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Auto-Zone Plus

Section 4

Start-Up and Troubleshooting

4-45

3.3

Helpful 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
more details 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 not
flicker you

do not have communications

, See the Communications Troubleshooting

section of this manual.

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Summary of Contents for Auto-Zone Plus

Page 1: ...Design Installation And Operations Manual Plus System Revision 02B firealarmresources com...

Page 2: ...firealarmresources com...

Page 3: ...Troubleshooting This document is subject to change without notice WattMaster Controls Inc assumes no responsibility for errors or omissions herein Auto Zone Plus Installation Operations Manual Form W...

Page 4: ...firealarmresources com...

Page 5: ...lection 12 Step 5 Bypass Damper Sizing 13 Step 6 Sizing the Zone Damper 15 Round Dampers 17 Rectangular Dampers 17 Pressure Independent Zone Dampers 18 Auxiliary Heat Control Options 19 Table of Figur...

Page 6: ...firealarmresources com...

Page 7: ...re 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 fu...

Page 8: ...COMM LIN K II COMM LIN K II L C M M O O O O M D P P E Constant Volume Units Up to 13 CV Units May Be added To Each Zone Manager Loop System Manager Local Loop Local Loop Network Loop 24VAC 24VAC Zone...

Page 9: ...of having to install multiple rooftop units to accommodate multiple zone requirements The Auto Zone Plus system is versatile and can be used with any packaged roof top unit or split system It control...

Page 10: ...eduling night set back trend logging of sensor values and automatic changeover Bypass Damper The bypass damper controls proper duct static pressure to insure proper airflow The damper is modulated by...

Page 11: ...a result of its unique design the zone sensor rejects the influence of internal wall temperature effects The sensor comes in four different configurations Sensor only Sensor w push button override ov...

Page 12: ...separate constant volume units The Auto Zone Plus system offers the designer considerable flexibility by allowing both multiple zoned units and single zone units to be connected within a single simple...

Page 13: ...settings which are so high you cause over cooling of the spaces Find a compromise position Bypass the air into the plenum instead of into the return air intake Be careful if you use this method since...

Page 14: ...ost commonly caused by a single zone being overridden for after hours use This causes the rooftop equipment to operate for only one zone The Auto Zone Plus system offers an improved solution to this c...

Page 15: ...has a minimum of nine distinct temperature or control zones that are affected uniquely by the outdoor load These zones are depicted in Figure 1 2 Depending on the size of the building and partition la...

Page 16: ...mance will generally be compromised and frequent changeover from the heating to the cooling mode will occur during the heating season if purely internal zones are combined on the same air conditioning...

Page 17: ...ized This is especially true for pressure dependent systems Pressure dependent refers to the typical Plus Zone Controller without the airflow sensor With larger trunk ducts it is easier to assure rela...

Page 18: ...the airflow 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...

Page 19: ...0 FPM When determining the bypass duct size be sure to take into account any transition fittings and associated pressure drops See Table 1 1 Damper Sizing Chart Whenever possible use a single bypass d...

Page 20: ...is often difficult to find in an installation a location in the main trunk where the tip is not in a negative pressure area e g just downstream of the inside curve of an elbow or an area where the tu...

Page 21: ...e the branch velocity used in the duct design program on the left hand column of the damper sizing chart Table 1 1 Move across the chart and find the damper which will provide the acceptable CFM to me...

Page 22: ...sions Figure 1 5 Rectangular Damper Dimensions Note Dimensions Are Identical For Round Zone Bypass Slave Dampers Note See Table 1 2 for Available A x B Rectangular Damper Sizes Note Dimensions Are Ide...

Page 23: ...2230 2400 2570 2740 2910 3090 18 770 980 1180 1380 1580 1780 1980 2180 2350 2550 2750 2950 3150 3350 3540 20 850 1090 1330 1550 1770 1990 2210 2430 2650 2870 3090 3310 3530 3750 3990 22 930 1210 1480...

Page 24: ...elow to set the calibration of the zone damper after installation Damper Size Flow Probe K Factor 6 474 8 950 10 1417 12 2120 14 2908 16 3700 Flow Probe K Factor CFM 1 Velocity Pressure Table 1 3 Pres...

Page 25: ...ftop unit does not have any heating capabilities Q Is the zone heat only to be used as a second stage where it will be activated only if the rooftop unit cannot maintain the space temperature such as...

Page 26: ...ng demands in other zones The space temperature must be below the AUX HEAT setpoint in the occupied mode before the Box Heat relay can be energized Relay 3 Aux Heat In the occupied mode the aux heat c...

Page 27: ...oller 20 CV Controller Wiring 21 CV Controller Addressing 23 Room Sensors 24 Supply Air Temperature Sensor 26 Return Air Temperature Sensor 26 Outside Air Temperature Sensor 27 Duct Static Pressure Se...

Page 28: ...13 Zone Controller Address Switch Settings 18 Figure 2 14 Slaved Zone Controller Wiring 19 Figure 2 15 CV Controller With Backplate Components 20 Figure 2 16 Constant Volume Controller Wiring 21 Figur...

Page 29: ...to communication wiring since the most common mistakes are made in this area Polarity is the most important rule Make notes on your wiring diagrams as to which color wire you will be using on each ter...

Page 30: ...ckaged or Split System Typical HVAC Unit H E A T I N G C O O L I N G F I L T E R NORMAL WARMER COOLER OVR W OVERRIDE AND SETPOINT ADJUST ZONE CONTROLLER MODULATING DAMPER AC LINE CONNECT TO OTHER ZONE...

Page 31: ...chnical Data section of the product data sheet when choosing a location The Zone Manager may be mounted without removing the controller from the mounting plate The unit is mounted by four 4 screws in...

Page 32: ...Section 2 Auto Zone Plus 2 4 Design Guide Figure 2 4 Auto Zone Plus Zone Manager Components firealarmresources com...

Page 33: ...COOL2 COOL1 FAN R 2 8 C SW1 16 A B 2 4 ADD LOCAL LOOP Local Loop T SH R TB3 COMM T SH R 32 16 8 4 1 2 MINILINK R9 R10 R8 I C EXP PORT PWR V4 V3 CLOSE OPEN FDBK REC GND GND 24VAC AUX1 OPEN K1 NETWORK L...

Page 34: ...e 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 D...

Page 35: ...CH ZONE MANAGER MUST HAVE A UNIQUE CLUSTER ADDRESS 1 2 3 4 ETC ZMGRSWP3 CDR 3 6 00 Remember You must power down the Zone Manager after changing the address switches in order for any changes to take ef...

Page 36: ...u increase your chance of problems Caution Make sure when you are inserting wires into the terminal blocks that strands of wire do not stick out and touch the next terminal This could cause a short or...

Page 37: ...required by local codes CommLink II Set For Multiple Loop Computer Optional To Other Zone Managers Up To 30 Per System Zone Manager 2 Zone Manager 1 RS 485 19200 Baud RS 485 19200 Baud RS 485 9600 Ba...

Page 38: ...gular Bypass Dampers Kit is supplied with the Damper Actuator and Bypass Wiring Interface Board factory mounted in a sheet metal enclosure This assembly is then field mounted over the Rectangular Damp...

Page 39: ...f sheet metal screws are used to mount the dampers be certain that they do not interfere with the movement of the damper blade Warning Never depress the actuator clutch with power applied Unplug the a...

Page 40: ...AGER BOARD FROM ZONE CONTROLLER BYPASS AND SLAVE INTERFACE YS101824 TO ACTUATOR OPEN CLOSE FDBK OPEN GND GND PJ1 PJ2 LD2 LD1 OPEN CLOSE CLOSE TB1 TB2 FROM ZONE CONTROLLER BYPASS AND SLAVE INTERFACE YS...

Page 41: ...factory mounted in a sheet metal enclosure This assembly is then field mounted over the Rectangular Damper shaft and secured to the ductwork with sheet metal screws Figure 2 10 Round And Rectangular...

Page 42: ...lly pull one edge of the snap track away from the board with your fingers and remove the board Caution Do not use any tools to pry the board loose This will damage the board and or the snap track Warn...

Page 43: ...16 2 4 ADDRESS ADD 1 U6 U5 R19 U9 CX9 R32 D5 C14 P U R22 C13 R27 D5 RAM C9 C8 80C55 2 CX5 PJ1 C3 R8 R7 R5 R6 R4 C2 C1 X1 U2 R1 R2 R3 CX2 Q1 16L8 32K R34 FLOW U8 1 RN1 CX8 U4 R18 CX4 8K RAM U3 CX3 U1...

Page 44: ...are ready to begin the checkout procedure This may help prevent damage if wiring errors occur elsewhere in the system during installation or start up This is particularly important with the Zone Contr...

Page 45: ...just Option 1 24 VAC Must Be Connected So That All Ground Wires Remain Common 2 All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications 3 AllCommunication Wiring To...

Page 46: ...The ADDRESS ADD Arrow Marked On The Zone Controller Circuit Board CX6 SW1 Q3 Q2 D3 VR1 7824 GND 24VAC R17 R16 U7 C7 R15 POWER R21 REV 2 YS101 562 MDL F1 250 D4 R26 LD3 L1 SCAN REC R12 C6 R11 TOKEN NET...

Page 47: ...E FDBK OPEN GND GND PJ1 PJ2 LD2 LD1 OPEN CLOSE CLOSE TB1 TB2 FROM ZONE CONTROLLER BYPASS AND SLAVE INTERFACE YS101824 TO ACTUATOR OPEN CLOSE FDBK OPEN GND GND PJ1 PJ2 LD2 LD1 OPEN CLOSE CLOSE TB1 TB2...

Page 48: ...ounted by securing with four 4 screws through the mounting holes in the mounting backplate Select the correct screws or other fasteners for the type of mounting material being utilized HVAC Unit Conne...

Page 49: ...ectrical Codes And Specifications 3 All Communication Wiring To Be 2 Conductor Twisted Pair With Shield Use Belden 82760 Or Equivalent Economizer Actuator Belimo Shown Consult Factory For Other Manufa...

Page 50: ...circuit boards The Constant Volume Controller requires the following electrical connections 18 Gauge minimum unless otherwise noted 24VAC Supply Voltage 2 Conductors Communications Loop 2 Conductor t...

Page 51: ...DRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 1 2 4...

Page 52: ...oid locating the sensor in dead air areas of a room This will result in slow response to temperature changes in the space Figure 2 18 Room Sensor Installation Mount the sensor approximately 50 60 inch...

Page 53: ...or to the terminal labeled TEMP on the Zone Controller terminal block for the TEMP SENSOR If the zone sensor has a setpoint adjust slider then connect the sensor terminal labeled AUX to the Zone Contr...

Page 54: ...cated as close to the rooftop unit return air intake as possible Avoid locations which will be exposed to extreme outside temperatures Locate the sensor in the center of the widest part of the duct Us...

Page 55: ...Damage Sensor 2 Unused Conduit Opening s Must Have Closure Plugs Installed And Must Be Coated with Sealing Compound To Provide Raintight Seal Water Can Damage Sensor 1 The Outside Air Sensor Must Be M...

Page 56: ...upstream of any elbow or takeoff See Figure 1 3 in section 1 of this manual for general mounting location information Figure 2 22 Duct Static Pressure Sensor Caution Mount the static pressure sensor...

Page 57: ...ure sensor will improve control performance by acting as a filter to remove pressure fluctuations caused by turbulence in the duct Figure 2 23 Static Pressure Sensor Wiring Note Refer to Figure 1 3 in...

Page 58: ...y Heat typically perimeter type Series Fan The board comes shipped with a modular cable which plugs directly into the Zone Controller connector marked Expansion After connecting the board the system w...

Page 59: ...ng cooling demands in other zones The space temperature must be below the AUX HEAT setpoint in the occupied mode before the Box Heat relay can be energized Relay 3 Aux Heat In the occupied mode the au...

Page 60: ...t be located close to the CommLink The CommLink II comes complete with computer and modem cables and a 110VAC plug in power supply The RemoteLink is also supplied with a 110 VAC plug in power supply T...

Page 61: ...Auto Zone Plus Section 2 Design Guide 2 33 Figure 2 26 CommLink Communications Loop Wiring firealarmresources com...

Page 62: ...9 Pin Female 25 Pin Female 9 Pin Female 120 24 Vac Transformer 25 Pin Male Warning Use The Molded Cable To Connect To The Computer DCE Connector Or Serious Damage To The CommLink Could Result This Ca...

Page 63: ...four line by twenty character backlighted LCD display and membrane keypad provide a user friendly interface All system variables setpoints and values can be viewed and modified from the System Manager...

Page 64: ...25VA Max MADE IN THE USA EPROM 1000uF10v YS101806 REV 1 DSPY1 UNIVERSAL SMART DISP UNIT SYSTEM MANAGER SERIAL U13 SERIAL 1000uF10v C9 470uF50v D2 PCB80C552 5 16WP 442860 2 5 DfD9722V7 Y PHILIPS CX13 L...

Page 65: ...BH SF PF 2 S SO SA SOA AH BH SF PF 3 S SO SA SOA AH BH SF PF 4 S SO SA SOA AH BH SF PF 5 S SO SA SOA AH BH SF PF 6 S SO SA SOA AH BH SF PF 7 S SO SA SOA AH BH SF PF 8 S SO SA SOA AH BH SF PF 9 S SO SA...

Page 66: ...No L 1 2 3 4 R t Li k I t ll d Y N Ph N Unit Address Unit Description or Location Sensor Type 18 S SO SA SOA 19 S SO SA SOA 20 S SO SA SOA 21 S SO SA SOA 22 S SO SA SOA 23 S SO SA SOA 24 S SO SA SOA...

Page 67: ...Screens 12 Zone Controller Setpoints 15 Zone Controller Force Modes 19 Zone Manager Read Reset Operations 20 Zone Manager Status 21 Zone Manager Configuration 24 Zone Manager Setpoints 27 Control Setp...

Page 68: ...firealarmresources com...

Page 69: ...ght forward utilizing non cryptic plain English messages The System Manager automatically detects the type of unit that has been selected and displays the appropriate status and setpoint screens The a...

Page 70: ...ystem Manager has been configured for Alarm Polling the user can select this item to get a list of unit addresses that are currently in alarm If an alarm exists the Alarm LED will be active on the rig...

Page 71: ...he Unit ID You would like to view the 12th zone on the 24th loop Enter 2412 as the Unit ID Zone Controller Temperature 75 4 F Cooling SP 75 F Heating SP 72 F If the selected Unit ID is correct and the...

Page 72: ...asscode xxxx Anytime you are prompted to enter a passcode the following screen will appear No reference is made as to the level of passcode to enter but if you attempt to access a Level 2 function wit...

Page 73: ...System Manager latches the alarm condition This makes it possible to determine if any intermittent alarm conditions have occured If you have Level 2 access you can enter the full system access mode se...

Page 74: ...field or screen DEC If entering a setpoint that requires a decimal point press this key where the decimal is located while entering the value MINUS If you need to enter a negative value you must pres...

Page 75: ...D indicates an Alarm condition if the Manager detects an alarm condition while polling the system The middle LED is active during actual communications or packet transfers This LED will normally flick...

Page 76: ...y to all other units on the system That means that you only need to program the System Manager time to set the Real Time Clocks for all units on your communications loop Programming Time Programming D...

Page 77: ...toggle the second line of the display 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 acce...

Page 78: ...none are connected This is useful during building startup when you don t want nuisance alarms bothering you The screen will display each address it is testing and if a unit has been found at that addr...

Page 79: ...ontinuing up to sixteen The Zone Manager is always at address seventeen and any Constant Volume units would start at eighteen and continue to thirty If this is a Constant Volume only system the addres...

Page 80: ...tatus Screens Note The top line of every Status Screen shows the selected Zone Address and its Software Version 1 Zone Status 2 Zone Setpoints 3 Zone Modes ESC To Exit If the Unit ID you entered was f...

Page 81: ...oling Setpoint CSP Heating Setpoint HSP Line 4 Optional Sensor Slide Adjust located on Zone Wall Sensor effect on current operating Setpoints Zone 1 v1 xx Damper Pos 20 Minimum Setpt 20 Maximum Setpt...

Page 82: ...alled Auxiliary Heat Off Box Heating On Aux Heating On Box Aux Heat On Line 3 Series Fan On or Blank Line if Fan is Off Line 4 Parallel Fan On or Blank Line if Fan is Off Zone 1 v1 xx Damper O K Zone...

Page 83: ...one Controller will not accept the new values The System Manager can t prevent the entry of invalid setpoints If invalid setpoints are entered the previous settings will be retained by the system and...

Page 84: ...r has the optional Setpoint Adjustment Slide enter the maximum effect it can have on the setpoints on the Slide Effect line Minimum Default Maximum AuxHeat Setpt 50 F 72 F 90 F Slide Effect 0 F 3 F 5...

Page 85: ...CFM PD Zone Nite Mode Min PI 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 Contr...

Page 86: ...ed mode Caution The normal calibration offset should be a fairly small value If you need several degrees of offset there might be a sensor problem or a location problem PD ZONE ADDRESS 1 Sensor Calibr...

Page 87: ...sition This is a percentage value that the damper drives to and stops In Pressure Independent boxes you can force the zone to maintain the Maximum or Minimum Airflow setpoints The damper doesn t actua...

Page 88: ...his Zone Manager MENU Next Menu Access the next Menu Page for the Zone Manager 1 Schedules 2 Configuration 3 Force Modes MENU Previous Menu 1 Schedules View or change any of the Week Schedules or Holi...

Page 89: ...upied Forced Fan Only Mode Purge Mode Line 3 Neutral Mode Vent Mode Cooling Mode Heating Mode Line 4 Binary Contact Alarm Blank Line if no Alarm Manager 1 vl xx Supply Air 78 6 F Return Air 77 3 F Out...

Page 90: ...Stage 0 The current quantity of active heating or cooling stages is displayed on this screen There are a maximum of six stages of heating and six stages of cooling available if the optional relay exp...

Page 91: ...e display shows No Priorities and line 2 displays four dots as a place holder for that line If the optional Economizer Module was installed the current calculated Wetbulb Temperature received by the Z...

Page 92: ...ss locations If you do skip an address the Zone Manager will presume there is a missing zone and an alarm will occur ZONE POLLING RANGE Last Zone Addr 1 First Zone Addr 1 Cooling Stages 1 Heating Stag...

Page 93: ...ays cycles with heating or cooling during unoccupied hours The Left Right Arrow keys will toggle the current setting to the opposite mode Economizer Enabled Use Left Right Arrow The Zone Manager has t...

Page 94: ...s is 1 to 7 Press To Force ReCalibration Of The Static Pr Sensor OR ENTER to Skip This The Zone Manager only calibrates the static pressure sensor one time This occurs on the initial powerup so it is...

Page 95: ...the outside air temperature rises 1 above this setpoint the any heating stages of heat are disabled If the outside air temperature drops 1 below this setpoint any heating stages above the first are re...

Page 96: ...angeover Interval 10 Min If the Zone Manager needs to change HVAC Modes between heating and cooling a Changeover Delay time must be satisfied first This prevents Chasing due to alternate hot and cold...

Page 97: ...80 F Min Econo 0 20 100 Economizer Setpoints Economizer Control Rate 10 During Economizer control the Economizer damper is allowed to move open or closed as required at a rate controlled by this valu...

Page 98: ...e 1 Occupied Forced to Continuous Day or Occupied Mode 2 Night Forced to Continuous Night or Unoccupied Mode If the Forced Occupied Binary Input Contact is closed this mode will override it to OFF Use...

Page 99: ...actually stop but continues to move if required to maintain one of these limits If the Force to Minimum is selected the current minimum position or airflow being used is the controlling position This...

Page 100: ...tus View the current temperatures and operating modes for this Constant Volume AHU 2 CVAHU Setpoints View or change any of the available setpoints for this Constant Volume AHU MENU Next Menu Access th...

Page 101: ...Active Push Button Override Forced Occupied Forced Unoccupied Forced Fan Only Mode Line 3 Neutral Mode Cooling Mode Heating Mode Line 4 Reserved for Future Use This Line is Blank CVAHU 18 vl xx Tempe...

Page 102: ...zer 10 Heating Locked Out Fan On Line 2 Shows the current Economizer Damper position if the CVAHU has been configured to control the Economizer This line is blank if the CVAHU does not control the Eco...

Page 103: ...than five degrees after a stage of heating or cooling has been activated for 30 minutes CVAHU 18 vl xx Zone Cooling ALARM Line 2 Zone Sensor O K Bad Zone Sensor Zone Cooling ALARM Zone Heating ALARM...

Page 104: ...the Cooling Setpoint or the CVAHU will not accept the new values Minimum Default Maximum Cooling Setpoint 50 F 75 F 90 F Heating Setpoint 50 F 72 F 90 F CVAHU Setpoints Unoccupied Setpoints Cool Setu...

Page 105: ...Effect 0 F 3 F 5 F SP 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 and cooling configured to best match your system...

Page 106: ...must have been off for a minimum amount of time before they can be activated or re activated As each additional stage of heating is added a minimum Staging Delay period must be satisfied between each...

Page 107: ...rent setting to the opposite mode Line 3 The CVAHU has the ability to control the Economizer operation If you require this feature select Enabled otherwise select Disabled CVAHU Setpoints Uses Schedul...

Page 108: ...e allowed to activate or remain on if they are already ON Minimum Default Maximum Cool Lockout 40 F 50 F 90 F Heat Lockout 30 F 65 F 99 F CVAHU Setpoints Economizer Setpoints Enable Setpt 50 F Supply...

Page 109: ...n set the voltages required to open and close the damper Some actuators use a 2 10 vdc signal instead of 0 10 vdc If the system is not configured for Economizer Control no economizer setpoint screens...

Page 110: ...rmister Type III Sensor readings can be calibrated The Outdoor Air calibration offset only applies to the CVAHU that has the sensor installed It has no effect on the Global Broadcast value of Outdoor...

Page 111: ...ESC Previous Menu This menu appears whenever the user accesses the Scheduling functions It allows the user to choose between schedules or holidays Line 1 may read Zone Manager or Constant Volume Unit...

Page 112: ...Day 101 EX 101 Jan 1 The screens will step through the eleven possible holidays one at a time Line 2 shows which holiday is currently being programmed Remember to combine the month and day into a sin...

Page 113: ...Humidity and calculated Wetbulb Temperature 2 Setpoints View or change any of the available setpoints for this Economizer Module WB xx vl xx Outdoor Air 76 9 F Humidity 75 Wetbulb 71 3 F Line 2 Curre...

Page 114: ...or other factors are causing the Outdoor Air Temperature reading to be incorrect the user can adjust the reading up or down with this offset Line 2 shows the current temperature when you first enter t...

Page 115: ...ime Date Day Sunday 0 1 Enter Hr 0 23 9 Enter Minues 53 Enter New Passcode Level 1 XXXX Level 2 XXXX Must Be 4 Digits Program Time Date Month 1 12 9 Day 1 31 18 Year 00 99 95 Daylight Savings Auto Adj...

Page 116: ...firealarmresources com...

Page 117: ...r with the Zone Manager 26 2 3 Troubleshooting 32 3 0Zone Controller Overview 38 3 1 How It Works 38 3 2 Becoming Familiar with the Zone Controller 40 3 3 Helpful Tips 45 4 0CV Controller Overview 46...

Page 118: ...out 26 Figure 4 9 Zone Manager Address Switches 30 Figure 4 10 Typical Zone Manager Wiring Diagram 31 Figure 4 11 Zone Controller Component Layout 40 Figure 4 12 Zone Controller Address Switches 43 Fi...

Page 119: ...g each piece of equipment 1 1 How It Works Auto Zone uses a token passing loop architecture which means in simple terms that an electronic message called a token is passed from controller to controlle...

Page 120: ...The CommLink II is always the master on the Network loop You must be sure the CommLink II is connected and functioning if you are troubleshooting the Network loop The MiniLink mounted on the Zone Man...

Page 121: ...em Zone Manager 2 Zone Manager 1 RS 485 19200 Baud RS 485 19200 Baud RS 485 9600 Baud RS 485 9600 Baud W C L I ATT MA STE R ON TRO S NC COMM LIN K II COMM LIN K II L C M M O O O O M D P P E Constant V...

Page 122: ...DDRESS SWITCH SET TO 2 ZONE CONTROLLER 1 ZONE CONTROLLER 16 CONSTANT VOLUME CONTROLLER IF USED COMM PWR COMM PWR RELAY OUTPUT COM 1 3 OUT OUT 1 2 COM 4 5 OUT OUT OUT 3 4 5 24VAC GND PWR COMM T SHLD LD...

Page 123: ...YSTEM MANAGER TO THE LOCAL LOOP S ZONE CONTROLLERS SHOULD BE CONNECTED TO THE LOCAL LOOP COMING FROM THE ROOFTOP UNIT WHICH SUPPLIES AIR FOR THAT CONTROLLER HVAC UNIT 1 ZONE MANAGER HVAC UNIT 2 ZONE M...

Page 124: ...Section 4 Auto Zone Plus 4 6 Start Up and Troubleshooting Figure 4 4 Local Loop Wiring firealarmresources com...

Page 125: ...le 9 Pin Female 25 Pin Female 9 Pin Female 120 24 Vac Transformer 25 Pin Male Warning Use The Molded Cable To Connect To The Computer DCE Connector Or Serious Damage To The CommLink Could Result This...

Page 126: ...able communications It is normal to see fluctuations at this point on the CommLink II The average value should be close to the acceptable range described below Values will vary upon initial powerup fo...

Page 127: ...mLink 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 is attempting to communica...

Page 128: ...g Proper loop voltages are essential for reliable communications It is normal to see fluctuations at this point on the CommLink II The average value should be close to the acceptable range described b...

Page 129: ...blem Note These tests assume that the CommLink II is connected and powered and that all Zone Managers which are connected are also powered Overview Proper loop voltages are essential for reliable comm...

Page 130: ...on Readings near Zero Volts Check for shorted wiring If voltages are too high or too low on either side 1 One or more devices connected to this loop may have damaged comm driver chips 2 Wiring errors...

Page 131: ...not flickering the unit is not communicating with the CommLink II Damage typically occurs when the communications loop is exposed to excessive voltage as may occur during installation due to wiring er...

Page 132: ...alues generally indicates a problem Note These tests assume the zone manager is powered up Overview Proper loop voltages are essential for reliable communications It is normal to see fluctuations on a...

Page 133: ...on Readings near zero volts Check for shorted wiring If voltages are too high or too low on either side 1 One or more devices connected to this loop may have damaged Comm Driver chips 2 Wiring errors...

Page 134: ...ll float both of their communications connections at about 2 45 Volts you can quickly check an entire loop by unplugging it at the Zone Manager Note Be sure that the loop you are testing does not have...

Page 135: ...Action If voltages are too high or to low on either side 1 One or more of the attached controllers has a damaged Comm Driver chip Locate and replace the driver chip s See 1 3 11Comm Driver Chip Replac...

Page 136: ...not functioning Proper loop voltages are essential for reliable communications It is normal to see fluctuations at this point on the Zone Manager The average value should be close to the acceptable r...

Page 137: ...alue should be close to the acceptable range described below Values will vary upon initial powerup for about 30 45 seconds The voltages may fluctuate as normal communications occur Measurements Local...

Page 138: ...ing installation due to wiring errors The driver chips are socketed on all boards to facilitate servicing It is unusual for driver chips to fail during normal operation Almost all failures occur as a...

Page 139: ...A Small Screwdriver May Be Inserted Between The Chip And The Socket To Aid In Removal Of The Chip 3 Be Very Careful Not To Insert The Screwdriver Under The Socket Damage To The Board Is Not Covered B...

Page 140: ...talling the chip backwards will in most cases destroy the device when power is reapplied Pin 1 can be located by looking for the notch in the end of the chip Pin 1 on some chips is identified with a d...

Page 141: ...ork 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...

Page 142: ...relays to energize for longer than a few seconds at any time except during calibration morning startup or end of day shutdown Fan relay activates After calibration zones are initialized then the FAN c...

Page 143: ...ructions that are continuously performed over and over during normal Zone Manager operations They are listed below a Update Time Date on LC Display Basic systems b Read analog inputs for temperatures...

Page 144: ...Section 4 Auto Zone Plus 4 26 Start Up and Troubleshooting 2 2 Becoming Familiar with the Zone Manager Figure 4 8 Zone Manager Component Layout firealarmresources com...

Page 145: ...mper wiring consists of four wires FDBK The bypass damper actuator has an integral 0 10 000 Ohm feedback potentiometer which is used by the Zone Manager to determine the exact position of the damper G...

Page 146: ...eparate isolated 24 VAC transformer to avoid damaging the Zone Manager GND Common return wire this point is tied to GND on the Zone Manager 2 2 5 Powered Exhaust Connector This connector provides a no...

Page 147: ...This input accepts a two wire 10K Type III thermistor temperature sensor The sensor measures 10 000 Ohms 77 F The resistance drops as the temperature increases The sensor is connected between this te...

Page 148: ...NIQUE CLUSTER ADDRESS 1 2 3 4 ETC ZMGRSWP3 CDR 3 6 00 Remember You must power down the Zone Manager after changing the address switches in order for any changes to take effect CLUSTER ADDRESS SWITCH N...

Page 149: ...Note 1 2 HEAT2 HEAT1 COOL2 COOL1 FAN R 2 8 C SW1 16 A B 2 4 ADD LOCAL LOOP Local Loop T SH R TB3 COMM T SH R 32 16 8 4 1 2 MINILINK R9 R10 R8 I C EXP PORT PWR V4 V3 CLOSE OPEN FDBK REC GND GND 24VAC A...

Page 150: ...5 0 volts if the attached contact is OPEN and less than 0 5 volts if the contact is CLOSED contacts CLOSE between the input and GND Note The Zone Manager must be powered for these tests Measurements M...

Page 151: ...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 too high 1 Check for open circuit wiring errors 2 Def...

Page 152: ...f you blow into the static pressure sensor tubes you will damage the sensor At TB1 5V terminal the voltage should be between 4 8 volts and 5 3 volts If the voltage is not correct then unplug the Stati...

Page 153: ...his test will provide a reliable quick check of the wiring The wiring should be considered OPEN if the resistance exceeds 10 000 Ohms or SHORTED if it is less than 50 Ohms Note The HVAC unit power mus...

Page 154: ...ator The actuator should be considered defective if the resistance at it s minimum position is 0 Ohms or is greater than 10 000 Ohms at maximum position See Bypass Actuator Troubleshooting for additio...

Page 155: ...Auto Zone Plus Section 4 Start Up and Troubleshooting 4 37 Notes firealarmresources com...

Page 156: ...1 2 Calibration During the powerup process a self check of the zone damper actuator is performed This guarantees the damper is operating and also records the feedback range for use in calculating 0 1...

Page 157: ...owing 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 up...

Page 158: ...5 R28 T STAT U11 C15 R20 C11 R24 8 16 2 4 ADDRESS ADD 1 U6 U5 R19 U9 CX9 R32 D5 C14 P U R22 C13 R27 D5 RAM C9 C8 80C55 2 CX5 PJ1 C3 R8 R7 R5 R6 R4 C2 C1 X1 U2 R1 R2 R3 CX2 Q1 16L8 32K R34 FLOW U8 1 RN...

Page 159: ...MP The Zone Controller is designed to use a standard 10K Type III thermistor as the temperature sensing element This input is also used to detect the override button The override button momentarily sh...

Page 160: ...tional airflow sensor for pressure independent applications The Zone Controller automatically senses the airflow sensor when it is connected 5V This wire provides power to the sensor SIG This wire car...

Page 161: ...OKEN NET LD2 32 R14 R13 R100 LD1 C5 D1 K1 V2 K2 D2 ACTUATOR R10 R9 PJ2 V1 C4 T SHLD R 8 16 2 4 ADDRESS ADD 1 U6 2 It Is Recommended That All Controllers Address Switches Are Set Before Installation 3...

Page 162: ...nsor Is Specified With Slide Adjust Option 1 24 VAC Must Be Connected So That All Ground Wires Remain Common 2 All Wiring To Be In Accordance With Local And National Electrical Codes And Specification...

Page 163: ...CAN LED Diagnostic Blink Codes immediately following application of power The LED provides valuable information about the Zone Controller for more details see How It Works Observe the REC LED Communic...

Page 164: ...atile EEPROM memory and initializes all outputs to an OFF condition Note All future references to the Constant Volume Unit in this document use CVAHU as the designation 4 1 2 Operating Summary At all...

Page 165: ...Mounting Hole Typ of 4 Comm LED Address Switch Set Between 1 30 Analog Inputs Space Sensor Slide Adjust Supply Air Temp Outdoor Air Temp Auxiliary Alarm Analog Output 0 10 VDC Economizer Power LED 24...

Page 166: ...ent failure Once a heating or cooling stage has activated the supply air has 30 minutes to change by 5 F or the controller assumes a mechanical failure has occurred The supply air also prevents coolin...

Page 167: ...Stage 4 Any combination of heating and cooling stages may be configured during setup as long as the required number of outputs does not exceed four If heat is used Output 2 will be the first stage of...

Page 168: ...D ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW1 SW...

Page 169: ...d National Electrical Codes And Specifications 3 All Communication Wiring To Be 2 Conductor Twisted Pair With Shield Use Belden 82760 Or Equivalent Economizer Actuator Belimo Shown Consult Factory For...

Page 170: ...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...

Page 171: ...ooling 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...

Page 172: ...oom sensor terminal block Using your meter check the resistance of the unplugged terminal block Use the supplied Temperature Resistance Chart to see if the sensor is within a reasonable range Readings...

Page 173: ...VERSE action The zone controller must be configured for correct operation if REVERSE action of the damper is required Caution Improper mounting and the associated adjustment of the damper blade positi...

Page 174: ...und 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 Ab...

Page 175: ...6047 1 927 54 16956 3 217 105 5453 1 805 56 16164 3 160 110 4923 1 687 58 15385 3 100 115 4449 1 575 60 14681 3 042 120 4030 1 469 62 14014 2 985 125 3656 1 369 64 13382 2 927 130 3317 1 274 66 12758...

Page 176: ...1 00 3 60 2 95 1 10 1 08 3 70 3 03 1 20 1 15 3 80 3 10 1 30 1 23 3 90 3 18 1 40 1 30 4 00 3 25 1 50 1 38 4 10 3 33 1 60 1 45 4 20 3 40 1 70 1 53 4 30 3 48 1 80 1 60 4 40 3 55 1 90 1 68 4 50 3 63 2 00...

Page 177: ...Auto Zone Plus Section 4 Start Up and Troubleshooting 4 59 Notes firealarmresources com...

Page 178: ...Section 4 Auto Zone Plus 4 60 Start Up and Troubleshooting Notes firealarmresources com...

Page 179: ...Auto Zone Plus Section 4 Start Up and Troubleshooting 4 61 Notes firealarmresources com...

Page 180: ...02B Printed in the USA March 2003 All rights reserved Copyright 2003 WattMaster Controls Inc 8500 NW River Park Drive Parkville Mo 64152 Phone 816 505 1100 www wattmaster com Fax 816 505 1101 firealar...

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