Orion Control Systems OE742-32-VAVZ User manual

Non-Modular
VAV/Zone Controller
Actuator Package
www.orioncontrols.com

Table of Contents
WattMaster Controls, Inc.
8500 NW River Park Drive, Parkville, MO 64152
Toll Free Phone: [phone]
PH: [phone] · FAX: [phone]
E-mail: [e-mail]
Controller Features.......................................................................................................................................... 3
Overview ......................................................................................................................................................................................3
Features .......................................................................................................................................................................................3
Non-Modular VAV/Zone Controller Actuator Package Dim. - P.D. ................................................................... 4
Non-Modular VAV/Zone Controller Actuator Pkg. - P.I. ................................................................................... 5
Non-Modular VAV/Zone Controller Actuator Package Components............................................................... 6
Zone Controller Expansion Module Dimensions and Components................................................................. 7
Inputs and Outputs .......................................................................................................................................... 8
VAV/Zone Controller Analog Inputs ..............................................................................................................................................8
Other Controller Connections.......................................................................................................................................................8
OE325-01 Zone Controller Expansion Module.............................................................................................................................8
Controller Installation & Wiring ...................................................................................................................... 9
General.........................................................................................................................................................................................9
Controller Mounting......................................................................................................................................................................9
Important Wiring Considerations..................................................................................................................................................9
Zone Controller Actuator Package Wiring .................................................................................................... 10
Wiring Considerations ................................................................................................................................................................10
Zone Controller Expansion Module Wiring.................................................................................................... 11
Expansion Board & Communications Wiring ................................................................................................ 14
Non-Modular Devices Transformer Sizing ..................................................................................................... 15
Slaved Zone Damper Wiring .......................................................................................................................... 16
Slaved Zone Damper Wiring ......................................................................................................................................................16
Addressing & Powering Up............................................................................................................................ 17
General.......................................................................................................................................................................................17
Controller Addressing.................................................................................................................................................................17
Power Wiring .............................................................................................................................................................................17
Initialization and Programming ..................................................................................................................... 18
Initialization.................................................................................................................................................................................18
Programming the Controller .......................................................................................................................................................18
VAV/Zone Conguration................................................................................................................................. 19
VAV/Zone Conguration & Setup ...............................................................................................................................................19
Scheduling and Operation Modes.................................................................................................................. 20
Scheduling..................................................................................................................................................................................20
Modes of Operation....................................................................................................................................................................20
Damper Positions.......................................................................................................................................................................21
Occupied Mode Sequences .......................................................................................................................................................21
Damper Positions and Occupied Mode Sequences ...................................................................................... 21
Unoccupied Mode Sequences ....................................................................................................................... 23
Damper Control..........................................................................................................................................................................25
Tenant Override Logs.................................................................................................................................................................25
Damper Control and Tenant Override Logs................................................................................................... 25
Zone Polling & Voting and Alarm Detection & Reporting ............................................................................ 26
Zoning ........................................................................................................................................................................................26
Alarm Detection and Reporting ..................................................................................................................................................26
Internal Trend Logging ...............................................................................................................................................................27
Force Modes or Overrides..........................................................................................................................................................27
Internal Trend Logging & Force Modes ........................................................................................................ 27
LED Troubleshooting ..................................................................................................................................... 28
Using LEDs To Verify Operation.................................................................................................................................................28
Other Checks .............................................................................................................................................................................29
Diagnostics .................................................................................................................................................... 29
Temperature Sensor Testing ......................................................................................................................... 30
Modular and Digital Room Sensor Testing .................................................................................................... 31
Visit our web site at www.orioncontrols.com
Form: OR-NMZCAP-TGD-01D Copyright 2015 WattMaster Controls, Inc.
AAONis a registered trademark of AAON, Inc., Tulsa, OK.
WattMaster Controls, Inc. assumes no responsibility for errors or omissions.
This document is subject to change without notice.

Overview
Modular & Non-Modular VAV/Zone Controllers
There are two variations of the VAV/Zone Controller Actuator Packages.
One is referred to as the Modular VAV/Zone Controller Actuator Pack-
age and the other as the Non-Modular VAV/Zone Controller Actuator
Package. This manual is written for the Non-ModularActuator Package.
If you have the Modular Actuator Package you will need to refer to the
Modular VAV/Zone Controller Actuator Package Technical Guide, Form
No: OR-MZCAP-TGD. Below is information regarding the differences
between the Modular & Non-Modular products.
Modular VAV/Zone Controller Act. Pkg.
The Modular VAV/Zone Controller Actuator Packages utilize modular
connectors on the VAV/Zone Controller board which connect to a Power/
Comm Board via pre-fabricated cables that have mating modular con-
nectors to provide power & communications to the VAV/Zone Controller
Actuator Package. The following Orion products use this type of com-
munications & power wiring architecture.
OE742-31-VAVZ VAV/Zone Controller
Actuator Package - Pressure Dependent
OE744-31-VAVZ VAV/Zone Controller Actuator Package
Pressure Independent
OE520-XX VAV/Zone Round Damper
Assembly - Pressure Dependent
OE521-XX VAV/Zone Round Damper Assembly
Pressure Independent
OE736-01 VAV/Zone Rectangular Damper Kit
Non-Modular VAV/Zone Controller
The Non-Modular VAV/Zone Controller Actuator Packages all utilize
wiring terminals instead of modular connectors on the VAV/Zone Con-
troller board. The 24 VAC power is supplied from a transformer wired
to the VAV/Zone Controller using standard stranded wire and 2 pole
terminal blocks. The communications wiring is connected between the
other VAV/Zone Controllers, CommLink, MiniLink, HVAC unit control-
ler or other controllers on the local loop by using 2 conductor twisted
pair with shield wire which is connected to the VAV/Zone controllers
via a standard 3 pole terminal block. The following Orion products use
this type of communications & power wiring architecture.
OE742-32-VAVZ N.M. VAV/Zone Controller
Actuator Package - Pressure Dependent
OE744-32-VAVZ N.M. VAV/Zone Controller
Actuator Package
Pressure Independent
OE520N-XX N.M. VAV/Zone Round Damper
Assembly - Pressure Dependent
OE521N-XX N.M. .VAV/Zone Round Damper
Assembly - Pressure Independent
OE736N-01 N.M VAV/Zone Rectangular Damper
Kit
Controller Features
Features
Non-Modular VAV/Zone Controller Act. Pkg.
The Non-Modular VAV/Zone Controller Actuator Package is used for
controlling airow and operation of VAV or Zoning terminal units. The
package contains the VAV/Zone Controller and Actuator mounted and
housed in a plastic enclosure. The VAV/Zone Controller is a program-
mable digital controller which allows for program setpoints to be stored
in non-volatile memory. The controller is connected to a room sensor
via a modular cable assembly which monitors space temperature al-
lowing the VAV/Zone Controller to modulate a damper in response to
space temperature, duct temperature, and airow requirements in the
controlled space.
The Non-Modular VAV/Zone Controller Actuator Package has four
integral modular jacks for connection to the actuator, the airow sen-
sor (for pressure independent applications), the room sensor, and the
VAV/Zone Controller Expansion Module via modular cables. Wire
terminal connections are provided for the 24 VDC power and system
communications. A quick connect terminal connector is also supplied
for connection of the Modular Service Tool to facilitate programming
of the controller. The controller has an on-board dip switch provided
for board addressing.
The VAV/Zone Controller is provided with two relays for tri-state control
of the damper actuator. All outputs and the relay common are electri-
cally isolated from all other circuitry on the board. All relay outputs are
supplied with transient suppression devices across each set of contacts
to reduce EMI and arcing. The relay output contacts are rated for pilot
duty control of a maximum of 1 Amps @ 24 VAC or 24 VDC. The
actuator connects via a modular cable to the board and provides the
VAV/Zone Controller with feedback monitoring for precise positioning
of the actuator.
OE325-01 Zone Controller Expansion Module
The OE325-01 Zone Controller Expansion Module is used in conjunction
with the Non-Modular VAV/Zone Controller Actuator Package to allow
for control of VAV and Zone terminal units, including series and parallel
fan terminal units with 1, 2 or 3 stages of electric heat, modulating hot
water heat, 2 position hot water heat, SCR electric heat, and/or auxiliary
heat devices.
The OE325-01 Zone Controller Expansion Module connects to the
VAV/Zone Controller board by means of a modular cable provided with
the expansion module. Power is supplied to the board by means of this
modular cable. Screw terminals are provided for connection of eld
wiring to the relay and analog outputs.
The relay outputs are N.O. contacts with one common terminal. All
outputs and the relay common are electrically isolated from all other
circuitry on the board. All relay outputs are supplied with transient
suppression devices across each set of contacts to reduce EMI and arcing.
The relay output contacts are rated for pilot duty control of a maximum
of 1 Amps @ 24 VAC or 24 VDC. The analog output provides a 0-10
VDC modulating signal output into a 1K Ohm minimum load.
3
Non-Modular ZCAP Technical Guide
Overview

Figure 1: OE742-32-VAVZ Non-Modular VAV/Zone Controller Actuator Package Dimensions - P.D.
Non-Modular VAV/Zone Controller Actuator Package Dim. - P.D.
4
Non-Modular ZCAP Technical Guide
Overview

Non-Modular VAV/Zone Controller Actuator Pkg. - P.I.
Figure 2: OE744-32-VAVZ Non-Modular VAV/Zone Controller Actuator Package Dimensions - P.I.
5
Non-Modular ZCAP Technical Guide
Overview

Figure 3: OE742-32 Pressure Dependent Non-Modular VAV/Zone Controller Actuator Pkg. Components
Non-Modular VAV/Zone Controller Actuator Package Components
Figure 4: OE744-32 Pressure Independent Non-Modular VAV/Zone Controller Actuator Pkg. Components
6
Non-Modular ZCAP Technical Guide
Overview

Figure 5: OE325-01 Zone Controller Expansion Module Dimensions
Figure 6: OE325-01 Zone Controller Expansion Module Components
Zone Controller Expansion Module Dimensions and Components
7
Non-Modular ZCAP Technical Guide
Overview

The following inputs and outputs are available on the VAV/Zone
Controller and the OE325-01 Zone Controller Expansion Module. For
component locations of the inputs on the VAV/Zone Controller and VAV
Zone Controller Expansion Module see Figures 3, 4, and 6. For wiring
of inputs and outputs, see Figures 7 through 13.
VAV/Zone Controller Analog Inputs
Space Temperature
The Modular Room Sensor that reads space temperature is attached
to this input. The Modular Sensor connects via a modular cable to the
Non-Modular VAV/Zone Controller Actuator Package.
Airow Sensor
If the OE744-32-VAVZ Non-Modular VAV/Zone Controller Actuator
Package is being used, the terminal unit’s pressure pick-up tube must be
connected with FRP tubing to the barb ttings on the side of the enclo-
sure. This pressure sensor input is used for CFM (airow) calculations.
If an Airow Sensor is attached to this input, the VAV/Zone Controller
will automatically detect this and switch to pressure independent opera-
tion. If the sensor is not attached or becomes defective, the controller
automatically reverts to pressure dependent operation.
Supply Air Temperature Sensor
A Supply Air Temperature Sensor can be connected to these terminals. It
should be mounted in the supply duct close to the terminal unit where the
VAV/Zone Controller is installed. This sensor can be used for monitor-
ing purposes or in place of the Supply Air Temperature Broadcast from
the VCM-X Controller.
Other Controller Connections
Expansion Board Modular Connector
This modular connector is used to connect the optional OE325-01 Zone
Controller Expansion Module to the Non-Modular VAV/Zone Controller
Actuator Package. This module is only required when electric or hot
water heating and/or fan terminal control is required. The Expansion
Module is not required for cooling only terminal units.
Actuator Modular Connector
This modular connector is used to connect a modular cable from the
VAV/Zone Controller to a tri-state actuator.
24 VAC Power Terminal Block
This two pole terminal block is used to wire the 24 Volt power to the
Non-Modular VAV/Zone Controller Actuator Packages If desired a
single transformer can be used to power multiple VAV/Zone Controller
Actuator Packages together, or a separate transformer can be used for
each controller.
Warning: If multiple controllers are to be wired to the same
transformer, polarity must be observed or damage
to the controller will result.
Communications Terminal Block
This three pole terminal block is used for connecting the communica-
tions wiring between each Non-Modular VAV/Zone Controller Actuator
Package and/or to the MiniLink Polling Device, CommLink, HVAC
Unit Controller or other controller on the local communications loop.
Communications wiring should be 18 gauge 2 conductor twisted pair
with shield Belden #82760 or its equivalent.
Modular Service Tool DIN Connector
This connector is used to connect a cable between the Modular Service
Tool or the USB-Link and the Non-Modular VAV/Zone Controller
Actuator Package for programing and conguration of the VAV/Zone
Controller.
OE325-01 Zone Controller Expansion
Module
As previously stated, when control of a fan or if heating is required, the
OE325-01 Zone Controller Expansion Module is required.
Relay Output #1 - Fan Enable
The rst expansion relay on the Output Expansion boards is used for
energizing the fan on Series or Parallel Fan Terminal Units.
Relay Output #2 - Heating Stage 1
If you have at least one stage of heating, this is the relay used to energize
the 1st stage of terminal unit heating. This heating stage can either be
used with electric heat or On/Off hot water valve control.
Relay Output #3 - Heating Stage 2
If you have two stages of electric heating, this relay controls the 2nd
stage of electric heat. For 3 stage heating, this relay output would be
energized for both the 2nd and 3rd stage of heat. See the following
paragraph for more information regarding 3 stage heating applications.
3 Stage Heating Applications
If three stages of electric heat are congured, relays #2 and #3 will stage
in a staggered sequence. This allows you to achieve 3 stages of heating
using only relays #2 and #3. Each of the 3 heating elements should be
sized for one third of the total KW output required. Both the 2nd and 3rd
stage heating contactors (C2 & C3) must be connected to Relay Output
#3. See Table 1 below for relay sequencing information.
Relay Staging
Stage No. Relay Output #2 Relay Output #3
1 VAV/Zone Controller
Package ON (C1)
OFF (C2 & C3)
2 OFF (C1) ON (C2 & C3)
3 ON (C1) ON (C2 & C3)
Table 1: Relay Sequencing For 3 Stage Heating
Auxiliary Heat Relay
If you have an auxiliary heat source you would like to control in addition
to or in lieu of the other heat options, you can connect it to relay R4 on
the expansion module. This relay has a separate setpoint available for
controlling an electric baseboard or duct heater or a two position hot
water valve for a baseboard radiator or duct heater.
Analog Output
If you are using hot water or steam heating via a modulating steam
or hot water valve, this output can supply a 0-10 Volts DC signal for
proportional control of the valve.
Inputs and Outputs
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Non-Modular ZCAP Technical Guide
Overview

Controller Installation & Wiring
General
Correct wiring of the VAV/Zone Controller is the most important factor
in the overall success of the controller installation process. The VAV/
Zone Controller wiring has been simplied by the use of modular con-
nectors and prefabricated modular cables.
Controller Mounting
If you purchased the Round Zone Damper or Rectangular Zone Damper
Kits from WattMaster, the controller and actuator are factory mounted
and wired in the damper control enclosure. If your VAV/Zone Control-
lers are pressure independent, an airow probe and pressure sensor will
also be factory mounted and wired.
Most terminal unit manufacturers will offer the option of factory mount-
ing the Orion controls in their terminal units for an additional charge.
An installation worksheet and instructions are available for the Orion
VAV/Zone Controller package which can be shipped with the VAV/Zone
control(s) to the terminal unit manufacturer to simplify factory mounting
and wiring of the controller.
When the Non-Modular VAV/Zone Controller Actuator Package is to be
eld mounted, it is important to mount it in a location that is free from
extreme high or low temperatures, moisture, dust, and dirt.
1. Leave the enclosure cover on the Non-Modular VAV/Zone
Controller Actuator Package circuit board during installation
to protect the circuit board from damage. The damper actuator
is factory mounted for what we refer to as right-hand terminal
unit mounting. This assumes you are standing downstream of
the terminal unit with air hitting you in the face. The side of the
unit towards your right arm would be the right side of the unit
and where the standard conguration Zone Controller Actuator
Package would be mounted over the damper shaft. If you have a
left-hand terminal unit, the actuator will need to be rotated 180
degrees within the plastic enclosure and the enclosure assembly
ipped over to mount over the damper shaft on the left side of
the terminal unit. The enclosure base is designed with the appro-
priate holes and cutouts to allow for these two mounting options.
A left-hand label is also included with the actuator and can be
applied over the right-hand label for left-hand control locations
when desired.
2. If you need to rotate the damper actuator from its factory
supplied position, rst unplug the actuator cable from the actua-
tor, then remove the (3) screws on the back side of the enclosure
base that secure the actuator to the enclosure’s base. Rotate
the actuator 180 degrees and re-install the (3) screws you just
removed into the mating holes on the enclosure base and tighten
them to secure the actuator to the base.
3. Turn the enclosure base/actuator assembly back over to its
original mounting position so the actuator is facing up. All instal-
lation instructions are based on the damper moving clockwise to
open (see the note below if your damper requires counterclock-
wise-to-open rotation). Check the damper for proper rotation and
mark the end of the damper shaft to indicate open and closed
positions. Loosen the (2) shaft mounting bracket nuts on the
ends of the universal mounting clamp enough to slide the entire
actuator and plastic enclosure assembly over the terminal unit
damper shaft. Rotate the enclosure base/actuator assembly until
it is approximately level and perpendicular with the terminal
unit mounting surface or enclosure side walls. Use the included
self-tapping mounting screw to secure the enclosure base to the
terminal unit sheet metal or terminal unit control enclosure sur-
face. This is done by inserting the screw through the anti-rotation
bushing, centering it and the bushing in the mounting slot, and
using a battery powered drill to tighten it until the screw head
is ush with the top surface of the anti-rotation bushing. Do not
over tighten the screw!
4. Turn the damper blade to its fully closed position. With the man-
ual override clutch button depressed, rotate the actuator clamp
to within approximately 1/16 in. to ⅛ in. of the distance between
the actuator stop and the clamp. This varies depending on the
damper seal design and thickness. Finger-tighten the universal
clamp mounting nuts. Then tighten the two nuts again with an
8 millimeter wrench to approximately 3-5 ft./lb. of torque. On
dampers with edge seals, the actuator will compress the damper
blade seal when reaching the end position. Adjust the end stops,
if required. Re-attach the actuator cable removed in step #1 to
the actuator.
Note: If the damper on the terminal unit cannot be installed for
clockwise-to-open operation, the Non-Modular VAV/
Zone Controller Actuator Package can be congured for
counterclockwise-to-open operation via the operator in-
terface or through the Prism software program. It must be
changed prior to system start-up for the designated units
for the zone damper to function properly. See page 19
of this manual for detailed, reverse acting conguration
information. Installation for reverse acting congurations
is the same as for clockwise-to-open units except all refer-
ences to clockwise will now be in the counter-clockwise
direction.
Important Wiring Considerations
Please carefully read and apply the following information when wiring
the Non-Modular VAV/Zone Controller Actuator Package. See Figure
7for Non-Modular VAV/Zone Controller Actuator Package wiring and
connections. See Figure 14 for connecting and wiring multiple Non-
Modular VAV/Zone Controller Actuator Packages in a system.
1. Size and wire the transformer to be used for powering the Non-
Modular VAV/Zone Controller Actuator Package(s) per the
instructions. Failure to size the transformer and/or wire the Non-
Modular VAV/Zone Controller Actuator Package(s) correctly
may cause the VAV/Zone Controller Actuator Package to operate
erratically or not at all. See Figure 15 for wiring and transformer
sizing information.
2. If a Supply Air Temperature Sensor is to be connected, the
minimum wire size used should be 24 gauge.
3. Do not pry on the connectors when connecting or
disconnecting the modular cables. Be sure to push in on the
connector release clip and then pull straight up.
4. Communications wiring should be 18 gauge 2 conductor twisted
pair with shield Belden #82760 or its equivalent. This type of
wire is available form WattMaster.
9
Non-Modular ZCAP Technical Guide
Installation & Wiring

Zone Controller Actuator Package Wiring
Figure 7: Non-Modular VAV/Zone Controller Actuator Package Wiring
Wiring Considerations
The OE325-01 Zone Controller Expansion Module connects to the
Non-Modular VAV/Zone Controller Actuator Package by means of a
modular cable provided with the expansion module. Power is supplied
to the Zone Controller Expansion Module by means of this modular
cable. Screw terminals are provided for connection of eld wiring to
the relay and analog outputs. The Expansion Module is used to supply
extra relays and/or analog outputs to control fan and heating functions
for the Non-Modular VAV/Zone Controller Actuator Package.
The OE325-01 Zone Controller Expansion Module is always shipped
loose for eld mounting by others. Be careful not to damage the elec-
tronic components when mounting the controller. Remove the controller
from its snap track mount. Mark the control enclosure base using the snap
track as a template. Drill pilot holes in the enclosure base and secure the
snap track to it using sheet metal screws. Do not allow metal shavings to
fall onto the circuit board. Re-attach the controller to the snap track. Be
sure the mounting location is close enough to the Non-Modular VAV/
Zone Controller Actuator Package so that the supplied modular cable
will reach from it to the Zone Controller Expansion Module.
Warning: The 3 relay outputs available on the OE325-01
Expansion Module are each rated for 1 Amp. @ 24
VAC. If your device load exceeds these limits, a
pilot duty relay (by others) must be used in the
circuit.
The wiring consideration information previously outlined for the Non-
Modular VAV/Zone Controller Actuator Package should be followed
when wiring the OE325-01 Zone Controller Expansion Module.
10
Non-Modular ZCAP Technical Guide
Installation & Wiring

Zone Controller Expansion Module Wiring
Figure 8: Zone Controller Expansion Module Wiring - Fan Terminals And/Or Staged Electric Heat
11
Non-Modular ZCAP Technical Guide
Installation & Wiring

Zone Controller Expansion Module Wiring
Figure 10: Zone Controller Expansion Module Wiring - Fan Terminals And/Or 2 Position HW Heat
Figure 9: Zone Controller Expansion Module Wiring - Fan Terminals And/Or Modulating Hot Water Heat
12
Non-Modular ZCAP Technical Guide
Installation & Wiring

Zone Controller Expansion Module Wiring
Figure 12: Zone Controller Expansion Module Wiring - Fan Terminals And/Or Auxiliary Electric Heat
Figure 11: Zone Controller Expansion Module Wiring - Fan Terminals And/Or SCR Electric Heat
13
Non-Modular ZCAP Technical Guide
Installation & Wiring

Expansion Board & Communications Wiring
Figure 13: Zone Controller Expansion Module Wiring - Fan Terminals And/Or Auxiliary 2 Position HW Heat
Figure 14: Communication & Power Wiring Diagram
14
Non-Modular ZCAP Technical Guide
Installation & Wiring

Non-Modular Devices Transformer Sizing
Figure 15: Non-Modular VAV/Zone Controller Actuator Package Transformer Sizing
15
Non-Modular ZCAP Technical Guide
Installation & Wiring

Slaved Zone Damper Wiring
For large zones, it may be necessary to have more than one air damper
controlled by a Non-Modular VAV/Zone Controller Actuator Package
and its associated space sensor. The Orion system allows for connecting
up to two additional slaved zone dampers to the master Non-Modular
VAV/Zone Controller Actuator Package. Slaving is not available for
pressure independent damper applications.
Note: Each slaved actuator is considered a modular device
rated at 6 VA each. This 6 VA load must be included in
the transformer sizing and branch circuit calculations
for the Power/Comm board. See the previous section
regarding transformer sizing of the Power/Comm board
for complete information.
Two Slave Wiring Adapters (OE267) consisting of a slave wiring inter-
face card and modular cable are supplied with the OE523 Round Slaved
Zone Damper, OE738 Slaved VAV/Zone Rectangular Damper Kit, and
the OE282-03 Slaved VAV/Zone Damper Kit. These are required when
attaching slave actuator(s) to the master zone damper. One slave wiring
interface card should be mounted near the control enclosure of the master
Non-Modular VAV/Zone Controller Actuator Package. It is mounted by
fastening the plastic snap-track to suitable sheet metal mounting surface
with the sheet metal screws provided. The other card is mounted in the
control enclosure of the slaved zone damper. Run 24 AWG minimum
wire between the slave wiring interface cards. Connect modular cables
to the slave wiring interface cards and to the zone actuators as shown.
See Figure 16 for complete wiring details.
Figure 16: Slaved Zone Damper Wiring & Connection Diagram
Slaved Zone Damper Wiring
16
Non-Modular ZCAP Technical Guide
Installation & Wiring

Addressing & Powering Up
Figure 17: Address Switch Setting
General
In order to have a trouble free start-up, it is important to follow a few
simple procedures. Before applying power for the rst time, it is very
important to correctly address the controller and run through a few
simple checks.
Controller Addressing
All Non-Modular VAV/Zone Controller Actuator Packages are equipped
with address switches. If the Non-Modular VAV/Zone Controller Actua-
tor Package is to operate as a Stand Alone controller (not connected to
any other HVAC unit or VAV/Zone Controller(s)), the controller address
switch should be set for address 1. When the Non-Modular VAV/Zone
Controller Actuator Package is to be connected to other Non-Modular
VAV/Zone Controller Actuator Packages on a communication loop, each
Non-Modular VAV/Zone Controller Actuator Package’s address switch
must be set with a unique address between 1 and 58.
When programming the Non-Modular VAV/Zone Controller Actuator
Package on a Stand Alone or Interconnected System and you are asked
to enter the Unit ID, you would enter the address for the controller you
wish to program. When programming the Non-Modular VAV/Zone
Controller Actuator Package on a Networked System and you are asked
to enter the Unit ID, you would rst enter the MiniLink PD loop address
for the loop the Non-Modular VAV/Zone Controller Actuator Package
is connected to and then enter the Non-Modular VAV/Zone Controller
Actuator Package’s address. See Figure 17 for a diagram depicting
address switch settings.
For detailed information regarding communication wiring and connec-
tion for Interconnected and Networked systems, please see the Orion
System Installation & Troubleshooting Guide.
Power Wiring
One of the most important checks to make before powering up the system
for the rst time is to conrm proper voltage and transformer sizing for
the Power/Comm board that is connected to it. Each Non-Modular VAV/
Zone Controller Actuator Package requires 6 VA of power delivered
to it at 24 VAC. See page 15 of this manual for complete wiring and
transformer sizing information for the VAV/Zone Controller.
Check all modular connectors to be sure they are completely pushed and
locked into their mating connectors. Conrm that all sensors required for
your system are mounted in the appropriate location and that the modu-
lar cables are plugged into the correct connectors on the Non-Modular
VAV/Zone Controller Actuator Package. Check the actuator cable and
be sure it is plugged in and secured to the modular connector on the
actuator and the Non-Modular VAV/Zone Controller Actuator Package
circuit board modular connector. Check that the Modular Room Sensor
modular connector is connected to one end of the modular sensor cable
and the other end is connected to the modular sensor connector on the
VAV/Zone ControllerActuator Package. Be sure any Expansion Modules
connected to the Non-Modular VAV/Zone Controller Actuator Packages
are also correctly wired per the Expansion Module wiring instructions
on pages 10 through 14 of this manual.
After all the above wiring checks are complete, apply power to the
transformer(s) that is connected to the Non-Modular VAV/Zone Con-
troller Actuator Packages.
17
Non-Modular ZCAP Technical Guide
Start-Up & Commissioning

Initialization and Programming
Figure 18: Operator Interfaces
Initialization
On system power-up, the “STAT” LED is extinguished for a few seconds
and then the controller “ashes” its address switch setting. If the address
switch were set to 7, you would see 7 ashes. After the address is n-
ished, the LED will extinguish for another 5 seconds. At the conclusion
of this 5-second delay, the LED will begin a continuous ashing while
the Damper Feedback limits are calibrated. If the Damper is driving
open, the LED will blink slowly. If the Damper is driving closed, the
LED will blink fast. When the calibration is completed, the normal di-
agnostic ashes will begin. These diagnostic ashes are described in the
Troubleshooting section of this guide. In addition, during the rst few
seconds of power-up, all default setpoints are initialized and all outputs
are turned off. There is also a 30 second start-up delay to protect the
fan and other components from short cycling during intermittent power
conditions. If all inputs are operating correctly, the LED will blink once
every ten seconds.
Programming the Controller
The next step is programming the controller for your specic require-
ments. In order to congure and program the Non-Modular VAV/Zone
Controller Actuator Package, you must have a central operator interface
or a personal computer with the Prism computer front end software
installed. Different operator interfaces are available for programming
of the VAV/Zone Controller. You may use the Modular Service Tool,
Modular System Manager, Tactio SI Touch Screen, System Manager
TS, or a personal computer with Prism software installed to access the
status and setpoints of any Non-Modular VAV/Zone Controller Actuator
Package or VCM-X controller on the system’s communications loop.
See the Modular Service Tool and System Manager Operator Interface
Technical Guide, the System Manager TS Technical Guide, or the Prism
Computer Front-End Technical Guide for complete VAV/Zone Controller
programming information. No matter which operator interface you use,
it is recommended that you proceed with the programming and setup of
the controller in the order that follows:
1. Congure The Controller For Your Application.
2. Program The Controller Setpoints.
3. Review Controller Status Screens To Verify System
Operation And Correct Controller Congurations
18
Non-Modular ZCAP Technical Guide
Start-Up & Commissioning

VAV/Zone Conguration & Setup
There are a few conguration selections available which can be used
to tailor the software operation to match the mechanical equipment the
controller is installed on. These are programmed using either the Modular
System Manager, the Modular Service Tool, the System Manager TS, or
a personal computer with Prism computer front end software installed
on it. See the Modular Service Tool and System Manager Operator
Interface Technical Guide, the System Manager TS Technical Guide,
or the Prism Computer Front End Technical Guide for complete VAV/
Zone Controller programming information.
General
Several options are available to congure the VAV/Zone Controller for
the appropriate equipment it is installed on. All of these options can be
set from the “Conguration” menu with the exception of “AHU Heat
Call” which is set from the “Setpoints” menu. Again, please refer to the
Operator’s Interface Technical Guide or the Prism Computer Front-End
Technical Guide for detailed programming information.
Box Control Method
Set this conguration item for the type of box the VAV/Zone Controller
is used on. The options available are:
0 = Cooling Only Box (With Reheat if Required)
1 = Heating/Cooling Changeover Box
2 = Series Fan Powered Box With Reheat
3 = Parallel Fan Powered Box With Reheat
Damper Operating Mode
This option sets the direction of rotation the damper moves when driving
towards its full open position. The options available are:
0 = Direct Acting (Clockwise-to-Open Damper)
1 = Reverse Acting (Counterclockwise-to-Open Damper)
Voting Zone
If this particular VAV/Zone Controller is being used on a “Zoning”
system as opposed to a true VAV system, this option must be set to al-
low the MiniLink Polling Device to determine if this controller should
be included in the zoning system voting process. If this is set to “Yes”,
this controller will be included in the voting process. If this is a zoning
system and it is set to “No”, this controller will not vote in the zoning
system voting process. If it is a true “VAV” system, the option should
be set to “No”. The options available are:
0 = Yes
1 = No
Pressure Independent Boxes-Airow @ 1”
W.C.
If this is a pressure independent box, this option allows you to calibrate
the box CFM correctly using the box manufacturer’s “K” factor. Enter
the correct “K” (CFM) factor for the inlet diameter of the box you are
conguring.
Expansion Relays - Steps of Reheat
If the box has reheat supplied by an electric coil, this option must be set
for the number of electric heating stages on the box. If the box has hot
water heat with a 2 position hot water valve, set the number of stages
to “1”. For hot water heat with a proportional hot water valve, this must
be set for “0”. Options available are:
0 = No Staging
1 = 1 Stage of Reheat
2 = 2 Stages of Reheat
3 = 3 Stages of Reheat
Proportional Heating Signal
If the box has hot water reheat using a proportional hot water valve, set
this option to match the voltage signal required by the hot water valve
you are using. Options available are:
0 = 0-10 VDC Voltage Signal
1 = 2-10 VDC Voltage Signal
Allow Box Heat With AHU Heat
If the box you are using has reheat or auxiliary heat, conguring this
setting to 1=Yes will allow the box heat to operate at the same time as
the HVAC unit heat. Options available are:
0 = No
1 = Yes
Main Fan Status
If the VAV/Zone Controller is installed on a non-fan powered box that
has reheat, set this option to “Yes” in order to enable box reheat only
when the HVAC unit fan is running. A full description of how this setting
affects the various box types in the occupied and unoccupied modes is
contained under the “Mode Sequence” heading that follows later in this
manual. Options available are:
0 = No Heat can operate without fan
1 = Yes Heat cannot operate without fan
Push-Button Override Group ID#
During Unoccupied Mode, all VAV/Zone Controllers with a correspond-
ing Group ID# will resume Occupied operation whenever any of the
VAV/Zone Controllers with the same Group ID # has its push-button
depressed to initiate an override condition. This allows you to group
zones in various areas of the building. For example, individual tenants
with several ofces could restore occupied mode for just their zones and
not affect other zones in the building. If you don’t want a specic zone
to be a part of any group, enter a ‘0’ for its Group ID #.
Dump Zone
If this VAV/Zone Controller is to be used as a “Dump Zone”, set this
conguration to 1=Yes. The dump zone is a controller without an
actuator that is used to control a duct heater or auxiliary heat. Options
available are:
0 = No
1 = Yes
AHU Heat Call
This setting is located under the “Setpoints” menu on screen #3. This
is used only for the unoccupied mode. For non-fan powered terminal
units, this temperature setpoint is used to allow auxiliary heat such as
baseboard heaters to be energized in an attempt to satisfy the heating
demand prior to initiating the HVAC unit Supply Air Heating mode.
For fan powered terminal units, this setpoint can be used to operate the
series or parallel box to satisfy the heating demand by using plenum
air and reheat prior to initiating the HVAC Supply Air Heating mode.
During unoccupied mode, when the temperature in the space drops
below the AHU Heat Call setpoint, the VAV/Zone Controller sends a
signal to the VCM-X Controller to initiate the HVAC unit Supply Air
Heating Mode. This setpoint temperature can be set higher or lower than
the Space Heating Setpoint.
VAV/Zone Conguration
19
Non-Modular ZCAP Technical Guide
Sequence of Operations

Scheduling
Occupied/Unoccupied Mode
The VAV/Zone Controller monitors the communications loop for its Oc-
cupied and Unoccupied mode of operation command. Either the VAV/
Zone Controller Package or the GPC Plus can transmit the Occupied
command to the VAV/Zone Controller. This requires the Non-Modular
VAV/Zone Controller Actuator Packages to all be connected to the system
communication loop through their RS-485 connector and to be properly
addressed for the command to be received.
Push-button Override Operation
During unoccupied hours, you can force the VAV/Zone Controller and
VCM-X Controller back to occupied operation by pressing the over-
ride button on the Modular Room Sensor or Digital Room Sensor. The
operation for the push-button override sequence is different depending
on which sensor you are using.
Modular Room Sensor
Pushing the override button for less than 3 seconds initiates the override
which will continue for a 2 hour duration. If during the override period
the button is pressed a second time for less than 3 seconds, an additional
2 hours will be added to the remaining override duration that is left at the
time of pushing the button. If the button is then depressed for more than
3 seconds anytime during the override duration, it cancels the override
and places the unit back into normal unoccupied operation.
Digital Room Sensor
Pushing the override button momentarily initiates the override which
will continue for a 2 hour duration. If during the override period the but-
ton is pressed a second time, it will cancel the override. If it is pressed
again, the override will be initiated again for a 2 hour duration. Every
other time the button is pushed, it cancels the override and places the
unit back into normal unoccupied operation.
Grouping Controllers For Overrides
On larger installations with several terminal units, the VAV/Zone Con-
trollers can be congured into groups so that an override generated by
one VAV/Zone Controller can cause several other controllers to follow
along and return to occupied mode for the programmed duration. Other
VAV/Zone Controllers not in the same group will simply maintain an
unoccupied damper or airow setting as set by the user.
Push-button overrides are broadcast continuously by the initiating VAV/
Zone Controller until the controller itself times out or the override is
cancelled by the user. This broadcast forces the air handler to start its
main fan and provide cooling or heating, if so congured. It will re-
main on until the override broadcast has not been detected for at least
2 consecutive minutes.
Modes of Operation
There are 7 possible modes of operation for the HVAC Unit and the
VAV/Zone Controller. These modes are determined by the supply air
and/or space demand conditions. They are:
• Supply Air Vent Mode
(Based on HVAC Unit SAT)
• Space Vent Mode
(Based on VAV/Zone Controller Space Temp.)
• Supply Air Cooling Mode
(Based on HVAC Unit SAT)
• Space Cooling Mode
(Based on VAV/Zone Controller Space Temp.)
• Supply Air Heating Mode
(Based on HVAC Unit SAT)
• Space Heating Mode
(Based on VAV/Zone Controller Space Temp.)
• Off Mode (Not displayed. See “Denitions of Modes”)
The process of determining each mode is in the following paragraph,
but the actual operation of each mode is explained in the sections that
follows.
Denitions of Modes
VAV & Zone Control Schemes
On all fan-powered and non-fan-powered terminal units, ‘VAV’ or ‘Zon-
ing’ supply air modes and space demands are calculated the same. If
the supply air temperature rises the deadband amount above the space
temperature, the supply air mode is heating. To cancel the supply air
heating mode, the supply air temperature must fall to within 2 °F of the
space temperature. If the supply air falls the deadband amount below the
space temperature, the supply air mode is cooling. To cancel the supply
air cooling mode, the supply air temperature must rise to within 2 °F
of the space temperature. If the supply air is between the heating and
cooling deadband amounts, it is considered vent mode.
Supply Air Vent Mode
This mode occurs when the Supply Air Temperature is within 2.0 °F
of the Space Temperature and stays in this mode until the Supply Air
Temperature is above or below the Space Temperature plus or minus
the Supply Air HVAC Mode Deadband.
Space Vent Mode
This mode occurs when the Space Temperature is between 0.5 °F below
the Cooling Setpoint and 0.5 °F above the Heating Setpoint.
Supply Air Cooling Mode
This mode occurs when the Supply Air Temperature falls to less than the
Space Temperature minus the Supply Air HVAC Deadband.
Space Cooling Mode
This mode occurs when the Space Temperature rises to 0.5 °F below
the Space Cooling Setpoint.
Supply Air Heating Mode
This mode occurs when the Supply Air Temperature rises to a tem-
perature that is greater than the Space Temperature plus the Supply Air
HVAC Deadband.
Space Heating Mode
This mode occurs when the Space Temperature falls to 0.5 °F above the
Space Heating Setpoint.
Scheduling and Operation Modes
20
Non-Modular ZCAP Technical Guide
Sequence of Operations