Hvac C I: Ontrols Ntroduction

Invensys Building Systems
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HVAC CONTROLS INTRODUCTION
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HVAC CONTROLS
INTRODUCTION
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ii Invensys Building Systems

Table of Contents
Preface......................................................................................................... vii
Purpose of this Document................................................................................................vii
Appendix A – Supporting Documents for IBS Products ...................................................vii
Glossary...........................................................................................................................vii
Examples Used in this Document ....................................................................................vii
Conventions Used in this Document ................................................................................vii
Introduction ................................................................................................... 1
Function of HVAC controls................................................................................................ 1
Location of Equipment....................................................................................................... 2
Mechanical Room ............................................................................................................. 3
Air Handling Units (AHUs) ................................................................................................. 9
Room Controls.................................................................................................................. 15
Basic Control System ................................................................................. 17

BASIC CONTROL SYSTEM .............................................................................................. 19
Sensor ............................................................................................................................... 20
Controller .......................................................................................................................... 22
Controlled Device ............................................................................................................. 24
Actuators........................................................................................................................... 26
Pneumatic Actuators....................................................................................................... 26
Hydraulic Actuators......................................................................................................... 27
Gear Train Actuators....................................................................................................... 28
Direct-Coupled Actuators ................................................................................................ 28
Valves ................................................................................................................................ 29
Normally Open (N.O.) ..................................................................................................... 29
Normally Closed (N.C.) ................................................................................................... 29
Three-Way valves ........................................................................................................... 30
Transducers ...................................................................................................................... 31
Dampers ............................................................................................................................ 32
Parallel Blade Dampers .................................................................................................. 32
Opposed Blade Dampers................................................................................................ 32
Invensys Building Systems iii

Control Theory Terminology.......................................................................36
Setpoint, Control Point, Offset.........................................................................................37
Setpoint ...........................................................................................................................37
Control Point....................................................................................................................37
Controller Action...............................................................................................................38
Reset ..................................................................................................................................44
Reverse Reset ...................................................................................................................45
Direct Reset.......................................................................................................................46
Identifying Reverse or Direct Reset.................................................................................47
Proportional Control.........................................................................................................52
Electronic Direct Digital Control System..........................................................................52
Throttling Range..............................................................................................................54
Proportional with Integral (P.I.) Control ...........................................................................55
ON / OFF Control...............................................................................................................56
Differential .......................................................................................................................57
Differential .......................................................................................................................57
Floating Control ...............................................................................................................58
Energy Management Techniques ...............................................................63

Time-Programmed Commands........................................................................................64
Duty Cycling ......................................................................................................................65
Optimum Start / Stop ........................................................................................................66
Electric Demand Limiting.................................................................................................67
Enthalpy Optimization ......................................................................................................68
Degree Day Calculations..................................................................................................69
Night Purge Cycle .............................................................................................................70
DDC Terminology ........................................................................................74

Points.................................................................................................................................75
Digital Inputs....................................................................................................................75
Digital Outputs................................................................................................................76
Analog Inputs ..................................................................................................................77
RTDs ...............................................................................................................................77
Analog Outputs................................................................................................................79
iv Invensys Building Systems

Universal Points ............................................................................................................... 83
Fixed Point Configuration................................................................................................ 83
Universal Point Arrangement .......................................................................................... 83
Pulse Inputs ...................................................................................................................... 83
Appendix A .................................................................................................. 84
Glossary ...................................................................................................... 91
Abbreviations.................................................................................................................... 91
Definitions ......................................................................................................................... 92
Invensys Building Systems v

vi Invensys Building Systems
PREFACE
Preface
Purpose of this Document
This document serves as an introduction to how a Heating, Ventilating, and Air-
Conditioning (HVAC) Control system is used to operate a building’s mechanical equipment
so as to maintain the desired environmental conditions.
Appendix A – Supporting Documents for IBS Products

A variety of documents are available to support IBS products. Two samples of these
are featured in Appendix A. The first sample shows pages from the IBS Catalog,
supporting the CP-8511 Transducer. The second sample shows pages from a General
Instructions sheet that supports the VM Series Erie PopTop™ Modulating Spring-Return
Valves. These are meant only as samples and do not represent the entire scope of IBS
product support. For complete information on IBS products, consult your local office or
wholesale distributor.
Glossary
The Glossary contains a list of abbreviations and alphabetically lists and defines
terms used in this document.
Examples Used in this Document

This document contains examples of HVAC equipment and applications. Many of
these applications include temperatures, setpoints, throttling ranges, and other examples of
conditions found in the HVAC world. When reading this document, keep in mind that these
are examples only. Many factors, including equipment, climate, building codes, and local
practices vary and can have a major impact on methods, procedures, and sequences used
to control buildings.
This document cites examples of products manufactured by Invensys™ Building
Systems (IBS). These products represent only a small portion of the IBS product offering,
and the applications, features and benefits of IBS controls used in this text represent only
their basic functions. IBS has a complete line of products for today’s modern building,
offering security, lighting, sophisticated energy management solutions, Internet-accessible
reporting and many other products to support the needs of a “smart” building.
Conventions Used in this Document

The following conventions apply throughout the HVAC Controls Introduction:
• Terms that are italic and underlined are defined in the glossary of this document.
Additionally, in the online version of this document, these terms appear in blue, to aid in
their visibility.
• Key terms in some paragraphs are bolded. Other terms needing emphasis appear in
italics.
Invensys Building Systems vii

PREFACE
viii Invensys Building Systems

INTRODUCTION
Introduction
Function of HVAC controls
A Heating, Ventilating, and Air-Conditioning (HVAC) Control system operates the

mechanical equipment (boilers, chillers, pumps, fans, etc.) to maintain the proper
environment in a cost-effective manner. A proper environment is described with four
variables: temperature, humidity, pressure and ventilation.
Temperature — The comfort zone for temperature is between 68°F (20°C) and 75°F ?
(25°C). Temperatures less than 68°F (20°C) may cause some people to feel too cool.
Temperatures greater than 78°F (25°C) may cause some people to feel too warm. Of
course, these values vary between people, regions and countries.
Humidity — The comfort zone for humidity is between 20% relative humidity (RH) ?
and 60% RH. Humidity less than 20% RH causes the room to be too dry, which has an
adverse effect on health, computers, printers, and many other areas. Humidity greater than
60% RH causes the room to be muggy and increases the likelihood of mildew problems.
Pressure — The rooms and buildings typically have a slightly positive pressure to
reduce outside air infiltration. This helps in keeping the building clean.
Ventilation — Rooms typically have several complete air changes per hour. Indoor
Air Quality (IAQ) is an important issue. The distribution pattern of the air entering room
must keep people comfortable without feeling any drafts, and this is important as well.
Invensys Building Systems 1

INTRODUCTION
Location of Equipment
Three areas in a building work together to maintain the proper environment. The
? HVAC equipment and their controls include the mechanical room, the Air Handling Units
(AHUs) and the individual room controls.
Mechanical Room: Boilers, chillers, pumps, heat exchangers, and other associated
equipment are found inside the mechanical room. This area is sometimes called the main
equipment room.
Air Handling Units (AHUs): AHUs may be found on the roof, in the main
equipment room, or in their own equipment room, which is referred to as the secondary
equipment room. AHUs may heat, cool, humidify, dehumidify, ventilate, or filter the air to
condition it, then distribute that air to a section of the building.
2 Invensys Building Systems

INTRODUCTION
Room Controls: Individual room controls regulate the air coming from the AHU to ?
serve a room or a part of a larger area called a zone. Devices such as wall thermostats
and Variable Air Volume (VAV) boxes provide local temperature control. ?
There are also room controls not associated with an AHU. These may directly ?
control mechanical equipment that only serve one room or zone (zone control). These
room controls are installed on equipment such as unit ventilators, fan coil units, and heat ?
pumps.
?
Mechanical Room
Heating
The mechanical room may contain a boiler or a group of boilers. The boilers provide ?
heat for the building. In cooler climates, boilers are large or consist of a number of smaller
modular boilers. In warmer climates, boilers are small or even absent from the mechanical
room. When enabled, boilers supply a source of hot water that is used by coils throughout
the building. The temperature of this hot water may be varied based on the outside
temperature. Note: Hot Water Supply (HWS) temperatures may vary because of the
application or the HVAC equipment.
AHU

INTRODUCTION
Most boilers produce hot water, but there are also boilers that produce steam.
Boilers develop their heat through gas, coal, oil burners, or electric coils. The previous
picture shows a hot water gas-fired boiler. The hot water developed by the boiler is used
by hot water coils, which are similar in appearance to car radiators. These coils are found
inside the air handling units and, in cold climates, may also be located around the outside
walls (perimeter fin-tubes) of the building. In the preceding example, a pump forces water
from the boiler to the coils, then back to the boiler. In cold climates, a normally open (N.O.)
valve is installed to control the volume of water flow through the coil. The amount of flow is
? expressed in gallons per minute (GPM) or, in metric units, in liters per second (L/s). The
valve is described as normally open because when no power or control signal is received,
the valve goes to 100% open.
Where a steam boiler is used, a steam converter is commonly incorporated into the
design. A steam converter is a type of heat exchanger. Steam provided from the boiler is
used to heat water inside the converter. In turn, the hot water developed by the converter
is used in the same way as the hot water is used from a hot water boiler. In the example
? above, a normally closed (N.C.) valve is used to control the amount of steam going to the
heat steam converter. When no power or signal is received at this type of valve, it closes.
Different types of heat exchangers may be used for other applications, including cooling.

INTRODUCTION
Water Pumps
Pumps are essential to move the water in a system, whether it is from the boiler to
the hot water coils, or from the chiller to the chilled water coils, or from the chiller to the
cooling tower. Some applications require at least two pumps so that a standby pump is
ready in case something happens to the operating pump. The operating pump is referred
to as the lead or primary pump, and the standby pump is the lag or secondary pump.
Cooling
The Chiller is the source of cooling for many buildings. There are a variety of chiller ?
types. A simple drawing of a centrifugal chiller is shown above. A chiller produces cool
water, for example 42°F (5°C), which is pumped to the chilled water coils inside the air
handling units. In this example, heat is being removed at the Air Handling Unit and being
rejected to the outdoors at the cooling tower. There are three basic steps to the heat
transferring process:
1) The chilled water supply (CHWS) is pumped to the cooling coils in the AHUs,
then the cooled return water, at 52°F (example only), is circulated back to the
chiller (chilled water return, or CHWR). At the cooling coil, the heat for the space
is transferred to the chilled water and the water carries the heat back to the
chiller.

INTRODUCTION
2) In the chiller, the heat is transferred to a refrigerant, which in turn transfers the
heat to the water going to a cooling tower.
3) The Cooling Tower expels the heat to the outside air. The cooling tower is a
container that is open to the atmosphere (Open System), through which water is
passed. When heated water comes from the chiller, it is forced upward to the top
of the cooling tower, then sprayed down into the container. Evaporation causes
the water to lose some of its heat. To increase the heat loss, fans may be turned
on, causing more evaporation. Once the water is cooled to around 85°F (30°C),
the water settles in the sump and is sent back to the chiller.
Evaporation is a cooling process that causes some of the water to be lost to the
atmosphere. As a result, make up water or fill is needed to maintain the proper water level.
Therefore, water in a cooling tower requires water treatment supervision.
There are other ways to cool the condenser water, including cooling ponds or air-
cooled condensers.

INTRODUCTION
Review
Mechanical Room
Match the identification number of the mechanical equipment with its name.
Matching
1._____ A) Boilers
2._____ B) Hot Water Pumps
3._____ C) Chillers
4._____ D) Cooling Tower
5._____ E) Chilled Water Pumps
6._____ F) Condenser Water Pumps

INTRODUCTION
Answers to Review
1. D) Cooling Tower
2. F) Condenser Water Pumps
3. C) Chillers
4. E) Chilled Water Pumps
5. B) Hot Water Pumps
6. A) Boilers

INTRODUCTION
Air Handling Units (AHUs)
Air Handling Units (AHUs) supply conditioned air to a particular part of a building.
AHUs can supply different sized areas, whether it is a part of a room, a zone, or an entire
group of rooms. In the diagram above, two AHUs supply air to a school auditorium. This
AHU contains a mixed air chamber, a filter, a chilled water coil (commonly called a cooling
coil), a hot water coil (commonly called a heating coil), a fan, and a humidifier. The parts of
an AHU are often referred to as the “water side,” composed of those parts that pass water
through the AHU, and the “air side,” which is composed of the devices that direct the air
within the AHU.
Mixed Air refers to the mixing of outside air with the air returning from inside the
building. This is accomplished by dampers controlling airflow in a way similar to venetian ?
blinds controlling sunlight. In the diagram above, there are dampers for the outside air and
the return air. It is important that these dampers work together. As outside air dampers ?
open, the return air dampers must close. An actuator (sometimes referred to as a motor or
operator) and linkage are set up so that this operation occurs. ?
INTRODUCTION
? Ventilation requirements determine the minimum position of the outside air dampers.
In the winter, when the chiller is shut down, the outside air dampers may open beyond the
minimum position to provide cooling. Using outside air for cooling rather than mechanical
? cooling is referred to as an economizer mode. During the summer, when the outside air is
too warm to use for cooling, the outside air dampers are set to the ventilation requirement,
? which is the minimum position. Exhaust air dampers allow air to leave the building in
proportion to the amount of outside air that enters.
Filters remove dirt particles from the mixed air. It is essential that these filters be
replaced periodically. A mixed air sensor is typically located after the filter. This sensor
averages the mixed air temperature throughout the cross-section of the duct. This is
? important because in mixed air, stratification, which is the layering of the warm and cold air
inside the duct, can occur, possibly resulting in control or comfort problems.
The Supply Fan moves the air through the air-handling unit and out into the rooms.
? The amount of air going through the fan may be controlled by the use of inlet vane dampers
(blades that cover the inlet of the fan), or by the use of a variable frequency drive (VFD)
? that controls the speed of the fan motor by varying the cycles of electricity. The fan may be
positioned before the coils as shown below (blow-through fan) or after the coils (draw-
through fan).
The Hot Water Coil heats the air as it passes over the coil. It may be necessary to
heat the air even when providing cooling to a building. This concept may be confusing at
first. To help understand this application, it is important to remember that the core of a
large building may require cooling year-round, regardless of the outside air temperature.
Typically, air used for cooling is delivered to the space at 55°F. If the mixed air
temperature is below 55°F, it may be necessary to heat the air to 55°F for a cooling
? application. In the drawing above, the discharge air sensor modulates a two-way normally
open (N.O.) valve to maintain the 55°F (13°C) discharge air temperature. With the removal
of the input signal, this valve goes completely open, putting as much hot water into the coil
as possible. This reduces the chance of the water freezing, which may destroy a coil.

INTRODUCTION
The Chilled Water Coil operates during the summer to drop the discharge air
temperature to 55°F (13°C). As shown in the preceding drawing, chilled water is modulated
through the coil by the use of a three-way mixing valve. The valve forces the chilled water ?
through the coil or bypasses the water around the coil. The Chilled Water coil may also be
used for dehumidification of the air, provided the temperature of the cooling coil surface is
below the dew point of the air passing over the coil. The humidity levels are controlled from ?
a sensor in the rooms being served by this AHU, or by a sensor in the return air duct.
A steam Humidifier, or some other form of humidifier, is placed inside an AHU to

add moisture to the air when needed. Humidity levels, sensed in the return air, are set at
35% RH, for example. The two-way normally closed (N.C.) valve is modulated to maintain
35% RH, plus or minus an acceptable tolerance.
The supply air fan distributes the air into the rooms or zones. After the air has gone
through the zones, it comes back to the Return Fan, which routes the return air back to the
return air dampers or the exhaust air dampers.

INTRODUCTION
Review
Observe the Air Handling Unit, below.

INTRODUCTION
Review
Referring to the drawing on the previous page, match the identification number of the
equipment with the correct letter.
Matching
1.__________ A. Supply Fan
2.__________ B. Filter
3.__________ C. Outside Air Dampers
4.__________ D. Return Air Temperature Sensor
5.__________ E. Hot Water Coil
6.__________ F. Mixed Air
7.__________ G. Return Air Dampers
8.__________ H. Return Air Humidity Sensor
9.__________ I. Discharge Air Temp. Sensor
10.__________ J. Return Fan
11.__________ K. Return Air
12.__________ L. Mixed Air Temperature Sensor
13.__________ M. Steam Humidifier
14.__________ N. Chilled Water Coil

INTRODUCTION
Answers to the Review
1. G. Return Air Dampers
2. J. Return Fan
3. D. Return Air Temperature Sensor
4. H. Return Air Humidity Sensor
5. K. Return Air
6. B. Filter
7. F. Mixed Air
8. C. Outside Air Dampers
9. L. Mixed Air Temperature Sensor
10. A. Supply Fan
11. N. Chilled Water Coil
12. E. Hot Water Coil
13. M. Steam Humidifier
14. I. Discharge Air Temp. Sensor

INTRODUCTION
Room Controls
One way to control the temperature in a room is with a Wall Thermostat (stat) that
sends a signal to an actuator that positions a damper to modulate the airflow in a variable
air volume (VAV) box. These VAV boxes are installed in the space between the ceiling tile
and the structural ceiling. This space is sometimes used as a return air plenum, as part of
the building air distribution system.
Actuator
The VAV box has a Damper that modulates to maintain the space temperature by
increasing or decreasing the volume of air being delivered to the space. The airflow is
measured in cubic feet per minute (CFM) or liters per second (L/s). If the space is too ?
warm, the damper is adjusted to allow more 55°F (13°C) air into the space. If the space is
too cool, less air is delivered to the space.
It is also important that these boxes filter the noise that is developed by the AHU.
The picture above shows a cooling-only VAV box. There are numerous other types of
boxes, including electric heaters, separate fans, or hot water coils.

INTRODUCTION
The airflow regulated by the VAV box is distributed into the space by Air Diffusers.
The airflow patterns in a zone or space should not cause people to feel a draft. Two types
of diffusers are shown below, but there are numerous other types of diffusers. Air leaving
the room passes through return air grilles, to the return air fan in the AHU.
Air Diffusers
Room controls can also control equipment independent from an AHU. This type of
equipment includes fan coil units, unit heaters, unit ventilators, and heat pumps.
A Unit Ventilator, common in schools, is shown above. It serves as the local air-
handling unit and has dampers for the outside and return air, a fan, and a hot water coil.
The hot water comes from the boiler. The diffusers are on the top of the unit. A space
thermostat controls the valve and dampers in this unit. A switch on the base of the
thermostat starts the fan inside the unit ventilator.
Fan Coil Units differ from unit ventilators in that they have no dampers. Fan coils
are typically installed above ceilings or as console units in a room.
There are many different ways to control the environment of a building. This has
only been an overview of some of the equipment that may be encountered.

BASIC CONTROL SYSTEM
Basic Control System
An important part of the mechanical equipment is the Control System. Control
systems are the “brains” of HVAC equipment. Pictured below is an AHU that serves only
one zone. This type of AHU is called a single zone AHU. In the example, a temperature
sensor (stat) sends a signal to a control panel, which sends a signal to a valve. These
controls make up a Basic Control System.
A. Sensor
B. Controller
C. Controlled Devices
1. Actuators
2. Valves
3. Transducers
4. Dampers

Every control system, from the simplest room thermostat to the most complicated
computerized control, has four basic elements. The next page a diagram shows an
example of a basic control system. A Basic Control System always has these parts.
1. A Sensor monitors and measures a variable. In the example, the

variable is temperature. The sensor provides information to the controller.
2. A Controller receives information from a sensor, selects a portion of that

? input for control, and then produces an intelligent output signal. While there
may be several other functions performed by controller, all controllers provide
? setpoint, sensitivity (differential or throttling range) and action. Details of
? these terms are cover in the next few pages.
? 3. A Controlled Device acts upon the signal from the controller. In the example,
the valve is the controlled device, modulating hot water to maintain the proper
? temperature in the room.
4. A Source of Energy is needed to power the control system. Control systems

? use either a pneumatic or electric power supply.
Pneumatic controls use a compressed gas as a source of energy, typically

compressed air. Care should be taken to ensure the air supply is clean, dry,
? and oil-free. Most HVAC pneumatic controls are powered with 15 to 22 psig.
? Electric and electronic controls could be powered by a variety of electrical

power supplies of either Alternating Current (AC) or Direct Current (DC). In
the United States of America, the electrical power supplies could be at 20, 24,
and 120 volts, 60 Hz. In many parts of Europe, 230 volts, 50 Hz is common.
These four parts are needed in any control system, however, two of these parts may
be combined under the same cover, as in the case of some thermostats. While there are
occasions when the sensor and controller are combined into one physical device, their
basic function remains the same. The sensor, controller, and controlled device are needed
for any control system, however an installed system may have additional parts beyond the
basics.
? The example on the next page shows an electronic-DDC (Direct Digital Control)
system. In this, a type of resistor senses the temperature. The controller in the control
panel receives the sensor information and sends an output signal to the valve. The
valve/actuator, which is the controlled device, receives the signal from the controller and
adjusts to the correct position. Here, electricity is the source of energy. Sensor, Controller
and Controlled Device are explained in detail on the following pages.

Energy
Source

Sensor
A sensor monitors and measures a variable. The HVAC variables are temperature,
humidity, and pressure. Different types of signals are produced by different types of
sensors.
Electric Controls ON / OFF signals complete or break (close or open) the control
signal.
Pneumatic Controls Transmitters sense the variable and produce a 3 psig to 15

psig (pound per square inch, gauge), [20 kPa (kiloPascals) -105 kPa] signal over a
? particular transmitter's range.
Electronic Controls Types of electronic sensors are:

? Resistance sensors are Resistance Temperature Devices (RTDs), and are used in
measuring temperature. Examples are Balco elements, Copper, Platinum, 10K
Thermistors, and 30K Thermistors.
Voltage sensors could be used for temperature, humidity and pressure. Typical
ranges are 0 to 5 Vdc (Volts direct current), 1 to 11 Vdc, and 0 to 10 Vdc.
Current sensors could be used for temperature, humidity, and pressure. The typical
current range is 4 to 20 mA (milliamps).
Examples of sensors are shown below:

The resistance outputs of a Balco sensor follow the diagrams below:
Electronic Sensor (Balco)

When 1000 ohms is measured across the Balco element, the temperature is
approximately 70°F (21°C). As the temperature increases, the resistance changes 2.2
ohms per 1°F (3.96 ohms per 1°C). This is called a Temperature Coefficient of Resistance
Curve (TCR Curve). In a Balco, as the temperature increases, the resistance increases
proportionally.

Controller
The controller receives the signal from the sensor and produces an output signal
with setpoint, sensitivity (differential or throttling range), and action. Types of signals from
these devices are as follows:
Electric Controls The majority of electric controls contain the sensor and controller
as one piece. Electric controls use ON / OFF signals.
Pneumatic Controls Controller outputs are 3 to 15 psi (21 to 105 kPa).
Electronic Controls There are basically two types of electronic signals.

Voltage outputs may be 0 to 10 Vdc, 2 to 15 Vdc, or other ranges depending on the
controller. Voltage outputs have the disadvantage, when compared to current signals,
that voltage signals are more susceptible to distortion over long wire distances.
Current outputs modulate from 4 to 20 mA. They have the advantage of producing
little signal distortion over long wire distances.
Examples of controllers are shown below:

Many controllers are housed inside a control panel. In the case of the DDC
electronic controls, the controller itself may be the control panel.
The operation of these controllers is similar. Review the diagram below.
A signal from the sensor is sent to the controller. In this example, 72.5°F (22.5°C) is
the setpoint or desired temperature for a room.
The electronic controller has an output of 6 Vdc at 70°F (21°C), and an output of
9 Vdc at 75°F (24°C). This throttling range of 3°F is used to identify the voltage change to
temperature change. The output is then sent to the controlled device.

Controlled Device
A controlled device acts upon a signal from the controller. There are a variety of
controlled devices. Some examples are;
Electronic Controlled Devices can be either modulating or two-position (ON/OFF).

? For example, hydraulic actuators are designed to accept a voltage (Vdc) or current (mA)
signal, while electronic relays are used for two-position outputs.
Electric Controlled Devices are ON / OFF or two-position devices used to control

electric heat, DX cooling, and two-position dampers or valves.
Pneumatic Controlled Devices are modulating. Pneumatic actuators are

described in terms of their spring range. Common spring ranges are 3 to 8 psig (21 to
56 kPa), 5 to 10 psig (35 to 70 kPa), and 8 to 13 psig (56 to 91 kPa).
Combinations of controlled devices are possible. For example, electronic controllers

can modulate a pneumatic actuator. Also, proportional electronic signals can be sent to a
? transducer, which converts these signals into proportional air pressure signals used by the
pneumatic actuators. These are known as electronic-to-pneumatic (E-P) transducers.
Electric motors with solid state adapters can accept electronic signals.
Pneumatic controllers can provide an output to pressure-to-electric (P-E) switches (on-off
or two position control).
An example of a pneumatic actuator is shown below:
This actuator operates with either a pneumatic controller or with an electronic

controller which sends its signal through a transducer.

As an example of an electronic controller connected to a transducer, 6 Vdc is

converted into 3 psig, causing the valve to be open. At 9 Vdc, the output from a transducer
is 13 psig, completely closing the valve. With a pneumatic controller, 3 psig is sent to the
actuator, completely opening the valve. When the controller sends a 13-psig signal to the
actuator, the valve strokes to the completely closed position.

Actuators
Actuators are devices that operate valves and dampers. There are several different
types of actuators, and four are covered here: pneumatic, hydraulic, gear-train, and direct-
coupled.
Pneumatic Actuators
Pneumatic actuators are common controlled devices in the United States. These
actuators use compressed air to operate valves and dampers. Pneumatic actuators are
easy to repair and can be very cost effective. Specific spring ranges are used for different
applications. Spring ranges are selected to provide the most force at close off or to
perform a specific sequence of operations. On a normally open valve, the spring range of 3
to 8 psig (21 to 56 kPa) would be common. On a normally closed valve, the range is
? typically 8 to13 psig (56 to 91 kPa). An additional device, a positive positioner, is used on
some actuators to them to perform as if they have a different range, or to provide precise
position control. It may also adjust the actuator’s start point, and possibly provide
additional force at the close off of a valve or damper.

Hydraulic Actuators
Hydraulic actuators and valve assemblies are another type of controlled device. The
actuator in the diagram above operates on 6 to 9 Vdc. The yellow wire is the signal
provided by a controller, and the blue wire is common, or 0 Vdc. The red wire is a source
of +20 Vdc used by certain controllers but is typically not a power supply to DDC control
systems controllers. Hydraulic actuators use hydraulic fluid to extend the shaft of the
actuator. An internal spring is used to retract the actuator.
Don’t be confused if the IBS hydraulic actuator is referred to as the “beer can” actuator.
The term “beer can” has been a slang term used by many IBS offices and customers for
years. It is helpful to understand the hydraulic alphanumeric model number system.
IBS Hydraulic Actuators used on both valves and dampers:
MA is for Two–Position Control

MA-5200 series is used for electric two-position control of valves and dampers. ?
MF is for Floating Control
MF-5500 series are floating actuators used in floating control applications ?
MP is for Proportional Control
MP-5200 series takes a signal of 6 to 9 Vdc and strokes between 6 and 9 Vdc
MP-5400 series comes from the factory set up to stroke between 6 and 9 Vdc and has an
adjustable start point and a positive positioning feature
MP-5500 series are compatible with a 0 to 10 Vdc signal

Gear Train Actuators
? Gear train actuators are electric controlled devices. In the picture above, a box-
shaped solid-state drive on the side of the actuator converts the signal (for example, 0 to
10 Vdc or 4 to 20 mA) on the yellow wire to operate the gear train actuator. The blue wire
is common and the red wire is a source of +20 Vdc. The gear train actuator may operate
in a clockwise or counterclockwise direction. An external linkage must be placed on the
actuator to operate a valve or damper. These actuators can develop a large amount of
torque, but caution should be taken to ensure that, in spring-return applications, the spring
has the necessary power to return the actuator to the fail-safe position.
IBS Gear Train Actuators are MP-300s, MP-400s, MP-2000s, and MP-3000. There
are a great variety of features within this product line. The gear train actuators can be used
for proportional, floating, and two-position applications of valves and dampers. (See the
? close-off ratings in the parts catalog.)
Direct-Coupled Actuators
When used on dampers, direct-coupled DuraDrive™ actuators require minimal or no

external linkage, making installation easy to perform. DuraDrive actuators may also be
used with ball and globe valves, and are also available as complete actuator and valve
? assemblies. They are manufactured in a variety of models, including spring-return, non-
spring return, two-position, proportional, and floating control.

Valves
Valves are an integral part of a building's operation. Two-way and three-way valves
are common. "Two-way" describes the number of ports found on a valve, not the different
ways the valve can be piped into a system. Water only flows in one direction through a
two-way valve. Two-way valves come in two types, Normally Open (N.O.) and Normally
Closed (N.C.). The term "normally" refers to the position at which the valve is set whenever
power or the control signal is lost. In Invensys globe valves, the “normal” or failed position
is based on stem-up.
Normally Open (N.O.)

Normally open valves are typically used on hot water coils in an air handling unit. When
the control signal is lost, the valve goes to the fail-safe position, completely open, allowing
the available hot water to flow through the coil. Note: Some applications may require the
control system to use Normally Closed (N.C.) valves in heating applications.
Normally Open Valve
Normally Closed (N.C.)

Normally closed valves are typically used on chilled water systems. When the controller
signal is lost, the valve goes to the fail-safe position, fully closed, stopping all water flow to
the coil. In very mild climates, where the threat of freezing is not a major consideration,
normally closed valves may be used for both heating and cooling.
Normally Closed Valve

Three-Way valves
Three-way valves are another type of valve, so named because of their three ports. Three-
way valves come in two types: mixing and diverting.
? Mixing valves are used more extensively than diverting valves, due to cost
considerations. A mixing valve is defined as a valve with two inputs and one output. This
valve may be used on chilled water coils to divert water through the coil or bypass around
it. The use of mixing valves prevents the buildup of water pressure found with two-way
valves.
Mixing Valve
A diverting valve is defined as a valve with one input and two outputs. A common
use of a diverting valve is with a cooling tower, where the valve diverts water to the top of
the cooling tower or bypasses the tower to the sump.
Diverting Valve

Transducers
Transducers allow electronic controllers to use pneumatic actuators. Transducers
convert one type of proportional energy into another. An electronic-to-pneumatic (E-P)
transducer converts a voltage or current input into a pneumatic (psig) output.
B M
24H
24G
+IN
COM
+20
OC
OE
AUTO MANUAL
A voltage transducer may convert a 0 to 5 Vdc, 0 to 10 Vdc, or 1 to 11 Vdc signal to

a pneumatic signal from 3 to 15 psig. Setup is required to modify the voltage signal to
match the desired pneumatic output signal.
Another E-P transducer converts a 4 to 20 mA current signal to a 3 to 15 psig

pneumatic signal. Setup is required on this transducer also, to adjust the current signal to
the desired pneumatic output signal.

Dampers
The proper damper operation is important to a building. The common types of
dampers are parallel blade and opposed blade.
Parallel Blade Dampers
Parallel Blade Dampers
Parallel blade dampers are pictured above. Note that the blades of the damper are
parallel to each other. Outside air dampers are linked normally closed, so that if any
? problem occurs, such as a low limit alarm, the outside air dampers go closed. In this
example, the return air dampers are linked normally open.
Opposed Blade Dampers
Opposed Blade Dampers
The diagram above shows opposed blade dampers in which the adjoining blades of
the damper are positioned in opposite directions. It is important that outside air dampers
and return air dampers work together. As one damper closes, the other damper opens. If
these two dampers fail to work properly and both become closed, the supply fan will
continue to pull in air, which could result in the ductwork collapsing.

Review
Review the following diagram and answer the questions on the next page.

Review the previous page and answer the following questions.
Answer questions 1 through 3 by filling in the identification number of the device.
Fill in the Blank
1. Which numbered device is a sensor? __________
2. Which numbered device is a controller? __________
3. Which two devices are controlled devices for water? _______ ______
Fill in the Blank
4. Device #1 shows _______________ blade dampers.
5. These dampers control ____________ air.
6. These dampers are linked normally _______________.
7. Device #3 is a __________________.
8. Device #3 converts an ___________ signal into a ____________ signal.
9. Device #2 is a three-way _______________ valve.
10. Device #5 is a two-way ______________________ valve.

Answers to the review
1. 6.
2. 4.
3. 2 and 5
4. Parallel
5. Return
6. Open
7. Transducer
8. Electronic signal into a Pneumatic signal
9. Mixing
10. Normally Open

CONTROL THEORY TERMINOLOGY
Control Theory Terminology
This section covers the following terms:
• Setpoint, Control Point, Offset

• Controller Action
• Reset
• Proportional Control
o Throttling Range
o Proportional with Integral (P.I.) Control
• ON/OFF control
o Differential
o Floating Control

Setpoint, Control Point, Offset
Setpoint
Setpoint is the desired condition of a variable that is to be maintained, such as
temperature. A room that needs relative humidity to be at 50% RH, or an air handler duct
pressure that is to be 2.0 in. w.c. (inches of water column) (500 Pa) are examples of ?
setpoints. In the example below, 75°F (24°C) is the room temperature setpoint.
Setpoint
Control Point
The Control Point is the actual temperature being sensed. The Control Point ?
(temperature) may not be on the setpoint, but instead may be above or below it. Systems
operate to maintain the setpoint, plus or minus some acceptable limits called differential ?
(two-position or on/off control) or throttling range (proportional control). Simply stated,
setpoint is what you want, while control point is what you get. In the example below, the ?
setpoint is 74°F (23°C), and the control point is at 72°F (22°C), and varying.
Offset is the amount away from setpoint, or the difference between the Setpoint and ?
the Control Point. In the example above, the offset is approximately 2°F(1°C).

Controller Action
? All controllers, from pneumatic to DDC electronic, have an action. They are either
Direct Acting or Reverse Acting (although other terms may be used).
?
Direct Action means that the controller's output increases as the sensor's input increases.
For example, as room temperature (the variable) changes from 70°F (21°C) to 71°F
(21.5°), the controller changes its output from 10 to 12 mA. Shown below, as the sensor
reads an increasing input (temperature), the controller responds by increasing its output
(pressure) to the valve, closing the normally open valve and reducing the hot water flow.
This relationship between the input to a controller (temperature) and its output
(current) can be displayed on a graph as follows:

Reverse Action means that as the variable (for example, temperature) increases, the
controller's output decreases. For example, as room temperature rises from 70 to 71°F, the
controller output decreases from 8.1 to 7.3 mA. In the example below, as the sensor reads
an increasing temperature, the controller responds by decreasing its output (pressure) to
the valve, closing the normally closed valve and reducing the amount of heating.
This relationship can is displayed on a graph as follows:

The action of the controller must match the proper HVAC application. Normally
open heating valves always use direct acting controllers. If a reverse acting controller were
to be placed on a normally open heating valve, the heating valve would open as
temperature rises. A reverse acting controller never properly controls a normally open
heating valve.
The table below was developed to help determine the correct controller action for
different applications. To use the table, first pick the correct application: for temperature,
select heating or cooling; for humidity, select humidification or dehumidification; for
pressure, select whether the sensor is downstream or upstream from the controlled device.
The second step is to determine how the application fails. Example, does the heat
fail to full ON or full OFF? Once these questions are answered, follow the column down
and follow the row across to the intersection to find the correct action for that application.
Controller Action Heating Cooling

Instructions: Humidification Dehumidification
1. Pick system application Pressure (sensed Pressure (sensed
downstream from upstream from
2. Pick fail safe condition
C/D) C/D)
3. Intersection shows action
System Fails to ON
• Normally open ports, valves, or dampers
D.A. R.A.
• Normally closed electric contacts
System Fails to OFF
• Normally closed ports, valves, or dampers
R.A. D.A.
• Normally open electric contacts
Example: In Florida, you are controlling a normally open chilled water valve. In this
example, the cooling column is used. In much of Florida, cooling is far more important than
heating. Since the valve is normally open, the "Fails to ON" row is used. The column and
the row intersect at R.A. or Reverse Acting. As the temperature increases, the signal
drops, allowing the chilled water valve to go to its normal open position. As the
temperature decreases, the signal increases, closing the normally open chilled water valve.
Controller action is very important. Review the examples on the next page and
determine if the controller should be D.A. (Direct Acting) or R.A. (Reverse Acting).

REVIEW
Circle the correct answer.
1. A discharge air sensor modulates a normally open hot water valve. What action is
needed for the controller?
Circle the correct answer. D.A. or R.A.
2. A return air humidity sensor modulates a normally closed chilled water valve for
dehumidification. What action is needed for the controller?

3. A static pressure sensor modulates normally closed inlet vane dampers to maintain 2.0"
w.c. (500 Pa). What action is needed for the controller?
4. A room sensor cycles DX cooling to maintain a room temperature of 75°F (24°C). The
DX Cooling has normally open electrical contacts. What action is needed for the
controller?
5. The mixed air sensor modulates the normally closed outside air dampers and the
normally open return air dampers to maintain a temperature of 55°F (13°C). What action is
needed for the controller?

1. Direct Acting
2. Direct Acting
3. Reverse Acting
4. Direct Acting
5. Direct Acting

Reset
? The word reset has different meanings in HVAC. Reset in this instance is the
automatic resetting of a setpoint based on a secondary signal. Reset of a setpoint is used
for comfort reasons, for better control, or to save energy. A common example of reset is
called hot water reset. Hot water reset automatically decreases the hot water temperature
setpoint as the outside air temperature rises. If the outside air temperature is 0°F (-18°C),
the building requires 180°F (82°C) water. If the outside air temperature is 70°F (21°C), the
building requires 90°F (32°C) water. As the outside temperature increases, the hot water
setpoint drops.
In every reset application there are at least two sensors. In the example above, the
two sensors are outside air temperature (O.A. Temp) and hot water supply temperature
(HWS). It is important to know which sensor is the primary sensor and which is the
secondary sensor. To determine which is the primary sensor, ask, "What are the controls
trying to control?" In this example, there is one sensor in outside air and one in hot water.
Of these two, the hot water is being controlled, therefore the hot water sensor is the primary
sensor. The outside air temperature sensor is the secondary sensor. The function of the
secondary sensor is to reset, or automatically change, the setpoint of the controller.
Each reset application uses a reset schedule. This schedule is determined by the
mechanical engineer or the application engineer. A hot water reset schedule is shown on
the next page.

RESET Schedule
Just as the term “action” is defined as reverse and direct, “reset” is also defined as
reverse and direct. The hot water reset, above, is an example of reverse reset.
?
Reverse Reset
The most common of the two types of reset is reverse reset. Reverse reset means
that as the signal from the secondary sensor drops, the setpoint of the controller increases.
In the example above, as the outside air temperature drops, the hot water setpoint rises.

Direct Reset
? With direct reset, as the signal for the secondary input increases, the setpoint
increases. Direct reset is less common than reverse reset. An example of direct reset is
an application called “summer compensation”, shown below.
Summer Compensation
When cooling (air conditioning) was first introduced, shopping malls advertised their
stores as being a comfortable 72°F (22°C) year round. This was fine until the summer
became very hot. People who were outside in 100°F (38°C) weather, dressed for hot
weather, would walk into a shopping mall and feel cold. Some people did not stay long in
the stores because it felt too cool. Summer compensation is used to counteract this
problem. Summer compensation raises the zone setpoint as the outside air temperature
increases. The secondary signal and the setpoint go in the same direction. A typical reset
schedule for this application may look like the following:
Summer Compensation Reset Schedule
This application is used in any building where a large number of people are entering
and leaving all day, such as a shopping mall or bank. If this application is used, it may be
important to ensure that the air is dehumidified for proper comfort.

Identifying Reverse or Direct Reset.
Identification of an application as reverse reset or direct reset is possible by looking
at the reset schedule and noting the relationship between the secondary signal and the
setpoint. If the secondary signal increases as the setpoint decreases, then the application
is reverse reset. If the secondary signal increases as the setpoint increases, then it is direct
reset.
Secondary Signal and Setpoint go in Opposite directions = Reverse Reset
Secondary Signal and Setpoint go in the Same direction = Direct Reset

Review
Review the following applications and answer the questions.
Application #1
The hot water supply is maintained by modulating two normally closed steam valves
supplying the steam converter.
Hot Water Reset using a Steam Converter
(Circle the correct answer)

1. Which is the primary sensor? Hot Water Supply (HWS)
or
Outside Air Temperature (OAT)
2. What type of reset is this? Direct Reset

or
Reverse Reset
3. What action is needed at the controller? Direct Action

or
Reverse Action
Answers follow application #3.

Application #2
The return air humidity sensor controls the normally closed valve on the steam
humidifier according to a reset schedule.
Humidity Reset
4. Which is the primary sensor? Return Air Humidity

or
O.A. Temperature

or
Reverse Reset

or
Reverse Action

Application #3
The mixed air temperature sensor controls the normally closed outside air dampers
and the return air dampers. The mixed air temperature setpoint is reset by the return air
temperature, according to the following reset schedule.
Mixed Air Reset
7. Which is the primary sensor? Return Air Temperature

or
Mixed Air Temperature

or
Reverse Reset

or
Reverse Action

1. Hot Water Supply
2. Reverse Reset
3. Reverse Action
4. Return Air Humidity
5. Direct Reset
6. Reverse Action
7. Mixed Air Temperature
8. Reverse Reset
9. Direct Action

Proportional Control
? There are a number of control systems that are proportional by their nature,
including pneumatics, electronic analog controls, and electronic digital controls.
?
Electronic Direct Digital Control System
Electronic Direct Digital Controls, better known as Direct Digital Controls (DDC),
were introduced to the market in the early 1980s. These controls are electronic and
microprocessor based, and require programming to operate correctly. These devices run
their programs over and over again. Each time a controller completes its program, it scans
(reads) the inputs. A DDC controller may scan as fast as several times each second. With
each scan, adjustments are made to the outputs. In the example below, a DDC controller
modulates a three-way mixing chilled water valve to maintain a room setpoint of 74°F
(23°C).
A Balco element may be used as the sensor, although numerous other sensor inputs
can be used, including platinum, copper, or 10K thermistors. These are referred to as
RTDs (resistance temperature devices). Other inputs might be voltage, from 1 to 5 Vdc, or
current of 4 to 20 mA (milliamps). The controller amplifies the signal and provides a
setpoint, an action, and a throttling range. The controller might optimize the output,
coordinate the output with other controllers, or trend the input and output. Information can
be shared with other controllers. The output from the controller goes to the actuator via the
yellow wire and varies from 0 to 12 Vdc or from 4 to 20 mA.

Proportional control is a common form of control. Proportional control maintains a
setpoint with variations above and below that temperature. A graph of proportional control
used with room cooling is shown below.
The DDC system on the previous page controls a room with a setpoint of 74°F
(23°C). At setpoint, the valve is at midstroke, representing 50% cooling output from the
coil*. Suppose there is a large influx of people into the room. People put out heat, causing
the room temperature to rise. The controller responds by increasing the signal, extending
the actuator and opening the normally closed chilled water valve. Based on the throttling
range and the setpoint, each temperature value represents a corresponding actuator
position. For example, midstroke is reached at 74°F (23°C). The heavy cooling load
resulting from the large number of people entering this space causes the temperature to
climb to 76°F (24°C) and the valve strokes to its fully open position. Next, suppose most of
the people leave this space, causing a light cooling load. The temperature drops and the
actuator retracts, closing the valve completely when the space temperature reaches 72°F
(22°C). The preceding two examples show that the temperature can swing anywhere
within the 4°F (2°C) throttling range, based on the system’s cooling load.** It is only when
the load is at 50% of its maximum that the space temperature matches the setpoint exactly.
However, such temperature swings are not noticeable to most people.
*HVAC systems are non-linear. A valve or damper that is 50% open, or at mid-stoke, does
not typically equate to 50% flow.
**If the requirement for cooling is beyond the limits of the cooling equipment, the controls
may be working properly even though the room temperature is outside the throttling range.
For example, if there is a meeting in a room that was designed for a maximum capacity of
twenty people but forty people actually attend, the heat generated by the additional people
will cause the room to become warmer than the controller setpoint plus the throttling range.

Throttling Range
System Throttling Range (TR) is the change in the measured variable
(i.e. temperature) that causes the controlled device to travel from one end of its stroke to
the other. In the example below, it takes a TR of 8°F (4°C) to cause the actuator to travel
from the completely open position to the completely closed position.
Throttling range is sometimes referred to as “sensitivity”. Typical throttling ranges

are 8° to 10°F (4° to 5°C) for mechanical controls such as mixed air control and the control
of hot water supply. In contrast, room controls must be much tighter, with a throttling range
between 2° and 4°F (1° to 2°C)
If the throttling range becomes too narrow, it causes the actuator to go into a mode
? called hunting. In this mode, the actuator continually searches (or “hunts”) for the proper
controlled position — full open, then full closed; then full open, then full closed, etc. A
control system that is hunting, is not in control. It may be possible to eliminate hunting by
increase the throttling range so that the controller is less sensitive.

Proportional with Integral (P.I.) Control
Assume that the room that is being controlled has an oversized valve. While there is
no substitute for a properly sized valve, Integral control can make this condition less ?
objectionable. To stop the actuator/valve assembly from hunting, a wide throttling range
8°F (4°C) may be set. However, room temperature swings of 8°F (4°C) are typically
unacceptable and complaints may become common place. A way to correct this situation
may be to use proportional plus integral, or P.I., control. Electronic digital controls use this
mode of control effectively. Electronic-analog and pneumatic controls can also be set up
for P.I. control, but may require considerable time and effort to do so.
Below is a graph of proportional with integral control.
Refer to the graph, above, for an example of how P.I. control works. Note that
starting at the left, the temperature matches the setpoint, and the output from the controller
is 50%. Then the load changes and there is an offset from the setpoint. The output from
the controller starts to compensate, first at 55%, then 60%, then 65% and so forth, until the
temperature returns to setpoint. This may cause some oscillation on the part of the
controller, but its output eventually stabilizes. In this example the output, at 65%, took
three minutes to stabilize and achieve the 74°F (23°C) setpoint. In other words, every time
the load changes, the controller attempts to make the setpoint and the control point the
same.
Since any temperature changes are amplified, it is important to make sure the
system does not hunt before adding integral control. This means the throttling range may
need to be increased, or even doubled, to ensure that the system is stable for P.I. control.

ON / OFF Control
A type of control system where the output is either 0% or 100% is sometimes
referred to as “two-position control” or “ON / OFF control”. Mechanical equipment such as
fans, pumps, chillers, boilers, electric heaters and Direct eXpansion (DX) cooling may be
controlled by a two- position control system. In the diagram below, a room sensor monitors
the temperature. The controller uses this sensor information to operate a relay output, by
using an appropriate program, the correct action, a setpoint, and a differential. Some
controller outputs cannot be used directly to control the large amperage of equipment. In
that case, a pilot duty relay is used, as shown below.
In the above example, when the room temperature rises, the controller sends a signal to
close the pilot duty relay. The normally open contact is then made to common. This
completes the circuit and starts the DX cooling. When the temperature drops, the controller
returns the relay output to its open (normal) position, thereby turning OFF the DX cooling.

Differential
A diagram of two-position control as it relates to time and temperature, appears
below.
When the temperature reaches 76°F (24°C), the controller turns the DX cooling ON,
causing the space to cool. When the temperature has cooled to 72°F (22°C), the controller
turns the DX Cooling OFF, causing the space temperature to rise. This 4°F (2°C) swing in
temperature is not noticeable to most people. The difference between the temperatures at
which the controller turns ON or OFF, is called the Differential. The differential is similar to
throttling range except that the output is two-position, not proportional. The differential
must be wide enough to prevent short-cycling, which can cause mechanical equipment to ?
break down prematurely.
The differential is the change in the measured variable (i.e. temperature) required to
cause the controlled device to go from ON to OFF. The example used in the discussion of
throttling range applies here also, with the exception that DX Cooling is cycled from ON to
OFF. A 4°F (2°C) differential exists between the temperatures at which DX Cooling comes
ON and goes OFF.
There are actually two differentials. Mechanical Differential is the difference in the
temperatures at which the equipment is turned ON or OFF. The other type is the Thermal
Differential, which is the swing that occurs in the actual room temperature. The thermal
differential is wider than the mechanical differential because the cooling or rising of the
actual room temperature always lags behind the equipment turning ON or OFF.

Floating Control
Another variation of ON / OFF Control is Floating Control. Below is an example of
this application, in which an electric actuator is used to maintain static pressure inside a
supply air duct in a VAV air-handling unit.
The DDC controller in this example is controlling an actuator that positions normally
closed inlet vane dampers on a supply fan. At start-up, the inlet vanes are closed and the
duct static pressure is low. Because the controller is set up to maintain the duct static
pressure at 2 in. w.c. (500 Pa), it completes the OPEN circuit. This in turn drives the
electric actuator clockwise, causing the dampers to open, thus allowing more air to enter
the duct. This does not necessarily mean the dampers are opened fully. Instead, the
system opens the dampers just enough to raise the static pressure to the setpoint, inside
the differential. Once this pressure is reached, the controller breaks the OPEN circuit.
If the static pressure is too great, the controller completes the CLOSE circuit. This
causes the actuator to drive counterclockwise (anti-clockwise), closing the dampers and
reducing the airflow, thus lowering the static pressure. Once the static pressure is within
the differential, the controller breaks the CLOSE circuit. At setpoint, neither the OPEN nor
CLOSE circuits are made, and the actuator "floats" at its last position.

The diagram of static pressure controlled with floating control, is shown below.
At the left of the graph, when duct pressure is 2 in. w.c. (500 Pa), the controller does
not respond. As the demand for cooling drops and several VAV boxes begin to close
down, the static pressure inside the supply duct rises. It is only the static pressure reaches
2.1 in. w.c. (525 Pa), that the controller responds. At that point, the controller completes
the CLOSE circuit and the actuator slowly drives the inlet vane dampers further closed. If
the CLOSE contacts stay closed for only 6 seconds, and it takes 120 seconds for the
actuator to travel from one end of its stroke to the other, this would mean than the actuator
closed the dampers 5%.
When the demand for cooling increases, some VAV boxes open, and static pressure
begins to drop. When the pressure reaches 1.9 in. w.c. (475 Pa), the OPEN contacts are
made for 12 seconds, so that the dampers are opened by 10%.
Pulsed Width Modulation

A variation of floating control, which is used in DDC controls, is called Pulsed Width
Modulation. This type of control pulses the OPEN or CLOSE contact for a certain number
of seconds, then waits for the variable (i.e. temperature) to respond. This type of
arrangement has had some success with temperature control.

Review
1. Assume that you are using proportional control. Identify each of the lettered items in
the graph, with one of the terms discussed in this section, then give its present numerical
value either in °F or °C.
Term Name Present Value
A. _____________ _______________
B. _____________ _______________
C. _____________ _______________
D. _____________ _______________

2. Review the multizone application below, then answer the questions that follow.
(Circle the correct answer)

A. Which is the primary sensor?
Hot Deck Temperature
or
Low Temperature Select
B. What type of reset is this?

Direct Reset
or
Reverse Reset
C. What type of valve is this?

Normally Open
or
Normally Closed
D. What type of control is this?

Proportional
or
Two-position
E. What action is needed at the controller?

Direct Action
or
Reverse Action

1. A. Throttling Range 4°F (2°C)

(the output is modulating, not two-position, therefore it is not differential)
B. Offset 2°F (1°C)
C. Setpoint 70°F (21°C)
D. Control Point 72°F (22°C)
2. A. Hot Deck Temp

B. Reverse Reset
C. Normally Open
D. Proportional
E. Direct Action

ENERGY MANAGEMENT TECHNIQUES
Energy Management Techniques
This section covers a number of different strategies used to save energy:
• Timed Programmed Commands

• Duty Cycle
• Optimum Start / Stop
• Electric Demand Limiting
• Enthalpy Optimization
• Degree Day Calculations
• Night Purge Cycle
Before energy management is discussed, it is important to remember that there may be ?

a trade-off with comfort. When a building operator attempts to save energy, some comfort
may be compromised.

Time-Programmed Commands
Time-Programmed Commands are an excellent way to save energy. However, this

strategy is only effective if a building, or a large portion of a building, has an unoccupied
time. During unoccupied time, typically at night, the heating setpoint shifts to 55°F (13°C)
? (night setback); the cooling setpoint shifts to 90°F (32°C) (night setup); and lights, fans,
? chillers, and other mechanical equipment are turned OFF.
Just before occupied time arrives, the heating setpoint shifts to 70°F (21°C) or the
cooling setpoint shifts to 75°F (24°C), and the lights, fans, and chillers are turned ON.
These temperature setpoints are merely suggestions and may vary. Also, certain types of
mechanical equipment, such as a boiler, typically stay ON during winter.
This strategy results in a loss of comfort for those individuals that enter the space during
the unoccupied times. If there are individuals who come in after hours, some type of
? override is required to turn the lights and mechanical equipment back to an occupied mode.

Duty Cycling
Duty cycling is a strategy that cycles certain loads, such as small exhaust fans, ON and ?
OFF. For example, exhaust fans may be cycled ON for 20 minutes, then shut OFF for 10
minutes, continuously throughout the occupied time. This is referred to as a fixed duty
cycle. At the end of the day, the OFF time may amount to a large portion of the time.
While this strategy may look good on paper, in practice it may not be cost effective. For
example, if this strategy is used on large fan motors of 15 hp or greater, there may be no
energy savings. That is because the money that is saved during the OFF time could be
offset by the large current draw required for starting up the large fan, and the ON and OFF
cycles can require more maintenance on the motor belts and other equipment.
A modification of this strategy is called the Temperature Compensated Duty Cycle.
This strategy is used with electric baseboard heaters. If the temperature in the space is
70°F (21°C), the heaters are ON for 1 minute and OFF for 14 minutes. If the space
temperature drops to 68°F (20°C), then the heaters are ON for 7 minutes and OFF for
8 minutes. If the space temperatures continue to drop to 66°F (19°C), then the heaters are
ON continuously and are not shut OFF until the temperature in the space reaches the
setpoint.

Optimum Start / Stop
Optimum Start can be a valuable strategy for saving energy if there are unoccupied
times in a building. The optimum start program computes the best, or optimum, time to
start the heating or cooling equipment so that at the precise beginning of occupied time, the
zone is at the desired temperature. Significant amounts of energy may be saved if the
occupied setpoint is achieved as close to occupied time as possible.
Note the example in the chart above. Using only Timed Program Commands (TPC),
and identifying the worst possible conditions in which to start cooling, it has been decided
that the cooling must be started at 4:00 a.m., 4 hours before occupied time, when it is 95°F
(35°C) outside and the zone temperature is 90°F (32°C). This may be a good strategy if
these worst-case conditions always exist. However, if the outside air and zone
temperatures are lower, the setpoint will be reached in a shorter time than necessary,
wasting energy. As the chart shows, if the outside air is 68°F (20°C) and the zone
temperature is 80°F (27°C), the cooling equipment would achieve the occupied setpoint 2-
1/2 hours before occupied time, which is much earlier than necessary. Instead, when
optimum start is used under these cooler conditions, the occupied cooling is started 1-1/4
hours before occupied time. This is much more efficient than the 4 hours chosen in the
earlier strategy.
Optimum start is used in the same way for heating. If heat is required in the morning to
raise the temperature to the occupied setpoint, the program would automatically calculate
the start time so that setpoint is achieved just before occupied time begins. That means
that on warmer mornings, the heating equipment is started at a later time than it is on
cooler mornings.
The Optimum Stop program calculates a stop time that allows the temperature of
the space to “coast” from the occupied setpoint towards the unoccupied setpoint, while
maintaining an allowable comfort level with the least amount of energy usage. For
example, the program would monitor the end of the occupied day and begin turning heating
and cooling equipment OFF as people leave the building, to “coast” to the unoccupied
setpoints.

Electric Demand Limiting
Power Demand Limiting is also referred to as EDL.
ELECTRIC DEMAND LIMITING (EDL),
Controlling energy costs is a major concern for today’s building owners. Trying to
manage the consumption of electricity is a concern for the utility provider, as well. One
strategy that electric companies have instituted to hold down electricity usage is to impose
demand charges, in which the utilities set a demand limit for a facility's electric usage. If
this limit is exceeded, the facility pays a penalty, or demand, charge. These demand
charges could comprise 30% to 70% of the electric energy bill. An additional problem is
that even one excursion beyond the demand limit could increase the utility bill for as long
as an entire year. Of course, utility companies and areas vary in the approach taken with
consumer utility management, therefore it is suggested that you consult with your providers
to ensure your programs are set up correctly.
An effective way to manage demand and limit the number of excursions is to use an
Electric Demand Limiting (EDL) program. In this strategy, automation equipment, using EDL,
monitors all the demand circuits. Through a technique known as sliding-window data, EDL
predicts (forecasts) an expected demand level before it occurs. The forecasted demand
level is then compared to the pre-established demand limit. If the forecasted value exceeds
this demand limit, the program computes the magnitude of the expected excursion and
automatically sheds sufficient loads (load shedding) to prevent the excursion from occurring. ?
Once the demand drops below the limit, those previously shed loads are brought back on
line.
Looking at the example above, the demand limit is 1500 KW, which is calculated
over a 15 minute window. As the kilowatt usage approaches the limit, non-essential loads
are shed, or turned OFF, to avoid exceeding the limit. This may occur, for example, when
there is a large demand for cooling. When the usage level drops to 1425 KW, these loads
are restored, or turned back ON.

A difficult part of using the EDL program is the determination of non-essential loads.
For instance, if air handling units are turned OFF, people may become uncomfortable. In
response to this, some EDL programs offer the option of choosing different methods of
shedding loads. An example of this is Linear Mode, which puts loads in priority so that the
least important areas are shed first. This is also described as First OFF, Last ON. Another
option is called Rotate, which places all the loads on an equal basis but rotates the
selection of which load will be shed first. In other words, one area is shed first this time but
another area is shed first the next time. This option is also described as First OFF, First
ON.
Note; Demand charges and energy management programs used by utility companies differ
greatly. Be sure to investigate the programs that are available in your area.
Enthalpy Optimization
During the cooling season, additional energy savings may be realized by choosing
the air source, either return air or outside air, that contains the least amount of total heat
? (Enthalpy). Enthalpy is determined by a combination of temperature and relative humidity.
There are energy savings if the cooling coil is presented with the air having the lower
enthalpy, whether this is return air or outside air.
In the example shown above, the outside air is 9°F (5°C) cooler than the return air.
However, the relative humidity of the outside air is 95%, fully 70% higher than the return air.
This combination of temperature and humidity means that the outside air has more
enthalpy than the return air. It would require more energy for the cooling coil to remove the
moisture from the outside air than the return air. Therefore, the Enthalpy Optimization
program selects the return air as the better choice for cooling.

Degree Day Calculations
Degree day calculations do not directly save energy but are designed, instead, to share ?
information. Degree day calculations keep track of outside air conditions and calculate the
demand for heating and cooling.
One method of tracking the outside air and the need for heating is the calculation of
heating degree day units, used by the National Weather Service. This is a unit, based
upon temperature and time, used in estimating fuel consumption and specifying nominal
heating load of a building in winter. One heating degree day is given for each degree that
the daily mean temperature is below 65°F (18°C), the temperature below which heating is
enabled. For example, if yesterday's high for outside air temperature was 60°F (15.5°C),
and the low was 40°F (4.5°C), then the average outside air temperature was 50°F (10°C).
Since the average outside air temperature is 15°F (8°C) below the heating enable point, 15
heating degree day units (8 heating units for metric) are calculated for that day. Programs
in DDC controllers follow the heating and cooling demands, providing the operator a useful
tool for energy discussions with the building managers or owners.

Night Purge Cycle
During the cooling season, if the inside temperature is considerably greater than the
outside air temperature, then the air handling units may be turned ON during the night, to
purge the warm air out of the building. This is called a Night Purge Cycle.
In the example shown above, the inside air temperature is 18°F (10°C) warmer than
the outside air temperature, which has cooled during the night. To correct this, the air
handling units are turned ON until only a 5.5°F (3°C) difference is present. This type of free
cooling reduces the amount of mechanical cooling that has to take place the following
morning. However, caution should be taken concerning the humidity of the outside air. To
address this concern, an enthalpy optimization program could be established to ensure that
only the lowest enthalpy air is used to cool the building at night. Whether or not to use the
night purge cycle is determined by comparing the cost of running the air handling units at
night versus the cost of running the mechanical cooling in the morning.

REVIEW
1. Which two energy management strategies are dependent upon the facility having
Unoccupied Times?
(Circle the two best answers)
A. Timed Program Commands
B. Duty Cycle
C. Optimum Start
D. Electric Demand Limiting
E. Enthalpy Optimization
F. Degree Day Calculations
G. Night Purge Cycle
2. Of the following energy management strategies, name the two that have had the
least success.
B. Duty Cycle
C. Optimum Start
3. Of the following energy management strategies, name the two that deal only with
cooling and do not deal with heating applications.
B. Duty Cycle
C. Optimum Start
4. Which of the following requires loads to be placed in a priority of importance, from

non-essential loads to essential loads?
(Circle the best answer)
B. Duty Cycle
C. Optimum Start

5. Which of the following allows yearly and monthly comparisons of the demands for
heating and cooling?
B. Duty Cycle
C. Optimum Start
6. Which one of the following programs uses setup and setback?

B. Duty Cycle
C. Optimum Start

1. A. Timed Program Commands

C. Optimum Start
2. B. Duty Cycle
3. E. Enthalpy Optimization
4. D. Electric Demand Limiting
5. F. Degree Day Calculations
6. A. Time Programmed Commands

DDC TERMINOLOGY
DDC Terminology
This section covers the following terms:
• Points
o Digital Input (DI)
o Digital Output (DO)
o Analog Input (AI)
o Analog Output (AO)
• Universal Points
• Pulse Input

DDC TERMINOLOGY
Points
Points are the communications connections between a DDC Controller, sensors and
controlled devices. There are four different types of points: Digital Inputs (DI), Digital
Outputs (DO), Analog Inputs (AI), and Analog Outputs (AO). Points may have names other
than these. For example, a digital input may be called a Contact Input (CI), instead. For
consistency, we will refer to points as digital inputs, digital outputs, analog inputs, and
analog outputs.
Digital Inputs
Digital means that a piece of equipment can be either ON or OFF. Input refers to
information being sent to the DDC Controller. Therefore, a digital input is an ON/OFF
signal sent to the controller. Other names for digital are contact, two-position, binary,
discrete, or logical. Examples of digital inputs are occupied/unoccupied switches, flow
switches, and static pressure switches (pictured below).
Static Pressure Switch
Shown below is a flow switch, a type of DI, wired to a DDC controller. The terminals
labeled on the controller are UI-7 and C. UI-7 is the controller’s seventh UI terminal; UI
stands for Universal Input, which is explained later. The terminal designation "C" stands for
common. No external power is applied to this sensor.

DDC TERMINOLOGY
Digital Outputs
A Digital Output (DO) is an ON/OFF signal sent out from the controller. Examples of
DOs are electric heaters, DX cooling, supply fans (pictured below), boiler enable, and
chiller enable.
Below is an example of a DO wired to a DDC controller (the MZ1). These particular

outputs are for pilot duty only, which means they cannot handle a large current. In this
example, the DO can handle only 1 amp, at either 24 or 120 Vac. Here, the pilot duty relay
is an electromagnetically activated switch that actually turns the electric heat or DX cooling
ON or OFF. Note that the DDC controller's terminals for this output are labeled NC1
(normally closed output #1), C1 (common for output #1), and NO1 (normally open #1). An
indicator is provided to show the status of this DO.
Contact types
? If a controller has dry contacts, power must be added to make the relay work, as
pictured above.
If a controller has powered contacts, then there is already power at the contacts and
external power is not wired to those terminals. Triacs are a very common type of powered
contacts.

DDC TERMINOLOGY
Analog Inputs
Analog Inputs (AIs) are another type of points. In contrast to digital signals, which
are either ON or OFF, analog signals can place the equipment in a range of positions. As
before, input refers to information being sent to the controller. Therefore, an analog input is
a varying, or modulating, signal that is sent to the controller. Other names for analog are
proportional, numerical, or modulating. Examples of AIs are hot water temperature, room
temperature, outside air temperature, zone humidity, and building static pressure.
The example, below, shows a room temperature sensor wired to a DDC controller.
The terminals for this input are labeled UI-1 (Universal Input #1) and C (Common). This
sensor is an RTD, a Resistance Temperature Device. These devices can have Balco,
Platinum, Copper or Thermistor elements, each of which features a different relationship
between temperature and resistance.
RTDs
Balco
Resistance = 1000 ohms at 70°F (1000 ohms at 21°C)
Range = -40° to 240°F (-40° to 115°C)
Ohms to Temp = Direct Relationship
IBS products using Balco resistors include the TS-8000 and TS-80000 series room
sensors, solar sensors, immersion sensors, averaging element sensors, outdoor air ?
sensors, and strap-on sensors. ?
Copper
Resistance= 1000 ohms at 70°F (1000 ohms at 21°C)
Range = -40° to 240°F (-40° to 115°C)
IBS products using copper include the TS-5900 series sensors

DDC TERMINOLOGY
Platinum
Resistance = 1000 ohms at 32°F (1000 ohms at 0°C)
Range = -40° to 240°F (-40° to 115°C)
An example of an IBS product using a platinum element is the TSMN-58001 Room Sensor
10K Thermistor
Resistance = 10K ohms at 77°F (10K ohms at 25°C)
Range = 40° to 104°F (4 ° to 40°C)
Ohms to Temp = Reverse Relationship
An example of an IBS product using a thermistor element is the TSMN-57001-850 Room
Sensor
Voltage and Current Inputs

Voltage Inputs are normally 1 to 5 Vdc. Current Inputs are usually 4 to 20 mA, and are
sometimes used for humidity or pressure sensors.

DDC TERMINOLOGY
Analog Outputs
An Analog Output (AO) is a varying, or modulating, signal sent from the controller.
Examples of AOs are hot water valves (shown below), outside air dampers, and variable
frequency drives.
The example shown below is an AO from a DDC controller. The terminals are
labeled AO2 (Analog Output #2) and C (Common). A transducer converts the 4 to 20 mA
signal to a 3 to15 psig pneumatic signal. This application is frequently used to retrofit
buildings with existing pneumatic actuators.

DDC TERMINOLOGY
Review
Study the drawing below and identify the numbered points as either: AI, DI, AO, or DO

DDC TERMINOLOGY
Identify the numbered points in the following diagram as either: AI, DI, AO, or DO

DDC TERMINOLOGY
Answers to the review
1. DO
2. DI
3. AI
4. AO
5. AO
6. AI
7. DI
8. DO
9. AO

DDC TERMINOLOGY
Universal Points
In reviewing a Local Control Unit, it is important to determine how many connections
(points) can be made to sensors and controlled devices. Each controller has a maximum
number of each point type. Some points have a fixed configuration, while other points have
universal, or adaptable, arrangements.
Fixed Point Configuration

Fixed points are those that are dedicated to be a specific type and cannot be
changed. For example, a controller may have four AIs. These AIs may not have to be
used, but they are AIs only and cannot be changed to another point type.
Universal Point Arrangement

To address the problem of having fixed points that go unused, some points may be
programmed as any of the four different types, that is, AI, AO, DI, or DO. These are
referred to as Universal Points. For example, if an additional temperature sensor (an AI)
is desired, and all that is available in a fixed configuration controller is a digital input,
another controller would be required to accommodate the sensor. By using a universal
point configuration, any point on the controller can be programmed as an AI after it has
been wired. This flexibility can be an advantage over a fixed point configuration.
Pulse Inputs
A Pulse Input point type allows a controller to monitor the power consumption of a
device such as a chiller, a fan, or an air hander. Pulse inputs are used to monitor the
power consumption of a whole building. Some electric companies offer a pulse input from
an electric meter, with each pulse representing a certain number of KW (kilowatts). In the
example below, the pulse input comes into terminals PC1 (Pulse Count #1) and C. The
controller in this example can sense a maximum of 8 pulses per second.
Current transformers and transducers can also monitor kilowatt usage, but they use
a 4 to 20 mA signal, so an AI point would be required.

APPENDIX A
Appendix A
This appendix contains examples of two documents that support IBS products. The first
sample consists of pages from the IBS Catalog, describing the CP-8511 Transducer. The
second sample contains pages from the General Instructions sheet that supports the
VM Series Erie PopTop™ Modulating Spring-Return Valves. These are meant only as
samples and do not represent the entire scope of IBS product support. For complete
information on IBS products, consult your local office or wholesale distributor.

APPENDIX A
CP-8511-XXX Series
8511-
Series
Electronic to Pneumatic Transducer
The CP-8511 transducer receives a variable

electronic input signal and produces a 3 to 15 psig
(21 to 103 kPa) pneumatic output signal to position
pneumatic damper and valve actuators in HVAC
systems.
Features:
• Durable enclosure with easily accessible wiring
terminations.
• Panel or DIN rail mounting for quick, snap-on installation.
• High accuracy with low hysteresis.
• Long-term driftless operation with high repeatability.
• Low air consumption and large air flow capacity.
• Field selectable input ranges.
• Integral +20 Vdc power output for auxiliary components.
• Factory installed branch pressure gauge
• Integral auto/manual override feature with indication.
• BAS indication of auto/manual override.
Model Chart
Field
Field Selectable Input
Model No.a Output Range Selectable Power Requirements
Input Range Impedance
Actionb
4 to 20 mAc 250 Ω
1 to 5 mA 1000 Ω
6 to 9 V D.A. 20 to 30 Vac,
3 to 15 psigd
CP-8511-024 1 to 5 V or 24 to 30 Vdc,
(21 to 103 kPa)
0 to 10 V > 10,000 Ω R.A. 3.8 W
1 to 11 V
2 to 10 V
a
CAUTION: This product contains a half-wave rectifier power supply and must not be powered off transformers used to power other devices utilizing non-
isolated full-wave rectifier power supplies.
b
D.A. = Direct acting, branch pressure rises as input increases.
R.A. = Reverse acting, branch pressure falls as input increases.
c
Factory configured as 4 to 20 mAdc.
d
A maximum of 18 psig output is available when the zero potentiometer is increased to 6 psig.
Specifications
Inputs Refer to Model Chart.
Adjustments
Calibration Potentiometer for adjusting mid-range branch pressure.
Action By pin selection, refer to Model Chart.
Power requirements Refer to Model Chart.
Power supply Requires 20 to 30 Vac, 50/60 hZ, or 24 to 30 Vdc power supply, 3.8 watts maximum.
20 psig (138 kPa) nominal, 30 psig (207 kPa) maximum. Clean, dry, oil free air required
Air supply required
(reference EN-123, F-22516).
Air consumption for sizing air
Maximum 0.012 scfm (5.66 ml/s).
compressor
87
Document Samples - IBS Catalog Page (1 of 2)

APPENDIX A
CP-8511-XXX Series
Air capacity for sizing air mains 550 scim (150.24 ml/s).
Air connections Male barbed fittings for flexible 1/4” O.D. pneumatic tubing.
Wiring connections Screw terminals for use with 16 to 22 AWG wire.
Specifications (Continued)
Outputs 3 to 15 psig (21 to 103 kPa).

Maximum pneumatic output 1 to 18 psig (7 to 124 kPa).
Action Refer to Model Chart.
Output air capacity & pressure 515 scim (141 ml/s) with a 20 psig (138 kPa) supply.
Operating characteristics
Linearity ±1% of span @ 75°F (24°C).
Hysteresis 0.75% of span @ 75°F (24°C).
Adjustments Field adjustable zero potentiometer.
Auxiliary power supply +20 Vdc @ 50 mA (maximum).
Auto/manual feedback Isolated open collector output transistor.
Auto/manual status Green LED.
Pressure gauge accuracy Within 2% of total scale range in middle portion of scale and 3% elsewhere (ANSI Class B).
Environment
Shipping and storage: -40 to 160°F (-40 to 71°C).
Ambient temperature limits
Operating: 32 to 140°F (0 to 60°C).
Humidity 5 to 95% RH, non-condensing.
Locations NEMA Type 1.
Upright position. Unit is provided with section of plastic track for panel mounting. AD-8912 enclosure
Mounting
can be ordered separately for remote installations.
Dimensions 4-1/4 H x 5 W x 2-5/32 D in. (108 x 127 x 55 mm).
Accessories
Model No. Description
K-335 In-line air filter.
M-636 4 in. (102 mm) T and B wire tie.
P-610 35 mm DIN rail (1-3/8 W x 36 L x 3/10 H in).
Typical Applications
CP-8511
M M
B Branch
24 Vac 24H
50/60 Hz 24G 1 +20 V supply: 50 mA maximum
current output to drive other devices.
+IN
Typical 2 2 COM terminal is internally connected to 24G. When
Controller multiple CP-8511s or other devices are powered
COM by a common source, uniform wiring polarity must
+20 be maintained between all 24H and 24G terminals.
1 Check to ensure that the controller's COM terminal is not
connected to any other ground reference.
Optional
Control
Equipment
(Not Provided)
Figure 1 Typical CP-8511 Wiring with Optional +20 Vdc Supply.
88
Document Samples - IBS Catalog Page (2 of 2)

APPENDIX A
VM Series
Erie PopTop™
Modulating Spring-Return Valves
General Instructions
Application
The VM series Modulating Spring-Return PopTop valve
assemblies are designed for closed hydronic heating
and cooling systems. They are used to control fluid flow
in fan coil units, VAV reheat, unit ventilators, AHUs, and
radiant applications.
PopTop valve assemblies allow the actuator to be
easily snapped onto, or off from, the valve body with
one hand. The actuator can be mounted quickly and
easily after the valve body has been installed into the
system, without the need for linkages or calibration.
Both two-way and three-way valves are available, and
the two-way valves are provided in either normally
open or normally closed configurations.
Features
• Models available for hot water and chilled water
applications
• 300 psia proof static pressure forged brass valve
body
• PopTop feature allows easy installation and removal
of the actuator from the valve body
• Magnetic clutch extends motor and gear train life
• Manual operating lever (position indicator) facilitates
field setup
• Spring-return to normal position occurs when power Applicable Literature
to the actuator is lost for more than 2 seconds.
• EN-205 Water and Steam System Guidelines,
Three-Wire Floating “T” Type F-26080
• Compatible with virtually any 24 Vac, three-wire
signal
• Standard time-out circuitry extends motor life
Proportional “P” Type
• Compatible with virtually any 0 to 10 Vdc or
4 to 20 mA signal
• Jumper-selectable operating range and action
Printed in U.S.A. 12-00 (1-61-123) F-26801
Document Samples - IBS General Instructions Sheet Sample Page (1 of 3)

APPENDIX A
Piping Refer to the piping diagrams in Figure-1 and Figure-2 for two-way valves. For three-way
valves, refer to Figure-3 and Figure-4.
Caution:
• The valve should be used in a closed loop system.
• All valves must be piped so that the plug closes against the direction of flow. For
two-way valves, flow is from port B to port A. For normally closed three-way valves, B
is the service port and A is the bypass port. For normally open three-way valves, A is
the service port and B is the bypass port.
• Three-way valves must be piped in a mixing configuration, not diverting.
Sweat End Valves

1. Slowly position the actuator’s manual operating lever (on the front of the actuator) to the
middle position, to manually open the valve so that the plug is not in contact with the
valve body.
Caution:
• The plug inside the valve is made of a plastic material. It may be damaged by heat
conducted through the valve body if it remains seated against its port during soldering.
Be sure to manually open the valve before soldering, to prevent damage.
• If the manual operating lever does not move freely for manual positioning, the solenoid
may have latched during shipping. Do not force the lever. Instead, first unlatch the
solenoid by placing the red manual solenoid latch lever (on the side of the actuator) in
the “up” position, then placing the manual operating lever in the middle position.
2. With the valve in mid-position, latch the solenoid by placing the manual solenoid latch
lever in the “up” position. Then, detach the actuator by depressing the release button
and pulling it away from the valve body (Figure-6).
Caution:
• Be sure to remove the actuator from the valve body before soldering, to avoid damage
to the actuator and to ease the soldering process.
• Use only lead or tin based solder with a melting point below 600°F (315°C).
Release
Button
Pin Mating Hole

Stem Mating Hole
Stem
Pin
Figure-6 Removal and Installation of Actuator on Valve Body.
3. Thoroughly clean the ends of the water supply tubing for a minimum distance of 1 inch
from the end, so that a good joint can be made in the shortest time and without an
excessively large flame.
4. Solder the valve body in place, directing the flame tip away from the valve and taking
care not to overheat the joint area. When finished, cool the valve quickly with a wet
cloth.

APPENDIX A
ADJUSTMENTS
None.
MAINTENANCE
The valve requires no maintenance. Regular maintenance of the total system is
recommended to assure sustained, optimum performance.
FIELD REPAIR
None. Replace an inoperative valve, actuator, or assembly with a functional unit (see Part
Numbering System on page 3).
DIMENSIONAL DATA
Table-1 Valve Mounting Dimensions (Figure-9).
Dimensions in inches (mm)
Valve Size
A B (2-Way) C (3-Way)
1/2” Sweat 1-5/16 (33) 15/16 (23) 1-5/16 (33)
3/4” Sweat 1-3/8 (35) 15/16 (23) 1-11/16 (43)
1” Sweat 1-11/16 (43) 15/16 (23) 1-11/16 (43)
1-1/4” Sweat 1-7/8 (47) 1 (25) 1-13/16 (47)
1/2” NPT, BSP 1-3/8 (35) 15/16 (23) 1-5/16 (33)
3/4” NPT, BSP 1-11/16 (43) 15/16 (23) 1-7/16 (37)
1” NPT, BSP 1-7/8 (47) 1 (25) 1-11/16 (43)
1/2” SAE Flare 2-1/4 (57) 5/16 (8) 2-1/4 (57)
4-1/4
(107) 1/16 (1)
3-3/16
(81)
3-11/16
(94)
4-1/2
(114)
3-11/16
(94)
B
2-Way C
3-Way
A A 1-9/16 1-3/16
Dimensions shown are
in inches (mm) (39) (31)
2 (51)
Figure-9 VM Series Spring-Return Modulating PopTop Valve Mounting Dimensions.
All specifications are nominal and may change as design improvements are introduced. Invensys Building
Systems shall not be liable for damages resulting from misapplication or misuse of its products.
PopTop is a trademark of Invensys plc and its subsidiaries and affiliates.
U.S. Patents: 5,397,098; DES. 400,967; other U.S. and foreign patents pending
F-26801 (1-61-123) Printed in U.S.A.

GLOSSARY
Glossary
Abbreviations
AHU: Air Handling Unit
BTU: British Thermal Unit
C: Common
CCW: Counter Clockwise
CFM: Cubic Feet per Minute
CR: Condensate Return
CW: Clockwise
CWR: Chilled Water Return
CWS: Chilled Water Supply
DDC: Direct Digital Control
D.A.: Discharge Air, Direct Action, Direct Acting
DIFF: Differential
EA: Exhaust Air
EMS: Energy Management System
EP: Electric-Pneumatic Switch
GPM: Gallons Per Minute
h: Enthalpy
HVAC: Heating, Ventilating, and Air Conditioning
HWR: Hot Water Return
HWS: Hot Water Supply
in. wc: inches of water column
mA: Milliamps
M.A.: Mixed Air
N.C.: Normally Closed
N.O.: Normally Open
O.A.: Outdoor Air
PE: Pneumatic-Electric switch
PSI: Pounds per Square Inch
R.A.: Return Air, Reverse Action, Reverse Acting
RH: Relative Humidity
SP: Setpoint
SPDT: Single-Pole, Double-Throw
SPST: Single-Pole, Single-Throw
SS: Steam Supply
TR: Throttling Range
Vac: Volts Alternating Current
VAV: Variable Air Volume
Vdc: Volts Direct Current
VFD: Variable Frequency Drive

GLOSSARY
Definitions
Absolute Pressure (psia): The sum of both atmospheric pressure (14.7) and gauge pressure (psig).
Example: If a pneumatic gauge indicates 8 psig, the absolute pressure will 22.7 psia (8+14.7).
Action: The direction of magnitude change of the output of a controller with respect to the change in the
variable that is being sensed. Example: Direct Action (D.A.): Variable increases, output increases. Reverse
Action (R.A.): Variable increases, output decreases.
Actuator: A device which is mechanically linked to a damper and positions the damper to regulate the flow of
air; or is mounted on a valve and repositions the valve to regulate the flow of steam or water. Actuators are
sometimes referred to as operators or motors.
Air Handling Unit (AHU): A mechanical system usually consisting of an enclosure housing a supply-air fan
(or fans), heating and/or cooling coils, filters, and outdoor air and return air dampers. May include return air
fan(s) and relief air damper(s). May deliver air to a single space, to a number of zones, or to numerous
constant-volume or variable-volume air terminal units.
Analog: A proportional type of signal whose level varies smoothly and continuously in amplitude or
frequency.
Averaging Element: A sensing device that can extend across the entire duct and sense the average
temperature.
Boiler: A closed vessel in which fuel is burned to generate steam or to heat water.
Branch Lines (Pneumatic): The tubing in a pneumatic control system which carries the output signal from
controller to auxiliary devices or actuators.
Btu (British thermal unit): The energy or heat required to raise the temperature of one pound of water °F
under standard pressure.
Butterfly Valve: A cylindrical flanged-end body with an internal, rotatable disc serving as a fluid flow
regulating device.
Chiller: A machine, usually centrifugal or reciprocating, that chills the water used to cool a building. Heat
removed from the water is rejected to a remote air-cooled condensing unit, or to a water-cooled condenser
that is usually an integral part of the chiller.
Close-Off: The maximum allowable pressure drop to which a valve may be subjected while fully closed.
Comfort Zone: The range of temperatures and humidities over which the majority of people feel comfortable.
Generally, between 60°F and 70°F and 20% to 60% relative humidity.
Control Point: The actual value of the controlled variable which the controller operates to maintain (under
any fixed set of conditions).
Controlled Device (C/D): An apparatus that receives the signal from a controller and positions the damper or
valve to match the capacity to the load. Example: Motorized damper or valve.
Controller: A device that monitors a controlled variable and changes the position of final control devices
(such as valves, dampers, or contacts) to maintain the value of the controlled variable at or near the
controller’s setpoint.
Cubic Feet Per Minute (cfm): A rate of air volume delivery. Standard measure for HVAC ducted systems.
Damper: A valve used to regulate the flow of air or some other gas.
Degree Day, Heating: A unit, based upon temperature and time, used in estimating fuel consumption and
specifying nominal heating load of a building in winter. One heating degree day is given for each degree that
the daily mean temperature is below 65°F (18°C).
Dew Point: The temperature at which a given mixture of air and water vapor is saturated.
Digital: An On/Off or two-position signal.
DIP Switch (Dual Inline Package Switch): A ganged array of switches on a circuit board. Each switch can
be set to one of two positions.

GLOSSARY
Direct Acting (D.A.): An increase in the sensed media causes an increase in the controller output (and vice
versa).
Direct Digital Control (DDC): Microprocessor-based control systems that provide direct control of the
individual components of an HVAC system without the use of conventional control devices such as
thermostats.
Direct Reset: On multiple (typically two) input applications, when a decrease at the second (open loop)
sensor causes the controller setpoint to decrease.
Diverting Valve: A three-way valve which has one inlet, two outlets, and can direct full flow to either outlet or
proportion the flow between the two outlets.
Dry Contact: A contact closure that does not impose an electronic signal from an outside source. A direct
short of normally open contacts.
Duty Cycling: An energy management function that reduces consumption by periodically turning off electrical
equipment for short intervals during normal operating hours.
Economizer Mode: A control mode in which outside return and relief dampers are controlled by air
temperature to provide the most economical heating and cooling.
Electric-Pneumatic Switch (EP): An electrically operated air flow switch with normally closed and normally
opened inputs which lead to a common output. Also known as solenoid air valve.
Electronic Controls: Using very low voltages (20V or less) and currents for sensing and transmitting.
Energy Management: A number of techniques for reducing a building’s energy consumption, while
maximizing operating efficiency, all without drastic degradation of comfort.
Engineering Units: The units that a medium is measured in, represented by an abbreviation. Examples
include degrees Fahrenheit (DEGF), kilowatts (KW), and feet per minute (FPM).
Enthalpy: For most HVAC applications, a measure of total heat (sensible plus latent) of air, measured above
an arbitrary datum. The specific enthalpy of dry air is assigned a value of zero at 0 [degrees] F and U.S.
standard atmospheric pressure (29.92 in. mercury), and is measured in Btu per pound of dry air.
Exhaust Air Damper: A damper usually associated with an air handling unit. Usually modulates open as the
outdoor air damper opens and the return air damper closes. Also called a relief damper.
Feet Per Minute (fpm): A unit of measure to quantify the velocity of air flow.
Floating Control/Action: While definitions vary, floating control is essentially two position control in which the
controlled device (i.e., MF-XXXX Actuators) can stop at any point in its stroke at loss of control signal. The
controlled device will hold this position until the controller senses another signal to reposition the controlled
device.
Flow Coefficient (Cv): The flow of water in gallons per minute (at 6°F) that causes a pressure drop of 1 psi
across a fully open valve.
Gallons per Minute (gpm): A unit of measure to quantify water flow.
Gauge Pressure (psig): The amount of pressure above atmospheric pressure, usually measured in pounds
per square inch, gauge (psig).
Gear Train Actuator: A controlled device that operates dampers or valves by producing a rotary motion as a
result of an induction motor driving the output shaft through a series of gears. The motor is driven in either
direction and can be stopped at any position so as to obtain proportional control. The electronic actuator drive
is necessary to interface the DC signal of the controller and the induction motor.
Heat Pump: A refrigeration machine which is arranged to either heat or cool a building by using heat from the
condenser section or by using cooling from the evaporator section..
Hunting: The action of a controller which causes the controlled device to continuously travel from one end of
its stroke to the other. Normally associated with proportional control. Hunting is an undesirable condition.

GLOSSARY
Hydraulic Actuator: A controlled device that operates dampers or valves by producing a linear motion as a
result of the fluid pressure developed from a running motor pumping hydraulic fluid through a transducer. As
the control signal increases the fluid pressure increases and as the control signal decreases the fluid pressure
decreases allowing the spring to retract the output shaft.
Hydronics: The science dealing with the control of and use of water as a heat transfer medium in air
conditioning systems.
Immersion Sensor: A device with an extended element, which can be inserted into a well in order to sense
the temperature in liquid lines and tanks.
Inches of Water Column (in. w.c.): A unit of pressure measurement used to measure and control low
differential pressures. These pressures include duct static pressure relative to space static pressure, space
statue pressure relative to that of other spaces or outside atmospheric pressure, and the velocity pressure of
air flowing in ducts.
Inlet Vane: An attachment to a centrifugal fan that restricts the flow of air into the fan housing. Also used on
centrifugal chillers to restrict refrigerant flow.
Integral Control: A control action designed to reduce offset in proportional control.
Load Shedding: The turning off of electrical loads to limit peak electrical demand.
Low Limit: A control/application to prevent a sensed variable from falling below a dangerous or undesirable
condition.
Low Temperature Thermostat: A duct thermostat with a capillary-type, vapor-filled sensing element installed
across a duct. When any given section of the element (usually one foot) falls below setpoint, the thermostat is
actuated, usually to stop the supply fan of an air handling unit and close the outdoor air and relief dampers.
Available with manual or automatic reset.
Minimum Position: A control sequence in which the controlled device is prevented from moving to the fully
closed position even though the signal from the controller is at a value that would cause the controlled device
to be fully closed. However, at a total loss of power or signal from the minimum position, the controlled device
will typically go to a fail safe position. i.e. Minimum Position of the outside air damper, for purposes of
ventilation, may require that a minimum of X% of outside air be introduced to the building when occupied.
However, if there is a loss of power or a low limit that could freeze the coil, the outside dampers will close
fully.
Mixing Valve: The three-way valve which has two inlets, one outlet, and can direct full flow from either inlet or
proportion the flow from the two inlets.
Night Setback (Heating): An application by which the setpoint is shifted to a lower value during unoccupied
hours during the heating season.
Night Setup (Cooling): An application by which the setpoint is shifted to a higher value during unoccupied
hours during cooling season.
Normally Closed (N.C.): Applies to the condition of a controlled device which closes when all operating force
(control pressure or electric energy) is removed. i.e., power failure.
Normally Open (N.O.): Applies to the condition of a controlled device which is open when all operating force
is removed.
Occupied Mode: A control mode used to heat or cool a building when it is occupied.
Offset: The amount of difference between control point and setpoint in a proportional control system.
Packaged Equipment: Off-the-shelf HVAC equipment.
Pneumatic: Controls powered by low-pressure compressed gas.
Pneumatic-Electric Switch (PE): An air pressure operated switch in which the contacts are made or broken
in order to operate electrical devices in a pneumatic control system.
Positive Positioner: Used where accurate positioning of the controlled device is required. Example:
Pneumatic positive positioners provide up to full main air to the actuator for any change in position required by
the controller. Positive positioners may also be referred to as pilot positioners.

GLOSSARY
Pressure Independent VAV: A control technique in which the flow of air (usually through a VAV terminal
unit) is maintained essentially at the setpoint of a flow controller regardless of variations (reasonably
controlled) in supply duct static pressure.
Proportional Control: A mode of control in which the controlled device may assume any position from fully
closed to fully open, depending on the load at any given point in time.
Range: (1) The minimum to maximum setpoint capability of a controller, (2) the minimum to maximum
sensing capability of a transmitter, or (3) the start point to finish point of an actuator. Examples:
Controller, 55 to 80°F
Transmitter, 40 to 24°F
Actuator, 5 to 10 psig
Relative Humidity: The ratio of the amount of moisture that is present in the air to the amount that can be in
the air at that temperature.
Reset: Making use of a second (open loop) sensor whose function is to change the effective/desired setpoint
of a controller automatically according to changes in the open loop conditions. Not to be confused with
Automatic Reset.
Resistance Temperature Device (RTD): An electronic device that senses temperature. As the sensed
temperature changes, the resistance changes. Example: Balco.
Return Air: Air returning to the heater or conditioner from the heated or conditioned space.
Reverse Acting (R.A.): A decrease in the sensed media causes an increase in controller output (and vice-
versa).
Reverse Reset: On multiple (typically two) input applications, when a decrease at the second (open loop)
sensor causes the controller setpoint to be increased..
Rooftop Unit: Packaged heating/cooling or heating/ cooling/ventilating unit designed to be mounted on the
roof of a building. May be a small, single-zone unit; a large, complex unite supplying air to many VAV
terminals; or anything in between.
Run Time: For HVAC equipment, the total hours of actual running time since installation, the last
maintenance, or a specified date.
Setpoint: The desired value assigned to a controller. Example: The setpoint dial on a thermostat indicates
the desired occupied condition.
Short-Cycling: When equipment is turned on and off at frequent intervals. Normally associated with two-
position control. (Short-cycling is an undesirable condition.)
Single-Pole, Double-Throw (SPDT): An electromechanical switch, which makes one circuit immediately
upon breaking the other.
Single-Pole, Single-Throw (SPST): An electromechanical switch, which makes or breaks one circuit.
Span: The difference between the start and finish point of range. Examples:
Transmitter range 50° to 100° = span of 50°
Voltage Range 6 to 9 Volts = span of 3 volts
Spring Range of three to 8 psig = span of 5 psi
Spring-Return: The movement of an actuator as a result of a decreasing voltage signal and therefore the
force is supplied by a coiled or compressed spring. Upon a power interruption the spring will drive the actuator
to a known position.
Staged Heating/Cooling: A temperature control technique in which heating or cooling is turned in stages.
For example, the farther away the temperature is from the setpoint, the more stages of heating or cooling are
turned on.
Staging: A method of control in which the total capacity of a two-position mode of control application is
divided into several levels of capacity so as to match the capacity to the load more evenly.
Stand-Alone: A device, such as a controller or computer, that does not require support from another device
or system.

GLOSSARY
Stand-Alone Operation: Performance independent of direction of any other component in the system.
Strap-On Thermostat: A Controller designed for mounting on and sensing the temperature of a surface.
Example: the surface of a pipe.
Stratification: Layers of air at different temperatures of different velocities flowing through a duct or plenum.
Summer/Winter: A combination of a direct acting and a reverse acting thermostat. The term heating/cooling
is synonymous.
Supply or Main Pressure (Pneumatic): The force per unit area (psig) of the compressed air supplied to a
controller. It is usually constant at 15 to 20 psig, but may have some other value in special cases.
Thermistor: A semiconductor whose resistance is extremely temperature sensitive. Like carbon, thermistors
have negative temperature coefficients; that is, their resistance increases as temperature decreases. They
are used to compensate for temperature variations in other parts of a circuit and are also used as
transducers.
Thermostat: An instrument which measures temperature and controls device(s) for maintaining a desired
temperature. Throttling Range (Controller): Throttling range is the change in measured variable (temperature,
pressure, liquid level, etc.) required to cause the controller output to vary a pre-defined range. In
System 8000™ this range is 6 to 9 volts. In Pneumatics, this range may be three to 13 psig or three to 15
psig.
Throttling Range (Controller): Throttling range is the change in the measured variable (temperature,
pressure, liquid level, etc.) required to cause the controller output to vary a predefined range. In System 8000
this range is 6 to 9 volts. In Pneumatics, this range may be 3 to 13 psig or 3 to 15 psig.
Throttling Range (System): The amount of change of the variable necessary for the controller to drive the
actuator(s) through their complete stroke(s).
Transducer: A device which converts one form of energy into another form of energy.
Tubeaxial Fan: An airfoil (propeller) fan within a cylinder and including driving mechanism supports for belt
drive or direct connection.
Two-Position Control: A method of control in which the control device is either 100% open or closed;
therefore, the controlled medium is flowing at these respective rates. Also called On-Off control..
Variable Air Volume (VAV): A system that controls space temperature by varying the quantity of supply air
rather than by varying the temperature of the supply air.
Variable Frequency Drive: A device that varies the voltage to an electric motor to vary the speed of the
motor (also called a speed drive.)
Zone: A space or group of spaces within a building with heating and/or cooling requirements sufficiently
similar so that comfort conditions can be maintained throughout by a single controlling device.
Zone Control: A control process in which a building is divided into different areas (zones). Each zone can be
controlled independently.

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Invensys Building Systems

HVAC CONTROLS INTRODUCTION

Pop-up Definitions in this Online Document

Printed in U.S.A. 3/01 F-26962

1354 Clifford Avenue (Zip 61111)

© Invensys Building Systems 2001

ii Invensys Building Systems

Air Handling Units (AHUs) ................................................................................................. 9

Basic Control System ................................................................................. 17

Controlled Device ............................................................................................................. 24

Invensys Building Systems iii

Reverse Reset ...................................................................................................................45

Energy Management Techniques ...............................................................63

Duty Cycling ......................................................................................................................65

Optimum Start / Stop ........................................................................................................66

Electric Demand Limiting.................................................................................................67

Enthalpy Optimization ......................................................................................................68

Degree Day Calculations..................................................................................................69

Night Purge Cycle .............................................................................................................70

DDC Terminology ........................................................................................74

iv Invensys Building Systems

Pulse Inputs ...................................................................................................................... 83

Invensys Building Systems v

Appendix A – Supporting Documents for IBS Products

Examples Used in this Document

Conventions Used in this Document

Invensys Building Systems vii

viii Invensys Building Systems

A Heating, Ventilating, and Air-Conditioning (HVAC) Control system operates the

Invensys Building Systems 1

2 Invensys Building Systems

Invensys Building Systems 3

4 Invensys Building Systems

Invensys Building Systems 5

6 Invensys Building Systems

2._____ B) Hot Water Pumps

4._____ D) Cooling Tower

5._____ E) Chilled Water Pumps

6._____ F) Condenser Water Pumps

Invensys Building Systems 7

2. F) Condenser Water Pumps

4. E) Chilled Water Pumps

5. B) Hot Water Pumps

8 Invensys Building Systems

10 Invensys Building Systems

A steam Humidifier, or some other form of humidifier, is placed inside an AHU to

Invensys Building Systems 11

Observe the Air Handling Unit, below.

12 Invensys Building Systems

1.__________ A. Supply Fan

3.__________ C. Outside Air Dampers

4.__________ D. Return Air Temperature Sensor

5.__________ E. Hot Water Coil

6.__________ F. Mixed Air

7.__________ G. Return Air Dampers

8.__________ H. Return Air Humidity Sensor

9.__________ I. Discharge Air Temp. Sensor

10.__________ J. Return Fan

11.__________ K. Return Air