Johnson Controls METASYS TC-9102 Series Service manual

System 91 Manual
TC-9102
Technical Bulletin
Issue Date 0698
© 1998 Johnson Controls, Inc. 1
Order No. MN-9100-2117
Introduction Page 3
• Model Types 4
• Controller Functions 5
• Output Types 10
• Fan Output Types 12
Installation 15
• Mounting 15
• Wiring 16
• Jumper and Switch Selections 22
• Startup 23
• Commissioning 23
Specifications & Technical Data 25
• Factory-Set Parameters 26
• Parameters for Supervisory System 27
• Ordering Codes 28
TC-9102 Fan Coil Unit Controller

2 Technical Bulletin—TC-9102

Technical Bulletin—TC-9102 3
Introduction
The TC-9102 series of microprocessor-based controllers is designed for
the control of Fan Coil Units (FCUs) with heating and cooling, and a
single-speed, 3-speed or variable-speed fan. The controller can regulate
water valves, one or 2-stage electric heating, or a cooling unit where the
compressor has its own short cycle protection.
The comfort temperature set point of the controller may be adjusted via a
TM-9100 Series Room Command Module, and the occupied and
unoccupied control modes of operation temporarily changed. A window
open sensing contact may be connected to switch the controller to the off
mode, and a low temperature limit protection feature is available.
The controller is factory-configured to control with default operating
parameters so that no external setup devices are necessary. However, a
software package for a PC is available to verify the correct operation of
the controller and to modify the configuration, if necessary.
Winter and summer compensation may be enabled when the controller
receives outdoor air temperature data via the communications bus, and
modes of operation may be set by time scheduling programs or control
processes in the supervisory system.
2357 2664
Figure 1: TC-9102 Controller Figure 2: TM-9160 Room
Command Module

4 Technical Bulletin—TC-9102
2333
Figure 3: TM-9180 Room Command Module
The TC-9102 Controller is available in several model types according to
the type of outputs and the range of the integrated or remote set point
input. Refer to Ordering Codes at the end of this bulletin for details.
Model Types

Technical Bulletin—TC-9102 5
The controller can be connected to a Room Command Module, from
which it receives the room temperature, the remote set point and other
override signals. The TM-9180 intelligent Room Command Module
provides these signals via a serial bus connection to the controller. The
other Room Command Modules (TM-9150/9160/9170) provide the
signals as individually connected physical inputs to the controller. In
addition, an NTC temperature sensor is available for mounting within the
FCU.
For installations without a Room Command Module, the controller is
available with an integrated set point adjuster. Alternatively, the remote
set point and fan override controls may be incorporated into a custom
FCU control panel. Refer to the Specifications and Technical Data
section of this bulletin for details of the components required.
Occupancy Sensor
Window Contact
Room Temp.*
Remote Setpoint
Occupancy Button
Fan Override
(3-speed only)
Output Heating
Output Cooling
Fan Control
Controller
Room
Command
Module
Communications Bus
(Supervisory Control,
Outdoor Air Temp.) NTC sensor may be
mounted in FCU.
*
tc2cwrcm
Figure 4: Controller with Room Command Module
Occupancy Sensor
Window Contact
Room Temp.
NTC Sensor
Fan Override
(3-speed only)
Output Heating
Output Cooling
Fan Control
Controller
(Setpoint)
Communications Bus
(Supervisory Control,
Outdoor Air Temp.)
tc2cwspa
Figure 5: Controller with Integrated Setpoint Adjuster
Controller
Functions

6 Technical Bulletin—TC-9102
The controller operates in standalone mode when it is not connected to a
supervisory system via the communications bus nor to a TM-9180 Room
Command Module. In standalone mode the controller may operate in one
of three control modes:
•COMFORT (occupied): control at comfort set point
•STANDBY (unoccupied): control at a standby level set point
•OFF (not in use): low limit control only
The control modes are set by the window contact and occupancy sensor
inputs, and may be modified by the occupancy button on the Room
Command Module as shown in Table 1.
Table 1: Standalone Modes
WINDOW CONTACT OCCUPANCY SENSOR CONTROL MODE ALTERNATE MODE
(OCCUPANCY BUTTON)
WINDOW OPEN NO ACTION OFF NO ACTION
WINDOW CLOSED OCCUPIED COMFORT STANDBY
UNOCCUPIED STANDBY COMFORT
When connected to a supervisory system via the communications bus or
to a TM-9180 Room Command Module, the controller may operate in
COMFORT, STANDBY or OFF control modes, and additionally in
NIGHT mode:
NIGHT (scheduled unoccupied): control at a night level set point.
The control modes are set by the supervisory system or TM-9180, and are
modified by the occupancy sensor input and occupancy button on the
Room Command Module as shown in Table 2. The window contact input
always switches the controller to OFF control mode, and a MANUAL
mode is available from the supervisory system to inhibit the action of the
occupancy sensor and occupancy button.
Table 2: Supervisory Modes
WINDOW
CONTACT SUPERVISORY MODE OCCUPANCY SENSOR CONTROL MODE ALTERNATE MODE (OCCUPANCY BUTTON)
OPEN ANY MODE NO ACTION OFF NO ACTION
OFF OCCUPIED OFF OFF
UNOCCUPIED OFF OFF
NIGHT OCCUPIED NIGHT COMFORT (T)*
UNOCCUPIED NIGHT COMFORT (T)*
STANDBY OCCUPIED STANDBY COMFORT
CLOSED UNOCCUPIED STANDBY COMFORT (T)*
COMFORT OCCUPIED COMFORT STANDBY
UNOCCUPIED STANDBY COMFORT
OFF/MANUAL OFF
NIGHT/MANUAL NO ACTION NIGHT NO ACTION
STANDBY/MANUAL STANDBY
COMFORT/MANUAL COMFORT
*(T) = Timed (Returns to Control Mode after 1 hour.)
Standalone
Mode
Supervisory
Mode

Technical Bulletin—TC-9102 7
The set point in all control modes may be modified from the integrated
set point adjuster or from the remote set point dial/control panel on the
Room Command Module, according to the controller model type. The
controller models with a remote set point of 12-28°C require that a Room
Command Module or an external potentiometer is connected to give the
set point. Controllers with a remote set point of +/-3 K have internal
factory set points of 20°C for heating and 22°C for cooling.
The set point is decreased or increased in the STANDBY control mode
by the factory-set “Standby Bias Heating” and “Standby Bias Cooling”
values to reduce the heating or cooling energy required when the room is
temporarily unoccupied.
When a supervisory system is connected, the set point can be further
decreased or increased in the NIGHT control mode to further reduce
energy requirements during scheduled unoccupied periods such as nights,
weekends and holidays.
In the controller there are two “comfort” set points (Comfort Set Point
Heating and Comfort Set Point Cooling), and the difference between
these two values determines the zero energy band where neither heating
nor cooling is required. The controller calculates two working set points
(WSP Heating and WSP Cooling), which are the sum of the comfort set
point values, the “Remote Set Point” value coming from the integrated
set point adjuster or the Room Command Module, and the “Common Set
Point” value. In the supervisory mode an adjustment may be made to the
working set points either by changing the “Comfort Set Points,” or by
changing the value in the “Common Set Point” parameter of the
controller which enables the supervisory system operator to adjust the
setpoints for heating and cooling at the same time without affecting the
zero energy band. In summary:
Working Set Point (Heating) = Comfort Set Point (Heating) (Supervisory System)
+ Remote Set Point (integrated adjuster or Command Module dial)
+ Common Set Point (Supervisory System)
+ STANDBY or NIGHT Bias Heating (if mode is active)
Working Set Point (Cooling) = Comfort Set Point (Cooling) (Supervisory System)
+ Remote Set Point (integrated adjuster or Command Module dial)
+ Common Set Point (Supervisory System)
+ STANDBY or NIGHT Bias Cooling (if mode is active)
When the room temperature is below the working set point for heating,
the heating output increases according to the proportional band and
integral time parameters set for the heating control loop. When the room
temperature is above the working set point for cooling, the cooling output
increases according to the proportional band and integral time parameters
set for the cooling control loop. Heating and cooling control is illustrated
in figures 8 and 9.
Controller Set
Points

8 Technical Bulletin—TC-9102
When pressed for about one second, the occupancy button on the Room
Command Module changes the mode of operation of the controller to the
“Alternate Mode” or back to the normal “Control Mode” as shown in
Table 2. The “COMFORT (T)” alternate mode is active only for a period
of one hour, after which the controller reverts to the normal control
mode.
The controllers with on/off fan control switch the fan on when the room
temperature is below the working set point for heating and above the
working set point for cooling, and switch the fan off when the room
temperature has entered the zero energy band by the value set for the fan
differential. The fan can optionally be set to continue running in the zero
energy band in the COMFORT (occupied) mode, using the software
commissioning tool.
In controllers with 3-speed fan control outputs, the fan stages are
switched in sequence as the room temperature decreases or increases, and
Speed 1 remains on in the zero energy band.
In controllers with a 0 to 10 VDC output for a fan speed controller, the
output increases as the room temperature falls below the working set
point for heating or rises above the working set point for cooling, and
maintains a minimum output (set by default at 50%) when the room
temperature has entered the zero energy band.
For all controllers, in OFF mode the fan is switched off and the heating
and cooling outputs are set to the fully closed or off level. Fan control
sequences are shown in figures 10, 11 and 12.
3-Speed Fan Override
The speed of a 3-speed fan may be set manually from the Room
Command Module when the controller is in COMFORT (occupied)
mode. In the “AUTO” position the speed is set by the controller
according to the room temperature. In the manual “OFF-1-2-3” positions
the fan runs at the selected speed. The fan override is not active in
STANDBY, NIGHT or OFF modes.
In controller models with 2-stage on/off heating and cooling outputs, all
outputs are switched off when the fan speed is set to “OFF” to protect
electrical heating and cooling devices that require a minimum air flow for
normal operation. This feature can be enabled for other types of outputs,
if required, using the software commissioning tool. Refer to
Commissioning later in this document.
Low Limit Mode
The low limit mode is active when the room temperature falls below the
low limit set point. The fan is switched on at full speed and the heating
output is set to the maximum level until the room temperature rises by the
low limit differential value.
Alternate Mode
Fan Control

Technical Bulletin—TC-9102 9
When the controller is connected to a supervisory system, the winter
and/or summer compensation modes may be enabled. The supervisory
system must be programmed to set the outdoor air temperature via the
communications bus on a periodic basis. After a power interruption the
winter and summer compensation modes are temporarily disabled until a
new outdoor air temperature value is received. When the outdoor
temperature falls below the winter set point, the working set point of the
controller will be raised or lowered in accordance with the winter
authority slope. When the outdoor temperature rises above the summer
set point the working set point of the controller will be raised in
accordance with the summer authority slope. The maximum amount of
compensation is limited by the Winter Authority Limit and the Summer
Authority Limit.
The effect of the winter and summer compensation on the controller set
point is shown below.
0
-5
-4
-3
-2
-10
1
2
3
4
5
-20-30
0
-1 10 20
30
40 50
Winter Authority Slope
(+0,1)
Winter Authority
Limit (-3 K))
Winter
Setpoint
(10°C)
Summer
Setpoint
(24°C)
Summer Authority Limit
(+5 K)
Summer Authority
Slope (+0,2)
Setpoint
Compensation
(K)
Outdoor Air
Temperature
(°C)
Winter Authority
Slope (-0,1)
tc2winsu.drw
Figure 6: Winter/Summer Compensation
Winter/Summer
Compensation

10 Technical Bulletin—TC-9102
When the controller is connected to a remote N2 Bus and supervised by a
Metasys N2 Dialer (NU-NDM101-0) which is linked to a Metasys
network by a telephone line, the following alarm conditions in the
controller will initiate the automatic dial feature:
•Window Open
•Low Limit mode
•High or low alarm limit violation of the room temperature when alarm
limits have been set by the supervisory system.
When any one of these alarm conditions occurs, the N2 Dialer will detect
the alarm and connect the remote N2 Bus to the Metasys network. When
the telephone line connection is established the controller alarm status
will automatically be reset and the controller is then ready to report
further alarm conditions as they occur. Refer to the Technical Bulletin of
the NU-NDM101-0 for further information.
The heating and cooling outputs are one of the following types,
depending on the controller model code:
The output is an analog voltage between 0 and 10 VDC in direct
proportion to the controller output from 0 to 100%.
The DAT output is a triac which is switched on for a duration within the
set heating or cooling valve cycle time in direct proportion to the
controller output from 0 to 100%. To avoid unnecessary switching of the
valve actuator when the output is between 0 and 5% the triac remains off,
and when the output is between 95 and 100% the triac remains on. The
default cycle time is 300 seconds.
OFF
ON 50% Output 30% Output
DAT C
y
cle Time
DAT C
y
cle Time
Figure 7: DAT Output
Auto-dial
Feature
Output Types
0 - 10 VDC
DAT - Duration
Adjust Type