Airflow Control Valve U.S. Patent # 6,991,177 Distributed by: Manufactured by: Tek-Air Systems, Inc. 41 Eagle Road Danbury, CT 06810 USA 600 Pepper Street, Monroe, CT 06468 USA WWW.ACCUVALVE.COM For Service, Call Tek-Air Systems at 203-791-1400 Contents of this Manual are Subject to Change Without Notification AV3000 MANUAL-TEKAIR-JULY 2010.DOC
LIMITED WARRANTY Tek-Air Systems, Inc. having its principal place of business at 41 Eagle Road, Danbury, CT USA ("Manufacturer") warrants its AccuValve, Model AV3000 product (the "Products") as follows: 1. Limited Warranty. Manufacturer warrants that the Products sold hereunder will be free from defects in material and workmanship for a period of thirty-six (36) months from the date of purchase. If the Products do not conform to this Limited Warranty during the warranty period (as herein above specified), Buyer shall notify Manufacturer in writing of the claimed defects and demonstrate to Manufacturer satisfaction that said defects are covered by this Limited Warranty. If the defects are properly reported to Manufacturer within the warranty period, and the defects are of such type and nature as to be covered by this warranty, Manufacturer shall, at its own expense, furnish, replacement Products or, at Manufacturer's option, replacement parts or services for the defective Products. Shipping and installation of the replacement Products or replacement parts shall be at Buyer's expense. 2. Other Limits. THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Manufacturer does not warrant against damages or defects arising out of improper or abnormal use of handling of the Products; against defects or damages arising from improper installation (where installation is by persons other than Manufacturer), against defects in products or components not manufactured by Manufacturer, or against damages resulting from such non-manufacturer made products or components. Manufacturer passes on to Buyer the warranty it received (if any) from the maker thereof of such non-manufacturer made products or components. This warranty also does not apply to Products upon which repairs have been affected or attempted by persons other than pursuant to written authorization by Manufacturer. This warranty also does not apply to any product provided by the buyer and mounted by the Manufacturer to Products. 3. Exclusive Obligation. THIS WARRANTY IS EXCLUSIVE. The sole and exclusive obligation of Manufacturer shall be to repair or replace the defective Products in the manner and for the period provided above. Manufacturer shall not have any other obligation with respect to the Products or any part thereof, whether based on contract, tort, strict liability or otherwise. Under no circumstances, whether based on this Limited Warranty or otherwise, shall Manufacturer be liable for incidental, special, or consequential damages. 4. Other Statements. Manufacturer's employees or representatives' ORAL OR OTHER WRITTEN STATEMENTS DO NOT CONSTITUTE WARRANTIES, shall not be relied upon by Buyer, and are not a part of the contract for sale or this limited warranty. 5. Entire Obligation. This Limited Warranty states the entire obligation of Manufacturer with respect to the Products. If any part of this Limited Warranty is determined to be void or illegal, the remainder shall remain in full force and effect. Contents of this Manual are Subject to Change Without Notification Page ii
TABLE OF CONTENTS LIMITED WARRANTY...ii TABLE OF CONTENTS...iii SECTION 1 - INTRODUCTION... 1 SECTION 2 - SPECIFICATIONS... 3 SECTION 3 MODEL CODE DESCRIPTION... 4 SECTION 4 PHYSICAL DIMENSIONS & WEIGHTS... 5 SECTION 5 - INSTALLATION... 6 SECTION 6 WIRING... 9 SECTION 7 OUTPUT CONFIGURATION... 12 SECTION 8 TEK-AIR CONTROLLER DIRECT INPUT... 13 SECTION 9 MAINTENANCE... 15 APPENDIX ACTUATOR TECHNICAL DATA SHEETS... 17 Contents of this Manual are Subject to Change Without Notification Page iii
SECTION 1 - INTRODUCTION 1.1 Description The AV3000 airflow control valve - AccuValve - incorporates high accuracy airflow sensing with a revolutionary but simple design. The AccuValve divides the airflow into two equal chambers using an airfoil shaped compression section. Each chamber is comprised of a vortex shedding airflow sensor, a modulating control blade and a static regain section. As air enters the chambers it accelerates and compresses, creating a laminar zone optimum for measuring airflow velocity. The vortex shedding airflow sensors provide a digital pulse train to the airflow transmitter which is directly proportional to the air flow velocity in each chamber of the AccuValve. The AccuValve transmitter provides an extremely accurate and repeatable analog output signal representing volumetric airflow which is compatible with all major BMS DDC controllers. 1.2 AV3100 Major Components Identified Airflow Transmitter Drive Shaft Electric Actuator Access Cover Valve Housing Round AccuValve Follower Shaft Modulating Control Blades Linkage Airflow Sensor Static Regain Section Compression Section Airflow Outlet View Airflow Inlet View Contents of this Manual are Subject to Change Without Notification Page 1
1.3 AV3200 Major Components Identified 1.3.1 AV3200-18 and -24 Linkage Airflow Transmitter Drive Shaft Electric Actuator Access Cover Airflow Sensor Center Compression Section Side Compression Section Airflow Inlet View Follower Shaft Center Regain Section Housing Modulating Control Blades Airflow Outlet View Side Regain Section 1.3.2 AV3200-36 and -48 Airflow Transmitter Actuator #1 Actuator #2 Airflow Inlet View Airflow Outlet View Contents of this Manual are Subject to Change Without Notification Page 2
SECTION 2 - SPECIFICATIONS AIRFLOW ACCURACY: +/- 5% of Reading SPEED OF RESPONSE: ~ 2 sec, full open to full closed using Actuator Options 1-5. SHUT OFF LEAKAGE: AV3100: < 2% FS, Optional Tight Shut-off -S < 0.5% FS AV3200: < 5% FS OPERATING PRESSURE: 0.3 wc to 3.0 wc ENVIRONMENTAL: Temperature Air stream -20 to 140 deg. F Ambient 25 to 125 deg. F Humidity 0 to 95% RH non-condensing TRANSMITTER ELECTRICAL: Input Power 24 VAC +/- 20% 50/60 Hz, 2.5 VA Max. or 24 VDC +/- 20%, 75mA Max. Power source must include a circuit breaker and be current limited to 8 amps maximum and grounded on the (-) side. Output Signal Configurable Using Jumpers JP1 and JP4: DC Voltage Output: 0-10 v or 2-10 v DC milliamp Output: 0-20 ma or 4-20 ma Electromagnetic Compatibility EMC Directive 2004/108/EC Low Voltage Directive 2004/108/EEC EN61326-1:2006 FCC Part 15 (Note 1) Product Safety IEC/EN/UL/CSA 61010-1:2001 CAN/CSA-C22.2 No. 61010-1 (Note 2) ACTUATOR ELECTRICAL: Reference Appendix VALVE MATERIALS OF CONSTRUCTION: Sheet Metal Parts Shafts Airflow Sensors OPERATING RANGE: Valve Model Available in Galvanized Steel, 304SS or 316SS All models use 316SS shafts Polycarbonate Plastic, UL94-V0 Min. Flow Max. Flow @ 0.3 wc DP Max. Flow @ 0.45 wc DP Transmitter Full Scale Range CFM CMH CFM CMH CFM CMH CFM CMH AV3100-L8 50 85 250 425 300 510 400 680 AV3100-08 80 136 650 1104 800 1359 850 1444 AV3100-10 120 204 1000 1699 1200 2039 1300 2209 AV3100-12 180 306 1450 2464 1800 3058 2000 3398 AV3100-14 250 425 2300 3908 2500 4248 2780 4723 AV3200-18 260 442 2500 4248 3200 5437 3300 5607 AV3200-24 350 595 3200 5437 4000 6796 4200 7136 AV3200-36 520 883 5000 8495 6400 10874 6600 11213 AV3200-48 700 1189 6400 10874 8000 13592 8400 14272 NOTES: 1. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at the user s own expense. This Class A digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations. 2. This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition, including Amendment 1, or later version of the same standard incorporating the same level of testing requirements. Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada. Contents of this Manual are Subject to Change Without Notification Page 3
SECTION 3 MODEL CODE DESCRIPTION Model Code Examples: 1. AV3112-12 12 Dia. Galvanized Valve with 0-10v Fail Last Position actuator. 2. AV3125-08-S 8 Dia. 304SS Valve with 2-10v Fail Open/Closed actuator and Tight Shut-off option. 3. AV3112-10-SI 10 Dia. Galvanized Valve with 0-10v Fail Last Postion actuator with Tight Shut-off and Insulation options. Contents of this Manual are Subject to Change Without Notification Page 4
SECTION 4 PHYSICAL DIMENSIONS & WEIGHTS 4.1 Round Sizes 12 (305mm) H L D Valve Model D L H Weight in. mm in. mm in. mm lbs. kg AV3100-L8 7.88 200 24 610 13 381 16 7.3 AV3100-08 7.88 200 24 610 13 381 16 7.3 AV3100-10 9.88 250 24 610 15 432 20 9.1 AV3100-12 11.88 300 27 686 17 483 26 11.8 AV3100-14 13.88 350 30 762 19 533 30 13.6 4.2 Rectangular Sizes 11.88 302mm H L W Valve Model W L H Weight in. mm in. mm in. mm lbs. kg AV3200-18 17.88 454 30 762 19 483 43 19.5 AV3200-24 23.88 607 30 762 19 483 49 22.2 AV3200-36 35.88 911 30 762 19 483 97 44.0 AV3200-48 47.88 1216 30 762 19 483 109 49.4 Note: All dimensions are to the outside and have a tolerance of +/-.062 (1.6mm). Contents of this Manual are Subject to Change Without Notification Page 5
SECTION 5 - INSTALLATION 1. Read all instructions completely before installing the valve. NOTE: Wear eye protection, protective gloves and clothing suitable for working with sheet metal which may have sharp edges. 2. Verify the tag number located on the valve label matches the HVAC schedule. 3. Select optimum mounting location for the valve. NOTE: The AccuValve does not require straight inlet duct runs to operate properly, however it s always best to locate any duct device away from transitions and bends to minimize impact on system static pressure. 4. Allow a minimum clearance of 14 inches (356 mm) unobstructed access to the transmitter, actuator and valve access cover. 5. To support the weight of the valve, install duct hangers within 12 inches (305 mm) of valve connections. NOTE: Reference Section 4 for valve weights. 6. After the duct section is properly supported to carry the weight of the valve, install valve into the duct in accordance with the Airflow Direction Label located on the side of the valve. Position valve so the transmitter, actuator and access cover are easily accessible. NOTE: The AccuValve is not position sensitive. It can be installed in any plane or rotational axis without having impact on the factory calibration. 7. Reference the appropriate diagram provided in this section for installation details. NOTE: Screws, nuts, fasteners, duct sealant, hangers, companion flanges and gaskets are NOT provided by Tek-Air.. Secure Using Sheet Metal Screws Duct Support 14 (356mm) Minimum Clearance For Access Apply Duct Sealant Round Valve Installation Standard Slip-Fit Valve - Using Sheet Metal Screws Contents of this Manual are Subject to Change Without Notification Page 6
14 (356mm) Minimum Clearance For Access Draw Band Round Valve Installation Standard Slip-Fit Valve - Using Draw Band 3/8 bolts, lock-washers and nuts Duct Support Gasket 14 (356mm) Minimum Clearance For Access Round Valve Installation Option F (Flanges) Contents of this Manual are Subject to Change Without Notification Page 7
Rectangular Valve Installation Standard Slip Fit Using Sheet Metal Screws Rectangular Valve Installation Option F (Flanges) In addition to supporting the duct within 12" of each end of valve, a Mounting Strut is provided with the 12x36 and 12x48" valves. Position the valve so the Mounting Strut is below the valve and supported from above on both ends of the strut. NOTE: Do NOT position the valve below the Mounting Strut or valve may fall causing serious injury or death. Support Hanger Mounting Strut 14" (356mm) Minimum Clearance Additional Requirements for Installing 12X36 and 12x48 Valves Contents of this Manual are Subject to Change Without Notification Page 8
SECTION 6 WIRING 6.1 Transmitter Wiring 6.1.1 Loosen the transmitter cover thumb-screw, lift and remove cover. NOTE: Reference the label on the inside of cover for identifying connection points. Thumb Screw 6.1.2 Remove the Power and Signal connectors from board and route cables through the strain relief fitting located on the side of the enclosure. NOTE: For installations requiring conduit, the plastic strain relief fitting can be removed and replaced with a.875 (22.2mm) conduit fitting. 6.1.3 Land the wires to the appropriate connector terminals, secure connector screws and reinstall the connectors to their respective locations. NOTE: Reference job-specific wiring diagrams for details of connections to field devices. If transformer is used to power multiple devices, polarity must be maintained. Cable Entry 6.1.4 Pull a few inches of cable into the enclosure, insert the ratcheting strain relief over cable and push down until snug. Strain Relief Strain Relief Fitting Input Power (X4) Output Signal (X2) NOTE: Ratcheting Strain Relief can be removed by inserting snap ring pliers with.040 tips into two holes on the part and spread open. 6.1.5 Reinstall the cover and secure by tightening thumb screw. 6.2 Actuator Wiring The AccuValve can be provided with various actuators depending on the application. The wiring for each type of actuator is similar, however reference the Appendix at the end of this manual for instructions specific to the actuator model provided for your project. Contents of this Manual are Subject to Change Without Notification Page 9
6.3 Field Wiring Schematics The following diagrams are intended to be used as examples for connecting the AccuValve AV3000 to Field Devices. Reference the inside of transmitter cover for identification of connectors. NOTE: Use 16-22 AWG Shielded Cable. 6.3.1Typical wiring between the AccuValve and DDC Control Panel Controller with Common I/O & Power Ground 6.3.2 Typical wiring between AccuValve and Tek-Air Fume Hood Controller. Contents of this Manual are Subject to Change Without Notification Page 10
6.3.3 Typical wiring between AccuValve and Tek-Air SmartLab Controller equipped with the AccuValve Direct Input board. 6.3.4 Typical wiring between AccuValve and Tek-Air SmartLab Controller using the SmartLab s Powered Analog Input (AI-3 or AI-4). Contents of this Manual are Subject to Change Without Notification Page 11
SECTION 7 OUTPUT CONFIGURATION Each AccuValve is tested and calibrated in the factory and performance is verified to ensure accuracy. The transmitter Full Scale Range is set per the table in Section 2 and the Analog Output Signal has been configured to provide either Voltage (0-10v or 2-10v) or Current (0-20mA or 4-20mA) by using Jumpers JP1 and JP4. The factory default transmitter output is 2-10v unless specified otherwise at the time of placing order. If desired, the Output Signal can be reconfigured in the field by setting Jumpers JP1 and JP4 as shown below. AV3000 Transmitter Desired Output Jumper Positions Signal JP4 JP1 4 to 20mA 2-3 OFF 2 to 10 v 1-2 OFF 0 to 20mA 2-3 ON 0 to 10 v 1-2 ON Transmitter pictured is configured for 2-10v output: JP4 is set 1-2 and JP1 is OFF. Contents of this Manual are Subject to Change Without Notification Page 12
SECTION 8 TEK-AIR CONTROLLER DIRECT INPUT 8.1 Overview The Tek-Air SmartLab (SLC2000) and Fume Hood (FVC2000) Controllers can be ordered from the factory with an AccuValve Direct input board installed. This board enables a direct connection between the AV3000 transmitter and Tek-Air Controller using the VorTek Direct input, which is normally reserved for the VT4000 probe. The picture to the right shows a SmartLab Controller with an AccuValve Direct Input board installed. 8.1.1 Fume Hood Controller Applications: All FVC2000 applications utilizing the AV3000 must use the AccuValve Direct input board to connect the AV3000 to the FVC controller. If the Fume Hood Controller does not include the AccuValve Direct input board, the controller will not have the ability to read the airflow volume signal provided by the AV3000. 8.1.2 SmartLab Applications: Because the SmartLab Controller includes other analog inputs in addition to the VorTek Direct input, the AccuValve Direct input board is not always required for SmartLab applications. The AccuValve Direct input board is only required for utilizing the SLC2000 VorTek Direct input. 8.2 Field Wiring Refer to Section 6 for field wiring instructions. AccuValve Direct 8.3 AV3000 Transmitter Configuration In order for the AV3000 Transmitter to operate properly with the AccuValve Direct Input Board the transmitter output jumpers must be configured for 2-10 v operation and the Transmitter Full-Scale Range must remain set to the factory default values as shown below. Transmitter Valve Model Full Scale @ 10 v CFM CMH AV3100-L8 400 680 AV3100-08 850 1444 AV3100-10 1300 2209 AV3100-12 2000 3398 AV3100-14 2780 4723 AV3200-18 3300 5607 AV3200-24 4200 7136 AV3200-36 6600 11213 AV3200-48 8400 14272 Contents of this Manual are Subject to Change Without Notification Page 13
8.4 Fume Hood Controller Configuration Standard calibration constants for the FVC VorTek Direct input have been derived for each AV3000 transmitter range. Using the FVC2000 Configuration Tool, set the three VorTek parameters as show below for the given size valve. FVC2000 Config. Tool Parameter AV3100-L8 AV3100-08 AV3100-10 AV3100-12 AV3100-14 AV3200-18 AV3200-24 AV3200-36 AV3200-48 0-400 CFM 0-680 CMH 0-850 CFM 0-1444 CMH 0-1300 CFM 0-2209 CMH 0-2000 CFM 0-3398 CMH 0-2780 CFM 0-4723 CMH 0-3300 CFM 0-5607 CMH 0-4200 CFM 0-7136 CMH 0-6600 CFM 0-11213 CMH 0-8400 CFM 0-14272 CMH Vortek Span FPM 161 178 136 108 131 119 154 119 118 Coef Bias FPM 56 56 56 56 56 56 56 56 56 Vortek Area Vortek Input Sq. F 0.20 0.50 0.50 0.5 1.00 1.00 2.00 2.00 2.5 Channel 08 08 08 08 08 08 08 08 08 After these parameters are saved to the FVC Controller, the VorTek Direct input will provide the properly scaled CFM value for the AV3000 transmitter to which it is connected. If it is necessary to adjust the airflow calibration in the field, the Vortek Coef Span FPM parameter can be modified. 8.5 SmartLab Controller Configuration Standard calibration constants for the SLC VorTek Direct input have been derived for each AV3000 transmitter range. Using the SmartLab Configuration Software, set the VorTek Direct input parameters as show below for the given size valve. Function Name: AV3100-L8 AV3100-08 AV3100-10 AV3100-12 AV3100-14 AV3200-18 AV3200-24 AV3200-36 AV3200-48 Input, Vortek Direct 0 400 CFM 0 680 CMH 0 850 CFM 0 1444 CMH 0 1300 CFM 0 2209 CMH 0-2000 CFM 0-3398 CMH 0-2780 CFM 0-4723 CMH 0-3300 CFM 0-5607 CMH 0-4200 CFM 0-7136 CMH 0-6600 CFM 0-11213 CMH 0-8400 CFM 0-14272 CMH Sensor Sel: 1x1 1x1 1x1 1x1 1x1 1x1 1x1 1x1 1x1 Threshold: (Hz) 50 50 50 50 50 50 50 50 50 Cal Bias: (Hz) 58 58 58 58 58 58 58 58 58 Cal Span: (Hz) 612 316 228 169 138 125 111 91.5 84.5 Duct (sq ft) 1 1 1 1 1 1 1 1 1 After these parameters are saved to the SmartLab Controller, the VorTek Direct input will provide the properly scaled CFM value for the AV3000 transmitter to which it is connected. If it is necessary to adjust the airflow calibration in the field, the Cal Span parameter can be modified. Contents of this Manual are Subject to Change Without Notification Page 14
SECTION 9 MAINTENANCE 9.1 Maintenance Due to the simplistic design of the AccuValve and high reliability of the vortex shedding airflow sensor and transmitter, scheduled maintenance is not required. However, each AccuValve does include an access cover which can be removed to inspect the airflow sensors if desired. 9.1.1 Round Valve Access Cover Equipment Required: 5/16 deep socket with ratchet drive or power driver, safety glasses and safety gloves suitable for sheet metal working. Access Cover 1. Loosen the 5/16 lock-nut, but do not remove it from the bolt. The nut only needs to be loose enough to allow the access door to slide forward. Loosen Nut CAUTION: If the lock-nut is removed from the bolt, the access cover can spring open possibly causing injury due to the sharp edges. Be sure to take precautions against this. 2. Using two hands; squeeze the access cover and slide it forward on the valve enough to uncover the access hole. Slide Cover Forward 3. Once the cover is slid forward, the airflow sensors can be visually inspected. 4. When inspection is complete, slide the access cover over the access hole, being careful not to damage gasket around the hole. Inspect Sensors 5. Verify the access cover is in position to completely cover the hole. Secure in place by tightening the 5/16 lock-nut using care not to over tighten. Contents of this Manual are Subject to Change Without Notification Page 15
9.1.1 Rectangular Valve Access Cover Equipment Required: 5/16 socket with ratchet drive or power driver, safety glasses and safety gloves suitable for sheet metal working. Access Cover 1. The access cover is secured to the valve using (12) Tek-Screws. Remove the (12) Tek-Screws using a 5/16 socket and put the screws aside for reinstalling the cover later. Remove (12) Screws 2. Remove the access cover from the valve. Inspect Sensors 3. Once the cover is removed the sensors are accessible for inspection. 4. When inspection is complete, place the access cover in position and secure using the (12) screws previously removed. Contents of this Manual are Subject to Change Without Notification Page 16
APPENDIX ACTUATOR TECHNICAL DATA SHEETS NOTE: Reference Model Code Description in Section 3. Actuator Code 1 : Fail Open/Closed (2-10v) Neptronic BM060F(TE3) Actuator Code 2 : Fail Last Position (0-10v) Belimo NMQB24-MFT-A FLP Actuator Code 3 : Fail Last Position (2-10v) Belimo NMQB24-MFT-B FLP Actuator Code 4 : Fail Open/Closed (0-10v) Belimo NKQ24-MFT-A FSP Actuator Code 5 : Fail Open/Closed (2-10v) Belimo NKQ24-MFT-B FSP Contents of this Manual are Subject to Change Without Notification Page 17