Johnson Controls METASYS VAV110 User manual

Application Specific Controllers Technical Manual 636.3
VAV Controller Section
Technical Bulletin
Issue Date 0309
©2009 Johnson Controls, Inc. 1
Code No. LIT-6363040
Introduction Page 5
  Description 5
 OEM Applications 8
 Standards Compliance *8
 Coordination of Factory Mounted VAV Systems 8
Configuring the Controller 11
 Using HVAC PRO for Windows Configuration Tool 11
 Defining a VAV Control Device Object in Metasys Software 13
Installation Procedures 17
 Tools Needed 17
 Environmental Information 17
 Mounting the Controller 18
 Power Line Wiring Transient Noise Precautions 21
 I/O and Communication Lines Wiring Transient Noise Precautions 23
Variable Air Volume (VAV) Controller
* Indicates those sections where changes have occurred since the last printing.

2 VAV Controller—Variable Air Volume (VAV) Controller
Wiring Details Page 25
 Power Source and Loads 26
 Grounding and Isolation 27
 I/O and Communication Terminals 29
 Power, Zone Bus, and N2 Connections 36
 Analog Inputs 36
 Binary Inputs 38
 Binary Outputs 38
 Analog Outputs 38
 Zone Bus 39
 Wiring to RLY50/002 Relays 39
 Wiring Sensors and Actuators 40
Networking the Controller 45
 N2 Bus Overview 45
 Installing the N2 Bus 46
 Zone Bus Communications 49
Application Examples 51
 Single Duct Applications 51
 Dual Duct Applications 63
Downloading/Commissioning 71
 Via Zone Bus 71
 Via N2 Bus 71
 Incremental Valve Actuator Stroke Time 72
 Incremental Damper Actuator Stroke Time 73
 Zone Terminal Setup for Balancing Contractors 73
* Indicates those sections where changes have occurred since the last printing.

VAV Controller—Variable Air Volume (VAV) Controller 3
Troubleshooting Page 75
 Hardware Installation Inspection 75
 Tools Needed for Troubleshooting 75
 Installation Checkout 76
 Troubleshooting the VAV Controller with HVAC PRO for Windows 81
 Troubleshooting the N2 Bus and Networked VAV Controller 82
 Zone Bus Troubleshooting -- HVAC PRO for Windows 83
Ordering Information 85
 Johnson Controls Code Numbers 85
 Vendor Code Numbers 87
Specifications *89
* Indicates sections where changes occurred since the last printing.

4 VAV Controller—Variable Air Volume (VAV) Controller

VAV Controller—Variable Air Volume (VAV) Controller 5
1 2FIntroduction
The Variable Air Volume (VAV) Controller is an electronic device for
digital control of single duct, dual duct, fan powered, and supply/exhaust
VAV box configurations. See 50HFigure 1. You may use the VAV as a
standalone controller or connected to the Metasysnetwork through a
Network Control Module (NCM) or Companionsystem.
When connected to the Metasys Network, the VAV provides all point and
control information to the rest of the network. The devices communicate
through an N2 Bus.
Each VAV Controller application uses a different sequence of operation,
all of which are covered in the HVAC PRO for Windows User’s Manual
(FAN 637.5).
Description

6 VAV Controller—Variable Air Volume (VAV) Controller
1 2 3 4 5 6
BINARY INANALOGINPUTS BINARY OUTPUTS
BINARY INPUT
ANALOG INPUTS
1 2 3 4 5 6 1 2 3 4
ANALOG INPUTS
COMMON
TO
ZONE
STAT
BINARY OUTPUT
1 2 3 4 5 6 7 8
ZBUS
DSI
P5 P6
1 2 3 4 5 6
BINARY COM
1 2 3 4 5 6
110-111
BINARY IN
ANALOGINPUTS BINARY OUTPUTS
BINARY INPUTANALOGINPUTS
1 2 3 4 5 6 1 2 3 4
ANALOG INPUTS
COMMON
TO
ZONE
STAT
BINARY OUTPUT
1 2 3 4 5 6
Z BUS
DSI
1 2 3 4 5 6
ANA OU
T
ANALOG
OUTPUT
1 2
BINARY COM
R
R
Figure 1: VAV110 (top) and VAV111 (bottom) Controller

VAV Controller—Variable Air Volume (VAV) Controller 7
Table 1: VAV Controller Model Features
Feature VAV100/101
(Discontinued) VAV110/111 VAV140/141
Ambient
Temperature
Rating
32 to 122F
(0 to 50C) 32 to 122F (0 to 50C) 32 to 122F (0 to 50C)
Analog Inputs 6
RTD temperature
elements (1000 ohm
nickel, platinum, or
silicon)
2k ohm setpoint
potentiometers
0 to 10 VDC or
0 to 2 VDC
transmitters
6
RTD temperature
elements (1000 ohm
nickel, platinum, or
silicon)
2k ohm setpoint
potentiometers
0 to 10 VDC or
0 to 2 VDC
transmitters
6
RTD temperature
elements (1000 ohm
nickel, platinum, or
silicon)
2k ohm setpoint
potentiometers
0 to 10 VDC or
0 to 2 VDC
transmitters
Binary Inputs 4
(4) Dry contacts
(1) Momentary push
button from zone
sensor for temporary
occupancy mode
BI 4 may be used as
an accumulator input
for frequencies less
than 100 Hz.
4
(4) Dry contacts
(1) Momentary push
button from zone
sensor for temporary
occupancy mode
BI 4 may be used as
an accumulator input
for frequencies less
than 100 Hz.
4
(4) Dry contacts
(1) Momentary push
button from zone
sensor for temporary
occupancy mode
BI 4 may be used as
an accumulator input
for frequencies less
than 100 Hz.
Analog
Outputs 0/2
0 to 10 VDC
@ 10 mA
0/2
0 to 10 VDC
@ 10 mA
0/2
0 to 10 VDC
@ 10 mA
Binary
Outputs 8/6
24 VAC Triacs
@ 0.5 amperes
8/6
24 VAC Triacs
@ 0.5 amperes, or
0.8 amperes if total
power is limited
8/6
24 VAC Triacs
@ 0.5 amperes, or
0.8 amperes if total
power is limited
N2 Bus Not Isolated * Isolated Isolated
Zone Bus Discrete connections
at controller Discrete connections at controller Discrete connections at controller
8-pin phone jack on
controller 8-pin phone jack on controller 8-pin and 6-pin phone
jack on controller *
6-pin phone jack at
zone sensor 6-pin phone jack at zone sensor 6-pin phone jack at zone sensor
LED Indication * LED Indication *
24 VAC Power
Terminations Quick Connects
(Spade Lugs) * Removable Screw Terminal Block Removable Screw Terminal Block
I/O
Terminations Quick Connects
(Spade Lugs) Quick Connects (Spade Lugs) Fixed Screw Terminal Block *
N2
Terminations Fixed Screw Terminal
Block * Removable Screw Terminal Block Removable Screw Terminal Block
* VAV Controller model feature differences

8 VAV Controller—Variable Air Volume (VAV) Controller
When providing VAVs for projects which use Traneor TITUS
terminal boxes, consider using the AS-VAVDPTx-1 product (refer to
Building VAVDPT Applications Application Note (LIT-6363042) in the
Application Specific Controllers Technical Manual (FAN 636.3). Trane
and TITUS are both Original Equipment Manufacturers (OEMs) who
provide VAV terminal boxes for projects. Trane typically provides the
damper actuator with their terminal box, and TITUS provides the damper
actuator with their QFPC Series Fan Powered Box. The VAVDPT comes
in two models, which include a VAV Controller and a DPT-2015 Velocity
Pressure Transducer. The DPT is mounted and prewired to the cover of
the VAV. Refer to the OEM Reference Manual (FAN 638).
The VAV Controller complies with the following standards:
zFCC Part 15, Subpart J, Class A
zIEEE 472, IEEE 518
zIEEE 587 Category A
zUL 916 Listed
zVDE 0871 Class B
A factory mounted VAV box control system requires close coordination
between a variety of different disciplines. Refer to the OEM Reference
Manual (FAN 638) for factory manufacturer’s details. Although the
responsibilities may differ per city or region, the following parties are
usually involved on the job:
zcontrols contractor
zmechanical contractor
zlocal VAV box manufacturer’s representative
zbalancing contractor
zelectrical contractor
Typically, the mechanical contractor is the focal point for coordinating the
entire process. The basic responsibilities under the domain of the
mechanical contractor are:
1. Purchasing the VAV box system. Most specifications include the
OEM mounting fees and enclosures for the control system in the
mechanical contractor’s price. Mounting fees vary per box
manufacturer but ranges can be found in the OEM Reference Manual
(FAN 638).
2. Providing the release schedule for the VAV boxes to the job.
3. Contracting, or working closely with, the balancing contractor to
ensure the system is set up per the mechanical prints.
Note: The owner often directly hires the balancing contractor. This
ensures neutrality in dealing with other contractors involved in the
project.
3F4F5FOEM
Applications
6F7F8FStandards
Compliance
9F10F11FCoordination of
Factory
Mounted VAV
Systems

VAV Controller—Variable Air Volume (VAV) Controller 9
In conjunction with the mechanical contractor, the controls contractor’s
responsibilities include:
1. Coordination of the control system release schedule to the box
manufacturer to ensure the mechanical system delivery schedule can
be met. Coordination with the local box manufacturer representative is
normally required.
2. Coordination with the electrical contractor to ensure the following
steps are covered.
z24 VAC power is provided at each VAV Controller.
zN2 Bus wiring is pulled and terminated.
zValve actuator wiring is pulled and terminated.
zZone sensor cables are pulled. The use of phone cable for
terminating zone sensor wiring allows basically anyone to
terminate zone sensors in certain locales.
zIf desired, the N2 address switches can be set by the electrical
contractor.
3. Initial loading of the HVAC PRO for Windowsconfiguration files is
done once the electrical contractor’s functions are completed in
preparation for the final system balancing.
4. Training of the balancing contractor to ensure the balancing contractor
knows how to use the Zone Terminal (ZT) or HVAC PRO for
Windows Commissioning mode so they can perform the final system
balancing.
5. Mounting and terminating the cable connections for the zone
temperature sensor. Set the N2 address switch if the electrical
contractor was not contracted to perform this function.
6. Configuring, downloading, and commissioning the controller.

10 VAV Controller—Variable Air Volume Controller

VAV Controller—Variable Air Volume (VAV) Controller 11
12F13F14FConfiguring the Controller
Use HVAC PRO for Windows to configure the VAV. VAV110/111 and
VAV140/141 models require HVAC PRO for Windows. HVAC PRO for
Windows also works with the VAV100/101 models. This easy-to-use
software tool configures, commissions, and downloads the VAV
Controller’s data base.
51HFigure 2 illustrates the HVAC PRO for Windows configuration process.
Refer to the HVAC PRO for Windows User’s Manual (FAN 637.5) for
specific information when configuring the VAV Controller.
Using
HVAC PRO
for Windows
Configuration
Tool

12 VAV Controller—Variable Air Volume Controller
PROFLO40
Download Controller
1. Attach MM-CVT101-1 Converter
or AS-CBLPRO-2.
2. Select Download - Current Configuration.
3. SelectBustype, comm. port, and
N2 address (if N2 Bus).
4. Select OK.
Exit HVAC PRO for Windows
Start HVACPROforWindows
Complete Configuration Process
1. Fill in job information.
-Option-JobInformation
2. Review and change inputs/outputs.
3. Review and change default parameters.
Commission Controller
1. Attach MM-CVT101-1 Converter
or AS-CBLPRO-2.
2. Select Commission - Current Configuration.
3. Select Bustype, comm. port, and
N2address (if N2Bus).
4. Select OK.
5. View/ Adjust parameter values.
6. Reviewcontroller information.
7. Exit Commissioning.
8. If adjustments were made, save
changes to controller and to file.
9. Unplug MM-CVT101-1 or AS-CBLPRO-2..
Save Configuration
1. File - Save As
2. Select device type. 3. Enter file name for configuration file.
Select File-New
1. Select VAV Applications. 2. Select Single or Dual Duct.
Complete Q/A Session
Figure 2: Steps in Configuring a VAV Controller Using
HVAC PRO for Windows

VAV Controller—Variable Air Volume (VAV) Controller 13
Note: You can load and commission the controller either locally with the
AS-CBLPRO-2 interface at the zone sensor (Figure 15) or from a
central location where the N2 has been pulled, controller’s field
hardware addressed, and an MM-CVT101-1 interfaced to the laptop.
Using a Metasys Network system, you need to define a VAV Controller
device object by entering data into the Attribute menu as seen on the
Operator Workstation.
1. Go to the Network Map.
2. Double-click the system name in which you want to add the new VAV
object.
3. Click New in the Item pull-down menu.
4. Click on Type: N2 devices in the Item New dialog box.
OK
CANCEL
Accumulator
Analog data
Analog input
Analog output digital
Analog output setpoint
Binary data
Binary input
Binary output
MS data
MS input
Type MS output
Control system
DL/LR group
LC group
PID loop
Fire Zone
L2 devices
N2 devices
S2 devices
Card Reader
Hardware system name:
Hardware object name:
Copy of (System\Object):
VAV - Item New
ITEM NEW
Figure 3: Item New Dialog Box
Note: The Hardware System and Hardware Object text fields are not
used for this object type.
5. Click OK to display the Add N2 Device dialog box.
15F16F17FDefining a VAV
Control Device
Object in
Metasys
Software

14 VAV Controller—Variable Air Volume Controller
n2dv
c
OK
CANC
EL
Har d ware -- A dd N2 Device
D e vi ce T ype
A HU
D
600
DCM
DR 9100
DX9100
I FC -2020
LCD
VAV
Figure 4: Add N2 Device Dialog Box
6. Highlight VAV.
7. Click OK to display the VAV Definition window (52HFigure 5).
F l oo r 1
S y s t em Name
Ob
j ec t Name
E x panded I D
NC
Name
G r aph i c S y mbo l #
Ope
r a ti ng I n s t r . #
Towe
r _ I
He l p
I t em E d it V i e w A c ti on G o To Accessory
Ha
r
dwa
r
e
N2 T r unk Numbe r
N2 De v i ce Add
r
es s
Po ll P r i o r it y
1
1
1
0
3
F l ag s
Au t o D i a l ou t
N
Comm D i sab l ed
N
Ha r dwa r e
NC #5
Bookma
r
k
windob
j
VAV Definition
Figure 5: VAV Control Device Object Definition Window
Note that some of the fields in the window are blank and some are already
filled in. You must fill in the blank attribute fields of required attributes.
An N2 device address from 1 to 255 must also be specified. Attribute
fields that are already filled in contain default values that may be accepted
or changed.

VAV Controller—Variable Air Volume (VAV) Controller 15
Table 2 explains the blank attributes. The Operator Workstation User’s
Manual (FAN 634) describes the general procedures for entering and
modifying data.
Table 2: Blank VAV Object Attributes
Attribute Description Entry Values . . .
Object Name Identifies the object
(i.e., ILC). The object name
cannot be duplicated in the
system.
1 to 8 alphanumeric
characters
Expanded ID Further identifies the object
(i.e., LC Device 1) 0 to 24 alphanumeric characters
(Optional)
8. To save the new VAV object, select Save from the Item pull-down
menu. The object is added to the NCM data base.
9. Upload the NCM to make an archive copy of the new object following
the instructions in the Operator Workstation User’s Manual (FAN
634), the Advanced User’s Guide tab, the Uploading and Downloading
Data Bases chapter, the Uploading from the NCM section.
Once you have defined the VAV object, you can modify or monitor its
attribute values online using the VAV object Focus window. See the
Operator Workstation User’s Manual (FAN 634) for more information on
using Focus windows.
Modifying and
Monitoring the
VAV Object

16 VAV Controller—Variable Air Volume Controller

VAV Controller—Variable Air Volume (VAV) Controller 17
18F19F20FInstallation Procedures
Instructions for the installation of the VAV Controller and its accessory
devices are detailed in this section. The types and numbers of components
(sensors and actuators) selected for use with the VAV vary according to
application. Analyze the proposed installation for logical places to locate
these devices and draw up an inventory based on that study. Information
on types of accessory devices available is in the Ordering Information
section of this technical bulletin.
Most VAV installation should be coordinated with the VAV box
manufacturer for factory mounting. The OEM Reference Manual
(FAN 638) describes the steps and pricing to coordinate a factory mount
solution.
Tools needed for a typical installation include:
HVAC PRO for Windows currently released software
IBMPC-compatible laptop computer
Windows3.x or Windows 95
two screwdrivers (1/8 in. and 1/4 in. flat-blade)
AS-CBLPRO-2 (Zone Bus communication tool)
MM-CVT101-0 (N2 Bus communication tool)
AS-ZTU100-1 (Zone Bus interface to application specific controllers)
The installation site of the VAV Controller must meet the following
environmental standards.
The atmosphere must be free of explosive vapors or escaping gases.
The atmosphere must be free of exposure to corrosive chemical or salt
vapors, which might damage electrical equipment.
The temperature must be maintained between 32 to 122F (0 to 50C)
with the relative humidity (non-condensing) maintained between 10 and
90%.
The power line must be “clean,” without electrical noise transients that
are often present in industrial environments. Commercial and
residential buildings typically have clean power, but may not, depending
on the location, nearby equipment, etc. Follow the power line wiring
transient noise precautions.
Tools Needed
21F22F23FEnvironmental
Information

18 VAV Controller—Variable Air Volume Controller
Typically the most cost effective and highest quality installation of the
VAV Controller, EDA-2040 Damper Operator, and DPT-2015 Velocity
Pressure Transducer can be accomplished by the box manufacturer. The
OEM Reference Manual (FAN 638) describes the relationship, pricing, and
process to accomplish factory mounting of the VAV control system at most
of the key box manufacturers.
If the job cannot be factory mounted, check with the VAV box
manufacturer to determine if a control enclosure for the VAV Controller
and Actuator/Velocity Pressure Transducer combination is already
available on the VAV box. If there is not an available enclosure, the
common packaging for the VAV Controller is an enclosure provided by the
contractor or the Johnson Controls EN-EWC10, EN-EWC15, BZ1000, or
AS-ENC enclosure. The controller requires a flat mounting surface area to
match its dimensions:
 6.5 x 6.4 x 2.2 in./165 x 163 x 56 mm (H x W x D) without enclosure
 6.8 x 7.3 x 4.7 in./173 x 185 x 119 mm (H x W x D) with the
AS-ENC100-0 enclosure
 7 x 13 x 6 in./180 x 330 x 150 mm (H x W x D) with the
EN-EWC10-0 and EN-EWC15-0 enclosure
Make sure you allow enough room to install the enclosure and conduit for
wiring terminations to the controller. 53HFigure 7 shows a common packaging
configuration for the VAV Controller.
24F25F26FMounting the
Controller
Factory Mounting

VAV Controller—Variable Air Volume (VAV) Controller 19
vavpwer
TM
+15VDC
24VAC
+15VDC
24VAC
COMMON
COMMON
TRACS
COMMON
COMMON
COMMON
Low Voltage
Wiring Trough
Figure 6: EWC10 Enclosure with VAV Controller
and 50 VA Transformer
The VAV can be directly mounted into an EWC10/15 enclosure. You may
also purchase the VAV premounted in a EWC10 enclosure with a
50 VA transformer. Refer to the Application Specific Controllers
Technical Manual (FAN 636.3) for instructions on mounting the enclosure
to a wall.
To mount the VAV in the EWC10:
1. Orient the VAV so that its terminals face the low voltage wiring
trough (Figure 6).
2. Align the three mounting holes in the base of the controller with the
holes in the back of the enclosure. On the side with four mounting
holes, use the two outside holes for mounting in the EWC. See the
Universal Packaging Module Technical Bulletin (FAN 636.3) for a
more detailed explanation.
3. Secure the controller with three No. 8 x 1 in. screws. For best results,
use a plastite-type thread. A thread-forming or sheet metal thread type
may also be used.
Position the controller (or controller’s enclosure) on the mounting surface
before installation to ensure the calculated mounting area is correct. You
can make precise measurements for distance between controller terminals
and sensor/actuator mounting points on the VAV terminal. Confirm
electrical power source and conduit requirements prior to mounting.
Mounting the
VAV into a
Universal
Packaging
Module
Field Mounting

20 VAV Controller—Variable Air Volume Controller
You can install a VAV Controller into a control panel or an AS-ENC100-0
enclosure.
Top / Bottom
Side
VAV Enclosure
(
Cover
)
VAV Controller
Do not use this knockout.
Otherwise, controller will
be in the way of wiring.
vavencl2
2
3
31
4
5
Figure 7: Installing the VAV Controller in an Enclosure Kit
Mount the VAV in any convenient location using the predrilled mounting
holes. The controller must be mounted on a wall or panel where it can be
easily wired through the enclosure cover. Mount the VAV vertically for
best DPT (differential pressure transmitter) performance. The same
instruction applies to remote location packages. Refer to 54HFigure 7 when
installing a VAV Controller.
1. Secure the VAV inside the enclosure kit , using three screws
through the mounting tabs on the sides of the controller board base.
2. Position the VAV and enclosure so that it rests firmly against the
mounting surface.
3. Using a flat-blade screwdriver and pliers, remove the necessary wire
passage knockouts .
Note: Do not use knockouts on the opposite sides of enclosure, as you
will not be able to remove the VAV board.
4. Attach the enclosure cover after installing wiring.