Johnson Controls METASYS VAV110, METASYS VAV111, METASYS VAV101, METASYS VAV100, METASYS VAV141 Technical Manual

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Application Specific Controllers Technical Manual 636.3 VAV Controller Section Technical Bulletin Issue Date 0309

Variable Air Volume (VAV) Controller

Introduction Page 5





Description 5

 OEM Applications 8  Standards Compliance *  Coordination of Factory Mounted VAV Systems

8 8

Configuring the Controller 11

 Using HVAC PRO for Windows Configuration Tool 11  Defining a VAV Control Device Object in Metasys Software 13

Installation Procedures 17

 Tools Needed 17  Environmental Information 17  Mounting the Controller 18  Power Line Wiring Transient Noise Precautions 21  I/O and Communication Lines Wiring Transient Noise Precautions 23

* Indicates those sections where changes have occurred since the last printing.

Wiring Details Page 25

 Power Source and Loads 26  Grounding and Isolation 27  I/O and Communication Terminals 29  Power, Zone Bus, and N2 Connections 36  Analog Inputs 36  Binary Inputs 38  Binary Outputs 38  Analog Outputs 38  Zone Bus  Wiring to RLY50/002 Relays

39 39

 Wiring Sensors and Actuators 40

Networking the Controller 45

 N2 Bus Overview 45  Installing the N2 Bus 46  Zone Bus Commu nications 49

Application Examples 51

 Single Duct Applications 51  Dual Duct Applications 63

Downloading/Commissioning 71

 Via Zone Bus 71  Via N2 Bus

 Incremental Valve Actuator Stroke Time  Incremental Damper Actuator Stroke Time  Zone Terminal Setup for Balancing Contractors

* Indicates those sections where changes have occurred since the last printing.

2 VAV Controller—Variable Air Volume (VAV) Controller

72 73 73

Troubleshooting Page 75

 Hardware Installation Inspection 75  Tools Needed for Troubleshooting 75  Installation Checkout 76  Troubleshooting the VAV Controller with HVAC PRO for Windows 81  Troubleshooting the N2 Bus and Networked VAV Controller 82  Zone Bus Troubleshooting -- HVAC PRO for Windows 83

Ordering Information 85

 Johnson Controls Code Numbers 85  Vendor Code Numbers

Specifications *89

* Indicates sections where changes occurred since the last printing.

VAV Controller—Variable Air Volume (VAV) Controller 3

4 VAV Controller—Variable Air Volume (VAV) Controller

12FIntroduction

Description

The Variable Air Volume (VAV) Controller is an electronic device for digital control of single duct, dual duct, fan powered, and supply/exhaust VAV box configurations. See 50HFigure 1. You may use the VAV as a standalone controller or connected to the Metasys network through a Network Control Module (NCM) or Companion system.

When connected to the Metasys Network, the VAV provides all point and control information to the rest of the network. The devices communicate through an N2 Bus.

Each VAV Controller application uses a different sequence of operation, all of which are covered in the HVAC PRO for Windows User’s Manual (FAN 637.5).

VAV Controller—Variable Air Volume (VAV) Controller 5

1 2 3 4 5 6

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

ANALOG INPUTS

COMMON

BINARY INPUT

BINARY COM

BINARY INANALOG INPUTS BINARY OUTPUTS

DSI

Z BUS

TO ZONE STAT

BINARY OUTPUT

1 2 3 4 5 6 7 8

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

1 2 3 4 5 6

COMMON

ANALOG INPUTS

Figure 1: VAV110 (top) and VAV111 (bottom) Controller

6 VAV Controller—Variable Air Volume (VAV) Controller

BINARY INPUTANALOG INPUTS

BINARY COM

BINARY IN

DSI

Z BUS

BINARY OUTPUT

1 2 3 4 5 6

ZONE STAT

BINARY OUTPUTS

ANALOG OUTPUT

1 2

ANA OU

110-111

Table 1: VAV Controller Model Features

Feature VAV100/101

(Discontinued)

Ambient Temperature Rating

Analog Inputs

Binary Inputs

Analog Outputs

Binary Outputs

N2 Bus Zone Bus

24 VAC Power Terminations

I/O Terminations

N2 Terminations

* VAV Controller model feature differences

32 to 122F

(0 to 50C)

RTD temperature elements (1000 ohm nickel, platinum, or silicon)

2k ohm setpoint potentiometers

0 to 10 VDC or 0 to 2 VDC transmitters

4 (4) Dry contacts (1) Momentary push

button from zone sensor for temporary occupancy mode

BI 4 may be used as an accumulator input for frequencies less than 100 Hz.

0/2

0 to 10 VDC

@ 10 mA

8/6

24 VAC Triacs

@ 0.5 amperes

Not Isolated * Isolated Isolated Discrete connections

at controller 8-pin phone jack on

controller 6-pin phone jack at

zone sensor LED Indication * LED Indication * Quick Connects

(Spade Lugs) * Quick Connects

(Spade Lugs) Fixed Screw Terminal

Block *

VAV110/111 VAV140/141

32 to 122F

(0 to 50C)

RTD temperature elements (1000 ohm nickel, platinum, or silicon)

2k ohm setpoint potentiometers

0 to 10 VDC or 0 to 2 VDC transmitters

4 (4) Dry contacts (1) Momentary push

button from zone sensor for temporary occupancy mode

BI 4 may be used as an accumulator input for frequencies less than 100 Hz.

0/2

0 to 10 VDC

@ 10 mA

8/6

24 VAC Triacs

@ 0.5 amperes, or

0.8 amperes if total power is limited

Discrete connections at controller

8-pin phone jack on controller

6-pin phone jack at zone sensor

Removable Screw Terminal Block

Quick Connects (Spade Lugs)

Removable Screw Terminal Block

32 to 122F

(0 to 50C)

RTD temperature elements (1000 ohm nickel, platinum, or silicon)

2k ohm setpoint potentiometers

0 to 10 VDC or 0 to 2 VDC transmitters

4 (4) Dry contacts (1) Momentary push

button from zone sensor for temporary occupancy mode

BI 4 may be used as an accumulator input for frequencies less than 100 Hz.

0/2

0 to 10 VDC

@ 10 mA

8/6

24 VAC Triacs

@ 0.5 amperes, or

0.8 amperes if total power is limited

Discrete connections at controller

8-pin and 6-pin phone jack on controller *

6-pin phone jack at zone sensor

Removable Screw Terminal Block

Fixed Screw Terminal Block *

Removable Screw Terminal Block

VAV Controller—Variable Air Volume (VAV) Controller 7

3F4F5FOEM

Applications

6F7F8FStandards

Compliance

9F10F11FCoordination of

Factory Mounted VAV Systems

When providing VAVs for projects which use Trane or TITUS terminal boxes, consider using the AS-VAVDPTx-1 product (refer to

Building VAVDPT Applications Application Note (LIT-6363042) in the Application Specific Controllers Technical Manual (FAN 636.3). Trane

and TITUS are both Original Equipment Manufacturers (OEMs) who provide VAV terminal boxes for projects. Trane typically provides the damper actuator with their terminal box, and TITUS provides the damper actuator with their QFPC Series Fan Powered Box. The VAVDPT comes in two models, which include a VAV Controller and a DPT-2015 Velocity Pressure Transducer. The DPT is mounted and prewired to the cover of the VAV. Refer to the OEM Reference Manual (FAN 638).

The VAV Controller complies with the following standards:

z FCC Part 15, Subpart J, Class A z IEEE 472, IEEE 518 z IEEE 587 Category A

z UL 916 Listed z VDE 0871 Class B

A factory mounted VAV box control system requires close coordination between a variety of different disciplines. Refer to the OEM Reference Manual (FAN 638) for factory manufacturer’s details. Although the responsibilities may differ per city or region, the following parties are usually involved on the job:

z controls contractor z mechanical contractor z local VAV box manufacturer’s representative z balancing contractor z electrical contractor

Typically, the mechanical contractor is the focal point for coordinating the entire process. The basic responsibilities under the domain of the mechanical contractor are:

1. Purchasing the VAV box system. Most specifications include the OEM mounting fees and enclosures for the control system in the mechanical contractor’s price. Mounting fees vary per box manufacturer but ranges can be found in the OEM Reference Manual (FAN 638).

2. Providing the release schedule for the VAV boxes to the job.

3. Contracting, or working closely with, the balancing contractor to ensure the system is set up per the mechanical prints.

Note: The owner often directly hires the balancing contractor. This

ensures neutrality in dealing with other contractors involved in the project.

8 VAV Controller—Variable Air Volume (VAV) Controller

In conjunction with the mechanical contractor, the controls contractor’s responsibilities include:

1. Coordination of the control system release schedule to the box manufacturer to ensure the mechanical system delivery schedule can be met. Coordination with the local box manufacturer representative is normally required.

2. Coordination with the electrical contractor to ensure the following steps are covered.

z 24 VAC power is provided at each VAV Controller. z N2 Bus wiring is pulled and terminated. z Valve actuator wiring is pulled and terminated. z Zone sensor cables are pulled. The use of phone cable for

terminating zone sensor wiring allows basically anyone to terminate zone sensors in certain locales.

z If desired, the N2 address switches can be set by the electrical

contractor.

3. Initial loading of the HVAC PRO for Windows configuration files is done once the electrical contractor’s functions are completed in preparation for the final system balancing.

4. Training of the balancing contractor to ensure the balancing contractor knows how to use the Zone Terminal (ZT) or HVAC PRO for Windows Commissioning mode so they can perform the final system balancing.

5. Mounting and terminating the cable connections for the zone temperature sensor. Set the N2 address switch if the electrical contractor was not contracted to perform this function.

6. Configuring, downloading, and commissioning the controller.

VAV Controller—Variable Air Volume (VAV) Controller 9

10 VAV Controller—Variable Air Volume Controller

12F13F14FConfiguring the Controller

Using HVAC PRO for Windows Configuration Tool

Use HVAC PRO for Windows to configure the VAV. VAV110/111 and VAV140/141 models require HVAC PRO for Windows. HVAC PRO for Windows also works with the VAV100/101 models. This easy-to-use software tool configures, commissions, and downloads the VAV Controller’s data base.

51HFigure 2 illustrates the HVAC PRO for Windows configuration process.

Refer to the HVAC PRO for Windows User’s Manual (FAN 637.5) for specific information when configuring the VAV Controller.

VAV Controller—Variable Air Volume (VAV) Controller 11

Sta rt HVAC PRO for Wind ows

Sele ct F il e -Ne w

1. Select VAV Applications.

2. Select Single or Dual Duct.

Complete Q/A Session

Complete Configuration Process

1. Fill in job information.

- O p tion - Jo b In fo rma tio n

2. Review and change inputs/outputs.

3. Review and change default parameters.

Save Co nfiguration

1. File - Save As

2. Select device type.

Download Controller

1. Attach MM-CVT101-1 Converter or AS-CBLPRO-2.

2. Select Download - Current Configuration.

Comm ission Controller

1. Attach MM -CVT101-1 Converter or A S-C BLP RO - 2 .

2. Select Commission - Current Configuration.

3. Sele c t Bus ty p e , c o mm. po rt, a n d N 2 a ddre ss (if N2 Bus ).

4. Select OK.

5. View / Adjust parameter values.

3. Enter file name for configuration file.

3. S elec t Bus type, c o mm . p o rt, a n d N 2 address (if N2 Bus).

4. Select OK.

6. Re v ie w contr o ller in fo rma t io n .

7. Exit Co mm is s ioning.

8. If adjustments were made, save changes to controller and to file.

9. Unplug MM-CVT101-1 or AS-CBLPRO-2..

PRO FLO 40

Figure 2: Steps in Configuring a VAV Controller Using

12 VAV Controller—Variable Air Volume Controller

Exit HVAC PRO for Windows

HVAC PRO for Windows

Note: You can load and commission the controller either locally with the

AS-CBLPRO-2 interface at the zone sensor (Figure 15) or from a central location where the N2 has been pulled, controller’s field hardware addressed, and an MM-CVT101-1 interfaced to the laptop.

15F16F17FDefining a VAV

Control Device Object in Metasys Software

Using a Metasys Network system, you need to define a VAV Controller device object by entering data into the Attribute menu as seen on the Operator Workstation.

1. Go to the Network Map.

2. Double-click the system name in which you want to add the new VAV object.

3. Click New in the Item pull-down menu.

4. Click on Type: N2 devices in the Item New dialog box.

VAV - Item New

Type

Accumulator Analog data Analog input Analog output digital Analog output setpoint Binary data Binary input Binary output MS data MS input

Hardware system name:

MS output Control system DL/LR group LC group PID loop Fire Zone L2 devices N2 devices S2 devices Card Reader

CANCEL

Hardware object name:

Copy of (System\Object):

ITEM NEW

Figure 3: Item New Dialog Box

Note: The Hardware System and Hardware Object text fields are not

used for this object type.

5. Click OK to display the Add N2 Device dialog box.

VAV Controller—Variable Air Volume (VAV) Controller 13

Hardware -- Add N2 Device

Device Type

600

DCM

9100

DX91 00

IFC-2020 LCD

VAV

CANC

n2dv

Figure 4: Add N2 Device Dialog Box

6. Highlight VAV.

7. Click OK to display the VAV Definition window (52HFigure 5).

VAV Definition

Item Ed

Towe

it View Action Go To Accessory

r_ I

Floor

Bookmark

Help

System Nam e Ob

ject

Name

Expanded I NC

Graphic Symbol # Ope

Name

rating Instr.

Hardware

NC #5

1 1

Hardware

N2 Trunk Numbe

N2 Device

ll Priorit

Addres

Comm Disabled

Flag

1 0

Auto Dialou

windob

Figure 5: VAV Control Device Object Definition Window

Note that some of the fields in the window are blank and some are already filled in. You must fill in the blank attribute fields of required attributes. An N2 device address from 1 to 255 must also be specified. Attribute fields that are already filled in contain default values that may be accepted or changed.

14 VAV Controller—Variable Air Volume Controller

Table 2 explains the blank attributes. The Operator Workstation User’s Manual (FAN 634) describes the general procedures for entering and

modifying data.

Table 2: Blank VAV Object Attributes

Attribute Description Entry Values . . .

Object Name

Expanded ID

Identifies the object (i.e., ILC). The object name cannot be duplicated in the system.

Further identifies the object (i.e., LC Device 1)

1 to 8 alphanumeric characters

0 to 24 alphanumeric characters (Optional)

8. To save the new VAV object, select Save from the Item pull-down menu. The object is added to the NCM data base.

9. Upload the NCM to make an archive copy of the new object following the instructions in the Operator Workstation User’s Manual (FAN

634), the Advanced User’s Guide tab, the Uploading and Downloading Data Bases chapter, the Uploading from the NCM section.

Modifying and Monitoring the VAV Object

Once you have defined the VAV object, you can modify or monitor its attribute values online using the VAV object Focus window. See the Operator Workstation User’s Manual (FAN 634) for more information on using Focus windows.

VAV Controller—Variable Air Volume (VAV) Controller 15

16 VAV Controller—Variable Air Volume Controller

18F19F20FInstallation Procedures

Instructions for the installation of the VAV Controller and its accessory devices are detailed in this section. The types and numbers of components (sensors and actuators) selected for use with the VAV vary according to application. Analyze the proposed installation for logical places to locate these devices and draw up an inventory based on that study. Information on types of accessory devices available is in the Ordering Information section of this technical bulletin.

Most VAV installation should be coordinated with the VAV box manufacturer for factory mounting. The OEM Reference Manual (FAN 638) describes the steps and pricing to coordinate a factory mount solution.

Tools Needed

21F22F23FEnvironmental

Information

Tools needed for a typical installation include:

 HVAC PRO for Windows currently released software  IBM PC-compatible laptop computer  Windows 3.x or Windows 95  two screwdrivers (1/8 in. and 1/4 in. flat-blade)  AS-CBLPRO-2 (Zone Bus communication tool)  MM-CVT101-0 (N2 Bus communication tool)  AS-ZTU100-1 (Zone Bus interface to application specific controllers)

The installation site of the VAV Controller must meet the following environmental standards.

 The atmosphere must be free of explosive vapors or escaping gases.  The atmosphere must be free of exposure to corrosive chemical or salt

vapors, which might damage electrical equipment.

 The temperature must be maintained between 32 to 122F (0 to 50C)

with the relative humidity (non-condensing) maintained between 10 and 90%.

 The power line must be “clean,” without electrical noise transients that

are often present in industrial environments. Commercial and residential buildings typically have clean power, but may not, depending on the location, nearby equipment, etc. Follow the power line wiring transient noise precautions.

VAV Controller—Variable Air Volume (VAV) Controller 17

24F25F26FMounting the

Controller

Factory Mounting

Typically the most cost effective and highest quality installation of the VAV Controller, EDA-2040 Damper Operator, and DPT-2015 Velocity Pressure Transducer can be accomplished by the box manufacturer. The OEM Reference Manual (FAN 638) describes the relationship, pricing, and process to accomplish factory mounting of the VAV control system at most of the key box manufacturers.

If the job cannot be factory mounted, check with the VAV box manufacturer to determine if a control enclosure for the VAV Controller and Actuator/Velocity Pressure Transducer combination is already available on the VAV box. If there is not an available enclosure, the common packaging for the VAV Controller is an enclosure provided by the contractor or the Johnson Controls EN-EWC10, EN-EWC15, BZ1000, or AS-ENC enclosure. The controller requires a flat mounting surface area to match its dimensions:

 6.5 x 6.4 x 2.2 in./165 x 163 x 56 mm (H x W x D) without enclosure  6.8 x 7.3 x 4.7 in./173 x 185 x 119 mm (H x W x D) with the

AS-ENC100-0 enclosure

 7 x 13 x 6 in./180 x 330 x 150 mm (H x W x D) with the

EN-EWC10-0 and EN-EWC15-0 enclosure

Make sure you allow enough room to install the enclosure and conduit for wiring terminations to the controller. 53HFigure 7 shows a common packaging configuration for the VAV Controller.

18 VAV Controller—Variable Air Volume Controller

+15VDC

24VAC 24VAC

TRACS

COMMON COMMON COMMON

COMMON

Low Voltage Wiring Trough

COMMON

vavpwer

Figure 6: EWC10 Enclosure with VAV Controller

and 50 VA Transformer

Mounting the VAV into a Universal Packaging Module

Field Mounting

The VAV can be directly mounted into an EWC10/15 enclosure. You may also purchase the VAV premounted in a EWC10 enclosure with a 50 VA transformer. Refer to the Application Specific Controllers Technical Manual (FAN 636.3) for instructions on mounting the enclosure to a wall.

To mount the VAV in the EWC10:

1. Orient the VAV so that its terminals face the low voltage wiring trough (Figure 6).

2. Align the three mounting holes in the base of the controller with the holes in the back of the enclosure. On the side with four mounting holes, use the two outside holes for mounting in the EWC. See the Universal Packaging Module Technical Bulletin (FAN 636.3) for a more detailed explanation.

3. Secure the controller with three No. 8 x 1 in. screws. For best results, use a plastite-type thread. A thread-forming or sheet metal thread type may also be used.

Position the controller (or controller’s enclosure) on the mounting surface before installation to ensure the calculated mounting area is correct. You can make precise measurements for distance between controller terminals and sensor/actuator mounting points on the VAV terminal. Confirm electrical power source and conduit requirements prior to mounting.

VAV Controller—Variable Air Volume (VAV) Controller 19

(

)

You can install a VAV Controller into a control panel or an AS-ENC100-0 enclosure.

Do not use this knockout.

Otherwise, controller wil l

be in the way of wiring.

Top / Bottom

VAV Controller

VAV Enclosure

vavencl2

Cover

Side

Figure 7: Installing the VAV Controller in an Enclosure Kit

Mount the VAV in any convenient location using the predrilled mounting holes. The controller must be mounted on a wall or panel where it can be easily wired through the enclosure cover. Mount the VAV vertically for best DPT (differential pressure transmitter) performance. The same instruction applies to remote location packages. Refer to

54HFigure 7 when

installing a VAV Controller.

1. Secure the VAV  inside the enclosure kit , using three screws through the mounting tabs  on the sides of the controller board base.

2. Position the VAV and enclosure so that it rests firmly against the mounting surface.

3. Using a flat-blade screwdriver and pliers, remove the necessary wire passage knockouts .

Note: Do not use knockouts on the opposite sides of enclosure, as you

will not be able to remove the VAV board.

4. Attach the enclosure cover  after installing wiring.

20 VAV Controller—Variable Air Volume Controller

27F28F29FPower Line

Wiring Transient Noise Precautions

Surge Levels

The standard VAV Controller, when powered by any typical separate isolation transformer or step-down transformer, operates reliably in an electrical environment defined as Location Category A by the IEEE 587 Standard, that is, when installed more than 30 feet/9 meters from electrical distribution panels or major bus and feeder systems in industrial plants.

IEEE 587 Location Category A power line surge/noise level is specified at 6 kV, 500A (Normal Mode Ringwave).

In addition, the VAV Controller actually exceeds this category specification by meeting these surge levels as well:

IEEE-587 style Common Mode Pulse: 1.5 kV, 3 kA IEEE-587 style Normal Mode Pulse: 3 kV, 3 kA IEEE-472 style Common Mode Ringwave: 1.5 kV IEEE-472 style Normal Mode Ringwave: 500V You must take further precautions to prevent unwanted Binary Output

cycling or other possible controller malfunctions, such as resetting, when the controller is installed within 30 feet/9 meters of electrical distribution panels or major bus and feeder systems in industrial plants. This electrical environment is defined as Location Category B by the IEEE 587 Standard.

To prevent electrical noise from adversely affecting the controller:

1. Connect an MOV (Metal Oxide Varistor) across the VAV supply transformer primary. The MOV must be rated appropriately for the line voltage.

2. Use the list in Table 3 to select the correct MOV sold through your electronics parts distributor.

The VAV Controller meets the following power line surge/noise standards when you correctly apply the MOV as described.

IEEE-577 Common Mode Pulse 1.5 kV, 3 kA Normal Mode Pulse 6 kV, 3 kA Normal Mode Ringwave 6 kV, 500A IEEE-472 Common Mode Ringwave 1.5 kV Normal Mode Ringwave 500V

VAV Controller—Variable Air Volume (VAV) Controller 21

Table 3: MOV Selection

Power Transformer Primary Voltage

Minimum Continuous Voltage Rating

Minimum Energy Rating Minimum Peak Current

(8 x 20 second pulse) UL Recognized Harris

Iskra

Malda

Mallory

Marcon

Oneida (CKE)

Panasonic

Phillips Siemens

Stetron

Thomson

* Indicates the preferred model if several are listed.

120 VAC 208 to 240 VAC 277 VAC 347 VAC

130 to 135 VRMS 250 to 280 VRMS

Only 250V types listed 30 Joules 55 Joules 80 Joules 85 Joules 4,000 Amperes 4,000 Amperes 4,000 Amperes 4,000 Amperes

Required Required Required Required V130LA10A

V130LA20A* V130LA20B* V130K14 V130K20* D6321ZOV131RA15* D6521ZOV131RA20* D6921ZOV131RA09 VSAC14DK201U VSAC20DK201U* TNR15G211KM TNR23G201KM* TNR23G211KM* OZ130LA10A OZ130LA20A* OZ130LA20B* OZ21L221 0216NR14-3 0216NR20-4* ERZ-C14DK201U ERZ-C20DK201U* 2322-595-51316 2322-595-52516 2322-595-53016 2322-595-53816

S14K130 S20K130* 0216NR14-3 0216NR20-4* 0216NR20DB*

VE17M00131K VD24M00131K

V250LA20A

V250LA40A*

V250LA40B*

V250K14

V250K20*

D6321ZOV251RA90*

D6521ZOV251RA130*

D6921ZOV251RA72

VSAC14DK391U

VSAC20DK391U*

TNR15G391KM

TNR23G391JM*

TNR23G391KM*

OZ250LA20A

OZ250LA40A*

OZ250LA40B*

ERZ-C14DK391U

ERZ-C20DK391U*

S14K250

S20K250*

0390NR14-3

0390NR20-4*

0416NR14-3

0416NR20-4*

VE17M00251K

VD24M00251K

300 to 320 VRMS 385 VRMS

None None

V300K14 V300K20* D6321ZOV301RA105* D6521ZOV301RA150* D6921ZOV301RA80 VSAC14DK471U VSAC20DK471U* TNR15G471K TNR23G471K*

OZ21L471 None

ERZ-C14DK471U ERZ-C20DK471U*

S14K300 S20K300* 0620NR14-3 0620NR20-4*

VE17M00301K VD24M00301K

V385K14 V385K20* None

VSAC14DK621U VSAC20DK621U* None

ERZ-C14DK621U ERZ-C20DK621U*

S14K385 S20K385* 0620NR14-3 0620NR20-4*

None

22 VAV Controller—Variable Air Volume Controller

I/O and Communication Lines Wiring Transient Noise Precautions

The I/O wiring and N2 Bus must be clean, without electrical noise transients from nearby lightning, heavy equipment switching, or inductive loads being driven.

For the N2 Bus, the Transient Eliminator, model TE/JC04C12, made by Advanced Protection Technologies (APT) is recommended. Refer to the

Metasys Network Technical Manual (FAN 636), the N2 Communications Bus Technical Bulletin (LIT-636018) for more information.

VAV Controller—Variable Air Volume (VAV) Controller 23

24 VAV Controller—Variable Air Volume Controller

30F31F32FWiring Details

Take special precautions and follow certain grounding procedures when installing the VAV Controller.

CAUTION: Possible Equipment Damage or Electrical Shock.

To avoid damaging equipment or possible electrical shock, ensure that all power supplies to the system have been disconnected prior to wiring installation. The CMOS (Complimentary Metal Oxide Semiconductor) circuits used in the controller are static sensitive. Use static protection (anti-static mats and/or grounding straps) when working on or near internal circuitry.

Follow these precautions:

z Make all wiring connections in accordance with the National Electrical

Code (NEC) as well as within local regulations.

z Locate equipment and route the wiring so that signal wiring is twisted

pair, and separated from power wiring to the maximum extent possible. To establish tight, reliable electrical connections, use the correct wire sizes for the terminals.

z Make all wiring connections to the VAV Controller using only copper

conductors.

z The N2 must be daisy-chained. The use of Y or T connections without a

repeater installed in the T tap may cause loss of communications.

z Do not run N2 Bus, Zone Bus, Analog Input (AI), Binary Input (BI), or

Binary Output (BO) wiring in the same conduit as line voltage wiring (above 30 VAC), or with wiring that switches power to highly inductive loads such as contactors, coils, motors, or generators.

z Do not run non-shielded N2 Bus wiring in the same conduit or bundle as

24 VAC power wiring.

z You may run Zone Bus, Analog Input, Analog Output, and Binary Input

wiring in the same bundle or conduit where convenient. If the Binary Output wiring is not wired through other switches or contacts, you may also bundle it with the other I/O wiring where convenient.

VAV Controller—Variable Air Volume (VAV) Controller 25

Power Source and Loads

Use a separate isolation transformer or step-down transformer for each VAV Controller. Refer to Standards Compliance in the Introduction section of this technical bulletin. The power transformer used must comply with:

z CSA 22.2 No. 205 z NEMA ICS 2, Part 2, 230

Limit the power to each VAV to 3 amperes or less. However, if you use one low voltage power trunk to power multiple controllers, follow these precautions:

z Ensure polarity is maintained at each 24 VAC connection. z As per NEC code, you must enclose 24 VAC power trunks with

greater than 4 amperes (100 VA) in conduit. Note: See NEC Article 725/Class 2 (30 VRMS Max) and (100 VA Max). Any individual binary output (triac) can drive up to 800 mA when you

limit the total 24 VAC power draw. You must limit the power draw of a controller and its load to avoid heat dissipation problems. You must limit the total 24 VAC power draw of a VAV Controller installed in an enclosure to a maximum of 40 VA. You must limit the total 24 VAC power draw of a VAV Controller mounted in an open air environment to a maximum of 75 VA.

When you determine the system load, consider all the actual loads as well as the basic load of the controller. The following tables assist you in determining the total 24 VAC power draw of your system.

Table 4: VAV Power and Load Specifications

System Loads Power Draw

VAV Controller with sensors/transmitters 10 VA (400 mA) BO Load Relay, Contactor, Solenoid, Incremental Actuator* Maximum allowable load for any individual binary output

(triac) is 19 VA** (800 mA at 24 VAC) Minimum required load for each binary output (triac)

used is 1.2 VA (50 mA at 24 VAC) Note: Relay loads less than 50 mA may cause

triac/relay chattering. If necessary, use a

1000 ohm 2W resistor across the binary output. AO Load Actuator Maximum allowable load for each AO is 10 mA with a

minimum load resistance of 1000 ohm. Zone Terminal or CBLPRO 1.2 VA (50 mA)

*Actuator VA requirements are found in Table 5. **With total controller power draw limited as described previously.

Refer to specific product documentation.

Refer to Table 5.

26 VAV Controller—Variable Air Volume Controller

Table 5: Actuator VA Requirements

Actuator Type VA Requirements

for 24 VAC Supply

EDA-2040 (ATP-2040) VA-7150 VA-7200 VA-8020 VA-8050 J Series Electric Zone Valve M9100-A, M9200-A M9100-G, M9200-G VA-7152 VA-7202 VA-8022 VA-8052

Incremental 3 VA Incremental 2.7 VA Incremental 5.5 VA Incremental 4 VA Incremental 6 VA On-Off 7 VA Floating 6.5 VA Proportional (Voltage or Current) 6.5 VA Voltage (0 to 10 VDC) 4.7 VA Voltage (0 to 10 VDC) 7.5 VA Voltage (0 to 10 VDC) 4 VA Voltage (0 to 10 VDC) 6 VA

33F34F35FGrounding and

Isolation

VAV100/101

On unit mounted controls, OEMs typically minimize wiring between digital controls and equipment interface relays by using one leg of the stepdown transformer as common.

Isola tio n

Transformer

ower

Transformer

24/24

ZBUS

AREF

24VAC

24VAC 24VAC

24VAC 24VAC 24VAC

+15VDC

N2+

N2-

See the below Figure 9

Load

CAUTION

Contactor

+15VDC

ZBUS AREF

N2+

N2-

Isola tio n

Relay

VAV100 / 101

Figure 8: Transformer and Relay Isolation Wiring Diagram for Series

100/101 VAV Controllers

visoxfmr

VAV Controller—Variable Air Volume (VAV) Controller 27

All VAV100/101 connections must be isolated from earth ground to protect the CBLPRO, laptop PC, or other system components from damage. Due to OEM system designs and/or electrical codes, the VAV may become earth grounded unless you take isolation measures. Typically, the VAV box manufacturer supplies a step-down isolation transformer as part of their mounting service.

CAUTION: Potential Equipment Damage and Improper

Functioning. Do not earth ground the 24 VAC high side of the VAV’s transformer or any of the VAV’s BO terminals. If you do, the VAV’s N2 Bus communications will cycle online and offline. You will also damage all of the interface components that are connected, including the CBLPRO, laptop PC, Companion PC, and MM-CVT101.

Depending on the primary voltage of the power transformer and the prevailing electrical code, the 24 VAC secondary might be earth grounded. Earth ground on one side of the secondary destroys hardware by creating a short circuit path through the CBLPRO and laptop PC serial card during a download. Earth ground on either side of the secondary can disrupt the isolation required for N2 communication integrity.

N2 Bus Isolation VAV 100/101

Power Transformer Isolation VAV100/101

Load Isolation VAV100/101

36F37F38FVAV110/111 and

VAV140/141

The box manufacturer supplies fan or electric heat relays that might also be earth grounded. This also disrupts the isolation required for N2 communication integrity.

Note: The Troubleshooting section of this technical bulletin contains a

detailed process that will reduce installation errors by ensuring proper isolation.

If the secondary of the power transformer is grounded, you must use a separate 24 VAC to 24 VAC isolation transformer such as the Y65GS (see Figure 8).

If VAV output loads are grounded, such as a driven contactor or solenoid coil, you must use a separate isolation relay for each load (see Figure 8).

28 VAV Controller—Variable Air Volume Controller

See

Load

Transformer

CAUTION

Contactor

ower

below

24VAC

COM

ZBUS

REF

N2-

N2+

BO1

Figure 9: Transformer Wiring Diagram for

Series 110/111 VAV Controllers

CAUTION: Some local electric codes require the secondary

common of stepdown transformers be connected to earth ground (typically on units powered by more than 150 VAC). You may have a maximum of one single earth ground connection, which must be at the transformer secondary common, whether one or multiple controllers are powered by the same transformer

+15VDC

TRIACS

24VAC

ZBUS

COMMON

+15VDC

COM

REF

N2-

N2+

transeri

Power Transformer Isolation VAV110/111 and VAV140/141

Load Isolation VAV110/111 and VAV140/141

39F40F41FI/O and

Communication Terminals

You may connect the Series VAV110/111 and VAV140/141 power transformer secondary directly to earth ground. If you elect to do so, the grounded side must connect to the Common power input terminal of the controller. You do not need a separate isolation transformer for these controllers.

If VAV output loads such as contactor or solenoid coils are grounded, you must use a separate isolation relay for each load.

The VAV terminal designations, which identify sensor, actuator, and power connection points, are illustrated in Figures 10 through 12 and Tables 6 through 8. Use the HVAC PRO for Windows Configuration Tool to assign the inputs and outputs for a specific application. The filename.PRN file identifies these connections after you assemble the configuration.

You may make connections to the VAV by connecting single wires to the individual screw or spade terminals.

VAV Controller—Variable Air Volume (VAV) Controller 29

VAV100

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

BINARY INANALOG INPUTS

24VAC

COMMON

BINARY INPUT

Z BUS

BINARY COM

BINARY INANALOG INPUTS BI NA RY OUTP UTS

DSI

BINARY OUTPUTS

BI NARY OU TPUT

1 2 3 4 5 6

ZONE

STAT

7 8

24VAC

COMMON

VAVterm6

VAV101

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

24 VAC

BINARY COM

24 VAC

COMMON

24 VAC

COMMON

BINARY INPUT

BINARY INANALOG INPUTS BIN ARY OUT PUTS

BI NARY OU TPUT

1 2 3 4 5 6

ZONE STAT

ANALOG OUTPUT

1 2

ANA OUT

Figure 10: VAV100/VAV101 Terminal Designations

30 VAV Controller—Variable Air Volume Controller

BINARY INANALOG INPUTS

24VAC

COMMON

BINARY OUTPUTS

ANA OUT

24VAC

COMMON

VAVterm3

Table 6: VAV100/101 Terminal Identification

Series 100/101 Controller

Terminal Description Terminal Description

AI COM

+15 VDC BI CM

BI CM

24 VAC POWER

ZBUS

N2A+ 24 VAC 24 VAC 24 VAC 24 VAC 24 VAC 24 VAC 24 VAC/AOCM*

24 VAC/AOCM**

VAV100 has eight BOs.

VAV101 has six BOs and two AOs.

Analog Input Common

+15 Volts DC Binary Input

Common Binary Input

Common Transformer High

Side Zone Bus

N2 Bus + 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC/

AO Common 24 Volts AC/

AO Common

AI 1

AI 2

AI 3

AI 4

AI 5

AI 6

+15 VDC BI 1

BI 2

BI 3

BI 4

24 VAC COMMON

AREF

N2A– BO 1 BO 2 BO 3 BO 4 BO 5 BO 6 BO 7/AO 1*

BO 8/AO 2**

Analog Input 1

Analog Input 2

Analog Input 3

Analog Input 4

Analog Input 5

Analog Input 6

+15 Volts DC Binary Input 1

Binary Input 2

Binary Input 3

Binary Input 4

Transformer Low Side

N2 Reference and ZBus Common

N2 Bus – Binary Output 1 Binary Output 2 Binary Output 3 Binary Output 4 Binary Output 5 Binary Output 6 Binary Output 7/

Analog Output 1 Binary Output 8/

Analog Output 2

VAV Controller—Variable Air Volume (VAV) Controller 31

VAV110

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

BINARY IN PUT

Z BUS

BINARY COM

BINARY INANALOG INPUTS BINARY OUTPUTS

DSI

TO ZONE STAT

BINARY OUTPUT

1 2 3 4 5 6 7 8

BINARY INANALOG INPUTS

DSI

BINARY OUTPUTS

VAVterm5

ANALOG OUTPUT

1 2

ANA OUT

VAV111

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

BINARY INPUT

Z BUS

BINARY COM

BINARY INANALOG INPUTS BINARY OUTPUTS

DSI

BINARY OUTPUT

1 2 3 4 5 6

ZONE

STAT

Figure 11: VAV110/VAV111 Terminal Designations

32 VAV Controller—Variable Air Volume Controller

BINARY INANALOG INPUTS

BINARY OUTPUTS

ANA OUT

DSI

VAVterm2

Table 7: VAV 110/111 Terminal Identification

Series 110/111 Controller

Terminal Description Terminal Description

AI CM

+15 VDC BI CM

BI CM

24 VAC POWER

COMMON

ZBUS REF N2N2+ 24 VAC 24 VAC 24 VAC 24 VAC 24 VAC 24 VAC 24 VAC/AO CM

24 VAC/AO CM

Analog Input Common

+15 Volts DC Binary Input

Common Binary Input

Common Transformer High

Side Transformer Low

Side Zone Bus N2 Reference N2 Bus N2 Bus + 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC 24 Volts AC/AO

Common 24 Volts AC/AO

Common

AI 1

AI 2

AI 3

AI 4

AI 5

AI 6

+15 VDC BI 1

BI 2

BI 3

BI 4

BO 1 BO 2 BO 3 BO 4 BO 5 BO 6 BO 7/AO 1

BO 8/AO 2

Analog Input 1

Analog Input 2

Analog Input 3

Analog Input 4

Analog Input 5

Analog Input 6

+15 Volts DC Binary Input 1

Binary Input 2

Binary Input 3

Binary Input 4

Binary Output 1 Binary Output 2 Binary Output 3 Binary Output 4 Binary Output 5 Binary Output 6 Binary Output 7/

Analog Output 1 Binary Output 8/

Analog Output 2

VAV Controller—Variable Air Volume (VAV) Controller 33

ZONE

STAT

BUS

AI2

COMACOM

Z BUS

+15

BI1

VDC

COM

DSI

BI2

BI3

COM

BI4 BO1

BO2 BO3 BO4 BO5

VAC

BO6 BO7 BO8

VAC24VAC24VAC

VAV140

1 2 3 4 5 6

AI1 AI3 AI4 AI5 AI6

COM

BO6 BO7

AI1

COM

AI3 AI4 AI5 AI6

AI2

COM

+15

VDC

COM

DSI

AI1 AI2 AI3 AI4 AI5 AI6 BI1 BI2 BI3 BI4 BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8

COM

+15

VDC

VDCBICOM

+15

BI1

COM

VDC

BI2 BI3 BI4 BO1

COM

BUS

VAC

COM

REF N2-N2

BO2 BO3 BO4 BO5 BO6 BO7 BO8

VAC

24 VAC

VAC

BO6

VAC

BO8

VAC

BO7 BO8

VAC

VAV141

BO6 AO1

AI1 AI3 AI4 AI5 AI6

COM

AI2

COM

+15

VDC

COM

DSI

AI1 AI2 AI3 AI4 AI5 AI6 BI1 BI2 BI3 BI4 BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO 8

COM

+15

VDC

+15

BI1

VDC

+15

VDCBICOM

BI2 BI3 BI4 BO1

COM

VAC

COM

BUS

COM

REF N2-N2

BO2 BO3 BO4 BO5 BO6 AO1 AO2

VAC

BO6 AO1

COM

AO2

COM

VAC

AO2

COM

Figure 12: VAV140 and VAV141--Terminal Strip Models

34 VAV Controller—Variable Air Volume Controller

vavterm4

Table 8: Series 140/141 Controller

Terminal Description

AI1 A COM AI2 AI3 A COM AI4 AI5 A COM AI6 +15 VDC +15 VDC BI1 BI COM BI2 BI3 BI COM BI4 BO1 24 VAC BO2 BO3 24 VAC BO4 BO5 24 VAC BO6 BO7/AO1 24 VAC/A COM BO8/AO2 24 VAC COM Z Bus REF N2N2+

Analog Input 1 Analog Input Common Analog Input 2 Analog Input 3 Analog Input Common Analog Input 4 Analog Input 5 Analog Input Common Analog Input 6 +15 Volts DC +15 Volts DC Binary Input 1 Binary Input Common Binary Input 2 Binary Input 3 Binary Input Common Binary Input 4 Binary Output 1 24 Volts AC Binary Output 2 Binary Output 3 24 Volts AC Binary Output 4 Binary Output 5 24 Volts AC Binary Output 6 Binary Output 7/Analog Output 1 24 Volts AC/Analog Output Common Binary Output 8/Analog Output 2 24 VAC Power–Transformer High Side Common–Transformer Low Side Zone Bus N2 Reference N2 Bus N2 Bus +

VAV Controller—Variable Air Volume (VAV) Controller 35

42F43F44FPower, Zone

Bus, and N2 Connections

The 24 VAC power connection to VAV100/101 is at the quick connects identified as 24 VAC Power and Common. The 24 VAC power connection to VAV110/111 or VAV140/141 is at the far left two positions of the 3position screw terminal block. The removable terminal block also allows you to disconnect power to the VAV without disrupting the 24 VAC that is daisy-chained to other controllers.

Zone Bus may be hard-wired to the VAV Controller instead of using the phone jack as described later in this technical bulletin. The Zone Bus connection to VAV100/101 is at the far left position of the 4-position terminal block identified as ZBUS/COM-N2 REF/N+/N2-. The Zone Bus connection to VAV110/111 or VAV 140/141 is at the far right position of the 3-position screw terminal block identified as 24 VAC/COM/ZBUS. For all VAVs, the other side of the two wire Zone Bus, the common side, may be connected to any available Common terminal.

The N2 connection to VAV100/101 is at the 4-position screw terminal block identified as ZBUS/COM-N2 REF/N2+/N2-. The N2 connection to VAV110/111 or VAV140/141 is at the 3-position screw terminal block identified as REF/N2-/N2+. The N2 screw terminal block is removable to allow you to disconnect the communication trunk without disrupting the N2 that is daisy-chained to other controllers.

45F46F47FAnalog Inputs

The six analog input terminals, their power supply, and their common points occupy the terminal strip. These inputs may be of two types: resistive or voltage. The VAV Controller processes and controls the configured control strategy. It reads the analog inputs through the analog input DIP switches located directly above the analog input terminals.

You use these switches and HVAC PRO for Windows to select the type of analog input. Use T for all RTD temperature sensors and setpoint potentiometers. Use 10V for DPT-2015 differential pressure transmitters. For 3-wire voltage transmitters such as the DPT-2015 Series, use the 15 VDC power supply terminals next to the inputs for AI 6. You can source 90 mA from 15V supply. The following table shows each configuration.

Table 9: Analog Input Configurations

AI Type

Voltage (V) Voltage (V) Resistance

Slaving

Range

0 to 2 VDC V 2 V 0 to 10 VDC V 10 V (T)1000 ohm Nickel,

Platinum, Silicon, 2k Potentiometer

(T)1000 ohm Nickel, Platinum, Silicon, 2k Potentiometer

Switch Position-Set

SW1 SW2

T 2 V

V 2 V

36 VAV Controller—Variable Air Volume Controller

The VAV Controller has two sets of DIP switches. One set is for configuring the analog input points, and the other for setting the address of the controller. Use Tables 9 and 10 to set the SW1 and SW2 analog input DIP switches.

Refer to the Networking the Controller section of this technical bulletin for instructions on setting the N2 address DIP switches.

SW2

SW1

10V

1 2 3 4 5 6

O N

1 2 3 4 5 6

O N

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

ANALOG INPUTS

COMMON

BINARY INPUT

BINARY COM

ARY IN

24 VAC

COMMON

24 VAC

COMMON

24 VAC

COMMON

24 VAC

COMMON

ZONE STAT

BINARY OUTPUT

1 2 3 4 5 6

BINARY OUTPUT S

ANALOG OUTPUT

1 2

ANA OUT

aiswtch

ANALO

Analog Input Switches

Figure 13: Setting the Analog Input DIP Switches

The AI switches are factory set with AI 1, 2, and 3 as resistive inputs and AI 4, 5, and 6 as 0 to 10 VDC inputs. However, you may configure them to any combination. Use the following table to set the switches. For example, if you connect a 10 VDC input to AI 4, set SW1-4 to Off and SW2-4 to On.

Table 10: Analog Input DIP Switch Settings

Hardware Point

AI 1 AI 2 AI 3 AI 4 AI 5 AI 6

SW1-1 SW2-1 ON OFF OFF OFF OFF ON SW1-2 SW2-2 ON OFF OFF OFF OFF ON SW1-3 SW2-3 ON OFF OFF OFF OFF ON SW1-4 SW2-4 ON OFF OFF OFF OFF ON SW1-5 SW2-5 ON OFF OFF OFF OFF ON SW1-6 SW2-6 ON OFF OFF OFF OFF ON

Switch

Temperature

(Resistive

Input)

2 VDC

(0 to 2 VDC

Input)

10 VDC

(0 to 10 VDC

Input)

VAV Controller—Variable Air Volume (VAV) Controller 37

48F49F50FBinary Inputs

51F52F53FBinary Outputs

There are four dry contact binary inputs on the controller. They are located in the center of the terminal strip. The VAV Controllers have an available momentary binary input option. This input is connected at the zone sensor input to initiate a temporary occupancy or boost mode of operation.

The binary inputs on the VAV Controllers are inactive when open. They are active when a contact closure to BI Common is applied. BI 4 may be used as an accumulator input for frequencies less than 100 Hz.

There are six or eight binary outputs (depending on the selected model) on the controller. Binary outputs are triacs on the controller hardware. These outputs switch the transformer’s low side (or common) to the output.

Each binary output must be connected between the BO terminal and 24 VAC terminal since it is low side switching.

IMPORTANT: Chattering Relays Driven by Binary Outputs.

Chattering may occasionally occur in relays from manufacturers other than Johnson Controls due to a low load condition across the binary output triac. The chattering relays are audible, and arcing may be visible at the contacts.

The minimum holding current for the triac is 50 mA. To eliminate chattering, use a 360 ohm, 5W resistor across the binary output, or use the AS-RLY100-1 Relay Kit.

There have been a few instances where loads have met the 50 mA current requirement, but still chattered. To date, the exceptions are Honeywell damper actuator (Model ML6161) and Finder relay (Model 60.12). In these instances we recommend a 1000 ohm, 2W resistor in parallel across the load.

54F55F56FAnalog Outputs

There are two analog outputs on the VAV101, VAV111, and VAV141 Controller. The load is connected between the analog output and analog output common terminals. Each output is controlled to generate a proportional voltage output of 0 to 10 VDC to common. The maximum load for each output is 10 mA with a minimum load resistance of 1000 ohm.

38 VAV Controller—Variable Air Volume Controller

57F58F59FZone Bus

Wiring to RLY50/002 Relays

The Zone Bus allows you to connect CBLPRO or the Zone Terminal to the VAV Controller. With CBLPRO connected, use HVAC PRO for Windows for commissioning downloading and uploading. The Zone Bus is available for connection at Metastat or a zone temperature sensor.

Connect power to the relay module and the transformer through the conduit knockouts in each box. Wire the module according to the following diagram, an example of a VAV140/141 wired to an RLY50/002. All BOs must be isolated from earth ground. VAV110/111 connections are similar.

Note 1

High Voltag

NC NO

BO 1

24 V

BO 2

BI 3

BICOM

BI 4

VAV

B COILS TRIAC

HAND

OFF HOA COM

Note 2

Low Voltage

S-RLY50-0 / AS-RLYOO2

vavrelay

Note 3

Note 1: Separate low voltage and line wiring with line voltage on the right. Note 2: Hand operation using the H-O-A (Hand-Off-Auto) switch requires 24 VAC to the COILS terminal

and COM to the TRIAC terminal to energize the relay. Note 3: The Hand or Off position signals the binary input connected to those terminals. These switches

can be hardwire “OR”ed and connected to one BI. This switch uses the HOA COM terminal, which is isolated from the relays.

Note 4: Choose BIs desired for H-O-A feedback.

Figure 14: VAV140/141 Wired to RLY50/002

CAUTION: Possible Equipment Damage or Electrical Shock.

Disconnect power circuit before wiring Relay Kit.

You can obtain a DPDT (Double-Pull, Double-Throw) relay configuration by connecting the BO signal to two terminals on the Relay Kit terminal block (e.g., B and C).

If you require a phone jack at a remote RLY kit, add an AS-CBLCON-0. For additional information, refer to the Grounding and Isolation section of

this technical bulletin.

VAV Controller—Variable Air Volume (VAV) Controller 39

60F61F62FWiring Sensors

and Actuators

Use 18 AWG/1.5 mm2 twisted pair wire for all sensor and output wiring. Shielding is not required but, if used, earth ground the shield at the transformer or the controller. You may use 24 AWG/0.6 mm diameter wire in some applications. However, the length of wire is reduced due to the resistance. To minimize sensor error caused by field wiring, the total resistance of all resistive sensor wiring should be less than 3 ohm.

CAUTIONS: Potential Controller Malfunctioning.

..Do not run AI, BI, AO, BO, ZBus, or N2 Bus wiring in the same conduit

as wiring carrying 30 VAC or more.

Do not run AI, BI, AO, BO, ZBus, or N2 Bus wiring

in the same conduit as wiring that switches power to highly inductive loads (such as contactors, coils, motors, or generators).

Input and Load Impedances

Table 11: Sensor Wire Sizes and Lengths

Sensor Type Run Length Wire Size

Feet Meters AWG mm2

AI Temperature AI Voltage BI Voltage/Contact

Single BO at 0.1 ampere Single BO at 0.5 ampere Zone Bus Zone Thermostat

* Note: If an AS-CBLPRO-1 and a Zone Terminal are used, the cable length must be limited to 50 feet/15 meters.

500 150 18 1.5 500 150 18 1.5 500 150 24 to 18 0.6 mm diameter

to 1.5 mm 500 150 18 1.5 100 30 18 1.5 500 150 18 1.5

100* 30* Eight conductor

phone cable

Eight conductor

phone cable

Table 12: Input and Load Impedances

Function

AI Voltage AI Voltage AI Temp/Pot

BI DC Sense AO Voltage BO AC Triac

Range

DC Input Impedance

Sensor or Load Impedance

0-2 VDC 470k ohm 0-5k ohm 0-10 VDC 128k ohm 0-5k ohm 1000 ohm Si, Ni, Pt,

or 0-2k ohm potentiometer 0-15 VDC, 2.5V Trig 47k ohm 0-5k ohm 0-10 VDC @ 10 mA maximum N/A 1K-10M ohm 24 VAC @ 50-800 mA* N/A *30-480 ohm

3540 ohm 0-2k ohm

40 VAV Controller—Variable Air Volume Controller

Temperature Sensors

DC Supply Out

14.6-17 VDC @ 90 mA N/A 162-10M ohm

* With total controller power draw limited as described previously.

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

CBLPRO

9-pin or 25-pin

Adapter

Laptop PC

6-pin to 8-pin

Metastat

Laptop PC

9-pin or 25-pin

Adapter

Zone Bus

CBLPRO

Zone Bus

6-pin to 6-pin

BINARY I NPUT

BINARY COM

BINARY I NANALOG INPUTS BINARY OUTPUTS

Z BUS

DSI

P5 P6

ZONE

STAT

8-pin

BINARY OUTPUT

1 2 3 4 5 6 7 8

vavconn2

Figure 15: VAV Interconnection

To make all of the necessary wiring terminations between the VAV Controller and the TE-6410 Series Metastat, use phone cable that has preterminated 8-pin RJ-45 connectors. These cables are available from Anixter. Refer to the Vendor Code Numbers in the Ordering Information section of this technical bulletin for specific information regarding cables.

Connect one end of the cable to the Zone Bus connector on the controller and the other end to the 8-pin connector on the back of the sensor as shown in Figure 15. In addition to the 8-pin RJ-45 connection, the TE-6410 Metastat also has a 6-pin RJ-12 connection under its cover. This allows remote connection of the CBLPRO (used during commissioning) or the Zone Terminal (used for system monitoring).

For VAV140/141 Series Controller, there is an additional 6-pin jack for Zone Bus communication. You may permanently connect a Metastat to the 8-pin jack of the controller and simultaneously connect a laptop PC, CBLPRO, or Zone Terminal to the Zone Bus via the 6-pin jack.

VAV Controller—Variable Air Volume (VAV) Controller 41

Phone Jack Polarization

Figure 16 illustrates the polarization of the 6-pin and 8-pin phone jacks on the VAV Controller or Metastat. Terminal 1 is to the extreme left as you face the jack opening, tab notch down.

PHONEJK

8-pin

6-pin

Figure 16: Phone Jack Polarization

The following table defines the pin usage for each jack.

Table 13: Phone Jack Pin Identification

8-Pin Jack (VAV Controller to Metastat) Pin Signal Pin Signal

1 2

3 4 5 6 7 8

AI 3 Heating Setpoint AI 2 Warmer, Cooler, or

Cooling Setpoint AI 1 Temperature Sensor AI 1 Sensor Common 24 VAC 24 VAC/ZnBs Common AI 2/3 Common Zone Bus

6-Pin Jack (VAV140/141 Controller to CBLPRO or ZT and CBLPRO or Zone Terminal to Metastat)

1 2

3 4 5 6

Not used 24 VAC

24 VAC/ZBus Common Not used Zone Bus Not Used

Note: Refer to the Vendor Code Numbers in the Ordering Information

section of this technical bulletin for information on cables.

42 VAV Controller—Variable Air Volume Controller

Fabricating an Interconnection Cable

You must construct any fabricated interconnection cable so the same color wire on both ends of the cable align with Pin 1 in the plug. This provides a consistent field assembly of the cable. Figure 17 illustrates the interconnection cable.

ZBUS AI2/3 COM COM

24VAC AI1COM AI1

AI2 AI3

8 7 6 5 4 3 2 1

Controller

Phone Plug

CBLFA

Metastat

Phone Plug

8 7 6 5 4 3 2 1

Figure 17: Interconnection Cable

Note: This is not typical of pre-assembled phone cable purchased in retail

stores. A telephone system cable is wired opposite the zone sensor requirements.

VAV Controller—Variable Air Volume (VAV) Controller 43

Sharing a Sensor

1 2 3 4 5 6

O N

1 2 3 4 5 6

O N

You may use one sensor as a master input to multiple VAV Controllers instead of mounting and wiring separate zone sensors for each controller. This application is especially beneficial when you have a mechanical system that uses more than one terminal unit to serve the same area, for example, a large conference room or open office space.

Note: The practical limitation to this application is four VAV Controllers

to one sensor.

Set for

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

2 VDC and

Voltage

BINARY I NPUT

BINARY INANALOG INPUTS BI NARY OUTPUT S

TO ZONE STAT

Z BUS

24 VAC

DSI

BINARY OUTPUT

1 2 3 4 5 6 7 8

1 2 3 4 5 6

O N

1 2 3 4 5 6

O N

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

N2 -

N2 +

N2 REF

Sensor +

Sensor -

Note: Route sensor wiring and N2 wiring together. Since the VAV Controller is a self-terminating device, end-of-line termination for the N2 Bus is not required.

Set for

2 VDC and

Temperature

BINARY I NPUT

BINARY INANALOG INPUTS BI NARY OUTPUT S

TO ZONE STAT

Z BUS

24 VAC

DSI

BINARY OUTPUT

1 2 3 4 5 6 7 8

Metastat

8-pin Connectio

on Back

sensors2

Figure 18: Example of Sharing a Sensor Among VAV Controllers

Figure 18 shows the wiring and analog input switch settings for two controllers that use one zone sensor. To ensure the noise immunity of the VAV Controllers, pull the N2 Bus wiring with the sensor wiring between controllers that share the same zone sensor.

Notes: This configuration shifts the AI value by one degree for each added

controller. Compensate for this temperature shift by entering an offset of -1°F (for each added controller) through the AI Offset Table. You can find this table in the Commissioning mode of HVAC PRO for Windows.

On the HVAC PRO for Windows Analog Input Modify screen,

verify that both controllers are set to the same temperature sensor type.

If the master zone sensor uses the Zone Bus connection, only the

master controller can be loaded and commissioned from the sensor connection.

44 VAV Controller—Variable Air Volume Controller

63F64F65FNetworking the Controller

N2 Bus Overview

Wiring the Controller to an NCU

N2 Bus Characteristics

If you are familiar with the N2 Bus, go to the next section of this technical bulletin: Installing the N2 Bus.

A hardware connection between the N2 Communications Bus and the NCM of the Network Control Unit (NCU) is required if the NCM is to service N2 devices. Refer to Table 14 for terminal locations and to the N2 Communications Bus Technical Bulletin for termination resistor values.

When installed in a Metasys Network, the VAV Controller receives commands from the Network Control Module (NCM) or Companion on the N2 Bus, and transmits status reports in return. The maximum electrical limitation on the N2 Bus is 255 devices. However, the number of controllers on the N2 Bus is a data base memory issue at the NCU or Companion. Refer to the N2 Communications Bus Technical Bulletin

(FAN 636) and either the Metasys Companion Technical Manual (FAN

628.1) or the Metasys Technical Manual (FAN 636) to determine practical

limitations to the number of controllers on the N2 Bus. The N2 Bus connections are electrically isolated from other series

VAV110/111 and VAV140/141 Controller circuitry by optical and magnetic coupling.

For runs of up to 5,000 feet/1,500 meters, use 22 AWG/0.6 mm diameter or higher twisted pair wire. (Electrically, 26 AWG wire works, but it is too fragile and prone to nicks and breaks.) Runs longer than 5,000 feet/1,500 meters require use of a bus repeater. An N2 network may be extended to a maximum length of 15,000 feet/4,500 meters, using two repeaters.

The N2 Bus is a daisy chain communications line. Essentially, it consists of three wires, which carry three signals: N2+, N2–, and REF. The N2+ and N2– lines carry the actual data signals. The REF line provides a common reference so that each connected device is capable of electrically receiving and transmitting data by creating a common voltage reference among all the devices connected together by the N2 lines. Three lines are required for optimum reliability. It is important that the N2+ and N2– lines must be twisted pair lines, which allows most induced noise (commonmode noise) from external sources to affect both lines equally, thereby canceling the noise.

Note: Do not run N2 Bus wiring in the same conduits as line voltage

wiring (above 30 VAC) or wiring that switches power to highly inductive loads (such as contactors, coils, motors, or generators).

VAV Controller—Variable Air Volume (VAV) Controller 45

66F67F68FInstalling the

N2 Bus

Setting the N2 Address

Set the N2 address and test for N2 voltage, polarity, and isolation before actually wiring the VAV Controller for operation. Refer to the ASC and

N2 Bus Networking and Troubleshooting Guide (LIT-6363003) in the Application Specific Controllers Technical Manual (FAN 636.3) for more information.

The switches located in the upper right corner of the VAV are set to the same number as was assigned to the module through software. The Metasys (or Companion) Facility Management System (FMS) uses this address for polling and commanding. The numbers are in binary format and vertically arranged with the least significant digit to the right.

For example, if the controller address is 17 (decimal), the binary representation is 00010001–Switches 1 and 16 must be set to the On position (1 + 16 = 17), as shown in Figure 19.

N O

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMON

1 2 3 4 5 6

BINARY INPUT

BINARY COM

BINARY INANALOG INPUTS BINARY OUTPUTS

Z BUS

DSI

P5 P6

TO ZONE STAT

BINARY OUTPUT

1 2 3 4 5 6

1 2 3 4 5 6 7 8

OFF

ANALOG OUTPUT 1 2

ANA OUT

Address Switches

dipswtch

Figure 19: Setting the N2 Address DIP Switches

IMPORTANT: When setting the N2 Address, do not use address “0.”

46 VAV Controller—Variable Air Volume Controller

N2 Wiring to the Network Control Module

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPUTS

COMMO N

1 2 3 4 5 6

BINARY INPUT

BINARY COM

BINARY INANALOG INPUTS BIN ARY OUTPUTS

DSI

BINARY OUTPU T

1 2 3 4 5 6 7 8

ZONE STAT

Z BUS

NCU

(TB1 o n C o m m u n ication

Terminal Board)

HRD GRD

SFT

GRD

N2-12

GRD

N2+

De vice

N2 REF

N2 -

N2 +

REF

N2 +

N2 -

N2 REF

Note: Since the VAV Controller is a self-terminating device, end-of-line termination for the N2 Bus is not required.

Figure 20: Connecting the VAV Controller to an NCM

Table 14: Terminal Locations

TB1 Terminal Function Number VAV Connection

Chassis Ground Soft Ground N2B Ref Ground Soft Ground

-N2B Connection +N2B Connection

6 None 5 None 4 AREF 3 None 2 N2 Bus: N21 N2 Bus: N2+

REF N2- N2+

n2wire1a

VAV Controller—Variable Air Volume (VAV) Controller 47

N2 Wiring to Companion

A hardware connection between the N2 Communications Bus and the Companion PC/Panel/LTD is required to service N2 devices. An MM-CVT101-0 Communications Converter is required to network to the PC Companion. See Figure 21 for terminal locations. Refer to the Metasys Companion Technical Manual (FAN 628.1) for information specific to the CVT101 or Companion Panel/LTD.

C ompanion PC Version

RS232-to-N2Bus

Converter

(N2 Bus Terminal)

REF

N2 -

N2 +

ANALOG INPU TS

1 2 3 4 5 6 1 2 3 4

1 2 3 4 5 6

ANALOG INPU TS

COMMON

1 2 3 4 5 6

N2 REF

N2 -

N2 +

BINARY INPUT

Z BUS

BINARY COM

BINARY INANALOG INPU TS BINARY O UTPUTS

DSI

ZONE

STAT

BINARY OUTPUT

1 2 3 4 5 6 7 8

N2 + N2 -

N2 REF

Devic

n2wire2

Figure 21: Connecting the VAV Controller to Companion

48 VAV Controller—Variable Air Volume Controller

69F70F71FZone Bus

Communications

Zone Bus Description

The Zone Bus is a 2-wire communications bus that allows a computer to communicate with the VAV to download the VAV’s data base and to communicate with Zone Terminals and M100 Actuators. A third wire is used for 24 VAC power to the CBLPRO, Zone Terminal, and CBLCON. The bus interface sustains no damage in presence of fault voltages of 24 VAC.

M100C Actuators must be powered with separate transformers; therefore, only the Zone Bus and Common wires need to be pulled.

The Zone Bus has the following specifications:

Table 15: Zone Bus Specifications

Type Speed Recommended Cable Type

Maximum Bus Length

Range of Addresses Voltages

Logic High-Voltage Logic Low-Voltage

Data Transmission

Multidrop serial communications bus 1200 baud (bits per second) 18 AWG/1.5 mm

24 AWG/0.6 mm diameter with no shield (unshielded telephone cable)

500 feet/150 meters with 18 AWG/1.5 mm 50 feet/15 meters with 24 AWG/0.6 mm diameter cable

0 to 63

4 VDC minimum (approximately) 1 VDC maximum (approximately)

1 Start Bit (low level) 8 Data Bits (least significant bit first) 1 Stop Bit (high level)

with shield (Beldon 8760) or

cable or

The VAV110/111 and VAV140/141 Series Controllers contain an LED that blinks to indicate Zone Bus activity with or without external connection. When a PC via CBLPRO communicates with the controller, the blink rate may appear to be more steady. See Table 37: Zone Bus LED Indications in the Troubleshooting section of this document for more information.

VAV Controller—Variable Air Volume (VAV) Controller 49

CBLPRO Description

CBLPRO (AS-CBLPRO) is an interface device for use between a computer running HVAC PRO for Windows and application specific controllers such as the VAV Controller. It is used for data base downloading, uploading, or commissioning via the Zone Bus communication port.

When used with a Zone Bus device, such as the VAV or ZT, the CBLPRO is strictly an electrical interface between the serial RS-232 port of the computer and the Zone Bus. CBLPRO operates on 24 VAC drawn from a VAV over the wire used to make the Zone Bus connections. The data rate on both the RS-232 and the Zone Bus is 1200 baud.

The connection to the RS-232 COM port of the computer is by means of a DB9 or DB25 connector supplied with the CBLPRO. After connecting it, make sure the CBLPRO is about a foot or more away from the computer monitor and system unit.

IMPORTANT: In some cases, a computer monitor or PC will give off

electromagnetic noise that may disturb CBLPRO communications. Therefore, do not position the CBLPRO near the monitor or PC.

Zone Bus communications to the application specific controllers or ZT may also be monitored with a CBLCON (AS-CBLCON-0). This device has a red and green LED whose purposes are described in the following table.

Table 16: CBLCON LEDs

Red LED--

Power

OFF OFF

ON OFF ON ON

ON Blinking

Green LED--

COMM

Cause

No power to VAV Zone Bus wire open Zone Bus wire shorted to Common or 24 VAC, or

CBLCON-0 switch in download position Normal communications

50 VAV Controller—Variable Air Volume Controller

72F73F74FApplication Examples

Single Duct Applications

The following examples are created by answering configuration questions using HVAC PRO for Windows to identify terminal locations of the inputs and outputs. Refer to the HVAC PRO for Windows User’s Manual (FAN

637.5), the VAV Controller section, for detailed information regarding controller configuration.

VAV Controller—Variable Air Volume (VAV) Controller 51

Select the VAV Control Strategy

1. Pressure Independent

2. Pressure Dependent without Feedback

3. Pressure Dependent with Feedback

4. Pressure Independent (User Defined Flow)

Select the Damper Output Type

1. Binary Outputs (Incremental Control)

2. Analog Outputs (Proportionall Control)

Define Diagnostics:

1. None 2 . A c tu a to r R u n tim e 3 . Mo v in g Avg . F lo w Er ro r

4. Moving Avg. Zone Temperature Error

5. Runtime and M oving Avg. Flow Error

6. Runtime and M oving Avg. Zone Temp Error

7. M ov ing A vg . F llow a nd Z o ne T e m p Er ro r

8. All of the Above

Select Fan Type

1. None

2. Series/On-Off

3. Series/Proportional

4. Parallel/Temperature

5. Parallel/Flow

Is there an exhaust box?

1. No

2. Yes

Type of Heating

1. None

2. Baseboard Heat Only

3. Box Heat Only

4. Both Baseboard and Box Heat

Select Type of Baseboard Heat

Select Type of Box Heat

1. Incremental

2. Proportional

3. N o rm a lly O p en Va lv e

4. Norm ally Closed Valve / Single Stage

5. 2-Stages

6. 3-Stages

1. Incre men ta l

2. Normally Ope n V a lve

3. Nor mally C los e d V a lve

Is lighting required?

1. No

2. Ye s

Power fail restart logic?

1 . No 2 . Yes

Use box supply tem perature for Warmup/Cooldown during unoccupied mode?

1. No

2. Ye s

Select the Damper Output Type

1. Binary Outputs (Incremental Control)

2. Analog Outputs (Proportionall Control)

Define Setpoint Type

1. Separate Heating and Cooling Setpoints

2. Single Setpoint with Bias

D e fin e Re mote AI p o in ts

1. None

2. R e mote Setp o in t

3. Warm er/Cooler Adjust

D e fine Re mo te AI P o ints

2. Cooling/Heating Setpoints

3. Warmer/Coo ler A d jus t

Define Occupied Mode

1. Software (N2) Command

2. Hardware BI Point

3. Both with BI Backup

4. Both can Activate

Define Standby Mode

1. Software (N2) Command

2. Hardware BI Point

3. Both with BI Backup

4. Both can Activate

Define Shutdown Mode

1. Software (N2) Command

2. Hardware BI Point

3. Both with BI Backup

4. Both can Activate

Do you want the Temporary Occupied feature?

1. No

2. Y e s

Do you want Boost mode?

1. N o

2. Ye s

Check Parameters and IO Points, then save the Configuration File.

1. None

chart

Figure 22: HVAC PRO for Windows Single Duct Configuration

52 VAV Controller—Variable Air Volume Controller

Hardware Point Assignment Table

The following table shows the HVAC PRO for Windows hardware point assignments and options for single duct configurations.

Table 17: Single Duct Point Assignments and Options

Point Type

Analog Inputs

Warmer/Cooler Adjust Potentiometer Cooling Setpoint Potentiometer AI 3 Unused Heating Setpoint Potentiometer Rename AI 4 Actuator Feedback on Pressure

CFM on Pressure Independent None Unused Rename AI 5 Proportional Series Fan CFM None Exhaust Box CFM None Unused Rename AI 6 Unused Box Supply Temperature for

Binary Inputs

BI 2 Unused Rename Standby

BI 3 Unused Rename Shutdown Box Open

BI 4 Unused Rename

Momentary BI

Continued on next page . . .

Point

Name

HVAC PRO for Windows Configuration

HVAC PRO for Windows Configuration Options

Assignments and Defaults

AI 1 Zone Temperature None

Unused Rename

None

Dependent

Standalone Warmup in Pressure Dependent with Feedback and Independent Path

BI 1 Unused Rename

Shutdown Box Closed

BI 5 Unused Temporary Occupancy Mode

Rename

Occupied

Boost Mode

VAV Controller—Variable Air Volume (VAV) Controller 53

Point Type (Cont.)

Binary

Outputs

BO 3 Parallel and Series On-Off Fans None Exhaust Box Open Unused Unused Rename

BO 4 Exhaust Box Close None Baseboard Heat On-Off None First Stage Box Heat*** None Unused Rename

BO 5 Baseboard Incremental Open None Box Heat Incremental Open None First Stage Box Heat** None Second Stage Box Heat*** None Lights On for VAV101 None Unused Rename

BO 6 Baseboard Incremental Close None Box Heat Incremental Close None On-Off/Single Stage Box Heat None Second Stage Box Heat** None Third Stage Box Heat*** None Lights Off for VAV101 None Unused Rename

Analog Outputs

** 2-Stages Box Heat *** 3-Stages Box Heat

Point

Name

HVAC PRO for Windows Configuration

HVAC PRO for Windows Configuration Options

Assignments and Defaults

BO 1 Supply Damper Open None BO 2 Supply Damper Close None

BO 7 Baseboard Incremental Open

on VAV100 Lights On for VAV100 None Unused Rename

BO 8 Baseboard Incremental Close

on VAV100 Lights Off for VAV100 None Unused Rename

AO 1 S66 Output for

Proportional Series Fan Unused Rename

AO 2 Proportional Box Heat None

Unused Rename

None

54 VAV Controller—Variable Air Volume Controller

Note: The examples contained in this technical bulletin do not reflect all

of the possible questions and answers. These examples are provided as a basic overview of wiring locations you might expect to see.

Table 18: Single Duct Wiring Example 1 Questions and Configuration Selections

HVAC PRO for Windows Questions Configuration Selections

Control Strategy Fan Type Exhaust Box Required Baseboard Heat Type Box Heat Type Lighting Integration

Pressure Independent Series/On-Off Not Available None 3-Stages Yes

Note: The OEM box manufacturer typically supplies the fan relays and

electric heat relays.

DPT1

Discharge

DA1

vav1

Plenum

Supply

Figure 23: Single Duct Wiring Example 1

Mechanical Flow Diagram

VAV Controller—Variable Air Volume (VAV) Controller 55

120/24VAC

120VAC 24VAC

ower

Transformer

TE1

Room

Sensor

DPT1

OUT 1

COM 2

VDC 3

BINARY INANALOG INPUTS

Fan

Relay

24 VAC

DSI

DA1

Damper

Actuator

Stage 1

Relay

24 VAC

BINARY OUTPUTS

Stage 2

24 VAC

Relay

Lighting

Relay

ON COM OFF

Stage 3

Relay

24 VAC

Figure 24: Single Duct Wiring Example 1

Pressure Independent Configuration

Table 19: Single Duct Wiring Example 1 Bill of Materials

Component Description Part Number

C1 TE1 R1 DA1 and DPT1

Digital Controller AS-VAV110-1 Metastat TE-6400 Series Lighting Relay GE-RR7 Actuator/Flow Sensor ATP-2040

Note: Box OEM manufacturers typically supply fan relays and electric

heat relays.

56 VAV Controller—Variable Air Volume Controller

vavwe1a

The following table illustrates the selections made through HVAC PRO for Windows for this example.

Note: The examples contained in this technical bulletin do not reflect all

of the possible questions and answers. These examples are provided as a basic overview of wiring locations you might expect to see.

Table 20: Single Duct Wiring Example 2 Questions and Configuration Selections

HVAC PRO for Windows Questions Configuration Selections

Control Strategy Fan Type Exhaust Box Required Baseboard Heat Type Box Heat Type Lighting Integration

Pressure Independent None Yes None Proportional Not Available

DA2

VA1DA1

TE1

DPT2

VAV2

DPT1

Exhaust Box

Figure 25: Single Duct Wiring Example 2

Mechanical Flow Diagram

VAV Controller—Variable Air Volume (VAV) Controller 57

120/24VAC

120VAC 24VAC

Power

Transformer

TE1

Room

Sensor

DPT1

OUT 1

COM 2

VDC 3

DPT2

OUT 1

COM 2

VDC 3

BINARY INANALOG INPUTS

DSI

BINARY OUTPUTS

DA1

Damper

Actuator

DA2

EXH

Figure 26: Single Duct Wiring Example 2

VA1

Proportional

Valve

Actuator

vavwe2a

Table 21: Single Duct Wiring Example 2 Bill of Materials

Component Description Part Number

C1 TE1 DA1 and DPT1 VA1 DA2 and DPT2

Digital Controller AS-VAV111-1 Metastat TE-6400 Series Actuator/P Sensor Valve Actuator VA-8022 Series Actuator/DP Sensor ATP-2040

58 VAV Controller—Variable Air Volume Controller

ATP-2040

The following table illustrates the selections made through HVAC PRO for Windows for this example.

Note: The examples contained in this technical bulletin do not reflect all

of the possible questions and answers. These examples are provided as a basic overview of wiring locations you might expect to see.

Table 22: Single Duct Wiring Example 3 Questions and Configuration Selections

HVAC PRO for Windows Questions Configuration Selections

Control Strategy Fan Type Exhaust Box Required Baseboard Heat Type Box Heat Type Lighting Integration

Pressure Dependent Without Feedback Not Available Not Available On-Off Incremental Yes

H T

DA1

VA2

TE1

VA1

B A S E B D

VAV3

Figure 27: Single Duct Wiring Example 3

Mechanical Flow Diagram

VAV Controller—Variable Air Volume (VAV) Controller 59

120/24VAC

120VAC 24VAC

ower

Transformer

TE1

Zone

Sensor

BO 1

24VAC BO 2

N2+

BINARY OUTPUTS

BO 3

BO 6

BO 4

BO 5

24VAC

BO 7

24VAC

BO 8

24VAC

BINARY INANALOG INPUTS

+15VDC

BI 1

BI 2

AI 1

AI 3

AI 4

AI 5

AI 6

AI CM

AI CM AI 2

AI CM

+15VDC

BI 3

COM MO N

COM MON

DSI

BI 4

COM MON

N2-

REF

COM

ZBUS

24VAC

DA1

Damper

Actuator

VA1

Basbd

Heat

VA2 Box

Heat

Figure 28: Single Duct Wiring Example 3

Table 23: Single Duct Wiring Example 3 Bill of Materials

Component Description Part Number

C1 TE1 VA1 VA2 DA1 R1

Digital Controller AS-VAV110-1 Metastat TE-6400 Series Baseboard Valve Actuator J Series Box Heat Valve Actuator VA-8020 Damper Actuator EDA-2040-nn Lighting Relay GE-RR7

Lighting

Relay

ON COM OFF

vavwe3a

60 VAV Controller—Variable Air Volume Controller

The following table illustrates the selections made through HVAC PRO for Windows for this example.

Note: The examples contained in this technical bulletin do not reflect all

of the possible questions and answers. These examples are provided as a basic overview of wiring locations you might expect to see.

Table 24: Example 4--Pressure Independent with Parallel Fan

HVAC PRO for Windows Questions Configuration Selections

Control Strategy Fan Type Exhaust Box Required Baseboard Heat Type Box Heat Type Lighting Integration

Pressure Independent Parallel Fan Temp Controlled No Analog Output Incremental No

Plenum

Supply

DPT1

DA1

T G

VA1

Discharge

TE1

VA2

B A S E B D

vav1

Figure 29: Mechanical System Flow Example 4

Pressure Independent w/Parallel Fan

VAV Controller—Variable Air Volume (VAV) Controller 61

TE1

Zone

Sensor

VAV111-1

DA1

BINARY OUTPUTS

Fan

Relay

VA1

Incremental

Box Heat

Actuator

Proportional

Valve Actuato

Baseboard

DPT1

OUT 1

COM 2

VDC 3

BINARY INANALOG INPUTS

DSI

Box Damper

Actuator

Figure 30: Single Duct Fan Powered Box Wiring Example 4

VA2

vavwe6a

Table 25: Fan Powered Box Wiring Example 4 Bill of Materials

Component Description Part Number

C1 TE1 DPT-1/DA-1

VA-1 VA-2

VAV w/6 BOs and 2 AOs AS-VAV111-1 Temperature Sensor TE-6400 Series Delta P Transducer/Damper

Actuator Valve Actuator Box Heat VA-8020-1 Electro-pneumatic Transducer

Baseboard Heat

Note: Box OEM manufacturers typically supply fan relays and electric

heat relays.

62 VAV Controller—Variable Air Volume Controller

ATP-2040

EP-8000-2

75F76F77FDual Duct

Applications

637.5), the VAV Controller section, for detailed information regarding controller configuration.

VAV Controller—Variable Air Volume (VAV) Controller 63

Select VAV Control Strategy

1. Pressure Independent

2. Constant Vol ume

3. Sing le D uct C o n v e rs io n

4. Ind. C o ld Deck with D e p . H ot Dec k

DPT Locality

1. Hot and Co ld D eck

2. Ho t Deck a nd Total Flow

3. Co ld Deck an d To t al Flow

Select Dam per O utput

1. Incremental

2. Proportional

Select Damper Output

1. In cr emental

2. Proportional

Is Discharge Lo w Limit Required?

1. No

2. Yes

Is Discharge Low Limit Required?

1. No

2. Ye s

Bu mp les s F low T ra n sfe r B e tw e e n Hot/Cold D e c ks

1. N o

2. Y es

Select Damper

1. Increm en tal

2. Pro po rtio na l

Is there an Exhaust Box?

1 . N o

2. Yes

Select Damper Type

1. Sep a r a te Dampe r s

2. Linked Damp ers

Select Damp er Output

1. Incremental

2. Proportional

Is Discharge Low Limit Required?

1 . N o

2. Y e s

Is Discharge Low Limit Required?

1 . N o

2. Y es

Select Dam per Output

1. Incremental

2. Proportional

Bum pless Flow Transfer Between H ot/Cold De cks

1. N o

2. Ye s

Is There an Exhaust Box?

1 . No 2 . Y es

Select Baseboard Heat Type

1. None

2. Incre mental

3. Normally Open Valve

4. Norma lly Closed Valve

Is Lighting Requ ired?

1. No

2. Yes

P o wer Fa il Res ta rt L ogic

1. No

2. Yes

Figure 31: HVAC PRO for Windows Dual Duct

Configuration Flowchart (Part One of Two)

Is There an Exhaust Box

1. No

2. Yes

Select Baseboard Heat Type

1. Non e

2. In c r ementa l 3 . Norma lly Op e n Valve

4. Norma lly Closed Valve

Is Lighting Requ ired?

1. No

2. Yes

P o wer Fa il R esta rt L ogic

1. No

2. Yes

chart b

64 VAV Controller—Variable Air Volume Controller

Define Remote AI Points

1. None

2. Cooling/Heating Setpoints

3. Warmer/ Cooler Adjust

Define "Occupied" Mode

1. Software (N2) Command

2. Hardware BI point

3. Both with BI Backup

4. Both can Activate

Define "Standby" Mode

1. Software (N2) Command

2. Hardware BI point

3. Both with BI Backup

4. Both can Activate

Def i ne " S hu t d ow n " M ode

1. Software (N2) Command

2. Hardware BI point

3. Both with BI Backup

4. Both can Activate

Do You Want the Temporary Occupied Feature

1. No

2. Yes

Do You Want Boost Mode

1. No

2. Yes

Go Check Parameters and IO Points Then Save the Configuration File

charta

Figure 32: HVAC PRO for Windows Dual Duct

Configuration Flowchart (Part Two of Two)

VAV Controller—Variable Air Volume (VAV) Controller 65

Table 26: Dual Duct Hardware Point Assignments and Options

Point Type Point

Name

Analog Inputs

AI 2 Unused Rename Cooling Setpoint Warmer/Cooler Adjust AI 3 Unused Rename Heating Setpoint AI 4 Cold Deck Delta P None Supply Delta P None AI 5 Hot Deck Delta P None Unused Rename AI 6 Discharge Air Temp None Exhaust Delta P None Unused Rename

Binary Inputs

BI 2 Unused Rename Standby BI 3 Unused Rename Shutdown Box Open BI 4 Unused Rename Shutdown Box Closed

Momentary BI

Boost Binary Outputs

Cold Deck Open None BO 2 Damper Close None

Cold Deck Close None BO 3 Heating/Cooling Changeover None Hot Deck Open None BO 4 Unused Rename Hot Deck Close None BO 5 Unused Rename Exhaust Open None BO 6 Unused Rename Exhaust Close None

AI 1 Zone Temperature None

BI 1 Unused Rename

BI 5 Unused Rename

BO 1 Damper Open None

BO 7 Unused Rename Basebd Heat None Basebd Open None Lights On None BO 8 Unused Rename Basebd Close None Lights Off None

HVAC PRO for Windows Configuration Assignments and Defaults

HVAC PRO for Windows Configuration Options

Occupied

Temp Occupancy

66 VAV Controller—Variable Air Volume Controller

The following table illustrates the selections made through HVAC PRO for Windows for this example.

Note: The examples contained in this technical bulletin do not reflect all

of the possible questions and answers. These examples are provided as a basic overview of wiring locations you might expect to see.

Table 27: Dual Duct Wiring Example 1 Questions and Configuration Selections

HVAC PRO for Windows Questions Configuration Selections

Control Strategy Discharge Air Low Limit Exhaust Box Required Baseboard Heat Type Lighting Integration

Constant Volume/Separate Dampers No No No No

Hot Deck

Cold Deck

DA2

DPT2

DPT1

DA1

Figure 33: Dual Duct Wiring Example 1

Mechanical Flow Diagram

TE1

VAV4

VAV Controller—Variable Air Volume (VAV) Controller 67

120/24VAC

DPT1

Flow Sensor

OUT 1

COM 2

VDC 3

120VAC 24VAC

Flow Sensor

Power

Transformer

DPT2

OUT 1

COM 2

VDC 3

BINARY INAN ALO G INPUTS

TE1

RM-T

RM-SP

BINARY OUTPUTS

DSI

DA1 Damper Actuator

DA2 Damper Actuator

Figure 34: Dual Duct Wiring Example 1

Table 28: Dual Duct Wiring Example 1 Bill of Materials

Component Description Part Number

C1 TE1 DA1 and DPT1 DA2 AND DPT2

Digital Controller AS-VAV110-1 Metastat TE-6400 Series Cold Deck ATP-2040-nn Hot Deck ATP-2040-nn

vavwe4a

68 VAV Controller—Variable Air Volume Controller

The following table illustrates the selections made through HVAC PRO for Windows for this example.

Note: The examples contained in this technical bulletin do not reflect all

of the possible questions and answers. These examples are provided as a basic overview of wiring locations you might expect to see.

Table 29: Dual Duct Wiring Example 2 Questions and Configuration Selections

HVAC PRO for Windows Questions Configuration Selections

Control Strategy Discharge Air Low Limit Exhaust Box Required Baseboard Heat Type Lighting Integration

Pressure Independent Yes No No Yes

Hot Deck

Cold Deck

DA2

DPT2

DA1

DPT1

Figure 35: Dual Duct Wiring Example 2

Mechanical Flow Diagram

TE1

VAV5

VAV Controller—Variable Air Volume (VAV) Controller 69

120/24VAC

120VAC 24VAC

Power

Transformer

TE1

Room

Sensor

DPT1

OUT 1

COM 2

VDC 3

DPT2

OUT 1

COM 2

VDC 3

BINAR Y INANALOG INPUTS

DSI

TE2

BINARY OUTPUTS

DA1 Damper Actuator

DA2 Damper Actuator

Figure 36: Dual Duct Wiring Example 2

vavwe5a

Lighting

Relay

ON COM OFF

Table 30: Dual Duct Wiring Example 2 Bill of Materials

Component Description Part Number

C1 TE1 TE2 DPT1 and DA1 DPT2 and DA2 R1

Digital Controller AS-VAV110-1 Metastat TE-6400 Discharge Air TE-6000 Series Cold Deck ATP-2040-nn Hot Deck ATP-2040-nn Lighting Relay GE-RR7

70 VAV Controller—Variable Air Volume Controller

78F79F80FDownloading/Commissioning

We recommend that you connect the zone sensor prior to performing the initial configuration download. Even if you do not permanently install the zone sensor at this time, terminate the N2 Bus wiring and pull it back to the equipment room location of the NCM or Companion System. Refer to HVAC PRO for Windows User’s Manual (FAN 637.5) for upload features.

Via Zone Bus

81F82F83FVia N2 Bus

Downloading and commissioning via the Zone Bus requires the use of the CBLPRO interface and a laptop or PC running the HVAC PRO for Windows software. You can connect to the Metastat 6-pin connector or directly at the controller. VAV140/141 models have a spare 6-pin connector making it unnecessary to disconnect the Metastat or zone sensor during download/commissioning. Communication rate is 1200 baud over the Zone Bus.

HVAC PRO for Windows allows you to perform downloading and commissioning over the N2 Bus. Because the communication rate is 9600 baud, performing downloading and commissioning over the N2 Bus saves a great deal of time in loading the initial controller configuration files and parameters into the controller prior to the balancing contractor’s final testing.

To perform the downloading and commissioning process over the N2 Bus, we recommend that you create a job file spreadsheet similar to the one illustrated in the following table.

Table 31: Example File per N2 Trunk for Pressure Independent Job

Filename

Size 8 Size 10

Address

1 300 800 300 300 80 2 300 1200 300 300 120

Cooling

Min CFM

Cooling

Max CFM

Heating

Min CFM

Heating

Max CFM

Damper

Deadband

You should develop a separate filename for each size box with a different configuration style. For example, if the inlet is 8 inches in diameter, “Size 8” would be a logical filename (Table 31). This allows you to have your base set of requirements in place before you adjust the CFM setpoint schedule per the mechanical prints.

VAV Controller—Variable Air Volume (VAV) Controller 71

84F85F86FIncremental

Valve Actuator Stroke Time

The stroke time of an incremental valve actuator is important because the controller uses it to position the actuator in reference to an analog 0-100% open position command. If the stroke time is grossly inaccurate, the controller drives the actuator under an incorrect assumption of total stroke time and causes inaccurate positioning, particularly at the near closed or near full open positions. If possible, measure the actual stroke time of the incremental actuator with water flow through the valve. Some valves have 1/2, 5/16, or 3/4 inch strokes, which require different stroke times.

If you do not measure the actual stroke time, you at least need to know the approximate stroke time of the valve and enter that in the HVAC PRO for Windows configuration tool. Conservatively, you can add up to 20% to the nominal time. Always add to the stroke time, never subtract. The controller modulates the valve based on a calculated stroke time of 150% of the stroke time you specify. This is done to compensate for variations in water system pressure, actuator wear, and manufacturing tolerances.

The VAV controller has a built-in overdrive algorithm that drives the actuator closed for an additional 50% of the entered stroke time when a 0 or 100% open command is issued. This ensures that the valve is fully closed or open. This fully opens or closes the valve, but does not correct the mid-stroke position errors due to a grossly incorrect valve stroke time. Refer to the following table for approximate stroke times.

Table 32: Approximate Stroke Times

Incremental Valve Actuators

VA-8050-1 VA-8051-1 VA-8050-1 VA-8051-1 VA-8020-1 VA-8050-1 VA-8051-1

1/2 in. stroke 65 sec (1.1 min) 1/2 in. stroke 65 sec (1.1 min) 3/4 in. stroke 90 sec (1.5 min) 3/4 in. stroke 90 sec (1.5 min) 5/16 in. stroke 90 sec (1.5 min) 5/16 in. stroke 45 sec (0.75 min) 5/l6 in. stroke 45 sec (0.75 min)

Stroke Time

Note: There may be no correlation between valve position and controller

output (0 to 100%). If you require correlation, use proportional control or actuators with position feedback.

72 VAV Controller—Variable Air Volume Controller

87F88F89FIncremental

Damper Actuator Stroke Time

90F91F92FZone Terminal

Setup for Balancing Contractors

The position accuracy of the VAV box damper is dependent upon the actuator stroke time entered. It is important that the true damper actuator stroke time be entered. The listed actuator times of 1, 2, or 5.5 minutes are for 90 degrees of rotational travel. If a VAV box has 45 or 60 degrees of travel, the stroke time must be adjusted. Multiply the listed stroke time by

0.5 for 45 degrees of travel by 0.667 for 60 degrees of rotation. Drive times that are inaccurate cause the controller to calculate a software

damper position that is not synchronous to the actual damper position. This error is particularly noticeable at the very end of the travel when the controller thinks the damper is fully closed, but is physically open. If a box has 45 or 60 degree travel, it is highly recommended that the entered stroke time used in HVAC PRO for Windows be tested under field conditions to verify that the box can be driven fully closed and open.

For simplicity, program a Zone Terminal to access only those values required for testing and balancing processes. For each box configuration style, determine which parameters the test and balance will require. Build a controller display file for each configuration. Up to three display files can be combined into one ZT load file. For example, a single duct box with reheat might require the values shown in Table 33.

Table 33: Parameters for Balancing a Single Duct Box with Reheat

Parameter name Function Purpose

Supply Setpt Supply Flow Supply Box Area Supply Mult Supply Delta P Damper Command Occ Clg Max Occ Clg Min Occ Htg Min Occ Htg Max Occ Setpt Occupied Status

view display present flow setpoint view display present flow rate view & adjust verify & correct box inlet area view & adjust calibration of flow measurement view secondary information view secondary information view & adjust verify & correct flow setpoint view & adjust verify & correct flow setpoint view & adjust verify & correct flow setpoint view & adjust verify & correct flow setpoint view & adjust change present control point view verify mode

Once you load the base configuration files into each controller, the balancing contractor can use a Zone Terminal to officially set the CFM schedules.

VAV Controller—Variable Air Volume (VAV) Controller 73

74 VAV Controller—Variable Air Volume Controller

93F94F95FTroubleshooting

Hardware Installation Inspection

96F97F98FTools Needed

for Troubleshooting

We recommend that once the mechanical contractor starts receiving delivery of the VAV boxes with factory mounted controls, arrangements are made to pull a sample of the shipment and bench test it by loading a job configuration before all the boxes are mounted in the ceiling.

It can also be advantageous to keep a box off to the side for use in training the balancing contractor on a bench setup, rather than a live box mounted in the ceiling.

CAUTION: Equipment Damage Hazard. Before starting, make

sure power is switched off.

Tools needed for typical troubleshooting include:

 ASC and N2 Bus Networking and Troubleshooting Guide

(LIT-6363003)

 Digital Multimeter (DMM)  100k ohm resistor  double banana plug (optional; shown in Figure 37; available from local

electronics store or ITT Pomona Stock No. 34F856 or 3F845), 1/4 watt for earth ground voltage tests

100k ohm, 1/4 watt

Use double banana plug for all tests that require a 100k ohm resistor placed in parallel with DMM.

Steps:

1. Connect 100k ohm resistor under plug's prongs.

2. Insert banana plug into DMM.

banana

3. Connect leads of DMM into banana plug.

Figure 37: Double Banana Plug Used with 100k ohm Resistor

VAV Controller—Variable Air Volume (VAV) Controller 75

99F100F101FInstallation

Checkout

Inspect the mounted VAV to ensure proper installation. Refer to the appropriate illustrations in the section of this technical bulletin titled Installation Procedures and to the engineering drawings.

1. Check that the mounting screws holding the subassembly onto the base frame are secure.

2. Verify that accessory equipment is connected and labeled correctly.

3. Ensure that the controller terminal connections are secure.

4. Verify that the N2 connections are secure and labeled correctly.

5. Verify that the VAV switches are appropriately positioned. (Refer to the Wiring Details and Networking the Controller sections of this technical bulletin.)

6. Verify that there are no unwanted earth ground connections to the controller following the procedures below.

No earth ground connections are allowed when wiring a Series VAV100/101 Controller. Although a single earth ground connection to the common terminal of Series VAV110/111 and VAV140/141 Controller is allowed, you may not want to use one. The same procedure as described in the following text for VAV100/101 may be used when no earth ground connections to VAV are intended.

Isolation and Grounding VAV100/101

This section will help you ensure proper isolation within your system. These procedures are not required, but are recommended to reduce installation errors. Use the following procedures to ensure proper isolation. Test the:

 field device wiring for proper isolation  transformer for isolation and correct polarity termination  connected field devices, transformer, and VAV for proper isolation  transformer and VAV for proper VA load requirements

76 VAV Controller—Variable Air Volume Controller

Field Device Wiring Isolation – VAV100/101

This section assists you in measuring field wiring terminated to the VAV. If you are confident that the field wiring has no earth grounds, you may go to the following section called Power Transformer Isolation - VAV100/101. A field device that is earth grounded becomes apparent when you test the entire controller.

 Before you terminate the field wires to the VAV, measure the

resistance of each wire to earth ground using an LED test circuit (preferred) or a DVM. For the LED test circuit, assemble the test circuit illustrated in Figure 38. Then, connect the circuit from each input to earth ground and then to each output to ground. For the DVM test, connect the DVM from each input to earth ground and then to each output to ground (Figure 38).

If the LED turns On (or you read a value less than 1 Megohm at any input or output), the circuit is improperly isolated. Replace or repair the wiring or the field device; or, for a binary output, add an isolation relay. Repeat the DVM test only.

If the LED does not turn On (or you read a value greater than 1 Megohm), the circuit may be properly isolated. (It will not be isolated if there are earth grounds that exist at higher voltages.) A value of infinite ohms indicates a completely isolated circuit at approximately zero volts. Connect this wire to the appropriate VAV terminal and check the next wire.

Field Device

IN / OUT

IN/OUT COM

DVM

VAV

LED Test Circuit (Preferred Method)

(+)

10 mA

Red

470 ohm

1/4 watt

Battery

Figure 38: Testing for an Isolated Circuit

(-)

IS OCIR CT

VAV Controller—Variable Air Volume (VAV) Controller 77

102FPower

Transformer Isolation – VAV100/101

 Before connecting the transformer to the VAV, connect the input

power to the primary leads of the 24 VAC transformer. Note: If you ground the secondary of the power transformer, you

must use a separate 24 VAC to 24 VAC isolation transformer (such as the Y65GS.)

 Measure the voltage of each secondary transformer lead to earth

ground with the DVM in parallel with a 100k ohm 1/4 watt resistor (Figure 39; if using double banana plug, insert plug into DVM).

- If you read 5 VAC or greater, the transformer is earth grounded.

You need an isolation transformer in order to isolate the connections from earth ground and protect system components. Wire a separate 24 VAC to 24 VAC isolation transformer (such as the Y65GS) to the VAV.

- If you read less than 5 VAC, the circuit is properly isolated.

Usually a value less than 0.10 VAC indicates a completely isolated circuit.

Line Voltage

24 VAC

100K ohm

1/4 watt

DVM

100K ohm

1/4 watt

DVM

TRANSFM1

Figure 39: Testing the Transformer

 Determine the polarity of the transformer’s leads by using a DVM

referenced to earth ground without the 100k ohm resistor. Connect the transformer’s secondary lead with the higher voltage potential to the 24 VAC terminal on the VAV. Connect the transformer’s secondary lead with the lower potential to the 24 VAC Common terminal on the VAV.

78 VAV Controller—Variable Air Volume Controller

Load Isolation – VAV100/101

If the field wires are not yet connected (because you skipped the section called Field Device Wiring Isolation - VAV100/101), disconnect one 24 VAC wire and terminate the field wires. Reconnect the 24 VAC wire.

Note: If you ground the contactor or solenoid coils to be driven by the

VAV, you must use a separate isolation relay for each load.

 Connect the leads of the DVM in parallel with the 100k ohm resistor

from the DC power supply (+15 VDC) output terminal of the VAV to earth ground (Figure 40). This tests whether the field devices, the VAV, and the transformer assembly are properly isolated.

VAV

24 VAC

Line

Voltage

24 VAC

24 VAC CO M

Field Wiring*

15 VDC

100k ohm

1/4 watt

DVM < 5 VDC/VAC = OK (Isolated)

DVM

DVM > 5 VD C/VAC = E arth Grounded

*AIC OM, B ICOM , ZB US CO M, A OC OM, BO CO M

GRDLOOP

Figure 40: Testing for Ground Loops

 If you read 5 VDC/VAC or greater, the circuit is improperly

isolated. Follow these steps:

1. Remove all the field wires and N2 Bus wires from the VAV, but leave the transformer wires attached. With the DVM still connected, reconnect each set of field wires, one at a time, until you read 5 VDC/VAC or greater. At this point, you have discovered one cause of the ground loop. Correct the problem.

2. Continue to reconnect each set of field wires until all ground loops are found and corrected. You’ll know that all grounds are corrected when you read less than 5 VDC/VAC on the DVM.

3. However, if you check all the field wires and you still read greater than 5 VDC/VAC, the transformer secondary is earth grounded. In this case, wire a 24 VAC to 24 VAC isolation transformer to the VAV and measure again. If the value is still 5 VDC/VAC or greater, replace the VAV.

Note: Binary outputs are often the cause of ground loops. Therefore, we

recommend that you test the binary outputs of the VAV before testing other points.

VAV Controller—Variable Air Volume (VAV) Controller 79

z If you read a value less than 5 VDC/VAC, the circuit is properly

isolated. A value of less than 0.10 VDC/VAC indicates a completely isolated circuit.

z Connect the DVM across the 24 VAC and the 24 VAC Common

terminal of the VAV. Read the voltage with all typical loads

energized. A reading of 24 VAC is required when the line voltage is nominal. If you read a value less than 20 VAC, make sure the primary voltage

matches the transformer’s voltage rating. For details, refer to the

Power Source and Loads section of this technical bulletin and

recalculate the VA requirements for the VAV Controller. You have completed the VAV isolation tests. If you plan to connect this

VAV to the N2 Bus for communication to other devices, refer to the

Application Specific Controllers Technical Manual (FAN 636.3), the Introduction tab, the ASC and N2 Bus Networking and Troubleshooting Guide Technical Bulletin.

80 VAV Controller—Variable Air Volume Controller

103F104F105FTroubleshooting

the VAV Controller with HVAC PRO for Windows

The following table indicates symptoms and corrections for typical control system malfunctions (primarily in pressure independent applications). We recommend that you use HVAC PRO for Windows Commissioning mode during all troubleshooting procedures.

Table 34: VAV Controller Troubleshooting Symptoms and Corrective Actions

Symptom Possible Cause Corrective Action

VAV Controller CFM readings are not within 10 percent of balancing contractors readings or flow readings are not repeatable.

No change in the CFM value while you are manually overriding the damper by changing the temperature setpoint or issuing a direct override to the damper command.

The damper actuator cycles excessively.

Series fan is not running.

Velocity Pressure Transducer out of calibration by more than 20 percent.

Damper does not seal. Box Multiplier Constant

and/or Box Area parameters are not set correctly.

One or both airflow pickup to DPT tubing connections are crossed, plugged, or open.

The ductwork configuration upstream of the airflow pickup is disturbing the air flow across the pickup.

Damper linkage is slipping or linked incorrectly.

Main system is not supplying enough air.

The Supply Deadband and/or Heating/Cooling Prop Bands are too narrow.

Electrical noise is present on zone temperature signal.

Unit is not in Occupied mode.

Unit in initial startup.

Command Auto Zero mode using HVAC PRO for Windows and read the offset value for the DPT sensor. If the value is greater than 20 percent of the sensor range, you need to replace or manually calibrate the transducer.

Override damper closed and verify. Verify the numbers displayed in the HVAC PRO for Windows

parameters screen against the information on the box, or check the OEM Reference Manual (FAN 638) for the recommended numbers per box type.

Check that the high or upstream side of the pickup connects to the DPT high side, and the downstream side of the pickup connects to the DPT low side. Check that the tubing is not plugged and that the test taps are capped.

Turns, transitions, and flex duct should be no closer than one duct diameter upstream from the airflow pickup. The takeoff should be at least three duct diameters upstream from the pickup.

Inspect the linkage while the actuator is being commanded to ensure tight connection.

If the VAV box actuator is linked correctly and you cannot obtain the maximum CFM setpoint, check the Central System Static Pressure to ensure enough primary air is being provided to properly balance the system.

Check the Supply Deadband value to ensure that it is greater than (48*(box inlet area))ft

If the cycling persists after changing the supply deadbands, check the heating and cooling prop bands to see if they are greater than 4°F/-15.5°C. If not, increase the prop band values to at least 4°F/-15.5°C and add an integration timer of 400.

Diagnose with HVAC PRO for Windows data graphing. If present, reroute wire or use twisted pair and/or shielded cable.

Check HVAC PRO for Windows parameter table to ensure occupied status shows on.

Before the series fan is commanded on, the damper fully closes to ensure the fan does not turn backwards.

/(4.5*(box inlet area))m2.

VAV Controller—Variable Air Volume (VAV) Controller 81

106F107F108FTroubleshooting

the N2 Bus and Networked VAV Controller

You need to troubleshoot the N2 Bus if the Metasys system is not properly communicating with the VAVs. This section first presents a troubleshooting table. Table 35 covers VAV or N2 communication problems and suggests which actions to take.

Second, specific troubleshooting tests are given. Before trying one of these tests, you may be able to determine the cause of the problem by asking yourself the following questions:

z Are the N2 Bus wires securely terminated to each VAV? z Is the N2 polarity correct? z Is the VAV powered and ready to respond? z Are the end-of-line device settings correct? z Have you cycled power on a VAV after changing its N2 address? z Is the W3 loop back jumper on the Companion Panel/LTD fully

pushed down on Pins 1 and 2?

z Are the VAVs configured properly with the correct number of points?

CAUTION: Electrical Shock Hazard. To avoid electrical shocks

when troubleshooting, always measure the REF to earth ground voltage with the DMM. If line voltage is measured, have a qualified electrician locate the fault.

109F110F111FTable 35: N2 Bus Troubleshooting Symptoms and

Corrective Action

Symptom Possible Cause Action

N2 Bus is offline.

VAV cycles online and offline.

VAV does not come online.

EOL jumpers and/or W3 jumper on MM-CVT101 or Companion Panel/LTD are not installed.

MM-CVT101 is not plugged into PC or 9 VDC source.

N2 Bus polarity is incorrect. Rewire N2 Bus wires for

A read-only point is defined in the Companion data base as a read/write point (AO or BO).

A Companion process is using an unconfigured point (i.e., not listed in HVACPRO.SYM file).

Two or more VAVs have the same address.

The address of the VAV was changed without its power being cycled afterw ard.

The ten second delay after downloading the VAV has not yet expired (HVAC PRO Revision 1.0 or earlier).

Install EOL jumpers and W3 jumper properly.

Plug MM-CVT101 into PC or plug it into a 9 VDC source.

proper polarity. Delete the AO or BO point and

read it as an AI or BI point to the Companion data base.

Delete the use of the unconfigured point in the Companion process.

Change each duplicate VAV address to a unique number.

Cycle power on the VAV.

Wait until the delay expires or cycle power on the VAV.

82 VAV Controller—Variable Air Volume Controller

112F113F114FZone Bus

Troubleshooting

-- HVAC PRO for Windows

Table 36 lists and describes the errors that may occur while using the HVAC PRO for Windows commissioning tool with the VAVs over the Zone Bus. The cause of the error is often a loose or improper connection between the CBLPRO (AS-CBLPRO), laptop PC, and the controller. A defective COM port on the laptop could also be at fault. Other times, a defective controller can cause an error.

Note: It takes ten seconds for a VAV Controller to reset and resume

communication after being downloaded.

An effective troubleshooting technique is to use a CBLCON and observe its LEDs, which will indicate the problem. You may also try exchanging the component that you believe is defective with a working component of the same type.

A noisy wire adjacent to the Zone Bus can also cause communication errors. Noise can be periodically induced into the Zone Bus, thereby causing sporadic communication failures between the laptop and the VAV. Most often, noisy lines cause intermittent disruption, not total loss of communication.

For more information on the HVAC PRO for Windows, refer to the

HVAC PRO for Windows User’s Manual (FAN 637.5).

Table 36: Communication Errors on Download

Error Number

or Description

Hardware

Communication

Error

Undefined command

Invalid message size

Invalid command

Not ready The VAV cannot process this

Bad E

No communication

Controller is still in reset mode.

Bad CRC The Cyclical Redundancy Check of

Invalid response

Cause

The device is being sent a message that contains an invalid command.

The size of the message sent does not correspond to the type of message sent.

The command issued is not valid for the data type.

message at this time. For example, the EEPROM is not functioning properly.

Write A problem with the EEPROM exists. Return the VAV for repair or

Some hardware problem exists, such as a loose connection or a failed component.

Resetting takes ten seconds after a download.

the message received is incorrect due to an error in transmission.

The message received is not what the HVAC PRO for Windows Load Utility expected.

Description

Solution

Check for tight and proper connections between the laptop PC, CBLPRO, and the VAV.

Cycle power on the VAV. If problem persists, return VAV for repair or replacement.

replacement. Check for tight and proper

connections between the laptop PC, CBLPRO, and the VAV.

Wait ten seconds for the reset period to expire before trying to commission the controller.

Check for tight and proper connections between the laptop PC, CBLPRO, and the VAV.

VAV Controller—Variable Air Volume (VAV) Controller 83

The green LED on the VAV110/111 and VAV140/141 Series Controllers may be used to troubleshoot problems with the Zone Bus.

Table 37: Zone Bus LED Indications

LED Status Indication

Off On Blinking

There is no power to the ASC. The Zone Bus is shorted to Common or 24 VAC. Normal communication is taking place.

84 VAV Controller—Variable Air Volume Controller

115F116F117FOrdering Information

Johnson Controls Code Numbers

Controllers

Sensors/ Transmitters

Table 38: Controller Code Numbers

Code Number Description

AS-VAV110-1 AS-VAV111-1

AS-VAV140-1 AS-VAV141-1 AS-VAVDPT1-1*

AS-VAVDPT2-1*

* Refer to Building VAVDPT Applications Application Note (LIT-6363042) in the

Application Specific Controllers Technical Manual (FAN 636.3).

VAV Controller with eight Binary Outputs (Quick Connects) VAV Controller with six Binary Outputs and two Analog Outputs

(Quick Connects) VAV Controller with screw terminals and eight BOs VAV Controller with screw terminals, six BOs and two AOs AS-VAV110-1 Control and DPT-2015-1 for Trane Single Duct

Applications AS-VAV111-1 Control and DPT-2015-1 for Trane Single Duct

Applications

Table 39: Sensor/Transmitters Code Numbers

Code Number Description

DPT-2015-1*

HE-6300

HE-6310

TE-6000 Series TE-6100-11,

TE-6100-12 Series TE-6300 Series TE-6400 Series

* DPT Transmitters are typically supplied as part of the actuator assembly (ATP Series)

or a controller assembly (VAV DPT Series).

Velocity Pressure Transducer (1.5 in. W.C.)

Wall Mount Humidity Sensor 0 to 5 VDC with 12 to 30 VDC

Duct Mount Humidity 0 to 5 VDC with 12 to 30 VDC

Temperature Sensor RTD Resistance Zone Temperature Sensor

(for T-4000 Cover) Temperature Sensor Nickel, Platinum, Silicon Metastat Zone Temperature

Sensor Series

1 to 5 VDC with 15 VDC Supply

Supply

Nickel, 1000 ohm with Phone Jack

Resistance

Type

VAV Controller—Variable Air Volume (VAV) Controller 85

Damper Actuator Assemblies

Valve Actuator Assemblies

Table 40: Damper/Actuator Code Numbers

Code Number Description

EDA-2040-21 or -22 EDA-2040-61 or -62 ATP-2040-212

ATP-2040-612

M100C Series M9000-500 Series

M9100-G Series

M9100-H Series

M9200-G Series

M9200-H Series

2-minute Rotation Time 24 VAC Incremental 6-minute Rotation Time 24 VAC Incremental EDA-2040-1 and DPT-2015-1 with

Cable EDA-2040-2 and DPT-2015-1 with

Cable Zone Bus Damper Actuators Zone Bus Addressable

Valve Linkage Assembly for M9100 and M9200 Direct Mount Actuators

Direct Mount Actuators Proportional - Voltage or

24 VAC Incremental 1 to 5 VDC Transmitter 24 VAC Incremental 1 to 5 VDC Transmitter

Current

Table 41: Valve Actuator Code Numbers

Code Number Description Ty pe

VA-715x Series

VA-7200 Series

VA-8020 Series

VA-8022 Series VA-8050 Series

VA-8051 Series

VA-8052 Series

VG-5000 Series

EP-8000-1 and -2

Valve Actuator Incremental or

0-10 VDC Proportional

Valve Actuator Incremental or

0-10 VDC Proportional

Valve Actuator Assemblies 1/2 in. 24 VAC

Triac/Incremental Valve Actuator Assemblies 1/2 in. 0-10 VDC Valve Actuator Assemblies

1/2 in., 3/4 in., 1 in., and 1-1/2 in." Valve Actuator Assemblies

1/2 in., 3/4 in., 1 in., and 1-1/2 in."

Valve Actuator Assemblies 1/2 in., 3/4 in., 1 in., and 1-1/2 in."

Valve/Actuator Assemblies 1/2 in., 3/4 in., and 1 in.

Electric to Pneumatic Transducer for Pneumatic Valves

24 VAC

Triac/Incremental

24 VAC

Triac/Incremental/ with

Feedback

0-10 VDC

24 VAC On/Off

Incremental 0-10 VDC

0 to 10 VDC to

Pneumatic High or Low

Volume

86 VAV Controller—Variable Air Volume Controller

Accessories

Table 42: Accessories Code Numbers

Code Number Description

AS-CBLPRO-2 AS-ENC100--0 AS-TBKIT-0 AS-XFR050-0 AS-ZTU100-1* EN-EWC10-0 EN-EWC15-0 MM-CVT101-0

P32 Series TE-6001-961

WS-WINPRO-0 WS-WINPRO-6

Y65XX-X Series

* Note: The AS-ZTU100-1 supports both AS-VAVxxx-0 and AS-VAVxxx-1 models. The AS-ZTU100-0 supports AS-VAVxxx-0 models only.

Zone Bus Communication Tool VAV System Enclosure for Field Installed Systems (Sheet Metal) Five Replacement N2 Bus and Five Power Terminal Block Connectors Transformer (50 VA) Zone Terminal Enclosure (UPM) Enclosure with 50 VA Transformer (UPM) RS-232/RS-485 Converter for N2 Download/Commissioning with

HVAC PRO for Windows Air Flow Switch Momentary Button Kit for Temporary Occupancy or Boost Modes

(for TE-6100-11,12 only) Configuration Tools Software (includes HVAC PRO for Windows) Configuration Tools Software Upgrade

(includes HVAC PRO for Windows) Transformer Option (24/120/220/277-480 VAC to 24 VAC)

118F119F120FVendor Code

Numbers

The following tables list code numbers and descriptions for VAV Controller equipment requirements. This equipment is available from:

Anixter 4701 W. Schroeder Drive Brown Deer, WI 53223 (414) 355-0222 (in Milwaukee) 1-800-242-5575 (structure wiring) 1-800-447-8565 (wire and cable)

Use the following table to order preconfigured cables from the factory.

Table 43: Preconfigured Cables

Description Cable Length Part Feet Meters Number

RJ45 Straight-through Cable Assembly Non-plenum Non-keyed plugs 24 Gauge/0.6 mm diameter 8 Conductor Solid Wire RJ45 Straight-through Cable Assembly Plenum Non-keyed plugs 24 Gauge/0.6 mm diameter 8 Conductor Solid Wire

25 7.5 889158 50 15 889161

100 30 889166

25 7.5 889315 50 15 889318

100 30 889324

VAV Controller—Variable Air Volume (VAV) Controller 87

Use the following table to order cable components for creating your own cables.

Table 44: Cable Components

Description Part Number

1000 ft/300 m Roll of Non-plenum Rated 24 Gauge/0.6 mm diameter 8 Conductor Solid Wire 1000 ft/300 m Roll of Plenum Rated 24 Gauge/0.6 mm diameter 8 Conductor Solid Wire 8-position Non-keyed Plugs for Solid Cable (Bag of 25) Hand Tool with 8-position Die Set for 24 AWG/0.6 mm diameter Solid Wire

CM-00424BAG-3

CMP-0042EAC-3

074683 Stewart

060612

88 VAV Controller—Variable Air Volume Controller

Specifications

Table 45: General Specifications

Product Name

Product Code Numbers

Power Input

Power Draw

Ambient Operating

Conditions

Ambient Storage

Conditions

Dimensions (H x W x D)

Shipping Weight

Processor

Word Size

EEPROM Size

ROM/EPROM Size

RAM Size

Interfaces

Inputs/Outputs

Standard Compliance

Agency Listings

Variable Air Volume (VAV) Controller AS-VAV100-0, AS-VAV101-0;

AS-VAV110-1, AS-VAV111-1; AS-VAV140-1, AS-VAV141-1

20-30 VAC @ 10 VA VAV with sensors/transmitters: 10 VA (400 mA) 32 to 122F/0 to 50C

10 to 90% RH

-40 to 158F/-40 to 70C 10 to 90% RH

6.5 x 6.4 x 2.2 in./165 x 163 x 56 mm without enclosure

6.8 x 7.3 x 4.7 in./173 x 185 x 119 mm with the AS-ENC100-0 enclosure

1.4 lb./0.64 kg 80C652 @ 11 MHz 8 bit 8k byte (2k byte for VAV 100/101) 64k byte 8k byte N2 and Zone Bus 8 Analog Inputs (0-10 VDC)

4 Binary Inputs 0/2 Analog Outputs (0-10 VDC) 8/6 Binary Outputs (24 VAC Triacs) IEEE 472

IEEE 518 IEEE 587 Category A FCC Part 15, Subpart J, Class A UL 916, Energy Management Listed, Class PAZX VDE 0871 Class B

UL 916 Listed and CSA Certified as part of the Metasys Network.

VAV Controller—Variable Air Volume (VAV) Controller 89

Table 46: Input/Output Specifications for VAV 100/101

Function Reso-

AI-Voltage

AITemperature

AIPotentiometer

ACCUM-DC

BI-DC Sense

AO Voltage

BO-AC Triac

DC Supply Out

N2 Bus

Zone Bus

State of Outputs During PWR. Fail = Disables when 24 VAC PWR drops below 18 VAC State of Outputs After PWR. is Restored = Remain disabled for 10 seconds minimum, and then come on per

Restart Configuration. * NM = normal mode, CM = common mode.

CM Cap is a common mode capacitor connected from the I/O point to a separate ground plane. ** To interface to TTL outputs such as demand meters, use an open collector output to drive the +15 VDC pull-up resistor and

contact cleaning current capacitor.

Sam-

lution

pling Time

14 bit 1.5 sec

15 bit 1.5 sec

16 bit 1.5 sec

17 bit 1.5 sec

32 bit 10 ms

(100 Hz)

1 bit 10 ms N/A 0-15 VDC,

8 bit 1.5 sec N/A 0-10 VDC @

N/A 1.5 sec N/A 24 VAC

N/A N/A N/A 14.6-17 VDC

N/A N/A N/A 5000 ft/

N/A N/A N/A 500 ft/150 m N/A N/A PTC +

Accu-

Range DC Input

racy

20 mV

0.5F

0.7F

1.3F

0.1F

N/A 0-15 VDC,

0-2 V or 0-10 VDC

1000 ohm Si 3540 ohm 0-2k ohm NM ResCap

1000 ohm Ni 3540 ohm 0-2k ohm NM ResCap

1000 ohm Pt 3540 ohm 0-2k ohm NM ResCap

0-2k ohm Potentiometer

2.5 V Trig **

10 mA maximum

@ 50-500 mA

@ 90 mA

1500 m

Sensor/ Impedance

470k ohm 0-5k ohm NM ResCap

3540 ohm 0-2k ohm NM ResCap

47k ohm 0-5k ohm NM ResCap

N/A 1k-10M ohm No Special

N/A 48-480 ohm Opto +

N/A 162-10M ohm Opto +

N/A N/A PTC +

Load

Impedance

Noise Protection*

+ CM Cap

Parts

CM Cap

Tranzorb

Noise/Surge Standard Tested To*

IEEE-587

a) CM Ringwave:

1.5k V b) NM Bi-Wave:

1.5k V, 3k A

IEEE-472 a) CM Ringwave:

1.5k V b) NM Ringwave:

500V

IEEE-587 CM Ringwave: 1.5k V

NM Ringwave: 500V IEEE-472 CM Ringwave: 1.5k V

NM Ringwave: 500V

90 VAV Controller—Variable Air Volume Controller

Table 47: Input/Output Specifications for VAV 110/111 and VAV 140/141

Function Reso-

lution

AI-Voltage

AITemperature

AIPotentiometer

ACCUM-DC

BI-DC Sense

AO Voltage

BO-AC Triac

DC Supply Out

N2 Bus

Zone Bus

State of Outputs During PWR. Fail = Disables when 24 VAC PWR drops below 18 VAC State of Outputs After PAR. is Restored = Remain disabled for 10 seconds minimum, and then come on per

Restart Configuration. * NM = normal mode, CM = common mode.

contact cleaning current capacitor.

14 bit 1.5 sec

15 bit 1.5 sec

16 bit 1.5 sec

17 bit 1.5 sec 0-2k ohm

32 bit 10 ms

1 bit 10 ms N/A 0-15 VDC,

8 bit 1.5 sec 0-10 VDC @

N/A 1.5 sec N/A 24 VAC

N/A N/A N/A 14.6-17 VDC

N/A N/A N/A 5000 ft/1500 m N/A N/A PTC + Opto +

N/A N/A N/A 500 ft/150 m N/A N/A PTC +

Sampling Time

(100 Hz)

Accu-

Range DC Input

racy

20 mV

0.5F

0.7F

1.3F

N/A 0-15 VDC,

0-2 V or 0-10 VDC

1000 ohm Si 3540 ohm 0-2k ohm NM ResCap +

1000 ohm Ni 3541 ohm 0-2k ohm NM ResCap +

1000 ohm Pt 3542 ohm 0-2k ohm NM ResCap +

Potentiometer

2.5 V Trig **

10 mA maximum

@ 50-500 mA

@ 90 mA

Sensor / Impedance

470k ohm 0-5k ohm NM ResCap +

3543 ohm 0-2k ohm NM ResCap +

47k ohm 0-5k ohm NM ResCap +

N/A 1k-10M ohm No Special

N/A 48-480 ohm CM Cap

N/A 162-10M

Load

Impedance

ohm

Noise Protection*

CM Cap

Parts

CM Cap

Tranzorb

Noise/Surge Standard Tested To*

IEEE-587

a) CM Ringwave:

1.5k V b) NM Bi-Wave:

1.5k V, 3k A

IEEE-472 a) CM Ringwave:

1.5k V b) NM Ringwave:

500 V

IEEE-587 CM Ringwave: 1.5k V

NM Ringwave: 500 V IEEE-472 CM Ringwave: 1.5k V

NM Ringwave: 500 V

VAV Controller—Variable Air Volume (VAV) Controller 91

Notes

Controls Group FAN 636.3

507 E. Michigan Street Application Specific Controllers Manual P.O. Box 423 Printed in U.S.A. Milwaukee, WI 53201

92 VAV Controller—Variable Air Volume Controller

Johnson Controls METASYS VAV110, METASYS VAV111, METASYS VAV101, METASYS VAV100, METASYS VAV141 Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual