Equipment Controller Applications Manual

Application 2021 VAV Cooling or Heating

Overview In Application 2021, the controller modulates the supply air damper of the
terminal box for cooling and heating. In order for it to work properly, the
central air handling unit must provide cool supply air in cooling mode and
warm air in heating mode. Refer to Figures 2021-1 and 2021-2.

Figure 2021-1. Application 2021 Control Drawing.

Notes:
1. Refer to Sequence of Operation, “Control Temperature Set Points”.
2. Refer to Sequence of Operation, “Heating/Cooling Switchover”.

Figure 2021-2. Application 2021 Control Schedule.

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Hardware inputs analog

• air velocity sensor
• duct temperature sensor (optional)
• room temperature sensor
• room temperature set point dial (optional)

digital
• night mode override (optional)
• wall switch (optional)

Hardware outputs analog

• none

digital
• Autozero Module (optional)
• damper actuator

Ordering notes Terminal Box Controller–Electronic Output 540-100

Refer to System 600 Configuration and Sizing Guidelines (125-1830) for

product numbers.

Autozero Module (optional)

Damper Actuator
Duct Temperature Sensor (100K Ω) (optional)
Terminal Equipment Controller Room Temperature Sensor

Point database Table 2021-1 presents the point database information for Application 2021.
Each point number is represented on a line in the point database table. If a
point number was added or there has been a change made to the factory
default, slope, and/or intercept in Application 2021, it is called out by a (
) in
the column "Rev. VV10 or Higher."

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Sequence of The following paragraphs present the sequence of operation for Application
Operation 2021, “VAV Cooling or Heating”.

Control Depending on the controller’s current operational mode (day or night), the
temperature control temperature set point, CTL STPT (number 92) holds the value of one
set points of the following set points:

Day Mode – In day mode, CTL STPT holds the value of the point
DAY CLG STPT (number 6). If the room temperature sensor has a set point
dial and the point STPT DIAL (number 14) is set to YES, then CTL STPT
holds the value of the point RM STPT DIAL (number 13).

If the set point dial is used and the value of RM STPT DIAL is less than the
value of the point RM STPT MIN (number 11), then CTL STPT holds the
value of RM STPT MIN. If the value of RM STPT DIAL is greater than the
value of the point RM STPT MAX (number 12), then CTL STPT holds the
value of RM STPT MAX.

Night Mode – In night mode, CTL STPT holds the value of the point
NGT CLG STPT (number 8).

Note: The value of the point CTL TEMP (number 78) is the same as the
value of the point ROOM TEMP (number 4), unless CTL TEMP is
overridden.

Day and night The day/night status of the space is determined by the status of the point
modes DAY.NGT (number 29). The control of this point differs depending on
whether the controller is monitoring the status of a wall switch or if the
controller is connected to a field panel.

When a wall switch is physically connected to the termination strip on the

controller at DI 2 (Figures 2021-1 and 2021-3), and the point WALL SWITCH
(number 18) equals YES, the controller monitors the status of DI 2. When
the status of the point DI 2 (number 24) is ON (the switch is closed), then
DAY.NGT will be set to DAY indicating that the controller is in day mode.
When the status of DI 2 is OFF (the switch is open), then DAY.NGT will be
set to NIGHT indicating that the controller is in night mode.

When WALL SWITCH equals NO, the controller does not monitor the status
of the wall switch, even if one is connected to it. In this case, if the controller
is operating stand-alone, then the controller stays in day mode all the time. If
the controller is operating with centralized control (that is, it is connected to a
field panel), then the field panel can send an operator or PPCL command to
override the status of the point DAY.NGT. Refer to Powers Process Control
Language (PPCL) User’s Manual (125-1896) and Field Panel User’s Manual
(125-1895) for more information.

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Night mode If an override switch is present on the room temperature sensor and a value
override switch (in hours) other than zero has been entered into the point OVRD TIME
(number 20), then by pressing the override switch a room occupant can
reset the controller to day operational mode of the time period that is set in
OVRD TIME. The status of the point NGT OVRD (number 21) changes to
DAY. After the override time elapses, the controller returns to night mode
and the status of NGT OVRD changes back to NIGHT.

It is only when the controller is in night mode that the override switch on the
room sensor will have any effect on the controller.

Heating/cooling There are three options for the heating/cooling switchover for this
switchover application. In order for the controller to function properly, one of the
following three options must be used:

a. A temperature sensor is installed in the supply air ductwork. The

controller uses the measured temperature point, SUPPLY TEMP
(number 15), to determine whether it is in heating or cooling mode.

When SUPPLY TEMP is below the value of the point COOL TEMP
(number 61), the controller sets the point HEAT.COOL (number 5) to
COOL, switching the controller to cooling mode.

When SUPPLY TEMP is above the value of the point HEAT TEMP
(number 62), the controller sets HEAT.COOL to HEAT, switching the
controller to heating mode.

b. If the controller is connected to a field panel, then the field panel can
command SUPPLY TEMP.

When SUPPLY TEMP is commanded below the value of

COOL TEMP, the controller sets HEAT.COOL to COOL, switching the
controller to cooling mode.

When SUPPLY TEMP is commanded above the value of

HEAT TEMP, the controller sets HEAT.COOL to HEAT, switching the
controller to heating mode.

c. If the controller is connected to a field panel, then the field panel can
switch the controller between heating and cooling modes by
commanding HEAT.COOL to HEAT or COOL.

Control loops The terminal box is controlled by three Proportional, Integral, and Derivative
(PID) control loops; two temperature loops and a flow loop.

Temperature Loops – The two temperature loops are a cooling loop and a
heating loop. The active temperature loop maintains room temperature at the
value in the point CTL STPT (number 92). Refer to “Control Temperature
Set Points”.

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The cooling temperature loop generates cooling loopout which is then used
to generate the point FLOW STPT (number 93). FLOW STPT is the result of
scaling the cooling loopout to the appropriate range of values determined by
the points CLG FLOW MIN (number 31) and CLG FLOW MAX (number 32).
In order to scale it, the loopout is multiplied by the range (MAX−MIN) and
then added to the minimum set point.

When CLG FLOW MIN does not equal 0 CFM, then FLOW STPT does not
equal the point CLG LOOPOUT (number 79). The minimum flow set point is
(CLG FLOW MIN÷CLG FLOW MAX)×100% flow. And FLOW STPT is
[CLG LOOPOUT×(100%−minimum set point)]+minimum set point.

For example:

If CLG FLOW MIN=200 CFM and CLG FLOW MAX=1000 CFM

then, the minimum flow set point is

(200 CFM÷1000 CFM)×100% flow=20%

When CLG LOOPOUT is 0%, FLOW STPT equals 20% flow.

[0%×(100%–20%)]+20%=20%
This ensures that the air flow out of the terminal box is no less
than CLG FLOW MIN.

When CLG LOOPOUT is 50%, FLOW STPT equals 60% flow.

[50%×(100%–20%)]+20%=60%

When CLG LOOPOUT is 100%, FLOW STPT equals 100% flow.

[100%×(100%–20%)]+20%=100%

The heating temperature loop generates heating loopout which is then used
to generate the FLOW STPT. FLOW STPT is the result of scaling the heating
loopout to the appropriate range of values determined by the points
HTG FLOW MIN (number 33) and HTG FLOW MAX (number 34). In order to
scale it, the loopout is multiplied by the range (MAX–MIN) and then added to
the minimum set point.

When HTG FLOW MIN does not equal 0 CFM, then FLOW STPT does not
equal the point HTG LOOPOUT (number 80). The minimum flow set point is
(HTG FLOW MIN÷HTG FLOW MAX)×100% flow. And FLOW STPT is
[HTG LOOPOUT×(100%–minimum set point)]+minimum set point.

For example:

If HTG FLOW MIN=100 CFM and HTG FLOW MAX=1000 CFM

then, the minimum flow set point is

(100 CFM÷1000 CFM)×100% flow=10%

When HTG LOOPOUT is 0%, FLOW STPT equals 10% flow.

[0%×(100%–10%)]+10%=10%

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This ensures that the air flow out of the terminal box is no less
than HTG FLOW MIN.

When HTG LOOPOUT is 50%, FLOW STPT equals 55% flow.

[50%×(100%–10%)]+10%=55%

When HTG LOOPOUT is 100%, FLOW STPT equals 100% flow.

[100%×(100%–10%)]+10%=100%

Flow Loop – The flow loop maintains minimum air flow and maximum air
flow through the points CTL FLOW MIN (number 76) and CTL FLOW MAX
(number 77).

When the controller is in cooling mode, CTL FLOW MIN equals

CLG FLOW MIN and CTL FLOW MAX equals CLG FLOW MAX.

When the controller is in heating mode, CTL FLOW MIN equals

HTG FLOW MIN and CTL FLOW MAX equals HTG FLOW MAX.

In Application 2021, you can set CLG FLOW MIN equal to, but not greater
than, CLG FLOW MAX and set HTG FLOW MIN equal to, but not greater
than, HTG FLOW MAX. If the minimum and maximum values are set equal,
then the flow loop becomes a constant volume loop and its ability to control
temperature is lost.

The flow loop maintains FLOW STPT by modulating the supply air damper
point, DMPR COMD (number 48). The flow loop maintains the air flow
between CTL FLOW MIN and CTL FLOW MAX.

The point FLOW (number 75) is the input value for the flow loop. It is
calculated as a percentage based on where the point AIR VOLUME
(number 35) is between 0 CFM and CTL FLOW MAX. In the following text,
this percentage will be referred to as % flow.

• If AIR VOLUME equals 0 CFM, then FLOW is 0% flow.

• If AIR VOLUME equals CTL FLOW MAX, then FLOW is 100% flow.

The low limit of FLOW STPT will be the percentage that corresponds to the
volume given in CTL FLOW MIN. This percentage can be calculated as:
(CTL FLOW MIN÷CTL FLOW MAX)×100% flow. The flow loop ensures that
the supply air will not be less than CTL FLOW MIN.

For example:

If CTL FLOW MIN equals 250 CFM, and if CTL FLOW MAX equals
1000 CFM

then,

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the low limit of FLOW STPT=(250 CFM÷1000 CFM)×100% flow

=0.25×100% flow
=25% flow

Since 25% of 1000 CFM equals 250 CFM, the minimum air flow out of
the terminal box will be 250 CFM.

Calibration Calibration of the controller’s internal air velocity transducers is periodically

required to maintain accurate air velocity readings. The point CAL SETUP
(number 95) is set with the desired calibration option during controller
startup. Depending upon the value of CAL SETUP, calibration may be set to
take place automatically or manually. If the status of the point CAL AIR
(number 94) is YES, then calibration is in progress.

• For a controller used without an Autozero Module (point

CAL MODULE, (number 87)=NO), the damper is commanded closed
to get a zero air flow reading during calibration.
• For a controller used with an Autozero Module (CAL MODULE=YES),
calibration occurs without closing the damper.

At the end of a calibration sequence, CAL AIR returns to NO automatically. A

status of NO indicates that the controller is not in a calibration sequence.

Damper status Under normal operation the point DMPR STATUS (number 84) reads “CAL”.
operation However, if using an Autozero Module, it is possible after a period of
operation for the calculated damper position point, DMPR POS (number 49),
to differ from the actual (physical) damper position.

If this occurs, the controller will automatically compensate for any difference
by setting DMPR STATUS to“RECAL” which readjusts the value of
DMPR POS. DMPR STATUS will be set to “RECAL” if all of the following
conditions are true:

DMPR POS = 100%

AIR VOLUME (number 35) > 0 CFM
FLOW < FLOW STPT

-or-

DMPR POS = 0%
AIR VOLUME > 0 CFM
FLOW (number 75) > FLOW STPT (number 93)

Note: To change the value of DMPR STATUS from “RECAL” back to

“CAL,” set DMPR STATUS to CAL, and then release it.

The Autozero Module is enabled when it is wired to DO 6 and the point

CAL MODULE (number 87) is set to YES.

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Fail-safe operation If the air velocity sensor fails, then the controller uses pressure dependent
control. The temperature loop controls the operation of the damper.

If the room temperature sensor fails, then the controller operates using the
last known temperature value.

Application notes 1. If the temperature swings in the room are excessive or if there is
trouble in maintaining the set point, then either the cooling loop, the
heating loop or both need to be tuned. If the point FLOW (number 75)
is oscillating while the point FLOW STPT (number 93) is constant,
then the flow loop requires tuning. Refer to System 600 Maintenance
and Troubleshooting Manual (125-1855) for more information.

2. The Terminal Box Controller – Electronic Output, as shipped from the

factory, keeps all associated equipment OFF. Refer to the “Equipment
Controllers” tab in System 600 Start-up Manual (125-1851) for
information on how to release the controller and its equipment to
application control.

3. Spare DOs can be used as auxiliary points that are controlled by the
field panel after being defined in the field panel’s database. DO 3 and
DO 4 or DO 5 and DO 6 may be used as auxiliary motor points. If
using a pair of spare DOs to control a motor, you must unbundle the
corresponding motor command point.

Wiring diagram The point wiring for Application 2021 is shown in Figure 2021-3.

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CAUTION:
The Terminal Box Controller controls 24 Vac loads only. The maximum rating is 12
VA for each DO. For higher VA requirements, 110 or 220 Vac requirements, or DC
power requirements, use an interposing 220 V 4-relay module (P/N 540-147).

Figure 2021-3. Application 2021 Wiring Diagram.

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Table 2021-1. Point Database for Application 2021.

Rev. Point Descriptor Factory Default Engr. Units Slope Intercept On Text Off Text
VV10 or Number (SI Units) (SI Units) (SI Units) (SI Units)
Higher

01 CTLR ADDRESS 99.000 -- 1.000 0.000 -- --

02 APPLICATION 2091 -- 1.000 0.000 -- --
{04} ROOM TEMP 74.000 (23.449) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
{05} HEAT.COOL COOL -- -- -- HEAT COOL
06 DAY CLG STPT 74.000 (23.449) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
07 DAY HTG STPT 70.000 (21.209) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
08 NGT CLG STPT 82.000 (27.929) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
09 NGT HTG STPT 65.000 (18.409) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
11 RM STPT MIN 55.000 (12.809) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
12 RM STPT MAX 90.000 (32.409) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
{13} RM STPT DIAL 74.000 (23.449) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
14 STPT DIAL NO -- -- -- YES NO
{15} SUPPLY TEMP 74.000 (23.496) DEG F (DEG C) 0.500 (0.280) 37.500 (3.056) -- --

18 WALL SWITCH NO -- -- -- YES NO
{19} DI OVRD SW OFF -- -- -- ON OFF
20 OVRD TIME 0.000 HRS 1.000 0.000 -- --
{21} NGT OVRD NIGHT -- -- -- NIGHT DAY
{24} DI 2 OFF -- -- -- ON OFF
{29} DAY.NGT DAY -- -- -- NIGHT DAY

31 CLG FLOW MIN 220.000 CFM (LPS) 4.000 (1.888) 0.000 -- --
(103.818)

32 CLG FLOW MAX 2200.000 CFM (LPS) 4.000 (1.888) 0.000 -- --
(1038.180)

33 HTG FLOW MIN 220.000 CFM (LPS) 4.000 (1.888) 0.000 -- --
(103.818)

34 HTG FLOW MAX 2200.000 CFM (LPS) 4.000 (1.888) 0.000 -- --
(1038.180)

{35} AIR VOLUME 0.000 CFM (LPS) 4.000 (1.888) 0.000 -- --
36 FLOW COEFF 1.000 -- 0.010 0.000 -- --

Notes:
1. Points not listed are not used in this application
2. A single value in a column means that the value is the same in English units and in SI units.
3. Point numbers that appear in brackets {} may be unbundled at the field panel.

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Table 2021-1. Point Database for Application 2021.

Rev. Point Descriptor Factory Default Engr. Units Slope Intercept On Text Off Text
VV10 or Number (SI Units) (SI Units) (SI Units) (SI Units)
Higher

{37} MTR3 COMD 0.000 PCT 0.400 0.000 -- --

{38} MTR3 POS 0.000 PCT 0.400 0.000 -- --

39 MTR3 TIMING 130.000 SEC 1.000 0.000 -- --
{41} DO 1 OFF -- -- -- ON OFF
{42} DO 2 OFF -- -- -- ON OFF
{43} DO 3 OFF -- -- -- ON OFF
{44} DO 4 OFF -- -- -- ON OFF
{45} DO 5 OFF -- -- -- ON OFF
{46} DO 6 OFF -- -- -- ON OFF
{48} DMPR COMD 0.000 PCT 0.400 0.000 -- --
{49} DMPR POS 0.000 PCT 0.400 0.000 -- --
51 MTR1 TIMING 95.000 SEC 1.000 0.000 -- --
{52} MTR2 COMD 0.000 PCT 0.400 0.000 -- --
{53} MTR2 POS 0.000 PCT 0.400 0.000 -- --
55 MTR2 TIMING 130.000 SEC 1.000 0.000 -- --
56 DMPR ROT ANG 90.000 -- 1.000 0.000 -- --
58 MTR SETUP 0.000 -- 1.000 0.000 -- --
59 DO DIR. REV 0.000 -- 1.000 0.000 -- --
61 COOL TEMP 65.000 (18.456) DEG F (DEG C) 0.500 (0.280) 37.500 (3.056) -- --
62 HEAT TEMP 80.000 (26.856) DEG F (DEG C) 0.500 (0.280) 37.500 (3.056) -- --
63 CLG P GAIN 20.000 (36.000) -- 0.250 (0.450) 0.000 -- --

64 CLG I GAIN 0.010 (0.018) -- 0.001 (0.0018) 0.000 -- --
65 CLG D GAIN 0.000 -- 2.000 (3.600) 0.000 -- --
66 CLG BIAS 0.000 PCT 0.400 0.000 -- --
67 HTG P GAIN 10.000 (18.000) -- 0.250 (0.450) 0.000 -- --

68 HTG I GAIN 0.010 (0.018) -- 0.001 (0.0018) 0.000 -- --
69 HTG D GAIN 0.000 -- 2.000 (3.600) 0.000 -- --
70 HTG BIAS 0.000 PCT 0.400 0.000 -- --

Notes:
1. Points not listed are not used in this application
2. A single value in a column means that the value is the same in English units and in SI units.
3. Point numbers that appear in brackets {} may be unbundled at the field panel.

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Table 2021-1. Point Database for Application 2021.

Rev. Point Descriptor Factory Default Engr. Units Slope Intercept On Text Off Text
VV10 or Number (SI Units) (SI Units) (SI Units) (SI Units)
Higher

71 FLOW P GAIN 0.250 -- 0.050 0.000 -- --

72 FLOW I GAIN 0.020 -- 0.001 0.000 -- --
73 FLOW D GAIN 0.000 -- 2.000 0.000 -- --
74 FLOW BIAS 50.000 PCT 0.400 0.000 -- --

{75} FLOW 0.000 PCT 0.250 0.000 -- --

{76} CTL FLOW MIN 220.000 CFM (LPS) 4.000 (1.888) 0.000 -- --
(103.818)

{77} CTL FLOW MAX 2200.000 CFM (LPS) 4.000 (1.888) 0.000 -- --
(1038.180)
{78} CTL TEMP 74.000 (23.449) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --
{79} CLG LOOPOUT 0.000 PCT 0.400 0.000 -- --
{80} HTG LOOPOUT 0.000 PCT 0.400 0.000 -- --

{84} DMPR STATUS CAL -- -- -- RECAL CAL

87 CAL MODULE NO -- -- -- YES NO

{91} TOTAL VOLUME 0.000 CF (L) 4.000 (113) 0.000 -- --
{92} CTL STPT 74.000 (23.449) DEG F (DEG C) 0.250 (0.140) 48.000 (8.889) -- --

{93} FLOW STPT 0.000 PCT 0.250 0.000 -- --
{94} CAL AIR NO -- -- -- YES NO
95 CAL SETUP 4.000 -- 1.000 0.000 -- --
96 CAL TIMER 12.000 HRS 1.000 0.000 -- --
97 DUCT AREA 1.000 (0.093) SQ. FT (SQ M) 0.025 (0.002) 0.000 -- --
98 LOOP TIME 5.000 SEC 1.000 0.000 -- --
{99} ERROR STATUS 0.000 -- 1.000 0.000 -- --

Notes:
1. Points not listed are not used in this application
2. A single value in a column means that the value is the same in English units and in SI units.
3. Point numbers that appear in brackets {} may be unbundled at the field panel.

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