Johnson Controls Metasys DX-9100 Service manual

M-Applications 653
Metasys Ventilation Controller Section
Issue Date 1000
© 2000 Johnson Controls, Inc. www.johnsoncontrols.com
Part No. 24-8395-26 Rev. —
Code No. LIT-653425
TECHNICAL BULLETIN
Metasys Ventilation Controller Application
for the DX-9100
Metasys Ventilation Controller Application for the DX-9100 .............3
Introduction........................................................................................................*3
Key Concepts...................................................................................................... 5
Johnson Controls CO2Concentration Samplers............................................................ *5
MVC-2000-1 Package ................................................................................................... *5
Universal Packaging Module (UPM) ............................................................................... 6
DX-9100 ........................................................................................................................*7
CO2Sensor................................................................................................................... *7
Air Valve ......................................................................................................................... 8
Air Pump......................................................................................................................... 8
Air Filter ......................................................................................................................... *8
Return, Supply, and Outdoor Air Ports............................................................................ 8
Sample System ............................................................................................................. *9
HVAC System Requirements........................................................................................ 10
Location Considerations ............................................................................................... 10
Procedure Overview ........................................................................................*12
Detailed Procedures ......................................................................................... 13
Installing a UPM........................................................................................................... *13
Installing Air Sampling Devices and Tubing .................................................................. 14
Trending Data.............................................................................................................. *15
Checking the Solenoid Valves ..................................................................................... *16
Calculating the OA Flow .............................................................................................. *16
Checking the Controller Application ............................................................................. *17
Reloading the Controller Application ............................................................................ *17
* Indicates those sections where changes have occurred since the last printing.

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Metasys Ventilation Controller Application for the DX-9100 3
Metasys Ventilation Controller
Application for the DX-9100
Introduction
A Johnson Controls Building Automation System (BAS), along with
the Metasys® Ventilation Controller (MVC) 2000-1 Multipoint Gas
Concentration Sampler, can provide building managers with a
cost-effective method of addressing the Ventilation Rate Procedure
found in ASHRAE (American Society of Heating, Refrigeration, and
Air Conditioning Engineers) Standard 62-1999. The MVC-2000-1 is
used to implement the Metasys Ventilation Controller Application
(MVCA) that allows a facility manager to:
•monitor the flow of outdoor air into a building, using a patented
tracer gas method
•control the flow of outdoor air into a building according to
ASHRAE guidelines, e.g., 20 cubic feet per minute (cfm)/person
for office spaces
•document the ventilation flow for future reference, which enables
the facility manager to compare the readings with established state,
local, federal, or ASHRAE guidelines
•perform CO2high-limit control (override of ventilation controller)
in response to greater than expected occupancy in critical areas
such as conference rooms
•view CO2concentrations in supply, return, and outdoor air at the
workstation
•diagnose the control system, since deviations in trended CO2
readings can suggest problems with the Heating, Ventilating, and
Air Conditioning (HVAC) equipment
•set alarms based on CO2levels exceeding a user-defined
maximum or differential

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This technical bulletin describes how to:
•install a Universal Packaging Module (UPM)
•install air sampling devices and tubing
•trend data
•check the solenoid valves
•calculate the Outdoor Air (OA) flow
•check the controller application
•reload the controller application

Metasys Ventilation Controller Application for the DX-9100 5
Key Concepts
Johnson Controls CO2Concentration Samplers
Johnson Controls offers two 3-point, multiplexed CO2measurement
devices, as shown in Table 1.
Table 1: Attributes of the MVC-2000-1
Product Intended Use Enclosure Controller Software Links
MVC-2000-1 3-point,
multiplexed CO2
measurement
UPM
Enclosure
One
Metasys
Extended
Digital
Controller
(DX-9100)
GX-9100 Application
for MVC is
pre-installed in the
DX-9100.
Metasys
Supervisory
Controller and
workstation links
possible but not
required.
This document gives procedures that are unique to the MVC-2000-1
and its components as shown in Figure 1. Refer to existing product
documentation for standard procedures involving these components.
MVC-2000-1 Package
Many of the components of the MVC-2000-1 package are
Johnson Controls products, including the:
•UPM
•DX-9100, Version 2.4 or later
•GX-9100 Configuration Tool Software for the DX-9100
•V11HGA-100 3-way Solenoid Air Valve
•A-4000-137 Air Filter

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Mvc2000B
DX-9100
3-Way
Valves
CO
Sensor
2
Ports for Outside,
Return, and Supply Air
Air Filter
Air Pump
Figure 1: Components of an MVC-2000-1
Universal Packaging Module (UPM)
The MVC-2000-1 product line utilizes the EN-EWC35-0 UPM. Each
EWC number ends with a “5,” which means that the UPM enclosure
with cover also comes equipped with a transformer and a power box.
Refer to the UPM literature for the following UPM procedures:
•engineering
•installation, which includes:
a. mounting
b. landing conduit
c. power connections
d. grounding and bonding
•commissioning

Metasys Ventilation Controller Application for the DX-9100 7
DX-9100
The DX-9100 is a controller manufactured and marketed by
Johnson Controls. The Metasys Ventilation Controller Application of
the GX-9100 Software Tool is used to program the DX-9100.
DX-9100 Hardware
The MVC-2000-1 product utilizes one DX-9100. The DX-9100 is
factory installed in the MVC-2000-1.
!
CAUTION: Do not use any additional inputs or outputs on
the DX-9100, which is performing the outdoor
air flow calculations. The GX-9100 software
uses the full capabilities of the controller and
adding additional inputs or outputs risks
overburdening the system.
GX-9100 Software Configuration Tool
To use the MVCA, it is necessary to know GX-9100 basics such as:
•opening a file
•downloading a file
•commissioning a DX-9100
These procedures are contained in the GX-9100 Software
Configuration Tool User’s Guide (LIT-6364060).
GX-9100 Application for MVC
The MVCA is factory downloaded into the DX-9100.
For an explanation of the GX-9100 application for MVCA, refer to the
Metasys Ventilation Controller Application (MVCA) Application Note
(LIT-653435).
CO2Sensor
Each MVC-2000-1 contains a single CO2sensor. It is used to sense the
CO2levels in three distinct airstreams:
•supply air
•return air
•outdoor air
This is achieved through the use of two 3-way pneumatic valves and
the associated multiplexing control. Three separate pneumatic lines
are multiplexed into the single CO2sensor.

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The CO2sensor is factory mounted and wired in the MVC-2000-1
enclosure. Since it is also factory calibrated, there is no need to
calibrate the CO2sensor before starting the MVCA.
Air Valve
Each MVC-2000-1 contains two solenoid air valves. These
two V11HGA-100 3-way solenoid air valves switch the input source
of sampled air from one of three sampling tubes to the CO2sensor.
This allows samples from three different airstreams to be multiplexed
into a single CO2sensor.
The solenoid air valves have already been installed in the
MVC-2000-1 enclosure. Electrical power has been connected.
No installation or commissioning procedures are necessary for the air
valves. If a problem arises with this product, refer to the V11 Series
Three-Way Solenoid Air Valve Technical Bulletin (LIT-7171550X)
found in the Pneumatic Control Manual (FAN 717.1).
Air Pump
The MVC-2000-1 comes equipped with an air pump. The pump
maintains proper air flow between the air sampling points and the
CO2sensor regardless of duct static pressure. No installation or
maintenance procedures are required for the air pump. The air pump is
factory installed in the MVC-2000-1 enclosure. If the pump should
fail, replace it with a 0.8 liters/minute (L/min.) pump. Eight L/min is
equivalent to 0.21 gallons/minute (gal/min).
Air Filter
Each MVC product contains an A-4000-137 air filter. This removes
particulate and moisture from the airstream, to prevent damage to the
CO2sensor. The A-4000-137 filter also inhibits contamination of the
pump and the CO2sensing chamber.
Inspect the air filter every few months. Replace the filter if a dark red
color appears on the outer surface, indicating oil or water
contamination.
Return, Supply, and Outdoor Air Ports
The return, supply, and outdoor air samples enter the UPM enclosure
through their respective ports.

Metasys Ventilation Controller Application for the DX-9100 9
Sample System
Figure 2 shows a sample system with an MVC-2000-1 connected to a
Metasys Supervisory Controller that supports the DX-9100 via an
N2 Bus. The Metasys Supervisory Controller is optional and the
workstation is only required for visual trending of data. Linked and
modulated outdoor air flow dampers and a supply air flow measuring
station are required parts of the system.
Supervisory
Controller
does data trending.
MVC-2000-1
VAV Air
Handling System
Supply Air Flow
Measuring Station
Coupled
Dampers
Workstation
Printer
archives and prints
trend data.
MVCAPB5
Calculates
outdoor air flow
and controls
the dampers.
Supply Air Flow
Multiplexed Samples
of Supply, Return,
Outdoor Air
Discharge Air Temperature
Mixed Air Damper Control
Supervisory
Controller
N2 Bus
Air Handling Unit
Controller
N2 Bus
Figure 2: Sample System Using MVC-2000-1
Connected to a Metasys Supervisory Controller

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HVAC System Requirements
In order to achieve optimum performance from the application, the
following checklist must be used to evaluate the HVAC system prior
to installation. Refer to items that are appropriate to the installation. If
any items below are questionable, contact a Johnson Controls technical
support representative.
•Is the HVAC system in good working condition?
•Are all controls and controlled systems properly calibrated?
•Are all control loops working as they were commissioned?
•Is the HVAC system appropriately sized for the building it serves?
•Are the ducts sized properly for the air handling system?
•Are the dampers, linkages, and actuators in good operating
condition?
•Is the air measuring station in the supply air duct installed and
operating properly?
•Is the outdoor air intake free from the re-entrainment of exhaust
air?
•Is the outdoor air intake free from the entrainment of pollution
sources, e.g., carbon monoxide from trucks and buses?
Location Considerations
Consider the following factors when deciding where to mount the
MVC-2000-1 enclosure:
•Stability: The enclosure should be mounted to a flat, stable,
non-vibrating mounting surface (heavy-duty drywall or concrete)
where the unit will not be subjected to moisture accumulation or
drastic temperature variation.
•Ambient Operating Conditions: Temperature: 0 to 40°C
(32 to 104°F); humidity: 10 to 95% Relative Humidity (RH),
non-condensing.
!
CAUTION: Because it contains delicate sensing instruments,
the MVC should be located in an environment in
which the ambient temperature is normally above
5°C (40°F). The MVC is not designed to be located
on an exposed rooftop.

Metasys Ventilation Controller Application for the DX-9100 11
•Position: Mount the enclosure vertically.
•Air Sampling Locations: Remote or local sensing is acceptable;
the outdoor and return air sampling devices can be mounted up to
30.5 m (100 ft) away from the unit. The supply air sampling device
can be mounted up to 9.2 m (30 ft) away from the unit.
•Outdoor Air Flow: The outdoor air flow sampling device can be
mounted in the outdoor air intake ductwork. However, if it is likely
that exhaust air could affect the sensor in the outdoor air intake
ductwork, then a mounting location outdoors (properly enclosed
and free from exposure to the elements) is preferred.
•Air Stratification: The air sampling devices must collect air that
is sufficiently mixed in order to deliver accurate CO2readings. The
sampling devices should extend into the middle of the air streams,
and be placed at a reasonable distance from where any two air
flows mix together.

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Procedure Overview
Table 2: Using the MVCA with the DX-9100
To Do This Follow These Steps:
Install a UPM In a secure location, install the UPM according to procedures listed in the
Universal Packaging Module Technical Bulletin (LIT-6363070). Note
shock and equipment damage hazards. Connect the N2 Bus to the
DX-9100. Complete field connections to the terminal blocks before the
controller is attached to the base. If you need more room, remove the
bottom endcap of the UPM by disconnecting the assembly screws.
Complete the field wiring and reassemble the endcap, making sure not to
pinch any wires. In cramped or poorly-lit areas, reassembly can be
difficult.
Install Air Sampling Devices
and Tubing
Select locations for the air sampling devices in the air flows. Place the
sampling device with the open end facing into the air flow. Seal the vent
around the tubing. Install the remaining devices. Remove the packing
material and tie-wrap from the air pump.
Trend Data For simple monitoring, refer to the appropriate workstation user’s manual
for your system.
Check the Solenoid Valves Make sure the valves change state every sixty seconds and verify that
these state changes are in the proper sequence.
Calculate the OA Flow After the system has stabilized and the Supply Air (SA) flow has been
checked, use the following equation to determine whether the system is
functioning correctly based on the CO2levels of OA, SA, and
RA (Return Air) flows: [OA CO2] ≤[SA_CO2] ≤[RA_CO2].
Check the Controller
Application
To check the controller application, use the GX-9100 software to verify
that the system remains stable as the control strategy changes from
OA flow to air temperature. If the OA Flow Controller is in stable control
and, for five minutes, the Discharge Air Temperature
Controller/Economizer control is calling for a larger output than the OA
Flow Controller, the Discharge Air Temperature Controller/Economizer will
take control. If, for five minutes, the Discharge Air
Temperature/Economizer is in control, and the feedback of the OA Flow
Controller is less than the setpoint of the OA Flow Controller, and the
30 ppm CO2 differential exists between the OA CO2and the RA CO2
concentration values, the OA Flow Controller will take control.
Reload the Controller
Application
No installation is required, but if you need to reload the MVCA, obtain
DXMVCA.EXE from The Advisor by clicking on Engineering/Technical >
Field Support Center > Digital Controllers > DX-9100 > DXMVCA.EXE.
For ABCS, on The Exchange, click on Technical Support > Digital
Controllers > DX-9100 > DXMVCA.EXE. Use the GX-9100 Configuration
Tool to download the contents into the controller.

Metasys Ventilation Controller Application for the DX-9100 13
Detailed Procedures
Installing a UPM
To install a UPM:
1. Decide on a location for the enclosure based on the Location
Considerations section of this document.
2. Install the MVC-2000-1 enclosure by following the procedures in
the Universal Packaging Module Technical Bulletin
(LIT-6363070).
a. Hang the enclosure.
b. Land the conduit.
c. Wire the 110 VAC power.
d. Connect the DX-9100 to the N2 Bus.
!
WARNING: Shock Hazard. Disconnect the power supply
before making wiring connections. Failure to do
so can result in serious personal injury.
Notes: This device complies with Part 15 of the FCC (Federal
Communications Commission) rules. Operation is subject to
the following two conditions: (1) device may not cause
harmful interference, and (2) device must accept any
interference received, including interference that may cause
undesired operation.
Wiring connections must be made in accordance with the
National Electrical Code and local regulations for low
voltage wiring.
!
WARNING: Equipment Damage Hazard. The CO2sensor
power input must be electrically isolated. Do
not connect the sensor’s power inputs to any
other terminal. A connection between the input
terminals and the signal return will permanently
damage the unit. Also, do not use the power
inputs to supply power to any other device
because the unit’s power transformer could be
overloaded.
3. Ensure the DX-9100 field connections are completed to the
terminal blocks before the controller is attached to the base.

Metasys Ventilation Controller
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4. For additional maneuvering space during the wiring operation,
remove the bottom endcap of the UPM by disconnecting the
two assembly screws.
5. Complete the field wiring to the DX-9100.
6. Reassemble the lower UPM endcap.
7. Take care not to pinch any wires.
Note: Be aware that in low lighting conditions or cramped spaces,
reassembly of the endcap may be difficult.
Installing Air Sampling Devices and Tubing
To install air sampling devices and tubing:
1. Read the Location Considerations section of this bulletin.
2. To ensure an acceptable response time, mount the enclosure so the
pneumatic tubing runs conform to the following specifications:
•supply air - 9.2 m (30 ft) maximum
•return air - 30.5 m (100 ft) maximum
•outdoor air - 30.5 m (100 ft) maximum
3. Select a mounting location on the first duct (supply, return,
or outdoor) for one of the air sampling devices.
4. Install the air sampling device on the duct with the open end facing
into the air stream. The connection can be made at any place along
the duct, including near heating or cooling coils.
Note: The outdoor air flow sampling device can be mounted in the
outdoor air intake ductwork; however, mount the device
outdoors if it is likely that exhaust air could affect the sensor in
the outdoor air intake ductwork.
5. Seal the space between the tube and the duct to prevent air loss
from the duct.
6. Use a length of 6.4 mm (1/4 in.) Outside Diameter (O.D.) flexible
tubing to connect the air sampling tube to the appropriate port
located inside of the enclosure. Tubing is labeled outdoor, supply,
and return.
7. Install the remaining air sampling devices in the other
two locations specified by Figure 3.

Metasys Ventilation Controller Application for the DX-9100 15
Sampling
DX-9100
3-Way
Valves
CO
Sensor
2
Ports for Outside,
Return, and Supply Air
To Air Sampling
Location 1
To Air Sampling
Location 3
Air Sampling
Device
Direction
of Flow
Air Sampling
Location 2
Air Filter
Air Pump
Figure 3: Air Sampling Device Installation
8. Open the enclosure cover and remove the packing material.
9. Remove the tie-wrap from the air pump.
Trending Data
To trend outdoor air flow and CO2values for this application, consult
the appropriate workstation user’s manual.
Some of the points that may be trended are:
•outdoor air CO2concentration
•return air CO2concentration
•supply air CO2concentration
•supply air flow (measured)
•outdoor air flow (calculated)

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Checking the Solenoid Valves
To check the solenoid valves:
1. Listen to the valves. They produce an audible click when changing
states. This should happen approximately every sixty seconds.
2. Time the changes in the valves. Are the solenoid valves changing
state in the proper sequence (as detailed in Table 3)?
Table 3: Commanded States of Solenoid Valves Relative to
Air Sampling Sites
Air Sampling Site Solenoid 1 Solenoid 2
Outdoor air On Off
Supply air Off On
Return air Off Off
Note: For more information, consult the Timing and Staging
diagrams in the CO2Multiplexer Application Note
(LIT-636212) located in the Metasys Network Technical
Manual (FAN 636).
Calculating the OA Flow
To calculate the outdoor air flow:
1. Wait ten minutes after initial startup or until the system appears to
have stabilized (when one CO2value is measured every minute).
2. After system has stabilized, verify that the CO2levels coordinate
with the following equation:
[OA CO2] ≤[SA_CO2] ≤[RA_CO2]
Note: For more information, consult the Outdoor Air Flow
Calculator Application Note (LIT-636222) located in the
Metasys Network Technical Manual (FAN 636).

Metasys Ventilation Controller Application for the DX-9100 17
Checking the Controller Application
Note: Check the controller application to verify that the system
remains stable when changing from the ventilation control
strategy to the temperature control strategy and that the
controller that demands the highest output is in control of the
system.
To check the controller application:
1. Through the GX-9100 software, verify that the OA Flow Controller
output is compared to the Discharge Air Temperature
Controller/Economizer Damper Controller output every minute.
2. If the OA Flow Controller is in stable control and the
Discharge/Economizer Controller is calling for a larger output than
the OA Flow Controller for five minutes, the
Discharge/Economizer takes control of the system.
3. If the Discharge/Economizer is in stable control for five minutes
and the following conditions are met, the OA Flow Controller takes
control of the system.
•The feedback of the OA Flow Controller is less than the
setpoint of the OA Flow Controller.
•A 30 ppm CO2differential exists between the outdoor air CO2
and the RA CO2concentration values.
Note: More information on this topic can be found in the Controller
Manager Application Note (LIT-636216) located in the
Metasys Network Technical Manual (FAN 636).
Reloading the Controller Application
To reload the controller application:
Note: The MVC-2000-1 comes with the DX-9100 already installed
containing the MVCA. Follow this procedure only if you need
to reload the MVCA.
1. Obtain DXMVCA.EXE from The Advisor by clicking on
Engineering/Technical > Field Support Center > Digital
Controllers > DX-9100 > DXMVCA.EXE. From The Exchange,
click on Technical Support > Digital Controllers > DX-9100 >
DXMVCA.EXE.
2. Use the GX-9100 Software Configuration Tool to download the
contents of the file to the controller.

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Notes

Metasys Ventilation Controller Application for the DX-9100 19
Notes

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Notes
Controls Group www.johnsoncontrols.com
507 E. Michigan Street FAN 653
P.O. Box 423 M-Applications
Milwaukee, WI 53201 Printed in U.S.A.