Johnson Controls Metasys DX-9100 Technical Bulletin

Brand: Johnson Controls

Model: Metasys DX-9100

Type: Technical Bulletin

Johnson Controls Metasys DX-9100 is a powerful and versatile device that can be used for a wide range of applications in building automation. It is ideal for controlling HVAC systems, lighting, and other building systems. The DX-9100 is easy to install and use, and it can be customized to meet the specific needs of your building.

Some of the key features of the DX-9100 include:

Open protocol support: The DX-9100 supports a variety of open protocols, including BACnet, Modbus, and LonWorks. This makes it easy to integrate the DX-9100 into your existing building automation system.
Graphical user interface: The DX-9100 features a user-friendly graphical user interface that makes it easy to configure and operate the device.

Some of the key features of the DX-9100 include:

Open protocol support: The DX-9100 supports a variety of open protocols, including BACnet, Modbus, and LonWorks. This makes it easy to integrate the DX-9100 into your existing building automation system.
Graphical user interface: The DX-9100 features a user-friendly graphical user interface that makes it easy to configure and operate the device.

M-Applications 653

Metasys Ventilation Controller Section

Issue Date 1000

Part No. 24-8395-26 Rev. —

Code No. LIT-653425

ECHNICAL

ULLETIN

Metasys Ventilation Controller Application

for the DX-9100

Metasys Ventilation Controller Application for the DX-9100.............3

Introduction........................................................................................................*3

Key Concepts......................................................................................................5

Johnson Controls CO

Concentration Samplers............................................................ *5

MVC-2000-1 Package ...................................................................................................*5

Universal Packaging Module (UPM) ............................................................................... 6

DX-9100 ........................................................................................................................*7

Sensor................................................................................................................... *7

Air Valve ......................................................................................................................... 8

Air Pump......................................................................................................................... 8

Air Filter ......................................................................................................................... *8

Return, Supply, and Outdoor Air Ports............................................................................ 8

Sample System .............................................................................................................*9

HVAC System Requirements........................................................................................ 10

Location Considerations ............................................................................................... 10

Procedure Overview ........................................................................................*12

Detailed Procedures .........................................................................................13

Installing a UPM........................................................................................................... *13

Installing Air Sampling Devices and Tubing .................................................................. 14

Trending Data.............................................................................................................. *15

Checking the Solenoid Valves ..................................................................................... *16

Calculating the OA Flow .............................................................................................. *16

Checking the Controller Application ............................................................................. *17

Reloading the Controller Application ............................................................................*17

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

Metasys Ventilation Controller

Metasys Ventilation Controller Application for the DX-9100

Metasys Ventilation Controller

Application for the DX-9100

Introduction

A Johnson Controls Building Automation System (BAS), along with

the Metasys® Ventilation Controller (MVC) 2000-1 Multipoint Gas

Concentration Sampler, can provide building managers with a

cost-effective method of addressing the Ventilation Rate Procedure

found in ASHRAE (American Society of Heating, Refrigeration, and

Air Conditioning Engineers) Standard 62-1999. The MVC-2000-1 is

used to implement the Metasys Ventilation Controller Application

(MVCA) that allows a facility manager to:

•

monitor the flow of outdoor air into a building, using a patented

tracer gas method

•

control the flow of outdoor air into a building according to

ASHRAE guidelines, e.g., 20 cubic feet per minute (cfm)/person

for office spaces

•

document the ventilation flow for future reference, which enables

the facility manager to compare the readings with established state,

local, federal, or ASHRAE guidelines

•

perform CO

high-limit control (override of ventilation controller)

in response to greater than expected occupancy in critical areas

such as conference rooms

•

view CO

concentrations in supply, return, and outdoor air at the

workstation

•

diagnose the control system, since deviations in trended CO

readings can suggest problems with the Heating, Ventilating, and

Air Conditioning (HVAC) equipment

•

set alarms based on CO

levels exceeding a user-defined

maximum or differential

Metasys Ventilation Controller

This technical bulletin describes how to:

•

install a Universal Packaging Module (UPM)

•

install air sampling devices and tubing

•

trend data

•

check the solenoid valves

•

calculate the Outdoor Air (OA) flow

•

check the controller application

•

reload the controller application

Metasys Ventilation Controller Application for the DX-9100

Key Concepts

Johnson Controls CO

Concentration Samplers

Johnson Controls offers two 3-point, multiplexed CO

measurement

devices, as shown in Table 1.

Table 1: Attributes of the MVC-2000-1

Product Intended Use Enclosure Controller Software Links

MVC-2000-1

3-point,

multiplexed CO

measurement

UPM

Enclosure

One

Metasys

Extended

Digital

Controller

(DX-9100)

GX-9100 Application

for MVC is

pre-installed in the

DX-9100.

Metasys

Supervisory

Controller and

workstation links

possible but not

required.

This document gives procedures that are unique to the MVC-2000-1

and its components as shown in Figure 1. Refer to existing product

documentation for standard procedures involving these components.

MVC-2000-1 Package

Many of the components of the MVC-2000-1 package are

Johnson Controls products, including the:

•

UPM

•

DX-9100, Version 2.4 or later

•

GX-9100 Configuration Tool Software for the DX-9100

•

V11HGA-100 3-way Solenoid Air Valve

•

A-4000-137 Air Filter

Metasys Ventilation Controller

Mvc2000B

DX-9100

3-Way

Valves

Sensor

Ports for Outside,

Return, and Supply Air

Air Filter

Air Pump

Figure 1: Components of an MVC-2000-1

Universal Packaging Module (UPM)

The MVC-2000-1 product line utilizes the EN-EWC35-0 UPM. Each

EWC number ends with a “5,” which means that the UPM enclosure

with cover also comes equipped with a transformer and a power box.

Refer to the UPM literature for the following UPM procedures:

•

engineering

•

installation, which includes:

mounting

landing conduit

power connections

grounding and bonding

•

commissioning

Metasys Ventilation Controller Application for the DX-9100

DX-9100

The DX-9100 is a controller manufactured and marketed by

Johnson Controls. The Metasys Ventilation Controller Application of

the GX-9100 Software Tool is used to program the DX-9100.

DX-9100 Hardware

The MVC-2000-1 product utilizes one DX-9100. The DX-9100 is

factory installed in the MVC-2000-1.

CAUTION: Do not use any additional inputs or outputs on

the DX-9100, which is performing the outdoor

air flow calculations. The GX-9100 software

uses the full capabilities of the controller and

adding additional inputs or outputs risks

overburdening the system.

GX-9100 Software Configuration Tool

To use the MVCA, it is necessary to know GX-9100 basics such as:

•

opening a file

•

downloading a file

•

commissioning a DX-9100

These procedures are contained in the GX-9100 Software

Configuration Tool User’s Guide (LIT-6364060).

GX-9100 Application for MVC

The MVCA is factory downloaded into the DX-9100.

For an explanation of the GX-9100 application for MVCA, refer to the

Metasys Ventilation Controller Application (MVCA) Application Note

(LIT-653435).

Sensor

Each MVC-2000-1 contains a single CO

sensor. It is used to sense the

levels in three distinct airstreams:

•

supply air

•

return air

•

outdoor air

This is achieved through the use of two 3-way pneumatic valves and

the associated multiplexing control. Three separate pneumatic lines

are multiplexed into the single CO

sensor.

Metasys Ventilation Controller

The CO

sensor is factory mounted and wired in the MVC-2000-1

enclosure. Since it is also factory calibrated, there is no need to

calibrate the CO

sensor before starting the MVCA.

Air Valve

Each MVC-2000-1 contains two solenoid air valves. These

two V11HGA-100 3-way solenoid air valves switch the input source

of sampled air from one of three sampling tubes to the CO

sensor.

This allows samples from three different airstreams to be multiplexed

into a single CO

sensor.

The solenoid air valves have already been installed in the

MVC-2000-1 enclosure. Electrical power has been connected.

No installation or commissioning procedures are necessary for the air

valves. If a problem arises with this product, refer to the V11 Series

Three-Way Solenoid Air Valve Technical Bulletin (LIT-7171550X)

found in the Pneumatic Control Manual (FAN 717.1).

Air Pump

The MVC-2000-1 comes equipped with an air pump. The pump

maintains proper air flow between the air sampling points and the

sensor regardless of duct static pressure. No installation or

maintenance procedures are required for the air pump. The air pump is

factory installed in the MVC-2000-1 enclosure. If the pump should

fail, replace it with a 0.8 liters/minute (L/min.) pump. Eight L/min is

equivalent to 0.21 gallons/minute (gal/min).

Air Filter

Each MVC product contains an A-4000-137 air filter. This removes

particulate and moisture from the airstream, to prevent damage to the

sensor. The A-4000-137 filter also inhibits contamination of the

pump and the CO

sensing chamber.

Inspect the air filter every few months. Replace the filter if a dark red

color appears on the outer surface, indicating oil or water

contamination.

Return, Supply, and Outdoor Air Ports

The return, supply, and outdoor air samples enter the UPM enclosure

through their respective ports.

Metasys Ventilation Controller Application for the DX-9100

Sample System

Figure 2 shows a sample system with an MVC-2000-1 connected to a

Metasys Supervisory Controller that supports the DX-9100 via an

N2 Bus. The Metasys Supervisory Controller is optional and the

workstation is only required for visual trending of data. Linked and

modulated outdoor air flow dampers and a supply air flow measuring

station are required parts of the system.

Supervisory

Controller

does data trending.

MVC-2000-1

VAV Air

Handling System

Supply Air Flow

Measuring Station

Coupled

Dampers

Workstation

Printer

archives and prints

trend data.

MVCAPB5

Calculates

outdoor air flow

and controls

the dampers.

Supply Air Flow

Multiplexed Samples

of Supply, Return,

Outdoor Air

Discharge Air Temperature

Mixed Air Damper Control

Supervisory

Controller

N2 Bus

Air Handling Unit

Controller

N2 Bus

Figure 2: Sample System Using MVC-2000-1

Connected to a Metasys Supervisory Controller

Metasys Ventilation Controller

HVAC System Requirements

In order to achieve optimum performance from the application, the

following checklist must be used to evaluate the HVAC system prior

to installation. Refer to items that are appropriate to the installation. If

any items below are questionable, contact a Johnson Controls technical

support representative.

•

Is the HVAC system in good working condition?

•

Are all controls and controlled systems properly calibrated?

•

Are all control loops working as they were commissioned?

•

Is the HVAC system appropriately sized for the building it serves?

•

Are the ducts sized properly for the air handling system?

•

Are the dampers, linkages, and actuators in good operating

condition?

•

Is the air measuring station in the supply air duct installed and

operating properly?

•

Is the outdoor air intake free from the re-entrainment of exhaust

air?

•

Is the outdoor air intake free from the entrainment of pollution

sources, e.g., carbon monoxide from trucks and buses?

Location Considerations

Consider the following factors when deciding where to mount the

MVC-2000-1 enclosure:

•

Stability: The enclosure should be mounted to a flat, stable,

non-vibrating mounting surface (heavy-duty drywall or concrete)

where the unit will not be subjected to moisture accumulation or

drastic temperature variation.

•

Ambient Operating Conditions: Temperature: 0 to 40°C

(32 to 104°F); humidity: 10 to 95% Relative Humidity (RH),

non-condensing.

CAUTION: Because it contains delicate sensing instruments,

the MVC should be located in an environment in

which the ambient temperature is normally above

5°C (40°F). The MVC is not designed to be located

on an exposed rooftop.

Metasys Ventilation Controller Application for the DX-9100

•

Position: Mount the enclosure vertically.

•

Air Sampling Locations: Remote or local sensing is acceptable;

the outdoor and return air sampling devices can be mounted up to

30.5 m (100 ft) away from the unit. The supply air sampling device

can be mounted up to 9.2 m (30 ft) away from the unit.

•

Outdoor Air Flow: The outdoor air flow sampling device can be

mounted in the outdoor air intake ductwork. However, if it is likely

that exhaust air could affect the sensor in the outdoor air intake

ductwork, then a mounting location outdoors (properly enclosed

and free from exposure to the elements) is preferred.

•

Air Stratification: The air sampling devices must collect air that

is sufficiently mixed in order to deliver accurate CO

readings. The

sampling devices should extend into the middle of the air streams,

and be placed at a reasonable distance from where any two air

flows mix together.

Metasys Ventilation Controller

Procedure Overview

Table 2: Using the MVCA with the DX-9100

To Do This Follow These Steps:

Install a UPM

In a secure location, install the UPM according to procedures listed in the

Universal Packaging Module Technical Bulletin (LIT-6363070). Note

shock and equipment damage hazards. Connect the N2 Bus to the

DX-9100. Complete field connections to the terminal blocks before the

controller is attached to the base. If you need more room, remove the

bottom endcap of the UPM by disconnecting the assembly screws.

Complete the field wiring and reassemble the endcap, making sure not to

pinch any wires. In cramped or poorly-lit areas, reassembly can be

difficult.

Install Air Sampling Devices

and Tubing

Select locations for the air sampling devices in the air flows. Place the

sampling device with the open end facing into the air flow. Seal the vent

around the tubing. Install the remaining devices. Remove the packing

material and tie-wrap from the air pump.

Trend Data

For simple monitoring, refer to the appropriate workstation user’s manual

for your system.

Check the Solenoid Valves

Make sure the valves change state every sixty seconds and verify that

these state changes are in the proper sequence.

Calculate the OA Flow

After the system has stabilized and the Supply Air (SA) flow has been

checked, use the following equation to determine whether the system is

functioning correctly based on the CO

levels of OA, SA, and

RA (Return Air) flows: [OA CO

] ≤ [SA_CO

] ≤ [RA_CO

Check the Controller

Application

To check the controller application, use the GX-9100 software to verify

that the system remains stable as the control strategy changes from

OA flow to air temperature. If the OA Flow Controller is in stable control

and, for five minutes, the Discharge Air Temperature

Controller/Economizer control is calling for a larger output than the OA

Flow Controller, the Discharge Air Temperature Controller/Economizer will

take control. If, for five minutes, the Discharge Air

Temperature/Economizer is in control, and the feedback of the OA Flow

Controller is less than the setpoint of the OA Flow Controller, and the

30 ppm CO

differential exists between the OA CO

and the RA CO

concentration values, the OA Flow Controller will take control.

Reload the Controller

Application

No installation is required, but if you need to reload the MVCA, obtain

DXMVCA.EXE from The Advisor by clicking on Engineering/Technical >

Field Support Center > Digital Controllers > DX-9100 > DXMVCA.EXE.

For ABCS, on The Exchange, click on Technical Support > Digital

Controllers > DX-9100 > DXMVCA.EXE. Use the GX-9100 Configuration

Tool to download the contents into the controller.

Metasys Ventilation Controller Application for the DX-9100

Detailed Procedures

Installing a UPM

To install a UPM:

Decide on a location for the enclosure based on the Location

Considerations section of this document.

Install the MVC-2000-1 enclosure by following the procedures in

the Universal Packaging Module Technical Bulletin

(LIT-6363070).

Hang the enclosure.

Land the conduit.

Wire the 110 VAC power.

Connect the DX-9100 to the N2 Bus.

WARNING: Shock Hazard. Disconnect the power supply

before making wiring connections. Failure to do

so can result in serious personal injury.

Notes:

This device complies with Part 15 of the FCC (Federal

Communications Commission) rules. Operation is subject to

the following two conditions: (1) device may not cause

harmful interference, and (2) device must accept any

interference received, including interference that may cause

undesired operation.

Wiring connections must be made in accordance with the

National Electrical Code and local regulations for low

voltage wiring.

WARNING: Equipment Damage Hazard. The CO

sensor

power input must be electrically isolated. Do

not connect the sensor’s power inputs to any

other terminal. A connection between the input

terminals and the signal return will permanently

damage the unit. Also, do not use the power

inputs to supply power to any other device

because the unit’s power transformer could be

overloaded.

Ensure the DX-9100 field connections are completed to the

terminal blocks before the controller is attached to the base.

Metasys Ventilation Controller

For additional maneuvering space during the wiring operation,

remove the bottom endcap of the UPM by disconnecting the

two assembly screws.

Complete the field wiring to the DX-9100.

Reassemble the lower UPM endcap.

Take care not to pinch any wires.

Note:

Be aware that in low lighting conditions or cramped spaces,

reassembly of the endcap may be difficult.

Installing Air Sampling Devices and Tubing

To install air sampling devices and tubing:

Read the Location Considerations section of this bulletin.

To ensure an acceptable response time, mount the enclosure so the

pneumatic tubing runs conform to the following specifications:

•

supply air - 9.2 m (30 ft) maximum

•

return air - 30.5 m (100 ft) maximum

•

outdoor air - 30.5 m (100 ft) maximum

Select a mounting location on the first duct (supply, return,

or outdoor) for one of the air sampling devices.

Install the air sampling device on the duct with the open end facing

into the air stream. The connection can be made at any place along

the duct, including near heating or cooling coils.

Note:

The outdoor air flow sampling device can be mounted in the

outdoor air intake ductwork; however, mount the device

outdoors if it is likely that exhaust air could affect the sensor in

the outdoor air intake ductwork.

Seal the space between the tube and the duct to prevent air loss

from the duct.

Use a length of 6.4 mm (1/4 in.) Outside Diameter (O.D.) flexible

tubing to connect the air sampling tube to the appropriate port

located inside of the enclosure. Tubing is labeled outdoor, supply,

and return.

Install the remaining air sampling devices in the other

two locations specified by Figure 3.

Metasys Ventilation Controller Application for the DX-9100

Sampling

DX-9100

3-Way

Valves

Sensor

Ports for Outside,

Return, and Supply Air

To Air Sampling

Location 1

To Air Sampling

Location 3

Air Sampling

Device

Direction

of Flow

Air Sampling

Location 2

Air Filter

Air Pump

Figure 3: Air Sampling Device Installation

Open the enclosure cover and remove the packing material.

Remove the tie-wrap from the air pump.

Trending Data

To trend outdoor air flow and CO

values for this application, consult

the appropriate workstation user’s manual.

Some of the points that may be trended are:

•

outdoor air CO

concentration

•

return air CO

concentration

•

supply air CO

concentration

•

supply air flow (measured)

•

outdoor air flow (calculated)

Metasys Ventilation Controller

Checking the Solenoid Valves

To check the solenoid valves:

Listen to the valves. They produce an audible click when changing

states. This should happen approximately every sixty seconds.

Time the changes in the valves. Are the solenoid valves changing

state in the proper sequence (as detailed in Table 3)?

Table 3: Commanded States of Solenoid Valves Relative to

Air Sampling Sites

Air Sampling Site Solenoid 1 Solenoid 2

Outdoor air

On Off

Supply air

Off On

Return air

Off Off

Note:

For more information, consult the Timing and Staging

diagrams in the CO

Multiplexer Application Note

(LIT-636212) located in the Metasys Network Technical

Manual (FAN 636).

Calculating the OA Flow

To calculate the outdoor air flow:

Wait ten minutes after initial startup or until the system appears to

have stabilized (when one CO

value is measured every minute).

After system has stabilized, verify that the CO

levels coordinate

with the following equation:

[OA CO

] ≤ [SA_CO

] ≤ [RA_CO

]

Note:

For more information, consult the Outdoor Air Flow

Calculator Application Note (LIT-636222) located in the

Metasys Network Technical Manual (FAN 636).

Metasys Ventilation Controller Application for the DX-9100

Checking the Controller Application

Note:

Check the controller application to verify that the system

remains stable when changing from the ventilation control

strategy to the temperature control strategy and that the

controller that demands the highest output is in control of the

system.

To check the controller application:

Through the GX-9100 software, verify that the OA Flow Controller

output is compared to the Discharge Air Temperature

Controller/Economizer Damper Controller output every minute.

If the OA Flow Controller is in stable control and the

Discharge/Economizer Controller is calling for a larger output than

the OA Flow Controller for five minutes, the

Discharge/Economizer takes control of the system.

If the Discharge/Economizer is in stable control for five minutes

and the following conditions are met, the OA Flow Controller takes

control of the system.

•

The feedback of the OA Flow Controller is less than the

setpoint of the OA Flow Controller.

•

A 30 ppm CO

differential exists between the outdoor air CO

and the RA CO

concentration values.

Note:

More information on this topic can be found in the Controller

Manager Application Note (LIT-636216) located in the

Metasys Network Technical Manual (FAN 636).

Reloading the Controller Application

To reload the controller application:

Note:

The MVC-2000-1 comes with the DX-9100 already installed

containing the MVCA. Follow this procedure only if you need

to reload the MVCA.

Obtain DXMVCA.EXE from The Advisor by clicking on

Engineering/Technical > Field Support Center > Digital

Controllers > DX-9100 > DXMVCA.EXE. From The Exchange,

click on Technical Support > Digital Controllers > DX-9100 >

DXMVCA.EXE.

Use the GX-9100 Software Configuration Tool to download the

contents of the file to the controller.

Metasys Ventilation Controller

Notes

Metasys Ventilation Controller Application for the DX-9100

Notes

Metasys Ventilation Controller

Notes

Controls Group www.johnsoncontrols.com

507 E. Michigan Street

FAN 653

P.O. Box 423 M-Applications

Milwaukee, WI 53201 Printed in U.S.A.

Johnson Controls Metasys DX-9100 Technical Bulletin

Brand: Johnson Controls

Model: Metasys DX-9100

Type: Technical Bulletin

Some of the key features of the DX-9100 include:

Open protocol support: The DX-9100 supports a variety of open protocols, including BACnet, Modbus, and LonWorks. This makes it easy to integrate the DX-9100 into your existing building automation system.
Graphical user interface: The DX-9100 features a user-friendly graphical user interface that makes it easy to configure and operate the device.

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