Basic System - Auto-Zone Control S

Design, Installation and Operations Manual

Basic System

Revision 02C

Auto-Zone Basic Design, Installation & Operations Manual

Section 1 ..............................................................................System Overview Section 2 ................................................................... Installation and Wiring Section 3 ....................................................................................Programming Section 4 ........................................................Start-Up and Troubleshooting

This document is subject to change without notice. WattMaster Controls, Inc. assumes no responsibility

for errors, or omissions herein.

Auto-Zone Basic Installation & Operations Manual - Form WM-AZB-IO-02C Auto-Zone is a registered trademark of WattMaster Controls, Inc.

Copyright 2009 WattMaster Controls, Inc. All rights reserved.

Section 1

Design Guide

Table of Contents Conventions .....................................................................1 General Information.........................................................3

Description of System Components.................................................................................3 Design Considerations.....................................................5

Zone Diversity .................................................................................................................5 Cooling - Partial Load Conditions ...................................................................................5 Heating - Partial Load Conditions ...................................................................................7 Override Conditions.........................................................................................................7 Building Pressurization....................................................................................................7

Design Guide....................................................................8 Step #1 - Zoning ..............................................................................................................8 Step #2 - Sizing the Central Unit ...................................................................................10 Step #3 - Duct Design Considerations...........................................................................10 Step #4 - Room Air Motion/Diffuser Selection.............................................................11 Step #5 - Bypass Damper Sizing ...................................................................................11 Step #6 - Sizing Zone Dampers .....................................................................................13 Round Dampers .............................................................................................................15 Rectangular Dampers.....................................................................................................15 Pressure Independent Zone Dampers ............................................................................16

Auxiliary Heat Control Options......................................17 Relay Expansion Board .................................................................................................18

Table of Figures & Tables Figure 1-1: Auto-Zone Basic Control System...............................................................2 Figure 1-2: Control Zones Affected by the Outdoor Load ............................................9 Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control ............12 Figure 1-4: Round Damper Dimensions......................................................................14 Figure 1-5: Rectangular Damper & Kit Dimensions...................................................14 Table 1-1: Round Air Damper Selection .....................................................................15 Table 1-2: Rectangular Damper Selection...................................................................15 Table 1-3: Pressure Independent Flow Factors............................................................16

Auto-Zone Basic Section 1

Design Guide 1-1

Conventions This document uses the following definitions throughout as a guide to the user in determining the nature of information presented: Note: Additional information which may be helpful

Tip: Suggestion to make installation, set-up, and troubleshooting easier.

Caution: Items which may cause the equipment not to function correctly, but will not otherwise damage components.

Warning: Errors which can result in damage to equipment and void warranties.

Section 1 Auto-Zone Basic

1-2 Design Guide

Computer(Optional)

Zone Air DampersUp to 16 Zone Air Dampers Allowed

SupplyAir Temp Sensor

To HVAC UnitControl Panel

ReturnAir TempSensor

Bypass AirDamper

Economizer(Actuator By Others)

OutsideAir TempSensor

StaticPressureSensor

#1 #16

Typical Zone

Velocity Sensor(Optional)

Zone ControllerDamper Actuator

RS-485Comm Loop

24 VAC

Room Sensorwith Optional

Override & Adj.

Single Loop

RS-4859600 Baud

24VAC

Remote Link II(Optional)

Optional IP Module Installs Into CommLink IV

And ProvidesLAN And Internet Communications

With The Control System

Ethernet Router(By Others)

When IP ModuleOption Is Used

Optional Remote Link II Connects to CommLink IV

And Provides Alarm Call-OutsA Second Remote Link Is Required

If Connection To Job SiteIs Desired From Remote Computer

Phone Cable ToTelephoneWall Outlet Jack

Ethernet Cable To Router

USB Cable To Computer

CommLink IVThe CommLink IV Is

Required For All Systems. The IP Module, Remote

Link II, And Computer Are Optional On All Systems.All Computers Require

Installation of Prism Graphical User Interface

Software

CommLink IV

Figure 1-1: Auto-Zone Basic Control System


Design Guide 1-3

General Information The primary application of the Auto-Zone Basic Control System is to provide multiple controlled comfort zones from a single zone, unitary heating and air-conditioning package unit. It can also be applied to existing installations for improved comfort to multiple zones currently controlled by a single thermostat.

Description of System Components A typical Auto-Zone Basic Control System is comprised of the following four basic components.

Zone Manager The Zone Manager is a microprocessor-based controller which monitors up to 16 zones in the system. The zone manager then controls the HVAC unit to satisfy the requirements of each individual zone while maintaining efficient operation and comfort. The zone manager is also responsible for controlling duct static pressure. In the Auto-Zone Basic version, the Zone Manager has a display and a keypad. The 4-line by 20-character display is backlighted, making it easier to read in low light environments.

Bypass Damper The bypass damper controls proper duct static pressure to insure proper airflow. The damper is modulated by the Zone Manager based on a signal received from the static pressure sensor connected to the main duct.

Zone Controller The Zone Controller monitors space temperature and allocates proper airflow to the assigned zone to achieve desired comfort and ventilation levels. If supply air temperature will benefit the local zone temperature setpoint, the zone damper modulates to reduce or increase airflow as needed. If supply air will not benefit the local zone, the controller will direct the damper actuator to a minimum position and wait for a change in supply air temperature.


1-4 Design Guide

Zone Sensor The patented zone sensor is a flush, wall-mounted design. A special plate on the face of the sensor accurately senses space conditions. As a result of its unique design, the zone sensor rejects the influence of internal wall temperature effects. The sensor comes in four different configurations: • Sensor only • Sensor w/push-button override (override is fixed at 2 hours) • Sensor w/setpoint adjustment • Sensor w/override & setpoint adjustment Any combination of these sensor configurations can be used with the system.


Design Guide 1-5

Design Considerations Consider the following items when designing a system using Auto-Zone.

Zone Diversity The Auto-Zone Basic Control System is designed to improve tenant comfort by dynamically re-balancing the air distribution when used with a typical constant volume rooftop heating/cooling unit. If zones with extremely different load conditions are serviced by a single rooftop unit, the result will be poor control and excessive wear due to cycling of the equipment. It is especially important to avoid mixing interior zones (which require cooling all year) with exterior zones (which may require constant heat during winter months). If you must mix zones under these conditions, consider using either VAV boxes with heat or separate baseboard heat on exterior zones. Auto-Zone Basic Control Systems offer a variety of methods to control additional zone heat to help you avoid problems.

Cooling - Partial Load Conditions The engineer must be aware of several potential problems when applying the Auto-Zone Basic Control System during cold weather operation.

Low Ambient Temperature Lockout During very cold weather it is common for mechanical systems to have “low temp lockouts” which protect equipment from damage if operated under these conditions. Auto-Zone also provides user programmed lockouts for protection purposes, although mechanical safeties should always be used as the final stage of protection. If the rooftop unit services interior zones with thermal loads which require cooling when outside temperatures are below the safe operating limits for your equipment, you should seriously consider installing an economizer on your rooftop unit. The Auto-Zone control system is designed to take advantage of an economizer if it is installed. The use of an economizer will save money on utilities and provide comfort under conditions when it is not possible to operate the mechanical cooling system.

Low Supply Air Temperatures Under lightly loaded conditions much of the supply air may be bypassed back into the return airside of the system. This bypassing will result in the lowering of the supply air


1-6 Design Guide

temperature, which may result in the supply air temperature reaching the low temp safety limit. If the supply air low temp safety limit is exceeded, the control system will “cut-off” the mechanical cooling to protect it from damage. Excessive cycling of the mechanical system will result if this condition persists. Comfort may also suffer if the system cannot run long enough to satisfy cooling demands. A number of things can be done to reduce this problem. Some of these things depend upon the type of installation. • Avoid oversizing the unit. Do your load calculations carefully. Since Auto-Zone

directs the heating or cooling to the zones which require it, you may find that you can use a smaller unit in many cases. Oversizing is the number one cause of excessive low supply air temperature cycling.

• Increase your cooling minimum airflow or damper position settings to allow more air

during cooling operation. Be careful to avoid settings which are so high you cause over cooling of the spaces. Find a compromise position.

• Bypass the air into the plenum instead of into the return air intake. Be careful if you

use this method since you may get “dumping” of cold air from your return air grilles. This method works best with plenum returns. Do not use this method with ducted returns unless you have carefully considered the consequences.

• Increase your static pressure setpoint to help reduce the amount of air being bypassed.

Be aware of increased noise levels and the cost of operation if you use excessive static pressures.

Warning: If the fan system has the capability of producing static pressures which could damage ductwork, you must provide a manual reset high pressure limit switch to cut-off the fan system in the event of high duct static. Do not use your Auto-Zone Basic Control System as a safety device!

• Use an Economizer. Although this is not a cure-all, it greatly improves operation

during cool weather when cooling loads are minimal. Using an Economizer also improves ventilation and lowers operating costs, both of which are significant.


Design Guide 1-7

Heating - Partial Load Conditions Heating difficulties are less common than cooling difficulties. They are similar in nature, however, and the cures are generally the same. • Increase the Heating minimum setpoints on as many zones as possible. • Increase the static pressure setting as high as is practical. Increasing static pressure

does not help if you are using pressure independent operation. • Bypass to plenum instead of the return air intake if acceptable. • Do not oversize your equipment. • Use auxiliary heat in either your VAV boxes or baseboard. Auto-Zone has a number of auxiliary heat control options which provide solutions to most problems. Refer to the Auxiliary Heat Control Options topic near the end of this section.

Override Conditions After-hours overrides can produce aggravated partial load conditions in both the heating and cooling modes. The problem is most commonly caused by a single zone being overridden for after-hours use. This causes the rooftop equipment to operate for only one zone. The Auto-Zone Basic Control System offers an improved solution to this common problem by allowing a single override to trigger a group of zones via a “global” override. This allows the system to operate with sufficient load to reduce cycling caused by light load conditions.

Building Pressurization If you are using an economizer, building pressurization must be addressed. Failure to properly handle building pressurization may result in doors remaining open when the economizer is operating. Pressurization problems can render economizer operation useless. The following suggestions will help to avoid potential problems. • Use powered exhaust when the system uses ducted returns. The return duct pressure

drop will cause most barometric relief dampers to function poorly or not at all. Auto-Zone has the ability to control a powered exhaust whenever the economizer is operating.

• Use a separate building pressure control which operates a relief fan or dampers.


1-8 Design Guide

Design Guide There are six basic steps to designing an Auto-Zone Basic Control System: 1. Zoning 2. Sizing the Central Unit 3. Duct Design Considerations 4. Room Air Motion / Diffuser Selection 5. Bypass Damper Sizing 6. Sizing Zone Dampers

Step #1 - Zoning Determine the number of zones. A single air handler unit can have no more than 16 zones. If the number of zones exceeds 16, then more than one Zone Manager will be required. Consider using the Auto-Zone Plus system if more than one Zone Manager is required. The primary precaution to be taken in applying the Auto-Zone Basic Control System is to select the zoning so that no zone will be at maximum (design) heating (or cooling) load when any other zone requires the opposite temperature air to satisfy its load. For example, depending on the wall, ceiling, floor material, and location within the building (e.g. top or middle floor), a typical floor of a building usually has a minimum of 9 distinct temperature or control zones that are affected uniquely by the outdoor load. These zones are depicted in Figure 1-2. Depending on the size of the building and partition layout, some of these zones may overlap or be insignificant from a zoning standpoint. For example, Zone 10 could be multiple conference or computer rooms where additional zoning would be required, or it could be as small as a corridor where no zoning is required. Similarly, zones 4 and 5 could have no external windows and no partitions between them and could be considered a single zone. Zone 3 could be divided into multiple offices with full partitions between them, thus requiring separate Zone Controllers because of different internal loads, but the same external load. Generally, the greater the number of individual Zone Controllers there are, the greater the comfort. The designer will have to look at the specific building, balancing the costs of multiple zones with the added comfort possible with multiple zones, to match the owner's requirements.


Design Guide 1-9

It is important to recognize that there are purely internal zones, such as Zone 10, which may contain separate offices/conference/computer rooms. These internal zones could easily have high cooling requirements while external zones (1, 2, 3, etc.) could be at or near design heating load. This is a misapplication of the Auto-Zone Basic or Plus (or any heating/cooling changeover) system. The interior zones with cooling-only loads should be served with a separate air-conditioning unit (that could be zoned between multiple rooms with a similar load profile). Supplemental heat could be added to the perimeter zones and controlled with the auxiliary heat control board from the Zone Controller. System performance will generally be compromised and frequent changeover from the heating to the cooling mode will occur during the heating season if purely internal zones are combined on the same air-conditioning unit serving perimeter zones.

Figure 1-2: Control Zones Affected by the Outdoor Load

N

SE

W

Room Sensor(Typical)

Supply Air Duct

Supply Air Duct

Return Air Plenum

Return Air Plenum

Round Zone Damper(Typical)

Bypass Damper

System Manager

Zoned HVAC Unit

Constant Volume HVAC Unit

1

4

2

5

3

6

9

8

07

Enter

Esc

*

Minus

Menu

Clear

Dec.

Alarm

Communication

Override

MANAGER

SYSTEM

Auto-Zone Plus

01/01/97 03:38PM WED

OCCUPIED

NO ALARMS

WATTMASTER CONTROLS INC.

NORMAL

OVR

W

A

RM

E

R

C

O

O

L

E

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NORMAL

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W

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RM

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RM

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RM

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1

3

2

4

5

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8

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107


1-10 Design Guide

Step #2 - Sizing the Central Unit Because the zones are controlled with variable air volume, it is unlikely that all zones will be at design load at the same time. The zoning allows for the diversity of loads to be taken into account and will often provide better comfort with a smaller HVAC unit. In sizing the system, the individual zone loads should be calculated using any dependable load estimating program. Because of diversity, the central unit should be selected for the instantaneous peak load, not the sum of the peak loads, as would be done with a constant volume single zone system. Consider the following when sizing the central unit. • Size the peak cooling load based on the month and hour of the greatest total

building/system load. • Heating should be sized for the lowest design temperature with an additional margin

for morning "pickup." This margin is generally recommended to be 20 to 25 percent of base design.

Step #3 - Duct Design Considerations The Auto-Zone Basic Control System uses a typical low pressure duct design. To reduce noise problems, duct pressures should not exceed 1 inch W.C. Primary trunk ducts should not be "undersized." This is especially true for "pressure dependent" systems. Pressure dependent refers to the typical Auto-Zone Zone Controller without the airflow sensor. With larger trunk ducts, it is easier to assure relatively constant pressure to each zone. Runs should be as short as possible and the trunk duct system kept as symmetrical as possible to facilitate system balancing. Wherever possible, run the trunk ducts above corridors and locate the zone dampers above corridors to reduce the noise in the space and facilitate service of the units. Trunk ducts should be sized for no more than 0.1 inch W.C. drop per 100 feet and a maximum duct velocity of 2000 FPM. Note: For pressure independent terminal units with velocity sensors and

conventional "VAV" boxes properly selected for "quiet" operation, this 2000 FPM rule can be exceeded by up to 50 percent. The designer, however, should be very experienced in VAV system design before considering modification of this general rule.

Typical VAV systems with pressure independent terminals use the static regain method for sizing ducts. The typical Auto-Zone Basic Control System is a low-pressure, pressure dependent system that utilizes conventional unitary air-conditioning units. These systems should use the equal-friction method of sizing the ducts and use the maximum loss of 0.1 inch per 100 feet as described above.


Design Guide 1-11

Step #4 - Room Air Motion/Diffuser Selection Air motion is a consideration for occupant comfort. The selection of diffusers for an Auto-Zone Basic Control System requires more care than a constant volume system due to varying flow of air into the zones. Slot diffusers are recommended due to their superior performance at low airflows. Because the zone airflow is variable volume, lower cost round or rectangular diffusers that were satisfactory for constant volume may prove unsatisfactory with an Auto-Zone Basic Control System. These diffusers may result in "dumping" of the cold air at low flows in the cooling mode and insufficient room air motion at low air flows in the heating mode. Although high air motion in the heating mode can be undesirable, a slot diffuser with a high induction ratio generally helps to reduce room air "stratification" when the heating comes from a ceiling diffuser. Linear slot diffusers should be properly selected for the airflow and "throw" suited to the specific installation or zone. Additional factors to consider in diffuser selection are sound level and throw at design flow. Generally, multiple diffusers will result in lower sound levels in the space, but this must be balanced with the additional hardware and installation costs. It is commonly recommended that slot diffusers be located near the perimeter or outside wall with the airflow directed into the room. Consult your diffuser supplier or catalog for proper diffuser sizing and location. Series fan boxes may be used instead of zone dampers where higher induction rates are desirable. If the heat loss on perimeter walls is high, such as large areas of glass, the use of Series Fan Boxes may be indicated to maintain higher induction rates to offset “downdrafts.” If the heat loss is greater than 275 BTUH/LINEAR FOOT, you should use high quality slot diffusers next to the outer wall with the airflow directed inward to counteract downdrafts during heating. Serious downdraft problems occur when heat losses exceed 400 BTUH/LINEAR FOOT. In such case, both high induction diffusers and series fan boxes are recommended.

Step #5 - Bypass Damper Sizing Using a load calculation program, the bypass damper should be sized to give you the maximum CFM of air to be bypassed, typically 60 to 70 percent of the HVAC units rated capacity. Bypass Dampers can either be round or rectangular depending on building or job requirements. Use the appropriate round or rectangular damper selection table to determine the correct damper size for your application. To size the damper, select a damper from the table based on calculated bypass CFM and a maximum velocity between 1750-2250 FPM. When determining the bypass duct size, be sure to take into account any transition fittings and associated pressure drops. (See Table 1-1: Round Damper Selection or Table 1-2: Rectangular Damper Selection.)


1-12 Design Guide

If space limitations or total airflow requires it, multiple bypass dampers can be controlled in parallel. For proper control of the Bypass Damper, the static pressure sensor location is very important. Refer to Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control below for proper mounting locations. Preferred Location If the trunk ducts are properly sized for minimum pressure drop, the location of the static pickup probe is not particularly critical. It should ideally be located at right angles to the airflow in a straight section of the supply duct approximately ⅔ the distance of the total length of the supply duct. Also, the probe should be located not less than 3 duct diameters downstream and 2 duct diameters upstream of any elbow or takeoff.

Fan

RA SensorSA Sensor

3D

Min.

2D

Min.

Return Air Duct

Su

pply

Air

Du

ct

SP Pickup

Bypass Damper

SP Sensor

Less Than Ideal, But Acceptable Since the "ideal" location is often difficult to find in an installation, a location in the main trunk where the tip is not in a "negative pressure area" (e.g. just downstream of the inside curve of an elbow) or an area where the tube opening is directly impacted by the velocity of the supply air is acceptable.

Fan

RA SensorSA Sensor

Return Air Duct

Supply Air Duct

SP Pickup

Bypass Damper

SP Sensor

Least Desirable, But Acceptable If the supply duct comes directly from the unit and immediately splits in opposite directions, the pressure pickup should be located ahead of the split or as close to it as possible, even if the bypass damper(s) are located downstream of the split.

Fan

RA Sensor

SA Sensor

Return Air Duct

Supply Air Duct

Tubing To Be EqualLength And Size

Bypass Damper

SP SensorSP Pickups

Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control


Design Guide 1-13

Step #6 – Sizing Zone Dampers Use a load program to determine the peak load for each zone. These calculations will be used in selecting the appropriate zone damper sizes. A round damper or rectangular damper can be selected depending on the building or job requirements. If the job requires pressure independent damper control, the damper selected must be a round damper. Rectangular dampers are not available for pressure independent control. Please see Table: 1-1 for round damper selection. Please see Table: 1-2 for rectangular damper selection. Using the maximum acceptable velocity for a branch duct (typically 1000-1500 FPM for minimal noise), find the smallest damper that will deliver the required CFM as determined by the load program. Go to either the Round Damper Selection table (Table: 1-1) or the Rectangular Damper Selection table (Table: 1-2) depending on your requirements to select the dampers. Locate the branch velocity used in the duct design program on the left hand column of either damper sizing chart (Table: 1-1 or Table: 1-2). Move across the chart and find the damper which will provide the acceptable CFM to meet each zone’s airflow requirements. Note: Compare the damper size selected against the duct size to determine if the

next size up or down will provide acceptable performance without requiring a transition fitting.

Up to two additional dampers may be slaved together for larger zones. See zone wiring diagram for details. This should be reserved for situations when it is not practical to use a single large damper.


1-14 Design Guide

Figure 1-4: Round Damper Dimensions

Figure 1-5: Rectangular Damper & Kit Dimensions

Note: Dimensions Are Identical For Round Zone, Bypass & Slave Dampers

Note: See Table 1-2 for Available “A” x “B” Rectangular Damper Sizes

Note: Dimensions Are Identical For Rectangular Zone, Bypass & Slave Dampers


Design Guide 1-15

Round Dampers

Table 1-1: Round Air Damper Selection

Rectangular Dampers

Table 1-2: Rectangular Damper Selection

Round Air Damper Selection Air Damper Round Duct Size

( Area Ft2 ) 6”

(0.188) 8”

(0.338) 10”

(0.532) 12”

(0.769) 14”

(1.050) 16”

(1.375) Velocity Through Round Air

Damper (FPM)

Volume Through Round Air Damper (CFM)

750 - Zone 141 254 399 577 788 1031 1000 - Zone 188 338 532 769 1050 1375 1250 - Zone 235 423 665 961 1313 1718 1500 - Zone 282 507 798 1154 1575 2062

1750 - Bypass Only 329 592 931 1346 1838 2405 2000 - Bypass Only 376 676 1064 1538 2100 2749 2250 - Bypass Only 423 761 1197 1730 2363 3094

Rectangular Damper Selection Damper Height

(B)

8”

10”

12”

14”

16”

18”

20”

22”

24”

26”

28”

30”

32”

34”

36”

Damper Width

(A)

Airflow Through Rectangular Damper CFM @ 1000 FPM Velocity

8” 410 530 640 740 850 970 1080 1190 1300 1410 1520 1630 1740 1850 1970 10” 510 590 690 800 910 1030 1150 1260 1380 1500 1610 1730 1840 2000 2080 12” 560 650 730 850 970 1090 1210 1330 1460 1580 1700 1820 1940 2060 2190 14” 660 770 880 1030 1180 1330 1480 1630 1760 1910 2060 2210 2360 2510 2640 16” 750 890 1030 1200 1370 1540 1710 1880 2060 2230 2400 2570 2740 2910 3090 18” 770 980 1180 1380 1580 1780 1980 2180 2350 2550 2750 2950 3150 3350 3540 20” 850 1090 1330 1550 1770 1990 2210 2430 2650 2870 3090 3310 3530 3750 3990 22” 930 1210 1480 1730 1980 2230 2480 2730 2950 3200 3450 3700 3950 4200 4440 24” 950 1290 1630 1900 2170 2440 2710 2980 3250 3520 3790 4060 4330 4600 4880 26” 990 1390 1780 2080 2380 2680 2980 3280 3550 3850 4150 4450 4750 NA NA 28” 1070 1500 1930 2250 2570 2890 3210 3530 3850 4170 4500 4820 NA NA NA 30” 1020 1550 2080 2430 2780 3130 3480 3830 4150 4500 4850 NA NA NA NA 32” 1090 1660 2230 2600 2970 3340 3710 4080 4450 4820 NA NA NA NA NA 34” 1150 1770 2380 2780 3180 3580 3980 4370 4750 NA NA NA NA NA NA 36” 1060 1790 2520 2670 3090 3510 3930 4350 5040 NA NA NA NA NA NA

Notes: 1.) Zone Dampers Should Be Sized Based On The Required Zone CFM. The Table Above Is Calculated Based On 1000 FPM Velocity Through The Rectangular Damper. Zone Damper Recommended Velocity Is 1000 – 1500 FPM. Select 1000 FPM or Less for Quiet Operation. For Other Velocities, Use The Following Multipliers To Obtain The Correct CFM: 500 FPM = 0.5, 750 FPM = 0.75, 1250 FPM = 1.25, 1500 FPM = 1.5, 2000 FPM = 2.0, 2250 FPM = 2.25. 2.) Bypass Dampers Should Be Selected for 60% to 70% of the HVAC Units Rated CFM Capacity. Recommended Bypass Damper Velocity is 1750 – 2250 FPM.


1-16 Design Guide

Pressure Independent Zone Dampers Pressure Independent operation is only available for round zone dampers. Use the chart below to set the calibration of the zone damper after installation.

Damper Size

Flow Probe “K” Factor

6” 474 8” 950

10” 1417 12” 2120 14” 2908 16” 3700

Flow Probe “K” Factor = CFM @ 1” Velocity Pressure

Table 1-3: Pressure Independent Flow Factors

Note: K Factors are programmed for each zone so that the correct CFM will be

calculated for the different size air valves.


Design Guide 1-17

Auxiliary Heat Control Options The Auto-Zone Basic Control System offers you a variety of methods to deal with zone heating requirements. When deciding how to handle zone heating requirements, you should consider the following: • Does the rooftop unit have heat? • Are you using fan-powered boxes? • Is auxiliary heat used such as baseboard or radiant ceiling panels? If the zone has some type of heat, you must consider how the heat is to be used. Typical questions that should be asked: Q: Should the zone heat be used as a first stage where it will become active before a

heating demand is created at the rooftop unit? A: This mode is useful if you expect to have both heating and cooling demands at the

same time. The zone will use its own heat and allow the rooftop unit to continue to provide cooling for other zones. This mode is also useful if the rooftop unit does not have any heating capabilities.

Q: Is the zone heat only to be used as a second stage where it will be activated only if

the rooftop unit cannot maintain the space temperature such as during very cold weather?

A: In this mode of operation the rooftop will examine the heating and cooling demands

and try to satisfy all of the zones by switching between heating and cooling as required. The zone heat will only be activated if the zone temperature falls below a selected limit.

Q: Should the zone heat be locked out if the rooftop unit is supplying warm air? A: In many instances, it is desirable to use the rooftop heating whenever possible and

only use zone heat when the rooftop unit is in cooling or vent mode. This often provides the most cost-effective operation since zone heat is typically electric. This mode of operation will lockout zone heat if the rooftop is delivering heated air.


1-18 Design Guide

Relay Expansion Board The following describes the operation of each of the relays on the optional relay expansion board. You can choose the appropriate relays for any given application.

Relay #1 - Parallel Fan If the Zone is in cooling mode or vent mode, the parallel fan can activate any time the zone temperature drops 0.5°F below the heating setpoint. It de-activates when the temperature rises above the heating setpoint. The space temperature must be below the AUX HEAT setpoint in the occupied mode before the Parallel Fan relay can be energized.

Relay #2 - Box Heat If the zone is in cooling mode or vent mode, the box heat can activate any time the zone temperature drops 1.5°F below the heating setpoint. It de-activates when the temperature rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate in the heating mode when there is hot air being supplied by the air handling unit. This output was intended to allow zone re-heat while the Zone Manager is satisfying cooling demands in other zones. The space temperature must be below the AUX HEAT setpoint in the occupied mode before the Box Heat relay can be energized.

Relay #3 - Aux Heat In the occupied mode, the aux heat can activate any time the zone temperature is 0.5°F below the aux heat setpoint. It de-activates when the temperature rises 0.5°F above the aux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heating setpoint with the same deadband values mentioned above. This prevents the zone from maintaining the same aux heat setpoint at night that it does during the daytime. This output was intended to allow zone heating to augment the normal heating mode and also to allow a zone an attempt to satisfy its own heating needs before creating a heating demand at the Zone Manager.

Relay #4 - Series Fan The series fan runs any time the main fan is running. This includes occupied and unoccupied modes. The fan can only start running when the zone damper is closed, so it determines that the damper is closed before starting the fan.


Design Guide 1-19

Index 1 inch W.C. ......................................... 10 After-Hours

Overrides........................................... 7 Air

Bypassing.......................................... 6 Air Motion .......................................... 11 Auto-Zone Plus System ........................ 8 AUX HEAT

Setpoint ........................................... 18 Auxiliary Heat

Control Board ................................... 9 Control Options............................... 17 Recommendation .............................. 7

Barometric Relief Dampers ................................. 7

Baseboard Heat ................................................. 17

Basic System Design Guide .................................... 8 Diagram............................................. 2

Boards Relay Expansion ............................. 18

Box Heat ............................................. 18 Building Pressurization......................... 7 Building Zones

Diagram............................................. 9 Bypass

Air ..................................................... 6 Plenum .............................................. 7 Return Air Intake .............................. 7

Bypass Damper Overview........................................... 3 Sizing .......................................... 8, 11

Bypass Duct Size ................................ 11 Ceiling Diffuser .................................. 11 Central Unit

Sizing .......................................... 8, 10 CFM

Correct ............................................ 16 Maximum........................................ 11

Comfort ............................................... 11

Cooling Partial Load Conditions .................... 5

Cooling Load Maximum.......................................... 8

Dampers Slaved.............................................. 13

Design Duct............................................. 8, 10 Room Air Motion.............................. 8 Zoning ............................................... 8

Design Guide ........................................ 8 Diagrams

Basic System..................................... 2 Diffusers

Ceiling............................................. 11 High Induction ............................ 11

Selection...................................... 8, 11 Slot .................................................. 11

Dimensions Rectangular Damper ....................... 14 Round Damper ................................ 14

Duct Design ........................................ 10 Considerations .................................. 8

Duct Static High................................................... 6

Duct Static Pressure .............................. 3 Ducted Returns ..................................... 6 Ducts

Undersizing..................................... 10 Ductwork

Damaging.......................................... 6 Economizer

Benefits Of ........................................ 6 Recommendation .............................. 5

Equipment Oversizing......................................... 7

Exhaust Powered............................................. 7

Exterior Zones....................................... 5 Global Override .................................... 7


1-20 Design Guide

Heat Auxiliary ........................................... 7 Baseboard........................................ 17 Supplemental..................................... 9

Heating Auxiliary ......................................... 17 Difficulties ........................................ 7 Partial Load Conditions .................... 7 Radiant Ceiling Panels.................... 17

Heating Load Maximum.......................................... 8

Heating Minimum Setpoints ................. 7 High Induction Diffusers .................... 11 High Pressure Switch

Manual Reset .................................... 6 Induction Ratio

High................................................. 11 Interior Zones........................................ 5 K Factors............................................. 16 Linear Slot Diffusers........................... 11 Load .................................................... 10

Diversity.......................................... 10 Load Calculation

Program........................................... 11 Load Estimating

Program........................................... 10 Lockout

Low Temp......................................... 5 Low Ambient Termperature Lockout ... 5 Low Supply Air Temperatures.............. 5 Low Temp Lockout............................... 5 Manual Reset

High Pressure Switch........................ 6 Maximum CFM ................................................ 11

Cooling Load .................................... 8 Duct Velocity .................................. 10 Heating Load..................................... 8

Mechanical Safeties .............................. 5 Mutliple Zones...................................... 8 Negative Pressure Area....................... 12 Noise Levels ......................................... 6 Noise Problems ................................... 10 Operation

Quiet................................................ 10 Override

After-Hours ....................................... 7 Conditions ......................................... 7

Global................................................ 7 Oversizing

Equipment ......................................... 7 Unit ................................................... 6

Overview Auto-Zone System ............................ 3 Bypass Damper ................................. 3 Zone Controller................................. 3 Zone Manager ................................... 3 Zone Sensor ...................................... 4

Parallel Fan ......................................... 18 Partial Load Conditions ........................ 5

Aggravated........................................ 7 Heating.............................................. 7

Plenum Returns..................................... 6 Powered Exhaust................................... 7 Pressure Dependent............................. 10 Pressure Independent

Flow Factors ................................... 16 Zone Dampers................................. 16

Pressurization Building ............................................ 7

Problems Noise ............................................... 10

Program Load Calculation............................. 11 Load Estimating .............................. 10

Quiet Operation................................... 10 Radiant Ceiling Panels........................ 17 Rectangular Damper

Dimensions ..................................... 14 Selection.......................................... 15

Relay Expansion Board ...................... 18 Relief Dampers

Barometric......................................... 7 Returns

Ducted ............................................... 6 Plenum .............................................. 6

Room Air Motion................................ 11 Design ............................................... 8

Round Air Damper

Dimensions ..................................... 14


Design Guide 1-21

Selection.......................................... 15 Safeties.................................................. 5 Selection

Diffuser ....................................... 8, 11 Rectangular Damper ....................... 15 Room Air Motion............................ 11 Round Air Damper.......................... 15

Series Fan............................................ 18 Boxes............................................... 11 Setpoints

AUX HEAT .................................... 18 Heating Minimum............................. 7 Static Pressure................................... 6

Sizing Bypass Damper ........................... 8, 11 Central Unit................................. 8, 10 Zone Dampers............................. 8, 13

Slaved Dampers .......................................... 13

Slot Diffusers ...................................... 11 Linear .............................................. 11

Static Pickup Probe............................. 12 Static Pressure

Setpoint ............................................. 6 Setting ............................................... 7

Static Pressure Sensor........................... 3 Location .......................................... 12

Stratification........................................ 11 Supplemental

Heat ................................................... 9 System

Design Guide .................................... 8 Overview........................................... 3 Performance ...................................... 9

Temperatures Low Supply Air................................. 5

Temperature Lockout

Low Ambient .................................... 5 Undersizing

Ducts ............................................... 10 Units

Oversizing......................................... 6 Velocity

Maximum Acceptable..................... 13 Zone

Comfort ............................................. 8 Design ............................................... 5 Diversity............................................ 5

Zone Controller Overview........................................... 3

Zone Dampers Pressure Independent ...................... 16 Sizing .......................................... 8, 13

Zone Heating Auxiliary ......................................... 17

Zone Manager Overview........................................... 3 Units Per ........................................... 8

Zone Sensor Overview........................................... 4

Zones Divided.............................................. 8 Exterior ............................................. 5 External ............................................. 9 Interior .............................................. 5 Internal .............................................. 9 Multiple............................................. 8 Number Of ........................................ 8 Overlapping ...................................... 8 Perimeter ........................................... 9

Zoning Design ............................................... 8


1-22 Design Guide

Section 2

Installation and Wiring

Table of Contents

Tips Before Beginning Installation..................................1 Zone Manager ..................................................................3

Communications Loop .....................................................8 Communications Loop Wiring Overview........................................................................9

Bypass Dampers ............................................................10

Zone Dampers................................................................13 Zone Controllers ............................................................14

Room Sensors ................................................................................................................21 Supply Air Temperature Sensor ....................................................................................23 Return Air Temperature Sensor .....................................................................................24 Outside Air Temperature Sensor ...................................................................................25 Duct Static Pressure Sensor ...........................................................................................26

Auxiliary Relay Board for Zone Controllers...................28 Zone Controller Auxiliary Relay Board Operation .......................................................29

CommLink IV Interface..................................................30 Basic System Worksheet................................................................................................33

Section 2

Installation and Wiring

Table of Figures Figure 2-1: System Overview........................................................................................2 Figure 2-2: Typical System Component Locations .......................................................2 Figure 2-3: Zone Manager Dimensions ........................................................................3 Figure 2-4: Zone Manager Component Locations.........................................................4 Figure 2-5: Zone Manager Wiring.................................................................................5 Figure 2-6: Zone Manager Address Switch Setting ......................................................7 Figure 2-7: Communication Loop Wiring, Daisy-Chain Configuration .......................9 Figure 2-8: Round and Rectangular Bypass Dampers.................................................10 Figure 2-9: Bypass Damper Wiring.............................................................................12 Figure 2-10: Round and Rectangular Zone Dampers .................................................13 Figure 2-11: Zone Controller Components.................................................................15 Figure 2-12: Zone Controller Wiring..........................................................................17 Figure 2-13: Zone Controller Address Switch Settings..............................................19 Figure 2-14: Slaved Zone Controller Wiring..............................................................20 Figure 2-15: Room Sensor Installation .......................................................................21 Figure 2-16: Room Sensor Wiring..............................................................................22 Figure 2-17: Supply or Return Air Sensor Dimensions and Installation ....................23 Figure 2-18: Outside Air Temperature Sensor Dimensions and Installation..............25 Figure 2-19: Duct Static Pressure Sensor Dimensions and Installation .....................26 Figure 2-20: Static Pressure Sensor Wiring................................................................27 Figure 2-21: Auxiliary Relay Board Layout ...............................................................28 Figure 2-22: CommLink IV Interface Communication Wiring..................................30 Figure 2-23: CommLink IV Interface Connections....................................................31 Figure 2-24: CommLink IVJumper Switch Settings ..................................................32


Installation and Wiring 2-1

Tips Before Beginning Installation Take a few moments to review the following before beginning installation of the Auto-Zone Basic Control System. • Familiarize yourself with all system components and review all documentation.

Pay special attention to “Cautions” and “Warnings” since these may keep you from experiencing unnecessary problems.

Before installing zone dampers, be sure to tag each damper with its appropriate location. It is also best to set the zone controller address switches before mounting in drop ceilings. Use the Basic System Worksheet found in the back of this section or in the Basic Submit-tal Package to list all zone locations and Zone Manager configurations. This will assist you greatly when setting up the system. • Be sure to install all wiring according to local, state, and national codes. • Pay close attention to communication wiring since the most common mistakes are

made in this area. Polarity is the most important rule. Make notes on your wiring dia-grams as to which color wire you will be using on each terminal.

• When in doubt - ask! Contact your local Auto-Zone distributor if you have any ques-

tions. The only dumb questions are the ones you don’t ask. • Remember - each electronic device contains only one puff of smoke. If you release it,

you have voided the warranty! So please be careful and pay attention.


2-2 Installation and Wiring

Figure 2-1: System Overview

Figure 2-2: Typical System Component Locations

Return Duct

Duct to Return

Supply Temp Sensor

Return Temp Sensor

(Ahead of Bypass Takeoff)

( Over Corridor for Easy Service )

(2/3 Of The Way Down Main Duct)

(Direct Airflow Inward Towards Center of Area)

(Avoid Mixed Air Area)

(Mount Away From Direct Sunlight))

(Preferred)

Bypass Damper

( Locate Where Easily Accessible )Static Pressure Pickup

Supply Duct

Zone Damper and Control

Above Corridor

Diffuser at Perimeter Wall

( Preferred Location )

Zone Sensor

Zone Manager

(4-1/2' to 5'; Shoulder Height)

Outdoor Air Sensor

LOCAL COMM LOOP

TWISTED PAIRWITH SHIELD TO

ZONE CONTROLLER

LOCAL COMM LOOP

TWISTED PAIRWITH SHIELD TO

ZONE CONTROLLER

LOCAL COMM LOOP

TWISTED PAIR WITHSHIELD TO OTHER

ZONE CONTROLLERS

NO

RM

AL

OV

R

W

A

R

M

E

R

C

O

O

L

E

R

FAN

CO

OL

1

CO

OL

2

HE

AT

1

HE

AT

2

BY

PAS

SO

PE

N

BY

PAS

SC

LO

SE

CO

MM

UN

ICATIO

N

ALA

RM

A=

ALL

ZO

NE

S

B=

EA

CH

ZO

NE

C=

HVA

CU

NIT

/CLE

AR

D=

ALA

RM

S

#=

STE

P/E

NTE

R

* =D

EC

IMA

L

+

+

+

+

®

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

(Packaged or Split System)

Typical HVAC Unit



Zone Manager The Zone Manager may be installed in any convenient, protected location. Observe the recommended environmental limitations for the Zone Manager (see Technical Data sec-tion of product data sheet) when choosing a location. The unit should be mounted with the display at eye level for easy viewing. When installing the Zone Manager with display and keypad, you must remove the cover. Use care not to damage the display while handling and protect the display from physical damage while removed. The ribbon cable should be unplugged from the display board which is mounted inside the front cover. The ribbon cable is keyed to prevent a reverse connection.

Warning: Always remove power before connecting or disconnecting the ribbon cable which joins the display and keypad to the Zone Manager. Fail-ure to observe this precaution may result in damage to the display or Zone Manager.

The Zone Manager may be mounted without removing the controller from the enclosure or mounting plate. The unit is mounted by four (4) screws in the corners. Select the cor-rect screws or other fasteners for the type of mounting material being utilized. Please see Figure 2-3, Figure 2-4, Figure 2-5, and Figure 2-6 for Zone Manager dimen-sions, components, wiring, and addressing information.

Figure 2-3: Zone Manager Dimensions

FAN

CO

OL

1

CO

OL

2

HE

AT

1

HE

AT

2

BY

PAS

SO

PE

N

BY

PAS

SC

LO

SE

CO

MM

UN

ICATIO

N

ALA

RM

A=

ALL

ZO

NE

S

B=

EA

CH

ZO

NE

C=

HVA

CU

NIT

/CLE

AR

D=

ALA

RM

S

#=

STE

P/E

NTE

R

* =D

EC

IMA

L

+

+

+

+

Cool

Mode

08-08-01

03:48PMFRI

OCCUPIED

NOALARMS

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

3.00

11.50

Keypad

Display

9.25



Figure 2-4: Zone Manager Component Locations

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

K2

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

OPEN

D1

7

R4

3R4

1

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN2

1

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

ANALOG

OUTPUTS

EXP

BUSS

ECONOMIZER

EXH/RELIEF

GND

TB8

TB5

YS101722

Rev. 2

C21 C20

X2

R4

2

D1

6

EXHAUST

CONTACTS

N.O.

TB4V2

C6U2

R7

R38

R37

C15 C16

R31

R30

R28

R27

R19

C13 C14

R14

R17

R16

R12

C7 C8

R11

TB3

GND

GND

AUX2

AUX3

SAT

RAT

OAT

AUX1

+12V

ANALOG

INPUTS

D2

D3

D5

D4

D8

D6

R15

C11

U7

CX7

Q2

PJ1

+5

V

SIG

GN

D

PRESSU

RE

SEN

SO

RJA

CK

TB1

R5

R4R2

R3

R1

U1

CX1

C4 C5

D1

R9

C1

C2 C3

VR2

VR1

SC1

24VAC

V1

R1

0

U3

CX3

U5

CX

5

Q1

R2

2

R2

1

D1

0

R2

3

R2

4

R2

0

R3

6

R2

9

R33

R35

R32

R34

CX

4

C1

2

R2

5

D1

2

VR3

R13

R26

D11

D9

R18

U6

CX

6

C17

D13

D14

D15

R39

R40

I2C EXP PORT

GND

TB2

POWER

D7

L1

C9

Y1

EW

DO

G

J0

1

U8

C18 C19

5.11V

ADJ

5.11V

ADJUST

PU1

PU2

PU3

PU4

PU5

PU6

RN1

REC

BYPASSPDAMPER

R6

1

HVAC Unit

Connections

(R) CommonFanCool 1Cool 2Heat 1Heat 2

Bypass

Damper

Connections

FDBKGNDOpenClose

RS-485

Communications

Loop Connection

TSHR

Typical

Pin 1

IndicatorRAM

ChipEPROM

Chip

PAL

Chip

RAM Size

Select

Jumper

RS-485

Communications

Driver Chip

Real Time

Clock Chip

Real Time

Clock Chip

Display &

Keypad

Ribbon Cable

Connector

Static Pressure

Sensor Inputs

+5VSIGGND

Static Pressure

Sensor - Optional

Modular Connection

Input

Comm

LED

Not Used

Address Switch

(Set To 0 WithoutCommLink. Set to 17With CommLink)

Analog Inputs

SAT

RATOATAUX1AUX2AUX3GND

Analog Output

0-10 VDCEconomizer

Binary Output

Relief/ExhaustFans

Power LED

24 VAC

Power Input

Mounting Holes

Typ. Of 4

Note:

Keypad & DisplayNot Shown



Figure 2-5: Zone Manager Wiring

Warning: Use extreme care not to damage any of the electronic components while mounting the enclosure. Mark the holes and then remove the Zone Manager before drilling. Do not allow metal shavings to fall onto the circuit boards.

Basic Zone Manager

Notes:

1.)24 VAC Must Be Connected So

That All Ground Wires Remain

Common.

3.)All Communication Wiring To Be 18

Ga. Minimum, 2 Conductor Twisted

Pair With Shield. Belden #82760 Or

Equivalent.

2.)All Wiring To Be In Accordance With

Local And National Electrical Codes

and Specifications.

RS-485Communications

To CommLinkWhen Used

RS-485Communications To Zone

Controllers

Return Air Temp.

Sensor

Suppy Air Temp.

Sensor

LineVoltage

HV

AC

Un

it

24VAC Only

Red

Blk

To Relief / Exhaust Fans

Grn

StaticPick-up


Splice AsRequired

LO HI

GND

24VAC

Belimo Actuator Wiring Shown.Consult Factory For Other

Models Of Economizer Actuators.Some Actuators Require IsolationTransformers In Order To PreventDamage To The Controller Board.

WARNING!

Use Extreme Care When Wiring

Economizer Actuators

Never Connect Or Disconnect

Wiring With Power Applied!

Never Apply Power If The

Gnd ( 1 Com ) Terminal On The

Actuator Is Not Connected.

See Note 1 &2

Outdoor Air Temp.

Sensor

(See Note 4)

Aux3Forced

OccupiedMode

Aux1Economizer

Disable

Aux2FilterAlarm

Auxiliary Inputs

( Dry Contacts )

R

G

Y1

Y2

W1

W2

Economizer Actuator

133 IN-LB

AF24-SR

1 COM

2 +

3 Y1

4 Y2

5 UBELIMO

C987

CABLE

R6

R5

HEAT 2 SW

1

W2

W1

Y2

HEAT2

HEAT1

COOL2

COOL1

FAN

HEAT 1

COOL 2

COOL 1

C 1992

11632

BNET

248

AD

D

COMM DRIVER

RS-485

75176

MADE IN U.S.A.

D1

7

D1

8

D1

9

D2

0

D2

1

D2

2

D2

3

D2

4

0* # D

R

SH

T

COMM

C1C2

+

P1

RIBBON

GN

D

G

Y1V6

V5

CLOSE

V4

V3

OPEN

GND

FDBK

FAN

CLOSE

OPEN

+

REC

+

GND

NE5090

4 5 6

KEYPAD

1 2 3

B

A

LCD DISPLAY

&

++

24VAC

TB2

POWER

+

++

ADJUST

5.11V

PJ1

++PRESSU

RE

SEN

SO

RJA

CK

+5

V

SIG

BUSS

EXP

TB2

A2

G

OUTPUTS

ANALOG

A1

N.O.

CONTACTS

EXHAUST

AUX3

GND

GND

AUX2

AUX1

ANALOG

SAT

OAT

RAT

INPUTS

+12V

TB1

2

BYPASS

BYPASS

Local Loop

OF

F>

RockerDown

Bypass & SlaveInterface Card

BypassAir Damper

Actuator

10

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2



The Zone Manager requires the following electrical connections: 18-Gauge minimum unless otherwise noted.

-24VAC Supply Voltage........................................................................... 2 Conductors -Communications Loop ...................................... 2 Conductor twisted pair with shield (Belden #82760 or equivalent) -Supply Air Temperature Sensor ........................................ (24 ga. Min.) 2 Conductors -Return Air Temperature Sensor ........................................ (24 ga. Min.) 2 Conductors -Outside Air Temperature Sensor....................................... (24 ga. Min.) 2 Conductors -Supply Static Pressure Sensor ........................................... (24 ga. Min.) 3 Conductors -Bypass Damper........................................................................................ 4 Conductors -HVAC Unit Control Wiring .....................................................................R - Common

G - Fan Y1 - Cool 1 Y2 - Cool 2 W1 - Heat 1 W2 - Heat 2 Tip: After making all electrical connections, you should unplug all terminal blocks

on the Zone Manager until you are ready to begin the checkout procedure. This may help to prevent damage if wiring errors occur elsewhere in the system dur-ing installation or start-up.



Figure 2-6: Zone Manager Address Switch Setting

Caution: Your Auto-Zone Basic Control System will not work properly unless you set the Address switch correctly. Remember, you must power down the Zone Manager after changing the address switch in order for the change to take effect.

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

R4

3

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN2

1

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

TB8

RN1

BYPASSPDAMPER



Address Switch Must Be SetTo Address 0 on Zone Manager Board

As Shown

Address Switch Must Be SetTo Address 17 on Zone ManagerBoard When CommLink Is Used

Zone ManagerAddress Switch


These Switches Must BeIn The OFF PositionAs Shown


ADD

ADD

1

1

2

2

4

4

8

8

16

16

32

32

B

B

NET

NET

AD

DA

DD

32

32

BB

NE

TN

ET

16

16

88

44

11

22

OF

F>

OF

F>

RockerDown

RockerDown

Basic System Without CommLink

Basic System With CommLink

2.)It Is Recommended That All

Controllers Address Switches Are

Set Before Installation.

3.)Power To The Zone Manager Must Be

Cycled Before Address Switch

Changes Will Take Affect.


Controllers

Notes:

1.)AllCommunication Wiring To Be

2 Conductor Twisted Pair With

Shield. Use Belden #82760 Or

Equivalent.

R

SH

T

R

SH

T

R

SH

T

R

SH

T

All Comm Loop Wiring IsStraight Thru

Local LoopRS-485

9600 Baud



Communications Loop The communications network is a two-wire shielded RS-485 loop. The loop is best con-nected in a daisy chain configuration, meaning the loop is connected from one controller to another. It is not necessary to sequentially address the zone controllers in relation to their location on the loop. Cable must be Belden No. 82760 or equivalent. Tip: Incorrect wiring of the communications loop is the most common mistake made

during installation. Before beginning installation, write down the wire color used on each terminal connection and consistently maintain that color code. It is recommended that a continuous wire run be made between devices. Any time a splice is made in the cable, you increase your chance of problems.

Caution: Make sure when you are inserting wires into the terminal blocks that strands of wire do not stick out and touch the next terminal. This could cause a short or erratic operation.

Note: The loop does not have to follow the controller address sequence.

Caution: If comm loop is not installed in conduit, be careful to position the cable away from high noise devices like fluorescent lights, transformers, VFDs, etc. Conduit is not required for comm loop wiring unless re-quired by local codes.



Communications Loop Wiring Overview The daisy chain is the best method for running a communications loop since there is only one starting point and one ending point. See Figure 2-7.

Figure 2-7: Communication Loop Wiring, Daisy-Chain Configuration

Even though the daisy chain configuration is preferred, the star configuration can also be used. If required, a combination of the two can also be used. Remember, the best comm loop wiring is the one which utilizes the minimum number of ends while using the short-est wiring path. See Figure 2-6 and Figure 2-13 for controller addressing information.



Bypass Dampers The Bypass Damper can be either round or rectangular. The Round Bypass Damper is supplied with the Damper Actuator and Bypass Wiring Interface Board factory mounted in a sheet metal enclosure attached to a Round Air Damper assembly. This Round Bypass Damper Package is field connected to the appropriate size round duct. Rectangular By-pass Dampers mount directly in the rectangular ductwork using flanged connections field formed in the rectangular ductwork. A Rectangular Bypass Damper Kit is required to complete the Rectangular Bypass Damper package. The Rectangular Bypass Damper Kit is supplied with the Damper Actuator and Bypass Wiring Interface Board factory mounted in a sheet metal enclosure. This assembly is then field mounted over the Rec-tangular Damper shaft and secured to the ductwork with sheet metal screws.

Figure 2-8: Round and Rectangular Bypass Dampers

Up to two additional Rectangular Bypass or Round Bypass Dampers can be slaved to-gether when it is not practical to use a single large damper. See Figure 2-9. The bypass damper(s) should be installed as close as possible to the rooftop unit. Round and Rectangular Bypass Dampers should be securely hung using either wire cra-dles or metal strapping. While the dampers may be hung in any position, avoid sharp kinks in flexible duct to prevent airflow restrictions. The Round Bypass Dampers are in-sulated for use in non-conditioned spaces to avoid sweating and to improve energy effi-ciency. See Figure 2-2 for a typical bypass damper mounting location. See Figure 2-9 for typical Bypass Wiring Interface Board wiring instructions.



Warning: If sheet metal screws are used to mount the dampers, be certain that they do not interfere with the movement of the damper blade.

Warning: Never depress the actuator clutch with power applied. Unplug the ac-tuator cable before depressing the clutch and attempting to rotate the damper blade. Do not force the damper blade as this can damage the gears in the damper actuator.



Figure 2-9: Bypass Damper Wiring

Warning: If the fan system has the capability of producing static pressures which could damage ductwork, you must provide a manual reset high pressure limit switch to cut-off the fan system in the event of high duct static. Do not use your Auto-Zone Basic Con-trol System as a safety device!

BYPASS ACTUATOR #3 (SLAVE)

(WHEN USED)BYPASS ACTUATOR #2 (SLAVE)

BYPASS ACTUATOR #1

(MASTER)

MODULAR CABLE

MODULAR

CABLE

MODULAR

CABLE

1 10 0

10

ZONE MANAGER BOARD

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2

V4

V3

REC

CLOSE

OPENK1

K2

NE

TW

OR

K

SH

R

T

NE5090

FDBK

GND

OPEN

CLOSE

NOT USED FORTHIS APPLICATION NOT USED FOR

THIS APPLICATION

NOT USED FORTHIS APPLICATION

FR

OM

ZO

NE

CO

NT

RO

LLER

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

101824

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2 LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2

BYPASS &

SLAVE INTERFACE CARD

BYPASS &


BYPASS &




Zone Dampers The Zone Damper can also be either round or rectangular. The Round Zone Damper is supplied with the damper actuator and Zone Controller factory mounted in a sheet metal enclosure attached to a Round Air Damper assembly. This Round Zone Damper Package is field-connected to the appropriate size round duct. Rectangular Zone Dampers mounted directly in the rectangular ductwork using flanged connections field formed in the rectangular ductwork. A Rectangular Zone Damper Kit is required to complete the Rectangular Zone Damper package. The Rectangular Zone Damper Kit is supplied with the Damper Actuator and Zone Controller factory-mounted in a sheet metal enclosure. This assembly is then field-mounted over the Rectangular Damper shaft and secured to the ductwork with sheet metal screws.

Figure 2-10: Round and Rectangular Zone Dampers

Up to two additional Rectangular Zone or Round Zone Dampers can be slaved together when it is not practical to use a single damper. See Figure 2-14. Generally this is not re-quired. Round and Rectangular Zone dampers should be securely hung using either wire cradles or metal strapping. While the dampers may be hung in any position, avoid sharp kinks in flexible duct to prevent airflow restrictions. The Round Zone Dampers are insulated for use in non-conditioned spaces to avoid sweating and to improve energy efficiency. See Figure 2-2 for typical Round Zone Damper mounting locations. See Figure 2-12 for Zone Controller wiring instructions.



Zone Controllers The Zone Controllers are mounted in snap-track which is typically located in the control enclosure on each zone damper. Orient the board in the snap-track so that the actuator, flow sensor (optional), and auxiliary relay board (optional) cables will reach their respec-tive connectors on the Zone Controller. Carefully press the board into the snap-track to avoid damaging any of the electronic components on the circuit board. To remove a board from the snap-track, carefully pull one edge of the snap-track away from the board with your fingers and remove the board.

Caution: Do not use any tools to pry the board loose. This will damage the board and/or snap-track.

Warning: When mounting the snap-track, be sure the heads of the screws do not protrude far enough to touch the bottom of the Zone Controller circuit board.

Consider serviceability of the location when mounting the Zone Controllers. They should be easily accessible to facilitate servicing. Tip: Use small stickers on the ceiling grid or tiles to help future service personnel

locate system components. If you use small stickers from an office supply store, you can get different colors to code the location of various components.



Figure 2-11: Zone Controller Components



The Zone Controller requires the following electrical connections:

24VAC Supply Voltage............................................................................ 2 Conductors

Communications Loop........................................ 2 Conductor twisted pair with shield (Belden #82760 or equivalent)

Room Temperature Sensor ...................................... 2 Conductors for standard sensors

3 Conductors for sensors with setpoint adjustment

Fan Terminal units / Auxiliary Heat...............2-4 Conductors see wiring diagrams for (Optional) Aux. Relay board Tip: After making all electrical connections, it is suggested that all terminal blocks

on the Zone Controller be unplugged until you are ready to begin the checkout procedure. This may help prevent damage if wiring errors occur elsewhere in the system during installation or start-up. This is particularly important with the Zone Controllers since an error on one unit may prevent any of the others from working until the problem is found and corrected.

Warning: Polarity is very important when connecting power to the controllers! The grounded side of the control transformer must be connected to the terminal labeled GND on the Zone Controller. If a single trans-former is used to power more than one Zone Controller, you must connect GND-to-GND and 24VAC-to-24VAC on each zone control-ler. Failure to observe polarity will result in damage to one or more components in your system.



Figure 2-12: Zone Controller Wiring



Set the Zone Controller Address Switch using the addressing instructions in Figure 2-13.

Caution: Incorrect addressing is the number one cause of communication prob-lems. Check the addressing carefully. Remember, the Zone Controller only reads the switch during a power-up. If the address switch is changed, the unit must be turned OFF and then ON before the new setting will be recognized.

Note: Ignore any markings or numbers on the switch. Use this chart!



Figure 2-13: Zone Controller Address Switch Settings



Figure 2-14: Slaved Zone Controller Wiring

SLAVED- ZONE ACTUATOR #2

(WHEN USED)SLAVED-ZONE ACTUATOR #1

ZONE ACTUATOR #1

(MASTER)

MODULAR CABLE

MODULAR CABLE

MODULAR

CABLE

MODULAR

CABLE

1 10 0

10

ZONE CONTROLLER BOARD

FR

OM

ZO

NE

CO

NT

RO

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BY

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SS

AN

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1018

24

TO

AC

TU

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OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2

FR

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CO

NT

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TO

AC

TU

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OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2

NOT USED FORTHIS APPLICATION NOT USED FOR

THIS APPLICATION

FR

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OR

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FDBK

OPEN

GND

GND

PJ1

PJ2 LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2PJ2PJ1

ACTUATOREXPANSION

BYPASS &


BYPASS &

SLAVE INTERFACE CARDBYPASS &




Room Sensors The Room Sensor uses a patented flush-mount design to isolate the temperature sensing element from the housing which mounts flush with the wall surface. Room Sensors should be located on an inside wall away from direct sunlight or heat-producing equipment such as computers, copiers, etc. Such devices can adversely affect the accuracy of the sensor. Although the sensor eliminates most of the effects of thermal coupling to the walls, try to avoid walls which retain large amounts of thermal energy (such as marble or steel). Walls containing either cold or warm air currents should also be avoided whenever possible. Avoid locating the sensor in dead air areas of a room. This will result in slow response to temperature changes in the space.

Figure 2-15: Room Sensor Installation

Mount the sensor approximately 50-60 inches from the floor for best results. The Room Sensor is designed to mount vertically in a standard 2- by 4-inch electrical box. The sen-sor may be mounted directly into the drywall where electrical codes do not require low voltage wiring to be enclosed in conduit. A template is supplied with the sensor to facili-tate cutting a hole of the correct size. Tip: Be careful when cutting the hole to make sure the sensor or the plastic bezel of

the sensor will completely cover the opening. Tip: If sensors must be installed on walls which are solid and cannot be penetrated,

surface-mounted boxes and raceway can be purchased from your local electrical distributor.



Figure 2-16: Room Sensor Wiring

Connect the terminal labeled GND on the zone sensor to the terminal labeled GND on the Zone Controller terminal block for the TEMP SENSOR. Connect the terminal labeled TMP on the zone sensor to the terminal labeled TEMP on the Zone Controller terminal block for the TEMP SENSOR. If the zone sensor has a setpoint adjust slider, connect the sensor terminal labeled AUX to the Zone Controller AUX terminal block labeled AUX1.

GND

AUX

TMP

OVR

RELO

C

REMR

O

AW

Room Sensor

Zone Controller

AUX

TEMP

GND

GND

AUX1

+VS

AUX2

TB2

++

TB1

TB1

Connection To AUXTerminal Required OnlyWhen Sensor Is SpecifiedWith Slide Adjust Option



Supply Air Temperature Sensor The supply air temperature sensor should be located as close to the rooftop unit dis-charge as possible for best response. It should also be mounted upstream of the bypass damper for best results. Locate the sensor in the center of the widest part of the duct. Use the supplied template and a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mount securely to the duct using the supplied sheet metal screws. Be sure the gasket is compressed to provide an airtight seal. For best accuracy, apply insula-tion on the outside of the duct, over the sensor. This will help prevent thermal gradients from affecting the sensor.

Figure 2-17: Supply or Return Air Sensor Dimensions and Installation

Mounting Plate

Gasket

Adhesive Backed Drill GuideMounting Template

11-1/2" (OE231)

5-1/2" (OE230) Mounting Plate

4.0"

3/4"

1/4" Hex Head Sheet Metal Screws

ThreadTogether

Duct Work

Drill 5/16" Hole In Ductwork For Probe

Leads Are Non-polarized.Butt Splice Leads To 24 GaugeWire Minimum. Connect LeadsTo "Analog In" And "Ground"At Controller.



Return Air Temperature Sensor The return air temperature sensor should be located upstream of where the Bypass con-nects to the return air duct so that the supply air does not affect the reading of the return air sensor. Avoid locations which will be exposed to extreme outside temperatures. Lo-cate the sensor in the center of the widest part of the duct. Use the supplied template and a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mount securely to the duct using the supplied sheet metal screws. Be sure the gasket is com-pressed to provide an airtight seal. For best accuracy, apply insulation on the outside of the duct over the sensor. This will help prevent thermal gradients from affecting the sen-sor.

Caution: Do not mount the return air sensor in the mixed air section. This will cause an error in the reading.



Outside Air Temperature Sensor The outside air sensor must be located where it will not be affected by direct sun or heat producing equipment. Mounting under the eve of a roof is often a good choice.

Caution: Complaints of inaccurate outside sensor readings are very common and can almost always be shown to be the result of poor sensor location.

Note: All sensors utilize the same type thermistor sensor element. For troubleshooting

sensors, refer to temperature sensor resetting instructions in section 3 of this manual.

Figure 2-18: Outside Air Temperature Sensor Dimensions and Installation

4.)All Wiring To Be In Accordance WithLocal And National Electrical CodesAnd Specifications.

3.)Gasket Must Be Installed Under CoverPlate To Provide Raintight Seal.Rainwater Can Damage Sensor!

2.)Unused Conduit Opening(s) MustHave Closure Plugs Installed And MustBe Coated with Sealing Compound ToProvide Raintight Seal. Water CanDamage Sensor!

1.)The Outside Air Sensor Must BeMounted In A Vertical Position AsShown (Sensor Tube PointingDown).

Sensor Must Be LocatedWhere It Will Not Be Affected ByDirect Sunlight Or Heat ProducingEquipment. If Possible Mount UnderRoof Eave Or Similar ProtectedLocation. If Sensor Is Not LocatedAs Specified, Erroneous Outside AirTemperature Readings Will Result.

Water Must Not Be

Allowed To Stand In Sensor

Tube. Rainwater Will Damage

Sensor.

Notes:

Closure PlugCAUTION!

See Note 2

Gasketed CoverCAUTION!

See Note3

CoverMountingScrew - Typ.

Mounting Tab& Screw - Typ.

0.21" Dia. x 0.73Lg. Slot - Typ.

4.5

0”

2.2

5”

3.00”

Front View Side View Back View

Closure PlugCAUTION!

See Note 2

Sensor TubeCAUTION!

See Note 1

Mounting Tab& Screws - Typ.

Correct

Incorrect

Incorrect

See Note #1

Sensor Mounting

Postion

2.70”

1.1

3”

2.30”

3.0

0”



Duct Static Pressure Sensor The duct static pressure sensor is designed to be mounted at the controller or on the ductwork near the pickup tube and may be connected via its modular plug. If the sen-sor is mounted on the ductwork, the modular plug must be cut off and 3-conductor wire spliced onto the sensor leads. If the trunk ducts are properly sized for minimum pressure drop, the location of the static pickup probe is not particularly critical. It should ideally be located at right angles to the airflow in a straight section of the sup-ply duct approximately ⅔ the distance of the total length of the supply duct. Also, the probe should be located not less than 3 duct diameters downstream and 2 duct diame-ters upstream of any elbow or takeoff. See Figure 1-3 in section 1 of this manual for general mounting location information.

Figure 2-19: Duct Static Pressure Sensor Dimensions and Installation

Caution: Mount the static pressure sensor on a vertical surface with the tube tips pointing downward. Avoid any kinks or sharp bends in the tubing which runs from the pickup tube to the sensor.

Warning: The plastic housing on the sensor is electrically conductive. Avoid contact with any electrical components. It is acceptable to mount the sensor on grounded sheet metal such as ductwork, electrical panels, etc.

Warning: Use extreme care when mounting the sensor to avoid damage to the plastic housing. Do not over-tighten the mounting screws! Do not use mounting screws which are too large for the holes!

OUT

IN

GND UP

(-)LO

0.35

"

0.55" 1.00"

2.20

"

0.15

" DIA

.0.

15"

2.94

"

2.50

"

0.12

5" (1

/8" T

ubin

g C

onn.

)

0.20

0" (3

/16"

Tub

ing

Con

n.)

1.95

"

0.60

"

12.0

" APP

RO

X.

1.29

"

OUT (Black)

GND (Green)

IN (Red)

OE2

71S.

P. S

enso

r



Tip: Having at least 10-20 feet of tubing between the pick-up tube and the pressure

sensor will improve control performance by acting as a “filter” to remove pres-sure fluctuations caused by turbulence in the duct.

Figure 2-20: Static Pressure Sensor Wiring

Note: Refer to Figure 1-3 in section 1 of this manual for instructions concerning

proper location of the static pressure sensor.



Auxiliary Relay Board for Zone Controllers An optional auxiliary relay board is available for the Zone Controllers. This board pro-vides additional outputs for the following applications: • Parallel Fan • Box Heat • Auxiliary Heat (typically perimeter type) • Series Fan The board comes shipped with a modular cable which plugs directly into the Zone Control-ler connector marked “Expansion.” After connecting the board, the system will need to be powered OFF and then ON for the system to recognize the presence of the relay board.

Figure 2-21: Auxiliary Relay Board Layout

Warning: Relay contacts are rated for 24VAC pilot duty only! Do not apply voltages higher than 24VAC.



Zone Controller Auxiliary Relay Board Operation

Relay #1 - Parallel Fan If the zone is in cooling mode or vent mode, the parallel fan relay will activate any time the zone temperature drops 0.5°F below the heating setpoint. It de-activates when the temperature rises 0.5°F above the heating setpoint. The space temperature must be below the AUX HEAT setpoint in the occupied mode before the Parallel Fan relay can be ener-gized.

Relay #2 - Box Heat If the zone is in cooling mode or vent mode, the box heat relay will activate any time the zone temperature drops 1.5°F below the heating setpoint. It de-activates when the tem-perature rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate in the heating mode when there is hot air being supplied by the air handler. This output was intended to allow zone re-heat while the Zone Manager is satisfying cooling de-mands in other zones. The space temperature must be below the AUX HEAT setpoint in the occupied mode before the Box Heat relay can be energized.

Relay #3 - Aux Heat In the occupied mode, the aux heat relay will activate any time the zone temperature is 0.5°F below the aux heat setpoint. It de-activates when the temperature rises 0.5°F above the aux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heating setpoint with the same deadband values mentioned above. This prevents the zone from maintaining the same aux heat setpoint at night that it does during the daytime. This output was intended to allow zone heating, to augment the normal heating mode, and also to allow a zone to attempt to satisfy its own heating needs before creating a heat-ing demand at the Zone Manager.

Relay #4 - Series Fan The series fan relay is energized any time the main fan is running. This includes occu-pied and unoccupied modes. In the unoccupied mode, the fan can only start when the zone damper is closed. The controller checks to be sure the damper is closed before start-ing the fan.



CommLink IV Interface The optional CommLink IV is used to transfer communications between controllers on your control system loops. It can also be used as an interface for connection of a com-puter to your system. The CommLink IV provides communication with any controller on the control system through a computer that is running Prism software or it can be used to communicate with most controllers by using only the Zone Manager. For remote com-munications, an IP Module Kit can be installed for LAN and Internet connections or a Remote Link II can be connected for dial-up connections.

Figure 2-22: CommLink IV Interface Communication Wiring

Locate the CommLink near the computer or modem. The cable connections between the CommLink and the computer or modem should be kept to less than 25 feet. The CommLink comes complete with computer and modem cables and a plug-in power supply. There is an optional IP Module that installs into the CommLink and provides TCP/IP Internet connection and an optional Remote Link II for dial-up connection or alarm call-outs. The Zone Manager address switch must be set to 17 when the CommLink is installed on the Auto-Zone Basic Control System. Also the jumper switch located on the CommLink circuit board must be set for single loop operation. See Figure 2-23 and Figure 2-24 for details.



Figure 2-23: CommLink IV Interface Connections



Figure 2-24: CommLink IV Jumper Switch Settings



Basic System Worksheet Project: _______________________ Location ______________________________________________

CommLink Installed: Yes No Remote Link Installed: Yes No Phone: _________________

Stages of Cooling ____ Stages of Heating ____ Gas Electric Economizer Yes No

Zoning: Pressure Dependent Pressure Independent

Zone Address

Zone Description or Location

Air Damper

Size

Room Sensor Type

Relay Exp. Board

1 S SO SA SOA AH BH SF PF
















[S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint adjust] [AH=Auxiliary Heat] [BH=Box Reheat] [SF=Series Fan Terminal] [PF=Parallel Fan Terminal]



Index 24VAC-to-24VAC.............................. 16 Actuator Cable .................................... 11 Actuator Clutch................................... 11 Address Sequence ................................. 8 Addressing

Checking ......................................... 18 Incorrect .......................................... 18 Zone Controller................................. 1 Zone Manager ................................... 7

Airflow Restrictions Preventing ................................. 10, 13

AUX Terminal.......................................... 22

Aux Heat ............................................. 28 AUX HEAT ........................................ 28 AUX1

Terminal.......................................... 22 Auxiliary Heat..................................... 27 Auxiliary Relay Board ........................ 27

Layout Diagram .............................. 27 Belden No. 82760 ................................. 8 Box Heat ....................................... 27, 28 Bypass Damper

Overview......................................... 10 Wiring ............................................. 12

Bypass Dampers Insulated.......................................... 10 Rectangular ..................................... 10 Round.............................................. 10

Bypass Wiring Interface Board........... 10 Cable

Actuator .......................................... 11 Belden No. 82760 ............................. 8 Splice ................................................ 8

Cables Auxiliary Relay Board .................... 14 Flow Sensor .................................... 14

Codes Wiring ............................................... 1

Color Code ............................................ 8

CommLink IV

Connections Diagram...................... 30 Jumper Switch Settings................... 31 Overview......................................... 28 Wiring ............................................. 29

Communication Problems Addressing Incorrectly.................... 18

Communications Loop.......................... 8 Wiring Overview .............................. 9

Component Locations ........................... 2 Components

Damage To...................................... 16 Zone Manager ................................... 4

Conduit.................................................. 8 Configuration

Daisy Chain....................................... 8 Cooling Mode ..................................... 28 Daisy Chain

Configuration .................................... 8 Damper Actuator

Gears, Damaging............................. 11 Overview......................................... 10

Damper Blade ..................................... 11 Forcing ............................................ 11

Dampers Tagging ............................................. 1

Dial-Up Connections .......................... 29 Dimensions

Zone Manager ................................... 3 Duct Static Pressure Sensor ................ 25

Mounting......................................... 25 Ductwork

Static Pressures ............................... 12 Electrical Connections

Zone Manager ................................... 6 Energy Efficiency

Improving.................................. 10, 13 Environmental Limitations

Zone Manager ................................... 3 Fluorescent Lights................................. 8



GND-to-GND ..................................... 16 Heating

Setpoint ........................................... 28 High Pressure Limit Switch

Manual Reset .................................. 12 Incorrect

Wiring ............................................... 8 Installation

Room Sensor................................... 21 SAT or RAT Sensor........................ 23 Zone Manager ................................... 3

Installing Zone Manager ................................... 3

IP Module Kit ..................................... 29 Kinks ................................................... 10

Avoiding ................................... 13, 25 LAN and Internet connections............ 29 Manual Reset

High Pressure Limit Switch ............ 12 Metal Shavings ..................................... 5 Metal Strapping............................. 10, 13 Mounting

Duct Static Pressure Sensor ............ 25 Outside Air Sensor.......................... 24 Room Sensor................................... 21 Snap-Track...................................... 14 Supply Air Temperature Sensor ..... 23 Zone Controllers ............................. 14 Zone Manager ................................... 3

Occupied Mode................................... 28 Operation

Auxiliary Relay Board .................... 28 Outside Air Sensor

Installing ......................................... 24 Location .......................................... 24 Mounting......................................... 24

Outside Sensor Readings Inaccurate........................................ 24

Parallel Fan ................................... 27, 28 Plastic Bezel........................................ 21 Polarity............................................ 1, 16 Prism ................................................... 29 Rectangular Zone Damper

Overview......................................... 13 Remote Link II.................................... 29 Return Air Temperature Sensor

Installing ......................................... 23 Location .......................................... 23 Mounting......................................... 23

Ribbon Cable ........................................ 3 Room Sensor

Installation ...................................... 21 Mounting......................................... 21 Wiring ............................................. 22

Room Sensors Best Location .................................. 21 Location .......................................... 21 Overview......................................... 21

Round Air Damper.............................. 10 Round Zone Damper

Overview......................................... 13 RS-485 Loop......................................... 8 Safety Device ...................................... 12 Sensor

Accuracy ......................................... 21 Series Fan...................................... 27, 28 Setpoints

AUX HEAT .................................... 28 Heating............................................ 28

Sheet Metal Screws............................. 11 Slaved............................................ 10, 13 Slaved Zone Controller Wiring........... 20 Snap-Track

Mounting......................................... 14 Splicing

Cable ................................................. 8 Star Configuration................................. 9 Static Pressure Sensor

Wiring ............................................. 26 Supply Air

Temperature Sensor ........................ 23 Supply Air Temperature Sensor

Location .......................................... 23 Mounting......................................... 23

Sweating Avoiding ......................................... 13 Improving........................................ 10

System Component Locations........................................... 2

System Overview

Diagram............................................. 2



Tagging Dampers ............................................ 1

TEMP Terminal.......................................... 22

TEMP SENSOR.................................. 22 Temperature Sensor

Return Air ....................................... 23 Supply Air....................................... 23

Thermistor Sensor............................... 24 Transformers ......................................... 8 Unoccupied Mode............................... 28 Vent Mode .......................................... 28 VFDs ..................................................... 8 Wire

Color Code ........................................ 8 Wire Color ............................................ 8 Wire Cradles ................................. 10, 13 Wiring ................................................... 1

Bypass Damper ............................... 12 Codes................................................. 1 CommLink IV................................. 29 Communications Loop...................... 9 Incorrect ............................................ 8 Room Sensor................................... 22 Star Configuration............................. 9 Static Pressure Sensor..................... 26 Zone Controller......................... 17, 20

Zone Manager ................................... 5 Worksheet Basic System................................... 32 Zone Controller

Address Switch Settings ................. 19 Address Switches .............................. 1 Component Diagram....................... 15 Damage Prevention......................... 16 Electrical Connections .................... 16 Setting Address ............................... 19 Slaved Wiring ................................. 20 Wiring ............................................. 17

Zone Controllers Mounting......................................... 14 Overview......................................... 14

Zone Damper ...................................... 13 Overview......................................... 13

Zone Manager Addressing Switch ............................ 7 Board................................................. 4 Dimensions ....................................... 3 Electrical Connections ...................... 6 Environmental Limitations ............... 3 Installation ........................................ 3 Mounting........................................... 3 Ribbon Cable .................................... 3 Wiring ............................................... 5

Section 3

Programming

Table of Contents LCD/Keypad Operations...................................................1

Main Screen Access.........................................................................................................1 Data Entry Functions .......................................................................................................2

Zone Summary Screen.....................................................2 Individual Zone Status Screens.......................................3 Zone Manager Status Screens ........................................5 Alarm Status Screens ......................................................7 Entering Passcodes .........................................................9 Main Menu Operation.......................................................9 Zone Controller Setpoints..............................................10 Zone Manager Setpoints................................................14

Week Schedules .............................................................................................................14 Holidays .........................................................................................................................15 Setting Time & Date ......................................................................................................16 Control Setpoints ...........................................................................................................16

Zone Manager Configuration .........................................20 System Overrides...........................................................24 Zone Manager Operations Summary .............................26


Programming 3-1

LCD/Keypad Operations

Main Screen

The Auto-Zone Zone Manager is your direct link into the status and setpoints of any Zone Controller on your communications loop. With the Zone Manager, you can view any temperature or output condition and change any setpoint to fine tune the operations of the total system. All keypad operations are simple and straightforward and use non-cryptic plain English messages. The remainder of this section will lead you through the system menus and keypad operation.

Main Screen Access

Keypad Layout

Vent Mode 03/19/02 03:05pm Tue Occupied 1 Alarm(s) 3

A - Summary Select the Zone Controller Summary Screen

B - Status Select Individual Zone Status Screens

C - Status Select the Zone Manager Status Screens

D - Alarms Select the Alarm Status Screens

# - Menu Select the Main Menu Screen

Current Polling Address


3-2 Programming

Data Entry Functions

Zone Summary Screen To see a summary of all attached Zone Controllers, press the "A" key while the Main Screen is active. The following screen will appear. Zones are shown in groups of three. Step to each additional screen by pressing the "#" key. If there are not three units available for any given screen, the remaining lines on that screen will be blank.

etc.

Note: The temperature displayed includes the slide effect offset.

A - Abort Used to exit from screens or from data entry. Use this key to return to the Main Menu from any screen in the system.

B - Backup Use this key to step backwards to previous screens or setpoints.

C - Clear If a data entry mistake is made, press this key to clear the data entry field and start over.

D - Negative If entering a setpoint that is negative in value, press this key for the minus sign.

* - Decimal Use this key as the decimal point when entering decimal values.

# - Enter Use this key to close a data entry field and advance to the next item or screen.

Zone TEMP CLSP HTSP 4 74.2 77.0 74.0 5 73.1 75.0 72.0 6 76.4 75.0 72.0


Zone TEMP CLSP HTSP 16 74.2 77.0 74.0


Programming 3-3

Individual Zone Status Screens To see the complete status of any attached Zone Controller, press the "B" key while the Main Screen is active. The following screens will appear. Step to each additional screen by pressing the "#" key. Press the "A" key to exit before all status screens have been viewed. If a zone doesn't respond, the screen will display " *** Missing *** ". If the zone is currently in the Calibration mode, the screen will display "Calibrating." No status or setpoints are available during calibration. Note: The top line of every status screen shows the selected zone address.

Status Screen #1

Status Screen #2

Line 2 - Unoccupied Mode Occupied Mode Push-button Override Force Mode Active!

Line 3 - Voting Unit Non-Voting Unit

Zone Number 1 Occupied Mode Voting Unit

Zone Number 1 Temperature: 75.4 CSP 75.0 HSP 72.0 Slide Adjust.: 0.0

Line 2 - Current Zone Temperature

Line 3 - Current Cooling Setpoint (CSP) & Heating Setpoint (HSP)

Line 4 - Optional Sensor Slide Adjust effect on Setpoints


3-4 Programming

Status Screen #3

Status Screen #4

Line 2 - Current Zone Damper Position

Line 3 - Currently active Minimum Damper/Airflow Setpoint. Each mode has its own minimum setpoint. These modes are vent, cooling and heating.

Line 4 - Currently active Maximum Damper/Airflow Setpoint. This value is user adjustable and is used in all modes of operation, unlike the Minimum Damper/Airflow Setpoint.

Zone Number 1 Damper Pos 20 Minimum Setpt 20 Maximum Setpt 100

Line 2 - Auxiliary Heat Off Box Heating On Aux Heating On Box & Aux Heat On

Line 3 - Series Fan On or Blank Line if Fan is Off

Line 4 - Parallel Fan On or Blank Line if Fan is Off

Zone Number 1 Auxiliary Heat Off Series Fan On


Programming 3-5

Zone Manager Status Screens To see the Zone Manager status, press the "C" key while the Main Screen is active. The following screens will appear. Step to each additional screen by pressing the "#" key. Press the "A" key to exit before all status screens have been viewed.

Status Screen #1

Status Screen #2

Line 2 - Current Supply Air Temperature

Line 3 - If the system is configured for VAV operation, this line shows the current Static Pressure in the duct. It is displayed in Inches of Water Column.

Line 4 - If the system is configured for VAV operation, this line shows the current Bypass Damper position currently required to maintain the displayed amount of Static Pressure.

HVAC Status Supply Air 78.6 Static Press 0.49 Bypass Damper 24%

Line 2 - Current Return Air Temperature

Line 3 - Current Outdoor Air Temperature

Line 4 - Current Economizer Damper Position if the system is configured for Economizer control.

HVAC Status Return Air 75.3 Outdoor Air 70.2 Economizer 20%


3-6 Programming

Status Screen #3

Status Screen #4

Line 2 - The currently Active Cooling Stages are displayed on this line. You can see the first two stages from the LED display on the front panel. This screen allows you to view systems with more than two stages of cooling and see how many are active.

Line 3 - The currently Active Heating Stages are displayed on this line. The same LED information is available for heating as described above.

Line 4 - If the optional Economizer Module has been installed on your system, this line will show the currently calculated Wetbulb Temperature.

HVAC Status Active Cool Stage: 0 Active Heat Stage: 0 Wetbulb Temp: xxx.x

HVAC Status Mavericks 0 Cool Total 0.0 Heat Total 0.0

Line 2 - The Zone Manager knows if any units have had a four-degree demand for at least one hour. It totals them up and displays this value as the total number of Maverick Zones.

Line 3 - As the Zone Manager polls its Zone Controllers, it totals up the heating and cooling demand so it can make an HVAC decision. The Cooling Total is displayed on this line.

Line 4 - The Heating Total, from the zone polling, is displayed on this line.


Programming 3-7

Alarm Status Screens If the last line on the Main Screen displayed one or more active alarms, you can press the "D" key while on the Main Screen to display a list of detected alarms. Each screen displays one alarm at a time. If no alarms are present when you press the "D" key, the message "No Alarms" will be displayed on the alarm screen.

Status Screen #1

Line 3 - Possible Alarm Messages that can be displayed, one at a time, on this line.

Zone Manager Messages Bad Supply Air Sensor Static Sensor Alarm Damper Feedback Fail Damper Opening Alarm Damper Closing Alarm Auxiliary Alarm COOLING FAILURE! HEATING FAILURE! OAT Broadcast Lost

Zone Controller Messages Missing Zone 1 Zone Damper Fail 1 Bad Zone Sensor 1 Maverick Zone 1 All Zone Controller messages are followed by the address of the unit that is causing the alarm. If any alarms are present, the Alarm LED on the Front Panel will be active, alerting you at a distance that an alarm is present.

Alarm Status No Alarms


3-8 Programming

Alarm Definitions Cooling Failure! or Heating Failure! - Once the heating or cooling is activated, the

Supply Air Temperature has 30 minutes to change by at least 5°F, or the Zone Manager assumes a mechanical failure has occurred and generates an alarm.

Bad Supply Air Sensor or Bad Zone Sensor

- The Zone Manager or Zone Controller was unable to detect the appropriate sensor installed.

Bypass Feedback Fail - During calibration the controller does not receive a signal from the Bypass Damper Actuator Feedback Pot.

Damper Opening Alarm - The Bypass Damper Actuator does not travel the full open position on a call to open.

Damper Closing Alarm - The Bypass Damper Actuator does not travel to its full closed position on a call close.

Static Sensor Alarm - The current static pressure reading has been above 3.0 inches or below 0.01 inches for more than 30 seconds.

Missing Zone - The Zone Manager has been out of contact with a specific zone for 5 consecutive pollings.

Zone Damper Fail - The zone damper either failed the startup calibration or it has stopped responding to commands.

Auxiliary Alarm - A contact closure is detected on the AUX2 input

Maverick Zone - The identified zone has exceeded a 4°F heating or cooling demand for at least 1 hour.


Programming 3-9

Entering Passcodes Any time you are prompted to enter a passcode, the following screen will appear. The actual passcode digits are never displayed. Instead, an "X" is placed on the screen for every digit entered, as a place holder, to allow you to know which digit you are entering. The default passcode is "1111" and is programmable to any other four-digit value.

Passcode Request

Main Menu Operation To gain access to the system setpoints and configurations, press "#" while on the Main Screen to select the Main Menu. There are four selections available on the Main Menu. Selection of the second item, Manager Setpoints, opens a second menu screen, shown later in this section. To return to the Main Screen from any other screen, press the "A" key until the Main Screen appears.

Main Menu

For detailed information on each of the Main Menu selections, refer to the appropriate paragraph heading as noted below. 1) Read/Reset Zones Zone Controller Setpoints 2) Manager Setpoints Zone Manager Setpoints 3) Configure System Zone Manager Configuration 4) System Overrides System Overrides

THIS ACTION REQUIRES PASSCODE CLEARANCE Enter Passcode: xxxx

1) Read/Reset Zones 2) Manager Setpoints 3) Configure System 4) System Overrides


3-10 Programming

Zone Controller Setpoints You will be prompted to enter the address of the Zone Controller that you want to read or reset. If you enter a non-existent zone address, the screen will display "*** Missing ***" and no setpoint screens will be displayed.

Zone Selection Screen

Note: The top line always displays the currently selected Zone Controller and the

controller type. PD ZONE ADDRESS means a Pressure Dependent Box is selected. PI ZONE ADDRESS means a Pressure Independent Box is selected.

Setpoint Screen #1

Minimum Default Maximum Cooling Setpoint 50°F 75°F 90°F Heating Setpoint 50°F 72°F 90°F

SELECT ZONE ENTER ADDRESS: 1

Enter the Occupied Heating and Cooling Setpoints on this screen. The Heating Setpoint should always be two degrees below the Cooling Setpoint or the Zone Controller will not accept the new values. The Zone Manager can't prevent the entry of invalid setpoints. If invalid setpoints are entered, the previous settings will be retained by the system and displayed the next time the Zone Setpoints are accessed.

PD ZONE ADDRESS 1 OCCUPIED SETPOINTS Cooling Setpt: 75 F Heating Setpt: 72 F


Programming 3-11

Setpoint Screen #2

Minimum Default Maximum Cool Setback 0°F 10°F 30°F Heat Setback 0°F -10°F -30°F

Setpoint Screen #3

Minimum Default Maximum AuxHeat Setpt 50°F 72°F 90°F Slide Effect 0°F 3°F 5°F

Note: If slide effect is set to 0°, the push-button override will not function.

Setpoint Screen #4

Minimum Default Maximum PD Zone Max Damper PI Zone Max Airflow

0% 0 CFM

100% 800 CFM

100% 30000 CFM

PD Zone Cool Mode Min PI Zone Cool Mode Min

0% 0 CFM

5% 200 CFM

100% 30000 CFM

PD Zone Heat Mode Min PI Zone Heat Mode Min

0% 0 CFM

20% 300 CFM

100% 30000 CFM

Enter the Unoccupied Heating and Cooling Setback values on this screen. The Occupied Cooling Setpoint will be increased by the Cooling Setback during Unoccupied Mode and the Heating Setpoint will be decreased by the Heating Setback.

PD ZONE ADDRESS 1 UNOCCUPIED SETPOINTS Cool SetUp...: 10 F Heat Setback.: -10 F

If your Zone Controller has the optional Relay Expansion Boardattached, one of the relays is reserved for an Auxiliary Heating Relay. Enter that setpoint on the AuxHeat Setpt line. If the relay board is not installed, this line will not be displayed. If your Zone Temperature sensor has the optional Setpoint Adjustment Slide, enter the maximum effect it can have on the setpoints on the Slide Effect line.

PD ZONE ADDRESS 1 AuxHeat Setpt: 72 F Slide Effect.: 3 F

PD ZONE ADDRESS 1 Max Damper....: 100% Cool Mode Min.: 5% Heat Mode Min.: 20%

On Pressure Dependent Zones, these setpoints are for damper position. On Pressure Independent Zones they are for Airflow (CFM) values, and the text will change to reflect that.


3-12 Programming

Setpoint Screen #5A

Minimum Default Maximum PD Zone Vent Mode Min 0% 50% 100% PD Zone Nite Mode Min 0% 100% 100%

Setpoint Screen #5B

Minimum Default Maximum PI Zone Vent Mode Min 0 CFM 500 CFM 30000 CFM PI Zone Nite Mode Min 0 CFM 0 CFM 30000 CFM PI Zone CFM @1" WG 0 CFM 2100 CFM 30000 CFM

Setpoint Screen #6

On Pressure Dependent Zones, the setpoints displayed are for damper position.

PD ZONE ADDRESS 1 Vent Mode Min.: 50% Nite Mode Min.: 100%

For Pressure Independent Zones the text changes to display airflow (CFM) values. On the third line - "CFM@1" WG", enter the appropriate "K" Flow Factor from Table 1-2 of this manual.

PD ZONE ADDRESS 1 Vent Mode xxxxx CFM Nite Mode xxxxx CFM CFM @1”WG xxxxx CFM

PD ZONE ADDRESS 1 Overrides..: Global Damper Mode: Direct PRESS (*) TO TOGGLE

The Zone Controller will respond to another zone’s push-button override if it is configured for global overrides. If single overrides are selected, the zone will only enter override if its own push-button is pressed. The normal damper operation is direct acting, which means it opens in a clockwise direction. If your system opens in a counter-clockwise direction, select reverse acting mode.


Programming 3-13

Setpoint Screen #7

Setpoint Screen #8

Note: The Thermistor Type III Sensors have a 0.4 degree accuracy. Tip: This calibration offset is also useful as a troubleshooting tool. If you need to

simulate a heating or cooling mode, you can raise or lower the current zone temperature far enough to put the zone into the desired mode.

Caution: The normal calibration offset should be a fairly small value. If you need several degrees of offset, there might be a sensor problem or a location problem.

PD ZONE ADDRESS 1 Voting Mode: Voting PRESS (*) TO TOGGLE

Normally, you want a zone to be included in the polling by the Zone Manager. This allows the demand in that zone to have a vote in determining the HVAC mode of operation. If you have a problem zone or an area that you don't want to include in the voting, select the NonVote mode of operation.

PD ZONE ADDRESS 1 Sensor Calibration Rdg Offset Zone: 75.4 0.0

If you have a tenant that doesn't agree with the current zone temperature reading, you can adjust or calibrate the zone temperature reading. Enter a positive number if the current reading is too low. Enter a negative number if the current reading is too high.


3-14 Programming

Zone Manager Setpoints The Zone Manager Setpoints are kept separate from the Zone Manager Configuration setpoints since these are the most commonly changed values. Enter the number shown below for the desired selection. When you are finished, press the "A" key to return to the Main Menu.

Zone Manager Setpoint Menu

Week Schedules Schedule Start Time

Schedule Stop Time

Note: The second line displays which day of the week is currently being programmed.

This automatically increments as you finish the Stop Time and continue to the next Start Time screen.

1) Control Setpoints 2) Schedules 3) Holidays 4) Time & Date

WEEK SCHEDULES Sunday Stop Time Enter Hrs/Mins: 0 (MILITARY FORMAT)

The screens will step through the Start Time and then the Stop Time for each day of the week. You can quit at any point in the process by pressing the "A" key. All times are in 24-hour format, so 5:00 PM would be entered as 1700.

WEEK SCHEDULES Sunday Start Time Enter Hrs/Mins: 0 (MILITARY FORMAT)

If both the Start and Stop Times are ZERO, the schedule is in a continuous OFF mode. If both the Start and Stop Times are 2359, the schedule is in a continuous ON mode.


Programming 3-15

Holidays

Holiday Day Selection

Holiday Start/Stop Times

The screens will step through the eleven possible holidays one at a time. Line 2 shows which holiday is currently being programmed. Remember to combine the month and day into a single four- digit value. EXAMPLE: 704 = July 4th

1225 = December 25th

Program Holidays Holiday # 1 Start Mon/Day: 101 (EX: 101 = Jan. 1)

The eleven holidays all use the same Start and Stop time which is entered on this screen. It is entered in 24-hour military format, the same as a regular week schedule.

Holiday Schedule Starting Time: 0 Stopping Time: 0


3-16 Programming

Setting Time & Date The Zone Manager has its own built-in real time clock. Although the times are displayed on the Main Screen in a standard 12-hour format, they are programmed using the 24-hour military format. If the Zone Manager was configured to use its own Internal Schedules, the Occupied/Unoccupied modes are calculated on the basis of the current real time clock reading.

Programming Time

Programming Date

Daylight Savings Adjustments

Day - Enter the Day of the Week (0 to 6) with Sunday = 0

Hours (Hr) - Enter Hours in 24-Hour Military Format (1700 = 5:00 PM)

Minutes - Enter the Minutes (0 to 59)

Program Time/Date Day (Sunday=0): 2 Enter Hr.(0-23): 14 Enter Min : 53

Month - Enter the Month (1 to 12)

Day - Enter the Day of the Month (1 to 31)

Year - Enter the current Year with two digits (00 to 99)

Program Time/Date Month (1-12): 3 Day (1-31): 19 Year (00-99): 02

If your area of the country requires Daylight Savings changes, the Zone Manager can automatically make the adjustment for you. This used to be the first Sunday in April and the second Sunday in October. However, the U.S. government has now decided to arbitrarily change these dates from time to time. So we recommend that you disable these automatic adjustments by pressing the "*" key to select Adjustments Disabled and make the adjustments yourself each year.

Daylight Savings Adjustments Enabled Press (*) To Toggle


Programming 3-17

Control Setpoints

Setpoint Screen #1

Minimum Default Maximum

Static Press 0.1" 0.5" 2.0"

Setpoint Screen #2

Minimum Default Maximum Cool Lockout -30°F -30°F 80°F Heat1 Lockout 30°F 65°F 99°F Heat2 Lockout 30°F 45°F 99°F

Manager Setpoints Static Press: 0.5”

If you have configured for variable HVAC type, this screen will be displayed to allow you to enter the controlling Static Pressure Setpoint.

Enter the Mechanical Cooling and Heating Lockouts on this page. There are two heating lockouts. Heat1 Lockout is for Stage #1 only, and Heat2 Lockout is for Stages #2 and up. This allows energy conservation during Spring and Fall conditions when a single stage of heating could handle the load.

Manager Setpoints Cool Lockout: 50 Heat1 Lockout: 65 Heat2 Lockout: 45


3-18 Programming

Setpoint Screen #3

Minimum Default Maximum Cool Staging 1 Min 4 Min 30 Min Min Cool Off 1 Min 4 Min 30 Min Heat Staging 1 Min 4 Min 30 Min Min Heat Off 1 Min 4 Min 30 Min

Setpoint Screen #4

Minimum Default Maximum Interval 1 Min 10 Min 30 Min

Setpoint Screen #5

Minimum Default Maximum Closed Volts 0.0 VDC 0.0 VDC 10.0 VDC Opened Volts 0.0 VDC 10.0 VDC 10.0 VDC

The heating and cooling stages must have been off for a minimum amount of time before they can be activated or re-activated. As each additional stage of heating or cooling is added, a minimum Staging Delay period must be satisfied between each additional stage required.

Cool Staging: 4 Min Min Cool Off: 4 Min Heat Staging: 4 Min Min Heat Off: 4 Min

If the Zone Manager needs to change HVAC modes between heating and cooling, a Changeover Delay time must be satisfied first. This prevents "chasing" due to alternate hot and cold air always being supplied to the zones after short intervals.

Manager Setpoints Heat/Cool Changeover Interval....: 15 Min

If the Zone Manager has been configured for Economizer Control, this screen will appear. You can set the voltages required to open and closed the damper. Some actuators use a 2-10 VDC signal instead of 0-10 VDC.

If the system is not configured for Economizer Control, no economizer setpoint screens will appear.

Economizer Setpoints Closed Volts: 0.0 Opened Volts: 10.0


Programming 3-19

Setpoint Screen #6

Minimum Default Maximum Econo Enable -30°F 50°F 99°F Supply Setpt 45°F 50°F 80°F Min Econo % 0% 20% 100%

Setpoint Screen #7

Minimum Default Maximum Interval .1 50 90.0

Setpoint Screen #8

Minimum Default MaximumSupply Sensor SAT -100.0°F 0.0°F +100.0°F Return Sensor RAT -100.0°F 0.0°F +100.0°F Outdoor Sensor OAT -100.0°F 0.0°F +100.0°F

The Econo Enable setpoint is the outdoor air or wetbulb temperature that enables the Economizer to open past its minimum position setpoint to control supply air temperature.

The Supply Setpt is the supply air temperature the Economizer tries to maintain.

The Min Econo % is the position the economizer holds during occupied mode when it is not enabled for operation due to outdoor air or wetbulb temperature.

Economizer Setpoints Econo Enable: 50 Supply Setpt: 50 Min Econo % : 20%

Economizer Setpoints Economizer Interval Seconds.....: 50.0

Sensor Rdg Offset SAT.: 82.9 0.0 RAT.: 77.2 0.0 OAT.: 70.2 0.0

During Economizer control, the Economizer damper is allowed to move open or closed, as required at a rate controlled by this value. Use this setpoint to speed up or slow down the operation of your economizer. The larger the number, the slower the damper will move.

As described in the Zone Controller section, the Thermistor Type III sensor readings can be calibrated. The Outdoor Air Calibration Offset only applies to the Zone Manager that has the sensor installed. It has no effect on the global broadcast value of outdoor air.


3-20 Programming

Zone Manager Configuration Normally, the configuration setpoints need to be entered only one time. For this reason, they occupy their own menu location and need not be addressed during normal setpoint read and reset operations. To access the configuration setpoints, press the "3" key while on the Main Menu screen. Note: On initial power up, the system must be configured before it can be successfully

operated.

Configuration Screen #1

Minimum Default Maximum Last Zone Addr 1 1 16 First Zone Addr 1 1 16 Cooling Stages 0 1 6 Heating Stages 0 1 6

Caution: The zones should be consecutively addressed with no skipped address locations. If an address is skipped, the Zone Manager will presume there is a missing zone, and an alarm will occur.

The Zone Manager needs to know the address range of the attached Zone Controllers to be polled. Enter the addresses of the first and last zones here. The quantity of cooling and heating stages is also entered on this screen.

Last Zone Addr: 1 First Zone Addr: 1 Cooling Stages: 1 Heating Stages: 1


Programming 3-21




Heat Type.: Electric Fan Mode.: Constant PRESS (*) TO TOGGLE

Economizer: Enabled PRESS (*) TO TOGGLE

HVAC Type: Variable PRESS (*) TO TOGGLE

The Zone Manager can control electric or gas heating. Each type of heat has its own protection limits built into the Zone Manager software. The Zone Manager can also operate the fan in one of two modes: Constant (Continuous) running during occupied hours. Cycle with heating or cooling during occupied hours. The fan always cycles with heating or cooling during unoccupied hours.

The Zone Manager has the ability to control the Economizer operation. To initiate Economizer operation, select Enabled. To toggle between the two Economizer modes, press the "*" key.

The Zone Manager normally reads the duct static pressure and controls it via the bypass damper. If your system doesn't require static pressure control, select the Constant mode of operation. To toggle between the two modes, press the "*" key.


3-22 Programming




The Zone Manager Bypass Damper normally opens in a clockwise direction. If your bypass damper opens in a counter-clockwise direction, select reverse acting instead of direct acting operation. To toggle between the two modes, press the "*" key.

Bypass Act: Direct PRESS (*) TO TOGGLE

The Zone Manager normally uses its own real-time clock and an internal week schedule to determine the Occupied/ Unoccupied mode of operation. The Zone Manager does have the ability to use a global broadcast from another scheduling device on the communications loop if a more powerful schedule is required. If an external schedule is used, the range of schedule numbers is 1 to 8.

Zone Manager Uses Schedule #: 0 0 = Internal Clock 1-8 = External Clock

Press (*) To Force Recalibration Of The Static Press. Sensor <#> To Skip This...

The Zone Manager only calibrates the static pressure sensor one time. That occurs on the initial powerup, so it is vital that the sensor be attached before the system is ever powered up. If you weren't able to do this or accidentally activated the system before the sensor was available, you can force it to restart and calibrate the static pressure sensor by pressing the "*" key. If you don't need to re-calibrate, simply press the "#" key to skip over this item.


Programming 3-23


Caution: If you forget your passcode, you WILL BE locked out of your system!

Tip: The BackDoor Passcode that will always get you into the system is "9288." This

passcode should not be given to the casual users of your system.

As mentioned earlier, the default passcode is "1111". This code must be entered before any configuration or setpoint changes can occur. If you would like to change this default passcode, enter four digits on this screen. The value entered must be between 1000 and 9999 to be a valid code. Values from 0000 to 0999 will be rejected and the last valid code will be retained.

Enter New Passcode CODE: xxxx [Must Be 4 Digits] Press <A> To Skip!


3-24 Programming

System Overrides The Zone Manager provides some user-selectable override modes. This allows you to troubleshoot the system or set up temporary conditions for those situations when normal operation of the system is not required.

Override Screen #1

The Zone Manager defaults to the Auto mode of operation when first powered up. Any force modes entered will be retained in non-volatile memory. The unit will resume the force mode of operation any time the power is cycled.

0) Auto - Use internal schedules for Day/Night Mode

1) Occupied - Forced to Continuous Day or Occupied Mode

2) Night - Forced to Continuous Night or Unoccupied Mode. If the Forced Occupied Binary Input Contact is closed, this mode will override it to OFF. Use the Auto mode programmed for continuous Unoccupied operation if you want to use the Forced Occupied Binary Input Contact.

3) Fan Only This is the mode that is active whenever you see the Purge Cycle message being displayed. It disables any heating or cooling and forces all the boxes to move their dampers to the full 100 percent open position. You can use this mode any time you want to manually purge your building.

0) AUTO (Time Clock) 1) FORCE Occupied 2) FORCE Unoccupied 3) FAN ONLY [Mode 0]


Programming 3-25

Override Screen #2

ZONE FORCE MODES Force to MINIMUM 0 Force to MAXIMUM 0 [0= Normal 1=Force]

The Zone Controller Dampers can all be forced at the same time to their Minimum or Maximum Damper/Airflow Setpoints. On Pressure Independent systems, this feature is useful during air balance operations. Enter a "1" next to the desired force mode to make it active. Enter "0" to disable the force mode.


3-26 Programming

Zone Manager Operations Summary

Vent Mode 06/05/96 08:05am Wed Occupied 1 Alarm(s) 3


1) Read/Reset Zones 2) Manager Setpoints 3) Configure System 4) System Overrides

Alarm Status No Alarms

Manager Setpoints Static Press: 0.50”

1) Control Setpoints 2) Schedules 3) Holidays 4) Time & Date

HVAC Status Supply Air 56.4 Static Press. 0.49" Bypass Damper 24%

Zone Number 1 Occupied Mode Voting Unit

Program Time/Date Day (Sunday=0): 3 Enter Hr. (0-23): 9 Enter Min. : 25

Program Holidays Holiday # 1 Start Mon/Day: 0 (EX: 101 = Jan. 1)

WEEK SCHEDULES Sunday Start Time Enter Hrs/Mins: 0 (MILITARY FORMAT)

Zone Summary Screens Press “A” Key

Zone Manager Status ScreenPress “C” Key

Control Setpoints Screen Press “1” Key

Schedules Screen Press “2” Key

Time & Date Screen Press “4” Key

Holidays Screen Press “3” Key

Zone Manager Menu Screen Press “2” Key

Main Screen

Zone Status ScreensPress “B” Key

Alarm Status ScreenPress “D” Key

Main Menu Screen Press “#” Key


Programming 3-27

Index "K" Flow Factor .................................. 12 # - Enter Button..................................... 2 # - Menu Button.................................... 1 # Key................................................. 2, 9 * - Decimal Button................................ 2 1111....................................................... 9 24-Hour Format .................................. 14 A - Abort Button ................................... 2 A - Summary Button............................. 1 A Key .................................................... 2 Active Cooling Stages .......................... 6 Active Heating Stages........................... 6 Address Range .................................... 20 Airflow (CFM) Setpoint ..................... 11 Airflow (CFM) Values........................ 12 Alarm

Definitions ........................................ 8 Status Screens ................................... 7

Alarm LED............................................ 7 Auto Mode .......................................... 24 Aux Heating On .................................... 4 AuxHeat Setpt..................................... 11 Auxiliary Alarm................................ 7, 8 Auxiliary Heat Off ................................ 4 Auxiliary Heating Relay ..................... 11 B - Backup Button ................................ 2 B - Status Button................................... 1 B Key .................................................... 3 Back Door Passcode ........................... 23 Bad Supply Air Sensor ..................... 7, 8 Bad Zone Sensor ............................... 7, 8 Box & Aux Heat On ............................. 4 Box Heating On .................................... 4 Buttons

# - Enter ............................................ 2 # - Menu............................................ 1 * - Decimal........................................ 2 A - Abort ........................................... 2 A - Summary..................................... 1 B - Backup ........................................ 2 B - Status........................................... 1 C - Clear............................................ 2

C - Status........................................... 1 D - Alarms......................................... 1 D - Negative...................................... 2

Bypass Damper Direct Acting................................... 22 Reverse Acting................................ 22

Bypass Damper Position ....................... 5 Bypass Feedback Fail ........................... 8 C - Clear Button.................................... 2 C - Status Button................................... 1 C Key .................................................... 5 Calibrating ............................................ 3 Calibration Offset ............................... 13 CFM @1”WG xxxxx CFM................. 12 Changeover Delay Time ..................... 18 Closed Volts........................................ 18 Configuration

Internal Week Schedule .................. 22 Real-Time Clock............................. 22

Configure System.................................. 9 Control Setpoints .......................... 14, 17

Zone Manager ................................. 14 Cool Lockout ...................................... 17 Cool Mode Min................................... 11 Cool SetUp.......................................... 11 Cool Staging ....................................... 18 Cooling.................................................. 4 Cooling Failure ..................................... 8 COOLING FAILURE........................... 7 Cooling Setback.................................. 11 Cooling Setpoint ................................. 10 Cooling Setpt ...................................... 10 Cooling Stages .................................... 20 Cooling Total ........................................ 6 CSP ....................................................... 3 Current Cooling Setpoint ...................... 3 Current Zone Temperature ................... 3 D - Alarms Button................................. 1 D – Negative Button ............................ 2 D Key .................................................... 7 Damper Closing Alarm..................... 7, 8 Damper Feedback Fail .......................... 7


3-28 Programming

Damper Mode: Direct ......................... 12 Damper Opening Alarm.................... 7, 8 Damper Position Setpoint ............. 11, 12 Damper Positions ................................ 12 Data Entry Functions ............................ 2 Daylight Savings................................. 16 Default passcode ................................... 9 Direct Acting

Bypass Damper ............................... 22 Damper Position.............................. 12

Duct Static Pressure ............................ 21 Econo Enable Setpoint........................ 19 Economizer Damper Position ............... 5 Economizer Interval............................ 19 Economizer Operation

Zone Manager ................................. 21 Economizer Setpoints ......................... 18 Electric Heat ....................................... 21 Entering Passcodes ............................... 9 Fan Mode

Continuous ...................................... 21 Cycle ............................................... 21

FAN ONLY ........................................ 24 Fan Operation

Unoccupied Hours .......................... 21 First Zone Addr................................... 20 Force Mode Active ............................... 3 Force Modes ....................................... 24 FORCE Occupied ............................... 24 FORCE Unoccupied ........................... 24 Gas Heat.............................................. 21 Global Broadcast................................. 22 Global Overrides................................. 12 Heat

Electric ............................................ 21 Gas .................................................. 21

Heat Mode Min................................... 11 Heat Staging........................................ 18 Heat/Cool Changeover........................ 18 Heat1 Lockout..................................... 17 Heat2 Lockout..................................... 17 Heating.................................................. 4 Heating Failure ..................................... 8 HEATING FAILURE!.......................... 7 Heating Lockout ................................. 17 Heating Setback .................................. 11

Heating Setpoint ............................. 3, 10 Heating Setpt....................................... 10 Heating Stages .................................... 20 Heating Total ........................................ 6 Holiday Start/Stop Times.................... 15 Holidays

Zone Manager ........................... 14, 15 HSP ....................................................... 3 Inches of Water ..................................... 5 Internal Week Schedule ...................... 22 Invalid Setpoints ................................. 10 K Flow Factor ..................................... 12 Keypad Layout...................................... 1 Keypad Operations ............................... 1 Keys

# ....................................................... 9 # - Enter ............................................ 2 # - Menu............................................ 1 # - Next Screen ................................. 2 * - Decimal........................................ 2 A ....................................................... 2 A - Abort ........................................... 2 A - Summary..................................... 1 B ....................................................... 3 B - Backup ........................................ 2 B - Status........................................... 1 C ....................................................... 5 C - Clear............................................ 2 C - Status........................................... 1 C - Zone Manager Status .................. 5 D - Alarm .......................................... 7 D - Alarms......................................... 1 D - Negative...................................... 2

Last Zone Addr ................................... 20 LCD Operations .................................... 1 Location Problem................................ 13 Main Menu

Operation .......................................... 9 Main Screen .......................................... 1 Manager Setpoints ................................ 9 Maverick Zone.................................. 7, 8 Maverick Zones..................................... 6 Max Damper ....................................... 11 Maximum Airflow

Setpoints.......................................... 25


Programming 3-29

Maximum Damper Setpoints.......................................... 25

Maximum Damper/Airflow Setpoint .... 4 Mechanical Cooling Lockout.............. 17 MILITARY FORMAT ....................... 14 Min Cool Off....................................... 18 Min Econo % ...................................... 19 Min Heat Off....................................... 18 Minimum Airflow

Setpoints.......................................... 25 Minimum Damper Setpoints............... 25 Minimum Damper/Airflow Setpoint..... 4 Missing............................................ 3, 10 Missing Zone .................................... 7, 8

Caution............................................ 20 New Passcode ..................................... 23 Night Mode ......................................... 24 Nite Mode Min.................................... 12 Nite Mode xxxxx CFM....................... 12 No Alarms............................................. 7 NonVote Mode.................................... 13 Non-Voting Unit ................................... 3 OAT Broadcast Lost ............................. 7 Occupied Heating and

Cooling Setpoints............................ 10 Occupied Mode..................................... 3 Opened Volts ...................................... 18 Outdoor Air Calibration Offset........... 19 Outdoor Air Temperature ..................... 5 Outdoor Sensor ................................... 19 Overrides....................................... 12, 24 Overrides..: Global.............................. 12 Parallel Fan Off..................................... 4 Parallel Fan On ..................................... 4 Passcode

Back Door ....................................... 23 Passcode Request .................................. 9 Passcodes .............................................. 9 PD ZONE ADDRESS......................... 10 PD Zone Cool Mode Min ................... 11 PD Zone Heat Mode Min.................... 11 PD Zone Max Damper ........................ 11 PD Zone Nite Mode Min .................... 12 PD Zone Vent Mode Min ................... 12 PI ZONE ADDRESS .......................... 10 PI Zone CFM @1" WG ...................... 12

PI Zone Cool Mode Min..................... 11 PI Zone Heat Mode Min ..................... 11 PI Zone Max Airflow.......................... 11 PI Zone Nite Mode Min...................... 12 PI Zone Vent Mode Min..................... 12 Polling Mode....................................... 13 Polling Range...................................... 20 Pressure Dependent Box..................... 10 Pressure Independent Box .................. 10 Programming

Day.................................................. 16 Hours............................................... 16 Minutes ........................................... 16 Month.............................................. 16 Year................................................. 16

Programming Date .............................. 16 Programming Time ............................. 16 Push-button Override............................ 3 Push-Button Override

Won't Work..................................... 11 Read/Reset Zones ................................. 9 Real Time Clock ................................. 16 Real-Time Clock

Configuration .................................. 22 Relay Expansion Board ...................... 11 Return Air Temperature........................ 5 Return Sensor...................................... 19 Reverse Acting

Bypass Damper ............................... 22 Damper Position.............................. 12

Schedules Zone Manager ................................. 14

Screens Zone Selection ................................ 10

Sensor Calibration............................... 13 Sensor Problem ................................... 13 Sensor Slide Adjust............................... 3 Series Fan Off ....................................... 4 Series Fan On........................................ 4 Setpoint

Airflow (CFM)................................ 11 Cooling............................................ 10 Heating............................................ 10

Setpoint Adjustment Slide .................. 11


3-30 Programming

Setpoints Adjustment Slide............................. 11 AuxHeat .......................................... 11 Cooling.............................................. 3 Damper Position........................ 11, 12 Heating.............................................. 3 Invalid ............................................. 10 Maximum Airflow .......................... 25 Maximum Damper .......................... 25 Maximum Damper/Airflow .............. 4 Minimum Airflow........................... 25 Minimum Damper........................... 25 Minimum Damper/Airflow............... 4 Occupied Heating and Cooling....... 10 Static Pressure................................. 17 Zone Controller............................... 10 Zone Manager ................................. 14

Setting Time & Date ........................... 16 Single Overrides ................................. 12 Slide Effect.......................................... 11 Staging Delay Period .......................... 18 Start Time............................................ 14 Static Press .......................................... 17 Static Pressure....................................... 5 Static Pressure Sensor

Re-Calibrate .................................... 22 Static Pressure Setpoint ...................... 17 Static Sensor Alarm .......................... 7, 8 Status

Zone Manager ................................... 5 Status Screens

Alarm ................................................ 7 Stop Time............................................ 14 Summary

Zone Controllers ............................... 2 Supply Air Temperature ....................... 5 Supply Sensor ..................................... 19 Supply Setpt ........................................ 19 System

Locked Out...................................... 23 System Overrides ............................ 9, 24 Thermistor Type III Sensors ............... 13

Time & Date Setting ............................................. 16 Zone Manager ................................. 14

Unoccupied Heating and Cooling Setback............................................ 11

Unoccupied Hours Fan Operation ................................. 21

Unoccupied Mode................................. 3 Vent....................................................... 4 Vent Mode Min................................... 12 Vent Mode xxxxx CFM...................... 12 Voting Mode ....................................... 13 Voting Unit ........................................... 3 Week Schedules

Zone Manager ................................. 14 Wetbulb Temperature ........................... 6 Zone CLSP............................................ 2 Zone Controller............................. 1, 3, 8

Setpoints...................................... 9, 10 Zone Controller Alarms ........................ 7 Zone Controller Dampers

Forced ............................................. 25 Zone Controllers

Summary ........................................... 2 Zone Damper Fail ............................. 7, 8 Zone Damper Position .......................... 4 Zone HTSP............................................ 2 Zone Manager

Configuration .............................. 9, 20 Control Setpoints ............................ 14 Economizer Operation .................... 21 Holidays .................................... 14, 15 Operations ......................................... 1 Operations Summary ...................... 26 Schedules ........................................ 14 Setpoints...................................... 9, 14 Status Screens ................................... 5 Time & Date ................................... 14 Week Schedules .............................. 14

Zone Manager Alarms .......................... 7 Zone Selection Screen ........................ 10 Zone Status Screens .............................. 3 Zone TEMP........................................... 2 Zones

Read/Reset ........................................ 9 ZoneTemperature Reading.................. 13


Programming 3-31

Notes


3-32 Programming

Notes

Section 4

Start-Up & Troubleshooting

Table of Contents Communications Overview..............................................1

How It Works...................................................................................................................1 Basic System Communications........................................................................................2 Zone Manager Communications......................................................................................3 Zone Controller Communications....................................................................................4 CommLink IV Communications (Optional) ....................................................................5 Basic System Communications Checklist .......................................................................7

Components & Wiring ......................................................8 Zone Manager IO & Components....................................................................................8 Zone Manager Wiring......................................................................................................9 Zone Controller IO & Components ...............................................................................10 Zone Controller Wiring .................................................................................................11

Startup & Commissioning..............................................12 Procedures......................................................................................................................12 Basic System Worksheet................................................................................................15 Start-Up..........................................................................................................................16 Blink Codes for Zone Controllers..................................................................................18

Troubleshooting.............................................................19 Trouble Shooting Checklist ...........................................................................................19 Trouble Shooting Chart .................................................................................................23 Troubleshooting Chart for Alarms.................................................................................25 Communications Loop...................................................................................................33 Zone Manager ................................................................................................................33 Zone Controller..............................................................................................................35 CommLink IV (Optional) ..............................................................................................37 Bypass Damper Troubleshooting...................................................................................38 Temperature Sensor Resistance Chart ...........................................................................39 Pressure Sensor Voltage Chart ......................................................................................40

Section 4

Start-Up & Troubleshooting

Table of Figures & Tables Figure 4-1: Basic System Communications Wiring ......................................................2 Figure 4-2: Zone Manager Communications Wiring & Address Switch Setting .........3 Figure 4-3: Zone Controller Communications Wiring & Address Switch Setting .......4 Figure 4-4: CommLink IV (Optional) Wiring...............................................................5 Figure 4-5: CommLink IV (Optional) Jumper Settings ................................................6 Figure 4-6: Zone Manager Components .......................................................................8 Figure 4-7: Zone Manager Wiring.................................................................................9 Figure 4-8: Zone Controller Components ...................................................................10 Figure 4-9: Zone Controller Wiring ............................................................................11 Figure 4-10: Basic Zone Manager ..............................................................................16 Table 4-1: SCAN LED Blink Codes............................................................................18 Figure 4-11: Bypass Damper Troubleshooting...........................................................38 Table 4-2: Temperature Sensor Resistance .................................................................39 Table 4-3: Pressure Sensor Voltage ...........................................................................40 Figure 4-12: Driver Chip Locations............................................................................41 Figure 4-13: Replacing Driver Chips..........................................................................42


Start-Up & Troubleshooting 4-1

Communications Overview Perhaps no other portion of the system seems as difficult to diagnose as the communica-tions loop, yet it really can be quite simple if you understand how it works. In fact, much of the troubleshooting can be done by simple observation. We will lead you through the system functions and then provide you with detailed instructions for checking each piece of equipment. This information is provided as a review and expanded guide to the Auto-Zone Basic Control System communications. Additional information about the Auto-Zone Basic Control System communications loop and its associated wiring is contained in Section 2 of this manual.

How It Works Auto-Zone uses a token-passing loop architecture, which means in simple terms that an “electronic message” called a token is passed from controller to controller in a round-robin fashion. A controller must wait to receive the token before it can send or request any data. Only one device on each loop is capable of sending the token, and this device is considered the loop master. The loop master varies depending on the type of system and the installed options. For the Auto-Zone Basic Control System, there is only one loop master. The loop master is the Zone Manager. The Zone Manager must be connected to the zone controllers in order for the communications loop to function. A typical Auto-Zone Basic Control System communication loop is shown in Figure 4-1. In order for the loop master to communicate with the various devices on that loop, each must have a unique address. With the Auto-Zone Basic Control System, each zone con-troller on the loop must have its own address from 1 to 16. The Zone Manager also has an address switch that must be set for the system to communicate. For the Basic System without an optional CommLink connected, the Zone Manager address should be set to 0. For the Basic System with the optional CommLink attached, the Zone Manager must be set as address 17 and the CommLink’s jumper switch must be set to single loop opera-tion.


4-2 Start-Up and Troubleshooting

Basic System Communications The Auto-Zone Basic Control System has only one communications loop. The Zone Manager is always the master on the Basic System loop. You must be sure the Zone Manager is connected, addressed correctly (see Figure 4-2), powered up, and functioning if you are starting up or troubleshooting the communications loop. The optional CommLink IV jumper switch must be set for single loop operation when used with the Basic system. See Figure 4-5.

Figure 4-1: Basic System Communications Wiring



Zone Manager Communications The Zone Manager is the main communication device on the Basic System. It must be wired correctly and connected to 24VAC power for the system to function. The Zone Manager must also be addressed correctly. The Zone Manager is normally addressed as address 0 but should be addressed as 17 if a CommLink is used. Always be sure to double-check all communication wiring and addressing before initial commissioning of the system. The address switch must be set and the power cycled in order for the address to be recognized by the system. Please see Figure 4-2 for the Basic Zone Manager addressing information.

Figure 4-2: Zone Manager Communications Wiring & Address Switch Setting

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

R4

3

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN21

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

TB8

RN1

BYPASSPDAMPER



Address Switch Must Be SetTo Address 0 on Zone Manager Board

As Shown

Address Switch Must Be SetTo Address 17 on Zone ManagerBoard When CommLink Is Used





ADD

ADD

1

1

2

2

4

4

8

8

16

16

32

32

B

B

NET

NET

AD

DA

DD

32

32

BB

NE

TN

ET

16

16

88

44

11

22

OF

F>

OF

F>

RockerDown

RockerDown

Basic System Without CommLink

Basic System With CommLink

2.)It Is Recommended That All

Controllers Address Switches Are

Set Before Installation.

3.)Power To The Zone Manager Must Be

Cycled Before Address Switch

Changes Will Take Affect.


Controllers

Notes:

1.)AllCommunication Wiring To Be

2 Conductor Twisted Pair With

Shield. Use Belden #82760 Or

Equivalent.

R

SH

T

R

SH

T

R

SH

T

R

SH

T

All Comm Loop Wiring IsStraight Thru

Local LoopRS-485

9600 Baud



Zone Controller Communications The Zone Controllers on the system must all be addressed from 1 to 16. They must be wired correctly and connected to 24VAC power for the system to function. Improper ad-dressing is one of the most common mistakes made when installing any system. If dupli-cate addresses are assigned on the same loop, fluctuating readings will occur. This can be a very frustrating error to find. Another common mistake is flipping (reversing) of the T and R wires on the communication loop between controllers or other communication de-vices. Always be sure to double-check all communication wiring and addressing before initial commissioning of the system. The address switches must be set and the power cy-cled in order for the address to be recognized by the system. Please see Figure 4-3 for Zone Controller addressing information.

Figure 4-3: Zone Controller Communications Wiring & Address Switch Setting



CommLink IV Communications (Optional) The CommLink IV is optional for the Auto-Zone Basic Control System. It is required only if alarm call-out, connection to an on-site computer, or connection to a remote com-puter is required. For the Basic Control System to function correctly, the CommLink IV must be set to single loop operation mode by setting the jumper position on the CommLink board. The CommLink IV must be wired correctly to the system and con-nected to a computer (if used). For remote communications or alarm call-outs, the CommLink IV connects to a Remote Link II or to an Ethernet router when the IP Module is used. See Figure 4-4 and Figure 4-5 for more information. The CommLink must also be powered up in order for either system to communicate. In addition, the Zone Manager address should be set to 17 instead of 0 when the CommLink is used.

Figure 4-4: CommLink IV (Optional) Wiring



Figure 4-5: CommLink IV (Optional) Jumper Settings



Basic System Communications Checklist Basic System without Optional CommLink

Zone Manager is correctly addressed as 0 Zone Controllers are correctly addressed from 1 to 16 Power has been cycled after changing addresses There are no duplicate addresses on the loop The first Zone Controller on the communication loop is connected to the

Zone Manager communication terminal All communication wiring is landed correctly, T to T, R to R, and SHLD to SHLD All Zone Controllers are wired to 24 Volt AC power supply Zone Manager is wired to 24 Volt AC power supply All 24 VAC power wiring is landed correctly - 24VAC to 24VAC and GND to GND Zone Manager is powered up Zone Controllers are powered up

Additional Checks for Basic System with Optional CommLink IV

CommLink IV is connected to the communications loop CommLink IV is set for single loop operation Zone Manager is correctly addressed as 17 CommLink IV is wired to 24 Volt AC power supply CommLink IV is powered up

Other Optional Equipment Computer is correctly connected to the CommLink IV Prism™ software is installed on a computer Remote Link II is correctly connected to the CommLink IV Remote Link II is connected to a working phone line Second Remote Link II is connected to a computer and working phone line off-site IP Module is correctly installed in the CommLink IV CommLink IV with installed IP Module is connected to an Ethernet router for off-site

communications



Components & Wiring

The following information is intended as a review of the procedures and design data pro-vided in Section 2 of this manual. Section 2 should be thoroughly studied before attempt-ing the initial installation of the system. If, however, you find yourself starting up or trou-bleshooting a system that was installed by someone else, the following information should be helpful in gaining a quick overview of the system you are working with.

Zone Manager IO & Components The Zone Manager inputs, outputs, and components are shown below. It is important to familiarize yourself with these components and their locations to facilitate proper connection, startup, and troubleshooting of the Basic System. See Figure 4-6.

Figure 4-6: Zone Manager Components

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

K2

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

OPEN

D1

7

R4

3R4

1

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN2

1

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

ANALOG

OUTPUTS

EXP

BUSS

ECONOMIZER

EXH/RELIEF

GND

TB8

TB5

YS101722

Rev. 2

C21 C20

X2

R4

2

D1

6

EXHAUST

CONTACTS

N.O.

TB4V2

C6U2

R7

R38

R37

C15 C16

R31

R30

R28

R27

R19

C13 C14

R14

R17

R16

R12

C7 C8

R11

TB3

GND

GND

AUX2

AUX3

SAT

RAT

OAT

AUX1

+12V

ANALOG

INPUTS

D2

D3

D5

D4

D8

D6

R15

C11

U7

CX7

Q2

PJ1

+5

V

SIG

GN

D

PRESSU

RE

SEN

SO

RJA

CK

TB1

R5

R4R2

R3

R1

U1

CX1

C4 C5

D1

R9

C1

C2 C3

VR2

VR1

SC1

24VAC

V1

R1

0

U3

CX3

U5

CX

5

Q1

R2

2

R2

1

D1

0

R2

3

R2

4

R2

0

R3

6

R2

9

R33

R35

R32

R34

CX

4

C1

2

R2

5

D1

2

VR3

R13

R26

D11

D9

R18

U6

CX

6

C17

D13

D14

D15

R39

R40

I2C EXP PORT

GND

TB2

POWER

D7

L1

C9

Y1

EW

DO

G

J0

1

U8

C18 C19

5.11V

ADJ

5.11V

ADJUST

PU1

PU2

PU3

PU4

PU5

PU6

RN1

REC

BYPASSPDAMPER

R6

1

HVAC Unit

Connections

(R) CommonFanCool 1Cool 2Heat 1Heat 2

Bypass

Damper

Connections

FDBKGNDOpenClose

RS-485

Communications

Loop Connection

TSHR

Typical

Pin 1

IndicatorRAM

ChipEPROM

Chip

PAL

Chip

RAM Size

Select

Jumper

RS-485

Communications

Driver Chip

Real Time

Clock Chip

Real Time

Clock Chip

Display &

Keypad

Ribbon Cable

Connector

Static Pressure

Sensor Inputs

+5VSIGGND

Static Pressure

Sensor - Optional

Modular Connection

Input

Comm

LED

Not Used

Address Switch

(Set To 0 WithoutCommLink. Set to 17With CommLink)

Analog Inputs

SAT

RATOATAUX1AUX2AUX3GND

Analog Output

0-10 VDCEconomizer

Binary Output

Relief/ExhaustFans

Power LED

24 VAC

Power Input

Mounting Holes

Typ. Of 4

Note:

Keypad & DisplayNot Shown



Zone Manager Wiring Correct wiring of the Zone Manager is critical to proper system operation. If components are wired to the wrong inputs, the system will not operate correctly or will not operate at all. Correct wiring of the 24VAC power is extremely critical. If voltage greater than 24VAC is applied to the terminal, it will damage the board beyond repair. All 24VAC wiring must be connected so that all ground wires remain common. Failure to comply with this will also result in damage to the board. See Figure 4-7. Also see Section 2 of this manual for more detailed wiring instructions and procedures.

Figure 4-7: Zone Manager Wiring

Basic Zone Manager

Notes:

1.)24 VAC Must Be Connected So

That All Ground Wires Remain

Common.

3.)All Communication Wiring To Be 18

Ga. Minimum, 2 Conductor Twisted

Pair With Shield. Belden #82760 Or

Equivalent.

2.)All Wiring To Be In Accordance With

Local And National Electrical Codes

and Specifications.




Controllers

Return Air Temp.

Sensor

Suppy Air Temp.

Sensor

LineVoltage

HV

AC

Un

it

24VAC Only

Re

d

Blk

To Relief / Exhaust Fans

Grn

StaticPick-up


Splice AsRequired

LO HI

GND

24VAC

Belimo Actuator Wiring Shown.Consult Factory For Other

Models Of Economizer Actuators.Some Actuators Require IsolationTransformers In Order To PreventDamage To The Controller Board.

WARNING!

Use Extreme Care When Wiring

Economizer Actuators

Never Connect Or Disconnect

Wiring With Power Applied!

Never Apply Power If The

Gnd ( 1 Com ) Terminal On The

Actuator Is Not Connected.

See Note 1 &2

Outdoor Air Temp.

Sensor

(See Note 4)

Aux3Forced

OccupiedMode

Aux1Economizer

Disable

Aux2FilterAlarm

Auxiliary Inputs

( Dry Contacts )

R

G

Y1

Y2

W1

W2

Economizer Actuator

133 IN-LB

AF24-SR

1 COM

2 +

3 Y1

4 Y2

5 UBELIMO

C987

CABLE

R6

R5

HEAT 2 SW

1

W2

W1

Y2

HEAT2

HEAT1

COOL2

COOL1

FAN

HEAT 1

COOL 2

COOL 1

C 1992

11632

BNET

248

AD

D

COMM DRIVER

RS-485

75176

MADE IN U.S.A.

D1

7

D1

8

D1

9

D2

0

D2

1

D2

2

D2

3

D2

4

0* # D

R

SH

T

COMM

C1C2

+

P1

RIBBON

GN

D

G

Y1V6

V5

CLOSE

V4

V3

OPEN

GND

FDBK

FAN

CLOSE

OPEN

+

REC

+

GND

NE5090

4 5 6

KEYPAD

1 2 3

B

A

LCD DISPLAY

&

++

24VAC

TB2

POWER

+

++

ADJUST

5.11V

PJ1

++PRESSU

RE

SEN

SO

RJA

CK

+5

V

SIG

BUSS

EXP

TB2

A2

G

OUTPUTS

ANALOG

A1

N.O.

CONTACTS

EXHAUST

AUX3

GND

GND

AUX2

AUX1

ANALOG

SAT

OAT

RAT

INPUTS

+12V

TB1

2

BYPASS

BYPASS

Local Loop

OF

F>

RockerDown

Bypass & SlaveInterface Card

BypassAir Damper

Actuator

10

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2



Zone Controller IO & Components The Zone Controller inputs, outputs, and components are shown below. As with the Zone Manager, knowing the location and function of the Zone Controllers inputs, outputs, and components is critical to proper start-up and troubleshooting of the Basic System. See Figure 4-8.

Figure 4-8: Zone Controller Components



Zone Controller Wiring Correct wiring of the Zone Controller is critical to proper system operation. If compo-nents are wired to the wrong inputs, the system will not operate correctly or will not op-erate at all. Correct wiring of the 24VAC power is extremely critical. If voltage greater than 24VAC is applied to the terminal, it will damage the board beyond repair. It is rec-ommended that a separate transformer be used for each Zone Controller. If one trans-former is used to power multiple Zone Controllers, all 24VAC wiring must be connected so that all ground wires remain common. DO NOT REVERSE POLARITY BETWEEN CONTROLLERS. Failure to comply with this will also result in damage to the board. See Figure 4-9. Also see Section 2 of this manual for more detailed wiring instructions and procedures.

Figure 4-9: Zone Controller Wiring



Startup & Commissioning Commissioning the system correctly is one of the most important steps in getting the sys-tem installed and functioning with the least amount of problems and in the shortest length of time.

Procedures The following is a list of items and reminders that are essential to the successful commis-sioning of your system. Some of these items have already been discussed in this manual and are repeated to confirm correct procedures. Familiarize yourself with this installation manual and system wiring diagrams before installing!

1) Check to see if you have all the correct components for your installation.

2) Establish the location for the Zone Manager first. This is where your commu-nication cable will begin for the Basic System.

3) Layout your communication wiring per the instructions in the previous por-tion of this manual.

4) The communications loop originates at the Zone Manager. All Zone Control-lers are connected to this loop.

Tip: Using the Auto-Zone color-coded and labeled Communication Cable en-sures a quality installation.

5) Always refer to the Basic System Wiring Diagrams for specific wiring de-tails. Communication cable must always be shielded – no exceptions!

6) Mount controllers in appropriate locations according to their operating speci-fication.

7) Use the Basic System Worksheet included in the back of this section or the ones included with the submittal package to document unit location, descrip-tions, addressing, and setup. Address controllers according to location and ad-dressing instructions located in this system manual.



Procedures (Continued) 8) With no power connected, wire the Zone Manager and Zone Controllers ac-

cording to wiring diagrams and in accordance with local codes. Do Not Apply Power!

9) After completing all wiring connections, unplug the terminals for power and communications on the Zone Manager and all Zone Controllers. Always un-plug the communications loop first and then the power. When reconnecting the wiring, connect the power first and then the communications loop. Even though the system does not have power applied to it at this time, it is a good habit to get into. Later, when power is applied, this is very important to ensure against the possibility of shorting the communications loop to ground.

10) If you are using the optional CommLink IV, locate and install the CommLink. Do Not Apply Power!

11) Reconnect the power and then the communications loop to the Zone Manager and the first Zone Controller on the loop.

12) Observe the LCD screen on the Zone Manager. It will go through a start-up procedure upon being powered up. See the Start-up Screens heading that fol-lows in this section of the manual for complete start-up Screen information.

13) The Zone Manager will proceed through system start-up, initialization, and calibration. This calibration could take up to five minutes. After the initializa-tion is complete, the main system screen will appear. In the bottom right hand corner, it will show the current zone polling address. See Section 3 of this manual for complete screen operations and programming. If the address shown is 1, the first zone controller on the loop is apparently communicating. To confirm this, press the “B” key on the Zone Manager keypad. Enter the Zone Address for the controller you are checking. If this is the first controller on the loop and it is addressed as 1, you would press 1 and then the “Enter” key. If the zone isn’t communicating, it will display “***Missing***.” If the zone is communicating but still calibrating, it will display “Calibrating.” If the zone is communicating, the display will change over to the Zone Status screen when calibration is complete. If the zone is communicating, proceed to step 15. If the screen shows that the zone is missing, proceed to step 14.



Procedures (Continued) 14) Check the Zone Controller for correct communications and addressing by ob-

serving the LED indicator for the blink codes as outlined in the troubleshoot-ing section of the manual. The blink code will first verify the address and then the operation. If the address is incorrect, reset the address switch, and then re-apply power to the controller. If you cannot communicate, verify wiring, volt-ages, etc. in accordance with the trouble-shooting section in the system man-ual. Do not proceed to the next device until you are properly communicating with the current device.

15) Reconnect the power to the next zone controller on the communications loop. Reconnect the wiring between the previous zone controller on the loop and the zone controller you are testing. Be sure the Zone Manager is still powered and connected to the communication loop and then press the “B” key on the Zone Manager keypad. Enter the Zone Address for the controller you are checking. If this is the third controller on the loop and it is addressed as 3, you would press 3 and then the “Enter” key. If the zone isn’t communicating, it will display “***Missing***.” If the zone is communicating but still calibrat-ing, it will display “Calibrating.” If the zone is communicating, the display will change over to the Zone Status screen when calibration is complete. If the screen shows that the zone is missing, revert to step 14. If the zone is commu-nicating, repeat this step with each zone controller on the loop, in sequence, until all zone controllers on the loop are communicating.

16) Once all devices on the loop are communicating, you must program and con-figure the Zone Manager and all Zone Controllers on the system per the pro-gramming section of this manual.

Remember that each controller only contains one puff of smoke. Making sure that all wir-ing terminations and voltages are correct prior to applying power to a controller will en-sure that you don’t use up that one puff.



Basic System Worksheet Project: _______________________ Location ______________________________________________

CommLink Installed: Yes No Remote Link Installed: Yes No Phone: _________________

Stages of Cooling ____ Stages of Heating ____ Gas Electric Economizer Yes No

Zoning: Pressure Dependent Pressure Independent

Zone Address

Zone Description or Location

Air Damper

Size

Room Sensor Type

Relay Exp. Board

















[S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint adjust] [AH=Auxiliary Heat] [BH=Box Reheat] [SF=Series Fan Terminal] [PF=Parallel Fan Terminal]



Start-Up On Auto-Zone Basic Control System power up, the following tests, calibration, initializa-tion, and procedures occur:

Figure 4-10: Auto-Zone Basic Zone Manager

Initializing System Please Wait

Start-Up Delay 49 Number of Zones 1 03/27/02 09:20am Wed STATIC NULL: 0.25




POWERUP TEST

FAN

CO

OL

1

CO

OL

2

HE

AT

1

HE

AT

2

BY

PAS

SO

PE

N

BY

PAS

SC

LO

SE

CO

MM

UN

ICATIO

N

ALA

RM

A=

ALL

ZO

NE

S

B=

EA

CH

ZO

NE

C=

HVA

CU

NIT

/CLE

AR

D=

ALA

RM

S

#=

STE

P/E

NTE

R

* =D

EC

IMA

L

+

+

+

+

Cool

Mode

04-22-02

03:48PMMON

OCCUPIED

NOALARMS

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

Keypad

Display

1.) The system setpoints are loaded and outputs are turned off and the LEDs are initialized ON. The screen displays, “Intialializing System.”

2.) System Diagnostics and Calibrations occur. a.) A 50-second startup delay occurs. While this

is counting down, the LEDs will extinguish, one every 6 seconds.

b.) The number of zones displays on the second line. If the Zone Manager has never been configured, the system will only show "1" zone. If this isn't the first power-up, it will display the number of zones for which the system is configured.

c.) The current date and time displays on the third line. If this is the first power-up, the date and time may be incorrect.

d.) The Static Pressure Sensor NULL Voltage displays on the bottom line. The static pres-sure sensor NULL voltage is read at the fac-tory during power-up checks prior to ship-ping. If necessary, you can re-calibrate the pressure sensor using the procedure de-scribed in Section 3, Zone Manager Configu-ration, Configuration Screen #7.



Bypass Calibration Please Wait...

Initializing Zones

Vent Mode 03/27/02 09:30pm Wed Occupied 1 Alarm(s) 3

3.) At the conclusion of the 50 second startup delay, the system proceeds with the bypass damper calibration. Depending on the degree of travel and the speed of the damper actuator, this process could take up to a maxi-mum of three minutes.

4.) The zones are all polled and initialized.

5.) The Main Operating Screen will now appear (see Sec-tion 3, LCD/Keypad Operations) and normal operation will begin. The total startup time is approximately four minutes.



Blink Codes for Zone Controllers The Zone Controller uses an on board SCAN LED to indicate various conditions during power up and operation. Starting with power up, the SCAN LED blink codes are as fol-lows:

• Off for 5 seconds • SCAN LED blinks the board address (Address 14 = 14 blinks) • 5-second pause • 20-second time delay - LED blinks 20 times • LED stays on continuously during damper calibration • Status code is repeatedly blinked every 10 seconds to indicate controller

status:

Priority Number of Blinks Status Lowest 1 Normal Operation

- 2 Override Active - 3 Bad Zone or Airflow Sensor - 4 Damper Failure

Highest 5 Communication Failure

Table 4-1: SCAN LED Blink Codes

Only the highest priority failure code will be shown. You must correct the highest prior-ity alarm before other problems will be indicated.



Troubleshooting The following is a guide to assist in troubleshooting the Auto-Zone Basic Control Sys-tem. It is provided as a systematic approach in determining and resolving common sys-tem problems.

Troubleshooting Checklist Begin troubleshooting by locating the general problem in the list below. Detailed compo-nent troubleshooting information follows later in this section.

Zone is too warm • Is cooling locked out due to outside air temperature? • Is cooling short cycling due to low supply air temp cut-off? • Is zone calling for cooling? • Is supply air temperature indicating cooling? • Is Economizer enabled? • Is Economizer opening? • Is cooling being held off by its minimum off timer? • Is the zone a “voting” zone? • Is the system currently trying to satisfy a higher heating demand? • Is the rooftop unit running? Check internal safeties. • Is the Zone Damper operating freely? • Is the LED blinking an error code? See Table 4-1.

Zone is too cool • Is heating locked out due to outside air temperature? • Is heating short cycling due to high supply air temp cut-off? • Is zone calling for heating? • Is supply air temperature indicating heating? • Is heating being held off by its minimum off timer? • Is the zone a “voting” zone? • Is the system currently trying to satisfy a “higher” cooling demand? • Is the rooftop unit running? Check internal safeties. • Is the Zone Damper operating freely? • Is the LED blinking an error code? See the BLINK CODE chart.



Zone Sensor reading incorrectly

• Is the sensor near a source of heat or a cold draft? Location is a common problem. The sensor should be mounted on an inside wall away from heat sources and in a location with adequate room air circulation.

• Is the voltage reading correct? Is the resistance reading correct? Check Table 4-2 in this section.

• Is wiring correct? Check for errors. Check the Room Sensor

• To meter the Room Sensor: With the sensor connected to the Zone Controller board, read the voltage on the sensor terminals. If the voltage does not match the TEMPERATURE/ RESISTANCE chart, unplug the two-position room sensor terminal block. Using your meter, check the resistance of the unplugged terminal block. Use the sup-plied TEMPERATURE/RESISTANCE chart to see if the sensor is within a rea-sonable range. Readings that are much too high or too low generally indicate wir-ing problems.

• To meter the Slide Adjust (optional):

Unplug the four-position AUX terminal block. Use your ohmmeter to check the resistance between the GND wire on the two-position room sensor terminal block and the AUX1 terminal on the unplugged terminal block.

The resistance for various positions of the slider on the sensor should be as follows:

Full UP position 15K Ω (± 500 Ω) MID position 12.5K Ω (± 500 Ω)

Full DN position 10K Ω (± 500 Ω)



Zone Damper does not appear to be working correctly

• Is the actuator plugged into the correct jack on the Zone Controller? • Is the actuator properly mounted? Check for loose shaft, etc. • Is the damper free to move? Check for binding and/or physical damage. Does the

damper move both directions when the controller is powered up? Set to mid posi-tion before applying power.

• Is the Zone Controller set for DIRECT/REVERSE action? The zone controller must be configured for correct operation if REVERSE action of the damper is re-quired.

Caution: Improper mounting and the associated adjustment of the damper blade positioning is the number one cause of damper related problems. It can be difficult to determine the full-open position if the damper shafts are not marked. It is sometimes helpful to “force” the damper to the full-open or full-closed position and then check for airflow at the diffusers. The damper may be forced using the control system or by unplugging the actuator then depressing the actuator clutch release and manually positioning the damper.

No zones are communicating

• If used, is the CommLink IV connected and plugged in? • Is the Zone Manager address set correctly?

Address = 17 if CommLink is used Address = 0 if no CommLink is used

• Are COMM LOOP voltages correct? See the COMM LOOP troubleshooting guide.

• Is the COMM LOOP open or shorted? • Are the Zone Controller address switches set correctly? See the addressing chart. • Are the Zone Controllers powered? Check 24VAC to the controllers.



Some zones are communicating but others are not:

• Is the Zone Manager set for the correct number of zones? • Are the Zone Controller address switches set correctly? See the addressing chart. • Are the Zone Controllers powered? Check 24VAC to the controllers. • Is the REC LED on the missing Zone Controller “flickering”? See Zone Control-

ler introduction for location of the REC LED. • Is the SCAN LED blinking an error code? See the BLINK CODE chart. • Are COMM LOOP voltages correct at the missing unit? See the COMM LOOP

troubleshooting guide.



Troubleshooting Chart Problem Possible Cause Solution

1 Display screen blank or solid black bars

Ribbon cable con-nectors loose

Check and re-seat plugs on ribbon ca-ble between the cover and mother-board. Re-cycle power if necessary. Check all “pluggable” components on the board to make sure they are all fully seated.

2 Display screen washed-out or difficult to see

Contrast needs ad-justment

Remove cover, but leave ribbon cable connected. Adjust contrast by turning adjustment pot located at the bottom edge of the control board located on the cover behind the display screen.

3 Zone Manager con-tinually initializes (start-up cycle re-peats)

Wiring fault such as shorted lead on the bypass actuator or on one of the heat-ing/cooling stages

Carefully check all wiring. Disconnect relay outputs and the bypass connector to isolate the source of the problem.

4 Can only read data from Zone 1 or only from some of the zones

Zone Manager con-figured for incorrect number of zones

Enter access code. Under “Configure System,” enter first and last zone num-ber.

Zone Controller(s) addressed incor-rectly

Check Zone Controller address using data from Figure 2-7 of this manual.

Comm Loop Prob-lem

Check Comm Loop using Comm Loop troubleshooting guide in this Section.



Problem Possible Cause Solution

5 Zones cold or hot and second stage of cooling or heating does not come on

Zone Manager not configured for two stages

Under the Configure System menu, enter correct number of stages. In the Cooling Mode, the supply tem-perature must be above 45°F for any additional stages of cooling to activate. In the Heating Mode, the supply tem-perature must be below 105°F for elec-tric heat and below 160°F for gas heat.

6 Zones calling for cooling but “Cool” light does not come on

Zone Manager con-figured for “0" stages of cooling

Under the Configure System menu, enter the correct number of cooling stages.

Supply temperature too cold or faulty duct temp sensor

Press “C” key and read supply air tem-perature. If less than 58°F, the supply temperature is too low to allow cooling to be energized or the duct sensor is faulty. Correct as appropriate.

Economizer is en-abled and acts as first stage of cool-ing. Will not allow mechanical cooling until damper is 100 percent open

Check Economizer setpoints and damper position

Outside air temp is below Cooling Lockout setpoint

Check Cooling Lockout setpoint and outside air temp.

Minimum cooling Off Time has not been met

Check minimum Off Time for cooling. Warning: Do not set minimum off time to less than manufacturers rec-ommended time. Damage to equipment may result.

Unit is in Heat-ing/Cooling Changeover delay

Check changeover delay. Default delay is ten minutes.



Troubleshooting Chart for Alarms Problem Possible Cause Solution

1 Bad Duct Sensor

Faulty Wiring/Sensor

The duct sensor reads actual tempera-ture between 35°F and 210°F. If the actual temperature at the sensor probe as measured with a thermometer is within these limits, check the sensor voltage. If voltage does not match the chart, then check the total sensor/wire resistance by removing wires from terminals SAT and GND on the TB3 terminal strip. Measure the resistance in the wires and compare it to the tem-perature/resistance chart. If the resis-tance measured does not match the chart, go to the sensor, disconnect it, and measure the resistance directly across the sensor. If resistance is cor-rect, check wiring between the control-ler and sensor. If sensor is not within tolerances, replace the sensor.

2 Bad Static Sensor

Too low/high duct static

With fan running (red fan LED is on), read duct static using “C” key on Zone Manager. If reading is below 0.01, check sensor tubing connectors for loose or reversed connections. Check if there is airflow (pressure) at the sensor location (mounted too close after an elbow may cause negative pressure). If reading is above 3.0, check actual static or see if sensor is pointing into air stream picking up total pressure. Disconnecting sensing tube from the sensor should cause reading to go to “0." If not, check wiring and replace sensor if it does not read correctly when wired directly to the Zone Man-ager.

Bypass damper action incorrect

Check bypass configuration for Direct or Reverse Acting. See Section 3, Zone Manager Configuration, Configuration Screen #5.




3 Bad Zone Sensor

Faulty Wiring/Sensor

An alarm occurs if the zone tempera-ture reading is below 40°F or above 105°F. If actual temperature at the sen-sor is between these temperatures and an alarm occurs, start troubleshooting at the zone sensor. Measure the sensor voltage either at the sensor or the Zone Controller. If it does not match the chart, remove it from the wall, discon-nect its wires and measure the resis-tance between TMP & GND. Resis-tance should compare to values in the Temperature/Resistance chart. (Re-member, temperature of sensor may be affected by the heat of your hands). If the resistance is significantly different from the chart, replace the sensor. On 3-wire sensors with a “Warmer-Cooler” pot, the resistance between AUX & GND should vary from 10K to 15K Ohms depending on the position of the pot. If the resistance is accept-able, check the wiring between the sen-sor and the controller by reconnecting the sensor and going to the zone con-troller, lifting the sensor terminal plug, and reading the resistance in the wires. Reversing TMP and GND wires on a 3-wire sensor will significantly affect the readings. In checking sensor wir-ing, also check for loose strands of braided wire shorting to ground at the terminals that may affect readings.




4 Bypass Damper Sticking Damper Depress Clutch button and check that the damper moves freely without bind-ing. Note: If the actuator has driven against its “stop” screw, rotating the actuator shaft by disengaging the clutch may not be possible. If this is the case, loosen the setscrews and ro-tate the damper shaft to observe bind-ing. If binding is observed, correct the binding problem and force recalibra-tion of the damper by cycling power to the Zone Manager. If setscrews were loosened, be sure damper shaft is prop-erly positioned before tightening. (Counter clockwise = closed = Direct Acting) Warning: Actuator can be damaged if rotation is forced! Make sure the clutch button is fully depressed before rotating damper.

Improper Wiring

Determine that wiring matches Figure 2-5. Note: If more than one bypass damper is wired in parallel, connect only one of the feedback pots as shown in the schematic wiring diagram Figure 2-9.

Actuator motor failure

Check voltage to the actuator during the calibration routine. During the “drive closed” part of the calibration, 24 VAC should be measured between “GND” and “Close” on the terminals. The red LED on the bypass and slave interface card should also light up. Similarly, 24 VAC should be measured between “Open” and “GND” in the drive open phase of the calibration rou-tine, and the green LED light on the bypass and slave interface card should also light up. If 24 VAC is present, but the actuator does not drive, replace ac-tuator. See Figure 4-11.




4 Bypass Damper Continued

Faulty Feedback pot

Verify the ability of the actuator to drive full open to full closed. Initialize a bypass calibration by cycling power to the Zone Manager. This will cause the actuator to first drive full open (ob-serve light(s) on the Zone Manager and Bypass and Slave Interface Card and damper action), then drive full closed, and then drive approximately 25% open. Also measure voltage from the bypass actuator feedback pot (termi-nals FDBK & GND on the Bypass Damper terminal strip). As the actuator drives toward the open position, this voltage should increase toward 0.0 VDC depending on the amount of travel. As the actuator drives closed, this voltage should increase toward 2.5 VDC. A change of less than 0.4 VDC from full open to closed results in an alarm, indicating either insufficient damper travel, a faulty actuator, or im-proper wiring.

5 Maverick Zone

Insufficient air flow to zone

If zone temperature is more than 4°F from the setpoint for more than one hour, this alarm appears. Check airflow to the zone by depressing the clutch on the actuator and rotating the damper fully counterclockwise. Damper should be fully closed and no airflow to the zone. Rotating the damper clock-wise should open the damper to maxi-mum flow. (Travel should be limited with stop screws for maximum rota-tion). Check damper for ease of movement, correct any sticking situa-tion, and reset the alarm. A Maverick Alarm will automatically be reset when the zone temperature comes within 2 degrees of its setpoint.




5 Maverick Zone Continued

This alarm may also be reset by tempo-rarily resetting the zone setpoint (heat-ing setpoint if zone is cool, cooling setpoint if zone is hot) to the tempera-ture reported by the zone sensor.

Unusual zone load

If a zone is loaded beyond system ca-pacity to cool/heat the space due to large crowds, process load, open doors etc., the result is the same as “insuffi-cient air” to space as listed above, and can only be corrected by removing the unusual load or increasing airflow to the zone.

6 Missing Zone Alarm

No power to zone controller

If LEDs on Zone Controller are not on, check for 24VAC on Zone Controller. If 24VAC is present, but LEDs are not on, check voltage polarity and replace zone board if required.

Improperly ad-dressed

Check dipswitches on zone board for proper setting (refer to Figure 2-13). Switches must be set before power is applied. Replace COMM connector, then remove and replace 24VAC con-nector. Approximately five seconds after power-up, the “SCAN” LED on the zone control board will “blink” its address. Confirm that the proper ad-dress is indicated. Thereafter, the SCAN LED will blink approximately once every ten seconds (refer to Table 4-1).

COMM incorrectly wired

If multiple zones are “missing” and it is not due to improper setting of zone addresses or the Zone Manager address as noted previously, it is a good indica-tion that either communication loop wires are crossed or the polarity on the 24VAC power supply has been crossed and damage to the communication driver chips has occurred.




6 Missing Zone Alarm Continued

If multiple zones are missing, but some zones are communicating, remove the communication plug on all missing zone cards and begin trouble shooting one zone at a time. 1. Check the communication loop for

crossed wires, starting at the Zone Manager (or the “communicating zone” nearest to the “missing” zone). If all zones are missing, start at the Zone Manager and connect only one zone at a time to isolate the problem. Also, check for strands of braided wire that may be loose at the terminal connection and touching adjacent wires. If wiring is crossed, correct the wiring problem. (Crossed COMM Loop wires will cause missing zones, but should not cause damage to the boards).

2. Check COMM Loop voltages. A. Refer to communication loop

troubleshooting guide in this sec-tion.

B. If the voltage on the board “pins” (Step A above) is correct, with the comm plug still removed from the board, measure the voltage on the comm line. If these voltages are not between 2 and 3 VDC it means either there is another controller on the loop with a bad driver chip, or there is a wiring connection problem on the loop that must be corrected by isolating the problem as out-lined above.




7 Missing Zone Alarm (All Zones Missing)

Zone Manager im-properly addressed

The Zone Manager should be ad-dressed as 0. If a CommLink is in-stalled, the address should be set to address 17.

8 Static Null Alarm

Incorrect NULL voltage detected for Pressure Sensor

The NULL voltage is measured with the fan off and no pressure in the duct. This measurement only occurs the first time the Zone Manager is powered up. To force the Zone Manager to re-calibrate the NULL voltage, select the Configure System menu and press the “*” key when prompted to force the restart with calibration.

Faulty Pressure Sensor

Check the voltage to the pressure transducer at TB1 with the fan off. Voltage between SIG and GND should be between 0.23 and 0.27 VDC. This is the NULL voltage. If this voltage is not present, confirm the +5V terminal supplies 5 VDC and wiring to sensor is correct. Before replacing the sensor, remove it from the duct and check the voltages with the sensor directly wired to the controller, using short wire leads, to confirm there are no wiring errors.

9 Zone Damper Fail

Travel Stop Screw slipped

Check the stop screws on the damper actuator. They should be set to prop-erly limit the travel. Reset if necessary.

Damper Binding

Depress the clutch and check the damper for free rotation. Note: If the actuator has driven against its

stop screw, rotating the shaft may not be possible. If this is the case, loosen the setscrews and rotate the damper shaft to observe binding. If the shaft turns freely, reconnect the damper actuator and proceed to the next step. The standard damper closes counterclockwise and is fully open after rotating 85 to 90 degreesclockwise.




9 Zone Damper Fail Continued

Feedback pot fail-ure

If you suspect an actuator feedback failure, replace the actuator with a known working unit to see if the prob-lem is corrected. If not, continue to fol-low troubleshooting procedures for controller, wiring, etc.

Calibration routine failure

Force auto calibrate of the actuator feedback pot: A: Remove the communication wire connector at the Zone Controller. B. Remove the 24VAC power connec-tion at the Zone Controller. C. Replace the 24VAC power connec-tion at the Zone Controller. D. Replace the communication connec-tor at the Zone Controller. E. The actuator will recalibrate the po-tentiometer by driving full closed, then full open, and then start to control. If the actuator does not drive after restor-ing the 24VAC power (in Step C) ei-ther the actuator or the Zone Controller is bad. If the calibration routine is com-pleted and the alarm disappears, the problem may have been an isolated in-cident caused by a power surge.

Connector Cable defective

Check cable by replacing with a known working cable. Replace if required.



Communications Loop Zone Manager Test the communications loop with the system powered up. Set meter to read DC Volts. These tests assume that if the optional CommLink IV is installed, it is also connected and powered up. Actual meter readings may deviate slightly depending on the number of units installed. Any significant deviation from these values generally indicates a problem. If voltages are not within specified ranges, the Zone Manager communications driver chip is likely damaged and will have to be replaced.

Step 1 Measure the voltage at the Zone Manager terminals with the Communications Loop con-nected to the Zone Manager.

Basic System - Without Optional CommLink Installed

Basic System - With Optional CommLink Installed

Measure Voltage Measure Voltage T to SHLD + 2.7 to 2.4 VDC T to SHLD + 3.1 to 2.9 VDC

R to SHLD + 2.6 to 2.3 VDC R to SHLD + 2.1 to 1.9 VDC If the voltages are within the specified voltage ranges, the Zone Manager and communi-cations loop are operating within specifications. If the measured voltages are not within the specified voltage ranges, proceed to Step 2.

+-

T

R

COMM

TB8

SHLD

+

-

+-

T

R

COMM

TB8

+

SHLD

-

Measuring R to SHLDMeasuring T to SHLD



Step 2 Measure the voltage at the Zone Manager terminals with the Communications Loop dis-connected from the Zone Manager.

Step 3 Measure the voltage on the Communications Loop terminals with the Communications Loop disconnected from the Zone Manager.



Measure Voltage Measure Voltage T to SHLD + 2.5 to 2.3 VDC T to SHLD + 2.5 to 2.3 VDC R to SHLD + 2.8 to 2.6 VDC R to SHLD + 2.8 to 2.6 VDC

If the voltages are not within the specified voltage ranges, the Zone Manager communi-cation driver chip is probably damaged and will require replacement. If the measured voltages are within the specified voltage range, the Zone Manager driver chip is not dam-aged, and the problem is related to another part of the loop. Proceed to Step 3.




If the voltages are not within the specified range when checking the communications loop as described above, then one of the Zone Controllers or the optional CommLink (if installed) is the problem. Proceed to the Zone Controller Troubleshooting Section. If a CommLink is installed, also see the CommLink Troubleshooting Section.

T

R

COMM

TB8

SHLD

+-

+

-T

R

COMM

TB8

SHLD

+-

+

-


T

R

COMM

TB8

SHLD

+-

+

-T

R

COMM

TB8

SHLD

+-+

-




Zone Controller Test the communications loop with the system powered. Set meter to read DC Volts. These tests assume that if the optional CommLink is installed, it is also connected and powered up. Actual meter readings may deviate slightly depending on the number of zones installed. Any significant deviation from these values generally indicates a prob-lem. If voltages are not within specified ranges, one of the Zone Controller communications driver chips is likely damaged and will have to be replaced.

Step 1 Measure the voltage at one of the Zone Controller terminals with the Communications Loop connected to the Zone Controller. If you can communicate with some zone control-lers on the loop but not others, start with the first Zone Controller you can’t communicate with to begin testing.




If the voltages are within the specified voltage ranges, the Zone Controller and communi-cations loop are operating within specifications. If the measured voltages are not within the specified voltage ranges, proceed to Step 2.

T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

- T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

-




Step 2 Measure the voltage at the suspect Zone Controller terminals with the Communications Loop disconnected form the Zone Controller.




If the voltages are not within the specified voltage ranges, the Zone Controller communi-cation driver chip is probably damaged and will require replacement. If the measured voltages are within the specified voltage range, the Zone Controller driver chip is not damaged and the problem is related to another part of the loop. Repeat Zone Controller troubleshooting Steps 1 & 2 for each controller on the loop to determine which one is causing the problem. If you have a CommLink (optional) installed, please see the CommLink Troubleshooting Section of this manual.

T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

-

T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

-




CommLink IV (Optional) CommLink IV must be powered for testing.

If the voltages are too high or too low on either side, the CommLink IV has a damaged comm driver chip. Replace the CommLink IV. The driver chip is not field replaceable.

Basic System with CommLink Installed Measure Voltage

T to G + 2.5 to 2.4 VDC R to G + 2.7 to 2.5 VDC

If the voltages are within the specified voltage ranges, the Zone Manager and communi-cation loop are operating within specifications. If the measured voltages are not within the specified voltage ranges, proceed to Step 2.



Bypass Damper Troubleshooting

Figure 4-11: Bypass Damper Troubleshooting

Meter Should Measure Approximately5000 Ohms With Actuator In MiddleOf Full Travel Position. See Item #3 BelowFor Instructions.

+-

Bypass

Actuator

Bypass Damper Package

Zone Manager Board

Transformer

10

+

+

PWR

V4

V3

CLOSE

OPEN

FDBK

GND

GND

24VAC

NE5090

LineVoltage

GND

24VACActuator Clutch

Modular Cable

Bypass Damper Components & Wiring

Power Connection Terminal

Jumper Wire Between24VAC And Open Or CloseTerminal As Required

Jumper WireBetween 24VACAnd Ground

Remove Terminal PlugFrom Zone Manager BoardWhen Performing JumperTesting Of Actuator

Bypass DamperTerminal Plug

Bypass DamperTerminal Socket

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1T

B2

1.) Confirm That All Wiring Is CorrectlyConnected To The Bypass & SlaveInterface Card Terminals And The ZoneManager Bypass Actuator Terminals. BeSure The Modular Cable Is Plugged In ToBoth The Actuator And The Modular PlugLabeled "To Actuator" On The Bypass &Slave Interface Card. If No Wiring ErrorsAre Found, Proceed To The Next Step.

2.) Remove Communications Wiring FromThe Zone Manager Board Then RemoveThe Power From The Zone ManagerBoard. Go To The Bypass DamperLocation And Depress Clutch On TheActuator. Rotate The Actuator Clamp AndDamper Shaft Back And Forth. Check ToVerify That The Damper Moves FreelyFrom Full Open To Full Closed Position.Check For Binding Or Interference ThatPrevents Full Opening And Closing Of TheBypass Damper. If The Damper AppearsTo Move Freely Proceed To The Next Step.

3.) Depress The Clutch On The Actuator.Rotate The Damper Shaft To The MiddleOf The Actuator (SeeDrawing Above For Middle Of Full StrokePosition Picture). Connect The MeterBetween The Ground And FeedbackWires On The Bypass & Slave InterfaceCard As Shown Above. Meter Should ReadApproximately 5000 Ohms. If The MeterDoes Not Read Approximately 5000 Ohms,Recheck The Wiring. If No Wiring ErrorsAre Found The Problem Is Probably A BadActuator Or Modular Cable.

Full Stroke Position

4.)

5.) Remove The Bypass Damper TerminalPlug From The Bypass Damper TerminalSocket On The Zone Manager Board AsShown Above. Run A Jumper Wire FromThe 24VAC Power Connection On TheZone Manager Board To The “Open”Terminal On The Bypass Damper TerminalPlug And A Jumper From The GNDConnection On The Zone Manager BoardTo The GND Terminal On The BypassDamper Terminal Plug.

Disconnect The Jumper Wire From The“Open” Terminal At The Bypass DamperTerminal Plug And Connect The JumperFrom 24VAC To The “Close” Terminal OnThe Bypass Damper Terminal Plug.

Go To The BypassDamper Location To Confirm That TheDamper Moves Towards Its “Closed”(Counterclockwise) Position. If TheActuator Drives In Only One Direction OrDoesn’t Drive In Either Direction It IsProbably A Bad Actuator Or ModularCable. If It Drives Open And Closed In TheJumper Test Just Performed But Not WhenConnected To The Zone Manager Board,The Problem Is Probably The ZoneManager Board.

Reconnect Power To The ZoneManager Board. The Damper ActuatorShould Start Its Calibration Procedure AndMove To Its Full Open (Clockwise) PositionAnd Then To Its Full Closed(Counterclockwise) Position. If The DamperActuator Does Not Move Through Its FullCalibration Range Proceed To The NextStep.

The Green Light OnThe Bypass/Slave Interface Card shouldGlow. Go To The Bypass Damper LocationTo Confirm That The Damper MovesTowards Its “Open" (Clockwise) Position.

TheRed Light On The Bypass/Slave InterfaceCard should Glow.

6.) If You Have Another Actuator MotorOf The Same Type (One Can BeBorrowed From Another Zone Or BypassDamper), You Can Try Switching OutThe Original Actuator And Using TheBorrowed Actuator To Verify Operation.Disconnect The 24VAC Power From TheZone Manager Board. Remove TheJumper Wire That Was Used In ThePrevious Checkout Step. Reconnect TheBypass Damper Terminal Block To TheZone Manager Board. Reconnect The24VAC Power To The Zone MangerBoard.

Replace The Defective Actuator With ANew Actuator.

The Damper Actuator ShouldStart Its Calibration Procedure And MoveTo Its Full Open (Clockwise) PositionAnd Then To Its Full Closed(Counterclockwise) Position. If TheBorrowed Damper Actuator MovesThrough Its Full Calibration Range

(Shown With ActuatorIn Middle Of Full Stroke)

BYPASS &




Temperature Sensor Resistance Chart

Table 4-2: Temperature Sensor Resistance

Temperature (ºF)

Resistance (Ohms)

Voltage @ Input (VDC)

Temperature (ºF)

Resistance (Ohms)

Voltage @ Input (VDC)

-10 93333 4.620 72 11136 2.695 -5 80531 4.550 73 10878 2.665 0 69822 4.474 74 10625 2.635 5 60552 4.390 75 10398 2.607

10 52500 4.297 76 10158 2.577 15 45902 4.200 78 9711 2.520 20 40147 4.095 80 9302 2.465 25 35165 3.982 82 8893 2.407 30 30805 3.862 84 8514 2.352 35 27140 3.737 86 8153 2.297 40 23874 3.605 88 7805 2.242 45 21094 3.470 90 7472 2.187 50 18655 3.330 95 6716 2.055 52 17799 3.275 100 6047 1.927 54 16956 3.217 105 5453 1.805 56 16164 3.160 110 4923 1.687 58 15385 3.100 115 4449 1.575 60 14681 3.042 120 4030 1.469 62 14014 2.985 125 3656 1.369 64 13382 2.927 130 3317 1.274 66 12758 2.867 135 3015 1.185 68 12191 2.810 140 2743 1.101 69 11906 2.780 145 2502 1.024 70 11652 2.752 150 2288 0.952 71 11379 2.722

Notes: 1. Use the resistance column to check the thermistor sensor while disconnected from the controllers

(not powered). 2. Use the voltage column to check sensors 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 sensor input terminal being investigated.

If the voltage is above 5.08 VDC, the sensor or wiring is “open.” If the voltage is less than 0.05 VDC, the sensor or wiring is shorted.



Pressure Sensor Voltage Chart

Table 4-3: Pressure Sensor Voltage

OE271 Duct Static Pressure Sensor

Pressure @

Sensor (“ W.C.)

Voltage @

Input (VDC)

Pressure@

Sensor(“ W.C.)

Voltage @

Input (VDC)

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

Notes: 1. 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 the GND ter-minal and the “+” (plus) lead on the SIG terminal on TB1.



Figure 4-12: Driver Chip Locations



Figure 4-13: Replacing Driver Chips

Small FlatheadScrewdriver

Chip

Chip

Printed CircuitBoard



Chip

WARNING!

Direction Of Pull

Notch

Dot

Pin1

Be sure the chip you have selected to replace is asocketed chip. Not all driver chips on the boardsare field replaceable. Only socketed chips may beremoved and replaced in the field. All other chipsthat are not socketed will require sending the boardto the WattMaster factory for repair.

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

Remove the communications loop connector andthen the 24VAC power connector on the controllerbefore attempting to change any components.

will occur if components are removed orinstalled with power applied.

If you are unsure how to safely remove the chip orabout the correct pin placement, please consult thefactory before proceeding.

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

Each chip be installed with Pin 1 in the correctlocation. Installing the chip “backwards” will in mostcases destroy the device when power is reapplied.

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

Be certain that pins are lined up in the socketbefore pressing the chip in. Failure to properly lineup the pins will result in damage to the chip.This is a common error -

Only after confirming that the chip has been correctlyinstalled with Pin 1 in the proper position and that thepins are lined up and none are bent or out of the socket,should communication or power wiring be reconnectedto the board. Tp prevent possible damage alwaysreconnect the power wiring first and then thecommunication wiring.

If you try to

remove a chip that is not socketed it will destroy

the circuit board.

DAMAGE

Damage to the board caused by failure to correctly

remove or install the chip is not covered by the

WattMaster warranty.

MUST

ALL

VERY BE CAREFUL.

Using I.C. Puller To Remove Socketed Chip

Using Screwdriver To Remove Socketed Chip

End View Of Socketed Chip AssemblyTop View Of Socketed Chip Assembly

I.C. Puller

Chip Socket

Chip Socket

Chip Socket

Gently Rock Chip Side To Side And ThenLift Straight Up To Remove Chip FromChip Socket.

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



Index 1 to 16 ............................................... 1, 4 24VAC Power

Wiring ............................................... 9 Actuator

Motor Failure .................................. 27 Troubleshooting .............................. 21

Address 0 Zone Manager ................................... 1

Address 17 Zone Manager ................................... 1

Address Switch Setting Zone Manager ................................... 3

Addressing 1 to 16 ............................................... 4 Duplicate ........................................... 4 Improper............................................ 4 Zone Controller................................. 4

Air Flow Insufficient ...................................... 28

Alarm Call-Out ..................................... 5 Bad Duct Sensor ................................. 25 Bad Static Sensor ................................ 25 Bad Zone Sensor ................................. 26 Basic System

Communications Checklist ............... 7 Wiring ............................................... 3 Worksheet ....................................... 15

Blink Codes Bad Airflow Sensor......................... 18 Bad Zone......................................... 18 Communication Failure .................. 18 Damper Failure ............................... 18 Normal Operation ........................... 18 Override Active............................... 18 Zone Controller............................... 18

Board Damage ....................................... 9, 11

Bypass Damper Sticking ........................................... 27 Troubleshooting .............................. 38

Bypass Damper Calibration ................ 17

Calibration Failure ............................................. 32 System............................................. 16

Checklist Troubleshooting .............................. 19 With CommLink ............................... 7 Without CommLink .......................... 7

Comm Loop Problems ......................................... 23

COMM LOOP Troubleshooting ........................ 21, 22

Commissioning ................................... 12 CommLink IV....................................... 7

Communications Loop, Troubleshooting .......................... 37

Driver Chip Location ...................... 41 Jumper Settings................................. 6 Jumper Switch................................... 2 Overview........................................... 5 R to G.............................................. 37 T to G .............................................. 37 Voltages .......................................... 37 Wiring ............................................... 5

Communications Overview........................................... 1

Communications Checklist Basic System..................................... 7 With CommLink ............................... 7 Without CommLink .......................... 7

Communications Loop.......................... 2 Diagnostics........................................ 1 Troubleshooting ................................ 1

Components Zone Controller............................... 10

Computer On-Site .............................................. 5 Remote .............................................. 5

Connector Cable Defective ......................................... 32

Cooling Locked Out...................................... 19 Short Cycling .................................. 19



Damage Board........................................... 9, 11

Damper Binding............................................ 31 Troubleshooting .............................. 21

Date and Time..................................... 16 Diagnostics

System............................................. 16 Display Screen

Black ............................................... 23 Troubleshooting .............................. 23 Washed Out..................................... 23

Display Screen Blank.......................... 23 Driver Chip

Locations......................................... 41 Driver Chips

Replacing ........................................ 42 Duct Temp Sensor

Faulty .............................................. 24 Economizer

Troubleshooting .............................. 19 Errors

Communication................................. 4 Ethernet Router ..................................... 7 Failure

Actuator .......................................... 27 Faulty

Feedback pot ................................... 28 Faulty Pressure Sensor........................ 31 Faulty Sensor ...................................... 25 Faulty Wiring ...................................... 25 Feedback pot

Faulty .............................................. 28 Feedback Pot Failure .......................... 32 Fluctuating Readings ............................ 4 Heating

Locked Out...................................... 19 Short Cycling .................................. 19

Initializing Zones............................................... 17

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

IP Module ............................................. 7 Jumper Settings

CommLink IV................................... 6 LEDs

Zone Controller............................... 18 Loop Master .......................................... 1 Maverick Zone

Troubleshooting .............................. 28 Missing Zone Alarm ........................... 29 Number of Zones ................................ 16 Optional Equipment .............................. 7 Phone Line ............................................ 7 Polarity

Reversing ........................................ 11 Polling For

Zones............................................... 17 Pressure Sensor

Faulty .............................................. 31 Voltage Chart .................................. 40

Prism ..................................................... 7 Procedures

System............................................. 12 Quick Overview

System............................................... 8 R to G

CommLink IV................................. 37 R to SHLD

Zone Controller............................... 35 Zone Manager ................................. 33

REC LED Troubleshooting .............................. 22

Remote Link II...................................... 7 Room Sensor

Metering.......................................... 20 Troubleshooting .............................. 20

Router.................................................... 7 SCAN LED ......................................... 18

Troubleshooting .............................. 22 Second Stage Heat

Troubleshooting .............................. 24 Won't Come On............................... 24

Sensor Faulty .............................................. 25

Single Loop Operation.......................... 1 Slide Adjust

Metering.......................................... 20 Start-Up Delay .................................... 16 Static Null Alarm ................................ 31 STATIC Pressure Null Voltage .......... 16 Static Sensor



Faulty .............................................. 25 Steps

System Setup..................................... 7 System

Commissioning ........................... 4, 12 Initiating.......................................... 12 Start-Up........................................... 16

System Diagnostics............................. 16 System Setup

Steps.................................................. 7 T and R Wires

Reversing .......................................... 4 T to G

CommLink IV................................. 37 T to SHLD

Zone Controller............................... 35 Zone Manager ................................. 33

Temperature Sensor Resistance Chart ............................. 39

token-passing ........................................ 1 Transformer......................................... 11 Troubleshooting Chart ........................ 23 Troubleshooting Checklist .................. 19 Voltage

Too Great .......................................... 9 Wires

Reversing .......................................... 4 Wiring

24VAC Power................................... 9 Basic System..................................... 3 CommLink IV................................... 5 Faulty .............................................. 25 Improper.......................................... 27 Reconnecting .................................. 13 Zone Controller........................... 4, 11 Zone Manager ............................... 3, 9

Worksheet Basic System................................... 15

Zone Too Cool ......................................... 19 Too Warm ....................................... 19

Zone Alarm Missing............................................ 29

Zone Controller Address ............................................. 1 Address Troubleshooting................ 21

Addressed Incorrectly ..................... 23 Addressing ........................................ 4 Blink Codes..................................... 18 Communications Loop,

Troubleshooting .......................... 35 Components .................................... 10 Driver Chip Location ...................... 41 Inputs .............................................. 10 LEDs ............................................... 18 Outputs............................................ 10 R to SHLD ...................................... 35 T to SHLD....................................... 35 Voltages .......................................... 35 Wiring ......................................... 4, 11

Zone Controllers Overview........................................... 4

Zone Damper Failed .............................................. 31 Not Working ................................... 21 Troubleshooting .............................. 21

Zone Manager Address ............................................. 1 Address 0 .......................................... 1 Address 17 .................................... 1, 5 Address Switch Setting..................... 3 Address Troubleshooting................ 21 Communications ............................... 3 Communications Loop,

Troubleshooting .......................... 33 Components ...................................... 8 Correct Wiring .................................. 9 Depicted .......................................... 16 Driver Chip Location ...................... 41 Function ............................................ 1 Initializing Continuously ................ 23 Inputs ................................................ 8 Location, Establishing .................... 12 Outputs.............................................. 8 Overview........................................... 3 R to SHLD ...................................... 33 T to SHLD....................................... 33 Troubleshooting .............................. 23 Voltages .......................................... 33 Wiring ........................................... 3, 9

Zone Sensor Bad .................................................. 26



Reading Incorrectly......................... 20 Troubleshooting .............................. 20

Zones

All Missing ..................................... 31 Aren't Communicating .................... 21

Cool Light Won't Come On ............ 24 Initializing....................................... 17 Not Communicating........................ 21 Polling For ...................................... 17 Troubleshooting .............................. 24

Form: WM-AZB-IO-02C Printed in the USA May 2009All rights reserved. Copyright 2009WattMaster Controls, Inc. • 8500 NW River Park Drive • Parkville, MO • 64152Phone (816) 505-1100 www.wattmaster.com Fax (816) 505-1101

Basic System - Auto-Zone Control S

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