Troubleshooting Variable Air Volume

Technical Bulletin
Issue Date 11/01/01
TECHNICAL BULLETIN
Troubleshooting Variable Air Volume Modular Assembly

(VMA) 1400 Series Controllers
Troubleshooting VMA1400 Series Controllers...................................3
Introduction......................................................................................................... 3
Key Concepts...................................................................................................... 5
Troubleshooting VAV System Operation .........................................................................5
Hardware Concerns.........................................................................................................6
VMA Control Performance Measures ..............................................................................9
Occupant Hot/Cold Complaints .....................................................................................12
VMA LED Indicator Status .............................................................................................14
Tools for Detecting Communication Problems ...............................................................14
N2 Bus Communication Problems .................................................................................14
Zone Bus Problems .......................................................................................................15
Lack of Heat During Commissioning..............................................................................16
Detailed Procedures......................................................................................... 17
Detecting Airflow and Temperature Problems................................................................17
Troubleshooting Airflow Leakage at a Fully Closed Damper..........................................20
Troubleshooting Low Air Velocity...................................................................................20
Correcting Distorted Flow Patterns Due to Duct Design ................................................20
Correcting Unstable Sensor (AI) Readings ....................................................................21
Checking Flow Problems by Verifying Velocity Pressure Sensor Operation ..................22
Checking Airflow Pickups for Debris or Water................................................................22
Checking for Incorrectly Wired Sensors and Misapplied Room Assignments ................23
Troubleshooting Balancer’s Flow Reading.....................................................................24
Detecting Communication Problems Using the VMA LED .............................................24
Identifying N2 Bus Configuration Problems ...................................................................25
Testing for N2 Bus Opens, Shorts, and Crossed Wires .................................................26
Verifying Proper Transformer Installation.......................................................................27
© 2001 Johnson Controls, Inc. www.johnsoncontrols.com

Code No. LIT-6363135 Software Release 5.0
2 Troubleshooting VMA1400 Series Controllers Technical Bulletin
Checking for Proper Device Isolation and Ground Loops ..............................................27

Troubleshooting Heating Problems................................................................................28
Troubleshooting VMA1400 Series Controllers Technical Bulletin 3
Troubleshooting VMA1400 Series

Controllers
Introduction
Although the Variable Air Volume Modular Assembly (VMA) has
been designed to provide years of reliable service, problems can
develop in the related building and Heating, Ventilating, and Air
Conditioning (HVAC) systems. Problems involving the VMA usually
surface in the form of occupant comfort issues or communication
failures. The causes of these problems range from device failures to
HVAC system maintenance and design issues, installation errors, or
changes in use of a zone. Troubleshooting must consider all of these
variables.
Note: This document focuses on the VMA1410, 1420, and
1430 controllers. The VMA1400 Series also includes the
VMA1440, which is used exclusively as part of the
Metasys Zoning Package. See the Metasys Zoning Package
Product Bulletin (LIT-639050) and the Metasys Zoning
Package Overview Technical Bulletin (LIT-639100) for
information on this specialized product.
This document describes how to:
• detect airflow and temperature problems
• troubleshoot airflow leakage at a fully closed damper
• troubleshoot low air velocity
• correct distorted flow patterns due to duct design
• correct unstable sensor (Analog Input [AI]) readings
• check flow problems by verifying velocity pressure sensor
operation
• check airflow pickups for debris or water
• check for incorrectly wired sensors and misapplied room

assignments
• troubleshoot Balancer’s flow reading
• detect communication problems using the VMA Light-Emitting
Diode (LED)
• identify N2 Bus configuration problems
• test for N2 Bus opens, shorts, and crossed wires
• verify proper transformer installation
• check for proper device isolation and ground loops
• troubleshoot heating problems
Note: Where this document refers to HVAC PRO software,
substitute EURO PRO in Europe.
Key Concepts
Troubleshooting Variable Air Volume (VAV) System Operation
Controller Configuration Problems
Mechanical, flow, and wiring problems occur far more often than
configuration problems. This is especially true since
Proportional-Integral-Derivative (PID) loop tuning is automatic with
the VMA.
As a rule of thumb, ensure all the equipment and wiring in the system
checks out before investigating errant configuration parameters in
HVAC PRO software.
Refer to the HVAC PRO User’s Guide for more information when
reviewing VMA configuration parameters.
HVAC PRO Software

HVAC PRO software provides various diagnostics to help you
pinpoint temperature and airflow control problems. Controller
information, VAV Box Flow Test, Collect VAV Diagnostics, and the
VMA Balancer Tool each have a role in diagnosis and correction of
Variable Air Volume (VAV) system problems, whether mechanical,
electrical, or configuration related.
Collected and calculated data about VMA inputs, outputs, and control
loop performance can be displayed through the Parameters list box in
the Commissioning mode. Refer to the HVAC PRO User’s Guide for
more information when using HVAC PRO tools.
VAV Box Flow Test

This test is provided in HVAC PRO software to collect flow
characteristics for the VMA. It can help determine if the VMA is
maintaining minimum flow for ventilation and for staged electric
reheat. It can also check for maximum flow and diagnose a starved
box, reversed polarity, or a loose set screw on an actuator.
Hardware Concerns
Sensor Errors
Zone temperature and pressure sensor errors can cause control
problems. The Analog Input (AI) range may be improperly selected in
the HVAC PRO configuration file. The sensor may need an offset for
cable length. This offset, whose default value is -0.8°C (-1.5°F), is an
attribute of the Zone Temperature AI. In addition, the sensor may be
improperly installed or an element may be damaged. Sensor errors can
occur when the temperature sensor is affected by the sun, other zones,
or supply air from the diffuser.
In the worst case, the Differential Pressure (DP) sensor may drift up to
±0.1793 Pascal per °C (±0.0004 inch W.C. per °F). This is usually
insignificant. However, it may produce noticeable flow measurement
error during periods of large ambient temperature change. Examples of
such periods are transitions between unoccupied and occupied, or
during project startup when electrical power may be off and building
temperature is not controlled. The controller autocalibrates the DP
sensor every two weeks by default to offset the long term affects of
temperature and humidity changes. If greater flow measurement
accuracy is required at low flow rates where box inlet velocity is under
1 m/s (200 fpm [feet per minute]), the Autocalibration Period can be
reduced to recalibrate every three hours.
IMPORTANT: During Autocalibration, airflow to the zone drops to

zero for the following durations (worst case):
VMA1410/1420 = 90 seconds (30 seconds to drive

open + 30 seconds to drive close + 30 seconds sensor
settle time)
VMA1430 = the sum of the damper actuator stroke

time and 30 seconds (amount of time to drive close
+ 30 seconds sensor settle time)
Damper/Actuator Operation
Damaged damper seals, bent damper blades, poorly designed dampers,
or a mis-aligned actuators can cause air leakage during the fully closed
position. This causes a small offset that the Balancer can usually
compensate for. However, if tight shutoff is required for the
application, replace the defective VAV box.
Ductwork Design
Air velocity is non-uniform if turns or transitions in hard duct or sags
in flexible duct are within close proximity to the flow pickups. In this
case, the pickup ports may not represent the true average air velocity.
In addition, different flow rates may distinctly change the velocity
profile.
A minimum of three duct diameters of straight, unrestricted duct
upstream from the airflow pickups is recommended. The flow profile
problem can be corrected by installing straightening vanes in the
offending duct section or changing the duct configuration to provide
greater separation between the transition and the pickup.
Flow rate measurement problems can also be caused by a duct length
that causes significant pressure drop or by sags present in flexible duct.
This can also be avoided by installing hard duct three diameters in
length, starting at the VAV box inlet.
Flow Pickup Performance

Flow pickup performance suffers when the device is not installed
correctly. It can also collect debris and must be checked for plugged
ports and leaks between the high and low-pressure sides.
Air Flow
Static Pressure
Total Pressure
Static Pressure Pickup High

Area of Increased Velocity
Pressure Manifold Pickup Low and Decreased Pressure
Pressure Manifold
Duct Wall
Airflow
Figure 1: Interaction of the Pickup and Air Stream

Referencing Figure 1 above, the upstream ports are exposed to total
pressure. In order to sense true static pressure, the pickup must have
openings that are perpendicular to the direction of flow. The
low-pressure ports open downstream, and the passing air exerts a pull
on these openings, resulting in a pressure less than static. This results
in airflow pickup gain, resulting in a differential pressure of
1.5- to 3-times the velocity pressure.
Following are typical flow pickup designs. Usually the cross and ring
types perform better than straight tubes because the sensing ports are
better distributed across the duct area.
Sensing Ports
Cross Tubes Squared Rings Straight Tubes

Sensing
Figure 2: Common Flow Pickups
VAV Box Size

The VAV box size and flow pickup gain must be entered accurately
for the controller to calculate proper airflow. VAV boxes may be
oversized for quieter operation or to reserve cooling capacity. Inlet
size and pickup gain for the VAV box are entered in
HVAC PRO software during configuration.
The size and capacity of the VAV box should match the zone loads.
If the installed unit is too small, insufficient cooling results. In
addition, high flow rates may cause the unit to emit an audible noise. If
the installed unit is too large, then proper control of airflow is difficult.
VMA Control Performance Measures

Temperature Control Measures
Table 1 lists key parameters indicating temperature control problems.
Table 1: Temperature Control Key Parameters

Parameter Description
MovAvg ZT Err Average of the zone temperature control loop error (setpoint minus temperature)
over the preceding eight hours of control in normal control modes. This calculation
is stopped in Shutdown, Warmup, Low Limit, Water System Flush, and when the
Zone Temperature sensor is unreliable. If the VMA is interlocked with supply air
(fan) availability, and the zone is well designed, this measure should always be
within ±0.5°C (±1°F). Since controller error is defined as setpoint minus process
variable feedback, negative numbers indicate a warm zone and positive values
indicate a cold zone.
MovAvg ABS ZT Err Average of the absolute or unsigned zone temperature control loop error (absolute
value of setpoint minus temperature) over the preceding eight hours of control in
normal control modes. This calculation is stopped in Shutdown, Warmup, Low
Limit, Water System Flush, and when the Zone Temperature sensor is unreliable. It
is just like the MovAvg ZT Err, except that the error is always considered positive. If
the VMA is interlocked with supply air (fan) availability, and the zone is well
designed, this measure should always be less than 0.5°C (1°F). Larger values may
indicate a cooling or heating problem, a cycling control, an extended cooldown, or
warmup in progress.
Inadequate Cooling When True, this indicates the zone cooling demand cannot be satisfied.
Specifically, it means the following:
• the controller is calling for cooling
• the controller is in neither Unoccupied nor Shutdown mode
• the Zone Temperature is reliable
• the box is not starved
• the cooling PID has been saturated high for 15 minutes
Inadequate Heating When True, this indicates the zone heating demand cannot be satisfied.
Specifically, it means the following:
• the controller is not in Heating Lockout
• the controller is calling for heating
• the controller is in neither Unoccupied nor Shutdown mode
• the Zone Temperature is reliable
• the heating PID to be sequenced has been saturated high for ten minutes.
This may indicate heating media is not available and Heating Lockout is False.
Zone Temperature If the sensed value of the zone temperature sensor is outside of the normal
Status operating range -45 to 121°C (-50 to 250°F) for several readings, the Present
Value of Temperature Loop is Unreliable. This condition is normally caused by an
open or short in the sensor.
Airflow Control Measures

Table 2 lists key parameters that can indicate airflow control problems.
Table 2: Airflow Control Key Parameters

Parameter Description
MovAvg Flow Err Average of the flow control loop error (setpoint minus calculated flow) over the
preceding 20 minutes of control in normal control modes. This calculation is
stopped in Shutdown, Warmup, Low Limit, Water System Flush, and when the
Delta P sensor is unreliable. Since error is (SP – flow), negative numbers indicate
a zone with too much flow.
MovAvg ABS Flow Err Average of the absolute or unsigned flow control loop error (difference between
setpoint and calculated) over the preceding 20 minutes of control in normal control
modes. This calculation is stopped in Shutdown, Warmup, Low Limit, Water
System Flush, and when the Delta P sensor is unreliable. It is just like the MovAvg
Flow Err, except that the error is always considered positive. If the VMA is
interlocked with supply air (fan) availability, and the supply system is well designed,
this measure should always be less than the cfm calculated in MovAvg Flow Err
above. Larger values may indicate a lack of supply air, duct blockage or
disconnection, or a damper or actuation problem.
Starved Box When True, this indicates the airflow setpoint cannot be satisfied. Specifically, it
means the controller has been calling for a 100% open damper position for at least
ten minutes, and is in neither Unoccupied nor Shutdown, and the Delta P is
reliable.
Delta P Status If the sensed value of the velocity pressure (Delta P) sensor is outside of the
normal operating range for several readings, the Present Value of Flow Loop is
Unreliable. This condition is normally caused by an open or short in the sensor or
too high a DP in duct.
Balancing Errors
Pressure independent VAV control jobs frequently require accuracy
within 5-10% of actual flow and indicated flow. The balancing
contractor must adjust and certify the flow rates specified by the
consulting engineer. Sometimes the Balancer’s readings disagree with
flow indicated by the controller.
When airflow readings disagree, a problem may exist or some air
delivery system fact may not be known or understood. There are
margins for error in the measurement equipment used by the
controller, as well as that used by the Balancer. Therefore, it is
important that both controls contractors and Balancers understand each
other’s equipment, techniques, and expectations.
Typical factors that contribute to Balancer flow reading errors include:

• not calibrating the flow hood as specified. Flow hood accuracy is
specified by the manufacturer and may range from ±5% to ±3% of
full scale reading on the better instruments.
• calibrating the flow hood on a different type of diffuser.
Calibrating the hood with one type of diffuser and then taking
measurements on a different type of diffuser results in less accurate
values.
• using multiple diffusers supplied by a single VAV box. When the
flow hood is placed over one diffuser, the hood may present a
restriction, causing less flow from the measured diffuser and more
flow from the others. In this case, the Balancer’s sum of the
readings taken at all diffusers served by the box is less than the
actual flow.
• performing airflow measurements using a hood rather than a
velocity probe type of instrument with a slotted diffuser. A slotted
diffuser consists of one to three slots, each about one inch wide
and four or more feet long. Tests show that hood readings of some
slotted diffusers may be as much as 40% erroneous. The diffuser
manufacturer’s literature specifies how to measure airflow and
what instrument to use.
• incorrectly mounting the balancing damper. If mounted directly on
the diffuser, turbulent flow patterns entering the hood may occur,
resulting in erroneous hood indication.
• mismatching the flow hood with the diffuser size such that the
diffuser is not completely covered
The Balancer may take two additional measurements to help find the
cause of flow reading discrepancies:
• verifying the controller differential pressure reading with a
high-accuracy differential pressure meter
• performing a duct traverse as detailed in 2001 ASHRAE Handbook
Fundamentals, I-P Edition, 14.16-17.
Occupant Hot/Cold Complaints

Zone temperature control problems, which are usually reported as
occupant hot/cold complaints, can have causes ranging from the
building or mechanical system to the control components. The
following guide can help locate the cause of zone temperature control
problems with Pressure Independent VAV Terminals.
Table 3: Occupant Hot/Cold Complaints

Symptom Cause Action
Occupant Hot Zone setpoint too high Lower the common setpoint.
Complaints Calibrate remote setpoint potentiometer.
Controller not in Occupied mode Check to see if mode is commanded by network
features.
Occupied Cooling Bias too large Set Occupied Cooling Bias to 1 degree or less for
greatest comfort.
Occupant Hot Insufficient airflow Check Starved Box.
Complaints or Check terminal box inlet obstructions.
MovAvg ZT Err
less than 1°C (-2°F)
Airflow not in control. Tighten damper shaft coupling.
(Indicated by MovAvg Flow Err Increase minimum flow setpoint.
greater than sq ft Box Area * 40.) Reconnect duct.
Check for differential pressure sensing problem
(refer to Variable Air Volume Modular Assembly
[VMA] 1400 Series Overview and Engineering
Guidelines Technical Bulletin [LIT-6363120]).
Reheat and/or supplemental heat Verify heating device operation.
stuck on, valve stuck open or
wrong stroke time/range
VAV box inlet air too warm With the box at maximum cooling flow, verify
diffuser air temperature is 10 to 15°C (50 to 60°F).
Warmer air temperature may indicate supply air
temperature problem, stuck reheat valve, or box
series fan adjusted to flow higher than maximum
cooling.
Zoning problem - VAV box See Zones in the Definition of Terms section of
serves multiple rooms/areas the Variable Air Volume Modular Assembly (VMA)
1400 Series Overview and Engineering
Guidelines Technical Bulletin (LIT-6363120).
Zone sensor placement resulting See Room Sensor Placement in the Variable Air
in non-representative Volume Modular Assembly (VMA) 1400 Series
temperature sensed Overview and Engineering Guidelines Technical
Bulletin (LIT-6363120).
Zone sensor wiring crossed Rewire VMA to appropriate sensor.
VAV outlet duct crossed Change duct routing or cross sensor wiring.
Cooling load exceeds design due Investigate possibility of increasing the Max
to change in use, or added Cooling Flow setpoint. (How much greater is
equipment or people present load than design? Is sufficient supply air
available? Is box large enough?)
Continued on next page . . .
Symptom (Cont.) Cause Action

Occupant Cold Zone setpoint too low Raise the Common Setpoint.
Complaints Calibrate remote setpoint potentiometer.
Controller not in Occupied mode Check to see if mode is commanded by network
features.
Occupied Heating Bias too large Set Occupied Heating Bias to 1 degree or less for
greatest comfort.
Occupant Cold Airflow not in control Tighten damper, shaft coupling (refer to the
Complaints or (Indicated by MovAvg Flow Err Mounting the VMA1410/1420 section in Mounting
MovAvg ZT Err greater than 40 times the Box and Wiring the Variable Air Volume Modular
Greater than 1°C Area [measured in sq ft].) Assembly [VMA] 1400 Series Controllers
(2°F) [LIT-6363125]). Decrease minimum flow setpoint.
Check for differential pressure sensing problem
(refer to Variable Air Volume Modular Assembly
[VMA] 1400 Series Overview and Engineering
Guidelines Technical Bulletin [LIT-6363120]).
Too much airflow Often due to minimum airflow when zone is not
occupied. An occupancy sensor may help.
VAV box inlet air too cold Supply air temperature too low. 10 to 15°C
(50 to 60°F) is typical. When most boxes are
operating near their minimum cooling flow, supply
air temperature may be reset higher via network
features.
Reheat and/or supplemental Often caused by disabling heating based on
heating media not available arbitrary means like calendar dates. Use network
features to enable heating based on demand.
Reheat heating media available If reheat water temperature is too low, or airflow is
and QA path increases flow too great, zone does not warm. Verify water
setpoint on full heating. temperature and airflow against design
Reheat media temperature too specifications.
low.
Reheat media not available and Issue a Heating Lockout via network features to
QA path increases flow setpoint prevent increased cold airflow when heating is not
on full heating. available.
Cold spots or drafts due to low Raise the supply air temperature, replace the
velocity air dropping on diffuser with one designed for low velocity, install
occupants a series fan, or control a parallel fan from flow
rather than temperature.
Reheat and/or supplemental heat Verify heating device operation.
stuck off or valve stuck closed or
wrong stroke time or range
Zoning problem - VAV box See the Zones topic in the Definition of Terms
serves multiple rooms/areas section in the Variable Air Volume Modular
Assembly (VMA) 1400 Series Overview and
Engineering Guidelines Technical Bulletin
(LIT-6363120).
Zone sensor placement resulting See Room Sensor Placement in the Variable Air
in non-representative Volume Modular Assembly (VMA) 1400 Series
temperature sensed Overview and Engineering Guidelines Technical
Zone sensor wiring crossed Rewire VMA to appropriate sensor.
VAV outlet duct crossed Change duct routing or cross sensor wiring
Heating load exceeds design due Investigate possibility of decreasing the Occ In
to change in use or less Cooling Flow setpoint (how much ventilation is
equipment and lights or fewer needed for the occupants?)
people
VMA LED Indicator Status

The VMA LED provides general diagnostics for VMA power supply
and communication status. Viewing the LED signal and understanding
what each type of signal indicates quickly isolates some problems. See
Detecting Communication Problems Using the VMA LED in the
Detailed Procedures section.
Tools for Detecting Communication Problems

Many communication problems can be detected with a DMM (digital
voltmeter). Ordinarily, this is the only equipment needed to
troubleshoot communication problems, such as shorts, opens, and
crossed wires. Refer to the N2 Communications Bus Technical Bulletin
(LIT-636018).
N2 Bus Communication Problems

N2 Bus Communications problems between the VMA and the
supervisory system are related to improper N2 Bus installation,
configuration errors, or both.
Typical communications problems include:
• broken or frayed wires
• improper transformer installation (improper wiring length or
gauge, improper termination, or wrong transformer type)
• incorrect End-of-Line (EOL) settings
Note: Incorrect EOL settings may cause signal reflections that
interfere with communication. The VMA is a
self-terminating device, which means it has EOL
terminations built in. However, the Metasys Network
Control Module (NCM), as well as other devices, provide an
EOL switch or jumper that the installer needs to set.
• internally shorted N2 device
• too many N2 devices
• N2 Bus too long
• “T” or “Y” connections on N2 Bus
• defective surge protector, defective repeater, or communications
terminal board failure at the NCM
• N2 address set to 0, 254, or 255 on the controller when software

addressing is not used
Note: Software addressing is enabled when hardware switches are
set to 0 or 255 and when the VMA has B12 firmware or later
and HVAC PRO Release 7.02 or later. Address 254 is
reserved for VMA broadcast messages and should not be
used. For more information on N2 addressing, refer to the N2
Address Switches topic in the Mounting and Wiring Variable
Air Volume Modular Assembly (VMA) 1400 Series
Controllers Technical Bulletin (LIT-6363125).
• more than one controller set to the same N2 address
• ground loops
Note: The N2 Bus shield, if used, must be earth-grounded at only
one location, preferably at the Network Control Unit (NCU).
The N2+, N2-, and REF lines can never be earth grounded.
Tie the shield to the SHLD terminal (soft ground) on the N2
connector of the VMA.
Refer to the N2 Communications Bus Technical Bulletin (LIT-636018)
for more information.
Zone Bus Problems
The Zone Bus uses +15 Volts Direct Current (VDC) from the VMA to
power the CablePRO or CVTPRO interface devices (24 Volts
Alternating Current [VAC] is not required). A communication error
may occur while using the HVAC PRO commissioning tool with the
VMA over the Zone Bus. The cause of the error is often a loose or
improper connection between the interface device, laptop Personal
Computer (PC), and the controller. A defective COM port on the
laptop could also be at fault. At other times, a defective controller can
cause an error.
Note: It takes 20 seconds for a VMA to reset and resume
communication after being downloaded or after power up.
An effective troubleshooting technique is to use a CBLCON and
observe its LEDs. The red LED indicates power from the VMA and
the green LED indicates that the Zone Bus is present. With no laptop
connected to the Zone Bus, the green LED blinks once every
10 seconds. With a laptop connected, the LED blinks several times per
second. If this is not the case, try exchanging a component that may be
defective with an identical working component.
A noisy wire adjacent to the Zone Bus can also cause communication
errors. Noise can be periodically induced into the Zone Bus, thereby
causing sporadic communication failures between the laptop and the
VMA. Most often, noisy lines cause intermittent disruption, not total
loss of communication.
For more information on HVAC PRO software, refer to the

HVAC PRO User’s Guide. For more information on CablePRO and
CVTPRO interface devices, see the Auxiliary Gear Technical Bulletin
(LIT-6363080).
Lack of Heat During Commissioning

A common method to enable heating during commissioning is to
override the zone temperature to less than the actual heating setpoint.
This method may not produce the expected results. The expectation
with this tactic is that the heating will come on immediately. However,
the VMA uses saturation timers to switch between modes, and these
timers require a minimum of ten minutes before switching modes.
Refer to the Application Logic section of the Variable Air Volume
Modular Assembly (VMA) 1400 Series Application Note
(LIT-6375125) for a more detailed explanation of the theory behind the
VMA State Machine.
See the Detailed Procedures section of this document for appropriate
troubleshooting tactics to address heating problems.
Detailed Procedures
Detecting Airflow and Temperature Problems
To detect airflow and temperature problems:
1. Connect a PC running HVAC PRO software to the VMA for the
VAV box you are testing.
2. On the Options menu, click Commissioning View.
3. Click Parameters to view the Parameters list box. Scroll and
observe parameters from Table 5 for problems.
4. On the Action menu, click VAV Box Flow Test to detect the
problems listed in Table 5. Use the Flow Test Parameters in Table
4. Refer to the HVAC PRO User’s Guide for more information on
how to set up this diagnostic.
Table 4: Flow Test Parameters

Parameter Value
Step Amount (%) 50%
Settle Time (0-60 sec) 15 sec
5. On the Action menu, click Collect Diagnostics. Print out data

graphing. Make any needed software adjustments.
Table 5: Parameters Used to Detect Airflow and Temperature Problems

If the Parameter Status Is Then
Zone Temperature Present Test for an open or a short on the zone temperature sensor.
Value = Unreliable See Correcting Unstable Sensor (AI) Readings in this document.
Zone Temperature Present Check sensor for an open condition after confirming that 37.8°C (100°F)
Value = 37.8°C (100°F) isn’t the actual temperature and that Reliability = Reliable.
Supply Delta P Present Value = See Correcting Unstable Sensor (AI) Readings, Checking Flow Problems
Unreliable by Verifying Velocity Pressure Sensor Operation, or Checking Airflow
Pickups for Debris or Water in this document.
Damper Command Reliability = Either the damper’s movement is obstructed or the actuator has failed.
Stalled During Positioning Visually inspect the damper.
If Starved Box = True • Perform Box Flow Test.
• Check the damper linkage.
• Check the static pressure near the box. Refer to Troubleshooting Low
Air Velocity section in this document.
• Check that the flow setpoints are realistic in comparison to the
installed box dimensions.
If Inadequate Cooling = True • Check the Starved Box parameter to determine if this is a flow
problem. If so, see the Starved Box parameter in this table for more
information.
• Increase Flow Setpoint Cooling Max Flow.
• Check for adequate supply air temperature from fan system.
If Inadequate Heating = True Check for a stuck valve actuator, incorrect spring range on pneumatic
valves, or other equipment related problems in the heating system or
device.
MovAvg ABS Flow Err = See Correcting Distorted Flow Patterns Due to Duct Design in this
(is much larger than the document to troubleshoot this problem.
deadband)
Table 6: VAV Box Flow Test Results

Symptom Cause Action
Flow high at Position 0 Actuator Direction Change the Direction To Close attribute of the Damper
and low at Position 100 Incorrect Actuator Output or Stepper Motor Output (SMO).
Flow too high at Damper Leakage Refer to Troubleshooting Airflow Leakage at a Fully
Position 0 Closed Damper section of this document.
(Flow > Area * 80)
No change in flow from Loose Actuator Refer to the Checking Flow Problems by Verifying
Position 0 to 100 Linkage Velocity Pressure Sensor Operation section of this
document, or type in -100% to cause the damper
actuator to close.
Unexpected stroke time Damper and 1. Reset stop positions. Refer to the Mounting and
(See Table 7.) Actuator stops Wiring Variable Air Volume Modular Assembly
not aligned (VMA) 1400 Series Controllers Technical Bulletin
(LIT-6363125).
2. Reset the controller using HVAC PRO software. On
the Action menu, click Reset Controller.
Loose Actuator 1. Tighten screw. Refer to the Mounting and Wiring
screw Variable Air Volume Modular Assembly (VMA) 1400
Series Controllers Technical Bulletin (LIT-6363125).
Bound Damper 1. Reset stop positions. Refer to Mounting and Wiring
Variable Air Volume Modular Assembly (VMA) 1400
Series Controllers Technical Bulletin (LIT-6363125).
2. Check for bent damper shaft.
3. Check for duct damage.
Blockage in Duct 1. Open duct and clear blockage.
Actuator travels 1. Reset stop positions. Refer to Mounting and Wiring
past damper full Variable Air Volume Modular Assembly (VMA) 1400
open Series Controllers Technical Bulletin (LIT-6363125).
Flow increases from 45°° box with Reset stop positions. Refer to Mounting and Wiring
Position 0 to 50 damper stops set Variable Air Volume Modular Assembly (VMA) 1400
and decreases from at 90°° Series Controllers Technical Bulletin (LIT-6363125).
Position 50 to 100
Table 7: Actuator Rotation Stroke Times for the VMA1410/1420 (Damper full
closed to full flow open)
Damper Rotation (Degrees) Nominal Stroke Time (Seconds)
90 30
60 20
45 15
30 10
Note: These times may vary when an external actuator is used (VMA1430).
Troubleshooting Airflow Leakage at a Fully Closed Damper

To troubleshoot airflow leakage at a fully closed damper:
1. Check damper stop positions. Refer to the Variable Air Volume
Modular Assembly (VMA) 1400 Series Overview and Engineering
Guidelines Technical Bulletin (LIT-6363120). On a 90° box,
install at the closed position.
2. Check that the actuator collar (or other linkage) is tightly locked
to the damper shaft. Refer to the Variable Air Volume Modular
Assembly (VMA) 1400 Series Overview and Engineering
Guidelines Technical Bulletin (LIT-6363120). Visually inspect for
a damaged damper seal, bent damper blades, or a poorly designed
damper. Replace if necessary.
Troubleshooting Low Air Velocity

To troubleshoot low air velocity:
1. Check airflow velocity in the Parameters list box in
HVAC PRO software. Typical minimum is 2 m/s (400 fpm).
2. Check whether the flow is due to an oversized box. If so, check
with the Balancer to determine if adjusting the box constant or
other system changes are reasonable.
Correcting Distorted Flow Patterns Due to Duct Design

To correct distorted flow patterns due to duct design:
1. Observe whether flexible duct is installed and connected to the
VAV box inlet.
2. Whether hard or flexible duct is installed, check if there is a duct
transition less than three diameters in length upstream of the
airflow pickups.
3. Check if inlet duct length is excessive. This also may result in
pressure drops that restrict airflow. These design conditions can
cause non-uniform air velocity across the flow pickup location.
4. To eliminate turbulent flow problems, install a section of straight
hard duct between the VAV box inlet and the flexible duct (or
duct transition). The straight hard duct must be at least three times
the length of the duct diameter.
Correcting Unstable Sensor (AI) Readings

To correct unstable sensor (AI) readings:
1. Within the HVAC PRO configuration file, verify that the AI range
(temperature, cfm, gpm, etc.) is defined properly in the hardware
tables.
2. Check sensor calibration. Verify that the input reading is the same
as the standard. For temperature readings, a glass thermometer
with 0.05°C (0.1°F) accuracy is necessary. Adjust the AI offset in
the configuration file. For velocity pressure readings, ensure that
Autocalibration was run from HVAC PRO software, then verify
flow readings within 5% of balancing hood reading.
3. Use the HVAC PRO commissioning tool to verify that the
AI point is reading steady (not unstable). If the velocity pressure
is unstable, this could be due to turbulence in the duct.
4. Ensure that there are 3-5 duct diameters of straight ductwork
upstream of the airflow pickups.
5. If AI point is still unstable, check the sensor for the following
problems:
• Is the wrong type sensor installed or is it installed improperly?
• Is the averaging element securely fastened?
• Are the wires secure?
6. If AI point is still unstable, use the anti-spike filter in the Analog
Input Modify option of HVAC PRO software to average out the
peaks and valleys and eliminate instability. Select the AI screen
then double click on the AI point. Set anti-spike to True and set
the spike fraction between 0.0 (none) to 1.0 (any amplitude spike).
The default attributes for zone temperature have anti-spike set to
True and spike function set to 0.3. This should correct most
problems. If not, increase the filter order from none to first or
second order. The filter weight can be set from 0.0 (low) to
1.0 (high).
Note: Filter values greater than 0.5 are not recommended and, if
too large, could make the loop respond too slowly. Filtering
must not be done on the velocity pressure sensor, because the
P-adaptive algorithm uses air turbulence values to
automatically tune.
Checking Flow Problems by Verifying Velocity Pressure Sensor

Operation
Note: To ensure accurate readings of the velocity pressure sensor,
allow at least 30 minutes stabilization time before installing a
product that just came from a storage environment which
differs from the installed temperature.
To check flow problems by verifying velocity pressure sensor
operation:
1. Recalibrate differential pressure by labeling and disconnecting the
high and low side tubing from the box pickup pressure taps
(preferred), or by commanding Autocalibration from
HVAC PRO software, which closes the VAV box to obtain
near-zero flow.
2. Autocalibrate the velocity pressure sensor while in
Commissioning mode in HVAC PRO software by setting
Autocalibration Request parameter to True.
3. Reconnect the high and low side tubing, ensuring the connections
are correct.
Checking Airflow Pickups for Debris or Water
! WARNING: Never blow into the VMA tubing. The velocity

pressure transducer is very sensitive and will be
destroyed by as little as 70 mbar (1 psi) of
pressure.
To check airflow pickups for debris or water:
1. Examine the pickup pressure taps inside the VAV box.
2. Check for plugged pickup ports and internal leaks between the
high-and low-pressure sides of the sensor.
3. Disconnect the high and low tubes between the VMA and box
pickup pressure taps to observe if there is water or condensation
disrupting the pressure reading. If necessary, clear water from the
tubes and reconnect.
4. Ensure that the VMA is installed vertically on the duct for best
performance. If mounted horizontally, Autocalibration adjusts for
position effect.
Checking for Incorrectly Wired Sensors and Misapplied Room

Assignments
To check for incorrectly wired sensors and misapplied room
assignments:
1. When experiencing problems with poor control, check that the
room sensor is connected to the correct VMA. Sometimes sensors
are miswired to an adjoining room’s VAV box (see Figure 3).
2. Check that the VMA is controlling the right room. Crossed
ductwork leads to mistakes similar to the one shown in Figure 4.
VMA VMA
Room Room
Sensor Sensor
Miswired
Figure 3: Incorrectly Wired Sensors
VMA VMA
Room Room
Sensor Sensor
Crossed
Figure 4: Crossed Ductwork

Troubleshooting Balancer’s Flow Reading

To troubleshoot Balancer’s flow reading:
Determine if there is a discrepancy of more than 5 to 10% between the
actual flow and Balancer’s indicated flow. If so, speak with the
Balancer about recalculating the Box Constant for the VAV Box
Calculation in HVAC PRO software. The default is 2.25.
Detecting Communication Problems Using the VMA LED

To detect communication problems using the VMA LED, use Table 8
to help to determine the source of the communications problem.
Table 8: Checking Performance with the VMA LED

If the LED Response Is Then
Not lit Power is not applied to the VMA or +15 VDC is shorted.
Irregular flashing four times Communications between the VMA and the supervisory system is normal.
every second
One flash every second The VMA is offline. Verify N2 address switches, and continue
troubleshooting possible causes as discussed in the following sections of
this document:
• Identifying N2 Bus Configuration Problems
• Testing for N2 Bus Opens, Shorts, and Crossed Wires
• Verifying Proper Transformer Installation
• Checking for Proper Device Isolation and Ground Loops
On solid If on steady for longer than 20 seconds, replace the VMA.
Rapid flashing 20 times per The VMA memory is corrupted. Download the firmware code into the
second controller.
Identifying N2 Bus Configuration Problems

To identify N2 Bus configuration problems, use Table 9 to
troubleshoot common offline configuration problems:
Table 9: Configuration Errors that Cause N2 Bus Communications Problems

Error/Trouble Possible Causes Solution
Condition
VMA cycles Two or more controllers have the Change each duplicate address to a unique
online and offline. same address. number.
A NCM process is using an Delete the use of the unconfigured point in the
unconfigured point (i.e., not listed in NCM process.
HVAC PRO.prn file).
There are ‘Y’ or ‘T’ taps. Refer to the N2 Communications Bus Technical
The repeater lost power or is wired Refer to the N2 Communications Bus Technical
wrong. Bulletin (LIT-636018).
The EOL is not set at the NCM or Refer to the N2 Communications Bus Technical
N30. Bulletin (LIT-636018).
VMA does not Two or more controllers have the Change each duplicate address to a unique
come online. same address. number.
The address of the VMA was Cycle power on the VMA.
changed without its power being
cycled afterward.
N2 Bus contains too many devices. A maximum of 100 N2 devices are allowed per
NCM.
VMA does not have power. Power the VMA.
Remove the short from the +15 VDC to COM.
N2 cable runs are broken. Locate and correct the wiring.
Entire N2 Bus is EOL jumpers on NCM/N30 or Install EOL jumpers or W3 jumper properly.
offline. W3 jumper on MM-CVT101 are not
installed.
MM-CVT101 is not plugged into PC Plug MM-CVT101 into PC or plug it into a 120 VAC
or 120 VAC source. source.
There are ‘Y’ or ‘T’ taps or the Refer to the N2 Communications Bus Technical
repeater lost power or is wired Bulletin (LIT-636018).
wrong.
N2 Bus wires open near the NCM. Connect the wires.
Testing for N2 Bus Opens, Shorts, and Crossed Wires
! CAUTION: To avoid electrical shocks when troubleshooting,

measure the voltage of each N2 wire to earth
ground with a 100 K ohm resistor at the DMM.
If line-voltage is measured, have a qualified
electrician locate the fault.
Test for N2 Bus opens, shorts, and crossed wires by either selecting all
of the N2 devices and performing a CommDisable at the Operator
Workstation (OWS), or by connecting an MM-CVT101 in place of the
NCM and verifying the NCM/N30 EOL separately. Use a DMM
(digital voltmeter) to detect polarity, shorts, crossed wires, and grounds.
To test for N2 Bus opens, shorts, and crossed wires:
1. Connect the DMM across the N2+ and REF screws on the
N2 terminal block.
2. Write down the DC voltage reading. Repeat for N2- and REF,
then for N2+ and N2-.
3. Compare the voltages on the DMM to the following values:
• N2+ to REF = +2.45 to 2.98 VDC
• N2– to REF = +2.06 to 2.54 VDC
• N2+ to N2– = +0.36 to 0.92 VDC
If the DMM readings are not approximately within the ranges
listed above, the wire is grounded, shorted, or crossed with
another wire.
4. Perform the following checks:
• Check that the polarity of the wiring is consistent from device
to device all along the N2 Bus.
• Check for breaks in the 24 American Wire Gauge (AWG)
(0.6 mm) wire.
• Check if the VMA is internally shorted by unplugging the
N2 connector and measuring the voltages from Step 3 on the
pins of the VMA. If these do not match Step 3 with power on
the VMA, replace it.
• N2 Bus is improperly terminated. There must be one switched
end-of-line device on each N2 Bus, typically the NCM or
N30.
• N2 Bus wiring has “T” or “Y” connections installed.
5. Correct and measure again. If the readings are approximately

within the ranges listed above, the Bus is properly wired.
Otherwise, proceed to Checking for Proper Device Isolation and
Ground Loops.
Verifying Proper Transformer Installation

To verify proper transformer installation:
1. Connect the DMM across the 24 VAC and the 24 VAC common
terminal of the VMA. Read the voltage with all typical loads
energized. A reading of 24-26 VAC is required when the line
voltage is nominal. If the DMM reads a value less than 22 VAC,
split the load in half and add a second transformer.
2. Check if the primary voltage matches the transformer’s voltage
rating.
3. Check the 24 VAC cable length versus wire gauge.
4. Recalculate the power requirements for the VMAs and loads on
that transformer.
If the procedures above did not correct the communications problem,
refer to the N2 Bus Communications Technical Bulletin (LIT-636018)
for more information.
Checking for Proper Device Isolation and Ground Loops

To check for proper device isolation and ground loops:
1. Connect the leads of the DMM in parallel with the 100 K ohm
resistor from the DC power supply (+15 VDC) output terminal of
the VMA to earth ground.
2. Read the voltage. If the voltage is 5 VDC/VAC or greater, the
circuit is improperly isolated or a valve actuator is connected,
which ties COM to an earth grounded Terminal 1. A single earth
ground is allowed.
3. Remove all the field wires and N2 Bus wires from the VMA, but
leave the transformer wires attached.
4. With the DMM still connected, reconnect each set of field wires
one at a time until the voltage is 5 VDC/VAC or greater. At this
point, you have discovered one cause of the ground loop.
5. Correct the problem. Continue to reconnect each set of field wires
until all ground loops are found and corrected. All grounds are
corrected when the voltage is less than 5 VDC/VAC on the DMM.
Troubleshooting Heating Problems

To troubleshoot heating problems:
1. In HVAC PRO software, switch to Commissioning view.
2. Check the VAV Box Mode Present Value parameter. Use Table
10 below to determine the next step based on the value of this
parameter.
Table 10: VAV Box Mode Present Value

If the VAV Box Mode Then
Present Value Is
Cooling Check the Cooling PID Present Value. Go to Table 11.
Satisfied Check the Heating Available parameter (in the
Command Mode parameter group) and the Actual
Heating Setpoint parameter (in the Temperature
Setpoint parameter group). Go to Table 13.
Heating Check the Box Heating PID Present Value. Go to
Table 14.
Note: The logic in this procedure also applies for
supplemental heating.
Table 11: Cooling PID Present Value

If the Cooling PID Then
Present Value Is
= 0% Check the Cooling PID Saturation Status. Go to Table
12.
> 0% VAV Box Mode does not switch to Satisfied until:
• PID deintegrates to 0%
• Saturation Status = Low
(Saturation Status switches from Normal to Low
after Cooling PID Present Value is equal to 0% for
ten minutes.)
Note: To test the heating mode and save time during commissioning, override the
VAV Box Mode Present Value to Satisfied with the Zone Temperature less
than the Actual Heating Setpoint. This bypasses the Cooling mode
saturation timers.
Table 12: Cooling PID Saturation Status

If the Cooling PID Then
Saturation Status Is
Normal Wait ten minutes for Low Saturation time to expire.
Note: Saturation times can be viewed in the
Diagnostic View. On the Options menu, click
View to change to Diagnostic view.
Low Recheck VAV Box Mode Present Value. It now equals
Satisfied.
Note: To test the heating mode and save time during commissioning, override the
VAV Box Mode Present Value to Satisfied with the Zone Temperature less
than the Actual Heating Setpoint. This bypasses the Cooling mode
saturation timers.
Table 13: Heating Available and Actual Heating Setpoint

If Then
Heating Available = BD169 is being commanded from Metasys
False Supervisory System.
Actual Heating Configuration was generated using
Setpoint > Zone HVAC PRO software Release 7.00 and saved using
Temperature Release 7.01.
and Workaround: Upgrade the controller in
VAV Box Mode Present HVAC PRO software Release 7.01. On the Upload
Value = Satisfied menu, click Upgrade Controllers. See the
Troubleshooting section of the Variable Air Volume
Modular Assembly (VMA) 1400 Series Application
Note (LIT-6375125) for more information.
Table 14: Box Heating PID Present Value

If Box Heating PID Then
Present Value is
=0% Check Box Heating PID Saturation Status. Go to Table
15.
>0% Check the Box Heating Make Limit parameter (in the
and Box Heating Output parameter group). The Box
Heating PID Present Value must exceed the Box
Box Heating = either
Heating Make Limit before the Box Heating Command
Binary Output
Output will become active.
(normally open valve)
or Binary Output
(normally closed valve)
>0% Check the Box Heating Make Limit parameter (in the
and Box Heating Output parameter group). The Box
Heating PID Present Value must exceed the Box
Box Heating = Electric
Heating Make Limit before the Box Heating Output
1-stage
Present Value and EHS Box Heating Command
Output will change from Off to Stage 1.
Table 15: Box Heating PID Saturation Status

If Box Heating PID Then
Saturation Status is
Low Wait 60 seconds and recheck Box Heating PID
Saturation Status. The status should change to
normal. The period for the PID is 60 seconds, and it
may take the full time to switch to Normal and begin to
ramp up the PID.
Normal Wait for 60 seconds and recheck Box Heating PID
Present Value. The period for the PID is 60 seconds,
and it may take the full time to begin to ramp up the
PID.
Controls Group
507 E. Michigan Street
P.O. Box 423 www.johnsoncontrols.com
Milwaukee, WI 53201 Printed in U.S.A.

Troubleshooting Variable Air Volume

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Troubleshooting Variable Air Volume

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Technical Bulletin

Issue Date 11/01/01

Troubleshooting Variable Air Volume Modular Assembly

Troubleshooting VMA1400 Series Controllers...................................3

© 2001 Johnson Controls, Inc. www.johnsoncontrols.com

Checking for Proper Device Isolation and Ground Loops ..............................................27

Troubleshooting VMA1400 Series

• check for incorrectly wired sensors and misapplied room

HVAC PRO Software

VAV Box Flow Test

IMPORTANT: During Autocalibration, airflow to the zone drops to

VMA1410/1420 = 90 seconds (30 seconds to drive

VMA1430 = the sum of the damper actuator stroke

Flow Pickup Performance

Static Pressure Pickup High

Figure 1: Interaction of the Pickup and Air Stream

Cross Tubes Squared Rings Straight Tubes

Figure 2: Common Flow Pickups

VAV Box Size

VMA Control Performance Measures

Table 1: Temperature Control Key Parameters

Airflow Control Measures

Table 2: Airflow Control Key Parameters

Typical factors that contribute to Balancer flow reading errors include:

Occupant Hot/Cold Complaints

Table 3: Occupant Hot/Cold Complaints

Symptom (Cont.) Cause Action

VMA LED Indicator Status

Tools for Detecting Communication Problems

N2 Bus Communication Problems

• N2 address set to 0, 254, or 255 on the controller when software

For more information on HVAC PRO software, refer to the

Lack of Heat During Commissioning

Table 4: Flow Test Parameters

5. On the Action menu, click Collect Diagnostics. Print out data

Table 5: Parameters Used to Detect Airflow and Temperature Problems

Table 6: VAV Box Flow Test Results

Troubleshooting Airflow Leakage at a Fully Closed Damper

Troubleshooting Low Air Velocity

Correcting Distorted Flow Patterns Due to Duct Design

Correcting Unstable Sensor (AI) Readings

Checking Flow Problems by Verifying Velocity Pressure Sensor

Checking Airflow Pickups for Debris or Water

! WARNING: Never blow into the VMA tubing. The velocity

Checking for Incorrectly Wired Sensors and Misapplied Room

Figure 3: Incorrectly Wired Sensors

Figure 4: Crossed Ductwork

Troubleshooting Balancer’s Flow Reading

Detecting Communication Problems Using the VMA LED

Table 8: Checking Performance with the VMA LED

Identifying N2 Bus Configuration Problems

Table 9: Configuration Errors that Cause N2 Bus Communications Problems

Testing for N2 Bus Opens, Shorts, and Crossed Wires

! CAUTION: To avoid electrical shocks when troubleshooting,

5. Correct and measure again. If the readings are approximately

Verifying Proper Transformer Installation

Checking for Proper Device Isolation and Ground Loops

Troubleshooting Heating Problems

Table 10: VAV Box Mode Present Value

Table 11: Cooling PID Present Value

Table 12: Cooling PID Saturation Status

Table 13: Heating Available and Actual Heating Setpoint

Table 14: Box Heating PID Present Value

Table 15: Box Heating PID Saturation Status