Polyaire Zonemaster Variable Air Volume Guía
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. TheVAVpowertransformer(s)arettedwith3pinplugsandshouldbe
pluggedin to their own power point separate from the A/C unit.
DONOTremovetheplugandhardwiretheVAVtotheA/Cpowersupplyas
thewideuctuationsintheA/CcurrentwilldamagetheVAVunit.
2. Don’tgetconfusedbetweenDataandControlCables.
Thepackagesareclearlymarked.DataCablehasleftlatchedplugsand
Controlcablehascentrelatchedplugs
3. Alwayscheckcables:Particularlyifmakingupyourowncables.Cablesand
plugscansometimesgettwistedorbefaulty,thewiresandcontactsarevery
small. To ensure that all cables are ok pre- test with Zonemaster Cable Tester
(AvailablefromPolyaire).Thiswillhelpeliminatefaultsbefore(ratherthan
after) installation.
4. Donottapeoverthebuttonatthebottomofthedamperbladewhenattaching
exibleduct.Thisiseasytodoandwillstopthedamperturningfreely.
5. All zones MUST have their own unique address allocated via the touchpad.
IE:Ifthereare6zonesthesystemmusthave6addresses.
6. Donotplug2touchpadsintoone3wayplug.
7. VAVsystemsshouldonlybettedtoFlexibleductwithlargeenoughdiameter
toeasilytaketherequiredvolumeofair.Smallductcreatesexcessivenoise
andvortexdraughtsanddoesn’tallowthesystemtoregulateproperly.
8. ReturnAirGrillesshouldbepositionedinthesamespaceasthedesignated
“Spill”zonetoensuretheVAVsensorcanoperateproperly.
9. Substantialdifferencesinzonetemperaturewillonlybeachievedinseparate
zonesiftheseareeffectivelyseparatedfromotherzones.IEDoorsmustbe
closedtopreventcrossowfromroomtoroom.
10. Theendusershouldbefullyinformedontheunitattimeofcommissioningso
thattheyfullyunderstandtheoperationoftheVAVunit.Theendusershould
beencouragedtoreadtheusermanual.
CONTENTS
Features 1
Application 1
Components 2
Conguration 3
Installation 5
BypassControl 7
Commissioning 8
1.InitiatingandExitSettingProcess 8
2. Initialisation of Touchpad Address 9
3.RoomTemperatureSensor 9
4. Minimum Ventilation 10
5.SupplyAirSafetyHigh&LowLimits-MasterTouchpad 10
6.Spill/BypassAirSetpoint-MasterTouchpad 11
7.NamingZones-MasterTouchpad 12
8. Damper on/off Test 12
InstallationInformationSheet 13
TroubleShootingGuide 15
User Manual 16
1.ZoneTouchpad 16
2. Master Touchpad 17
3.ProgrammingMode 18
AppendixA-TechnicalSpecications 25
AppendixB-StandardCongurationofVAVSystem 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
• Manualandtimeprogrammablezonetemperaturecontrol.
• Supportsupto16zones.
• Addressofeachzoneissetdirectlyfromthetouchpad.
• Maintainsroomtemperaturewithin±1°Cusinganonboardsensor.
• LCDindicatorforzonestatusandparameterdisplay.
• User-friendlytemperatureandprogramsetting.
• Realtimeclockwithbatterybackup.
• 5-1-1programmabletemperaturesettingpointandstarttime.
• Personalisedzonelabelling.
• Autospill/bypass---thedesignatedzones/bypassareforced
open when all zones are turned off.
• Safetysystem---Opensalldampersifthesupplyair
temperatureislessthanlowlimitormorethanhighlimit.
• Allzonesautomaticallyreturntotheiroriginalon/offstateonce
power up.
APPLICATION
TheZonemasterVAV(VariableAirVolume)isafullyfeaturedsystem
designedtoaccuratelymanageairowbyzoneinDuctedreversecycle,
heatingandevaporativeairconditioningsystems.
ItmanagesairowfromtheA/Cunitbyassessingtemperaturesineach
zoneandopeningandclosingdamperstoincreaseordecreaseairowto
achieve and maintain a preset temperature in that zone.
The temperature difference that the Zonemaster can achieve will not be
lower(cooling)orhigher(heating)thanthetemperaturesetbytheACunit.
Page 1
COMPONENTS
1) Main Controller
The main controller collects and processes all the information.
2) Master Touchpad
6buttontouchpad.
Toprogramandcontrolallthezonesinthesystem.
3) Zone Touchpad
3buttontouchpad.
4) Bypass Damper and Controller (optional) Green
Dampercontrollerreceivesbypasscontrolsignalfromthe
maincontrollertoopenorclosethebypassdamper.
5) Supply Air Sensor
Supplyairsensormeasuresthetemperatureofthesupplyair.
6) Power Supply
The24VACtransformerprovidespowertotherst8touchpads
- dampers and main controller.
7) Battery
3.6Vrechargeablebatteryformaincontroller.
8) LeftLatchedDoubleAdaptor&CableKit
Double adaptor connects the main controller/touchpads via the
data bus.
9) CentreLatchedTripleAdaptor&CableKit
Tripleadaptorconnectsthe24VACpowersupplyviathe
control bus.
10)MountingBracket
For the touchpads.
Page 2
Page 3
Figure1.MainControllerConnectionDiagram
ZonemasterVAVisaserialbusbasedsystemwhichhasaControlbusand
Data bus. The Control bus provides 24VAC power for up to 8 Dampers
viathemaincontrollerasshowninFig2.
Figure2.WiringdiagramofZone1toZone8
CONFIGURATION
Main controller collects and processes all the information. The connections
tothemaincontrollerareshowninFigure1.
Page 4
The Data bus provides communication between the main controller and
the touchpads.
NOTE:TheMainControllerprovidespowerforupto8Touchpadsand
damper motors. If more than 8 touchpads and dampers are installed
auxiliarypowermustbeprovidedviaseparate24VACand9VDCpower
suppliesasshowningure3.
Figure3.WiringdiagramofZone9toZone16
Page 5
INSTALLATION
1) Removethe3coversfromthemaincontrolboard.
2) Position the main controller on top of the fan coil unit or on the
supplyairductandsecure.
3) Connectthe24VACpowersupplytotheterminalsN+Lonthemain
controllerboard.Whenturningonthepower,theredLEDwill
illuminatetoshowthatthemaincontrollerisready.
3) Mountthesupplyairsensorinthesupplyairductupstreamfromthe
motoriseddampers.Plugthesensorintothesocketonthemain
controller board.
4) Connectthebatterybypluggingintothesocketonthemain
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,asshowninFigure2.TheLCDonthe
touchpadshouldshowtheclockaftersettinga
unique address to the touchpad. (Refer to the
commissioningsection)Otherwise,checkthe
connection and the cables.
SENSORSOCKET
TOUCHPAD 1-8
TOUCHPAD 9-16
LED
24 VAC
VAV DAMPERS
BYPASS DAMPER
BATTERY CONNECTOR
BATTERY
6) Repeat step 5) to connect all the
touchpadsaccordingtoFigure2and3.
Makesureeverytouchpadisworking
correctlybycheckingtheclockandthe
temperaturedisplayedonthetouchpad.
7) Plugacontrolcableintothe‘VAV’socket
on the main board and the other end into
the‘24VacIN’portonatripleadaptor.
Plugthetripleadaptorintothemotorised
damper closest to the main board.
Warning - Only yellow Polyaire™
Dampers are compatible with the
system.
8) Useanothercontrolcabletopluginto
‘24VacOUT’portonthetripleadaptor
andtheotherendofthecableto‘24Vac
IN’portontheotheradaptorforthenext
motorised damper.
9) Follow Step 8) to connect all motorised
dampersinseriesasshowninFigure2.
10) Plugoneendofacontrolcableintothe
‘touchpad’socketonthetripleadaptor
and the other end into the socket on
the back of the touchpad.
11) Follow step 10) to connect all the
dampersandtouchpadstogether
asshowninFigure2.
Page 6
Page 7
12) Turn off the power and disconnect
the touchpad.
13) Positionthetouchpadattheright
place.Ideally,itspositionshould
beapproximately1.6metresoff
theooronthewall.Fitthedata
cableandthecontrolcablethrough
thewallcavityandconnectto
thetouchpadagain.Mountthe
touchpad onto the bracket in the
wallcavity.
Please note that the touchpad should not be
exposedtodirectsunlightandotherheat
sources.
13) Applythepoweragaintothetransformer.The
LCD should show clock time and temperature
wherethetouchpadislocatedaftershowing
‘initiate’onthesecondlineforabout15
seconds.
BYPASS CONTROL
1) Ifbypasscontrolischosenforthe
system,mountthegreendamper
controlleronthetopofagreen
motoriseddamperandplugthe
bridgecablein.
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