User Manual - Cristal Controls

User Manual - Cristal Controls
CCE-32 1.01.3
Image may differ from the actual product
2012-11-19
By Martin Labbé, eng.,
Jasmin Goupil & Louis Perreault
Cristal Contrôles Ltd
2025 Lavoisier, Local 135
Québec, (Québec) Canada G1N 4L6
Tél 418-681-9590 Fax 418-681-7393
http://www.cristalcontrols.com
Index
1.
General description ........................................................................................ 5
2.
Applications ................................................................................................... 5
3.
Installation...................................................................................................... 5
4.
Connections ................................................................................................... 6
CAUTION: ELECTRICAL HASARD ............................................................... 6
4.1. Terminal description................................................................................. 8
5.
Inputs ............................................................................................................. 9
5.1. 0-10 VDC ................................................................................................. 9
5.2. 4-20 mA ................................................................................................... 9
5.3. Resistive .................................................................................................. 9
5.4. Temperature ............................................................................................ 9
6.
CCE-32 Outputs .......................................................................................... 10
6.1. 8x Relays ............................................................................................... 10
6.2. Modulated .............................................................................................. 10
7.
Configuration ............................................................................................... 11
7.1. Activation times ...................................................................................... 11
7.2. Number of steps .................................................................................... 12
7.3. Fan or circulating pump ......................................................................... 12
7.4. Fan or circulating pump activation time.................................................. 12
7.5. Modulating step ..................................................................................... 13
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7.6. PWM time base ..................................................................................... 13
7.7. Inversion ................................................................................................ 14
7.8. Proportional Integral control (PI) ............................................................ 14
7.9. Control Mode ......................................................................................... 14
FIFO Mode................................................................................................... 14
LIFO Mode ................................................................................................... 16
Binary Mode................................................................................................. 17
Manual mode ............................................................................................... 17
7.10.
MSTP BACnet Network Address ........................................................ 18
7.11.
MSTP BACnet Network speed ........................................................... 18
7.12.
BACnet Read Property Multiple .......................................................... 19
7.13.
Resistive input .................................................................................... 20
8.
Communication ............................................................................................ 20
8.1. Network characteristics .......................................................................... 20
8.2. Network Objects .................................................................................... 21
9.
Status .......................................................................................................... 23
10.
Software Algorithm .................................................................................... 23
10.1.
Proportional–Integral control............................................................... 23
11.
Dimensions ............................................................................................... 24
12.
Hardware specifications ............................................................................ 25
12.1.
Outputs ............................................................................................... 25
12.2.
Inputs .................................................................................................. 25
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12.3.
Jumpers .............................................................................................. 25
12.4.
Switches ............................................................................................. 25
13.
Switches listing.......................................................................................... 26
Charts List
Chart 1 – SW1 1-6 .............................................................................................. 11
Chart 2 – SW2 1-5 .............................................................................................. 12
Chart 3 – SW1 7-8 .............................................................................................. 13
Chart 4 – SW3 3-4 .............................................................................................. 13
Chart 5 – SW4 1-2 .............................................................................................. 14
Chart 6 – Example FIFO 1 .................................................................................. 15
Chart 7 – Example FIFO 2 .................................................................................. 15
Chart 8 – Example FIFO 3 .................................................................................. 15
Chart 9 – Example LIFO 1 .................................................................................. 16
Chart 10 – Example LIFO 2 ................................................................................ 16
Chart 11 – Example LIFO 3 ................................................................................ 16
Chart 12 – Example Binary Mode ....................................................................... 17
Chart 13 – SW4 3-4 ............................................................................................ 18
Chart 14 – SW4 5-7 ............................................................................................ 19
Chart 15 – BACnet Objects ................................................................................. 22
Chart 16 – Status ................................................................................................ 23
Chart 17 – Switches Listing ................................................................................ 27
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1. General description
Cristal Control CCE-32 step controller is a basic 1 x Analog output + 8 ON-OFF
steps controller. Up to 4 CCE-32 can be stack for a total of 1 x Analog output and
32 ON-OFF steps using the BACnet protocol between the 4 CCE-32. The first
CCE 32 is a master the other 3 (slave) only offers ON-OFF relays outputs.
The CCE-32 offers 8 ON-OFF relay outputs with one which can be configured for
a fan or circulating pump. The analog output can drive upon configuration either
an SSR or a SCR. 3 inputs are available (0-10 VDC, 4-20 mA, resistive 0-20K
Ohms or 0-135 Ohms).
2. Applications
The Cristal Control CCE-32 is design to control multiples outputs base on the
inputs value. The following mode are supported FIFO (First In First Out, LIFO
(Last In Last Out) or binary mode is also supported. In addition, a power integrator
can be applied to the calculation steps. The CCE-32 offers manual control on all
steps using the onboard buttons.
3. Installation
The Cristal Control CCE-32 uses a 35 mm (1.4’’) Din-rail enclosure to facilitate
the installation.
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4. Connections
All connections on the CCE-32 are screw type terminals.
7
24Vac
…
AC
AC
AC
Install
jumper to
feed 24L on
relay
Heater
Heater
Heater
AC
Heater
Figure 1 - Connections with jumper (24L from board)
CAUTION: ELECTRICAL HASARD
It Is recommended to shut power off before proceeding to inputs
and load connections.
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7
…
24Vac
Remove
jumper to
get a dry
contact relay
Heater
AC
AC
Heater
Heater
AC
AC
Heater
Figure 2 - Connections witout jumper (Dry contact)
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4.1.
Terminal description
Output 1-8 On-Off contacts for steps.
FAN
Contact for fan or circulating pump.
Modulated Analog Output.
Ω
0-20K Ohms or polarize 0-135 Ohms Input.
4-20mA
4-20 mA input.
Temp. 10k
Temperature sensor input (reserved).
0-10V
0-10 Volt input.
A(+)
RS-485 positive connection.
B(-)
RS-485 negative connection.
24L+
Positive power supply.
24N-
Negative power supply.
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5. Inputs
The CCE-32 controller has 3 inputs. The controller reads the input signal and
converts it in a percentage to select the number of steps needed to be activated.
A 2% hysteresis cycle is applied to the algorithm to avoid relay cycling.
Internally connected to 24N
Figure 3 - Inputs
5.1.
0-10 VDC
0-10 Vdc input, uninsulated with a 30K Ω impedance
5.2.
4-20 mA
4-20mA input uninsulated.
5.3.
Resistive
0-20K Ohms input or 0-135 Ohms uninsulated.
5.4.
Temperature
The temperature input is reserved for advanced configurations when integrating
with a BACnet building management server.
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6. CCE-32 Outputs
7
Figure 4 - Outputs
6.1.
8x Relays
The CCE-32 outputs relays are latching type low power 24 Volts @ 1A. The 2
buttons above the relays allows manual override of the output. To avoid relay
changes from the internal software, we must also enable the manual mode from
the configuration dip switches. See « 7.9 Control Mode » to configure manual
mode.
6.2.
Modulated
The CCE-32 has a modulation output which can drive an SSR or a SCR. The
selection is done using the configuration buttons. When using an SCR the
voltage output range from 0 to 10 Volts. When using an SSR the voltage output is
0 or 10 Volts.
The analog output is protected against polarity inversion using a 140 mA auto
reset fuse. To reset the auto fuse feature disconnect the 24 Vac power supply for
1 second.
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7. Configuration
The CCE-32 is manually configurable using 4 x 8 buttons switches. When more
than one CCE-32 are connected together, the following settings shall be done
from the Master CCE-32
Cristal Control offers an online configuration tool at: www.cristalcontrols.com
under « Products/ step controller ». This configuration tool will easy guide you in
the CCE-32 settings; you will see exact switch positions to reproduce on your
step controller.
7.1.
Activation times
The activation time between stages can be set using SW1 pos. 1 to 6. The
configuration uses a binary mode with a 1 second delay. The activation time can
also be set from 0-63 seconds using the following formula:
5
4
3
0
Activation Delay = position 6 * (2 ) + position 5 * (2 ) + position 4 * (2 ) + position 1 * (2 )
Activation times examples:
SW Positions
1
2
3
4
5
6
Activation Times
ON
OFF
ON
OFF
OFF
OFF
5 seconds
OFF
ON
OFF
ON
OFF
OFF
10 seconds
OFF
ON
ON
ON
ON
OFF
30 seconds
OFF
OFF
ON
ON
ON
ON
1 minute
Chart 1 – SW1 1-6
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7.2.
Number of steps
On SW2 pos. 1 to 5 let you set the number of stages to be controlled, the setting
use a binary mode. 1 to 32 steps are available using the following formula:
4
3
2
0
Number of steps = (position 5 * (2 ) + position 4 * (2 ) + position 3 * (2 ) +… position 1 * (2 )) +1
Setting examples:
SW Positions
1
2
3
4
5
Steps number
OFF
OFF
OFF
OFF
OFF
1
ON
ON
ON
OFF
OFF
8
ON
ON
ON
ON
ON
32
Chart 2 – SW2 1-5
7.3.
Fan or circulating pump
SW2 pos. 6 allows the configuration of a relay for a fan or a circulating pump.
When « ON » the fan / circulating pump relay is used. This relay is always the
first one on the master controller. It is turned ON when one of the steps is
activated and stays activated until the last step is turned off and activation time
elapsed.
7.4.
Fan or circulating pump activation time
SW1 pos. 7 and 8 configure the time the fan / circulating pump is maintained ON
after every steps is turned OFF. Time settings are 10 seconds, 30 seconds, 2
minutes or 5 minutes.
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SW2 Position
SW1 Positions
6
7
8
Delay
ON
OFF
OFF
10 seconds
ON
ON
OFF
30 seconds
ON
OFF
ON
2 minutes
ON
ON
ON
5 minutes
OFF
X
X
Not used
Chart 3 – SW1 7-8
7.5.
Modulating step
On SW2, pos. 7, sets the Modulating step mode. OFF: 0-10V mode is activated
for the use with an SCR. ON: PWM mode is activated for the use with an SSR.
7.6.
PWM time base
On SW3, pos. 3 and 4 are for the PWM time base, 4 pre set time are available.
Positions
3
4
Time base
OFF
OFF
3 seconds
ON
OFF
1 minute
OFF
ON
5 minutes
ON
ON
10 minutes
Chart 4 – SW3 3-4
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7.7.
Inversion
On SW3, pos. 1, ON invert the control signals. Example: a 0 volt input signal will
enable 100% of the outputs and 10 volts input signal with disable every outputs
(0%).
7.8.
Proportional Integral control (PI)
On SW3 pos. 2, ON activate the PI Mode. For detailed explanation see section
« 10.1 Proportional–Integral ».
7.9.
Control Mode
On SW4, pos. 1 and 2 are for the control modes selection (4 available). The
CCE-32 offers the following modes: FIFO, LIFO, BINARY and MANUAL.
SW Position
1
2
Mode
OFF
OFF
Manual
ON
OFF
Fifo
OFF
ON
Lifo
ON
ON
Binary
Chart 5 – SW4 1-2
FIFO Mode
With this mode the first step to go ON will also be the first to go OFF
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As an example for a 4 steps system:
-
An input signal rises to 50%; step 1 will go ON first and 2 next.
Relays
1
2
3
4
ON
ON
OFF
OFF
Chart 6 – Example FIFO 1
-
When input signal falls to 0% then step 1 will go OFF and 2 next.
Relays
1
2
3
4
OFF
OFF
OFF
OFF
Chart 7 – Example FIFO 2
-
Finally, when input signal increase again, the next step to go ON will be
number 3.
Relays
1
OFF
2
OFF
3
ON
4
OFF
Chart 8 – Example FIFO 3
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LIFO Mode
On the LIFO mode the last step that goes ON Is the first to go OFF. So the first
step to be ON is the last to be OFF.
Example on a 4 steps controller:
-
With an input signal rising to 50%, step 1 will go ON and then step 2.
Relays
1
2
3
4
ON
ON
OFF
OFF
Chart 9 – Example LIFO 1
-
With an input signal falling to 0%, the step 2 will go OFF and then step 1 next.
Relays
1
2
3
4
OFF
OFF
OFF
OFF
Chart 10 – Example LIFO 2
-
Then when the input signal rises, the next step to be ON will be the first one.
Relays
1
2
3
4
ON
OFF
OFF
OFF
Chart 11 – Example LIFO 3
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Binary Mode
With this mode all steps are binary controlled. The steps state is related to the
activated steps. Binary mode is useful when each relay load is twice the capacity
than the previous one.
Example :
4
3
2
1
(800
(400
(200
(100
Watts)
Watts)
Watts)
Watts)
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
Set to OFF
Set to ON
Relays
Chart 12 – Example Binary Mode
Manual mode
This mode disables software commands to the relays to allow manual operation
of all steps using the on board buttons.
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7.10.
MSTP BACnet Network Address
To allow the master controller communication of relay states to the slaves, we
must configure an address and tie a network between the controllers.
On SW3, pos. 3 and 4 configure the MSTP network address.
Positions
3
4
Information
Relays
OFF
OFF
Master
1-8
ON
OFF
Slave 1
9-16
OFF
ON
Slave 2
17-24
ON
ON
Slave 3
25-32
Chart 13 – SW4 3-4
When the controller is accessed from BACnet tools, the DIP switches affect
BACnet properties « Device Name », « Device Identifier » and « MSTP MAC »
address.
The DIP switches configure controllers on a consecutive address
range.
7.11.
MSTP BACnet Network speed
The default network speed is 38400 baud.
This speed can be changed for
BACnet integration of the step controller with a building management server.
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On (SW4) switches 5, 6, 7 are used to change the default factory setting. The
following chart shows the procedure.
Positions
5
6
7
Baudrate
OFF
OFF
OFF
9600
ON
OFF
OFF
19200
OFF
ON
OFF
38400
ON
ON
OFF
57600
OFF
OFF
ON
76800
ON
OFF
ON
115200
OFF
ON
ON
230400
ON
ON
ON
38400
(Default
setting)
Chart 14 – SW4 5-7
7.12.
BACnet Read Property Multiple
On SW4 pos 8 identify if the BACnet service “Read Property Multiple” is used. At
ON position the service is in use by the CCE-32. This function may be used when
integrating the CCE-32 with a building management server and is generally
enabled.
Note: The step controller is not using this feature for communication between the
master and its slaves.
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7.13.
Resistive input
The resistive control input is set using a jumper on (JPM1). The available settings
are 20K Ohms (with the jumper on the left side) or 135 Ohms (with the jumper on
the right side)
It is important to place the jumper on one of the 2 positions even when another
type of control input is use.
8. Communication
The communication between CCE-32 master and slaves is based on BACnet
MSTP protocol on a RS 485 network. This network is also use to control inputs
values.
8.1.
Network characteristics
When the CCE-32 controller is at one end of a RS-485 network, we must enable
the 120-Ω terminating resistor by installing JP2 to end the network.
For more information, refer to the Cristal Controls manual “Setting up a RS-485
Network”.
Next is the BACnet objects list. This list is simple and many objects allow direct
control on inputs and outputs of the controller. Communication with these objects
allows integration of the CCE-32 controller with a building management server.
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8.2.
Network Objects
The CCE-32 has different type of Bacnet objects. (They are listed in the next
chart)
Object
Description
Value
Value Type
0-100%
Percentage
0-100%
Percentage
0-100%
Percentage
Default Value
Represents the input value
IN 0-10V
Object Type
0
Analog Input
0-10 V
Represents the input value
IN 4-20mA
0
Analog Input
4-20 mA
Represents the input value
IN OHMS
0
Analog Input
resistive
IN
Represents the input value
degree
in temperature
Celsius
TEMPERATU
RE
CURRENTINPUT
MODULATE
Input value used by the control
sequence
0-100%
0
degree Celsius
0
Percentage
Value of the modulated output
0-100%
Percentage
RELAY 1
Relay 1
ON or OFF
Boolean
RELAY 2
Relay 2
ON or OFF
Boolean
RELAY 3
Relay 3
ON or OFF
Boolean
RELAY 4
Relay 4
ON or OFF
Boolean
D
Analog Input
Value determined by the
controller
State relay according to
the controller
State relay according to
the controller
State relay according to
the controller
State relay according to
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the controller
Analog Value
Analog Value
Binary Output
Binary Output
Binary Output
Binary Output
2012-11-19
21
RELAY 5
Relay 5
ON or OFF
Boolean
RELAY 6
Relay 6
ON or OFF
Boolean
RELAY 7
Relay 7
ON or OFF
Boolean
RELAY 8
Relay 8
ON or OFF
Boolean
SET-POINT
Temperature setpoint
Degree C
Degree C
State relay according to
the controller
State relay according to
the controller
State relay according to
the controller
State relay according to
PERCENT
PER
the controller
21
Binary Output
Binary Output
Binary Output
Binary Output
Analog Value
10
Weight percentage of a degree
Celsius.
0-100%
Percentage
Analog Value
Minimum temperature set point
Degree C
Degree C
Maximum temperature set point
Degree C
Degree C
-
-
-
BACnet File
-
-
-
Device
DEGREE
SET-POINTMIN
SET-POINTMAX
FILE 0
CCE-32
Controller configuration steps
CCE-32 Information
15
25
Analog Value
Analog Value
Chart 15 – BACnet Objects
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9. Status
A LED indicates the status of the CCE-32controller
Description
Master
Slaves
Blinking rates
Shows normal working mode.
Shows normal working mode
Shows
Shows
the
master
cannot
the
slave
did
1 Hz
not
communicate relay commands
received relay commands from
to its slaves.
its master CCE-32.
10 Hz
Chart 16 – Status
10. Software Algorithm
The CCE-32 controller does auto detection of the analog input in service. The
input with the highest signal is selected the control algorithm. The number of
steps is calculated in function of the percentage of the input signal.
If the fan / circulating pump output is enabled, this output goes ON at the same
time than the first stage. This output stays ON while any step is active and turns
OFF after all fixed and modulated steps are fully OFF and the configured delay
elapsed.
10.1.
Proportional–Integral control
The CCE-32 proportional–integral controller (PI controller) is a generic control
loop feedback mechanism (controller) widely used in industrial control systems –
a PI is the most commonly used feedback controller. A PID controller calculates
an "error" value as the difference between a measured process variable and a
desired setpoint. The controller attempts to minimize the error by adjusting the
process control inputs
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3.8"
96.52 mm
11. Dimensions
7
6.4"
162.56mm
Figure 5 - CCE-32 Dimensions
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12. Hardware specifications

Microcontroller : Freescale MCF51QE128

Communication : RS-485 / BACnet MSTP.

Supply Voltage : 18 – 28 Vac « Half Wave »

Supply Current : 40 mA typical, 50 mA max

Operating temperature : 10ºC à 45ºC (50ºF à 113ºF)

Storage temperature : -30ºC à 80ºC (-22ºF à 176ºF)
12.1.
Outputs

8x Dry Contact: 1A @ 24Vac / 30Vdc

1x Analog 0-10Vdc protected @ 5mA
12.2.
Inputs

1x Analog 0-10 Vdc with a 30k Ω impedance

1x Resistive Analog, 0-20K Ω or 0-135 Ω

1x Analog 4-20 mA

1x Thermistor NTC 10 KΩ (10°C to 60°C)
12.3.
Jumpers

JMP1 : Resistive input type selection

JP2 : Termination RS-485 of 120Ω.
12.4.

Switches
4x Modules DIP of 8 positions each.
Cristal Contrôles Ltd
2025 Lavoisier, Local 135
Québec, (Québec) Canada G1N 4L6
Tél 418-681-9590 Fax 418-681-7393
http://www.cristalcontrols.com
2012-11-19
25
Switch #2
SWITC #1
13. Switches listing
Position
Description
1
Activation delay
2
Activation delay
3
Activation delay
4
Activation delay
5
Activation delay
6
Activation delay
7
Motor activation time
8
Motor activation time
1
Stages numbers
2
Stages numbers
3
Stages numbers
4
Stages numbers
5
Stages numbers
6
Motor Step
7
Modulating step
8
Cristal Contrôles Ltd
2025 Lavoisier, Local 135
Québec, (Québec) Canada G1N 4L6
Tél 418-681-9590 Fax 418-681-7393
http://www.cristalcontrols.com
2012-11-19
26
Switch #3
1
Inversion
2
Proportional Integral Control
3
PWB Base Time
4
PWB Base Time
5
6
7
Switch #4
8
1
Control Mode
2
Control Mode
3
Bacnet MSTP Network address
4
Bacnet MSTP Network address
5
BACnet MSTP Network Speed
6
BACnet MSTP Network Speed
7
BACnet MSTP Network Speed
8
BACnet Read Property Multiple
Chart 17 – Switches Listing
Cristal Contrôles Ltd
2025 Lavoisier, Local 135
Québec, (Québec) Canada G1N 4L6
Tél 418-681-9590 Fax 418-681-7393
http://www.cristalcontrols.com
2012-11-19
27
Legal Disclaimer
Any representation or reproduction, in whole or in part, made without the permission of Cristal
Controls Ltd, is unlawful. Such unlawful representation or reproduction, made by any means,
would be an infringement of copyright punished under the provisions of the copyright law. All
products are registered trademarks of their respective companies.
This product uses portions of code source from the project « BACnet Stack at SourceForge ».
The original source code can be provided on demand or downloaded on the project’s web site at
the following address: http://bacnet.sourceforge.net.
© Cristal Controls Ltd - All Rights Reserved 1996 - 2012
Cristal Contrôles Ltd
2025 Lavoisier, Local 135
Québec, (Québec) Canada G1N 4L6
Tél 418-681-9590 Fax 418-681-7393
http://www.cristalcontrols.com
2012-11-19
28
2 YEAR LIMITED WARRANTY
CRISTAL CONTROLS warrants to the original user that its products will be free from
defects in materials and workmanship for a period of two years after the date CRISTAL
CONTROLS shipped such products.
If any of CRISTAL CONTROLS’ products is found to be defective in material or
workmanship during the applicable warranty period, CRISTAL CONTROLS' liability shall
be limited to the repair or replacement of the product, or the refund of the purchase
price, at CRISTAL CONTROLS’ discretion. CRISTAL CONTROLS shall not be held
liable for any costs or expenses, whether direct or indirect, associated with the
installation, removal or re-installation of any defective product.
CRISTAL CONTROLS’ limited warranty shall not be effective unless there is compliance
with all installation and operating instructions furnished by CRISTAL CONTROLS, if the
products have been modified or altered without the written consent of CRISTAL
CONTROLS, or if such products have been subject to accident, misuse, mishandling,
tampering, negligence, or improper maintenance. Any warranty claim must be submitted
to CRISTAL CONTROLS in written form within the stated warranty period.
CRISTAL CONTROLS’ limited warranty is made in lieu of, and CRISTAL CONTROLS
disclaims all other warranties, whether expressed or implied, including but not limited to
any implied warranty of the products.
CRISTAL CONTROLS shall not, under any circumstances, be liable for any direct,
indirect, accidental, special, or consequential damage (including but not limited to loss of
profits, revenues, or business opportunities) or damage or injury to persons or property
in any way related to the manufacture or the use of its products. The exclusion applies
regardless of whether such damages are sought based on breach of warranty, breach of
contract, negligence, strict liability in tort, or any other legal theory, even if CRISTAL
CONTROLS was noticed of the possibility of such damages.
By purchasing CRISTAL CONTROLS’ products, the purchaser agrees to the terms and
conditions of this limited warranty.
Cristal Contrôles Ltd
2025 Lavoisier, Local 135
Québec, (Québec) Canada G1N 4L6
Tél 418-681-9590 Fax 418-681-7393
http://www.cristalcontrols.com
2012-11-19
29
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