Mounting and Wiring VMA1200 Series Controllers

Transcription

1 Technical Bulletin Issue Date July 1, 2003 Mounting and Wiring VMA1200 Series Controllers Mounting and Wiring VMA1200 Series Controllers...2 Introduction... 2 Key Concepts... 3 VMA Position and Orientation... 3 Determine and Set Damper Polarity... 3 Wiring and Cabling Precautions... 4 VMA Internal Schematic Diagram... 6 Phone Jack Polarization... 8 Detailed Procedures Preparing the VMA for Mounting Mounting the VMA Setting the Damper Position Wiring the VMA Connecting the LONWORKS Network Bus Johnson Controls, Inc. Code No. LIT M-Tool Release 5.3

2 2 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin Mounting and Wiring VMA1200 Series Controllers Introduction The integrated Variable Air Volume Modular Assembly (VMA), which is a controller/actuator/pressure sensor, mounts on the Variable Air Volume (VAV) terminal box and fastens to the damper shaft. Instructions for wiring the VMA and its accessory devices are also provided in this document. This document describes how to: prepare the VMA for mounting mount the VMA set the damper position wire the VMA connect the LONWORKS Network Bus

3 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 3 Key Concepts VMA Position and Orientation Note: Extra mounting brackets, linkage, or couplers are not required for standard mounting. Consider the following when positioning and orienting the VMA: Mount the VMA on a vertical and flat surface where it functions best, such as the side of the VAV box. Route the tubing so a portion of it is lower than the pressure sensor or loop the tubing. This creates a moisture trap that prevents any condensation from entering the sensor. Do not make any sharp bends in the tubing. This could collapse the tube and block the pressure path. Ensure that wiring terminals and service pin are accessible. Make sure the VMA1200 Installation Bulletin (Part No ) is available for properly identifying terminals. Locate the VMA so that it has adequate clearance for future servicing and is protected from moisture and corrosive fumes. Determine and Set Damper Polarity Damper polarity is established upon installation. Incorrect damper positions in a zone easily result in misdiagnosis of readings, resulting in unnecessary repetition of setup and diagnostics. Many dampers seal properly only when closed in the rotation direction specified by the manufacturer. To simplify maintenance, use the same direction to close on all boxes of the same type. To determine whether the damper is closed Clockwise (CW) or Counterclockwise (CCW): Visually verify which direction opens the damper before duct work is completed and note the information for future reference. Look up the manufacturer s damper model specifications. Once there is airflow in the zone, use a commissioning tool to command the actuator to 100%. If this causes the flow to decrease, it is an indication that the Damper Polarity configuration property must be reversed from its current setting.

4 4 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin To change the damper polarity, set the Damper Polarity configuration property to Reverse, using a Palm compatible handheld device (Version 2.0 or higher operating system) with the VMA1200 Balancing Tool (VBT) software, the Comm Pro commissioning tool, or a LONWORKS Network Services (LNS ) network management tool. Note: The default setting for damper polarity is set to normal, which rotates the damper CCW to close. If it closes in a CW direction, the damper polarity must be changed. Wiring and Cabling Precautions! WARNING: Risk of Electrical Shock. Disconnect each of multiple power supplies before making electrical connections. More than one disconnect may be required to completely de-energize equipment. Contact with components carrying hazardous voltage can cause electrical shock and may result in severe personal injury or death. IMPORTANT: Disconnect all power supplies, as shorting of binary outputs while energized destroys the VMA triac. Read these precautions before touching the terminals or wiring the VMA and its accessories: Make all wiring connections in accordance with the National Electrical Code (NEC) and state and local regulations. For transformer primaries above 150 VAC, the secondary must be earth grounded at the transformer to meet NEC. You can use Terminal 1 as the earth ground. Notes: 24 VAC to 24 VAC isolation transformers are not necessary. The power supply is internally isolated. See VMA Internal Schematic Diagram in this section. For specific methods for wiring the VMA to meet Underwriters Laboratories, Inc. (UL) 864 requirements, refer to the Metasys Smoke Control Wiring Technical Bulletin (LIT ). Locate equipment and route the wiring so that sensor signal wiring is separated from power wiring by at least 150 mm (6 in.). Make all wiring connections to the VMA using only copper conductors. To establish tight, reliable electrical connections, use the correct wire sizes for the terminals. Avoid very thin wire, such as 26 AWG (less than 0.6 mm solid), which tends to break. Follow LONWORKS Network Bus installation rules for either the Bus topology or Free topology bus types.

5 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 5 Do not run LONWORKS Network Bus, Zone Bus, Analog Input (AI), Binary Input (BI), Analog Output (AO), or Binary Output (BO) wiring in the same conduit as line voltage wiring (above 30 VAC), or with wiring that switches power to highly inductive loads such as contactors, coils, motors, or generators. Run Zone Bus, AI, AO, and BI wiring in the same bundle or conduit where convenient. If the BO wiring is not wired through other switches or contacts, such as actuator end-of-travel switches, you may also bundle it with the other I/O (Input/Output) wiring where convenient. The following are additional general wiring considerations: The VMA includes an isolated LONWORKS Network Bus, isolated binary outputs, and isolated 24 VAC. See VMA Internal Schematic Diagram in this section. The 24 VAC power input is internally transformer isolated by the VMA. To meet NEC requirements for line voltage greater than 150 VAC, Terminal 1 (24 VAC) can be earth grounded. Up to 14 cooling-only VMAs (Model VMA1210) are powered from one 100 VA low voltage power limited, Class 2 transformer. The number of VMA1220s per transformer varies, depending on power requirements of the valve actuators and relays. Conduit is not needed for 24 VAC at 100 VA or less. Large insulated spade lugs with a polarizing tab (for high voltage) do not fit on the VMA.

6 6 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin VMA Internal Schematic Diagram Figure 1 is a key diagram showing the different regions of the larger schematic diagram in Figure 2. This detailed diagram displays the following elements as shown in the key diagram below: 1. Isolated Power Supply 2. Earth Ground Connection 3. Airflow and High Temperature Safety Switches 4. Isolated Triacs and Power Wiring for the Airflow and High Temperature Safety Switches 5. Isolated LONWORKS Network Bus 6. Valve Actuators 7. Zone Bus 2. Earth Ground Connection 1. Isolated Power Supply 3. Airflow and High Temperature Safety Switches 4. Isolated Triacs and Power Wiring 5. Isolated LONWORKS Network Bus 6. Valve Actuators 7. Zone Bus vma_small Figure 1: Key to Internal Schematic Diagram (Figure 2)

7 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 7 = Optical or Magnetic Isolation Earth ground is required by NEC if primary is greater than 150 VAC. Primary 24 VAC AFS 24 VAC 1 Synchronous Motor (Actuator) VMA XFR Manual Reset High Temperature +15V 18 BI +15 VDC 26 AI BCOM 0.01 uf +5V up AO 14 AO OPTO Fan Relay BO-1 Reheat BO-2 R R 4 6 Triacs Reheat BO-3 R 8 LONWORKS Network Bus 15 COM 23 COM COM 2 Water Valve 3 CablePRO or CVTPRO 4 In Laptop 1 vma_large Figure 2: VMA Internal Schematic Diagram

8 8 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin Phone Jack Polarization The figure below illustrates the polarization of the 6-pin and 8-pin phone jacks on the VMA or room sensor. Pin 1 is to the extreme left as you face the jack opening, tab notch down. If you need to create your own cable, refer to Fabricating Your Own Interconnection Cable in Appendix A: Reference Information located in the Variable Air Volume Modular Assembly (VMA) 1200 Series Overview and Engineering Guidelines Technical Bulletin (LIT ). Pin 1 VMA Room Sensor 8-pin 6-pin phonejack Figure 3: Phone Jack Polarization Table 1: VMA Phone Jack Pinouts Pin Signal 1 BI-1 Temp Occ/LED (Light-Emitting Diode) 2 AI-2 Setpoint 3 AI-1 Temperature Sensor 4 AI-1 COM (sensor) VDC COM/ZB COM 7 COM (setpoint) 8 ZB

9 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 9 Table 2: TE-6700 Phone Jack Pinouts 8-Pin Jack 6-Pin Jack Pin Signal Pin Signal 1 Heating Setpoint or LED and Manual Override 1 Not Used 2 Setpoint (Cooling) VDC 3 Temperature Sensor 3 COM 4 Temperature Sensor Common 4 Not Used VDC 5 Zone Bus 6 Power Common or Zone Bus Common 6 Not Used 7 Setpoint Common 8 Zone Bus Table 3: TE-6700 Room Sensor Terminal Block Wiring Identification Terminal Signal Destination 1 2 Temperature Sensor and Manual Override* 3 Setpoint Common 4 Setpoint VDC 6 Power Common and Zone Bus Common and Manual Override Common and LED Common* 7 Zone Bus 8 LED and Manual Override* * Manual Override for Temporary Occupied Mode is selected using DIP switches for either Terminals 1 and 2 or 6 and 8 with LED. For more information, see the TE-6700 Series 2nd Generation Temperature Elements Installation Bulletin (LIT ). Note: A dual setpoint is not available with terminal block versions of the TE Table 4: TMZ Phone Jack Pinouts 8-Pin Phone Jack on VMA 6-Pin Phone Jack on TMZ Pin Signal Pin Signal 1 Not Used 1 Not Used 2 Not Used 2 Supply: +15 VDC 3 AI-1, Zone Temperature Sensor 3 Supply/Zone Bus Common 4 AI-1, Sensor Common 4 Not Used 5 Supply: +15 VDC 5 Zone Bus 6 Supply/Zone Bus Common 6 Not Used 7 Not Used 8 Zone Bus

10 10 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin Detailed Procedures Preparing the VMA for Mounting To prepare the VMA for mounting: 1. Check that you have the following equipment: VMA TE-6700, TE-7000 (Europe only), or the TMZ1600 room sensor room sensor cable or wire for connecting the room sensor to the VMA 2. Check that you have the following tools: 8 mm (5/16 in.) square wrench or 10 mm (3/8 in.) 12 point socket for actuator collar screw pliers to turn the damper shaft (if needed) 8 mm (5/16 in.) hex nut driver or 4 in. extension for 5/16 in. socket and power screwdriver for self-drilling screw 3.5 mm (9/64 in.) drill bit (optional) Note: The VMA requires a damper shaft protrusion of at least 44 mm (1-3/4 in.) from the VMA mounting surface. 3. Ensure the VMA installation site meets the following environmental requirements: The VMA location is protected from direct contact with water caused by leaking pipes, condensation, or solder from sweating reheat pipes. The atmosphere is free of explosive vapors or escaping gases. The atmosphere is free of exposure to corrosive chemical or salt vapors, which might damage electrical equipment. The temperature is maintained between 0 to 50 C (32 to 122 F), with the relative humidity (non-condensing) maintained between 10 and 90%. These are operating limits. Flow measurement accuracy suffers if the ambient temperature varies widely within this band. 4. Make sure the VMA mounting location has adequate clearance for future servicing.

11 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 11 Mounting the VMA To mount the VMA: 1. Place the VMA in the desired mounting position on the damper shaft so the wiring terminals are easily accessible. To allow space for VMA movement during damper rotation, locate the shoulder washer at the center of the slot. Make sure the VMA is parallel and mounted flat with the VAV box. If needed, use a spacer to offset tipping of the VMA created by shaft bushings that protrude beyond the box surface. 2. Secure the self-drilling No. 10 screw provided into the VMA mounting slot, using a power screwdriver and socket with 4 in. extension. Alternate mounting: 1. Perform Step 1 as shown previously. 2. Use a punch to mark the position of the shoulder washer, then drill a hole into the VAV box through the mark using a 3.5 mm (9/64 in.) bit. 3. Position the VMA so the shoulder washer is over the hole; insert the mounting screw and tighten against the washer. Note: The mounting screw is threaded into sheet metal and the threads can strip. Do not overtighten. Make sure the screw does not interfere with full damper rotation. Service Pin (Broadcasts Neuron ID) Phone Jack (for Sensor) Mounting Screw Shoulder Washer Bar Code (Neuron ID) Mounting Slot Mount Figure 4: Mounting Screw with Shoulder Washer

12 12 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin Setting the Damper Position To set the damper position: 1. Locate the damper position. The following figure shows three possible icons on the end of the damper shaft. damposit Figure 5: Typical Damper Shaft End Icons 2. Grasp the damper shaft firmly with a pliers and manually position it to fully closed (icon perpendicular to airflow) for 90 boxes. (Use the fully open position for 45 or 60 boxes.) 3. For 90 boxes, push the VMA gear release lever down and position the actuator collar against its internal stop corresponding to the fully closed position. This provides a hard stop for this position. The hard stop for the open position is provided by the VMA. For 45 and 60 boxes, push the VMA gear release down and position the actuator to the fully open damper position. By installing the VMA at the fully open position, the VMA provides the open stop for 45 and 60 boxes. The closed damper seal provides the fully closed stop. Set Screw Collar is rotated to its fully closed position. (CW to close in this example.) LON A LON B SHLD Damper shaft is in fully closed position. Gear Release Lever Endstop Figure 6: Positioning the End Stop

13 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin Tighten the set screw to the shaft using a 8 mm (5/16 in.) wrench or 10 mm (3/8 in.) 12 point socket wrench. Tighten to 17 to 21 N m (150 to 180 lb in [14 lb ft]). Default configuration for the VMA is 90 rotation in 90 seconds. Adjust the Damper Time configuration property for 45 seconds when using a 45 box. 5. Push the gear release lever down, and turn the VMA coupler by hand to ensure that the damper can rotate from full closed to full open positions without binding. 6. Plug or seal the end of a hollow damper shaft to stop cold duct air from affecting the circuitry when the VMA is mounted in another enclosure. 7. Attach the pneumatic tubing to the pressure sensor with the HI (red) tubing connected to the inlet or high pressure side, and clear tubing connected to the low pressure side. 8. Route the tubing as shown below, or tape a loop in the tubing. This provides a low spot for collecting condensation. Low Spot for Collecting Condensation Stdmount Figure 7: Standard Mounting

14 14 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin Wiring the VMA All field wiring, with the exception of the LONWORKS Network Bus, must be kept in the same room with the controllers, to comply with UL smoke control requirements. Refer to the Metasys Smoke Control Wiring Technical Bulletin (LIT ) for details on smoke control requirements. Refer to the project engineering drawings for wiring details. To wire the VMA: 1. Disconnect all power to the VMA. 2. Determine if spade lugs or removable 2- or 3- position screw terminals or phone cable is to be used. See the Variable Air Volume Modular Assembly (VMA) 1200 Series Overview and Engineering Guidelines Technical Bulletin (LIT ) for screw terminal kit order number. 2-position Removable Screw Terminal Connector Snapons Figure 8: Optional Removable Screw Terminals, 2- or 3-position (Accessory) 3. Terminate wiring per engineering drawings. Table 5: Terminations for Cooling Only Applications (VMA1210) Name Description AI-1 * Zone temperature AI-2 * BI-1 * BI-2 BI-3 Zone Bus * Zone setpoint Temporary occupied (TE-6700 and TE-7000 [Europe only]) Comfort (occupied) Window, off (shutdown) Local communication bus * Connected through an 8-pin phone cable from the room sensor.

15 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 15 Table 6: Terminations for Cooling with Reheat Applications (VMA1220) Name Description AI-1 * Zone temperature AI-2 * Zone setpoint AI-3 Humidity transmitter, sideloop, or CO 2 AI-4 AO-1 BI-1 * BI-2 BI-3 BO-1, BO-2, BO-3, BO-4, and BO-5 Zone Bus* Discharge air temperature Primary or Secondary proportional heat Temporary occupied (TE-6700) Comfort (occupied) or occupancy sensor Window, off (shutdown) Fan, primary heat, secondary heat, humidity Local communication bus * Connected through an 8-pin phone cable from the room sensor Note: AI-5 (velocity pressure) and the damper actuator motor are not listed in either of the above tables because they are internal and no wiring is required. Connecting the LONWORKS Network Bus A connection between the VMA and the Network Control Module (NCM) is required if the VMA is to communicate with the Metasys Network. For more information on LONWORKS Networks, see the LONWORKS Network Layout Technical Bulletin (LIT ). To connect the LONWORKS Network Bus: 1. Connect the LonWorks Network Bus wires to the VMA, and continue to the next VMA. Repeat this process for each VMA. Notes: The FTT-10 LONWORKS Network Bus is polarity insensitive. LON A and LON B terminal connections to the FTT-10 bus may be swapped between controllers. A doubly terminated bus gives the greatest wiring distance and requires two terminators on each FTT-10 segment. Free topology requires only one terminator. Contact Johnson Controls customer service at , for more information about LONWORKS network needs.

16 16 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin SHLD LON A LON B To Next LONWORKS Compatible Device Shield LON A LON B To Next LONWORKS Compatible Device or NCM NCMConnect Figure 9: Connecting the VMA to an NCM 2. Apply power. Locate and observe the VMA LEDs. See Tables 7 and 8 for details on the Service and Running LED. Red LED (Service) Green LED (Running) NewLedvm Figure 10: VMA LED Indicator Location

17 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 17 LO Set Screw CW End Stop HI (Red) Screw Numbers 8 TB1-1 6 TB2-7 (18) BI-1 (19) COM (20) BI-2 (21) COM (22) BI-3 (23) COM (24) +15 VDC* (25) +15 VDC (26) AI-1 (27) COM (28) AI-2 (29) COM (30) AI-3* (31) COM* (32) AI-4* (33) COM* (34) ZB+ (35) COM Primary Class2 Energy Limited Transformer** wire Proportional Valve Actuator 24 VAC 3-wire Incremental Valve Actuator 3 7 SHLD Coupler COM Fan Relay 3-wire Baseboard Heat Earth Ground BCOM open close open close (1) 24 VAC (2) 24 VAC (3) Earth Gnd. (optional) (4) BO-1* (5) BCOM* (6) BO-2* (7) BCOM* (8) BO3* (9) BCOM* (10) BO-4* (11) BCOM* (12) BO-5* (13) BCOM* (14) AO-1* (15) COM* LED Color Red (Service) To L ON W ORKS Network Bus AWG (0.8 mm mm 2 ) Green (Running) * ** Off Blinking 3 Blinks then Off On Blinking On Off Description Controller operating properly Included on VMA1220 Only Safety Isolation Transformer in Europe The network table is not configured. Use Comm Pro or a Network Management tool to configure the controller. Response to Wink command from VBT, Comm Pro, or LNS tool To Next LON W ORKS Compatible Device Pneumatic Tubing (differential pressure) Controller problem. Download new firmware. Application is running normally, LED blinks at 1 second interval. TB2-8 TB1-3 TB1-4 TB1-2 Application is not running. Check the power and download a new application. Replace the unit if necessary. TB2-5 TB2-6 Red LED Green LED TE-6700*** TE-7000 (Europe Only) O N *** Preferred DIP Switch Position for TE CCW End Stop 120 VAC -277 VAC State Figure 11: Connections to VMA1200 Series Controllers

18 18 Mounting and Wiring VMA1200 Series Controllers Technical Bulletin Table 7: Service LED Color Name State Description Red Service LED Off Controller is operating properly (lights momentarily on power up and when service pin is pressed). Blinking Unconfigured. Use a network management tool to configure into a network or download new firmware. On Controller problem. Download new firmware. 3 Blinks Wink command has been received. Table 8: Running LED Color Name State Description Green Running LED Blinking Application is running normally, LED blinks at one second interval. On Steady Off Steady Application is not running. Try the following: 1. Check the power. 2. Download a new application. If Steps 1 and 2 do not resolve the problem, replace the VMA controller. Application is not running. Try the following: 1. Check the power. 2. Download a new application. If Steps 1 and 2 do not resolve the problem, replace the VMA controller. Controls Group 507 E. Michigan Street P.O. Box 423 Milwaukee, WI Published in U.S.A.