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Design, InstallationAnd Operations Manual

Basic System

Revision 02B

Auto-Zone BasicDesign, 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-02BAuto-Zone is a registered trademark of WattMaster Controls, Inc.

Copyright 2003 WattMaster Controls, Inc.All rights reserved.

Section 1

Design Guide

Table of ContentsConventions .....................................................................1General Information.........................................................3

Description of System Components.................................................................................3Design Considerations.....................................................5

Zone Diversity .................................................................................................................5Cooling - Partial Load Conditions ...................................................................................5Heating - Partial Load Conditions ...................................................................................7Override Conditions.........................................................................................................7Building Pressurization....................................................................................................7

Design Guide....................................................................8Step #1 - Zoning ..............................................................................................................8Step #2 - Sizing the Central Unit ...................................................................................10Step #3 - Duct Design Considerations...........................................................................10Step #4 - Room Air Motion/Diffuser Selection.............................................................11Step #5 - Bypass Damper Sizing ...................................................................................11Step #6 - Zone Dampers ................................................................................................13Round Dampers .............................................................................................................15Rectangular Dampers.....................................................................................................15Pressure Independent Zone Dampers ............................................................................16

Auxiliary Heat Control Options......................................17Relay Expansion Board .................................................................................................18

Table of Figures & TablesFigure 1-1: Auto-Zone Basic System .............................................................................2Figure 1-2: Control Zones Affected by the Outdoor Load .............................................9Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control ............12Figure 1-4: Round Damper Dimensions.......................................................................14Figure 1-5: Rectangular Damper & Kit Dimensions....................................................14Table 1-1: Round Air Damper Selection .....................................................................15Table 1-2: Rectangular Damper Selection...................................................................15Table 1-3: Pressure Independent Flow Factors............................................................16

Auto-Zone Basic Section 1

Design Guide 1-1

ConventionsThis document uses the following definitions throughout as a guide to the user indetermining 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 willnot otherwise damage components.

Warning: Errors which can result in damage to equipment and void warranties.

Section 1 Auto-Zone Basic

1-2 Design Guide

Figure 1-1: Auto-Zone Basic System

CommLink IISingle Loop

(Optional)

Computer(Optional)

Zone Air DampersUp to 16 Zone Air Dampers Allowed

RS-4859600 Baud

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Design Guide 1-3

General InformationThe primary application of the Auto-Zone system is to provide multiple controlledcomfort zones from a single zone, constant volume, and unitary heating and air-conditioning package unit. It can also be applied to existing installations for improvedcomfort to multiple zones currently controlled by a single thermostat.

Description of System ComponentsA typical Auto-Zone system is comprised of the following four basic components.

Zone ManagerThe Zone Manager is a microprocessor based controller which monitors up to 16 zonesin the system. The zone manager then controls the HVAC unit to satisfy the requirementsof each individual zone while maintaining efficient operation and comfort. The zonemanager is also responsible for controlling duct static pressure.

In the Auto-Zone Basic version, the Zone Manager has a display and a keypad. The 4 lineby 20 character display is backlighted making it easier to read in low light environments.

Bypass DamperThe bypass damper controls proper duct static pressure to insure proper airflow. Thedamper is modulated by the Zone Manager, based on a signal received from the staticpressure sensor connected to the main duct.

Zone ControllerThe Zone Controller monitors space temperature and allocates proper airflow to theassigned zone to achieve desired comfort and ventilation levels. If supply air temperaturewill benefit the local zone temperature setpoint, the zone damper modulates to reduce orincrease airflow as needed. If supply air will not benefit the local zone, the controller willdirect the damper actuator to a minimum position and wait for a change in supply airtemperature.


1-4 Design Guide

Zone SensorThe patented zone sensor is of a flush, wall mounted design. A special plate on the faceof the sensor accurately senses space conditions. As a result of its unique design, the zonesensor rejects the influence of internal wall temperature effects. The sensor comes in fourdifferent 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.


Design Guide 1-5

Design ConsiderationsConsider the following items when designing a system using Auto-Zone.

Zone DiversityThe Auto-Zone system is designed to improve tenant comfort by dynamically re-balancing the air distribution when used with a typical constant volume rooftopheating/cooling unit. If zones with extremely different load conditions are serviced by asingle rooftop unit, the result will be poor control and excessive wear due to cycling ofthe 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 mustmix zones under these conditions, consider using either VAV boxes with heat or separatebaseboard heat on exterior zones. Auto-Zone systems offer a variety of methods tocontrol additional zone heat to help you avoid problems.

Cooling - Partial Load ConditionsThe engineer must be aware of several potential problems when applying the Auto-Zonesystem during cold weather operation.

Low Ambient Temperature LockoutDuring very cold weather it is common for mechanical systems to have “low templockouts” which protect equipment from damage if operated under these conditions.Auto-Zone also provides user programmed lockouts for protection purposes, althoughmechanical safeties should always be used as the final stage of protection.

If the rooftop unit services interior zones with thermal loads which require cooling whenoutside temperatures are below the safe operating limits for your equipment, you shouldseriously consider installing an economizer on your rooftop unit. The Auto-Zone controlsystem is designed to take advantage of an economizer if it is installed. The use of aneconomizer will save money on utilities and provide comfort under conditions when it isnot possible to operate the mechanical cooling system.

Low Supply Air TemperaturesUnder lightly loaded conditions much of the supply air may be bypassed back into thereturn airside of the system. This bypassing will result in the lowering of the supply air


1-6 Design Guide

temperature, which this may result in the supply air temperature reaching the low tempsafety 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 themechanical system will result if this condition persists. Comfort may also suffer if thesystem cannot run long enough to satisfy cooling demands.

A number of things can be done to reduce this problem. Some of these things dependupon the type of installation.

• Avoid oversizing the unit. Do your load calculations carefully. Since Auto-Zonedirects the heating or cooling to the zones which require it, you may find that you canuse a smaller unit in many cases. Oversizing is the number one cause of excessivelow 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 causeover 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 ductedreturns 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 excessivestatic pressures.

Warning: If the fan system has the capability of producing static pressures whichcould damage ductwork you must provide a manual reset, highpressure limit switch to cut-off the fan system in the event of highduct static. Do not use your Auto-Zone system as a safety device!

• Use an Economizer. Although this is not a cure-all, it greatly improves operationduring cool weather when cooling loads are minimal. Using an Economizer alsoimproves ventilation and lowers operating costs, both of which are significant.


Design Guide 1-7

Heating - Partial Load ConditionsHeating 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 tomost problems. Refer to the Auxiliary Heat Control Options topic near the end of thissection.

Override ConditionsAfter-hours overrides can produce aggravated partial load conditions in both the heatingand cooling modes. The problem is most commonly caused by a single zone beingoverridden for after-hours use. This causes the rooftop equipment to operate for only onezone. The Auto-Zone system offers an improved solution to this common problem byallowing a single override to trigger a group of zones via a “global” override. This allowsthe system to operate with sufficient load to reduce cycling caused by light loadconditions.

Building PressurizationIf you are using an economizer, building pressurization must be addressed. Failure toproperly handle building pressurization may result in doors remaining open when theeconomizer is operating. Pressurization problems can render economizer operationuseless. The following suggestions will help to avoid potential problems.

• Use powered exhaust when the system uses ducted returns. The return duct pressuredrop will cause most barometric relief dampers to function poorly or not at all. Auto-Zone has the ability to control a powered exhaust whenever the economizer isoperating.

• Use a separate building pressure control which operates a relief fan or dampers.


1-8 Design Guide

Design GuideThere are six basic steps to designing an Auto-Zone system:

1. Zoning2. Sizing the Central Unit3. Duct Design Considerations4. Room Air Motion / Diffuser Selection5. Bypass Damper Sizing6. Sizing Zone Dampers

Step #1 - ZoningDetermine the number of zones. A single air handler unit can have no more than 16zones. If the number of zones exceeds 16 then more than one Zone Manager will berequired. Consider using the Auto-Zone Plus system if more than one Zone Manager isrequired.

The primary precaution to be taken in applying the Auto-Zone System is to select thezoning so that no zone will be at maximum (design) heating (or cooling) load when anyother zone requires the opposite temperature air to satisfy its load. For example,depending on the wall, ceiling and 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 distincttemperature or control zones that are affected uniquely by the outdoor load. These zonesare depicted in Figure 1-2.

Depending on the size of the building and partition layout, some of these zones mayoverlap or be insignificant from a zoning standpoint. For example, Zone 10 could bemultiple conference or computer rooms where additional zoning would be required, or itcould be as small as a corridor where no zoning is required. Similarly, zones 4 and 5could have no external windows and no partitions between them and could be considereda single zone. Zone 3 could be divided into multiple offices with full partitions betweenthem, thus requiring separate Zone Controllers because of different internal loads, but thesame external load.

Generally, the greater the number of individual Zone Controllers, the greater the comfort.The designer will have to look at the specific building, balancing the costs of multiplezones with the added comfort possible with multiple zones, to match the owner'srequirements.


Design Guide 1-9

It is important to recognize that there are purely internal zones, such as Zone 10, whichmay contain separate offices/conference/computer rooms. These internal zones couldeasily have high cooling requirements while external zones (1,2,3, etc.) could be at ornear design heating load. This is a misapplication of the Auto-Zone – Basic or Plus (orany heating/cooling changeover) system. The interior zones with cooling only loadsshould be served with a separate air-conditioning unit (that could be zoned betweenmultiple rooms with a similar load profile). Supplemental heat could be added to theperimeter zones and controlled with the auxiliary heat control board from the ZoneController. System performance will generally be compromised and frequent changeoverfrom the heating to the cooling mode will occur during the heating season if purelyinternal zones are combined on the same air-conditioning unit serving perimeter zones.

Figure 1-2: Control Zones Affected by the Outdoor Load

N

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Room Sensor(Typical)

Supply Air Duct

Supply Air Duct

Return Air Plenum

Return Air Plenum

Round Zone Damper(Typical)

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1-10 Design Guide

Step #2 - Sizing the Central UnitBecause the zones are controlled with variable air volume, it is unlikely that all zoneswill be at design load at the same time. The zoning allows for the diversity of loads to betaken 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 dependableload estimating program. Because of diversity, the central unit should be selected for theinstantaneous peak load, not the sum of the peak loads, as would be done with a constantvolume 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 totalbuilding/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 percentof base design.

Step #3 - Duct Design ConsiderationsThe Auto-Zone system uses a typical low pressure duct design. To reduce noiseproblems, duct pressures should not exceed 1 inch W.C.

Primary trunk ducts should not be "undersized." This is especially true for "pressuredependent" systems. Pressure dependent refers to the typical Auto-Zone Zone Controllerwithout the airflow sensor. With larger trunk ducts, it is easier to assure relatively constantpressure to each zone. Runs should be as short as possible, and the trunk duct system keptas symmetrical as possible to facilitate system balancing. Wherever possible, run the trunkducts above corridors and locate the zone dampers above corridors to reduce the noise inthe space and facilitate service of the units. Trunk ducts should be sized for no more than0.1 inch W.C. drop per 100 feet, and a maximum duct velocity of 2000 FPM.

Note: For pressure independent terminal units with velocity sensors andconventional "VAV" boxes properly selected for "quiet" operation, this 2000FPM rule can be exceeded by up to 50 percent. The designer, however, shouldbe very experienced in VAV system design before considering modificationof this general rule.

Typical VAV systems with pressure independent terminals use the static regain methodfor sizing ducts. The typical Auto-Zone system is a low-pressure, pressure dependentsystem that utilizes conventional unitary air-conditioning units. These systems should usethe equal-friction method of sizing the ducts, and use the maximum loss of 0.1 inch per100 feet as described above.


Design Guide 1-11

Step #4 - Room Air Motion/DiffuserSelectionAir motion is a consideration for occupant comfort. The selection of diffusers for anAuto-Zone system requires more care than a constant volume system due to varying flowof air into the zones. Slot diffusers are recommended due to their superior performance atlow airflows. Because the zone airflow is variable volume, lower cost round orrectangular diffusers that were satisfactory for constant volume may prove unsatisfactorywith an Auto-Zone system. These diffusers may result in "dumping" of the cold air at lowflows in the cooling mode, and insufficient room air motion at low air flows in theheating mode. Although high air motion in the heating mode can be undesirable, a slotdiffuser 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 properlyselected for the airflow and "throw" suited to the specific installation or zone.

Additional factors to consider in diffuser selection is sound level and throw at designflow. Generally, multiple diffusers will result in lower sound levels in the space, but thismust be balanced with the additional hardware and installation costs. It is commonlyrecommended that slot diffusers be located near the perimeter or outside wall with theairflow directed into the room. Consult your diffuser supplier or catalog for properdiffuser sizing and location.

Series fan boxes may be used instead of zone dampers where higher induction rates aredesirable. If the heat loss on perimeter walls is high, such as large areas of glass, the useof 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 usehigh quality slot diffusers next to the outer wall with the airflow directed inward tocounteract downdrafts during heating. Serious downdraft problems occur when heatlosses exceed 400 BTUH/LINEAR FOOT and both high induction diffusers and seriesfan boxes are recommended.

Step #5 - Bypass Damper SizingUsing a load calculation program, the bypass damper should be sized to give you themaximum CFM of air to be bypassed, typically 60 to 70 percent of the HVAC units ratedcapacity. Bypass Dampers can either be round or rectangular depending on building orjob requirements. Use the appropriate round or rectangular damper selection table todetermine the correct damper size for your application. To size the damper, select adamper from the table based on calculated bypass CFM and a maximum velocitybetween 1750-2250 FPM. When determining the bypass duct size, be sure to take intoaccount any transition fittings and associated pressure drops. (See Table 1-1: RoundDamper Selection or Table 1-2: Rectangular Damper Selection)


1-12 Design Guide

If space limitations or total airflow requires it, multiple bypass dampers can be controlledin parallel. For proper control of the Bypass Damper, the static pressure sensor location isvery important. Refer to Figure 1-3: Locating the Static Pressure Sensor for BypassDamper Control below for proper mounting locations.

Preferred LocationIf the trunk ducts are properly sizedfor minimum pressure drop, thelocation of the static pickup probe isnot particularly critical. It shouldideally be located at right angles tothe airflow in a straight section of thesupply duct approximately 2/3 thedistance of the total length of thesupply duct. Also the probe should belocated not less than 3 duct diametersdownstream and 2 duct diametersupstream of any elbow or takeoff.

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Bypass Damper

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Fan

RA SensorSA Sensor

Return Air Duct

Supply Air Duct

SP Pickup

Bypass Damper

SP Sensor

Least Desirable, ButAcceptableIf the supply duct comes directlyfrom the unit and immediatelysplits in opposite directions, thepressure pickup should be locatedahead of the split, or as close to itas possible, even if the bypassdamper(s) are located downstreamof the split.

Fan

RA Sensor

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Tubing To Be EqualLength And Size

Bypass Damper

SP SensorSP Pickups

Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control


Design Guide 1-13

Step #6 - Zone DampersUse a load program to determine the peak load for each zone. These calculations will beused in selecting the appropriate zone damper sizes.

A round damper or rectangular damper can be selected depending on the building or jobrequirements. If the job requires pressure independent damper control the damperselected must be a round damper. Rectangular dampers are not available for pressureindependent 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 forminimal noise), find the smallest damper that will deliver the required CFM asdetermined by the load program.

Go to either the Round Damper Selection table (Table: 1-1) or the Rectangular DamperSelection 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 ofeither damper sizing chart (Table: 1-1 or Table: 1-2). Move across the chart and find thedamper which will provide the acceptable CFM to meet each zones airflow requirements.

Note: Compare the damper size selected against the duct size to determine if thenext size up or down will provide acceptable performance without requiring atransition fitting.

Up to two additional dampers may be slaved together for larger zones. See zone wiringdiagram for details. This should be reserved for situations when it is not practical to use asingle large damper.


1-14 Design Guide

Figure 1-4: Round Damper Dimensions

Figure 1-5: Rectangular Damper & Kit Dimensions

Note: Dimensions AreIdentical For Round Zone,Bypass & Slave Dampers

Note: See Table 1-2 forAvailable “A” x “B”Rectangular Damper Sizes

Note: Dimensions Are IdenticalFor Rectangular Zone, Bypass &Slave Dampers


Design Guide 1-15

Round Dampers

Table 1-1: Round Air Damper Selection

Rectangular Dampers

Table 1-2: Rectangular Damper Selection

Round Air Damper SelectionAir Damper Round Duct Size

( Area Ft2 )6”

(0.188)8”

(0.338)10”

(0.532)12”

(0.769)14”

(1.050)16”

(1.375)Velocity Through Round Air

Damper(FPM)

Volume Through Round Air Damper (CFM)

750 - Zone 141 254 399 577 788 10311000 - Zone 188 338 532 769 1050 13751250 - Zone 235 423 665 961 1313 17181500 - Zone 282 507 798 1154 1575 2062

1750 - Bypass Only 329 592 931 1346 1838 24052000 - Bypass Only 376 676 1064 1538 2100 27492250 - Bypass Only 423 761 1197 1730 2363 3094

Rectangular Damper SelectionDamperHeight

(B)8” 10” 12” 14” 16” 18” 20” 22” 24” 26” 28” 30” 32” 34” 36”

DamperWidth

(A)

Airflow Through Rectangular DamperCFM @ 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

Notes: 1.) Zone Dampers Should Be Sized Based On The Required Zone CFM. The Table Above IsCalculated Based On 1000 FPM Velocity Through The Rectangular Damper. Zone DamperRecommended Velocity Is 1000 – 1500 FPM. Select 1000 FPM or Less for Quiet Operation. For OtherVelocities, 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.


1-16 Design Guide

Pressure Independent Zone DampersPressure Independent operation is only available for round zone dampers. Use the chartbelow to set the calibration of the zone damper after installation.

DamperSize

Flow Probe “K” Factor

6” 4748” 950

10” 141712” 212014” 290816” 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 correct CFM will be calculatedfor the different size air valves.


Design Guide 1-17

Auxiliary Heat ControlOptionsThe Auto-Zone system offers the user a variety of methods to deal with zone heatingrequirements. When deciding how to handle zone heating requirements the user shouldconsider 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, the user 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 aheating demand is created at the rooftop unit?

A: This mode is useful if you expect to have both heating and cooling demands at thesame time. The zone will use it’s own heat and allow the rooftop unit to continue toprovide cooling for other zones. This mode is also useful if the rooftop unit does nothave any heating capabilities.

Q: Is the zone heat only to be used as a second stage, where it will be activated only ifthe rooftop unit cannot maintain the space temperature, such as during very coldweather?

A: In this mode of operation the rooftop will examine the heating and cooling demandsand try to satisfy all of the zones by switching between heating and cooling asrequired. The zone heat will only be activated if the zone temperature falls below aselected 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 andonly use zone heat when the rooftop unit is in cooling or vent mode. This oftenprovides the most cost effective operation since zone heat is typically electric. Thismode of operation will lockout zone heat if the rooftop is delivering heated air.


1-18 Design Guide

Relay Expansion Board

The following describes the operation of each of the relays on the optional relayexpansion board. The user can choose the appropriate relays for any given application.

Relay #1 - Parallel FanIf the Zone is in cooling mode or vent mode, the parallel fan can activate anytime thezone temperature drops 0.5°F below the heating setpoint. It de-activates when thetemperature rises above the heating setpoint. The space temperature must be below theAUX HEAT setpoint in the occupied mode before the Parallel Fan relay can beenergized.

Relay #2 - Box HeatIf the zone is in cooling mode or vent mode, then the box heat can activate anytime thezone temperature drops 1.5°F below the heating setpoint. It de-activates when thetemperature rises to within 1.0°F of the heating setpoint. Box heat is not allowed toactivate 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 satisfyingcooling demands in other zones. The space temperature must be below the AUX HEATsetpoint in the occupied mode before the Box Heat relay can be energized.

Relay #3 - Aux HeatIn the occupied mode, the aux heat can activate anytime the zone temperature is 0.5°Fbelow the aux heat setpoint. It de-activates when the temperature rises 0.5°F above theaux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heatingsetpoint with the same deadband values mentioned above. This prevents the zone frommaintaining 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 andalso to allow a zone an attempt to satisfy its own heating needs before creating a heatingdemand at the Zone Manager.

Relay #4 - Series FanThe series fan runs anytime the main fan is running. This includes occupied andunoccupied modes. The fan can only start running when the zone damper is closed, so itdetermines that the damper is closed before starting the fan.

Section 2

Installation and Wiring

Table of ContentsTips Before Beginning Installation..................................1Zone Manager ..................................................................3Communications Loop .....................................................8

Communications Loop Wiring Overview........................................................................9Bypass Dampers ............................................................10Zone Dampers................................................................13Zone Controllers ............................................................14

Room Sensors ................................................................................................................21Supply Air Temperature Sensor ....................................................................................23Return Air Temperature Sensor .....................................................................................23Outside Air Temperature Sensor ...................................................................................24Duct Static Pressure Sensor ...........................................................................................25

Auxiliary Relay Board for Zone Controllers...................27Zone Controller Auxiliary Relay Board Operation .......................................................28

CommLink II Interface...................................................29Basic System Worksheet................................................................................................31

Section 2

Installation and Wiring

Table of FiguresFigure 2-1: System Overview........................................................................................2Figure 2-2: Typical System Component Locations .......................................................2Figure 2-3: Zone Manager Component Locations..........................................................3Figure 2-4: Zone Manager Component Locations..........................................................4Figure 2-5: Zone Manager Wiring..................................................................................5Figure 2-6: Zone Manager Address Switch Setting .......................................................7Figure 2-7: Communication Loop Wiring, Daisy-Chain Configuration .......................9Figure 2-8: Round And Rectangular Bypass Dampers.................................................10Figure 2-9: Bypass Damper Wiring.............................................................................12Figure 2-10: Round And Rectangular Zone Dampers .................................................13Figure 2-11: Zone Controller Components..................................................................15Figure 2-12: Zone Controller Wiring..........................................................................17Figure 2-13: Zone Controller Address Switch Settings...............................................19Figure 2-14: Slaved Zone Controller Wiring..............................................................20Figure 2-15: Room Sensor Installation ........................................................................21Figure 2-16: Room Sensor Wiring..............................................................................22Figure 2-17: Supply or Return Air Sensor Installation...............................................23Figure 2-18: Outside Air Temperature Sensor.............................................................24Figure 2-19: Duct Static Pressure Sensor ....................................................................25Figure 2-20: Static Pressure Sensor Wiring................................................................26Figure 2-21: Auxiliary Relay Board Layout ...............................................................27Figure 2-22: CommLink II Interface Communication Wiring ...................................29Figure 2-23: CommLink II Interface Connections .....................................................30


Installation and Wiring 2-1

Tips Before BeginningInstallationTake a few moments to review the following before beginning installation of theAuto-Zone Basic System.

• Familiarize yourself with all system components and review all documentation. Payspecial attention to “Cautions” and “Warnings” since these may keep you from expe-riencing 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 Sub-mittal Package, to list all zone locations and Zone Manager configurations. This will as-sist you greatly when setting up the system. • Be sure and 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 dia-grams 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 ques-

tions. 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.


2-2 Installation and Wiring

Figure 2-1: System Overview

Figure 2-2: Typical System Component Locations

HEATIN

G

COOLING

FILTER

NORMAL

WARMER

COOLER

OVR

W/OVERRIDE AND SETPOINT ADJUST

ZONECONTROLLER

MODULATINGDAMPER

AC LINEVOLTAGE

ZONE MANAGER

SUPPLY AIR

MODULATING

CONTROL CABLE

MIXEDAIR OUTSIDE AIR

RETURN AIR

EXHAUST AIR

STATIC PRESSURE SENSOR

& PICKUP TUBE

24 VAC

COMMUNICATION LINE

GROUND

FAN

SUPPLY AIR DUCT

OCCUPIED

WED JANUARY11 2001

AUTO ZONE

HILO

TEMPERATURESENSOR

RETURN AIR SENSOR

ZONE 1TEMPERATURE SENSOR

CONTROLLERZONE

DAMPERMODULATING

ZONE 2TEMPERATURE SENSOR

UP TO 16 ZONES

BYPASS DAMPER

OUTSIDE AIRSENSOR

AVOIDDIRECT

SUNLIGHT

2 CONDUCTOR

24 GA.

3 CONDUCTOR24 GA.

2 CONDUCTOR

24 GA.

2 CONDUCTOR

24 GA.

COMM LINK IIRemote Link

COMM LINK IIINTERFACE

( OPTIONAL )

120/24 VACTRANSFORMER120/9 VAC

TRANSFORMER REMOTE LINK(OPTIONAL MODEM)

COMPUTER(OPTIONAL)

C O N T R O L S

C O N T R O L S

Return Duct

Duct to Return

Supply Temp Sensor

Return Temp Sensor

(Ahead of Bypass Takeoff)

( Over Corridor for Easy Service )

(2/3 Of The Way Down Main Duct)

(Direct Airflow Inward Towards Center of Area)

(Avoid Mixed Air Area)

(Mount Away From Direct Sunlight))

(Preferred)

Bypass Damper( Locate Where Easily Accessible )Static Pressure Pickup

Supply Duct

Zone Damper and Control

Above Corridor

Diffuser at Perimeter Wall

( Preferred Location )

Zone Sensor

Zone Manager

(4-1/2' to 5'; Shoulder Height)

Outdoor Air SensorLOCAL COMM LOOP

TWISTED PAIRWITH SHIELD TO

ZONE CONTROLLER

LOCAL COMM LOOPTWISTED PAIR

WITH SHIELD TOZONE CONTROLLER

LOCAL COMM LOOPTWISTED PAIR WITHSHIELD TO OTHER

ZONE CONTROLLERS

NORMAL

OVR

WARMER

COO

L

E

R

FAN

COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

®

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

(Packaged or Split System)

Typical HVAC Unit



Zone ManagerThe Zone Manager may be installed in any convenient protected location. Observe therecommended environmental limitations for the Zone Manager (see Technical Data sec-tion of product data sheet) when choosing a location. The unit should be mounted withthe display at eye level for easy viewing.

When installing the Zone Manager with display and keypad, the cover must be removed.Use care not to damage the display while handling and protect the display from physicaldamage while removed.

The ribbon cable should be unplugged from the display board, which is mounted insidethe front cover. The ribbon cable is keyed to prevent a reverse connection.

Warning: Always remove power before connecting or disconnecting the ribboncable which joins the display and keypad to the Zone Manager. Fail-ure to observe this precaution may result in damage to the display orZone Manager.

The Zone Manager may be mounted without removing the controller from the enclosureor mounting plate. The unit is mounted by four (4) screws in the corners. Select the cor-rect screws or other fasteners for the type of mounting material being utilized.Please see Figure 2-4, Figure 2-5 and Figure 2-6 for Zone Manager component, wiringand addressing information.

Figure 2-3: Zone Manager Component Locations

FAN

COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

Cool

Mode

08-08-01

03:48PMFRI

OCCUPIED

NOALARMS

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

3.00

11.50

Keypad

Display9.25



Figure 2-4: Zone Manager Component Locations

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

K2

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

OPEN

D1

7

R4

3R4

1

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN2

1

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

ANALOG

OUTPUTS

EXP

BUSS

ECONOMIZER

EXH/RELIEF

GND

TB8

TB5

YS101722

Rev. 2

C21 C20

X2

R4

2

D1

6

EXHAUST

CONTACTS

N.O.

TB4V2

C6U2

R7

R38

R37

C15 C16

R31

R30

R28

R27

R19

C13 C14

R14

R17

R16

R12

C7 C8

R11

TB3

GND

GND

AUX2

AUX3

SAT

RAT

OAT

AUX1

+12V

ANALOG

INPUTS

D2

D3

D5

D4

D8

D6

R15

C11

U7

CX7

Q2

PJ1

+5

V

SIG

GN

D

PRESSU

RE

SEN

SO

RJA

CK

TB1

R5

R4R2

R3

R1

U1

CX1

C4 C5

D1

R9

C1

C2 C3

VR2

VR1

SC1

24VAC

V1

R1

0

U3

CX3

U5

CX

5

Q1

R2

2

R2

1

D1

0

R2

3

R2

4

R2

0

R3

6

R2

9

R33

R35

R32

R34

CX

4

C1

2

R2

5

D1

2

VR3

R13

R26

D11

D9

R18

U6

CX

6

C17

D13

D14

D15

R39

R40

I2C EXP PORT

GND

TB2

POWER

D7

L1

C9

Y1

EW

DO

G

J0

1

U8

C18 C19

5.11V

ADJ

5.11V

ADJUST

PU1

PU2

PU3

PU4

PU5

PU6

RN1

REC

BYPASSPDAMPER

R6

1

HVAC UnitConnections(R) CommonFanCool 1Cool 2Heat 1Heat 2

BypassDamperConnectionsFDBKGNDOpenClose

RS-485CommunicationsLoop ConnectionTSHR

TypicalPin 1IndicatorRAM

ChipEPROMChip

PALChip

RAM SizeSelectJumper

RS-485CommunicationsDriver Chip

Real TimeClock Chip

Real TimeClock Chip

Display &KeypadRibbon CableConnector

Static PressureSensor Inputs+5VSIGGND

Static PressureSensor - OptionalModular ConnectionInput

CommLED

Not Used

Address Switch(Set To 0 WithoutCommLink. Set to 17With CommLink)

Analog InputsSATRATOATAUX1AUX2AUX3GND

Analog Output0-10 VDCEconomizer

Binary OutputRelief/ExhaustFans

Power LED

24 VACPower Input

Mounting HolesTyp. Of 4

Note:Keypad & DisplayNot Shown



Figure 2-5: Zone Manager Wiring

Warning: Use extreme care not to damage any of the electronic componentswhile mounting the enclosure. Mark the holes then remove the ZoneManager before drilling. Do not allow metal shavings tofall onto the circuit boards.

Basic Zone Manager

Notes:

1.)24 VAC Must Be Connected SoThat All Ground Wires RemainCommon.

3.)All Communication Wiring To Be 18Ga. Minimum, 2 Conductor TwistedPair With Shield. Belden #82760 OrEquivalent.

2.)All Wiring To Be In Accordance WithLocal And National Electrical Codesand Specifications.

RS-485Communications

To CommLinkWhen Used

RS-485Communications To Zone

Controllers

Return Air Temp.Sensor

Suppy Air Temp.Sensor

LineVoltage

HV

AC

Un

it

24VAC Only

Red

Blk

To Relief / Exhaust Fans

Grn

StaticPick-up


Splice AsRequired

LO HI

GND

24VAC

Belimo Actuator Wiring Shown.Consult Factory For Other

Models Of Economizer Actuators.Some Actuators Require IsolationTransformers In Order To PreventDamage To The Controller Board.

WARNING!

Use Extreme Care When WiringEconomizer Actuators

Never Connect Or DisconnectWiring With Power Applied!

Never Apply Power If TheGnd ( 1 Com ) Terminal On The

Actuator Is Not Connected.

See Note 1 &2

Outdoor Air Temp.Sensor

(See Note 4)

Aux3Forced

OccupiedMode

Aux1Economizer

Disable

Aux2FilterAlarm

Auxiliary Inputs( Dry Contacts )

R

G

Y1

Y2

W1

W2

Economizer Actuator

133 IN-LB

AF24-SR

1 COM

2 +

3 Y1

4 Y2

5 UBELIMO

C987

CABLE

R6

R5

HEAT 2 SW

1

W2

W1

Y2

HEAT2

HEAT1

COOL2

COOL1

FAN

HEAT 1

COOL 2

COOL 1

C 1992

11632

BNET

248

AD

D

COMM DRIVER

RS-485

75176

MADE IN U.S.A.

D1

7

D1

8

D1

9

D2

0

D2

1

D2

2

D2

3

D2

4

0* # D

R

SH

T

COMM

C1C2

+

P1

RIBBON

GN

D

G

Y1V6

V5

CLOSE

V4

V3

OPEN

GND

FDBK

FAN

CLOSE

OPEN

+

REC

+

GND

NE5090

4 5 6

KEYPAD

1 2 3

B

A

LCD DISPLAY

&

++

24VAC

TB2

POWER

+

++

ADJUST

5.11V

PJ1

++PRESSU

RE

SEN

SO

RJA

CK

+5

V

SIG

BUSS

EXP

TB2

A2

G

OUTPUTS

ANALOG

A1

N.O.

CONTACTS

EXHAUST

AUX3

GND

GND

AUX2

AUX1

ANALOG

SAT

OAT

RAT

INPUTS

+12V

TB1

2

BYPASS

BYPASS

Local Loop

OF

F>

RockerDown

Bypass & SlaveInterface Card

BypassAir Damper

Actuator

10

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2



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 - CommonG - Fan

Y1 - Cool 1Y2 - Cool 2W1 - Heat 1W2 - Heat 2

Tip: After making all electrical connections, it is advised to unplug all terminalblocks on the Zone Manager until you are ready to begin the checkout proce-dure. This may help to prevent damage if wiring errors occur elsewhere in thesystem during installation or start-up.



Figure 2-6: Zone Manager Address Switch Setting

Caution: Your Auto-Zone system will not work properly unless you set the Ad-dress switch correctly. Remember you must power down the ZoneManager after changing the address switch in order for the change totake effect.

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

R4

3

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN2

1

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

TB8

RN1

BYPASSPDAMPER



Address Switch Must Be SetTo Address 0 on Zone Manager Board

As Shown

Address Switch Must Be SetTo Address 17 on Zone ManagerBoard When CommLink Is Used

Zone ManagerAddress Switch


These Switches Must BeIn The OFF PositionAs Shown


ADD

ADD

1

1

2

2

4

4

8

8

16

16

32

32

B

B

NET

NET

AD

DA

DD

32

32

BB

NE

TN

ET

16

16

88

44

11

22

OF

F>

OF

F>

RockerDown

RockerDown

Basic System Without CommLink

Basic System With CommLink

2.)It Is Recommended That AllControllers Address Switches AreSet Before Installation.

3.)Power To The Zone Manager Must BeCycled Before Address SwitchChanges Will Take Affect.


Controllers

Notes:

1.)AllCommunication Wiring To Be2 Conductor Twisted Pair WithShield. Use Belden #82760 OrEquivalent.

R

SH

T

R

SH

T

R

SH

T

R

SH

T

All Comm Loop Wiring IsStraight Thru

Local LoopRS-485

9600 Baud



Communications LoopThe communications network is a two wire shielded RS-485 loop. The loop is best con-nected in a daisy chain configuration, meaning the loop is connected from one controllerto another. It is not necessary to sequentially address the zone controllers in relation totheir location on the loop. Cable must be Belden No. 82760 or equivalent.

Tip: Incorrect wiring of the communications loop is the most common mistake madeduring installation. Before beginning installation, write down the wire colorused on each terminal connection and consistently maintain that color code. It isrecommended that a continuous wire run be made between devices. Anytime asplice is made in the cable you increase your chance of problems.

Caution: Make sure when you are inserting wires into the terminal blocks thatstrands of wire do not stick out and touch the next terminal. This couldcause 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 cableaway from high noise devices like fluorescent lights, transformers,VFD’s, etc. Conduit is not required for comm loop wiring unless re-quired by local codes.



Communications Loop Wiring OverviewThe daisy chain is the best method for running a communications loop since there is onlyone 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 beused. If required, a combination of the two can also be used. Remember, the best commloop wiring is the one which utilizes the minimum number of ends while using the short-est wiring path. See Figure 2-6 and Figure 2-13 for controller addressing information.


Computer

Zone Manager

Optional Components

Zone 1

Zone 8

Zone 9

Zone 13

Zone 2

Zone 7

Zone 10

Zone 14

Zone 3

Zone 6

Zone 11

Zone 15

Zone 4

Zone 5

Zone 12

Zone 16

A Maximum of 16 Zone Controllers Can Be Connected To The Basic Zone Manager

CO

MM

LINKII

L

C

M

M

O

O

O

O

MD

P

PE

FAN

COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

®

Remote Link

Remote

Link

SIG

DE

T

RD

Y

SN

D

RE

C

PW

R

End Of Loop

RS-4859600 Baud

The Comm LoopRouting Does Not

Have To FollowThe BoardAddress

Sequence



Bypass DampersThe Bypass Damper can be either round or rectangular. The Round Bypass Damper issupplied with the Damper Actuator and Bypass Wiring Interface Board factory mountedin a sheet metal enclosure attached to a Round Air Damper assembly. This Round BypassDamper Package is field connected to the appropriate size round duct. Rectangular By-pass Dampers mount directly in the rectangular ductwork using flanged connections fieldformed in the rectangular ductwork. A Rectangular Bypass Damper Kit is required tocomplete the Rectangular Bypass Damper package. The Rectangular Bypass Damper Kitis supplied with the Damper Actuator and Bypass Wiring Interface Board factorymounted in a sheet metal enclosure. This assembly is then field mounted over the Rec-tangular 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 to-gether when it is not practical to use a single large damper. See Figure 2-9. The bypassdamper(s) should be installed as close as possible to the rooftop unit.

Round and Rectangular Bypass Dampers should be securely hung using either wire cra-dles or metal strapping. While the dampers may be hung in any position, avoid sharpkinks in flexible duct to prevent airflow restrictions. The Round Bypass Dampers are in-sulated for use in non-conditioned spaces to avoid sweating and to improve energy effi-ciency.

See Figure 2-2 for a typical bypass damper mounting location. See Figure 2-9 for typicalBypass Wiring Interface Board wiring instructions.



Warning: If sheet metal screws are used to mount the dampers, be certain thatthey do not interfere with the movement of the damper blade.

Warning: Never depress the actuator clutch with power applied. Unplug the ac-tuator cable before depressing the clutch and attempting to rotate thedamper blade. Do not force the damper blade as this can damage thegears in the damper actuator.



Figure 2-9: Bypass Damper Wiring

Warning: If the fan system has the capability of producing static pressureswhich could damage ductwork, you must provide a manual reset,high pressure limit switch to cut-off the fan system in the event ofhigh duct static. Do not use your Auto-Zone System asa safety device!

BYPASS ACTUATOR #3 (SLAVE)(WHEN USED) BYPASS ACTUATOR #2 (SLAVE)

BYPASS ACTUATOR #1(MASTER)

MODULAR CABLE

MODULARCABLE

MODULARCABLE

1 10 0

10

ZONE MANAGER BOARD

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2

V4

V3

REC

CLOSE

OPENK1

K2

NE

TW

OR

K

SH

R

T

NE5090

FDBK

GND

OPEN

CLOSE

NOT USED FORTHIS APPLICATION NOT USED FOR

THIS APPLICATION

NOT USED FORTHIS APPLICATION

FR

OM

ZO

NE

CO

NT

RO

LLER

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

101824

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2 LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2

BYPASS &SLAVE INTERFACE CARD





Zone DampersThe Zone Damper can also be either round or rectangular. The Round Zone Damper issupplied with the damper actuator and Zone Controller factory mounted in a sheet metalenclosure attached to a Round Air Damper assembly. This Round Zone Damper Packageis field connected to the appropriate size round duct. Rectangular Zone Dampers mountdirectly in the rectangular ductwork using flanged connections field formed in the rectan-gular ductwork. A Rectangular Zone Damper Kit is required to complete the RectangularZone Damper package. The Rectangular Zone Damper Kit is supplied with the DamperActuator and Zone Controller factory mounted in a sheet metal enclosure. This assemblyis then field mounted over the Rectangular Damper shaft and secured to the ductworkwith sheet metal screws.

Figure 2-10: Round And Rectangular Zone Dampers

Up to two additional Rectangular Zone or Round Zone Dampers can be slaved togetherwhen it is not practical to use a single damper. See Figure 2-14. Generally this is not re-quired.

Round and Rectangular Zone dampers should be securely hung using either wire cradlesor metal strapping. While the dampers may be hung in any position, avoid sharp kinks inflexible duct to prevent airflow restrictions. The Round Zone Dampers are insulated foruse 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 forZone Controller wiring instructions.



Zone ControllersThe Zone Controllers are mounted in snap-track which is typically located in the controlenclosure 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 re-spective connectors on the Zone Controller, if they are used. Press the board into thesnap-track carefully to avoid damaging any of the electronic components on the circuitboard. To remove a board from the snap-track, carefully pull one edge of the snap-trackaway from the board with your fingers and remove the board.

Caution: Do not use any tools to pry the board loose. This will damage theboard and/or the snap-track.

Warning: When mounting the snap-track, be sure the heads of the screws do notprotrude far enough to touch the bottom of the Zone Controller circuitboard.

Consider serviceability of the location when mounting the Zone Controllers. They shouldbe easily accessible to facilitate servicing.

Tip: Use small stickers on the ceiling grid or tiles to help future service personnel lo-cate system components. If you use small stickers from an office supply store,you can get different colors to code the location of various components.



Figure 2-11: Zone Controller Components

CX

6

SW

1

U10

75176

EX

PA

NS

ION

Q3

Q2

D3

VR

17824

GND

24VAC

R17

R16

U7

C7

R15

PO

WE

RR

21

RE

V.2

YS

101

562

MDL

F1

250D4

R26

LD3

L1

SCAN REC

R12

C6

R11

TOKEN

NET

LD

2

32

R14

R13

R100

LD

1

C5

D1

K1

V2

K2

D2

AC

TU

AT

OR

R10

R9

PJ2

V1

C4

EPROM

VR

EF

AD

J

R23

C10

EW

DO

G

CO

MM

D7

CX10

R25

R28

T'STAT

U11

C15

R20

C11

R24

8

16

2

4

ADDRESS

ADD

1 U6

U5

R19

U9CX9

R32

D5

C14

P.U.

R22

C13

R27

D5

RAM

C9

C8

80C55

2

CX

5P

J1

C3

R8

R7

R5

R6

R4

C2

C1

X1

U2

R1

R2

R3

CX2

Q1

16L8

32K

R34FLOW

U8

1

RN1

CX8 U4

R18 CX4

8K

RAM

U3

CX3

U1

CX1

Diagnostic BlinkCode LED

Power LED

RS-485CommunicationsLoop Connection

TypicalPin 1Indicator

RAMChip

EPROMChip

PALChip


Air Flow SensorModular Connector

Auxiliary InputTerminals

Expansion BoardModular Connector

Damper ActuatorModular Connector

Address Switch(Set Between 1 & 16)Space Sensor

Terminals

Fuse

24 VACPower Input



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 sensors3 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 blockson the Zone Controller be unplugged until you are ready to begin the checkoutprocedure. This may help prevent damage if wiring errors occur elsewhere in thesystem during installation or start-up. This is particularly important with theZone Controllers since an error on one unit may prevent any of the others fromworking 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 tothe terminal labeled GND on the Zone Controller. If a single trans-former is used to power more than one Zone Controller you mustconnect GND-to-GND and 24VAC-to-24VAC on each zone control-ler. Failure to observe polarity will result in damage to one or morecomponents in your system.



Figure 2-12: Zone Controller Wiring

Notes:

See Note 1

R

SH

T

R

SH

T

R

SH

T

R

SH

T


Required VA For TransformerEach Zone Controller = 10 VA Max.

24VAC

GND

GND

AUX

TMP

NORMAL

OVR

RELO

C

REMR

O

AW

Room Sensor

Zone Actuator

Local LoopRS-485

9600 Baud

Airflow Sensor (Optional)Only Used For PressureIndependent Applications

Connect ToNext Controller

On Loop OrIf This Is FirstController On

Loop AlsoConnect To

Zone Manager

Connect ToRelay

ExpansionBoard When

Used

Connection To AUXTerminal Required OnlyWhen Sensor Is SpecifiedWith Slide Adjust Option


2.)All Wiring To Be In AccordanceWith Local And National ElectricalCodes And Specifications.


10

SHIELD

R

T

HiLo

Airflow

CX

6

SW

1

U1

0

75

17

6

EX

PA

NS

ION

Q3

Q2

D3

VR

17

82

4

GND

24VAC

R1

7

R1

6

U7

C7

R1

5

PO

WE

RR

21

RE

V.

2

YS

10

1

56

2

MDL

F1

250D4

R26

LD3

L1

SCAN REC

R1

2

C6

R11

TOKEN

NET

LD

2

32

R1

4

R1

3

R1

00

LD

1

C5

D1

K1

V2

K2

D2

AC

TU

AT

OR

R1

0

R9

PJ2

V1

C4

EPROM

VR

EF

AD

J

R23

C1

0

EW

DO

G

CO

MM

D7

CX10

R25

R28

T'STAT

U11

C1

5

R20

C11

R24

8

16

2

4

ADDRESS

ADD

1 U6

U5

R19

U9CX9

R32

D5

C1

4

P.U.

R22

C1

3

R27

D5

RAM

C9

C8

80C55

2

CX

5P

J1

C3

R8

R7

R5

R6

R4

C2

C1

X1

U2

R1

R2

R3

CX2

Q1

16L8

32K

R3

4FLOW

U8

1

RN1

CX8 U4

R1

8 CX48K

RAM

U3

CX3

U1

CX1



Set the Zone Controller Address Switch following the following addressing instruc-tions.

Caution: Incorrect addressing is the number one cause of communication prob-lems. Check the addressing carefully. Remember, the Zone Controlleronly reads the switch during a power-up. If the address switch ischanged, the unit must be turned OFF then ON before the new settingwill be recognized.

Note: Ignore any markings or numbers on the switch. Use this chart!



Figure 2-13: Zone Controller Address Switch Settings

Address Switch Shown IsSet For Address 1


ControllerAddress Switch


ADDRESSADD

ADDRESSADD

1 14 4

8 82 2

16 1632 32TOKENTOKENNET

NET

ADDRESSADD

SW

1

1122

44881616

32 (Always OFF- Not Used)32TOKEN

NETTOKEN (Always OFF)NET(Always ON)

Address Switch Values

Switch Shown IsSet For Address 5

Note:1.) Ignore Any Markings On The Switch Body.2.) Use The Address Charts Below Or Address Switch

Value Table Above To Determine Correct Switch Setting.3.) Power To Controller Must Be Turned Off And

Back On In Order For Switch Settings To Take Effect.

Zone Controller Address Switch SettingAddress Switch ValuesAddress Switch Values AreAdded Together When TheRocker Is Pushed Down InThe Direction Of The “ADDRESSADD” Arrow Marked On The ZoneController Circuit Board

CX

6

SW

1

Q3

Q2

D3

VR

17824

GND

24VAC

R1

7

R1

6

U7

C7

R1

5

PO

WE

RR

21

RE

V.2

YS

101

56

2

MDL

F1

250D4

R26

LD3

L1

SCAN REC

R1

2

C6

R11

TOKEN

NET

LD

2

32

R1

4

R1

3

R100

LD

1

C5

D1

K1

V2

K2

D2

AC

TU

AT

OR

R10

R9

PJ2

V1

C4

T

SHLD

R

8

16

2

4

ADDRESSADD

1 U6


3.)Power To The Zone Controller MustBe Cycled Before Address SwitchChanges Will Take Affect.

RS-485Communications To Next

Zone Controller


Zone Controller

Notes:


R

SH

T

R

SH

T

R

SH

T

R

SH

T


Local LoopRS-485

9600 Baud

ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD ADDRESS ADD



ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

SW1

1 1 1 1

1 1 1 1 1

1 1 1 1 1

1

2 2 2 2 2

2 2 2 2 2

2 2 2 2 2

2

4 4 4 4 4

4 4 4 4 4

4 4 4 4 4

4

8 8 8 8 8

8 8 8 8 8

8 8 8 8 8

8

16 16 16 16 16

16 16 16 16 16

16 16 16 16 16

16

32 32 32 32 32

32 32 32 32 32

32 32 32 32 32

32

TOKEN TOKEN TOKEN TOKEN TOKEN



TOKEN

NETWORK NETWORK NETWORK NETWORK NETWORK



NETWORK

1

6

11

16

12 13 14 15

2

7

3

8

4

9

5

10



Figure 2-14: Slaved Zone Controller Wiring

SLAVED- ZONE ACTUATOR #2(WHEN USED) SLAVED-ZONE ACTUATOR #1

ZONE ACTUATOR #1(MASTER)

MODULAR CABLE

MODULAR CABLE

MODULARCABLE

MODULARCABLE

1 10 0

10

ZONE CONTROLLER BOARD

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2

NOT USED FORTHIS APPLICATION NOT USED FOR

THIS APPLICATION

FR

OM

ZO

NE

CO

NT

RO

LLER

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

101824

TO

AC

TU

AT

OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2 LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2PJ2PJ1

ACTUATOREXPANSION






Room SensorsThe Room Sensor uses a patented flush mount design to isolate the temperature sensingelement from the housing which mounts flush with the wall surface.

Room Sensors should be located on an inside wall away from direct sunlight or heat pro-ducing equipment such as computers, copiers, etc. Such devices can adversely affect theaccuracy of the sensor. Although the sensor eliminates most of the effects of thermalcoupling 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 beavoided whenever possible. Avoid locating the sensor in dead air areas of a room. Thiswill 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 RoomSensor is designed to mount vertically in a standard 2 by 4 inch electrical box. The sensormay be mounted directly into the drywall where electrical codes do not require low volt-age wiring to be enclosed in conduit. A template is supplied with the sensor to facilitatecutting a hole of the correct size.

Tip: Be careful when cutting the hole for the sensor or the plastic bezel of the sensormay not 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 electricaldistributor.



Figure 2-16: Room Sensor Wiring

Connect the terminal labeled GND on the zone sensor to the terminal labeled GND on theZone Controller terminal block for the TEMP SENSOR. Connect the terminal labeledTMP on the zone sensor to the terminal labeled TEMP on the Zone Controller terminalblock for the TEMP SENSOR. If the zone sensor has a setpoint adjust slider, then con-nect the sensor terminal labeled AUX to the Zone Controller AUX terminal block labeledAUX1.

GND

AUX

TMP

OVR

RELO

C

REMR

O

AW

Room Sensor

Zone Controller

AUX

TEMP

GND

GND

AUX1

+VS

AUX2

TB2

++

TB1

TB1




Supply Air Temperature SensorThe supply air temperature sensor should be located as close to the rooftop unit dis-charge as possible for best response. It should also be mounted upstream of the bypassdamper for best results. Locate the sensor in the center of the widest part of the duct. Usethe supplied template and a 5/16" drill to make a hole for the sensor. Install the gasketover the probe and mount securely to the duct using the supplied sheet metal screws. Besure the gasket is compressed to provide an air tight seal. For best accuracy, apply insu-lation on the outside of the duct, over the sensor. This will help prevent thermal gradientsfrom affecting the sensor.

Figure 2-17: Supply or Return Air Sensor Installation

Return Air Temperature SensorThe return air temperature sensor should be located upstream of where the Bypass con-nects to the return air duct so that the supply air does not effect the reading of the returnair sensor. Avoid locations which will be exposed to extreme outside temperatures. Lo-cate the sensor in the center of the widest part of the duct. Use the supplied template anda 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mountsecurely to the duct using the supplied sheet metal screws. Be sure the gasket is com-pressed to provide an air tight seal. For best accuracy, apply insulation on the outside ofthe duct, over the sensor. This will help prevent thermal gradients from affecting the sen-sor.

Caution: Do not mount the return air sensor in the mixed air section. This willcause an error in the reading.

Mounting Plate

Gasket

Adhesive Backed Drill GuideMounting Template

11-1/2" (OE231)

5-1/2" (OE230) Mounting Plate

4.0"

3/4"

1/4" Hex Head Sheet Metal Screws

ThreadTogether

Duct Work

Drill 5/16" Hole In Ductwork For Probe

Leads Are Non-polarized.Butt Splice Leads To 24 GaugeWire Minimum. Connect LeadsTo "Analog In" And "Ground"At Controller.



Outside Air Temperature SensorThe outside air sensor must be located where it will not be affected by direct sun or heatproducing equipment. Mounting under the eve of a roof is often a good choice.

Caution: Complaints of inaccurate outside sensor readings are very common andcan almost always be shown to be the result of poor sensor location

Note: All sensors utilize the same type thermistor sensor element. For troubleshootingsensor problems refer to temperature sensor resetting instructions in section 3 ofthis manual.

Figure 2-18: Outside Air Temperature Sensor

4.)All Wiring To Be In Accordance WithLocal And National Electrical CodesAnd Specifications.

3.)Gasket Must Be Installed Under CoverPlate To Provide Raintight Seal.Rainwater Can Damage Sensor!

2.)Unused Conduit Opening(s) MustHave Closure Plugs Installed And MustBe Coated with Sealing Compound ToProvide Raintight Seal. Water CanDamage Sensor!

1.)The Outside Air Sensor Must BeMounted In A Vertical Position AsShown (Sensor Tube PointingDown).

Sensor Must Be LocatedWhere It Will Not Be Affected ByDirect Sunlight Or Heat ProducingEquipment. If Possible Mount UnderRoof Eave Or Similar ProtectedLocation. If Sensor Is Not LocatedAs Specified, Erroneous Outside AirTemperature Readings Will Result.

Water Must Not Be

Allowed To Stand In Sensor

Tube. Rainwater Will Damage

Sensor.

Notes:

Closure PlugCAUTION!See Note 2

Gasketed CoverCAUTION!See Note3

CoverMountingScrew - Typ.

Mounting Tab& Screw - Typ.

0.21" Dia. x 0.73Lg. Slot - Typ.

4.5

0”

2.2

5”

3.00”

Front View Side View Back View

Closure PlugCAUTION!See Note 2

Sensor TubeCAUTION!See Note 1

Mounting Tab& Screws - Typ.

Correct

Incorrect

Incorrect

See Note #1

Sensor MountingPostion

2.70”

1.1

3”

2.30”

3.0

0”



Duct Static Pressure SensorThe duct static pressure sensor is designed to be mounted at the controller, or on theductwork near the pickup tube, and may be connected via its modular plug. If the sen-sor is mounted on the ductwork, the modular plug must be cut off and 3-conductorwire spliced onto the sensor leads. If the trunk ducts are properly sized for minimumpressure drop, the location of the static pickup probe is not particularly critical. Itshould ideally be located at right angles to the airflow in a straight section of the sup-ply duct approximately 2/3 the distance of the total length of the supply duct. Also theprobe should be located not less than 3 duct diameters downstream and 2 duct diame-ters upstream of any elbow or takeoff. See Figure 1-3 in section 1 of this manual forgeneral mounting location information.

Figure 2-19: Duct Static Pressure Sensor

Caution: Mount the static pressure sensor on a vertical surface with the tube tipspointing downward. Avoid any kinks or sharp bends in the tubing whichruns from the pickup tube to the sensor.

Warning: The plastic housing on the sensor is electrically conductive. Avoidcontact with any electrical components. It is acceptable to mount thesensor on grounded sheet metal such as ductwork, electrical panels,etc.

Warning: Use extreme care when mounting the sensor to avoid damage to theplastic housing. Do not over tighten the mounting screws! Do not usemounting screws which are too large for the holes!

OUT

IN

GND UP

(-)LO

0.35

"

0.55" 1.00"

2.20

"

0.15

" DIA

.0.

15"

2.94

"

2.50

"

0.12

5" (1

/8" T

ubin

g C

onn.

)

0.20

0" (3

/16"

Tub

ing

Con

n.)

1.95

"

0.60

"

12.0

" AP

PR

OX

.

1.29

"

OUT (Black)

GND (Green)

IN (Red)

OE2

71S.

P. S

enso

r



Tip: Having at least 10-20 feet of tubing between the pick-up tube and the pressuresensor will improve control performance by acting as a “filter” to remove pres-sure 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 concerningproper location of the static pressure sensor.



Auxiliary Relay Board forZone ControllersAn optional auxiliary relay board is available for the Zone Controllers. This board pro-vides 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 Control-ler connector marked “Expansion.” After connecting the board, the system will need to bepowered OFF 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 applyvoltages higher than 24VAC.



Zone Controller Auxiliary Relay BoardOperation

Relay #1 - Parallel FanIf the zone is in cooling mode or vent mode, the parallel fan relay will activate anytimethe zone temperature drops 0.5°F below the heating setpoint. It de-activates when thetemperature rises 0.5°F above the heating setpoint. The space temperature must be belowthe AUX HEAT setpoint in the occupied mode before the Parallel Fan relay can be ener-gized.

Relay #2 - Box HeatIf the zone is in cooling mode or vent mode, the box heat relay will activate anytime thezone temperature drops 1.5°F below the heating setpoint. It de-activates when the tem-perature rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activatein the heating mode when there is hot air being supplied by the air handler. This outputwas intended to allow zone re-heat while the Zone Manager is satisfying cooling de-mands in other zones. The space temperature must be below the AUX HEAT setpoint inthe occupied mode before the Box Heat relay can be energized.

Relay #3 - Aux HeatIn the occupied mode, the aux heat relay will activate anytime the zone temperature is0.5°F below the aux heat setpoint. It de-activates when the temperature rises 0.5°F abovethe aux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heatingsetpoint with the same deadband values mentioned above. This prevents the zone frommaintaining 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 andalso to allow a zone to attempt to satisfy its own heating needs before creating a heatingdemand at the Zone Manager.

Relay #4 - Series FanThe series fan relay is energized anytime the main fan is running. This includes occupiedand unoccupied modes. In the unoccupied mode, the fan can only start when the zonedamper is closed. The controller checks to be sure the damper is closed before startingthe fan.



CommLink II InterfaceAn optional CommLink Interface is available for the Auto-Zone Basic system to provideon site computer hook-up or modem interface for remote communications. TheCommLink is wired as shown below.

Figure 2-22: CommLink II Interface Communication Wiring

Locate the CommLink near the computer or modem. The cable connections between theCommLink 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 powersupply. The Zone Manager address switch must be set to 17 when the CommLink is in-stalled on the Basic system. Also the jumper switch located on the CommLink circuitboard must be set for single loop operation. See Figure 2-23 on the following page fordetails.

COMPUTER(DCE)

REMOTE LINK(DTE)

TO REMOTE LINK(DTE)

TO COMPUTER



Figure 2-23: CommLink II Interface Connections

Notes:

R

SH

T

R

SH

T

R

SH

T

R

SH

T

All Communication LoopWiring Is Straight Through

Caution:Disconnect All Communication Loop WiringFrom The CommLink Before Removing PowerFrom The CommLink. Reconnect Power And ThenReconnect Communication Loop Wiring.

Connect To The Basic Zone ManagerCommunications Terminals (T-S-R)

Network LoopRS-485

19200 Baud

Local LoopRS-485

9600 Baud

Line Voltage

See Note 1

24VAC

Required VA For TransformerCommLink = 14VA Max.

CommLink Is Supplied With 110/24VAC Power Supply.If Desired A Transformer (By Others)

May Be Wired To The CommLink Instead. See Note 1.COMMLINK II COMMUNICATIONS INTERFACE

(Multiple Loop or Single Loop)

Molded Modem Cable.Supplied With CommLink

(DTE)

REMOTE LINKREMOTE LINK

485 LOOP485 LOOP

COMPUTER(DCE)

GT R

G2

V4

DN

POWER

4 Piece ComputerCable Kit. 4Supplied WithCommLink

Use 25 Pin Or 9 Pin Connector As Required ByAvailable Serial (COM) Port On Computer.

Connect To Remote Link .Only

9P

inF

em

ale

9 PinFemale

25 PinFemale

9P

inF

em

ale

120/24 VacTransformer

25 PinMale

Warning: Use The “Molded Cable” ToConnect To The Computer (DCE) ConnectorOr Serious Damage To The CommLink CouldResult. This Cable Is Only To Be Used ToConnect From The CommLink (DTE)Connection To The Remote Link (When Used).

Do Not

Warning: Use The “25 Pin Or 9 Pin Cable”To Connect To The Remote Link (DTE) Connector OrSerious Damage ToThe CommLink Could Result.This Cable Is Only To Be Used To Connect From TheCommLink (DCE) Connection To The Computer

Do Not

Connect Supplied RJ12 Modular Phone CableTo Supplied 9 Pin Or 25 Pin Connector As ReqdBy Your Computer Com Port Connection



Note:Place Jumper BetweenBetween Pins 2 & 3 ForSingle Loop Application.This Is The Correct SettingFor The Basic System.

3.)Network and/or Local LoopCommunication Wiring To Be 2Conductor Twisted Pair WithShield. Use Belden #82760 OrEquivalent.

4.)The Basic System Requires TheJumper To Be Set For SingleLoop Operation.

COMM DRIVER CHIP( U1 )PIN 1

MULTI

SINGLE

12

3

CommLink Jumper Switch Settings



Basic System WorksheetProject: _______________________ Location ______________________________________________

CommLink Installed: Yes No Remote Link Installed: Yes No Phone:_________________

Stages of Cooling ____ Stages of Heating ____ Gas Electric Economizer Yes No

Zoning: Pressure Dependent Pressure IndependentZone

AddressZone Description or Location

AirDamper

Size

RoomSensor Type

RelayExp. Board

1 S SO SA SOA AH BH SF PF
















[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]

Section 3

Programming

Table of ContentsLCD/Keypad Operations...................................................1

Main Screen Access.........................................................................................................1Data Entry Functions .......................................................................................................2

Zone Summary Screen.....................................................2Individual Zone Status Screens.......................................3Zone Manager Status Screens ........................................5Alarm Status Screens ......................................................7Entering Passcodes .........................................................9Main Menu Operation.......................................................9Zone Controller Setpoints..............................................10Zone Manager Setpoints................................................14

Week Schedules .............................................................................................................14Holidays .........................................................................................................................15Setting Time & Date ......................................................................................................16Control Setpoints ...........................................................................................................17

Zone Manager Configuration .........................................20System Overrides...........................................................24Zone Manager Operations Summary .............................26


Programming 3-1

LCD/Keypad Operations

Main Screen

The Auto-Zone Zone Manager is your direct link into the status and setpoints of anyZone Controller on your communications loop. With the Zone Manager the user can viewany temperature or output condition and change any setpoint to fine tune the operationsof the total system. All keypad operations are simple and straightforward, utilizing non-cryptic plain English messages.

The remainder of this section will lead the user through the system menus and keypadoperation.

Main Screen Access

Keypad Layout

Vent Mode 03/19/02 03:05pm Tue Occupied 1 Alarm(s) 3

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

Current Polling Address


3-2 Programming

Data Entry Functions

Zone Summary ScreenTo see a summary of all attached Zone Controllers, press the "A" key while the MainScreen 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 unitsavailable for any given screen, the remaining lines on that screen will be blank.

etc..

Note: The temperature displayed includes the slide effect offset.

A - Abort Used to exit from screens or from data entry.Use this key to return to the Main Menu fromany screen in the system.

B - Backup The user can step backwards to previousscreens or setpoints by pressing this key.

C - Clear If a data entry mistake is made, press this keyto clear the data entry field and start over.

D - Negative If the user is entering a setpoint that isnegative in value, press this key for the minussign.

* - Decimal Use this key as the decimal point whenentering decimal values.

# - Enter This key is used to close a data entry fieldand advance to the next item or screen.

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


Zone TEMP CLSP HTSP 16 74.2 77.0 74.0


Programming 3-3

Individual Zone StatusScreensTo see the complete status of any attached Zone Controller, press the "B" key while theMain Screen is active. The following screens will appear. Step to each additional screenby pressing the "#" key. Press the "A" key to exit before all status screens have beenviewed. If a zone doesn't respond, the screen will display " *** Missing *** ". If thezone is currently in the Calibration mode, the screen will display "Calibrating." Nostatus or setpoints are available during calibration.

Note: The top line of every status screen shows the selected zone address.

Status Screen #1

Status Screen #2

Line 2 - Unoccupied ModeOccupied ModePush-button OverrideForce Mode Active!

Line 3 - Voting UnitNon-Voting Unit

Zone Number 1 Occupied Mode Voting Unit

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


3-4 Programming

Status Screen #3

Status Screen #4

Line 2 - Current Zone Damper Position

Line 3 - Currently active Minimum Damper/AirflowSetpoint. Each mode has its own minimum setpoint.These modes are vent, cooling and heating.

Line 4 - Currently active Maximum Damper/AirflowSetpoint. This value is user adjustable and is used inall modes of operation, unlike the MinimumDamper/Airflow Setpoint.

Zone Number 1 Damper Pos 20 Minimum Setpt 20 Maximum Setpt 100

Line 2 - Auxiliary Heat OffBox Heating OnAux Heating OnBox & Aux Heat On

Line 3 - Series Fan On orBlank Line if Fan is Off

Line 4 - Parallel Fan On orBlank Line if Fan is Off

Zone Number 1 Auxiliary Heat Off Series Fan On


Programming 3-5

Zone Manager StatusScreensTo see the Zone Manager status, press the "C" key while the Main Screen is active. Thefollowing 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

Status Screen #2

Line 2 - Current Supply Air Temperature

Line 3 - If the system is configured for VAV operation, thisline shows the current Static Pressure in the duct. Itis displayed in Inches of Water Column.

Line 4 - If the system is configured for VAV operation, thisline shows the current Bypass Damper positioncurrently required to maintain the displayed amountof Static Pressure.

HVAC Status Supply Air 78.6 Static Press 0.49 Bypass Damper 24%

Line 2 - Current Return Air Temperature

Line 3 - Current Outdoor Air Temperature

Line 4 - Current Economizer Damper Position if the system isconfigured for Economizer control.

HVAC Status Return Air 75.3 Outdoor Air 70.2 Economizer 20%


3-6 Programming

Status Screen #3

Status Screen #4

Line 2 - The currently Active Cooling Stages are displayed onthis line. The user can see the first two stages fromthe LED display on the front panel. This screenallows systems with more than two stages of cooling,to see how many are active.

Line 3 - The currently Active Heating Stages are displayedon this line. The same LED information is availablefor heating, as described above.

Line 4 - If the optional Economizer Module has been installedon your system, this line will show the currentlycalculated Wetbulb Temperature.

HVAC Status Active Cool Stage: 0 Active Heat Stage: 0 Wetbulb Temp: xxx.x

HVAC Status Mavericks 0 Cool Total 0.0 Heat Total 0.0

Line 2 - The Zone Manager knows if any units have had afour degree demand for at least one hour. It totalsthem up and displays this value as the total numberof Maverick Zones.

Line 3 - As the Zone Manager polls its Zone Controllers, ittotals up the heating and cooling demand so it canmake an HVAC decision.The Cooling Total is displayed on this line.

Line 4 - The Heating Total, from the zone polling, isdisplayed on this line.


Programming 3-7

Alarm Status ScreensIf the last line on the Main Screen displayed one or more active alarms, the user can pressthe "D" key while on the Main Screen to display a list of detected alarms. Each screendisplays one alarm at a time. If no alarms are present when the user presses the "D" key,the message "No Alarms" will be displayed on the alarm screen.

Status Screen #1

Line 3 - Possible Alarm Messages that can be displayed, oneat 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 MessagesMissing Zone 1Zone Damper Fail 1Bad Zone Sensor 1Maverick Zone 1

All Zone Controller messages are followed by theaddress of the unit that is causing the alarm.

If any alarms are present, the Alarm LED on theFront Panel will be active, alerting the user at adistance that an alarm is present.

Alarm Status

No Alarms


3-8 Programming

Alarm DefinitionsCooling Failure! or Heating Failure! - Once the heating or cooling is activated, the

Supply Air Temperature has 30 minutes tochange by at least 5°F or the Zone Managerassumes a mechanical failure has occurred andgenerates an alarm.

Bad Supply Air Sensor or Bad ZoneSensor

- The Zone Manager or Zone Controller wasunable to detect the appropriate sensorinstalled.

Bypass Feedback Fail - During calibration the controller does notreceive a signal from the Bypass DamperActuator Feedback Pot.

Damper Opening Alarm - The Bypass Damper Actuator does not travelthe full open position on a call to open.

Damper Closing Alarm - The Bypass Damper Actuator does not travelto its full closed position on a call close.

Static Sensor Alarm - The current static pressure reading has beenabove 3.0 inches or below 0.01 inches for morethan 30 seconds.

Missing Zone - The Zone Manager has been out of contactwith a specific zone for 5 consecutive pollings.

Zone Damper Fail - The zone damper either failed the startupcalibration or it has stopped responding tocommands.

Auxiliary Alarm - A contact closure is detected on the AUX2input

Maverick Zone - The identified zone has exceeded a 4°F heatingor cooling demand for at least 1 hour.


Programming 3-9

Entering PasscodesAnytime the user is prompted to enter a passcode, the following screen will appear. Theactual passcode digits are never displayed. Instead, an "X" is placed on the screen for everydigit entered, as a place holder, to allow the user to know which digit is being entered. Thedefault passcode is "1111" and is programmable to any other four digit value.

Passcode Request

Main Menu OperationTo gain access to the system setpoints and configurations, press "#", while on the MainScreen, 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, shownlater in this section. To return to the Main Screen from any other screen, press the "A"key until the Main Screen appears.

Main Menu

For detailed information on each of the Main Menu selections refer to the appropriateparagraph heading as noted below.

1) Read/Reset Zones Zone Controller Setpoints2) Manager Setpoints Zone Manager Setpoints3) Configure System Zone Manager Configuration4) System Overrides System Overrides

THIS ACTION REQUIRES PASSCODE CLEARANCE Enter Passcode: xxxx

1) Read/Reset Zones2) Manager Setpoints3) Configure System4) System Overrides


3-10 Programming

Zone Controller SetpointsThe user is prompted to enter the address of the Zone Controller whose setpoints theywant to read or reset. If the user enters a non-existent zone address, the screen willdisplay "*** Missing ***" and no setpoint screens will be displayed.

Zone Selection Screen

Note: The top line always displays the currently selected Zone Controller and thecontroller type.

PD ZONE ADDRESS means a Pressure Dependent Box is selected.PI ZONE ADDRESS means a Pressure Independent Box is selected.

Setpoint Screen #1

Minimum Default MaximumCooling Setpoint 50°F 75°F 90°FHeating Setpoint 50°F 72°F 90°F

SELECT ZONE ENTER ADDRESS: 1

The Occupied Heating and Cooling Setpoints are entered onthis screen. The Heating Setpoint should always be twodegrees below the Cooling Setpoint, or the Zone Controllerwill not accept the new values. The Zone Manager can'tprevent the entry of invalid setpoints. If invalid setpoints areentered, the previous settings will be retained by the systemand displayed the next time the Zone Setpoints are accessed.

PD ZONE ADDRESS 1 OCCUPIED SETPOINTS Cooling Setpt: 75 F Heating Setpt: 72 F


Programming 3-11

Setpoint Screen #2

Minimum Default MaximumCool Setback 0°F 10°F 30°FHeat Setback 0°F -10°F -30°F

Setpoint Screen #3

Minimum Default MaximumAuxHeat Setpt 50°F 72°F 90°FSlide Effect 0°F 3°F 5°F

Note: If slide effect is set to 0°, the pushbutton override will not function.

Setpoint Screen #4

Minimum Default MaximumPD Zone Max DamperPI Zone Max Airflow

0%0 CFM

100%800 CFM

100%30000 CFM

PD Zone Cool Mode MinPI Zone Cool Mode Min

0%0 CFM

5%200 CFM

100%30000 CFM

PD Zone Heat Mode MinPI Zone Heat Mode Min

0%0 CFM

20%300 CFM

100%30000 CFM

The Unoccupied Heating and Cooling Setback values areentered on this screen. The Occupied Cooling Setpoint will beincreased by the Cooling Setback during Unoccupied Modeand the Heating Setpoint will be decreased by the HeatingSetback.

PD ZONE ADDRESS 1 UNOCCUPIED SETPOINTS Cool SetUp...: 10 F Heat Setback.: -10 F

If your Zone Controller has the optional Relay Expansion Boardattached, one of the relays is reserved for an Auxiliary HeatingRelay. Enter that setpoint on the AuxHeat Setpt line. If therelay board is not installed, this line will not be displayed.If your Zone Temperature sensor has the optional SetpointAdjustment Slide, enter the maximum effect it can have on thesetpoints on the Slide Effect line.

PD ZONE ADDRESS 1 AuxHeat Setpt: 72 F Slide Effect.: 3 F

PD ZONE ADDRESS 1 Max Damper....: 100% Cool Mode Min.: 5% Heat Mode Min.: 20%

On Pressure Dependent Zones, these setpoints are for damperposition, on Pressure Independent Zones they are for Airflow(CFM) values, and the text will change to reflect that.


3-12 Programming

Setpoint Screen #5A

Minimum

Default Maximum

PD Zone Vent Mode Min 0% 50% 100%PD Zone Nite Mode Min 0% 100% 100%

Setpoint Screen #5B

Minimum

Default Maximum

PI Zone Vent Mode Min 0 CFM 500 CFM 30000 CFMPI Zone Nite Mode Min 0 CFM 0 CFM 30000 CFMPI Zone CFM @1" WG 0 CFM 2100 CFM 30000 CFM

Setpoint Screen #6

On Pressure Dependent Zones, the setpoints displayed are fordamper position.

PD ZONE ADDRESS 1 Vent Mode Min.: 50% Nite Mode Min.: 100%

For Pressure Independent Zones the text changes to displayairflow (CFM) values. On the third line - "CFM@1" WG",enter the appropriate "K" Flow Factor from Table 1-2 of thismanual.

PD ZONE ADDRESS 1 Vent Mode xxxxx CFM Nite Mode xxxxx CFM CFM @1”WG xxxxx CFM

PD ZONE ADDRESS 1 Overrides..: Global Damper Mode: Direct PRESS (*) TO TOGGLE

The Zone Controller will respond to another zones push-buttonoverride if it is configured for global overrides. If singleoverrides are selected, the zone will only enter override if itsown push-button is pressed.

The normal damper operation is direct acting, which means itopens in a clockwise direction. If your system opens in acounter-clockwise direction, select reverse acting mode.


Programming 3-13

Setpoint Screen #7

Setpoint Screen #8

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 tosimulate a heating or cooling mode, you can raise or lower the current zonetemperature far enough to put the zone into the desired mode.

Caution: The normal calibration offset should be a fairly small value. If you needseveral degrees of offset, there might be a sensor problem or a locationproblem.

PD ZONE ADDRESS 1 Voting Mode: Voting

PRESS (*) TO TOGGLE

Normally, you want a zone to be included in the polling by theZone Manager. This allows the demand in that zone to have avote in determining the HVAC mode of operation. If you havea problem zone or an area that you don't want to include in thevoting, select the NonVote mode of operation.

PD ZONE ADDRESS 1 Sensor Calibration Rdg OffsetZone: 75.4 0.0

If you have a tenant that doesn't agree with the current zonetemperature reading, you can adjust or calibrate the zonetemperature reading.Enter a positive number if the current reading is too low.Enter a negative number if the current reading is too high.


3-14 Programming

Zone Manager SetpointsThe Zone Manager Setpoints are kept separate from the Zone Manager Configurationsetpoints since these are the most commonly changed values. Enter the number shownbelow for the desired selection. When you are finished, press the "A" key to return to theMain Menu.

Zone Manager Setpoint Menu

Week SchedulesSchedule Start Time

Schedule Stop Time

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 thenext Start Time screen.

1) Control Setpoints2) Schedules3) Holidays4) Time & Date

WEEK SCHEDULES Sunday Stop Time Enter Hrs/Mins: 0 (MILITARY FORMAT)

The screens will step through the Start Time and then the StopTime for each day of the week. You can quit at any point inthe process by pressing the "A" key.

All times are in 24 hour format, so 5:00 PM would be enteredas 1700.

WEEK SCHEDULES Sunday Start Time Enter Hrs/Mins: 0 (MILITARY FORMAT)

If both the Start and Stop Times are ZERO, the schedule is ina continuous OFF mode.

If both the Start and Stop Times are 2359, the schedule is in acontinuous ON mode.


Programming 3-15

Holidays

Holiday Day Selection

Holiday Start/Stop Times

The screens will step through the eleven possible holidays, oneat a time. Line 2 shows which holiday is currently beingprogrammed.Remember to combine the month and day into a single fourdigit value.EXAMPLE: 704 = July 4th

1225 = December 25th

Program Holidays Holiday # 1 Start Mon/Day: 101 (EX: 101 = Jan. 1)

The eleven holidays all use the same Start and Stoptime which is entered on this screen. It is entered in 24-hour military format, the same as a regular weekschedule.

Holiday Schedule

Starting Time: 0 Stopping Time: 0


3-16 Programming

Setting Time & DateThe Zone Manager has its own built in real time clock. Although the times are displayedon the Main Screen in a standard 12-hour format, they are programmed using the 24-hourmilitary 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 clockreading.

Programming Time

Programming Date

Daylight Savings Adjustments

Day - Enter the Day of the Week (0 to 6) withSunday = 0

Hours (Hr) - Enter Hours in 24-Hour Military Format(1700 = 5:00 PM)

Minutes - Enter the Minutes (0 to 59)

Program Time/Date Day (Sunday=0): 2 Enter Hr.(0-23): 14 Enter Min : 53

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 (00to 99)

Program Time/Date Month (1-12): 3 Day (1-31): 19 Year (00-99): 02

If your area of the country requires Daylight Savings changes,the Zone Manager can automatically make the adjustment foryou. If you want the adjustment to occur, make sure the secondline shows Adjustments Enabled, otherwise, press the "*" keyto make it show Adjustments Disabled.

If the adjustment is Enabled, the unit springs ahead the firstSunday in April and falls back the last Sunday in October.

Daylight Savings Adjustments Enabled

Press (*) To Toggle


Programming 3-17

Control Setpoints

Setpoint Screen #1

Minimum Default Maximum

Static Press 0.1" 0.5" 2.0"

Setpoint Screen #2

Minimum Default MaximumCool Lockout -30°F -30°F 80°FHeat1 Lockout 30°F 65°F 99°FHeat2 Lockout 30°F 45°F 99°F

Manager Setpoints Static Press: 0.5”

If you have configured for variable HVAC type, this screenwill be displayed to allow the user to enter the controllingStatic Pressure Setpoint.

The mechanical Cooling and Heating Lockouts are enteredon this page. There are two heating lockouts. Heat1 Lockout isfor Stage #1 only, and Heat2 Lockout is for Stages #2 and up.This allows energy conservation, during Spring and Fallconditions, where a single stage of heating could handle theload.

Manager Setpoints Cool Lockout: 50 Heat1 Lockout: 65 Heat2 Lockout: 45


3-18 Programming

Setpoint Screen #3

Minimum Default MaximumCool Staging 1 Min 4 Min 30 MinMin Cool Off 1 Min 4 Min 30 MinHeat Staging 1 Min 4 Min 30 MinMin Heat Off 1 Min 4 Min 30 Min

Setpoint Screen #4

Minimum Default MaximumInterval 1 Min 10 Min 30 Min

Setpoint Screen #5

Minimum Default MaximumClosed Volts 0.0 VDC 0.0 VDC 10.0 VDCOpened Volts 0.0 VDC 10.0 VDC 10.0 VDC

The heating and cooling stages must have been off for aminimum amount of time before they can be activated or re-activated. As each additional stage of heating or cooling isadded, a minimum Staging Delay period must be satisfied,between each additional stage required.

Cool Staging: 4 Min Min Cool Off: 4 Min Heat Staging: 4 Min Min Heat Off: 4 Min

If the Zone Manager needs to change HVAC modesbetween heating and cooling, a Changeover Delay timemust be satisfied first. This prevents "chasing" due toalternate hot and cold air always being supplied to thezones after short intervals.

Manager Setpoints Heat/Cool Changeover Interval....: 15 Min

If the Zone Manager has been configured for EconomizerControl, this screen will appear. The user can set the voltagesrequired to open and closed the damper. Some actuators use a2-10 VDC signal instead of 0-10 VDC.

If the system is not configured for Economizer Control, noeconomizer setpoint screens will appear.

Economizer Setpoints Closed Volts: 0.0 Opened Volts: 10.0


Programming 3-19

Setpoint Screen #6

Minimum Default MaximumEcono Enable -30°F 50°F 99°FSupply Setpt 45°F 50°F 80°FMin Econo % 0% 20% 100%

Setpoint Screen #7

Minimum Default MaximumInterval .1 50 90.0

SetpointScreen #8

Minimum Default MaximumSupply Sensor SAT -100.0°F 0.0°F +100.0°FReturn Sensor RAT -100.0°F 0.0°F +100.0°FOutdoor Sensor OAT -100.0°F 0.0°F +100.0°F

The Econo Enable setpoint is the outdoor air or wetbulbtemperature that enables the Economizer to open past itsminimum position setpoint to control supply air temperature.

The Supply Setpt is the supply air temperature theEconomizer tries to maintain.

The Min Econo % is the position the economizer holds duringoccupied mode when it is not enabled for operation, due tooutdoor air or wetbulb temperature.

Economizer Setpoints Econo Enable: 50 Supply Setpt: 50 Min Econo % : 20%

Economizer Setpoints Economizer Interval Seconds.....: 50.0

Sensor Rdg Offset SAT.: 82.9 0.0 RAT.: 77.2 0.0 OAT.: 70.2 0.0

During Economizer control, the Economizer damper isallowed to move open or closed, as required, at a ratecontrolled by this value. Use this setpoint to speed up or slowdown the operation of your economizer. The larger thenumber, the slower the damper will move.

As described in the Zone Controller section, the ThermistorType III sensor readings can be calibrated. The Outdoor AirCalibration Offset only applies to the Zone Manager that hasthe sensor installed. It has no effect on the global broadcastvalue of outdoor air.


3-20 Programming

Zone ManagerConfigurationNormally, the configuration setpoints need to be entered only one time. For this reasonthey occupy their own menu location and need not be addressed during normal setpointread and reset operations. To access the configuration setpoints, press the "3" key whileon the Main Menu screen.

Note: On initial power up, the system must be configured before it can be successfullyoperated.

Configuration Screen #1

Minimum Default MaximumLast Zone Addr 1 1 16First Zone Addr 1 1 16Cooling Stages 0 1 6Heating Stages 0 1 6

Caution: The zones should be consecutively addressed with no skipped addresslocations. If an address is skipped, the Zone Manager will presume thereis a missing zone, and an alarm will occur.

The Zone Manager needs to know the address range of theattached Zone Controllers to be polled. The user enters theaddresses of the first and last zones here.The quantity of cooling and heating stages are also entered onthis screen.

Last Zone Addr: 1 First Zone Addr: 1 Cooling Stages: 1 Heating Stages: 1


Programming 3-21




Heat Type.: Electric Fan Mode.: Constant

PRESS (*) TO TOGGLE

Economizer: Enabled

PRESS (*) TO TOGGLE

HVAC Type: Variable

PRESS (*) TO TOGGLE

The Zone Manager can control electric or gas heating. Eachtype of heat has its own protection limits built into the ZoneManager software.The Zone Manager can also operate the fan in one of twomodes.

Constant (Continuous) running during occupied hours.Cycle with heating or cooling during occupied hours.

The fan always cycles with heating or cooling duringunoccupied hours.

The Zone Manager has the ability to control the Economizeroperation. To initiate Economizer operation, select Enabled.To toggle between the two Economizer modes, press the "*"key.

The Zone Manager normally reads the duct static pressureand controls it via the bypass damper. If your system doesn'trequire static pressure control, select the Constant mode ofoperation. To toggle between the two modes, press the "*"key.


3-22 Programming




The Zone Manager Bypass Damper normally opens in aclockwise direction. If your bypass damper opens in a counter-clockwise direction, select reverse acting instead of directacting operation. To toggle between the two modes, press the"*" key.

Bypass Act: Direct

PRESS (*) TO TOGGLE

The Zone Manager normally uses its own real-time clock andan internal week schedule to determine theOccupied/Unoccupied mode of operation. The Zone Managerdoes have the ability to use a global broadcast from anotherscheduling device on the communications loop if a morepowerful schedule is required. If an external schedule is used,the range of schedule numbers is 1 to 8.

Zone Manager Uses Schedule #: 0 0 = Internal Clock 1-8 = External Clock

Press (*) To Force Recalibration Of The Static Press. Sensor <#> To Skip This...

The Zone Manager only calibrates the static pressure sensorone time. That occurs on the initial powerup, so it is vital thatthe sensor be attached before the system is ever powered up. Ifyou weren't able to do this, or, accidentally activated thesystem before the sensor was available, you can force it torestart 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 3-23


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." Thispasscode should not be given to the casual users of your system.

As mentioned earlier, the default passcode is "1111". Thiscode must be entered before any configuration or setpointchanges can occur. If the user would like to change thisdefault passcode, enter four digits on this screen. The valueentered must be between 1000 and 9999 to be a valid code.Values from 0000 to 0999 will be rejected and the last validcode will be retained.

Enter New Passcode CODE: xxxx [Must Be 4 Digits] Press <A> To Skip!


3-24 Programming

System OverridesThe Zone Manager provides some user selectable override modes. This allows the user totroubleshoot the system or setup temporary conditions for those situations when normaloperation of the system is not required.

Override Screen #1

The Zone Manager defaults to the Auto mode of operationwhen first powered up. Any force modes entered will beretained in non-volatile memory. The unit will resume the forcemode of operation anytime the power is cycled.

0) Auto - Use internal schedules for Day/NightMode

1) Occupied - Forced to Continuous Day or OccupiedMode

2) Night - Forced to Continuous Night orUnoccupied Mode. If the Forced OccupiedBinary Input Contact is closed, this modewill override it to OFF. Use the Auto modeprogrammed for continuous Unoccupiedoperation if you want to use the ForcedOccupied Binary Input Contact.

3) Fan Only This is the mode that is active wheneveryou see the Purge Cycle message beingdisplayed. It disables any heating orcooling and forces all the boxes to movetheir dampers to the full 100 percent openposition. You can use this mode anytimeyou want to manually purge your building.

0) AUTO (Time Clock)1) FORCE Occupied2) FORCE Unoccupied3) FAN ONLY [Mode 0]


Programming 3-25

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 sametime to their Minimum or Maximum Damper/AirflowSetpoints. On Pressure Independent systems, this feature isuseful during air balance operations.

Enter a "1" next to the desired force mode to make it active.Enter "0" to disable the force mode.


3-26 Programming

Zone Manager OperationsSummary

Vent Mode 06/05/96 08:05am Wed Occupied 1 Alarm(s) 3


1) Read/Reset Zones2) Manager Setpoints3) Configure System4) System Overrides

Alarm Status

No Alarms

Manager Setpoints Static Press: 0.50”

1) Control Setpoints2) Schedules3) Holidays4) Time & Date

HVAC Status Supply Air 56.4 Static Press. 0.49" Bypass Damper 24%

Zone Number 1 Occupied Mode Voting Unit

Program Time/DateDay (Sunday=0): 3Enter Hr. (0-23): 9Enter Min. : 25

Program Holidays Holiday # 1 Start Mon/Day: 0 (EX: 101 = Jan. 1)

WEEK SCHEDULESSunday Start TimeEnter Hrs/Mins: 0 (MILITARY FORMAT)

Zone Summary ScreensPress “A” Key

Main Screen

Zone Status ScreensPress “B” Key

Zone Manager Status ScreenPress “C” Key

Alarm Status ScreenPress “D” Key

Control Setpoints ScreenPress “1” Key

Main Menu ScreenPress “#” Key

Schedules ScreenPress “2” Key

Time & Date ScreenPress “4” Key

Holidays ScreenPress “3” Key

Zone Manager Menu ScreenPress “2” Key

Section 4

Start-Up & Troubleshooting

Table of ContentsCommunications Overview..............................................1

How It Works...................................................................................................................1Basic System Communications........................................................................................2Zone Manager Communications......................................................................................3Zone Controller Communications....................................................................................4CommLink Communications (Optional) .........................................................................5Basic System Communications Checklist .......................................................................6

Components & Wiring ......................................................7Zone Manager IO & Components....................................................................................7Zone Manager Wiring......................................................................................................8Zone Controller IO & Components .................................................................................9Zone Controller Wiring .................................................................................................10

Startup & Commissioning..............................................11Procedures......................................................................................................................11Procedures (Continued) .................................................................................................12Procedures (Continued) .................................................................................................13Basic System Worksheet................................................................................................14Start-Up..........................................................................................................................15Blink Codes For Zone Controllers.................................................................................17

Troubleshooting.............................................................18Trouble Shooting Checklist ...........................................................................................18Trouble Shooting Chart .................................................................................................22Troubleshooting Chart for Alarms.................................................................................24Communications Loop...................................................................................................32Zone Manager ................................................................................................................32Zone Controller..............................................................................................................34CommLink II(Optional).................................................................................................36Bypass Damper Troubleshooting...................................................................................37Temperature Sensor Resistance Chart ...........................................................................38Pressure Sensor Voltage Chart ......................................................................................39

Notes:.............................................................................42Notes:.............................................................................43

Section 4

Start-Up & Troubleshooting

Table of Figures & TablesFigure 4-1: Basic System Communications Wiring .......................................................3Figure 4-2: Zone Manager Communications Wiring & Address Switch Setting...........4Figure 4-3: Zone Controller Communications Wiring & Address Switch Setting ........5Figure 4-4: CommLink (Optional) Wiring & Jumper Settings ......................................6Figure 4-5: Zone Manager Components.........................................................................7Figure 4-6: Zone Manager Wiring..................................................................................8Figure 4-7: Zone Controller Components.......................................................................9Figure 4-8: Zone Controller Wiring .............................................................................10Figure 4-9: Basic Zone Manager ..................................................................................15Table 4-1: SCAN LED Blink Codes.............................................................................17Figure 4-10: Bypass Damper Troubleshooting............................................................37Table 4-2: Temperature Sensor Resistance ..................................................................38Table 4-3: Pressure Sensor Voltage ............................................................................39Figure 4-11: Driver Chip Locations.............................................................................40Figure 4-12: Driver Chip Locations.............................................................................41


Start-Up & Troubleshooting 4-1

CommunicationsOverviewPerhaps no other portion of the system seems as difficult to diagnose as the communica-tions loop, yet it really can be quite simple if you understand how it works. In fact, muchof the troubleshooting can be done by simple observation. We will lead you through thesystem functions and then provide you with detailed instructions for checking each pieceof equipment. This information is provided as a review and expanded guide to the Basicsystem communications. Additional information about the Basic system communicationsloop and its associated wiring is contained in section 2 of this manual.

How It WorksAuto-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 round-robin fashion. A controller must wait to receive the token before it can send or requestany data. Only one device on each loop is capable of sending the token, and this device isconsidered the loop master. The loop master varies depending on the type of system andthe installed options. For the Basic system there is only one loop master. The loop mas-ter is the Zone Manager. The Zone Manager must be connected to the zone controllers orthe communications loop will not function. A typical Basic system communication loopis shown in Figure 4-1.

In order for the loop master to communicate with the various devices on that loop, eachmust have a unique address. With the Basic system, each zone controller on the loopmust have its own address from 1 to 16. The Zone Manager also has an address switchthat must be set for the system to communicate. For the Basic system without an optionalCommLink connected, the Zone Manager address should be set to 0. For the Basic sys-tem with the optional CommLink attached, the Zone Manager must be set as address 17.When the optional CommLink is used it must be set for single loop operation by settingthe jumper switch on the back of the CommLink circuit board.


4-2 Start-Up and Troubleshooting

Basic System CommunicationsThe Basic system has only one communications loop. The Zone Manager is always themaster on the Basic system loop. You must be sure the Zone Manager is connected, ad-dressed correctly (see Figure 4-2) and powered up and functioning if you are starting upor troubleshooting the communications loop. The optional CommLink II jumper switchmust be set for single loop operation when used with the Basic system. See Figure 4-4.

Figure 4-1: Basic System Communications Wiring


Computer

Zone Manager

Optional Components

Zone 1

Zone 8

Zone 9

Zone 13

Zone 2

Zone 7

Zone 10

Zone 14

Zone 3

Zone 6

Zone 11

Zone 15

Zone 4

Zone 5

Zone 12

Zone 16

A Maximum of 16 Zone Controllers Can Be Connected To The Basic Zone Manager

CO

MM

LINKII

L

C

M

M

O

O

O

O

MD

P

PE

FAN

COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

®

Remote Link

Remote

Link

SIG

DE

T

RD

Y

SN

D

RE

C

PW

R

End Of Loop

RS-4859600 Baud

The Comm LoopRouting Does Not

Have To FollowThe BoardAddress

Sequence



Zone Manager CommunicationsThe Zone Manager is the main communication device on the Basic system. It must bewired correctly and it must be connected to 24 VAC power for the system to function.The Zone Manager must also be addressed correctly. The Zone Manager is normallyaddressed as address 0. If a CommLink is to be used it must be addressed as 17. Alwaysbe sure to double check all communication wiring and addressing before initialcommissioning of the system. The address switch must be set and the power cycled inorder for the address to be recognized by the system. Please see Figure 4-2 for the BasicZone Manager addressing information.

Figure 4-2: Zone Manager Communications Wiring & Address Switch Setting

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

R4

3

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN21

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

TB8

RN1

BYPASSPDAMPER



Address Switch Must Be SetTo Address 0 on Zone Manager Board

As Shown

Address Switch Must Be SetTo Address 17 on Zone ManagerBoard When CommLink Is Used





ADD

ADD

1

1

2

2

4

4

8

8

16

16

32

32

B

B

NET

NET

AD

DA

DD

32

32

BB

NE

TN

ET

16

16

88

44

11

22

OF

F>

OF

F>

RockerDown

RockerDown

Basic System Without CommLink

Basic System With CommLink


3.)Power To The Zone Manager Must BeCycled Before Address SwitchChanges Will Take Affect.


Controllers

Notes:


R

SH

T

R

SH

T

R

SH

T

R

SH

T


Local LoopRS-485

9600 Baud



Zone Controller CommunicationsThe Zone Controllers on the system must all be addressed from 1 to 16. They must bewired correctly and they must be connected to 24 VAC power for the system to function.Improper addressing is one of the most common mistakes made when installing any sys-tem. 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 (revers-ing) of the T and R wires on the communication loop between controllers or other com-munications devices. Always be sure to double check all communication wiring and ad-dressing before initial commissioning of the system. The address switches must be setand the power cycled in order for the address to be recognized by the system. Please seeFigure 4-3 for Zone Controller addressing information.

Figure 4-3: Zone Controller Communications Wiring & Address Switch Setting





ADDRESSADD

ADDRESSADD

1 14 4

8 82 2

16 1632 32TOKENTOKENNET

NET

ADDRESSADD

SW

1

1122

44881616

32 (Always OFF- Not Used)32TOKEN

NETTOKEN (Always OFF)NET(Always ON)

Address Switch Values

Switch Shown IsSet For Address 5

Note:1.) Ignore Any Markings On The Switch Body.2.) Use The Address Charts Below Or Address Switch

Value Table Above To Determine Correct Switch Setting.3.) Power To Controller Must Be Turned Off And

Back On In Order For Switch Settings To Take Effect.

Zone Controller Address Switch SettingAddress Switch ValuesAddress Switch Values AreAdded Together When TheRocker Is Pushed Down InThe Direction Of The “ADDRESSADD” Arrow Marked On The ZoneController Circuit Board

CX

6

SW

1

Q3

Q2

D3

VR

17

82

4

GND

24VAC

R1

7

R1

6

U7

C7

R1

5

PO

WE

RR

21

RE

V.

2

YS

10

15

62

MDL

F1

250D4

R26

LD3

L1

SCAN REC

R1

2

C6

R11

TOKEN

NET

LD

2

32

R1

4

R1

3

R1

00

LD

1

C5

D1

K1

V2

K2

D2

AC

TU

AT

OR

R1

0

R9

PJ2

V1

C4

T

SHLD

R

8

16

2

4

ADDRESSADD

1 U6


3.)Power To The Zone Controller MustBe Cycled Before Address SwitchChanges Will Take Affect.


Zone Controller


Zone Controller

Notes:


R

SH

T

R

SH

T

R

SH

T

R

SH

T


Local LoopRS-485

9600 Baud




ADDRESS ADD

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

SW1

1 1 1 1

1 1 1 1 1

1 1 1 1 1

1

2 2 2 2 2

2 2 2 2 2

2 2 2 2 2

2

4 4 4 4 4

4 4 4 4 4

4 4 4 4 4

4

8 8 8 8 8

8 8 8 8 8

8 8 8 8 8

8

16 16 16 16 16

16 16 16 16 16

16 16 16 16 16

16

32 32 32 32 32

32 32 32 32 32

32 32 32 32 32

32




TOKEN




NETWORK

1

6

11

16

12 13 14 15

2

7

3

8

4

9

5

10



CommLink Communications (Optional)The CommLink is optional for the Basic system. It is required only if alarm call-out,connection to an on-site PC or remote PC is required. For the Basic system to functioncorrectly the CommLink must be set to single loop operation mode by setting the jumperposition on the CommLink board. Also the CommLink communications must be wiredcorrectly to the system and connected correctly to the computer (if used) and RemoteLink. It must also be powered up in order for either system to communicate. In additionthe Zone Manager address should be set to 17 instead of 0 when the CommLink is to beused. See Figure 4-4 for more information.

Figure 4-4: CommLink (Optional) Wiring & Jumper Settings

Notes:

R

SH

T

R

SH

T

R

SH

T

R

SH

T

All Communication LoopWiring Is Straight Through

Caution:Disconnect All Communication Loop WiringFrom The CommLink Before Removing PowerFrom The CommLink. Reconnect Power And ThenReconnect Communication Loop Wiring.

Connect To The Basic Zone ManagerCommunications Terminals (T-S-R)

Network LoopRS-485

19200 Baud

Local LoopRS-485

9600 Baud

Line Voltage

See Note 1

24VAC

Required VA For TransformerCommLink = 14VA Max.

CommLink Is Supplied With 110/24VAC Power Supply.If Desired A Transformer (By Others)

May Be Wired To The CommLink Instead. See Note 1.COMMLINK II COMMUNICATIONS INTERFACE

(Multiple Loop or Single Loop)

Molded Modem Cable.Supplied With CommLink

(DTE)

REMOTE LINKREMOTE LINK

485 LOOP485 LOOP

COMPUTER(DCE)

GT R

G2

V4

DN

POWER

4 Piece ComputerCable Kit. 4Supplied WithCommLink

Use 25 Pin Or 9 Pin Connector As Required ByAvailable Serial (COM) Port On Computer.

Connect To Remote Link .Only

9P

inF

em

ale

9 PinFemale

25 PinFemale

9P

inF

em

ale

120/24 VacTransformer

25 PinMale

Warning: Use The “Molded Cable” ToConnect To The Computer (DCE) ConnectorOr Serious Damage To The CommLink CouldResult. This Cable Is Only To Be Used ToConnect From The CommLink (DTE)Connection To The Remote Link (When Used).

Do Not

Warning: Use The “25 Pin Or 9 Pin Cable”To Connect To The Remote Link (DTE) Connector OrSerious Damage ToThe CommLink Could Result.This Cable Is Only To Be Used To Connect From TheCommLink (DCE) Connection To The Computer

Do Not

Connect Supplied RJ12 Modular Phone CableTo Supplied 9 Pin Or 25 Pin Connector As ReqdBy Your Computer Com Port Connection



Note:Place Jumper BetweenBetween Pins 2 & 3 ForSingle Loop Application.This Is The Correct SettingFor The Basic System.

3.)Network and/or Local LoopCommunication Wiring To Be 2Conductor Twisted Pair WithShield. Use Belden #82760 OrEquivalent.

4.)The Basic System Requires TheJumper To Be Set For SingleLoop Operation.

COMM DRIVER CHIP( U1 )PIN 1

MULTI

SINGLE

12

3

CommLink Jumper Switch Settings



Basic SystemCommunications ChecklistBasic 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 WithOptional CommLink

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

Other Optional Equipment Personal computer is correctly connected to the CommLink Prism™ software installed on personal computer Remote Link is correctly connected to the CommLink Remote Link connected to a working phone line



Components & WiringThe following information is intended as a review of the procedures and design data pro-vided in section 2 of this manual. Section 2 should be thoroughly studied before at-tempting the initial installation of the system. If however you find yourself starting up ortroubleshooting a system that was installed by someone else, the following informationshould be helpful in gaining a quick overview of the system you are working with.

Zone Manager IO & ComponentsThe Zone Manager inputs and outputs and components are shown below. It is importantto familiarize yourself with these components and their locations to facilitate properconnection, startup and troubleshooting of the Basic system. See Figure 4-5.

Figure 4-5: Zone Manager Components

U1

3

CX

13

EPROM

U11

CX11

U10

RAM

CX

10

JO2

32

K

8K

16

32 28 4

AD

D

1

NET

B

V9

V8

V7

R

FAN

COOL1

COOL2

HEAT1

HEAT2

K8

K7

K6

K5

K4

K3

K2

CLOSE

OPEN

GND

FDBK

V4

V3

V6

V5

TB7

R5

7

HEAT2

D3

1

HEAT1

D2

2

R5

6

D2

1

R5

2

COOL2

COOL1

R4

6

D2

0

FAN

D1

9

R4

4

CLOSE

D1

8

OPEN

D1

7

R4

3R4

1

D2

3

D2

4

D2

6

D2

5

D2

9

D3

0

D2

8

D2

7

SW

1

U1

4

CX

14

MADE IN U.S.A.

1992

RN2

1

R5

8

U1

5

CX

15

R5

9

R6

0

RS-485

COMM DRIVER

T

SH

R

U12

CX12

R49

R55

R45

R47

R48

C22

COMM

P1

CX9

U9

ANALOG

OUTPUTS

EXP

BUSS

ECONOMIZER

EXH/RELIEF

GND

TB8

TB5

YS101722

Rev. 2

C21 C20

X2

R4

2

D1

6

EXHAUST

CONTACTS

N.O.

TB4V2

C6U2

R7

R38

R37

C15 C16

R31

R30

R28

R27

R19

C13 C14

R14

R17

R16

R12

C7 C8

R11

TB3

GND

GND

AUX2

AUX3

SAT

RAT

OAT

AUX1

+12V

ANALOG

INPUTS

D2

D3

D5

D4

D8

D6

R15

C11

U7

CX7

Q2

PJ1

+5

V

SIG

GN

D

PRESSU

RE

SEN

SO

RJA

CK

TB1

R5

R4R2

R3

R1

U1

CX1

C4 C5

D1

R9

C1

C2 C3

VR2

VR1

SC1

24VAC

V1

R1

0

U3

CX3

U5

CX

5

Q1

R2

2

R2

1

D1

0

R2

3

R2

4

R2

0

R3

6

R2

9

R33

R35

R32

R34

CX

4

C1

2

R2

5

D1

2

VR3

R13

R26

D11

D9

R18

U6

CX

6

C17

D13

D14

D15

R39

R40

I2C EXP PORT

GND

TB2

POWER

D7

L1

C9

Y1

EW

DO

G

J0

1

U8

C18 C19

5.11V

ADJ

5.11V

ADJUST

PU1

PU2

PU3

PU4

PU5

PU6

RN1

REC

BYPASSPDAMPER

R6

1

HVAC UnitConnections(R) CommonFanCool 1Cool 2Heat 1Heat 2

BypassDamperConnectionsFDBKGNDOpenClose

RS-485CommunicationsLoop ConnectionTSHR

TypicalPin 1IndicatorRAM

ChipEPROMChip

PALChip


RS-485CommunicationsDriver Chip

Real TimeClock Chip

Real TimeClock Chip

Display &KeypadRibbon CableConnector

Static PressureSensor Inputs+5VSIGGND

Static PressureSensor - OptionalModular ConnectionInput

CommLED

Not Used

Address Switch(Set To 0 WithoutCommLink. Set to 17With CommLink)

Analog InputsSATRATOATAUX1AUX2AUX3GND

Analog Output0-10 VDCEconomizer

Binary OutputRelief/ExhaustFans

Power LED

24 VACPower Input

Mounting HolesTyp. Of 4

Note:Keypad & DisplayNot Shown



Zone Manager WiringCorrect wiring of the Zone Manager is critical to proper system operation. If componentsare wired to the wrong inputs, the system will not operate correctly or will not operate atall. Correct wiring of the 24VAC power is extremely critical. If voltage greater than24VAC is applied to the terminal it will damage the board beyond repair. All 24VACwiring must be connected so that all ground wires remain common. Failure to complywith this will also result in damage to the board. See Figure 4-6. Also see Section 2 ofthis manual for more detailed wiring instructions and procedures.

Figure 4-6: Zone Manager Wiring

Basic Zone Manager

Notes:


3.)All Communication Wiring To Be 18Ga. Minimum, 2 Conductor TwistedPair With Shield. Belden #82760 OrEquivalent.

2.)All Wiring To Be In Accordance WithLocal And National Electrical Codesand Specifications.




Controllers

Return Air Temp.Sensor

Suppy Air Temp.Sensor

LineVoltage

HV

AC

Un

it

24VAC Only

Re

d

Blk

To Relief / Exhaust Fans

Grn

StaticPick-up


Splice AsRequired

LO HI

GND

24VAC

Belimo Actuator Wiring Shown.Consult Factory For Other

Models Of Economizer Actuators.Some Actuators Require IsolationTransformers In Order To PreventDamage To The Controller Board.

WARNING!

Use Extreme Care When WiringEconomizer Actuators

Never Connect Or DisconnectWiring With Power Applied!

Never Apply Power If TheGnd ( 1 Com ) Terminal On The

Actuator Is Not Connected.

See Note 1 &2

Outdoor Air Temp.Sensor

(See Note 4)

Aux3Forced

OccupiedMode

Aux1Economizer

Disable

Aux2FilterAlarm

Auxiliary Inputs( Dry Contacts )

R

G

Y1

Y2

W1

W2

Economizer Actuator

133 IN-LB

AF24-SR

1 COM

2 +

3 Y1

4 Y2

5 UBELIMO

C987

CABLE

R6

R5

HEAT 2 SW

1

W2

W1

Y2

HEAT2

HEAT1

COOL2

COOL1

FAN

HEAT 1

COOL 2

COOL 1

C 1992

11632

BNET

248

AD

D

COMM DRIVER

RS-485

75176

MADE IN U.S.A.

D1

7

D1

8

D1

9

D2

0

D2

1

D2

2

D2

3

D2

4

0* # D

R

SH

T

COMM

C1C2

+

P1

RIBBON

GN

D

G

Y1V6

V5

CLOSE

V4

V3

OPEN

GND

FDBK

FAN

CLOSE

OPEN

+

REC

+

GND

NE5090

4 5 6

KEYPAD

1 2 3

B

A

LCD DISPLAY

&

++

24VAC

TB2

POWER

+

++

ADJUST

5.11V

PJ1

++PRESSU

RE

SEN

SO

RJA

CK

+5

V

SIG

BUSS

EXP

TB2

A2

G

OUTPUTS

ANALOG

A1

N.O.

CONTACTS

EXHAUST

AUX3

GND

GND

AUX2

AUX1

ANALOG

SAT

OAT

RAT

INPUTS

+12V

TB1

2

BYPASS

BYPASS

Local Loop

OF

F>

RockerDown

Bypass & SlaveInterface Card

BypassAir Damper

Actuator

10

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CL

OS

E

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2



Zone Controller IO & ComponentsThe Zone Controller inputs, outputs and components are shown below. As with the ZoneManager knowing the location and function of the Zone Controllers inputs, outputs andcomponents is critical to proper start-up and troubleshooting of the Basic system. SeeFigure 4-7.

Figure 4-7: Zone Controller Components

CX

6

SW

1

U10

75176

EX

PA

NS

ION

Q3

Q2

D3

VR

17824

GND

24VAC

R17

R16

U7

C7

R15

PO

WE

RR

21

RE

V.2

YS

101

562

MDL

F1

250D4

R26

LD3

L1

SCAN REC

R12

C6

R11

TOKEN

NET

LD

2

32

R14

R13

R100

LD

1

C5

D1

K1

V2

K2

D2

AC

TU

AT

OR

R10

R9

PJ2

V1

C4

EPROM

VR

EF

AD

J

R23

C10

EW

DO

G

CO

MM

D7

CX10

R25

R2

8

T'STAT

U11

C15

R2

0

C11

R24

8

16

2

4

ADDRESS

ADD

1 U6

U5

R1

9

U9CX9

R32

D5C

14

P.U.

R22

C13

R2

7

D5

RAM

C9

C8

80C55

2

CX

5P

J1

C3

R8

R7

R5

R6

R4

C2

C1

X1

U2

R1

R2

R3

CX2

Q1

16L8

32K

R34FLOW

U8

1

RN1

CX8 U4

R18 CX4

8K

RAM

U3

CX3

U1

CX1

Diagnostic BlinkCode LED

Power LED

RS-485CommunicationsLoop Connection

TypicalPin 1Indicator

RAMChip

EPROMChip

PALChip


Air Flow SensorModular Connector

Auxiliary InputTerminals

Expansion BoardModular Connector

Damper ActuatorModular Connector

Address Switch(Set Between 1 & 16)Space Sensor

Terminals

Fuse

24 VACPower Input



Zone Controller WiringCorrect wiring of the Zone Controller is critical to proper system operation. If compo-nents are wired to the wrong inputs, the system will not operate correctly or will not op-erate at all. Correct wiring of the 24VAC power is extremely critical. If voltage greaterthan 24VAC is applied to the terminal it will damage the board beyond repair. It is rec-ommended that a separate transformer be used for each Zone Controller. If one trans-former is used to power multiple Zone Controllers, all 24VAC wiring must be connectedso that all ground wires remain common. DO NOT REVERSE POLARITYBETWEEN CONTROLLERS. Failure to comply with this will also result in damage tothe board. See Figure 4-8. Also see Section 2 of this manual for more detailed wiringinstructions and procedures.

Figure 4-8: Zone Controller Wiring

Notes:

See Note 1

R

SH

T

R

SH

T

R

SH

T

R

SH

T


Required VA For TransformerEach Zone Controller = 10 VA Max.

24VAC

GND

GND

AUX

TMP

NORMAL

OVR

RELO

C

REMR

O

AW

Room Sensor

Zone Actuator

Local LoopRS-485

9600 Baud

Airflow Sensor (Optional)Only Used For PressureIndependent Applications

Connect ToNext Controller

On Loop OrIf This Is FirstController On

Loop AlsoConnect To

Zone Manager

Connect ToRelay

ExpansionBoard When

Used





10

SHIELD

R

T

HiLo

Airflow

CX

6

SW

1

U1

0

75

17

6

EX

PA

NS

ION

Q3

Q2

D3

VR

17

82

4

GND

24VAC

R1

7

R1

6

U7

C7

R1

5

PO

WE

RR

21

RE

V.

2

YS

10

1

56

2

MDL

F1

250D4

R26

LD3

L1

SCAN REC

R1

2

C6

R11

TOKEN

NET

LD

2

32

R1

4

R1

3

R1

00

LD

1

C5

D1

K1

V2

K2

D2

AC

TU

AT

OR

R1

0

R9

PJ2

V1

C4

EPROM

VR

EF

AD

J

R23

C1

0

EW

DO

G

CO

MM

D7

CX10

R25

R28

T'STAT

U11

C1

5

R20

C11

R24

8

16

2

4

ADDRESS

ADD

1 U6

U5

R19

U9CX9

R32

D5

C1

4

P.U.

R22

C1

3

R27

D5

RAM

C9

C8

80C55

2

CX

5P

J1

C3

R8

R7

R5

R6

R4

C2

C1

X1

U2

R1

R2

R3

CX2

Q1

16L8

32K

R3

4FLOW

U8

1

RN1

CX8 U4

R1

8 CX48K

RAM

U3

CX3

U1

CX1



Startup & CommissioningCommissioning the system correctly is one of the most important steps in getting a sys-tem installed and functioning with the least amount of problems and in the shortest lengthof time.

ProceduresThe following is a list of items and reminders that are essential to the successful commis-sioning of your system. Some of these items have already been discussed in this manualand are repeated to confirm correct procedures. Familiarize yourself with this installationmanual 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 commu-nication cable will begin for the Basic system.

3) Layout your communication wiring per the instructions in the previous por-tion of this manual.

4) The communications loop originates at the Zone Manager. All Zone Control-lers are connected to this loop.

Tip: Using the Auto-Zone color-coded and labeled Communication Cable in-sures a quality installation.

5) Always refer to the Basic System Wiring Diagrams for specific wiring de-tails. Communication cable must always be shielded – no exceptions!

6) Mount controllers in appropriate locations according to their operating speci-fication.

7) Use the Basic System Worksheet included in the back of this section or theones included with the submittal package to document unit location, descrip-tions, addressing and setup. Address controllers according to location and ad-dressing instructions located in this system manual.



Procedures (Continued)8) With no power connected, wire the Zone Manager and Zone Controllers ac-

cording to wiring diagrams and in accordance with local codes. Do Not ApplyPower!

9) After completing all wiring connections, unplug the terminals for power andcommunications on the Zone Manager and all Zone Controllers. Always un-plug the communications loop first and then the power. When reconnectingthe wiring, connect the power first and then the communication loop. Eventhough the system does not have power applied to it at this time, it is a goodhabit to get into. Later when power is applied, this is very important to insureagainst the possibility of shorting the communications loop to ground.

10) If your system uses the optional CommLink, locate and install the CommLink.Do Not Apply Power!

11) Reconnect the power and then the communications loop to the Zone Managerand the first Zone Controller on the loop.

12) Observe the LCD screen on the Zone Manager. It will go through a start-upprocedure upon being powered up. See the Start-up Screens heading whichfollows, in this section of the manual, for complete start-up Screen informa-tion.

13) The Zone Manager will proceed through system start-up, initialization andcalibration. This calibration could take up to five minutes. After the initializa-tion is complete the main system screen will appear. In the bottom right handcorner it will show the current zone polling address. See Section 3 of thismanual for complete screen operations and programming. If the addressshown 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 theZone Address for the controller you are checking. If this is the first controlleron the loop and 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 iscommunicating but still calibrating it will display “Calibrating”. If the zone iscommunicating, the display will change over to the Zone Status screen whencalibration is complete. If the zone is communicating, proceed to step 16. Ifthe screen shows that the zone is missing, proceed to step 15.



Procedures (Continued)14) Check the Zone Controller for correct communications and addressing by ob-

serving the LED indicator for the blink codes as outlined in the troubleshoot-ing section of the manual. The blink code will first verify the address, then theoperation. If the address is incorrect, reset the address switch, then reapplypower to the controller. If you cannot communicate, verify wiring, voltages,etc. in accordance with the trouble-shooting section in the system manual. Donot proceed to the next device until you are properly communicating with thecurrent 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 andthe zone controller you are testing. Be sure the Zone Manager is still poweredand connected to the communication loop, press the “B” key on the ZoneManager keypad. Enter the Zone Address for the controller you are checking.If this is the third controller on the loop and is addressed as 3, you wouldpress 3 and then the “Enter” key. If the zone isn’t communicating it will dis-play “***Missing***. If the zone is communicating but still calibrating it willdisplay “Calibrating”. If the zone is communicating the display will changeover to the Zone Status screen when calibration is complete. If the screenshows that the zone is missing, proceed to step 14. If the zone is communi-cating, repeat this step with each zone controller on the loop, in sequence, un-til all zone controllers on the loop are communicating.

16) Once all devices on the loop are communicating, you must program and con-figure the Zone Manager and all the Zone Controllers on the system per theprogramming section of this manual.

Remember that each controller only contains one puff of smoke. Making sure that allwiring terminations and voltages are correct prior to applying power to a controller willinsure that you don’t use that one puff up.



Basic System WorksheetProject: _______________________ Location ______________________________________________

CommLink Installed: Yes No Remote Link Installed: Yes No Phone:_________________

Stages of Cooling ____ Stages of Heating ____ Gas Electric Economizer Yes No

Zoning: Pressure Dependent Pressure IndependentZone

AddressZone Description or Location

AirDamper

Size

RoomSensor Type

RelayExp. Board

















[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]



Start-UpOn Auto-Zone Basic system power up, the following tests, calibration and initializationand procedures occur:

Figure 4-9: Basic Zone Manager

Initializing System

Please Wait

Start-Up Delay 49 Number of Zones 1 03/27/02 09:20am Wed STATIC NULL: 0.25




POWERUP TEST

FAN

COO

L1

COO

L2

HEAT1

HEAT2

BYPASSO

PEN

BYPASSCLO

SE

COM

MUNIC

ATION

ALARM

A=

ALLZO

NES

B=

EACHZO

NE

C=

HVACUNIT

/CLEAR

D=

ALARMS

#=

STEP/ENTER

* =DECIM

AL

+

+

+

+

Cool

Mode

04-22-02

03:48PMMON

OCCUPIED

NOALARMS

2

8

5

0

A

C

B

D

1

7

4

*

3

9

6

#

Keypad

Display

1.) The system setpoints are loaded and outputs areturned off and the LED's are initialized ON. Thescreen displays

2.) System Diagnostics and Calibrations occur.a.) A 50 second startup delay occurs. While this

is counting down, the LED's will extinguish,one every 6 seconds.

b.) The number of zones is displayed on thesecond line. If the Zone Manager has neverbeen configured, the system will only show"1" zone. If this isn't the first power-up, itwill display the number of zones for whichthe system is configured.

c.) The current date and time will be displayedon the third line. If this is the first power-up,the date and time may be incorrect.

d.) The Static Pressure Sensor NULL Voltagewill be displayed on the bottom line. Thestatic pressure sensor NULL voltage is readat the factory during power-up checks priorto shipping. If necessary, the user can re-calibrate the pressure sensor, using the pro-cedure described in Section 3, Zone ManagerConfiguration, Configuration Screen #7.



Bypass Calibration Please Wait...

Initializing Zones

Vent Mode 03/27/02 09:30pm Wed Occupied 1 Alarm(s) 3

3.) At the conclusion of the 50 second startup delay, thesystem will proceed with the bypass damper calibra-tion. Depending on the degree of travel and the speedof the damper actuator, this process could take up to amaximum of three minutes.

4.) The zones are all polled and initialized.

5.) The Main Operating Screen will now appear (seeSection 3, LCD/Keypad Operations) and normal op-eration will begin. The total startup time is approxi-mately four minutes.



Blink Codes For Zone ControllersThe Zone Controller uses an on board SCAN LED to indicate various conditions duringpower up and operation. Starting with power up the SCAN LED the blink codes are asfollows:

• 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 continuous during damper calibration• Status code is repeatedly blinked every 10 seconds to indicate controller

status:

Priority Number of Blinks StatusLowest 1 Normal Operation

- 2 Override Active- 3 Bad Zone or Airflow Sensor- 4 Damper Failure

Highest 5 Communication Failure

Table 4-1: SCAN LED Blink Codes

Only the highest priority failure code will be shown. You must correct the highest prior-ity alarm before other problems will be indicated.



TroubleshootingThe following is a guide to assist in troubleshooting the Auto-Zone Basic System. It isprovided as a systematic approach to determining and resolving common system prob-lems.

Trouble Shooting ChecklistBegin troubleshooting by locating the general problem in the list below. Detailed compo-nent 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 it’s 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.



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 alocation with adequate room air circulation.

• Is the voltage reading correct? Is the resistance reading correct? Check with theTable 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 thesensor terminals. If the voltage does not match theTEMPERATURE/RESISTANCE chart, unplug the two position room sensorterminal block. Using your meter, check the resistance of the unplugged terminalblock. Use the supplied TEMPERATURE/RESISTANCE chart to see if the sen-sor is within a reasonable range. Readings which are much too high or too lowgenerally indicate wiring problems.

• To meter the Slide Adjust (optional):

Unplug the four position AUX terminal block. Use your ohmmeter to check theresistance between the GND wire on the two position room sensor terminal blockand 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 15K Ω (± 500 Ω)MID position 12.5K Ω (± 500 Ω)

Full DN position 10K Ω (± 500 Ω)



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 posi-tion before applying power.

• Is the Zone Controller set for DIRECT/REVERSE action? The zone controllermust be configured for correct operation if REVERSE action of the damper is re-quired.

Caution: Improper mounting and the associated adjustment of the damper bladepositioning is the number one cause of damper related problems. It canbe difficult to determine the full open position if the damper shafts arenot 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 unpluggingthe actuator then depressing the actuator clutch release and manuallypositioning the damper.

No Zones are Communicating

• If used, is the CommLink II connected and plugged in?• Is the Zone Manager address set correctly?

Address = 17 if CommLink II is usedAddress = 0 if no CommLink II is used.

• Are COMM LOOP voltages correct? See the COMM LOOP troubleshootingguide.

• 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.



Some Zones are communicating but others are not:

• 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 Control-

ler 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.



Trouble Shooting Chart

Problem Possible Cause Solution1 Display screen

blank or solid blackbars

Ribbon cable con-nectors loose.

Check and re-seat plugs on ribbon ca-ble between the cover and mother-board. Re-cycle power if necessary.Check all “pluggable” components onthe board to make sure they are allfully seated.

2 Display screenwashed-out ordifficult to see.

Contrast needs ad-justment

Remove cover, but leave ribbon cableconnected. Adjust contrast by turningadjustment pot located at the bottomedge of the control board located onthe cover, behind the display screen.

3 Zone Manager con-tinually Initializes(start-up cycle re-peats)

Wiring fault such asshorted lead on thebypass actuator oron one of the heat-ing/cooling stages

Carefully check all wiring. Disconnectrelay outputs and the bypass connectorto isolate the source of the problem.

4 Can only read datafrom Zone 1 or onlyfrom some of thezones.

Zone Manager con-figured for incorrectnumber of zones.

Enter access code, and under “Config-ure System” enter first and last zonenumber.

Zone Controller(s)addressed incor-rectly.

Check Zone Controller address usingdata from Figure 2-7 of this manual.

Comm Loop Prob-lem

Check Comm Loop using Comm Looptroubleshooting guide in this Section.



Problem Possible Cause Solution5 Zones cold or hot

and second stage ofcooling or heatingdoes not come on.

Zone Manager notconfigured for twostages.

Under the Configure System menu,enter correct number of stages.In the Cooling Mode, the supply tem-perature must be above 45°F for anyadditional stages of cooling to activate.In the Heating Mode the supply tem-perature must be below 105°F forelectric heat and below 160°F for gasheat.

6 Zones calling forcooling but “Cool”light does not comeon.

Zone Managerconfigured for “0"stages of cooling.

Under the Configure System menu,enter the correct number of coolingstages.

Supply temperaturetoo cold or faultyduct temp sensor

Press “C” key and read supply air tem-perature. If less than 58°F, the supplytemperature is too low to allow coolingto be energized or the duct sensor isfaulty. Correct as appropriate.

Economizer is en-abled and acts asfirst stage of cool-ing. Will not allowmechanical coolinguntil damper is 100percent open.

Check Economizer setpoints anddamper position

Outside air temp isbelow CoolingLockout setpoint.

Check Cooling Lockout setpoint andoutside air temp.

Minimum coolingOff Time has notbeen met.

Check minimum Off Time for cooling.Warning: Do not set minimum offtime to less than manufacturers rec-ommended time. Damage to equipmentmay result.

Unit is in Heat-ing/CoolingChangeover delay.

Check changeover delay. Default delayis ten minutes.



Troubleshooting Chart for Alarms

Problem Possible Cause Solution1 Bad Duct Sensor Faulty Wiring/Sensor The duct sensor reads actual tempera-

ture between 35°F and 210°F. If theactual temperature at the sensor probeas measured with a thermometer iswithin these limits, check the sensorvoltage. If voltage does not match thechart, then check the total sensor/wireresistance by removing wires fromterminals SAT and GND on the TB3terminal strip. Measure the resistancein the wires and compare it to the tem-perature/resistance chart. If the resis-tance measured does not match thechart, go to the sensor, disconnect itand measure the resistance directlyacross the sensor. If resistance is cor-rect, check wiring between the con-troller and sensor. If sensor is notwithin tolerances, replace the sensor.

2 Bad Static Sensor Too low/high ductstatic

With fan running (red fan LED is on),read duct static using “C” key on ZoneManager. If reading is below 0.01,check sensor tubing connectors forloose or reversed connections. Check ifthere is airflow (pressure) at the sensorlocation (mounted too close after anelbow may cause negative pressure). Ifreading is above 3.0, check actualstatic or if sensor is pointing into airstream picking up total pressure. Dis-connecting sensing tube from the sen-sor should cause reading to go to “0."If not, check wiring and replace sensorif it does not read correctly when wireddirectly to the Zone Manager.

Bypass damper actionincorrect.

Check bypass configuration for Director Reverse Acting. See Section 3, ZoneManager Configuration, ConfigurationScreen #5.



Problem Possible Cause Solution3 Bad Zone Sensor Faulty Wiring/Sensor An alarm occurs if the zone tempera-

ture reading is below 40°F or above105°F. If actual temperature at the sen-sor is between these temperatures andan alarm occurs, start troubleshootingat the zone sensor. Measure the sensorvoltage either at the sensor or the ZoneController. If it does not match thechart, remove it from the wall, discon-nect its wires and measure the resis-tance between TMP & GND. Resis-tance should compare to values in theTemperature/Resistance chart. (Re-member temperature of sensor may beaffected by the heat of your hands). Ifthe resistance is significantly differentfrom the chart, replace the sensor. On3-wire sensors with a “Warmer-Cooler” pot, the resistance betweenAUX & GND should vary from 10K to15K Ohms depending on the positionof the pot. If the resistance is accept-able, check the wiring between thesensor and the controller by recon-necting the sensor and going to thezone controller, lifting the sensor ter-minal plug and reading the resistancein the wires. Reversing TMP and GNDwires on a 3-wire sensor will signifi-cantly affect the readings. In checkingsensor wiring, also check for loosestrands of braided wire shorting toground at the terminals that may affectreadings.



Problem Possible Cause Solution4 Bypass Damper Sticking Damper Depress Clutch button and check that

the damper moves freely withoutbinding. Note: If the actuator hasdriven against its “stop” screw, rotat-ing the actuator shaft by disengagingthe clutch may not be possible. If thisis the case, loosen the setscrews androtate the damper shaft to observebinding. If binding is observed, correctthe binding problem and force recali-bration of the damper by cyclingpower to the Zone Manager. Ifsetscrews were loosened, be suredamper shaft is properly positionedbefore tightening. (Counter clockwise= closed = Direct Acting)Warning: Actuator can be damagedif rotation is forced! Make sure theclutch button is fully depressed beforerotating damper.

Improper Wiring Determine that wiring matches Figure2-5.Note: If more than one bypassdamper is wired in parallel, connectonly one of the feedback pots asshown in the schematic wiring diagramper Figure 2-9.

Actuator motorfailure

Check voltage to the actuator duringthe 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 slaveinterface card should also light up.Similarly, 24 VAC should be measuredbetween “Open” and “GND” in thedrive open phase of the calibrationroutine and the green LED light on thebypass and slave interface card shouldalso light up. If 24 VAC is present, butthe actuator does not drive, replaceactuator. See Figure 4-10.



Problem Possible Cause Solution4 Bypass Damper

ContinuedFaulty Feedbackpot

Verify the ability of the actuator todrive full open to full closed. Initializea bypass calibration by cycling powerto the Zone Manager. This will causethe actuator to first drive full open (ob-serve light(s) on the Zone Manager andBypass and Slave Interface Card anddamper action), then drive full closed,and then drive approximately 25%open. Also measure voltage from thebypass actuator feedback pot (termi-nals FDBK & GND on the BypassDamper terminal strip). As the actuatordrives toward the open position, thisvoltage should increase toward 0.0VDC depending on the amount oftravel. As the actuator drives closed,this voltage should increase toward 2.5VDC. A change of less than 0.4 VDCfrom full open to closed results in analarm, indicating either insufficientdamper travel, a faulty actuator, or im-proper wiring.

5 Maverick Zone Insufficient air flowto zone

If zone temperature is more than 4°Ffrom the setpoint for more than onehour, the alarm appears. Check airflowto the zone by depressing the clutch onthe actuator and rotating the damperfully counterclockwise. Dampershould be fully closed and no airflowto the zone. Rotating the damperclockwise should open the damper tomaximum flow. (Travel should be lim-ited with stop screws for maximumrotation). Check damper for ease ofmovement and correct any stickingsituation and reset the alarm. A Mav-erick Alarm will automatically be resetwhen the zone temperature comeswithin 2 degrees of its setpoint.



Problem Possible Cause Solution5 Maverick Zone

ContinuedThis alarm may also be reset by tempo-rarily resetting the zone setpoint(heating setpoint if zone is cool, cool-ing setpoint if zone is hot) to the tem-perature reported by the zone sensor.

Unusual zone load If a zone is loaded beyond system ca-pacity to cool/heat the space due tolarge crowds, process load, open doorsetc., the result is the same as “insuffi-cient air” to space as listed above, andcan only be corrected by removing theunusual load or increasing airflow tothe zone.

6 Missing ZoneAlarm

No power to zonecontroller

If LEDs on Zone Controller are not on,check for 24 VAC on Zone Controller.If 24 VAC is present, but LEDs are noton, check voltage polarity and replacezone board if required.

Improperly ad-dressed

Check dipswitches on zone board forproper setting (refer to Figure 2-13).Switches must be set before power isapplied. Replace COMM connector,then remove and replace 24 VAC con-nector. Approximately five secondsafter power-up the “SCAN” LED onthe zone control board will “blink” itsaddress. Confirm that the proper ad-dress is indicated. Thereafter, theSCAN LED will blink approximatelyonce every ten seconds (refer to Table4-1).

COMM incorrectlywired

If multiple zones are “missing” and itis not due to improper setting of zoneaddresses or the Zone Manager addressas noted previously, it is a good indi-cation that either communication loopwires are crossed or the polarity on the24 VAC power supply has beencrossed and damage to the communi-cation driver chips has occurred.



Problem Possible Cause Solution6 Missing Zone

AlarmContinued

If multiple zones are missing, but somezones are communicating, remove thecommunication plug on all missingzone cards and begin trouble shootingone zone at a time.1. Check the communication loop for

crossed wires, starting at the ZoneManager, (or the “communicatingzone” nearest to the “missing”zone). If all zones are missing, startat the Zone Manager and connectonly one zone at a time to isolatethe problem. Also, check forstrands of braided wire that may beloose at the terminal connection andtouching adjacent wires. If wiring iscrossed, correct the wiring problem.(Crossed COMM Loop wires willcause missing zones, but should notcause damage to the boards).

2. Check COMM Loop voltages.A. Refer to communication loop

troubleshooting guide in thisSection.

B. If the voltage on the board “pins”(step A above) is correct, withthe comm plug still removedfrom the board, measure thevoltage on the comm line. Ifthese voltages are not between 2and 3 VDC it means either thereis another controller on the loopwith a bad driver chip, or there isa wiring connection problem onthe loop that must be correctedby isolating the problem as out-lined above.



Problem Possible Cause Solution7 Missing Zone

Alarm (All ZonesMissing)

Zone Manager Im-properly Addressed

The Zone Manager should be ad-dressed as "0." If a CommLink is in-stalled, the address should be set toaddress "17."

8 Static Null Alarm Incorrect NULLvoltage detected forPressure Sensor

The NULL voltage is measured withthe fan off and no pressure in the duct.This measurement only occurs the firsttime the Zone Manager is powered up.To force the Zone Manager to re-calibrate the NULL voltage, select theConfigure System menu and press the“*“ key when prompted, to force therestart with calibration.

Faulty Pressuresensor

Check the voltage to the pressuretransducer at TB1 with the fan off.Voltage between SIG and GND shouldbe between 0.23 and 0.27 VDC. This isthe NULL voltage. If this voltage isnot present, confirm the +5V terminalsupplies 5 VDC and wiring to sensor iscorrect. Before replacing the sensor,remove it from the duct and check thevoltages with the sensor directly wiredto the controller, using short wireleads, to confirm there are no wiringerrors.

9 Zone Damper Fail Travel Stop Screwslipped

Check the stop screws on the damperactuator. They should be set to prop-erly limit the travel. Reset if necessary.

Damper Binding Depress the clutch and check thedamper for free rotation.Note: If the actuator has driven against its

stop screw, rotating the shaft maynot be possible. If this is the case,loosen the setscrews and rotate thedamper shaft to observe binding. Ifthe shaft turns freely, reconnect thedamper actuator and proceed to thenext step. The standard dampercloses counter clockwise and isfully open after rotating 85 to 90degrees clockwise.



Problem Possible Cause Solution9 Zone Damper Fail

ContinuedFeedback pot fail-ure

If you suspect an actuator feedbackfailure, replace the actuator with aknown working unit to see if the prob-lem is corrected. If not, continue tofollow troubleshooting procedures forcontroller, wiring, etc.

Calibration routinefailure

Force auto calibrate of the actuatorfeedback pot by:a: Remove the communication wireconnector at the Zone Controller.b. Remove the 24 VAC power connec-tion at the Zone Controller.c. Replace the 24 VAC power connec-tion at the Zone Controller.d. Replace the communication con-nector at the Zone Controller.d. The actuator will recalibrate the po-tentiometer by driving full closed, thenfull open, then start to control. If theactuator does not drive after restoringthe 24 VAC power (in step c) either theactuator or Zone Controller is bad. Ifthe calibration routine is completed andthe alarm disappears, the problem mayhave been an isolated incident causedby a power surge.

Connector CableDefective

Check cable by replacing with a knownworking cable. Replace if required.



Communications LoopZone ManagerTest the communications loop with the system powered. Set meter to read DC Volts.These tests assume that if the optional Comm Link is installed, it is also connected andpowered up. Actual meter readings may deviate slightly depending on the number ofunits installed. Any significant deviation from these values generally indicates a problem.

If voltages are not within specified ranges, the Zone Manager communications driverchip is likely damaged and will have to be replaced.

Step 1:Measure the voltage at the Zone Manager terminals with the Communications Loop con-nected to the Zone Manager.

Basic System - Without OptionalCommLink Installed

Basic System - With OptionalCommLink Installed

Measure Voltage Measure VoltageT to SHLD + 2.7 to 2.4 VDC T to SHLD + 3.1 to 2.9 VDC

R to SHLD + 2.6 to 2.3 VDC R to SHLD + 2.1 to 1.9 VDCIf the voltages are within the specified voltage ranges, the Zone Manager and communi-cation loop are operating within specifications. If the measured voltages are not withinthe specified voltage ranges proceed to step 2.

+-

T

R

COMM

TB8

SHLD

+

-

+-

T

R

COMM

TB8

+

SHLD

-

Measuring R to SHLDMeasuring T to SHLD



Step 2:Measure the voltage at the Zone Manager terminals with the Communications Loop dis-connected from the Zone Manager.

Step 3:Measure the voltage on the Communications Loop terminals with the CommunicationsLoop disconnected from the Zone Manager.



Measure Voltage Measure VoltageT to SHLD + 2.5 to 2.3 VDC T to SHLD + 2.5 to 2.3 VDCR to SHLD + 2.8 to 2.6 VDC R to SHLD + 2.8 to 2.6 VDC

If the voltages are not within the specified voltage ranges, the Zone Manager communi-cation driver chip is probably damaged and will require replacement. If the measuredvoltages are within the specified voltage range the Zone Manager driver chip is not dam-aged and the problem is related to another part of the loop. Proceed to step 3.




If the voltages are not within the specified range when checking the communicationsloop as described above, then one of the Zone Controllers or the optional CommLink (ifinstalled) is the problem. Proceed to the Zone Controller troubleshooting section. If aCommLink is installed also see the CommLink troubleshooting section.

T

R

COMM

TB8

SHLD

+-

+

-T

R

COMM

TB8

SHLD

+-

+

-


T

R

COMM

TB8

SHLD

+-

+

-T

R

COMM

TB8

SHLD

+-+

-




Zone ControllerTest the communications loop with the system powered. Set meter to read DC Volts.These tests assume that if the optional Comm Link is installed, it is also connected andpowered up. Actual meter readings may deviate slightly depending on the number ofzones installed. Any significant deviation from these values generally indicates a prob-lem.

If voltages are not within specified ranges, one of the Zone Controller communicationsdriver chips is likely damaged and will have to be replaced.

Step 1:Measure the voltage at one of the Zone Controller terminals with the CommunicationsLoop connected to the Zone Controller. If you can communicate with some zone con-trollers on the loop but not others, start with the first Zone Controller you can’t commu-nicate with to begin testing.




If the voltages are within the specified voltage ranges, the Zone Controller and communi-cation loop are operating within specifications. If the measured voltages are not withinthe specified voltage ranges proceed to step 2.

T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

- T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

-




Step 2:Measure the voltage at the suspect Zone Controller terminals with the CommunicationsLoop disconnected form the Zone Controller.




If the voltages are not within the specified voltage ranges, the Zone Controller communi-cation driver chip is probably damaged and will require replacement. If the measuredvoltages are within the specified voltage range the Zone Controller driver chip is notdamaged and the problem is related to another part of the loop. Repeat Zone Controllertroubleshooting step 1 & 2 for each controller on the loop to determine which one iscausing the problem. If you have a CommLink (optional) installed, please see theCommLink troubleshooting section of this manual.

T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

-

T

SHLD

R

COMMLOOP

+-

T

R

SHLD

+

-




CommLink II(Optional)

CommLink must be powered for testing.

If the voltages are not within specified ranges, the CommLink driver chip is probablydamaged and will have to be replaced.

Basic System with CommLink InstalledMeasure Voltage

T to G + 2.5 to 2.4 VDCR to G + 2.7 to 2.5 VDC

If the voltages are within the specified voltage ranges, the Zone Manager and communi-cation loop are operating within specifications. If the measured voltages are not withinthe specified voltage ranges proceed to step 2.

COMPUTER(DCE)

REMOTE LINK(DTE)



Bypass Damper Troubleshooting

Figure 4-10: Bypass Damper Troubleshooting

Meter Should Measure Approximately5000 Ohms With Actuator In MiddleOf Full Travel Position. See Item #3 BelowFor Instructions.

+-

BypassActuator

Bypass Damper Package

Zone Manager Board

Transformer

10

+

+

PWR

V4

V3

CLOSE

OPEN

FDBK

GND

GND

24VAC

NE5090

LineVoltage

GND

24VACActuator Clutch

Modular Cable

Bypass Damper Components & Wiring

Power Connection Terminal

Jumper Wire Between24VAC And Open Or CloseTerminal As Required

Jumper WireBetween 24VACAnd Ground

Remove Terminal PlugFrom Zone Manager BoardWhen Performing JumperTesting Of Actuator

Bypass DamperTerminal Plug

Bypass DamperTerminal Socket

FR

OM

ZO

NE

CO

NT

RO

LLE

R

BY

PA

SS

AN

DS

LAV

EIN

TE

RFA

CE

YS

1018

24

TO

AC

TU

AT

OR

OP

EN

CLO

SE

FDBK

OPEN

GND

GND

PJ1

PJ2LD

2

LD

1

OPEN

CLOSE

CLOSE

TB

1TB

2

1.) Confirm That All Wiring Is CorrectlyConnected To The Bypass & SlaveInterface Card Terminals And The ZoneManager Bypass Actuator Terminals. BeSure The Modular Cable Is Plugged In ToBoth The Actuator And The Modular PlugLabeled "To Actuator" On The Bypass &Slave Interface Card. If No Wiring ErrorsAre Found, Proceed To The Next Step.

2.) Remove Communications Wiring FromThe Zone Manager Board Then RemoveThe Power From The Zone ManagerBoard. Go To The Bypass DamperLocation And Depress Clutch On TheActuator. Rotate The Actuator Clamp AndDamper Shaft Back And Forth. Check ToVerify That The Damper Moves FreelyFrom Full Open To Full Closed Position.Check For Binding Or Interference ThatPrevents Full Opening And Closing Of TheBypass Damper. If The Damper AppearsTo Move Freely Proceed To The Next Step.

3.) Depress The Clutch On The Actuator.Rotate The Damper Shaft To The MiddleOf The Actuator (SeeDrawing Above For Middle Of Full StrokePosition Picture). Connect The MeterBetween The Ground And FeedbackWires On The Bypass & Slave InterfaceCard As Shown Above. Meter Should ReadApproximately 5000 Ohms. If The MeterDoes Not Read Approximately 5000 Ohms,Recheck The Wiring. If No Wiring ErrorsAre Found The Problem Is Probably A BadActuator Or Modular Cable.

Full Stroke Position

4.)

5.) Remove The Bypass Damper TerminalPlug From The Bypass Damper TerminalSocket On The Zone Manager Board AsShown Above. Run A Jumper Wire FromThe 24VAC Power Connection On TheZone Manager Board To The “Open”Terminal On The Bypass Damper TerminalPlug And A Jumper From The GNDConnection On The Zone Manager BoardTo The GND Terminal On The BypassDamper Terminal Plug.

Disconnect The Jumper Wire From The“Open” Terminal At The Bypass DamperTerminal Plug And Connect The JumperFrom 24VAC To The “Close” Terminal OnThe Bypass Damper Terminal Plug.

Go To The BypassDamper Location To Confirm That TheDamper Moves Towards Its “Closed”(Counterclockwise) Position. If TheActuator Drives In Only One Direction OrDoesn’t Drive In Either Direction It IsProbably A Bad Actuator Or ModularCable. If It Drives Open And Closed In TheJumper Test Just Performed But Not WhenConnected To The Zone Manager Board,The Problem Is Probably The ZoneManager Board.

Reconnect Power To The ZoneManager Board. The Damper ActuatorShould Start Its Calibration Procedure AndMove To Its Full Open (Clockwise) PositionAnd Then To Its Full Closed(Counterclockwise) Position. If The DamperActuator Does Not Move Through Its FullCalibration Range Proceed To The NextStep.

The Green Light OnThe Bypass/Slave Interface Card shouldGlow. Go To The Bypass Damper LocationTo Confirm That The Damper MovesTowards Its “Open" (Clockwise) Position.

TheRed Light On The Bypass/Slave InterfaceCard should Glow.

6.) If You Have Another Actuator MotorOf The Same Type (One Can BeBorrowed From Another Zone Or BypassDamper), You Can Try Switching OutThe Original Actuator And Using TheBorrowed Actuator To Verify Operation.Disconnect The 24VAC Power From TheZone Manager Board. Remove TheJumper Wire That Was Used In ThePrevious Checkout Step. Reconnect TheBypass Damper Terminal Block To TheZone Manager Board. Reconnect The24VAC Power To The Zone MangerBoard.

Replace The Defective Actuator With ANew Actuator.

The Damper Actuator ShouldStart Its Calibration Procedure And MoveTo Its Full Open (Clockwise) PositionAnd Then To Its Full Closed(Counterclockwise) Position. If TheBorrowed Damper Actuator MovesThrough Its Full Calibration Range

(Shown With ActuatorIn Middle Of Full Stroke)




Temperature Sensor Resistance Chart

Table 4-2: Temperature Sensor Resistance

Temperature(ºF)

Resistance(Ohms)

Voltage @Input (VDC)

Temperature(ºF)

Resistance(Ohms)

Voltage @Input (VDC)

-10 93333 4.620 72 11136 2.695-5 80531 4.550 73 10878 2.6650 69822 4.474 74 10625 2.6355 60552 4.390 75 10398 2.607

10 52500 4.297 76 10158 2.57715 45902 4.200 78 9711 2.52020 40147 4.095 80 9302 2.46525 35165 3.982 82 8893 2.40730 30805 3.862 84 8514 2.35235 27140 3.737 86 8153 2.29740 23874 3.605 88 7805 2.24245 21094 3.470 90 7472 2.18750 18655 3.330 95 6716 2.05552 17799 3.275 100 6047 1.92754 16956 3.217 105 5453 1.80556 16164 3.160 110 4923 1.68758 15385 3.100 115 4449 1.57560 14681 3.042 120 4030 1.46962 14014 2.985 125 3656 1.36964 13382 2.927 130 3317 1.27466 12758 2.867 135 3015 1.18568 12191 2.810 140 2743 1.10169 11906 2.780 145 2502 1.02470 11652 2.752 150 2288 0.95271 11379 2.722

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 voltagewith meter set on DC volts. Place the “-”(minus) lead on GND terminal and the “+”(plus) lead onthe sensor input terminal being investigated.

If the voltage is above 5.08 VDC, then the sensor or wiring is “open.” If the voltage is less than0.05 VDC, the sensor or wiring is shorted.



Pressure Sensor Voltage Chart

Table 4-3: Pressure Sensor Voltage

2ZPS004704324 Duct StaticPressure Sensor

Pressure@

Sensor(“ W.C.)

Voltage @

Input(VDC)

Pressure@

Sensor(“ W.C.)

Voltage @

Input(VDC)

0.00 0.25 2.60 2.200.10 0.33 2.70 2.280.20 0.40 2.80 2.350.30 0.48 2.90 2.430.40 0.55 3.00 2.500.50 0.63 3.10 2.580.60 0.70 3.20 2.650.70 0.78 3.30 2.730.80 0.85 3.40 2.800.90 0.93 3.50 2.881.00 1.00 3.60 2.951.10 1.08 3.70 3.031.20 1.15 3.80 3.101.30 1.23 3.90 3.181.40 1.30 4.00 3.251.50 1.38 4.10 3.331.60 1.45 4.20 3.401.70 1.53 4.30 3.481.80 1.60 4.40 3.551.90 1.68 4.50 3.632.00 1.75 4.60 3.702.10 1.83 4.70 3.782.20 1.90 4.80 3.852.30 1.98 4.90 3.932.40 2.05 5.00 4.002.50 2.13

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 ter-minal and the “+”(plus) lead on the SIG terminal on TB1.



Figure 4-11: Driver Chip Locations

Comm Driver Chip( U1 )Pin 1

Commlink II

Warning!Use Extreme Caution When Removing Any ChipsTo Avoid Damaging Any Circuit Board Traces WhichAre Under The Chip.

Be Sure That Any Small Screwdriver Or OtherSharp Object Used To Remove The Chip Does NotCome Into Contact With The Printed Circuit BoardSurface.

A Small Screwdriver May Be Inserted Between TheChip And The Socket To Aid In Removal Of The Chip.

Be Very Careful Not To Insert The Screwdriver UnderThe Socket!! Damage To The Board Is Not CoveredBy Warranty.

Pin 1

Dot

Socket

PrintedCircuitBoard

Typical RS-485 CommunicationsDriver Chip Detail

Comm Driver Chip( U10 )

Pin 112

3456

78

OFF

1248

16

ADDRESS

T'STAT

CO

MM

PO

WE

R

Zone Controller

Zone Manager

Network LoopComm Driver Chip

( U5 )

Local LoopComm Driver Chip

( U8 )

Zone ManagerComm Driver Chip

( U15 )

Pin 1

Pin 1

Pin 1



Figure 4-12: Driver Chip Locations

Small FlatheadScrewdriver

Chip

Chip

Printed CircuitBoard



Chip

WARNING!

Direction Of Pull

Notch

Dot

Pin1

Be sure the chip you have selected to replace is asocketed chip. Not all driver chips on the boardsare field replaceable. Only socketed chips may beremoved and replaced in the field. All other chipsthat are not socketed will require sending the boardto the WattMaster factory for repair.

Once you have determined that thechip needing replacement is indeed a socketed chipplease proceed in the following manner.

Remove the communications loop connector andthen the 24VAC power connector on the controllerbefore attempting to change any components.

will occur if components are removed orinstalled with power applied.

If you are unsure how to safely remove the chip orabout the correct pin placement, please consult thefactory before proceeding.

Use extreme care to avoid inserting the screwdriveror I.C. Puller under the socket. You must insert the tipof the screwdriver or ends of the I.C. Puller betweenthe body of the chip and the chip socket.

Each chip be installed with Pin 1 in the correctlocation. Installing the chip “backwards” will in mostcases destroy the device when power is reapplied.

Pin 1 can be located by looking for the notch in the endof the chip. Pin 1 on "some" chips is identified with a dot.

Be certain that pins are lined up in the socketbefore pressing the chip in. Failure to properly lineup the pins will result in damage to the chip.This is a common error -

Only after confirming that the chip has been correctlyinstalled with Pin 1 in the proper position and that thepins are lined up and none are bent or out of the socket,should communication or power wiring be reconnectedto the board. Tp prevent possible damage alwaysreconnect the power wiring first and then thecommunication wiring.

If you try toremove a chip that is not socketed it will destroythe circuit board.

DAMAGE

Damage to the board caused by failure to correctlyremove or install the chip is not covered by theWattMaster warranty.

MUST

ALL

VERY BE CAREFUL.

Using I.C. Puller To Remove Socketed Chip

Using Screwdriver To Remove Socketed Chip

End View Of Socketed Chip AssemblyTop View Of Socketed Chip Assembly

I.C. Puller

Chip Socket

Chip Socket

Chip Socket

Gently Rock Chip Side To Side And ThenLift Straight Up To Remove Chip FromChip Socket.

Gently Lift The Chip On One End And Rock ChipBack And Forth With Screwdriver As Shown.Repeat This Process On The Other End Of Chip.Alternate This Process On Both Ends Of Chip UntilThe Chip Is Free From The Chip Socket.



Notes:



Notes:

Form: WM-AZB-IO-02B Printed in the USA March 2003All rights reserved Copyright 2003

WattMaster Controls Inc. • 8500 NW River Park Drive • Parkville, Mo. • 64152Phone (816) 505-1100 www.wattmaster.com Fax (816) 505-1101

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