Orion Zoning User Manual
ZoningZoning
Zoning
ZoningZoning
Design GuideDesign Guide
Design Guide
Design GuideDesign Guide
Zone
Zone
This manual is intended as a general guide and reference for the correct application of Orion zoning systems.
It is not intended to be a substitute for careful HVAC system engineering design and layout. WattMaster
assumes no responsibility for incorrect or poor system application or design implemented by any of
WattMaster’s representatives or their respective customers.
8500 NW River Park Drive · Parkville , MO 64152
Toll Free Phone: 866-918-1100
PH: (816) 505-1100 · FAX: (816) 505-1 101 · E-mail: mail@wattmaster.com
Visit our web site at www.orioncontrols.com
Form: OR-SYS-ZDG-01B Copyright 2002 WattMaster Controls, Inc.
AAON is a registered trademark of AAON, Inc., Tulsa, OK.
WattMaster Controls, Inc. assumes no responsibility for errors, or omissions.
This document is subject to change without notice.
Table Of Contents
Zoning Systems Versus True VAV Systems ..........................................................................5
How Orion Works .................................................................................................................. 6
Why Should I Use Orion?...................................................................................................... 8
What Is Unique About Orion? ..........................................................................................8-10
Basics Of Designing A Zoning System................................................................................ 11
Design Considerations ...................................................................................................12-13
Zoning Design Procedures.............................................................................................14-23
System Installation .........................................................................................................24-27
Application Notes ................................................................................................................29
Appendix ........................................................................................................................30-31
Table Of Figures & Tables
Figure 1-1: Typical Orion Zoning System Overview ............................................................7
Figure 1-2: Zones Affected By Outdoor Load.................................................................. .14
Figure 1-3: Zone Layout With External Zones Only ......................................................... .15
Figure 1-4: Zones With North And South Exposures ....................................................... .15
Figure 1-5: Zoning And Constant Volume Units ................................................................15
Figure 1-6: Round Bypass Damper.................................................................................. .17
Figure 1-7: Rectangular Bypass Damper & Kit ................................................................ .17
Figure 1-8 Preferred Sensor Location ..............................................................................1 8
Figure 1-9: Acceptable Sensor Location ........................................................................... 18
Figure 1-10: Least Desirable Sensor Location .................................................................... 18
Figure 1-11: Pressure Dependent Damper .........................................................................1 9
Figure 1-12: Pressure Independent Damper.......................................................................1 9
Figure 1-13: Rectangular Damper & Damper Kit ................................................................ 21
Figure 1-14: WattMaster Communication Wire................................................................... 25
Figure 1-15: Networked System Communications Loop Wiring.......................................... 28
Figure 1-16: Transformer & Wire Sizing Considerations Without Modular Connectors ...... 30
Figure 1-17: Transformer & Wire Sizing Considerations With Modular Connectors ........... 31
Zoning Design Guide
Zoning Systems Versus True VAV Systems
General
Even though there are some similarities between zone
control systems and Variable Air Volume (VAV) systems, there are some major differences. In many cases
systems will be called VAV when in fact they are really
a zoning system or are referred to as a zoning system
when they are really a VAV system. Always make sure
that you do not try to adapt a zoning system to a VAV
design system. Understanding the differences will help
you to prevent misapplication of the Orion zoning system. In the paragraphs that follow we will try to explain the differences, advantages and disadvantages of
each and explain their operation.
V AV Systems
These systems consist of an HVAC unit that is generally a cooling only unit and VAV terminal units located
in the downstream ductwork that are used to control
the amount of constant temperature air delivered to the
various building zones. Sometimes the HVAC unit may
have gas or electric heat, but it is typically sized and
applied for morning warm-up purposes. The HVAC unit
is designed to vary the volume of air that is supplied to
the duct system by using either inlet vanes or an electronic variable frequency drive. These devices modulate to control the air flow through the supply fan in
response to the static pressure in the duct system. VAV
systems typically use high velocity VAV terminal units
to distribute the air to the zones. As the various VAV
terminal units in the different zones open and close to
supply the constant temperature air to the spaces, the
HVAC unit varies the volume of constant temperature
air based on the static pressure in the ductwork. The
HVAC unit is designed to maintain a constant cold supply air temperature regardless of the air flow volume in
the system. The HVAC unit cycles it’s cooling stages
to maintain a constant predetermined supply air temperature. It typically runs continuously based on a schedule.
For perimeter zones requiring heat, reheat coils (electric or hot water) located in the terminal units are used
to supply heated air to the space. Many times fan powered terminal boxes are used and most of them incorporate electric or hot water heating coils to provide perimeter zone heating. In summary a true VAV system
uses a variable volume fan supplying constant temperature air to the system with variable volume terminal
units used to control the volume of constant temperature air delivered to the space. Generally these systems
use pressure independent damper control.
Orion Zoning Systems
The Orion zoning system is quite different in operation
and design from the VAV system previously discussed.
Air volume control of the zoning system can either be
achieved by utilizing a VFD drive to modulate the unit
fan speed or achieved by bypassing air from the HVAC
unit supply duct back into the HVAC unit return air
duct on the unit inlet. The supply fan VFD or the bypass air damper is controlled and modulated based on
the static pressure value sensed by a static pressure sensor located in the supply air duct downstream of the
unit supply air discharge. The supply fan VFD modulates the fan speed or the bypass damper modulates open
and closed based on the static pressure in the duct. The
temperature at the HVAC unit discharge varies in relation to the demand from the zones.
HVAC units used for the zoning system will typically
have both heating and cooling capabilities. The unit supplies a variable volume of cold or hot air to the duct
system which is fed to the individual zones by modulating zone dampers. Each zone controller relays its heating or cooling demand to the Polling Device installed
on it’s local communications loop. The Polling Device
determines the HVAC unit mode of operation (heating,
cooling or vent mode) depending on the demand from
the zone controllers and relays this to the HVAC unit
controller. The Polling Device utilizes a voting system
to determine the correct mode of operation. Each zone
controller determines (based on its heating and cooling
setpoints) whether or not to use the air being supplied
by the HVAC unit. For example, one of the zones is
calling for cooling when the temperature in the duct is
above the zones cooling setpoint. This zone will move
to its minimum cooling position to prevent warm air
being introduced into the space. With the zoning system the zone dampers are generally pressure dependent.
Pressure independent operation is available but is not
very common. Reheat and/or fan powered terminal units
can be used but aren’t commonly part of the typical
zoning system.
Conclusion
T ypically a VAV, HVAC unit and associated controls is
more expensive than a CAV (Constant Volume) unit
utilizing zoning system control, especially on smaller
HVAC units. Many times the system can be redesigned
to a zoning system with a significant cost savings and
equal or better performance and comfort than a VAV
system would provide. Orion Systems allow you the
option of which one is best for your application. Or if
desired, VAV and zoned HVAC systems can also be
mixed and matched on the same control system.
Orion Systems 5
Zoning Design Guide
How Orion Works
As previously discussed, in contrast to the VAV system
the zoning system supplies variable temperature air to
the supply ductwork. The zone dampers modulate and
supply the correct amount of conditioned air to the building zones and the zone dampers The Polling Device
calculates the heating and cooling requirements for each
zone based on real time information received from each
Zone Controller/Damper. The Polling Device then directs the HVAC unit to provide the appropriate amount
of heating, cooling, and ventilation to satisfy each zone’s
requirements. A static air pressure sensor is used to allow the controller to modulate a bypass damper or a
VFD (variable frequency drive) to maintain constant
duct pressure.
The Orion system uses a unique 3 tier approach to controlling the system:
• Voting Zones
• System Demand
• Priority
This 3 tier system works in an integrated fashion to
maintain proper control of the equipment and effective
control of comfort in the zone.
First the zone must initiate a vote to the HVAC unit.
This occurs when a zone becomes more than 1 degree
off setpoint. At this time a vote is placed for heating or
cooling. Next the Polling Device evaluates the total cooling demand or heating demand of the zones served by
the HV AC unit, to determine which requirement is more
critical. Finally, the system looks for any priority conditions, which would take precedence over other zones.
All three of these elements working together provide
accurate and stable control of comfort.
Additional control features are taken into account to
provide very effective control of the system. Some of
these include priority override, supply air temperature
limits, outside air temperature lockouts, and minimum
/maximum position control over the zone dampers.
Substantial savings can be realized using the Orion Zoning system instead of having to install multiple rooftop
units to accommodate multiple zone requirements. The
Orion Zoning system is versatile and can be used with
any packaged roof top unit or split system. It controls a
variety of terminal unit functions including single duct
pressure dependent, pressure independent, series fan ,
parallel fan terminals and electric or hot water reheat.
6 Orion Systems
Outside Air
Temp Sensor
Rooftop
HVAC
Unit
Zoning Design Guide
Return Air
To Other Zone
Modular Cables
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Modular Cables
Controllers On Loop 1
Static Pressure Sensor
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Note:
Either a Modular System Manager,a
Modular Service Tool or a Personal
Computer Using the Prism Computer
Front End Software is Required for
Programming and Configuration of the
Orion System. They May Also be Used
in Combination with Each Other.
Figure 1-1: Typical Orion Zoning System Overview
Orion Systems 7
Zoning Design Guide
Why Should I Use Orion?
Orion system was designed using proven technology
with a long history of successful installations. Our systems have been refined over the years with the help of
feedback from people in the field who work and live
with these systems on a daily basis. Our success is
greatly due to the fact that we have implemented changes
and enhancements based on real world experience not
from tinkering with equipment in an isolated lab environment. This real world approach provides engineers,
contractors, and end users with a control system that is
efficient, reliable, and most importantly , keeps the customers comfortable!
What Is Unique About Orion?
Orion is unique because it has many features not found
on other systems. These features include
Integration with Existing Equipment
The Orion HVAC unit controller is usually factory installed by AAON. However, if you have a job with
new AAON equipment being installed and you would
like to tie in existing AAON or other manufacturers
HVAC equipment to the system, the Orion controllers
are designed to work with any manufacturers HVAC
equipment that will accept a standard thermostat connection. Another value added feature is that the Orion
controllers include very comprehensive documentation,
which was written in a format specifically for a “noncontrols technician”. All setup and configuration procedures are simple and easy to implement.
Pre-Engineered Software
System design, software, and documentation has already
been done for you. This eliminates the costly expense
usually associated with conventional DDC systems,
making the Orion system more competitive and easier
to install and operate.
One Controller for VAV, Zoned or Single
Zone CAV Systems
The VAV/CAV unit controller can be field configured
for VAV, zoning or constant volume applications.Not
only does Orion provide a networked zone control system for one or multiple V AV or zoned HVAC units, you
can also connect individual CAV (constant volume)
single zone units the system eliminating the need to
use programmable thermostats. Add-on devices are
available which can control lighting, exaust fans, boilers and other building equipment on the same controls
system.
User Friendly Set Up
Since the Orion comes with menu driven, fill in the
blank programming, system setup is simple. The system manual takes you step by step through the set up
process. Default parameter values are programmed into
permanent memory so the system can be operational at
start-up. Specialized training is not required.
8 Orion Systems
Zoning Design Guide
True Network Communications
The Orion uses a three wire, RS-485 loop for communication between all controllers in the system. This provides a very reliable form of communication with flexibility of installation. The loop can be wired in a “daisy
chain” or “star” configuration. Many other zoning systems utilize “home run” wiring that requires all communication cables to be brought back to a central point
adding additional cost to the project and complicating
wiring.
High Integrity Communications
Many communicating control systems are susceptible
to electrical interference. One major manufacturer of
zoning systems recommends that their communication
cable should not be strapped to conduit because of potential interference. The Orion Systems have a communication bus that is almost immune to any noise or
electrical interference problems that can be found in
many commercial facilities.This feature makes installation problems non-existent and insures the continued
reliability of the controls system.
Microprocessor Controllers
All controllers in the Orion System have an on board
microprocessor. This is what gives the Orion its powerful features and capabilities not found in other systems.
Communications Via Optional Modem
The Remote Link is used for achieving remote communications with the Orion system. It connects to the
CommLink II communications interface and a local
phone line. With the Remote Link, the Orion system
can be programmed and monitored from a remote location, using a computer and the Prism graphical computer front end software package. An internet interface
is also available when using the Prism software package.
Modulating, Heavy Duty Actuators with
Real Time Feedback
All Orion actuators utilize true modulating control unlike many systems, which are two position. This gives
the system-improved control, which translates, to better comfort levels. Our actuators are also rated for 2.5
million cycles, making our actuators some of the most
reliable in the industry . One other critical feature is the
real time feedback. Many other systems have no feedback at all. They blindly estimate the travel time of their
actuator, which, in the real world, is not a very repeatable estimate. To help correct the problems inherent
with this approach, they recycle all the actuators in the
system once or twice a day. They may save a few dollars by not including feedback but they sacrifice system performance. Not so with Orion.
Stand Alone Systems
All Orion Systems are true stand-alone and do not require a computer to operate. Unit controllers maintain
their own 7 day time clock, 365 day holiday scheduling, and setpoints within each controller.
Menu Driven Operators’ Interface
All Orion systems have the ability to be connected to
an operators’ keypad and display terminal. This gives
you access to system status and parameter values without the need for a computer. The Modular Service tool
or the Modular System Manager have 4 line by 20 character displays that are backlighted making them easy to
read even in low light environments. Function keys and
menu driven programming makes the system extremely
user friendly. In addition, the interface panel is password protected to keep unauthorized users from accessing the system.
Commercial Grade – Insulated Round
Zone Dampers
Orion Systems utilize commercial grade zone dampers, not cheap, flimsy, “light commercial” or “residential” style dampers like many other manufacturers. Our
round damper is ARI certified and comes from the factory fully insulated. Why? When many zone dampers
are installed they are improperly insulated or not insulated at all. This can cause problems with the damper
“sweating” from condensation. With factory insulated
zone dampers, we eliminate a common problem for the
contractor while insuring the end user will not have
problems with condensation dripping down onto the
ceiling.
Rectangular Dampers
Orion uses only top of the line, aluminum air foil rectangular control dampers. No other zone system on the
market today utilizes a damper of this quality and performance!
Orion Systems 9
Zoning Design Guide
What Is Unique About Orion?
Patented Flush Mount Room Sensors
Our flush mount room sensors are so unique, they are
patented (U.S. Patent No. 4,659,236). Even though part
of the sensor is recessed into the wall to provide an
attractive yet tamper proof flush mounting, internal wall
temperatures do not influence the sensor. A special plate
on the face of the sensor accurately senses space temperature. Even though the attractive off white plastic
housing is a preferred color, the sensor housing can be
painted or wallpapered to blend with room decor without affecting sensor performance. The sensors are offered in four different configurations:
• Sensor
• Sensor w/override
• Sensor w/setpoint adjustment
• Sensor w/setpoint adjustment & override
Modular Connections
The VAV/Zone Controllers used with the Orion System are designed with modular connections for easy,
error free wiring. A Power/Comm board is used to supply power and communications to the branch circuits.
The V AV/Zone Controller boards and the Power/Comm
board are provided with Molex connectors. Prefabricated cables with Molex connectors are supplied in
various lengths for connection between the VAV/Zone
Controllers and the Power/Comm Board. In addition to
the power and communications wiring between the
Power/Comm Board and the VAV/Zone Controllers
many Orion auxiliary devices are connected to the controllers via modular plugs like the ones used on telephones. This also simplifies installation and eliminates
the possibility of wiring errors. The devices, which utilize this method are the damper actuators for zone control, modular room sensors used with the zone control-
lers, auxiliary relay boards, and static pressure/air flow
sensors. There is one interesting side note about the
auxiliary relay board and airflow sensors. These devices
are typically used on the zone controllers in the Orion
systems. When the system is powered up, it automatically looks to see if these devices are connected to the
controller. If they are, the controller automatically
reconfigures itself to utilize these devices and activates
the appropriate set up screens back at the operators interface. This feature makes setup a breeze!
FREE! Windows™ Graphics Software
Each Orion system can be monitored on site or remotely
using a PC and our Windows 98, “Prism” computer front
end software. This full-featured package is very user
friendly and can be used to monitor one system or hundreds. Prism is not copy protected so it can be installed
on multiple PC’s’ without additional expense. Just some
of its many features include but are not limited to:
• Pre-designed status screens for all controllers
• Alarm dial out capability
• Programming of all system parameters
• Trend logging
• Alarm Handling
• Custom graphics capability
Open Protocol System
Orion is an open protocol based system allowing other
manufacturers to develop direct interfaces to the communications loop. This gives you the ability to integrate the Orion system into products from other vendors. Our engineering staff will be glad to assist any
vendor in this process.
10 Orion Systems
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