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Heat Controller Water Source Heat Pump manual

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Table of contents for the manual

  • Page 1

    WHP - Water Source Heat Pump Design, Installation & Operations Manual[...]

  • Page 2

    [...]

  • Page 3

    WattMaster WHP Installation & Operations Manual Section 1 .................................................................................... Desig n Guide Section 2 ................................................................... Insta l latio n and Wiring Section 3 ..........................................................................[...]

  • Page 4

    [...]

  • Page 5

    Section 1 Design Guide T able of Contents Conventions ..................................................................... 1 General Information ......................................................... 2 Water Source Heat Pump Units .......................................................................................2 Water Source Heat Pump Sy [...]

  • Page 6

    [...]

  • Page 7

    WattMaster WHP Section 1 Design Guide 1-1 Con v entions This document uses the following definiti ons throug hout as a guide to the user in determining the nature of the information prese nted: Note: Additional information which may be helpful. Tip: Sugge stion to make installati on, set-up, and troubleshooting easier. Caution: I tems which may cau[...]

  • Page 8

    Section 1 WattMaster WHP 1-2 Design Guide Gener al Inf or ma tion Water Source Heat Pump Units A water source heat pump is a self-contained water-cooled p ackag ed heating and cooling unit with a reversible refrigerant cy cle. Its components are ty pically enclosed in a common casing, and include a t ube-in-tube heat ex changer, a heating/cooling c[...]

  • Page 9

    WattMaster WHP Section 1 Design Guide 1-3 Typical Water Source Heat Pum p During the cooling mode, the tube-in-tube h eat ex changer functions as a condenser and the coil as an evaporator. I n heati ng mode, the tube-in-tube heat exchanger functions as an evaporator and the coil as a condenser. A re versing valve is installed in the refrigerant cir[...]

  • Page 10

    Section 1 WattMaster WHP 1-4 Design Guide accommodate changes in location and siz es as thermal zones or zone occupancy change . This sy stem is often installed in ceiling plenums, which frees up valuable floor space. Another valuable benefit of water source heat pumps is that they can accommodate simultaneous calls from zone s requiring hea ting o[...]

  • Page 11

    WattMaster WHP Section 1 Design Guide 1-5 Pump Reset and Aux. Heating or Cooling. An internal seven da y schedule and holiday schedule functions are also built into each WHP Controller. With the WHP sy stem the sometimes complex control requirements of a large water source heat pump sy st em can be handled with an off th e shelf controls system tha[...]

  • Page 12

    Section 1 WattMaster WHP 1-6 Design Guide WHP Sequence of Oper a tion HVAC Mode of Operation There are four possible modes of operati on. These are Cooling Mode, Heating Mode, Vent Mode, and the Off Mode. The HVAC mode of operation is calcu lated the same way in both occupied and unocc upied modes of operation. Off Mode The schedule is off and no o[...]

  • Page 13

    WattMaster WHP Section 1 Design Guide 1-7 Occupied/Unoccupied Mode of Operation Since the WHP conta ins its own built in Real Time Clock, it can operate from its own internal scheduling sy stem. This schedule supports two Start & Stop events per day and up to 14 Holiday periods. The Holiday s all use the same special Holiday Start/Stop times pr[...]

  • Page 14

    Section 1 WattMaster WHP 1-8 Design Guide HVAC Operation w/ Reversing Relay I f the user has config ured the WHP to control a Re versing Valve and a Compressor, the following sequence of operation occurs during a heating or cooling demand. Note: I f y ou configure the WHP to look for a proof of flow Enable signal from the Loop Controller then the f[...]

  • Page 15

    WattMaster WHP Section 1 Design Guide 1-9 HVAC Operation w/ Heat/Cool Relays I f the user has configured the WHP to cont rol I ndividual Heating and Cooling relay s the following sequence of operation occurs during a heating or cooling demand. NOTE: I f y ou configure the WHP to look for a proof of flow Enable signal from the Loop Controller then t[...]

  • Page 16

    Section 1 WattMaster WHP 1-10 Design Guide WHP Loop Contr oller Sequence of Operations Summary The Water Source Heat Pump Loop Controller waits for a Request to Run signal from a Heat Pump or from a Binary Contact Closure. Once th e request is received t he Loop Controller ac tivates a Pump to initiate water flow to the Hea t Pumps. Once the pump i[...]

  • Page 17

    WattMaster WHP Section 1 Design Guide 1-11 pump exceeds the first pumps run time by th e same amount. This keeps both pumps with roughly the same number of hours on each pump. Changeover occurs at the time the run time setpoint is exceeded. The running pump is shut off at the same time the standby pump is e nerg ized, this prevents a ny down time o[...]

  • Page 18

    Section 1 WattMaster WHP 1-12 Design Guide Heat Rejection Control I f the compressor is not running, no heat rejec tion can be active. I f any heat rejection is still active when the co mpressor is turned off, the heat reje ction will be immediate ly removed, without regard to any minimum run or off times. Heat rejection cannot be active at the sam[...]

  • Page 19

    WattMaster WHP Section 1 Design Guide 1-13 Staged Heat Addition Heat Addition is st aged up based on a differe nt deadband level for each stage. Basically , if the user programmed a 2° deadband, then the first stage could activ ate at the setpoint, stage 2 would activate 2° below the setpoint, stage 3 would activate 4° below the setpoint, etc...[...]

  • Page 20

    Section 1 WattMaster WHP 1-14 Design Guide Water Temperature Alarming The controlling water temperature is monito red to prevent it from ex ceeding both a user defined High and L ow Alarm Limit. I f either limit is exceeded for a user defined length of time, an alar m is genera ted and the compre ssor output is de-activated. If the high limit is ex[...]

  • Page 21

    WattMaster WHP Section 1 Design Guide 1-15 Modem (Optional) CommLink II Multiple Loop Interface System Manager #30 #30 #30 #29 #1 #1 #1 #1 RS-485 19200 Baud RS-485 9600 Baud RS-485 9600 Baud RS-485 9600 Baud RS-485 9600 Baud Supply Air Sensor RS-485 Comm Loop 24 V AC Dirty Filter Alarm or Leaving W ater T emp Room Sensor with Optional Override &[...]

  • Page 22

    Section 1 WattMaster WHP 1-16 Design Guide Notes:[...]

  • Page 23

    Section 2 Installation and Wiring T able of Contents Tips Before Beginning Installation .................................. 1 Communications Loops ................................................... 3 Communications Loop Wiring Overview ....................................................4 WHP Loop Controller ........................................[...]

  • Page 24

    Section 2 Installation and Wiring T able of Figur es Figure 2-1: Sy stem Overview ........................................................................................2 Figure 2-2: Communication L oop Wiring, Daisy -Chain Configuration .......................4 Figure 2-3: WHP Loop Controller.......................................................[...]

  • Page 25

    WattMaster WHP Section 2 Installation and Wiring 2-1 Tips Bef or e Be ginning Installa tion Take a few moments to review the followi ng before beginning insta llation of the WattMaster WHP Sy stem. • Familiarize y ourself with a ll system components and re view all documentation. Pay special attention t o “Cautions” and “W arnings” since [...]

  • Page 26

    Section 2 WattMaster WHP 2-2 Installation and Wiring Modem (Optional) CommLink II Multiple Loop Interface System Manager #30 #30 #30 #29 #1 #1 #1 #1 RS-485 19200 Baud RS-485 9600 Baud RS-485 9600 Baud RS-485 9600 Baud RS-485 9600 Baud Supply Air Sensor RS-485 Comm Loop 24 V AC Dirty Filter Alarm or Leaving W ater T emp Room Sensor with Optional Ove[...]

  • Page 27

    WattMaster WHP Section 2 Installation and Wiring 2-3 Communica tions Loops The Communications L oop is two wire shield ed RS-485. The loop is best connected in daisy chain configuration, meaning the loop is c onnected from one controller to another. I t is not necessary to sequentially address the WHP Controllers in relation to their location on th[...]

  • Page 28

    Section 2 WattMaster WHP 2-4 Installation and Wiring Communications Loop Wiring Overview Comm unicatio n Loop Wiring, Daisy -Chain Config uration COMPUTER (OPTIONAL) SYSTEM M ANAGER Remote Link (OPTIONAL) UNIT COMES WITH ST ANDARD WALL MOUNT 120/24 V AC POWER SUPPL Y ( MAY AL S O BE PO WE RE D FRO M 2 4VAC ) COMM LINK II INTERF ACE (SET T O MUL TIP[...]

  • Page 29

    WattMaster WHP Section 2 Installation and Wiring 2-5 The daisy chain is the best method for runni ng a communications l oop since there is only one starting point and one ending point for each of the communications loops. Even though the daisy chain config uration is preferred, the star configuration can also be used. I f required, a combination of[...]

  • Page 30

    Section 2 WattMaster WHP 2-6 Installation and Wiring WHP Loop Contr oller The WHP Loop Controller may be installed in any conve nient protected location. I t is recommended that the loop controller be mounted indoors in a secure location, that is not subject to extremes in tempera ture or moisture. R L Y 1 D 1 D 2 D 3 D 4 D 5 C X 3 RAM EPROM C 3 C [...]

  • Page 31

    WattMaster WHP Section 2 Installation and Wiring 2-7 R (24 V AC By O thers) WHP Loop Controller Expansion B oard WHP Loop Controller Expansion Board Compresso r Enable Main Pump St andby Pump Alarm Indicator R10 R9 R8 R7 R6 R5 R4 R1 R2 R3 R1 1 Fire Al arm Contact (N.C.)(See Note 5) Request to Run Contact (N.O. ) 4.)When a W a ter Pressure T ransmit[...]

  • Page 32

    Section 2 WattMaster WHP 2-8 Installation and Wiring Warning: Polarity is very important when connecting power to the controllers! The grounded side of the control transformer must be connected to the terminal labeled GND on the contro ller. If a sing le transformer is used to power more than one controller y ou must connect GND-to- GND and 24VAC-t[...]

  • Page 33

    WattMaster WHP Section 2 Installation and Wiring 2-9 WHP Loop Contr oller Addr essing The WHP Loop Controller must be set for address #30. See addre ss setting instructions for the WHP Loop Controller that follow. A maximum of 29 WHP Controllers are allowed on the loop that contains the WHP L oop Controller. All othe r loops may have 30 WHP Control[...]

  • Page 34

    Section 2 WattMaster WHP 2-10 Installation and Wiring Suppl y & R etur n W a ter T emperatur e Sensor s Sensors for monitoring supply and return wa ter temperature are available in two main ty pes, fluid immersion temperature sensors (See Figure 2-6 ) and strap-on sensors (See Figure 2-7 ). Both are 0-10000 ohm thermistor ty pe sensors. The flu[...]

  • Page 35

    WattMaster WHP Section 2 Installation and Wiring 2-11 The strap-on ty pe sensor has a brass housing that senses th e water temperature through contact with the exterior surface of the pi pe. The sensor should be mounted in contact with the underside of the pipe in order to insure accurate temperature readings. The sensor assembly is secured to the [...]

  • Page 36

    Section 2 WattMaster WHP 2-12 Installation and Wiring Outside Air T emperature Sensor The outside air sensor must be located where it will not be affec ted by direct sun or heat producing equipment. Mounting under the ev e of a roof is often a good choice. Caution: Complain ts of inaccurate outside sensor readings are very common and can almost alw[...]

  • Page 37

    WattMaster WHP Section 2 Installation and Wiring 2-13 CommLink II Interface The Comm Link II Interface provides for communications between the MiniL ink communication interfaces instal led on the sy stem. The CommLink II is required for proper communications, even if a PC is not used. L ocate the CommL ink I I near the computer or modem if they are[...]

  • Page 38

    Section 2 WattMaster WHP 2-14 Installation and Wiring WHP Contr oller The WHP Controller may be installed in any convenient protected location. Observe the recommended e nvironmental limitations for the WHP Controlle r when selecting a installation location. The environmental limitations are a temperature range of 10 ° F to 149 ° F, and a maximum[...]

  • Page 39

    WattMaster WHP Section 2 Installation and Wiring 2-15 Rev . V alve-On/O ff Fan- On/O ff 24V AC Compressor-On/Off Heat Pump Res et Aux. Hea ti ng Or Coo ling Wate r Source Heat Pump Unit Connec tions WHP C ont r o ll e r R SH T R SH T R SH T R SH T All Comm Lo op Wi ring Is S t raight Thru Requir ed VA For Transformer Each WHP Co ntroller = 10V A MI[...]

  • Page 40

    Section 2 WattMaster WHP 2-16 Installation and Wiring The WHP Controll er requi res the fol low ing electri cal conn ections : 18 Gauge minimum unless otherwise noted. -24VAC Supply Voltage ........................................................................... 2 Conductors -Communications L oop ...................................... 2 Conducto[...]

  • Page 41

    WattMaster WHP Section 2 Installation and Wiring 2-17 WHP Contr oller Addr essing CAUTI ON: YOU MUST POWER DOWN THE CONTROLLER AFTER CHANGING THE ADDRESS SWITCHES IN ORDER FOR ANY CHANGES TO T AKE EFFECT . AL WA YS REMOVE THE COMMUNICA TIONS LOOP PRIOR TO DI SCONNECTING POWER. RECONNECT POWER AND THEN RECONNECT THE COMMUNICA TIONS LOOP T O THE CONT[...]

  • Page 42

    Section 2 WattMaster WHP 2-18 Installation and Wiring MiniLink Addr essing Notes: R SH T R SH T R SH T R SH T All Com m un i c atio n Loop Wiring Is Straight Thro ugh 16 32 8 4 2 1 Caution! The MiniLinks M ust Have Address Swi tches Set Between 1 And 30 ( U p T o 30 Mi n iLin ks Are Allow e d Per WH P Sy stem Sys te m). The Mini Li nks Shoul d Be A[...]

  • Page 43

    WattMaster WHP Section 2 Installation and Wiring 2-19 R oom Sensor s The room sensor uses a patented flush mount design to isolate the temperature sensing element from the housing which mounts flush with the wall surface. Room sensors should be located on an inside wall away from direct sunlight or heat producing equipment such as computers, copier[...]

  • Page 44

    Section 2 WattMaster WHP 2-20 Installation and Wiring Connect the terminal labeled GND on the zone sensor to the termin al labeled GND on the WHP Controller Analog I nput terminal block. Connect the terminal labeled TMP on the zone sensor to the terminal labeled AIN 1 on the WHP Controller Analog I nput terminal block. I f the zone sensor has a set[...]

  • Page 45

    WattMaster WHP Section 2 Installation and Wiring 2-21 Suppl y Air T emper a tur e Sensor The supply air tem perature sensor should be located in the duct, as close to the rooftop unit discharge as possible for best response. L ocate the sensor in the center of the wide st part of the duct. Use the supplied template and a 5/16" drill to make a [...]

  • Page 46

    Section 2 WattMaster WHP 2-22 Installation and Wiring Lea ving W a ter T emperatur e Sensor s The leaving water temperature sensor (optional) when used should be located on the leaving water piping close to the water sour ce heat pump unit. Either a thermowell ty pe or a surface mount sensor may be us ed depending on job requirements. OE291 St ainl[...]

  • Page 47

    Section 3 Programming Table of Contents LCD/Keypad Operations ................................................... 1 Sy stem Manager Lay out ...................................................................................................2 Key pad Functions ...........................................................................................[...]

  • Page 48

    [...]

  • Page 49

    WattMaster WHP Section 3 Programming 3-1 L CD/K eypad Oper a tions Main Screen The Water Source Heat Pum p System Manager i s the operato r’s interface to the status and setpoints of any WattMaster Water Source H eat Pump (WHP) component on y our communications loop. With the Sy stem Manage r, y ou can view any temperature or output condition and[...]

  • Page 50

    Section 3 WattMaster WHP 3-2 Programming System Manager Layout Keypad Functions The Sy stem Manager ke y pad is labeled either numerically or as to actual function for that key . Below is a summary of the labeled keys and their functions. MENU This key is used to gain access to the first menu, and the user will be notified, on the L C D, if any sub[...]

  • Page 51

    WattMaster WHP Section 3 Programming 3-3 System Manager LED Indicators There are two LED indicators located on the right hand side of the Sy stem Manager. The top L ED indicates an Alarm c ondition if the Manag er detects an a larm condition while polling the sy stem. The bottom LED is active during actual com munications or packet t ransfers. This[...]

  • Page 52

    Section 3 WattMaster WHP 3-4 Programming Hea t Pump Sta tus Scr eens View Status Only By selecting the View Status Only menu item, y ou can access any heat pump or the l oop controller and read all available temperat ures, out puts, and operating conditions for the selected unit. No passcode is required to access these status screens, and no setpoi[...]

  • Page 53

    WattMaster WHP Section 3 Programming 3-5 I f y ou selected menu item #1 View Status Only and y ou entered the Unit ID of an installed W HP Control ler, the followi ng Status Screens are available. Status Screen #1 Status Screen #2 Line 2 - Current Zone Temperature Line 3 - Current Cooling Setpoint ( CSP ) and Heating Setpoint ( HSP ) Line 4 - Effec[...]

  • Page 54

    Section 3 WattMaster WHP 3-6 Programming Status Screen #3 Status Screen #4 Status Screen #5 Line 2 - Current Operatin g Status Unoccupi ed Mode Occupi ed Mode Pushbutton Overrid e Forced Occup ied Forced Unoccup ied Forced Fan Only Mode Line 3 - Current Fan Status Fan Start Delay! ON OFF Line 4 - Current Enable Status from L oop Controller Operatio[...]

  • Page 55

    WattMaster WHP Section 3 Programming 3-7 Status Screen #6 Note: I f no alarms ex ist, th en the screen display s the message shown for No Alarms! I f ANY alarm exists then the three lin es display one of the messag es shown above. The Cooling Failure and He ating Failure alarms are generated as follows: As the unit enters the cooling mode, th e cur[...]

  • Page 56

    Section 3 WattMaster WHP 3-8 Programming View Alarms Alarm Address Locations Alarm Clearing The Sy stem Manager can be progra mmed to poll all the units on y our heat pump system for alarm information. This allows the cen trally located Sy stem Manager to display an Alarm Indicator whenever an alarm condition ex ists any where on your sy stem. The [...]

  • Page 57

    WattMaster WHP Section 3 Programming 3-9 Menu Setpoints Full Setpoint Access Set Time & Da te The Sy stem Mana ger has its own built in Real Time Cloc k. I t broadcasts this time once a day , at midnight, to sy nchronize all of the WHPs on y our sy stem. Although the times are display ed on the Main Screen in a standard 12-hour format, they are[...]

  • Page 58

    Section 3 WattMaster WHP 3-10 Programming Programming Date Daylight Savings Adjustments Month - Enter the Month (1 to 12) Day - Enter the Day of the Month (1 to 31) Year - Enter the current Year with 2 digits (00 to 99) I f y our area of the country re quires Day light Savings chang es, y ou can enable the Sy stem Manag er to automatic ally reset i[...]

  • Page 59

    WattMaster WHP Section 3 Programming 3-11 New P asscodes Programming Passcodes The Sy stem Manager has two levels of passcode. L evel 1 users a re limited to view ing Setpoints and Ala rms only . Le vel 2 users have complete sy stem access. Any status or setpoint field can be read or reset from WHP System Manag er. The default passcode is “1111?[...]

  • Page 60

    Section 3 WattMaster WHP 3-12 Programming R ebuild Alar m Ma p Rebuilding Screens I f y ou would like the L ED Alarm Indicator to function on the front of y our Sy stem Manag er, y ou must enable Alarm Polling by building an Alarm Map. This map ke eps track of which units exist on your communications loop so the System Manag er will poll only those[...]

  • Page 61

    WattMaster WHP Section 3 Programming 3-13 Hea t Pump Setpoints Heat Pump Setpoint Menu 1) WHP Setpoints Setpoint Screen #1 The Occupied Heating and Cooling Setpoints are programmed on this screen. The se tpoints must be at least one degre e apart. I f you try to enter the same value or to cross the cooling a nd heating se tpoints, the value y ou en[...]

  • Page 62

    Section 3 WattMaster WHP 3-14 Programming Setpoint Screen #2 Setpoint Screen #3 Setpoint Screen #4 ° ° The Unoccupied Heating and Coolin g Setbacks are programmed on this screen. The Cooling SetUp is added to the Occupied Cooling Setpt to create the Unoccupied Cooling Setpoint. The Heating SetBack is added to the Occ upied Heating Setpt to create[...]

  • Page 63

    WattMaster WHP Section 3 Programming 3-15 Setpoint Screen #5 Setpoint Screen #6 Setpoint Screen #7 The Min Run Tim e determines how long the compressor must remain on once it has been activated. The Min Off Tim e determines how long the compressor must remain off once it is de-activat ed. The Min Cycle time dete rmines how many times per hour the c[...]

  • Page 64

    Section 3 WattMaster WHP 3-16 Programming Setpoint Screen #8 Setpoint Screen #9 Setpoint Screen #10 I f y our heat pump uses a reversing valve to determine the heating or cooling mode of operation, select the message R/VALVE & COMPRESSOR . If y ou are controlling separate stages of heating and cooling select t he INDIVIDUAL STAGING message. I f[...]

  • Page 65

    WattMaster WHP Section 3 Programming 3-17 Setpoint Screen #11 Setpoint Screen #12 Setpoint Screen #13 I f y our system is configured to use the reversing valve and y ou only have one stag e of h eating a nd cooling, that la st relay becomes available for ot her uses. The AUXILIARY RELAY MODE can be used to operate the relay manually from the Prism [...]

  • Page 66

    Section 3 WattMaster WHP 3-18 Programming Setpoint Screen #14 Setpoint Screen #15 Setpoint Screen #16 The Hea t Pump Controlle r can use the internal time clock for a setting an occupied sc hedule, for this the se tpoint will be 0. I t can also be programmed to follow an external schedule command. You must have an OSS Optimal Start Schedule r insta[...]

  • Page 67

    WattMaster WHP Section 3 Programming 3-19 Setpoint Screen #17 Setpoint Screen #18 Setpoint Screen #19 Note: You must do a Rebuild Alarm Map afte r all controllers are powered up and communicating . ° This setpoint is to shut the heating off when the supply air temperature is too warm. When the supply air temperature is above this setpoint, it will[...]

  • Page 68

    Section 3 WattMaster WHP 3-20 Programming 2) WHP Schedules The Water Source Heat Pump controlle rs contain their own built in scheduling capability for calculating Occupied/Unoccupied peri ods. Select item #2 from Schedules menu to access the following schedule programming menu. Schedule Menu Week Schedule Programming Event #1 Event #2 There are tw[...]

  • Page 69

    WattMaster WHP Section 3 Programming 3-21 Holidays Holiday Day Selection There are 14 Hol iday periods available, organized as a Start Day / Stop Day event. If the Holiday only la sts one day , enter the same da te for the Star t & Stop day s. There is no limit to the duration or number of day s that can be included in one holiday , other than [...]

  • Page 70

    Section 3 WattMaster WHP 3-22 Programming 3) Reset Pumps I f one of y our heat pumps ha s tripped off, it can be manually reset from the following screen. You will have ente red the Unit I D to access the WHP Menu screen, so th at is the uni t that will receive this rese t command. I f you don’t want to send the command, select the Disabled messa[...]

  • Page 71

    WattMaster WHP Section 3 Programming 3-23 Loop Contr oller Sta tus Loop Controller Status Menu From the main menu screen sel ect MENU on the keypad. Then select “View Status Only” (key pad #1) and finally enter the l oop and zone number for the desired unit. As the screen above shows, there are tw o areas of status available for the Loop Contro[...]

  • Page 72

    Section 3 WattMaster WHP 3-24 Programming Status Screen #2 Status Screen #3 Status Screen #4 Line 2 - Current operating Mode: No Call To Run ACTIVE CALL TO RUN FREEZ E PROTECTION! Line 3 - Current Water Flow Status: Water Flow Proved! No Flow Detected Line 4 - Current Request to Operate Status: LOOP ENABLED LOOP DISABLED Line 2 - L EAD Pump #1 On o[...]

  • Page 73

    WattMaster WHP Section 3 Programming 3-25 Status Screen #5 Status Screen #6 Note: I f none of the above options have been configured, then the values in this status screen will be 0. Line 2 - Current Loop Water Pressure Line 3 - Current Variable Speed Pump Voltag e Signa l Line 4 - Current Proportional Heat Voltage Sig nal Line 1 - Cool/Heat S tage[...]

  • Page 74

    Section 3 WattMaster WHP 3-26 Programming Status Screen #7 Note: I f no alarms ex ist, th en the screen display s the message shown for No Alarms! If ANY alarm exists, then the three lines di splay one of the messag es shown above. The Fire/Smoke Alarm is genera ted as follows: I f the NC (normall y closed) contact from a firest at or smoke det ect[...]

  • Page 75

    WattMaster WHP Section 3 Programming 3-27 Loop Contr oller Setpoints Loop Controller Setpoint Menu Setpoint Screen #1 Setpoint Screen #2 I f the controlling water temp erature rises above this Setpoint , the Heat Rejection or Cooling St ages beg in to stage on. As the temperature continues to rise above the Setpoint by the Deadband amount, an addit[...]

  • Page 76

    Section 3 WattMaster WHP 3-28 Programming Setpoint Screen #3 Setpoint Screen #4 Setpoint Screen #5 I f the controlling water tempera ture drops below this Setpoint, the Heat Addition or Boilers begin to stage on. As the temperature continues to drop below the Setpoint by the Deadband amount, an additional stage is added. Each additional stage can o[...]

  • Page 77

    WattMaster WHP Section 3 Programming 3-29 Setpoint Screen #6 Setpoint Screen #7 Setpoint Screen #8 I f the controlling water te mperature rises above the Water Hi Limit setpoint, all hea t addition will be removed a nd one stage of he at rejection will be activated. I f the controlling water tempera ture drops below the Water Lo Lim it setpoint, al[...]

  • Page 78

    Section 3 WattMaster WHP 3-30 Programming Setpoint Screen #9 Setpoint Screen #10 Setpoint Screen #11 The two pumps will switch afte r this programmed amount of time so that each pump accumulates roughly the same number of run time hours. I f a pump is currently running and this time period is exceeded, the changeover will occur as soon as pump run [...]

  • Page 79

    WattMaster WHP Section 3 Programming 3-31 Setpoint Screen #12 Setpoint Screens #13 Note: Due to memory limitations in the Loop Controller, the maximum amount of calibration offset is 10.0 ° F. Setpoint Screen #14 Setpoint Screen #15 I f y ou configured the sy stem for Variable Speed Pumping with a Pressure Sensor for proof of flow, the Loop Contro[...]

  • Page 80

    Section 3 WattMaster WHP 3-32 Programming Notes:[...]

  • Page 81

    Section 4 Start-Up and Troubleshooting T able of Contents 1.0 Communications Overview ........................................ 1 1.1 How I t Works ...........................................................................................................1 1.2 WattMaster WHP Sy stem ...................................................................[...]

  • Page 82

    Section 4 Start-Up and Troubleshooting 5.0 Troubleshooting ...................................................... 21 5.1 General Troubleshooting........................................................................................21 5.1.1 Communications Troubleshooting Checklist .................................................21 5.1.2 General Tr[...]

  • Page 83

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-1 1.0 Communica tions Ov er view Perhaps no other portion of the system seems as difficult to diagnose as the comm unica- tions loop, y et it really can be quite simple if y ou understand how it works. In fact, much of the troubleshooting can be done by simple observation. We will lead you thr[...]

  • Page 84

    WattMaster WHP Section 4 4-2 Start-Up and Troubleshooting Modem (Optional) CommLink II Multiple Loop Interface System Manager #30 #30 #30 #29 #1 #1 #1 #1 RS-485 19200 Baud RS-485 9600 Baud RS-485 9600 Baud RS-485 9600 Baud RS-485 9600 Baud Supply Air Sensor RS-485 Comm Loop 24 V AC Dirty Filter Alarm or Leaving W ater T emp Room Sensor with Optiona[...]

  • Page 85

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-3 All communications wiring should be labele d to avoid confusion and to aid future servicing . COMPUTER (OP T ION AL ) SYSTEM MANAGER Remote Link (OPTIONAL) UNIT C OMES WITH ST ANDARD W AL L MOUNT 120/24 VAC POWER SUPPLY ( MAY AL SO BE PO WERE D FRO M 2 4VAC ) COMM LI NK II INTERFACE (MUL TIP[...]

  • Page 86

    WattMaster WHP Section 4 4-4 Start-Up and Troubleshooting 2.0 WHP Contr oller Ov erview 2.1 How It Works 2.1.1 Initialization On sy stem powerup the COMM L ED remains ex tinguished for five seconds. After this delay , the COMM LE D will blink out the a ddress of the controller (Address Switch Setting). The COMM L ED will then ex tinguish fo r anoth[...]

  • Page 87

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-5 2.2 Becoming Familiar with the WHP Controller E W D O G 0-5 VDC 0-1 VDC DIAGN OSTIC BLINK CODE LED ADDRESS S WITCH ( AD DRES S 18 SHOWN ) EPRO M PIN 1 INDICATION RAM RAM SIZE SELEC T J UMPE R PA L REAL TIME CLOCK CHIP 24V AC POWER INPUT POWER LED COMMUNICA TIONS DRIVER CH IP COMMUNICA TIONS [...]

  • Page 88

    WattMaster WHP Section 4 4-6 Start-Up and Troubleshooting 2.2.2 Analog Inputs This connector carries the analog and binary control input signals. AIN1 - Space Temp - This input accepts a two wire 10K Type III t h e r m i s t or t e m - perature sensor. The sens or measures 10,000 Ohms @ 77 ° F. The resistance drops as the temperature increases. Th[...]

  • Page 89

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-7 OUT3 - Compressor or Heat 2 - This output enables the compressor if you have configured the WHP Controll er for a co mpressor and reversing valve configura- tion. I f the WHP Controller is configured for individual staging of heating and cooling (no reversing valve) then this output enables [...]

  • Page 90

    WattMaster WHP Section 4 4-8 Start-Up and Troubleshooting 2.2.6 WHP Controller Wiring Typical WHP Con troller Wiri ng Di agram Communicatio n LED[...]

  • Page 91

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-9 3.0 Loop Contr oller Ov erview 3.1 How It Works 3.1.1 Initialization On sy stem powerup LED2 remains extinguished for five seconds. After this delay , the L ED2 will blink out the address of the controller (Address Switch Setting ). The L ED2 will then extinguish for another five seconds and[...]

  • Page 92

    WattMaster WHP Section 4 4-10 Start-Up and Troubleshooting 3.2 Loop Controller Inputs & Outputs 3.2.1 Analog Inputs AIN1 - Return Water Temp - This input accepts a two wire 10K Ty pe III t h e r - mistor temperature sensor. The sensor measures 10,000 Ohms @ 77 ° F. The re- sistance drops as the temp erature increases . The sensor is connected [...]

  • Page 93

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-11 3.2.3 Binary Output R1 – Compressor Enable – Energizes th e first stage of cooling. R2 – Main Pump – Energizes the lead water pump. R3 – Standby Pum p – Energizes the standby pump if the main pump fails to start. R4 – Alarm Indicator – Energ izes when an alarm occurs on the [...]

  • Page 94

    WattMaster WHP Section 4 4-12 Start-Up and Troubleshooting 3.2.6 Comm Connector - Communications RS-485 Comm unications Connector - This connector provides the connection point for the L ocal Loop RS-485 communications loop. The wiring consists of a twisted pair of wires with a shield. T - RS-485 (+) Communications termina l SHLD - Common return wi[...]

  • Page 95

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-13 Figure 4-5: Loop Contro ller Inputs & Outputs Line Voltage Loca l Lo o p R S- 4 85 9600 Baud (See Note 3). Connect To Next Controller And/ Or MiniLink On Local Loop Opti onal Pressure sens or[...]

  • Page 96

    WattMaster WHP Section 4 4-14 Start-Up and Troubleshooting 4.0 Star t-Up 4.1 Blink Codes for WHP Controllers The WHP Controller uses an on board LED to indicate various diagnostic conditions during powerup and operation. The W HP Unit L ED is labeled “C OMM”. Starting with power up the LED blink codes are as follows: • Off for five seconds ?[...]

  • Page 97

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-15 4.2 Blink Codes for Loop Controllers The L oop Controller uses an on board L ED to indicate various diagnostic conditions during powerup and operation. The Loop Cont roller Unit L ED is labeled “L ED2”. Starting with power up the L ED blink codes are as follows: • Off for five seconds[...]

  • Page 98

    WattMaster WHP Section 4 4-16 Start-Up and Troubleshooting 4.4 Installation and Commissioning Information Fam iliarize yourse lf with the installation manual and system wiring diagr ams before installing! 1. Check to see if y ou have all the co rrect components for your installation. 2. Establish the l ocation for the C ommLink I nterface first. Th[...]

  • Page 99

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-17 10. Install CommL ink and power-up. At this point y ou are ready to begin commissioning the sy stem. It is preferred, though not nece ssary , to use a PC with P rism software to assist in the commissioning process. 11. Start with the first controller on the co mmunication loop or in multipl[...]

  • Page 100

    WattMaster WHP Section 4 4-18 Start-Up and Troubleshooting Com m uni cations Loop Wiri ng SYSTEM MANAGER COMM LI NK II INTERF ACE (MUL TIPLE LOOP) TO OTHE R MINI LIN KS (NETWORK T ERMINALS O NL Y) TO OTHER WHP CONTROLLERS Y S101 716 REV. 1 SYSTEM MANAGER POWER SUPPLY SHLD COMMU NI CATIONS RS-485 R T GND 24VAC POWER LOOP NETWORK T T SH SH R R 24VAC [...]

  • Page 101

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-19 4.5 Setting Address Switches 4.5.1 Setting the MiniLink Address Switch L O O P N E T W O R K LOOP ADDRESS S WITCH ADDRESS SW ITCH SHO W N IS SET FOR ADDRESS 1 ADD RESS S WITCH SH OWN IS SET FOR ADDRESS 13 LOOP ADDRESS SWITCH T SH R 24V AC GND T SH R 32 16 8 4 1 2 1 2 3 4 7 5 6 8 OFF > 32[...]

  • Page 102

    WattMaster WHP Section 4 4-20 Start-Up and Troubleshooting 4.5.2 Loop Controller Addressing The Loop Controller address should alway s be set for address #30. A maximum of 29 WHP Controllers on the loop that contains th e L oop Controller. All other loops may have 30 WHP Controllers. (Refer to Figure 2-10 for more detail) 4.5.3 WHP Controller Addre[...]

  • Page 103

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-21 5.0 T r oubleshooting 5.1 General Troubleshooting The following is a guide to assist in troubleshooting the W attMaster WHP System. I t is provided as a sy stematic approach to determining and resolving common sy stem problems. 5.1.1 Communications Troubleshooting Checklist No WHP or Loop C[...]

  • Page 104

    WattMaster WHP Section 4 4-22 Start-Up and Troubleshooting 5.1.2 General Troubleshooting Checklist Beg in troubleshooting by locating the genera l problem in the list below. Detailed component troubleshooting information follows later in this section. Zone is too warm • I s zone calling for cooling? • I s the compressor disabled due to minimum [...]

  • Page 105

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-23 5.2 Alarms When an alarm occurs in the WHP or Loop Controller, it is reported to the System Manag er. The alarms cause the light on the Sy stem Manage r to illuminate. The View Alarms sc reen will indicate the address of th e a larms. The Status sc reen will display the ty pe of alarm that [...]

  • Page 106

    WattMaster WHP Section 4 4-24 Start-Up and Troubleshooting 5.3 Checking Comm. Loop Voltages 5.3.1 Checking the CommLink II Network Loop Diagram Overvie w This test checks for proper Network loop v oltages at the Comm Link II . The Loop LED (located on the front panel) should “flicker” when the Com mLink I I is attempting to communicate. The Loo[...]

  • Page 107

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-25 5.3.2 Checking the Comm Loop at the CommLink II Diagram The indicated v alues are typical of a normal sy stem, actual readings m ay deviate slightly due to the number of units connected and other sy stem specific factors. All of the connected Minilinks should be pow ered up for this test. O[...]

  • Page 108

    WattMaster WHP Section 4 4-26 Start-Up and Troubleshooting 5.3.3 Checking the CommLink II Driver Diagram Overvie w This test checks for proper Network loop v oltages coming from the Com mLink I I. The Loop LED (located on the front panel) should “flicker” when the Com mLink I I is attempting to communicate. The Loop LED will flick er more notic[...]

  • Page 109

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-27 5.3.4 Checking the MiniLink Network Loop Diagram Meter Set To Read DC Volts The indicated readings are typical of a normally operating system . Actual reading s may vary slightly due to the number of units inst alled and other factors. Any sig nificant devia- tion from these v alues general[...]

  • Page 110

    WattMaster WHP Section 4 4-28 Start-Up and Troubleshooting 5.3.5 Checking the MiniLink Network Driver Diagram Meter Set To Read DC Volts These tests assume that the MiniLink being check ed is powered up Overvie w This check is intended to determine if th e Network Com m Driv er chip on a MiniLink is damag ed. Before unplug ging the Network loop fro[...]

  • Page 111

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-29 5.3.6 Checking the MiniLink Local Loop Diagram Meter Set To Read DC Volts The indicated readings are typical of a norm a lly operating system . Actual readings m ay v ary slightly due to the number of units installed and other factors. Any sig nificant deviation from these v alues generally[...]

  • Page 112

    WattMaster WHP Section 4 4-30 Start-Up and Troubleshooting 5.3.7 Checking the Local Loop at MiniLink Diagram Meter Set To Read DC Volts The indicated values are ty pical of a normal system . Actual readings m ay dev iate slightly due to the number of units connected and other sy stem specific factors These tests assume that the controllers being ch[...]

  • Page 113

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-31 5.3.7 (continued) Action If voltag es are too high or too low on either side 1. One or m ore of the attached controllers has a dam aged Comm Driver chip. Lo- cate and replace the driver chip (s). See "1.3.11 Comm Driver Chip Re- placement”. 2. Wiring errors such as "crossed conn[...]

  • Page 114

    WattMaster WHP Section 4 4-32 Start-Up and Troubleshooting 5.3.8 Checking the MiniLink Local Loop Driver Diagram Meter Set To Read DC Volts The indicated values are ty pical of a normal operating sy stem. A ctual readings m ay deviate slightly . These tests assume that the MiniLink is powered up. Overvie w This test checks for proper Local Loop vo [...]

  • Page 115

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-33 5.3.9 Checking the Local Loop at a WHP Controller Diagram Meter Set To Read DC Volts The indicated readings are typical of a norm a l operating system . Actual readings m ay v ary slightly due to the number of units installed and other factors. Any sig nificant deviation from these v alues [...]

  • Page 116

    WattMaster WHP Section 4 4-34 Start-Up and Troubleshooting 5.3.10 Checking WHP Controller Driver Chip Diagram Meter Set To Read DC Volts These tests assume that the controller being checked is powered up. Overvie w This check is intended to determ ine if the Comm Driver chip on a controller is damag ed. Damag e typically occurs when the com municat[...]

  • Page 117

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-35 5.4 Troubleshooting Loop Controller 5.4.1 Checking the Loop Controller Analog Inputs Diagram Overvie w 12V GND AIN1 AIN2 AIN3 AIN4 AOUT2 GND + - R SE T ME T ER TO READ DC V OLT S ALL READINGS ARE T AKEN WITH THE (-) LEAD OF THE METER ON THE GND TERMINAL + AIN5 AIN7 GND AOUT1 - The analog in[...]

  • Page 118

    WattMaster WHP Section 4 4-36 Start-Up and Troubleshooting 5.4.1 (continued) AIN4 Outdoor Air Temp 1.9 volts (100 ° F) - 3.6 volts (40 ° F) Typical is 2.5 volts @ 77 ° F AIN5 Manual Reset If the input is O PEN, the vo ltage will be g r eater than 5.0 volts If the input is C LOSED, the v oltage will be less than 0.5 volts AIN7 Phase Loss If the i[...]

  • Page 119

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-37 5.4.2 Checking the Loop Controller Outputs Diagram Overvie w + - R SET M E TER TO READ DC VOLTS ALL READI NGS ARE T AKEN WITH THE (-) LEAD OF THE METER ON THE GND TERMINAL + - The analog output wiring can be checked at the Loop Controller by check ing voltages on the Analog Output Connector[...]

  • Page 120

    WattMaster WHP Section 4 4-38 Start-Up and Troubleshooting 5.4.3 Checking the Local Loop at a WHP Loop Controller Diagram Meter Set To Read DC Volts The indicated readings are typical of a norm a l operating system . Actual readings m ay vary slightly due to the number of units installed and other factors. Any significant deviation from these v alu[...]

  • Page 121

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-39 5.4.4 Checking WHP Loop Controller Driver Chip Diagram Meter Set To Read DC Volts These tests assume that the controller being checked is powered up. Overvie w This check is intended to determ ine if the Comm Driver chip on a controller is damag ed. Damag e typically occurs when the com mun[...]

  • Page 122

    WattMaster WHP Section 4 4-40 Start-Up and Troubleshooting 5.4.5 Comm Driver Chip Replacement LOOP CO NTRO LLER CPU B OARD COMM DR IVER CHIP ( U1 ) PIN 1 COMMLINK II COMMUN ICA TION S DRIVER CHIP WHP CO NTRO LLER MINILI NK CO MMUNI CA T IONS INTERFACE PIN 1 WHP CO NTR O LLE R COMM DR IV ER CH IP ( U5 ) WAR N I N G! USE EXT REME CA UTION W HEN REMOV[...]

  • Page 123

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-41 5.5 Temperature Sensor Resistance Chart º 82 8893 2.407 84 8514 2.352 86 8153 2.297 88 7805 2.242 90 7472 2.187 95 6716 2.055 100 6047 1.927 105 5453 1.805 110 4923 1.687 115 4449 1.575 120 4030 1.469 125 3656 1.369 130 3317 1.274 135 3015 1.185 140 2743 1.101 145 2502 1.024 150 2288 0.952[...]

  • Page 124

    WattMaster WHP Section 4 4-42 Start-Up and Troubleshooting 5.6 Pressure Sensor Voltage Chart 0 4.00 1.00 1 4.32 1.08 2 4.64 1.16 3 4.96 1.24 4 5.28 1.32 5 5.60 1.40 6 5.92 1.48 7 6.24 1.56 8 6.56 1.64 9 6.88 1.72 10 7.20 1.80 11 7.52 1.88 12 7.84 1.96 13 8.16 2.04 14 8.48 2.12 15 8.80 2.20 16 9.12 2.28 17 9.44 2.36 18 9.76 2.44 19 10.08 2.52 20 10.[...]

  • Page 125

    WattMaster WHP Section 4 Start-Up and Troubleshooting 4-43 Notes:[...]

  • Page 126

    Form: W M-W HP -I O-02A Printed in t he USA October 2004 All right s reserved Copyright 2004 W attm aster Contr ols Inc. • 8500 NW River P ark Drive • Parkville MO • 64152 Phone (816) 505-1100 E-m ail: mail@wattmaster.com Fax (816) 505-1101[...]