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Honeywell W180 User Manual

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W180 ZONE CONTROL SYSTEM
W180 Zone Control System
M2815
J.F. • 4-94 • ©Honeywell Inc. 1994 • Form Number 68-0139
1
68-0139

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  • Page 1 W180 ZONE CONTROL SYSTEM W180 Zone Control System M2815 J.F. • 4-94 • ©Honeywell Inc. 1994 • Form Number 68-0139 68-0139...
  • Page 2: Table Of Contents

    If you have additional questions, need further information, or would like to comment on our products or services, please write or phone: 1. Your local Honeywell Home and Building Control Sales Office (check the white pages of your phone directory).
  • Page 3: W180 Zone Control System Overview

    See the Hardware Required section for a list of equip- — Permits separate temperature setpoints (for each zone) ment used in the W180 Zone Control System. For basic for any Temperature Profile. information on HVAC systems, see Appendix C: HVAC —...
  • Page 4: Applicable Literature

    Form Number Title 50-7626 W180 Zone Control System Brochure 60-2133 V4043A,B,E; V4044A,B; V8043A,B,E,F,J; V8044A,B,E Motorized Valves Specification NOTE: The W180 System uses only the V8043 and V8044 Low Voltage Valves. 60-2200 T675A,B; T678A Temperature Controllers 62-0104 S321A Touchpad Specification 63-2044...
  • Page 5: S321A Touchpad

    Name Description/Notes T675A1508 Temperature Controller Mount sensor in return air duct. SENSORS Table 5 lists the temperature sensors supported by the W180 System. A temperature sensor is required in each zone. TABLE 5—SENSORS. OS Number Name Description/Notes 107323A Outdoor Temperature Sensor Shield Used to house the 198212CA Outdoor Temperature Sensor.
  • Page 6: Dampers

    W180 ZONE CONTROL SYSTEM DAMPERS Tables 6 and 7 list the most commonly used damper sizes. Several other damper sizes are available. See the Honeywell ® Trol-A-Temp Zone Control Dampers Specification, form 68-0100, and D635 Zone Damper Specification, form 68-0143, for more information.
  • Page 7: Valves

    W180 ZONE CONTROL SYSTEM VALVES Table 8 lists the available valves. TABLE 8—ZONE VALVES. Flow Capacity Rating OS Number Pipe Connections De-energized Position Valve Body Pattern V8043A1003 1/2 in. flare Normally closed Straight-through V8043A1011 1/2 in. sweat V8043A1029 3/4 in. sweat V8043A1037 1 in.
  • Page 8: Specifications

    One; using HBus communications. Additional W180 ® Systems can be connected to TotalHome only through W180A CONTROLLER contact closures to the W180 input configured as a Pro- MODEL: W180A1001. file Trigger input. POWER INPUT: 24 Vac/40 VA (transformer not included, NUMBER OF ZONES: but is required).
  • Page 9: S321A Touchpad

    Shielded cable is recommended for lengths longer than SENSORS 50 ft [15m]). 198212CA Outdoor Temperature Sensor ACCESSORIES: Provides outdoor temperature readings for the W180 Shielded Cable: Suggested for wiring at distances ® System and Honeywell TotalHome System when the sys- greater than 50 ft [15m] to prevent possible electri- tems are connected together using HBus communications.
  • Page 10: C7180A Flush Mount Temperature Sensor

    W180 ZONE CONTROL SYSTEM MOUNTING: Two holes provided in base of device for T7660A/T7660B Space Temperature Sensor mounting onto wall 2 x 4 in. conduit box. The MODELS: C7130A1019 (white) model can be mounted vertically T7660A1017: beige. or horizontally. T7660B1015: with override switch and status LED.
  • Page 11: Dampers

    NOTE: If a custom-sized damper is required, it may be 20 gauge galvanized steel, 12 to 16 inch. used with an ML6161A1000 Direct Coupled Actuator DIMENSIONS: and be fully compatible with the W180 System. Damper Portion: See Fig. 9. Actuator: See Fig. 10. MODELS: Includes ML6161A1000 Actuator (35 lb.-in.
  • Page 12: D635B1005

    W180 ZONE CONTROL SYSTEM Fig. 9—D635 Damper dimensions in in. [mm]. LENGTH ALLOW MINIMUM 5 1/2 in. [14 cm] CLEARANCE FOR ACTUATOR REMOVAL AIR FLOW DIAMETER LENGTH PRESSURE DROP FLOW RATE OS NUMBER AREA IN SQ. IN. IN IN. [CM.] IN IN.
  • Page 13 W180 ZONE CONTROL SYSTEM Fig. 10—ML6161 Direct Coupled Actuator dimensions in in. [mm]. [77.8] [42.4] OPTIONAL [3.2] [25.4] AUXILIARY SWITCH [123.4] [108] [141.2] [11.9] [17.8] [3.2] [32.8] [7.9] [43.2] [86] M2063B [86.4] 68-0139...
  • Page 14: Aobd And Aobd-Bm Rectangular Dampers

    W180 ZONE CONTROL SYSTEM AOBD and AOBD-BM Rectangular Dampers MOUNTING: Install into a 3-in. [76 mm] opening in the air duct and secure using sheet metal screws provided. NOTE: Do not use static pressure regulating dampers WIRING CONNECTIONS: Screw terminals on electronic with the W180 System.
  • Page 15: Tools Required

    LISTED DAMPER WIDTH = ACTUAL AIR DUCT WIDTH TOOLS REQUIRED — Utility knife The following tools and equipment are required to in- — Voltmeter/multimeter stall a W180 Zone Control System: — Thermometer — Hammer — 3/4-inch plywood (20 in. by 17 in.) and mounting — Screwdriver (flathead) hardware suitable for the wall on which the W180A —...
  • Page 16: Pc Requirements

    Fig. 13—RS-232 Cable pin-out. W180 PROGRAMMING CABLE W180 TO 9 PIN SERIAL PORT CABLE CONNECTIONS W180 TO 25 PIN SERIAL PORT CABLE CONNECTIONS (HONEYWELL PART NO. 204119 ; WITH NULL MODEM 204169) (HONEYWELL PART NO. 204162)
  • Page 17: Determine The W180 System Requirements

    CAUTION needs a temperature sensor. A temperature zone with no damper or valve designated operates the associ- The W180 System requires an earth ground from ated heating/cooling system like a thermostat would the earth ground terminal (18 AWG or heavier in the same location.
  • Page 18 W180 ZONE CONTROL SYSTEM HVAC CONFIGURATION TABLE (Continued). Function Definition Minimum Maximum Default Anticipation For heating equipment. A value greater than 1 —Heat increases the equipment cycle rate; a value less than 1 decreases the equipment cycle rate. Recommended values: —Electric: 1.5.
  • Page 19 W180 ZONE CONTROL SYSTEM 3. Determine if power is available at the W180A Con- • On an interior wall. troller location. The W180A Controller is powered by a • Near the return air flow. separate dedicated 24 Vac transformer. When suitable power •...
  • Page 20 W180 ZONE CONTROL SYSTEM gauge that will allow a minimum of 19 Vac to be CAUTION applied to the HVAC controls. Use isolating relays to lower long loop current requirements. To prevent damage to the equipment, do not con- l. Use UL Listed/CSA Approved cable to connect to nect any voltage source greater than 24 Vac to any the 24 Vac power to the unit.
  • Page 21 Where required. WARNING Wherever possible, avoid connecting separate power sources to the same relay set common. See the W180 Zone Control System Programmer's Manual, form 69-0761, for more information regarding relay assignments. If HVAC unit is more than 100 ft [30.5m]...
  • Page 22 W180 ZONE CONTROL SYSTEM TABLE 9—WIRING (Continued). Device Mounting Location Notes 198212CA Outdoor Away from radiation from sun, preferably Accessory Cables (ft [m]): Temperature Sensor on north wall. a. 4074CAV: shielded cable, 50 [15]. b. 4074CAW: shielded cable, 100 [30.4].
  • Page 23 CONTROL POWER TO A CIRCULATION PUMP AND MOTOR. Fig. 16—Typical standard combination unit 4. CIRCULATION PUMPS MUST BE CONTROLLED THROUGH A wiring. SEPARATE RELAY OUTPUT. THE W180 WILL NOT OPERATE CORRECTLY IF PUMPS ARE CONTROLLED SOLELY BY A VALVE END SWITCH. M7110A...
  • Page 24: Determine The Temperature Profiles

    2. DO NOT MIX DAMPER TYPES ON ONE RELAY PAIR. FOR DAMPERS, CALCULATE 3. USE 24 VAC POWER SOURCE OTHER THAN THAT USED FOR POWERING THE W180. TRANSFORMER SIZE NEEDED 4. CONNECT DAMPER TO THE RELAY PAIR DESIGNATED THROUGH SOFTWARE CONFIGURATION.
  • Page 25 W180 ZONE CONTROL SYSTEM 68-0139...
  • Page 26: Installation And Wiring

    OFTEN IMPOSSIBLE TO ESTABLISH ITS RELIABILITY screws. AS AN EARTH GROUND. 4. TO AVOID POSSIBLE DAMAGE TO THE W180 CONTROLLER, DO NOT 4. Start a 3/4-inch wood screw in each of the remaining CONNECT THE EARTH GROUND TO THE SECONDARY SIDE OF THE holes.
  • Page 27 POWER OFF/ON RS232 Wire Termination Board sensor pwr sensor gnd copyright 1993, all rights reserved assy. no xxx-xxxx A 20 VDC 5 VDC –1 –9 RLY 9 24 VAC RLY 1 RLY 17 9/10 com 17/18 com 1/2 com –2 –10 EARTH GND RLY 2...
  • Page 28: Honeywell Totalhome ® System

    4. Installer must be a trained, experienced service ® Wiring and connections between the TotalHome Sys- technician. tem and the W180 System are provided by the installer of 5. The Touchpad may be mounted in a 3-gang junction ® ® the TotalHome System.
  • Page 29 W180 ZONE CONTROL SYSTEM Fig. 24—Removing the trim ring. Fig. 25—Mounting S321A Touchpad in a 3-gang junction box. 3-GANG JUNCTION BOX IN DRYWALL 6 WIRE CABLE TRIM RING M3504A ALUMINUM TRACK Fig. 26—Wiring the S321A Touchpad to the W180A Controller.
  • Page 30 W180 ZONE CONTROL SYSTEM Fig. 27—Wiring three S321A Touchpads to the W180A Controller. TOUCHPADS YELLOW DATA – GREEN YELLOW – GREEN 12 VDC JUMPER BLACK – BLOCK int. 12 VDC external – SHIELD GROUNDED AT W180A CONTROLLER CHASSIS GROUND POWER CONNECTIONS:...
  • Page 31 W180 ZONE CONTROL SYSTEM ® Fig. 29. Wiring between TotalHome and W180A Controller. W180A CONTROLLER POWER OFF/ON RS232 Wire Termination Board sensor pwr sensor gnd copyright 1993, all rights reserved assy. no xxx-xxxx A 20 VDC HBUS LABEL 5 VDC –1...
  • Page 32: High Limit Controller

    W180 ZONE CONTROL SYSTEM — Drywall without junction box (Fig. 30): HIGH LIMIT CONTROLLER a. Make sure that the location chosen is clear of studs and other possible obstructions behind the NOTES: drywall. 1. Locate the high limit controller where it will be ex- b.
  • Page 33: Sensors

    W180 ZONE CONTROL SYSTEM SENSORS Fig. 32—Shortening the bulb holder. Temperature Sensors CAUTION Disconnect the power supply before making wiring connections to prevent electrical shock or equip- ment damage. NOTES: 1. Check the ratings given in the instructions and on the...
  • Page 34: C7130A Wall Mount Temperature Sensor

    W180 ZONE CONTROL SYSTEM C7130A WALL MOUNT TEMPERATURE SENSOR Fig. 35—Typical 198212CA Outdoor Tempera- ture Sensor wiring. NOTES: 1. Locate the sensor where it will not be subject to SENSOR GND CABLE SHIELD tampering. (IF REQUIRED) 2. Locate the sensor on an inside wall about 5 ft [1.5m] above the floor.
  • Page 35: C7180A Flush Mount Temperature Sensor

    W180 ZONE CONTROL SYSTEM Install and wire C7130 Wall Mount Temperature Sen- 4. Make sure there is good air circulation at average sors as follows: temperature at the location. Avoid the following 1. Mark the area on the wall where the sensor or conduit locations because they can introduce errors in tem- box will be mounted.
  • Page 36: T7660A/T7660B Space Temperature Sensor

    W180 ZONE CONTROL SYSTEM T7660A/T7660B SPACE TEMPERATURE SENSOR TABLE 10—MOUNTING ACCESSORIES. 230517 NOTES: Type 230514 230515/16* Black 1. All wiring must conform to local codes, ordinances, Adapter Finish Mounting and regulations. Mounting Plate Plate Ring 2. Do not run space sensor wiring in the same conduit Direct to wall —...
  • Page 37 W180 ZONE CONTROL SYSTEM 2. Wire the sensor as shown in the job drawings and Figs. 40 through 42. Fig. 41—Typical T7660A Space Temperature Sensor wiring. 3. Mount the space sensor circuit board on the mount- ing plate (Fig. 43).
  • Page 38: C7600C Solid State Humidity Sensor

    W180 ZONE CONTROL SYSTEM NOTES: Fig. 43—Mounting the T7660A/T7660B Space 1. Check the ratings given in the instructions and on the Temperature Sensor circuit board on the product to make sure the product is suitable for the mounting plate. application.
  • Page 39: D635 Zone Dampers

    W180 ZONE CONTROL SYSTEM D635 Zone Dampers 2. Insert and secure the damper into the ductwork. NOTE: The damper must be kept at the full 90 NOTES: setting for proper system operation. 1. Install the motor in any location except where acid 3.
  • Page 40: Aobd Dampers

    W180 ZONE CONTROL SYSTEM 3. Applications in air ducts wider than 30 inches re- AOBD DAMPERS quire multiple dampers and damper mounting tracks Install AOBD dampers as follows: (Fig. 48). 1. Cut a 3 in. [76 mm] opening in one side of the air duct 4.
  • Page 41: Aobd-Bm Dampers

    W180 ZONE CONTROL SYSTEM Fig. 49—Installing automatic opposed blade dampers. 3 IN. [76 mm] DUCT OPENING USE 1/4 IN. [6 mm] SHEET METAL SCREWS PROVIDED. FOR LONGER DUCTS OR VERTICAL DUCT DAMPER MOTOR ACTUATOR AND DRIVE APPLICATIONS, SECURE REAR OF DUCT LINKAGE MUST BE TOWARD TOP OF DUCT.
  • Page 42: Checkout And Test

    2. See the W180 Zone Control System Owner’s Manual, a) Verify that the damper opens and closes form 69-0770, for operating information on the appropriately.
  • Page 43: Sensors

    W180 ZONE CONTROL SYSTEM 2) Verify that the heating and cooling equipment Damper Checkout operates according to the setpoints set at each Checkout the D635 Damper/ML6161 Actuator as Touchpad. follows: 3) Verify operation at each of the Auto/Heat/ 1. Disconnect the devices from the W180A Controller.
  • Page 44 W180 ZONE CONTROL SYSTEM Fig. 52—Determining damper position. ® HONEYWELL/TROL-A-TEMP AOBD THE DAMPER IS CLOSED WHEN THE CRANK ARM THE DAMPER IS OPEN WHEN THE CRANK ARM POINTS AWAY FROM THE DAMPER. POINTS TOWARD THE DAMPER. D635 ALLOW MINIMUM SET SCREWS (2) 5 1/2 in.
  • Page 45: W180 System Checkout Using Atouchpad

    5. Manually close each damper (one at a time) using the PC. Confirm that each damper closed by feeling the ab- sence of or minimal airflow through the duct vent. Program the System Refer to the W180 Zone Control System Programmer’s Manual, form 69-0761, to program the W180 System. 68-0139...
  • Page 46: Appendix A: Troubleshooting

    Touchpad 1. Turn off power to the W180A Controller. does not 2. Remove five screws to expose the W180 motherboard. respond to 3. Turn on power to the W180A Controller and monitor the two LEDs located under the relay card the W180A on the right side.
  • Page 47 W180 ZONE CONTROL SYSTEM TABLE 14—TEMPERATURE SENSORS. Problem Solution Reading 1. Verify that there are no inductive loads nearby. wrong 2. Verify that nothing is covering the sensor. temperature. 3. Verify that there is not a heating or cooling source nearby.
  • Page 48: Appendix B: Worksheets

    W180 ZONE CONTROL SYSTEM Appendix B: Worksheets Two worksheets are available to aid in programming the d. Used for Stages (1, 2, or 3). This specifies the W180A Controller: equipment function for each stage of heating or — HVAC Configuration Form: Used to gather data cooling.
  • Page 49: Homeowner Lifestyle Worksheet

    W180 ZONE CONTROL SYSTEM Stage 1: Min: 0 F; Max: 20 F; Default: 0 F. — Heat Pump: 1.0. Stage 2: Min: Stage 1 + 1 F; Max: 20 F; — Hydronic/Radiant: 0.8. Default: 4 F. b. Cooling: For cooling equipment. A value greater Stage 3: Min: Stage 2 + 1 F;...
  • Page 50 W180 ZONE CONTROL SYSTEM 68-0139...
  • Page 51 W180 ZONE CONTROL SYSTEM 68-0139...
  • Page 52: Appendix C: Hvac System Basics

    W180 ZONE CONTROL SYSTEM Appendix C: HVAC System Basics AIRFLOW CHARACTERISTICS increases. Manual dampers in each takeoff duct are Air, when enclosed, pushes equally against all sides of a adjusted after the system is installed to equalize the container. When an opening is provided in the container, air air distribution.
  • Page 53: Radial Perimeter System

    When necessary, install two rectangular dampers back-to-back; this application requires SYSTEM SIZING FOR FORCED U-channel mounting tracks, available from Honeywell, to AIR APPLICATIONS keep the damper stable under conditions of high velocity air The key to providing even, comfortable environmental flow.
  • Page 54: Valve Selection

    W180 ZONE CONTROL SYSTEM Using the graph in Fig. 5, find the maximum valve operat- b) Draw a line upward from the flow rate to the ing temperature as follows (to find maximum ambient intersection of the curve. temperature for a valve when fluid temperature is known,...
  • Page 55 W180 ZONE CONTROL SYSTEM Fig. 55—Flow characteristics of 1 Cv [0.86 kV] Fig. 57—Flow characteristics of 3.5 Cv [3.0 kV] valve. valve. PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE] PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE]...
  • Page 56 W180 ZONE CONTROL SYSTEM Fig. 59—Flow characteristics of 7 Cv [6.0 kV] Fig. 60—Flow characteristics of 8 Cv [6.9 kV] valve. valve. PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE] PRESSURE DROP, EQUIVALENT FEET OF PIPE [EQUIVALENT METERS OF PIPE] [2.4]...