Variable Air Volume Retrofit

Replacement of VRD2 by VRD3-RE

VRD3-RE Retrofit Documentation

This documentation describes the retrofitting of an existing system involving the replacement of a VRD2 by a VRD3RE. The documentation can be applied accordingly for other controllers that are to be replaced (e.g. VRD).

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For the replacement of necessary and/or helpful tools and accessories:

The calibrate key ZKO-VRD3 is required for setting the differential pressure at V'nom.

The necessary settings can be made simply and easily with the VAV adjustment and diagnostics device ZTH-VAV. Detailed documentation can be downloaded from www.belimo.eu. Screwdriver No. 1 Phillips screwdriver No. 1 Multimeter Documentation of the components used

Please note in particular:

A VAV system is comprised of various components which influence the control behaviour and the quality of the control. It is for that reason that the functional capability of all of the individual components should be checked and defective modules should be replaced as well. The damper actuator is to be checked with special care, because moving parts are also subject to a certain amount of wear. These can be replaced by the following actuators, which are tailored to the VRD3 controller: LM24A-V, 5 Nm, 150 s NM24A-V, 10 Nm, 150 s SM24A-V, 20 Nm, 150 s The pick-up device should also be checked. In view of the fact that the danger of soiling is very great with this sensitive element, it should be cleaned or (if necessary) replaced. The existing pick-up device can be replaced with: ZMDS-100, 100 mm length ZMDS-125, 125 mm length ZMDS-160, 160 mm length ZMDS-200, 200 mm length ZMDS-250, 250 mm length If the conditions which one encounters are not entirely clear, it is recommended that one have all of the spare parts on hand whenever possible. A special set can be obtained for such cases. It contains all of the parts which are necessary for making quick and simple replacements. VRD3-RE2-SET, comprised of: o Controller VRD3-RE2 o Damper actuator NM24A-V o Pick-up device o Complete installation accessories such as screws, hose, hose connectors, etc. All of the specifications and precise descriptions of the products above can be called up under www.belimo.eu; otherwise contact your local Belimo dealership for further information.

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Inventory of the data of the existing VAV-Box:

As much data as possible regarding the existing VAV-Box should be recorded before the replacement of the VRD2. These data could, for example, be recorded on an inventory sheet. This could include the following, e.g.: Inventory sheet Object name Name of room/zone Fresh air supply/exhaust ventilation Control (0-10/2-10 V) VAV Box Size Air quantities (V'nom V'max V'min) Differential pressure with V'nom Override control

Dismantling the existing VRD2 controller

Disconnect respective connection from the supply voltage. Undo supply cable/signal cable in the control cabinet from the outgoing terminal. Observe/note wire designations. Undo supply/signal cable from the VRD2 controller to be replaced. Observe/note wire designations. Undo the air connections to the pick-up device on the controller. Mark pos. and neg. pressure connections. Unplug the actuator plug. Dismantling the controller.

Note:
Is the actuator still completely functional or does it need to be replaced? Is the pick-up device still functional and are the connection hoses clean? For further information concerning actuator and differential pressure sensor: www.belimo.eu

Installation with the new VRD3 controller:

Installation with the new controller. The holes for fastening the VRD2 and the VRD3 are identical. Plug in the actuator plug. Connect the air connections of the pick-up device to the controller. Observe pos. and neg. pressure connections. Connect supply/signal cable to the VRD3 controller. Observe wire designations. Connect supply cable/signal cable in the control cabinet. Observe wire designations. Switch on supply voltage

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Settings:
The following three parameters are to be adjusted on the VRD3 as a general rule: (see page 4) V'min in % of V'nom (see page 4) V'max in % of V'nom p for V'nom (see page 5) Note: In contrast to the VRD2, the % values for V'min and V'max are always in reference to V'nom with the VRD3.

Adjustment of V'min in % of V'nom or V'max in % of V'nom

V'min and/or V'max can always be adjusted with either the potentiometers or with the ZTH-VAV setting device. If the values are adjusted with the corresponding potentiometers, then these are to be set to the corresponding % values of V'nom. If the values are to be adjusted with the ZTH-VAV , then both potentiometers are to be set to the "Tool" position. Example: V'nom = 1000 m3/h. V'min = 200 m3/h (20% of V'nom = 20% of 1000 m3/h =200 m3/h) V'max = 850 m3/h (85% of V'nom = 85% of 1000 m3/h =850 m3/h) With potentiometer setting: The corresponding values can be set with the two potentiometers. A 20% setting corresponds to 200 m3/h Adjustment with ZTH-VAV: Both potentiometers must be set to the "Tool" position.

An 85% setting corresponds to 850 m3/h

Currently set value for V'max = 850 m3/h. A new value can be entered with the keys +/- and OK. V'min can be selected and adjusted analogously with the arrow keys.

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Setting p@V'nom
The calibrate key ZKO-VRD3 can be used for setting the differential pressure at V'nom.

ZKO-VRD3

Procedure: The prevailing differential pressure for V'nom can be set with the calibrate key. The value to be set can be obtained from the scale (50300 Pa) accordingly. For checking and/or for simpler handling, the ZTH-VAV can be connected and the set value can be uploaded under the menu item p@V'nom. See corresponding illustration above. The information as to which differential pressure is to be set can, as a general rule, come from different sources. Among others... Specifications for the VAV-Box are known (e.g. plate on the box) Retrofitting with the use of a pick-up device ZDMS Retrofitting a quadrangular VAV-Box Specifications for VAV-Box are not known See case 1 See case 2 See case 3 See case 4

Case 1: Specifications for VAV-Box are known (e.g. plate on the box)

Case 2: Retrofitting with the use of a pick-up device ZDMS-xxx

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If the diameter of the round air duct corresponds to the length of the pick-up device ZDMS that is used, then the value of the differential pressure can be obtained from the following tables.

Note The D3 sensor is a "quasi-static pressure sensor". That means that only a very small amount of air flows through the sensor. For practical applications, therefore, it can be assumed that p1 = p2.

ZDMS-100 3 p1 [Pa] V' [m /h] 2 36 5 61 10 89 15 111 20 126 25 143 30 156 35 168 40 180 45 193 50 202 55 214 60 224 70 245 80 259 90 279 100 293 110 307 120 319 130 332 140 346 150 358 160 375 170 385 180 397 190 407 200 418 ZDMS-200 3 p1 [Pa] V' [m /h] 2 161 5 244 10 345 15 435 20 514 25 575 30 627 35 675 40 725 45 769 50 812 55 855 60 896 70 975 80 1032 90 1076

ZDMS-125 3 p1 [Pa] V' [m /h] 2 66 5 102 10 141 15 173 20 207 25 230 30 252 35 275 40 290 45 308 50 326 55 345 60 361 70 395 80 418 90 442 100 466 110 488 120 508 130 529 140 551 150 571 160 590 170 608 180 623 190 646 200 665 ZDMS-250 3 p1 [Pa] V' [m /h] 2 205.0 5 359.0 10 532.0 15 659.0 20 759.0 25 858.0 30 948.0 35 1027.0 40 1094.0

ZDMS-160 3 p1 [Pa] V' [m /h] 2 104 5 163 10 238 15 293 20 339 25 372 30 417 35 447 40 487 45 513 50 538 55 568 60 592 70 645 80 687 90 728 100 765 110 805 120 844 130 882 140 914 150 947 160 973 170 998 180 1025 190 1049

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Case 3: Retrofitting a quadrangular VAV-Box If the data are not known, then a new active calibration must be carried out. Case 4: Specifications for the VAV-Box are not known An active calibration must be carried out in such cases.

Function test
The functioning of the system can be checked with the aid of the hardware constraints if necessary. The corresponding data can be uploaded readily by means of the ZTH-VAV.

Additional information:
PP setting (Belimo factory setting) If the PP position of the calibrate key ZKO-VRD3 is selected, then a programmed preset p@V'nom will be in effect. This pressure can only be programmed at the factory and is OEM-specific. The set value can be extracted with the ZTH-VAV. Jumper for input w (terminal 3) VRD2 VRD3 Plugging the jumper in at position VRD2 causes the VRD3 to behave like the predecessor model VRD2 (i.e. no CAV control function via input w). as VAV comp. Closed, V'min , V'max , Open

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