MACH-Zone
Controller
Quick Start Guide
Ideal for low-point applications
where unrestricted programming
and full data acquisition are
required.
Can be networked on the main
network or subnetwork, rendering
easy communication with the full
line of Reliable Controls
products.
The MACH-Zone is a
high-performance,
fully programmable
DDC controller
designed to meet the
needs of unitary
equipment.
Four different models have a
selection of output types and
universal inputs;
Flash EEPROM;
SMART-SensorTM support.
Communication ports include
SMART-NetTM and
EIA-485 Network.
...people and technology
you can rely onTM
2003 Reliable Controls Corporation
MACH-Zone Controller
Document Conventions
Reliable Controls Quick Start Guides use several
conventions to aid in your understanding of the material and
to make information more readily accessible. These
conventions are outlined below.
Software menu items will appear in bold faced type and follow
the form:
Start>Programs>Reliable Controls>RC-Studio
Two symbols are used to draw your attention to items
warranting special attention:
The Attention Symbol is used to
draw your attention to concepts
and particular items that require
caution or thought before
implementation.
The Light Bulb is used to draw your
attention to information and
practices that will make your life
easier.
ii
2003 Reliable Controls Corporation
MACH-Zone Controller
2003 Reliable Controls Corporation
All rights Reserved
Printed in Canada
This manual is for information purposes only. The contents and products
described are subject to change without notice. Reliable Controls
Corporation makes no representation with respect to this manual. In no
event shall Reliable Controls Corporation be liable for damages, direct
or incidental, arising out of or related to the use of this manual. No part of
this document may be reproduced or transmitted in any form or by any
means, without the express written permission of Reliable Controls
Corporation.
Reliable Controls Corporation
207-3375 Whittier Avenue
Victoria, BC, Canada V8Z 3R1
Tel: 250-475-2036
Fax: 250-475-2096
Toll Free: 1-877-457-9301
www.reliable-controls.com
iii
MACH-Zone Controller
iv
2003 Reliable Controls Corporation
MACH-Zone Controller
Contents
Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Getting Started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Workstation Connection . . . . . . . . . . . . . . . . . . . . . . . . 11
Peer to Peer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Direct via X-Port Converter . . . . . . . . . . . . . . . . . 12
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Universal Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Universal Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Single Stage Triac Outputs. . . . . . . . . . . . . . . . . . . 20
Dual Stage Triac Outputs . . . . . . . . . . . . . . . . . . . . 21
SETUP-Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MSet Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SMART-Sensor Connection . . . . . . . . . . . . . . . . . . . . 24
Cable Configuration . . . . . . . . . . . . . . . . . . . . . . . . 24
Workstation Jumper Settings . . . . . . . . . . . . . . . . . 25
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
iv
2003 Reliable Controls Corporation
MACH-Zone Controller
Network Connection . . . . . . . . . . . . . . . . . . . . . . . . 26
End-of-Line Termination . . . . . . . . . . . . . . . . . . . . . 28
Real Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . 30
2003 Reliable Controls Corporation
MACH-Zone Controller
vi
2003 Reliable Controls Corporation
MACH-Zone Controller
vi
2003 Reliable Controls Corporation
MACH-Zone Controller
Package Contents
Package Contents
Your new MACH-Zone controller package should include:
1. The MACH-Zone controller.
2. A package of four mounting screws
2003 Reliable Controls Corporation
MACH-Zone Controller
Getting Started
Getting Started
This guide identifies the physical installation procedure and
connection of the MACH-Zone controller within a
Reliable Controls MACH-System.
There are many important concepts and practices that
accompany the use of the MACH-Zone controller. This
document is intended to provide installation and setup
procedures for first time users. The most important concepts
that are crucial to the reliable operation of the MACH-Zone
are introduced.
Product Overview
The MACH-Zone controller features:
Four user configurable inputs.
Four models with different output configurations.
SMART-Net port.
EIA-485 - Network port.
2003 Reliable Controls Corporation
MACH-Zone Controller
Getting Started
24VAC 60Hz Power
Outputs
TM
SMART-Net Jumpers
SMART-NetTM Port
EIA-485 Network Port
Inputs
Input Jumpers
MACH-Zone network settings, such as baud
rate, network type, controller address, and last
panel must be configured using the SETUP-Tool
(see SETUP-Tool, Part# MAZ-ST). Alternatively,
RC-Toolkit and the X-Port converter may be
used.
The MACH-Zone controller does not have a Real
Time Clock. The controller receives its time from a
MACH1, MACH2, or MACH-Global controller
or an ETHER-Link portal that is addressed as
number one on the network.
2003 Reliable Controls Corporation
MACH-Zone Controller
Getting Started
The MACH-Zone controller does not have an
EIA-232 port. In order to access a MACH-Zone
controller from a workstation, it is necessary to
connect to a MACH1, MACH2, or MACHGlobal controller, or an ETHER-Link portal on
the same network.
The MACH-Zone controller may be directly
connected to an operator workstation with the aid
of the X-Port converter. Consult the X-Port
Converter Quick Start Guide for complete details.
2003 Reliable Controls Corporation
MACH-Zone Controller
Installation
Installation
The MACH-Zone controller is screw mounted vertically in
an enclosure:
Use the self-tapping
metal Robertson
screws supplied to
mount the controller.
Do not use bevel
headed or wood
screws.
Mount all peripheral
devices in a separate
enclosure.
Ground yourself before touching
the controller to avoid damaging
the electronics. Touch a grounded
metal surface to discharge static
electricity.
This controller is intended to be
installed in accordance with the
National Electric Code or the
Canadian Electric Code, Part1,
and in a manner acceptable to the
local authority having jurisdiction.
Attach power wiring and
I/O wiring.
Ensure that the MACHZone has been
configured with the SETUP-Tool prior to attaching
the network wiring (alternatively use the X-Port
converter and RC-Toolkit).
2003 Reliable Controls Corporation
MACH-Zone Controller
Physical Dimensions
Physical Dimensions
4.2cm
[ 1.62"]
17.0cm
[ 6.75"]
17.0cm
[ 6.75"]
14.3cm
[ 5.62"]
2.5cm
[ 1.0"]
15.7cm
[ 6.19"]
16.0cm
[ 6.25"]
6.6cm
[ 2.62"]
9.0cm
[ 3.5"]
2003 Reliable Controls Corporation
MACH-Zone Controller
Power Wiring
Power Wiring
The MACH-Zone controller
is powered with a Class 2,
24 VAC or 24 VDC power
supply.
One or more controllers can
be powered from the same
source.
24 VAC
Use only a Class 2 transformer.
Refer to the Technical
Specifications at the back of this
document.
The neutral wire of the power must
be grounded.
GND
1. Connect the hot wire to
the 24 VAC connection
at the right side of the
controller.
Do not connect any I/O peripherals
to the same power source as the
MACH-Zone controller.
2. Connect the neutral wire to the GND connection at the
right side of the controller.
3. The neutral wire of the 24 VAC must be connected to
the Earth ground.
2003 Reliable Controls Corporation
MACH-Zone Controller
Power Wiring
MACH-Zone Controller Power Wiring
#1
GND
Neutral of 24 VAC
connected to Earth Ground
#2
#3
120VAC
24VAC
Transformer
2003 Reliable Controls Corporation
MACH-Zone Controller
Status LED
Status LED
The MACH-Zone controller status LED provides power
indication and shows the EIA-485 network activity. The status
LED is located just below the power connection at the top
right side of the controller.
MACH-Zone Controller Status LED
2003 Reliable Controls Corporation
MACH-Zone Controller
Status LED
MACH-Zone Controller Status LED Indication
LED Indication
Panel Activity
On for one second and off
for one second.
Normal operation - port is idle.
Flickers
Normal operation - port is busy.
Flashes four times for one
second, off for half second.
No firmware is loaded.
Is on or off continuously.
Panel is defective or not powered on.
Continuous rapid flashing,
(6 flashes / second).
Self check failure.
(Service required)
Continuous, very rapid
flashing (at 96 Hz).
Network error.
(Holding network token)
On for half second, off for
half second (2 flashes/
second).
Network error.
(Check connections and settings)
10
2003 Reliable Controls Corporation
MACH-Zone Controller
Workstation Connection
Workstation Connection
Peer to Peer
The MACH-Zone controller is designed to be programmed
using a workstation running the RC-Studio software. The
workstation must be connected to a MACH1, MACH2,or
MACH-Global controller, or ETHER-Net portal that
resides on the same system as the MACH-Zone controller.
No EIA-232 port is available on the MACH-Zone controller.
Alternative access to the
MACH-Zone controller is
available with the use of the XA MACH1, MACH2, MACHPort converter. Consult the
X-Port converter Quick Start Global controller, or ETHERLink portal must be configured
Guide for complete connection as address one in the system (See
details.
MACH-Zone Real Time Clock).
Peer to Peer Communications
Operator Workstation
MACH1
2003 Reliable Controls Corporation
MACH-Zone
11
MACH-Zone Controller
Workstation Connection
Direct via X-Port Converter
If direct communication is absolutely necessary between a
workstation and the MACH-Zone controller, an X-Port
converter can be used. Consult the X-Port Converter Quick
Start Guide for complete details.
MACH-ZoneTM Controller
X-PortTM Converter
EIA-485
EIA-232
Operator Workstation
12
2003 Reliable Controls Corporation
MACH-Zone Controller
Models
Models
The MACH-Zone controller is manufactured in four models
providing flexibility for diverse applications. Each model has
four universal inputs and four outputs which are configured
based on the model ordered. The output types are Universal,
Single Stage Triac, and Dual Stage Triac. The different
configurations are shown below:
MACH-Zone Universal - offers four universal inputs
and four universal outputs.
2003 Reliable Controls Corporation
13
MACH-Zone Controller
Models
MACH-Zone 3TRIAC - offers four universal inputs
and three triac outputs as well as one universal
output.
MACH-Zone 4TRIAC - offers four universal inputs
and four triac outputs.
MACH-Zone Roof Top - offers four inputs that share
two common grounds. The output configuration
consists of one triac output, two dual stage triac
outputs, and one universal output.
All triacs are capable of switching
24 VAC at 1 Ampere.
14
2003 Reliable Controls Corporation
MACH-Zone Controller
Inputs
Inputs
The MACH-Zone controller is designed with four user
configurable universal inputs.
Universal Inputs
Inputs one through four (IN1, IN2, IN3, IN4) are universal
inputs that can be configured as digital (binary) or analogue
(modulating).
Each universal input can be
connected to a two-wire input
device (temperature sensor,
pressure transducer, etc.).
Connect the input signal to
the positive (+) terminal and
the input common to the
corresponding negative (-)
terminal.
MACH-Zone UNIVERSAL
IN1+
IN1 IN2+
IN2 IN3+
IN3 IN4+
IN4 -
The MACH-Zone roof top model (RT) has two common
grounds for the four inputs as seen below.
MACH-Zone Roof Top
IN1+
GND
IN2+
IN3+
GND
IN4+
2003 Reliable Controls Corporation
The maximum voltage measured
by an input is 5 VDC.
15
MACH-Zone Controller
Inputs
Jumper Settings
The input type, for inputs IN1, IN2, IN3, and IN4, is selected
using jumper shunts J1, J2, J3, and J4 respectively. Three
different input types can be set using the jumper shunts:
1. 0-5 VDC
Thermistor setting is a 10k Ohm
pullup to +5 VDC.
2. 4-20 mA
3. Thermistor (dry contact)
J-1
J-2
J-3
J-4
16
2003 Reliable Controls Corporation
MACH-Zone Controller
Inputs
MACH-Zone Controller Input Jumper Settings
Jumper
Selection
No Jumper
0-5 VDC
Inside Jumper*
Thermistor
Outside Jumper
4-20 mA
* Factory Default (shown above)
4-20 mA
Thermistor
0-5 VDC
2003 Reliable Controls Corporation
17
MACH-Zone Controller
Outputs
Outputs
The MACH-Zone controller is designed with four outputs,
which can be ordered in four different configurations.
1. MACH-Zone - U: 4 universal outputs.
2. MACH-Zone - 3T: 3 triac outputs, 1 universal
output.
3. MACH-Zone - 4T: 4 triac outputs.
4. MACH-Zone - RT: 2 dual stage triac outputs, 1
single stage triac output, and 1 universal output.
Universal Outputs
Universal outputs can be configured as digital (binary) or
analogue (modulating).
The maximum voltage provided by
an output is 12 VDC. The
maximum current sourced by an
output is 75 mA.
18
Each universal output can
be connected to a twowire output device (relay,
motor, etc.)
Connect the output signal
to the positive (+) terminal
and the output common
to the corresponding
negative (-) terminal
2003 Reliable Controls Corporation
MACH-Zone Controller
Outputs
.
Universal outputs
OUT1+
OUT1 OUT2+
OUT2 OUT3+
OUT3 OUT4+
OUT4 -
Only consider relays approved by
Reliable Controls when selecting
relays for output connection.
Before powering up for the first
time, ensure that no voltage (AC or
DC) can be read on the outputs.
2003 Reliable Controls Corporation
19
MACH-Zone Controller
Outputs
Single Stage Triac Outputs
The MZ-3T, MZ-4T, and MZ-RT controller models contain at
least one single stage triac.
Single stage triac outputs are
capable of switching 24 VAC at 1
ampere.
Triac outputs are
configured as digital
(binary).
Each output can be
connected to a load or
switching device (relay).
Triacs switch AC voltage only.
Connect the device as shown
in the diagram below.
LOAD
TRIAC 1
RTN-T1
120 VAC 24 VAC
Transformer
LOAD
TRIAC 2
RTN-T2
LOAD
TRIAC 3
RTN-T3
OUT4+
OUT4-
20
2003 Reliable Controls Corporation
MACH-Zone Controller
Outputs
Dual Stage Triac Outputs
The MZ-RT model contains two dual stage triacs. Each dual
stage triac can be connected to a two stage load.
Both triac stages are
OFF when the
output is
commanded to 0
volts.
Dual Stage Triac States
Voltage
T1
T2
OFF
OFF
ON
OFF
10
ON
ON
The first stage triac
(T1) is ON when the
output is commanded to 5 volts.
Both triac stages (T1 & T2) are ON when the
output is commanded to 10 volts.
Connect the two stages as shown in the diagram below.
MACH-Zone Roof Top
TRIAC 1
RTN-T1
STAGE 1
120 VAC 24 VAC
Transformer
STAGE 2
STAGE 1
STAGE 2
DS1-T1
DS1-T2
RTN-DS1
DS2-T1
DS2-T2
RTN-DS2
OUT 4+
OUT 4-
2003 Reliable Controls Corporation
21
MACH-Zone Controller
SETUP-Tool
SETUP-Tool
The SETUP-Tool is a specially designed SMART-Sensor
used to configure the MACH-Zone controller. Each
MACH-Zone controller must have the baud rate, network
type, controller address, and last panel configured with the
SETUP-Tool prior to connection to the network or
programming. The SETUP-Tool requires a voice cable
connection between the SETUP-Tool and the SMART-Net
port on the MACH-Zone controller. The SETUP -Tool is
powered by the MACH-Zone controller and does not
require a separate external power supply.
The SETUP-Tool has two modes of operation, MSET and
Flow mode. Mode selection is achieved with the rocker switch
on the bottom of the tool. MSet mode is discussed below.
Flow mode is user configurable, refer to the SETUP-Tool
Quick Start Guide for further information.
ADDRESS
LAST
MTR-CAL
UPDATE
Flow
22
BAUD
SUBNET
MSet
2003 Reliable Controls Corporation
MACH-Zone Controller
SETUP-Tool
MSet Mode
With the SETUP-Tool in MSet
mode, the buttons are used to
change the address, baudEach MACH-Zone controller
rate, network type, and last
must be MSet using either the
panel settings.
1. Select the parameter to
change
2. Use the Up or Down
arrows to change the
default value
3. When all changes are
complete press the
Update button and use
the Up arrow to
change the value from
No to Yes. This sends
the changes to the
controller. Changes are
complete when the
value changes back to
No.
The MACH-Zone does not
support a Baud rate of 57,600 bps.
2003 Reliable Controls Corporation
SETUP-Tool or an X-Port
converter and RC-Toolkit.
Consult the X-Port converter
Quick Start Guide for complete
details.
Refer to the SETUP-Tool Quick
Start Guide for user information.
The SETUP-Tool utilizes power
from the MACH-Zone controller
and does not require a separate
power supply.
To ensure the controller has
retained the new settings, turn the
unit off and then on and check
that the settings have remained.
23
MACH-Zone Controller
SMART-Sensor Connection
SMART-Sensor Connection
The MACH-Zone controller supports up to four
SMART-Sensors. The SMART-Sensors are ideal for
measuring space/zone temperatures and providing user level
adjustments to temperature set points.
See the SMART-Sensor Quick Start Guide for installation
details.
Cable Configuration
MACH-Zone
Ensure that the SMART-Sensor
voice cable is connected to the
Smart-Net port.
Voice Cable
SMART-Sensors need to be
properly addressed using the
configurable internal jumpers.
Data Cable
24
SMART-Sensors
2003 Reliable Controls Corporation
MACH-Zone Controller
SMART-Sensor Connection
Workstation Jumper Settings
The MACH-Zone controller (Rev. D and later) includes
jumpers J9 and J10 which are used to connect the SMARTNet port to the EIA-485 network.
Panels are shipped with the jumpers installed to
indicate the correct orientation. Remove the jumpers
in the event that no workstation access to the EIA-485
network through a SMART-Sensor connection is
required. This minimizes network stubs.
In the event that workstation access to the EIA-485
network through a SMART-SensorTM connection is
required, then leave jumpers J9 and J10 installed.
Refer to the SMART-Sensor Quick Start Guide for
workstation connection details.
Power Connection
EIA-485 Jumpers installed
EIA-485 Jumpers
SMART-NetTM Port
EIA-485 Network Port
2003 Reliable Controls Corporation
EIA-485 Jumpers not installed
25
MACH-Zone Controller
Networking
Networking
The Reliable Controls MACH-System can be networked in a
variety of ways, which are discussed in the Networking the
Reliable Controls MACH-System document.
When employing EIA-485 networks with the MACH-Zone
controller, the next three sections are relevant.
Network Connection
The MACH-Zone controllers network connector is located
on the middle right of the controller.
Connect one conductor to the A terminal and the
other to the B terminal.
When shielded cable is used, ground the shielding in
one place only and join the shields together using a
wire nut (marrette) where appropriate.
Try to Daisy-Chain the network cable as shown below.
Avoid Star and Stub connections.
26
2003 Reliable Controls Corporation
MACH-Zone Controller
Networking
Shielded Network cable Connections
Panel #1
Panel #2
Panel #3
Network
JP2
EOL
JP2
EOL
EOL
JP1
JP1
EOL
JP2
EOL
JP1
EOL
EOL Jumper
Shunts Removed
/////
//////// ////////////
///////
///////
///////
///////
//////////////////
///////
EOL Jumper
Shunts Installed
Shield
Grounded
Network
//////
//////// ////
Network
Shields Connected
with Marrette
EOL Jumper
Shunts Installed
Glowing network bulbs indicate a
problem which could be either the
network wiring (A & B) are crossed
between two panels or the class 2
power is crossed (24 VAC & GND)
between two panels.
2003 Reliable Controls Corporation
27
MACH-Zone Controller
Networking
End-of-Line Termination
On all EIA-485 networks it is necessary to add end-of-line
(EOL) terminators to prevent reflected noise returning into the
network. The EOL terminators must be installed on the
controllers at the extremities of the network. To determine
the network extremities, calculate the maximum network
length between any two controllers. The controllers at the
extremities must be terminated.
To terminate a MACH-Zone
controller, install EOL jumper
shunts on JP1 and JP2 as
shown in the diagram below.
If the network is not terminated
correctly, the controller may fail to
network properly.
EOL
JP1
EOL
JP2
EOL
Terminators
28
2003 Reliable Controls Corporation
MACH-Zone Controller
Networking
Real Time Clock
The MACH-Zone controller does not contain a Real Time
Clock (RTC) chip.
To access real time functions using the MACHZone controller, it is necessary to network the
MACH-Zone controller to a controller or portal
that has RTC capabilities, (e.g. MACH1,
MACH2, MACH-Global controllers or ETHERLink portal)
The MACH-Zone controller acquires time from
the device addressed as #1 on the network. If
controller address #1 is not on line or does not
have an RTC the system time will remain virtual.
The controller with the RTC must
be configured as address #1.
2003 Reliable Controls Corporation
29
MACH-Zone Controller
Technical Specifications
Technical Specifications
Specifications
Processor
16-bit embedded microprocessor
Memory
32k RAM
Firmware
64k Flash EEPROM
Software
RC-Studio
Power
Supply Voltage
24 VAC Class 2
Power Rating
12 VA maximum power consumption
5 VA nominal power consumption
Maximum Energy
Consumption
12 VA/12 W
Connector
2-pole K1 connector (24 VAC, GND)
Indication
One LED, green
Communications
EIA-485 Serial
Connector, 2-pin, 76.8 kbps max.
SMART-Net
RJ-11 connector, 6 pin
30
2003 Reliable Controls Corporation
MACH-Zone Controller
Technical Specifications
Ambient Limits
Operating Temperature
-18C to 40C (0F to 120F)
Shipping Temperature
-20C to 60C (-40F to 140F)
Humidity
10% to 90% RH non-condensing
Physical Specifications
Dimensions
9 cm L x 17 cm W x 4.2 cm H
(3.5 L x 6.75 W x 1.62 H)
Weight
0.7 kg (1.8 lb)
Cover
Cold rolled steel, powder coat finish
Mounting
Four mount holes provided
2003 Reliable Controls Corporation
31
MACH-Zone Controller
Technical Specifications
Inputs
Quantity
Three universal inputs
Converter
10-bit A-D
Analogue Input
0-5 VDC, 4-20 mA, thermistor
Digital Input
Dry contact
Input Impedance
15 k on 0-5 VDC range
Input Type Selection
Jumper configurable
Pulse counting
40 Hz maximum
Overload protection
24 VAC over-voltage protection
32
2003 Reliable Controls Corporation
MACH-Zone Controller
Universal Outputs
Quantity
Four universal outputs
Converter
8-bit D-A
Analogue Output
0-12 VDC, scalable in software
Digital Output
0-12 VDC
Output Power
75 mA, 12 VDC maximum
Overload Protection
24 VAC over-voltage and short protection
Single & Dual Stage Triac Outputs
Quantity
Based on model
Output Power
24 VAC, 1 A maximum,
24 VAC, 20 mA minimum
Output
Characteristics
Digitally controlled switch
2003 Reliable Controls Corporation
33
MACH-Zone Controller
MACH-Zone Rev 1.5 PLC 05/03
207-3375 Whittier Ave., Victoria, BC, Canada, V8Z 3R1
Toll Free 1(877)475-9301 Tel (250) 475-2036 Fax (250) 475-2096
www.reliable-controls.com
