Phason AutoFlex Connect II User manual

Copyright Phason Inc. Printed in Canada
All rights reserved. 35140000
ii

iii
Table of contents
Chapter 1: Introduction ....................................................................................................... 5
Introducing AutoFlex Connect .................................................................................................................. 5
Features ................................................................................................................................................ 6
Available modules ................................................................................................................................. 7
Chapter 2: Installation ....................................................................................................... 10
What you need to know before installing................................................................................................ 10
Understanding power surges and surge suppression ....................................................................... 10
Reducing electrical noise using filters................................................................................................. 11
Control and module electrical ratings ................................................................................................. 12
Using power contactors to increase the capacity of relays ................................................................ 12
Enclosure dimensions and mounting guidelines................................................................................ 13
Installing modules ............................................................................................................................... 14
AutoFlex layout.................................................................................................................................... 15
AutoFlex Mini layout ............................................................................................................................ 16
Connecting equipment to modules ........................................................................................................ 17
Connecting equipment to ACT-1 and ACT-1V modules..................................................................... 17
Connecting sensors to IN-4 modules ................................................................................................. 19
Connecting equipment to RM-2, RM-2-3PH, and RM-4 modules....................................................... 22
Connecting equipment to VAC-1 modules ......................................................................................... 24
Connecting equipment to VCM-DC modules ..................................................................................... 25
Connecting equipment to VDC-4 modules ......................................................................................... 26
Connecting equipment to Feed Loop Kits .......................................................................................... 27
Connecting an alarm system .............................................................................................................. 28
Connecting the power source............................................................................................................. 29
Finishing the installation.......................................................................................................................... 30
Chapter 4: Overview of AutoFlex Connect ....................................................................... 31
Getting started......................................................................................................................................... 31
Log in................................................................................................................................................... 31
Go through the screens ...................................................................................................................... 31
Configure the network......................................................................................................................... 32
Create users ........................................................................................................................................ 34
Select the AutoFlex type ..................................................................................................................... 34
Select the units of measure................................................................................................................. 35
Create rooms and equipment groups................................................................................................. 35
Check for modules .............................................................................................................................. 36
Assign equipment to groups............................................................................................................... 37
Arrange the Home screen ................................................................................................................... 37
Adjust master set points...................................................................................................................... 38
Adjust equipment settings .................................................................................................................. 38

iv
Appendixes........................................................................................................................ 39
Appendix A: Troubleshooting ................................................................................................................. 39
Troubleshooting module communication ........................................................................................... 41
Display Controller states and statuses................................................................................................ 42
Proper shutdown procedure ............................................................................................................... 43
Appendix B: Calibrating and troubleshooting actuators......................................................................... 43
Calibrating actuators ........................................................................................................................... 43
Determining correct actuator feedback wiring.................................................................................... 44
Appendix C: Additional modules and repair kits .................................................................................... 45

5
Chapter 1: Introduction
Introducing AutoFlex Connect
Your facility management solution
AutoFlex Connect brings flexibility and versatility to your fingertips. With AutoFlex Connect, you
can control and manage ventilation, supplemental cooling, heating, lighting, feeding, and more.
Flexible, versatile, and expandable
AutoFlex Connect controls are modular. This means you have the flexibility to build the control
with only the features you need and to expand in the future.
Smart Modules are available to control variable or fixed-speed fans, air inlets, curtains, lighting, feed
loops, and more. On the monitoring side, you can choose to monitor conditions such as
temperature, humidity, ammonia, carbon dioxide, and more.
One size does not fit all
Each facility has its own needs. With AutoFlex Connect, you have two sizes of controls to choose
from. This allows you to choose the right control for your application.
Up to 14 modules for AFX-CONNECT
Up to 6 modules for AFXMINI-CONNECT
Expansion Boxes are available to add additional capacity.
Stay connect anywhere, anytime
Not at the control? No problem. AutoFlex
Connect is accessible from any web-enabled
device. No matter where you are, your AutoFlex
Connect controls are always within reach.

Introducing AutoFlex Connect
6
Features
Intuitive user interface with 10-inch capacitive touch display
Local configuration and monitoring at the control using the touchscreen
Remote configuration and monitoring from any web-enabled device
Smart Modules for controlling equipment and monitoring sensors
Two ventilation control modes: traditional staged and VentGrid™ combi table
16 zones available for control and monitoring
Monitor or manage:
Temperature
Humidity
Carbon dioxide (CO2)
Ammonia (NH3)
Static pressure
Barometric pressure
Wind speed
Wind direction
Rain
Light level
Current
Digital switches
Pulses
THI
Wind chill
Full analytics package with customizable reports sent at your convenience
Two sizes of controls available, 14 or 6 modules
Available Expansion Boxes to increase module capacity
EXPANSION-14: 14 modules
EXPANSION-6: 6 modules
NEMA 4X enclosure (corrosion-resistant, water-resistant, and fire-retardant)
QPS certification
2-year limited warranty

7
AutoFlex Connect AutoFlex Connect Mini
Room for 14 modules Room for 6 modules
Available modules
Actuator Module (model ACT-1)
The ACT-1 is a Smart Module that has one open and one close relay to control
inlets and curtain machines, with potentiometer feedback or without (timed).
The ACT-1 features a built-in microprocessor that precisely controls equipment
and provides safety protection.
For installation information, read Connecting equipment to ACT-1 and ACT-1V
modules on page 17.
Actuator Module (model ACT-1V)
The ACT-1V is a Smart Module that has one open and one close relay to
control drive motors that have 0-10 V DC signal output, such as actuators or
curtain machines. The ACT-1V features a built-in microprocessor that precisely
controls equipment and provides safety protection.
For installation information, read Connecting equipment to ACT-1 and ACT-1V
modules on page 17.
11.85 in. (30 cm)
3.95 in. (10 cm)
11 in. (28 cm)
14.9 in. (37.8 cm)
7.1 in. (18.0 cm)
22.0 in. (55.9 cm)

Introducing AutoFlex Connect
8
Input Module (model IN-4)
The IN-4 is a four-input Smart Module that precisely measures analog, digital,
and pulse/count sensors. The IN-4 has a built-in microprocessor that
continuously monitors the sensors and communicates the status and any fault
conditions.
For installation information and a list of supported sensors, read Connecting
sensors on page 19.
Relay Module with current sensing (model RM-2)
The RM-2 is a Smart Module that has two high-capacity relays, each with a
current sensor. The relays can be used to control equipment such as single-
speed fans, heaters, lights, and other equipment. The RM-2 features a built-in
microprocessor that precisely controls equipment while continuously
monitoring the current and providing safety protection.
For installation information, read Connecting equipment to RM-2, RM-2-3PH,
and RM-4 modules on page 22.
Three-Phase Relay Module (model RM-2-3PH)
The RM-2-3PH is a Smart Module that has two high-capacity relays and two
pilot relays for controlling three-phase motors and equipment. The relays
operate as pairs, with one high-capacity and one pilot relay in each pair. The
high-capacity relays have current sensing.
For installation information, read Connecting equipment to RM-2, RM-2-3PH,
and RM-4 modules on page 22.
Relay Module (model RM-4)
The RM-4 is a Smart module that has four relays to control fans, heaters, lights,
and other equipment. The RM-4 features a built-in microprocessor that
precisely controls equipment.
For installation information, read Connecting equipment to RM-2, RM-2-3PH,
and RM-4 modules on page 22.
Variable AC module (model VAC-1)
The VAC-1 is a single-output Smart Module with a current sensor that can
control variable-speed fans, heat mats, and lights. A temperature probe
connector is included for heat mat control. There is also a connection for a
Variable Load Expansion Box.
For installation information, read Connecting equipment to VAC-1 modules on
page 24. For information about Variable Load Expansion Boxes, visit
www.phason.ca.

9
Variable Chimney Module (model VCM-DC)
The VCM-DC is a Smart Module that monitors and precisely controls airflow
using a chimney fan, damper, and measuring fan. The VCM-DC features a
built-in microprocessor that precisely controls equipment and continuously
monitors and handles fault conditions.
For installation information, read Connecting equipment to VCM-DC modules
on page 25.
Variable DC Module (model VDC-4)
The VDC-4 is a Smart Module that has four outputs for controlling variable
frequency drives (VFD), FanDRIVEs, or other equipment requiring a 0 to 10 V
DC signal. The VDC-4 features a built-in microprocessor that precisely controls
equipment while also providing safety protection.
For installation information, read Connecting equipment to VDC-4 modules on
page 26.
Feed Loop Kit (model AFX-FEED-LOOP)
The Feed Loop Kit contains a drive module and a sensor module. The drive
module has one relay for a chain/drive motor and one for an auger/fill motor.
Both relays include current sensing. The sensor module has one input for a
proximity sensor and one for a chain safety sensor. There are two inputs for
additional sensors.
For installation information, read Connecting equipment to Feed Loop Kits on
page 27.

What you need to know before installing
10
Chapter 2: Installation
What you need to know before installing
If you do not install external surge suppression devices, you risk damage to the
electronics inside the control, which may cause the control to fail.
Because it is not possible to completely protect this product internally from the
effects of power surges and other transients, we highly recommend that you
install external surge suppression devices. For specific recommendations, see
your electrical contractor.
If you do not take these precautions, you acknowledge your willingness to
accept the risk of loss or injury.
You can connect more than one piece of equipment to a variable stage or relay if
they are the same type (for example, two fans) and the total current draw and
horsepower does not exceed the relay’s limit.
The maximum wire gauge for all terminals is 12 AWG, solid or stranded.
Understanding power surges and surge suppression
Power surges can be caused by external influences (outside the barn –for example, lightning or
utility distribution problems) or they can be caused internally (inside the barn –for example, starting
and stopping inductive loads such as motors).
One of the most common causes of power surges is lightning. When lightning strikes the ground, it
produces an enormously powerful electromagnetic field. This field affects nearby power lines, which
transmit a surge to any device connected to it, such as lights, computers, or environmental controls
like the control. Lightning does not have to strike a power line to transmit a surge.
Surge suppression devices offer some protection from power surges. Because it is not possible to
internally protect this product completely from the effects of power surges and other transients,
Phason highly recommends that you install external surge suppression devices. For specific
recommendations, see your electrical contractor. If you do not take these precautions, you
acknowledge your willingness to accept the risk of loss or injury.

11
Reducing electrical noise using filters
Electrical noise is caused by high voltage transients created when inductive loads, such as power
contactors, are switched on or off. The strength of the transients can be over 1000 volts and can
vary with the type of equipment and wiring, as well as several other factors.
Symptoms of electrical noise include erratic control operation, cycling inlets, communication
problems, and more. However, the effects of electrical noise are not always visible. Over time,
electrical noise can cause electronic circuits, relay contacts, and power contactors to deteriorate.
Phason highly recommends installing filters on all inductive loads.
Installing filters helps extend the life of equipment
Filters help prevent electrical noise problems by absorbing the transient energy. Even if you do not
have visible symptoms of electrical noise, filters help keep controls operating reliably and can extend
the life of the controls and equipment connected to them.
Phason’s snubber filters (part number 127-0) are for use with solenoids, timer relays, DC motors,
furnaces, and other equipment connected to the control’s relays. You can also use the filters with
loads connected to power contactors.
Install a filter in parallel with the load, as shown in the following example.
Do not use Snubber filters with variable stages.
Some power contactors include snubber filters. For more information, read Using
power contactors to increase the capacity of relays on page 12.
For more information about snubber filters or other Phason accessories, see your
dealer or visit www.phason.ca.

What you need to know before installing
12
Control and module electrical ratings
Control power 85 to 264 VAC, 50/60 Hz
Alarm relay 0.4 A at 125 VAC; 2 A at 30 VDC, resistive load
0.2 A at 125 VAC; 1 A at 30 VDC, inductive load
ACT-1 and ACT-1V 15 A at 120/230 VAC, general-purpose (resistive)
1/2 HP at 120 VAC, 1 HP at 230 VAC
0-10 V DC signal feedback (ACT-1V only)
RM-2 and LOOP-DRIVE 20 A at 120/230 VAC, general-purpose (resistive)
1 HP at 120 VAC, 2 HP at 230 VAC
RM-2-3PH 1 HP at 120 VAC, 2 HP at 230 VAC
230 VAC coil, 70 VA inrush, pilot duty
RM-4 15 A at 120/230 VAC, general-purpose (resistive)
1/2 HP at 120 VAC, 1 HP at 230 VAC
VAC-1 7 A at 120/230 VAC, general-purpose (resistive)
4.9 FLA at 120/230 VAC, PSC motor
1/2 HP at 120 VAC, 1 HP at 230 VAC
800 W @ 120 VAC, 1600 W @ 230 VAC
VDC-4 and VCM-DC 0 to 10 VDC, 2K Ω load
Using power contactors to increase the capacity of relays
Phason’s Manual Override Box (model MOB-4) has four 240-volt power contactors that allow you to
increase the load handling capability of control relays. Manual Override Box is ideal for secondary
ventilation fans and electric heaters.
MOB-4 electrical ratings
Coil: 10.2 mA at 240 VAC
Contact: 25 A at 240 VAC; resistive
2 HP at 240 VAC, 1 HP at 120 VAC; motor, power factor 0.4
1300 W at 120 VAC; tungsten
For more information about power contactors, visit www.phason.ca.

13
Enclosure dimensions and mounting guidelines
Mount the control on a sheltered, vertical surface.
Mount the control with the electrical knockouts facing down.
Mount the control away from sources of moisture and heat.
AutoFlex Connect II
Mount high-voltage modules next to the trough and then run the cabling through the
trough. These are the high-voltage modules:
ACT-1
ACT-1V
RM-2
RM-2-3PH
RM-4
VAC-1
LOOP-DRIVE
Mount low-voltage modules in the outer positions and then run the cabling along the
inside of the enclosure. These are the low-voltage modules:
IN-4
VCM-DC
VDC-4
LOOP-SENSE
Mounting holes (x5)
12 in.
12 in.
12 in. (30.5 cm)
12 in.
14.9 in. (37.8 cm)
7.1 in. (18.0 cm)
22.0 in. (55.9 cm)

What you need to know before installing
14
AutoFlex Connect II Mini
Mount high-voltage modules only in any of the bottom four module positions. These are
the high-voltage modules:
ACT-1
ACT-1V
RM-2
RM-2-3PH
RM-4
VAC-1
LOOP-DRIVE
Module positions 1 and 2 are for low-voltage modules only. Run the cabling along the
inside of the enclosure for modules 1 and 2. These are the low-voltage modules:
IN-4
VCM-DC
VDC-4
LOOP-SENSE
Installing modules
1. Position the module over the connector (A)
and then press straight on to the connector.
2. Fasten the module in place using all four
screws (B) provided.
12 in. (30.5 cm)
12 in.
Mounting holes (x4)
12 in.
12 in.
11.85 in. (30 cm)
3.95 in. (10 cm)
11 in. (28 cm)

15
AutoFlex layout
1
Mounting board: make sure all module boards, incoming power, and the ribbon cable from the communication
controller are properly connected.
2
Incoming power terminal: connect 120/230 VAC, 50/60 Hz power. See page 29.
3
Ground terminals: connect any equipment grounds to these terminals. See page 29.
4
12 VDC output terminal: connect any equipment that requires 12 VDC power, such as iWire radios. You cannot
connect VFDs here.
5
ON/OFF switch: switch the AutoFlex ON or OFF using this switch.
6
Cable trough: route AC power equipment cables through the trough. Route data and signal cables along the inner
walls of the enclosure.
7
Communication Controller: make sure the ribbon cable is connected from the communication controller to the
mounting board.
8
Expansion Box cable connection: connect an optional Expansion Box (model EXPANSION-6 or EXPANSION-14).
9
Alarm relay terminal: If you have an external alarm system, connect it here. See page 28.
10
Display Controller: make sure the power supply (top board) is properly connected to the bottom board, and all
cables are properly connected.
11
USB drives: (appearance may vary) make sure the USB drives are properly connected to the USB ports.
12
USB cable: make sure the cable is properly connected from the display controller to the display board.
13
HDMI cable: make sure the cable is properly connected from the controller board to the display board.
13
2
11
6
1
3
10
7
5
4
9
8
12

What you need to know before installing
16
AutoFlex Mini layout
1
Mounting board: make sure all module boards, incoming power, and the ribbon cable from the communication
controller are properly connected.
2
Incoming power terminal: connect 120/230 VAC, 50/60 Hz power. See page 29.
3
Ground terminals: connect any equipment grounds to these terminals. See page 29.
4
12 VDC output terminal: connect any equipment that requires 12 VDC power, such as iWire radios. You cannot
connect VFDs here.
5
ON/OFF switch: switch the AutoFlex ON or OFF using this switch.
6
Communication Controller: make sure the ribbon cable is connected from the communication controller to the
mounting board.
7
Expansion Box cable connection: connect an optional Expansion Box (model EXPANSION-6 or EXPANSION-14).
8
Alarm relay terminal: If you have an external alarm system, connect it here. See page 28.
9
Display Controller: make sure the power supply (top board) is properly connected to the bottom board, and all
cables are properly connected.
10
USB drives: (appearance may vary) make sure the USB drives are properly connected to the USB ports.
11
USB cable: make sure the cable is properly connected to the display controller.
12
HDMI cable: make sure the cable is properly connected at both ends.
9
6
12
10
2
5
1
8
4
3
7
11

17
Connecting equipment to modules
You can connect more than one piece of equipment to a variable stage or relay if
they are the same type (for example, two fans) and the total current draw and
horsepower does not exceed the relay’s limit.
The maximum wire gauge for all terminals is 12 AWG, solid or stranded.
Connecting equipment to ACT-1 and ACT-1V modules
Actuator Modules have one OPEN and one CLOSE relay. The ACT-1 has a connection for
potentiometer feedback; the ACT-1V has a connection for 0 - 10 V DC-signal feedback. You can
connect an actuator or a curtain machine to an Actuator Module.
The ratings of the actuator or curtain machine must not exceed the relay ratings of
the Actuator Module.
15 A at 120/230 VAC, general-purpose (resistive)
1/2 HP at 120 VAC, 1 HP at 230 VAC
0-10 V DC signal feedback (ACT-1V only)
Actuators
Actuator control is for equipment that opens and closes, and positions to an exact location. For
example, inlets can be open between 0 and 100 percent. Actuators use a feedback potentiometer to
indicate their position to the control.
Feedback
Each actuator you connect must have either potentiometer or DC-signal feedback. The feedback lets
the control know how far the actuator’s arm is extended.
Most linear actuators with potentiometer feedback have internal adjustable limit switches. A 10,000
ohm, 10-turn feedback potentiometer is preferred, but the internal feedback potentiometer can
range between 1000 and 20,000 ohms. Potentiometers outside of this range will affect the precision
to which the control can control the actuator.
A system operates more precisely when using the largest amount of stroke that is
feasible with the actuator. The stroke is the distance the actuator arm extends or
retracts.

Connecting equipment to modules
18
To connect actuators
1. Connect actuators to the control as shown below. Refer to your actuator’s installation guide for
information about its power supply requirements.
2. Calibrate the actuator. You can calibrate by pressing the CALIBRATE button, or using the
display. For more information the calibration process, and instructions for calibrating using the
display, read Calibrating actuators on page 43.
Actuators with potentiometer feedback
AC-powered DC-powered
Actuators with DC-signal feedback
When routing the actuator feedback
wires, do not run them in or along the
same conduit as AC-power lines.
If you are unsure of the potentiometer
wiring for your actuator, read
Determining correct actuator feedback
wiring on page 44.
If you are measuring AC power with a
digital multimeter (DMM) and a limit
switch opens the circuit, the DMM
measures voltage after the relay
switch even if the relay is open.

19
Curtain machines
Curtain machines, sometimes referred to as winches, open and close curtains or louvers to let in
more air or less air. The idea is that more air cools the building. Curtain machines use a timer and do
not have a feedback potentiometer.
To connect curtain machines
Connecting sensors to IN-4 modules
The IN-4 Input Module has connections for four analog sensors, dry contact switches, or dry
contact pulse outputs.
Compatible sensors and devices
Function
Model
Version
Maximum cable distance
Temperature
3K series
All
500 ft. 152 m
DOL15
--
500 152
Temperature and humidity
DOL114
4 - 20 mA only
100 30
Humidity
RHS
All
100 30
Carbon dioxide (CO2)
DOL19
4 - 20 mA only
656 200
Ammonia (NH3)
DOL53
0 - 10 V only
500 152
Light
DOL16
100/1000 lx only
328 100
Static pressure
SPS-2
--
300 91
Rain
PRS
--
500 152
Wind speed
WINDSPEED-03
--
1500 457
Wind speed and direction, barometric pressure
*Temperature not supported
DOL58
0 - 10 V only;
656 200
Current
CURRENTSENSE-2
--
500 152

Connecting equipment to modules
20
Other devices
Dry contact pulse output, such as a water meter
Dry contact digital switch
Guidelines for connecting sensors
Do not run the sensor cable in the same conduit as AC power cables
Do not run the sensor cable beside AC power cables or near electrical equipment.
When crossing other cables or power lines, cross them at a 90-degree angle.
Wired connections and shunt positions
1. Place the shunts in the proper positions for the type of sensor you are connecting. For each
sensor, there are four shunts to position.
2. Connect the wiring for the sensor. Refer to the sensor’s installation guide for more information.
The DOL 19 carbon dioxide, DOL 53 ammonia, and DOL 58 weather sensors require
external power supplies. For more information, refer to the installation guides for
those products.
3K series DOL 15 DOL 114, temperature only
DOL 114, temp. and humidity DOL 114, humidity only RHS