UNDERFLOOR AIRWAY™ SYSTEMS · The AirFixture Dual Airway System is a pioneering concept in...

Form 130.16-EG1 (506)

JOHNSON CONTROLS 1

UNDERFLOOR AIRWAY™ SYSTEMS

ENGINEERING GUIDE

ASHRAE90.1

COMPLIANT

Meets ASHRAE 90.1 - 2001Efficiency Requirements

Form 130.16-EG1 (506)

JOHNSON CONTROLS2

TABLE OF CONTENTS

FOREWORD ................................................................................................................................... 3

INTRODUCTION ........................................................................................................................... 4DEVELOPING INNOVATIVE PRODUCTS AND IDEAS..................................................... 4FROM PLENUM TO AIRWAY SPACE................................................................................... 4WHAT IS A FLEXSYS UNDERFLOOR AIRWAY SYSTEM? .............................................. 4ABOUT THIS MANUAL......................................................................................................... 4

NOMENCLATURE......................................................................................................................... 5

AIRWAY COMPONENTS .............................................................................................................. 6BASIC AIRWAY SYSTEM COMPONENTS .......................................................................... 6COMPONENT NOMENCLATURE ........................................................................................ 6VARIABLE-AIR-VOLUME DIFFUSERS............................................................................... 6

MIT2-C ............................................................................................................................... 6MIT2-G............................................................................................................................... 6

CONSTANT-VOLUME DIFFUSERS...................................................................................... 6MIT2-A............................................................................................................................... 7MIT2-H............................................................................................................................... 7PCD .................................................................................................................................... 7

FAN-POWERED TERMINAL UNITS .................................................................................... 8UFE..................................................................................................................................... 8UFW ................................................................................................................................... 9HCE .................................................................................................................................. 10HCW ................................................................................................................................. 10

ACCESSORIES ...................................................................................................................... 10CX-FlexFloor ................................................................................................................... 10TCD-C .............................................................................................................................. 11TCD-S............................................................................................................................... 11IBOX ................................................................................................................................ 12PM .................................................................................................................................... 12QBX-C .............................................................................................................................. 12QBX-H ............................................................................................................................. 12PAP Cables ....................................................................................................................... 13

TERMINALS ................................................................................................................................ 18TERMINAL SIZING FUNDAMENTALS ............................................................................. 18

VAV Systems .................................................................................................................... 18CV Systems ...................................................................................................................... 18

SUPPLY DIFFUSERS FOR HEATING SERVICE ................................................................ 19DIFFUSERS USED FOR RETURN SERVICE IN HEATING SYSTEMS ........................... 19LOCATING SUPPLY DIFFUSERS ....................................................................................... 19LOCATING RETURN AIR INLETS ..................................................................................... 19

PERIMETER HEATING SYSTEMS ............................................................................................ 20RECOMMENDED PERIMETER HEATING SYSTEM ....................................................... 20LOCATING FAN-POWERED TERMINAL UNITS IN PERIMETER HEATING APPLICATIONS. 20UFE AND UFW HEATING PERFORMANCE ..................................................................... 21

GUIDE SPECIFICATIONS ........................................................................................................... 23

Form 130.16-EG1 (506)

JOHNSON CONTROLS 3

YORK developed the FlexSys™ Underfloor AirSystems using the best features of traditional overheadVAV air supply and underfloor displacement ventilationsystems. The result was “Convection EnhancedVentilation,” which has a proven track record as anextremely flexible and reliable technology that iscapable of providing the highest level of occupantcomfort. YORK’s Modular Integrated Terminal (MIT),designed to provide constant velocity air supply in bothconstant-volume and variable-air-volume applications,has been the mainstay of the FlexSys system.

Underfloor air distribution systems provide excellentoccupant comfort and reduced energy usage, andprovide a sustainable and flexible HVAC system.

In 2004, YORK introduced the AirFixture® Airway™System of above ceiling, ductless air distribution usingthe pioneering concept of pulse-modulated air delivery.Pulse modulation enables true variable-air-volumesupply while maintaining air movement and diffuserthrow characteristics over the full range of foreseeableloads in the conditioned space.

Introduction of MIT2, the second generation of modularintegrated terminals for underfloor systems, is the nextlogical step. MIT2 combines the best of FlexSysUnderfloor Air Systems with the innovative approachof pulse-modulated air delivery.

This document, the FlexSys Underfloor Airway™Systems Engineering Guide is designed for both noviceand experienced designers. It presents helpful, hands-on information to assist the HVAC engineer in thedesign and layout of underfloor Airway™ systems. TheFlexSys Underfloor Airway™ System ApplicationGuide is a companion document that examines thefundamentals of underfloor air distribution and pulse-modulated airflow control.

If you have a question about any of the informationprovided, or just want to send us a comment, pleasewrite us at [email protected] or call (800) 861-1001, and we will be happy to respond.

Foreword

Form 130.16-EG1 (506)

JOHNSON CONTROLS4

IntroductionDEVELOPING INNOVATIVE PRODUCTS ANDIDEAS

YORK developed the Modular Integrated Terminal(MIT), also known as the FlexSys underfloor airdistribution system, using the concept of ConvectionEnhanced Ventilation (CEV). CEV is a hybrid thatoffers the advantages of both displacement effectventilation and traditional well-mixed ventilation, andat the same time overcomes their disadvantages. CEVsupplies air at floor level similar to displacement effectventilation, but at a constant velocity. Supply air entersthe conditioned space with enough velocity to providemixing in the breathing zone, which is the occupiedspace up to about 6 feet (1.8 meters) above the floor.Warm air stratification occurs naturally above this level.

The AirFixture Dual Airway System is a pioneeringconcept in above-ceiling ductless air distribution. Bycreating separate supply and return Airway spacesabove the ceiling, efficient air distribution can beaccomplished without ductwork and at very low staticpressures. (See Applying AirFixture® Technology, Form130.30-AG1.)

Now, YORK is combining MIT–FlexSys and theAirFixture Airway System in MIT2, a new generation ofproducts that provide more air-conditioning options andbetter comfort control.

FROM PLENUM TO AIRWAY SPACE

The interstitial space beneath a raised floor (and abovea structural floor) has traditionally been called a plenum.When adapting the ductless distribution concept to anabove-ceiling system, the name plenum createsproblems. A plenum can be many things: a chamber, aroom, or a sheet metal component of an air-handlingunit. A code official reading the word plenum, mayapply inappropriate code provisions leading to anincorrect interpretation. To reduce confusion in thecontext of ductless air distribution, YORK literatureuses the term Airway space to describe the airdistribution spaces (supply and return) above ceilingsand below raised access floors.

WHAT IS A FLEXSYS UNDERFLOOR AIRWAYSYSTEM?

A FlexSys underfloor Airway space is an interstitialvolume created between a structural floor and a raised

access floor. Underfloor Airway spaces are notspecifically designed to only deliver conditioned air;they perform several functions, of which only one isair distribution. Constructed from architectural buildingcomponents, Airway spaces can be used for convenientdistribution of electricity, communications and datacabling, small piping systems, and air distribution. Anunderfloor Airway space may also make limited use ofsheet metal ducts to achieve certain performancecharacteristics. When conveying air, an underfloorAirway space operates at slow velocities and at a verylow static pressure.

PERSONAL COMFORT DIFFUSERS

As mentioned throughout this guide, the primary buildingblock of the FlexSys system is the Modular IntegratedTerminal—MIT. The MIT is generally used as aVariable-Air-Volume (VAV) device that automaticallyadjusts the delivered airflow in response to a thermostatsetting and space conditions. While an all-VAVunderfloor system is superior to a system with constant-volume, manually adjustable diffusers in terms ofoccupant comfort and building automation, we recognizethat some applications will require the use of personalcomfort diffusers—PCDs. For this reason, YORK hasexpanded the product line to include PCDs that offeradvantages over any other manually adjustable floordiffuser on the market. The PCDs have been designedto operate in systems with 100% manual adjustablediffusers or in a blended system with VAV MITs.

ABOUT THIS MANUAL

This manual provides technical descriptions of FlexSysunderfloor air distribution systems with pulse-modulated variable-air-volume controls. It alsoprovides practical guidelines and recommendations forusing a new generation of YORK products. The variousdiscussions identify differences between the technologyof this air delivery system and the traditional overheadducted systems. The combination of FlexSys andAirFixture is cost effective and provides flexibility beyondany ducted system. It must be emphasized that thismanual is only an introduction to the many issuesinvolved in applying this technology. Experiencedengineers familiar with this technology should carefullyreview final design parameters and equipment selection.

Form 130.16-EG1 (506)

JOHNSON CONTROLS 5

Typical Diffuser Model Number A N G OM I T 2 -

S = Square Grille Face (standard), 10" x 10"N = Narrow Grille Face (optional), 5" x 10"R = Round Grille Face (optional), 10" dia.

Modular Integrated Terminal, 2nd Generation

Terminal Type

A = Constant VolumeC = Variable Volume, Cooling OnlyG = Variable Volume, Cooling, Ducted HeatingH = Constant Volume, Manual Adj.

Typical Fan-Powered Terminal UnitModel Number

1 12E -U F

E = ElectricW = Hot Water

Type of Heat

-

1 = 150 CFM (71 L/sec)2 = 300 CFM (142 L/sec)3 = 600 CFM (283 L/sec)

Nominal Airflow

24 = 240 V / 1 Ph / 50 Hz27 = 277 V / 1 Ph / 60 Hz48 = 480 V / 3 Ph / 60 Hz

Voltage

12 = 120 V / 1 Ph / 60 Hz20 = 208 V / 1 Ph / 60 Hz23 = 208 V / 3 Ph / 60 Hz

00-

00 = None (fan only)02 = 1.5 kW03 = 3.0 kW05 = 4.5 kW06 = 6.0 kW09 = 9.0 kW1L = Hot Water, 1 row, left-hand coil connections1R = Hot Water, 1 row, right-hand coil connections2L = Hot Water, 2 rows, left-hand coil connections2R = Hot Water, 2 rows, right-hand coil connections

Heating Coil

08RP C D - G-

Personal Comfort Diffuser

Plug and Play

Terminal Type

08R = 8" Round grille

10R = 10" Round grille

O = NoneT = Tamper Resistant

G = Grille Color

Security

G = Grille Color

UF = Underfloor Fan TerminalHC = Heating/Cooling Terminal

0 = Shot BlastA = BeigeB = PuttyC = Dark BrownD = GrayE = BlackF = Antique GrayG = Silver HammertoneH = Antique SilverI = Antique CopperJ = Antique GoldZ = Custom

Grille Color

1 = General purpose, blue, 25 ft. (7.6m)1S = Short PAP-1, 5 ft. (1.5m) 2 = External device (whip), yellow, 50 ft. (15m)2S = Short PAP-2, 10 ft. (3.0m) 3 = Extender, blue, 25 ft. (7.6m) 4 = Communications, white, 100 ft. (30m) 5 = Power, Green, 25 ft. (7.6m) 6 = Heating/chaining, orange 100 ft. (30m) 7 = Thermostat, white, 10 ft. (3.0m)

PAP - 7

Temperature Control Device C = Communicating, Heat/CoolS = Standalone, Cooling-only

TCD - C

Integrations BoxBACNETIP = Bacnet IPMSTP = Bacnet MS/TPLON = LonSA = Stand-alone (http)

IBOX - BACNET IP

Signal Conversion DeviceC = Integrates MIT2 w/MIT1 controlH = Allows TCD-C to control external heating control devices

QBX - H

Nomenclature TABLE A - FLEXSYS DIFFUSER AND FAN TERMINAL NOMENCLATURE

TABLE B - FLEXSYS CONTROLS AND ACCESSORIES NOMENCLATURE

Form 130.16-EG1 (506)

JOHNSON CONTROLS6

Airway ComponentsBASIC AIRWAY SYSTEM COMPONENTS

YORK has assembled a variety of FlexSys airdistribution components to meet most commercialapplications. FlexSys components are specificallydesigned for underfloor Airway system air distributionand are available in both constant-volume (CV) andvariable-air-volume (VAV) styles. VAV terminals arespecially designed for operation with pulse-modulatedairflow controls.

COMPONENT NOMENCLATURE

Table A shows the model numbers and nominalperformance ratings for the newest FlexSys MIT2

components. Please refer to the original “ConvectionEnhanced Ventilation Technical Manual” (Form130.15-EG2) for the nomenclature and description offirst generation MIT terminals and other underfloor airdistribution components.

VARIABLE-AIR-VOLUME DIFFUSERS

FlexSys VAV terminals are designed to operate in anunderfloor Airway distribution system pressurized at 0.05inches w.g. (12.4 Pa). The internal automatic controldamper, called an air valve, uses pulse modulation tovary the total air delivered to the space. Pulse-modulatedair delivery supplies air to a space using short-duration,on-off cycles (pulses). When the air valve is open, airpasses at the rated capacity; when the air valve is closed,airflow stops. If the thermostat calls for less air theduration and frequency of ON periods decrease and theOFF periods increase. If more air is necessary, theopposite is true: the duration and frequency of ONperiods increase and the OFF periods decrease. This isreferred to as the duty cycle. Because the air valve iseither fully open or fully closed, discharge air velocityis constant any time the air valve is open.

MIT2-C

Shown in Figure 1, the MIT2-C is a variable-air-volume,constant-velocity air terminal for use in cooling-onlyservice. It features galvanized steel construction and apowder-coated (painted), cast aluminum top grille. Thestandard 10-inch (254-mm) square aluminum grille, witha nominal 150-cfm (71-L/sec) airflow rating, has twoadjustable halves that can provide up to 16 differentairflow patterns. Optional grilles include a 10-inch (254-

mm) round version with a nominal 150-cfm (71-L/sec)airflow rating, and a narrow rectangular grille (5" x 10",127 mm x 254 mm) with a nominal 100-cfm (47-L/sec)rating. Grilles may be ordered in many standard colors,and custom colors are available as a special order.

MIT2-G

Similar in basic construction and performance to theMIT2-C, the MIT2-G is a constant-velocity air terminalthat provides variable-air-volume cooling and constant-volume heating. The unit has a 5-inch (127-mm) ductconnection for heating applications, as shown in Figure2. The unit also has the ability to operate as a returnair grille when used in a heating system with a fan-powered terminal unit.

CONSTANT-VOLUME DIFFUSERS

CV air terminals are designed to release air at a constantvelocity while operating in an underfloor distributionsystem pressurized at 0.05 inches w.g. (12.4 Pa). Theyare manually adjustable to vary both the airflowdirection and rate.

Fig. 1. MIT2-C is a variable-air-volume supplyterminal designed for cooling-onlyapplications

Form 130.16-EG1 (506)

JOHNSON CONTROLS 7

MIT2-A

The MIT2-A is a constant-volume, constant-velocity airterminal and features galvanized steel construction witha cast aluminum top grille identical to the MIT2-C and

MIT2-G. The primary difference is that the MIT2-A hasno internal air valve or controls. The unit is availablewith either a 10-inch (254-mm) square grille rated at150 cfm (71 L/sec), or 5-inch by 10-inch (127-mm by254-mm) narrow model rated at 100 cfm (47 L/sec).

MIT2-H

The MIT2-H is a manually adjustable, constant volumeair terminal and features galvanized steel constructionwith a cast aluminum top grille identical to the otherMIT. The MIT2-H has a manual damper inside theterminal unit which can adjust the airflow rate. Theunit is available with either a 10 inch (254 mm) squaregrille rated at 150 cfm (71 L/sec), 5 inch (127 mm) by10 inch (254 mm) narrow grille rated at 100 CFM, or10 inch (254 mm) round grille rated at 150 cfm.

PCD

The round-style PCD-08R is a manually adjustable,constant-volume air terminal rated at 60 cfm (28 L/sec). It features galvanized steel construction and asolid, cast-aluminum grille. The unit installs in a floorpanel through an 8-1/4 inch (210-mm) round opening,as shown in Figure 5. Airflow direction may be changedby loosening the single mounting screw and rotatingthe diffuser. The grille is available in many standardcolors and a manually adjustable thumbwheel variesthe airflow rate.

The PCD-10R is a manually adjustable, constant-volume air terminal rated at 90 cfm (42 L/sec). It issimilar in construction to the PCD-08R and installs ina floor panel through a round opening 10-9/16 inches(268-mm) in diameter. A manually adjustable

Fig. 2. MIT2-G is a variable-air-volume supplyterminal designed for both cooling andheating applications

Fig. 3. MIT2-A

Fig. 4. MIT2-H

7.562

AIRFLOW

DAMPERROD

END PANEL

DAMPER WALL11.38 11.38

10.3510.25

TRIM RING

CHASSIS

DIFFUSERGRILLES

SOLIDENDPANEL

Form 130.16-EG1 (506)

JOHNSON CONTROLS8

Airway Components (continued)

thumbwheel mounted in the grille varies the airflow rate,and airflow direction may be changed by loosening thesingle mounting screw and rotating the diffuser. ThePCD-10R grille is also available in many standard colors.

FAN-POWERED TERMINAL UNITS

Fan-powered terminal units are designed to be installedin the supply Airway space below the raised floorsystem. All units have galvanized steel constructionwith an internal, dual-density, insulating liner. Otherfeatures common to all units include:

• Single point power connection

• Centrifugal fan with forward-curved blades

• Permanent split capacitor (PSC) electric motorwith overload protection

• Insulating liner meets current indoor air qualitytesting standards (e.g., ASTM C-665, C-1071, C-

21 and C-22) and fire classification standardsincluding NFPA 90A

• 1-inch (25-mm) replaceable filter

• Removable fan access panel

• ETL listed

• Meets NEC requirements

• NEMA 1 electrical enclosure

• Control transformer

UFE

The model UFE fan-powered terminal is used withMIT2-G terminals for perimeter and other heatingapplications. UFE terminals are available with nominalairflow ratings of 150, 300, and 600 cfm (71, 142 and283 L/sec). A 150-cfm (71 L/sec) model UFE-1 isshown in figure 6. A 600-cfm (283 L/sec) model UFE-3 is shown in Figure 7. The unit provides heat usingone or two UL-listed finned tubular electric heatersdepending on the unit’s total heating capacity. In allmodels, the unit controls first attempt to satisfy theheating requirement using the fan only (1st stage) beforeenergizing the heating elements (2nd stage). UFE fan-powered terminals may be ordered with one of severalheating capacity options (no heat, 1.5 kW, 3.0 kW, 4.5kW, 6.0 kW and 9.0 kW), and all units are manufacturedwith a single-point electrical connection. Electricaldisconnects are standard with all FlexSys fan terminals,and thermal disconnects are standard with all terminalswith electric heating coils. Table A (on page 5) listsoptional power supply characteristics, and Table E (onpage 21) defines the available heating capacity for eachunit size and power option.

Fig. 5. PCD-08R is an adjustable, constant-volumesupply terminal that installs in a 8-1/4” (210mm) round opening. Construction of thePCD-10R is similar.

TOP VIEW

SIDE VIEW

6"

DIRT/DUSTCOLLECTION PAN

RETENTION BAR

RETENTION SCREW

SELF-LOCKING NUTWITH NYLON

INSERT

Thermostat

Valve 24VAC

Power In5" Round Duct (Both Ends)Disconnect Switch

28.6"22.2"

6.1"

Air Filter(6" x 22")

8"2"

9"

2"3"

4"

AIRFLOW

Fig. 6. Casing for UFE-1.

Form 130.16-EG1 (506)

JOHNSON CONTROLS 9

UFW

The model UFW fan-powered terminal is used withMIT2-G terminals for perimeter and other heatingapplications. UFW terminals are available withnominal airflow ratings of 150, 300, and 600 cfm (71,142 and 283 L/sec). The unit provides heat using one-

or two-row hot water coils. Figure 9 shows a 600-cfm(283-L/sec) model UFW-3.

Heating coils are made from seamless copper tubing with,brazed return bends and aluminum fins. The first heatingstage is fan only, and the second heating stage is fanplus 100% of the heating coil capacity. Table F (on page22) lists coil heating and pressure drop characteristicsfor each available model. All units are manufacturedwith a single-point electrical connection. The UFW isavailable with either 120/1/60, 240/1/50 or 277/1/60(volts/Phase/Hz) incoming power.

Thermostat

Air Valve (24VAC)

Power In5" Round Duct (Both Ends)

Disconnect Switch

28.6"22.2"

6.1"

Air Filter(6" x 22")

8"2"

9"

2"3"HOT WATER COIL - 3/8" OD CONNECTIONS

4"

4.75

1.255.45

6.30

3/8" OD COILCONNECTIONS

CONNECTIONS FOR HOT WATER VALVE

AIRFLOW

Fig. 8. Casing for a UFW-1. All UFW-1 modelscome with 2-row hot water coil with right-hand coil connections.

10.0"

7.0"

FILTER ACCESS

AIR FILTER (9.5" x 21.0")

POWER IN

DISCONNECT SWITCH

24VAC

T-stat

Air Valve (24VAC)

Thermostat

20.5"

22.0"

X

4.5"

HOT WATER COIL - 1/2" OD COPPER TUBING WITH 5/8" SWEAT CONNECTIONS

INLET AND OUTLET ARE 7.0" X 20.5"

CONNECTIONS FOR HOT WATER VALVE

AIRFLOW

Fig. 9. Casing for a UFW-2 or UFW-3. For sizes -2and -3, hot water coils are available with 1or 2 rows; left or right hand coil connections(right-hand coil connections shown).

TWO - ROW WATER COILX = 39.63" LONG

ONE - ROW WATER COILX = 40.75" LONG

8.80

3.10

1.00 0.75

2.10

8.80

2.50

0.75

10.0"

7.0"

FILTER ACCESS

AIR FILTER(9.5" x 21.0")

POWER IN

DISCONNECT SWITCH

24VAC

T-stat

Air Valve (24VAC)

Thermostat

20.5"

22.0"36.0"

4.5"

INLET AND OUTLETARE 7.0" X 20.5"

AIRFLOW

Fig. 7. Casing for UFE-2 or UFE-3.

Form 130.16-EG1 (506)

JOHNSON CONTROLS10

HCE

The model HCE heating/cooling terminal with electricheat incorporates the functionality of 2 MIT2-G and aUFE-1 into a single piece construction. It is suspendedfrom the raised access floor through the use of 2 squaretrim rings. The same trim rings and grilles are usedwith the HCE as a square MIT2 terminal.

The HCE provides a nominal 300 CFM through 2 airvalves during cooling mode—fan is off during coolingmode. During heating mode, the air valves close andthe fan provides a nominal 150 CFM—drawing air fromone grille and supplying air through the other. Figure10 shows a model HCE. The HCE is available witheither 120/1/60, 208/1/60, 240/1/50, 277/1/60 (volts/phase/Hz) incoming power, and is provided with 1.5kwof electric heating capacity (1.1 kw for 240 volt).

HCW

The model HCW heating/cooling terminal with hydronicheat is very similar to the HCE, but uses the same heatingcoil as the UFW-1. Table F (on page 22) lists coil heatingand pressure drop characteristics for the HCW. TheHCW is available with either 120/1/60, 240/1/50 or 277/1/60 (volts/phase/Hz) incoming power.

ACCESSORIES

YORK offers a complete line of accessory products toenable single-source supply for FlexSys underfloorAirway systems.

CX-FlexFloor

The CX-FlexFloor monitors the air pressure andtemperature of the FlexSys underfloor supply Airwayspace. Preassembled in a galvanized steel housingwith prewired sensors and controller, the CX-FlexFloor installs into an MIT2-size opening in theraised access floor.

The CX-FlexFloor can control the underfloor Airwayspace pressure by regulating the VFD fan speed or thedamper between the supply air duct and the underfloorAirway space. The controller maintains the supply airtemperature by controlling the return air bypass damper.

Operation can be as a stand-alone device, or as part ofa Building Automation System (BAS) using BACnetMSTP. For non-BACnet systems, analog outputs areavailable from the CX-FlexFloor for input to any BASor AHU. These signals provide the necessary data for

Valve 24VACThermostat

82.44"

12.97"

5.94"

Power In

Disconnect Switch

BLOWERACCESSCOVER MIT2 "Daisy-chaining"

AIR FILTER (5" X 12")

78.00"

57.00"

Airflow

REMOVEFOR

SERVICE

REMOVEFOR

SERVICE

Fig. 10. HCE.


Valve 24VACThermostat

12.97"

5.94"

Power In

Disconnect Switch

Water Valve Control Connections

BLOWERACCESSCOVER

Hot Water Coil 3/8" O.D. Connec-tions

MIT2 "Daisy-chaining"

AIR FILTER (5" X 12")

12.97"

57.00"

78.00"

82.44"

Airflow

REMOVEFOR

SERVICE

REMOVEFOR

SERVICE

Fig. 11. HCW.

Form 130.16-EG1 (506)

JOHNSON CONTROLS 11

a BAS to monitor underfloor air conditions andcoordinate air handler control.

TCD-C

Temperature Control Device, or AirSwitch™, is a wall-mounted, heating and cooling thermostatic devicedesigned for pulse-modulated control of YORKFlexSys MIT2 fan-powered terminal units anddiffusers. The unit is wall-mounted with a frontappearance as shown in Figure 12. A small LCD screenon the front displays set point and room temperature ineither Fahrenheit or Centigrade. An internal DIP switch

provides up to 62 network addresses, address 0 and 43cannot be used. Communication with an IBOX occursthrough PAP-4 cabling. Set points are permanently heldin non-volatile memory and retained during poweroutages. When operating with fan-powered terminalunits, the TCD-C AirSwitch controls up to three stagesof heating.

TCD-S

The TCD-S is similar in appearance and function tothe TCD-C, but does not have communication orheating control capability.

3.50

3.50Set Room

74

Front View Back View

Damper/Power

Comm./Heat

J1 - #1 - RS-485 B J2 - #1 - COMMON #2 - HTG FAN #2 - OPEN #3 - HTG STAGE 1 #3 - CLOSE #4 - RS - 485 A #4 - 24 VAC

Fig. 12. TCD-C.

Form 130.16-EG1 (506)

JOHNSON CONTROLS12


IBOX

The IBOX is a communication device that integratesTCD-C AirSwitch™ thermostats with a third partybuilding automation system. The IBOX interrogatesthe thermostat network, gathering read and write datafor the building automation system using either theBACnet or LonWorks protocols. BACnet setup canbe: BACnet/IP, BACnet MS/TP, BACnet Ethernet, orStand-alone (HTTP only). The Stand-alone versionallows integration of the TCD-C Airswitch thermostatswith an internet-style (HTTP) browser.

The IBOX integration platform requires no proprietarysoftware to connect to the device. Internet Explorer oran equivalent software package is the only softwarerequired to connect to the IBOX. Each IBOX cansupport up to 32 AirSwitch thermostats.

It is possible to communicate with an IBOXwith nothing more than a common World WideWeb connection in the absence of a building automationsystem.

PM

A Power Module PM is a power supply module designedspecifically for use with the FlexSys system. It providespower for all MIT, TCD and QBX devices in the system.It has a single control transformer mounted on a 4 inchby 4 inch (102 mm by 102 mm) steel junction box withstandard knockouts for conduit. The control transformeris rated at 90VA with an output of 24 volts ac. This isadequate to power a total of 14 MIT2 and TCD devices.All PM can be wired for 120, 240 or 277 volts ac; 50 or60 Hertz.

QBX-C

The QBX-C is a cooling control signal conversiondevice. It is designed for plug-and-play installationand permits YORK controls designed for firstgeneration MIT equipment to function with secondgeneration MIT2 devices. See QBX-C data sheet (Form130.00-S3) for more details.

QBX-H

The QBX-H is a control interface device that enables aTCD thermostat to operate with third-party heatingdevices, such as, on-off solenoid valves, or modulatingcontrol valves (0-10 vdc).

To next TCD-C Thermostat/zone

I-BOX TCD-CTCD-CTCD-CTCD-CTCD-C

To Bacnet IP; Bacnet MS/TP; or LonWorks

MIT2

MIT2

MIT2

Fan Terminal

MIT2

MIT2

MIT2

Fan Terminal

MIT2

MIT2

MIT2

PM

MIT2

MIT2

MIT2

Fan Terminal

MIT2

MIT2

MIT2

PM

Fig. 13. Simplistic FlexSys System Cabling Diagram.

Form 130.16-EG1 (506)

JOHNSON CONTROLS 13

PAP CABLES

Plug and Play (PAP) cable wiring is used to connectthe controllable FlexSys components. Available PAPCables are shown in Figure 14 on page 14.

The PAP-1 cable ships with each MIT2-C, MIT2-G,HCE and HCW. It’s most common use is between twoair valves which are part of the MIT2-C, MIT2-G, HCE,and HCW assemblies.

PAP-2 (or PAP-2S) may be necessary when applyingthe QBX-C.

The PAP-3 exterior cable can lengthen any of the otherPAP cables.

The PAP-4 communications-only cable daisy chains theTCD-C AirSwitch thermostats to the IBOX. Each TCD-C is shipped with a PAP-4.

The PAP-5 power-only cable is used to bring only 24Vacpower between Flexsys components. The mostcommon use is from a PM or fan terminal (which actsas 24 Vac power sources to a chain of up to 14 devices(i.e. 13 air valves and a TCD). Extending the distancebetween the PM and the furthest FlexSys device beyond400' of PAP cabling can create enough voltage loss forthe Flexsys components not to operate properly orbecome damaged. The voltage loss can be minimizedby wiring the power source into the middle of a chainof air valves.

The PAP-6 heating cable is most commonly used tocarry the signal from the TCD-C to the fan terminal forheating outputs. Another use for the PAP-6 is forcontinuing the air valve/cooling signal from the TCD-C to additional chain(s) of air valves and power sources.1 power course (PM or fan terminal) with 13 air valves.

If a zone needs more than 13 air valves (typically 1,950CFM), then additional power source(s) must be used.Each PAP-6 can continue the air valve/cooling signalto an additional 14 air valves while isolating the powerbetween the chain of air valves. Note: when using thePAP-6 in this manner, tie the grounding for each powersource (serving a common TCD) together for properoperation of all of the chains of air valves. See theright side of Figure 16 for an example.

The PAP-7 thermostat cable is shipping with each TCD-C. It connects TCD-C to other PAP cables under theraised access floor. See Table C for a listing of cablesprovided with the various Flexsys Models.

ZONE CABLING DIAGRAMS

Typical zone cabling diagrams are shown in Figures15 through 19 as follows:

• Small Cooling Only Zone – Figure 15

• Cooling Only / BAS Interface – Figure 16

• UFE / UFW / BAS Interface – Figure 17

• HCE / HCW / BAS Interface – Figure 18

• QBX-H / BAS Interface – Figure 19

TABLE C - PAP Cables Provided with FlexSys Equipment

FlexSys Model PAP cables provided

MIT2-C & MIT2-G PAP-1

PM PAP-5

TCD-C PAP-4 & PAP-7

UFE & UFW PAP-5 & PAP-6

HCE & HCW PAP-1, PAP-5 & PAP-6

QBX-H PAP-5S & PAP-6S

Form 130.16-EG1 (506)

JOHNSON CONTROLS14


Fig. 14. PAP-Cables

Form 130.16-EG1 (506)

JOHNSON CONTROLS 15

Fig. 15. Small Cooling Only Zone

PMPower In –120, 240 or 277 Volt, 1 phase , 50/60 Hz

MIT-2MIT-2MIT-2

PAP-5PAP-1

TCD-SJ2

PAP-1

PAP-1

MIT-2MIT-2

PAP-5 PAP-1

TCD-SJ2

PAP-1

MIT-2MIT-2MIT-2

PAP-5 PAP-1

TCD-SJ2

PAP-1

PAP-1

MIT-2MIT-2

PAP-5 PAP-1

TCD-SJ2

PAP-1

Simple Zone

J1

TCD-CJ2

PAP-7 J1

TCD-CJ2

PAP-7

To the IBOX

MIT-2(TYP.)...

PAP-4

PAP-4

To the next

TCD-C

PAP-5

Maximum 13 MIT-2 per power source

PMPower In –120 , 240 or 277 Volt,

1 phase , 50/60 Hz

PAP-1(TYPICAL)

Simple Zone

MIT-2(TYP.)...


PAP-5PAP-1 (TYPICAL)

PMPower In –120, 240 or 277 Volt,

1 phase, 50/60 Hz

PAP-6

MIT-2(TYP.)...




1 phase, 50/60 Hz

PAP-6

MIT-2(TYP.)...




1 phase, 50/60 Hz

PAP-6

To next chain of MIT-2

Common side of each transformer

must be connected

Fig. 16. Cooling Only Zones with BAS Interface

Form 130.16-EG1 (506)

JOHNSON CONTROLS16

J1

TCD-CJ2

PAP-7J1

TCD-CJ2

PAP-5 24 VAC

UFE/UFW T-Stat

Power In –120/1/60, 208/1/60, 208/3/60, 240/1/50, 277/1/60, 480/3/60

Power In –120/1/60, 208/1/60, 208/3/60, 240/1/50, 277/1/60, 480/3/60

PAP-6

PAP-6To the next UFE/UFW

PAP-7

PAP-6

24 VACUFE/UFW

T-StatPower In –

Line Voltage

24 VACUFE/UFW

T-Stat

To the IBOX

MIT-2(TYP.)

PAP-1(TYPICAL)

MIT-2(TYP.)

...

...

Maximum 13 MIT-2 per PM or fan terminal

PAP-1

PAP-6

MIT-2(TYP.)...

PAP-4

PAP-4

To the next

TCD-C

PAP-5


PAP-1(TYPICAL)

PAP-1


must be connected

Simple Zone

2 position or modulating (0-10 VDC) valve control



Fig. 17. UFE/UFW Zones with BAS Interface


Form 130.16-EG1 (506)

JOHNSON CONTROLS 17

J1

TCD-CJ2

PAP-7 J1

TCD-CJ2

PAP-6 To the next HCW

PAP-7

MIT-2(TYP.)

PAP-1(TYPICAL)

MIT-2(TYP.)

...

...

Maximum 10 MIT-2

PAP-1

PAP-4

To the next

TCD-CPAP-1

PAP-5Power In –

120/1/60, 240/1/50, or 277/1/60

HCE/HCW

To the IBOX

PAP-4

Simple Zone

PAP-5Power In –

120/1/60, 240/1/50, or 277/1/60

HCE/HCW

Power In –120/1/60, 240/1/50,

or 277/1/60

HCE/HCW

PAP-6




PAP-6

PAP-6

PAP-1

PAP-1

T-Stat 24 VAC

T-Stat 24 VAC

T-Stat 24 VAC


must be connected

Fig. 18. HCE/HCW Zones with BAS Interface

Fig. 19. QBX-H Zone with BAS Interface

PMPower In –120 , 208, 240 or 277

Volt, 1 phase, 50/60 Hz

J1

TCD-CJ2

PAP-7

PAP-1S

To the IBOX

MIT-2(TYP.)...

PAP-4

To the next

TCD-C

PAP-5


PAP-1(TYPICAL)

PAP-1

QBX-H

2 position or modulating (0-10 VDC) control

PAP-5

Form 130.16-EG1 (506)

JOHNSON CONTROLS18

TerminalsTERMINAL SIZING FUNDAMENTALS

The nature of FlexSys underfloor air distribution systemsideally suits them to using an array of relatively smallsupply air diffusers. In a large open area, traditionaloverhead systems may use a small number of relativelylarge diffusers in an effort to control ductwork costs.This provides a generalized level of comfort averagedover all occupants, which infers that there will be noindividual comfort control. In contrast, underfloorsystems seek to provide a greater degree of individualcontrol, which then implies using more, smaller diffusersthat function on a personalized level. Without ductwork,a FlexSys underfloor Airway system has almost no costpenalty for using an array of smaller diffusers ascompared to one or more large overhead diffusers.

FlexSys supply diffuser sizes are standardized to simplifydesign and improve flexibility. The practical limit forlow-pressure Airway technology in underfloorapplications is about 150 cfm (71 L/sec) per diffuser. Ifmore than 150 cfm (71 L/sec) is necessary, use severalterminals arranged in an array to distribute air uniformly.In the end, this is much simpler than selecting a differentsize diffuser or register for each zone, and the flexibilityof the systems means that building owners aren’t lockedinto a specific configuration by the high cost of achange, as would be the case in traditional overheadVAV systems.

VAV Systems

In traditional overhead air distribution systems, designersmust be cautious to avoid selecting oversized terminals.When airflow is less than design conditions, the exitvelocity and throw characteristics of conventionaldiffusers decrease. At low loads, cool supply air leavingthe diffuser at a slow velocity will not induce enoughroom air to create adequate mixing. The supply air may“dump” into the space, causing perceptions of cold draftsamong the occupants. Likewise, oversized andundersized VAV boxes are a problem. If undersized, aVAV box will be short of airflow capacity at peak loadconditions and may induce higher noise levels. Anoversized VAV box has poor modulation and controlcharacteristics, and may have a “whistling” damper atlow volumes. With Airway systems and pulse-modulated, variable-air-volume controls, the problemsof traditional VAV systems disappear.

Traditional VAV devices throttle a control damper toadjust the airflow rate. Conversely, pulse-modulated

air valves have only two positions: fully open and fullyclosed. When the air valve is open, the diffuser exitvelocity and throw characteristics are at the diffuser’srated conditions; when the air valve is closed, the supplyis effectively stopped. Airflow is adjusted by changingthe timing and ratio of open pulses to closed pulses.For instance, consider a room with a peak airflowrequirement of 100 cfm (47 L/sec) that is served by a150 cfm (71 L/sec) diffuser. At peak load, the roomthermostat will adjust the pulse rate of the diffuser’sair valve so that the summation of the open time isapproximately equal to twice the summation of theclosed time (e.g., open 12 seconds, closed 6 seconds,open 12 seconds, closed 6 seconds, etc.). Over a periodof time, the net effect is that the diffuser is open two-thirds the time and closed one-third the time producinga net airflow of 100 cfm (47 L/sec). An oversizedterminal with pulse-modulated, VAV control willprovide good mixing, maintain its throw characteristicsand not dump at part-load conditions.

To ensure quiet operation, air valves do not seal whenin the OFF position. If it had seals, an air valve wouldmake a mechanical contact noise every time the devicecycled. Instead, there is a narrow clearance betweenthe cycling damper and the stationary air valve body.The clearance gap allows a small amount of air to leakthrough when in the OFF position. For instance, a 150-cfm (71-L/sec) MIT2-C diffuser will provide 15 cfm (7L/sec) when the air valve is closed and the pressuredifference between the underfloor Airway space andthe room is 0.05 inches w.g. (12.4 Pa).

CV Systems

In constant-volume systems, the supply terminalsshould not have a combined capacity greater than thesupply fan capacity. For instance, if the supply fanprovides 4,000 cfm (1,888 L/sec), the summation ofthe rated capacity of all supply terminals should nottotal more than 4,000 cfm (1,888 L/sec). Installing toomany supply terminals prevents the underfloor Airwaysupply space from becoming properly pressurized.

Small, isolated areas with airflow requirements under150 cfm (71 L/sec) may be served by PCD terminals.They have lower standard airflow ratings than MIT2

style diffusers, and are individually adjustable by theroom occupant. In a VAV system, a 150-cfm (71-L/sec) rated diffuser may be used because the problem ofoversized diffusers (dumping) does not appear insystems using pulse-modulated controls.

Form 130.16-EG1 (506)

JOHNSON CONTROLS 19

SUPPLY DIFFUSERS FOR HEATING SERVICE

The nominal airflow ratings of all MIT2 supply diffusersare for cooling service. Depending upon theapplication, YORK recommends reducing the actualairflow for heating service from 150 cfm (71 L/sec) toabout 100 to 120 cfm (47 to 57 L/sec) because warmair rises. For instance, a UFE-3 or UFW-3 fan-poweredterminal unit, rated at 600 cfm (283 L/sec) may supplyfive or six MIT2-G terminals rather than four. Withfive, the MIT2-G supply rate will be 120 cfm (57 L/sec) and with six the MIT2-G supply rate will be 100cfm (47 L/sec). See Figure 2 on page 7.

DIFFUSERS USED FOR RETURN SERVICE INHEATING SYSTEMS

When MIT2-G supply diffusers are combined with afan-powered terminal unit in a heating system, thediffusers upstream of the fan-powered terminal unit willoperate as supply diffusers while the system is in thecooling mode, and as a return diffusers when the systemis in the heating mode. As a return terminal, the MIT2-G airflow rate may be increased up to 200 cfm withoutadverse effect. For instance, a UFE-3 or UFW-3 fan-powered terminal unit, rated at 600 cfm (283 L/sec)may draw return air through three MIT2-G terminals.See Figures 7 and 9 on page 9.

LOCATING SUPPLY DIFFUSERS

It is not necessary to specify the exact location of allMIT2 diffusers on the plan drawings when using anunderfloor Airway system for air distribution.Location selection for many diffusers can actually waituntil partitioning is complete and tenants havearranged their furniture.

Selecting locations for perimeter heating units is acompromise between the arrangement of interiorpartitions and furniture, and the coverage effectivenessof diffusers. Perimeter units should be positioned withtheir airflow patterns uniformly directed horizontallyaway from or parallel to the wall and window surfaces.Although counter-intuitive, experience has shown thatcold convection currents flowing down the wall (orwindow) will be intercepted and mixed with the warmdiffuser discharge before they can becomeuncomfortable drafts. This also permits warmconvection currents that form during the cooling seasonto flow upward without mixing and exit through the

return. Table D lists the maximum recommendeddistance between MIT2-G units.

MIT2 units have removable grilles that can be turnedto blow in any of 16 patterns, from straight up to a full360-degree flare. They can be safely located almostanywhere. However, they should not be installeddirectly under an occupant or where there will be highpedestrian traffic. YORK also offers a tamper-resistantoption for MIT2 grilles.

Since MIT2 terminals can be relocated in minutes, it ispossible to use a trial-and-error method of finding thebest locations and grille orientations for optimumcomfort.

LOCATING RETURN AIR INLETS

Return air grilles should be located above occupant headlevel so that they do not interfere with convection airpatterns. For normal ceiling heights up to 10 feet (3meters), the returns should be mounted in the aestheticceiling and the space above the ceiling used for a returnAirway space. In areas with higher ceilings, the returnlocation can be in the wall as long as the bottom edgeof the opening is at least 6 feet (1.8 meters) above thefloor.

Return air locations in perimeter spaces should becontinuous or evenly spaced in the wall above thewindow. Upward convection currents forming on thewall or window surface transfer a portion of the roomsolar and transmission load directly to the return air.This reduces the required supply air quantity andimproves system efficiency.

ELBAT D MIXAM- ECNATSIDDEDNEMMOCERMUTIMRETEMIREPNEEWTEB 2 G-

SUPPLY SERVICEGNITAEHNISLANIMRET

,daoLgnitaeH)m/W(tf/rh/utB

,gnicapSmumixaM)sreteM(teeF

)042(052< timiLoN)stfardnwodrofnrecnocwoL(

)483ot042(004ot052 )0.3ot4.2(01ot8

)483(004> )4.2ot2.1(8ot4

Form 130.16-EG1 (506)

JOHNSON CONTROLS20

Fig. 20. Plan view of a system using MIT2-G diffusers and fan-powered terminal units (shown with a model UFW).Both heating and cooling modes of operation are shownto compare the different equipment functions in eachmode.

Perimeter Heating SystemsMIT2 diffusers used in FlexSys underfloor Airwaysystems are ideal for heating because they supply airfrom floor level. In the heating mode, MIT2 diffusersremain consistent with the convection enhancedventilation scheme by inducing cold air near the floorand mixing it with warm supply air. This offsets colddown drafts that may occur when the building envelopeheat loss (including transmission and infiltration)exceeds 250 Btu/hr per lineal foot (240 w/m) ofperimeter wall.

FlexSys underfloor air distribution systems may alsobe combined with traditional baseboard radiation orradiant ceiling panels. The best choice must beevaluated by considering specific project requirementsand conditions. Significant decision criteria include:the source of heat, the building layout, anticipatedheating loads, and budgets (e.g., electric heat offers lowfirst cost whereas hot water heating may provide loweroperating cost at somewhat higher first cost).

RECOMMENDED PERIMETER HEATING SYSTEM

YORK recommends that perimeter heating systems usemodel UFE/UFW fan-powered terminal units, installedunder the raised access floor and combined with MIT2-G heating and cooling diffusers. This is the most efficientheating approach when using underfloor air distribution.

MIT2-G diffusers can operate in any of three modes: 1)VAV cooling, 2) CV heating, and 3) return air inlet. Thismultifunction capability allows system configurationssimilar to that shown in Figures 20 and 21.

When the system operates in the cooling mode the fan-powered terminal unit is idle. The MIT2-G diffusersoperate as VAV cooling diffusers taking air from theunderfloor air distribution space and responding to localthermostats. In the heating mode, the pulse-modulatedair valves in the upstream and downstream MIT2-Gdiffusers close to the underfloor airway, and the UFE(or UFW) fan and heating coil are energized. Theupstream MIT2-G (connected to the inlet side of thefan-powered terminal unit) acts as a return grille fromthe conditioned space. The downstream MIT2-G(connected to the fan-powered terminal outlet) operatesas a constant-volume warm air supply diffuser.

The UFE, UFW, HCE and HCW fan-powered terminalunits operate independently of the central coolingsystem. This permits perimeter heating to functionwhile maintaining the central system for cooling interiorzones, or permits heating capabilities to operate whenthe main supply fan is shut down (e.g., nights, weekendsand holidays). Since fan-powered terminals operateonly in the heating mode, ECM motors for variable-speed fan operation would not offer an advantage.

LOCATING FAN-POWERED TERMINALUNITS IN PERIMETER HEATINGAPPLICATIONS

Fan-powered terminals units used forperimeter heating systems in combinationwith MIT2-G diffusers should be locatedconveniently adjacent to the diffusers. Figure20 shows a simple arrangement of a single,150-cfm (71 L/sec) UFW-1 fan-poweredterminal unit operating with a pair of MIT2-G diffusers. During the cooling season, bothdiffusers operate as supply diffusers and thefan-powered terminal unit is idle. When thesystem enters the heating mode, the diffuserair valves close. The fan-powered terminalunit operates, drawing return air through theinterior diffuser and supplying warm air tothe diffuser near the building’s exterior wall.

Figure 21 shows a perimeter heating zonesimilar in concept to the example in Figure20; however, this example uses a 600-cfm

Form 130.16-EG1 (506)

JOHNSON CONTROLS 21

Fig. 21. Plan view of a perimeter system using a single, 600 cfm (283 L/sec) UFW-3 fan-poweredterminal unit for heating service. MIT2-G diffusers along the exterior wall supply air forboth heating and cooling. Interior MIT2-G diffusers supply cool air during the coolingmode and serve as return inlets while heating with the fan-powered terminal unit.

UFW-3600 CFM

MIT2-G (TYP. OF 3)150 CFM SUPPLY COOLING200 CFM RETURN HEATINGRAISED ACCESS

FLOOR GRID

HOT WATER COILCONNECTIONS

(PIPING NOT SHOWN)MIT2-G (TYP. OF 5)

150 CFM SUPPLY COOLING120 CFM SUPPLY HEATING

(283 L/sec) UFW-3 fan-powered terminal unitsupplying air through five MIT2-G diffusers locatednear the building’s exterior wall. Interior MIT2-Gdiffusers automatically convert to return service whenoperating in the heating mode. Short sections ofductwork connect the fan-powered terminal unit withthe supply and return diffusers. If possible, fan-poweredterminal units serving multiple diffusers should bepositioned centrally to intrinsically balance airflow toand from the diffusers.

UFE, UFW, HCE AND HCW HEATINGPERFORMANCE

Electric heating coils for UFE fan-powered terminalsare available for service in several electrical voltagesand capacities. Models are available for power supplyfrom 120 volt, single-phase to 480 volt three-phase.Heating elements are finned, stainless steel sheathed.

The range of available heating elements for the UFEare shown in Table E. The HCE is available with 120/1/60, 208/1/60, 240/1/50 or 277/1/60, incoming power withone stage of heat—1.5kW (1.1kW for 240 volt). Thenotes in Table E apply to the HCE, as well.

Hot water heating coils for UFW fan-powered terminalsare available in two physical sizes, with one or two

TABLE E - UFE HEATING OPTION

zH/hP/stloVeziStinU)wolfriA(

egatSenOWk

egatSowTWk

06/1/021

)mfc051(1 5.1 A/N

)mfc003(2 5.1 0.3

)mfc006(3 A/N A/N

06/1/802

)mfc051(1 5.1 A/N

)mfc003(2 5.1 5.4ro0.3

)mfc006(3 A/N 5.4

06/1/772

)mfc051(1 5.1 A/N

)mfc003(2 5.1 5.4ro0.3

)mfc006(3 A/N 0.9ro0.6,5.4

06/3/802

)mfc051(1 A/N A/N

)mfc003(2 A/N 5.4

)mfc006(3 A/N 0.9ro5.4

06/3/084

)mfc051(1 A/N A/N

)mfc003(2 A/N 5.4

)mfc006(3 A/N 0.9ro5.4

05/1/042

)mfc051(1 1.1 A/N

)mfc003(2 1.1 5.4ro1.3

)mfc006(3 A/N 5.8ro0.6,5.4

setoN :.)taehkcalb(ngisedralubutdenniferasliocgnitaehcirtcelellA.1

htiwslanimretnafllanodradnatsdehsinrufsituotuclamrehtA.2.sliocgnitaehcirtcele

.slanimretnafllahtiwdradnatssitcennocsidlacirtcelenA.3lacirtceletniop-elgnisrofderiw-yrotcaferaslanimretnafllA.4

.dleifehtninoitcennoc

Form 130.16-EG1 (506)

JOHNSON CONTROLS22

rows, and with one or two circuits. Hot water coils forUFW Size 1 or HCW terminals are made with 3/8-inchOD seamless copper tube and have 6 aluminum finsper inch. Hot water coils for Size 2 and Size 3 terminalsare made with 1/2-inch OD seamless copper tube; have10 aluminum fins per inch and are meant for 5/8" sweat

connections in the field. Hot water heating coilcapacities and performance characteristics are shownin Table F.

TABLE F - UFW/HCW HEATING OPTIONS

UFWor

HCWSize 1

UFWSize 2

UFWSize 2

UFWSize 3

UFWSize 3

noitpircseD wolfriA)mfc(

erusserPriA).g.w.ni(,porD

)mpg(wolFretaWlioC

05.0 57.0 00.1 52.1 05.1

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051 92.0

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6.0 3.1 3.2 5.3 0.5)HBM(yticapaCgnitaeH

6.5 1.6 4.6 6.6 7.6

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05.0 57.0 00.1 52.1 05.1

"22x"01woR1

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5.8 6.01 4.11 9.11 2.21



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05.0 57.0 00.1 52.1 05.1

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2.21 4.31 1.51 9.61 7.71



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4.31 6.51 9.61 8.71 5.81



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05.0 57.0 00.1 52.1 05.1

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.)TAE(erutrepmetriagniretneF07dna,)TWE(erutarepmetretawgniretneF081nodesabatadecnamrofreP.3:noitauqegniwollofehtesu,TAEdnaTWEtnereffidnodesabecnamrofrepgnitaehroF.4

011/)TAE-TWE(=rotcaFnoitcerroCecnamrofreP

Perimeter Heating Systems (continued)

Form 130.16-EG1 (506)

JOHNSON CONTROLS 23

Guide SpecificationsINTRODUCTION

These guide specifications are provided for referencepurposes. They are annotated to assist in editing thespecifications for a particular project. They are in thestandard CSI three-part format. Section and paragraphnumbering may change as necessary to address

SECTION 23 30 00 – UNDERFLOOR AIRWAYDISTRIBUTION SYSTEM

[The section number shown is based on CSIMasterFormat 2004. Adjust section numbers asnecessary to fit in numbering system used.]

PART 1 – GENERAL

1.01 WORK INCLUDED

A. The Contractor shall furnish and install a completeaccess floor air distribution system as shown on thedrawings, including all wiring, controls and otheraccessories required for a complete system.Contractor shall provide submittals, samples, andoperation and maintenance documentation. Specificequipment includes: [List each type of terminalrequired on the project.]

CX-FlexFloor, underfloor monitoring device

HCE-1, underfloor heating/cooling terminal unitwith electric heat

HCW-1, underfloor heating/cooling terminal unitwith hydronic heat

IBOX, communication interface (between TCD-Cand building automation system)

MIT2-A, constant volume unit

MIT2-C, variable-air-volume unit, cooling only

MIT2-G, variable-air-volume cooling, constant-volume heating unit

MIT2-H, constant volume, manually adjustable unit

PAP-1, -2, -3, -4, -5, -6, and -7 modular controlwiring

PCD-08R and -10R, constant-volume, manuallyadjustable diffuser, for round panel cutout

PM, power module

QBX-C, signal conversion device (between MITand MIT2 units)

QBX-H, signal conversion device (between TCDand heating devices)

TCD-C, DDC space thermostat for pulse-modulation control with communications andtemperature display

TCD-S, DDC space thermostat for pulse-modulation control

UFE-1, 2, or 3, underfloor fan-powered electricheating units

UFW-1, 2, or 3, underfloor fan-powered hydronicheating units

1.02 RELATED WORK NOT INCLUDED

A. The Access Floor Contractor shall furnish andinstall all floor panels, structural supports,underfloor Airway barriers, carpet cutouts and anyother floor-related components and accessoriesnecessary for a complete raised access floor system.

B. The General Contractor shall be responsible forsealing the access floor system and all penetrationsthrough the building wall and floors that occurbelow the raised floor elevation.

C. All openings in access floor panels required forinstallation of diffusers and terminals shall becoordinated with the Access Floor Contractor whoshall also be responsible for cutting the panelopenings and installing panels as indicated on thedrawings.

D. The Electrical Contractor shall furnish and installall electric power-related materials and componentsnecessary for system operation.

E. The Controls Contractor shall furnish and installall control system interfaces, Building Automation

coordination with other sections of the projectspecifications. Annotations [are shown in italics andenclosed in brackets.] Design options [that must beedited by the specification writer are shown in standardfont and brackets.]

Form 130.16-EG1 (506)

JOHNSON CONTROLS24

Guide Specifications (continued)

System (BAS) integration, and other control system-related materials and accessories.

F. The Mechanical Contractor shall be responsible forsealing and repairing any holes, penetration, oropenings made in the underfloor airway for itemsinstalled by the Mechanical Contractor.

G. The Mechanical Contractor is responsible fortesting described in part 3—execution.

1.03 QUALITY ASSURANCE

A. All equipment and components shall be suitable foruse in an environmental Airway space.

B. All components within the air stream includingunderfloor terminals shall conform to the NFPA 90AStandard for Flame/Smoke/Fire contribution of 25/50/0.

C. All units shall be the product of a singlemanufacturer who is regularly engaged in theproduction of underfloor air distribution system.

D. Units shall be specifically designed for installationin an underfloor air distribution system and shallbe furnished complete with all necessary controlsand wiring to provide operation according tomanufacturer’s recommendations.

E. Terminal operation shall be coordinated with theair-handling system and control system to assurecomplete compatibility.

F. Equipment shall be listed under and conform toappropriate sections of U.L., CSA, E.T.L. and othertesting laboratory requirements.

1.04 SUBMITTALS

A. Submit dimensioned drawings, performance andproduct data for approval. Include listing ofdischarge and radiated sound power level for thesecond, third, fourth, fifth and sixth octave bandsfor fan-powered terminal units. Data shall includeall wiring diagrams, control sequences and powerrequirements as applicable to the product andcoordination with other systems.

1.05 OPERATION AND MAINTENANCE DATA

A. Quantity: [6]

B. Content:

1. Maintenance and Service Contracts: Provide alist for each product and include the name,address and telephone number of:

a. Subcontractor or installer.

b. Maintenance Contractors, as appropriate.Identify area of responsibility of each.

c. Local source of supply for parts andreplacement.

2. Table of Contents: List all products in the orderin which they appear in the specifications andlabel accordingly.

3. Sections: All sections shall be separated with anappropriate tabbed section divider with theappropriate specification section number.Provide the manufacturer’s written installationand maintenance instructions for all itemssupplied.

4. Routine Maintenance: Provide a list indicatingall routine maintenance procedures andrecommended intervals.

5. Contents: Include copies of approved submittaldata, installation instructions, operation andmaintenance instructions and parts lists.

1.06 WARRANTY

A. The underfloor Airway distribution systemcomponents, materials and workmanship shall beguaranteed to be free from defects for a period ofone year after start-up or 18 months from date ofshipment from the factory, whichever occurs first.

B. Contractor and/or vendor shall maintain availabilityof replacement parts compatible with the terminalsfor no less than ten years after acceptance.

PART 2 – PRODUCTS

2.01 GENERAL DESCRIPTION

A. The Contractor shall furnish a pre-engineered,prefabricated, access floor air terminal system thatincludes all necessary components from a singlemanufacturer. All components, including controls andwiring, shall be furnished as a “plug-and-play” systemof modular and interchangeable components that arefactory prepared to operate as a complete system.

Form 130.16-EG1 (506)

JOHNSON CONTROLS 25

2.02 SUPPLY TERMINALS

A. General Requirements: All supply air terminalsshall have the following basic construction features.

1. Construction of unit shall permit easy cleaningand prevent dirt and debris from entering system;and no plastic dampers, grilles or other parts shallbe exposed to the Airway space or air stream inaccordance with NFPA 90A.

2. Unit chassis shall be minimum 20-gaugegalvanized steel and shall enclose and supportall components. Chassis construction shall admitunderfloor air from only one direction to permitadjusting delivery volume independent ofunderfloor air velocity pressure.

3. Supply air terminals shall have grilles made ofdie cast aluminum material that matches the trimring in color. Grilles shall include a means foradjusting air throw and pattern, and shall fitsecurely within the trim ring and chassis withoutmechanical fasteners. Grilles shall be capableof supporting a load of 1,250 pounds (567 kg)without permanent damage. No grille openingsshall be larger than 0.30 inches (7.6 mm) for shoeheel penetration protection.

4. Grille trim rings shall be die-cast aluminumdesigned to engage the chassis and floor toprovide complete support for the air grilles. Trimring color shall match the grille color.

5. Panel Size: Unless noted otherwise, the nominaldimensions of all floor-mounted systemcomponents shall be suitable for installation ina standard 24-inch by 24-inch (610-mm by 610-mm) raised access floor suspension grid.

6. Airflow Performance: The manufacturer shallprovide published airflow data for the all supplyand return terminals in accordance with ANSI/ASHRAE Standard 70-1991.

7. Variable-Air-Volume Controls: Terminalsspecified for variable-air-volume service shallincorporate the following requirements:

a. Terminal construction shall include anintegral pulse-modulation damper and motor(air valve) that is specifically designed forlow static pressure air distribution. Thedamper motor shall be a 90-degree steppertype motor having no stops, springs, gears,belts or linkages. The motor shall directly

drive the damper blade. Modulation shallinvolve the timed duty cycle of fully openand closed periods to produce an averageopen time corresponding to the averageterminal air volume required.

b. Terminal shall include a microprocessorcontrol that controls the damper movementin response to a remote open/close signal.The open/close signals and power shall bedelivered to the device through a 4-conductor, plenum-rated modular cable. A“daisy-chain” output port shall be furnishedthat repeats the open/close signals with anominal 6 second delay, and provides parallelconnection of the 24 volts ac control powersupply to other connected terminals. Themodular cable input and output ports shallbe interchangeable with no difference inoperation occurring regardless of which portis used for input or output in a chain.

c. The damper and motor shall be designed forcontinuous use with a nominal design life of100,000,000 cycles. The installed damperand motor operation shall be inaudible witha background sound level of 30 dbA. Theunit shall feature all solid-state electronics,self-contained within the housing usingprinted circuit board mounted componentswith no relays, mechanical switches, or othermechanical devices required for operation ofthe device.

d. The terminal shall not require periodiclubrication or other maintenance. The deviceshall be delivered to the job site fullyassembled and operational, needing noprogramming, setup or adjustment.

B. MIT2-A, CV Terminal Units[These are constant-volume air supply terminalswith no dampers or controls.]

1. MIT2-AS Grille: nominal 10.5 inch by 10.5 inch(267 mm by 267 mm).

2. MIT2-AR Grille: nominal 10.56 inch round (268mm).

3. MIT2-AN Grille: nominal 5.5 inch by 10.5 inch(140 mm by 267 mm).

4. MIT2-A Supply Rating: constant-volume, 150cfm (71 L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure.

Form 130.16-EG1 (506)

JOHNSON CONTROLS26


5. MIT2-AR Supply Rating: constant volume, 150cfm (71 L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure.

6. MIT2-AN Supply Rating: constant-volume, 100cfm (47 L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure.

7. Color: as shown on the finish schedule. [ormanufacturer’s standard color to be selectedfrom submittal data].

[Special colors are available at additional cost.]

C. MIT2-C; VAV Terminal Units[These units provide automatic, variable-air-volume control.]

1. MIT2-CS Grille: nominal 10.5 inch by 10.5 inch(267 mm by 267 mm).

2. MIT2-CR Grille: nominal 10.56 inch round (268mm).

3. MIT2-CN Grille: nominal 5.5 inch by 10.5 inch(140 mm by 267 mm).

4. MIT2-CS Supply Rating: variable-air-volume,150 cfm (71 L/sec) at 0.05 inches w.g. (12.4 Pa)static pressure.

5. MIT2-CR Supply Rating: variable-air-volume,150 cfm (71 L/sec) at 0.05 inches w.g. (12.4 Pa)static pressure.

6. MIT2-CN Supply Rating: variable-air-volume,100 cfm (47 L/sec) at 0.05 inches w.g. (12.4 Pa)static pressure.

7. Color: as shown on the finish schedule; [ormanufacturer’s standard color to be selectedfrom submittal data].


D. MIT2-G; VAV Terminal Units for Heating andCooling Service[These units provide control of the airflow fromthe Airway space for cooling and from anattached duct for heating.]

1. The unit chassis shall include a 5-inch (127 mm)diameter duct connection set in the end panelfor heating air. The duct position shall bearranged to admit heating airflow into the unitchassis perpendicular to the airflow directionthrough the cooling air valve (damper).

2. MIT2-GS Grille: nominal 10.5 inch by 10.5 inch(267 mm by 267 mm).

3. MIT2-GR Grille: nominal 10.8 inch round (268mm)

4. MIT2-GN Grille: nominal 5.5 inch by 10.5 inch(140 mm by 267 mm).

5. MIT2-GS Supply Rating:

a. Cooling: variable-air-volume, 150 cfm (71L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure.

b. Heating: constant-volume, 150 cfm (71 L/sec).

6. MIT2-GR Supply Rating:



7. MIT2-GN Supply Rating:





9. The unit’s cooling air valve (damper) shall besequenced to remain in the closed position whenoperating in the heating mode. In the heatingmode, the unit shall also be capable of acting asa return air grille that accepts airflow from theconditioned space and deliver it through the ductconnection to a fan-powered terminal unitmounted under the raised access floor.

E. MIT2-H, CV, Manually Adjustable Terminal Units[These are constant-volume, air supply terminalswith a manually adjustable damper.]

1. MIT2-HS Grille: nominal 10.5 inch by 10.5 inch(267 mm by 267 mm).

2. MIT2-HR Grille: nominal 10.56 inch round (268mm).

3. MIT2-HN Grille: nominal 5.5 inch by 10.5 inch(140 mm by 267 mm).

Form 130.16-EG1 (506)

JOHNSON CONTROLS 27

4. MIT2-HS Supply Rating: constant-volume, 150cfm (71 L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure.

5. MIT2-HR Supply Rating: constant-volume, 150cfm (71 L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure.

6. MIT2-HN Supply Rating: constant-volume, 100cfm (47 L/sec) at 0.05 w.g. (12.4 Pa) staticpressure.


[Special colors are available at an additionalcost].

F. PCD, Manually Adjustable, Round, CV Terminals[These are constant-volume, floor-mountedsupply terminals with manually adjustableairflow and throw pattern.]

1. Grille: single round grille shall be removablefrom the top of the raised floor panel and madeof die cast aluminum material that fits securelywithin the trim ring and chassis withoutmechanical fasteners.

[Edit as required for PCD-08R or PCD-10R]

2. PCD-08R Supply Rating: constant-volume, 60cfm (24 L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure (when adjustment is fully open).

3. PCD-10R Supply Rating: constant-volume, 90cfm (47 L/sec) at 0.05 inches w.g. (12.4 Pa) staticpressure (when adjustment is fully open).

4. Unit shall be suitable for installation in an [8-1/4 inch (210-mm)][10-9/16 inch (268-mm)]diameter round panel cutout. Unit shall installentirely from the upper side of the raised floorpanel.


[Special colors are available at an additionalcost].

2.03 FAN-POWERED TERMINAL UNITS

A. General Requirements: All fan-power terminalunits shall have the following construction features:

1. Unit casing: 20-gauge minimum galvanized steellined with a removable side or top panel suitablefor equipment service. Casing leakage shall notexceed 2% at 2.0 inches w.g. (498 Pa).

2. Casing Insulation: 1 inch (25 mm) thick, dual-density, thermal and acoustical fiberglassinsulation meeting NFPA 90A requirements, andU.L. 181 erosion control requirements.

3. Fan assembly: Direct drive centrifugal withforward curved blades, internally suspended onrubber isolators. Motor shall be permanent splitcapacitor type with thermal overload protection.

4. Filter: 1 inch (25 mm) thick, throwaway type.Frame mounted on the casing interior with aneasily reachable access cover.

5. [The unit shall have an accessible, toggle-typedisconnect mounted on the casing exterior.] Oras an option for single-phase units: [The unitshall be equipped with a modular power cableand connector.]

6. Plug-and-play connectors shall be mounted onthe casing exterior for attachment of: 24 VACpower and TCD-C (thermostat) input.

7. All factory wiring shall be internal to the unit.Internal wiring shall be rated for the applicationand ETL approved. Electrical components shallbe UL listed.

B. UFE-1, 2, 3, Underfloor Fan-Powered TerminalUnit with Electric Resistance Heat

1. UFE-1 Power Supply: [120] [208] [240] or [277]volts, single-phase, 60 [50] Hertz; or [asindicated on the drawings].

2. UFE-2 and UFE-3 Power Supply: [120][208][240][277] [480] volts, [single][three]-phase, 60 [50] Hertz; or [as indicated on thedrawings].

3. UFE-1 Fan Capacity: 150 cfm (71 L/sec).



6. Electric Heating Coil:[Edit coil requirements as necessary todistinguish between different capacityrequirement for UFE-1, -2 and –3 units.]

Form 130.16-EG1 (506)

JOHNSON CONTROLS28


a. Heating Elements: finned, stainless steelsheathed. Coils shall be mounted on thecasing interior.

b. Heating Capacity: [1.5 kW], [3.0 kW], [4.5kW], [6.0 kW], [9.0 kW], [as indicated onthe drawings].

c. Unit shall be equipped with automatic resetthermal cutouts for each element, magneticcontactor, line and control terminal blocks,interlocking disconnect, and main supplyfuses.

7. Control Power Transformer: 100 volt-amperecapacity, output 24 volts ac, integral circuitbreaker and thermal overload.

8. Unit shall be tested with the fan terminal inaccordance with E.T.L. standards, meet allN.E.C. requirements, and shall be E.T.L. listed.

9. Electrical enclosure: NEMA 1 with single-pointconnection for heater and fan. Wiring diagramwith specific wiring for each unit shall beincluded with unit.

C. UFW-1, 2, 3, Underfloor Fan-Powered Terminalwith Hot Water Heat

1. Power Supply: [120][240][277] volts, single-phase, 60 [50] Hertz; or [as indicated on thedrawings].

2. UFW-1 Fan Capacity: 150 cfm (71 L/sec).



5. Hot Water Heating Coil:

a. Heating coil shall be integral with the fan-powered terminal unit, with the pipingconnections extended beyond the unit casingon the supply and return connections on thesame side of the casing.

b. UFW-1 Coils: constructed from seamlesscopper tube, 3/8-inch (10 mm) O.D., 0.020inch (0.5 mm) wall thickness, with brazedreturn bends. Coils shall have [two rows].

c. UFW-2 and -3 Coils: constructed fromseamless copper tube, 1/2-inch (12 mm)O.D., 0.020 inch (0.5 mm) wall thickness,with brazed return bends. Coil meant for 5/8-inch sweat connections. Coils shall have

[one or two rows], [rows as indicated on thedrawings].

d. Fins: mechanically bonded to tubes, plate-type aluminum fins.

e. Maximum working ratings shall be 225 psigat 325°F (1,551 kPa at 163°C).

f. Casing: galvanized steel.

g. Heating Capacity: as indicated on thedrawings.

6. Control Power Transformer: 100 volt-amperecapacity, output 24 volts ac, integral circuitbreaker and thermal overload.


8. Electrical enclosure: NEMA 1 with single-pointconnection. Wiring diagram with specific wiringfor each unit shall be included with unit.

D. HCE-1, Underfloor fan-powered heating terminalwith electric resistance heat and air valve cooling.

1. HCE-1 Power Supply: [120] [208] [240] or [277]volts, single-phase, 60 [50] Hertz; or [asindicated on the drawings].

2. HCE-1 Fan Capacity: 150 cfm (71 L/sec).

3. Electric Heat Coil:

a. Heating Elements: finned, stainless steel,sheathed. Coils shall be mounted on thecasing interior.

b. Heating Capacity: 1.5 kW.

c. Unit shall be equipped with automatic resetthermal cutouts for each element, magneticcontactor, line and control terminal blocks,interlocking disconnect, and main supplyfuses.

4. Control Power Transformer; 100 volt-amperecapacity, output 24 volts ac, integral circuitbreaker and thermal overload.


6. Electrical Enclosure: NEMA 1 with single-pointconnection for heater and fan. Wiring diagram

Form 130.16-EG1 (506)

JOHNSON CONTROLS 29

with specific wiring for unit shall be includedwith unit.

E. HCW-1, Underfloor fan-powered heating terminalwith hydronic heat and air valve cooling.

1. HCW-1 Power Supply: [120] [240] or [277]volts, single-phase, 60 [50] Hertz; [or as indicatedon the drawings].

2. HCW-1 Fan Capacity: 150 cfm (71 L/sec).

3. Hot-Water Heating Coil:

a. Heating Coil shall be integral with the fan-powered terminal unit, with pipingconnections extended beyond the unit casingon the supply and return connections on thesame side of the casing.

b. HCW-1 coils: constructed from seamlesscopper tube, 3/8-inch (10 mm) O.D., 0.020inch (0.5 mm) wall thickness with brazedreturn bands. Coils shall have 2 rows.

c. Fins: mechanically bonded to tubes, plate-type aluminum fins.

d. Maximum working ratings shall be 225 psigat 325ºF (1,551 kPa at 163ºC).

e. Casing: galvanized steel.

f. Heating Capacity: as indicated on drawings.

4. Control Power Transformer; 100 volt-amperecapacity, output 24 volts ac, integral circuitbreaker and thermal overload.


6. Electrical Enclosure: NEMA1 with single-pointconnection. Wiring diagram with specific wiringfor each unit shall be supplied with unit.

2.04 SYSTEM ACCESSORIES

A. CX-FLEXFLOOR, underfloor monitoring device.[Required for coordinated control of theunderfloor temperature and pressure conditions.]

1. CX-FlexFloor shall manage the air pressure andtemperature of the underfloor supply Airwayspace used in the FlexSys air distribution system.The unit shall be factory assembled in agalvanized steel housing, and shall be completewith prewired sensors and an controller.

2. The CX-FlexFloor shall be designed for recessedinstallation from the upper side of a raised accessfloor.

3. The unit shall be operable as a stand-alonedevice, as part of a small, local network, or aspart of a Building Automation System usingBACnet. Analog outputs shall be available forconnection to a BAS or AHU.

4. Input sensors shall be furnished with the unitand shall include: underfloor air pressure,underfloor air temperature, slab temperature, andunderfloor relative humidity. The slabtemperature sensor is mounted remotely.Controller logic shall also incorporate time ofday, occupied and unoccupied status, damperposition, heat demand, and user set point.

5. CX-FlexFloor shall be factory pre-programmedwith default set points. Set points shall becapable of being modified using a PDA, laptopcomputer, or [an optional] keypad and displaymodule. [Specify if the keypad and displaymodule is to be furnished.]

6. Access to the unit shall be through the floorgrille. Operational status LED’s, RS-232 andkeyboard ports shall be accessible when thegrille is raised.

7. Power Supply: 115/230 volts ac, single-phase.

8. Sensor Accuracy:

a. Airway space temperature: ±0.36°F(±0.20°C).

b. Airway space pressure: ±1% of full scale.

c. Airway space relative humidity: ±3%

d. Slab temperature: ±0.36°F (±0.20°C).

9. Interface: local area network, BACnet MS/TP;RS-485.

10. Outputs: two, 0 to 10 volts dc analog signals.

a. Damper control

b. Variable speed drive control

11. BACnet BAS Outputs: five analog signals.

a. Underfloor temperature, 50°F to 100°F(10.0°C to 37.8°C).

b. Slab temperature, 40°F to 90°F (4.4°C to32.2°C).

Form 130.16-EG1 (506)

JOHNSON CONTROLS30


c. Percent relative humidity, 0 to 100%.

d. Differential dew point, 0°F to 20°F (0°C to -11.1°C).

e. Supply Airway space pressure, 0 to 0.25inches w.g. (0 to 62 Pa).

12. Sequence of Control

a. Under-floor Pressure Monitoring andControl: The CX-FlexFloor shall measure theunder-floor pressure relative to the space andprovide a 0-10 VDC output signal tomodulate the [supply fan VFD/under-floorsupply air damper(s)]. The CX-FlexFloorshall modulate airflow into the plenum tomaintain the under-floor pressure setpoint(nominal 0.05 in. w.g.). For under-floorplenums served by multiple air handling unitsor supply ducts, the CX-FlexFloor shallmodulate all dampers in unison to maintainthe under-floor pressure.

b. Under-floor Temperature Monitoring andControl: The CX-FlexFloor shall monitorunder-floor supply air temperature andprovide a 0-10 VDC output to control theAHU bypass damper and bypass-heating coilin sequence to maintain under-floor supplyair temperature.

c. Under-floor Humidity/Dew pointMonitoring: The CX-FlexFloor shall monitorunder-floor humidity, supply air temperatureand slab temperature. The CX-FlexFloorshall use these inputs to calculate the dewpoint temperature of the supply air andprovide a 0-10 VDC output proportional tothe difference between the slab temperatureand the dew point. As the dew pointapproaches the slab temperature, the AHUcontroller shall use this signal to lower thedew point of the supply air by lowering thetemperature of the primary air off the coolingcoil.

B. IBOX, communications interface sequence

1. Each IBOX communications interface shall becompatible with modular, plug-and-play wiringsystem.

2. The IBOX shall communicate with the system’sTCD-C AirSwitch thermostats, and gather readand write data for use by a third party buildingautomation system using [BACnet] [LonWorks]protocol.

3. Each unit shall also be designed for networkcommunication with up to 32 TCD-CAirSwitches.

4. Input power supply: 24 volts ac, single-phase,60 hertz.

C. Modular Control System Cables:

[These items may be included in Division 16, butwill require coordination between the MechanicalContractor and the Electrical Contractor.]

All modular control cables shall be rated for plenumservice and shall be equipped (unless indicatedotherwise) with modular plug-and-play electricalconnectors. All cables shall be factory-tested forcontinuity, shorts, opens and proper impedance.

1. PAP-1, General purpose cable: 4-conductor, 18-gauge, 25 feet (7.6 m) long, with modularreceptacle at both ends. Identification color:blue.

2. PAP-2, External device (whip) cable: 4-conductor, 18-gauge, 50 feet (15.2 m) long, withmodular receptacle on one end and pig tail onthe other. Identification color: yellow.

3. PAP-3, Extension cable: 4-conductor, 18-gauge,25 feet (7.6 m) long, with modular receptacleon one end and plug on the other end.Identification color: blue.

4. PAP-4, Communications Cable: 2-conductor,22-gauge, 100 feet (30 m) long, with receptacleat one end and both receptacle and plug on theother end. Identification color: white.

5. PAP-5, Power only cable: 2-conductor, 18-gauge, 25 feet (7.6 m) long, with receptacles atboth ends. One end shall have an additional shortextension with a plug to permit daisy-chainingone power distribution cable to another. For 24volts ac, single-phase, 60 hertz power only.Identification color: green.

6. PAP-6, Heating cable: 2-conductor, 22-gauge,100 feet (30 m) long, with receptacle at one end

Form 130.16-EG1 (506)

JOHNSON CONTROLS 31

and both receptacle and plug on the other end.Identification color: orange.

7. PAP-7, Thermostat cable: 8-conductor, 18-gaugeshielded, 10 feet (3.0 m) long, with 3 plugs onone end, and 2 receptacles on the other end.Identification color: white.

D. PM, Power Module[This unit can serve up to a combined total of 14MIT2 terminals and TCD AirSwitches with pulse-modulated control. This item may be included inDivision 16, to define furnishing and installationrequirements for the Electrical Contractor.]

1. Input power: [120], [240] or [277] volts ac,single-phase, 60 [50] Hertz.

2. Transformer Output Rating: 90 volt-ampere, 24volts ac.

3. Output connection: modular “plug-and-play”connector compatible with MIT2 wiring system.

4. Housing: steel junction box with knockouts forconduit.

E. QBX-C, Signal Conversion Device

1. QBX-C signal conversion device shall providea communication link between early generationFlexSys system controls and MIT2 components.The device shall provide isolation of the floatingpoint circuit from the AirFixture pulsemodulation circuit while allowing up to 3amperes of drive current at 24 volts ac forproportional devices.

2. Modular connections: three required as follows

a. FlexSys terminal device port: shall supplyup to 3 amperes at 24 volts ac to drive up to14 terminals.

b. AirFixture device port: shall be capable ofsupplying up to 10 terminals.

c. Thermostat input port: for cooling-only, four-wire connection that goes to the first FlexSysdevice in the control chain. Compatible withW7763, T6984, FlexHeat or Flex Coolthermostat/controller.

F. QBX-H, Signal Conversion Device[Required when connecting TCD thermostats tothird party heating devices.]

1. QBX-H signal conversion device shall providea communication link between a TCD-C andthird party heating devices, such as solenoidvalves or modulating control valves.

2. The device shall be powered through normal PAPcables with a 24 volts ac power supply from theoriginal FlexSys System.

3. Outputs to third party devices shall be screwterminal connections

4. QBX-H shall have three control signalconversion capabilities. Using a TCD-C heatingcontrol signal, the output options shall be:

a. A 24 volts ac on/off device.

b. A 0 to 10 volts dc proportional device.

G. TCD-C, AirSwitch™, Heating and Cooling SpaceThermostat for Pulse-Modulation Control[Required when using pulse-modulationcontrolled terminals and networkcommunications. Provides local control anddisplay, and remote set point adjustment andmonitoring.]

1. TCD-C AirSwitch shall be a wall-mountedheating and cooling thermostat device.

2. Enclosure: plastic, in accordance with UL 94.Enclosure shall be suitable for mounting on asingle gang electrical box in either the horizontalor vertical orientation.

3. Wiring connections: modular.

4. Setpoint Adjustment: push button (higher andlower)

5. Display: LCD display of set point and spacetemperature.

6. Set point range: 45°F to 90°F (7.2°C to 32.2°C).

7. Device shall provide 63 network addresses usingan integral DIP switch, and use an RS-485network to provide remote connection to an areacontroller or communications device. Networkprotocol and voltages shall be compatible withplug-and-play modular wiring and shall beresistant to tampering by others. TCD-C Unit

Form 130.16-EG1 (506)

JOHNSON CONTROLS32


shall operate as a stand-alone unit or as part ofa proprietary area network compatible withIBOX units.

8. Device shall provide floating-point and pulse-modulation control to enable control of older-style MIT with floating point actuators.

9. Device shall have self-test capability.

10. Device shall comply with FCC Part 15, NECClass 2, and be listed by UL.

11. Color: white.


a. Temperature Sensor: The TCD monitorsroom air temperature as sensed by the roomtemperature sensor with setpoint adjustment.The TCD uses this information to determinethe control action required to maintain roomcomfort. The single setpoint input providesthe cooling setpoint, while the heatingsetpoint is equal to the cooling setpoint minusthe deadband value. An LCD display andbuttons allow the customer to adjust thetemperature setpoint within defined limits.

b. Initial Power Up: On initial power beingapplied or after a power failure, all MIT2motorized dampers connected to the powersource will close. After the dampers areclosed, the TCD-C begins a normal operatingsequence by sending pulse modulated controlsignals to the first MIT2 unit in the chainand by starting heating stages, as necessarywith 60 second intervals between stages.

c. Normal Operation – Cooling, temperaturerise above the cooling setpoint (or loweringof the setpoint): When the sensor indicates atemperature greater than the cooling setpoint,the TCD will send open signals to the MIT2connected to the TCD to cool the temperatureof the zone. The TCD gradually andincrementally increases the amount of timethe MIT2 damper stays in the open position,until the temperature reaches the setpoint andthe controller takes no further action. If thetemperature starts to fall below the coolingsetpoint, the TCD increases the amountof time the MIT2 damper stays in the closedposition, thereby reducing the cooling tothe zone.

d. Normal Operation – Heating, temperaturefalls below the heating setpoint (or raisingof the setpoint): If the temperature continuesto fall below the heating setpoint, then theTCD-C controls the MIT2 damper to stay inthe closed position 98% of the time. [for HCEor UFE heat: Then the fan is activated toreturn the space temperature to the heatingsetpoint. If, after the fan is activated, thetemperature remains below the setpoint, thefirst stage of electrical heating is introduced.If additional heat is required, additionalstages of heat are activated, if available.] [forHCW or UFW heat: Then the fan is activatedto return the space temperature to the heatingsetpoint. If, after the fan is activated, thetemperature remains below the setpoint, thehydronic heating is introduced.] [for QBX-H heating signal: Then the heating devicesare activated. Describe heating method.] Asthe temperature rises above the heatingsetpoint the heating stages are sequenced off.

e. Box Calibration: All MIT2 motorizeddampers are programmed to re-synch to theopen or closed position within 3 cycles ofthe damper. 3 cycles of the damper will takea maximum of 15 minutes. This prevents theMIT2 from being out if its expectedsequence.

f. TCD-C Operating Parameters, FactoryDefaults:

1. The occupied cooling setpoint is 74° F –project setting shall be [specify setpoint].

2. The deadband setting is 2° F – projectsetting shall be [2° F] [5° F].

3. Setpoint adjustment: 45-90° F – projectsetting shall be [specify setpoint range]

g. Diagnostic Mode: Diagnostic mode is usedto test MIT2 motorized dampers, heatingdevices, and the wiring connected to theTCD. During this mode, the MIT2 dampersare continuously cycled every 30 seconds,and the heating stages are cycled every 60seconds. To enter diagnostic mode, use theIBOX to communicate this operating modeor enter manually by decreasing the setpointto the minimum and pressing both setpointadjustment buttons. Exit by pressing bothsetpoint adjustment buttons.

Form 130.16-EG1 (506)

JOHNSON CONTROLS 33

H. TCD-S, AirSwitch™, Cooling Only SpaceThermostat for Pulse-Modulation Control[Provides local control and display for pulsemodulation controlled terminals.]

1. TCD-S AirSwitch shall be a wall-mountedcooling only thermostat device.

2. Enclosure: plastic, in accordance with UL 94.Enclosure shall be suitable for mounting on asingle gang electrical box in either the horizontalor vertical orientation.

3. Wiring connections: modular.

4. Setpoint adjustment: push button (higher andlower)

5. Display: LCD display of set point and spacetemperature.

6. Set point range: 45°F to 90°F (7.2°C to 32.2°C).

7. Device shall have self-test capability.

8. Unit shall comply with FCC Part 15, NEC Class2, and be listed by UL.

9. Color: white.


a. Temperature Sensor: The TCD monitorsroom air temperature as sensed by the roomtemperature sensor with setpoint adjustment.The TCD uses this information to determinethe control action required to maintain roomcomfort. The single setpoint input providesthe cooling setpoint. An LCD display andbuttons allow the customer to adjust thetemperature setpoint within defined limits.

b. Initial Power Up: On initial power beingapplied or after a power failure, all MIT2motorized dampers connected to the powersource will close. After the dampers areclosed, the TCD-S begins a normal operatingsequence by sending pulse modulated controlsignals to the first MIT2 unit in the chain.

c. Normal Operation – Cooling, temperaturerise above the cooling setpoint (or loweringof the setpoint): When the sensor indicates atemperature greater than the cooling setpoint,the TCD will send open signals to the MIT2connected to the TCD to cool the temperatureof the zone. The TCD gradually and

incrementally increases the amount of timethe MIT2 damper stays in the open position,until the temperature reaches the setpoint andthe controller takes no further action. If thetemperature starts to fall below the coolingsetpoint, the TCD increases the amount oftime the MIT2 damper stays in the closedposition, thereby reducing the cooling to thezone.

d. Box Calibration: All MIT2 motorizeddampers are programmed to re-synch to theopen or closed position within 3 cycles ofthe damper. 3 cycles of the damper will takea maximum of 15 minutes. This prevents theMIT2 from being out if its expectedsequence.

e. TCD-S Operating Parameters, FactoryDefaults:

1. The occupied cooling setpoint is 74° F –project setting shall be [specify setpoint].

2. The deadband setting is 2° F – projectsetting shall be [2° F] [5° F].

3. Setpoint adjustment: 45-90° F.

f. Diagnostic Mode: Diagnostic mode is usedto test MIT2 motorized dampers, heatingdevices, and the wiring connected to theTCD. During this mode, the MIT2 dampersare continuously cycled every 30 seconds,and the heating stages are cycled every 60seconds. To enter diagnostic mode, use theIBOX to communicate this operating modeor enter manually by decreasing the setpointto the minimum and pressing both setpointadjustment buttons. Exit by pressing bothsetpoint adjustment buttons.

PART 3 – EXECUTION

3.01 INSTALLATION

A. Prior to installing underfloor Airway distributioncomponents, verify that all penetrations andopenings in the area under the raised access floorhave been sealed.

B. Verify that the building area under the raised accessfloor has been cleaned and is free of dust, dirt,debris, standing water and other contaminants.

Form 130.16-EG1 (506)

JOHNSON CONTROLS34

3.02 INSTALLATION - GENERAL

A. Install all underfloor Airway distribution systemcomponents, including supply air terminals, fan-powered terminals and controls in accordance withthe manufacturer’s instructions.

B. Prior to installation, all components shall be storedin a clean, dry location that is protected fromweather and damage from other constructionactivities.

C. Coordinate installation of underfloor Airwaydistribution components with the Access FloorContractor, who is responsible for erection of theraised access floor.

D. Coordinate location and size of all cut openings inraised access floor panels with the Access FloorContractor.

E. Install supply air terminals, fan-powered terminalsand other components in the locations indicated onthe drawings.

F. All power and control wiring shall be installed inaccordance with the requirements of specificationSection [ ].

1. All power and control wiring for the underfloorAirway distribution system components shall beinstalled in a neat and workmanlike manner.

2. Line voltage and sensor wiring shall not beinstalled in the same harness.

3. Low voltage and communication wiring (lessthan 30 volts) may be installed in the same wiringharness.

3.03 FAN-POWERED TERMINAL UNITS

A. See schedule on Drawings.

B. Support fan-powered terminal units from thebuilding floor in accordance with themanufacturer’s instructions.

C. Position fan-powered terminals so that unit-mounted disconnect switch, fuses, and control cableconnections are easily accessible.

D. Position units so that the filter is easily accessiblefor removal and replacement.

E. Install pipe, fittings, valves, insulation and relatedaccessories as indicated on the Drawings and asrequired in specification Section [ ].

F. Verify that all piping connections are tight and leakfree.

G. Fabricate and install ductwork in accordance withspecification Section [ ]. Flexible connectionsand other ductwork accessories shall be inaccordance with specification Section [ ].

H. Install all fan-powered terminal units with a 1-inch(52-mm) disposable filter that shall remain in placeduring construction. After construction is complete,replace the filters in all units with new filters [orremove filters].

3.04 TESTING

A. Upon completion of all installation activities,perform the manufacturer’s pre-start checkoutinstructions (found in Form 130.16-N1).

B. Start-up and operate underfloor Airway distributionsystem components to demonstrate functionaloperation and compliance with specifications.

C. Perform testing, adjustment and balancing ofhydronic piping systems serving fan-poweredterminal units.

D. Perform testing, adjustment and balancing of thesupply-side of the duct work served by the fan-powered terminal units.

3.05 OCCUPIED SPACE TO RETURN AIRWAYDIFFERENTIAL STATIC PRESSURE TEST

After supply Airway leakage is verified withinacceptable limits, and with the system operating in itsnormal configuration, the Mechanical Contractor shallmeasure the static air pressure drop between theoccupied space and the return Airway space. Thepressure difference shall not exceed 0.02 inches w.g.(5 Pa). If the return air pressure differential is greaterthan 0.02 inches w.g. (5 Pa), then additional return airterminals or larger return air terminals must be installedin the system.

3.06 BUILDING PRESSURIZATION TEST

The return Airway space pressure shall be verified asslightly positive relative to outside ambient in the rangeof 0.008 to 0.01 inches w.g. (2 to 2.5 Pa). This requiresthe system to be operating normally with the Airwayscomplete and all fixtures in place. With variable-air-volume systems, the Mechanical Contractor shalldemonstrate the pressure controller and associated


Form 130.16-EG1 (506)

JOHNSON CONTROLS 35

controls are capable of maintaining a stable buildingpressure as the system supply volume modulates.

For constant-volume systems, the outside air damperand exhaust dampers shall modulate to maintain a stablebuilding pressure during both unoccupied and occupiedoperating modes and throughout the modulating rangeof outside air damper if a demand control ventilationsequence (carbon dioxide measurement) is used.

3.07 AIR LEAKAGE TEST - EACH FAN SYSTEM

The purpose of this test is the determination of howmuch air is lost to leakage by the duct and plenumsystem. Too much leakage can cause loss oftemperature control and poor performance. A typicalgood system will leak no more than 10-15% of totalvolume and a marginal system may leak up to 20-25%.If leakage is beyond that which was specified as theminimum VAV flow through the air handler, then thesystem should be repaired to yield leakage no greaterthan this level.

To determine plenum/duct leakage, all supply airwayterminals are to be covered or sealed. (This test couldbe performed with blank panels, also.) This can beaccomplished by using the optional self-adhesiveprotective sheets, if this has not been done previouslyto protect the supply airway terminals from constructiondebris. All panels and closures must be in place. Checkaccess doors for good fit and closure. Verify allpenetrations at duct/drywall transitions are sealedairtight.

With the plenum and supply airway terminals sealed,the system is brought to normal working pressure withthe controls (typically .05 inches w.g. in the plenum).The airflow of the supply fan system is measured bythe air balance personnel and compared to maximumdelivery volumes. The test volumes are recorded inthe commissioning report. Correct and retest anysystems that demonstrate leakage/uncontrolled flowin excess of design maximum.

3.08 SUPPLY AIRWAY TERMINALS/MFTFUNCTION TEST AND ZONING VERIFICATION

The purpose of this test is the assurance that the supplyairway terminals are correctly installed and functional.Each supply airway terminal is checked to be sure thatit is installed properly and secured to the floor. Referto the appropriate installation instructions (form 130.16-

N1). The trim ring should be tight to the floor with nogaps or rocking motion. The grilles should be open(no casting flash or debris), and correctly oriented asrequired on the drawings. Identify any damagedgrilles, trim rings, scratched finishes, bent chassis,excessive dirt etc. and correct as necessary.

Using the project documents, each zone is tested toverify the supply airway terminal units with automaticdampers are correctly wired to a thermostat, and thedampers within the supply airway terminals areoperating correctly. Using the thermostat test modeeach thermostat location has its connected supplyairway terminal driven open and closed with thedrawing marked up indicating pass/fail of each unit.MIT2-G units connected to fan-powered terminalsshould demonstrate little or no airflow in the heatingposition with the fan off and the damper in the fullheating position. If substantial airflow is indicated inthis mode then the ductwork under the floor may haveexcessive leakage or be disconnected.

Incorrect operation or zoning is to be corrected andthe test repeated. Manually operated supply airwayterminals are to be verified as correctly located andinstalled. Verify fan powered terminals have filtersinstalled if required and all stages operate correctly.Refer to fan powered terminals installation instructionform 130.16-N1.

Each thermostat should be verified as being the correctstyle and type for the location. If thermostats areconnected to a Building Automation System, then eachthermostat should be observed as communicatingcorrectly. The drawings should identify where eachthermostat is located by address.

3.09 AIR DELIVERY TEST AND ADJUSTMENT

The purpose of this test is the determination that thefan system can provide adequate air to all of the supplyairway terminal devices as installed. If diversity isincluded on the design, the maximum number of supplyairway terminal devices should be opened fully on adistributed basis throughout the floor plates.

After the leakage test has been passed successfully, thesealing material from the supply airway terminals isremoved and all the required supply airway terminalsare opened fully by means of the thermostat tester. Thefan system should be under automatic control deliveringa nominal 0.05 inches w.g. to the floor. Random testing

Form 130.16-EG1 (506)

JOHNSON CONTROLS36

of MIT2 units on each floor plate or area should indicatean airflow from the fully open MIT2 units of design(100 or 150 CFM depending on model). Generally testone MIT per 10,000 square feet minimum. If the MIT2

units are generally above or below design, the pressurecontrol should be adjusted using program setpoint withthe CX-FlexFloor) to provide the correct designvolume. If the system fails because the fan can notlower/raise the pressure, it should be identified andcorrected. The commissioning report should identifycorrect and incorrect operation along with the valueof required settings to achieve design airflow. Fanvolume (VFD speed) should be noted on the drawings.

3.10 LOADING BALANCING

The floor plate that has multiple injection points shouldbe observed to assure that the load is being equally

divided between systems. For example, one fan maybe operating at 100% and another at 25%. The floorpressure controls may need to be adjusted to cause thefan running at 100% to be lowered to 62.5% (lower thepressure setpoint) and the fan running at 25% to beraised to 62.5% (raise the pressure setpoint). Theseadjustments may require very small adjustments to thepressure controls and should be observed over time toassure correct effect is achieved.

Verify that the limits on TCD setpoint have beenadjusted to prevent the user from raising or loweringthe setpoint past 70-80 degrees. This will preventneighboring zones from competing with each other.


P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA© 2006 Johnson Controls, Inc. www.york.com ALL RIGHTS RESERVEDForm 130.16-EG1 (406)Supercedes: Nothing

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