BlackBox Nexus Lite

Installation Manual

www.ias.net.au
Page II
Publisher
Innovative Air Systems Pty Ltd (ias)
1/49 Miller Street
Murarrie QLD 4172
Phone 1300 306 125
Fax 07 3870 8270
www.ias.net.au
[email protected]
Version 1.0 September 2005
This Install Guide documents the BlackBox Series Nexus Lite
Copyright
This publication is Copyright © 2005 Innovative Air Systems Pty Ltd (IAS).
All rights reserved. No part of this publication may be reproduced, stored in
any retrieval system or transmitted, in any form or by any means, electronic,
mechanical, photocopying, recording or otherwise, without the prior written
permission of Innovative Air Systems Pty Ltd.
Disclaimer
IAS reserves the right to make changes and improvements to any of
the products described in this document without prior notice. Under no
circumstances shall IAS be responsible for any loss of income or any
special, incidental, consequential or indirect damages howsoever caused.
Warranty
The contents of this document are provided “as is”. Except as required
by applicable law, no warranties of any kind, either express or implied,
including, but not limited to, the implied warranties of merchantability
and fitness for a particular purpose, are made in relation to the accuracy,
reliability or contents of this document. IAS reserves the right to revise this
document or withdraw it at any time without prior notice.
Sourcing
Proudly designed and manufactured in Australia by Innovative Air Systems
Pty Ltd, an independent Australian-owned company.
Product support
Freecall: 1800 354 434 (Australia-wide)

Page III
Contents
1 INSTALLATION ..................................................1
1.1 Wiring ............................................................................ 1
1.1.1 Device I/O Cabling Requirements........................................1
1.2 Component Positioning ............................................... 1
1.3 Controller Configuration .............................................. 2
1.4 Nexus Technical Specifications .................................. 2
1.4.1 Inputs/Outputs......................................................................2
1.4.2 Special Inputs ......................................................................3
1.4.3 Default Hardware Settings ...................................................4
1.5 Connection Diagrams .................................................. 5
1.5.1 Configuration 311 .................................................................5
1.5.2 Configuration 122.................................................................6
2 COMMISSIONING ..............................................7
2.1 Before connecting 240 VAC power ............................. 7
2.2 Before first run ............................................................. 7
2.3 Power on ....................................................................... 7
2.4 Prior to departure ......................................................... 7

Page IV
1 INSTALLATION
1.1 Wiring
All electrical installation is to be carried out by a licensed trades
person in accordance with AS3000 and manufacturers connection
diagrams.
1.1.1 Device I/O Cabling Requirements
All touchpad and sensor cables should be shielded, and kept
the maximum practical distance from any power cables ≥ 240
volts (minimum recommended distance = 300 mm).
Shielded 4 core data cable is acceptable provided the drain is
firmly connected by a mechanical means to the SH terminal. The
mechanical connection of the earth terminal on the Relay Module to
a suitable point enables this shielded cable to function as intended.

1.2 Component Positioning

The Nexus Lite Module can be positioned in the mechanical
services switchboard or, on or near the systems air handling unit.
Maintain a minimum distance of 300 mm from the indoor fan motor
or similar inductive fields.

The External Touchpad should be mounted in a central position

within the air conditioned space. It has been designed to be flush
mounted to a cavity wall, or surface mounted through the use of a
15 mm mounting block.

The Return Air Sensor should be mounted either, inside the return
air duct as close to the return air grille as possible, or wall mounted
1.5 meters from floor level close to the return air grille. Most
importantly, the return air/room sensor should always be protected
from direct sources of heat such as direct sunlight and office equipment.

The Outside Air Sensor (131E touchpad required) should be

protected from direct sunlight, mounted inside the outside air duct as
close to the outside air grille as possible.

Page 1
1.3 Controller Configuration
The Nexus is capable of controlling many different A/C configurations
of up to 5 relay outputs. The configuration is dictated by the model
number of the touchpad. E.g. Touchpad Model: CC-BB-LCD-311...
uses the 311 configuration. See section 1.3 for wiring details.

1.4 Nexus Technical Specifications

Power input to Controller ............... 240 volt ± 10%
Line frequency ............................... 50 Hz
Power Consumption ...................... 6 VA (max)
Operating temperature .................. 0 °C to 65 °C
Altitude .......................................... 0 to 2000 meters
Operating Relative Humidity ........... 10% to 80%
Unit Dimensions (mm) .................... 173 (L) x 116 (W) x 55 (H)
Weight ............................................ 550 g
Avoid static electricity hazards
Avoid electromagnetic radiation sources
Avoid dust contamination
Avoid highly corrosive environments

1.4.1 Inputs/Outputs

5 x relay outputs
• Max load through all relay terminals is 7Amps (inductive).

1 x digital input
• Flow input. Open circuit = lock out compressor relays.

2 x analogue outputs
• 1 x 0-10 VDC linked to cooling control band - V1
• 1 x 0-10 VDC linked to heating control band - V2

2 x analogue inputs
• 1 x NTC thermistor - 47 kΩ @ 25 °C
• 1 x Multi purpose

Page 2
1.4.2 Special Inputs

Analogue inputs S1 and S2 provide additional digital inputs in the

following manner (voltage free clean contacts required):

• S2 Closed Circuit = System Fault

Close circuit analogue input 2 terminals (S2 and SC) to shutdown
all conditioning relays (compressors and electric duct heaters).
The fan relay will remain energised only if the system is On.
For 3 speed fan models in auto fan mode the controller will default
to low fan speed. Manual changes to fan speed will be accepted.
• S1 Closed Circuit = Remote On/Off
Close circuit analogue input 1 terminals (S1 and SC) to
shutdown all relays.

• S1 Open Circuit = Forced Vent Mode

Open circuit analogue input 1 terminals (S1 and SC) to
shutdown all conditioning relays (compressors and electric
duct heaters), the fan and reversing valve relays will remain
energised. If the system is Off, the relay for the currently
selected fan speed will be energised.
For 3 speed fan models in auto fan mode the controller will
default to low fan speed. Manual changes to fan speed will be
accepted.

Any connected LCD touchpad will display a message on the screen

for each digital input trigger and the service timer trigger.
If multiple trigger events occur at the same time the message
displayed is based on the following priority.
1. SYSTEM FAULT
2. SERVICE TIMER
3. REMOTE ON/OFF
4. FORCED VENT

The factory default messages may be replaced by one from the

message library via the Advanced Settings Menu.
The library contains one custom entry of 2x8 character lines.

Page 3
1.4.3 Default Hardware Settings

The following table details the function of the main processor

module DIP switches located next to the sensor inputs.

Table 1.4.3a
Main Processor Module DIP Switch Settings
DIP OFF
Function ON
# (Factory Default)
Software Selectable 4 seconds max
1 Compressor Delay
(4 minute default) (overrides software)
Memory Lock Memory locked. Settings
2 Disabled
(Diagnostic Use Only) changes are discarded.
Restore Factory Restore factory defaults
3 Disabled
Defaults at next reboot.

4 Heat Type Reverse Cycle EDH or Cool Only

Page 4
1.5 Connection Diagrams
Select the appropriate connection diagram from the following pages.

1.5.1 Configuration 311

IASnet RJ and terminals, digital and analogue input / output terminals

Terminal (-TL) Return Air Analogue Output
Innocab (-IC)
Touchpad Touchpad Sensor Common

Proof of Flow*
D1 D2 V- V+ Configuration Analogue Output 1
DIP switches 0-10V Cooling Ramp

Analogue Output 2
1 0-10V Heating Ramp
ON
SH D1 D2 V- V+ I1 IC SH S1 SC S2 VC V1 V2
IASNET Optional Clock
RJ JP1 Socket
* Digital input 1 is proof of flow input. Green LED indicates flow status.
Flow must be proved before compressor relays are energised.
Short Circuit JP1 for constant flow (short circuit digital input 1).

240VAC Line in and relay output terminals

Maximum load through each relay is 7 A (inductive)
240V
AC
A1 N1 E1 C1 R1 Q1 C2 R2 Q2 C3 R3 Q3 C4 R4 Q4 C5 R5 Q5

240V Active
Fan Control Active

Cool Control Active

Heat Control Active

240V Neutral
Low Fan

Medium Fan

High Fan

Compressor

Rev. Valve / EDH

Earth

Page 5
1.5.2 Configuration 122

IASnet RJ and terminals, digital and analogue input / output terminals

Return Air Analogue Output
Innocab (-IC) Terminal (-TL)
Touchpad Touchpad Sensor Common

Proof of Flow*
D1 D2 V- V+ Configuration Analogue Output 1
DIP switches 0-10V Cooling Ramp

Analogue Output 2
1 0-10V Heating Ramp
ON
SH D1 D2 V- V+ I1 IC SH S1 SC S2 VC V1 V2
IASNET Optional Clock
RJ JP1 Socket
* Digital input 1 is proof of flow input. Green LED indicates flow status.
Flow must be proved before compressor relays are energised.
Short Circuit JP1 for constant flow (short circuit digital input 1).

240VAC Line in and relay output terminals

Maximum load through each relay is 7 A (inductive)
240V
AC
A1 N1 E1 C1 R1 Q1 C2 R2 Q2 C3 R3 Q3 C4 R4 Q4 C5 R5 Q5

240V Active
Fan Control Active

Cool Control Active

Heat Control Active

240V Neutral
Fan

Compressor 1

Compressor 2

Rev. Valve / EDH 1

Rev. Valve / EDH 2

Earth

Page 6
2 COMMISSIONING

2.1 Before connecting 240 VAC power

Verify the the correct wiring diagram has been followed by checking
the model number on the touchpad.
Ensure all electrical connections are in accordance with the supplied
connection diagrams and local bylaws.
Verify the sensor has been connected as per the connection
diagrams in section 1.5.

2.2 Before first run

Set all the system settings as detailed in the touchpad’s user guide.

2.3 Power on
Operate the controller in heat, cool and try each fan speed setting.

2.4 Prior to departure

Ensure that the Delay software setting is restored to Safety and
verify the hardware delay DIP switch # 1 is returned to the off
position prior to finishing commissioning.

Page 7
Product Support
Freecall 1800 354 434
www.ias.net.au
[email protected]

National Sales
Phone: 1300 306 125
[email protected]

Designed and manufactured in Australia by

Innovative Air Systems Pty Ltd