Johnson Controls WT-4002-MCR, WT-4002-MCM, WT-4002-MFR, WT-4002-MFM Installation Instructions Manual

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC)

24- 10732- 5, Rev. D

Room Thermostats

Installation Instructions

WT-4002-MCR, WT-4002-MCM,
WT-4002-MFR, WT-4002-MFM

Refer to the QuickLIT website for the most up-to-date version of this document.

Application

The WT-4000 Series Pneumatic-to-Direct Digital
Control (DDC) Room Thermostats provide reliable
zone comfort and enhanced energy economy via
remote monitoring and temperature setpoint
management. This arrangement provides greater
energy policy compliance, and facilitates trending of
floor space usage in commercial, industrial, and
municipal HVAC environments.

The WT-4000 Series Room Thermostats are ideally
suited for energy-saving, pneumatic-to-DDC building
upgrades. Designed for non-invasive replacement
of existing manual pneumatic thermostats, the
WT-4000 Series Room Thermostats provide a number
of DDC features, including remote wireless setpoint
control and occupancy scheduling, and continuous
room temperature, branch line pressure, and battery
status monitoring. All of these features were previously
unavailable in existing pneumatic HVAC control
systems.

The innovative design of the WT-4000 Series Room
Thermostats completely reshapes the pneumatic
HV AC control industry. The room thermostat itself does
not utilize any mechanical parts. A solid state
temperature sensor replaces the bi-metallic strip
elements for precise room temperature mo n ito rin g. In
addition, an advanced piezoelectric air valve replaces
the mechanical relay for improved branch line pressure
control. All of these technologies provide longer, more
dependable, and maintenance-free operation.

Models are available for wireless mesh
communications, or they can be configured in the field
for stand-alone applications. In a wireless mesh
network application, the WT- 4000 Series Room
Thermostat communicates with the controller by
means of a Johnson Controls® WT-ROUTER Router
and Johnson Controls WT-BAC-IP Gateway.

Some WT-4000 Series Room Thermostats include a
binary dry contact input for an occupancy sensor (field
furnished), to detect motion and determine if a space is
occupied. This feature maximizes up to 30% energy
savings in high-energy usage environments such as
schools, dormitories, offices, and hospit als by adjusting
the temperature of the space based on the occupancy
status.

Part No. 24-10732-5, Rev. D

Issued August 2017

All WT-4000 Series Room Thermostats include an
LCD, with either a Fahrenheit or Celsius temperature
display. Depending on the model chosen, the room
thermostat can transmit sensed temperature, setpoint
temperature, occupancy status, and low battery
conditions to an associated router and gateway. The
WT-4000 Series Room Thermostat is designed for
indoor, intra-building applications only.

The WT-4000 Series uses a proprietary
direct-sequence, spread-spectrum RF technology,
and operates on the 2.4 GHz Industrial, Scientific, and
Medical (ISM) band. The room thermostat meets the
IEEE 802.15.4 standard for low power, low duty cycle
RF transmitting systems.

IMPORTANT: The WT -4000 Series
Pneumatic-to-DDC Room Thermostat is intended to
provide an input to equipment under normal
operating conditions. Where failure or malfunction of
the room thermostat could lead to personal injury or
property damage to the controlled equipment or
other property, additional precautions must be
designed into the control system. Incorporate and
maintain other devices, such as supervisory or
alarm systems or safety or limit controls, intended to
warn of or protect against failure or malfunction of
the room thermostat.

IMPORTANT: Le WT-4000 Series
Pneumatic-to-DDC Room Thermostat est destiné à
transmettre des données entrantes à un équipement
dans des conditions normales de fonctionnement.
Lorsqu'une défaillance ou un dysfonctionnement du
room thermostat risque de provoquer des blessures
ou d'endommager l'équipement contrôlé ou un autre
équipement, la conception du système de contrôle
doit intégrer des dispositifs de protection
supplémentaires. Veiller dans ce cas à intégrer de
façon permanente d'autres dispositifs, tels que des
systèmes de supervision ou d'alarme, ou des
dispositifs de sécurité ou de limitation, ayant une
fonction d'avertissement ou de protection en cas de
défaillance ou de dysfonctionnement du room
thermostat.

WT-4 000 Series Pneumatic-to-Direct Digital Control (DDC)

Room Thermostats Installation Instructions

1

IMPORTANT: The WT-4000 Series
Pneumatic-to-DDC Room Thermostat is not
designed or intended for use in mission-critical or
life/safety applications.

North American Emissions Compliance

United States

Compliance Statement (Part 15.19)

This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:

1. This device may not cause harmful interference,
and

2. This device must accept any interference
received, including interference that may cause
undesired operation.

Warning (Part 15.21)

Changes or modifications not expressly approved by
the party responsible for compliance could void the
user’s authority to operate the equipment.

Canada

Industry Canada Statement

The term IC before the certification/registration
number only signifies that the Industry Canada
technical specifications were met.

Installation

The first step of the installation process is to plan the
layout of the devices on the building floor plan. This
process includes identifying the desired locations for all
WT-4000 Series Pneumatic-to-DDC Room
Thermostats, as well as the Johnson Controls
WT-BAC-IP Gateway.

Next, measure the radial distances between each
WT-4000 Ser ies Room Thermostat and the
WT-BAC-IP Gateway, to determine if the distances are
within 200 ft (61 m). If the distance exceeds 200 ft
(61 m), Johnson Controls WT-ROUTER Routers must
be installed to relay signals between each room
thermostat and the associated gateway.

The ideal installation provides each room thermostat
with at least two routes of transmission to the gateway,
to ensure signal transmission success. The nominal
transmission range of each router in a standard
building is 200 ft (61 m). To ensure proper signal
transmission in a wireless mesh network, there should
be at least two routers, or one router and one ga teway,
located within a 200 ft (61 m) radius of every room
thermostat.

In order for the devices to connect to the same mesh
network, they all must have the same group ID. Both
the group ID and the device ID can be changed in the
field; see Net Config Screen
details.

on page 10 for more

Le terme « IC » précédant le numéro d'accréd itation /
inscription signifie simplement que le produit est
conforme aux spécifications techniques d'Industry
Canada.

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

2

Dimensions

(21)

(95)

(120)

Figure 1: WT-4000 Series Pneumatic-to-DDC Room Thermostat,

Dimensions, in. (mm)

4-23/32

13/16

3-3/4

Mounting

The WT-4000 Series Room Thermostats require the
WT-BAC-IP Gateway and WT-ROUTER Router to
operate as a complete wireless solution. Refer to the

WT-BAC-IP Gateway Installation Instructions
(Part No. 24-10732-21) for details on installing the
gateway, and the WT-ROUTER Router Installation
Instructions (Part No. 24-10732-13) for details on

installing the router.

Tools and Hardware Required

• Couplings or reducers to connect room
thermostats to existing air lines

• Needle nose pliers

• Small level

• Fasteners and anchors to se cure room thermost ats
(site specific)

• Plastic tie wraps to secure routers (site specific)

• Electric drill (optional)

• Building floor plans identifying where the system is
to be installed, serving multiple purposes:

- To plan the wireless network before

installation, by identifying room thermostat
locations

- To document the location of where each
wireless device is installed

Mounting Procedure

Mount the WT- 4000 Series Room Thermostat
according to the steps that follow. Only those
individuals that are experienced with HVAC
maintenance and commercial room thermostats sh ould
perform this installation.

1. Remove the old room thermostat from the
mounting surface and disconnect the air lines
connected to it. Be sure to label the branch line and
the main line.

2. Bend the four locking tabs on the wallplate
outward to separate the wallplate from the new
WT-4000 Series Room Thermostat.

3. Mount the wallplate to the mounting surface:
a. Thread the existing air lines from the wall

through the large opening in the wallplate.

b. Position the wallplate against the mounting

surface to be sure it seats flush with the
surface.

c. Use a small level or visually check that the

wallplate is level.

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

3

d. Mounting holes on the wallplate are designed

Figure 2: LCD during Initialization

to fit a standard electrical box. If additional
mounting holes are required, mark the
locations on the mounting surface.

e. Remove the wallplate from the mounting

surface and drill any additional mounting holes
as needed at each of the marked locations.

f. Use the appropriate mounting hardware (field

furnished) for the specific mounting surface
and secure the wallplate to the surface.

Figure 2 illustrates the LCD during room
thermostat initialization.

4. Connect the air lines to the room thermostat. See

Clean Air Requirements

on page 5 to ensure that

the air supply is clean, dry, and oil-free.

IMPORTANT: Avoid applying excessive pressure
while making the air line connections to the barbed
fittings on the room thermostat. Failure to do so may
damage the room thermostat and void the warranty.

5. Install the four 3.6 V lithium batteries included with
the room thermostat into the battery compartment.
Be sure to match the positive (+) battery ends with
the positive (+) battery terminals in the battery
compartment.

Note: The room thermostat can operate with just two
batteries installed; however, it operates for a
significantly shorter period of time. To maximize battery
life, we recommend that all four batteries be installed.

6. Once powered up, the room thermostat initializes
in:

a. 30 seconds if the room thermostat can connect

to a network.

b. 3 minutes if a network is not present.

IMPORTANT: Do not press any buttons during the
initialization process. Configuration changes made
during initialization are not saved.

FIG:lcd_initliztn

7. Check the wireless connectivity at the intended
room thermostat installation location. It may take
approximately 30 seconds for the room thermostat
to initialize.

a. Look at the wireless connection status

indicator on the room thermostat LCD
(Figure 4). If shows on the upper-right

corner of the LCD, the wireless connection is
established and the room thermostat is
operating properly. If the LCD is blank in the
upper-right corner, there is no wireless
connection.

b. Look at the number of routes to the

WT-BAC-IP Gateway on the room thermostat
LCD (Figure 4). If the number of routes is
blank, the room thermostat is not connected to
the gateway. If the number 1 shows, there is
one connection. If the number 2 shows, there
are two or more connections and the room
thermostat is operating properly.

8. Attach the room thermostat to the previously
installed wallplate by aligning the slot in the room
thermostat housing with the top of the wallplate
and sliding the bottom of the room thermostat
housing over the bottom of the wallplate.

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

9. Document the device ID and the location of each
room thermostat on the floor plan.

4

Safety Measures for Electrostatic Sensitive
Devices (ESDs)

The WT-4000 Series Room Thermostat includes an
ESD-sensitive circuit board. Use caution when
handling the room thermostat when the backplate
(wallplate) is removed. Do not physically touch any part
of the circuit board while connecting air lines, without
wearing ESD protective gear . Even minimal
electrostatic discharge can severely damage the room
thermostat.

Clean Air Requirements

Before installing WT-4000 Series Room Thermostats,
check that the air in the pneumatic lines is properly
cleaned. Clean, dry, and oil-free air in the main supply
line is required for normal room thermostat operation.

The pneumatic system must include a properly
operating air dryer and coalescing air filter that
removes water, oil, and other impurities from the main
supply air before it reaches the room thermostat. If the
existing pneumatic system is contaminated with water
or oil, Johnson Controls recommends installation of a
pre-filter before each room thermostat to protect the
device from contaminants and failure.

Note: Room thermostat failures due to main supply air
contamination with impurities including water, oil, dust,
or other solid particles are not replaceable under the
product warranty.

Johnson Controls recommends using the following
in-line air filter with WT-4000 Series Room
Thermostats:

• Johnson Controls A-4000-1037 In-Line Air Filter
Before installing room thermostats, check for the

following:

• An air dryer that is operating properly

• A coalescing air filter that is replaced and
maintained properly

• In-line air filters before each room thermostat
where necessary

Order of Installation for Wireless Room
Thermostat Models

The WT-4000 Series Room Thermostats look for a
wireless network as soon as they are powered up. We
recommend that the WT-BAC-IP Gateway and
WT-ROUTER Router are installed first to establish a
network connection before the room thermostats are
installed and powered.

If the room thermostats are installed before
establishing a wireless network, be aware of the
following:

• Once powered up, the room thermostat initializes
and looks for a network for 3 minutes. During
initialization, the LCD shows code 512 (Figure 2).

IMPORTANT: Do not press any buttons during the
initialization process. Configuration changes made
during initialization are not saved.

• The room thermostat operates in the Occupied
Mode with the following default settings:

• Setpoint temperature: 70°F (21°C)

• Comfort Zone: ±3F° (±1.8C°)

• The default settings can only be changed from the
controller tool, once the WT-BAC-IP Gateway is
installed.

• Once the WT-BAC-IP Gateway and the
WT-ROUTER Routers are inst alled, check the LCD
on each room thermostat to confirm that they are
connected to the network (Figure 4).

• The default sampling interval is 5 minutes, so it
may take some time for all of the room the rmost at s
to establish a network connection.

In summary, install the components of the mesh
network in the following order:

1. Install the WT-BAC-IP Gateway.

2. Install the WT-ROUTER Routers.

3. Configure the WT -4000 Series Room Th ermostat s;
see Setup and Adjustments

4. Install the WT -4000 Series Room Thermost ats; see

Mounting Procedure

on page 3.

on page 6.

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

5

Setup and Adjustments

Shoulder Mode Button –

Triggers Manual Shoulder
(Unoccupied) Mode

Override Mode Button –
Triggers Manual Override
(Occupied) Mode

Light Button – Lights the
Display for 10 Seconds

Up Button –

Increases the Room

Temperature Setpoint

Down Button –

Decreases the Room

Temperature Setpoint

LCD – See Figure 4

for LCD Details

Figure 3: WT-4000 Series Pneumatic-to-DDC Room Thermostat

Button Descriptions

Figure 4: Expanded View of LCD Showing Details

Error Code Display

Fan Outp ut

WT-BAC-IP Ga teway

Requested Branch

Line Pressure (psig)

Received Signal

Strength Indicator

Actual Branch

Line Pressure (psig)

Room Temperature or

Requested Setpoint

(When Up or Down

Buttons ar e Pressed)

Since the room thermostats are battery-po wered
devices with internal memory, they can be configured
prior to, or right after, installation. Johnson Controls
recommends that all of the room thermostats be
configured before installation, to prevent any possible
issues with operation.

Operating Mode

Wireless Connection Status

Number of Routes to the

Battery Voltage Level

Heat or Coo l O utput

FIG:lcd_dtls

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

6

LCD Details

Battery Voltage Level

Operating Mode

a. Occupied – Scheduled Occupied Mode: The

temperature can be adjusted within the
Comfort Zone.

b. Unoccupied – Scheduled Unoccupied

Mode: The HVAC controls are off and the
temperature cannot be adjusted. To turn the
HVAC controls on, press the Override button

to put the room thermostat in the

Override mode, and then adjust the
temperature setting using the Up/Down
buttons.

c. Override – Manual Override Mode: The

temperature can be adjusted within the
Comfort Zone.

d. Shoulder – Manual Unoccupied Mode: The

temperature cannot be adjusted. To put the
room thermostat back to its scheduled mode,

press the Shoulder button again;

Occupied reappears on the main screen.

Wireless Connection Status

Indicates if the room thermostat is connected to the
WT-BAC-IP Gateway.

a. : A connection is established.
b. Blank: There is no connection.

Number of Routes to the WT-BAC-IP Gateway

Indicates how many communication paths exist
between the room thermostat and the WT-BAC-IP
Gateway.

a. Blank: The room thermostat is not connected

to the WT-BAC-IP Gateway.
b. 1: One connection exists.
c. 2: Two or more connections exist and the room

thermostat is operating properly.

a. : The battery is fully charged.

b. : The battery charge is low and the

batteries should be replaced.

Heat or Cool Output

a. : Cooling is on.

b. : Heating is on.

Requested Branch Line Pressure – psig (kPa)

Indicates the required branch line pressure based on
the control calculation.

Actual Branch Line Pressure – psig (kPa)

Indicates the measured values of the branch line
pressure. The actual branch line pressure should be
within 0.6 psig (4 kPa) of the requested branch line
pressure.

Display Codes
Table 1: Display Codes

Display

Description

Code

2 0 psig (0 kPa) available in main line
4 Insufficient branch line pressure
8 Pressure down leak in the system (pressure

12 Insufficient branch line pressure and pressure

16 Pressure up leak in the system (pressure

22 Insufficient branch line pressure and pressure

24 Both pressure down leak and pressure up leak

512 Configuring wireless network
1024 Time and Date need to be configured

Any
Other
Number

decreases when it should remain constant)

down leak in the system

increases when it should remain constant)

up leak in the system

in the system

(Stand-Alone Mode)
Product error; contact the local

Johnson Controls representative

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

7

Received Signal Strength Indicator

Indicates the relative strength of the wireless signal
between the room thermostat and the device it is
communicating with.

a. -39 and higher: A strong and solid wireless

connection exists; no further analysis is

required.
b. -44 to -40: The wireless signal is getting

through; however, the room thermostat should

be monitored. If the signal strength

deteriorates further, there is a risk of data loss.

Consider adding a WT-ROUTER Router

between the devices to strengthen the signal.
c. -45 and lower, or --- : The room thermostat

has a very weak wireless connection or it is

failing to connect to other devices on the

network, resulting in the loss of a significant

number of data packets. The room thermostat

may be located too far from the other devices

or there may be wireless interference in the

area. To strengthen the wireless signal, add a

WT-ROUTER Router between the problematic

devices on the network to create an additional

connection point.

Room Temperature or Requested Setpoint

Indicates the current room temperature. Pressing the
Up/Down buttons once shows the locally-defined
setpoint temperature.

Adjusting the Room Setpoint Temperature

The WT-4000 Series Room Thermostat operates in
conjunction with the preset building configuration
parameters; therefore, the room setpoint temperature
can only be changed within predefined Comfort Zone
limits.

1. Confirm that the room thermostat is in the
scheduled Occupied Mode; the top of the LCD
must read Occupied.

2. The temperature reading on the LCD displays the
current room temperature. To increase or decrease
the room setpoint temperature, press the Up/Down
buttons to select the desired setpoint.

a. When the Up/Down buttons are pressed once,

the LCD shows the user-defined room setpoint
value and the LCD reads Setpoint.

c. When the setpoint is displayed, keep pressing

the Up/Down buttons to reach the desired
room setpoint temperature.

d. If the Up/Down buttons are pressed and the

setpoint stops increasing or decreasing,
predefined Comfort Zone limits have been
reached. If the setpoint does not change, the
local controls are disabled.

Note: Contact the building administrator if the room
temperature minimum or maximum allowable settings
are not comfortable.

e. The room thermostat decides to heat or cool

based on the current room temperature and
the specified setpoint.

3. When the desired setpoint is specified, the LCD
returns to the main screen within 5 seconds.

4. If the LCD reads Unoccupied, the room
thermostat is scheduled to be in the Unoccupied
Mode. If the area requires heating or cooling while
the room thermostat is in the Unoccupied Mode,

press the Override button to change the
room thermostat to the Override Mode. See Using

the Override Mode Button that follows.

Using the Override Mode Button

If the LCD reads Unoccupied, the room thermostat is
scheduled to be in the Unoccupied Mode and the local
room thermostat controls are disabled. If the area
requires heating or cooling:

1. Press the Override button to change the
room thermostat to the Override Mode.

2. The room thermostat stays in the Override Mode,
as defined by the configuration parameters (default
2 hours). The room setpoint temperature can be
adjusted within predefined Comfort Zone limits for
the duration of the Override Mode period.

3. See Step 2 in the Adjusting the Room Setpoint
Temperature section to change the room setpoint
temperature.

4. Once the Override Mode period expires, the room
thermostat returns to its originally scheduled mo de.
If the heating or cooling period needs to be

Note: When the room temperature and the setpoint
value are the same, the HVAC equipment is off.

b. If neither the Up or Down button is pressed

again, the LCD returns to the main screen
within 5 seconds.

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

extended, press the Override button again
and follow Step 2 in the Adjusting the Room

Setpoint Temperature section.

8

Using the Shoulder Mode Button

Figure 5: WT-4000 Series Room Thermostat Firmware Version Screen

CH:

GI:

Device Net w or k G r oup ID

DI:

Unique Thermostat Device ID

DF:

Display Firmware Number

The Shoulder Mode button allows the WT-4000 Series
Room Thermostat to be placed into a shallow setback
mode. When the room thermostat is activated, it does
not use HV AC equipment as lon g as the temperature is
within the Shoulder Mode configured setpoint limits
(default ±5F° [±3C°]).

For example, with a setpoint of 70°F (21°C) and the
Shoulder Mode activated, the room thermostat does
not turn the HVAC equipment on as long as the room
temperature is between 65 and 75°F (18 and 24°C).
Use the Shoulder Mode to save energy wh en a room or
zone is vacated earlier than when the Unoccupied
Mode is scheduled to begin.

Configuration

The following steps describe pre-installation,
device-level configuration.

Room Thermostat Configuration Mode

1. Bend the four locking tabs on the wallplate outward
to separate the wallplate from the room thermost at.

2. Install the four 3.6 V lithium batteries included with
the room thermostat into the battery compartment.
Be sure to match the positive (+) battery ends with
the positive (+) battery terminals in the battery
compartment.

3. Once powered up, the room thermostat initializes
in:

1. Press the Shoulder button to activate the
Shoulder Mode.

2. The Shoulder Mode period has a limited duration;
the room thermostat goes back to its regularly
scheduled mode at the next scheduled Unoccupied
Mode change.

3. Press the Shoulder button again to return to
the Occupied Mode.

a. 30 seconds if the room thermostat can connect

to a network.

b. 3 minutes if a network is not present.

IMPORTANT: Do not press any buttons during the
initialization process. Configuration changes made
during initialization are not saved.

Figure 2 illustrates the LCD during room
thermostat initialization.

4. Press and hold the Shoulder button and the

Override button simultaneously for
6 seconds to set the room thermostat in the

Configuration Mode. Initially, the LCD changes to
the firmware version screen (Figure 5), and then
after 10 seconds the configuration menu appears
(Figure 6).

5. Use the Up/Down buttons to navigate thr o ug h th e
room thermostat menu. All further configuration
settings must be made while in the Configuration
Mode.

Note: If the configuration screen is left idle for
10 seconds, it returns to the normal operation screen.

RF:

Radio Module Firmware Number

WT-4000 Series Pneumatic-to-Direct Digital Control (DDC) Room Thermostats Installation Instructions

Radio Ch annel Num ber

Firmware
DF 0. 3. 37

RF 1. 16. 14
CH 11
GI 111.111
DI 71.40

FIG:frmwr_vrsn_ scrn

9