Engineering Report: H215

Engineering Services
FAN 351

Johnson Controls, Inc.

Controls Group

507 E. Michigan Street CONTROL OF FAN-COIL AIR CONDITIONING SYSTEMS

P.O. Box 423
Milwaukee, WI 53201

The greatest advantage of the fan-coil system is its flexibility for adaptation to many
building requirements. The fan-coil conditioner system is primarily applied to air
condition perimeter spaces. Proper conditions within the perimeter space are
obtained by use of terminal units called room fan-coil air conditioners. The basic
elements of these units are a finned-tube coil and a fan section (Figure 1).

Figure 1. Typical Fan-Coil Unit

Fan-coil systems are generally classified into two major groups; single pipe systems
(2-pipe) and multipipe systems (3 or 4-pipe). A single pipe system contains a single
supply of water to each fan-coil unit and a single return. Cold or hot water is
supplied depending on the season. A multipipe system contains a double supply of
water, one hot and one cold to each fan-coil unit. A 3-pipe system has a common
return, while a 4-pipe system has a separate return for hot and for cold water
supplies.

9/83 1
 Engineering Report: H215

The chilled water and hot water piped to each fan-coil conditioner is supplied from
central heating and cooling equipment. The type of water piping required will
depend on whether both chilled and hot water are simultaneously available at each
fan-coil conditioner, or are available separately by manual or automatic change-
over.

Room fan-coil conditioners are similar to unit ventilators except that fan-coil units
generally have a smaller capacity and they admit either no outside air or a small,
fixed quantity of outdoor air. (Some units are provided with a damper to admit from
0 to 100 percent outside air. This damper can be controlled automatically.) The units
are generally available in nominal sizes of 200, 300, 400, and 600 CFM. Several
manufacturers also offer 800 and 1200 CFM models.

Although fan-coil units are usually sold with covers, most manufacturers provide
basic units for furred-in, recessed and concealed installation and for use with covers
made by sheet metal fabricators.

Unit Controls Required

The temperature of the space served by vertical fan coil unit may be controlled by a
standard heating cooling deadband thermostat mounted in one of the end
compartments of the unit. Horizontal units are usually installed in or near the ceiling.
A wall mounted thermostat is recommended for such installations. This
recommendation also applies to most concealed and recessed vertical units. Control
pressure from the thermostat operates throttling valves, or three-way mixing valves
to control the flow of water through the coil. When automatic damper control is
provided, the usual manual control assembly is omitted and a damper actuator is
applied. Valves for fan coil units should have flared connections. Factory piping
packages and direct shipment of valves to fan-coil unit manufactures are available.

Features

The system is designed to provide individual space temperature control without

utilizing central station air handling equipment and/or ductwork. Either a mixture of
outside and return air, or return air alone, is supplied to the unit. The coil heats the
air during the winter and cools the air during the summer. Filters are used to clean
the air. Some features of fan-coil units are:

1. Individual Room Temperature Control: The system is adaptable to this type of

control because each unit has an integral heating and cooling coil designed for
chilled or hot water.

2. Confined Room Air Circulation: Since most units recirculate only room air (some
use outside air), circulation of the air between rooms is minimized.

9/83 2
 Engineering Report: H215

3. Economy of Operation: Outside air is available on some units during marginal

weather for free cooling. An outside air proportioning damper at the unit provides
control.
4. Minimum Ductwork: Design costs of ductwork are minimized since supply and
return air ductwork are not normally required.
5. Under-The-Window Air Distribution: Under-the-window air distribution is ideal for
small rooms, particularly those having heating or cooling year-round loads.

Two-Pipe Systems

The two-pipe system is the oldest and lowest first cost method. During cold weather,
hot water is circulated to all fan-coil units. During hot weather, chilled water is
circulated to all fan-coil units.

TYPICAL SYSTEM (FIGURE 2) CENTRAL HEATER

Chiller Controls

Supply Water Readjustment

As TT-1 senses the temperature of the return water, it reversely readjusts the
setpoint of TCR-1 within predetermined limits as set on PL-1. TT-2 senses the
supply water temperature leaving the chiller plant and, depending upon the offset
incurred, produces an output through TCR-1 adjusting the position of the chiller
plant capacity control inlet vanes displayed on PI-1. Return and supply chilled water
temperature are displayed on TI-3 and TI-1 respectively.

Condenser Water Readjusted From Wet Bulb Temperature

As TT-3 senses the temperature of the leaving tower water, it produces an output
through the circuitry of TCR-2 which is dependent upon the offset between the set-
point of TCR-2 and the value of the variable at TT-3. The output of TCR-2 modu-
lates the tower bypass valve and stages the tower fan(s) to achieve the desired set-
point. TLN-1 senses the dew point (TT-5) and dry bulb (TT-4) temperature of the
outside air and produces a 3 to 15 PSI signal equivalent to a 66 to 78 web bulb
temperature respectively. This signal, when applied in input III of TCR-2, will directly
readjust its setpoint within predetermined limits as adjusted into TCR-2 and the
limits of PL-2. The condenser supply water temperature is indicated by TI-2. Fan
tower staging PE's, ammeter, and a run time meter is also shown in figure 2.

Water Heater Controls

As TT-4 senses the outside air temperature, it reversely readjusts the setpoint of
TCR-3. TT-6 senses the hot water supply temperature, depending on the offset

9/83 3
 Engineering Report: H215

Figure 2

9/83 4
 Engineering Report: H215

incurred, produces an output signal through TCR-3 adjusting the position of valves
TV-1 and TV-2 in sequence. TCR-3 should be reset to provide hot water at a
temperature which is always 10 to 15 degrees higher than normally required. This
permits each unit thermostat to provide individual space control under all conditions.

Heating Switchover

When PSM-1 is in the "Heating" position, zone valves TV-3, TV-4, TV-5 and TV-6
are in their normal positions. Hot water flows though TV-3 and TV-5 to the zone,
then back to the main hot water circuit through TV-4. Valve TV-6 is closed and
thermostat TC-1 is inoperative.

Cooling Switchover

When PSM-1 is placed in the "Cooling" position, TV-4 is closed and TV-3 opens to
return water. The zone pump temporarily recirculates all the water to avoid dumping
hot water into the chilled water circuit. When the return water cools to 90F, TC-1
opens TV-5 to chilled water and opens TV-6 to chilled water return, thus completing
the switchover from heating to cooling. The chiller should not be started until the
switchover is complete and flows have been established through the chiller.

Unit Controls

Unit thermostat TC-2 operates the water supply to the unit coil. As stated earlier,
TC-2 may be a wall mounted thermostat or a thermostat mounted within the unit.
The valve may be a throttling valve or a three-way mixing valve, as shown in figures
8 and 9.

If the unit valve is a throttling valve, the volume of water circulated by the zone
pump is variable. If this volume is reduced appreciably, an objectionable increase in
pressure drop across the valve will result unless a pump with a flat pressure-volume
characteristic is used, and a system bypass is used to maintain a relatively constant
flow through the system.

If the unit valve is a three-way mixing valve, the volume of water circulated by the
zone pump is constant since a varying portion of the water flows through the unit
coil while the reset bypasses the coil.

Thermostat TC-2 is direct acting during heating operation and reverse acting during
cooling operation. Switchover is accomplished by changing supply air pressure to
TC-2 by means of switch PSM-1 and three-way air valve ASV-1.

9/83 5
 Engineering Report: H215

TYPICAL SYSTEM (FIGURE 3) ZONE WATER HEATERS

The control arrangement shown in Figure 3 is basically the same as the

arrangement shown in Figure 2 except that; 1) each zone has its own water heater
and controls, and 2) there is a difference in the valves required for switching from
heating to cooling.

Chiller Controls

Supply Water Readjustment

As TT-1 senses the temperature of the return water, it reversely readjusts the
setpoint of TCR-1 within predetermined limits as set on PL-1. TT-2 senses the
supply water temperature leaving the chiller plant and, depending upon the offset
incurred, produces an output through TCR-1 adjusting the position of the chiller
plant capacity control inlet vanes displayed on PI-1. Return and supply chilled water
temperature are displayed on TI-3 and TI-1 respectively.

Condenser Water Readjusted From Wet Bulb Temperature

As TT-3 senses the temperature of the leaving tower water, it produces an output
through the circuitry of TCR-2 which is dependent upon the offset between the
setpoint of TCR-2 and the value of the variable at TT-3. The output of TCR-2
modulates the tower bypass valve and stages the tower fan(s) to achieve the
desired setpoint. TLN-1 senses the dew point (TT-5) and dry bulb (TT-4) tempera-
ture of the outside air and produces a 3 to 15 PSI signal equivalent to a 66 to 78
wet bulb temperature respectively. This signal, when applied in input III of TCR-2,
will directly readjust its setpoint within predetermined limits as adjusted into TCR-2
and the limits of PL-2. The condenser supply water temperature is indicated by TI-2.
Fan tower staging PE's, ammeter, and a run time meter is also shown in Figure 3.

Water Heater Controls

Each zone water heater is controlled by a receiver controller TCR-3 operating steam
valve TV-1. As TT-4 senses outside air temperature, it reversely readjusts the
setpoint of TCR-3. TT-6 senses the hot water supply temperature, depending on the
offset incurred, produces an output signal through TCR-3 adjusting the position of
TV-1. TCR-3 should be reset 10 to 15 degrees higher than normally required. This
permits each unit thermostat to provide individual space control under all conditions.
A second steam valve operated in sequence is not required unless the zone heater
is quite large.

Heating Switchover

When PSM-1 is in the "Heating" position, zone valves TV-2, TV-3 and TV-4 are in
their normal positions and TCR-3 controls TV-1. Water flows from the zone heater
through TV-2 to the units in that zone and then back to the zone heater.

9/83 6
 Engineering Report: H215

Cooling Switchover

When PSM-1 is placed in the "Cooling" position, steam valve TV-1 is closed to shut
off the steam supply to the water heater by 3-way air valve ASV-2. The zone pump
temporarily recirculates all the water. When the return water cools down to 90F,
thermostat TC-1 closes TV-2 and opens TV-3 and TV-4, thus permitting circulation
of chilled water to the zone.

Figure 3

9/83 7
 Engineering Report: H215

Comparison

The control arrangement shown in Figure 2 uses common sources of chilled and hot
water for all zones. The control arrangement in Figure 3 has a common source of
chilled water for all zones, but has a separate water heater for each zone. Three-
way air valve ASV-2 of Figure 3 may be deleted if there is no steam supply to the
water heater when the system is on cooling operation.

Three-Pipe Systems

The three-pipe system is more versatile than the two-pipe system because this
system can supply both hot and chilled water to the fan coil units throughout the
year. The need for central changeover is eliminated. Each fan coil unit functions
independently of every other unit in the building because its control valve selects
either hot or chilled water depending on the space needs. A common return is used
for both hot and chilled water supplies. Figure 10 shows the terminal unit piping
arrangement. Energy loss is not as large as one might think with a common return
because little or no mixing occurs during Summer and Winter seasons. Mixing will
occur during periods of reduced heating or cooling loads, but with both hot and cold
water temperatures reversely readjusted to outside air temperature, the energy loss
is minimized. Despite these factors three pipe systems are usually quite inefficient
and are seldom installed today. However, energy conservation potential does exist
for present systems.

TYPICAL SYSTEM - CENTRAL HEATER (FIGURE 4)

The central heating and cooling controls outlined in figure 2 is the same
configuration that would be used in a three-pipe system, except no season
changeover controls are needed. A heating/cooling deadband thermostat is required
for each unit.

TYPICAL SYSTEM - ZONE HEATERS (FIGURE 5)

This system features central cooling with zone heating. It's the same as the two-pipe
system with zone heaters (Figure 3) except that no season changeover controls are
needed. A receiver-controller is needed for each zone heater with the output placed
directly on the zone steam valve TV-1, rather than through air switching valve ASV-
2, as shown in Figure 3. A heating/cooling deadband thermostat is needed to
control each fan coil unit.

9/83 8
 Engineering Report: H215

Figure 4. Three-Pipe System - Central Heater

Figure 5. Three-Pipe System - Zone Heater

9/83 9
 Engineering Report: H215

FOUR-PIPE SYSTEMS (FIGURES 6 AND 7)

Though the individual control and piping vary for application purposes, the four-pipe
fan-coil system consists of basically the same equipment as the two-pipe system.

A four-pipe fan-coil system is designed to provide hot and cold water at each of its
fan-coil units the year round. In effect, each unit is a separate zone and functions
independently. The unit's control valve selects either hot or cold water, depending
on the requirement at the time of selection. A four-pipe system completely isolates
the cold and hot water systems so that the piping for each system can be designed
independently, allowing for diversity of application. Four-pipe systems can be
separated into two basic types; those using room units with single coils and those
using room units with split coils.

In four-pipe systems, direct acting thermostats may be utilized and changeover

controls are not required. Figures 11, 12 and 13 of the Terminal Unit Piping section
of this report illustrate how the throttling valves and three-way valves are applied in
four-pipe systems.

System Features

In addition to the features of the fan-coil system as itemized under Two-Pipe

Systems, additional features of the Four-Pipe system are:

1. Quick Response to Thermostat Settings

A change in thermostat setting is immediately apparent because hot and cold
water are available at each unit.

2. Elimination of Zoning by Exposure

Multiple pumps, zoned piping and allied controls are eliminated because each
space is a zone in itself as compared to the two-pipe system.

3. Elimination of Operation Difficulties of Changeover

When the system is properly designed, changeover is not required and operation
is simplified.

4. Year-Round Room Temperature Control

Intermediate temperature control problems are eliminated because of the
availability of both heating and cooling.

9/83 10
 Engineering Report: H215

Figure 6. Four-Pipe System - Central Heater

Figure 7. Four-Pipe System - Zone Heater

9/83 11
 Engineering Report: H215

Multi-Unit Control

In many cases building areas are divided into relatively small rooms or offices, each
served by a single unit. Each of these units is controlled by a separate thermostat
and valve. For larger areas, however two or more units may be required. In such
cases a single wall mounted thermostat can serve as many as eight or ten units,
provided the thermostat is located to respond to representative conditions. If valve
top thermostats are employed in such areas, it is recommended that no more than
four units be controlled from a single thermostat located in a representative unit. If
there are more than four units, they should be divided into groups of four or less
with a separate valve top thermostat serving each group.

Valves

Although it is recommended that each unit have its own control valve, it is possible
to control a group of units with a single control valve arranged to serve the units
under control of a single wall mounted thermostat.

One serious disadvantage of this method is that later subdivision of the space
requires extensive piping changes. It also requires very accurate sizing of orifices or
adjustment of balancing cocks to assure even heat distribution to the units.

Terminal Unit Piping

The following piping arrangements are examples of typical applications for terminal
unit piping. It is important that the contractor and unit manufacturer involved
understand each of the arrangements. Figures 8-13 and their explanations clearly
identify the basic piping arrangements and valve applications for the two-, three-
and four-pipe systems.

9/83 12
 Engineering Report: H215

Typical Terminal Unit Piping Arrangements

The piping arrangement shown in Figure 8 is used in a two-pipe system. It utilizes a

throttling valve. Since normally open and normally closed valves are available, the
arrangement can be used for either a heating or a cooling application. It is essential
that the arrow on the valve be piped in the direction of the system flow. Failure to do
so will result in an unstable condition. The valve can be controlled by either a valve
top thermostat or a room thermostat.

Figure 8

The piping arrangement shown in Figure 9 is also used in a two-pipe system but
utilizes a three-way valve. This arrangement can also be used for either a cooling or
a heating application. When used in a heating application, the valve is usually piped
normally open to the coil; when used in a cooling application, the valve is usually
piped normally closed to the coil; assuming in both applications that a direct acting
thermostat is used. The valve can be controlled by either a valve top thermostat or a
room thermostat.

Figure 9

9/83 13
 Engineering Report: H215

The piping arrangement shown in Figure 10 is used in a three-pipe system. It

utilizes a special range three-way valve. The normally open port operates over a 4-6
psi spring range; the normally closed port operates over a 9-12 psi spring range.
Because of the special spring ranges there is a dead zone between six and nine psi.
As is clearly indicated in the diagram, both hot and chilled water are available to the
unit at all times. The return is common. The valve can be controlled by either a
valve top thermostat or a room thermostat.

Figure 10
The piping arrangement shown in Figure 11 is used in a four-pipe double coil
application. It utilizes two (2) three-way sequencing valves. The heating coil, piped
normally open to the coil, operates over a 4-8 psi spring range; the cooling coil,
piped normally closed to the coil, operates over a 9-13 psi spring range. The heating
valve can be controlled by either a valve top thermostat or a room thermostat. The
cooling valve is positioned by a valve actuator.

Figure 11

9/83 14
 Engineering Report: H215

The piping arrangement shown in Figure 12 is also used in a four-pipe double coil
application. It utilizes one normally open throttling valve and one normally closed
throttling valve. The heating coil is controlled by the normally open valve with a 3-6
psi spring range. The cooling coil is controlled by the normally closed valve with a 9-
13 psi spring range. The heating valve is controlled by a valve top thermostat or a
room thermostat. The cooling valve is positioned by a valve actuator.

Figure 12

The piping arrangement shown in Figure 13 is a four-pipe application utilizing two

(2) three-way valves. The hot water supply is piped to the normally open port and
operates over a 4-6 psi spring range. The chilled water supply is piped to the
normally closed port and operates over a 9-12 psi spring range. The return valve is
piped common to the coil with the normally open port and the normally closed port
operating over a 6-9 psi spring range. The supply valve can be controlled by either a
valve top thermostat or a room thermostat. The return valve is positioned by a valve
actuator.

Figure 13

9/83 15