WattMaster VAV User Manual

www.wattmaster.com

WattMaster VAV

Component & System

Wiring - Technical Guide

Table Of Contents

WattMaster Controls Inc. 8500 NW River Park Drive · Parkville , MO 64152 Toll Free Phone: 866-918-1100 PH: (816) 505-1100 · FAX: (816) 505-1101 · E-mail: mail@wattmaster.com Visit our web site at www.wattmaster.com Form: WM-VAVWIRE-TGD-01C Copyright 2008 WattMaster Controls, Inc. WattMaster Controls, Inc. assumes no responsibility for errors, or omissions. This document is subject to change without notice.

System Configurations Installation & Commissioning .................................................................................. 5

Networked Single Loop System ........................................................................................................................................................................... 6

Networked Single Loop - Computer Connection With Remote Link .................................................................................................................... 7

Networked Single Loop - Computer Connection With IP-Link ............................................................................................................................. 8

Networked Multiple Loop System ......................................................................................................................................................................... 9

Networked Multiple Loop - Computer Connection With Remote Link ................................................................................................................ 10

Networked Multiple Loop - Computer Connection With IP-Link ......................................................................................................................... 11

Systems Overview .............................................................................................................................................................................................. 12

General Information ............................................................................................................................................................................................ 12

Installation Procedures ....................................................................................................................................................................................... 12

System Commisioning ........................................................................................................................................................................................ 15

Transformer & Wire Sizing ................................................................................................................................................................................. 16

WMVAV Controller Wiring .............................................................................................................................. 17

WMVAV Controller Wiring .................................................................................................................................................................................. 18

WMVAV Controller Addressing ........................................................................................................................................................................... 19

Space Sensor Wiring .......................................................................................................................................................................................... 20

Supply & Return Sensor Wiring .......................................................................................................................................................................... 21

Outside Air Sensor Wiring .................................................................................................................................................................................. 22

Remote Occupied Contact To WMVAV Wiring ................................................................................................................................................... 23

Humidity Sensor Wiring ...................................................................................................................................................................................... 24

Supply Fan VFD Wiring ...................................................................................................................................................................................... 25

Bypass Damper Actuator Wiring ........................................................................................................................................................................ 26

2 Slot Expansion Base Board Wiring ................................................................................................................................................................. 27

4 Slot Expansion Base Board Wiring ................................................................................................................................................................. 28

4 Analog Input 1 Analog Output Expansion Board Wiring .................................................................................................................................. 29

4 Analog Input 1 Analog Output Expansion Board Wiring (Cont’d) .................................................................................................................... 30

4 Analog Input 1 Analog Output Expansion Board Wiring (Cont’d) .................................................................................................................... 31

4 Binary Input Expansion Board Wiring .............................................................................................................................................................. 32

4 Relay Output Expansion Board Wiring ............................................................................................................................................................ 33

VAVBOX Controller Diagrams .......................................................................................................................35

VAVBOX Controller Wiring ................................................................................................................................................................................. 36

3 Relay Output Expansion Board Wiring ............................................................................................................................................................ 37

3 Relay Output Expansion Board Wiring (Cont’d) .............................................................................................................................................. 38

3 Relay Output Expansion Board Wiring (Cont’d) .............................................................................................................................................. 39

Communication Devices Diagrams ............................................................................................................... 41

System Manager Modular Cable Pigtail - Wiring Schematic ............................................................................................................................. 42

System Manager Modular Cable Pigtail - Wiring Detail ..................................................................................................................................... 43

Modular Service Tool Connections ..................................................................................................................................................................... 44

CommLink II Wiring & Cabling Connections ...................................................................................................................................................... 45

MiniLink Polling Device Wiring Using Wire Terminals ........................................................................................................................................ 46

RS-232 Serial Port To USB Port Converter ........................................................................................................................................................ 47

Table Of Contents

Add-On Devices Diagrams ............................................................................................................................. 49

Lighting Panel Wiring For Standard Lighting Contactors ................................................................................................................................... 50

Lighting Panel Wiring For GE® Latching Relay Lighting Contactors ................................................................................................................. 51

Optimal Start Scheduler Wiring .......................................................................................................................................................................... 52

GPC Wiring ......................................................................................................................................................................................................... 53

GPC-17 Wiring ................................................................................................................................................................................................... 54

Miscellaneous Diagrams & Technical Information ...................................................................................... 55

Over Voltage Board Wiring ................................................................................................................................................................................. 56

Chip Locations .................................................................................................................................................................................................... 57

Chip Locations (Cont’d) ...................................................................................................................................................................................... 58

Chip Installation Procedures ............................................................................................................................................................................... 59

Temperature & Humidity Sensor Voltage-Resistance Tables ............................................................................................................................. 60

Pressure Sensors Voltage-Resistance Tables ................................................................................................................................................... 61

Notes .................................................................................................................................................................................................................. 62

Notes .................................................................................................................................................................................................................. 63

Component & System Wiring 3

Component & System Wiring4

System Configurations

Installation &

Commissioning

Component & System Wiring 5

Networked Single Loop System

EPROM

U3

U5

RAM

C

X

2

1

U2

R

1

C3

U4

CX3

CX4

YS101818P552

PROCESSORPBOARD

CX5

C1

U1

R2

CX1

CX6

WDOG

U6

PHILIPS

D

1

P1

X1

C2

C4

0-10V

4-20mA

THERM

R

27

R

31

D

4

G

N

D

24VA

C

TB1

D5

C11

U12

LED2

POWER

V

1

R

25

R

26

C7

C

X15

C

X

13

PROC.

DRIVER

LOOP

DRIVER

LOCALLOOP

G

N

D

A

IN

2

A

IN

1

+5V

T

B2

P4

OFF=0-5V

AIN2

AIN1

0-10V

4-20mA

THERM

TB

3

U

15

LD5

LD6

U

13

C8

LED1

RV1

R

4

V

R

EF

C

X

2

U11

YS101900PMINILINK

POLLING

DEVICE

REV.1

OFF

1

2

4

8

16

32

C

X

14

NETWORK

DRIVER

RN3

SH

LD

S

H

LD

T

TB

4

R

U14

NETWORK

LOOP

P5

A

D

P

3

R

24

LD4

C9

U10

RN2

SW1

R30X2R29

R28

C10

U6

C

X6 C

X1

U7

U1

X

1

C3

C

1

R

3

CX7

Line Voltage

Network

Local

24 VAC

(8 VA)

24 VAC

(6 VA)

24 VAC

(6 VA)

Back View of CommLink

Front View of CommLink

CLIIomm ink

LOOP

24V

T

G

R

GND

REMOTE LINK

(DTE)

COMPUTER

(DCE)

485

LOOP

STATUS

POW

ER

COM

P

RLINK

SERIAL #

CONTROLS

110 VAC To

24 VAC

Power Pack

CommLink

MiniLink PD Loop 1

VAVBOX

Controller

VAVBOX

Controller

VAVBOX

Controller

WMVAV Controller

(1MEG)

TB1

Connect To Modular

I/O Connectors

Located On Back

Of The System Manager

ENTER

CLEAR

ESC

DOWN

UP

6

5

4

DEC

7

0

8

13

2

9

MINUS

-

STATUS

SETPOINTS

SCHEDULES

ALARMS

OVERRIDES

Modular System Manager

Note: A Modular System

Manager, A Modular Service

Tool Or A PC With Prism

Software Installed Can Be

Used To Program And

Configure TheWattMaster

VAV System.

Note: See Page 2 Of

This Drawing For

Optional Computer

And Remote Link

Connection Diagram.

1 1

1

0 0

0

Modular Service

Tool

Mode

Selection

ENTER

CLEAR

ESC

DOWN

UP

6

5

4

DEC

7

0

8

13

2

9

MINUS

-

STATUS

SETPOINTS

SCHEDULES

CONFIGURATION

ALARMS

ON

OVERRIDES

BALANCE-TEST

Connect To Next

VAVBOX Controller

Local Loop

SHLD

T

R

Typical Terminal Blocks. All

Wiring To Be T To T, SHLD (G)

To SHLD (G)&RToR

T

G

R

485 LOOP

Typical Single Loop Networked System

05/12/04

VAV-Network-SingleLoop1B.CDR

Network System - Single Loop

FILENAME

DATE:

B. Crews

DESCRIPTION:

PAGE

DRAWN BY:

Wiring & Connection Diagram

JOB NAME

1of3

WHITE (T)

DRAIN WIRE (SHLD)

BLACK (R)

RED (24 VAC)

Line Voltage

24 VAC

(6VA Min.)

BROWN (GND)

GREEN (GND)

CX6

SW1

U10

75176

EXPANSION

Q3Q2

D3

VR1

7824

GND

R

SHLD

GND

AUX2

AUX1

AUX

+VS

TMP

T

24VAC

R17

R16

U7

C7

R15

POWER

R21

R35

YS101

562REV 3

D4

R26

LD3

L1

SCAN

REC

R12C6R11

TOKEN

NET

LD2

32

R14

R13

R100

LD1

C5

D1

K1

V2

V3

K2

D2

ACTUATOR

R10

R9

PJ2

V1

C4

EPROM

VREF

ADJ

R23

C10

EWDOG

COMM

D7

CX10

R25

R28

T'STAT

U11

C15

R20

C11

R24

8

16

2

4

ADDRESS

ADD

1

U6

U5

R19

U9

CX9

R32

D5

C14

P.U.

R22

C13

R27

D5

RAM

C9

C8

80C55

2

CX5

PJ1

C3

R8

R7

R5

R6

R4

C2C1

X1

U2

R1

R2

R3

CX2

Q1

16L8

R34

FLOW

U8

1 RN1

CX8

U4

R18

CX4

U3

CX3

U1

PAL

CX1

CX6

SW1

U10

75176

EXPANSION

Q3Q2

D3

VR1

7824

GND

R

SHLD

GND

AUX2

AUX1

AUX

+VS

TMP

T

24VAC

R17

R16

U7

C7

R15

POWER

R21

R35

YS101

562REV 3

D4

R26

LD3

L1

SCAN

REC

R12C6R11

TOKEN

NET

LD2

32

R14

R13

R100

LD1

C5

D1

K1

V2

V3

K2

D2

ACTUATOR

R10

R9

PJ2

V1

C4

EPROM

VREF

ADJ

R23

C10

EWDOG

COMM

D7

CX10

R25

R28

T'STAT

U11

C15

R20

C11

R24

8

16

2

4

ADDRESS

ADD

1

U6

U5

R19

U9

CX9

R32

D5

C14

P.U.

R22

C13

R27

D5

RAM

C9

C8

80C55

2

CX5

PJ1

C3

R8

R7

R5

R6

R4

C2C1

X1

U2

R1

R2

R3

CX2

Q1

16L8

R34

FLOW

U8

1 RN1

CX8

U4

R18

CX4

U3

CX3

U1

PAL

CX1

CX6

SW1

U10

75176

EXPANSION

Q3Q2

D3

VR1

7824

GND

R

SHLD

GND

AUX2

AUX1

AUX

+VS

TMP

T

24VAC

R17

R16

U7

C7

R15

POWER

R21

R35

YS101

562REV 3

D4

R26

LD3

L1

SCAN

REC

R12C6R11

TOKEN

NET

LD2

32

R14

R13

R100

LD1

C5

D1

K1

V2

V3

K2

D2

ACTUATOR

R10

R9

PJ2

V1

C4

EPROM

VREF

ADJ

R23

C10

EWDOG

COMM

D7

CX10

R25

R28

T'STAT

U11

C15

R20

C11

R24

8

16

2

4

ADDRESS

ADD

1

U6

U5

R19

U9

CX9

R32

D5

C14

P.U.

R22

C13

R27

D5

RAM

C9

C8

80C55

2

CX5

PJ1

C3

R8

R7

R5

R6

R4

C2C1

X1

U2

R1

R2

R3

CX2

Q1

16L8

R34

FLOW

U8

1 RN1

CX8

U4

R18

CX4

U3

CX3

U1

PAL

CX1

Line Voltage

24 VAC

(6VA Min.)

24 VAC

(6VA Min.)

Component & System Wiring6

Networked Single Loop - Computer Connection With Remote Link

VAV-Network-SingleLoop1B.CDR

9Pin

Female

End

Telephone

Cable

Assembly

9Pin

Female

Connector

9Pin

Female

Connector

Molded

Cable Assembly

25 Pin

Male End

25 Pin

Female

Connector

(If Reqd)

Connect To Computer

Serial Port

Personal Computer

(By Others)

Dedicated Telephone

Outlet

(By Others)

Back View of CommLink

Back View of Remote Link

Front View of CommLink

Note: If Direct Computer Connection

Is Required, Connect To PC As Shown.

Remote Link Is Only Required If

Alarm Callout Or Remote Computer

Connection Is Required.

Front View of Remote Link

CLIIomm ink

LOOP

24V

T

G

R

GND

REMOTE LINK

(DTE)

COMPUTER

(DCE)

485

LOOP

STATUS

POW

ER

COMP

RLINK

SERIAL #

CONTROLS

RL

emote ink

SIG

TELCO

LINE

TELCO

LINE

SERIAL DATA

DET

RDY

SND

REC

PWR

SERIAL #

CONTROLS

8 Conductor

Modular Cable

Assembly

110 VAC To

9 VDC

Power Pack

110 VAC To

24 VAC

Power Pack

CommLink

Remote Link

(Optional)

Connect To MiniLink PD Network Terminals

See Page 1 Of This Drawing

POWER

9VDC @

500mA

SHLD

T

R

Typical Terminal Blocks. All

Wiring To Be T To T, SHLD (G)

To SHLD (G)&RToR

T

G

R

485

LOOP

FILENAME

DATE:

B. Crews

DESCRIPTION:

PAGE

DRAWN BY:

Wiring & Connection Diagram

JOB NAME

2of3

Network System - Single Loop

03/24/04

Optional Computer Connection Diagram

Using Remote Link For Remote Connection

Component & System Wiring 7

Networked Single Loop - Computer Connection With IP-Link

JOB NAME

FILENAME

B. Crews

DRAWN BY:

DESCRIPTION:

Wiring & Connection Diagram

Network System - Single Loop

03/24/04

DATE:

VAV-Network-SingleLoop1B.CDR

PAGE

3of3

Note: If Direct Computer Connection

Using IP-Link For Remote Connection

Optional Computer Connection Diagram

Is Required, Connect To PC As Shown. IP-Link Is

Only Required If E-mail Alarm Notification Or

Remote Computer Connection Is Required.

Connect To MiniLink PD Network Terminals

See Page 1 Of This Drawing

Note:

1.Set CommLink Internal Switch To”Multi”

2. Replace CommLink EPROM With IP-Link

EPROM Supplied With IP-Link Kit

110 VAC To

RLINK

COM

P

LOOP

CommLink

Front View of CommLink

omm ink

CLII

SHLD

T

R

LOOP

485

R G T

24 VAC

Power Pack

CONTROLS

STATUS

Typical Terminal Blocks. All

ER

GND 24V

LOOP

R

G

T

(DCE)

COMPUTER

(DTE)

Back View of CommLink

REMOTE LINK

SERIAL #

Wiring To Be T To T, SHLD (G)

To SHLD (G)&RToR

25 Pin

Female

9 Pin

(If Reqd)

Connector

Female

Connector

(By Others)

Personal Computer

ne

onnect C

9 VDC

110 VAC To

Power Pack

PWR

R E

S

V

C

R

K

N

L

T

C

A

IP-Link

(Optional)

Front View of IP- Link

Serial Port

POW

485

Connect To Computer

9 Pin

Female

Connector

Assembly

8 Conductor

Modular Cable

Molded

Supplied With

Cable Assembly

IP-Link Kit

9 Pin Male End

Port On IP-Link

Connect To Serial

Mode

9VDC

Serial

10BaseT

Back View of IP-Link

End

9 Pin

Female

Assembly

On IP-Link

RJ45 Cable

To 10BaseT Port

Connect Ethernet

Or Modem

(By Others)

Cable Assembly

Connect Ethernet RJ45

(By Others)

On Ethernet Router

To 10 BaseT Connection

Component & System Wiring8

Networked Multiple Loop System

SHLD

T

R G T

R

485 LOOP

Typical Terminal Blocks. All

Wiring To Be T To T, SHLD (G)

ToSHLD(G)&RToR

Typical Multiple Loop Networked System

WMVAV Controller

WHITE (T)

Note: A Modular System Manager,

A Modular Service Tool Or A PC

With Prism Software Installed Can

UP

DOWN

ENTER

ESC

Mode

SETPOINTS

OVERRIDES

SCHEDULES

Selection

(1MEG)

Line Voltage

DRAIN WIRE (SHLD)

RED (24 VAC)

BLACK (R)

Be Used To Program And

Configure The WattMaster VAV

System.

24 VAC

110 VAC To

RLINK

COM

P

STATUS

LOOP

CommLink

Front View of CommLink

6

9

8

2

5

13

7

4

ALARMS

BALANCE-TEST

CONFIGURATION

24 VAC

(6 VA)

GREEN (GND)

BROWN (GND)

Connect To Modular

I/O Connectors

Located On Back

Power Pack

CONTROLS

Back View of CommLink

-

MINUS

0

DEC

ON

24 VAC

TB1

Of The System Manager

POW

ER

GND 24V

LOOP

485

R

G

T

(DCE)

COMPUTER

(DTE)

REMOTE LINK

Tool

Modular Service

(8 VA)

Line Voltage

Connect To

STATUS

SETPOINTS

OVERRIDES

SCHEDULES

UP

DOWN

ESC

2

5

13

4

Next VAVBOX

Controller On

1

0

1

0

1

0

ALARMS

ENTER

9

-

MINUS

0

8

7

DEC

Loop 1

Modular System Manager

U1

MiniLink PD Loop 1

VAVBOX

1

CX7

U7

C

X

1

P1

RV1

V2

K2

D2

Q3Q2

D1

K1

R10

R9

V1

ACTUATOR

PJ2

C4

C3

R8

EXPANSION

PJ1

R7 R6 R5

CX5

R4

C2C1

U2

X1

Q1

CX2

R3

EPROM R2 R1

16L8

PAL

U1

U3

CX1

CX3

Controller

V2

K2

D2

D1

K1

R10

R9

V1

ACTUATOR

PJ2

C4

C3

R8

EXPANSION

PJ1

R7 R6 R5

CX5

R4

C2C1

U2

X1

Q1

CX2

R3 R2 R1

16L8

PAL

Controller

U1

U3

CX1

CX3

V2

K2

D2

D1

K1

R9

V1

ACTUATOR

PJ2

C4

C3

R8

EXPANSION

PJ1

R7 R6 R5

CX5

R4

C2C1

U2

X1

Q1

CX2

R3 R2 R1

16L8

Controller

PAL

U1

U3

CX1

CX3

C

3

C

X

1

R3

YS101900PMINILINK

POLLING

DEVICE

REV.1

C

X

6

U6

U10

D

1

C4

U6

CX6

U1

C2

PHILIPS

X1

CX1

C3

YS101818P552

PROCESSORPBOARD

C1

1

R

1

U2

CX5

U5

CX4

U4

CX3

U3

C

X2

R

4

V

R

E

F

LED1

LED2

24 VAC

(6VA Min.)

GND

R17

R16

U7

R15

R12C6R11

R13

R100

C5

CX6

CX4

24VAC

7824

C7

D3

VR1

V3

L1

562REV 3

SCAN

REC

R35

YS101

R21

LD2

LD1

D4

R14

R26

NET TOKEN

POWER

LD3

32

R

16

SHLD

8

U10

SW1

4

75176

COMM

2

U6

U5

2 80C55

T

1

CX10

ADD

ADDRESS

D7

R25

EWDOG

C15

GND

R20

C11

R19

TMP

U11

R24

R28

T'STAT

R23

R32

C10

P.U.

VREF

ADJ

D5

R22

C14

C8

RAM

GND

C13

C9

U9

AUX2

CX9

AUX1

+VS

R27

AUX

D5

1 RN1

U8

U4

CX8

FLOW

R34

R18

Line Voltage

JOB NAME

B. Crews

DRAWN BY:

DESCRIPTION:

Network System - Multiple Loop

Wiring & Connection Diagram

05/12/04

24 VAC

Q3Q2

R15

R12C6R11

R13

R100

C5

CX6

EPROM

CX4

Q3Q2

R15

R12C6R11

R10

R13

R100

C5

CX6

EPROM

CX4

24VAC

7824

C7

D3

VR1

V3

L1

562REV 3

SCAN

REC

R35

YS101

R21

LD2

LD1

D4

R14

R26

NET TOKEN

POWER

LD3

32

R

16

SHLD

8

U10

SW1

4

75176

COMM

2

U6

U5

2 80C55

U7

D3

R14

U6

U5

2 80C55

T

1

CX10

ADD

ADDRESS

D7

R25

EWDOG

C15

GND

R20

C11

R19

TMP

U11

R24

R28

T'STAT

R23

R32

C10

P.U.

VREF

ADJ

D5

R22

C14

C8

RAM

GND

C13

C9

U9

AUX2

CX9

AUX1

+VS

R27

AUX

D5

1 RN1

U8

U4

CX8

FLOW

R34

R18

GND

R17

R16

24VAC

7824

C7

VR1

V3

L1

562REV 3

SCAN

REC

R35

YS101

R21

LD2

LD1

D4

R26

NET TOKEN

POWER

LD3

32

R

16

SHLD

8

U10

SW1

4

75176

COMM

2

T

1

CX10

ADD

ADDRESS

D7

R25

EWDOG

C15

GND

R20

C11

R19

TMP

U11

R24

R28

T'STAT

R23

R32

C10

P.U.

VREF

ADJ

D5

R22

C14

C8

RAM

GND

C13

C9

U9

AUX2

CX9

AUX1

+VS

R27

AUX

D5

1 RN1

U8

U4

CX8

FLOW

R34

R18

Line Voltage

24 VAC

(6VA Min.)

Line Voltage

(6VA Min.)

GND

R17

R16

U7

FILENAME

DATE:

VAV-Network-MultLoop1B.CDR

Loop 3

Connect To

MiniLink Polling Device

Connect To Loop 2

1of3

PAGE

VAVBOX Controller

Or WMVAV Controller

Local

C10

R30X2R29

R28

OFF

SW1

32

U11

C9

16

8 4 2

RN2

1

RN3

D

A

3

P

P5

R

24

LD4

R

U

14

LD

H

S

WDOG

T

NETWORK

DRIVER

C

X14

4

TB

NETWORK

LOOP

R2

3

TB

U

13

LD5

R

LD

SH

LOOP

DRIVER

T

C

X

13

U

15

PROC.

DRIVER

LOCALLOOP

C

X

15

LD6

P4

D

N

G

0-10V

THERM

4-20mA

C

X2

2

IN

A

AIN2

1

AIN

RAM

OFF=0-5V

C8

+5V

AIN1

TB

2

0-10V

THERM

4-20mA

R

27

C7

EPROM

U12

C

R

25

R

26

R

31

V1

POWER

Network

C11

D5

D

N

G

24VA

T

B1 D

4

Local

(6 VA)

C

3

C

1

X1

R

3

CX7

U7

C

X

6 C

X

1

U1

U6

U10

C4

P1

C2

PHILIPS

X1

YS101818P552

PROCESSORPBOARD

C1

CX5

U5

CX4

U4

CX3

MiniLink PD Loop 2

U3

C

X2

RV1

R

4

VR

EF

LED1

YS101900PMINILINK

POLLING

D

1

LED2

Network

C10

R30X2R29

R28

U11

C9

DEVICE

REV.1

RN2

RN3

3

P

R

24

LD4

U6

U

14

CX6

U1

1

LD

WDOG

NETWORK

DRIVER

C

X

14

NETWORK

LOOP

R2

CX1

U

13

LD5

LD

LOOP

DRIVER

C3

C

X

13

U

15

PROC.

R

1

DRIVER

U2

LOCALLOOP

C

X15

LD6

0-10V

THERM

4-20mA

C

X2

2

AIN2

1

RAM

OFF=0-5V

C8

AIN1

0-10V

THERM

4-20mA

R

27

C7

EPROM

D

U12

C

R

25

R

26

R

31

V1

POWER

Network

OFF

SW1

32 16 8 4 2 1

D

AD

P5

R

H

S

T

4

TB

3

TB

R

SH

T

P4

D

N

G

AIN

IN

A

+5V

TB

2

C11

D5

N

G

24VA

TB1 D

4

omm ink

CLII

SERIAL #

Note: See Page 2 and

IP-LinkConnections

3 Of This Drawing For

Optional Computer To

Remote Link or

24 VAC

(6 VA)

Component & System Wiring 9

Networked Multiple Loop - Computer Connection With Remote Link

03/24/04

VAV-Network-MultLoop1B.CDR

FILENAME

DATE:

B. Crews

DESCRIPTION:

PAGE

DRAWN BY:

Wiring & Connection Diagram

JOB NAME

2of3

Network System - Multiple Loop

9Pin

Female

End

Telephone

Cable

Assembly

9Pin

Female

Connector

9Pin

Female

Connector

Molded

Cable Assembly

25 Pin

Male End

25 Pin

Female

Connector

(If Reqd)

Connect To Computer

Serial Port

Personal Computer

(By Others)

Dedicated Telephone

Outlet

(By Others)

Back View of CommLink

Back View of Remote Link

Front View of CommLink

Note: If Direct Computer Connection

Is Required, Connect To PC As Shown.

Remote Link Is Only Required If

Alarm Callout Or Remote Computer

Connection Is Required.

Front View of Remote Link

CLII

omm ink

LOOP

24V

T

G

R

GND

REMOTE LINK

(DTE)

COMPUTER

(DCE)

485 LOOP

STATUS

POWER

COMP

RLINK

SERIAL #

CONTROLS

RL

emote ink

SIG

TELCO

LINE

TELCO

LINE

SERIAL DATA

DET

RDY

SND

REC

PWR

SERIAL #

CONTROLS

8 Conductor

Modular Cable

Assembly

110 VAC To

9 VDC

Power Pack

110 VAC To

24 VAC

Power Pack

CommLink

Remote Link

(Optional)

Connect To MiniLink PD Network Terminals

See Page 1 Of This Drawing

POWER

9VDC @

500mA

SHLD

T

R

Typical Terminal Blocks. All

Wiring To Be T To T, SHLD (G)

To SHLD (G)&RToR

T

G

R

485 LOOP

Optional Computer Connection Diagram

Using Remote Link For Remote Connection

Component & System Wiring10

Networked Multiple Loop - Computer Connection With IP-Link

JOB NAME

FILENAME

VAV-Network-MultLoop1B.CDR

B. Crews

DRAWN BY:

DESCRIPTION:

Network System - Multiple Loop

03/24/04

DATE:

3of3

PAGE

Wiring & Connection Diagram

Note: If Direct Computer Connection

Using IP-Link For Remote Connection

Optional Computer Connection Diagram

Is Required, Connect To PC As Shown. IP-Link Is

Only Required If E-mail Alarm Notification Or

Connect To MiniLink PD Network Terminals

See Page 1 Of This Drawing

Remote Computer Connection Is Required.

Note:

1.Set CommLink Internal Switch To”Multi”

2. Replace CommLink EPROM With IP-Link

EPROM Supplied With IP-Link Kit

110 VAC To

RLINK

COMP

LOOP

CommLink

Front View of CommLink

CLIIomm ink

SHLD

T

R

LOOP

485

R G T

24 VAC

Power Pack

CONTROLS

STATUS

Typical Terminal Blocks. All

ER

GND 24V

R

G

T

(DCE)

COMPUTER

(DTE)

Back View of CommLink

REMOTE LINK

SERIAL #

Wiring To Be T To T, SHLD (G)

To SHLD (G)&RToR

25 Pin

Female

9Pin

(If Reqd)

Connector

Female

Connector

(By Others)

Personal Computer

ne

onnect

C

9 VDC

110 VAC To

Power Pack

PWR

R

E

S

V

C

R

K

N

L T C

A

IP-Link

(Optional)

Front View of IP- Link

Serial Port

POW

485 LOOP

Connect To Computer

9Pin

Female

Connector

Assembly

8 Conductor

Modular Cable

Molded

Supplied With

Cable Assembly

IP-Link Kit

9 Pin Male End

Port On IP-Link

Connect To Serial

Mode

9VDC

Serial

10BaseT

Back View of IP-Link

End

9Pin

Female

Assembly

On IP-Link

RJ45 Cable

To 10BaseT Port

Connect Ethernet

Or Modem

(By Others)

Cable Assembly

Connect Ethernet RJ45

(By Others)

On Ethernet Router

To 10 BaseT Connection

Component & System Wiring 11

Systems Overview

General Information

The WattMaster VAV system components can be configured into different types of systems depending on the type and number of controllers required. It is a good idea to become familiar with the types of systems and their architecture by reading the information in this section and looking at the configuration diagrams in the System Configurations Installation & Commissioning section of this manual. The information below is designed to help you understand how the system components integrate with each other and the available configuration options.

System Types

Two different system configurations are available depending on the type and number of controllers that you have on your system.

1. Networked Single Loop

(See Pages 6 Through 8 For Connection Diagrams)

2. Networked Multiple Loop

(See Pages 9 Through 11 For Connection Diagrams)

System Type Definitions

Networked Single Loop

The Networked Single Loop system, as its name implies, consists of a single communications loop. The system can consist of the following controllers and devices.

1. A single WMVAV controller used as a VAV controller and

it’s associated VAVBOXcontrollers. Other WMVAV controllers used for constant volume units and/or and Addon Devices may also be connected as long as the total of all controllers on the loop does not exceed 59. Only one VAV controller with it’s VAVBOX controllers can be installed per loop. If more than one VAV controller with VAVBOX controllers is required, you must have a separate loop for each.

This system requires one CommLink communications interface and one MiniLink Polling Device. Programming and status monitoring are accomplished by the following methods.

1. By using an operators interface. This can be either a Modular System Manager, a Modular Service Tool or both devices. The System Manager or Modular Service Tool can connect to any controller on the local loop.

2. A computer interface can also be used in conjunction with the other operators interfaces listed above, or by itself. This requires a personal computer with the Prism computer front end software installed. The PC connects to the CommLink via a supplied cable.

2. A single WMVAV controller used as a VAV controller and

its associated VAVBOX controllers. Other WMVAV controllers used for constant volume units and/or and Addon Devices may also be connected as long as the total of all controllers on the loop does not exceed 59. Only one VAV controller with its VAVBOX controllers can be installed per local loop.

To form the Networked Multiple Loop System the following network devices are required.

1. A MiniLink Polling Device is required per loop (Local Loop). This allows the controllers to share information that is broadcast from one controller to all controllers on that local loop and also provides alarming and trend logging capabilities.

2. One CommLink is required for the entire system. It resides on the Network Loop and allows for communications between all the local loops and provides for global broadcasts to all controllers on the entire system.

Programming and status monitoring are accomplished by one or more of the following methods.

1. By using an operator interface. This can be either a Modular System Manager, a Modular Service Tool or both devices. The System Manager or Modular Service Tool can connect to any controller on any “Local Loop” on the entire system.

2. A computer interface can also be used in conjunction with the other operators interfaces listed above, or by itself. This requires a personal computer with the Prism computer front end software installed. The PC connects to the CommLink via a supplied cable.

Network Communications Devices

MiniLink Polling Device

1. This device is required for all Networked Single loop systems.

2. One of these device is required on each local loop of all Networked Multiple Loop systems

CommLink

1. One CommLink is required on all Networked Single Loop or Multiple Loop Systems

2. Up to 60 local loops can be connected to the CommLink

Installation Procedures

Networked Multiple Loop

This Networked Multiple Loop System consists of two or more loops, each being called ‘Local Loops’, with one ‘Network Loop’ that ties the “Local Loops” together. Each of these local loops can consist of the following controllers and devices.

1. A series of WMVAV controllers for constant volume units

and/or Add-on devices without any VAVBOX controllers. Up to 59 controllers may be connected on the loop in this manner.

The installation procedures that follow are based on recommended methods of wiring connection and controller installation. Installation procedures vary depending on the which Networked system you are installing. The system you are installing could be “Networked Single Loop” or a “Networked Multiple Loop” system. The Networked Systems also have installation variations based on the type of components you are installing for that system. The following information explains the procedures for all of these systems. Please find the system and components that closely match your system and follow the outlined procedures.

Component & System Wiring12

Networked Single Loop Systems

See the “Networked System - Single Loop Wiring” on pages 6 through 8 of this manual for detailed wiring information. Also see page 16 for wire and transformer sizing information. You should review these diagrams before attempting connections or powering up the controller or interface devices.

1. Connect all WMVAV or Add-on Device controllers in a daisy chain or star ring format by connecting from each controller’s communication terminal block to the next using 18 gauge, 2 conductor shielded cable. Install a separate 24 VAC, transformer for each controller and wire from each controller’s power terminal block to its transformer using 18 gauge minimum, 2 wire cable for power. See Wire and Transformer Sizing section on page 16 for detailed transformer and wire sizing information. Observe polarity on all board power wiring. Install a separate 24 VAC, 6 VA minimum, transformer for each VAVBOX controller on the loop and wire from each controller’s power terminal block to its transformer using 18 gauge minimum, 2 wire cable. Observe polarity on all boards! As an alternative, a single transformer that connects to all VAVBOX controllers may also be used. It must be sized to handle the minimum load of 6 VA per VAVBOX controller connected to it. When

using this method, the polarity of all wiring between the transformer and the VAVBOX controllers is extremely critical and must be maintained to prevent damage to all boards connected! See the wire and transformer sizing

information on page 16 of this manual for complete wire and transformer sizing information.

Warning: If polarity between controllers is not maintained,

severe damage to the controllers may result. WattMaster recommends using a separate transformer for each controller in order to eliminate the potential for damaging controllers due to incorrect polarity.

2. Using 18 gauge 2 conductor shielded cable, connect from the WMVAV controller’s 3 wire communications connector to the MiniLink PD’s 3 wire communications connector marked “Local Loop”.

3. Connect 2 conductor shielded cable from the MiniLink PD’s 3 wire communications terminal blocks labeled “Network Loop” to the CommLink’s 3 wire communications terminal block located on the back of the CommLink. Find the 110 VAC/24 VAC power supply furnished with the CommLink and connect the 2 stripped wire leads to the 24 VAC terminals on the back of the CommLink. The CommLink’s internal jumper must be set to “Multiple” for all WattMaster VAV systems. See page 45 of this manual for complete CommLink wiring and jumper setting information. After determining all wiring and jumper settings are correct, connect the power supply plugin transformer to a 110 V receptacle.

4. Install a 24 VAC, 6 VA minimum, transformer for the MiniLink PD and wire it to the 24 VAC power terminal block on the MiniLink PD using 18 gauge minimum, 2 wire cable. See page 46 of this manual for complete MiniLink PD wiring diagrams and instructions.

5. When the Modular Service Tool is to be used for programming and monitoring of the controllers it can be connected to the WMVAV controllers using the supplied cable with DIN connectors on both ends. The DIN connector on the WMVAV controller is located near the communications terminals. To connect the Modular Service Tool to a VAVBOX controller first unplug the 3 wire communication terminal block from the VAVBOX controller. Connect the DIN to terminal adapter terminal end to the communication terminals block socket on the VAVBOX controller then connect the DIN connector side of the adapter to the Modular Service Tool cable DIN connector. See page 44 of this manual for complete Modular Service Tool connection diagrams and instructions.

6. The Modular System Manager comes supplied with a 12 foot modular cable pigtail with a modular connector on one end and stripped wires on the other. Plug the modular connector end into the System Manager modular connector. Run 18 gauge, 2 conductor shielded cable for communications from the MiniLink PD or any controller on the local loop by connecting one end of the controller’s or MiniLink PD’s 3 wire “Local Loop” communications terminal block to a junction box located within 12 feet of the System Manager. Run 18 gauge, 2 wire, power wires supplied by a separate 24 VAC, 6 VA minimum transformer into the junction box. Splice the stripped modular cable ends from the System Manager to the communications and power wire inside of the junction box using solid connections made with wire nuts or butt-splice connectors. See Modular System Manager wiring on pages 42 and 43 of this manual for wiring color coding and complete wiring instructions. The Modular System Manager MUST always be connected on the “Local Loop”, never the “Network Loop”.

Networked Multiple Loop Systems

See the “Networked System - Multiple Loop Wiring” on pages 9 through 11 of this manual for detailed wiring diagrams. Also see page 16 for wire and transformer sizing information. You should review these diagrams before attempting connections or powering up the controller or interface devices.

Loop(s) with WMVAV Controllers without VAVBOX Controllers

1. For each local loop on the system, connect all controllers in a daisy chain or star ring format by connecting from each controllers communication terminal block to the next using 18 gauge, 2 conductor shielded cable. Install a separate 24 VAC, 8 VA minimum, transformer for each controller and wire from each controller’s power terminal block to its transformer using 18 gauge minimum, 2 wire cable for power. Observe polarity on all boards.

2. Select one of the local loops and connect 2 conductor shielded cable from one of its WMVAV controller’s 3 wire communications terminal blocks to it’s associatedMiniLink PD’s 3 wire communications terminal block marked “Local Loop”. Repeat this procedure for all loops on the entire system.

Component & System Wiring 13

System Installation

3. Connect 2 conductor shielded cable from one of the systems MiniLink PD’s 3 wire communications terminal blocks labeled “Network Loop” to the CommLink’s 3 wire communications terminal block located on the back of the CommLink. Find the 110 VAC/24 VAC power supply furnished with the CommLink and connect the 2 stripped wire leads to the 24 VAC terminals on the back of the CommLink. The CommLink’s internal jumper must be set to “Multiple” for all WattMaster VAV systems. See page 45 of this manual for complete CommLink wiring and jumper setting information. After determining all wiring and jumper settings are correct, connect the power supply plug-in transformer to a 110 V receptacle.

4. Connect 2 conductor shielded cable for network communications between each MiniLink PD on the system including the one that was just connected to the CommLink. This is accomplished by connecting between each MiniLink PD’s 3 wire communications terminal block labeled “Network Loop” and the next MiniLink PD’s communications terminal block labeled “Network Loop”. Install a 24 VAC, 6 VA minimum, transformer for each of the MiniLink PDs on the system and wire each transformer to the 24 VAC power terminal block for its respective MiniLink PD using 18 gauge minimum, 2 wire cable. See page 46 of this manual for complete MiniLink PD wiring diagrams and instructions.

5. When the Modular Service Tool is to be used for programming and monitoring of the controllers it can be connected to the WMVAV controllers using the supplied cable with DIN connectors on both ends. The DIN connector on the WMVAV controller is located near the communications terminals. See page 44 of this manual for complete Modular Service Tool connection diagrams and instructions.

6. The Modular System Manager comes supplied with a 12 foot modular cable pigtail with a modular connector on one end and stripped wires on the other. Plug the modular connector end into the System Manager modular connector. Run 18 gauge, 2 conductor shielded cable for communications from the MiniLink PD or any controller on the local loop by connecting one end the controller’s or MiniLink PD’s 3 wire “Local Loop” communications terminal block to a junction box located within 12 feet of the System Manager. Run 18 gauge, 2 wire, power wires supplied by a separate 24 VAC, 6 VA minimum transformer into the junction box. Splice the stripped modular cable ends from the System Manager to the communications and power wire inside of the junction box using solid connections made with wire nuts or butt-splice connectors. See Modular System Manager wiring on pages 42 and 43 of this manual for wiring color coding and complete wiring instructions. The Modular System Manager MUST always be connected on the “Local Loop”, never the “Network Loop”.

Loop(s) with WMVAV and VAVBOX Controllers

1. Select one of the local loops on your system. Connect all WMVAV or Add-on Device controllers in a daisy chain or star ring format by connecting from each controller’s communication terminal block to the next using 18 gauge, 2 conductor shielded cable. Install a separate 24 VAC, transformer for each controller and wire from each controller’s power terminal block to its transformer using 18 gauge minimum, 2 wire cable for power. See Wire and Transformer Sizing section on page 16 for detailed transformer and wire sizing information. Observe polarity on all board power wiring. Install a separate 24 VAC, 8 VA minimum, transformer for each VAVBOX controller on the loop and wire from each controller’s power terminal block to it’s transformer using 18 gauge minimum, 2 wire cable. Observe polarity on all boards! As an alternative, a single transformer that connects to all VAVBOX controllers may also be used. It must be sized to handle the minimum load of 6 VA per VAVBOX controller connected to it. When

using this method, the polarity of all wiring between the transformer and the VAVBOX controllers is extremely critical and must be maintained to prevent damage to all boards connected! See the wire and transformer sizing

information on page 16 of this manual for complete wire and transformer sizing information. Repeat this procedure for each loop with VAVBOX controllers on your system.

Warning: If polarity between controllers is not maintained,

severe damage to the controllers may result. WattMaster recommends using a separate transformer for each controller in order to eliminate the potential for damaging controllers due to incorrect polarity.

2. For each local loop on the system do the following. Using 18 gauge 2 conductor shielded cable, connect from one of the WMVAV controller’s on the loop, 3 wire communications connector to that loop’s MiniLink PD 3 wire communications terminal block marked “Local Loop”.

3. To install the CommLink, connect 2 conductor shielded cable from one of the system’s MiniLink PD’s 3 wire communications terminal blocks labeled “Network Loop” to the CommLink’s 3 wire communications terminal block located on the back of the CommLink. Find the 110 VAC/ 24 VAC power supply furnished with the CommLink and connect the 2 stripped wire leads to the 24 VAC terminals on the back of the CommLink. The CommLink’s internal jumper must be set to “Multiple” for all WattMaster VAV systems. See page 45 of this manual for complete CommLink wiring and jumper setting information. After determining all wiring and jumper settings are correct, connect the power supply plug-in transformer to a 110 V receptacle.

4. The following procedure must be performed for each MiniLink PD on your system. Install a 24 VAC, 6 VA minimum, transformer for theMiniLink PD and wire it to the 24 VAC power terminal block on the MiniLink PD using 18 gauge minimum, 2 wire cable. See page 46 of this manual for complete MiniLink PD wiring diagrams and instructions. Be sure that all MiniLink PDs on the entire system are wired as required.

Component & System Wiring14

5. When the Modular Service Tool is to be used for programming and monitoring of the controllers it can be connected to the WMVAV controllers using the supplied cable with DIN connectors on both ends. The DIN connector on the WMVAV controller is located near the communications terminals. To connect the Modular Service Tool to a VAVBOX controller, first unplug the 3 wire communication terminal block from the VAVBOX controller. Connect the DIN to terminal adapter terminal end to the communication terminals block socket on the VAVBOX controller then connect the DIN connector side of the adapter to the Modular Service Tool cable DIN connector. See page 44 of this manual for complete Modular Service Tool connection diagrams and instructions.

System Commissioning

6. The Modular System Manager comes supplied with a 12foot modular cable pigtail with a modular connector on one end and stripped wires on the other. Plug the modular connector end into the System Manager modular connector. Run 18 gauge, 2 conductor shielded cable for communications from the MiniLink PD or any controller on the local loop by connecting one end the controller’s or MiniLink PD’s 3 wire “Local Loop” communications terminal block to a junction box located within 12 feet of the System Manager. Run 18 gauge, 2 wire, power wires supplied by a separate 24 VAC, 6 VA minimum transformer into the junction box. Splice the stripped modular cable ends from the System Manager to the communications and power wire inside of the junction box using solid connections made with wire nuts or butt-splice connectors. See Modular System Managerl wiring on pages 42 and 43 of this manual for wiring color coding and complete wiring instructions. The Modular System Manager MUST always be connected on the “Local Loop”, never the “Network Loop”.

The following information is a brief overview of the procedures required to commission a typical WattMaster VAV System.

1. Address each MiniLink PD on the system with a unique address from 1 to 60.

2. On a loop of WMVAV controllers and/or Add-on Devices, without VAVBOX Controllers, address the controllers and devices from 1 to 59.

3. On a loop which has VAVBOX controllers, address the VAVBOX controllers from 1 to 58. Address the WMVAV controller serving the VAVBOX controllers as address 59. Address all other controllers with addresses not already used by other controllers on the loop.

4. Always apply power to the system in the following order.

WMVAV controllers or Add-on Devices, MiniLink PD(s), CommLink, VAVBOX controllers (if used).

5. After powering up verify diagnostics LED indicator for proper operation of all controllers. See the technical guide for each specific controller for detailed information on the location of its diagnostic LED, and each controller’s start-up sequence.

6. If a computer is used, install the Prism computer front end software on it and connect it to the CommLink to access all of the controllers on the entire system for programming.

7. If a computer is not used, and if a Modular System Manger is not already connected on the local loop, connect a Modular Service Tool to one of the controllers to perform programming of all controllers on the entire system.

Component & System Wiring 15

Transformer & Wire Sizing

24VAC Power - Transformer & Wire Sizing Considerations For VAVBOX Controllers

Some installers like to use one large 24VAC transformer to power several devices. This is allowable as long as polarity is maintained to each device on the transformer circuit.

using a separate transformer for each device in order to eliminate the potential for damaging controllers due to incorrect polarity.

separate transformers also allows redundancy in case of a transformer failure. Instead of having 8 controllers inoperative because of a malfunctioning transformer you have only 1 controller off line. If the installer does decide to use a large transformer to supply power to several devices, the following transformer and wire sizing information is presented to help the installer correctly supply 24VAC power to the devices.

Following is a typical example to help the installer to correctly evaluate transformer and wiring designs.

Each VAVBOX Controller requires 6 VA @ 24VAC power. In the examples below we have a total of 10 VAV Controllers.

10 VAVBOX Controllers @ 6VA each................ 10 x 6VA =60VA.

The above calculation determines that our transformer will need to be sized for a minimum of 60VA if we are to use one transformer to power all the controllers. We will use a 75 VA transformer, as this is a readily available size that meets our VA load requirements.

Next we must determine the maximum length of run allowable for the wire gauge we wish to use in the installation. Each wire gauge below has a voltage drop per foot value we use to calculate total voltage drop.

18ga wire.................................0.00054 = voltage drop per 1’ length of wire

16ga wire.................................0.00034 = voltage drop per 1’ length of wire

14ga wire.................................0.00021 = voltage drop per 1’ length of wire

For our example we will use 18 gauge wire. WattMaster recommends 18 gauge as a minimum wire size for all power wiring.

Next use the voltage drop per foot value for 18 gauge wire from the list above and multiply by the total VA load of the 10 controllers to be installed.

0.00054 (Voltage drop per foot for 18 gauge wire) x 60VA controller load = Volts/Ft.

WattMaster VAVBOX controllers will operate efficiently with a voltage drop no greater than 2 Volts. Divide the total allowable voltage drop of 2 Volts by the number you arrived at above and you have the maximum number of feet you can run the 18 gauge wire with an 75 VA transformer with no more thana2Voltdrop at the farthest controller from the transformer..

Parallel circuiting of the wiring instead of wiring all 10 controllers in series allows for longer wire runs to be used with the same size wire (as shown in our examples below). transformer size, multiple transformers, circuiting, etc., when laying out an installation. No matter what layout scheme is decided upon, it is mandatory that the farthest controller on the circuit is supplied with a minimum of 22 Volts and that the polarity is maintained to all controllers connected to the transformer.

Warning:

It is often necessary for the installer to calculate and weigh the cost and installation advantages and disadvantages of wire size,

If polarity is not maintained, severe damage to the devices may result. WattMaster Controls recommends

0.0324

2 (Volts total allowable voltage drop)

0.0324 (Voltage drop per 1 ft. @ 60VA load)

= 61.73

feet

Using

B

A

120 / 24VAC

Distance A to B cannot exceed 61.73 Ft.

Component Power Requirements

VAV/CAV Controller ..................8VA

VAVBOX Controller..... ..............6VA

Optimal Start Scheduler............10VA

GPC Controller.................. .......8VA

BC

A

120 / 24VAC

Distance from A to B cannot exceed 123.46 Ft. Distance from A to C cannot exceed 123.46 Ft.

GPC-17 Controller....................10VA

Lighting Panel Controller ..........10VA

MiniLink Polling Device............. 6VA

Distance from A to B cannot exceed 230.40 Ft. Distance from A to C cannot exceed 308.64 Ft. Distance from A to D cannot exceed 308.64 Ft. Distance from A to E cannot exceed 308.64 Ft. Distance from A to F cannot exceed 308.64 Ft.

FILENAME

VAV-WIRSIZ1.CDR

DATE:

05/12/04

PAGE

1of1

Wire & Transformer Sizing

F

E

D

C

B

JOB NAME

DRAWN BY:

DESCRIPTION:

WattMaster VAV

A

120 / 24VAC

B. CREWS

Component & System Wiring16

WMVAV Controller Wiring

Component & System Wiring 17

WMVAV Controller Wiring

3 2 1

+

_

All Comm Loop Wiring Is

Straight Thru

TtoT

RtoR

SHLD to SHLD

Connect To Next Controller,

MiniLink PD Or System Manager

See Individual Sensor

Wiring Diagrams For

Detailed Sensor Wiring

VFD 0-10VDC Input

GND

Supply Fan

Variable Frequency Drive

(By Others)

The VFD Unit Must Be Configured For 0-10VDC Input. The Input Resistance At The VFD Must Not Be Less Than 1000 Ohms When Measured At The VFD Terminals With All Input Wires Removed.

Local Loop RS-485

9600 Baud

On Local Loop

Analog Inputs

C21

RN1

1

TB1

COMM

T

SHLD

R

CX5

LD6

COMM

LD7

1

PWR

LD8 LED1

RN3

LD9 LED2

R1

+VREF

TESTPOINT

U7

RV1 VREFADJ

INPUTS

+VDC

RN5

AIN1

AIN2 AIN3

AIN4

AIN5

C10

GND

GND AOUT1

AOUT2

AIN7

GND

PJ1

TB3

PRESSURE SENSOR

EXPANSION

Splice If Req’d

S.P.

Transducer

CX1

U2

U1

U5

RS-485

COMM

5.11V

C12

C17

P1

EWDOG

R26

RAM

HH

C1

R28

ADDRESS

PU1 D6 PU2

D7 PU3

D8 PU4

SW1 D9 PU5

D11 PU7

0-5

VDC

D14

U13

CX13

D15

U15

C20

CX15

PJ2

CX2

U6

PHILIPS

0-1

ADD

2 4 8

16 32 TOKEN NETWORK

VDC

JP1

U3

CX3

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV.2

CX6

C2

X1

C3

1

CX10

U10

CX12

C11

X2

R15

U12

CX14

C14

R19

U14

C15

R22

R24

R25

D18

D17

PJ3

C18

T'STAT

Not Used

Connect To Expansion Board Base (When Used)

D1

CX4

U4

RLY1

D2

RLY2

D3

PAL

1

RLY3

D4

RN2

RLY4

D5

RLY5

1

RN4

U9

C7

R7

D10

L1

R10

D13

D12

R13

SC1

D19

C19

VR1

VR2

Jumper Must Be In 0-5V Position As Shown

CX8

D16

COM1-3

COM4-5

NE5090NPB3192 0PS

R6

C9

R11

R27

V6

R1 R2 R3

R4

R5

U8

9936

V1

V2

V3

V5

U11

MC34064A

C13

C16

GND

POWER

24VAC

R - 24VAC

G - Fan ON/OFF Only

TB2

Relay Output Dry Contacts R2 Thru R5 May Be User Configured

V4

For The Following:

1 - Heating (Aux. Heating)Stages 2 - Cooling (Compressor) Stages 3 - Warm-up Mode Command For Boxes 4 - Reversing Valve (Air To Air Heat Pumps) 5 - Gas Reheat Control For Dehumidification 6 - Exhaust Fan Interlock 7 - Preheat Coil 8 - Alarm Relay 9 - Override 10 - Occupied 11 - Economizer

Note: Up To 16 More Relays Are Available By Adding Relay Expansion Boards. All Expansion Board Relay Outputs Are User Configurable As Listed Above.

TB4

GND

24VAC

Size Transformer For Correct Total Load. WMVAV Controller = 8 VA Power Consumption. If Economizer Option Is Used The Economizer Actuator VA load Must Also Be Considered When Sizing The Transformer.

Line Voltage

Economizer

Actuator

(Belimo Shown)

Consult Factory For

Other Manufacturers

Wiring Connections

Warning: 24 VAC Must Be Connected So That All Ground Wires Remain Common. Failure To Do So Will Result In Damage To The Controllers.

Notes:

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With

Local And National Electrical Codes and Specifications.

3.)All Communication Wiring To Be 18 Ga. Minimum, 2 Conductor Twisted Pair With Shield. Belden #82760 Or Equivalent.

4.)When Humidity Sensor Is To Be

Installed A 250 Ohm Resistor Must Be Installed On The Ground Side Of The Sensor And Pull Up Resistor PU5 Must Be Removed From The Controller. See Humidity Sensor Wiring Diagram In The WMVAV section of this manual.

Connect Tubing To High Pressure Port (Bottom Tube) and Route To Static Pressure Pickup Probe Located In Unit Discharge. Leave Port Marked “Lo” Open

GND

To Atmosphere

24VAC

5.)If The Slide Adjust Option Is Used On The Room Sensor , The AUX Connection Must Be Wired To AIN7. The Fan Proof Of Flow Switch, Which Normally Connects To AIN7, Is Not Available For Use When The Slide Adjust Option Is Used.

FILENAME

VAV-WMVAVWIR1A.CDR

DATE:

05/12/04

PAGE

1of2

JOB NAME

DRAWN BY:

B. Crews

DESCRIPTION:

WMVAV Controller

Component Wiring Diagram

Component & System Wiring18

WMVAV Controller Addressing

This Switch Should Be In The OFF Position As Shown

ADDRESS ADD

Address Switch Shown Is

Set For Address 1

The Address For Each Controller

Must Be Unique To The Other Controllers

On The Local Loop And Be Between 1 and 59

INPUTS

+VDC

AIN1

AIN2 AIN3

AIN4

AIN5

GND GND AOUT1

AOUT2

AIN7 GND

PJ1

TB3

PRESSURE SENSOR

ADDRESS ADD

Controller Address Switch

RN5

C10

C17

C12

R26

C20

D15

PU1 D6 PU2

D7 PU3

D8 PU4

D9 PU5

D11 PU7

D14

PJ2

EXPANSION

1 2 4

8 16 32 TOKEN

NETWORK

ADDRESS ADD

Address Switch Shown Is

Set For Address 13

0-5

CX13

CX15

U15

SW1

VDC

0-1

ADD

1

2

4 8 16

32

TOKEN

NETWORK

VDC

JP1

PJ3

C14

C15

U10

C11

X2

R15

R19

R22

R24

R25

ADDRESS

U13

U14

D17

CX10

U12

CX14

D18

CX12

Note:

The Power To The Controller Must Be Removed And Reconnected After Changing The Address Switch Settings In Order For Any Changes To Take Effect.

Caution

Disconnect All Communication Loop Wiring From The Controller Before Removing Power From The Controller. Reconnect Power And Then Reconnect Communication Loop Wiring.

C7

D16

R6

C9

R11

U11

C13

C16

TB4

GND

R27

V6

POWER

C18

D10

D12

R13

SC1

D19

C19

R7

L1

R10

D13

24VAC

VR1

VR2

JOB NAME

FILENAME

VAV-WMVAVWIR1A.CDR

PAGE

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DATE:

05/12/04

DRAWN BY:

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WMVAV Controller

Component Wiring Diagram

B. Crews

Component & System Wiring 19

Space Sensor Wiring

Note: If The Slide Adjust Option Is Used On The Room Sensor The AUX Terminal Must Be Wired To AIN7. The Fan Proof Of Flow Switch, Which Normally Connects To AIN7, Is Not Available For Use When The Slide Adjust Option Is Used.

Space Temperature Sensor

NORMAL

OVR

W

A R M E R C O O L E R

TMP

GND

AUX (See Note)

Fan Proof Of

Flow Switch

(See Note)

INPUTS

+VDC AIN1

AIN2 AIN3 AIN4 AIN5 GND

GND AOUT1

AOUT2 AIN7 GND

WMVAV Controller Board

Space Temperature Sensor Information

The Space Temperature Sensor is typically used for constant volume HVAC unit applications controlling one zone. The Space Temperature Sensor is a 10K Type III thermistor sensor. The Space Temperature Sensor should be mounted approximately 5 ft. above the floor in the space that is to be controlled. The Space Temperature Sensor is available in a sensor only, sensor with override button, sensor with slide adjust and sensor with slide adjust and override configurations. If the Space Temperature Sensor with Slide Adjust option is to be used, the Fan Proof of Flow Switch cannot be used.

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

FILENAME

VAV-SpaceTempWire1.CDR

DATE:

05/12/04

PAGE

1

Space Temperature Sensor To

WMVAV Controller Wiring

JOB NAME

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Component & System Wiring20

Supply & Return Sensor Wiring

Supply

Air Temperature

Sensor

Mount In HVAC

Unit Supply

Air Duct

Return

Air Temperature

Sensor

INPUTS

+VDC AIN1

AIN2 AIN3 AIN4 AIN5 GND

GND

AOUT1

AOUT2 AIN7 GND

Mount In HVAC

Unit Return

Air Duct

WMVAV Controller Board

Supply & Return Sensor Information

The Supply and Return Air Temperature Sensors must be wired as shown in the illustration below for proper operation. The Supply and Return Air Temperature Sensors are 10K Type III thermistor sensors. The Supply Air Temperature Sensor should be mounted in the unit discharge plenum or in the supply air duct. The Return Air Temperature Sensor should be mounted in the return air duct. If the system has a bypass damper installed, be sure the return air sensor is located upstream of the bypass duct connection.

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

FILENAME

VAV-SupRetTempWire1.CDR

DATE:

03/24/04

PAGE

Supply & Return Air Temperature Sensor To

1

JOB NAME

DRAWN BY:

DESCRIPTION:

WMVAV Controller Wiring

B. Crews

Component & System Wiring 21

Outside Air Sensor Wiring

Caution:

Be sure to mount the Outside Air Sensor in an area that is not exposed to direct sunlight. A

shaded area under the eve of the building or under the HVAC unit rainhood is normally a good

location. If sensor is not located as specified, erroneous outside air temperature readings will

result. Unused conduit opening(s) must have closure plugs installed and must be coated with a

sealing compound to provide raintight seal. Water can damage sensor!

Outdoor

Air Temperature

Sensor

Make Splice Connections Inside Sensor Enclosure As Shown.

INPUTS

+VDC AIN1

AIN2 AIN3 AIN4 AIN5 GND

GND

AOUT1

AOUT2 AIN7 GND

WMVAV Controller

Outside AirTemperature Sensor

The Outside Air Sensor must be wired as shown in the illustration above for proper operation. The Outside Air Temperature Sensor is a 10K Type III thermistor sensor. The sensor should be mounted in the upright position as shown, in an area that is protected from the elements and direct sunlight. Be sure to make the wiring splices inside of the OutsideAirTemperature Sensor weathertight enclosure.

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

FILENAME

VAV-OATempWire1.CDR

DATE:

05/12/04

PAGE

1

Outside Air Temperature Sensor To

Component & System Wiring22

JOB NAME

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DESCRIPTION:

WMVAV Controller Wiring

B. Crews

Remote Occupied Contact To WMVAV Wiring

Note: If Remote Occupied Contact Is Required When Humidity Sensor Is Used, The Remote Occupied Contact Must Be Relocated To AIN2 On The 4 Analog Input 1 Analog Output Expansion Board. See Expansion Board Wiring For Detailed Wiring.

Remote Occupied

Contact

(Relay By Others)

INPUTS

+VDC AIN1

AIN2 AIN3 AIN4 AIN5 GND

GND

AOUT1

AOUT2 AIN7 GND

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

WMVAV Controller Board

FILENAME

VAV-RemoteOccConWire1.CDR

DATE:

03/24/04

PAGE

1

Remote Occupied Contact To

WMVAV Controller Wiring

JOB NAME

DRAWN BY:

DESCRIPTION:

B. Crews

Component & System Wiring 23

Humidity Sensor Wiring

Outdoor

Air Humidity

Sensor - 4-20mA

Warning:

It is very important to be certain that all wiring

is correct as shown in the wiring diagram

below. Failure to observe the correct polarity

will result in damage to the Humidity Sensor or

controller.

The Pull-up Resistor (PU5) Must Be Removed When Using A 4-20ma Device

INPUTS

+VDC

AIN1

4-20 mA4-20 mA

SpanSpan

ZeroZero

GNDGND

0-5V or 0-10V0-5V or 0-10V

VACorDCVACorDC

AIN2

44

3333222211

ONON

AIN3

AIN4 AIN5 GND GND

AOUT1

445566

11

ONON

250 Ohm

Resistor

(Shipped With Sensor)

To be Installed Between

AIN5 and GND

AOUT2 AIN7 GND

WMVAV Controller Board

Note: If Remote Occupied Contact Is Required When Humidity Sensor Is Used, The Remote Occupied Contact Must Be Relocated To AIN2 On The 4 Analog Input 1 Analog Output Expansion Board.

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

FILENAME

VAV-HumidSensorWire1B.CDR

02/21/08

DATE:

PAGE

1

DESCRIPTION:

Humidity Sensor To

WMVAV Controller Wiring

Component & System Wiring24

JOB NAME

DRAWN BY:

B. Crews

+

_

Supply Fan VFD Wiring

The VFD Unit Must Be Configured For 0-10VDC Input. The Input Resistance At The VFD Must Not Be Less Than 1000 Ohms When Measured At The VFD Terminals With All Input Wires Removed.

VFD 0-10VDC Input

GND

Supply Fan

Variable Frequency Drive

(By Others)

Caution:

Variable Frequency Drive Units Can Cause Large Transient Noise Spikes Which Can Cause Interference To Be Propagated On Other Electronic Equipment. Use Shielded Wire Wherever Possible And Route All Sensor/controller Wiring Away From The Variable Frequency Drive And The Air Handling Unit Electrical Wiring.

INPUTS

+VDC AIN1

AIN2 AIN3 AIN4 AIN5 GND GND AOUT1 AOUT2 AIN7 GND

WMVAV Unit Controller Board

JOB NAME

FILENAME

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

VAV-SupplyVFDWR1.CDR

DATE:

03/24/04

PAGE

1

DRAWN BY:

DESCRIPTION:

B. Crews

Supply Fan VFD To

WMVAV Controller Wiring

Component & System Wiring 25

Bypass Damper Actuator Wiring

OE281-04 Bypass Damper Actuator

10

0

1

Set Rotation Switch To Correct Damper Operating Rotation. Standard WattMaster Rotation Is Counterclockwise To Open (1) As Shown.

WMVAV Unit Controller Board

1

2

3

?

Y

?

2

1

3

24 VAC

INPUTS

+VDC AIN1

AIN2 AIN3 AIN4 AIN5 GND GND AOUT1 AOUT2 AIN7 GND

LINE

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

GND

Transformer-8VAMinimum

FILENAME

VAV-BypassActuatorWire1B.CDR

DATE:

02/20/08

PAGE

1

Component & System Wiring26

JOB NAME

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Bypass Damper Actuator To

WMVAV Controller Wiring

VR5

MC

7824CT

C6

TB2

VR3

7805ACT

R14

VR2

D3

7824CT

MC

VR4

7812CT

MC

GND

+24VDC-OUT

GND

24VAC-IN

TB1

CX3

R13

PWR

LD1

C1

PJ2

R11

C2 C3

U1

PJ1

R9

R7

D2D1 R8

P1

R1

CX1

R2

R3

JP1

2 SLOT

MODULAR

I/O

VR6

7824CT

MC

LM358N

YS101780

C4 C5

U2

VR1

R12

R6

CX2

R10

R4

R5

P2 JP2

2 Slot Expansion Base Board Wiring

Jumpers Must Be Set According To Type Of Expansion Board Used See Expansion Board Specific Wiring For Jumper Settings

Connect To Unit Controller Board

24VAC

Line Voltage

GND

Transformer Load = 10VA

WARNING!!

Observe Polarity! All boards must be wired with

GND-to-GND and 24VAC-to-24VAC.

Failure to observe polarity will result in damage

to one or more of the boards. Expansion Boards

must be wired in such a way that power to both

the expansion boards and the

controller are always powered together. Loss of

power to the expansion board will cause the

controller to become inoperative until power is

restored to the expansion board.

2 SLOT MODULAR I/O

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes

JOB NAME

and Specifications.

FILENAME

VAV-2SlotExpBase.CDR

PAGE

1of1

DATE:

03/24/04

DRAWN BY:

DESCRIPTION:

2 Slot Expansion Base Board

Component Wiring Diagram

B. Crews

Component & System Wiring 27

4 Slot Expansion Base Board Wiring

Connect To Unit Controller Board

Jumpers Must Be Set According To Type Of Expansion Board Used See Expansion Board Specific Wiring For Jumper Settings

Line Voltage

24VAC

GND

Transformer Load = 14VA

Observe Polarity! All boards must be wired with

GND-to-GND and 24VAC-to-24VAC.

Failure to observe polarity will result in damage

to one or more of the boards. Expansion Boards

must be wired in such a way that power to both

the expansion boards and the

controller are always powered together. Loss of

power to the expansion board will cause the

controller to become inoperative until power is

restored to the expansion board.

WARNING!!

TB1

TB2

PJ1

PJ2

+24VDC-OUT

GND

LD1 PWR

24VAC-IN

GND

R20

C8

P1 JP1

R2

R1

R3

CX1

R15

R17

D3

P82B715P

D1

D2

R13

R14

U1

C1

R19

CX3

7824CT

VR2

VR3

7805ACT

C3C2

7812CT

VR4

VR5 VR6

P2

LM358N

U2

C4 C5

7824CT

JP2

CX2

7824CT

P3

JP3

R5R4 R6

C6

7824CT

VR7

R9R8R7

P4 JP4

C7

4 SLOT MODULAR I/O BD.

7824CT

YS101782

VR8

R11

R10

R12

R16

VR1

R18

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

FILENAME

VAV-OE353-4SLOTEXP.CDR

DATE:

03/24/04

PAGE

1

OE353 - 4 Slot Expansion Base Board

Component Wiring Diagram

Component & System Wiring28

JOB NAME

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DESCRIPTION:

B. Crews

4 Analog Input 1 Analog Output Expansion Board Wiring

For Proper Operation Pullup Resitors PU1, PU3 & PU4 Must Be Removed As Shown

Voltage Is Selectable For AIN1 Only

Jumper On = 0-10VDC Input Setting

Jumper Off = 0-5 VDC Input Setting

Jumper Must Be Off For AIN2 & 4

Analog Inputs

Input #9 - Supply Setpoint Reset

Input #10 - Remote Occupied Contact

Input #11 - Carbon Dioxide Sensor

Input #12 - Relief Pressure Sensor

Analog Output

Output #3 - Relief Fan VFD Signal (0-10VDC)

Mount Expansion Board To Either The OE352 2 Slot Or OE353 4 Slot Expansion Base Board

TB1

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

R10

R5

R6

R7

R8 R9

D5

Q1

PU1

PU2

PU3

PU4

U2

JO1

C2

JO2

C3

JO3

C4

JO4

C5

C1

LM358

Jumper Must Be ON For AIN3

R1

D1

R2

D2

R3

D3

R4

D4

CX2

4 ANALOG IN MOD. I/O BD.

YS101784

CX1

Address Jumpers Located On Base Board Under Expansion Board

U1

PCF8591P

P1

Base Board

Edge of

4 Analog Input 1 Analog Output Expansion Board Overview

+

_

Other Device That Is

Supplying Reset Signal

Supply Setpoint ResetSignal 0-5VDC or 0-10VDC

GND

Jumper J01 Must Be Removed For 0-5VDC Operation

Pullup Resistor PU1 Must Be Removed For Proper Operation

AIN1

R5

AIN2

R6

AIN3

R7

AIN4

GND

R8 R9

AOUT1

R10

D5

Q1

TB1

PU1

C2

PU2

C3

PU3

C4

PU4

C5

C1

U2

LM358

Input #9 - Supply Setpoint Reset - Wiring

JO1

JO2

JO3

JO4

Jumper J01 Must Be On As Shown For 0-10VDC Operation

R1

D1

R2

D2

R3

D3

R4

D4

CX2

4 ANALOG IN MOD. I/O BD. YS101784

CX1

PCF8591P

P1

U1

JOB NAME

FILENAME

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

VAV-OE354-4ANALOGIN1OUT.CDR

DATE:

03/24/04

PAGE

1of3

OE354 - 4 Analog Input 1 Analog Output Expansion Board

DESCRIPTION:

Component Wiring Diagram

DRAWN BY:

B. Crews

Component & System Wiring 29

4 Analog Input 1 Analog Output Expansion Board Wiring (Cont’d)

Pullup Resistor PU2 Must Be Installed

Jumper Must Be Off For AIN2

JO1

R1

JO2

D1

R2

JO3

D2

R3

JO4

D3

R4

D4

CX2

4 ANALOG IN MOD. I/O BD. YS101784

CX1

P1

U1

PCF8591P

Input #10 - Remote Occupied Contact

CO Sensor

2

(0-10VDC Signal)

Normally Open Dry Contact (By Others)

AIN1

R5

AIN2

R6

AIN3

R7

AIN4

GND

R8 R9

AOUT1

TB1

D5

R10

PU1

C2

PU2

C3

PU3

C4

PU4

C5

C1

U2

Q1

LM358

Input #10 - Remote Occupied Contact - Wiring

VAV/CAV Unit Controller Board

GND

1. AC+/DC+

2. AC/GND

Pin Designations

7. Signal Ground

8. 0-10V Output

6. 4-20mA Output

24VAC

GND

Pullup Resistor PU3 Must Be Removed As Shown

4. Relay Common

5. Relay Norm Closed

3. Relay Norm Open

1. - Not Used

2. - Not Used Pin Designations

AIN1

R5

AIN2

R6

AIN3

R7

AIN4

GND

R8 R9

AOUT1

R10

D5

Q1

TB1

Input #11 - Carbon Dioxide Sensor - Wiring

Line Voltage

Warning

24VAC

24 VAC Must Be Connected So That All Ground Wires Remain Common. Failure To Do So Will Result In Damage To The Controllers.

:

Jumper J03 Must Be On As Shown For CO Sensor

With 0-10VDC Signal If

CO Sensor With 0-5VDC

2

Signal Is Used It Must Be Removed

PU1

PU2

PU3

PU4

U2

JO1

C2

C3

C4

C5

C1

JO2

JO3

JO4

LM358

R1

D1

R2

D2

R3

D3

R4

D4

CX2

4 ANALOG IN MOD. I/O BD. YS101784

CX1

U1

PCF8591P

2

P1

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

FILENAME

VAV-OE354-4ANALOGIN1OUT.CDR

DATE:

03/24/04

PAGE

2of3

OE354 - 4 Analog Input 1 Analog Output Expansion Board

DESCRIPTION:

Component Wiring Diagram

Component & System Wiring30

JOB NAME

DRAWN BY:

B. Crews

+

_

4 Analog Input 1 Analog Output Expansion Board Wiring (Cont’d)

VAV/CAV Unit Controller Board

INPUTS

+VDC

AIN

1

AIN

2

Building Pressure Sensor

Tubing To Building Pressure Sensing Location

Tubing To Atmospheric Pressure Sensing Location

HIGH

LOW

+

-

AIN

3

AIN

4

AIN

5

GND

AOUT1

AOUT2

AIN

7

GND

PRESSURE SENSOR

TB1

EXPANSION

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

Warning

: 24 VAC Must Be Connected So That All Ground Wires Remain Common. Failure To Do So Will Result In Damage To The Controllers.

Pullup Resistor PU4 Must Be

R10

Removed

PU1

R5

R6

R7

R8 R9

D5

U2

Q1

PU2

PU3

PU4

JO1

C2

JO2

C3

JO3

C4

JO4

C5

C1

LM358

Jumper J04 Must Be Off As Shown For Proper 0-5VDC Operation

R1

D1

R2

D2

R3

D3

R4

D4

CX2

4 ANALOG IN MOD. I/O BD.

YS101784

CX1

PCF8591P

P1

U1

Relief Fan Variable Frequency Drive

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

(By Others)

Input #12 - Relief Pressure Sensor - Wiring

VFD 0-10VDC Input

GND

Warning: The VFD Unit Must Be configured for 0-10VDC input. The input resistance at the VFD must not be less than 1000 ohms when measured at the VFD terminals with all input wires removed. Higher voltages or lower resistance will cause improper operation and could result in damage to circuit boards

AIN1

R5

AIN2

R6

AIN3

R7

AIN4

GND

R8 R9

AOUT1

TB1

D5

R10

PU1

C2

PU2

C3

PU3

C4

PU4

C5

C1

U2

Q1

Output #3 - Relief Fan VFD Signal - Wiring

FILENAME

VAV-OE354-4ANALOGIN1OUT.CDR

DATE:

PAG E

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JO1

JO2

JO3

JO4

LM358

R1

D1

R2

D2

R3

D3

R4

D4

CX2

4 ANALOG IN MOD. I/O BD.

YS101784

CX1

PCF8591P

P1

U1

JOB NAME

03/24/04

DRAWN BY:

B. Crews

DESCRIPTION:

OE354 - 4 Analog Input 1 Analog Output Expansion Board

Component Wiring Diagram

Component & System Wiring 31

R4

R3

R2

R1

YS101788

BIN 4

BIN 3

BIN 2

BIN 1

COM

TB1

OPTO2

R10

R12

4 DIG. IN MOD. I/O BD.

P2506-2

R8

R6

R5

P2506-2

OPTO1

74HC14N

PCF8574P

U2

C4

C3

U1

CX2

C2

C1

CX1

P1

4 Binary Input Expansion Board Wiring

OE265-06 Humidistat

RD

Address Jumpers Located On Base Board Under Expansion Board

Base Board

Edge of

Remote Forced Heat Mode

Remote Forced Cool Mode

24Volt Power Only

Dirty Filter

Relay Contacts

(By Others)

BIN 1

BIN 2

BIN 3

BIN 4

4 DIG. IN MOD. I/O BD.

4 Binary Input Expansion Board

Mount Expansion Board To Either The OE352 2 Slot Or OE353 4 Slot Expansion Base Board

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

FILENAME

VAV-OE356-4BINARYINPUT.CDR

DATE:

03/24/04

PAGE

1of1

OE356 4 Binary Input Expansion Board

Component Wiring Diagram

Component & System Wiring32

JOB NAME

DRAWN BY:

DESCRIPTION:

B. Crews

K3

K2

4RLY IO BD.

V4

K4

YS101790

TB1

V1

K1

K3

U2

K4

RN1

PCF8574P

U3

CX3

U1

ULN2803A/

K2

K1

74HC04N

P1

CX2

CX1

4 Relay Output Expansion Board Wiring

Relay Output Dry Contacts R6 Through R21 May Be User Configured For The Following:

24Volt Power

Not Used Heating (Aux. Heating)Stages Cooling (Compressor) Stages Warm-up Mode Command For Boxes Reversing Valve (Air To Air Heat Pumps) Gas Reheat Control For Dehumidification Exhaust Fan Interlock Preheat Coil Alarm Relay Override Occupied Economizer

Configure Relays By Utilizing The System Manager, Modular Service Tool or Prism Computer Front End Software.

Typical Wiring For Relay Outputs - 6 Through 21

Pilot Duty Relays (By Others)

R1

R2

R3

R4

Note:

All Circuit Board Contacts Are N.O.

!

All Contacts Are Rated For 2 Amps @

!

24VAC Pilot Duty Only Do Not Apply Any Voltage Greater Than

!

24VAC

Address Jumpers Located On Base Board Under Expansion Board

UL 5A250VAC CONTACT: 24VDC G5L-114P-PS

OMRON

4RLY IO BD.

Mount Expansion Board To Either The OE352 2 Slot

UL 5A250VAC CONTACT: 24VDC G5L-114P-PS

OMRON

UL 5A250VAC CONTACT: 24VDC

G5L-114P-PS

OMRON

UL 5A250VAC CONTACT: 24VDC

G5L-114P-PS

OMRON

4 Relay Output Expansion Board

Or OE353 4 Slot Expansion Base Board

Relays 6-9

Relays 10-13

Relays 14-17

Relays 18-21

ULN2803A/

Base Board

Edge of

Base Board

Edge of

Base Board

Edge of

Base Board

Edge of

JOB NAME

FILENAME

Notes:

1.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

VAV-OE357-4RELAYOUT.CDR

DATE:

05/12/04

PAGE

1of1

OE357 4 Relay Output Expansion Board

DESCRIPTION:

Component Wiring Diagram

DRAWN BY:

B. Crews

Component & System Wiring 33

Component & System Wiring34

VAVBOX Controller

Diagrams

Component & System Wiring 35

VAVBOX Controller Wiring

Airflow Sensor (Optional)

Only Used For Pressure

Independent Applications

Airflow

Room Sensor (See Note 3)

W

A R M E R

NORMAL

C O O

OVR

L E R

Connection To AUX Terminal Required Only When Sensor Is Specified With Slide Adjust Option

TMP

GND

AUX

Local Loop

RS-485

9600 Baud

All Comm Loop Wiring Is

Straight Thru

T

SH

R

T

SH

R

Lo

T

SH

R

Hi

Connect To

Next VAVBOX

Controller

And/Or WMVAV

Controller On

Local Loop

24VAC

See Note 1

Required VA For Transformer

Each VAVBOX Controller=6VAMin.

(Includes Actuator)

Diagnostic Blink Code LED

Caution!

VAVBOX Controllers Must Have Address Switches Set Between 1 And 58

GND

SHIELD

AIRFLOW

P.U .

D5

D6

P.U .

R32

T'STAT

R33

D7

COMM

T

R

YS101562 REV. 3

R35

V3

24VAC

GND

RN1

U8

PJ3

R27

C13

C14

VREF

ADJ

R28

U11

C15

R25

CX10

485

DR

V

R26

D4

OI

C16

R22

P.U.

R23

R24

CX8

CX9

C11

U9

R20

EWDOG

OFF

U10

SW1

POWER

R21

VR1

7824

L1

R34

R18

C9

C10

R19

ADDRESS

R17

R16

ADD

SCAN

U4

C8

1

2 4 8

16

32 TOKEN NET

CX4

U6

R14

REC

D3

C7

U7

CX3

CX1

U3

EPROM

U5

CX5

R8

CX6

C4

C5

R100

R13

V1

R9

R12

R11

C6

Q2

D1

R15

Q3

D2

U1

PAL

R1 R2 R3

X1

C1

C2

R5 R6 R7

PJ1

C3

PJ2

Q1

CX2

U2

R4

EXPANSION

ACTUATOR

K1

K2

V2

VAVBOX Damper Actuator

10

ADDRESS ADD

This Switch Must Be In The ON Position As Shown

ADDRESS ADD

1 2 4 8

16 32 TOKEN NET

Switches Labeled 32 And Token Should Be In The OFF Position As Shown

ADDRESS ADD

Note:

The Power To The VAVBOX Controller Must Be Removed And Reconnected After Changing The Address Switch Settings In Order For Any Changes To Take Effect.

Caution:

Disconnect All Communication Loop Wiring From The VAVBOX Controller Before Removing Power From The VAVBOX Controller. Reconnect Power And Then Reconnect Communication Loop Wiring.

Address Switch Shown Is

Set For Address 9

Notes:

1.) All wiring to be in accordance with local and national electrical codes and specifications.

2.) All communication wiring to be 2 conductor twisted pair with shield. Use Belden #82760 or equivalent.

3.)The Supply Air Sensor is not required when the VAVBOX Controllers are connected with WMVAV Unit Controller boards. A global supply air temperature is broadcast by the one of the WMVAV Unit Controllers. The Supply Air Sensor is only required if the VAVBOX Controller is required to operate as a “Stand Alone” controller.

Controller Address Switch

Address Switch Shown Is

The Address For Each Controller

Must Be Between 1 And 58 And Be

Unique To The Other Controllers

On The Local Loop

JOB NAME

FILENAME

VAV-VAVBOXWire1.CDR

DATE:

05/12/04

PAGE

1of1

DESCRIPTION:

WattMaster VAV System

VAVBOX Controller

Component & System Wiring36

Set For Address 13

CONTROLS

DRAWN BY:

B. CREWS

3 Relay Output Expansion Board Wiring

2RAOUT BD.

K1

WattMaster Part #OE322

Q3

Relay Expansion Board

R3

w/ Modular Cable Supplied by WattMaster

R6

Q2

Mounted by Others

Q1

Connect To VAVBOX Controller Using Modular Cable Supplied By WattMaster

R7

PJ1

WattMaster Part # BK000047 Snaptrack Supplied by WattMaster Mounted by Others. Remove Control Board from Snaptrack & Mount Snaptrack on Box

D4

RLY

1

R10

D3

RLY

2

R9R5R2

D2

RLY

3

R8R4R1

U1

C1

C3

C6

D1

C2

C4

YS101714

REV.3

V4

TB2

COM

1

2

V3

K2

3

TB3

V2

+V

K3

GND

ANALOG

V1

OUTV5

C5

LM358

Q4

R11

R12

VR2

I

7824CT

O

VR1

+

Note: 3 Stage Heating is Attained by Sizing All 3

TB1 GND

R14

R13

M

Heating Elements For Equal KW Output. Each Element Should be Sized for 1/3 of the Total KW Output Required. To Achieve 3 Stage Heating the System would be Configured to Energize

SERIAL #

Contactor C1 for First Stage Heat. For 2nd Stage Heat the System Would be Configured to Deenergize Contactor C1 and Energize Contactor C2 & C3. For 3rd Stage Heat the System Would be Configured to Leave Contactor C2 & C3 Energized and also Energize Contactor C1.

24VAC

COM

C1

C3

24 VAC Transformer Supplied & Wired by Others. Size For Required Contactor(s) Load.

1st Stage Heat Contactor

2nd Stage Heat Contactor

C2

3rd Stage Heat Contactor

24 VAC Contactor(s) Supplied & Installed By Others. 2 Amp Max. Load Each.

Typical Wiring for Single Duct Terminal with Electric Heat

WattMaster Part #OE322 Relay Expansion Board w/ Modular Cable Supplied by WattMaster Mounted by Others

Connect To VAVBOX Controller Using Modular Cable Supplied By WattMaster

WattMaster Part # BK000047

Q3

RLY

1

R3

R6

R10

D3

RLY

Q2

2

R9R5R2

D2

Q1

RLY

3

R8R4R1

U1

C1

R7

PJ1

D1

C5

LM358

C3

C6

R11

VR2

I

O

C2

VR1

C4

K1

D4

Snaptrack Supplied by WattMaster Mounted by Others. Remove Control Board from Snaptrack & Mount Snaptrack on Box

K1

WattMaster Part #OE322 Relay Expansion Board w/ Modular Cable Supplied by WattMaster Mounted & Wired by Others

Connect To VAVBOX Controller Using Modular Cable Supplied By WattMaster

WattMaster Part # BK000047

R3

PJ1

D4

Q3

RLY

1

R6

R10

D3

RLY

Q2

2

R9R5R2

D2

Q1

RLY

3

R8R4R1

U1

C1

R7

D1

C5

LM358

C3

C6

R11

VR2

I

O

C2

VR1

C4

Snaptrack Supplied by WattMaster Mounted by Others. Remove Control Board from Snaptrack & Mount Snaptrack on Box

Notes:

1.) All Wiring to be in Accordance With Local & National Electrical Codes & Specifications.

2RAOUT BD.

K2

K3

Q4

R12

M

7824CT

2RAOUT BD.

K2

K3

Q4

R12

M

7824CT

YS101714

REV.3

V4

COM

1

2

V3

3

V2

+V

GND

V1

TB1 GND

R14

R13

YS101714

REV.3

V4

COM

1

2

V3

3

V2

+V

GND

V1

TB1 GND

R14

R13

24VAC

COM

TB2

Fan Relay

R1

ANALOG

OUTV5

TB3

+

SERIAL #

TB2

24 VAC Fan Relay Supplied & Installed By Others. 2 Amp Max. Load.

24VAC

COM

Fan Relay

R1

TB3

C1

ANALOG

OUTV5

+

Note: 3 Stage Heating is Attained by Sizing All 3 Heating Elements For Equal KW Output. Each Element Should be Sized for 1/3 of the Total KW Output Required. To Achieve 3 Stage Heating the System would be Configured to Energize Contactor C1 for First Stage Heat. For 2nd Stage Heat the System Would be Configured to De-energize Contactor C1

SERIAL #

and Energize Contactor C2 & C3. For 3rd Stage Heat the System Would be Configured to Leave Contactor C2 & C3 Energized and also Energize Contactor C1.

PAGE

1of3

C3

FILENAME

VAV-OE322-3RELAY1OUTBD.CDR

DATE:

1st Stage Heat Contactor

2nd Stage Heat Contactor

C2

3rd Stage Heat Contactor

09/26/06

OE322-3Relay -1 Analog Output Board

Component Wiring Diagram

24 VAC Transformer Supplied & Wired by Others. Size For Required Fan Relay Load.

Typical Wiring for Fan Terminal Unit with Cooling Only

24 VAC Transformer Supplied & Wired by Others. Size For Required Fan Relay & Contactor(s) Load.

24 VAC Fan Relay & Contactor(s) Supplied & Installed By Others. 2 Amp Max. Load Each.

Typical Wiring for Fan Terminal Unit with Electric Heat

JOB NAME

DRAWN BY:

DESCRIPTION:

B. Crews

Component & System Wiring 37

3 Relay Output Expansion Board Wiring (Cont’d)

2RAOUT BD.

K1

WattMaster Part #OE322 Relay Expansion Board w/ Modular Cable

R3

Supplied by WattMaster Mounted & Wired by Others

Connect To VAVBOX Controller Using Modular Cable Supplied By WattMaster

PJ1

WattMaster Part # BK000047 Snaptrack Supplied by WattMaster Mounted by Others. Remove Control Board from Snaptrack & Mount Snaptrack on Box

WattMaster Part #OE322 Relay Expansion Board w/ Modular Cable

R3

R6

Supplied by WattMaster Mounted & Wired by Others

Connect To VAVBOX Controller Using Modular Cable Supplied By WattMaster

R7

PJ1

WattMaster Part # BK000047 Snaptrack Supplied by WattMaster Mounted by Others. Remove Control Board from Snaptrack & Mount Snaptrack on Box

D4

Q3

RLY

1

R6

R10

D3

RLY

Q2

2

R9R5R2

D2

Q1

RLY

3

R8R4R1

U1

C1

R7

C3

C6

D1

C2

C4

D4

Q3

RLY

1

R10

D3

RLY

Q2

2

R9R5R2

D2

Q1

RLY

3

R8R4R1

U1

C1

C3

C6

D1

C2

C4

YS101714

REV.3

V4

TB2

COM

1

2

V3

K2

3

TB3

V2

+V

K3

GND

ANALOG

V1

OUTV5

C5

LM358

Q4

TB1 GND

R11

R12

R14

R13

VR2

I

M

7824CT

O

VR1

SERIAL #

0-10 VDC Signal

+

HWV

0-10 VDC Modulating

Hot Water Valve Supplied & Installed by Others

2RAOUT BD.

K1

YS101714

REV.3

V4

TB2

COM

1

2

V3

K2

3

TB3

V2

+V

K3

GND

ANALOG

V1

OUTV5

C5

LM358

Q4

R11

R12

VR2

I

7824CT

O

VR1

+

TB1 GND

R14

R13

M

SERIAL #

24VAC

COM

R1

Fan Relay

0-10 VDC Signal

0-10 VDC Modulating

Hot Water Valve Supplied & Installed by Others

24 VAC Fan Relay Supplied and Installed by Others. 2 Amp Max. Load For Fan Relay.

Supply Power

Of Required Voltage

To Valve Motor

(By Others)

24 VDC Power Only

(12 Watts Max.)

Is Available From TB3

Terminals (+V & GND)

Typical Wiring For Single Duct Terminal With Modulating Hot Water Heat

24 VAC Transformer Supplied & Wired by Others. Size For Required Fan Relay Load.

Supply Power

Of Required Voltage

To Valve Motor

(By Others)

24 VDC Power Only

HWV

(12 Watts Max.)

Is Available From TB3

Terminals (+V & GND)

Typical Wiring For Fan Terminal Unit With Modulating Hot Water Heat

Notes:

1.) All Wiring to be in Accordance With Local & National Electrical Codes & Specifications.

FILENAME

VAV-OE322-3RELAY1OUTBD.CDR

09/26/06

DATE:

PAGE

2of3

OE322-3Relay -1 Analog Output Board

Component Wiring Diagram

Component & System Wiring38

JOB NAME

DRAWN BY:

DESCRIPTION:

B. Crews

3 Relay Output Expansion Board Wiring (Cont’d)

24VAC

WattMaster Part #OE322 Relay Expansion Board w/ Modular Cable

R3

R6

Supplied by WattMaster Mounted & Wired by Others

Connect To VAVBOX Controller Using Modular Cable Supplied By WattMaster

PJ1

WattMaster Part # BK000047 Snaptrack Supplied by WattMaster Mounted by Others. Remove Control Board from Snaptrack & Mount Snaptrack on Box

WattMaster Part #OE322 Relay Expansion Board w/ Modular Cable

R3

R6

Supplied by WattMaster Mounted & Wired by Others

Connect To VAVBOX Controller Using Modular Cable Supplied By WattMaster

PJ1

WattMaster Part # BK000047 Snaptrack Supplied by WattMaster Mounted by Others. Remove Control Board from Snaptrack & Mount Snaptrack on Box

2RAOUT BD.

K1

D4

Q3

RLY

1

R10

D3

RLY

Q2

2

R9R5R2

D2

Q1

RLY

3

R8R4R1

U1

C1

R7

C3

C6

D1

C2

C4

D4

Q3

RLY

1

R10

D3

Q2

RLY

2

R9R5R2

D2

Q1

RLY

3

R8R4R1

U1

C1

R7

C3

C6

D1

C2

C4

YS101714

REV.3

V4

TB2

COM

1

2

V3

K2

3

TB3

V2

+V

K3

GND

ANALOG

V1

OUTV5

R14

R13

M

2RAOUT BD.

YS101714

REV.3

V4

COM

1

2

V3

K2

3

V2

+V

K3

GND

V1

R14

R13

M

+

TB1 GND

SERIAL #

TB2

TB3

ANALOG

OUTV5

+

TB1 GND

24 VAC Fan Relay and HW Valve Supplied and Installed by Others. 2 Amp Max. Load Each For HW Valve and Fan Relay.

SERIAL #

C5

LM358

Q4

R11

R12

VR2

I

7824CT

O

VR1

K1

C5

LM358

Q4

R11

R12

VR2

I

7824CT

O

VR1

COM

24 VAC HW Valve Supplied and Installed by Others. 2 Amp Max. Load.

24VAC

COM

Fan Relay

24 VAC - Transformer Supplied and Installed by Others. Size For Required HW Valve Load.

HWV

Typical Wiring for Single Duct Terminal With 2 Position HW Valve

24 VAC - Transformer Supplied and Installed by Others. Size For Required Fan Relay and HW Valve Load.

R1

HWV

Typical Wiring for Fan Terminal With 2 Position HW Valve

JOB NAME

FILENAME

VAV-OE322-3RELAY1OUTBD.CDR

Notes:

1.) All Wiring to be in Accordance With Local & National Electrical Codes & Specifications.

DATE:

PAGE

3of3

09/26/06

OE322-3Relay -1 Analog Output Board

Component Wiring Diagram

DRAWN BY:

DESCRIPTION:

B. Crews

Component & System Wiring 39

Component & System Wiring40

Communication Devices

Diagrams

Component & System Wiring 41

P1

P2

VAR1

U13

RS-485P COMM

R14

U6

V62C518256L-70P

CX11

CX12

U12

U11

CX7

PAL

EPROM

RAM

CX13

75176

U8

74HC573

CX8

RN1

SC1

YS101830PREV. 2PMODULARPSYSTEM

MANAGER

PCB80C552-5-16WPP442860=2/5 PDfD9722V7Y

C2

U7

X1

C1

R1

R4

EWDOG

PHILIPS

X2

C3

PHILIPS

U3

CX5

R3

R9

8583

CX6

D3

U4

24C128

CX4

74HC259

U1

U2

CX2

R3

R2

U14

C8

CX9

C7

470uF50v

1000uF10v

470uF50v

1000uF10v

R12

R11

COMMOUT

COMMIN

D6

C4

R13

MC34064A

U9

9936

D5

L1

U10

74HC540

CX14

C6

P3

CX10

C5

74HC923

R10

D4

CX3

82B715

PJ1

D2

R6

R5

D1

U3

DSPY1

R7

RV1

System Manager Modular Cable Pigtail - Wiring Schematic

YS101830PREV. 2PMODULARPSYSTEM

PHILIPS

PCB80C552-5-16WPP442860=2/5 PDfD9722V7Y

COMMOUT

COMMIN

470uF50v

Modular System Manager Back of Front Cover

Use Supplied Modular

Cable With Stripped Ends

For Connection To Terminal

Block And Transformer

WHITE (T) DRAIN WIRE (SHLD)

BLACK (R)

RED (24 VAC) BROWN (GND)

GREEN (GND)

Class 2 Transformer

Rated For 6 VA Minimum

System Manager Wiring Schematic For Using The Pigtail

See Page 2 of this Diagram for Additional Pigtail Wiring Details

Notes:

1.) All wiring to be in accordance with local and national electrical codes and specifications.

Controller Board

FILENAME

VAV-SYSTEMMGRWIRE1A.CDR

05/12/04

DATE:

PAGE

1of2

OE392 Modular System Manager

Component Wiring Diagram

T

SHLD

R

JOB NAME

DRAWN BY:

DESCRIPTION:

B. Crews B. Light

Component & System Wiring42

P1

P2

VAR1

U13

RS-485P COMM

R14

U6

V62C518256L-70P

CX11

CX12

U12

U11

CX7

PAL

EPROM

RAM

CX13

75176

U8

74HC573

CX8

RN1

SC1

YS101830PREV.

2PMODULARPSYSTEM

MANAGER

PCB80C552-5-16WPP442860=2/5 PDfD9722V7Y

C2

U7

X1

C1

R1

R4

EWDOG

PHILIPS

X2

C3

PHILIPS

U3

CX5

R3

R9

8583

CX6

D3

U4

24C128

CX4

74HC259

U1

U2

CX2

R3

R2

U14

C8

CX9

C7

470uF50v

1000uF10v

470uF50v

1000uF10v

R12

R11

COMMOUT

COMMIN

D6

C4

R13

MC34064A

U9

9936

D5

L1

U10

74HC540

CX14

C6

P3

CX10

C5

74HC923

R10

D4

CX3

82B715

PJ1

D2

R6

R5

D1

U3

DSPY1

R7

RV1

System Manager Modular Cable Pigtail - Wiring Detail

YS101830PREV.

MANAGER

PHILIPS

Handy Box , Conduit,

Fittings, Wire Nuts,

Butt Splices Etc.,

( By Others)

PCB80C552-5-16WPP442860=2/5 PDfD9722V7Y

CX11

24C128

COMMOUT

COMMIN

MC34064A

1000uF10v

470uF50v

1000uF10v

470uF50v

Modular System Manager Back of Front Cover

HZ000121 Modular Pigtail Cable Supplied With System Manager

RED (24 VAC)

WHITE (T)

BLACK (R)

LINE VOLTAGE

BRO

(G

N

W

GREEN (GND)

ND)

Class 2 Transformer

Rated For 6 VA Minimum

(By Others)

LINE VOLTAGE

System Manager Wiring Details For Using The Pigtail

See Page 1 of this Diagram for Pigtail Wiring Schematic

Notes:

1.) All wiring to be in accordance with local and national electrical codes and specifications.

Drain Wire (Shld)

VAV-SYSTEMMGRWIRE1A.CDR

PAGE

2of2

2-Conductor Shielded

18-Guage

Communications Wire

Controller Board

JOB NAME

FILENAME

DATE:

05/12/04

OE392 Modular System Manager

Component Wiring Diagram

DRAWN BY:

DESCRIPTION:

T SHLD

R

B. Crews B. Light

Component & System Wiring 43

Modular Service Tool Connections

Optional Connection For Controllers Without DIN Connector

Male DIN Connector

Connector Cable

PL101904 Adapter Board

erminal

T Block Base

(Remove Terminal Block)

COMM

T SHLD R

Female DIN Connector

Typical Controller Board

The Modular Service Tool Can Be Connected To Most Controllers By Plugging One End Of The Supplied Cable Into the Modular Service Tool DIN Connector And The Other End Into The DIN Connector On The Controllers.

Some Controllers Without DIN Connectors Require Use Of The Supplied PL101904 Adapter Board Shown Above. To Connect With Adapter Board, First Unplug COMM Terminal Block From Controller Board. Plug PL101904 Adapter Board Terminal End Into Terminal Block Base On Controller. Plug DIN Connector Cable Into DIN Connector On PL101904 Adapter Board . See Optional Connection For Controllers Without DIN Connector Above For Illustration Of This Connection.

Mode

Selection

STATUS

SETPOINTS

SCHEDULES

OVERRIDES

ALARMS

CONFIGURATION

BALANCE - TEST

ON

UP

ESC

ENTER

13

4

708

DEC

2

5

6

9

MINUS

-

Power On Button

Modular Service Tool

Be Sure The Modular Service Tool Is Connected To The Supplied Power Pack Or Has Fresh Batteries Installed Before Attempting Programming Of The Controller. Be Sure The Power Is Turned Off On The Modular Service Tool Before Connecting The Cable To The Controller.

G-ModServiceTool1A.CDR

DATE:

PAGE

1of1

FILENAME

02/11/04

JOB NAME

DRAWN BY:

DESCRIPTION:

B. Crews

OE391 Modular Service Tool

Connection Diagram

Component & System Wiring44

(DTE)

REMOTE LINK

485 LOOP

COMPUTER

(DCE)

GT

R

G

2

V

4

D

N

POWER

CommLink II Wiring & Cabling Connections

Part #OE361-04

Molded Modem Cable.

Part #HZ000098

Supplied With CommLink

Commlink II Communications Interface

(Jumper Set For Multiple Loop)

485 LOOP

REMOTE LINK

Female

9Pin

Female

9Pin

RS-485

19200 Baud

Connect Supplied RJ12 Modular Phone Cable To Supplied 9 Pin Or 25 Pin Connector As Reqd By Your Computer Com Port Connection

CommLink Is Supplied With 110/24VAC Power Supply.

If Desired A Transformer (By Others)

May Be Wired To The CommLink Instead

Required VA For Transformer

CommLink = 14VA Max.

24VAC

See Note 1

120/24 Vac

Transformer

Part # PX000015

Connect To First Device On Loop. See System Application Documentation For

Your Specific Systems Controller Connection & Wiring Information

All Communication Loop

Wiring Is Straight Through

T

4 Piece Computer Cable Kit. Part # HZ000112 Supplied With CommLink

Caution:

Disconnect All Communication Loop Wiring From The CommLink Before Removing Power From The CommLink. Reconnect Power And Then Reconnect Communication Loop Wiring.

T

SH

R

Line Voltage

T

SH

R

T

SH

R

25 Pin

Male

Connect To Remote Link .

Remote Link Is Part # OE419-04

Caution: Use The “Molded Cable” To

Do Not Connect To The Computer (DCE) Connector. This Cable Is Only To Be Used To Connect From The CommLink (DTE) Connection To The Remote Link (When Used).

Only

Notes:

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

3.)All Communication Wiring To Be 2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

9Pin

Female

Use 25 Pin Or 9 Pin Connector As Required By Available Serial (COM) Port On Computer.

Caution: Use The “25 Pin Or 9 Pin Cable” To

Do Not Connect To The Remote Link (DTE) Connector. This Cable Is Only To Be Used To Connect From The CommLink (DCE) Connection To The Computer (When Used)

Serial Port (COM) Connection.

25 Pin

Female

4.)CommLink Is Usually Shipped With The Jumper In The Multiple Loop Configuration. Check The Application Documentation For Your Specific System For Correct Jumper Position Setting.

PIN 1

Note: Place Jumper Between Pins1&2forMultiple Loop Applications & Between Pins2&3for Single Loop Applications See Note 4.

CommLink Jumper Switch Settings

FILENAME

G-CommLinkWire.CDR

02/11/04

DATE:

PAGE

1

CommLink II Wiring

COMM DRIVER CHIP

(U1)

JOB NAME

DRAWN BY:

DESCRIPTION:

OE361-04

EPROM CHIP

B. CREWS

1 2 3

MULTI

SINGLE

Component & System Wiring 45

Notes:

1.) All Wiring To Be In Accordance With Local And National Electrical Codes

And Specifications.

2.) All Communication Wiring To Be 2 Conductor Twisted Pair With Shield.

Use Belden #82760 Or Equivalent.

Component Wiring Diagram

03/24/04

VAV-MiniLinkPolDevWr1A.CDR

MiniLink Polling Device

1of1

MiniLink Polling Device

CommLink

Terminals

Only First MiniLink PD

To Be Connected To

CommLink, Otherwise

Connect MiniLink PD To

Network Terminals Of

Previous Or Next

MiniLink PD On Loop

24 VAC

Class 2

Transformer

Rated For

6 VA Load

Minimum

Not Used

To WMVAV

Controller

Terminals

MiniLink PD

Network

Terminals

Connect

MiniLink PD To

Network

Terminals Of

Previous Or

Next MiniLink

PD On Loop.

EPROM

U3

U5

RAM

CX2

1

U2

R1

C3

U4

CX3

CX4

YS101818P552

PROCESSORPBOARD

CX5

C1

U1

R2

CX1

CX6

WDOG

U6

PHILIPS

D1

P1

X1

C2

C4

0-10V

4-20mA

THERM

R27

R31

D4

GND

24VAC

TB1

D5

C11

U12

LED 2

POWER

V1

R25

R26

C7

CX15

CX13

PROC.

DRIVER

LOOP

DRIVER

LOCAL LOOP

GND

AIN 2

AIN 1

+5V

TB2

P4

OFF=0-5V

AIN2

AIN1

0-10V

4-20mA

THERM

TB3

U15

LD5

LD6

U13

C8

LED 1

RV1

R4

VREF

CX2

U11

YS101900PMINILINK

POLLING

DEVICE

REV.1

OFF

1

2

4

8

16

32

CX14

NETWORK

DRIVER

RN3

SHLD

T

G

T

TB4

R

485 LOOP

R

U14

NETWORK

LOOP

P5

ADD

P3

R24

LD4

C9

U10

RN2

SW1

R30X2R29

R28

C10

U6

CX6

CX1

U7

U1

X1

C3

C1

R3

CX7

Line Voltage

16

32

8

4

2

1

Address Switch Shown Is

Set For Address 1

Address Switch Shown Is

Set For Address 13

Controller

Address Switch

This Switch Should Be

In The OFF Position

As Shown

Note:

The Power To The MiniLink PD Must Be Removed And

Reconnected After Changing The Address Switch

Settings In Order For Any Changes To Take Effect.

Caution

Disconnect All Communication Loop Wiring From The

MiniLink PD Before Removing Power From The MiniLink

PD. Reconnect Power And Then Reconnect

Communication Loop Wiring.

ADD

The Address For Each MiniLink PD

Must Be Unique To The Other MiniLink PDs

On The Local Loop And Be Between 1 and 60

FILENAME

DATE:

B. Crews

DESCRIPTION:

PAGE

DRAWN BY:

JOB NAME

Communication

Wiring To Be Wired

T to T, SHLD (G) to

SHLD (G) & R to R

3.) All Communication Wiring To Be

2 Conductor Twisted Pair With

Shield. Use Belden #82760 Or

Equivalent.

MiniLink Polling Device Wiring Using Wire Terminals

Component & System Wiring46

RS-232 Serial Port To USB Port Converter

Features & Specifications

Converts a USB port into a 9-pin male RS-232 serial port capable of speeds up to 115 Kbps. The USB Serial Adapter is designed to make serial port expansion

Cable Length = 12 inches

quick and simple. Installs as a standard Windows COM port, Full RS-232 modem control signals, RS-232 data signals; TxD, RxD, RTS, CTS, DSR, DTR, DCD, RI, GND Self Powered by USB port Supports Windows 98/SE, ME & 2000 and XP

Packages Includes::

USB-232 Converter cable with short 12inch USB Type A end Installation Instructions USB Driver CD for win98/ME/2K/XP

SERIAL #

REMOTE LINK

(DTE)

Top View

End View

CommLink

COMPUTER

TGR

(DCE)

Female

9 Pin

9Pin

Female

GND

24V

485 LOOP

POWER

Connect 9 Pin Serial Cable Supplied With CommLink To Port Labeled “Computer (DCE) On CommLink As Shown

9 Pin Serial Cable Assembly Supplied With CommLink

Connect 9 Pin Serial Cable Supplied With CommLink To USB Serial Adapter As Shown

Installing the USB adapter

Follow the instructions provided inside the USB Serial Adapter package for installation and driver setup of the USB Serial Adapter. A CD-ROM is included that contains the correct drivers.

Changing the COM ports:

To change the COM port to a different COM port is accomplished by changing the COM port I/O range in the Windows Device Manager.

Right-click on "My Computer" Click the "Device Manager" tab. Click the "+" by "Ports" Select "USB to Serial Port (COM5)" Click the "Properties" button Click the "Resources" Tab. Uncheck the box that says "Use automatic settings". Select the "Input/Output range" Click the "Change Settings " button. Click the little arrows until you find an appropriate setting. "02E8-02EF" should give you a COM4 setting after you restart the computer. Make sure to click "OK" on all screens. Use the following settings to get the following COM ports: COM1 - 3F8h-03FFh COM2 - 2F8h-02FFh COM3 - 3E8h-03EFh COM4 - 2E8h-02EFh

JOB NAME

Connect To

USB Serial Adapter

Connection Detail

USB Port On Computer

FILENAME

USB-RS232Cnvrt1A.CDR

08/20/03

DATE:

PAGE

1

RS-232 to USB Converter

CONTROLS

DRAWN BY:

DESCRIPTION:

OE299

B. CREWS

Component & System Wiring 47

Component & System Wiring48

Add-On Devices Diagrams

Component & System Wiring 49

EPROM

RAM

PAL

PIN 1

CPU

Lighting Panel Wiring For Standard Lighting Contactors

Required VA For Transformer

Caution: If Lighting Contactor Coil Current Draw Is More Than 2 Amps And/Or Does Not Use A 24VAC Coil, A Pilot Duty Relay That Has A Current Draw Of Less Than 2 Amps @ 24VAC Must Be Used To Energize The Lighting Contactor. A Separate Transformer Rated For The Total Lighting Contactor(s)Or Pilot Relay Current Draw Must Always Be Used To Power The Circuit.

GND

Line Voltage

24V

Lighting Contactors Or Pilot Duty Relays (By Others)

Light Circuit 1

Light Circuit 2

Light Circuit 3

Light Circuit 4

Light Circuit 5

Light Circuit 6

Light Circuit 7

C1

C2

C3

C4

C5

C6

C7

Note:

All Circuit Board Contacts Are N.O.

!

All Contacts Are Rated For 2 Amps @

!

24VAC Pilot Duty Only Do Not Apply Any Voltage Greater Than

!

24VAC

All Lighting Contactors Must Be Wired For N.C. Operation So That System Fails To Lights On Mode.

This Switch Must Be In The ON Position As Shown

The Address For Each Controller

Must Be Unique To The Other Controllers

On The Local Loop

Each Controller = 10 VA Min.

See Note 1

Line Voltage

24VAC

GND

K1

K2

K3

K4

K5

K6

K7

Lighting Panel Controller

These Switches Should Be In The OFF Position As Shown

ADD

Light Sensor (Optional)

GND

+5V

SIG

Momentary Pushbuttons

T

SH

R

PIN 1

ANALOG

INPUTS

+V +V

1 2 3 4 5 6 7 8 G G

ANALOG

OUTPUTS

A1 A2

G

T

SH

R

Note: Set-up, Programming And Monitoring Of The Lighting Panel Controller Requires The Use Of A Personal Computer And Prism Software.

(Optional)

Override Circuit #1

Override Circuit #2

Override Circuit #3

Override Circuit #4

Override Circuit #5

Override Circuit #6

Override Circuit #7

Local Loop RS-485

Communications To Other

Controllers On The Local

Loop

ADD

Address Switch Shown Is

Set For Address 1

Caution!

Controller Must Have Address Switch Set Between 1 And 60

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

16

4

8

1

2

Controller Address Switch

Address Switch Shown Is

Set For Address 13

3.)All Communication Wiring To Be 18 Ga. Minimum, 2 Conductor Twisted Pair With Shield. Belden #82760 Or Equivalent.

4.)It Is Recommended That All Controllers Address Switches Are Set Before Installation.

ADD

W-LightingPnlStd1.CDR

DATE:

PAGE

1

JOB NAME

FILENAME

CONTROLS

05/12/04

DRAWN BY:

DESCRIPTION:

OE310 Lighting Panel Controller Wiring

Using Standard Lighting Relays

Component & System Wiring50

B. Crews

EPROM

RAM

PAL

PIN 1

CPU

Lighting Panel Wiring For GE® Latching Relay Lighting Contactors

Required VA For Transformer Each Controller = 10 VA Min..

Line Voltage

See Note 1

Light Circuit 1

Light Circuit 2

Light Circuit 3

Light Circuit 4

Light Circuit 5

Light Circuit 6

Light Circuit 7

Caution: If Lighting Contactor Coil Current Draw Is More Than 2 Amps And/Or Does Not Use A 24VAC Coil, A Pilot Duty Relay That Has A Current Draw Of Less Than 2 Amps @ 24VAC Must Be Used To Energize The Lighting Contactor. A Separate Transformer Rated For The Total Lighting Contactor(s) Or Pilot Relay Current Draw Must Always Be Used To Power The Circuit.

GND

+5V

SIG

24VAC

GND

K1

ANALOG

INPUTS

ANALOG

OUTPUTS

K2

K3

K4

K6

K7

K5

PIN 1

+V +V

1

2 3 4 5 6 7 8 G G

A1 A2

G

T

SH

R

Light Sensor

(Optional)

Momentary Pushbuttons

T

SH

R

Typical Wiring Shown For Circuit #1 All Other Circuits Are To Be Wired Identically. Up to 7 Lighting Circuits May Be Wired To Each Lighting Panel Controller.

Note:

All Circuit Board

!

Contacts Are N.O. All Contacts Are

!

Rated For 2 Amps

(Optional)

Override Circuit #1

Override Circuit #2

Override Circuit #3

Override Circuit #4

Override Circuit #5

Override Circuit #6

Override Circuit #7

@ 24VAC Pilot Duty Only Do Not Apply Any

!

Voltage Greater Than 24VAC

Note: Set-up, Programming And Monitoring Of The Lighting Panel Controller Requires The Use Of A Personal Computer And PrismSoftware.

All switches (1 thru 4) must be in the “ON” position

OFF

24VAC

ON

GE Lighting Relay- Circuit #1

(By Others)

This Switch Must Be In The ON Position As Shown

The Address For Each Controller

Must Be Unique To The Other Controllers

On The Local Loop

Address Switch Shown Is

Set For Address 1

Caution!

Controller Must Have Address Switch Set Between 1 And 60

Lighting Panel Controller

These Switches Should Be In The OFF Position As Shown

16

4

8

ADD

Controller Address Switch

2

Local Loop RS-485

Communications To Other

Controllers On The Local

Loop

ADD

1

Address Switch Shown Is

Set For Address 13

ADD

R1

R2

R3

R4

R5

R6

Light Circuit 5

Light Circuit 6

R7

R8

24V

Ribbon Connector

Relay Expansion Board

JOB NAME

Light Circuit 1

Light Circuit 2

Light Circuit 3

Light Circuit 4

Light Circuit 7

Ground

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

3.)All Communication Wiring To Be 18 Ga. Minimum, 2 Conductor Twisted Pair With Shield. Belden #82760 Or Equivalent.

4.)It Is Recommended That All Controllers Address Switches Are Set Before Installation.

FILENAME

W-LightingPnl-GE1.CDR

DATE:

05/12/04

PAGE

1

OE310 Lighting Panel Controller Wiring

CONTROLS

DRAWN BY:

B. Crews

DESCRIPTION:

Using GE Latching Relays

Component & System Wiring 51

EPROM

RAM

PAL

PIN 1

CPU

Optimal Start Scheduler Wiring

Required VA For Transformer

Caution: If Equipment Contactor Coil Current Draw Is More Than 2 Amps And/Or Does Not Use A 24VAC Coil, A Pilot Duty Relay That Has A Current Draw Of Less Than 2 Amps @ 24VAC Must Be Used To Energize The Equipment Contactor. A Separate Transformer Rated For The Total Pilot Relay Current Draw Must Always Be Used To Power The Circuit.

Direct Control Of Equipment

(Optional)

GND

24V

Equipment Contactors Or Pilot Duty Relays (By Others)

Equipment Circuit 1

Equipment Circuit 2

Equipment Circuit 3

Equipment Circuit 4

Equipment Circuit 5

Equipment Circuit 6

Equipment Circuit 7

Line Voltage

C1

C2

C3

C4

C5

C6

C7

Note:

All Circuit Board Contacts Are N.O.

!

All Contacts Are Rated For 2 Amps @

!

24VAC Pilot Duty Only Do Not Apply Any Voltage Greater Than

!

24VAC

Each Controller = 10 VA Min.

See Note 1

24VAC

GND

K1

K2

K3

K4

K5

K6

K7

Optimal Start Scheduler

Line Voltage

GND

+5V

SIG

Momentary Pushbuttons

T

SH

R

(Optional)

Override Circuit Schedule #1

Override Circuit Schedule #2

Override Circuit Schedule #3

Override Circuit Schedule #4

Override Circuit Schedule #5

Override Circuit Schedule #6

Override Circuit Schedule #7

Local Loop RS-485

Communications To Other

Controllers On The Local

Loop

PIN 1

ANALOG

INPUTS

+V +V

1 2 3 4 5 6 7 8 G G

ANALOG

OUTPUTS

A1 A2

G

T

SH

R

Note: Set-up, Programming And Monitoring Of The Optimal Start Scheduler Requires The Use Of A Personal Computer And Prism Software.

This Switch Must Be In The ON Position As Shown

The Address For Each Controller

Must Be Unique To The Other Controllers

On The Local Loop

ADD

Address Switch Shown Is

Set For Address 1

Caution!

Controller Must Have Address Switches Set Between 1 And 60

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

These Switches Should Be In The OFF Position As Shown

ADD

16

4

8

1

2

Controller Address Switch

Address Switch Shown Is

Set For Address 13

3.)All Communication Wiring To Be 18 Ga. Minimum, 2 Conductor Twisted Pair With Shield. Belden #82760 Or Equivalent.

4.)It Is Recommended That All Controllers Address Switches Are Set Before Installation.

ADD

WM-OptStartSched1.CDR

DATE:

PAGE

1

JOB NAME

FILENAME

CONTROLS

05/12/04

DRAWN BY:

DESCRIPTION:

OE310 Optimal Start Scheduler

Component Wiring

B. Crews

Component & System Wiring52

GPC Wiring

T

Local Loop 9600 Baud

Analog Input(s) And/Or Digital Input(s) From Devices As Required By Application

Analog Output To Device (WhenUsed) (0-10 VDC)

Note: Set-up, Programming And Monitoring Of The General Purpose Controller Requires The Use Of A Personal Computer And Prism Software.

SHLD

R

COMM

LD4

REC.

PRESSURE

SENSOR

T

SHLD

R

12V

AIN

1

AIN

2

AIN

3

AIN

4

AIN

5

GND

AOUT

YS101564

GPC Controller

RAM EPROM

485

COMM

PU1

ADDRESS ADD

PU2

PU3

EWDOG

PU4

PU5

This Switch Must Be In The ON Position As Shown

32K

8K

RELAY OUTPUT

COM 1-3

OUT

COMM

OUT

COM 4-5

4-5

1

2

3

4

5

Relay Output(s) To Device(s) As Required By Application

TEST

0-5

VDC

0-1

VDC

PWR

GND

24VAC

GND

24VAC

LINE

VOLTAGE

See Note 1

Required VA For

Transformer=8VAMin.

ADDRESS ADD

1 2 4 8

16

These Switches Should Be In The OFF Position As Shown

Caution!

GPC Controllers Must Have Address Switches Set Between 1 And 60.

Note:

The Power To The GPC Controller Must Be Removed And Reconnected After Changing The Address Switch Settings In Order For Any Changes To Take Effect.

Caution:

Disconnect All Communication Loop Wiring From The GPC Controller Before Removing Power From The GPC Controller. Reconnect Power And Then Reconnect Communication Loop Wiring.

Notes:

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

ADDRESS ADD

Address Switch Shown Is

Set For Address 9

Caution!

GPC Controller Must Have Address Switch Set Between 1 And 60

GPC Controller Address Switch Setting

3.)All Communication Wiring To Be 18 Ga. Minimum, 2 Conductor Twisted Pair With Shield. Belden #82760 Or Equivalent.

4.)It Is Recommended That All Controllers Address Switches Are Set Before Installation.

Controller Address Switch

W-GPC-Control1.CDR

DATE:

05/12/04

PAGE

1

ADDRESS ADD

Address Switch Shown Is

Set For Address 28

JOB NAME

CONTROLS

DRAWN BY:

DESCRIPTION:

OE330 GPC

Controller Wiring

B. Crews

Component & System Wiring 53

EPROM

RAM

PAL

PIN 1

CPU

GPC-17 Wiring

Required VA For Transformer

Each Controller = 10 VA Min.

Line Voltage

See Note 1

Line Voltage

Relay Outputs To DevicesAs Required By Application

This Switch Must Be In The ON Position As Shown

The Address For Each Controller

Must Be Unique To The Other Controllers

On The Local Loop

Address Switch Shown Is

Set For Address 1

Caution!

Controller Must Have Address Switch Set Between 1 and 60

24VAC

GND

ADD

K1

K2

K3

K4

K5

K6

K7

GPC-17 Controller

These Switches Should Be In The OFF Position As Shown

16

4

8

Controller Address Switch

ADD

1

2

GND

+5V

SIG

ANALOG

INPUTS

+V +V

1 2 3 4 5 6 7 8 G G

ANALOG

OUTPUTS

A1 A2

G

PIN 1

Local Loop RS-485

Communications To Other

Controllers

And/Or System Manager

T

SH

R

Optional Relay Expansion Board

ADD

Address Switch Shown Is

Set For Address 13

Analog Inputs And/Or Digital Inputs From Devices As Required By Application

Analog Output To Device (0-10 VDC)

Note:

!

Note: Set-up, Programming And Monitoring Of The GPC-17 Controller Requires The Use Of A Personal Computer And Prism Software.

All switches (1 thru 4) must be in the “ON” position

Ribbon Connector

R1

R2

R3

R4

R5

R6

R7

R8

Ribbon Connector

LD1

24V

PWR

COM

ANALOG OUT1

+

-

ANALOG OUT2

+

-

ANALOG OUT3

+

-

ANALOG OUT4

+

-

RN1

All Circuit Board Contacts Are N.O. All Contacts Are Rated For 2 Amps @ 24VAC Pilot Duty Only Do Not Apply Any Voltage Greater Than 24VAC

Relay Outputs to Devices As Required By Application

Ground

24V

2

1

ADDR

Optional Analog

ANALOGOUTPUT BOARD

Output

YS101428REV.1

WATTMASTER

Board

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes and Specifications.

3.)All Communication Wiring To Be 18 Ga. Minimum, 2 Conductor Twisted Pair With Shield. Belden #82760 Or Equivalent.

4.)It Is Recommended That All Controllers Address Switches Are Set Before Installation.

FILENAME

W-GPC-17CNTRL1A.CDR

DATE:

05/12/04

PAGE

1

GPC-17 Controller

Component & System Wiring54

JOB NAME

CONTROLS

DRAWN BY:

DESCRIPTION:

OE310-21-GPC

B. Crews

Miscellaneous Diagrams

& Technical Information

Component & System Wiring 55

Over Voltage Board Wiring

OE-268 Over Voltage Board

NOTE: This board goes between the supply transformers

low voltage output and the controllers low voltage input. WattMaster Controllers do not like to see more than 28 VAC on their input side. When the line voltage to the transformer is too high, generally the output side of the transformer (low voltage) is too high, thus requiring this Over Voltage Board.

+

R3

AC_IN GND

TB1

INPUT

24-32VAC

D1

TRANSFORMER

R2

C3

HV POWER BD.

YS101750

REV 1.0

C2

+

U1

+V GND

D2

R1

TB2

POWER

OUTPUT

Note:

This output is DC voltage. Our controllers will accept DC voltage if the voltage is above 28 VDC.

Warning

This board is designed to power one controller with expansion boards only.

To the 24 VAC input side of WattMaster Controller

LINE VOLTAGE

FILENAME

VAV-OE268-OVBoard.cdr

DATE:

03/24/04

PAGE

1

OE-268 Over Voltage Board

Component & System Wiring56

JOB NAME

CONTROLS

DRAWN BY:

DESCRIPTION:

Barry Light

Chip Locations

Comm Driver Chip

(U5) Pin 1

COMM

INPUTS

TB3

C21

TB1

T

SHLD

R

CX5

LD6

COMM

LD7 PWR

LD8

LED1

LD9

LED2

R1

U7

RV1 VREFADJ

+VDC

AIN1

AIN2 AIN3

AIN4

AIN5

GND GND AOUT1

AOUT2

AIN7 GND

PJ1

PRESSURE SENSOR

RAM Chip (U2) Pin 1

CX1

RN1

1

U5

RS-485

COMM

1

RN3

P1

+VREF

5.11V

TESTPOINT

EWDOG

RN5

C10

C12

C17

R26

EXPANSION

U3

CX2

U2

U1

EPROM

RAM

HH

C1

R28

ADDRESS

PU1 D6 PU2

D7 PU3

D8 PU4

D9 PU5

D11 PU7

D14

U13

D15

C20

PJ2

TUC-5RPLUS

YS101816REV. 2

U6

PHILIPS

ADD

1 2 4 8 16

32 TOKEN

NETWORK

U10

SW1

C11

X2

0-5

0-1

VDC

JP1

R15

C14

R19

U14

CX13

U15

C15

R22

R24

R25

CX15

PJ3

MG331-21-VAV

WMVAV Controller

EPROM Chip

(U3) Pin 1

CX3

U4

(1MEG)

CX6

C2

X1

C3

1

RN4

U9

CX10

CX12

U12

CX14

D18

D17

C18

VR1

T'STAT

PAL Chip

(U4) Pin 1

D1

CX4

RLY1

D2

RLY2

D3

PAL

1

RLY3

D4

RN2

RLY4

D5

RLY5

C7

R7

D10

L1

D13

D12 R13

SC1

D19

C19

7824CT

M

VR2

CX8

R10

D16

COM1-3

COM4-5

NE5090NPB3192 0PS

R6

R11

R27

V6

V1

V2

V3

R1 R2 R3

R4

R5

TB2

V4

V5

U8

C9

9936

U11

MC34064A

C13

C16

TB4

GND

POWER

24VAC

EPROM Chip

(U3) Pin 1

U1

CX1

CX3

U3

32K

RAM

8K

CX4

U4

9936

MS6264L-70PC

R18

R34

74HC573N

CX8

B31920PS

U8

RN1

1

FLOW

PAL Chip

(U1) Pin 1

Q1

74HC259 B31920PS

16L8

CX2

R1

R2

R3

X1

EPROM

80C55

2

C8

RAM

C10

C9

U9

LMC662

R23

P.U.

R22

CX9

VREF

C14

ADJ

C13

R27

D5

R32

D5

Comm Driver Chip

(U10) Pin 1

VAVBOX Controller

EXPANSION

U2

R4

C2C1

R5

R6

R7

PJ1

CX5

C3

R8

DFD9940SM

CX6

500650=1/3 PCB80C552-5-16WP

93C46

PHILIPS

U6

PHILIPS

U5

1

2

4

8

16

32

ADD

R19

ADDRESS

SW1

U10

EWDOG

R20

C11

R24

75176

U11

CX10

C15

R25

COMM

R28

D7

T'STAT

MG320 - VAV

ACTUATOR

PJ2

G5L-114P-PS

24VDC

CONTACT:

V1

C4

R9

R10

R11

R100

R12

C5

R13

R14

C6

LD1

NET

TOKEN

REC

LD2

SCAN

L1

R21

POWER

LD3

D4

R26

YS101562

REV.2

V2

G5L-114P-PS

24VDC

CONTACT:

UL/ CSA 5A250VAC

K2

K1

D2

D1

Q3Q2

R15

D3

MC340

U7

9936

C7

R16

R17

7824

VR1

M

T

7824C

GND

24VAC

PAL Chip

(U7) Pin 1

EPROM Chip

(U11) Pin 1

RAM Chip

(U12) Pin 1

Comm Driver Chip

(U13) Pin 1

Warning!

Use Extreme Caution When Removing Any Chips To Avoid Damaging Any Circuit Board Traces Which Are Under The Chip.

Be Sure That Any Small Screwdriver Or Other Sharp Object Used To Remove The Chip Does Not Come Into Contact With The Printed Circuit Board Surface.

A Small Screwdriver May Be Inserted Between The Chip And The Socket To Aid In Removal Of The Chip.

Be Very Careful Not To Insert The Screwdriver Under The Socket!! Damage To The Board Is Not Covered By Warranty.

C1

C2

U7

PAL

CX7

CX11

YS101830PREV.2 MODULAR SYSTEMMANAGER

R1 R4

X1

U11

CX12

U12

U1

U3

U8

CX2

R3

R2

U2

EWDOG

R3

CX5

C3

X2

RN1

CX8

EPROM

RAM

CX3

CX4

CX6

U6

SC1

CX13

U3

U4

R9

D3

P1

P2

VAR1

U13

RS-485P

COMM

R14

MG392

System Manager

DSPY1

D1 R5 R6 D2

PJ1

COMMOUT

COMMIN

D5

R11 R12

U9

D6

C7

R10

D4

L1

CX10

C4

C5

R13

CX9

C6

C8

CX14

RV1

Comm Driver Chip

R7

U10

P3

U14

(U1) Pin 1

TB1

24VAC

GND

VAR1

C2

CR2

C5

R7

U6

CX7

R12

R11

U7

C10

Y2

R1

CR1

J1

L1

R9

R13

JO3

WDOG

C11

C12

SERIALNUMBER

COMM

TB2

R

T

C1

SHLD

J01

R2

TERM

RS-485

GND

U1

R4

R3

R5

CX5

CX8

U8

RN1

R14

D1

LOOP

P1

COMPUTER DCE PORT

CX1

CX9

U9

R15

D2

COMP

MODEM

EPROM Chip

P

YS101693 REV 3

MADE IN U.S.A.

C3

CX2

U2

R6

C4

R10

CX10

U10

R16

D3

(U11) Pin 1

P

P2

MODEM

DTE PORT

Y1

C6

C8

C7

C9

CX11

U11

MULTI

SINGLE

JO4

TP1

GND

MODEL

Single/Multi

Loop Jumper

(J04)

OE361-04 Commlink II

JOB NAME

FILENAME

VAV-DRCHPREP.CDR

DATE:

PAGE

1of3

05/12/04

DRAWN BY:

DESCRIPTION:

WattMaster VAV Components

Chip Replacement Information

B. CREWS

Component & System Wiring 57

Chip Locations (Cont’d)

Comm Driver Chip

(U5 ) Pin 1

C22

COMM

T

SHLD

R

TB4

R1

Q1

REC.

Q2

C3

Q3

U6

C4

R11

INPUTS

C5

12V

AIN

1

AIN

2

AIN

3

C6

AIN

4

AIN

5

GND

C7

GND

AOUT

TB3

C8

PRESSURE SENSOR

R21

EPROMChip

(U2) Pin 1

CX1

RN1

U1

CX5

U5

485 COMM

R2 R3

R4

C2 R5 D6 R6

R7

U7

D7

R8 PU1 R6 D8

ADDRESS

D9

PU2 R13 D10 PU3

EWDOG

R15

D11

R22

D12 PU4 R17

D13

R23

D14 PU5 R19

CX11

D15

D16

U11 R26 R27

C11

R28

R20

CX3

CX2U2

U3

80C552

ADD

U9

1 2 4 8 16 32

CX9

NET

SW1

R24

R25

C9

SC1

C10

0-5

D17

VDC

D18

0-1

JP1

VDC

TUC-5R

YS101564

REV.4

SERIAL#

OE330 - GPC Controller

RAM Chip

(U3) Pin 1

RAM

D1

CX4

32K

U4

8K

PAL

D2

CX8

D3

U8

D4

R29

CX7

C12

COMM

R30

TEST

X1

C13

R31

D5

C14

CX10

X2

U10

CLK

C16

D19

R32

R33

R34

C18

D20

R36

1.21K

U12

C20

R37

L1

C21

D21

PAL Chip

(U4) Pin 1

SENSORJACK

PRESSURE

K1

V1

K2

COM 1-3

OUT

1

V2

OUT

K3

2

OUT

3

OUT

4

OUT

5

V3

COM

K4

4-5

TB2

V4

K5

V5

C17

D22

VR2

C19

VR1

R38

PWR

TB1

GND

V6

POWER

24VAC

R39

VR3

R63

V8

24V

GND

TB4

C30

+

R62

U17

REC

V1

OUT1

TB5 TB6 TB7 TB8 TB9

V2

OUT2

V3

OUT3

V4

OUT4

V5

OUT5

V6

OUT6

V7

OUT7

TB11TB10

D33

P3

D34

LEDDISPLAY

K1

K2

K3

K4

K5

K6

K7

VR2

C26

C27

C32

U14

C31

C28

CX14

WDOG

R58

L1

+

SC1

PWR

R61

C29

U16

X2

R60

C24

R59

U15

CX17

P2

R49 R50

OUT1

D26

R51

OUT2

D27

R52

OUT3

D28

R53 R54

OUT4

D29

OUT5

R55

D30

OUT6

D31

R56

OUT7

R57

D32

RAM Chip

(U11) Pin 1

SERIAL#

R42

R41

R44

R46

D25

R45

R40

Q2

C21

Q3

U5

JO5

JO4

C22

R43

EWDOG

BATT

R39

C25

C23

U9

U13

CX13

R48

R64

JO3

8K

U12

D24

D23

D19

D21

D20

D18

D22

SW1

16

B

4

2

A

C

8

R36

R35

R34

R47

+

C34

R38

R37

R65

5.11V

C17

X1

C18

RAM

C20

32K

1

RN2

CX12

D17

ADD

1

R33

PJ1

D1

Q4

C21

U5

D3

CX5C33

D5

R31

Q5

D7

5.11V

T.P.

D9

VR1

R32

ADJ

D11

C16

D13

D15

C19

U10

U11

EPROM

CX10

PAL

C13

C12

C14

C15

EPROMChip

(U10) Pin 1

+5V

SIG

GND

R7

PU

R8

ANALOG

C4

C3

INPUTS

+V

R9

PU

+V

R10

R11

1

PU

R12

C5

C6

2

3

R13

PU

R14

4

R15

5

PU

R16

C8

C7

6

7

R17

PU

R18

8

R19

G

PU

R20

C9

C10

G

TB1

R21

PU

R22

JO1

ANALOG

YS101560

REV.4

THERM8

OUTPUTS

A1

A2

CX1

G

TB2

EXP

BUSS

U1

R23

RN1 R24

R25

R1

U2

CX6

CX2

R29

R27

TERM

R28

R30

C

U3

JO2

CX3

P1

R6

C1

COMM

T

SH

AB

R

R26

TB3

C2

PAL Chip

(U6) Pin 1

Comm Driver Chip

(U3) Pin 1

U6

C11

Q1

U7

OE310 - GPC-17 Controller,

Lighting Controller, OSS Scheduler

PAL Chip

(U6) Pin 1

EPROM Chip

(U10) Pin 1

Comm Driver

Display Must Be Removed To Access Driver Chip

RV1 CONT.

1

U6

PAL

CX8

U8

CX7

U7

CX10

R3

R4

C5

CX11

U11

X2

SC1

U10

R7

D3

R9

Q1

D7

R10

R11

R12

R13

Chip

(U1) Pin 1

U4

SERIAL #

C7

C6

U12

D5

L1

P3

485 DRIVER

RN1

CX4

CX1

U1

CX9

U9

C3

C4

EPROM

SYSM HAND HELD YS101890 REV 2

D9C8D8R8D4

D6

B2

B1

R2

CX14

NETWORK LOOP

TB4

C2

NETWORK DRIVER

T

P2

P1

WDOG

Polling Device

PAL Chip

(U2) Pin 1

C4

EPROM

D1

CX10

U1

U6

CX6

CX11

R24

LD4

U14

R

SHLD

U1

U6

U10

P3

SERIAL#

P5

ADD

Network Loop

Comm Driver Chip

(U14) Pin 1

Polling Device

EPROM Chip

(U3) Pin 1

C2

RV1

VREF

CX2

R4

POWER

C13

LED 1

LED 2

C12

R1

P1

VR2

D1P2R5R6D2

U3

R

D4

R31

V1

GND

24VAC

TB1

CX3

U4

EPROM

RAM

C7

AIN1 AIN2

0-10V

R27

4-20mA

THERM

OFF=0-5V

AIN 1

+24VDC

C11

D5

TB2

Processor

Comm Driver Chip

(U15) Pin 1

CX4

C8

AIN 2

U5

CX2

0-10V 4-20mA THERM

GND

Polling Device

CX5

R1

U2

PROC. DRIVER

CX15

LD6

R35

P4

RAM Chip

(U4) Pin 1

YS101818P552 BOARD

X1

PROCESSOR

C1

C3

CX1

ULLABEL

LOOP

DRIVER

CX13

U13

U15

LD5

LOCALLOOP

T

R

SHLD

TB3

Local Loop

Comm Driver Chip

(U13) Pin 1

RN2

RN3

1

2

4

MiniLink

EPROM Chip

(U6) Pin 1

CX7

U7

CX1

CX6

YS101900 MINILINK

POLLING DEVICE REV.1

U11

C9

X2 R28 R29 R30

16

8

32

SW1

C1

R3

X1

C3

C10

MG364-22 - MiniLink Polling Device

JOB NAME

9V

MG391

Service Tool

FILENAME

VAV-DRCHPREP.CDR

DATE:

05/12/04

PAGE

2of3

WattMaster VAV Components

Chip Replacement Information

Component & System Wiring58

DRAWN BY:

DESCRIPTION:

B. CREWS

Chip Installation Procedures

Small Flathead Screwdriver

Gently Rock Chip Side To Side And Then Lift Straight Up To Remove Chip From Chip Socket.

I.C. Puller

Using I.C. Puller To Remove Socketed Chip

Gently Lift The Chip On One End And Rock Chip Back And Forth With Screwdriver As Shown. Repeat This Process On The Other End Of Chip. Alternate This Process On Both Ends Of Chip Until The Chip Is Free From The Chip Socket.

Direction Of Pull

Using Screwdriver To Remove Socketed Chip

Chip

Chip Socket

Printed Circuit Board

Chip Socket

Printed Circuit Board

Chip

WARNING!

Be sure the chip you have selected to replace is a socketed chip. Not all driver chips on the boards are field replaceable. Only socketed chips may be removed and replaced in the field. All other chips that are not socketed will require sending the board to the WattMaster factory for repair.

remove a chip that is not socketed it will destroy the circuit board.

Once you have determined that the chip needing replacement is indeed a socketed chip please proceed in the following manner.

Remove the communications loop connector and then the 24VAC power connector on the controller before attempting to change any components.

DAMAGE

will occur if components are removed or

installed with power applied.

If you are unsure how to safely remove the chip or about the correct pin placement, please consult the factory before proceeding.

Damage to the board caused by failure to correctly remove or install the chip is not covered by the WattMaster warranty.

Use extreme care to avoid inserting the screwdriver or I.C. Puller under the socket. You must insert the tip of the screwdriver or ends of the I.C. Puller between the body of the chip and the chip socket.

Each chip be installed with Pin 1 in the correct

MUST

location. Installing the chip “backwards” will in most cases destroy the device when power is reapplied.

Pin 1 can be located by looking for the notch in the end of the chip. Pin 1 on "some" chips is identified with a dot.

Be certain that pins are lined up in the socket

ALL

before pressing the chip in. Failure to properly line up the pins will result in damage to the chip. This is a common error -

VERY BE CAREFUL.

Only after confirming that the chip has been correctly installed with Pin 1 in the proper position and that the pins are lined up and none are bent or out of the socket, should communication or power wiring be reconnected to the board. Tp prevent possible damage always reconnect the power wiring first and then the communication wiring.

If you try to

Notch

Dot

Pin1

Top View Of Socketed Chip Assembly

Socket

Dot

Pin 1

Printed

Circuit

Board

Typical RS-485 Communications

Driver Chip Detail

End View Of Socketed Chip Assembly

JOB NAME

FILENAME

VAV-DRCHPREP.CDR

DATE:

PAGE

3of3

05/12/04

WattMaster VAV Components

Chip Replacement Information

DRAWN BY:

DESCRIPTION:

Chip

Chip Socket

Printed Circuit Board

B. CREWS

Component & System Wiring 59

Temperature & Humidity Sensor Voltage-Resistance Tables

Sensor Checks

The following sensor voltage and resistance tables are provided to aid in checking sensors that appear to be operating incorrectly. Many system operating problems can be traced to incorrect sensor wiring. Be sure all sensors are wired per the wiring diagrams in this manual.

Temperature – Resistance – Voltage For Type III 10 K Ohm Thermistor Sensors

Temp

(ºF)

-10 93333 4.620 60 14681 3.042 86 8153 2.297

-5 80531 4.550 62 14014 2.985 88 7805 2.242

10 52500 4.297 68 12191 2.810 100 6047 1.927

15 45902 4.200 69 11906 2.780 105 5453 1.805

20 40147 4.095 70 11652 2.752 110 4923 1.687

25 35165 3.982 71 11379 2.722 115 4449 1.575

30 30805 3.862 72 11136 2.695 120 4030 1.469

35 27140 3.737 73 10878 2.665 125 3656 1.369

40 23874 3.605 74 10625 2.635 130 3317 1.274

45 21094 3.470 75 10398 2.607 135 3015 1.185

50 18655 3.330 76 10158 2.577 140 2743 1.101

52 17799 3.275 78 9711 2.520 145 2502 1.024

54 16956 3.217 80 9302 2.465 150 2288 0.952

56 16164 3.160 82 8893 2.407

58 15385 3.100 84 8514 2.352

Resistance

(Ohms)

0 69822 4.474 64 13382 2.927 90 7472 2.187

5 60552 4.390 66 12758 2.867 95 6716 2.055

Voltage @

Input (VDC)

Temp

(ºF)

Resistance

Thermistor Sensor Testing Instructions

Use the resistance column to check the thermistor sensor while disconnected from the controllers (not powered). Use the voltage column to check sensors while connected to powered controllers. Read voltage

If the sensors still do not appear to be operating or reading correctly, check voltage and/or resistance to confirm that the sensor is operating correctly per the tables. Please follow the notes and instructions below each chart when checking sensors.

(Ohms)

Voltage @

Input (VDC)

Temp

(ºF)

Resistance

(Ohms)

with meter set on DC volts. Place the “-”(minus) lead on GND terminal and the “+”(plus) lead on the sensor input terminal being investigated.

If the voltage is above 5.08 VDC, then the sensor or wiring is “open.”

If the voltage is less than 0.05 VDC, the sensor or wiring is shorted.

Voltage @

Input (VDC)

OE265-03 Relative Humidity Transmitter – Humidity vs. Voltage

Humidity

Percentage

(RH)

Voltage

@

Input

(VDC)

Humidity

Percentage

(RH)

Voltage

@

Input

(VDC)

0% 1.00 26% 2.04 52% 3.08 78% 4.12

2% 1.08 28% 2.12 54% 3.16 80% 4.20

4% 1.16 30% 2.20 56% 3.24 82% 4.28

6% 1.24 32% 2.28 58% 3.32 84% 4.36

8% 1.32 34% 2.36 60% 3.40 86% 4.44

10% 1.40 36% 2.44 62% 3.48 88% 4.52

12% 1.48 38% 2.52 64% 3.56 90% 4.60

14% 1.56 40% 2.60 66% 3.64 92% 4.68

16% 1.64 42% 2.68 68% 3.72 94% 4.76

18% 1.72 44% 2.76 70% 3.80 96% 4.84

20% 1.80 46% 2.84 72% 3.88 98% 4.92

22% 1.88 48% 2.92 74% 3.96 100% 5.00

24% 1.96 50% 3.00 76% 4.04

OE265-03 Relative Humidity Sensor Testing Instructions:

Use the voltage column to check the Humidity Sensor while connected to a powered expansion board. Read voltage with meter set on DC volts.

Humidity

Percentage

(RH)

Voltage

@

Input

(VDC)

Humidity

Percentage

(RH)

Voltage

@

Input

(VDC)

Place the “-”(minus) lead on terminal labeled GND and the “+” lead on terminal AIN4 on the Analog Input/Output Expansion Board.

Component & System Wiring60

Pressure Sensors Voltage-Resistance Tables

OE271 Duct Static Pressure Sensor

This sensor is used to sense duct static pressure for the WattMaster VAV system controllers. The OE271 sensor is a 0-5” W.C. pressure range, 0-5 VDC voltage range sensor. Use the table and testing information below to check for proper sensor operation.

OE271 Duct Static Pressure Sensor

Pressure

@ Sensor (“ W.C.)

0.00 0.25 2.60 2.20

0.10 0.33 2.70 2.28

0.20 0.40 2.80 2.35

0.30 0.48 2.90 2.43

0.40 0.55 3.00 2.50

0.50 0.63 3.10 2.58

0.60 0.70 3.20 2.65

0.70 0.78 3.30 2.73

0.80 0.85 3.40 2.80

0.90 0.93 3.50 2.88

1.00 1.00 3.60 2.95

1.10 1.08 3.70 3.03

1.20 1.15 3.80 3.10

1.30 1.23 3.90 3.18

1.40 1.30 4.00 3.25

1.50 1.38 4.10 3.33

1.60 1.45 4.20 3.40

1.70 1.53 4.30 3.48

1.80 1.60 4.40 3.55

1.90 1.68 4.50 3.63

2.00 1.75 4.60 3.70

2.10 1.83 4.70 3.78

2.20 1.90 4.80 3.85

2.30 1.98 4.90 3.93

2.40 2.05 5.00 4.00

2.50 2.13

Voltage

@

Input

(VDC)

Pressure

@

Sensor

(“ W.C.)

Voltage

@

Input

(VDC)

OE258 Building Pressure Sensor

This sensor is used to sense building pressure for the WattMaster VAV system controllers. The OE258 sensor is a -0.25” to +0.25” W.C. pressure range, 0-5 VDC voltage range sensor. Use the table and testing information below to check for proper sensor operation.

OE258 Building Pressure Sensor

Pressure

@

Sensor

(“ W.C.)

-0.25 0.00 0.01 2.60

-0.24 0.10 0.02 2.70

-0.23 0.20 0.03 2.80

-0.22 0.30 0.04 2.90

-0.21 0.40 0.05 3.00

-0.20 0.50 0.06 3.10

-0.19 0.60 0.07 3.20

-0.18 0.70 0.08 3.30

-0.17 0.80 0.09 3.40

-0.16 0.90 0.10 3.50

-0.15 1.00 0.11 3.60

-0.14 1.10 0.12 3.70

-0.13 1.20 0.13 3.80

-0.12 1.30 0.14 3.90

-0.11 1.40 0.15 4.00

-0.10 1.50 0.16 4.10

-0.09 1.60 0.17 4.20

-0.08 1.70 0.18 4.30

-0.07 1.80 0.19 4.40

-0.06 1.90 0.20 4.50

-0.05 2.00 0.21 4.60

-0.04 2.10 0.22 4.70

-0.03 2.20 0.23 4.80

-0.02 2.30 0.24 4.90

-0.01 2.40 0.25 5.00

0.00 2.50

Voltage

@

Input

(VDC)

Pressure

@

Sensor

(“ W.C.)

Voltage

@

Input

(VDC)

OE271 Pressure Sensor Testing Instructions

Use the voltage column to check the Duct Static Pressure Sensor while connected to powered controllers. Read voltage with meter set on DC volts. Place the “-”(minus) lead on GND terminal and the “+”(plus) lead on the 0-5 pin terminal on (JP1) with the jumper removed. Be sure to replace the jumper after checking.

OE258 Building Pressure Sensor Testing Instructions

Use the voltage column to check the Building Static Pressure Sensor while connected to a powered expansion board. Read voltage with meter set on DC volts. Place the “-”(minus) lead on terminal labeled GND and the “+” lead on terminal AIN4 on the Analog Input/Output Expansion Board.

Component & System Wiring 61

Notes

Component & System Wiring62

Notes

Component & System Wiring 63

WattMaster Controls Inc. • 8500 NW River Park Drive • Parkville MO • 64152

Phone (816) 505-1100 E-mail: mail@wattmaster.com Fax (816) 505-1101

WattMaster VAV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual