BACnet Flow Controller for Fan Filter Units

BACnet Flow Controller for Fan Filter Units
MANUAL – SERVICE + INSTALLATION
BACnet Flow Controller for Fan Filter Units
BFC Series
v300 – Issue Date: 06/21/17
© 2017 Price Industries Limited. All rights reserved.
BACNet Flow Controller
TABLE OF CONTENTS
Product Overview
General Information........................................................ 1
Installation & Mounting Instructions
Typical Wiring................................................................. 2
Input/Output Description................................................ 2
Display Navigation
Initial Startup.................................................................. 3
Service Menu................................................................. 4
Service Menu – Fan........................................................ 5
Service Menu – Filter...................................................... 6
Service Menu – I/O......................................................... 7
Service Menu – BACnet................................................. 8
Service Menu – Diagnostics........................................... 8
Networking & Setup
Network Wire Specifications........................................... 9
Network Layout............................................................ 10
BAS Input Signal.......................................................... 12
Analog RPM Feedback................................................ 13
Wiring and Cables........................................................ 14
Maintenance
Troubleshooting............................................................ 15
Specifications............................................................... 16
BACnet points list for BFC firmware v1.10.................... 17
BACNet Flow Controller
PRODUCT OVERVIEW
General Information
The BACnet Flow Controller (BFC) is a BTL listed DDC fan controller designed specifically for controlling flow through Fan Filter
Units (FFU) with EC motor technology. The BFC can control up to two ECM motors through a local setpoint which is adjustable
using a push button interface on the BFC, by an analog BAS input voltage, or over BACnet.
In addition to fan control, the BFC can monitor filter pressure drop, filter loading, signal for filter changes, monitor the motor and
filter lifetime in hours, as well as report airflow and air temperature over the filter. This information can be viewed from the LCD
screen on the front of the BFC controller, or over BACnet on a building management system.
NOTE: This manual only covers the BFC controller. For troubleshooting an ECM motor, please visit http://www.priceindustries.com
and download the ECM Motor Troubleshooting Manual.
FRONT OF BFC CONTROLLER
3
1
2
1
Service Port RJ12 Jack
2
BACnet Connection RJ45
Jacks
3
Up and Down arrow
buttons for navigation
4
Menu button for info
menu and entering
Service menus
4
2
BACK OF BFC CONTROLLER
12 BACnet MS/TP Terminals
2
2
1
11 Motor #2 Jack
3
10 Motor #1 Jack
12
11
4
10
9
8
7
6
5
5
9
Thermistor Input
8
Analog Inputs
7
Contact Closure
6
24 VAC Binary Outputs
5
0-10 VDC Analog Outputs
4
Pressure Transducer
3
24 VAC Power Connection
2
BACnet Connection RJ45
Jacks
1
Service Port RJ12 Jack
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1
BACNet Flow Controller
INSTALLATION & MOUNTING INSTRUCTIONS
Typical Wiring
Factory Wired
-24V COM
+24V HOT
RED LED
GREEN LED
COMMON
RED CABLE
WHITE CABLE
BLACK CABLE
*Factory wired
(Optional)
*Factory
wiredLED
LED
(Optional)
*See FFU-HE Manual for LED Status
*See FFU-HE Manual for LED Status.
Input/Output Description
Analog Outputs
AO1
Configurable for Unit Pressure, CFM (Air Flow),
RPM (Motor Speed), Filter Load and BAS.
AO2
Configurable for Unit Pressure, CFM (Air Flow),
RPM (Motor Speed), Filter Load and BAS.
24 VAC Binary Outputs
BO1
Red LED out
BO3
Green LED out
COM
COMMON
Analog Inputs
AI1
Input voltage for remote fan speed control
AI2
Spare
Inputs
2
Thermistor Input
Analog input for monitoring air over filter
temperature, 10k type J thermistor
Contact Closure
Binary input used for night setback
BACNet Flow Controller - Manual | priceindustries.com
BACNet Flow Controller
DISPLAY NAVIGATION
Initial Startup
When the BFC controller is powered up with 24VAC it will display the following information.
PRICE
ELECTRONICS
Start–up screen
BFC
VERSION X.X.X
Displays firmware version
ECM SPEED
X RPM
Displays RPM of motor 1
ECM SETPOINT
X%
UNIT STATUS
XXX
CURRENT MODE
XXX
Displays ECM setpoint in % motor speed
Displays current unit status ( Off, Normal, No RPM Signal, and Overspeed)
Displays current control over the unit (BACnet, BAS, Local)
*LCD display will cycle between ECM SPEED, ECM SETPOINT, UNIT STATUS, CONTROL MODE, BAS SIGNAL, and BAS
SETPOINT during normal operation.
Change ECM motor setpoint using
LOCAL SETPOINT
58%
and
arrow keys
Setpoint will save after being adjusted with arrow keys
NOTE: Local setpoints are stored to EEPROM and will remain set after power failures.
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BACNet Flow Controller
DISPLAY NAVIGATION
Service Menu
Hold down Menu button for 5 seconds, display will show ‘Passcode’. Use Up and Down arrow buttons to enter this sequence:
Down, Up, Up, Down.
Allows you to see or adjust:
Current CFM
CFM Offset
CFM Tweak
SERVICE MENU
FAN
Fan Type
Unit Size ie. 2X2
Wheel Type
Voltage Type
Motor Runtime (in hours)
Reset Motor Runtime
Filter Load
Load Trip
SERVICE MENU
FILTER
Current Pressure
Filter Type
Filter Runtime (in hours)
Reset Filter
BAS (Analog In 1)
Analog In 2
SERVICE MENU
I/O
Analog Out 1
Analog Out 1 Present Value
Analog Out 2
Analog Out 2 Present Value
MAC Address
SERVICE MENU
BACNET
Device Instance
Baud Rate
RS-485 Termination
SERVICE MENU
DIAGNOSTICS
4
Restore Defaults
BACNet Flow Controller - Manual | priceindustries.com
BACNet Flow Controller
DISPLAY NAVIGATION
Service Menu – Fan
Press Menu button to enter this menu. Use Up and Down arrow buttons to navigate through.
CURRENT CFM
XXXX CFM
Read Only
Adjust airflow reading +/- up to 500 CFM to coincide with balancer measured airflow
CFM OFFSET
0 CFM
Example: flow hood reads 550 CFM
Airflow reading on BFC is 500 cfm
Adjust CFM offset to +50 CFM
Adjust airflow reading between 50 to 200%
CFM TWEAK
100 %
Example: flow hood reads 550 CFM
Airflow reading on BFC is 500 cfm
Adjust CFM tweak to +110%
FAN TYPE
XXX
UNIT SIZE
2X2
Adjust fan type from Constant Volume to Constant Torque. Airflow (CFM) will be hidden if fan type is constant torque
Displays the ECM motor calibration for FFU nominal size (2x2)
Selectable sizes are: 2’ x 2’, 2’ x 3’, 2’ x 4’
NOTE: Must match actual configuration of FFU.
Adjust unit wheel type from FC to BC. Read only varying on fan type and unit size
WHEEL TYPE
XXX
The wheel type is factory set, but it can be adjusted only under the Constant Torque setting. From there, you can set the
wheel type to BC on 2’ x 3’ and 2’ x 4’ units only.
NOTE: BC wheel type is for Constant Torque only.
VOLTAGE TYPE
XXX
MOTOR RUNTIME
0 HRS
RESET MOTOR
RUNTIME
Adjust unit voltage type from 115/240/277.
Read Only – Displays number of hours on motor since last reset
Resets Motor Runtime
PRESS MENU
TO EXIT
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BACNet Flow Controller
DISPLAY NAVIGATION
Service Menu – Filter
Press Menu button to enter this menu. Use Up and Down arrow buttons to navigate through.
FILTER LOAD
XX %
Read Only - Displays % of filter loading based on new, clean filter pressure drop
Adjust filer load trip point
LOAD TRIP
1.50
Example: Filter loading trip point at 1.50 inH2O
Filter calibrated pressure: 0.16 inH2O
Filter load will trip at .24 inH2O
CURRPRESSURE
0 IN H2O
FILTER TYPE
XXX
FILTER RUNTIME
0 HRS
RESET
FILTER
Read Only – Displays the current differential pressure measured across the filter
Adjust filter type, BTR, RSR.
BTR = Bench Top Removable RSR = Room Side Removable
Read Only – Displays number of hours on filter since last reset
Resets Filter Runtime
PRESS MENU
TO EXIT
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BACNet Flow Controller
DISPLAY NAVIGATION
Service Menu – I/O
Press Menu button to enter this menu. Use Up and Down arrow buttons to navigate through.
BAS (AI1)
0 VDC
AI2
0 VDC
Read Only – Displays current input BAS voltage for motor speed control
Read Only – Displays input voltage to Analog Input 2
Configure Analog Output 1 for:
Unit Press - Unit Pressure; Range (0"-2" of H2O)
AO1 USAGE
CFM
CFM - Airflow; Range (0 - 5000 CFM)
RPM - Range (0 - 2500 RPM). See page 11 for RPM details.
Filter Life - Range (0 - 100%)
BAS - 0-10VDC signal to BAS
Disabled
AO1 PRESVAL
0 VDC
Read Only - Present Value for Analog Output 1
Configure Analog Output 2 for:
Unit Press - Unit Pressure; Range (0”-2” of H2O)
AO2 USAGE
CFM
CFM - Airflow; Range (0 - 5000 CFM)
RPM - Range (0 - 2500 RPM). See page 11 for RPM details.
Filter Life - Range (0 - 100%)
BAS - 0-10VDC signal to BAS
Disabled
AO2 PRESVAL
0 VDC
Read Only - Present Value for Analog Output 2
PRESS MENU
TO EXIT
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BACNet Flow Controller
DISPLAY NAVIGATION
Service Menu – BACnet
MAC ADDRESS
1
DEVICE INST
0, 000, 101
Sets unit’s MAC address
NOTE: the MAC address (range 1-99) is added to the device instance.
Example: MAC address = 1, device instance = 100, total address for this BFC would be 101
This is the ‘software’ BACnet address and must be unique to your building site.
Range: 1 – 4,194,303
BAUD RATE
This sets the BACnet MS/TP baud rate
BAUD RATE
76800
9600 baud (all BACnet devices must at least support this speed) – slowest
19200 baud
38400 baud
76800 baud (default baud rate for Price products) - fastest
RS-485 TERM,
DISABLED
Enable and disable RS-485 termination on MS/TP segment.
PRESS MENU
TO EXIT
Service Menu – Diagnostics
RESTORE
DEFAULTS
This allows a full controller reset, and will revert all user changes back to Price defaults
PRESS MENU
TO EXIT
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BACNet Flow Controller
NETWORKING & SETUP
Network Wire Specifications
For the BACnet MS/TP network
specific wire is required. Do not use
standard power or “thermostat” wire.
This wire does not have the necessary
requirements for digital communications.
While it’s possible it may work
(temporarily) the network will be
unreliable and not operating at optimal.
BACnet MS/TP Wire type
recommendations
•
Use 1 balanced twisted pair
•
Low capacitance (17pF or less)
•
Plenum rated (FT6, CMP ratings)
•
100-120 ohm, Balanced
•
(CAT5, CAT5E, CAT6 network cable
has excellent specifications and will
work in almost any BACnet MS/TP
application.)
•
Price recommends using the
Orange (B/-) and Orange
compliment (A/+) and Brown (NET
COM) and Brown Compliment (NET
COM) wire pair from a standard
CAT5 cable. Also pre-terminated
CAT5 cables are available from
Price. Model code: NETc35 (35 ft
plenum rated cable, terminated with
RJ45 plugs, 568-B standard)
WIRING
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
WIRING DETAIL
CONNECT AS SHOWN:
- ¨ B/- (ORANGE)
+ ¨ A/+ (ORANGE/WHITE)
SC ¨ NETCOM (BROWNS)
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BACNet Flow Controller
NETWORKING & SETUP
Network Layout
The BFC can be connected over BACnet MS/TP and added to an existing BAS front end system. Price also offers its own mini
front-end system known as FFU-HE-BFC-FE which acts as a graphics package. The Price WEB Server allows the user to view
variables such as filter status, CFM, etc. for each FFU and modify setpoints as needed.
Devices
Webserver: Provides the graphical web interface, plugs into IP Router. 2000 node capacity.
IP Router: Acts as interface between Internet and internal system. 5 ports. 1 Port for Building WAN (Internet/Building Network –
You cannot plug a BACnet Router or IP Switch into this port). 4 LAN Ports available (Used for BACnet Routers and IP Switches).
BACnet Router: Interfaces between BACnet MS/TP system and IP Router (internet). Supports 30 FFU-HE.
IP Switch: Expands available connections for BACnet router. 5 ports.
CONNECTION EXAMPLE (LESS THAN 30 UNITS) FFU 1
FFU 1
FFU 2
CFM - 312
FIlter Hours - 1280
Filter Status - Clean
CFM - 310
FIlter Hours - 1125
Filter Status - Clean
FFU 3
FFU 4
CFM - 312
FIlter Hours - 1225
Filter Status - Replace
CFM - 310
FIlter Hours - 1300
Filter Status - Clean
FFU 3
ANTEROOM
FFU 5
FFU 6
FFU 7
CFM - 312
FIlter Hours - 1430
Filter Status - Clean
CFM - 315
FIlter Hours - 1400
Filter Status - Replace
CFM - 312
FIlter Hours - 1350
Filter Status - Clean
FFU 30
Webserver Interface
10
FFU 2
BACnet MS/TP to
BACnet IP Router
BACNet Flow Controller - Manual | priceindustries.com
FFU 4
BACNet Flow Controller
NETWORKING & SETUP
CONNECTION EXAMPLE (GREATER THAN 30 UNITS) IP Router
WIRING
Power
Ethernet Network
MS/TP Network
Network
Connection
IP switches or BACnet routers
Webserver
IP Switch
IP Router
BACnet
Router
BACnet
Router
BACnet
Router
IP Switch
IP Switch
BACnet
Router
BACnet
Router
BACnet
Router
BACnet
Router
BACnet
Router
BACnet
Router
BACnet
Router
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
FFU-HE
- Up to 30 FFUs on each BACnet router.
- Up to 30 FFUs on each BACnet router.
- When no more IP Switches are required to add
more FFU-HE‘s, up to 4 BACnet Routers can be
connected to the final siwtch.
- Up to 30 FFUs on each BACnet router.
Example Systems
Max # of Units
BACNET WIRING
B/A/+
NETCOM
30
60
90
120
150
180
210
240
270
300
330
QTY of BACnet
QTY of IP Switches QTY of IP Router
Routers
1
0
1
2
0
1
3
0
1
4
1
1
5
1
1
6
1
1
7
2
1
8
2
1
9
2
1
10
3
1
11
3
1
Assumes two ports on IP router are filled with BACnet routers (i.e. 60 FFU-HE’s total).
More units are supported, contact Critical Environments applications team for more
information.
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BACNet Flow Controller
NETWORKING & SETUP
BAS Input Signal
The BAS input signal overrides the local setpoint using a remote 0 – 10VDC signal. If the BAS signal drops below 1VDC local
control (via the push buttons) is restored.
BAS Voltage
Response
Notes
0-1 VDC
Local control mode using push buttons
1-2 VDC
Motor Off
2-9 VDC
Modulating Control
2 – 9 VDC modulates motor from 0 – 100%
9-10 VDC
Maximum Speed
Motor is running at maximum speed (100%)
Local setpoint can be adjusted from 0 – 100% using push buttons
Recommend sending a 1.5 VDC signal to command motor off
BAS equations exist in each fan powered terminal product service and installation manual to relate CFM to volts DC. The VDC in
the equations however are for the 1-5 volt scale of voltage measured across the manual mode POT taps. The BAS input voltage is
a 2-10 VDC scale, and therefore VDC calculated for a given CFM using the equation must be doubled to achieve that cfm using
the BAS input. See standard speed controller BAS section for an example of calculating the voltage required for a specific CFM.
If the BFC will be connected to BACnet, the BACnet motor speed setpoint will override both the BAS analog input, and the local
setpoint for motor speed control.
Motor speed setpoint priorities are:
1. BACnet
2. BAS analog signal
3. Local setpoint adjust
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BACNet Flow Controller
NETWORKING & SETUP
Analog RPM Feedback
A two wire connection supplies an analog (0-10 VDC) signal that is directly proportional to the MOTOR 1 RPM. The range is 0 –
2500 RPM and it will output a proportional 0 – 10 VDC signal. If a dual blower system is used, only the RPM of motor 1 can be
read.
NOTE: The minimum speed of an ECM is approximately 250 RPM. Formula for outputs below (tolerance +/- 5%):
•
VDC output = (RPM /250)
•
Rpm = (VDC * 250)
Output signal: 0 – 10 VDC @ 20 k ohm minimum input impedance and is short circuit protected (output impedance is 511 ohm to
protect against incorrect wiring).
•
Black Wire – Analog RPM output com (-)
•
White Wire – Analog RPM output signal (+)
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BACNet Flow Controller
NETWORKING & SETUP
Wiring and Cables
*For In depth ECM motor troubleshooting, please refer to ECM Troubleshooting Manual on Price Industries’ website.
The ECM speed controller requires 24 VAC power from a transformer and outputs control signals to the ECM motor on dual MTA100 jacks. Either jack or both jacks can be used (for dual fan systems).
The control cable (with RED connector) must be plugged into the circuit board correctly. (See Figure 2)
FIGURE 2 - ECM STANDARD SPEED CONTROLLER WITH CONTROL CABLE PLUGGED INTO MTR1 MTR1 JACK
ECM CONTROL CABLE (NOTE: ORIENTATION)
NOTE: Make sure that this cable is connected properly. It is keyed one way, and make sure all of the pins are covered.
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BACNet Flow Controller
MAINTENANCE
Troubleshooting
Fault
Solution
Binary Outputs not functioning
The Binary outputs send out 24VAC and are factory wired to the LED on the FFU-HE. Make sure the BFC
has 24VAC power, and then check voltage at binary outputs and COM terminals if the LED does not light up.
Analog Outputs not functioning
The Analog outputs send out 0-10VDC. Make sure the BFC has 24VAC power, and then check voltage at
the suspect analog output with a multimeter. You should see a voltage range of 0-10VDC.
BACnet Communication Errors
Option #1
BACnet - MS/TP is based on a RS-485 network. It must be wired in a daisy chain configuration. A daisy
chain means that there is only one main cable, and every network device is connected directly along its path.
DO NOT use Star, Bus, “T”, or any other type of network configuration. Any of these other network
configurations will result in an unreliable network, and make troubleshooting almost impossible.
Correct polarity is imperative on MSTP wiring. Always ensure that the positive terminal on a device has
the same color wire connected to it throughout the network, same for the negative terminal.Eg. 2 wire
conductor with black and white wires – black to the positive terminal, and white to the negative terminal.
Keep this consistency throughout the network.
Option #2
Price does not use EOL or termination on their devices. Terminating a device is almost never required
at the low baud rate of MS/TP devices. In fact terminating can create more problems than it solves.
The network speed or baud rate must be the same throughout the network.
NOTE: The default speed for Price BACnet MS/TP controls is 76800. BACnet MS/TP currently supports
4 standard speeds which are: 9600, 19200, 38400 and 76800.
Option #3
Binary Address must be unique for each device on the network. No two devices can have the same
Address. This includes if you are incorporating a Price product into an existing network. Determine
the existing Addressing scheme for the existing network. The Address is set on the Addressable dip
switches on the UMCB.
Option #4
Grounding and 24VAC polarity: Proper grounding is absolutely essential when wiring the MS/TP
BACnet Network. Proper grounding will prevent many potential problems that can occur in a network
of devices. Common symptoms of a poorly grounded network can include inconsistent BACnet MS/
TP communications and damage from voltage spikes. The most practical method of grounding is to
ground every 24VAC transformer common/neutral used to power the controls.
Connect the “common/neutral” wire of the SECONDARY side of the transformer to earth ground –
such as the ground screw on in the electrical box.
Option #5
NOTE: Flipping 24VAC HOT and COMMON will cause the BACnet MS/TP Network to stop
communicating!!! Ensure HOT and COMMON are not reversed on ANY controllers.
WARNING: Controllers will still power up and run even if HOT and COMMON are reversed. However
output signals to other devices such as heaters, relays, etc will not work as intended!
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BACNet Flow Controller
MAINTENANCE
Specifications
Power:
Pluggable 24 VAC, 50/60 Hz, 50 VA Class 2
Input Power:
24 VAC, 50/60 Hz, 5 VA (plus external loads), Class 2
Environmental (operating):
10°C to 50°C (50°F to 122°F), 0% to 95% RH (non-condensing)
Environmental (storage):
-30°C to 50°C (50°F to 122°F), 0% to 95% RH (non-condensing)
1 Thermistor Input (10K Ohm, Type J)
Inputs:
2 Analog Inputs: 0-10 VDC
1 Contact Closure Input
3 Binary Outputs (24 VAC) for LEDs
Outputs:
2 Analog Outputs (10 mA maximum, 0-10 VDC)
2 ECM motor connections
Networking:
BACnet (MS/TP)
Indicators:
BACnet RX/TX and Fault lights
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BACNet Flow Controller
MAINTENANCE
BACnet points list for BFC firmware v1.10
Object
Name
Units
Default
Range
Description
R/W
AO1
Analog Output 1
Volts DC
N/A
0-10VDC
Configurable for Unit Pressure, CFM,
RPM, Filter Load and BAS
R/W
AO2
Analog Output 2
Volts DC
N/A
0-10VDC
Configurable for Unit Pressure, CFM,
RPM, Filter Load and BAS
R/W
AO3
ECM Setpoint
%
50
0-100
Set ECM motor setpoint
R/W
AI1
Analog Input 1 (BAS)
Volts DC
Dynamic
Dynamic
Analog Output can be tied to several signals.
See O&M manual for detail. I/O Menu
R
AI2
Analog Input 2
Volts DC
Dynamic
Dynamic
Analog Output can be tied to several signals.
See O&M manual for detail. I/O Menu
R
AI3
Thermistor
°F°/°C
Dynamic
(-59)-300
Current air temperature over filter
R
AI4
ECM Speed
r/min
Dynamic
0-2500
Current RPM of motor
R
AI5
Unit Pressure
inH20
Dynamic
Dynamic
Current differential pressure measured across the filter
R
BI1
Contact Closure
Contacts
Open/
Closed
Dynamic
Contacts
Open/
Closed
Binary Input can be tied to several signals.
See O&M manual for detail. Input Menu
R
AV1
Filter Load
%
0
0-100%
Current percent of filter loading based
on new, clean filter pressure drop
R
AV2
Filter Runtime
Hours
N/A
0-99999
Current number of hours on filter since last reset. Enter
value of zero after filter has been replaced to calibrate
R/W
AV3
Motor Runtime
Hours
N/A
0-99999
Current number of hours on motor since last reset
R
AV4
Airflow
CFM
N/A
0-9999
Current airflow
R
AV5
Filter Calibrated Pressure
inH2O
N/A
Dynamic
Unit pressure when filter was calibrated
R
AV6
Filter Trip Pressure
inH2O
0
Dynamic
Filter trip pressure
R
AV7
Filter Loading Trip Point
Numeric
1.5
1-3
Set filter loading trip point
R/W
MV1
Unit Status
Text
Dynamic
4 States
1 - Off 2 - Normal 3 - No RPM Signal 4 - Overspeed
R
MV2
Control Mode
Text
Dynamic
3 States
1 - BACnet 2 - BAS 3 - Local
R
MV3
Unit Fan Type
Text
Dynamic
2 States
1 - Constant Torque 2 - Constant Volume
R
MV4
Unit Size
Text
Dynamic
3 States
1 - 2x2 2 - 2x3 3 - 2x4
R
MV5
Unit Filter Type
Text
Dynamic
2 States
1 - BTR 2 - RSR
R
MV6
Unit Wheel Type
Text
Dynamic
2 States
1 - FC 2 - BC
R
MV7
Unit Voltage Type
Text
Dynamic
3 States
1 - 115 2 - 240 3 - 277
R
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© 2017 Price Industries Limited. All rights reserved.
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