CV & CV-EX System - autozonecontrols.comCV Controllers in relation to their location on the loop. Cable must be Belden No. 82760 or equivalent. Tip: Incorrect wiring of the communications

Design, Installation

and Operations Manual

CV & CV-EX System

Revision 01C

Auto-Zone CV & CV-EX

Design, Installation & Operations Manual

Section 1..............................................................................System Overview Section 2................................................................... Installation and Wiring Section 3....................................................................................Programming Section 4....................................................... Start-Up and Troubleshooting

This document is subject to change without notice. WattMaster Controls, Inc. assumes no responsibility

for errors or omissions herein.

Auto-Zone CV & CV-EX Design Installation & Operations Manual - Form WM-AZC-IO-01C Auto-Zone is a registered trademark of WattMaster Controls, Inc.

Copyright 2009 WattMaster Controls, Inc. All rights reserved.

Section 1

System Overview

Table of Contents

Conventions .....................................................................1

Introduction .....................................................................2 CV System Overview.......................................................................................................2 CV System Features.........................................................................................................3 CV-EX System Overview................................................................................................4 CV-EX System Features ..................................................................................................5

Table of Figures Figure 1-1: Typical Building for CV System....................................2

Figure 1-2: Typical CV System........................................................3

Figure 1-3: Typical Building for CV-EX System ..............................4

Figure 1-4: Typical CV-EX System ..................................................5

System Overview

Auto-Zone CV & CV-EX Section 1

System Overview 1-1

Conventions This document uses the following definitions throughout as a guide to the user in determining the nature of information presented:

Note: Additional information which may be helpful.

Tip: Suggestion to make installation, set-up, and troubleshooting easier.

Caution: Items which may cause the equipment not to function correctly but will not otherwise damage components.

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

Section 1 Auto-Zone CV & CV-EX

1-2 System Overview

Introduction

CV System Overview The Auto-Zone CV system is used in buildings which have multiple rooftop units and is an excellent alternative over programmable thermostats. The CV system provides one central location to monitor and program the controllers instead of having to program each thermostat individually. The system has many features typically not found with programmable thermostats such as: central operators interface, heating/cooling failure alarm, change filter alarm, full energy saving economizer control, and holiday scheduling. This gives the end user a very versatile constant volume control system at a price well below a building automation system. Below are a few of the typical building applications the CV system is commonly used for.

Figure 1-1: Typical Building for CV System

• Office Buildings • Retail Stores • Theaters • Warehouses • Restaurants • Supermarkets • Schools • Manufacturing • Houses of Worship


System Overview 1-3

CV System Features

Computer(Optional)

Single Loop

CV ControllersUp to 30 Units with Standard CV System

RS-4859600 Baud

SupplyAir

Sensor

RS-485Comm Loop 24 VAC

Economizer(Actuator By Others)

Generic AlarmDirty Filter Alarm

Shown

*OutsideAir

SensorRoom Sensorwith Optional

Override & Adj.

Typical Constant Volume Unit

NOTE: * Only One Outside Air Sensor is Required per CV System

24VAC

System Manager

Local Loop

24VAC 24VAC

#1 #30

System Manager

24VAC

Remote Link II(Optional)

Optional IP Module Installs Into CommLink IV

And ProvidesLAN And Internet Communications

With The Control System

Ethernet Router(By Others)

When IP ModuleOption Is Used

Optional Remote Link II Connects to CommLink IV

And Provides Alarm Call-OutsA Second Remote Link Is Required

If Connection To Job SiteIs Desired From Remote Computer

Phone CableTo TelephoneWall Outlet Jack

Ethernet Cable To Router

USB Cable To Computer

CommLink IVThe CommLink IV Is

Required For All Systems. The IP Module, Remote

Link II, And Computer Are Optional On All Systems.All Computers Require

Installation of Prism Graphical User Interface

Software

CommLink IV

Figure 1-2: Typical CV System

Below is a list of some of the many features available with the CV system.

• CV system supports up to thirty constant volume units. For systems with more than thirty constant volume units, use the CV-EX system.

• System Manager is housed in an attractive, plastic enclosure suitable for wall mounting in the space and can be connected anywhere in the communications network.

• Complete modulating economizer control functions.

• CommLink IV interface included with the system. Provides connections for computer and Remote Link II (modem) for on-site or remote communications or connection for TCP/IP communications using the IP Module. Remote Link II, IP Module & personal computer are optional.

• Trend Logging capability if connected to a personal computer with free Prism™ Windows®-based software installed.


1-4 System Overview

CV-EX System Overview The Auto-Zone CV-EX system is used in buildings that because of their size or design requirements have more than thirty rooftop units. Standard CV-EX systems can facilitate up to sixty constant volume units. With the addition of a CV-EX Loop Expansion Kit, an additional thirty units may be added to the CV-EX system. Two loop expansion kits can be added to the CV-EX system bringing the maximum total system capability up to 120 units. The versatile CV-EX system provides one central location to monitor and program the controllers instead of having to program individual thermostats. The system has many features typically not found with programmable thermostats such as: central operators interface, heating/cooling failure alarm, change filter alarm, full energy saving economizer control, and holiday scheduling.

Below are a few of the typical applications the CV-EX system is commonly used for.

Figure 1-3: Typical Building for CV-EX System

• Office Buildings • Retail Stores • Theaters • Warehouses • Restaurants • Supermarkets • Schools • Manufacturing • Houses of Worship


System Overview 1-5

CV-EX System Features

CommLink IVThe CommLink IV Is

Required For All Systems. The IP Module, Remote

Link II, And Computer Are Optional On All Systems.All Computers Require

Installation of Prism Graphical User Interface

Software


And Provides LAN And Internet CommunicationsWith The Control System

Phone CableTo TelephoneWall Outlet Jack

Optional Remote Link II Connects to CommLink IV

And Provides Alarm Call-OutsA Second Remote Link Is Required

If Connection To Job SiteIs Desired From Remote Computer

NOTE: * Only One Outside Air Sensor is Required per CV-EX System

Figure 1-4: Typical CV-EX System

Below is a list of some of the many features available with the CV-EX system.

• CV-EX system supports from thirty-one to one hundred twenty constant volume units. For systems with thirty or less constant volume units, use the CV system.

• System Manager is housed in an attractive, plastic enclosure suitable for wall mounting in the space and can be connected anywhere in the communications network.

• Complete modulating economizer control functions.

• CommLink IV interface included with the system. Provides connections for computer and Remote Link II (modem) for on site or remote communications or connection for TCP/IP network communications using IP Module. Remote Link II, IP Module, & personal computer are optional.

• Trend Logging capability if connected to a personal computer with free Prism™ Windows®-based software installed.


1-6 System Overview

Index 120 Units............................................... 4 CommLink IV

Described ...................................... 3, 5 Conventions .......................................... 1 CV System

Features ............................................. 3 Overview........................................... 2

CV Units < 30 ................................................... 3 > 30 ................................................... 4 60....................................................... 4

CV-EX Loop Expansion Kit ................. 4 CV-EX System...................................... 3

Features ............................................. 5 Overview........................................... 4

Features

CV System ........................................ 3 CV-EX System.................................. 5

IP Module.......................................... 3, 5 Modem

Described ...................................... 3, 5 Network Communications ................ 3, 5 Overview


Prism ................................................. 3, 5 Remote Link II

Described ...................................... 3, 5 Rooftop Units

< 30 ................................................... 3 > 30 ................................................... 4

System Manager Described ...................................... 3, 5

Trend Logging................................... 3, 5 Void Warranties .................................... 1 Warranties ............................................. 1

Section 2

Installation and Wiring

Table of Contents

Tips Before Beginning Installation..................................1

Systems Overview ...........................................................2 CV System .......................................................................................................................2 CV-EX System.................................................................................................................3

Communications Loop.....................................................4 CV & CV-EX Communications Loops ...........................................................................4 Communications Loop Wiring Overview........................................................................5

CV Controller ...................................................................8 CV Controller Wiring ......................................................................................................9 CV Controller Addressing .............................................................................................11

CV System Sensors........................................................12 Room Sensor..................................................................................................................12 Supply Air Temperature Sensor.....................................................................................14 Outside Air Temperature Sensor ...................................................................................15

CommLink IV Interface..................................................16 Optional IP Module Kit .................................................................................................16 Optional Remote Link II ................................................................................................17 CommLink IV Wiring....................................................................................................18 CommLink IV DIP Switch Setting ................................................................................19 Installing the CommLink IV ..........................................................................................21

System Manager ............................................................22 System Manager Wiring ................................................................................................23

MiniLink Interface..........................................................24 MiniLink Interface Wiring.............................................................................................25 CV & CV-EX Worksheet ..............................................................................................26

Index ..............................................................................27

Section 2

Installation and Wiring

Table of Figures Figure 2-1: CV System Overview .................................................................................2

Figure 2-2: CV-EX System Overview...........................................................................3

Figure 2-3: CV Communication Loop Wiring, Daisy-Chain Configuration.................5

Figure 2-4: CV-EX Communication Loop Wiring, Daisy-Chain Configuration ..........6

Figure 2-5: CV Controller with Backplate - Components.............................................8

Figure 2-6: Constant Volume Controller Wiring...........................................................9

Figure 2-7: CV Controller Address Switch Setting.....................................................11

Figure 2-8: Room Sensor Installation..........................................................................12

Figure 2-9: Room Sensor Wiring ................................................................................13

Figure 2-10: Supply Air Temperature Sensor Installation ..........................................14

Figure 2-11: Outside Air Temperature Sensor............................................................15

Figure 2-12: CommLink IV Interface Wiring & Jumper Setting................................18

Figure 2-13: CommLink IV DIP Switch Setting ........................................................19

Figure 2-14: CommLink IV to MiniLink Wiring .......................................................20

Figure 2-15: CommLink IV to CV Controller Wiring................................................20

Figure 2-16: System Manager Dimensional Data .......................................................22

Figure 2-17: System Manager Wiring.........................................................................23

Figure 2-18: MiniLink Interface Overview.................................................................24

Figure 2-19: MiniLink Interface Wiring .....................................................................25


Installation and Wiring 2-1

Tips Before Beginning

Installation Take a few moments to review the following before beginning installation of the Auto-Zone CV and CV-EX systems. • Familiarize yourself with all system components and review all documentation. Pay

special attention to “Cautions” and “Warnings” since these may keep you from experiencing unnecessary problems.

• Before installing each controller, be sure to tag it with its appropriate location. It is

also best to set the controller address switches before mounting. Use the CV and CV-EX Address Worksheet included at the end of this section and in the CV and CV-EX submittal package to list all CV unit locations. This will assist you greatly when setting up the system and later for any necessary system troubleshooting.

• 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 diagrams as to which color wire you will be using on each terminal.

• When in doubt - ask! Contact your local Auto-Zone distributor if you have any

questions. The only dumb questions are the ones you don’t ask. • Remember - each electronic device contains only one puff of smoke. If you release it,

you have voided the warranty! So please be careful and pay attention.


2-2 Installation and Wiring

Systems Overview

CV System

Figure 2-1: CV System Overview



CV-EX System

Figure 2-2: CV-EX System Overview



Communications Loop The Communications Loop for both the CV and CV-EX systems is two-wire shielded RS-485. The loop is best connected in daisy-chain configuration, meaning the loop is connected from one controller to another. It is not necessary to sequentially address the CV Controllers in relation to their location on the loop. Cable must be Belden No. 82760 or equivalent. Tip: Incorrect wiring of the communications loop is the most common mistake made

during installation. Before beginning installation, write down the wire color used on each terminal connection and consistently maintain that color code. It is recommended that a continuous wire run be made between devices. Anytime a splice is made in the cable, you increase your chance of problems.

Caution: Make sure when you are inserting wires into the terminal blocks that strands of wire do not stick out and touch the next terminal. This could cause a short or erratic operation.

CV & CV-EX Communications Loops The CV and CV-EX communications loops are different in one respect. The CV has only one communication loop while the CV-EX has two. On the CV system, all of the CV controllers are daisy-chained together and tied into the CommLink on one end of the loop. Each controller is assigned a numbered address by setting the DIP switch on each one. See Figure 2-3 for the CV system communication wiring diagram. This is the only communications loop required on the CV system. For the CV-EX system communications wiring, see Figure 2-4. As is shown in the diagram, all of the CV Controllers are daisy-chained together just like the CV system. This is referred to as the “Local Loop.” This local communications loop is then tied into the MiniLink communication interface to the terminals marked Local Loop instead of the CommLink. On the CV-EX system, all of the MiniLinks terminals marked “Network Loop” are then daisy-chained to each other and on one end to the CommLink communication terminals. Each MiniLink is then addressed with a different number by setting its DIP switch in similar fashion to the CV controllers.



Communications Loop Wiring Overview The daisy-chain is the best method for running a communications loop since there is only one starting point and one ending point for each of the communications loops. See Figure 2-3 and Figure 2-4. The general concept is the same for both the CV and the CV-EX.

Computer(Optional)

End Of Loop

RS-485

Comm Loop

Loop Start

CV ControllerCV Controller

System Manager

CV Controller

CV Controller

CV Controller

CV Controller

The Comm LoopRouting Does Not

Have To FollowThe Board Address Sequence

The System Manager Can Be Connected Anywhere

On The Loop


And Provides LAN And InternetCommunications




Optional Remote Link II Connects to CommLink IV And

Provides Alarm Call-Outs. ASecond Remote Link Is Required IfConnection To Job Site Is Desired

From Remote Computer.

Phone Cable To TelephoneWall Outlet Jack

Serial Cable To Remote Link



All Components Shown Inside This Box Are Optional

CommLink IVThe CommLink IV Is Required For

All Systems. The IP Module, Remote Link II, And Computer Are

Optional On All Systems. All Computers Require Installation of

Prism Graphical User Interface Software

9600 Baud

Figure 2-3: CV Communication Loop Wiring, Daisy-Chain Configuration



Computer(Optional)

End Of Local Loop

MiniLink

RS-4859600 Baud

RS-48519200 Baud

Local LoopNetwork Loop Start

Network Loop

Connect ToNetwork LoopConnection OnNext MiniLink

Local Loop Start

CV Controller

CV Controller

CV Controller


CV Controller

System Manager




On The Local Loop

Optional IP Module Installs Into CommLink IV And

Provides LAN And InternetCommunications





Provides Alarm Call-Outs. A SecondRemote Link Is Required If Connection To

Job Site Is Desired From Remote Computer.










Figure 2-4: CV-EX Communication Loop Wiring, Daisy-Chain Configuration



Even though the daisy-chain configuration is preferred, the star configuration can also be used for the CV or CV-EX systems. If required, a combination of the two can also be used. Remember, the best communications loop wiring scheme is the one that utilizes the minimum number of ends while using the shortest wiring path.

Note: The communication loops do not have to follow the controller or MiniLink address sequence.

Caution: If the communications loop is not installed in conduit, be careful to position the cable away from high noise devices like fluorescent lights, transformers, variable frequency drives, radio or TV transmitting equipment, furnace ignition system wires, etc. Conduit is not required for communication loop wiring unless required by local codes.



CV Controller The CV Controller (Constant Volume Controller) may be installed in any convenient protected location. Observe the recommended environmental limitations for the CV Controller. It should not be mounted in locations subject to extreme low or high temperatures (below 20° F or above 140° F) or in damp or wet environments (maximum of 90% RH). If it is to be mounted outdoors, it must be enclosed in a weather-tight enclosure. The CV Controller may be mounted without removing the controller from the mounting plate. The unit is mounted by securing four (4) screws through the mounting holes in the mounting backplate. Select the correct screws or other fasteners for the type of mounting material being utilized.

Relay OutputsTerminals

Diagnostic BlinkCode LED 1


RS-485CommunicationsTerminal Block

CPUChip

TypicalPin 1Indicator

RAMChip

EPROMChip

PALChip

RS-485CommunicationsDriver Chip

Real TimeClock Chip

CommunicationsLED

Address Switch

Power LED

24 VACPower InputTerminal

Figure 2-5: CV Controller with Backplate - Components



CV Controller Wiring

Notes:

Line Voltage

Line Voltage

See Note 1 & 2

See Note 1 & 2

Wx or Yx (Htg or Clg Stage x)Wx or Yx (Htg or Clg Stage x)Wx or Yx (Htg or Clg Stage x)Wx or Yx (Htg or Clg Stage x)

G (Fan-On/Off)R (24VAC)

Constant VolumeUnit Connections

CV Controller

RSHT

RSHT

RSHT

RSHT

All Comm Loop Wiring IsStraight Thru

Required VA For TransformerEach CV Controller = 20VA Min.

24VAC

24VAC

GND

GND

Mount In HVACUnit Supply

Air Duct

Auxiliary AlarmInput

Switch SuppliedBy Others

DischargeAir Temp.

Sensor

GND

AUX

TMP

NORMAL

OVR

RELO

CREMR

O

AW

Room Sensor Local LoopRS-485

9600 Baud

Connect To Next Controller

And/Or MiniLink On Local Loop

Connection ToAUX Terminal is ReqdOnly When SensorIs Specified WithSlide Adjust Option

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

3.)All Communication Wiring To Be 2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

EconomizerActuator

(Belimo Shown)Consult Factory For Other ManufacturersWiring Connections

Note:Up To 4 Stages Of Heating Or Cooling Or Any Combination Of Each Is Allowed And Programmable Via The System Manager or Computer Front End Software. If The Unit Has Heat, Heating Stages Must Be Connected To The First Outputs in Consecutive Order And Cooling Stages To The Remaining Outputs In Consecutive Order.

Outside AirTemp. Sensor(See Note 4)

4.)Only One Outside Air Sensor Is Required Per System. It May Be Connected To Any CV Controller On The System. If The Wetbulb Module Is Used, The OA Sensor Must Be Connected To The Wetbulb Module.

Y 3+ 2

COM 1

AIN 1 +VDC

TB2

RELAYOUTPUTS

AIN 2AIN 3AIN 4AIN 5GNDGNDAOUT

TB3

Caution:When Wiring The CV Controller Be Sure To Disconnect All Communication Loop WiringFrom The CV Controller Before Removing PowerFrom The CV Controller. Reconnect Power And Then Reconnect Communication Loop Wiring.

TSHLDR COM1-3

R1R2R3R4R5

TB1

24VACGND

COM4-5

EXPANSION T'STAT

NETWORK

16

TOKEN32

8

4

1

2

Figure 2-6: Constant Volume Controller Wiring



Warning: Polarity is very important when connecting power to the controllers! The grounded side of the control transformer must be connected to the terminal labeled GND on the CV Controller. If a single transformer is used to power more than one CV Controller, you must connect GND-to-GND and 24VAC-to-24VAC on each CV controller. Failure to observe polarity will result in damage to one or more components in your system.

Warning: Use extreme care not to damage any of the electronic components while mounting the backplate. Mark the holes and then remove the CV Controller from the backplate before drilling.

Do not allow metal shavings to fall onto the circuit boards.

The Constant Volume Controller requires the following electrical connections: 18-Gauge minimum unless otherwise noted.

-24 VAC 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 -Room Air Temperature Sensor...........(24 ga. Min.) 2 Conductors for standard sensor

3 Conductors for sensors with setpoint adjustment -Outside Air Temperature Sensor ....................................... (24 ga. Min.) 2 Conductors -HVAC Unit Control Wiring .....................................................................R - Common

G - Fan Heat/Cool Stage 1 Heat/Cool Stage 2 Heat/Cool Stage 3 Heat/Cool Stage 4 Tip: After making all electrical connections, we recommend that you unplug all

terminal blocks on the CV Controller until you are ready to begin the checkout procedure. This may help to prevent damage if wiring errors occur elsewhere in the system during installation or start-up.



CV Controller Addressing

Figure 2-7: CV Controller Address Switch Setting

Address Switch Shown IsSet For Address 9


ControllerAddress Switch

ADDRESSADD

SW1 SW1

ADDRESSADD

CV Controller Address Switch SettingCV Controller Address Switch Values

Address Switch Setting Chart For CV Controllers

ADDRESS ADD

ADDRESS ADD

ADDRESS ADD ADDRESS ADD ADDRESS ADD 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

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

1

2

4816

32 (Always OFF- Not Used)

TOKEN (Always OFF)NETWORK (Always ON)

1

6

11

16

21

26

12

17

22

27

13

18

23

28

14

19

24

29 30

15

20

25

2

7

3

8

4

9

5

10

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.

Address Switch Values Are NotLabeled On The CV ControllerUse The Table Below

Address Switch Values AreAdded Together When TheRocker Is Pushed Down InThe Direction Of The “ADDRESSADD” Arrow Marked On The CVController Circuit Board



CV System Sensors

Room Sensor The Room Sensor uses a patented flush-mount design to isolate the temperature sensing element from the housing which mounts flush with the wall surface. Room Sensors should be located on an inside wall away from direct sunlight or heat producing equipment such as computers, copiers, etc. Such devices can adversely affect the accuracy of the sensor. Although the sensor eliminates most of the effects of thermal coupling to the walls, try to avoid walls which retain large amounts of thermal energy (such as marble or steel). Walls containing either cold or warm air currents should also be avoided whenever possible. Avoid locating the sensor in dead air areas of a room. This will result in slow response to temperature changes in the space.

Figure 2-8: Room Sensor Installation

Mount the sensor approximately 50-60 inches from the floor for best results. The Room Sensor is designed to mount vertically in a standard 2-by-4-inch electrical box. The sensor may be mounted directly into the drywall where electrical codes do not require low-voltage wiring to be enclosed in conduit. A template is supplied with the sensor to facilitate cutting a hole of the correct size.



Tip: Be careful when cutting the hole for the sensor or the plastic bezel of the sensor

may not completely cover the opening. Tip: If sensors must be installed on walls that are solid and cannot be penetrated,

surface-mounted boxes and raceway can be purchased from your local electrical distributor.

GNDAUX

TMP

OVR

RELO

C

REMR

O

AW

12V

AIN1

2

3

4

5

GND

GND

AOUT

AIN

AIN

AIN

AIN

PRESSURE

SENSOR

YS

ROOM SENSORCV CONTROLLER

Connect To AUXTerminal Required OnlyWhen Sensor Is SpecifiedWith Slide Adjust Option

Figure 2-9: Room Sensor Wiring

Connect the terminal labeled GND on the room sensor to the terminal labeled GND on the CV Controller terminal block TB3. Connect the terminal labeled TMP on the room sensor to the terminal labeled AIN1 on the CV Controller terminal block. If the room sensor has a setpoint adjust slider, connect the sensor terminal labeled AUX to the CV Controller AIN2 terminal block.



Supply Air Temperature Sensor The Supply Air Temperature Sensor should be located as close to the rooftop unit discharge as possible for the best response. Locate the sensor in the center of the widest part of the duct. Use the supplied template and a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mount securely to the duct using the supplied sheet metal screws. Be sure the gasket is compressed to provide an air-tight seal. For best accuracy, apply insulation on the outside of the duct, over the sensor. This will help prevent thermal gradients from affecting the sensor.

Figure 2-10: Supply Air Temperature Sensor Installation

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 Sensor The Outside Air Temperature Sensor must be located where it will not be affected by direct sun or heat-producing equipment. Mounting under the eave of a roof is often a good choice.

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

Note: All sensors utilize the same type thermistor sensor element. For troubleshooting sensor problems, refer to temperature sensor resetting instructions in Section 3 of this manual.

Figure 2-11: 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 BeAllowed To Stand In SensorTube. Rainwater Will DamageSensor.

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”



CommLink IV Interface

The CommLink IV Interface is used to transfer communications between controllers on your control system loops. It can also be used as an interface for connection of a computer to your system. The CommLink IV provides communication with any controller on the control system through a computer that is running Prism software, or it can be used to communicate with most controllers by using only the System Manager. For remote communications, an IP Module Kit can be installed for LAN and Internet connections, or a Remote Link II can be connected for dial-up connections.

STATUS

Optional IP Module Kit The IP Module Kit, when installed and configured in the CommLink IV, provides TCP/IP Internet and/or intranet connection for Ethernet networked computer systems allowing them to communicate with your control system.

The OE415-02 IP Module Kit consists of the IP Module and a 10-foot-long CAT5 Ethernet crossover cable. Using standard TCP/IP Protocol, with WattMaster’s Prism software, you are able to monitor and configure your controllers without a modem or a direct connection from a PC. Utilizing existing routers, proxies, or firewalls allows a PC running Prism to connect to a controller in a remote accessible location or building. Several IP connection profiles can be created to facilitate monitoring several CommLink IVs with IP Module Kits installed on individual sites. See the IP-Module Technical Guide —WM-IPM-TGD for complete product details and installation instructions.



Optional Remote Link II The Remote Link II is a 14,400 baud modem that can be used with a CommLink IV or a computer. It is used to provide remote dial-up communications with the CommLink IV. When it is used as a computer modem (at the remote computer location), it connects to the remote computer.

Note: WattMaster will not support any other internal or external modems by other manufacturers.

The OE419-06 Remote Link II connects to the CommLink IV communications interface at the control system location via a DB9 serial cable. A telephone line connects the Remote Link to the local phone service. Using another Remote Link modem connected to a computer and phone service at a remote location, you can monitor and control the system using the Prism computer front-end software. Connection is made by dialing the telephone number of the job site where the Remote Link is located. See the Remote Link II Technical Guide—WM-RLII-TGD for complete product details and installation instructions.



CommLink IV Wiring

24 VAC Power

If Desired A 24 VAC Transformer Rated At 12 VA Minimum May Be

Used Instead Of The Supplied Power Pack. Use 18 Gauge Minimum 2 Conductor Wire Between The Transformer & CommLink IV Terminals.

(Not Included)

120 to 24 VAC Power Pack (Included) Connect To 120/1/60 DuplexReceptacle (By Others)

USB Cable (Included). Connect This Cable To Your Computer USB Port For Directly Connecting To CommLink IV. Also Used For Advanced Configuration of CommLink IV.

CommLink IVCommunications Interface

Notes:1) Use 18-Gauge Minimum, 2-Conductor Twisted Pair With Shield Cable Belden #82760 Or Equivalent (Not Included) To Connect The CommLink IV To The MiniLink On Network Loop Or Controller Or System Manager On Local Loop.

2) For Direct Connection Via USB, Your Computer Must Have An Unused USB Port Available. Drivers For Your USB Port Are Provided On A CD Supplied With The CommLink IV And Will Need To Be Installed On Your Computer In Order For It To Function Correctly. Please Refer to the CommLink IV Installation Technical Guide Form: WM-CLIV-TGD Which Is Supplied With The CommLink IV.

3) The CommLink IV Cannot Communicate With The Control System Through Its Ethernet Port And USB Port At The Same Time.

4) All Wiring Must Conform To Applicable Federal, State & Local Electrical Wiring Codes.

18-Gauge, 2-ConductorWith Shield (Not Included)

Connect To The Controller Or SystemManager On Local Loop Or MiniLinkOn Network Loop. See Note 1.

MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D

485 LOOP POWERACT LNK USBC

on

fig

No

rmal

Optional - Prefabricated Ft. Long CAT5 Ethernet Cable (Included With Optional OE415-02 IP Module Kit).

If A Longer Ethernet Cable Is Required, You Will Need To Obtain (From Others) And Install An Ethernet Cable Of The Required Length For Your Installation.

10

Connect To A 10/100 Base-T Ethernet Router On Your LAN.

When An Optional Remote Link Is Used, Connect This Cable To CommLink IV And Remote Link As Shown. Cable Is Included With Remote Link.

Molded Modem Cable.Part #HZ000098Supplied With RemoteLink II

9P

inF

emale

25 PinMale

WARNING!

If You Are Using The IP ModuleWith Your CommLink, Do Not Have YourEthernet Connection And USB ConnectionConnected At The Same Time. This CouldCause Unreliable Communications.

Optional Items Not Required For CommLink Only Installations.

USB SwitchShould Be SetTo Normal

Figure 2-12: CommLink IV Interface Wiring



CommLink IV DIP Switch Setting

DIP Switch 1 & 2 Off =Multiple Loop CommunicationsRequired Setting For Auto-Zone CV-EX System

CommLink IV Communication Settings

The SW1 DIP Switch Located On The Circuit Board Inside The CommLink IV Housing Must Be Set Correctly For Your Specific Application In Order To Function Properly.

To Check And/Or Set The SW1 Dip Switch, First Remove The (2) Enclosure Screws That Hold The Top And Bottom Of The CommLink IV Enclosure Together. Remove The Top Half Of The Enclosure To Access The Circuit Board And Dip Switches.

The DIP Switch Setting Should Be Set To “Multiple” For The Auto-Zone System

The CommLink IV Is Factory Set For Multiple Loop Applications.

SW1 CV-EX .

Replace The CommLink IV Cover And Secure The Enclosure Halves Back Together With The (2) Enclosure Screws That Were Previously Removed.

ALTERAEPM3032

WattMaster Controls Inc.COMMLINK IVYS102074REV6 MADE IN USA

Figure 2-13: CommLink IV DIP Switch Setting



MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D

485 LOOP POWERACT LNK USB

Co

nfig

No

rmal

LocalComm Loop

T RS

HIE

LD

Figure 2-14: CommLink IV Wiring for CV System

MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D


Con

fig

Nor

mal

Local Communications LoopTo CV Controllers

And System Manager

NetworkComm Loop

LocalComm Loop

T RS

HIE

LD

LOO

P

24VACGND

T

SH

R

321684

1

2

OFF >

MiniLink Communications Interface

ADD

NETWORK

SH

T

R

Figure 2-15: CommLink IV to MiniLink Wiring for CV-EX System



Installing the CommLink IV When you are using the CommLink IV with the Auto-Zone CV or CV-EX System and are not going to use a Computer, Remote Link II, or IP Module, you only need to perform three steps to install your CommLink IV. Step #1: Check and make sure your CommLink’s communication switch is set to Multiple if using the CV-EX system. See Figure 2-13 for details on setting the DIP Switch on the CommLink IV. Step #2: Install communications wiring (18-gauge minimum, 2-conductor twisted pair with shield) from the CommLink IV to a CV Controller (CV system) or MiniLink (CV-EX system). For the CV system, the communication wiring should connect from the T, G, & R terminals on the CommLink IV to the T, SHLD, & R terminals on the CV Controller. See Figure 2-14. Be sure that you wire the CommLink “T” terminal to the CV Controller “T” terminal, The CommLink “G” Terminal to the CV Controller “SHLD” terminal, and the CommLink “R” terminal to the CV Controller “R” terminal as shown. For the CV-EX system, the communication wiring should connect from the T, G, & R terminals on the CommLink IV to the network T, SH, & R terminals on the MiniLink. See Figure 2-15. Be sure that you wire the CommLink “T” terminal to the MiniLink “T” terminal, The CommLink “G” Terminal to the MiniLink “SH” terminal, and the CommLink “R” terminal to the MiniLink “R” terminal as shown. Step #3: Wire the supplied 120/24 VAC power pack to the 24 VAC and GND terminals on the CommLink IV. Plug the power pack into a standard 120 VAC duplex outlet. If you intend to use a Computer, Remote Link II, or IP Module in addition to the steps just performed, you will need to perform additional installation procedures. Please refer to the CommLink IV Technical Guide—WM-CLIV-TGD which is supplied with the CommLink IV. It will instruct you regarding installation and troubleshooting of the CommLink when an optional personal computer and/or other communication devices are used. This manual is also available from any of the WattMaster websites for downloading as are the USB drivers and Prism Software. These are required for installation when using the optional personal computer or other communication devices.



System Manager The microprocessor-based System Manager is a device which allows the CV Controller or any add-on device connected to the system to be programmed and monitored from a central location. The System Manager is connected via the RS-485 communication network. The System Manager is mounted in an attractive, white, plastic housing, suitable for wall mounting. A four-line-by-twenty-character, backlighted, LCD display and membrane keypad provide a user-friendly interface. All system variables, setpoints, and values can be viewed and modified from the System Manager. Menu-driven programming makes the System Manager easy to set up your system and operate it without the need for specialized training.

1.90

9.00

6.25

MembraneKeypad

Four Line by 20 CharacterBacklighted Display

Figure 2-16: System Manager Dimensional Data



System Manager Wiring The System Manager can be connected anywhere on the CV or CV-EX system local communications loop. Do Not Connect the System Manager to the CV-EX System Network Loop! The system will not function if the System Manager is connected to the network loop. The System Manager must also be connected to 24 VAC in order to operate. See Figure 2-17 for System Manager wiring.

Notes:1.) 24 VAC Must Be Connected So

That All Ground Wires Remain Common.

2.) All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

3.) All Communication Wiring To Be 2-Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

Line Voltage

See Note 1

See Note 324VAC

GND

Required VA For TransformerSystem Manager = 25VA Max.

MADE INTHE USA

EP

RO

M

1000uF10v

YS101806 REV. 1

DSPY1

UNIVERSAL SMART DISP. UNIT

SYSTEM MANAGER

SERIAL # :

U13 SERIAL #1000uF10v

C9

470uF50v

D2

PC

B80

C5

52

-5-16

WP

442

860

=2

/5D

fD97

22

V7

Y

PH

ILIPS

CX

13

LD8

CX

9

SS0017vx.xx 1234

V62C518256L-70P

U9

U8

LD7

RN

1

LD6

U7

CX7

74

HC

573

LD5

LD4

74HC573

CX

8

RN2

X2

CX

4

470uF50v

TB

2

GN

D24V

AC

R10 75176

RS-485 COMM

U12

CX

12

RA

M

SC1

T

TB

1

SH

LD

C7

C11

L1

C4

R

D6

85

83

U6

CX6C3

D3

24C

128

U5

R7

VAR1

D4

PJ1

R3

U1

74HC259

LD3

LD2

LD1

R2

R1

EW

DO

G

PH

ILIPS

U3

U2

CX

1

82B715CX5

CX

3

U3

DSPY1

R5

D1

R6

MC

34064A

C6

R11

9936 C8

R9

U10

U11

R8

R12

C5

74H

C92

3

CX10 P1

R4

RV1

C2

C1

X1

The Ideal Recommended Location For The System Manager Is As The First Device On The Local Loop. The System Manager May Be Connected To TheLocal Loop At Any Point On The Local Loop.

For CV Systems, Connect To Any CV Controller On The Local Loop Or To The CommLink. For The CV-EX System, Connect To Any Controller On The Local Loop Or To The Local Loop Terminal On The MiniLink. Do Not Connect To The Network Loop On CV-EX Systems!

System ManagerTop

03/20/09 06:38PM FRI

OCCUPIED

NO ALARMS

System ManagerBase

Figure 2-17: System Manager Wiring



MiniLink Interface The MiniLink Interface is only required and used with the CV-EX system. It is not required for the CV system. It functions as the loop master for each CV-EX system local loop. With the CV-EX system, each local loop of CV controllers (maximum of 30) is connected to a MiniLink. Two MiniLinks are supplied with the standard CV-EX system. This allows up to 60 CV controllers (30 maximum per local loop) to be tied together to form an integrated system. A CV-EX expansion kit is available which provides another MiniLink to allow an additional 30 CV controllers to be connected to the system. A maximum of two expansion kits can be used on the CV-EX system to provide integration of up to 120 CV controllers. See Figure 2-18 for an overview of the MiniLink.

24 VACPower

Network LoopCommunications

Driver Chip

Network LoopCommunications

LED

Local LoopCommunications

LED

Local LoopCommunications

Driver Chip

Address Switch( Each Board Must Be Addressed Uniquely )

( 1,2,3,4)Switch Shown Set For Address 1

Local LoopConnector

Network LoopConnector

7.50”

4.50

"

LOO

P

24VAC

GND

T

SH

R

321684

1

2

OFF >

ADD

NETWORK

SH

T

R

Figure 2-18: MiniLink Interface Overview



MiniLink Interface Wiring All MiniLinks on the CV-EX system must be wired to each other with a Network communications loop, daisy-chaining the Network loop terminals together. One end of the CV-EX system Network loop must be connected to the CommLink IV interface. Each MiniLink on the CV-EX system is then wired from its Local loop terminals to the CV Controllers on that Local loop. The MiniLink also requires 24 VAC power to operate. Each MiniLink must be addressed from 1 to 4 with a unique address. The addresses are set with the address switch at each MiniLink board. See Figure 2-18 for the address switch location. See Figure 2-19 for wiring information.

RSHT

RSHT

RSHT

RSHT

All Communication LoopWiring Is Straight Through

Required VA For TransformerMiniLink = 10VA Max.

See Note 1.

LOO

P

24VAC

GND

T

SH

R

32168

4

1

2

OFF >

Local LoopRS-485

9600 Baud(See Note 3).

Connect To CV Controller or

System Manager On Local Loop

Connect To Next MiniLink And/Or CommLink On Network Loop

Network LoopRS-485


Line Voltage24VAC

GND


ADD

NETWORK

SH

T

R

Notes:

1.)24 VAC Must Be Connected So That All Ground Wires Remain Common.

2.)All Wiring To Be In Accordance With Local And National Electrical Codes And Specifications.

3.) All Communication Wiring To Be 2 Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

Figure 2-19: MiniLink Interface Wiring



CV & CV-EX Worksheet

Project: ___________________________ Location ___________________________

Stages of Cool: ___ Stages of Heat: ___ �Gas �Electric Economizer Yes� No �

Loop: 1� 2� 3� 4� Remote Link Installed Yes � No � Phone No. ___________

Unit Address

Unit Description or Location Sensor Type

1 S � SO � SA � SOA � 2 S � SO � SA � SOA �

3 S � SO � SA � SOA �

4 S � SO � SA � SOA �

5 S � SO � SA � SOA �

6 S � SO � SA � SOA �

7 S � SO � SA � SOA �

8 S � SO � SA � SOA �

9 S � SO � SA � SOA �

10 S � SO � SA � SOA �

11 S � SO � SA � SOA �

12 S � SO � SA � SOA �

13 S � SO � SA � SOA �

14 S � SO � SA � SOA �

15 S � SO � SA � SOA �

16 S � SO � SA � SOA �

17 S � SO � SA � SOA �

18 S � SO � SA � SOA �

19 S � SO � SA � SOA �

20 S � SO � SA � SOA �

21 S � SO � SA � SOA �

22 S � SO � SA � SOA �

23 S � SO � SA � SOA �

24 S � SO � SA � SOA �

25 S � SO � SA � SOA �

26 S � SO � SA � SOA �

27 S � SO � SA � SOA �

28 S � SO � SA � SOA �

29 S � SO � SA � SOA �

30 S � SO � SA � SOA � [S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint Adj.



Index

< 30 Controllers .................................. 24 > 30 Controllers .................................. 24 120 CV controllers.............................. 24 14,400 Baud Modem........................... 17 24VAC-to-24VAC.............................. 10 90% RH................................................. 8 Above 140° F ........................................ 8 Addresses

CV Worksheet................................... 1 CV-EX Worksheet ............................ 1 List .................................................. 26

Address Switch Setting CV Controller.................................. 11

Addressing Controllers......................................... 1 CV Controller.................................. 11 MiniLinks........................................ 24

AIN1.................................................... 13 AIN2.................................................... 13 AUX.................................................... 13 Belden No. 82760 ................................. 4 Below 20° F .......................................... 8 Cable

Belden 82760 .................................... 4 DB9 ................................................. 17 Serial ............................................... 17 Telephone Line ............................... 17 Two Wire Shielded ........................... 4

Codes, Standard Wiring ............................................... 1

CommLink IV Connecting to MiniLink.................. 20 Dip Switch Setting .......................... 19 Installing.......................................... 21 Jumper Setting ................................ 19 Overview......................................... 16 Technical Guide .............................. 21 Wiring ............................................. 18

Communication Loop Wiring Diagram, CV EX System...... 6

Communication Loop Wiring CV System ........................................ 5

Communications Loops CV System ........................................ 4 CV System Wiring Diagram ............. 5 CV-EX System.................................. 4 Local Loop ........................................ 4 Network Loop ................................... 4 Overview........................................... 4 Wiring Overview .............................. 5

Conduit.................................................. 7 Configuration

Daisy Chain....................................... 4 Star .................................................... 7

Controllers < 30 ................................................. 24 > 30 ................................................. 24 Addressing ........................................ 1 Damage ........................................... 10 List .................................................. 26

CV Address Worksheet......................... 1 CV Controller

Address Switch Setting ................... 11 Addressing ...................................... 11 Backplate Components ..................... 8 Electrical Connections .................... 10 Installing............................................ 8 Mounting........................................... 8 Wiring ............................................... 9 Wiring Diagram ................................ 9

CV System Communications Loops .................... 4 Diagram............................................. 2 Overview........................................... 2 Sensors ............................................ 12 Wiring Diagram ................................ 5

CV Worksheet..................................... 26 CV-EX Address Worksheet .................. 1



CV-EX System Communication Loop Wiring ........... 6 Communications Loops .................... 4 Diagram............................................. 3 Expansion Kit ................................. 24 Overview........................................... 3

Worksheet ....................................... 26 Daisy Chain..................................... 4, 25

Configuration .................................... 4 Daisy-Chain Configuration

CV-EX System Wiring Diagram ...... 6 Diagram............................................. 5

Damage Controller ........................................ 10

Damp Environments ............................. 8 DB9 Serial Cable ................................ 17 Diagram


Dial-up Communications .................... 17 Dial-up Connections ........................... 16 Dimensions

System Manager.............................. 22 DIP Switch ............................................ 4 Electrical

Short.................................................. 4 Electrical Connections

CV Controller.................................. 10 Enclosure

Weathertight...................................... 8 Environmental Limitations

Installation......................................... 8 Environments

Damp................................................. 8 Wet.................................................... 8

Expansion Kit ..................................... 24 Extreme High Temperatures ................. 8 Extreme Low Temperatures.................. 8 Firewall ............................................... 16 Fluorescent Lights................................. 7 Furnace Ignition System Wires ............. 7 GND-to-GND ..................................... 10 Humidity

90% RH............................................. 8

Installation CommLink IV................................. 21 CV Controller.................................... 8 CV System ........................................ 1 CV-EX System.................................. 1 Environmental Limitations ............... 8 Outside Air Sensor.......................... 15 Room Sensors ................................. 12 Supply Air Temperature Sensor...... 14 System Manager.............................. 22 Tips ................................................... 1

Intranet Connection............................. 16 IP Module

Overview......................................... 16 IP-Module Technical Guide................ 16 Jumper Setting

CommLink IV................................. 18 LAN and Internet Connections ........... 16 LCD Display

System Manager.............................. 22 Local Codes........................................... 7 Local Loop ............................................ 4 Marble Walls....................................... 12 Metal Shavings.................................... 10 MiniLink ............................................... 4

Address Location ............................ 24 Overview......................................... 24 Wiring ............................................. 25

Modem Internal ............................................ 17 Other Manufacturers’...................... 17 Remote Link II ................................ 17

Mounting Room Sensors ................................. 12

Mounting Backplate.............................. 8 Multiple Setting .................................. 21 Network Loop ....................................... 4 OE415-02 IP Module Kit.................... 16 OE419-06 Remote Link II .................. 17 Outside Air Sensor

Inaccurate Readings ........................ 15 Installing.......................................... 15

Outside Air Temperature Sensor......... 15



Overview CommLink IV................................. 16 Communications Loops .................... 4 CV System ........................................ 2 CV-EX System.................................. 3 IP Module........................................ 16 MiniLink ......................................... 24 Remote Link II ................................ 17 System Manager.............................. 22 Systems ............................................. 2

Plastic Bezel........................................ 13 Polarity............................................ 1, 10 Prism ....................................... 16, 17, 21 Radio Transmitting Equipment............. 7 Remote Link II .................................... 16

Described ........................................ 17 Overview......................................... 17

Requirements Electrical, CV Controller ................ 10

Rooftop Unit Discharge ...................... 14 Room Sensors ..................................... 12

Installing.......................................... 12 Mounting......................................... 12 Wiring ............................................. 13

Router.................................................. 16 RS-485 ............................................ 4, 22 Sensors

CV System ...................................... 12 Outside Air Temperature ................ 15 Room............................................... 12 Supply Air Temperature.................. 14

Short Electrical ........................................... 4

Splice..................................................... 4 Star Configuration

Wiring ............................................... 7 Steel Walls .......................................... 12 Supply Air Temperature Sensor

Installing.......................................... 14 Location .......................................... 14

System Manager Dimensions ..................................... 22 Installling ........................................ 22 Overview......................................... 22 Wiring ............................................. 23

Systems Overview........................................... 2

TB3 ..................................................... 13 TCP/IP Internet ................................... 16 Telephone Line ................................... 17 Temperatures

Above 140° F .................................... 8 Below 20° F ...................................... 8 Extreme High .................................... 8 Extreme Low..................................... 8 Humid ............................................... 8

Terminals AIN1................................................ 13 AIN2................................................ 13 TB3 ................................................. 13 TMP ................................................ 13

TMP .................................................... 13 Transformers ......................................... 7 TV Transmitting Equipment ................. 7 Two Wire Shielded ............................... 4 USB Drivers........................................ 21 Variable Frequency Drives ................... 7 Voiding, Warranty ................................ 1 Warranty, Voiding ................................ 1 Weathertight Enclosure......................... 8 Wet Environments ................................ 8 Wiring ................................................... 1

24VAC-to-24VAC.......................... 10 Color ................................................. 4 CommLink IV................................. 18 Communication Loops...................... 5 Conduit.............................................. 7 Continuous ........................................ 4 CV Communication Loop................. 5 CV Controller.................................... 9 CV Controller, Diagram.................... 9 CV-EX System.................................. 6 Diagram, CV System ........................ 5 GND-to-GND ................................. 10 Incorrect ............................................ 4 Local Codes....................................... 7 Mapping ............................................ 1 MiniLink ......................................... 25 Path ................................................... 7 Polarity........................................ 1, 10



Room Sensor................................... 13 Shortest Path ..................................... 7 Splice................................................. 4 Star Configuration............................. 7

System Manager.............................. 23 System Manager

LCD Display ................................... 22

Section 3

Programming

Table of Contents

LCD/Keypad Operations...................................................1 Keypad Functions ............................................................................................................1 System Manager LED Indicators .....................................................................................2

Screen Menus ..................................................................2

View Alarms Screen ........................................................5

Full System Access .........................................................6

Set Time & Date ..............................................................6

New Passcodes................................................................8

Rebuild Alarm Map...........................................................9

Read/Reset Units ...........................................................10

CV Controller Force Modes ...........................................11

CV Controller Read/Reset Operations...........................12

CV Controller Status......................................................13

CV Controller Setpoints.................................................16

CV Controller Scheduling and Holidays ........................22 Week Schedules .............................................................................................................22 Holidays .........................................................................................................................23

Economizer Module (Wetbulb) Read/Reset Operations 24

System Manager Keypad Operations Summary............26

Index ..............................................................................27


Programming


Programming 3-1

LCD/Keypad Operations

Keypad Functions The System Manager keypad is labeled either numerically or as to actual function for that key. Below is a summary of the labeled keys and their functions.

03/20/09 06:38PM FRI

OCCUPIED

NO ALARMS

MENU This key is used to gain access to the first menu, and you will be

notified on the LCD if any subsequent use of the key will be required for further access.

ESC The ESCape key allows you to abort what you are doing or exit back to previous menus. Also, anytime you want to leave the system unattended, you should press the ESC key until the Main Screen appears.

CLEAR If you make a mistake while entering setpoint data, you can clear the bad data from the display by pressing the Clear key.

ENTER Use the Enter key to close out a data entry. The Enter key can also be used to advance to the next field or screen.

DEC If entering a setpoint that requires a decimal point, press this key where the decimal is located while entering the value.

MINUS If you need to enter a negative value, you must press the Minus key before entering the digits for that value.

UP/DOWN Arrows

Use these keys to step forward or backward through Status Screens or Setpoint Data Fields.

LEFT/RIGHT Arrows

If the screen prompts you to use these keys, it is used normally to toggle modes of operation. In some cases, they may be used for other functions and you will be prompted as to what these might be.


3-2 Programming

System Manager LED Indicators There are two LED indicators located on the right-hand side of the System Manager. The top LED indicates an Alarm condition if the Manager detects an alarm condition while polling the system. The bottom LED is active during actual communications or packet transfers. This LED will normally "flicker" and not remain on constantly.

Screen Menus

Main Screen

The Auto-Zone System Manager is your direct link to the status and setpoints of any Auto-Zone component on your communications loop. With the System Manager, you can view any temperature or output condition and change any setpoint to fine-tune the operations of the total system. All keypad operations are simple and straight-forward, utilizing non-cryptic plain English messages. The System Manager automatically detects the type of unit that has been selected and displays the appropriate status and setpoint screens. The attractive plastic case of the System Manager allows for placement in any area of your building. The remainder of this section will lead you through the system menus and keypad operations. All user functions are accessed by pressing the Menu button. Once the button is pressed, the Main User Menu is displayed.

vX.XX Friday Operations 03/20/09 09:46 AM Outdoor Air 78.0°F


Programming 3-3

Main User Menu

View/Change Zone

1) View/Change Zone 2) View Alarms MENU) Full Access ESC) Main Screen

1) View/Change Zone

For quick access to an individual zone, select this menu item. Any Constant Volume unit can be selected. You can view the room temperature and change the current cooling and heating setpoints. You must be at least a Level 1 user to change the setpoints.

2) View Alarms If the System Manager has been configured for Alarm Polling, you can select this item to get a list of unit addresses that are currently in alarm. If an alarm exists, the Alarm LED will be active on the right side of the panel.

MENU) Full

Access

If you are a Level 2 user, the full system Read/Reset capabilities are available to you. These capabilites are accessed via this Menu button.

ESC) Main

Screen

When you have finished viewing the system, you can exit this menu and return to the Main Screen by pressing the ESC button.

View/Change [ Enter Unit ID# ] Selected Unit: 101

If you have selected the View/Change Zone menu item, you will be allowed to view any selected zone temperature and its current cooling and heating setpoints. If you are at least a Level 1 user, you can also change the cooling and heating setpoints from this screen. The first screen that appears prompts you for the Unit ID you wish to view. For the CV system, the Unit ID is actually the address of the CV controller you assigned to each board with the Address Switch—a number between 1 and 30. For the CV-EX system, it would also be the same CV controller address you assigned, but it would be preceded by the network loop address, which is the address number (between 1 and 4) you set for the MiniLink whose loop the particular CV controller resides on. For example, the CV controller address is 28 and it is on the loop with the MiniLink addressed 2. The ID number you would enter would be 228.


3-4 Programming

Constant Volume Status

Entering Passcodes

Constant Volume Unit

Temperature: 75.4°F Cooling SP.: 75°F Heating SP.: 72°F

If the selected Unit ID is correct, and the unit responds, the following screen will appear. If you are a Level 1 user, you can select either the Cooling or the Heating setpoint with the Up/Down Arrow keys. To change the setpoint, use the Left/Right Arrow keys. The setpoints are fully adjustable between their normal limits of 50 to 90 degrees. When you are finished viewing this screen, simply press the ESC button to exit. The Heating Setpoint is never allowed to get any closer than one degree of the Cooling setpoint. If you are lowering the Cooling setpoint or raising the Heating setpoint, both values will be kept apart automatically by the correct amount.

THIS ACTION REQUIRES PASSCODE CLEARANCE Enter Passcode: xxxx

Anytime you are prompted to enter a passcode, the following screen will appear. No reference is made as to the level of passcode to enter, but if you attempt to access a Level 2 function with a Level 1 passcode, the system will prompt you to enter the correct passcode again.


Programming 3-5

View Alarms Screen

Alarm Address Locations

Alarm Clearing

SYSTEM ALARM STATUS Alarm @ Unit ID 118

The System Manager can be programmed to poll all Auto-Zone units on your system for alarm information. This allows the centrally located System Manager to display an Alarm Indicator whenever an alarm condition exists anywhere on your system. The actual alarms are not displayed on this screen; only the Unit ID where the alarm is located is displayed. The example shows that a unit at location 118 has experienced an alarm condition. This alarm may or may not be current, as the System Manager latches the alarm condition. This makes it possible to determine if any intermittent alarm conditions have occured. If you have Level 2 access, you can enter the full system access mode, select that unit for display, and determine the exact alarm condition for that unit. The alarm conditions are always displayed on the Status Screens.

SYSTEM ALARM STATUS Clear Alarms? YES To Change Response Use Left/Right Arrow

If all the alarm conditions have been corrected at the individual units, you can clear these alarms from the System Manager on the following screen. Use the Left/Right arrow keys to select the YES/NO response desired. If you clear the alarms, but some still exist, the System Manager will show an alarm indication when the affected unit is polled again.


3-6 Programming

Full System Access

Full Access Menu

Set Time & Date The System Manager has its own built-in Real Time Clock. It broadcasts this time once a day at midnight to synchronize all of the other units on your Auto-Zone system. Although the times are displayed on the Main Screen in a standard 12-hour format, they are programmed using the 24-hour Military format. Once the time has been entered, it is also broadcast immediately to all other units on the system. That means that you only need to program the System Manager time to set the Real Time Clocks for all units on your communications loop.

Programming Time

1) Set Time & Date 2) Read/Reset Units 3) New Passcodes 4) Rebuild Alarm Map

If you selected the MENU key from the first menu screen, you can gain full system access. However, you must be a Level 2 user. If you haven't already been asked to enter the passcode, you will be asked before the Full Access Menu is displayed. This prevents a Level 1 user from being overwhelmed with the full amount of data and setpoints available to the Level 2 user.

Program Time/Date Day (Sunday=0): 1 Enter Hr. (0-23): 9 Enter Minutes : 53

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

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

Minutes - Enter the Minutes (0 to 59)


Programming 3-7

Programming Date

Daylight

Savings Adjustments

Program Time/Date Month (1-12): 3 Day (1-31): 20 Year (00-99): 09

Month - Enter the Month (1 to 12)

Day - Enter the Day of the Month (1 to 31)

Year - Enter the current Year with 2 digits (00 to 99)

If your area of the country requires Daylight Savings changes, you can enable the System Manager to automatically reset its own clock during the Daylight Savings changeover. However, if you enable this operation, be aware it will changeover the first Sunday in April and then switch back the last Sunday in October. These used to be the standard dates every year that were constant from year to year.

The U.S. government has seen fit recently to arbitrarily determine the switch over dates each year so it is recommended that you disable this function and manually change the schedules from year to year.

Use the Left or Right arrow keys to toggle the second line of the display between Adjustments Enabled and Adjustments Disabled.

Daylight Savings Adjustments Enabled Use Left/Right Arrow


3-8 Programming

New Passcodes

Programming Passcodes

Caution: If you change the Level 2 passcode and cannot remember what it is, you will be locked out of your system!

Enter New Passcode Level 1.....: XXXX Level 2.....: XXXX [Must Be 4 Digits]

The System Manager has two levels of user access.

Level 1 users are limited to viewing or changing Zone Temperatures and their Heating and Cooling Setpoints and to viewing Unit ID numbers for those in alarm conditions.

Level 2 users have complete system access. Any status or setpoint field can be read or reset from the Auto-Zone system.

These two levels of passcodes are programmable by any Level 2 user. The default Level 1 passcode is 1111, and the default Level 2 passcode is 2222.

The actual digits in your passcodes are never displayed. An "X" is used as a place holder for each digit entered. Passcodes must always be four digits in length, so the useable range of numbers is 1000 to 9999.


Programming 3-9

Rebuild Alarm Map

Rebuilding Screens

Clearing Old Map .................... ................

Building New Map Loop: 1 Unit: 1 FOUND

If you would like the LED Alarm Indicator to function on the front of your System Manager, you must enable Alarm Polling by building an Alarm Map. This map keeps track of which units exist on your communications loop so that the System Manager will poll only those units. That means you will need to rebuild this map anytime units are added or removed from your system. It also means you can disable alarm polling. To do this, disconnect the RS-485 communications plug from the back of your CommLink IV. Then select the Rebuild Alarm Map menu. The System Manager will not find any units to poll for alarms since none are connected. This is useful during building startup, when you don't want nuisance alarms bothering you.

The screen will display each address it is testing if a unit is FOUND at that address. If you have a CV system, you don't have to wait for the System Manager to check for all 30 loops; rather, you can press the ESC key as soon as the first loop has been checked since the CV system only has one loop. All units found up to that point will be saved in memory. The CV system volume configuration only contains one loop, but the System Manager will always attempt to determine if more than one loop really exists. The CV-EX system will have 2 to 4 loops. Be sure to allow time for the System Manager to find all the local loops.

The System Manager does not rebuild this map automatically on powerup! You must do this manually. This rebuild should only be performed one time, when all units are up and running. It is not a regular requirement. As mentioned above, only when the number of units connected changes should the alarm map be rebuilt.

Alarm Unit Map Built Press Any Key To Continue


3-10 Programming

Read/Reset Units

Read/Reset Address Entry

Read/Reset [ Enter Unit ID# ] Selected Unit: 101

You must know the Unit ID of the controller you wish to view. This number is created by combining the network loop address with the CV Controller board address on CV-EX systems. On CV systems, the Unit ID is simply the CV controller board address. The CV Controllers should always be addressed starting with number 1 and continuing up to 30. The CV-EX MiniLinks (network loop address) should be numbered starting with 1 and continuing up to 4 (assuming you have 4 loops). Don’t skip numbers.

Once you have finished the Read/Reset function, you can exit this mode by pressing the ESC key. This will return you to the Full Access Menu.


Programming 3-11

CV Controller Force

Modes

OPERATING MODE 0) Auto 1) Occupied 2) Night 3) Fan Only Enter Clock Mode: 0

The Constant Volume Units default to the Auto Mode of operation when first powered up. Any force modes entered will be retained in non-volatile memory. The unit will resume the force mode of operation anytime the power is cycled.

0) Auto - Use internal schedules for Day/Night Mode

1) Occupied - Forced to Continuous Day or Occupied Mode

2) Night - Forced to Continuous Night or Unoccupied Mode.

3) Fan Only - This mode disables any heating or cooling and operates the Fan only. You can use this mode anytime you want to manually purge your building.


3-12 Programming

CV Controller

Read/Reset Operations If the Unit ID you entered found a Constant Volume AHU, the following menus will appear. Any references in this section to CVAHU are referring to the Constant Volume Air Handling Unit or its controller.

CV Controller Menu #1

CV Controller Menu #2

1) CVAHU Status

2) CVAHU Setpoints

MENU) Next Menu

ESC) To Exit

1) CVAHU Status View the current temperatures and operating modes for this Constant Volume AHU.

2) CVAHU Setpoints View or change any of the available setpoints for this Constant Volume AHU.

MENU) Next Menu Access the next Menu Page for the Constant Volume AHU.

1) Schedules 2) Force Modes MENU) Previous Menu

1) Schedules View or change any of the Week Schedules or Holidays for this Constant Volume AHU.

2) Force Modes Select this menu to override the currently scheduled operating mode.

MENU) Previous

Menu

Return to the previous menu shown above.


Programming 3-13

CV Controller Status Line 1 displays the currently selected CVAHU and its current operating software version on all Status Screens shown below.

Status Screen #1

Status Screen #2

CVAHU # 18 vl.xx Occupied Mode Neutral Mode

Line 2 - Unoccupied Mode

Occupied Mode

Holiday Active

Push-button Override

Forced Occupied

Forced Unoccupied

Forced Fan Only Mode

Line 3 - Neutral Mode

Cooling Mode

Heating Mode

Line 4 - (Reserved for Future Use) This Line is Blank

CVAHU # 18 vl.xx Temperature: 78.6ºF CSP 75.0 HSP 72.0º Slide Adjust.: 0.0°

Line 2 - Displays the current Zone Temperature.

Line 3 - Displays the currently active Cooling Setpoint (CSP) and Heating Setpoint (HSP).

Line 4 - Displays the current effect the optional Sensor Slide Adjust has on the Heating and Cooling Setpoints.


3-14 Programming

Status Screen #3

Status Screen #4

Status Screen #5

CVAHU # 18 vl.xx

Supply Air.: 65.0° Outdoor Air.: 70.2° Wetbulb Temp: 0.0°

Line 2 - Displays the current Supply Air Temperature.

Line 3 - Displays the current Outdoor Air Temperature.

Line 4 - Displays the current Wetbulb Temperature if available.

CVAHU # 18 vl.xx Economizer...: 10% Heating Locked Out Fan On

Line 2 - Shows the current Economizer Damper position if the CVAHU has been configured to control the Economizer. (This line is blank if the CVAHU does not control the Economizer.)

Line 3 - No Lockouts Active

Cooling Locked Out

Heating Locked Out

Line 4 - Fan Off

Fan On

Heating Stage #1 OFF Heating Stage #2 OFF Cooling Stage #1 OFF Cooling Stage #2 OFF

This screen shows how the relays were configured, either for Heating or Cooling. The first line shows the status of Relay #2, the second line shows the status of Relay #3, etc.

The message will show ON/OFF status for that relay.


Programming 3-15

Status Screen #6

Note: If no alarm conditions exist, then line 3 will display the words No Alarms!

Line 4 - Mech Cooling ALARM

Mech Heating ALARM

This line remains blank if no alarm condition exists. These alarms are generated when the Supply Temperature does not change more than five degrees after a stage of heating or cooling has been activated for 30 minutes.

CVAHU # 18 vl.xx Zone Cooling ALARM

Line 2 - Zone Sensor O.K.

Bad Zone Sensor!

Zone Cooling ALARM

Zone Heating ALARM

The line will show Zone Sensor OK if none of the above alarm conditions exist.

Line 3 - Binary Input ALARM

This line will remain blank if the contact has not closed. This input is normally used for Dirty Filter Alarms.

If no alarm conditions exist, then line 3 will display the words No Alarms!


3-16 Programming

CV Controller Setpoints Line 1 displays CVAHU Setpoints message for identification only.

Setpoint Screen #1

Setpoint Screen #2

CVAHU Setpoints Occupied Setpoints

Cooling Setpt: 75°F Heating Setpt: 72°F

The Occupied Heating and Cooling Setpoints are entered on this screen. The Heating Setpoint should always be at least one degree below the Cooling Setpoint, or the CVAHU will not accept the new values.

Minimum Default Maximum

Cooling Setpoint 50°F 75°F 90°F Heating Setpoint 50°F 72°F 90°F

CVAHU Setpoints Unoccupied Setpoints

Cool Setup...: 10°F Heat Setback.: -10°F

The Unoccupied Heating and Cooling Setup values are entered on this screen. The Occupied Cooling Setpoint will be increased by the Cooling Setup during Unoccupied Mode, and the Heating Setpoint will be decreased by the Heating Setback.


Cooling Setup 0°F 10°F 30°F Heating Setback 0°F -10°F -30°F


Programming 3-17

Setpoint Screen #3

Setpoint Screen #4

CVAHU Setpoints

Slide Effect.: 3°F SP Deadband..: 1°F

If the Zone Temperature Sensor has the optional Sensor Slide Adjustment, the maximum effect it can have on the Heating and Cooling Setpoints is programmed here.

The SP Deadband is divided in half across the current heating or cooling setpoint and is used in staging the heating or cooling on or off.


Slide Effect 0°F 3°F 5°F SP Deadband 0°F 1°F 10°F

CVAHU Setpoints Cooling Stages: 2 Heating Stages: 2

The CVAHU can support a total of four stages of heating and cooling, configured to best match your system. As long as the total number of heating and cooling stages does not exceed four, you can specify any quantity between zero and four for each mode.

EXAMPLE:

3 Heating Stages (Relays #2 to #4)

1 Cooling Stage (Relay #5)

or

0 Heating Stages (No Relays)

4 Cooling Stages (Relays #2 to #5)

The heating stages are always allocated first, starting with Relay #2 (Fan is Relay #1), and assigned sequentially up to a maximum of four heating and/or cooling stages.


3-18 Programming

Setpoint Screen #5

Setpoint Screen #6

Setpoint Screen #7

CVAHU Setpoints Minimum On/Off Times Cool Staging: 4 Min Cooling Off : 5 Min

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


Cool Staging 1 Min 2 Min 30 Min Cooling Off 1 Min 5 Min 30 Min

CVAHU Setpoints Minimum On/Off Times Heat Staging: 4 Min Heating Off : 5 Min

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


Heat Staging 1 Min 2 Min 30 Min Heating Off 1 Min 5 Min 30 Min

CVAHU Setpoints Changeover Delay Between Heat/Cool Modes......: 15 Min.

To prevent rapid cycling back and forth between the heating and cooling modes, the CVAHU has a programmable Changeover Delay Timer. This timer prevents a change in mode from bringing on any heating or cooling (based on last mode) until this delay is satisfied.

Normally, you do not want to change modes more than four or five times per hour.


Changeover Delay

1 Min 10 Min 30 Min


Programming 3-19

Setpoint Screen #8

Setpoint Screen #9

CVAHU Setpoints Fan Mode.: Constant Economizer: Enabled Use Left/Right Arrow

Line 2 - The CVAHU can operate the fan in one of two modes:

Continuous or Constant running during occupied hours.

Cycle with heating or cooling during occupied hours.

The fan always cycles with heating or cooling during unoccupied hours. The Left/Right Arrow keys will toggle the current setting to the opposite mode.

Line 3 - The CVAHU has the ability to control the Economizer operation. If you require this feature, select Enabled; otherwise, select Disabled.

Constant Volume Unit Uses Schedule #: 0 0 = Internal Clock 1-8 = External Clock

The CVAHU normally uses its own Real Time Clock and an Internal Week Schedule to determine the Occupied/ Unoccupied mode of operation. The CVAHU does have the ability to use a Global Broadcast from another scheduling device on the communications loop if a different schedule is required. If an external schedule is used, the range of schedule numbers is one to eight.


3-20 Programming

Setpoint Screen #10

Setpoint Screen #11

Setpoint Screen #12

CVAHU Setpoints

Cool Lockout.: 50°F Heat Lockout.: 65°F

The mechanical heating and cooling can be locked out from operating based on the Outdoor Air Temperature. If the Outdoor Air Temperature is above the Heating Lockout, no heating stages are allowed to activate or remain on if they are already ON. If the Outdoor Air drops below the Cooling Lockout, no cooling stages are allowed to activate or remain on if they are already ON.


Cool Lockout -40°F 50°F 90°F Heat Lockout 30°F 65°F 99°F

CVAHU Setpoints Economizer Setpoints

Enable Setpt.: 50°F Supply Setpt.: 55°F

If the CVAHU has been configured for Economizer Control, this screen will appear.

The Econo Enable setpoint is the Outdoor Air or Wetbulb Temperature that enables the Economizer to open past its minimum position setpoint to control Supply Air Temperature.

The Supply Setpt is the Supply Air Temperature the Economizer tries to maintain.


Enable Setpt -40°F 50°F 99°F Supply Setpt 50°F 55°F 90°F

The Min Econo % is the position the economizer holds during occupied mode when it is not enabled for operation due to Outdoor Air or Wetbulb Temperature.

During economizer control, the economizer damper is allowed to move open or closed, as required, at a rate controlled by this value. Use this to speed up or slow down the operation of your economizer. The larger the number, the slower the damper moves.


Min Position 0 % 10 % 100 % Control Rate 1 50 90

CVAHU Setpoints Economizer Setpoints Min Position: 10 % Control Rate:. 50


Programming 3-21

Setpoint Screen #13

Setpoint Screen #14

Setpoint Screen #15

CVAHU Setpoints Economizer Setpoints Min Voltage: 0.0 v Max Voltage: 10.0 v

You can set the voltages required to open and close the damper. Some actuators use a 2-10 VDC signal instead of 0-10 VDC.

If the system is not configured for Economizer Control, no economizer setpoint screens will appear.


Min Voltage 0.0 VDC 0.0 VDC 10.0 VDC Max Voltage 0.0 VDC 10.0 VDC 10.0 VDC

CVAHU Setpoints Fan Starting Delay Multiplier...: 10

If there are several air handling units on a system and you don’t want them to all start at the same time when going into the occupied mode or after a power outage, you can input a Fan Starting Delay Multiplier. The multiplier is multiplied times the address number of the unit and this becomes the number of seconds this unit waits before starting the fan. For example, if the Multiplier is 5 and this unit is at address #18, then the time delay will be 90 seconds.


Multiplier 0 0 30

Sensor Rdg Offset ZNT.: 73.6 0.0 SAT.: 76.5 0.0 OAT.: 70.2 0.0

The Thermister Type III Sensor readings can be calibrated. Enter Positive values to increase the reading or Negative values to decrease the reading. The Outdoor Air calibration offset only applies to the CVAHU that has the sensor installed. It has no effect on the Global Broadcast value of Outdoor Air.


Zone Sensor ZNT -100.0°F 0.0°F +100.0°F Supply Sensor SAT -100.0°F 0.0°F +100.0°F Outdoor Sensor OAT -100.0°F 0.0°F +100.0°F


3-22 Programming

CV Controller

Scheduling and Holidays The Constant Volume AHU controllers contain their own built-in scheduling capability for calculating Occupied/Unoccupied periods. All schedules are entered in 24-Hour Military Format. See the Constant Volume Menu Operations Screen for information on how to access these programming functions.

Scheduling/Holiday Menu

Week Schedules

Start Time

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 continues to the next Start Time screen.

Constant Volume Unit 1) Week Schedules 2) Holidays MENU) Previous Menu

This menu appears whenever you access the Scheduling functions. It allows you to choose between schedules or holidays.

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

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

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

If both the Start and Stop Times are ZERO, the schedule is in a Continuous OFF mode.

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

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


Programming 3-23

Holidays

Holiday Day Selection

Holiday Start / Stop Times

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

The screens will step through the eleven possible holidays one at a time. Line 2 shows which holiday is currently being programmed.

Remember to combine the month and day into a single four- digit value.

EXAMPLE: 0704 = July 4th

1225 = December 25th

Program Holidays Holiday Schedule Starting Time: 0 Stopping Time: 0

The eleven holidays all use the same Start and Stop time which you enter on this screen. You enter it in 24-hour military format, the same as a regular week schedule.


3-24 Programming

Economizer Module

(Wetbulb) Read/Reset

Operations If the Unit ID you entered was for the Economizer Module, the following menu will appear. Any references in this section to wetbulb are referring to the Economizer Module.

Wetbulb Menu

Wetbulb Status

1) Wetbulb Status 2) Setpoints ESC) To Exit

1) Wetbulb

Status

View the current Outdoor Air Temperature, Humidity, and calculated Wetbulb Temperature.

2) Setpoints View or change any of the available setpoints for this Economizer Module.

WB # xx vl.xx

Outdoor Air: 76.9°F Humidity...: 75 %

Wetbulb....: 71.3°F

Line 2 - Current Outdoor Air Temperature reading. The Outdoor Air Sensor must be installed on this unit. It will not read a Global Broadcast of the Outdoor Air Temperature from another controller.

Line 3 - Current Outdoor Relative Humidity.

Line 4 - Current calculation of the Wetbulb Temperature.


Programming 3-25

Wetbulb Setpoints

WB Setpoints Calibration Offset Outdoor Air..: 77.1 Cal. Offset..: 0.0

The only setpoint available for this unit is the Calibration Offset for the Thermistor Outdoor Air Temperature Sensor. If location or other factors are causing the Outdoor Air Temperature reading to be incorrect, you can adjust the reading up or down with this offset. Line 2 shows the current temperature when you first enter this screen, but it is not dynamically updated after the offset is changed. You will need to exit this screen and then return to this screen to see the effect of the entered offset.


Cal. Offset -100.0°F 0.0°F 100.0°F


3-26 Programming

System Manager Keypad

Operations Summary

View/Change [ Enter Unit ID# ] Selected Unit: 101

SYSTEM ALARM STATUS Clear Alarms? YES To Change Response Use Left/Right Arrow

Constant Volume Unit

Temperature: 75.4°F Cooling SP.: 75°F Heating SP.: 72°F

SYSTEM ALARM STATUS Alarm @ Unit ID 118

vX.XX 1 Friday Operations 03/20/09 09:46 AM Outdoor Air 78.0°F

Program Time/Date Day (Sunday=0): 1 Enter Hr. (0-23): 9 Enter Minutes : 53

1) Set Time & Date 2) Read/Reset Units 3) New Passcodes 4) Rebuild Alarm Map

Program Time/Date Month (1-12): 9 Day (1-31): 18 Year (00-99): 09

Daylight Savings Adjustments Enabled Use Left/Right Arrow

Enter New Passcode Level 1.....: XXXX Level 2.....: XXXX [Must Be 4 Digits]

Clearing Old Map .................... ................

Building New Map Loop: 1 Unit: 1 FOUND

Alarm Unit Map Built Press Any Key To Continue

Read/Reset [ Enter Unit ID# ] Selected Unit: 101

1) CVAHU Status 2) CVAHU Setpoints MENU) Next Menu ESC) To Exit

1) Schedules 2) Force Modes MENU) Previous Menu

1) Wetbulb Status 2) Setpoints ESC) To Exit

1) View/Change Zone 2) View Alarms MENU) Full Access ESC) Main Screen


Programming 3-27

Index 12-Hour Format .................................... 6 2359

Start and Stop Times....................... 22 24-Hour Format .................................. 22 24-Hour Military Format ................ 6, 22 50 to 90 Degrees ................................... 4 Address Entry

Read/Reset ...................................... 10 Addresses

Entering............................................. 3 Addressing

MiniLinks........................................ 10 Adjustments Disabled ........................... 7 Adjustments Enabled ............................ 7 AHU.................................................... 12 Alarm

Mech Cooling Alarm ...................... 15 Zone Heating Alarm........................ 15

Alarm Address Locations............................. 5 Clearing............................................. 5 Condition .......................................... 2 Indicator ............................................ 9

LED................................................... 2 Map ................................................... 9 Polling............................................... 9 Alarms

Bad Zone Sensor ............................. 15 Binary Input Alarm ......................... 15 Clearing............................................. 5 Dirty Filter Alarm ........................... 15 Mech Heating Alarm....................... 15 Zone Cooling Alarm ....................... 15

Auto Mode .......................................... 11 Bad Zone Sensor!................................ 15 Binary Input ALARM ......................... 15 Building New Map................................ 9 Calibration Offset................................ 25 Changeover Delay Timer .................... 18 Clearing Old Map ................................. 9

Communications

LED................................................... 2 Constant Volume AHU

Operating Modes, View .................. 12 Setpoints, View or Change ............. 12 Temperatures, View........................ 12

Continuous Day Mode ........................ 11 Continuous Night ................................ 11 Continuous OFF Mode ....................... 22 Continuous ON Mode......................... 22 Continuous or Constant

Fan Mode ........................................ 19 Control Rate ........................................ 20 Cool Lockout ...................................... 20 Cool Staging........................................ 18 Cooling Locked Out............................ 14 Cooling Mode

CV Controller.................................. 13 Cooling Off ......................................... 18 Cooling Setpoint

CV Controller.................................. 13 Cooling Setpoints.................................. 3 Cooling Stages Setpoints .................... 17 Current Outdoor Air Temperature ...... 24 Current Outdoor Relative Humidity ... 24 Current Year.......................................... 7 CV Controller

Address ............................................. 3 Force Modes.................................... 11 Holidays .......................................... 22 Read/Reset Operations.................... 12 Scheduling....................................... 22 Setpoints.......................................... 16 Software Version ............................ 13 Status............................................... 13

CVAHU .............................................. 12 Economizer Damper ....................... 14 Force Modes.................................... 12 Schedules ........................................ 12 Setpoints.......................................... 12 Status............................................... 12


3-28 Programming

Cycle with Heating or Cooling Fan Mode ........................................ 19

Date Programming..................................... 7

Day of the Month .................................. 7 Day/Night Mode ................................. 11 Daylight Savings Adjustments.............. 7 DEC....................................................... 1 Default Level 1 Passcode...................... 8 Default Level 2 Passcode...................... 8 Dirty Filter Alarm ............................... 15 Econo Enable Setpoint ........................ 20 Economizer

Control Rate .................................... 20 Min Position.................................... 20

Economizer Control ............................ 20 Economizer Damper

CVAHU .......................................... 14 Economizer Module

Read/Reset Operations.................... 24 Economizer Operation

Setpoint ........................................... 19 Economizer Setpoint

Max Voltage.................................... 21 Min Voltage .................................... 21

ENTER.................................................. 1 Entering Passcodes................................ 4 External Clock .................................... 19 Fan Off ................................................ 14 Fan On................................................. 14 Fan Only Mode ................................... 11 Fan Starting Multiplier........................ 21 Force Modes

CV Controller.................................. 11 CVAHU .......................................... 12

Forced Fan Only Mode CV Controller.................................. 13

Forced Occupied CV Controller.................................. 13

Forced Unoccupied CV Controller.................................. 13

Full Access............................................ 3 Full Access Menu ................................. 6 Full System Access

Menu ................................................. 6

Function LCD/Keypad ..................................... 1

Global Broadcast................................. 19 Heat Lockout....................................... 20 Heat Staging........................................ 18 Heating Locked Out ............................ 14 Heating Mode

CV Controller.................................. 13 Heating Off ......................................... 18 Heating Setpoint

CV Controller.................................. 13 Heating Setpoints .................................. 3 Heating Stages..................................... 17

Setpoints.......................................... 17 Holiday Active

CV Controller.................................. 13 Holiday Day Selection ........................ 23 Holiday Start and Stop Time............... 23 Holidays

CV Controller.................................. 23 Internal Clock...................................... 19 Internal Schedules ............................... 11 Internal Week Schedule ...................... 19 Keypad Functions ................................. 1 Keypad Operations Summary ............. 26 LCD/Keypad Operations....................... 1 LED Alarm Indicator ............................ 9 LED Indicators ...................................... 2 LEDs

Alarm Condition ............................... 2 Communications ............................... 2 Transfers ........................................... 2

LEFT/RIGHT........................................ 1 Level 1 User ...................................... 3, 8 Level 2 User ...................................... 3, 8 Main Screen ...................................... 2, 3 Main User Menu ............................... 2, 3 Max Voltage........................................ 21 Mech Cooling ALARM ...................... 15 Mech Heating ALARM ...................... 15 MENU................................................... 1 Menu Items

Full Access........................................ 3 Main Screen ...................................... 3 View Alarms ..................................... 3


Programming 3-29

View/Change..................................... 3 View/Change Zone ........................... 3

Menus Full System Access ........................... 6 Holiday Day Selection .................... 23 Scheduling/Holiday......................... 22 Week Schedules .............................. 22 Wetbulb........................................... 24

Min Econo % ...................................... 20 Min Position........................................ 20 Min Voltage ........................................ 21 MiniLinks

Addressing ...................................... 10 MINUS.................................................. 1 Month.................................................... 7 Neutral Mode

CV Controller.................................. 13 New Passcodes...................................... 8 No Alarms........................................... 15 No Lockouts Active ............................ 14 Occupied Cooling

Setpoints.......................................... 16 Occupied Heating

Setpoint ........................................... 16 Occupied Mode................................... 11 Operating Modes................................. 11 Outdoor Air Calibration Offset ........... 21 Outdoor Air Sensor ............................. 24 Outdoor Air Temperature.................... 25

CV Controller.................................. 14 Outdoor Relative Humidity................. 24 Outdoor Sensor OAT .......................... 21 Passcodes

Entering............................................. 4 Entering New .................................... 8

Polling for Units ............................................ 9

Powerup ................................................ 9 Programming

Passcodes .......................................... 8 Programming Date ................................ 7 Programming Time ............................... 6 Push-button Override

CV Controller.................................. 13

Read/Reset Address Entry.................................. 10

Read/Reset Capabilities ........................ 3 Read/Reset Operations

CV Controller.................................. 12 Economizer Module........................ 24 Wetbulb........................................... 24

Read/Reset Units................................. 10 Real Time Clock ................................. 19 Real Time Clocks.................................. 6 Rebuild Alarm Map .............................. 9 RS-485 Communications Plug.............. 9 Schedules

CVAHU .......................................... 12 Start Time........................................ 22 Stop Time........................................ 22

Scheduling CV Controller.................................. 22

Scheduling/Holiday Menu .................. 22 Screens

Alarm Address Locations.................. 5 Clear Alarms ..................................... 5 Constant Volume Status.................... 4 CV Controller Force Modes............ 11 Entering Passcodes............................ 4 Full System Access ........................... 6 Holiday Day Selection .................... 23 Main .................................................. 2 New Passcodes.................................. 8 Read/Reset Units............................. 10 Rebuild Alarm Map .......................... 9 Scheduling/Holiday......................... 22 Set Time & Date ............................... 6 View Alarms ..................................... 5 View/Change Zone ........................... 3 Week Schedules .............................. 22 Wetbulb........................................... 24

Sensor Slide Adjust CV Controller.................................. 13

Sensor Slide Adjustment..................... 17 Set Time & Date ................................... 6


3-30 Programming

Setpoints................................................ 2 Cooling.............................................. 3 CV Controller.................................. 16 Heating.............................................. 3 Wetbulb..................................... 24, 25

Setpoints, Entering Changeover Delay Timer ................ 18 Cooling Lockout ............................. 20 Cooling Stages ................................ 17 Economizer Control ........................ 20 Economizer Operation .................... 19 Fan Mode ........................................ 18 Fan Starting Multiplier.................... 21 Heating Lockout.............................. 20 Heating Stages................................. 17 Min Econo % .................................. 20 Occupied Cooling ........................... 16 Occupied Heating............................ 16 Sensor Slide Adjustment................. 17 Slide Effect...................................... 17 SP Deadband................................... 17 Staging Delay Period....................... 18 Staging Delay Period, Heating........ 18 Unoccupied Cooling Setup ............. 16 Unoccupied Heating Setback .......... 16

Slide Effect Setpoint ........................... 17 Software Version

CV Controller.................................. 13 SP Deadband Setpoint......................... 17 Staging Delay Period

Cooling............................................ 18 Heating Stages................................. 18

Start and Stop Times 2359................................................. 22 Zero ................................................. 22

Start Time............................................ 22 Status..................................................... 2

Wetbulb........................................... 24 Stop Time............................................ 22 Summary

Keypad Operations.......................... 26 Supply Air Temperature

CV Controller.................................. 14 Supply Sensor SAT............................. 21 Supply Setpt ........................................ 20

System Manager Keypad .............................................. 1 Keypad Operations Summary ......... 26

Temperature 50 to 90 Degrees ............................... 4 Setpoints............................................ 4 Wetbulb........................................... 24

Thermister Type III Sensor ................. 21 Thermistor Outdoor Air Temperature

Sensor.............................................. 25 Time

12-Hour Format ................................ 6 24-Hour Military Format ............ 6, 22 Continuous OFF Mode ................... 22 Continuous ON Mode..................... 22 Daylight Savings ............................... 7 Programming..................................... 6 Real Time Clocks.............................. 6

Transfers LED................................................... 2

Unit Polling............................................... 9

Unit ID .................................................. 3 Unoccupied Cooling Setup Setpoint ... 16 Unoccupied Heating

Setback Setpoint.............................. 16 Unoccupied Mode

CV Controller.................................. 13 Unoccupied Mode. .............................. 11 UP/DOWN............................................ 1 View Alarms ......................................... 3 View Alarms Screen ............................. 5 View/Change......................................... 3 View/Change Zone ............................... 3 Week Schedules .................................. 22 Wetbulb

Read/Reset Operations.................... 24 Menu ............................................... 24

Setpoints.................................... 24, 25 Status............................................... 24 Wetbulb Temperature ......................... 24

CV Controller.................................. 14 Zero

Start and Stop Times....................... 22 Zone Cooling ALARM ....................... 15


Programming 3-31

Zone Heating ALARM ....................... 15 Zone Sensor O.K................................. 15 Zone Sensor ZNT................................ 21

Zone Temperature ................................. 3 CV Controller.................................. 13


3-32 Programming

Notes

Section 4

Start-Up & Troubleshooting

Table of Contents

Communications Overview..............................................1 How It Works...................................................................................................................1 CV System .......................................................................................................................2 CV-EX System.................................................................................................................3 CommLink IV ..................................................................................................................4 CommLink IV DIP Switch Setting ..................................................................................5 MiniLink ..........................................................................................................................6 System Manager...............................................................................................................7 CV Controller Communications ......................................................................................8 CV Controller Address Switches ....................................................................................9 CV and CV-EX System Communications Checklist.....................................................10

CV Controller Overview .................................................11 How It Works.................................................................................................................11 CV Controller Inputs & Outputs....................................................................................12 CV Controller Wiring ....................................................................................................14

Startup & Commissioning..............................................15 Procedures......................................................................................................................15 CV & CV-EX Worksheet ..............................................................................................17

Troubleshooting.............................................................18 General Communications...............................................................................................18 Blink Codes....................................................................................................................19 Communications Loops .................................................................................................20 CV Controller.................................................................................................................32 Room Sensor..................................................................................................................33 Driver Chip Replacement ..............................................................................................35

Index ..............................................................................37

Section 4

Start-Up & Troubleshooting

Table of Figures & Tables Figure 4-1: CV System Communications Wiring .........................................................2

Figure 4-2: CV-EX System Communications Wiring...................................................3

Figure 4-3: CommLink IV Wiring.................................................................................4

Figure 4-4: CommLink IV DIP Switch Setting .............................................................5

Figure 4-5: MiniLink Wiring and Addressing...............................................................6

Figure 4-6: System Manager Component Location & Wiring ......................................7

Figure 4-7: CV Controller Component Locations.........................................................8

Figure 4-8: CV Controller Addressing..........................................................................9

Figure 4-9: Typical CV Controller Wiring Diagram ...................................................14

Table 4-1: Diagnostic LED Blink Codes .....................................................................19

Table 4-2: Temperature Sensor Resistance .................................................................34

Figure 4-10: Driver Chip Locations............................................................................35

Figure 4-11: General Chip Replacement Procedures .................................................36


Start-Up and Troubleshooting 4-1

Communications

Overview

Perhaps 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, much of the troubleshooting can be done by simple observation. We will lead you through the system functions and then provide you with detailed instructions for checking each piece of equipment.

How It Works Auto-Zone uses a token-passing loop architecture, which means in simple terms that an “electronic message” called a token is passed from controller to controller in a round-robin fashion. A controller must wait to receive the token before it can send or request any data. Only one device on each loop is capable of sending the token, and this device is considered the loop master. The loop master varies depending on the type of system and the installed options. For the CV system, the loop master is the CommLink. The CommLink must be connected to the system or the communications will not function. For the CV-EX system, the Local Loop master for the CV controllers is the MiniLink, and the Network Loop master is the CommLink.

Note: It is very important to know which device is the loop master on the loop you are troubleshooting.

In order for the loop master to communicate with the various devices on that loop, each must have a unique address. With the CV or CV-EX system, each CV controller on the local loop must have its own address from 1 to 30. For the CV system, this is all that is required. For the CV-EX system, in addition to each CV controller being addressed, the MiniLink on each local loop must have its own unique address between 1 and 4. Please see Figure 4-5 for address switch setting information.


4-2 Start-Up and Troubleshooting

CV System The standard CV system has only one communications loop. If you are using the CV-EX System (for systems with more than 30 CV Controllers), please see the next page - CV-EX System. The CommLink IV is always the master on the CV system loop. You must be sure the CommLink IV is connected and functioning if you are troubleshooting the communications loop. The CommLink IV jumper switch must be set for single loop operation when used with the CV system. See Figure 4-1 for communications wiring connections and Figure 4-4 for jumper switch settings.

Computer(Optional)

End Of Loop

RS-485

Comm Loop

Loop Start


System Manager

CV Controller

CV Controller

CV Controller

CV Controller




On The Loop


And Provides LAN And InternetCommunications





Provides Alarm Call-Outs. ASecond Remote Link Is Required IfConnection To Job Site Is Desired

From Remote Computer.










9600 Baud

Figure 4-1: CV System Communications Wiring



CV-EX System See Figure 4-2. The CV-EX system has two types of communications loops. The loops which the CV controllers are connected to are called the Local Loops. The MiniLink is always the loop master on the CV-EX local loop. You must be sure the MiniLink is connected, powered up, and functioning if you are troubleshooting a Local communica-tions loop. The other type of loop on the CV-EX system is called the Network Loop. This loop connects all the MiniLinks together and then ties into the CommLink IV which is the Network Loop Master. The CommLink IV jumper switch must be set for multiple loop operation when used with the CV-EX system. See Figure 4-4 for the correct jumper switch setting.

Computer(Optional)

End Of Local Loop

MiniLink

RS-4859600 Baud

RS-48519200 Baud

Local LoopNetwork Loop Start

Network Loop

Connect ToNetwork LoopConnection OnNext MiniLink

Local Loop Start

CV Controller

CV Controller

CV Controller


CV Controller

System Manager




On The Local Loop

Optional IP Module Installs Into CommLink IV And

Provides LAN And InternetCommunications





Provides Alarm Call-Outs. A SecondRemote Link Is Required If Connection To

Job Site Is Desired From Remote Computer.










Figure 4-2: CV-EX System Communications Wiring



CommLink IV As previously described, the CommLink is the Local Loop Master for the CV system and the Network Loop Master for the CV-EX system. For both systems to function, the CommLink must be set to the correct operation mode by setting the correct jumper position on the CommLink board. Also, the CommLink communications must be wired correctly to the system and connected correctly to the computer (if used) and Remote Link II. It must also be powered up in order for either system to communicate. See Figure 4-3 for information.

24 VAC Power

If Desired A 24 VAC Transformer Rated At 12 VA Minimum May Be

Used Instead Of The Supplied Power Pack. Use 18 Gauge Minimum 2 Conductor Wire Between The Transformer & CommLink IV Terminals.

(Not Included)

120 to 24 VAC Power Pack (Included) Connect To 120/1/60 DuplexReceptacle (By Others)

USB Cable (Included). Connect This Cable To Your Computer USB Port For Directly Connecting To CommLink IV. Also Used For Advanced Configuration of CommLink IV.

CommLink IVCommunications Interface

Notes:1) Use 18-Gauge Minimum, 2-Conductor Twisted Pair With Shield Cable Belden #82760 Or Equivalent (Not Included) To Connect The CommLink IV To The MiniLink On Network Loop Or Controller Or System Manager On Local Loop.

2) For Direct Connection Via USB, Your Computer Must Have An Unused USB Port Available. Drivers For Your USB Port Are Provided On A CD Supplied With The CommLink IV And Will Need To Be Installed On Your Computer In Order For It To Function Correctly. Please Refer to the CommLink IV Installation Technical Guide Form: WM-CLIV-TGD Which Is Supplied With The CommLink IV.

3) The CommLink IV Cannot Communicate With The Control System Through Its Ethernet Port And USB Port At The Same Time.

4) All Wiring Must Conform To Applicable Federal, State & Local Electrical Wiring Codes.

18-Gauge, 2-ConductorWith Shield (Not Included)

Connect To The Controller Or SystemManager On Local Loop Or MiniLinkOn Network Loop. See Note 1.

MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D


Co

nfig

No

rmal

Optional - Prefabricated Ft. Long CAT5 Ethernet Cable (Included With Optional OE415-02 IP Module Kit).

If A Longer Ethernet Cable Is Required, You Will Need To Obtain (From Others) And Install An Ethernet Cable Of The Required Length For Your Installation.

10

Connect To A 10/100 Base-T Ethernet Router On Your LAN.

When An Optional Remote Link Is Used, Connect This Cable To CommLink IV And Remote Link As Shown. Cable Is Included With Remote Link.

Molded Modem Cable.Part #HZ000098Supplied With RemoteLink II

9P

inF

emale

25 PinMale

WARNING!

If You Are Using The IP ModuleWith Your CommLink, Do Not Have YourEthernet Connection And USB ConnectionConnected At The Same Time. This CouldCause Unreliable Communications.

Optional Items Not Required For CommLink Only Installations.

USB SwitchShould Be SetTo Normal

Figure 4-3: CommLink IV Wiring



CommLink IV DIP Switch Setting

DIP Switch 1 & 2 Off =Multiple Loop CommunicationsRequired Setting For Auto-Zone CV-EX System

CommLink IV Communication Settings

The SW1 DIP Switch Located On The Circuit Board Inside The CommLink IV Housing Must Be Set Correctly For Your Specific Application In Order To Function Properly.

To Check And/Or Set The SW1 Dip Switch, First Remove The (2) Enclosure Screws That Hold The Top And Bottom Of The CommLink IV Enclosure Together. Remove The Top Half Of The Enclosure To Access The Circuit Board And Dip Switches.

The DIP Switch Setting Should Be Set To “Multiple” For The Auto-Zone System

The CommLink IV Is Factory Set For Multiple Loop Applications.

SW1 CV-EX .

Replace The CommLink IV Cover And Secure The Enclosure Halves Back Together With The (2) Enclosure Screws That Were Previously Removed.

ALTERAEPM3032


Figure 4-4: CommLink IV DIP Switch Setting



MiniLink The MiniLink communications interface is only required when you are installing a CV-EX system. It is not required for the CV system. Its address switch must be set correctly, it must be correctly wired into the system, and it must be powered up in order for the CV-EX system to operate correctly. The address switches must be set and the power cycled in order for the address to be recognized by the system. See Figure 4-5 for MiniLink wiring and addressing.

Notes:

1632

8421

Caution!The MiniLinks Must Have Address Switches Set Between 1 And 4 (Up To 4 MiniLinks Are Allowed Per CV-EX System). The MiniLinks Should Be Addressed In Consecutive Order Starting With Address #1. Address #1 Must Be Present On The Loop For The System To Function.



MiniLinkAddress Switch

These Switches Must BeIn The OFF PositionAs Shown

Note:The Power To The MiniLink Must Be Removed And Reconnected After Changing The Address Switch.

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

ADD

The Address For Each MiniLinkMust Be Unique To The Other MiniLinksOn The Network Loop. Loop #1 MiniLink

Should Be Addressed As #1Loop #2 MiniLink Should Be Addressed

As #2 Etc.

1.) 24 VAC Must Be Connected So That All Ground Wires Remain Common.



R

SHT

R

SHT

R

SHT

R

SHT

All Communication LoopWiring Is Straight Through

Required VA For TransformerMiniLink = 10VA Max.

See Note 1.

LOO

P

24VACGND

T

SH

R

32168

4

1

2

OFF >

Local LoopRS-485


Connect To CV Controller or

System Manager On Local Loop

Connect To Next MiniLink And/Or CommLink On Network Loop

Network LoopRS-485


Line Voltage24VAC

GND


ADD

NETWORK

SH

T

R

Figure 4-5: MiniLink Wiring and Addressing



System Manager The System Manager is the central operator interface for the CV or CV-EX system. It must also be connected correctly to the communications loop in order to view the system status and configure or change setpoints. It must be supplied with 24 VAC power in order to operate. The System Manager does not require addressing. The System Manager is always connected to the “Local” loop. For the CV system, this is the only loop on the system. The System Manager can be connected anywhere on the CV communications loop. In contrast, the CV-EX has two types of loops—the “Network” and “Local” loops. The System Manager must be connected to the local loop on the CV-EX system. It will not function correctly if connected to the network loop! See Figure 4-6 for wiring and component location information for the System Manager.

Notes:1.) 24 VAC Must Be Connected So

That All Ground Wires Remain Common.


3.) All Communication Wiring To Be 2-Conductor Twisted Pair With Shield. Use Belden #82760 Or Equivalent.

Line Voltage

See Note 1

See Note 324VAC

GND

Required VA For TransformerSystem Manager = 25VA Max.

MADE INTHE USA

EP

RO

M

1000uF10v

YS101806 REV. 1

DSPY1

UNIVERSAL SMART DISP. UNIT

SYSTEM MANAGER

SERIAL # :

U13 SERIAL #1000uF10v

C9

470uF50v

D2

PC

B80

C552

-5-16

WP

442860=

2/5D

fD9

722V

7Y

PH

ILIPS

CX

13

LD8

CX

9

SS0017vx.xx 1234

V62C518256L-70P

U9

U8

LD7

RN

1

LD6

U7

CX7

74H

C57

3

LD5

LD4

74HC573

CX

8

RN2

X2

CX

4

470uF50v

TB2

GN

D24VA

CR

10 75176

RS-485 COMM

U12

CX

12

RA

M

SC1

T

TB

1

SH

LD

C7

C11

L1

C4

R

D6

8583

U6

CX6C3

D3

24C128

U5

R7

VAR1

D4

PJ1

R3

U1

74HC259

LD3

LD2

LD1

R2

R1

EW

DO

G

PHILIP

S

U3

U2

CX

1

82B715CX5

CX

3

U3

DSPY1

R5

D1

R6

MC

34064A

C6

R11

9936 C

8

R9

U10

U11

R8

R12

C5

74HC

923

CX10 P1

R4

RV1

C2

C1

X1

The Ideal Recommended Location For The System Manager Is As The First Device On The Local Loop. The System Manager May Be Connected To TheLocal Loop At Any Point On The Local Loop.

For CV Systems, Connect To Any CV Controller On The Local Loop Or To The CommLink. For The CV-EX System, Connect To Any Controller On The Local Loop Or To The Local Loop Terminal On The MiniLink. Do Not Connect To The Network Loop On CV-EX Systems!

System ManagerTop

03/20/09 06:38PM FRI

OCCUPIED

NO ALARMS

System ManagerBase

Figure 4-6: System Manager Component Location & Wiring



CV Controller Communications One CV controller is required for each Constant Volume AHU unit to be connected to the system. As with the communications devices on the system described previously, it must be wired correctly, and it must be connected to 24 VAC power for the system to function. Each controller must also be addressed correctly. Improper addressing is one of the most common mistakes made when installing a CV or CV-EX system. If duplicate addresses are assigned on the same loop, fluctuating readings will occur. First, one controller’s setpoints and status will be passed and then the other. This can be a very frustrating error to find. Another common mistake is flipping (reversing) of the T and R wires on the communication loop between controllers or other communications devices. Always be sure to double-check all communication wiring and addressing before initial commissioning of the system. It is much easier to set the address switch on a controller prior to installation than after it is installed in a ceiling or rooftop unit control panel. The address switches must be set and the power cycled in order for the address to be recog-nized by the system. Please see Figure 4-7 and Figure 4-8 for CV Controller component location and addressing information.

Relay OutputsTerminals



RS-485CommunicationsTerminal Block

CPUChip

TypicalPin 1Indicator

RAMChip

EPROMChip

PALChip

RS-485CommunicationsDriver Chip

Real TimeClock Chip

CommunicationsLED

Address Switch

Power LED

24 VACPower InputTerminal

Figure 4-7: CV Controller Component Locations



CV Controller Address Switches

Figure 4-8: CV Controller Addressing



ControllerAddress Switch

ADDRESSADD

SW1 SW1

ADDRESSADD

CV Controller Address Switch SettingCV Controller Address Switch Values

Address Switch Setting Chart For CV Controllers

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

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

SW1 SW1 SW1 SW1 SW1

1

2

4816

32 (Always OFF- Not Used)

TOKEN (Always OFF)NETWORK (Always ON)

1

6

11

16

21

26

12

17

22

27

13

18

23

28

14

19

24

29 30

15

20

25

2

7

3

8

4

9

5

10

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.

Address Switch Values Are NotLabeled On The CV ControllerUse The Table Below

Address Switch Values AreAdded Together When TheRocker Is Pushed Down InThe Direction Of The “ADDRESSADD” Arrow Marked On The CVController Circuit Board



CV and CV-EX System

Communications Checklist

CV & CV-EX Systems

� CV Units on each loop are correctly addressed from 1 to 30 � Power has been cycled after changing addresses � There are no duplicate addresses on the loop � CommLink is connected to the communications loop � All CV Controllers are connected to the communication loop � System Manager is connected to the communications loop � All communication wiring is landed correctly, T to T, R to R, and SHLD to SHLD � CommLink is set for single loop operation (on CV System) � CommLink is set for multiple loop operation (on CV-EX System) � CV Controllers are wired to 24 Volt AC power supply � CommLink is wired to 24 Volt AC power supply � All 24 VAC power wiring is landed correctly—24VAC to 24VAC and GND to GND � CommLink is powered up � CV Units are powered up � System Manager is powered up

Additional Checks for the CV-EX System

� MiniLinks are correctly addressed from 1 to 4 � MiniLink Power has been cycled after changing addresses � There are no duplicate addresses on the loop � All CV Controllers are connected to a Local communications loop � CommLink is connected to the Network communications loop only � System Manager is connected to one of the Local communications loops

Optional Equipment

� Personal computer is correctly connected to the CommLink � Prism™ software installed on personal computer � Remote Link II is correctly connected to the CommLink � Remote Link II connected to a working phone line � IP Module is correctly installed in the CommLink � IP Module’s Ethernet cable is connected to router



CV Controller Overview

How It Works

Initialization

On system power-up, the COMM LED remains extinguished for five seconds. After this delay, the COMM LED will blink out the address of the controller (Address Switch Setting). The COMM LED will then extinguish for another five seconds and then begin to blink for a twenty second startup delay. At the conclusion of this twenty second period, the COMM LED will begin blinking a diagnostic code every ten seconds. See the Blink Code section of this manual. The duration of a power-up initialization sequence is roughly one minute. During this initialization period, the controller retrieves all operating setpoints from its non-volatile EEPROM memory and initializes all outputs to an OFF condition.

Operating Summary

At all times, after the conclusion of the initialization sequence, the CV controller performs a specific set of operating instructions in the following order: (1-7 repeat continuously)

1. Reads Analog Inputs for Temperatures and Overrides.

2. Checks the RS-485 communications port for any new setpoints from the System Manager and keeps the status updated for the System Manager.

3. If the push-button override is active, it checks the timer to see if the override is finished.

4. Calculates the current occupied/unoccupied mode from its internal week scheduling.

5. Calculates what state the output relays and analog output should be set to.

6. Updates the diagnostic COMM LED blinking.

7. Stores data in the internal trend log if ready for another log.



CV Controller Inputs & Outputs

24 VAC Power Connector

This connector provides power to the CV Controller.

24VAC - The “hot” side of the control transformer. GND - The grounded side of the control transformer. If the secondary of the con-trol transformer is not grounded, you must still observe polarity if the trans-former powers any other device!

Warning: Connect only the GND terminal to the grounded side of a transformer. Failure to properly observe polarity will result in damage to the system. Observe polarity at all points in the system.

Analog Input Descriptions

Input #1 - Space temperature is read on this input. If the room sensor with override is installed, the input is also monitored for push-button override commands. The push-button is only active during unoccupied hours, so a push during occupied hours has no effect.

Input #2 - This input is only used if a space temperature sensor that has the slide adjust option is installed. The slide adjust can be used to offset the current heating and cooling setpoints.

Input #3 - Supply air temperature is read on this input. The supply air reading is used to detect equipment failure. Once a heating or cooling stage has activated, the supply air has thirty minutes to change by 5°F or the controller assumes a mechanical failure has occurred. The supply air also prevents cooling stages from activating if the temperature is 45°F or lower in the cooling mode and prevents heating stages from activating if the temperature is 140°F or higher in the heating mode.

Input #4 - Outdoor air temperature is read on this input. If you have more than one CV controller installed on the RS-485 communication loop, only one controller needs this sensor. The unit that has this sensor will automatically broadcast the outdoor air tempera-ture to all other controllers on the loop.

Input #5 - This input can be used to monitor an alarm contact closure. If the contact is closed, the alarm is active.



Note: All temperature sensors must be Thermistor Type III which provides 77°F @ 10K Ohms Resistance.

Analog Output Description

Analog Output - This output is used to control the Outdoor Air Damper if you configure the unit for Economizer control. The output voltage range is user-programmable to cover all types of proportional actuators. 0 - 10 VDC, 2 - 10 VDC outputs are possible.

Relay Output Descriptions

Output #1 - Main Fan ON/OFF Control Output #2 - Mechanical Heating / Cooling Stage #1 Output #3 - Mechanical Heating / Cooling Stage #2 Output #4 - Mechanical Heating / Cooling Stage #3 Output #5 - Mechanical Heating / Cooling Stage #4 Any combination of heating and cooling stages may be configured during setup as long as the required number of outputs does not exceed four.

RS-485 Communications Connector

This connector provides the connection point for the Local Loop RS-485 communications loop. The wiring consists of a twisted pair of wires with a shield.

T - RS485 (+) Communications terminal SHLD - Common return wire, this point is internally tied to GND on the

CV Controller. R - RS485 (-) Communications terminal



CV Controller Wiring

Notes:

Line Voltage

Line Voltage

See Note 1 & 2

See Note 1 & 2

Wx or Yx (Htg or Clg Stage x)Wx or Yx (Htg or Clg Stage x)Wx or Yx (Htg or Clg Stage x)Wx or Yx (Htg or Clg Stage x)

G (Fan-On/Off)R (24VAC)

Constant VolumeUnit Connections

CV Controller

RSHT

RSHT

RSHT

RSHT

All Comm Loop Wiring IsStraight Thru

Required VA For TransformerEach CV Controller = 20VA Min.

24VAC

24VAC

GND

GND

Mount In HVACUnit Supply

Air Duct

Auxiliary AlarmInput

Switch SuppliedBy Others

DischargeAir Temp.

Sensor

GND

AUX

TMP

NORMAL

OVR

RELO

CREMR

O

AW

Room Sensor Local LoopRS-485

9600 Baud

Connect To Next Controller

And/Or MiniLink On Local Loop

Connection ToAUX Terminal is ReqdOnly When SensorIs Specified WithSlide Adjust Option

1.) 24 VAC Must Be Connected So That All Ground Wires Remain Common.



EconomizerActuator

(Belimo Shown)Consult Factory For Other ManufacturersWiring Connections

Note:Up To 4 Stages Of Heating Or Cooling Or Any Combination Of Each Is Allowed And Programmable Via The System Manager or Computer Front End Software. If The Unit Has Heat, Heating Stages Must Be Connected To The First Outputs in Consecutive Order And Cooling Stages To The Remaining Outputs In Consecutive Order.

Outside AirTemp. Sensor(See Note 4)

4.) Only One Outside Air Sensor Is Required Per System. It May Be Connected To Any CV Controller On The System. If The Wetbulb Module Is Used, The OA Sensor Must Be Connected To The Wetbulb Module.

Y 3+ 2

COM 1

AIN 1 +VDC

TB2

RELAYOUTPUTS

AIN 2AIN 3AIN 4AIN 5GNDGNDAOUT

TB3

Caution:When Wiring The CV Controller Be Sure To Disconnect All Communication Loop WiringFrom The CV Controller Before Removing PowerFrom The CV Controller. Reconnect Power And Then Reconnect Communication Loop Wiring.

TSHLDR COM1-3

R1R2R3R4R5

TB1

24VACGND

COM4-5

EXPANSION T'STAT

NETWORK

16

TOKEN32

8

4

1

2

Figure 4-9: Typical CV Controller Wiring Diagram



Startup & Commissioning Commissioning the system correctly is one of the most important steps in getting a system installed and functioning with the least amount of problems and in the shortest length of time.

Procedures The following is a list of items and reminders that are essential to the successful commis-sioning of your system. Some of these items have already been discussed in this manual and are repeated to confirm correct procedures. Familiarize yourself with this installation manual and the system wiring diagrams before installing!

1) Check to see if you have all of the correct components for your installation.

2) Establish the location for the CommLink Interface first. This is where your communication cable will begin for the CV & CV-EX systems.

3) Lay out your communication wiring per the instructions in the previous portion of this manual. For CV Systems, it is only one loop. For CV-EX Sys-tems, there are two communication loops:

4) The Network Loop - This loop originates at the CommLink and interconnects MiniLinks together.

5) The Local Loop – This loop originates at the MiniLink. All controllers and the System Manager are connected to this loop.

6) Tip: Using the Auto-Zone color-coded and labeled Communication Cable ensures a quality installation. It also makes your installation much easier and makes it less likely that your system will have communications wiring errors!

7) Always refer to the CV and CV-EX Wiring Diagrams for specific wiring details. Communication cable must always be shielded – no exceptions!

8) Mount controllers in appropriate locations according to their operating specification.

9) Use the CV and CV-EX Worksheets included in the back of this section or the ones included with the submittal package to document unit location, descrip-tions, addressing, and setup. Address controllers according to location and addressing instructions located in this system manual.



Procedures (Continued) 10) With no power connected, wire controller according to wiring diagrams and

in accordance with local codes. Never apply power until you have completed these procedures in accordance to all system instructions.

11) After completing all wiring connections, unplug the terminals for power and communications. Always unplug the communications loop first and then the power. When reconnecting the wiring, connect the power first and then the communication loop.

12) Repeat Steps 8 through 11 until all devices have been wired and the power and communication terminals have been unplugged.

13) Install the CommLink and power it up. At this point, you are ready to begin commissioning of the system. It is preferred, though not necessary, to use a PC with Prism™ software installed to assist in the commissioning process. If you are not using a PC, the System Manager is required to be connected and powered up in order to communicate with the system.

14) For the CV system, start with the first CV controller on the communication loop. Plug in the Communication terminal and then plug in the Power terminal. With the CV-EX multiple loop system, start with the MiniLink. Plug in the Communication terminal and then plug in the Power terminal. With the CV-EX system, confirm correct addressing of the MiniLink by verifying its blink code. Then connect the first CV controller on that local loop and proceed to the next step.

15) Check the CV Controllers for correct communications and addressing by observing the LED indicator for the blink codes as outlined in the trouble shooting section of the manual. The blink code will first verify the address and then the operation. If the address is incorrect, reset the address switch, and then reapply power to the controller.

16) After each controller is connected and completes its initialization sequence, use the PC or System Manager to verify communication to that device. If you cannot communicate, verify wiring, voltages, etc. in accordance with the trouble-shooting section in the system manual. Do not proceed to the next device until you are properly communicating with the current device.

17) Continue this process for each CV Controller on the loop and repeat the process on each loop for the CV-EX system until all controllers are connected and properly communicating.

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



CV & CV-EX Worksheet Project: ___________________________ Location ___________________________

Stages of Cool: ___ Stages of Heat: ___ �Gas �Electric Economizer Yes� No �

Loop: 1� 2� 3� 4� Remote Link Installed Yes � No � Phone No. ___________

Unit Address

Unit Description or Location Sensor Type

1 S � SO � SA � SOA � 2 S � SO � SA � SOA �

3 S � SO � SA � SOA �

4 S � SO � SA � SOA �

5 S � SO � SA � SOA �

6 S � SO � SA � SOA �

7 S � SO � SA � SOA �

8 S � SO � SA � SOA �

9 S � SO � SA � SOA �

10 S � SO � SA � SOA �

11 S � SO � SA � SOA �

12 S � SO � SA � SOA �

13 S � SO � SA � SOA �

14 S � SO � SA � SOA �

15 S � SO � SA � SOA �

16 S � SO � SA � SOA �

17 S � SO � SA � SOA �

18 S � SO � SA � SOA �

19 S � SO � SA � SOA �

20 S � SO � SA � SOA �

21 S � SO � SA � SOA �

22 S � SO � SA � SOA �

23 S � SO � SA � SOA �

24 S � SO � SA � SOA �

25 S � SO � SA � SOA �

26 S � SO � SA � SOA �

27 S � SO � SA � SOA �

28 S � SO � SA � SOA �

29 S � SO � SA � SOA �

30 S � SO � SA � SOA � [S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint Adj.



Troubleshooting The following is a guide to assist in troubleshooting the CV and CV-EX systems. It is provided as a systematic approach to determining and resolving common system problems.

General Communications

No CV Units are communicating

� Is the CommLink connected and plugged in?

� For the CV System, is the CommLink jumper set for single loop operation? See Figure 4-4.

� For the CV-EX System, is the CommLink jumper set for multiple loop operation? See Figure 4-4.

� Are Comm Loop voltages correct? See the Comm Loop troubleshooting section.

� Is the Comm Loop open or shorted?

� Are the CV Controller address switches set correctly? See Figure 4-8.

� Are the CV Controllers powered? Check 24 VAC to the controllers. The PWR LED should be lit.

� Is the Communications Loop shorted? Check Comm Loop voltages.

� Is the System Manager connected to the Communications Loop?

Some CV Units are communicating, but others are not

� Are the CV Controller address switches set correctly? See the addressing chart (Figure 4-8.)

� Are the CV Controllers powered? Check 24 VAC to the controllers. The PWR LED should be lit.

� Is the COMM LED on the missing CV Controller “flickering”? See Figure 4-7 for location of the COMM LED.

� Is the LED2 on the CV Controller blinking an error code? See the Blink Code chart on the next page.

� Are Comm Loop voltages correct at the missing unit? See the Comm Loop troubleshooting section.



Blink Codes The CV Controller uses LED2 to indicate various diagnostic conditions during powerup and operation. Starting with power up, the LED blink codes are as follows:

• Off for five seconds • LED2 blinks the board address (Address 14 = 14 blinks) • Five second pause • Twenty second time delay – LED2 blinks twenty times • Status code is repeatedly blinked every ten seconds to indicate controller

status:

Priority No. of Blinks Status

Lowest 1 Normal Operation - 2 Override Active - 3 Bad Zone Sensor

N/A 4 Not Used for this System Highest 5 Communication Failure

Table 4-1: Diagnostic LED Blink Codes

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



Communications Loops

Checking CommLink Local Loop – CV

Diagram

MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D


Co

nfi

g

No

rmal

To Zone ManagerNetwork Loop

The CommLink IV Must BePowered Up For These Tests

Set Your MeterTo Read DC Volts

+-

+-

+-

+-

To 24 VACPower SupplyT-To-G

+2.0 VDC To

+4.0 VDC

R-To-G

+2.0 VDC To

+4.0 VDC

CommLink IV

Overview

This test checks for proper loop voltages at the CommLink IV.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink IV is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the Loop LED does not flicker, the unit is defective.

Proper loop voltages are essential for reliable communications. It is normal to see fluctua-tions at this point on the CommLink IV. The average value should be close to the accept-able range described below. Values will vary upon initial powerup for about 10-15 sec-onds as the unit attempts to communicate.

Measurements

Network Loop Acceptable Range

T - G (SHLD) 2.0 - 4.0 Volts DC

R - G (SHLD) 2.0 - 4.0 Volts DC

Action

Condition Action

If voltages are too high or too low on either side.

1. Unplug the Comm loop from the CommLink IV and Check for proper loop voltages. If a problem exists, disconnect each CV Unit from the loop until the problem is isolated.

2. Replace the CommLink IV. The driver chip is not field-replaceable. See Page 4-22.



Checking the CV Local Loop

Diagram


+-

+- Communications

LoopDisconnected

Communications Loop

Disconnected+

-

T-To-G

+2.4 VDC To

+3.3 VDC

R-To-G

+2.4 VDC To

+3.3 VDC

CommLink IV

To 24 VACPower Supply

MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D


Con

fig

No

rmal


+

-

The indicated values are typical of a normal system; actual readings may deviate slightly due to the number of units connected and other system specific factors.

Note: All of the connected CV Controllers should be powered up for this test.

Overview

This is a “quick check” to determine if any of the driver chips on the attached CV Control-lers are damaged. Since all units will “float” both of their communications connections at about 2.45 Volts, you can quickly check the entire communications loop by unplugging it at the CommLink IV.

Note: Be sure that the loop you are testing does not have a short circuit from T to R.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink IV is attempting to communicate with the CV Controllers. There is a noticeable change in the flicker when the loop is disconnected if you observe a normal functioning unit. When the loop is reconnected, it may take up to 60 seconds before the CommLink IV re-establishes communications with the CV Controllers.

Measurements




Action

Condition Action


One or more of the CV Controllers has a damaged Comm driver chip. Disconnect CV Controllers one at a time to isolate the problem.



Checking CommLink Driver – CV

Diagram


+-

+-

+-

T-To-G

+3.1 VDC To

+3.2 VDC

R-To-G

+3.4 VDC To

+3.6 VDC

Communications Loop

Disconnected

CommLink IV


MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T

T

G

G

R

R

GN

D

485 LOOP

485 LOOP

POWERACT LNK USB

Co

nfi

g

No

rmal


Overview

This test checks for proper Communications Loop voltages coming from the CommLink IV.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink IV is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the LED does not flicker, the unit is not functioning.


Measurements

Local Loop Acceptable Range



Action

Condition Action


1. The CommLink IV has a damaged comm driver chip. Replace the CommLink IV. The driver chip is not field-replaceable.



Checking CommLink Network Loop – CV-EX

Diagram

MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D


Co

nfi

g

No

rmal

To Zone ManagerNetwork Loop



+-

+-

+-

+-

To 24 VACPower SupplyT-To-G

+2.0 VDC To

+4.0 VDC

R-To-G

+2.0 VDC To

+4.0 VDC

CommLink IV

Overview

This test checks for proper Network Loop voltages at the CommLink IV.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink IV is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the Loop LED does not flicker, the unit is defective.


Measurements




Action

Condition Action


1. Unplug the Network Loop from the CommLink IV and check for proper loop voltages. If a prob-lem exists, disconnect each MiniLink Network Loop until the problem is isolated.

2. Check the CommLink IV Driver chip. Replace the CommLink IV. The driver chip is not field-replaceable.



Checking CommLink Network Loop – CV-EX

Diagram


+-

+- Communications

LoopDisconnected

Communications Loop

Disconnected+

-

T-To-G

+2.4 VDC To

+3.3 VDC

R-To-G

+2.4 VDC To

+3.3 VDC

CommLink IV


MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T G R GN

D


Co

nfi

g

No

rmal


+

-

The indicated values are typical of a normal system; actual readings may deviate slightly due to the number of units connected and other system specific factors.

Note: All of the connected CV controllers should be powered up for this test.

Overview

This is a “quick check” to determine if any of the driver chips on the Network loop are damaged. Since all units will “float” both of their communications connections at about 2.45 Volts, you can quickly check the entire Network loop by unplugging it at the CommLink IV.

Note: Be sure that the loop you are testing does not have a short circuit from T to R.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink is attempting to communicate with the MiniLinks. There is a noticeable change in the flicker when the loop is disconnected if you observe a normal functioning unit. When the loop is reconnected, it may take up to 60 seconds before the CommLink re-establishes communications with the MiniLinks.

Measurements




Action

Condition Action


1. One or more of the MiniLinks has a damaged Network driver chip. Disconnect one at a time to isolate the prob-lem. See Figure 4-10.



Checking CommLink Driver – CV-EX

Diagram


+-

+-

+-

T-To-G

+3.1 VDC To

+3.2 VDC

R-To-G

+3.4 VDC To

+3.6 VDC

Communications Loop

Disconnected

CommLink IV


MODEMRS-232

Serial #COMPUTER

USB

10/100ETHERNET

DIAG

24V

T

T

G

G

R

R

GN

D

485 LOOP

485 LOOP

POWERACT LNK USB

Co

nfig

No

rmal


Overview

This test checks for proper Network Loop voltages coming from the CommLink IV.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the LED does not flicker, the unit is not functioning.

Proper loop voltages are essential for reliable communications. It is normal to see fluctua-tions at this point on the CommLink. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 10-15 seconds as the unit attempts to communicate.

Measurements




Action

Condition Action


1. The CommLink IV has a damaged comm driver chip. Replace the CommLink IV. The driver chip is not field-replaceable.



Checking the MiniLink Network Loop – CV-EX

Diagram

Meter Set To Read DC Volts

+-

+

-

+ . VDCto

+4.0 VDC

R - to - G T - to - G

+-

+

-

To Other MiniLinksOr CommLinkOn The Network Loop


MiniLinkMiniLink

To CV ControllersAnd System ManagerOn Local Loop


2 0 + . VDCto

+4.0 VDC

2 0

The indicated readings are typical of a normally operating system. Actual readings may vary slightly due to the number of units installed and other factors. Any significant deviation from these values generally indicates a problem.

Note: These tests assume that the CommLink is connected and powered, and that all MiniLinks, which are connected, are also powered.

Overview

Proper loop voltages are essential for reliable communications. It is normal to see fluctua-tions on an operating communications loop. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 15-30 seconds as normal communications occur.

Measurements




Action

Condition Action

Readings near Zero Volts. Check for shorted wiring.


1. One or more devices connected to this loop may have damaged comm driver chips. Replace the driver chip. See Figure 4-10 & 4-11.

2. Wiring errors. Check for multiple loops inadver-tently “cross connected”, short circuits, etc.



Checking the MiniLink Network Driver – CV-EX

Diagram


+-

+

-

+2.4 VDCto

+3.3 VDC

R - to - G T - to - G

+-

+

-+2.4 VDC

to+3.3 VDC



MiniLinkMiniLink



Note: These tests assume that the MiniLink being checked is powered up.

Overview

This check is intended to determine if the Network Comm Driver chip on a MiniLink is damaged.

Tip: Before unplugging the Network loop from the MiniLink, observe the Network Loop LED (located near the connector). It should periodically “flicker” as the CommLink requests data from the MiniLink. The LED will also flicker when power to the CommLink is cycled. If the LED is not flickering, the unit is not communicating with the CommLink.

Damage typically occurs when the communications loop is exposed to excessive voltage, as may occur during installation due to wiring errors. The driver chips are socketed on all boards to facilitate servicing. It is unusual for driver chips to fail during normal operation. Almost all failures occur as a result of wiring related problems.

Measurements


T - SHLD 2.4 - 3.3 Volts DC

R - SHLD 2.4 - 3.3 Volts DC

Note: .Minor variances may not indicate a problem if both tests indicate similar values.

Action

Condition Action


The MiniLink has a damaged Network Comm Driver chip. Replace the driver chip. See Figure 4-10 & 4-11.



Checking the MiniLink Local Loop – CV-EX

Diagram


NE

TW

OR

KLO

OP

GT

RG

TR

+-

+

-

+1.9 VDCto

+2.1 VDC

R - to - G T - to - G NE

TW

OR

KLO

OP

GT

RG

TR

+-

+

-+2.9 VDCto

+3.1 VDC



MiniLinkMiniLink



The indicated readings are typical of a normally operating system. Actual readings may vary slightly due to the number of units installed and other factors. Any significant deviation from these values generally indicates a problem.


Overview

Proper loop voltages are essential for reliable communications. It is normal to see fluctua-tions on an operating communications loop. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 30-45 seconds. Voltages fluctuate as normal communications occur.

Measurements




Action

Condition Action

Readings near zero volts. Check for shorted wiring.


1. One or more devices connected to this loop may have damaged Comm Driver chips. Replace the driver chip. See Figure 4-10 & 4-11.

2. Wiring errors. Check for multiple loops inadver-tently “cross connected”, short circuits etc.



Checking the Local Loop at the MiniLink – CV-EX

Diagram


+-

+

-

+2.4 VDCto

+3.3 VDC

R - to - G T - to - G

+-

+

-+2.4 VDC

to+3.3 VDC



MiniLinkMiniLink



The indicated values are typical of a normal system. Actual readings may deviate slightly due to the number of units connected and other system-specific factors


Overview

This is a “quick check” to determine if any of the CV Units on a Local Communications Loop are damaged. Since all CV Units will “float” their communications connections at about 2.45 Volts, you can quickly check an entire loop by unplugging it at the MiniLink.

Note: Be sure that the loop you are testing does not have a short circuit from T - R.

Damage typically occurs when the communications loop is exposed to excessive voltage as may occur during installation due to wiring errors. The driver chips are socketed on all boards to facilitate servicing. It is unusual for driver chips to fail during normal operation. Almost all failures occur due to wiring-related problems.

Measurements




Action

Condition Action

If voltages are too high or to low on either side.

1. One or more of the attached controllers has a damaged Comm Driver chip. Replace the driver chip. See Figure 4-10 & 4-11.

2. Wiring errors such as "crossed connections", short circuits, etc.



Checking Local Loop at a CV Controller – CV & CV-EX

Diagram


COMMLOOP

TSHLDR

+-

T

RSHLD

+

-

+2.9 VDC to

+3.1 VDC

COMMLOOP

TSHLDR

+-

T

RSHLD

+

-

+1.9 VDC to

+2.1 VDC

T to SHLD

CV Controller CV Controller

R to SHLD

The indicated readings are typical of a normal operating system. Actual readings may vary slightly due to the number of units installed and other factors. Any significant deviation from these values generally indicates a problem.

Note: These tests assume that a CommLink IV is connected and powered up.

Overview

Proper loop voltages are essential for reliable communications. It is normal to see fluctua-tions on an operating communications loop. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 30-45 seconds. The voltages may fluctuate as normal communications occur.

Measurements




Action

Condition Action

If meter reads between 2.4 VDC and 2.5 VDC.

The Comm Loop “floats” at 2.4 - 2.5 VDC when only controllers are connected to the loop. When a CommLink IV is connected, it will “bias” each side of the loop to the values listed above.

1. No CommLink IV is connected and powered up.

2. If a CommLink IV is connected, look for “open” wiring.


One or more devices connected to this loop have damaged Comm Driver chips. Replace the driver chip. See Figure 4-10 & 4-11.



Checking CV Controller Drivers – CV & CV-EX

Diagram


T to SHLD

CV Controller CV Controller

R to SHLD

+-

T

RSHLD

+

-

+2.4 VDC to

+3.3 VDC

COMMLOOP

TSHLDR

+-

T

RSHLD

+

-

+2.4 VDC to

+3.3 VDC

COMMLOOP

TSHLDR

Note: These tests assume that the CV controller being checked is powered up.

Overview

This check is intended to determine if the Comm Driver chip on a controller is damaged. Damage typically occurs when the communications loop is exposed to excessive voltage as may occur during installation due to wiring errors. The driver chips are socketed on all boards to facilitate servicing. It is unusual for driver chips to fail during normal operation. Almost all failures occur as a result of wiring-related problems.

Measurements


T - SHLD 2.4 – 3.3 Volts DC

R - SHLD 2.4 – 3.3 Volts DC

Note: Minor variances may not indicate a problem if both tests indicate similar values.

Action

Condition Action


The controller has a damaged Comm Driver chip. Replace the driver chip. See instructions for "CV Controller Driver Chip Replacement.” See Figure 4-10 & 4-11.



CV Controller The following is a guide to assist in troubleshooting the CV controller and its associated CV controller problems.

CV Controller Troubleshooting Checklist

Begin troubleshooting by locating the general problem in the list below.

Space 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 space 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 rooftop unit running? Check internal safeties. � Is the LED blinking an error code? See Table 4-1.

Space 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 space calling for heating? � Is supply air temperature indicating heating? � Is the rooftop unit running? Check internal safeties. � Is the LED blinking an error code? See Table 4-1.



Room Sensor

Room Sensor Troubleshooting Checklist

Begin troubleshooting by locating the general problem in the list below

Room Sensor reading incorrectly

� Is the sensor near a source of heat or a cold draft? Location is a common problem. The sensor should be mounted on an inside wall away from heat sources and in a location with adequate room air circulation.

� Is the resistance reading correct? Check with the Temperature/Resistance Chart in this section.

� Is wiring correct? Check for errors.

Meter the Room Sensor

To meter the Room Sensor:

1. With the sensor connected to the controller, power up the controller. Using your meter, check the voltage at the controller terminal block where the sensor is con-nected. Use the supplied Temperature Sensor Voltage & Resistance Chart to see if the sensor is within a reasonable range. Readings which are much too high or too low generally indicate wiring problems or a defective sensor.

2. Unplug the room sensor terminal block. Using your meter, check the resistance of

the unplugged terminal block. Use the supplied Temperature/Resistance Chart to see if the sensor is within a reasonable range. Readings which are much too high or too low generally indicate a wiring problem or a defective sensor.

To meter the Slide Adjust (optional):

Use your ohmmeter to check the resistance between the room sensor GND wire and the AUX1 terminal on the unplugged terminal block.

The resistance for various positions of the slider on the sensor should be as follows: Full UP position 15K Ω (± 500 Ω) MID position 12.5K Ω (± 500 Ω) Full DN position 10K Ω (± 500 Ω)



Temperature Sensor Voltage & Resistance

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 2.665

0 69822 4.474 74 10625 2.635 5 60552 4.390 75 10398 2.607 10 52500 4.297 76 10158 2.577 15 45902 4.200 78 9711 2.520 20 40147 4.095 80 9302 2.465 25 35165 3.982 82 8893 2.407 30 30805 3.862 84 8514 2.352 35 27140 3.737 86 8153 2.297 40 23874 3.605 88 7805 2.242 45 21094 3.470 90 7472 2.187 50 18655 3.330 95 6716 2.055 52 17799 3.275 100 6047 1.927 54 16956 3.217 105 5453 1.805 56 16164 3.160 110 4923 1.687 58 15385 3.100 115 4449 1.575 60 14681 3.042 120 4030 1.469 62 14014 2.985 125 3656 1.369 64 13382 2.927 130 3317 1.274 66 12758 2.867 135 3015 1.185 68 12191 2.810 140 2743 1.101 69 11906 2.780 145 2502 1.024 70 11652 2.752 150 2288 0.952 71 11379 2.722

Notes: 1. Use the resistance column to check the thermistor sensor while it is disconnected from

the controllers (not powered). 2. Use the voltage column to check sensors while they are connected to powered controllers.

Read voltage with meter set on DC volts. Place the “-” (minus) lead on GND terminal and the “+” (plus) lead on the sensor input terminal being tested.

If the voltage is above 5.08 VDC, then the sensor or wiring is “open.” If the voltage is less than 0.05 VDC, then the sensor or wiring is shorted.



Driver Chip Replacement

Pin 1

DotSocket

PrintedCircuitBoard

Typical RS-485 Communications Driver Chip Detail

System Manager

CommLink IV

Comm Driver Chip(U12)

CV Controller, CV-EX ControllerGPC Plus Controller, Wetbulb Controller

Pin 1

Pin 1

Pin 1

Comm Driver Chip( U5 )

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

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

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

LOO

P

32

1684

12

NE

TW

OR

KNetwork LoopComm

Driver Chip

Local LoopComm

Driver Chip

T

SH

R

T

SH

R

MINILINK

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

Notes:

24V

AC

GN

D

SH

LD

EP

RO

M

SYSTEM MANAGERYS101806 REV. 1

U13

CX

13

R10

CX

12 U12

L1

RN

1

U2

C3

U6

CX7

CX

9

U7

SY

S48

K2V

U9

U8

CX

8

RN2

X2

C2

C1

X1

CX

4

U4R2R1

EW

DO

G

R3

SC1

T

TB

1

R

TB

2

D3

U5

CX5

U1

CX

1

ALTERAEPM3032


MiniLink

Figure 4-10: Driver Chip Locations



Figure 4-11: General Chip Replacement Procedures

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.



Index

24 VAC Power.............................. 10, 12 Address

1-30 ............................................. 1, 10 1-4 ............................................... 1, 10 Duplicate ..................................... 8, 10 Unique............................................... 1

Address Switch Setting ....................... 11 Addressing

CV Controller.................................... 9 Improper............................................ 8 MiniLink ........................................... 6

Alarm Contact Closure Analog Input ................................... 12

Analog Input Descriptions .................................... 12 Input #2 ........................................... 12 Input #3 - Supply Air Temperature. 12 Input #5 ........................................... 12 Slide Adjust Option ........................ 12

Analog Output Description...................................... 13

Bad Zone Sensor ................................. 19 Blink Codes......................................... 19 Checklist

IP Module........................................ 10 Personal Computer.......................... 10 Remote Link II ................................ 10

Comm Driver Chips Damaged .................................. 21 - 31

COMM LED ....................................... 11 CV Controller.................................. 11 Troubleshooting .............................. 18

Comm Loop Troubleshooting .............................. 18

Comm Loop Voltages ......................... 18 Comm Loop Voltages - CV

CommLink IV................................. 22 Commissioning ................................... 15 CommLink Driver

CV-EX Troubleshooting................. 25

CommLink Driver - CV Troubleshooting .............................. 22

CommLink IV............................. 1, 2, 18 Checklist ......................................... 10 Damaged Comm Driver Chip ... 23, 25 Damaged Driver Chip ..................... 22 Defective ......................................... 25 Dip Switch Setting ............................ 5

Local Loop - CV Troubleshooting .................... 20, 21 Location, Establishing..................... 15 Loop Voltages

Troubleshooting - CV ................. 20 Network Loop - CV-EX

Troubleshooting .................... 23, 24 Network Loop Voltages .................. 23 Overview........................................... 4 Wiring ............................................... 4 CommLink

Common Return Wire......................... 13 Communication Failure ...................... 19 Communication Wiring

Layout ............................................. 15 Communications

CV Controller.................................... 8 Overview........................................... 1

Communications Checklist CV & CV EX Systems.................... 10

Communications Loop Local................................................ 10 Network........................................... 10 Troubleshooting .......................... 1, 20

Communications Terminal.................. 13 Components

CV Controller.................................... 8 Installation....................................... 15 System Manager................................ 7

Connector RS-485 Communications................ 13

Controllers Wiring ............................................. 16



Cooling Locked Out...................................... 32 Minimum Off Timer ....................... 32 Short Cycling .................................. 32

CV Controller 24 VAC Power Connector .............. 12 Addressing ........................................ 9 Communications ............................... 8 Components ...................................... 8 Initialization .................................... 11 Inputs............................................... 12 Internal Trend Log .......................... 11 Operating Summary ........................ 11 Outputs............................................ 12 Overview......................................... 11 Push-Button Override ..................... 11 RS-485 Communications Port ........ 11 Troubleshooting .............................. 18 Troubleshooting Checklist .............. 32 Wiring ............................................. 14

CV Controller Drivers Troubleshooting .............................. 31

CV Controller, Local Loop Troubleshooting .............................. 30

CV Controllers Checklist ......................................... 10 Not Communicating........................ 18

CV System Communications Checklist ............. 10 Overview........................................... 2 Troubleshooting .............................. 18 Wiring ............................................... 2

CV System Loop Master ............................................... 2

CV Units Not Communicating........................ 18

CV-CV-EX Worksheets...................... 17 CV-EX System

CommLink Driver........................... 25 Communications Checklist ............. 10 MiniLink ........................................... 6 Troubleshooting .............................. 18 Wiring ............................................... 3

Diagnostic LED Blink Codes.............. 19

Dip Switch Setting, CommLink............ 5 Driver Chip

Locations......................................... 35 Replacement.................................... 35

Economizer Control ............................................ 13 Enabled ........................................... 32 Opening........................................... 32

EEPROM ............................................ 11 Ethernet Cable..................................... 10 Excessive Voltage............................... 29 Full DN Position

Sensor Slide Resistance .................. 33 Full UP Position

Sensor Slide Resistance .................. 33 General Communications.................... 18 GND.................................................... 12 GND to GND ...................................... 10 Heating

Locked Out...................................... 32 Short Cycling .................................. 32

Improper Addressing............................. 8 Initialization

CV Controller.................................. 11 Input #1 - Space Temperature ............. 12 Input #2 ............................................... 12 Input #3 - Supply Air Temperature

Analog Input ................................... 12 Input #4 - Outdoor Air Temperature

Analog Input ................................... 12 Input #5 - Analog Input....................... 12 Inputs

CV Controller.................................. 12 Installation

Components .................................... 15 Internal Trend Log

CV Controller.................................. 11 IP Module

Checklist ......................................... 10 Jumper Settings - CommLink ............... 5 LEDs

COMM............................................ 11 Error Code....................................... 32

Indicator .......................................... 16



Local Communications Loop.................... 10

Local Loop ............................................ 7 Startup ............................................. 15

Loop LED ........................................... 24 Troubleshooting .............................. 25

Loop LED - CV Troubleshooting .............................. 21

Loop Master .......................................... 1 Main Fan ON/OFF Control

Relay Output ................................... 13 Mechanical Heating /

Cooling Stages ................................ 13 MID position

Sensor Slide Resistance .................. 33 MiniLink ......................................... 1, 16

Addressing ........................................ 6 Communicating............................... 24 Damaged Network Driver Chip ...... 24 Overview........................................... 6 Wiring ............................................... 6

MiniLink Local Loop - CV-EX Troubleshooting ........................ 28, 29

MiniLink Network Driver - CV-EX, Troubleshooting.......... 26, 27

MiniLink Network Loop..................... 23 MiniLinks

Checklist ......................................... 10 Network

Communications Loop.................... 10 Network Comm Driver Chip

MiniLink, Damaged ........................ 27 Network Driver Chip

Damaged, MiniLink ........................ 24 Network Loop

Startup ............................................. 15 Network Loop LED

Troubleshooting .............................. 27 Network Loop Master ........................... 1 Network Loop Voltages ...................... 25

CommLink IV................................. 23 Normal Operation ............................... 19 Not Used for this System .................... 19 Operating Summary

CV Controller.................................. 11

Outdoor Air Damper ........................... 13 Output #1-5

Relay Outpust.................................. 13 Outputs

CV Controller.................................. 12 Override Active................................... 19 Overview

CommLink IV................................... 4 Communications ............................... 1 CV Controller.................................. 11 CV System ........................................ 2 MiniLink ........................................... 6 System Manager................................ 7

Personal Computer Checklist ......................................... 10

Polarity................................................ 12 Power Applying.......................................... 16 Cycled ............................................. 10 Prism ............................................. 10, 16 Procedures

Startup ............................................. 15 Proper Loop Voltages - CV

CommLink IV................................. 20 Push-Button Override

CV Controller.................................. 11 R - G (SHLD)...................................... 21

CommLink Driver Range.......... 22, 25 CommLink Local Loop, Range....... 20 MiniLink Network Loop, Range..... 26 CommLink Local Loop, Range....... 20 CommLink Network Loop,

Range .................................... 22, 23 R - RS485 (-)....................................... 13 R - SHLD

CV Controller Drivers, Range ........ 31 CV Controller Local Loop, Range .. 30 MiniLink Local Loop, Range.... 28, 29 MiniLink Network Driver, Range... 27

Read Analog Inputs CV Controller.................................. 11

REC LED Troubleshooting .............................. 18



Relay Output Descriptions .................................... 13 Output #1 ........................................ 13 Output #2 ........................................ 13 Output #3 ........................................ 13 Output #4 ........................................ 13 Output #5 ........................................ 13

Remote Link II .................................... 10 Replacement

Driver Chip ..................................... 35 Room Sensor

Location Problem............................ 33 Metering.......................................... 33 Reading Incorrectly......................... 33 Resistance Reading ......................... 33 Troubleshooting Checklist .............. 33 Wiring Problems ............................. 33

Router.................................................. 10 RS-485 Communications Connector .. 13 RS-485 Communications Port

CV Controller.................................. 11 Sensor Slide Resistance

Full DN Position ............................. 33 Full UP Position.............................. 33 Mid Position.................................... 33

SHLD .................................................. 13 Short Circuit

T - R ................................................ 29 T to R .............................................. 24

Shorted Wiring.................................... 26 Slide Adjust

Metering.......................................... 33 Slide Adjust Option

Analog Input ................................... 12 Space

Too Cool ......................................... 32 Too Warm ....................................... 32

Startup ................................................. 15 System Manager.................................. 16

Checklist ......................................... 10 Components ...................................... 7 Overview........................................... 7 Wiring ............................................... 7

T - G (SHLD)...................................... 21 CommLink Driver Range.......... 22, 25 CommLink Local Loop, Range....... 20 CommLink Network Loop,

Range .................................... 23, 24 MiniLink Network Loop, Range..... 26

T - R Short Circuit.................................... 29

T - RS485 (+) ...................................... 13 T – SHLD

CV Controller Drivers, Range ........ 31 CV Controller Local Loop, Range .. 30 MiniLink Local Loop, Range.... 28, 29 MiniLink Network Driver, Range... 27

T to R Short Circuit.................................... 24

Temperature Sensor Voltage and Resistance Chart ......... 34

Thermistor Type III............................. 13 Token-Passing....................................... 1 Troubleshooting .................................. 18

COMM LED ................................... 18 CommLink Driver - CV.................. 22 CommLink IV Driver Chip............. 23 CommLink Local Loop - CV.... 20, 21 CommLink Network Loop -

CV-EX .................................. 23, 24 Communications Loop................ 1, 20 CV Controller Drivers..................... 31 CV Controller, Local Loop ............. 30 Loop LED - CV............................... 21 MiniLink Local Loop -

CV-EX .................................. 28, 29 MiniLink Network Driver -

CV-EX ........................................ 27 MiniLink Network Loop -

CV-EX ........................................ 26 Network Loop LED......................... 27 REC LED ........................................ 18

Troubleshooting Checklist CV Controller.................................. 32 Room Sensor................................... 33

Voltage Excessive................................... 27, 29



Voltage & Resistance Chart Temperature Sensor ........................ 34

Wires Reversing .......................................... 8

Wiring Checklist ......................................... 10 CommLink IV................................... 4 Correctly.......................................... 10

CV Controller.................................. 14 CV System ........................................ 2 CV-EX System.................................. 3 MiniLink ........................................... 6 Shorted ............................................ 26 System Manager................................ 7

Wiring Errors ...................................... 26 Zero Volts ..................................... 26, 28

Form: WM-AZC-IO-01C Printed in the USA February 2009 All rights reserved Copyright 2009

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

Documents

CV & CV-EX System - autozonecontrols.comCV Controllers in relation to their location on the loop. Cable must be Belden No. 82760 or equivalent. Tip: Incorrect wiring of the communications