitters. All analog inputs operate at 4-20mA. They must be powered from the 24 VDC power supply included with the controller.

5.5 Memory

The logic is stored in a non-removable EEPROM chip which can be updated from the RS-232 program port on the CPU or from a memory card. The user setup data is stored in non-volatile memory or fixed RAM. The fixed RAM requires power to hold the information. While the controller is powered up, the CPU controller provides the power to save the user values. When the controller is powered down a 3V Lithium battery provides the power to store the user values. When the battery voltage drops below 2.5 VDC the controller will display ALRM. After pressing the HELP key the display will indicate Battery!. You will have approximately 25 weeks to replace the battery before losing memory due to an under voltage condition during a power loss.

5.6

CPU

The CPU does not require any maintenance, and it cannot be replaced as a field repair.

5.7

Power Supply

The power supply provides 24 VDC for all digital and analog signals as well as the CPU. It is specifically rated only for the controller and other loads should not be applied without factory approval.

5.8 Protection

Analog inputs - the analog inputs provided on the ZoneSav Controller must be wired according to the wiring diagram that shipped with the unit.

Protection - all analog inputs are protected from high voltage, crossed wiring, etc. A sustained fault will be limited to 20mA by the current limiting circuit.

Digital Inputs - as long as input power is derived from the integral 24VDC power supply they are protected.

Digital Outputs - each output shall not exceed the ratings on the digital output module.

5.9

Instruments and their Use

With the diagnostics described herein, extensive instruments are not required. However, the instruments used should be quality units to meet the following at a minimum.

Under no circumstances shall any instrument be used to test any on board components. Especially risky is an ohmmeter with battery voltage higher than TTL logic or applied with incorrect polarity.

5.9.1 AC/DC Voltmeter

Input impedance Not less than 10 MEGOHM. Accuracy - AC ± 2% of Full Scale

- DC ± 3% of Full Scale Rated circuit to 1000V. ground voltage

5.9.2

Ohmmeter

Accuracy ± 2.5% Max open circuit voltage 0.5 V

5.9.3

Milliamp Meter

Accuracy ± 2% of Full Scale

5.9.4

Signal Generator (analyzer) - recommended

The following signal generators are recommended: Beta calibrator Model 434 20mA signal analyzer, Altek calibrator Model 334 4-20mA loop analyzer or Druck UPS III loop calibrator. The instruments may be purchased from a Local Process Control Distributor.

Note: If some other instrument is used it must float above ground, preferably battery powered.

Section 5 - Maintenance

5.10

Field Repair

General - typical field repair should include: replacing fuses, replacing input/output modules and assuring connections are correct and secure.

5.11

Special Programs

If your nameplate does not indicate a standard model number, the program was created per specific customer needs. Job specific setup menus and drawings will be included with the unit. If additional information is required, contact your local Bell & Gossett representative.

5.12

Program Updating

To update to a new version of the program, the program must be downloaded through the RS 232 port on the CPU or using a memory card. Contact your Bell & Gossett representative for the preferred method of upgrading your software.

5.13

Controller Information Screen

To check the program type, scheme, or version numbers, press the INFO key while in one of the status screens shown in section 4.1. The screen will now display the Controller Information Screen shown below.

SYS INFO CPU V = #.## OS V = #.## AS V = #.#.## Scheme = #

Press the CLEAR key to exit this screen. If the factory is called for information or service on this unit, this information may be requested.

5.14

Maintenance (Physical)

5.14.1 Electrical

No maintenance is required for the electrical panel except to keep the modules free of dirt and dust that might hold moisture. Cabinet door should be kept closed, and the components kept dry.

5.14.2 Mechanical

For more instruction on the parts used in the ZoneSav system, see the I.O.M.s for the flow transmitter, the temperature transmitters, the valve, and any other sensors used.

DANGER: Troubleshooting live control panels exposes personnel to hazardous voltages. Electrical trouble-

shooting must only be done by a qualified electrician.

FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.

SYSTEM PIPING AND UNIT

INSTALLATION – FINAL CHECK LIST

____ 1. Is the unit base properly installed?

____ 2. Are all lubrication points properly lubricated?

____ 3. Are the shut-off valves to the transmitters open?

____ 4. Is the system purged of debris and air?

____ 8. Is the valve actuator operational?

____ 9. Does the valve modulation correspond to the control

signal sent to it? (0%=Closed, 100%=Open)

ELECTRICAL WIRING AND CONTROL

SETTINGS – FINAL CHECK LIST

____ 1. Does the feeder line voltage correspond to the unit

voltage? Check the unit nameplate.

____ 2. Are the feeder wires correctly sized for the load?

____ 3. Is the unit properly grounded?

____ 4. Have all the power terminals in the control panel

been checked for tightness? This is imperative since stranded wires tend to “flow” and become loose after initial installation.

____ 5. Are all I/O connected per the wiring diagram?

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: 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.

DANGER: High voltage AC power can kill. Dis-

connect and lockout power prior to servicing unit.

FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.

CAUTION: Seal damage may occur. Do not run

pumps dry. Fill and vent the pump volute prior to

operation.

FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE AND/OR MODERATE PERSONAL INJURY.

Appendix A

Appendix B

Appendix C - Valid I/O Codes

Code Function Description I/O Type Range Equate to the Signal

0 None DO N/A N/A 1 Alarm Output DO 1/0 On/Off 2 Normally Closed Alarm Output DO 1/0 On/Off 3 Flow Limit Operation DO 1/0 On/Off 4 System Supply Temperature Limit Operation DO 1/0 On/Off 5 System On/Off DO 1/0 On/Off 6 System Auto/Manual DO 1/0 On/Off

0 None DI N/A N/A 1 Summer/Winter Switch DI 1/0 Winter/Summer 2 Push to Silence Switch DI 1/0 On/Off 3 Local/Remote/Off Switch DI 1/0 Local/Remote, Off

0 None AO N/A N/A 1 Analog Input 1 AO 0-Span 4 - 20 ma 2 Analog Input 2 AO 0-Span 4 - 20 ma 3 Analog Input 3 AO 0-Span 4 - 20 ma 4 Analog Input 4 AO 0-Span 4 - 20 ma 5 Analog Input 5 AO 0-Span 4 - 20 ma 6 Analog Input 6 AO 0-Span 4 - 20 ma 7 Analog Input 7 AO 0-Span 4 - 20 ma 8 Analog Input 8 AO 0-Span 4 - 20 ma 9 Valve Output AO 0 - 100% 4 - 20 ma, or 0 - 10V

Appendix D - BACnet Protocol Implementation

Conformance Statement for BACnet IP

BACnet Protocol Implementation Conformance Statement

Date

: 9/13/06

Vendor Name: ITT Bell & Gossett Product Name: Technologic 5500 Series ZoneSav Valve Controller Product Model Number: N/A Applications Software Version: 1.71 or above Firmware Revision: N/A BACnet Protocol Revision: 2.0

Product Description: The ZoneSav is a valve controller for HVAC. It operates either as a stand-alone controller or as part of a

building-wide integrated system. The BACnet communication interface will provide communication between the ZoneSav and the BACnet system residing on Ethernet media.

BACnet Standardized Device Profile (Annex L): BACnet Application Specific Controller (B-ASC) List all BACnet Interoperability Building Blocks Supported (Annex K): DS-RP-B, DS-RPM-B, DS-WP-B, DS-WPM-B, DM-TS-B Segmentation Capability: None Standard Application Services Supported:

Application Service Initiate Requests Executes Requests

Read Property No Yes Read Property Multiple No Yes Write Property No Yes Write Property Multiple No Yes Time Synchronization No Yes Who-Has No Yes I-Have Yes Yes Who-Is No Yes I-Am Yes Yes

Standard Object Types Supported:

Object Type Dynamically Creatable Dynamically Deletable Optional Properties Supported Writable Properties

Analog Input No No None Analog Output No No None Analog Value No No None Present Value Binary Input No No None Binary Output No No None Binary Value No No None Present Value

Data Link Layer Options:

 BACnet IP, (Annex J)  BACnet IP, (Annex J), Foreign Device  ISO 8802-3, Ethernet (Clause 7)  ANSI/ATA 878.1, 2.5 Mb. ARCNET (Clause 8)  ANSI/ATA 878.1, RS-485 ARCNET (Clause 8), baud rate(s) ____________  MS/TP master (Clause 9), baud rate(s): ____________  MS/TP slave (Clause 9), baud rate(s): ____________  Point-To-Point, EIA 232 (Clause 10), baud rate(s): ____________  Point-To-Point, modem, (Clause 10), baud rate(s): ____________  LonTalk, (Clause 11), medium: __________  Other: ____________

Device Address Binding:

Is static device binding supported? (This is currently necessary for two-way communication with MS/TP slaves and certain other devices.)

 Yes  No

Networking Options:

 Router, Clause 6 - List all routing configurations, e.g., ARCNET-Ethernet, Ethernet-MS/TP, etc.  Annex H, BACnet Tunneling Router over IP  BACnet/IP Broadcast Management Device (BBMD).

 Does the BBMD support registrations by Foreign Devices?  Yes  No

Character Sets Supported:

Indicating support for multiple character sets does not imply that they can all be supported simultaneously.

 ANSI X3.4  IBM™/Microsoft™ DBCS  ISO 8859-1  ISO 10646 (UCS-2)  ISO 10646 (UCS-4)  JIS C 6226

Appendix E - BACnet Protocol Implementation

Conformance Statement for BACnet MS/TP

BACnet Protocol Implementation Conformance Statement

Date

: 9/13/06

Product Description: The ZoneSav is a valve controller for HVAC. It operates either as a stand-alone controller or as part of a

building-wide integrated system. The BACnet communication interface will provide communication between the ZoneSav and the BACnet system residing on EIA-485 media.

Application Service Initiate Requests Executes Requests

Read Property No Yes Read Property Multiple No Yes Write Property No Yes Write Property Multiple No Yes Time Synchronization No Yes Who-Has No Yes I-Have Yes Yes Who-Is No Yes I-Am Yes Yes

Standard Object Types Supported:

Object Type Dynamically Creatable Dynamically Deletable Optional Properties Supported Writable Properties

Analog Input No No None Analog Output No No None Analog Value No No None Present Value Binary Input No No None Binary Output No No None Binary Value No No None Present Value

Data Link Layer Options:

 BACnet IP, (Annex J)  BACnet IP, (Annex J), Foreign Device  ISO 8802-3, Ethernet (Clause 7)  ANSI/ATA 878.1, 2.5 Mb. ARCNET (Clause 8)  ANSI/ATA 878.1, RS-485 ARCNET (Clause 8), baud rate(s) ____________  MS/TP master (Clause 9), baud rate(s): ____________  MS/TP slave (Clause 9), baud rate(s): 9600, 19200, 38400  Point-To-Point, EIA 232 (Clause 10), baud rate(s): ____________  Point-To-Point, modem, (Clause 10), baud rate(s): ____________  LonTalk, (Clause 11), medium: __________  Other: ____________

Device Address Binding:

Is static device binding supported? (This is currently necessary for two-way communication with MS/TP slaves and certain other devices.)

 Yes  No

Networking Options:

 Router, Clause 6 - List all routing configurations, e.g., ARCNET-Ethernet, Ethernet-MS/TP, etc.  Annex H, BACnet Tunneling Router over IP  BACnet/IP Broadcast Management Device (BBMD).

 Does the BBMD support registrations by Foreign Devices?  Yes  No

Character Sets Supported:

Indicating support for multiple character sets does not imply that they can all be supported simultaneously.

 ANSI X3.4  IBM™/Microsoft™ DBCS  ISO 8859-1  ISO 10646 (UCS-2)  ISO 10646 (UCS-4)  JIS C 6226

Appendix F - BACnet Communications Points

Object Identifier Object Name Object Type Present Value/Range

Binary Input, 1 System Start/Stop BINARY_INPUT 1 = Start 0 = Stop Binary Input, 2 Op. Mode BINARY_INPUT 1 = Auto 0 = Manual Binary Input, 3 AI #1 Failure BINARY_INPUT 1 = Failure 0 = O.K. Binary Input, 4 AI #2 Failure BINARY_INPUT 1 = Failure 0 = O.K. Binary Input, 5 AI #3 Failure BINARY_INPUT 1 = Failure 0 = O.K. Binary Input, 6 AI #4 Failure BINARY_INPUT 1 = Failure 0 = O.K. Binary Input, 7 AI #5 Failure BINARY_INPUT 1 = Failure 0 = O.K. Binary Input, 8 AI #6 Failure BINARY_INPUT 1 = Failure 0 = O.K.

Binary Input, 9 AI #7 Failure BINARY_INPUT 1 = Failure 0 = O.K. Binary Input, 10 AI #8 Failure BINARY_INPUT 1 = Failure 0 = O.K. Binary Input, 11 General Alarm BINARY_INPUT 1 = Failure 0 = O.K.

Binary Output, 1 System Start / Stop BINARY_OUTPUT 1 = Start 0 = Stop Binary Output, 2 System Purge BINARY_OUTPUT 1 = Start (positive edge = start purge) Binary Output, 3 Summer/Winter BINARY_OUTPUT 0 = Summer 1 = Winter

Analog Value, 1 System Supply Temp ANALOG_VALUE(R/W) 0 to Span Analog Value, 2 Zone Supply Temp ANALOG_VALUE(R/W) 0 to Span Analog Value, 3 Zone Return Temp ANALOG_VALUE(R/W) 0 to Span Analog Value, 4 Flow ANALOG_VALUE(R/W) 0 to Span Analog Value, 5 Zone Supply Setpoint ANALOG_VALUE(R/W) 0 to 999 Analog Value, 6 Zone Return Setpoint ANALOG_VALUE(R/W) 0 to 999 Analog Value, 7 Active PV ANALOG_VALUE 0 to span Analog Value, 8 Active SP ANALOG_VALUE 0 to 999 Analog Value, 9 Valve Position ANALOG_VALUE 0 - 100%

Analog Value, 10 Valve Feedback ANALOG_VALUE 0 - Span Analog Value, 11 Summer/Winter Mode ANALOG_VALUE 0 = disabled, 1 = Summer, 2 = Winter

Appendix G - LonWorks Communications Points

SNVT

NV Length

Index Name SNVT Type (bytes) POINT DESCRIPTION RANGE/VALUE Units

0 nvoStart_Stop SNVT_Switch (95) 2 System Start/Stop status 1 = Start 0 = Stop N/A 1 nvoAuto_Manual SNVT_Switch (95) 2 Auto/Manual Status 1 = Auto 0 = Manual N/A 2 nvoAI1_Fail SNVT_Switch (95) 2 Analog Input #1 Failure 1 = Failure 0 = O.K. N/A 3 nvoAI2_Fail SNVT_Switch (95) 2 Analog Input #2 Failure 1 = Alarm 0 = O.K. N/A 4 nvoAI3_Fail SNVT_Switch (95) 2 Analog Input #3 Failure 1 = Failure 0 = O.K. N/A 5 nvoAI4_Fail SNVT_Switch (95) 2 Analog Input #4 Failure 1 = Failure 0 = O.K. N/A 6 nvoAI5_Fail SNVT_Switch (95) 2 Analog Input #5 Failure 1 = Failure 0 = O.K. N/A 7 nvoAI6_Fail SNVT_Switch (95) 2 Analog Input #6 Failure 1 = Alarm 0 = O.K. N/A 8 nvoAI7_Fail SNVT_Switch (95) 2 Analog Input #7 Failure 1 = Failure 0 = O.K. N/A

9 nvoAI8_Fail SNVT_Switch (95) 2 Analog Input #8 Failure 1 = Failure 0 = O.K. N/A 10 nvoGen_Alarm SNVT_Switch (95) 2 General Alarm 1 = Alarm 0 = O.K. N/A 11 nvoSys_Temp User defined (0) 2 System Temperature 0 to Span °F 12 nvoZS_Temp User defined (0) 2 Zone Supply Temperature 0 to Span °F 13 nvoZR_Temp User defined (0) 2 Zone Return Temperature 0 to Span °F 14 nvoFlow User defined (0) 2 Zone Flow 0 to Span GPM 15 nvoSupply_SP User defined (0) 2 Zone Supply Setpoint 0 to 999 °F 16 nvoReturn_SP User defined (0) 2 Zone Return Setpoint 0 to 999 °F 17 nvoActive_PV User defined (0) 2 Active Process Variable 0 to Span °F 18 nvoActive_SP User defined (0) 2 Active Setpoint 0 to 999 °F 19 nvoValve_Pos SNVT_Count (8) 2 Valve Position 0 - 100% % 20 nvoValve_Fdbk SNVT_Count (8) 2 Valve Feedback 0 - Span % 21 nvoSeason_Mode SNVT_Count (8) 2 Season Mode 0 = Summer, 1 = Winter N/A 22 nviStart_Stop SNVT_Switch (95) 2 Remote Start/Stop 1 = Start 0 = Stop N/A 23 nviPurge SNVT_Switch (95) 2 Remote Purge 1 = Start Purge (Positive Edge) N/A 24 nviSum_Wint SNVT_Switch (95) 2 Remote Sum/Winter switch 0 = Summer, 1 = Winter N/A 25 nviOvrd_Sys_Temp User defined (0) 2 Override System Temp 0 to Span °F 26 nviOvrd_ZS_Temp User defined (0) 2 Override Zone Supply Temp 0 to Span °F 27 nviOvrd_ZR_Temp User defined (0) 2 Override Zone Return Temp 0 to Span °F 28 nviOvrd_Flow User defined (0) 2 Override Zone Flow 0 to Span GPM 29 nviOvrd_ZS_SP User defined (0) 2 Override Zone Supply Setpoint 0 to 999 °F 30 nviOvrd_ZR_SP User defined (0) 2 Override Zone Return Setpoint 0 to 999 °F

Appendix H - Metasys N2 Communications Points

NPT NPA POINT DESCRIPTION RANGE/VALUE WRITABLE

BI 1 System Start/Stop 1 = Start 0 = Stop No BI 2 Op. Mode 1 = Auto 0 = Manual No BI 3 AI # 1 Failure 1 = Failure 0 = O.K. No BI 4 AI # 2 Failure 1 = Alarm 0 = O.K. No BI 5 AI # 3 Failure 1 = Failure 0 = O.K. No BI 6 AI # 4 Failure 1 = Failure 0 = O.K. No BI 7 AI # 5 Failure 1 = Failure 0 = O.K. No BI 8 AI # 6 Failure 1 = Alarm 0 = O.K. No BI 9 AI # 7 Failure 1 = Failure 0 = O.K. No BI 10 AI # 8 Failure 1 = Failure 0 = O.K. No BI 11 General Alarm 1 = Alarm 0 = O.K. No

BO 1 System Start / Stop 1 = Start 0 = Stop Yes BO 2 System Purge 1 = Start Purge (positive edge) Yes BO 3 Summer/Winter Mode 0 = Summer 1 = Winter Yes

ADI 1 System Supply Temp 0 to 999 Yes ADI 2 Zone Supply Temp 0 to 999 Yes ADI 3 Zone Return Temp 0 to 999 Yes ADI 4 Flow 0 to 65535 Yes ADI 5 Zone Supply Setpoint 0 to 999 Yes ADI 6 Zone Return Setpoint 0 to 999 Yes ADI 7 Active Process Variable 0 to Span No ADI 8 Active Setpoint 0 to 999 No ADI 9 Valve Position 0 - 100% No ADI 10 Valve Feedback 0 - Span No ADI 11 Summer/Winter Mode 0 = disabled, 1 = Summer, 2 = Winter No

Appendix I - Modbus Communications Points

Function Modbus

Code Point # Point Description Range/Value Address

02 1 System Start/Stop 1 = Start 0 = Stop 10001 02 2 Op. Mode 1 = Auto 0 = Manual 10001 02 3 Analog Input #1 Failure 1 = Failure 0 = O.K. 10003 02 4 Analog Input #2 Failure 1 = Failure 0 = O.K. 10004 02 5 Analog Input #3 Failure 1 = Failure 0 = O.K. 10005 02 6 Analog Input #4 Failure 1 = Failure 0 = O.K. 10006 02 7 Analog Input #5 Failure 1 = Failure 0 = O.K. 10007 02 8 Analog Input #6 Failure 1 = Failure 0 = O.K. 10008 02 9 Analog Input #7 Failure 1 = Failure 0 = O.K. 10009 02 10 Analog Input #8 Failure 1 = Failure 0 = O.K. 10010 02 11 General Alarm 1 = Alarm 0 = O.K. 10019

05 1 System Start/Stop 1 = Start 0 = Stop 00001 05 2 System Purge 1 = Start Purge (positive edge) 00002 05 3 Summer/Winter 0 = Summer 1 = Winter 00003

04, 06 1 System Supply Temp 0 to Span 30001, 40001 04, 06 2 Zone Supply Temp 0 to Span 30002, 40002 04, 06 3 Zone Return Temp 0 to Span 30003, 40003 04, 06 4 Flow 0 to Span 30004, 40004 04, 06 5 Zone Supply Setpoint 0 to Span 30005, 40005 04, 06 6 Zone Return Setpoint 0 to Span 30006, 40006 04, 06 7 Active Process Variable 0 to Span 30007, 40007 04, 06 8 Active Setpoint 0 to Span 30008, 40008 04, 06 9 Valve Position 0 to 100% 30009, 40009 04, 06 10 Valve Feedback 0 to Span 30010, 40010 04, 06 11 Summer/Winter Mode 0 = disabled, 1 = Summer, 2 = Winter 30011, 40011

Appendix J – Drawings

Drawing # Description

1 ZoneSav Front View Door Closed 2 ZoneSav Front View Door Opened 3 ZoneSav Field Connection Diagram 4 ZoneSav Operator Interface

Drawing 1: Technologic 5500 Series ZoneSav (Front View Door Closed)

WARNING LABEL PART #S11550

LOCAL-REMOTE-OFF

SWITCH

ProcessProcess

SetSet

VariableVariable

PointPoint

Alter-

F1F1

nationnation

YesYes

F3F3 F4F4

EnterEnter

NoNo

Bell & Gossett ITT Fluid Technology

OPERATOR INTERFACE

SetupSetup

F2F2

ClearClear

BACNET IP PORT

(

)

Drawing 2: Technologic 5500 Series ZoneSav (Front View Door Open)

Drawing 3: Technologic 5500 Series ZoneSav Field Connection Diagram

(OPTIONAL)

RS COMMUNICATION

PORT SLOT 1

(OPTIONAL)

CPU & OPERATOR

INTERFACE

RACK 1

RACK O DIGITAL INPUT

RACK 0

RACK O DIGITAL OUTPUTS

CUSTOMER CONNECTIONS

ANALOG

OUTPUT

SLOT 3

(OPTIONAL)

ANALOG

INPUT

SLOT 4

OPTIONAL

ANALOG INPUT SLOT 5

ANALOG OUTPUT SLOT 6

24VDC POWER SUPPLY

HMS AB7009 (OPTIONAL)

4 LINE DISPLAY

NUMERIC KEY PAD

FUNCTION KEYS WITH LEDS

EnterEnter

YesYes

NoNo

F3F3 F4F4

ClearClear

SetSet PointPoint

ProcessProcess

Alternationnation

Alter-

VariableVariab l e

F1F1

SetupSetup

F2F2

Bell & Gossett ITT Fluid Technology

}

Drawing 4: Technologic 5500 Series ZoneSav Operator Interface

ITT

8200 N. Austin Avenue Morton Grove, IL 60053 Phone: (847) 966-3700 Fax: (847) 966-9052 http://www.bellgossett.com

THE ITT ENGINEERED BLOCKS SYMBOL AND ENGINEERED FOR LIFE ARE REGISTERED TRADEMARKS OF ITT CORPORATION

Bell & Gossett S14333 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual