Upgrade or convert an existing Varitrac CCP II to a Varitrac CCP III

Issue:

Upgrade or convert an existing Varitrac CCP II to a Varitrac CCP III

Resolution:

 

An existing Comfort manager 1995 or newer bypass system as well as a Varitrac CCP II can be upgraded to a Varitrac CCP III by making the following modifications:

1. Replace older Comfort manger or CCP II hardware panel with Varitrac CCP III panel with or without optional operator display (Order CCP III relay board option if older CCP or CM controlled a generic rooftop or split system
2. Add communicating bypass module to AHU supply duct to replace the SA sensor and static flow sensor used with older comfort manager and CCP II. The existing bypass damper is reused and cables to the replacement communicating bypass controller. A replacement cable is available to allow connection to the UCM
3. Move Comm4 wiring coming from existing VAV UCMs and Voyager with TCI to the replacement CCP III. Extend Comm4 link to the new communicating bypass assembly.

 

 

Tracker upgrade

 

The EMTK Tracker was available as a Stat4 / Stat7 / Stat16 and can be converted to a BMTK Tracker 12 or Tracker 24 depending on the device loading for the entire site.

• VariTrac CCP - The newer style Tracker BMTK communicates on a LonTalk link. This means it cannot talk to the older style CCPII, only the newer style CCPIII. 

   

   

• Binary controllers - Old EMTK Tracker uses TCMs to control lighting and generic HVAC equipment. The new BMTK Tracker uses MP503s for controlling binary outputs and ZN517 to control generic HVAC equipment. This equipment will need to be changed.

• PC interface for Tracker EMTK and CCP II is with Hyperterminal, for the Tracker BMTK and CCP III is with Tracker (optional purchase) and/or VariTrac PC software (VariTrac software is free with CCP purchase). New software is not backwards compatible.

• Constant Volume Units - The new Trackers use LonTalk to communicate to the UCM link. The original used Comm3. The rooftop units would all need new LCI cards. TCM controlled devices would need to be replaced by either ZN517 for 2heat/2cool or heat pump operations or the MP503 for slave controlled loads.

 

 

 

VariTrac CCP upgrade

 

CCPII (X13650529010, or BRD01723) communicates Comm3 to the Tracker EMTK or a BCU and Comm4 to the VAVs and rooftop unit. The CCPIII uses LonTalk communications to Tracker and Comm4 to VAVs and the air handler. This means that in most cases the zone UCMs will not need to be replaced.

If the CCP will never be tied to a Summit BCU, then certainly upgrade to a CCPIII. Order an Operator Display if not making use of the "free" Windows based software, (VariTrac not Tracker PC software).

The TCI card for the rooftop unit is addressed differently.

For the new CCP the address is all dip switches off. For the old CCP the address is all on.

The new CCP III uses a communicating bypass assembly (addressed at #33) to control the bypass damper. In the CCPII, this is done with connections directly to the board. This means that the flow sensor and supply air temperature sensors will need to be replaced.

If you have an existing bypass damper actuator, SAT sensor and static pressure sensor, they can be wired to a new VAV 4.2 UCM instead of ordering a whole new assembly.

• Will have to add a change over bypass VAV controller
  The Comfort Manager controls the changeover bypass damper differently than the new CCP III which uses a communicating bypass controller, so you will also need a communicating bypass assembly retrofit kit. The communicating bypass damper assembly for the CCPIII also incorporates the Supply Air Temperature and Static Pressure sensor right on the controller.

   

   

  Will need to change out the cable for the bypass valve.

   

  The cable is VACOMMODL010

   

  The X number for the cable is X19052133010 The Service parts # is WIR05077
• X13650943010 is the part number for the  CCP III Relay Kit
• 501860870100 is the part number for the Communicating Sensor/Bypass Control (SEN01157)
• Will need to replace the Tracker if a Tracker EMTK is present
• The VariTrac III Central Control Panel will not talk to the BCU.

 

 

 

 

 

 

VariTrac Comfort Manager upgrade

First verify whether you have Comfort Manager. The CM was mounted in a metal enclosure, the CCP II was mounted in a plastic enclosure (like the old Tracker can). The CCP II can be replaced with a new CCP II, the only issues have to do with Summit or Tracker communication.

• Any VAV 1 UCMs have to be replaced
  The Comfort Manger was developed in the late 1980's. At that time, the only DDC VAV controller around was the UCM 1 which only supports the non-isolated Comm3 protocol. As such, the Comfort Manager had to use the non-isolated Comm3 protocol to communicate to its UCMs.
  
  The UCM 2 was released in February 1993. The UCM 2 added support for the non-isolated Comm4 protocol but was also backwards compatible for non-isolated Comm3 support (for example, it could be used as a service part for a failed UCM 1 on a Comfort Manager or VAV Command Unit 1). The Comfort Manager continued to be sold up until the mid 1990's so it is certainly possible that it may already have Comm4 capable UCMs on it (the UCM 3 was released in May 1994). The date the Comfort Manager was installed should give you a good indication of whether you're dealing with Comm4 capable UCMs or not. That being said, even if the Comfort Manager was installed prior to February 1993, there could have been some UCMs replaced in later years that would be Comm4 capable. As such, before blindly replacing all UCMs, remove the VAV link from the Comfort Manager and hook it up to your Rover Comm4 service tool. Any UCMs that Rover is able to see are Comm4 UCMs. If you don't have Rover Comm4, you could spot check a few boards (find the X number on the board) to see if they might be Comm4 capable (use the following history matrix)

 

• VAV History Matrix
  
  The old VAV UCM I also used a 1K ohm RTD style zone sensor, where the UCM 1A (release date May 1991) and newer use a 10K ohm thermistor style zone sensor. Thus, if you really have UCM 1's, you will likely need to replace the zone sensors as well (because those old 1K ohm RTD style zone sensors will only work on UCM 1's).

 

Notes:

 

Changes:

 

Other Question/Problem/Cause Statements:

• Can I upgrade an existing CCP II to a CCP III?
• Convert an existing comfort manager site to Varitrac CCP III?
• Can I upgrade an older CCP to a new model?
• What do I need to upgrade my EMTK Tracker / CCPII to BMTK Tracker / CCPIII?
• Issues to consider when converting an old Tracker EMTK / Varitrac (CCP II) system to a new Tracker BMTK / Varitrac (CCP III) system?
• Tracker BMTK and Comm4
• Devices that work with Tracker
• Tracker VariTrac conversion
• Tracker old EMTK to tracker new BMTK
• What is required to upgrade a existing Varitrac CCP II site to Varitrac CCP III
• Can I use the CCPII bypass assembly with the CCPIII?

• What do I need to order to upgrade an EMTK Tracker system to the BMTK Tracker?

• Backward compatibility for VAV Comm3/Comm4 on CCPIII

• Can we replace the old CCP II with a new CCP II? Are there compatibility issues?
• What are the considerations in replacing the old Comfort Manager with the new VariTrac III Central Control Panel?
• Can you replace a Comfort Manager with a VariTrac III Central Control Panel?
• Can you replace a CCP II with a VariTrac III Central Control Panel?
• How do I upgrade a VariTrac system to the new CCP III?
• CCPII needs replacement. Can I replace with a CCPIII? Should I replace with a CCPII if it's still available?
• replacing the CCP2, will the VAV boxes and rooftop still be able to talk to the new CCP2?
• What is the part number for the VAV damper cable?

Facts:

• Applies to bypass systems and a Varitrac CCP III configured as bypass system.
• VariTrac III Central Control Panel (CCP)
• VAV UCM

Original wave: wave48814