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Transcription

Basic System
Design, Installation
and Operations Manual
Revision 02C
Auto-Zone Basic
Design, Installation & Operations Manual
Section 1 .............................................................................. System Overview
Section 2 ................................................................... Installation and Wiring
Section 3 ....................................................................................Programming
Section 4 ........................................................Start-Up and Troubleshooting
This document is subject to change without notice.
WattMaster Controls, Inc. assumes no responsibility
for errors, or omissions herein.
Auto-Zone Basic Installation & Operations Manual - Form WM-AZB-IO-02C
Auto-Zone is a registered trademark of WattMaster Controls, Inc.
Copyright 2009 WattMaster Controls, Inc.
All rights reserved.
Section 1
Table of Contents
Conventions ..................................................................... 1
General Information......................................................... 3
Description of System Components.................................................................................3
Design Considerations ..................................................... 5
Zone Diversity .................................................................................................................5
Cooling - Partial Load Conditions ...................................................................................5
Heating - Partial Load Conditions ...................................................................................7
Override Conditions.........................................................................................................7
Building Pressurization....................................................................................................7
Design Guide .................................................................... 8
Step #1 - Zoning ..............................................................................................................8
Step #2 - Sizing the Central Unit ...................................................................................10
Step #3 - Duct Design Considerations...........................................................................10
Step #4 - Room Air Motion/Diffuser Selection.............................................................11
Step #5 - Bypass Damper Sizing ...................................................................................11
Step #6 - Sizing Zone Dampers .....................................................................................13
Round Dampers .............................................................................................................15
Rectangular Dampers.....................................................................................................15
Pressure Independent Zone Dampers ............................................................................16
Auxiliary Heat Control Options...................................... 17
Relay Expansion Board .................................................................................................18
Table of Figures & Tables
Figure 1-1: Auto-Zone Basic Control System ...............................................................2
Figure 1-2: Control Zones Affected by the Outdoor Load ............................................9
Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control ............12
Figure 1-4: Round Damper Dimensions......................................................................14
Figure 1-5: Rectangular Damper & Kit Dimensions...................................................14
Table 1-1: Round Air Damper Selection .....................................................................15
Table 1-2: Rectangular Damper Selection...................................................................15
Table 1-3: Pressure Independent Flow Factors............................................................16
Design Guide
Auto-Zone Basic
Section 1
Conventions
This document uses the following definitions throughout as a guide to the user in
determining the nature of information presented:
Note: Additional information which may be helpful
Tip: Suggestion to make installation, set-up, and troubleshooting easier.
Caution: Items which may cause the equipment not to function correctly, but will
not otherwise damage components.
Warning: Errors which can result in damage to equipment and void warranties.
Design Guide
1-1
Auto-Zone Basic
Section 1
To HVAC Unit
Control Panel
Supply
Air Temp
Sensor
Return
Air Temp
Sensor
Economizer
(Actuator By Others)
Outside
Air Temp
Sensor
Zone Air Dampers
Bypass Air
Damper
Computer
Up to 16 Zone Air Dampers Allowed
#1
#16
(Optional)
USB Cable To Computer
Optional Remote Link II
Phone Cable To
Telephone
Wall Outlet Jack
Connects to CommLink IV
And Provides Alarm Call-Outs
A Second Remote Link Is Required
If Connection To Job Site
Is Desired From Remote Computer
24VAC
Remote Link II
(Optional)
CommLink IV
The CommLink IV Is
Required For All Systems.
The IP Module, Remote
Link II, And Computer Are
Optional On All Systems.
All Computers Require
Installation of Prism
Graphical User Interface
Software
RS-485
9600 Baud
Static
Pressure
Sensor
Optional IP Module
Typical Zone
Installs Into CommLink IV
And Provides
LAN And Internet
Communications
With The Control System
Damper Actuator
Zone Controller
CommLink IV
Single Loop
Velocity Sensor
Ethernet Cable To Router
Room Sensor
(Optional)
with Optional
Override & Adj.
Ethernet Router
(By Others)
When IP Module
Option Is Used
RS-485
Comm Loop
24 VAC
Figure 1-1: Auto-Zone Basic Control System
1-2
Design Guide
Auto-Zone Basic
Section 1
General Information
The primary application of the Auto-Zone Basic Control System is to provide multiple
controlled comfort zones from a single zone, unitary heating and air-conditioning
package unit. It can also be applied to existing installations for improved comfort to
multiple zones currently controlled by a single thermostat.
Description of System Components
A typical Auto-Zone Basic Control System is comprised of the following four basic
components.
Zone Manager
The Zone Manager is a microprocessor-based controller which monitors up to 16 zones
in the system. The zone manager then controls the HVAC unit to satisfy the requirements
of each individual zone while maintaining efficient operation and comfort. The zone
manager is also responsible for controlling duct static pressure.
In the Auto-Zone Basic version, the Zone Manager has a display and a keypad. The 4line by 20-character display is backlighted, making it easier to read in low light
environments.
Bypass Damper
The bypass damper controls proper duct static pressure to insure proper airflow. The
damper is modulated by the Zone Manager based on a signal received from the static
pressure sensor connected to the main duct.
Zone Controller
The Zone Controller monitors space temperature and allocates proper airflow to the
assigned zone to achieve desired comfort and ventilation levels. If supply air temperature
will benefit the local zone temperature setpoint, the zone damper modulates to reduce or
increase airflow as needed. If supply air will not benefit the local zone, the controller will
direct the damper actuator to a minimum position and wait for a change in supply air
temperature.
Design Guide
1-3
Section 1
Auto-Zone Basic
Zone Sensor
The patented zone sensor is a flush, wall-mounted design. A special plate on the face of
the sensor accurately senses space conditions. As a result of its unique design, the zone
sensor rejects the influence of internal wall temperature effects. The sensor comes in four
different configurations:
• Sensor only
• Sensor w/push-button override (override is fixed at 2 hours)
• Sensor w/setpoint adjustment
• Sensor w/override & setpoint adjustment
Any combination of these sensor configurations can be used with the system.
1-4
Design Guide
Auto-Zone Basic
Section 1
Design Considerations
Consider the following items when designing a system using Auto-Zone.
Zone Diversity
The Auto-Zone Basic Control System is designed to improve tenant comfort by
dynamically re-balancing the air distribution when used with a typical constant volume
rooftop heating/cooling unit. If zones with extremely different load conditions are
serviced by a single rooftop unit, the result will be poor control and excessive wear due
to cycling of the equipment.
It is especially important to avoid mixing interior zones (which require cooling all year)
with exterior zones (which may require constant heat during winter months). If you must
mix zones under these conditions, consider using either VAV boxes with heat or separate
baseboard heat on exterior zones. Auto-Zone Basic Control Systems offer a variety of
methods to control additional zone heat to help you avoid problems.
Cooling - Partial Load Conditions
The engineer must be aware of several potential problems when applying the Auto-Zone
Basic Control System during cold weather operation.
Low Ambient Temperature Lockout
During very cold weather it is common for mechanical systems to have “low temp
lockouts” which protect equipment from damage if operated under these conditions.
Auto-Zone also provides user programmed lockouts for protection purposes, although
mechanical safeties should always be used as the final stage of protection.
If the rooftop unit services interior zones with thermal loads which require cooling when
outside temperatures are below the safe operating limits for your equipment, you should
seriously consider installing an economizer on your rooftop unit. The Auto-Zone control
system is designed to take advantage of an economizer if it is installed. The use of an
economizer will save money on utilities and provide comfort under conditions when it is
not possible to operate the mechanical cooling system.
Low Supply Air Temperatures
Under lightly loaded conditions much of the supply air may be bypassed back into the
return airside of the system. This bypassing will result in the lowering of the supply air
Design Guide
1-5
Section 1
Auto-Zone Basic
temperature, which may result in the supply air temperature reaching the low temp safety
limit. If the supply air low temp safety limit is exceeded, the control system will “cut-off”
the mechanical cooling to protect it from damage. Excessive cycling of the mechanical
system will result if this condition persists. Comfort may also suffer if the system cannot
run long enough to satisfy cooling demands.
A number of things can be done to reduce this problem. Some of these things depend
upon the type of installation.
•
Avoid oversizing the unit. Do your load calculations carefully. Since Auto-Zone
directs the heating or cooling to the zones which require it, you may find that you can
use a smaller unit in many cases. Oversizing is the number one cause of excessive
low supply air temperature cycling.
•
Increase your cooling minimum airflow or damper position settings to allow more air
during cooling operation. Be careful to avoid settings which are so high you cause
over cooling of the spaces. Find a compromise position.
•
Bypass the air into the plenum instead of into the return air intake. Be careful if you
use this method since you may get “dumping” of cold air from your return air grilles.
This method works best with plenum returns. Do not use this method with ducted
returns unless you have carefully considered the consequences.
•
Increase your static pressure setpoint to help reduce the amount of air being bypassed.
Be aware of increased noise levels and the cost of operation if you use excessive
static pressures.
Warning: If the fan system has the capability of producing static pressures
which could damage ductwork, you must provide a manual reset high
pressure limit switch to cut-off the fan system in the event of high
duct static. Do not use your Auto-Zone Basic Control System as a
safety device!
•
Use an Economizer. Although this is not a cure-all, it greatly improves operation
during cool weather when cooling loads are minimal. Using an Economizer also
improves ventilation and lowers operating costs, both of which are significant.
1-6
Design Guide
Auto-Zone Basic
Section 1
Heating - Partial Load Conditions
Heating difficulties are less common than cooling difficulties. They are similar in nature,
however, and the cures are generally the same.
•
•
•
•
•
Increase the Heating minimum setpoints on as many zones as possible.
Increase the static pressure setting as high as is practical. Increasing static pressure
does not help if you are using pressure independent operation.
Bypass to plenum instead of the return air intake if acceptable.
Do not oversize your equipment.
Use auxiliary heat in either your VAV boxes or baseboard.
Auto-Zone has a number of auxiliary heat control options which provide solutions to
most problems. Refer to the Auxiliary Heat Control Options topic near the end of this
section.
Override Conditions
After-hours overrides can produce aggravated partial load conditions in both the heating
and cooling modes. The problem is most commonly caused by a single zone being
overridden for after-hours use. This causes the rooftop equipment to operate for only one
zone. The Auto-Zone Basic Control System offers an improved solution to this common
problem by allowing a single override to trigger a group of zones via a “global” override.
This allows the system to operate with sufficient load to reduce cycling caused by light
load conditions.
Building Pressurization
If you are using an economizer, building pressurization must be addressed. Failure to
properly handle building pressurization may result in doors remaining open when the
economizer is operating. Pressurization problems can render economizer operation
useless. The following suggestions will help to avoid potential problems.
•
Use powered exhaust when the system uses ducted returns. The return duct pressure
drop will cause most barometric relief dampers to function poorly or not at all. AutoZone has the ability to control a powered exhaust whenever the economizer is
operating.
•
Use a separate building pressure control which operates a relief fan or dampers.
Design Guide
1-7
Section 1
Auto-Zone Basic
Design Guide
There are six basic steps to designing an Auto-Zone Basic Control System:
1.
2.
3.
4.
5.
6.
Zoning
Sizing the Central Unit
Duct Design Considerations
Room Air Motion / Diffuser Selection
Bypass Damper Sizing
Sizing Zone Dampers
Step #1 - Zoning
Determine the number of zones. A single air handler unit can have no more than 16
zones. If the number of zones exceeds 16, then more than one Zone Manager will be
required. Consider using the Auto-Zone Plus system if more than one Zone Manager is
required.
The primary precaution to be taken in applying the Auto-Zone Basic Control System is to
select the zoning so that no zone will be at maximum (design) heating (or cooling) load
when any other zone requires the opposite temperature air to satisfy its load. For
example, depending on the wall, ceiling, floor material, and location within the building
(e.g. top or middle floor), a typical floor of a building usually has a minimum of 9
distinct temperature or control zones that are affected uniquely by the outdoor load.
These zones are depicted in Figure 1-2.
Depending on the size of the building and partition layout, some of these zones may
overlap or be insignificant from a zoning standpoint. For example, Zone 10 could be
multiple conference or computer rooms where additional zoning would be required, or it
could be as small as a corridor where no zoning is required. Similarly, zones 4 and 5
could have no external windows and no partitions between them and could be considered
a single zone. Zone 3 could be divided into multiple offices with full partitions between
them, thus requiring separate Zone Controllers because of different internal loads, but the
same external load.
Generally, the greater the number of individual Zone Controllers there are, the greater the
comfort. The designer will have to look at the specific building, balancing the costs of
multiple zones with the added comfort possible with multiple zones, to match the owner's
requirements.
1-8
Design Guide
Auto-Zone Basic
Section 1
It is important to recognize that there are purely internal zones, such as Zone 10, which
may contain separate offices/conference/computer rooms. These internal zones could
easily have high cooling requirements while external zones (1, 2, 3, etc.) could be at or
near design heating load. This is a misapplication of the Auto-Zone Basic or Plus (or any
heating/cooling changeover) system. The interior zones with cooling-only loads should
be served with a separate air-conditioning unit (that could be zoned between multiple
rooms with a similar load profile). Supplemental heat could be added to the perimeter
zones and controlled with the auxiliary heat control board from the Zone Controller.
System performance will generally be compromised and frequent changeover from the
heating to the cooling mode will occur during the heating season if purely internal zones
are combined on the same air-conditioning unit serving perimeter zones.
Zoned HVAC Unit
Supply Air Duct
Return Air Plenum
Supply Air Duct
Bypass Damper
9
System Manager
Constant Volume HVAC Unit
Round Zone Damper
(Typical)
8
Return Air Plenum
R
MANAGE
Alarm
Plus
WED
SYSTEM
Communication
Override
03:38PM
Auto-Zone
OCCUPIED
01/01/97 ALARMS
NO
1
4
7
Dec.
2
5
8
3
INC.
Esc
CONTROLS
Menu
WATTMASTER
6
9
Enter
Clear
Minus
0
*
Room Sensor
(Typical)
1
7
10
6
W
A
R
NORMAL M
E
R
OVR
W
A
R
M
E
R
W
A
R
NORMAL M
E
R
OVR
C
O
O
L
E
R
C
O
O
L
E
R
RV
C
O
O
L
E
R
2
ON
MR
LA
O
3
5
W
A
R
NORMAL M
E
R
OVR
C
O
O
L
E
R
4
W
A
R
M
E
R
C
O
O
L
E
R
W
S
W
A
R
M
E
R
C
O
O
L
E
R
ON
MR
LA
RV
O
ON
MR
LA
RV
O
N
E
Figure 1-2: Control Zones Affected by the Outdoor Load
Design Guide
1-9
Section 1
Auto-Zone Basic
Step #2 - Sizing the Central Unit
Because the zones are controlled with variable air volume, it is unlikely that all zones
will be at design load at the same time. The zoning allows for the diversity of loads to be
taken into account and will often provide better comfort with a smaller HVAC unit.
In sizing the system, the individual zone loads should be calculated using any dependable
load estimating program. Because of diversity, the central unit should be selected for the
instantaneous peak load, not the sum of the peak loads, as would be done with a constant
volume single zone system. Consider the following when sizing the central unit.
•
Size the peak cooling load based on the month and hour of the greatest total
building/system load.
•
Heating should be sized for the lowest design temperature with an additional margin
for morning "pickup." This margin is generally recommended to be 20 to 25 percent
of base design.
Step #3 - Duct Design Considerations
The Auto-Zone Basic Control System uses a typical low pressure duct design. To reduce
noise problems, duct pressures should not exceed 1 inch W.C.
Primary trunk ducts should not be "undersized." This is especially true for "pressure
dependent" systems. Pressure dependent refers to the typical Auto-Zone Zone Controller
without the airflow sensor. With larger trunk ducts, it is easier to assure relatively constant
pressure to each zone. Runs should be as short as possible and the trunk duct system kept
as symmetrical as possible to facilitate system balancing. Wherever possible, run the trunk
ducts above corridors and locate the zone dampers above corridors to reduce the noise in
the space and facilitate service of the units. Trunk ducts should be sized for no more than
0.1 inch W.C. drop per 100 feet and a maximum duct velocity of 2000 FPM.
Note: For pressure independent terminal units with velocity sensors and
conventional "VAV" boxes properly selected for "quiet" operation, this 2000
FPM rule can be exceeded by up to 50 percent. The designer, however, should
be very experienced in VAV system design before considering modification
of this general rule.
Typical VAV systems with pressure independent terminals use the static regain method
for sizing ducts. The typical Auto-Zone Basic Control System is a low-pressure, pressure
dependent system that utilizes conventional unitary air-conditioning units. These systems
should use the equal-friction method of sizing the ducts and use the maximum loss of 0.1
inch per 100 feet as described above.
1-10
Design Guide
Auto-Zone Basic
Section 1
Step #4 - Room Air Motion/Diffuser
Selection
Air motion is a consideration for occupant comfort. The selection of diffusers for an
Auto-Zone Basic Control System requires more care than a constant volume system due
to varying flow of air into the zones. Slot diffusers are recommended due to their superior
performance at low airflows. Because the zone airflow is variable volume, lower cost
round or rectangular diffusers that were satisfactory for constant volume may prove
unsatisfactory with an Auto-Zone Basic Control System. These diffusers may result in
"dumping" of the cold air at low flows in the cooling mode and insufficient room air
motion at low air flows in the heating mode. Although high air motion in the heating
mode can be undesirable, a slot diffuser with a high induction ratio generally helps to
reduce room air "stratification" when the heating comes from a ceiling diffuser. Linear
slot diffusers should be properly selected for the airflow and "throw" suited to the
specific installation or zone.
Additional factors to consider in diffuser selection are sound level and throw at design
flow. Generally, multiple diffusers will result in lower sound levels in the space, but this
must be balanced with the additional hardware and installation costs. It is commonly
recommended that slot diffusers be located near the perimeter or outside wall with the
airflow directed into the room. Consult your diffuser supplier or catalog for proper
diffuser sizing and location.
Series fan boxes may be used instead of zone dampers where higher induction rates are
desirable. If the heat loss on perimeter walls is high, such as large areas of glass, the use
of Series Fan Boxes may be indicated to maintain higher induction rates to offset
“downdrafts.” If the heat loss is greater than 275 BTUH/LINEAR FOOT, you should use
high quality slot diffusers next to the outer wall with the airflow directed inward to
counteract downdrafts during heating. Serious downdraft problems occur when heat
losses exceed 400 BTUH/LINEAR FOOT. In such case, both high induction diffusers
and series fan boxes are recommended.
Step #5 - Bypass Damper Sizing
Using a load calculation program, the bypass damper should be sized to give you the
maximum CFM of air to be bypassed, typically 60 to 70 percent of the HVAC units rated
capacity. Bypass Dampers can either be round or rectangular depending on building or
job requirements. Use the appropriate round or rectangular damper selection table to
determine the correct damper size for your application. To size the damper, select a
damper from the table based on calculated bypass CFM and a maximum velocity
between 1750-2250 FPM. When determining the bypass duct size, be sure to take into
account any transition fittings and associated pressure drops. (See Table 1-1: Round
Damper Selection or Table 1-2: Rectangular Damper Selection.)
Design Guide
1-11
Auto-Zone Basic
Section 1
If space limitations or total airflow requires it, multiple bypass dampers can be controlled
in parallel. For proper control of the Bypass Damper, the static pressure sensor location is
very important. Refer to Figure 1-3: Locating the Static Pressure Sensor for Bypass
Damper Control below for proper mounting locations.
Least Desirable, But
Acceptable
If the supply duct comes directly
from the unit and immediately
splits in opposite directions, the
pressure pickup should be located
ahead of the split or as close to it
as possible, even if the bypass
damper(s) are located downstream
of the split.
Fan
RA Sensor
SA Sensor
Supply Air Duct
Preferred Location
If the trunk ducts are properly sized
for minimum pressure drop, the
location of the static pickup probe is
not particularly critical. It should
ideally be located at right angles to
the airflow in a straight section of the
supply duct approximately ⅔ the
distance of the total length of the
supply duct. Also, the probe should
be located not less than 3 duct
diameters downstream and 2 duct
diameters upstream of any elbow or
takeoff.
Less Than Ideal, But
Acceptable
Since the "ideal" location is often
difficult to find in an installation, a
location in the main trunk where
the tip is not in a "negative
pressure area" (e.g. just
downstream of the inside curve of
an elbow) or an area where the
tube opening is directly impacted
by the velocity of the supply air is
acceptable.
Return Air Duct
Bypass Damper
SP Pickup
3D
Min.
SP Sensor
2D
Min.
Fan
RA Sensor
Bypass Damper
SA Sensor
Supply Air Duct
SP Pickup
Return Air Duct
SP Sensor
Fan
RA Sensor
Bypass Damper
Supply Air Duct
Return Air Duct
Tubing To Be Equal
Length And Size
SA Sensor
SP Pickups
SP Sensor
Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control
1-12
Design Guide
Auto-Zone Basic
Section 1
Step #6 – Sizing Zone Dampers
Use a load program to determine the peak load for each zone. These calculations will be
used in selecting the appropriate zone damper sizes.
A round damper or rectangular damper can be selected depending on the building or job
requirements. If the job requires pressure independent damper control, the damper
selected must be a round damper. Rectangular dampers are not available for pressure
independent control. Please see Table: 1-1 for round damper selection. Please see Table:
1-2 for rectangular damper selection.
Using the maximum acceptable velocity for a branch duct (typically 1000-1500 FPM for
minimal noise), find the smallest damper that will deliver the required CFM as
determined by the load program.
Go to either the Round Damper Selection table (Table: 1-1) or the Rectangular Damper
Selection table (Table: 1-2) depending on your requirements to select the dampers.
Locate the branch velocity used in the duct design program on the left hand column of
either damper sizing chart (Table: 1-1 or Table: 1-2). Move across the chart and find the
damper which will provide the acceptable CFM to meet each zone’s airflow
requirements.
Note: Compare the damper size selected against the duct size to determine if the
next size up or down will provide acceptable performance without requiring a
transition fitting.
Up to two additional dampers may be slaved together for larger zones. See zone wiring
diagram for details. This should be reserved for situations when it is not practical to use a
single large damper.
Design Guide
1-13
Auto-Zone Basic
Section 1
Note: Dimensions Are
Identical For Round Zone,
Bypass & Slave Dampers
Figure 1-4: Round Damper Dimensions
Note: See Table 1-2 for
Available “A” x “B”
Rectangular Damper Sizes
Note: Dimensions Are Identical
For Rectangular Zone, Bypass &
Slave Dampers
Figure 1-5: Rectangular Damper & Kit Dimensions
1-14
Design Guide
Auto-Zone Basic
Section 1
Round Dampers
Round Air Damper Selection
Air Damper Round Duct Size
( Area Ft2 )
6”
(0.188)
8”
(0.338)
Velocity Through Round Air
Damper
(FPM)
750 - Zone
1000 - Zone
1250 - Zone
1500 - Zone
1750 - Bypass Only
2000 - Bypass Only
2250 - Bypass Only
10”
(0.532)
12”
(0.769)
14”
(1.050)
16”
(1.375)
Volume Through Round Air Damper
(CFM)
141
188
235
282
329
376
423
254
338
423
507
592
676
761
399
532
665
798
931
1064
1197
577
769
961
1154
1346
1538
1730
788
1050
1313
1575
1838
2100
2363
1031
1375
1718
2062
2405
2749
3094
Table 1-1: Round Air Damper Selection
Rectangular Dampers
Rectangular Damper Selection
Damper
Height
(B)
8”
10”
12”
14”
16”
Damper
Width
(A)
18”
20”
22”
24”
26”
28”
30”
32”
34”
36”
Airflow Through Rectangular Damper
CFM @ 1000 FPM Velocity
8”
410
530
640
740
850
970
1080
1190
1300
1410
1520
1630
1740
1850
1970
10”
510
590
690
800
910
1030
1150
1260
1380
1500
1610
1730
1840
2000
2080
12”
560
650
730
850
970
1090
1210
1330
1460
1580
1700
1820
1940
2060
2190
14”
660
770
880
1030
1180
1330
1480
1630
1760
1910
2060
2210
2360
2510
2640
16”
750
890
1030
1200
1370
1540
1710
1880
2060
2230
2400
2570
2740
2910
3090
18”
770
980
1180
1380
1580
1780
1980
2180
2350
2550
2750
2950
3150
3350
3540
20”
850
1090
1330
1550
1770
1990
2210
2430
2650
2870
3090
3310
3530
3750
3990
22”
930
1210
1480
1730
1980
2230
2480
2730
2950
3200
3450
3700
3950
4200
4440
24”
950
1290
1630
1900
2170
2440
2710
2980
3250
3520
3790
4060
4330
4600
4880
26”
990
1390
1780
2080
2380
2680
2980
3280
3550
3850
4150
4450
4750
NA
NA
28”
1070
1500
1930
2250
2570
2890
3210
3530
3850
4170
4500
4820
NA
NA
NA
30”
1020
1550
2080
2430
2780
3130
3480
3830
4150
4500
4850
NA
NA
NA
NA
32”
1090
1660
2230
2600
2970
3340
3710
4080
4450
4820
NA
NA
NA
NA
NA
34”
1150
1770
2380
2780
3180
3580
3980
4370
4750
NA
NA
NA
NA
NA
NA
36”
1060
1790
2520
2670
3090
3510
3930
4350
5040
NA
NA
NA
NA
NA
NA
Table 1-2: Rectangular Damper Selection
Notes:
1.) Zone Dampers Should Be Sized Based On The Required Zone CFM. The Table Above Is
Calculated Based On 1000 FPM Velocity Through The Rectangular Damper. Zone Damper
Recommended Velocity Is 1000 – 1500 FPM. Select 1000 FPM or Less for Quiet Operation. For Other
Velocities, Use The Following Multipliers To Obtain The Correct CFM: 500 FPM = 0.5, 750 FPM =
0.75, 1250 FPM = 1.25, 1500 FPM = 1.5, 2000 FPM = 2.0, 2250 FPM = 2.25.
2.) Bypass Dampers Should Be Selected for 60% to 70% of the HVAC Units Rated CFM Capacity.
Recommended Bypass Damper Velocity is 1750 – 2250 FPM.
Design Guide
1-15
Auto-Zone Basic
Section 1
Pressure Independent Zone Dampers
Pressure Independent operation is only available for round zone dampers. Use the chart
below to set the calibration of the zone damper after installation.
Damper
Size
6”
8”
10”
12”
14”
16”
Flow Probe
“K” Factor
474
950
1417
2120
2908
3700
Flow Probe “K” Factor =
CFM @ 1” Velocity Pressure
Table 1-3: Pressure Independent Flow Factors
Note: K Factors are programmed for each zone so that the correct CFM will be
calculated for the different size air valves.
1-16
Design Guide
Auto-Zone Basic
Section 1
Auxiliary Heat Control
Options
The Auto-Zone Basic Control System offers you a variety of methods to deal with zone
heating requirements. When deciding how to handle zone heating requirements, you
should consider the following:
•
•
•
Does the rooftop unit have heat?
Are you using fan-powered boxes?
Is auxiliary heat used such as baseboard or radiant ceiling panels?
If the zone has some type of heat, you must consider how the heat is to be used. Typical
questions that should be asked:
Q: Should the zone heat be used as a first stage where it will become active before a
heating demand is created at the rooftop unit?
A: This mode is useful if you expect to have both heating and cooling demands at the
same time. The zone will use its own heat and allow the rooftop unit to continue to
provide cooling for other zones. This mode is also useful if the rooftop unit does not
have any heating capabilities.
Q: Is the zone heat only to be used as a second stage where it will be activated only if
the rooftop unit cannot maintain the space temperature such as during very cold
weather?
A: In this mode of operation the rooftop will examine the heating and cooling demands
and try to satisfy all of the zones by switching between heating and cooling as
required. The zone heat will only be activated if the zone temperature falls below a
selected limit.
Q: Should the zone heat be locked out if the rooftop unit is supplying warm air?
A: In many instances, it is desirable to use the rooftop heating whenever possible and
only use zone heat when the rooftop unit is in cooling or vent mode. This often
provides the most cost-effective operation since zone heat is typically electric. This
mode of operation will lockout zone heat if the rooftop is delivering heated air.
Design Guide
1-17
Section 1
Auto-Zone Basic
Relay Expansion Board
The following describes the operation of each of the relays on the optional relay
expansion board. You can choose the appropriate relays for any given application.
Relay #1 - Parallel Fan
If the Zone is in cooling mode or vent mode, the parallel fan can activate any time the
zone temperature drops 0.5°F below the heating setpoint. It de-activates when the
temperature rises above the heating setpoint. The space temperature must be below the
AUX HEAT setpoint in the occupied mode before the Parallel Fan relay can be
energized.
Relay #2 - Box Heat
If the zone is in cooling mode or vent mode, the box heat can activate any time the zone
temperature drops 1.5°F below the heating setpoint. It de-activates when the temperature
rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate in the
heating mode when there is hot air being supplied by the air handling unit. This output
was intended to allow zone re-heat while the Zone Manager is satisfying cooling
demands in other zones. The space temperature must be below the AUX HEAT setpoint
in the occupied mode before the Box Heat relay can be energized.
Relay #3 - Aux Heat
In the occupied mode, the aux heat can activate any time the zone temperature is 0.5°F
below the aux heat setpoint. It de-activates when the temperature rises 0.5°F above the
aux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heating
setpoint with the same deadband values mentioned above. This prevents the zone from
maintaining the same aux heat setpoint at night that it does during the daytime.
This output was intended to allow zone heating to augment the normal heating mode and
also to allow a zone an attempt to satisfy its own heating needs before creating a heating
demand at the Zone Manager.
Relay #4 - Series Fan
The series fan runs any time the main fan is running. This includes occupied and
unoccupied modes. The fan can only start running when the zone damper is closed, so it
determines that the damper is closed before starting the fan.
1-18
Design Guide
Auto-Zone Basic
Section 1
Index
1 inch W.C. ......................................... 10
After-Hours
Overrides........................................... 7
Air
Bypassing.......................................... 6
Air Motion .......................................... 11
Auto-Zone Plus System ........................ 8
AUX HEAT
Setpoint ........................................... 18
Auxiliary Heat
Control Board ................................... 9
Control Options............................... 17
Recommendation .............................. 7
Barometric
Relief Dampers ................................. 7
Baseboard
Heat ................................................. 17
Basic System
Design Guide .................................... 8
Diagram............................................. 2
Boards
Relay Expansion ............................. 18
Box Heat ............................................. 18
Building Pressurization......................... 7
Building Zones
Diagram............................................. 9
Bypass
Air ..................................................... 6
Plenum .............................................. 7
Return Air Intake .............................. 7
Bypass Damper
Overview........................................... 3
Sizing .......................................... 8, 11
Bypass Duct Size ................................ 11
Ceiling Diffuser .................................. 11
Central Unit
Sizing .......................................... 8, 10
CFM
Correct ............................................ 16
Maximum........................................ 11
Comfort ............................................... 11
Design Guide
Cooling
Partial Load Conditions .................... 5
Cooling Load
Maximum.......................................... 8
Dampers
Slaved.............................................. 13
Design
Duct............................................. 8, 10
Room Air Motion.............................. 8
Zoning ............................................... 8
Design Guide ........................................ 8
Diagrams
Basic System..................................... 2
Diffusers
Ceiling............................................. 11
High Induction ............................ 11
Selection...................................... 8, 11
Slot .................................................. 11
Dimensions
Rectangular Damper ....................... 14
Round Damper ................................ 14
Duct Design ........................................ 10
Considerations .................................. 8
Duct Static
High................................................... 6
Duct Static Pressure .............................. 3
Ducted Returns ..................................... 6
Ducts
Undersizing ..................................... 10
Ductwork
Damaging.......................................... 6
Economizer
Benefits Of ........................................ 6
Recommendation .............................. 5
Equipment
Oversizing ......................................... 7
Exhaust
Powered............................................. 7
Exterior Zones....................................... 5
Global Override .................................... 7
1-19
Section 1
Heat
Auxiliary ........................................... 7
Baseboard........................................ 17
Supplemental..................................... 9
Heating
Auxiliary ......................................... 17
Difficulties ........................................ 7
Partial Load Conditions .................... 7
Radiant Ceiling Panels.................... 17
Heating Load
Maximum.......................................... 8
Heating Minimum Setpoints ................. 7
High Induction Diffusers .................... 11
High Pressure Switch
Manual Reset .................................... 6
Induction Ratio
High................................................. 11
Interior Zones........................................ 5
K Factors............................................. 16
Linear Slot Diffusers........................... 11
Load .................................................... 10
Diversity.......................................... 10
Load Calculation
Program........................................... 11
Load Estimating
Program........................................... 10
Lockout
Low Temp......................................... 5
Low Ambient Termperature Lockout ... 5
Low Supply Air Temperatures.............. 5
Low Temp Lockout............................... 5
Manual Reset
High Pressure Switch........................ 6
Maximum
CFM ................................................ 11
Cooling Load .................................... 8
Duct Velocity .................................. 10
Heating Load..................................... 8
Mechanical Safeties .............................. 5
Mutliple Zones ...................................... 8
Negative Pressure Area....................... 12
Noise Levels ......................................... 6
Noise Problems ................................... 10
Operation
Quiet................................................ 10
Override
1-20
Auto-Zone Basic
After-Hours ....................................... 7
Conditions ......................................... 7
Global................................................ 7
Oversizing
Equipment ......................................... 7
Unit ................................................... 6
Overview
Auto-Zone System ............................ 3
Bypass Damper ................................. 3
Zone Controller................................. 3
Zone Manager ................................... 3
Zone Sensor ...................................... 4
Parallel Fan ......................................... 18
Partial Load Conditions ........................ 5
Aggravated........................................ 7
Heating.............................................. 7
Plenum Returns..................................... 6
Powered Exhaust................................... 7
Pressure Dependent............................. 10
Pressure Independent
Flow Factors ................................... 16
Zone Dampers................................. 16
Pressurization
Building ............................................ 7
Problems
Noise ............................................... 10
Program
Load Calculation............................. 11
Load Estimating .............................. 10
Quiet Operation................................... 10
Radiant Ceiling Panels........................ 17
Rectangular Damper
Dimensions ..................................... 14
Selection.......................................... 15
Relay Expansion Board ...................... 18
Relief Dampers
Barometric......................................... 7
Returns
Ducted ............................................... 6
Plenum .............................................. 6
Room Air Motion................................ 11
Design ............................................... 8
Round Air Damper
Dimensions ..................................... 14
Design Guide
Auto-Zone Basic
Selection.......................................... 15
Safeties.................................................. 5
Selection
Diffuser ....................................... 8, 11
Rectangular Damper ....................... 15
Room Air Motion............................ 11
Round Air Damper.......................... 15
Series Fan............................................ 18
Boxes............................................... 11
Setpoints
AUX HEAT .................................... 18
Heating Minimum............................. 7
Static Pressure................................... 6
Sizing
Bypass Damper ........................... 8, 11
Central Unit................................. 8, 10
Zone Dampers............................. 8, 13
Slaved
Dampers .......................................... 13
Slot Diffusers ...................................... 11
Linear .............................................. 11
Static Pickup Probe ............................. 12
Static Pressure
Setpoint ............................................. 6
Setting ............................................... 7
Static Pressure Sensor........................... 3
Location .......................................... 12
Stratification........................................ 11
Supplemental
Heat ................................................... 9
System
Design Guide .................................... 8
Overview........................................... 3
Performance ...................................... 9
Temperatures
Low Supply Air................................. 5
Section 1
Ducts ............................................... 10
Units
Oversizing ......................................... 6
Velocity
Maximum Acceptable..................... 13
Zone
Comfort ............................................. 8
Design ............................................... 5
Diversity............................................ 5
Zone Controller
Overview........................................... 3
Zone Dampers
Pressure Independent ...................... 16
Sizing .......................................... 8, 13
Zone Heating
Auxiliary ......................................... 17
Zone Manager
Overview........................................... 3
Units Per ........................................... 8
Zone Sensor
Overview........................................... 4
Zones
Divided.............................................. 8
Exterior ............................................. 5
External ............................................. 9
Interior .............................................. 5
Internal .............................................. 9
Multiple............................................. 8
Number Of ........................................ 8
Overlapping ...................................... 8
Perimeter ........................................... 9
Zoning
Design ............................................... 8
Temperature Lockout
Low Ambient .................................... 5
Undersizing
Design Guide
1-21
Section 1
1-22
Auto-Zone Basic
Design Guide
Section 2
Table of Contents
Tips Before Beginning Installation .................................. 1
Zone Manager .................................................................. 3
Communications Loop ..................................................... 8
Communications Loop Wiring Overview........................................................................9
Bypass Dampers ............................................................ 10
Zone Dampers ................................................................ 13
Zone Controllers ............................................................ 14
Room Sensors ................................................................................................................21
Supply Air Temperature Sensor ....................................................................................23
Return Air Temperature Sensor .....................................................................................24
Outside Air Temperature Sensor ...................................................................................25
Duct Static Pressure Sensor ...........................................................................................26
Auxiliary Relay Board for Zone Controllers................... 28
Zone Controller Auxiliary Relay Board Operation .......................................................29
CommLink IV Interface.................................................. 30
Basic System Worksheet................................................................................................33
Installation and Wiring
Section 2
Table of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
2-1: System Overview........................................................................................2
2-2: Typical System Component Locations .......................................................2
2-3: Zone Manager Dimensions ........................................................................3
2-4: Zone Manager Component Locations.........................................................4
2-5: Zone Manager Wiring.................................................................................5
2-6: Zone Manager Address Switch Setting ......................................................7
2-7: Communication Loop Wiring, Daisy-Chain Configuration .......................9
2-8: Round and Rectangular Bypass Dampers.................................................10
2-9: Bypass Damper Wiring.............................................................................12
2-10: Round and Rectangular Zone Dampers .................................................13
2-11: Zone Controller Components.................................................................15
2-12: Zone Controller Wiring..........................................................................17
2-13: Zone Controller Address Switch Settings..............................................19
2-14: Slaved Zone Controller Wiring..............................................................20
2-15: Room Sensor Installation .......................................................................21
2-16: Room Sensor Wiring..............................................................................22
2-17: Supply or Return Air Sensor Dimensions and Installation ....................23
2-18: Outside Air Temperature Sensor Dimensions and Installation..............25
2-19: Duct Static Pressure Sensor Dimensions and Installation .....................26
2-20: Static Pressure Sensor Wiring................................................................27
2-21: Auxiliary Relay Board Layout ...............................................................28
2-22: CommLink IV Interface Communication Wiring..................................30
2-23: CommLink IV Interface Connections....................................................31
2-24: CommLink IVJumper Switch Settings ..................................................32
Auto-Zone Basic
Section 2
Tips Before Beginning
Installation
Take a few moments to review the following before beginning installation of the
Auto-Zone Basic Control System.
•
Familiarize yourself with all system components and review all documentation.
Pay special attention to “Cautions” and “Warnings” since these may keep you
from experiencing unnecessary problems.
Before installing zone dampers, be sure to tag each damper with its appropriate location.
It is also best to set the zone controller address switches before mounting in drop ceilings.
Use the Basic System Worksheet found in the back of this section or in the Basic Submittal Package to list all zone locations and Zone Manager configurations. This will assist
you greatly when setting up the system.
•
Be sure to install all wiring according to local, state, and national codes.
•
Pay close attention to communication wiring since the most common mistakes are
made in this area. Polarity is the most important rule. Make notes on your wiring diagrams as to which color wire you will be using on each terminal.
•
When in doubt - ask! Contact your local Auto-Zone distributor if you have any questions. The only dumb questions are the ones you don’t ask.
•
Remember - each electronic device contains only one puff of smoke. If you release it,
you have voided the warranty! So please be careful and pay attention.
2-1
Auto-Zone Basic
Section 2
Figure 2-1: System Overview
Typical HVAC Unit
(Packaged or Split System)
Supply Temp Sensor
(Ahead of Bypass Takeoff)
Bypass Damper
Static Pressure Pickup
( Locate Where Easily Accessible )
Return Duct
(2/3 Of The Way Down Main Duct)
Supply Duct
LOCAL COMM LOOP
TWISTED PAIR
WITH SHIELD TO
ZONE CONTROLLER
Above Corridor
( Preferred Location )
Return Temp Sensor
Zone Damper and Control
Duct to Return
( Over Corridor for Easy Service )
L
COO
L
(Avoid Mixed Air Area)
(Preferred)
+
FAN
1
2
COO
®
T
HEA
T
HEA
LOCAL COMM LOOP
TWISTED PAIR
WITH SHIELD TO
ZONE CONTROLLER
1
2
OPE
N
ASS
SE
BYP
CLO
N
ASS
TIO
BYP
ICA
MUN
+
COM
ALA
RM
ZON
A
B
A
3
B
2
6
1
C
5
9
4
D
8
#
7
0
*
C
D
#
=
=
=
=
=
*=
ALL
EAC
H
C
ES
E
ZON
T/C
LEA
Outdoor Air Sensor
R
UNI
HVA
ALA
STE
RMS
P/E
DEC
NTE
R
L
IMA
(Mount Away From Direct Sunlight))
+
LOCAL COMM LOOP
TWISTED PAIR WITH
SHIELD TO OTHER
ZONE CONTROLLERS
Zone Sensor
(4-1/2' to 5'; Shoulder Height)
Zone Manager
+
NOR
OVR
W
A
R
M
E
MAL R
C
O
O
L
E
R
Diffuser at Perimeter Wall
(Direct Airflow Inward Towards Center of Area)
Figure 2-2: Typical System Component Locations
2-2
Auto-Zone Basic
Section 2
Zone Manager
The Zone Manager may be installed in any convenient, protected location. Observe the
recommended environmental limitations for the Zone Manager (see Technical Data section of product data sheet) when choosing a location. The unit should be mounted with
the display at eye level for easy viewing.
When installing the Zone Manager with display and keypad, you must remove the cover.
Use care not to damage the display while handling and protect the display from physical
damage while removed.
The ribbon cable should be unplugged from the display board which is mounted inside
the front cover. The ribbon cable is keyed to prevent a reverse connection.
Warning: Always remove power before connecting or disconnecting the ribbon
cable which joins the display and keypad to the Zone Manager. Failure to observe this precaution may result in damage to the display or
Zone Manager.
The Zone Manager may be mounted without removing the controller from the enclosure
or mounting plate. The unit is mounted by four (4) screws in the corners. Select the correct screws or other fasteners for the type of mounting material being utilized.
Please see Figure 2-3, Figure 2-4, Figure 2-5, and Figure 2-6 for Zone Manager dimensions, components, wiring, and addressing information.
3.00
Display
+
9.25
N
FA
OL
CO
OL
CO
AT
HE
AT
HE
+
deM
Mo8P
4
ol3: D
Co 0PIEMS
1 U
-0CC AR
08 O AL
NO
08
A
=
M
AR
S
AL
NE
ZO
L
AL
NE
ZO
AR
LE
CH
/C
EA
IT
UN
AC
HV
S
M
AR
AL
ER
NT
/E
EP
ST
=
AL
#
CIM
DE
=
B
11.50
2
2
EN
OP
SS
E
PA
OS
BY
CL
N
SS
IO
PA
AT
BY
IC
UN
M
M
CO
I
FR
A
3
B
2
6
1
C
5
9
4
D
8
#
7
0
*
1
1
C
D
=
=
=
*
+
Keypad
+
Figure 2-3: Zone Manager Dimensions
2-3
Auto-Zone Basic
Section 2
Static Pressure
Sensor - Optional
Modular Connection
Input
Real Time
Clock Chip
Mounting Holes
Typ. Of 4
Static Pressure
Sensor Inputs
+5V
SIG
GND
CX1
C5
R7
D2
R11
D3
R12
PU1
C7
C8
D4
D5
5.11V
ADJUST
D7
D8
VR3
Y1
SC1
D11
I2C EXP PORT
R19
J01
D13
C15
GND
C16
TB3
R37
D14
C18
C17
D15
C19
R38
U8
PU6
EXHAUST
CONTACTS
N.O.
5.11V
ADJ
R39
CX6
U6
R40
Comm
LED
U7
REC
Q2
V2
D16
OPEN
K2
CX7
BYPASSPDAMPER
GND
R42
R41
D17
FDBK
C21
X2
EXH/RELIEF
YS101722
Rev. 2
OPEN
RAM
Analog Output
0-10 VDC
Economizer
ECONOMIZER
C20
CLOSE
GND
TB5
CX9
EPROM
R43
D18
CLOSE
TB4
V3
EXP
BUSS
FAN
K4
V4
D19
R44
V5
COOL1
K5
TB7
R47
R46
D20
8K
COOL2
K6
JO2
1
U12
R52
D21
U14
P1
R55
CX14
HEAT1
U13
HEAT1
C22
CX12
CX13
K7
D30
D29
D28
D27
D26
D25
D24
D23
COMM
T
R60
R59
1992
U15
HEAT2
CX15
MADE IN U.S.A.
R58
R56
D22
V8
RS-485
Communications
Loop Connection
T
SH
R
SH
R
K8
V9
R49
CX11
RN2
COOL1
COOL2
HEAT2
R48
U11
CX10
U10
32K
R
FAN
V7
ADD
SW1
R57
D31
1
2
EPROM
Chip
4
8
16
Address Switch
(Set To 0 Without
CommLink. Set to 17
With CommLink)
32
RAM
Chip
B
NET
RAM Size
Select
Jumper
RN1
R45
Note:
Keypad & Display
Not Shown
Display &
Keypad
Ribbon Cable
Connector
U9
V6
HVAC Unit
Connections
(R) Common
Fan
Cool 1
Cool 2
Heat 1
Heat 2
Binary Output
Relief/Exhaust
Fans
ANALOG
OUTPUTS
K3
Bypass
Damper
Connections
FDBK
GND
Open
Close
GND
PU5
R31
EWDOG
R36
R35
R34
AUX3
R30
U5
Real Time
Clock Chip
AUX2
PU4
R28
CX5
R29
CX4
U3
R33
R32
AUX1
C14
R27
R61
R24
R23
D10
R22
R21
R26
OAT
PU3
C13
CX3
RAT
PU2
R17
R20
C12
D9
R16
C11
Q1
R25
R18
Analog Inputs
SAT
RAT
OAT
AUX1
AUX2
AUX3
GND
SAT
R14
R15
R13
D12
TB2
GND
ANALOG
INPUTS
+12V
D6
POWER
L1
TB1
C4
C9
GND
C6
C3
SIG
C2
+5V
U2
24VAC
PJ1
U1
R9
D1
V1
24 VAC
Power Input
Not Used
PRESSURE
SENSOR JACK
VR2
VR1
Power LED
R5
R4
R3
R2
R1
R10
C1
PAL
Chip
TB8
RS-485
COMM DRIVER
Typical
Pin 1
Indicator
RS-485
Communications
Driver Chip
Figure 2-4: Zone Manager Component Locations
2-4
Auto-Zone Basic
Section 2
Suppy Air Temp.
Sensor
Splice As
Required
Bypass
Air Damper
Actuator
Static
Pressure
Sensor
0
LO
1
Static
Pick-up
Outdoor Air Temp.
Sensor
(See Note 4)
Grn
Blk
Red
Basic Zone Manager
TO ACTUATOR
TB2
OAT
TB2
AUX1
AUX2
+
OPEN
FROM ZONE
CONTROLLER
CLOSE
LD2
AUX3
GND
Aux1
Economizer
Disable
GND
+
LD1
Auxiliary Inputs
( Dry Contacts )
RAT
CLOSE
PJ2
TB1
FDBK
EXHAUST
CONTACTS
N.O.
+
+
GND
REC
OPEN
CLOSE
NE5090
LCD DISPLAY
&
KEYPAD
BYPASS
FDBK
GND
OPEN
CLOSE
V3
V4
V5
V6
OPEN
BYPASS
ANALOG
OUTPUTS
CLOSE
1
2
3
A
FAN
COOL1
4
5
6
B
7
8
9
C
*
0
#
D
G
TB2
G
EXP
BUSS
FAN
Y1
R5
COOL 2
R6
W1
HEAT 1
COMM
D17
D18
D19
D20
D21
D22
D23
D24
HEAT2
W2
C 1992
>
OFF
ADD
SW1
HEAT 2
MADE IN U.S.A.
75176
Rocker Down
24VAC Only
CABLE
C2
HEAT1
Y2
1
2
4
8
16
32
B
NET
RS-485
COMM DRIVER
RS-485
Communications To Zone
Controllers
24VAC
T
SH
R
Local Loop
GND
See Note 1 &2
RS-485
Communications
To CommLink
When Used
RIBBON
+
C1
COOL2
To Relief / Exhaust Fans
A2
COOL 1
R
G
Y1
Y2
W1
W2
Aux3
Aux2
Forced Filter
Occupied Alarm
Mode
A1
P1
HVAC Unit
SAT
+
GND
+
BYPASS AND
SLAVE INTERFACE
YS101824
+
+
+
GND
OPEN
+12V
5.11V
ADJUST
POWER
PJ1
GND
ANALOG
INPUTS
PJ1
24VAC
TB12
SIG
+5V
PRESSURE
SENSOR JACK
Bypass & Slave
Interface Card
Line
Voltage
Return Air Temp.
Sensor
HI
Notes:
1.)24 VAC Must Be Connected So
That All Ground Wires Remain
Common.
2.)All Wiring To Be In Accordance With
Local And National Electrical Codes
and Specifications.
3.)All Communication Wiring To Be 18
Ga. Minimum, 2 Conductor Twisted
Pair With Shield. Belden #82760 Or
Equivalent.
Economizer Actuator
5 U
4 Y2
BELIMO
AF24-SR
3 Y1
133 IN-LB
2 +
1 COM
WARNING!
Use Extreme Care When Wiring
Economizer Actuators
Never Connect Or Disconnect
Wiring With Power Applied!
Never Apply Power If The
Gnd ( 1 Com ) Terminal On The
Actuator Is Not Connected.
Belimo Actuator Wiring Shown.
Consult Factory For Other
Models Of Economizer Actuators.
Some Actuators Require Isolation
Transformers In Order To Prevent
Damage To The Controller Board.
Figure 2-5: Zone Manager Wiring
Warning: Use extreme care not to damage any of the electronic components
while mounting the enclosure. Mark the holes and then remove the
Zone Manager before drilling. Do not allow metal shavings
to fall onto the circuit boards.
2-5
Section 2
Auto-Zone Basic
The Zone Manager requires the following electrical connections:
18-Gauge minimum unless otherwise noted.
-24VAC Supply Voltage........................................................................... 2 Conductors
-Communications Loop ...................................... 2 Conductor twisted pair with shield
(Belden #82760 or equivalent)
-Supply Air Temperature Sensor ........................................(24 ga. Min.) 2 Conductors
-Return Air Temperature Sensor ........................................(24 ga. Min.) 2 Conductors
-Outside Air Temperature Sensor....................................... (24 ga. Min.) 2 Conductors
-Supply Static Pressure Sensor ...........................................(24 ga. Min.) 3 Conductors
-Bypass Damper........................................................................................ 4 Conductors
-HVAC Unit Control Wiring .....................................................................R - Common
G - Fan
Y1 - Cool 1
Y2 - Cool 2
W1 - Heat 1
W2 - Heat 2
Tip: After making all electrical connections, you should unplug all terminal blocks
on the Zone Manager until you are ready to begin the checkout procedure. This
may help to prevent damage if wiring errors occur elsewhere in the system during installation or start-up.
2-6
Auto-Zone Basic
Section 2
BYPASSPDAMPER
FDBK
GND
CLOSE
K3
RS-485
Communications
To CommLink
When Used
OPEN
RAM
CX9
EPROM
R43
D18
CLOSE
V3
FAN
K4
V4
D19
R44
V5
U9
V6
COOL1
K5
RN1
R45
TB7
R47
R46
D20
8K
COOL2
FAN
K6
JO2
1
P1
U14
R52
D21
CX14
U13
HEAT1
C22
CX12
CX13
K7
COMM
D30
D29
D28
D27
D26
D24
D25
D23
CX15
R60
1992
R59
HEAT2
U15
MADE IN U.S.A.
R58
R56
D22
V8
K8
V9
U12
R55
HEAT1
V7
R49
CX11
RN2
COOL1
COOL2
HEAT2
R48
U11
CX10
U10
32K
R
T
SH
R
All Comm Loop Wiring Is
Straight Thru
ADD
SW1
D31
R57
T
SH
R
T
SH
R
T
SH
R
1
2
4
8
16
B
32
NET
Local Loop
RS-485
9600 Baud
TB8
RS-485
COMM DRIVER
T
SH
R
RS-485
Controllers
These Switches Must Be
In The OFF Position
As Shown
AD
Rocker Down
OFF
>
D
ADD
1
2
4
8
16
B T
E
N
Address Switch Must Be Set
To Address 0 on Zone Manager Board
As Shown
32
2.)It Is Recommended That All
Controllers Address Switches Are
Set Before Installation.
1
2
4
8
16
32
B
NET
Notes:
1.)AllCommunication Wiring To Be
2 Conductor Twisted Pair With
Shield. Use Belden #82760 Or
Equivalent.
Zone Manager
Address Switch
Basic System Without CommLink
3.)Power To The Zone Manager Must Be
Cycled Before Address Switch
Changes Will Take Affect.
In The OFF Position
As Shown
Zone Manager
Address Switch
AD
Rocker Down
OFF
>
D
ADD
1
1
2
4
8
16
32
B
NET
2
4
8
16
32
B T
E
N
To Address 17 on Zone Manager
Board When CommLink Is Used
Basic System With CommLink
Figure 2-6: Zone Manager Address Switch Setting
Caution: Your Auto-Zone Basic Control System will not work properly unless
you set the Address switch correctly. Remember, you must power
down the Zone Manager after changing the address switch in order for
the change to take effect.
2-7
Section 2
Auto-Zone Basic
Communications Loop
The communications network is a two-wire shielded RS-485 loop. The loop is best connected in a daisy chain configuration, meaning the loop is connected from one controller
to another. It is not necessary to sequentially address the zone controllers in relation to
their location on the loop. Cable must be Belden No. 82760 or equivalent.
Tip: Incorrect wiring of the communications loop is the most common mistake made
during installation. Before beginning installation, write down the wire color
used on each terminal connection and consistently maintain that color code. It is
recommended that a continuous wire run be made between devices. Any time a
splice is made in the cable, you increase your chance of problems.
Caution: Make sure when you are inserting wires into the terminal blocks that
strands of wire do not stick out and touch the next terminal. This could
cause a short or erratic operation.
Note: The loop does not have to follow the controller address sequence.
Caution: If comm loop is not installed in conduit, be careful to position the cable
away from high noise devices like fluorescent lights, transformers,
VFDs, etc. Conduit is not required for comm loop wiring unless required by local codes.
2-8
Auto-Zone Basic
Section 2
Communications Loop Wiring Overview
The daisy chain is the best method for running a communications loop since there is only
one starting point and one ending point. See Figure 2-7.
Figure 2-7: Communication Loop Wiring, Daisy-Chain Configuration
Even though the daisy chain configuration is preferred, the star configuration can also be
used. If required, a combination of the two can also be used. Remember, the best comm
loop wiring is the one which utilizes the minimum number of ends while using the shortest wiring path. See Figure 2-6 and Figure 2-13 for controller addressing information.
2-9
Auto-Zone Basic
Section 2
Bypass Dampers
The Bypass Damper can be either round or rectangular. The Round Bypass Damper is
supplied with the Damper Actuator and Bypass Wiring Interface Board factory mounted
in a sheet metal enclosure attached to a Round Air Damper assembly. This Round Bypass
Damper Package is field connected to the appropriate size round duct. Rectangular Bypass Dampers mount directly in the rectangular ductwork using flanged connections field
formed in the rectangular ductwork. A Rectangular Bypass Damper Kit is required to
complete the Rectangular Bypass Damper package. The Rectangular Bypass Damper Kit
is supplied with the Damper Actuator and Bypass Wiring Interface Board factory
mounted in a sheet metal enclosure. This assembly is then field mounted over the Rectangular Damper shaft and secured to the ductwork with sheet metal screws.
Figure 2-8: Round and Rectangular Bypass Dampers
Up to two additional Rectangular Bypass or Round Bypass Dampers can be slaved together when it is not practical to use a single large damper. See Figure 2-9. The bypass
damper(s) should be installed as close as possible to the rooftop unit.
Round and Rectangular Bypass Dampers should be securely hung using either wire cradles or metal strapping. While the dampers may be hung in any position, avoid sharp
kinks in flexible duct to prevent airflow restrictions. The Round Bypass Dampers are insulated for use in non-conditioned spaces to avoid sweating and to improve energy efficiency.
See Figure 2-2 for a typical bypass damper mounting location. See Figure 2-9 for typical
Bypass Wiring Interface Board wiring instructions.
2-10
Auto-Zone Basic
Section 2
Warning: If sheet metal screws are used to mount the dampers, be certain that
they do not interfere with the movement of the damper blade.
Warning: Never depress the actuator clutch with power applied. Unplug the actuator cable before depressing the clutch and attempting to rotate the
damper blade. Do not force the damper blade as this can damage the
gears in the damper actuator.
2-11
Auto-Zone Basic
Section 2
ZONE MANAGER BOARD
BYPASS ACTUATOR #1
(MASTER)
CLOSE
OPEN
TB1
OPEN
K2
GND
FDBK
CLOSE
K1
LD1
PJ2
NOT USED FOR
THIS APPLICATION
OPEN
FROM ZONE
CONTROLLER
1
LD2
0
NE5090
REC
CLOSE
FDBK
GND
CLOSE
TB2
OPEN
CLOSE
OPEN
GND
V3
T
SH
R
NETWORK
PJ1
TO ACTUATOR
BYPASS AND
SLAVE INTERFACE
YS101824
V4
BYPASS &
SLAVE INTERFACE CARD
MODULAR CABLE
BYPASS ACTUATOR #3 (SLAVE)
(WHEN USED)
0
BYPASS ACTUATOR #2 (SLAVE)
1
0
MODULAR
CABLE
BYPASS &
MODULAR
CABLE
BYPASS AND
SLAVE INTERFACE
YS101824
TO ACTUATOR
BYPASS &
TO ACTUATOR
BYPASS AND
SLAVE INTERFACE
YS101824
1
PJ1
PJ1
GND
TB2
TB2
GND
OPEN
OPEN
OPEN
PJ2
FDBK
TB1
TB1
FDBK
GND
NOT USED FOR
THIS APPLICATION
FROM ZONE
CONTROLLER
CLOSE
LD2
PJ2
CLOSE
LD1
OPEN
LD2
NOT USED FOR
THIS APPLICATION
FROM ZONE
CONTROLLER
CLOSE
LD1
CLOSE
GND
OPEN
OPEN
CLOSE
CLOSE
Figure 2-9: Bypass Damper Wiring
Warning: If the fan system has the capability of producing static pressures
which could damage ductwork, you must provide a manual reset
high pressure limit switch to cut-off the fan system in the event of
high duct static. Do not use your Auto-Zone Basic Control System as a safety device!
2-12
Auto-Zone Basic
Section 2
Zone Dampers
The Zone Damper can also be either round or rectangular. The Round Zone Damper is
supplied with the damper actuator and Zone Controller factory mounted in a sheet metal
enclosure attached to a Round Air Damper assembly. This Round Zone Damper Package
is field-connected to the appropriate size round duct. Rectangular Zone Dampers
mounted directly in the rectangular ductwork using flanged connections field formed in
the rectangular ductwork. A Rectangular Zone Damper Kit is required to complete the
Rectangular Zone Damper package. The Rectangular Zone Damper Kit is supplied with
the Damper Actuator and Zone Controller factory-mounted in a sheet metal enclosure.
This assembly is then field-mounted over the Rectangular Damper shaft and secured to
the ductwork with sheet metal screws.
Figure 2-10: Round and Rectangular Zone Dampers
Up to two additional Rectangular Zone or Round Zone Dampers can be slaved together
when it is not practical to use a single damper. See Figure 2-14. Generally this is not required.
Round and Rectangular Zone dampers should be securely hung using either wire cradles
or metal strapping. While the dampers may be hung in any position, avoid sharp kinks in
flexible duct to prevent airflow restrictions. The Round Zone Dampers are insulated for
use in non-conditioned spaces to avoid sweating and to improve energy efficiency.
See Figure 2-2 for typical Round Zone Damper mounting locations. See Figure 2-12 for
Zone Controller wiring instructions.
2-13
Auto-Zone Basic
Section 2
Zone Controllers
The Zone Controllers are mounted in snap-track which is typically located in the control
enclosure on each zone damper. Orient the board in the snap-track so that the actuator,
flow sensor (optional), and auxiliary relay board (optional) cables will reach their respective connectors on the Zone Controller. Carefully press the board into the snap-track to
avoid damaging any of the electronic components on the circuit board. To remove a
board from the snap-track, carefully pull one edge of the snap-track away from the board
with your fingers and remove the board.
Caution: Do not use any tools to pry the board loose. This will damage the
board and/or snap-track.
Warning: When mounting the snap-track, be sure the heads of the screws do not
protrude far enough to touch the bottom of the Zone Controller circuit
board.
Consider serviceability of the location when mounting the Zone Controllers. They should
be easily accessible to facilitate servicing.
Tip: Use small stickers on the ceiling grid or tiles to help future service personnel
locate system components. If you use small stickers from an office supply store,
you can get different colors to code the location of various components.
2-14
Auto-Zone Basic
Section 2
Figure 2-11: Zone Controller Components
2-15
Section 2
Auto-Zone Basic
The Zone Controller requires the following electrical connections:
24VAC Supply Voltage............................................................................ 2 Conductors
Communications Loop........................................ 2 Conductor twisted pair with shield
(Belden #82760 or equivalent)
Room Temperature Sensor ...................................... 2 Conductors for standard sensors
3 Conductors for sensors with setpoint adjustment
Fan Terminal units / Auxiliary Heat...............2-4 Conductors see wiring diagrams for
(Optional) Aux. Relay board
Tip: After making all electrical connections, it is suggested that all terminal blocks
on the Zone Controller be unplugged until you are ready to begin the checkout
procedure. This may help prevent damage if wiring errors occur elsewhere in the
system during installation or start-up. This is particularly important with the
Zone Controllers since an error on one unit may prevent any of the others from
working until the problem is found and corrected.
Warning: Polarity is very important when connecting power to the controllers!
The grounded side of the control transformer must be connected to
the terminal labeled GND on the Zone Controller. If a single transformer is used to power more than one Zone Controller, you must
connect GND-to-GND and 24VAC-to-24VAC on each zone controller. Failure to observe polarity will result in damage to one or more
components in your system.
2-16
Auto-Zone Basic
Section 2
Figure 2-12: Zone Controller Wiring
2-17
Section 2
Auto-Zone Basic
Set the Zone Controller Address Switch using the addressing instructions in
Figure 2-13.
Caution: Incorrect addressing is the number one cause of communication problems. Check the addressing carefully. Remember, the Zone Controller
only reads the switch during a power-up. If the address switch is
changed, the unit must be turned OFF and then ON before the new
setting will be recognized.
Note: Ignore any markings or numbers on the switch. Use this chart!
2-18
Auto-Zone Basic
Section 2
Figure 2-13: Zone Controller Address Switch Settings
2-19
Auto-Zone Basic
Section 2
MODULAR CABLE
BYPASS &
ZONE ACTUATOR #1
(MASTER)
CLOSE
OPEN
TB1
GND
FDBK
PJ2
CLOSE
PJ2
TB2
OPEN
PJ1
CLOSE
1
LD1
0
OPEN
FROM ZONE
CONTROLLER
ACTUATOR
LD2
EXPANSION
GND
BYPASS AND
SLAVE INTERFACE
YS101824
PJ1
TO ACTUATOR
ZONE CONTROLLER BOARD
MODULAR CABLE
SLAVED- ZONE ACTUATOR #2
(WHEN USED)
0
SLAVED-ZONE ACTUATOR #1
1
0
MODULAR
CABLE
BYPASS &
MODULAR
CABLE
BYPASS AND
SLAVE INTERFACE
YS101824
TO ACTUATOR
BYPASS &
TO ACTUATOR
BYPASS AND
SLAVE INTERFACE
YS101824
1
PJ1
PJ1
GND
TB2
TB2
GND
OPEN
OPEN
OPEN
PJ2
FDBK
TB1
TB1
FDBK
GND
NOT USED FOR
THIS APPLICATION
FROM ZONE
CONTROLLER
CLOSE
LD2
PJ2
CLOSE
LD1
OPEN
LD2
NOT USED FOR
THIS APPLICATION
FROM ZONE
CONTROLLER
CLOSE
LD1
CLOSE
GND
OPEN
OPEN
CLOSE
CLOSE
Figure 2-14: Slaved Zone Controller Wiring
2-20
Auto-Zone Basic
Section 2
Room Sensors
The Room Sensor uses a patented flush-mount design to isolate the temperature sensing
element from the housing which mounts flush with the wall surface.
Room Sensors should be located on an inside wall away from direct sunlight or heatproducing equipment such as computers, copiers, etc. Such devices can adversely affect
the accuracy of the sensor. Although the sensor eliminates most of the effects of thermal
coupling to the walls, try to avoid walls which retain large amounts of thermal energy
(such as marble or steel). Walls containing either cold or warm air currents should also be
avoided whenever possible. Avoid locating the sensor in dead air areas of a room. This
will result in slow response to temperature changes in the space.
Figure 2-15: Room Sensor Installation
Mount the sensor approximately 50-60 inches from the floor for best results. The Room
Sensor is designed to mount vertically in a standard 2- by 4-inch electrical box. The sensor may be mounted directly into the drywall where electrical codes do not require low
voltage wiring to be enclosed in conduit. A template is supplied with the sensor to facilitate cutting a hole of the correct size.
Tip: Be careful when cutting the hole to make sure the sensor or the plastic bezel of
the sensor will completely cover the opening.
Tip: If sensors must be installed on walls which are solid and cannot be penetrated,
surface-mounted boxes and raceway can be purchased from your local electrical
distributor.
2-21
Auto-Zone Basic
Section 2
Zone Controller
Room Sensor
AUX
+VS
AUX1
OVR
+
GND
W
A
R
M
E
R
C
O
O
L
E
R
AUX2
TB1
TMP
GND
AUX
TEMP
GND
TB2
Connection To AUX
Terminal Required Only
When Sensor Is Specified
With Slide Adjust Option
Figure 2-16: Room Sensor Wiring
Connect the terminal labeled GND on the zone sensor to the terminal labeled GND on the
Zone Controller terminal block for the TEMP SENSOR. Connect the terminal labeled
TMP on the zone sensor to the terminal labeled TEMP on the Zone Controller terminal
block for the TEMP SENSOR. If the zone sensor has a setpoint adjust slider, connect the
sensor terminal labeled AUX to the Zone Controller AUX terminal block labeled AUX1.
2-22
Auto-Zone Basic
Section 2
Supply Air Temperature Sensor
The supply air temperature sensor should be located as close to the rooftop unit discharge as possible for best response. It should also be mounted upstream of the bypass
damper for best results. Locate the sensor in the center of the widest part of the duct. Use
the supplied template and a 5/16" drill to make a hole for the sensor. Install the gasket
over the probe and mount securely to the duct using the supplied sheet metal screws. Be
sure the gasket is compressed to provide an airtight seal. For best accuracy, apply insulation on the outside of the duct, over the sensor. This will help prevent thermal gradients
from affecting the sensor.
Leads Are Non-polarized.
Butt Splice Leads To 24 Gauge
Wire Minimum. Connect Leads
To "Analog In" And "Ground"
At Controller.
4.0"
Thread
Together
3/4"
5-1/2" (OE230)
11-1/2" (OE231)
Mounting Plate
1/4" Hex Head Sheet Metal Screws
Mounting Plate
Gasket
Adhesive Backed Drill Guide
Mounting Template
Duct Work
Drill 5/16" Hole In Ductwork For Probe
Figure 2-17: Supply or Return Air Sensor Dimensions and Installation
2-23
Section 2
Auto-Zone Basic
Return Air Temperature Sensor
The return air temperature sensor should be located upstream of where the Bypass connects to the return air duct so that the supply air does not affect the reading of the return
air sensor. Avoid locations which will be exposed to extreme outside temperatures. Locate the sensor in the center of the widest part of the duct. Use the supplied template and
a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mount
securely to the duct using the supplied sheet metal screws. Be sure the gasket is compressed to provide an airtight seal. For best accuracy, apply insulation on the outside of
the duct over the sensor. This will help prevent thermal gradients from affecting the sensor.
Caution: Do not mount the return air sensor in the mixed air section. This will
cause an error in the reading.
2-24
Auto-Zone Basic
Section 2
Outside Air Temperature Sensor
The outside air sensor must be located where it will not be affected by direct sun or heat
producing equipment. Mounting under the eve of a roof is often a good choice.
Caution: Complaints of inaccurate outside sensor readings are very common and
can almost always be shown to be the result of poor sensor location.
Note: All sensors utilize the same type thermistor sensor element. For troubleshooting
sensors, refer to temperature sensor resetting instructions in section 3 of this
manual.
Gasketed Cover
CAUTION!
See Note3
Cover
Mounting
Screw - Typ.
3.00”
Closure Plug
CAUTION!
See Note 2
2.70”
2.30”
Mounting Tab
& Screws - Typ.
1.13”
4.50”
2.25”
0.21" Dia. x 0.73
Lg. Slot - Typ.
Mounting Tab
& Screw - Typ.
3.00”
Closure Plug
CAUTION!
See Note 2
Sensor Tube
CAUTION!
See Note 1
Front View
Notes:
1.)The Outside Air Sensor Must Be
Mounted In A Vertical Position As
Shown (Sensor Tube Pointing
Down). Water Must Not Be
Allowed To Stand In Sensor
Tube. Rainwater Will Damage
Sensor. Sensor Must Be Located
Where It Will Not Be Affected By
Direct Sunlight Or Heat Producing
Equipment. If Possible Mount Under
Roof Eave Or Similar Protected
Location. If Sensor Is Not Located
As Specified, Erroneous Outside Air
Temperature Readings Will Result.
Side View
Back View
2.)Unused Conduit Opening(s) Must
Have Closure Plugs Installed And Must
Be Coated with Sealing Compound To
Provide Raintight Seal. Water Can
Damage Sensor!
3.)Gasket Must Be Installed Under Cover
Plate To Provide Raintight Seal.
Rainwater Can Damage Sensor!
And Specifications.
Incorrect
See Note #1
Incorrect
Correct
Sensor Mounting
Postion
Figure 2-18: Outside Air Temperature Sensor Dimensions and Installation
2-25
Auto-Zone Basic
Section 2
Duct Static Pressure Sensor
1.00"
0.55"
1.95"
UP
2.20"
2.50"
IN
(-)LO
OE271
S.P. Sensor
OUT (Black)
GND (Green)
OUT
GND
0.125" (1/8" Tubing Conn.)
0.60"
0.200" (3/16" Tubing Conn.)
0.15" DIA.
12.0" APPROX.
The duct static pressure sensor is designed to be mounted at the controller or on the
ductwork near the pickup tube and may be connected via its modular plug. If the sensor is mounted on the ductwork, the modular plug must be cut off and 3-conductor
wire spliced onto the sensor leads. If the trunk ducts are properly sized for minimum
pressure drop, the location of the static pickup probe is not particularly critical. It
should ideally be located at right angles to the airflow in a straight section of the supply duct approximately ⅔ the distance of the total length of the supply duct. Also, the
probe should be located not less than 3 duct diameters downstream and 2 duct diameters upstream of any elbow or takeoff. See Figure 1-3 in section 1 of this manual for
general mounting location information.
0.35"
2.94"
1.29"
0.15"
IN (Red)
Figure 2-19: Duct Static Pressure Sensor Dimensions and Installation
Caution: Mount the static pressure sensor on a vertical surface with the tube tips
pointing downward. Avoid any kinks or sharp bends in the tubing which
runs from the pickup tube to the sensor.
Warning: The plastic housing on the sensor is electrically conductive. Avoid
contact with any electrical components. It is acceptable to mount the
sensor on grounded sheet metal such as ductwork, electrical panels,
etc.
Warning: Use extreme care when mounting the sensor to avoid damage to the
plastic housing. Do not over-tighten the mounting screws! Do not use
mounting screws which are too large for the holes!
2-26
Auto-Zone Basic
Section 2
Tip: Having at least 10-20 feet of tubing between the pick-up tube and the pressure
sensor will improve control performance by acting as a “filter” to remove pressure fluctuations caused by turbulence in the duct.
Figure 2-20: Static Pressure Sensor Wiring
Note: Refer to Figure 1-3 in section 1 of this manual for instructions concerning
proper location of the static pressure sensor.
2-27
Auto-Zone Basic
Section 2
Auxiliary Relay Board for
Zone Controllers
An optional auxiliary relay board is available for the Zone Controllers. This board provides additional outputs for the following applications:
• Parallel Fan
• Box Heat
• Auxiliary Heat (typically perimeter type)
• Series Fan
The board comes shipped with a modular cable which plugs directly into the Zone Controller connector marked “Expansion.” After connecting the board, the system will need to be
powered OFF and then ON for the system to recognize the presence of the relay board.
Figure 2-21: Auxiliary Relay Board Layout
Warning: Relay contacts are rated for 24VAC pilot duty only! Do not apply
voltages higher than 24VAC.
2-28
Auto-Zone Basic
Section 2
Zone Controller Auxiliary Relay Board
Operation
Relay #1 - Parallel Fan
If the zone is in cooling mode or vent mode, the parallel fan relay will activate any time
the zone temperature drops 0.5°F below the heating setpoint. It de-activates when the
temperature rises 0.5°F above the heating setpoint. The space temperature must be below
the AUX HEAT setpoint in the occupied mode before the Parallel Fan relay can be energized.
Relay #2 - Box Heat
If the zone is in cooling mode or vent mode, the box heat relay will activate any time the
zone temperature drops 1.5°F below the heating setpoint. It de-activates when the temperature rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate
in the heating mode when there is hot air being supplied by the air handler. This output
was intended to allow zone re-heat while the Zone Manager is satisfying cooling demands in other zones. The space temperature must be below the AUX HEAT setpoint in
the occupied mode before the Box Heat relay can be energized.
Relay #3 - Aux Heat
In the occupied mode, the aux heat relay will activate any time the zone temperature is
0.5°F below the aux heat setpoint. It de-activates when the temperature rises 0.5°F above
the aux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heating
setpoint with the same deadband values mentioned above. This prevents the zone from
maintaining the same aux heat setpoint at night that it does during the daytime.
This output was intended to allow zone heating, to augment the normal heating mode,
and also to allow a zone to attempt to satisfy its own heating needs before creating a heating demand at the Zone Manager.
Relay #4 - Series Fan
The series fan relay is energized any time the main fan is running. This includes occupied and unoccupied modes. In the unoccupied mode, the fan can only start when the
zone damper is closed. The controller checks to be sure the damper is closed before starting the fan.
2-29
Section 2
Auto-Zone Basic
CommLink IV Interface
The optional CommLink IV is used to transfer communications between controllers on
your control system loops. It can also be used as an interface for connection of a computer to your system. The CommLink IV provides communication with any controller on
the control system through a computer that is running Prism software or it can be used to
communicate with most controllers by using only the Zone Manager. For remote communications, an IP Module Kit can be installed for LAN and Internet connections or a
Remote Link II can be connected for dial-up connections.
Figure 2-22: CommLink IV Interface Communication Wiring
Locate the CommLink near the computer or modem. The cable connections between the
CommLink and the computer or modem should be kept to less than 25 feet.
The CommLink comes complete with computer and modem cables and a plug-in power
supply. There is an optional IP Module that installs into the CommLink and provides
TCP/IP Internet connection and an optional Remote Link II for dial-up connection or
alarm call-outs. The Zone Manager address switch must be set to 17 when the
CommLink is installed on the Auto-Zone Basic Control System. Also the jumper switch
located on the CommLink circuit board must be set for single loop operation. See Figure
2-23 and Figure 2-24 for details.
2-30
Auto-Zone Basic
Section 2
Figure 2-23: CommLink IV Interface Connections
2-31
Auto-Zone Basic
Section 2
Figure 2-24: CommLink IV Jumper Switch Settings
2-32
Auto-Zone Basic
Section 2
Basic System Worksheet
Project: _______________________ Location ______________________________________________
CommLink Installed: Yes No Remote Link Installed: Yes No Phone:
_________________
Stages of Cooling ____ Stages of Heating ____ Gas Electric
Zoning: Pressure Dependent
Zone
Address
Economizer Yes No
Room
Sensor Type
Relay
Exp. Board
1
S SO SA SOA
AH BH SF PF
2
S SO SA SOA
AH BH SF PF
3
S SO SA SOA
AH BH SF PF
4
S SO SA SOA
AH BH SF PF
5
S SO SA SOA
AH BH SF PF
6
S SO SA SOA
AH BH SF PF
7
S SO SA SOA
AH BH SF PF
8
S SO SA SOA
AH BH SF PF
9
S SO SA SOA
AH BH SF PF
10
S SO SA SOA
AH BH SF PF
11
S SO SA SOA
AH BH SF PF
12
S SO SA SOA
AH BH SF PF
13
S SO SA SOA
AH BH SF PF
14
S SO SA SOA
AH BH SF PF
15
S SO SA SOA
AH BH SF PF
16
S SO SA SOA
AH BH SF PF
Zone Description or Location
Air
Damper
Size
[S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint adjust]
[AH=Auxiliary Heat] [BH=Box Reheat] [SF=Series Fan Terminal] [PF=Parallel Fan Terminal]
2-33
Section 2
Auto-Zone Basic
Index
24VAC-to-24VAC.............................. 16
Actuator Cable .................................... 11
Actuator Clutch................................... 11
Address Sequence ................................. 8
Addressing
Checking ......................................... 18
Incorrect .......................................... 18
Zone Controller................................. 1
Zone Manager ................................... 7
Airflow Restrictions
Preventing ................................. 10, 13
AUX
Terminal.......................................... 22
Aux Heat ............................................. 28
AUX HEAT ........................................ 28
AUX1
Terminal.......................................... 22
Auxiliary Heat..................................... 27
Auxiliary Relay Board ........................ 27
Layout Diagram .............................. 27
Belden No. 82760 ................................. 8
Box Heat ....................................... 27, 28
Bypass Damper
Overview......................................... 10
Wiring ............................................. 12
Bypass Dampers
Insulated.......................................... 10
Rectangular ..................................... 10
Round.............................................. 10
Bypass Wiring Interface Board........... 10
Cable
Actuator .......................................... 11
Belden No. 82760 ............................. 8
Splice ................................................ 8
Cables
Auxiliary Relay Board .................... 14
Flow Sensor .................................... 14
Codes
Wiring ............................................... 1
Color Code ............................................ 8
2-34
CommLink IV
Connections Diagram...................... 30
Jumper Switch Settings................... 31
Overview......................................... 28
Wiring ............................................. 29
Communication Problems
Addressing Incorrectly.................... 18
Communications Loop.......................... 8
Wiring Overview .............................. 9
Component Locations ........................... 2
Components
Damage To...................................... 16
Zone Manager ................................... 4
Conduit.................................................. 8
Configuration
Daisy Chain....................................... 8
Cooling Mode ..................................... 28
Daisy Chain
Configuration .................................... 8
Damper Actuator
Gears, Damaging............................. 11
Overview......................................... 10
Damper Blade ..................................... 11
Forcing ............................................ 11
Dampers
Tagging ............................................. 1
Dial-Up Connections .......................... 29
Dimensions
Zone Manager ................................... 3
Duct Static Pressure Sensor ................ 25
Mounting......................................... 25
Ductwork
Static Pressures ............................... 12
Electrical Connections
Zone Manager ................................... 6
Energy Efficiency
Improving.................................. 10, 13
Environmental Limitations
Zone Manager ................................... 3
Fluorescent Lights................................. 8
Auto-Zone Basic
GND-to-GND ..................................... 16
Heating
Setpoint ........................................... 28
High Pressure Limit Switch
Manual Reset .................................. 12
Incorrect
Wiring ............................................... 8
Installation
Room Sensor................................... 21
SAT or RAT Sensor........................ 23
Zone Manager ................................... 3
Installing
Zone Manager ................................... 3
IP Module Kit ..................................... 29
Kinks ................................................... 10
Avoiding ................................... 13, 25
LAN and Internet connections ............ 29
Manual Reset
High Pressure Limit Switch ............ 12
Metal Shavings ..................................... 5
Metal Strapping............................. 10, 13
Mounting
Duct Static Pressure Sensor ............ 25
Outside Air Sensor.......................... 24
Room Sensor................................... 21
Snap-Track...................................... 14
Supply Air Temperature Sensor ..... 23
Zone Controllers ............................. 14
Zone Manager ................................... 3
Occupied Mode................................... 28
Operation
Auxiliary Relay Board .................... 28
Outside Air Sensor
Installing ......................................... 24
Location .......................................... 24
Mounting......................................... 24
Outside Sensor Readings
Inaccurate........................................ 24
Parallel Fan ................................... 27, 28
Plastic Bezel........................................ 21
Polarity............................................ 1, 16
Prism ................................................... 29
Rectangular Zone Damper
Overview......................................... 13
Remote Link II.................................... 29
Return Air Temperature Sensor
Section 2
Installing ......................................... 23
Location .......................................... 23
Mounting......................................... 23
Ribbon Cable ........................................ 3
Room Sensor
Installation ...................................... 21
Mounting......................................... 21
Wiring ............................................. 22
Room Sensors
Best Location .................................. 21
Location .......................................... 21
Overview......................................... 21
Round Air Damper.............................. 10
Round Zone Damper
Overview......................................... 13
RS-485 Loop......................................... 8
Safety Device ...................................... 12
Sensor
Accuracy ......................................... 21
Series Fan...................................... 27, 28
Setpoints
AUX HEAT .................................... 28
Heating............................................ 28
Sheet Metal Screws............................. 11
Slaved............................................ 10, 13
Slaved Zone Controller Wiring........... 20
Snap-Track
Mounting......................................... 14
Splicing
Cable ................................................. 8
Star Configuration................................. 9
Static Pressure Sensor
Wiring ............................................. 26
Supply Air
Temperature Sensor ........................ 23
Supply Air Temperature Sensor
Location .......................................... 23
Mounting......................................... 23
Sweating
Avoiding ......................................... 13
Improving........................................ 10
System Component
Locations........................................... 2
System Overview
Diagram............................................. 2
2-35
Section 2
Tagging
Dampers ............................................ 1
TEMP
Terminal.......................................... 22
TEMP SENSOR.................................. 22
Temperature Sensor
Return Air ....................................... 23
Supply Air....................................... 23
Thermistor Sensor............................... 24
Transformers ......................................... 8
Unoccupied Mode............................... 28
Vent Mode .......................................... 28
VFDs ..................................................... 8
Wire
Color Code ........................................ 8
Wire Color ............................................ 8
Wire Cradles ................................. 10, 13
Wiring ................................................... 1
Bypass Damper ............................... 12
Codes................................................. 1
CommLink IV................................. 29
Communications Loop...................... 9
Incorrect ............................................ 8
Room Sensor................................... 22
Star Configuration............................. 9
Static Pressure Sensor..................... 26
Zone Controller......................... 17, 20
2-36
Auto-Zone Basic
Zone Manager ................................... 5
Worksheet
Basic System................................... 32
Zone Controller
Address Switch Settings ................. 19
Address Switches .............................. 1
Component Diagram....................... 15
Damage Prevention......................... 16
Electrical Connections .................... 16
Setting Address ............................... 19
Slaved Wiring ................................. 20
Wiring ............................................. 17
Zone Controllers
Mounting......................................... 14
Overview......................................... 14
Zone Damper ...................................... 13
Overview......................................... 13
Zone Manager
Addressing Switch ............................ 7
Board................................................. 4
Dimensions ....................................... 3
Electrical Connections ...................... 6
Environmental Limitations ............... 3
Installation ........................................ 3
Mounting........................................... 3
Ribbon Cable .................................... 3
Wiring ............................................... 5
Section 3
Table of Contents
LCD/Keypad Operations ................................................... 1
Main Screen Access.........................................................................................................1
Data Entry Functions .......................................................................................................2
Zone Summary Screen..................................................... 2
Individual Zone Status Screens....................................... 3
Zone Manager Status Screens ........................................ 5
Alarm Status Screens ...................................................... 7
Entering Passcodes ......................................................... 9
Main Menu Operation....................................................... 9
Zone Controller Setpoints.............................................. 10
Zone Manager Setpoints................................................ 14
Week Schedules .............................................................................................................14
Holidays .........................................................................................................................15
Setting Time & Date ......................................................................................................16
Control Setpoints ...........................................................................................................16
Zone Manager Configuration ......................................... 20
System Overrides........................................................... 24
Zone Manager Operations Summary ............................. 26
Programming
Auto-Zone Basic
Section 3
LCD/Keypad Operations
Main Screen
Vent Mode
03/19/02 03:05pm Tue
Occupied
1 Alarm(s)
3
Current Polling Address
The Auto-Zone Zone Manager is your direct link into the status and setpoints of any
Zone Controller on your communications loop. With the Zone Manager, you can view
any temperature or output condition and change any setpoint to fine tune the operations
of the total system. All keypad operations are simple and straightforward and use noncryptic plain English messages.
The remainder of this section will lead you through the system menus and keypad
operation.
Main Screen Access
Keypad Layout
Programming
A - Summary
Select the Zone Controller Summary Screen
B - Status
Select Individual Zone Status Screens
C - Status
Select the Zone Manager Status Screens
D - Alarms
Select the Alarm Status Screens
# - Menu
Select the Main Menu Screen
3-1
Auto-Zone Basic
Section 3
Data Entry Functions
A - Abort
Used to exit from screens or from data entry.
Use this key to return to the Main Menu from
any screen in the system.
B - Backup
Use this key to step backwards to previous
screens or setpoints.
C - Clear
If a data entry mistake is made, press this key
to clear the data entry field and start over.
D - Negative
If entering a setpoint that is negative in value,
press this key for the minus sign.
* - Decimal
Use this key as the decimal point when
entering decimal values.
# - Enter
Use this key to close a data entry field and
advance to the next item or screen.
Zone Summary Screen
To see a summary of all attached Zone Controllers, press the "A" key while the Main
Screen is active. The following screen will appear. Zones are shown in groups of three.
Step to each additional screen by pressing the "#" key. If there are not three units
available for any given screen, the remaining lines on that screen will be blank.
Zone TEMP CLSP HTSP
1 74.2 77.0 74.0
2 73.1 75.0 72.0
3 76.4 75.0 72.0
Zone TEMP CLSP HTSP
4 74.2 77.0 74.0
5 73.1 75.0 72.0
6 76.4 75.0 72.0
etc.
Zone TEMP CLSP HTSP
16 74.2 77.0 74.0
Note: The temperature displayed includes the slide effect offset.
3-2
Programming
Auto-Zone Basic
Section 3
Individual Zone Status
Screens
To see the complete status of any attached Zone Controller, press the "B" key while the
Main Screen is active. The following screens will appear. Step to each additional screen
by pressing the "#" key. Press the "A" key to exit before all status screens have been
viewed. If a zone doesn't respond, the screen will display " *** Missing *** ". If the
zone is currently in the Calibration mode, the screen will display "Calibrating." No
status or setpoints are available during calibration.
Note: The top line of every status screen shows the selected zone address.
Status Screen #1
Zone Number 1
Occupied Mode
Voting Unit
Line 2 - Unoccupied Mode
Occupied Mode
Push-button Override
Force Mode Active!
Line 3 - Voting Unit
Non-Voting Unit
Status Screen #2
Zone Number 1
Temperature:
75.4
CSP 75.0
HSP 72.0
Slide Adjust.:
0.0
Line 2 - Current Zone Temperature
Line 3 - Current Cooling Setpoint (CSP) & Heating Setpoint
(HSP)
Line 4 - Optional Sensor Slide Adjust effect on Setpoints
Programming
3-3
Auto-Zone Basic
Section 3
Status Screen #3
Zone Number 1
Damper Pos
20
Minimum Setpt
20
Maximum Setpt
100
Line 2 - Current Zone Damper Position
Line 3 - Currently active Minimum Damper/Airflow
Setpoint. Each mode has its own minimum setpoint.
These modes are vent, cooling and heating.
Line 4 - Currently active Maximum Damper/Airflow
Setpoint. This value is user adjustable and is used in
all modes of operation, unlike the Minimum
Damper/Airflow Setpoint.
Status Screen #4
Zone Number 1
Auxiliary Heat Off
Series Fan On
Line 2 - Auxiliary Heat Off
Box Heating On
Aux Heating On
Box & Aux Heat On
Line 3 - Series Fan On
or
Blank Line if Fan is Off
Line 4 - Parallel Fan On
or
Blank Line if Fan is Off
3-4
Programming
Auto-Zone Basic
Section 3
Zone Manager Status
Screens
To see the Zone Manager status, press the "C" key while the Main Screen is active. The
following screens will appear. Step to each additional screen by pressing the "#" key.
Press the "A" key to exit before all status screens have been viewed.
Status Screen #1
HVAC Status
Supply Air
78.6
Static Press
0.49
Bypass Damper
24%
Line 2 - Current Supply Air Temperature
Line 3 - If the system is configured for VAV operation, this
line shows the current Static Pressure in the duct. It
is displayed in Inches of Water Column.
Line 4 - If the system is configured for VAV operation, this
line shows the current Bypass Damper position
currently required to maintain the displayed amount
of Static Pressure.
Status Screen #2
HVAC Status
Return Air
75.3
Outdoor Air
70.2
Economizer
20%
Line 2 - Current Return Air Temperature
Line 3 - Current Outdoor Air Temperature
Line 4 - Current Economizer Damper Position if the system is
configured for Economizer control.
Programming
3-5
Auto-Zone Basic
Section 3
Status Screen #3
HVAC Status
Active Cool Stage: 0
Active Heat Stage: 0
Wetbulb Temp: xxx.x
Line 2 - The currently Active Cooling Stages are displayed on
this line. You can see the first two stages from the
LED display on the front panel. This screen allows
you to view systems with more than two stages of
cooling and see how many are active.
Line 3 - The currently Active Heating Stages are displayed on
this line. The same LED information is available for
heating as described above.
Line 4 - If the optional Economizer Module has been installed
on your system, this line will show the currently
calculated Wetbulb Temperature.
Status Screen #4
HVAC Status
Mavericks
0
Cool Total
0.0
Heat Total
0.0
Line 2 - The Zone Manager knows if any units have had a
four-degree demand for at least one hour. It totals
them up and displays this value as the total number of
Maverick Zones.
Line 3 - As the Zone Manager polls its Zone Controllers, it
totals up the heating and cooling demand so it can
make an HVAC decision.
The Cooling Total is displayed on this line.
Line 4 - The Heating Total, from the zone polling, is
displayed on this line.
3-6
Programming
Auto-Zone Basic
Section 3
Alarm Status Screens
If the last line on the Main Screen displayed one or more active alarms, you can press the
"D" key while on the Main Screen to display a list of detected alarms. Each screen
displays one alarm at a time. If no alarms are present when you press the "D" key, the
message "No Alarms" will be displayed on the alarm screen.
Status Screen #1
Alarm Status
No Alarms
Line 3 - Possible Alarm Messages that can be displayed, one
at a time, on this line.
Zone Manager Messages
Bad Supply Air Sensor
Static Sensor Alarm
Damper Feedback Fail
Damper Opening Alarm
Damper Closing Alarm
Auxiliary Alarm
COOLING FAILURE!
HEATING FAILURE!
OAT Broadcast Lost
Zone Controller Messages
Missing Zone 1
Zone Damper Fail 1
Bad Zone Sensor 1
Maverick Zone 1
All Zone Controller messages are followed by the
address of the unit that is causing the alarm.
If any alarms are present, the Alarm LED on the
Front Panel will be active, alerting you at a distance
that an alarm is present.
Programming
3-7
Section 3
Auto-Zone Basic
Alarm Definitions
Cooling Failure! or Heating Failure! - Once the heating or cooling is activated, the
Supply Air Temperature has 30 minutes to
change by at least 5°F, or the Zone Manager
assumes a mechanical failure has occurred and
generates an alarm.
Bad Supply Air Sensor or Bad Zone
Sensor
- The Zone Manager or Zone Controller was
unable to detect the appropriate sensor
installed.
Bypass Feedback Fail
- During calibration the controller does not
receive a signal from the Bypass Damper
Actuator Feedback Pot.
Damper Opening Alarm
- The Bypass Damper Actuator does not travel
the full open position on a call to open.
Damper Closing Alarm
- The Bypass Damper Actuator does not travel
to its full closed position on a call close.
Static Sensor Alarm
- The current static pressure reading has been
above 3.0 inches or below 0.01 inches for more
than 30 seconds.
Missing Zone
- The Zone Manager has been out of contact
with a specific zone for 5 consecutive pollings.
Zone Damper Fail
- The zone damper either failed the startup
calibration or it has stopped responding to
commands.
Auxiliary Alarm
- A contact closure is detected on the AUX2
input
Maverick Zone
- The identified zone has exceeded a 4°F heating
or cooling demand for at least 1 hour.
3-8
Programming
Auto-Zone Basic
Section 3
Entering Passcodes
Any time you are prompted to enter a passcode, the following screen will appear. The
actual passcode digits are never displayed. Instead, an "X" is placed on the screen for every
digit entered, as a place holder, to allow you to know which digit you are entering. The
default passcode is "1111" and is programmable to any other four-digit value.
Passcode Request
THIS ACTION REQUIRES
PASSCODE CLEARANCE
Enter Passcode: xxxx
Main Menu Operation
To gain access to the system setpoints and configurations, press "#" while on the Main
Screen to select the Main Menu. There are four selections available on the Main Menu.
Selection of the second item, Manager Setpoints, opens a second menu screen, shown
later in this section. To return to the Main Screen from any other screen, press the "A"
key until the Main Screen appears.
Main Menu
1)
2)
3)
4)
Read/Reset Zones
Manager Setpoints
Configure System
System Overrides
For detailed information on each of the Main Menu selections, refer to the appropriate
paragraph heading as noted below.
1)
2)
3)
4)
Read/Reset Zones
Manager Setpoints
Configure System
System Overrides
Programming
Zone Controller Setpoints
Zone Manager Setpoints
Zone Manager Configuration
System Overrides
3-9
Auto-Zone Basic
Section 3
Zone Controller Setpoints
You will be prompted to enter the address of the Zone Controller that you want to read or
reset. If you enter a non-existent zone address, the screen will display "*** Missing ***"
and no setpoint screens will be displayed.
Zone Selection Screen
SELECT ZONE
ENTER ADDRESS:
1
Note: The top line always displays the currently selected Zone Controller and the
controller type.
PD ZONE ADDRESS means a Pressure Dependent Box is selected.
PI ZONE ADDRESS means a Pressure Independent Box is selected.
Setpoint Screen #1
PD ZONE ADDRESS 1
OCCUPIED SETPOINTS
Cooling Setpt: 75 F
Heating Setpt: 72 F
Enter the Occupied Heating and Cooling Setpoints on this
screen. The Heating Setpoint should always be two degrees
below the Cooling Setpoint or the Zone Controller will not
accept the new values. The Zone Manager can't prevent the
entry of invalid setpoints. If invalid setpoints are entered, the
previous settings will be retained by the system and displayed
the next time the Zone Setpoints are accessed.
Cooling Setpoint
Heating Setpoint
3-10
Minimum
Default
Maximum
50°F
50°F
75°F
72°F
90°F
90°F
Programming
Auto-Zone Basic
Section 3
Setpoint Screen #2
PD ZONE ADDRESS 1
UNOCCUPIED SETPOINTS
Cool SetUp...: 10 F
Heat Setback.: -10 F
Enter the Unoccupied Heating and Cooling Setback values on
this screen. The Occupied Cooling Setpoint will be increased
by the Cooling Setback during Unoccupied Mode and the
Heating Setpoint will be decreased by the Heating Setback.
Minimum
Cool Setback
Heat Setback
Default
0°F
0°F
Maximum
10°F
-10°F
30°F
-30°F
Setpoint Screen #3
PD ZONE ADDRESS 1
AuxHeat Setpt: 72 F
Slide Effect.:
3 F
If your Zone Controller has the optional Relay Expansion Board
attached, one of the relays is reserved for an Auxiliary Heating
Relay. Enter that setpoint on the AuxHeat Setpt line. If the
relay board is not installed, this line will not be displayed.
If your Zone Temperature sensor has the optional Setpoint
Adjustment Slide, enter the maximum effect it can have on the
setpoints on the Slide Effect line.
Minimum
Default
50°F
0°F
72°F
3°F
AuxHeat Setpt
Slide Effect
Maximum
90°F
5°F
Note: If slide effect is set to 0°, the push-button override will not function.
Setpoint Screen #4
PD ZONE ADDRESS 1
Max Damper....: 100%
Cool Mode Min.:
5%
Heat Mode Min.: 20%
On Pressure Dependent Zones, these setpoints are for damper
position. On Pressure Independent Zones they are for Airflow
(CFM) values, and the text will change to reflect that.
PD Zone Max Damper
PI Zone Max Airflow
PD Zone Cool Mode Min
PI Zone Cool Mode Min
PD Zone Heat Mode Min
PI Zone Heat Mode Min
Programming
Minimum
0%
0 CFM
0%
0 CFM
0%
0 CFM
Default
100%
800 CFM
5%
200 CFM
20%
300 CFM
Maximum
100%
30000 CFM
100%
30000 CFM
100%
30000 CFM
3-11
Auto-Zone Basic
Section 3
Setpoint Screen #5A
PD ZONE ADDRESS 1
Vent Mode Min.: 50%
Nite Mode Min.: 100%
On Pressure Dependent Zones, the setpoints displayed are for
damper position.
PD Zone Vent Mode Min
PD Zone Nite Mode Min
Minimum
0%
0%
Default
50%
100%
Maximum
100%
100%
Setpoint Screen #5B
PD ZONE ADDRESS 1
Vent Mode xxxxx CFM
Nite Mode xxxxx CFM
CFM @1”WG xxxxx CFM
For Pressure Independent Zones the text changes to display
airflow (CFM) values. On the third line - "CFM@1" WG",
enter the appropriate "K" Flow Factor from Table 1-2 of this
manual.
PI Zone Vent Mode Min
PI Zone Nite Mode Min
PI Zone CFM @1" WG
Minimum
0 CFM
0 CFM
0 CFM
Default
500 CFM
0 CFM
2100 CFM
Maximum
30000 CFM
30000 CFM
30000 CFM
Setpoint Screen #6
PD ZONE ADDRESS 1
Overrides..: Global
Damper Mode: Direct
PRESS (*) TO TOGGLE
The Zone Controller will respond to another zone’s pushbutton override if it is configured for global overrides. If single
overrides are selected, the zone will only enter override if its
own push-button is pressed.
The normal damper operation is direct acting, which means it
opens in a clockwise direction. If your system opens in a
counter-clockwise direction, select reverse acting mode.
3-12
Programming
Auto-Zone Basic
Section 3
Setpoint Screen #7
PD ZONE ADDRESS 1
Voting Mode: Voting
PRESS (*) TO TOGGLE
Normally, you want a zone to be included in the polling by the
Zone Manager. This allows the demand in that zone to have a
vote in determining the HVAC mode of operation. If you have
a problem zone or an area that you don't want to include in the
voting, select the NonVote mode of operation.
Setpoint Screen #8
PD ZONE ADDRESS 1
Sensor Calibration
Rdg
Offset
Zone:
75.4
0.0
If you have a tenant that doesn't agree with the current zone
temperature reading, you can adjust or calibrate the zone
temperature reading.
Enter a positive number if the current reading is too low.
Enter a negative number if the current reading is too high.
Note: The Thermistor Type III Sensors have a 0.4 degree accuracy.
Tip: This calibration offset is also useful as a troubleshooting tool. If you need to
simulate a heating or cooling mode, you can raise or lower the current zone
temperature far enough to put the zone into the desired mode.
Caution: The normal calibration offset should be a fairly small value. If you need
several degrees of offset, there might be a sensor problem or a location
problem.
Programming
3-13
Auto-Zone Basic
Section 3
Zone Manager Setpoints
The Zone Manager Setpoints are kept separate from the Zone Manager Configuration
setpoints since these are the most commonly changed values. Enter the number shown
below for the desired selection. When you are finished, press the "A" key to return to the
Main Menu.
Zone Manager Setpoint Menu
1)
2)
3)
4)
Control Setpoints
Schedules
Holidays
Time & Date
Week Schedules
Schedule Start Time
WEEK SCHEDULES
Sunday
Start Time
Enter Hrs/Mins:
0
(MILITARY FORMAT)
The screens will step through the Start Time and then the Stop
Time for each day of the week. You can quit at any point in
the process by pressing the "A" key.
All times are in 24-hour format, so 5:00 PM would be entered
as 1700.
Schedule Stop Time
WEEK SCHEDULES
Sunday
Stop Time
Enter Hrs/Mins:
0
(MILITARY FORMAT)
If both the Start and Stop Times are ZERO, the schedule is in
a continuous OFF mode.
If both the Start and Stop Times are 2359, the schedule is in a
continuous ON mode.
Note: The second line displays which day of the week is currently being programmed.
This automatically increments as you finish the Stop Time and continue to the
next Start Time screen.
3-14
Programming
Auto-Zone Basic
Section 3
Holidays
Holiday Day Selection
Program Holidays
Holiday # 1
Start Mon/Day: 101
(EX: 101 = Jan. 1)
The screens will step through the eleven possible holidays one
at a time. Line 2 shows which holiday is currently being
programmed.
Remember to combine the month and day into a single fourdigit value.
EXAMPLE:
704 = July 4th
1225 = December 25th
Holiday Start/Stop Times
Holiday Schedule
Starting Time:
Stopping Time:
Programming
0
0
The eleven holidays all use the same Start and Stop
time which is entered on this screen. It is entered in 24hour military format, the same as a regular week
schedule.
3-15
Auto-Zone Basic
Section 3
Setting Time & Date
The Zone Manager has its own built-in real time clock. Although the times are displayed
on the Main Screen in a standard 12-hour format, they are programmed using the 24-hour
military format. If the Zone Manager was configured to use its own Internal Schedules,
the Occupied/Unoccupied modes are calculated on the basis of the current real time clock
reading.
Programming Time
Program Time/Date
Day (Sunday=0):
2
Enter Hr.(0-23): 14
Enter Min
: 53
Day
- Enter the Day of the Week (0 to 6) with
Sunday = 0
Hours (Hr)
- Enter Hours in 24-Hour Military Format
(1700 = 5:00 PM)
Minutes
- Enter the Minutes (0 to 59)
Programming Date
Program Time/Date
Month (1-12):
3
Day
(1-31):
19
Year
(00-99): 02
Month
- Enter the Month (1 to 12)
Day
- Enter the Day of the Month (1 to 31)
Year
- Enter the current Year with two digits (00
to 99)
Daylight Savings Adjustments
Daylight Savings
Adjustments Enabled
Press (*) To Toggle
3-16
If your area of the country requires Daylight Savings changes,
the Zone Manager can automatically make the adjustment for
you. This used to be the first Sunday in April and the second
Sunday in October. However, the U.S. government has now
decided to arbitrarily change these dates from time to time. So
we recommend that you disable these automatic adjustments
by pressing the "*" key to select Adjustments Disabled and
make the adjustments yourself each year.
Programming
Auto-Zone Basic
Section 3
Control Setpoints
Setpoint Screen #1
Manager Setpoints
Static Press:
0.5”
If you have configured for variable HVAC type, this screen
will be displayed to allow you to enter the controlling Static
Pressure Setpoint.
Static Press
Minimum
Default
Maximum
0.1"
0.5"
2.0"
Setpoint Screen #2
Manager Setpoints
Cool Lockout:
50
Heat1 Lockout:
65
Heat2 Lockout:
45
Enter the Mechanical Cooling and Heating Lockouts on this
page. There are two heating lockouts. Heat1 Lockout is for
Stage #1 only, and Heat2 Lockout is for Stages #2 and up.
This allows energy conservation during Spring and Fall
conditions when a single stage of heating could handle the
load.
Cool Lockout
Heat1 Lockout
Heat2 Lockout
Programming
Minimum
Default
Maximum
-30°F
30°F
30°F
-30°F
65°F
45°F
80°F
99°F
99°F
3-17
Auto-Zone Basic
Section 3
Setpoint Screen #3
Cool Staging:
Min Cool Off:
Heat Staging:
Min Heat Off:
4
4
4
4
Min
Min
Min
Min
The heating and cooling stages must have been off for a
minimum amount of time before they can be activated or reactivated. As each additional stage of heating or cooling is
added, a minimum Staging Delay period must be satisfied
between each additional stage required.
Cool Staging
Min Cool Off
Heat Staging
Min Heat Off
Minimum
1 Min
1 Min
1 Min
1 Min
Default
4 Min
4 Min
4 Min
4 Min
Maximum
30 Min
30 Min
30 Min
30 Min
Setpoint Screen #4
Manager Setpoints
Heat/Cool Changeover
Interval....: 15 Min
If the Zone Manager needs to change HVAC modes
between heating and cooling, a Changeover Delay time
must be satisfied first. This prevents "chasing" due to
alternate hot and cold air always being supplied to the
zones after short intervals.
Interval
Minimum
1 Min
Default
10 Min
Maximum
30 Min
Setpoint Screen #5
Economizer Setpoints
Closed Volts:
0.0
Opened Volts:
10.0
If the Zone Manager has been configured for Economizer
Control, this screen will appear. You can set the voltages
required to open and closed the damper. Some actuators use a
2-10 VDC signal instead of 0-10 VDC.
If the system is not configured for Economizer Control, no
economizer setpoint screens will appear.
Closed Volts
Opened Volts
3-18
Minimum
0.0 VDC
0.0 VDC
Default
0.0 VDC
10.0 VDC
Maximum
10.0 VDC
10.0 VDC
Programming
Auto-Zone Basic
Section 3
Setpoint Screen #6
Econo Enable:
50
Supply Setpt:
50
Min Econo % :
20%
The Econo Enable setpoint is the outdoor air or wetbulb
temperature that enables the Economizer to open past its
minimum position setpoint to control supply air temperature.
The Supply Setpt is the supply air temperature the Economizer
tries to maintain.
The Min Econo % is the position the economizer holds during
occupied mode when it is not enabled for operation due to
outdoor air or wetbulb temperature.
Minimum
Default
Maximum
-30°F
45°F
0%
50°F
50°F
20%
99°F
80°F
100%
Econo Enable
Supply Setpt
Min Econo %
Setpoint Screen #7
Economizer Interval
Seconds.....: 50.0
During Economizer control, the Economizer damper is
allowed to move open or closed, as required at a rate
controlled by this value. Use this setpoint to speed up or slow
down the operation of your economizer. The larger the
number, the slower the damper will move.
Interval
Minimum
.1
Default
50
Maximum
90.0
Setpoint Screen #8
Sensor Rdg
SAT.: 82.9
RAT.: 77.2
OAT.: 70.2
Offset
0.0
0.0
0.0
As described in the Zone Controller section, the Thermistor
Type III sensor readings can be calibrated. The Outdoor Air
Calibration Offset only applies to the Zone Manager that has
the sensor installed. It has no effect on the global broadcast
value of outdoor air.
Supply Sensor
Return Sensor
Outdoor Sensor
Programming
SAT
RAT
OAT
Minimum
Default
Maximum
-100.0°F
-100.0°F
-100.0°F
0.0°F
0.0°F
0.0°F
+100.0°F
+100.0°F
+100.0°F
3-19
Auto-Zone Basic
Section 3
Zone Manager
Configuration
Normally, the configuration setpoints need to be entered only one time. For this reason,
they occupy their own menu location and need not be addressed during normal setpoint
read and reset operations. To access the configuration setpoints, press the "3" key while
on the Main Menu screen.
Note: On initial power up, the system must be configured before it can be successfully
operated.
Configuration Screen #1
Last Zone Addr:
First Zone Addr:
Cooling Stages:
Heating Stages:
1
1
1
1
The Zone Manager needs to know the address range of the
attached Zone Controllers to be polled. Enter the addresses of
the first and last zones here.
The quantity of cooling and heating stages is also entered on
this screen.
Last Zone Addr
First Zone Addr
Cooling Stages
Heating Stages
Minimum
1
1
0
0
Default
1
1
1
1
Maximum
16
16
6
6
Caution: The zones should be consecutively addressed with no skipped address
locations. If an address is skipped, the Zone Manager will presume there
is a missing zone, and an alarm will occur.
3-20
Programming
Auto-Zone Basic
Section 3
Heat Type.: Electric
Fan Mode.: Constant
PRESS (*) TO TOGGLE
The Zone Manager can control electric or gas heating. Each
type of heat has its own protection limits built into the Zone
Manager software.
The Zone Manager can also operate the fan in one of two
modes:
Constant (Continuous) running during occupied hours.
Cycle with heating or cooling during occupied hours.
The fan always cycles with heating or cooling during
unoccupied hours.
Economizer: Enabled
PRESS (*) TO TOGGLE
The Zone Manager has the ability to control the Economizer
operation. To initiate Economizer operation, select Enabled.
To toggle between the two Economizer modes, press the "*"
key.
HVAC Type: Variable
PRESS (*) TO TOGGLE
Programming
The Zone Manager normally reads the duct static pressure
and controls it via the bypass damper. If your system doesn't
require static pressure control, select the Constant mode of
operation. To toggle between the two modes, press the "*"
key.
3-21
Auto-Zone Basic
Section 3
Bypass Act:
Direct
PRESS (*) TO TOGGLE
The Zone Manager Bypass Damper normally opens in a
clockwise direction. If your bypass damper opens in a counterclockwise direction, select reverse acting instead of direct
acting operation. To toggle between the two modes, press the
"*" key.
Zone Manager
Uses Schedule #:
0
0 = Internal Clock
1-8 = External Clock
The Zone Manager normally uses its own real-time clock and
an internal week schedule to determine the Occupied/
Unoccupied mode of operation. The Zone Manager does have
the ability to use a global broadcast from another scheduling
device on the communications loop if a more powerful schedule
is required. If an external schedule is used, the range of
schedule numbers is 1 to 8.
Press (*) To Force
Recalibration Of The
Static Press. Sensor
<#> To Skip This...
3-22
The Zone Manager only calibrates the static pressure sensor
one time. That occurs on the initial powerup, so it is vital that
the sensor be attached before the system is ever powered up. If
you weren't able to do this or accidentally activated the system
before the sensor was available, you can force it to restart and
calibrate the static pressure sensor by pressing the "*" key. If
you don't need to re-calibrate, simply press the "#" key to skip
over this item.
Programming
Auto-Zone Basic
Section 3
Enter New Passcode
CODE: xxxx
[Must Be 4 Digits]
Press <A> To Skip!
As mentioned earlier, the default passcode is "1111". This
code must be entered before any configuration or setpoint
changes can occur. If you would like to change this default
passcode, enter four digits on this screen. The value entered
must be between 1000 and 9999 to be a valid code. Values
from 0000 to 0999 will be rejected and the last valid code will
be retained.
Caution: If you forget your passcode, you WILL BE locked out of your system!
Tip: The BackDoor Passcode that will always get you into the system is "9288." This
passcode should not be given to the casual users of your system.
Programming
3-23
Auto-Zone Basic
Section 3
System Overrides
The Zone Manager provides some user-selectable override modes. This allows you to
troubleshoot the system or set up temporary conditions for those situations when normal
operation of the system is not required.
Override Screen #1
0)
1)
2)
3)
AUTO (Time Clock)
FORCE Occupied
FORCE Unoccupied
FAN ONLY [Mode 0]
The Zone Manager defaults to the Auto mode of operation when
first powered up. Any force modes entered will be retained in
non-volatile memory. The unit will resume the force mode of
operation any time the power is cycled.
0) Auto
- Use internal schedules for Day/Night
Mode
1) Occupied - Forced to Continuous Day or Occupied
Mode
2) Night
3) Fan Only
3-24
- Forced to Continuous Night or Unoccupied
Mode. If the Forced Occupied Binary Input
Contact is closed, this mode will override it
to OFF. Use the Auto mode programmed
for continuous Unoccupied operation if you
want to use the Forced Occupied Binary
Input Contact.
This is the mode that is active whenever
you see the Purge Cycle message being
displayed. It disables any heating or cooling
and forces all the boxes to move their
dampers to the full 100 percent open
position. You can use this mode any time
you want to manually purge your building.
Programming
Auto-Zone Basic
Section 3
Override Screen #2
ZONE FORCE MODES
Force to MINIMUM 0
Force to MAXIMUM 0
[0= Normal 1=Force]
The Zone Controller Dampers can all be forced at the same
time to their Minimum or Maximum Damper/Airflow
Setpoints. On Pressure Independent systems, this feature is
useful during air balance operations.
Enter a "1" next to the desired force mode to make it active.
Enter "0" to disable the force mode.
Programming
3-25
Auto-Zone Basic
Section 3
Zone Manager Operations Summary
Main Screen
Vent Mode
06/05/96 08:05am Wed
Occupied
1 Alarm(s)
3
Zone Summary Screens
Press “A” Key
Zone TEMP CLSP HTSP
1 74.2 77.0 74.0
2 73.1 75.0 72.0
3 76.4 75.0 72.0
Zone Status Screens
Press “B” Key
Zone Number
1
Occupied Mode
Voting Unit
Zone Manager Status Screen
Press “C” Key
Main Menu Screen
Press “#” Key
HVAC Status
Supply Air
56.4
Static Press. 0.49"
Bypass Damper
24%
Alarm Status Screen
Press “D” Key
Alarm Status
No Alarms
1)
2)
3)
4)
Read/Reset Zones
Manager Setpoints
Configure System
System Overrides
Control Setpoints Screen
Press “1” Key
Manager Setpoints
Static Press: 0.50”
Schedules Screen
Press “2” Key
Holidays Screen
Press “3” Key
Zone Manager Menu Screen
Press “2” Key
1)
2)
3)
4)
Control Setpoints
Schedules
Holidays
Time & Date
3-26
WEEK SCHEDULES
Sunday
Start Time
Enter Hrs/Mins:
0
(MILITARY FORMAT)
Program Holidays
Holiday #
1
Start Mon/Day:
0
(EX: 101 = Jan. 1)
Time & Date Screen
Press “4” Key
Program Time/Date
Day
(Sunday=0):
3
Enter Hr. (0-23):
9
Enter Min.
: 25
Programming
Auto-Zone Basic
Section 3
Index
"K" Flow Factor.................................. 12
# - Enter Button..................................... 2
# - Menu Button .................................... 1
# Key................................................. 2, 9
* - Decimal Button................................ 2
1111....................................................... 9
24-Hour Format .................................. 14
A - Abort Button ................................... 2
A - Summary Button............................. 1
A Key .................................................... 2
Active Cooling Stages .......................... 6
Active Heating Stages........................... 6
Address Range .................................... 20
Airflow (CFM) Setpoint ..................... 11
Airflow (CFM) Values........................ 12
Alarm
Definitions ........................................ 8
Status Screens ................................... 7
Alarm LED............................................ 7
Auto Mode .......................................... 24
Aux Heating On .................................... 4
AuxHeat Setpt..................................... 11
Auxiliary Alarm ................................ 7, 8
Auxiliary Heat Off ................................ 4
Auxiliary Heating Relay ..................... 11
B - Backup Button ................................ 2
B - Status Button................................... 1
B Key .................................................... 3
Back Door Passcode ........................... 23
Bad Supply Air Sensor ..................... 7, 8
Bad Zone Sensor ............................... 7, 8
Box & Aux Heat On ............................. 4
Box Heating On .................................... 4
Buttons
# - Enter ............................................ 2
# - Menu............................................ 1
* - Decimal........................................ 2
A - Abort ........................................... 2
A - Summary..................................... 1
B - Backup ........................................ 2
B - Status........................................... 1
C - Clear............................................ 2
Programming
C - Status........................................... 1
D - Alarms......................................... 1
D - Negative...................................... 2
Bypass Damper
Direct Acting................................... 22
Reverse Acting................................ 22
Bypass Damper Position ....................... 5
Bypass Feedback Fail ........................... 8
C - Clear Button .................................... 2
C - Status Button................................... 1
C Key .................................................... 5
Calibrating ............................................ 3
Calibration Offset ............................... 13
CFM @1”WG xxxxx CFM................. 12
Changeover Delay Time ..................... 18
Closed Volts........................................ 18
Configuration
Internal Week Schedule .................. 22
Real-Time Clock............................. 22
Configure System.................................. 9
Control Setpoints .......................... 14, 17
Zone Manager ................................. 14
Cool Lockout ...................................... 17
Cool Mode Min................................... 11
Cool SetUp.......................................... 11
Cool Staging ....................................... 18
Cooling.................................................. 4
Cooling Failure ..................................... 8
COOLING FAILURE........................... 7
Cooling Setback .................................. 11
Cooling Setpoint ................................. 10
Cooling Setpt ...................................... 10
Cooling Stages .................................... 20
Cooling Total ........................................ 6
CSP ....................................................... 3
Current Cooling Setpoint ...................... 3
Current Zone Temperature ................... 3
D - Alarms Button................................. 1
D – Negative Button ............................ 2
D Key .................................................... 7
Damper Closing Alarm ..................... 7, 8
Damper Feedback Fail .......................... 7
3-27
Section 3
Damper Mode: Direct ......................... 12
Damper Opening Alarm.................... 7, 8
Damper Position Setpoint ............. 11, 12
Damper Positions ................................ 12
Data Entry Functions ............................ 2
Daylight Savings................................. 16
Default passcode ................................... 9
Direct Acting
Bypass Damper ............................... 22
Damper Position.............................. 12
Duct Static Pressure ............................ 21
Econo Enable Setpoint........................ 19
Economizer Damper Position ............... 5
Economizer Interval............................ 19
Economizer Operation
Zone Manager ................................. 21
Economizer Setpoints ......................... 18
Electric Heat ....................................... 21
Entering Passcodes ............................... 9
Fan Mode
Continuous ...................................... 21
Cycle ............................................... 21
FAN ONLY ........................................ 24
Fan Operation
Unoccupied Hours .......................... 21
First Zone Addr................................... 20
Force Mode Active ............................... 3
Force Modes ....................................... 24
FORCE Occupied ............................... 24
FORCE Unoccupied ........................... 24
Gas Heat.............................................. 21
Global Broadcast................................. 22
Global Overrides................................. 12
Heat
Electric ............................................ 21
Gas .................................................. 21
Heat Mode Min ................................... 11
Heat Staging........................................ 18
Heat/Cool Changeover........................ 18
Heat1 Lockout..................................... 17
Heat2 Lockout..................................... 17
Heating.................................................. 4
Heating Failure ..................................... 8
HEATING FAILURE!.......................... 7
Heating Lockout ................................. 17
Heating Setback .................................. 11
3-28
Auto-Zone Basic
Heating Setpoint ............................. 3, 10
Heating Setpt....................................... 10
Heating Stages .................................... 20
Heating Total ........................................ 6
Holiday Start/Stop Times.................... 15
Holidays
Zone Manager ........................... 14, 15
HSP ....................................................... 3
Inches of Water ..................................... 5
Internal Week Schedule ...................... 22
Invalid Setpoints ................................. 10
K Flow Factor ..................................... 12
Keypad Layout...................................... 1
Keypad Operations ............................... 1
Keys
# ....................................................... 9
# - Enter ............................................ 2
# - Menu............................................ 1
# - Next Screen ................................. 2
* - Decimal........................................ 2
A ....................................................... 2
A - Abort ........................................... 2
A - Summary..................................... 1
B ....................................................... 3
B - Backup ........................................ 2
B - Status........................................... 1
C ....................................................... 5
C - Clear............................................ 2
C - Status........................................... 1
C - Zone Manager Status .................. 5
D - Alarm .......................................... 7
D - Alarms......................................... 1
D - Negative...................................... 2
Last Zone Addr ................................... 20
LCD Operations .................................... 1
Location Problem................................ 13
Main Menu
Operation .......................................... 9
Main Screen .......................................... 1
Manager Setpoints ................................ 9
Maverick Zone .................................. 7, 8
Maverick Zones..................................... 6
Max Damper ....................................... 11
Maximum Airflow
Setpoints.......................................... 25
Programming
Auto-Zone Basic
Maximum Damper
Setpoints.......................................... 25
Maximum Damper/Airflow Setpoint.... 4
Mechanical Cooling Lockout.............. 17
MILITARY FORMAT ....................... 14
Min Cool Off....................................... 18
Min Econo % ...................................... 19
Min Heat Off....................................... 18
Minimum Airflow
Setpoints.......................................... 25
Minimum Damper Setpoints............... 25
Minimum Damper/Airflow Setpoint..... 4
Missing............................................ 3, 10
Missing Zone .................................... 7, 8
Caution............................................ 20
New Passcode ..................................... 23
Night Mode ......................................... 24
Nite Mode Min.................................... 12
Nite Mode xxxxx CFM....................... 12
No Alarms............................................. 7
NonVote Mode.................................... 13
Non-Voting Unit ................................... 3
OAT Broadcast Lost ............................. 7
Occupied Heating and
Cooling Setpoints............................ 10
Occupied Mode..................................... 3
Opened Volts ...................................... 18
Outdoor Air Calibration Offset........... 19
Outdoor Air Temperature ..................... 5
Outdoor Sensor ................................... 19
Overrides....................................... 12, 24
Overrides..: Global.............................. 12
Parallel Fan Off..................................... 4
Parallel Fan On ..................................... 4
Passcode
Back Door ....................................... 23
Passcode Request .................................. 9
Passcodes .............................................. 9
PD ZONE ADDRESS......................... 10
PD Zone Cool Mode Min ................... 11
PD Zone Heat Mode Min.................... 11
PD Zone Max Damper ........................ 11
PD Zone Nite Mode Min .................... 12
PD Zone Vent Mode Min ................... 12
PI ZONE ADDRESS .......................... 10
PI Zone CFM @1" WG ...................... 12
Programming
Section 3
PI Zone Cool Mode Min ..................... 11
PI Zone Heat Mode Min ..................... 11
PI Zone Max Airflow.......................... 11
PI Zone Nite Mode Min...................... 12
PI Zone Vent Mode Min ..................... 12
Polling Mode....................................... 13
Polling Range...................................... 20
Pressure Dependent Box ..................... 10
Pressure Independent Box .................. 10
Programming
Day.................................................. 16
Hours............................................... 16
Minutes ........................................... 16
Month.............................................. 16
Year................................................. 16
Programming Date .............................. 16
Programming Time ............................. 16
Push-button Override ............................ 3
Push-Button Override
Won't Work..................................... 11
Read/Reset Zones ................................. 9
Real Time Clock ................................. 16
Real-Time Clock
Configuration .................................. 22
Relay Expansion Board ...................... 11
Return Air Temperature........................ 5
Return Sensor...................................... 19
Reverse Acting
Bypass Damper ............................... 22
Damper Position.............................. 12
Schedules
Zone Manager ................................. 14
Screens
Zone Selection ................................ 10
Sensor Calibration............................... 13
Sensor Problem ................................... 13
Sensor Slide Adjust............................... 3
Series Fan Off ....................................... 4
Series Fan On........................................ 4
Setpoint
Airflow (CFM)................................ 11
Cooling............................................ 10
Heating............................................ 10
Setpoint Adjustment Slide .................. 11
3-29
Section 3
Setpoints
Adjustment Slide............................. 11
AuxHeat .......................................... 11
Cooling.............................................. 3
Damper Position........................ 11, 12
Heating.............................................. 3
Invalid ............................................. 10
Maximum Airflow .......................... 25
Maximum Damper .......................... 25
Maximum Damper/Airflow .............. 4
Minimum Airflow........................... 25
Minimum Damper........................... 25
Minimum Damper/Airflow............... 4
Occupied Heating and Cooling....... 10
Static Pressure................................. 17
Zone Controller............................... 10
Zone Manager ................................. 14
Setting Time & Date ........................... 16
Single Overrides ................................. 12
Slide Effect.......................................... 11
Staging Delay Period .......................... 18
Start Time............................................ 14
Static Press .......................................... 17
Static Pressure....................................... 5
Static Pressure Sensor
Re-Calibrate .................................... 22
Static Pressure Setpoint ...................... 17
Static Sensor Alarm .......................... 7, 8
Status
Zone Manager ................................... 5
Status Screens
Alarm ................................................ 7
Stop Time............................................ 14
Summary
Zone Controllers ............................... 2
Supply Air Temperature ....................... 5
Supply Sensor ..................................... 19
Supply Setpt ........................................ 19
System
Locked Out...................................... 23
System Overrides ............................ 9, 24
Thermistor Type III Sensors ............... 13
3-30
Auto-Zone Basic
Time & Date
Setting ............................................. 16
Zone Manager ................................. 14
Unoccupied Heating and Cooling
Setback............................................ 11
Unoccupied Hours
Fan Operation ................................. 21
Unoccupied Mode................................. 3
Vent....................................................... 4
Vent Mode Min................................... 12
Vent Mode xxxxx CFM ...................... 12
Voting Mode ....................................... 13
Voting Unit ........................................... 3
Week Schedules
Zone Manager ................................. 14
Wetbulb Temperature ........................... 6
Zone CLSP............................................ 2
Zone Controller............................. 1, 3, 8
Setpoints...................................... 9, 10
Zone Controller Alarms ........................ 7
Zone Controller Dampers
Forced ............................................. 25
Zone Controllers
Summary ........................................... 2
Zone Damper Fail ............................. 7, 8
Zone Damper Position .......................... 4
Zone HTSP............................................ 2
Zone Manager
Configuration .............................. 9, 20
Control Setpoints ............................ 14
Economizer Operation .................... 21
Holidays .................................... 14, 15
Operations ......................................... 1
Operations Summary ...................... 26
Schedules ........................................ 14
Setpoints...................................... 9, 14
Status Screens ................................... 5
Time & Date ................................... 14
Week Schedules .............................. 14
Zone Manager Alarms .......................... 7
Zone Selection Screen ........................ 10
Zone Status Screens .............................. 3
Zone TEMP........................................... 2
Zones
Read/Reset ........................................ 9
ZoneTemperature Reading.................. 13
Programming
Auto-Zone Basic
Section 3
Notes
Programming
3-31
Section 3
Auto-Zone Basic
Notes
3-32
Programming
Section 4
Table of Contents
Communications Overview .............................................. 1
How It Works...................................................................................................................1
Basic System Communications........................................................................................2
Zone Manager Communications......................................................................................3
Zone Controller Communications....................................................................................4
CommLink IV Communications (Optional) ....................................................................5
Basic System Communications Checklist .......................................................................7
Components & Wiring ...................................................... 8
Zone Manager IO & Components....................................................................................8
Zone Manager Wiring......................................................................................................9
Zone Controller IO & Components ...............................................................................10
Zone Controller Wiring .................................................................................................11
Startup & Commissioning .............................................. 12
Procedures......................................................................................................................12
Basic System Worksheet................................................................................................15
Start-Up..........................................................................................................................16
Blink Codes for Zone Controllers..................................................................................18
Troubleshooting ............................................................. 19
Trouble Shooting Checklist ...........................................................................................19
Trouble Shooting Chart .................................................................................................23
Troubleshooting Chart for Alarms.................................................................................25
Communications Loop...................................................................................................33
Zone Manager ................................................................................................................33
Zone Controller..............................................................................................................35
CommLink IV (Optional) ..............................................................................................37
Bypass Damper Troubleshooting...................................................................................38
Temperature Sensor Resistance Chart ...........................................................................39
Pressure Sensor Voltage Chart ......................................................................................40
Start-Up & Troubleshooting
Section 4
Table of Figures & Tables
Figure 4-1: Basic System Communications Wiring ......................................................2
Figure 4-2: Zone Manager Communications Wiring & Address Switch Setting .........3
Figure 4-3: Zone Controller Communications Wiring & Address Switch Setting .......4
Figure 4-4: CommLink IV (Optional) Wiring...............................................................5
Figure 4-5: CommLink IV (Optional) Jumper Settings ................................................6
Figure 4-6: Zone Manager Components .......................................................................8
Figure 4-7: Zone Manager Wiring.................................................................................9
Figure 4-8: Zone Controller Components ...................................................................10
Figure 4-9: Zone Controller Wiring ............................................................................11
Figure 4-10: Basic Zone Manager ..............................................................................16
Table 4-1: SCAN LED Blink Codes............................................................................18
Figure 4-11: Bypass Damper Troubleshooting...........................................................38
Table 4-2: Temperature Sensor Resistance .................................................................39
Table 4-3: Pressure Sensor Voltage ...........................................................................40
Figure 4-12: Driver Chip Locations............................................................................41
Figure 4-13: Replacing Driver Chips..........................................................................42
Auto-Zone Basic
Section 4
Communications
Overview
Perhaps no other portion of the system seems as difficult to diagnose as the communications loop, yet it really can be quite simple if you understand how it works. In fact, much
of the troubleshooting can be done by simple observation. We will lead you through the
system functions and then provide you with detailed instructions for checking each piece
of equipment. This information is provided as a review and expanded guide to the AutoZone Basic Control System communications. Additional information about the AutoZone Basic Control System communications loop and its associated wiring is contained
in Section 2 of this manual.
How It Works
Auto-Zone uses a token-passing loop architecture, which means in simple terms that an
“electronic message” called a token is passed from controller to controller in a roundrobin fashion. A controller must wait to receive the token before it can send or request
any data. Only one device on each loop is capable of sending the token, and this device is
considered the loop master. The loop master varies depending on the type of system and
the installed options. For the Auto-Zone Basic Control System, there is only one loop
master. The loop master is the Zone Manager. The Zone Manager must be connected to
the zone controllers in order for the communications loop to function. A typical AutoZone Basic Control System communication loop is shown in Figure 4-1.
In order for the loop master to communicate with the various devices on that loop, each
must have a unique address. With the Auto-Zone Basic Control System, each zone controller on the loop must have its own address from 1 to 16. The Zone Manager also has an
address switch that must be set for the system to communicate. For the Basic System
without an optional CommLink connected, the Zone Manager address should be set to 0.
For the Basic System with the optional CommLink attached, the Zone Manager must be
set as address 17 and the CommLink’s jumper switch must be set to single loop operation.
4-1
Auto-Zone Basic
Section 4
Basic System Communications
The Auto-Zone Basic Control System has only one communications loop. The Zone
Manager is always the master on the Basic System loop. You must be sure the Zone
Manager is connected, addressed correctly (see Figure 4-2), powered up, and functioning
if you are starting up or troubleshooting the communications loop. The optional
CommLink IV jumper switch must be set for single loop operation when used with the
Basic system. See Figure 4-5.
Figure 4-1: Basic System Communications Wiring
4-2
Start-Up and Troubleshooting
Auto-Zone Basic
Section 4
Zone Manager Communications
The Zone Manager is the main communication device on the Basic System. It must be
wired correctly and connected to 24VAC power for the system to function. The Zone
Manager must also be addressed correctly. The Zone Manager is normally addressed as
address 0 but should be addressed as 17 if a CommLink is used. Always be sure to
double-check all communication wiring and addressing before initial commissioning of
the system. The address switch must be set and the power cycled in order for the address
to be recognized by the system. Please see Figure 4-2 for the Basic Zone Manager
addressing information.
BYPASSPDAMPER
FDBK
GND
CLOSE
K3
RS-485
Communications
To CommLink
When Used
OPEN
RAM
CX9
EPROM
R43
D18
CLOSE
V3
FAN
K4
V4
D19
R44
V5
U9
V6
COOL1
K5
RN1
R45
TB7
R47
R46
D20
8K
COOL2
K6
JO2
1
U14
CX14
U13
HEAT1
C22
CX12
CX13
K7
CX15
R60
1992
R59
HEAT2
R58
MADE IN U.S.A.
U15
V8
COMM
D30
D29
D28
D27
D26
D25
D24
D23
R56
D22
V7
P1
R55
HEAT1
K8
V9
U12
R52
D21
COOL2
R49
CX11
RN2
COOL1
HEAT2
U11
CX10
U10
32K
R
FAN
R48
T
SH
R
All Comm Loop Wiring Is
Straight Thru
ADD
SW1
R57
D31
RS-485
COMM DRIVER
T
SH
R
T
SH
R
T
SH
R
T
SH
R
1
2
4
8
16
32
B
NET
Local Loop
RS-485
9600 Baud
TB8
RS-485
Controllers
In The OFF Position
As Shown
AD
Rocker Down
OFF
>
D
ADD
1
2
4
8
16
B T
E
N
To Address 0 on Zone Manager Board
As Shown
32
2.)It Is Recommended That All
Controllers Address Switches Are
Set Before Installation.
1
2
4
8
16
32
B
NET
Notes:
1.)AllCommunication Wiring To Be
2 Conductor Twisted Pair With
Shield. Use Belden #82760 Or
Equivalent.
Zone Manager
Address Switch
Basic System Without CommLink
3.)Power To The Zone Manager Must Be
Cycled Before Address Switch
Changes Will Take Affect.
In The OFF Position
As Shown
Zone Manager
Address Switch
D
AD
OFF
>
Rocker Down
ADD
1
1
2
4
8
16
32
B
NET
2
4
8
16
32
B T
E
N
To Address 17 on Zone Manager
Board When CommLink Is Used
Basic System With CommLink
Figure 4-2: Zone Manager Communications Wiring & Address Switch Setting
4-3
Section 4
Auto-Zone Basic
Zone Controller Communications
The Zone Controllers on the system must all be addressed from 1 to 16. They must be
wired correctly and connected to 24VAC power for the system to function. Improper addressing is one of the most common mistakes made when installing any system. If duplicate addresses are assigned on the same loop, fluctuating readings will occur. This can be
a very frustrating error to find. Another common mistake is flipping (reversing) of the T
and R wires on the communication loop between controllers or other communication devices. Always be sure to double-check all communication wiring and addressing before
initial commissioning of the system. The address switches must be set and the power cycled in order for the address to be recognized by the system. Please see Figure 4-3 for
Zone Controller addressing information.
Figure 4-3: Zone Controller Communications Wiring & Address Switch Setting
4-4
Auto-Zone Basic
Section 4
CommLink IV Communications
(Optional)
The CommLink IV is optional for the Auto-Zone Basic Control System. It is required
only if alarm call-out, connection to an on-site computer, or connection to a remote computer is required. For the Basic Control System to function correctly, the CommLink IV
must be set to single loop operation mode by setting the jumper position on the
CommLink board. The CommLink IV must be wired correctly to the system and connected to a computer (if used). For remote communications or alarm call-outs, the
CommLink IV connects to a Remote Link II or to an Ethernet router when the IP Module
is used. See Figure 4-4 and Figure 4-5 for more information. The CommLink must also
be powered up in order for either system to communicate. In addition, the Zone Manager
address should be set to 17 instead of 0 when the CommLink is used.
Figure 4-4: CommLink IV (Optional) Wiring
4-5
Auto-Zone Basic
Section 4
Figure 4-5: CommLink IV (Optional) Jumper Settings
4-6
Auto-Zone Basic
Section 4
Basic System
Communications Checklist
Basic System without Optional CommLink

Zone Manager is correctly addressed as 0
Zone Controllers are correctly addressed from 1 to 16
Power has been cycled after changing addresses
There are no duplicate addresses on the loop
The first Zone Controller on the communication loop is connected to the
Zone Manager communication terminal
All communication wiring is landed correctly, T to T, R to R, and SHLD to SHLD
All Zone Controllers are wired to 24 Volt AC power supply
Zone Manager is wired to 24 Volt AC power supply
All 24 VAC power wiring is landed correctly - 24VAC to 24VAC and GND to GND
Zone Manager is powered up
Zone Controllers are powered up
Additional Checks for Basic System with
Optional CommLink IV

CommLink IV is connected to the communications loop
CommLink IV is set for single loop operation
Zone Manager is correctly addressed as 17
CommLink IV is wired to 24 Volt AC power supply
CommLink IV is powered up
Other Optional Equipment

Computer is correctly connected to the CommLink IV
Prism™ software is installed on a computer
Remote Link II is correctly connected to the CommLink IV
Remote Link II is connected to a working phone line
Second Remote Link II is connected to a computer and working phone line off-site
IP Module is correctly installed in the CommLink IV
CommLink IV with installed IP Module is connected to an Ethernet router for off-site
communications
4-7
Auto-Zone Basic
Section 4
Components & Wiring
The following information is intended as a review of the procedures and design data provided in Section 2 of this manual. Section 2 should be thoroughly studied before attempting the initial installation of the system. If, however, you find yourself starting up or troubleshooting a system that was installed by someone else, the following information
should be helpful in gaining a quick overview of the system you are working with.
Zone Manager IO & Components
The Zone Manager inputs, outputs, and components are shown below. It is important to
familiarize yourself with these components and their locations to facilitate proper
connection, startup, and troubleshooting of the Basic System. See Figure 4-6.
Static Pressure
Sensor - Optional
Modular Connection
Input
Real Time
Clock Chip
Mounting Holes
Typ. Of 4
Static Pressure
Sensor Inputs
+5V
SIG
GND
CX1
D2
R11
D3
R12
PU1
C7
C8
D4
D5
5.11V
ADJUST
D7
D8
VR3
L1
R25
SC1
D11
R16
R61
R24
R23
D10
R22
R21
J01
C15
GND
GND
C16
TB3
R37
D14
C19
C18
C17
D15
PU6
R38
U8
EXHAUST
CONTACTS
N.O.
5.11V
ADJ
R39
CX6
U6
R40
Comm
LED
U7
REC
Q2
V2
D16
OPEN
K2
R42
R41
D17
FDBK
GND
C21
X2
EXH/RELIEF
YS101722
Rev. 2
OPEN
RAM
Analog Output
0-10 VDC
Economizer
ECONOMIZER
C20
CLOSE
GND
TB5
CX9
EPROM
R43
D18
CLOSE
TB4
V3
EXP
BUSS
FAN
K4
V4
D19
R44
V5
COOL1
K5
TB7
R47
R46
D20
8K
COOL2
K6
JO2
1
U14
P1
R55
CX14
HEAT1
U13
HEAT1
C22
CX12
CX13
K7
D30
D29
D28
D27
D26
D24
D25
D23
COMM
T
R60
R59
1992
U15
HEAT2
CX15
MADE IN U.S.A.
R58
R56
D22
V8
RS-485
Communications
Loop Connection
T
SH
R
SH
R
K8
V9
U12
R52
D21
COOL2
R49
CX11
RN2
COOL1
HEAT2
R48
U11
CX10
U10
32K
R
FAN
V7
ADD
SW1
D31
R57
1
2
EPROM
Chip
4
8
16
Address Switch
(Set To 0 Without
CommLink. Set to 17
With CommLink)
B
RAM
Chip
32
NET
RAM Size
Select
Jumper
RN1
R45
Note:
Keypad & Display
Not Shown
Display &
Keypad
Ribbon Cable
Connector
U9
V6
HVAC Unit
Connections
(R) Common
Fan
Cool 1
Cool 2
Heat 1
Heat 2
Binary Output
Relief/Exhaust
Fans
ANALOG
OUTPUTS
CX7
BYPASSPDAMPER
K3
Bypass
Damper
Connections
FDBK
GND
Open
Close
AUX3
PU5
R31
EWDOG
D13
PU4
R28
R30
R36
R35
U5
R33
R34
AUX1
AUX2
R27
CX5
R29
CX4
U3
Real Time
Clock Chip
R32
RAT
OAT
C14
C13
R26
CX3
PU2
PU3
R17
R19
R20
D9
I2C EXP PORT
Analog Inputs
SAT
RAT
OAT
AUX1
AUX2
AUX3
GND
SAT
R14
R15
C11
Q1
C12
GND
R13
Y1
D12
R18
ANALOG
INPUTS
+12V
D6
POWER
TB2
TB1
C5
SIG
C4
GND
C3
C9
+5V
C2
C6
R7
24VAC
PJ1
U1
R9
D1
V1
U2
Not Used
PRESSURE
SENSOR JACK
R4
VR2
VR1
24 VAC
Power Input
Power LED
R5
R3
R2
R1
R10
C1
PAL
Chip
TB8
RS-485
COMM DRIVER
Typical
Pin 1
Indicator
RS-485
Communications
Driver Chip
Figure 4-6: Zone Manager Components
4-8
Auto-Zone Basic
Section 4
Zone Manager Wiring
Correct wiring of the Zone Manager is critical to proper system operation. If components
are wired to the wrong inputs, the system will not operate correctly or will not operate at
all. Correct wiring of the 24VAC power is extremely critical. If voltage greater than
24VAC is applied to the terminal, it will damage the board beyond repair. All 24VAC
wiring must be connected so that all ground wires remain common. Failure to comply
with this will also result in damage to the board. See Figure 4-7. Also see Section 2 of
this manual for more detailed wiring instructions and procedures.
Suppy Air Temp.
Sensor
Splice As
Required
Bypass
Air Damper
Actuator
Static
Pressure
Sensor
0
LO
1
Static
Pick-up
Outdoor Air Temp.
Sensor
(See Note 4)
Grn
Blk
Red
Basic Zone Manager
TO ACTUATOR
TB2
AUX1
+
AUX2
OPEN
FROM ZONE
CONTROLLER
CLOSE
LD2
GND
Aux1
Economizer
Disable
GND
+
LD1
AUX3
PJ2
TB1
FDBK
EXHAUST
CONTACTS
N.O.
+
+
GND
REC
OPEN
CLOSE
NE5090
LCD DISPLAY
&
KEYPAD
BYPASS
FDBK
GND
OPEN
CLOSE
V3
V4
V5
V6
OPEN
BYPASS
ANALOG
OUTPUTS
FAN
COOL1
CLOSE
1
2
3
A
4
5
6
B
7
8
9
C
*
0
#
D
G
TB2
G
EXP
BUSS
FAN
Y1
R5
COOL 2
C2
R6
W1
HEAT 1
COMM
W2
C 1992
>
OFF
ADD
SW1
HEAT 2
MADE IN U.S.A.
1
2
4
8
16
32
B
NET
24VAC
75176
Rocker Down
24VAC Only
CABLE
D17
D18
D19
D20
D21
D22
D23
D24
HEAT2
Y2
RS-485
COMM DRIVER
RS-485
Controllers
T
SH
R
Local Loop
GND
See Note 1 &2
RS-485
Communications
To CommLink
When Used
RIBBON
+
C1
COOL2
HEAT1
To Relief / Exhaust Fans
A1
COOL 1
R
G
Y1
Y2
W1
W2
Aux3
Aux2
Forced Filter
Occupied Alarm
Mode
A2
P1
HVAC Unit
Auxiliary Inputs
( Dry Contacts )
RAT
OAT
TB2
CLOSE
Line
Voltage
SAT
+
GND
+
BYPASS AND
SLAVE INTERFACE
YS101824
+
+
POWER
OPEN
+12V
5.11V
ADJUST
+
24VAC
GND
ANALOG
INPUTS
PJ1
PJ1
TB12
SIG
+5V
PRESSURE
SENSOR JACK
Bypass & Slave
Interface Card
GND
Return Air Temp.
Sensor
HI
Notes:
1.)24 VAC Must Be Connected So
That All Ground Wires Remain
Common.
and Specifications.
3.)All Communication Wiring To Be 18
Ga. Minimum, 2 Conductor Twisted
Pair With Shield. Belden #82760 Or
Equivalent.
Economizer Actuator
5 U
4 Y2
BELIMO
AF24-SR
3 Y1
133 IN-LB
2 +
1 COM
WARNING!
Use Extreme Care When Wiring
Economizer Actuators
Never Connect Or Disconnect
Wiring With Power Applied!
Never Apply Power If The
Gnd ( 1 Com ) Terminal On The
Actuator Is Not Connected.
Belimo Actuator Wiring Shown.
Consult Factory For Other
Models Of Economizer Actuators.
Some Actuators Require Isolation
Transformers In Order To Prevent
Damage To The Controller Board.
Figure 4-7: Zone Manager Wiring
4-9
Section 4
Auto-Zone Basic
Zone Controller IO & Components
The Zone Controller inputs, outputs, and components are shown below. As with the Zone
Manager, knowing the location and function of the Zone Controllers inputs, outputs, and
components is critical to proper start-up and troubleshooting of the Basic System. See
Figure 4-8.
Figure 4-8: Zone Controller Components
4-10
Auto-Zone Basic
Section 4
Zone Controller Wiring
Correct wiring of the Zone Controller is critical to proper system operation. If components are wired to the wrong inputs, the system will not operate correctly or will not operate at all. Correct wiring of the 24VAC power is extremely critical. If voltage greater
than 24VAC is applied to the terminal, it will damage the board beyond repair. It is recommended that a separate transformer be used for each Zone Controller. If one transformer is used to power multiple Zone Controllers, all 24VAC wiring must be connected
so that all ground wires remain common. DO NOT REVERSE POLARITY
BETWEEN CONTROLLERS. Failure to comply with this will also result in damage to
the board. See Figure 4-9. Also see Section 2 of this manual for more detailed wiring
instructions and procedures.
Figure 4-9: Zone Controller Wiring
4-11
Section 4
Auto-Zone Basic
Startup & Commissioning
Commissioning the system correctly is one of the most important steps in getting the system installed and functioning with the least amount of problems and in the shortest length
of time.
Procedures
The following is a list of items and reminders that are essential to the successful commissioning of your system. Some of these items have already been discussed in this manual
and are repeated to confirm correct procedures. Familiarize yourself with this installation
manual and system wiring diagrams before installing!
1) Check to see if you have all the correct components for your installation.
2) Establish the location for the Zone Manager first. This is where your communication cable will begin for the Basic System.
3) Layout your communication wiring per the instructions in the previous portion of this manual.
4) The communications loop originates at the Zone Manager. All Zone Controllers are connected to this loop.
Tip: Using the Auto-Zone color-coded and labeled Communication Cable ensures a quality installation.
5) Always refer to the Basic System Wiring Diagrams for specific wiring details. Communication cable must always be shielded – no exceptions!
6) Mount controllers in appropriate locations according to their operating specification.
7) Use the Basic System Worksheet included in the back of this section or the
ones included with the submittal package to document unit location, descriptions, addressing, and setup. Address controllers according to location and addressing instructions located in this system manual.
4-12
Auto-Zone Basic
Section 4
Procedures (Continued)
8) With no power connected, wire the Zone Manager and Zone Controllers according to wiring diagrams and in accordance with local codes. Do Not Apply
Power!
9) After completing all wiring connections, unplug the terminals for power and
communications on the Zone Manager and all Zone Controllers. Always unplug the communications loop first and then the power. When reconnecting
the wiring, connect the power first and then the communications loop. Even
though the system does not have power applied to it at this time, it is a good
habit to get into. Later, when power is applied, this is very important to ensure
against the possibility of shorting the communications loop to ground.
10) If you are using the optional CommLink IV, locate and install the CommLink.
Do Not Apply Power!
11) Reconnect the power and then the communications loop to the Zone Manager
and the first Zone Controller on the loop.
12) Observe the LCD screen on the Zone Manager. It will go through a start-up
procedure upon being powered up. See the Start-up Screens heading that follows in this section of the manual for complete start-up Screen information.
13) The Zone Manager will proceed through system start-up, initialization, and
calibration. This calibration could take up to five minutes. After the initialization is complete, the main system screen will appear. In the bottom right hand
corner, it will show the current zone polling address. See Section 3 of this
manual for complete screen operations and programming. If the address
shown is 1, the first zone controller on the loop is apparently communicating.
To confirm this, press the “B” key on the Zone Manager keypad. Enter the
Zone Address for the controller you are checking. If this is the first controller
on the loop and it is addressed as 1, you would press 1 and then the “Enter”
key. If the zone isn’t communicating, it will display “***Missing***.” If the
zone is communicating but still calibrating, it will display “Calibrating.” If the
zone is communicating, the display will change over to the Zone Status screen
when calibration is complete. If the zone is communicating, proceed to step
15. If the screen shows that the zone is missing, proceed to step 14.
4-13
Auto-Zone Basic
Section 4
Procedures (Continued)
14) Check the Zone Controller for correct communications and addressing by observing the LED indicator for the blink codes as outlined in the troubleshooting section of the manual. The blink code will first verify the address and then
the operation. If the address is incorrect, reset the address switch, and then reapply power to the controller. If you cannot communicate, verify wiring, voltages, etc. in accordance with the trouble-shooting section in the system manual. Do not proceed to the next device until you are properly communicating
with the current device.
15) Reconnect the power to the next zone controller on the communications loop.
Reconnect the wiring between the previous zone controller on the loop and
the zone controller you are testing. Be sure the Zone Manager is still powered
and connected to the communication loop and then press the “B” key on the
Zone Manager keypad. Enter the Zone Address for the controller you are
checking. If this is the third controller on the loop and it is addressed as 3, you
would press 3 and then the “Enter” key. If the zone isn’t communicating, it
will display “***Missing***.” If the zone is communicating but still calibrating, it will display “Calibrating.” If the zone is communicating, the display
will change over to the Zone Status screen when calibration is complete. If the
screen shows that the zone is missing, revert to step 14. If the zone is communicating, repeat this step with each zone controller on the loop, in sequence,
until all zone controllers on the loop are communicating.
16) Once all devices on the loop are communicating, you must program and configure the Zone Manager and all Zone Controllers on the system per the programming section of this manual.
Remember that each controller only contains one puff of smoke. Making sure that all wiring terminations and voltages are correct prior to applying power to a controller will ensure that you don’t use up that one puff.
4-14
Auto-Zone Basic
Section 4
Basic System Worksheet
Project: _______________________ Location ______________________________________________
CommLink Installed: Yes No Remote Link Installed: Yes No Phone:
_________________
Stages of Cooling ____ Stages of Heating ____ Gas Electric
Zoning: Pressure Dependent
Zone
Address
Economizer Yes No
Room
Sensor Type
Relay
Exp. Board
1
S SO SA SOA
AH BH SF PF
2
S SO SA SOA
AH BH SF PF
3
S SO SA SOA
AH BH SF PF
4
S SO SA SOA
AH BH SF PF
5
S SO SA SOA
AH BH SF PF
6
S SO SA SOA
AH BH SF PF
7
S SO SA SOA
AH BH SF PF
8
S SO SA SOA
AH BH SF PF
9
S SO SA SOA
AH BH SF PF
10
S SO SA SOA
AH BH SF PF
11
S SO SA SOA
AH BH SF PF
12
S SO SA SOA
AH BH SF PF
13
S SO SA SOA
AH BH SF PF
14
S SO SA SOA
AH BH SF PF
15
S SO SA SOA
AH BH SF PF
16
S SO SA SOA
AH BH SF PF
Zone Description or Location
Air
Damper
Size
[S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint adjust]
[AH=Auxiliary Heat] [BH=Box Reheat] [SF=Series Fan Terminal] [PF=Parallel Fan Terminal]
4-15
Auto-Zone Basic
Section 4
Start-Up
On Auto-Zone Basic Control System power up, the following tests, calibration, initialization, and procedures occur:
Display
+
N
FA
OL
CO
OL
CO
AT
HE
1
2
1
2
EN
OP
SS
E
PA
OS
BY
CL
N
SS
A
IO
P
AT
BY
IC
UN
M
M
CO
M
R
A
S
AL
NE
ZO
L
AL
NE
=
ZO
A
AR
LE
CH
/C
EA
IT
=
N
B
U
AC
HV
=
S
C
M
AR
AL
ER
=
NT
D
/E
EP
ST
=
AL
#
CIM
DE
=
AT
HE
deM
Mo8P
4
ol3: D
Co 0PIEMS
2 U
-0CC LAR
2
O
A
-2
NO
04
+
N
MO
A
3
B
2
6
1
C
5
9
4
D
8
#
7
0
*
*
+
Keypad
+
Figure 4-10: Auto-Zone Basic Zone Manager
Initializing
System
1.)
Please Wait
2.)
POWERUP TEST
Start-Up Delay 49
Number of Zones 1
03/27/02 09:20am Wed
STATIC NULL: 0.25
Start-Up Delay 49
Number of Zones 1
03/27/02 09:20am Wed
STATIC NULL: 0.25
Start-Up Delay 49
Number of Zones 1
03/27/02 09:20am Wed
STATIC NULL: 0.25
Start-Up Delay 49
Number of Zones 1
03/27/02 09:20am Wed
STATIC NULL: 0.25
4-16
The system setpoints are loaded and outputs are
turned off and the LEDs are initialized ON. The
screen displays, “Intialializing System.”
System Diagnostics and Calibrations occur.
a.) A 50-second startup delay occurs. While this
is counting down, the LEDs will extinguish,
one every 6 seconds.
b.) The number of zones displays on the second
line. If the Zone Manager has never been
configured, the system will only show "1"
zone. If this isn't the first power-up, it will
display the number of zones for which the
system is configured.
c.) The current date and time displays on the
third line. If this is the first power-up, the
date and time may be incorrect.
d.) The Static Pressure Sensor NULL Voltage
displays on the bottom line. The static pressure sensor NULL voltage is read at the factory during power-up checks prior to shipping. If necessary, you can re-calibrate the
pressure sensor using the procedure described in Section 3, Zone Manager Configuration, Configuration Screen #7.
Auto-Zone Basic
Bypass Calibration
Please Wait...
Section 4
3.)
At the conclusion of the 50 second startup delay, the
system proceeds with the bypass damper calibration.
Depending on the degree of travel and the speed of the
damper actuator, this process could take up to a maximum of three minutes.
4.)
The zones are all polled and initialized.
5.)
The Main Operating Screen will now appear (see Section 3, LCD/Keypad Operations) and normal operation
will begin. The total startup time is approximately four
minutes.
Initializing Zones
Vent Mode
03/27/02 09:30pm Wed
Occupied
1 Alarm(s)
3
4-17
Auto-Zone Basic
Section 4
Blink Codes for Zone Controllers
The Zone Controller uses an on board SCAN LED to indicate various conditions during
power up and operation. Starting with power up, the SCAN LED blink codes are as follows:
•
•
•
•
•
•
Off for 5 seconds
SCAN LED blinks the board address (Address 14 = 14 blinks)
5-second pause
20-second time delay - LED blinks 20 times
LED stays on continuously during damper calibration
Status code is repeatedly blinked every 10 seconds to indicate controller
status:
Priority
Lowest
Highest
Number of Blinks
1
2
3
4
5
Status
Normal Operation
Override Active
Bad Zone or Airflow Sensor
Damper Failure
Communication Failure
Table 4-1: SCAN LED Blink Codes
Only the highest priority failure code will be shown. You must correct the highest priority alarm before other problems will be indicated.
4-18
Auto-Zone Basic
Section 4
Troubleshooting
The following is a guide to assist in troubleshooting the Auto-Zone Basic Control System. It is provided as a systematic approach in determining and resolving common system problems.
Troubleshooting Checklist
Begin troubleshooting by locating the general problem in the list below. Detailed component troubleshooting information follows later in this section.
Zone is too warm
•
•
•
•
•
•
•
•
•
•
•
•
Is cooling locked out due to outside air temperature?
Is cooling short cycling due to low supply air temp cut-off?
Is zone calling for cooling?
Is supply air temperature indicating cooling?
Is Economizer enabled?
Is Economizer opening?
Is cooling being held off by its minimum off timer?
Is the zone a “voting” zone?
Is the system currently trying to satisfy a higher heating demand?
Is the rooftop unit running? Check internal safeties.
Is the Zone Damper operating freely?
Is the LED blinking an error code? See Table 4-1.
Zone is too cool
•
•
•
•
•
•
•
•
•
•
Is heating locked out due to outside air temperature?
Is heating short cycling due to high supply air temp cut-off?
Is zone calling for heating?
Is supply air temperature indicating heating?
Is heating being held off by its minimum off timer?
Is the zone a “voting” zone?
Is the system currently trying to satisfy a “higher” cooling demand?
Is the rooftop unit running? Check internal safeties.
Is the Zone Damper operating freely?
Is the LED blinking an error code? See the BLINK CODE chart.
4-19
Auto-Zone Basic
Section 4
Zone Sensor reading incorrectly
•
•
•
Is the sensor near a source of heat or a cold draft? Location is a common problem.
The sensor should be mounted on an inside wall away from heat sources and in a
location with adequate room air circulation.
Is the voltage reading correct? Is the resistance reading correct? Check Table 4-2
in this section.
Is wiring correct? Check for errors.
Check the Room Sensor
• To meter the Room Sensor:
With the sensor connected to the Zone Controller board, read the voltage on the
sensor terminals. If the voltage does not match the TEMPERATURE/
RESISTANCE chart, unplug the two-position room sensor terminal block. Using
your meter, check the resistance of the unplugged terminal block. Use the supplied TEMPERATURE/RESISTANCE chart to see if the sensor is within a reasonable range. Readings that are much too high or too low generally indicate wiring problems.
•
To meter the Slide Adjust (optional):
Unplug the four-position AUX terminal block. Use your ohmmeter to check the
resistance between the GND wire on the two-position room sensor terminal block
and the AUX1 terminal on the unplugged terminal block.
The resistance for various positions of the slider on the sensor should be as follows:
Full UP position
MID position
Full DN position
4-20
15K Ω (± 500 Ω)
12.5K Ω (± 500 Ω)
10K Ω (± 500 Ω)
Auto-Zone Basic
Section 4
Zone Damper does not appear to be working correctly
•
•
•
•
Is the actuator plugged into the correct jack on the Zone Controller?
Is the actuator properly mounted? Check for loose shaft, etc.
Is the damper free to move? Check for binding and/or physical damage. Does the
damper move both directions when the controller is powered up? Set to mid position before applying power.
Is the Zone Controller set for DIRECT/REVERSE action? The zone controller
must be configured for correct operation if REVERSE action of the damper is required.
Caution: Improper mounting and the associated adjustment of the damper blade
positioning is the number one cause of damper related problems. It can
be difficult to determine the full-open position if the damper shafts are
not marked. It is sometimes helpful to “force” the damper to the fullopen or full-closed position and then check for airflow at the diffusers.
The damper may be forced using the control system or by unplugging
the actuator then depressing the actuator clutch release and manually
positioning the damper.
No zones are communicating
•
•
•
•
•
•
If used, is the CommLink IV connected and plugged in?
Is the Zone Manager address set correctly?
Address = 17 if CommLink is used
Address = 0 if no CommLink is used
Are COMM LOOP voltages correct? See the COMM LOOP troubleshooting
guide.
Is the COMM LOOP open or shorted?
Are the Zone Controller address switches set correctly? See the addressing chart.
Are the Zone Controllers powered? Check 24VAC to the controllers.
4-21
Section 4
Auto-Zone Basic
Some zones are communicating but others are not:
•
•
•
•
•
•
4-22
Is the Zone Manager set for the correct number of zones?
Are the Zone Controller address switches set correctly? See the addressing chart.
Are the Zone Controllers powered? Check 24VAC to the controllers.
Is the REC LED on the missing Zone Controller “flickering”? See Zone Controller introduction for location of the REC LED.
Is the SCAN LED blinking an error code? See the BLINK CODE chart.
Are COMM LOOP voltages correct at the missing unit? See the COMM LOOP
troubleshooting guide.
Auto-Zone Basic
Section 4
Troubleshooting Chart
Problem
1 Display screen
Possible Cause
Solution
Check and re-seat plugs on ribbon cable between the cover and motherboard. Re-cycle power if necessary.
Check all “pluggable” components on
the board to make sure they are all
fully seated.
Contrast needs adRemove cover, but leave ribbon cable
2 Display screen
washed-out or
justment
connected. Adjust contrast by turning
difficult to see
adjustment pot located at the bottom
edge of the control board located on
the cover behind the display screen.
3 Zone Manager con- Wiring fault such as Carefully check all wiring. Disconnect
tinually initializes
shorted lead on the relay outputs and the bypass connector
(start-up cycle rebypass actuator or
to isolate the source of the problem.
peats)
on one of the heating/cooling stages
Can
only
read
data
Zone Manager con- Enter access code. Under “Configure
4
from Zone 1 or only figured for incorrect System,” enter first and last zone numfrom some of the
number of zones
ber.
zones
Zone Controller(s)
Check Zone Controller address using
addressed incordata from Figure 2-7 of this manual.
rectly
Comm Loop ProbCheck Comm Loop using Comm Loop
lem
troubleshooting guide in this Section.
blank or solid black
bars
Ribbon cable connectors loose
4-23
Auto-Zone Basic
Section 4
Problem
5 Zones cold or hot
and second stage of
cooling or heating
does not come on
6 Zones calling for
cooling but “Cool”
light does not come
on
Possible Cause
Solution
Zone Manager not
configured for two
stages
Under the Configure System menu,
enter correct number of stages.
In the Cooling Mode, the supply temperature must be above 45°F for any
additional stages of cooling to activate.
In the Heating Mode, the supply temperature must be below 105°F for electric heat and below 160°F for gas heat.
Under the Configure System menu,
enter the correct number of cooling
stages.
Zone Manager configured for “0"
stages of cooling
Supply temperature
too cold or faulty
duct temp sensor
Economizer is enabled and acts as
first stage of cooling. Will not allow
mechanical cooling
until damper is 100
percent open
Outside air temp is
below Cooling
Lockout setpoint
Minimum cooling
Off Time has not
been met
Unit is in Heating/Cooling
Changeover delay
4-24
Press “C” key and read supply air temperature. If less than 58°F, the supply
temperature is too low to allow cooling
to be energized or the duct sensor is
faulty. Correct as appropriate.
Check Economizer setpoints and
damper position
Check Cooling Lockout setpoint and
outside air temp.
Check minimum Off Time for cooling.
Warning: Do not set minimum off
time to less than manufacturers recommended time. Damage to equipment
may result.
Check changeover delay. Default delay
is ten minutes.
Auto-Zone Basic
Section 4
Troubleshooting Chart for Alarms
Problem
Possible Cause
Solution
1 Bad Duct Sensor
Faulty Wiring/Sensor
2 Bad Static Sensor
Too low/high duct
static
The duct sensor reads actual temperature between 35°F and 210°F. If the
actual temperature at the sensor probe
as measured with a thermometer is
within these limits, check the sensor
voltage. If voltage does not match the
chart, then check the total sensor/wire
resistance by removing wires from
terminals SAT and GND on the TB3
terminal strip. Measure the resistance
in the wires and compare it to the temperature/resistance chart. If the resistance measured does not match the
chart, go to the sensor, disconnect it,
and measure the resistance directly
across the sensor. If resistance is correct, check wiring between the controller and sensor. If sensor is not within
tolerances, replace the sensor.
With fan running (red fan LED is on),
read duct static using “C” key on Zone
Manager. If reading is below 0.01,
check sensor tubing connectors for
loose or reversed connections. Check if
there is airflow (pressure) at the sensor
location (mounted too close after an
elbow may cause negative pressure). If
reading is above 3.0, check actual
static or see if sensor is pointing into
air stream picking up total pressure.
Disconnecting sensing tube from the
sensor should cause reading to go to
“0." If not, check wiring and replace
sensor if it does not read correctly
when wired directly to the Zone Manager.
Check bypass configuration for Direct
or Reverse Acting. See Section 3, Zone
Manager Configuration, Configuration
Screen #5.
Bypass damper action
incorrect
4-25
Auto-Zone Basic
Section 4
Problem
3 Bad Zone Sensor
4-26
Possible Cause
Solution
Faulty Wiring/Sensor An alarm occurs if the zone temperature reading is below 40°F or above
105°F. If actual temperature at the sensor is between these temperatures and
an alarm occurs, start troubleshooting
at the zone sensor. Measure the sensor
voltage either at the sensor or the Zone
Controller. If it does not match the
chart, remove it from the wall, disconnect its wires and measure the resistance between TMP & GND. Resistance should compare to values in the
Temperature/Resistance chart. (Remember, temperature of sensor may be
affected by the heat of your hands). If
the resistance is significantly different
from the chart, replace the sensor. On
3-wire sensors with a “WarmerCooler” pot, the resistance between
AUX & GND should vary from 10K to
15K Ohms depending on the position
of the pot. If the resistance is acceptable, check the wiring between the sensor and the controller by reconnecting
the sensor and going to the zone controller, lifting the sensor terminal plug,
and reading the resistance in the wires.
Reversing TMP and GND wires on a
3-wire sensor will significantly affect
the readings. In checking sensor wiring, also check for loose strands of
braided wire shorting to ground at the
terminals that may affect readings.
Auto-Zone Basic
Problem
4 Bypass Damper
Section 4
Possible Cause
Solution
Sticking Damper
Depress Clutch button and check that
the damper moves freely without binding. Note: If the actuator has driven
against its “stop” screw, rotating the
actuator shaft by disengaging the
clutch may not be possible. If this is
the case, loosen the setscrews and rotate the damper shaft to observe binding. If binding is observed, correct the
binding problem and force recalibration of the damper by cycling power to
the Zone Manager. If setscrews were
loosened, be sure damper shaft is properly positioned before tightening.
(Counter clockwise = closed = Direct
Acting)
Warning: Actuator can be damaged
if rotation is forced! Make sure the
clutch button is fully depressed before
rotating damper.
Determine that wiring matches Figure
2-5.
Note: If more than one bypass
damper is wired in parallel, connect
only one of the feedback pots as
shown in the schematic wiring diagram
Figure 2-9.
Check voltage to the actuator during
the calibration routine. During the
“drive closed” part of the calibration,
24 VAC should be measured between
“GND” and “Close” on the terminals.
The red LED on the bypass and slave
interface card should also light up.
Similarly, 24 VAC should be measured
between “Open” and “GND” in the
drive open phase of the calibration routine, and the green LED light on the
bypass and slave interface card should
also light up. If 24 VAC is present, but
the actuator does not drive, replace actuator. See Figure 4-11.
Improper Wiring
Actuator motor
failure
4-27
Auto-Zone Basic
Section 4
Problem
Possible Cause
Solution
4 Bypass Damper
Continued
Faulty Feedback
pot
5 Maverick Zone
Insufficient air flow
to zone
Verify the ability of the actuator to
drive full open to full closed. Initialize
a bypass calibration by cycling power
to the Zone Manager. This will cause
the actuator to first drive full open (observe light(s) on the Zone Manager and
Bypass and Slave Interface Card and
damper action), then drive full closed,
and then drive approximately 25%
open. Also measure voltage from the
bypass actuator feedback pot (terminals FDBK & GND on the Bypass
Damper terminal strip). As the actuator
drives toward the open position, this
voltage should increase toward 0.0
VDC depending on the amount of
travel. As the actuator drives closed,
this voltage should increase toward 2.5
VDC. A change of less than 0.4 VDC
from full open to closed results in an
alarm, indicating either insufficient
damper travel, a faulty actuator, or improper wiring.
If zone temperature is more than 4°F
from the setpoint for more than one
hour, this alarm appears. Check airflow
to the zone by depressing the clutch on
the actuator and rotating the damper
fully counterclockwise. Damper
should be fully closed and no airflow
to the zone. Rotating the damper clockwise should open the damper to maximum flow. (Travel should be limited
with stop screws for maximum rotation). Check damper for ease of
movement, correct any sticking situation, and reset the alarm. A Maverick
Alarm will automatically be reset when
the zone temperature comes within 2
degrees of its setpoint.
4-28
Auto-Zone Basic
Problem
Section 4
Possible Cause
5 Maverick Zone
Continued
Unusual zone load
6 Missing Zone
Alarm
No power to zone
controller
Improperly addressed
COMM incorrectly
wired
Solution
This alarm may also be reset by temporarily resetting the zone setpoint (heating setpoint if zone is cool, cooling
setpoint if zone is hot) to the temperature reported by the zone sensor.
If a zone is loaded beyond system capacity to cool/heat the space due to
large crowds, process load, open doors
etc., the result is the same as “insufficient air” to space as listed above, and
can only be corrected by removing the
unusual load or increasing airflow to
the zone.
If LEDs on Zone Controller are not on,
check for 24VAC on Zone Controller.
If 24VAC is present, but LEDs are not
on, check voltage polarity and replace
zone board if required.
Check dipswitches on zone board for
proper setting (refer to Figure 2-13).
Switches must be set before power is
applied. Replace COMM connector,
then remove and replace 24VAC connector. Approximately five seconds
after power-up, the “SCAN” LED on
the zone control board will “blink” its
address. Confirm that the proper address is indicated. Thereafter, the
SCAN LED will blink approximately
once every ten seconds (refer to Table
4-1).
If multiple zones are “missing” and it
is not due to improper setting of zone
addresses or the Zone Manager address
as noted previously, it is a good indication that either communication loop
wires are crossed or the polarity on the
24VAC power supply has been crossed
and damage to the communication
driver chips has occurred.
4-29
Auto-Zone Basic
Section 4
Problem
6 Missing Zone
Alarm
Continued
4-30
Possible Cause
Solution
If multiple zones are missing, but some
zones are communicating, remove the
communication plug on all missing
zone cards and begin trouble shooting
one zone at a time.
1. Check the communication loop for
crossed wires, starting at the Zone
Manager (or the “communicating
zone” nearest to the “missing”
zone). If all zones are missing, start
at the Zone Manager and connect
only one zone at a time to isolate
the problem. Also, check for
strands of braided wire that may be
loose at the terminal connection and
touching adjacent wires. If wiring is
crossed, correct the wiring problem.
(Crossed COMM Loop wires will
cause missing zones, but should not
cause damage to the boards).
2. Check COMM Loop voltages.
A. Refer to communication loop
troubleshooting guide in this section.
B. If the voltage on the board “pins”
(Step A above) is correct, with
the comm plug still removed
from the board, measure the
voltage on the comm line. If
these voltages are not between 2
and 3 VDC it means either there
is another controller on the loop
with a bad driver chip, or there is
a wiring connection problem on
the loop that must be corrected
by isolating the problem as outlined above.
Auto-Zone Basic
Section 4
Problem
Possible Cause
Solution
7 Missing Zone
Zone Manager improperly addressed
The Zone Manager should be addressed as 0. If a CommLink is installed, the address should be set to
address 17.
The NULL voltage is measured with
the fan off and no pressure in the duct.
This measurement only occurs the first
time the Zone Manager is powered up.
To force the Zone Manager to recalibrate the NULL voltage, select the
Configure System menu and press the
“*” key when prompted to force the
restart with calibration.
Check the voltage to the pressure
transducer at TB1 with the fan off.
Voltage between SIG and GND should
be between 0.23 and 0.27 VDC. This is
the NULL voltage. If this voltage is
not present, confirm the +5V terminal
supplies 5 VDC and wiring to sensor is
correct. Before replacing the sensor,
remove it from the duct and check the
voltages with the sensor directly wired
to the controller, using short wire
leads, to confirm there are no wiring
errors.
Check the stop screws on the damper
actuator. They should be set to properly limit the travel. Reset if necessary.
Depress the clutch and check the
damper for free rotation.
Note: If the actuator has driven against its
Alarm (All Zones
Missing)
8 Static Null Alarm
Incorrect NULL
voltage detected for
Pressure Sensor
Faulty Pressure
Sensor
9 Zone Damper Fail
Travel Stop Screw
slipped
Damper Binding
stop screw, rotating the shaft may
not be possible. If this is the case,
loosen the setscrews and rotate the
damper shaft to observe binding. If
the shaft turns freely, reconnect the
damper actuator and proceed to the
next step. The standard damper
closes counterclockwise and is fully
open after rotating 85 to 90 degrees
clockwise.
4-31
Auto-Zone Basic
Section 4
Problem
9 Zone Damper Fail
Continued
Possible Cause
Solution
Feedback pot failure
If you suspect an actuator feedback
failure, replace the actuator with a
known working unit to see if the problem is corrected. If not, continue to follow troubleshooting procedures for
controller, wiring, etc.
Force auto calibrate of the actuator
feedback pot:
A: Remove the communication wire
connector at the Zone Controller.
B. Remove the 24VAC power connection at the Zone Controller.
C. Replace the 24VAC power connection at the Zone Controller.
D. Replace the communication connector at the Zone Controller.
E. The actuator will recalibrate the potentiometer by driving full closed, then
full open, and then start to control. If
the actuator does not drive after restoring the 24VAC power (in Step C) either the actuator or the Zone Controller
is bad. If the calibration routine is completed and the alarm disappears, the
problem may have been an isolated incident caused by a power surge.
Check cable by replacing with a known
working cable. Replace if required.
Calibration routine
failure
Connector Cable
defective
4-32
Auto-Zone Basic
Section 4
Communications Loop
Zone Manager
Test the communications loop with the system powered up. Set meter to read DC Volts.
These tests assume that if the optional CommLink IV is installed, it is also connected and
powered up. Actual meter readings may deviate slightly depending on the number of
units installed. Any significant deviation from these values generally indicates a problem.
If voltages are not within specified ranges, the Zone Manager communications driver
chip is likely damaged and will have to be replaced.
Step 1
Measure the voltage at the Zone Manager terminals with the Communications Loop connected to the Zone Manager.
-
+
+
COMM
T
SHLD
R
-
TB8
Measuring T to SHLD
Basic System - Without Optional
CommLink Installed
Measure
Voltage
+ 2.7 to 2.4 VDC
T to SHLD
R to SHLD
+ 2.6 to 2.3 VDC
+
+
COMM
T
SHLD
R
TB8
Measuring R to SHLD
Basic System - With Optional
CommLink Installed
Measure
Voltage
+ 3.1 to 2.9 VDC
T to SHLD
R to SHLD
+ 2.1 to 1.9 VDC
If the voltages are within the specified voltage ranges, the Zone Manager and communications loop are operating within specifications. If the measured voltages are not within
the specified voltage ranges, proceed to Step 2.
4-33
Auto-Zone Basic
Section 4
Step 2
Measure the voltage at the Zone Manager terminals with the Communications Loop disconnected from the Zone Manager.
-
+
+
-
-
+
-
COMM
T
SHLD
R
+
TB8
Measuring T to SHLD
CommLink Installed
Measure
Voltage
+ 2.5 to 2.3 VDC
T to SHLD
+ 2.8 to 2.6 VDC
R to SHLD
COMM
T
SHLD
R
TB8
Measuring R to SHLD
CommLink Installed
Measure
Voltage
+ 2.5 to 2.3 VDC
T to SHLD
+ 2.8 to 2.6 VDC
R to SHLD
If the voltages are not within the specified voltage ranges, the Zone Manager communication driver chip is probably damaged and will require replacement. If the measured
voltages are within the specified voltage range, the Zone Manager driver chip is not damaged, and the problem is related to another part of the loop. Proceed to Step 3.
-
+
+
COMM
T
SHLD
R
TB8
-
Measuring T to SHLD
+
COMM
T
SHLD
R
TB8
+
Measuring R to SHLD
Step 3
Measure the voltage on the Communications Loop terminals with the Communications
Loop disconnected from the Zone Manager.
CommLink Installed
Measure
Voltage
+ 2.5 to 2.4 VDC
T to SHLD
+ 2.5 to 2.4 VDC
R to SHLD
CommLink Installed
Measure
Voltage
+ 3.2 to 2.7 VDC
T to SHLD
+ 2.3 to 1.9 VDC
R to SHLD
If the voltages are not within the specified range when checking the communications
loop as described above, then one of the Zone Controllers or the optional CommLink (if
installed) is the problem. Proceed to the Zone Controller Troubleshooting Section. If a
CommLink is installed, also see the CommLink Troubleshooting Section.
4-34
Auto-Zone Basic
Section 4
Zone Controller
Test the communications loop with the system powered. Set meter to read DC Volts.
These tests assume that if the optional CommLink is installed, it is also connected and
powered up. Actual meter readings may deviate slightly depending on the number of
zones installed. Any significant deviation from these values generally indicates a problem.
If voltages are not within specified ranges, one of the Zone Controller communications
driver chips is likely damaged and will have to be replaced.
Step 1
Measure the voltage at one of the Zone Controller terminals with the Communications
Loop connected to the Zone Controller. If you can communicate with some zone controllers on the loop but not others, start with the first Zone Controller you can’t communicate
with to begin testing.
-
+
+
-
T
SHLD
R
COMM
LOOP
T
SHLD
R
+
T
SHLD
R
COMM
LOOP
T
SHLD
R
+
Measuring T to SHLD
CommLink Installed
Measure
Voltage
+ 2.7 to 2.4 VDC
T to SHLD
+ 2.6 to 2.3 VDC
R to SHLD
Measuring R to SHLD
CommLink Installed
Measure
Voltage
+ 3.1 to 2.9 VDC
T to SHLD
+ 2.1 to 1.9 VDC
R to SHLD
If the voltages are within the specified voltage ranges, the Zone Controller and communications loop are operating within specifications. If the measured voltages are not within
4-35
Auto-Zone Basic
Section 4
Step 2
Measure the voltage at the suspect Zone Controller terminals with the Communications
Loop disconnected form the Zone Controller.
-
+
+
T
SHLD
R
-
-
+
-
COMM
LOOP
T
SHLD
R
T
SHLD
R
COMM
LOOP
T
SHLD
R
+
Measuring T to SHLD
CommLink Installed
Measure
Voltage
+ 2.5 to 2.4 VDC
T to SHLD
+ 2.5 to 2.4 VDC
R to SHLD
Measuring R to SHLD
CommLink Installed
Measure
Voltage
+ 2.5 to 2.4 VDC
T to SHLD
+ 2.5 to 2.4 VDC
R to SHLD
If the voltages are not within the specified voltage ranges, the Zone Controller communication driver chip is probably damaged and will require replacement. If the measured
voltages are within the specified voltage range, the Zone Controller driver chip is not
damaged and the problem is related to another part of the loop. Repeat Zone Controller
troubleshooting Steps 1 & 2 for each controller on the loop to determine which one is
causing the problem. If you have a CommLink (optional) installed, please see the
CommLink Troubleshooting Section of this manual.
4-36
Auto-Zone Basic
Section 4
CommLink IV (Optional)
CommLink IV must be powered for testing.
Basic System with CommLink Installed
Measure
Voltage
+ 2.5 to 2.4 VDC
T to G
+ 2.7 to 2.5 VDC
R to G
If the voltages are within the specified voltage ranges, the Zone Manager and communication loop are operating within specifications. If the measured voltages are not within
If the voltages are too high or too low on either side, the CommLink IV has a damaged
comm driver chip. Replace the CommLink IV. The driver chip is not field replaceable.
4-37
Auto-Zone Basic
Section 4
Bypass Damper Troubleshooting
Bypass Damper Package
Line
Voltage
Bypass
Actuator
Transformer
Power Connection Terminal
Zone Manager Board
(Shown With Actuator
In Middle Of Full Stroke)
TO ACTUATOR
1
BYPASS AND
SLAVE INTERFACE
YS101824
0
BYPASS &
PJ1
CLOSE
OPEN
LD1
LD2
TB2
GND
24VAC
Jumper Wire
Between 24VAC
And Ground
GND
CLOSE
Remove Terminal Plug
From Zone Manager Board
When Performing Jumper
Testing Of Actuator
PJ2
TB1
CLOSE
Bypass Damper
Terminal Plug
Bypass Damper
Terminal Socket
-
GND
+
+
NE5090
FDBK
GND
OPEN
CLOSE
GND
OPEN
Meter Should Measure Approximately
5000 Ohms With Actuator In Middle
Of Full Travel Position. See Item #3 Below
For Instructions.
PWR
Jumper Wire Between
24VAC And Open Or Close
Terminal As Required
FDBK
Modular Cable
24VAC
OPEN
FROM ZONE
CONTROLLER
Actuator Clutch
V3
V4
+
Bypass Damper Components & Wiring
1.) Confirm That All Wiring Is Correctly
Connected To The Bypass & Slave
Interface Card Terminals And The Zone
Manager Bypass Actuator Terminals. Be
Sure The Modular Cable Is Plugged In To
Both The Actuator And The Modular Plug
Labeled "To Actuator" On The Bypass &
Slave Interface Card. If No Wiring Errors
Are Found, Proceed To The Next Step.
4.) Reconnect Power To The Zone
Manager Board. The Damper Actuator
Should Start Its Calibration Procedure And
Move To Its Full Open (Clockwise) Position
And Then To Its Full Closed
(Counterclockwise) Position. If The Damper
Actuator Does Not Move Through Its Full
Calibration Range Proceed To The Next
Step.
2.) Remove Communications Wiring From
The Zone Manager Board Then Remove
The Power From The Zone Manager
Board. Go To The Bypass Damper
Location And Depress Clutch On The
Actuator. Rotate The Actuator Clamp And
Damper Shaft Back And Forth. Check To
Verify That The Damper Moves Freely
From Full Open To Full Closed Position.
Check For Binding Or Interference That
Prevents Full Opening And Closing Of The
Bypass Damper. If The Damper Appears
To Move Freely Proceed To The Next Step.
5.) Remove The Bypass Damper Terminal
Plug From The Bypass Damper Terminal
Socket On The Zone Manager Board As
Shown Above. Run A Jumper Wire From
The 24VAC Power Connection On The
Zone Manager Board To The “Open”
Terminal On The Bypass Damper Terminal
Plug And A Jumper From The GND
Connection On The Zone Manager Board
To The GND Terminal On The Bypass
Damper Terminal Plug. The Green Light On
The Bypass/Slave Interface Card should
Glow. Go To The Bypass Damper Location
To Confirm That The Damper Moves
Towards Its “Open" (Clockwise) Position.
Disconnect The Jumper Wire From The
“Open” Terminal At The Bypass Damper
Terminal Plug And Connect The Jumper
From 24VAC To The “Close” Terminal On
The Bypass Damper Terminal Plug. The
Red Light On The Bypass/Slave Interface
Card should Glow. Go To The Bypass
Damper Location To Confirm That The
Damper Moves Towards Its “Closed”
(Counterclockwise) Position. If The
Actuator Drives In Only One Direction Or
Doesn’t Drive In Either Direction It Is
Probably A Bad Actuator Or Modular
Cable. If It Drives Open And Closed In The
Jumper Test Just Performed But Not When
Connected To The Zone Manager Board,
The Problem Is Probably The Zone
Manager Board.
3.) Depress The Clutch On The Actuator.
Rotate The Damper Shaft To The Middle
Of The Actuator Full Stroke Position (See
Drawing Above For Middle Of Full Stroke
Position Picture). Connect The Meter
Between The Ground And Feedback
Wires On The Bypass & Slave Interface
Card As Shown Above. Meter Should Read
Approximately 5000 Ohms. If The Meter
Does Not Read Approximately 5000 Ohms,
Recheck The Wiring. If No Wiring Errors
Are Found The Problem Is Probably A Bad
Actuator Or Modular Cable.
6.) If You Have Another Actuator Motor
Of The Same Type (One Can Be
Borrowed From Another Zone Or Bypass
Damper), You Can Try Switching Out
The Original Actuator And Using The
Borrowed Actuator To Verify Operation.
Disconnect The 24VAC Power From The
Zone Manager Board. Remove The
Jumper Wire That Was Used In The
Previous Checkout Step. Reconnect The
Bypass Damper Terminal Block To The
Zone Manager Board. Reconnect The
24VAC Power To The Zone Manger
Board. The Damper Actuator Should
Start Its Calibration Procedure And Move
To Its Full Open (Clockwise) Position
And Then To Its Full Closed
(Counterclockwise) Position. If The
Borrowed Damper Actuator Moves
Through Its Full Calibration Range
Replace The Defective Actuator With A
New Actuator.
Figure 4-11: Bypass Damper Troubleshooting
4-38
Auto-Zone Basic
Section 4
Temperature Sensor Resistance Chart
Temperature
(ºF)
Resistance
(Ohms)
Voltage @
Input (VDC)
Temperature
(ºF)
Resistance Voltage @ Input
(Ohms)
(VDC)
-10
-5
0
5
10
15
20
25
30
35
40
45
50
52
54
56
58
60
62
64
66
68
69
70
71
93333
80531
69822
60552
52500
45902
40147
35165
30805
27140
23874
21094
18655
17799
16956
16164
15385
14681
14014
13382
12758
12191
11906
11652
11379
4.620
4.550
4.474
4.390
4.297
4.200
4.095
3.982
3.862
3.737
3.605
3.470
3.330
3.275
3.217
3.160
3.100
3.042
2.985
2.927
2.867
2.810
2.780
2.752
2.722
72
73
74
75
76
78
80
11136
10878
10625
10398
10158
9711
9302
2.695
2.665
2.635
2.607
2.577
2.520
2.465
82
84
86
88
90
95
100
105
110
115
120
125
130
135
140
145
150
8893
8514
8153
7805
7472
6716
6047
5453
4923
4449
4030
3656
3317
3015
2743
2502
2288
2.407
2.352
2.297
2.242
2.187
2.055
1.927
1.805
1.687
1.575
1.469
1.369
1.274
1.185
1.101
1.024
0.952
Table 4-2: Temperature Sensor Resistance
Notes:
1. Use the resistance column to check the thermistor sensor while disconnected from the controllers
(not powered).
2. Use the voltage column to check sensors while connected to powered controllers. Read voltage
with meter set on DC volts. Place the “-” (minus) lead on GND terminal and the “+” (plus) lead
on the sensor input terminal being investigated.
If the voltage is above 5.08 VDC, the sensor or wiring is “open.” If the voltage is less than 0.05
VDC, the sensor or wiring is shorted.
4-39
Auto-Zone Basic
Section 4
Pressure Sensor Voltage Chart
OE271 Duct Static
Pressure Sensor
Pressure
@
Sensor
(“ W.C.)
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
Voltage Pressure
@
@
Input
Sensor
(VDC)
(“ W.C.)
0.25
0.33
0.40
0.48
0.55
0.63
0.70
0.78
0.85
0.93
1.00
1.08
1.15
1.23
1.30
1.38
1.45
1.53
1.60
1.68
1.75
1.83
1.90
1.98
2.05
2.13
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
3.40
3.50
3.60
3.70
3.80
3.90
4.00
4.10
4.20
4.30
4.40
4.50
4.60
4.70
4.80
4.90
5.00
Voltage
@
Input
(VDC)
2.20
2.28
2.35
2.43
2.50
2.58
2.65
2.73
2.80
2.88
2.95
3.03
3.10
3.18
3.25
3.33
3.40
3.48
3.55
3.63
3.70
3.78
3.85
3.93
4.00
Table 4-3: Pressure Sensor Voltage
Notes:
1. Use the voltage column to check the Duct Static Pressure Sensor while connected to powered
controllers. Read voltage with meter set on DC volts. Place the “-” (minus) lead on the GND terminal and the “+” (plus) lead on the SIG terminal on TB1.
4-40
Auto-Zone Basic
Section 4
Figure 4-12: Driver Chip Locations
4-41
Auto-Zone Basic
Section 4
Gently Rock Chip Side To Side And Then
Lift Straight Up To Remove Chip From
Chip Socket.
WARNING!
Be sure the chip you have selected to replace is a
socketed chip. Not all driver chips on the boards
are field replaceable. Only socketed chips may be
removed and replaced in the field. All other chips
that are not socketed will require sending the board
to the WattMaster factory for repair. If you try to
remove a chip that is not socketed it will destroy
the circuit board. Once you have determined that the
chip needing replacement is indeed a socketed chip
please proceed in the following manner.
I.C. Puller
Remove the communications loop connector and
then the 24VAC power connector on the controller
before attempting to change any components.
DAMAGE will occur if components are removed or
installed with power applied.
Chip
Chip Socket
If you are unsure how to safely remove the chip or
about the correct pin placement, please consult the
factory before proceeding.
Using I.C. Puller To Remove Socketed Chip
Printed Circuit
Board
Damage to the board caused by failure to correctly
remove or install the chip is not covered by the
WattMaster warranty.
Use extreme care to avoid inserting the screwdriver
or I.C. Puller under the socket. You must insert the tip
of the screwdriver or ends of the I.C. Puller between
the body of the chip and the chip socket.
Gently Lift The Chip On One End And Rock Chip
Back And Forth With Screwdriver As Shown.
Repeat This Process On The Other End Of Chip.
Alternate This Process On Both Ends Of Chip Until
The Chip Is Free From The Chip Socket.
Small Flathead
Screwdriver
Each chip MUST be installed with Pin 1 in the correct
location. Installing the chip “backwards” will in most
cases destroy the device when power is reapplied.
Direction Of Pull
Chip
Chip Socket
Printed Circuit
Board
Using Screwdriver To Remove Socketed Chip
Pin 1 can be located by looking for the notch in the end
of the chip. Pin 1 on "some" chips is identified with a dot.
Be certain that ALL pins are lined up in the socket
before pressing the chip in. Failure to properly line
up the pins will result in damage to the chip.
This is a VERY common error - BE CAREFUL.
Only after confirming that the chip has been correctly
installed with Pin 1 in the proper position and that the
pins are lined up and none are bent or out of the socket,
should communication or power wiring be reconnected
to the board. Tp prevent possible damage always
reconnect the power wiring first and then the
communication wiring.
Notch
Chip
Dot
Pin1
Chip Socket
Printed Circuit
Board
Top View Of Socketed Chip Assembly
End View Of Socketed Chip Assembly
Figure 4-13: Replacing Driver Chips
4-42
Auto-Zone Basic
Section 4
Index
1 to 16 ............................................... 1, 4
24VAC Power
Wiring ............................................... 9
Actuator
Motor Failure .................................. 27
Troubleshooting .............................. 21
Address 0
Zone Manager ................................... 1
Address 17
Zone Manager ................................... 1
Address Switch Setting
Zone Manager ................................... 3
Addressing
1 to 16 ............................................... 4
Duplicate ........................................... 4
Improper............................................ 4
Zone Controller................................. 4
Air Flow
Insufficient ...................................... 28
Alarm Call-Out ..................................... 5
Bad Duct Sensor ................................. 25
Bad Static Sensor ................................ 25
Bad Zone Sensor ................................. 26
Basic System
Communications Checklist ............... 7
Wiring ............................................... 3
Worksheet ....................................... 15
Blink Codes
Bad Airflow Sensor......................... 18
Bad Zone......................................... 18
Communication Failure .................. 18
Damper Failure ............................... 18
Normal Operation ........................... 18
Override Active............................... 18
Zone Controller............................... 18
Board
Damage ....................................... 9, 11
Bypass Damper
Sticking ........................................... 27
Bypass Damper Calibration ................ 17
Calibration
Failure ............................................. 32
System............................................. 16
Checklist
With CommLink ............................... 7
Without CommLink .......................... 7
Comm Loop
Problems ......................................... 23
COMM LOOP
Troubleshooting ........................ 21, 22
Commissioning ................................... 12
CommLink IV....................................... 7
Communications Loop,
Troubleshooting .......................... 37
Driver Chip Location ...................... 41
Jumper Settings................................. 6
Jumper Switch................................... 2
Overview........................................... 5
R to G.............................................. 37
T to G .............................................. 37
Voltages .......................................... 37
Wiring ............................................... 5
Communications
Overview........................................... 1
Communications Checklist
Basic System..................................... 7
With CommLink ............................... 7
Without CommLink .......................... 7
Communications Loop.......................... 2
Diagnostics........................................ 1
Troubleshooting ................................ 1
Components
Zone Controller............................... 10
Computer
On-Site .............................................. 5
Remote .............................................. 5
Connector Cable
Defective ......................................... 32
Cooling
Locked Out...................................... 19
Short Cycling .................................. 19
4-43
Section 4
Damage
Board........................................... 9, 11
Damper
Binding............................................ 31
Date and Time..................................... 16
Diagnostics
System............................................. 16
Display Screen
Black ............................................... 23
Washed Out..................................... 23
Display Screen Blank.......................... 23
Driver Chip
Locations......................................... 41
Driver Chips
Replacing ........................................ 42
Duct Temp Sensor
Faulty .............................................. 24
Economizer
Errors
Communication................................. 4
Ethernet Router ..................................... 7
Failure
Actuator .......................................... 27
Faulty
Feedback pot ................................... 28
Faulty Pressure Sensor........................ 31
Faulty Sensor ...................................... 25
Faulty Wiring ...................................... 25
Feedback pot
Faulty .............................................. 28
Feedback Pot Failure .......................... 32
Fluctuating Readings ............................ 4
Heating
Locked Out...................................... 19
Short Cycling .................................. 19
Initializing
Zones............................................... 17
Installation
Procedures....................................... 12
IP Module ............................................. 7
Jumper Settings
CommLink IV................................... 6
LEDs
4-44
Auto-Zone Basic
Zone Controller............................... 18
Loop Master .......................................... 1
Maverick Zone
Missing Zone Alarm ........................... 29
Number of Zones ................................ 16
Optional Equipment .............................. 7
Phone Line ............................................ 7
Polarity
Reversing ........................................ 11
Polling For
Zones............................................... 17
Pressure Sensor
Faulty .............................................. 31
Voltage Chart .................................. 40
Prism ..................................................... 7
Procedures
System............................................. 12
Quick Overview
System............................................... 8
R to G
CommLink IV................................. 37
R to SHLD
Zone Controller............................... 35
Zone Manager ................................. 33
REC LED
Remote Link II...................................... 7
Room Sensor
Metering.......................................... 20
Router.................................................... 7
SCAN LED ......................................... 18
Second Stage Heat
Won't Come On............................... 24
Sensor
Faulty .............................................. 25
Single Loop Operation.......................... 1
Slide Adjust
Metering.......................................... 20
Start-Up Delay .................................... 16
Static Null Alarm ................................ 31
STATIC Pressure Null Voltage .......... 16
Static Sensor
Auto-Zone Basic
Faulty .............................................. 25
Steps
System Setup..................................... 7
System
Commissioning ........................... 4, 12
Initiating.......................................... 12
Start-Up........................................... 16
System Diagnostics............................. 16
System Setup
Steps.................................................. 7
T and R Wires
Reversing .......................................... 4
T to G
CommLink IV................................. 37
T to SHLD
Zone Controller............................... 35
Zone Manager ................................. 33
Temperature Sensor
Resistance Chart ............................. 39
token-passing ........................................ 1
Transformer......................................... 11
Troubleshooting Chart ........................ 23
Troubleshooting Checklist.................. 19
Voltage
Too Great .......................................... 9
Wires
Reversing .......................................... 4
Wiring
24VAC Power................................... 9
Basic System..................................... 3
CommLink IV................................... 5
Faulty .............................................. 25
Improper.......................................... 27
Reconnecting .................................. 13
Zone Controller........................... 4, 11
Zone Manager ............................... 3, 9
Worksheet
Basic System................................... 15
Zone
Too Cool ......................................... 19
Too Warm ....................................... 19
Zone Alarm
Missing............................................ 29
Zone Controller
Address ............................................. 1
Address Troubleshooting ................ 21
Section 4
Addressed Incorrectly ..................... 23
Addressing ........................................ 4
Blink Codes..................................... 18
Components .................................... 10
Inputs .............................................. 10
LEDs ............................................... 18
Outputs............................................ 10
R to SHLD ...................................... 35
T to SHLD....................................... 35
Voltages .......................................... 35
Wiring ......................................... 4, 11
Zone Controllers
Overview........................................... 4
Zone Damper
Failed .............................................. 31
Not Working ................................... 21
Zone Manager
Address ............................................. 1
Address 0 .......................................... 1
Address 17 .................................... 1, 5
Address Switch Setting..................... 3
Address Troubleshooting................ 21
Communications ............................... 3
Components ...................................... 8
Correct Wiring .................................. 9
Depicted .......................................... 16
Function ............................................ 1
Initializing Continuously ................ 23
Inputs ................................................ 8
Location, Establishing .................... 12
Outputs.............................................. 8
Overview........................................... 3
R to SHLD ...................................... 33
T to SHLD....................................... 33
Voltages .......................................... 33
Wiring ........................................... 3, 9
Zone Sensor
Bad .................................................. 26
4-45
Section 4
Reading Incorrectly......................... 20
Zones
All Missing ..................................... 31
Aren't Communicating .................... 21
4-46
Auto-Zone Basic
Cool Light Won't Come On ............ 24
Initializing....................................... 17
Not Communicating........................ 21
Polling For ...................................... 17
Auto-Zone Basic
Section 4
4-47
Form: WM-AZB-IO-02C
Printed in the USA
May 2009
All rights reserved.
Copyright 2009
WattMaster Controls, Inc. • 8500 NW River Park Drive • Parkville, MO • 64152
Fax (816) 505-1101
Phone (816) 505-1100
www.wattmaster.com