MODEL CUSTOM CONTROLLER HARDWARE CODE MAX ALLOWABLE AMBIENT TEMP: 70 C (158 F) 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 AND 2) THIS DEVICE MUST ACCEPT ANY INTERFERENCE RECEIVED, INCLUDING INTERFERENCE THAT MAY CAUSE UNDESIRED OPERATION. 20M1 SOFTWARE CODE LISTED ENERGY MANAGEMENT EQUIPMENT C SUBASSEMBLY 20M1 NOVAR CONTROLS CORPORATION COPLEY, OH 44321 5705380-B SERIAL NUMBER MODULE ADDRESS A B C D E F RELAY OUTPUT STATUS The LOGIC ONE Building Management System Custom Controller Installation Instructions DOC. #560309000 A 7/30/04 PRINTED IN U.S.A.
Regulatory Compliance Safety This device has been tested and found to be in compliance with the requirements set forth in UL 916, Energy Management Equipment, and is listed by Underwriters Laboratories, Inc., for installations in the United States. This device has been tested and found to be in compliance with the requirements set forth in C22.2, No. 205-M1983, Signal Equipment, and is Certified by Underwriters Laboratories, Inc., for installations in Canada. Disclaimer Logic One is a registered trademark of Novar Controls Corporation. The material in this manual is for information purposes only. The contents and the product it describes are subject to change without notice. Novar Controls Corporation makes no representations or warranties with respect to this manual. In no event shall Novar Controls Corporation be liable for technical or editorial omissions or mistakes in this manual, nor shall it be liable for any damages, direct or incidental, arising out of or related to the use of this manual. Copyright 2004 by Novar Controls Corporation. All rights reserved. No part of this manual may be reproduced in any form or by any means without prior written permission from Novar Controls Corporation. Novar Controls Corporation 6060 Rockside Woods Blvd., Cleveland, OH 44131 Tel: 800.348.1235 www.novarcontrols.com
Description The Custom Controller (CC) is a dedicated, direct digital control module that provides precise and integrated control of custom applications for rooftop and air-handling units. This Logic One module efficiently controls heating and cooling stages, the fan, and damper operation to provide a fully integrated temperature control system. The CC also incorporates an analog input to monitor the outside air damper position. This document provides instructions for mounting the CC, supplying it with power, wiring the inputs and outputs, connecting it to network communications, setting its address, and checking the installation. Specifications Agency Approvals Listed device: Standards used: CUL/UL E90949 UL 916, Energy Management Equipment CSA C22.2, No. 205-M1983, Signal Equipment Power Requirements Voltage: 24 VAC, Class 2 Consumption: 8 VA Operating Environment Temperature: Humidity: Physical Dimensions Height: Width: Depth: Weight: 40 to 158 F ( 40 to 70 C) 0 to 99% Relative, noncondensing 5.5 inches 8 inches 1.875 inches 1.75 lb Precautions Take the following precautions during installation: Observe national and local electrical codes. Observe voltage and current limits marked on the module. Do not connect 115 volts to any terminal of the CC. It is a Class 2 (low voltage) control device. Doc. #560309000 A 7/30/04 1
Custom Controller Installation Instructions Mounting the Custom Controller The CC is designed to be mounted in the control compartment of the rooftop or air-handling unit. It must be installed so that the unit and mounting hardware do not interfere with proper operation of the rooftop or air-handling equipment. Use the following procedure and refer to Figure 1, as necessary, to mount the CC. Step Procedure 1 Turn off all power to the rooftop or air-handling unit before mounting the CC. 2 Position the CC against the mounting surface and mark the surface to show the location of the four mounting holes. 3 Drill a hole at each of the places marked on the mounting surface. 4 Insert metal screws (not included) through each of the four mounting holes on the CC and into the holes in the mounting surface, tightening each to secure the controller. 8" Mounting Holes 5½" MODEL CUSTOM CONTROLLER HARDWARE CODE MAX ALLOWABLE AMBIENT TEMP: 70 C (158 F) 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 AND 2) THIS DEVICE MUST ACCEPT ANY INTERFERENCE RECEIVED, INCLUDING INTERFERENCE THAT MAY CAUSE UNDESIRED OPERATION. SOFTWARE CODE LISTED ENERGY MANAGEMENT EQUIPMENT C 20M1 SUBASSEMBLY 20M1 NOVAR CONTROLS CORPORATION COPLEY, OH 44321 5705380-B SERIAL NUMBER MODULE ADDRESS A B C D E F RELAY OUTPUT STATUS Mounting Holes The LOGIC ONE Building Management System Figure 1. Mounting holes on the Custom Controller 2 Doc. #560309000 A 7/30/04
Supplying the Custom Controller with Power The CC is powered by 24-volts alternating current and rated 8 VA. Connect the 24 volts to Terminals 15 and 16, located under the Power VAC 8VA label (see Figure 2). NOTE! The 24-VAC power connection is isolated. One transformer can be used to power multiple modules within the restrictions of an 8-VA consumption. Wiring the Inputs Auxiliary Potentiometer The CC has a removable terminal strip that uses screw connections. The inputs are Terminals 1 through 10, located on the left side of the strip (see Figure 2). Terminals 13 and 14 under the Analog Outputs label are also used as inputs to monitor feedback from an electric damper actuator. The following procedure should be used to connect an auxiliary potentiometer to the CC. Step Procedure 1 Connect the wiper wire to Terminal 1 under the Aux Pot label. 2 Connect the clockwise wire to Terminal 2 under the Aux Pot label. 3 Connect the counterclockwise wire to Terminal 4 at the Temp Sensor Input label. This connection makes it possible to adjust the zone setpoint. The Novar Controls Futura Temperature Sensor (Model FTS-3A) can be used with the CC to provide optional setpoint adjustment (potentiometers). Installation instructions are supplied with the sensor. Figure 2. Custom Controller terminal strip Doc. #560309000 A 7/30/04 3
Temperature Sensor Each CC must use a Remote Temperature Sensor (RTS-UVC) for discharge air in addition to one of the following: UVC Wall-Mount Indoor Temperature Sensor (WTS-UVC) Futura Temperature Sensor (FTS-3 or FTS-3A) with temperature setpoint adjustment The temperature sensor input terminals are located under the Temp Sensor Input label on the terminal strip. Use the following procedure to connect the temperature sensors. Step Procedure 1 Connect the Wall-Mount Temperature Sensor s plus (+) wire to Terminal 3. 2 Connect the Remote Temperature Sensor s red wire to Terminal 5. 3 Connect the black ( ) wire from both sensors to Terminal 4. To wire the other sensors to the CC, refer to their specific installation instructions. NOTE! Maximum recommended sensor wire length for connecting the temperature sensors to the CC is 100 feet, using 22-gauge wire (Belden 8761, Novar Controls WIR-1010, or equivalent). Status Input Override Switch Input Terminals 6, 7, and 8, labeled Status Input, are for digital input connections. Terminals 6 and 7 are for the fan status and Terminals 7 and 8 are for the dirty filter status. These are dry contact closure, digital inputs and are connected as normally open with the fan status closing when the fan is on and the filter status closing when the filter is dirty. A normally open momentary contact switch and a status light-emitting diode (LED) can be connected to Terminals 9 and 10 under the Override Switch label. The override s effective time period is defined in the software. The Novar Controls Futura Temperature Sensor provides an override switch and status LED. Its installation instructions outline the proper connections. 4 Doc. #560309000 A 7/30/04
Damper Feedback Sensor Terminals 13 and 14, under the Analog Outputs label, can be used as an analog input (0 to 10 VDC) to monitor a feedback signal from an electric damper actuator. This feedback signal measures actual damper motor feedback between 0 and 10 VDC, linear. Figure 3 provides a wiring diagram of this feedback signal. AUX POT TEMP SENSOR INPUT STATUS INPUT OVER- RIDE SWITCH ANALOG OUTPUTS 0-10VDC, 1mA MAX ADJ +5V S1 COM S2 DI 1 RET DI 2 O/R RET D E F GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 + FEEDBACK FROM DAMPER ACTUATOR 0-10 VDC Figure 3. Damper analog input wiring Wiring the Outputs Table 1 shows the output configuration for the CC. Terminal 11 (D) Terminal 12 (E) Terminal 13 (F) Table 1. ANALOG DIGITAL OUTPUTS Custom Controller Outputs CONTROL OPERATION Damper output signal Not Active Analog input CONTROL OPERATION Terminal 21 (A) Fan Terminal 22 (B) Cooling 2 Terminal 23 (C) Heating 2 Terminal 24 (D) Not Active Terminal 25 (E) Heating 1 Terminal 26 (F) Cooling 1 Doc. #560309000 A 7/30/04 5
Damper Analog Output Relay Outputs The analog output terminals are listed under the Analog Outputs label, immediately to the right of the input connections (see Figure 2). Connect the damper to the CC at Terminal 11 (analog output D). This isa0to10-vdc, 1 ma maximum connection. Terminals 13 (output F) and 14 are used as an analog input for a feedback signal from a damper actuator (see Wiring the Inputs ). Terminal 12 (output E) is not active. The digital relay output terminals are located at the far right side of the terminal strip under the Relay Outputs label (see Figure 2). Terminals 21 through 26 (outputs A through F) are the actual output connections. Figure 2 and Table 1 can be used to determine the proper connections. Digital relay output D is not active because of the analog damper connection. The digital relay outputs tie in directly to the six relay output status LEDs located on the case of the CC. The relay output status LEDs match the status of the relay. If the contact is closed, the relay is energized and the LED is on. If the contact is open, the relay is de-energized and the LED is off. Terminal 20 is for one side of a 24-volt source to be controlled (switched) through outputs A through F. The relay outputs are isolated from the other connections to permit the additional power source. One transformer can be used to power both the CC and the relay outputs if the transformer has enough capacity. Network Communications A suitable two-conductor shielded cable (Novar Controls WIR-1010 or equivalent recommended) should be used to make the communication connections between the CC and the module communications terminals of the executive module. On the CC, the connections are Terminals 17, 18, and 19, located under the Module Network label. The plus (+) and minus ( ) connections must be made correctly. CAUTION! The Shield connection is not a ground like the other common grounds on the terminal strip. It is dedicated for communications only. Do not connect any other grounds to the Shield connection (Terminal 18). 6 Doc. #560309000 A 7/30/04
Setting the Module Address Every Logic One module must have a unique address for the executive module to identify it. Addresses are assigned in the software during programming. The system printout shows the address of the CC being installed. Set the switches with the correct address from 00 to 63 (see Figure 4) and record the setting on the module address label. The address switches are located in the center of the terminal strip (see Figure 2). NOTE! Address 00 should not be used by the CC if it is operating on an Executive Controller (EC) or Savvy. The IOM section of the EC or Savvy uses address 00. Figure 4. Custom Controller address settings Doc. #560309000 A 7/30/04 7
Checking Installation The following items should be checked to verify proper installation. Turn on the power to the CC and the rooftop or air-handling unit and its control circuitry. If the executive module is operating properly, the CC begins to control the air-handling equipment in about 3 minutes (after performing a self-diagnostic check and establishing communications with the executive module). A schedule status indicator LED is located on the module s case above the terminal strip. If the module is communicating properly, this LED should be flashing according to the schedule mode. When the CC is in scheduled off mode, the LED is off and flashes on briefly when communicating. When the CC is in scheduled on mode, the LED is on and flashes off briefly when communicating. If a timed override switch has been installed and programmed, it can be tested for proper operation by pressing it during a scheduled off mode. The LED flashes rapidly until the override period ends. The six relay output status LEDs indicate the status of each active digital output. Verify that the LEDs are lit when the corresponding digital output is on. Monitor the executive module. If any faults or malfunctions still exist, they are picked up by the executive module and announced by alarm messages. The CC s setpoints can be altered from the executive module s keypad, and the status display can be monitored for proper equipment response. Model and Part Numbers Use the part numbers shown in Table 2 to order the appropriate Novar Controls parts. Table 2. Novar Controls Part Numbers PRODUCT MODEL NO. PART NO. Custom Controller 738008000 Futura Temperature Sensor (20 to 127 F) FTS-3 with temperature adjustment potentiometer FTS-3 FTS-3A 732403000 732401000 Remote Temperature Sensor (for use with UVC, ETC, HPC Plus, and ETM-3051) Wall-Mount Temperature Sensor (for use with UVC, ETC, HPC Plus, and ETM-3051) Two-conductor shielded cable (Belden equivalent #8761) RTS-UVC 736003000 WTS-UVC 736002000 WIR-1010 709001000 8 Doc. #560309000 A 7/30/04