Chief Dispatcher Model JC-CDST

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1 Chief Dispatcher Model JC-CDST Modulating Control System Installation and Operation SDI-JC-CDST Revision 3 10/15/ Boiler Modulating Lead/Lag Controller with: Smart Boiler Sequencing Building Automation System Disable Boilers Base Load Auto-Shift Boiler Firing Rate based Start-Stop Header Pressure based Start-Stop Lead-Lag Sequence CONTENTS System Overview 2 Front Panel 7 Display Navigation 9 Soft Buttons And Editable Numbers 12 Boiler Operation 14 INTRODUCTION This manual is intended to describe the installation, operation and troubleshooting of a Chief Dispatcher Model JC-CDST. This manual is intended to be used by operators, plant engineers and service engineers. This manual is based on a 5 Steam Boiler application and will be useful for applications from 2 to 5 boilers. Historical Trending 20 Telephone Modem 22 Installation 25 Tuning Adjustments 33 Modbus Addressing 40 Troubleshooting 44 Preferred Instruments Danbury, CT USA

2 SYSTEM OVERVIEW CHIEF DISPATCHER MODEL JC-CDST 2-10 STEAM BOILERS Typical for Each Boiler 2

3 SYSTEM OVERVIEW The Chief Dispatcher Model JC-CDST will optimize steam system performance and help extend boiler life. FEATURES SMART BOILER SEQUENCING Boilers are automatically sequenced on/off to ensure that the number of boilers in service meets the pressure demand. If any boiler fails to start when called, or if a boiler trips during operation, the Chief Dispatcher immediately starts another boiler to replace the faulted boiler. The operator may manually select the lead boiler or allow the lead boiler to rotate automatically. Additionally, the total number of boilers in service may be set automatically or manually as selected by the operator or all boilers may be shutdown by a building automation system (BAS) Enable/Disable contact input. FIRING RATE OUPUT The Chief Dispatcher, Model JC-CDST2/5, is capable of outputing any combination of 135 ohm or 4-20mA outputs. Output cards are purchased seperately and can be installed in the field. No programming change is required to change output type or quantity. DAY NIGHT SETBACK Two adjustable setpoints are provided, with day night setback. User can enter the time of day and days of week to use the setback setpoint. BASE LOAD AUTO-SHIFT Normally the lag boilers remain base loaded for peak total plant efficiency. If the lead boiler firing rate approaches high fire, the lag boiler(s) will increase firing rate to help the lead boiler. If the lead boiler approaches low fire, the lag boilers will decrease firing rate to help the lead boiler. This method minimizes boiler on/off cycling due to short-term load swings while maximizing total boiler plant efficiency. If desired, unison modulation can also be field selected (all boilers fire at the same rate). LCD GRAPHIC DISPLAY LCD graphic display brings plant overviews, alarms, event status, and setup displays right to the operator s touch. ALARMS / EVENT SUMMARY Up to 200 alarms, system events, and operator actions are listed in first-in, first-out order with a time/date stamp. Alarms include system fault, boiler failure, and both over and under pressure conditions. HARD MANUAL BACKUP Hard-wired control switches and dials provide simple manual control for easy troubleshooting and service. Each boiler has an individual firing rate bar graph, a manual firing rate output knob, and an Auto/Manual switch. MODBUS COMMUNICATION INTERFACE A factory-configured RS485 MODBUS interface is available for building automation or SCADA system monitoring and control. OPTIONS HISTORICAL TRENDS (OPTION P/N ) Easy to use four pen charts allow quick steam system assessment and maintenance monitoring, such as header pressure and boiler operating hour trends. TELEPHONE MODEM (OPTION P/N ) The modem allows the Chief Dispatcher to dial out to an alphanumeric pager and allows a technician to dial in to the Chief Dispatcher to view all Chief Dispatcher displays and make tuning adjustments. WARM STANDBY Two user selectable warm standby modes. When in the All Units mode (default mode), each off line boiler is periodically started and held at low fire until it returns to the warm standby temperature (aquastat supplied by boiler manufacturer). In the Next Boiler mode, only the next in line boiler is started and kept warm. Boiler warm standby helps to minimize thermal shock and decrease the time it takes to produce steam when called on line. EASY INSTALLATION / EASY SETUP The Chief Dispatcher integrates Modbus communications, relays, 24Vdc power supplies and outdoor reset functions into a single wall mountable controller. Simple menu style fill-in-the-blanks setup displays minimize commissioning and training time. 3

4 SYSTEM OVERVIEW START SEQUENCE FEATURES Lead Start 1st Lag Start 2nd Lag Start 3rd Lag Start Boiler Firing Rate & Plant Load Percent Fast (sudden) Load Change Slow Load Change Slow Load Change Boiler Firing Rate Total Plant Load 120 Setpoint Header Pressure Notes: Lead Boiler Start - The header pressure is below the adjustable lead boiler start deviation for longer than the boiler start time delay. This deviation is calculated from current setpoint and can be a positive or negative number. If the lead boiler is desired to start prior to falling below setpoint, simple put in a positive number in the deviation parameter. Pressure Increase Hold Off - To reduce boiler cycling, a lag boiler is not started if the header pressure is rising faster than an adjustable PSI/min rate of change. Header Pressure Based Lag Boiler Start - The header pressure is below the adjustable lag boiler start deviation for longer than the boiler start time delay, or the boilers are at high fire and the pressure is not rising. The above is an example of a lag boiler starting as a result of rapid total steam load change. Firing Rate % Based Lag Boiler Start - The boiler firing rate has been at the adjustable limit for longer than the adjustable time delay. The above is an example of a lag boiler starting as a result of slow total steam load change (i.e. outdoor temperature changes). 4

5 STOP SEQUENCE FEATURES SYSTEM OVERVIEW 3rd Lag Stop 2nd Lag Stop 1st Lag Stop Lead Stop 100 Boiler Firing Rate & Plant Load Percent Fast (sudden) Load Change Slow Load Change Boiler Firing Rate Total Plant Load Slow Load Change 3 0 Header Pressure Notes: Header Pressure Based Lag Boiler Stop - The header pressure is above the adjustable lag boiler stop deviation and the firing rate is below an adjustable low fire setpoint longer than the boiler stop delay and the pressure is not falling. The above is an example of a lag boiler stopping as a result of rapid total heat load change. Pressure Falling Hold Off - To reduce boiler cycling, another lag boiler is not stopped if the header pressure is falling faster than an adjustable PSI/Min rate of change. Firing Rate Based Lag Boiler Stop - The boiler firing rate has been at the adjustable low fire limit for longer than the adjustable time delay. The above is an example of a lag boiler stopping as a result of slow total steam load change. Firing Rate Based Lead Boiler Stop When the plant load is less than the low fire output of the lead boiler, the lead boiler must be cycled on and off to regulate the header pressure. When the lag boilers are off, the boiler firing rate has been at the adjustable low fire limit, and the pressure has been above the adjustable lead boiler stop deviation for longer than the adjustable time delay, then the lead boiler stops. This is a result of slow total steam load change. 5

6 SYSTEM OVERVIEW Chief Dispatcher with key lockable viewing window open Chief Dispatcher front view with both doors open 6

7 FRONT PANEL FRONT PANEL LAYOUT CPU OK Light: Blink = CPU Hardware OK Off = CPU Board Bad RUN Light: On = Blockware Running OK Blink = Blockware Warnings Off = Blockware Not Running FORCED Light: On = Block(s) Forced Off = No Block(s) Forced BATTERY Light: On = Clock Battery OK Off = Clock Battery Low ALARM Light: Blink = New Alarm(s) Off = Alarms Silenced MODBUS Status (Optional): Tx = Chief Dispatcher COM 2 Transmitting Rx = Chief Dispatcher COM 2 Receiving LCD Display Contrast Adj. MODEM Status: Tx = Modem Transmitting Rx = Modem Receiving CD = Carrier Detect AA = Auto Answer Enabled Green Light: AUTO mode command: On = Start Off = Stop Red Light: Output Status, All modes: On = Start Off = Stop ON-OFF-AUTO Switch: AUTO = Chief Dispatcher CPU Control the output OFF = Output is OFF (Chief Dispatcher can NOT turn on the output) ON = Output is ON Boiler 3 Limits Light: On = Boiler 3 Non-Recycling Limits are energized Off = Boiler 3 Non-Recycling Limits are de-energized Boiler 3 Lockout Light: On = Boiler 3 Lockout is energized Off = Boiler 3 Lockout is deenergized CPU OK LIGHT The CPU OK light blinks when power is on and there are no hardware faults. RUN LIGHT The RUN light indicates the health of the blockware control logic. The RUN light should be active continuously. This means that there is blockware loaded into the Chief Dispatcher memory, and there were no errors found. If the RUN light is either blinking or off, a technician should be called to determine the cause of the blockware problem. The technician will need a laptop or desktop computer with PWC_Edit software in order to diagnose the problem and re-load the blockware into the Chief Dispatcher. FORCED LIGHT The block(s) FORCED feature has not been implemented. BATTERY LIGHT The BATTERY light is on when the time/date clock backup battery voltage is ok. This battery is only used to power the time of day and date clock chip when the 120 Vac power is removed from the Chief Dispatcher. When new, the battery can power the clock for approx. 2 years with 120 Vac Power removed. The clock battery has a shelf life of approximately 8 years (with 120 Vac applied). The battery is located under the plastic guard on the lower door. Blockware is stored in non-volatile flash memory. This battery is not used to retain the blockware memory. ALARM LIGHT The ALARM lights blink after a new alarm occurs, and will continue to blink until the ALARM SILENCE button on the keypad is pressed. The home page display screen lists the three most recent alarms. Press the ALARM LIST button to view a complete alarm, event, and operator action history. Press the HOME PAGE button to exit the alarm history screens. 7

8 FRONT PANEL FRONT PANEL LAYOUT Firing Rate Command Bargraph: On = even 10% value (+/- 2.5%) Blink = 5% value (+/- 2.5%) Firing Rate Manual Mode Adjustment Knob Firing Rate AUTO/MAN switch: AUTO = Chief Dispatcher CPU sets the Firing Rate demand MAN = Knob sets the Firing Rate demand Controls are common for each boiler Normal operating settings are: AUTO AUTO AUTO AUTO REMOTE All boiler ON-OFF-AUTO boiler start switches. The ON-OFF-AUTO switch bypasses the Chief Dispatcher control logic in the on or off positions. All boiler MAN-AUTO modulation output switches. The MAN-AUTO switch bypasses the Chief Dispatcher control logic in the MAN position. BLR QTY soft button on the home page. FIRING% soft button on the home page. All LOCAL-OFF-REMOTE switches on each boiler should be in REMOTE to allow the Chief Dispatcher to properly control the header pressure. Note: The operator is responsible for the proper operation of the boilers in the ON, OFF, MAN or LOCAL positions. 8

9 DISPLAY NAVIGATION Pressing HOME PAGE, MENU or ALARM LIST buttons will immediately change the screen to the respective screen, no matter what is currently being displayed. HOME PAGE MENU ALARM LIST Note: Screens in this section are typical. Actual screens may vary according to model. HOME PAGE Press the HOME PAGE button to display the boiler overview from any other page. HOME PAGE Pressing the HOME PAGE button changes the LCD display to the primary operating screen. BAS ENABLE: ENABLE HEADER: 92 PSI LEAD BLR: 1 ROTATE SETPOINT: 95 AUTO BLR QTY: 3 AUTO MODE: SETBACK FIRING%: 56 AUTO LAG MODE: UNISON BOILER: LEAD NI COMMAND:START START START START FAULT: FAULT FIRING%: :55 12/25 BLR 3 FAULT ALARM 9

10 DISPLAY NAVIGATION Press the ALARM LIST button to view the most recent 16 alarms and events. ALARM LIST 16:08 12/25 BLR 2 FAULT CLEAR 16:08 12/25 BLR 4 FAULT CLEAR 16:07 12/25 BLR 5 CALL FOR HEAT START 16:06 12/25 ADD 1 BOILER 16:06 12/25 ADD 1 BOILER ADD 1 16:06 12/25 BLR 4 FAULT ALARM 16:05 12/25 BLR 4 CALL FOR HEAT START 16:05 12/25 ADD 1 BOILER 16:05 12/25 ADD 1 BOILER ADD 1 15:55 12/25 BLR 3 CALL FOR HEAT START 15:55 12/25 ADD 1 BOILER 15:55 12/25 ADD 1 BOILER ADD 1 15:35 12/25 BLR 2 CALL FOR HEAT START 15:15 12/25 BLR 4 FIRE % A/M AUTO 15:35 12/25 BLR 4 FIRE % A/M MANUAL 15:35 12/25 BLR 10 ON-OFF-AUTO SW AUTO Press the PAGE UP button to view the more recent alarms and events. PAGE UP ALARM LIST Chief Dispatcher stores the last 200 alarms or events that have occurred in a time and date stamped memory. When the memory is full, the oldest alarm or event is erased when a new alarm or event occurs. Press either HOME PAGE or MENU to exit the ALARM LIST screens. ALARMS VS. EVENTS Alarms appear on the ALARM LIST screens, blink the alarm lights, sound optional external bells, and appear in the alarm windows of the home page group screens. The alarm status is either ALARM or CLEAR, and is indented one space for easy recognition. Events appear on the ALARM LIST screens. Events do not blink the ALARM lights, sound optional external bells, or appear in the alarm windows of the home page group screens. The events track system operation and help speed troubleshooting and system tuning. Press the PAGE DOWN button to view the next 16 older alarms and events. PAGE DOWN ALARM SILENCE Each new alarm causes the alarm lights to blink. Press the ALARM SILENCE button to turn off the alarm lights. Press the ALARM SILENCE after an alarm occurs to silence any optional external alarm bell and turn off blinking alarm lights on the CPU board. ALARM SILENCE BAS ENABLE: ENABLE HEADER: 92 PSI LEAD BLR: 1 ROTATE SETPOINT: 95 AUTO BLR QTY: 3 AUTO MODE: SETBACK FIRING%: 56 AUTO LAG MODE: UNISON BOILER: LEAD NI COMMAND:START START START START FAULT: FAULT FIRING%: ALARM WINDOW The home page includes a three-line alarm window at the bottom of the screen that shows the three most recent alarms. Events are not shown here. Alarms are listed with the most recent on the top, and the oldest on the bottom. If more than 3 alarms are active, the older alarms are removed from the bottom of the alarm window. Alarms that return to normal are automatically deleted from the alarm window, and the next oldest active alarm is added back to the alarm window. 15:55 12/25 BLR 3 FAULT ALARM Home Screen includes an ALARM WINDOW 10

11 DISPLAY NAVIGATION MENU DISPLAYS The main menu is a combination of menus and screens that are linked together. MENU Press HOME PAGE or ALARM LIST at any time to exit the menus and linked screens. Menus have up to nine (9) numbered line items that can open other sub-menus or screens when selected. To return to the main menu from any sub-menu or menu screen, press MENU. A menu line can activate a screen such as the BLR LEAD/ LAG TUNING screen shown below. The cursor, soft button, and number entry selections all work the same as the home page display group screen. (See screen Soft Buttons and Editable Values in this manual for details.) The PAGE UP key closes the current screen and re-opens the previous menu. MAIN MENU > 1. TUNING 2. UTILITIES 3. HISTORICAL CHARTS 4. PAGER TUNING > 1. FIRING RATE PID TUNING 2. BOILER SEQUENCING TUNING 3. BOILER SETUP DATA 4. LEAD ROTATE SCHEDULE 5. SETBACK SCHEDULE 6. CHIEF DISPATCHER OPTIONS UTILITIES > 1. SET CLOCK TIME/DATE 2. EDIT PARAMETERS 3. EXAMINE BLOCK OUTPUTS / INPUTS 4. SYSTEM DATA 5. HISTORICAL UTILITIES 6. ENGINEERING UNITS 7. MODBUS SETUP HISTORICAL CHARTS > 1. SYSTEM OVERVIEW 2. BLR 1-4 FIRING RATES 3. BLR 5 FIRING RATES PAGER > 1. PAGER SETUP 2. PAGER SCHEDULE 3. SELECT PAGER ALARMS 4. PAGER SETTINGS 5. PAGER SERVICE SETTINGS 11

12 SOFT BUTTONS AND EDITABLE NUMBERS EDITABLE ITEMS Many screens have values and/or soft buttons that the operator can change. These are called editable items. HOME PAGE The cursor is not visible initially. The operator must press any one of the cursor arrow keys (up, right, down, left) to make the cursor visible. If no key is pressed on the keyboard for ten seconds, the cursor disappears again. Pressing ARROW keys moves the cursor BAS ENABLE: ENABLE HEADER: 92 PSI LEAD BLR: 1 ROTATE SETPOINT: 95 AUTO BLR QTY: 3 AUTO MODE: SETBACK FIRING%: 56 AUTO LAG MODE: UNISON BOILER: LEAD NI COMMAND:START START START START FAULT: FAULT FIRING%: :55 12/25 BLR 3 FAULT ALARM The right and down arrows both move the cursor from the upper left corner down towards the lower right corner. For these keys, the cursor moves left to right across each line, then moves down to the next line, and then left to right again. The left and up arrows both move the cursor from the lower right corner towards the upper left corner. For these keys, the cursor moves right to left across each line, then moves up to the next line, and then right to left again. When the cursor disappears, it remains in the same position. The first press of an arrow key makes it visible at its last location; the second press moves the cursor. BAS ENABLE: ENABLE HEADER: 92 PSI LEAD BLR: 1 ROTATE SETPOINT: 95 AUTO BLR QTY: 3 AUTO MODE: SETBACK FIRING%: 56 AUTO LAG MODE: UNISON BOILER: LEAD NI COMMAND:START START START START FAULT: FAULT FIRING%: :55 12/25 BLR 3 FAULT ALARM To change a soft button, move the cursor to the soft button to highlight it, then press the ENTER key. The display text changes to confirm the key press. SOFT BUTTONS A soft button is text on the screen that functions as an on/off pushbutton. The figure to the right highlights all editable screen items (on real screens, only one item is highlighted at a time). ROTATE, AUTO and AUTO are all soft buttons. To change a soft button, move the cursor to the soft button (to highlight it), then press the ENTER key. The displayed text changes to confirm the key press. 12

13 EDITABLE NUMBERS Numbers that the cursor highlights are changed via the number keypad or the arrows to the right of the number keys. To change a number, move the cursor to the number (to highlight it), type in the value with the numeric keys, and then press ENTER. The displayed number changes to a rotating bar character while it is being saved to confirm the entry. SOFT BUTTONS AND EDITABLE NUMBERS ALARM SILENCE ALARM LIST To change a number, move the curser to the number to highlight it, type in the value, with the numeric keys, and press ENTER. ESC ENTER Alternatively, the up and down arrows by the number keys can be used to change the displayed value, and then press ENTER. The single up and single down keys change the right hand digit, and the double up and double down keys change the next digit to the left. (i.e. If the value displayed is 215, the single up arrow changes the value to 216, the double up arrow changes the value to 225.) If the rotating bar character does NOT appear after pressing ENTER, then the Chief Dispatcher blockware logic is temporarily preventing the operator from changing the value, or the ENTER key was not pressed hard enough (try again). The following editable values can only be changed when the soft button is in MANUAL: The LEAD BLR number can only be changed when the ROTATE / MANUAL soft button is in MANUAL. The SETPOINT value can only be changed when the RESET / MANUAL soft button is in MANUAL. The BLR QTY value can only be changed when the AUTO / MANUAL soft button is in MANUAL. The FIRING % value can only be changed when the AUTO / MANUAL soft button is in MANUAL. ABC 1 JKL 4 STU 7 % #, 0 : < >. / + - SPACE ESC DEF 2 MNO 5 VWX 8 : < >. GHI 3 PQR 6 YZ " 9 / + - SPACE Use this key for a decimal place. Use this key for a minus sign If you notice a mistake and do not want to proceed with the change, press the ESC key (instead of the ENTER key). Use either of these keys to increase the display value and then press ENTER. Use either of these keys to decrease the display value and then press ENTER. 13

14 BOILER OPERATION 92 PSI HEADER: SETPOINT: 95 AUTO MODE: SETBACK SETPOINT: 95 = (0-XX) SETPOINT display and Editable Value. This can only be changed by the operator in MANUAL. AUTO = AUTO/MANUAL in auto, the setpoint uses the schedule to move between the two setpoints. In manual, the schedule is overridden and the operator enters the setpoint desired. HOME PAGE BAS ENABLE: ENABLE LEAD BLR: 1 ROTATE BLR QTY: 3 AUTO FIRING%: 56 AUTO LAG MODE: UNISON BOILER: LEAD NI COMMAND:START START START START FAULT: FAULT FIRING%: :55 12/25 BLR 3 FAULT ALARM LAG MODE: MODE = BASE LD/UNISON. In BASE LD the lag boilers fire at their most efficient firing rate (field adj.) while the lead boiler modulates to account for plant load changes. In UNISON, all boilers fire at same rate. BAS ENABLE: ENABLE = Boiler run permit DISABLE = BAS is commanding all boilers to turn off LEAD BOILER: ROTATE = ROTATE/MANUAL soft button. Press button to change between ROTATE and MAN- UAL 1 = (1-10) Lead boiler selection. Enter the lead boiler number. This can only be changed by the operator in MANUAL. BOILER QUANTITY: AUTO = AUTO/MANUAL soft button. Press button to change between AUTO and MANUAL boiler quantity control. 2 = (1-10) MANUAL boiler start quantity. Enter the total quantity of boilers to be called upon to start. This can only be changed by the Operator in MANUAL. FIRING RATE %: AUTO= AUTO/MANUAL soft button. Press button to change between AUTO and MANUAL boiler firing rate adjustment. 56 = (0-100%) Enter the boiler firing rate %. This can only be changed by the operator in MANUAL. SETPOINT The setpoint is field adjustable through the home page display. The values are determined by the pressure range entered through the Engineering Units Page FIRING RATE % This is the plant master firing rate demand for all boilers in auto modulation and in operation. When in AUTO the Chief Dispatcher determines the firing rate. When in MANUAL the operator adjusts the firing rate manually and the Chief Dispatcher will not change the firing rate. In BASE LD mode, the firing rate is the lead boiler firing rate. The lag boilers will stay at their optimal firing rate. BAS ENABLE An input from the building automation system (BAS) can ENABLE the boilers to operate or shutdown all boilers. When the ENABLE input is active the BAS allows the boiler to fire. When the DISABLE input is active all boilers are shut down. LEAD BOILER The lead boiler is the first to be started and the last to be stopped. When ROTATE is selected the Chief Dispatcher automatically changes the lead boiler every 168 hrs (7 days, adjustable) in a circular pattern: 1,2,3,4,1,2,3,4. When in MANUAL the operator selects the lead boiler and the Chief Dispatcher will not change the lead boiler. BOILER QUANTITY The boiler start quantity may either be selected by the operator or selected automatically by the Chief Dispatcher. When in AUTO the Chief Dispatcher determines the quantity of boilers required to be started. In MANUAL, the boiler start quantity will not change in response to header pressure or load. Manual boiler quantity mode can be used to force all boilers off-line (for summer), or to synchronize the Chief Dispatcher to the actual number of boilers running. Manual quantity mode overrides the BAS DISABLE contact. 14

15 HOME PAGE (CONTINUED) BOILER OPERATION BOILER: Static Text, Boiler Reference Number. LEAD INDICATION: LEAD = Chief Dispatcher has this boiler as lead. NI = This boiler channel does note have the daughter card installed. COMMAND INDICATION: START = Chief Dispatcher is calling for this boiler to START. WARM = Chief Dispatcher is running boiler at low fire. FAULT INDICATION: FAULT = FAULT means any one of the following: 1) The boiler is tripped, 2) The Chief Dispatcher toggle switch is not in AUTO, or 3) The boiler limits are not satisfied after the Chief Dispatcher commanded a START 92 PSI HEADER: SETPOINT: 95 AUTO MODE: SETBACK BAS ENABLE: ENABLE LEAD BLR: 1 ROTATE BLR QTY: 3 AUTO FIRING%: 56 AUTO LAG MODE: UNISON BOILER: LEAD NI COMMAND:START START START START FAULT: FAULT FIRING%: :55 12/25 BLR 3 FAULT ALARM ALARM WINDOW The HOME screen includes a 3 line Alarm Window (one current alarm shown) at the bottom of the screen that shows the three most recent alarms. Events are not shown here. FIRING %: The individual boiler firing rate percent. CLEARED FAULT OVERLAP After a boiler fault, the chief dispatcher automatically starts a replacement boiler to cover the load needed. After a boiler fault clears, or the ON-OFF-AUTO switch is placed into AUTO the boiler continues to be skipped in the lead/ lag logic for the amount of time in the cleared fault overlap time listed in the tuning section. This allows the boiler to start generating heat prior to removing the replacement boiler. This also stops cycling if the boiler were to fault again. 15

16 BOILER OPERATION CLOCK TIME AND DATE PAGE Set Time and Date 08:46:44 Saturday, Dec 25, 2004 Time (24 hour) Date 08:46:44 12/25/04 hh mm ss mm dd yy ******WARNING!****** Time and date changes will generate gaps in historical memory or cause data to be erased. Use Historical Utilities to identify any resulting problems. TIME: 08:46:44 = Time of day Enter Hours:Minutes:Seconds in military time ( Military format, 13:03:01 = 1:03:01 PM). DATE: 12/25/04 = Month / Day / Year. ENTER the date. WARNING: Warning message shows when Optional Historical Trending board is installed TIME AND DATE The Chief Dispatcher has a battery backed time and date clock that automatically corrects for leap years. The time and date must be set up in order for the alarm list and historical trending to start to work. Times are entered in 24 hr Military format (i.e. 13:30 = 1:30 PM). WARNING The Warning window shows when historical trending is installed. Changing the time back or forward can cause data to be lost. This will not effect the operation of the Chief Dispatcher, but some historical data may be lost. See the Historical Trending section for more details. After setting the date, verify that the day of the week shown in the status line is correct. If the day is incorrect, re-enter the date correctly. 16

17 BOILER OPERATION LEAD AUTO ROTATE SCHEDULE PAGE AUTO ROTATE SCHEDULE ROTATE TIME: 09:30 CURRENT TIME: 15:42 DAYS OF THE WEEK MON TUES WED THURS FRI SAT SUN YES NO NO NO NO NO NO ***OR*** DAY OF THE MONTH DAY OF THE MONTH: 0 **OR** LAST DAY OF THE MONTH: NO <TO USE DAY OF WEEK, SET DAY OF MONTH=0 AND LAST DAY OF MONTH TO NO.> TIME: 09:30 = Time the rotation will occur in military time. ( Military format, 1300: 1 PM). 15:42 = Current time is given for reference. You can set the time from the Date and Time page. DAYS OF WEEK: MON = Monday is selected. With this setup, the rotation will happen every monday at 9:30 AM. DAY OF THE MONTH: 0 = Any day of the month can be entered. By entering a number, the days of the week is disabled. NO = By selecting the Last day of the month, the day of the month is overridden and the rotation occurs on the last day of the month at the appointed time. SCHEDULE The Chief Dispatcher automatically rotates the lead boiler according to the time selected on this schedule. This feature can be turned off by placing the lead boiler in Manual from the home page. The schedule can be used in days of the week mode or day of the month mode. DAY OF THE MONTH MODE The day of the month mode is activated by entering a day on which to rotate or selecting the last day of the month. If a day is selected that does not exist during that month, then no rotation will occur. For instance, if the 30 is entered, there will be no rotation in the month of February. DAYS OF THE WEEK MODE The days of the week mode is active when Day of the month is 0 and last day of the month is NO. You can select multiple days or only one. Selecting no days will result in the system never rotating. 17

18 BOILER OPERATION ENGINEERING UNIT EDITOR Global EGU Editor ID Name Value 0% Value 100% DecPt A1 PSI PSI: 0, 200 = To change the scaling associated with the Pressure range, change the span value of the PSI EGU. Value for 0% must be set to 0. Use Double/Single Arrows to Scroll GLOBAL EGU EDITOR The Global Engineering Unit Editor internal screen mimics PWC Edit s Engineering Units screen. It allows the user to edit the value at 0%, value at 100% and the decimal point of the currently selected egu. All changes will take effect immediately and be written to EEPROM shortly thereafter (within a few seconds). Edits made to the 0% and 100% fields assume the current decimal point location and have a minimum and maximum of (raw value). The decimal point field has a minimum of 0 and a maximum of 4. 18

19 HEATING SCHEDULE PAGE BOILER OPERATION Schedule: SETPOINT SETBACK Day MM.DD.YY Normal Setback Type MON :00 20:00 STD TUE :00 20:00 STD WED :00 20:00 STD THU :00 20:00 STD FRI :00 20:00 HOLIDAY SAT :00 20:00 HOLIDAY SUN :00 20:00 STD Go To Date: (MM.DD) (Double Arrow Jumps 1 Week) Use [ENTER] To Change STD/HOLIDAY Type DATE: Press double arrow keypad keys to show next or previous weeks. ALL USED: If all 16 holidays are used, the Chief Dispatcher asks which holiday should be replaced. NORMAL TIME 6:00 = (0:00-24:00) Enter the time to switch to normal SP. (24:00 to never switch) SETBACK TIME 20:00 = (0:00-24:00) Enter the time to switch to setback SP. (24:00 to never switch) Note: To retain normal or setback for an entire day, set time: Normal Setback Normal All Day 00:00 24:00 Setback All Day 24:00 00:00 TYPE STD = STD/HOLIDAY Soft Button. Press button to change between standard and holiday schedule. **16 Holidays Are Already In Use** Change Holiday #: 0 to 08.20?? (Press CURSOR DOWN, Type Holiday Number Then press ENTER OR ESC to Cancel) Holiday # Date Holiday # Date HEATING SCHEDULE This feature is used in certain applications to save energy by lowering the setpoint (SP) during times when the heating requirement is reduced such as at nights or on weekends and holidays. This display is used to setup weekly time and date schedules for a NORMAL vs SETBACK mode selection. TIME FORMAT Times are entered in 24 hr military time, 13:00 = 1 PM. CAUTION Change from STD to HOLIDAY before changing the schedule! CAUTION If the NORMAL/SETBACK times are changed when the type = STD, then the schedule for that day of the week will be changed for the entire year. The double arrow keys in the numeric keypad area are used to change the week being displayed. TYPE A STD day uses the same schedule every week on that day of the week, unless a HOLIDAY date overrides the standard schedule. A schedule can have up to 16 HOLI- DAYS. The STD/HOLIDAY field is a soft button. HOLIDAY If a new HOLIDAY date is selected when all 16 HOLIDAY dates are already in use, the option to replace one of the existing holidays appears. NOTE To disable switching set times to 24:00. Since 24:00 does not exist, the Chief Dispatcher does not switch. Whatever setting is current will stay active. NOTE An optional setback override can override the schedule via a screen soft button or building automation interface. 19

20 HISTORICAL TRENDING MENU Select Historical Chart Chart Setup Chart Span Start Time (24) 1. 8 Min 08:24:54 -> Min h m s 3. 2 Hour 4. 8 Hour Hour Start Date -Select 1-5 for Span. 12/25/04 -Edit Time and Date m d y -Press ENTER to run. ENTER Chart Commands Help Screen *** Press ENTER to Display The Chart *** Key ESC Go To Previous menu MENU Go to Main Menu PAGE UP Increase Time Span PAGE DN Decrease Time Span Upper Arrows Pan: Right, Left, Up, Down Lower Arrows Move Cursor: Right, Left 1,2,3,4 Select Pen 1, 2, 3, 4 0 Show / Hide Current Pen 5 Show All Pens 6 Hide All Pens HISTORICAL TRENDING (OPTIONAL) These screens require the optional 128 MB Historical Trending Memory board ( part number). The Chief Dispatcher saves analog values every second. The 128 MB Historical Memory can store up to 1-6 months of data (number of points monitored, sample interval, and data compression ratio affect duration). CHART SETUP SCREEN The first screen determines the starting time and date of the chart, and also the span of time that the chart covers. This screen defaults to the current time and date with a 40 minute wide chart. Changing Chart Span: With none of the fields highlighted, press a number (1-5) on the numeric keypad. The arrow should move to the new span. Do not press ENTER; do not press any cursor keys until the time and date are entered. Editing the Start Time and Start Date: Use the normal home page cursor, soft buttons, and number editing keys to make all changes. See Soft Buttons and Editable Numbers above for more information. After making any desired changes, press ENTER to proceed to the Chart Commands Help Screen. CHART COMMANDS HELP SCREEN The Chart Commands Help Screen lists the commands that can be used on the chart displays. Pressing ENTER again advances the screen to the historical trend display. ENTER Chart Title CHARTS The Chief Dispatcher includes the following charts: SYSTEM OVERVIEW Pen Legend Description 1 HDR Supply Header Pressure 2 HDR SP Supply Header PSI Setpoint 3 FR% Boiler Firing Rate 4 SPARE BLR x-x FIRING RATES Pen Legend Description 1 B1 FR% Boiler 1 Firing Rate 2 B2 FR% Boiler 2 Firing Rate 3 B3 FR% Boiler 3 Firing Rate 4 B4 FR% Boiler 4 Firing Rate Pen Identification 20

21 HISTORICAL TRENDING HISTORICAL TREND DISPLAY SCREEN Each chart can display up to 4 traces or pens. The bottom of the screen shows the symbol and name of each pen. Pen Selection: Each Pen trace has a unique name, chart scale, and engineering units. However, only one pen scale can be displayed at a time. Press a number (1-4) on the numeric key pad to select a pen. Just because a pen is selected does not mean that pen is visible. Press 0 on the keypad to show or hide the current Pen, Press 5 to show all pens, and 6 to hide all pens. Use the cursor up and down arrows to scroll the scale up or down for the selected pen. The new span is saved until power is cycled on the Chief Dispatcher. Chart Cursor Readout: When a chart is first displayed, the chart cursor is located at the right hand edge of the screen. Use the numeric keypad arrows to move the chart cursor. Scroll scales Up or Down HOME PAGE Moves Forward or Back in Time Adjust Cursor The number on the top line of the screen is the value of the currently selected pen trace where it touches the chart cursor. Press a number (1-4) on the numeric keypad to display the values for the other pens. ABC 1 DEF 2 GHI 3 Pen Selection (Scale & Cursor) The chart cursor will display the pen trace value even if the trace is not visible on the chart. Start Time Panning: Use the cursor left and right arrows to shift the start time backward or forward in time. The time is shifted 7/8 of the span to provide chart display overlap. When moving the chart to the right, panning left from 13:18 would shift the start times to 13:11, 13:04, Show/Hide current pen JKL 4 STU 7 % #, 0 MNO 5 VWX 8 : < >. PQR 6 YZ " 9 / + - SPACE Hide all pens Show all pens Changing Chart Span: Use the PAGE UP and PAGE DOWN keys to change the chart span to 8 minutes, 40 minutes, 2 hours, 8 hours, or 24 hours. The current curser position is used as the new start time for the chart. To find a section of time, use a larger span (i.e. 24 hours) and curser to the desired time frame. Use PAGE DOWN to zoom into the desired time frame. Press ESC to return to the chart setup screen. Press HOME PAGE, MENU, or ALARM LIST to exit the chart screens. NOTE: When changing to 8H (8 Hour) and longer spans, the Chief Dispatcher can take up to 1 minute to find, average, scale, and plot the data on the graph. The delay is longer if more points are being trended, and if the data is constantly changing. The lower left corner displays a SEARCHING, PLOT- TING, status during this delay. Adjust Chart Time PAGE UP PAGE DOWN 21

22 TELEPHONE MODEM Telephone Connection Status Remote Chief Dispatcher Keypad Functions same as actual Chief Dispatcher Keypad The Telephone Modem option allows the Chief Dispatcher to dial out to an alphanumeric pager and allows a technician to dial into the Chief Dispatcher to view all Chief Dispatcher displays & make tuning adjustments. PWC_REMOTE SOFTWARE The PWC_Remote software allows a technician to dial into the Chief Dispatcher from a remote location using a standard analog phone line. Once connected, the Chief Dispatcher front panel buttons are completely accessible from the PWC_Remote software. This may be used to view current status, adjust tuning parameters, view historical data (with optional historical card) and acknowledge alarms by pressing alarm silence button. The PWC_Remote software can be used to document historical and tuning data. While the desired screen is visible, press Copy Screen to Clipboard. The page is place in the Windows clipboard. It can be pasted into a MS Word or other document. Hard copies can be printed for records. Use Copy Screen to Clipboard to document tuning parameters and Historical charts. 22

23 TELEPHONE MODEM PAGING Pages are triggered by alarms or events that have been defined through the Select Paging Alarms Screen. An example page looks like: 02/14 02:30 NEW YORK NY BOILER 1 FAULT. The location and up to eight different pager numbers can be defined through the PAGER SETUP screen. PAGER SETUP Use the left cursor and right arrows to highlight the character location or telephone # and IDPIN # you want to edit. Use the number pad to enter the desired letter. Use the number pad to input letters and numbers. Pressing 1 will show the character 1 at the cursor position. Pressing 1 again will show the character A, then B, then C and then back to 1. Use a comma (4th push of the 0 button) to indicate a delay. Example: 9, PAGER SETUP Location: MAIN PLANT NEW YORK, NY Pager# Telephone# ID/PIN# 1: Test Pager Save Records Use Num Pad to Edit Location and Numbers Use Comma for Delay, Use Space to Erase PGUP/PGDN - Switch Pager # Press ESC, Menu, or HOME to Exit Select Character HOME PAGE Move Fields PAGE UP PAGE DOWN Select Next Telephone Once you are satisfied with the entry, press the down arrow twice to highlight the SAVE RECORDS field. Press the ENTER button to save your changes. If you leave this screen without saving, your changes will be lost. Press PAGE UP or PAGE DOWN to change the current pager number and make any other changes. Enter Characters ABC 1 JKL 4 DEF 2 MNO 5 GHI 3 PQR 6 PAGER TEST Use this display to test a pager. Messages that appear under the title are also displayed in the alarm list. Exiting this screen before the page completes will abort the page. If a page fails, check the alarm list for the specific reason. STU 7 % #, 0 VWX 8 : < >. YZ " 9 / + - SPACE TESTING PAGER #1 PAGING PRIMARY * Step Waiting To Connect Location: Main Plant New York, NY Tel.# : ID/PIN# : TimeOut Message : Pager Test Backup Pager Disabled for Test 47 Press ESC to Abort or Return to Setup 23

24 TELEPHONE MODEM Pager Schedule Shift 1 Shift 2 Shift 3 Start: 2:30 10:45 18: Pri Back Pri Back Pri Back MON: TUE: WED: THU: FRI: SAT: SUN: Enter 0 in Pri. Column to Disable Paging Enter 24:00 to Eliminate Shift 3 Select Pager Alarms Page Description Blk Output YES HIGH HEADER PSI 021 MAIN YES LOW HEADER PSI 022 MAIN NO BLR 1 FAULT 241 MAIN NO BLR 2 FAULT 242 MAIN NO BLR 3 FAULT 243 MAIN NO BLR 4 FAULT 244 MAIN NO BLR 5 FAULT 245 MAIN PAGER SETTING SCHEDULING You may select primary and backup pagers based on the time and day of the week through the pager schedule screen. You may define 2 or 3 different shifts during the day and choose the active primary and backup pagers for each shift. The pager numbers entered correspond to those defined in the PAGER SETUP screen. Enter the start times for each of the shifts on the top of the screen and enter the primary and backup pagers for each day and particular shift. Entering a zero in the primary pager column will disable paging during that shift on the corresponding day. SELECT PAGER ALARMS The select pager alarms screen shows all alarms setup in the Chief Dispatcher. Use PAGE UP and PAGE DOWN to scroll through the alarms. The modem will only page on alarms marked YES. PAGER SETTINGS The pager settings screen allows the user to enable or disable the pager system. If the enable pager setting is OFF, then the system will not attempt to send any pages. Since the telephone modem is optional, this setting is defaulted to OFF. The send test page option functions just like a regular alarm in the system. If it is not acknowledged by the timeout period, then the pager will page the backup pager. OFF TEST ENABLE PAGER SEND TEST PAGE (MUST ACKNOWLEDGE) PAGER SERVICE SETTINGS The pager service settings screen allows the user to adjust the settings that the PWC s Modem, will use to connect to the TAP pager service provider. Most pager services auto-detect these settings, however if they require a specificdata size, parity or number of stop bits, the user can adjust them here. Pager Service Settings Data Bits: 8 (7 or 8) Parity: 0 (0=NONE 1=ODD 2=EVEN) Stop Bits: 1 (1 or 2) Service Response Timeout: 6 (5-30 SEC) NOTE: TAP Suggested Atandard For Pagers: 7 Data Bits, EVEN Parity, 1 Stop Bit. Contact our Service Provider For The Correct Settings Service Response Timout is the time the PWC will wait for the ID= string from the pager service before sending another <CR>. NOTE: These values have no affect on the modem settings used to connect with PWC Remote. PWC Remote requires 8 data bits, no parity and 1 stop bit. Please ensure your PC s modem settings are set to these values. Some PC programs (eg. Hyperterminal) override your modems settings even when they are not running. 24

25 CPU OK RUN FORCED BATTERY ALARM Tx COM 2 Rx LCD CONTRAST Tx MODEM 1 Rx CD AA FAN FUEL VALVE LOCKOUT FAN FUEL VALVE LOCKOUT G G G G G ON - OFF - AUTO ON - OFF - AUTO ON - OFF - AUTO ON - OFF - AUTO ON - OFF - AUTO MAN AUTO MAN AUTO MAN AUTO MAN AUTO MAN AUTO ABC JKL STU % #, HOME PAGE ALARM ALARM SILENCE LIST DEF MNO VWX : < > GHI PQR YZ " / + - SPACE ESC PAGE UP PAGE DOWN MENU ENTER INSTALLATION 18 " Wide (8 1/2 " Deep) CPU Module BOILER 1 BOILER 1 BOILER 1 COM 1 PROGRAMMING PORT BOILER 2 BOILER 2 BOILER 3 FAN FUEL VALVE LOCKOUT LOW FEEDWTR PSI LOW FEED TANK LEV BOILER 3 FEED PUMP 1 BOILER 2 BOILER 3 FEED PUMP /4" 20 1/8" 21 1/8" PREFERRED INSTRUMENTS /16" 15 5/8" 3/4" Conduit Knockouts (typ. 7) MOUNTING OVERVIEW The Chief Dispatcher is designed for wall mounting in a NEMA 1 indoor environment. Continuous operation is guaranteed over a F ambient temperature range without derating. The controller should not be subjected to excessive vibration. The Chief Dispatcher is UL508 recognized for NEMA 1 dry indoor applications. FRONT ACCESS The Chief Dispatcher case is 8-1/2 deep and 18 wide. The front doors are hinged on the left and swing approximately 27 away from the wall. In addition, sufficient clearance should be provided to allow an operator to stand in front of the Chief Dispatcher to view the display and operate the keypad and switches. UPPER DOOR LOCK AND REMOVAL The upper door is provided with a key lock to restrict access to the upper control switches (if desired). The lower door is interlocked with the upper door to restrict access when the upper door is locked. The lower door covers the field wiring terminals. If the upper control switches are going to be accessed frequently, the upper door can be removed by removing three nuts inside the Chief Dispatcher. WARNING The Chief Dispatcher is commonly used to control potentially dangerous combustion and chemical processes. VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED, ISOLAT- ED, OR BYPASSED (AS REQUIRED BY THE SITE CONDITIONS) BEFORE REMOVING POWER FROM THE Chief Dispatcher CONTROLLER. FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE, OPERATOR INJURY, OR DEATH. It is very common to have multiple sources of power among the wires connected to a Chief Dispatcher. VERIFY THAT ALL SOURCES OF POWER HAVE BEEN DISCONNECTED BEFORE WORKING ON WIR- ING. FAILURE TO DO SO CAN RESULT IN INJURY OR DEATH. WARNING All panel and field wiring should conform to national and local electrical codes. 25

26 INSTALLATION 26 FIELD WIRING COMPARTMENT All field wiring connections are behind the lower front Chief Dispatcher door. The lower door is interlocked with the upper door and will not open unless the upper door is opened first. 120 VAC POWER AND GROUND Connect the incoming AC power ground (i.e., green wire) to the screw and lug marked GROUND in the lower left corner. Connect the 120 Vac power supply to the terminals marked POWER INPUT in the lower left corner. The Chief Dispatcher internal 120 Vac load is 0.5 A. However, up to an additional 12 amps of 120 Vac load can be connected to external field loads via the Chief Dispatcher auxiliary power output terminals.! TERMINAL BLOCKS All field wiring terminals are separable, and plug-in to the Chief Dispatcher I/O boards. This allows rapid board level replacement without disconnecting individual field wires. Verify that terminals are inserted properly before applying power. All terminals accept 24 to 12 ga. wire and should be tightened to 4.5 in-lb. Each terminal can accept up to (2) 14 ga. wires. WIRE TYPE All wiring (AC, DC, and shielded cable) should be copper, stranded, 150 V min., and 60 C minimum. SHIELDED CABLE All pressure sensor and 4-20 ma input and output wiring should be 22 gauge minimum, shielded, and have twisted pairs (Belden 8737 or equal). 100% foil shielding is preferred, instead of braided shielding. The shields of all cables should be connected at one end only, as shown on the drawings that follow. Generally, the shield is connected to the DC common of the power supply that is powering the signal. All shield foils and shield wires should be insulated (tape or heat shrink) to prevent accidental connection to earth or power ground. Shields connected at both ends or unintentionally grounded can actually add extra noise to a signal instead of reducing noise. To prevent noise pick-up, shielded cable field wiring should never be run in conduits or trays with AC wiring (any voltage). Ignition transformer and variable frequency drive AC wiring is particularly noisy and must be run in separate conduit from all DC signal wiring. Within the Chief Dispatcher, minimize the distance that DC and AC wires are run together. Wherever possible cross AC and DC wires at a 90 degree angle to each other. DC SIGNAL COMMON ISOLATION A thorough understanding of the signal common will prevent ground loop problems. Ground loops can cause lower than expected 4-20 ma values at a Chief Dispatcher input due to a portion of the current bypassing the intended circuit path and traveling through some unintended parallel path. GREEN WIRE GROUND The incoming AC power ground (the green wire) is only connected to case ground (i.e., the Chief Dispatcher metal enclosure). Case ground is isolated from all neutrals and all DC commons inside the Chief Dispatcher. Case ground should always be connected to an appropriate NEC code power supply ground for safety. DC SIGNAL COMMON The DC signal commons ( - ) are all isolated from case ground and AC neutral. The DC signal commons of the 24 Vdc field power, CPU and AIN analog inputs are interconnected with each other. 4-20MA ANALOG OUTPUTS All terminals of each analog output channel on the A/M- AOUT boards are isolated from DC common and AC power ground, and each channel is isolated from each other analog output channel. ISOLATED RS485 Terminal 11 ( S ) is the isolated common of the isolated RS485 communications link. The RS485 data + and - (terminals 9 & 10) are also isolated from the CPU Board. 250 OHM RESISTORS FOR 4-20 MA INPUTS Each Chief Dispatcher 4-20 ma analog input channel has an internal 250 ohm precision resistor across the input when the input type switch is set to The 250 ohm resistor converts a 4-20 ma signal into a 1-5 Vdc signal. 24, 15 & 5 VDC FIELD POWER SUPPLIES The internal DC power supplies are large enough to supply any combination of I/O boards and connected field loads at any temperature up to 125 F ambient with a 120 Vac +/- 15% supply. Each field wiring DC power output terminal is individually protected by a solid state self-resetting fuse (PTC thermistor): Board Voltage Max. ma: CPU terminal Vdc 300 ma CPU 4-20 ma Analog Input +24 Vdc 35 ma CPU Thermistor Analog Input +5 Vdc 15 ma

27 INSTALLATION FUSES All fuses are located behind the lower door in the field wiring area. Fuses used in the Chief Dispatcher include: Board Service Amps Type Littlefuse Part Number Power Entrance F1, DC Power Supplies 2 Slo-Blo 250 V, ¼ x 1¼ Power Entrance F2, Auxiliary 120 V (Motherboard bus + F3) 12 Slo-Blo 250 V, ¼ x 1¼ Power Entrance F3 Auxiliary 120 V Output 8 Slo-Blo 250 V, ¼ x 1¼ DIN, HOA-ROUT F1 & F2 Auxiliary 120 V Output 2 Slo-Blo 250 V, ¼ x 1¼ AC POWER DISTRIBUTION The Chief Dispatcher 120 Vac power input is fused and then distributed via the motherboard to all I/O boards that can use 120 Vac. Each board that can use 120 Vac has fuses and auxiliary power output terminals. DC Power Supply (0.5A Load) 5 V 24 V +12 V -12 V COM DIN Board V ac Discrtete Input Optical Isolators 4 'Common' is NOT connected to 'N' 120 Vac Power Input Load: (0.5 A + Aux. Outputs) H N F1 2A F2 12A 2A 2A F1 F1 F2 F2 N N Auxiliary Power Outputs 120 Vac Aux. Output 7A Max. Load F3 N F3 8A PWC Power Entrance Board Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 PWC Mother Board / Backplane 27

28 INSTALLATION 9 10 ORG WHT D+ D- 11 Chief Dispatcher RS485 COMMUNICATIONS WIRING BLU Belden 3106A or equal RS-485 communications wiring (terminals 9-11) is optically isolated and is not electrically connected to any other circuits within the Chief Dispatcher. This means that an accidental short of the RS485 cable will not affect the operation of the Chief Dispatcher controllers. RS-485 cabling may be up to 4000 feet in length. Longer distances can be accommodated by using RS-485 repeaters. RS-485 Network cabling should always be arranged in a bus. Do not wire cabling in a star or with stub connections. Belden P/N 3106A is the recommended shielded cable for all Chief Dispatcher RS-485 communications data highways. Belden 3106A has a characteristic impedance of 120 ohms, has 22 ga. conductors, and is rated for 60C. SHIELDING AND RS-485 COMMONS COM Building Automation System RS485 The shield should be connected to the RS-485 common terminal at the master station. At each Chief Dispatcher, on the network, the shields should NOT be connected to each controller s RS-485 common. The shields of the network cables should be wired together so as to continue the shield to the next controller. The blue wire in the cable should be connected to all the Communications DC Commons on the RS-485 network. Insulate the bare shield wire and any exposed shield and connect as shown above. NOTE: 4000 ft. cable length max. (Use repeaters if greater than 4000 ft.) Modbus Setup Address: 1 (1-32) Baud Rate: 1 (0 = 38400) (1 = 19200) (2 = 9600) (3 = 4800) (4 = 2400) Parity: 0 (0=ODD 1=EVEN 2=NONE) Protocol: 0 (0=RTU 1=ASCII) Word Length: 8 Stop Bits: 1 Address: 1 = This is the device address. Baud Rate: 1 = Choose the desired Baud Rate. Parity: 0 = Choose the desired Parity setting. Protocol: 0 = Choose between RTU or ASCII MODBUS SETUP This page allows you to change the MODBUS settings used for the RS-485 port on the CPU board. Enter the desired values. 28

29 INSTALLATION WIRING DIAGRAM PROVIDED SEPERATELY 29

30 INSTALLATION INSTALLATION OF AOUT CARDS AOUT CARDS Since any combination of 4-20mA or 135 OHM output cards can be installed, it is up to the user to field install each daughter card in the proper slot. This process is not difficult, and can be completed by following the step by step instructions. WHAT S NEEDED Proper amount of AOUT daughter cards (either 4-20mA or 135 OHM) Flat head scredriver NOTE: Power must be off before removing any boards from the unit! Care should be taken to ground youself prior to handling any circuit board to avoid static shock! Step 1: Remove the AOUT Board With Power Off to unit, remove the Analog Output board by removing the two screws that hold the Analog Output board into the unit. Ch 1 NOTE: If you take out the empty filler panel to the right of the AOUT card it is easier to remove the AOUT card. Ch 2 Ch 3 Step 2: Locate the correct connections With the AOUT board in hand, locate the 5 slots for daughter cards on the printed circuit board. Note that the first slot is located near the top of the IO card. Ch 4 Ch 5 30

31 INSTALLATION INSTALLATION OF AOUT CARDS Step 3: Install the desired cards in the slot required Each daughter card has a 10 pin connector, a 3 pin connector, and a hole for a standoff screw. The 4-20mA board looks like: The 135Ohm board looks like: Shown to the Right is a 5 boiler installation where boilers 1, 2 and 3 are 4-20mA outputs and boilers 4 an 5 are 135 Ohm output. Step 4: Reinstall AOUT Board Install the AOUT board back into the PWC and atttach using screws removed. Be sure that the white connector plug plugs into the PWC s backplane. Reappply power to the unit. 31

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