Tri-Stack Smart System TM
Notes & Warnings - The protection provided by this equipment may be impaired if it is not used in the manner specified herein. - Ensure all wiring meets applicable national and local codes. Ensure all standard safety precautions are taken when working with electricity. - Incoming supply line disconnect, if not already installed, shall be provided and installed by others. Circuit breakers are included in the PLC control panel, which isolate the incoming supply from the rest of the panel s components. Specifications General Size (Length x Height x Depth) Shipping Weight Power Supply Voltage Frequency Maximum Power Consumption Operating Temperature Range Storage Temperature Range Relative Humidity Enclosure Rating 24.09 x 30.51 x 12.95 (inches) 612 x 775 x 329 (mm) 120 lbs (55 kg) 120/240 VAC 50/60 Hz 1200 VA 32 to 122 F (0 to 50 C) -4 to 158 F (-20 to 70 C) 20 to 80% (non-condensing) NEMA 4X (IP66) See specific component manuals for more information. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 1
Wiring Refer to the wiring diagrams included in the package. Ensure all wiring meets applicable national and local codes. Ensure all standard safety precautions are taken when working with electricity. A 110VAC, 15A line must be brought into the unit and connected to the hot (L1), neutral (L2) and ground (GND) terminals located below Terminal Block 1. Isolation & bypass actuator neutrals must be wired to terminal L2. 14 AWG should be used for all 110VAC wiring. Below is a list of the unit I/O with descriptions. Terminal numbers will depend on the number of fans present in the system. Refer to the wiring diagrams for corresponding terminal numbers. Terminal Block 1 - Digital Inputs Description Comment VFD Run Status From VFD relay contact VFD Fault From VFD relay contact Isolation Damper Feedback From isolation actuator auxiliary switches Terminal Block 2 - Relay Outputs Description Comment VFD Run Command To VFD logic input - sends signal to start VFD General Alarm Relay closed = alarm present Isolation Damper Open Command To isolation damper - sends signal to open damper Terminal Block 3 - Analog Inputs System Pressure From pressure transducer (4-20mA) System Set Point Override From Customer BAS (4-20mA)(optional) Plenum Pressure From pressure transducer (4-20mA) Bypass Damper Position Feedback From bypass actuator feedback (2-10V) Terminal Block 4 - Analog Outputs Description Comment VFD Speed Command To VFD analog input - sends speed reference to VFD (4-20mA) Bypass Damper Command Sends control signal to bypass damper (2-10V) For logic input/output wiring, 16 AWG should be used. For analog input/output wiring, 18 AWG shielded twisted pair cable is recommended. Terminal L3 is available to supply 110VAC to any auxiliary equipment that may be present. Terminal L3 is hot when the controller s main circuit breaker is thrown. Auxiliary 24VDC terminals are also provided. The bypass damper supply terminal (L12) provides 24VAC power to the bypass actuators. The digital inputs of Terminal Block 1 are provided with 24VDC from the Smart System TM. The relay outputs of Terminal Block 2 are dry contacts. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 2
Certain parameters in the VFDs must be configured to work properly with the Smart System TM. The drive logic inputs connected to the VFD Run Command terminals should be configured to start the drive when a signal is sent. The drive analog inputs connected to the VFD Speed Command terminals should be configured to accept a speed reference (4-20mA, where 4mA = 0Hz & 20mA = max speed (default 60Hz)). The drive relay contacts connected to the VFD Run Status terminals should be configured to be closed when the drive is running. If the VFD Fault terminals are used, the drive relay contacts wired to them should be configured to close when the VFD faults. The Smart System will report a VFD fault, and it will stop the corresponding fan unless otherwise specified. If it is desired to send the static pressure set point remotely from the building control system, a 4-20mA signal can be sent to the System Set Point Override terminal. 4mA will correspond to 0 SP; 20mA will correspond to the System SP Trans. Range parameter on the Service screen (see pg. 7). If a signal is present in the override terminal, the SP Set Point parameter on the unit will be ignored. Display This section explains the operation of the touch screen display. Note that some Smart System TM units may ship with a differently sized display on which the layouts will be different, though the functionality will be identical. This manual uses screens designed for a 3-fan system. Menu Screen Push the hard key at any time to display the Menu screen. 1. The six hard keys on the left will perform the following functions from all screens: o MAIN Go to Main screen o ALARMS Go to Alarm screen o STPTS Go to Setpoints screen o ALT Go to Alternation screen o TREND - Go to the Trend screen V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 3
o TUNE Go to the Tune screen 2. Touch LOG ON to enter user name and password. 3. Touch LOG OFF lock out password protected screens. 4. Touch SERVICE to go to the Service screen. 5. Touch RUN TIME to go to the Run Time screen. 6. Touch BP DAMPERS to go to the Bypass Dampers screen. 7. Touch ISO DAMPERS to go to the Isolation Dampers screen. Main Screen a c b d e f g h a f i d The main screen shows the status of the following system parameters: a. System static pressure b. Static pressure set point c. Minimum VFD speed (see Sequence of Operations, pg. 13) d. Bypass damper position (percent open) e. Hand/Off/Automatic buttons f. Fan run status g. VFD speed h. Isolation damper status i. Alarm status None of the parameter values can be changed on this screen except for H/O/A status. Alarm Screen V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 4
If an alarm occurs, it will be listed on this screen with a time stamp. 1. Touch PREV and NEXT to cycle through the alarm list if necessary. 2. Touch ACCEPT to clear an active alarm. 3. Touch RESET after the causal condition has cleared to resume normal operation. 4. Touch EVENT LOG to go to the Events screen. If the unit is connected to a network, it can be configured to send an e-mail or text message to notify appropriate personnel of an alarm. Contact the factory for more information. Events Screen All alarm events that have occurred since the last time the list has been cleared will be listed on this screen with a time stamp. These events include alarms occurring, alarms accepted and alarms reset. The information on this screen will be logged to the CompactFlash card. 1. Touch PREV and NEXT to cycle through the event list if necessary. 2. Touch CLEAR to erase all of the event information on this screen. This will not affect the information already saved on the CompactFlash card. 3. Touch ALARMS to return to the Alarm screen. Setpoints Screen Various parameters can be set on the Setpoints screen. Touch any value to bring up a numerical entry pad. Use NEXT to toggle between screens. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 5
The following are descriptions of the parameters on this page (also see Sequence of Operations, pg. 13): a. Lag On Freq VFD frequency at which lag fans will energize. This should match the maximum frequency parameter of the drive. There are separate lag on frequency parameters for each lag fan in the system. b. Lag Off Freq - VFD frequency at which lag fans will de-energize. If the value of this parameter is below the minimum frequency as set by the controller, it will be ignored. See Sequence of Operations on pg. 13 for more information on minimum frequency. There are separate lag off frequency parameters for each lag fan in the system. c. Hi SP Shut Down All fans in the system will de-energize when the system static pressure reaches the value of this parameter. d. Hi SP Alarm An alarm will occur when the system static pressure reaches the value of this parameter. e. Hi SP Alarm Reset The alarm caused by the above parameter will be able to be reset when the system static pressure drops below this value. Alternation Screen This screen shows which fans are currently lead & lag. Press ALT NOW to manually change the lead/lag sequence. The lead/lag sequence will change automatically at the Alt. Hour on the Alt. Day of Month. To alternate less than the full amount of fans, change the Alternate Qty value. For example, if this value is set to 2 only the Lead & Lag fans will change position when a fan alternation is called. Log On Screen The Setpoints, Alternate, Service, Tune, Bypass Damper & Isolation Damper screens are password protected. When an attempt is made to access these screens, or when LOG ON is pressed, the above screen will pop up. Press the enter button to bring up the following screen where user name and password can be entered. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 6
If the user name and password are unknown, contact the factory. The factory set user name & password will be written on a label inside the Smart System enclosure. The user will also be prompted to log on when attempting to use the Hand/Off/Auto buttons. Several other options are available, including multiple levels of password protection. Contact the factory for more information. Trend Screen The trend screen shows a real-time graph of the system static pressure (red line) and the static pressure set point (green line). The numerical values of these parameters can be seen below the graph. These parameters, along with the time and date, are logged on the flash card provided with the unit. The default interval at which these values are logged is 30 seconds. To change this interval, contact the factory. Press the arrow keys to scroll back and forth through the graph. Use the IN and OUT keys to zoom in and out. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 7
Service Screen Touch any value to bring up a numerical entry pad. The following are descriptions of the parameters on this page (also see Sequence of Operations, pg. 13): a. System SP Trans. Range This parameter is set to the upper range of the system static pressure transducer. Default value matches transducer supplied with system. b. Fan SP Trans. Range This parameter is set to the upper range of the fan static pressure transducer. Default value matches transducer supplied with system. c. System SP Trans. Filter & Fan SP Trans. Filter Filter the incoming system and fan static pressure signals. The higher the values, the more the signals will be filtered. d. Bypass Cutoff The percentage open of the bypass dampers at which the lag fan will de-energize. e. Bypass At Startup If on, the bypass dampers will open to 100% before the first fan is energized in Auto mode. If off, the first fan will energize with the bypass dampers remaining closed. f. Startup Delay Duration of time after the system is started (i.e. at least one fan is placed in Auto mode) before the controller begins to follow the static pressure set point. g. Isolation Damper Delay Duration of time after a fan is energized before its isolation damper will begin to open. Also the duration of time after a fan is de-energized before its isolation damper will begin to close. h. Lag On Delay Duration of time before lag fan is energized after drive frequency has reached Lag On Freq parameter value. i. Lag Off Delay - Duration of time before lag fan is de-energized after the Bypass Cutoff parameter value has been reached. j. General Alarm Delay Duration of time after a fan alarm condition occurs before the system will show an alarm. k. Isolation Alarm Delay - Duration of time after an isolation damper alarm condition occurs before the system will show an alarm. Should be set for at least the full run time of the isolation actuators. l. Pressure Alarm Delay Duration of time after a high static pressure alarm condition occurs before the system will show an alarm. m. Bypass Alarm Delay - Duration of time after an bypass damper alarm condition occurs before the system will show an alarm. Should be set for at least the full run time of the bypass actuators. n. # Fans/System The number of fans in the attached system. o. Max Fans To Run The maximum number of fans that will run simultaneously at any time. For example, set to one less than # Fans/System for a system with one redundant fan. p. BRITE Adjusts the display brightness. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 8
q. CONTR Adjusts the display contrast. r. COMMUNICATIONS Press to go to the Communications screen. This will show relevant network parameters. The values cannot be changed from this screen. s. USER MAINTENANCE Press to go to the User Maintenance screen (see below). Passwords for user accounts can be changed on this screen. Use the PREV and NEXT keys to cycle through different users, if applicable. Use the SET PASS key to change the password for the user shown. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 9
Tune Screen This screen is used to fine tune the system. Touch any value to bring up a numerical entry pad. The following are descriptions of the parameters on this page (also see Sequence of Operations, pg. 13): a. System SP The current system static pressure. b. SP Set Point The static pressure set point the controller will follow. c. Min Drive Freq The current minimum VFD frequency as determined by the controller (cannot be changed manually). See Sequence of Operations on pg. 13 for more information on minimum frequency. d. Max Drive Freq Maximum frequency of the VFDs. This should match the maximum frequency parameter of the drives. Default value is 60 Hz. e. PID Gain PID gain value. Set in the field to tune system. f. PID Reset Time PID reset time value. Set in the field to tune system. g. PID Deadband Value around the static pressure set point to which the unit will control fan speed. h. PID Output Value of the PID Output. The value cannot be changed if the PID Auto parameter is set to On. i. PID Status When On, the controller will automatically adjust the PID output to follow the static pressure set point. When Off, the PID output will be as set by the user in the PID Output parameter. This parameter will automatically be set to On when any of the fans are set to Auto (after the initial control delay) & automatically set to Off when all fans are set to Off or Hand. j. Bypass Gain Rate in percent per second at which bypass dampers will operate. Note that the damper will not be able to open faster than its actuator s rated speed. Default value is 1% per second. k. Bypass Deadband Value around the static pressure set point to which the unit will control bypass damper position. l. Bypass Damper Open The current percentage open of the bypass dampers. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 10
Run Time This screen displays the total run time for each fan. Touch Toggle Format to switch the display between hours & days + hours. Touch Reset to reset all fan run times to 0 hours. Bypass Dampers When all fans are in either Off or Hand, this screen can be used to control the percentage open of the bypass dampers. The Open & Close buttons will open or close the bypass dampers by 1% for each press. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 11
Isolation Dampers When all fans are Off, this screen can be used to open or close the isolation dampers. There are three front panel LEDs as seen below: Front Panel LEDs The following is a description of the LED status: 1 Contact factory if this occurs. 2 Do not turn off power to the unit while this light is flickering. The unit writes data in two minute intervals. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 12
CompactFlash Card Below is a description of the unit s CompactFlash operation. The unit is supplied with a 2 Gb CompactFlash card. If changing cards it is recommended that the SanDisk brand be used. Data Logging The Smart System TM will log the system static pressure and static pressure set point at 30 second intervals with a time and date stamp onto the CompactFlash card. Alarm events with a time & date stamp will also be logged on the card. This data is available to view as an Excel spreadsheet if the unit is connected to a computer via the unit s USB port (Type B). To log other parameters or change logging interval, contact the factory. Remote Viewing The display can be viewed remotely if the unit is connected to a network. The display will appear on the remote terminal exactly as it appears on the unit. If desired, all actions that can be performed on the unit display can be performed remotely. The contents of the CompactFlash card are also available over the network. Contact the factory for more information. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 13
Sequence of Operations Items in [red] refer to display parameters (see Display section). The system is started when the H/O/A switch of at least one fan is switched to Auto. If [Bypass At Startup] is on, the bypass dampers will open to 100%. The lead fan in the system will energize. A startup timer begins when the fan is started. The VFD speed is forced to the minimum VFD speed [Min Speed]. As the pressure at the fan inlet increases (as measured by the fan static pressure transducer) the minimum VFD speed [Min Speed] changes. The minimum VFD speed is determined to be the frequency at which the nozzle outlet velocity is 3000 ft/min. The VFD speed will not drop below this value. After the startup timer exceeds the [Startup Delay] value, the PID control will start to follow the system static pressure [System SP] and static pressure set point [SP Set Point]*. A fan s isolation damper begins to open a certain amount of time after the fan is energized as determined by the [Isolation Damper Delay] value. A fan s isolation damper begins to close a certain amount of time after the fan is de-energized as determined by the same parameter. The system static pressure [System SP] drives [PID Output] based on the parameters on the Tune screen. [PID Output] controls the VFD speed. All fans running concurrently will run at the same speed. Lag fans are energized when the VFD speed is equal to the [Lag On Freq] for the duration of the [Lag On Delay]. The bypass dampers modulate open when the VFD speed matches the minimum VFD speed [Min Speed] and the system static pressure [System SP] is greater than the static pressure set point [SP Set Point]*. It opens at a rate determined by the [Bypass Gain] parameter. The bypass dampers modulate closed when the system static pressure [System SP] is less than the static pressure set point [SP Set Point]*. It closes at a rate determined by the [Bypass Gain] parameter. [PID Output] is frozen when bypass damper operation is active. Minimum VFD speed [Min Speed] is frozen when bypass damper operation is active. Lag fans are de-energized when the VFD speed is below the [Lag Off Freq] value or the bypass damper is fully open based on the [Bypass Cutoff] value for the duration of the [Lag Off Delay]. The lead/lag sequence will alternate once per month based on the [AltDate] and [AltHour] parameters on the Alternation screen. If a failure is sensed on a running fan, a lag fan will be energized (if available) to take its place. The failed fan will automatically be place at the end of the run sequence on the Alternation screen. An alarm will occur if the system static pressure [System SP] reaches the value of the [Hi SP Alarm] parameter. If the system static pressure [System SP] drops below the [Hi SP Alarm Reset] value, the alarm will be able to be reset. If the system static pressure [System SP] reaches the [Hi SP Shut Down] value, the system will automatically shut down. * If it is desired to send the static pressure set point remotely from the building control system, a 4-20mA signal can be sent to the Setpoint Override terminal. 4mA will correspond to 0 SP; 20mA will correspond to the [System SP Trans. Range] parameter on the Service screen. If a signal is present in the override terminal, the [SP Set Point] parameter on the unit will be ignored. V1.0.8 - Strobic Air Tri-Stack Smart System TM Page 14