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Design Guide
Zone
Zone
AC LINE
VOLTAGE 24 VAC
GROUND
MODULATING MODULATING
DAMPER DAMPER
COMPUTER
(OPTIONAL)
ZONE ZONE
CONTROLLER CONTROLLER
COOLER
Auto-Zone CV OVR
1 2 3 Menu Esc
4 5 6
ZONE 1 ZONE 2
Override
7 8 9
Dec.
* 0 Minus Clear Enter
WATTMASTER CONTROLS INC.
TEMPERATURE SENSOR TEMPERATURE SENSOR
COMM LINK II
120/24 VAC
W/OVERRIDE AND SETPOINT ADJUST
SYSTEM MANAGER
Remote Link
120/9 VAC C O N T R O L S
C O N T R O L S
TRANSFORMER
TRANSFORMER REMOTE LINK COMM LINK II UP TO 16 ZONES
(OPTIONAL MODEM) INTERFACE
( OPTIONAL )
6 Auto-Zone Systems
Zoning Design Guide
Auto-Zone Systems 7
Zoning Design Guide
Modular Connections
Many Auto-Zone auxiliary devices are connected to the
controllers via modular plugs like the ones used on tele-
phones. This simplifies installation and eliminates the
possibility of wiring errors. The devices, which utilize
this method, are damper actuators for zone and bypass
control, auxiliary relay boards, and static pressure/air
flow sensors. There is one interesting side note about
the auxiliary relay board and airflow sensors. These
devices are typically used on the zone controllers in the
Auto-Zone Basic & Plus systems. When the system is
powered up, it automatically looks to see if these de-
vices are connected to the controller. If they are, the
controller automatically reconfigures itself to utilize
these devices and activates the appropriate set up screens
back at the operators interface. Pretty neat don’t you
think! Open Protocol System
Auto-Zone is an open protocol based system allowing
FREE! Windows™ Graphics Software other manufacturers to develop direct interfaces to the
Each Auto-Zone system can be monitored on site or communications loop. This gives you the ability to in-
remotely using a PC and our ZoneView Plus™ Win- tegrate the Auto-Zone system into products from other
dows 98 software. This full-featured package is very vendors. Our engineering staff will be glad to assist any
user friendly and can be used to monitor one system or vendor in this process.
8 Auto-Zone Systems
Zoning Design Guide
• Always group zones with similar load • Pressure Independent Zones must always use
profiles on the same HVAC unit. round dampers or VAV boxes, never
rectangular - no exceptions!
• Never mix perimeter zones with interior
zones on the same HVAC unit. • Never attempt to use a zone control system
on a true VAV application. See “ Zoning
• Each zoned HVAC unit should have a
Systems Versus True VAV Systems” on page
minimum of 3 to 4 zones. Any less and you
9 of this guide for detailed information.
should consult the factory.
• Bypass dampers should always be sized for
• Each zoned HVAC unit can support a
60%-70% of the HVAC units rated CFM.
maximum of 16 voting zones. Any more
zones and you should contact the factory. • Even though the Auto-Zone system has
certain features to help protect your
• When using auxiliary heat for individual
equipment, never override or disconnect any
zones, perimeter heat such as baseboard is
safety devices associated with the HVAC
always preferred and more economical to
unit.
operate than a fan terminal unit with reheat.
10 Auto-Zone Systems
Zoning Design Guide
Design Considerations
Load Diversity on utilities and provide comfort under conditions when
A zoning system is designed to improve tenant comfort it is not possible to operate the mechanical cooling sys-
by dynamically rebalancing the air distribution when tem.
used with a typical constant volume rooftop heating/
cooling unit. If zones with extremely different load con- 2.) Low Supply Air Temperatures. Under lightly
ditions are serviced by a single rooftop unit, the result loaded conditions much of the supply air may be by-
will be poor control and excessive wear due to cycling passed back into the return air side of the HVAC unit.
of the equipment. This bypassing will result in the lowering of the supply
air temperature, which may result in the supply air tem-
It is especially important to avoid mixing interior zones perature reaching the low temperature safety limit. If
(which require cooling all year) with exterior zones the supply air low temperature safety limit is exceeded,
(which may require constant heat during winter months). the control system will “cut off” the mechanical cool-
If you must mix zones under these conditions, consider ing to protect it from damage. Excessive cycling of the
using either VAV boxes with heat or separate external mechanical system will result if this condition persists.
heat on perimeter zones. Auto-Zone Zoning systems Comfort may also suffer if the system cannot run long
offer a variety of methods to control additional zone enough to satisfy cooling demands.
heat to help you avoid problems.
A number of things can be done to reduce this problem.
Group similar loads on an individual unit and use more Some of these things depend upon the type of installa-
than one zoned unit if required. Any special loads can tion.
be handled by using separate constant volume units.
Avoid oversizing the unit. Do your all load calculations
The Auto-Zone Plus system offers the designer consid- carefully. Since the zoning system directs the heating
erable flexibility by allowing both multiple-zoned units or cooling to the zones which require it, you may find
and single-zone units to be connected within a single that you can use a smaller unit in many cases. Oversizing
simple system. is the number one cause of excessive low supply air
temperature cycling.
Cooling - Partial Load Conditions
Use an economizer. Although this is not a cure-all, it
The engineer must be aware of several potential prob-
greatly improves operation during cool weather when
lems when applying a zoning system for cold weather
cooling loads are minimal. Using an economizer also
operation.
improves ventilation and lowers operating costs.
1.) Low Ambient Temperature Lockout. During very
Increase cooling minimum airflow. Increase your cool-
cold weather it is common for mechanical systems to
ing minimum airflow or damper position settings to al-
have “low temperature lockouts” which protect equip-
low more air during cooling operation. Be careful to
ment from damage if operated under these conditions.
avoid minimum settings that are so high they may cause
Auto-Zone also provides user programmed lockouts for
over cooling of the spaces.
protection purposes, although mechanical safeties
should always be used as the final stage of protection.
Bypass the air into the ceiling plenum. If you have a
system without ducted return, bypass the air into the
If the rooftop unit services interior zones with thermal
ceiling plenum instead of into the return air intake. Be
loads, which require cooling when outside temperatures
careful if you use this method since you may get “dump-
are below the safe operating limits for your equipment,
ing” of cold air from your return air grilles. This method
you should seriously consider installing an economizer
works best with plenum returns. Do not use this method
on your rooftop unit. The Auto-Zone control system is
with ducted returns.
designed to take advantage of an economizer if it is
installed. The use of an economizer will save money
Auto-Zone Systems 11
Zoning Design Guide
Design Considerations
Increase your static pressure setpoint. This will help method works best with plenum returns. Do not use
reduce the amount of air being bypassed. Be aware of this method with ducted returns
increased noise levels and the cost of operation if you
use excessive static pressures. This will not work if you Use auxiliary heat . Use an auxiliary heat source in
are using pressure independent zone controllers, since either your VAV boxes or use baseboard heaters.
they will maintain a constant flow of air to the zones
regardless of duct static pressure. This technique will Auto-Zone has a number of auxiliary heat control op-
likely cause over cooling of the spaces due to increased tions which provide solutions to most problems. Refer
airflow at minimum positions. to the Auxiliary Heat Control Options topic near the
end of this section.
Warning:
Override Conditions
If the fan system has the capability of producing static After-hours overrides can produce aggravated partial
pressures which could damage ductwork you must pro- load conditions in both the heating and cooling modes.
vide a manual reset, high pressure limit switch (Dwyer A single zone being overridden for after-hours use most
1900-5-MR or equal) to cut off the fan system in the commonly causes the problem. This causes the rooftop
event of high duct static. Do not use your Auto-Zone equipment to operate for only one zone. The Auto-Zone
Zoning system as a safety device! system offers an improved solution to this common
problem by allowing a single override to trigger a group
of zones via a “global” override. This allows the sys-
Heating - Partial Load Conditions
tem to operate with sufficient load to reduce cycling
Heating difficulties are less common than cooling dif- caused by light load conditions.
ficulties. They are similar in nature, however, and the
cures are generally the same. Again, a number of things Building Pressurization
can be done to reduce the effects of this problem.
If you are using an economizer, building pressurization
must be addressed. Failure to properly handle building
Increase heating minimum airflow. Increase your heat-
pressurization may result in doors remaining open when
ing minimum airflow or damper position settings to
the economizer is operating. Pressurization problems
allow more air during heating operation. Be careful to
can render economizer operation useless. The follow-
avoid minimum settings that are so high they may cause
ing suggestions will help to avoid potential problems.
over heating of the spaces.
Use powered exhaust. A power exhaust fan(s) must be
Increase the static pressure. Set the static pressure
used when the system utilizes ducted returns. The re-
setpoint to be as high as practical. Increasing static pres-
turn duct pressure drop will cause most barometric re-
sure does not help if you are using pressure indepen-
lief dampers to function poorly or not at all. Auto-Zone
dent control operation.
has the ability to control a powered exhaust whenever
the economizer is operating.
Avoid oversizing the unit. Do your all load calculations
carefully. Since the zoning system directs the heating
Use a separate building pressure control. Use a con-
or cooling to the zones which require it, you may find
trol that operates a relief fan or dampers to relieve build-
that you can use a smaller unit in many cases.
ing pressure
Bypass the air into the ceiling plenum. If you have a
system without ducted return, bypass the air into the
ceiling plenum instead of into the return air intake. This
12 Auto-Zone Systems
Zoning Design Guide
Auto-Zone Systems 13
Zoning Design Guide
14 Auto-Zone Systems
Zoning Design Guide
Step #2 - Sizing the Central Unit Note For pressure independent terminal units
Because the zones are controlled with variable air vol- with velocity sensors and conventional
ume, it is unlikely that all zones will be at design load “VAV” boxes properly selected for
at the same time. The zoning allows for the diversity of “quiet” operation, this 2000 FPM rule
loads to be taken into account and will often provide
can be exceeded by up to 50 percent. The
better comfort with a smaller HVAC unit.
designer, however, should be very
experienced in VAV system design before
In sizing the system, the individual zone loads should
be calculated using any dependable load estimating pro- considering modification of this general
gram. Because of diversity, the central unit should be rule.
selected for the instantaneous peak load, not the sum of
the peak loads, as would be done with a constant vol- Typical VAV systems with pressure independent termi-
ume single zone system. Consider the following when nals use the static regain method for sizing ducts. The
sizing the central unit. typical Auto-Zone Zoning system is a low-pressure,
pressure dependent system that utilizes conventional
• Size the peak cooling load based on the unitary air-conditioning units. These systems should use
month day hour of the greatest total building the equal-friction method of sizing the ducts, and use
system load the maximum loss of 0.1 inch per 100 feet as described
above.
• Heating should be sized for the lowest design
temperature with an additional margin for Step #4 - Air Motion/Diffuser Selection
morning “pickup”. This margin is generally Air motion is a consideration for occupant comfort. The
recommended to be 20 to 25 percent of base selection of diffusers for an Auto-Zone Zoning system
design. requires more care than a constant volume system due
to varying flow of air into the zones. Slot diffusers are
Step #3 - Duct Design Considerations recommended due to their superior performance at low
The Auto-Zone system uses a typical low pressure duct airflows. Because the zone airflow is variable volume,
design. To reduce noise problems duct pressures should lower cost round or rectangular diffusers that were sat-
not exceed 1 inch W.C. isfactory for constant volume may prove unsatisfactory
with an Auto-Zone Zoning system. These diffusers may
Primary trunk ducts should not be “undersized.” This result in “dumping” of the cold air at low flows in the
is especially true for “pressure dependent” systems. cooling mode, and insufficient room air motion at low
Pressure dependent refers to the typical Auto-Zone, air flows in the heating mode. Although high air mo-
Zone Controller without the airflow sensor. With larger tion in the heating mode can be undesirable, a slot dif-
trunk ducts, it is easier to assure relatively constant pres- fuser with a high induction ratio generally helps to re-
sure to each zone. Runs should be as short as possible, duce room air “stratification” when the heating comes
and the trunk duct system kept as symmetrical as pos- from a ceiling diffuser. Linear slot diffusers should be
sible to facilitate system balancing. Wherever possible, properly selected for the airflow and “throw” suited to
run the trunk ducts above corridors and locate the zone the specific installation or zone.
dampers above corridors to reduce the noise in the space
and facilitate service of the units. Trunk ducts should Additional factors to consider in diffuser selection is
be sized for no more than 0.1 inch W.C. drop per 100 sound level and throw at design flow. Generally, mul-
feet., and a maximum duct velocity of 2000 FPM. tiple diffusers will result in lower sound levels in the
space, but this must be balanced with the additional
hardware and installation costs. It is commonly recom-
Auto-Zone Systems 15
Zoning Design Guide
Figure 1-6: Round Bypass Damper Figure 1-7: Rectangular Bypass Damper & Kit
16 Auto-Zone Systems
Zoning Design Guide
Fan
Fan
RA Sensor
SA Sensor Bypass Damper
RA Sensor
SA Sensor
Supply Air Duct
SP Pickup
Return Air Duct Return Air Duct
Supply Air Duct
SP Pickup SP Sensor
3D 2D
Min. Min.
Figure 1-10: Least Desirable Sensor Location
Figure 1-8: Preferred Sensor Location If the supply duct comes directly from the unit and im-
mediately splits in opposite directions, the pressure
If the trunk ducts are properly sized for minimum pres- pickup should be located ahead of the split, or as close
sure drop, the location of the static pickup probe is not to it as possible, even if the bypass damper(s) are lo-
particularly critical. It should ideally be located at right cated downstream of the split.
angles to the airflow in a straight section of the supply
duct approximately 2/3 the distance of the total length Step #6 - Sizing the Zone Damper
of the supply duct. Also the probe should be located
Use a load program to determine the peak load for each
not less than 3 duct diameters downstream and 2 duct
zone. These calculations will be used in selecting the
diameters upstream of any elbow or takeoff. See Fig-
appropriate zone damper sizes.
ure 1-8.
Using the maximum acceptable velocity for a branch
duct (typically 1000-1500 FPM for minimal noise), find
Fan
the smallest damper that will deliver the required CFM
as determined by the load program.
RA Sensor
Bypass Damper
Supply Air Duct Locate the branch velocity used in the duct design pro-
Return Air Duct
Tubing To Be Equal gram on the left hand column of the damper sizing chart
Length And Size
SA Sensor
(Table 1-1). Move across the chart and find the damper
which will provide the acceptable CFM to meet your
specific zone requirements.
SP Pickups SP Sensor
Auto-Zone Systems 17
Zoning Design Guide
18 Auto-Zone Systems
Zoning Design Guide
W
O
A
FL
IR
W
IR
FL
O
A
AI
O
FL
W
R
R
FL
AI
O
W
Actuator Actuator
Rectangular Dampers can cause air flow problems. These slide-in dampers
Auto-Zone rectangular dampers are high quality alu- require that the damper frame be inside the duct. Imag-
minum construction with opposed/air foil designed ine an 8 x 10 rectangular duct using a slide in damper
blades for superior control and have both blade and jamb with a frame thickness of 1”. The frame alone would
seals for tight shut off. The dampers are installed using reduce the opening to 6 x 8.
a mounting flange. The purpose for the flange mount-
ing is to allow as much unrestricted free space within Another possible problem encountered with rectangu-
the duct as possible. lar dampers is the blade width. Many damper manufac-
turers supply dampers with 6” or 8” dampers blades.
Many companies utilize slide-in type dampers which This can become a major problem, for example, if the
Auto-Zone Systems 19
Zoning Design Guide
Damper Airflow Data with Full Open Damper – CFM @ 1000 FPM Velocity
Width (∆PS - inches W.C. @ 1000 FPM Velocity)
“A” For airflow CFM at other velocities use these multipliers: 750 FPM = 0.75, 1250 FPM = 1.25, 1500 FPM = 1.5, 2000 = 2.0, 2250 = 2.25
8” 410 530 640 740 850 970 1080 1190 1300 1410 1520 1630 1740 1850 1970
(0.16) (0.10) (0.07) (0.05) (0.04) (0.03) (0.03) (0.02) (0.02) (0.02) (0.01) (0.02) (0.01) (0.01) (0.01)
10” 510 590 690 800 910 1030 1150 1260 1380 1500 1610 1730 1840 2000 2080
(0.10) (0.07) (0.05) (0.03) (0.03) (0.02) (0.02) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01)
12” 560 650 730 850 970 1090 1210 1330 1460 1580 1700 1820 1940 2060 2190
(0.07) (0.05) (0.03) (0.02) (0.02) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (-) (-) (-)
14” 660 770 880 1030 1180 1330 1480 1630 1760 1910 2060 2210 2360 2510 2640
(0.05) (0.03) (0.02) (0.02) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (-) (-) (-) (-) (-)
16” 750 890 1030 1200 1370 1540 1710 1880 2060 2230 2400 2570 2740 2910 3090
(0.04) (0.03) (0.02) (0.01) (0.01) (0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-)
18” 770 980 1180 1380 1580 1780 1980 2180 2350 2550 2750 2950 3150 3350 3540
(0.03) (0.03) (0.01) (0.01) (0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-)
20” 850 1090 1330 1550 1770 1990 2210 2430 2650 2870 3090 3310 3530 3750 3990
(0.03) (0.02) (0.01) (0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-) (-)
22” 930 1210 1480 1730 1980 2230 2480 2730 2950 3200 3450 3700 3950 4200 4440
(0.02) (0.01) (0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-) (-) (-)
24” 950 1290 1630 1900 2170 2440 2710 2980 3250 3520 3790 4060 4330 4600 4880
(0.02) (0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-) (-) (-) (-)
26” 990 1390 1780 2080 2380 2680 2980 3280 3550 3850 4150 4450 4750 NA NA
(0.02) (0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-) (-)
28” 1070 1500 1930 2250 2570 2890 3210 3530 3850 4170 4500 4820 NA NA NA
(0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-) (-)
30” 1020 1550 2080 2430 2780 3130 3480 3830 4150 4500 4850 NA NA NA NA
(0.01) (0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-)
32” 1090 1660 2230 2600 2970 3340 3710 4080 4450 4820 NA NA NA NA NA
(0.01) (0.01) (-) (-) (-) (-) (-) (-) (-) (-)
34” 1150 1770 2380 2780 3180 3580 3980 4370 4750 NA NA NA NA NA NA
(0.01) (0.01) (-) (-) (-) (-) (-) (-) (-)
36” 1060 1790 2520 2670 3090 3510 3930 4350 5040 NA NA NA NA NA NA
(0.01) (0.01) (-) (-) (-) (-) (-) (-) (-)
WattMaster reserves the right to change specifications without notice
20 Auto-Zone Systems
Zoning Design Guide
Q: Should the zone heat be locked out if the rooftop Relay #4 - Series Fan
unit is supplying warm air? The series fan runs anytime the main fan is running.
This includes occupied and unoccupied modes. The fan
A: Many times it is desirable to use the rooftop can only start running when the zone damper is closed,
heating whenever possible and only use zone heat so it determines that the damper is closed before start-
when the rooftop unit is in cooling. This mode of ing the fan.
operation will lockout zone heat if the rooftop is
delivering heated air.
Auto-Zone Systems 21
Zoning Design Guide
System Installation
Mounting Of Controllers device. Possible problems you may encounter using
All Auto-Zone Round Dampers or Rectangular Damper common transformers to power multiple devices are:
Kits have the required controllers, actuators etc. fac-
tory mounted in an indoor rated control enclosure. If • If polarity is not maintained between devices,
you wish to use another manufacturers dampers for zon- shorting of the transformer will occur resulting
ing control you must purchase Zone or Bypass Pack- in damage to the electronics.
ages from WattMaster. These are furnished without a
mounting enclosure. Most local codes require these • When using one transformer to power multiple
components be mounted in an enclosure. If yours does devices it is possible to lose most or all of your
not require this it is still strongly recommended that system if the transformer fails.
you do mount them in an enclosure. Components that
are not in an enclosure are in danger of being damaged, • It is important when powering multiple devices
and are susceptible to dirt and moisture contamination. from one transformer that total VA load and
You may furnish your own enclosure or one is avail- wiring voltage drops be taken into account for
able from WattMaster. The part number for the proper sizing of the transformer and wire.
WattMaster enclosure is EE000075-01. This is an in- (See Table 3 on page 23)
door rated enclosure. If the zone mounting location is
susceptible to water damage, watertight enclosures can It is therefore recommended that in most installations
be purchased at any local electrical supply. Mounting individual transformers be installed for each device.
location for the controllers should not violate any lo- This will greatly reduce the possibility of errors and
cal, state or national codes. possible damage to the system.
22 Auto-Zone Systems
Zoning Design Guide
WattMaster requires that all communication wire be 18 should be color coded to facilitate error free wiring.
gauge minimum, two wire shielded cable, Belden The communication loops will not work if any of the
#82760 or equivalent. WattMaster offers AZWR series wires are reversed or otherwise landed incorrectly. Com-
communications cable for this purpose. The 18 gauge munications loops can be run up to a maximum of ap-
color coded and labeled wire is available for the local proximately 4000 ft. in total length. If your system ex-
loop and the network loop communications wiring. The ceeds this length, please consult the WattMaster fac-
local loop wire is supplied in 1000 ft. spools and is la- tory for more information regarding extended commu-
beled “Local Loop” with a green candy stripe. The nication loop lengths and solutions.
network loop wire is supplied in 500 ft. spools and is
labeled “Network Loop” with a red candy stripe. Caution: Unless the communications loop
is installed in conduit, be careful to
position the cable away from high
noise devices like fluorescent
lights, transformers, VFD’s, etc.
Conduit is not required for com-
munications loop wiring unless
required by local codes.
Auto-Zone Systems 23
Zoning Design Guide
System Installation
Computer
(Optional)
CO
MM
LIN
K II Zone Controllers Occupy
HVAC Unit Addresses 1 through 16.
L
O C
O O
P M
M O
P D
24VAC
E
M
Zone Manager
WATTM
AST
Zone
ER
CON
Zone
TRO
LS,
INC
R34
R18
R34
R18
FLOW CX4 FLOW CX4
CX3 CX1 CX3 CX1
CX8 U4 U3 CX8 U4 U3
U8
U8
RN1 RN1
U1
U1
1 1
TCU32K2V
TCU32K2V
MS6264L-70PC
MS6264L-70PC
V4.00F C094
V4.00F C094
B31920PS
74HC573N
B31920PS
74HC573N
AZZONE
AZZONE
9936
9936
D5 D5
R27
R27
16L8 16L8
AUTO ZONE CX9 U9 R1
CX9 U9 R1
C13
C9
C13
C9
WED JANUARY11 2001
LMC662
LMC662
R2 R2
RAM EPROM R3 RAM EPROM R3
C8
C8
OCCUPIED 80C55 80C55
C14 ADJ
C14 ADJ
R22 R22
2 CX2 2 CX2
D5 D5
P.U. P.U.
VREF
VREF
Q1
Q1
R32 R32
C10
C10
PHILIPS
PHILIPS
R23 R23
X1
X1
PCB80C552-5-16WP
PCB80C552-5-16WP
B31920PS
74HC259
B31920PS
74HC259
T'STA T'STA
C1
U2
C1
U2
T R24 T R24
R28
R28
DFD9940SM
DFD9940SM
500650=1/3
500650=1/3
U11
U11
C2
C2
R19
R19
C11
C11
R20
R20
PHILIPS
PHILIPS
R4 R4
C15
C15
CX5
CX5
EWDOG
EWDOG
D7
R25 R5 D7
R25 R5
U5
U5
ADDRE R6 ADDRE R6
SS ADD R7 SS ADD R7
CX10 CX10
1 1
PJ1
PJ1
93C46
93C46
U6
U6
2 2
SION
EXPAN
SION
EXPAN
R8
R8
4 4
COMM
COMM
75176
75176
8 8
SW1
SW1
CX6
CX6
U10
C3
U10
C3
16 16
32 32
LD3 LD3
TOKEN TOKEN
Sy
POWER
POWER
C5
C5
C4
C4
ch NET NET
R100
R100
ro
PJ2
PJ2
R26 R26
no
R13
R13
TOR
ACTUA
TOR
ACTUA
R14
R14
us 250 250
V1
V1
Da D4 D4
ta
Lin F1 F1
LD2
LD1
LD2
LD1
R21
R21
k
R9
R9
C6
C6
562
YS101
562
YS101
SIG
REV. 2
REV. 2
SCAN REC SCAN REC
fTimes New fTimes New
DET
R12
R11
R10
R12
R11
R10
Roman|b0|i0| Roman|b0|i0|
RDY
L1
L1
Roman|b0|i0|c0|p18; Roman|b0|i0|c0|p18;
c0|p18;OMRON c0|p18;OMRON
SND
G5L-114P-PS G5L-114P-PS
24VDC 24VDC
REC
CONTACT: CONTACT:
PWR
MDL MDL
UL / CSA 5A250VAC UL / CSA 5A250VAC
Q2
Q2
VR1
VR1
D1
K1
D1
K1
D3 D3
C
O
T C7 fTimes New T C7 fTimes New
24VAC Roman|b0|i0| 24VAC Roman|b0|i0|
7824C 7824C
fTimes New fTimes New
7824
7824
R15
R15
N
T
Roman|b0|i0|c0|p18; Roman|b0|i0|c0|p18;
c0|p18;OMRON c0|p18;OMRON
R M 9936 M 9936
O
64A
G5L-114P-PS 64A
G5L-114P-PS
RS485 Loop
L
24VDC 24VDC
MC340 MC340
S
CONTACT: CONTACT:
UL / CSA 5A250VAC UL / CSA 5A250VAC
Q3
Q3
U7
U7
R16
D2
R16
D2
R17
R17
K2
K2
GND GND
Remote Link
V2 V2
(Optional)
R18
R34
R18
U8
RN1 RN1
U1
U1
1 1
COMM
TCU32K2V
TCU32K2V
RELAY
MS6264L-70PC
MS6264L-70PC
V4.00F C094
V4.00F C094
B31920PS
74HC573N
B31920PS
74HC573N
AZZONE
AZZONE
9936
9936
D5 D5 T OUTPUT
COM
SHLD 1-3
R27
R27
OUT
16L8 16L8
CX9 CX9
R
U9 U9
R1 R1
1
C13
C9
C13
C9
LMC662
LMC662
R2 R2
RAM EPROM R3 RAM EPROM R3 OUT
C8
C8
Computer
80C55 80C55
C14 ADJ
C14 ADJ
R22 R22
2 CX2 2 CX2 COMM
D5
P.U.
D5
P.U. OUT
VREF
VREF
Q1
Q1
R32 R32 3
REC.
C10
C10
PHILIPS
PHILIPS
R23 R23
OUT
X1
X1
PCB80C552-5-16WP
PCB80C552-5-16WP
B31920PS
74HC259
B31920PS
74HC259
T'STA T'STA 4
C1
U2
C1
U2
T R24 T R24
R28
R28
DFD9940SM
DFD9940SM
OUT
(Optional)
500650=1/3
500650=1/3
U11
U11
C2
C2
R19
R19
5
C11
C11
R20
R20
PHILIPS
PHILIPS
R4 R4
C15
C15
COM
CX5
CX5
EWDOG
EWDOG
R25 R5 R25 R5
D7 D7
4-5
U5
U5
COMM
ADDRE R6 ADDRE R6
SS ADD SS ADD
RS485
R7 R7
CX10 CX10
1 1
PJ1
PJ1
93C46
93C46
U6
U6
2 2
SION
EXPAN
SION
EXPAN
R8
R8
4 4
COMM
COMM
75176
75176
8 8
12V TEST
SW1
SW1
CX6
CX6
U10
C3
U10
C3
16 16
ADDRESS ADD
LD3
32
TOKEN
LD3
32
TOKEN AIN
1
POWER
POWER
C5
C5
Network Loop
C4
C4
NET NET
R100
R100
PJ2
PJ2
R26 R26
AIN
R13
R13
TOR
ACTUA
TOR
ACTUA
R14
R14
250 250
V1
V1
2
EWDOG
D4 D4
F1 F1
LD2
LD1
LD2
LD1
AIN
R21
R21
3
R9
R9
C6
C6
562
YS101
562
YS101
REV. 2
REV. 2
R12
R11
R10
Roman|b0|i0|
fTimes New Roman|b0|i0|
fTimes New
4
L1
L1
Roman|b0|i0|c0|p18; Roman|b0|i0|c0|p18;
c0|p18;OMRON
G5L-114P-PS c0|p18;OMRON
G5L-114P-PS
MDL
24VDC
CONTACT:
UL / CSA 5A250VAC
MDL
24VDC
CONTACT:
UL / CSA 5A250VAC
AIN
5
Q2
Q2
VR1
VR1
D1
K1
D1
K1
D3 D3
19200 Baud
24VAC
T
7824C
C7 fTimes New
Roman|b0|i0|
fTimes New 24VAC
T
7824C
C7 fTimes New
Roman|b0|i0|
fTimes New GND
7824
7824
R15
R15
Roman|b0|i0|c0|p18; Roman|b0|i0|c0|p18;
c0|p18;OMRON c0|p18;OMRON
M 9936 M 9936
64A
G5L-114P-PS 64A
G5L-114P-PS
24VDC 24VDC
GND
MC340 MC340
CONTACT: CONTACT:
UL / CSA 5A250VAC UL / CSA 5A250VAC
Q3
Q3
U7
U7
VDC
R16
D2
R16
D2
0-5
R17
R17
K2
K2
GND GND
V2 V2
AOUT
PWR
PRESSURE GND
SENSOR
VDC
0-1
YS101564
24VAC
Constant Volume
O M
P M O
P D
E
M
WATTM
Controller
AST
ER
CON
24VAC
INC
R18
R34
R18
U8
RN1 RN1
U1
U1
1 1
COMM
TCU32K2V
TCU32K2V
RELAY
MS6264L-70PC
MS6264L-70PC
V4.00F C094
V4.00F C094
B31920PS
74HC573N
B31920PS
74HC573N
AZZONE
AZZONE
9936
9936
D5 D5 T OUTPUT
COM
SHLD 1-3
R27
R27
CX9
16L8
CX9
16L8
OUT
R
U9 U9
R1 R1
1
C13
C9
C13
C9
LMC662
LMC662
R2 R2
RAM EPROM R3 RAM EPROM R3 OUT
C8
C8
C14 ADJ
R22 R22
2 CX2 2 CX2 COMM
D5
P.U.
D5
P.U. OUT
VREF
VREF
Q1
Q1
R32 R32 3
REC.
C10
C10
PHILIPS
PHILIPS
R23 R23
OUT
X1
X1
PCB80C552-5-16WP
PCB80C552-5-16WP
B31920PS
74HC259
B31920PS
74HC259
T'STA T'STA 4
C1
U2
C1
U2
T R24 T R24
R28
R28
DFD9940SM
DFD9940SM
OUT
500650=1/3
500650=1/3
U11
U11
C2
C2
R19
R19
5
C11
C11
R20
R20
PHILIPS
PHILIPS
R4 R4
C15
C15
COM
CX5
CX5
EWDOG
EWDOG
R25 R5 R25 R5
D7 D7
4-5
U5
U5
COMM
ADDRE R6 ADDRE R6
SS ADD R7 SS ADD R7
CX10 CX10
1 1
PJ1
PJ1
93C46
93C46
U6
U6
2 2
SION
EXPAN
SION
EXPAN
R8
R8
4 4
COMM
COMM
75176
75176
8 8
12V TEST
SW1
SW1
CX6
CX6
U10
C3
U10
C3
16 16
ADDRESS ADD
Sy
LD3
32
TOKEN
LD3
32
TOKEN AIN
1
POWER
POWER
C5
C5
C4
C4
ch NET NET
R100
R100
ro
PJ2
PJ2
R26 R26
no
AIN
R13
R13
TOR
ACTUA
TOR
ACTUA
R14
R14
us 250 250
V1
V1
Da
2
EWDOG
D4 D4
ta
Lin F1 F1
LD2
LD1
LD2
LD1
AIN
R21
R21
k
3
R9
R9
C6
C6
562
YS101
562
YS101
SIG
REV. 2
REV. 2
R12
R11
R10
R12
R11
R10
Roman|b0|i0| Roman|b0|i0|
RDY
L1
Roman|b0|i0|c0|p18; Roman|b0|i0|c0|p18;
c0|p18;OMRON c0|p18;OMRON
SND
G5L-114P-PS G5L-114P-PS
24VDC 24VDC
AIN
REC
CONTACT: CONTACT:
PWR
MDL MDL
UL / CSA 5A250VAC UL / CSA 5A250VAC
5
Q2
Q2
VR1
VR1
D1
K1
D1
K1
D3 D3
C
O
24VAC
T
7824C
C7 fTimes New
Roman|b0|i0|
fTimes New 24VAC
T
7824C
C7 fTimes New
Roman|b0|i0|
fTimes New GND
7824
7824
R15
R15
N
T
Roman|b0|i0|c0|p18; Roman|b0|i0|c0|p18;
c0|p18;OMRON c0|p18;OMRON
R M 9936 M 9936
O
64A
G5L-114P-PS 64A
G5L-114P-PS
GND
L
24VDC 24VDC
MC340 MC340
S
CONTACT: CONTACT:
UL / CSA 5A250VAC UL / CSA 5A250VAC
Q3
Q3
U7
U7
VDC
R16
D2
R16
D2
0-5
R17
R17
K2
K2
GND GND
AOUT
Remote Link
V2 V2
PWR
PRESSURE GND
SENSOR
VDC
0-1
YS101564
(Optional) 24VAC
24 Auto-Zone Systems
Zoning Design Guide
Auto-Zone Systems 25
Zoning Design Guide
System Installation
24VAC Power - Transformer & Wire Sizing Considerations
Some installers like to use one large 24VAC transformer to power several controllers. This is allowable as long as polarity is maintained to each
controller on the transformer circuit. Warning: If polarity is not maintained, severe damage to the controllers may result. WattMaster Controls
recommends using a separate transformer for each controller in order to eliminate the potential for damaging controllers due to incorrect
polarity. Using separate transformers also allows redundancy in case of a transformer failure. Instead of having 8 controllers inoperative because of a
malfunctioning transformer you have only 1 controller off line. If the installer does decide to use a large transformer to supply power to several
controllers, the following transformer and wire sizing information is presented to help the installer correctly supply 24VAC power to the controllers.
Following is a typical example to help the installer to correctly evaluate transformer and wiring designs.
Each Zone Controller with actuator requires 10 VA @ 24VAC power. In the examples below we have a total of 8 Zone Controllers.
8 Zone Controllers @ 10VA each................ 8 x 10VA = 80VA.
The above calculation determines that our transformer will need to be sized for a minimum of 80VA if we are to use one transformer to power all the
controllers.
Next we must determine the maximum length of run allowable for the wire gauge we wish to use in the installation. Each wire gauge below has a
voltage drop per foot value we use to calculate total voltage drop.
18ga wire.................................0.00054 = voltage drop per 1’ length of wire
16ga wire.................................0.00034 = voltage drop per 1’ length of wire
14ga wire.................................0.00021 = voltage drop per 1’ length of wire
For our example we will use 18 gauge wire. WattMaster recommends 18 gauge as a minimum wire size for all power wiring.
Next use the voltage drop per foot value for 18 gauge wire from the list above and multiply by the total VA load of the 8 controllers to be installed.
0.00054 (Voltage drop per foot for 18 gauge wire) x 80VA controller load = 0.0432 Volts/Ft.
WattMaster controllers will operate efficiently with a voltage drop no greater than 2 Volts. Divide the total allowable voltage drop of 2 Volts by the
number you arrived at above and you have the maximum number of feet you can run the 18 gauge wire with an 80VA transformer with no more than a
2 Volt drop at the farthest controller from the transformer..
2 (Volts total allowable voltage drop)
= 46.30 feet
0.0432 (Voltage drop per 1 ft. @ 80VA load)
Parallel circuiting of the wiring instead of wiring all 8 controllers in series allows for longer wire runs to be used with the same size wire (as shown in
our examples below). It is often necessary for the installer to calculate and weigh the cost and installation advantages and disadvantages of wire size,
transformer size, multiple transformers, circuiting, etc., when laying out an installation. No matter what layout scheme is decided upon, it is mandatory
that the farthest controller on the circuit is supplied with a minimum of 22 Volts.
ZONE ZONE
ZONE ZONE CONTROLLER CONTROLLER ZONE ZONE
CONTROLLER CONTROLLER ZONE ZONE
CONTROLLER CONTROLLER CONTROLLER CONTROLLER
B C
B B C D E
A
ZONE ZONE
ZONE ZONE CONTROLLER CONTROLLER ZONE ZONE
CONTROLLER CONTROLLER ZONE ZONE
CONTROLLER CONTROLLER CONTROLLER CONTROLLER
120 / 24VAC
ZONE ZONE
ZONE ZONE CONTROLLER CONTROLLER
CONTROLLER CONTROLLER
ZONE ZONE
ZONE ZONE CONTROLLER CONTROLLER
CONTROLLER CONTROLLER
A
120 / 24VAC
JOB NAME
Component Power Requirements
System Manager ......................25VA GPC Controller .........................20VA
FILENAME
Zone Manager ..........................25VA Wetbulb Module .......................20VA
WIRSIZ1.CDR C O N T R O L S
Zone Controller ........................10VA Lighting Panel Controller ..........25VA
DATE: 11/30/99 DRAWN BY: B. CREWS
CV Controller............................20VA Zone Relay Expansion Board ...10VA
PAGE DESCRIPTION:
CV-C Controller ........................20VA Staging Expansion Board .........20VA
Auto-Zone
Optimal Start Scheduler ...........25VA 1 Wire & Transformer Sizing
Figure 1-16: Transformer And Wire Sizing Considerations
26 Auto-Zone Systems
Zoning Design Guide
Application Notes:
Zoning 30 And 40 Ton Units • Bypass dampers should be sized for 60 to
When using large HVAC units for zoning applications, 70% of the rated CFM of the unit. Because of
several rules must be considered to prohibit potential the large air volumes involved, rectangular
problems. dampers should be used instead of round
dampers. Consult the rectangular damper
Because of the large air flow capacities of the 30 and sizing guide (Table 1-2 on page 25), for CFM
40 ton units, great care must be taken in sizing zone ratings.
and bypass dampers.
• Large units should always have a minimum
Use these guidelines to help keep you out of trouble. of 6 zones due to the high air flow capacities.
• Always use the Auto-Zone Plus system even • To prevent excessive noise in the system,
if you only have one unit that you are zoning. zone damper total minimum airflow settings
should be equal to or preferably greater than
• Generally you should use constant volume 30% of the units rated CFM.
units in your zoning system design. If your
units are to be equipped with variable As an added precaution, we recommend a high duct
frequency drives or inlet vanes, please static safety switch be installed (Dwyer Model 1900-
consult WattMaster Controls for assistance. 5-MR or equal) to prevent over pressurization of the
ductwork.
• The OE340-10-AGSTG relay expansion card
is usually required for each Zone Manager
controlling two or more stages of cooling.
Auto-Zone Systems 27
Form: WM-AZA-ZDG-01B Printed in the USA October 2001
All rights reserved Copyright 2001
WattMaster Controls Inc. • 8500 NW River Park Drive • Parkville MO • 64152
Phone (816) 505-1100 E-mail: mail@wattmaster.com Fax (816) 505-1101