DDC Technical Manual

Table of Contents
Control of Supply Air Temperature ....................................................................................................... 1

Control of Humidity ............................................................................................................................. 3
Space or Room Air Control ................................................................................................................... 5
Control of Duct Static Pressure.............................................................................................................. 7
Outside Air Temperature Lockout......................................................................................................... 9
Temperature Setpoint Reset ................................................................................................................ 10
Outside Air Economizer ...................................................................................................................... 11
Optimal Start ...................................................................................................................................... 13
Filter Clean/Dirty Pickup Installation .................................................................................................. 14
Duct Static Pressure Pickup Installation ............................................................................................... 15
Typical Averaging Element Installation ............................................................................................... 16
Pressure Device Mounting Detail ......................................................................................................... 17
Typical Pipe Strap-on Element Installation .......................................................................................... 18
Typical Immersion Type Element Installation...................................................................................... 19
Typical Outside Air Temperature Element Installation ........................................................................ 20
Typical Space Temperature Element Installation ................................................................................. 21
Typical Space Temperature/Humidity Element Installation ................................................................. 22
Typical Duct High/Low Limit Switch Installation ................................................................................ 23
Typical Current Sensor Installation ..................................................................................................... 24
Typical KW/KWH Transducer ............................................................................................................ 25
Typical Belimo Actuator Wiring Schematic ......................................................................................... 26
Typical Control Enclosure................................................................................................................... 27
Tips for Bending Conduit for Stub-ups ................................................................................................ 28
Valve Piping Illustrations .................................................................................................................... 30
Drill and Screw Size Chart ................................................................................................................... 32
Sensor Networks ................................................................................................................................. 33
Reference Data .................................................................................................................................... 34
Corey Simon, Project Engineer

Computrols, Inc.
826 Lafayette Street New Orleans, Louisiana 70113
Phone: 504.529-1413 Fax 504.529.1463 www.computrols.com
Control of Supply Air Temperature

System Flow Diagram
Sequence of Operation
The DDC controller uses a temperature sensor mounted in the supply air duct to modulate control
valves or mixing dampers to maintain a supply air temperature setpoint. In most systems that employ a
heating and cooling coil, the hot water valve and the chilled water valve should be modulated in
sequence.
When the supply air temperature falls below setpoint, the hot water valve begins to modulate open and
consequently, the cooling valve begins to modulate closed. If the supply air temperature continues to fall
below the setpoint, the heating valve will open fully and the cooling valve will close completely.
When the supply air temperature rises above setpoint, the hot water valve begins to modulate closed and
consequently, the cooling valve begins to modulate open. If the supply air temperature continues to rise
above the setpoint, the heating valve will fully close and the cooling valve will open completely.
A temperature sensor located in the mixed air stream (between the unit filters and the coils) is used to
provide mixed air low limit control. When the temperature sensed by this element falls below the
setpoint, the outside air damper fully closes, the return air damper fully opens, the exhaust air damper
closes to a minimum position, and the valves on all coils will fully open. This sequence should always be
used on systems with wetted coils.
When the unit fan is turned off, the outside air damper fully closes, the return air damper fully opens,
the exhaust air damper fully closes, and all control valves return to their normal positions.
Design Considerations
Control Valves
Avoid using spring return actuators on control valves for wetted coil applications.
When selecting two-way valves for control of wetted coils:
For hot water coils, have the valve configured in the normally open position.
For chilled water coils, have the valve configured in the normally closed position.
When selecting three-way valves for control of wetted coils:
For hot water coils, have the valve piped such that when the valve is in the normal position,
the water flows through the coil.
For chilled water coils, have the valve piped such that when the valve is in the normal
position, the water bypasses the coil. It is recommended that mixing valves be used in all threeway applications unless otherwise specified. Caution - Do not pipe globe valves that are
designed for mixing applications for diverting service. The fluid flow will cause a hammering
effect and severe noise and damage will follow.
Mixing Dampers
Always use opposed blade dampers in control applications that require the mixing of air. Opposed blade
dampers cause turbulence in the air flowing through them. This turbulence causes more complete
mixing of the air streams and reduces the risk of freezing coils due to air stratification. Use opposed
blade dampers for outside air dampers and return air dampers. Parallel blade dampers should be used
for smoke dampers and exhaust air dampers. Use spring return actuators for all dampers. Mixing
dampers should be properly sized to provide good control. Improper sizing will result in the
stratification of air streams of different temperatures.
Low Limit Switch or Freezestat
This device should be positioned across the face of the heating coil (if the heating coil is before the
cooling coil) or across the face of the preheat coil if one is employed. The capillary element must
serpentine horizontally across the face of the coil. If the capillary element is not arranged in this manner,
the device will not function properly. It is recommended that a low limit switch with a set of normally
closed contacts and a set of normally open set of contacts be used. The normally closed contacts
should be wired directly into the fans starter circuit to de-energize the fan when the setpoint is reached.
The normally open set of contacts should be wired to one of the DDC controllers binary input points.
Always use a manual reset low limit device.
Mixed Air Sensor
Always use an averaging type element when access to the mixed air plenum is possible. If the mechanical
room is used as the mixed air plenum, place the averaging element in front of the units filter bank. Do
not attach the averaging element to the filter bank. If access is a problem, then appropriately place a
duct-mounted temperature probe in a position that is most representative of the temperature of the
mixed air stream. Try to avoid positions near bends in the duct.
Supply Air Sensor
Use a duct-mounted probe placed far enough down the supply air duct so that the supply air stream has
been properly mixed.
Software Configuration
Use separate analog outputs for the chilled water and hot water valves. The PID loops for the chilledwater valve and the hot-water valve should be configured as direct acting. In order for this configuration
to be used, the guidelines in item #1 Control Valves must be adhered to completely. Always return all
control valves to the normal position when the fan is off.
Never cut power to a proportional spring return actuator to return the actuator to the normal
position. Always use the software to return the spring return actuator to the normal position. The
spring return feature is incorporated to ensure that the controlled device returns to the fail-safe position
upon loss of control power. Note: These guidelines do not apply to spring return on-off type actuators.
Control of Humidity
System Flow Diagram
The DDC controller uses a humidity sensor mounted in the return air duct or the space to modulate
control valves or to stage electronic humidity control equipment to maintain a relative humidity
setpoint. In most systems that employ humidity control equipment, the controlled equipment will
usually include a cooling coil used for dehumidification and/or either a steam valve humidifier or an
electronic humidifier.
When the return air or space-relative humidity rises above setpoint, the chilled water valve fully opens.
As a result of this action, the reheat devices, whether a duct-mounted reheat coil or a space-mounted
radiant heater, temper the cooler air produced by the fully-opened cooling coil to maintain either the
supply air temperature setpoint or the space temperature setpoint. Dehumidification is accomplished by
cooling the air below the dew point causing the air to dry.
When the return air or space relative humidity falls below setpoint, the humidifier steam valve begins to
modulate open or the electric humidifier begins to stage on.
When both dehumidification and humidification equipment are employed, the supply air humidity
sensor provides humidity high limit control. This high limit overrides the humidifiers steam valve to the
closed position or the electric humidifier off when the humidity high limit setpoint is reached.
When the unit fan is turned off, the steam valve will close or the electric humidifier will be turned off
and all other control valves will return to their normal position.
Control Valves
Avoid using spring-return actuators on control valves for wetted coil applications.

effect and severe noise and damage will result.
Humidity Sensor
For space-mounted locations, avoid mounting the sensor near direct sources of cool or hot air. Avoid
mounting near appliances that release steam or condensation such as coffee makers, stoves, or ovens.
Use separate analog outputs for the chilled water, hot water, and steam valves. The PID loops for the
chilled water valve and the hot water valve should be configured as direct acting. In order for this
configuration to be used, the guidelines in item #1 Control Valves must be adhered to completely.
Always return all control valves to the normal position when the fan is off.
position. Always use the software to return the spring return actuator to the normal position. For
proportional spring return actuators that incorporate a phase cut feature, this may be used in
conjunction with the software to return the proportional actuator to the normal position. The springreturn feature is incorporated to ensure that the controlled device returns to the fail-safe position upon
loss of control power. Note: These guidelines do not pertain to spring-return on-off type actuators.
Space or Room Air Control

System Flow Diagram
The DDC controller uses a temperature sensor mounted in the supply air duct to modulate control
valves or mixing dampers to maintain a supply air temperature setpoint. In most systems that employ a
heating and cooling coil, the hot water valve and the chilled water valve should be modulated in
sequence.
When the supply air temperature falls below setpoint, the hot water valve begins to modulate open and
consequently, the cooling valve begins to modulate closed. If the supply air temperature continues to fall
below the setpoint, the heating valve will open fully and the cooling valve will close completely.
When the supply air temperature rises above setpoint, the hot water valve begins to modulate closed and
consequently, the cooling valve begins to modulate open. If the supply air temperature continues to rise
above the setpoint, the heating valve will fully close and the cooling valve will open completely.
A temperature sensor located in the mixed air stream (between the unit filters and the coils) is used to
provide mixed air low-limit control. When the temperature sensed by this element falls below the
setpoint, the outside air damper fully closes, the return air damper fully opens, the exhaust air damper
closes to a minimum position, and the valves on all coils will fully open. This sequence should always be
used on systems with wetted coils.
Control Valves
Avoid using spring return actuators on control valves for wetted coil applications.
effect and severe noise and damage will result.
Mixing Dampers
Always use opposed blade dampers in control applications that require the mixing of air. Opposed blade
dampers cause turbulence in the air flowing through them. This turbulence causes more complete
mixing of the air streams and reduces the risk of freezing coils due to air stratification. Use opposed
blade dampers for outside air dampers and return air dampers. Parallel blade dampers should be used
for smoke dampers and exhaust air dampers. Use spring return actuators for all dampers. Mixing
dampers should be properly sized to provide good control. Improper sizing will result in the
stratification of air streams of different temperatures.
Low Limit Switch or Freezestat
This device should be positioned across the face of the heating coil (if the heating coil is before the
cooling coil) or across the face of the preheat coil if one is employed. The capillary element must
serpentine horizontally across the face of the coil. If the capillary element is not arranged in this manner,
the device will not function properly. It is recommended that a low limit switch with a set of normally
closed contacts and a set of normally open contacts be used. The normally closed contacts should
be wired directly into the fans starter circuit to de-energize the fan when the setpoint is reached. The
normally open set of contacts should be wired to one of the DDC controllers binary input points.
Always use a manual reset low-limit device.
Mixed Air Sensor
Always use an averaging type element when access to the mixed air plenum is possible. If the mechanical
room is used as the mixed air plenum, place the averaging element in front of the units filter bank. Do
not attach the averaging element to the filter bank. If access is a problem, then appropriately place a
duct-mounted temperature probe in a position that is most representative of the temperature of the
mixed air stream. Try to avoid positions near bends in the duct.
Supply Air Sensor: Use a duct-mounted probe placed far enough down the supply air duct so
that the supply air stream has been properly mixed.
Space Sensor: For space-mounted locations, avoid mounting the sensor near direct sources of
cool or hot air. Avoid mounting near appliances that release steam or condensation such as
coffee makers, stoves, or ovens.
Use separate analog outputs for the chilled water and hot water valves. The PID loops for the chilled
water valve and the hot water valve should be configured as direct acting. In order for this configuration
to be used, the guidelines in item #1 Control Valves must be adhered to completely. Always return all
control valves to the normal position when the fan is off.
position. Always use the software to return the spring return actuator to the normal position. The
spring return feature is incorporated to ensure that the controlled device returns to the fail-safe position
upon loss of control power. Note: These guidelines do not apply to spring return on-off type actuators.
Control of Duct Static Pressure

System Flow Diagram
Supply Fan Variable Frequency Drive Control
Supply Fan Inlet Vane Control
Supply Duct Dump Damper Control
The DDC controller uses a differential pressure transmitter connected to a static pressure sensing tip
mounted in the supply air duct just before the last VAV box on the duct branch to modulate a VFD,
inlet vanes, or a dump damper to maintain a supply air static pressure setpoint.
When the supply air static pressure falls below setpoint, the VFD, inlet vanes, or dump damper begins to
modulate open. If the supply air static pressure continues to fall below the setpoint, the VFD, inlet vanes,
or dump damper will continue to open.
When the supply air static pressure rises above setpoint, the VFD, inlet vanes, or dump damper begins to
modulate closed. If the supply air static pressure continues to fall below the setpoint, the VFD, inlet
vanes, or dump damper will continue to close.
A duct-mounted high-static pressure safety switch is mounted in the supply air stream to prevent overpressurization of the duct. This switch must be wired into the safety circuit of the units VFD or motor
starter.
Differential Pressure Transmitters
Choose a device with a maximum range that most closely matches the units maximum static pressure
output.
For most systems, a 0 3 W.C. device is adequate. Mount this device as close to the static pressure
sensing tip as possible to avoid long pneumatic tubing runs.
Static Pressure Sensing Tip
See the Duct Static Pressure Pickup Installation section of this manual for proper mounting.
Static Pressure High Limit
This device should be positioned in the supply air stream. It is recommended that a manual-reset static
pressure high-limit switch with a set of normally closed contacts and a set of normally open
contacts be used. The normally closed contacts should be wired directly into the fans motor starter or
VFDs safety circuit to de-energize the fan when the setpoint is reached. The normally open set of
contacts should be wired to one of the DDC controllers binary input points. Always use a manual reset
low-limit device.
The PID loops for the VFD, inlet vanes, or dump damper should be configured as reverse acting. For
VFD applications, set the acceleration and deceleration times on the VFD to 120 seconds. This will
ensure that the VFD does not quickly ramp up or down in response to small changes in the static
pressure.
Outside Air Temperature Lockout

System Flow Diagram
The DDC controller uses a temperature sensor mounted in the outside air to lockout the mechanical
means of cooling or heating.
When the outside air temperature falls below the lockout setpoint for cooling, the DDC system will
provide a signal to turn off the mechanical cooling means.
When the outside air temperature rises above the lockout setpoint for heating, the DDC system will
provide a signal to turn off the mechanical heating means.
Outside Air Temperature Sensor
This sensor should be mounted on the wall with the northernmost exposure. If mounting the sensor on
an outside wall is not possible, then mount a probe-type sensor in the outside air duct. Mounting the
sensor in the duct has one drawback: in this location, the sensor is subject to reading stagnant air when
the outside air damper is closed. Use a weatherproof housing with a sun shield and a windshield to
reduce the possibility of false readings. It is recommended that a humidity element be incorporated in the
housing for other control functions.
This control strategy should be used to lockout mechanical heating or cooling equipment such as
chillers, boilers, or direct expansion (DX) units and should not be used to close heating or cooling
valves. Do not confuse this control strategy with the low-limit control strategies found in earlier sections
of this manual. When mechanical equipment is turned off using the outside air temperature lockout
strategy, it is generally good practice to signal all control valves and/or on-off type equipment associated
with the respective system to return to the normal position.
Always incorporate at least a two-degree temperature differential when using this control strategy to
avoid cycling the equipment too frequently.
Temperature Setpoint Reset

System Flow Diagram
The DDC controller uses a temperature sensor mounted in the return air duct or the space to reset the
setpoint of the supply air temperature. In order to accomplish this, the supply air temperature is varied
based on the readings from the return air or space sensor.
Once the corresponding supply air temperature setpoint has been determined, supply air temperature
control uses the setpoint to maintain the supply air temperature.
Return Air Temperature Sensor
This sensor should be mounted in the return air duct. Use a probe-type sensor for the installation.
To implement this control strategy, program the system to use a similar reference table as shown below:
Return Air or Space
Temperature
O
( F)
Supply Air
Temperature Reset
O
Setpoint ( F)
69O
70O
72O
74O
76O
60O
58O
55O
54O
53O
Keep in mind that when wetted coils are employed as the heating and cooling means to control the
supply air temperature, the lowest possible supply air temperature that is attainable for discharge is
nominally about 52O F. If direct expansion (DX) coils are employed, the discharge air temperature can be
reduced to as low as 42O F.
10
Outside Air Economizer

System Flow Diagram
The outside air economizer strategy is employed so that the outside air or the return air can be used to
lessen the load experienced by the cooling coil. This in turn reduces the need for mechanical cooling
from the related equipment providing energy savings. There are two types of economizer strategies:
Enthalpy Comparison
The DDC controller uses a combination temperature and humidity sensor mounted in both the outside
air and return air ducts to close the outside air damper to a minimum position when the outside air
enthalpy exceeds the return air enthalpy. Enthalpy, in a simplified sense, is nothing more than the total
heat capacity of the air. In humid climates, the enthalpy (or total heat) of the outside air may be greater
than that of the return air even though the dry bulb temperature of the outside air may be lower than
that of the return air. When the outside air enthalpy is less than the return air enthalpy, the outside air
damper, the return air damper, and the cooling valve may be modulated in sequence to provide the
proper supply air temperature. This strategy should be used in climates where the humidity is high or is
not constant.
Dry Bulb
The DDC controller uses a temperature sensor mounted in the outside air to close the outside air
damper to a minimum position when the outside air temperature exceeds the economizer setpoint. When
the outside air temperature is less than the economizer setpoint, the outside air damper, the return air
damper, and the cooling valve may be modulated in sequence to provide the proper supply air
temperature. This strategy should only be used in climates where the humidity is constant.
Return Air Enthalpy Sensor
This sensor should be mounted in the return air duct. Use a transmitter assembly that provides a 0-10vdc
signal output to indicate enthalpy conditions. This sensor must have an insertion probe or ductmounting capabilities.
11
Outside Air Enthalpy Sensor

This sensor should be mounted in the outside air duct. Use a transmitter assembly that provides a 010vdc signal output to indicate enthalpy conditions. The transmitter housing must be weatherproof and
must have an insertion probe or duct-mounting capabilities.
an outside wall is not possible, then mount a probe-type sensor in the outside air duct. Mounting the
the outside air damper is closed. Use a weatherproof housing with a sun shield and a windshield to
12
Optimal Start
System Flow Diagram
The DDC controller uses a temperature sensor mounted in the outside air, the space, or a mass sensor in
the walls of the building to determine the optimal time to start the air-handling unit.
Temperature Sensor
Avoid using a space mounted temperature sensor. Use a mass sensor for this application. The reason for
this sensor choice is because the floors, walls, and ceilings in a building can cause the space to feel cold
even if the space temperature setpoint is satisfied. It is very important not to mount the mass sensor in
any hollow spaces such as behind a wall where drafts may be present. This sensor must be mounted
inside of the wall material. When using this sensor on a new project, be sure to have the sensor mounted
in the walls material before the wall is finished. Do not place the mass sensor in an exterior wall or
within five feet of an exterior wall.
an outside wall is not possible, then mount a probe type sensor in the outside air duct. Mounting the
the outside air damper is closed. Use a weatherproof housing with a sun shield and a wind shield to
13
Filter Clean/Dirty Pickup Installation

Gage Installation Diagrams
Filter Clean/Dirty Status

Notice the orientation of the sensing tubes. This is the proper mounting and installation of the sensing
tubes for the proper indication of the pressure drop across the filter bank. This method should be used
for all situations regardless of the type of sensing device to indicate the pressure drop of the air across a
medium NO EXCEPTIONS!
Part Number
RH-3-2
#21121
Description
0.05-2 W.C. Differential Pressure Switch
Duct Impact Tube
14
Vendor
Kele
Kele
Duct Static Pressure Pickup Installation
Duct Static Pressure

Notice the orientation of the sensing tube. This is the proper mounting and installation of the sensing
tube for the proper indication of duct static pressure. This method should be used for all situations
regardless of the type of sensing device to indicate the duct static pressure NO EXCEPTIONS! When
used on a VAV system air-handling unit, mount the sensing tube at the farthest VAV box from the unit.
This will ensure that all VAV boxes are supplied with the proper amount of air.
Part Number
PV3
T30-030
A-301
A-345
Description
0-5 W.C. Differential Pressure Transmitter
0-3 W.C. Differential Pressure Transmitter
Duct Sensing Tube
Duct Flange Kit
15
Vendor
Computrols
Kele
Kele
Kele
Typical Averaging Element Installation
Install the averaging element in a serpentine fashion as shown. Use M648 capillary supports for
connection to the duct.
Part Number
ST-FZ3-12
ST-FZ3-25
M-648
Description
12 Averaging Temperature Element
25 Averaging Temperature Element
Capillary Mounting Clip
16
Vendor
Kele
Kele
Kele
Pressure Device Mounting Detail
When mounting any type of device to a pipe, the mounting shown above must be used to provide
adequate vibration isolation NO EXCEPTIONS!
Part Number
P74FA-5
Description
FNPT Liquid Differential Pressure Switch
17
Vendor
Kele
Typical Pipe Strap-On Element Installation
Part Number
ST-R3S
APB-28
TCC-12
Description
Pipe Strap-on Temperature Element
Adjustable Pipe Bracket
Thermal Conductive Compound
18
Vendor
Kele
Kele
Kele
Typical Immersion Type Element Installation
Part Number
ST-W3-XH
ST-W3-XW
TCC-12
Description
Immersion Temperature Element
with Well and Handibox
Immersion Temperature Element
with Well and Weatherproof Box
Thermal Conducting Compound
19
Vendor
Kele
Kele
Kele
Typical Outside Air Temperature Element Installation
Install sensor on the wall with the northernmost exposure.

Part Number
ST-O3
Description
Outside Air Temperature Element
20
Vendor
Kele
Typical Space Temperature Element Installation
Part Number
ST-S3E
ST-S3E-XA
ST-S3E-XJ1
ST-S3E-XA-XJ1
Description
Space Temperature Element
Space Temperature Element with Setpoint
Adjustment
Space Temperature Element with Internal
Communications Jack
Space Temperature Element with Setpoint
Adjustment and Internal Communications
Jack
21
Vendor
Kele
Kele
Kele
Kele
Typical Space Temperature/Humidity Element Installation
Part Number
HW10K-T3
Description
Space Temperature/Humidity Element
22
Vendor
Kele
Typical Duct High/Low Limit Switch Installation
Part Number
A70HA-1
A70KA-1
Description
Manual Reset Low Limit Switch
Manual Reset High Limit Switch
23
Vendor
Kele
Kele
Typical Current Sensor Installation
Part Number
H-800
H-900
H-930
H-922
H-932
Description
Solid Core Go/No Current Sensor
Split Core Go/No Current Sensor
Split Core Go/No Current Sensor with Start/Stop Relay
Split Core Analog Current Sensor
Split Core Analog Current Sensor with Start/Stop Relay
24
Vendor
Veris
Veris
Veris
Veris
Veris
Typical KW/KWH Transducer
Part Number
H6001
H6002
H6004
H6005
6810-100
6810-200
6810-300
6811-400
6811-600
6811-800
6812-800
6812-1000
6812-2400
Description
KW/KWH Transducer in NEMA 1 Enclosure
KWH LCD Display Front Mounted in H6001
KW/KWH LCD Displays Front Mounted in H6001
KW/KWH Transducer for Mounting in Field Enclosure
100 Ampere CT Small
200 Ampere CT Small
300 Ampere CT Small
400 Ampere CT Medium
800 Ampere CT Large
1000 Ampere CT Large
2400 Ampere CT Large
25
Vendor
Veris
Veris
Veris
Veris
Veris
Veris
Veris
Veris
Veris
Veris
Veris
Veris
Veris
Typical Belimo Actuator Wiring Schematic
Actuator Sizing Guidelines

For control damper actuators, the force needed for 1 square foot of damper = 3.8 in-lb.
Part Number
LM24
LM24SR
NM24
NM24SR
AM24
AM24SR
GM24
GM24SR
Description
On-Off 35 in-lb 24VAC Actuator
Proportional 2-10VDC 35 in-lb 24VAC Actuator
26
Vendor
Belimo
Belimo
Belimo
Belimo
Belimo
Belimo
Belimo
Belimo
Typical Control Enclosure
Part Number
RET1820
RET2620
RET3826
RET4230
Description
18 X 20 NEMA 1 Enclosure with Perf Panel
27
Vendor
Kele
Kele
Kele
Kele
Tips for Bending Conduit for Stub-ups

Bending Method 1 - Marking the Conduit
From the desired stub-up height, subtract the bender take-up and make a mark on the conduit at a
distance from the end equal to the result. Tool take-up for stubs is a characteristic of the bender and is
usually marked on the bender as shown above. The following table lists the take-up for common sizes of
hand benders:
Hand Bender Size EMT
in Inches
1
1
Groove Take-up in Inches

5
6
7
11
The figures listed in the above table are for benders with a shoe designed to make bend to NFPA 70
(N.E.C.) radii.
Example: Assume that a bender has a 6 take-up. To make a 9 high stub using either EMT or
rigid conduit, subtract 6 from 9 and mark the conduit 3 from the end. Position the arrow on the
bender opposite this mark and make a 90-degree bend. If the bender doesnt have an arrow, use the
mouth of the bender groove in place of the arrow as the starting point and make the bend. Check the
result against the intended rise and mark your own arrow on the bender at the appropriate point.
28
Bending Method 2 - Thumbnail and Eyeball
The second way for making 90-degree stub-up bends when time is a major factor. This method uses no
rulers or marking. Just place your thumbnail on the conduit at the stub height distance and position the
conduit in the bender so that an imaginary plumb line from the outside heel of the bender groove is in
alignment with your thumbnail as shown above. For the best results, bend the conduit on the floor.
29
Valve Piping Illustrations

Valve Tips
The water system should always be flushed before the valves are installed to remove welding debris and
other foreign material that may cause the valves to stick.
Never pipe globe valves designated as mixing valves in diverting applications. The valve will
hammer as the plug gets closer to the seat. This does not apply to ball valves.
All pneumatic valves should be mounted in the upright position. If the valve must be mounted
in excess of 45-degrees from the vertical position, the actuator must be supported.
A valve with an electric actuator should never be mounted beyond the horizontal position. The
electric actuator must be mounted above the valve so that condensation or leaks from faulty
packing doesnt short the actuator.
Never remove or cover the tag on the valve with insulation material.
30
3-Way Butterfly Valve Configurations
31
Drill and Screw Size Chart

This chart lists the high-speed steel drill bits that are used in installations. The tap sizes, wood screw,
and self-tapping sheet metal screw sizes for each drill bit are also listed.
Bit Size
Decimal
Equivalent
#36
#29
#25
5/32
3/16
#7
7/32
5/16
3/8
7/16
1/2
.1069
.1360
.1495
.1562
.1875
.2010
.2187
.2500
.3125
.3250
.4375
.5000
To Tap For
This Size Bolt
or Screw
6 X 32
8 X 32
10 X 24
----------1/4 X 20
1/4 Pipe
-----1/8 Pipe
-----1/4 Pipe
------
32
Wood Screw
Sheet Metal
Screw
#9
#12
#14
-----#18
------------------------------------
#6
#8 & #10
#10 & #12
#12
#14
------------------------------------
Sensor Networks
The following schematic shows various 10K ohm thermistor TYPE III sensor networks. These networks
may be used when only one analog input point is used to receive readings from multiple sensors. An
example is when an averaging-type element is used to sense the temperature across the face of a coil. The
averaging element must be installed in a serpentine fashion across the coil. A problem arises when the
coil face is large enough that one averaging element is not long enough to span the entire face of the coil.
In this case, a sensor network must be used.
TYPICAL SENSOR NETWORKS
The following equations are used to determine the total required serpentine length of the sensing
element.
Vertical Serpentine:
Length in Feet = W x (H2 + 144)

144
Horizontal
Serpentine:
Length in Feet = H x (W2 + 144)

144
) Note: H = Height in inches

W = Width in inches
33
Reference Data
Conversion Factors
MULTIPLY
BY
TO OBTAIN
MULTIPLY
Atmospheres
(Absolute)
Atmospheres
(Absolute)
14.70
Lbs./sq. inch
Gallons of Water
8.34
Pounds
2116.8
Lbs./sq. inch
Horsepower (Boiler)
Horsepower (Boiler)
33.479
9.803
B.T.U./hr.
Kilowatt-hrs.
0.02356
0.01757
Horsepower
Kilowatts
Inches
2.54
Centimeters
Inches of Water
0.03613
Lbs./sq. inch
B.T.U/min.
B.T.U/min.
BY
TO OBTAIN
Feet
30.48
Centimeters
Feet of Water
0.4335
Lbs./sq. inch (62F)
Liters
Liters
61.02
0.264
Cubic inches
Gallons
Gallons
231
Cubic inches
Tons of Refrigeration
12000
B.T.U./hr
Heating and Cooling Calculations

CFM
Weight per cu ft
Sp ht
To
T
T1
T2
H1
H2
=
=
=
=
=
=
=
=
=
Cubic feet of air per minute passing through the coil

Weight of 1 pound (.075)
BTU required to raise the temperature of 1 lb of air 1 degree F (.24)
Temperature of air entering coil in degrees F.
Temperature of air leaving coil in degrees F.
Temperature of water leaving coil in degrees F.
Temperature of water entering coil in degrees F.
Enthalpy of entering air.
Enthalpy of leaving air.
Capacity of Chilled Water Coil

GPM = (H1 H2) X CFM X .075 X 60
(T2 T1) X 500
Capacity of Hot Water Coil

GPM = CFM X 1.08 X (T To)
(T2 T1) X 500
Chiller Tonnage
TONS = GPM X (CHWR CHWS)
24
Chiller Coefficient of Performance

COP = (CHWR CHWS) X GPM X 0.0417
0.28433 X KW
rent Kilowatts KW = {Amps X Volts}/1000

AC Single Phase Kilowatts KW ={Amps X Volts X Power Factor}/1000
AC Three Phase Kilowatts KW = {Amps X Volts X 1.73 X Power Factor}/10
34
D
C
C
u
r
VAV Box Air Flow Rate (CFM)

CFM
A
V
Pv
Cubic feet of air per minute passing through the duct

=
Duct area in sq. ft.
=
Velocity of the air
=
Pressure in inches of H2O from PV3
Equation Q = AV
0.0763 is the density of dry air at 60o F
The duct diameter units are in ft.
CFM = 1096(Duct Diameter/2)2((Pv/.0763))
Linear Reset Schedule Formula

The linear reset schedule is used to reset a particular setpoint based on a particular parameter. Some examples
are:
Boiler hot water supply temperature reset based on the outside air temperature. In this instance, the hot
water bypass valve is modulated to control the temperature of the water flow.
Supply air temperature reset based on the space zone calling for the most cooling or heating.
Chilled water supply temperature reset based on the chilled water return temperature.
Y
m
x
b
Y1
Y2
X1
X2
=
=
=
=
=
=
=
=
The variable that is reset

The slope of the reset line
The parameter that the reset is based upon
System constant that defines the equation of the line
Minimum value of the reset variable
Maximum value of the reset variable
Minimum value of the dependent value
Maximum value of the dependent value
STEP 1: Determine the minimum and maximum values of the system, i.e. Y1, Y2, X1, and X2.
Example: Boiler hot water reset schedule. When the outside air temperature is 50 degrees F or below, the
hot water supply temperature should be reset to 140 degrees F. When the outside air temperature is 90
degrees F or above, the hot water supply temperature should be reset to 110 degrees F.
From the sequence of operation above, Y1 = 140, Y2 = 110, X1 = 50, and X2 = 90.
STEP 2: Determine the slope of the line.
m = Y2 Y1 = 110 140 = -30 = -0.75
90 50
40
X2 X1
STEP 3: Determine b. Plug in the known parameters into the equation of the line and solve for b.
Y = mx + b b = Y mx = 140 (-0.75)(50) = 72.5
b = 177.5
STEP 4: Plug in the calculated values for m and b into the equation for a line.
35
Y = mx + b = (-0.75)x + 177.5
Here, Y is the HOT WATER SUPPLY TEMPERATURE and x is the OUTSIDE AIR TEMPERATURE.
Although CBAS 2000 calculates linear reset equations automatically with the RESET SCHEDULE
function, a sample calculation point in another program for this example would look like:
HOT WATER SUPPLY TEMPERATURE = -0.75 X OUTSIDE AIR TEMPERATURE + 177.5
36
Control Valve Sizing

General Guidelines
Most control valves used for HVAC control fall into one of four categories:
1. Two position valves (water or steam)
2. Proportional control of water varying the amount of flow (chilled and hot water coils, differential
pressure control)
3. Proportional control of water varying the temperature of the flow (boiler hot water bypass and
condenser water bypass)
4. Proportional control of steam
Usually, the pipe size will be larger than the valve size. In this case, the pipe must be fitted down to the valve.
This reduction affects the flow characteristics of the valve and reduces the effective Cv of the valve. This effect is
known as the PIPING GEOMETRY FACTOR (symbol = Fp). Use the charts on the reverse side of this page to
determine the actual Cv of a valve when it is installed in a larger pipe.
STEP 1 Determining The Correct Pressure Drop (P)

1.
TWO POSITION VALVES: WATER OR STEAM

A low-pressure drop across the valve is desirable.
2.
3.
If pressure is not known, it is best to go with a

line size valve.
PROPORTIONAL CONTROL OF WATER:

VARYING THE AMOUNT OF FLOW
A high-pressure drop across the valve is desirable.
Use a P = 4.3 for control valves for chilled and

hot water coils.
A P = 4.3 may also be used for differential

pressure control applications.
In this system, 4.3 PSI should be used as

the pressure drop.
PROPORTIONAL CONTROL OF WATER:

VARYING THE TEMPERATURE OF THE FLOW
A low-pressure drop across the valve is desirable.
4.
In this system, 20 PSI is the available

pressure. Valve should be sized to have
a 2 PSI drop.
P = 10% of the available pressure
In this system, the amount of water to

the coil doesnt change. The valve
controls the percentage of the flow
coming from the boiler. By modulating
the valve, the supply temperature is
varied.
P = 10% of the available pressure

P = 25% of the P thru load @ full flow
Under 15 PSI
PROPORTIONAL CONTROL OF STEAM

A very high-pressure drop across the valve is
desirable.
Inlet pressure:
X (80%):
10 PSI
.8
8 PSI
8 PSI is the desired pressure drop
For 15 PSI steam or less:

- P = 80% of inlet gauge pressure
- Choose valve which is at least 1 size smaller than
line size
Over 15 PSI
Inlet pressure:
35 PSI
Adjust to PSIA (Absolute): +14.7
49.7 PSI
X 0.42
20.87 PSI
20.87 PSI is the desired pressure drop
For greater than 15 PSI steam:

- P = 42% of absolute pressure
(Gauge pressure + 14.7 then multiply by 0.42)
Do not be alarmed by the seemingly high Ps that
are recommended for steam. Due to the nature of
steam and its heating abilities, it requires a highpressure drop for proper control.
37
STEP 2 Calculating Cv
1.
WATER SYSTEMS:
Cv =
GPM
P
2.
STEAM SYSTEMS:
Cv =
LBS per HOUR
3 X (P X PO) Where PO = Inlet pressure (PI) - P
STEP 3 Valve Selection

Select the type of valve needed, i.e. ball, globe, or butterfly which most closely matches the required Cv calculated
in Step 2. Choose a valve that has a slightly larger Cv than the calculated Cv.
STEP 4 Correct For Piping Geometry Factor (Fp)

On the reverse side of this page, find the corrected Cv by referencing the pipe size and the valve size on the
PIPING GEOMETRY CORRECTION FACTOR CHART. Verify that the corrected Cv is not less than the
calculated Cv. If the corrected Cv is less than the calculated Cv, choose the next larger size valve. The selected
valve should never be smaller than the pipe size.
38
Adjusted CV Ratings For Piping Geometry Factor (Fp)
2-Way Ball Valves

Valve
Valve
Size
Model #
Pipe Size
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
5"
6"
0.50
05-2-004
0.4
.39
.39
.39
---
---
---
---
---
---
---
0.50
05-2-01
1.00
.99
.99
.99
---
---
---
---
---
---
---
0.50
05-2-02
2.00
1.96
1.94
1.92
---
---
---
---
---
---
---
0.50
05-2-04
4.00
3.75
3.58
3.50
---
---
---
---
---
---
---
0.50
05-2-10
9.80
7.38
6.30
5.86
---
---
---
---
---
---
---
0.75
75-2-25
---
25.00
19.53
16.26
14.75
---
---
---
---
---
---
1.00
1-2-35
---
---
35.00
31.08
27.35
23.80
---
---
---
---
---
1.25
125-2-47
---
---
---
47.00
43.97
37.55
34.48
---
---
---
---
1.50
150-2-81
---
---
---
---
81.00
68.01
58.84
54.25
---
---
---
2.00
2-2-105
---
---
---
---
---
105.00
97.89
90.30
81.66
---
---
3.00
3-2-390
---
---
---
---
---
---
---
390.00
307.76
257.40
233.89
0.75
75-2-33
---
33.00
22.71
17.96
15.98
---
---
---
---
---
---
1.00
1-2-47
---
---
47.00
38.60
32.06
26.71
---
---
---
---
---
1.25
125-2-81
---
---
---
81.00
67.90
49.46
43.00
---
---
---
---
1.50
150-2-105
---
---
---
---
105.00
80.47
66.15
59.97
---
---
---
2.00
2-2-210
---
---
---
---
---
210.00
165.90
134.61
110.48
---
---
2.50
250-2-440
---
---
---
---
---
---
440.00
329.00
217.00
184.31
---
Example: What is the correct Cv rating of a 75-2-25 valve when placed in a 1" pipe?
Look at 1" column and cross over to the valve model #. As one can see, the correct Cv rating is 19.53.
These values also apply to stainless steel ball and stem (SSBS) and stainless steel bodied valves (SS) where applicable.
2-Way Flanged Ball Valve

Valve
Valve
Size
Model #
Pipe Size
3"
4"
5"
6"
8"
10"
12"
3.00
3-2-600
600.00
384.6
297.47
262.77
---
---
---
4.00
4-2-1200
---
1200.00
803.00
605.63
476.85
---
---
6.00
6-2-3300
---
---
---
3300.00
1713.11
1265.42
1102.07
3-Way Ball Valves

Valve
Valve
Pipe Size
Size
Model #
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
5"
6"
0.50
05-3-02
2.00
1.96
1.94
1.92
---
---
---
---
---
---
---
0.50
05-3-06
6.00
5.25
4.82
4.62
---
---
---
---
---
---
---
0.75
75-3-12
---
12.00
11.20
10.46
10.02
---
---
---
---
---
---
1.00
1-3-14
---
---
14.00
13.70
13.33
12.85
---
---
---
---
---
1.25
125-3-21
---
---
---
21.00
20.70
19.90
19.40
---
---
---
---
1.50
150-3-30
---
---
---
---
30.00
29.17
28.31
27.75
---
---
---
2.00
2-3-50
---
---
---
---
---
50.00
49.16
48.08
46.66
---
---
2.00
2-3-91
---
---
---
---
---
91.00
86.25
80.77
74.53
---
---
3-Way Flanged Ball Valve

Valve
Valve
Size
Model #
Pipe Size
3"
3.00
3-3-135
135.00
4.00
4-3-230
---
6.00
6-3-330
---
---
4"
5"
6"
130.00
125.59
230.00
224.97
---
39
8"
10"
12"
122.56
---
---
---
218.55
210.31
---
---
330.00
325.61
320.82
317.59
Adjusted CV Ratings For Piping Geometry Factor (Fp)
2-Way Globe Valves

Valve
Valve
Size
Model #
Pipe Size
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
5"
6"
0.50
DG05-2-03
2.5
2.43
2.38
2.36
---
---
---
---
---
---
---
0.75
DG75-2-07
---
6.3
6.17
6.04
5.95
---
---
---
---
---
---
1.00
DG1-2-10
---
---
10
9.89
9.74
9.55
---
---
---
---
---
1.25
DG125-2-16
---
---
---
16
15.86
15.49
15.25
---
---
---
---
1.50
DG150-2-25
---
---
---
---
25
24.51
23.99
23.65
---
---
---
2.00
DG2-2-40
---
---
---
---
---
40
39.57
38.99
38.22
---
---
2.50
DG250-2-63
---
---
---
---
---
---
63
62.50
61.08
59.6
---
3.00
DG3-2-100
---
---
---
---
---
---
---
100
98.06
94.62
---
4.00
DG4-2-160
---
---
---
---
---
---
---
---
160
155.99
---
5.00
DG5-2-250
---
---
---
---
---
---
---
---
---
248.06
242.52
6.00
DG6-2-400
---
---
---
---
---
---
---
---
---
400
371.35
1-1/2"
3-Way Mixing Valves

Valve
Valve
Size
Model #
Pipe Size
1/2"
3/4"
1"
1-1/4"
0.50
DG05-3-03
2.5
2.43
2.38
2.36
---
---
---
---
---
---
---
---
---
0.75
DG75-3-07
---
6.3
6.17
6.04
5.95
---
---
---
---
---
---
---
---
1.00
DG1-3-10
---
---
10
9.89
9.74
9.55
---
---
---
---
---
---
---
1.25
DG125-3-16
---
---
---
16
15.86
15.49
15.25
---
---
---
---
---
---
1.50
DG150-3-25
---
---
---
---
25
24.51
23.99
23.65
---
---
---
---
---
2.00
DG2-3-40
---
---
---
---
---
40
39.57
38.99
38.22
---
---
---
---
2.50
DG250-3-63
---
---
---
---
---
---
63
62.50
61.08
60.16
59.6
---
---
3.00
DG3-3-100
---
---
---
---
---
---
---
100
98.06
95.99
94.62
---
---
4.00
DG4-3-160
---
---
---
---
---
---
---
---
160
158.28
155.99
154.21
---
5.00
DG5-3-250
---
---
---
---
---
---
---
---
---
250
248.06
245.09
242.54
6.00
DG6-3-400
---
---
---
---
---
---
---
---
---
---
400
380.77
371.37
2"
2-1/2"
3"
4"
5"
6"
8"
10"
3-Way Mixing Valves

Valve
Size
Valve
Pipe Size
Model #
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
5"
6"
8"
0.50
DDG05-3-04
3.75
3.58
3.5
---
---
---
---
---
---
---
---
0.75
DDG75-3-08
---
7.75
7.49
7.32
---
---
---
---
---
---
---
1.00
DDG1-3-15
---
---
15
14.6
14.19
13.6
---
---
---
---
---
---
1.25
DDG125-3-20
---
---
---
20
19.74
19.04
18.06
---
---
---
---
---
1.50
DDG150-3-28
---
---
---
---
28
27.32
26.61
26.15
---
---
---
---
2.00
DDG2-3-40
---
---
---
---
---
40
39.57
38.99
32.22
---
---
---
2.50
DDG250-3-68
---
---
---
---
---
---
68
67.37
65.61
64.47
---
---
3.00
DDG3-3-85
---
---
---
---
---
---
---
85
83.80
82.49
81.62
---
4.00
DDG4-3-160
---
---
---
---
---
---
---
---
160
158.28
155.99
152.91
5.00
DDG5-3-195
---
---
---
---
---
---
---
---
---
195
194
191.4
6.00
DDG6-3-250
---
---
---
---
---
---
---
---
---
---
250
248.07
Example: What is the correct Cv rating of a 75-3-07 valve when placed in a 1" pipe?
Look at 1" column and cross over to the valve model #. As one can see, the correct Cv rating is 6.17.
These values also apply to stainless steel trim valves (SS).
40

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Table of Contents

Control of Supply Air Temperature ....................................................................................................... 1

Corey Simon, Project Engineer

Control of Supply Air Temperature

When selecting three-way valves for control of wetted coils:

Space or Room Air Control

Control of Duct Static Pressure

Supply Fan Variable Frequency Drive Control

Supply Fan Inlet Vane Control

Supply Duct Dump Damper Control

Outside Air Temperature Lockout

Temperature Setpoint Reset

Outside Air Economizer

Outside Air Enthalpy Sensor

Filter Clean/Dirty Pickup Installation

Filter Clean/Dirty Status

Duct Static Pressure Pickup Installation

Duct Static Pressure

Typical Averaging Element Installation

Pressure Device Mounting Detail

Typical Pipe Strap-On Element Installation

Typical Immersion Type Element Installation

Typical Outside Air Temperature Element Installation

Install sensor on the wall with the northernmost exposure.

Typical Space Temperature Element Installation

Typical Space Temperature/Humidity Element Installation

Typical Duct High/Low Limit Switch Installation

Typical Current Sensor Installation

Typical KW/KWH Transducer

Typical Belimo Actuator Wiring Schematic

Actuator Sizing Guidelines

Typical Control Enclosure

Tips for Bending Conduit for Stub-ups

Groove Take-up in Inches

Bending Method 2 - Thumbnail and Eyeball

Valve Piping Illustrations

3-Way Butterfly Valve Configurations

Drill and Screw Size Chart

TYPICAL SENSOR NETWORKS

Length in Feet = W x (H2 + 144)

Length in Feet = H x (W2 + 144)

) Note: H = Height in inches

Lbs./sq. inch (62F)

Heating and Cooling Calculations

Cubic feet of air per minute passing through the coil

Capacity of Chilled Water Coil

Capacity of Hot Water Coil

Chiller Coefficient of Performance

rent Kilowatts KW = {Amps X Volts}/1000

VAV Box Air Flow Rate (CFM)

Cubic feet of air per minute passing through the duct

Linear Reset Schedule Formula

The variable that is reset

Control Valve Sizing

STEP 1 Determining The Correct Pressure Drop (P)

TWO POSITION VALVES: WATER OR STEAM

If pressure is not known, it is best to go with a

PROPORTIONAL CONTROL OF WATER:

Use a P = 4.3 for control valves for chilled and

A P = 4.3 may also be used for differential

In this system, 4.3 PSI should be used as

PROPORTIONAL CONTROL OF WATER:

In this system, 20 PSI is the available

P = 10% of the available pressure