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.

Page 4
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.