Carrier VVT Bypass Installation manual

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VV VT T B By yp pa as ss s C Co on nt tr ro ol ll le er r
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CARRIER CORPORATION ©2010
A member of the United Technologies Corporation family · Stock symbol UTX · Catalog No. 11-808-436-01 · 6/24/2010

VVT Bypass Controller i
Table of Contents
Introduction.................................................................................................................................................................. 1
What is a VVT Bypass Controller? ......................................................................................................................1
Specifications ........................................................................................................................................................3
Safety Considerations ..........................................................................................................................................4
Installation ................................................................................................................................................................... 6
Field-supplied hardware ......................................................................................................................................6
Mounting the VVT Bypass Controller..................................................................................................................7
To mount the controller ........................................................................................................................ 7
Wiring the VVT Bypass Controller for power.....................................................................................................9
To wire the controller for power............................................................................................................ 9
To address the VVT Bypass Controller ............................................................................................................ 10
Wiring the VVT Bypass Controller to the MS/TP network............................................................................ 10
Wiring specifications ...........................................................................................................................11
To wire the controller to the network .................................................................................................11
VVT Bypass Controller inputs and outputs..................................................................................................... 11
Wiring a Duct Air Temperature sensor to an input ............................................................................12
Wiring specifications ................................................................................................................12
To wire and mount the DAT sensor .........................................................................................12
Wiring field-supplied actuators to the analog output........................................................................12
High-torque actuators ..............................................................................................................13
Linked actuators.......................................................................................................................13
Start-up.......................................................................................................................................................................15
Configuring the VVT Bypass Controller's properties ..................................................................................... 15
Performing system checkout........................................................................................................................... 16
Bypass damper....................................................................................................................................16
Variable frequency drive (VFD) ...........................................................................................................17
Sequence of operation..............................................................................................................................................19
Duct static pressure control............................................................................................................................. 19
LAT monitoring and limiting............................................................................................................................. 19
Equipment fan off detection ............................................................................................................................ 20
Supply Air Temperature Alarm ........................................................................................................................ 20
Airside linkage.................................................................................................................................................... 20
Troubleshooting .........................................................................................................................................................21
LED's .................................................................................................................................................................... 21
Serial number..................................................................................................................................................... 22
Replacing the VVT Bypass Controller's battery ............................................................................................. 22
Compliance ................................................................................................................................................................23
FCC Compliance................................................................................................................................................. 23
CE Compliance ................................................................................................................................................... 23
BACnet Compliance........................................................................................................................................... 23
Appendix A: VVT Bypass Controller Points/Properties ..........................................................................................24
Status................................................................................................................................................................... 24
Unit Configuration.............................................................................................................................................. 24
Maintenance....................................................................................................................................................... 26
Alarms ................................................................................................................................................................. 26
Linkage................................................................................................................................................................ 27
I/O Points............................................................................................................................................................ 27
Index ...........................................................................................................................................................................29

VVT Bypass Controller 1
What is a VVT Bypass Controller?
The VVT Bypass Controller (#OPN-VVTBP), a component of the i-Vu Open Control System, regulates the supply
duct static pressure by controlling one of the following:
•The system's bypass damper
The controller's built-in damper actuator provides 35 in/lbs of torque. If the built-in actuator's torque is
insufficient, the VVT Bypass Controller can be used to drive an external high-torque actuator. Or, the
controller can drive multiple external damper actuators.
•The air source supply fan's variable frequency drive (VFD)
The i-Vu Open Control System uses linkage to exchange data between the zone terminals and their air source
to form a coordinated HVAC system. The system's air source controller, zone controllers, and bypass controller
are linked so that their data exchange can be managed by one zone controller configured as the VVT Master.
The following illustration shows the VVT Bypass Controller in a typical i-Vu Open Control System.
VVT Zone
(OPN-VVTZC)
VVT Zone
(OPN-VVTZC)
VVT Zone
(OPN-VVTZC)
VVT Zone
(OPN-VVTZC)
VVT Bypass
(OPN-VVTBP)
MAN UAL O N WARM ER
Occupied
INFO COOLER
F
MAN UAL O N WARM ER
Occupied
INFO COOLER
F
MAN UAL O N WARM ER
Occupied
INFO COOLER
F
MAN UAL O N WARM ER
Occupied
INFO COOLER
F
Introduction

Introduction
2 VVT Bypass Controller
0134 5
2
78
9 6
0134 5
2
78
9 6
VFD/ACT
Gnd
Analog
Output
n/a
n/a
n/a n/a n/a n/a
DAT Gnd
Gnd
Rnet +
Rnet - +12V
R n e t BACnet Power
On
4
3
2
1
-
+
Batt
CR2032 10's
1's
Thermistor
DAT
FactoryDefaults
Rnet
MSTP
Not used Conductors Only
Class 2
Use Copper
26Vdc, 0.1A, 3W
14VA, 0.58A
24Vac, 50-60 Hz
This product was designed
CAUTION:
to be mounted inside the
building envelope.Warranty
voided if mounted outside.
Interconnect the Outputs of
Different Class 2 Circuits.
To ReduceThe Risk of Fire
or Electric Shock, Do Not
CAUTION:
BACnet
VVT Bypass
®
AO: 0-10 Vdc
5mAMax
Local
Access
Short pins
Not used
Not used
Not used
Not used
CW CCW
Motor
Error
Run
Power
Made in USA
Input
Tx
Rx
MSTPBaud
76.8k38.4k19.2k9600
Damper release buttoninside
TYPE: 002101
E143900
88FO
Enclosed Energy
Management Equipment
R
Net + Net -
Shield
Ground
24V ac
Rnet+
Sense
+12V
Rnet-
Gnd
n/a n/a n/a n/a
(OPN-VVTBP)
BT485
High
Low
Flow
(with filter)
NOTE This document gives instructions for field-installation of a VVT Bypass Controller in an i-Vu Open Control
System.

Introduction
VVT Bypass Controller 3
Specifications
Module driver drv_bpopen_<latest version>.driver
Maximum number of control
programs
1
Maximum number of
BACnet objects
300, depending on available memory
Power 24 Vac ±10%, 50–60 Hz
14 VA power consumption (20 VA with BACview
BACnet port
attached)
26 Vdc (25 V min, 30 V max)
Single Class 2 source only, 100 VA or less
For communication with the controller network using MS/TP (9600 bps, 19.2
kbps, 38.4 kbps, or 76.8 kbps)
Rnet port For connection of a BACview6
Local Access port
keypad/display unit.
For system start-up and troubleshooting using a PC or BACview6
Inputs
(115.2 kbps)
1 input for connecting the Duct air temperature sensor (#33ZCSENDAT)
Input resolution 10 bit A/D
Analog output 1 analog output, 0–10 Vdc (5 mA max). The controlled device must have a
minimum of 2000 Ohms resistance measured from its input to ground and
must share the same ground as the controller.
Output resolution 8 bit D/A
Integral airflow sensor Precision low flow AWM series 0–2 in. H2O, sensitive down to ±0.001 in.
H2O. Barbed tapered airflow connections accept 3/16 in. (4.75 mm) I.D.
tubing. Allows for readings across the 0–2 in. H2O range, accurate to ±5% of
full flow at 2 in. H2O.
Integral actuator Brushless DC motor, torque 35 inch-pounds (4 Nm), runtime 205 seconds for
90 degree travel during control, or 25 seconds in high-speed test and
balance mode
Battery 10-year Lithium CR2032 battery provides a minimum of 10,000 hours of
data retention during power outages
Protection Incoming power and network connections are protected by non-replaceable
internal solid-state polyswitches that reset themselves when the condition
that causes a fault returns to normal. The power, network, input, and output
connections are also protected against voltage transient and surge events.
BT485 connector
You attach a BT485 (not included) to a controller at the beginning and end of
a network segment to add bias and to terminate a network segment.
Status indicators LED's indicate status of communications, running, errors, power, and digital
outputs
Environmental operating
range
0 to 130° F (-18 to 54°C), 0 to 90% relative humidity, non-condensing
Storage temperature range -24 to 140°F (-30 to 60°C), 0 to 90% relative humidity, non-condensing

Introduction
4 VVT Bypass Controller
Physical UL94-5VA plenum rated enclosure for installation in plenum (or other space
for environmental air) in accordance with NEC Section 300.22 (c) and (d)
Overall dimensions A:
B:
C:
7 in. (17.8 cm)
6 1/32 (15.4 cm)
6 in. (15.24 cm)
Mounting dimensions D:
E:
F:
G:
H:
5 5/8 in. (14.3 cm)
4 9/16 in. (24.3 cm)
1 5/16 in. (3.3 cm.)
7/8 in. (2.2 cm)
1 5/16 in. (3.3 cm)
Panel depth 2 1/2 in. (6.4 cm) minimum
Shaft dimension Minimum shaft diameter: 3/8 in. (.95 cm.)
Maximum shaft diameter: 1/2 in. (1.27 cm)
Minimum shaft length: 1 3/4 in. (4.45 cm)
Weight 1.7 lbs (0.77 kg)
BACnet support Conforms to the Advanced Application Controller (B-AAC) Standard Device
Profile as defined in ANSI/ASHRAE Standard 135-2004 (BACnet) Annex L
Listed by UL-916 (PAZX), cUL-916 (PAZX7), FCC Part 15-Subpart B-Class A, CE
EN50082-1997
Safety Considerations
Air conditioning equipment will provide safe and reliable service when operated within design
specifications. The equipment should be operated and serviced only by authorized personnel who have a
thorough knowledge of system operation, safety devices, and emergency procedures.
SAFETY NOTE
Good judgment should be used in applying any manufacturer's instructions to avoid injury to personnel or
damage to equipment and property.

Introduction
VVT Bypass Controller 5
Failure to follow this warning could cause personal injury, death, and/or equipment damage.
ELECTRICAL SHOCK HAZARD
Disconnect all power to the unit before performing maintenance or service. Unit may automatically start if
power is not disconnected.
Follow all local, state, and federal laws regarding disposal of equipment containing hazardous materials
such as mercury contactors.

Installation
6 VVT Bypass Controller
Bypass
damper
Bypass
controller
w/actuator
Transformer
Supply
air
Duct
temperature
sensor
Low pressure
open to space Power
supply
To communication
bus
High pressure
tubing
To
building Static
pressue pickup
To install the VVT Bypass Controller:
1 Mount the controller (page 7).
2 Wire the controller for power (page 9).
3 Set the controller's address (page 10).
4 Wire the controller to the MS/TP network (page 10).
5 Connect the inputs and outputs (page 11).
Field-supplied hardware
Each VVT Bypass Controller installation requires the following field-supplied components:
•damper
•damper actuator (if high-torque actuator or slaved dampers are required)
•duct air temperature sensor
•transformer— 24 Vac, 40 Va
•wiring
Installation

Installation
VVT Bypass Controller 7
Mounting the VVT Bypass Controller
Mount the VVT Bypass Controller on the bypass duct damper actuator shaft. For service access, allow at least
1 foot (.3 m) of clearance between the front of the controller and adjacent surfaces.
End view inlet
Controller
Allow 1 ft. (.3 m) clearance
for service access
2.5 in.
(6.35
cm)
To mount the controller
1 Turn the damper shaft to fully close the damper.
2 Remove the controller’s cover.
3 Mount the controller to the VVT box by sliding the clamp assembly onto the damper shaft.
Damper ShaftVVT Box Controller
Anti-rotation slot
4 Secure the controller by installing the screw provided through the anti-rotation slot's bushing and o-ring.
O-ring Bushing
Anti-rotation slot
NOTE Center the bushing in the slot. Failure to do so may cause the actuator to stick or bind.
5 Hold down the controller’s damper release button and rotate the actuator clamp in the same direction
that closed the damper. Rotate the clamp until it stops, then rotate it back one notch.

Installation
8 VVT Bypass Controller
Damper
release
button
5/8-in. nuts
6 Release the button.
7 Tighten the actuator clamp to the damper shaft by tightening the two 5/16 inch nuts.
8 Hold down the damper release button and rotate the damper from fully closed to fully open. If the
damper traveled less than 90 degrees, do the following to set the actuator's fully open position:
a) Loosen the appropriate stop clamp screw. See figure below.
b) Move the stop clamp until it contacts the
edge of the actuator cam.
c) Tighten the screw.
Move stop
clamp if
necessary
9 Hold down the damper release button, rotate the damper to verify that it fully opens and closes, then
release the button.
10 Connect the filter tube provided to the controller's High connector. See figure below. Using 1/4" poly
tubing, connect the other end to a static pressure pickup located in the supply air duct downstream of
the bypass damper, but before the first branching of ductwork. See diagram in Installation (page 6).
NOTE Tubing should be at least 2 feet long for stable airflow measurement.
11 Leave the controller's Low connector open for plenum return or to a room space if using ducted return.
High
Low
Tube installation
12 Replace the controller’s cover.

Installation
VVT Bypass Controller 9
Wiring the VVT Bypass Controller for power
The VVT Bypass Controller is powered by a Class 2 power source. Take appropriate isolation measures
when mounting it in a control panel where non-Class 2 circuits are present.
Carrier controllers can share a power supply as long as you:
• Maintain the same polarity
• Use the power supply only for Carrier controllers
To wire the controller for power
1 Remove power from the power supply.
2 Pull the screw terminal connector from the controller's power terminals labeled Gnd and 24 Vac or Hot.
3 Connect the transformer wires to the screw terminal connector.
4 Apply power to the power supply.
5 Measure the voltage at the VVT Bypass Controller’s power input terminals to verify that the voltage is
within the operating range of 21.6–26.4 Vac.
6 Connect a 4-inch (10.2 cm) wire from Gnd to earth ground.
7 Insert the screw terminal connector into the VVT Bypass Controller's power terminals.
8 Verify that the Power LED is on and the Run LED is blinking.

Installation
10 VVT Bypass Controller
To address the VVT Bypass Controller
You must give the VVT Bypass Controller an address that is unique on the network. You can address the VVT
Bypass Controller before or after you wire it for power.
1 If the VVT Bypass Controller has been wired for power, pull the screw terminal connector from the
controller's power terminals labeled Gnd and 24 Vac. The controller reads the address each time you
apply power to it.
2 Using the rotary switches, set the controller's address. Set the Tens (10's) switch to the tens digit of the
address, and set the Ones (1's) switch to the ones digit.
EXAMPLE If the controller’s address is 25, point the arrow on the Tens (10's) switch to 2 and the arrow
on the Ones (1's) switch to 5.
10's
1's
1
3
4
5
2
7
8
9
6
0
1
3
4
5
2
7
8
9
6
0
NOTE The factory default setting is "00" and must be changed to successfully install your VVT Bypass
Controller.
Wiring the VVT Bypass Controller to the MS/TP network
The VVT Bypass Controller communicates using BACnet on an MS/TP network segment communications at
9600 bps, 19.2 kbps, 38.4 kbps, or 76.8 kbps.
Wire the controllers on an MS/TP network segment in a daisy-chain configuration.
Install a BT485 on the first and last controller on a network segment to add bias and prevent signal
distortions due to echoing.
See the MS/TP Networking and Wiring Installation Guide for more details.

Installation
VVT Bypass Controller 11
Wiring specifications
Cable: 22 AWG or 24 AWG, low-capacitance, twisted, stranded, shielded copper wire
Maximum length: 2000 feet (610 meters)
To wire the controller to the network
1 Pull the screw terminal connector from the controller's power terminals labeled Gnd and 24 Vac or Hot.
2 Check the communications wiring for shorts and grounds.
3 Connect the communications wiring to the BACnet port’s screw terminals labeled Net +, Net -, and
Shield.
NOTE Use the same polarity throughout the network segment.
4 Verify that the MSTP jumper is set to MSTP.
5 Set DIP switches 1 and 2 to the appropriate baud rate. See the MSTP baud diagram on the VVT Bypass
Controller. The default baud rate is 76.8 kbps.
NOTE Use the same baud rate for all controllers on the network segment.
6 Insert the power screw terminal connector into the VVT Bypass Controller's power terminals.
7 Verify communication with the network by viewing a module status report.
VVT Bypass Controller inputs and outputs
Disconnect electrical power to the VVT Bypass Controller before wiring it. Failure to follow this warning
could cause electrical shock, personal injury, or damage to the controller.
•Do not run sensor or relay wires in the same conduit or raceway with Class 1 AC or DC service wiring.
•Do not abrade, cut, or nick the outer jacket of the cable.
•Do not pull or draw cable with a force that may harm the physical or electrical properties.
•Avoid splices in any control wiring.

Installation
12 VVT Bypass Controller
Wiring a Duct Air Temperature sensor to an input
Part #33ZCSENDAT
The VVT Bypass Controller must be connected to a Duct Air Temperature (DAT) sensor that monitors the
temperature of the air delivered by the air source.
NOTE This document gives instructions for wiring the sensor to the VVT Bypass Controller. For mounting and
wiring the sensor, see the Carrier Sensors Installation Guide.
Wiring specifications
Cable from sensor to controller: If <100 ft (30.5 meters) 22 AWG, unshielded
If >100 ft (30.5 meters) 22 AWG, shielded
Maximum length: 500 feet (152 meters)
To wire and mount the DAT sensor
1 Wire the sensor to the controller. See diagram below.
NOTE Sensor wiring does not have polarity. The wires can be connected to either terminal.
2 Using electrical tape, insulate any exposed wire to prevent shorting.
Wiring field-supplied actuators to the analog output
You can wire a high-torque actuator or parallel actuators to the controller's 0–10 Vdc analog output.
NOTE You cannot use the VVT Bypass Controller's built-in actuator if wiring external actuator(s) to the analog
output.

Installation
VVT Bypass Controller 13
High-torque actuators
You can wire one of the following Belimo actuators to the VVT Bypass Controller's analog output instead of
using the controller's built-in, 35 in.-lb actuator.
NMX24-MFT P-10028 90 in.-lb actuator with 0–10 Vdc control and 0–10 Vdc feedback
AMX24-MFT P-10028 180 in.-lb actuator with 0–10 Vdc control and 0–10 Vdc feedback
1 Install the actuator according to the manufacturer's instructions.
2 Wire the actuator to the controller using the diagram below.
NOTE For proper operation and to prevent damage to the devices, use the same polarity for the actuator's
power and the VVT Bypass Controller's power.
Linked actuators
You can wire up to 4 of the following Belimo actuators to the VVT Bypass Controller's analog output. Link
actuators whose travel times and other parameters coincide.
LMX24-MFT P-10028 45 in.-lb actuator with 0–10 Vdc control
NMX24-MFT P-10028 90 in.-lb actuator with 0–10 Vdc control
AMX24-MFT P-10028 180 in.-lb actuator with 0–10 Vdc control
1 Install the actuators according to the manufacturer's instructions.
2 Wire the actuators to the controller using the diagram below.
3 Set the direction rotation switch on each actuator to CW.

Installation
14 VVT Bypass Controller
NOTE Maintain polarity if using the same power supply for more than one actuator.

Start-up
VVT Bypass Controller 15
To start up the VVT Bypass Controller, you need one of the following user interfaces. These items let you
access the controller information, read sensor values, and test the controller.
This interface...
Provides a...
i-Vu Open
Permanent interfacesoftware
Field Assistant
software -
runs on a laptop connected to controller's Local Access port
Temporary interface
1
Virtual BACview
software -
runs on a laptop connected to controller's Local Access port
Temporary interface
1, 2
BACview6 Handheld
keypad/display unit -
connects to controller's Local Access port
Temporary interface
1, 2
BACview6
keypad/display unit
connected to controller's Rnet port
Permanent interface
2
1Requires a USB Link (USB-L).
2See the BACview Installation and User Guide for instructions on connecting and using the above items.
Configuring the VVT Bypass Controller's properties
To start up the VVT Bypass Controller, you need to configure the properties described below. These properties
affect the unit operation and/or control. Review and understand the meaning and purpose of each property
before changing it.
See Appendix A (page 24) for a complete list of the controller's points/properties.
Navigation:
i-Vu / Field Assistant:
BACview:
Properties
>
Equipment
>
Unit Configuration
HOME
>
CONFIG
Point Name/Description
Default/Range
Control Device Type
D:– The device the controller uses to control static
pressure. R:
Actuator
Actuator/VFD drive
Maximum Heating SAT
– The value that the SAT must exceed to cause
the static pressure setpoint to be set to the
LAT Duct Static Pressure
Setpoint
. This is also the
Supply Air Temperature Alarm
D:
's high limit.
R:
120°F
40 to 180°F
Minimum Cooling SAT
– The minimum low limit value that the SAT must
exceed to cause the static pressure setpoint to be set to the LAT Duct
Static Pressure Setpoint. This is also the
Supply Air Temperature Alarm
D:
's
low limit.
R:
45°F
40 to 180°F
Start-up

Start-up
16 VVT Bypass Controller
Point Name/Description
Default/Range
Bypass Control
Direction Clockwise
D:– Set this field to the damper's position when it
rotates clockwise.
(Only in i-Vu/Field Assistant) R:
Close
Open/Close
Duct Static Pressure Setpoint
D:– The normal static pressure setpoint
the controller will maintain. R:
.5 in. H2
.1 to 2.0 in. H
O
2
O
LAT Duct Static Pressure Setpoint
– The static pressure setpoint
that the controller will maintain if the SAT exceeds the
Maximum
Heating SAT
or
Minimum Cooling SAT
value. To disable this
function, set this value less than or equal to the
Duct Static Pressure
Setpoint
D:
.
R:
.8 in. H2
.1 to 2.0 in. H
O
2
O
Performing system checkout
Bypass damper
1 Verify the VVT Bypass Controller is securely fastened to the bypass damper shaft and duct work.
2 Verify duct air temperature sensor is installed at the inlet of the damper or in the air source supply duct
upstream of the bypass damper connection.
3 Verify that the high pressure tubing from the controller's airflow (pressure) sensor is connected to the
supply duct static pickup downstream of the bypass damper. Then verify that the low pressure connector
is not blocked.
4 Calibrate damper and pressure sensor:
a) Disable the air source heating, cooling, and fan outputs using one of the following methods:
•Physically disconnect the air source controller’s output wiring to the unit.
•In the i-Vu or Field Assistant tree, select the RTU Open controller. Go to Properties > Equipment >
Configuration > Service Configuration > Service Test, then enable Service Test. Make sure all
other outputs under Service Test are disabled.
b) Select the Bypass controller in the tree, then go to Properties > Equipment > Unit Configuration >
Bypass Control > Details
c) Click
tab.
Damper Full Close
d) Click
, then verify that the damper is fully closed.
Damper Full Open
e) Click
, then verify that the damper is fully open.
Zero Cal to close the bypass damper and zero the pressure sensor. When Done appears, click
Apply
f) Enable the air source fan output using one of the following methods:
.
•Physically connect the air source controller’s fan enable wiring at the unit.
•In the i-Vu or Field Assistant tree, select the RTU Open controller. Go to Properties > Equipment >
Configuration > Service Configuration > Service Test, then enable Fan Test. Make sure all
other outputs under Service Test are disabled.
g) Select the Bypass controller in the tree, then go to Properties > Equipment > Unit Configuration >
Bypass Control > Details tab.