Variable Air Volume (VAV) Controller Technical Bulletin
Application Specific Controllers Technical Manual 636.3VAV Controller SectionTechnical BulletinIssue Date 0309Variable Air Volume (VAV) ControllerIntroductionPage5 Description5 OEM Applications8 Standards Compliance Coordination of Factory Mounted VAV Systems*88Configuring the Controller11 Using HVAC PRO for Windows Configuration Tool11 Defining a VAV Control Device Object in Metasys Software13Installation Procedures17 Tools Needed17 Environmental Information17 Mounting the Controller18 Power Line Wiring Transient Noise Precautions21 I/O and Communication Lines Wiring Transient Noise Precautions23* Indicates those sections where changes have occurred since the last printing. 2009 Johnson Controls, Inc.Code No. LIT-63630401
Wiring DetailsPage25 Power Source and Loads26 Grounding and Isolation27 I/O and Communication Terminals29 Power, Zone Bus, and N2 Connections36 Analog Inputs36 Binary Inputs38 Binary Outputs38 Analog Outputs38 Zone Bus39 Wiring to RLY50/002 Relays39 Wiring Sensors and Actuators40Networking the Controller45 N2 Bus Overview45 Installing the N2 Bus46 Zone Bus Communications49Application Examples51 Single Duct Applications51 Dual Duct Applications63Downloading/Commissioning71 Via Zone Bus71 Via N2 Bus71 Incremental Valve Actuator Stroke Time72 Incremental Damper Actuator Stroke Time73 Zone Terminal Setup for Balancing Contractors73* Indicates those sections where changes have occurred since the last printing.2 VAV Controller—Variable Air Volume (VAV) Controller
TroubleshootingPage75 Hardware Installation Inspection75 Tools Needed for Troubleshooting75 Installation Checkout76 Troubleshooting the VAV Controller with HVAC PRO for Windows81 Troubleshooting the N2 Bus and Networked VAV Controller82 Zone Bus Troubleshooting -- HVAC PRO for Windows83Ordering Information85 Johnson Controls Code Numbers85 Vendor Code Numbers87Specifications*89* Indicates sections where changes occurred since the last printing.VAV Controller—Variable Air Volume (VAV) Controller 3
4 VAV Controller—Variable Air Volume (VAV) Controller
1 2FDescriptionIntroductionThe Variable Air Volume (VAV) Controller is an electronic device fordigital control of single duct, dual duct, fan powered, and supply/exhaustVAV box configurations. See Figure 1. You may use the VAV as astandalone controller or connected to the Metasys network through aNetwork Control Module (NCM) or Companion system.50HWhen connected to the Metasys Network, the VAV provides all point andcontrol information to the rest of the network. The devices communicatethrough 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).VAV Controller—Variable Air Volume (VAV) Controller 5
RBINARY INPUTANALOG INPUTS1234561234Z BUS1 2 3 45 6ANALOG INPUTSCOMMONTOZONESTATBINARY OUTPUT12345678BINARY COM1 2 3 45 6ANALOG INPUTSBINARY INBINARY OUTPUTSDSIP5P6RANALOG INPUTS1234 56BINARY INPUT123 4Z BUS1 2 3 45 6ANALOG INPUTSCOMMONTOZONESTATANALOGBINARY OUTPUTOUTPUT12 345 6 12BINARY COM1 2 3 45 6ANALOG INPUTSBINARY INBINARY OUTPUTS ANA OUTDSI110-111Figure 1: VAV110 (top) and VAV111 (bottom) Controller6 VAV Controller—Variable Air Volume (VAV) Controller
Table 1: VAV Controller Model AV140/141AmbientTemperatureRating32 to 122 F32 to 122 F32 to 122 F(0 to 50 C)(0 to 50 C)(0 to 50 C)Analog Inputs6RTD temperatureelements (1000 ohmnickel, platinum, orsilicon)2k ohm setpointpotentiometers0 to 10 VDC or0 to 2 VDCtransmitters6RTD temperatureelements (1000 ohmnickel, platinum, orsilicon)2k ohm setpointpotentiometers0 to 10 VDC or0 to 2 VDCtransmitters6RTD temperatureelements (1000 ohmnickel, platinum, orsilicon)2k ohm setpointpotentiometers0 to 10 VDC or0 to 2 VDCtransmittersBinary Inputs4(4) Dry contacts(1) Momentary pushbutton from zonesensor for temporaryoccupancy modeBI 4 may be used asan accumulator inputfor frequencies lessthan 100 Hz.4(4) Dry contacts(1) Momentary pushbutton from zonesensor for temporaryoccupancy modeBI 4 may be used asan accumulator inputfor frequencies lessthan 100 Hz.4(4) Dry contacts(1) Momentary pushbutton from zonesensor for temporaryoccupancy modeBI 4 may be used asan accumulator inputfor frequencies lessthan 100 Hz.AnalogOutputs0/20 to 10 VDC@ 10 mA0/20 to 10 VDC@ 10 mA0/20 to 10 VDC@ 10 mABinaryOutputs8/624 VAC Triacs@ 0.5 amperes8/624 VAC Triacs@ 0.5 amperes, or0.8 amperes if totalpower is limited8/624 VAC Triacs@ 0.5 amperes, or0.8 amperes if totalpower is limitedN2 BusNot Isolated *IsolatedIsolatedZone BusDiscrete connectionsat controller8-pin phone jack oncontrollerDiscrete connectionsat controller8-pin phone jack oncontroller6-pin phone jack atzone sensor6-pin phone jack atzone sensorDiscrete connectionsat controller8-pin and 6-pin phonejack on controller *6-pin phone jack atzone sensorLED Indication *LED Indication *24 VAC PowerTerminationsQuick Connects(Spade Lugs) *Removable ScrewTerminal BlockRemovable ScrewTerminal BlockI/OTerminationsQuick Connects(Spade Lugs)Quick Connects(Spade Lugs)Fixed Screw TerminalBlock *N2TerminationsFixed Screw TerminalBlock *Removable ScrewTerminal BlockRemovable ScrewTerminal Block* VAV Controller model feature differencesVAV Controller—Variable Air Volume (VAV) Controller 7
OEMApplicationsWhen providing VAVs for projects which use Trane or TITUS terminal boxes, consider using the AS-VAVDPTx-1 product (refer toBuilding VAVDPT Applications Application Note (LIT-6363042) in theApplication Specific Controllers Technical Manual (FAN 636.3). Traneand TITUS are both Original Equipment Manufacturers (OEMs) whoprovide VAV terminal boxes for projects. Trane typically provides thedamper actuator with their terminal box, and TITUS provides the damperactuator with their QFPC Series Fan Powered Box. The VAVDPT comesin two models, which include a VAV Controller and a DPT-2015 VelocityPressure Transducer. The DPT is mounted and prewired to the cover ofthe VAV. Refer to the OEM Reference Manual (FAN 638).StandardsComplianceThe VAV Controller complies with the following standards:3F4F5F6F7F8FCoordination ofFactoryMounted VAVSystems9F10F1FzFCC Part 15, Subpart J, Class AzUL 916 ListedzIEEE 472, IEEE 518zVDE 0871 Class BzIEEE 587 Category AA factory mounted VAV box control system requires close coordinationbetween a variety of different disciplines. Refer to the OEM ReferenceManual (FAN 638) for factory manufacturer’s details. Although theresponsibilities may differ per city or region, the following parties areusually involved on the job:zcontrols contractorzmechanical contractorzlocal VAV box manufacturer’s representativezbalancing contractorzelectrical contractorTypically, the mechanical contractor is the focal point for coordinating theentire process. The basic responsibilities under the domain of themechanical contractor are:1.Purchasing the VAV box system. Most specifications include theOEM mounting fees and enclosures for the control system in themechanical contractor’s price. Mounting fees vary per boxmanufacturer 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 toensure the system is set up per the mechanical prints.Note: The owner often directly hires the balancing contractor. Thisensures neutrality in dealing with other contractors involved in theproject.8 VAV Controller—Variable Air Volume (VAV) Controller
In conjunction with the mechanical contractor, the controls contractor’sresponsibilities include:1.Coordination of the control system release schedule to the boxmanufacturer to ensure the mechanical system delivery schedule canbe met. Coordination with the local box manufacturer representative isnormally required.2.Coordination with the electrical contractor to ensure the followingsteps are covered.z24 VAC power is provided at each VAV Controller.zN2 Bus wiring is pulled and terminated.zValve actuator wiring is pulled and terminated.zZone sensor cables are pulled. The use of phone cable forterminating zone sensor wiring allows basically anyone toterminate zone sensors in certain locales.zIf desired, the N2 address switches can be set by the electricalcontractor.3.Initial loading of the HVAC PRO for Windows configuration files isdone once the electrical contractor’s functions are completed inpreparation for the final system balancing.4.Training of the balancing contractor to ensure the balancing contractorknows how to use the Zone Terminal (ZT) or HVAC PRO forWindows Commissioning mode so they can perform the final systembalancing.5.Mounting and terminating the cable connections for the zonetemperature sensor. Set the N2 address switch if the electricalcontractor was not contracted to perform this function.6.Configuring, downloading, and commissioning the controller.VAV Controller—Variable Air Volume (VAV) Controller 9
10 VAV Controller—Variable Air Volume Controller
12F13F14FConfiguring the ControllerUse HVAC PRO for Windows to configure the VAV. VAV110/111 andVAV140/141 models require HVAC PRO for Windows. HVAC PRO forWindows also works with the VAV100/101 models. This easy-to-usesoftware tool configures, commissions, and downloads the VAVController’s data base.UsingHVAC PROfor WindowsConfigurationToolFigure 2 illustrates the HVAC PRO for Windows configuration process.Refer to the HVAC PRO for Windows User’s Manual (FAN 637.5) forspecific information when configuring the VAV Controller.51HVAV Controller—Variable Air Volume (VAV) Controller 11
Start HVAC PRO for WindowsSelect File-New1. Select VAV Applications.2. Select Single or Dual Duct.Complete Q/A SessionComplete Configuration Process1. Fill in job information.- Option - Job Information2. Review and change inputs/outputs.3. Review and change default parameters.Save Configuration1. File - Save As2. Select device type.3. Enter file name for configuration file.Download Controller1. Attach MM-CVT101-1 Converter3. Select Bus type, comm. port, andor AS-CBLPRO-2.N2 address (if N2 Bus).2. Select Download - Current Configuration. 4. Select OK.Commission Controller1. Attach MM-CVT101-1 Converteror AS-CBLPRO-2.2. Select Commission - Current Configuration.3. Select Bus type, comm. port, andN2 address (if N2 Bus).4. Select OK.5. View / Adjust parameter values.6. Review controller information.7. Exit Commissioning.8. If adjustments were made, savechanges to controller and to file.9. Unplug MM-CVT101-1 or AS-CBLPRO-2.PROFLO40Exit HVAC PRO for WindowsFigure 2: Steps in Configuring a VAV Controller UsingHVAC PRO for Windows12 VAV Controller—Variable Air Volume Controller
Note: You can load and commission the controller either locally with theAS-CBLPRO-2 interface at the zone sensor (Figure 15) or from acentral location where the N2 has been pulled, controller’s fieldhardware addressed, and an MM-CVT101-1 interfaced to the laptop.Defining a VAVControl DeviceObject inMetasysSoftware15F16F17FUsing a Metasys Network system, you need to define a VAV Controllerdevice object by entering data into the Attribute menu as seen on theOperator Workstation.1.Go to the Network Map.2.Double-click the system name in which you want to add the new VAVobject.3.Click New in the Item pull-down menu.4.Click on Type: N2 devices in the Item New dialog box.VAV - Item NewTypeAccumulatorAnalog dataAnalog inputAnalog output digitalAnalog output setpointBinary dataBinary inputBinary outputMS dataMS inputOKMS outputControl systemDL/LR groupLC groupPID loopFire ZoneL2 devicesN2 devicesS2 devicesCard ReaderCANCELHardware system name:Hardware object name:Copy of (System\Object):ITEM NEWFigure 3: Item New Dialog BoxNote: The Hardware System and Hardware Object text fields are notused for this object type.5.Click OK to display the Add N2 Device dialog box.VAV Controller—Variable Air Volume (VAV) Controller 13
Hardware -- Add N2 DeviceOKDevice cFigure 4: Add N2 Device Dialog Box6.Highlight VAV.7.Click OK to display the VAV Definition window (Figure 5).52HVAV DefinitionItem EditView ActionHelpGo To AccessoryTower IBookmarkFloor 1System NameObject NameExpanded IDNC NameGraphic Symbol #Operating Instr. #HardwareNC #511HardwareN2 Trunk NumberN2 Device AddressPoll Priority103Comm DisabledNFlagsAuto DialoutNwindobjFigure 5: VAV Control Device Object Definition WindowNote that some of the fields in the window are blank and some are alreadyfilled in. You must fill in the blank attribute fields of required attributes.An N2 device address from 1 to 255 must also be specified. Attributefields that are already filled in contain default values that may be acceptedor changed.14 VAV Controller—Variable Air Volume Controller
Table 2 explains the blank attributes. The Operator Workstation User’sManual (FAN 634) describes the general procedures for entering andmodifying data.Table 2: Blank VAV Object AttributesModifying andMonitoring theVAV ObjectAttributeDescriptionEntry Values . . .Object NameIdentifies the object(i.e., ILC). The object namecannot be duplicated in thesystem.1 to 8 alphanumericcharactersExpanded IDFurther identifies the object(i.e., LC Device 1)0 to 24 alphanumericcharacters(Optional)8.To save the new VAV object, select Save from the Item pull-downmenu. The object is added to the NCM data base.9.Upload the NCM to make an archive copy of the new object followingthe instructions in the Operator Workstation User’s Manual (FAN634), the Advanced User’s Guide tab, the Uploading and DownloadingData Bases chapter, the Uploading from the NCM section.Once you have defined the VAV object, you can modify or monitor itsattribute values online using the VAV object Focus window. See theOperator Workstation User’s Manual (FAN 634) for more information onusing Focus windows.VAV Controller—Variable Air Volume (VAV) Controller 15
16 VAV Controller—Variable Air Volume Controller
18F19F20FInstallation ProceduresInstructions for the installation of the VAV Controller and its accessorydevices are detailed in this section. The types and numbers of components(sensors and actuators) selected for use with the VAV vary according toapplication. Analyze the proposed installation for logical places to locatethese devices and draw up an inventory based on that study. Informationon types of accessory devices available is in the Ordering Informationsection of this technical bulletin.Most VAV installation should be coordinated with the VAV boxmanufacturer for factory mounting. The OEM Reference Manual(FAN 638) describes the steps and pricing to coordinate a factory mountsolution.Tools NeededEnvironmentalInformation21F2F23FTools 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 followingenvironmental standards. The atmosphere must be free of explosive vapors or escaping gases. The atmosphere must be free of exposure to corrosive chemical or saltvapors, 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 and90%. The power line must be “clean,” without electrical noise transients thatare often present in industrial environments. Commercial andresidential buildings typically have clean power, but may not, dependingon the location, nearby equipment, etc. Follow the power line wiringtransient noise precautions.VAV Controller—Variable Air Volume (VAV) Controller 17
Mounting theController24F25F26FFactory MountingTypically the most cost effective and highest quality installation of theVAV Controller, EDA-2040 Damper Operator, and DPT-2015 VelocityPressure Transducer can be accomplished by the box manufacturer. TheOEM Reference Manual (FAN 638) describes the relationship, pricing, andprocess to accomplish factory mounting of the VAV control system at mostof the key box manufacturers.If the job cannot be factory mounted, check with the VAV boxmanufacturer to determine if a control enclosure for the VAV Controllerand Actuator/Velocity Pressure Transducer combination is alreadyavailable on the VAV box. If there is not an available enclosure, thecommon packaging for the VAV Controller is an enclosure provided by thecontractor or the Johnson Controls EN-EWC10, EN-EWC15, BZ1000, orAS-ENC enclosure. The controller requires a flat mounting surface area tomatch 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 theAS-ENC100-0 enclosure 7 x 13 x 6 in./180 x 330 x 150 mm (H x W x D) with theEN-EWC10-0 and EN-EWC15-0 enclosureMake sure you allow enough room to install the enclosure and conduit forwiring terminations to the controller. Figure 7 shows a common packagingconfiguration for the VAV Controller.53H18 VAV Controller—Variable Air Volume Controller
TM 15VDC 15VDC24VAC24VACTRACSCOMMONCOMMONCOMMONCOMMONLow VoltageWiring TroughCOMMONvavpwerFigure 6: EWC10 Enclosure with VAV Controllerand 50 VA TransformerMounting theVAV into aUniversalPackagingModuleThe VAV can be directly mounted into an EWC10/15 enclosure. You mayalso purchase the VAV premounted in a EWC10 enclosure with a50 VA transformer. Refer to the Application Specific ControllersTechnical Manual (FAN 636.3) for instructions on mounting the enclosureto a wall.To mount the VAV in the EWC10:Field Mounting1.Orient the VAV so that its terminals face the low voltage wiringtrough (Figure 6).2.Align the three mounting holes in the base of the controller with theholes in the back of the enclosure. On the side with four mountingholes, use the two outside holes for mounting in the EWC. See theUniversal Packaging Module Technical Bulletin (FAN 636.3) for amore 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 typemay also be used.Position the controller (or controller’s enclosure) on the mounting surfacebefore installation to ensure the calculated mounting area is correct. Youcan make precise measurements for distance between controller terminalsand sensor/actuator mounting points on the VAV terminal. Confirmelectrical power source and conduit requirements prior to mounting.VAV Controller—Variable Air Volume (VAV) Controller 19
You can install a VAV Controller into a control panel or an AS-ENC100-0enclosure.Do not use this knockout.Otherwise, controller willbe in the way of wiring.42Top / Bottom3Side13VAV Controller5vavencl2VAV Enclosure (Cover)Figure 7: Installing the VAV Controller in an Enclosure KitMount the VAV in any convenient location using the predrilled mountingholes. The controller must be mounted on a wall or panel where it can beeasily wired through the enclosure cover. Mount the VAV vertically forbest DPT (differential pressure transmitter) performance. The sameinstruction applies to remote location packages. Refer to Figure 7 wheninstalling a VAV Controller.54H1.Secure the VAV inside the enclosure kit , using three screwsthrough the mounting tabs on the sides of the controller board base.2.Position the VAV and enclosure so that it rests firmly against themounting surface.3.Using a flat-blade screwdriver and pliers, remove the necessary wirepassage knockouts .Note: Do not use knockouts on the opposite sides of enclosure, as youwill not be able to remove the VAV board.4.Attach the enclosure cover after installing wiring.20 VAV Controller—Variable Air Volume Controller
Power LineWiringTransient NoisePrecaut
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
Variable-Air-Volume (VAV) Box Controller VAV-SVX07*-EN — Tracer UC400 Programmable BACnet Controller for VAV Units VAV-SVP01*-EN — VAV VV550 LonTalk Controller VAV-SVX01*-EN — VAV-UCM 4.2 IOM VAV-SVX02*-EN — VariTrane Pneumatic Controls ReceivingandHandl
VAV air-conditioning system is composed of AHU, fresh air/exhaust air/supply air/back air duct, VAV BOX, room temperature controller, VAV BOX is the most important part of this system. VAV AIR-CONDITIONING SYSTEM PLATFORM TASK . The introduction of the system platform . This task’s VAV syst
VAV systems are the most modern, energy efficient all air systems available for comfort air conditioning. VAV sys-tems require less fan capacity than a comparable constant volume system because with VAV only the required air is used. Typically a VAV system fan volume is 60% of a CAV system. Control of air flow in a VAV system is accomplished
2 BACnet MS/TP and IP VAV Controller I&O Manual 026-1221 Rev 3 1.1.2.BACnet MS/TP VAV Controller (810-8006) The VAV controller is designed to control and monitor various types of HVAC equipment such as baseboards, single and multi-stage duct heaters, fans, valves, and lights. The VAV controller features 4 universal hardware
zones. A Bypass VAV box provides constant or variable airflow depending on the temperature demands of the space. As the temperature raises the VAV damper opens to send a designed amount of airflow to the space/ or room. The Bypass VAV system combines the comfort benefits of VAV with the cost effectiveness and simplicity. The VAV System that works.
The ASM02427 VAV/Zone BACnet Controller (VAVZB) is designed for Pressure Independent VAV Box and Zone Damper applications. It is supplied with an integral Airflow Sensor and is mounted in a plastic enclosure. The ASM02426 VAV/Zone BACnet Controller (VAVZB) is designed for
Controller by means of a prefabricated E-BUS cable. There is a Pressure Dependent VAV/Zone Controller Package available which includes the Zone Controller and Actuator. Mounting The VAV/Zone Controller
men’s day worship service. It is recommended that the service be adjusted for specific local needs. This worship service is designed to honor men, and be led by men. Music: Led by a male choir or male soloist, young men’s choir, intergenerational choir or senior men’s choir. Themes: Possible themes for Men’s Day worship service include:
