iWorX VAV Series User manual

© 2011 Taco Electronic Solutions, Inc. 1
Installation Guide 502-011
VAV Series Terminal Unit Controller
Self-Contained Interoperable Controller Model CM2
SUPERSEDES: November 17, 2010 EFFECTIVE: March 16, 2011
Plant ID: 001-3959
Table of Contents
VAV Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Representations and Warranties . . . . . . . . . . . . . . . . . 2
Applicable Documentation . . . . . . . . . . . . . . . . . . . . . . 3
Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . 4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FCC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
About this Document . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspecting the Equipment . . . . . . . . . . . . . . . . . . . . 5
What is Not Included with this Equipment . . . . . . . . 5
Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . 5
Selecting a Power Source . . . . . . . . . . . . . . . . . . . . 5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting the Device. . . . . . . . . . . . . . . . . . . . . . . . .6
Routing Cabling to the Device . . . . . . . . . . . . . . . . .7
Grounding the Device. . . . . . . . . . . . . . . . . . . . . . . .8
Wiring Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting Input Devices. . . . . . . . . . . . . . . . . . . . .8
Connecting Output Devices . . . . . . . . . . . . . . . . . . .9
Other Connections . . . . . . . . . . . . . . . . . . . . . . . . . .9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . .12

iWorx® VAV Series
2 502-011, Effective: March 16, 2011
© 2011 Taco Electronic Solutions, Inc.
VAV SERIES
The VAV Series terminal units are stand alone microprocessor based controllers for either pressure independent (VAVI)
or pressure dependent (VAVD) terminal box applications.
Overview
A digital input is provided for an indoor air quality alarm. Analog inputs are provided for discharge air temperature and
primary air temperature sensing. A two-wire serial interface is provided for the thermostat. The controller incorporates
digital outputs in the form of triacs for fan start/stop and two heating stages or heating valve open/close.
The controller is based on LONWORKS®networking technology. It can be networked to a higher-level control system for
monitoring and control applications.
Features
• On-board air-flow sensor (VAVI)
• Integral damper actuator
• Optional indoor air quality (IAQ) alarm input (contact closure)
• Optional discharge air temperature (DAT) monitoring
• Two stages of electric reheat or floating point or modulating 0-10V setpoint hot water reheat valves
• Option to use auxiliary local heat sources for first stage of heating
• Parallel or series fan
• Pressure dependent or pressure independent flow control
• Individual temperature setpoints for occupied/unoccupied heating
• Networked operation using LONWORKS Technology
• Thermostat with space temperature, setpoint adjust, occupancy override
• Integrates with Multiplex Package Unit controller (MPU2)
• Integrates with Variable Air Volume Package Unit controller (VPU2)
• “Stand Alone Mode” for independent operation
• Indoor air quality compensation
• Selection between thermostat types: TS30x and 10K Precon type III thermistor
• Optional normally open dry contact occupancy sensor input
• Optional Primary Air Temperature sensor for use in "Stand Alone Mode"
• Automatic configuration with the Local Control Interface (LCI)
• Alarm/Event reporting
REPRESENTATIONS AND WARRANTIES
This Document is subject to change from time to time at the sole discretion of Taco Electronic Solutions, Inc. All
updates to the Document are available at www.taco-hvac.com. When installing this product, it is the reader’s responsi-
bility to ensure that the latest version of the Document is being used.
iWorx® products shall only be used for the applications identified in the product specifications and for no other pur-
poses. For example, iWorx® products are not intended for use to support fire suppression systems, life support sys-
tems, critical care applications, commercial aviation, nuclear facilities or any other applications where product failure
could lead to injury to person, loss of life, or catastrophic property damage and should not be used for such purposes.

iWorx® VAV Series
502-011, Effective: March 16, 2011 3
© 2011 Taco Electronic Solutions, Inc.
Taco Electronic Solutions, Inc. will not be responsible for any product or part not installed or operated in conformity with
the Document and instructions or which has been subject to accident, disaster, neglect, misuse, misapplication, inade-
quate operating environment, repair, attempted repair, modification or alteration, or other abuse. For further informa-
tion, please refer to the last page of this Document for the company’s Limited Warranty Statement, which is also issued
with the product or available at www.taco-hvac.com.
APPLICABLE DOCUMENTATION
See the table below for additional documentation that may be applicable to this controller.
Description Audience Purpose
iWorx® LCI2 Application Guide, Doc-
ument No. 505-002
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides instructions for setting up and using
the iWorx® Local Control Interface.
iWorx® VAV Series Application
Guide, Document No. 505-011
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides instructions for setting up and using
the iWorx® VAV Series controllers.
iWorx® VPU2 Application Guide,
Document No. 505-010
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides instructions for setting up and using
the iWorx® VPU controller.
iWorx® MPU2 Application Guide,
Document No. 505-009
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides instructions for setting up and using
the iWorx® MPU controller.
iWorx® TS100 Series Installation
Guide, Document No. 502-015
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides instructions for installing and using the
iWorx® TS100 Series sensors.
iWorx® TS300 Series Installation
Guide, Document No. 502-017
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides instructions for installing and using the
iWorx® TS300 Series sensors.
http://iWorxWizard.taco-hvac.com – Application Engineers
– Wholesalers
– Contractors
An on-line configuration and submittal package
generator based on user input. Automatically
generates bill of materials, sequence of opera-
tions, flow diagrams, wiring diagrams, points
and specifications.
Additional
Documentation
LonWorks FTT-10A Free Topology Transceiver User’s Guide, published by Echelon Corpo-
ration. It provides specifications and user instructions for the FTT-10A Free Topology Trans-
ceiver. See also: www.echelon.com/support/documentation/manuals/transceivers.

iWorx® VAV Series
4 502-011, Effective: March 16, 2011
© 2011 Taco Electronic Solutions, Inc.
INSTALLATION INSTRUCTIONS
Precautions
General
This symbol is intended to alert the user to the presence of important installation and maintenance (servic-
ing) instructions in the literature accompanying the equipment.
WARNING: Electrical shock hazard. Disconnect ALL power sources when installing or servicing this
equipment to prevent electrical shock or equipment damage.
Make all wiring connections in accordance with these instructions and in accordance with pertinent national and local
electrical codes. Use only copper conductors.
Static Electricity
Static charges produce voltages that can damage this equipment. Follow these static electricity precautions when han-
dling this equipment.
• Work in a static free area.
• Touch a known, securely grounded object to discharge any charge you may have accumulated.
• Use a wrist strap when handling printed circuit boards. The strap must be secured to earth ground.
Location
Avoid locations where corrosive fumes, excessive moisture, vibration or explosive vapors are present.
Avoid electrical noise interference. Do not install near large contactors, electrical machinery, or welding equipment.
This equipment is suitable for indoor or outdoor use. Preferably, or as required by National Electrical Code, the unit is
intended to be installed within an electrical control enclosure. Operate where ambient temperatures do not exceed
122 °F (50 °C) or fall below 32 °F (0 °C) and relative humidity does not exceed 90%, non-condensing.
FCC Compliance
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of
the FCC rules. These limits are designed to provide reasonable protection against harmful interference. This equip-
ment can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no guarantee that interference will not occur in a par-
ticular installation. If this equipment does cause harmful interference to radio or television reception, which can be
determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or
more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment to a power source different from that to which the receiver is connected.
• Consult the equipment supplier or an experienced radio/TV technician for help.
You are cautioned that any changes or modifications to this equipment not expressly approved in these instructions
could void your authority to operate this equipment in the United States.

iWorx® VAV Series
502-011, Effective: March 16, 2011 5
© 2011 Taco Electronic Solutions, Inc.
BEFORE INSTALLING
About this Document
The instructions in this manual are for the Terminal Unit Controller controllers.
Inspecting the Equipment
Inspect the shipping carton for damage. If damaged, notify the carrier immediately. Inspect the equipment for damage.
Return damaged equipment to the supplier.
What is Not Included with this Equipment
• A power source for the equipment electronics and peripheral devices.
• Tools necessary to install, troubleshoot and service the equipment.
• The screws or DIN rail needed to mount the device.
• Peripheral devices, such as sensors, actuators, etc.
• Cabling, cabling raceway, and fittings necessary to connect this equipment to the power source, FTT-10A network
and peripheral devices.
Equipment Location
Abide by all warnings regarding equipment location provided earlier in this document.
Optimally, the equipment should be installed within a secure enclosure.
If the equipment is to be installed outdoors, it must be contained within a protective enclosure. The enclosure must
maintain internal temperature and humidity within the ranges specified for this equipment.
The equipment must be installed within 500 feet of all input peripherals (smoke detectors, sensors, etc.) that will be
connected to the equipment.
Selecting a Power Source
This equipment requires a UL recognized Class 2 external power source (not supplied) to operate. The controller
power input requires a voltage of 24 Volts AC.
To calculate power source current requirements, add the power consumption of all peripheral devices to that of the
controller.
The controller and triac output loads can use the same power source. If both are using the same power source, the
loads must have EMF protection. This protection can be integral to the load, or installed in the 24 VAC wiring across the
load’s coil.
To provide necessary RFI and transient protection, the controller’s ground (GND) pin (T10) must be con-
nected to earth ground or the earth ground of the packaged unit’s enclosure ground. Failure to properly
ground the controller may cause it to exceed FCC limits. Excessive noise could also produce inaccurate
sensor data. The power source must be capable of operating with this connection to ground.
INSTALLATION
Warning: Electrical shock hazard. To prevent electrical shock or equipment damage, disconnect ALL
power sources to controllers and loads before installing or servicing this equipment or modifying any wir-
ing.

iWorx® VAV Series
6 502-011, Effective: March 16, 2011
© 2011 Taco Electronic Solutions, Inc.
Mounting the Device
1.Open the damper halfway.
2.Press the black motor release on the motor housing and rotate the actuator so that its flat edge is parallel to the
edge of the housing as shown in Figure 1.
3.Slide the controller down over the damper shaft so that the shaft goes through the round opening above the actu-
ator motor.
4.Tighten the retaining nuts to secure the actuator to the damper shaft.
5.Remove tape that secures the mounting screw to the mounting tab at the left of the controller.
6.Drive the mounting screw through the hole in the mounting tab and into the metal of the damper box.
7.Set the motor stops to prevent the actuator motor from over driving the damper.
a.Rotate the damper shaft until the damper is completely closed.
b.Loosen the screw that holds the low stop, and slide it around until it rests against the actuator.
c. Tighten the screw to secure the low stop.
d.Rotate the damper until it is completely open, and set the high stop.
8.Attach the differential pressure sensor tubes from the duct to the inputs at the top of the controller. Make sure to
attach the “Low” and “High” tubes to the “Low” and “High” attachment points on the controller.
9.Wire the controller (see “Wiring Information” below).

iWorx® VAV Series
502-011, Effective: March 16, 2011 7
© 2011 Taco Electronic Solutions, Inc.
Figure 1: Mounting Dimensions
Routing Cabling to the Device
Cabling used to connect the power source and cabling used to connect the FTT-10A network must remain
separated within the control enclosure and wiring conduit.

iWorx® VAV Series
8 502-011, Effective: March 16, 2011
© 2011 Taco Electronic Solutions, Inc.
Grounding the Device
The ground terminal (T10) must be securely connected to earth ground, and T9 must be connected to T10
using a jumper wire. Failure to properly ground this equipment may increase the risk of electrical shock
and the possibility of interference to radio/TV reception, and will decrease the reliability of the device’s sen-
sor readings.
Connecting the device commons (COM) to earth ground will also connect the power source to earth
ground.
WIRING INFORMATION
WARNING: Terminals 9, 14, 17, and 20 are connected internally on all Terminal Unit Controller controllers.
Disconnect ALL power sources when installing or servicing this equipment to prevent electrical shock or
equipment damage.
Figure 2: VAV Series Terminal Connections
Connecting Input Devices
Thermostat (STAT)
Connect one wire of a TS300 Series sensor to the STAT (T15) terminal. Connect the other wire to the adjacent com-
mon (T14).
Discharge Air Temperature (DAT)
To connect the discharge air thermistor to the unit, attach one wire from the thermistor to DAT (T16) and the other wire
to the adjacent common (T17). The thermistor used must be 10K Precon Type III.

iWorx® VAV Series
502-011, Effective: March 16, 2011 9
© 2011 Taco Electronic Solutions, Inc.
Indoor Air Quality (IAQ)
To connect the digital CO2level sensor to the unit, attach one wire from the sensor to IAQ (T18) and the other wire to
the adjacent common (T17). The sensor must provide a contact closure when the CO2limit is exceeded.
Primary Air Temperature (PAT)
To connect the primary air temperature to the unit, attach one wire from the thermistor to PAT (T19) and the other wire
to the adjacent common (T20). The thermistor used must be 10K Precon Type III.
Occupancy Sensor (OCC)
To connect the digital occupancy sensor to the unit, attach one wire of the sensor to OCC (T21) and the other to the
adjacent common (T20). The sensor must provide a contact closure when the occupancy button is pressed.
Connecting Output Devices
Heating Stages 2 (H1, H2)
The heating stage outputs must be connected to 24 VAC pilot relays with EMF protection. Connect Heat Stage 1 to T5
and the adjacent common on T6. Connect Heat Stage 2 To T4 and the adjacent common on T3. See Figure 2 for
details.
Fan Start/Stop (FAN)
The fan outputs must be connected to a 24 VAC pilot relay with EMF protection. Connect the Fan to T7 and the adja-
cent common on T6. See Figure 2 for details. If the controller is being used with auxiliary heat sources, this output is
used as the auxiliary heat output.
Analog Reheat Valve (AO1)
To connect the reheat valve output, attach one wire to AO1 (T13) and the other wire to the adjacent common (T14).
Other Connections
Network (LON)
Network wiring must be twisted pair. One network wire must be connected to terminal NETA (T11) and the other net-
work wire must be connected to terminal NETB (T12). Polarity is not an issue since an FTT-10A network is used for
communications. Terminals T9 and T10 must be jumpered together.
Power (PWR)
Connect one output wire from a 24 VAC power supply to PWR (T8) and the other output wire from the power supply to
the adjacent common terminal (T9).
Ground (GND)
Terminal GND (T10) must be connected to earth ground. Failure to properly ground this equipment will
result in improper operation. Improper grounding may also increase the risk of electrical shock, and may
increase the possibility of interference with radio and TV reception.

iWorx® VAV Series
10 502-011, Effective: March 16, 2011
© 2011 Taco Electronic Solutions, Inc.
SPECIFICATIONS
Electrical
Inputs
• Cabling: twisted shielded pair, 18 AWG recommended—500 feet max. (152 meters)
• Resolution: 10 bit
Thermostat Network
•12Volt nominal, internally limited to 0.04 A
Primary Air Temperature, Discharge Air Temperature Sensors
• Precon Type III 10K thermistor
Indoor Air Quality
• Dry Contact
• Normally open
•5Volts DC max
Outputs
Fan Start/Stop, Heating Stages 1 & 2 or Heating Valve Open & Close
• 20 to 28 Volts AC
• 0.7A maximum each
Power
Power Requirements
•24VAC nominal, 100VA max (requires an external class 2 supply)
Power Consumption
• 15VA with no external loads, maximum limited by the class 2 supply rating
Recommended Sensor Wire
FTT-10A Network
• Speed: 78KBPS
• Cabling: Maximum node-to-node distance: 1312 feet (400 meters)
• Maximum total distance: 1640 feet (500 meters)
For detailed specifications, refer to the FTT-10A Free-Topology Transceiver User’s Guide published by Echelon Corpo-
ration (www.echelon.com/support/documentation/manuals/transceivers).
Mechanical
Housing
• Dimensions: 5.25" (13.34 cm) high, 8.87" (22.53 cm) wide, 2.75" (6.99 cm) deep
Cable Type Pairs Details Taco Catalog No.
18AWG 1 Stranded Twisted Shielded Pair, Plenum WIR-018
Cable Type Pairs Details Taco Catalog No.
Level 4 22AWG (0.65mm) 1 Unshielded, Plenum, U.L. Type CMP WIR-022