Johnson Controls METASYS VAV140 Technical Manual

Application Specific Controllers Technical Manual 636.3

VAV Controller Section

Technical Bulletin

Issue Date 0309

Code No. LIT-6363040

Introduction Page 5





Description 5

 OEM Applications 8

 Standards Compliance *

8

 Coordination of Factory Mounted VAV Systems

8

Configuring the Controller 11

 Using HVAC PRO for Windows Configuration Tool 11

 Defining a VAV Control Device Object in Metasys Software 13

Installation Procedures 17

 Tools Needed 17

 Environmental Information 17

 Mounting the Controller 18

 Power Line Wiring Transient Noise Precautions 21

 I/O and Communication Lines Wiring Transient Noise Precautions 23

Variable Air Volume (VAV) Controller

* Indicates those sections where changes have occurred since the last printing.

2 VAV Controller—Variable Air Volume (VAV) Controller

Wiring Details Page 25

 Power Source and Loads 26

 Grounding and Isolation 27

 I/O and Communication Terminals 29

 Power, Zone Bus, and N2 Connections 36

 Analog Inputs 36

 Binary Inputs 38

 Binary Outputs 38

 Analog Outputs 38

 Zone Bus

39

 Wiring to RLY50/002 Relays

39

 Wiring Sensors and Actuators 40

Networking the Controller 45

 N2 Bus Overview 45

 Installing the N2 Bus 46

 Zone Bus Communications 49

Application Examples 51

 Single Duct Applications 51

 Dual Duct Applications 63

Downloading/Commissioning 71

 Via Zone Bus 71

 Via N2 Bus

71

 Incremental Valve Actuator Stroke Time

72

 Incremental Damper Actuator Stroke Time

73

 Zone Terminal Setup for Balancing Contractors

73

* Indicates those sections where changes have occurred since the last printing.

VAV Controller—Variable Air Volume (VAV) Controller 3

Troubleshooting Page 75

 Hardware Installation Inspection 75

 Tools Needed for Troubleshooting 75

 Installation Checkout 76

 Troubleshooting the VAV Controller with HVAC PRO for Windows 81

 Troubleshooting the N2 Bus and Networked VAV Controller 82

 Zone Bus Troubleshooting -- HVAC PRO for Windows 83

Ordering Information 85

 Johnson Controls Code Numbers 85

 Vendor Code Numbers

87

Specifications *89

* Indicates sections where changes occurred since the last printing.

4 VAV Controller—Variable Air Volume (VAV) Controller

VAV Controller—Variable Air Volume (VAV) Controller 5

1 2FIntroduction

The Variable Air Volume (VAV) Controller is an electronic device for

digital control of single duct, dual duct, fan powered, and supply/exhaust

VAV box configurations. See 50HFigure 1. You may use the VAV as a

standalone controller or connected to the Metasys network through a

Network Control Module (NCM) or Companion system.

When connected to the Metasys Network, the VAV provides all point and

control information to the rest of the network. The devices communicate

through an N2 Bus.

Each VAV Controller application uses a different sequence of operation,

all of which are covered in the HVAC PRO for Windows User’s Manual

(FAN 637.5).

Description

6 VAV Controller—Variable Air Volume (VAV) Controller

1 2 3 4 5 6

BINARY INANALOG INPUTS BINARY OUTPUTS

BINARY INPUT

ANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

ANALOG INPUTS

COMMON

TO

ZONE

STAT

BINARY OUTPUT

1 2 3 4 5 6 7 8

Z BUS

DSI

P5

P6

1 2 3 4 5 6

BINARY COM

1 2 3 4 5 6

110-111

BINARY IN

ANALOG INPUTS

BINARY OUTPUTS

BINARY INPUTANALOG INPUTS

1 2 3 4 5 6 1 2 3 4

ANALOG INPUTS

COMMON

TO

ZONE

STAT

BINARY OUTPUT

1 2 3 4 5 6

Z BUS

DSI

1 2 3 4 5 6

ANA OU

T

ANALOG

OUTPUT

1 2

BINARY COM

R

Figure 1: VAV110 (top) and VAV111 (bottom) Controller

VAV Controller—Variable Air Volume (VAV) Controller 7

Table 1: VAV Controller Model Features

Feature VAV100/101

(Discontinued)

VAV110/111 VAV140/141

Ambient

Temperature

Rating

32 to 122F

(0 to 50C)

32 to 122F

(0 to 50C)

32 to 122F

(0 to 50C)

Analog Inputs

6

RTD temperature

elements (1000 ohm

nickel, platinum, or

silicon)

2k ohm setpoint

potentiometers

0 to 10 VDC or

0 to 2 VDC

transmitters

6

RTD temperature

elements (1000 ohm

nickel, platinum, or

silicon)

2k ohm setpoint

potentiometers

0 to 10 VDC or

0 to 2 VDC

transmitters

6

RTD temperature

elements (1000 ohm

nickel, platinum, or

silicon)

2k ohm setpoint

potentiometers

0 to 10 VDC or

0 to 2 VDC

transmitters

Binary Inputs

4

(4) Dry contacts

(1) Momentary push

button from zone

sensor for temporary

occupancy mode

BI 4 may be used as

an accumulator input

for frequencies less

than 100 Hz.

4

(4) Dry contacts

(1) Momentary push

button from zone

sensor for temporary

occupancy mode

BI 4 may be used as

an accumulator input

for frequencies less

than 100 Hz.

4

(4) Dry contacts

(1) Momentary push

button from zone

sensor for temporary

occupancy mode

BI 4 may be used as

an accumulator input

for frequencies less

than 100 Hz.

Analog

Outputs

0/2

0 to 10 VDC

@ 10 mA

0/2

0 to 10 VDC

@ 10 mA

0/2

0 to 10 VDC

@ 10 mA

Binary

Outputs

8/6

24 VAC Triacs

@ 0.5 amperes

8/6

24 VAC Triacs

@ 0.5 amperes, or

0.8 amperes if total

power is limited

8/6

24 VAC Triacs

@ 0.5 amperes, or

0.8 amperes if total

power is limited

N2 Bus

Not Isolated * Isolated Isolated

Zone Bus

Discrete connections

at controller

Discrete connections

at controller

Discrete connections

at controller

8-pin phone jack on

controller

8-pin phone jack on

controller

8-pin and 6-pin phone

jack on controller *

6-pin phone jack at

zone sensor

6-pin phone jack at

zone sensor

6-pin phone jack at

zone sensor

LED Indication * LED Indication *

24 VAC Power

Terminations

Quick Connects

(Spade Lugs) *

Removable Screw

Terminal Block

Removable Screw

Terminal Block

I/O

Terminations

Quick Connects

(Spade Lugs)

Quick Connects

(Spade Lugs)

Fixed Screw Terminal

Block *

N2

Terminations

Fixed Screw Terminal

Block *

Removable Screw

Terminal Block

Removable Screw

Terminal Block

* VAV Controller model feature differences

8 VAV Controller—Variable Air Volume (VAV) Controller

When providing VAVs for projects which use Trane or TITUS

terminal boxes, consider using the AS-VAVDPTx-1 product (refer to

Building VAVDPT Applications Application Note (LIT-6363042) in the

Application Specific Controllers Technical Manual (FAN 636.3). Trane

and TITUS are both Original Equipment Manufacturers (OEMs) who

provide VAV terminal boxes for projects. Trane typically provides the

damper actuator with their terminal box, and TITUS provides the damper

actuator with their QFPC Series Fan Powered Box. The VAVDPT comes

in two models, which include a VAV Controller and a DPT-2015 Velocity

Pressure Transducer. The DPT is mounted and prewired to the cover of

the VAV. Refer to the OEM Reference Manual (FAN 638).

The VAV Controller complies with the following standards:

z FCC Part 15, Subpart J, Class A

z IEEE 472, IEEE 518

z IEEE 587 Category A

z UL 916 Listed

z VDE 0871 Class B

A factory mounted VAV box control system requires close coordination

between a variety of different disciplines. Refer to the OEM Reference

Manual (FAN 638) for factory manufacturer’s details. Although the

responsibilities may differ per city or region, the following parties are

usually involved on the job:

z controls contractor

z mechanical contractor

z local VAV box manufacturer’s representative

z balancing contractor

z electrical contractor

Typically, the mechanical contractor is the focal point for coordinating the

entire process. The basic responsibilities under the domain of the

mechanical contractor are:

1. Purchasing the VAV box system. Most specifications include the

OEM mounting fees and enclosures for the control system in the

mechanical contractor’s price. Mounting fees vary per box

manufacturer but ranges can be found in the OEM Reference Manual

(FAN 638).

2. Providing the release schedule for the VAV boxes to the job.

3. Contracting, or working closely with, the balancing contractor to

ensure the system is set up per the mechanical prints.

Note: The owner often directly hires the balancing contractor. This

ensures neutrality in dealing with other contractors involved in the

project.

3F4F5FOEM

Applications

6F7F8FStandards

Compliance

9F10F11FCoordination of

Factory

Mounted VAV

Systems

VAV Controller—Variable Air Volume (VAV) Controller 9

In conjunction with the mechanical contractor, the controls contractor’s

responsibilities include:

1. Coordination of the control system release schedule to the box

manufacturer to ensure the mechanical system delivery schedule can

be met. Coordination with the local box manufacturer representative is

normally required.

2. Coordination with the electrical contractor to ensure the following

steps are covered.

z 24 VAC power is provided at each VAV Controller.

z N2 Bus wiring is pulled and terminated.

z Valve actuator wiring is pulled and terminated.

z Zone sensor cables are pulled. The use of phone cable for

terminating zone sensor wiring allows basically anyone to

terminate zone sensors in certain locales.

z If desired, the N2 address switches can be set by the electrical

contractor.

3. Initial loading of the HVAC PRO for Windows configuration files is

done once the electrical contractor’s functions are completed in

preparation for the final system balancing.

4. Training of the balancing contractor to ensure the balancing contractor

knows how to use the Zone Terminal (ZT) or HVAC PRO for

Windows Commissioning mode so they can perform the final system

balancing.

5. Mounting and terminating the cable connections for the zone

temperature sensor. Set the N2 address switch if the electrical

contractor was not contracted to perform this function.

6. Configuring, downloading, and commissioning the controller.

10 VAV Controller—Variable Air Volume Controller

VAV Controller—Variable Air Volume (VAV) Controller 11

12F13F14FConfiguring the Controller

Use HVAC PRO for Windows to configure the VAV. VAV110/111 and

VAV140/141 models require HVAC PRO for Windows. HVAC PRO for

Windows also works with the VAV100/101 models. This easy-to-use

software tool configures, commissions, and downloads the VAV

Controller’s data base.

51HFigure 2 illustrates the HVAC PRO for Windows configuration process.

Refer to the HVAC PRO for Windows User’s Manual (FAN 637.5) for

specific information when configuring the VAV Controller.

Using

HVAC PRO

for Windows

Configuration

Tool

12 VAV Controller—Variable Air Volume Controller

PROFLO40

Download Controller

1. Attach MM-CVT101-1 Converter

or AS-CBLPRO-2.

2. Select Download - Current Configuration.

3. Select Bus type, comm. port, and

N2 address (if N2 Bus).

4. Select OK.

Exit HVAC PRO for Windows

Start HVAC PRO for Windows

Complete Configuration Process

1. Fill in job information.

- Option - Job Information

2. Review and change inputs/outputs.

3. Review and change default parameters.

Commission Controller

1. Attach MM-CVT101-1 Converter

or AS-CBLPRO-2.

2. Select Commission - Current Configuration.

3. Select Bus type, comm. port, and

N2 address (if N2 Bus).

4. Select OK.

5. View / Adjust parameter values.

6. Review controller information.

7. Exit Commissioning.

8. If adjustments were made, save

changes to controller and to file.

9. Unplug MM-CVT101-1 or AS-CBLPRO-2..

Save Configuration

1. File - Save As

2. Select device type.

3. Enter file name for configuration file.

Select File-New

1. Select VAV Applications.

2. Select Single or Dual Duct.

Complete Q/A Session

Figure 2: Steps in Configuring a VAV Controller Using

HVAC PRO for Windows

VAV Controller—Variable Air Volume (VAV) Controller 13

Note: You can load and commission the controller either locally with the

AS-CBLPRO-2 interface at the zone sensor (Figure 15) or from a

central location where the N2 has been pulled, controller’s field

hardware addressed, and an MM-CVT101-1 interfaced to the laptop.

Using a Metasys Network system, you need to define a VAV Controller

device object by entering data into the Attribute menu as seen on the

Operator Workstation.

1. Go to the Network Map.

2. Double-click the system name in which you want to add the new VAV

object.

3. Click New in the Item pull-down menu.

4. Click on Type: N2 devices in the Item New dialog box.

OK

CANCEL

Accumulator

Analog data

Analog input

Analog output digital

Analog output setpoint

Binary data

Binary input

Binary output

MS data

MS input

Type

MS output

Control system

DL/LR group

LC group

PID loop

Fire Zone

L2 devices

N2 devices

S2 devices

Card Reader

Hardware system name:

Hardware object name:

Copy of (System\Object):

VAV - Item New

ITEM NEW

Figure 3: Item New Dialog Box

Note: The Hardware System and Hardware Object text fields are not

used for this object type.

5. Click OK to display the Add N2 Device dialog box.

15F16F17FDefining a VAV

Control Device

Object in

Metasys

Software

14 VAV Controller—Variable Air Volume Controller

n2dv

c

OK

CANC

EL

Har

d

ware -- A

dd

N2 Device

D

e

vi

ce

T

ype

A

HU

D

600

DCM

DR

9100

DX9100

I

FC

-2020

LCD

VAV

Figure 4: Add N2 Device Dialog Box

6. Highlight VAV.

7. Click OK to display the VAV Definition window (52HFigure 5).

F

l

oo

r

1

S

y

s

t

em

Name

Ob

j

ec

t

Name

E

x

panded

I

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Name

G

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aph

i

c

S

y

mbo

l

#

Op e

r

a

ti

ng

I

n

s

t

r

.

#

Towe

r

_

I

He

l

p

I

t

em

E

d

it

V

i

e

w

A

c

ti

on

G

o

To

Accessory

Ha

r

dwa

r

e

N2

T

r

unk

Numbe

r

N2

De

v

i

ce

Add

r

es

s

Po

ll

P

r

i

o

r

it

y

1

0

3

F

l

ag

s

Au

t

o

D

i

a

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ou

t

N

Comm

D

i

sab

l

ed

N

Ha

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dwa

r

e

NC

#5

Book ma

r

k

windob

j

VAV Definition

Figure 5: VAV Control Device Object Definition Window

Note that some of the fields in the window are blank and some are already

filled in. You must fill in the blank attribute fields of required attributes.

An N2 device address from 1 to 255 must also be specified. Attribute

fields that are already filled in contain default values that may be accepted

or changed.

VAV Controller—Variable Air Volume (VAV) Controller 15

Table 2 explains the blank attributes. The Operator Workstation User’s

Manual (FAN 634) describes the general procedures for entering and

modifying data.

Table 2: Blank VAV Object Attributes

Attribute Description Entry Values . . .

Object Name

Identifies the object

(i.e., ILC). The object name

cannot be duplicated in the

system.

1 to 8 alphanumeric

characters

Expanded ID

Further identifies the object

(i.e., LC Device 1)

0 to 24 alphanumeric

characters

(Optional)

8. To save the new VAV object, select Save from the Item pull-down

menu. The object is added to the NCM data base.

9. Upload the NCM to make an archive copy of the new object following

the instructions in the Operator Workstation User’s Manual (FAN

634), the Advanced User’s Guide tab, the Uploading and Downloading

Data Bases chapter, the Uploading from the NCM section.

Once you have defined the VAV object, you can modify or monitor its

attribute values online using the VAV object Focus window. See the

Operator Workstation User’s Manual (FAN 634) for more information on

using Focus windows.

Modifying and

Monitoring the

VAV Object

16 VAV Controller—Variable Air Volume Controller

VAV Controller—Variable Air Volume (VAV) Controller 17

18F19F20FInstallation Procedures

Instructions for the installation of the VAV Controller and its accessory

devices are detailed in this section. The types and numbers of components

(sensors and actuators) selected for use with the VAV vary according to

application. Analyze the proposed installation for logical places to locate

these devices and draw up an inventory based on that study. Information

on types of accessory devices available is in the Ordering Information

section of this technical bulletin.

Most VAV installation should be coordinated with the VAV box

manufacturer for factory mounting. The OEM Reference Manual

(FAN 638) describes the steps and pricing to coordinate a factory mount

solution.

Tools needed for a typical installation include:

 HVAC PRO for Windows currently released software

 IBM PC-compatible laptop computer

 Windows 3.x or Windows 95

 two screwdrivers (1/8 in. and 1/4 in. flat-blade)

 AS-CBLPRO-2 (Zone Bus communication tool)

 MM-CVT101-0 (N2 Bus communication tool)

 AS-ZTU100-1 (Zone Bus interface to application specific controllers)

The installation site of the VAV Controller must meet the following

environmental standards.

 The atmosphere must be free of explosive vapors or escaping gases.

 The atmosphere must be free of exposure to corrosive chemical or salt

vapors, which might damage electrical equipment.

 The temperature must be maintained between 32 to 122F (0 to 50C)

with the relative humidity (non-condensing) maintained between 10 and

90%.

 The power line must be “clean,” without electrical noise transients that

are often present in industrial environments. Commercial and

residential buildings typically have clean power, but may not, depending

on the location, nearby equipment, etc. Follow the power line wiring

transient noise precautions.

Tools Needed

21F22F23FEnvironmental

Information

18 VAV Controller—Variable Air Volume Controller

Typically the most cost effective and highest quality installation of the

VAV Controller, EDA-2040 Damper Operator, and DPT-2015 Velocity

Pressure Transducer can be accomplished by the box manufacturer. The

OEM Reference Manual (FAN 638) describes the relationship, pricing, and

process to accomplish factory mounting of the VAV control system at most

of the key box manufacturers.

If the job cannot be factory mounted, check with the VAV box

manufacturer to determine if a control enclosure for the VAV Controller

and Actuator/Velocity Pressure Transducer combination is already

available on the VAV box. If there is not an available enclosure, the

common packaging for the VAV Controller is an enclosure provided by the

contractor or the Johnson Controls EN-EWC10, EN-EWC15, BZ1000, or

AS-ENC enclosure. The controller requires a flat mounting surface area to

match its dimensions:

 6.5 x 6.4 x 2.2 in./165 x 163 x 56 mm (H x W x D) without enclosure

 6.8 x 7.3 x 4.7 in./173 x 185 x 119 mm (H x W x D) with the

AS-ENC100-0 enclosure

 7 x 13 x 6 in./180 x 330 x 150 mm (H x W x D) with the

EN-EWC10-0 and EN-EWC15-0 enclosure

Make sure you allow enough room to install the enclosure and conduit for

wiring terminations to the controller. 53HFigure 7 shows a common packaging

configuration for the VAV Controller.

24F25F26FMounting the

Controller

Factory Mounting

VAV Controller—Variable Air Volume (VAV) Controller 19

vavpwer

TM

+15VD C

24VAC

+15VD C

24VAC

COMMON

TRACS

COMMON

Low Voltage

Wiring Trough

Figure 6: EWC10 Enclosure with VAV Controller

and 50 VA Transformer

The VAV can be directly mounted into an EWC10/15 enclosure. You may

also purchase the VAV premounted in a EWC10 enclosure with a

50 VA transformer. Refer to the Application Specific Controllers

Technical Manual (FAN 636.3) for instructions on mounting the enclosure

to a wall.

To mount the VAV in the EWC10:

1. Orient the VAV so that its terminals face the low voltage wiring

trough (Figure 6).

2. Align the three mounting holes in the base of the controller with the

holes in the back of the enclosure. On the side with four mounting

holes, use the two outside holes for mounting in the EWC. See the

Universal Packaging Module Technical Bulletin (FAN 636.3) for a

more detailed explanation.

3. Secure the controller with three No. 8 x 1 in. screws. For best results,

use a plastite-type thread. A thread-forming or sheet metal thread type

may also be used.

Position the controller (or controller’s enclosure) on the mounting surface

before installation to ensure the calculated mounting area is correct. You

can make precise measurements for distance between controller terminals

and sensor/actuator mounting points on the VAV terminal. Confirm

electrical power source and conduit requirements prior to mounting.

Mounting the

VAV into a

Universal

Packaging

Module

Field Mounting

20 VAV Controller—Variable Air Volume Controller

You can install a VAV Controller into a control panel or an AS-ENC100-0

enclosure.

Top / Bottom

Side

VAV Enclosure

(

Cover

)

VAV Controller

Do not use this knockout.

Otherwise, controller will

be in the way of wiring.

vavencl2

2

3

1

4

5

Figure 7: Installing the VAV Controller in an Enclosure Kit

Mount the VAV in any convenient location using the predrilled mounting

holes. The controller must be mounted on a wall or panel where it can be

easily wired through the enclosure cover. Mount the VAV vertically for

best DPT (differential pressure transmitter) performance. The same

instruction applies to remote location packages. Refer to

54HFigure 7 when

installing a VAV Controller.

1. Secure the VAV  inside the enclosure kit , using three screws

through the mounting tabs  on the sides of the controller board base.

2. Position the VAV and enclosure so that it rests firmly against the

mounting surface.

3. Using a flat-blade screwdriver and pliers, remove the necessary wire

passage knockouts .

Note: Do not use knockouts on the opposite sides of enclosure, as you

will not be able to remove the VAV board.

4. Attach the enclosure cover  after installing wiring.

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