WattMaster VAVBOX User Manual
www.wattmaster.com
VAVBOX Contr oller
Technical Guide
Table Of Contents
Controller Overview ........................................................................................................................................ 3
Features...................................................................................................................................................................................... 3
Controller Inputs and Outputs ........................................................................................................................ 5
General ....................................................................................................................................................................................... 5
VAVBOX Controller Analog Inputs:............................................................................................................................................. 5
Other Controller Connections ..................................................................................................................................................... 5
Optional - Expansion Board Outputs .......................................................................................................................................... 5
Controller Installation & Wiring ...................................................................................................................... 6
Important Wiring Considerations ................................................................................................................................................ 6
General ....................................................................................................................................................................................... 7
Controller Mounting .................................................................................................................................................................... 7
Transformer Sizing & Wiring ....................................................................................................................................................... 7
Expansion Board Installation & Wiring .......................................................................................................... 8
Wiring Considerations ................................................................................................................................................................ 8
Start-up & Commissioning ............................................................................................................................10
General ..................................................................................................................................................................................... 10
Controller Addressing ............................................................................................................................................................... 10
Power Wiring .............................................................................................................................................................................11
Initialization ................................................................................................................................................................................11
Programming The Controller .................................................................................................................................................... 12
Sequence Of Operations ............................................................................................................................... 13
Initialization ............................................................................................................................................................................... 13
VAVBOX Configuration & Setup............................................................................................................................................... 13
Scheduling ................................................................................................................................................................................ 14
Modes Of Operation ................................................................................................................................................................. 14
Damper Positions ..................................................................................................................................................................... 15
Occupied Mode Sequences ..................................................................................................................................................... 15
Unoccupied Mode Sequences .................................................................................................................................................. 16
Damper Control ........................................................................................................................................................................ 18
Tenant Override Logs ............................................................................................................................................................... 19
Alarm Detection And Reporting ................................................................................................................................................ 19
Internal Trend Logging.............................................................................................................................................................. 19
Force Modes or Overrides ........................................................................................................................................................ 20
Troubleshooting ............................................................................................................................................ 21
Using LED’s To Verify Operation .............................................................................................................................................. 21
Other Checks............................................................................................................................................................................ 22
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-VAVBOX-TGD-01C Copyright 2006 WattMaster Controls, Inc.
WattMaster Controls, Inc. assumes no responsibility for errors, or omissions.
This document is subject to change without notice.
Controller Over view
Technical Guide
Features
VAVBOX Controller
This manual applies to the VAVBOX controller that is included in the
following W attMaster products:
MG742-VAV Pressure Dependent VAVBOX Kit For
Terminal Units w/oFan Electric or Hot
Water Heat
MG744-VAV Pressure Independent VAVBOX Kit For
Terminal Units w/oFan Electric or Hot
Water Heat
MG742-03-VAV Pressure Dependent VAVBOX Kit For
Terminal Units or Fan Terminal Units
With Electric or Hot Water Heat
MG744-03-VAV Pressure Independent VAVBOX Kit For
Terminal Units or Fan Terminal Units
With Electric or Hot Water Heat
The VAVBOX Controller is used for controlling airflow and operation
of VAV terminal units. It is a programmable digital controller, which
allows for program setpoints to be stored in non-volatile memory. The
controller is connected to a room sensor which monitors space temperature allowing the VAVBOX controller to modulate a damper in response to space temperature, duct temperature and airflow requirements
in the controlled space.
The VAVBOX controller is provided with two relays for tri-state control of the damper actuator. All outputs and the relay common are electrically isolated from all other circuitry on the board. All relay outputs
are supplied with transient suppression devices across each set of contacts to reduce EMI and arcing. The relay output contacts are rated for
pilot duty control of a maximum of 2 Amps @ 24 VAC or 24 VDC.
The actuator connects via a modular cable to the board and provides the
VAVBOX controller with feedback monitoring for precise positioning
of the actuator.
OE322 Output Expansion Board
The OE322, 3 Relay with Analog Output Expansion board is used in
conjunction with the VAVBOX Controller board to allow for control
of VAV terminal units, including series and parallel fan terminal units
with up to 2 stages of electric heat or modulating hot water heat. The
OE322, 3 Relay with Analog Output Expansion board provides 3
relay outputs for pilot duty switching control, and 1 Analog output for
control of a 0-10 V modulating hot water valve.
The OE322 Output Expansion board connects to the VAVBOX
controller board by means of a modular cable provided with the
expansion board. Power is supplied to the board by means of this
modular cable. Screw terminals are provided for connection of field
wiring to the relay and analog outputs.
The relay outputs are N.O. contacts with one common terminal. All
outputs and the relay common are electrically isolated from all other
circuitry on the board. All relay outputs are supplied with transient
suppression devices across each set of contacts to reduce EMI and
arcing. The relay output contacts are rated for pilot duty control of a
maximum of 2 Amps @ 24 VAC or 24 VDC. The analog output provides
a 0 – 10 VDC modulating signal output into a 1K ohm minimum load.
The VAVBOX controller has three integral modular jacks for connection to the actuator, airflow sensor (for pressure independent applications), and relay or analog expansion boards, via modular cables. The
controller has an on-board dip switch provided for board addressing.
562 REV 3
YS101
R35
R26
D4
LD3
POWER
R21
L1
SCAN
LD2
REC
C6
R12
R11
R10
TOKEN
32
NET
16
LD1
R14
R13
C5
R100
R9
C4
V1
PJ2
ACTUATOR
4.00”
GND
V2
24VAC
R17
R16
U7
Q3Q2
D2
K2
7824
R15
V3
VR1
C7
D3
D1
K1
7.00"
AUX2
AUX1
AUX
+VS
GND
TMP
T'S TAT
D7
COMM
CX10
75176
U10
SW1
ADDRESS
ADD
2
4
8
1
U6
CX6
R8
C3
PJ1
R6
R7
EXPANSION
R28
R25
C15
U11
R24
C11
R20
EWDOG
R19
U5
CX5
R5
C2C1
R4
U2
GND
R32
D5
ADJ
C14
VREF
R23
P.U.
R22
C10
RAM
C8
EPROM
X1
R2
R3
CX2
Q1
D5
FLOW
R27
C13
CX9
U9
C9
R1
16L8
1
RN1
U8
CX8
R34
R18
U4
CX4
U3
CX3
CX1
U1
PAL
Figure 1: V AVBOX Controller Dimensions
V A VBO X Controller 3
Technical Guide
Controller Over view
Figure 2: OE322 Output Expansion Boards
Air Flow Sensor
Modular Connector
Auxiliary
Wiring
Terminals
Room
Sensor Wiring
Terminals
Address Switch
(SetBetween1&58)
Communication
Wiring
Terminals
Communications
Driver Chip
Power LED
24 VAC Power
Terminals
Typical
Pin 1
Indicator
FLOW
D5
AUX
+VS
AUX1
AUX2
GND
D5
R32
T'S TAT
TMP
GND
T
SHLD
R
YS101
R35
562 REV 3
V3
24VAC
GND
RAM
Chip
R34
CX8
U8
RN1
1
R27
CX9
U9
C13
C14
R22
ADJ
VREF
P.U.
R23
R28
R24
U11
R19
C11
R20
C15
EWDOG
R25
D7
COMM
R26
D4
CX10
75176
ADDRESS
SW1
U10
LD3
POWER
R21
L1
VR1
7824
EPROM
Chip
R18
CX4
U4
C9
RAM
C8
C10
U5
ADD
1
U6
2
4
8
16
32
TOKEN
NET
R14
LD2
LD1
REC
SCAN
C7
U7
R16
R17
80C55
2
D3
U3
EPROM
R8
CX6
C5
C4
R100
R13
R9
R10
R12C6R11
Q2
K1
D1
R15
Q3
D2
PAL
Chip
CX3
CX1
U1
PAL
16L8
R1
R2
R3
CX2
X1
CX5
PJ1
C3
PJ2
V1
K2
V2
U2
C2C1
R4
R5
R6
R7
Q1
EXPANSION
ACTUATOR
Damper Actuator
Positioning Relay
“Open”
Damper Actuator
Positioning Relay
“Close”
Snap Track
For Controller
Mounting
Expansion Board
Modular Connector
Damper Actuator
Modular Connector
Figure 3: V AVBOX Controller Component Locations
4
“REC” LED
“SCAN” LED
V A VBO X Controller
Controller Inputs and Outputs
Technical Guide
General
The following inputs and outputs are available on the VAVBOX controller and the OE322 Output Expansion Board that can be added by
connecting it to the main controller board expansion port. For component locations of the inputs on the VAVBOX Controller see Figure 3.
For wiring of inputs and outputs see Figure 4 thru 9.
V AVBOX Controller Analog Inputs:
Input #1: Space Temperature Sensor
The Room Sensor that reads space temperature is attached the TMP and
GND terminals. If the Room Sensor with slide adjust option is used a
third wire connects to terminal AUX1.
Input #2: Airflow Sensor
If the VA VBOX Controller is to be configured for pressure independent
operation, you need to install the OE274 Airflow Sensor and connect
the modular plug from the pressure sensor to this input. The pressure
signal from the Airflow Sensor is used for CFM (airflow) calculations.
If an OE274 Airflow Sensor is attached to this input, the VAVBOX
controller will automatically detect this and switch to pressure independent operation. If the sensor is not attached or becomes defective, the
controller automatically reverts to pressure dependent operation.
Input #3: Supply Air Temperature Sensor
The optional Supply Air Temperature Sensor is connected to terminals
AUX2 and GND when it is used. If it is to be used as a Supply Air
Sensor , it should be mounted in the supply duct close to the terminal
unit where the VA VBOX controller is installed. This sensor can be used
for monitoring purposes or in place of the Supply Air T emperature Broadcast from the WMVAV Controller.
Note: All temperature sensors must be Thermistor Type III.
Optional - OE322 Expansion Board
As previously stated when control of a fan or if heating is required the
OE322 Output Expansion board must be used.
Relay Output #1 - Fan Enable
The first expansion relay on the Output Expansion boards is used for
enabling the fan for Series or Parallel Fan Terminal Units.
Relay Output #2 - Stage 1 Heating
If you have at least one stage of auxiliary heating, this is the relay used
to energize the 1st stage of terminal unit heating. This heating stage can
either be used with electric heat or On/Off hot water valve control.
Relay Output #3 - Stage 2 Heating
If you have two stages of auxiliary heating, this relay controls the 2nd
stage of electric heat. For 3 stage heating, this relay output would be
energized for both the 2nd and 3rd stage of heat. See the following
section for more information regarding 3 stage heating applications.
3 Stage Heating Applications
If three stages of electric heat are configured, relays #2 and #3 will
stage in a staggered sequence. This allows you to achieve 3 stages of
heating using only relays #2 and #3. Each of the 3 heating elements
should be sized for 1/3 of the total KW output required. Both the 2nd
and 3rd stage heating contactors (C2 & C3) must be connected to Relay
Output #3. See Table 1 for relay sequencing information.
Stag e No. Relay Output #2 Relay Output #3
#1 ON (C1) OFF (C2 & C3)
#2 OFF (C1) ON (C2 & C3)
#3 ON (C1) ON (C2 & C3)
Table 1: Relay Sequencing For 3 Stage Heating
Other Controller Connections
Expansion Board Modular Connector
This modular connector is used to connect the optional OE322 Output
Expansion Board to the VAVBOX controller. These boards are only
required when electric or hot water heating and/or fan terminal control
is required. The expansion boards are not required for cooling only
terminal units.
Actuator Modular Connector
This modular connector is used to connect a modular cable from the
VAVBOX controller to a tri-state actuator.
V A VBO X Controller
24 VDC Power Terminals (+V & GND)
These terminals can supply 24 Volts DC for a 24 VDC hot water valve
actuator if desired. This output is rated at 12 Watts maximum load.
Analog Output
If you are using hot water or steam heating via a modulating steam or
hot water valve, this output can supply a 0-10 Volts DC signal for proportional control of the valve.
5
Technical Guide
Hi
Lo
Controller Inputs and Outputs
Airflow Probe & Sensor
(For Pressure Independent Applications Only)
Airflow
Duct Supply
Or Discharge
Temperature
Sensor
(See Note 2)
Connection To AUX
Terminal Is Only Required
When Sensor Is Specified
With Slide Adjust Option
Connect To Next VAVBOX
Controller Or WMVAV
Controller On Local
Communications Loop
Line Voltage
Locate In Supply Or
Discharge Duct
Near Zone Damper
Room Sensor
W
A
R
M
E
R
C
O
O
OVR
L
E
R
TMP
GND
AUX
Notes:
1.) All wiring to be in accordance with local and national electrical codes
and specifications.
2.) A Duct SupplyAir Temperature Sensor is not required when the VAVBOX
Controller is connected to an WMVAV Unit Controller board. A global Supply
Air temperature is broadcast by the WMVAV Unit Controller. The Supply Air
Temperature Sensor is required if the VAVBOX Controller is required to
operate as a “Stand Alone” controller. The Duct Sensor can also be placed on
the discharge side of the VAVBOX duct and used as a Discharge
Temperature Sensor to monitor VAVBOX discharge air temperature if desired.
This is normally used only if the VAV Terminal unit has heating capabilties.
Zone Actuator
R34
R18
CX4
CX3
CX8
U4
U8
RN1
1
R27
CX9
U9
C13
C9
RAM
C8
C14
ADJ
VREF
R28
U11
C15
R25
D7
CX10
COMM
R26
D4
80C55
R22
2
P.U.
C10
R23
R24
R19
C11
R20
EWDOG
U5
ADDRESS
ADD
1
U6
2
75176
4
SW1
U10
8
16
32
LD3
POWER
TOKEN
NET
R14
LD2
LD1
R21
REC
SCAN
L1
VR1
D3
C7
7824
U7
R16
R17
CX1
U3
U1
PAL
16L8
R1
R2
EPROM
R3
CX2
Q1
X1
C1
U2
C2
R4
CX5
R5
R6
R7
PJ1
EXPANSION
R8
CX6
C3
C5
C4
R100
PJ2
R13
R12C6R11
R10
Q2
R15
Q3
ACTUATOR
V1
R9
K1
D1
D2
K2
V2
To Optional Relay
Expansion Board
SHLD
24VAC
GND
AUX1
AUX2
GND
TMP
GND
FLOW
D5
AUX
+VS
AUX1
AUX2
GND
D5
R32
T'STAT
TMP
GND
T
R
YS101
R35
562REV 3
V3
24VAC
GND
10
24 VAC Transformer
Size For 6 VA
Maximum Load
Figure 4: V AVBOX Controller Wiring
Controller Installation & Wiring
General
Correct wiring of the VAVBOX controller is the most important factor
in the overall success of the controller installation process. The VA VBOX
controller wiring has been simplified by the use of modular connectors
and prefabricated modular cables.
Controller Mounting
If the Round Zone Dampers were purchased from W attMaster , the controller and actuator are factory mounted and wired in the damper control enclosure. If your VAVBOX controllers are pressure independent,
an airflow probe and pressure sensor will also be factory mounted and
wired.
Most terminal unit manufacturers will offer the option of factory mounting the WattMaster controls in their terminal units for an additional
charge. An installation worksheet and instructions are available for the
WattMaster VAVBOX controller package which can be shipped with
the VAVBOX control(s) to the terminal unit manufacturer to simplify
third party factory mounting and wiring of the controller.
When the VAVBOX controller is to be field mounted, it is important to
mount the controller in a location that is free from extreme high or low
temperatures, moisture, dust and dirt. The VAVBOX controller board
must be mounted within 10” of the damper actuator in order for the
actuator cable to extend between the controller and the actuator.
Be careful not to damage the electronic components when mounting
the controller. Remove the controller from its snap track mount. Mark
the control enclosure base using the snap track as a template. Drill pilot
holes in the enclosure base and secure the snap track to it using sheet
metal screws. Do not allow metal shavings to fall onto the circuit board.
Reattach the controller to the snap track. Mount the damper actuator to
the damper shaft following the instructions supplied with the damper
actuator.
Important Wiring Considerations
Please carefully read and apply the following information when wiring
the WMVAV controller. See Figure 4 for VAVBOX controller wiring
diagram.
1. Size and wire the transformer per the instructions. Failure
to size the transformer and/or wire the transformer
correctly may cause the VAVBOX controllers to not
operate erratically or not at all. See Figure 5 for wiring
and transformer sizing information.
2. If a Duct Sensor is to be connected, the minimum
wire size used should be 24 gauge.
3. Do not pry on the connectors when connecting or
disconnecting the modular cables. Be sure to push in on the
connector release clip and then pull straight up.
6
V A VBO X Controller
Technical Guide
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
thana2Voltdropatthefarthest 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
24VAC Power - Transformer & Wire Sizing Considerations For VAVBOX Controllers
BC
B
A
120 / 24VAC
Distance A to B cannot exceed 61.73 Ft.
Distance from A to B cannot exceed 123.46 Ft.
Distance from A to C cannot exceed 123.46 Ft.
A
Figure 5: WMVAV Controller Transformer Sizing
Transformer Sizing & Wiring
Each VAVBOX controller requires 6 VA minimum at 24 VAC in order
to function properly. Wiring and transformer information shown above
is provided to help correctly size and layout wiring schemes for the
VAVBOX controllers. As stated above, all wiring should be 18 Ga.
minimum. Long runs may require heavier gauge wire to keep the voltage drop within the 2 volt maximum range. Please follow these guidelines.
V A VBO X Controller
F
E
D
C
120 / 24VAC
B
120 / 24VAC
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.
Warning: If polarity between controllers is not maintained,
severe damage to the controllers may result.
W attMaster recommends using a separate transformer
for each controller in order to eliminate the potential
for damaging controllers due to incorrect polarity.
A
7
Technical Guide
Expansion Board Installation & Wiring
Figure 6: Expansion Board Wiring For Two Position Hot Water Heat Applications
Wiring Considerations
Warning: The 3 relay outputs available on the OE322
Expansion boards are used to supply extra relays and/or analog outputs
to control fan and heating functions for the VAVBOX controller.
When Round VAVBOX Dampers or Rectangular VAVBOX Controller
Kits are ordered from W attMaster, the OE322 Expansion board is shipped
loose for field mounting by others.
Mounting of the OE322 Expansion Board is identical to the previously
described mounting for the VAVBOX controller. Mount the Expansion
board near the VAVBOX controller using the sheet metal screws provided. Be sure the mounting location is close enough so that the supplied modular cable will reach from the VAVBOX controller to the
Expansion board.
The wiring consideration information previously outlined for the
VAVBOX controller should be followed when wiring the OE322 Expansion Boards.
Output Expansion board are each rated for 2 Amps
@ 24 VAC. If your device load exceeds these limits,
a pilot duty relay (by others) must be used in the
circuit.
8
V A VBO X Controller
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