WattMaster Water Source Heat Pump Operations Manual

WHP - Water Source Heat Pump

Design, Installation &

Operations Manual

Revision 02A

WattMaster WHP

Installation & Operations Manual

Section 1.................................................................................... Design Guide

Section 2................................................................... Installation and Wiring

Section 3....................................................................................Programming

Section 4....................................................... Start-Up and Troubleshooting

This document is subject to change without notice.

WattMaster Controls, Inc. assumes no responsibility for errors, or omissions herein.

WHP Installation & Operations Manual - Form WM-WHP-IO-02A

Copyright 2004 WattMaster Controls, Inc.

All rights reserved.

Section 1

Table of Contents

Conventions ..................................................................... 1

General Information......................................................... 2

Water Source Heat Pump Units .......................................................................................2

Water Source Heat Pump Systems ..................................................................................3

WattMaster WHP Control System...................................................................................4

WHP Controller ...........................................................................................................4

Make Up Air Controller...............................................................................................5

WHP Sequence of Operation ........................................... 6

HVAC Mode of Operation...............................................................................................6

Occupied/Unoccupied Mode of Operation ......................................................................7

Vent Mode Operation ......................................................................................................7

Off Mode of Operation ....................................................................................................7

HVAC Operation w/ Reversing Relay.............................................................................8

HVAC Operation w/ Heat/Cool Relays ...........................................................................9

WHP Loop Controller Sequence of Operations ............. 10

Summary ........................................................................................................................10

Pump Control .............................................................................................................10

Pump VFD Control ....................................................................................................11

Compressor Control ...................................................................................................11

Heat Rejection Control ..................................................................................................12

Staged Heat Rejection................................................................................................12

Heat Addition Control ...................................................................................................12

Staged Heat Addition .................................................................................................13

Proportional Heat Addition........................................................................................13

Water Temperature Alarming ........................................................................................14

Fire Alarm......................................................................................................................14

Notes: ............................................................................. 16

Table of Figures

Figure 1-1: Typical Water Source Heat Pump..............................................................3

Figure 1-2: Typical Water Source Heat Pump System.................................................3

Figure 1-3: Typical WattMaster WHP System...........................................................15

Design Guide

WattMaster WHP

Section 1

Conventions

This document uses the following definitions throughout as a guide to the user in determining the nature of the information presented:

Note: Additional information which may be helpful.

Tip: Suggestion to make installation, set-up, and troubleshooting easier.

Caution: Items which may cause the equipment not to function correctly but will not otherwise damage components.

Warning:

Errors which can result in damage to equipment and void warranties.

Design Guide

1-1

Section 1

WattMaster WHP

General Information

Water Source Heat Pump Units

A water source heat pump is a self-contained water-cooled packaged heating and cooling unit with a reversible refrigerant cycle. Its components are typically enclosed in a common casing, and include a tube-in-tube heat exchanger, a heating/cooling coil, a compressor, a fan, a reversing valve and controls .

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Design Guide

WattMaster WHP

Section 1

Figure 1-1: Typical Water Source Heat Pump

During the cooling mode, the tube-in-tube heat exchanger functions as a condenser and the coil as an evaporator. In heating mode, the tube-in-tube heat exchanger functions as an evaporator and the coil as a condenser. A reversing valve is installed in the refrigerant circuit permitting changeover from heating to cooling, and vice versa. The condenser and evaporator tubes are designed to accept hot and cold refrigerant liquid or gas.

Water Source Heat Pump Systems

The water source heat pump system is, by definition, a heat recovery system. It is best applied to buildings that have simultaneous cooling and heating loads. This is the case during winter months when the interior zones of a typical building require cooling while the exterior zones require heating. When a water source heat pump system is used, the heat rejected by the cooling units is used to warm the zones calling for heat. A water heater is generally used for adding heat to the condensing water during peak heating periods, if necessary. The system also utilizes a water cooling tower to reject the heat energy from the condenser water loop during periods of high cooling demand.

Water source heat pump units can be suspended in the ceiling plenum, floor mounted behind walls or placed directly in the occupied space as a console unit. There are also rooftop and unit ventilator type water source heat pumps.

Figure 1-2: Typical Water Source Heat Pump System

Water source heat pump systems generally cost less to install than central built-up systems. They offer individual zone control with the added flexibility of being able to

Design Guide

1-3

Section 1

WattMaster WHP accommodate changes in location and sizes as thermal zones or zone occupancy change.

This system is often installed in ceiling plenums, which frees up valuable floor space.

Another valuable benefit of water source heat pumps is that they can accommodate simultaneous calls from zones requiring heating or cooling. Depending on the climate, outside air may require preheat or cooling prior to being introduced to the unit. In the example of ceiling mounted water source heat pumps, put outside air ducts near each unit to improve indoor air quality.

Normally, multiple units serve an occupied space. This gives component redundancy to the system so if one unit were to fail, the other units could back it up until the unit was repaired. The packaged design of most unit types allows quick change-out by service personnel so maintenance can typically be performed off site.

As with any HVAC system, there is a negative side as the water source heat pump system often requires higher maintenance costs than conventional air side systems. The system also typically has a shorter replacement life than other systems because of continuous fan and compressor operation during heating and cooling modes. The system can also create room noise since the compressor and fan are commonly located close to the zone occupant. Placing units away from the occupied space and ducting the supply air to the zone can minimize potential noise problems.

WattMaster WHP Control System

The WattMaster WHP system is used to control the water loop and the individual water source heat pumps installed in a typical water source heat pump system. The WHP system is an excellent alternative over programmable thermostats. The WHP control system provides one central location to monitor and program all the water source heat pumps on the system instead of having to program each water source heat pumps thermostat individually. The system has many features typically not found with programmable thermostats such as: central operators interface, heating/cooling failure alarm, auxiliary alarm, and holiday scheduling, to name but a few.

WHP Controller

The Water Source Heat Pump Controller (WHP) is used for controlling individual water source heat pump units. The WHP Controller can operate stand-alone or it can be used with the Water Source Heat Pump Loop Controller and in this configuration shares common data, such as outside air temperature, proof of flow etc., over a network. A

System Manager is connected to the WHP Controller to provide a central operators interface to all WHP Controllers on the network. WHP Controllers are designed with

Room Temperature, Room Setpoint Adjust, Discharge Air Temperature, Leaving Water

Temp or Dirty Filter Alarm and Auxiliary Lockout inputs. Relay outputs provided are;

Fan (Continuous or Cycling), Reversing Valve-ON/OFF, Compressor-ON/OFF, Heat

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Design Guide

WattMaster WHP

Section 1

Pump Reset and Aux. Heating or Cooling. An internal seven day schedule and holiday schedule functions are also built into each WHP Controller.

With the WHP system the sometimes complex control requirements of a large water source heat pump system can be handled with an off the shelf controls system that has most of the features of a full blown building automation system but at a much lower cost.

Included with the WHP system is a communications interface module, which allows you to connect a computer to the system onsite and a modem connection for remote monitoring.

Prism, a Windows based software package is available at no additional charge. Some of

Prism’s features include graphics, trend logging, and remote alarm call out capabilities.

WHP Loop Controller

The Water Source Heat pump Loop Controller can be supplied with the system to control the water loop and its various pieces of equipment. The Loop Controller can operate stand-alone or used with the Water Source Heat Pump Controller (WHP) and in this configuration communicates common data, such as outside air temperature, proof of flow etc., over a network. A System Manager is connected to the Loop Controller to provide a central operator’s interface to the Loop Controller’s setpoints and operating configurations. The Loop Controller is designed with inputs for Supply and Return Water

Temperature, Outdoor Air Temperature, Loop Water Pressure Switch or 0-50 PSI Loop

Pressure Sensor (4-20ma), Manual Reset Contact, Phase Loss Contact, Request to Run

Relay, and Fire/Smoke Relay. Analog outputs (0-10VDC) are supplied for Pump VFD and Proportional Heat. Binary outputs are provided for Compressor Enable, Main Pump

Relay, Standby Pump Relay, Alarm Contacts and (8) Relays that can be configured for

Heat Rejection or Heat Addition.

Make Up Air Controller

A Make Up Air Controller, for treating 100% outdoor air, is available for use with the

Water Source Heat Pump system. Please consult factory for more information on this product.

Design Guide

1-5

Section 1

WattMaster WHP

WHP Sequence of

Operation

HVAC Mode of Operation

There are four possible modes of operation. These are Cooling Mode, Heating Mode,

Vent Mode, and the Off Mode. The HVAC mode of operation is calculated the same way in both occupied and unoccupied modes of operation.

Off Mode The schedule is off and no overrides are active. There is no heating or cooling demand in the space. Under these conditions, all outputs will be off and the analog output will be set to 0.0 vdc.

Vent Mode No heating or cooling demand exists during the occupied mode of operation. The fan will be on if the WHP is programmed for Constant Fan operation. The compressor demand request will not be sent to the Loop

Controller. If no WHP units are sending a request, the Loop Controller will discontinue operation after 15 minutes.

Cool Mode A cooling demand is generated when the space temperature rises half the amount of the Deadband Setpoint above the currently active Cooling

Setpoint. The space is considered satisfied when it drops that amount below the Cooling Setpoint.

Heat Mode A heating demand is generated when the space temperature drops half the amount of the Deadband Setpoint below the currently active Heating

Setpoint. The space is considered satisfied when it rises that amount above the Heating Setpoint.

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Design Guide

WattMaster WHP

Section 1

Occupied/Unoccupied Mode of

Operation

Since the WHP contains its own built in Real Time Clock, it can operate from its own internal scheduling system. This schedule supports two Start & Stop events per day and up to 14 Holiday periods. The Holidays all use the same special Holiday Start/Stop times programmed by the user.

If the current operating mode is unoccupied, the WHP can accept a push-button override back to the occupied mode. Push-button overrides are not recognized if the current mode is already occupied. The push-button override duration is user programmed. If the user wants to extend the current override without reprogramming the Duration, they can reinitialize the existing programmed period by pressing the override button anytime during the current override. If the current override had been active for 1 hour and 45 minutes and the user presses the push-button again, the override will reset for another 2 hour period (if

they programmed a 2 hour period), bringing the total override time to 3 hours and 45 minutes. If the user wants to cancel an override before it can time-out, simply hold the push-button for a period of time between 3 and 10 seconds.

The WHP calculates its current heating and cooling setpoints based on the current mode of operation. If the command is for unoccupied mode, the WHP adds the unoccupied setbacks to the occupied heating and cooling setpoints.

Vent Mode Operation

During occupied hours when there is no heating or cooling demand, the WHP reverts to a

Vent Mode of operation. The fan is running and the heating and cooling outputs are held off.

See the section titled HVAC Mode of Operation for a graphical description of how the

Vent Mode is calculated.

Off Mode of Operation

After the schedule goes unoccupied and both heating and cooling demands go away, the fan stops running, all relay outputs are turned off. No outputs are allowed to activate in the Off Mode until a heating or cooling demand occurs. During occupied hours this would be the Vent Mode.

Design Guide

1-7

Section 1

WattMaster WHP

HVAC Operation w/ Reversing Relay

If the user has configured the WHP to control a Reversing Valve and a Compressor, the following sequence of operation occurs during a heating or cooling demand.

Note: If you configure the WHP to look for a proof of flow Enable signal from the

Loop Controller then the following sequence assumes a request was made by the WHP during a demand condition and that the Loop Controller gave permission for the WHP to start its compressor. Otherwise, the WHP will ignore the Enable signal and operate anytime there is a heating or cooling demand.

a. b. If the unit is configured to control an Isolation Valve, the valve relay is activated ( Relay #5 ). The Minimum Off Timer is reset to ZERO and must be satisfied before any further operations are allowed.

c.

If the last mode was the opposite of the current demand mode, make sure the Changeover Delay has been satisfied.

If the current mode requires the Reversing Valve to be activated, its relay contact is closed and a 10 second delay is started.

d. Ten seconds after the Reversing Valve is activated, the Compressor relay is activated.

e. If the Space Temperature continues to exceed the affected setpoint by the full amount of Deadband and you have configured for 2 stages in the current mode of operation, relay #5 will activate for the second stage of heating and/or cooling. A second stage of either implies that no Isolation

Valve exists!

f. Once the Space Temperature has crossed back over the affected setpoint, stage 2 will be turned off if the unit has a stage 2.

g. As the Space Temperature continues to cross back over the affected setpoint by half the Deadband value, the compressor will then be allowed to turn off if the Minimum Run Time has been satisfied.

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Design Guide

WattMaster WHP

Section 1

HVAC Operation w/ Heat/Cool Relays

If the user has configured the WHP to control Individual Heating and Cooling relays the following sequence of operation occurs during a heating or cooling demand.

NOTE: If you configure the WHP to look for a proof of flow Enable signal from the

Loop Controller then the following sequence assumes a request was made by the WHP during a demand condition and that the Loop Controller gave permission for the WHP to operate its heating or cooling. Otherwise, the WHP will ignore the Enable signal and operate anytime there is a heating or cooling demand.

Once a heating or cooling demand exists, the following conditions must be met before any relays can be activated: a. Make sure any stages of the opposite mode are staged off.

b. Verify the system has been configured for at least one stage of heating or cooling.

c. Make sure the Minimum Cycle Time has been satisfied.

d. If the last mode was the opposite demand mode, make sure the

Changeover Delay has been satisfied.

e. Check the current Minimum Off Timer to make sure this stage has been off long enough since the last time it was cycled on and back off.

f. g.

If there is more than 1 stage, check the Minimum Run Time from the previous stage to be sure it has elapsed before activating the second stage.

Make sure the Space Temperature Demand is the full amount of Deadband from the setpoint before activating the second stage.

h. Once the compressor or stage 2 has been turned off, a Minimum Off Time must be satisfied before it can stage on again. A Minimum Cycle time can also be utilized to limit the number of times per hour that the compressor can be activated. If you don’t need this limitation, set the Minimum Cycle

Time to be shorter than the Minimum Run Time setpoint.

i. If the Reversing Valve was configured to cycle with the compressor, it will now turn off also. It can be configured to remain active until the opposite mode of operation is called for to reduce wear on the valve.

Design Guide

1-9

Section 1

WattMaster WHP

WHP Loop Controller

Sequence of Operations

Summary

The Water Source Heat Pump Loop Controller waits for a Request to Run signal from a

Heat Pump or from a Binary Contact Closure. Once the request is received the Loop

Controller activates a Pump to initiate water flow to the Heat Pumps. Once the pump is activated and proof of flow has been determined, a Global is broadcast to all Heat Pumps to enable them to go ahead and run their compressors. The main goal of the Loop

Controller is to provide water flow and to maintain the loop water temperature by monitoring either the Loop Inlet or Loop Outlet temperature. If a higher temperature is required, Heat Addition is enabled. If the temperature needs to be lowered, Heat

Rejection is enabled.

Once the Loop Controller has been activated by a request, it will run for a minimum of 15 minutes to prevent cycling on and off due to borderline requests from the Heat Pumps.

If a Fire Alarm is detected, the Loop Controller generates a Global broadcast to all Heat

Pumps to turn off.

If the High Pressure option is configured, the Loop Controller can generate a Global broadcast to force the Heat Pumps to open their Isolation Valves to reduce loop pressure if the high limit has been exceeded.

Pump Control

If WattMaster Water Source Heat Pump Controllers are used in conjunction with the

Loop Controller, a Global Binary signal from the attached Heat Pumps sends a Request to run or Enable to Run command to the Loop Controller. If the Loop Controller is used in a stand alone configuration, a contact closure on the AIN 2 of the Analog Expansion board gives the controller a request to run. When a request to run is received, the Loop

Controller activates a pump to initiate water flow to the heat pumps. The pumps can either be constant flow or controlled by a VFD. If the request goes away for at least one minute, the request to run command is removed. If the loop controller has been running a minimum of 15 minutes then it can be turned off, since there is no longer a request to run.

If the proof of flow is lost while the pumps are running, the pump is shut off immediately if the changeover to the Standby Pump had already been made.

The pumps are Lead/Lag controlled based on a user definable number of hours. If one pump exceeds the other pumps run time by this amount, the lead is changed until that

1-10

Design Guide

WattMaster WHP

Section 1 pump exceeds the first pumps run time by the same amount. This keeps both pumps with roughly the same number of hours on each pump. Changeover occurs at the time the run time setpoint is exceeded. The running pump is shut off at the same time the standby pump is energized, this prevents any down time or alarms. The unit can be configured to control either the Loop Inlet temperature or the loop outlet temperature.

A user adjustable low outdoor air temperature setting of XX degrees will allow the unit to run the pumps continuously for protection against freezing.

If the pump is constant volume, and the pump has been started, it has 3 seconds to generate flow or the standby pump is activated. If the pump is controlled by a VFD, once it starts, it has 60 seconds to generate flow and if it doesn’t the standby pump is activated.

If the standby pump fails, an alarm is generated and the Loop controller deactivates any active heat rejection or addition stages. At the same time an alarm is generated, we energize relay #5 on the Loop Controller board so that it may used to turn on a local alarm signal.

Loop flow can be determined by a binary contact closure on input #3 or a 0 to 50 PSI pressure sensor on input #3. If a pressure sensor is used, the user can program the pressure setpoint that needs to be met for proof of flow.

Pump VFD Control

An optional Pump VFD signal can be modulated if the system is configured for proportional control and a pressure sensor is attached to analog input #3.

At a user defined rate, the VFD signal is ramped up when the pressure is below a user defined setpoint by a user defined deadband. The signal ramps down when the pressure exceeds the setpoint by the deadband value. If the pressure ever exceeds the high pressure setpoint, an emergency override activates and begins cutting the VFD signal in half each time the control loop is polled by the software. This protects against run away over-pressurization.

The pump relay outputs are still activated and Lead/Lagged as described above and the pump relay remains on until the Request signal is removed, provided it has been operating for at least 15 minutes.

Compressor Control

Anytime a pump is running and proof of flow has been established, the compressor output is activated.

Design Guide

1-11

Section 1

WattMaster WHP

Heat Rejection Control

If the compressor is not running, no heat rejection can be active. If any heat rejection is still active when the compressor is turned off, the heat rejection will be immediately removed, without regard to any minimum run or off times.

Heat rejection cannot be active at the same time as heat addition, so any heat addition is removed or staged off before the heat rejection can be started.

A maximum of 8 stages of heat rejection can be controlled.

Staged Heat Rejection

Heat Rejection is staged up based on a different deadband level for each stage. Basically, if the user programmed a 2° deadband, then the first stage could activate at the setpoint, stage 2 would activate 2° above the setpoint, stage 3 would activate 4° above the setpoint, etc...

Staging down is calculated in the same manner, except the water temperature would need to drop below the setpoint by the deadband amount. If stage 3 was activated at 4° above setpoint, it would de-activate when the temperature fell to within 2° of setpoint, stage 2 would de-activate at setpoint and stage 1 would de-activate 2° below setpoint.

A user defined staging up and down interval must be met before any heat rejection stages can be added or removed. If the selected Water Temperature is above the current staging level and the timer has been satisfied, an additional stage can be added, up to the maximum available 8 stages. If the selected Water Temperature is below the staging down level and the timer has been satisfied, a stage can be removed.

Heat Addition Control

If the compressor is not running, no heat addition can be active. If any heat addition is still active when the compressor is turned off, the heat addition will be immediately removed, without regard to any minimum run or off times.

Heat addition cannot be active at the same time as heat rejection, so any heat rejection is removed or staged off before the heat addition can be started.

A maximum of 4 stages of heat addition can be controlled or proportional heating can be configured, and an analog output signal will be modulated to control the heat.

1-12

Design Guide

WattMaster WHP

Section 1

Staged Heat Addition

Heat Addition is staged up based on a different deadband level for each stage. Basically, if the user programmed a 2° deadband, then the first stage could activate at the setpoint, stage 2 would activate 2° below the setpoint, stage 3 would activate 4° below the setpoint, etc...

Staging down is calculated in the same manner, except the water temperature would need to increase above the setpoint by the deadband amount. If stage 3 was activated at 4° below setpoint, it would de-activate when the temperature rises to within 2° of setpoint, stage 2 would de-activate at setpoint and stage 1 would de-activate 2° above setpoint.

A user defined staging up and down interval must be met before any heat addition stages can be added or removed. If the selected Water Temperature is below the current staging level and the timer has been satisfied, an additional stage can be added, up to the maximum available 8 stages. If the selected Water Temperature is above the staging down level and the timer has been satisfied, a stage can be removed.

Proportional Heat Addition

If the Water Temperature is below the addition setpoint, a Boiler Enable relay is activated. If the Water Temperature rises 1° above the setpoint the Boiler Enable relay is de-activated.

At a user defined rate, the analog output signal is proportionally controlled from 0.0 VDC at 1° above setpoint to the full 10.0 VDC signal as the water temperature drops below the setpoint by the user defined deadband amount. If a 5° deadband was entered, the maximum voltage would be reached at 4° below the setpoint and the minimum voltage would be set at 1° above the setpoint. Since this is strictly proportional control, at 1.5° below setpoint the controller would set 5.0 VDC since that would be half the deadband amount.

Design Guide

1-13

Section 1

WattMaster WHP

Water Temperature Alarming

The controlling water temperature is monitored to prevent it from exceeding both a user defined High and Low Alarm Limit. If either limit is exceeded for a user defined length of time, an alarm is generated and the compressor output is de-activated. If the high limit is exceeded, the heat addition outputs are de-activated and if the low limit is exceeded, the heat rejection outputs are de-activated. The alarming and shutdown only pertains to the controlling water temperature. This does not affect the pump operation.

If a external manual alarm reset button is connected between ground and input #5, All outputs are turned off and ALL timers are reset. This forces the loop controller to stage off. This reset WILL shut down the pumps and force them to restart!

Fire Alarm

If the Fire Alarm is activated on input #1 of the Analog Input Expansion Board (Contact

OPENS for Alarm!) then ALL outputs and timers are reset and held off for the duration of the Fire Alarm signal.

If the Fire Alarm is not required, input #1 of the Analog Input Expansion Board must have a shorting wire to ground to allow the equipment to operate.

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Design Guide

WattMaster WHP

COMPUTER

(OPTIONAL)

Section 1

RS-485

Comm Loop

Room Sensor with Optional

Override & Adj.

COMM

T

LD4

REC.

SHLD

R

12V

AIN

1

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

24 VAC

110/24 VAC

Power Pak

Supply

Air

Sensor

F

Dirty Filter Alarm or Leaving Water Temp

Modem

(Optional)

110/24 VAC

Power Pak

Typical WHP Controller Wiring

MR

TR

SD

RD

OH

CD

AA

HS

CommLink II

Multiple Loop

Interface

COMM

MM

LINK

II

P

C

P

Network Loop

RS-485

19200 Baud

#1

32K

8K

COMM

T

SHLD

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

3

OUT

4

OUT

4-5

5

COM

4-5

COM

1-3

OUT

1

OUT

2

OUT

OUT

PWR GND

24VAC

Loop #1

WHP

Controllers

#30

32K

8K

COMM

T

SHLD

LD4

R

REC.

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

YS101564

485

COMM

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

3

OUT

4

OUT

4-5

5

COM

4-5

COM

1-3

OUT

1

OUT

2

OUT

OUT

PWR GND

24VAC

W

AT

TM

AST

ER C

ONT

L

S, I

MiniLink

Loop # 1

T

SH

R

16

32

24VAC

GND

T

SH

R

Local Loop

RS-485

9600 Baud

System Manager

24VAC

MiniLink

Loop # 2

T

SH

R

16

32

GND

T

SH

R

03:38PM

OCCUPIED

NO

ALARMS

WED

MiniLink

Loop # 3

T

SH

R

24VAC

Local Loop

RS-485

9600 Baud

24VAC

Typical Network & Local Loop Wiring

2 Conductor Twisted Pair with Shield

(Beldon #82760 or Equivalent)

NOTE: * Only One Outside Air Sensor is Required per WHP System

MiniLink

Loop # 4

T

SH

R

16

32

T

SH

R

T

SH

R

24VAC

GND

24VAC

24VAC

Local Loop

RS-485

9600 Baud

*OutsideAir

Sensor

WHP Loop

Controller

RN1

CX1

U1

U2 CX2

TB1

COMM

T

SHLD

R CX5

LD6

COMM

U5

RS-485

COMM

HH

LD8

LED1

R1

LD9

LED2 P1

U7

+VREF

5.11V

TEST POINT

EWDOG

RV1

VREF ADJ R28

C1

INPUTS ADDRESS

RAM

U6

ADD

TB3

+VDC

RN5

AIN1

AIN2

AIN3

AIN4

AIN5

GND

GND

C10

AOUT1 C12

AOUT2

AIN7

GND

PJ1

C17 D15

D8

PU4

D9

PU5

PU1

D6

PU2

D7

PU3

D11

PU7

D14

U13

SW1

CX13

U15

16

TOKEN

NETWORK

JP1

X2

CX15

C15

R22

R24

R25

R15

C14

R19

C20

R26

PRESSURE

SENSOR

EXPANSION

U3

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

U10

U14

CX10

U12

CX14

CX6

CX12

T'STAT

U4

CX4

U9

VR1

PAL

C7

D12

R13

SC1

D19

VR2

L1

7824CT

V1

V2

V3

COM1-3

R1

R2

R3

R4

R5

COM4-5

V4

V5

TB2

R6

C9

U8

NE5090NPB3192

0PS

MC34064A

C13

C16

TB4

GND

24VAC

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

Loop # 4 24VAC

#1

32K

8K

COMM

T

SHLD

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

2

3

OUT

4

OUT

4-5

5

COM

4-5

PWR GND

24VAC

#1

32K

8K

COMM

T

SHLD

R

LD4

REC.

485

COMM

RAM EPROM

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

1

OUT

2

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#1

32K

8K

COMM

T

SHLD

R

LD4

REC.

RAM EPROM

12V

AIN

1

AIN

2

AIN

AIN

AIN

5

GND

GND

AOUT

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

24VAC

Loop #2

WHP

Controllers

Loop #3

WHP

Controllers

See Note #3

Loop #4

WHP

Controllers

Local Loop

RS-485

9600 Baud

Notes:

1.) 24 VAC Must Be Connected

So That All Ground Wires

Remain Common.

3.) The Local Loop With The Loop Controller

Installed Can Only Have Up To 29

WHP Controllers Attached As The WHP

Loop Controller Occupies Address #30.

2.) All Wiring To Be In Accordance

With Local And National Electrical

Codes and Specifications.

#30

32K

8K

COMM

T

SHLD

R

LD4

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

2

3

OUT

4

OUT

4-5

5

COM

4-5

PWR GND

24VAC

#30

32K

8K

COMM

T

SHLD

LD4

R

REC.

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

485

COMM

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

1

OUT

2

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#29

32K

8K

COMM

T

SHLD

LD4

R

REC.

RAM EPROM

12V

AIN

1

AIN

2

AIN

AIN

AIN

5

GND

GND

AOUT

YS101564

CPU

ADDRESS ADD

COMM

TEST

4.) Systems may consist of up to 20 Local

Loops (600 WHP Controllers). Consult factory for systems that exceed these quantities.

RELAY

3

OUT

4

OUT

4-5

5

COM

4-5

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

OUT

PWR GND

24VAC

Figure 1-3: Typical WattMaster WHP System

Design Guide

1-15

Section 1

Notes:

WattMaster WHP

1-16

Design Guide

Section 2

Table of Contents

Tips Before Beginning Installation.................................. 1

Communications Loops ................................................... 3

Communications Loop Wiring Overview....................................................4

WHP Loop Controller ....................................................... 6

WHP Loop Controller Addressing .................................... 9

Supply & Return Water Temperature Sensors .............. 10

Outside Air Temperature Sensor................................... 12

CommLink II Interface................................................... 13

WHP Controller .............................................................. 14

WHP Controller Addressing ........................................... 17

MiniLink Addressing ...................................................... 18

Room Sensors ................................................................ 19

Supply Air Temperature Sensor .................................... 21

Leaving Water Temperature Sensors............................ 22

Installation and Wiring

Section 2

Table of Figures

Figure 2-1: System Overview ........................................................................................2

Figure 2-2: Communication Loop Wiring, Daisy-Chain Configuration .......................4

Figure 2-3: WHP Loop Controller.................................................................................6

Figure 2-4: WHP Loop Controller Wiring ....................................................................7

Figure 2-5: WHP Loop Controller Address Switch Setting ..........................................9

Figure 2-6: Duct Sensor with Thermowell...................................................................10

Figure 2-7: Strap-On Water Temperature Sensor ........................................................11

Figure 2-8: Outside Air Temperature Sensor ...............................................................12

Figure 2-9: CommLink Interface Wiring.....................................................................14

Figure 2-10: WHP Controller .....................................................................................14

Figure 2-11: WHP Controller Wiring .........................................................................15

Figure 2-12: WHP Controller Address Switch Setting...............................................17

Figure 2-13: MiniLink Address Switch Setting.........................................................18

Figure 2-14: Room Sensor Wiring..............................................................................19

Figure 2-15: Room Sensor ..........................................................................................20

Figure 2-16: Supply Air Temperature Sensor..............................................................21

Figure 2-17: Water Temperature Sensor .....................................................................22

Figure 2-18: Water Temperature Sensor .....................................................................22

Installation and Wiring

WattMaster WHP Section 2

Tips Before Beginning

Installation

Take a few moments to review the following before beginning installation of the

WattMaster WHP System.

•

Familiarize yourself with all system components and review all documentation. Pay special attention to “Cautions” and “Warnings” since these may keep you from experiencing unnecessary problems.

•

Before installing controllers, be sure to tag it with its appropriate location. It is also best to set the controller address switches before mounting. Use the WHP Address

Worksheet to list all WHP unit locations. This will assist you greatly when setting up the system.

•

Be sure and install all wiring according to local, state, and national electric codes.

•

Pay close attention to communication wiring since the most common mistakes are made in this area. Polarity is the most important rule. Make notes on your wiring diagrams as to which color wire you will be using on each terminal.

•

When in doubt - ask! Contact your local WattMaster distributor if you have any questions. The only dumb questions are the ones you don’t ask.

•

Remember - each electronic device contains only one puff of smoke. If you release it, you have voided the warranty! So please be careful and pay attention.

Installation and Wiring 2-1

Section 2 WattMaster WHP

COMPUTER

(OPTIONAL)

RS-485

Comm Loop

Room Sensor with Optional

Override & Adj.

32K 8K

COMM

T

LD4

REC.

SHLD

R

12V

AIN

1

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

24 VAC

110/24 VAC

Power Pak

Supply

Air

Sensor

F

Dirty Filter Alarm or Leaving Water Temp

Modem

(Optional)

110/24 VAC

Power Pak

Typical WHP Controller Wiring

MR

TR

SD

RD

OH

CD

AA

HS

CommLink II

Multiple Loop

Interface

COMM

MM

LINK

II

P

C

P

Network Loop

RS-485

19200 Baud

#1

32K

8K

COMM

T

SHLD

LD4

R

REC.

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

YS101564

485

COMM

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

3

OUT

4

OUT

4-5

5

COM

4-5

COM

1-3

OUT

1

OUT

2

OUT

OUT

PWR GND

24VAC

W

AT

TM

ASTE

R C

ONT

L

S, I

NC

MiniLink

Loop # 1

T

SH

R

16

32

24VAC

GND

T

SH

R

Local Loop

RS-485

9600 Baud

System Manager

24VAC

MiniLink

Loop # 2

T

SH

R

16

32

24VAC

GND

T

SH

R

03

/3

1/

04

NO

OC

03

:3

CU

PI

AL

AR

8P

M

WE

D

MiniLink

Loop # 3

24VAC

Local Loop

RS-485

9600 Baud

24VAC

Typical Network & Local Loop Wiring

2 Conductor Twisted Pair with Shield

(Beldon #82760 or Equivalent)

T

SH

R

32 16

NOTE: * Only One Outside Air Sensor is Required per WHP System

MiniLink

Loop # 4

T

SH

R

16

32

T

SH

R

T

SH

R

24VAC

GND

GND

24VAC

Local Loop

RS-485

9600 Baud

*OutsideAir

Sensor

WHP Loop

Controller

RN1

CX1

U1

U2 CX2

TB1

COMM

T

SHLD

R CX5

LD6

COMM

U5

RS-485

COMM

HH

INPUTS

LD8

LED1

LD9

LED2

R1

P1

C1

U7

+VREF

5.11V

TEST POINT

EWDOG

RV1

VREF ADJ R28

ADDRESS

RAM

U6

ADD

U3

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

CX6

U4

CX4

PAL

TB3

+VDC

AIN1

RN5

AIN2

AIN3

AIN4

AIN5

GND

GND

C10

AOUT1

AOUT2

AIN7

GND

PJ1

C17

C12

D15

D8

PU4

D9

PU5

PU1

D6

PU2

D7

PU3

D11

PU7

D14

U13

CX13

U15

SW1

32

16

TOKEN

NETWORK

U10

CX15

JP1

C14

C15

X2

R15

R19

R22

R24

R25

U14

C20

R26

PRESSURE

SENSOR

EXPANSION

CX10

U12

CX14

CX12

T'STAT

U9

VR1

C7

D12

R13

SC1

D19

L1

VR2

7824CT

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V4

V5

V1

V2

V3

U8

NE5090NPB3192

0PS

R6

C9

MC34064A

C13

C16

TB4

GND

24VAC

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

Loop # 4 24VAC

#1

32K

8K

COMM

T

SHLD

R

LD4

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

2

3

OUT

4

OUT

4-5

5

COM

4-5

PWR GND

24VAC

#1

32K

8K

COMM

T

SHLD

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

1

OUT

2

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#1

32K

8K

COMM

T

SHLD

LD4

R

REC.

RAM EPROM

12V

AIN

1

AIN

2

AIN

AIN

AIN

5

GND

GND

AOUT

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

3

OUT

4

OUT

4-5

5

COM

4-5

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

OUT

PWR GND

24VAC

Loop #1

WHP

Controllers

Loop #2

WHP

Controllers

Loop #3

WHP

Controllers

See Note #3

Loop #4

WHP

Controllers

Local Loop

RS-485

9600 Baud

Notes:

1.) 24 VAC Must Be Connected

So That All Ground Wires

Remain Common.

3.) The Local Loop With The Loop Controller

Installed Can Only Have Up To 29

WHP Controllers Attached As The WHP

Loop Controller Occupies Address #30.

2.) All Wiring To Be In Accordance

With Local And National Electrical

Codes and Specifications.

#30

32K

8K

COMM

T

SHLD

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

3

OUT

4

OUT

4-5

5

COM

4-5

COM

1-3

OUT

1

OUT

2

OUT

OUT

PWR GND

24VAC

#30

32K

8K

COMM

T

SHLD

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

#30

32K

8K

COMM

T

SHLD

LD4

R

REC.

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

485

COMM

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

1

OUT

2

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#29

32K

8K

COMM

T

SHLD

LD4

R

REC.

RAM EPROM

12V

AIN

1

AIN

2

AIN

AIN

AIN

5

GND

GND

AOUT

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

3

OUT

4

OUT

4-5

5

COM

4-5

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

OUT

PWR GND

24VAC

4.) Systems may consist of up to 20 Local

Loops (600 WHP Controllers). Consult factory for systems that exceed these quantities.

3

OUT

4

OUT

4-5

5

COM

4-5

RELAY

OUTPUT

COM

1-3

OUT

1

2

PWR GND

24VAC

Figure 2-1: System Overview

2-2 Installation and Wiring

WattMaster WHP Section 2

Communications Loops

The Communications Loop is two wire shielded RS-485. The loop is best connected in

daisy chain configuration, meaning the loop is connected from one controller to another.

It is not necessary to sequentially address the WHP Controllers in relation to their location on the loop. Cable must be Belden No. 82760 or equivalent.

Tip: Incorrect wiring of the communications loop is the most common mistake made during installation. Before beginning installation, write down the wire color used on each terminal connection and consistently maintain that color code. It is recommended that a continuous wire run be made between devices. Anytime a splice is made in the cable you increase your chance of problems.

Caution: Make sure when you are inserting wires into the terminal blocks that strands of wire do not stick out and touch the next terminal. This could cause a short or erratic operation.

Installation and Wiring 2-3

Section 2 WattMaster WHP

Communications Loop Wiring Overview

03/31/04 03:38PM WED

OCCUPIED

NO ALARMS

COMPUTER

(OPTIONAL)

POWER

24VAC

GND

COMMUNICATIONS

T

RS-485

SHLD

R

SYSTEM MANAGER POWER SUPPLY

YS101716 REV. 1

SYSTEM MANAGER

COMM LINK II

INTERFACE

(SET TO MULTIPLE LOOP)

UNIT COMES WITH

STANDARD WALL MOUNT

120/24 VAC POWER SUPPLY

( MAY ALSO BE POWERED FROM 24VAC )

Remote Link

(OPTIONAL)

NETWORK

LOOP

U3

1

RN1

CX1

U1

U2 CX2

U4

CX4

TB1

COMM

T

SHLD

R

CX5

LD6

COMM

LD7

PWR

AIN1

AIN2

AIN3

AIN4

AIN5

1

+VDC

U5

RS-485

COM M

HH

LD8

LED1

R1

LD9

LED2 P1

+VREF

5.11V

U7 TE ST POINT

EWDOG

C1

RV1

VRE F A DJ R28

INPUTS

RN5

RA M

U6

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

PU1

D6

PU2

D7

PU3

D8

PU4

D9

PU5

D11

PU7

D14

ADDRESS

SW1

ADD

1

2

4

8

32

16

TOKEN

NETWORK

U10

J P1

X2

CX10

CX6

CX12

TB3

GND

GND

C10

C12

AOUT1

AOUT2

AIN7

GND

PJ1

C17 D15

C20

U13

CX13

U15

C14

R15

R19 U14

C15

R22

R24

R25

U12

CX14

CX15

U9

1

PAL

C7

1

D12

R13

SC1

D19

R26

PRESSURE

SENSOR

EXPANSION

T'STAT VR1

L1

VR2

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V4

V5

V1

V2

V3

U8

NE5090NPB3192

0PS

R6

C9

C13

C16

TB4

GND

24VAC

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

32K

8K

COMM

T

LD4

SHLD

R

REC.

12V

AIN

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

5

GND

GND

AOUT

YS101564

0-5 VD

PWR

GND

24VAC

RELAY

OUTPUT

1-3

OUT

OUT

OUT

4-5

32K

8K

COMM

T

SHLD

LD4

R

REC.

12V

AIN

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

5

GND

GND

AOUT

YS101564

PWR

GND

24VAC

COM

1-3

OUT

OUT

4-5

TO OTHER WHP CONTROLLERS

TO OTHER MINILINKS

(NETWORK TERMINALS ONLY)

Figure 2-2: Communication Loop Wiring, Daisy-Chain Configuration

2-4 Installation and Wiring

WattMaster WHP Section 2

The daisy chain is the best method for running a communications loop since there is only one starting point and one ending point for each of the communications loops. Even though the daisy chain configuration is preferred, the star configuration can also be used.

If required, a combination of the two can also be used. Remember, the best communication loop wiring is the one which utilizes the minimum number of ends while using the shortest wiring path.

Note: The loop does not have to follow the controller address sequence.

Caution: If the comm loop is not installed in conduit, be careful to position the cable away from high noise devices like fluorescent lights, transformers,

VFD’s, etc. Conduit is not required for comm loop wiring unless required by local codes.

Make sure CommLink jumper is set for “Multi”.

Installation and Wiring 2-5

Section 2 WattMaster WHP

WHP Loop Controller

The WHP Loop Controller may be installed in any convenient protected location. It is recommended that the loop controller be mounted indoors in a secure location, that is not subject to extremes in temperature or moisture.

.20 Dia.

Typ. of 4

6.2’’

4.0”

7.3”

U3

1

RN1

CX1

U2

CX2

CX4

U1

U4

TB1

COMM

T

SHLD

R

CX5

U5

LD6

COMM

LD7

PWR

1

RS-485

COMM

HH

RAM EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

LD8

LED1

P1

C1

LD9

LED2

R1

U7

+VREF

5.11V

TEST POINT

EWDOG

RV1

VREF ADJ

R28

U6

CX6

1

INPUTS

TB3

ADDRESS

+VDC

RN5

AIN1

AIN2

AIN3

AIN4

AIN5

GND

GND

C10

AOUT1

C12

AOUT2

AIN7

GND

PJ1

C17

D15

PU1

D6

PU2

D7

PU3

D8

PU4

D9

PU5

D11

PU7

D14

U13

SW1

CX13

U15

ADD

1

2

4

8

16

32

TOKEN

NETWORK

JP1

X2

R15

C14

R19

C20

CX15

C15

R22

R24

R25

U10

U14

CX10

U12

CX14

CX12

U9

PAL

C7

1

D12

R13

SC1

D19

R26

PRESSURE

SENSOR

EXPANSION T'STAT

VR1

L1

VR2

7824CT

M

6.7”

V1

V2

V3

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V4

V5

U8

NE5090NPB3192

0PS

34064A

9936

R6

C9

MC

C13

C16

TB4

GND

24VAC

WHP Loop Controller Main Board

6.6”

9.5”

TB

1

TB

1

TB

1

0 2 R

V4

V1

V1

G

D

C A V

: T

0

S P P

N

5 2

C

4

A

1

T

A 5 L

C D

1 -

N

V

L

O

M

U

C

4 2

5 G

C

-IN

K1

R

C A V

: T

0

S P P

N

5 2

C

4

A

1

T

A 5 L

C D

1 -

N

V4

4RLY IO BD.

V

L

O

M

U

C

4 2

5 G

K4

C A V

: T

0

S P P

C

2

4

A

1

T

A 5 L

C D

1 -

N

L

V

O

4

5

C

2

G

N O R M O

4RLY IO BD.

K4

K1

C A V

: T

0

S P P

C

2

4

A

1

T

A 5 L

C D

1 -

N

L

V

O

4

5

C

2

G

N O R M O

N

D

+

24

VD

-O

C A V

: T

0 5

C

2

A T

S P P

N

A

O

UT

R

5

N O

4 1

C

1 -

D V

L

L

4

M

U

C

2

K2

O

K1

/ A 3 0 8 2 N L U

C A V

: T

S P P

0 5

N

C

4

2

A T

1

A

C

O R

-

5

N

V

L

L U

O C

4

M

2

O

K2

K3

RN1

YS101790

K2

C A V

:

S P P

T

0 5

C

4

2

1

T

A 5 L

C

1 -

N

V

L

O C

4 2

5 G

N O R M O

K3

K4

K1

K2

C A V

: T

S P P

0 5

C

4

2

1

T

A

C

1 -

5

L

V

O

L U

4 2

5 G

N O R M O

K3

RN1

0 4 7

P 4 7 5 8 F C P

/ A 3 0 8 2 N L U

0 4 7

P 4 7 5 8 F C P

YS101790

K3

K4

PHILIPS

HA

I D U1

U2

PHILIPS T L

I D U1

C

X2

U2

P1

U3

CX3

P1

U3

CX3

AIN1

R5

AIN2

AIN3

AIN4

R6

R7

GND

AOUT1

R8

R9

D5

1

R10

U2

PU1

PU2

C2

C3

PU3

C4

PU4

C5

C1

8 5 3 M L

JO1

JO2

JO3

JO4

R1

D1

R2

D2

R3

D3

R4

D4

4 ANALOG IN MOD. I/O BD.

YS101784

R9

CX1

1P

59

F8

PC

T L

PHILIP S

I D

U1

P1

YS

82

T

C

24

78

.

BD

I/O

D

UL

T M

O

0

2

1

1

1

R

R

1 R

P4

8.29”

8.96”

2.12” 0.28”

4.24”

WHP Loop Controller Expansion Board

Figure 2-3: WHP Loop Controller

2-6 Installation and Wiring

WattMaster WHP Section 2

Optional Pressure

Transmitter

Connect To Next WHP Controller

And/Or MiniLink On Local Loop

Local Loop RS-485

9600 Baud

Outside Air

Temp. Sensor

Return Water

Temp Sensor

Supply Water

Temp Sensor

See Note 4

Proof of

Flow

WHP Loop Controller Expansion Board

U3

CX1

1

RN1 U2

CX2

CX4

U1

U4

TB1

COMM

T

SHLD

R

CX5

LD6

U5

COMM

LD7

PWR

1

RS-485

COMM

HH

RAM

LD8

LED1

LD9

LED2

R1

P1

C1

+VREF

5.11V

U7 TEST POINT

EWDOG

RV1

VREF ADJ

R28

INPUTS

ADDRESS

TB3

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

RN5

GND

C10

GND

AOUT1

C12

AOUT2

AIN7

GND

PJ1

C17

D15

U6

PU4

D9

PU5

D11

PU7

D14

PU1

D6

PU2

D7

PU3

SW1

ADD

1

2

4

8

16

32

TOKEN

NETWORK

JP1

X2

U13

CX13

U15

R15

C14

R19

C20

CX15

C15

R22

R24

R25

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

U10

U14

CX10

U12

CX14

CX6

CX12

1

U9

PAL

1

C7

D12

R13

SC1

D19

R26

PRESSURE

SENSOR

EXPANSION T'STAT

VR1

T

L1

VR2

7824C

M

V1

V2

V3

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V4

V5

U8

NE5090NPB3192

0PS

R6

C9

9936

34064A MC

C13

C16

TB4

GND

24VAC

R1

R2

R3

R (24 VAC By Others)

Compressor Enable

Main Pump

Standby Pump

N.C. Pilot Duty Relays

(By Others)

Alarm Indicator

Required VA For Transformer

Loop Controller = 8VA Min.

GND

Line Voltage

24VAC

See Note 1

Manual

Reset

Phase

Loss

Pump VFD

-

+

Optional

Modulating Heat

-

+

Notes:

1.)24 VAC Must Be Connected So

That All Ground Wires Remain

Common.

2.)All Wiring To Be In Accordance

With Local And National Electrical

Codes And Specifications.

3.)All Communication Wiring To Be

2 Conductor Twisted Pair With

Shield. Use Belden #82760 Or

Equivalent.

4.)When a Water Pressure Transmitter

Is Used, a 250 Ohm Resistor is

Installed Between AIN3 & GND and

The Pull Up Resistor PU3 is

Removed.

5.)If a Fire Alarm Contact is Not

Connected to AIN1 on The Analog

Expansion Board, Then a Jumper

Must Installed Between AIN1 and

GND.

Figure 2-4: WHP Loop Controller Wiring

N.C. Pilot Duty Relays

(By Others)

Heating/Cooling #1

Heating/Cooling #2

Heating/Cooling #3

Heating/Cooling #4

24 VAC

R5

R7

R4

R6

Heating/Cooling #1

Heating/Cooling #2

Heating/Cooling #3

R9

Heating/Cooling #4

24 VAC

Fire Alarm Contact (N.C.)(See Note 5)

R11

Request to Run Contact (N.O.)

R8

R10

Relay Contacts

(By Others)

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

WHP Loop Controller Expansion Board

Installation and Wiring 2-7

Section 2 WattMaster WHP

Warning:

Polarity is very important when connecting power to the controllers!

The grounded side of the control transformer must be connected to the terminal labeled GND on the controller. If a single transformer is used to power more than one controller you must connect GND-to-

GND and 24VAC-to-24VAC on each controller. Failure to observe polarity will result in damage to one or more components in your system.

The WHP Loop Controller requires the following electrical connections:

-24VAC Supply Voltage.................................................... 2 Conductors (18 Ga. Min.)

-Communications Loop ....... 2 Conductor twisted pair with shield (18 Ga. Minimum)

(Belden #82760, WattMaster Cable or equivalent)

-Supply Water Temperature Sensor................................... (24 ga. Min.) 2 Conductors

-Return Water Temperature Sensor .................................... (24 ga. Min.) 2 Conductors

-Outside Air Temperature Sensor ....................................... (24 ga. Min.) 2 Conductors

-Loop Pressure Sensor (Optional)........................................ (24 ga. Min) 2 Conductors

-Fire/Smoke Alarm Contacts .............................................. (24 ga. Min.) 2 Conductors

-Loop Pressure Switch ......................................................... (24 ga. Min) 2 Conductors

-Manual Reset Switch.......................................................... (24 ga. Min) 2 Conductors

-Request to Run Contacts .................................................... (24 ga. Min) 2 Conductors

-Analog Outputs................................................................... (24 ga. Min) 2 Conductors

-Binary Outputs.................................................................... (24 ga. Min) 2 Conductors

Tip: After making all electrical connections it is advised to unplug all terminal blocks on the WHP Loop Controller until you are ready to begin the checkout procedure. This may help to prevent damage if wiring errors occur elsewhere in the system during installation or start-up.

2-8 Installation and Wiring

WattMaster WHP Section 2

WHP Loop Controller

Addressing

The WHP Loop Controller must be set for address #30. See address setting instructions for the WHP Loop Controller that follow. A maximum of 29 WHP Controllers are allowed on the loop that contains the WHP Loop Controller. All other loops may have 30

WHP Controllers.

This Switch Should Be

In The OFF Position

As Shown

ADDRESS ADD

1

2

4

8

16

32

TOKEN

NETWORK

Controller

Address Switch

Address Switch Must Be Set For

Address 30 As Shown

Note:

The Power To The Controller Must Be Removed And

Reconnected After Changing The Address Switch

Settings In Order For Any Changes To Take Effect.

Caution

Disconnect All Communication Loop Wiring From The

Controller Before Removing Power From The Controller.

Reconnect Power And Then Reconnect Communication

Loop Wiring.

INPUTS

TB3

ADDRESS

+VDC

RN5

AIN1

AIN2

AIN3

AIN4

AIN5

GND

C10

GND

AOUT1 C12

AOUT2

AIN7

GND

PJ1

C17

D15

PU1

D6

PU2

D7

PU3

D8

PU4

D9

PU5

D11

PU7

D14

U13

SW1

CX13

U15

ADD

1

2

4

8

16

32

TOKEN

NETWORK

JP1

X2

U10

CX10

R15

C14

R19 U14

U12

CX14

C15

R22

R24

R25

C20 CX15

CX12

R26

PRESSURE

SENSOR

EXPANSION

VR1

C7

D12

R13

SC1

D19

L1

VR2

R6

C9

C13

C16

TB4

GND

24VAC

Figure 2-5: WHP Loop Controller Address Switch Setting

Installation and Wiring 2-9

Section 2 WattMaster WHP

Supply & Return Water

Temperature Sensors

Sensors for monitoring supply and return water temperature are available in two main types, fluid immersion temperature sensors (See Figure 2-6) and strap-on sensors (See

Figure 2-7). Both are 0-10000 ohm thermistor type sensors. The fluid immersion sensor generally has better accuracy than the strap-on type but either is suitable for typical water source heat pump temperature requirements. The fluid immersion type sensor requires that a thermowell be installed in the pipe and the strap-on type, as its name implies, simply straps around the outside of the pipe. The fluid immersion sensor requires that the pipe be at least 4” in diameter in order to accept the thermowell. The strap-on type sensor is adjustable for use on 1/2” to 6” or larger diameter pipe.

The fluid immersion sensor is provided with a 4” long stainless steel thermowell. It has

½” MPT external threads and ½” FPT internal threads. A ½” FPT fitting to accept the thermowell must be provided by others in the pipe to be monitored, for connection of the thermowell. The thermowell is screwed into the ½” FPT fitting installed by others in the pipe and the sensor probe is then screwed into the ½” FPT fitting on the thermowell.

Leads Are Non-polarized.

Butt Splice Leads To 24 Gauge

Wire Minimum. Connect Leads

To "Analog In" And "Ground"

At Controller.

1/8-27 NPT External Thread

5.50

OE230 Duct Sensor

The OE230 Duct Sensor Threads Into The OE291 Stainless

Steel Thermowell. The OE291 Thermowell Threads Into A 1/2”

FPT Elbow or Tee in the Water Piping of the Water Coil

Where You Wish to Measure the Water Temperature. The

Pipe must be a minimum of 4” Diameter or an Extended Tee and Bushing Configuration Must be Used to Accommodate the

Length of the Thermowell Assembly.

1/8-27 NPSM Internal Thread

1/2" NPT External Thread

3.25

4.94

5.13

OE291 Stainless Steel Thermowell

0.5

Figure 2-6: Duct Sensor with Thermowell

2-10 Installation and Wiring

WattMaster WHP Section 2

The strap-on type sensor has a brass housing that senses the water temperature through contact with the exterior surface of the pipe. The sensor should be mounted in contact with the underside of the pipe in order to insure accurate temperature readings. The sensor assembly is secured to the pipe by using the supplied wire ties to wrap and secure the sensor to the pipe. Thermal conductive compound is also supplied to insure a good thermal connection with the pipe. The sensors are supplied with 3 foot long wire leads.

Wire Tire

(Supplied)

Supply Or Return

Water Pipe.

Sensing Element

(Supplied)

Thermal Mastic Strip

(Supplied)

Figure 2-7: Strap-On Water Temperature Sensor

Installation and Wiring 2-11

Section 2 WattMaster WHP

Outside Air Temperature

Sensor

The outside air sensor must be located where it will not be affected by direct sun or heat producing equipment. Mounting under the eve of a roof is often a good choice.

Caution: Complaints of inaccurate outside sensor readings are very common and can almost always be shown to be the result of poor sensor location.

Note: All temperature sensors supplied with the system utilize the same thermistor type sensing element. For troubleshooting sensor problems refer to the

TEMPERATURE SENSOR RESISTANCE CHART at the end of Section 4.

Gasketed Cover

3.00”

Cover

Mounting

Screw - Typ.

2.30”

2.70”

Closure Plug

0.21" Dia. x 0.73

Lg. Slot - Typ.

Mounting Tab

& Screws - Typ.

Sensor Tube

Front View Side View

Figure 2-8: Outside Air Temperature Sensor

Mounting Tab

& Screw - Typ.

Closure Plug

Back View

2-12 Installation and Wiring

WattMaster WHP Section 2

CommLink II Interface

The CommLink II Interface provides for communications between the MiniLink communication interfaces installed on the system. The CommLink II is required for proper communications, even if a PC is not used. Locate the CommLink II near the computer or modem if they are installed on the system. The cable connections between the CommLink II and the computer or modem should be kept to less than twenty-five feet. The CommLink II comes complete with computer and modem cables, and a plug-in power supply.

03/31/04 03:38PM WED

OCCUPIED

NO ALARMS

COMPUTER

(OPTIONAL)

POWER

24VAC

GND

COMMUNICATIONS

T

RS-485

SHLD

R

SYSTEM MANAGER POWER SUPPLY

YS101716 REV. 1

SYSTEM MANAGER

COMM LINK II

INTERFACE

(MULTIPLE LOOP)

UNIT COMES WITH

STANDARD WALL MOUNT

120/24 VAC POWER SUPPLY

( MAY ALSO BE POWERED FROM 24VAC )

Remote Link

(OPTIONAL)

NETWORK

LOOP

U3

1

RN1

CX1

U1

U2 CX2

TB1

COMM

LD6

T

SHLD

R

CX5

U5

COMM

LD7

PWR

LD8

LED1

1

RS-485

COMM

C1

R1

LD9

LED2 P1

+VREF

5.11V

U7

RV1

TEST POINT

VREF ADJ

EWDOG

R28

HH

INPUTS ADDRESS

RAM

U6

ADD

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

CX6

U4

1

CX4

PAL

1

TB3

+VDC

RN5

AIN1

AIN2

AIN3

AIN4

AIN5

GND

GND

C10

AOUT1

AOUT2

AIN7

GND

PJ1

C17

C12

D15

PU1

D6

PU2

D7

PU3

D8

PU4

D9

PU5

D11

PU7

D14

U13

SW1

CX13

U15

1

2

4

8

16

32

TOKEN

NETW ORK

U10

JP1

X2

R15

C14

R19 U14

C15

R22

R24

R25

C20 CX15

CX10

U12

CX14

CX12

PRESSURE

SENSOR

R26

EX PANSION

T'STAT

U9

VR1

C7

D12

R13

SC1

D19

L1

VR2

7824CT

V1

V2

V3

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V4

V5

U8

NE5090NPB3192

0PS

9936

34064A

R6

C9

C13

C16

TB4

GND

24VAC

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

32K

8K

COMM

T

LD4

SHLD

R

REC.

12V

AIN

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

GND

AOUT

PRESSURE

SENSOR

YS101564

PWR

GND

24VAC

1-3

OUT

OUT

OUT

4-5

32K

8K

COMM

REC.

12V

AIN

4

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

485

COMM

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

OUT

OUT

4-5

PWR

GND

24VAC

TO OTHER WHP CONTROLLERS

TO OTHER MINILINKS

(NETWORK TERMINALS ONLY)

Figure 2-9: CommLink Interface Wiring

Installation and Wiring 2-13

Section 2 WattMaster WHP

WHP Controller

The WHP Controller may be installed in any convenient protected location. Observe the recommended environmental limitations for the WHP Controller when selecting a installation location. The environmental limitations are a temperature range of 10

°

F to

149

°

F, and a maximum operating humidity of 90% RH non-condensing.

The WHP Controller may be mounted by fastening to a flat surface through the mounting plate. The unit is mounted by four (4) screws in the corners. Select the correct screws or other fasteners for the type of mounting material being utilized.

RS-485

COMMUNICATIONS

LOOP

COMMUNICATIONS

LED

ADDRESS SWITCH

( ADDRESS 18 SHOWN )

ANALOG INPUTS

Space Sensor

Slide Adjust

Supply Air Temp

Leaving Water

Temp or

Dirty Filter

Lockout

COMMUNICATIONS

DRIVER CHIP

COMM

T

LD4

SHLD

R

REC.

12V

AIN

2

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

PIN 1

INDICATION

485

COMM

RAM

RAM EPROM

RAM SIZE

SELECT JUMPER

PAL

32K

8K

CPU

EPROM

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

2

OUT

OUT

4

OUT

5

COM

4-5

PWR

GND

STATIC PRESSURE

SENSOR INPUT

24VAC

24 VAC Common for Inputs 1 - 3

Fan-On/Off

Rev. Valve-On/Off (Heat 1)

Compressor-On/Off (Heat 2)

Heat Pump Reset (Cool 1)

Aux. Heating or Cooling (Cool 2)

24 VAC Common for Inputs 1 - 3

DIAGNOSTIC BLINK

CODE LED

REAL TIME

CLOCK CHIP

POWER LED

24VAC

POWER

INPUT

Mounting Backplate

Figure 2-10: WHP Controller

2-14 Installation and Wiring

WattMaster WHP

T

All Comm Loop Wiring Is

Straight Thru

T T T

SH SH SH SH

R R R R

Connect To

Next Controller

And/Or

MiniLink On

Local Loop

RS-485

9600 Baud

Room Sensor

TMP

NORMAL

OVR

E

R

W

A

R

M

C

O

O

L

E

R

Discharge

Air Temp.

Sensor

Mount In HVAC

Unit Supply

Air Duct

GND

AUX

Connection To

AUX Terminal is Reqd

Only When Sensor

Is Specified With

Slide Adjust Option

COMM

T

SHLD

R

LD4

REC.

WHP Controller

R

A

M

E

P

R

O

M

12V

AIN

1

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

ADDRESS ADD

COMM

TEST

Dirty Filter

Alarm Contact

Section 2

RELAY

OUTPUTS

COM

1-3

OUT

1

OUT

2

OUT

3

OUT

4

OUT

5

COM

4-5

Water Source Heat Pump

Unit Connections

24VAC

Fan-On/Off

Rev. Valve-On/Off

Compressor-On/Off

Heat Pump Reset

Aux. Heating Or Cooling

Diagnostic Blink Code LED

PWR

GND

GND

Required VA For Transformer

Each WHP Controller = 10VA MIN.

24VAC

24VAC

Thermowell

Or Surface Mount

Temp Sensor

(Leaving Water Temp)

Lockout

Optional Features

CAUTION!

WHP CONTROLLERS

MUST HAVE ADDRESS SWITCHES

SET BETWEEN 1 AND 30

(UP TO 30 UNITS PER LOCAL LOOP)

EXCEPT ON THE LOOP WITH THE

LOOP CONTROLLER CONNECTED.

THE LOOP CONTROLLER ADDRESS

IS 30, WHICH ALLOWS FOR ONLY

29 WHP CONTROLLERS ON THIS

LOCAL LOOP.

Figure 2-11: WHP Controller Wiring

Warning:

Polarity is very important when connecting power to the controllers!

The grounded side of the control transformer must be connected to the terminal labeled GND on the WHP Controller. If a single transformer is used to power more than one WHP Controller you must connect GND-to-GND and 24VAC-to-24VAC on each WHP

Controller. Failure to observe polarity will result in damage to one or more components in your system.

Warning:

Use extreme care not to damage any of the electronic components while mounting the backplate. Mark the holes then remove the WHP

Controller from the backplate before drilling.

Do not allow metal shavings to fall onto the circuit boards.

Installation and Wiring 2-15

Section 2 WattMaster WHP

The WHP Controller requires the following electrical connections:

18 Gauge minimum unless otherwise noted.

-24VAC Supply Voltage........................................................................... 2 Conductors

-Communications Loop ...................................... 2 Conductor twisted pair with shield

(WattMaster Cable, Belden #82760 or equivalent)

-Discharge Air Temperature Sensor .................................. (24 ga. Min.) 2 Conductors

-Room Air Temperature Sensor...........(24 ga. Min.) 2 Conductors for standard sensor

3 Conductors for sensors with setpoint adjustment

-Outside Air Temperature Sensor ....................................... (24 ga. Min.) 2 Conductors

-WHP Unit Control Wiring ......................................................... (24 ga.Min.) 24 VAC

Fan- ON/OFF

Rev Valve-ON/OFF

Compressor-ON/OFF

Heat Pump Reset

Aux. Heating or Cooling

Tip: After making all electrical connections it is advised to unplug all terminal blocks on the WHP Controller until you are ready to begin the checkout procedure. This may help to prevent damage if wiring errors occur elsewhere in the system during installation or start-up.

2-16 Installation and Wiring

WattMaster WHP

WHP Controller

Addressing

NOTE:

IGNORE ANY MARKINGS

OR NUMBERS ON THE SWITCH

USE THE CHART!

To determine the boards address, add the values of all the switches which are toggled down in the direction of the arrow

Section 2

Figure 2-12: WHP Controller Address Switch Setting

NOTE:

ADDRESS 30 CANNOT BE USED

ON THE LOOP THAT HAS THE WHP LOOP

CONTROLLER ATTACHED. ADDRESS 30

ON THAT LOOP IS RESERVED FOR THE

WHP LOOP CONTROLLER.

CAUTION:

YOU MUST POWER DOWN THE CONTROLLER

AFTER CHANGING THE ADDRESS SWITCHES

IN ORDER FOR ANY CHANGES TO TAKE EFFECT.

ALWAYS REMOVE THE COMMUNICATIONS LOOP

PRIOR TO DISCONNECTING POWER. RECONNECT

POWER AND THEN RECONNECT THE COMMUNICATIONS

LOOP TO THE CONTROLLER.

Installation and Wiring 2-17

Section 2 WattMaster WHP

MiniLink Addressing

Connect To Next

MiniLink And/Or

CommLink On

Network Loop

MiniLink Communications Interface

Network Loop

RS-485

19200 Baud

ADD

T

NETWORK

SH 8

16

32

2

4

R

1

OFF >

All Communication Loop

Wiring Is Straight Through

T

SH

T

SH

T

SH

T

SH

R R R R

24VAC

GND

24VAC

T

SH

LOOP

R

Local Loop

RS-485

9600 Baud

Line Voltage

Required VA For Transformer

MiniLink = 6VA Min.

See Note 1.

Connect To Next

Controller or

System Manager

1

2

4

8

16

32

ADD

Caution!

The MiniLinks Must Have Address Switches Set Between 1

And 30 (Up To 30 MiniLinks Are Allowed Per WHP System

System). The MiniLinks Should Be Addressed In

Consecutive Order Starting With Address #1. Address #1

Must Be Present On The Loop For The System To Function.

Note:

The Power To The MiniLink Must Be Removed And

Reconnected After Changing The Address Switch

Settings In Order For Any Changes To Take Effect.

Caution:

Disconnect All Communication Loop Wiring

From The MiniLink Before Removing Power

From The MiniLink. Reconnect Power And Then

Reconnect Communication Loop Wiring.

Notes:

1.)24 VAC Must Be Connected So

That All Ground Wires Remain

Common.

2.)All Wiring To Be In Accordance

With Local And National Electrical

Codes And Specifications.

3.) All Communication Wiring To Be

2 Conductor Twisted Pair With

Shield. Use Belden #82760 Or

Equivalent.

These Switches Must Be

In The OFF Position

As Shown

MiniLink

Address Switch

Address Switch Shown Is

Set For Address 1

Address Switch Shown Is

Set For Address 4

The Address For Each MiniLink

Must Be Unique To The Other MiniLinks

On The Network Loop. Loop #1 MiniLink

Should Be Addressed As #1

Loop #2 MiniLink Should Be Addressed

As #2 Etc..

Figure 2-13: MiniLink Address Switch Setting

2-18 Installation and Wiring

WattMaster WHP Section 2

Room Sensors

The room sensor uses a patented flush mount design to isolate the temperature sensing element from the housing which mounts flush with the wall surface.

Room sensors should be located on an inside wall away from direct sunlight or heat producing equipment such as computers, copiers, etc. Such devices can adversely affect the accuracy of the sensor.

Although the sensor eliminates most of the effects of thermal coupling to the walls, try to avoid walls which retain large amounts of thermal energy (such as marble or steel). Walls containing either cold or warm air currents should also be avoided whenever possible.

Avoid locating the sensor in dead air areas of a room. This will result in slow response to temperature changes in the space.

Mount the sensor approximately 50-60 inches from the floor for best results.

The room sensor is designed to mounted vertically in a standard 2 by 4 inch electrical box. The sensor may be mounted directly into the drywall where electrical codes do not require low voltage wiring to be enclosed in conduit. See enclosed sheet for dimensional and installation data.

Tip: Be careful when cutting the hole for the sensor or the plastic bezel of the sensor may not completely cover the opening.

WHP CONTROLLER

ROOM SENSOR WITH OVERRIDE

AND ADJUSTABLE SETPOINT

OVR

C

O

O

L

E

R

W

A

R

M

E

R

TMP

GND

AUX

ADJUSTABLE

SETPOINT

OVERRIDE

ONLY REQUIRED WHEN

USING ADJUSTABLE

SETPOINT

12V

2

3

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS

Figure 2-14: Room Sensor Wiring

Installation and Wiring 2-19

Section 2 WattMaster WHP

Connect the terminal labeled GND on the zone sensor to the terminal labeled GND on the

WHP Controller Analog Input terminal block. Connect the terminal labeled TMP on the zone sensor to the terminal labeled AIN 1 on the WHP Controller Analog Input terminal block. If the zone sensor has a setpoint adjust slider, then connect the sensor terminal labeled AUX to the WHP Controller AIN 2 terminal block.

Tip: If sensors must be installed on walls which are solid and cannot be penetrated, surface mounted boxes and raceway can be purchased from your local electrical distributor.

2.00“

2.75“

0.88“

TMP

GND

AUX

OUT W

A

R

M

E

R

C

O

O

L

E

R

0.25“

Wall Cut-Out Dimensions

When Sensor Is To Be

Mounted Without

Handy Box (By Others)

Figure 2-15: Room Sensor

2-20 Installation and Wiring

WattMaster WHP Section 2

Supply Air Temperature

Sensor

The supply air temperature sensor should be located in the duct, as close to the rooftop unit discharge as possible for best response.

Locate the sensor in the center of the widest part of the duct. Use the supplied template and a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mount securely to the duct using the supplied sheet metal screws. Be sure the gasket is compressed to provide an air tight seal.

For best accuracy, apply insulation on the outside of the duct, over the sensor. This will help prevent thermal gradients from affecting the sensor.

Leads Are Non-polarized.

Butt Splice Leads To 24 Gauge

Wire Minimum. Connect Leads

To "Analog In" And "Ground"

At Controller.

Thread

Together

4.0"

3/4"

5-1/2" (OE230)

11-1/2" (OE231)

Mounting Plate

1/4" Hex Head Sheet Metal Screws

Mounting Plate

Gasket

Adhesive Backed Drill Guide

Mounting Template

Duct Work

Drill 5/16" Hole In Ductwork For Probe

Figure 2-16: Supply Air Temperature Sensor

Installation and Wiring 2-21

Section 2 WattMaster WHP

Leaving Water

Temperature Sensors

The leaving water temperature sensor (optional) when used should be located on the leaving water piping close to the water source heat pump unit. Either a thermowell type or a surface mount sensor may be used depending on job requirements.

Leads Are Non-polarized.

Butt Splice Leads To 24 Gauge

Wire Minimum. Connect Leads

To "Analog In" And "Ground"

At Controller.

1/8-27 NPT External Thread

5.50

OE230 Duct Sensor

The OE230 Duct Sensor Threads Into The OE291 Stainless

Steel Thermowell. The OE291 Thermowell Threads Into A 1/2”

FPT Elbow or Tee in the Water Piping of the Water Coil

Where You Wish to Measure the Water Temperature. The

Pipe must be a minimum of 4” Diameter or an Extended Tee and Bushing Configuration Must be Used to Accommodate the

Length of the Thermowell Assembly.

1/8-27 NPSM Internal Thread

1/2" NPT External Thread

3.25

4.94

5.13

OE291 Stainless Steel Thermowell

0.5

Figure 2-17: Water Temperature Sensor

Supply Or Return

Water Pipe.

Wire Tire

(Supplied)

Sensing Element

(Supplied)

Figure 2-18: Water Temperature Sensor

2-22

Thermal Mastic Strip

(Supplied)

Installation and Wiring

Section 3

Table of Contents

LCD/Keypad Operations................................................... 1

System Manager Layout...................................................................................................2

Keypad Functions ............................................................................................................2

System Manager LED Indicators .....................................................................................3

Heat Pump Status Screens.............................................. 4

View Status Only .............................................................................................................4

View Alarms ....................................................................................................................8

Menu Setpoints ................................................................................................................9

Set Time & Date .............................................................. 9

New Passcodes.............................................................. 11

Rebuild Alarm Map......................................................... 12

Heat Pump Setpoints ..................................................... 13

Heat Pump Setpoint Menu .............................................................................................13

1) WHP Setpoints ..........................................................................................................13

2) WHP Schedules .........................................................................................................20

Holidays .........................................................................................................................21

3) Reset Pumps ..............................................................................................................22

Loop Controller Status .................................................. 23

Loop Controller Status Menu.........................................................................................23

Loop Controller Status Screens .................................... 23

Loop Controller Setpoints ............................................. 27

Loop Controller Setpoint Menu .....................................................................................27

Notes: ............................................................................. 32

Programming

WattMaster WHP Section 3

LCD/Keypad Operations

Main Screen

Heat Pump v1.xx

Tuesday Operations

04/13/04 09:15 AM

Outdoor Air 58.7°F

The Water Source Heat Pump System Manager is the operator’s interface to the status and setpoints of any WattMaster Water Source Heat Pump (WHP) component on your communications loop. With the System Manager, you can view any temperature or output condition and change any setpoint to fine tune the operations of the total system. All keypad operations are simple and straight-forward, utilizing non-cryptic plain English messages. The System Manager automatically detects the type of unit that has been selected, and displays the appropriate status and setpoint screens. The attractive plastic case of the System Manager allows for placement in any area of your building.

The remainder of this document will lead the user through the system menus and keypad operation.

All user functions are accessed by pressing the Menu button. Once the button is pressed, the Main User Menu is displayed.

Programming 3-1

Section 3

System Manager Layout

WattMaster WHP

Heat Pump v2.11

Wednesday Operations

7/21/04 04:35 PM

Outdoor Air 85.6°

Keypad Functions

The System Manager keypad is labeled either numerically or as to actual function for that key. Below is a summary of the labeled keys and their functions.

MENU

ESC

CLEAR

ENTER

DEC

MINUS

UP/DOWN

Arrows

LEFT/RIGHT

Arrows

This key is used to gain access to the first menu, and the user will be notified, on the LCD, if any subsequent use of the key will be required for further access.

The ESCape key allows the user to abort what they are doing or exit back to previous menus. Also, anytime you want to leave the system unattended you should press the ESC key until the Main Screen appears.

If you make a mistake while entering setpoint data, you can clear the bad data from the display by pressing the Clear key.

Use the Enter key to close out a data entry. It can also be used to advance to the next field or screen.

If entering a setpoint that requires a decimal point, press this key where the decimal is located while entering the value.

If you need to enter a negative value, you must press the Minus key before entering the digits for that value.

Use these keys to step forward or backward through Status Screens or

Setpoint Data Fields.

If the screen prompts you to use these keys, it is used normally to toggle modes of operation.

3-2 Programming

WattMaster WHP Section 3

System Manager LED Indicators

There are two LED indicators located on the right hand side of the System Manager.

The top LED indicates an Alarm condition if the Manager detects an alarm condition while polling the system.

The bottom LED is active during actual communications or packet transfers. This LED will normally “flicker” and not remain on constantly.

Main User Menu

1) View Status Only

2) View Alarms

MENU) Setpoints

ESC) Main Screen

1) View Status Only

2) View Alarms

MENU) Setpoints

ESC) Main Screen

For quick access to an individual heat pump or the loop controller, select this menu item. No passcode is required to access the status of any unit installed on your system.

If the System Manager has been configured for Alarm Polling, the user can select this item to get a list of unit addresses that are currently in alarm. If an alarm exists, the Alarm LED will be active on the right side of the panel.

If you are a Level 2 user, all system setpoints are available to you.

These setpoints are accessed via this Menu button.

When you have finished viewing the system you can exit this menu and return to the Main Screen by pressing the ESC button.

Programming 3-3

Section 3 WattMaster WHP

Heat Pump Status

Screens

View Status Only

Status Only View

[ Enter Unit ID# ]

Selected Unit: 101

By selecting the View Status Only menu item, you can access any heat pump or the loop controller and read all available temperatures, outputs, and operating conditions for the selected unit. No passcode is required to access these status screens, and no setpoints are available to the user from these screens. To access a unit, enter the Unit ID you wish to view. The Unit ID is actually two separate numbers, combined into one value. The first part of the number contains the Loop Address at which the zone is located. The second part of the number contains the actual

Board Address.

EXAMPLE: You would like to view the 3rd heat pump on the 5th loop. Enter 503 as the Unit ID

You would like to view the 12th heat pump on the 24th loop. Enter 2412 as the Unit ID

3-4 Programming

WattMaster WHP Section 3

If you selected menu item #1 View Status Only and you entered the Unit ID of an installed WHP Controller, the following Status Screens are available.

Status Screen #1

WSHPRV 1 V2.03

Space Temp.:xxx.x

°

F

CSP xx.x

°

HSP xx.x

°

Slide Adjust: x.x

°

F

Line 2 Current Zone Temperature

Line 3 -

Current Cooling Setpoint ( CSP

) and Heating

Setpoint ( HSP )

Line 4 Effect of optional Sensor Slide Adjustment on the current operating setpoints.

Status Screen #2

WSHPRV 1 V2.03

Supply Air.:xxx.x

°

F

Water Temp.:xxx.x

°

F

Outdoor Air:xxx.x

°

F

Line 2 Current Supply Air Temperature

Line 3 Current Leaving Water Temperature if Sensor is installed.

Line 4 -

Current Outdoor Air Temperature.

Programming 3-5

Section 3 WattMaster WHP

Status Screen #3

WSHPRV 1 V2.03

Occupied Mode

Fan Status...: ON

Operations Enabled

Line 2 Current Operating Status

Unoccupied Mode

Occupied Mode

Pushbutton Override

Forced Occupied

Forced Unoccupied

Forced Fan Only Mode

Line 3 Current Fan Status

Fan Start Delay!

ON

OFF

Line 4 Current Enable Status from Loop

Controller

Operations Disabled

Operations Enabled

Status Screen #4

WSHPRV 1 V2.03

Compressor...: ON

Reverse Valve: OFF

Aux / Stage#2: OFF

Line 2 Current Compressor ON/OFF Status

Line 3 Current Reversing Valve ON/OFF Status

Line 4 Current Status of Relay #5. Operation depends on how the user configures this output.

Status Screen #5

WSHPRV 1 V2.03

Cooling Mode

Line 2 Current HVAC Operating Mode

Neutral Mode

Cooling Mode

Heating Mode

Line 3 Reserved for future option.

Line 4 Reserved for future option.

3-6 Programming

WattMaster WHP

Status Screen #6

WSHPRV 1 V2.03

Space Temp Sensor OK

Filter OK

Cooling Failure

Line 2 -

Line 3 -

Line 4 -

Bad Space Sensor

Hi Space Temp Alarm!

Lo Space Temp Alarm!

Space Temp Sensor OK

Dirty Filter Alarm

Filter OK

Cooling Failure!

Heating Failure!

Section 3

Note: If no alarms exist, then the screen displays the message shown for No Alarms!

If ANY alarm exists then the three lines display one of the messages shown above.

The Cooling Failure and Heating Failure alarms are generated as follows:

As the unit enters the cooling mode, the current Supply Air Temperature reading is stored in memory. After 10 minutes, if the temperature hasn’t changed by 5 ° F a

Cooling Failure alarm is generated.

A Heating Failure is generated in the same manner, only during the heating mode instead of the cooling mode.

The Hi Space Temp and Lo Space Temp Alarms are generated as follows:

If the space temperature gets 5 ° F above the cooling setpoint, a Hi Space Temp

Alarm is generated. If the space temperature gets 5 ° F below the heating setpoint, a Lo Space Temp Alarm is generated.

Programming 3-7

Section 3

View Alarms

WattMaster WHP

Alarm Address Locations

SYSTEM ALARM STATUS

Alarm @ Unit ID 118

The System Manager can be programmed to poll all the units on your heat pump system for alarm information. This allows the centrally located System Manager to display an

Alarm Indicator whenever an alarm condition exists anywhere on your system. The actual alarms are not displayed on this screen, only the Unit ID where the alarm is located. The example screen shows that a unit at location

118 has experienced an alarm condition. This alarm may or may not be current, as the System Manager latches the condition. This makes it possible to determine if any intermittent alarm conditions have occured. To find out what the alarm is, if it is still current, access the status screens for the Unit IDs that are displayed on the SYSTEM

ALARM STATUS screens.

Alarm Clearing

SYSTEM ALARM STATUS

Clear Alarms? YES

To Change Response

Use Left/Right Arrow

If all the alarm conditions have been corrected at the individual units, you can clear these alarms from the

System Manager on the following screen. Use the

Left/Right arrow keys to select the YES/NO response desired. If you clear the alarms, but some still exist, the

System Manager will show an alarm indication, when the affected unit is polled again.

3-8 Programming

WattMaster WHP

Menu Setpoints

Section 3

Full Setpoint Access

1) Set Time & Date

2) Access Units

3) New Passcodes

4) Rebuild Alarm Map

If you selected the Menu key from the first menu screen you can access all setpoints available from any unit on your system.

You must be a Level 2 user to access these setpoints. If you haven’t already been asked to enter the passcode, you will be asked before the Full Setpoint Access menu is displayed. This prevents the casual user from being able to affect the operation of your heat pump system.

Set Time & Date

The System Manager has its own built in Real Time Clock. It broadcasts this time once a day, at midnight, to synchronize all of the WHPs on your system. Although the times are displayed on the Main Screen in a standard 12-hour format, they are programmed using the 24-hour Military format. Once the time has been entered, it is also broadcast immediately to all other units on the system. That means that you only need to program the System Manager time to set the Real Time Clocks for all units on your system. In order for the System Manager to broadcast the time and date to all controllers, they must be powered up and communicating.

Programming Time

Program Time/Date

Day (Sunday=0): 1

Enter Hr. (0-23): 9

Enter Minutes : 53

Day

Hours (Hr)

Minutes

- Enter the Day of the Week (0 to 6) with

Sunday = 0

- Enter Hours in 24-Hour Military Format

(1700 = 5:00 PM)

- Enter the Minutes (0 to 59)

Programming 3-9

Section 3 WattMaster WHP

Programming Date

Program Time/Date

Month (1-12): 4

Day (1-31): 18

Year (00-99): 04

Month

Day

Year

- Enter the Month (1 to 12)

- Enter the Day of the Month (1 to 31)

- Enter the current Year with 2 digits (00 to 99)

Daylight Savings Adjustments

Daylight Savings

Adjustments Enabled

Use Left/Right Arrow

If your area of the country requires Daylight Savings changes, you can enable the System Manager to automatically reset its own clock during the Daylight Savings changeover. If you enable this operation, it knows to changeover the first Sunday in April and then switch back the last Sunday in October. No other programming is required for this function.

Use the Left or Right arrow keys to toggle the second line of the display between Adjustments Enabled and Adjustments

Disabled.

3-10 Programming

WattMaster WHP Section 3

New Passcodes

Programming Passcodes

Enter New Passcode

Level 1....: XXXX

Level 2....: XXXX

[Must Be 4 Digits]

The System Manager has two levels of passcode.

Level 1 users are limited to viewing Setpoints and Alarms only.

Level 2 users have complete system access. Any status or setpoint field can be read or reset from WHP System Manager.

The default passcode is “1111” for level 1 and “2222” for level

2. If you need to change these defaults you can enter any 4 digit number between 1000 and 9999.

If you “forget” the passcode you programmed, you can still access the system with a built in backdoor code. This backdoor code is “9288” and is not programmable. It is not recommended that you give out this backdoor code since it would allow the user access without regard to the standard programmable passcode that most operators should be using.

The actual digits in your passcodes are never displayed. An "X" is used as a place holder for each digit entered. Passcodes must

always be four digits in length.

Programming 3-11

Section 3 WattMaster WHP

Rebuild Alarm Map

Rebuilding Screens

Clearing Old Map

....................

................

Build New Map?

(ESC = NO)

Building New Map

Loop: 1 Unit: 1

Dec) Go To Next Loop

ESC) Abort Process

Alarm Unit Map Built

Press Any Key To

Continue

If you would like the LED Alarm Indicator to function on the front of your System Manager, you must enable Alarm Polling by building an Alarm Map. This map keeps track of which units exist on your communications loop so the System

Manager will poll only those units. That means you will need to rebuild this map anytime units are added or removed from your system. It also means you can disable alarm polling. To do this, disconnect the RS-485 communications plug from the back of your Comm Link II. Then, select the Rebuild Alarm

Map menu. The System Manager will not find any units to poll for alarms since none are connected. This is useful during building startup, when you don't want nuisance alarms bothering you.

The screen will display each address it is testing and if a unit is found at that address. If you don't want to wait for the System

Manager to check for all 30 loops, you can press the ESC key as soon as the number of loops on your system are exceeded and the test will conclude. All units found up to that point will be saved in memory.

The System Manager does not rebuild this map

automatically on powerup! You must do this manually. This rebuild need only be performed one time, when all units are up and running. It is not a regular requirement. As mentioned above, only when the number of units connected changes should the alarm map be rebuilt.

3-12 Programming

WattMaster WHP

Heat Pump Setpoints

Section 3

Heat Pump Setpoint Menu

1) WHP Setpoints

2) WHP Schedules

3) Reset Pumps

ESC) To Exit

From the main menu screen select MENU on the keypad, select MENU again for Setpoints. Then select “Access Units”

(keypad #2) and finally enter the loop and zone number for the desired unit.

As the screen above shows, there are three areas of programming available for each WHP Controller. Menu item

#1 accesses all the standard temperature and configuration settings for the heat pump. Menu item #2 accesses the week schedule and holiday programming for the individual unit.

Menu item #3 can be selected to force the heat pump to manually reset in the case of an operating problem.

1) WHP Setpoints

Setpoint Screen #1

WHP #1 Setpoints

Occupied Setpoints

Cooling Setpt: xx

°

F

Heating Setpt: xx

°

F

The Occupied Heating and Cooling Setpoints are programmed on this screen. The setpoints must be at least one degree apart. If you try to enter the same value or to cross the cooling and heating setpoints, the value you enter will not be accepted.

Cooling Setpt

Heating Setpt

Minimum Default Maximum

50 ° F 74 ° F 90 ° F

50 ° F 72 ° F 90 ° F

Programming 3-13

Section 3 WattMaster WHP

Setpoint Screen #2

WHP #1 Setpoints

Unoccupied Setpoints

Cool Setup.: xx

°

F

Heat SetBk.: xx

°

F

The Unoccupied Heating and Cooling Setbacks are programmed on this screen. The Cooling SetUp is added to the Occupied

Cooling Setpt to create the Unoccupied Cooling Setpoint. The

Heating SetBack is added to the Occupied Heating Setpt to create the Unoccupied Heating Setpt.

Cool SetUp

Heat SetBack

Minimum Default Maximum

1 ° F 10 ° F 30 ° F

-1 ° F -10 ° F -30 ° F

Setpoint Screen #3

WHP #1 Setpoints

Slide Effect: x

°

F

SP Deadband.: xx

°

F

OV Duration.:x.x Hr

If the Space Temperature Sensor has the optional slide adjustment, then the Slide Effect is the maximum amount of change that it can have on the Heating and Cooling Setpoint and it is programmed here.

The SP Deadband is divided in half across the current heating and cooling setpoint, and is used in staging the heating and cooling on or off.

If you have an override pushbutton on the space sensor, the OV

Duration is the length of time the unit will be in the occupied mode after pushing the button

Slide Effect

Minimum Default Maximum

0 ° F 3 ° F 5 ° F

SP Deadband

OV Duration

0 ° F

0.0 Hr

1 ° F

1.0 Hr

20 ° F

8.0 Hr

Setpoint Screen #4

WHP #1 Setpoints

Cooling Stages: x

Heating Stages: x

If the Heat Pump is configured to operate with a Reversing

Valve, relay #5 can be configured as a second stage for either heating or cooling or both. If the Heat Pump is configured for individual heating and cooling, this determines how many of each stage there are.

Cooling Stages

Heating Stages

Minimum Default Maximum

0 1 2

0 1 2

3-14 Programming

WattMaster WHP Section 3

Setpoint Screen #5

WHP #1 Setpoints

Min Run Time: x Min

Min Off Time: x Min

Min Cycle...:xx Min

The Min Run Time determines how long the compressor must remain on once it has been activated. The Min Off Time determines how long the compressor must remain off once it is de-activated. The Min Cycle time determines how many times per hour the compressor can be started. If you entered

10 minutes, the compressor could start a maximum of 6 times in a one hour period.

Min Run Time

Minimum Default Maximum

0 Min 1 Min 20 Min

Min Off Time

Min Cycle

0 Min

0 Min

6 Min

12 Min

20 Min

60 Min

Setpoint Screen #6

WHP #1 Setpoints

Changeover Delay

Between Heat/Cool

Modes......:xx Min.

To prevent rapid cycling between heating and cooling modes, you can enter a time period that must be satisfied before the changeover can occur.

Changeover Delay

Minimum Default Maximum

1 Min 30 Min 60 Min

Setpoint Screen #7

WHP #1 Setpoints

Enable Signal Select

NO ENABLE REQUIRED

Use Left/Right Arrow

Normally you would want to have an Enable Signal that gave assurance of water flow before you activate the heat pumps compressor. If you need to operate without this enable signal, use the arrow keys to select the NO ENABLE REQUIRED message. Otherwise, select the LOOP FLOW REQUIRED message so that the signal must be present for the compressor to run.

Programming 3-15

Section 3 WattMaster WHP

Setpoint Screen #8

WHP #1 Setpoints

WHP Configuration

R/VALVE & COMPRESSOR

Use Left/Right Arrow

If your heat pump uses a reversing valve to determine the heating or cooling mode of operation, select the message

R/VALVE & COMPRESSOR. If you are controlling separate stages of heating and cooling select the

INDIVIDUAL STAGING

message.

Setpoint Screen #9

WHP #1 Setpoints

Reversing Valve Used

During: COOLING MODE

Use Left/Right Arrow

If you have configured the system to use the reversing valve, you must select which mode requires it to be active. Select either the COOLING MODE or the HEATING MODE message.

Setpoint Screen #10

WHP #1 Setpoints

Reverse Valve Mode

CYCLES w/COMPRESSOR

Use Left/Right Arrow

If you have configured the system to use the reversing valve, you can also set it to cycle on and off with the compressor,

(CYCLES w/COMPRESSOR) or, to remain on once it is activated, and stay on until the opposite mode or unoccupied mode is selected (RUNS CONTINUOUS MODE). The valve always activates 10 seconds before the compressor starts no matter which method you select.

3-16 Programming

WattMaster WHP Section 3

Setpoint Screen #11

WHP #1 Setpoints

Relay5 Configuration

AUXILIARY RELAY MODE

Use Left/Right Arrow

If your system is configured to use the reversing valve and you only have one stage of heating and cooling, that last relay becomes available for other uses. The AUXILIARY

RELAY MODE can be used to operate the relay manually from the Prism computer front end program. If you select

ISOLATION VALVE MODE, the relay activates anytime the compressor is called for or whenever the Loop Controller sends an override command to activate and reduce loop pressure.

If the relay needs to follow an external week schedule, select the AUXILIARY RELAY MODE and then see the Aux

Relay #5 Schedule assignment screen.

Setpoint Screen #12

WHP #1 Setpoints

Fan Mode of Op

RUNS CONTINUOUS MODE

Use Left/Right Arrow

You can program the fan to run continuously during the occupied mode,

(RUNS CONTINUOUS MODE) or you can program it to cycle on and off with the compressor during both the occupied and the unoccupied mode of operation.

(CYCLES W/COMPRESSOR)

Setpoint Screen #13

WHP 1# Setpoints

Aux Relay #5 Uses

Uses Schedule #: x

0) None 1-7) Clock

If you configured relay #5 as an Auxiliary Relay, you can also program it to follow an external schedule command.

You must have an OSS Optimal Start Scheduler installed somewhere on you communications loop to provide the external schedule you select here.

Programming 3-17

Section 3 WattMaster WHP

Setpoint Screen #14

WHP #1 Setpoints

Heat Pump Scheduling

Uses Schedule #: x

0) Int. 1-7) Clock

The Heat Pump Controller can use the internal time clock for a setting an occupied schedule, for this the setpoint will be 0.

It can also be programmed to follow an external schedule command. You must have an OSS Optimal Start Scheduler installed somewhere on you communications loop to provide the external schedule, and you select the schedule number here.

Setpoint Screen #15

WHP Setpoints

Startup Delay Period

x Seconds Times

Board Address Switch

If you entered the same starting time for several heat pumps, they are prevented from all starting their fans at the same time by a Startup Delay Period that is determined by their address switch setting. The address is multiplied by the number of seconds you enter on this screen, up to a maximum of 60 seconds per address. This is the time period the fan must wait before it starts when the schedule goes occupied.

If you entered 5 seconds and the address was 10 then the fan would start 5 x 10 or 50 seconds after the schedule goes occupied.

Setpoint Screen #16

WHP Setpoints

Energy Demand Limits

Max Effect: xx

°

F

An Energy Demand Limit sequence is programmed into all heat pump controllers. It is currently an option that is not

supported by a controller that can send the Demand Limit signal to initiate a limiting condition. It is included here for future use only.

Max Effect

Minimum Default Maximum

0 ° F 3 ° F 30 ° F

3-18 Programming

WattMaster WHP Section 3

Setpoint Screen #17

WHP # 1 Setpoints

Heat Stage #2

SAT Lockout: 60 ° F

This setpoint is to shut the heating off when the supply air temperature is too warm. When the supply air temperature is above this setpoint, it will prevent the second stage of heat from coming on.

Max Effect

Minimum Default Maximum

30 ° F 60 ° F 200 ° F

Setpoint Screen #18

SENSOR CALIBRATION

SPC xxx.x

°

xxxx.x

°

°

SAT xxx.x

°

° xxxx.x

°

°

WAT xxx.x

°

° xxxx.x

°

°

The Thermister Type III Sensor readings can be calibrated.

Enter Positive values to increase the reading or Negative values to decrease the reading. If no sensor is attached, the calibration offset will still allow a value to be input and read for diagnostic purposes.

Minimum Default Maximum

Space Sensor SPC -100.0°F 0.0°F +100.0°F

Supply Air Sensor SAT -100.0°F 0.0°F +100.0°F

Water Sensor WAT -100.0°F 0.0°F +100.0°F

Setpoint Screen #19

WHP #1 Setpoints

Alarms: Enabled

Use Left/Right Arrow

Select if you want the notification LED on the front of the

System manager to illuminate when an alarm occurs. If

Enabled is selected, any WHP alarm will cause the Alarm

LED on the front panel to light up. If Disable is selected, the

Alarm LED will not light up but the alarm will still show up in the Status screen.

Note: You must do a Rebuild Alarm Map after all controllers are powered up and communicating.

Programming 3-19

Section 3 WattMaster WHP

2) WHP Schedules

The Water Source Heat Pump controllers contain their own built in scheduling capability for calculating Occupied/Unoccupied periods. Select item #2 from Schedules menu to access the following schedule programming menu.

Schedule Menu

WSHP Schedules

1) Week Schedules

2) Holidays

MENU) Previous Menu

Week Schedule Programming

Event #1

WEEK SCHEDULES

Sunday Event #1

Start Time..: xxxx

Stop Time..: xxxx

Event #2

WEEK SCHEDULES

Sunday Event #2

Start Time..: xxxx

Stop Time..: xxxx

There are two Start / Stop events available per day.

The first line is the start time for event #1 and the next line is the stop time for event #1.

The screens will step through the Start Time and then the Stop

Time for each day of the week. You can quit at any point in the process by pressing the "ESC" key.

If no second event is required, simply leave a ZERO for both the start and stop times on the event #2 screens.

All times are in 24-hour format, so 5:00 PM would be entered as 1700.

If both the Start and Stop Times are ZERO, the schedule is in a

Continuous OFF mode.

If both the Start and Stop Times are 2359, the schedule is in a

Continuous ON mode.

3-20 Programming

WattMaster WHP

Holidays

Section 3

Holiday Day Selection

There are 14 Holiday periods available, organized as a Start Day / Stop Day event. If the

Holiday only lasts one day, enter the same date for the Start & Stop days. There is no limit to the duration or number of days that can be included in one holiday, other than it cannot extend past December 31st. If you have a holiday that crosses the end of year border, you will need to use two holiday periods to accomplish this event.

Program Holidays

Holiday # 1

Start Mon/Day: xxxx

(EX: 101 = Jan. 1)

The screens will step through the 14 possible holidays, one at a time. Line 2 shows which holiday is currently being programmed.

Program Holidays

Holiday # 1

Stop Mon/Day: xxxx

(EX: 102 = Jan. 2)

Line 3 shows which event, the Start Day or Stop Day, is currently being programmed.

Remember to combine the month and day into a single four digit value.

EXAMPLE: 0704 = July 4th

1225 = December 25th

Holiday Start / Stop Times

WHP CONTROLLER

Holiday Schedule

Start Event #1..: xxxx

Stop Event #1..: xxxx

The 14 holidays all use the same Holiday Start / Stop time. The start/stop times are programmed back on the

Week Schedule screens. The holiday schedule screen appears after the Saturday schedule screen, as you are stepping through the days of the week.

Note: Normally there is no schedule in the Loop Controller device. It simply looks at all the Water Source Heat Pumps for a request to run signal. Scheduling is maintained separately in each Water Source Heat Pump. If you want to be able to schedule all Water Source Heat Pumps on and off at the same time, you can input a schedule on the Loop Controller and it will broadcast that schedule to all

WHPs.

Programming 3-21

Section 3 WattMaster WHP

3) Reset Pumps

WSHPRV 1 v2.03

Tripped Pump Reset

Reset Mode: Disabled

Use Left/Right Arrow

If one of your heat pumps has tripped off, it can be manually reset from the following screen. You will have entered the

Unit ID to access the WHP Menu screen, so that is the unit that will receive this reset command. If you don’t want to send the command, select the Disabled message with the arrow keys. If you do want to send the command, select the

Enabled message with the arrow keys and then press the

Enter button. This command will automatically clear itself when the WHP detects it and performs the reset.

There are two methods of resetting:

1.

Relay #4, on the WHP will activate with the reset command and can be wired to provide the reset action.

2.

The compressor relay will be cycled off. On newer heat pumps, this is all that is required to reset the operation.

3-22 Programming

WattMaster WHP Section 3

Loop Controller Status

Loop Controller Status Menu

1) View Status Only

2) View Alarms

Menu) Setpoints

ESC) To Exit

From the main menu screen select MENU on the keypad. Then select “View Status

Only” (keypad #1) and finally enter the loop and zone number for the desired unit.

As the screen above shows, there are two areas of status available for the Loop

Controller. Menu item #1 accesses all the status screens for the Loop Controller. Menu item #2 accesses the alarms for the Loop Controller. “Menu” can be selected to access the

Setpoints screens.

Loop Controller Status

Screens

If you selected menu item #1, View Status Only, and you entered the Unit ID of the Loop

Controller, the following Status Screens are available.

Status Screen #1

Loop Control v1.06

OCCUPIED

Return Temp: xx.x

° F

Supply Temp: xx.x

°

F

Line 2 Current operating Mode:

OCCUPIED

UNOCCUPIED

Line 3 Current Return Water Temperature

Line 4 -

Current Supply Water Temperature

Programming 3-23

Section 3 WattMaster WHP

Status Screen #2

Loop Control v1.06

No Call to Run

Water Flow Proved!

LOOP ENABLED

Line 2 Current operating Mode:

No Call To Run

ACTIVE CALL TO RUN

FREEZE PROTECTION!

Line 3 Current Water Flow Status:

Water Flow Proved!

No Flow Detected

Line 4 Current Request to Operate Status:

LOOP ENABLED

LOOP DISABLED

Status Screen #3

Loop Control v1.06

LEAD Pump #1: ON

STANDBY Pump #2: OFF

Line 2 -

LEAD Pump #1 On or Off

Line 3 STANDBY Pump #2 On or Off

Status Screen #4

Cool Stage # 1.: OFF

Cool Stage # 2.: OFF

Cool Stage # 3.: OFF

Cool Stage # 4.: OFF

Line 1 -

Line 2 -

Cool/Heat Stage #1 On/Off

Cool/Heat Stage #2 On/Off

Line 3 -

Line 4 -

Cool/Heat Stage #3 On/Off

Cool /Heat Stage #4 On/Off

3-24 Programming

WattMaster WHP

Status Screen #5

Cool Stage # 5.: OFF

Cool Stage # 6.: OFF

Cool Stage # 7.: OFF

Cool Stage # 8.: OFF

Line 1 -

Line 2 -

Cool/Heat Stage #5 On/Off

Cool/Heat Stage #6 On/Off

Line 3 -

Line 4 -

Cool/Heat Stage #7 On/Off

Cool/Heat Stage #8 On/Off

Section 3

Status Screen #6

Loop Control v1.06

Pressure.: xxx.x PSI

Pump VFD.: xx.x VDC

Heat VFD.: xx.x VDC

Line 2 Current Loop Water Pressure

Line 3 Current Variable Speed Pump Voltage Signal

Line 4 Current Proportional Heat Voltage Signal

Note: If none of the above options have been configured, then the values in this status screen will be 0.

Programming 3-25

Section 3 WattMaster WHP

Status Screen #7

Loop Control v1.06

No Alarms!

Line 2 Pump Failure or Blank Line

Line 3 -

Line 4 -

Hi Control Water Temp

Lo Control Water Temp

Fire/Smoke Alarm

Phase Shutdown

Note: If no alarms exist, then the screen displays the message shown for No Alarms! If

ANY alarm exists, then the three lines display one of the messages shown above.

The Fire/Smoke Alarm is generated as follows:

If the NC (normally closed) contact from a firestat or smoke detector that is wired between GND and AIN1, on the Analog Input expansion board, opens, the

Fire/Smoke Alarm is generated.

The Phase Shutdown Alarm is generated as follows:

If the NO (normally open) contact from a phase monitoring device, that is wired between GND and AIN7 is made, the Phase Shutdown Alarm is generated.

Status Screen #8

Loop Control v1.06

Pump Run Times

#1: xxxxx Hrs xx Min

#2: xxxxx Hrs xx Min

Line 2 -

Message Only

Line 3 Pump #1 Hours and Minutes Run Time

Line 4 Pump #2 Hours and Minutes Run Time

3-26 Programming

WattMaster WHP Section 3

Loop Controller Setpoints

Loop Controller Setpoint Menu

1) LC Setpoints

2) LC Schedules

3) LC Force Modes

ESC) To Exit

Setpoint Screen #1

WHP Loop Setpoints

HEAT REJECTION

Setpoint......: xx

°

F

Stage Deadband: xx

°

F

If the controlling water temperature rises above this Setpoint, the Heat Rejection or Cooling Stages begin to stage on. As the temperature continues to rise above the Setpoint by the

Deadband amount, an additional stage is added. Each additional stage can only activate if the temperature rises above the Setpoint by the number of active stages times the deadband value.

Example: There are 2 stages on, a 3 ° deadband and the setpoint is 79 °

2 x 3 ° + 79 ° = 85 ° before stage 3 can activate

Minimum Default Maximum

Setpoint 50 ° F 79 ° F 99 ° F

Stage Deadband 1 ° F 3 ° F 10 ° F

Setpoint Screen #2

WHP Loop Setpoints

HEAT REJECTION

Stage Delay...: x M

The Staging Delay period must also be satisfied before an additional stage of cooling or heat rejection can be activated.

The maximum number of heat rejection stages are programmed on this screen also.

Stage Delay

Minimum Default Maximum

1 Minute 1 Minute 60 Minutes

Programming 3-27

Section 3 WattMaster WHP

Setpoint Screen #3

WHP Loop Setpoints

HEATING ADDITION

Setpoint......: xx

°

F

Stage Deadband: xx

°

F

If the controlling water temperature drops below this Setpoint, the Heat Addition or Boilers begin to stage on. As the temperature continues to drop below the Setpoint by the

Deadband amount, an additional stage is added. Each additional stage can only activate if the temperature drops below the Setpoint by the number of active stages times the deadband value.

Example: There are 2 stages on, a 3 ° deadband and the setpoint is 79 °

79 ° - 2 x 3 ° = 73 ° before stage 3 can activate

Setpoint

Stage Deadband

Minimum Default Maximum

50 ° F 76 ° F 99 ° F

1 ° F 3 ° F 10 ° F

Setpoint Screen #4

WHP Loop Setpoints

HEATING ADDITION

Stage Delay...: x M

The Staging Delay period must also be satisfied before an additional boiler or heat addition stage can be activated.

The maximum number of heat addition stages are programmed on this screen also.

Stage Delay

Minimum Default Maximum

1 Minute 1 Minute 60 Minutes

Setpoint Screen #5

WHP Loop Setpoints

OA FREEZE PROTECTION

Setpoint.....: xx ° F

If the outdoor air temperature drops below this setpoint, the pump will be energized to prevent the water lines from freezing.

Setpoint

Minimum Default Maximum

-50

°

F 40

°

F 50

°

F

3-28 Programming

WattMaster WHP Section 3

Setpoint Screen #6

WHP Loop Setpoints

Water Hi Limit: xx

°

Water Lo Limit: xx

°

Alarm Delay...: xM

If the controlling water temperature rises above the Water Hi

Limit setpoint, all heat addition will be removed and one stage of heat rejection will be activated. If the controlling water temperature drops below the Water Lo Limit setpoint, all heat rejection stages will be removed and one heat addition stage will be activated. An alarm will be generated if it remains out of limits for the Alarm Delay Time.

Water Hi Limit

Water Lo Limit

Alarm Delay

Minimum Default Maximum

0 ° F 120 ° F 120 ° F

0 ° F

0 Min

0 ° F

30 Min

120 ° F

120 Min

Setpoint Screen #7

WHP Loop Setpoints

Pump Speed: CONSTANT

Flow Proof: CONTACT

Use Left/Right Arrow

The Loop Controller can modulate a Variable Speed Pump.

Select the PRESSURE option in place of the CONSTANT option for variable speed pumping.

The water flow proving can be accomplished by a differential pressure contact closure or an actual pressure sensor. If you select Variable Speed Pumping, you must select the

PRESSURE option in place of the CONTACT option for

Flow Proof.

Setpoint Screen #8

WHP Loop Setpoints

STEP HEATING CONTROL

RETURN WATER CONTROL

Use Left/Right Arrow

There are two methods of Heat Addition control, STEP

HEATING CONTROL or PROPORTIONAL HEATING

The Loop Controller can be configured to maintain Return

Water Temperature ( RETURN WATER CONTROL ) or the Supply Water Temperature ( SUPPLY WATER

CONTROL )

Programming 3-29

Section 3 WattMaster WHP

Setpoint Screen #9

WHP Loop Setpoints

Lead/Lag Changeover

Switch After xxx Hrs

The two pumps will switch after this programmed amount of time so that each pump accumulates roughly the same number of run time hours. If a pump is currently running and this time period is exceeded, the changeover will occur as soon as pump run time exceeds the setpoint. The current pump will shut off and the standby pump will start at the same time.

Changeover

Minimum Default Maximum

1 Hour 40 Hours 240 Hours

Setpoint Screen #10

WHP Loop Setpoints

Water Loop Proof Of

Flow Pr. SP: xxx PSI

If you attached a Pressure Sensor for proof of flow instead of a differential pressure contact closure for proof of flow, the controlling pressure is programmed on this screen. This

Setpoint represents the amount of pressure that you set to prove water flow exists in the system. Otherwise, this screen will not appear.

Flow PR. SP

Minimum Default Maximum

0 5 PSI 50 PSI

Setpoint Screen #11

WHP Loop Setpoints

Pressure SP: xxx PSI

SP Deadband: xx PSI

Adjust Time: x.x Sec

If you configured the system for Variable Speed Pumping with a Pressure Sensor for proof of flow, the controlling pressure, deadband and control adjust time period are programmed on this screen. Otherwise, this screen will not appear.

Pressure SP

SP Deadband

Adjust Time

Minimum Default Maximum

1 PSI 40 PSI 50 PSI

1 PSI 2 PSI 50 PSI

0.1 Seconds 1.0 Seconds 25 Seconds

3-30 Programming

WattMaster WHP Section 3

Setpoint Screen #12

WHP Loop Setpoints

Isolation Valves Set

Open if PSI is Above

Hi Limit...: xxx PSI

If you configured the system for Variable Speed Pumping with a

Pressure Sensor for proof of flow, the Loop Controller can send a signal to all the Heat Pumps to open their Isolation Valves whenever a Hi Limit Pressure is exceeded. If the Heat Pumps do not control an Isolation Valve, then the only reaction is to reduce the variable speed pump voltage signal.

Hi Limit

Minimum Default Maximum

1 PSI 50 PSI 50 PSI

Setpoint Screens #13

SENSOR CALIBRATION

RWT xxx.x

°

xxxx.x

°

°

SWT xxx.x

°

° xxxx.x

°

°

OAT xxx.x

°

° xxxx.x

°

°

The Thermister Type III Sensor readings can be calibrated.

Enter a Positive value to increase the reading or a Negative value to decrease the reading. If no sensor is attached, the calibration offset will still allow a value to be input and read for diagnostic purposes.

Minimum Default Maximum

Return Water RWT -10.0°F 0.0°F +10.0°F

Supply Water SWT -10.0°F 0.0°F +10.0°F

Outdoor Air OAT -10.0°F 0.0°F +10.0°F

Note: Due to memory limitations in the Loop Controller, the maximum amount of calibration offset is 10.0

° F.

Setpoint Screen #14

WHP Loop Setpoints

Alarms: Enabled

Use Left/Right Arrow

Alarms can be configured to light the LED on the front of the

System Manager by setting Alarms to Enabled, if you do not wish to report alarms, select Disabled.

Setpoint Screen #15

WHP Loop Setpoints

Relay Configurations

Rly 1: ADDITION

Use Left/Right Arrow

Use this screen to configure the relays on the expansion board for heat ADDITION, REJECTION or NOT USED. All 8 relays come up one at a time.

Programming 3-31

Section 3

Notes:

WattMaster WHP

3-32 Programming

Section 4

Table of Contents

1.0 Communications Overview........................................ 1

1.1 How It Works...........................................................................................................1

1.2 WattMaster WHP System ........................................................................................1

2.0 WHP Controller Overview .......................................... 4

2.1 How It Works...........................................................................................................4

2.1.1

Initialization .....................................................................................................4

2.1.2

Operating Summary .........................................................................................4

2.2 Becoming Familiar with the WHP Controller .........................................................5

2.2.1

24 VAC Power Connector ...............................................................................5

2.2.2

Analog Inputs ...................................................................................................6

2.2.3

Analog Output Description ..............................................................................6

2.2.4

Relay Output Descriptions ...............................................................................6

2.2.5

RS-485 Communications Connector ...............................................................7

2.2.6

WHP Controller Wiring...................................................................................8

3.0 Loop Controller Overview......................................... 9

3.1 How It Works...........................................................................................................9

3.1.1

Initialization .....................................................................................................9

3.1.2

Operating Summary .........................................................................................9

3.2 Loop Controller Inputs & Outputs .........................................................................10

3.2.1

Analog Inputs .................................................................................................10

3.2.2

Analog Output................................................................................................10

3.2.3

Binary Output.................................................................................................11

3.2.4

Relay Expansion Board - Outputs..................................................................11

3.2.5

Analog Input Expansion Board......................................................................11

3.2.6

Comm Connector - Communications ............................................................12

3.2.7

Power Terminal..............................................................................................12

4.0 Start-Up.................................................................... 14

4.1 Blink Codes for WHP Controllers .........................................................................14

4.2 Blink Codes for Loop Controllers..........................................................................15

4.3 Communications Checklist ...................................................................................15

4.4 Installation and Commissioning Information ........................................................16

4.5 Setting Address Switches.......................................................................................19

4.5.1

Setting the MiniLink Address Switch............................................................19

4.5.2

Loop Controller Addressing...........................................................................20

4.5.3

WHP Controller Addressing ..........................................................................20

Start-Up and Troubleshooting

Section 4

5.0 Troubleshooting ...................................................... 21

5.1 General Troubleshooting........................................................................................21

5.1.1

Communications Troubleshooting Checklist.................................................21

5.1.2

General Troubleshooting Checklist ...............................................................22

5.2 Alarms......................................................................................................................23

5.3 Checking Comm. Loop Voltages.............................................................................24

5.3.1

Checking the CommLink II Network Loop ...................................................24

5.3.2

Checking the Comm Loop at the CommLink II ............................................25

5.3.3

Checking the CommLink II Driver ................................................................26

5.3.4

Checking the MiniLink Network Loop..........................................................27

5.3.5

Checking the MiniLink Network Driver........................................................28

5.3.6

Checking the MiniLink Local Loop...............................................................29

5.3.7

Checking the Local Loop at MiniLink...........................................................30

5.3.8

Checking the MiniLink Local Loop Driver ...................................................32

5.3.9

Checking the Local Loop at a WHP Controller .............................................33

5.3.10 Checking WHP Controller Driver Chip.........................................................34

5.4 Troubleshooting Loop Controller ..........................................................................35

5.4.1

Checking the Loop Controller Analog Inputs ................................................35

5.4.2

Checking the Loop Controller Outputs ..........................................................37

5.4.3

Checking the Local Loop at a WHP Loop Controller....................................38

5.4.4

Checking WHP Loop Controller Driver Chip ...............................................39

5.4.5

Comm Driver Chip Replacement...................................................................40

5.5 Temperature Sensor Resistance Chart ...................................................................41

5.6 Pressure Sensor Voltage Chart...............................................................................42

Notes: ............................................................................ 43

Table of Figures

Figure 4-1: System Wiring Overview.............................................................................2

Figure 4-2: Communications Loop Routing...................................................................3

Figure 4-3: WHP Controller Component Layout ...........................................................5

Figure 4-4: Typical WHP Controller Wiring Diagram...................................................8

Figure 4-5: Loop Controller Inputs & Outputs .............................................................13

Figure 4-6: Diagnostic LED Blink Codes.....................................................................14

Figure 4-7: Diagnostic LED Blink Codes.....................................................................15

Figure 4-8: Communications Loop Wiring ..................................................................18

Figure 4-9: MiniLink Address Switch Setting.............................................................19

Figure 4-10: WHP Controller Address Switch Setting...............................................20

Figure 4-11: Comm Driver Chip Replacement............................................................40

Start-Up and Troubleshooting

WattMaster WHP Section 4

1.0 Communications

Overview

Perhaps no other portion of the system seems as difficult to diagnose as the communications loop, yet it really can be quite simple if you understand how it works. In fact, much of the troubleshooting can be done by simple observation. We will lead you through the system functions and then provide you with detailed instructions for checking each piece of equipment.

1.1 How It Works

WattMaster uses a token-passing loop architecture, which means in simple terms that an

“electronic message” called a token is passed from controller to controller in a roundrobin fashion. A controller must wait to receive the token before it can send or request any data.

Note: It is very important to know which device is the loop master on the loop you are troubleshooting.

1.2 WattMaster WHP System

The standard WattMaster WHP system may have only one communications loop or as many as thirty communication loops depending on the number of WHP Controllers to be connected to the system. It is important to remember that each loop must have its own master.

If you are using the multiple loop version of the WHP system (for systems with more than

30 WHP Controllers) a loop is required for each group of 30 WHP Controllers. The WHP

Loop Controller may be connected to any of the Local Loops. The Local Loop that has the WHP Loop Controller installed can only have 29 WHP Controllers on that loop. Each

Local Loop is connected to a MiniLink loop interface. The MiniLink is always the

master on the Local Loops. The MiniLinks are connected to the CommLink II and to each other via the Network Loop.

.

The CommLink II is always the master on the Network Loop. You must be sure the

CommLink II is connected and functioning if you are troubleshooting the communications loops. Make sure the CommLink II is set for multiple loops

Start-Up and Troubleshooting 4-1

WattMaster WHP

COMPUTER

(OPTIONAL)

Section 4

RS-485

Comm Loop

Room Sensor with Optional

Override & Adj.

32K 8K

COMM

T

SHLD

R

LD4

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

2

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

PWR GND

24VAC

24 VAC

110/24 VAC

Power Pak

Supply

Air

Sensor

F

Dirty Filter Alarm or Leaving Water Temp

Modem

(Optional)

110/24 VAC

Power Pak

Typical WHP Controller Wiring

MR

TR

SD

RD

OH

CD

AA

HS

CommLink II

Multiple Loop

Interface

LINK

II

Network Loop

RS-485

19200 Baud

O

P

C

O

M

P

O

E

W

AT

TM

AST

ER

C

ONTR

O L

S,

I

NC

MiniLink

Loop # 1

T

SH

R

16

32

24VAC

GND

T

SH

R

Local Loop

RS-485

9600 Baud

System Manager

24VAC

MiniLink

Loop # 2

T

SH

R

16

32

24VAC

GND

T

SH

R

03:38PM

WED

MiniLink

Loop # 3

24VAC

Local Loop

RS-485

9600 Baud

24VAC

Typical Network & Local Loop Wiring

2 Conductor Twisted Pair with Shield

(Beldon #82760 or Equivalent)

T

SH

R

16

32

NOTE: * Only One Outside Air Sensor is Required per WHP System

MiniLink

Loop # 4

T

SH

R

16

32

T

SH

R

T

SH

R

GND

24VAC

GND

24VAC

Local Loop

RS-485

9600 Baud

*OutsideAir

Sensor

WHP Loop

Controller

RN1

CX1

U1

U2 CX2

TB1

COMM

T

SHLD

R

CX5

LD6

COMM

LD7

PWR

U5

RS-485

COMM

LD8

LED1

C1

R1

LD9

LED2 P1

+VREF

5.11V

TEST POINT

U7

RV1

VREF ADJ

EWDOG

R28

INPUTS

HH

ADDRESS

RAM

U6

ADD

+VDC

AIN1

RN5

AIN2

AIN3

AIN4

AIN5

GND

GND

C10

AOUT1

C12

TB3

AOUT2

AIN7

GND

PJ1

C17 D15

D8

PU4

D9

PU5

PU1

D6

PU2

D7

PU3

D11

PU7

D14

U13

SW1

CX13

U15

TOKEN

NETWORK

JP1

X2

CX15

U3

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

U10

CX10

R15

C14

R19

C15

U14

R22

R24

R25

U12

CX14

CX6

CX12

C20

PRESSURE

R26

SENSOR

EXPANSION T'STAT

U4

CX4

U9

PAL

VR1

C7

D12

R13

SC1

D19

VR2

L1

7824CT

V1

V2

V3

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V5

V4

R6

C9

MC34064A

U8

NE5090NPB3192

0PS

C13

C16

TB4

GND

24VAC

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

Loop # 4

24VAC

Notes:

1.) 24 VAC Must Be Connected

So That All Ground Wires

Remain Common.

#1

32K

8K

COMM

T

SHLD

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

2

AIN

3

AIN

4

AIN

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

COMM

TEST

ADDRESS ADD

RELAY

OUTPUT

COM

1-3

OUT

1

2

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#1

32K

8K

COMM

T

LD4

REC.

SHLD

R

12V

AIN

1

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

485

COMM

RAM EPROM

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4 OUT

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#1

RAM EPROM

32K

8K

COMM

T

LD4

REC.

SHLD

R

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#1

RAM EPROM

32K

8K

COMM

T

LD4

REC.

SHLD

R

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

Loop #1

WHP

Controllers

Loop #2

WHP

Controllers

Loop #3

WHP

Controllers

See Note #3

Loop #4

WHP

Controllers

Local Loop

RS-485

9600 Baud

3.) The Local Loop With The Loop Controller

Installed Can Only Have Up To 29

WHP Controllers Attached As The WHP

Loop Controller Occupies Address #30.

2.) All Wiring To Be In Accordance

With Local And National Electrical

Codes and Specifications.

#30

32K

8K

COMM

T

SHLD

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

1

AIN

2

AIN

3

AIN

4

AIN

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

COMM

TEST

ADDRESS ADD

RELAY

OUTPUT

COM

1-3

OUT

1

2

OUT

3

OUT

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#30

32K

8K

COMM

T

LD4

REC.

SHLD

R

485

COMM

RAM EPROM

12V

AIN

1

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4 OUT

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#30

RAM EPROM

32K

8K

COMM

T

LD4

REC.

SHLD

R

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

#29

RAM EPROM

32K

8K

COMM

T

LD4

REC.

SHLD

R

12V

AIN

2

AIN

3

AIN

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

1

OUT

2

OUT

3

4

OUT

4-5

5

COM

4-5

PWR

GND

24VAC

4.) Systems may consist of up to 20 Local

Loops (600 WHP Controllers). Consult factory for systems that exceed these quantities.

Figure 4-1: System Wiring Overview

4-2 Start-Up and Troubleshooting

WattMaster WHP Section 4

All communications wiring should be labeled to avoid confusion and to aid future servicing.

03/31/04 03:38PM WED

OCCUPIED

NO ALARMS

COMPUTER

(OPTIONAL)

POWER

24VAC

GND

COMMUNICATIONS

T

RS-485

SHLD

R

SYSTEM MANAGER POWER SUPPLY

YS101716 REV. 1

SYSTEM MANAGER

COMM LINK II

INTERFACE

(MULTIPLE LOOP)

UNIT COMES WITH

STANDARD WALL MOUNT

120/24 VAC POWER SUPPLY

( MAY ALSO BE POWERED FROM 24VAC )

Remote Link

(OPTIONAL)

NETWORK

LOOP

U3

1

RN1

CX1

U1

U2

CX2

U4

CX4

TB1

COMM

T

SHLD

R

CX5

LD6

COMM

LD7

PWR

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

GND

1

U5

RS-485

RN5

COMM

GND

AOUT1

C12

HH

U13

RAM

R15

EPROM

TUC-5R PLUS

(1 MEG)

YS101816 REV. 2

LD8

LED1

C1

LD9

LED2

R1

U7

+VREF

5.11V

TEST POINT

EWDOG

RV1

VREF ADJ

R28

INPUTS

P1

ADDRESS

C10

PU1

D6

PU2

D7

PU3

D8

PU4

D9

PU5

D11

PU7

D14

U6

SW1

ADD

1

2

4

32

8

16

TOKEN

NETWORK

U10

JP1

X2

CX10

CX6

CX12

AOUT2

U12

CX14 C14

R19 U14

TB3

AIN7

GND

PJ1

C17

D15 CX13

U15

C20 CX15

C15

R22

R24

R25

1

U9

PAL

1

C7

D12

R13

SC1

D19

R26

PRESSURE

SENSOR

EXPANSION T'STAT VR1

L1

VR2

7824C T

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V4

V5

V1

V2

V3

U8

NE5090NPB3192

0PS

R6

64A

9936

C9

MC340

C13

C16

TB4

GND

24VAC

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

32K

8K

COMM

T

LD4

SHLD

R

REC.

RAM EPROM

12V

AIN

1

2

3

4

AIN

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

PWR

GND

24VAC

OUTPUT

COM

OUT

OUT

OUT

OUT

4-5

32K

8K

COMM

485

COMM

RAM EPROM

REC.

12V

2

3

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

PWR

GND

24VAC

RELAY

OUTPUT

1-3

OUT

OUT

2

OUT

OUT

4-5

TO OTHER WHP CONTROLLERS

TO OTHER MINILINKS

(NETWORK TERMINALS ONLY)

Figure 4-2: Communications Loop Routing

Start-Up and Troubleshooting 4-3

Section 4 WattMaster WHP

2.0 WHP Controller

Overview

2.1

How It Works

2.1.1

Initialization

On system powerup the COMM LED remains extinguished for five seconds. After this delay, the COMM LED will blink out the address of the controller (Address Switch

Setting). The COMM LED will then extinguish for another five seconds and then begin to blink for a twenty second startup delay. At the conclusion of this twenty second period, the COMM LED will begin blinking a diagnostic code every ten seconds. This code is described later in this document. The duration of a powerup initialization sequence is roughly one minute.

During this initialization period, the controller retrieves all operating setpoints from its non-volatile EEPROM memory and initializes all outputs to an OFF condition.

Note: All future references to the Water Source Heat Pump Controller in this document use WHP as the designation.

2.1.2

Operating Summary

At all times, after the conclusion of the initialization sequence, the WHP performs a specific set of operating instructions in the following order: (a - g repeat continuously) a. Read Analog Inputs for Temperatures and Overrides.

b. Check the RS-485 communications port for any new setpoints from the System

Manager and keeps the status updated for the System Manager.

c. If the push-button override is active, it checks the timer to see if the override is finished.

d. Calculates the current occupied/unoccupied mode from its internal week scheduling.

e. Calculates what state the output relays and analog output should be set to.

f.

Updates the diagnostic COMM LED blinking.

g. Stores data in the internal trend log if ready for another log.

4-4 Start-Up and Troubleshooting

WattMaster WHP Section 4

2.2

Becoming Familiar with the WHP

Controller

COMMUNICATIONS

DRIVER CHIP PIN 1

INDICATION

RAM EPROM

RAM SIZE

SELECT JUMPER

PAL

32K

8K

RS-485

COMMUNICATIONS

LOOP

COMMUNICATIONS

LED

ADDRESS SWITCH

( ADDRESS 18 SHOWN )

ANALOG INPUTS

Space Sensor

Slide Adjust

Supply Air Temp

Leaving Water

Temp or

Dirty Filter

Lockout

COMM

T

SHLD

LD4

R

REC.

12V

2

3

AIN

4

AIN

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

485

COMM

RAM

CPU

EPROM

ADDRESS ADD

COMM

TEST

RELAY

OUTPUT

COM

1-3

OUT

2

OUT

OUT

4

OUT

5

COM

4-5

24 VAC Common for Inputs 1 - 3

Fan-On/Off

Rev. Valve-On/Off (Heat 1)

Compressor-On/Off (Heat 2)

Heat Pump Reset (Cool 1)

Aux. Heating or Cooling (Cool 2)

24 VAC Common for Inputs 1 - 3

DIAGNOSTIC BLINK

CODE LED

REAL TIME

CLOCK CHIP

POWER LED

24VAC

POWER

INPUT

STATIC PRESSURE

SENSOR INPUT

24VAC

Figure 4-3: WHP Controller Component Layout

2.2.1

24 VAC Power Connector

This connector provides power to the WHP Controller.

Mounting Backplate

24VAC - The “hot” side of the control transformer.

GND - The grounded side of the control transformer. If the secondary of the control transformer is not grounded, you must still observe polarity if the trans- former powers any other device!

Warning:

Connect only the GND terminal to the grounded side of a transformer

- Failure to properly observe polarity will result in damage to the system. Observe polarity at all points in the system.

Start-Up and Troubleshooting 4-5

WattMaster WHP Section 4

2.2.2

Analog Inputs

This connector carries the analog and binary control input signals.

AIN1 - Space Temp - This input accepts a two wire 10K Type III thermistor temperature sensor. The sensor measures 10,000 Ohms @ 77

°

F. The resistance drops as the temperature increases. The sensor is connected between this terminal and the GND terminal. This input is also monitored for push-button override commands. The push-button is only active during unoccupied hours so a push during occupied hours has no effect.

AIN2 - Slide Adjust - If the OE212 or OE213 space temperature sensor is installed, the sensor contains a slide adjust control for varying the current heating and cooling setpoints. If the OE210 or OE211 sensors are used, this input will not be used.

AIN3 - Discharge Temp - The discharge temperature reading is used to detect discharge air temperature and to monitor for equipment failure. Once the compressor has activated, the discharge air temperature has 10 minutes to change by

5

°

F or the controller assumes a mechanical failure has occurred.

AIN4 - Leaving Water Temp and/or Dirty Filter Alarm - Can provide status only water temperature and/or dirty filter contact closure. If both are used at the same time, water temperature will be lost when the dirty filter contact is closed.

AIN5 - Lockout - If this input is active all operations are terminated to protect the equipment.

GND - Common return wire. This point is tied to ground on the WHP

Controller.

2.2.3

Analog Output Description

AOUT - Analog Output - This output is not used.

2.2.4

Relay Output Descriptions

COM1-3 - Common 1 thru 3. - This ties the common return of the first 3 outputs together.

OUT1 - Fan On/Off - The fan is enabled to run when this contact is closed.

OUT2 - Reversing Valve or Heat 1 - This output enables the reversing valve if you have configured the WHP Controller for a compressor and reversing valve configuration. If the WHP Controller is configured for individual staging of heating and cooling (no reversing valve) then this output enables heating stage 1.

4-6 Start-Up and Troubleshooting

WattMaster WHP Section 4

OUT3 - Compressor or Heat 2 - This output enables the compressor if you have configured the WHP Controller for a compressor and reversing valve configuration. If the WHP Controller is configured for individual staging of heating and cooling (no reversing valve) then this output enables heating stage 2.

OUT4 - Heat Pump Reset or Cool 1 - This output can be used to reset a compressor that has gone off line. If the WHP Controller is configured for individual staging of heating and cooling (no reversing valve) then this output enables cooling stage 1.

OUT5 - Aux. Relay or Cool 2 - If you have configured the WHP Controller for a compressor and reversing valve configuration this output can be configured as follows:

1.) Stage 2 for cooling and/or heating mode.

2.) Auxiliary scheduling relay. In this mode it can be programmed to follow an externally broadcast schedule signal.

3.) Auxiliary relay. In this mode it can be used for any function requiring a manual user intervention.

4.) Isolation valve. May be used to initiate opening of an isolation valve in case of high loop water pressure even if the WHP Controller is satisfied or in an unoccupied mode. In occupied mode this relay operates in conjunction with the compressor.

If the WHP Controller is configured for individual staging of heating and cooling

(no reversing valve) then this output enables cooling stage 2.

COM4-5 - Common 4 and 5. - This ties the common return of the last 2 outputs together. Jumper this terminal to COM1-3 if the unit does not have separate cooling and heating power supplies.

2.2.5

RS-485 Communications Connector

This connector provides the connection point for the Local Loop RS-485 communications loop. The wiring consists of a twisted pair of wires with a shield.

T - RS-485 (+) Communications terminal

SHLD - Common return wire, this point is internally tied to GND on the WHP

Controller.

R - RS-485 (-) Communications terminal

Start-Up and Troubleshooting 4-7

WattMaster WHP

2.2.6

WHP Controller Wiring

Communication LED

Section 4

Figure 4-4: Typical WHP Controller Wiring Diagram

4-8 Start-Up and Troubleshooting

WattMaster WHP Section 4

3.0 Loop Controller

Overview

3.1

How It Works

3.1.1

Initialization

On system powerup LED2 remains extinguished for five seconds. After this delay, the

LED2 will blink out the address of the controller (Address Switch Setting). The LED2 will then extinguish for another five seconds and then the LED2 will begin blinking a diagnostic code every ten seconds. This code is described in the troubleshooting section.

The duration of a powerup initialization sequence is roughly thirty seconds.

During this initialization period, the controller retrieves all operating setpoints from its non-volatile EEPROM memory and initializes all outputs to an OFF condition.

3.1.2

Operating Summary

There is a standard set of operating instructions that are continuously performed over and over during normal Loop Controller operations. They are listed below.

a b

Read analog inputs for temperatures, pressures and binary contact closures

Checks for new setpoints from System Manager or Prism Software and keeps the status values updated for these interfaces.

c Looks for “request to run” broadcast from any installed WHP Controller or from an on-board binary input.

d. Set all outputs to match calculations for heat rejection or addition.

e. Store data in internal trend log if ready for another log f. Broadcasts the operating commands to all WHP Controllers.

g. Tests for lead/lag pump changeover if both pumps are off.

h. Repeat steps a-g continuously

Start-Up and Troubleshooting 4-9

WattMaster WHP Section 4

3.2

Loop Controller Inputs & Outputs

3.2.1

Analog Inputs

AIN1 - Return Water Temp - This input accepts a two wire 10K Type III thermistor temperature sensor. The sensor measures 10,000 Ohms @ 77

°

F. The resistance drops as the temperature increases. The sensor is connected between this terminal and the GND terminal.

AIN2 - Supply Water Temp - This input accepts a two wire 10K Type III thermistor temperature sensor. The sensor measures 10,000 Ohms @ 77

°

F. The resistance drops as the temperature increases. The sensor is connected between this terminal and the GND terminal.

AIN3 – Proof of Flow/Loop Pressure - This input accepts a differential pressure contact closure for proof of flow or a 0-50 PSI (0-5VDC) pressure transducer signal.

AIN4 - Outdoor Air Temp - The OA temperature is used to determine if pumps should be turned on during off periods, to prevent freezing. When the OA temperature is below 40

°

F, the pumps will be turned on.

AIN5 - Manual Reset Input - Used to restart equipment after alarm condition has occurred. When this input is shorted to GND by a momentary pushbutton, a signal to restart is sent.

AIN7 – Phase Loss – If a phase monitor is being used, a normally open contact is connected here. When a loss of phase is detected, this contact closes shutting down the Loop Controller.

GND - Common return wire. This point is tied to ground on the Loop Controller.

3.2.2

Analog Output

This connector carries a 0-10 volt control signal for the following items:

AOUT1- Pump VFD Signal - If you have selected the variable speed pump option this output signal is used to control the loop pressure.

AOUT2 - Proportional Heat Signal - This output may be used when a modulating signal is required to control heat addition temperature.

GND - Common return wire, this point is tied to GND on the Loop Controller.

4-10 Start-Up and Troubleshooting

WattMaster WHP Section 4

3.2.3

Binary Output

R1 – Compressor Enable – Energizes the first stage of cooling.

R2 – Main Pump – Energizes the lead water pump.

R3 – Standby Pump – Energizes the standby pump if the main pump fails to start.

R4 – Alarm Indicator – Energizes when an alarm occurs on the Loop Controller.

R5 – Not Used – This output is not used.

COM 1-3 - Common – 24 VAC from the AHU is connected to this terminal and is the common for inputs 1 through 3.

COM 4-5 - Common – 24 VAC from the AHU is connected to this terminal and is the common for inputs 4 and 5.

3.2.4

Relay Expansion Board - Outputs

This connector carries the output relay dry contact open/closed signal.

Relays 1-4 - Heat Addition/Rejection Stages - Can be configured to be used for either stages of heating or cooling of water when required.

Relays 5-8 - Heat Addition/Rejection Stages – Same as above, can be used for heating or cooling of the water.

3.2.5

Analog Input Expansion Board

The following inputs use dry contact open/closed signals.

AIN1 – Fire Alarm Contact - Used to shut down all equipment in case of a smoke or fire condition.

AIN2 - Request to Run - Used to initiate system start when a water source heat pump controller other than the WattMaster WHP Controller is used.

Warning:

Fire Alarm Contact input must be connected to the AIN1- GND terminal if it is not used, a jumper must be connected between AIN1 and GND, since this is a normally closed contact input. If this is not done the system will not operate.

Start-Up and Troubleshooting 4-11

WattMaster WHP Section 4

3.2.6

Comm Connector - Communications

RS-485 Communications Connector - This connector provides the connection point for the Local Loop RS-485 communications loop. The wiring consists of a twisted pair of wires with a shield.

T - RS-485 (+) Communications terminal

SHLD - Common return wire, this point is internally tied to GND on the WHP

Controller.

R - RS-485 (-) Communications terminal

3.2.7

Power Terminal

This connector provides power to the Loop Controller

24 VAC - Connect to the “HOT” side of the control transformer.

GND - The grounded side of the control transformer. If the secondary of the control transformer is not grounded, you must still observe polarity if the trans- former powers any other device!

Warning:

Connect only the GND terminal to the grounded side of a transformer

Failure to properly observe polarity will result in damage to the

system. Observe polarity at all points in the system.

4-12 Start-Up and Troubleshooting

WattMaster WHP

Connect To Next Controller And/Or

MiniLink On Local Loop

Local Loop RS-485

9600 Baud

(See Note 3).

Optional

Pressure sensor

Section 4

Line Voltage

Figure 4-5: Loop Controller Inputs & Outputs

Start-Up and Troubleshooting 4-13

WattMaster WHP Section 4

4.0 Start-Up

4.1

Blink Codes for WHP Controllers

The WHP Controller uses an on board LED to indicate various diagnostic conditions during powerup and operation. The WHP Unit LED is labeled “COMM”. Starting with power up the LED blink codes are as follows:

•

Off for five seconds

•

COMM LED blinks the board address (Address 14 = 14 blinks)

•

Five second pause

•

Twenty second time delay - LED blinks twenty times

•

Status code is repeatedly blinked every ten seconds to indicate controller status:

Priority

Lowest

-

-

-

Highest

No. of Blinks

1

2

3

4

5

Figure 4-6: Diagnostic LED Blink Codes

Status

Normal Operation

Override Active

Bad Space Sensor

Heat Pump Lockout

Communication Failure

Only the highest priority failure code will be shown. You must correct the highest priority alarm before other problems will be indicated.

4-14 Start-Up and Troubleshooting

WattMaster WHP Section 4

4.2

Blink Codes for Loop Controllers

The Loop Controller uses an on board LED to indicate various diagnostic conditions during powerup and operation. The Loop Controller Unit LED is labeled “LED2”.

Starting with power up the LED blink codes are as follows:

•

Off for five seconds

•

COMM LED blinks the board address (Address 14 = 14 blinks)

•

Five second pause

•

Status code is repeatedly blinked every ten seconds to indicate controller status:

Priority

Lowest

-

-

-

-

Highest

No. of Blinks

1

2

3

4

5

6

Figure 4-7: Diagnostic LED Blink Codes

Status

Normal Operation

Pump and/or Flow Failure

Bad Water Temp Sensor

Single Phase Shutdown

Water Pressure Alarm

Fire Alarm

Only the highest priority failure code will be shown. You must correct the highest priority alarm before other problems will be indicated.

4.3

Communications Checklist

•

WHP Controllers are addressed from 1 to 30 on each loop except the loop with the

WHP Loop Controller. This loop can only use address 1 thru 29 for the WHP Controllers. WHP Loop Controller is addressed as 30 on the loop it is connected to.

•

Power has been cycled after changing addresses

•

A multiple loop CommLink II is powered and connected to the communications loop.

•

System Manager is connected to one of the local loops.

•

The MiniLinks on each local loop are addressed with a unique address 1 thru 30, depending on the number of loops on your system.

Start-Up and Troubleshooting 4-15

WattMaster WHP Section 4

4.4

Installation and Commissioning

Information

Familiarize yourself with the installation manual and system wiring diagrams before installing!

1. Check to see if you have all the correct components for your installation.

2. Establish the location for the CommLink Interface first. This is where your communication cable will begin.

3. Layout your communication wiring. For systems with more than 30 WHPs or more than one MiniLink, there are multiple communication loops:

A. The Network Loop - This loop originates at the CommLink and interconnects

MiniLinks together.

B. The Local Loop – This loop originates at the MiniLink. The WHPs, Loop

Controllers and the System Manager are connected to this loop.

Tip: Using the WattMaster color-coded and labeled Communication Cable insures a quality installation. It also makes your installation much easier and less likely to have communications wiring errors!

4 .

Communication cable must always be shielded – no exceptions!

5. Mount controllers in appropriate locations according to their operating specification.

6. Address controllers according to location and addressing instructions located in the system manual.

7. With no power connected, wire controller according to wiring diagrams and in accordance with local codes. Never apply power until you have completed these procedures in accordance to all system instructions.

8. After completing all wiring connections, unplug the terminals for power and communications. Always unplug the communications loop first and then the power. When reconnecting the wiring, connect the power first and then the communication loop.

9. Continue step 8 until all devices have been wired and the power and communication terminals have been unplugged.

4-16 Start-Up and Troubleshooting

WattMaster WHP Section 4

10. Install CommLink and power-up. At this point you are ready to begin commissioning the system. It is preferred, though not necessary, to use a PC with Prism software to assist in the commissioning process.

11. Start with the first controller on the communication loop or in multiple loop systems; start with the MiniLink or with the System Manager. Plug in the Communication terminal then plug in the Power terminal.

12. Observe the LED indicator for the blink codes as outlined in the troubleshooting section of the manual. The blink code will first verify the address, then the operation.

If the address is incorrect, reset the dipswitch, then reapply power to the controller.

13. After each controller is connected and completes its initialization sequence, use the

PC or System Manager to verify communication to that device. If you cannot communicate, verify wiring, voltages, etc. in accordance with the troubleshooting section in the system manual. Do not proceed to the next device until you are properly communicating with the current device.

Continue this process until all controllers are connected and properly communicating.

By following the above steps and procedures, your installation will be much faster and trouble free. Remember that each controller only contains one puff of smoke. Making sure that all wiring terminations and voltages are correct prior to applying power to a controller will insure that you don’t use that one puff.

Start-Up and Troubleshooting 4-17

WattMaster WHP

COMM LINK II

INTERFACE

(MULTIPLE LOOP)

03/31/04 03:38PM WED

OCCUPIED

NO ALARMS

POWER

24VAC

GND

COMMUNICATIONS

T

SHLD

RS-485

R

SYSTEM MANAGER POWER SUPPLY

YS101716 REV. 1

SYSTEM MANAGER

Section 4

NETWORK

LOOP

U3

1

RN1

CX1

U1

U2 CX2 CX4

U4

T B1

COMM

T

SHLD

LD6

COMM

U5

RS -485

COMM

LD7

P WR

1

HH

LD8

LED1

P1

C1

R1

LD9

LED2

U7

+V RE F

5.11V

TES T POINT

EWDOG

RV 1

V REF ADJ

R28

INPUTS ADDRES S

RAM

U6

+VDC

AIN1

AIN2

AIN3

AIN4

AIN5

GND

GND

RN5

C10

AOUT1

C12

P U1

D6

P U2

D7

P U3

D8

P U4

D9

P U5

D11

P U7

D14

U13

SW1

ADD

1

2

4

8

16

32

TO KEN

NE TWORK

U10

J P1

X2

R15

EP ROM

TUC-5R PLUS

( 1 MEG)

YS101816 RE V. 2

CX10

U12

CX6

CX12

TB 3

R

CX 5

AOUT2

AIN7

GND

PJ 1

C17

D15

C20

CX13

U15

CX15

C14

R19

U14

CX14

C15

R22

R24

R25

U9

1

PA L

1

C7

D12

R13

SC1

D19

R26

PRESSURE

SENSOR

EXPANSION T'STAT

V R1

L1

VR2

V1

V2

V3

COM1-3

R1

R2

R3

R4

R5

COM4-5

TB2

V4

V 5

U8

NE 5090NP B3192

0P S

R6

C9

340 64A

C13

C16

TB4

GND

24VAC

4RLY IO BD.

YS101790

4RLY IO BD.

YS101790

AIN1

AIN2

AIN3

AIN4

GND

AOUT1

4 ANALOG IN MOD I/O BD.

YS101784

32K

8K

COMM

LD4

SHLD

R

REC.

RAM EPROM

12V

AIN

3

4

AIN

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

PWR

GND

24VAC

RELAY

OUTPUT

1-3

OUT

OUT

COM

4-5

32K

8K

COMM

LD4

R

REC.

485

COMM

RAM EPROM

12V

AIN

2

3

4

AIN

5

GND

GND

AOUT

PRESSURE

SENSOR

YS101564

CPU

ADDRESS ADD

COMM

TEST

PWR

GND

24VAC

OUTPUT

COM

1-3

OUT

2

OUT

OUT

5

4-5

TO OTHER WHP CONTROLLERS

TO OTHER MINILINKS

(NETWORK TERMINALS ONLY)

Figure 4-8: Communications Loop Wiring

4-18 Start-Up and Troubleshooting

WattMaster WHP

4.5

Setting Address Switches

4.5.1

Setting the MiniLink Address Switch

LOOP

ADDRESS SWITCH

ADD

8

16

32

1

2

4

4

3

2

8

7

6

5

1

OFF >

LOOP

ADDRESS SWITCH

ADDRESS SWITCH SHOWN IS

SET FOR ADDRESS 1

ADDRESS SWITCH SHOWN IS

SET FOR ADDRESS 13

T

SH

R

4

8

1

2

16

32

8

7

6

5

4

3

2

1

OFF >

T

SH

R

24VAC

GND

NOTE:

THE POWER TO THE MINILINK MUST BE

REMOVED AND RECONNECTED AFTER

CHANGING THE ADDRESS SWITCH SETTINGS

IN ORDER FOR ANY CHANGES TO TAKE

EFFECT.

CAUTION:

DISCONNECT ALL COMMUNICATION

LOOP WIRING FROM THE MINILINK BEFORE

REMOVING POWER FROM THE MINILINK.

RECONNECT POWER AND THEN RECONNECT

COMMUNICATION LOOP WIRING.

Figure 4-9: MiniLink Address Switch Setting

Section 4

Start-Up and Troubleshooting 4-19

WattMaster WHP Section 4

4.5.2

Loop Controller Addressing

The Loop Controller address should always be set for address #30. A maximum of 29

WHP Controllers on the loop that contains the Loop Controller. All other loops may have

30 WHP Controllers. (Refer to Figure 2-10 for more detail)

4.5.3

WHP Controller Addressing

NOTE:

IGNORE ANY MARKINGS

OR NUMBERS ON THE SWITCH

USE THE CHART!

To determine the boards address, add the values of all the switches which are toggled down in the direction of the arrow

Figure 4-10: WHP Controller Address Switch Setting

NOTE:

ADDRESS 30 CANNOT BE USED

ON THE LOOP THAT HAS THE WHP LOOP

CONTROLLER ATTACHED. ADDRESS 30

ON THAT LOOP IS RESERVED FOR THE

WHP LOOP CONTROLLER.

CAUTION:

YOU MUST POWER DOWN THE CONTROLLER

AFTER CHANGING THE ADDRESS SWITCHES

IN ORDER FOR ANY CHANGES TO TAKE EFFECT.

ALWAYS REMOVE THE COMMUNICATIONS LOOP

PRIOR TO DISCONNECTING POWER. RECONNECT

POWER AND THEN RECONNECT THE COMMUNICATIONS

LOOP TO THE CONTROLLER.

4-20 Start-Up and Troubleshooting

WattMaster WHP

5.0 Troubleshooting

Section 4

5.1

General Troubleshooting

The following is a guide to assist in troubleshooting the WattMaster WHP System. It is provided as a systematic approach to determining and resolving common system problems.

5.1.1

Communications Troubleshooting Checklist

No WHP or Loop Controller Units are Communicating

•

Is the CommLink II connected and plugged in?

•

Is the CommLink II installed, a single or multiple loop version. A jumper in the

CommLink can be set for “Single” or “Multi”. On the WHP system is considered a

Multiple Loop version and the CommLink jumper must be set on Multi.

•

Are Comm Loop voltages correct? See the Comm Loop troubleshooting guides.(page

4-24)

•

Is the Comm Loop open or shorted?

•

Is the CommLink II connected and plugged in?

•

Is the MiniLink Voltage correct?

•

Are the WHP and Loop Controller address switches set correctly? See the addressing chart. (WHP Loop Controller should always be set to address 30, see Figure 4-10)

•

Is the MiniLink address switch set correctly? See the addressing chart.(see Figure 4-

10)

•

Are the WHP and Loop Controllers powered? Check 24 VAC to the controllers.

•

Is the System Manager connected to the Local Communications loop?

Some WHP Units are communicating but others are not:

•

Are the WHP Controller address switches set correctly? See the addressing chart.

•

Is the WHP Loop Controller address switch set correctly? See the addressing chart.

•

Are the WHP Controllers and Loop Controller powered? Check 24 VAC to the controllers.

•

Is the REC LED on the missing WHP Controller “flickering”? See WHP Controller introduction for location of the REC LED. (see Figure 4-4)

•

Is the COMM LED on the WHP Controller blinking an error code? See the Blink

Code chart. (see Figure 4-6)

•

Are Comm Loop voltages correct at the missing unit? See Comm Loop troubleshooting guide starting on page 4-24.

Start-Up and Troubleshooting 4-21

WattMaster WHP Section 4

5.1.2

General Troubleshooting Checklist

Begin troubleshooting by locating the general problem in the list below. Detailed component troubleshooting information follows later in this section.

Zone is too warm

•

Is zone calling for cooling?

•

Is the compressor disabled due to minimum off time setting?

•

Is water proof of flow signal disabled?

•

Is the LED blinking an error code? See Figure 4-6.

Zone is too cool

•

Is zone calling for heating?

•

Is the compressor disabled due to minimum off time setting?

•

Is water proof of flow signal disabled?

•

Is the LED blinking an error code? See Figure 4-6.

Zone Sensor reading incorrectly

•

Is the sensor near a source of heat or a cold draft? Location is a common problem.

The sensor should be mounted on an inside wall away from heat sources and in a location with adequate room air circulation.

•

Is the resistance reading correct? Check with the Temperature/Resistance Chart in this section. (see page 4-42)

•

Is wiring correct? Check for errors.

Check the Room sensor

•

To meter the Room sensor:

Unplug the room sensor terminal block. Using your meter, check the resistance of the unplugged terminal block. Use the supplied Temperature/Resistance Chart (page 4-

42) to see if the sensor is within a reasonable range. Readings which are much too high or too low generally indicate wiring problems.

•

To meter the Slide Adjust (optional):

Use your ohmmeter to check the resistance between the room sensor GND wire and the AIN2 terminal on the unplugged terminal block.

The resistance for various positions of the slider on the sensor should be as follows:

Full UP position 15K

Ω

(

±

500

Ω

)

MID position 12.5K

Ω

(

±

500

Ω

)

Full DN position 10K

Ω

(

±

500

Ω

)

4-22 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.2 Alarms

When an alarm occurs in the WHP or Loop Controller, it is reported to the System

Manager. The alarms cause the light on the System Manager to illuminate. The View

Alarms screen will indicate the address of the alarms. The Status screen will display the type of alarm that has occurred. Here is a list of the alarms that are reported to the System

Manager.

WHP:

Bad Space Sensor – Space sensor is either open or shorted

Hi Space Temp Alarm – If space temperature is 5

°

or more above cooling setpoint

Lo Space Temp Alarm – If space temperature is 5

°

or more below heating setpoint

Dirty Filter Alarm – Contacts between AIN4 and GND are shorted

Cooling Failure – If supply air doesn’t drop 5

°

in 10 minutes in cooling mode

Heating Failure - If supply air doesn’t go up 5

°

in 10 minutes in heating mode

Loop Controller:

Pump Failure – No proof of flow within 5 seconds after pump starts

No Flow Detected – The contact between AIN3 and GND is open, no water flow

Phase Shutdown – The contact between AIN7 and GND is open, loss of phase

Lo Water Temp Alarm – Water Temp is below Lo Limit setpoint

Hi Water Temp Alarm - Water Temp is above Hi Limit setpoint

Start-Up and Troubleshooting 4-23

WattMaster WHP Section 4

5.3 Checking Comm. Loop Voltages

5.3.1

Checking the CommLink II Network Loop

Diagram

Overview

This test checks for proper Network loop voltages at the CommLink II.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink II is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the Loop LED does not flicker, the unit is defective.

Make sure CommLink II jumper is set to “Multi” position.

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations at this point on the CommLink II. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 10-15 seconds as the unit attempts to communicate.

Measurements

Network Loop

T - G (SHLD) 2.9 - 3.1 Volts DC

Acceptable Range

R - G (SHLD)

Action

1.9 - 2.1 Volts DC

Condition

If voltages are too high or too low on either side

Action

1. Unplug the Network loop from the

CommLink II and check for proper loop voltages. If a problem exists, disconnect each MiniLink Network loop until the problem is isolated.

2. Check the CommLink II Driver chip.

Replace the driver chip if necessary

4-24 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.3.2

Checking the Comm Loop at the CommLink II

Diagram

The indicated values are typical of a normal system, actual readings may deviate slightly due to the number of units connected and other system specific factors.

Note: All of the connected Minilinks should be powered up for this test.

Overview

This is a “quick check” to determine if any of the driver chips on the Network loop are damaged. Since all units will “float” both of their communications connections at about

2.45 Volts, you can quickly check the Network loop by unplugging it at the CommLink II.

Note: Be sure that the loop you are testing does not have a short circuit from T to R.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink II is attempting to communicate with the MiniLinks. There is a noticeable change in the flicker when the loop is disconnected, if you observe a normal functioning unit. When the loop is reconnected it may take up to 60 seconds before the CommLink II reestablishes communications with the MiniLinks.

Measurements

Network Loop

T – G (SHLD) 2.4-to-2.5 Volts DC

Acceptable Range

R – G (SHLD) 2.4-to-2.5 Volts DC

Action

Condition

If voltages are too high or too low on either side

Action

One or more of the MiniLinks has a damaged

Network driver chip. Disconnect the Mini-

Links one at a time to isolate the problem.

Start-Up and Troubleshooting 4-25

WattMaster WHP

5.3.3

Checking the CommLink II Driver

Diagram

Section 4

Overview

This test checks for proper Network loop voltages coming from the CommLink II.

Tip: The Loop LED (located on the front panel) should “flicker” when the CommLink II is attempting to communicate. The Loop LED will flicker more noticeably for a few seconds when first powered up. If the LED does not flicker, the unit is not functioning.

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations at this point on the CommLink II. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 10-15 seconds as the unit attempts to communicate.

Measurements

Local Loop

T – G

(SHLD)

2.4 - 2.5 Volts DC

Acceptable Range

R – G

(SHLD)

Action

2.5 - 2.7 Volts DC

Condition

If voltages are too high or too low on either side

Action

1. The CommLink II has a damaged comm driver chip. Replace the driver chip.

See instructions in section 1.3.11 for

“Comm Driver Chip Replacement”.

2. The CommLink II is defective.

4-26 Start-Up and Troubleshooting

WattMaster WHP

5.3.4

Checking the MiniLink Network Loop

Diagram

Meter Set To Read DC Volts

Section 4

The indicated readings are typical of a normally operating system. Actual readings may vary slightly due to the number of units installed and other factors. Any significant deviation from these values generally indicates a problem.

Note: These tests assume that the CommLink II is connected and powered, and that all

MiniLinks which are connected are also powered.

Overview

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations on an operating communications loop. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 15-30

seconds as normal communications occur.

Measurements

LOCAL LOOP

T - G (SHLD) 2.9 - 3.1 Volts DC

Acceptable Range

R - G (SHLD)

Action

1.9 - 2.1 Volts DC

Condition

Readings near Zero Volts

If voltages are too high or too low on either side

Action

Check for shorted wiring.

1. One or more devices connected to this loop may have damaged Comm driver chips.

2. Wiring errors. Check for multiple loops

“cross connected”, short circuits, etc.

Start-Up and Troubleshooting 4-27

WattMaster WHP

5.3.5

Checking the MiniLink Network Driver

Diagram

Meter Set To Read DC Volts

Section 4

Note: These tests assume that the MiniLink being checked is powered up

Overview

This check is intended to determine if the Network Comm Driver chip on a MiniLink is damaged.

Tip: Before unplugging the Network loop from the MiniLink, observe the Network Loop

LED (located near the connector). It should periodically “flicker” as the CommLink II requests data from the MiniLink. The LED will also flicker when power to the

CommLink II is cycled. If the LED is not flickering, the unit is not communicating with the CommLink II.

Damage typically occurs when the communications loop is exposed to excessive voltage, as may occur during installation due to wiring errors. The driver chips are socketed on all boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.

Almost all failures occur as a result of wiring related problems.

Measurements

Network Loop

T – SHLD 2.4 - 2.5 Volts DC

Acceptable Range

R – SHLD 2.4 - 2.5 Volts DC

Note: Minor variances may not indicate a problem if both tests indicate similar values

Action

Condition

If voltages are too high or too low on either side

Action

The MiniLink has a damaged Network

Comm Driver chip. Replace the driver

chip. See "1.3.11Comm Driver Chip Re- placement”.

4-28 Start-Up and Troubleshooting

WattMaster WHP

5.3.6

Checking the MiniLink Local Loop

Diagram

Meter Set To Read DC Volts

Section 4

The indicated readings are typical of a normally operating system. Actual readings may vary slightly due to the number of units installed and other factors. Any significant deviation from these values generally indicates a problem.

Note: These tests assume the MiniLink is powered up

Overview

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations on an operating communications loop. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 30-45 seconds. Voltages fluctuate as normal communications occur.

Measurements

Local Loop

T – SHLD 2.9 - 3.1 Volts DC

Acceptable Range

R – SHLD 1.9 - 2.1 Volts DC

Action

Condition

Readings near zero volts

Action

Check for shorted wiring.

If voltages are too high or too low on either side

1. One or more devices connected to this loop may have damaged Comm Driver chips.

2. Wiring errors. Check for multiple loops inadvertently “cross connected”, short circuits, etc.

Start-Up and Troubleshooting 4-29

WattMaster WHP

5.3.7

Checking the Local Loop at MiniLink

Diagram

Meter Set To Read DC Volts

Section 4

The indicated values are typical of a normal system. Actual readings may deviate slightly due to the number of units connected and other system specific factors

Note: These tests assume that the controllers being checked are powered up.

Overview

This is a “quick check” to determine if any of the WHP Controllers or WHP Loop Controller on a Local Communications Loop are damaged. Since all WHP Controllers will “float” both of their communications connections at about 2.45 Volts, you can quickly check an entire loop by unplugging it at the MiniLink.

Note: Be sure that the loop you are testing does not have a short circuit from T - R.

Damage typically occurs when the communications loop is exposed to excessive voltage, as may occur during installation, due to wiring errors. The driver chips are socketed on all boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.

Almost all failures occur due to wiring related problems.

Measurements

Local Loop

T – SHLD 2.4 - 2.5 Volts DC

Acceptable Range

R – SHLD 2.4 - 2.5 Volts DC

Note: Minor variances may not indicate a problem if both tests indicate similar values.

4-30 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.3.7

(continued)

Action

Condition

If voltages are too high or too low on either side

Action

1. One or more of the attached controllers has a damaged Comm Driver chip. Lo- cate and replace the driver chip(s).

See "1.3.11 Comm Driver Chip Replacement”.

2. Wiring errors such as "crossed connections", short circuits, etc.

Start-Up and Troubleshooting 4-31

WattMaster WHP

5.3.8

Checking the MiniLink Local Loop Driver

Diagram

Meter Set To Read DC Volts

Section 4

The indicated values are typical of a normal operating system. Actual readings may deviate slightly.

Note: These tests assume that the MiniLink is powered up.

Overview

This test checks for proper Local Loop voltages coming from the MiniLink.

Tip: The Local Loop LED (located near the connector) should “flicker” when the Mini-

Link is operating and when first powered up. If the LED is not flickering, the unit is not functioning.

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations at this point on the MiniLink. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 10-15 seconds. The voltage will fluctuate as the unit attempts to communicate.

Measurements

Local Loop

T – G

(SHLD)

2.9 - 3.1 Volts DC

Acceptable Range

R – G

(SHLD)

1.9 - 2.1 Volts DC

Action

Condition

If voltages are too high or too low on either side

Action

1. The MiniLink has a damaged Comm

Driver chip. Locate and replace the

driver chip(s). See "1.3.11 Comm

Driver Chip Replacement”.

2. The MiniLink is not functioning.

4-32 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.3.9

Checking the Local Loop at a WHP Controller

Diagram

Meter Set To Read DC Volts

The indicated readings are typical of a normal operating system. Actual readings may vary slightly due to the number of units installed and other factors. Any significant deviation from these values generally indicates a problem.

Note: These tests assume that a MiniLink is connected and powered up.

Overview

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations on an operating communications loop. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 30-45 seconds. The voltages may fluctuate as normal communications occur.

Measurements

Local Loop

T – SHLD 2.9 - 3.1 Volts DC

Acceptable Range

R – SHLD 1.9 - 2.1 Volts DC

Action

Condition

If meter reads between 2.4 VDC and 2.5

VDC

The Comm Loop “floats” at 2.4 - 2.5VDC

when only controllers are connected to the loop. When a MiniLink is connected it will

“bias” each side of the loop to the values listed above.

If voltages are too high or too low on either side

Action

1) No CommLink II or MiniLink is connected and powered up.

2) If a CommLink II or MiniLink is connected, look for “open” wiring.

One or more devices connected to this loop have damaged Comm Driver chips.

Start-Up and Troubleshooting 4-33

WattMaster WHP

5.3.10 Checking WHP Controller Driver Chip

Diagram

Meter Set To Read DC Volts

Section 4

Note: These tests assume that the controller being checked is powered up.

Overview

This check is intended to determine if the Comm Driver chip on a controller is damaged.

Damage typically occurs when the communications loop is exposed to excessive voltage, as may occur during installation, due to wiring errors. The driver chips are socketed on all boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.

Almost all failures occur as a result of wiring related problems.

Measurements

Local Loop

T – SHLD 2.4 - 2.5 Volts DC

Acceptable Range

R – SHLD 2.4 - 2.5 Volts DC

Note: Minor variances may not indicate a problem if both tests indicate similar values.

Action

Condition

If voltages are too high or too low on either side

Action

The controller has a damaged Comm

Driver chip. Replace the driver chip. See

"1.3.11 Comm Driver Chip Replacement”.

4-34 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.4

Troubleshooting Loop Controller

5.4.1

Checking the Loop Controller Analog Inputs

Diagram

SET METER TO

READ DC VOLTS

+

R

ALL READINGS ARE TAKEN

WITH THE (-) LEAD OF THE

METER ON THE GND

TERMINAL

-

+

12V

AIN1

AIN2

AIN3

AIN4

AIN5

GND

GND

AOUT1

AOUT2

AIN7

GND

Overview

The analog input wiring can be checked at the

Loop Controller by checking voltages on the

Analog Input Connector.

If any of the RWT, SWT, OAT inputs read greater than 5.0 volts then it is OPEN (no sensor is connected), an input that reads less than 0.1 volts is SHORTED. Check for wiring problems before proceeding.

The Loop Pressure, Manual Reset, Phase

Loss, Fire Alarm and Request to Run inputs should read greater than 5.0 volts if the attached contact is OPEN and less than 0.5 volts if the contact is CLOSED (contacts CLOSE between the input and GND). The Fire Alarm and Request to Run contacts are located on the Analog Input Expansion Board.

Note The Loop Controller must be powered for these tests.

Measurements

Meter

AIN1

Return Water Temp

AIN2

Supply Water Temp

AIN3

Proof of Flow

Acceptable Range

Ignore readings for any connections which are not used in the equipment.

1.9 volts (100

°

F) - 3.6 volts (40

°

F)

Typical is 2.5 volts @ 77

°

F

1.9 volts (100

°

F) - 3.6 volts (40

°

F)

Typical is 2.5 volts @ 77

°

F

When used with the Low Pressure Switch option:

If the input is OPEN, the voltage will be greater than 5.0 volts

If the input is CLOSED, the voltage will be less than 0.5 volts

When used with 0-50 PSI Loop Pressure Sensor option:

5.1 VDC = 50 PSI – 0.0 VDC = 0 PSI

Start-Up and Troubleshooting 4-35

WattMaster WHP Section 4

5.4.1

(continued)

AIN4

Outdoor Air Temp

1.9 volts (100

°

F) - 3.6 volts (40

°

F)

Typical is 2.5 volts @ 77

°

F

AIN5 If the input is OPEN, the voltage will be greater than 5.0 volts

Manual Reset If the input is CLOSED, the voltage will be less than 0.5 volts

AIN7

Phase Loss

If the input is OPEN, the voltage will be greater than 5.0 volts

If the input is CLOSED, the voltage will be less than 0.5 volts

AIN1-Exp. Bd.

Fire Alarm

If the input is OPEN, the voltage will be greater than 5.0 volts

If the input is CLOSED, the voltage will be less than 0.5 volts

Caution:

AIN1 – Fire/Smoke input must be connected to the AIN1- GND terminal. If it is not used, a jumper must be installed, since this is a normally closed contact input. If this is not done the system will not operate.

AIN2-Exp. Bd.

If the input is OPEN, the voltage will be greater than 5.0 volts

Request to Run If the input is CLOSED, the voltage will be less than 0.5 volts

Condition Action

SWT, RWT, OAT Input voltage reads too low

1. Check for shorts or other wiring errors.

2. Defective Sensor. Check using the chart.

3. High temperature at sensor. See chart.

SWT, RWT, OAT input voltage reads too high

LPR (when optional 0-5VDC Loop Pressure Sensor is used) input voltage reads too low.

1. Check for open circuit wiring errors.

2. Defective sensor. Check using the chart.

3. Low temperature at sensor. See chart.

1. Check for shorts or other wiring errors.

2. Defective Sensor. Check using the chart.

3. High pressure at sensor. See chart.

LPR (When Loop Pressure Switch is used) input voltage reads too high.

1. Check for open circuit wiring errors.

4-36 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.4.2

Checking the Loop Controller Outputs

Diagram

SET METER TO

READ DC VOLTS

+

Overview

The analog output wiring can be checked at the Loop Controller by checking voltages on the Analog Output Connector.

Note: The Loop Controller must be powered for these tests.

ALL READINGS ARE TAKEN

WITH THE (-) LEAD OF THE

METER ON THE GND

TERMINAL

R

-

+

12V

AIN1

AIN2

AIN3

AIN4

AIN5

GND

GND

AOUT1

AOUT2

AIN7

GND

Measurements

Meter Acceptable Range

Ignore readings for any connections which are not used in the equipment.

AOUT1

Pump VFD

AOUT2

Mod. Heat

This output will vary between 0 and 10 VDC to correspond with pump pressure setpoint.

This output will vary between 0 and 10 VDC to correspond with Heat

Addition setpoint.

Start-Up and Troubleshooting 4-37

WattMaster WHP Section 4

5.4.3

Checking the Local Loop at a WHP Loop Controller

Diagram

Meter Set To Read DC Volts

The indicated readings are typical of a normal operating system. Actual readings may vary slightly due to the number of units installed and other factors. Any significant deviation from these values generally indicates a problem.

Note: These tests assume that a MiniLink is connected and powered up.

Overview

Proper loop voltages are essential for reliable communications. It is normal to see fluctuations on an operating communications loop. The average value should be close to the acceptable range described below. Values will vary upon initial powerup for about 30-45 seconds. The voltages may fluctuate as normal communications occur.

Measurements

Local Loop

T – SHLD 2.9 - 3.1 Volts DC

Acceptable Range

R – SHLD 1.9 - 2.1 Volts DC

Action

Condition

If meter reads between 2.4 VDC and 2.5

VDC

The Comm Loop “floats” at 2.4 - 2.5VDC

when only controllers are connected to the loop. When a MiniLink is connected it will

“bias” each side of the loop to the values listed above.

If voltages are too high or too low on either side

Action

1) No CommLink II or MiniLink is connected and powered up.

2) If a CommLink II or MiniLink is connected, look for “open” wiring.

One or more devices connected to this loop have damaged Comm Driver chips.

4-38 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.4.4

Checking WHP Loop Controller Driver Chip

Diagram

Meter Set To Read DC Volts

Note: These tests assume that the controller being checked is powered up.

Overview

This check is intended to determine if the Comm Driver chip on a controller is damaged.

Damage typically occurs when the communications loop is exposed to excessive voltage, as may occur during installation, due to wiring errors. The driver chips are socketed on all boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.

Almost all failures occur as a result of wiring related problems.

Measurements

Local Loop

T – SHLD 2.4 - 2.5 Volts DC

Acceptable Range

R – SHLD 2.4 - 2.5 Volts DC

Note: Minor variances may not indicate a problem if both tests indicate similar values.

Action

Condition

If voltages are too high or too low on either side

Action

The controller has a damaged Comm

Driver chip. Replace the driver chip. See

"1.3.11Comm Driver Chip Replacement”.

Start-Up and Troubleshooting 4-39

WattMaster WHP Section 4

5.4.5

Comm Driver Chip Replacement

WHP CONTROLLER

PIN 1

MINILINK COMMUNICATIONS INTERFACE

T

SH

R

1

2

4

8

16

32

WHP CONTROLLER

COMM DRIVER CHIP

( U5 )

NETWORK LOOP

COMMUNICATIONS

DRIVER CHIP

(U5) T

SH

R

24VAC

GND

U7

R1

R4

U2

U1

SYSTEM MANAGER

U3 CX4

U4

RN1

CX5

C3

X2

CX6

U6

CX7

U8

SC1

U9

Comm Driver Chip

(U13) Pin 1

U13

U3

PJ1

D1

R5

R6

D2

DSPY1

R13

U12

System Manager

RV1

LOCAL LOOP

COMMUNICATIONS

DRIVER CHIP

(U8)

R7

PIN 1

LOOP CONTROLLER CPU BOARD

COMMUNICATIONS

DRIVER CHIP

PIN 1

COMM DRIVER CHIP

( U1 )

COMMLINK II

DOT

PIN 1

SOCKET

PRINTED

CIRCUIT

BOARD

TYPICAL RS-485

DRIVER CHIP

WARNING!

USE EXTREME CAUTION WHEN REMOVING ANY CHIPS

TO AVOID DAMAGING ANY CIRCUIT BOARD TRACES WHICH

ARE UNDER THE CHIP.

BE SURE THAT ANY SMALL SCREWDRIVER OR OTHER

SHARP OBJECT USED TO REMOVE THE CHIP DOES NOT

COME INTO CONTACT WITH THE PRINTED CIRCUIT BOARD

SURFACE.

A SMALL SCREWDRIVER MAY BE INSERTED BETWEEN THE

CHIP AND THE SOCKET TO AID IN REMOVAL OF THE CHIP.

BE VERY CAREFUL NOT TO INSERT THE SCREWDRIVER UNDER

THE SOCKET!! DAMAGE TO THE BOARD IS NOT COVERED

BY WARRANTY.

Figure 4-11: Comm Driver Chip Replacement

4-40 Start-Up and Troubleshooting

WattMaster WHP Section 4

5.5 Temperature Sensor Resistance

Chart

21094

18655

17799

16956

16164

15385

14681

14014

13382

12758

12191

11906

11652

RESISTANCE

Ω*

93333

80531

69822

60552

52500

45902

40147

35165

30805

27140

23874

11379

11136

10878

10625

10398

10158

9711

9302

68

69

70

62

64

66

56

58

60

45

50

52

54

TEMPERATURE

º

F

-10

-5

0

5

10

30

35

40

15

20

25

74

75

76

71

72

73

78

80

3.470

3.330

3.275

3.217

3.160

3.100

3.042

2.985

2.927

2.867

2.810

2.780

2.752

VOLTAGE AT

INPUT*

4.620

4.550

4.474

4.390

4.297

4.200

4.095

3.982

3.862

3.737

3.605

2.722

2.695

2.665

2.635

2.607

2.577

2.520

2.465

TEMPERATURE

º

F

82

84

86

88

90

95

100

105

110

115

120

125

130

135

140

145

150

RESISTANCE

Ω*

8893

8514

8153

7805

7472

6716

6047

5453

4923

4449

4030

3656

3317

3015

2743

2502

2288

*Notes:

1. Use the resistance column to check the thermistor sensor while disconnected from the controllers (not powered).

2. Use the voltage column to check sensors while connected to powered controllers. Read voltage with meter set on DC volts. Place the

“-”(minus) lead on GND terminal and the

“+”(plus) lead on the sensor input terminal being investigated.

If the voltage is above 5.08 VDC, then the sensor or wiring is “open.” If the voltage is less than 0.05 VDC, the sensor or wiring is shorted.

VOLTAGE AT

INPUT*

2.407

2.352

2.297

2.242

2.187

2.055

1.927

1.805

1.687

1.575

1.469

1.369

1.274

1.185

1.101

1.024

0.952

Start-Up and Troubleshooting 4-41

WattMaster WHP Section 4

5.6 Pressure Sensor Voltage Chart

22

23

24

19

20

21

16

17

18

13

14

15

10

11

12

8

9

6

7

PRESSURE

PSI

0

1

2

3

4

5

28

29

30

25

26

27

31

32

33

2.52

2.60

2.68

2.76

2.84

2.92

2.04

2.12

2.20

2.28

2.36

2.44

VOLTAGE AT

INPUT

VDC*

1.00

1.08

1.16

1.24

1.32

1.40

1.48

1.56

1.64

1.72

1.80

1.88

1.96

3.00

3.08

3.16

3.24

3.32

3.40

3.48

3.56

3.64

10.08

10.40

10.72

11.04

11.36

11.68

8.16

8.48

8.80

9.12

9.44

9.76

CURRENT

MILIAMPS

4.00

4.32

4.64

4.96

5.28

5.60

5.92

6.24

6.56

6.88

7.20

7.52

7.84

12.00

12.32

12.64

12.96

13.28

13.60

13.92

14.24

14.56

44

45

46

40

41

42

43

PRESSURE

PSI

34

35

36

37

38

39

47

48

49

50

CURRENT

MILIAMPS

14.88

15.20

15.52

15.84

16.16

16.48

16.80

17.12

17.44

17.76

18.08

18.40

18.72

19.04

19.36

19.78

20.00

VOLTAGE AT

INPUT

VDC*

3.72

3.80

3.88

3.96

4.04

4.12

4.20

4.28

4.36

4.44

4.52

4.60

4.68

4.76

4.84

4.92

5.00

*Notes:

1. Use the voltage column to compare the meter voltage with the sensor connected to the controller and with the controller powered.

2. Read voltage with meter set on DC volts.

Place the “-”(minus) lead on GND terminal and the “+”(plus) lead on the sensor input terminal being investigated.

3. If the voltage is less than 0.05 VDC, then the sensor or wiring is “shorted” or “open”

4-42 Start-Up and Troubleshooting

WattMaster WHP

Notes:

Section 4

Start-Up and Troubleshooting 4-43

Form: WM-WHP-IO-02A Printed in the USA October 2004

All rights reserved Copyright 2004

Wattmaster Controls Inc.

•

8500 NW River Park Drive

•

Parkville MO

•

64152

Phone (816) 505-1100 E-mail: [email protected]

Fax (816) 505-1101