Variable Air Volume Modular Assembly (VMA) 1200 Series Overview and Engineering Guidelines

Transcription

1 LONWORKS Systems Manual Section Issue Date 0501 TECHNICAL BULLETIN Variable Air Volume Modular Assembly () 1200 Series Overview and Engineering Guidelines 1200 Series Overview and Engineering Guide... *3 Introduction...*3 Key Concepts...* Series Models... *4 Definition of Terms... *6 Theory of Operation... *9 Establish Zones...12 Room Sensor Placement...12 Pressure Independent...13 Airflow Rate... *13 Power Source... *14 LONWORKS Network Topology... *17 Inputs and Outputs... *19 CablePRO... *21 CVTPRO... *21 Software Tools... *21 Related Documentation... *22 Procedure Overview Detailed Procedures...*24 Determining VAV Box Requirements... *24 Establishing the Room Schedule...25 Developing Bills of Material and Placing Orders...26 Configuring the...27 *Indicates those sections where changes have occurred since the last printing Johnson Controls, Inc. Code No. LIT

2 Appendix A: Reference Information... *28 Introduction Wiring List... *29 Wiring Interface Diagram... *31 Parts List... *32 FCC Part 15 Label...33 Specifications... *34 Fabricating Your Own Interconnection Cable... *38 Sensor Interface... *39 Appendix B: Application Example... *42 Single Duct Application Example... *42 *Indicates those sections where changes have occurred since the last printing.

3 1200 Series Overview and Engineering Guidelines Series Overview and Engineering Guide Introduction The Variable Air Volume Modular Assembly () 1200 Series is a configurable, integrated module that includes a Variable Air Volume (VAV) controller, actuator, and differential pressure sensor. The is offered as two models: cooling only and cooling with reheat. The models, which use the LonTalk protocol, are designed for pressure independent, single duct systems. The reheat model can be used with parallel or series fan powered boxes. This manual is a reference tool for engineering 1200 installations and applications. It is also a training tool to learn about the 1200 Series controllers. It is task oriented for easy reference to specific tasks. Refer to the appendixes at the end of this document for wiring tables and diagrams, a parts list, specifications, and an application example. This document describes how to: determine VAV box requirements establish the room schedule develop bills of material and place orders configure the

4 Key Concepts 1200 Series Models Table 1: Feature Checklist Features Applications Pattern Recognition Adaptive Control (PRAC) on Zone Proportional Plus Integral (PI) Temperature Loops Adaptive Flow Control Loops Single Duct, Pressure Independent VAV Side Loops without Interlocking Fan Powered Boxes Incremental, Proportional, and Three Stages of Box Heat Incremental, Proportional Two Position, or One Stage Supplemental Heat Damper Actuator Clockwise (CW)/Counterclockwise (CCW) Rotation Selection Table 1 lists 1200 Series features. Table 2 shows available 1200 models. Comments Eliminates manual tuning and seasonal retuning. No manual tuning, improved control and energy savings Meets most VAV applications. Single Analog Input (AI) to Analog Output (AO)/Binary Output (BO) Series or parallel Up to three stages or normally open/closed valves Normally open or closed valves Set via M-Pro software, 1200 Balancing Tool (VBT) software, or network management tool for either direction to close. Software/Tools Ability to Download Code Firmware Firmware code is upgradeable without removing the. Diagnostics Moving Average Flow/Temperature Provides standard measure of control loop performance Diagnostic over time. Actuator Duty Cycle Diagnostic Indicates shaft slippage. Commissioning Balancing Tool with Automatic K-factor Palm compatible handheld device (Version 2.0 or later Calculation operating system) on Zone Bus Hardware 24 VAC Isolation Eliminates 24 to 24 VAC transformer and polarity concerns. Multiple s Powered by a 100 VA Transformer Isolated Communication, Binary Outputs, and 24 VAC Ability to Drive Low Current Relays Down to 25 ma 13-Bit Analog Input/8-Bit Analog Output Resolution Analog Input Jumpers Eliminated Continued on next page... Up to 14 cooling only. Number of reheat/fan units depends on power consumption of valve/fan relays. Saves installed cost and improved electrical noise rejection. Eliminates relay chatter. High accuracy and good device control All analog inputs are preset reducing labor.

5 1200 Series Overview and Engineering Guidelines 5 Features (Cont.) Differential Pressure Transducer Dead Ended Transducer Capacitive Technology Industry Accepted Flow Measurement Accuracy Temperature Sensors Variety of Sensors Temporary Occupied Button Temporary Occupied Light-Emitting Diode (LED) LED Indicator for Operation Power/Communication Physical Small, One Piece Assembly 102 x 153 x 102 mm (4 x 6 x 4 in.) Plenum Plastic Housing Rating Removable Input/Output (I/O) Screw Terminals Node Installation Service Pin Message Wink Function Bar Code Label Comments No filters or maintenance required. Improved stability Even for flows below 250 fpm (1.25 m/s) typical Nickel, 1K platinum, 2.25K NTC On TMZ1600, TE-6700, TE-7000 (Europe only) Series room sensors On TMZ1600, TE-6700, TE-7000 (Europe only) Series room sensors for Occupied and Unoccupied modes Verifies operation and power connections. Prewired to reduce installed cost. UL 94-5VB plenum flammability may eliminate metal box (check local codes). Two or three position accessory kits Local pushbutton and remote access from Palm compatible handheld device Initiate via Palm compatible handheld device or network management tool. Two removable bar code labels printed with Neuron ID

6 Table 2: 1200 Series Models Inputs/Outputs Points Rating 1210 (Cooling Only) Analog Inputs: Zone Temperature AI-1 1K Ni or Pt or 2.25K NTC Zone Setpoint AI-2 1.6K ohm Potentiometer (Pot.) Humidity, Dewpoint, or Sideloop AI VDC Supply Air Temperature or AI-4 1K Ni or Pt or 2.25K NTC Supplemental Heat Temperature Velocity Pressure Internal inch W.C. (0-436 pa) Binary Inputs: Temporary Occupied/ Standby/Room Sensor LED Occupied Off or Window or Shutdown BI-1 BI-2 BI-3 Dry contact Dry contact Dry contact 1220 (Cooling w/reheat) Analog Outputs: Proportional Heat AO ma Binary Outputs: Fan Box Heat--Incremental Valve or 1-3-stage Electric Supplemental Heat--Incremental Valve or 1-3-stage Electric BO-1 to BO-5 24 VAC 0.5A Actuator Motor Internal Definition of Terms Auto Calibration The has an Auto Calibration mode that runs periodically to adjust the pressure sensor calibration due to offset tolerance and mounting position. Binding A process performed by a network management tool that connects Network Variable Outputs (NVOs) and Network Variable Inputs (NVIs). These connections provide for peer-to-peer data transfers. Commissioning Verification of controller inputs and outputs and modification of the controller configuration properties to meet installation specifications. Configuration Properties Data stored in non-volatile memory (Flash) in the controller that is accessible from a network management tool.

7 1200 Series Overview and Engineering Guidelines 7 Configuring Building an application within the controller to establish the required control sequence, setting the functionality of the controller. Downloading Writing the Heating, Ventilating, and Air Conditioning (HVAC) application data and configuration properties to the controller. This is accomplished using a software tool with a Personal Computer (PC). LONWORKS Network Services (LNS ) Protocol Network management system protocol for LONWORKS devices. LONWORKS FTT-10A Transceiver The Free Topology Transceiver (FTT) interface between the 1200 and the physical network. M-Pro A software tool used to configure and download controllers. M-Pro software is part of the System Tools in M-Tool. Neuron The microprocessor used in the. Each neuron has a unique 48-bit ID for node identification. NVI/NVO LONMARK term for Network Variable Inputs/Outputs. These variables may be read/written by network management tools. They may be bound to other network variables in a system. Palm Compatible Handheld Device A handheld computer that uses software to configure and balance the The PalmPilot unit is an example of this device. SCPT/UCPT LONMARK terms for Standard Configuration Property Type and User Configuration Property Type. SNVT/UNVT LONMARK term for Standard/User Network Variable Types. A SNVT/UNVT defines the units, structure, and resolution of the configuration properties, NVIs and NVOs.

8 Test and Balance (TAB) Test and Balance (TAB) is a function performed to ensure the installed system operates to design specifications. Balancing of the zone indicates whether the VAV terminal box achieves minimum/maximum airflow settings. TAB must also be performed for the air handler and the air duct distribution to the VAV box. Variable Air Volume (VAV) Controller An Application Specific Controller (ASC) used for digital control of single duct, dual duct, fan powered, and supply/exhaust VAV box applications. Variable Air Volume Modular Assembly () Includes a digital controller with integrated pressure transducer and actuator. Zone Bus A local interface between the controller and the room sensor. By connecting a Palm compatible handheld device with the proper software to the CablePRO or CVTPROx00-0 and room sensor, the Zone Bus allows you to monitor and commission directly through the room sensor.

9 1200 Series Overview and Engineering Guidelines 9 Theory of Operation VAV systems are most easily understood by considering them as cooling applications. As the zone temperature increases due to heat produced by people, computers, or other heat sources, the opens the VAV box damper and lets cooler air in. The size of the space and the internal and external heat loads dictate the volume of air required to maintain a zone temperature setpoint. In addition, since the size of the VAV box dictates its maximum cooling capacity, VAV box performance is dependent upon the design engineer sizing the box for each zone. If the installed unit is too small, insufficient cooling results, and excessive flow rates cause audible noise. If the installed unit is too large, proper control is difficult to maintain, since a small change in damper position causes excessive airflow change. Boxes are sometimes oversized to ensure quiet operation or to reserve cooling capacity as zone usage changes. A cooling only VAV system maintains a constant zone temperature while varying the flow of air to the space. This is unlike a constant volume system that maintains a constant volume of airflow to the space but varies the temperature of the air stream in response to space temperature changes. VAV systems are predominantly single duct, but some are dual duct designs. The can be configured for most single duct pressure independent VAV applications. The M-Pro software (part of M-Tool Release 2.0) is used to configure and download 1200 applications. The actuator drives the damper from full open to full closed in 90 seconds. The incorporates flow feedback to accurately position the damper and to minimize position hunting and motor runtime. Control performance metrics are recorded and are available via network variables to the Metasys Operator Workstation (OWS). Figure 1 shows the 1200 in the Metasys Network. Figure 2 is a functional block diagram of the 1200.

10 N1 LAN Network Control Module (NCM) Operator Workstation (with OWS, M-Pro, and LNS Software) LONWORKS Compatible Devices LONWORKS Network Bus Zone Bus Room Sensor FTT-10 Palm Compatible Handheld Device CVTPRO Converter CablePRO Converter Zone Bus Room Sensor Palm Compatible Handheld Device Figure 1: 1200 Controllers in Metasys Network Diagram MNET

11 1200 Series Overview and Engineering Guidelines 11 LONW ORKS Network FTT-10 Interface Window Open Occupancy Sensor Temp Occ Button Digital Inputs x3 Neuron Application Processor Phone Jack TE-6700, TMZ1600, or Palm Compatible Handheld Device COP8 IO Processor Zone Bus Space Temperature Space Setpoint Auxiliary Temperature Analog Inputs x5 Isolated Analog Output x1 Heating Valve Auxiliary 0-10V Triac Outputs x7 Five 24 VAC Outputs for Fan, Staged Heating, etc. CW CCW Hi Low Differential Pressure (DP) Sensor Actuator Motor Fblock2 Figure 2: 1200 Functional Block Diagram

12 Establish Zones Room Sensor Placement When designing systems, establishing zones correctly is critical to take maximum advantage of the s exceptional accuracy and rapid response capabilities. The designer strives for the most uniform indoor environmental conditions possible. A single thermostatic device (room sensor) controls each area. A zone could also be thought of as an area where the load is considered the same for every square foot of floor space. HVAC system zones fall into two major categories: exterior zones and interior zones. Exterior zones are spaces directly affected by outdoor weather conditions. Heat losses or outdoor air conditions do not influence interior zones. Interior zones usually have cooling or ventilation requirements only. Further divisions of interior/exterior zones may be required to accommodate different occupancy schedules and/or solar loads. Variations in internal loading dictate the selection of separate zones. For example, in a restaurant, the kitchen has vastly different heating and cooling requirements from the seating area. Consider room sensor placement for each zone, making sure to: Verify that the room sensor is the correct one for the application. Review architectural requirements such as furniture height and location, aesthetics, and type of mounting. Wall plates are required if mounting on a conduit handibox. Review room sensor location. The best room sensor location is on an interior wall, about five feet above the floor, out of direct sunlight, out of the direct path of supply air from the diffuser, away from heat sources, such as equipment, machines, and perimeter radiation, and away from doors and other draft sources. Mounting height may be affected by local codes or the accessibility needs of persons with disabilities. Do not locate a sensor near zone boundaries where primary influence is from an adjacent zone.

13 1200 Series Overview and Engineering Guidelines 13 Pressure Independent Airflow Rate The pressure independent employs patented self-tuning, cascaded proportional/integral control loops. The zone temperature loop samples space temperature and resets the airflow setpoint between the minimum and maximum flow settings. Since inlet duct static pressure influences the amount of air passing through the VAV box, the airflow loop samples airflow via a flow pickup in the box inlet. It modulates the damper to control the flow. Thus, the VAV box flow is independent of duct static pressure. The engineering basis for this method of control is that the temperature of a space with a constant load is linearly proportional to the flow of conditioned air into the space. The engineer must accurately determine the required maximum and minimum flow for each space based on heating, cooling, and ventilation loads. The determines airflow rate by dynamic pressure measurement. The contains a Differential Pressure Transmitter (DPT) to sense differential pressure in pressure independent VAV applications. The DPT is connected to the VAV box airflow pickups. It measures differential pressure and generates a proportional voltage signal. The voltage signal from the DPT is read by the and converted to airflow in cubic feet per minute (cfm) or liters per second. The DPT provides maintenance-free performance within the control range of 1.25 to 18 m/s (250 to 3500 feet per minute [fpm]) when used as recommended. The minimum 1.25 m/s (250 fpm) velocity and the gain of the airflow pickup produce an accurately measured pressure difference. The Auto Calibration function helps reduce the temperature effect error by zeroing offset errors. As the ambient temperature swings relative to the temperature at which the Auto Calibration occurred, an offset error may occur (typically ±0.179 Pa/ C [± inch W.C./ F]). When calibration occurs, this error becomes zero. The error envelope becomes smaller with increased airflow pickup gain and with smaller ambient temperature deviations at the transmitter location.

14 Power Source You can use one 24 VAC power trunk to power multiple s. In this case, transformers of up to 100 VA are centrally located, and the secondary run is without conduit and without concern about polarity. Notes: The 24V power transformer must be UL/CSA listed as NEC Class 2 Power Limited. See NEC Article 725/Class 2 (30 VRMS maximum) and (100 VA maximum). The 1210 draws 7 VA including the internal damper actuator. Therefore, 14 s can be powered from one 100 VA transformer without conduit. The number of 1220s is dependent on the binary output loads and reheat actuators. The reheat actuators must be added to the 7 VA of the controller, then divided into the 100 VA transformer power. For example, the 1220 draws 7 VA without loads. If there were only a single VA-8020 reheat valve per, its 4 VA must be added to the for a total of 11 VA. Then nine /VA8020s can be powered from one 100 VA transformer. Table 3 shows the power rating for several cooling/heating coil valve actuators. The valve power plus the power must not exceed 100 VA. If a device is not listed in the following table, refer to the product literature for that device. Table 3: Actuator VA Power Rating Actuator Type Power Rating VA-8020 Incremental 4 VA VA-8050 Incremental 6 VA VA-7200 Incremental 6.7 VA J Series Electric Zone Valve On Off 7 VA VA-8022 Voltage (0 to 10 VDC) 4 VA VA-8052 Voltage (0 to 10 VDC) 6 VA VA-7202 Voltage (0 to 10 VDC) 6.7 VA VA-7450 Incremental 2.5 VA VA-7452 Voltage (0 to 10 VDC) 2.5 VA VA-7050 Thermal (DAO) 3 VA VA-7310 Incremental 2 VA VA-7312 Voltage (0 to 10 VDC) 2 VA VA-7010 On/Off 7 VA VA-7150 Incremental 2.7 VA VA-7152 Voltage (0 to 10 VDC) 4.7 VA

15 1200 Series Overview and Engineering Guidelines 15 When using a single transformer and running 24 VAC to multiple s, use a wire gauge large enough for the load. The voltage drop on the 24 VAC cabling is much higher than for line voltage wiring for the same power draw. For a 100 VA (equivalent to 100 watt) load at 120 VAC, only 0.8 ampere is required. However, at 24 VAC, over four amperes are needed. Current draw determines the wire size. Two connection methods are available. In the first method, individual spade lugs accept a single 10 to 22 American Wire Gauge (AWG)/4 mm 2 to 0.8 mm wire and still fit on 6 mm (1/4 inch) tabs. In the second method, optional screw terminals are assembled over the spade lugs. The screw terminals accept up to a single 12 AWG (4 mm 2 ) wire or two 14 AWG (2.5 mm 2 ) wires. When two wires are crimped into one spade lug, a larger spade lug barrel is needed. Alternately, a wire nut can connect two heavy wires to a short 152 mm (6 inch) thinner wire. < 88 ft of 14 AWG > 24 VAC 100 VA Example 1: All s are at one end. 24 VAC 100 VA < 176 ft of 14 AWG > < 176 ft of 14 AWG > Example 2: Transformer is centered. Cablelength Figure 3: Power Cable Lengths A standard 14 AWG (2.5 mm 2 ) wire (top example in Figure 3) is limited to 27m (88 feet) with 14 cooling only s when the s are all located at one end of the cable. If the transformer is centered (bottom example in above figure) with seven s on the left and seven s on the right, the distance in each direction can be increased. This is because the current (and voltage drop) are halved in each direction. In this example, both the left and the right legs can be increased to 54m (176 feet) from the transformer, creating a 108m (352 foot) total length.

16 Table 4 and Table 5 indicate the relationship between wire length and power at the end of wires. Table 4: Maximum Wire Length for Given Power/Gauge (U.S. Measurements) Power (VA) at End of Wire Wire Size 8 Gauge 10 Gauge 12 Gauge 14 Gauge 16 Gauge 18 Gauge Wire Length (Feet) Table 5: Maximum Wire Length for Given Power/ Wire Gauge (Metric Measurements) Power (VA) at End of Wire Wire Size 4 mm mm mm 2 Wire Length (Meters)

17 1200 Series Overview and Engineering Guidelines 17 LONWORKS Network Topology The LONWORKS FTT-10A used by the 1200 supports free network topologies. Table 6 describes free topologies, and Figures 4 and 5 show supported topologies. For more information, see the LONWORKS Network Layout Technical Bulletin (LIT ). Table 6: Free Topologies Category Architecture Termination Connection Free Topology Bus, star, ring, or mixed Single termination for star, ring, or mixed Double termination for bus Connected by stub/multi-drop Free Topology (Tree or Star) Legend: LONW ORKS Compatible Device (Including NCM350/361) Free Topology Terminator Free_Top Figure 4: Free Topology

18 Daisy-chained Bus Topology Stub-wired Bus Topology Legend: LONW ORKS Compatible Device (Including NCM350/361) Bus End-of-Line (EOL) Terminator Bus_Top Figure 5: Bus Topology Table 7 contains a specification example for the FTT-10A Transceiver. This is just one example of the many available wiring styles. For more complete information, refer to Echelon Corporation LONWORKS FTT-10A Transceiver User s Guide. Table 7: FTT-10A Transceiver Specification Example Transceiver Topology Bit Rate Maximum Node to Node Distance Maximum Total Wire Length FTT-10/FTT-10A Free Maximum Nodes 64 Node Application Current * Belden 85102, 8471 Cable 78 kbps 500m (1640 ft)* 500m (1640 ft)* NA

19 1200 Series Overview and Engineering Guidelines 19 Inputs and Outputs For specific input/output range, wire length, wire size issues, refer to the Wiring List in Appendix A: Reference Information at the back of this document. Note: All terminals are spade lug type except the LONWORKS Network Bus terminals, which are removable screw terminals. Optional two or three position kits can be ordered to convert the spade lugs to removable screw terminals. See Table 12. Binary Inputs There are three dry contact binary inputs on the A manual override button on the room sensor initiates a Temporary Occupancy mode of operation. The TE-6700 room sensor includes an LED in series with the button to show the occupancy mode. The switch can be pushed for as little as 0.2 seconds to detect a change. The binary inputs on the are inactive when open. They are active when a contact closure to binary input common (COM) is applied. Binary Outputs The has zero (1210) or five (1220) user accessible binary outputs. The damper actuator is wired internal to the. Each load is connected between the BO terminal and BCOM common terminal. When required to meet codes, the 24 VAC terminal of the /transformer can be earth grounded. In this situation, the binary outputs switch the transformer s low side to the relays and actuators. Analog Outputs There is one analog output on the The 1210 has no analog outputs. The load is connected between the analog output and analog output common (COM) terminals. The output is controlled to generate a proportional voltage output of 0 to 10 VDC. The maximum load for each output is 10 ma with a minimum load resistance of 1000 ohms.

20 Analog Inputs There are two external and one internal analog inputs on the 1210 and four external and one internal analog inputs on the They are preset for either temperature, setpoint, or voltage. There are no jumpers to set. Shielding is not required, but if used, earth ground the shield only at the. You may use 24 AWG (0.6 mm) twisted pair wire; however, this reduces the allowable wire length due to the resistance. To minimize sensor error caused by field wiring, the total resistance of the nickel or platinum resistive sensor wiring should be less than 3 ohms. The NTC sensor accepts a larger wire resistance. This wiring error effect is corrected through configuration properties using a commissioning tool. Do not share the temperature or setpoint common wire with voltage or current transmitters on the Zone Bus. The maximum voltage drop on the common wire must be less than 1 mv. Zone Bus The Zone Bus is a 2-wire local communications bus that allows a Palm compatible handheld device with Johnson Controls 1200 Balancing Tool (VBT) software to commission and balance the. The Zone Bus connector also provides 15 VDC power to the CablePRO or CVTPRO. The bus sustains no damage in the presence of fault voltages of 15 VDC or 24 VAC. Table 8: Zone Bus Specifications Type Multi-drop serial communications bus Speed 1200 baud (bits per second) Recommended Cable Type 1.5 mm 2 (18 AWG) with or without shield (Belden 8760) or 0.6 mm (24 AWG) without shield (unshielded telephone cable) Maximum Bus Length 150 meters (500 feet) with 1.5 mm 2 (18 AWG) cable or 15 meters (50 feet) with 0.6 mm (24 AWG) cable Voltages Logic High Voltage Logic Low Voltage 4 VDC minimum (approximately) 1 VDC maximum (approximately) Data Transmission 1 Start Bit (low level) 8 Data Bits (least significant bit first) 1 Stop Bit (high level) Isolation Isolated from 24 VAC, Binary Outputs (BO), and LONWORKS Network Bus

21 1200 Series Overview and Engineering Guidelines 21 CablePRO CVTPRO Software Tools CablePRO (AS-CBLPRO) is an interface device used between a Palm compatible handheld device and the. It is used for box balancing or commissioning via the Zone Bus communication port. When used with a, the CablePRO is strictly an electrical interface between the serial RS-232 port of the Palm compatible handheld device and the Zone Bus. CablePRO operates on 15 VDC, drawn from a through the Zone Bus phone jack. The data rate on both the RS-232 and the Zone Bus is 1200 baud. The connection to the RS-232 COM port of the Palm compatible handheld device is by means of a DB9 or DB25 connector supplied with the CablePRO. Refer to the Auxiliary Gear Technical Bulletin (LIT ) for more information on the CablePRO. CVTPRO (AS-CVTPROx00-0) is a Zone Bus/N2 interface device that is used between a Palm compatible handheld device and the. It is used for box balancing or commissioning via the Zone Bus communication port. When used with a, the CVTPRO is strictly an electrical interface between the serial RS-232 port of the Palm compatible handheld device and the Zone Bus. CablePRO operates on 15 VDC, drawn from a through the Zone Bus phone jack. The data rate on both the RS-232 and the Zone Bus is 1200 baud. Refer to the Auxiliary Gear Technical Bulletin (LIT ) for more information on the CVTPRO. M-Tool software tools allow you to commission, configure, and balance the Use M-Pro software to configure and download applications. The 1200 Balancing Tool (VBT) software allows you to balance and perform limited commissioning. The Comm Pro commissioning tool performs commissioning operations, such as reading and writing network variables and configuration properties or downloading new firmware to the controller. In addition, a number of third-party network management tools (e.g., LonMaker software) allow you to read/write network variables and configuration properties and bind network variables. See Table 13 in Appendix A: Reference Information for additional software details.

22 Related Documentation Table 9: Related Documentation Table 9 lists related 1200 documentation. For Information on This Use This Document: Sales and Marketing information 1200 Series Controller Product Bulletin (LIT ) in the Metasys Network Sales Resource Manual (FAN 635) and the LONWORKS Systems Manual (FAN 1162) Installing the 1200 Installation Bulletin, Part No (Packed with product) Downloading and Commissioning Details Mounting and Wiring Information Downloading and Commissioning 1200 Series Controllers Technical Bulletin (LIT ) Comm Pro User s Guide (LIT ) Mounting and Wiring 1200 Series Controllers Technical Bulletin (LIT ) Troubleshooting 1200 Troubleshooting 1200 Series Controllers Technical Bulletin (LIT ) Connecting to the Metasys Network Technical Manual (FAN 636) NCM/Workstation Installing M-Pro and VBT M-Tool Manual (FAN 693) Configuring the 1200 M-Pro User s Guide (LIT ) Variable Air Volume Modular Assembly () 1200 Series Controllers Application Note (LIT ) Balancing the 1200 Using the 1200 Balancing Tool (VBT) Software Technical Bulletin (LIT ) Working with LONWORKS Networks and Devices LONWORKS Network Layout Technical Bulletin (LIT ) and LONWORKS Compatible Devices Supported by NCM350 Technical Bulletin (LIT ).

23 1200 Series Overview and Engineering Guidelines 23 Procedure Overview Table 10: Engineering the Procedure Overview To Do This Follow These Steps: Determine VAV Box Select the. Requirements Establish sensor placement in zones. Coordinate and authorize mounting. Establish the Room Schedule Develop application configuration files. Determine control strategy. Select room sensors. Create source power drawings. Determine quantity needed of all components. Develop Bills of Material and Make sure all items are included. Place Orders Coordinate parts ordering and delivery. Configure the Reference appropriate room schedules. Select control sequences using M-Pro. Create configuration files. Archive and document applications. Download applications.

24 Detailed Procedures Determining VAV Box Requirements To determine VAV box requirements: 1. Select the based on control sequence, Input/Output (I/O), side loops, and flow measurement accuracy requirements for single duct boxes. Refer to the discussion of Airflow Rate in the Key Concepts section of this document. 2. Establish sensor placement in zones. 3. Contact box manufacturer s representative to authorize mounting or mount on site. Notes: Damper shafts must protrude 44 mm (1-3/4 in.) or more from the box. The accommodates damper shafts greater than 44 mm (1-3/4 in.) in length from the box exit. Shaft bushings may interfere with flat mounting of the. If needed, use a spacer to keep the parallel to the mounting surface. Things to consider: project install date plans and specifications wiring diagrams and specifications to box manufacturer who does what including: mounting, connecting, downloading, testing, and shipping who provides which parts including: control enclosure and transformer 4. Coordinate field or factory mounting.

25 1200 Series Overview and Engineering Guidelines 25 Establishing the Room Schedule To establish the room schedule: 1. Develop application configuration files based on project requirements. For flow calculation constants, refer to the Variable Air Volume Modular Assembly () 1200 Series Controllers Application Note (LIT ). 2. Determine control strategy. Note: The 1200 is for single duct applications only. Use other standard Johnson Controls VAV controllers for dual duct and supply/exhaust applications. 3. Select appropriate room sensors based on project specifications. Typically, each requires a room sensor. 4. Create source power drawings. Determine such things as line length, transformer count and layout, and power distribution. 5. Determine number of: s other control devices room sensors valves valve actuators transformers phone cables accessories such as screw terminal kits

26 Developing Bills of Material and Placing Orders To write up the bill of material and place orders: 1. Make sure the following items are included as required: valves valve actuators room sensors (one per ) s cables transformers box fan speed controllers - for information about the Johnson Controls S66 Series Electronic Fan Speed Control, refer to the S66 Series Electronic Fan Speed Control Product/Technical Bulletin (LIT ) Part No in the Installation Sheets Manual (FAN 121). Notes: The differential pressure sensor and the damper actuator are included as part of the. Room sensors cannot be hardwired/shared between s; however, sensors may be shared by connecting network variables using a LONMARK network management tool. 2. Coordinate parts ordering and delivery, including: placing orders through Johnson Controls Customer Service determining shipping destinations coordinating manufacturing and delivery issues coordinating box manufacturer issues coordinating boxes with s delivered to job determining status of software, documentation, and drawings Note: The can be shipped in individual packages or bulk shipped (maximum ten s per box).

27 1200 Series Overview and Engineering Guidelines 27 Configuring the Configure the as specified in room schedules. To configure the : 1. Refer to the appropriate room schedule for room specifications. 2. Select control sequences using M-Pro software. Refer to M-Pro User s Guide (LIT ). 3. Create individual configuration files for each device or each set of similar devices. 4. Archive and document the applications and configuration as needed. Downloading can be performed through the LONWORKS Network Bus. Refer to the M-Pro User s Guide (LIT ) for additional configuration information.

28 Appendix A: Reference Information Introduction The following tables are to be used for wiring, parts, and specification reference.

29 1200 Series Overview and Engineering Guidelines 29 Wiring List Table 11 provides a wiring list for the Figure 6 highlights the electronic isolation of the Note: Table 11: Wiring List Point Description Range Input or Load Impedance AI-1* AI-2* AI-3* AI-4* AI-5* BI-1* BI-2* BI-3* Zone Temperature Zone Setpoint Humidity Transmitter or CO 2 Sensor Perimeter Temperature or Supply Air Temperature Velocity Pressure (internal) Temporary Occupied Comfort (occupied) Window, Off (shutdown) 1K ohm Nickel, or Pt 2.25K ohm NTC 1.6K ohm 2-wire Pot. All field terminals are power limited when powered by a Class 2 transformer. Maximum Voltage Maximum Current 10K ohm 5 VDC 0.5 ma Wire Size in mm 2 or mm (AWG) 10K ohm 5 VDC 0.5 ma 0.6 mm to 1.5 mm 2 (24 to 18) 10K ohm 5 VDC 0.5 ma 0-10 VDC 1.1M ohm 16.5 VDC 15 ua 0.6 mm to 1.5 mm 2 (24 to 18) 1K ohm Nickel, or Pt 2.25K ohm NTC 0 to 1.75 in. W.C./0.5 to 2.0 VDC 0-5 VDC, 3V trigger 0-15 VDC, 2.5V trigger 0-15 VDC, 2.5V trigger 10K ohm 5 VDC 0.5 ma 10K ohm 5 VDC 0.5 ma 0.6 mm to 1.5 mm 2 (24 to 18) Cable Length in Meters (Feet) 1.5 mm 2 (18) 150 (500) 0.6 mm (24) 30 (100) 150 (500) 1.5 mm 2 (18) 150 (500) 0.6 mm (24) 30 (100) 150 (500) 1.5 mm 2 (18) 150 (500) 0.6 mm (24) 30 (100) 150 (500) 100K ohm 5 VDC 20 ua NA Internal 440 ohm 5 VDC 10 ma 47K ohm 17 VDC 0.1 ma 0.6 mm to 1.5 mm 2 (24 to 18) 47K ohm 17 VDC 0.1 ma 0.6 mm to 1.5 mm 2 (24 to 18) AO-1* Proportional Heat/ Humidity Fan Speed 0-10 VDC 1K-10M ohm 10 VDC 10 ma * Isolated from 24 VAC Continued on next page mm 2 (18) 150 (500) 0.6 mm (24) 30 (100) 150 (500) 150 (500) 1.5 mm 2 (18) 150 (500) 0.6 mm (24) 60 (200)

30 Point (Cont.) BO-1, 2,3,4,5^ AM-1^ Network Bus*^ Zone Bus* Room Sensor Cable* +15 VDC* 24 VAC Power In^ Description Range Input or Load Impedance Fan, Box/ Supplemental Heat, Electric Heat, Lighting Actuator motor (internal) Networking Bus Local Room Sensor Bus AI-1, AI-2, BI-1, Zone Bus, and +15 VDC DC Output Supply AC Supply Voltage ma 24 VAC 4 VA ±5V transmit, ±0.2V receive Maximum Voltage Maximum Current ohm 30 VAC 100 ma 100 ma 500 ma 500 ma Wire Size in mm 2 or mm (AWG) 1.5 mm 2 (18) 0.6 mm (24) 1.5 mm 2 (18) 0.6 mm (24) Cable Length in Meters (Feet) 150 (500) 30 (100) 30 (100) 6 (20) 144 ohm 30 VAC 100 ma NA Internal 200 ohm line 5 VDC 100 ma 0.6 mm to 1.5 mm 2 (24 to 18) See + 0 to 5V >3000 ohm 5 VDC 100 ma 1.5 mm 2 (18) 150 (500) 0.6 mm (24) 30 (100) See above. 0.6 mm (24) 7.5 (25) eight conductor 15 (50) phone cable 22.5 (75) 30 (100) VDC 1K-10M ohm 18 VDC 35 ma 1.5 mm 2 (18) 150 (500) 0.6 mm (24) 60 (200) VAC ohm 30 VAC 0.3 ampere 6 mm 2 (10) 67 (222) ~ for 6 mm 2 (12) 42 (140) ~ 1210; 1.3 ampere 2.5 mm 2 (14) 27 (88) ~ for 1.5 mm 2 (16) 17 (55) ~ mm 2 (18) 11 (35) ~ Notes: * Isolated from 24 VAC ^ Isolated from AI, BI, AO, Zone Bus, 15 VDC + See LONWORKS Network Layout Technical Bulletin (LIT ). ~ Length using 100 VA VAC, Motor, BO AI AO BI Microprocessor +15 VDC Power Supply ZB LONWORKS Communications Circuit Isolation Figure 6: Electronic Isolation

31 1200 Series Overview and Engineering Guidelines 31 Wiring Interface Diagram LO Set Screw CW End Stop HI (Red) Pneumatic Tubing (Differential pressure) Screw Numbers 8 TB1-1 6 TB2-7 (18) BI-1 (19) COM TB2-8 TB1-3 TB1-4 TB TB2-5 TB (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+ LON B LON A SHLD TE-6700*** TE-7000 (Europe Only) (35) COM O N *** Preferred DIP Switch Position for TE ON ORKS To L W Network Bus AWG (0.8 mm mm 2 ) Coupler CCW End Stop Primary 120 VAC -277 VAC Class 2 Energy Limited Transformer** 2-wire Proportional Valve Actuator 24 VAC COM Fan Relay 3-wire 3-wire Earth Ground BCOM Open Close Open (1) 24 VAC (2) 24 VAC (3) Earth Gnd. (Optional) (4) BO-1* (5) BCOM* (6) BO-2* (7) BCOM* (8) BO-3* (9) BCOM* (10) BO-4* (11) BCOM* (12) BO-5* (13) BCOM* (14) AO-1* (15) COM* Incremental Valve Actuator Close Baseboard Heat LED Color Red (Service) Green (Running) * ** State Off Blinking 3 Blinks then Off On Blinking On Off Description Controller operating properly Included on 1220 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 Controller problem Download new firmware. Application is running normally, LED blinks at one second interval. Application is not running. Check the power and download a new application. Replace the unit if necessary. Red LED Green LED To Next LONWORKS Compatible Device Figure 7: Wiring Interface

32 Parts List Table 12 lists hardware accessories. Table 13 lists software requirements and options. Table 12: Hardware Accessories (Order Separately) Transformer AS-XFR050 AS-XFR100 Y63 through Y66 Series Screw Terminal Kit AP-TBK Removable 2-position screw terminal kit (100 pcs)* AP-TBK Removable 3-position screw terminal kit (100 pcs)* AP-TBK3COMM-0 Replacement LONWORKS Network Bus 3-position screw terminal kit (10 pcs) * These terminals fit over the existing I/O spade lugs. Room Sensors TMZ-1600, TE-6700, TE-7000 (Europe only) 8-pin Room Sensor Communication Cables Electronic Fan Speed Controller Handheld Interface (for Balancing Tool software) Converter (for Handheld Interface) Interface Accessories (for Converter) See the Room Sensor with LCD Display (TMZ1600) Technical Bulletin (LIT ) and the TE-6700 Series 2nd Generation Temperature Elements Product Bulletin (LIT ) for information on room sensor accessories. S66AA-1C or S66DC-1C. See S66 Series Electronic Fan Speed Control Product/Technical Bulletin (LIT ) for specifications. Palm compatible handheld device (Version 2.0 or later operating system). See Using the 1200 Balancing Tool (VBT) Software Technical Bulletin (LIT ) for more information on device compatibility. AS-CBLPRO-2 or AS-CVTPROx00-0 Required for AS-CBLPRO-2 only: Palm V Travel Kit cable (for the Palm V) or Palm HotSync cable (for all other Palm models), DB9M/DB9F Null Modem Adapter, DB9M/DB9M Gender Changer. Table 13: Software Item Microsoft Windows 95, Windows 98, or Windows NT software 1200 Balancing Tool (VBT) M-Pro software Comm Pro Commissioning Tool LONWORKS Network Services (LNS) Network Management Tool (Optional) Comments Platform Used for Balancing. Part of M-Tool. (Required for Configuration.) Can be used as a plug-in with third-party network management tools or standalone. Part of M-Tool. Can be used to commission a 1200 controller. Part of M-Tool. Use a network management tool (e.g., LonMaker software) for commissioning tasks.

33 1200 Series Overview and Engineering Guidelines 33 FCC Part 15 Label This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of Federal Communications Commission (FCC) rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his/her own expense. This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference. 2. This device must accept any interference that may cause undesired operation. This Class A and B digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations.

34 Specifications Table 14: Basic Specifications Product Name Product Code Number Supply Voltage Optional Fuse Current Power Consumption Ambient Operating Conditions Ambient Storage Conditions Terminations Optional Terminations Network Interfaces LONWORKS Controller Addressing Communications Protocols Mounting Housing Variable Air Volume Modular Assembly () AP (cooling only) or AP (cooling with reheat/fan) 20 to 30 VAC at 50 or 60 Hz 0.3 ampere for 1210, 1.3 ampere for a 1220 fully loaded 7 VA maximum (relay and valve requirements not included) 0 to 50 C (32 to 122 F) 10 to 90% RH non-condensing, limited by a 30 C (86 F) maximum dewpoint -40 to 70 C (-40 to 158 F) 6.3 mm (1/4 inch) spade lugs. (Communications has removable screw terminals included.) 2 or 3 position screw terminals that plug into spade lugs (accessories) LONWORKS Network Bus and Zone Bus Unique 48-bit ID LONWORKS Network Bus between controller and NCM (2-wire) Zone Bus between controller and room sensor (8 pin phone jack or wire to spade lugs) One screw mounts the to the VAV box. One screw attaches damper shaft to the actuator 8 mm (5/16 inch) square head set screw with 44 N. m (375 lb. in) of axial holding torque for up to 13 mm (1/2 inch) round damper shafts. Minimum damper shaft length is 44.5 mm (1 3/4 inch). Plastic housing for controller, sensor and actuator with UL 94-5V Plenum Flammability Rating x x mm (6 x 4 x 4 inch) Dimensions (L x W x H) Actuator Rating 4 N. m (35 lb. in) minimum Shipping Weight 13.1 kg (29 lb) for a box of ten; 1.3 kg (2.8 lb) each Electrical Inputs Analog Inputs: (Input configurations vary based on model type) - Nickel (1K ohm Johnson Controls), or Platinum (1K ohm DIN 385) or NTC (2.25K ohm Fenwal) room sensors - 1.6K ohm setpoint potentiometer (2-wire) - Voltage Input for 0 to 10 VDC (humidity, dewpoint sensor, or sideloop) Binary Inputs: dry contacts Combination contact input w/led driver for temporary occupancy on TE-6700 Velocity Pressure Velocity Pressure for 0 to 436 Pascal (0 to 1.75 inch W.C.) Outputs No outputs on AP , except internal damper actuator Binary Outputs: 24 VAC triac switched; 25 to 500 ma loads Damper Actuator: 90 rotation in 90 seconds Analog Output: 0 to 10 VDC at 10 ma Standards Compliance CSA 22.2 No. 205 UL 916 UL 864 (UUKL) UL 94-5VB FCC Part 15, Subpart B, Class A and B CISPR 22, Residential Class B CE Directive (89/336/EEC, EN50081/1, EN50082/2) Industrial and Residential IEEE 472 ANSI C62.41 A/B (IEEE 587 Category A/B) C-tick Australia/NZ, AS/NZS IEC 950 IEC , -2, -3, -4, -5, -6 Refer to the Metasys Smoke Control Wiring Technical Bulletin (LIT ) in the Metasys Network Technical Manual (FAN 636) for details on smoke control compliance requirements.

35 1200 Series Overview and Engineering Guidelines 35 All specifications are for the controller pressure sensor and actuator only, measured at the midpoint of each range within 90 days of calibration at room temperature. Table 15: Additional Detailed Specifications Power Input Voltage Range Input Current Transient Protection LONWORKS Network Bus Communications Bus Type and Voltage Bus Speed Transient Protection Zone Bus Communications Bus Type and Voltage Bus Speed Transient Protection Microprocessor/Memory Microprocessor Memory DC Supply Output Voltage Range Load Current Overload and Transient Protection Pressure Input (AI-5) Range Proof Pressure Burst Pressure Resolution Non-repeatability and Hysteresis 20 to 30 VAC; 50 or 60 Hz 0.3 ampere without relays or valves Control circuitry is transformer isolated from input power. Common and Normal mode capacitor FTT-10A, 2.5V differential signal 78k Baud Transformer isolated from 24 VAC, BOs, AI, BI, AO, ZBus, +15 VDC; Spark gaps, series blocking capacitors, clamping diodes, transformer Single-ended 5 VDC 1200 Baud Isolated from 24 VAC, BOs, and LONWORKS communications circuit; PTC+Transorb; Common mode capacitors Neuron 3150 processor operating at 10 MHz 56K byte Flash 14 to 18 VDC 0 to 35 ma Current Foldback; Isolated from 24 VAC, BOs, and LONWORKS communications circuit; Common mode capacitors 0 to 435 Pascal (0 to 1.75 inch W.C.) 6895 Pascal (1 psi) Pascal (10 psi) Pascal ( inch W.C.) ±0.187 Pascal (± inch W.C. maximum) Non-linearity (Best Fit) ±2 Pascal (±0.008 inch W.C. maximum) for 0 to 249 Pa (0 to 1 inch W.C.) ±3 Pascal (±0.012 inch W.C. maximum) above 249 Pa (>1 inch W.C.) Thermal Effect on Zero* ±0.179 Pascal per degree C (± inch W.C. per degree F maximum) Thermal Effect on Span ±0.179 Pascal per degree C (± inch W.C. per degree F maximum) Position Effect on Zero* ±0.623 Pascal (± inch W.C. maximum) Position Effect on Full Span ±0.623 Pascal (± inch W.C. maximum) Long Term Zero Drift* ±2.49 Pascal per year (±0.01 inch W.C. per year maximum) Long Term Span Drift ±2.49 Pascal per year (±0.01 inch W.C. per year maximum) Sample Time One second Continued on next page...

36 Additional Specifications (Cont.) Temperature Inputs (AI-1, AI-2, AI-4) (AP-1220 only for AI-4) Range NTC: 0 to 40 C (32 to 104 F) Platinum: 0 to 40 C (32 to 104 F) Nickel: 0 to 40 C (32 to 104 F) Setpoint: 18 to 30 C (65 to 85 F) Resolution (13 bit) NTC: C ( F) Platinum: C ( F) Nickel: C ( F) Setpoint: C ( F) Non-repeatability and Hysteresis (estimate) NTC: Platinum: Nickel: Setpoint: ±0.009 C (±0.016 F) maximum ±0.189 C (±0.340 F) ±0.138 C (±0.248 F) ±0.005 C (±0.009 F) maximum Measurement Accuracy NTC: ±0.03 C (±0.05 F) maximum Platinum: ±0.68 C (±1.23 F) maximum Nickel: ±0.50 C (±0.90 F) maximum Setpoint: ±0.15 C (±0.27 F) maximum Thermal Tolerance Long Term Drift Sample Time Transient Protection Temporary Occupied Response Time (AI-1) Voltage Input (AI-3) ±0.020% per C (±0.036% per F) maximum ±0.07% per year maximum One second Isolated from 24 VAC, BOs, and LONWORKS communications circuit; Normal mode RC; Common mode capacitors 100 ms (AP-1220 only) Range 0 to 10.0 VDC (0 to 2000 PPM CO 2) Resolution (13 bit) mv (0.15 PPM CO 2) Non-repeatability and Hysteresis (estimate) ±0.012 V maximum (±2.4 PPM CO 2) Measurement Accuracy ±75 mv maximum (±15 PPM CO 2) Thermal Tolerance Long Term Drift Sample Time Transient Protection Binary Inputs Voltage Range and Trigger Level Sample Time Transient Protection Continued on next page... ±0.028% per C (±0.050% per F) maximum ±0.7% per year maximum One second Isolated from 24 VAC, BOs, and LONWORKS communications circuit; Normal mode RC; Common mode capacitors BI-1: 0 to 5 VDC with 3.1 VDC threshold BI-2 and BI-3: 0 to 5 VDC with 2.5 VDC threshold 50 ms pulse width (10 Hz maximum) Isolated from 24 VAC, BOs, and LONWORKS communications circuit Normal mode RC; Common mode capacitors

37 1200 Series Overview and Engineering Guidelines 37 Additional Specifications (Cont.) Analog Output (AO-1) (AP-1220 only) Voltage Range Load Current Voltage Resolution (8 bit) Linearity and Hysteresis Voltage Accuracy Thermal Tolerance Long Term Drift Time Constant Transient Protection Binary Outputs (BO-1 through BO-5) Voltage Range Load Current Time Constant Transient Protection Motor Actuator Output Rated Running Torque Unpowered Holding Torque Stall Torque Stroke Angular Velocity Full Stroke Life Reposition Stroke Life Reposition Accuracy Acoustic Noise 0 to 10 VDC 0 to 10 ma 0.04 VDC ±0.04 VDC maximum ±3% full scale ±0.005% per C (±0.009% per F) maximum ±0.7% per year maximum one second (seven seconds for steady state) Isolated from 24 VAC, BOs, and LONWORKS communications circuit; Common mode capacitors (AP-1220 only) 20 to 30 VAC 25 to 500 ma 50 ms Isolated from AI, BI, AO, ZBus, +15 VDC, and LONWORKS communications circuit; Common mode capacitors; Normal mode capacitors and resistors 4 N m (35 lb in) minimum 5.1 N m (45 lb in) minimum 9.1 N m (80 lb in) maximum 93±3 degrees maximum 1 degree per second nominal 100,000 cycles minimum 2,500,000 cycles minimum ±1 degree maximum 30 dba at one meter maximum * Use the Auto Calibration function to correct. Specifications are deemed accurate but are subject to change.

38 Fabricating Your Own Interconnection Cable You must construct any fabricated interconnection cable, so the same color wire on both ends of the cable align with Pin 1 in the plug. This provides a consistent field assembly of the cable. Figure 8 illustrates the interconnection cable Controller Phone Plug BI-1 AI-2 AI-1 AI-1 COM +15 VDC ZB COM AI COM ZB+ Phone Connectors (Clip Side Out) TE-6700 Room Sensor Phone Plug Cblfab_1 Figure 8: Interconnection Cable Note: This is not typical of preassembled phone cable purchased in retail stores. A telephone system cable is wired opposite of the Zone Sensor requirements.