Polyaire Zonemaster Variable Air Volume Guide

VAV
(VARIABLE AIR VOLUME)
CLIMATE ZONING SYSTEM
Technical Manual
&
User Manual
Polyaire™ Pty Ltd
11-13 White Road
GEPPS CROSS
South Australia, 5094
Tel: [phone]
Fax: [phone]
www.polyaire.com.au
www.zonemaster.com.au
2008 EDITION

IMPORTANT INSTALLERS NOTE
The Installer MUST be familiar with the features of the VAV and the installation
process BEFORE INSTALLATION COMMENCES.
Zonemaster/Polyaire does not take responsibility for poorly designed or
installed VAV systems. Neither will we take responsibility for customer
complaints due to poor design and installation. We strongly suggest that any
installer wishing to install a Zonemaster VAV system should fully acquaint
himself with the design features and capabilities of the system before
commencing the job , either by reading the installation manual thoroughly
or consulting with a Polyaire staff member conversant with this system
(Preferably both). Contact Polyaire re VAV installation training.
INSTALLATION TIPS & COMMON PROBLEMS
1. TheVAVpowertransformer(s)arettedwith3pinplugsandshouldbe 
 pluggedin to their own power point separate from the A/C unit.
 DONOTremovetheplugandhardwiretheVAVtotheA/Cpowersupplyas
 thewideuctuationsintheA/CcurrentwilldamagetheVAVunit.
2. Don’tgetconfusedbetweenDataandControlCables.
 Thepackagesareclearlymarked.DataCablehasleftlatchedplugsand 
 Controlcablehascentrelatchedplugs
3. Alwayscheckcables:Particularlyifmakingupyourowncables.Cablesand
 plugscansometimesgettwistedorbefaulty,thewiresandcontactsarevery
small. To ensure that all cables are ok pre- test with Zonemaster Cable Tester
 (AvailablefromPolyaire).Thiswillhelpeliminatefaultsbefore(ratherthan 
after) installation.
4. Donottapeoverthebuttonatthebottomofthedamperbladewhenattaching
 exibleduct.Thisiseasytodoandwillstopthedamperturningfreely.
5. All zones MUST have their own unique address allocated via the touchpad.
 IE:Ifthereare6zonesthesystemmusthave6addresses.
6. Donotplug2touchpadsintoone3wayplug.
7. VAVsystemsshouldonlybettedtoFlexibleductwithlargeenoughdiameter
 toeasilytaketherequiredvolumeofair.Smallductcreatesexcessivenoise
 andvortexdraughtsanddoesn’tallowthesystemtoregulateproperly.
8. ReturnAirGrillesshouldbepositionedinthesamespaceasthedesignated
 “Spill”zonetoensuretheVAVsensorcanoperateproperly.
9. Substantialdifferencesinzonetemperaturewillonlybeachievedinseparate
 zonesiftheseareeffectivelyseparatedfromotherzones.IEDoorsmustbe
 closedtopreventcrossowfromroomtoroom.
10. Theendusershouldbefullyinformedontheunitattimeofcommissioningso
 thattheyfullyunderstandtheoperationoftheVAVunit.Theendusershould
 beencouragedtoreadtheusermanual.

CONTENTS
Features 1
Application 1
Components 2
Conguration 3
Installation 5
 BypassControl 7
Commissioning 8
 1.InitiatingandExitSettingProcess 8
2. Initialisation of Touchpad Address 9
 3.RoomTemperatureSensor 9
4. Minimum Ventilation 10
 5.SupplyAirSafetyHigh&LowLimits-MasterTouchpad 10
 6.Spill/BypassAirSetpoint-MasterTouchpad 11
 7.NamingZones-MasterTouchpad 12
8. Damper on/off Test 12
 InstallationInformationSheet 13
TroubleShootingGuide 15
User Manual 16
 1.ZoneTouchpad 16
2. Master Touchpad 17
 3.ProgrammingMode 18
AppendixA-TechnicalSpecications 25
AppendixB-StandardCongurationofVAVSystem 27
Liability
Please read the instructions carefully before installing this
Zonemaster VAV Climate Control System. Polyaire Pty Ltd does
not accept any responsibility for loss or damage that may occur
as a result of the incorrect installation of this system.

FEATURES
• Manualandtimeprogrammablezonetemperaturecontrol.
• Supportsupto16zones.
• Addressofeachzoneissetdirectlyfromthetouchpad.
• Maintainsroomtemperaturewithin±1°Cusinganonboardsensor.
• LCDindicatorforzonestatusandparameterdisplay.
• User-friendlytemperatureandprogramsetting.
• Realtimeclockwithbatterybackup.
• 5-1-1programmabletemperaturesettingpointandstarttime.
• Personalisedzonelabelling.
• Autospill/bypass---thedesignatedzones/bypassareforced 
open when all zones are turned off.
• Safetysystem---Opensalldampersifthesupplyair 
 temperatureislessthanlowlimitormorethanhighlimit.
• Allzonesautomaticallyreturntotheiroriginalon/offstateonce 
power up.
APPLICATION
TheZonemasterVAV(VariableAirVolume)isafullyfeaturedsystem
designedtoaccuratelymanageairowbyzoneinDuctedreversecycle,
heatingandevaporativeairconditioningsystems.
ItmanagesairowfromtheA/Cunitbyassessingtemperaturesineach
zoneandopeningandclosingdamperstoincreaseordecreaseairowto
achieve and maintain a preset temperature in that zone.
The temperature difference that the Zonemaster can achieve will not be
lower(cooling)orhigher(heating)thanthetemperaturesetbytheACunit.
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COMPONENTS
1) Main Controller
The main controller collects and processes all the information.
2) Master Touchpad
6buttontouchpad.
  Toprogramandcontrolallthezonesinthesystem.  
3) Zone Touchpad
3buttontouchpad.
4) Bypass Damper and Controller (optional) Green
Dampercontrollerreceivesbypasscontrolsignalfromthe 
  maincontrollertoopenorclosethebypassdamper.
5) Supply Air Sensor
Supplyairsensormeasuresthetemperatureofthesupplyair.
6) Power Supply
The24VACtransformerprovidespowertotherst8touchpads
- dampers and main controller.
7) Battery
3.6Vrechargeablebatteryformaincontroller.
8) LeftLatchedDoubleAdaptor&CableKit
Double adaptor connects the main controller/touchpads via the
data bus.
 9) CentreLatchedTripleAdaptor&CableKit
Tripleadaptorconnectsthe24VACpowersupplyviathe 
control bus.
 10)MountingBracket
For the touchpads.
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Page 3
Figure1.MainControllerConnectionDiagram
ZonemasterVAVisaserialbusbasedsystemwhichhasaControlbusand
Data bus. The Control bus provides 24VAC power for up to 8 Dampers
viathemaincontrollerasshowninFig2.
Figure2.WiringdiagramofZone1toZone8
CONFIGURATION
Main controller collects and processes all the information. The connections
tothemaincontrollerareshowninFigure1.

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The Data bus provides communication between the main controller and
the touchpads.
NOTE:TheMainControllerprovidespowerforupto8Touchpadsand
damper motors. If more than 8 touchpads and dampers are installed
auxiliarypowermustbeprovidedviaseparate24VACand9VDCpower
suppliesasshowningure3.
Figure3.WiringdiagramofZone9toZone16

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INSTALLATION
1) Removethe3coversfromthemaincontrolboard.
2) Position the main controller on top of the fan coil unit or on the
 supplyairductandsecure.
3) Connectthe24VACpowersupplytotheterminalsN+Lonthemain
 controllerboard.Whenturningonthepower,theredLEDwill 
 illuminatetoshowthatthemaincontrollerisready.
3) Mountthesupplyairsensorinthesupplyairductupstreamfromthe
 motoriseddampers.Plugthesensorintothesocketonthemain 
controller board.
4) Connectthebatterybypluggingintothesocketonthemain
controller board.
5) Use two pre-tested data cables to connect the main controller
(touchpad 1-8 socket) and a touchpad via a double left latched
 adaptor,asshowninFigure2.TheLCDonthe
 touchpadshouldshowtheclockaftersettinga
unique address to the touchpad. (Refer to the
 commissioningsection)Otherwise,checkthe  
connection and the cables.
SENSORSOCKET
TOUCHPAD 1-8
TOUCHPAD 9-16
LED
24 VAC
VAV DAMPERS
BYPASS DAMPER
BATTERY CONNECTOR
BATTERY

6) Repeat step 5) to connect all the
 touchpadsaccordingtoFigure2and3.
 Makesureeverytouchpadisworking
 correctlybycheckingtheclockandthe
 temperaturedisplayedonthetouchpad.
7) Plugacontrolcableintothe‘VAV’socket
on the main board and the other end into
 the‘24VacIN’portonatripleadaptor.
 Plugthetripleadaptorintothemotorised
damper closest to the main board.
Warning - Only yellow Polyaire™
Dampers are compatible with the
system.
8) Useanothercontrolcabletopluginto
 ‘24VacOUT’portonthetripleadaptor
 andtheotherendofthecableto‘24Vac
 IN’portontheotheradaptorforthenext 
motorised damper.
9) Follow Step 8) to connect all motorised
 dampersinseriesasshowninFigure2.
10) Plugoneendofacontrolcableintothe
 ‘touchpad’socketonthetripleadaptor
and the other end into the socket on
the back of the touchpad.
11) Follow step 10) to connect all the
 dampersandtouchpadstogether 
 asshowninFigure2.
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Page 7
12) Turn off the power and disconnect
the touchpad.
13) Positionthetouchpadattheright
 place.Ideally,itspositionshould
 beapproximately1.6metresoff
 theooronthewall.Fitthedata
 cableandthecontrolcablethrough
 thewallcavityandconnectto 
 thetouchpadagain.Mountthe
touchpad onto the bracket in the
 wallcavity.
Please note that the touchpad should not be
 exposedtodirectsunlightandotherheat 
sources.
13) Applythepoweragaintothetransformer.The 
LCD should show clock time and temperature
  wherethetouchpadislocatedaftershowing
  ‘initiate’onthesecondlineforabout15
seconds.
BYPASS CONTROL
1) Ifbypasscontrolischosenforthe
 system,mountthegreendamper
 controlleronthetopofagreen
 motoriseddamperandplugthe
 bridgecablein.

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2) Take off the small cover on the top of the
damper controller and set a special address
 forthebypassdampercontroller.
3) Use a pre-tested control cable to
 connectthebypassdamper
 controllertothe‘point’socketonthe
main controller board. Make sure
 theredlightonthedampercontroller
 ison.Otherwise,checkthecableand
the connection.
COMMISSIONING
TheZonemasterVAVsystemhasseveralparametersthatmustbesetin
thecommissioningstage.
Zonetouchpad(3button)canonlysetthreezoneparameters:
1) Touchpad Address
2) Temperature Sensor
3) Minimum Ventilation
Mastertouchpad(6button)cansettheaboveparametersandthree
systemparameterslistedbelow:
1) SupplyAirSafetyHigh&LowLimits
2) SpillBypass/AirSetpoint
3) NamingZones
1.InitiatingandExitSettingProcess
1) Holddownbothandbuttonsforabout
  5secondsuntiltheLCDdisplays‘Setting’onthe 
top line of the LCD screen.

2) Forzonetouchpads,pressingbuttonafter 
  thesettingofallthreeparameterswillreturntothe
normal operation mode.
3) For the master touchpad,pressingbutton 
will return to the normal operation mode.
2.InitialisationofTouchpadAddress
Each touchpad (zone) must have a unique address
 from1to16tobeidentiedbythemaincontroller. 
 Thetouchpadhasafactorydefaultof‘Noaddr’that
 cannotbeidentiedbythemaincontroller.
Thetouchpadneedstobeinitiatedbyallocating 
a unique address. The allocation can be carried
 outbypressingorbutton,andthen 
 pushing(zonetouchpad)or  
(master touchpad) button.
Please note that each touchpad (zone) must have
 auniqueaddress.Thesameaddressforanyoftwo
touchpads will cause communications problem
between the main controller and touchpads, and
 thetouchpadLCDshows‘CheckAddress’
3. Room Temperature Sensor
Each touchpad has an onboard sensor to measure the temperature of
the room for temperature control. The sensor can be calibrated to provide
more accurate temperature control.
1) Usinganaccurateprobetomeasurethe 
temperature of the area user wants to calibrate
and record the value.
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2) Atthesettingmode,press(zone 
touchpad) or (master touchpad) button
       untiltheLCDdisplaysthe‘Sensor’screen
3) Press or button to adjust the
       displayedvaluetotherecordedvalue.
4. Minimum Ventilation
Customersmaypreferminimumventilationduringtheclimatecontrol.
Thisventilationallowsaminimumairowintothezonethatisswitchedon.
Theamountofventilationcanbesetfrom0to30%openwithadefault
of0%.
1) Atthesettingmode,press(zone 
touchpad) or (master touchpad) button
       untiltheLCDdisplaysthe‘MinVent’screen.
2) Press or button to adjust the
percent value of the minimum ventilation as
desired.
5.SupplyAirSafetyHigh&LowLimits-MasterTouchpad
Forsafetyreasons,thesystemmonitorsthesupply
      airtemperatureclosely.Ifthetemperaturemoves 
      outsideofthelimits,alldampersinthesystemare 
      forcedopenandtheLCDdisplays‘Safety’
      onscreen.Thefactorydefaultsofsupplyairsafety
      high&lowlimitsare60°Cand5°Crespectivelyand
      thesafetycontrolisdisabled.
1) Atthesettingmode,pressbuttonuntil 
       theLCDdisplaysthe‘H_limit’screen.
2) Pressorbuttontochangethe 
       highlimittothedesiredvalue.Theadjustable 
       rangeofthehighlimitisfrom45°Cto75°C

3) Pressbuttononceagain,theLCD 
       screenwilldisplaythe‘L_Limit’.
4) Pressorbuttontochangethe 
low limit to the desired value. The adjustable
       rangeofthelowlimitisfrom0°Cto15°C.
 Ifthecustomerdoesnotwantthesafety 
       function,thesafetyH-limitandL-limit
       MUSTbedisabledbypressingbutton
       duringthesetup.
Spill or Bypass Modes
A‘Spill’or“Bypass”functionisdesignedtorelievepressureintheductif
toomanyzoneshavebeenturnedoff.
Spill Mode
TheVAVsystemhasaninbuilt“Spill”systemthatwillautomaticallyopen
ventsiftoomanyhaveinadvertentlybeenclosed.Thepresetfactory
defaultis30%ofthetotalnumberofzones.ThePresetFactorydefault
canbevariedbutwerecommend30%asthelowestsafevaluetoprotect
theduct.InSpillmodethezoneswiththelowestaddressesinthesystem
areautomaticallyopenedifthetotalnumberofopenzonesislessthanthe
assignedspillsetpoint.(IE:Ifthesystemhas10zonesnumbered1-10
andallhavebeenclosedtheVAVwillautomaticallyopenzones1,2,3to
relievethepressure.Theonlywaytoclosethese“spill”zonesistomake
sureatleast3otherzonesareopen.
Bypass Mode
Thealternativewaytorelievepressureintheductistoinstallaductfrom
theA/Coutletviaamotorizeddampertothereturnairduct.Thissystem
shouldonlybeusedwherethespillfunctionisconsideredunsatisfactory.
InBypassmode,aspecicdamperisusedtoreturntheairdirectlytothe
return air duct if the total number of zones open is less than the setpoint.
Thebypassdamperiscontrolledbyaspecicdampercontrollerwithits
own unique address.
Note:EnsurethattheAirConUnitReturnAirSensorispositionedinthe
returnairductbetweentheBypassductandtheunitsothatitcanregister
theairfromthebypassduct.
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7.NamingZones-MasterTouchpad
Thenameofazoneiscalled‘Zone_addr’.Forexample,zone1,which
hasanaddressof1,iscalled‘Zone_1’onitsfactorydefault.Thenames
canbecustomisedasfollows:
1) Atthesettingmode,pressbuttonuntil 
       theLCDdisplaysthe‘Spill’or‘Bypass’screen.
2) Pressbuttontoselectspillorbypassmode.
3) Pressorbuttontochangethe 
       spill/bypasssetpointtoitsdesiredvalue.
       Theadjustablerangeisfrom0%to50%.
 Werecommendasettingof30%ormoreto
       safeguardDuct.Ifnospillorbypasscontrolis
required in the system, the setpoint MUST be
       setto0%.
1) Atthesettingmode,pressbuttonuntil 
      theLCDdisplaystherstzonename,for  
      example‘Z1Name’onthetoplineoftheLCD. 
The second line shows the current name of
zone 1.
2) Press or button to select one of
the preset zone names for the zone. There are
      26presetnamesinthelist.
3) Tomakechangestothepresetselectedname, 
press button to move to the character
      thatisashing.
4) Use or button to select the
      characterfromthelistasdesired.Thereare26 
      lettersincapitalandnormalcase,10numbers 
and a space in the list.
5) Pressbuttontoselectthenextzone  
      namingscreenandfollowsteps2to4to  
customise the name of the zone.
8. Damperon/offTest
1) Switch on the air conditioner.
2) Press button to turn a zone on or off to check if the damper is
 correctlyconnectedbyfeelingtheairattheoutlet.RefertoUser’s 
manual for the operation.

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INSTALLATION INFORMATION SHEET
Thefollowingzonetableisdesignedtoassistinstallationand
commissioning.
Address DefaultName Zone Name Program
1 Zone_1
2 Zone_2
3 Zone_3
4 Zone_4
5 Zone_5
6 Zone_6
7 Zone_7
8 Zone_8

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Please note the following:
Zone name is the actual name of the zone, for example; lounge, kitchen,
bedroom etc.
Spill zones should be assigned lower addresses, and they should be
located near return air grilles.
Parameter Default Custom Value
Address No addr
Sensor
Min Vent 0%
Highlimit Disable/
60oC
Low limit Disable/
5oC
Spill Spill/
30%

TROUBLE SHOOTING GUIDE
Problem SuggestedAction
Touchpad has
nothingshownon
LCD.
• Disconnect the data cable from the touchpad
immediately.
• Check if the cable is crossed over with the
Zonemaster Cable Tester.
•Checkthepowersupply.
LCD shows the
touchpad address.
• Check the cables and the connection of the
data bus.
LCD shows
‘CheckAddress’. • Check addresses for all touchpads.
Touchpaddisplayis
not normal.
•Resetthetouchpadbydisconnectingthedata
cableandthenpluggingitinagain.
•Resetthemaincontrollerbyturningoffpower
supplyandturningonagain.
Dampers have no
response when
turned on or off.
• Check the control cable between the touchpad
and the damper.
•Checkthe24VACpowersupply.
Temperature is
beyond±1°Crange.
•AirConditionerdoesnothaveenoughcapacity
for the area at the particular moment.
•Toomuchaircomingfromotherareas.
Pleasecontactdistributorsforanyother
problems not listed as above.
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Page 16
USER MANUAL
Touchpad Layout
TheMastertouchpadhasaLCDwithsixbuttons,whereastheZone
touchpadhasaLCDscreenwithonlythreebuttons,asshowninFigure5.
Innormaldisplaymode,theLCDscreenswilldisplayclocktimeandtheir
local zone temperatures.
Figure5.LayoutofMasterandZoneTouchpads
Master Touchpad Zone Touchpad
Zone Touchpad
ZoneOn/OffControl
1) In‘on’status,theLCDofthetouchpaddisplays
       zonetemperatureorsetpoint.Pressing
button once will turn off the zone and the
       secondlineofthescreenwilldisplay‘off’.
2) In‘off’status,pressingbuttononcewill
turn on the zone and the second line of the
       LCDscreenwilldisplaythesetpointofthe 
       zonefor20seconds,andthenwillreturntothe
       normaldisplayofthezonetemperature.

ZoneTemperatureSetting
1) In‘on’status,pressorbutton 
once to allow the setpoint of the zone to be
       displayedonthesecondlineoftheLCD.
2) Pressorbuttonagaintoadjust 
the setpoint to the desired value.
3) The screen will return to zone temperature
       displayin20secondswithnokeybeing 
pressed.
Master Touchpad
ZoneOn/OffControlandTemperatureSetting
Master touchpad controls the temperature of the zone where it is located
besidesitsfunctionofsettingotherzonestemperatures.Itsoperationfor
on/offcontrolandtemperaturesettingarethesameasthezonetouchpad
described in above section.
All Zone Browse
1) Amastertouchpadcanbrowsethroughallthe
       zonesbypressingbutton.Whenazone
       hasbeenselected,thezone’snameandits 
       setpointor‘off’statusareshownontheLCD 
screen.
2) Inbrowsemode,pressingbuttononce 
will turn the selected zone on or off.
3) Whenaselectedzoneisin‘on’status,press
or button to adjust the setpoint to
the desired value for the zone.
4) Pressbuttonagain,usercanselectnext
       zonefortemperaturesettingoron/offcontrol.
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