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Zonex GEN III VVT Series Installation And Application Manual

Vote based auto changeover vav with wireless programmable thermostats
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GEN III - VVT
VOTE BASED AUTO CHANGEOVER VAV
WIRELESS PROGRAMMABLE THERMOSTATS
with
A
M O D U L A T I N G
S Y S T E M
70°
68°
75°
72°
INSTALLATION AND APPLICATIONS MANUAL

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Summary of Contents for Zonex GEN III VVT Series

  • Page 1 GEN III - VVT VOTE BASED AUTO CHANGEOVER VAV WIRELESS PROGRAMMABLE THERMOSTATS with M O D U L A T I N G S Y S T E M 70° 68° 75° 72° INSTALLATION AND APPLICATIONS MANUAL...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS OVERVIEW System Operation Component Selection Sequence Of Operation System Schematic Overview SYSTEM COMPONENTS GEN III Controller Communicating Damper Board Wireless Thermostat INSTALLATION INSTRUCTIONS GEN III Controller Damper 1 Installation Thermostat Installation / Battery Replacement COMMISSIONING AND START UP Sync Dampers To Wireless Zone Thermostats Sync Monitor Thermostat To GEN III Controller Confirm Communications...

  • Page 4: Overview

    SYSTEM OVERVIEW GEN III – VVT is a commercial modulating zone control system controlling 2-20 independent zones per unit utilizing wireless Zonex thermostats. The GEN III controller is designed for Auto Changeover, multi-stage Heat Pump (2C/3H) or Gas Electric (2C/2H) applications.

  • Page 5: Component Selection

    Part # STBP + Damper Size - Round Bypass Dampers STCDBP + Damper Size - Rectangular Bypass Dampers 1-24 VAC / 40VA Transformer to Power Bypass Damper For assistance, contact Zonex at (800) 288-2966 or visit zonexproducts.com for more information...

  • Page 6: Sequence Of Operation

    GEN III– VVT SEQUENCE OF OPERATION Vote Based Auto Changeover Bypass VAV with Programmable Wireless Thermostats GEN III controller wires to the HVAC unit with legacy style connections Y1, Y2, W1, W2, OB, G, R. Once every minute the controller communicates to each damper via RS485 connection daisy chained along with 24 V of power wired damper to damper.

  • Page 7: System Schematic Overview

    SUPPLY LAT LOCATED BEFORE THE BYPASS. RETURN LAT LAT DISCHARGE SENSORS LOCATED AFTER THE BYPASS INTEGRATED SUPPLIED WITH THE ZONEX BYPASS DAMPER (FACTORY PRE-WIRED) STATIC PRESSURE CONTROL STATIC PRESSURE TUBE LOCATED AFTER THE BYPASS BEFORE THE FIRST SUPPLY TAKEOFF BYPASS DAMPER MOTOR...

  • Page 8: System Components

    GEN III– VVT SYSTEM COMPONENTS GEN III CONTROLLER Controller Description The GEN III is a micro-controller based, auto change-over Universal Gas/Electric or Heat Pump system controller (Part #GEN III ). The GEN III controls a zoned 2H/2C Gas/Electric HVAC unit or 3H/2C zoned Heat Pump unit and communicates with and supports up to 20 zones, utilizing pressure dependent, modulating dampers and wireless thermostats.

  • Page 9: Communicating Damper Board

    GEN III– VVT COMMUNICATING DAMPER BOARD A damper board resides on each zone damper to carry power and communications information from the damper to the GEN III controller. The damper control board has four LED lights providing damper and system information.

  • Page 10: Wireless Thermostat

    GEN III– VVT GEN III WIRELESS THERMOSTAT WSTAT – Wireless GEN III Modulating Thermostat The WSTAT wireless thermostat is used in conjunction with the modulating damper to communicate calls for HEAT/COOL/VENT to the GEN III controller. Once the wireless thermostat is synced with its damper, the thermostat is polled each minute and sends information to the communicating damper board and then to GEN III controller.

  • Page 11: Installation Instructions

    GEN III– VVT INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS Wire Unit to GEN III Controller Using standard 18 ga. thermostat wire, connect GEN III unit outputs to HVAC unit. Standard HVAC control terminal designations are used, R Y1 Y2 W1(O/B) W2 G, and energize HVAC unit. 1.
  • Page 12 GEN III– VVT Install Leaving Air Temperature Sensor (LAT) ( ) to the LVAIR terminals on the GEN III controller and place the sensor in the supply duct prior to the bypass takeoff. Install Return Air Temperature Sensor (LAT) ( ) to the RA terminals on the GEN III controller and place the sensor in the return duct after the bypass takeoff.

  • Page 13: Damper 1 Installation

    GEN III– VVT DAMPER INSTRUCTIONS Dampers Install dampers into HVAC duct so damper actuators and control boards are easily accessed. Damper may be mounted in an area where the ambient temperature is between 32 and 125 degrees Fahrenheit. Round dampers should be mounted with damper actuators between 9 and 3 O’clock position. Once GEN III controller and supply dampers are installed, install 24 VAC 40 VA transformer and wire secondary 24 volts to the C R (IN - D) terminals on GEN III controller.

  • Page 14: Thermostat Installation / Battery Replacement

    GEN III– VVT WIRELESS THERMOSTAT MOUNTING AND BATTERY INSTALLATION Battery Installation/Replacement Wireless Thermostat requires two AA batteries. Expected life with thermostat in active operation is 8-9 months or longer based on end user interaction. An energy savings mode is available to prolong battery life to a year or more.

  • Page 15: Commissioning And Start Up

    GEN III– VVT COMMISSIONING AND START UP COMMISSIONING START-UP Sync Dampers and Wireless Thermostats Each Damper will need to be ID’d and Synced with its control thermostat. Beginning with the first damper in the daisy chain closest to the GEN III controller, place provided label #1 on the damper. Locate associated zone thermostat and insert batteries, confirm display appears on stat.

  • Page 16: Sync Monitor Thermostat To Gen Iii Controller

    GEN III– VVT While still in ZONE SETUP use the UP or DOWN to highlight and select item (A) SYNCHRONIZE DAMPER. Go to the damper control board and press the SYNC button and hold until blue communications light flashes continuously and then press YES on thermostat to Synchronize. When damper and stat are synced, the message SYNC IS COMPLETE will be displayed on the thermostat.

  • Page 17: Confirm Communications

    GEN III– VVT COMMISSIONING AND STARTUP Once GEN III controller is mounted, Monitor Thermostat is synced with GEN III controller and associated damper and zone stats are synced with their associated dampers, system is ready to be commissioned and started up. Prior to wiring control outputs to the HVAC unit, turn on the GEN III controller and confirm all communicating damper boards are flashing blue lights, this indicates that all dampers are powered.

  • Page 18: Set Clock

    GEN III– VVT Set Clock From the MONITOR STAT the master clock is set for all system devices. To set the clock time and day, access SYSTEM CONFIGURATION Menu on the MONITOR STAT, use the UP or DOWN buttons to highlight MENU Item 15 —...

  • Page 19: Set Fan Operation

    GEN III– VVT CONFIRM SYSTEM OPERATION Set Fan Operation Configuration of FAN is set at the factory for AUTO operation, when there is a call for HEAT or COOL, fan will run. If continuous fan is required, fan will need to be configured for fan ON and will run anytime during Occupied time, and AUTO during unoccupied.

  • Page 20: Confirm Heat Call And Damper Operation

    GEN III– VVT Confirm Heat Call and Damper Operation From the MONITOR STAT access SYSTEM CONFIGURATION MENU and highlight menu item (3) MASTER TEMP SET menu option and press select. TEMP SET ID will appear on display, using the UP and DOWN buttons, select STAT ID: GLOBAL and press NEXT button.

  • Page 21: Auxiliary Heat / Reheat / W1 First Operation

    GEN III– VVT AUXILIARY HEAT/REHEAT The Wireless Thermostat provides Auxiliary Heat options; Baseboard, Baseboard W1 and Reheat options are configured using the menu screen on the thermostat. When zone temperature drops 2 degrees below heat set point, auxiliary heat operations are energized. If configured for Reheat operation when zone temperature drops 2 degrees below thermostat set point, damper modulate to 40% open providing air flow over electric heat strips, the AUX terminal will energize and strip heat will provide reheat.

  • Page 22: Supplemental Heat - Wiring Options

    GEN III– VVT SUPPLEMENTAL HEAT APPLICATIONS BASEBOARD ELECTRIC HEAT Wire from AUX/C terminals to the 24v coil on a field supplied SPDT relay. ZONE Wire baseboard heat to the load side of the relay to the baseboard heater. DAMPER MOTOR DAMPER BOARD CONTROL...

  • Page 23: Thermostat Overview And Operation

    GEN III– VVT THERMOSTAT OVERVIEW AND OPERATION WIRELESS PROGRAMMABLE THERMOSTAT DESCRIPTION The WSTAT wireless thermostat is a microprocessor based, auto changeover, programmable communicating zone thermostat. The zone thermostat controls modulating round or rectangular commercial modulating dampers. The communicating zone thermostat is used with the GEN III-VVT zoning system and communicates over a proprietary wireless network protocol, with up to 100’...

  • Page 24: Thermostat Operation - End User Guide

    GEN III– VVT END USER THERMOSTAT OPERATION Set Thermostat Set Point Press any button to access Operations Mode of the Thermostat. Press the SET button - COOL or HEAT icon will flash on top right of the display. 70.3 If COOL icon is flashing, use the UP or DOWN buttons to raise or lower COOL set point to desired temperature.

  • Page 25: Zone Setup Menu

    GEN III– VVT Two menus are available at each zone thermostat. A Zone Setup Menu and System Configuration Menu. ZONE SETUP MENU is available from every thermostat in the system. SYSTEM CONFIGURATION MENU may be viewed on every thermostat BUT only controllable from the assigned MONITOR THERMOSTAT in the system. The ZONE SETUP MENU allows you to: A.
  • Page 26 GEN III– VVT ENERGY SAVING MODE Energy savings mode prolongs battery life and starts 30 minutes after your selection. Display will appear blank. In the Zone Setup Menu select item (D), Energy Savings Mode and press Select. ENERGY SAVING MODE ENERGY SAVING ON Use up and down buttons to toggle between Energy Savings OFF or ON EXIT...

  • Page 27: Monitor Thermostat Configuration

    GEN III– VVT Monitor Thermostat One wireless zone thermostat in the system is enabled as the Monitor Thermostat and synced with the GEN III controller to interact and initiate control decisions for the system, the Monitor coordinates global or individual schedules for the system, locks thermostats individually and provides a user interface to make adjustments and establish master temperature settings individually or globally for the system.

  • Page 28: Set Schedules

    Press and hold the Menu followed by the SET button simultaneously until system configuration is displayed. TO ENTER System Configuration Then use the Up and Down button to scroll through the System Configuration options. SCHEDULE While in SYSTEM CONFIGURATION menu, press on the SCHEDULE menu SELECT item, (instructions above).

  • Page 29: Lock Thermostats, Master Temperature Set

    Press and hold the Menu followed by the seT button simultaneously until System Configuration is displayed. TO ENTER System Configuration Then use the Up and Down button to scroll through the System Configuration options. LOCK Thermostats can be locked independently or globally through the MONITOR STAT, when a thermostat is locked, the end user will have limited operability of thermostat, with adjustment of only +/- 2°...

  • Page 30: System Diagnostic, High / Low Limit

    NEXT SCREEN Use the to set the desired OCCUPIED COOL temperature. Down Press to advance to the Occupied Heat menu. NEXT SET OCCUPIED COOL SET OCCUPIED COOL NEXT SCREEN OCCUPIED COOL THEN OCCUPIED HEAT Use the to set the desired OCCUPIED HEAT temperature. Down BACK NEXT...

  • Page 31: Second Stage Delay, Override Hours, Priority Vote

    SET button simultaneously until System Configuration is displayed. Press and hold the Menu followed by the TO ENTER System Configuration Then use the Up and Down button to scroll through the System Configuration options. SECOND Monitor thermostat is used to configure GEN III controller for TIME/TEMP or TIME only second stage operation.

  • Page 32: Fan Mode, Unit Type, Sync Monitor, Maverick Call

    Press and hold the Menu followed by the SET button simultaneously until System Configuration is displayed. TO ENTER System Configuration Then use the Up and Down button to scroll through the system configuration options. FAN MODE Fan operation is configured for either Fan ON or AUTO. When system is configured for ON operation, the Fan will run during Occupied Schedule and will revert to Auto operations during unoccupied schedule.

  • Page 33: System Air Balance, Temp Format, Clock, Password

    SET button simultaneously until system configuration is displayed. Press and hold the Menu followed by the TO ENTER System Configuration Then use the up and down button to scroll through the system configuration options. SYSTEM system diagnostic During the start up and commissioning of the system, an air balance may be required. From the System Configuration menu, use the UP or DOWN button to highlight System AIR BALANCE Air Balance and press the select button.

  • Page 34: Number Of Dampers, Lat Calibration, Morning Warm Up

    Press and hold the Menu followed by the SET button simultaneously until system configuration is displayed. TO ENTER System Configuration Then use the up and down button to scroll through the system configuration options. NUMBER Installer should set the number of dampers in the system. This reduces the time needed for the GEN III controller to poll and review each zone’s OF DAMPERS needs.

  • Page 35: Manufacturer's Default

    Press and hold the Menu followed by the SET button simultaneously until system configuration is displayed. TO ENTER System Configuration Then use the up and down button to scroll through the system configuration options. If there is a need to return the MONITOR stat and GEN III controller to factory defaults, MFG DEFAULT can be used to reset controls to the manufacturer’s defaults.

  • Page 36: Wireless Remote Sensor

    GEN III– VVT WIRELESS REMOTE SENSOR Description The wireless remote sensor part # WRS is a microprocessor based, auto changeover, programmable communicating zone thermostat without a local display. The zone sensor controls modulating round, rectangular dampers or WD-Fusers. The communicating remote sensor is used with the GEN III-VVT zoning system.

  • Page 37: Temperature Settings

    GEN III– VVT Set Auxiliary Heat: Remove the battery, set the jumper to select Base Board, Base Board W1, or Reheat. Heat band is 2 degrees. Do not set jumper while the power is on. The BB - Baseboard Heat BB W1 - Basedboard Heat First code only checks it one time right after power up.

  • Page 38: Zone Dampers

    (downstream) when the damper is closed. Round Medium Pressure Zone Dampers Zonex Systems round (part #WST size) medium pressure zone dampers are recommended for systems with a maximum differential static pressure up to 1.75”. The damper is equipped with a damper board designed to support and communicate with a Zonex wireless programmable thermostat.
  • Page 39 Sizes available from 8” x 8” up to 48” x 48” Rectangular Heavy Duty Zone Dampers (WCD) Zonex Systems rectangular heavy duty dampers are recommended for systems 7.5 tons or larger with a maximum differential static pressure of 1.75”. The damper is equipped with a damper board designed to support and communicate with a Zonex wireless programmable thermostat.
  • Page 40 For accurate selection use duct sizing table or device. WD-Fuser Zone Damper Zonex Systems D-Fuser is a combination zone damper and diffuser. It mounts in a standard 2’ x 2’ T-bar ceiling opening, providing for simple installation and easy maintenance access. The D-Fuser is a cone shaped fluidic nozzle with a platen that modulates up and down to control air flow.

  • Page 41: Slaving Zone Dampers

    GEN III– VVT SLAVING DAMPERS Slaving Up To Three Zone Dampers Up to three dampers can be directly controlled by one GEN III damper control board. The first damper must be a WST round or WCD rectangular damper, slave dampers will be STMPD round or STCD rectangular dampers without damper control boards.

  • Page 42: Bypass Dampers

    16”. Never undersize the bypass damper. Round Bypass Damper Selection The Zonex Systems STBP damper is used for round bypass applications. When you know the bypass CFM requirements, use the ROUND BYPASS SELECTION TABLE to confirm the round damper size.

  • Page 43: Slaving Bypass Dampers

    GEN III– VVT RECTANGULAR BYPASS SELECTION TABLE WIDTH IN INCHES 1000 1167 1333 1500 1667 1833 2000 2333 2667 3000 3333 3667 4000 1042 1250 1458 1667 1875 2083 2292 2500 2917 3333 3750 4167 4583 5000 1000 1250 1500 1750 2000 2250...

  • Page 44: Ipc - Static Pressure Controller

    GEN III– VVT BYPASS DAMPER WITH INTEGRATED PRESSURE CONTROL (Part # STBP or STCDBP) Bypass Damper with Integrated Pressure Control is used to control bypass operations. The bypass damper modulates to maintain static pressure as zone dampers open and close. The bypass system reduces air noise from the supply registers caused by excessive air velocity.
  • Page 45 Y outputs to unit on the zone control board and to make full cool calls on all thermostats. This will modulate dampers fully open and lock out compressor. On Zonex Systems use air balance modes for simplified bypass setup.

  • Page 46: Troubleshooting

    GEN III– VVT TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION WIRELESS THERMOSTAT THERMOSTAT NOT STAT / Damper ID Mismatch Confirm STAT ID and Damper ID Re-Sync STAT and Damper COMMUNICATING Replace Batteries and Re-Sync STAT and Damper THERMOSTAT SCREEN BLANK Thermostat in Sleep Mode Press any button to activate display, Zone Setup may be set for energy savings mode, blank screen during normal operations saves power.

  • Page 47: Fan Operation

    GEN III– VVT TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION GEN III CONTROLLER NO FLASHING No power Check 24 volt Power from transformer Check Power Switch is in ON position COMMUNICATIONS LIGHTS NO COOL CALL – Y1 LIGHT Thermostat(s) not calling for Press any button to activate display, Zone Setup may be set for energy savings mode, blank cooling...
  • Page 48 GEN III– VVT TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION DAMPER OPERATIONS NO LIGHTS ON THE No power to damper control Check 24 volt power to damper control board, R board or faulty damper control and C terminals COMMUNICATING DAMPER - If 24 volt power is present, replace damper board control board BOARD...

  • Page 50: Final System Review

    GEN III– VVT FINAL SYSTEM REVIEW MONITOR STAT - Configurations Have you SYNCED the MONITOR thermostat with GEN III controller? MENU ITEM #11 Have you confirmed TIME and DAY are correct on thermostat display? MENU ITEM #15 Is a PASSWORD required? If so, has it been set? MENU ITEM #16 Do you need to enable MORNING WARMUP? MENU ITEM #19...
  • Page 52 GEN III - VVT HOTLINE (800) 228-2966 5622 Engineer Drive, Huntington Beach, CA 92649 (714) 898-9963 | (714) 898-6802 FACTORY Quick Quote Online www.zonexproducts.com The easy way to Get Quotes Fast Part # GENIIIMAN January 2017...

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