Page 1
W180 ZONE CONTROL SYSTEM
W180 Zone Control System
M2815
J.F. • 4-94 • ©Honeywell Inc. 1994 • Form Number 68-0139
1 68-0139
Page 2
W180 ZONE CONTROL SYSTEM
Contents
Ordering Information ............................................................... 2
W180 Zone Control System Overview .................................... 3
Applicable Literature ............................................................... 4
Glossary ................................................................................... 4
Hardware Required .................................................................. 4
W180A Controller .............................................................. 4
S321A Touchpad ................................................................ 5
Transformer ........................................................................ 5
High Limit Controller ......................................................... 5
Sensors ............................................................................... 5
Dampers ............................................................................. 6
Valves................................................................................. 7
Specifications........................................................................... 8
W180A Controller .............................................................. 8
S321A Touchpad ................................................................ 9
Sensors ............................................................................... 9
198212CA Outdoor Temperature Sensor ...................... 9
C7130A Wall Mount Temperature Sensor .................... 9
C7180A Flush Mount Temperature Sensor................. 10
T7660A/T7660B Space Temperature Sensor .............. 10
C7600C Solid State Humidity Sensor ......................... 10
Dampers ........................................................................... 11
D635 Zone Dampers ................................................... 11
AOBD and AOBD-BM Rectangular Dampers ........... 14
Tools Required ................................................................. 15
PC Requirements .............................................................. 16
Application ............................................................................ 16
General ............................................................................. 16
Determine the W180 System Requirements ..................... 17
Determine the Temperature Profiles ................................. 24
Installation and Wiring .......................................................... 26
General ............................................................................. 26
W180A Controller ............................................................ 26
Honeywell TotalHome
S321A Touchpads ............................................................ 28
High Limit Controller ....................................................... 32
Sensors ............................................................................. 33
®
System ...................................... 28
Temperature Sensors ................................................... 33
198212CA Outdoor Temperature Sensor............... 33
C7130A Wall Mount Temperature Sensor............. 34
C7180A Flush Mount Temperature Sensor ........... 35
T7660A/T7660B Space Temperature Sensor ........ 36
C7600C Solid State Humidity Sensor ......................... 38
Dampers ........................................................................... 38
D635 Zone Dampers ................................................... 39
Rectangular Dampers .................................................. 39
AOBD Dampers..................................................... 40
AOBD-BM Dampers ............................................. 41
Checkout and Test ................................................................. 42
Sensors ............................................................................. 43
Dampers ........................................................................... 43
Damper Checkout ....................................................... 43
W180 System Checkout Using a Touchpad ..................... 45
W180 System Checkout Using a PC ................................ 45
Program the System ............................................................... 45
Appendix A: Troubleshooting ............................................... 46
Appendix B: Worksheets ....................................................... 48
HVAC Configuration Form .............................................. 48
Homeowner Lifestyle Worksheet ..................................... 49
Appendix C: HVAC System Basics....................................... 52
Airflow Characteristics..................................................... 52
Zoning .............................................................................. 52
Purpose of Zoning ....................................................... 52
Zone Selection............................................................. 52
Duct Systems .................................................................... 52
Loop Perimeter System ............................................... 52
Radial Perimeter System ............................................. 53
System Sizing for Forced Air Applications ...................... 53
Damper Selection ............................................................. 53
System Sizing for Hydronic/Radiant
Heating Applications................................................... 53
Valve Selection................................................................. 54
Ordering Information
When purchasing replacement and modernization products from your Perfect Climate® and authorized systems distributors, refer to the
TRADELINE
1. Model number.
2. Accessories, if desired.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Home and Building Control Sales Office (check the white pages of your phone directory).
2. Home and Building Control Customer Satisfaction
In Canada—Honeywell Limiteé, 740 Ellesmere Road, Scarborough, Ontario M1P 2V9. International Sales and Service offices in all
principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain,
Taiwan, United Kingdom, U.S.A.
68-0139 2
®
Catalog or price sheets for complete ordering number, or specify:
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 (612) 951-1000
Page 3
W180 ZONE CONTROL SYSTEM
W180 Zone Control System Overview
This manual presents application information and installation, checkout, and troubleshooting procedures for the
W180 Zone Control System (W180 System) (Fig. 1). The
W180 System is used to optimize comfort and energy
savings in a variety of residential and light commercial
applications.
The W180 System:
— Can operate with the Honeywell TotalHome® Sys-
tem (versions 1.14 and greater), providing remote
access and control for the homeowner. W180 Profiles and settings can change automatically with
TotalHome® Modes.
— Can control different types of HVAC equipment (for
example, radiant hydronic heating and air conditioning) as well as multiple sets of equipment (for example, four air conditioning units and four furnaces).
— Allows central control with the easy-to-use S321A
Touchpad.
— Allows multiple S321A Touchpads to be located
throughout the house or building for convenient
operation.
— Supports a maximum of three Touchpads with the dc
power supply provided by the W180A Controller.
— Allows unique and personalized names to be defined
for each zone.
— Allows user to individually adjust settings in each zone.
— Has user-definable, system-wide Temperature Pro-
files for quick, easy control and adjustments.
— Permits separate temperature setpoints (for each zone)
for any Temperature Profile.
— Allows PC interface for configuration and monitoring.
— Supports a wide variety of sensors, modulating damp-
ers, 2-position valves, and HVAC equipment.
— Permits a maximum of 16 zones for heating only or
cooling only, or a maximum of 10 zones for heating
and cooling for each W180A Controller, depending
on the equipment used.
— Accommodates virtually any HVAC configuration
and provides the following zoned or individual room
temperature control:
• Damper zoning.
• Hydronic valve zoning.
• Equipment zoning.
• Combination of damper, hydronic valve, and equipment zoning.
• Mixture of various HVAC systems.
— Does not require bypass dampers.
— Offers programmable HVAC equipment protection:
• Minimum air flow maintained via minimum duct
area(for dampered forced air systems with standard induction blower motors).
• Temperature setpoint limits (range boundaries).
• Damper position tracking (with optional end
switches and once-per-day position calibration).
• Minimum equipment off-time setting.
• Heat-to-cool switchover delay.
• Fan overrun periods.
The W180 System is customized for each specific application using a Microsoft® Windows™-based PC setup
program.
NOTE: The W180 System air distribution algorithm adjusts
dampers to maintain a minimum airflow through each
piece of controlled equipment. This algorithm is de-
signed to work with all standard induction blower mo-
tors. If other blower motor types are used, alternate
bypass damper strategies must be used.
NOTE: When the W180 System is used in conventional
forced air systems, a return air temperature limit (for
example, T675A) is required as a backup for high tem-
perature limit.
See the Hardware Required section for a list of equipment used in the W180 Zone Control System. For basic
information on HVAC systems, see Appendix C: HVAC
System Basics.
Fig. 1—W180 Zone Control System block
diagram.
S321
TOUCHPAD
S321
TOUCHPAD
PC FOR
CONFIGURATION
HBUS
HBUS
RS-232
W180A
CONTROLLER
DAMPERS
VALVES
HIGH LIMIT
CONTROLLER
HVAC
EQUIPMENT
ROOM
SENSORS
OUTDOOR
SENSOR
HUMIDITY
SENSOR
M5536C
3 68-0139
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W180 ZONE CONTROL SYSTEM
Form Number Title
50-7626 W180 Zone Control System Brochure
60-2133 V4043A,B,E; V4044A,B; V8043A,B,E,F,J; V8044A,B,E Motorized Valves Specification
NOTE: The W180 System uses only the V8043 and V8044 Low Voltage Valves.
60-2200 T675A,B; T678A Temperature Controllers
62-0104 S321A Touchpad Specification
63-2044 C7130A Wall Mount Temperature Sensor Specification
63-4334 T7660A-D Space Temperature Sensors Specification
68-0100 Honeywell Trol-A-Temp® Zone Control Dampers Specification
68-0143 D635 Zone Damper Specification
69-0761 W180 Zone Control System Programmer’s Manual
69-0770 W180 Zone Control System Owner’s Manual
69-0807 W180 Zone Control System Installation Instructions
71-9204 Honeywell W180 Zone Control System Overview
71-9301 W180 Zone Control System Prewiring Guide
71-9302 W180 Zone Control System HVAC Configuration Form
71-9303 W180 Zone Control System Homeowner Lifestyle Worksheet
Applicable Literature
AOBD-BM—Automatic Opposed Blade Damper-Bottom
Mount.
AOBD-SM—Automatic Opposed Blade Damper-Side
Mount.
AOBD—Automatic Opposed Blade Damper.
HBus—A Honeywell communications protocol.
HVAC System—A set of HVAC equipment that supplies
heating and/or cooling to one or more zones.
PC—Personal Computer.
Schedule—A day and time associated with the start of a
profile.
System Configuration—A unique grouping of equipment
and zones that identifies a specific application for a
W180A Controller.
W180A CONTROLLER
A PC is required for initial configuration, but not for
daily operation. The W180A Controller (Table 1) accepts
inputs from sensors and controls dampers, valves, and
HVAC equipment.
Glossary
Temperature Demand—A situation requiring heating or
cooling in a temperature zone.
Temperature Profile—A group of temperature settings
for each zone in the home or building.
Temperature Setpoint—A temperature value maintained
in a zone.
Temperature Zone—A separate area of temperature
control.
TotalHome® System—A Honeywell home automation
system that includes the integration of security, HVAC,
and lights and appliances.
Hardware Requir ed
TABLE 1—W180A CONTROLLER.
OS Number Name Description/Notes
W180A1001 Zone Controller Control panel in
enclosure.
68-0139 4
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W180 ZONE CONTROL SYSTEM
S321A TOUCHPAD
The S321A Touchpad (Table 2) is a user interface panel
used to:
— Adjust temperature settings for individual zones—
temporarily (override) or permanently.
— Adjust groups of settings throughout the system us-
ing Temperature Profiles.
— Change schedule times and/or temperature setpoints.
TRANSFORMER
Table 3 lists the transformers supported by the W180 System.
TABLE 3—TRANSFORMER.
OS Number Name Description/Notes
AT72D1006 Transformer 24 Vac, 40 VA transformer. One required for W180A Controller. 4 x 4 in. plate-
mounted. Additional transformer(s) required for dampers and valves.
AT72D1683 Transformer 24 Vac, 40 VA transformer. SUPER TRADELINE® model. One required for W180A
Controller. Can be foot-mounted; plate-mounted on 4 x 4 in., 4 in. octagon, or 2 x 4
in. electrical boxes; or clamp-mounted via a junction box knockout. Additional
transformer(s) required for dampers and valves.
AT140A1000 Transformer 24 Vac, 40 VA transformer. One required for W180A Controller. Foot-mounted,
plate-mounted on 4 x 4 in., 4 in. octagon, or 2 x 4 in. electrical boxes; clamp-mounted
via a junction box knockout, or panel-mounted. Additional transformer(s) required for
dampers and valves.
AT140B1206 Transformer 24 Vac, 40 VA transformer. One required for W180A Controller. Foot-mounted.
Additional transformer(s) required for dampers and valves.
— Change the equipment settings and other system
parameters.
TABLE 2—S321A TOUCHPAD.
OS Number Name Description/Notes
S321A1005 Touchpad White with white trim ring
and with backlighting.
HIGH LIMIT CONTROLLER
Table 4 lists the high limit controller supported by the W180 System.
TABLE 4—HIGH LIMIT CONTROLLER.
OS Number Name Description/Notes
T675A1508 Temperature Controller Mount sensor in return air duct.
SENSORS
Table 5 lists the temperature sensors supported by the W180 System. A temperature sensor is required in each zone.
TABLE 5—SENSORS.
OS Number Name Description/Notes
107323A Outdoor Temperature Sensor Shield Used to house the 198212CA Outdoor Temperature Sensor.
198212CA Outdoor Temperature Sensor Used for outdoor temperature display and improved control.
C7130A1019 Wall Mount Temperature Sensor White enclosure, wall mount.
C7180A1000 Flush Mount Temperature Sensor White, round; flush mounts on wall. Can be lightly painted.
C7600C1008 Solid State Humidity Sensor Mount in return air duct.
T7660A1017 Space Temperature Sensor Beige enclosure, wall mount.
T7660B1015 Space Temperature Sensor Wall mount sensor with override switch and status LED.
5 68-0139
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W180 ZONE CONTROL SYSTEM
DAMPERS
Tables 6 and 7 list the most commonly used damper sizes. Several other damper sizes are available. See the Honeywell
Trol-A-Temp® Zone Control Dampers Specification, form 68-0100, and D635 Zone Damper Specification, form 68-0143,
for more information.
TABLE 6—RECTANGULAR TROL-A-TEMP
®
SIDE-MOUNT (SM) AND BOTTOM-MOUNT (BM) ZONE DAMPERS.
Size
Dimensions
in in. [mm]
Area in sq. in.
[sq. mm] Size
Dimensions
in in. [mm]
Area in sq. in.
[sq. mm]
6 inch 6 x 8 [152 x 203] 48 [30,856] 10 inch 10 x 10 [254 x 254] 100 [64,516]
6 x 10 [152 x 254] 60 [38,608] 10 x 12 [254 x 305] 120 [77,470]
6 x 12 [152 x 305] 72 [46,360] 10 x 14 [254 x 356] 140 [90,424]
6 x 14 [152 x 356] 84 [54,112] 10 x 16 [254 x 406] 160 [103,124]
6 x 16 [152 x 406] 96 [61,712] 10 x 18 [254 x 457] 180 [116,078]
6 x 18 [152 x 457] 108 [69,464] 10 x 20 [254 x 508] 200 [129,032]
6 x 20 [152 x 508] 120 [77,216] 12 inch 12 x 12 [305 x 305] 144 [93,025]
8 inch 8 x 8 [203 x 203] 64 [41,209] 12 x 14 [305 x 356] 168 [108,580]
8 x 10 [203 x 254] 80 [51,562] 12 x 16 [305 x 406] 192 [123,830]
8 x 12 [203 x 305] 96 [61,915] 12 x 18 [305 x 457] 216 [139,385]
8 x 14 [203 x 356] 112 [72,268] 12 x 20 [305 x 508] 240 [145,940]
8 x 16 [203 x 406] 128 [82,418] 14 inch 14 x 14 [356 x 356] 196 [126,736]
8 x 18 [203 x 457] 144 [92,771] 14 x 16 [356 x 406] 224 [144,536]
8 x 20 [203 x 508] 160 [103,124] 14 x 18 [356 x 457] 252 [162,692]
8 x 22 [203 x 559] 176 [113,477] 14 x 20 [356 x 508] 280 [180,848]
8 x 24 [203 x 610] 192 [123,830]
TABLE 7—ROUND ZONE DAMPERS.
Size
Diameter
in in. [mm]
Area in sq. in.
[sq. mm] Size
Diameter
in in. [mm]
Area in sq. in.
[sq. mm]
D635B1005 6 [152] 28.27 [18,146] D635E1002 12 [305] 113.1 [73,062]
D635C1004 8 [203] 50.27 [32,365] D635F1001 14 [356] 153.94 [99,538]
D635D1003 10 [254] 78.54 [50,671] D635G1000 16 [406] 201.06 [129,462]
68-0139 6
Page 7
W180 ZONE CONTROL SYSTEM
VALVES
Table 8 lists the available valves.
TABLE 8—ZONE VALVES.
Flow Capacity
Rating
OS Number Cv kV Pipe Connections De-energized Position Valve Body Pattern
V8043A1003 3.5 3.0 1/2 in. flare Normally closed Straight-through
V8043A1011 3.5 3.0 1/2 in. sweat
V8043A1029 3.5 3.0 3/4 in. sweat
V8043A1037 3.5 3.0 1 in. sweat
V8043A1193
a
3.5 3.0
1/2 in. inverted flare
V8043B1019 3.5 3.0 1/2 in. sweat Normally open
V8043B1027 3.5 3.0 3/4 in. sweat
V8043E1004
V8043E1012
V8043E1020
V8043E1061
V8043E1079
V8043E1111
V8043E1129
V8043F1028
V8043F1036
V8043F1051
V8043F1093
V8043F1101
V8043J1003
b
b
b
b
b
c
b,a
d,b
d,b
d,b
d,b
d,b
e
3.5 3.0
3.5 3.0
3.5 3.0
8.0 6.9
8.0 6.9
3.5 3.0
3.5 3.0
3.5 3.0
3.5 3.0
3.5 3.0
8.0 6.9
8.0 6.9
——
1/2 in. sweat
3/4 in. sweat
1 in. sweat
3/4 in. sweat
1 in. sweat
3/4 in. sweat
1/2 in. inverted flare
1/2 in. sweat
3/4 in. sweat
1 in. sweat
3/4 in. sweat
1 in. sweat
1/2 in. sweat
Normally closed
Normally open
V8044A1002 4.0 3.4 1/2 in. flare Port A normally closed 2-position diverting
V8044A1010 4.0 3.4 1/2 in. sweat
V8044A1044 7.0 6.0 3/4 in. sweat
V8044A1051 4.0 3.4 1/2 in. sweat
V8044B1018
V8044E1003
V8044E1011
V8044E1078
a
Order fittings separately (4074EJA, 4074EJB).
b
Includes end switch for sequencing auxiliary equipment.
c
Includes six sweat fittings (two each: 4074EHP, 4074EHM, 4074EHN).
d
Terminal board connector.
e
Steam only.
f
Includes integral spdt Aquastat® Controller.
f
b
b
b,a
4.0 3.4
4.0 3.4
7.0 6.0
4.0 3.4
1/2 in. sweat
1/2 in. sweat
3/4 in. sweat
1/2 in. inverted flare
7 68-0139
Page 8
W180 ZONE CONTROL SYSTEM
Specifications
NOTE: The specifications given in this publication do not
include normal manufacturing tolerances. Therefore, an
individual unit may not exactly match the listed specifications. Also, the products are tested and calibrated
under closely controlled conditions and some minor
differences in performance can be expected if those
conditions are changed.
W180A CONTROLLER
MODEL: W180A1001.
POWER INPUT: 24 Vac/40 VA (transformer not included,
but is required).
POWER CONSUMPTION: 40 VA max.
INPUTS: 16 analog/digital inputs configurable as switch,
temperature, or general purpose type sensors.
Fig. 2—W180A Controller Enclosure dimensions in in. [mm].
3
1 [44]
4
2
[51]
OUTPUTS: 24 relays configured in 12 relay pairs. Each
relay in a pair can be configured for individual devices
that are powered from a common source.
PORTS: RS-232 for PC communication.
NUMBER OF W180 SYSTEMS THAT CAN BE CON-
NECTED TO A HONEYWELL TotalHome® SYSTEM:
One; using HBus communications. Additional W180
Systems can be connected to TotalHome® only through
contact closures to the W180 input configured as a Pro-
file Trigger input.
NUMBER OF ZONES:
Maximum of 16 for heating only or cooling only sys-
tems, depending on the application and equipment.
Maximum of 10 for heating and cooling forced air sys-
tems, depending on the application and equipment.
[51]
17
[432]
3
15
4
[400]
1
7
2
[191]
1
2
2
[64]
2
5
[137]
1
1
2
[38]
3 [76]
1
[191]
7
2
2
3
[51]
8
5 [127]
1
[394]
15
2
19 [483]
UPSET KNOCKOUT, 9 PLCS
1 3/8 SMALL DIA.
1 3/4 LARGE DIA.
13 [330]
20 [508]
M8158
68-0139 8
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W180 ZONE CONTROL SYSTEM
NUMBER OF TOUCHPADS:
Maximum of three using power provided through the
W180A Controller.
Maximum of five with addition of separate power supply.
NUMBER OF TEMPERATURE PROFILES: Maximum
of 20.
ENVIRONMENTAL LIMITS:
Ambient Temperature Operating Range: 32° to 110° F
[0° to 43° C].
Shipping Temperature Range: –20° to 120° F [–29° to
49° C].
Ambient Humidity Rating: 5 to 90% RH.
Corrosion: Minimum of ten year life in urban environment.
DIMENSIONS IN IN. [MM]: See Fig. 2.
WEIGHT IN LB [KG]: 20.3 [9.21].
S321A TOUCHPAD
MODEL: S321A1005.
POWER INPUT: 8 to 14 Vdc, Class 2, provided by the
W180A Controller (maximum 250 mA required).
SIGNAL: HBus, 5V typical.
TERMINALS: Four pigtail wires interconnect to two
power and four signal inputs from the controller.
ENVIRONMENTAL LIMITS:
Ambient Temperature Operating Range: 32° to 110° F
[0° to 43° C].
Shipping Temperature Range: –10° to 120° F [–23° to
49° C].
Ambient Humidity Rating: 5 to 90% RH.
Corrosion: Minimum of ten year life in urban environment.
DIMENSIONS IN IN. [MM]: See Fig. 3.
WEIGHT IN OZ [G]: 14 [390].
Fig. 3—S321A Touchpad dimensions in in.
[mm].
3
6 [162]
8
1
5 [130]
8
SENSING ELEMENT: 3000 ohms, platinum, positive tem-
perature coefficient (3484 ±6.5 ohms at 77° F [25° C];
4.8 ohms per degree F [8.6 ohms per degree C]).
CABLE LENGTH: Maximum of 300 ft [90m] with
18 AWG twisted pair solid or stranded wire. For runs
up to 150 ft [95m], 22 AWG wire may be used.
Shielded cable is recommended for lengths longer than
50 ft [15m].
ACCESSORIES:
107323A Shield.
Shielded Cable: Suggested for wiring distances
greater than 50 ft [15m] to prevent possible elec-
trical noise from causing erratic sensing.
4074CAV: 50 ft [15m].
4074CAW: 100 ft [30.4m].
4074CAY: 200 ft [61m].
DIMENSIONS: See Fig. 4.
Fig. 4—198212CA Outdoor Temperature
Sensor dimensions in in. [mm].
198212CA OUTDOOR TEMPERATURE SENSOR
1
[10]
3
4
5
8
[19]
1 [38]
2
[51]
2
3
[76]
2 [51] 57 [1448]
107323A SHIELD
6 [152]
3
[19]
4
3
[19]
4
M9177A
11
4
16
TRIM RING
[119]
1
4
2
[114]
OUTER HOLES
FOR DRYWALL
MOUNTING
2 [51]
11
2
16
[69]
M3509A
SENSORS
198212CA Outdoor Temperature Sensor
Provides outdoor temperature readings for the W180
System and Honeywell TotalHome® System when the systems are connected together using HBus communications.
MODEL: 198212CA: (5 ft [1.5m] cable attached).
SENSING RANGE: –40° to 120° F [–40° to 49° C].
C7130A Wall Mount Temperature Sensor
MODELS:
C7130A1001: beige and brown.
C7130A1019: white.
SENSING ELEMENT: 3000 ohms, platinum, positive tem-
perature coefficient (3484 ±6.5 ohms at 77° F [25° C];
4.8 ohms per degree F [8.6 ohms per degree C]).
SENSING RANGE: 32° to 120° F [0° to 49° C].
CABLE LENGTH: Maximum of 300 ft [90m] with
18 AWG twisted pair solid or stranded wire. For runs
up to 150 ft [95m], 22 AWG wire may be used.
Shielded cable is recommended for lengths longer than
50 ft [15m]).
ACCESSORIES:
Shielded Cable: Suggested for wiring at distances
greater than 50 ft [15m] to prevent possible electrical noise from causing erratic sensing.
4074CAV: 50 ft [15m].
4074CAW: 100 ft [30.4m].
4074CAY: 200 ft [61m].
9 68-0139
Page 10
W180 ZONE CONTROL SYSTEM
MOUNTING: Two holes provided in base of device for
mounting onto wall 2 x 4 in. conduit box. The
C7130A1019 (white) model can be mounted vertically
or horizontally.
DIMENSIONS: See Fig. 5.
Fig. 5—C7130A Wall Mount Temperature
Sensor dimensions in in. [mm].
5
[117.5]
4
8
13
2
16
[71.4]
1
[35]
3
8
21
32
[16.6]
21
32
[16.6]
3
1
8
[35]
M8155
C7180A Flush Mount Temperature Sensor
MODEL: C7180A1000.
SENSING RANGE: 0° to 100° F [–18° to 38° C].
ELECTRICAL RATINGS:
Input: 5V typical from W180A Controller.
Output: 0 to 2 mA corresponding to 0° to 100° F [0° to
38° C].
Maximum Power Consumption: 0.3 VA.
CABLE LENGTH: Maximum of 1000 ft [300m] using 16
to 22 AWG twisted pair, solid or stranded wire.
MOUNTING: 1 inch (max) hole. Sensor body is approxi-
mately 1 in. tapered to 1-1/8 in. diameter.
DIMENSIONS: See Fig. 6.
Fig. 6—C7180A Flush Mount Temperature
Sensor dimensions in in. [mm].
LABEL
1 [25]
1
[38]
1
2
TAPERED
TO 1-1/8 [28]
RED
(TO + TERMINAL)
WHITE
(TO – TERMINAL)
T7660A/T7660B Space Temperature Sensor
MODELS:
T7660A1017: beige.
T7660B1015: with override switch and status LED.
SENSING ELEMENT: 3000 ohms, platinum, positive tem-
perature coefficient (3484 ±6.5 ohms at 77° F [25° C];
4.8 ohms per degree F [8.6 ohms per degree C]).
SENSING RANGE: 32° to 120° F [0° to 49° C].
OVERRIDE SWITCH/LED (T7660B): Momentary con-
tact switch with status LED.
CABLE LENGTH: Maximum of 300 ft [90m] with
18 AWG twisted pair solid or stranded wire. For runs
up to 150 ft [95m], 22 AWG wire may be used.
Shielded cable is recommended for lengths longer than
50 ft [15m]).
ACCESSORIES:
Shielded Cable: Suggested for wiring at distances
greater than 50 ft [15m] to prevent possible electrical noise from causing erratic sensing.
4074CAV: 50 ft [15m].
4074CAW: 100 ft [30.4m].
4074CAY: 200 ft [61m].
MOUNTING: Wall or electrical box.
DIMENSIONS: See Fig. 7.
C7600C Solid State Humidity Sensor
MODEL: C7600C Solid State Humidity Sensor. Provides a
4 to 20 mA output in direct proportion to the relative
humidity.
ELECTRICAL RATINGS:
Input: 20 Vdc (provided by the W180A Controller).
Output: 4 to 20 mA current signal; increases from 4 mA
to 20 mA as humidity increases.
Maximum Power Consumption: 0.3 VA.
MAXIMUM POWER CONSUMPTION: 0.48 VA.
AMBIENT TEMPERATURE RANGES:
Operating: 32° to 125° F [0° to 52° C].
Shipping: –40° to 150° F [–40° to 66° C].
HUMIDITY RANGE: 10 to 90% RH.
RESPONSE TIME: 90 percent of change at 75° F [24° C].
Airflow: 500 fpm.
Time: two minutes.
HUMIDITY SENSING ELEMENT: Polyimide film (ca-
pacitance changes with change in humidity).
DIMENSIONS: See Fig. 8.
MOUNTING: Duct mount indoors, or outdoors protected
from rain and direct sunlight.
ELECTRICAL CONNECTIONS: Two 1/4-inch quick-
connect terminals.
APPROVAL: UL Flammability Rating: UL94V-0.
6 [152]
C7180A
M8156
68-0139 10
Page 11
Fig. 7—T7660A/T7660B Space Temperature Sensor dimensions in in. [mm].
2 [51]
1
W180 ZONE CONTROL SYSTEM
NO. 4-40 ALLEN
HD COVER
MOUNTING
SCREW (2)
5
2 [51]
1 LIGHTED BUTTON ON T7660B ONLY.
1
[41]
8
Fig. 8—C7600C Solid State Humidity Sensor
dimensions in in. [mm].
3
[80]
7
[6]
32
3
2
4
[70]
5
32
7
3 [96]
8
M3129
16
[14]
9
1[25]
5
[8]
16
DAMPERS
D635 Zone Dampers
NOTE: If a custom-sized damper is required, it may be
used with an ML6161A1000 Direct Coupled Actuator
and be fully compatible with the W180 System.
MODELS: Includes ML6161A1000 Actuator (35 lb.-in.
torque, 90 second timing to control 90° dampers).
OS Number Damper Diameter (Inches)
D635B1005 6
D635C1004 8
D635D1003 10
D635E1002 12
D635F1001 14
D635G1000 16
15
16
[24]
1
[32]
1
4
1
[29]
1
8
1
2
4
[57]
3
[83]
COVER
MOUNTING
TABS
1
4
M8157
3
[83]
1
4
ELECTRICAL RATINGS:
Input Voltage: 24 Vac +20%/–30%, 50/60 Hz.
Power Consumption (Maximum) at 24 Vac: 2W, 85 mA,
2.2 VA.
TEMPERATURE RATINGS:
Ambient: 32° to 130° F [0° to 52° C].
Shipping and Operating: –20° to 130° F [–29° to 40° C].
HUMIDITY RATING: 5 to 95% RH, noncondensing.
DAMPER LEAKAGE: 1% nominal of flow.
DAMPER POSITION VERSUS FLOW RATE: See the
Specifications packed with the damper.
TORQUE RATINGS:
Running: 35 lb.-in. [4.0 N•m].
Breakaway: 35 lb.-in. [4.0 N•m].
Stall: 45 lb.-in.[5.0 N•m] minimum. 65 lb.-in. [7.4 N•m]
maximum.
MOTOR TIMINGS: 90 seconds for 90° stroke.
MATERIALS:
Damper Blade: 16 gauge corrosion resistant steel.
Blade Seal: Neoprene rubber with UL94HF1 rating.
Damper Shell: 24 gauge galvanized steel, 60 to 10 inch;
20 gauge galvanized steel, 12 to 16 inch.
DIMENSIONS:
Damper Portion: See Fig. 9.
Actuator: See Fig. 10.
APPROVALS:
Underwriter’s Laboratories Component Recognized:
File No. E4436, Guide No. XAPX.
CSA certified.
ACCESSORIES:
201052B Two Auxiliary Switches.
7640QW Metal Enclosure (to run conduit to actuator).
11 68-0139
Page 12
W180 ZONE CONTROL SYSTEM
Fig. 9—D635 Damper dimensions in in. [mm].
AIR FLOW
OS NUMBER AREA IN SQ. IN.
D635B1005
D635C1004
D635D1003
D635E1002
D635F1001
D635G1000
28.3
50.3
78.5
113.1
153.9
201.1
LENGTH
DIAMETER
IN IN. [CM.]
6 [15.24]
8 [20.32]
10 [25.40]
12 [30.48]
14 [35.56]
16 [60.64]
LENGTH
IN IN. [CM.]
12 [30.48]
12 [30.48]
12 [30.48]
13 [33.02]
15 [38.10]
17 [43.18]
ALLOW MINIMUM
5 1/2 in. [14 cm]
CLEARANCE FOR
ACTUATOR REMOVAL
DIAMETER
PRESSURE DROP
IN IN.WC [kPa]
0.05 [0.167]
0.075 [0.254]
0.1 [0.339]
0.05 [0.167]
0.075 [0.254]
0.1 [0.339]
0.05 [0.167]
0.075 [0.254]
0.1 [0.339]
0.05 [0.167]
0.075 [0.254]
0.1 [0.339]
0.05 [0.167]
0.075 [0.254]
0.1 [0.339]
0.05 [0.167]
0.075 [0.254]
0.1 [0.339]
FLOW RATE
cfm
180
210
240
410
485
580
693
849
980
1200
1460
1600
1336
1636
1890
1690
2080
2400
M8159
68-0139 12
Page 13
Fig. 10—ML6161 Direct Coupled Actuator dimensions in in. [mm].
W180 ZONE CONTROL SYSTEM
1
3
[77.8]
16
11
1
[42.4]
16
[11.9]
1
[25.4]
OPTIONAL
AUXILIARY
[3.2]
1
8
SWITCH
CW
COM
CCW
15
32
1
8
[3.2]
5
[7.9]
16
11
1
[43.2]
16
4
[108]
7
4
8
[123.4]
1
4
[17.8]
9
5
16
[141.2]
11
16
5
1
16
[32.8]
3
[86]
2
8
3
[86.4]
3
8
M2063B
13 68-0139
Page 14
W180 ZONE CONTROL SYSTEM
AOBD and AOBD-BM Rectangular Dampers
NOTE: Do not use static pressure regulating dampers
with the W180 System.
AMBIENT TEMPERATURE RANGE: –55° to 200° F
[–48° to 93° C].
ELECTRIC ACTUATOR: AOBD and AOBD-BM only:
24 Vac, 50/60 Hz. Mounts horizontally or vertically.
Locks to damper drive shaft. Torque rated to fit damper
size. 30 second cycling time.
ELECTRICAL RATINGS: Power Supply: 24 Vac, 50/60 Hz.
HUMIDIFIER: For humidification, use evaporative type
or return air type humidifiers. Do not use spray or
atomization type humidifiers installed in the furnace
plenum or air supply duct.
Fig. 11—Automatic opposed blade damper dimensions.
AIR DUCT
1
3
4
[83]
MOUNTING: Install into a 3-in. [76 mm] opening in the air
duct and secure using sheet metal screws provided.
WIRING CONNECTIONS: Screw terminals on electronic
actuator face plate. Actuator cover protects terminals
after installation.
BLADES: Heavy gauge extruded aluminum. Aerodynamic
blades reduce air turbulence, noise, vortexing, and loss
of air velocity.
DIMENSIONS:
AOBD: See Fig. 11.
AOBD-BM: See Fig. 12.
ACCESSORIES: Set of Damper Mounting Tracks (Model
SDMT): Two U channel mounting tracks 12 in. [305 mm]
long used to hold large size dampers, multiple dampers,
and undersized dampers in proper alignment.
1
2
8
[54]
3
2
8
[60]
[127]
5
5
LISTED
DAMPER
HEIGHT
2
HEIGHT DIMENSIONS:
TO ENSURE PROPER FIT, DAMPER HEIGHT IS 3/16 INCH [5 MILLIMETERS] LESS THAN THE
LISTED HEIGHT DIMENSION.
WIDTH DIMENSIONS:
TO ENSURE PROPER FIT, DAMPER WIDTH IS 1/8 INCH [3 MILLIMETERS] LESS THAN THE
LISTED WIDTH DIMENSION.
1
ADDITIONAL SIZES AVAILABLE (WIDTH X HEIGHT): 16X16, 18X16, 18X18, 20X16, 20X18, AND 20X20.
SIZES NOT AVAILABLE (WIDTH X HEIGHT): 8X10, 8X12, 8X14, 10X12, 10X14, AND 12X14.
2
LISTED DAMPER HEIGHT = ACTUAL AIR DUCT HEIGHT
4, 6, 8, 10, 12, OR 14 INCHES [102, 152, 203, 254, 305, OR 356 MILLIMETERS]
8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, OR 30 INCHES [203, 254, 305, 356, 406,
457, 508, 559, 610, 660, 711, OR 762 MILLIMETERS].
3
[60]
8
1
HEIGHT
WIDTH
1
M2269A
68-0139 14
Page 15
Fig. 12—Automatic opposed blade damper-bottom mount dimensions.
HEIGHT
5
3
8
AIR DUCT
[92]
W180 ZONE CONTROL SYSTEM
WIDTH
3
2
8
[60]
1
2
8
[54]
HEIGHT DIMENSIONS:
TO ENSURE PROPER FIT, ACTUAL DAMPER HEIGHT IS 1/8 INCH [3 MILLIMETERS] LESS THAN LISTED HEIGHT DIMENSION.
WIDTH DIMENSIONS:
TO ENSURE PROPER FIT, ACTUAL DAMPER WIDTH IS 3/16 INCH [5 MILLIMETERS] LESS THAN LISTED WIDTH DIMENSION.
1
ADDITIONAL SIZES AVAILABLE (HEIGHT X WIDTH): 16X16, 16X18, 16X20, 18X18, 18X20, 20X20.
SIZES NOT AVAILABLE (HEIGHT X WIDTH): 10X8, 12X8, 12X10, 14X8, 14X10, 14X12.
2
LISTED DAMPER WIDTH = ACTUAL AIR DUCT WIDTH
6, 8, 10, 12, AND 14 INCHES [152, 203, 254, 305, 356, MILLIMETERS].
8, 10, 12, 14, 16, 18, AND 20 INCHES [203, 254, 305, 356, 406, 457, 508, MILLIMETERS].
TOOLS REQUIRED
The following tools and equipment are required to install a W180 Zone Control System:
— Hammer
— Screwdriver (flathead)
— Pliers
— Wire cutters
— Wire strippers
— Electric drill
— Sheet metal shears
3
[83]
5
1
[127]
4
LISTED
DAMPER
WIDTH
2
1
1
M2270A
— Utility knife
— Voltmeter/multimeter
— Thermometer
— 3/4-inch plywood (20 in. by 17 in.) and mounting
hardware suitable for the wall on which the W180A
Controller enclosure will be mounted.
NOTE: Studs at 16 in. o.c. may also be used for
mounting.
15 68-0139
Page 16
W180 ZONE CONTROL SYSTEM
PC REQUIREMENTS
1. IBM® PC/AT™ or compatible 286, 386, or 486
personal computer. The 386 or 486 personal computer are
recommended.
2. At least 4 MB of RAM.
3. MS-DOS version 5.0 or later.
4. Microsoft® Windows™ version 3.1 or later.
5. A 20 MB (minimum) hard disk drive. A 40 MB or
larger hard disk drive is recommended.
Fig. 13—RS-232 Cable pin-out.
W180 PROGRAMMING CABLE
W180 TO 9 PIN SERIAL PORT CABLE CONNECTIONS
(HONEYWELL PART NO. 204162)
W180
(FEMALE)
RXD
TXD
GND
1
2
3
4
5
6
7
8
9
PC SERIAL PORT
(FEMALE)
1
2
RXD
3
TXD
4
5
GND
6
7
8
9
6. A 3-1/2 or 5-1/4 in., high-density disk drive.
7. A serial or bus mouse.
8. Serial port for RS-232 connection to W180A
Controller.
9. Serial port for serial mouse, if used.
10. RS-232 interconnect cable from the W180A Con-
troller to the PC (Fig. 13).
W180 TO 25 PIN SERIAL PORT CABLE CONNECTIONS
(HONEYWELL PART NO. 204119 ; WITH NULL MODEM 204169)
W180
(FEMALE)
RXD
TXD
GND
1
2
3
4
5
6
7
8
9
PC SERIAL PORT
(FEMALE)
1
TXD
2
RXD
3
4
5
6
7
GND
8
9
•
•
•
24
25
M8160
GENERAL
The following must be accomplished to properly plan a
job and order the equipment:
— Determine the W180 System requirements:
• Required equipment, zones served, and number
of stages.
• Required auxiliary equipment.
• Zoning requirements and the number and type
of sensors, dampers, and valves.
• Power requirements.
• Inputs (including special inputs) and outputs.
• Number of S321A Touchpads.
Application
• Equipment mounting locations.
• Wiring.
— Determine the Temperature Profiles.
CAUTION
To prevent damage to the W180A Controller, do
not connect either side of the 24 Vac transformer
secondary that is used to power the W180A Controller to earth ground.
68-0139 16
Page 17
CAUTION
The W180 System requires an earth ground from
the earth ground terminal (18 AWG or heavier
wire connected to a cold water pipe) as shown in
Fig. 24.
DETERMINE THE W180 SYSTEM
REQUIREMENTS
1. Obtain a copy of the floor plans and check that there
is no conflict between the building design and the proposed installation.
NOTES:
a. Mount the W180A Controller in a centralized loca-
tion to minimize wire runs though the building.
b. Mount the S321A Touchpads in any convenient in-
door locations.
c. Use low voltage controls for HVAC units.
2. Complete the HVAC Configuration Form to determine the temperature sensor inputs and zoning, relay output usage (set automatically by the Setup software), HVAC
system information, and number of S321A Touchpads.
NOTES:
a. HVAC Configuration Worksheet—Use the configu-
ration worksheet (located in Appendix B) to make
sure that System configuration and hardware limits
are not exceeded. Before entering temperature sensor
data or other information, enter the customer data on
the worksheets.
W180 ZONE CONTROL SYSTEM
b. Temperature input usage—Each temperature zone
needs a temperature sensor. A temperature zone with
no damper or valve designated operates the associated heating/cooling system like a thermostat would
in the same location. When the heating system is
zoned, indicate if dampers or valves are to be used.
Make sure the names used correspond to the names
used on the relay assignments. When combining
hydronic or radiant heating with forced air cooling to
serve common areas, use separate sensors for each
system.
c. Relay output usage—The 12 relay sets are electri-
cally independent and perform different tasks depending on the assignments. There are a total of 24
relays available. Add together all relays required to
operate the HVAC equipment. The remaining relay
pairs can be used to operate dampers and valves.
Each modulating damper requires two relays in a
relay pair. All other valves and HVAC equipment
loads require one relay each. Calculate the total number of relays required by the proposed system. The
total number of relays required cannot total more
than 24. Note that a relay set shares the same input;
therefore, the devices connected to each relay of a set
must use the same voltage supply. If the two devices
controlled by the two relays within a relay pair are
powered by different voltage supplies (transformers), use a separate relay to isolate the two voltage
supplies (Fig. 23).
d. T7660B Space Temperature Sensor—This sensor
requires two sensor inputs and one relay output.
e. HVAC—The System is compatible with all common
residential HVAC systems that use low voltage controls (thermostats) for operation. The following are
required for configuration:
HVAC CONFIGURATION TABLE.
Function Definition Minimum Maximum Default
Auto Switchover Time
(Minutes)
Minimum
Duct Area—
Heat (Percent)
Minimum
Duct Area—
Cool
(Percent)
This is the minimum length of time the system
will wait before automatically switching from
heat to cool or cool to heat.
The minimum aggregate damper open area will
never be lower than this setting in the heating
mode. Dampers to zones not calling for heat
will modulate partially open when the system
demand alone does not provide adequate open
damper area.
The minimum aggregate damper open area will
never be lower than this setting in the cooling
mode. Dampers to zones not calling for cooling
will modulate partially open when the system
demand alone does not provide adequate open
damper area.
10 240 10
25 100 25 (75 to
85% max cfm)
35 100 35 (65 to
75% max cfm)
(Continued)
17 68-0139
Page 18
W180 ZONE CONTROL SYSTEM
Function Definition Minimum Maximum Default
Anticipation
—Heat
Anticipation
—Cool
Overrun
Time—Heat
Overrun
Time—Cool
Minimum Off
Time—Heat
Minimum Off
Time—Cool
Lockout
Temperature
—Heat
Lockout
Temperature
—Cool
Outside Temp
for Alt. Eq.—
Heat
Outside Temp
for Alt. Eq.—
Cool
Stage
Differential—
Heat
Stage
Differential—
Cool
Stage
Attributes—
Emergency
Heat
For heating equipment. A value greater than 1
increases the equipment cycle rate; a value less
than 1 decreases the equipment cycle rate.
Recommended values:
—Electric: 1.5.
—Forced Air: 1.2.
—Heat Pump: 1.0.
—Hydronic/Radiant: 0.8.
For cooling equipment. A value greater than 1
increases the equipment cycle rate; a value less
than 1 decreases the equipment cycle rate.
Recommended values:
—Cooling Compressor: 1.0.
The length of time in minutes the fan defined
for this stage is active following a call for
heating.
The length of time in minutes the fan defined
for this stage is active following a call for
cooling.
The length of time in minutes that must expire
following a call for heating before the stage
equipment may be activated again.
The length of time in minutes that must expire
following a call for cooling before the stage
equipment may be activated again.
When the outdoor temperature is above this
temperature, the stage is locked out.
When the outdoor temperature is below this
temperature, the stage is locked out.
When the actual outdoor temperature is below
this value, any heating equipment set up during
configuration as Alt. Eq.—Heat will be
activated in place of the equipment defined as
Normal—Heat.
When the actual outdoor temperature is above
this value, any cooling equipment set up during
configuration as Alt. Eq.—Cool will be
activated in place of the equipment defined as
Normal—Cool.
The number of degrees below setpoint the
average zone demand must exceed before this
stage is activated.
The number of degrees above setpoint the
average zone demand must exceed before this
stage is activated.
Use this equipment during manual system
override to Emergency Heat mode in place of
the first stage heat pump equipment in heating.
HVAC CONFIGURATION TABLE (Continued).
0.0 1.5 1.0
0.0 1.5 1.0
0302
0302
3303
3303
10° F99° F90° F
10° F99° F50° F
10° F99° F40° F
10° F99° F90° F
1st Stage: 0° F
2nd Stage: 1st Stage
+ 1° F
3rd Stage: 2nd Stage
+ 1° F
1st Stage: 0° F
2nd Stage: 1st Stage
+ 1° F (1° F)
3rd Stage: 2nd Stage
+ 1° F (2° F)
1st Stage: 20° F
2nd Stage: 20° F
3rd Stage: 20° F
1st Stage: 20° F
2nd Stage: 20° F
3rd Stage: 20° F
1st Stage: 0° F
2nd Stage: 4° F
3rd Stage: 6° F
1st Stage: 0° F
2nd Stage: 4° F
3rd Stage: 6° F
68-0139 18
Page 19
W180 ZONE CONTROL SYSTEM
3. Determine if power is available at the W180A Controller location. The W180A Controller is powered by a
separate dedicated 24 Vac transformer. When suitable power
is not available where the W180A Controller will be located, add the appropriate power connections. A maximum
of three S321A Touchpads can be powered through the
W180A Controller.
CAUTION
To prevent damage to the W180A Controller, do
not connect either side of the 24 Vac transformer
secondary to earth ground.
4. Determine the equipment locations. For single family residential buildings, a separate drawing for the HVAC
system might not be available. If a separate HVAC drawing
is not available, draw the duct and damper layout on the
architectural plans. If any of the temperature control zones
of a particular forced air HVAC system are controlled by
motorized dampers, all zones on that particular HVAC
system must be controlled by dampers. Observe the following when determining equipment locations:
— W180A Controller: Locate the W180A Controller in
a central location that will minimize the length of
wire runs.
— Touchpad: Mount the Touchpads in any room conve-
nient for the user. However, mounting in bathrooms
and other high humidity areas is not advised. The
power supply provided with the W180A Controller
supports a maximum of three Touchpads. If more
Touchpads are required, additional power supplies
must be provided. Mount the Touchpad 5 ft 4 in.
[1.6m] above the floor or as specified by the customer for easy viewing.
— Dampers and valves (observe the following):
• Locate dampers where they can be easily accessed after installation.
• Locate the dampers close to the HVAC unit.
• If the HVAC equipment supplies more than one
zone, because all zones served by the equipment
have at least one damper or valve.
• To assure proper operation, properly size dampers
for the air duct. If the damper is forced into an
undersized air duct, the excess pressure can jam
the damper blades and cause improper operation.
• Do not install dampers in heating systems where
spray or atomizing type humidifiers are installed
in the furnace plenum or air supply duct. Excessive lime or mineral deposits accumulate on damper
blades and cause improper operation. For
humidification, use evaporative or return air type
humidifiers.
— Indoor temperature sensors. (One temperature sensor
is required for each control zone; three types of
indoor temperature sensors can be used with the
system: C7130, C7180, and T7660.) Locate indoor
temperature sensors:
• On an interior wall.
• Near the return air flow.
• Out of the sun.
• Away from supply registers.
• Away from hot or cold sources.
• About 60 inches above the floor.
• Free from obstructions.
— Outdoor temperature sensor. An outdoor temperature
sensor is required whenever alternate fuel equipment
is going to be controlled or if outdoor temperature
lockout is desired. A typical location would be under
the roof overhang on the least sunny side of the
building. Locate the outdoor temperature sensor:
• Out of the sun (consider the seasonal position of
the sun).
• Away from exhausts that may affect the temperature reading.
— Humidity sensor:
• Exposed to freely circulating air.
• Duct mount indoors, or outdoors protected from
rain, snow, and direct sunlight.
• In areas with 500 ft/min minimum air flow.
— Alternate fuel equipment. For mounting location re-
quirements, see the literature for the equipment.
5. Determine the wiring. Fig. 14 and Table 9 detail the
various wires that are allowed. Figs. 15 through 20 show
typical device wiring.
NOTES:
a. All wiring must conform to all local codes and
ordinances.
b. Keep large inductive loads such as motors and fans
off the power circuits feeding any portion of the
system.
c. Motorized damper wiring should not be run through
air ducts or plenums. If such routing is necessary,
only type FPLP (fire) wire may be used.
d. Verify the number of conductors required to operate
each HVAC unit.
e. Leave at least 24 inches of wire at the device end
and 24 inches at the W180A Controller end.
f. Label all wires at both ends and record wire data on
the job drawings.
g. Use twisted pair cables for wiring to the temperature
sensors and S321A Touchpads.
h. Run wiring so that it will not be damaged during
other installations.
i. Prewire all devices as home runs back to the W180A
Controller.
j. Do not wire a mechanical thermostat in parallel with
the system controls.
k. When the HVAC unit is more than 100 cable feet
from the W180A Controller, calculate the voltage
drop on the cable. Determine the worst-case power
consumption, loop resistance of the cable, and cable
19 68-0139
Page 20
W180 ZONE CONTROL SYSTEM
gauge that will allow a minimum of 19 Vac to be
applied to the HVAC controls. Use isolating relays to
lower long loop current requirements.
l. Use UL Listed/CSA Approved cable to connect to
the 24 Vac power to the unit.
m. Do not run sensor or S321A Touchpad wires with
HVAC control switching wires.
Fig. 14—Wiring specifications.
18 AWG, THREE
TWISTED PAIRS,
SOLID OR
STRANDED, 600 FT
[180 M] MAX FOR
EACH S321A
TOUCHPAD.
22 AWG WIRE
CAN BE
USED FOR
RUNS UP TO
250 FT [76 M].
TO 24 VAC/40 VA
TRANSFORMER AND
EARTH GROUND
FOR POWERING
W180A CONTROLLER.
18 AWG, SOLID,
100 FT [30 M] MAX.
S321A
TOUCHPAD
S321A
TOUCHPAD
S321A
TOUCHPAD
W180A
CONTROLLER
HBUS
CAUTION
To prevent damage to the equipment, do not connect any voltage source greater than 24 Vac to any
circuit of the system.
T675A HIGH LIMIT CONTROLLER
18 AWG (MIN). SOLID OR STRANDED. TO BE WIRED IN SERIES WITH THE HEATING
CONTROL ON CONVENTIONAL FORCED AIR SYSTEMS.
HVAC EQUIPMENT
18 AWG (MIN). SOLID OR STRANDED. VERIFY THE NUMBER OF CONDUCTORS REQUIRED
TO OPERATE EACH HVAC UNIT. 100 FT [30 M] MAX. IF DISTANCE IS MORE THAN 100 FT
[30 M], CALCULATE WORST-CASE POWER CONSUMPTION, CABLELOOP RESISTANCE,
AND WIRE GAUGE TO ALLOW 19 VAC (MIN) TO BE APPLIED TO HVAC EQUIPMENT. USE
ISOLATING RELAYS TO LOWER LONG LOOP CURRENT REQUIREMENTS.
AOBD HONEYWELL/ TROL-A-TEMP RECTANGULAR DAMPERS
18-22 AWG, THREE CONDUCTORS, SOLID OR STRANDED, 1000 FT [300 M] MAX.
D635B-G ZONE DAMPERS
18-22 AWG, THREE CONDUCTORS, SOLID OR STRANDED, 1000 FT [300 M] MAX.
V8043A,B,E,F,J; V8044A,B,E MOTORIZED VALVES
18-22 AWG, TWO CONDUCTORS, SOLID OR STRANDED, 1000 FT [300 M] MAX. IF AN END
SWITCH IS USED, ADDITIONAL WIRES ARE REQUIRED TO POWER THE CIRCULATION PUMP.
C7130A WALL MOUNT ROOM TEMPERATURE SENSOR
T7660A SPACE TEMPERATURE SENSOR
18 AWG, TWISTED PAIR, SOLID OR STRANDED, 300 FT [90 M] MAX. 22 AWG WIRE CAN BE
USED FOR RUNS UP TO 150 FT [45 M]. DO NOT RUN WIRING WITH LOAD SWITCHING OR
POWER WIRES. USE SHIELDED CABLE FOR RUNS GREATER THAN 50 FT [15 M] TO MINIMIZE
ELECTRICAL NOISE ON SENSOR WIRES. ACCESSORY SHIELDED CABLES (FT [M]):
4074CAV, 50 [15]; 4074CAW, 100 [30]; 4074CAY, 200 [61].
C7180A FLUSH MOUNT TEMPERATURE SENSOR
18-22 AWG, TWISTED PAIR, SOLID OR STRANDED, 1000 FT [300 M] MAX. DO NOT RUN WIRING
WITH LOAD SWITCHING OR POWER WIRES.
T7660B SPACE TEMPERATURE SENSOR WITH OCCUPIED OVERRIDE
18 AWG, THREE TWISTED PAIRS, SOLID OR STRANDED, 300 FT [90 M] MAX. 22 AWG WIRE
CAN BE USED FOR RUNS UP TO 150 FT [45 M]. DO NOT RUN WIRING WITH LOAD SWITCHING
OR POWER WIRES.
198212CA OUTDOOR TEMPERATURE SENSOR
18 AWG, TWISTED PAIR, SOLID OR STRANDED, 300 FT [90 M] MAX. 22 AWG WIRE CAN BE
USED FOR RUNS UP TO 150 FT [45 M]. DO NOT RUN WIRING WITH LOAD SWITCHING OR
POWER WIRES. USE SHIELDED CABLE FOR RUNS GREATER THAN 50 FT [15 M] TO MINIMIZE
ELECTRICAL NOISE ON SENSOR WIRES. ACCESSORY SHIELDED CABLES (FT [M]):
4074CAV, 50 [15]; 4074CAW, 100 [30]; 4074CAY, 200 [61].
M5597A
68-0139 20
Page 21
W180 ZONE CONTROL SYSTEM
TABLE 9—WIRING.
Device Mounting Location Notes
W180A Controller Locate to minimize wire runs. 1. Requires dedicated 24 Vac, 40 VA
transformer to power W180A Controller.
CAUTION
To prevent damage to the W180A
Controller, do not connect either side of
the 24 Vac transformer secondary
to earth ground.
CAUTION
The W180 Zone Control System requires
an earth ground (18 AWG or heavier wire
connected to a cold water pipe).
HVAC Equipment Where required.
WARNING
Wherever possible, avoid connecting
separate power sources to the same relay
set common. See the W180 Zone Control
System Programmer's Manual,
form 69-0761, for more information
regarding relay assignments.
2. If HVAC unit is more than 100 ft [30.5m]
from W180A Controller, calculate worst-case
power consumption, cable loop resistance,
and wire gauge that will allow 19 Vac (min)
to be applied to HVAC equipment. Use
isolating relays to lower long loop current
requirements.
3. Any HVAC control that requires more than
1A of continuous current at 24 Vac must be
separated from the W180A Controller output
with an isolating relay.
4. HVAC units must have low voltage controls.
Forced air zoning requires tree structure
where each zone has individual damper/valve
for control.
5. Requires separate transformer. Number of
actuators powered by each transformer
depends on transformer VA rating.
S321A Touchpad In any room about 5 ft, 4 in. [1.6m] above
floor or as specified by customer. Do not
mount in high humidity areas. Can mount
6. Up to three S321A Touchpads can be
powered from the dc power provided by the
W180A Controller.
in 3-gang electrical box.
T675A Temperature
Controller
In duct where the sensing element is
exposed to the average temperature. Do
—
not mount near hot pipes and cooling
coils.
C7180A Flush
Mount Temperature
Sensor
On inside wall about 5 ft [1.5m] above
floor, away from hot or cold areas, water
pipes, air ducts, discharge air, dead air,
and radiation from lights, appliances, and
the sun.
(Continued)
21 68-0139
Page 22
W180 ZONE CONTROL SYSTEM
Device Mounting Location Notes
198212CA Outdoor
Temperature Sensor
C7130A Wall
Mount Room
Temperature Sensor
Away from radiation from sun, preferably
on north wall.
On inside wall about 5 ft [1.5m] above
floor, away from hot or cold areas, water
pipes, air ducts, discharge air, and radiation from lights, appliances, and the sun.
T7660A Space
Temperature Sensor
T7660B Space
Temperature Sensor
with Occupied
Override
C7600C Solid State
Humidity Sensor
Where it is exposed to freely circulating
air (500 ft/min minimum air flow), but
protected from rain and direct sunlight.
AOBD Honeywell/
Trol-A-Temp
®
Where required. 9. Requires transformer separate from the
Rectangular
Dampers
D635B-G Zone
Where required. 11. Requires transformer separate from the
Dampers
V8043A,B,E,F,J
Where required. 13. Requires transformer separate from the
V8044A,B,E
Motorized Valves
TABLE 9—WIRING (Continued).
7. Accessory Cables (ft [m]):
a. 4074CAV: shielded cable, 50 [15].
b. 4074CAW: shielded cable, 100 [30.4].
c. 4074CAY: shielded cable, 200 [61].
8. Connect the 20 Vdc input wire from the
W180A to the + terminal. Connect the
W180A analog input wire to the sensor–
terminal.
W180A Controller transformer. Five damper
actuators (max) per 40 VA transformer.
10. Use a modified 3-wire daisy chain wiring
technique to simplify wiring or use five wires
and wire as home runs.
W180A Controller transformer. Eighteen
damper actuators (max) per 40 VA
transformer.
12. Use the daisy chain wiring technique to
simplify wiring and eliminate multiple wires
at the W180A Controller.
W180A Controller transformer. Five V8043
Zone Valves (max) per 40 VA transformer.
14. On all hydronic systems, the W180A must
have direct and independent control of all
valves and pumps. Therefore, valve end
switches must not control circulation pumps.
68-0139 22
Page 23
W180 ZONE CONTROL SYSTEM
Fig. 15—Typical standard heat pump wiring.
HEAT PUMP (TYPICAL)
INDOOR
HEATING
AND FAN
UNIT
OUTDOOR
COMPRESSOR
UNIT
18 AWG STRANDED WIRE OR
BETTER, AT SHORT ENOUGH LENGTH,
IN ORDER TO PROVIDE REQUIRED
VOLTAGE TO HEAT PUMP CONTROLS
AUXILIARY STRIP 1
AUXILIARY STRIP 2
TRANSFORMER COMMON
REVERSING VALVE
COMPRESSOR LOW
COMPRESSOR HIGH
24 VAC
FAN LOW
FAN HIGH
CTRLS COMMON
HEAT PUMP WIRING NOTES
1. USE 24 VAC POWER SUPPLIED BY HEAT PUMP.
2. ACTUAL HEAT PUMP TERMINAL LABELING/NAMING WILL VARY.
3. CONNECT COMPONENTS TO RELAYS ASSIGNED
THROUGH SOFTWARE CONFIGURATION.
RELAY CONNECTIONS
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
Fig. 16—Typical standard combination unit
wiring.
CONVENTIONAL
FORCED AIR UNIT (TYPICAL)
24 VAC
FURNACE BURNER
BURNER/FAN
AC COMPRESSOR
18 AWG STRANDED WIRE OR
BETTER, AT SHORT ENOUGH LENGTH,
IN ORDER TO PROVIDE REQUIRED
VOLTAGE TO HEAT PUMP CONTROLS
CONVENTIONAL FORCED AIR
UNIT WIRING NOTES
1. USE 24 VAC POWER SUPPLIED BY
COMBINATION UNIT.
2. ACTUAL HEAT PUMP TERMINAL
LABELING/NAMING WILL VARY.
3. CONNECT COMPONENTS TO RELAYS
ASSIGNED THROUGH SOFTWARE
CONFIGURATION.
RELAY CONNECTIONS
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
M7107
M7108
Fig. 17—Typical hydronic system equipment
wiring.
RELAY CONNECTIONS
HONEYWELL
VALVES
V8043A, B, E, F, J
V8044A, B, E
CIRCULATION
PUMP AND
MOTOR
AC SOURCE
AS REQUIRED BY
PUMP MOTOR
CAUTION
DO NOT ATTEMPT TO CONTROL PUMP MOTOR DIRECTLY
THROUGH W180A RELAYS.
(MAX LOAD ON RELAYS = 24 VAC, AT 1 AMP)
WIRING NOTES:
1. DISCONNECT POWER SUPPLY BEFORE BEGINNING INSTALLATION.
2. CONNECT UP TO THREE VALVES IN PARALLEL TO THE SAME
CONTROLLER RELAY.
3. USE APPROPRIATE POWER SOURCE AND POWER RELAY TO
CONTROL POWER TO A CIRCULATION PUMP AND MOTOR.
4. CIRCULATION PUMPS MUST BE CONTROLLED THROUGH A
SEPARATE RELAY OUTPUT. THE W180 WILL NOT OPERATE
CORRECTLY IF PUMPS ARE CONTROLLED SOLELY BY A
VALVE END SWITCH.
24 VAC
50/60 HZ
EXTERNAL POWER
RELAY TO MATCH
SOURCE POWER
24 VAC
OR LESS
50/60 HZ
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
M7110A
Fig. 18—Typical fire switch wiring.
FIRE SYSTEM SWITCH
OR OTHER DRY
CONTACT CLOSURE
SENSOR/INPUT
CONNECTIONS
M7109
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
+8
23 68-0139
Page 24
W180 ZONE CONTROL SYSTEM
Fig. 19—Typical D635 damper wiring.
END SWITCH
SET TO TRIP
AT FULLY
OPEN
POSITION
END SWITCH
SET TO TRIP
AT FULLY
CLOSED
POSITION
CW = OPEN
CCW = CLOSED
GENERAL DAMPER WIRING NOTES:
1. CONNECT NO MORE THAN FOUR DAMPERS TO ONE RELAY PAIR.
2. DO NOT MIX DAMPER TYPES ON ONE RELAY PAIR.
3. USE 24 VAC POWER SOURCE OTHER THAN THAT USED FOR POWERING THE W180.
4. CONNECT DAMPER TO THE RELAY PAIR DESIGNATED THROUGH SOFTWARE CONFIGURATION.
5. MAXIMUM DISTANCE FROM DAMPER TO CONTROLLER IS 1000 FT. [300 M] USING 18 AWG SOLID OR
STRANDED WIRE.
6. WHEN MORE THAN ONE WIRE MUST BE CONNECTED TO A TERMINAL, RUN A SHORT WIRE OUT FROM
THE TERMINAL AND CONNECT THE WIRES TO THE SHORT WIRE USING A WIRE NUT.
COM
OPEN
CLOSE
COM
SINGLE D635
D635 W/END SWITCHES
NC
NC
CW
COM
CCW
MULTIPLE D635
D635 HONEYWELL D635
CW
COM
CCW
HONEYWELL D635
CW
COM
CCW
RELAY CONNECTIONS
CW
COM
CCW
USE ADDITIONAL TRANSFORMERS
FOR DAMPERS, CALCULATE
TRANSFORMER SIZE NEEDED
BY ADDING 2.2VA PER DAMPER.
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
24 VAC
M7111A
Fig. 20—Typical Trol-A-Temp® damper wiring.
RELAY CONNECTIONS
1
4
2
5
3
6
X
Z
SINGLE AOBD
1
4
2
5
3
6
X
Z
MULTIPLE AOBD
GENERAL DAMPER WIRING NOTES:
1. CONNECT NO MORE THAN FOUR DAMPERS TO ONE RELAY PAIR.
2. DO NOT MIX DAMPER TYPES ON ONE RELAY PAIR.
3. CONNECT THE LAST DAMPER (MULTIPLE DAMPERS CONNECTED
TO ONE RELAY PAIR) AS SHOWN FOR THE RESPECTIVE DAMPER TYPE.
4. USE 24 VAC POWER SOURCE OTHER THAN THAT USED
FOR POWERING THE W180.
5. CONNECT DAMPER TO THE RELAY PAIR DESIGNATED THROUGH
SOFTWARE CONFIGURATION.
6. MAXIMUM DISTANCE FROM DAMPER TO CONTROLLER IS 1000 FT.
[300 M] USING 18 AWG SOLID OR STRANDED WIRE.
1
4
2
5
3
6
X
Z
USE ADDITIONAL TRANSFORMERS
FOR DAMPERS. CALCUATE
TRANSFORMER SIZE NEEDED BY
ADDING 8.0 VA PER DAMPER.
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
M8165A
DETERMINE THE TEMPERATURE PROFILES
Determine and enter the Profile Name, Profile Start
Time, Days the profile is used, and desired heating and
cooling temperatures for each room in the house/building.
The example below shows a typical schedule for a house. A
profile:
— Can have different start times for different days of
the week.
— May be scheduled for only some days.
— May not have a start time at all.
Complete the Homeowner Lifestyle Worksheet in Ap-
pendix B for the customer. Use it when programming the
System.
68-0139 24
Page 25
No.
Profile
Name
Start
Time
Days
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Zone 7 Zone 8 Zone 9 Zone 10
1
2
3
4
5
6
7
8
9
10
M8328
W180 Zone Control System
W180 ZONE CONTROL SYSTEM
Preferred Temperature Setpoints*
Occupied—Heating __________ Unoccupied—Heating _________
Occupied—Cooling __________ Unoccupied—Cooling _________
Homeowner Lifestyle Worksheet
Directions:
1. Provide Zone Names (up to 10), Profile Names (up to 20), and Start Times.
3 . Identify with a 4 which zones are occupied for each profile.
2 . Indicate the desired heating and cooling setpoints.
* Setpoints can be different than "preferred setpoints", see example.
25 68-0139
Page 26
W180 ZONE CONTROL SYSTEM
24 VAC
EARTH GND
POWER TO
MAIN BOARD
18 AWG SOLID
OR STRANDED
100 FT. [30 M] MAX.
24 VAC TRANSFORMER
40 VA MINIMUM
EARTH GROUND
CAUTION:
1. EARTH GROUND CONNECTION IS MANDATORY.
2. EARTH GROUND MUST BE A RELIABLE CONNECTION:
– COLD WATER PIPE
– GROUNDING ROD
– BUILDING METAL FRAMEWORK
3. THE THIRD WIRE GROUND IN THE ELECTRICAL WIRING OF A
BUILDING SHOULD NOT BE USED BECAUSE IT IS DIFFICULT AND
OFTEN IMPOSSIBLE TO ESTABLISH ITS RELIABILITY
AS AN EARTH GROUND.
4. TO AVOID POSSIBLE DAMAGE TO THE W180 CONTROLLER, DO NOT
CONNECT THE EARTH GROUND TO THE SECONDARY SIDE OF THE
24 VAC TRANSFORMER.
M8166A
Installation and W iring
GENERAL
Check the equipment for damage immediately upon
receipt and note any visible damage with the carrier. Unpack the W180A Controller and check to see that nothing
was jarred loose during shipping.
NOTE: The following procedures explain how to install the
hardware in pre-existing buildings. See Fig. 14 and
Table 9 for prewiring information.
W180A CONTROLLER
Fig. 2 shows the W180A Controller enclosure mounting
hole locations. The W180A Controller enclosure can be
surface mounted in any dry, accessible area. Avoid areas of
excessive heat and/or humidity. Mount the W180A Controller enclosure as follows:
CAUTION
Do not allow material from the wall (for example,
wood or metal shavings) to enter the enclosure.
1. If mounting the W180A Controller enclosure on a wall
that does not have studs 16 inches OC, obtain a 3/4-inch
thick piece of plywood and trace the outline of the keyhole
slots and round holes onto the plywood and secure the
plywood to the supporting wall as indicated in the job
drawings. If mounting the W180A Controller enclosure on
a wall with studs 16 inches OC, position the enclosure on
the studs as indicated in the job drawings and trace the
outline of the keyholes on the studs.
2. Start a 3/4-inch wood screw in each of the top
keyholes.
3. Hang the W180A Controller enclosure from the
screws.
4. Start a 3/4-inch wood screw in each of the remaining
holes.
5. Tighten all wood screws.
6. Remove all appropriate knockouts and install bushings (obtained locally) to protect the wires entering the
enclosure.
7. Connect the field wiring to the W180A Controller
termination board as shown on the job drawings and Fig. 21.
NOTES:
a. When more than one wire must be connected to a
terminal, use the same gauge wires.
b. See Fig. 22 for terminal designations.
c. See Fig. 23 for proper power supply isolation
when wiring two HVAC systems.
Fig. 21—W180A Controller power source and
ground wiring.
68-0139 26
Page 27
Fig. 22—Input/output terminal designations.
27 68-0139
H4
H1
H2
H3
H4
H3
POWER
OFF/ON
POWER TO
MAIN BOARD
RS485
TOUCHPADS
AB
24 VAC
EARTH GND
+
–
CABLE SHIELD
+
DATA
–
+
END
–
+
12 VDC
–
+
–
12 VDC
external
int.
RS232
1
RELAY CONNECTIONS
Wire Termination Board
copyright 1993, all rights reserved
assy. no xxx-xxxx A
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
1
RLY 9
9/10 com
RLY 10
spare E
RLY 11
11/12 com
RLY 12
spare F
spare G
RLY 13
13/14 com
RLY 14
spare H
RLY 15
15/16 com
RLY 16
C
DE
RLY 17
17/18 com
RLY 18
spare I
RLY 19
19/20 com
RLY 20
spare J
spare K
RLY 21
21/22 com
RLY 22
spare L
RLY 23
23/24 com
RLY 24
11
sensor pwr sensor gnd
20 VDC
5 VDC
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
SENSOR/INPUT CONNECTIONS
+8
–9
+9
–10
+10
–11
+11
–12
+12
–13
+13
–14
+14
–15
+15
–16
+16
F
W180 ZONE CONTROL SYSTEM
M7105
Page 28
W180 ZONE CONTROL SYSTEM
Fig. 23—Typical wiring for two HVAC systems to assure power supply isolation.
120 VAC
SYSTEM #1
R1
W
G
Y
COMP
120 VAC
SYSTEM #2
COMP
NOTE:
1. TO ENSURE ISOLATION, R1 MUST NOT BE CONNECTED TO R2.
2. TO ENSURE ISOLATION, THE TRANSFORMER AT POINT X MUST NOT BE CONNECTED TO AN EARTH GROUND.
R2
W
G
Y
HONEYWELL TotalHome® SYSTEM
Wiring and connections between the TotalHome® System and the W180 System are provided by the installer of
the TotalHome® System. The TotalHome® System and the
W180 System should each have their own, separate HBus
networks. This allows the systems to work independently
of each other. After verifying that both systems are operating properly as stand-alone systems, they can be interconnected through the HBus network.
The TotalHome® installer will connect two wires between the two controllers, one for HBus Data + (H3) and
one for HBus Data – (H4), and mark these wires at both
ends.
Prior to servicing either system, disconnect the interconnecting wires. Reconnect these wires after servicing
is completed. Verify proper operation of the combined
system.
S321A TOUCHPADS
NOTES:
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous
condition.
2. Check the ratings and description given on the product to make sure the product is suitable for your
application.
3. Installer must comply with all local building codes
and ordinances when installing this product.
RELAY CONNECTIONS
RLY 1
1/2 com
RLY 2
R8285A1048
OR EQUIVALENT
X
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
M8167
4. Installer must be a trained, experienced service
technician.
5. The Touchpad may be mounted in a 3-gang junction
box or in a hole cut in a drywall panel.
6. After installation is complete, check out product
operation as provided in these instructions.
CAUTION
Disconnect power before installation to prevent
electrical shock or equipment damage.
The Touchpad may be located in any room. However,
mounting in bathrooms and other high humidity areas is not
advised. Multiple Touchpads may be installed for convenience. Because the Touchpad does not perform temperature sensing, location is not as limited as for a thermostat.
The Touchpad may be located at a customer-specified
height above the floor. When the customer does not specify,
mount the Touchpad for best viewing (at or slightly below
eye level; usually 5 ft., 4 in. [1.63m] above the floor).
Install and wire the Touchpad as follows:
1. Remove the Touchpad from its package. Set aside all
mounting materials (for example, screws, plastic screw
anchors) until later in the mounting procedure.
2. Use a flat-bladed screwdriver to remove the trim ring
from the Touchpad (Fig. 24). Set aside the cover until the
Touchpad has been mounted.
68-0139 28
Page 29
W180 ZONE CONTROL SYSTEM
Fig. 24—Removing the trim ring.
ALUMINUM
TRACK
SCREWDRIVER
M3507
3. Mount the Touchpad in a 3-gang junction box or
drywall as follows:
— 3-gang junction box (Fig. 25):
a. Make sure that the location chosen is clear of
studs and other possible obstructions behind the
drywall.
b. Place the 3-gang junction box on the wall at the
selected location and use it as a stencil to outline
the portion of the drywall to be cut away.
c. Cut the opening for the junction box.
d. Mount the junction box in the cutout.
e. Run the 6-wire connecting cable (Belden
for example) from the junction box to the advance
zoning controller, leaving a minimum of 3 in.
[76 mm] of wire exposed in the junction box for
connection to the Touchpad.
f. Connect the four Touchpad signal and power
wires to the 6-wire connecting cable (red wire for
input power, black wire for common, green and
yellow wires for signals) using wire nuts. See
Fig. 26 and 27. If more than three Touchpads are
being wired to the W180A Controller, see Fig. 28
for auxiliary power wiring. If required, connect
the wiring between TotalHome® System and W180
System (Fig. 29).
®
8742,
TRIM
RING
Fig. 25—Mounting S321A Touchpad in a 3-gang
junction box.
3-GANG JUNCTION
BOX IN DRYWALL
6 WIRE
CABLE
M3504A
Fig. 26—Wiring the S321A Touchpad to the
W180A Controller.
18-22 AWG WIRE SHIELDED,
S321
TOUCHPAD
SOLID OR STRANDED,
THREE TWISTED
PAIRS AS SHOWN
YELLOW
GREEN
RED
BLACK
WIRE NUTS
(TYPICAL)
YELLOW
GREEN
YELLOW
GREEN
RED
BLACK
TO TOUCHPADS
W180 TERMINATION PANEL
g. Mount the Touchpad in the junction box in the
four inside mounting holes, using the screws
supplied.
h. Position the trim ring on the Touchpad (note the
UP reference on the rear surface of the trim ring)
and snap it onto the Touchpad.
+
–
+
–
+
12 VDC
–
+
12 VDC
–
DATA
END
int.
external
M8168
29 68-0139
Page 30
W180 ZONE CONTROL SYSTEM
Fig. 27—Wiring three S321A Touchpads to the W180A Controller.
RED
BLACK
YELLOW
RED
BLACK
GREEN
YELLOW
RED
BLACK
GREEN
YELLOW
HBUS WIRING NOTES:
1. USE 6-CONNECTOR, 3 TWISTED PAIR SHIELDED CABLE, 18 GAUGE.
2. IF POWER IS RUN IN SEPARATE CABLE, DATA CABLE CAN BE 24 GAUGE AS SHOWN, DISTANCE LESS THAN 400 FT. [120 M].
3. POWER CABLING = 2.8V DROP AT MAXIMUM LOAD.
4. GROUND DATA CABLE SHIELD TO ENCLOSURE CHASSIS.
5. DO NOT EXTEND YELLOW OR GREEN WIRES COMING FROM TOUCHPADS WITH A SINGLE WIRE.
ONLY CONNECT DATA LINES DIRECTLY AS SHOWN ABOVE.
GREEN
TOUCHPADS
SHIELD GROUNDED
AT W180A CONTROLLER
POWER CONNECTIONS:
18 AWG, SOLID OR STRANDED
SIGNAL CONNECTIONS:
TWISTED PARIS, SHIELDED, 24 AWG STRANDED
CHASSIS GROUND
+
YELLOW
DATA
–
GREEN
+
YELLOW
END
–
GREEN
RED
+
12 VDC
BLACK
–
+
12 VDC
external
–
int.
JUMPER
BLOCK
M8170
Fig. 28. Auxiliary power wiring for wiring more than three S321A Touchpads to the W180A Controller.
12 Vdc POWER SUPPLY
(USE POWER SUPPLY
RATED AT 250 mA PER
TOUCHPAD)
1 TOUCHPAD = 250mA
2 TOUCHPADS = 500mA
3 TOUCHPADS = 750mA
4 TOUCHPADS = 1 A
5 TOUCHPADS = 1.25 A
+
LEAD
–
LEAD
SAMPLE POWER SUPPLIES:
-ALTRONIX SMP3 POWER SUPPLY (2.5 A)
-AlarmSaf ASPS1 (1.0 A)
WIRING NOTES:
1. DISCONNECT POWER SUPPLY BEFORE BEGINNING INSTALLATION.
2. AN EXTERNAL POWER SUPPLY IS REQUIRED WHEN CONNECTING
MORE THAN THREE S321A TOUCHPADS TO ONE W180A CONTROLLER.
3. USE ANY 12 Vdc REGULATED OR UNREGULATED PLUG-IN OR
STANDARD SECURITY SYSTEM AUXILIARY POWER SUPPLY.
+
DATA
–
+
END
–
+
12 VDC
–
+
12 VDC
–
EXTERNAL
PLACE JUMPER
TO CONNECT
THE TWO LEFT
HEADER PINS
(SIDE OPPOSITE
INT)
int.
M7215
68-0139 30
Page 31
Fig. 29. Wiring between TotalHome® and W180A Controller.
W180A CONTROLLER
POWER
HBUS LABEL
OFF/ON
®
POWER TO
MAIN BOARD
HBUS+ H3
W180/TotalHome HBus Connections
RS485
HBUS– H4
TOUCHPADS
AB
24 VAC
EARTH GND
+
–
CABLE SHIELD
+
DATA
–
+
END
–
+
12 VDC
–
+
12 VDC
external
–
RS232
ext.
RELAY CONNECTIONS
Wire Termination Board
copyright 1993, all rights reserved
assy. no xxx-xxxx A
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
C
RLY 9
9/10 com
RLY 10
spare E
RLY 11
11/12 com
RLY 12
spare F
spare G
RLY 13
13/14 com
RLY 14
spare H
RLY 15
15/16 com
RLY 16
sensor pwr sensor gnd
20 VDC
RLY 17
17/18 com
RLY 18
spare I
RLY 19
19/20 com
RLY 20
spare J
spare K
RLY 21
21/22 com
RLY 22
spare L
RLY 23
23/24 com
RLY 24
DE
5 VDC
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
SENSOR/INPUT CONNECTIONS
+8
W180 ZONE CONTROL SYSTEM
–9
+9
–10
+10
–11
+11
–12
+12
–13
+13
–14
+14
–15
+15
–16
+16
F
TotalHome
®
CONTROL PANEL
TB1–19
TB1–12
TB1–11
TB1–9
TB1
+13.8V
HBUS+ H3
HBUS– H4
PGM
SIG 1
1N4001 OR
EQUIVALENT
FIRE TRIGGER
OPTION
NC
NO
C
ALARM/SAF RELAY
(AS/RBK-624)
M7214
31 68-0139
Page 32
W180 ZONE CONTROL SYSTEM
— Drywall without junction box (Fig. 30):
a. Make sure that the location chosen is clear of
studs and other possible obstructions behind the
drywall.
b. Place the back of the Touchpad on the wall at the
selected location and use it as a stencil to outline
the area of drywall to be cut out
c. Cut the opening for the S321A Touchpad.
d. Place the Touchpad in the opening and mark the
locations for the four mounting screws using the
outer four mounting holes.
e. Use a 3/16 in. [5 mm] drill bit to drill the four
starter holes for the plastic screw anchors.
f. Install the four plastic screw anchors in the starter
holes.
g. Run the 6-wire connecting cable from the drywall
cutout to the advance zoning controller, leaving a
minimum of 3 in. [76 mm] of wire exposed in the
cutout for connection to the Touchpad.
h. Connect the four Touchpad signal and power
wires to the 6-wire connecting cable (red wire for
input power, black wire for common, green and
yellow wires for signals) using wire nuts (Figs. 26
and 27). If more than three Touchpads are being
wired to the W180A Controller, see Fig. 28 for
auxiliary power wiring. If required, connect the
wiring between TotalHome® System and W180
System (Fig. 29).
i. Mount the Touchpad in the drywall, using the
screws provided.
j. Position the trim ring on the Touchpad (note the
UP reference on the rear surface of the trim ring)
and snap it onto the Touchpad.
4. Wire the Touchpad as shown in the job drawings and
Fig. 47.
Fig. 30—Mounting S321A Touchpad in
drywall.
HOLE IN DRYWALL
PLASTIC SCREW
ANCHORS (4)
HIGH LIMIT CONTROLLER
NOTES:
1. Locate the high limit controller where it will be exposed to average air temperature in the duct.
2. Do not locate the high limit controller near hot pipes
and cooling coils.
3. To support the bulb in the duct, use Bulb Holder
No. 107324A (supplied with the adjustable differential model; order separately for the fixed differential
model).
Install and wire the T675A Temperature Controller as
follows:
1. Mount the controller case as follows:
a. Remove the cover.
b. Use the case as a template and mark three screw-
hole locations on the mounting surface.
c. Punch or drill the holes.
d. Secure the T675A to the mounting surface with
the screws provided.
2. Install the sensing bulb in the duct as follows:
a. Drill a hole in the duct wall large enough to admit
the sensing bulb in the holder.
b. Using the holder as a template, mark and drill holes
for the bulb holder mounting screws (Fig. 31).
c. Break off the bulb holder to the desired length
Fig. 32).
NOTE: The holder should be long enough to hold
the sensing bulb in freely circulating air, away
from the duct wall.
d. Neatly coil any excess capillary tubing at the con-
troller or bulb holder.
e. Place the capillary tubing in the bulb holder chan-
nel and pinch together the top edges of the holder
at each segment (Fig. 33).
f. Insert the bulb and bulb holder into the duct
through the drilled hole (Fig. 31).
g. Secure the bulb holder to the duct wall with the
screws provided.
Wire the T675A according to the instructions provided
with the heating or cooling system and Fig. 34.
6 WIRE
CABLE
M3506
68-0139 32
Fig. 31—T675A Temperature Controller
mounting.
CONTROLLED
AREA
SCREW
HOLES (2)
IN DUCT WALL
MOUNTING
SCREWS (2)
M8332
Page 33
Fig. 32—Shortening the bulb holder.
M7216
Fig. 33—Securing the bulb to the bulb holder.
CAPILLARY
TUBING
SENSING
BULB
BE SURE THIS TUBE IS
UNDER BULB HOLDER AS SHOWN
M7218
Fig. 34—Typical T675A Temperature Controller wiring.
W180 ZONE CONTROL SYSTEM
SENSORS
Temperature Sensors
CAUTION
Disconnect the power supply before making wiring
connections to prevent electrical shock or equipment damage.
NOTES:
1. Check the ratings given in the instructions and on the
product to make sure the product is suitable for the
application.
2. After installation is complete, check out the operation as provided in these instructions.
198212CA OUTDOOR TEMPERATURE SENSOR
NOTES:
1. Locate the sensor where it will not be subject to
tampering.
2. Locate the sensor away from exhausts and direct
sunlight that may affect the temperature reading. A
typical location would be under the roof overhang on
the least sunny side of the building.
3. Use a 107323A Sun Shield, if desired.
4. All wiring must agree with local codes, ordinances,
and regulations.
5. Do not route temperature sensor wiring:
a. With building power wiring.
b. Next to control conductors.
c. Near electric motors.
d. Near welding equipment.
e. Near ballast of gas-bulb lighting power transformer.
6. Improper shield grounding or bad connectors can
cause erratic readings.
OPEN ON
T675 MOUNTED
IN RETURN AIR
PLENUM
FURNACE
FAN
A/C COMPRESSOR
24 VAC
24 VAC COM
T675 WIRING FOR CONVENTIONAL FORCED AIR SYSTEMS
TEMP RISE
SETPOINT = 80
O
F (TYPICAL)
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
M8169
Install and wire 198212CA Outdoor Temperature Sen-
sors as follows:
1. Mark the area on the wall where the sensor or sun
shield will be mounted.
2. Wire the sensor as shown on the job drawings and
Fig. 35.
3. Mount the sensor to the wall or in the sun shield.
33 68-0139
Page 34
W180 ZONE CONTROL SYSTEM
Fig. 35—Typical 198212CA Outdoor Temperature Sensor wiring.
CABLE SHIELD
(IF REQUIRED)
198212CA OUTDOOR
TEMPERATURE SENSOR
SENSOR GND
SENSOR/INPUT
CONNECTIONS
M8171
C7130A WALL MOUNT TEMPERATURE SENSOR
NOTES:
1. Locate the sensor where it will not be subject to
tampering.
2. Locate the sensor on an inside wall about 5 ft [1.5m]
above the floor.
3. Make sure the wire run between the sensor and the
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
+8
controller is 300 ft [91m] or less.
4. Make sure there is good air circulation at average
temperature at the location. Avoid the following
locations because they can introduce errors in temperature sensor measurements (Fig. 36):
a. Hot areas caused by:
1) Concealed pipes or ducts.
2) Drafts from fireplaces or other heat sources.
3) Convection or radiant heat from the sun or
electrical equipment.
b. Cold areas caused by:
1) Concealed pipes or ducts.
2) Drafts from windows and doors.
3) Unheated areas on the other side of the wall
location.
c. Dead air areas:
1) Behind doors, furniture, and curtains.
2) In corners and alcoves.
Fig. 36—C7130A Wall Mount Temperature Sensor mounting location.
M9175
68-0139 34
Page 35
W180 ZONE CONTROL SYSTEM
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
+8
SENSOR/INPUT
CONNECTIONS
M8173A
18-22 AWG
TWISTED PAIR
GENERAL SENSOR WIRING NOTES:
SEE SYSTEM SPECIFICATIONS FOR
COMPLETE INSTALLATION INSTRUCTIONS.
C7180A (ONE-INCH INDOOR) NOTES:
1. ONE-INCH HOLE REQUIRED FOR INSTALLATION
INTO PLASTER OR WALLBOARD.
2. MAXIMUM DISTANCE FROM CONTROLLER TO
SENSOR IS 1000 FT. [300 M].
WHITE
RED
C7180A
SENSOR
Install and wire C7130 Wall Mount Temperature Sen-
sors as follows:
1. Mark the area on the wall where the sensor or conduit
box will be mounted.
2. Wire the sensor as shown on the job drawings and
Fig. 37.
NOTES:
a. All wiring must agree with local codes, ordinances,
and regulations.
b. Do not route temperature sensor wiring:
1) With building power wiring.
2) Next to control conductors.
3) Near electric motors.
4) Near welding equipment.
c. Improper shield grounding or bad connectors can
cause erratic readings.
3. Mount the sensor to the wall or conduit box.
Fig. 37—Typical C7130A Wall Mount Temperature Sensor wiring.
CABLE SHIELD
(IF REQUIRED)
C7130A WALL MOUNT
TEMPERATURE SENSOR
C7180A FLUSH MOUNT TEMPERATURE SENSOR
NOTES:
1. Locate the sensor where it will not be subject to
tampering.
2. Locate the sensor on an inside wall about 5 ft [1.5m]
above the floor.
3. Make sure the wire run between the sensor and the
controller is 1000 ft [300m] or less.
SENSOR GND
SENSOR/INPUT
CONNECTIONS
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
+8
M8172
4. Make sure there is good air circulation at average
temperature at the location. Avoid the following
locations because they can introduce errors in temperature sensor measurements:
a. Hot areas caused by:
1) Concealed pipes or ducts.
2) Drafts from fireplaces or other heat sources.
3) Convection or radiant heat from the sun or
electrical equipment.
4) Outside walls.
b. Cold areas caused by:
1) Concealed pipes or ducts.
2) Drafts from windows and doors.
3) Unheated areas on the other side of the wall
location.
4) Outside walls.
c. Dead air areas:
1) Behind doors, furniture, and curtains.
2) In corners and alcoves.
Install and wire C7180A Flush Mount Temperature
Sensors as follows:
1. Drill a one-inch hole for installation into plaster or
wallboard.
2. Wire the sensor as shown in the job drawings and
Fig. 38.
3. Press the sensor body into the hole until the sensor
fits snugly.
Fig. 38—C7180A Flush Mount Temperature
Sensor typical wiring.
35 68-0139
Page 36
W180 ZONE CONTROL SYSTEM
T7660A/T7660B SPACE TEMPERATURE SENSOR
NOTES:
1. All wiring must conform to local codes, ordinances,
and regulations.
2. Do not run space sensor wiring in the same conduit
with ac wires.
3. The maximum distance between the space sensor
and the controller is 300 ft [91m] using 18 AWG
thermostat wire. To reduce noise on the sensor wires,
use shielded cable with the shield connected to
ground on the controller only.
4. Mount the space sensor on an inside wall approximately 54 in. [1372 mm] from the floor (or where
specified) where it is exposed to the average space
temperature.
5. Do not mount the space sensor on an outside wall or
a wall containing water pipes or air ducts near the
space sensor.
6. Avoid locations that are exposed to discharge air
from registers or radiation from lights, appliances, or
the sun.
Install and wire T7660A/T7660B Space Temperature
Sensors as follows:
1. Mount the space sensor mounting plate on a wall,
mullion (1-7/8 in. [48 mm] wide minimum), or electrical
box (Fig. 39 and Table 10).
TABLE 10—MOUNTING ACCESSORIES.
230517
Type
of
Mounting
230514
Adapter
Plate
230515/16*
Finish
Plate
Black
Mounting
Ring
Direct to wall — — —
2 x 4 inch
XX —
electrical box
2 x 4 inch
— Optional Optional †
electrical box
with 230518
Plaster Ring
4 x 4 inch
XX —
electrical box
with mud ring
4 x 4 inch
— Optional Optional †
electrical box
with 230518
Plaster Ring
*230515 Black.
230516 Beige.
† Required only when plaster ring standoff extends from
wall surface.
Fig. 39—T7660A/T7660B Space Temperature Sensor mounting.
STANDARD
UTILITY
CONDUIT
BOX
230514 ADAPTER
PLATE (NOT USED
WITH 230518
PLASTER RING)
230516/17
FINISH PLATE
P
4 X 4 UTILITY
CONDUIT BOX
FLANGES REMOVED FOR 2 X 4 MOUNTING
230518 PLASTER RING
P
MOUNTING
PLATE
230517 MOUNTING
RING (OPTIONAL)
SWITCH LED
ASSEMBLY (T7660B ONLY)
SENSOR
CIRCUIT
BOARD
MOUNTING PLATE
CIRCUIT BOARD
68-0139 36
GND
OUT
V
+
M9176
Page 37
2. Wire the sensor as shown in the job drawings and
Figs. 40 through 42.
3. Mount the space sensor circuit board on the mount-
ing plate (Fig. 43).
4. Mount the cover on the mounting plate (Fig. 44).
Fig. 40—T7660A Space Temperature Sensor
terminal connections.
LED LIGHT
TEMPERATURE
SENSOR
ANALOG;
COMMON
LED
T
A
JUMPER W1
PB
D
W1
PUSHBUTTON
DIGITAL;
COMMON
M8162
W180 ZONE CONTROL SYSTEM
Fig. 41—Typical T7660A Space Temperature
Sensor wiring.
SENSOR GND
CABLE SHIELD
(IF REQUIRED)
T7660A SENSOR
HONEYWELL T7660A SENSOR
MAXIMUM DISTANCE FROM CONTROLLER
IS 300 FT. [91 M] USING 18 AWG
THERMOSTAT WIRE.
T
A
18-22 AWG
TWISTED PAIR
SENSOR/INPUT
CONNECTIONS
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
+8
M8174
Fig. 42—Typical T7660B Space Temperature Sensor wiring.
SENSOR GND
SENSOR/INPUT
CONNECTIONS
RTD SENSOR WIRES
T7660B SENSOR
T
A
D
LED
PB
22 AWG
R2
2.2K,
1/4 WATT
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
+8
R1
220 ,
1/8 WATT
SENSOR PWR
RELAY
CONNECTIONS
20 VDC
5 VDC
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
M8175
37 68-0139
Page 38
W180 ZONE CONTROL SYSTEM
Fig. 43—Mounting the T7660A/T7660B Space
Temperature Sensor circuit board on the
mounting plate.
COVER MOUNTING
SCREWS
MOUNTING
PLATE
P
SPRING
CLIPS
UPPER
NOTCH
TEMPERATURE
SENSOR
SWITCH/LED
ASSEMBLY
CIRCUIT
BOARD
M9179
NOTES:
1. Check the ratings given in the instructions and on the
product to make sure the product is suitable for the
application.
2. Locate the sensor:
a. Where there is a minimum of 500 ft/min airflow.
b. Locate the sensor where it is exposed to freely
circulating air, but protected from rain and direct
sunlight.
c. Locate the sensor away from traffic areas, on an
inside wall, at least 3 ft (1m) from an outside wall
and 54 in. (1.4m) from the floor.
Mount and install the C7600C Solid State Humidity
Sensor as described in the instructions furnished by the
manufacturer. Wire the C7600C Solid State Humidity Sensor as shown in the job drawings and Fig. 45.
Fig. 45—Typical C7600C Solid State Humidity
Sensor wiring.
CABLE SHIELD
(IF REQUIRED)
SENSOR GND
Fig. 44—Mounting the T7660A/T7660B Space
Temperature Sensor cover.
3
[81]
2 [51]
3
16
2 [51]
COVER MOUNTING SLOTS
1
[38]
1
2
SWITCH/LED
ASSEMBLY
M8163
C7600C Solid State Humidity Sensor
CAUTION
Disconnect the power supply before making wiring
connections to prevent electrical shock or equipment damage.
The sensor may be installed in any position in a duct or
outdoors.
C7600C
DAMPERS
CAUTION
Do not attempt to turn the damper shaft by hand
or with a wrench because this will damage the
actuator.
+
–
SENSOR PWR
SENSOR/INPUT
CONNECTIONS
M8176
20 VDC
5 VDC
–1
+1
–2
+2
–3
+3
–4
+4
–5
+5
–6
+6
–7
+7
–8
+8
68-0139 38
Page 39
W180 ZONE CONTROL SYSTEM
D635 Zone Dampers
NOTES:
1. Install the motor in any location except where acid
fumes or other harmful vapors might attack the metal
parts of the actuator or in atmospheres of escaping
gas or other explosive vapors.
2. Choose a location for the damper/actuator that allows enough clearance for servicing (Fig. 46).
3. Mount the ML6161 Actuator with the motor shaft in
any position so the motor is flush with the damper
housing. Failure to do so can cause unbalanced gear
wear and result in premature failure. In the event the
motor cannot be mounted flush against the damper
housing, add a spacer or washer between the mounting tab and the damper housing.
Install the D635 Damper as follows:
1. Cut and remove enough ductwork into which the
damper can be inserted.
Fig. 46—Damper clearance.
2. Insert and secure the damper into the ductwork.
NOTE: The damper must be kept at the full 90°
setting for proper system operation.
3. Wire the ML6161 Actuator as shown in the job
drawings and Fig. 47.
WARNING
Disconnect power supply before wiring to prevent electrical shock or equipment damage.
NOTES:
1. All wiring must comply with local electrical codes,
ordinances and regulations.
2. The voltage and frequency of the transformer used
with the ML6161 must correspond to the characteristics of the power supply and motor.
ALLOW MINIMUM
5 1/2 in. [14 cm]
CLEARANCE FOR
ACTUATOR REMOVAL
AIR FLOW
Fig. 47—ML6161 typical wiring with optional
end switch.
END SWITCH
SET TO TRIP
AT FULLY OPEN
POSITION
END
SWITCH
(OPTIONAL)
END SWITCH
SET TO TRIP
AT FULLY CLOSED
POSITION
COM
OPEN
CLOSE
COM
NC
NC
RELAY CONNECTIONS
ML6161
CW
COM
CCW
24 VAC
RLY 1
1/2 com
RLY 2
spare A
RLY 3
3/4 com
RLY 4
spare B
spare C
RLY 5
5/6 com
RLY 6
spare D
RLY 7
7/8 com
RLY 8
M7112A
M8161
Rectangular Dampers
CAUTION
1. To prevent damage to the damper or keep it
from moving through its full range, do not
distort the damper shape, or put screws or
anything else into the damper.
2. Ensure the high limit setting is 200° F [93° C]
or lower. Higher settings can damage the
electric actuator.
NOTES:
1. Install AOBD and AOBD-BM dampers in squared
air ducts. Frame misalignment jams damper blades.
2. Secure AOBD and AOBD-BM dampers by inserting
screws in the sides of the damper, not on the top or
bottom.
39 68-0139
Page 40
W180 ZONE CONTROL SYSTEM
3. Applications in air ducts wider than 30 inches require multiple dampers and damper mounting tracks
(Fig. 48).
4. In multiple damper applications, do not weld dampers together.
5. Do not weld dampers to air ducts or damper mounting tracks.
6. When securing dampers with sheet metal screws,
refer to the installation instructions. Improper use of
sheet metal screws can damage damper blades and
the electric actuator.
7. Mount each damper for easy accessibility and servicing after installation.
8. Dampers can be mounted in any position.
9. Properly support, tape, and insulate the dampers and
duct.
10. For retrofit applications or other special purposes,
use register dampers. Note that the design of the
register dampers prevents them from being positioned as precisely as the round type.
Fig. 48—Installing damper mounting tracks.
3 IN. [76 mm]
DUCT OPENING
AOBD DAMPERS
Install AOBD dampers as follows:
1. Cut a 3 in. [76 mm] opening in one side of the air duct
at the location selected. Ensure the opening is cut fully to
the top and bottom air duct seams (Fig. 49).
2. Slide the AOBD into the air duct. Ensure the electric
actuator is mounted toward the top of the air duct.
3. For small air duct sizes (smaller than 20 x 8, 18 x 10,
16 x 12), secure the AOBD mounting plate to the air duct
with sheet metal screws provided.
4. For large air duct sizes (20 in. x 8 in., 18 in. x 10 in.,
16 in. x 12 in., and larger), secure the mounting plate to the
air duct with sheet metal screws provided. Then secure the
back of the AOBD as shown in Fig. 50. If the back of the
AOBD cannot be reached, install two mounting tracks as
shown in Fig. 40.
5. For air duct sizes longer than 30 inches, use multiple dampers and install mounting tracks in the air ducts
(Fig. 48).
6. Wire the AOBD as shown on the job drawings and
Fig. 19.
3 IN. [76 mm]
DUCT OPENING
3
1
2
12DAMPER MOTOR ACTUATOR AND DRIVE LINKAGE
MUST BE TOWARD TOP OF DUCT.
USE 1/4 IN. [6 mm] SHEET METAL SCREWS PROVIDED.
3
DAMPER MOUNTING TRACKS INSTALLED INTO TOP
AND BOTTOM OF AIR DUCT.
M2274B
68-0139 40
Page 41
Fig. 49—Installing automatic opposed blade dampers.
3 IN. [76 mm]
DUCT OPENING
1
2
USE 1/4 IN. [6 mm] SHEET METAL SCREWS PROVIDED.
3
12DAMPER MOTOR ACTUATOR AND DRIVE
LINKAGE MUST BE TOWARD TOP OF DUCT.
FOR LONGER DUCTS OR VERTICAL DUCT
APPLICATIONS, SECURE REAR OF DUCT
USING TWO SHEET METAL SCREWS.
W180 ZONE CONTROL SYSTEM
3
M2275B
Fig. 50—Securing back of automatic opposed
blade dampers to air duct.
1
1
SECURE BACK OF DAMPER TO AIR DUCT USING
TWO 1/4 IN. [6mm] SHEET METAL SCREWS.
M514
AOBD-BM DAMPERS
Install AOBD-BM dampers as follows:
1. Cut a 3 in. [76 mm] opening in the bottom or top of
the air duct at the location selected. Ensure the opening
is cut fully to the air duct seams on each side (Fig. 51).
2. Slide the AOBD-BM into the air duct.
3. Secure the AOBD-BM mounting plate to the air duct
using the sheet metal screws provided.
4. Wire the AOBD-BM as shown on the job drawings.
41 68-0139
Page 42
W180 ZONE CONTROL SYSTEM
Fig. 51—Automatic opposed blade damper-bottom mount installation.
3 IN. [76mm]
DUCT
OPENING
2
1
USE 1/4 IN. [6 mm] SHEET METAL
SCREWS PROVIDED.
2
1
FOR LONGER AIR DUCTS, SECURE
REAR OF DUCT USING TWO SHEET
METAL SCREWS PROVIDED.
M2276B
NOTES:
1. Use the W180M software to easily monitor the system status.
2. See the W180 Zone Control System Owner’s Manual,
form 69-0770, for operating information on the
S321A Touchpad.
3. See Appendix A: Troubleshooting section for
troubleshooting information.
Before operating the system, perform the following
checks and tests:
1. Verify that all wiring is securely connected to the
correct terminals.
2. Verify that the temperature displayed on the Touchpad
for each sensor is within range and reasonable for the site
conditions.
3. Verify that the humidity reading displayed on the
Touchpad for the humidity sensor is within range and
reasonable for the site condition.
4. Verify that each alternate fuel device operates within
the specifications stated in the literature for the device.
5. Verify that each piece of HVAC equipment operates
properly as follows:
a. Dampers and fans:
1) Disable the heating/cooling equipment and manually turn On the fans. Verify fan operation.
Checkout and Test
2) Set the System Mode to Auto and use the
override function to change the setpoint in
each zone, one at a time.
a) Verify that the damper opens and closes
appropriately.
b) If using a PC on site, use the W180M Soft-
ware at the PC to check that dampers are
positioned as shown on the monitor screen.
Dampers may also be positioned manually
to assist in system checkout.
3) Enable the heating/cooling equipment from
step 1) and verify that the equipment operates
according to the setpoints set at each Touchpad.
4) Verify operation at each of the Auto/Heat/
Cool settings. Use the override function to
create a demand, if necessary.
b. Hydronic valves:
1) Use the override function to change a setpoint
in each zone, one at a time.
a) Verify that the circulation pump turns On
and that the temperature in that zone
changes.
b) If using a PC on site, use the W180M Soft-
ware at the PC to check that the valve is
open or closed.
68-0139 42
Page 43
W180 ZONE CONTROL SYSTEM
2) Verify that the heating and cooling equipment
operates according to the setpoints set at each
Touchpad.
3) Verify operation at each of the Auto/Heat/
Cool settings. Use the override function to
create a demand, if necessary.
SENSORS
Check out the sensors as follows:
1. Check the shield ground (if used) on wiring (zero
resistance to ground). Replace if necessary.
2. Check the connectors at both ends of the wiring for
proper connection. Tighten or replace if necessary.
3. Check the sensor for correct installation.
4. Verify proper readings at the S321A Touchpad and
installation monitor screen.
5. T7660B only:
a. Push and hold the override button for one second.
The LED should light to indicate override.
b. Push again and hold. The LED should go Off.
DAMPERS
CAUTION
Do not check operation by shorting across the
terminals of the system controls.
Damper Checkout
Checkout the D635 Damper/ML6161 Actuator as
follows:
1. Disconnect the devices from the W180A Controller.
2. Apply 24 volts across the appropriate common cw
(clockwise) terminals; verify that the damper opened. It
takes 90 seconds for the damper to run a full cycle. If the
damper opened, go to step 3; otherwise, go to step 4.
3. Apply 24 volts across the appropriate common ccw
(counterclockwise) terminals; verify that the damper closed.
If the damper opened, this procedure is completed; otherwise, go to step 4.
4. If the damper did not function properly, check that
the damper blade is not obstructed. If the damper blade can
move freely, replace the ML6161.
Checkout the AOBD Damper as follows:
1. Disconnect the devices from the W180A Controller.
2. Apply 24 Vac between Terminals 1 and 4 for 15 seconds and then remove the 24 Vac.
3. Apply 24 Vac between Terminals 1 and 6 for 15 seconds and then remove the 24 Vac.
4. Verify that the damper is fully closed (Fig. 52).
5. Reapply 24 Vac between Terminals 1 and 4 for
15 seconds.
6. Verify that the damper is fully open.
7. If the damper did not function properly, check that
the damper blade is not obstructed. If the damper blade can
move freely, replace the damper.
43 68-0139
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W180 ZONE CONTROL SYSTEM
Fig. 52—Determining damper position.
HONEYWELL/TROL-A-TEMP AOBD
THE DAMPER IS OPEN WHEN THE CRANK ARM
POINTS TOWARD THE DAMPER.
1
SET SCREWS (2)
D635
ALLOW MINIMUM
5 1/2 in. [14 cm]
CLEARANCE FOR
ACTUATOR REMOVAL
®
THE DAMPER IS CLOSED WHEN THE CRANK ARM
POINTS AWAY FROM THE DAMPER.
1
2
CW
CCW
AIR FLOW
1
REMOVE ACTUATOR COVER TO VIEW CRANK ARM POSITION.
2
DAMPER IS FULLY OPEN WHEN SET SCREWS ARE IN CW POSITION.
3
DAMPER IS FULLY CLOSED WHEN SET SCREWS ARE IN CCW POSITION.
3
SLOT
M7113A
68-0139 44
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W180 ZONE CONTROL SYSTEM
W180 SYSTEM CHECKOUT USING A
TOUCHPAD
Check out the W180 System using a Touchpad as
follows:
Heating
1. Set Mode to Heat for the HVAC system being checked.
2. Set all zone setpoints except one to 10 degrees F
[6 degrees C] below the zone temperature.
3. Set the zone setpoint from step 2 to 10 degrees F
[6 degrees C] above the zone temperature.
— The furnace should start after the expiration of
the switchover time or minimum off time.
— The fan should start after a short delay.
— Visually verify that the damper(s) or valve(s)
for the selected zone opens fully.
4. Set one of the remaining zone setpoints to 10 de-
grees F [6 degrees C] above the zone temperature.
— The zone damper should open.
5. Set the same zone setpoint to 10 degrees F [6 de-
grees C] below the zone temperature.
— The zone damper should close.
NOTE: Depending on the minimum airflow re-
quirements, the damper may not fully close.
6. Repeat steps 4 and 5 for all remaining zones.
7. Set the setpoint for the first zone worked on to 10 de-
grees F [6 degrees C] below the zone temperature.
— The furnace should stop immediately.
— The fan should stop after a short delay.
8. Return to the correct profile and mode setting.
Cooling
CAUTION
Do not operate cooling equipment when the out-
door air temperature is below 50° F [10° C]. See
the manufacturer’s recommendations.
1. Set Mode to Cool.
2. Set all zone setpoints except one to 10 degrees F
[6 degrees C] above the zone temperature.
3. Set the zone setpoint from step 2 to 10 degrees F
[6 degrees C] below the zone temperature.
— The cooling equipment and fan should start fol-
lowing the expiration of the switchover time or
minimum off time.
— Visually verify that the damper(s) for the se-
lected zone open fully.
4. Set one of the remaining zone setpoints to 10 de-
grees F [6 degrees C] below the zone temperature.
— The zone damper should open.
5. Set the same zone setpoint to 10 degrees F [6 de-
grees C] above the zone temperature.
— The zone damper should close.
NOTE: Depending on the minimum airflow re-
quirements, the damper may not fully close.
6. Repeat steps 4 and 5 for all remaining zones.
7. Set the setpoint for the first zone worked on to 10 de-
grees F [6 degrees C] above the zone temperature.
— The cooling equipment and fan should stop
immediately.
8. Return to the correct profile and mode setting.
W180 SYSTEM CHECKOUT USING A PC
Check out the W180 System using a PC as follows:
1. Verify that communication was established between
the PC and the W180A Controller.
2. Verify that the proper configuration was down-
loaded to the W180A Controller and is running.
3. Turn On the fan using the PC and verify that the fan
turned On.
4. Manually open each damper to 100 percent using the
PC. Confirm that each damper opened by feeling the airflow through the duct vent.
5. Manually close each damper (one at a time) using the
PC. Confirm that each damper closed by feeling the absence of or minimal airflow through the duct vent.
Program the System
Refer to the W180 Zone Control System Programmer’s Manual, form 69-0761, to program the W180 System.
45 68-0139
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W180 ZONE CONTROL SYSTEM
Problem Solution
No functions
work.
Problem Solution
No display. 1. Verify there is 12 Vdc between the red and black wires at the S321A Touchpad.
Keys do not
work.
Incorrect
displays/
screens.
Touchpad
does not
respond to
the W180A
1. Verify power is properly connected.
2. Verify the dc power connections and polarity.
3. Observe the LED on the motherboard. During normal operation, the LED flashes once per second.
a. If the LED does not flash, check the power connections.
b. If the LED flashes two times per second, no application has been loaded.
4. Verify all cable connections between the W180A Controller chassis and the wire termination
board.
5. Verify that all relay cards are seated properly.
6. Verify that the relay cards are installed with the components facing to the right.
2. Readjust the contrast setting. See the S321A Touchpad Specification, form 63-0104, for more
information.
3. Replace the S321A Touchpad and reset the system.
1. Verify that the W180A Controller is operating (LED is flashing once per second).
2. Verify the connection and the wiring between the S321A Touchpad and W180A Controller.
3. Replace the S321A Touchpad and reset the system.
1. Verify that the correct application was downloaded into the W180A Controller.
2. Interrupt power to the W180A Controller and the S321A Touchpad. Reconnect the power and wait
two to three minutes for the proper application to be displayed.
1. Turn off power to the W180A Controller.
2. Remove five screws to expose the W180 motherboard.
3. Turn on power to the W180A Controller and monitor the two LEDs located under the relay card
on the right side.
a. If the LEDs do not flash, the EEPROM above the LEDs is inserted incorrectly or the W180A
is not communicating and must be replaced.
b. If the LEDs only flash together at the same time, the W180A is sending data to the Touchpad,
but the Touchpad is not sending data to the W180A. Verify that the H3 and H4 wiring is
correct.
NOTE: If the LEDs flash together most of the time, but occasionally flash out of unison, the
W180A and Touchpad are communicating correctly.
Appendix A: T roubleshooting
TABLE 11—W180A CONTROLLER.
TABLE 12—S321A TOUCHPAD.
TABLE 13—HIGH LIMIT CONTROLLER.
Problem Solution
Heating
equipment not
operational.
68-0139 46
1. Verify the limit controller setpoint does not interface with normal return air temperatures.
2. Make sure the device is mounted in an area of the return air that is not subject to temperature
extremes (for example, attics, garages, and unconditioned crawl spaces).
Page 47
TABLE 14—TEMPERATURE SENSORS.
Problem Solution
Reading
wrong
temperature.
1. Verify that there are no inductive loads nearby.
2. Verify that nothing is covering the sensor.
3. Verify that there is not a heating or cooling source nearby.
4. Verify that all connections are secure.
5. Verify the zoning assignments.
6. If equipped, check the override button.
7. Verify that the W180A Controller is operating (LED is flashing once per second).
8. Verify the wiring between the sensor and the W180A Controller.
9. Replace the sensor.
No
temperature
reading.
1. Verify that the W180A Controller is operating (LED is flashing once per second).
2. Verify that all connections are secure.
3. Verify the wiring between the sensor and the W180A Controller.
4. Replace the sensor.
5. Verify that the sensor input is working by inserting a 3.3K resistor between the input + and –.
This should give a reading of about 43° F (C7130A and T7660A/T7660B) and 71° F (C7180A).
TABLE 15—DAMPERS.
Problem Solution
No airflow when
damper should
be open or airflow when the
damper is closed.
Damper makes
squeaking or
scratching
sounds.
Noisy air flow. Insulate around the duct where the noise is heard.
1. Verify that the damper is open/closed as required.
NOTE: The D635 damper is bidirectional and takes 90 seconds to fully open or close.
AOBD dampers are unidirectional and take 15 seconds to complete a cycle. They must
complete a cycle before another cycle can begin.
2. Verify that 24 Vac is present at the damper.
3. Verify that the damper is wired properly and verify the zone assignment.
4. Verify that the W180A Controller is operating (LED is flashing once per second).
5. Verify that the relay cards are seated properly.
6. Verify that there are no obstructions at the damper.
7. Verify that there is not a hole in the duct.
8. Verify that the actuator operates.
9. Verify that the gear box, crank arm, and/or collar are functional.
10. Replace the damper.
1. Verify that the damper is not out of round or square.
2. Verify that the damper blade is secure in the shaft.
3. Verify that the shaft is in the collar.
4. Verify that there is not water in the drive mechanism.
5. Verify that there is nothing between the damper and duct.
W180 ZONE CONTROL SYSTEM
TABLE 16—VALVES.
Problem Solution
Valve does not
open or close.
1. Verify that the W180A Controller is operating (LED is flashing once per second).
2. Verify that the valve is wired to the correct relay output.
3. Verify that the relay output is configured properly.
4. Verify that the relay cards are seated properly.
5. Verify that there are no obstructions at the valve.
6. Replace the valve.
47 68-0139
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W180 ZONE CONTROL SYSTEM
Appendix B: Worksheets
Two worksheets are available to aid in programming the
W180A Controller:
— HVAC Configuration Form: Used to gather data
regarding individual HVAC Systems. Complete one
HVAC Configuration Form for each HVAC System.
An HVAC System can be any one of the following:
• Furnace, A/C, and Fan supplying conditioned air
by dampers to one or more zones.
• Heat Pump supplying conditioned air by dampers
to one or more zones.
• Boiler/Circulation Pump supplying hot water heat
by valves to one or more zones.
• An electric baseboard heater controlled through a
24 Vac relay.
— Homeowner Lifestyle Worksheet: Used to determine
the schedules for the Profiles based on the preferences of the customer.
HVAC CONFIGURATION FORM
Complete as follows:
1. File Name. Enter a name for this job site (8 characters max). This must be the same for each HVAC System
on a job site.
2. Enter the Customer Name and Customer Address.
This must be the same for each HVAC System on a job site.
3. Enter the HVAC System Name. This can be any
name that best describes the HVAC System. (System #1,
Lower Level, West Wing, etc.)
4. Enter the HVAC System Description (1 Stage Cool,
2 Stage Heat Pump, Furnace with 2-Stage A/C, Radiant
Heating, etc.)
5. For each piece of equipment, enter the:
a. Name. This can be any name that best describes
the equipment.
b. Type. This describes the equipment function
(Fan, Furnace, Elec Heat, A/C Unit, Heat Pump
[Compressor], Reversing Valve, Circ Pump,
Other).
c. Used For. This specifies the actual condition in
which the equipment should be activated.
— Heating: Activates the equipment when the
stage is calling for heat.
— Cooling: Activates the equipment when the
stage is calling for cool.
— Normal: Activates the equipment in connec-
tion with the Heat or Cool selection for normal
operating conditions.
— Alternate Alt Fuel: Activates the equipment
in connection with the Heat or Cool selection
for operation in alternate fuel conditions. An
alternate fuel condition is when the outside
temperature is below (for heat) or above (for
cool) the Outside Temperature for Use of Alt
Equipment setting.
— Overrun: Activates the equipment when the
stage is in the fan Overrun mode.
d. Used for Stages (1, 2, or 3). This specifies the
equipment function for each stage of heating or
cooling.
6. For each stage, enter the Stage attributes:
a. Emergency Heat: If checked, all heating equip-
ment defined in this stage will be used during
manual system override to Emergency Heat mode
in place of the first stage heat pump equipment
in heating.
b. Fan Overrun Time (minutes):
— Heating: The length of time in minutes the fan
defined for this stage is active following a call
for heating. Min: 2; Max: 30; Default: 2.
— Cooling: The length of time in minutes the fan
defined for this stage is active following a call
for cooling. Min: 2; Max: 30; Default: 2.
c. Minimum Off Time (minutes):
— Heating: The length of time in minutes that
must expire following a call for heating before
another call may begin. Min: 3; Max: 30;
Default: 3.
— Cooling: The length of time in minutes that
must expire following a call for cooling before
another call may begin. Min: 3; Max: 30;
Default: 3.
d. Outdoor Temp for Lockout (°F):
— Heating: The outdoor temperature that, when
exceeded, will lock out calls for heating. Min:
10° F; Max: 99° F; Default: 90° F.
— Cooling: The outdoor temperature that, when
exceeded, will lock out calls for cooling. Min:
10° F; Max: 99° F; Default: 50° F.
e. Outdoor Temp for Alt Fuel Equip:
— Heating: When the actual outdoor temperature
is below this value, any heating equipment set
up during configuration as Alternate—Heat
will be activated in place of the equipment
defined as Normal—Heat. Min: 10° F; Max:
99° F; Default: 40° F.
— Cooling: When the actual outdoor temperature
is above this value, any cooling equipment set
up during configuration as Alternate—Cool
will be activated in place of the equipment
defined as Normal—Cool. Min: 10° F; Max:
99° F; Default: 90° F.
f. Differential (∆° F offset from 1st Stg):
— Heating: The number of degrees below setpoint
the average zone demand must exceed before
this stage is activated.
Stage 1: Min: 0° F; Max: 20° F; Default: 0° F.
Stage 2: Min: Stage 1 + 1° F; Max: 20° F;
Default: 4° F.
Stage 3: Min: Stage 2 + 1° F; Max: 20° F:
Default: 6° F.
— Cooling: The number of degrees above setpoint
the average zone demand must exceed before
this stage is activated.
68-0139 48
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W180 ZONE CONTROL SYSTEM
Stage 1: Min: 0° F; Max: 20° F; Default: 0° F.
Stage 2: Min: Stage 1 + 1° F; Max: 20° F;
Default: 4° F.
Stage 3: Min: Stage 2 + 1° F; Max: 20° F;
Default: 6° F.
7. For each Zone Controlled on this HVAC System,
enter the:
a. Zone name (14 alphanumeric characters) (Living
Room, Dining Room, Master Bedroom, etc.)
b. Temperature Sensor Used (one per zone) (C7180,
C7130, T7660A, or T7660B).
c. T7660B Override Duration in hours and the heat-
ing and cooling Setpoints (if T7660B sensor is
used).
d. Dampers Used (D635 or AOBD)and Total Area
(sq in.). If more then one damper is used per zone,
sum the damper area for each and enter the total.
e. Valves Used (NO or NC).
f. Priority Zone check mark. This will cause the
system to prioritize this zone when deciding how
to satisfy simultaneous demands for heating and
cooling.
8. Enter the Changeover time. This is the minimum
length of time between system mode changes. Min: 10 min;
Max: 100 min; Default: 10 min.
9. Enter the Minimum Aggregate Damper Opening:
a. Heating: Minimum aggregate damper open area
will never be lower than this setting in the heating
mode. Dampers to zones not calling for heat will
modulate partially open when the system demand
alone does not provide adequate open damper
area. Min: 35; Max: 100; Default: 35 (75 to 85%
max cfm).
b. Cooling: Minimum aggregate damper open area
will never be lower than this setting in the cooling
mode. Dampers to zones not calling for cooling
will modulate partially open when the system
demand alone does not provide adequate open
damper area. Min: 25; Max: 100; Default: 25 (65
to 75% max cfm).
10. Enter the Anticipation Settings:
a. Heating: For heating equipment. A value greater
than 1 increases the equipment cycle rate; a value
less than 1 decreases the equipment cycle rate.
Min: 0.0; Max: 1.5; Default: 1.0. Recommended
values:
— Electric: 1.5.
— Forced Air: 1.2.
— Heat Pump: 1.0.
— Hydronic/Radiant: 0.8.
b. Cooling: For cooling equipment. A value greater
than 1 increases the equipment cycle rate; a value
less than 1 decreases the equipment cycle rate.
Min: 0.0; Max: 1.5; Default: 1.0. Recommended
values:
— Cooling Compressor: 1.0.
HOMEOWNER LIFESTYLE WORKSHEET
Prior to filling out this form, verify that for each of the
HVAC Systems there are adequate relay outputs and sensor
inputs to satisfy the requirements. If not, reduce the number
of zones.
Complete this form as follows:
1. Explain to the homeowner that you need to know the
normal sequence of events in the house for each day of the
week so that you can determine what the various Profiles
are. Explain that a Profile is a part of the schedule entered
into the W180A Controller that controls selected equipment in user-selected zones and times.
2. Determine what zones are required and enter the
Zone Names (14 alphanumeric characters maximum) on
the form.
3. Enter the profile information beginning with Sunday.
Determine what happens first (Profile Name—14 alphanumeric characters maximum), what time the event happens (Start Time), Days (day of the week) which rooms
(Zones) are involved, and the heating and cooling setpoints
(entered under the appropriate zone). For example, the
parents get up at 7:00 AM and use the master bedroom,
master bathroom, and kitchen. On the form you would
enter Parents Awake (Profile Name); 6:50 AM (Start Time);
S (Days); 72H, 70C (setpoints under the zones for the
master bedroom, master bathroom, and kitchen).
4. Ask what event happens next. Determine what time
it happens, which rooms (zones) are used, and the heating
and cooling setpoints. Enter the information as required.
5. Enter the required information for each event that
happens during the day.
6. Repeat steps 3 through 5 for each day of the week.
NOTE: Some profiles can be used on multiple days in those
cases, indicate the days that the profile is used.
49 68-0139
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W180 ZONE CONTROL SYSTEM
68-0139 50
Page 51
*
W180 Zone Control System
Preferred Temperature Setpoints
Occupied—Heating Unoccupied—Heating
Occupied—Cooling Unoccupied—Cooling
W180 ZONE CONTROL SYSTEM
Form 71-9303 9/93
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Zone 7 Zone 8 Zone 9 Zone 10
Profile Start Days
Homeowner Lifestyle Worksheet
Directions:
1. Provide Zone Names (up to 10), Profile Names (up to 20), and Start Times.
2. Indicate the desired heating and cooling setpoints.
3. Identify with a √ which zones are occupied for each profile.
No. Name Time
2
3
4
5
6
1
7
51 68-0139
7:00 AM Sat., Sun. √√69/74* √
8
9
10
1 Wake 5:30 AM M-F Living Room Kitchen/Dining Den Master Bath Master Bath Kid’s Room Guest Room Study Rec Room
Example:
*Setpoints can be different than “preferred setpoints;” see example.
Page 52
W180 ZONE CONTROL SYSTEM
Appendix C: HVAC System Basics
AIRFLOW CHARACTERISTICS
Air, when enclosed, pushes equally against all sides of a
container. When an opening is provided in the container, air
flows out of the container until the pressure inside and
outside are equal. Air always flows from regions of higher
pressure to regions of lower pressure. The greater the
pressure differential, the faster the air flows.
In HVAC system design, the ratio of airflow pressure to
total pressure is controlled to ensure that each room receives the right amount of air flow to supply the heating or
cooling requirements. Total pressure has two components:
static pressure and velocity pressure.
Static pressure is the pressure exerted by air against the
sides of a container (in this case the duct). Static pressure is
measured as the difference between duct pressure and
atmospheric pressure, and can be positive or negative. In a
forced-air heating/cooling system, static pressure is supplied by the blower. It is positive on the supply side and
negative on the return side.
When the container has an outlet so that air flows, part
of the static pressure is transformed into velocity pressure, which is the pressure exerted by the air in the direction
of the airflow. Like static pressure, velocity pressure is
measured as the difference between duct pressure and
atmospheric pressure, but can only be positive. Velocity
pressure correlates directly with air speed.
At any given point in the duct, static pressure and
velocity pressure always equal total pressure. So if static
pressure increases and total pressure remains the same,
velocity pressure drops.
Total pressure is greatest at the face of the blower. As air
moves through the duct system, total pressure drops. It is
neutral once the air leaves the outlet and mixes with the
room air, but negative in the return air ducts. Pressure is lost
because of friction, leakage and turbulence. Friction is
caused by moving air rubbing against the sides of the duct.
Friction losses must be known to determine the blower
capacity required to provide adequate air flow to each zone.
Leakage should be minimal in a well-constructed duct
system. Turbulence is increased whenever the duct
changes size or direction; thus such changes should be
kept to a minimum and should be gradual.
Some factors that affect air flow and pressure in an
HVAC system are:
• Duct size. As the duct size increases, static pressure
increases and velocity pressure decreases.
• Transitions, angles, and rough surfaced ducts. These
all cause greater friction losses than straight, smooth
ducts and thus cause pressure loss. To simplify
calculations, these friction losses are measured as
equivalent lengths of straight, smooth ducts.
• Fan characteristics. Blade efficiency, fan speed, and
fan horsepower all affect the amount of pressure that
can be supported.
• Dampers. When a damper with seals closes, the total
pressure downstream matches the atmospheric pressure and the total pressure in the rest of the system
increases. Manual dampers in each takeoff duct are
adjusted after the system is installed to equalize the
air distribution.
• Register or grille design. To the extent that the grille
or register offers resistance to air flow, it adds to
pressure drop. The primary considerations when
choosing registers are throw—how far will the airstream move into the room before it dissipates; and
spread—how much the airstream will fan out immediately after leaving the register.
ZONING
Purpose of Zoning
Zoning is a way of ensuring that each area of a home or
building receives the right amount of heating or cooling.
Zoning allows the occupant to independently control the
temperature in each area of the home or building. If desired,
all areas can be kept at the same temperature or each area
can be adjusted for occupancy patterns and uses.
Zoning is particularly useful where normal heat distribution patterns result in uneven temperature control. For
example, a building that is partly below grade can use
zoning to eliminate uneven temperature control between
the basement and the rest of the building. Large or sprawling buildings that might have long, unequal length duct
runs can use zoning to equalize the delivery of conditioned
air. Buildings with many large windows can use zoning to
compensate for solar heat gain and radiation losses at night.
Zoning can add to comfort and possibly energy savings
by keeping various zones at different temperatures. Temperature settings can be scheduled to fine-tune a zoned
system to match usage patterns.
Zone Selection
Location, heat gain (loss), usage, and size are the primary considerations in defining zones. Rooms in a zone
should be in the same area of the building. Also, they
should have similar uses and occupancy patterns. Rooms
that are subjected to heavy heat loads or heat loss because
of large windows, exposure to prevailing winds, or other
reasons should be zoned separately.
DUCT SYSTEMS
The basic duct system types are:
• Loop perimeter.
• Radial perimeter.
• Extended plenum.
Generally, systems with low outlets on outside walls are
more suited to locations where heating is a primary concern, and systems with high outlets on either outside or
inside walls are better choices where cooling is a primary
concern.
Loop Perimeter System
Zoning is not recommended for loop perimeter systems.
68-0139 52
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W180 ZONE CONTROL SYSTEM
Radial Perimeter System
The radial perimeter system (Fig. 53) is also often used
in single story slab construction. In areas where heating is
of primary importance, ducts can be below the flow with
low wall outlets. In areas where cooling is a primary
concern, the heating/cooling equipment and ducts can be
located in the attic with high sidewall outlets. The system is
best used where the heating/cooling equipment is centrally
located and all the runs can be about the same length.
Because extra headroom is required where ducts must cross
floor joists, this system is not as popular for basement
applications.
Fig. 53—Radial perimeter system.
M2286A
SYSTEM SIZING FOR FORCED
AIR APPLICATIONS
The key to providing even, comfortable environmental
control in any system, but especially in a zoned system, is
choosing the best combination of duct size, mechanical
equipment size, and fan size and type for the application.
The necessary steps are summarized below and explained
in greater detail in books on comfort conditioning system
design such as the Air Conditioning Contractors of America
Manual D, “Duct Design for Residential Winter and Summer Air Conditioning and Equipment Selection.”
NOTE: Never undersize the ducts. Oversize to the next
damper size.
1. Calculate the sensible winter heat loss and the sum-
mer heat gain, both sensible and latent, for each room.
2. Add the loads for each room to obtain the total
system design load. In a zoned system, also add loads for
each zone.
3. Calculate the design cfm for each room, each zone
when the system is zoned, and for the system.
4. Choose heating and cooling equipment that meets
the design load. Depending on the zone layout and anticipated occupancy patterns, it may be possible to select
slightly smaller equipment for a zoned system. Make sure
that the blower cfm is in the range of the design cfm.
5. Locate enough supply outlets in each room to cover
the design heat loss/cooling gain and sketch the duct layout. Avoid angles and abrupt changes in duct size where
possible.
6. Size the zone takeoff, branch ducts, and trunk to
provide the required cfm to each room, remembering that
velocity should not exceed 700 cfm in the main trunk and
600 cfm in each supply and that every run should have
the same pressure loss.
7. Locate the return inlets; sketch the return runs; and
repeat step 6 for the return system.
8. Choose outlet registers and inlet grilles to provide
the desired air distribution pattern.
9. Include a return for every room; include two returns
for rooms with three or more supplies.
DAMPER SELECTION
If at all possible, install dampers where they are accessible for service. Models are available for side or bottom
insertion into existing rectangular ducts, for internal mounting as the ductwork is assembled, and for use with round
ducts. The dampers can be mounted in any position, except
side and internal mount models used in horizontal ducts
must be mounted with the actuator toward the top of the
duct to reduce operating friction and minimize dirt accumulation on the linkage.
Rectangular dampers are sized smaller to fit in the ductwork. Choose a damper the same nominal size as the duct.
Round dampers are sized slightly smaller than the duct air
inlet and slightly larger on the air outlet so they will slip in
easily and be less likely to bind. Never force a damper into
an undersized duct because the resulting pressure will
cause the blades to bind. When necessary, install two
rectangular dampers back-to-back; this application requires
U-channel mounting tracks, available from Honeywell, to
keep the damper stable under conditions of high velocity air
flow. Mounting tracks are also required with rectangular
dampers over 20 x 8 in. [508 x 203 mm], 18 x 10 in. [457 x
254 mm], and 16 x 12 in. [406 x 305 mm] unless they can
be secured from both sides of the duct.
When an internally mounted motorized damper is
used, install it just upstream from a register, or install the
damper just ahead of a right angle to allow access for motor
service.
Motorized dampers are usually installed close to the
heating and cooling equipment. They can be installed in a
divided plenum on a two-zone system; they must be
downstream from the manual balancing dampers.
For humidification, use evaporative type or return air
type humidifiers. Do not use spray or atomization type
humidifiers installed in the furnace plenum or air supply
duct.
SYSTEM SIZING FOR HYDRONIC/RADIANT
HEATING APPLICATIONS
The key to providing even, comfortable environmental
control in any system is choosing the best system type,
valves, and other components for the application. The necessary steps are summarized below.
1. Size the piping for adequate water flow.
2. Size the system for adequate head pressure.
3. Determine the maximum valve operating temperature. The maximum operating temperature for motorized
valves depends on the maximum ambient temperature at
the valve location, and on the maximum fluid temperature.
53 68-0139
Page 54
W180 ZONE CONTROL SYSTEM
Using the graph in Fig. 5, find the maximum valve operating temperature as follows (to find maximum ambient
temperature for a valve when fluid temperature is known,
reverse this procedure):
a. Measure ambient temperature at the valve and
locate this temperature on the ambient temperature scale on the graph.
b. Draw a line from this ambient temperature, paral-
lel with the fluid temperature scale, to the maximum fluid temperature line.
c. Draw a line from this point down to the fluid
temperature scale to find maximum operating
temperature. (Note the example, shown by the
dashed line, in Fig. 54.)
4. Size the expansion tank.
5. Determine the elbow equivalents.
6. Determine the pipe flow resistances.
7. Determine the valve pressure drop. The pressure
drop in psi [kPa], equivalent feet [meters] of pipe, or feet of
water [kPa] can be calculated from Figs. 55 through 60 as
follows:
a. Calculate the flow rate needed to heat the zone.
b. Determine the Cv [kV] rating of the motorized
valve.
c. Select the graph corresponding to the Cv [kV]
rating (Figs. 55 through 60).
d. Determine pressure drop across valve using pro-
cedure 1), 2), or 3).
1) Pressure drop in psi [kPa].
a) Locate the flow rate at the bottom of graph.
b) Draw a line upward from the flow rate to the
intersection of the curve.
c) Draw a line from the curve intersection to
the left edge of the graph to determine
pressure drop in psi [kPa].
2) Pressure drop in equivalent ft [m] of pipe.
NOTE: Both 1/2 and 3/4 in. pipe conversion
scales are available for this determination.
a) Locate the flow rate at the bottom of graph.
b) Draw a line vertically to top of the graph.
Determine pressure drop for either 1/2 or 3/4
in. pipe.
3) Pressure drop in ft of water [kPa].
a) Locate the flow rate at the bottom of graph.
b) Draw a line upward from the flow rate to the
intersection of the curve.
c) Draw a line from the curve intersection to
the right edge of the graph to determine
pressure drop in ft of water [kPa].
8. Determine the friction head for the system.
9. Size the pump or circulator.
10. Determine the piping arrangement (one-pipe, two-
pipe, direct return, or two-pipe reverse return).
11. Determine the type of air removal vent to be used.
12. Determine if a pressure relief valve should be used.
VALVE SELECTION
Use Table 8 to choose the correct valve for the application based on the Cv rating determined during system
sizing.
Fig. 54—Maximum temperature characteristics of valves with Class F motors.
210
[99]
200
[93]
190
[88]
180
[82]
170
[77]
160
[71]
150
[66]
140
[60]
AMBIENT TEMPERATURE
130
[54]
120
[49]
110
[43]
100
[38]
90
[32]
80
[27]
DEGREES F
DEGREES C
MAXIMUM AMBIENT
TEMPERATURE LINE
70
80
[21]
[27]
EXAMPLE: 150O F [66O C] IS THE AMBIENT TEMPERATURE AT THE VALVE,
O
F [113O C] IS MAXIMUM FLUID TEMPERATURE.
235
140
130
[60]
[54]
FLUID TEMPERATURE
150
[66]
160
[71]
170
[77]
[32]
90
100
[38]
110
[43]
120
[49]
180
[82]
190
[88]
200
[93]
210
[99]
220
[104]
MAXIMUM FLUID
TEMPERATURE
LINE
230
[110]
[116]
240
250
[121]
M8164
68-0139 54
Page 55
W180 ZONE CONTROL SYSTEM
Fig. 55—Flow characteristics of 1 Cv [0.86 kV]
valve.
PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE]
100
90
[30]
[27]
30 [207]
20 [138]
10 [69]
9 [62]
8 [55]
7 [48]
6 [41]
5 [34]
4 [28]
3 [21]
PRESSURE DROP psi [kPa]
2 [14]
1 [7]
0
120
[37]
2
[0.13]
140
[43]
1CV
[0.86 KV]
6
4
[0.38]8[0.5]
[0.25]
GAL/MIN [l/s] FLOW RATE
500
600
[152]
[183]
10
[0.63]12[0.76]
700
[213]
(3/4 IN. PIPE)(1/2 IN. PIPE)
750
[229 ]
-50 [149]
-40 [119]
-30 [89.5]
-20 [60]
-10 [30]
-5 [15]
Fig. 57—Flow characteristics of 3.5 Cv [3.0 kV]
valve.
PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE]
(3/4 IN. PIPE)
9.0
[2.7]
10
8.0
[3]
[2.4]
50.0 [345]
10.0 [69]
5.0 [34]
1.0 [7]
0.50 [3.4]
PRESSURE DROP psi. [kPa]
FT. OF WATER psi [kPa] PRESSURE DROP
M9183A
0.10 [0.69]
0.05 [0.34]
0
0
45
[13.7]
12
11
[3.6]
[3.4]
2
[0.13]4[0.25]
GAL/MIN [l/s] FLOW RATE
60
[18]
12.5
[3.8]
[0.38]
65
[20]
13
[4]
3.5CV
[3.0 KV]
8
6
[0.5]10[0.63]12[0.76]
70
[21.3]
(1/2 IN. PIPE)
14
[0.88]
80
[24.3]
-50 [149]
-40 [119]
-30 [89.5]
-20 [60]
-10 [30]
-5 [15]
-1 [3]
-0.5 [1.5]
-0.1 [0.3]
PRESSURE DROP FT. OF WATER psi. [kPa]
-0.05 [0.15]
M5979B
Fig. 56—Flow characteristics of V4043A
model with 2.5 Cv [2.1 kV] rating and V4044A
bypass port (B) with 2.5 Cv [2.1 kV] (reduced)
rating.
PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE]
45
[13.7]60[18]
8
[2.4]9[2.7]10[3]
50.0 [345]
10.0 [69]
5.0 [34]
1.0 [7]
.50 [3.4]
PRESSURE DROP psi [kPa]
.10 [0.69]
.05 [0.34]
0
0
[0.13]
2
65
[20]
70
[21.3]
11
[3.4]12[3.5]
4
6
[0.25]
[0.38]8[0.5]
GAL/MIN [l/s] FLOW RATE
12.5
[3.8]
2.5CV
[2.1 KV]
13
[4]
80
[24.4]
(3/4 IN. PIPE)
(1/2 IN. PIPE)
10
[0.63]12[0.76]14[0.88]
Fig. 58—Flow characteristics of 4 Cv [3.4 kV]
valve.
50
[1.5]
50.0 [345]
-50 [149]
-40 [119]
-30 [89.5]
-20 [60]
-10 [30]
-5 [15]
-1 [3]
-0.5 [1.5]
FT. OF WATER psi [kPa] PRESSURE DROP
-0.1 [0.3]
-0.05 [0.15]
M9184A
10.0 [69]
5.0 [34]
1.0 [7]
0.50 [3.4]
PRESSURE DROP psi [kPa]
0.10 [0.69]
0.05 [0.34]
PRESSURE DROP
EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE]
6.0
[1.8]
7.0
[2.1]
0
02
[0.13]
[2.4]
10
8.0
9.0
[3]
[2.7]
4
8
10
6
[0.63]
[0.38]
[0.25]
[0.5]
GAL/MIN [l/s]
30
[9.1]40[12.2]
4CV
[3.4 KV]
12
14
[0.88]
[0.76]
45
50
[13.7]
[15.2]
(3/4 IN. PIPE)(1/2 IN. PIPE)
16
18
[1.1]
[1.0]
[1.3]
FLOW RATE
55
[16.8]
20
22
[1.4]
24
[1.5]
[18]
[1.6]
60
-50 [149]
-40 [119]
-30 [89.5]
-20 [60]
-10 [30]
-5 [15]
-1 [3]
-0.5 [1.5]
-0.1 [0.3]
PRESSURE DROP FT. OF WATER psi [kPa]
-0.05 [0.15]
26
28
30
[1.9]
[1.8]
M5717B
55 68-0139
Page 56
W180 ZONE CONTROL SYSTEM
PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE]
2.0
[0.6]
2.5
[0.8]
1.5
[0.5]
19
[5.8]
17
[5.2]18[5.5]
15
[4.6]16[4.9]
14
[4.3]
10
[3]12[3.7]
13
[4]
8
[2.4]
1
[3.4]
9
[2.7]
7
[2.1]
-50 [149]
-40 [119]
-30 [89.5]
-20 [60]
(3/4 IN. PIPE)
(1/2 IN. PIPE)
50.0 [345]
10.0 [69]
5.0 [34]
1.0 [7]
0.50 [3.4]
0.10 [0.69]
0.05 [0.34]
0.01
0
2
[0.13]
4
[0.25]
6
[0.38]
8
[0.5]
10
[0.63]
12
[0.76]
14
[0.88]
16
[1.0]
18
[1.1]
20
[1.3]
22
[1.4]
24
[1.5]
26
[1.6]
28
[1.8]
30
[1.9]
-0.05 [0.15]
-0.1 [0.3]
-0.5 [1.5]
-1 [3]
-5 [15]
-10 [30]
M9186A
GAL/MIN [l/s] FLOW RATE
FT. OF WATER psi [kPa] PRESSURE DROP
PRESSURE DROP psi [kPa]
8CV
[6.9 KV]
Fig. 59—Flow characteristics of 7 Cv [6.0 kV]
valve.
PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE]
50.0 [345]
10.0 [69]
5.0 [34]
1.0 [7]
0.50 [3.4]
PRESSURE DROP psi [kPa]
0.10 [0.69]
0.05 [0.34]
17
15
13
[4]10[3]
0
0
[4.6]
[0.6]
2.0
[0.13]
[5.8]
[5.2]
4
2
[0.25]
21
23
19
[6.4]
[6]
3.0
3.5
[0.9]
[1]
(1/2 IN. PIPE)
10
6
[0.38]
12
8
[0.63]
[0.76]
[0.5]
GAL/MIN [l/s] FLOW RATE
22
[6.7]23[7]
7CV
[6.0 KV]
14
16
[0.88]
[1.0]
[7.3]25[7.6]
18
20
[1.1]
[1.3]
24
22
[1.4]
[1.5]
24
26
[1.6]
[1.8]
(3/4 IN. PIPE)
28
[1.9]
-50 [149]
-40 [119]
-30 [89.5]
-20 [60]
-10 [30]
-5 [15]
-1 [3]
-.5 [1.5]
-.1 [0.3]
-0.05 [0.15]
30
M9185A
Fig. 60—Flow characteristics of 8 Cv [6.9 kV]
valve.
FT. OF WATER psi [kPa]
Home and Building Control Home and Building Control Helping You Control Your World
Honeywell Inc. Honeywell Limited—Honeywell Limitée
1985 Douglas Drive North 740 Ellesmere Road
Golden Valley, MN 55422 Scarborough, Ontario
68-0139 56
Printed in U.S.A.
M1P 2V9
QUALITY IS KEY
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