Reliable Controls MACH-Air User manual

2002 Reliable Controls™ Corporation
MACH-Air™
VAV Controller
Quick Start Guide
Ideal for low-point VAV applications
where unrestricted programming
and full data acquisition are
required.
Can be networked on the main
or subnetwork, rendering easy
communication with the full line of
Reliable Controls™
products.
Three user configurable universal
or triac inputs and outputs;
Onboard velocity sensor and
relocatable damper actuator;
Flash EEPROM;
SMART-Sensors™ support.
Communication ports include
SMART-Net™ and
EIA-485 Network.
The MACH-Air™ is a
high-performance,
fully programmable
DDC controller
designed to meet the
needs of Variable Air
Volume control within
the Reliable Controls™
MACH-System.
...people and technology
you can rely onTM

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MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Document Conventions
Reliable Controls™ Quick Start Guides use several
conventions to aid in your understanding of the material and
to make information more readily accessible. These
conventions are outlined below.
Software menu items will appear in bold faced type and follow
the form:
Start>Programs>Reliable Controls™>RC-Studio™
Two symbols are used to draw your attention to items
warranting special attention:
The Attention Symbol is used to
draw your attention to concepts
and particular items that require
caution or thought before
implementation.
The Light Bulb is used to draw your
attention to information and
practices that will make your life
easier.

iii
MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
2002 Reliable Controls™ Corporation
All rights Reserved
Printed in Canada
This manual is for information purposes only. The contents and products
described are subject to change without notice. Reliable Controls™
Corporation makes no representation with respect to this manual. In no
event shall Reliable Controls™ Corporation be liable for damages, direct
or incidental, arising out of or related to the use of this manual. No part of
this document may be reproduced or transmitted in any form or by any
means, without the express written permission of Reliable Controls™
Corporation.
Reliable Controls™ Corporation
207-3375 Whittier Avenue
Victoria, BC, Canada V8Z 3R1
Tel: [phone]
Fax: [phone]
Toll Free: 1-877-457-9301
www.reliable-controls.com

MACH-AirTM VAV Controller
iv 2001 Reliable Controls Corporation

MACH-Air™ VAV Controller
iv
2002 Reliable Controls™ Corporation
Contents
Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Getting Started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Optional Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Workstation Connection . . . . . . . . . . . . . . . . . . . . . 14
Peer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Direct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Universal Inputs . . . . . . . . . . . . . . . . . . . . . . . . 16
Dedicated Inputs. . . . . . . . . . . . . . . . . . . . . . . . 17
Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . 18
Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MACH-Air™ Universal Outputs . . . . . . . . . . . . . 20
MA-T™ Single Stage Triac Outputs . . . . . . . . . 21
MA-T™ Dual Stage Triac Outputs . . . . . . . . . . . 22
Dedicated Outputs . . . . . . . . . . . . . . . . . . . . . . 23
SETUP-Tool™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MSet Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Motor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . 27

MACH-Air™ VAV Controller
v
2002 Reliable Controls™ Corporation
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Calibration Procedure (RC-Toolkit™) . . . . . . . . 28
SMART-Sensor™Connection . . . . . . . . . . . . . . . . . 29
Networking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Network Connection . . . . . . . . . . . . . . . . . . . . . 30
End-of-Line Termination . . . . . . . . . . . . . . . . . . 31
Real Time Clock . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical Specifications . . . . . . . . . . . . . . . . . . . . . 33

1
MACH-Air™ VAV Controller
Package Contents
2002 Reliable Controls™ Corporation
Package Contents
Your new MACH-Air™ VAV controller package should
include:
1. The MACH-Air™ VAV controller.
2. Self-tapping mounting screw taped to the controller body.

2
MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Getting Started
Getting Started
This guide identifies the physical installation procedure and
connection of the MACH-Air™ VAV controller within a Reliable
Controls™ MACH-System.
There are many important concepts and practices that
accompany the use of the MACH-Air™ controller. This
document is intended to provide installation and setup
procedures for first time users. The most important concepts
that are crucial to the reliable operation of the MACH-Air™ are
introduced.
Product Overview
The MACH-Air™ VAV controller features:
!Three user configurable universal inputs.
!Three user configurable universal outputs.
!Onboard velocity sensor.
!Relocatable damper actuator.
!SMART-Net™ port.
!EIA-485 network port.
The MACH-Air-T™ VAV controller outputs:
!One single stage triac (24 VAC, 1A binary output).
!One dual stage triac (24 VAC, 1A binary output).
!One user configurable universal output.

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MACH-Air™ VAV Controller
Getting Started
2002 Reliable Controls™ Corporation
MACH-Air™ VAV Controller Features
Power Connection
EIA-485 Network Connection
Output Connection
Input Connection
SMART-Net
TM
Port
Velocity Sensor
Damper Actuator
MACH-Air
™
-T Connector WiringMACH-Air
™
Connector Wiring

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MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Getting Started
!Inputs four, five, and six (IN4, IN5, IN6) and outputs four and
five (OUT4, OUT5) are dedicated to air flow and motor
functions (see Inputs and Outputs).
!Variable one (VAR1) of the MACH-Air™ is reserved for the
‘Flow Calibration Constant’.
!MACH-Air™ network settings, such as baud rate, network
type, controller address, and last panel must be configured
using the SETUP-Tool™ (see SETUP-Tool).
!A sample Control BASIC™ program is preloaded on the
MACH-Air™ VAV controller. This program is a template for
basic VAV operation.
!The MACH-Air™ controller does not have a Real Time Clock.
The controller receives its time from a MACH1™, MACH2™,
or MACH-Global™ controller or an ETHER-Link™ portal that
is addressed as number one on the network.
!The MACH-Air™ controller does not have an EIA-232 port. In
order to access a MACH-Air™ controller from a workstation,
it is necessary to connect to a MACH1™, MACH2™, or
MACH-Global™ controller, or an ETHER-Link™ portal on the
same network.
!The X-Port™ converter is available to facilitate EIA-232
communications between the SMART-Net™ port of the
MACH-Air™ controller and any workstation or laptop. The X-
Port™ converter could also be used for remote access by
connecting a modem instead of a workstation.

5
MACH-Air™ VAV Controller
Installation
2002 Reliable Controls™ Corporation
Installation
The MACH-Air™ VAV controller is typically mounted directly
on the sheet metal of an air duct:
!Mount the MACH-Air™ VAV controller on the mixing box.
!Clamp the motor to the damper control shaft using the
universal U-bolt clamp assembly.
!Secure the controller using the self-tapping metal screw
supplied with the MACH-Air™ VAV controller.
!Attach the two differential pressure tubes to the flow sensor
spouts on the MACH-Air™ VAV controller. High pressure
goes to the red spout and low pressure goes to the
unmarked spout.
!Attach power wiring, network wiring, and I/O wiring.
Ground yourself before touching
the controller to avoid damaging
the electronics. Touch a grounded
metal surface to discharge static
electricity.

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MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Installation
Optional Cover
The MACH-Air™ VAV controller may be ordered with an
optional connector cover that protects the connector terminal
from exposure or interference. The connector terminal is
located on the right side of the controller.
MACH-Air™without optional cover
MACH-Air™with optional cover
Connector Terminal
Optional Cover

7
MACH-Air™ VAV Controller
Installation
2002 Reliable Controls™ Corporation
Orientation
The MACH-Air™ VAV controller can be mounted in three
possible orientations:
1. Default.
2. Reverse.
3. Relocated motor.
Default Mounting
The default mounting for the MACH-Air™ VAV controller has
the motor mounted in the black plastic housing with the drive
on the top side of the assembly. The default direction of motor
rotation is clockwise to open. The controller can be set to
open with counter-clockwise rotation (see Outputs).
Reverse Mounting
The MACH-Air™ motor can be rotated with the motor drive on
the top or bottom side of the controller assembly.
!Remove three bolts on the underside of the assembly to
rotate the motor.
The motor cable can be configured to exit either side of the
controller by removing and replacing the cover.
Relocated Motor Mounting
The motor can be removed from the controller assembly and
mounted separately on a duct using one of two different
length custom cables available from Reliable Controls™
(Part# MA-MEC-1, 1 meter/3.3 ft & MA-MEC-2, 2 meter/6.6 ft).

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MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Installation
MACH-Air™ VAV Controller Orientations

9
MACH-Air™ VAV Controller
Physical Dimensions
2002 Reliable Controls™ Corporation
Physical Dimensions
35.8
[1.41]
35.8
[1.41]
36.6
[1.44] 112.8
[4.44]
205.5
[8.09]
58.4
[2.30]
49.5
[1.95]
241.3
[9.50]
53.9
[2.12]
22.4
[0.88]
62.5
[2.46]
19.0
[0.75]
19.0
[0.75]
133.0
[4.84]
179.3
[7.06]
OPTIONAL
CONNECTOR
COVER
TOP VIEW
This controller is intended to be
installed in accordance with the
National Electric Code or the
Canadian Electric Code, Part 1,
and in a manner acceptable to the
local authority having jurisdiction.

10
MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Power Wiring
Power Wiring
The MACH-Air™ VAV
controller is powered with a
non-isolated Class 2, 24 VAC
or 24 VDC power supply.
One or more controllers can
be powered from the same
source.
1. Connect the hot wire to the 24
VAC connection at the right side
of the controller.
2. Connect the neutral wire to the
GND connection at the right
side of the controller.
3. The neutral wire of the 24 VAC
must be connected to the Earth
ground.
Use only a Class 2 transformer.
Refer to the Technical
Specifications at the back of this
document.
The neutral wire of the power must
be grounded.
Do not connect any I/O peripherals
to the same power source as the
MACH-Air™ VAV controller.
Refer to Page 3 for a complete
connector wiring diagram.

11
MACH-Air™ VAV Controller
Power Wiring
2002 Reliable Controls™ Corporation
MACH-Air™ VAV Controller Power Wiring

12
MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Status LED
Status LED
The MACH-Air™ VAV controller status LED provides power
indication and shows the EIA-485 network activity. The status
LED is located just below the SMART-Net™ port at the bottom
right side of the controller.
MACH-Air™ VAV controller Status LED

13
MACH-Air™ VAV Controller
Status LED
2002 Reliable Controls™ Corporation
Status LED Indication
LED Indication Panel Activity
On for one second and off
for one second.
Normal operation.
Flickers. Normal operation - indicates
possession of network token.
Flashes four times for one
second, off for half second.
No firmware is loaded. Use the OS
Send tool in RC-Toolkit™ to load the
correct firmware file.
Is on or off continuously. Panel is defective or not powered on.
Continuous rapid flashing,
(6 flashes / second)
Self check failure.
(Service required)
Continuous, very rapid
flashing (at 96 Hz)
Network error.
(Holding network token)
On for half second, off for
half second.
Network error.
(Check connections and settings)

14
MACH-Air™ VAV Controller
2002 Reliable Controls™ Corporation
Workstation Connection
Workstation Connection
Peer
The MACH-Air™ VAV controller is designed to be
programmed using a workstation running the RC-Studio™
software. The workstation must be connected to a MACH1™,
MACH2™,or MACH-Global™ controller, or ETHER-Net™
portal that resides on the same system as the MACH-Air™
VAV controller.
No EIA-232 port is available on
the MACH-Air™ VAV controller.
One way to access the
controller is through an EIA-
232 enabled controller on the
same system (as illustrated
below). An alternative is to use
the X-Port™ converter through
the SMART-Net™ port as
discussed on the next page.
A MACH1™, MACH2™, or MACH-
Global™ controller, or ETHER-
Link™ portal must be configured
as address one in the system.
(See MACH-Air™ Real Time Clock)
MACH1™MACH-Air™
Operator Workstation
Peer Communications