Verasys ZEC510 Manual de usuario
(barcode for factory use only)
LC-ZEC510-3
Building Technologies & Solutions
www.johnsoncontrols.com
2021-04-08
*241014301485B*
Verasys ZEC510 VAV Controllers
Installation Guide
Part No. 24-10143-01485
Rev. B
2 Verasys ZEC510 VAV Controllers Installation Guide
Contents
ContentsApplications..................................................................................................................................................... 5
Installation...................................................................................................................................................... 5
Parts included...................................................................................................................................... 5
Materials and special tools needed................................................................................................... 5
Mounting......................................................................................................................................................... 6
Safety guidelines................................................................................................................................. 6
Mounting the ZEC510.......................................................................................................................... 6
Wiring.............................................................................................................................................................. 9
Input and output terminals.............................................................................................................. 10
Sensor bus terminal block...................................................................................................................... 10
Zone bus terminal block......................................................................................................................... 10
Modular ports........................................................................................................................................... 11
Supply power terminal block.................................................................................................................. 12
Wiring diagrams................................................................................................................................ 13
ZEC510-1 controller - VAV with staged reheat control wiring example............................................. 13
ZEC510-2 controller - VAV with incremental reheat control wiring example.................................... 15
ZEC510-3 controller - Multizone unit VAV with proportional reheat control wiring
example...................................................................................................................................................... 17
ZEC510 terminal functions, ratings, requirements, and wiring guidelines................................ 19
Input and output wiring guidelines....................................................................................................... 19
System and zone bus supply power wiring guidelines....................................................................... 19
Sequence of operation................................................................................................................................ 24
Occupied mode.................................................................................................................................. 24
Unoccupied mode............................................................................................................................. 24
Unit enable................................................................................................................................................ 24
Fan control (optional).............................................................................................................................. 24
Occupancy lighting switch (optional).................................................................................................... 24
Demand control ventilation (optional).................................................................................................. 25
Configuring the NS sensors........................................................................................................................ 25
Setup and adjustments............................................................................................................................... 26
Setting the ZEC510 device address................................................................................................. 26
Accessories.................................................................................................................................................... 27
Troubleshooting........................................................................................................................................... 28
Status LEDs......................................................................................................................................... 28
Communication bus problems........................................................................................................ 29
Input and output wiring problems........................................................................................................ 29
Invalid address......................................................................................................................................... 29
Duplicate addresses................................................................................................................................ 29
Correcting physical communication bus problems............................................................................. 30
Repair information....................................................................................................................................... 31
Technical specifications............................................................................................................................... 31
Verasys ZEC510 VAV Controllers Installation Guide 3
North American emissions compliance..................................................................................................... 31
United States...................................................................................................................................... 31
Canada................................................................................................................................................ 32
Product warranty......................................................................................................................................... 32
Software terms............................................................................................................................................. 32
Single point of contact................................................................................................................................. 32
Contact information..................................................................................................................................... 33
Verasys ZEC510 VAV Controllers Installation Guide4
Applications
The ZEC510 VAV controller is a component of the Verasys SMART Equipment family. The ZEC510
variable air volume (VAV) controller runs a pre-engineered HVAC zoning sequence and provides the
inputs and outputs you require for VAV applications.
The ZEC510 controller has an optional occupancy feature that makes it possible for the controller
to switch from occupied mode to standby mode based on zone activity. Standby mode maximizes
energy savings by using setpoints that are higher and lower than occupied mode setpoints.
The ZEC510 controller uses plug and play technology to detect which network sensor types are
connected. See Accessories for additional sensor information.
Use the Verasys Smart Building Hub (SBH) to configure the ZEC510 controller. Use the SBH or the
VAV Balancing Thermostat to commission the controller.
Important: Use this ZEC510 VAV controller only as an operating control. Where failure or
malfunction of the ZEC510 controller could lead to personal injury or property damage to the
controlled equipment or other property, additional precautions must be designed into the
control system. Incorporate and maintain other devices, such as supervisory or alarm systems
or safety or limit controls, intended to warn of or protect against failure or malfunction of the
ZEC510 VAV controller.
Important: Utiliser ce ZEC510 VAV controller uniquement en tant que dispositif de contrôle
de fonctionnement. Lorsqu'une défaillance ou un dysfonctionnement du controller risque de
provoquer des blessures ou d'endommager l'équipement contrôlé ou un autre équipement, la
conception du système de contrôle doit intégrer des dispositifs de protection supplémentaires.
Veiller dans ce cas à intégrer de façon permanente d'autres dispositifs, tels que des systèmes
de supervision ou d'alarme, ou des dispositifs de sécurité ou de limitation, ayant une fonction
d'avertissement ou de protection en cas de défaillance ou de dysfonctionnement du ZEC510
VAV controller.
Installation
Follow these guidelines when you install a ZEC510 controller:
• Transport the ZEC510 controller in the original container to minimize vibration and shock
damage.
• Do not drop the ZEC510 controller or subject it to physical shock.
Parts included
• One ZEC510 VAV Controller with removable system and zone buses, and power terminal blocks
• One self-drilling No. 10 mm x 25 mm (1 in.) screw
Materials and special tools needed
• 6 mm (1/4 in.) female spade terminals for input and output wiring and crimping tool or spade
mounted terminal blocks
• A small straight-blade screwdriver for securing wires in the terminal blocks
• An 8 mm (5/16 in.) wrench or a 10 mm (3/8 in.) 12-point socket to tighten the square coupler
bolt
• Shims or washers to mount the ZEC510 if necessary
• A power screwdriver
5Verasys ZEC510 VAV Controllers Installation Guide
• A 100 mm (4 in.) extension socket or a punch
• A drill
• 3.5 mm (9/64 in.) drill bits
• A pliers to open and close the damper
• 3.97 mm (5/32 in.) ID poly tubing
Mounting
Safety guidelines
Follow these safety guidelines before mounting the controller:
Important: When the air supply to the VAV box is below 10°C (50°F), make sure that
any condensation on the VAV box, particularly on the damper shaft, does not enter the
ZEC510 electronics. Mount the ZEC510 vertically above the damper shaft so that any shaft
condensation falls away from the ZEC510. Additional measures may be required in some
installations.
• Ensure that the mounting surface can support the ZEC510 and any user-supplied enclosure.
• Mount the ZEC510 on a hard, even surface.
• Use shims or washers to mount the ZEC510 securely and evenly on the mounting surface if
necessary.
• Mount the ZEC510 in an area free of corrosive vapors that matches the ambient conditions
specified in the Technical specifications section.
• Provide at least 50 mm (2 in.) on the top, bottom, sides, and front of the controller for cable
and wire connections and adequate ventilation through the controller.
• Do not mount the ZEC510 in areas where electromagnetic emissions from other devices or
wiring can interfere with controller communication.
• Avoid mounting the ZEC510 on surfaces with excessive vibration.
• Wear the appropriate personal protective equipment (PPE). For example, a hard hat, safety
glasses, steel toe boots, and gloves.
Follow these additional guidelines when mounting the ZEC510 in a panel or enclosure:
• Do not install the ZEC510 in an airtight enclosure.
• Mount the ZEC510 so that the enclosure walls do not obstruct cover removal or ventilation
through the controller.
• Mount the ZEC510 so that the power transformer and other devices do not radiate excessive
heat to the controller.
Mounting the ZEC510
To mount the controller, complete the following steps:
1. Disconnect power from the controller transformer, the VAV box fan, and heater circuits if
applicable.
2. Set all the switches on the field controller to their known settings. See Setup and adjustments.
3. Set the MS/TP address. See Setup and adjustments.
Verasys ZEC510 VAV Controllers Installation Guide6
4. Ensure that the end of line (EOL) switch is set to the off position.
5. Use the zone bus address range 4-127 for Verasys zone bus controllers.
6. Place the ZEC510 on the actuator shaft so that the wiring connections are easily accessible.
7. Ensure that the ZEC510 base is parallel to the VAV box, perpendicular to the damper shaft. If
necessary, use a spacer to offset tipping of the ZEC510 caused by the shaft bushings.
Note: Use the alignment marks to center the captive spacer to ensure sufficient
movement in either direction.
Figure 1: Captive spacer alignment marks
8. Secure the self-drilling no.10 screw through the captive spacer with a power screwdriver
and 100 mm (4 in.) extension socket. Alternatively, use a punch to mark the position of the
shoulder washer.
9. Drill a hole into the VAV box using a 5/16 in. drill bit.
10. Insert the mounting screw and tighten it against the spacer.
Important: Do not over-tighten the screw. Over-tightening can cause the threads to strip.
If you mount the ZEC to the VAV box, make sure that the screws do not interfere with
damper blade movement.
11. Locate the damper position using the marking on the end of the damper shaft.
12. Note the direction, clockwise (CW) or counterclockwise (CCW), required to close the damper.
The actuator configuration depends on the amount of rotation necessary for the damper to go
from the full-open to the full-closed position. Decide between the following options:
- For 90° rotation, install the damper in the full-closed position.
- For 45° or 60° rotation, install the damper in the full-open position.
13. Push down and hold the manual override button and turn the actuator coupler until it contacts
the mechanical end-stop at either the full-closed or full-open position.
7Verasys ZEC510 VAV Controllers Installation Guide
Figure 2: Manual override and actuator coupler
Table 1: Manual override and actuator coupler
1 Manual override button
2 Actuator coupler
14. If the damper for a 45° or 60° box closes CCW or CW, rotate the coupler to the CW mechanical
limit. This action sets the open end-stop; the closed end-stop is set by the closed damper.
For 45° and 60° boxes, you must provide hard stops at both full-closed and full-open damper
positions. If you install the ZEC510 at the full-open position, it provides the open stop for 45°
and 60° boxes. The closed damper seal provides the full-closed stop.
15. Tighten the square coupler bolt to the shaft using an 8 mm (5/16 in.) wrench or 10 mm (3/8 in.)
12-point socket. Tighten to 10.5 N·m to 11.5 N·m (95 lb·in to 105 lb·in).
16. Put a loop in the poly tubing to trap condensation when you attach the poly tubing to
the ZEC510 pressure transducer ports. Loop the poly tubing before you make the final
connections.
17. Push the manual override button, and turn the actuator coupling manually to ensure that the
actuator can rotate from the full-closed to the full-open positions without binding.
18. Rotate the damper to the full-open position.
Verasys ZEC510 VAV Controllers Installation Guide8
Wiring
WARNING
Risk of Electric Shock
Disconnect power from the controller before making any adjustments. Do not touch any part of the
printed circuit board while power is applied. Failure to follow these precautions can result in personal
injury or death.
AVERTISSEMENT
Risque de décharge électrique
Déconnecter l'alimentation du controller avant toute opération de réglage. Veiller à ne toucher aucune
partie du circuit imprimé lorsque celui-ci est sous tension. Le non-respect de ces précautions peut
provoquer des blessures graves, voire mortelles.
Important:
• Do not exceed the controller electrical ratings. Exceeding controller electrical ratings can
result in permanent damage to the controller and void any warranty.
• Do not connect supply power to the controller before finishing wiring and checking all
wiring connections. Short circuits or improperly connected wires can result in damage to
the controller and void any warranty.
• Use copper conductors only. Make all wiring in accordance with local, national, and
regional regulations.
To wire the ZEC510, complete the following steps:
1. Use the appropriate figures according to your particular configuration:
- Figure 9 and Figure 10 if you are using staged outputs for the heating control
- Figure 11 and Figure 12 if you are using incremental outputs for the heating control
- Figure 14 and Figure 15 if you are using proportional outputs for the heating control
2. Wire the network temperature sensor and CO2 sensor to the sensor bus on the ZEC510. See
Sensor bus terminal block.
Note: The CO2 sensors require a 24 VAC power supply in addition to wiring the +, -, COM,
and SA PWR terminals. For more information, refer to the NS Series CO2 Network Sensors
Installation Instructions (Part No. 24-10424-6).
3. Wire the zone bus in a daisy-chain configuration. See Zone bus terminal block.
4. Set the device address DIP switch to the appropriate address. See Setting the ZEC510 device
address.
5. If the ZEC510 is at the end or beginning of the line, set the EOL switch to the ON position.
6. Connect the ZEC510 to 24 VAC, Class 2 power.
9Verasys ZEC510 VAV Controllers Installation Guide
Input and output terminals
Sensor bus terminal block
The sensor bus terminal block is a brown, removable, 4-terminal plug that fits only into the brown,
board-mounted sensor bus jack. Wire the removable sensor bus terminal block plugs on the
ZEC510 and other field devices in a daisy-chain configuration using 4-wire twisted, shielded cable as
shown in Figure 3 and Figure 4.
Figure 3: Sensor bus terminal block wiring
Figure 4: Sensor bus daisy chaining configuration
Table 2: Sensor bus daisy chaining configuration
1 Terminating device on the sensor bus
2 Sensor bus terminal block plug on the terminating device
3 Daisy-chained device on a sensor bus segment
4 Sensor bus terminal block plug on the daisy-chained device
5 Cable shield connection
6Connects to the next device on the sensor bus. Connects to the NS-xxxx sensors. See the Accessories
section for a list of the NS-xxxx sensors.
Zone bus terminal block
The zone bus terminal block is a gray, removable, 4-terminal plug that fits only into the black,
board-mounted, zone bus jack. Wire the removable zone bus terminal block plugs on the ZEC510
and other zone bus controllers in a daisy-chain configuration using 3-wire twisted, shielded cable,
as shown in Figure 5 and Figure 6.
Verasys ZEC510 VAV Controllers Installation Guide10
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