mounting and wiring vma1200 series controllers technical

Technical BulletinIssue Date July 1, 2003

© 2003 Johnson Controls, Inc. www.johnsoncontrols.comCode No. LIT-1162360 M-Tool Release 5.3

Mounting and Wiring VMA1200 Series Controllers

Mounting and Wiring VMA1200 Series Controllers............................2

Introduction......................................................................................................... 2

Key Concepts...................................................................................................... 3

VMA Position and Orientation ........................................................................................... 3Determine and Set Damper Polarity ................................................................................. 3Wiring and Cabling Precautions........................................................................................ 4VMA Internal Schematic Diagram ..................................................................................... 6Phone Jack Polarization.................................................................................................... 8

Detailed Procedures......................................................................................... 10

Preparing the VMA for Mounting..................................................................................... 10Mounting the VMA........................................................................................................... 11Setting the Damper Position ........................................................................................... 12Wiring the VMA ............................................................................................................... 14Connecting the LONWORKS Network Bus........................................................................ 15

Mounting and Wiring VMA1200 Series Controllers Technical Bulletin2

Mounting and Wiring VMA1200Series Controllers

Introduction The integrated Variable Air Volume Modular Assembly (VMA),which is a controller/actuator/pressure sensor, mounts on the VariableAir Volume (VAV) terminal box and fastens to the damper shaft.

Instructions for wiring the VMA and its accessory devices are alsoprovided in this document.

This document describes how to:

• prepare the VMA for mounting

• mount the VMA

• set the damper position

• wire the VMA

• connect the LONWORKS® Network Bus

Mounting and Wiring VMA1200 Series Controllers Technical Bulletin 3

Key Concepts VMA Position and Orientation

Note: Extra mounting brackets, linkage, or couplers are notrequired for standard mounting.

Consider the following when positioning and orienting the VMA:

• Mount the VMA on a vertical and flat surface where it functionsbest, such as the side of the VAV box.

• Route the tubing so a portion of it is lower than the pressure sensoror loop the tubing. This creates a moisture trap that prevents anycondensation from entering the sensor.

• Do not make any sharp bends in the tubing. This could collapse thetube and block the pressure path.

• Ensure that wiring terminals and service pin are accessible.

• Make sure the VMA1200 Installation Bulletin (Part No. 24-9310-5)is available for properly identifying terminals.

• Locate the VMA so that it has adequate clearance for futureservicing and is protected from moisture and corrosive fumes.

Determine and Set Damper PolarityDamper polarity is established upon installation. Incorrect damperpositions in a zone easily result in misdiagnosis of readings, resultingin unnecessary repetition of setup and diagnostics.

Many dampers seal properly only when closed in the rotation directionspecified by the manufacturer. To simplify maintenance, use the samedirection to close on all boxes of the same type.

To determine whether the damper is closed Clockwise (CW) orCounterclockwise (CCW):

● Visually verify which direction opens the damper before duct workis completed and note the information for future reference.

● Look up the manufacturer’s damper model specifications.

● Once there is airflow in the zone, use a commissioning tool tocommand the actuator to 100%. If this causes the flow to decrease,it is an indication that the Damper Polarity configuration propertymust be reversed from its current setting.


● To change the damper polarity, set the Damper Polarityconfiguration property to Reverse, using a Palm™ compatiblehandheld device (Version 2.0 or higher operating system) with theVMA1200 Balancing Tool (VBT) software, the Comm Procommissioning tool, or a LONWORKS Network Services (LNS™)network management tool.

Note: The default setting for damper polarity is set to normal,which rotates the damper CCW to close. If it closes in a CW direction,the damper polarity must be changed.

Wiring and Cabling Precautions

! WARNING: Risk of Electrical Shock.Disconnect each of multiple power supplies before making electricalconnections. More than one disconnect may be required to completelyde-energize equipment. Contact with components carrying hazardousvoltage can cause electrical shock and may result in severe personal injuryor death.

IMPORTANT: Disconnect all power supplies, as shorting of binary outputswhile energized destroys the VMA triac.

Read these precautions before touching the terminals or wiring theVMA and its accessories:

• Make all wiring connections in accordance with the NationalElectrical Code (NEC) and state and local regulations. Fortransformer primaries above 150 VAC, the secondary must beearth grounded at the transformer to meet NEC. You can useTerminal 1 as the earth ground.

Notes: 24 VAC to 24 VAC isolation transformers are not necessary.The power supply is internally isolated. See VMA Internal SchematicDiagram in this section.

For specific methods for wiring the VMA to meetUnderwriters Laboratories®, Inc. (UL) 864 requirements, refer to theMetasys® Smoke Control Wiring Technical Bulletin (LIT-636331).

• Locate equipment and route the wiring so that sensor signal wiringis separated from power wiring by at least 150 mm (6 in.).

• Make all wiring connections to the VMA using only copperconductors. To establish tight, reliable electrical connections, usethe correct wire sizes for the terminals. Avoid very thin wire, suchas 26 AWG (less than 0.6 mm solid), which tends to break.

• Follow LONWORKS Network Bus installation rules for either theBus topology or Free topology bus types.


• Do not run LONWORKS Network Bus, Zone Bus,Analog Input (AI), Binary Input (BI), Analog Output (AO), orBinary Output (BO) wiring in the same conduit as line voltagewiring (above 30 VAC), or with wiring that switches power tohighly inductive loads such as contactors, coils, motors, orgenerators.

• Run Zone Bus, AI, AO, and BI wiring in the same bundle orconduit where convenient. If the BO wiring is not wired throughother switches or contacts, such as actuator end-of-travel switches,you may also bundle it with the other I/O (Input/Output) wiringwhere convenient.

The following are additional general wiring considerations:

• The VMA includes an isolated LONWORKS Network Bus, isolatedbinary outputs, and isolated 24 VAC. See VMA Internal SchematicDiagram in this section.

• The 24 VAC power input is internally transformer isolated by theVMA. To meet NEC requirements for line voltage greater than150 VAC, Terminal 1 (24 VAC) can be earth grounded.

• Up to 14 cooling-only VMAs (Model VMA1210) are poweredfrom one 100 VA low voltage power limited, Class 2 transformer.The number of VMA1220s per transformer varies, depending onpower requirements of the valve actuators and relays. Conduit isnot needed for 24 VAC at 100 VA or less.

• Large insulated spade lugs with a polarizing tab (for high voltage)do not fit on the VMA.


VMA Internal Schematic DiagramFigure 1 is a key diagram showing the different regions of the largerschematic diagram in Figure 2. This detailed diagram displays thefollowing elements as shown in the key diagram below:

1. Isolated Power Supply

2. Earth Ground Connection

3. Airflow and High Temperature Safety Switches

4. Isolated Triacs and Power Wiring for the Airflow and HighTemperature Safety Switches

5. Isolated LONWORKS Network Bus

6. Valve Actuators

7. Zone Bus1. Isolated Power Supply

2. Earth Ground Connection

3. Airflow and High Temperature Safety Switches

4. Isolated Triacs and Power Wiring

6. Valve Actuators 7. Zone Busvma_small

5. Isolated Network Bus

L WON ORKS

Figure 1: Key to Internal Schematic Diagram (Figure 2)


vma_large

Primary

Manual Reset

AFS

Earth ground is required by NEC if primary is greater than 150 VAC.

1

2

XFR

Synchronous Motor(Actuator)

COM

Water Valve

1

2

4

3

In

LONWORKS Network

Bus

VMA

+15V

+5V

Triacs

COM COM

AO

15 23

14

OPTO

24 VAC

BCOM

CablePRO or CVTPRO

Laptop

R

R

ReheatBO-3

ReheatBO-2

FanRelayBO-1

24 VAC

4

6

8

BI18

AI26

5

= Optical or Magnetic Isolation

30.01 uF

HighTemperature

+15 VDC

AO uP

R

Figure 2: VMA Internal Schematic Diagram


Phone Jack PolarizationThe figure below illustrates the polarization of the 6-pin and 8-pinphone jacks on the VMA or room sensor. Pin 1 is to the extreme left asyou face the jack opening, tab notch down.

If you need to create your own cable, refer to Fabricating Your OwnInterconnection Cable in Appendix A: Reference Information locatedin the Variable Air Volume Modular Assembly (VMA) 1200 SeriesOverview and Engineering Guidelines Technical Bulletin(LIT-1162350).

8-pin 6-pin

VMA Room Sensor

Pin 1

phonejack

Figure 3: Phone Jack Polarization

Table 1: VMA Phone Jack PinoutsPin Signal1 BI-1 Temp Occ/LED (Light-Emitting Diode)2 AI-2 Setpoint3 AI-1 Temperature Sensor4 AI-1 COM (sensor)5 +15 VDC6 +15 COM/ZB COM7 COM (setpoint)8 ZB


Table 2: TE-6700 Phone Jack Pinouts8-Pin Jack 6-Pin Jack

Pin Signal Pin Signal1 Heating Setpoint or LED and Manual

Override1 Not Used

2 Setpoint (Cooling) 2 +15 VDC3 Temperature Sensor 3 COM4 Temperature Sensor Common 4 Not Used5 +15 VDC 5 Zone Bus6 Power Common or Zone Bus Common 6 Not Used7 Setpoint Common8 Zone Bus

Table 3: TE-6700 Room Sensor Terminal Block Wiring IdentificationTerminal Signal Destination12

Temperature Sensor and Manual Override*

3 Setpoint Common4 Setpoint5 +15 VDC6 Power Common and Zone Bus Common and Manual Override Common and LED Common*7 Zone Bus8 LED and Manual Override** Manual Override for Temporary Occupied Mode is selected using DIP switches for either Terminals 1 and2 or 6 and 8 with LED. For more information, see the TE-6700 Series 2nd Generation Temperature ElementsInstallation Bulletin (LIT-216332).Note: A dual setpoint is not available with terminal block versions of the TE-6700.

Table 4: TMZ Phone Jack Pinouts8-Pin Phone Jack on VMA 6-Pin Phone Jack on TMZ

Pin Signal Pin Signal1 Not Used 1 Not Used2 Not Used 2 Supply: +15 VDC3 AI-1, Zone Temperature Sensor 3 Supply/Zone Bus Common4 AI-1, Sensor Common 4 Not Used5 Supply: +15 VDC 5 Zone Bus6 Supply/Zone Bus Common 6 Not Used7 Not Used8 Zone Bus


Detailed ProceduresPreparing the VMA for Mounting

To prepare the VMA for mounting:

1. Check that you have the following equipment:

• VMA

• TE-6700, TE-7000 (Europe only), or the TMZ1600 roomsensor

• room sensor cable or wire for connecting the room sensor tothe VMA

2. Check that you have the following tools:

• 8 mm (5/16 in.) square wrench or 10 mm (3/8 in.) 12 pointsocket for actuator collar screw

• pliers to turn the damper shaft (if needed)

• 8 mm (5/16 in.) hex nut driver or 4 in. extension for 5/16 in.socket and power screwdriver for self-drilling screw

• 3.5 mm (9/64 in.) drill bit (optional)

Note: The VMA requires a damper shaft protrusion of at least44 mm (1-3/4 in.) from the VMA mounting surface.

3. Ensure the VMA installation site meets the followingenvironmental requirements:

• The VMA location is protected from direct contact with watercaused by leaking pipes, condensation, or solder from sweatingreheat pipes.

• The atmosphere is free of explosive vapors or escaping gases.

• The atmosphere is free of exposure to corrosive chemical orsalt vapors, which might damage electrical equipment.

• The temperature is maintained between 0 to 50°C(32 to 122°F), with the relative humidity (non-condensing)maintained between 10 and 90%. These are operating limits.Flow measurement accuracy suffers if the ambient temperaturevaries widely within this band.

4. Make sure the VMA mounting location has adequate clearance forfuture servicing.


Mounting the VMA To mount the VMA:

1. Place the VMA in the desired mounting position on the dampershaft so the wiring terminals are easily accessible.

To allow space for VMA movement during damper rotation,locate the shoulder washer at the center of the slot.

Make sure the VMA is parallel and mounted flat with the VAVbox. If needed, use a spacer to offset tipping of the VMA createdby shaft bushings that protrude beyond the box surface.

2. Secure the self-drilling No. 10 screw provided into the VMAmounting slot, using a power screwdriver and socket with 4 in.extension.

Alternate mounting:

1. Perform Step 1 as shown previously.

2. Use a punch to mark the position of the shoulder washer, thendrill a hole into the VAV box through the mark using a 3.5 mm(9/64 in.) bit.

3. Position the VMA so the shoulder washer is over the hole; insertthe mounting screw and tighten against the washer.

Note: The mounting screw is threaded into sheet metal and thethreads can strip. Do not overtighten. Make sure the screw does notinterfere with full damper rotation.

ShoulderWasher

MountingScrew

Mounting Slot

MountBar Code

(Neuron ID)

Phone Jack(for Sensor)

Service Pin(Broadcasts Neuron ID)

Figure 4: Mounting Screw with Shoulder Washer


Setting the Damper Position To set the damper position:

1. Locate the damper position. The following figure showsthree possible icons on the end of the damper shaft.

damposit

Figure 5: Typical Damper Shaft End Icons2. Grasp the damper shaft firmly with a pliers and manually position

it to fully closed (icon perpendicular to airflow) for 90° boxes.(Use the fully open position for 45° or 60° boxes.)

3. For 90° boxes, push the VMA gear release lever down andposition the actuator collar against its internal stop correspondingto the fully closed position. This provides a hard stop for thisposition. The hard stop for the open position is provided by theVMA.

For 45° and 60° boxes, push the VMA gear release down andposition the actuator to the fully open damper position. Byinstalling the VMA at the fully open position, the VMA providesthe open stop for 45° and 60° boxes. The closed damper sealprovides the fully closed stop.

Gear ReleaseLever

Damper shaft is infully closed position.

Set Screw

Collar is rotated to itsfully closed position.

(CW to close in this example.)

Endstop

LON ALON BSHLD

Figure 6: Positioning the End Stop


4. Tighten the set screw to the shaft using a 8 mm (5/16 in.) wrenchor 10 mm (3/8 in.) 12 point socket wrench. Tighten to17 to 21 N⋅m (150 to 180 lb⋅in [14 lb⋅ft]).

Default configuration for the VMA is 90° rotation in 90 seconds.Adjust the Damper Time configuration property for 45 secondswhen using a 45° box.

5. Push the gear release lever down, and turn the VMA coupler byhand to ensure that the damper can rotate from full closed to fullopen positions without binding.

6. Plug or seal the end of a hollow damper shaft to stop cold duct airfrom affecting the circuitry when the VMA is mounted in anotherenclosure.

7. Attach the pneumatic tubing to the pressure sensor with theHI (red) tubing connected to the inlet or high pressure side, andclear tubing connected to the low pressure side.

8. Route the tubing as shown below, or tape a loop in the tubing.This provides a low spot for collecting condensation.

Low Spot forCollecting Condensation

Stdmount

Figure 7: Standard Mounting


Wiring the VMAAll field wiring, with the exception of the LONWORKS Network Bus,must be kept in the same room with the controllers, to comply withUL smoke control requirements. Refer to the Metasys Smoke ControlWiring Technical Bulletin (LIT-636331) for details on smoke controlrequirements.

Refer to the project engineering drawings for wiring details.

To wire the VMA:

1. Disconnect all power to the VMA.

2. Determine if spade lugs or removable 2- or 3- position screwterminals or phone cable is to be used. See the Variable AirVolume Modular Assembly (VMA) 1200 Series Overview andEngineering Guidelines Technical Bulletin (LIT-1162350) forscrew terminal kit order number.

2-position Removable Screw Terminal ConnectorSnapons

Figure 8: Optional Removable Screw Terminals, 2- or 3-position(Accessory)

3. Terminate wiring per engineering drawings.

Table 5: Terminations for Cooling Only Applications (VMA1210)Name DescriptionAI-1 * Zone temperatureAI-2 * Zone setpointBI-1 * Temporary occupied (TE-6700 and TE-7000 [Europe only])BI-2 Comfort (occupied)BI-3 Window, off (shutdown)Zone Bus * Local communication bus* Connected through an 8-pin phone cable from the room sensor.


Table 6: Terminations for Cooling with Reheat Applications (VMA1220)Name DescriptionAI-1 * Zone temperatureAI-2 * Zone setpointAI-3 Humidity transmitter, sideloop, or CO2

AI-4 Discharge air temperatureAO-1 Primary or Secondary proportional heatBI-1 * Temporary occupied (TE-6700)BI-2 Comfort (occupied) or occupancy sensorBI-3 Window, off (shutdown)BO-1, BO-2, BO-3,BO-4, and BO-5

Fan, primary heat, secondary heat, humidity

Zone Bus* Local communication bus* Connected through an 8-pin phone cable from the room sensor

Note: AI-5 (velocity pressure) and the damper actuator motor arenot listed in either of the above tables because they are internal and nowiring is required.

Connecting the LONWORKS Network BusA connection between the VMA and the Network ControlModule (NCM) is required if the VMA is to communicate with theMetasys Network. For more information on LONWORKS Networks, seethe LONWORKS Network Layout Technical Bulletin (LIT-1162150).

To connect the LONWORKS Network Bus:

1. Connect the LonWorks Network Bus wires to the VMA, andcontinue to the next VMA. Repeat this process for each VMA.

Notes: The FTT-10 LONWORKS Network Bus is polarity insensitive.LON A and LON B terminal connections to the FTT-10 bus may beswapped between controllers.

A doubly terminated bus gives the greatest wiring distance andrequires two terminators on each FTT-10 segment. Free topologyrequires only one terminator.

Contact Johnson Controls® customer service at 1-800-275-5676, formore information about LONWORKS network needs.

http://www.esusa.com/


To NextL WCompatible

Device

ON ORKS

SHLD

ShieldLON ALON B

LON

A

LON

B

NCMConnect

To Next L WCompatibleDevice or NCM

ON ORKS

Figure 9: Connecting the VMA to an NCM2. Apply power. Locate and observe the VMA LEDs. See Tables 7

and 8 for details on the Service and Running LED.

NewLedvm

Green LED (Running)Red LED (Service)

Figure 10: VMA LED Indicator Location


(18)

BI-1

(19)

CO

M(2

0) B

I-2(2

1) C

OM

(22)

BI-3

(23)

CO

M(2

4) +

15 V

DC

*(2

5) +

15 V

DC

(26)

AI-1

(27)

CO

M(2

8) A

I-2(2

9) C

OM

(30)

AI-3

*(3

1) C

OM

*(3

2) A

I-4*

(33)

CO

M*

(34)

ZB+

Prim

ary

24 V

AC

Cla

ss2

Ener

gy L

imite

dTr

ansf

orm

er**

3-w

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2-w

ire P

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alVa

lve

Actu

ator

Set

Scr

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Scr

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Fan

Rel

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clos

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Hea

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open

clos

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BCO

M(1

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C(2

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C(3

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rth G

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(opt

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-1*

(5)

BCO

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(6)

BO-2

*(7

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OM

*(8

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3*(9

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OM

*(1

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O-4

*(1

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CO

M*

(12)

BO

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(13)

BC

OM

*(1

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O-1

*(1

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24-1

8 AW

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OR

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LO

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SHLD

Des

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Col

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inks

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6700

Figure 11: Connections to VMA1200 Series Controllers


Table 7: Service LEDColor Name State Description

Off Controller is operating properly (lightsmomentarily on power up and when service pinis pressed).

Blinking Unconfigured. Use a network management toolto configure into a network or download newfirmware.

Red ServiceLED

On Controller problem. Download new firmware.3 Blinks “Wink” command has been received.

Table 8: Running LEDColor Name State Description

Blinking Application is running normally, LED blinks atone second interval.

OnSteady

Application is not running. Try the following:1. Check the power.2. Download a new application.If Steps 1 and 2 do not resolve the problem,replace the VMA controller.

Green RunningLED

OffSteady

Application is not running. Try the following:1. Check the power.2. Download a new application.If Steps 1 and 2 do not resolve the problem,replace the VMA controller.

Controls Group507 E. Michigan StreetP.O. Box 423 www.johnsoncontrols.comMilwaukee, WI 53201 Published in U.S.A.

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