VentGenie Ventilation Controller – Setup & User Guide

System overview

Thank you for purchasing the VentGenie System. The VentGenie is designed for easy installation and the ultimate in cow comfort. The system controls the ventilation equipment for an entire dairy barn.

It is easy to scale the VentGenie System to any size of barn with modular Expansion boxes. The modular approach allows the VentGenie System to be expanded or customized to each barn. The software included in the VentGenie controls up to 24 curtains, 50 circulating fans, 30 tunnel fans and six sprinkler circuits. All you need to do is simply add additional expansion boxes at any time to accommodate more equipment.

This user’s guide is divided into two sections:

• Section 1 – Electrician’s Guide. For the electrical contractor who is responsible for wiring the VentGenie System. It includes information on wiring fans, curtains, sensors, and the VentGenie System itself.
• Section 2 – Setup Guide. For whoever sets the parameters to operate the VentGenie System. This might be the electrician, the farmer, or someone with the responsibility of operating and maintaining the barn.

The VentGenie System components are the VentGenie Master, the VentGenie Expansion Box, the wind meter, the humidity sensor, and the rain sensor.

Main features

The VentGenie System is designed for the unique challenges of dairy cow facilities. The VentGenie System:

• Is engineered to improve cow comfort and electricity savings from existing equipment
• Controls curtains by inside temperature versus outside temperature differential
• Has integrated electronic overload protection for curtain motors
• Has humidity sensors for enhanced cow comfort
• Provides wind chill detection to protect cows during the winter
• Has smart humidity compensating sprinkler management
• Saves electricity by turning fans off when it is windy outside
• Automatically controls the transition to and from tunnel mode and natural ventilation
• Has toggle switch overrides for all output relays

Electrician-supplied wire & components

The VentGenie recommends that a qualified electrician install all of the components and wiring of the system. The components identified in Section 1 are provided when the VentGenie is delivered. However, some wire and electrical components will need to be supplied by the electrician.

Wire

• Temperature sensor wire: each temperature sensor uses two 18–22 AWG conductors. Ideally the wire is twisted pair or shielded wire. Non-twisted or shielded wire should be kept at least four feet away from 120 volt or higher if the wires are running parallel. A typical 96′ × 200′ barn may require approximately 750 feet of wire for temperature sensors.
• Wind meter wire: you may need to make an extension cord for the wind meter using four-conductor 18–24 AWG wire and RJ-14 male and RJ-14 socket (RJ-14 is telephone-style plug). A typical length is approximately 100 feet. Cat5e wire can be used.
• Input wire: use 18–24 AWG wire, two conductors per input.
• DC curtain motor wire: typical 24 volt DC 100–300 watt curtain motors can use 12 AWG wire. It takes only two conductors per motor for DC motors.
• AC curtain motor wire: check the motor’s documentation for required wire size. It will require at least three conductors plus ground.
• Circulating and tunnel fan wires: the circulating and tunnel fans need to have external contactors to control them. Do not use the VentGenie to directly switch the fan motors. Use stranded 18 AWG wire to control the contactors to allow the VentGenie faceplate to swing easier.
• Sprinkler valve wires: typically 18 AWG wire is used to power water valves.
• Variable speed fan control wires: typical control wires for the 0–10v and start/stop signal is four-conductor 18 AWG twisted pair or shielded wire. Cat5e can also be used. Each variable frequency drive will need to have its own individual control cable wired to the VentGenie.

Components

The electrician will need to supply the following electrical components:

• Sealed plastic junction boxes to enclose temperature sensor connections
• Soldering tools or gel filled crimp connectors for temperature sensor connections
• Sealed plastic junction box to enclose wind meter connections
• A 4″–6″ × 3′–5′ trough to bring all the wires into the bottom of the VentGenie System
• Contactors for fans

Installing the VentGenie System

Consider the following before installing the VentGenie System:

• Protect the Master Controller and Expansion boxes from moisture – mount them in a secure and dry place.
• Allow a minimum of 36 inches of wall space for the VentGenie Master Controller and Expansion box combination.
• Place the Master Controller and Expansion box where cows are not able to come in contact with them.

Mounting the Master Controller

Mount the VentGenie Master and Expansion Box within approximately one foot of each other (the TTL Xnet wire is short) on a wall in or near the barn. Putting a trough below the system is a good method to bring the wires into the system. Drill holes within three inches of bottom only in the VentGenie Master or Expansion boxes. Connect the Master and Expansion box with a ¾ in. conduit to route TTL Xnet wire through.

Supplying power

Power the system with 120 VAC. Surge protection is recommended.

Connecting a Master with a single Expansion Box

Route the TTL Xnet wire through the ¾ inch conduit and connect to matching connector in the Expansion Box. Do not run 120 volt (or greater) wire with the TTL Xnet cord.

Verifying the network connection

If the Expansion Box is powered and in communication with the Master, the clear status LED (inside of the Expansion Box) blinks green.

Call your dealer for help if you cannot get the status LED to blink green.

Installing the wind sensor

Deciding where to install the wind meter

The meter needs to be installed outside and above obstructions. Keep away from silos by 100 ft. The peak of the barn usually is an accurate and convenient location. You will mount the wind sensor on a 1″–1.5″ pipe, which should be at least three feet above the roofline of the structure on which you will mount the wind sensor.

Assembling the wind meter

The wind meter comes partially assembled. Assemble it before mounting and wiring:

1. Push the wind cups up onto the stainless steel shaft as far as possible. Use the Allen wrench provided to tighten the set screw on the side of the wind cups. The wind cups should drop slightly when you let go.
2. Mount the wind vane on the top and tighten the setscrew.
3. Slide the anemometer arm into the base while taking care to protect the cable.
4. Route the cable through the channel.
5. Install the screw and nut.
6. Install the U bolt (not pictured) and nuts loosely onto wind meter base.

Mounting the wind meter

1. Slide the assembled wind meter over the pipe which you mounted above the roofline.
2. Rotate the anemometer arm until it points 10:00 in relationship to the barn.
3. Lift the wind meter until it is approximately three feet above the roofline.
4. Tighten the U bolt securely while taking care not to pinch the cable.

The north most side of the barn is considered the 12:00 position. You do not need to know exactly where true north is.

Extending the wind meter wire

1. If the 40 ft of wire on the wind meter is too short, extend it with the included phone-style jacks.
2. The 1st phone-style jack goes inside the VentGenie Master.
3. The 2nd phone-style jack mounts in a sealed box, up near the wind meter.
4. Connect the two with phone wire.

Always mount the phone-style jacks in a sealed enclosure, otherwise they will corrode. Corroded terminals give bad readings and unhappy cows. Plug the wind meter cord into the VentGenie Master jack (marked WIND). Included parts for the wind meter: two phone-style jacks and one phone jack cord.

Verifying the wind meter installation

To verify that the wind meter is wired and operating correctly, the LED light marked “wind wheel” on the VentGenie Master blinks once for every rotation of the wind wheel. To double check the orientation, press the Parameter decrease button and verify that the wind meter vane is pointed toward the direction that the screen is displaying.

Common problem with extension cords

“The wind cups are spinning but the wind wheel LED blinks randomly.” Likely the wind direction and wind speed wires are crossed. This should only happen when using an extension cord. Check the polarity of all the extension cord.

Installing the temperature sensors

Before you begin, determine the number of temperature sensors to install. For large barns, it is recommended to use five temperature sensors. For small barns, only three sensors may be needed. These would need to be positioned in the Ridge Vent, the north eave and just inside the south sidewall.

Position considerations

Wiring the temperature sensor to the controller

1. Run a length of 18 AWG wire (twisted or shielded if possible) from each temperature sensor to the VentGenie Master Controller. Use one pair per temperature sensor. Keep the wires at least 12 inches away from any other 120 volt (or greater) wires (if possible). Cross these high voltage wires at a 90° angle.
2. Solder or use gel filled crimps to connect the wires to the temperature sensor.
3. Waterproof the connection.
4. Connect the temperature sensors to the VentGenie Master Controller. Slide the wire into the terminal and tighten firmly using a small screwdriver. It is possible to have inserted the wire below the terminal’s internal clamp, so tug on each wire after it is tightened to make sure it is fastened securely.

Installing the rain sensor

First decide where you want it to be installed. The sensor needs to be outside and exposed to the sky. Rain needs to be able to hit the sensor lens from all directions. Mount away from dusty conditions. Make sure the rain sensor will not get ripped off by sliding snow. The rain sensor will adjust automatically to lens dirt over time, but it is best to have it in a relatively clean location (not in barn exhaust air).

Running the wires

Included with the rain sensor is a 50 foot extension cord. Route the sensor’s wire at least one foot away from 120 volt (or higher). To connect the cord sets, push together and tighten firmly. Additional extension cords can be purchased from your AutoVent dealer as needed. Most any 4 conductor wire can be used to extend the rain sensor up to 500 ft.

Connecting the rain sensor to the VentGenie Master

1. Locate the rain sensor terminal block inside the VentGenie Master. It has four terminals marked Blue, Black, Brown, and White.
2. Connect the female m12 (provided with the rain sensor) to the rain sensor terminals as per wire colors marked on the board.

Installing the humidity sensor

The humidity sensor can be mounted outside of a barn under an eave. It can be mounted inside, but the sensor’s life will then be approximately one to two years instead of approximately five years. The sensor includes 15 feet of cord with a male m12 connector. Additional extension cords can be purchased from your AutoVent dealer as needed, or you can extend it with regular wire.

Connecting the humidity sensor to the VentGenie Master

1. Locate the terminal block marked Humidity Sensor inside the VentGenie Master. It has four terminals marked Blue, Black, Brown, and White.
2. Connect the female m12 (provided with the humidity sensor) as per wire color marked on the humidity terminal block.

Installing & wiring inputs

Sometimes the curtains on cow barns are mounted across access aisles. The VentGenie has “Curtain as door” functionality to allow you to fully open or close a curtain with a pushbutton mounted beside the access point. The VentGenie uses an input to connect to the pushbutton.

More advanced operations may wish to turn off circulating fans or sprinklers for a section of the barn when cows are out of the barn being milked. “Bathroom fan” style timers can be used to hold circulating fans and/or sprinklers off when no cows are present or the farmer is bedding the stalls. The VentGenie uses an input to connect to a timer.

Assigning inputs

There are four inputs in the VentGenie Master. Up to 16 additional inputs can be added with an optional Input Expander Module. Certain inputs in the VentGenie Master, labeled #18, #19 and #20, are shared with other VentGenie functions and cannot be used if the rain sensor and tunnel mode are installed.

Curtains and circulating fans must be assigned to an input in order for them to recognize when the input circuit is closed. You will need to do this after installing and wiring the input.

Wiring inputs

The inputs are normally open dry contacts to allow the VentGenie to sense momentary normally open pushbuttons and normally open timers or sensors. A normally open pushbutton can be used for “curtain as door” functionality. A timer with a closed-while-timing output can be used to keep circulating fans and sprinklers off.

• “Curtain as door” inputs: connect the momentary NO switch between input and common. Whenever the circuit is momentarily closed, the curtain will open or close.
• Circulating fan or sprinkler inputs: connect the timer between common and input. Whenever the circuit is closed, the assigned fans will be off.

Installing the Input Expander Module

The Input Expander Module is an add-on module to enable you to use an additional 16 inputs in addition to the inputs on the VentGenie Master.

1. Mount the Input Expander Module within two feet of the VentGenie Master.
2. Connect with conduit. Always drill holes in the bottom of enclosures only.
3. Connect the TTL Xnet connector. Keep TTL Xnet wire away from 120 volt or higher wires.

The Input Expander Module uses the same wiring scheme as inputs in the VentGenie Master. Inputs are numbered Input #1 to Input #16.

Variable speed module (0–10v)

The variable speed module is designed to control HVLS (High Volume Low Speed) and other variable speed fans. It controls the speed with a 0–10v signal. The module itself is not designed to provide the stop/start signal.

1. Mount the Variable Speed Module within two feet of the VentGenie Master.
2. Connect with conduit. Always drill holes in the bottom of enclosures only.
3. Connect the TTL Xnet connector. Keep TTL Xnet wire away from 120 volt or higher wires.

Running wires

Typically the fans in the barn will be divided into multiple banks to allow individual banks to start at different temperatures and turn off sooner when wind is coming from the side of the barn on which the bank is mounted. Multiple VFDs (variable frequency drives) are wired to the single 0–10 volt signal. The start/stop wires from VFDs are wired to circulating fan output relays. This allows separate start/stop banks of fans.

Run 0–10v wires two feet away from 120 volt or higher wires. Improper shielded power wires from VFD to motors can cause interference to 0–10v wires.

Connecting the 0–10v signal wires

Connect all 0 volt or common wires to the 0v terminal. Connect all the 10v wires to the 10v terminal in the Variable Speed Module.

Connecting the start/stop wires

Connect the start/stop wires to the circulating fan’s output relays. Connect them as if the fans were normal circulating fans. Protect the start/stop wires from coming in contact with any high voltage when wiring in close proximity to other circuits.

Configuring the VFDs

Configure the VFD (variable frequency drive) to be at 100% speed when the 0–10v signal is 10 volts. Consult the VFD manual to configure VFD parameters. AutoVent LLC is not responsible for 3rd party VFD configuration.

Troubleshooting the 0–10v signal

If the fans run but do not seem to run at a correct speed:

1. Disconnect the fan’s 0–10 volt wires from the Variable Speed Module.
2. Connect a 9 volt battery to the fan’s 0–10 volt control wires.

If the fans rotate at exactly 90% of their speed with the 9 volt battery, then the fans and wiring are correct – contact AutoVent LLC. If the fans do not rotate at 90% speed, then the VFDs may not be set to 100% speed at 10 volts, or there is serious interference from improper VFD wiring/installation. Possible solutions to eliminate interference:

• Use VFD rated wire between VFD and fan.
• Keep power cord from VFD to the motor less than 25 feet long.
• Make sure motor ground is connected to ground connection point provided by the VFD manufacturer.
• Double check to make sure that 0–10 volt wires are not installed within two feet and parallel to VFD power wires.

Alternatively, use an oscilloscope to check the 0–10v signal. Properly wired systems should have very little noise on the 0–10v signal. Any amount of “jitters” on the 0–10v signal may cause the VFD to misread the signal.

Installing the 24vdc curtain motor power supply

The curtain power supply box (24 VDC) is an optional addition to the VentGenie System. It powers 24vdc curtain motors, but not if motor leads are 200–300 ft long or for tunnel vent barns. Mount the curtain power supply in a convenient location close to the VentGenie System. Connect with conduit; always drill holes in the bottom of enclosures only. Power the curtain power supply with 120 VDC. Use the output terminals to power the curtain motors.

Wiring curtain motors

The VentGenie System was designed to allow the curtain motors to be easily wired if the barn is not tunnel ventilated. In non-tunnel ventilated barns, the curtain motors switch on one at a time. This allows up to 24 curtain motors to be wired from a single power source. However, in barns that switch between tunnel and natural ventilation, the motors run simultaneously. The power source must be large enough to accommodate all the motors running simultaneously for barns that switch between natural and tunnel ventilation.

Connecting curtain motors to the controller

After relays are mapped, parameter A6 is the starting relay for the curtains. This will be the CLOSE relay for curtain #1. Odd numbered relays are switched on when the curtain is closing, and even numbered relays are switched on when the curtain is opening.

Wiring the onboard electronic amp meter

Route the curtain motor’s positive wire through the electronic amp meter, then loop through four additional times.

DC motors, non-tunnel ventilated

The following schematic shows how to wire multiple DC curtain motors when the barn does not switch between natural and tunnel ventilation. Reverse the leads to swap a motor’s direction. Each relay is rated 15 amps max.

AC curtain motors, non-tunnel ventilated

All curtain motors can be powered from one circuit breaker. Loop the positive/hot wire through the electronic amp meter 5 times and power all the curtain motors from this circuit. The even numbered relays are energized for Close and odd numbered relays are energized for OPEN.

Additional wiring & backup power

Baffles

The baffles’ function is to close when the VentGenie switches the barn into tunnel mode and open when switching to natural mode. The curtain circuits to use for baffles are set in Menu D, “Location curtain is mounted.” Any curtain circuit can be set to be a baffle. Wire the baffles the same as a curtain.

Garage doors

The garage door circuits get a 0.5 second pulse when the VentGenie switches the ventilation mode. The curtain circuits to be used for garage doors are set in Menu D, “Location curtain is mounted.” Wire the Open output relay to the open button on the garage door control and the Close output relay to the close button on the garage door control.

Circulating fans

Typically the circulating fan control circuit is wired with 18 AWG wire. Power the control circuit separately from the VentGenie. Parameter [A7] “First # for circ. fans” is the output relay for circulating fan #1. Backup switches should be wired into the fan circuits to allow operation of the fans if the VentGenie System fails.

Tunnel fans

Typically the circulating or tunnel fan control circuit is wired with 18 AWG wire. Power the control circuit separately from the VentGenie. Parameter [A8] “First # for tunnel fans” is the output relay for tunnel fan #1. Backup switches should be wired into the fan circuits to allow operation of the fans if the VentGenie System fails.

Sprinklers

Typically the sprinkler circuits are wired with 18 AWG wire. Parameter [A9] “First # for sprinklers” is the output relay for sprinkler #1.

Overload alarm relay

A relay can be assigned as the overload alarm output (set by parameter A10). The alarm is a dry contact you can wire to an external alarm or annunciator.

The battery backup system

The battery backup scheme is intended for tunnel ventilated barns that automatically switch between natural and tunnel ventilation. The VentGenie logic senses when there is no voltage from the 24vdc normal power and will automatically go into natural ventilation mode. The backup system was designed to work well with 24 VDC curtain motors. Curtain motors must also be powered from backup batteries. Normally the VentGenie and the 24VDC curtain motors use the same backup batteries.

Fuses

The fuses are ¼ by 1¼ inch fuses. Do not replace them with larger fuses.

Mapping the output relays

Mapping the output relays is the process of setting up the VentGenie for the number of circuits (curtains, sprinklers and fans) that will be controlled and which output relays the individual items will use. This must be done so that the VentGenie software knows which output relays are connected to the curtain, fan and sprinkler circuits.

To begin, decide exactly how many curtain (including baffles and garage doors) circuits are going to be controlled, and how many circulating fan, tunnel fan, and sprinkler circuits will be controlled. Then decide which output relay the curtain circuits will begin on. Typically it is Relay #1 (labeled R#1 on the faceplate).

Each curtain circuit uses two consecutive output relays. Each fan circuit uses one output relay. Each sprinkler circuit uses one output relay. Typically the fan circuits start immediately after the curtain circuits end, and the sprinkler circuits begin after the fan circuits end.

To access the VentGenie Configuration Menu in order to set up the output relays:

1. Turn off all power to the VentGenie Master controller.
2. Power the VentGenie controller while pressing the Enter Menu button. The screen displays “Config menu, use with care.” You are now in Menu A, the VentGenie Configuration Menu.
3. Using the parameters you decided, enter the parameters and write them down for future reference.

If an item (curtains, circulating fans, tunnel fans, or sprinklers) is not going to be controlled by the VentGenie, its “number of circuits being controlled” needs to be set to zero.

Setting the toggle switch mode

The VentGenie’s toggle switches have two operating modes:

• Curtain Mode: a pair of switches is interlocked to prevent open and close output relays from being manually switched on at the same time.
• Fan or Sprinkler Mode: each switch is independent.

The mode of the toggle switches for each pair of output relays is controlled by the slide switch:

1. For all curtain circuits, push the slide switch to “Curtains.”
2. For all fan or sprinkler circuits, push the slide switch up to “Fans or Sprinklers.”

Electrician checklist

1. Double check all curtain motor limit switches. The motor’s limit switch must stop the motor before it reaches the top of the curtain, and must also be adjusted to stop the curtain before it hits the bottom of the curtain opening.
2. Verify that all the toggle switches are labeled with what is being controlled.
3. Using the VentGenie and CMR manual override toggle switches, verify that the curtain’s open and close are not swapped.
4. Verify equipment stops and starts via the manual toggle switches on the VentGenie.
5. Verify temperature readings on the VentGenie screen. Verify the wind meter LED blinks when the wind meter rotates.

The faceplate & menu system

The front of the VentGenie Master Controller is called the “faceplate” and contains three general sections:

• The screen and menu buttons – where you enter and change the VentGenie parameters.
• The toggle switches – overrides for the ventilation system. The overrides are absolute; the controller cannot switch the circuit on if the switch is in the manual position.
• Important settings – for your convenience, the most important curtain settings are printed on the faceplate.

The blue menu screen shows two parts: the Parameter ID and the parameter value (or set point). The parameter ID is a unique identifier for each parameter – the first letter identifies the submenu while the number designates the parameter in that submenu. The parameter value (or set point) is shown in the lower right corner of the screen.

Using the menu

• Accessing the menu: press the button marked “Up Enter.”
• Selecting a submenu: scroll through the list of submenus using the Menu Up and Down buttons, then press the Save/Enter submenu button to access it. Each submenu shows a Menu ID in the top left corner.
• Changing a value: scroll through the available parameters using the Up and Down buttons, then use the decrease and increase buttons to raise and lower the value. Press Save to save the setting – the screen displays “saved” whenever a parameter is changed.

Curtain parameters

The VentGenie System controls curtain motors and machines to provide the optimum environment for the cows at all times using the exclusive VentGenie “Temperature Differential Technology.” This technology provides greater cow comfort all year round. When it is raining and windy, the curtains can automatically shut using the optional rain sensor, which helps keep the stall beds drier. The electronic overload safely stops the curtains when the curtain motor draws too much electricity because the curtain movement is impeded.

Temperature Differential Technology

The temperature differential technology compares the inside temperature of the barn against the outside temperature. This is expressed as the “temperature differential.” The barn’s temperature differential changes with the animal stocking density and wind speed. The curtains use this temperature differential to decide if they should open or close. You can modify the desired temperature differential settings to suit your barn’s specific ventilation needs.

Wind chill

Wind chill is a response to the wind. The colder it is outside, the more it affects the curtains. Wind chill works by having the curtains try to raise the barn temperature. It only affects the curtains on the side facing the wind. Modifying the desired wind chill affects how quickly the curtains shut. The top and bottom curtains each have their own desired temperature differentials and wind chill settings.

The VentGenie screen continuously loops through different temperatures and settings so you can tell what the ventilation equipment is “thinking.” Part of this loop displays each curtain’s desired opening and closing settings.

Curtain deadspans & miscellaneous (Menu F)

These additional parameters affect the operation of the curtains. The defaults are set to provide the best control for most situations. Typically these do not need to be adjusted unless you fully understand how the curtains operate.

Rain & bedding saver

Closing curtains when it rains: rain is sometimes a problem when it is warm and wind blows the rain inside. You set the MPH it takes to close a curtain when it is raining.

Bedding saver: at times strong wind blows bedding out of the stalls, usually in summer when you normally want curtains open. You set the MPH it takes to close a curtain so bedding does not blow out of the stalls.

Knowing if the controller thinks it is raining

On the faceplate is a Rain LED light (labeled Rain). This LED is lit whenever the VentGenie senses rainfall. It blinks if it is too hot (temperature override). The rain and bedding saver turn off if it is too hot (95°), for safety purposes. You can adjust the 95° with parameter [C1]. When the temperature is above the override threshold, the rain LED will blink.

Setting the thresholds

Wind MPH threshold: the wind speed it takes for wind to blow water into the barn. A curtain closes during rain only if wind MPH is above the threshold. There is an individual threshold for each curtain. Typically bottom curtains can be set to 4 MPH and top curtains to 8 MPH, depending on barn design. The curtains only respond to rain that hits their side of the barn.

Bedding saver thresholds: the wind speed MPH for bedding to blow out of the stalls. A curtain immediately runs fully shut when wind MPH exceeds its threshold. Typically a bottom curtain could be set to shut at 12 MPH. The top curtain would be set to 0.0 so it would not shut, because normally the top curtain stays open for ventilation. The curtains only respond to wind that hits their side of the barn.

Preventing top and bottom motor collisions

If top and bottom curtains are set to the same MPH, the top curtain might close first. To prevent this, set which curtain # must shut first. Set bottom curtains to 0.0.

Curtain setup & location

Where you mount the curtain plays an important role in controlling the curtain. Each curtain’s location only needs to be set during installation.

• Garage doors are typically only connected when VentGenie Tunnel Mode is used. They get a short pulse each time the VentGenie switches ventilation modes.
• Ceiling baffles are motorized curtain-fabric baffles hung from the ceiling to reduce the cross-sectional area in a tunnel ventilated barn. They are lifted up in Natural Ventilation mode and dropped down in Tunnel Mode, typically only when Tunnel Mode is used. The baffles are switched on for parameter [F4] seconds each time the VentGenie switches ventilation modes.

Setting the location of each curtain (Menu D)

Decide which location best describes each of the curtain circuits:

Parameters D1 (C#1 is a…) through D24 set the mounted location for each curtain. Default is 1 (Bottom N West); range 1 (Bottom N West) to 19 (Ceiling baffle). There are a maximum of 24 parameter IDs for setting curtain locations.

Wind chill direction control

Each curtain’s wind chill uses only a portion of the wind when the prevailing wind is coming from the opposite direction that the curtain is facing. You adjust which wind directions the curtain responds to with the percentage of wind used.

Curtain inputs & electronic overload

The VentGenie has “Curtain as Door” functionality to fully open or close a curtain with a pushbutton mounted beside the access point. The curtain is switched on for parameter [F4] seconds whenever the pushbutton is pressed. After a curtain is operated, it waits 20 minutes before going back to normal ventilation mode. If you do not wish to use a “curtain as door,” set the curtain’s input to 0. (See Menu G under Inputs above.)

Curtains electronic overload

The VentGenie’s curtain Electronic Overload is an integrated electronic overload sensor to interrupt the curtains when the curtain motors overload. It is an auxiliary safety function and does not replace electrical fusing. Two modes are available:

• AutoReset: allows the curtain to continue to operate if the curtain can still go in the opposite direction it had overloaded in.
• Stopdead: disables the curtain completely until it is manually cleared.

Knowing how many amps a curtain normally uses

After the system is installed and powered and all curtains are functioning properly, you can find out how many amps each curtain motor draws. The VentGenie Master displays the amp load on the screen any time there is more than .8 amps.

1. Switch all the curtains’ toggle switches to manual off.
2. Cycle each curtain with the toggle switches, fully open and closed, while watching how many amps each curtain takes.
3. Take note of the amp load for each curtain.

The curtain motors will take more amps in the winter because the fabric is colder (stiffer) and rolls harder. Typically you can set the amp limit 25% more than what the curtain normally uses (especially for DC curtain motors). It takes trial and error to decide how close you can set the amp limit without causing nuisance tripping.

When a curtain overloads, the screen displays “Curtain #x is overloaded” and “Press Save to clear.” The controller will not energize that curtain again until the overload is cleared (you can still run the curtain with the toggle switches). To clear the overload, press the Save button, then physically inspect the curtain – often something is impeding curtain movement.

VentGenie tunnel mode

VentGenie Tunnel Mode is intended for barns which automatically switch between natural and tunnel ventilation. It uses temperature, humidity and wind to decide when the barn should be in tunnel mode. It can even reduce the number of fans running whenever a sliding curtain is switched on, to prevent the sliding curtain from sticking to the wall. There is a four second delay between each fan circuit start to prevent the fans from all starting simultaneously.

The “tunnel mode temperature” is the barn temperature plus parameters [P2] and [P3] if the humidity or high temperature is triggered. The VentGenie goes into tunnel mode whenever the tunnel mode temperature exceeds the tunnel start temperature [P1]. To keep from cycling modes too much, adjust the temperature deadspan [P16]. When wind MPH exceeds [P4–P6] the VentGenie goes into natural mode and stays there until the wind slows below the wind deadspan [P17].

Other tunnel mode information

Manual control: closing the circuit for Input #19 puts the barn into natural mode; closing Input #20 puts the barn into tunnel mode. If the system was specified for a tunnel ventilated barn, there will be a toggle switch for the ventilation mode override installed in the VentGenie Master; you can add this switch at any time or wire an external switch.

Power failure: when a battery backup is installed, the VentGenie checks the voltage of the main power supply. If there is a power failure, the barn goes into natural mode unless it is set manually in tunnel mode, and the tunnel fans automatically turn off.

Curtain open, closed or nixed in tunnel mode (Menu R)

Each curtain is set to be open, closed or nixed in tunnel mode. The curtains across the air inlets are typically open in tunnel mode. When in tunnel mode, curtains set to open will not respond to rain or temperature until tunnel fans turn off. If you want some curtains to ignore tunnel mode, set those curtains to Nixed.

Sliding curtains that stick (SP sensitive) – Menu S

When sliding curtains are used on a tunnel mode barn, the curtain may not slide because the vacuum from the fans is holding the fabric to the sidewall. A curtain that sticks this way is called “SP sensitive.” You set the maximum amount of fans that can run when any SP-sensitive curtain is moving (parameter P11) and which curtains are SP sensitive (Menu S).

Curtain reopen (Menu U)

A curtain that is closed in tunnel mode can be set to “Reopen” several seconds to allow a small opening, letting fresh air in the length of the tunnel ventilated barn.

Tunnel fan start sequence (Menu Q)

The tunnel fans use the same start temperatures as any other fan (set per fan in Menu H). Menu Q simply sets whether or not the fan looks at tunnel mode for its operation.

Circulating fans

The circulating fans can be affected by tunnel mode functions. They can turn off when it is windy outside or if cows are not in the pen, to save electricity. They can start sooner when the humidity or high temperature is triggered. The fans look at the “circulating fan temperature” to decide if the barn is warm enough to begin running. When humidity is triggered, several degrees [M2] are added to the circulating fan temperature; when high temp is triggered, additional degrees [M1] are added.

The circulating fans can shut off when enough wind is blowing on the outside of the barn to save electricity. The amount of wind required increases with temperature, set by [M3] (at 55°), [M4] (at 65°) and [M5] (at 80°). After the wind has shut off the fans, the deadspan [M10] sets how much the wind must decrease before the fans switch on again.

Fan location (Menu I), circulating fan inputs (Menu J), and % wind used per fan location (Menu K) further refine how each bank responds.

Variable speed fans (0–10 volt)

The variable speed module is an optional addition designed to control the speed of HVLS fans. It does not control the starting temperature of these fans – the start signal is provided by a VentGenie circulating fan.

Controlling the speed signal

The speed of the fans is ramped between the Low [L1] and High [L2] temperatures, using the “circulating fan temperature.” When the circulating fan temperature is below the Low temperature, the 0–10V signal remains at the low speed [L3]. This lets the fans rotate at a flat-line speed when the start/stop circuit is switched on at a cooler temperature than Low. When the circulating fan temperature is at the High temperature, the speed signal is at 100%.

Manual speed control

The 0–10v signal can be manually held to a constant speed. The manual speed [L4] is where you set the desired constant speed. On the Variable Speed Module there is a switch marked Auto, Off, and Manual; set the toggle switch to manual to switch the fans to the manual speed.

Sprinklers

The sprinkler function is intended for soaker-type functionality. The amount of water used and how often it sprays is controlled by the temperature and optionally by the humidity. The sprinkler zones look at the “sprinkler temperature” to decide when the barn is warm enough to begin sprinkling the cows. When humidity is triggered, the humidity trigger adds several degrees [N23] to the sprinkler temperature; when high temperature is triggered, the high temperature trigger adds additional degrees [N22].

The sprinklers activate when the sprinkler temperature reaches the Low temperature [N1]. Each zone switches on consecutively. The sprinkle time ramps between Low and High sprinkle seconds with the barn temperature; each zone has its own sprinkle seconds. The dry off / interval time ramps between Low [N3] and High [N4] dry-off minutes with the barn temperature; all zones share the dry off / interval time.

Sprinkler humidity settings

The humidity settings allow the water usage to change as the humidity rises, reducing water at high humidity, expressed as a percentage change compared to the normal sprinkler settings.

• Dry off time: increases as the humidity climbs above the Dry Off Base Humidity [N19], continuing until the humidity reaches 95%. At 95% RH the dry off time is increased by [N20] percent (expressed as % of interval time). Unaffected by humidity if [N20] is zero.
• Spray time: decreases as the humidity climbs above the Sprinkle Base Humidity [N17], continuing until the humidity reaches 95%. At 95% RH the sprinkle time is reduced by [N18] percent (expressed as % of sprinkle time).

Thermostats

The VentGenie has thermostat ability. You can use it to control heaters or cooling pumps. High or low humidity functions are programmed into the thermostat logic. The idea of the humidity logic is for cardboard cooling pad pumps. For example, with a thermostat set for 70° and Max humidity set to 80%: as temperature rises the pump turns on, but then humidity climbs above 80% and the cooling pad turns off; since the pad is off, humidity begins to drop, and the cooling pad restarts.

Effective temperature triggers

The VentGenie computes an effective temperature for the fans and sprinklers. Effective temperature makes the cooling equipment stay on longer during high-stress periods, providing additional cooling when the cows’ core body temperature may be elevated. It is calculated using the “Humidity” and “High Temperature” triggers.

High temperature trigger

The high temperature trigger looks at the running average temperature, usually set to 12 hours. If it was extra hot in the last 12 hours, the fans will usually stay on for an extra 5°. This trigger is activated whenever the average temperature exceeds [V1]. The high temp trigger adds [N22] to sprinklers, [M1] to circulating and variable speed fans, and [P2] to tunnel mode.

Humidity trigger

When the humidity is high, it too increases the effective temperature. When humidity exceeds the RH% trigger point [V3], usually an additional 5° is added. The humidity trigger adds [N23] to sprinklers, [M2] to circulating and variable speed fans, and [P3] to tunnel mode.

Configuration menu

The configuration menu contains the parameters that control the setup and functions of the VentGenie System. Do not modify these parameters unless you understand the function of each one. To access the Configuration Menu, turn off all power to the VentGenie Master controller, then power it while pressing the Enter Menu button. The screen displays “Config menu, use with care.” You are now in Menu A.

Understanding screen information

When you are not working in the menus and the system is active, the VentGenie screen automatically scrolls through status information about the curtains, sprinklers, and fans. Only the screens relevant to your configuration are displayed; for example, if the number of sprinklers is zero, no sprinkler information is shown.

• Temperature screens: show the inside and outside temperature with the barn’s current temperature differential (e.g., “In 69.8° Out 65.0, 4.8° difference”), the readings from the first four sensors, and the reading from sensor #5 and the humidity sensor. A sensor that is disconnected or shorted is not displayed.
• High temp & humidity trigger screens: four screens show whether the high temperature and humidity triggers are active.
• Wind information screen: shown only when MPH is above zero (e.g., “5.3 MPH from E”).
• Curtain screens: show each curtain’s desired open and close temperature differential and its location (e.g., “C#1 opens at 1.8° difference,” “C#1 closes at 2.1° difference,” “C#1 is a Bottom North”).
• Circulating fan screen: shows the circulating fan temperature.
• Sprinkler screens: show the sprinkler temperature, the cycle length, and, with humidity compensation, the interval % and spray time % the sprinklers are using.
• Tunnel mode screens: shown only when tunnel mode is used; they show the tunnel mode temperature, mode-switch timeout, remaining tunnel-fan run time, and whether the system is manually fixed in natural or tunnel mode.
• Curtain overload screens: displayed when a curtain is overloaded (e.g., “Curtain #6 is overloaded,” “Press Save to clear”).
• Electronic amp meter screens: show the amps a curtain is using and the amps at which it trips, displayed whenever at least 1 amp is detected.

Latching output relays in an emergency

The output relays can be manually latched on so the ventilation equipment can be switched on even if the VentGenie System is not powered. To latch a relay on, lift the tab on the cover of the output relay and push until the tab points straight out. Normally the tab is flush with the cover.

Toggle switch override

The VentGenie System toggle switches are independent of the controller. The controller does not know when you have a circuit manually switched on with a toggle switch.

Troubleshooting

Common wind meter problems

“The anemometer head is tilted when I mount the wind meter.” With the Allen wrench provided, loosen the screws holding the wind meter head on the arm (on the bottom of the head). Turn the head so it is straight and tighten the screws.

“The wind cups are spinning, but the wind wheel LED does not blink.” The signal may not be making it back to the display. Remove the cups (loosen the set screw), put them back on the shaft as far as possible, check the cables for nicks and cuts, and look for corrosion on the connector and jack. If using an extension cord, remove and test using only the wind meter cable. Make sure the wind meter is plugged into the jack marked Wind.

“The wind direction is stuck on Northwest.” Likely a short between the wind vane and the VentGenie. Check the cables for nicks or cuts, check for corrosion on the Wind jack, and confirm the wind meter is plugged into the jack marked Wind. If using an extension cord, remove and test using only the wind meter cable.

“The wind cups don’t spin or don’t spin as fast as they should.” The wind may be blocked, or friction may be interfering. Remove the cups (loosen set screw) and clear out any debris. Turn the shaft; if it feels gritty or stiff, contact your AutoVent Dealer.

“The readings are not what I expected.” Comparing the wind speed to newspaper, weather reports or neighbors is NOT a valid method of verifying readings. Readings can vary significantly over short distances. If you have questions, contact AutoVent LLC.

Temperature sensor problems

“Not all the temperature sensors are shown on the screen anymore.” The VentGenie automatically senses when a sensor is disconnected or shorted and removes its reading from the display. Check that the sensors are firmly connected by tugging on each wire, check the wires for cuts, and check all connections.

“A temperature sensor reading is way too low.” The wire most likely has an intermittent connection. Check the connection at the VentGenie and check for corrosion at any connections.

“A temperature sensor reading is too high.” A sensor may be exposed to direct sunlight (it is important that it is not). Check all the connections for corrosion.

Other possible issues

“An output relay seems burned out.” Relays can burn out and still show their indicator light on. Swap relays to see if you can replicate the problem in another circuit. Replace relays as needed.

“I am controlling a VFD with an output relay, and it does not seem to make a connection.” Try connecting the wires manually to verify your VFD is working. Low voltage circuits do not arc enough to “clean” the output relay’s contact surface; try a new relay or contact AutoVent LLC for a special low voltage relay. Make sure your 0–10v speed signal is connected and working correctly.

Curtain motors troubleshooting

“The curtain motors do not run.” For 24 VDC curtain motors, the power supply fuse may have blown – check the fuse in the curtain motor power supply box and check for voltage from the supply. For AC curtain motors, check the fuse/breaker supplying the curtain motors.

“Only one curtain does not run.” If using Auto-Reset overload mode, the curtain may have overloaded and not yet reset; removing power to the VentGenie and repowering will reset the partial overload. Check for loose wires. Check the curtain motor limit switches to make sure they stop the motor before the curtain fabric is wound tight.

New features & updates

• V4.22: Changed where the rain meter connects to the computer board. Now input 18 is usable even when the rain sensor is installed.
• V4.28: Added F16 – how long the curtain stays open after a wireless remote is used is now adjustable. Added an option for an 18 second pause before another curtain can activate. Added an option to adjust an individual curtain’s runtime from 2–255% of normal. Added an option to multiply an individual curtain’s pause minutes from 1–200× (intended so garage doors only move once per x hours). Added a basic HMI for PC, logging ability for PC, and changed the screen logic so a partially overloaded curtain is displayed.
• V4.42: Added humidity logic to thermostats. Fixed a bug that sometimes increased the time for a curtain’s rain closing time.
• V4.43: For tunnel ventilated systems, allows some curtains to ignore tunnel mode.
• V4.65: Added wind direction to the tunnel logic, allowing each of the 8 directions to be adjusted individually (Menu M). Removed the tunnel fan start pattern – any previously called circulating fans can now look at tunnel mode and start and stop with it if it is warm enough for that fan. Changed so an electric outage can stop tunnel mode even if it is forced into tunnel. Changed the wind minutes parameter so it runs a rolling average, settable as high as 50 minutes.

Glossary

• Mapping Relays: the process of setting how many curtains, fans, and sprinklers the VentGenie is controlling and which relays will be used.
• Output Relay: the relays on the inside of the VentGenie enclosures that control all the ventilation system components.
• VFD: Variable Frequency Drive. Typically used on larger HVLS fans, these units provide variable speed control to large motors.
• VentGenie Tunnel Mode: when the VentGenie controls the transition of the curtains and the fans to and from natural to tunnel ventilation.

Specifications

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