TEL AFA4000/E User manual

AFA4000/E
VAV Airflow Controller
Installation and operating manual
Issue 2

AFA4000/E VAV Airflow Controller / p.2
Contents
1. Introduction......................................................................................................................5
1.1 Features ........................................................................................................................................ 5
2. Safety................................................................................................................................6
2.1 Safety practices............................................................................................................................. 6
2.2 Precautions ................................................................................................................................... 6
2.3 Warnings....................................................................................................................................... 6
2.4 Operating conditions .................................................................................................................... 7
2.5 Electrical safety............................................................................................................................. 8
2.6 Electrical protection...................................................................................................................... 9
2.7 EMC compliance.......................................................................................................................... 10
3. Overview: Airflow Monitor..............................................................................................11
3.1 Introduction ................................................................................................................................ 11
3.2 Display......................................................................................................................................... 12
3.3 Alarms and events....................................................................................................................... 14
3.4 Controls and indicators............................................................................................................... 16
3.5 Operator display panel menu navigation ................................................................................... 18
3.6 External connections................................................................................................................... 20
3.7 Functions..................................................................................................................................... 22
3.8 Components................................................................................................................................ 33
4. Overview: Auto Sash Controller.......................................................................................36
4.1 Features ...................................................................................................................................... 36
4.2 Auto Sash control options........................................................................................................... 37
4.3 Control system components....................................................................................................... 41
5. Installation: Airflow Monitor ...........................................................................................48
5.1 Location....................................................................................................................................... 48
5.2 Installation .................................................................................................................................. 50
5.3 Connections ................................................................................................................................ 55
5.4 Dimensions.................................................................................................................................. 61
5.5 Start up........................................................................................................................................ 63

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6. Installation: Auto Sash Controller ....................................................................................65
6.1 Auto Sash Control Unit................................................................................................................ 65
6.2 Auto Sash motor drive unit......................................................................................................... 68
6.3 Sash light curtain......................................................................................................................... 74
6.4 Installing and aligning the Under Sash sensor ............................................................................ 82
6.5 Tilt switch.................................................................................................................................... 84
6.6 Sash Low switch .......................................................................................................................... 85
6.7 Sash position sensor ................................................................................................................... 87
6.8 Personnel sensor......................................................................................................................... 89
6.9 Auto Sash System Control Box - general wiring diagram............................................................ 96
6.10 Start up........................................................................................................................................ 97
7. Calibration ......................................................................................................................98
7.1 AFA4000/E and AFA4000/E/AS Airflow Monitors ...................................................................... 98
7.2 Auto Sash Controller 1, 2 or 3 position..................................................................................... 101
7.3 Sash lock function ..................................................................................................................... 104
7.4 Over Current Monitor…………………………………………………………………………………………………………..105
7.5 Auto Stop……………………………………………………………………………………………………………………………..106
7.6 Auto Sash Controller –stand-alone.......................................................................................... 107
8. Configuration ................................................................................................................117
8.1 AFA4000/E configuration menus.............................................................................................. 118
8.2 Control settings......................................................................................................................... 125
8.3 Control Setup Guide.................................................................................................................. 132
8.4 AFA4000/E/AS configuration menus ........................................................................................ 133
8.5 Dual Output –Econ Output 2.................................................................................................... 145
8.6 Auto Sash Controller system menus......................................................................................... 157
9. Auxiliary features and connections ................................................................................166
9.1 Dual set point (occupancy) operation....................................................................................... 166
9.2 Optional input function - temperature sensor ......................................................................... 168
9.3 Optional input function –close sash alarm .............................................................................. 171
9.4 Fail safe damper operation....................................................................................................... 175
10.RS485 communications output ......................................................................................177

AFA4000/E VAV Airflow Controller / p.4
10.1 Overview and connections........................................................................................................ 177
10.2 Configuration settings............................................................................................................... 178
10.3 Config Manager......................................................................................................................... 181
11. Operation: Airflow Monitor...........................................................................................183
11.1 Run screen................................................................................................................................. 183
12. Operation: Auto Sash Controller....................................................................................184
12.1 Control philosophy.................................................................................................................... 184
12.2 Modes of operation .................................................................................................................. 184
12.3 Operation and alarm indication................................................................................................ 187
13. Troubleshooting............................................................................................................189
13.1 Fault finding .............................................................................................................................. 189
13.2 Diagnostics menu...................................................................................................................... 192
13.3 Auto sash alarm indications...................................................................................................... 194
14. Cleaning and maintenance.............................................................................................196
14.1 Cleaning..................................................................................................................................... 196
14.2 Contamination .......................................................................................................................... 197
14.3 Maintenance............................................................................................................................. 197
15. Technical specifications .................................................................................................198
15.1 AFA4000/E Airflow Monitor...................................................................................................... 198
15.2 Auto Sash Controller................................................................................................................. 199
16. Warranty.......................................................................................................................205
17. Index.............................................................................................................................206

AFA4000/E VAV Airflow Controller / p.5
1. Introduction
The TEL AFA4000 is a system for controlling and monitoring airflow in industrial and educational
fume cupboards and biological safety cabinets for user safety. The AFA4000 airflow monitor and
controller is available with optional Auto Sash integration. Using the Auto Sash with the
AFA4000 controller means you will no longer need a separate Auto Sash keypad.
The AFA4000 user interface is full colour, intuitive and is easy to navigate. It features a simple
two-step calibration process with on-screen prompts to guide end users. The unrivalled
reliability of the AFA4000 means that once calibrated, you will not need to re-calibrate in the
future. The AFA4000 has in-built communications as standard and it can be used with either
Modbus or BACnet protocol.
Featuring an innovative hot wire sensor, the AFA4000 has no inherent drift meaning that the
sensor will provide stable readings over many years of operation ensuring reliability and safety.
The AFA4000 has full alarm diagnostics and test functionality, a sixty-minute timeline of
environmental conditions and field-upgradable software, with password protected menus and
diagnostic menus to aid installation and commissioning.
This manual covers the AFA4000/E and AFA4000/E/AS VAV airflow controllers.
1.1 Features
•Full colour 3.5” LCD Display for continuous velocity reading in m/sec
•Auto Sash integration
•BACnet and Modbus on board
•Velocity bar graph or fault timeline over the last 60 minutes
•Visual & audible alarms
•Three digital inputs and three digital outputs
•Diagnostics Menu
•Bespoke overlay designs, with a choice of two, coloured cases
•Bespoke software options tailored to customer requirements
•Touch sensitive buttons

AFA4000/E VAV Airflow Controller / p.6
2. Safety
2.1 Safety practices
This guide is a supplement to the safety codes of the user’s country. Not every safety procedure
that should be followed is covered by this guide. Maintaining a safe laboratory environment is
the responsibility of the user.
Review product documentation prior to use and follow instructions carefully.
If the Airflow Monitor or Auto Sash Controller are not used or operated in accordance with this
manual, the protection provided by the devices may be impaired.
2.2 Precautions
•Ensure the equipment voltage corresponds to the voltage available at the installation
position.
•Do not remove equipment panels without shutting down the equipment and disconnecting
the power supply.
2.3 Warnings
2.3.1 Warning notices
WARNINGS must be followed in order to avoid personal injury.
2.3.2 Warning labels
WARNINGS appear as follows:
Switch off the mains voltage and remove the mains cord before maintenance.
Always follow the instructions given by warning labels on the equipment. For further
information refer to this guide and other documentation provided.

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2.4 Operating conditions
2.4.1 General operation
The Airflow Monitor and associated equipment have been designed and tested in accordance
with the International Electrotechnical Commissions (IEC) safety requirements. The Airflow
Monitor conforms to IEC61010-1 (Safety Requirements for electrical equipment for
measurement, control and laboratory use) as it applies to IEC Class 1 (earthed) appliances, and
therefore meets the requirements of EC directive 2014/30/EU.
Adjustment, maintenance or repair of the equipment whilst covers are open or the equipment is
in operation is only to be done by skilled persons who are aware of the potential hazards.
Make unsafe equipment inoperative.
Examples of unsafe equipment:
•Appears damaged
•Fails to perform correctly
•Has undergone transport stresses
•Has been stored incorrectly
2.4.2 Environmental conditions
Ensure the equipment is used under the following conditions:
•Indoors
•Temperature, 5°C to 40°C
•Relative humidity below 80% for temperatures up to 31°C, decreasing linearly to 50% at
40°C
•Electrical supply fluctuations not to exceed +10% of nominal voltage
The protection provided by the equipment may be impaired if the environmental
conditions do not lie within these parameters.

AFA4000/E VAV Airflow Controller / p.8
2.5 Electrical safety
Lethal voltages are present at certain points within the equipment.
When the equipment is connected to mains power, removing the equipment's
covers is likely to expose live parts.
Even when the power switch is off, high voltage can still be present. Capacitors
within the equipment may still be charged even if the equipment has been
disconnected from all live voltage sources.
Connect the Airflow Monitor and associated equipment correctly to a suitable electrical supply.
The supply must have a correctly installed protective conductor (earth or ground), which must
be installed and checked by a qualified electrician before initial power up.
Any interruption of the protective conductor inside or outside the Airflow Monitor
and Auto-Sash Controller Systems, or disconnection of the protective conductor
terminal is likely to make the equipment dangerous.
Never interrupt the protective conductor.
If the mains power cord needs to be replaced, ensure that the replacement cord is
appropriately rated and approved for the intended use.
To prevent potential personal injury and damage to the equipment, switch OFF all
components in the system and disconnect them from the mains power supply
before altering or making any new electrical connections.
When working with the Airflow Monitor System and/or the Auto Sash Controller System:
•Only connect the equipment to a correctly installed mains power outlet that has a
protective conductor connection.
•Do not operate equipment with any covers or internal parts removed.
•Disconnect the equipment from live voltage sources before adjustments, replacements,
maintenance or repairs are carried out. If the equipment must be operated during
adjustment, maintenance or repair, only a supplier’s Service Engineer is to carry out the
procedure.

AFA4000/E VAV Airflow Controller / p.9
•Ensure equipment that is not electrically safe is made inoperative. Secure the equipment
against unauthorised or unintentional operation. Examples of electrically unsafe equipment
conditions are as follows:
•Appears damaged
•Has undergone transport stresses
•Has been stored incorrectly
2.6 Electrical protection
Observe the following electrical protection precautions:
Insulation:
Class I rating for external circuits.
Only connect equipment that meets the requirements of IEC
61010-1, IEC 60950 or equivalent standards.
Installation category:
The equipment can withstand transient over-voltages typically
present on the mains supply. The normal level of transient over-
voltages is impulse withstand (overvoltage) Category II of IEC
60364-4-443.
Pollution degree 2:
Normally only non-conductive pollution occurs. Occasionally,
however, temporary conductivity caused by condensation must
be expected.
External circuits:
External circuits which are connected to the Auto Sash controller,
except mains connection, shall be insulated by double or
reinforced insulation from the mains.

AFA4000/E VAV Airflow Controller / p.10
2.7 EMC compliance
2.7.1 EC Directive
The Airflow Monitor and Auto Sash Controller Systems are designed and tested to meet the
requirements of the EC directive 2014/30/EU and complies with the EMC standard EN61326
(EMC standard for electrical equipment for measurement, control and laboratory use) and
EN55011 (ISM) Class A (RF emissions).
2.7.2 FCC Rules and Regulations
The Airflow Monitor System and Auto Sash Controller Systems are classified as digital devices
used exclusively as industrial, commercial or medical test equipment. They are exempt from the
technical standards specified in Part 15 of the FCC Rules and Regulations based on Section
15.103 (c).

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3. Overview: Airflow Monitor
3.1 Introduction
3.1.1 AFA4000/E
The AFA4000/E VAV Controller can be configured in the field to suit all applications, with
password-protected menus and diagnostic menus to aid installation and commissioning.
3.1.2 AFA4000/E/AS
The AFA4000/E/AS VAV Controller is integrated with the Auto Sash Controller. To set up the
Airflow controller, set the Auto Sash controller to Disabled, Disconnected or Not Configured to
ensure that the sash is under manual control whilst the AFA4000/E/AS airflow monitor is
commissioned. The AFA4000/E/AS auto-detects that the Auto Sash Controller is connected and
the Auto Sash menus and Operation status will not be displayed if the Auto sash is not
connected.
Note The Auto Sash can be used to provide a sash position signal to the AFA4000/E/AS when a
volumetric output is required from the AFA4000/E/AS .This should be set up once both
the AFA4000/E/AS and Auto Sash Controller have been set up and calibrated.

AFA4000/E VAV Airflow Controller / p.12
3.2 Display
3.2.1 Operator display panel
A
Airflow bargraph or timeline display and
control status, with ECON operation status
where applicable.
B
Airflow velocity display with LED halo
(red/amber/green) and optional
temperature display
C
Status window, airflow alarm status Auto
Sash status
D
Airflow monitor pushbutton icons
E
Airflow monitor pushbuttons
F
Menu pushbuttons and alarm mute Auto
Sash Up/Down/Cancel buttons
Figure 1: Operator display panel
Note: Access to the Calibration and Configuration menus is password protected and is factory
set.
To access and or change the password contact the supplier for the engineer’s password
and enter the passwords in the Main Menu, or alternatively use a laptop connected to
the Com port and use the Upload/Download software provided.
3.2.2 Display features
The airflow monitor displays the following features:
•The digital display is a backlit, full colour high resolution graphic unit with a visual display
area of approximately 70 x 52 mm. The display operates through the software allowing the
generation of figures, words and icons. You can choose either blue or black for the
background colour of the display.
•Using the alarm keypad, you can configure the display to show the fume cupboard velocity
in m/sec or fpm. Alternatively, you can configure the display to show AIR FAIL /AIR SAFE
continuously.
A
B
C
D
F
E

AFA4000/E VAV Airflow Controller / p.13
The colour of the velocity on the display screen changes when in an alarm condition, to the
following:
•Air Safe
Green
•Low/ High Air Alarm
Red
•Warning Air Alarm
Amber
An segmented into 60 x 1 minute segments scroll across the display (when
enabled). The event time line is displayed as a graphical scale ranging over 0-1.00 m/sec that
progresses across the screen, representing the airflow value at each segment.
The segment colour changes, as follows, if the value is in the range of an airflow alarm:
•Air Safe
White
•Low/ High Air Alarm
Red
•Warning Air Alarm
Amber
The alternative to the event time line is a dynamic representing the airflow velocity.
The output status is permanently displayed under the bar graph or event time line as either
Manual or Automatic. If the controller is configured to dual set-point mode, the status is
displayed as Manual, High Set Point or Low Set Point.
The display shows an up and down arrow icon, , in the bottom right hand corner of the
screen when an input function is set to Hi / Lo (2 speed operation). The up arrow indicates High
speed and the down arrow indicates Low speed.
•The display shows a Horn icon (with a line across it) when the audible alarm is muted.
•The display backlight dims to save energy when the following functions are in use:
•Fan Off activated - display backlight dims until Fan On is selected.
Backlight brightens to normal level when you access the Set Up or Diagnostics menus.
•Setback activated - display backlight dims until the Setback is deactivated.
Backlight brightens to normal level when you access the Set Up or Diagnostics menus.
•Min Pushbutton activated –display backlight dims until Pushbutton III is set to Run or
Max. Backlight brightens to normal level when you access the Set Up or Diagnostics
menus.
•Auto Dim Screen velocity is exceeded - display backlight dims if the airflow is above the
set value. Backlight brightens to normal level when you access the Set Up or Diagnostics
menus.

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3.3 Alarms and events
Message
Displayed when
Sash high
The Sash alarm is activated, and the sash is raised above the maximum
safe working opening. Sash high alternates on/off with the velocity
reading.
External alarm
The external alarm input is activated (when enabled). External alarm
alternates on/off with the velocity reading.
Air safe
The airflow is at a safe velocity. Air Safe alternates on/off with the
velocity reading.
Air fail
The airflow is less than the low air alarm point. Air Fail alternates on/off
with the velocity reading.
High air (alarm)
The airflow is more than the high air alarm point. High air alternates
on/off with the velocity reading.
High Air
The airflow is more than the high air cut off value. High air is displayed
without the velocity reading.
Setback
The night setback function is activated. Setback alternates on/off with
the velocity reading. The display backlight dims.
Standby
Pushbutton 3 Min function is activated. Standby alternates on/off with
the velocity reading. The display backlight dims.
Alarm disabled
The alarm disable function is activated. Alarm disable alternates on/off
with the velocity reading.
Close sash
The sash is raised and the operator is not present (when activated). Close
sash alternates on/off with the velocity reading.
Emergency
The emergency input is activated or if the MAX or Purge pushbuttons are
pressed. Emergency alternates on/off with the velocity reading.
Fire Alarm
The Fire alarm input is activated. Fire alarm alternates on/off with the
velocity reading.
Filter Exp
The Hours Counter is enabled and the set hours limit is exceeded. Filter
Exp alternates on/off with the velocity reading. A revolving clock icon
displays when the fan is on and the counter is active.

AFA4000/E VAV Airflow Controller / p.15
Message
Displayed when
Off
Pushbutton I is set to Fan On/Off, hide airflow is enabled when the Fan is
switched off. The display backlight dims. All other alarm functions are
inhibited in hide airflow fan off condition.
Start Up
Pushbutton I is set to Fan On/Off, the start-up timer is enabled from 0 -
600 seconds when the Fan is switched on. The remaining start up time is
displayed. All other alarm functions are inhibited during the start-up
period.
Automatic
Econ output is set to Automatic control. It displays at the top of the
screen.
Manual
Econ output is set to Manual output. It displays at the top of the screen.
High Set Point
High Set Point (occupied) mode if Dual Set Operation Point is enabled. It
displays at the top of the screen.
Low Set Point
Low Set Point (unoccupied) mode if Dual Set Operation Point is enabled.
It displays at the top of the screen.
Mute
The audible alarm is muted.
Up / down arrow
The Hi/Lo 2 Speed operation is enabled.
Mains fail
The power fails to connect to the monitor, when activated.
Note: This is an optional extra feature that requires an additional
battery unit.
Low temperature
The cupboard temperature drops below the low temperature alarm
point, when activated. The display alternates on/off with the velocity
reading.
Note: This is an optional extra feature that requires an additional
temperature sensor.
High temperature
The fume cupboard temperature rises above the high temperature alarm
point, when activated. The display alternates on/off with the velocity
reading.
Note: This is an optional extra feature that requires an additional
temperature sensor.

AFA4000/E VAV Airflow Controller / p.16
3.4 Controls and indicators
3.4.1 LED Halo indicator
The alarm unit has a LED Halo indicator that changes colour:
•Red
Alarm
•Amber
Caution
•Green
Safe
The Red Alarm LED Halo is illuminated when pushbutton I is set to Fan On/Off and is switched
off.
3.4.2 Audible alarm sounder
The AFA4000/E has an audible sounder with local or remote mute facilities. You can
permanently disable the alarm in the Cal Config Menu.
The audible alarm is muted when Fan Off is selected on pushbutton I or when the Setback or
Alarm Disable functions are activated.
When the audible alarm is muted/ disabled, the mute icon displays at the bottom left side of the
screen.
When an input is set to the mute function the keypad Mute button is disabled and you can only
mute the alarm by using the selected mute input.
3.4.3 Pushbuttons
The AFA4000/E has 3 menu configurable pushbuttons. Each pushbutton can be configured to a
different function. The pushbutton icon and status is shown on the display above the
pushbutton.
Pushbutton I:
Fan On/Off
Displayed when the pushbutton is set to FAN operation.
Setback O/R
Displayed when the pushbutton is set to Setback Override
operation.

AFA4000/E VAV Airflow Controller / p.17
Pushbutton II:
Lights On/Off
Displayed when the pushbutton is set to Lights operation.
UV Lights On/Off
Displayed when the pushbutton is set to UV Lights operation.
Services On/Off
Displayed when the pushbutton is set to Australian Standards
operation.
Pump On/Off
Displayed when the pushbutton is set to Pump operation.
Setback O/R
Displayed when the pushbutton is set to Night Setback Override
operation.
Pushbutton III:
Scrubber On/Off
Displayed when the pushbutton is set to Scrubber operation.
Lights On/Off
Displayed when the pushbutton is set to Lights operation.
Purge On/Off
Displayed when the pushbutton is set to Purge VAV operation.
MIN
Displayed with the pushbutton is set to Min/Run/Max VAV
operation
RUN
Displayed with the pushbutton is set to Min/Run/Max VAV
operation
MAX
Displayed with the pushbutton is set to Min/Run/Max VAV
operation
Mute
The alarm has a multifunctional Mute button, .
Press Mute once, when the alarm is sounding to mute the alarm.
Press Mute for 5 seconds to access the calibration and
configuration menus.
↑ / ↓
Use the ↑and ↓buttons to scroll through the calibration and
configuration menus or to select options and values.

AFA4000/E VAV Airflow Controller / p.18
3.5 Operator display panel menu navigation
To scroll through menu items, press the ↑and ↓arrows, then press Mute to select an option.
3.5.1 Main menu
To display the Main Menu, from the Run Screen, press and hold the Mute button for 5 seconds
until the Main Menu is displayed.
Menu item
Option
Instructions
Run
Run screen
See Operation section
Set up Monitor
Monitor setup menu
See Monitor set up menu
section
Set up Auto Sash
Note: This option is only
available if the Auto Sash is
connected.
Auto Sash Configuration menu
See Auto Sash Configuration
menu section
3.5.2 Monitor set up menu
Menu item
Option
Instructions
Configure *
Monitor config menu
See section 8.
Calibration *
Calibration
See section 7.
Brightness
Screen Brightness
Adjust Brightness level then
press the Mute button.
Passwords *
Monitor passwords menu
Select the password to set:
•Admin
•Calibration
•Configure
Enter and re-enter the new
password, then press the
Mute button.
Select Done to return to the
Main menu.

AFA4000/E VAV Airflow Controller / p.19
Menu item
Option
Instructions
Done
Return to Main menu
Note: Menu items marked * are password protected. To enter the password, use ↑/ ↓to
change each digit of the password, then press Mute.
3.5.3 Auto Sash Configuration menu
Note: This option is only available if the Auto Sash is connected.
Menu item
Option
Instructions
TEL Sash Closer
Shows the firmware (F/W) and
Hardware (H/W) versions
Read-only information
Setup Menu *
Auto Sash setup menu
See section 8.4.1.
Engineering Menu *
Auto Sash engineering menu
See section 8.4.2.
Exit
Return to Main menu
Note: Menu items marked * are password protected. To enter the password, use ↑/ ↓to
change each digit of the password, then press Mute.

AFA4000/E VAV Airflow Controller / p.20
3.6 External connections
3.6.1 Inputs
The AFA4000/E has the following inputs:
3.6.1.1 Input 1, Input 2, Input 3
These are volt-free inputs configurable for:
•Normally closed relays
•Normally open relays or
•Analogue 0 - 5 Vdc input
The inputs can be configured as:
Digital input functions (closed or
open volt free contact):
Note: Default values are:
Input 1: Night setback
Input 2: None
Input 3: Sash high
Fire Alarm
Sash high
Mute
Emergency
Fan stop
External alarm
Personnel sensor
Night set-back
Mains fail
Alarm disable
Sash warning
None
High / Low
Analogue input functions:
Duct pressure
Sash position
Volume pressure
Temperature
Damper feedback
3.6.2 Outputs
The AFA4000/E has the following outputs:
3.6.2.1 Relay outputs 1, 2, 3
These are volt-free outputs configurable for:
•Normally closed relays or
•Normally open relays
Note: Changeover relays are available with the Econ power supply relay interface unit. The
relay interface has an AUX relay output that can be selected to duplicate the action of
R1, R2 or R3 via a DIP switch.