VMA1420
VMA1420
VMA1420
Introduction......................................................................................................... 2
Key Concepts...................................................................................................... 3
VMA Controller.................................................................................................................. 3
Theory of Operation .......................................................................................................... 7
Application Logic ............................................................................................................. 11
VMA Single Duct Applications......................................................................................... 21
VMA Dual Duct Applications ........................................................................................... 27
VMA Diagnostics............................................................................................................. 41
Detailed Procedures......................................................................................... 45
Creating a VMA Single Duct Application ......................................................................... 45
Creating a VMA Dual Duct Application ........................................................................... 56
Changing the VMA Parameter View ............................................................................... 63
Configuring a VMA Application ....................................................................................... 64
Commissioning a VMA Application ................................................................................. 64
Testing and Balancing a VMA Single Duct Supply/Exhaust Application ......................... 65
Testing and Balancing a VMA Dual Duct Application ..................................................... 68
Troubleshooting ............................................................................................... 73
VMA Firmware Revisions ................................................................................................ 78
Introduction
The Variable Air Volume Modular Assembly (VMA) 1400 Series is
an integrated module that includes a controller, differential pressure
sensor, and actuator (except VMA1430 models, which are intended to
be used with an external actuator).
Note: This document focuses on the VMA1410, 1420, and 1430
controllers. The VMA1400 Series also includes the VMA1440, which
is used exclusively as part of the Metasys® Zoning Package. Refer to
the Metasys Zoning Package Product Bulletin (LIT-639050) and the
Metasys Zoning Package Overview Technical Bulletin (LIT-639100)
for information on this specialized product.
This application note introduces the VMA controller and provides
procedures for the creation, configuration, and commissioning of
single duct and dual duct applications.
This document describes how to:
• create a VMA single duct application
• create a VMA dual duct application
• change the VMA parameter view
• configure a VMA application
• commission a VMA application
• test and balance a VMA single duct supply/exhaust application
• test and balance a VMA dual duct application
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 3
Key Concepts
VMA Controller
Description
The Variable Air Volume Modular Assembly (VMA) models
VMA1410 and VMA1420 are integrated modules that include the
controller, actuator, and differential pressure sensor. The VMA1430
includes the controller and differential pressure sensor and is designed
for use with a floating/3-wire (incremental) external actuator or
proportional external actuator. The VMA applications are developed
using standard objects, assembly objects and application objects
created by the Metasys system application basic programming
language. These applications are built using Configuration Tools
Release 7.00 or later, and are downloaded to the VMA. The VMA1430
is supported at Configuration Tools Release 7.02 or later.
Note: This document focuses on the VMA1410, 1420, and 1430
controllers. The VMA1400 Series also includes the VMA1440, which
is used exclusively as part of the Metasys Zoning Package. Refer to
the Metasys Zoning Package Product Bulletin (LIT-639050) and the
Metasys Zoning Package Overview Technical Bulletin (LIT-639100)
for information on this specialized product.
VMA1410 VMA1430
VMA1420
VMA14xx
Revisions
Table 1 compares HVAC PRO software revisions and VMA
application revisions. See the Troubleshooting section of this
document for more information on VMA firmware revisions.
Table 1: Revisions
HVAC PRO VMA Application Description of Changes
Software Revision Revision
7.00 2 Original Release
7.01 3 • Units attribute added for flow parameters.
• State machine fixes to prevent stuck conditions:
- VAV Box mode
- Heating mode
7.02 4 • State machine fix to prevent Cooling state when a
constant volume box (maximum flow is achieved during
Satisfied state).
• Autocalibration Duration is now calculated automatically.
• Additional actuator support for flow control loop:
- Floating/3-wire
- Proportional
• Users must set a new attribute for proportional actuators
Stroke Time.
7.03 4 Application fix to correct error in pressure dependent
operation
8.00 Single Duct – 4 Support added for TMZ Digital Room Sensor.
Dual Duct – 1 Original release of dual duct application
8.01 Single Duct – 4 Supply exhaust application added to single duct application.
Dual Duct – 2 Application fix to correct error with proportional band reset
8.03 Single Duct – 5 • State machines moved to sub-application to enable large
supply/exhaust applications to download.
• Optional minimum flow protection added for proportional
(AO, Duration Adjust Output [DAO]) box heating outputs.
Changes to both • Schedule attribute added to Occupancy Mode (ADI 78)
applications: for network command. If N2 communication fails, the
Single Duct – 5 Occupancy Mode Input is the default mode. See the Key
Concepts section for complete description.
Dual Duct – 3
• Setpoint threshold added to enable application to bypass
state machine saturation timers when a large setpoint
change occurs.
• Configurable maximum damper positions added for
pressure dependent mode.
• Pattern Recognition Adaptive Control (PRAC) disabled
for Proportional-Integral-Derivative (PID) control loops
dependent on flow when Starved Box flag is True.
• Min PID Prop Band limit added to provide a lower tuning
limit for PRAC.
• Sideloop PID Direct Acting parameter mapped (BD 171)
Continued on next page . . .
6 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Related Documentation
Table 2 lists related VMA documentation.
Theory of Operation
VAV System
A VAV air handling system typically consists of a single air handling
unit and multiple terminal units. Terminal units typically consist of a
damper and flow sensing probe installed in an enclosure. VAV
terminal units are also called VAV boxes. VAV systems are
predominantly single duct, but about 15% are dual duct designs. In
either case, the supply air temperature and static pressure of the air
handling unit are controlled by an AHU controller, while each zone
has its own VMA controller.
The air handling unit typically maintains a static pressure in the range
of 125 to 375 Pa (0.5 to 1.5 inches w.c.) inside the longest run of duct
away from the supply fan. This ensures that each VAV terminal unit
has enough pressure at its inlet to deliver the maximum required flow
of air into the space. The supply temperature is typically in the range
of 7 to 16°C (45 to 60°F) for a single duct VAV system or the cold
deck of a dual duct VAV system. The hot deck temperature of a dual
duct VAV system is typically in the range of 29 to 49°C (85 to 120°F).
VAV systems are most easily understood by first considering a cooling
only application. As the zone temperature increases, the VAV
controller opens the VAV box damper to allow more cool air to reach
the space. The volume of air required to maintain a particular zone
temperature setpoint is dictated by the size of the space and the
internal and external heat loads. In addition, since the size of the VAV
box dictates its maximum cooling capacity, a VAV box’s performance
is dependent upon the mechanical engineer’s correct box sizing for
each zone.
Sometimes the size, and thus the capacity, of the VAV box may not
match the zone loads. If the installed unit is too small, insufficient
cooling results and audible noise may be emitted at high flow. If the
installed unit is too large, proper control may be difficult to attain,
since a small change in damper position causes a large change in
airflow. Boxes can be oversized to allow for quieter operation or
reserve cooling capacity at the expense of controllability. For a more
in-depth explanation of VAV control, refer to the Variable Air Volume
Modular Assembly (VMA) 1400 Series Overview and Engineering
Guidelines Technical Bulletin (LIT-6363120).
8 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Control Loops
Proportional-Integral-Derivative (PID)
The Heating, Ventilating, and Air Conditioning (HVAC) industry uses
PID feedback control algorithms. The derivative portion is available in
the VMA, but it is typically not used because it can amplify noise and
lead to instability. Thus, PI algorithms are most commonly used in
actual installations. PI control algorithms have two parameters that
affect controller performance: proportional gain and integral time.
The HVAC controls’ manufacturer typically uses default PI control
parameters shipped with the controller. The default parameters may
not be appropriate, and using them can lead to poor control
performance. Also, many control loops require frequent re-tuning
because HVAC systems have time-varying dynamics. These dynamics
are caused by the inherent non-linear behavior of HVAC system
components and the time-varying nature of the load disturbances. The
loads for HVAC systems change with time or season.
P-Adaptive Control2
The P-Adaptive flow control algorithm uses a patented fixed gain,
proportional control loop with a self-adjusting deadband whose value
is related to an estimate of the noise variance. The P-Adaptive control
strategy is used in the secondary flow control loop for pressure
independent applications. P-Adaptive control has the advantage of
much tighter flow control without oscillation, because it dynamically
adjusts the flow deadband, based on the turbulence (noise) measured
on the pressure sensor. P-Adaptive does not require any tuning.
2
Federspiel, c., 1997. “Flow Control with Electric Actuators”,
International Journal of Heating, Ventilating, Air Conditioning,
and Refrigeration Research, Vol. 3, No 3.
10 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Airflow Measurement
Airflow (supply flow) is calculated for the VMA using
two parameters: the supply box area (area at the inlet of the box where
the airflow pickup is located), and the flow pickup gain (supply pickup
gain). Appendix B: VAV Controller Flow Calculation Constants
(LIT-6375185) provides the flow pickup gain (supply pickup gain) or
K-factor for most Original Equipment Manufacturer (OEM) boxes.
With this information, the VMA calculates the airflow (supply flow)
using the following equation:
SupplyFlow =
SupplyDeltaP
SupplyBoxArea * FlowCoefficient *
SupplyPickupGain
Alternatively, if you know the supply flow and differential pressure
(SupplyDeltaP), calculate the flow pickup gain (SupplyPickupGain)
using the following equation:
SupplyPickupGain =
2
⎛ FlowCoefficient ∗ SupplyBoxArea ⎞
SupplyDeltaP ∗ ⎜⎜ ⎟⎟
⎝ SupplyFlow ⎠
Note: Exhaust flow is calculated using the same equations.
SI (Metric) Units
SupplyFlow = airflow calculated in m3/hr (liters/second in Canada)
SupplyDeltaP = differential pressure in Pascal (1 inch w.c. = 249 Pa)
FlowCoefficient = defaults to 4644 at sea level for airflow in m3/hr or
1290 at sea level for airflow in liters per second (l/s)
(These values are a function of elevation.)
SupplyPickupGain = airflow pickup gain (dimensionless)
SupplyBoxArea = area in square meters
Inch-Pound Units
SupplyFlow = airflow calculated in cubic feet per minute (cfm)
SupplyDeltaP = differential pressure (inches w.c.)
FlowCoefficient = defaults to 4005 at sea level
(This value is a function of elevation.)
SupplyPickupGain = airflow pickup gain or K-factor (dimensionless)
SupplyBoxArea = area in square feet. Calculated from 3.1416 * r2,
where r is the inlet radius in feet.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 11
Application Logic
The VMA operates in several modes. Some modes occur under normal
operating conditions, and some are commanded only by a supervisory
system. The VAV Box mode determines which PID control loops are
active and controls VMA supervisory Command modes. The current
Occupancy mode determines the current occupancy state. Velocity
pressure status and zone temperature status determine the failsoft
functioning of the VMA.
State Diagram
The following is a brief explanation of how to read a state diagram.
See Figure 2 for a state diagram illustration.
A circle represents a state, and its name is listed in the circle. The
number in the circle corresponds to the state name in the enumeration
set for the present value. A rectangle with a shaded header bar
represents a super-state. A super-state allows related states to be
grouped under one heading.
Only one state can be active at any one time. The active state is also
the present value of the VAV Box mode. The present value can change
two ways. The present value is a prioritized attribute and can be
overridden to a new value. The present value is equal to the override
value with the highest priority.
12 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
When no overrides are present, the active state can change via a
transition (designated by an arc). Transitions may occur between both
states and super-states. The arc points from the current state
(or super-state) to the next state (or super-state). The next-state
function is described on each arc. The next-state function must be True
for the transition to occur. Any input not listed for a particular
transition is a “don’t care” condition, meaning that transition can occur
regardless of the current value of any input that is not listed.
If the transition leaves from a super-state, the transition can occur if
any of the individual states within that super-state are active. If a
transition goes to a super-state, then that super-state must have an
entry state defined. This state is designated in the diagram by a large
dot with an arrow pointing at the entry state. When more than
one level of hierarchy is defined, a super-state may be defined as the
entry state for a higher level super-state.
VAV Box Mode
Command Modes
0 1
Shutdown Shutdown
Closed Open
Auto Modes
Transition 2
2 3
State A State B
Entry
Entry State
State
Transition 1
boxmode
Autocalibration
Autocalibration first occurs after a reset of the controller. A reset is a
cycle of the controller power which causes a refresh of the memory. A
reset also occurs after an application download. During the first
autocalibration, the integrated actuator fully opens and then fully
closes to measure the stroke time. If needed, you can disable this
autorange test by setting the Startup Autorange parameter to False. If
you disable the autorange test, however, you must manually configure
the stroke time for rotations other than 90 degrees (see the Integral
Stepper Motor Actuator section under Key Concepts in this document
for more information).
During normal autocalibration, the actuator closes during the actuator
stroke time plus sensor settling time, and then the differential pressure
sensor analog input offset adjusts to give a velocity pressure reading of
zero. For the dual duct application, both pressure sensors autocalibrate
at the same time.
For the single duct supply/exhaust application, when you also select an
exhaust box, both pressure sensors autocalibrate at the same time. Due
to the critical flow requirements of most supply/exhaust
configurations, the autocalibration period default is set to zero to allow
the user to manually command autocalibration (using the Autocal Req
attribute) at a time when the zone is not occupied and the dampers are
closed.
Starting with HVAC PRO 8.05 and later, another option is available
for autocalibration using a BO to actuate a solenoid air valve when the
sensor calibration is active instead of closing the damper. During
autocalibration, the BO is set active for approximately 24 seconds
(8 times the On Pulse Count. See VMA Single Duct Parameters). At
the end of that time period, a new offset calculates for the Differential
Pressure (dP) sensor(s). The flow controller is prevented from moving
the damper actuator while the BO is active and for approximately
8 seconds after the BO deactivates. This allows the normal differential
pressure signal to restore before returning control to the flow
controller. For supply/exhaust applications, both pressure sensors
autocalibrate at the same time. Dual duct applications do not currently
support this feature.
Install the solenoid in an arrangement similar to Figure 3. When the
solenoid air valve is active and the normally closed port opens to the
common port, the low-pressure pickup port connects to both ports of
the dP sensor so that the sensor receives a zero differential pressure.
14 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Solenoid Valve c
Flow
no nc
dP Sensor
Duct
Occupancy Mode
Occupancy mode has three possible states: Occupied, Unoccupied, and
Standby (Table 3). The state depends on the input received from
binary inputs, such as window contact, occupancy sensor, or
temporary occupancy button. Communications status with a
supervisory system, and commands from a supervisory system to the
Occupancy mode request, also affect the Occupancy mode.
Temperature Setpoints
The VMA applications support highly flexible temperature setpoint
configuration options. The single duct application uses the following
equations to determine the actual heating and cooling setpoints.
Depending on the flow setpoint configuration, the dual duct
application uses either the following equations or an alternative
method described in the VMA Dual Duct Applications topic later in
this section:
Actual Heating Setpoint = Heating Setpoint + Remote Adjustment +
Common Setpoint + Actual Heating Bias + Winter Compensation
Actual Cooling Setpoint = Cooling Setpoint + Remote Adjustment +
Common Setpoint + Actual Cooling Bias + Summer Compensation
Note: The heating setpoint and the common setpoint are additive in
the Actual Heating Setpoint calculation. To prevent the Actual Heating
Setpoint from becoming a very large value, use either the common
setpoint or the heating setpoint, not both. The same applies to the
Actual Cooling Setpoint calculation.
Remote Adjustment
Connected to Analog Input 2, (AI2) this potentiometer input can be
configured using the User-Defined Ohms linearization to be defined as
a remote adjustment or remote setpoint. The default range for remote
adjust is ± 3°C (±°5°F). The default range for remote setpoint is
12-28°C (65-85°F). If the remote setpoint is selected, the heating,
cooling, and common setpoints should all be zero (see previous note).
If the remote adjustment is unreliable at startup, the controller
automatically uses the startup value. For remote adjustment, the
default startup value is 0°. For remote setpoint, the default startup
value is 21°C (70°F). If a reliable value is read and then the remote
setpoint becomes unreliable, the controller uses the last reliable value
received.
Common Setpoint
This setpoint provides the main supervisory setpoint if a single base
setpoint is specified. The VMA defaults to this configuration. If a
Remote Setpoint is used, the Common Setpoint defaults to zero.
Otherwise, the default Common Setpoint is equal to 21°C (70°F).
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 17
Temperature Loop
Temperature status is the result of failsoft monitoring of the zone
temperature analog input. It includes states described in Table 4.
Flow Loop
Flow Loop is the result of failsoft monitoring of the supply delta
pressure analog input. When the Flow Loop is reliable, it indicates the
supply differential pressure is reliable, and normal flow control is
occurring.
The Velocity Pressure (VP) Unreliable state indicates the supply
differential pressure is unreliable. The VMA operates in a pressure
dependent mode until the supply differential pressure is reliable. For
the dual duct application, if either pressure sensor is unreliable, the
controller operates in pressure-dependent mode.
Compute the required position of the damper for the single duct
(supply only) application using the following equation:
⎛ SupplySetpoint ⎞
DamperPosition = ⎜⎜ ⎟⎟ * PDSupplyMaxPos
⎝ ClgMaxFlow ⎠
For single duct applications, the supply setpoint is equal to the flow
span output during the Cooling mode (see Figure 4) and the heating
flow setpoint during the Heating modes.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 19
ExhaustDamperPos =
⎛ SupplySetpoint + Differential ⎞
⎜⎜ ⎟⎟ ∗ PDExhaustMaxPos
⎝ ClgMaxFlow ⎠
HotDeckDamperPosition =
⎛ HotDeckSetpoint ⎞
⎜ ⎟ * PDHotDeckMaxPos
⎝ HotDeckMaxFlow ⎠
Both single and dual duct applications have parameters that must be
set by the supervisory system over the N2 bus to give the current
percentage of outdoor air being brought into each deck at the main air
handler. The single duct has a single parameter (OA Fraction), and the
dual duct has two parameters (CD OA Percent and HD OA Percent).
Use the design OA fraction/percentage if the air handler maintains that
fraction/percentage. If the outdoor air included in each deck may be
different or may vary in time, program the supervisory system to
calculate the actual current fraction/percentage and set these
parameters accordingly. Percent outdoor air is measured by the
Metasys Ventilation Controller Application (MVCA) or another
outdoor airflow measurement system. Percent outdoor air is not equal
to the position of the outdoor air damper or the mixing damper,
because airflow is not directly proportional to damper position. For
more information on the MVCA, see the Metasys Ventilation
Controller (MVC-2000-1) Product Bulletin (LIT-653410).
The VMA application multiplies the occupancy level by the outdoor
air requirement to determine the required ventilation rate (OA Flow
Reqmnt). When the Occupancy Mode is Occupied, the minimum flow
setpoints of the applications are adjusted based on this ventilation rate.
When the Occupancy Mode is not Occupied, the minimum flow
setpoints are calculated without adjusting for IAQ.
The single duct IAQ minimum flow is calculated using the following
equation.
IAQ Min Flow = OA Flow Reqmnt * 100 / OA Fraction
For dual duct applications, the ventilation rate is met by the sum of the
outdoor air in the hot and cold decks. If both decks have outdoor air
available (Deck Available = True and OA Percent > 0.0), then the
actual cold and hot deck minimum flow setpoints based on IAQ are
calculated to share the outdoor air requirement across both decks
taking into consideration the relative outdoor air content of each deck.
The minimum IAQ flow for each deck is calculated using the
following equations.
OA Flow Reqmnt * 100 * CD OA Percent
CD IAQ Min Flow =
(
CD OA Percent 2 + HD OA Percent 2 )
OA Flow Reqmnt * 100 * HD OA Percent
HD IAQ Min Flow =
(
CD OA Percent 2 + HD OA Percent 2 )
If only one deck has outdoor air available, the IAQ minimum flow for
that deck is calculated by dividing the ventilation rate by the percent
outdoor air of that deck (same as single duct). This IAQ strategy works
with the existing VMA applications, is easy to alter, and optimizes
energy usage by dealing with each zone independently.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 21
Cool Loop
Flow
Setpoint
Flow Loop
Flow
Delta P
Calculation
control2
Because the supply air is cool, the zone airflow increases when the
zone temperature is above setpoint, and decreases when the zone
temperature is below setpoint. To satisfy ventilation requirements,
there is usually a minimum supply airflow.
For exterior zones, reheat coils are commonly installed at the VAV
box. If the VAV box is at its minimum flow and additional heat is
required to maintain the zone setpoint, a reheat coil is used. This is
accomplished via the actuator or electric heat control logic shown in
Figure 4. Additional supplemental heat (baseboard radiation) may also
be sequenced.
Note: In this document, supplemental heat refers to heating devices
not in the airstream of the VAV box (for example, baseboard and
radiant panels).
For more details about the PID, PRAC, and P-Adaptive, see the
Control Loops topic in the Theory of Operation section.
The automatic control modes of the VMA are Cooling, Satisfied, and
Heating (if present). The VMA automatically selects the mode
required to heat or cool the space, as necessary. If the configuration of
the controller is cooling only, or if the Heating Available parameter
(Commissioning view) is false, then the state machine does not
transition into heating. The Heating Available flag can be used to
prevent the Heating modes from being entered when heating devices
are physically present but currently unavailable (for example, the
boiler is shut off for the summer).
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 25
When the present value of VAV Box mode is equal to Heating, the
operation of the VMA is determined by the present value of the
Heating mode state machine. Figure 6 shows the logic of the Heating
mode on a separate state.
VAV Box Mode
Command Modes
3
1
Water
Shutdown System
0 Open 2 Flush 4
Shutdown Warmup Low Limit
Closed
Water System
Supply Air Temperature > Flush = True
No Overrides Zone Temperature Low Limit
Warmup Differential Contact = Active
Auto Modes
SD-VAV_Box_Mode
Heating Mode
0
No
Heating
Required
VAV Box Mode =
VAV Box Mode < > “Heating” “Heating” and Supplemental Heating PID
Zone Temp < HSP Saturation Status = Low
3
1
Box Heating PID Supplemental
Box Saturation Status = High and Heating
Heating Heating Flow Reset = True
and Heating Configuration =
“Box Only”
2 4
Supplemental Box Heating
Heating with with Full
Full Box Supplemental
Heating Supplemental Heating PID Heating Flow PID Heating
Saturation Status = High and Saturation Status = Low
Heating Flow Reset = True and Heating Configuration =
“Supplemental First”
SD-Heating_Mode
CD
CONVERT
Setpt Flow Control
Energy Heat Transfer
Balance PI Loops
with PRAC Rate to
HD (P-Adaptive)
Flow Setpoints Setpt
Working
Setpoint
Room Loop
Temperature
Transmitter DD-Overview
Figure 7: Basic Control Diagram for the VMA Dual Duct Application
Heat Transfer to Flow Setpoint Conversion for VMA Dual Duct Applications
The heat transfer rate specified by the Energy Balance PID is
converted to hot and cold deck flow setpoints based on a heat transfer
model of the dual duct box and an energy balance analysis on the zone.
For steady state conditions with the zone temperature near setpoint, the
heat transfer to the zone can be calculated using the following formula:
Q zone = Qconvert* [WCD * (TCD Tzone,SP) + WHD* (THD Tzone,SP)]
In this equation, WCD and WHD are the cold and hot deck volume flow
rates. By this definition, the heat transfer is positive when the zone is
being heated and negative when the zone is being cooled. The term
Qconvert is dependent on the flow and temperature measurement units
and is used to convert the product of flow and temperature difference
to heat transfer. Table 6 shows the values required for Qconvert.
HD Flow
Estimate CD Temp
Discharge Air
Current Deck
Temperature HD Temp
Temperatures
CD Flow CD Flow
Heat Calculate Setpoint
Transfer Flow
Rate Setpoints HD Flow
Setpoint
conversion
Flow
CD Flow dP Sensor
Calculation
CD dP
CD Flow CD CD Actuator
Setpoint P-Adaptive Command
Dual Duct Mixed Air
VAV Box to Zone
HD Flow HD HD Actuator
Setpoint P-Adaptive Command
HD dP
Flow
HD Flow dP Sensor
Calculation
controlloops
Figure 9: Flow Control Loops for the VMA Dual Duct Application
The maximum flow setpoints specify the total flow for the VAV Box
and do not vary with occupancy. The minimum flow setpoints are
specified separately for the Occupied and Unoccupied Occupancy
modes. The unoccupied flow setpoints are used when the Occupancy
mode is either Standby or Unoccupied. Depending on the values of
these five parameters, the flow schedule takes one of three basic
forms: constant volume, variable volume with mixing (or blending),
and variable volume without mixing.
To specify a constant volume flow schedule, the flow setpoints should
be equal for the Cooling Maximum Flow, Heating Maximum Flow,
and Box Minimum Flow. The sum of the Cold and Hot Deck Min
Flow setpoints should be less than this maximum flow. Figure 10
shows an example of a flow schedule. Table 7 shows the flow
setpoints for each of the example profiles.
Note: In Figures 10-12, the horizontal axis represents the range of
output of the controller (between full heating at one end of the axis and
full cooling at the other). Because PI Control is used, this axis does not
have any direct correlation to temperature or proportional bands. The
control range indices are used to allow simple representation of the
flow setpoint configuration profile.
1000 1000
Total Flow SP
CD Flow SP
HD Flow SP
Box Min Flow
Cooling Maximum Flow
500 500
0 0
1 2 3 4
Control Range constant
Flow
Setpoint Heating
Maximum Flow
500 500
0 0
1 2 3 4
Control Range varwithmix
1000 1000
Total Flow SP
CD Flow SP
HD Flow SP
Box Min Flow
Cooling Maximum Flow
Flow
Setpoint
Heating
Maximum Flow
500 500
0 0
1 2 3 4
Control Range varwithoutmix
The basic flow setpoint configuration specified by the deck and total
minimum and maximum flow setpoints is modified depending upon
the availability of each deck, the status of the warmup, cooldown, and
low limit flags, the IAQ requirements, and the discharge air
temperature low limit.
The VMA dual duct application has up to five automatic modes for
control: Satisfied, Mixing, Cooling, Heating, and Supplemental
Heating (Suppl Heating). Figure 13 shows the full state diagram for
the VAV Box mode. Each of the transition paths between the Auto
modes is designated by a letter and each path may have multiple
transition conditions. Figures 14 and 15 show specific transition
conditions for each configuration. Some transitions are used only when
the application configuration changes (for example, constant volume
during occupied and variable volume during unoccupied). Paths A-F in
Figure 13 are examples of transitions that occur in these instances.
For single duct applications, the Heating and Cooling modes are
fundamentally different processes because cooling involves
modulating the airflow while heating involves modulating a heating
device while maintaining a constant flow. Traditionally, dual duct
applications have approached the modes in a similar manner.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 37
Shutdown
No Overrides
Auto
3
C F Mixing
H
G D
M 6 A
E
5 Suppl
B
Heating Heating
N
L
K
J
P 4
2
O Cooling
Satisfied
I
DD-VAV_Box_Mode
Figure 13: VMA Dual Duct VAV Box Mode State Diagram
38 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
M
6
5
Suppl
Heating Heating
N
singlezone
I CD Cooling Max > CD Cooling Min M Suppl Heating PID Saturation = High
and Zone Temp > Cooling Setpoint and HD Heating Max > HD Heating Min
J Energy Balance PID Saturation = High N Energy Balance PID Saturation = Low
and Zone Temp < Cooling Setpoint and Suppl Heating Available = True
K Zone Temp < Heating Setpoint O Zone Temp < Heating Setpoint
and Suppl Heating Available = True and HD Heating Max > HD Heating Min
and Suppl Heating Available = False
L Suppl Heating PID Saturation = Low
and Zone Temp > Heating Setpoint P Energy Balance PID Saturation = Low
and Zone Temp > Heating Setpoint
and Suppl Heating Available = False
M
5 6
Heating Suppl
Heating
N
L
K
P J
O 2 4
Satisfied Cooling
I
separatezone
VMA Diagnostics
Data Analysis and Compression
The VMA has the ability to collect data about its inputs, outputs, and
internally calculated variables. Inside the VMA, Exponentially
Weighted Moving Averages (EWMA) minimize memory
requirements, reduce communication traffic, and provide an easy way
to analyze collected data.
The most common method for representing a large amount of data
with a single variable estimate is to calculate the mean (or average) of
the data. Means are also useful because they smooth out random data
fluctuations. When collecting data over a long period of time, it is
desirable to give a higher weighting (level of importance) to the most
recent data, since it represents current conditions more accurately than
old data. An EWMA provides both of these characteristics. The
general form used in the VMA is given below:
X k = X k-1 + λ (X k X k-1)
(
where:
(
Starved Box
The Starved Box diagnostic feature indicates when the VAV damper is
open to 100% in the Occupied mode for 10 minutes. For single duct
supply/exhaust applications, the starved status of both the supply and
exhaust are calculated independently. For the dual duct application, the
starved status of each deck is calculated separately (Starved Cold Deck
and Starved Hot Deck). This point can be trended and viewed to
diagnose a potential problem before the zone occupants complain of
discomfort. If the output of the damper command is set to 100% for
10 minutes, the starved box saturation flag is on. Once the damper
command drops below 100%, the flag is off.
When the Starved Box flag is True, the PRAC adaptive tuner is
disabled for PIDs that require flow to maintain control of the zone.
This means that in single duct applications, the Cooling PID is
disabled if Starved Box is True. Similarly, the Box Heating PID for
single duct applications is disabled if Starved Box is True and there is
no box fan active. In dual duct applications, the Energy Balance PID is
disabled if either Starved Cold Deck or Starved Hot Deck is true.
If the flag is on for an extensive period of time, use the following steps
to diagnose the problem:
1. Check the static pressure near the box inlet to ensure that enough
air is being delivered to the zone to meet maximum flow
requirements.
2. Verify the VMA design flow setpoints are correct.
3. Check the damper linkage to ensure that the box is fully open.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 43
4. Verify that the supply air temperature at the box inlet is correct.
Actuator Stall
On the VMA1410/1420, feedback to the microprocessor indicates
when the integral stepper motor has stalled. The calculated damper
position can be viewed in the SMO attribute list as Damper Output.
If the stall is greater than 5% from the estimated stall position, the
Reliability attribute indicates Stalled during Positioning.
Flow Test
A flow profile is performed for the single duct applications (without an
exhaust box) at one or more VAV boxes using the VAV Box Flow
Test function in HVAC PRO software. This test provides an automatic
means of obtaining a damper position vs. flow plot. To quickly check
if damper direction is correct, use Step Amount % = 50% and Settle
Time (0-60 s) = 15 s. The flow should increase for 0-100%.
For additional information, refer to the HVAC PRO User’s Guide.
Data Graphing
Data graphing allows you to graph up to three analog values in real
time. The data graphing feature is available under the Commission
menu in HVAC PRO software. Refer to the HVAC PRO User’s Guide
for further explanation of this feature.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 45
Detailed Procedures
Creating a VMA Single Duct Application
To create a VMA single duct application:
1. On the Options menu, click Job Information.
2. Select either English or Metric units. Click OK.
3. On the File menu, click New.
4. In the Application Group drop-down list, click VAV Applications.
5. In the Application box, click VMA Single Duct.
Note: Refer to the HVAC PRO User’s Guide for further
explanation.
6. Answer the questions as they are presented. The sequence of
questions and answers appears in Figures 16-19. An explanation of
each question and answer appears following the figure in which the
question is shown. The chosen answer for each question provides
default parameter values. The user changes those values, when
required.
1 Select the single duct VAV box control strategy:
Q1
1 Pressure independent
2 Press Indep w BO for autocal solenoid(s)
Q2
A1 A2-5
3 Fan type and output type:
1 No fan
Q4 2 Series fan - BO
3 Series fan - AO
4 Parallel fan - BO - temperature based
5 Parallel fan - BO - flow based
Continued at
Question 5
4 Exhaust Box actuator type:
1 No exhaust box
2 Position Adjust Output (floating/3-wire)
3 Analog Output (proportional)
sd_q1-4
Table 10: Select the Single Duct VAV Box Control Strategy
Option Description
Pressure A pressure independent application controls the VAV box
Independent supply flow, independent of the supply duct static pressure
variations. The controller uses a P-adaptive control
algorithm, along with a flow sensor, to modulate the supply
damper to maintain the required flow setpoint. For further
explanation of the point configuration, refer to the
Variable Air Volume Modular Assembly (VMA) 1400 Series
Overview and Engineering Guidelines Technical Bulletin
(LIT-6363120).
Press Indep w BO This option allows autocalibration using BO activated
for autocal solenoid air valve(s) that zeros the differential pressure
solenoid(s) across the velocity pressure sensor(s). It allows
autocalibration to occur without closing the damper(s). For
more information, refer to the Autocalibration topic in the
Application Logic section of this document.
5 Heating configuration:
Q5
1 None (cooling only)
2 Box heating
3 Supplemental heating (basebrd, radiant)
4 Both box and supplemental heating
A1 A2 A3 A4
6 Box heating:
1 Position Adjust Output (floating/3-wire)
Q6 Q7 Q6 2 Analog Output (proportional)
3 Duration Adjust Output
4 Binary Output (normally open valve)
5 Binary Output (normally closed valve)
Q7 6 Electric 1-stage
7 Electric 2-stages
8 Electric 3-stages
Q8
7 Supplemental heating:
1 Position Adjust Output (floating/3-wire)
2 Analog Output (proportional)
3 Duration Adjust Output
Q9 Q9
4 Binary Output (normally open valve)
5 Binary Output (normally closed valve)
6 Electric 1-stage
Heating Configuration
Choose from the options in Table 14.
10 Thermostat type:
Q10
1 No remote adjustment
2 Warmer/cooler adjust
A1-3 A4 3 Remote setpoint
4 TMZ Digital Room Sensor
5 R F Wireless -
Q11 No remote adjustment
6 R F Wireless -
Warmer/cooler adjust
7 R F Wireless -
Remote setpoint
Q12
Continued at
Question 13
Thermostat Type
The temperature setpoint calculation is described in detail in the
Key Concepts section of this document. Choose from the options in
Table 18.
16 Lighting control:
Q16 1 No lighting control
2 Start-Stop Output (on BO, off BO)
3 Pulsed Binary Output (BO w/status BI)
Table 19: Initiate Warmup Mode if Supply Air is Much Warmer than
Zone Temperature
Option Description
No No points, parameters, or logic are assigned for this answer.
The Warmup mode for this application can be activated only
by a user override of the VAV Box mode.
Supply Air Temp This option loads a network variable to allow a supervisory
Via a Network system to provide the supply air temperature to the
Variable controller. If this temperature is greater than the zone
temperature by the warmup differential, the Warmup mode
is automatically activated. When the supply air temperature
drops below the zone setpoint, the controller reverts to
normal operation.
Supply Air Temp This option loads an analog input to sense the supply air
Via a Hardware temperature. If this temperature is greater than the zone
Input temperature by the warmup differential, the Warmup mode
is automatically activated. When the supply air temperature
drops below the zone setpoint, the controller reverts to
normal operation.
Note: If the supply air temperature is measured locally
with an AI, the sensor must be mounted upstream of any
heating coils in the VAV box.
Lighting Control
The lighting output turns the lights on when the controller is in the
Occupied mode. When the controller transitions to the Unoccupied or
Standby mode, the lights turn off for two seconds and then turn back
on (blink). After the Light Shutoff Delay (user configurable with
default of two minutes), the lights turn off completely. There are
two types of lighting relays, start-stop output and pulsed binary output.
Note that only three BOs are left on the VMA1430 for lights/heating,
for example, when an incremental damper actuator is used.
Choose from the options in Table 22.
Exhaust Box
The current release of the VMA dual duct application does not support
exhaust box control.
7 Supplemental heating output type:
Q7 1 No supplemental heating
2 Position Adjust Output (floating/3-wire)
3 Analog Output (proportional)
4 Duration Adjust Output
Continued at 5 Binary Output (normally open valve)
Question 8 6 Binary Output (normally closed valve)
7 Electric 1-stage
dd_q7
Q8 8 Thermostat type:
1 No remote adjustment
2 Warmer/cooler adjust
A1-3 A4
3 Remote setpoint
4 TMZ Digital Room Sensor
Q9
9 Button for occupancy mode,
and its action when pressed:
1 No occupancy button
2 Occupied mode (timed)
Q10 3 Next mode (timed): Unocc - Standby - Occ
Figure 22: VMA Dual Duct Thermostat and Occupancy Input Questions
60 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Thermostat Type
The temperature setpoint calculation for the dual duct application is
described in the Application Logic and VMA Dual Duct Applications
topics in the Key Concepts section of this document.
Choose from the options in Table 24.
13 Lighting control:
1 No lighting control
Q13 2 Start-Stop output (on BO, off BO)
3 Pulsed Binary Output (BO w/status BI)
Lighting Control
The lighting output turns the lights on when the controller is in the
Occupied mode. When the controller transitions to the Unoccupied or
Standby mode, the lights turn off for two seconds and then turn back
on (blink). After the Light Shutoff Delay (user configurable with
default of two minutes), the lights turn off completely. There are
two types of lighting relays, start-stop output and pulsed binary output.
Note that only one BO is left on the VMA1430 for lights/heating when
two incremental damper actuators are used. Choose from the options
in Table 27.
5. Override the outputs and verify that the installed hardware actuates
correctly. If a discharge air sensor is installed, the box heat
operation can be verified by checking for temperature rise when
the box heat is activated.
6. On the Action menu, click VAV Box Flow Test (single duct
applications only). See the Flow Test topic in the Key Concepts,
VMA Diagnostics section for more details.
7. On the Action menu, click Collect VAV Diagnostics. This tool
scans the N2 trunk for VMA controllers and collects temperature,
flow and actuator diagnostics for both single and dual duct
configurations. Controllers with large errors should be examined
more closely.
Startup
Start up the test and balancing session.
Note: Before starting, ensure that the Area and Flow Coefficient
are correct for both the supply and exhaust decks. Also record the
current Pickup Gain for each deck. These parameters can be found in
the Supply Flow Config and Exhaust Flow Config parameter groups.
1. Start HVAC PRO software.
2. On the File menu, click Open.
3. Open the file corresponding to the current VMA to be balanced.
4. On the Options menu, click View > Test and Balance.
66 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Finish
To finish testing and balancing:
1. Write the new pickup gain values for the supply and exhaust
configurations (Supply Flow Config and Exhaust Flow Config
groups).
2. Override the parameter (VAV Box mode) Present Value to
Satisfied.
3. Wait 10 seconds and then release the override. This returns the
application to the necessary automatic mode.
4. On the Commission menu, click Exit Commissioning Mode.
5. Click the Exit/Save Changes button.
68 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Startup
To start up the testing and balancing session:
Note: Before starting, ensure that the Area and Flow Coefficient
are correct for both the cold and hot decks. Also record the current
Pickup Gain for each deck. These parameters can be found in the Cold
Flow Config and Hot Flow Config parameter groups.
1. Start HVAC PRO software.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 69
2
⎛ MinFlow VMA ⎞
PickupGain MinFlow = ⎜⎜ ⎟⎟ ∗ PickupGain VMA
⎝ MinFlow Hood ⎠
2
⎛ MaxFlow VMA ⎞
PickupGain MaxFlow = ⎜⎜ ⎟⎟ ∗ PickupGain VMA
⎝ MaxFlow Hood ⎠
6. Replace the (Cold Deck) Pickup Gain with the value calculated for
the minimum flow or maximum flow or an average of the two.
7. Release the overrides on (VAV Box mode) Present Value and
(Command modes) Hot Deck Available and Cold Deck Percent.
Finish
To finish test and balancing:
1. Override the parameter (VAV Box mode) Present Value to
Satisfied. Wait 10 seconds and then release the override. This
returns the application to the necessary Automatic mode.
2. On the Commission menu, click Exit Commissioning Mode.
3. Click the Exit/Save Changes button.
Note: The test and balance application overrides also can be done
via an Operator Workstation (OWS) if a second person is in
communication with the person making the overrides on the OWS.
Table 30 shows the mapping for the required parameters referenced in
the previous sections. Figure 13 shows the VAV Box mode
enumeration set.
Table 30: VMA Dual Duct Application Test and Balance Attributes
Mapped to the Metasys Network
Attribute Short Name Long Name Address
VAV Box Mode
BOXMODE Present Value ADI 67
Command Modes
CDAVAIL Cold Deck Available BD 75
HDAVAIL Hot Deck Available BD 76
CDPERCNT Cold Deck Percent ADF 71
HDPERCNT Hot Deck Percent ADF 72
Cold Deck
CDAREA Area ADF 11
CDPKUPGN Pickup Gain ADF 12
CDFLCOEF Flow Coefficient ADF 13
CDFLOSP Setpoint ADF 65
CDFLOW Cold Deck Flow ADF 36
Hot Deck
HDAREA Area ADF 14
HDPKUPGN Pickup Gain ADF 15
HDFLCOEF Flow Coefficient ADF 16
HDFLOSP Setpoint ADF 66
HDFLOW Hot Deck Flow ADF 37
Total Flow
TOTAREA Area ADF 17
TOTPKPGN Pickup Gain ADF 18
TOTFCOEF Flow Coefficient ADF 19
TOTFLOSP Setpoint ADF 67
TOTFLOW Total Deck Flow ADF 38
Autocalibration
ACREQ Autocal Request BD 70
ACACT Autocal Active BD 60
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 73
Troubleshooting
Table 31 describes known problems and their solutions.
Correct:
CSMS
"ADI140",Y,Y,"BOXHTG","Off",0,"Stage1",1,
"Stage2",2,"Stage3",3
CSMS
"ADI2",N,N,"BHACTSTG","Off",0,"Stage1",1,
"Stage2",2,"Stage3",3
Permanent Solution:
1. Install HVAC PRO Release 7.03.
2. Open the configuration files.
3. Save the file with the Generate .DDL box
checked.
VMA Binary VMA BIs and BOs are offline to Workaround:
Inputs (BIs) and Metasys software Release 10.0 or From Metasys software Release 9.01c or 10.0,
Binary Outputs earlier after commissioning with override the points and release. This
(BOs) Are Offline HVAC PRO Release 7.02. This is re-establishes communication and brings them
not an HVAC PRO software online.
problem; it is a Metasys Operator
Workstation (OWS) problem. The Permanent Solution:
BIs and BOs, which are online to Install a revision of Metasys software later than
Metasys software prior to Release 10.0.
commissioning, go offline during
commissioning, but never return to
online after commissioning is
completed. Other points mapped
into the controller return to online.
Continued on next page . . .
76 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Analog Input
The analog input provides the main process information to the VMA,
including temperature and velocity pressure measurements and
occupant setpoint adjustment. The default attributes of this input are
set up by the configuration tool, depending on the type of signal being
measured. If the analog input is unreliable at startup, the controller
automatically uses the startup value. If a reliable value is read and then
the input becomes unreliable, the controller uses the last reliable value
received. Table 34 describes the attributes for the analog input.
Note: Firmware Revision C00 or later is required to support all of
the additional setup options for the AI ranges.
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 81
Binary Input
The binary input provides digital feedback to the controller from
sensors including the temporary occupancy button, occupancy sensor,
and low limit contact. Table 35 describes the attributes for the binary
input.
Analog Output
The analog output provides a proportional voltage output signal.
Table 36 describes the attributes for the analog output.
Binary Output
The binary output is a 24 V output suitable for activating a relay, fan
starter, or two-position heating device. Table 37 describes the
attributes for the binary output.
Binary outputs are also to be used by other output types (described in
the following sections) that provide special functionality. The slot of
any BO reserved by these special output collections (PAO, DAO,
EHS, Start Stop Output [SSO]) must be changed by modifying the slot
attribute of the output collection.
When the EHS is set up as integral, there is only one make limit and
one break limit. The make limit must be greater than the break limit. In
this setup, the first BO energizes after the make limit is exceeded by
the heating command. The second BO energizes after the make limit is
exceeded again and the interstage on delay has expired. The BOs are
de-energized in reverse order. The second BO de-energizes after the
heating command drops below the break limit. After the heating
command drops below the break limit again and the interstage off
delay expires, the first BO is de-energized.
The interstage delays apply to both integral and proportional setups.
Table 41 describes the attributes of the Electric Heat Sequencer.
Table 91: VMA Single Duct Application Input and Output Attributes Mapped to the
Metasys Network
Attribute Short Name Long Name Address
Zone Temperature (AI)
ZN-T Present Value AI n
ZTREL Reliability ADI 20
Remote Adjust (AI)
W-C-ADJ Present Value AI n
RAREL Reliability ADI 21
Remote Setpoint (AI)
REM-SET Present Value AI n
RSREL Reliability ADI 22
Box Supply Temp (AI)
BOXS-T Present Value AI n
BSTREL Reliability ADI 24
Supply Delta P (AI)
S-VP Present Value AI n
DPREL Reliability ADI 23
Exhaust Delta P (AI)
E-VP Present Value AI n
EDPREL Reliability ADI 26
Sideloop Input (AI)
SLAI Present Value AI n
SLIREL Reliability ADI 25
Occupancy Button (BI)
TEMP-OCC Present Value BI n
OCCCNREL Reliability ADI 10
Occupancy Sensor (BI)
OCC-S Present Value BI n
OCCSNREL Reliability ADI 9
Low Limit Contact (BI)
LT-ALM Present Value BI n
LLCNREL Reliability ADI 11
Continued on next page . . .
110 Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note
Table 138: VMA Dual Duct Application Input and Output Attributes Mapped to the
Metasys Network
Attribute Short Name Long Name Address
Zone Temperature (AI)
ZN-T Present Value AI n
ZTREL Reliability ADI 20
Remote Adjust (AI)
W-C-ADJ Present Value AI n
RAREL Reliability ADI 21
Remote Setpoint (AI)
REM-SET Present Value AI n
RSREL Reliability ADI 22
Discharge Air Temp (AI)
DA-T Present Value AI n
DATREL Reliability ADI 24
Cold Deck Delta P (AI)
CD-VP Present Value AI n
CDDPREL Reliability ADI 26
Hot Deck Delta P (AI)
HD-VP Present Value AI n
HDDPREL Reliability ADI 27
Total Flow Delta P (AI)
TOT-VP Present Value AI n
TOTDPREL Reliability ADI 28
Sideloop Input (AI)
SLAI Present Value AI n
SLIREL Reliability ADI 25
Occupancy Button (BI)
TEMP-OCC Present Value BI n
OCCCNREL Reliability ADI 10
Occupancy Sensor (BI)
OCC-S Present Value BI n
OCCSNREL Reliability ADI 9
Continued on next page . . .
Variable Air Volume Modular Assembly (VMA) 1400 Series Application Note 131
Controls Group
507 E. Michigan Street
P.O. Box 423 www.johnsoncontrols.com
Milwaukee, WI 53201 Published in U.S.A.