TCX 850 Installation Guide. Andover Controls Corporation. Downloaded from -

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1 TCX 850 Installation Guide Andover Controls Corporation Downloaded from - i

2 Version F Reproduction or distribution forbidden. Copyright 1997 by Andover Controls. Subject to change without notice. Order No Copyright 1997 Andover Controls Corporation 300 Brickstone Square Andover, Massachusetts All Rights Reserved. Published by the Engineering Department at Andover Controls Corporation. IMPORTANT NOTICE This product is subject to change without notice. This document does not constitute any warranty, express or implied. Andover Controls Corporation reserves the right to alter capabilities, performance, and presentation of this product at any time. ii TCX 850 Installation Guide

3 Preface The Andover Controls TCX 850 Installation Guide presents instructions for installing the TCX 850 on an Infinet network. It first presents site preparation information and then step-by-step installation instructions. Andover Controls Corporation iii

4 iv TCX 850 Installation Guide

5 Contents Setting Up the TCX 850 Controller and Infinet Site/System Setup Requirements...2 Controller Dimensions and Weight...3 Power Requirements...3 Cable Limitations...3 Lightning Protection...4 Building Ground Requirements...4 Inspecting the Ground...5 Environmental Requirements...5 Output Equipment Requirements...5 Input Circuit Specifications...6 Special Factors for Thermistors...6 Air Flow Sensor Requirements...8 Laying Out the Site Setup...8 Installing the TCX Unpacking...9 Parts Required...9 Mounting...9 Connecting the Battery...11 Connecting the AC Power...11 Wiring the Infinet to the TCX Wiring the Infinet to the Infinity CX Andover Controls Corporation v

6 Wiring the Inputs...16 Connecting the Air Flow Sensor...20 Wiring the Outputs...27 Wiring Tristate Output...27 Wiring Form A Outputs...27 Connecting Modules to the Expansion Port...28 Powering Up the TCX Reset Button...30 Setting the Air Flow Potentiometers...30 Completing the Installation...30 Connecting the Andover Controls Service Tool...30 vi TCX 850 Installation Guide

7 Figures Figure 1. The Front of the TCX Figure 2. Locations of Screw Holes and Parts Inside TCX Figure 3. Diagram of the TCX 853 Controller...13 Figure 4. Metal Plate and Screw for AC Power Wire...14 Figure 5. Infinet Cable Wiring to FASTON Receptacles...15 Figure 6. Schematic of Input Wiring for Thermistor...18 Figure 7. Schematic of Wiring for Counter or Digital Input...18 Figure 8. Schematic of Wiring for Voltage Input...18 Figure 9. Schematic of Wiring for Current Input Figure 10. TCX 850 Connecting Tubes/Wiring Air Flow Sensor in VAV Box (VAV Cooling Only)...22 Figure 11. TCX 850 Connecting Tubes/Wiring Air Flow Sensor in VAV Box (One Stage Electric Heat)...23 Figure 12. TCX 850 Connecting Tubes/Wiring Air Flow Sensor in VAV Box (Two Stage Electric Heat)...24 Figure 13. TCX 850 Connecting Tubes/Wiring Air Flow Sensor in VAV Box (One Stage Electric Heat and One Fan)...25 Figure 14. TCX 850 Connecting Tubes/Wiring Air Flow Sensor in VAV Box (Two Stage Electric Heat and One Fan)...26 Figure 15. Schematic of Tristate Output Wiring...27 Figure 16. Schematic of Form A Output Wiring...28 Andover Controls Corporation vii

8 Tables Table 1. Table 2. Table 3. Wire Gauges and Corresponding Maximum Runs for Sensing Temperatures Up to 70º F...7 Wire Gauges and Corresponding Maximum Runs for Sensing Temperatures Up to 100º F...7 Wire Gauges and Corresponding Maximum Runs for Sensing Temperatures Up to 150º F...8 viii TCX 850 Installation Guide

9 Setting Up the TCX 850 Controller and Infinet This manual covers the following: Site/System Setup Requirements Installing the TCX 850 or any controller in the TCX 850 family All of the instructions in this manual referring to the TCX 850 apply to the other TCX controllers, except those for the air flow sensor, found only on the 850 model. Warranty Registration Your warranty is effective for 18 months starting on the date the system is shipped. Warning All wiring and installations must comply with local, state, and national electrical codes.

10 Site/System Setup Requirements Hardware Installation Before you proceed to install the system, you should map out where you plan to install each controller, terminal/workstation, and modem. When planning the sites, be aware of any electrical interference that may occur. You also need to be aware of cabinet dimensions, power requirements, cable limitations, and environmental requirements. Note This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions in this manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Note This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. Avis Le présent appareil numérique n émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la class A prescrites dans le Règlement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada. 2 TCX 850 Installation Guide

11 Controller Dimensions and Weight Each TCX 850 is in. and weighs 2.5 lbs. Power Requirements Caution The TCX 850 should receive power from its own independent, unswitched circuit. The TCX 850 operates on a power supply of 24 VAC +/ 20% 50 or 60 Hz (for smoke control applications, +10/ 15%, 60 Hz). The TCX 850 consumes 20 VA of power. Cable Limitations The maximum cable length for Infinet is 4,000 ft at 19,200 baud (up to 32 Infinet controllers). You can extend Infinet beyond 4,000 ft or put more than 32 Infinet controllers on less than 4,000 ft by using the InfiLink 200 amplification module. Note You must use shielded cables for Infinet to ensure compliance with the Class A FCC limits and to provide reliable communications. Cables that form Infinet are 24-gauge, single-twisted-pair, tinned, shielded copper wire. Use the following cables 1 or their equivalents: Brand Rex # H 9002 (single-pair) Anixter # 9J (single-pair plenum cable) The cable should have a nominal impedance of 100 Ohms and a nominal velocity of propagation of 78%. 1. You can also use any cables you may already have in place for ACNET or LBU. TCX 850 Installation Guide 3

12 Capacitance of Infinet cable should be nominal, below 12.5 pf/ft between conductors and below 22 pf/ft between the conductor connected to ground and the next conductor. Lightning Protection Each TCX 850 has two 1500 V spark gap capacitors and a metal oxide varistor built into the board to protect against line transients. However, this protection is not sufficient to protect against lightning. Lightning arresters are required at each point where Infinet cable enters or exits a building. Use the following arrester: Two pair gas tube arrester, Andover Controls # Building Ground Requirements Warning Be sure that all Infinity products from Andover Controls Corporation are grounded to true earth ground. This kind of ground protects the equipment from transients and other power surges in the area. We cannot guarantee that the controller system will operate as documented unless you properly ground all controllers. Warning Be sure to have your grounds inspected before you begin the installation process to be sure your municipality follows the National Electrical Code. Many municipalities do not and often have substandard electrical grounds. An example of a substandard ground is a galvanized steel cold water pipe. As the pipe corrodes, it does not act as a true ground. The corrosion acts as an insulator, raising the potential of the pipe with respect to the ground. 4 TCX 850 Installation Guide

13 When lightning strikes in the area of the installation, it drastically changes the potential of the earth. Since properly grounded Andover Controls units respond to changes in potential more rapidly than poorly grounded electrical systems, a poorly grounded building tries to reach ground through the Andover Controls system. The surge of current can destroy electronic components on the controller board. Surges of much lower potential than lightning also impact the reliability of Andover Controls equipment. Inspecting the Ground You can check your ground as follows: 1. Check your ground by first inspecting the building power distribution panel for earth ground termination. If the ground termination is any of the following, it is not adequate and must be corrected: Does not exist. Is connected to a corroded or galvanized pipe. Is connected using a small gauge wire (less than 14 AWG). 2. Be sure your Andover Controls cabinet is connected to the ground with a copper conductor that terminates at the distribution panel. Environmental Requirements The TCX 850 operates in rooms with temperatures ranging from 32 to 120 F and with humidity up to 85%, non-condensing. The controller must be in an Underwriter Laboratories listed enclosure. Output Equipment Requirements The four outputs on the TCX 850 provide direct digital control for electronic devices and bi-directional motors and actuators. The first three outputs are Form A (single pole, single throw) and the fourth is Form K tristate. TCX 850 Installation Guide 5

14 Both types of outputs have pulse width modulation (PWM). PWM lets you modulate valves and dampers to 0.1 sec resolution. All outputs are programmable. Since there is no manual override switch, the controller always controls all outputs. The Form A relay of each output is rated for 5 A at 50 VAC. Input Circuit Specifications Caution Andover Controls inputs are designed to be used with two-wire devices and do not provide sufficient power to operate sensors or transducers requiring an external power supply. The following specifications apply to the four TCX 850 inputs: Voltage Range 0 to V Resolution V Accuracy +/ V Maximum Pulse Frequency 5 Hz at a duty cycle of 50% with a minimum pulse width of 100 ms Input Impedance 10KΩ referenced to V Filtering Corner Frequency at 15 Hz, 20 db/decade Over-Voltage Protection 24 VAC RMS or 24 VDC indefinitely on any single channel; +/ 1500 V transient for 50 µs on all channels Calibration Permanent (factory) Special Factors for Thermistors To keep thermistor errors minimal, lay out your site so you can limit the length of wire runs to the maximum for the gauge wire you select. 6 TCX 850 Installation Guide

15 Table 1 shows the maximum runs for wires of various gauges to keep errors within.5 F,.25 F, and.10 F when sensing temperatures up to 70 F. Table 1. Wire Gauges and Corresponding Maximum Runs for Sensing Temperatures Up to 70 F Gauge 1 /2 F Error 1 /4 F Error 1 /10 F Error #14 26,700 ft 13,300 ft 5300 ft #16 16,700 ft 8300 ft 3300 ft #18 10,500 ft 5200 ft 2100 ft # ft 3300 ft 1300 ft # ft 2000 ft 800 ft Table 2 shows the maximum runs for wires of various gauges to keep errors minimal when sensing temperatures up to 100 F. Table 2. Wire Gauges and Corresponding Maximum Runs for Sensing Temperatures Up to 100 F Gauge 1 /2 F Error 1 /4 F Error 1 /10 F Error #14 12,600 ft 6300 ft 2500 ft # ft 3900 ft 1500 ft # ft 2500 ft 1000 ft # ft 1500 ft 600 ft # ft 900 ft 300 ft Table 3 shows the maximum runs for wires of various gauges to keep errors minimal when sensing temperatures up to 150 F. TCX 850 Installation Guide 7

16 Table 3. Wire Gauges and Corresponding Maximum Runs for Sensing Temperatures Up to 150 F Gauge 1 /2 F Error 1 /4 F Error 1 /10 F Error # ft 2000 ft 800 ft # ft 1300 ft 500 ft # ft 800 ft 300 ft # ft 500 ft 200 ft # ft 300 ft 100 ft Air Flow Sensor Requirements Air flow sensors each require a 5 micron air filter that is shipped with the TCX 850. Each also requires two 1/4-in OD pneumatic tubes for connecting the pitot tube or cross flow sensor to the air flow sensor. The pneumatic tubes can be up to 15 in. long Laying Out the Site Setup You may want to draw a map of where you plan to put each controller and store it in a notebook. Find the tag attached to each controller that gives the number of the controller. Before you remove any tags, be sure the tag has all of the following information on it: Location of the controller. Serial number. Model name and number. Communications port the Infinet connects to on Infinity CX Then collect the tags. You will need to know where your controllers are located when you later assign a name to each controller and each input and output. 8 TCX 850 Installation Guide

17 Installing the TCX 850 Unpacking Be careful when unpacking the unit to not damage the packaging material you must reuse it if you ship the product back for repair. Parts Required TCX 850 Controller AC Power Cable Input and Output Wires Two 1/4-in. Diameter Tubes for Air Flow Sensor Three to six varistors 5-micron Ramay Filter (shipped with TCX 850) Infinet Cable (twisted pair) InfiLink 200s as Hubs, Repeaters, or Cable Switching Boxes Mounting Caution You must encase the TCX 850 in a UL listed cabinet to keep its Open Class rating. 1. Before you begin, look at the top of the TCX 850 cabinet. Figure 1 shows the front and top of the TCX The top of the TCX 850 has a finger-cutout. Insert your index finger in the cutout and pull. The snap latch releases and the front cover disconnects from the unit. 3. Remove the front cover and place it to one side. TCX 850 Installation Guide 9

18 Figure 1. The Front of the TCX 850 Finger Cutout MIN MAX SP CPU TD RD 10 TCX 850 Installation Guide

19 Warning Never drill holes in the TCX 850 cabinet or boards. A metal shaving could easily short circuit the electronics. 4. Screw the TCX 850 to the wall using standard No. 6 screws in the.156 diameter pre-cut holes in the four corners of the base plate. Figure 2 shows the location of the corner screw holes. It also shows the locations of the openings on the side of the TCX 850 that access inputs, outputs, and the Infinet connection. Note that many parts are labeled in this drawing. You may want to refer to this figure throughout the installation process for locations of other parts. Connecting the Battery When you have the controller mounted, find the AA battery in the lower right corner (see Figure 2). Remove the plastic tab under the clip on the battery to activate the battery. The battery is a 850 ma-hr 3.6 V primary lithium battery that maintains RAM when AC power goes out. Connecting the AC Power Warning Be sure the AC power cable is not connected to an electrical power source while you are wiring the controller, or you could receive an electrical shock that is life-threatening The AC power connection is in the upper left corner of the controller (see Figure 2). You must wire the AC cable to the three screws on the far left. TCX 850 Installation Guide 11

20 Figure 2. Locations of Screw Holes and Parts Inside TCX PLACES.72 2 PLACES PLACES G N D N E U H O T IN1 RET IN2 RET IN3 RET IN4 RET + Inputs AC Power Connection High Port P PLACES INPUT 8 C OUT1 NO C OUT2 NO C OUT3 NO C OUT4 + + ON IN5 IN6 IN7 MIN MAX SP Potentiometers Low Infinet Port Connection P2 Reset Button Service Port ON SHLD + Outputs Expansion Module Battery + (The TCX 851 is the same as the TCX 850, but it has only the first four inputs.) 12 TCX 850 Installation Guide

21 Figure 3 shows the TCX 853 controller. This particular controller has inputs and outputs similar to those on the TCX 850, only in this case 7 and 8 are both air flow sensors. Figure 3. Diagram of the TCX 853 Controller G N D N E U H O T IN1 RET + C OUT1 NO C OUT2 NO C OUT3 Outputs Inputs IN2 RET IN3 RET IN5 RET Inputs + NO C OUT4 + ON ON IN4 IN6 RET RET INPUT 7 INPUT 8 + SHLD + TCX 850 Installation Guide 13

22 Caution Be sure to connect all three wires, HOT, NEUTRAL, and GROUND. Otherwise, the controller could malfunction. Note the parts of the controller labeled here. You may want to refer to this figure for assistance in locating parts during the installation process. The three screws are labeled HOT NEU GND. The three wires at the end of your AC cord are black, white, and green. Take the following steps to connect the AC power wire: 1. Place the green wire under the metal plate behind the top screw, labeled GND. 2. Tighten the screw with a flathead screw driver. Figure 4 shows the position of the plate, where to place the wire, and how the screw fits on the plate. You can see how the screw holds the plate in place once you tighten it. Figure 4. Metal Plate and Screw for AC Power Wire Metal Plate Insert Wire Here 3. Place the white wire under the metal plate behind the middle screw, labeled NEU. 4. Tighten the screw with a flathead screw driver. 5. Place the black wire under the metal plate behind the bottom screw, labeled HOT. 6. Tighten the screw with a flathead screw driver. 14 TCX 850 Installation Guide

23 Wiring the Infinet to the TCX 850 Figure 5 illustrates how to wire the Infinet cable to the FASTON terminals in the lower right corner of the TCX 850. Figure 5. Infinet Cable Wiring to FASTON Receptacles WHITE WHITE + BLACK SHLD BLACK 1. Trim back the shield over the wires. 2. Using a right angled fast-on connector, clip the appropriate wire to the first terminal labeled with a plus sign. 3. Using a right angled fast-on connector, clip the appropriate wire to the first terminal labeled with a minus sign. 4. Using a right angled fast-on connector, clip the appropriate wire to the second terminal labeled with a plus sign. 5. Using a right angled fast-on connector, clip the appropriate wire to the second terminal labeled with a minus sign. Later when you want to break the Infinet for testing purposes, you need only disconnect one set of wires. 6. Connect the shields from both the first and second controllers to the terminal labeled SHLD. Use a right angled fast-on connector to clip the shield to the terminal. Wiring the Infinet to the Infinity CX 9000 You connect the last piece of Infinet cabling to the Infinity CX See the Infinity CX 9000 Hardware Installation Guide for instructions. TCX 850 Installation Guide 15

24 Wiring the Inputs Caution Do not remotely ground any part of the sensor wiring. Remote grounds connected to the TCX 850 return terminal could make the controller operate incorrectly or damage the equipment. The signal return is not true earth ground. It is an electronic reference point necessary to interpret the sensor properly. Do not externally ground sensor or switch terminals that return to the TCX 850. Caution Although inputs usually function properly with unshielded sensor wire, you may need shielded wire if you run the wire as follows: In the same conduit with other noise-generating conductors such as 60 Hz AC power. In long runs close to large power-consuming or power-generating equipment that can produce 60 Hz noise. We recommend you run input wiring in a conduit separate from AC power or output wiring and avoid long wiring runs. 16 TCX 850 Installation Guide

25 Caution Follow the rules below when wiring inputs and outputs: Never lay wires across the surface of the printed circuit board. You should bring input wires in from the left and output wires in from the right. Bundle excess wires toward the back of the cabinet to avoid any contact with circuit boards. Wires should never be within 1 in. of any component on the printed circuit board. Keep cabinet free of foreign materials (extra power supplies, relays, and so on). Be careful when stripping wire not to drop small pieces of wire inside the cabinet. If you violate any of these rules, the controller could malfunction. Caution Never apply a voltage to a thermistor. Doing so alters the thermistor s accuracy and reliability. You should replace a thermistor that has had voltage applied to it. Never bring a soldering iron to within 3 inches of the thermistor s sensing tip. The first four inputs are on the upper left side of the TCX 850, below the AC power connection. Notice that the inputs are labeled IN1, RET, IN2, RET and so on. Each return terminal goes with the preceding input. Inputs 5, 6, and 7 are labeled MIN, MAX, and SP, in that order. They are to the right side of the TCX 850, below the outputs. Input 8 is the air flow sensor connection just below and to the left of the center on the TCX 850 board. Input 8 has the P1 and P2 port labels. TCX 850 Installation Guide 17

26 Figure 6 shows a thermistor attached to an input point. One lead connects to the numbered input terminal, the other to a return terminal. Figure 6. Schematic of Input Wiring for Thermistor IN1 (input point 1) RET (return) Follow these steps to connect Inputs 1 through 4: 1. Using a right angled fast-on connector, clip the first wire for the first sensor to the terminal labeled for input Again, using a right angled fast-on connector, clip the ground wire for the first sensor to the first terminal labeled RETURN. 3. Repeat the steps 1 and 2 for each input. Figure 7 shows a counter wired to an input point. Figure 7. Schematic of Wiring for Counter or Digital Input 1 (input point 1) RET (return) Figure 8 shows a voltage sensor wired to an input point. Figure 8. Schematic of Wiring for Voltage Input 1 (input point 1) V RET (return) 18 TCX 850 Installation Guide

27 Figure 9 shows a current sensor wired to an input point. You must wire a resistor across the input. Figure 9. Schematic of Wiring for Current Input V Ref = R Pullup = 10K 1 (input point 1) R Sensor = 249Ω with wattage rating 1 --Watt 4 RET (return) The exact number of Ohms resistance required varies based on the range of current while we recommend 249Ω for a 0 to 20 ma input, you can also calculate the appropriate resistance with the following formula: VIN = RS 10K Imax RS + 10K For 20 ma (the maximum current), the input voltage is approximately 5 V if you have a sensor resistance of 249 Ω. The input voltage must be between 0 and V. To account for the input current rising slightly above the maximum (such as slightly over 20 ma), you should choose a value slightly below the maximum resistance that solves the equation. You then select the next standard resistor with a 0.1% or 1% tolerance. (The accuracy of the input is directly proportional to the tolerance of the resistor. So the lower the tolerance, the greater the accuracy.) The wattage rating should be greater than or equal to watt. Be sure you check the Andover Controls Infinity CX Programmer s Guide for details on how to convert the voltage from a current input to other units. TCX 850 Installation Guide 19

28 Connecting the Air Flow Sensor Follow these steps to connect Input 8, the air flow sensor: 1. Attach the 5 micron filter to one piece of 1/4-in. OD tubing for the air flow sensor. 2. Run the tubing through the side opening on the controller. 3. Connect one end of the tubing with the filter on it to the sensor tube marked high port (P1) on the controller. See Figure 10 to determine where you connect the 1/4-in. tubing to the controller and to the VAV box. This drawing illustrates how to wire the inputs for a VAV box that does cooling only. 4. Connect the other end of the tubing to the HI opening on the VAV box. 5. Connect one end of the tubing with no filter on it to the sensor tube marked low port (P2) on the controller. 6. Connect the other end of the tubing to the LO opening on the VAV box. 7. When you wire the damper motor on the VAV box (again, see Figure 9), you connect a varistor from the COMMON connection to the OPEN connection and from the COMMON connection to the CLOSE connection. When the contact is open (the motor stopped), the magnetic field in the motor produces a large electrical spike. Varistors at the source arrest the spike. 20 TCX 850 Installation Guide

29 Caution In rare cases, you may install varistors at the alternate location (shown in Figures 10 through 14), but if you do, you must not directly terminate them to the TCX 850 or the controller will fail. Figure 11 shows the VAV connections for cooling with one stage electric heat. Figure 12 shows the VAV connections for cooling with two stage electric heat. Figure 13 shows the VAV connections for cooling with one stage electric heat and one fan. Figure 14 shows the VAV connections for cooling with two stage electric heat and one fan. TCX 850 Installation Guide 21

30 g Fi To Other VAV Boxes As Required TCX 850 to VAV Terminations (VAV Cooling Only) 39 V Varistor VAV Box 39 V 24 VAC See Note 120 VAC 120 V Constant Fused Power Earth Ground 39 V Varistors (Alternate Location If Absolutely Necessary) 39 V Varistors (Preferred Location) COM OPEN CLOSE AIR FLOW 24 VAC OUTPUTS INPUTS 1/4 Inch O.D. Tygon or Equivalent Tubing for Distances Less Than or Equal To 15 Inches (TYP) High Port Low Port PARTS LIST OUT IN FILTER Note Direction of Filter ( + ) ( + ) ( ) ( ) + - SHLD INFINET ANDOVER CONTROLS BOX MANUFACTURER S Qty Part No. Description Qty. Part No. Description VAC Varistor VAC to 24 VAC Transformer Micron Ramay Filter Bi-Directional Damper Motor TCX Mounted on Plate Control Wire Tubing (1/4 Inch O.D.) Sheet Metal Screws Typical TCX 850 Enclosure (Not Necessarily Provided by Andover Controls) Varistors should be installed at actuators if possible. If alternate position must be used, varistors must not be directly terminated to TCX or TCX failure may occur. Note: If the installation requires the secondary of the 24V transformer to be grounded, always connect the "neutral" to ground and only ground it at the transformer. 22 TCX 850 Installation Guide

31 u g Fi 39 V Varistor TCX 850 to VAV Terminations (VAV Cooling Only with One Stage Electric Heat) VAV Box Heater Control Circuit COM Stage 1 To Other VAV Boxes As Required 39 V 24 VAC See Note 120 VAC 120 V Constant Fused Power Earth Ground 39 V Varistors (Alternate Location If Absolutely Necessary) 39 V Varistors (Preferred Location) COM OPEN CLOSE E L E C T R C R E H E A T AIR FLOW OUTPUTS 24 VAC INPUTS High Port Low Port 1/4 Inch O.D. Tygon or Equivalent Tubing for Distances Less Than or Equal To 15 Inches (TYP) Relay 39 V Varistor Installed Across Relay Coil OUT IN PARTS LIST FILTER Note Direction of Filter ( + ) ( + ) ( ) ( ) + SHLD - INFINET ANDOVER CONTROLS BOX MANUFACTURER S Qty. Part No. Description Qty. Part No. Description VAC Varistor VAC to 24 VAC Transformer Micron Ramay Filter Bi-Directional Damper Motor TCX Mounted on Plate Control Wire Tubing (1/4 Inch O.D.) Sheet Metal Screws VAC, DPDT, 10 A Relay Typical TCX Enclosure (Not Necessarily Provided by Andover Controls) Varistors should be installed at actuators if possible. If alternate position must be used, varistors must not be directly terminated to TCX or TCX failure may occur. Note: If the installation requires the secondary of the 24V transformer to be grounded, always connect the "neutral" to ground and only ground it at the transformer. I TCX 850 Installation Guide 23

32 g Fi 39 V Varistor TCX 850 to VAV Terminations (VAV Cooling Only with Two Stage Electric Heat) VAV Box COM OPEN CLOSE E L E C T R Heater Control Circuit COM Stage 1 To Other VAV Boxes As Required 39 V 24 VAC See Note 230 VAC Earth Ground 120 V Constant Fused Power 39 V Varistors (Alternate Location If Absolutely Necessary) 39 V Varistors (Preferred Location) C R E H E A T AIR FLOW OUTPUTS 24 VAC INPUTS High Port Low Port 1/4 Inch O.D. Tygon or Equivalent Tubing for Distances Less Than or Equal To 15 Inches (TYP) 39 V Varistor Installed Across Relay Coil OUT IN FILTER Note Direction of Filter ( + ) ( + ) ( ) ( ) + SHLD - INFINET PARTS LIST ANDOVER CONTROLS BOX MANUFACTURER S Qty. Part No. Description Qty. Part No. Description VAC Varistor VAC to 24 VAC Transformer Micron Ramay Filter Bi-Directional Damper Motor TCX Mounted on Plate Control Wire Tubing (1/4 Inch O.D.) Sheet Metal Screws VAC, DPDT, 10 A Relay Typical TCX Enclosure (Not Necessarily Provided by Andover Controls) Note: If the installation requires the secondary of the 24V transformer to be grounded, always connect the "neutral" to ground and only ground it at the transformer. Varistors should be installed at actuators if possible. If alternate position must be used, varistors must not be directly terminated to TCX or TCX failure may occur. I 24 TCX 850 Installation Guide

33 u g Fi TCX 850 to VAV Terminations (VAV Cooling Only with One Stage Electric Heat and One Fan (Integral or Constant)) 39 V 24 VAC 120 VAC COM OPEN CLOSE VAV Box E L E C T R C R E H E A T Heater Control Circuit COM Stage 1 To Other VAV Boxes As Required 39 V Varistor See Note Earth Ground 120 V Constant Fused Power 39 V Varistors (Alternate Location If Absolutely Necessary) 39 V Varistors (Preferred Location) Air Flow OUTPUTS 24 VAC INPUTS Fan Fan Power 1/4 Inch O.D. Tygon or Equivalent Tubing for Distances Less Than or Equal To 15 Inches (TYP) 39 V Varistor High Port Low Port Heating Stage 1 OUT IN FILTER Note Direction of Filter ( + ) ( + ) ( ) ( ) + SHLD - Infinet INFINET Qty. PARTS LIST ANDOVER CONTROLS BOX MANUFACTURER S V Varistor Part No. Description Qty. Part No. Description VAC Varistor VAC to 24 VAC Transformer Micron Ramay Filter Bi-Directional Damper Motor TCX Mounted on Plate Control Wire Tubing (1/4 Inch O.D.) Sheet Metal Screws VAC, DPDT, 10 A Relay Typical TCX 850 Enclosure (Not Necessarily Provided by Andover Controls) Varistors should be installed at actuators if possible. If alternate position must be used, varistors must not be directly terminated to TCX or TCX failure may occur. Note: If the installation requires the secondary of the 24V transformer to be grounded, always connect the "neutral" to ground and only ground it at the transformer. I TCX 850 Installation Guide 25

34 g i F 39 V Varistor TCX to VAV Terminations 39 V 24 VAC 120 VAC VAV Box C E L E C T R COM OPEN CLOSE R E H E A T Heater Control Circuit COM Stage 2 24 VAC OUTPUTS INPUTS Fan Fan Power 39 V Varistor High Port Low Port OUT IN ( + ) ( + ) ( ) ( ) Infinet INFINET Qty. PARTS LIST ANDOVER CONTROLS BOX MANUFACTURER S Part No. Description Qty. Part No. Description VAC Varistor VAC To 24 VAC Transformer Micron Ramay Filter Bi-Directional Damper Motor TCX Mounted on Plate Control Wire Tubing (1/4 Inch O.D.) Sheet Metal Screws VAC, DPDT, 10 A Relay Heating Stage 1 39 V Varistor Typical TCX Enclosure (Not Necessarily Provided by Andover Controls) I Stage 1 To Other VAV Boxes As Required (VAV Cooling Only with Two Stage Electric Heat and One Fan (Integral or Constant)) See Note Earth Ground 120 V Constant Fused Power 39 V Varistors (Alternate Location If Absolutely Necessary) 39 V Varistors (Preferred Location) 1/4 Inch O.D. Tygon or Equivalent Tubing for Distances Less Than or Equal To 15 Inches (TYP) Heating Stage 2 FILTER Note Direction of Filter + SHLD - Note: If the installation requires the secondary of the 24V transformer to be grounded, always connect the "neutral" to ground and only ground it at the transformer. Varistors should be installed at actuators if possible. If alternate position must be used, varistors must not be directly terminated to TCX or TCX failure may occur. Air Flow 26 TCX 850 Installation Guide

35 Wiring the Outputs The outputs are along the upper right side of the TCX 850. All output wires should enter from the right. Notice that the first three outputs, Form A, are labeled from the top down C, NO, C, NO, C, NO. The last output is the tristate one, labeled C, +,. Wiring Tristate Output Only the fourth output is tristate. To wire it, you connect three terminations only Common (C), Plus (+), and Minus ( ). 1. Wire the tristate output as shown in the diagram. Figure 15 shows the diagram. 2. Use a right angled fast-on connector and clip the appropriate wire to each terminal. Figure 15. Schematic of Tristate Output Wiring C +ON ON Note that all tristate outputs fail in the OFF state if there is no power. They are forced to the OFF position for 2 min upon reset or powerup before being program controlled. Wiring Form A Outputs You wire the outputs for Form A as follows: 1. Use a right angled fast-on connector and clip the C and NO wires to the C and NO terminals. 2. When switching inductive loads (relays, contactors, motors, or valves), be sure to install metal oxide varistors across the coil of the device being switched. TCX 850 Installation Guide 27

36 Figure 16 shows the schematic for wiring a Form A output. Figure 16. Schematic of Form A Output Wiring C NO Connecting Modules to the Expansion Port The expansion port at the bottom center of the controller board allows you to connect modules to expand the capabilities of the controller. Refer to the installation guide for the model for how to install a particular expansion module. 28 TCX 850 Installation Guide

37 Powering Up the TCX 850 Before you proceed, be sure the following are correct: 1. Be sure the battery is connected. 2. Be sure the AC power is wired properly. Check to be sure all three wires have been connected. 3. Be sure the controller has a true earth ground. 4. Be sure you have used the proper cables and wires and correct lengths. 5. Be sure you have properly labeled the tag with the name of the controller before removing it. 6. Be sure the Infinet cable has been properly wired. 7. Be sure the Infinet cable shields are properly connected. If you have completed all previous sections in this manual, you are now ready to power up the controller. Turn on the AC power source (or close the power connection) and the controller starts automatically. The following occurs (also occurs when you press RESET): 1. If the controller has been off, relays remain off. If you have pressed RESET, relays de-energize. 2. The CPU light flashes every.2 sec after you let go of the button. 3. The TD light immediately starts flashing after you let go of the button to show data is being transmitted. 4. The RD light begins flashing only if data is being received from other controllers on the network. This may not happen immediately. 5. If the CPU light flashes every.1 sec, the CPU has failed an internal test. See the Andover Controls Infinet Controller Troubleshooting Guide. TCX 850 Installation Guide 29

38 Reset Button The reset button is the red square button just left of the horizontal center of the board near the bottom. You press it to initiate a warm start. The same process that occurs when you power up AC power occurs when you press RESET. Setting the Air Flow Potentiometers Three air flow potentiometers are on the front of the cabinet: MIN Sets the minimum air flow. MAX Sets the maximum air flow. SP Special. You can program it for any purpose you want, such as to set the setpoint. The controller reads the information from these three pots as Inputs 5, 6, and 7. You set these three inputs manually. They read voltage, from 0 to 5.12 V. You can program them as you choose. (For more information, see the Andover Controls Infinity CX Programmer s Guide.) Turn the pots clockwise to increase the voltage. Turn the pots counterclockwise to decrease the voltage. Completing the Installation To complete the installation of your TCX 850 replace the cabinet cover by snapping the cover onto the board. Connecting the Andover Controls Service Tool The SERVICE PORT on the far right side of the bottom of the controller is to connect the Andover Controls Service Tool to the TCX 850. The service tool will access all Infinet controllers on the same network. The connector is a 4-pin Berg connector. You need the Andover Controls adaptor cable to connect the Service Tool, which normally plugs into an RJ 11 (phone) connector. 30 TCX 850 Installation Guide

39 For information on availability of the Andover Controls Service Tool and adaptor, contact your Andover Controls representative. TCX 850 Installation Guide 31

40 32 TCX 850 Installation Guide

41 A AC power connecting 11 accuracy wire gauge factors 7 air flow sensor connecting 20 Andover Controls Service Tool using 30 B backup power connecting 11 battery connecting 11 C cabinet dimensions 3 cable for Infinet 3 length 3 circuit requirements for power 3 configuration planning 8 counter inputs wiring 18 cover removing front 9 replacing 30 current sensors wiring 19 D dimensions cabinet 3 E enclosure Underwriter Laboratories requirements 5, 9 environments for operating 5 expansion modules connecting 28 expansion port purpose of 28 F Form A outputs wiring 27, 28 front cover removing 9 replacing 30 G ground correcting 5 inspecting 5 requirements 4 H holes for mounting screws 12 I Infinet lightning arrester for 4 Infinet cable connecting 15 Infinet cable numbers 3 inputs circuit specifications 6 wiring rules 17 inside controller parts 12 installation parts required for 9 L lightning protection against 4 lightning arrester for Infinet 4 TCX 250 Installation Guide Index-1

42 line transients protection against 4 M magnetic field avoid electrical spikes from 20 mounting screw holes for 12 O outputs equipment requirements 5 wiring 27 wiring rules 17 P parts found inside controller 12 required for installation 9 points air flow inputs 20 counter inputs 18 current inputs 19 thermistor inputs 18 voltage inputs 18 power battery backup 11 power requirements circuit 3 power surges preventing 4 powering up preparations for 29 protection against lightning 4 against line transients 4 R RESET button 30 S screw holes for mounting 12 locations for mounting 11 sensors air flow 20 counter 18 current 19 thermistor 6, 7, 18 voltage 18 service port purpose of 30 shields required for sensor wire 16 T temperatures for operating 5 thermistors reducing errors 6 wiring 18 tristate outputs wiring 27 U Underwriter Laboratories enclosure requirements 5, 9 V varistors where and when to use 20 voltage sensors wiring 18 W wires gauge for thermistors 7 wiring AC power connection 11 connecting Infinet cable 15 counter inputs 18 current sensors 19 outputs 27 rules for inputs and outputs 17 thermistors 18 voltage sensors 18 Index-2 TCX 250 Installation Guide

43 TCX 850 Installation Guide Rev F