Johnson Controls SE-ZEC510-1 User manual

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 1

Smart Equipment Controls

Installation, Operation, and Maintenance

Manual

Johnson Controls

SE-ZEC500-1 and SE-ZEC510-1 Controllers

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 2

Table of Contents

Initial Setup..............................................................................................................................................................................3

Mounting..............................................................................................................................................................................3

Networking ..........................................................................................................................................................................4

Field Controller (FC) Bus ................................................................................................................................................4

SE-ZEC Controller Address............................................................................................................................................4

End-of-line (EOL) Switch.................................................................................................................................................5

Optional Components .........................................................................................................................................................5

Sensor Actuator (SA) Bus...............................................................................................................................................5

Supply Air Temp. Sensor ................................................................................................................................................5

Discharge Air Temp. Sensor...........................................................................................................................................6

Occupancy Sensor..........................................................................................................................................................6

Control Sequences..................................................................................................................................................................7

Controller Parameters.............................................................................................................................................................7

Parameter Descriptions.......................................................................................................................................................7

Static Parameters (All Applications)................................................................................................................................7

Application Specific Parameters ...................................................................................................................................11

Factory Programmed Parameters.....................................................................................................................................12

Default Parameters .......................................................................................................................................................12

Size Dependent Parameters.........................................................................................................................................13

Sequence Dependent Parameters................................................................................................................................14

Commissioning......................................................................................................................................................................16

Mobile Access Portal (MAP) Gateway..............................................................................................................................16

VAV Handheld Balancing Tool..........................................................................................................................................17

Troubleshooting ....................................................................................................................................................................17

Power Status LED.............................................................................................................................................................18

Communication Bus Problems..........................................................................................................................................18

I/O Wiring ......................................................................................................................................................................18

Duplicate Addresses .....................................................................................................................................................18

Correcting Physical Communication Bus Problems......................................................................................................18

Parts and Accessories ..........................................................................................................................................................18

Additional Information ...........................................................................................................................................................19

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 3

Initial Setup

Mounting

To mount the SE-ZEC Controllers:

1. Ensure that you have the appropriate personal protective equipment (PPE), such as a hard hat, safety glasses,

steel toe boots, and gloves.

2. Disconnect power to the VAV unit.

3. Set the MS/TP address, and ensure the end of line (EOL) switch is set to off. Instructions on setting the VAV

address and EOL are in the sections below.

4. Place the SE-ZEC Controller in the proper mounting position on the actuator shaft so that the wiring connections

are easily accessible. Make sure the SE-ZEC Controller base is parallel to the VAV box (perpendicular to the

damper shaft). If needed, use a spacer to offset tipping of the SE-ZEC Controller caused by the shaft bushings.

5. Use the alignment marks to center the captive spacer to ensure sufficient movement in either direction.

Fig. 1: Captive Spacer Alignment Marks

6. Secure the self-drilling #10 screw through the captive spacer with a power screwdriver and 4” (100 mm) extension

socket. Otherwise, use a punch to mark the position of the shoulder washer, and then drill a hole into the VAV box

using a 5/16” drill bit. Insert the mounting screw and tighten against the spacer.

7. Locate the damper position using the typical marking on the end of the damper shaft.

8. Note the direction, clockwise (CW) or counterclockwise (CCW), required to close the damper. The actuator setup

depends on the necessary amount of rotation required for the damper to go from full-open to full-closed. For 90°

rotation, install the damper full-closed.

9. Push down and hold the manual override button and turn the SE-ZEC Controller until it contacts the mechanical

end-stop at either the full-closed or full-open position.

Fig. 2: Manual Override and Coupler

10. Tighten the square coupler bolt to the shaft using a 5/16” (8 mm) wrench or a 3/8” (10 mm) 12-point socket.

Tighten to 95 to 105 lb·in (10.5 to 11.5 N·m)

11. Put a loop in the pneumatic tubing, to trap condensation, when you attach the tubing to the SE-ZEC Controller

pressure transducer ports. Loop the tubing before you make the final connections.

Alignment

guide

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 4

12. Push the manual override button, and turn the actuator coupling manually to ensure the actuator can rotate from

full-closed to full-open positions without binding.

13. Complete the mounting by rotating the damper to the full-open position.

Networking

Field Controller (FC) Bus

The field controller (FC) Bus terminal block is a blue, removable, 4-terminal plug that is keyed to only fit in to the board-

mounted, gray FC Bus jack. Wire the removable FC Bus terminal block plugs on the SE-ZEC Controller and other FC Bus

controllers in a daisy-chain configuration using 3-wire twisted, shielded cable.

Fig. 3: FC Bus Connections

SE-ZEC Controller Address

SE-ZEC Controllers are master devices on BACnet MS/TP (SA or FC) Buses. Before operating field controllers on a Bus,

you must set a valid and unique device address for each controller on the Bus. You set a field controller’s device address

by setting the positions of the switches on the devise address DIP switch block at the top of the controller. Device

addresses 4-127 are the valid addresses for the SE-ZEC controller. SE-ZEC Controllers ship with all address switches set

to ON. Set a valid and unique device address on the field controller before applying power to the controller on the Bus.

The DIP switch block has eight switches numbered 128, 64, 32, 16, 8, 4, 2, and 1.

To set the device addresses on a ZEC field controller:

1. Set all of the switches on the field controller’s device address DIP switch block (128 through 1) to OFF.

2. Set one or more of the seven address switches from 64 to 1 to ON, so that the sum of the switch numbers set to ON

equals the intended device address. Set the highest number switch that is less than or equal to the intended device

address to ON. Then continue setting lower numbered switches until the total equals the intended address.

For example: If the intended device address is 21, set the switches so that 16 + 4 + 1 = 21.

a. Set switch 16 to ON

b. Set switch 4 to ON

c. Set switch 1 to ON

3. Set a unique and sequential device address for each of the field controllers connected on the FC Bus, starting with

device address 4. To ensure the best Bus performance, set sequential device addresses with no gaps in the device

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 5

address range (4, 5, 6, and so on). The field controllers do not need to be physically connected on the Bus in their

numerical device address order.

4. Write each field controller’s device address on the white label below the DIP switch block on the controller’s cover.

End-of-line (EOL) Switch

The EOL switch must be set to ON for the two devices located at either end of each bus segment on an FC bus. The EOL

switches must be set to OFF for all other devices on the bus segment on an FC bus.

Optional Components

Sensor Actuator (SA) Bus

Factory or field supplied zone sensors are wired to the SA bus on the SE-ZEC Controller. The SA Bus is a brown,

removable 4-terminal plug that is keyed to only fit into the board mounted SA bus. Wire the removable SA bus terminal

block plugs on the SE-ZEC Controller and other field devices in a daisy-chain configuration using 4-wire, shielded cable.

Fig. 4: SA Bus Connections

Supply Air Temp. Sensor

Factory or field-supplied supply air temperature sensors can be used to measure the supply air temperature at the inlet of

the VAV box. The supply air temperature is wired between terminals ICOM3 and IN3 on the SE-ZEC Controller. The

sensor should be mounted in the inlet duct centered in the side of the ductwork. Avoid installing the sensor near an elbow,

take off or transition. Avoid blocking air to the primary airflow sensor.

Factory provided nickel (1k ohm) temperature sensors have 4” long probes and stainless steel mounting flanges with (2)

provided hex-head self-drilling mounting screws. Sensors come equipped with 10 ft. plenum rated cables with ¼” internal

thread insulated quick-connect terminations on leads. Install sensor by drilling a hole into the ductwork, inserting the

sensor, and securing with provided screws. The sensor tip should not touch any part of the ductwork.

With the supply air temperature sensor installed, the SE-ZEC controller will change its control sequence based on the

measured supply air temperature. When parameter Heating Limit Enable is TRUE the controller will not allow re-heat to

engage when the supply air temperature is greater than the value set in Heating Supply Air Limit.

Additionally, the controller will switch to warmup mode when warmup conditions are present. Warmup conditions are

present when the supply air temperature (SAT) sensor value exceeds the zone temperature (ZNT) sensor in unoccupied

mode or exceeds it by the Warmup Differential in occupied mode. While in Warmup mode the minimum flow will be set to

the Warmup Min Flow.

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 6

Discharge Air Temp. Sensor

Factory or field supplied discharge air temperature sensors can be used to measure the temperature of the air being

discharged from the VAV box. The discharge air temperature sensor is wired between terminals ICOM1 and IN1 on the

SE-ZEC controller. The sensor should be mounted a minimum of 36” from the discharge of the unit and be centered in the

side of the ductwork. Avoid installing the sensor near an elbow, take off, or transition.

Factory provided nickel (1k ohm) temperature sensors have 4” long probes and stainless steel mounting flanges with (2)

provided hex-head self-drilling mounting screws. Sensors come equipped with 10 ft. plenum rated cables with ¼” internal

thread insulated quick-connect terminations on leads. Install sensor by drilling a hole into the ductwork, inserting the

sensor, and securing with provided screws. The sensor tip should not touch any part of the ductwork.

Occupancy Sensor

The SE-ZEC Controllers adjust the heating and cooling temperature setpoints, as well as the airflow setpoints based on

the zone occupancy. There are three different states of zone occupancy:

•Occupied Mode

oUses Occupied Heating (68°F) and Occupied Cooling (72°F) temperature setpoints as well as Occupied

Heating and Occupied Cooling Airflow setpoints

oFor Series Fan Powered Terminals the Fan is always on

oFor Parallel Fan Powered Terminals the Fan is only on during a call for heating

•Standby Mode

oUses Standby Heating (66°F) and Standby Cooling (77°F) temperature setpoints as well as Unoccupied

Heating and Unoccupied Cooling Airflow setpoints

oFor Series Fan Powered Terminals the Fan is always on

oFor Parallel Fan Powered Terminals the Fan is only on during a call for heating

•Unoccupied Mode

oUses Unoccupied Heating (55°F) and Unoccupied Cooling (85°F) temperature setpoints as well as

Unoccupied Heating and Unoccupied Cooling Airflow setpoints

oFor Series Fan Powered Terminals the Fan is only on during a call for heating or cooling

oFor Parallel Fan Powered Terminals the Fan is only on during a call for heating

Table 1 below shows how occupancy states are determined for the SE-ZEC Controllers.

Table 1: SE-ZEC Occupancy Determination

SE-ZEC Occupancy Determination

Terminal Unit Type

Controller Type

ZEC500 (Standalone)

ZEC510 (Networked)

Single Duct Terminal Unit

The controller will switch from

Occupied to Unoccupied states by

comparing the measured airflow to

the Occupancy Determination Flow

Setpoint. When the measured airflow

is below the Occupancy

Determination Flow Setpoint the state

is set to Unoccupied. When the

measured airflow is above the

Occupancy Determination Flow

Setpoint the state is set to Occupied

The building automation system

(BAS) will schedule when the

controller will switch from Occupied

and Unoccupied states. A room

occupancy sensor (wired to IN2 and

ICOM2 on the controller) can be used

to temporarily set the VAV box to

Standby mode when occupancy is not

sensed.

Fan Powered Terminal Unit

The controller will read the occupancy

sensor wired between IN2 and

ICOM2 on the controller to switch

between Occupied and Unoccupied

The building automation system

(BAS) will schedule when the

controller will switch from Occupied

and Unoccupied states. A room

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 7

states. The occupancy sensor can be

a room occupancy sensor or another

kind of occupancy detection (such as

a duct pressure switch*). Without an

occupancy sensor, the controller will

always be in Occupied mode.

occupancy sensor (wired to IN2 and

ICOM2 on the controller) can be used

to temporarily set the VAV box to

Standby mode when occupancy is not

sensed.

*An optional factory provided occupancy pressure switch is available for standalone fan powered terminal units to

determine occupancy by measuring duct pressure to determine whether the air handler is on (zone is occupied) or off

(zone is unoccupied).

Control Sequences

VAV boxes with Smart Equipment Controls will be factory mounted and wired according to the selected control sequence.

Links to each individual control submittal are shown below:

Table 2: Control Sequences

Smart Equipment Controls - Control Sequences

Description

Single Duct

Series Fan Powered

Parallel Fan Powered

ZEC500

ZEC510

ZEC500

ZEC510

ZEC500

ZEC510

Cooling Only

6101

7101

6201

7201

6301

7301

1-Stage Electric Heat

6102

7102

6202

7202

6302

7302

2-Stage Electric Heat

6103

7103

6203

7203

6303

7303

3-Stage Electric Heat

6104

7104

6204

7204

6304

7304

Proportional Electric Heat

6105

7105

6205

7205

6305

7305

On/Off Hot Water Heat

6106

7106

6206

7206

6306

7306

Floating Hot Water Heat

6107

7107

6207

7207

6307

7307

Proportional Hot Water Heat

6108

7108

6208

7208

6308

7308

Supplemental Heat

6109

7109

6209

7209

6309

7309

Controller Parameters

Parameter Descriptions

This section provides information on the SE-ZEC Controller Parameters.

Static Parameters (All Applications)

The list of available SE-ZEC Controller Parameters changes depending on the application type that is selected

(Staged/Incremental/SCR). Table 2 shows the SE-ZEC Controller parameters that are available for every application

(Staged/Incremental/SCR).

Table 3: Default SE-ZEC Controller Parameters

Menu 1

Menu 2

Parameter Name

Parameter Description

Parameter Values

Home Page Setup Active Baud Rate

Displays the active baud rate used for network

communication.

Read Only

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 8

Menu 1

Menu 2

Parameter Name

Parameter Description

Parameter Values

Home Page Setup Actuator Stroke

Time Sets the damper actuator stroke time. Note: The

SE-ZEC5X0-1 actuator is a 60 second motor. Adjustable:

30-120 seconds

Home Page Setup Application Type Set the type of application for the VAV Box.

Adjustable:

Incremental/Staged/

Proportional SCR

Home Page Setup Auto Tune

Enable

Allows PRAC+ auto tuning algorithm to

continuously tune the loops in the controller.

Setting this to Disable turns off this feature.

Adjustable:

Enable/Disable

Home Page Setup Autocalibration

Command

This feature drives the VAV box damper shut and

once shut offsets the differential pressure sensor

so it reads zero.

Adjustable:

False/True

Home Page Setup BACnet Id

Sets the BACnet ID for the BACnet MS/TP

system.

Read Only:

0-4194302

Home Page Setup

Box Heating

Installed

Specifies if box re-heat is installed (local re-heat).

Adjustable:

False/True

Home Page Setup Box Heating Type Displays the type of heat installed.

Read Only: No

Heat/1 Stage

Electric /2 Stage

Electric/Modulating

Hot Water Valve/3

Stage Electric

Home Page Setup Damper Mode Defines the direction of the damper rotation.

(Normal = CCW to close, Reverse = CW to close) Adjustable:

Normal/Reverse

Home Page Setup

Discharge Air

Temperature

Offset

Used to calibrate the supply air temperature

sensor. Adjustable:

-5°F to 5°F

Home Page Setup Fan Control Type Set the type of fan for the VAV Box.

Adjustable:

None/Parallel/Series

Home Page Setup Heating Limit

Enable

Enables/Disables the activation of re-heat when

the incoming air temperature exceeds the

temperature set in Heating Supply Air Limit. This

is to avoid engaging re-heat when the inlet

temperature is too high.

Adjustable:

False/True

Home Page Setup Heating Priority

Determines whether box or supplemental heat is

turned on first.

Adjustable:

Supplemental/Box

Home Page Setup Heating Supply

Air Limit

Sets the highest inlet air temperature at which re-

heat can be engaged when Heating Limit Enable

is set to True. When the inlet air temperature is

higher than Heating Supply Air Limit, re-heat

cannot engage.

Adjustable

Home Page Setup Occupancy

Determination

Flow Setpoint

Sets airflow threshold for determining occupancy

when Occupancy Sensor Enable is false.

Whenever the measured flow exceeds the

Occupancy Determination Flow Setpoint, the

system will be in the occupied mode. Whenever

the measured flow is less than the Occupancy

Determination Flow Setpoint, the system will be in

the unoccupied mode.

Adjustable:

0 cfm to 10000 cfm

Home Page Setup

Occupancy

Polarity

Sets input polarity of occupancy sensor when

Occupancy Sensor Enable is True. Open =

Adjustable:

Close/Open

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 9

Menu 1

Menu 2

Parameter Name

Parameter Description

Parameter Values

Unoccupied when open, Closed = Unoccupied

when closed.

Home Page Setup Occupancy

Sensor Enable

Enables determining occupancy by reading IN2

and ICOM2 on the controller via an occupancy

sensor. When Occupancy Sensor Enable is

disabled, occupancy is determined by comparing

measured airflow to the Occupancy Determination

Flow Setpoint.

Adjustable:

Enable/Disable

Home Page Setup PID Tuning Reset

Resets the PRAC+ tuning parameters of the PID

controllers to the factory defaults.

Adjustable:

Enable/Disable

Home Page Setup Power Fail

Restart Time

Sets the amount of time the controller waits to

operate the unit after power is restored when

Power Fail Restart Enable is True. This is to avoid

a power surge with lights, computers, and other

electrical loads that come back on immediately

when power is restored.

Adjustable

Home Page Setup Standalone Min

Occupied Time

After switching to occupied mode, the box will stay

in occupied mode for at least the amount of time

specified in Standalone Min Occupied Time,

before being able to switch back to unoccupied

mode.

Adjustable:

0-360 minutes

Home Page Setup Standalone Mode

Enables Standalone Mode. This mode is intended

to allow the controller to utilize unoccupied

setpoints when there is no connection to a

building automation system. When Standalone

Mode is enabled, occupancy is determined by

comparing the measured flow against the

Occupancy Determination Flow Setpoint when

Occupancy Sensor Enable if False, or by using

the Occupancy Sensor when Occupancy Sensor

Enable is True.

Adjustable: Off/On

Home Page Setup

Supplemental

Heating Installed

Specifies if re-heat is installed in the zone/space

(non box re-heat).

Adjustable:

False/True

Home Page Setup

Supply Air

Temperature

Offset

Used to calibrate the supply air temperature

sensor. Adjustable:

-5°F to 5°F

Home Page Setup

Supply Airflow

Pickup Gain

Amplification provided by the pitot tube for supply

flow.

Adjustable

Home Page Setup Supply Area

Shows the supply inlet area used to calculate the

supply flow.

Adjustable:

0 sq. ft. to 8.0 sq. ft.

Home Page Setup Supply Flow The supply airflow measured by the VAV box. Read Only

Home Page Setup Supply Flow

Setpoint

The flow setpoint the damper is controlling the

supply air flow to. This will be based on the unit

conditions (occupancy, temperature setpoint,

morning warmup conditions, etc.)

Read Only

Home Page Setup

Warmer/Cooler

Adjust Enable

Enables the warmer/cooler adjustment to offset

the current setpoint.

Adjustable:

False/True

Home Page Setup

Zone

Temperature

Offset

Used to calibrate the zone temperature sensor. Adjustable:

-5°F to 5°F

Home Page Setpoints

Effective Cooling

Setpoint

Effective Cooling Setpoint Read Only

Smart Equipment Controls

Installation, Operation and Maintenance Manual

Form No. SECIOM.A

Effective Date: 07/05/19

Page 10

Menu 1

Menu 2

Parameter Name

Parameter Description

Parameter Values

Home Page Setpoints

Effective Heating

Setpoint

Effective Heating Setpoint Read Only

Home Page Setpoints Occupied Cooling

Setpoint

When occupied the thermostat controls cooling to

this level. Set above Occupied Heating Setpoint.

Defaults to 72°F.

Adjustable:

46°F to 99°F

Home Page Setpoints Occupied Heating

Setpoint

When occupied the thermostat controls heating to

this level. Set below Occupied Cooling Setpoint.

Defaults to 68°F.

Adjustable:

45°F to 98°F

Home Page Setpoints Standby Cooling

Setpoint

In order for the Standby Cooling Setpoint to

appear, set the Occupancy Schedule to external.

When set to external the zone switches to this

setpoint when motion is no longer sensed and the

unit is occupied. Defaults to 74°F.

Adjustable:

46°F to 99°F

Home Page Setpoints Standby Heating

Setpoint

In order for the Standby Heating Setpoint to

appear, set the Occupancy Schedule to external.

When set to external, the zone switches to this

setpoint when motion is no longer sensed and the

unit is occupied. Defaults to 66°F.

Adjustable:

45°F to 98°F

Home Page Setpoints

Unoccupied

Cooling Setpoint

When unoccupied the thermostat controls cooling

to this level. Defaults to 80°F.

Adjustable:

46°F to 99°F

Home Page Setpoints Unoccupied

Heating Setpoint

When unoccupied the thermostat controls heating

to this level. Set below Unoccupied Cooling

Setpoint. Defaults to 60°F.

Adjustable:

45°F to 98°F

Home Page Setpoints Warmer/Cooler

Adjust Range

This is the range that the warmer cooler

adjustment on the sensor can affect the setpoint.

Setting it to zero (0) means the user has no

adjustment at the sensor. Defaults to 5°F.

Adjustable:

0°F to 5°F

Home Page Setpoints Warmup

Differential

Sets the required differential between the supply

air temperature (SAT) sensor and the zone

temperature (ZNT) sensor in occupied mode to

notify the controller that warmup conditions are

present. When warmup conditions are present the

minimum supply airflow will be set to Warmup Min

Flow.

Home Page Commissioning Cooling Max Flow

Sets the maximum supply air flow of the VAV box

when cooling.

Adjustable:

0 cfm to 10000 cfm

Home Page Commissioning

Occupied Cooling

Min Flow

Sets the minimum supply air flow of the VAV box

when cooling.

Adjustable:

0 cfm to 10000 cfm

Home Page Commissioning Occupied Heating

Min Flow

Sets the minimum supply air flow of the VAV box

when heating. Note: When the zone is in heating

mode, the supply air flow is constant. Thus, no

maximum heating air flow. This value must

exceed Staged Device Min Flow to allow electric

heat to energize.

Adjustable:

0 cfm to 10000 cfm

Home Page Commissioning Staged Device

Min Flow

Sets the minimum heating flow for electric reheat

control. This parameter serves an additional

control safety to the high-limit switches in the box.

It is best practice to set this parameter to 70 cfm

per kW of electric heat.

Adjustable:

0 cfm to 10000 cfm

Home Page Commissioning Unoccupied

Cooling Min Flow

Sets the minimum supply air flow of the VAV box

when unoccupied cooling and in the cooling

mode.

Adjustable:

0 cfm to 10000 cfm

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