Polyaire Zonemaster Variable Air Volume Guida

VAV

(VARIABLE AIR VOLUME)

CLIMATE ZONING SYSTEM

Technical Manual

User Manual

Polyaire™ Pty Ltd

11-13 White Road

GEPPS CROSS

South Australia, 5094

Tel: (08) 8349 8466

Fax: (08) 8349 8446

www.polyaire.com.au

www.zonemaster.com.au

2008 EDITION

IMPORTANT INSTALLERS NOTE

The Installer MUST be familiar with the features of the VAV and the installation

process BEFORE INSTALLATION COMMENCES.

Zonemaster/Polyaire does not take responsibility for poorly designed or

installed VAV systems. Neither will we take responsibility for customer

complaints due to poor design and installation. We strongly suggest that any

installer wishing to install a Zonemaster VAV system should fully acquaint

himself with the design features and capabilities of the system before

commencing the job , either by reading the installation manual thoroughly

or consulting with a Polyaire staff member conversant with this system

(Preferably both). Contact Polyaire re VAV installation training.

INSTALLATION TIPS & COMMON PROBLEMS

1. TheVAVpowertransformer(s)arettedwith3pinplugsandshouldbe 

 pluggedin to their own power point separate from the A/C unit.

 DONOTremovetheplugandhardwiretheVAVtotheA/Cpowersupplyas

 thewideuctuationsintheA/CcurrentwilldamagetheVAVunit.

2. Don’tgetconfusedbetweenDataandControlCables.

 Thepackagesareclearlymarked.DataCablehasleftlatchedplugsand 

 Controlcablehascentrelatchedplugs

3. Alwayscheckcables:Particularlyifmakingupyourowncables.Cablesand

 plugscansometimesgettwistedorbefaulty,thewiresandcontactsarevery

small. To ensure that all cables are ok pre- test with Zonemaster Cable Tester

 (AvailablefromPolyaire).Thiswillhelpeliminatefaultsbefore(ratherthan 

after) installation.

4. Donottapeoverthebuttonatthebottomofthedamperbladewhenattaching

 exibleduct.Thisiseasytodoandwillstopthedamperturningfreely.

5. All zones MUST have their own unique address allocated via the touchpad.

 IE:Ifthereare6zonesthesystemmusthave6addresses.

6. Donotplug2touchpadsintoone3wayplug.

7. VAVsystemsshouldonlybettedtoFlexibleductwithlargeenoughdiameter

 toeasilytaketherequiredvolumeofair.Smallductcreatesexcessivenoise

 andvortexdraughtsanddoesn’tallowthesystemtoregulateproperly.

8. ReturnAirGrillesshouldbepositionedinthesamespaceasthedesignated

 “Spill”zonetoensuretheVAVsensorcanoperateproperly.

9. Substantialdifferencesinzonetemperaturewillonlybeachievedinseparate

 zonesiftheseareeffectivelyseparatedfromotherzones.IEDoorsmustbe

 closedtopreventcrossowfromroomtoroom.

10. Theendusershouldbefullyinformedontheunitattimeofcommissioningso

 thattheyfullyunderstandtheoperationoftheVAVunit.Theendusershould

 beencouragedtoreadtheusermanual.

CONTENTS

Features 1

Application 1

Components 2

Conguration 3

Installation 5

 BypassControl 7

Commissioning 8

 1.InitiatingandExitSettingProcess 8

2. Initialisation of Touchpad Address 9

 3.RoomTemperatureSensor 9

4. Minimum Ventilation 10

 5.SupplyAirSafetyHigh&LowLimits-MasterTouchpad 10

 6.Spill/BypassAirSetpoint-MasterTouchpad 11

 7.NamingZones-MasterTouchpad 12

8. Damper on/off Test 12

 InstallationInformationSheet 13

TroubleShootingGuide 15

User Manual 16

 1.ZoneTouchpad 16

2. Master Touchpad 17

 3.ProgrammingMode 18

AppendixA-TechnicalSpecications 25

AppendixB-StandardCongurationofVAVSystem 27

Liability

Please read the instructions carefully before installing this

Zonemaster VAV Climate Control System. Polyaire Pty Ltd does

not accept any responsibility for loss or damage that may occur

as a result of the incorrect installation of this system.

FEATURES

• Manualandtimeprogrammablezonetemperaturecontrol.

• Supportsupto16zones.

• Addressofeachzoneissetdirectlyfromthetouchpad.

• Maintainsroomtemperaturewithin±1°Cusinganonboardsensor.

• LCDindicatorforzonestatusandparameterdisplay.

• User-friendlytemperatureandprogramsetting.

• Realtimeclockwithbatterybackup.

• 5-1-1programmabletemperaturesettingpointandstarttime.

• Personalisedzonelabelling.

• Autospill/bypass---thedesignatedzones/bypassareforced 

open when all zones are turned off.

• Safetysystem---Opensalldampersifthesupplyair 

 temperatureislessthanlowlimitormorethanhighlimit.

• Allzonesautomaticallyreturntotheiroriginalon/offstateonce 

power up.

APPLICATION

TheZonemasterVAV(VariableAirVolume)isafullyfeaturedsystem

designedtoaccuratelymanageairowbyzoneinDuctedreversecycle,

heatingandevaporativeairconditioningsystems.

ItmanagesairowfromtheA/Cunitbyassessingtemperaturesineach

zoneandopeningandclosingdamperstoincreaseordecreaseairowto

achieve and maintain a preset temperature in that zone.

The temperature difference that the Zonemaster can achieve will not be

lower(cooling)orhigher(heating)thanthetemperaturesetbytheACunit.

Page 1

COMPONENTS

1) Main Controller

The main controller collects and processes all the information.

2) Master Touchpad

6buttontouchpad.

  Toprogramandcontrolallthezonesinthesystem.  

3) Zone Touchpad

3buttontouchpad.

4) Bypass Damper and Controller (optional) Green

Dampercontrollerreceivesbypasscontrolsignalfromthe 

  maincontrollertoopenorclosethebypassdamper.

5) Supply Air Sensor

Supplyairsensormeasuresthetemperatureofthesupplyair.

6) Power Supply

The24VACtransformerprovidespowertotherst8touchpads

- dampers and main controller.

7) Battery

3.6Vrechargeablebatteryformaincontroller.

8) LeftLatchedDoubleAdaptor&CableKit

Double adaptor connects the main controller/touchpads via the

data bus.

 9) CentreLatchedTripleAdaptor&CableKit

Tripleadaptorconnectsthe24VACpowersupplyviathe 

control bus.

 10)MountingBracket

For the touchpads.

Page 2

Page 3

Figure1.MainControllerConnectionDiagram

ZonemasterVAVisaserialbusbasedsystemwhichhasaControlbusand

Data bus. The Control bus provides 24VAC power for up to 8 Dampers

viathemaincontrollerasshowninFig2.

Figure2.WiringdiagramofZone1toZone8

CONFIGURATION

Main controller collects and processes all the information. The connections

tothemaincontrollerareshowninFigure1.

Page 4

The Data bus provides communication between the main controller and

the touchpads.

NOTE:TheMainControllerprovidespowerforupto8Touchpadsand

damper motors. If more than 8 touchpads and dampers are installed

auxiliarypowermustbeprovidedviaseparate24VACand9VDCpower

suppliesasshowningure3.

Figure3.WiringdiagramofZone9toZone16

Page 5

INSTALLATION

1) Removethe3coversfromthemaincontrolboard.

2) Position the main controller on top of the fan coil unit or on the

 supplyairductandsecure.

3) Connectthe24VACpowersupplytotheterminalsN+Lonthemain

 controllerboard.Whenturningonthepower,theredLEDwill 

 illuminatetoshowthatthemaincontrollerisready.

3) Mountthesupplyairsensorinthesupplyairductupstreamfromthe

 motoriseddampers.Plugthesensorintothesocketonthemain 

controller board.

4) Connectthebatterybypluggingintothesocketonthemain

controller board.

5) Use two pre-tested data cables to connect the main controller

(touchpad 1-8 socket) and a touchpad via a double left latched

 adaptor,asshowninFigure2.TheLCDonthe

 touchpadshouldshowtheclockaftersettinga

unique address to the touchpad. (Refer to the

 commissioningsection)Otherwise,checkthe  

connection and the cables.

SENSORSOCKET

TOUCHPAD 1-8

TOUCHPAD 9-16

LED

24 VAC

VAV DAMPERS

BYPASS DAMPER

BATTERY CONNECTOR

BATTERY

6) Repeat step 5) to connect all the

 touchpadsaccordingtoFigure2and3.

 Makesureeverytouchpadisworking

 correctlybycheckingtheclockandthe

 temperaturedisplayedonthetouchpad.

7) Plugacontrolcableintothe‘VAV’socket

on the main board and the other end into

 the‘24VacIN’portonatripleadaptor.

 Plugthetripleadaptorintothemotorised

damper closest to the main board.

Warning - Only yellow Polyaire™

Dampers are compatible with the

system.

8) Useanothercontrolcabletopluginto

 ‘24VacOUT’portonthetripleadaptor

 andtheotherendofthecableto‘24Vac

 IN’portontheotheradaptorforthenext 

motorised damper.

9) Follow Step 8) to connect all motorised

 dampersinseriesasshowninFigure2.

10) Plugoneendofacontrolcableintothe

 ‘touchpad’socketonthetripleadaptor

and the other end into the socket on

the back of the touchpad.

11) Follow step 10) to connect all the

 dampersandtouchpadstogether 

 asshowninFigure2.

Page 6

Page 7

12) Turn off the power and disconnect

the touchpad.

13) Positionthetouchpadattheright

 place.Ideally,itspositionshould

 beapproximately1.6metresoff

 theooronthewall.Fitthedata

 cableandthecontrolcablethrough

 thewallcavityandconnectto 

 thetouchpadagain.Mountthe

touchpad onto the bracket in the

 wallcavity.

Please note that the touchpad should not be

 exposedtodirectsunlightandotherheat 

sources.

13) Applythepoweragaintothetransformer.The 

LCD should show clock time and temperature

  wherethetouchpadislocatedaftershowing

  ‘initiate’onthesecondlineforabout15

seconds.

BYPASS CONTROL

1) Ifbypasscontrolischosenforthe

 system,mountthegreendamper

 controlleronthetopofagreen

 motoriseddamperandplugthe

 bridgecablein.

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