CSI MR-VAV-AX Assembly instructions

Control Systems
International
®
MR-VAV-AX
Installation Sheet (TCON148 06/97) 1
Installation Sheet
Controller Installation
1. Check the mounting location for the MR-AHU. The MR-
VAV-AX is typically mounted with the controller extending
down or to the right from the damper shaft. However, the
controller can be operated in any position.
Note:
Installing the controller to the right (with the
barbed fittings pointing down) will help to prevent
condensate from migrating into the on-board
velocity sensor.
With a downward extension, the available area around the
damper shaft must measure 6" (160 mm) down from the
lower edge of the shaft, 4.5" (120 mm) to the right, 1.5" (40
mm) to the left and 1.75"(45 mm) above the shaft. Ensure
the location allows enough clearance for servicing.
The actuator is designed to mount over a
1
⁄
2
" (12.7 mm)
diameter shaft with a minimum of 1" (25.4 mm) of exposed
shaft. If the damper shaft is less than
1
⁄
2
" an adapter is
required. The MR-VAV-AX will not work with larger shaft
diameters.
Note:
Optional adapters are available for
3
⁄
8
" (9.5 mm)
diameter damper shafts (CSI Part Number 603500-
0018).
2. If the exposed damper shaft is less than 2" (51 mm) long,
move the two damper shaft mounting screws to the
alternate damper shaft positions (see Figure 1).
3. Select the mounting bracket (see Figure 1) that will provide
the most stability for the operation of the actuator. Position
the mounting clip in the desired mounting bracket. Do not
insert the clip more than half-way into the bracket. This will
allow the clip and the back of the actuator to properly align
with the VAV box.
4. Rotate the VAV damper shaft by hand to the fully closed
position. Note whether the damper is rotated clockwise
(CW) or counter-clockwise (CCW) to close.
5. Slip the controller over the damper shaft. Position the
actuator and, using a self tapping sheet metal screw, secure
the mounting clip to the VAV box. Next, press the actuator
toward the box until the actuator comes into contact with
the VAV box, or the mounting clip snaps into the bracket.
6. Press and hold the red actuator clutch release (see Figure 1)
and rotate the actuator collar to the 5 ° index mark if the
damper shaft was rotated counter-clockwise to close (Step
4). Rotate the actuator collar to the 85 ° index mark if the
damper shaft was rotated clockwise to close (Step 4).
Figure 1. MR-AHU (Covered) Figure 2. MR-AHU (Cover Removed)
LAN -
LAN +
GROUND
POWER
DATA
GROUND
THIS DEVICE COMPLIES WITH PART15 OF THE FCC RULES.THE OPERATION
IS SUBJECT TO THE FOLLOWING TWO CONDITIONS:
1) THIS DEVICE MAYNOT CAUSE HARMFUL INTERFERENCE, AND
2) THIS DEVICE MUST ACCEPTANY INTERFERENCE RECEIVED INCLUDING
INTERFERENCE THAT MAYCAUSE UNDESIRED OPERATION.
+12V
INPUT 4
INPUT 3
INPUT 2
INPUT 1
OUTPUT 2
OUTPUT 1
OUTPUT 3
24VAC
GROUND
12
11
10
9
8
7
6
5
4
3
2
1
24VAC 50/60 Hz CLASS 2
9VA + EXTERNAL LOAD
(40VA MAX)
MR-VAV-AX CONTROLLER
POWERED BY A SINGLE
CLASS 2 SOURCE
SERIAL NO:
24VAC, CLASS 2
36VA MAX
(12VA MAX EACH)
OUTPUT:
INPUT:
P1
P2
(LO)
(HI)
Alternate
Mounting
Bracket
Mounting Bracket Cover Release
Actuator Clutch Release
Alternate Damper Shaft
Mounting Screw Position
Damper Shaft
Torx Mounting Screws
Damper
Shaft
Velocity
Sensor
Inputs
Cover Release
Cover Release
Mounting
Clip
UL
®LISTED
ENERGY MANAGEMENT EQUIPMENT
MAY BE USED IN PLENUM
APPLICATIONS
63M4
60572-0001
TB1 TB2
TB3TB4TB5
SWITCHES
FUNCTION
SELECT
ADDRESS
SELECT
P.O. BOX 59469: DALLAS, TX 75229
Thermistor/Discrete
Inputs
I/STAT Port
Sub-LAN Port 24VAC Power Input
Control Outputs
Address/Function
Select Dip Switches
Adjustable Stops
Damper Position
Indicator
Alternate Damper Shaft
Mounting Screw Position
Damper Shaft
Collar
Control Systems
®
International
HI
LO
2.9"
2.9"
P3
P4 EPROM
IN OUT
GND
(-)LO
ROM
Memory
4A FB
Replaceable
Fuse

MR-VAV-AX
2 Installation Sheet (TCON148 06/97)
Control Systems
International
®
7. Tighten the two damper shaft Torx  mounting screws
using a T25 Torx driver. The minimum torque required to
secure the MR-AHU to the damper shaft depends on the
shaft material. The maximum torque for the socket screws
is 30 inch-pounds.
Note:
The damper should rotate freely when the clutch is
released. If it does not, the actuator may not be
properly aligned with the damper shaft – it may be
necessary to repeat Steps 3 through 5 using a new
orientation.
8. If the damper does not provide a mechanical stop in the
open direction, or it is not desirable to use the damper’s
open stop, set the adjustable stops on the MR-VAV-AX to
the desired open position. Use a
1
⁄
4
" hex driver to adjust the
screw stop on the MR-VAV-AX.
Connecting the Velocity Sensor
1. Connect the low pressure side of the velocity sensor to the
barbed fitting labeled P1 on the MR-AHU (see Figure 1).
2. Connect the high pressure side of the velocity sensor to the
barbed fitting labeled P2 on the MR-AHU.
Note: Use a maximum length of 4' (1.4 m) of 0.170" (4.3
mm) I.D. FRPE polyethylene tubing or 0.25" (6.34
mm) O.D./0.125" (3.175 mm) I.D. Tygon tubing.
Note:
Do not expose the velocity sensor to moisture. If
moisture condensate is a potential problem, orient
the tubing and controller so that the barbed fittings
are above the lowest part of the tubing to create a
moisture trap.
Connecting the Input Devices
Warning!!! Ensure that no power is connected to the MR-
AHU during electrical installation. Failure to
disconnect power from all interconnected
equipment when performing electrical
installation may result in damage to the
components and/or electrical shock or burns
1. Connect the external input devices (contact or thermistor)
leads to terminals TB5 – 1 (Input 1) through TB5 – 4 (Input
4), see Figure 4.
2. Connect the other input device lead to the signal ground
terminal, TB5 –6 (Ground).
I/STAT, W/STAT, and S/STAT Connections
1. Connect the I/STAT, W/STAT, or S/STAT white, red, and
black conductors to TB4 – 1, TB4 – 2, and TB4 –3 (Data,
Power, and Ground) as shown in Figure 5.
2. When connecting an S/STAT connect the blue and yellow
conductors to TB5 – 4 (Input 4). Refer to Table 2, “DIP
Switch Configuration Settings”.
Figure 3. Velocity Sensor Connections
P1
P2
(LO)
(HI)
Velocity
Sensor
High Low
Airflow
Figure 4. Input Device Connections
LAN -
LAN +
GROUND
POWER
DATA
GROUND
+12V
INPUT 4
INPUT 3
INPUT 2
INPUT 1
TB3TB4TB5
10K Ohm Thermistor
Figure 5. I/STAT, W/STAT and S/STAT Connections
LAN -
LAN +
GROUND
POWER
DATA
GROUND
+12V
INPUT 4
INPUT 3
INPUT 2
INPUT 1
TB3TB4TB5
White
Red
Black
Blue
Yellow
S/STAT Only
I/STAT, W/STAT and S/STAT

Control Systems
International
®
MR-VAV-AX
Installation Sheet (TCON148 06/97) 3
Connecting the Sub-LAN
1. Connect the + lead of the twisted pair sub-LAN cable to
terminal TB3 – 1 (LAN+), see Figure 6.
2. Connect the – lead of the twisted pair sub-LAN cable to
terminal TB3 – 2 (LAN –).
3. Shield drain wire continuity must be maintained as the sub-
LAN cable passes through each MR-VAV-AX. Shield drain
wires from each controller sub-LAN cable must be twisted
together, insulated, and tied back such that wires do not
come in contact with ground or any conductive surface.
Note:
Connect the shield drain wire directly to Electrical
Service Earth Ground at only one end of the cable
(e.g., at the MCI, MRI, or at one MR-VAV-AX).
Auxiliary Fan and Heat Control Connections
1. Connect one lead of the control relays to terminal TB2 – 1
(Output 1) through TB2 –3 (Output 3) as shown in
Figure 7.
2. Connect the other lead of the control relays to earth ground
as shown.
Note: You must establish a proper earth ground
connection point prior to connecting wires to
electrical equipment.
• Electrical Service Earth Ground wire must be securely
connected to the equipment chassis.
•
The 24 VAC transformer secondary lead must be securely
connected to the Electrical Service Earth Ground wire.
•
The Electrical Service Earth Ground wire must be connected
to the ground terminal on the controller power input
terminal, TB1 – 2 (Ground).
Connecting the Power Supply
1. Connect the 24 VAC input lead from a separate, isolated 24
VAC transformer to TB1 – 1 (24 VAC), see Figure 7.
2. Connect TB1 – 2 (Ground) to earth ground using 14-AWG
wire (2.1 mm
2
). TB1 –2 connects to the same earth ground
connection as the neutral lead from the transformer.
Note:
Connecting TB1 – 2 to a chassis bonding post
separated by seams, welds, or fasteners in the metal
chassis could produce continuity ground faults.
Switch Settings
The DIP switch settings define the sub-LAN address and basic
configuration of the unit. Define the sub-LAN address using
switches 1 – 5 to set an address ranging from 0 to 31. The value
is the accumulated value of switches 1 – 5 when set to the ON
position. The ON position of the switch is away from the “Open”
label on the switch base. The operational configuration can be
initially set using the DIP switch settings in Table 2. For
information concerning specific application configurations refer
Figure 6. Sub-LAN Connections
LAN -
LAN +
GROUND
POWER
DATA
GROUND
+12V
INPUT 4
INPUT 3
INPUT 2
INPUT 1
TB3TB4TB5
LAN
Shield
+
–
Figure 7. Fan and Heat Control Connections
OUTPUT 2
OUTPUT 1
OUTPUT 3
24VAC
GROUND
12
11
10
9
8
7
6
5
4
3
2
1
TB1 TB2 SWITCHES
FUNCTION
SELECT
ADDRESS
SELECT
24VAC
Transformer
Aux/Fan/Heat
Relay Loads
24VAC @ 0.5A each (max.)
Line Voltage Input

MR-VAV-AX
4 Installation Sheet (TCON148 06/97)
Control Systems
International
®
to TCON147, Application Specific Controller Installation Guide .
Specifications
Dimensions
MR-AHU: 7.75" W × 6.25" L × 2.5" H
(197 cm × 159 cm × 63.5 mm)
Damper Shaft Mounting Screws
Torque Minimum: Varies according to shaft material
Torque Maximum: 30 inch-pounds
Torx head screws: 10-32 (T25)
Operating Environment
Temperature: 32 ° to 122 ° F (0 ° to 50 ° C)
Humidity: 10 to 90% RH, non-condensing
Input power: 24 VAC ± 10%, 50/60 Hz @ 7 VA plus output
load (with I/STAT)
24 VAC @ 6 VA plus output load (without
I/STAT)
Cable Requirements
MR LAN Maximum Length: 5,000 ft. (1,500 m)
22 AWG (0.324 mm
2
) shielded, twisted pair
(Belden 9184 equivalent) 5,000 feet (1,500 m)
maximum
or
24 AWG (0.206 mm
2
) shielded, twisted
pair (Belden 9841 equivalent) 4,000 feet (1,200 m).
30 pF/ft. or less between conductors, 55 pF/ft. or less
conductor to shield, 85 to 150 ohm impedance.
Inputs/Outputs
Inputs: Digital — Dry Contact, excitation 5 V at 0.5 mA
Analog — 10K Ohm NTC Thermistor, Dale
1M1002-C3 (Reference CSI TTS100 specification)
Accuracy: 1%
Resolution: 0.4% Span
Velocity Pressure Input:
Span: 0 – 1" (0 – 250 Pa) Water Column
Resolution: 0.0043" WC (1.07 Pa)
Accuracy: 5% @ 1.00" WC (250 Pa)
Outputs: 24 VAC @ 0.5A max. each output (1.5A max.)
© 1996, 1997 by Control Systems International. All rights reserved.
Table 1. MR-VAV-AX LAN Address
Switch Number 1 2 3 4 5
Switch Value (Switch On) 1 2 4 8 16
Table 2. DIP Switch Configuration Settings
Central Plant Heat or
Warmup Present Fan Present Auxiliary Heating Stages Fan Type S/STAT Damper Rotation (Close Direction)
SW 6 SW7 SW8 SW9 SW10 SW11 SW12
No Off No Off None Off Off Series On Yes On CCW Off
Yes On Yes On 1 Heat Stage On Off Parallel Off No Off CW On
2 Heat Stages Off On
Not Available On On