CONTROL · PDF fileAuto-Zone CONTROL SYSTEM Auto-Zone Plus System with Zone Manager MC Design, Installation & Operations Manual

Auto-ZoneC O N T R O L S Y S T E M

Auto-Zone Plus Systemwith Zone Manager MC

Design, Installation &Operations Manual

Auto-ZoneC O N T R O L S Y S T E M

Auto-Zone Pluswith Zone Manager MC

Installation & Operations Manual

Section 1.........................................................................................Data SheetDesign Guide

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 Installation & Operations Manual - Form WM-AZP-IO-01AAuto-Zone is a registered trademark of WattMaster Controls, Inc.

Copyright 1997 WattMaster Controls, Inc.All rights reserved.

Section 1

Design Guide

Table of ContentsConventions .................................................................................................1General Information ...................................................................................3

Description of System Components..............................................................................3Design Considerations.................................................................................6

Zone Diversity.............................................................................................................6Cooling - Partial Load Conditions ................................................................................6Heating - Partial Load Conditions ................................................................................9Override Conditions.....................................................................................................9Building Pressurization ................................................................................................9

Design Guide .............................................................................................10Step #1 - Zoning ........................................................................................................ 10Step #2 - Sizing the Central Unit ................................................................................ 12Step #3 - Duct Design Considerations........................................................................ 12Step #4 - Room Air Motion/Diffuser Selection........................................................... 13Step #5 - Bypass Damper Sizing ................................................................................ 13Step #6 - Sizing the Zone Damper.............................................................................. 16

Auxiliary Heat Control Options ...............................................................18

Table of FiguresFigure 1-1: Auto-Zone Plus System................................................................................2Figure 1-2: Control Zones Affected by the Outdoor Load ............................................. 11Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control................. 15Table 1-1: Damper Sizing Chart................................................................................... 16Table 1-2: Pressure Independent Flow Factors............................................................. 17

Auto-Zone Plus Section 1

Design Guide 1-1

ConventionsThis document uses the following definitions throughout as a guide to the user indetermining 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 willnot otherwise damage components.

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

Section 1 Auto-Zone Plus

1-2 Design Guide

CommLink IIMultiple Loop

Computer(Optional)

To Other ZoneManagers

(Up To 30 Per System)

ZoneManager

ZoneManager

RS-4859600 Baud

SupplyAir Temp Sensor

SupplyAir Temp Sensor

To HVAC Unit #1Control Panel

To HVAC Unit #2Control Panel

ReturnAir TempSensor

ReturnAir TempSensor

Bypass AirDamper

Bypass AirDamper

Economizer(Actuator By Others)

OutsideAir TempSensor

StaticPressureSensor

StaticPressureSensor 24VAC

Constant Volume UnitsUp to 13 CV Units May Be added To

Each Zone Manager Loop

System Manager

Local Loop

Local Loop

Network Loop

24VAC

24VAC

Zone Air DampersUp to 16 Zone Air Dampers Allowed

Zone Air DampersUp to 16 Zone Air Dampers Allowed#1

#1

#18#16

#16

#30

24VAC

Remote Link(Optional)

Figure 1-1: Auto-Zone Plus System


Design Guide 1-3

General InformationThe Auto-Zone Plus control system converts single-zone, or Variable Air Volume rooftoppackaged HVAC units into variable air volume/variable temperature multiple zonesystems. The microprocessor based Zone Manager MC calculates the heating and coolingrequirements for each zone based on real time information received from each ZoneController. The Zone Manager MC then directs the HVAC unit to provide the appropriateamount of heating, cooling, and ventilation to satisfy each zone's requirements. A static airpressure sensor modulates a bypass damper, or controls the supply fan speed through aVariable Frequency Drive (VFD) to maintain constant duct pressure.

The Auto-Zone Plus System Manager allows multiple Zone Managers to be programmedand monitored from a central operator's panel. Single-zone constant volume rooftopHVAC units can also be connected to the Auto-Zone Plus communication network,allowing for both multizone and single-zone equipment to be controlled from the samesystem.

Substantial savings can be realized using the Auto-Zone Plus system instead of having toinstall multiple rooftop units to accommodate multiple zone requirements. The Auto-ZonePlus system is versatile and can be used with any packaged roof top unit or split system. Itcontrols a variety of terminal unit functions including single duct pressure dependent orpressure independent systems.

An optional color graphics software package is available for on site or remote monitoring.

Description of System ComponentsA typical Auto-Zone Plus system is comprised of the following basic components.

System ManagerThe microprocessor based System Manager allows multiple Zone Managers and anysingle-zone constant volume HVAC units to be programmed and monitored from a centraloperator's panel. The System Manager is connected via the Auto-Zone Pluscommunication network.

The System Manager is mounted in an attractive, white plastic housing, suitable for wallmounting. A four line by twenty character backlighted LCD display and membrane keypadprovide a user friendly interface. All system variables, setpoints, and values can be viewedand modified from the System Manager. Menu driven programming makes the Auto-ZonePlus easy to set up and operate without the need for specialized training.


1-4 Design Guide

CommLink IIThe CommLink II communications interface allows user access to any controller. Locally,access is by means of an on-site computer. Remote access is obtained via modem. TheCommLink II may also be configured for Call-Out on Alarm. The CommLink II comespackaged in an attractive plastic enclosure and is powered by a small wall mountedtransformer. The CommLink II should be located near the computer which will be used tomonitor the system. If no on-site computer is to be used then locate the CommLink II nearthe phone line jack if a modem is to be used. The cables from the CommLink II-to-modemand the CommLink II-to-computer should not exceed twenty-five feet.

Zone Manager MCThe Zone Manager MC is a microprocessor based controller which monitors up tosixteen zones in the system. The zone manager then controls the HVAC unit to satisfy therequirements of each individual zone while maintaining efficient operation and comfort.The Zone Manager MC operates the fan, heating, cooling, duct static pressure, andeconomizer functions. Each Zone Manager also features time scheduling, night set back,trend logging of sensor values, and automatic changeover.

Bypass Damper or VFD ControlThe bypass damper controls proper duct static pressure to insure proper air flow. Thedamper is modulated by the Zone Manager MC, based on a signal received from the staticpressure sensor connected to the main duct. The VFD control sends a 0 – 10 vdc signal toa variable frequency drive based on a signal received from the static pressure sensorconnected to the main duct.

Zone ControllerThe Zone Controller monitors space temperature and allocates proper air flow to theassigned zone to achieve desired comfort and ventilation levels. If supply air temperaturewill benefit the local zone temperature setpoint, the zone damper modulates to reduce orincrease air flow as needed. If supply air will not benefit the local zone, the controller willdirect the damper actuator to a minimum position and wait for a change in supply airtemperature.

Constant Volume ControllerThe Constant Volume (CV) Controller is a microprocessor based controller designed tooperate packaged roof top HVAC units. Up to thirteen stand alone CV controllers can beconnected to each Zone Manager's local communications loop to provide a fully integratedmultizone/single-zone control system. The CV controller operates the fan, heating,cooling, and economizer functions. Each CV controller also features time scheduling,night set back, trend logging of sensor values, and automatic changeover.


Design Guide 1-5

Zone SensorThe patented zone sensor is of a flush, wall mounted design. A special plate on the face ofthe sensor accurately senses space conditions. As a result of its unique design, the zonesensor rejects the influence of internal wall temperature effects. The sensor comes in fourdifferent configurations:

• Sensor only• Sensor w/push-button override (Override time 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.

Expansion BoardsThe available expansion board configurations allow for 2 additional analog outputs tocontrol modulating hot water and/or chilled water valves and up to 4 additional binary(relay) outputs for up to 6 stages of heating or cooling.


1-6 Design Guide

Design ConsiderationsConsider the following items when designing an Auto-Zone Plus system.

Zone DiversityAn Auto-Zone Plus system is designed to improve tenant comfort by dynamically re-balancing the air distribution when used with a typical constant volume rooftopheating/cooling unit. If zones with extremely different load conditions are serviced by asingle rooftop unit, the result will be poor control and excessive wear due to cycling of theequipment.

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 mustmix zones under these conditions, consider using either VAV boxes with heat or separatebaseboard heat on exterior zones. Auto-Zone Plus systems offer a variety of methods tocontrol additional zone heat to help you avoid problems.

Group similar loads on an individual unit and use more than one zoned unit if required.Any special loads can be handled by using separate constant volume units.

The Auto-Zone Plus system offers the designer considerable flexibility by allowing bothmultiple-zoned units and single-zone units to be connected within a single simple system.

Cooling - Partial Load ConditionsThe engineer must be aware of several potential problems when applying an Auto-ZonePlus system during cold weather operation.

Low Ambient Temperature LockoutDuring very cold weather it is common for mechanical systems to have “low templockouts” which protect equipment from damage if operated under these conditions.Auto-Zone Plus 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 whenoutside temperatures are below the safe operating limits for your equipment, you shouldseriously consider installing an economizer on your rooftop unit. The Auto-Zone Pluscontrol system is designed to take advantage of an economizer if it is installed. The use of


Design Guide 1-7

an economizer will save money on utilities and provide comfort under conditions when itis not possible to operate the mechanical cooling system.

Low Supply Air TemperaturesUnder lightly loaded conditions much of the supply air may be bypassed back into thereturn air side of the system. This bypassing will result in the lowering of the supply airtemperature, which may result in the supply air temperature reaching the low temp safetylimit. 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 mechanicalsystem will result if this condition persists. Comfort may also suffer if the system cannotrun long enough to satisfy cooling demands.

A number of things can be done to reduce this problem. Some of these things dependupon the type of installation.

• Avoid oversizing the unit. Do your load calculations carefully. Since Auto-Zone Plusdirects the heating or cooling to the zones which require it, you may find that you canuse a smaller unit in many cases. Oversizing is the number one cause of excessive lowsupply 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 causeover 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 ductedreturns 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 staticpressures. This will not work if you are using pressure independent zone controllers,since they will maintain a constant flow of air to the zones regardless of duct staticpressure. This technique will likely cause over cooling of the spaces due to increasedairflows at minimum positions.


1-8 Design Guide

Warning: If the fan system has the capability of producing static pressures whichcould damage ductwork you must provide a manual reset, highpressure limit switch to cut-off the fan system in the event of high ductstatic. Do not use your Auto-Zone Plus system as asafety device!

• Use an Economizer. Although this is not a cure-all, it greatly improves operationduring cool weather when cooling loads are minimal. Using an Economizer alsoimproves ventilation and lowers operating costs.


Design Guide 1-9

Heating - Partial Load ConditionsHeating 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 Plus has a number of auxiliary heat control options which provide solutions tomost problems. Refer to the Auxiliary Heat Control Options topic near the end of thissection.

Override ConditionsAfter-hours overrides can produce aggravated partial load conditions in both the heatingand cooling modes. The problem is most commonly caused by a single zone beingoverridden for after-hours use. This causes the rooftop equipment to operate for only onezone. The Auto-Zone Plus system offers an improved solution to this common problem byallowing a single override to trigger a group of zones via a “global” override. This allowsthe system to operate with sufficient load to reduce cycling caused by light loadconditions.

Building PressurizationIf you are using an economizer, building pressurization must be addressed. Failure toproperly handle building pressurization may result in doors remaining open when theeconomizer is operating. Pressurization problems can render economizer operationuseless. The following suggestions will help to avoid potential problems.

• Use powered exhaust when the system uses ducted returns. The return duct pressuredrop will cause most barometric relief dampers to function poorly or not at all. Auto-Zone Plus has the ability to control a powered exhaust whenever the economizer isoperating.

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


1-10 Design Guide

Design GuideThere are six basic steps to designing an Auto-Zone Plus system:

1. Zoning2. Sizing the Central Unit3. Duct Design Considerations4. Room Air Motion / Diffuser Selection5. Bypass Damper Sizing6. Sizing Zone Dampers

Step #1 - ZoningDetermine the number of zones. A single air handler unit can have no more than sixteenzones. If the number of zones exceeds sixteen then more than one Zone Manager will berequired.

The primary precaution to be taken in applying the Auto-Zone Plus System is to select thezoning so that no zone will be at maximum (design) heating (or cooling) load when anyother zone requires the opposite temperature air to satisfy its load. For example,depending on the wall, ceiling and floor material and location within the building (e.g. topor middle floor), a typical floor of a building usually has a minimum of nine distincttemperature or control zones that are affected uniquely by the outdoor load. These zonesare depicted in Figure 1-2.

Depending on the size of the building and partition layout, some of these zones mayoverlap or be insignificant from a zoning standpoint. For example, Zone 9 could bemultiple conference or computer rooms where additional zoning would be required, or itcould be as small as a corridor where no zoning is required. Similarly, zones 7 and 8 couldhave no external windows and no partitions between them and could be considered asingle zone. Zone 6 could be divided into multiple offices with full partitions betweenthem, thus requiring separate Zone Controllers because of different internal loads, but thesame external load.

Generally, the greater the number of individual Zone Controllers, the greater the comfort.The designer will have to look at the specific building, balancing the costs of multiplezones with the added comfort possible with multiple zones, to match the owner'srequirements.


Design Guide 1-11

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

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


1-12 Design Guide

Step #2 - Sizing the Central UnitBecause the zones are controlled with variable air volume, it is unlikely that all zones willbe at design load at the same time. The zoning allows for the diversity of loads to be takeninto 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 dependableload estimating program. Because of diversity, the central unit should be selected for theinstantaneous peak load, not the sum of the peak loads, as would be done with a constantvolume 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 totalbuilding/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 ofbase design.

Step #3 - Duct Design ConsiderationsThe AZ Plus system uses a typical low pressure duct design. To reduce noise problemsduct pressures should not exceed 1 inch W.C.

Primary trunk ducts should not be "undersized." This is especially true for "pressuredependent" systems. Pressure dependent refers to the typical Auto-Zone, Zone Controllerwithout the air flow sensor. With larger trunk ducts, it is easier to assure relatively constantpressure to each zone. Runs should be as short as possible, and the trunk duct system keptas symmetrical as possible to facilitate system balancing. Wherever possible, run the trunkducts above corridors and locate the zone dampers above corridors to reduce the noise inthe space and facilitate service of the units. Trunk ducts should be sized for no more than0.1 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 canbe exceeded by up to 50 percent. The designer, however, should be veryexperienced in VAV system design before considering modification of thisgeneral rule.

Typical VAV systems with pressure independent terminals use the static regain method forsizing ducts. The typical Auto-Zone Plus system is a low-pressure, pressure dependentsystem that utilizes conventional unitary air-conditioning units. These systems should usethe equal-friction method of sizing the ducts, and use the maximum loss of 0.1 inch per100 feet as described above.


Design Guide 1-13

Step #4 - Room Air Motion/DiffuserSelectionAir motion is a consideration for occupant comfort. The selection of diffusers for an Auto-Zone Plus system requires more care than a constant volume system due to varying flowof air into the zones. Slot diffusers are recommended due to their superior performance atlow air flows. Because the zone air flow is variable volume, lower cost round orrectangular diffusers that were satisfactory for constant volume may prove unsatisfactorywith an Auto-Zone Plus system. These diffusers may result in "dumping" of the cold air atlow flows in the cooling mode, and insufficient room air motion at low air flows in theheating mode. Although high air motion in the heating mode can be undesirable, a slotdiffuser with a high induction ratio generally helps to reduce room air "stratification" whenthe heating comes from a ceiling diffuser. Linear slot diffusers should be properly selectedfor the air flow and "throw" suited to the specific installation or zone.

Additional factors to consider in diffuser selection is sound level and throw at design flow.Generally, multiple diffusers will result in lower sound levels in the space, but this must bebalanced with the additional hardware and installation costs. It is commonly recommendedthat slot diffusers be located near the perimeter or outside wall with the airflow directedinto the room. Consult your diffuser supplier or catalog for proper diffuser sizing andlocation.

Series fan boxes may be used instead of zone dampers where higher induction rates aredesirable. If the heat loss on perimeter walls is high, such as large areas of glass, the use ofSeries 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 usehigh quality slot diffusers next to the outer wall with the airflow directed inward tocounteract downdrafts during heating. Serious downdraft problems occur when heatlosses exceed 400 BTUH/LINEAR FOOT and both high induction diffusers and series fanboxes are recommended.

Step #5 - Bypass Damper SizingUsing a load calculation program, the bypass damper should be sized to give you themaximum CFM of air to be bypassed, typically 60 to 70 percent of the HVAC units ratedcapacity.

To size the damper, select a damper from the table based on calculated bypass CFM and amaximum velocity between 1750-2250 FPM. When determining the bypass duct size, besure to take into account any transition fittings and associated pressure drops. (See Table1-1: Damper Sizing Chart)


1-14 Design Guide

Whenever possible, use a single bypass damper and round duct for the bypass. If spacelimitations or total airflow requires it, multiple bypass dampers can be controlled inparallel.

For proper control of the Bypass Damper or a VFD, the static pressure sensor location isvery important. Refer to Figure 1-3: Locating the Static Pressure Sensor for BypassDamper Control for proper mounting locations.


Design Guide 1-15

Preferred LocationIf the trunk ducts are properly sizedfor minimum pressure drop, thelocation of the static pickup probeis not particularly critical. It shouldideally be located at right angles tothe airflow in a straight section ofthe supply duct approximately 2/3the distance of the total length ofthe supply duct. Also the probeshould be located not less than 3duct diameters downstream and 2duct diameters upstream of anyelbow or takeoff.

Less Than Ideal, ButAcceptableSince the "ideal" location is oftendifficult to find in an installation, alocation in the main trunk wherethe tip is not in a "negative pressurearea" (e.g. just downstream of theinside curve of an elbow) or an areawhere the tube opening is directlyimpacted by the velocity of thesupply air.

Least Desirable, ButAcceptableIf the supply duct comes directlyfrom the unit and immediately splitsin opposite directions, the pressurepickup should be located ahead ofthe split, or as close to it aspossible, even if the bypassdamper(s) are located downstreamof the split.

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


1-16 Design Guide

Step #6 - Sizing the Zone DamperUse a load program to determine the peak load for each zone. These calculations will beused in selecting the appropriate zone damper sizes.

Using the maximum acceptable velocity for a branch duct (typically 1000-1500 FPM forminimal noise), find the smallest damper that will deliver the required CFM as determinedby the load program.

Locate the branch velocity used in the duct design program on the left hand column of thedamper sizing chart (Table 1-1). Move across the chart and find the damper which willprovide the acceptable CFM to meet zone requirements.

Note: Compare the damper size selected against the duct size to determine if the nextsize up or down will provide acceptable performance without requiring atransition fitting.

One additional damper may be slaved together for large zones. See zone wiring diagramfor details. This should be reserved for situations when it is not practical to use a singlelarge damper.

Damper Sizeè 6" 8" 10" 12" 14" 16"Area SQ./FTè 0.188 0.338 0.532 0.769 1.050 1.375Velocity FPM

êCFMê

500 94 169 266 385 525 687750 141 254 399 577 788 10311000 188 338 532 769 1050 13751250 235 423 665 961 1313 17181500 282 507 798 1154 1575 20621750 329 592 931 1346 1838 24052000 376 676 1064 1538 2100 2749

Table 1-1: Damper Sizing Chart


Design Guide 1-17

DamperSize

Flow Probe “K” Factor

6” 4748” 950

10” 141712” 212014” 290816” 3700Flow Probe “K” Factor =

CFM @ 1” Velocity Pressure

Table 1-2: Pressure Independent Flow Factors

Note: K Factors are programmed for each zone so correct CFM will be calculated forthe different size air valves.


1-18 Design Guide

Auxiliary Heat ControlOptionsThe Auto-Zone Plus system offers the user a variety of methods to deal with zone heatingrequirements. When deciding how to handle zone heating requirements the user shouldconsider 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, the user 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 aheating demand is created at the rooftop unit?

A: This mode is useful if you expect to have both heating and cooling demands at thesame time. The zone will use it’s own heat and allow the rooftop unit to continue toprovide cooling for other zones. This mode is also useful if the rooftop unit does nothave any heating capabilities.

Q: Is the zone heat only to be used as a second stage, where it will be activated only ifthe rooftop unit cannot maintain the space temperature, such as during very coldweather?

A: In this mode of operation the rooftop will examine the heating and cooling demandsand try to satisfy all of the zones by switching between heating and cooling asrequired. The zone heat will only be activated if the zone temperature falls below aselected 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 andonly use zone heat when the rooftop unit is in cooling or vent mode. This often providesthe most cost effective operation since zone heat is typically electric. This mode ofoperation will lockout zone heat if the rooftop is delivering heated air.


Design Guide 1-19

The following describes the operation of each of the relays on the optional relay expansionboard. The user can choose the appropriate relays for any given application.

Relay #1 - Parallel FanIf the Zone is in cooling mode or vent mode, the parallel fan can activate anytime the zonetemperature drops 0.5°F below the heating setpoint. It de-activates when the temperaturerises above the heating setpoint. The space temperature must be below the AUX HEATsetpoint in the occupied mode, before the Parallel Fan relay can be energized.

Relay #2 - Box HeatIf the zone is in cooling mode or vent mode then the box heat can activate anytime thezone temperature drops 1.5°F below the heating setpoint. It de-activates when thetemperature rises to within 1.0°F of the heating setpoint. Box heat is not allowed toactivate 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 satisfyingcooling demands in other zones. The space temperature must be below the AUX HEATsetpoint in the occupied mode, before the Box Heat relay can be energized.

Relay #3 - Aux HeatIn the occupied mode, the aux heat can activate anytime the zone temperature is 0.5°Fbelow the aux heat setpoint. It de-activates when the temperature rises 0.5°F above theaux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heatingsetpoint with the same deadband values mentioned above. This prevents the zone frommaintaining 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 andalso to allow a zone an attempt to satisfy its own heating needs before creating a heatingdemand at the Zone Manager.

Relay #4 - Series FanThe series fan runs anytime the main fan is running. This includes occupied andunoccupied modes. The fan can only start running when the zone damper is closed, so itdetermines that the damper is closed before starting the fan.


1-20 Design Guide

Notes:

Section 2

Installation and Wiring

Table of ContentsTips Before Beginning Installation .............................................................1Zone Manager MC......................................................................................3

Expansion Boards ........................................................................................................5Zone Manager MC Addressing ..................................................................7Communications Loops...............................................................................8

Communications Loop Wiring Overview......................................................................8Bypass Damper .........................................................................................11Zone Controllers........................................................................................13Constant Volume Controllers ...................................................................17Constant Volume Controller Addressing .................................................20Zone Sensors..............................................................................................21Supply Air Temperature Sensor...............................................................23Return Air Temperature Sensor ..............................................................23Outside Air Temperature Sensor .............................................................24Static Pressure Sensor...............................................................................25Auxiliary Relay Board for Zone Controllers ...........................................27

Auto-Zone Zone Controller Relay Expansion Board Operation.................................. 28CommLink II Interface.............................................................................29Notes: .........................................................................................................31

Table of FiguresFigure 2-1: System Overview.....................................................................................2Figure 2-2: Auto-Zone Plus Zone Manager................................................................3Figure 2-3: Zone Manager Wiring..............................................................................4Figure 2-4 Expansion Board Wiring ............................................................................5Figure 2-5: Zone Manager Address Switch Setting ....................................................7Figure 2-6: Communication Loop Wiring, Daisy-Chain Configuration........................9Figure 2-7: Bypass Actuator Wiring......................................................................... 12Figure 2-8: Zone Controller Wiring.......................................................................... 15Figure 2-9: Zone Controller Address Switch Settings............................................... 16Figure 2-10: Constant Volume Controller ............................................................... 17Figure 2-11: Constant Volume Controller Wiring .................................................... 18Figure 2-12: CV Controller Address Switch Setting ................................................ 20Figure 2-13: Zone Sensor Wiring ............................................................................ 21Figure 2-14: Static Pressure Sensor Wiring ............................................................. 26Figure 2-15: Auxiliary Relay Board Layout ............................................................. 27Figure 2-16: CommLink Interface Wiring................................................................ 30


Installation and Wiring 2-1

Tips Before BeginningInstallationTake a few moments to review the following before beginning installation of the Auto-Zone Plus System.

• Familiarize yourself with all system components and review all documentation. Payspecial attention to “Cautions” and “Warnings” since these may keep you fromexperiencing unnecessary problems.

• Before installing zone dampers, be sure to tag each damper with its appropriate

location. A set of labels is included with this manual. It is also best to set the zonecontroller address switches before mounting in drop ceilings. Use the Zone AddressWorksheet to list all zone locations. This will assist you greatly when setting up thesystem.

• Be sure and 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 wiringdiagrams as to which color wire you will be using on each terminal.

Note: Auto-Zone Plus systems use two separate types of communications loops. TheNetwork Loop connects only to the Zone Managers and the CommLink II.The Local Loops connect between the Zone Manager and the Zone Controllersfor that HVAC unit. Each Zone Manager has its own Local Loop forconnection to associated Zone Controllers and any additional Constant Volumeunits and the System Manager.

Do not connect zone controllers, constant volume unitsor the system manager to the network loop!

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



Zone Manager MCThe Zone Manager MC may be installed in any convenient protected location. Observethe recommended environmental limitations for the Zone Manager (see Technical Datasection of the product data sheet) when choosing a location.

The Zone Manager MC may be mounted without removing the controller from themounting plate. The unit is mounted by four (4) screws in the corners. Select the correctscrews or other fasteners for the type of mounting material being utilized.

Figure 2-2: Auto-Zone Plus Zone Manager MC



Figure 2-3: Zone Manager Wiring

See Figure 2-4 forExpansion Board wiring.



Expansion Boards

Figure 2-4 Expansion Board Wiring

The Expansion Boards are connected to the Zone Manager MC board with a modularcable. The Analog Expansion Board is plugged into the Base board. The chilled watervalve is wired from AOUT1 and GND, and the hot water valve is wired from AOUT2 andGND. Both outputs send a 0-10 VDC signal to the valve actuators.The Relay Expansion Board is also plugged into the base board. Two Relay ExpansionBoards can be used in place of the Analog board if more than 4 extra relay outputs arerequired.

Cool/Heat 3Cool/Heat 4Cool/Heat 5Cool/Heat 6

4RLY IO BD. YS101790

24VA

C

GN

D

4 AOUT MOD I/O BD YS101786

AOUT4

AOUT3

AOUT2

AOUT1

GND

CW

HW

Modulating

CW

VAlve

Modulating

HW

VAlve

NOTE:All three jumpersmust be installed forthe modulating watervalve control!

NOTE:The center jumper mustbe removed for relayexpansion board!



Warning: Use extreme care not to damage any of the electronic components whilemounting the backplate. Mark the holes then remove the Zone Managerbefore drilling. Do not allow metal shavings to fall onto the circuitboards.

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

-24VAC Supply Voltage ........................................................................2 Conductors-Communications Loops .....................................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 - CommonG - Fan

Y1 - Cool 1Y2 - Cool 2W1 - Heat 1W2 - Heat 2

The Following Outputs Require Additional Expansion Boards:-Analog Output for Modulating Chilled Water valve…….(24 ga. Min.) 2 Conductors-Analog Output for Modulating Hot Water valve……..….(24 ga. Min.) 2 Conductors

Additional wires depending on stages:Y3 through Y6 ( optional board required )W3 through W6 ( optional board required )

Tip: After making all electrical connections it is advised to unplug all terminal blockson the Zone Manager until you are ready to begin the checkout procedure. Thismay help to prevent damage if wiring errors occur elsewhere in the system duringinstallation or start-up.



Zone Manager MC Addressing

Figure 2-5: Zone Manager Address Switch Setting



Communications LoopsBoth the Network Loop and the Local Loops are two wire shielded RS-485. The loopsare best connected in daisy chain configuration, meaning the loops are connected fromone controller to another. It is not necessary to sequentially address the zone controllers inrelation 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 madeduring installation. Before beginning installation, write down the wire color usedon each terminal connection and consistently maintain that color code. It isrecommended that a continuous wire run be made between devices. Anytime asplice is made in the cable you increase your chance of problems.

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

Communications Loop Wiring OverviewThe daisy chain is the best method for running a communications loop since there is onlyone starting point and one ending point for each of the communications loops. (see Figure2-5).

Note: Auto-Zone Plus systems use two separate types of communications loops. TheNetwork Loop connects only to the Zone Managers and the CommLink II.The Local Loops connect between the Zone Manager and the Zone Controllersfor that HVAC unit. Each Zone Manager has its own Local Loop forconnection to associated Zone Controllers and any additional Constant Volumeunits and the System Manager.

Do not connect zone controllers, constant volume unitsor the system manager to the network loop!



Figure 2-6: Communication Loop Wiring, Daisy-Chain Configuration



Even though the daisy chain configuration is preferred, the star configuration can also beused. If required, a combination of the two can also be used. Remember, the best commloop wiring is the one which utilizes the minimum number of ends while using the shortestwiring path.

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 cableaway from high noise devices like fluorescent lights, transformers,VFD’s, etc. Conduit is not required for comm loop wiring unlessrequired by local codes.



Bypass DamperThe bypass damper is mounted similar to the zone dampers, in fact the only difference inmost cases is the size. The bypass damper should typically be sized for at least 60-70percent of the total design CFM. More than one bypass damper may be slaved togetherwhen it is not practical to use a single large damper. As with the zone dampers it is ofteneasier to mount the actuators before installing the bypass damper in the ceiling.

See Figure 2-7 for damper actuator mounting instructions.

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

Warning: Never depress the actuator clutch with power applied. Unplug theactuator cable before depressing the clutch and attempting to rotate thedamper blade.

The bypass damper should be installed as close as possible to the rooftop unit.



BYPASS ACTUATOR #3 (SLAVE)(WHEN USED) BYPASS ACTUATOR #2 (SLAVE)

BYPASS ACTUATOR #1(MASTER)

MODULAR CABLE

MODULAR CABLE

MODULAR CABLE

1 10 0

10

OE282 OE282

HZ000095HZ000095

ZONE MANAGER BOARD

FDBK

OPEN

GND

GND

PJ1

PJ2LD2

LD1

OPEN

CLOSE

CLOSE

TB1

TB2

FDBK

OPEN

GND

GND

PJ1

PJ2LD2

LD1

OPEN

CLOSE

CLOSE

TB1

TB2

REC

CLOSE

OPENN

ET

WO

RK

SH

R

T

FDBK

GND

OPEN

CLOSE

NOT USED FORTHIS APPLICATION NOT USED FOR

THIS APPLICATION

NOT USED FORTHIS APPLICATION

FDBK

OPEN

GND

GND

PJ1

PJ2 LD2

LD1

OPEN

CLOSE

CLOSE

TB1

TB2

(PL101824) BYPASS ANDSLAVE INTERFACE CARD



HZ000095

OE282

Figure 2-7: Bypass Actuator Wiring

Warning: If the fan system has the capability of producing static pressures whichcould damage ductwork you must provide a manual reset, high pressurelimit switch to cut-off the fan system in the event of high duct static. Donot use your Auto-Zone System as a safety device!



Zone ControllersGenerally, Zone Controllers are supplied mounted on the zone dampers. The ZoneControllers are mounted in snap-track which is typically located on the zone dampers.Orient the board in the snap-track so that the actuator, flow sensor (optional), andauxiliary relay board (optional) cables will reach their respective connectors on the ZoneController, if they are used. Press the board into the snap-track carefully to avoiddamaging any of the electronic components on the circuit board. To remove a board fromthe snap-track, carefully pull one edge of the snap-track away from the board with yourfingers and remove the board.

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

Warning: When mounting the snap-track be sure the heads of the screws do notprotrude far enough to touch the bottom of the Zone Controller circuitboard.

Consider serviceability of the location when mounting the Zone Controllers. They shouldbe easily accessible to facilitate servicing.

Tip: Use small stickers on the ceiling grid or tiles to help future service personnellocate system components. If you use small stickers from an office supply store,you can get different colors to code the location of various 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 sensors3 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 onthe Zone Controller be unplugged until you are ready to begin the checkoutprocedure. This may help prevent damage if wiring errors occur elsewhere in thesystem during installation or start-up. This is particularly important with the ZoneControllers since an error on one unit may prevent any of the others fromworking 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 theterminal labeled GND on the Zone Controller. If a single transformer isused to power more than one Zone Controller you must connect GND-to-GND and 24VAC-to-24VAC on each zone controller. Failure toobserve polarity will result in damage to one or more components inyour system.



Figure 2-8: Zone Controller Wiring



Set the Zone Controller Address Switch following the supplied addressinginstructions.

Caution: Incorrect addressing is the number one cause of communicationproblems. Check the addressing carefully. Remember, the ZoneController only reads the switch during a power-up. If the address switchis changed, the unit must be turned OFF then ON before the newsetting will be recognized.

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

Figure 2-9: Zone Controller Address Switch Settings



Constant VolumeControllersThe Constant Volume Controller may be installed in any convenient protected location.Observe the recommended environmental limitations for the Constant Volume Controller(see the Technical Data section of the product data sheet) when choosing a location.

The Constant Volume Controller may be mounted without removing the controller fromthe mounting plate. The unit is mounted by four (4) screws in the corners. Select thecorrect screws or other fasteners for the type of mounting material being utilized.

Figure 2-10: Constant Volume Controller



Figure 2-11: Constant Volume Controller Wiring



Warning: Use extreme care not to damage any of the electronic components whilemounting the backplate. Mark the holes then remove the CV Controllerbefore drilling. Do not allow metal shavings to fall onto the circuitboards.

The Constant Volume Controller 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-Room Air Temperature Sensor ..........(24 ga. Min.) 2 Conductors for standard sensor

3 Conductors for sensors with setpoint adjustment-Outside Air Temperature Sensor...................................... (24 ga. Min.) 2 Conductors-HVAC Unit Control Wiring...................................................................R - Common

G - FanHeat/Cool Stage 1Heat/Cool Stage 2Heat/Cool Stage 3Heat/Cool Stage 4

NOTE: If unit has heating , the heating stages must be connected to the outputs inconsecutive order with heating as the first two outputs.

Tip: After making all electrical connections it is advised to unplug all terminal blockson the CV Controller until you are ready to begin the checkout procedure. Thismay help to prevent damage if wiring errors occur elsewhere in the system duringinstallation or start-up.



Constant Volume Controller Addressing

Figure 2-12: CV Controller Address Switch Setting



Zone SensorsThe zone sensor uses a patented flush mount design to isolate the temperature sensingelement from the housing which mounts flush with the wall surface.

Zone sensors should be located on an inside wall away from direct sunlight or heatproducing equipment such as computers, copiers, etc. Such devices can adversely affectthe accuracy of the sensor.

Although the sensor eliminates most of the effects of thermal coupling to the walls, try toavoid walls which retain large amounts of thermal energy (such as marble or steel). Wallscontaining 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 totemperature changes in the space.

Mount the sensor approximately 50-60 inches from the floor for best results.

The zone sensor is designed to mount vertically in a standard 2 by 4 inch electrical box.The sensor may be mounted directly into the drywall where electrical codes do not requirelow voltage wiring to be enclosed in conduit. A template is supplied with the sensor tofacilitate cutting a hole of the correct size.

Tip: Be careful when cutting the hole for the sensor or the plastic bezel of the sensormay not completely cover the opening.

Figure 2-13: Zone Sensor Wiring

Zone Controller



Connect the terminal labeled GND on the zone sensor to the terminal labeled GND on theZone Controller terminal block for the TEMP SENSOR. Connect the terminal labeledTMP on the zone sensor to the terminal labeled TEMP on the Zone Controller terminalblock for the TEMP SENSOR. If the zone sensor has a setpoint adjust slider, then connectthe sensor terminal labeled AUX to the Zone Controller AUX terminal block labeledAUX1.

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 electricaldistributor.



Supply Air TemperatureSensorThe supply air temperature sensor should be located as close to the rooftop unitdischarge as possible for best response and mounted upstream of the bypass damper forbest results.

Locate the sensor in the center of the widest part of the duct. Use the supplied templateand a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mountsecurely to the duct using the supplied sheet metal screws. Be sure the gasket iscompressed to provide an air tight seal.

For best accuracy, apply insulation on the outside of the duct, over the sensor. This willhelp prevent thermal gradients from affecting the sensor.

Return Air TemperatureSensorThe return air temperature sensor should be located as close to the rooftop unit returnair intake as possible. Avoid locations which will be exposed to extreme outsidetemperatures.

Locate the sensor in the center of the widest part of the duct. Use the supplied templateand a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mountsecurely to the duct using the supplied sheet metal screws. Be sure the gasket iscompressed to provide an air tight seal.

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

For best accuracy, apply insulation on the outside of the duct, over the sensor. This willhelp prevent thermal gradients from affecting the sensor.



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

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

Note: All sensors utilize the same type thermistor sensor sensing element. Fortroubleshooting sensor problems refer to temperature sensor resettinginstructions at the end of section 4



Static Pressure SensorThe static pressure sensor is designed to be mounted at the controller, or on the ductworknear the pickup tube, and may be connected via its modular plug. If the sensor is mountedon the ductwork, the modular plug must be cut off and 3-conductor wire spliced onto thesensor leads. The controller has a terminal block which is paralleled with the modular jackto allow connection when this method is utilized.

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

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

Warning: Use extreme care when mounting the sensor to avoid damage to theplastic housing.

Do not over tighten the mounting screws!

Do not use mounting screws which are too large for the holes!



Figure 2-14: Static Pressure Sensor Wiring

Note: Refer to Figure 1-3 for instructions concerning proper location of the staticpressure sensor.



Auxiliary Relay Board forZone ControllersAn optional auxiliary relay board is available for the Zone Controllers. This boardprovides 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 Controllerconnector marked “Expansion.” After connecting the board, the system will need to bepowered OFF then ON for the system to recognize the presence of the relay board.

Figure 2-15: Auxiliary Relay Board Layout

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



Auto-Zone Zone Controller RelayExpansion Board Operation

Relay #1 - Parallel FanIf the zone is in cooling mode or vent mode, the parallel fan can activate anytime thezone temperature drops 0.5°F below the heating setpoint. It de-activates when thetemperature rises above the heating setpoint. The space temperature must be below theaux heat setpoint in the occupied mode, before the parallel fan relay can be energized.

Relay #2 - Box HeatIf the zone is in cooling mode or vent mode, the box heat can activate anytime the zonetemperature drops 1.5°F below the heating setpoint. It de-activates when the temperaturerises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate in theheating mode when there is hot air being supplied by the air handler. This output wasintended to allow zone re-heat while the Zone Manager is satisfying cooling demands inother zones. The space temperature must be below the aux heat setpoint in the occupiedmode, before the box heat relay can be energized.

Relay #3 - Aux HeatIn the occupied mode, the aux heat can activate anytime the zone temperature is 0.5°Fbelow the aux heat setpoint. It de-activates when the temperature rises 0.5°F above theaux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heatingsetpoint with the same deadband values mentioned above. This prevents the zone frommaintaining 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 andalso to allow a zone to attempt to satisfy its own heating needs before creating a heatingdemand at the Zone Manager.

Relay #4 - Series FanThe series fan runs anytime the main fan is running. This includes occupied andunoccupied modes. The fan can only start running when the zone damper is closed, so itfirst makes sure the damper is closed, before starting the fan.



CommLink II InterfaceThe CommLink II Interface provides on site computer hook-up or modem interface forremote communications. The Commlink II is wired as shown in Figure 2-16.

Locate the CommLink near the computer or modem. The cable connections between theCommLink II and the computer or modem should be kept to less than twenty-five feet.

The CommLink II comes complete with computer and modem cables, and a plug-in powersupply.



Figure 2-16: CommLink Interface Wiring

Section 3

Programming

Table of ContentsLCD/Keypad Operations ............................................................................1

System Manager Layout ..............................................................................................2View Alarms Screen....................................................................................5Full System Access ......................................................................................6

Keypad Functions ........................................................................................................6System Manager LED Indicators .................................................................................7

Set Time & Date..........................................................................................8New Passcodes.............................................................................................9Rebuild Alarm Map..................................................................................10Read / Reset Units .....................................................................................11Zone Controller Read/Reset Operations ..................................................12Individual Zone Status Screens ................................................................12Zone Controller Setpoints .........................................................................15Zone Controller Force Modes...................................................................19Zone Manager MC Read/Reset Operations.............................................20Zone Manager MC Status.........................................................................22Zone Manager MC Configuration............................................................25Zone Manager MC Setpoints....................................................................30

Control Setpoints....................................................................................................... 30Zone Manager MC Scheduling, Holidays and Optimal Start .................36

Week Schedules......................................................................................................... 36Holidays .................................................................................................................... 37Optimal Start ............................................................................................................. 38

Zone Manager MC and Constant Volume AHU Force Modes ...............39Constant Volume AHU Read/Reset Operations ......................................41Constant Volume AHU Status ..................................................................42Constant Volume AHU Setpoints .............................................................45Constant Volume AHU Scheduling and Holidays....................................52

Week Schedules......................................................................................................... 52Holidays .................................................................................................................... 53

Economizer Module (Wetbulb) Read/Reset Operations.........................54System Manager LCD/Keypad Operations Summary ............................56Notes: .........................................................................................................57


Programming 3-1

LCD/Keypad Operations

Main Screen

The Auto-Zone System Manager is your direct link to the status and setpoints of anyAuto-Zone component on your communications loop. With the System Manager, you canview any temperature or output condition and change any setpoint to fine tune theoperations of the total system. All keypad operations are simple and straight-forward,utilizing non-cryptic plain English messages. The System Manager automatically detectsthe type of unit that has been selected, and displays the appropriate status and setpointscreens. The attractive plastic case of the System Manager allows for placement in anyarea of your building.

The remainder of this document will lead the user through the system menus and keypadoperation.

All user functions are accessed by pressing the Menu button. Once the button is pressed,the Main User Menu is displayed.

Auto-Zone v1.xx Thursday Operations 04/25/96 09:46 AM Outdoor Air 78.0°F


3-2 Programming

System Manager Layout

Main User Menu 1) View/Change Zone 2) View Alarms MENU) Full Access ESC) Main Screen

1) View/ChangeZone

For quick access to an individual zone,select this menu item. Any Zone orConstant Volume unit can be selected.The user can view the roomtemperature and change the currentcooling and heating setpoints. Youmust be at least a Level 1 user tochange the setpoints.

2) View Alarms If the System Manager has beenconfigured for Alarm Polling, the usercan select this item to get a list of unitaddresses that are currently in alarm. Ifan alarm exists, the Alarm LED will beactive on the right side of the panel.


Programming 3-3

View/Change Zone

MENU) FullAccess

If you are a Level 2 user, the full systemRead/Reset capabilities are available toyou. These capabilites are accessed viathis Menu button.

ESC) MainScreen

When you have finished viewing thesystem you can exit this menu and returnto the Main Screen by pressing the ESCbutton.

View/Change AutoZone [ Enter Unit ID# ] Selected Unit: 101

If you have selected the View/Change Zone menu item, youwill be allowed to view any selected zone temperature andits current cooling and heating setpoints. If you are at least aLevel 1 user, you can also change the cooling and heatingsetpoints from this screen. The first screen that appears,prompts you for the Unit ID you wish to view. The Unit IDis actually two separate numbers, combined into one value.The first part of the number contains the Loop Address atwhich the zone is located. The second part of the numbercontains the actual Board Address.EXAMPLE: You would like to view the 3rd zone on the

5th loop. Enter 503 as the Unit IDYou would like to view the 12th zone on the24th loop. Enter 2412 as the Unit ID


3-4 Programming

Zone Controller Status

ConstantVolume Unit

Entering Passcodes

Zone Controller Temperature: 75.4°F Cooling SP.: 75°F Heating SP.: 72°F

If the selected Unit ID is correct, and the unit responds, one ofthe following screens will appear. If you are a Level 1 user, youcan select either the Cooling or the Heating setpoint with theUp/Down Arrow keys. To change the setpoint, use theLeft/Right Arrow keys. The setpoints are fully adjustablebetween their normal limits of 50 to 90 degrees. When you arefinished viewing this screen, simply press the ESC button toexit.

Constant Volume Unit Temperature: 75.4°F Cooling SP.: 75°F Heating SP.: 72°F

The Heating Setpoint is never allowed to get any closer thantwo degrees of the Cooling setpoint on Zone Controllers andone degree on Constant Volume Units. If you are lowering theCooling setpoint or raising the Heating setpoint, both valueswill be kept apart automatically by the correct amount.

THIS ACTION REQUIRES PASSCODE CLEARANCE Enter Passcode: xxxx

Anytime you are prompted to enter a passcode, the followingscreen will appear. No reference is made as to the level ofpasscode to enter, but if you attempt to access a Level 2function with a Level 1 passcode, the system will prompt you toenter the correct passcode again.


Programming 3-5

View Alarms Screen

Alarm Address Locations

Alarm Clearing

SYSTEM ALARM STATUS Alarm @ Unit ID 118 The System Manager can be programmed to poll all the Auto-

Zone units on your system for alarm information. This allowsthe centrally located System Manager to display an AlarmIndicator whenever an alarm condition exists anywhere on yoursystem. The actual alarms are not displayed on this screen, onlythe Unit ID where the alarm is located. The example shows thata unit at location 118 has experienced an alarm condition. Thisalarm may or may not be current, as the System Managerlatches the alarm condition. This makes it possible to determineif any intermittent alarm conditions have occured. If you haveLevel 2 access, you can enter the full system access mode,select that unit for display, and determine what the exact alarmcondition is for that unit. The alarm conditions are alwaysdisplayed on the Status Screens.

SYSTEM ALARM STATUS Clear Alarms? YES To Change Response Use Left/Right Arrow

If all the alarm conditions have been corrected at the individualunits, you can clear these alarms from the System Manager onthe following screen. Use the Left/Right arrow keys to selectthe YES/NO response desired. If you clear the alarms, but somestill exist, the System Manager will show an alarm indication,when the affected unit is polled again.


3-6 Programming

Full System Access

Full Access Menu

Keypad FunctionsThe System Manager keypad is labeled either numerically or as to actual function for thatkey. Below is a summary of the labeled keys and their functions.

MENU This key is used to gain access to the first menu, and the user will benotified, on the LCD, if any subsequent use of the key will be requiredfor further access.

ESC The ESCape key allows the user to abort what he/she is doing or exitback to previous menus. Also, anytime you want to leave the systemunattended you should press the ESC key until the Main Screenappears.

CLEAR If you make a mistake while entering setpoint data, you can clear thebad data from the display by pressing the Clear key.

ENTER Use the Enter key to close out a data entry. It can also be used toadvance to the next field or screen.

DEC If entering a setpoint that requires a decimal point, press this key wherethe decimal is located while entering the value.

MINUS If you need to enter a negative value, you must press the Minus keybefore entering the digits for that value.

UP/DOWNArrows

Use these keys to step forward or backward through Status Screens orSetpoint Data Fields.

LEFT/RIGHTArrows

If the screen prompts you to use these keys, it is used normally totoggle modes of operation. In some cases they may be used for otherfunctions and the user will be prompted as to what these might be.

1) Set Time & Date 2) Read/Reset Units 3) New Passcodes 4) Rebuild Alarm Map

If you selected the MENU key from the first menu screen youcan gain full system access. However, you must be a Level 2user. If you haven't already been asked to enter the passcode,you will be asked before the Full Access Menu is displayed.This prevents the casual user from being overwhelmed with thefull amount of data and setpoints available to the Level 2 user.


Programming 3-7

System Manager LED IndicatorsThere are three LED indicators located on the right hand side of the System Manager.

The top LED indicates an Alarm condition if the Manager detects an alarm conditionwhile polling the system.

The middle LED is active during actual communications or packet transfers. This LEDwill normally "flicker" and not remain on constantly.

The bottom LED is reserved for Override indications and is not used for this applicationof the System Manager.


3-8 Programming

Set Time & DateThe System Manager has its own built in Real Time Clock. It broadcasts this time once aday, at midnight, to synchronize all the other units on your Auto-Zone system. Althoughthe times are displayed on the Main Screen in a standard 12-hour format, they areprogrammed using the 24-hour Military format. Once the time has been entered, it is alsobroadcast immediately to all other units on the system. That means that you only need toprogram the System Manager time to set the Real Time Clocks for all units on yourcommunications loop.

Programming Time

Programming Date

Program Time/Date Day (Sunday=0): 1 Enter Hr. (0-23): 9 Enter Minutes : 53

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

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

Minutes - Enter the Minutes (0 to 59)

Program Time/Date Month (1-12): 9 Day (1-31): 18 Year (00-99): 95

Month - Enter the Month (1 to 12)

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

Year - Enter the current Year with 2 digits (00 to99)


Programming 3-9

Daylight Savings Adjustments

New Passcodes

Programming Passcodes

Caution: If you change the Level 2 passcode and cannot remember what it is, youwill be locked out of your system!

Daylight SavingsAuto Adjustments: YES

Use Left/Right Arrow

If your area of the country requires Daylight Savings changes, youcan enable the System Manager to automatically reset its own clockduring the Daylight Savings changeover. If you enable thisoperation, it knows to changeover the first Sunday in April and thenswitch back the last Sunday in October. No other programming isrequired for this function.

Use the Left or Right arrow keys to toggle the second line of thedisplay between Adjustments Enabled and Adjustments Disabled.

Enter New Passcode Level 1.....: XXXX Level 2.....: XXXX [Must Be 4 Digits]

The System Manager has two levels of user access.

Level 1 users are limited to viewing or changing ZoneTemperatures and their Heating and Cooling Setpoints, and toviewing Unit ID numbers for those in alarm conditions.

Level 2 users have complete system access. Any status orsetpoint field can be read or reset from the Auto-Zone system.

These two levels of passcodes are programmable by any Level 2user. The default Level 1 passcode is "1111" and the defaultLevel 2 passcode is "2222."

The actual digits in your passcodes are never displayed. An "X"is used as a place holder for each digit entered. Passcodes mustalways be four digits in length, so the useable range of numbersis 1000 to 9999.


3-10 Programming

Rebuild Alarm Map

Rebuilding Screens

Clearing Old Map .................... ................

Build New Map?

[ESC = NO]

If you would like the LED Alarm Indicator to function on thefront of your System Manager, you must enable Alarm Pollingby building an Alarm Map. This map keeps track of which unitsexist on your communications loop so the System Manager willpoll only those units. That means you will need to rebuild thismap anytime units are added or removed from your system. Italso means you can disable alarm polling. To do this, disconnectthe RS-485 communications plug from the back of your CommLink II. Then, select the Rebuild Alarm Map menu. The SystemManager will not find any units to poll for alarms since none areconnected. This is useful during building startup, when youdon't want nuisance alarms bothering you.

The screen will display each address it is testing and if a unit hasbeen found at that address. If you know you only have twoloops on your system and you don't want to wait for it to testthe remaining twenty-eight loops, you can press the ESC key assoon as Loop 3 is displayed and the test will conclude. All unitsfound up to that point will be saved in memory.

The System Manager does not rebuild this map automaticallyon powerup! You must do this manually. This rebuild shouldonly be performed one time, when all units are up and running.It is not a regular requirement. As mentioned above, only whenthe number of units connected changes should the alarm map berebuilt.

Building New Map Loop: 1 Unit: 1 Dec) Go To Next Loop ESC) Abort Process

Alarm Unit Map Built Press Any Key To Continue


Programming 3-11

Read / Reset Units

Read/Reset Address Entry

Read/Reset AutoZone [ Enter Unit ID# ] Selected Unit: 101

You must know the Unit ID of the controller you wish to view.This number is created by combining the Loop Address with thecontroller Board Address. The Zone Controllers are alwaysaddressed starting at one and continuing up to sixteen. TheZone Manager is always at address seventeen and any ConstantVolume units would start at eighteen and continue to thirty. Ifthis is a Constant Volume only system, the address range of thecontrollers would simply be one to thirty.

Example Unit ID Numbers:

Controller @ Loop 3, Board Address 1Unit ID = 301

Controller @ Loop 12, Board Address 14Unit ID = 1214

Once you have finished the Read/Reset function, you can exitthis mode by pressing the ESC key. This will return you to theFull Access Menu.


3-12 Programming

Zone ControllerRead/Reset Operations

Zone Controller Menu

Individual Zone StatusScreensIf Zone Controller Menu Item #1, Zone Status, was selected, the following Status Screenswill be displayed. Use the Enter Key or the Up & Down Arrow keys to move forward orbackward through the Status Screens.

Note: The top line of every Status Screen shows the selected Zone Address and itsSoftware Version.

1) Zone Status 2) Zone Setpoints 3) Zone Modes ESC) To Exit

If the Unit ID you entered was for a Zone Controller, thefollowing menu will appear.

1) Zone Status View the current temperaturesand operating modes for thisZone Controller.

2) Zone Setpoints View or Change any of theavailable setpoints for thisZone Controller.

3) Zone Modes Access the Damper ForceModes for this ZoneController.


Programming 3-13

Status Screen #1

Status Screen #2

NOTE: If slide adjust is set for 0°, the pushbutton override will not function.

Status Screen #3

Note: On Pressure Independent zones, cfm will be substituted for the word Setpt orthe % symbol.

Zone # 1 v1.xx Occupied Mode Voting Unit

Line 2 - Unoccupied ModeOccupied ModePushbutton OverrideForce Mode Active!

Line 3 - Voting UnitNon-Voting Unit

Zone # 1 v1.xx Temperature: 75.4°F CSP 75.0° HSP 72.0° Slide Adjust.: 0.0°

Line 2 - Current Zone Temperature

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

Line 4 - Optional Sensor Slide Adjust (located on ZoneWall Sensor) effect on current operating Setpoints.

Zone # 1 v1.xx Damper Pos 20% Minimum Setpt 20% Maximum Setpt 100%

Line 2 - Current Zone Damper Position in the percentage itis open for pressure dependent dampers, forpressure independent, the damper position and theCFM will be displayed.

Line 3 - Currently active Minimum Damper/AirflowSetpoint. Each mode has its own minimumsetpoint. These are Vent Mode, Cooling Mode,Heating Mode and Nite Mode.

Line 4 - Currently active Maximum Damper/AirflowSetpoint. This value is user adjustable, but it isused in all modes of operation, unlike the MinimumDamper/Airflow Setpoint.


3-14 Programming

Status Screen #4

Status Screen #5

Zone # 1 v1.xx Auxiliary Heat Off Series Fan On

Line 2 - No Auxiliary Heating - Aux HeatingBoard Not Installed

Auxiliary Heat OffBox Heating OnAux Heating OnBox & Aux Heat On

Line 3 - Series Fan On orBlank Line if Fan is Off

Line 4 - Parallel Fan On orBlank Line if Fan is Off

Zone # 1 v1.xx Damper O.K. Zone Sensor O.K.

Line 2 - Damper O.K.Damper Feedback FailDamper Fail Opening!Damper Fail Closing!

Line 3 - Zone Sensor O.K.Zone Sensor Failure

Line 4 - Blank Line


Programming 3-15

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

controller type.

PD ZONE ADDRESS means a Pressure Dependent Zone is selected.PI ZONE ADDRESS means a Pressure Independent Zone is selected.

Setpoint Screen #1

Setpoint Screen #2

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

The Occupied Heating and Cooling Setpoints are entered onthis screen. The Heating Setpoint should always be twodegrees below the Cooling Setpoint, or the Zone Controllerwill not accept the new values. The System Manager can'tprevent the entry of invalid setpoints. If invalid setpoints areentered, the previous settings will be retained by the system anddisplayed the next time the Zone Setpoints are accessed.

Minimum Default MaximumCooling Setpoint 50°F 75°F 90°FHeating Setpoint 50°F 72°F 90°F

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

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

Minimum Default MaximumCool Setup 0°F 10°F 30°FHeat Setback 0°F -10°F -30°F


3-16 Programming

Setpoint Screen #3

NOTE: If slide effect is set to 0°, the pushbutton override will not function.

Setpoint Screen #4 (Pressure Dependent)

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

If your Zone Controller has the optional Relay ExpansionBoard attached, one of the relays is reserved for an AuxiliaryHeating Relay. Enter that setpoint on the AuxHeat Setpt line. Ifthe relay board is not installed, this line will not be displayed.If your Zone Temperature sensor has the optional SetpointAdjustment Slide, enter the maximum effect it can have on thesetpoints on the Slide Effect line.

Minimum Default MaximumAuxHeat Setpt 50°F 72°F 90°FSlide Effect 0°F 3°F 5°F

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

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

Minimum Default MaximumPD Zone Max DamperPI Zone Max Airflow

0 %0 CFM

100 %800 CFM

100 %30000 CFM

PD Zone Cool Mode MinPI Zone Cool Mode

0 %0 CFM

5 %200 CFM

100 %30000 CFM

PD Zone Heat Mode MinPI Zone Heat Mode

0 %0 CFM

20 %300 CFM

100 %30000 CFM


Programming 3-17

Setpoint Screen #5 (Pressure Dependent)

Setpoint Screen #6

Note: If the direction is changed, you will need to cycle power to the Zone Controllerso it can re-calibrate the damper feedback limits.

Setpoint Screen #7

PD ZONE ADDRESS 1 Vent Mode Minl: 50% Nite Mode Min.: 100% CFM @ 1"WG: 2100 cfm

On Pressure Dependent Zones, these setpoints are for damperposition, on Pressure Independent Zones they are for Airflow(CFM) values, and the text will change to reflect that. The lastline is not shown on Pressure Dependent Zones. On the linethat reads CFM @ 1” WG enter the appropriate “K” FlowFactor from Table 1-2 of this manual

Minimum Default MaximumPD Zone Vent Mode MinPI Zone Vent Mode

0 %0 CFM

50 %500 CFM

100 %30000 CFM

PD Zone Nite Mode MinPI Zone Nite Mode

0 %0 CFM

100 %0 CFM

100 %30000 CFM

CFM @ 1" WG 0 CFM 2100 CFM 30000 CFM

PD ZONE ADDRESS 1 Overrides..: Global Damper Mode: Direct Use Left/Right Arrow

The Zone Controller will respond to another zones pushbuttonoverride if it is configured for global overrides. If singleoverrides are selected, the zone will only enter override if itsown pushbutton is pressed.

The normal damper operation is direct acting, which means itopens in a clockwise direction. If your Damper opens in acounter-clockwise direction, select reverse acting mode.

PD ZONE ADDRESS 1 Voting Mode: Voting


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


3-18 Programming

Setpoint Screen #8

Note: The Thermister Type III Sensors have a 0.4 degree accuracy.

TIP: This Calibration Offset is also useful as a troubleshooting tool. If you need tosimulate a heating or cooling mode, you can raise or lower the current zonetemperature far enough to put the zone into the desired mode.

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

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

If you have a more accurate digital thermometer that doesn'tagree with the current Zone Temperature reading, you canadjust 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.


Programming 3-19

Zone Controller ForceModesAs a means of troubleshooting the system, the System Manager can Force the ZoneController to drive its damper, or force its Heating or Fan relays ON, regardless of thecurrent operating mode. The following screens show the available force modes for a ZoneController.

Note: Be sure to remove the force mode when you are finished, or normal operationswill not resume!

Min/Max Force Modes

Open/CloseForce Modes

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

In Pressure Dependent boxes you can force the damper to theMaximum or the Minimum programmed damper position. Thisis a percentage value that the damper drives to and stops.

In Pressure Independent boxes you can force the zone tomaintain the Maximum or Minimum Airflow setpoints. Thedamper doesn't actually stop, but continues to move, ifrequired, to maintain one of these limits.

If the Force to Minimum is selected, the current minimumposition or airflow being used is the controlling position. Thisminimum is based on the vent, heat, cool or unoccupied modeof operation.

ZONE FORCE MODES Force Full Open 0 Force Full Close 0 [0=Normal 1=Force]

The Force Full Open and Force Full Close modes ignore thePressure Dependent or Independent style of box. If one of themodes is selected, the damper either drives to its full openposition and stops, or to its fully closed position and stops.

There is no mechanism for forcing the heating OFF.


3-20 Programming

Zone Manager MCRead/Reset OperationsIf the Unit ID you entered was for a Zone Manager, the following menus will appear.

Zone Manager Menu #1

Zone Manager Menu #2

1) MC Manager Status 2) Change Setpoints MENU) Next Menu ESC) To Exit

1) MC Manager Status View the current temperaturesand operating modes for thisZone Manager.

2) Change Setpoints View or change any of theavailable setpoints for thisZone Manager.

MENU) Next Menu Access the next Menu Page forthe Zone Manager.

1) Schedules 2) Configuration 3) Force Modes MENU) Previous Menu


Programming 3-21

1) Schedules View or change any of theWeek Schedules or Holidaysfor this Zone Manager.

2) Configuration View or change the operatingconfiguration of the ZoneManager. These setpoints arenormally set one time andnever changed again. Theyinclude parameters such as thenumber of zones, or heatingand cooling stages, etc..

3) Force Modes Select this menu to overridethe currently scheduledoperating mode.

MENU) Previous Menu Return to the previous menushown above.


3-22 Programming

Zone Manager MC StatusLine 1 Displays the currently selected Zone Manager and its current operating softwareversion on all Status Screens shown below.

Status Screen #1

Status Screen #2

Manager # 1 vl.xx Occupied Mode Vent Mode

Line 2 - Unoccupied ModeOccupied ModePush Button OverrideForced OccupiedForced UnoccupiedForced Fan Only ModePurge Mode

Line 3 - Neutral ModeVent ModeCooling ModeHeating Mode

Line 4 - Binary Contact AlarmBlank Line if no Alarm

Manager # 1 vl.xx Supply Air: 78.6°F Return Air: 77.3°F Outdoor Air: 70.2°F

The Supply Air Temperature, Return Air Temperature andOutdoor Air Temperature are displayed on this screen.

The Outdoor Air Temperature is either the onboard sensorreading, or it can be the Global Broadcast value received fromanother unit. Only one unit per system needs to have theOutdoor Air Sensor installed.


Programming 3-23

Status Screen #3

Status Screen #4

Status Screen #5

Manager # 1 vl.xx Static Pr..: 0.49" Bypass Dmpr: 18 % Economizer.: 50 %

The Static Pressure, measured in Inches of Water Column, isdisplayed along with the Bypass Damper position currentlybeing used to maintain that amount of static.

The last line shows the Economizer Damper position if yoursystem is configured for Economizer Control.

Manager # 1 vl.xx CW Valve ...: 0% HW Valve ...: 0%

The current quantity of active cooling stages and the positionof the hot water valve is displayed on this screen. There are amaximum of six stages of cooling available, if the optional relayexpansion board is used.

Manager # 1 vl.xx Cool Total.: 0.0°F Heat Total.: 0.0°F Mavericks..: 0

As the Zone Manager polls its Zone Controllers, it totals up theheating and cooling demand so it can make an HVAC decision.The Cooling Total and Heating Total are displayed on thisscreen.

The Zone Manager also knows if any units have had a fourdegree demand for at least one hour. It totals them up anddisplays this value as the total number of Mavericks.


3-24 Programming

Status Screen #6

Status Screen #7

Status Screen #8

Note: Although the Zone Manager knows about Zone Controller alarms, they areonly displayed on their respective zone screens.

Manager # 1 vl.xx COOLING PRIORITY HEATING PRIORITY Wetbulb....: xxx.x°F

If any zones have a four degree heating or cooling demand, butthey haven't been that way for an hour, they create a PriorityHeating or Priority Cooling demand. If neither priority exists,the third line of the display shows No Priorities and line 2displays four dots as a place holder for that line.

If the optional Economizer Module was installed, the currentcalculated Wetbulb Temperature received by the Zone Mangerwill be displayed on the last line, otherwise, it will remain blank.

MGR ALARMS PAGE #1 No Alarms!

If the Zone Manager has any alarm conditions, they will bedisplayed on this page as follows:

Line 2 - Supply Sensor Failed

Line 3 - Static Pr. Alarm

Line 4 - Bypass Damper Failed

MGR ALARMS PAGE #2

OAT Broadcast Lost

Additional Alarm messages are available on a second screen:

Line 2 - Maverick Zones

Line 3 - Hi Supply Alarm! orLo Supply Alarm!

Line 4 - OAT Broadcast Lost


Programming 3-25

Zone Manager MCConfigurationThese configuration setpoints are normally entered only one time and then never accessedagain. This is why they occupy their own menu location, so the user is not required to stepthrough these during normal setpoint Read and Reset.

Note: On initial power up, the system must be configured before it can besuccessfully operated.

Configuration Screen #1

Caution: The zones should be consecutively addressed with no skipped addresslocations. If you do skip an address, the Zone Manager will presumethere is a missing zone, and an alarm will occur.

ZONE POLLING RANGE First Zone Addr: 1 Last Zone Addr: 1 [0 = RA Control]

The Zone Manager needs to know the address range of theattached Zone Controllers to be polled. The user enters theaddresses of the first and last zones here. If you are controllingfrom Return Air Temperature instead of voting zones, input –1for both the first and last address.

The quantity of cooling and heating stages are also entered onthis screen.

Minimum Default MaximumFirst Zone Addr 1 1 16Last Zone Addr 1 1 16


3-26 Programming





TEMPERATURE READINGS Are Scaled in Deg. F


All temperature readings can be displayed in either Fahrenheitor Celsius.

The Left/Right Arrow keys will toggle the current setting to theopposite mode.

STATIC CONTROL STATIC PR. CONTROL


STATIC CONTROL USES BYPASS DAMPER


BYPASS DAMPER MODE CW DIRECT ACTING


The Zone Manager MC normally reads the duct staticpressure and controls it via the bypass damper. If your systemdoes not require static pressure control, select the ConstantVolume Mode of operation. To toggle between the StaticControl types, use the Left/Right Arrow keys.

There are two methods of controlling duct static pressurewhich may be selected, a BYPASS DAMPER or a USESVFD VOLTAGE OUT. To toggle between the two modes,use the Left/Right Arrow Keys.

The Zone Manager Bypass Damper normally opens in aclockwise direction. If your bypass damper opens in acounter-clockwise direction, select reverse acting instead ofdirect acting operation. To toggle between the two modes,use the Left/Right Arrow Keys.


Programming 3-27





FAN MODE CONTROL CONTINOUS OPERATION


The Zone Manager MC can operate the fan in one of twomodes. Continuous Operation means the fan run constantlyduring the occupied mode, Cycles w/ Heat/Cool runs the fanonly on a call for heating or cooling. The fan always cycles withheating and cooling during unoccupied mode. To togglebetween the two modes, use the Left/Right Arrow Keys.

ECONOMIZER CONTROL Handled by AHU.: YES


The Zone Manager MC has the ability to control theEconomizer operation. To initiate Economizer operation, selectYES, if there is no economizer or it is being controlled by othermeans, then select NO. To toggle between the two Economizermodes, use the Left/Right Arrow keys.

COOLING CONTROL TYPE COOLING VALVE MODE


The Zone Manager MC has the ability to control the cooling byone of two methods. Cooling Valve Mode is a modulatingchilled water valve, DX Stage Cooling is up to six stages ofcooling. To toggle between the two modes, use the Left/RightArrow keys.

HEATING CONTROL TYPE HEATING VALVE MODE


The Zone Manager MC has the ability to control the heating byone of two methods. Heating Valve Mode is modulating a hotwater valve, Staged Heat Mode is up to six stages of heating.To toggle between the two modes, use the Left/Right Arrowkeys.


3-28 Programming



Note: If no External Scheduler is used, enter a " 0 " for the Schedule!



ZONE MAVERICK TEST Testing is Enabled


Maverick zones are reported to the Zone Manager MC, if youhave some problem zones or during startup if not all of thesensors are wired in, you may want to eliminate the Mavericktesting. To do this select Disabled instead of Enabled. Totoggle between the two modes, use the Left/Right Arrow keys.

Zone Manager Uses Schedule #: 0 0 = Internal Clock 1-7 = External Clock

The Zone Manager MC normally uses its own real-time clockand an internal week schedule to determine theOccupied/Unoccupied mode of operation. The Zone Managerdoes have the ability to use a global broadcast from anotherscheduling device on the communications loop if a morepowerful schedule is required. If an external schedule is used,the range of schedule numbers is 1 to 7.

ECONOMIZER CONTROL [0-10 VDC Range]


The Zone Manager MC has four voltage ranges to choose fromfor control of the economizer damper. To toggle between 2-10VDC, 10-0 VDC and 10-2 VDC, use the Left/Right Arrowkeys.

CW VALVE CONTROL [0-10 VDC Range]


The Zone Manager MC has four voltage ranges to choose fromfor control of the chilled water valve. To toggle between 2-10VDC, 10-0 VDC and 10-2 VDC, use the Left/Right Arrowkeys.


Programming 3-29




HW VALVE CONTROL [0-10 VDC Range]


The Zone Manager MC has four voltage ranges to choose fromfor control of the hot water valve. To toggle between 2-10VDC, 10-0 VDC and 10-2 VDC, use the Left/Right Arrowkeys.

AUX#1 CONFIGURATION HEAT/COOL DISABLE


Auxiliary Input #1 can be used for two different applications, itcan be used to disable the heating or cooling depending onwhich mode is active or it can be used for a fan proving switch.To toggle between Heat/Cool Disable and Fan Proving, usethe Left/Right Arrow keys.

Press < - > To Force ReCalibration Of The Static Pr. Sensor OR ENTER to Skip This.

The Zone Manager MC only calibrates the static pressuresensor one time. This occurs on the initial powerup, so it is vitalthat the sensor be attached before the system is ever poweredup. If you were not able to do this, or accidentally activated thesystem before the sensor was available, you can force it torestart and calibrate the Static Pressure Sensor by pressing theMinus Sign key. If you don't need to re-calibrate, simply pressthe Enter or Down arrow key to skip over this item.


3-30 Programming

Zone Manager MC Setpoints

Control Setpoints

Setpoint Screen #1

Setpoint Screen #2

Cooling LockoutIf the outside air temperature drops 1° below this setpoint themechanical cooling is disabled. Cooling is re-enabled at 1°above this setpoint.

Heat LockoutIf the outside air temperature rises 1° above this setpoint thefirst stage of heat is disabled. The first stage of heat is re-enabled at 1° below this setpoint.

DUCT STATIC SETPOINT Static Press: 0.5"

This screen will be displayed to allow you to enter thecontrolling duct Static Pressure Setpoint.

Minimum Default MaximumStatic Press 0.1" 0.5" 2.0"

LOCKOUT SETPOINTS Cool Lockout: 0° Heat Lockout: 65°

The Mechanical Cooling and Heating Lockouts are entered onthis screen.

Minimum Default MaximumCool Lockout -40°F 50°F 80°FHeat Lockout 30°F 75°F 99°F


Programming 3-31

Setpoint Screen #3

Setpoint Screen #4

Setpoint Screen #5

RETURN AIR SETPOINTS Cooling Mode: 72° Heating Mode: 70°

SUPPLY AIR SETPOINTS Cooling Mode: 58° Heating Mode: 105°

SUPPLY AIR SETPOINTS Cool SAT DB: 2° Heat SAT DB: 2°

If 0 has been selected for first zone and last zone or if thecommunications is lost with all of the zone controllers, theZone Manager MC will control the Return Air Temperature.The setpoints for both cooling and heating are entered here.

Minimum Default MaximumCooling Mode 50°F 72°F 90°FHeating Mode 50°F 686°F 90°F

The Supply Air Sensor is the controlling sensor in both theheating and cooling mode. The setpoints for both cooling andheating are entered here.

Minimum Default MaximumCooling Mode 50°F 58°F 80°FHeating Mode 70°F 105°F 220°F

This is used for DX Cooling and Heat Stages only, and is notused for modulating heating and cooling.


3-32 Programming

Setpoint Screen #6

Setpoint Screen #7

Setpoint Screen #8

CW VALVE SETPOINTS PID Calculation Rate Enter Period: 15 Sec

CW VALVE SETPOINTS Kp Constant..: 20 Ki Constant..: 5 Kd Constant..: 20

HW VALVE SETPOINTS PID Calculation Rate Enter Period: 15 Sec

The PID control positions the chilled water valve based onhow far the supply air is from setpoint and the currentposition of the valve. It looks at the position of the valve attimed intervals, this interval is set by the PID CalculationRate.

Minimum Default MaximumCalculation Rate 5 Sec 15 Sec 60 Sec

The Kp Constant is “proportional” constant which meanshow many degrees from setpoint will make the valve open100%. For example if the Kp is set for 10 then a 10°temperature rise above setpoint, would cause the chilledwater valve to go 100% open. Ki Constant is the “integral”constant which prevents the valve from stopping at a pointwhere the proportional error is not changing. The amount ofeffect the Integral can have is limited by the Ki constant. KdConstant is the “derivative” constant. This is used to trackthe rate of change in temperature error from setpoint. If thelast change was small, the derivative would have very littleaffect since the (error – old error) subtraction would be asmall value. If the last error was large, indicating thetemperature was rapidly moving toward or away from thesetpoint, the valve position would make a large adjustment.

Minimum Default MaximumKp Constant 1 20 100Ki Constant 1 5 100Kd Constant 1 20 100

The PID control positions the hot water valve based on howfar the supply air is from setpoint and the current position ofthe valve. It looks at the position of the valve at timedintervals, this interval is set by the PID Calculation Rate.

Minimum Default MaximumCalculation Rate 5 Sec 15 Sec 60 Sec


Programming 3-33

Setpoint Screen #9

Setpoint Screen #10

HW VALVE SETPOINTS Kp Constant..: 20 Ki Constant..: 5 Kd Constant..: 20

Heat/Cool Changeover Interval....: 10 Min

If the Zone Manager needs to change HVAC Modes betweenheating and cooling, a Changeover Delay time must be satisfiedfirst. This prevents "Chasing" due to alternate hot and cold airalways being supplied to the zones after short intervals.

Minimum Default MaximumInterval 1 Min 10 Min 30 Min

The Kp Constant is “proportional” constant which meanshow many degrees from setpoint will make the valve open100%. For example if the Kp is set for 10 then a 10°temperature drop below setpoint, would cause the hot watervalve to go 100% open. Ki Constant is the “integral”constant which prevents the valve from stopping at a pointwhere the proportional error is not changing. The amount ofeffect the Integral can have is limited by the Ki constant. KdConstant is the “derivative” constant. This is used to trackthe rate of change in temperature error from setpoint. If thelast change was small, the derivative would have very littleaffect since the (error – old error) subtraction would be asmall value. If the last error was large, indicating thetemperature was rapidly moving toward or away from thesetpoint, the valve position would make a large adjustment.

Minimum Default MaximumKp Constant 1 20 100Ki Constant 1 5 100Kd Constant 1 20 100


3-34 Programming

Setpoint Screen #11

Setpoint Screen #12

Setpoint Screen #13

ECONOMIZER SETPOINTS Econo Enable: 50° Supply Setpt: 50° Min Econo %.: 20%

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

The Supply Setpt is the supply air temperature the Economizertries to maintain.

The Min Econo % is the position the economizer holds duringoccupied mode when it is not enabled for operation, due tooutdoor air or wetbulb temperature.

Minimum Default MaximumEcono Enable -30°F 55°F 99°FSupply Setpt 45°F 55°F 80°FMin Econo % 0 % 20 % 100 %

Economizer Setpoints Economizer Control Rate.....: 90

The Control Rate can be used to speed up or slow down theoperation of the outside air damper to prevent hunting. Largevalues speed up the damper, and small values slow down thedamper.

Minimum Default MaximumControl Rate 10 90 99

SUPPLY AIR SETPOINTS Alarm Delay Period Mechanical Failure Detection: 30 Min

Once a heating or cooling stage is activated, the Supply Airmust change accordingly by 5° before this amount of timeelapses, or a mechanical failure is assumed and an alarm isgenerated.

Minimum Default MaximumAlarm Delay 0 Min. 30 Min. 300 Min.


Programming 3-35

Setpoint Screen #14

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

As described in the Zone Controller section, the ThermistorType III sensor readings can be calibrated. The Outdoor AirCalibration Offset only applies to the controller that has thesensor installed. It has no effect on the global broadcast value ofoutdoor air.

Minimum Default MaximumSupply Sensor SAT -100.0°F 0.0°F +100.0°FReturn Sensor RAT -100.0°F 0.0°F +100.0°FOutdoor Sensor OAT -100.0°F 0.0°F +100.0°F


3-36 Programming

Zone Manager MCScheduling, Holidays andOptimal StartIf the Unit ID you entered was for a Zone Manager, the following menu will appear.

Scheduling/Holiday/Optimal Start Menu

Week Schedules

Schedule Start/Stop Time for Event #1

Schedule forEvent #2

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 thenext Start Time screen.

1) Week Schedules 2) Holidays 3) Optimal Starts ESC) Previous Menu

This menu appears whenever the user accesses the Schedulingfunctions. It allows the user to choose between Schedules,Holidays or Optimal Starts.

Zone Manager Sunday Event #1 Start Time..: 0 Stop Time...: 0

The screens will step through the Start Time and then the StopTime for each day of the week. You can quit at any point in theprocess by pressing the "ESC" key. After the Stop Time forEvent #1 is entered, the screen for Event #2 will come up.

All times are in 24-hour format, so 5:00 PM would be enteredas 1700.

If both the Start and Stop Times are ZERO, the schedule is in aContinuous OFF mode.

If both the Start and Stop Times are 2359, the schedule is in aContinuous ON mode.

Zone Manager Sunday Event #2 Start Time..: 0 Stop Time...: 0


Programming 3-37

Holidays

Holiday Day Selection

Holiday Start / Stop Times

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

The screens will step through the fourteen possible holidays,one at a time. Line 2 shows which holiday is currently beingprogrammed.

Remember to combine the month and day into a single fourdigit value.

EXAMPLE: 0704 = July 4th

1225 = December 25th

Zone Manager Holiday Schedule Start Event #1: 0 Stop Event #1: 0

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

Zone Manager Holiday Schedule Start Event #2: 0 Stop Event #2: 0


3-38 Programming

Optimal Start

Optimal Start Setpoints

OPTIMAL START SETPTS Target Zones...: 0 [-1 = Average Zones] Soak Multiplier: 0.0

If you are using the internal time clock of the Zone Managerand you have entered a “0” on the Schedule Configurationscreen, you can enable this internal schedule to perform anoptimal start. The Target Zone is the zone, that you choose,to be the control point. In other words the zone that youchoose will be the one that is used to determine how early theunit should start in order to bring that zone under control bythe time the space is occupied. If you input a –1 for theTarget Zone, it averages all of the zones instead ofcontrolling just one. The Soak Multiplier is used to increasethe normal optimal start calculation whenever the building hasbeen unoccupied for 24 consecutive hours or more. If youused a 1.5 multiplier and the optimal start had calculated a 30minute pre-start, the soak multiplier would add an additional15 minutes to the pre-start for a total of 45 minutes (1.5 x30). The system would then start 45 minutes earlier thannormal scheduled time.


Programming 3-39

Zone Manager MC andConstant Volume AHUForce ModesThis screen applies to both types of AHU Controllers so it will only appear one time inthis manual.

Note: The Binary Input Contact only applies to the Zone Manager!

Both AHU controllers default to the Auto mode of operationwhen first powered up. Any force modes entered will beretained in non-volatile memory. The unit will resume the forcemode of operation anytime the power is cycled.

0) Auto - Use internal schedules for Day/NightMode

1) Occupied - Forced to Continuous Day or OccupiedMode

2) Night - Forced to Continuous Night orUnoccupied Mode. If the Forced OccupiedBinary Input Contact is closed, this modewill override it to OFF. Use the Auto modeprogrammed for continuous Unoccupiedoperation if you want to use the ForcedOccupied Binary Input Contact.

3) Fan Only This is the mode that is active wheneveryou see the Purge Cycle message beingdisplayed. It disables any heating orcooling and forces all the boxes to movetheir dampers to the full 100 percent openposition. You can use this mode anytimeyou want to manually purge your building.

OPERATING MODE 0) Auto 1) Occupied 2) Night 3) Fan Only Enter Clock Mode: 0


3-40 Programming

Min/Max Force Modes

Open/CloseForce Modes

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

In Pressure Dependent boxes you can force the damper to theMaximum or the Minimum programmed damper position. Thisis a percentage value that the damper drives to and stops.

In Pressure Independent boxes you can force the zone tomaintain the Maximum or Minimum Airflow setpoints. Thedamper doesn't actually stop, but continues to move, ifrequired, to maintain one of these limits.

If the Force to Minimum is selected, the current minimumposition or airflow being used is the controlling position. Thisminimum is based on the vent, heat, cool or unoccupied modeof operation.

ZONE FORCE MODES Force Full Open 0 Force Full Close 0 [0=Normal 1=Force]

The Force Full Open and Force Full Close modes ignore thePressure Dependent or Independent style of box. If one of themodes is selected, the damper either drives to its full openposition and stops, or to its fully closed position and stops.

There is no mechanism for forcing the heating OFF.


Programming 3-41

Constant Volume AHURead/Reset OperationsIf the Unit ID you entered was for a Constant Volume AHU, the following menus willappear. Any references in this section to CVAHU are referring to the Constant VolumeAir Handling Unit.

CVAHU Menu #1

CVAHU Menu #2

1) CVAHU Status 2) CVAHU Setpoints MENU) Next Menu ESC) To Exit

1) CVAHU Status View the current temperaturesand operating modes for thisConstant Volume AHU.

2) CVAHU Setpoints View or change any of theavailable setpoints for thisConstant Volume AHU.

MENU) Next Menu Access the next Menu Page forthe Constant Volume AHU.

1) Schedules 2) Force Modes

MENU) Previous Menu

1) Schedules View or change any of the WeekSchedules or Holidays for thisConstant Volume AHU.

2) Force Modes Select this menu to override thecurrently scheduled operatingmode.

MENU) PreviousMenu

Return to the previous menushown above.


3-42 Programming

Constant Volume AHUStatusLine 1 Displays the currently selected CVAHU and its current operating software versionon all Status Screens shown below.

Status Screen #1

Status Screen #2

CVAHU # 18 vl.xx Occupied Mode Neutral Mode

Line 2 - Unoccupied ModeOccupied ModeHoliday ActivePush Button OverrideForced OccupiedForced UnoccupiedForced Fan Only Mode

Line 3 - Neutral ModeCooling ModeHeating Mode

Line 4 - (Reserved for Future Use)This Line is Blank

CVAHU # 18 vl.xx Temperature: 78.6°F CSP 75.0° HSP 72.0° Slide Adjust.: 0.0°

Line 2 - Displays the current Zone Temperature.

Line 3 - Displays the currently active CoolingSetpoint (CSP) and Heating Setpoint (HSP)

Line 4 - Displays the current effect the optionalSensor Slide Adjust has on the Heating andCooling Setpoints


Programming 3-43

Status Screen #3

Status Screen #4

Status Screen #5

CVAHU # 18 vl.xx Supply Air.: 65.0° Outdoor Air.: 70.2° Wetbulb Temp: 0.0°

Line 2 - Displays the current Supply Air Temperature.

Line 3 - Displays the current Outdoor Air Temperature.

Line 4 - Displays the current Wetbulb Temperature, ifavailable. This value is broadcast by a separateEconomizer Module.

CVAHU # 18 vl.xx Economizer...: 10% Heating Locked Out Fan On

Line 2 - Shows the current Economizer Damper position, ifthe CVAHU has been configured to control theEconomizer.(This line is blank if the CVAHU does not controlthe Economizer)

Line 3 - No Lockouts ActiveCooling Locked OutHeating Locked Out

Line 4 - Fan OffFan On

Heating Output.: OFF Heating Output.: OFF Cooling Output.: ON Cooling Output.: ON

This screen shows how the relays were configured, either forHeating or Cooling. The first line shows the status of Relay #2,the second line shows Relay #3, etc.

The message will show ON/OFF status for that relay.


3-44 Programming

Status Screen #6

Line 4 - Mech Cooling ALARMMech Heating ALARM

This line remains blank if no alarm condition exists.

These alarms are generated when the SupplyTemperature does not change more than fivedegrees after a stage of heating or cooling has beenactivated for 30 minutes.

CVAHU # 18 vl.xx Zone Cooling ALARM

Line 2 - Zone Sensor O.K.Bad Zone Sensor!Zone Cooling ALARMZone Heating ALARMThe line will show No Alarms if none of the abovealarm conditions exist.

Line 3 - Binary Input ALARM

This line will remain blank if the contact has notclosed. This input is normally used for Dirty FilterAlarms.


Programming 3-45

Constant Volume AHUSetpointsLine 1 displays CVAHU Setpoints message for identification only.

Setpoint Screen #1

Setpoint Screen #2

CVAHU Setpoints Occupied Setpoints Cooling Setpt: 75°F Heating Setpt: 72°F

The Occupied Heating and Cooling Setpoints are entered onthis screen. The Heating Setpoint should always be one degreebelow the Cooling Setpoint, or the CVAHU will not accept thenew values.

Minimum Default MaximumCooling Setpoint 50°F 75°F 90°FHeating Setpoint 50°F 72°F 90°F

CVAHU Setpoints Unoccupied Setpoints Cool Setback.: 10°F Heat Setback.: -10°F

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

Minimum Default MaximumCooling Setback 0°F 10°F 30°FHeating Setback 0°F -10°F -30°F


3-46 Programming

Setpoint Screen #3

Setpoint Screen #4

CVAHU Setpoints Slide Effect.: 3°F SP Deadband..: 1°F

If the Zone Temperature Sensor has the optional Sensor SlideAdjustment, the maximum effect it can have on the Heating andCooling Setpoints is programmed here.

The SP Deadband is divided in half across the current heatingor cooling setpoint, and is used in staging the heating or coolingon or off.

Minimum Default MaximumSlide Effect 0°F 3°F 5°FSP Deadband 0°F 1°F 10°F

CVAHU Setpoints Cooling Stages: 2 Heating Stages: 2

The CVAHU can support a total of four stages of heating andcooling, configured to best match your system. As long as thetotal number of heating and cooling stages does not exceedfour, you can specify any quantity between zero and four foreach mode.

EXAMPLE:

3 Heating Stages (Relays #2 to #4)

1 Cooling Stage (Relay #5)

OR

0 Heating Stages (No Relays)

4 Cooling Stages (Relays #2 to #5)

The heating stages are always allocated first, starting with Relay#2 (Fan is Relay #1), and assigned sequentially up to amaximum of four heating and/or cooling stages.


Programming 3-47

Setpoint Screen #5

Setpoint Screen #6

Setpoint Screen #7

CVAHU Setpoints Minimum On/Off Times Cool Staging: 4 Min Cooling Off : 5 Min

The cooling stages must have been off for a minimum amountof time before they can be activated or re-activated. As eachadditional stage of cooling is added, a minimum Staging Delayperiod must be satisfied, between each additional stagerequired.

Minimum Default MaximumCool Staging 1 Min 4 Min 30 MinCooling Off 1 Min 5 Min 30 Min

CVAHU Setpoints Minimum On/Off Times Heat Staging: 2 Min Heating Off : 5 Min

The heating stages must have been off for a minimum amountof time before they can be activated or re-activated. As eachadditional stage of heating is added, a minimum Staging Delayperiod must be satisfied, between each additional stagerequired.

Minimum Default MaximumHeat Staging 1 Min 2 Min 30 MinHeating Off 1 Min 5 Min 30 Min

CVAHU Setpoints Changeover Delay Between Heat/Cool Modes......: 15 Min.

To prevent rapid cycling back and forth between the heatingand cooling modes, the CVAHU has a programmableChangeover Delay Timer. This timer prevents a change inmode from bringing on any heating or cooling (based on lastmode) until this delay is satisfied.

Normally, you do not want to change modes more than four orfive times per hour.

Minimum Default MaximumChangeover Delay 1 Min 20 Min 30 Min


3-48 Programming

Setpoint Screen #8

Setpoint Screen #9

CVAHU Setpoints Fan Mode.: Constant Economizer: Enabled Use Left/Right Arrow

Line 2 - The CVAHU can operate the fan in one of twomodes:

Continuous or Constant running duringoccupied hours.

Cycle with heating or cooling during occupiedhours.

The fan always cycles with heating or cooling duringunoccupied hours.The Left/Right Arrow keys will toggle the currentsetting to the opposite mode.

Line 3 - The CVAHU has the ability to control theEconomizer operation. If you require this feature,select Enabled, otherwise, select Disabled.

Constant Volume Unit Uses Schedule #: 0 0 = Internal Clock 1-7 = External Clock

The CVAHU normally uses its own Real Time Clock and anInternal Week Schedule to determine theOccupied/Unoccupied mode of operation. The CVAHU doeshave the ability to use a Global Broadcast from anotherscheduling device on the communications loop if a morepowerful schedule is required. If an external schedule is used,the range of schedule numbers is one to seven.


Programming 3-49

Setpoint Screen #10

Setpoint Screen #11

CVAHU Setpoints Cool Lockout.: 50°F Heat Lockout.: 65°F

The mechanical heating and cooling can be locked out fromoperating based on the Outdoor Air Temperature. If theOutdoor Air Temperature is above the Heating Lockout, noheating stages are allowed to activate or remain on if they arealready ON. If the Outdoor Air drops below the CoolingLockout, no cooling stages are allowed to activate or remain onif they are already ON.

Minimum Default MaximumCool Lockout -40°F 50°F 90°FHeat Lockout 30°F 65°F 99°F

CVAHU Setpoints Economizer Setpoints Enable Setpt.: 50°F Supply Setpt.: 55°F

If the CVAHU has been configured for Economizer Control,this screen will appear.

The Econo Enable setpoint is the Outdoor Air or WetbulbTemperature that enables the Economizer to open past itsminimum position setpoint to control Supply Air Temperature.

The Supply Setpt is the Supply Air Temperature theEconomizer tries to maintain.

Minimum Default MaximumEnable Setpt -40°F 50°F 99°FSupply Setpt 50°F 55°F 90°F


3-50 Programming

Setpoint Screen #12

Setpoint Screen #13

Setpoint Screen #14

CVAHU Setpoints Economizer Setpoints Min Position: 10 % Control Rate: 90

The Min Econo % is the position the economizer holds duringoccupied mode when it is not enabled for operation, due toOutdoor Air or Wetbulb Temperature.

During economizer control, the economizer damper is allowedto move 1 percent open or closed, as required, at a rate equal tothis value. Use this to speed up or slow down the operation ofyour economizer.

Minimum Default MaximumMin Position 0 % 10 % 100 %Control Rate 0 90 100

CVAHU Setpoints Economizer Setpoints Min Voltage: 0.0 v Max Voltage: 10.0 v

The user can set the voltages required to open and close thedamper. Some actuators use a 2-10 vdc signal instead of 0-10vdc.

If the system is not configured for Economizer Control, noeconomizer setpoint screens will appear.

Minimum Default MaximumMin Voltage 0.0 VDC 0.0 VDC 10.0 VDCMax Voltage 0.0 VDC 10.0 VDC 10.0 VDC

CVAHU Setpoints Fan Starting Delay Multiplier...: 10

If there are several air handling units on a system and you don’twant them to all start at the same when going into the occupiedmode or after a power outage, you can input a Fan StartingMultiplier. The multiplier is multiplied times the addressnumber of the unit and this becomes the number of seconds thisunit waits before starting the fan. For example if the Multiplieris 5 and this unit is at address #18, then the time delay will be90 seconds.

Minimum Default MaximumMultiplier 0 0 30


Programming 3-51

Setpoint Screen #15

Sensor Rdg Offset ZNT.: 73.6 0.0 SAT.: 76.5 0.0 OAT.: 70.2 0.0

As described in the Zone Controller section, the ThermisterType III Sensor readings can be calibrated. The Outdoor Aircalibration offset only applies to the CVAHU that has thesensor installed. It has no effect on the Global Broadcast valueof Outdoor Air.

Minimum Default MaximumZone Sensor ZNT -100.0°F 0.0°F +100.0°FSupply Sensor SAT -100.0°F 0.0°F +100.0°FOutdoor Sensor OAT -100.0°F 0.0°F +100.0°F


3-52 Programming

Constant Volume AHUScheduling and HolidaysIf the Unit ID you selected was for a Constant Volume controller, the following menu willappear.

Scheduling/Holiday Menu

Week SchedulesSchedule Start Time

Schedule StopTime

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 thenext Start Time screen.

Constant volume Unit 1) Week Schedules 2) Holidays ESC) Previous Menu

This menu appears whenever the user accesses the Schedulingfunctions. It allows the user to choose between schedules orholidays.

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

The screens will step through the Start Time and then the StopTime for each day of the week. You can quit at any point in theprocess by pressing the "ESC" key.

All times are in 24-hour format, so 5:00 PM would be enteredas 1700.

If both the Start and Stop Times are ZERO, the schedule is in aContinuous OFF mode.

If both the Start and Stop Times are 2359, the schedule is in aContinuous ON mode.

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


Programming 3-53

Holidays

Holiday Day Selection

Holiday Start / Stop Times

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

The screens will step through the eleven possible holidays, oneat a time. Line 2 shows which holiday is currently beingprogrammed.

Remember to combine the month and day into a single fourdigit value.

EXAMPLE: 0704 = July 4th

1225 = December 25th

Program Holidays Holiday Schedule Starting Time: 0 Stopping Time: 0

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


3-54 Programming

Economizer Module(Wetbulb) Read/ResetOperationsIf the Unit ID you entered was for the Economizer Module, the following menu willappear. Any references in this section to wetbulb are referring to the Economizer Module.

Wetbulb Menu

Wetbulb Status

1) Wetbulb Status 2) Setpoints

ESC) To Exit

1) WetbulbStatus

View the current Outdoor AirTemperature, Humidity, and calculatedWetbulb Temperature.

2) Setpoints View or change any of the availablesetpoints for this Economizer Module.

AZ WB # xx vl.xx Outdoor Air: 76.9°F Humidity...: 75 % Wetbulb....: 71.3°F

Line 2 - Current Outdoor Air Temperature reading. TheOutdoor Air Sensor must be installed on this unit. Itwill not read a Global Broadcast of the Outdoor AirTemperature from another controller.

Line 3 - Current Outdoor Relative Humidity.

Line 4 - Current calculation of the Wetbulb Temperature.The formula for calculating Wetbulb is as follows:

Wetbulb = (0.315 x OutdoorAir x (Humidity ^ ¼))


Programming 3-55

Wetbulb Setpoints

AZ WB Setpoints Calibration Offset Outdoor Air..: 77.1 Cal. Offset..: 0.0

The only setpoint available for this unit is the CalibrationOffset for the Thermistor Outdoor Air Temperature Sensor. Iflocation or other factors are causing the Outdoor AirTemperature reading to be incorrect, the user can adjust thereading up or down with this offset. Line 2 shows the currenttemperature when you first enter this screen but it is notdynamically updated after the offset is changed. You will needto exit this screen, then return to this screen to see the effect ofthe entered offset.

Minimum Default MaximumCal. Offset -100.0°F 0.0°F 100.0°F


3-56 Programming

System ManagerLCD/Keypad OperationsSummary


Programming 3-57

Notes:

Section 4

Start-Up and Troubleshooting

Table of Contents1.0 Communications Overview ....................................................................1

1.1 How It Works.............................................................................................................11.2 Auto-Zone Plus System .............................................................................................1

1.2.1 Communications Checklist .................................................................................41.3 Troubleshooting .........................................................................................................7

1.3.1 Checking the COMMLINK II Network Loop.....................................................71.3.2 Checking the Network Loop at the COMMLINK II...........................................81.3.3 Checking the COMMLINK II Driver .................................................................91.3.4 Checking the Zone Manager Network Loop.....................................................101.3.5 Checking the Zone Manager Network Driver...................................................121.3.6 Checking the Zone Manager Local Loop..........................................................131.3.7 Checking the Local Loop at the Zone Manager ................................................151.3.8 Checking the Zone Manager Local Loop Driver ..............................................171.3.9 Checking the Local Loop at a Controller ..........................................................181.3.10 Checking Zone Controller and CV Unit Drivers ............................................191.3.11 Comm Driver Chip Replacement....................................................................201.3.12 Troubleshooting Checklist ..............................................................................21

2.0 Zone Manager MC Overview...............................................................232.1 How It Works...........................................................................................................23

2.1.1 Initialization ......................................................................................................232.1.2 Calibration.........................................................................................................232.1.3 Operating Summary ..........................................................................................24

2.2 Becoming Familiar with the Zone Manager MC .....................................................252.2.1 24 VAC Power Connector ................................................................................262.2.2 Bypass Damper Connector................................................................................262.2.3 HVAC Unit Connector .....................................................................................262.2.4 Economizer Connector......................................................................................272.2.5 Powered Exhaust Connector .............................................................................272.2.6 Static Pressure Sensor Connector .....................................................................272.2.7 Analog Input Connector....................................................................................282.2.8 Setting the Zone Manager Address Switches....................................................302.2.9 Typical Zone Manager Wiring Diagram...........................................................31

2.3 Troubleshooting .......................................................................................................322.3.1 Checking the Zone Manager Analog Inputs .....................................................322.3.2 Checking the Zone Manager Static Sensor .......................................................34

Section 4


2.3.3 Zone Manager HVAC Unit Wiring Checks......................................................362.3.4 Zone Manager Bypass Damper Wiring Checks................................................37

3.0 Zone Controller Overview ................................................................... 393.1 How It Works...........................................................................................................39

3.1.1 Initialization ......................................................................................................393.1.2 Calibration.........................................................................................................393.1.3 Operating Summary ..........................................................................................40

3.2 Becoming Familiar with the Zone Controller ..........................................................413.2.1 24 VAC Power Connector ................................................................................423.2.2 Room Sensor Connector ...................................................................................423.2.3 Auxiliary Inputs ................................................................................................423.2.4 RS-485 Communications Connector ................................................................433.2.5 Airflow Sensor Input Jack.................................................................................433.2.6 Relay Expansion Board Jack.............................................................................433.2.7 Damper Actuator Jack.......................................................................................433.2.8 Setting the Zone Controller Address Switch.....................................................443.2.9 Zone Controller Wiring.....................................................................................45

3.3 Helpful Tips .............................................................................................................464.0 CV Controller Overview ...................................................................... 47

4.1 How It Works...........................................................................................................474.1.1 Initialization ......................................................................................................474.1.2 Operating Summary ..........................................................................................47

4.2 Becoming Familiar with the CV Controller.............................................................484.2.1 24 VAC Power Connector ................................................................................494.2.2 Analog Input Descriptions ................................................................................494.2.3 Analog Output Description ...............................................................................504.2.4 Relay Output Descriptions ................................................................................504.2.5 RS-485 Communications Connector ................................................................504.2.6 Setting the CV Controller Address Switch .......................................................514.2.7 CV Controller Wiring .......................................................................................52

5.0 Start-Up.................................................................................................. 535.1 Blink Codes for Zone and CV Controllers...............................................................535.2 General Troubleshooting..........................................................................................54

5.2.1 Trouble Shooting Checklist ..............................................................................545.2.2 Bypass Actuator Troubleshooting.....................................................................57

5.3 Temperature Sensor Resistance Chart .....................................................................58

Section 4


Table of FiguresFigure 4-1: Communications Loop Overview ....................................................................3Figure 4-2: Communications Loop Routing .......................................................................4Figure 4-3: Network Loop Wiring ......................................................................................5Figure 4-4: Local Loop Wiring ...........................................................................................6Figure 4-5: Zone Manager MC Component Layout .........................................................25Figure 4-6: Zone Manager MC Address Switches............................................................30Figure 4-7: Typical Zone Manager Wiring Diagram ........................................................31Figure 4-8: Zone Controller Component Layout ..............................................................41Figure 4-9: Zone Controller Address Switches.................................................................44Figure 4-10: Typical Zone Controller Wiring Diagram....................................................45Figure 4-11: CV Controller Component Layout ...............................................................48Figure 4-12: CV Controller Address Switches .................................................................51Figure 4-13: Typical CV Controller Wiring Diagram ......................................................52Figure 4-14: Bypass Actuator Troubleshooting................................................................57Table 4-1: Diagnostic LED Blink Codes ..........................................................................53


Start-Up and Troubleshooting 4-1

1.0 CommunicationsOverview

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, muchof the troubleshooting can be done by simple observation. We will lead you through thesystem functions and then provide you with detailed instructions for checking each pieceof equipment.

1.1How It WorksAuto-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 requestany data. Only one device on each loop is capable of sending the token, and this device isconsidered the loop master. The loop master varies depending on the type of system andthe installed options.

Note: It is very important to know which device is the loop master on the loopyou are troubleshooting.

1.2Auto-Zone Plus SystemThe Auto-Zone Plus system has more than one communications loop so it is important toremember that each loop must have it’s own master.

The main communications loop is the Network loop. It connects all of the Zone Managers(with MiniLinks) to the CommLink II. Each Zone Manager also has its own Local loopwhich connects it to the Zone Controllers and any CV Controllers or System Managerswhich you have chosen to be connected to this particular loop. Study the loop wiringdiagrams until you understand this arrangement.

The CommLink II is always the master on the Network loop. You must be sure theCommLink II is connected and functioning if you are troubleshooting the Network loop.

The MiniLink (mounted on the Zone Manager) is always the master on the Local loop.The MiniLink will pass tokens to the Zone Manager and any Zone Controllers, CVControllers, or System Manager found on the Local loop.


4-2 Start-Up and Troubleshooting

The MiniLink continues to “pass the token” even if the Network loop is not functioning.This is important to remember since the Zone Manager and the Zone Controllers willcontinue to communicate even if the Network loop is damaged. This feature allows eachrooftop unit with a Zone Manager and its associated Zone Controllers to functionindependently in the event of a “fault “ on another part of the system.



Figure 4-1: Communications Loop Overview

Each Zone Manager (HVAC unit) has a separate Local communications loop for associ-ated Zone Controllers and any Constant Volume units used.

Each Local loop must have a unique cluster address. It is typical for each Local loop tohave a sequential cluster address (e.g. 1, 2, 3, etc.).

Note: No controllers should be connected to the Network communications loop.

The Network communications loop should only be connected to the MiniLink’s Networkterminals on the Zone Manager(s), and the CommLink II.

All communications wiring should be labeled to avoid confusion and to aid futureservicing.



Figure 4-2: Communications Loop Routing

1.2.1 Communications Checklist• All Zone Managers are set to address 17• Each Local loop has a unique cluster address• Zone Controllers are addressed from 1 to 16• CV Units are addressed from 18 to 30• Power has been cycled after changing addresses• A CommLink II is powered and connected to the Network loop• Be sure Local loops are not connected to each other• System Manager is connected to a Local loop, not the network loop



TO OTHERTemp-Zone AZ PLUSZONE MANAGERS

CAUTION!

NETWORKASSURE THAT THE NETWORK LOOP ONLY

CONNECTS TO ZONE MANAGER TERMINALS.

DO NOT CONNECT ANYTHING OTHER THAN ZONE MANAGERSAND THE COMMLINK II TO THE NETWORK TERMINALS.

CONNECT ZONE CONTROLLERS, CV UNITS AND THESYSTEM MANAGER TO THE LOCAL LOOP(S).

ZONE CONTROLLERS SHOULD BE CONNECTED TOTHE LOCAL LOOP COMING FROM THE ROOFTOP

UNIT WHICH SUPPLIES AIR FOR THAT CONTROLLER

HVAC UNIT #1ZONE MANAGER

HVAC UNIT #2ZONE MANAGER

CLUSTER ADDRESSSWITCH SET TO 1

CLUSTER ADDRESSSWITCH SET TO 2

LOCAL LOOP #1

LOCAL LOOP #2

TO HVAC UNIT #2ZONE CONTROLLERS

andCONSTANT VOLUME

UNITS IF USED

T

RSHLD

T

RSHLD

TO MODEM( OPTIONAL )

TO COMPUTER( OPTIONAL ) NETWORK LOOP

TO24VAC

POWERSUPPLY

COMMLINK II

Figure 4-3: Network Loop Wiring



Figure 4-4: Local Loop Wiring



1.3Troubleshooting

1.3.1 Checking the CommLink II Network LoopDiagram

OverviewThis test checks for proper Network loop voltages at the CommLink II.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink II isattempting to communicate. The Loop LED will flicker more noticeably for a few sec-onds when first powered up. If the Loop LED does not flicker, the unit is defective.

Proper loop voltages are essential for reliable communications. It is normal to see fluctuationsat this point on the CommLink II. The average value should be close to the acceptable rangedescribed below. Values will vary upon initial powerup for about 10-15 seconds as theunit attempts to communicate.

MeasurementsNetwork Loop Acceptable Range

T - G (SHLD) 2.9 - 3.1 Volts DC

R - G (SHLD) 1.9 - 2.1 Volts DC

ActionCondition Action

If voltages are too high or too low on eitherside

1. Unplug the Network loop from theCommLink II and Check for proper loopvoltages. If a problem exists, disconnecteach Zone Manager Network Loop untilthe problem is isolated.

2. Check the CommLink II Driver chip.Replace the driver chip if necessary.



1.3.2 Checking the Network Loop at the CommLink IIDiagram

The indicated values are typical of a normal system, actual readings may deviate slightly dueto the number of units connected and other system specific factors.

Note: All of the connected zone managers should be powered up for this test.

OverviewThis is a “quick check” to determine if any of the driver chips on the Network loop are dam-aged. Since all units will “float” both of their communications connections at about 2.45Volts, you can quickly check the entire Network loop by unplugging it at the CommLink II.

Note: Be sure that the loop you are testing does not have a short circuit from T to R.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink II isattempting to communicate with the Zone Managers. There is a noticeable change in theflicker when the loop is disconnected, if you observe a normal functioning unit. Whenthe loop is reconnected it may take up to 60 seconds before the CommLink II re-establishes communications with the Zone Managers.


T - G (SHLD) 2.4-to-2.5 Volts DC

R - G (SHLD) 2.4-to-2.5 Volts DC



One or more of the Zone Manager Mini-Links has a damaged Network driver chip.Disconnect Zone Managers one at a time toisolate the problem.



1.3.3 Checking the CommLink II DriverDiagram

OverviewThis test checks for proper Network loop voltages coming from the CommLink II.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink II isattempting to communicate. The Loop LED will flicker more noticeably for a few sec-onds when first powered up. If the LED does not flicker, the unit is not functioning.

Proper loop voltages are essential for reliable communications. It is normal to see fluctuationsat this point on the CommLink II. The average value should be close to the acceptable rangedescribed below. Values will vary upon initial powerup for about 10-15 seconds as theunit attempts to communicate.

MeasurementsLocal Loop Acceptable Range





1. The CommLink II has a damaged commdriver chip. Replace the driver chip.See "1.3.11Comm Driver Chip Re-placement”.

2. The CommLink II is defective.



1.3.4 Checking the Zone Manager Network LoopDiagram

Meter Set To Read DC Volts

The indicated readings are typical of a normally operating system. Actual readings may varyslightly due to the number of units installed and other factors. Any significant deviation fromthese values generally indicates a problem.

Note: These tests assume that the CommLink II is connected and powered, and that allZone Managers which are connected are also powered.

OverviewProper loop voltages are essential for reliable communications. It is normal to see fluctuationson an operating communications loop. The average value should be close to the acceptablerange described below. Values will vary upon initial powerup for about 15-30 seconds asnormal communications occur.

MeasurementsLOCAL LOOP Acceptable RangeT - G (SHLD) 2.9 - 3.1 Volts DC




1.3.4 (continued)Action

Condition Action

Readings near Zero Volts Check for shorted wiring.


1. One or more devices connected to thisloop may have damaged comm driverchips.

2. Wiring errors. Check for multiple loopsinadvertently “cross connected”, shortcircuits, etc.



1.3.5 Checking the Zone Manager Network DriverDiagram


Note: These tests assume that the Zone Manager being checked is powered up

OverviewThis check is intended to determine if the Network Comm Driver chip on a Zone Manager isdamaged.

Tip: Before unplugging the Network loop from the Zone Manager, observe the NetworkLoop LED (located near the connector). It should periodically “flicker” as theCommLink II requests data from the Zone Manager. The LED will also flicker whenpower to the CommLink II is cycled. If the LED is not flickering, the unit is not com-municating with the CommLink II.

Damage typically occurs when the communications loop is exposed to excessive voltage, asmay occur during installation due to wiring errors. The driver chips are socketed on all boardsto facilitate servicing. It is unusual for driver chips to fail during normal operation. Almost allfailures occur as a result of wiring related problems.


T - SHLD 2.4 - 2.5 Volts DC

R - SHLD 2.4 - 2.5 Volts DC

Note Minor variances may not indicate a problem if both tests indicate similar values



The Zone Manager MiniLink has a dam-aged Network Comm Driver chip. Replacethe driver chip. See "1.3.11Comm DriverChip Replacement”.



1.3.6 Checking the Zone Manager Local LoopDiagram


The indicated readings are typical of a normally operating system. Actual readings may varyslightly due to the number of units installed and other factors. Any significant deviation fromthese values generally indicates a problem.

Note: These tests assume the zone manager is powered up

OverviewProper loop voltages are essential for reliable communications. It is normal to see fluctuationson an operating communications loop. The average value should be close to the acceptablerange described below. Values will vary upon initial powerup for about 30-45 seconds. Volt-ages fluctuate as normal communications occur.







Condition Action

Readings near zero volts Check for shorted wiring.


1. One or more devices connected to thisloop may have damaged Comm Driverchips.

2. Wiring errors. Check for multiple loopsinadvertently “cross connected”, shortcircuits, etc.



1.3.7 Checking the Local Loop at the Zone ManagerDiagram


The indicated values are typical of a normal system. Actual readings may deviate slightly dueto the number of units connected and other system specific factors

Note: These tests assume that the controllers being checked are powered up.

OverviewThis is a “quick check” to determine if any of the Zone Controllers or CV Units on a LocalCommunications Loop are damaged. Since all Zone Controllers and CV Units will “float”both of their communications connections at about 2.45 Volts, you can quickly check an en-tire loop by unplugging it at the Zone Manager.

Note: Be sure that the loop you are testing does not have a short circuit from T - R.

Damage typically occurs when the communications loop is exposed to excessive voltage, asmay occur during installation, due to wiring errors. The driver chips are socketed on allboards to facilitate servicing. It is unusual for driver chips to fail during normal operation.Almost all failures occur due to wiring related problems.




Note Minor variances may not indicate a problem if both tests indicate similar values.




Condition Action

If voltages are too high or to low on eitherside

1. One or more of the attached controllershas a damaged Comm Driver chip. Lo-cate and replace the driver chip(s). See"1.3.11Comm Driver Chip Replace-ment”.

2. Wiring errors such as "crossed connec-tions", short circuits, etc.



1.3.8 Checking the Zone Manager Local Loop DriverDiagram


The indicated values are typical of a normal operating system. Actual readings may deviateslightly.

Note: These tests assume that the zone manager is powered up.

OverviewThis test checks for proper Local Loop voltages coming from the Zone Manager.

Tip: The Local Loop LED (located near the connector) should “flicker” when the ZoneManager is operating and when first powered up. If the LED is not flickering, the unit isnot functioning.

Proper loop voltages are essential for reliable communications. It is normal to see fluctuationsat this point on the Zone Manager. The average value should be close to the acceptable rangedescribed below. Values will vary upon initial powerup for about 10-15 seconds. The voltagewill fluctuate as the unit attempts to communicate.






1. The Zone Manager has a damagedComm Driver chip on either the Mini-Link or the Zone Manager main board.Locate and replace the driver chip(s).See "1.3.11Comm Driver Chip Re-placement”.

2. The Zone Manager is not functioning.



1.3.9 Checking the Local Loop at a ControllerDiagram


The indicated readings are typical of a normal operating system. Actual readings may varyslightly due to the number of units installed and other factors. Any significant deviation fromthese values generally indicates a problem.

Note: These tests assume that a zone manager is connected and powered up.

OverviewProper loop voltages are essential for reliable communications. It is normal to see fluctuationson an operating communications loop. The average value should be close to the acceptablerange described below. Values will vary upon initial powerup for about 30-45 seconds. Thevoltages may fluctuate as normal communications occur.





If meter reads between 2.4 VDC and 2.5VDC

The Comm Loop “floats” at 2.4 - 2.5VDCwhen only controllers are connected to theloop. When a Zone Manager is connected itwill “bias” each side of the loop to the val-ues listed above.

1) No CommLink II or Zone Manager isconnected and powered up.

2) If a CommLink II or Zone Manager isconnected look for “open” wiring.


One or more devices connected to this loophave damaged Comm Driver chips.



1.3.10 Checking Zone Controller and CV Unit DriversDiagram


Note: These tests assume that the controller being checked is powered up.

OverviewThis check is intended to determine if the Comm Driver chip on a controller is damaged.Damage typically occurs when the communications loop is exposed to excessive voltage, asmay occur during installation, due to wiring errors. The driver chips are socketed on allboards to facilitate servicing. It is unusual for driver chips to fail during normal operation.Almost all failures occur as a result of wiring related problems.




Note Minor variances may not indicate a problem if both tests indicate similar values.



The controller has a damaged Comm Driverchip. Replace the driver chip. See"1.3.11Comm Driver Chip Replacement”.



1.3.11 Comm Driver Chip Replacement

TSHLD

G

TEMPGND

ZONE CONTROLLERCOMM DRIVER CHIP

( U10 )

PIN 11248

16

ADDRESS

T'STAT

CO

MM

PO

WE

R

ZONE CONTROLLER

SYSTEM MANAGER

COMM DRIVER CHIP( U1 )PIN 1

COMMLINK II

COMMUNICATIONSDRIVER CHIP

PIN 1

CV CONTROLLER / WETBULB CONTROLLER

PIN 1

CV CONTROLLERCOMM DRIVER CHIP

( U5 )

WARNING!

USE EXTREME CAUTION WHEN REMOVING ANY CHIPSTO AVOID DAMAGING ANY CIRCUIT BOARD TRACES WHICHARE UNDER THE CHIP.BE SURE THAT ANY SMALL SCREWDRIVER OR OTHERSHARP OBJECT USED TO REMOVE THE CHIP DOES NOTCOME INTO CONTACT WITH THE PRINTED CIRCUIT BOARDSURFACE.A SMALL SCREWDRIVER MAY BE INSERTED BETWEEN THECHIP AND THE SOCKET TO AID IN REMOVAL OF THE CHIP.

BE VERY CAREFUL NOT TO INSERT THE SCREWDRIVER UNDERTHE SOCKET!! DAMAGE TO THE BOARD IS NOT COVEREDBY WARRANTY.

ZONE MANAGER

NETWORK LOOPCOMM DRIVER CHIP

( U5 )

LOCAL LOOPCOMM DRIVER CHIP

( U8 )

ZONE MANAGERCOMM DRIVER CHIP

( U15 )

PIN 1

PIN 1

PIN 1

TYPICALRS-485

DRIVER CHIP

PIN 1

DOTSOCKET

PRINTEDCIRCUITBOARD



1.3.12 Troubleshooting Checklist

No Zones are Communicating

• Is the CommLink II connected and plugged in?• Are the Zone Manager addresses set to 17?

In an Auto-Zone Plus system all Zone Managers are set to Address = 17.• Are Comm Loop voltages correct? See the Comm Loop troubleshooting guides.• 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 24 VAC to the controllers.• Is the Network Loop shorted to or connected to any of the Local loops? Check

Network Loop voltages.• Is the System Manager connected to a Local loop?

Do not connect the system manager to the network loop!

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 24 VAC to the controllers.• Is the REC LED on the missing Zone Controller “flickering”? See Zone Controller

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 trouble-

shooting guide.



Notes:



2.0 Zone Manager MCOverview

2.1How It Works

2.1.1 InitializationOn system powerup the Zone Manager MC will go through the following process:

• Initial startup delay of one minute.• Bypass damper open relay activates.• Bypass damper close relay activates.

This bypass damper close relay should remain active for at least 30-45 seconds.(See Bypass Troubleshooting Procedures if the relay only remains active for 15seconds)

• After the bypass damper close relay turns off, the unit enters a short delay.• Bypass damper opens to twenty-five percent in preparation for fan start.

If either the bypass open or the bypass close relays continue to energize with in-creasing ON duration, see bypass troubleshooting procedures. It is abnormal forthe bypass open or closed relays to energize for longer than a few seconds at anytime except during calibration, morning startup, or end of day shutdown.

• Fan relay activates.After calibration, zones are initialized, then the FAN can start if one of the follow-ing conditions exist:∗ If the schedule is currently in the occupied period.∗ There is a heat or cool demand during Nite operation.∗ An override is in effect.

• During this initialization period, the controller retrieves all operating setpoints from itsnon-volatile EEPROM memory and initializes all outputs to an OFF condition.

2.1.2 CalibrationAt the conclusion of the fifty second startup delay, the system will proceed with theBypass Damper calibration. Depending upon the degree of travel and the speed of thedamper actuator, this process could take up to a maximum of four minutes. The StaticPressure Null Voltage is read at the factory during powerup checks before shipping. If theuser requires the system to re-calibrate the Pressure Sensor, check the Auto-Zone Plusmanual for keypad operations to perform this calibration.



The bypass damper always drives to its OPEN position first and then to its CLOSEDposition. If your damper appears to be operating in reverse you may need to selectReverse Acting damper operation from the Configuration menu. (See Section 3)

At the conclusion of the calibration process, all configured zones are polled and initializedwith the current operating conditions and modes. The total startup time is approximatelyfour minutes.

2.1.3 Operating SummaryThere is a standard set of operating instructions that are continuously performed over andover during normal Zone Manager operations. They are listed below.

a. Update Time & Date on LC Display (Basic systems)b. Read analog inputs for temperatures, pressures and binary contact closuresc. Poll all the configured zones and save all the temperatures and setpointsd. Broadcast the operating commands and temperatures to the zonese. Calculate Occupied/Unoccupied mode of operationf. Calculate HVAC mode of operationg. Set all outputs to match calculations for heating, cooling, or vent modeh. Keep alarms and mode of operation updated on LC Displayi. Store data in internal trend log if ready for another logj. Repeat steps a - i continuously



2.2 Becoming Familiar with the ZoneManager MC

Figure 4-5: Zone Manager MC Component Layout



2.2.1 24 VAC Power ConnectorThis connector provides power to the Zone Manager.

24 VAC - The “HOT” side of the control transformer.

GND - The grounded side of the control transformer. If the secondary of the con-trol transformer is not grounded, you must still observe polarity if the trans-former powers any other device!

Warning: Connect only the GND terminal to the grounded side of a transformer- Failure to properly observe polarity will result indamage to the system. Observe polarity at all points in thesystem.

2.2.2 Bypass Damper ConnectorThis connector carries the control signals for the Bypass Damper. The Bypass Damperwiring consists of four wires.

FDBK - The bypass damper actuator has an integral 0-10,000 Ohm feedback po-tentiometer which is used by the Zone Manager to determine the exact position ofthe damper.

GND - Common return wire.

OPEN - The Zone Manager will apply 24 VAC to this connection when attempt-ing to drive the bypass damper OPEN.

CLOSED - The Zone Manager will apply 24 VAC to this connection when at-tempting to drive the bypass damper CLOSED.

2.2.3 HVAC Unit ConnectorThis connector carries the control signals for the HVAC system. The HVAC wiringconsists of six wires.

R - Common return wire (normally the HVAC system will place 24 VAC on thiswire)

FAN - (G) The Zone Manager will make the connection to the “R” terminal whenthe fan is energized.



COOL1 - (Y1) The Zone Manager will make the connection to the “R” terminalwhen activating the first stage of cooling.

COOL2 - (Y2) The Zone Manager will make the connection to the “R” terminalwhen activating the second stage of cooling.

HEAT1 - (W1) The Zone Manager will make the connection to the “R” terminalwhen activating the first stage of heating.

HEAT2 - (W2) The Zone Manager will make the connection to the “R” terminalwhen activating the second stage of heating.

2.2.4 Economizer ConnectorThis connector carries a 0-10 volt control signal for the Economizer motor. The wiringconsists of two wires.

A1 - This analog output provides a 0-10 volt control signal which modulates theEconomizer Damper motor position.

Warning: This output must not be shorted to 24 VAC. The Economizer motormust be powered from a separate isolated 24 VAC transformer toavoid damaging the Zone Manager.

GND - Common return wire, this point is tied to GND on the Zone Manager.

2.2.5 Powered Exhaust ConnectorThis connector provides a normally open set of isolated contacts which CLOSE when theEconomizer is driven open past its minimum position setpoint. The wiring consists of twowires which are interchangeable.

2.2.6 Static Pressure Sensor ConnectorThe Static Pressure Sensor may be connected to this terminal block. The sensor mayalternatively be connected via its modular plug to the Static Pressure Sensor modular jack,located next to this connector. The Static Pressure Sensor wiring consists of three wires.

+5V - (RED) This wire provides power to the sensor

SIG - (BLK) This wire carries the 0-5V signal from the pressure sensor. The sig-nal is proportional to the static pressure.



GND - (GRN) Common return wire, this point is tied to GND on the Zone Man-ager.

2.2.7 Analog Input ConnectorThis connector provides the termination point for all of the temperature sensors and theauxiliary contact closure inputs.

All of the temperature sensor inputs (SAT, RAT, OAT) are designed to accept a standard10K Type III thermistor temperature sensor. The sensors can be checked by disconnectingthe wires at the terminal block and comparing the resistance against the chart at the end ofthis section. The sensors may also be checked by measuring the voltage (DC Volts) at theterminal block and comparing the measured value to the chart. The negative meter leadshould be on the GND terminal.

Tip: Any inputs that measure +5.1 VDC are OPEN, and any inputs which have lessthan +0.1 VDC are SHORTED. Look for wiring errors if this is a temperatureinput.

The wiring consists of the following six inputs:

SAT - Supply Air TemperatureThis input accepts a two wire 10K Type III thermistor temperature sensor. Thesensor measures 10,000 Ohms @ 77°F. The resistance drops as the temperatureincreases. The sensor is connected between this terminal and the GND terminal.

RAT - Return Air Temperature (Same as SAT)

OAT - Outside Air Temperature (Same as SAT)

AUX1 - Economizer DisableThis input allows the Economizer to be disabled when it is SHORTED to the GNDterminal. This input is typically connected to an enthalpy sensor to disable econo-mizer operation during high humidity periods.

AUX2 - Filter AlarmThis input allows connection of a Dirty Filter switch, an alarm condition is createdat the System Manager when it is SHORTED to the GND terminal. This input istypically connected to a normally-open switch contact.

AUX3 - Forced Occupied Mode



This input allows another system to force the Zone Manager into the Occupiedmode of operation when it is SHORTED to the GND terminal. This input is alsouseful as a test when checking the system during unoccupied periods. This input istypically connected to a normally-open switch contact.

2.2.8 Expansion Board ConnectorThe Expansion Board is connected to this modular plug. The relay expansion board can beeither analog outputs or extra relays.



2.2.8 Setting the Zone Manager Address Switches

Figure 4-6: Zone Manager Address Switches

CAUTION!THE Auto-Zone Plus SYSTEM WILL NOT WORK PROPERLYUNLESS YOU SET THE ADDRRESS SWITCHES CORRECTLY.



2.2.9 Typical Zone Manager Wiring Diagram

Figure 4-7: Typical Zone Manager MC Wiring Diagram



2.3Troubleshooting

2.3.1 Checking the Zone Manager Analog InputsDiagram Overview

The analog input wiring can be checked at theZone Manager by checking voltages on theAnalog Input Connector.

If any of the RAT, SAT, OAT inputs readgreater than 5.0 volts then it is OPEN (no sen-sor is connected), an input that reads less than0.1 volts is SHORTED. Check for wiringproblems before proceeding.

The AUX1-3 inputs should read greater than5.0 volts if the attached contact is OPEN andless than 0.5 volts if the contact is CLOSED(contacts CLOSE between the input andGND).

Note The Zone Manager must be poweredfor these tests.

MeasurementsMeter Acceptable Range

Ignore readings for any connections which are not used in the equipment

+12 23.4 – 25.2 volts

SAT 1.9 volts (100°F) - 3.6 volts (40°F)

Typical is 2.5 volts @ 77°F

RAT 1.9 volts (100°F) - 3.6 volts (40°F)


OAT 1.9 volts (100°F) - 3.6 volts (40°F)


AUX1 If the input is OPEN, the voltage will be greater than 5.0 volts

If the input is CLOSED, the voltage will be less than 0.5 volts

AUX2 see AUX1 above

AUX3 see AUX1 above



2.3.1(continued)Action

Condition Action

SAT, RAT, OAT Input voltage reads toolow

1. Check for shorts or other wiring errors.

2. Defective Sensor. Check using the chart.

3. High temperature at sensor. See chart.

SAT, RAT, OAT input voltage reads toohigh

1. Check for open circuit wiring errors.

2. Defective sensor. Check using the chart.

3. Low temperature at sensor. See chart.

AUX1 - AUX3 1. Check for open circuit wiring errors.



2.3.2 Checking the Zone Manager Static SensorDiagram

OverviewThe Static Pressure sensor can be checked at the Zone Manager by checking voltages on theStatic Pressure Sensor Connector.

At the TB1 - SIG terminal the voltage should be between 0.25 volts with no static pressureand 4.75 Volts @ 5” H2O.

If you get an incorrect reading, check all wiring to the Static Pressure Sensor carefully. Thesensors are extremely reliable and are unlikely to be the cause of the problem.

Warning: Do not blow into the static pressure sensor tubes, you will damage the sen-sor!

At TB1 - +5V terminal the voltage should be between 4.8 volts and 5.3 volts. If the voltage isnot correct, then unplug the Static Pressure Sensor and check the terminals on the board. Ifthe voltage at the board is correct, check for wiring errors (common) or a defective StaticPressure Sensor (very rare). If the voltage at the TB1 - +5V terminal is not within limits whenthe Static Pressure Sensor is unplugged, the Zone Manager is defective (this type of defect isunusual).

Note: The zone manager must be powered for these tests.


+5 - GND 4.9 - 5.15 volts

SIG - GND 0.25 volts @ 0” Static pressure - 4.75 Volts @ 5” Static pressure




Condition Action

If sensor reading is too high or too low Replace the Static Pressure Sensor (Rare)



2.3.3 Zone Manager HVAC Unit Wiring ChecksExample Diagram Overview

The HVAC unit wiring can be checked at theZone Manager by unplugging the HVAC UnitConnector and metering the wiring.

All meter readings are taken with one meterlead on the "R" terminal of the plug.

Readings may vary considerably due to thedifferences found in equipment from variousmanufacturers. Under most conditions this testwill provide a reliable “quick check” of thewiring.

The wiring should be considered OPEN if theresistance exceeds 10,000 Ohms orSHORTED if it is less than 50 Ohms.

Note: The HVAC unit power must be offfor this test.


Ignore readings for any connections which are not used in the equipment

FAN - R Typically between 100 Ohms and 2500 Ohms

COOL1 - R Typically between 100 Ohms and 2500 Ohms

COOL2 - R Typically between 100 Ohms and 2500 Ohms

HEAT1 - R Typically between 100 Ohms and 2500 Ohms

HEAT2 - R Typically between 100 Ohms and 2500 Ohms


Resistance is less than 50 Ohms Check for shorts or other wiring errors.

Resistance is greater than 10,000 Ohms Check for open circuit wiring errors.



2.3.4 Zone Manager Bypass Damper Wiring Checks

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

+-

BypassActuator

Zone Manager BoardTransformer

PWR

V4

V3

CLOSEOPEN

FDBKGND

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 Wire Between 24VAC And Ground

Remove Terminal Plug From Zone Manager Board When Performing Jumper Testing Of Actuator

Bypass DamperTerminal Plug

Bypass DamperTerminal Socket

FDBK

OPEN

GND

GND

PJ1

PJ2LD2

LD1

OPEN

CLOSE

CLOSE

TB1

TB2


1.) Confirm That All Wiring Is Correctly Connected To The Bypass & Slave Interface Card Terminals And The Zone Manager Bypass Actuator Terminals. Be Sure The Modular Cable Is Plugged In To Both The Actuator And The Modular Plug Labeled "To Actuator" On The Bypass & Slave Interface Card. If No Wiring Errors Are Found, Proceed To The Next Step.

2.) Remove Communications Wiring From The Zone Manager Board Then Remove The Power From The Zone Manager Board. Go To The Bypass Damper Location And Depress Clutch On The Actuator. Rotate The Actuator Clamp And Damper Shaft Back And Forth. Check To Verify That The Damper Moves Freely From Full Open To Full Closed Position. Check For Binding Or Interference That Prevents Full Opening And Closing Of The Bypass Damper. If The Damper Appears To Move Freely Proceed To The Next Step.

3.) Depress The Clutch On The Actuator. Rotate The Damper Shaft To The Middle Of The Actuator (See Drawing Above For Middle Of Full Stroke Position Picture). Connect The Meter Between The Ground And Feedback Wires On The Bypass & Slave Interface Card As Shown Above. Meter Should Read Approximately 5000 Ohms. If The Meter Does Not Read Approximately 5000 Ohms, Recheck The Wiring. If No Wiring Errors Are Found The Problem Is Probably A Bad Actuator Or Modular Cable.

Full Stroke Position

4.)

5.) Remove The Bypass Damper Terminal Plug From The Bypass Damper Terminal Socket On The Zone Manager Board As Shown Above. Run A Jumper Wire From The 24VAC Power Connection On The Zone Manager Board To The “Open” Terminal On The Bypass Damper Terminal Plug And A Jumper From The GND Connection On The Zone Manager Board To The GND Terminal On The Bypass Damper Terminal Plug.

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

Go To The Bypass Damper Location To Confirm That The Damper Moves Towards Its “Closed” (Counterclockwise) Position. If The Actuator Drives In Only One Direction Or Doesn’t Drive In Either Direction It Is Probably A Bad Actuator Or Modular Cable. If It Drives Open And Closed In The Jumper Test Just Performed But Not When Connected To The Zone Manager Board, The Problem Is Probably The Zone Manager Board.

Reconnect Power To The Zone Manager Board. The Damper Actuator Should Start Its Calibration Procedure And Move To Its Full Open (Clockwise) Position And Then To Its Full Closed (Counterclockwise) Position. If The Damper Actuator Does Not Move Through Its Full Calibration Range Proceed To The Next Step.

The Green Light On The Bypass/Slave Interface Card should Glow. Go To The Bypass Damper Location To Confirm That The Damper Moves Towards Its “Open" (Clockwise) Position.

The Red Light On The Bypass/Slave Interface Card should Glow.

6.) If You Have Another Actuator Motor Of The Same Type (One Can Be Borrowed From Another Zone Or Bypass Damper), You Can Try Switching Out The Original Actuator And Using The Borrowed Actuator To Verify Operation. Disconnect The 24VAC Power From The Zone Manager Board. Remove The Jumper Wire That Was Used In The Previous Checkout Step. Reconnect The Bypass Damper Terminal Block To The Zone Manager Board. Reconnect The 24VAC Power To The Zone Manger Board.

Replace The Defective Actuator With A New Actuator.

The Damper Actuator Should Start Its Calibration Procedure And Move To Its Full Open (Clockwise) Position And Then To Its Full Closed (Counterclockwise) Position. If The Borrowed Damper Actuator Moves Through Its Full Calibration Range

(Shown With ActuatorIn Middle Of Full Stroke)



Notes:



3.0 Zone ControllerOverview

3.1How It Works

3.1.1 InitializationOn system powerup the SCAN LED remains extinguished for five seconds. After thisdelay, the SCAN LED will blink out the address of the controller (Address SwitchSetting). The SCAN LED will then extinguish for another five seconds and then begin toblink for a twenty second startup delay. At the conclusion of this twenty second period,the SCAN LED will begin blinking a diagnostic code every ten seconds. This code isdescribed later in this document. The duration of a powerup initialization sequence isroughly one minute.

During this initialization period, the controller retrieves all operating setpoints from itsnon-volatile EEPROM memory and initializes all outputs to an OFF condition. It also teststo see if the optional relay expansion board is installed.

3.1.2 CalibrationDuring the powerup process, a self check of the zone damper actuator is performed. Thisguarantees the damper is operating and also records the feedback range for use incalculating 0 - 100 percent damper position readings. The damper is first driven to its fullyclosed position. While the damper is fully closed, the controller checks for an airflowsensor connected to the Airflow input. If it exists, the null voltage reading is stored awayfor future use in airflow calculations. Next, the damper drives to its full open position. Atthis point, it stores feedback values and remains open if no relay expansion board isattached. If the relay expansion is attached, the damper drives to its fully closed position.This is to protect series fan boxes from air in the main duct causing the series fan to spinbackwards before it can be powered up.

Note: If you change the zone damper operation from direct acting to reverse acting,you must remove power from the zone and allow it to re-start and perform thedamper calibration in the new open/close directions.



During calibration, a “flag” is read by the Zone Manager which prevents the user fromreading any status values or changing any setpoints. The Zone Manager status screens willindicate that zone to be calibrating. Also during this time, the zone is eliminated from anyHVAC voting.

3.1.3 Operating SummaryAt all times, after the conclusion of the initialization and calibration sequence, the ZoneController performs a specific set of operating instructions in the following order:

a. Reads analog inputs for temperatures, overrides and setpoint offset adjustments.b. Checks the RS-485 communications port for any new setpoints from the Zone

Manager and keeps the status updated for the Zone Manager. (If RS-485 commu-nications is lost, the controller goes into a protection mode, described later)

c. If the push-button override is active, it checks the timer to see if the override isfinished.

d. Calculates what the damper position should be and what condition the relaysshould be in if the optional relay expansion board is connected.

e. Updates the diagnostic SCAN LED blinking.f. Stores data in the internal trend log if ready for another log.g. Repeats steps a - f continuously.



3.2Becoming Familiar with the ZoneController

Figure 4-8: Zone Controller Component Layout



3.2.1 24 VAC Power ConnectorThis connector provides power to the Zone Controller.

24VAC - The “HOT” side of the control transformer.

GND - The Grounded side of the control transformer. If the secondary of thecontrol transformer is not grounded, you must still observe polarity if the trans-former powers any other device!


3.2.2 Room Sensor ConnectorThis terminal block provides the connection point for the room sensor. The room sensorwiring consists of two wires (Three if the optional temperature adjust feature is used).

TEMP - The Zone Controller is designed to use a standard 10K Type III ther-mistor as the temperature sensing element. This input is also used to detect theoverride button. The override button momentarily “shorts” this terminal to theGND terminal. The sensor can be checked by disconnecting the wires at the termi-nal block and comparing the resistance against the chart at the end of this section.The sensor may also be checked by measuring the voltage (DC volts) at the termi-nal block and comparing the measured value to the chart. The negative meter leadshould be on the GND terminal.

GND - Common return wire.

Tip: If the TEMP input measures +5.1 VDC the wiring is OPEN. If the input has lessthan +0.1 VDC the wiring is SHORTED. Look for wiring errors.

3.2.3 Auxiliary InputsThis terminal block is used to connect optional inputs to the Zone Controller.

+VS - Provides access to power for auxiliary devices.

Caution: Do not power unapproved devices from this supply.



AUX1 - Connect the Room Sensor Slide Adjust to this input if used.

AUX2 - Spare input for future applications.

GND - Common return wire

3.2.4 RS-485 Communications ConnectorThis connector provides the connection point for the Local Loop RS-485 communicationsloop. The wiring consists of a twisted pair of wires with a shield.

T - RS-485 (+) Communications terminal

SHLD - Common return wire, this point is tied to GND on the Zone Controller.

R - RS-485 (-) Communications terminal

3.2.5 Airflow Sensor Input JackThis four pin modular jack is used to connect the optional airflow sensor for pressureindependent applications. The Zone Controller automatically senses the airflow sensorwhen it is connected.

+5V - This wire provides power to the sensor

SIG - This wire carries the 0-5V signal from the pressure sensor. The signal isproportional to the velocity pressure.

GND - Common return wire, this point is tied to GND on the Zone Controller

3.2.6 Relay Expansion Board JackThis eight pin modular jack is used to connect the optional relay expansion board. TheRelay Expansion Board is used in applications requiring fan powered boxes or auxiliaryheat at the zone. The Zone Controller automatically senses the Relay Expansion Boardwhen it is connected.

3.2.7 Damper Actuator JackThis six pin modular jack is used to connect the zone damper actuator.



3.2.8 Setting the Zone Controller Address Switch

Figure 4-9: Zone Controller Address Switches



3.2.9 Zone Controller Wiring

Figure 4-10: Typical Zone Controller Wiring Diagram



3.3Helpful Tips• Position the damper to its mid position before applying power. Observe that the

damper drives in both directions during the calibration cycle following powerup. • Observe the SCAN LED (Diagnostic Blink Codes) immediately following application

of power. The LED provides valuable information about the Zone Controller, for moredetails see How It Works.

• Observe the REC LED (Communications LED), this LED will “flicker” anytime it

detects a request for data from this controllers address. If the REC LED does notflicker you do not have communications, See the Communications Troubleshootingsection of this manual.



4.0 CV ControllerOverview

4.1How It Works

4.1.1 InitializationOn system powerup the COMM LED remains extinguished for five seconds. After thisdelay, the COMM LED will blink out the address of the controller (Address SwitchSetting). The COMM LED will then extinguish for another five seconds and then begin toblink for a twenty second startup delay. At the conclusion of this twenty second period,the COMM LED will begin blinking a diagnostic code every ten seconds. This code isdescribed later in this document. The duration of a powerup initialization sequence isroughly one minute.

During this initialization period, the controller retrieves all operating setpoints from itsnon-volatile EEPROM memory and initializes all outputs to an OFF condition.

Note: All future references to the Constant Volume Unit in this document useCVAHU as the designation.

4.1.2 Operating SummaryAt all times, after the conclusion of the initialization sequence, the CVAHU performs aspecific set of operating instructions in the following order: (a - g repeat continuously)

a. Read Analog Inputs for Temperatures and Overrides.b. Check the RS-485 communications port for any new setpoints from the System

Manager and keeps the status updated for the System Manager.c. If the push-button override is active, it checks the timer to see if the override is

finished.d. Calculates the current occupied/unoccupied mode from its internal week schedul-

ing.e. Calculates what state the output relays and analog output should be set to.f. Updates the diagnostic COMM LED blinking.g. Stores data in the internal trend log if ready for another log.



4.2Becoming Familiar with the CV Con-troller

Figure 4-11: CV Controller Component Layout



4.2.1 24 VAC Power ConnectorThis connector provides power to the CV Controller.

24VAC - The “hot” side of the control transformer.

GND - The grounded side of the control transformer. If the secondary of thecontrol transformer is not grounded, you must still observe polarity if the trans-former powers any other device!


4.2.2 Analog Input DescriptionsInput #1 - Space temperature is read on this input. If the room sensor with override(OE211) sensor is installed, the input is also monitored for push-button override com-mands. The push-button is only active during unoccupied hours so a push during occupiedhours has no effect.

Input #2 - If the OE212 or OE213 space temperature sensor is installed, the sensorcontains a slide adjust control for varying the current heating and cooling setpoints. If theOE210 or OE211 sensors are used, this input will not be used.

Input #3 - Supply air temperature is read on this input. The supply air reading is used todetect equipment failure. Once a heating or cooling stage has activated, the supply air hastwo minutes to change by 5°F or the controller assumes a mechanical failure has occurred.The supply air also prevents cooling stages from activating if the temperature is 45°F orlower in the cooling mode and heating stages from activating if it is 140°F or higher in theheating mode.

Input #4 - Outdoor air temperature is read on this input. If you have more than oneCVAHU controller installed on the RS-485 communication loop, only one controllerneeds this sensor. The unit that has this sensor will automatically broadcast the outdoor airtemperature to all other controllers on the loop.



Input #5 - This input can be used to monitor a dirty filter alarm contact closure. If thecontact is closed, the alarm is active.

Note: All temperature sensors must be Thermister Type III which provide 77°F @10K Ohms Resistance.

4.2.3 Analog Output DescriptionAnalog Output - This output is used to control the Outdoor Air Damper if you configurethe unit for Economizer control. The output voltage range is user programmable to coverall types of proportional actuators. 0 - 10 VDC, 2 - 10 VDC and 4 - 20ma outputs are allpossible.

4.2.4 Relay Output DescriptionsOutput #1 - Main Fan ON/OFF Control

Output #2 - Mechanical Heating/Cooling Stage #1

Output #3 - Mechanical Heating / Cooling Stage #2



Any combination of heating and cooling stages may be configured during setup as long asthe required number of outputs does not exceed four. If both heating and cooling stagesare used, the heating stages must be first.

4.2.5 RS-485 Communications ConnectorThis connector provides the connection point for the Local Loop RS-485 communicationsloop. The wiring consists of a twisted pair of wires with a shield.

T - RS-485 (+) Communications terminal

SHLD - Common return wire, this point is tied to GND on the CV Controller.

R - RS-485 (-) Communications terminal



4.2.6 Setting the CV Controller Address Switch

CAUTION:YOU MUST POWER DOWN THE CONTROLLER AFTER CHANGING THE ADDRESS SWITCHES IN ORDER FOR ANY CHANGES TO TAKE EFFECT

NOTE:IGNORE ANY MARKINGS OR NUMBERS ON THE SWITCHUSE THE CHART!

TO DETERMINE THE BOARDS ADDRESS, ADD THE VALUES OF ALL THE SWITCHES WHICH ARE TOGGLED DOWN IN THE DIRECTION OF THE ARROW

NOTE: SWITCH IS ALWAYS ON

Figure 4-12: CV Controller Address Switches



4.2.7 CV Controller Wiring

Figure 4-13: Typical CV Controller Wiring Diagram



5.0 Start-Up

5.1Blink Codes for Zone and CVControllersThe Zone Controller and the CV Controller use an on board LED to indicate variousdiagnostic conditions during powerup and operation. The Zone Controller LED is labeled“SCAN” and the CV Unit LED is labeled “COMM”. Starting with power up the LEDblink codes are as follows:

• Off for five seconds• SCAN LED blinks the board address (Address 14 = 14 blinks)• Five second pause• Twenty second time delay - LED blinks twenty times• LED stays on continuous during damper calibration (No damper calibration on

the CV Unit)• Status code is repeatedly blinked every ten seconds to indicate controller

status:

Priority No. of Blinks StatusLowest 1 Normal Operation

- 2 Override Active- 3 Bad Zone or Airflow

Sensor- 4 Damper Failure

(Not used on CV Units)Highest 5 Communication Failure

Table 4-1: Diagnostic LED Blink Codes

Only the highest priority failure code will be shown. You must correct the highest priorityalarm before other problems will be indicated.



5.2General TroubleshootingThe following is a guide to assist in troubleshooting the Auto-Zone Plus System. It isprovided as a systematic approach to determining and resolving common systemproblems.

5.2.1 Trouble Shooting ChecklistBegin troubleshooting by locating the general problem in the list below. Detailedcomponent 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 it’s 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 Table 4-1.



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 alocation with adequate room air circulation.

• Is the resistance reading correct? Check with the Temperature/Resistance Chart inthis section.

• Is wiring correct? Check for errors.

Check the Room sensor• To meter the Room sensor:

Unplug the two position room sensor terminal block. Using your meter, check theresistance of the unplugged terminal block. Use the supplied Temperature/ResistanceChart to see if the sensor is within a reasonable range. Readings which are much toohigh or too low generally indicate wiring problems.

• To meter the Slide Adjust (optional):

Unplug the four position AUX terminal block. Use your ohmmeter to check theresistance between the GND wire on the two position room sensor terminal block andthe 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 positionbefore applying power.

• Is the Zone Controller set for DIRECT/REVERSE action? The zone controller mustbe configured for correct operation if REVERSE action of the damper is required.

• Is the actuator defective? See ACTUATOR troubleshooting chart.

Caution: Improper mounting and the associated adjustment of the damper bladepositioning is the number one cause of damper related problems. It canbe difficult to determine the full open position if the damper shafts arenot marked. It is sometimes helpful to force the damper to the full openor full closed position and then check for airflow at the diffusers. Thedamper may be forced using the control system or by unplugging theactuator then depressing the actuator clutch release and manuallypositioning the damper.



5.2.2 Bypass Actuator Troubleshooting

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

+-

BypassActuator

Zone Manager BoardTransformer

PWR

V4

V3

CLOSEOPEN

FDBKGND

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 Wire Between 24VAC And Ground

Remove Terminal Plug From Zone Manager Board When Performing Jumper Testing Of Actuator

Bypass DamperTerminal Plug

Bypass DamperTerminal Socket

FDBK

OPEN

GND

GND

PJ1

PJ2LD2

LD1

OPEN

CLOSE

CLOSE

TB1

TB2


1.) Confirm That All Wiring Is Correctly Connected To The Bypass & Slave Interface Card Terminals And The Zone Manager Bypass Actuator Terminals. Be Sure The Modular Cable Is Plugged In To Both The Actuator And The Modular Plug Labeled "To Actuator" On The Bypass & Slave Interface Card. If No Wiring Errors Are Found, Proceed To The Next Step.

2.) Remove Communications Wiring From The Zone Manager Board Then Remove The Power From The Zone Manager Board. Go To The Bypass Damper Location And Depress Clutch On The Actuator. Rotate The Actuator Clamp And Damper Shaft Back And Forth. Check To Verify That The Damper Moves Freely From Full Open To Full Closed Position. Check For Binding Or Interference That Prevents Full Opening And Closing Of The Bypass Damper. If The Damper Appears To Move Freely Proceed To The Next Step.

3.) Depress The Clutch On The Actuator. Rotate The Damper Shaft To The Middle Of The Actuator (See Drawing Above For Middle Of Full Stroke Position Picture). Connect The Meter Between The Ground And Feedback Wires On The Bypass & Slave Interface Card As Shown Above. Meter Should Read Approximately 5000 Ohms. If The Meter Does Not Read Approximately 5000 Ohms, Recheck The Wiring. If No Wiring Errors Are Found The Problem Is Probably A Bad Actuator Or Modular Cable.

Full Stroke Position

4.)

5.) Remove The Bypass Damper Terminal Plug From The Bypass Damper Terminal Socket On The Zone Manager Board As Shown Above. Run A Jumper Wire From The 24VAC Power Connection On The Zone Manager Board To The “Open” Terminal On The Bypass Damper Terminal Plug And A Jumper From The GND Connection On The Zone Manager Board To The GND Terminal On The Bypass Damper Terminal Plug.

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

Go To The Bypass Damper Location To Confirm That The Damper Moves Towards Its “Closed” (Counterclockwise) Position. If The Actuator Drives In Only One Direction Or Doesn’t Drive In Either Direction It Is Probably A Bad Actuator Or Modular Cable. If It Drives Open And Closed In The Jumper Test Just Performed But Not When Connected To The Zone Manager Board, The Problem Is Probably The Zone Manager Board.

Reconnect Power To The Zone Manager Board. The Damper Actuator Should Start Its Calibration Procedure And Move To Its Full Open (Clockwise) Position And Then To Its Full Closed (Counterclockwise) Position. If The Damper Actuator Does Not Move Through Its Full Calibration Range Proceed To The Next Step.

The Green Light On The Bypass/Slave Interface Card should Glow. Go To The Bypass Damper Location To Confirm That The Damper Moves Towards Its “Open" (Clockwise) Position.

The Red Light On The Bypass/Slave Interface Card should Glow.

6.) If You Have Another Actuator Motor Of The Same Type (One Can Be Borrowed From Another Zone Or Bypass Damper), You Can Try Switching Out The Original Actuator And Using The Borrowed Actuator To Verify Operation. Disconnect The 24VAC Power From The Zone Manager Board. Remove The Jumper Wire That Was Used In The Previous Checkout Step. Reconnect The Bypass Damper Terminal Block To The Zone Manager Board. Reconnect The 24VAC Power To The Zone Manger Board.

Replace The Defective Actuator With A New Actuator.

The Damper Actuator Should Start Its Calibration Procedure And Move To Its Full Open (Clockwise) Position And Then To Its Full Closed (Counterclockwise) Position. If The Borrowed Damper Actuator Moves Through Its Full Calibration Range

(Shown With ActuatorIn Middle Of Full Stroke)

Figure 4-14: Bypass Actuator Troubleshooting



5.3 Temperature Sensor ResistanceChart

TEMPERATURE

ºFRESISTANCE

O*VOLTAGE AT

INPUT*-10 93333 4.620-5 80531 4.5500 69822 4.4745 60552 4.39010 52500 4.29715 45902 4.20020 40147 4.09525 35165 3.98230 30805 3.86235 27140 3.73740 23874 3.60545 21094 3.47050 18655 3.33052 17799 3.27554 16956 3.21756 16164 3.16058 15385 3.10060 14681 3.04262 14014 2.98564 13382 2.92766 12758 2.86768 12191 2.81069 11906 2.78070 11652 2.75271 11379 2.72272 11136 2.69573 10878 2.66574 10625 2.63575 10398 2.60776 10158 2.57778 9711 2.52080 9302 2.465

TEMPERATURE

ºFRESISTANCE

O*VOLTAGE AT

INPUT*82 8893 2.40784 8514 2.35286 8153 2.29788 7805 2.24290 7472 2.18795 6716 2.055

100 6047 1.927105 5453 1.805110 4923 1.687115 4449 1.575120 4030 1.469125 3656 1.369130 3317 1.274135 3015 1.185140 2743 1.101145 2502 1.024150 2288 0.952

*Notes:1. Use the resistance column to check the

thermistor sensor while disconnected from thecontrollers (not powered).

2. Use the voltage column to check sensors whileconnected to powered controllers. Readvoltage with meter set on DC volts. Place the“-”(minus) lead on GND terminal and the“+”(plus) lead on the sensor input terminalbeing investigated.

If the voltage is above 5.08 VDC, then thesensor or wiring is “open.” If the voltage isless than 0.05 VDC, the sensor or wiring isshorted.

Form: WM-AZPMC-IO-01A Printed in the USA October 2000All rights reserved Copyright 2000

WattMaster Controls Inc. • 8500 NW River Park Drive • Parkville, Mo. • 64152Phone (816) 505-1100 Fax (816) 505-1101

Documents

CONTROL · PDF fileAuto-Zone CONTROL SYSTEM Auto-Zone Plus System with Zone Manager MC Design, Installation & Operations Manual