READ AND SAVE THESE INSTRUCTIONS LIRE ET CONSERVER CES INSTRUCTIONS Retrofit & Conditioning Humidification STULZ Ultra-Series Controller For STULZ Ultrasonic Humidifiers IOM Installation, Operation & Maintenance ® STULZ Ultra-Series Controller IMPORTANT NOTE This document applies to STULZ Ultra-Series Controllers with Revision 1.05 or higher software and communicating with humidifiers equipped with Revision 3.0.7 or higher software. FOR INITIAL STARTING, SEE SECTION 3.0 Notice This document contains information protected by copyright. All rights are reserved. The owner of the equipment for which this manual is written may photocopy the contents of this manual for internal use only. No part of this document may be photocopied, reproduced, or translated into another language for use by anyone other than the owner of the equipment for which this manual is written without the prior written consent of STULZ Air Technology Systems, Inc. (STULZ). This document contains confidential and proprietary information of STULZ. Distributing or photocopying this document for external distribution is in direct violation of United States copyright laws and is strictly prohibited without the express written consent of STULZ. Unpublished rights reserved under the copyright laws of the United States and of other countries. Other brands and trade names are trademarks of their respective owners. © 2011 STULZ Air Technology Systems, Inc. Printed in the United States of America. All rights reserved. STULZ Air Technology Systems, Inc. 1572 Tilco Drive Frederick, MD 21704 USA (© Feb, 2008) Air Technology Systems, Inc. STULZ Ultra-Series Humidifier Controller Table of Contents 1.0 GENERAL INFORMATION ........................ 1 4.0 OPERATION ............................................ 12 1.1 1.2 1.3 1.4 Forward ...................................................... 1 Safety Summary ......................................... 1 Warnings & Cautions ................................. 1 Product Warranty ....................................... 2 2.0 DESCRIPTION ........................................... 3 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2 2.4 2.5 2.5.1 2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.6.7 2.6.8 2.6.9 General....................................................... 3 Features ..................................................... 3 BMS Interface............................................. 3 Field Configurable ...................................... 3 Password Protection .................................. 3 Timed Drain Cycle ...................................... 4 Restorable Set Points ................................ 4 User Interface Display Panel...................... 4 Function Keys............................................. 4 Alarms ........................................................ 4 Controller Nomenclature ............................ 5 Controller I/O Module ................................. 6 Controller I/O Module Layout ..................... 6 Auxiliary Terminals ..................................... 6 Control Sensors.......................................... 6 Alarm Contacts ........................................... 6 Water Conductivity Probe .......................... 7 Air Velocity Sensor ..................................... 7 Air Proving Switch ...................................... 7 Water Leak Detector .................................. 7 Remote On/Off ........................................... 7 Multiple Humidifier Grouping ...................... 7 BMS Operation ........................................... 8 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.3 4.3.1 4.3.2 4.3.3 4.4 4.4.1 4.4.2 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 General Theory of Operation ................... 12 Humidification Control .............................. 12 Operating Modes ...................................... 12 P/I- Proportional/Integral Control.............. 13 Navigating Controller Screens ................. 14 Menu Selection......................................... 14 Menu Loops .............................................. 14 Password Authorization ........................... 16 Password Protected Screens ................... 16 Wrong Password ...................................... 16 Setting the Passwords.............................. 16 Start-up / Commissioning ......................... 17 Main Info Screen ...................................... 18 Saving & Restoring Set points ................. 18 Controller Features................................... 18 Alarms ...................................................... 18 Remote On/Off ......................................... 19 Automatic Drain Cycle .............................. 19 Manual Drain ............................................ 19 Communication with the Controller .......... 20 Loading New Software ............................. 20 5.0 MENU SCREENS .................................... 21 3.0 INSTALLATION .......................................... 9 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 Uncrating and Inspection ........................... 9 Mounting..................................................... 9 Wiring Connections .................................... 9 AC Input ..................................................... 9 DC Output to Humidifier(s) ......................... 9 Control Wiring to Humidifiers ..................... 9 Sensors .................................................... 10 Water Conductivity Probe ........................ 10 Remote On/Off ......................................... 11 Remote Alarm Signal Contacts ................ 11 Water Leak Detector ................................ 11 5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4 5.4.1 5.4.2 Main Menu ................................................ 21 Information Menu ..................................... 21 Main Info Screen ...................................... 21 Control Sensor ......................................... 22 Limit Sensor ............................................. 22 Conductivity .............................................. 22 Control Points ........................................... 22 Cabinet Temperature ............................... 22 NTC Temperature Sensors ...................... 22 Air Speed (optional).................................. 23 Humidifier Information (Loop) ................... 23 About Screen............................................ 23 Alarm Log ................................................. 23 Alarms ...................................................... 24 Non-Critical Alarms .................................. 24 Critical Alarms .......................................... 24 Alarm Screen Messages .......................... 25 Control Menu ............................................ 26 Set Point Screens..................................... 26 Alarm Set Point Screens .......................... 27 (April 2013) (August, 2013) i STULZ Ultra-Series Humidifier Controller 5.4.3 5.4.4 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8 5.5.9 5.5.10 5.6 5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7 5.7.8 5.7.9 5.8 Clock Screen ............................................ 28 Version Screen ......................................... 29 Service Menu ........................................... 29 Humidifier Configuration ........................... 30 Alarms ...................................................... 35 Sensors .................................................... 35 Options Menu Loop .................................. 36 Digital In ................................................... 38 Run Hours ................................................ 38 BMS Communication ............................... 39 Factory Configuration ............................... 40 Sys Configuration ..................................... 40 Save Configuration ................................... 40 Factory Configuration ............................... 41 Sys Configuration ..................................... 44 Basic System Configuration ..................... 44 Humidifiers and Cabinet Fan.................... 45 Drain, BMS and Integration ...................... 45 Input Configuration ................................... 45 Digital Input Configuration ........................ 46 Output Configuration ................................ 46 Sensor Options......................................... 46 Measurement Units .................................. 46 Screens Visible Only by Config Password..... 46 Factory Default Set Points ....................... 47 6.0 MAINTENANCE ....................................... 49 6.1 General..................................................... 49 7.0 TROUBLESHOOTING ............................. 49 7.1 7.2 General..................................................... 49 Control I/O Module Signal LED's ............. 50 ii 8.0 REPAIR PROCEDURES.......................... 51 8.1 8.2 General ..................................................... 51 Component Replacement ........................ 51 9.0 PRODUCT SUPPORT ............................. 51 9.1 9.2 9.3 Technical Support .................................... 51 Obtaining Warranty Parts ......................... 51 Obtaining Spare/Replacement Parts........ 52 10.0 APPENDIX A - BMS Parameters ............. 53 10.1 10.2 10.3 10.4 10.5 10.6 Signed Values ......................................... 53 Unsigned Values ..................................... 54 Boolean Values ........................................ 55 Alarm Packed Bit Variables ...................... 56 Input Packed Bit Variables ....................... 57 Output Packed Bit Variables .................... 57 11.0 APPENDIX B - Input/Output ..................... 58 LIST OF FIGURES Figure 1 - Ultra-Series Control Box ............................ 3 Figure 2 - User Interface Display Panel ..................... 4 Figure 3 - Control Box Internal Layout ....................... 5 Figure 4 - Controller I/O Module................................. 6 Figure 5 - Multiple Humidifier Groups ........................ 7 Figure 6- Humidifier Grouping .................................... 8 Figure 7 - Serial Interface Ports ................................. 8 Figure 8 - Supervisory Control of Humidifiers ............ 8 Figure 9 - RJ45 Connector ....................................... 10 Figure 10 - Locating Wall Mount Sensor .................. 10 Figure 11 - Control Inputs and Outputs .................... 12 Figure 12 - Control Logic.......................................... 13 Figure 13 - Main Menu Selections ........................... 14 (August, 2013) STULZ Ultra-Series Humidifier Controller 1.0 1.1 GENERAL INFORMATION Forward Congratulations, this microprocessor based, Ultra-Series Humidifier controller is designed and manufactured by STULZ Air Technology Systems, Inc. (STULZ) utilizing the latest, state-of-the-art control technology. Recognized as a world leader, STULZ provides humidification systems and controllers manufactured with the highest quality craftsmanship using the finest materials available in the industry. The controller will provide years of trouble free service if it is installed, operated and maintained in accordance with this manual. Damage to the unit from improper installation, operation or maintenance is not covered by the warranty. This manual contains information for the installation, operation, troubleshooting, maintenance and repair of the controller. STUDY the instructions contained in this manual. They must be followed to ensure proper operation of the equipment. Spare parts are available from STULZ to ensure continuous operation. Using substitute parts or bypassing electrical components in order to continue operation is not recommended and will VOID THE WARRANTY. Ultra-series controllers are designed primarily to precisely operate, control and monitor STULZ Ultrasonic humidification systems. Any use beyond this is deemed to be not intended. STULZ is not liable for any damage resulting from improper use. All Ultra-series controllers are designed for indoor use. 1.2 Safety Summary Read and understand all instructions in this manual relating to the specific function prior to starting the task. Carefully read and understand all notes, cautions and warnings contained in this manual that pertain to the task to be performed. Warnings indicate potential threat to personnel safety. Cautions indicate potential threat of damage to equipment. Carefully read and understand all WARNING and/or CAUTION plates located on the unit. 1.3 Warnings & Cautions STULZ uses NOTES along with CAUTION and WARNING symbols throughout this manual to draw attention to important operational and safety information. A bold text NOTE marks a short message in the information alerting to an important detail. (August, 2013) A bold text CAUTION safety alert appears with information that is important for protecting of the equipment and performance. Be especially careful to read and follow all cautions that apply to your application. A bold text WARNING safety alert appears with information that is important for protecting personnel from harm and the equipment from damage. Pay very close attention to all warnings that apply to the particular application. A safety alert symbol accompanies a general WARNING or CAUTION safety statement. A safety alert symbol accompanies an electrical shock hazard WARNING or CAUTION safety statement. CAUTION Prior to performing any installation, operation, maintenance or troubleshooting procedure read and understand all instructions, recommendations and guidelines contained within this manual. CAUTION All maintenance and/or repairs must be performed by a qualified technician. NOTE We recommend consulting the STULZ customer service department for the adjustment and maintenance of the controller or the humidification system. WARNING Never operate the unit with any cover, guard, screen, panel, etc., removed unless the instructions specifically state otherwise, then do so with extreme caution to avoid personal injury. WARNING Always disconnect the main power supply to the equipment at the main power disconnect switch before beginning work on the equipment. A lockout tag-out procedure should be followed to ensure that power is not inadvertently reconnected. CAUTION Air vent openings must be completely free of obstructions. 1 STULZ Ultra-Series Humidifier Controller 1.4 Product Warranty 2-Year Standard Limited Warranty: STULZ Air Technology Systems, Inc., warrants to the original buyer of its products that the goods are free from defects in material and workmanship. STULZ Air Technology Systems, Inc.’s obligation under this warranty is to repair or replace, at its option, free of charge to the customer, any part or parts which are determined by STULZ Air Technology Systems Inc. to be defective for a period of 24 months from date of shipment when a completed start-up form has been submitted to STULZ Air Technology Systems, Inc. within 90 days from shipment. In the event that a completed start-up form is not received by STULZ Air Technology Systems, Inc. within 90 days from shipment, the company’s obligation will be for a period of 12 months from date of shipment. Parts repaired or replaced under this warranty are shipped FOB Factory, and warranted for the balance of the original warranty period or for 90 days from the date of installation, whichever is greater. STULZ Air Technology Systems, Inc.’s warranty does not cover failures caused by improper installation, abuse, misuse, misapplication, improper or lack of maintenance, negligence, accident, normal deterioration (including wear and tear), or the use of improper parts or improper repair. Purchaser’s remedies are limited to replacement or repair of non-conforming materials in accordance with the written warranty. This warranty does not include costs for transportation, costs for removal or reinstallation of equipment or labor for repairs or replacement made in the field. If any sample was shown to the buyer, such sample was used merely to illustrate the general type and quality of the product, and not to represent that the equipment would necessarily conform to the sample. This is the only warranty given by the seller, and such warranty is only given to buyers for commercial or industrial purposes. This warranty is not enforceable until the invoice(s) is paid in full. THE FOREGOING SHALL CONSTITUTE STULZ’S ENTIRE LIABILITY AND YOUR EXCLUSIVE REMEDY. IN NO EVENT SHALL STULZ BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING LOST PROFITS (EVEN IF ADVISED OF THE POSSIBILITY THEREOF) ARISING IN ANY WAY OUT OF THE INSTALLATION, USE OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 2 (August, 2013) STULZ Ultra-Series Humidifier Controller 2.0 2.1 DESCRIPTION General The microprocessor based, Ultra-Series controller is a highly versatile and flexible humidification controller. It is designed primarily for STULZ Ultrasonic Humidifiers with variable humidity output. The controller is equipped with factory configured software designed to precisely control the operation of this Ultrasonic Humidifier. The Ultra-Series controller is factory programmed therefore most applications will require no additional field setup except for the addressing of the humidifiers. However, the set points and their ranges are easily adjusted from the user interface display panel. The program and operating parameters are permanently stored in FLASH-MEMORY in case of power failure. The Ultra-Series controller may be configured to monitor and control a complete humidification system consisting of multiple ultrasonic humidification units. Depending on the Humidifier capacity, a full size UltraSeries controller may hold output power supplies for up to 8 STULZ Ultrasonic Humidifiers. When controlling groups of Humidifiers, auxiliary control boxes, containing additional Humidifier output power supplies, may be utilized to achieve up to 16 humidifiers on a system. Auxiliary control boxes contain no controller or interface display panel. They are powered independently of the controller allowing them to be installed near the Humidifiers they operate, resulting in reduced wire lengths and wire size. control box are provided with a door interlocked, main power disconnect switch with a lockable handle. The switch must be turned "Off" to open the door of the box. The disconnect switch isolates power only from the Humidifiers connected to that box. The Ultra-Series controller is designed to manage humidity or dew point levels to a user defined set point via proportionally controlled output signals to the Humidifier(s). Control set points are established to maintain the necessary level of humidification needed to achieve the room's design conditions. The controller has the ability to monitor the conditions (such as humidity, temperature, supply air velocity) via sensors or BMS control inputs. The internal logic determines if the room conditions require humidification. The controller communicates with the Humidifiers the percentage output they need to be delivering in response to the demand for humidification. The controller responds accordingly to changes in conditions and proportionally varies the output(s) controlling humidity production to maintain humidity levels to the control set point. 2.2 2.2.1 Features BMS Interface The controller may incorporate a communication port that can be field connected through a serial interface to a Building Management System via Modbus, BACnet, SNMP or HTTP protocol. 2.2.2 Field Configurable Ultra-Series controllers are field configurable, allowing the operator the capability of selecting control set points specific to the application. Operator interface for the controller is provided via an attractive, user interface display panel. The display panel has a backlit LCD display and function keys allowing the user to scroll through and enter various menu loops. The menu driven loop structure is user friendly with operator prompts making it easy to navigate through the various screens. Monitoring of room conditions and system operation is allowed without entering a password. Modifications to the control set points may be made with the use of a password. 2.2.3 Figure 1 - Ultra-Series Control Box A smaller space saving "Trim" control box is also available for powering smaller groups of humidifiers consisting of four units or less. The Ultra-Series control box and auxiliary (August, 2013) Password Protection Access to the Information menu and Alarms log is allowed without the use of a password. The controller is programmed to recognize predetermined security levels before allowing access to display screens containing critical variables. Only authorized personnel who possess a thorough understanding of the system should make 3 STULZ Ultra-Series Humidifier Controller changes to Control and Service menu settings. These screens must have accurate variables entered, otherwise erratic operation may occur. The secured menu levels support unique passwords that must be entered to access the menu screens so only authorized personnel may perform modifications to the settings. See Password Authorization, Section 4.3. 2.2.4 Timed Drain Cycle The Ultra-Series controller is programmed to enable timed drain cycles when the Humidifier(s) have been idle to help ensure proper water quality in the reservoir. 2.2.5 2.3.1 KEY FUNCTION Accesses active alarm screens Silences audible alarms Resets active alarms Prg Displays the main menu Esc Returns to the next menu level up Cancels a changed entry Restorable Set Points Upon initial start-up the system operates using the set points programmed by the factory. The set points for the system may be re-adjusted in the Control menu at any time. The customer may enter new operating parameters in the Control>Set points and Control>Tuning menus and the system will operate accordingly. If it becomes necessary, the customer may restore the set points back to saved customer parameters or to the original factory (primary) parameters. 2.3 Function Keys Steps back to the previous screen in a menu loop Increases the value of a modifiable numeric field "Enter Key"- Accesses the menu loops Moves the cursor into a modifiable field Accepts the current value of a modifiable field Steps to the next menu screen in a menu loop Decreases the value of a modifiable numeric field User Interface Display Panel 184.108.40.206 Contrast Adjustment Press and hold the Alarm ( ) and (Prg) keys; then repeatedly press the Up (↑) and Down (↓) keys to adjust the contrast. 2.3.2 Figure 2 - User Interface Display Panel The user interface panel features an easy to read, backlit liquid-crystal alphanumeric display giving a quick-glance operational overview of the humidification system. The display is equipped with LED illuminated function keys allowing the operator complete control and monitoring capability of the humidification system. The screens available on the interface display panel present data that originates from the controller I/O module. The controller is operated via a 6-key menu-driven windows type loop structure providing the ability to scroll through and enter various menus (Information, Control, and Service). These menus permit the user to easily view, control and adjust operating parameters for the humidification system. (See Menu Selections, Figure 13.) 4 Alarms Alarm conditions activate a red LED indicator that backlights the alarm function key. As an option, an alarm condition may also be enunciated by an audible alarm signal. An alarm is acknowledged by pressing the alarm key. This calls up alarm display screen(s) that provide a text message detailing the alarm condition(s). After an alarm condition is corrected, the alarm may be cleared by pressing the alarm key. 220.127.116.11 Alarm Log The alarm log provides a history of the alarms in sequential order with a time and date stamp. To access the alarm log, press the (Prg) key, then press the Down (↓) arrow key until the "ALARM LOG " screen is reached. Press the Enter (←) key to access the loop. When access is gained to the Alarm Log, use the Up and Down arrow keys to scroll through the log for additional alarm messages. (August, 2013) STULZ Ultra-Series Humidifier Controller 2.4 Controller Nomenclature The Ultra-Series controller box contains the main operating components. The control box layout, shown in Figure 3, is a typical layout showing power supplies for up to eight individual Humidifiers. One power supply is provided for each Humidifier to be controlled. The higher the Humidifier capacity is, the larger the power supply for it must be. Depending on the number of Humidifiers that need to be controlled (up to 16), the number of power supplies required may not fit inside the Ultra-Series enclosure. In that case auxiliary control boxes are utilized to house additional power supplies as needed. Figure 3 - Control Box Internal Layout The item numbers below coincide with the call outs in Figure 3. 1. 2. 3. 4. 5. 6. 7. 8. 9. Controller I/O module (Figure 4) Expansion I/O module (for conductivity sensor) Humidifier power supplies (8 maximum) Controller transformer Vent Fan Sensor averaging board (optional) Power supply circuit breakers (8 maximum) Humidifier output relays Water detector control module (optional) 10. Service disconnect switch (*see note) 11. Cabinet ground lug 12. Knock-out for power cable 13. Humidifier(s) output terminal block 14. Knock-outs for Humidifier cables (8 max) 15. Knock-out for control wires 16. Control interface terminal blocks 17. Humidifier circuit breakers (8 maximum) *Note: The service disconnect switch removes power from the Ultra-Series controller and only the Humidifiers connected directly to it. Auxiliary boxes power the Humidifiers they are connected to, but the Humidifiers will time out and shutdown if the control signal is interrupted by turning off the Control Box disconnect switch or if the control signal is lost over the Modbus. Auxiliary Boxes must have their service disconnect switch turned off to stop the operation of the Humidifiers connected to them while other Humidifiers are continuing to run off the Control Box and other Auxiliary Boxes. (August, 2013) 5 STULZ Ultra-Series Humidifier Controller 2.5 Controller I/O Module The Ultra-Series controller is equipped with a microprocessor based controller I/O module (see Figure 4). The controller I/O module contains the software that manages the operating parameters of the humidification system. Figure 4 - Controller I/O Module 2.5.1 Controller I/O Module Layout The controller I/O module contains the logic and input/output terminals. See Figure 4 for details of the I/O module layout. The item numbers below coincide with the call-outs in Figure 4. 1. RJ11 Telephone connector (J10) for display 2. Hatch for BMS serial interface port 3. Power on LED (1- yellow) 4. Signal LED's (3- red, yellow, and green) 5. Hatch for RS485 connector for network control bus 6. Power connector (J1) 2.6 Auxiliary Terminals The Ultra-Series controller is equipped with customer interface positions on terminal blocks located in the control box. For auxiliary device wiring connections, refer to the electrical drawing(s) provided with the unit. 2.6.1 Control Sensors The controller is equipped with terminal positions for the connection of sensors (temperature, or relative humidity). If customer supplied, the sensor(s) may be a 4 to 20mA, a 0-1V, a 0-10V or a 0-5V signal to the system controller. Parameters inside the controller need to be set appropriately before connecting the sensors. Sensor(s) may 6 be duct mounted to monitor return or supply air and/or wall mounted to monitor the room air to determine the humidification demand against the control set points for automatic control of humidity production. A wall mounted sensor or return duct mounted sensor is typically used to control room conditions. A duct mounted supply humidity sensor is typically used as a high humidity limit sensor. 2.6.2 Alarm Contacts Dry relay contacts (N/O or N.C.), are available for remote monitoring of alarm conditions. The alarm contacts are rated for a resistive load at 250VAC/ 8 Amps. 18.104.22.168 Summary Alarm A summary alarm dry-contact is provided for remote notification of an alarm condition. As programmed into the system controller, an alarm condition activates the summary alarm logic which energizes a summary alarm relay and audible alarm if enabled. 22.214.171.124 Custom Alarm In addition to the summary alarm, dry contact relays may be optionally provided for remote annunciation of customer selected alarm condition(s). Any alarm may be programmed in the controller to activate the user configurable custom alarm logic. (August, 2013) STULZ Ultra-Series Humidifier Controller 2.6.3 Water Conductivity Probe To ensure proper demineralized water supply quality, the controller is equipped with terminal positions for the connection of a conductivity probe. The conductivity probe is shipped loose with a 10 ft. long cable. The conductivity of the demineralized water is monitored via the sensor (probe) mounted in the pipe supplying water to the Humidifier (see Section 3.3.5). The controller alerts the operator with a "High Conductivity Pre-alarm" if the water conductivity rises to between 5 and 20 microSiemens. Above 20 microSiemens, the controller shuts down Humidifier operation following a 5 minute time delay and signals a "High Conductivity" alarm. 2.6.4 Shutdown". The humidification system is automatically reenabled when the remote On/Off signal calls for the unit to turn back on. 2.6.8 Multiple Humidifier Grouping The Ultra-Series controller can be configured to operate two individual groups of Humidifiers (Figure 5) via a common Modbus. Air Velocity Sensor This controller is equipped with terminal positions for the connection of an optional Air Velocity Sensor/Transmitter to allow monitoring of the air flow in ductwork. The system controller displays a “Low Airflow” or a "High Airflow" alarm when the measured air velocity is outside the established range (too high or too low). The system controller is programmed to recognize an "Air Velocity" alarm condition as a Non-Critical alarm. This alerts the operator of the alarm condition but allows the Humidifier(s) to continue operating. 2.6.5 Air Proving Switch The controller is equipped with terminal positions for the connection of an optional Air Proving Switch for use as a safety feature. The switch contacts close when there is sufficient airflow in the ductwork. The contacts open upon loss of Airflow, triggering an alarm. The controller displays a “Loss of Airflow” alarm when this occurs. Additionally, the system controller is programmed to provide a “Summary Alarm” indication. The system controller is programmed to recognize a “Loss of Airflow” alarm condition as a “Critical Alarm” and shut the Humidifier(s) down. The system will automatically resume operation when airflow is restored. 2.6.6 Water Leak Detector The controller is equipped with terminal positions for the connection of optional Water Leak Detector(s). The water leak detector(s) may be a spot or cable (20 ft.) type sensor. The system controller is programmed to recognize a "Water Leak" alarm condition as a critical alarm. Upon sensing a water leak, the system controller shuts down Humidifier operations and displays a “Water" alarm message. It remains shut down until the cause has been determined and corrected. Once corrected, the alarm can be reset. 2.6.7 Remote On/Off If the controller is configured for the Remote On/Off option, terminal positions are provided to connect a remotely located, On/Off switching control device. If the Humidifier is turned on and the Ultra-Series controller receives a remote input signal to turn it off, the controller disables all controller outputs and provides a status message "Off by Remote (August, 2013) Figure 5 - Multiple Humidifier Groups The 2 groups can be configured with duty assignments: Rotating, Capacity-Assist, and Bank Select. 126.96.36.199 Group Rotation In Rotating mode, controller will rotate duty between the Humidifier groups to promote equal run time. The rotation time period is typically 1 week, however it may be set by the user via the Factory menu. Call STULZ Product Support for assistance when accessing the Factory menu. 188.8.131.52 Capacity Assist In Capacity Assist mode, the system can be used to maximize efficiency for conservation of energy and to allow more precise control of humidity production during periods of low demand. The Capacity-Assist option enables one group of Humidifiers to proportionally handle the demand for humidification up to their maximum capacity. If the output of the first group of Humidifiers reaches 100% capacity and they are unable to satisfy the demand, the controller enables the second group of Humidifiers to operate, controlling their output proportionally while the first group continues to operate at 100% capacity. As humidity conditions approach set point, the controller scales back the proportional output control signal to the second group accordingly until they are no longer required. At this point 7 STULZ Ultra-Series Humidifier Controller the Humidifiers in the second group are turned off and the Humidifiers in the first group return to proportional control. Rotation of which group is the lead group occurs as in the Rotate mode. 184.108.40.206 Bank Select Bank select is controlled by a digital input from an external source. It selects which group will operate. The other group does not assist. If customer provided, the bank select control contacts must be sized appropriately. The contacts must have a minimal rating of 24 VAC. 220.127.116.11 Proportional Humidifier/Duct Limitation The Proportional Limitation option limits humidity production of a group of Humidifiers based on humidity or dew point to prevent condensation from forming on cold surfaces. For example, Humidifiers that may be positioned near the ceiling or floor of an AHU, where condensation may occur, can be configured as a group with a threshold applied to limit humidity production. In this case, the limited Humidifiers will be in Group A (see Figure 6) and limited by the Limit Sensors. Group A would be selected to be limited. The Humidifiers in Group A and B operate up to their full rated output capacity based on the demand for humidification. As the user selected limit humidity or limit dew point temperature limit set point is reached, the Humidifiers in Group A start scaling output back humidity output proportionally until it is zero output. Limitation can be set for either Group, but based on only one limit sensor. The enables for Proportional limitation are set in the Service Option Loop>Startup Menu. Multiple Humidifier controllers can be connected to a BMS or central control terminal allowing the communication of data and information to the BMS. Instead of sensors, control signals from an Ethernet interface may be used to mimic sensors used by the Ultra-Series controller to manage humidity levels. The controller develops and transmits control output signal(s) to the Humidifiers based on those input signals. Modbus RTU BACnet IP, BACnet Ethernet HTTP, SNMP & Modbus IP BACnet MS/TP Figure 7 - Serial Interface Ports Each controller added to the network must be configured for BMS communication and assigned an address. Figure 6- Humidifier Grouping 2.6.9 BMS Operation The Ultra-Series controller may be equipped with a serial communication port (Figure 7) that can be interfaced to a Building Management System (BMS) via Modbus, BACnet, SNMP or HTTP protocol as configured by the factory. A controller interfaced to a network must be configured for BMS communication. 8 Figure 8 - Supervisory Control of Humidifiers (August, 2013) STULZ Ultra-Series Humidifier Controller 3.0 3.1 INSTALLATION The controller has been tested and inspected prior to shipment. Perform a visual inspection of the packaging immediately upon delivery to ensure the equipment has been delivered in excellent condition. If there is visible shipping damage, it must be noted on the freight carrier's delivery forms BEFORE signing for the equipment. Any freight claims MUST be done through the freight carrier. STULZ ships all equipment FOB factory. STULZ can assist in the claim filing process with the freight carrier. Carefully remove all protective packaging, open the controller access door and thoroughly inspect for any signs of transit-incurred damage. Should any such damage be present, notify STULZ prior to attempting any repairs. Refer to the last section of this manual for instructions. NOTE The controller should always be stored indoors in a dry location prior to installation. A Data Package has been sent with the unit. It contains this manual, an IOM for the Humidifier, system drawings and any other applicable instructions based on the configuration and options furnished with the unit. These documents should be kept with the unit for reference. NOTE Shipped loose items such as sensors are shipped separately unless specified otherwise by the customer. Remove and store these items in a safe place unless they are being installed immediately. 3.2 CAUTION Uncrating and Inspection Mounting The control box is designed for indoor installation only. Mount the control box within 10 feet of the supply water source for the STULZ supplied water conductivity probe to reach. Avoid installing the controller in locations where ambient temperatures are above 90°F or where the relative humidity is above 90%. Do not install the controller where it will be subjected to strong vibrations or bumps. Avoid mounting in areas exposed to direct sunlight or with wide and rapid temperature fluctuations. The control box may be mounted to an equipment rack, a wall or a flat surface. Secure the enclosure through the 4 mounting holes taking care not to damage the internal components. Ensure the mounting surface is capable of supporting the total weight of the unit. Ensure that the areas around the enclosure vents are free of obstructions that may impede Airflow. (August, 2013) When the unit is operating, the enclosure vent openings must be completely free of obstructions. 3.3 Wiring Connections The controller is provided with terminals for all required field-wiring connections. Refer to Figure 3 for the location of the interconnect terminals and see the electrical drawing(s) supplied with the unit for all field wired power and control connections. It is important to identify the options that were purchased with the unit in order to assure which field connections are required. WARNING Verify power is turned off connections to the equipment. 3.3.1 before making AC Input It is important that the controller nameplate be examined to determine the operating voltage, frequency and phase of the system. The supply voltage measured at the unit must be within ±10% of the voltage specified on the system nameplate. The unit nameplate is located inside the controller enclosure. The nameplate also provides the full load amps (FLA), the current that the unit will draw under full design load, the maximum fuse size for circuit protection, and the minimum circuit ampacity (MCA) for wire sizing. When the main power wires are connected, the electric box has power to the main power non-fused service switch. A separate equipment ground lug is provided within the electrical box for termination of an earth ground wire. 3.3.2 DC Output to Humidifier(s) Consult the wire sizing table in the Humidifier IOM to determine the correct wire gauge, by Humidifier model, for the length of wire to be run. Insufficient wire gauge will result in excessive voltage drop between the controller and Humidifier(s). Distances over 75 feet are not recommended. STULZ recommends the use THHN or NTW, stranded conductor (not solid conductor) wire. 3.3.3 Control Wiring to Humidifiers CAT 5e cable, with RJ45 connector terminations; connect the controller to the Humidifier(s) in a daisy chain fashion (See Figure 5). Do not exceed 1,000 feet in total length. Ensure the termination resistor (shipped loose) is plugged on the last Humidifier in the string as shown in the electrical drawing(s). Older systems use shielded 3 conductor cable. Ask STULZ Product Support for instructions on wiring these systems. 9 STULZ Ultra-Series Humidifier Controller EIA/TIA-568B wiring Standard shall be used. Figure 9 is the pin side of the connector (tab on the other side). Figure 9 - RJ45 Connector A Jack is mounted in the control box to connect to the humidifiers. The wires marked Shield are not connected to the humidifiers, but passes through all units as a generic shield. It is connected to chassis ground in the Control Box. Pin 1 2 3 4 5 6 7 8 3.3.4 Color Orange/White Orange Green/White Blue Blue/White Green Brown/White Brown NOTE All wiring should conform to local and national electrical code requirements. Use of copper conductors only is required. Wiring terminations may become loose during transportation of the equipment. Therefore, it is required to verify that all wiring terminations are secure. 18.104.22.168 Room Temperature/Humidity Sensors Mount a room control sensor/transmitter in the center of the room where air circulation is good. The sensor should not be mounted near a doorway or an area where it would be exposed to direct sunlight. Wall-mounted control devices should typically be mounted 4-5 feet up from the floor in the conditioned space (see Figure 10). Care should be taken not to install the sensor in an area with excessive changes in humidity and temperature. Name DC Ground DC Ground RS-485 + RS-485RS-485+ RS-485Shield Shield Sensors The Ultra-Series control box is equipped with a terminal block for the connection of a humidity sensor and/or an optional temperature/humidity or dew point sensor. A sensor/transmitter is required regardless of the control mode selected. If provided by STULZ, sensors and transmitters are shipped loose for installation by the customer. Interconnecting field wiring should be installed in accordance with NFPA 70 of the National Electrical Code (N.E.C.). The wiring connections for sensors must be made using shielded cable with a minimum AWG 22 (0.5 mm2 cross section) for each lead. Trim the length of the sensor cables where possible to minimize wire resistance and avoid wrapping the cable around power devices. A remote sensor must be located so that it will properly sense the conditions to be controlled. Refer to Sections 22.214.171.124 or 126.96.36.199 when mounting sensor(s). Refer to Figure 3 for the location of the controller interface terminals and to the electrical drawing for wiring details. Figure 10 - Locating Wall Mount Sensor Make the wiring connections to the controller interface terminal block as shown in the electrical drawing(s). CAUTION Do not damage the exposed temperature/humidity sensors on the PC board while screwing in the cover fastening screw. The circuitry can be damaged if handled improperly. 188.8.131.52 Duct Mounted Sensors Cut a hole in the side of the duct and mount the sensor, (temperature, humidity and or air velocity) to the duct using the screws provided. Position the supply air sensors approximately 10 feet down stream of the Humidifier outlet. Each supply air sensor is to be field connected to the controller at the terminal positions designated in the electrical drawing. 3.3.5 Water Conductivity Probe The Ultra-Series control box monitors water quality via a probe (sensor) shipped loose. It is to be field installed in the 10 (August, 2013) STULZ Ultra-Series Humidifier Controller demineralized water supply piping to sense water quality entering the Humidifier. The length of control cable provided is 10 feet long. Do not cut the control cable or add to its length because a change in wire resistance will affect the sensor's calibration. Because the conductivity circuit is sensitive to electromagnetic interference, the control cable should not be run near high voltage wires. Connect the leads from the conductivity sensor to the designated terminal positions in the controller as shown in the electrical drawing. 3.3.6 Remote On/Off A remote on/off control device may be an On/Off switch, thermostat or a humidistat. If customer provided, the remote On/Off control contacts must be sized appropriately. The Remote On/Off contacts must have a minimal rating of 24 VAC. Refer to the electrical drawing(s) included with the unit for wiring details. 3.3.7 Remote Alarm Signal Contacts The Summary Alarm and Custom (user configured) Alarm(s) have dry contact relay interface terminals inside the controller. The customer may connect a 2 conductor, alarm signal cable to each relay for remote annunciation of alarm conditions. The alarm contact positions are NO/C/NC, rated at 250VAC / 8 Amps. 3.3.8 Water Leak Detector Optional remote water detector(s) are normally placed on the floor or in a customer supplied drain pan located beneath the Humidifier(s). The detector(s) may be secured using double sided tape or cable ties with mounting pads. Prepare the surface before applying the tape. Apply tape to the bottom of the detector and secure it in place. (August, 2013) 11 STULZ Ultra-Series Humidifier Controller 4.0 4.1 OPERATION General Theory of Operation This Ultra-Series controller is designed to control the output of an ultrasonic humidification system in a space or process application to humidity levels as defined by the user. Humidified air is supplied to the conditioned space as needed to maintain the relative humidity or dew point control set point. The controller may also be networked with a group of Humidifiers to manage their outputs as a system. The controller I/O module includes inputs and outputs as depicted in Figure 11: 184.108.40.206 Dew Point Control The controller calculates dew point based on signal inputs from temperature and humidity sensor(s) to manage humidity production against a dew point control set point. 220.127.116.11 Proportional Control The controller uses an external input signal representing 0 to 100% output to control humidity production. 4.1.2 Operating Modes There are 6 operating modes for the controller depending on how many and what types of inputs are used. The operating mode has been pre-set by the factory and should not require adjustment. BMS Signal indicates the input is sourced by the serial BMS interface. Sensor indicates the input is a physical signal and may originate from a sensor or a voltage/current generated by another control system. 1 Input 1 (Control) BMS Signal Input 2 (Limit) None 2 Control Sensor None 3 BMS Signal BMS Signal 4 Control Sensor Limit Sensor 5 BMS Signal Limit Sensor 6 Control Sensor BMS Signal Mode Function Room Control Return duct monitoring with proportional high limit 18.104.22.168 Room Control The controller may be configured for room installations with only one control input. In room installations the controller maybe configured to manage humidity production based on a control signal from a return air humidity sensor or optionally from a relative humidity and temperature sensor for dew point control or, a signal from an external controller or BMS can be used (Modes 1 & 2). Figure 11 - Control Inputs and Outputs 4.1.1 Humidification Control The method of operation depends on the controller's programmed operating mode. Control takes place by means of the controller analyzing signal inputs from sensor(s) and/or from an external supervising controller or Building Management System (BMS). 22.214.171.124 Return Air Duct Monitoring (DAH Units) When used for duct installed, DAH Humidifiers in air handling units, two inputs may be utilized. Input 1 is the control for the humidity in the return air duct and input 2 as a proportional high limit signal downstream of the Humidifier. The inputs may be from a BMS/external controller and/or remote sensors (Modes 3 - 6). 126.96.36.199 Humidity Control The controller responds to relative humidity sensor signal input(s) to manage humidity production against a relative humidity control set point. 12 (August, 2013) STULZ Ultra-Series Humidifier Controller 4.1.3 P/I- Proportional/Integral Control The controller calculates proportional control output signal(s) based on the analysis of sensor input signals, which determines the amount of humidification needed (see Figure 12). Signal 1 represents the return air humidity and is calculated by the controller as a percentage value compared to the maximum control set point value for input 1, taking into account the prop band. Signal 1 is compared to the maximum control set point value for input 1 resulting in a control value that will be proportional to signal 1. Signal 2 represents the limit humidity and is calculated as a percentage value for input 2 taking into account the prop band. Signal 2 is compared to the maximum control set point value for input 2 resulting in a control value that will be proportional to signal 2. The control output signal to the Humidifier(s) will be directly proportional to the combined input signals by the following process: Signal 1 x Signal 2 100 If input 2 is not used, the controller only works with reference to signal 1. The effect of integral on the control signal (Signal 1) has been neglected from the above calculation for simplification. With integral control, the added element of time is factored into the Humidifier output algorithm. The integral value is used to gradually adjust the proportional output when the calculated output does not move the process variable closer to set point in a given period of time. Decreasing the integral value decreases the interval for the output corrections (speeding the rate of adjustment). Increasing the integral value increases the interval for corrections (slowing the rate of adjustment). The P/I control factors are hard coded in the controller and cannot be user adjusted. Figure 12 - Control Logic (August, 2013) 13 STULZ Ultra-Series Humidifier Controller 4.2 4.2.1 Navigating Controller Screens Menu Selection The Ultra-Series controller provides five user selectable menus needed to view operating data and enter set points for the system (see Figure 13). These menus may be accessed by pressing the Program (Prg) key to reveal the Main Menu screens. Scroll between adjacent menu selections within the Main Menu by use of the Up (↑) and Down (↓) arrow keys. When the desired menu is centered in the screen with bold capital letters and an arrow symbol pointing towards the Enter (←) key, press the Enter (←) key to access that menu loop. The user can access the menu loop screens located within the designated menu selection using the Up (↑) and Down (↓) arrow keys. Access to some menus may be protected by a built in security protocol and may require the use of a password to gain access (see Section 4.3). 4.2.2 Menu Loops Press the Program (Prg) key from any screen to select from among the five menu loops shown in Figure 13. Figure 13 - Main Menu Selections 14 (August, 2013) STULZ Ultra-Series Humidifier Controller 188.8.131.52 Display Variables The user interface display panel provides screens with three (3) different forms of both the read only and the modifiable variables: Numbers are displayed as positive (+) or negative (-) integers. Dual-State can be toggled between two (2) values i.e. On/Off, Yes/No. Word Variables have a unique text message for each of the variable's possible choices. 184.108.40.206 Cursor Position in Screens The following display screen is shown as an example after accessing a new menu loop display screen using the function keys. The name of the menu loop is the line in the upper-most field of the screen. A flashing window also appears in the left of the uppermost field. Flashing Window → ▬ CONTROL MENU field of the current screen. From here advancement to the next adjacent menu loop screen will occur when the Up or Down key is pressed. Successive use of the Enter key will advance the cursor through the various modifiable fields of the display screen eventually returning to the first field. Values that are already correct may simply be skipped by using the Enter (←) key without modification of the variable. The current value, if not changed, will be retained after pressing the Enter (←) key. Values for fields being adjusted will automatically wrap when adjusted beyond the high or low limit established for that field. Whenever the flashing cursor is located in a modifiable field, pressing the Escape (Esc) key one time returns the user to the next menu up. Each successive use of the Escape key returns to the next menu level up until the Main screen is reached. 220.127.116.11 SET CLOCK Alarm Set CLOCK Version From this position the Up (↑) and Down (↓) arrow keys may be used to access additional selections within the current display menu. Each screen supports a specific functional requirement. Pressing the Enter (←) key allows access to the selected display screens to adjust any of the modifiable fields. If a screen with modifiable values is accessed, Use the Enter key to insert a flashing cursor in the modifiable fields within that screen. SET CLOCK Flashing Cursor Time: █00:00 Date: 00/00/0000 Day: XXXXXXXX Modifiable Variables Time: █00:00 Date: 00/00/0000 Day: XXXXXXXX ← Modifiable Variable For the purpose of this manual the examples of user modifiable variables within display screens will be denoted by bold text. (Please note the actual display may not use bold text.) Pressing the Enter (←) key accepts the value displayed and advances the cursor to the next modifiable field. The Up (↑) or Down (↓) key may be used to modify the values of these fields. If the modifiable field is a positive (+) number, the positive value is indicated by the absence of a (+) or (-) symbol in front of it. The (-) negative symbol will be displayed to the left of the first digit for negative numbers. If the flashing cursor is located in a modifiable field, the value of the field will be changed with the use of the Up (↑) and Down (↓) arrow keys. When the Enter (←) key is pressed the cursor moves to the next modifiable field. After entering the last modifiable field within a screen, pressing the Enter key removes the cursor and the flashing window reappears in the left-hand corner of the upper-most (August, 2013) 15 STULZ Ultra-Series Humidifier Controller 4.3 Password Authorization 4.3.2 Access to a menu loop may be requested from the main menu. Modifiable control screens have variables that affect system performance. Improper settings may result in erratic operation and possible system failure or damage. Anyone is allowed direct access to the Info and Alarm log display menus with no security password. Only authorized personnel who possess a thorough understanding of the system operation should perform modifications to secured menu settings (Control, Service and Factory). These menus are configured with password protection, thus requiring a higher level of authority to access them. The screens must have accurate variables entered otherwise erratic operation may occur. 4.3.1 Password Protected Screens Upon first attempting to select a secure menu in a given session, the "Enter Password" screen will be displayed. This screen displays the current security level authorized. █ Enter Password: Level:0 0 ← (Current Security Level) Enter Password Screen A session is defined as from the time access is gained to a secure menu until 60 seconds elapses with no key activity. Security access will be terminated at this point and the password will have to be reentered to gain access. The menus that may be password protected by the user are the Control and Service menus. The Factory level menu screens are also password protected, however the password is set at the factory to limit access. It is intended that access to the Factory menu screens only be established while the user is working with the guidance of STULZ Product Support (see Section 9.0). Incorrect settings made at the Factory level could unintentionally damage the equipment. Wrong Password █ Enter Password: 0 JD 0 Level:0 ** WRONG PASSWORD ** The “WRONG PASSWORD” message is displayed any time an incorrect password has been entered and the Enter (←) key has been pressed. If the “Wrong Password” message appears, use of the Enter (←) key will return the operator to the “Enter Password” field. A requested menu screen is displayed any time a valid password has been entered and the Enter ( ) key has been pressed. NOTE If the Control menu is requested and the Service menu password is entered, access to both is granted. 4.3.3 Setting the Passwords The initial password for the Control menu (Level 1) and Service menu (Level 2) are factory set. Upon entering the Service menu, the operator is allowed to change the passwords for the menus (see Section 18.104.22.168). If changed, from that point on access may only be gained to that menu by personnel who know the password. MENU PASSWORD Control Service 1 2 Consult STULZ Product Support Factory Operators, who are allowed access to the Service menu (level 2) for example, must know the password to enter that level. If the entered password equals or exceeds the level requested during a given session, the operator is allowed to access the requested loop. For example, if the entered password allows access to level 2 and the Control menu (level 1) is requested, access will be allowed. If the entered password authority level is lower than the level requested, the words "WRONG PASSWORD" will appear for several seconds at the bottom of the screen. 16 (August, 2013) STULZ Ultra-Series Humidifier Controller 4.4 Start-up / Commissioning CAUTION by pressing the Enter (←) key when "CONTROL " appears in bold letters in the center of the screen. A password entry screen will be displayed. Ensure all system hook-ups to the Humidifier(s) have been completed and that DI water is available. 1. Turn the On/Off door switch to "On". Upon application of control power, the interface display panel function keys illuminate and the controller begins conducting internal diagnostics to confirm functionality. After about 30 seconds the controller will display the Main Info screen (see Section 4.4.1). 2. If the controller is configured for "Automatic On" operation (standard), it calculates the percentage humidification for each Group of Humidifiers and sends that information to the Humidifiers over the RS-485 Modbus interface. 3. If the status message "OFF- Manual Restart Req" appears, the Automatic On feature may not be enabled. In this case turn the Humidifier on by pressing the Enter (←) key for 1 to 2 seconds until the unit switches state. NOTE The Humidifier may be turned off at any time by pressing and holding the Enter (←) key for 3 seconds. Other status messages that may appear at the bottom of the screen are: "OFF by remote shutdown"- Indicates the Remote Start/Stop feature is enabled and requires a remote start switch to be turned on. "OFF by Network"- Indicates the BMS communication feature is enabled and the controller received a network signal to pause operation. 4. If the actual room humidity is below the set point minus dead band, the Humidifier(s) will operate. The controller automatically enables the control outputs and records the date and time in the alarm history log. An animated icon (shown below) appears in the display indicating the Humidifier is operating. = Humidifying 5. If the Humidifiers don’t operate, operation may be started by creating a demand for humidification. If direct BMS control is used, generate a demand with the BMS proportional input and skip to step 11. Otherwise generate a demand using the Control menu loop (see steps 6- 10). Enter Password: █ 0 Flashing Cursor Level:0 8. To access the Control menu, press the Enter (←) key to insert a flashing cursor in the "Enter Password" field. Change the "0" to "1" (or to the current Control menu password if it was changed in the Service menu) with the Up (↑) arrow key and then press the Enter (←) key to accept the password. Press the Enter (←) key again to access the Control menu screens. 9. From the Control menu, select set points by scrolling through the menu selections with the Up (↑) and Down (↓) arrow keys and pressing the Enter (←) key when "SET " appears in bold capital letters in the center of the screen. Control Menu Version SET Alarm Set 10. After entering the set points screens, select the Humidity set point screen by scrolling through the menu selections with the Up (↑) and Down (↓) arrow keys (see Section 5.4.1). Press the Enter (←) key to move the cursor over to the set point value. Increase the Humidity set point with the "UP" arrow key until the humidity set point exceeds the actual room humidity. Press the Enter key again to accept the set point. Press the Escape key twice to exit the set points screens and return to the Main Menu screen. 6. From the Main screen, access the Main Menu (see Section 5.1) by pressing the program (Prg) key. 11. Listen for the ultrasonic Humidifier transducers to energize or visually check for humidity leaving the Humidifier(s) to confirm that they are operational. 7. Scroll through the Main Menu selections with the Up (↑) and Down (↓) arrow keys and select the Control menu 12. Observe the animated icon in the Main screen to determine if the unit is operating. (August, 2013) 17 STULZ Ultra-Series Humidifier Controller 13. One to six hours may be required to see a desired level or rise of humidity in the conditioned space. Once room conditions have been programmed or set, a repeat visit to the conditioned site may be required to ensure the Humidifier is meeting the room's requirements. 4.4.1 Main Info Screen (Date) (Time) 00.0°F 00%Rh 100 100 Unit On Grp A On Dp 00.0°F ← ← See Note See Note Grp B On The main information screen is displayed approximately 30 seconds after power is applied to the unit. The main screen is a status screen displaying current system operating information. See Section 5.2.1 for details on the fields in this screen. NOTE The relative humidity (%Rh) is always displayed but the current temperature (°F) and dew point (DP) appear only if an optional temperature or dew point sensor is provided. Operator interface to the menu loops is available by pressing the “Prg” key. The controller initiates a timer whenever a key sequence is initiated. Every time a button is pressed, the timer is reset. If there is no key activity for two minutes, the controller will return to the Main Info screen. The time delay is preset at the factory. 4.4.2 Saving & Restoring Set points Upon initial start-up the system operates using the set points programmed by the factory (Factory Parameters) as the operating set points. As described in Section 4.4, steps 6 - 10, the customer may enter new operating parameters in the Control the new set points in the Service menu if it is intended to save them (Section 5.5.8). Once stored, the set points now become the restorable Customer Parameters. The Factory set points entered by the factory still remain stored in the controllers' memory as the Factory Parameters. At any time, set points for the system may be re-adjusted to any value and the system will operate accordingly. If it becomes necessary however, the customer may enter the Service menu and restore the set points to the stored Customer Parameters values. The original Factory Parameter values may also be restored from the Service menu. Whichever set points are restored (Factory or Customer); they become the current operating set points. 18 4.5 4.5.1 Controller Features Alarms As programmed into the system controller, an alarm condition activates the summary alarm logic which illuminates the alarm key and energizes an audible alarm (if that option is selected). A message detailing the alarm condition is displayed by pressing the alarm () key. Some alarms are programmed by the factory to automatically shut down the Humidifier until the alarm condition is remedied and the alarm is cleared by pressing the alarm key. Alarms that may be enabled by the factory are listed in Section 5.3. 22.214.171.124 Summary Alarm A summary alarm will activate when the controller senses any programmed alarm condition. This illuminates the alarm key and activates an audible alarm. A summary alarm also energizes Normally Open/Normally Closed summary alarm contacts to remotely monitor alarms. If a Critical alarm condition is detected, a summary alarm will be accompanied by Humidifier shutdown. 126.96.36.199 Custom Alarms A Custom Alarm (user configured) is activated upon detection of one or more individual alarm conditions as selected by the operator in the Service>Options>Custom menu loop (see Section 188.8.131.52.2). When a custom alarm condition is detected, the alarm key illuminates and a designated set of N.O. & N.C. Custom Alarm relay contacts are energized to provide remote indication of the selected alarm condition(s). For example, it may desired to have a remote notification when a High Conductivity pre-alarm is detected, giving notice that the mineral content of the supply water is approaching an unsafe level. This gives an alert before the mineral content of the water reaches the high conductivity threshold and the Humidifier is shut down. The controller may be factory configured to activate up to four Custom Alarms. One user configurable Custom Alarm with relay contacts is provided as a standard and up to three additional may be provided as an option. 184.108.40.206 Customer Alarms A customer provided digital (on/off switching) alarm sensor may be connected to the terminals provided in the electric box. This may be for any site specific alarm condition the user wishes to monitor that may or may not be provided in the standard alarms menu; i.e. gas detection, intrusion alarm, etc. Upon detection of a customer alarm, the alarm key illuminates and the alarm display screen provides a message indicating a customer alarm message. The screen message "Customer Alarm 1" will appear (default) in the controller display or the user may re-configure the controller to display any alpha-numeric message desired, up to 20 characters long, in the Service>Options>Custom Setup menu loop (see Section 220.127.116.11.1). One Customer alarm (August, 2013) STULZ Ultra-Series Humidifier Controller input is provided as a standard and up to two additional customer alarm inputs may be enabled as an option. 18.104.22.168 Air Flow Proving (DAH option) When the Airflow proving switch detects an insufficient air flow condition, the system controller will display a "Loss of Air Flow" alarm and shut down the Humidifier(s). When the Airflow problem is corrected and the alarm is re-set, the Humidifier(s) will automatically resume operation. 22.214.171.124 Air Velocity Monitoring (DAH option) The Humidifier outlet air velocity may be monitored by a sensor. If enabled, the controller provides a display screen with the current air velocity. An air velocity alarm will be triggered if the velocity falls outside a selectable minimum and maximum range. 126.96.36.199 Low Temperature Limiting (Optional) The Humidifier return air temperature may be monitored by a sensor. As the low air temperature threshold is approached, the controller linearly limits the humidification signal. If the return air temperature drops below a selectable threshold temperature, a low temperature alarm will be signaled. The controller is programmed to shut down the Humidifier and drain the reservoir upon sensing a low temperature alarm to prevent damage due to freezing. 188.8.131.52 Cabinet Temperature Monitoring A digital output signal from the controller turns on a cooling fan located inside the control cabinet when the internal temperature rises to a threshold plus dead band. If the enclosure temperature continues to rise, the controller activates a high temperature alarm and stops Humidifier operation. The "Fan On" set point and "High Cabinet Temperature Alarm" threshold are adjustable in the Control>Alarm Set menu loop (see Section 5.4.2). 184.108.40.206 Water Conductivity Monitoring A sensor installed in the water supply piping permits monitoring the water conductivity as a measure of determining when the mineral content is too high. This will ensure clean, mineral free mist production. The supply water quality specified for STULZ Ultrasonic Humidifiers during normal operation should not exceed 5 microSeimens. The controller will provide a pre-alarm message if this water conductivity rises above 5 microSeimens for more than 5 minutes. If water conductivity rises above 20 microSeimens for more than 5 minutes, the controller will shut down the Humidifier(s) and provide a full alarm text message and indicate a summary alarm condition, energizing the N.O./N.C. summary alarm contacts, and optional audible alarm. 220.127.116.11 Water Leak Detection (Optional) The Humidifier controller may monitor water leaks via optional water detector(s). Refer to Section 2.6.6. Upon sensing a water leak, the controller activates the summary (August, 2013) alarm logic and displays a "Water" alarm message. The controller recognizes a water alarm as a Critical Alarm and shuts down Humidifier operation. 4.5.2 Remote On/Off For Remote On/Off operation, terminal positions are provided to connect a remotely located, On/Off switching control device. If the Humidifier is turned on and the Ultra series controller receives a remote input signal to turn off the Humidifier, the controller disables all control outputs and a message "Off by Remote Shutdown" appears in the main display screen. The system will automatically be re-enabled when the remote On/Off signal calls for the Humidifier unit to turn back on. The control device may be an On/Off switch, thermostat or a humidistat. If customer provided, the remote On/Off control contacts must be sized appropriately. The Remote On/Off contacts must have a minimal rating of 24 VAC. Refer to the electrical drawing included with the unit for the electrical specifications and for wiring details. 4.5.3 Automatic Drain Cycle The controller is configured to activate a drain cycle of the Humidifier reservoir(s) during periods of inactivity. This ensures a fresh supply of water in the reservoir. If the total demand for humidity production has been below 10% for the time interval for the drain cycle is programmed (Default of 72 hours, the humidifiers will be commanded to drain. The idle time and drain duration may be adjusted in the Service menu (see Section 18.104.22.168). When a drain cycle is initiated due to the idle time elapsing, the following occurs: 1. Humidification stops. 2. The drain valve is energized open. 3. At the end of the drain duration time, the drain valve closes. 4. When a demand is present, the fill valve opens and humidification returns to normal. The water reservoir is emptied entirely during the auto drain cycle. If there is a demand for humidification, the drain cycle is interrupted. The drain valve closes and the fill valve opens. When the water level in the reservoir is at an appropriate level, the unit begins producing humidity. 4.5.4 Manual Drain The operator may manually drain the reservoir of an individual Humidifier by energizing its drain solenoid valve. This is accomplished with the controller by accessing the Manual Control screen from the Service>Humid menu loop (see Section 22.214.171.124). 19 STULZ Ultra-Series Humidifier Controller From this screen the controller operation may be bypassed to turn certain features On or Off. The left hand column displays the current On/Off control command for the indicated feature; the right hand column is the modifiable field to change to the control state the feature. this method of control, the humidification output level of the Humidifiers is directly controlled by a proportional/integral input signal from the BMS. (i.e. 4mA = 0% output; 20mA = 100% output) 4.5.6 Humidifier 1 of 1 Override Off Off Hum Enable Off Off Fan Off Off Nebulizer Off Off Drain Valve Off Off Fill Valve Off Off 1. Select the Humidifier desired to manually drain in the uppermost field with the Up/Down arrow keys. Press Enter. 2. Change the "Override" field from "Off" to "On". Press Enter repeatedly until the "Drain Valve" field is reached. 3. Change the "Drain Valve" field from "Off" to "On". Press Enter. (Water will begin to drain). 4. Allow the water to drain from the reservoir. 5. Return to the Manual Control screen in the Service>Humid menu loop. Change the "Drain Valve" field from "On" to "Off". Press Enter. 6. Change the "Override" field from "On" to "Off". Press Enter (←), and then press Esc. The Humidifier returns to normal operation. 4.5.5 Communication with the Controller It is possible for the controller to communicate in a variety of ways. 126.96.36.199 Serial Communication Using an expansion card, the controller may be connected to a BMS for monitoring and control of data points using a choice of available serial communication protocols (see Section 5.5.7). Loading New Software The procedure must be executed if new software is emailed to a site and then uploaded onto a Smart Key (STULZ typically sets up Smart Keys before shipping them to a site). After downloading the emailed software onto a Smart Key, the technician must upload the new software from the Smart Key into the controller. 1. Turn the controller off. 2. Disconnect the Interface Display Panel from the Controller I/O module. 3. Plug-in the Smart Key. 4. Turn the controller on. 5. Wait until the LED’s stop blinking on the Smart Key and the start button illuminates. 6. Press the start button on the Smart Key. 7. When the upload operation is complete, a chime sounds. 8. Turn the controller off. 9. Unplug the Smart Key. 10. Turn the controller on. 188.8.131.52 Multiple Humidifier Units The Ultra-Series controller is designed to be the central terminal for up to 16 Humidifiers (Figure 5). This enables the monitoring and management of the operation of multiple humidifiers from a single Ultra-Series controller interface display panel. The controller interface display panel allows access to the data and operating functions for each networked Humidifier via additional menu screens. See Section 184.108.40.206 to set up Humidifier groups. When serial communication is utilized, the controller incorporates a communication port that is field connected through an optional serial interface to a central BMS. Inputs & outputs are remotely monitored (address readable) and remotely controlled (address writable) via a BMS control system that communicates with the controller via Modbus RTU, BACnet MS/TP or IP based protocols such as BACnet over IP, HTTP, or SNMP protocols. Each E-Ultra Controller added to the network must be configured for BMS communication. 220.127.116.11 Direct BMS Control The output of the unit may be controlled directly via a proportional current or voltage signal in certain modes. In 20 (August, 2013) STULZ Ultra-Series Humidifier Controller 5.0 5.1 MENU SCREENS Main Menu Main Menu Factory INFO Alarm Log The Main Menu is accessed from the Main screen by pressing the Prg key. The Main Menu screen Scroll through the menu categories using the Up (↑) and Down (↓) arrow keys. From the Main Menu screen, select from among the following standard menus: access this section. It is not selectable by the normal means; the settings can be observed but not changed in the service menu. 5.2 The Info menu screens may be accessed by simply scrolling with the Up (↑) and Down (↓) arrow keys. The same screens may also be viewed if the Info menu loop is entered by pressing the "Prg" key. The Info menu displays screens that provide current temperature and relative humidity conditions and shows icons indicating the state of operation. There are no adjustable parameters in this loop. From the Info loop, the following display screens may be viewed as they apply to the unit Configuration by pressing the Enter (←) key. Main Menu Factory "Info"- Displays the basic read-only status information. It allows the monitoring of system operational parameters. No password is needed at this level. "Service"- Allows modification of advanced control parameters such as set point offsets, sensor calibration, BMS set-up and permits the user to save new customer operating parameters and/or reset the controller to the previous customer or factory (default) parameter values. It also allows the viewing but not modifying Level 2 password is needed to enter this menu. "Factory"- Allows modification of more advanced control parameters such as sensor scaling, start-up delays and grouping parameters. Level 3 password is needed to enter this menu. Entry to the Factory menu is intended for qualified technicians working under the guidance of the STULZ Product Support during start-up and commissioning of the system. The settings can be observed but not changed in the service menu. The password to enter this menu may be obtained by contacting Product Support. (See section 9.0 of this manual). “Config” – This section is used to set up basic configuration information at the factory before the system is shipped. Only STULZ Product Support should need to (August, 2013) INFO "Alarm Log"- Displays all alarms and "power-ups" in sequential order with a time and date stamp. No password is needed at this level. "Control"- Allows modification of basic control parameters such as set points, temperature alarms and setting the clock. Level 1 password is needed to enter this menu. Information Menu Alarm Log 5.2.1 Main Info Screen The first Info screen is constantly displayed when no keypad operation is taking place. It displays the current Date, Time and provides State of Operation data. The actual relative humidity (%Rh) is always displayed but the temperature (°F) and dew point (DP) will only appear if an optional temperature or dew point sensor is provided. The values displayed are used by the controller to develop control output signals for managing system operations. An output value appears beneath the "Humidifying" ( ) icon showing the percentage of the proportional output signal controlling humidity production. For grouped units, a percentage output value is provided for group A and group B. (Date) (Time) 00.0°F 00%Rh 100 100 Unit On Grp A On Dp 00.0°F Grp B On 21 STULZ Ultra-Series Humidifier Controller 5.2.2 Control Sensor This screen displays Temperature and Relative Humidity as measured by the control temperature and RH sensor inputs. If the controller is configured for proportional control, the %RH value is replaced with the percentage (%) of the proportional input signal controlling humidity production. The control dew point is calculated by the controller based on the control temperature and relative humidity sensor inputs and then shown at the bottom of the display screen. ** See Note 2. Control Sensor 67.8°F 38%Rh dew point 5.2.3 41.7°F Conductivity 0.3uS Sensor Scaling 5.2.5 If Limit is active, then the Limit Active line will appear and the next two lines show the set point and the actual limit value and will display in %RH if humidity limit is configured or in °F if dew point limit is configured. Cabinet Temperature 100.0°F FAN Off 67.8°F 38%Rh 5.2.4 This screen is displayed if the conductivity sensor option is selected. It shows the current conductivity in MicroSiemens as well as the selected scaling factors being applied to the sensor (low or high). 22 Trip Point Hi Al Setpt 41.7°F Conductivity Cabinet Temperature This screen displays the current operating temperature inside the controller cabinet and the "On/Off" operating status of the cooling fan. The screen also displays the set point for the cabinet fan to turn on and the temperature threshold for triggering a high temperature alarm. Limit Sensor Limit dew point Control Points This screen displays the control points and the actual values. The top two lines show the set point and the actual control value and will display in % if proportional control is configured, %RH if humidity control is configured or in °F if dew point control is configured. 5.2.6 Limit Sensor This screen appears if the controller is configured with limit sensors. It displays Temperature and Relative Humidity as measured by the limit temperature and RH sensor inputs. The limit dew point is calculated by the controller based on the limit sensor inputs. ** Note 2. Low 5.2.7 104.0°F 130.0°F NTC Temperature Sensors A screen is provided for each optional NTC sensor utilized with the unit (up to four). These screens appear only if the option is selected. The NTC numbers coincide with the reference designators that appear in the electrical drawing. These screens display the current operating temperature measured by the sensor. The screen also displays the set points for triggering a high temperature and a low temperature alarm. (August, 2013) STULZ Ultra-Series Humidifier Controller 5.2.10 NTC2 Temperature 89.7°F About Screen This screen displays the type of Humidifier being controlled, the current software version and the date of the installed software. EUltra DRH __________________________ Hi Al Setpt Lo Al Setpt 5.2.8 80.0°F 60.0°F STULZ Air Speed (optional) The Air Speed screen displays the speed of the air as measured by an Airflow sensor typically placed in a supply air duct. The controller compares the measured value against a control set point and signals an "Airflow" alarm if the value drops to an unsafe level. _____________ Ver. 5.3 1. 4. 1 1/08/13 Alarm Log Airspeed Main Menu 337.4fpm Info ALARM LOG Control 5.2.9 Humidifier Information (Loop) The Humidifier Information screen displays current operating status information for each configured Humidifier. Press the Enter (←) to move the flashing cursor to the Humidifier number and press Up (↑) and Down (↓) to select the Humidifier (1 to 16) to display depending on how many Humidifiers are enabled. Enable is the signal to the humidifier to operate. The nebulizer percentage value appearing at the bottom of the screen is the magnitude of the output signal controlling humidity production (0-100%). When this is greater than 10%, the humidifier is enabled. If the humidifier needs to fill the tank, the Fill Solenoid is turned on. If the humidifier is in a drain cycle, the Drain Solenoid will turn on. Humidifier 1 of 16 Enable Fill Solenoid Drain Solenoid Nebulizer (August, 2013) Off Off Off 0% No password is required to view alarm display messages. Press the Enter (←) key to enter the Alarm Log loop. When access is gained to the Alarm Log loop, use of the Up (↑) and Down (↓) arrow keys allows the scrolling through the log for additional alarm messages. The alarms log may be cleared in the Service>Alarm log menu loop. Alarm History 1 1/08/2013 10:46 Airflow Alarm Temperature: Humidity: 73.0°F 43.7% The first number on the top line is the alarm number. 1 is the first alarm that occurred since the log was cleared, 2 is the second, etc. The date and time of the alarm is also shown on the top line. The alarm that occurred is shown in the middle of the screen and the temperature and humidity at the time of the alarm is also shown. Use of the Up (↑) and Down (↓) arrow keys allows the scrolling for any additional alarm messages. 23 STULZ Ultra-Series Humidifier Controller 5.3.1 Alarms The red LED backlight within the alarm key will illuminate any time an active alarm condition is present or previous alarms existed without having been reset or cleared. An audible alarm in the display will also activate when an alarm condition occurs. The audible alarm may be enabled or disabled in the Service>Options menu loop. The first active alarm screen may be displayed by pressing the Alarm ( ) key. The Alarm display provides a text message describing the abnormal operating condition. Use of the Up (↑) and Down (↓) arrow keys allows scrolling for any additional alarm messages. Only active alarm screens will be displayed when the Alarm ( ) key is pressed. The alarm screen display will remain unchanged until the alarm condition is corrected and the alarm key is pressed again to clear the alarm. The application software supports two (2) types of alarms, “Non-Critical” and “Critical”. Any alarm may be programmed to activate the “User Configured” alarm relay contacts. 5.3.2 5.3.3 Critical Alarms Critical Alarms will coincide with automatic shutdown of the Humidifier(s) as needed to prevent possible system damage. Any Critical alarm may be programmed to activate the Custom alarm relay contacts. The Humidifier(s) will remain shut down until the alarm condition(s) are no longer sensed and the controller has been reset. Critical alarms are “Hard” coded and cannot be changed to Non-Critical. The Critical alarms are: Smoke Alarm Airspeed Sensor Failure Water Detector Alarm Condensate Pan Alarm High Humidity Limit Alarm Airflow Alarm Control Humidity Sensor Failure Alarm Cabinet Temperature Alarm NTC2 Alarm NTC3 Alarm NTC4 Alarm In addition, the custom alarm outputs can be configured to shut down the system. Non-Critical Alarms A Non-Critical alarm will activate the alarm screen with which it is associated. These alarms may be programmed to activate the “Summary Fault” alarm and close the “Summary Fault" relay contacts or the Custom alarm contacts without stopping unit operation. The factory programmed, Non-Critical alarms are: • Low Humidity • High Conductivity Pre-alarm • Customer Alarm Input • Low Air Velocity • High Air Velocity 24 (August, 2013) STULZ Ultra-Series Humidifier Controller 5.3.4 Alarm Screen Messages ALARM MESSAGE DESCRIPTION OF ALARM CONDITION Control Temperature Sensor Failure Control Humidity Sensor Failure Limit Temperature Sensor Failure Limit Humidity Sensor Failure Conductivity Sensor Failure Air Speed Sensor Failure High Control Temperature High Control Humidity High Cabinet Temperature Low Cabinet Temperature Low Control Temperature Control temperature sensor is disconnected or failed Low Control Humidity Control air humidity is below user defined alarm point Remote Shutdown Customer Alarm 1 Airflow Alarm Water Alarm Condensate Pan Full Alarm Smoke Alarm Customer Alarm 2 Customer Alarm 3 Humidifier n Alarm Conductivity Pre-alarm Conductivity Alarm NTC 2 High Temperature Alarm NTC 2 Low Temperature Alarm NTC 3 High Temperature Alarm NTC 3 Low Temperature Alarm NTC 4 High Temperature Alarm NTC 4 Low Temperature Alarm Humidity Limit Alarm High Limit Temperature Low Limit Temperature High Limit Humidity Low Limit Humidity High Airflow Alarm Low Airflow Alarm Freeze Alarm Remote shutdown as occurred and configured to be an alarm (August, 2013) Control humidity sensor is disconnected or failed Limit temperature sensor is disconnected or failed Limit humidity sensor is disconnected or failed Conductivity sensor is disconnected or failed Air Velocity sensor is disconnected or failed Control air temperature is above user defined alarm point Control air humidity is above user defined alarm point Cabinet Temperature is above user defined high alarm point Cabinet Temperature is below user defined low alarm point Control air temperature is below user defined alarm point The customer defined alarm #1 input is active The airflow alarm switch input is active The water detector alarm input is active The condensate pan full alarm input is active The smoke alarm input is active The customer defined alarm #2 input is active The customer defined alarm #3 input is active An alarm on humidifier n (n=1-16) has occurred Mineral content of supply water is approaching high level. Mineral content of supply water too high. NTC2 temperature is above user defined high alarm point NTC2 temperature is below user defined high alarm point NTC3 temperature is above user defined high alarm point NTC3 temperature is below user defined high alarm point NTC4 temperature is above user defined high alarm point NTC4 temperature is below user defined high alarm point The high humidity alarm switch input is active Limit air temperature is above user defined alarm point Limit air temperature is below user defined alarm point Limit air humidity is above user defined alarm point Limit air humidity is below user defined alarm point Airflow velocity is above user defined alarm point Airflow velocity is below user defined alarm point Freeze thermostat indicates water temperature is at or below freezing 25 STULZ Ultra-Series Humidifier Controller 5.4 Control Menu From the Control Menu 4 menus may be selected: Set points, Alarm Set points, Clock and Version. The controller may be programmed by the user to require level 1 password authorization to enter this menu (see Section 4.3). Once password access is granted, selecting and adjusting basic settings controlling the performance of the system, enabling alarms and determining their set points and setting the clock is allowed. Some fields in the Control Menu screens are read only. Main Menu Alarm CONTROL Service 5.4.1 Set Point Screens Press Enter (←) at this screen to enter into the Set Point screens. Control Version SET Alarm Set 18.104.22.168 Humidity Control Set Point If humidity control is selected, the Humidity Control screen shows the current set point and the conditions related to control. If the control temperature sensor is enabled, the “Temp” and “Dew” will be visible. If the control temperature sensor is not enabled, they will not appear. Press the Enter (←) at this screen to enter move to the set point value. Use the Up (↑) and Down (↓) keys to change the value. When the desired value is displayed, press the Enter (←) key. The cursor will return to the upper left hand corner, allowing the use of the Up (↑) and Down (↓) keys to move to the next set point. 26 Humidity Control Cntrl Set Point: 45.0% STATUS-------------------Temp: 67.8°F Hum: 38.9% Dew: 41.7°F 22.214.171.124 Dew Point Control Set Point If dew point control is selected, the Humidity Control screen shows the current set point and the conditions related to control. Press the Enter (←) at this screen to enter move to the set point value. Use the Up (↑) and Down (↓) keys to change the value. When the desired value is displayed, press the Enter (←) key. The cursor will return to the upper left hand corner, allowing the use of the Up (↑) and Down (↓) keys to move to the next set point. dew point Control Cntrl Set Point: 45.0°F STATUS-------------------Temp: 67.8°F Hum: 38.9% Dew: 41.7°F 126.96.36.199 Humidity Limit Set Point The Limit Set Point field appears if the E-Ultra controller is configured with an optional remote humidity sensor. The sensor may be located in the duct downstream of the Humidifier where condensation could form. A value is entered in the Limit Set Point field to limit humidity production based on a remote humidity or dew point sensor input to prevent condensation from forming in the duct. If the limit temperature sensor is enabled, the “Temp” and “Dew” will be visible. If the limit temperature sensor is not enabled, they will not appear. Press the Enter (←) at this screen to enter move to the set point value. Use the Up (↑) and Down (↓) keys to change the value. When the desired value is displayed, press the Enter (←) key. The cursor will return to the upper left hand corner, allowing the use of the Up (↑) and Down (↓) keys to move to the next set point. (August, 2013) STULZ Ultra-Series Humidifier Controller 5.4.2 Humidity Limit Limit Set Point: 80.0% STATUS-------------------Temp: 74.6°F Hum: 74.9% Dew: 66.0°F 188.8.131.52 Dew Point Limit Set Point The Dew Point Limit Set Point field appears if the unit is configured with an optional remote dew point sensor and the Limit is selected to be dewpoint. The sensor may be located in the duct downstream of the Humidifier where condensation could form. A value is entered in the Limit Set Point field to prevent condensation from forming in the duct. Press the Enter (←) at this screen to enter move to the set point value. Use the Up (↑) and Down (↓) keys to change the value. When the desired value is displayed, press the Enter (←) key. The cursor will return to the upper left hand corner, allowing the use of the Up (↑) and Down (↓) keys to move to the next set point. dew point Limit Limit SetPoint: 50.0°F STATUS-------------------Temp: 67.8°F Hum: 38.9% Dew: 41.7°F 184.108.40.206 Manual Group Control The Manual Control screen allows the selection of the lead Group and manual rotation of the Humidifier groups, bypassing the programmed rotation schedule. Manual Control Alarm Set Point Screens Enter the alarm set menu to change trip points for common alarms on analog inputs. Control Set ALARM SET Clock 220.127.116.11 Control Temperature Alarms If the control temperature sensor is enabled, high and low alarms may be enabled and set to specific trip points. The entered offset applies to both the "High" and "Low" Trip Point values entered in the screens. The offset is subtracted when it's applied to the high alarm trip point and it is added when it's applied to the low alarm trip point. If the offset for the temperature alarm is set at 5.0°F (default), the high temperature alarm will turn off when the actual temperature drops to the High Temperature Alarm trip point (80.0°F) - the Offset (5.0°F) or, 80.0°F - 5.0°F = 75.0°F The High Temperature Alarm will clear at 75°F. Conversely, the low temperature alarm will turn off when the actual temperature rises to the Low Temperature Alarm trip point (60.0°F) + the Offset (5.0°F) or, 60.0°F + 5.0°F = 65.0°F. The Low Temperature Alarm will clear at 65.0°F Control Temperature High alarm Enable:No Trip point: 80.0°F Low alarm Enable:No Trip point: 60.0°F Offset: 5.0°F Lead Group: A Rotate Group: No (August, 2013) 27 STULZ Ultra-Series Humidifier Controller 18.104.22.168 Control Humidity Alarms If the control humidity sensor is enabled, high and low alarms may be enabled and set to specific trip points. The offset behaves in the same manner as described in section 22.214.171.124. It applies to both the high and low alarms. Control Humidity 126.96.36.199 Conductivity Alarms If the conductivity sensor is enabled, a conductivity alarm can be enabled and the trip point in MicroSiemens can be adjusted. A Pre-conductivity alarm can be enabled and the trip point in MicroSiemens can be adjusted. The offset behaves in the same manner as described in section 188.8.131.52. It applies to both the high and low alarms. Conductivity Alarm High alarm Enable:No Trip point: 80.0%RH Low alarm Enable:No Trip point: 30.0%RH Offset: 1.0%RH 184.108.40.206 Limit Temperature Alarms If the limit temperature sensor is enabled, high and low alarms may be enabled and set to specific trip points. The offset behaves in the same manner as described in section 220.127.116.11. It applies to both the high and low alarms. Limit TemperatureHigh alarm Enable:No Trip point: 80.0°F Low alarm Enable:No Trip point: 40.0°F Offset: 1.0°F 18.104.22.168 Limit Humidity Alarms If the control humidity sensor is enabled, high and low alarms may be enabled and set to specific trip points. The offset behaves in the same manner as described in section 22.214.171.124. It applies to both the high and low alarms. Conduct. Enable:No Trip point: 20.0uS Pre-Alarm Enable:No Trip point: 5.0uS Offset: 1.0°F Alarm Delay: 90 sec 126.96.36.199 Airflow Alarm If the airflow sensor is enabled, high and low alarms may be enabled and set to specific trip points. The offset behaves in the same manner as described in section 188.8.131.52. It applies to both the high and low alarms. Airflow Alarm High alarm Enable: No Trip point: 1200.0 fpm Low alarm Enable: No Trip point: 600.0 fpm Offset: 20.0 fpm 5.4.3 Clock Screen Enter the Clock menu to change trip points for common alarms on analog inputs. Control Limit Humidity High alarm Enable:No Trip point: 80.0%RH Low alarm Enable:No Trip point: 40.0%RH Offset: 1.0° 28 Alarm Set CLOCK Version (August, 2013) STULZ Ultra-Series Humidifier Controller 184.108.40.206 Set Clock The Set Clock screen allows the setting and/or adjusting the current time (in 24 hour format), date and day. 220.127.116.11 InformationTwo Version pCO type: pCO3 Large Total flash: 2048KB RAM: 1024KB Built-In Type: Display Type: 10 Main Cycle: 60.1 cycle/s 16ms Set Clock Time: 16:41 Date: 10/26/2013 Day: Thursday 5.5 5.4.4 Version Screen Enter the Version menu to view the details of the version of the installed software. Two Version screens are provided for information only. They show controller hardware and software details that are useful to STULZ Product Support if technical assistance is needed. Control Two Version Version Info Screen 2 Service Menu The Service screens allow the user to enter cut-in and cutout values, calibrate control sensor(s), save and restore parameters and view the alarm history log. The Service menu may be entered via the password screen (requires level 2 password). Main Menu Version Control Clock SERVICE VERSION Factory Set 18.104.22.168 Version Info Screen 1 InformationTwo Version Carel S.p.A. EUltra Code: Ver.:1.4B01 01/08/13 Carel Code: Bios: 5.00 19/09/01 Boot: 4.00 19/09/01 (August, 2013) 29 STULZ Ultra-Series Humidifier Controller 5.5.1 Humidifier Configuration Once password access is granted, the user may access the service menus. The first menu allows detailed setup of overall settings for the humidifiers and also detailed information from individual humidifiers. SERVICE MENU Two Save Cfg HUMID Alarms 22.214.171.124 Humidifier Cut-in/Cut-out The first screen in the Service->Humidifier loop allows adjustment of the cut-in / cut-out setpoints for the control and limit inputs. If the control is set up for humidity, the cutin and cut-out are in terms of %RH. If the control is set for dew point, the cut-in and cut-out is in terms of °F or °C (depending on the selection of US or SI units). If a limit sensor is setup, the cut-in and cut-out values appear, again in RH or dew point. The restrictor imposes a scaling on the actual output of each group of humidifiers. In the example above, Group A will physically output 0 to 100% over the range of the called for humidification of 0 to 100%. Group B will physically output 0 to 90% over the range of the called for humidification of 0 to 100%. It is equivalent of taking the output of control output and multiplying it by 0.9. This is useful if the installation has a group of humidifiers that would cause condensation due to proximity to objects. The output of the humidifiers can be prevented from reaching maximum capacity. 126.96.36.199 Humidifier Drain This screen is used to set the interval and time duration for the automatic drain cycle to occur when the Humidifier(s) have been inactive (no command to humidify). The "Drain Now" field to initiate a manual drain cycle by changing "No" to "Yes". The Humidifier drain valve will stay open for the duration set in the "Drain Time" field and then return to the closed position (for either Manual or Auto drain). The word "Draining" appears in the status field when in the Auto or Manual drain mode. The bottom line shows the number of hours left until a drain will occur. It is reset to zero whenever there is a call for humidification. Humidifier Drain Cut-in and Cut-out work based on the set point and set the span of the control range. In the example below, the control cut-in is set to -4%RH. Assume the humidity set point is 45%RH. With this value of the cut-in, 100% humidification will be reached at 41%RH. The cut-out is the point at which 0% humidification occurs. Again, the control would be at 0% when the humidity reaches 46%RH. The span is the difference between the cut-in and cut-out and in this case over a 5%RH change in RH, the output would go from 0 to 100%. In the example below, the limit goes from 0% at the set point to 100% at 5%RH below the set point. Cut-in must always be less than cut-out. Humidifier Ctrl RH Cutin: -4.0%RH Ctrl RH Cutout: 1.0%RH Lim RH Cutin: -5.0%RH Lim RH Cutout: 0.0%RH Grp A Restrictor: 100% Grp B Restrictor: 90% 30 Idle Time: 999Hrs Drain Time: 10 Min Drain Now? No <Drain status> Drains in 124Hrs 188.8.131.52 Humidifier Group Configuration Humidifier Config Humidifier Current Group Place in Group Store Value? 1 X A No Group B Assist Humidifier group Configuration parameters are adjustable from this screen. Advance the cursor using the ENTER (August, 2013) STULZ Ultra-Series Humidifier Controller (←) to the Humidifier number in the first field to select which Humidifier to view. Use the up (↑) and down (↓) keys to change the humidifier number. Its current group placement is displayed. It may be assigned to a different group by advancing to the "Place in Group" field. If the unit is assigned to a new group, it must be confirmed in the "Store value?" field. Valid entries for groups are X (not active), A, or B. The duty assignment for group B can be changed to "Capacity Assist", Unison or "Rotate" in the lowermost field (reference Section 184.108.40.206 & 220.127.116.11). 18.104.22.168 Change Humidifier Modbus Address If a new Humidifier is added to an existing group of multiple ultrasonic Humidifiers, it must be configured with a new unique address for Modbus communication. From this screen a Humidifier may be selected and its assigned Modbus address number may be changed. A new Humidifier is typically shipped from the factory with its Modbus address set to one. In this case it will need to be assigned a new address to differentiate it from the current Humidifier in the group that is already addressed as number one. Change Modbus addr Caution: Read Manual! Current Humidifier 1 Change to Hum 2 New Hum available Current hum ready Change Address? No Current Humidifier: The Humidifier that will have its address changed. Change to Hum: The address the current Humidifier will be changed to. New Hum available/New Hum in use/Wait is an indication of the new humidifier number availability. “New Hum available” means no humidifier is responding to the address shown as the Change to Hum number. New Hum in use indicates that a humidifier is responding to the Change to Hum number already. Wait is displayed during changing of the display number, waiting for the assignment change to be complete. This should last typically 30 seconds. (August, 2013) 22.214.171.124.1 Procedure to Change Humidifier Assignment: With power turned off at the control box, complete the Modbus and power wiring connections to the Humidifier to be added. Turn Off all the Humidifier circuit breakers inside the control box and any in auxiliary boxes (see Figure 3 Control Box Internal Layout; item 17), except the one power supply for the Humidifier to be addressed. This isolates the existing Humidifiers from the Modbus allowing only the address of the new humidifier to be changed. When power is re-applied to the control box (and with the circuit breaker turned on only for the new Humidifier to be addressed in the appropriate control or auxiliary box), bring up this screen. Go to the last line and change the “NO” to “Yes” indicating the desire to change the address of the humidifier. The third line in the screen displays "Wait” while the E-Ultra sends out the change command and waits for a response at the new address. The third line will change to New Hum in Use” and the fourth line will change to “Current hum not ready” indicating it is communicating using the "Change to Hum" address and not the original address. If the third line displays "New Hum Available", it indicates the Humidifier did not accept the change. 31 STULZ Ultra-Series Humidifier Controller 126.96.36.199 Humidifier Input Status Humidifier 1 of XX Commanded Duty 31% High Water Sw Full Low Water Sw OK Voltage 49.6V Nebul temp 95.0°F State NORMAL Modbus Status Online From this screen a Humidifier may be selected to view the displayed controller operating input parameters. If the system consists of multiple Humidifiers, advance the flashing cursor to the Humidifier number in the top line by pressing Enter (←). The cursor will move the humidifier number. Select which Humidifier to view by using the Up (↑) and Down (↓) arrow keys then press Enter to view that humidifier’s data. The "Commanded Duty" field is the proportional control output signal the Humidifier reports it received from the controller. The high water switch indicates “Full” or “Low”. When it is “Low” the fill solenoid should open to bring the tank level back to “Full”. The low water switch indicates “OK” or “Empty”. “OK” indicates enough water is over the transducers to operate them. The Voltage is the voltage at the humidifier after line losses from the power supply. This should be drop below 46 volts when the humidifier is running at full output. The Nebul temp is the nebulizer temperature. The State is either “NORMAL”, or “DRAIN” The Modbus Status indicates the state of the communication interface: Display Sub list INV Data Offline Comm Err Online Ill Func Ill Adr Ill Data Dev Fail Ack Busy 32 Meaning Sub list number = 0 for the required Modbus command. Code managed with BIOS >= 5.07. Invalid data for the requested Modbus command. Summarizes one or more data errors from Modbus sub lists. Timeout (no response after query for all repeated attempts) Invalid response (incomplete with CRC error) Command successfully completed. All commands requested by sub lists were successfully completed ILLEGAL FUNCTION. The command code does not correspond to any foreseen action. ILLEGAL DATA ADDRESS. The received address is not permitted. ILLEGAL DATA VALUE. The value to be assigned is not permitted. SLAVE DEVICE FAILURE. Error during requested action. ACKNOWLEDGE. The Slave accepted the request and is processing it, but this requires a certain amount of time. This result is returned to prevent Master timeout errors. SLAVE DEVICE BUSY. The Slave is busy running a command that requires a certain amount of time. (August, 2013) STULZ Ultra-Series Humidifier Controller 188.8.131.52 Humidifier Output Status 184.108.40.206 Humidifier 1 of XX Duty cycle 100 Modbus addr 6 Volt cal 31 Temp cal 50 Max fill time 10 Config 0 Clock Adj 0 Humidifier 1 of XX Coil Status Enable Status Fan Drain Valve Fill Valve Version Off Off Off Off 3. 0. 6 From this screen a Humidifier may be selected to view the displayed controller operating output parameters. If the system consists of multiple Humidifiers, advance the flashing cursor to the Humidifier number in the top line by pressing Enter (←). The cursor will move the humidifier number. Select which Humidifier to view by using the Up (↑) and Down (↓) arrow keys then press Enter to view that humidifier’s data. The version number appearing at the bottom of the screen is the software version of that Humidifier's Level Controller. The field displays either the software version number or it will display "99.99.99" indicating the Level Controller software is version 1.x.x or 2.x.x and can’t report the version number. 220.127.116.11 From this screen a Humidifier may be selected to view the controller readable registers. If the system consists of multiple Humidifiers, advance the flashing cursor to the Humidifier number in the top line by pressing Enter (←). The cursor will move the humidifier number. Select which Humidifier to view by using the Up (↑) and Down (↓) arrow keys then press Enter to view that humidifier’s data. Humidifier Alarms Status 1 2 3 4 5 6 8 Humidifier 1 of XX Low Volt Alarm No High Volt Alarm No Freeze Alarm No High Temp Alarm No Low Water Alarm No Water Fill Alarm No Transducer alarm No From this screen a Humidifier may be selected to view the displayed controller alarms. If the system consists of multiple Humidifiers, advance the flashing cursor to the Humidifier number in the top line by pressing Enter (←). The cursor will move the humidifier number. Select which Humidifier to view by using the Up (↑) and Down (↓) arrow keys then press Enter to view that humidifier’s data. An alarm condition is indicated by "Yes" to the right of each field. The Humidifier level control board includes a blinking LED for fault indication (see the Humidifier IOM Section 1.6, Level Controller).The number in the left side of each field coincides with the number of blinks that will be observed from the LED on the board if a fault occurs. Humidifier Readable Modbus Parameters 18.104.22.168 Duty Cycle: Actual duty cycle Modbus Adr: physical Modbus address (unit one is 6, unit two is 7, etc.). Volt cal: the current calibration factor for the voltage sensor Temp cal: the current temperature calibration factor for the temperature sensor Max fill time: the maximum time in minutes the humidifier will attempt to fill the tank before declaring a fill alarm. Config a bit packed word showing the current configuration of the level controller board. o Bit 0: Fan Present o Bit 1: Standalone if 1, Modbus if 0 o Bit 2: Drain disabled o Bit 3: No high Level Check on startup Clock Adjust: adjusts Level Controller internal clock- caution! This should only be modified if directed by STULZ Product Support. Otherwise, communications with the humidifier may be permanently lost. Voltage Calibration Screen Config Hum 1 of XX Voltage Calibration Voltage reading: Voltage offset: New offset Update 49.7V 30 0 No From this screen a Humidifier may be selected to modify the voltage calibration. If the system consists of multiple (August, 2013) 33 STULZ Ultra-Series Humidifier Controller Humidifiers, advance the flashing cursor to the Humidifier number in the top line by pressing Enter (←). The cursor will move the humidifier number. Select which Humidifier to view by using the Up (↑) and Down (↓) arrow keys then press Enter to view that humidifier’s data. To properly calibrate the voltage sensor at the humidifier, power off the humidifier and remove the cover(s) to expose the Level Controller. Power up the humidifier and set the output to 100%. Measure the power supply voltage at the humidifier and compare to the displayed value. If the reading is different, enter a new offset. And then change the Update field to Yes. The new offset will be written into the humidifier and the voltage reading will be updated. From this screen a Humidifier may be selected to modify the maximum fill time. If the system consists of multiple Humidifiers, advance the flashing cursor to the Humidifier number in the top line by pressing Enter (←). The cursor will move the humidifier number. Select which Humidifier to view by using the Up (↑) and Down (↓) arrow keys then press Enter to view that humidifier’s data. The maximum fill time stored in the humidifier is 10 minutes when shipped from the factory. If water pressures are low, it is possible on the larger humidifiers to need more time to fill. If a new maximum fill time is entered, it must be confirmed in the "Update" field. 22.214.171.124 Component Config Screen 126.96.36.199 Temperature Calibration Screen Config Hum 1 of XX Temp. Calibration Temp. reading Temp. offset New offset Update 113°F 50 0 Config Hum 1 of XX Component Config Is Fan Present: Off Drain Disable: Off No Fill Flush: Off Update: No If the humidifier temperature sensor feature is turned on, this screen appears to allow a Humidifier to be selected to modify the temperature calibration. If the system consists of multiple Humidifiers, advance the flashing cursor to the Humidifier number in the top line by pressing Enter (←). The cursor will move the humidifier number. Select which Humidifier to view by using the Up (↑) and Down (↓) arrow keys then press Enter to view that humidifier’s data. New Off Off Off No In this screen the current humidifier configuration On/Off status of the features are displayed in the "Is" field. The values may be altered by changing the value in the "New" field. If a feature is changed to On or Off, it must be confirmed in the "Update" field. Fan Present must be on for any DRH humidifier as well as any DAH with a booster fan. Drain Disable disables the operation of the drain valve. To properly calibrate the temperature sensor at the humidifier, power off the humidifier and remove the cover(s) to expose the temperature sensor. Power up the humidifier. Measure the temperature with an infrared meter at the sensor and compare to the displayed value. If the reading is different, enter a new offset. And then change the Update field to Yes. The new offset will be written into the humidifier and the temperature reading will be updated. When "No Fill Flush" is off, and the Humidifier is called to start and water level is full, the drain valve will open to drain the water to the Fill level. The drain valve is then closed and the fill valve is opened to bring the water level back to the Full level. Then the nebulizers begin operation. The purpose of this feature is to assure the water level is not too high. 188.8.131.52 Maximum Fill Time Screen 184.108.40.206 Humidifier Array Screen Config Hum 1 of XX Maximum Fill Time Hum Array 1 of XX Time in Minutes Current Fill Time: 10 New Fill Time: 0 Update 34 No 0001 0000 0000 0000 0000 0000 0000 0000 0000 0000 2003 0020 0000 004A 0000 0000 0000 0000 0000 0000 The information codes in this screen provide an overview of all information known about the humidifiers. The codes (August, 2013) STULZ Ultra-Series Humidifier Controller are useful to STULZ Product Support if technical assistance is needed. All information is in hexadecimal (base 16) format. 5.5.2 A log of events is stored for view from the Service>Alarms menu. The first line contains the index into the array of data kept for all humidifiers, the read value of the coils, the write value of the coils, and the read value of the discrete inputs. SERVICE MENU provided Humid The second line contains the read voltage, the read status register, the read value of the temperature and duty cycle of the nebulizers. ALARMS Sensors The third line contains the Modbus address of the humidifier, the voltage calibration value, the configuration register and the temperature calibration value. Alarm Historyrovided The fourth line contains the maximum fill time, the index into the register last written, the value last written. The last word is not used. 1 Humidifier 1 of XX Coil Overrides Override Off Hum Enable Off Fan Off Nebulizer Off Drain Valve Off Fill Valve Off Off Off Off Off Off Off This screen allows manual control over the coils in the selected humidifier. The left hand column displays the current controller On/Off command for the indicated component, the right hand column is the modifiable field to change to change the state of the coil. To use this feature, the Override Coil must be changed to "On". With the Override Coil turned On, manual control of the listed coils may be turned On or Off. The coils will remain in the commanded state until the Override Coil is set to OFF. At that point, the coils revert to normal operations. NOTE: On Humidifiers equipped with fans, the fan coil will automatically be turned on by the humidifier if the nebulizer coil is turned on. (August, 2013) 1/08/2013 10:46 Airflow Alarm The fifth line contains the major revision number, the minor revision number, the third part of the version number referred to as the version tweak number, and the clock tweak value. 220.127.116.11 Manual Control Screen Alarms Temperature: 73.0°F Humidity: 43.7% Press Alarm to Clear SERVICE This menu is identical to the Alarm Log accessed from the main menu. It displays the last 50 events sequentially numbered in order of occurrence. The alarm log may be erased by pressing the Alarm ( ) key while in this menu. IMPORTANT NOTE If the Alarm ( ) key is pressed when in any of the Service>Alarms screens, all stored alarm messages will be permanently erased from the controller's memory. 5.5.3 Sensors SERVICE MENU provided Alarms SENSORS Options This group of screens allows the setting of an offset to analog inputs. The offsets are added to the analog input value for minor corrections of the displayed values. 35 STULZ Ultra-Series Humidifier Controller Sensor Offsetprovided "Auto on power up"- If set to Yes, the unit turns on automatically when main power is applied. "Auto on remote"- If set to Yes, the unit may be turned on via a remote On/Off switch. Cntrl Air Humidity Apply Offset: Displayed: 0.0% 45.0% Example Sensors Offset screen Sensor Offsets are available for the following sensors: Control Air Temperature (if enabled) Control Air Humidity Water Conductivity (if enabled) Limit Air Temperature (if enabled) Limit Air Humidity (if enabled) Air Speed (if enabled) Cabinet Temperature NTC2 Sensor (if enabled) NTC3 Sensor (if enabled) NTC4 Sensor (if enabled) NOTE When calibrating sensors, an offset at one extreme may produce an error at the other extreme. Always verify that any offset is valid over the entire range of the sensor. 5.5.4 Options Menu Loop SERVICE MENU software Sensors 18.104.22.168 Unit Timers Unit Timers Unit Timers provided Startup delay: Airflow delay: 10s 5s Recovery time: 1min Group Rotation: 8hr Startup delay is the number of seconds before control output signals are sent to the Humidifiers after the system is turned on. Airflow delay is the number of seconds after start-up to allow the Airflow switch to close before an alarm is signaled is the airflow switch is enabled. Recovery time is the number of minutes before Humidifier(s) re-start after a critical alarm is cleared. 22.214.171.124 Custom Alarm Setup CustoStup Custom CustomSetup Setup provided DigitalIn Startup Control Startup Control 36 The limit sensors may be enabled on one, both or neither group of Humidifiers. Setting a Group to Yes enables the limit function on that group. Group Rotation is the number of operating hours before Humidifier groups rotate duty. OPTIONS 126.96.36.199 "Suppress Buzzer?"- Enables or disables the alarm signal buzzer. Auto on powerup: Auto on remote: Suppress Buzzer? Yes Yes No Limit sensor limits Grp A: Yes Grp B: No Setup the alarm text and custom alarms. Press the Enter (← ) key to access a menu loop to set-up optional customer alarm inputs and set-up and select conditions for custom (dry contact) alarm outputs. (August, 2013) STULZ Ultra-Series Humidifier Controller 188.8.131.52.1 Customer Alarm Input Setup The Ultra-Series controller may monitor a customer supplied digital alarm input device and annunciate a Customer Alarm message. One set of Customer Alarm input terminals is standard and up to two more may be added as an option depending on the size of the E-Ultra controller. Upon receiving a Customer Alarm input the controller presents a user selectable message in the alarm display screen. A Customer Alarm message may simply be displayed as "CUSTOMER ALARM #" as shown below, or press (←) to advance to the next character and use the (↑) and (↓) arrow keys to scroll through the ASCII character set to construct a specific alpha/numeric message in the line stating the specific alarm condition; i.e. "GAS DETECTION", "INTRUSION ALARM", etc. The Customer Alarm message may be setup with up to 20 characters. Customer Alarm1 Text for Custom Alarm 1 Product Ctrl Hum High Al Ctrl Hum Low Al Lim Hum High Al Lim Hum Low Al Air Proving Al Water Detect Al Custom Alarm 1 Product Smoke Alarm Cab High Temp Al Cab Low Temp Al NTC2 High Temp Al NTC2 Low Temp Al Customer Alarm3 Text 184.108.40.206.2 Custom Alarm Output Setup In addition to the Summary Alarm output to a designated dry contact relay, the Ultra-Series controller may also activate Custom Alarm outputs to energize separate dry contact relay(s). Up to four custom alarm outputs may be configured depending on the size of the E-Ultra controller. A custom alarm output is set up by selecting specific alarm conditions that trigger a custom alarm output from the menu screens in this loop. Upon entering this loop, press Enter and select the Custom Alarm number (1 to 4) in the uppermost field. Then press Enter to scroll through each field to select any mix of the alarm conditions shown in the screens with the Up/Down arrow keys. The alarm must be enabled in order to be sensed as a custom alarm. Yes No No No No Custom Alarm 1 Product Customer Alarm 1 Shutdown on Alarm: Yes No No No No No Yes Customer Alarm 1 Customer Alarm 2 Conductivity Alarm No No Yes Shutdown: No NOTE On the above screen is the option to shut down the system when this custom alarm is active. Custom Alarm 1 Product Customer Alarm 3 No NTC3 NTC3 NTC4 NTC4 No No No No High Temp Al Low Temp Al High Temp Al Low Temp Al Custom Alarm 1 Product Ctrl Temp High Al Ctrl Temp Low Al Lim Temp High Al Lim Temp Low Al Remote Shutdown High Hum Stat Al (August, 2013) No No No No No Yes Custom Alarm 1 Product Customer Alarm 3 No NTC3 NTC3 NTC4 NTC4 No No No No High Temp Al Low Temp Al High Temp Al Low Temp Al 37 STULZ Ultra-Series Humidifier Controller Digital Inputs is needed. Custom Alarm 1 Product Humid Humid Humid Humid Humid Humid Humid Frz Alarm Hi T Alarm Low W Alarm Fill Alarm Comm Alarm Xducer Alarm Volt Alarm No No No No No No No NOTE The selections in the above screen are the alarms from the humidifiers. Custom Alarm 1 Product High Airflow Alarm Low Airflow Alarm No No 111111111 123456789012345678 pco: CCCCCCCCCC00000000 This screen is provided for information only. It shows the state of each digital input as either Closed or Open. Only the first 10 inputs are used on the E-Ultra controller to date. The rest are shown as zeros. 5.5.6 Run Hours SERVICE MENU software DigitalIn RUN HOURS BMS Comm NOTE The above screen is shown only a large E-Ultra Controller. As an example, for a custom alarm based only on the occurrence of high humidity, water detection, smoke and high water conductivity scroll through the screens and enter "Yes" in the appropriate fields as shown. Upon detection of any of the selected alarm conditions, the alarm key illuminates and the controller energizes the designated custom alarm relay. 5.5.5 Digital In SERVICE MENU software Starts/Run Hours Product Humidifier Starts 0018hrs 1 Reset Off The run hours display screen shows the number of hours the humidifiers have been running at 10% or greater output. Also shown is number of starts logged for the humidifier (transition from below to above 10% output. The run hours and starts values may be reset to 0 from this display screen. The values displayed are the values logged since the last time the screen was reset. Options DigitalIn Run Hours 38 (August, 2013) STULZ Ultra-Series Humidifier Controller 5.5.7 If multiple Ultra-Series controllers are connected to a BMS, each controller must be configured with a unique address for BMS communication. This is done by programming the serial interface port from a lap top. Contact STULZ Product Support for assistance (see Section 9.0). BMS Communication SERVICE MENU software Run Hours 220.127.116.11 Direct BMS Control The controller may be configured to accept proportional analog signals that mimic sensors. The controller will act on that signal whether it comes from a real sensor or a BMS analog output. Refer to Appendix A for the UltraSeries controller BMS parameters. BMS COMM Factory The BMS Comm menu is used to set up parameters to allow a Building Management System (BMS) to interface with the controller. The unit may be connected to a BMS for monitoring and control of data points using a multitude of different serial communication protocols. When BMS communication is utilized, the controller must be equipped with an expansion card designed for one of a variety of serial communication protocols available. A RS-485 serial port is available for Modbus or BACnet MS/TP protocols and a 10BaseT port is available for TCP/IP based protocols such as BACnet over IP, BACnet over Ethernet, SNMP or HTTP. Supported Protocols BACnet over IP BACnet over Ethernet HTTP SNMP V1, V2c Modbus over IP BACnet MS/TP Modbus RTU Direct Connection Media Connection 10 BaseT 10 BaseT RJ45 direct RJ45 direct 10 BaseT 10 BaseT 10 BaseT Twisted pair Twisted pair RJ45 direct RJ45 direct RJ45 direct Daisy chain Daisy chain Daisy Chain Connection 18.104.22.168 BMS Set-up The following menu screen is accessed from the Service>BMS COMM screen to set-up the parameters for a BMS interface to monitor controller operation for the serial-based networks such as BACnet MS/TP. Units using the BACnet over IP, BACnet over Ethernet, or HTTP protocols do not need to change anything in this menu loop. BMS Communications Address: Baud Rate: 19200 Comm Timeout: Protocol: BACnet 1 10m The BMS address and baud rate have meaning only on RS-485 networks and with the serial protocols of Modem, Modbus RTU, Commission, and Carel. The baud rate is fixed for BACnet. Systems utilizing a 10BaseT interface should use the defaults of address 1, baud rate 19200, and protocol BACnet. If the mode selected uses a BMS supplied signal via the communications interface (modes 1, 3 or 5), the loss of BMS active (which is held true as long as the toggling of the keep alive is switched between 1 and 2), will simply cause the system to shut down and display “Off by Network”. The general procedure is to set up variables like return humidity/proportional control and then toggle the value (1 or 2) to the BMS "keep alive" address. For further details on utilizing BMS control, contact STULZ Product Support (see Section 9.0). (August, 2013) 39 STULZ Ultra-Series Humidifier Controller 5.5.8 Factory Configuration SERVICE MENU software BMS Comm 22.214.171.124 Set Passwords FACTORY Sys Cfg The Factory Configuration menu loop contains settings for the options that should not need to be adjusted once the system ships from the factory. When entered using the Service Password, all parameters are read only and cannot be changed. See Section 5.6 for details. 5.5.9 The next screen in the Service Menu after the System Configuration review menu is the Service Level Save of the configuration. Passwords may be changed and the default set points may be restored and from this loop. Set Passwords Control: Service: 1 2 This screen allows setting new passwords for entering the Control and Service menus. Sys Configuration SERVICE MENU software Customer Save Factory SYS CFG Save Cfg The System Configuration menu loop contains configuration screens to set up options selected at the time of sale. When accessed using the Service password, the parameters are read only and cannot be changed. Not all options are available on a particular E-Ultra Controller. Depending on the size of the controller, (small, medium or large), some inputs and outputs are not available. See Section 5.7 for details. 5.5.10 126.96.36.199 Customer Save Save Configuration SERVICE MENU software Save Parameters No Restore Parameters To Customer: No To Factory: No This screen allows the save of any adjustments made in Service level menu screens as new "Customer" parameters or restore the controller to the previously saved "Customer" parameters. The user may also restore the controller to the original "Factory" parameter values shown in Table 1. Use the Enter (←) key to move the flashing cursor to the field to be confirmed and press the Up (↑) or Down (↓) arrow key. The word "No" will momentarily change to "Yes" indicating the command has been accepted. Then exit by pressing the Enter (↓) key repeatedly until the flashing cursor returns to the top left corner of the screen. Sys Cfg SAVE CFG Humid 40 (August, 2013) STULZ Ultra-Series Humidifier Controller 5.6 Factory Configuration SERVICE MENU software BMS Comm FACTORY Sys Cfg The x values for 4-20 ma sensors are nominally 20.0 and 100.0. The x values for all other sensors is nominally 0.0 and 100.0 188.8.131.52.1 The Factory menu loop may be accessed from the Service>Factory screen. Enter the factory level password to gain access to the loop. Only authorized personnel who possess a thorough understanding of the system operation should perform modifications to the Factory menu. The menu screens must have accurate variables entered otherwise erratic operation may occur. These menu screens are configured with higher password protection, thus requiring a higher level of authority to access them. It is intended that access to the Factory menu screens only be established while the user is working with the guidance of STULZ Product Support (see Section 9.0) because incorrect settings made at that level could unintentionally damage the equipment. The Factory Configuration menu loop contains settings for the options that should not need to be adjusted once the system ships from the factory. When entered using the Service Password, all parameters are read only and cannot be changed. 184.108.40.206 value of X corresponds to the maximum value of Y. The bottom line shows the raw input (X) and the corresponding display value (Y). Note that the minimum and maximum values of Y for temperatures are always in Celsius. The display value for Y is in the units selected. Control Temperature Setup SENSOR INPUT SETUP Control Air Temp: Enable Type: 4-20mA Minimum X: 20.0 Maximum X: 100.0 Minimum Y: 0.0°c Maximum Y: 100.0°c X: 36.0 Y: 67.8°F 220.127.116.11.2 Control Humidity Setup SENSOR INPUT SETUP Control Air Humid: Enable Type: 4-20mA Minimum X: 20.0 Maximum X: 100.0 Minimum Y: 0.0%RH Maximum Y: 100.0%RH X: 36.0 Y: 67.8%RH Sensor Input Setup FACTORY. Factory Save SENSORS Digital In The Sensor inputs are analog inputs comprising of a signal that is one of the following: 4-20 mA, 0-1 Volt, 0-5 Volt, 010 Volt or an NTC sensor. The range of the input is translated into a value for display. The Sensor Input Setup screens define the relationship between the input (X) and the display value (Y). The minimum value of X corresponds to the minimum value of Y and the maximum (August, 2013) 18.104.22.168.3 Conductivity SENSOR INPUT SETUP Conductivity: Enable Scaling: Low Internal table is Used for scaling Table output: 3 1024 41 STULZ Ultra-Series Humidifier Controller 22.214.171.124.4 Limit Temperature Setup 126.96.36.199.8 SENSOR INPUT SETUP SENSOR INPUT SETUP Limit Air Temp: Enable Type: 4-20mA Minimum X: 20.0 Maximum X: 100.0 Minimum Y: 0.0°c Maximum Y: 100.0°c X: 39.1 Y: 74.6°F 188.8.131.52.5 Limit Humidity Setup SENSOR SENSOR INPUT INPUT SETUP SETUP Limit Air Humid: Enable Type: 4-20mA Minimum X: 20.0 Maximum X: 100.0 Minimum Y: 0.0%RH Maximum Y: 100.0%RH X: 51.2 Y: 74.6%RH 184.108.40.206.6 Airspeed Setup SENSOR INPUT SETUP Airspeed: Enable Minimum X: Maximum X: Minimum Y: Maximum Y: X: 33.5 220.127.116.11.7 Type: 4-20mA 20.0 100.0 0.0 2000.0 Y: 337.4 Cabinet Temperature Setup NTC2 Temperature Setup NTC2 Temp: Enable Minimum X: Maximum X: Minimum Y: Maximum Y: X: 13.8 Y: 0.0 100.0 0.0°c 100.0°c 56.6°F NTC2, NTC3 and NTC4 are always NTC sensors. 18.104.22.168.9 NTC3 Temperature Setup SENSOR INPUT SETUP NTC3 Temp: Enable Minimum X: Maximum X: Minimum Y: Maximum Y: X: 13.8 Y: 0.0 100.0 0.0°c 100.0°c 56.6°F 22.214.171.124.10 NTC4 Temperature Setup SENSOR INPUT SETUP NTC4 Temp: Enable Minimum X: Maximum X: Minimum Y: Maximum Y: X: 13.8 Y: 0.0 100.0 0.0°c 100.0°c 56.6°F SENSOR INPUT SETUP 126.96.36.199 Factory Digital Input Setup Cabinet Air Temp: Minimum X: Maximum X: Minimum Y: Maximum Y: X: 13.8 Y: 0.0 100.0 0.0°c 100.0°c 56.6°F The cabinet temperature sensor is always enabled and is always an NTC sensor. FACTORY. Sensors DigitalIn Options The Factory Digital Input setup screens allow modifying the nature of the input. Digital inputs are switch inputs tied to ground or open. 42 (August, 2013) STULZ Ultra-Series Humidifier Controller The input may have the ability to be enabled or disabled. Some inputs cannot be disabled. 188.8.131.52.4 Digital Input Setup is Invert allows the polarity of the signal to be set. “Yes” means to interpret an Open as On and Closed as Off. “No” means to interpret an Open as Off and Closed as On. Customer Al 2:Disabled Invert:Yes Position:Closed Shutdown: No Freeze Alarm :Disabled Invert:Yes Position:Closed The Position is the current state of the input, Open or Closed to ground. Some inputs may have the ability to shut down the system when the input is On and the enabling or disabling of that shutdown is included in the screen. 184.108.40.206.1 220.127.116.11.5 Remote and Customer Alarm 1 Setup Customer Al 3:Disabled Invert:Yes Position:Closed Shutdown: No Group Select :Disabled Invert:Yes Position:Closed Remote On/Off:Enabled Invert:Yes Position:Closed Customer AL 1: Disabled Invert:Yes Position:Closed Shutdown:Disabled 18.104.22.168 Factory Options Airflow Switch and Pin 4 Function Setup FACTORY Support if Digital Input Setup is Digital In Airflow Sw :Enabled Invert:Yes Position:Closed OPTIONS Modbus Pin 4: None Invert:Yes Position:Closed 22.214.171.124.1 Pin 4 can be configured to be None, Water Detector or Condensate Pan. 126.96.36.199.3 Customer Alarm 3 and Group Select Setup Digital Input Setup is Digital Input Setup is 188.8.131.52.2 Customer Alarm 2 and Freeze Alarm Setup Smoke Detector and High Humidity Limit Switch Setup Digital Input Setup is Smoke Detect :Disabled Invert:Yes Position:Closed High Hum Lim :Disabled Invert:Yes Position:Closed (August, 2013) Timers and Miscellaneous Setup Timers, misc setup Sensor fail delay: 15s Clock Adjust: 3600 Disp Timeout: Enabled Disp Backlite Dly:300s Humd Comm Timeout: 60s Sensor fail delay masks the failure alarm to make sure the sensor has really failed. 43 STULZ Ultra-Series Humidifier Controller Clock Adjust is the number of seconds considered to be in an hour. 5.7.1 System Configuration In order to extend the life of the backlight on the display, it can be enabled to turn off after a period of time when no key has been pressed. Disp Timeout can be set to “Enabled” or “Disabled”. If enabled, Disp Backlite Dly is the number of seconds to wait after the last key press before turning the display off. Unit Type: DRH Control: Humidity Limit: None Mode: C=Cntrl L=Limit Analog C No L CPU: Large Humd Comm Timeout is the number of seconds to wait for a response from the humidifier before declaring it offline. 184.108.40.206.2 Startup, Alarms Startup, alarms Auto on power up: Yes Auto on remote: Yes Smoke Shutdown: Yes Auto power up set to Yes will start the system when power is restored without having to press the ENTER key. Auto on Remote will start the system without having to press the ENTER key. Smoke shutdown will prevent the system to start until the smoke alarm has been cleared. 5.7 Sys Configuration SERVICE MENU software Factory SYS CFG Save Cfg Basic System Configuration Unit type is set to DRH or DAH, depending on what type of humidifiers are connected to the E-Ultra controller. Control is the means by which the humidifiers will be controlled. It is selectable to be a proportional input, by humidity or by dew point. Limit is an option to apply a limit control using a separate sensor. It can be None, Humidity or Dew Point. Mode is one of six operating modes. Inputs for control can be by sensor signals or commands over a BMS serial interface. 1 Input 1 (Control) BMS Signal Input 2 (Limit) None 2 Control Sensor None 3 BMS Signal BMS Signal 4 Control Sensor Limit Sensor 5 BMS Signal Limit Sensor 6 Control Sensor BMS Signal Mode Function Room Control Return duct monitoring with proportional high limit Mode 1 displays as: “BMS C no L” Mode 2 displays as: “Analog C no L” Mode 3 displays as: “BMS C & L” Mode 4 displays as: “Analog C & L” Mode 5 displays as: “BMS C Analog L” Mode 6 displays as: “Analog C BMS L” The System Configuration menu loop contains configuration screens to set up options selected at the time of sale. When accessed using the Service password, the parameters are read only and cannot be changed. Not all options are available on a particular E-Ultra Controller. Depending on the size of the controller, (small, medium or large), some inputs and outputs are not available. Check 44 (August, 2013) STULZ Ultra-Series Humidifier Controller Drain Enable determines if the system will drain the humidifiers after being idle for a long period of time. 5.7.2 Humidifiers and Cabinet Fan Unit is DRH Num of humidifiers: 16 Humidifier version: 3 Humidifier Temp: No B2 is Temperature: No Cabinet Fan: Yes Cabinet Fan Alarm: No The top line reflects the type of humidifier that is being controlled. The number of humidifiers is set to number of humidifiers attached to the E-Ultra Controller. This should be set to the exact number of humidifiers. If it is set too high, time is wasted in the Modbus communications trying to access the non-existent humidifiers. The line with “Humidifier Temp” is set to YES if the humidifiers have nebulizer temperature sensors. The line with “B2 is Temperature” only appears on the small controller and allows the use of a control temperature sensor instead of a limit humidity sensor. This allows a small controller to have dewpoint control. BMS Keep Alive set to Yes requires the BMS system to toggle the keep-alive parameter between 1 and 2 at a maximum of 10 minutes between changes. The purpose is to allow the E-Ultra to determine control outputs when the BMS goes off line. Integration time is the number of cycles used in the PI loop for Humidity or Dew Point Control. The larger the number, the longer it takes to wind up the integrator and increase the percentage output when the humidity does not change. Cabinet Fan Start temperature is the trip point for the cabinet fan to start. The Cabinet Fan high and low alarm points are shown. 5.7.4 Input Configuration Input Config Cntrl Temp Sensor: Log Rem. Shutdown: Air Flow: Pin 4: None Fire/Smoke: High Limit Hstat: Hstat Alarm: No No No No No No The Control Temperature sensor, if available, can be enabled in this screen. The cabinet fan can be enabled or disabled by setting this parameter to “Yes” or “No”. All E-Ultra cabinets ship with a NTC temperature, so this parameter should always be set to “Yes”. The Log Remote Shutdown, if set to YES, will be treated as an alarm and logged as such. An alarm can be enabled if the cabinet temperature falls out of range (too hot or too cold, by setting the last parameter to “Yes”. Pin 4 can be assigned to None, Water Detector or Condensate Pan depending on the sensor and function. 5.7.3 Drain, BMS and Integration Air Flow is the Air Flow Switch input. Fire/Smoke and High Limit Humidistat can also be enabled on this screen. Optionally, the High Limit Humidistat may be set to cause an alarm. System Config Drain Enable: BMS Keep Alive: Integration Time: Alarm Delay: Cab. Fan Start: Cab Hi T Alarm: Cab Lo T Alarm: (August, 2013) Yes Yes 900 10s 104°F 130°F 40°F 45 STULZ Ultra-Series Humidifier Controller 5.7.5 Digital Input Configuration 5.7.7 Digital Input Config Sensor Options Conductivity: Limit Temp Sensor: Limit Hum Sensor: Airspeed Sensor: NTC2 Temp Sensor: NTC3 Temp Sensor: NTC4 Temp Sensor: Customer Alarm 1: No Customer Alarm 2: No Customer Alarm 3: No Freeze Alarm: No Group Select: No This screen allows the enabling of the customer alarm inputs. Freeze Alarm, when set to Yes, allows that input to disable the humidification function. Yes No No No No No No This screen allows the enabling of the rest of the analog sensors. 5.7.8 Measurement Units Measurement Units Group Select, when set to Yes, allows the Group Select input to determine which Group operates (A or B). This overrides any auto rotation when set to Yes. 5.7.6 Sensor Options Temperature Units: Output Configuration Air Speed: °F fpm Output Config Custom Alarm 1 Enable: No Shutdown: No Custom Alarm 2 Enable: No Shutdown: No Output Config Custom Alarm 3 Enable: No Shutdown: No Custom Alarm 4 Enable: No Shutdown: No Change Units? No The temperature units may be selected to be °F or °C. The air speed units may be selected as meters per minute (m/m) or feet per minute (fpm). Since this affects many parts of the program, the changing of the units can only be done by using the Config password and changing the bottom line from No to Yes. It will change back to No when it is finished modifying the system. 5.7.9 Screens Visible Only by Config Password The following screens appear only when the configuration password is in effect. They will not appear when any other password is in effect. The custom alarms can be enabled and can be configured to shut down the system. 46 (August, 2013) STULZ Ultra-Series Humidifier Controller 220.127.116.11 Set Passwords Set Passwords Control: Service: Factory: Config: 18.104.22.168 1 2 xxxxx xxxxx Password Config FACT SAVE Initialize Variables Factory Save Factory Save MUST SAVE BOTH FACTORY AND CUSTOMER VALUES No No No After the factory settings have been completed, they can be saved into permanent memory. It also should be saved into the customer’s memory. This allows the restoration to the factory settings, if the customer inadvertently sets up situations that cause erratic behavior. By returning to this screen the STULZ Product Support technician can restore the settings back to the factory settings. 22.214.171.124.1 Factory Default Set Points Table 1- Default Set Points software details that are Save Factory Save Customer Restore Factory When it is done, it will go back to the Basic System Configuration screen. 5.8 Factory Save Access 126.96.36.199 This screen is used to set the entire permanent memory values back to their default values. This must be done any time new software is downloaded. Use the Enter key to position the cursor at the “No” text and then press either the Up or Down key to start the initialization process. The area labeled status will show the progress. Initialization Initialization DEFAULT INITIALIZATION Erase user settings and install global default values: No Parameter Remote Enable Customer Alarm 1 Enable Airflow Enable BMS keep alive Override Smoke Alarm Enable High humidity Switch Enable Customer Alarm 2 Enable Humidifier Temperature Enable Customer Alarm 3 Enable Group Select Cabinet Fan Enable Custom Alarm 1 Output Enable Custom Alarm 2 Output Enable Custom Alarm 3 Output Enable Custom Alarm 4 Output Enable Log Remote Shutdown Bank Enable High Airflow Alarm Enable Low Airflow Alarm Enable High limit humidity alarm Enable Control Temperature Enable Control Humidity Enable Conductivity Enable Limit Temperature Enable Limit Humidity Enable Airspeed Enable Low Limit Humidity Alarm Enable NTC2 Temperature Sensor Enable NTC3 Temperature Sensor Enable NTC4 Temperature Sensor Enable Control Temperature X Low Scale Control Temperature X High Scale Control Humidity X Low Scale Control Humidity X High Scale Limit Temperature X Low Scale Limit Temperature X High Scale Limit Humidity X Low Scale Limit Humidity X High Scale Remote On/OFF Invert Customer Alarm 1 Invert Airflow Switch Invert Water Detector Invert Smoke Alarm Invert High Humidistat Invert Customer Alarm 2 Invert Freeze Alarm Invert Set Point Yes No No No No No No No No No Yes No No No No No No No No No No Yes Yes No No No No No No No 0 50.0 0 100.0 0 50.0 0 100.0 Yes Yes Yes Yes Yes Yes Yes Yes status (August, 2013) 47 STULZ Ultra-Series Humidifier Controller Customer Alarm 3 Invert Group Select Invert Parameter Group A Limit Enable Group B Limit Enable Cabinet Temperature Alarm Shutdown NTC2 Temperature Alarm Shutdown NTC3 Temperature Alarm Shutdown Custom Alarm 1 Shutdown Enable Custom Alarm 2 Shutdown Enable Custom Alarm 3 Shutdown Enable Custom Alarm 4 Shutdown Enable Cabinet Low Temperature Alarm Enable Cabinet High Temperature Alarm Enable NTC2 Low Temperature Alarm Enable NTC2 High Temperature Alarm Enable NTC3 Low Temperature Alarm Enable NTC3 High Temperature Alarm Enable NTC2 Low Temperature Alarm Enable NTC2 High Temperature Alarm Enable Humidity Limit Alarm Enable Demo Case Selected Control Temperature Offset Control Humidity Offset Conductivity Offset Airspeed Offset Cabinet Temperature Offset NTC2 Temperature Offset NTC3 Temperature Offset NTC4 Temperature Offset Customer Alarm 1 Shutdown Enable Customer Alarm 2 Shutdown Enable Customer Alarm 3 Shutdown Enable Airflow Shutdown Enable Control Mode Limit Humidity Set Point Limit Temperature Set Point Startup Delay Pin 4 Airflow Delay Alarm delay Airflow offset dew point Cut-in dew point Cutout Sensor Fail Delay Recovery Delay Limit dew point Cut-in Limit dew point Cutout Control Password Service Password Factory Password System Configuration Password Number of humidifiers First Modbus address of Humidifiers Airspeed Type High Limit Humidity Alarm Set Point Low Limit Humidity Alarm Set Point Limit Humidity Alarm Offset BMS Timeout BMS Address BMS Baud rate BMS Protocol Select Control Humidity Sensor Type Control Humidity Set Point Control Humidity Cut-in Control Humidity Cutout 48 Yes Yes Set Point Yes Yes No No No No No No No Yes Yes No No No No No No No No 0.0°F 0.0%RH 0.0 uS 0.0 fpm 0.0°F 0.0°F 0.0°F 0.0°F No No No No Humidity 80.0%RH 72.0°F 10 Sec None 5 sec 10 sec 0.0 fpm -4.0°F 0.0°F 15 sec 1 sec 5.0°F 0.0°F 1 2 1 6 4-20mA 95.0%RH 20.0%RH 5.0%RH 10 sec 1 19,200 BACnet 4-20mA 45.0%RH -4%RH 0.0%RH Limit Humidity Sensor Type Control Temperature Sensor Type Parameter High Control Humidity Alarm Low Control Humidity Alarm Control Humidity Alarm Offset Drain Duration Cabinet Temperature Sensor X minimum Cabinet Temperature Sensor X minimum Cabinet Temperature Sensor Y minimum Cabinet Temperature Sensor Y minimum NTC2 Temperature Sensor X minimum NTC2 Temperature Sensor X minimum NTC2 Temperature Sensor Y minimum NTC2 Temperature Sensor Y minimum NTC3 Temperature Sensor X minimum NTC3 Temperature Sensor X minimum NTC3 Temperature Sensor Y minimum NTC3 Temperature Sensor Y minimum NTC4 Temperature Sensor X minimum NTC4 Temperature Sensor X minimum NTC4 Temperature Sensor Y minimum NTC4 Temperature Sensor Y minimum Group Rotation Hours Humidifier Type Limit Temperature Sensor Type Conductivity Delay Group A Restrictor Group Switch Time Group B Restrictor Limit Humidity Cut-in Limit Humidity Cutout Limit Temperature Cut-in Limit Temperature Cutout Group B Assist Humidifier Modbus number of stop bits Humidifier Modbus parity Humidifier Modbus Baud rate Operating Mode Clock Adjust Drain hours high Drain hours low part High Control Temperature Alarm Enable Low Control Temperature Alarm Enable High Control Humidity Alarm Enable Low Control Humidity Alarm Enable Fahrenheit is Temperature Unit of Measure Auto Reset Auto Reset Remote Smoke Shutdown on Alarm Drain Enable Suppress Buzzer High Limit Temperature Alarm Enable Air Speed Units Low Limit Temperature Alarm Enable Freeze Alarm Enable 4-20mA 4-20mA Set Point 70.0%RH 30% RH 5.0%RH 10 mins. 0.0 100.0 0.0°C 100.0°C 0.0 100.0 0.0°C 100.0°C 0.0 100.0 0.0°C 100.0°C 0.0 100.0 0.0°C 100.0°C 24 hours 3 4-20mA 10 sec 100% 24 hours 100% -4.0%rH 0.0%RH -4.0°F 0.0°F Rotate 0 None 19,200 2 (See Table, Section 5.7.1) 3600 0 72 hours No No Yes Yes Yes Yes Yes No Yes Yes No fpm No No (August, 2013) STULZ Ultra-Series Humidifier Controller 6.0 6.1 MAINTENANCE General 7.0 7.1 Because conditions vary greatly, individual maintenance schedules must be determined for each location, based upon periodic examination of the controller. Check for corrosion on the exterior of the enclosure. Touch-up the finish if required. WARNING Power is still present inside the control box when the On/Off switch on the enclosure door is Off. Turn off main supply power before performing maintenance to the interior of the box. Check the interior of the enclosure for accumulated dust or dirt. Vacuum if required. Check for corrosion on the electrical connections. Clean corrosion if necessary and apply anti-corrosion grease. Periodically, check and tighten all terminal connections. Check the interior of the enclosure for signs of overheating. If evidence of overheating is observed, Ensure the vent openings are free of obstructions and the vent fan operates when the cabinet temperature is above 104°F. A system should be established for trend analysis of problems, defects and deficiencies noted by operators and discovered during maintenance inspections together with the corrective actions taken. For maintenance assistance, contact the STULZ Product Support. TROUBLESHOOTING General The Ultra-Series controller is designed for continuous and dependable operation. In the event that a problem is encountered with the humidification system, the system controller may be used to diagnose the cause. The controller signals an alarm condition when the red backlight LED is illuminated behind the alarm function key. An alarm indication is accompanied by a screen text message with a brief description of the cause (See Alarm Screen Messages, Section 5.3.4). Often the remedy is simple to determine by reading the alarm message i.e. “High Conductivity Alarm” (Check supply water quality). The following abbreviated guidelines are included to assist in troubleshooting the system due to operational or performance problems. Refer to the Humidifier IOM for troubleshooting guidelines when there are system performance issues. If the problem can’t be resolved using the alarm screens and the guidelines, contact STULZ Product Support for assistance (See Section 9.0). Problem: “Alarm” Lamp is ON 1. Use the system controller to check the Alarm display message(s). 2. Identify and correct cause of alarm condition. 3. Reset if necessary. Problem: Control Is Erratic 1. Wiring improperly connected or broken. 2. Wires shorted. Check all wire connections to ensure they are tight and that no shorts are present. Also check wiring against the schematic diagram included with the unit to ensure the wire terminations are correct. WARNING Keep hands, clothing and tools clear of live electrical terminals. Turn off all power to the unit before conducting any troubleshooting or repair procedures unless the procedure specifically requires the system to operate. (August, 2013) 49 STULZ Ultra-Series Humidifier Controller 7.2 Control I/O Module Signal LED's The control I/O module includes 3 LED's (red, yellow and green) that provide information on the operation of the control module and status of the connection to the pLAN. These signal LED's are positioned adjacent to the yellow, "Power On" LED (see Figure 4). The signal LED's may be used for diagnostic purposes if a problem arises. 50 (August, 2013) STULZ Ultra-Series Humidifier Controller 8.0 8.1 REPAIR PROCEDURES General Under normal operating conditions and with the proper preventive maintenance, the unit should provide excellent service for many years. If necessary, the unit may be returned to the manufacturer for major overhaul and refurbishment. All work must be performed by qualified technicians. 8.2 Component Replacement Replaceable components may be removed and replaced from the controller using common hand tools. Ensure power is disconnected from the controller before removing or replacing components. WARNING Power is still present inside the controller enclosure when the On/Off switch on the enclosure door is in the Off position. 9.0 PRODUCT SUPPORT STULZ provides its customers with Product Support which not only provides technical support and parts but the following additional services, as requested: • Performance Evaluations • Start-up Assistance • Training 9.1 Technical Support The STULZ Technical Support Department is dedicated to the prompt reply and solution to any problem encountered with a unit. Should a problem develop that cannot be resolved using this manual, call (888) 529-1266 Monday through Friday from 8:00 a.m. to 5:00 p.m. EST. If a problem occurs after business hours, provide your name and telephone number. One of our service technicians will return your call. When calling to obtain support, it is important to have the following information readily available, (information is found on the unit’s nameplate): • Unit Model Number • STULZ Sales Order Number • STULZ Item Number • Unit Serial Number • Description of Problem 9.2 Obtaining Warranty Parts Warranty inquiries are to be made through the Technical Support Department at (888) 529-1266 Monday through Friday from 8:00 a.m. to 5:00 p.m. EST. A service technician at STULZ will troubleshoot the system over the telephone with a field service technician to determine the defect of the part. If it is determined that the part may be defective a replacement part will be sent via UPS ground. If the customer requests that warranty part(s) be sent by any other method than UPS ground the customer is responsible for the shipping charges. If you do not have established credit with STULZ you must give a freight carrier account number. A written (or faxed) purchase order is required on warranty parts and must be received prior to 12:00 p.m. for same day shipment. The purchase order must contain the following items: • Purchase Order Number • Date of Order • STULZ Stated Part Price • Customer Billing Address • Shipping Address • Customer’s Telephone and Fax Numbers • Contact Name • Unit Model No., Serial No. & STULZ Item No. (August, 2013) 51 STULZ Ultra-Series Humidifier Controller The customer is responsible for the shipping cost incurred for returning the defective part(s) back to STULZ. Return of defective part(s) must be within 30 days at which time an evaluation of the part(s) is conducted and if the part is found to have a manufacturing defect a credit will be issued. When returning defective part(s) complete the Return Material Authorization Tag and the address label received with the replacement part. See the STULZ Standard Warranty located in section one of this manual. 9.3 Obtaining Spare/Replacement Parts Spare and replacement parts requests are to be made through Product Support by fax (301) 620-1396, telephone (888) 529-1266 or E-mail (parts@stulz-ats. com). Quotes are given for specified listed parts for a specific unit. STULZ accepts Visa and MasterCard. STULZ may extend credit to its customers; a credit application must be prepared and approved (this process could take one week). A 25% minimum restocking charge will be applied on returned stocked parts that were sold as spare/ replacement parts. If the returned part is not a stocked item, a 50% restocking charge may be applied. Additionally a Return Material Authorization Number is required when returning parts. To receive credit for returned repair/replacement parts, the parts must be returned to STULZ within 30 days of the purchase date. Spare part sales over 30 days old will be considered final and the parts will remain the sole property of the ordering party. 52 (August, 2013) STULZ Ultra-Series Humidifier Controller 10.0 APPENDIX A - BMS Parameters Supported Protocols BACnet over IP BACnet over Ethernet HTTP SNMP V1, V2c Modbus over IP BACnet MS/TP Modbus RTU Speed 10 Mbps 10 Mbps 10 Mbps 10 Mbps 10 Mbps 19200 baud 19200 baud Media 10pBaseT 10pBaseT 10pBaseT 10pBaseT 10pBaseT Twisted Pair Twisted Pair Connection RJ45 direct communications RJ45 direct communications RJ45 direct communications RJ45 direct communications RJ45 direct communications Daisy chain connection Daisy chain connection Notes Uses BMS addresses Uses BMS addresses Uses BMS addresses Uses BMS addresses Uses Modbus addresses Uses BMS addresses Uses Modbus addresses 10.1 Signed Values for HTTP, SNMP / Modbus Holding Registers / Analog Values for BACnet Modbus TCP/IP BMS Address Modbus Address BACnet Address 40002 40003 40004 40005 40006 40007 40008 40009 40010 40011 40012 40013 40014 40015 40016 40017 40018 40019 40020 40021 40022 40023 40024 40025 40026 40027 40028 40029 40030 40031 40032 40033 40034 40035 40036 40037 40038 40039 40040 40041 40042 40043 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 40002 40003 40004 40005 40006 40007 40008 40009 40010 40011 40012 40013 40014 40015 40016 40017 40018 40019 40020 40021 40022 40023 40024 40025 40026 40027 40028 40029 40030 40031 40032 40033 40034 40035 40036 40037 40038 40039 40040 40041 40042 40043 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 (August, 2013) Description Control Dew point Set Point Control Humidity Set Point Control temperature sensor current value Control humidity sensor current value dew point from return temp and humidity Limit temperature sensor value Limit humidity sensor value dew point from limit temperature and humidity Airspeed sensor current value Control Cabinet Temperature NTC2 Temperature NTC3 Temperature NTC4 Temperature Conductivity Humidifier 1 Temperature (xxx.x°C) Humidifier 1 Voltage (xx.x volts) Humidifier 2 Temperature (xxx.x°C) Humidifier 2 Voltage (xx.x volts) Humidifier 3 Temperature (xxx.x°C) Humidifier 3 Voltage (xx.x volts) Humidifier 4 Temperature (xxx.x°C) Humidifier 4 Voltage (xx.x volts) Humidifier 5 Temperature (xxx.x°C) Humidifier 5 Voltage (xx.x volts) Humidifier 6 Temperature (xxx.x°C) Humidifier 6 Voltage (xx.x volts) Humidifier 7 Temperature (xxx.x°C) Humidifier 7 Voltage (xx.x volts) Humidifier 8 Temperature (xxx.x°C) Humidifier 8 Voltage (xx.x volts) Humidifier 9 Temperature (xxx.x°C) Humidifier 9 Voltage (xx.x volts) Humidifier 10 Temperature (xxx.x°C) Humidifier 10 Voltage (xx.x volts) Humidifier 11 Temperature (xxx.x°C) Humidifier 11 Voltage (xx.x volts) Humidifier 12 Temperature (xxx.x°C) Humidifier 12 Voltage (xx.x volts) Humidifier 13 Temperature (xxx.x°C) Humidifier 13 Voltage (xx.x volts) Humidifier 14 Temperature (xxx.x°C) Humidifier 14 Voltage (xx.x volts) Default Min Max 72.0 45.0 10.0 95.0 Read/ Write R/W R/W R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R 53 STULZ Ultra-Series Humidifier Controller Modbus TCP/IP BMS Address Modbus Address BACnet Address 40044 40045 40046 40047 40050 40051 40052 40053 40054 40055 40101 40102 40103 40104 40105 40106 40107 43 44 45 46 49 50 51 52 53 54 100 101 102 103 104 105 106 40044 40045 40046 40047 40050 40051 40052 40053 40054 40055 40101 40102 40103 40104 40105 40106 40107 43 44 45 46 49 50 51 52 53 54 100 101 102 103 104 105 106 40108 107 40108 107 40109 40110 108 109 40109 40110 108 109 40111 110 40111 110 40112 111 40112 111 40113 112 40113 112 40114 40115 40116 40117 40118 40119 40120 40121 40122 113 114 115 116 117 118 119 120 121 40114 40115 40116 40117 40118 40119 40120 40121 40122 113 114 115 116 117 118 119 120 121 Description Humidifier 15 Temperature (xxx.x°C) Humidifier 15 Voltage (xx.x volts) Humidifier 16 Temperature (xxx.x°C) Humidifier 16 Voltage (xx.x volts) Dew Point Setpoint Limit Dewpoint Limit humidity low alarm point Limit temperature high alarm point Limit temperature low alarm point Limit humidity high alarm point Control temperature high alarm point Control temperature low alarm point Control humidity high alarm point Control humidity low alarm point dew point Limit Point Humidity Limit Point Limit high humidity cutout Limit high humidity cut-in (band is cutout-cutin) Conductivity Pre Alarm limit Conductivity Alarm limit Network supplied Contol Humidity set point /Proportional Control * Network supplied control temperature Network supplied dew point Value (when dew point configured) Network supplied Limit Temperature Value Network supplied Limit Humidity Value High Airflow Alarm trip point Low Airflow Alarm trip point dew point Control cut-in dew point Control cutout dew point Limit cut-in dew point Limit cutout Network supplied dew point limit Default Min Max Read/ Write 30.0 80.0 60.0 70.0 80.0 60.0 70.0 30.0 72.0 80.0 79.0 R R R R R R R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W 75.0 R/W 5.0 20.0 R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W -4.0 0.0 -4.0 0.0 * If configured for humidity, this is return humidity; if configured proportional, this the percent output 10.2 Unsigned Values for HTTP, SNMP / Modbus Holding Registers / Analog Values for BACnet Modbus TCP/IP BMS Address Modbus Address BACnet Address 5002 5003 5004 5005 5006 5007 5008 5009 5010 5011 5012 5013 5014 5015 5016 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 40130 40131 40132 40133 40134 40135 40136 40137 40138 40139 40140 40141 40142 40143 40144 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 54 Description Group A proportional output Group B proportional output Packed bits for BMS – Alarms 1 Packed bits for BMS – Alarms 2 Packed bits for BMS – Humidifier 1 Alarms Packed bits for BMS – Humidifier 2 Alarms Packed bits for BMS – Humidifier 3 Alarms Packed bits for BMS – Humidifier 4 Alarms Packed bits for BMS – Humidifier 5 Alarms Packed bits for BMS – Humidifier 6 Alarms Packed bits for BMS – Humidifier 7 Alarms Packed bits for BMS – Humidifier 8 Alarms Packed bits for BMS – Humidifier 9 Alarms Packed bits for BMS – Humidifier 10 Alarms Packed bits for BMS – Humidifier 11 Alarms Default Read/ Write R R R R R R R R R R R R R R R (August, 2013) STULZ Ultra-Series Humidifier Controller Modbus TCP/IP BMS Address Modbus Address BACnet Address 5017 5018 5019 5020 5021 5022 5023 5024 5025 5026 5027 5028 5029 5030 5031 5032 5033 5034 5035 5036 5037 5038 5039 5040 5041 5042 5043 5044 5045 5048 5101 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 100 40145 40146 40147 40148 40149 40150 40151 40152 40153 40154 40155 40156 40157 40158 40159 40160 40161 40162 40163 40164 40165 40166 40167 40168 40169 40170 40171 40172 40173 40048 40229 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 47 1100 5102 101 40230 1101 5103 5104 5124 5125 5126 5127 5128 102 103 123 124 125 126 127 40231 40232 40252 40253 40254 40255 40256 1102 1103 1123 1124 1125 1126 1127 Description Packed bits for BMS – Humidifier 12 Alarms Packed bits for BMS – Humidifier 13 Alarms Packed bits for BMS – Humidifier 14 Alarms Packed bits for BMS – Humidifier 15 Alarms Packed bits for BMS – Humidifier 16 Alarms Packed bits for BMS – Raw digital inputs Packed bits for BMS – Digital inputs 2 Packed bits for BMS – Digital outputs Packed bits for BMS – Humidifier 1 Digital outputs Packed bits for BMS – Humidifier 2 Digital outputs Packed bits for BMS – Humidifier 3 Digital outputs Packed bits for BMS – Humidifier 4 Digital outputs Packed bits for BMS – Humidifier 5 Digital outputs Packed bits for BMS – Humidifier 6 Digital outputs Packed bits for BMS – Humidifier 7 Digital outputs Packed bits for BMS – Humidifier 8 Digital outputs Packed bits for BMS – Humidifier 9 Digital outputs Packed bits for BMS – Humidifier 10 Digital outputs Packed bits for BMS – Humidifier 11 Digital outputs Packed bits for BMS – Humidifier 12 Digital outputs Packed bits for BMS – Humidifier 13 Digital outputs Packed bits for BMS – Humidifier 14 Digital outputs Packed bits for BMS – Humidifier 15 Digital outputs Packed bits for BMS – Humidifier 16 Digital outputs Humidifier communications protocol level Number of hours left until drain occurs Not used Percentage restriction on Group A output (0-100) Percentage restriction on Group B output (0-100) Limit Mode 0=disabled;1=humidity;2=dewpoint Type of humidifier system (1 – DRH, 2 = DAH) Control method (0 = humidity, 1 = dew point, 2 = proportional) Regulation mode – see section 5.7.1 BMS keep alive (toggle between 1 & 2 every 10 mins.) Current day Current month Current year Current hour Current minute Default Read/ Write R R R R R R R R R R R R R R R R R R R R R R R R R R/W 0 0 R/W R/W R/W R 1 R 2 0 1 1 0 0 0 R R/W R/W R/W R/W R/W R/W 10.3 Boolean Values for HTTP, SNMP / Modbus Coils / Binary Values for BACnet Modbus TCP/IP BMS Address Modbus Address BACnet Address 002 003 004 005 006 007 008 009 010 011 012 1 2 3 4 5 6 7 8 9 10 11 002 003 004 005 006 007 008 009 010 011 012 1 2 3 4 5 6 7 8 9 10 11 (August, 2013) Description Global alarm output System on status Airflow has been proven Call for humidification Lead Group (0 = Group A, 1 = Group B) Customer alarm input 1 Condensate Pan Airflow Switch Water Detector High Limit Stat Smoke Default Read/ Write R R R R R/W R/W R R R R R 55 STULZ Ultra-Series Humidifier Controller Modbus TCP/IP BMS Address Modbus Address BACnet Address 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 057 058 059 060 102 103 104 105 106 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 53 56 57 58 59 101 102 103 104 105 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 057 058 059 060 102 103 104 105 106 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 56 57 58 59 101 102 103 104 105 Description Default Customer alarm input 2 Customer alarm input 3 Custom Alarm 1 Custom Alarm 2 Custom Alarm 3 Custom Alarm 4 Cabinet Fan High control temperature alarm Low control temperature alarm High control humidity alarm Low control humidity alarm Cabinet high temperature alarm Cabinet low temperature alarm NTC2 high temperature alarm NTC2 low temperature alarm NTC3 high temperature alarm NTC3 low temperature alarm NTC4 high temperature alarm NTC4 low temperature alarm Control temperature sensor fail Control humidity sensor fail Limit temperature sensor fail Limit humidity sensor fail Conductivity sensor fail Airspeed sensor fail Conductivity Pre-Alarm Conductivity Alarm High Control Temperature Alarm Enable Low Control Temperature Alarm Enable High Return Humidity Alarm Enable Low Return Humidity Alarm Enable High Airflow Alarm Low Airflow Alarm High limit temperature alarm Low limit temperature alarm Enable high limit temperature alarm Enable low limit temperature alarm High limit humidity alarm Enable high humidity alarm Enable low humidity alarm Low limit humidity alarm Airflow Shut Down Enable Airflow Shut down BMS Freeze Alarm Enable Freeze alarm Remote shutdown --Group Select Reset Alarms Group Select Enable Read/ Write R/W R/W R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R/W R/W R R/W R/W R R/W R R/W R R/W --R/W R/W R/W 10.4 Alarm Packed Bit Variables Bit 0 1 56 Value 1 2 Alarms 1 High control temperature alarm Low control temperature alarm Alarms 2 Control temperature sensor fail Control humidity sensor fail Humidifier x Alarms Low water alarm Fill failure alarm (August, 2013) STULZ Ultra-Series Humidifier Controller Bit 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Value Alarms 1 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768 High control humidity alarm Low control humidity alarm Cabinet high temperature alarm Cabinet low temperature alarm NTC2 high temperature alarm NTC2 low temperature alarm NTC3 high temperature alarm NTC3 low temperature alarm NTC4 high temperature alarm NTC4 low temperature alarm Conductivity Pre-Alarm Conductivity Alarm High Airflow Alarm Low Airflow Alarm Alarms 2 Limit temperature sensor fail Limit humidity sensor fail Conductivity sensor fail Airspeed sensor fail High limit temperature alarm Low limit temperature alarm High limit humidity alarm Low limit humidity alarm Freeze Alarm Humidifier x Alarms High temperature alarm Freeze alarm High voltage alarm Low voltage alarm Humidifier off line alarm Transducer failure alarm 10.5 Input Packed Bit Variables Bit Value Raw Digital Inputs 0 1 2 3 4 5 6 7 8 9 10 1 2 4 8 16 32 64 128 256 512 1024 Remote enable Customer input 1 Condensate Pan Airflow Switch Water Detector High Limit Stat Smoke --Customer input 2 Customer input 3 Group Select 11 2048 Reset Alarms 12 13 14 15 4096 8192 16384 32768 Description Set to a 1 to reset alarms that have cleared. 10.6 Output Packed Bit Variables (August, 2013) Bit Value 0 1 2 3 4 5 6 7 1 2 4 8 16 32 64 128 Digital Output Global Alarm Custom Alarm 1 Custom Alarm 2 Custom Alarm 3 Custom Alarm 4 Cabinet Fan Humidifier x Outputs Fill Valve State Drain Valve State Fan State Drain enabled Drain to fill level on startup In Group A In Group B Humidifier Enable State 57 STULZ Ultra-Series Humidifier Controller 8 9 10 11 12 13 14 15 256 512 1024 2048 4096 8192 16384 32768 Fan Configured High Water Switch State Low Water Switch State Temperature Switch State 11.0 APPENDIX B - Inputs/Outputs Notes on basic units Option Name U = Universal ID1 ID1 Remote shut down Remote Shutdown std. all units DI 2 ID2 ID2 ID2 Customer Alarm 1 Customer Alarm 1 std. all units DI 3 ID3 ID3 ID3 Air proving switch Air Proof opt all units DI 4 ID4 ID4 ID4 Water Alarm Water detection opt all units DI 5 ID5 ID5 ID5 Fire/Smoke detector Fire/smoke opt all units DI 6 ID6 ID6 ID6 High limit humidistat High limit humidistat opt all units DI 7 ID7 ID7 ID7 Customer Alarm 2 customer alarm 2 opt all units DI 8 ID8 ID8 ID8 Freeze Alarm Freeze Alarm opt all units DI 9 ID9 ID9 Customer Alarm 3 Customer Alarm 3 opt med & large DI 10 ID10 ID10 Bank Select Bank select opt med & large DI 11 ID11 ID11 open DI 12 ID12 ID12 open DI 13 ID13 ID13 open DI 14 ID14 ID14 open DO 1 NO1 NO1 NO1 Summary alarm Summary Alarm std. all units DO 2 NO2 NO2 NO2 Custom alarm 1 Custom Alarm 1 std. all units DO 3 NO3 NO3 NO3 Custom alarm 2 custom alarm 2 opt all units N = NTC only Pco3 large ID1 Use Pco3 medium 1 Pco3 small DI Type 58 Virtual Pin number The inputs/outputs available for the various size controllers are listed in the following table: (August, 2013) Not available DO 5 NO5 NO5 NO5 Cabinet fan enable DO 6 NO6 NO6 NO6 Not available DO 7 NO7 NO7 NO7 open DO 8 NO8 NO8 NO8 open DO 9 NO9 NO9 DO 10 NO10 NO10 DO 11 NO11 NO11 DO 12 NO12 NO12 DO 13 NO13 NO13 AI 1 B1 B1 B1 Control Air Humidity AI 2 B2 B2 B2 AI 3 B3 B3 B3 AI 4 B6 B6 AI 5 B4 B4 B4 AI 6 B5 B5 B5 AI 7 B7 B9 AI 8 B8 B10 AI 9 B7 AI 10 B8 AO 1 Y1 Y1 Y1 AO 2 Y2 Y2 Y2 AO 3 Y3 Y3 Y3 AO 4 Y4 Y4 Y4 AO 5 Y5 AO 6 Y6 (August, 2013) Notes on basic units NO4 Option Name NO4 N = NTC only NO4 U = Universal Pco3 large 4 Use Pco3 medium DO Type Pco3 small Virtual Pin number STULZ Ultra-Series Humidifier Controller Cabinet fan std. all units Custom alarm 3 custom alarm 3 opt all units Custom alarm 4 custom alarm 4 opt all units U Remote sensor std. all units Limit Air Humidity U standard std. all units Conductivity U standard std. all units U remote sensor opt all units N Cabinet Temperature std. all units N 2 temperature sensor nd opt all units N 3 temperature sensor rd opt all units N 4 temperature sensor th opt all units U limit sensor opt all units U remote sensor opt all units Control Air Temperature Cabinet Temperature NTC2 input temperature NTC3 input temperature NTC4 input temperature Limit Air Temperature Airflow Sensor 59 Production Facilities: U.S.A. • Germany • Italy • China • India ® STULZ mission is to be the premier provider of energy efficient temperature and humidity control solutions for mission critical applications. STULZ Air Technology Systems, Inc. 1572 Tilco Drive, Frederick, Maryland 21704 Phone: 301.620.2033 • Fax: 301.662.5487 E-mail: email@example.com www.STULZ.com Registered ISO9001 Quality System ISO-9001 Quality Management System - Requirements August., 2013 OUU0078D Specifications subject to change without notice.
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