Bard TCS22-***-003 User Manual

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OPERATIONS MANUAL

TELCOM

CLIMATEWATCH

SYSTEM

MODEL

TCS22-***-003

Manual:

2100-444-003A

Supersedes:

2100-444-003

File:

Vol. III, Tab 19

 

Table Of Contents

 

1.0

INTRODUCTION ...........................................................................................................

1

1.1

Shipping Damage .........................................................................................................................

1

1.2

Package Contents .........................................................................................................................

1

1.3

Additional Requirements ............................................................................................................

1

1.4

Copyright Notice ..........................................................................................................................

1

1.5

General..........................................................................................................................................

2

1.5.1

Building Points to be Monitored:...........................................................................................

2

1.5.2

Wallmount Points to be Monitored for Each Unit:................................................................

2

1.5.3

Building Points to be Controlled: ..........................................................................................

2

1.5.4

System Points to be Controlled:.............................................................................................

3

1.5.5

Wallmount Points to be Controlled: ......................................................................................

3

1.5.6

Alarm Points: .........................................................................................................................

3

1.6

Model Nomenclature....................................................................................................................

5

2.0

SPECIFICATIONS.........................................................................................................

5

2.1

Electrical Specifications...............................................................................................................

5

2.2

Mechanical Specifications ...........................................................................................................

5

2.3

Environmental Specifications .....................................................................................................

5

2.4

Sensor Specifications ...................................................................................................................

6

2.4.1

Temperature Sensors..............................................................................................................

6

2.4.2

Humidity Sensors...................................................................................................................

6

2.4.3

Compressor Current Sensor ...................................................................................................

6

2.4.4

Dirty Filter Sensor..................................................................................................................

6

2.4.5

Blower Airflow Switch ..........................................................................................................

7

3.0

INSTALLATION...........................................................................................................

11

3.1

Mounting.....................................................................................................................................

11

3.2

Wiring .........................................................................................................................................

11

3.2.1

High Voltage Wiring............................................................................................................

11

3.2.2

Wiring - Low Voltage ..........................................................................................................

12

 

2100-444-003A

 

 

Page ii

 

3.2.3

 

Wiring - Sensors ..................................................................................................................

12

3.2.4

 

Wiring – Inputs & Outputs...................................................................................................

13

3.2.5

 

Wiring - Telephone Line......................................................................................................

14

3.2.6

 

Wiring - Ethernet .................................................................................................................

14

3.3

Installation Check List ..............................................................................................................

18

3.4

System Startup ...........................................................................................................................

19

3.4.1

 

Wallmount Startup Checklist...............................................................................................

19

3.4.2

 

TCS22 Startup Checklist .....................................................................................................

20

4.0

OPERATION................................................................................................................

21

4.1

General........................................................................................................................................

21

4.2

Sequence of Operation...............................................................................................................

21

4.2.1

 

Cooling Sequence with Economizers ..................................................................................

21

4.2.2

 

Heating Sequence.................................................................................................................

21

4.2.3

 

Fan Sequence .......................................................................................................................

21

4.2.4

 

Occupied / Unoccupied Mode Sequence .............................................................................

22

4.2.5

 

Alarm Sequence ..................................................................................................................

22

4.2.6

 

Dehumidification sequence..................................................................................................

24

4.2.7

 

Thermal Shock Protection Sequence ...................................................................................

24

4.2.8

 

Modem Sequence.................................................................................................................

24

4.2.9

 

Power Management Sequence .............................................................................................

24

4.2.10

Setpoints...............................................................................................................................

25

5.0

DISPLAY & KEYPAD OPERATION (DAK).................................................................

25

5.1

Display & Keypad Physicals .....................................................................................................

25

5.2

Power Up.....................................................................................................................................

26

5.3

Menu Tree...................................................................................................................................

26

5.3.1

 

Buildings Status Screen .........................................................................................................

27

5.3.1.1

Room Temperature ..............................................................................................................

28

5.3.1.2

Room Humidity ...................................................................................................................

28

5.3.1.3

Outdoor Temperature...........................................................................................................

28

5.3.1.4

Outdoor Humidity................................................................................................................

28

5.3.1.5

Active Cooling Setpoint.......................................................................................................

28

5.3.1.6

Active Heating Setpoint.......................................................................................................

28

5.3.1.7

Free Cooling On / Off ........................................................................................................

29

5.3.1.8

Room Occupied Yes/No ...................................................................................................

29

5.3.1.9

Outdoor Enthalpy................................................................................................................

29

 

 

2100-444-003A

 

 

 

Page iii

 

5.3.2

Unit Status Screen..................................................................................................................

30

5.3.2.1

Unit #1 Economizer .............................................................................................................

30

5.3.2.2

Unit #1 Compressor .............................................................................................................

30

5.3.2.3

Unit #1 Heater......................................................................................................................

30

5.3.2.4

Unit #1 Blower.....................................................................................................................

30

5.3.2.5

Unit #1 FILTER ...................................................................................................................

31

5.3.2.6 Unit #1 Discharge Air Temperature.....................................................................................

31

5.3.3

Alarms Menu..........................................................................................................................

31

5.3.3.1

 

Space Temp Alarm .............................................................................................................

32

5.3.3.2

 

Space Humidity Alarm........................................................................................................

32

5.3.3.4

 

#1 Compressor Alarm .........................................................................................................

33

5.3.3.5

 

#1 Filter Alarm....................................................................................................................

33

5.3.3.6

 

Utility Power Fail................................................................................................................

33

5.3.3.7

 

Fire Trouble .....................................................................................................................

34

5.3.3.8

 

Fire Alarm...........................................................................................................................

34

5.3.3.9

 

Outdoor Temp Alarm..........................................................................................................

34

5.3.3.10

Outdoor Humidity Alarm.................................................................................................

34

5.3.3.11

Door Alarm ......................................................................................................................

34

5.3.4 Setpoints Screen ............................................................................................................................

35

5.3.4.1

Occupied Cooling Setpoint ..................................................................................................

36

5.3.4.2

Unoccupied Cooling Setpoint ..............................................................................................

36

5.3.4.3

Occupied Heating Setpoint ..................................................................................................

37

5.3.4.4

Unoccupied Heating Setpoint ..............................................................................................

37

5.3.4.5 High Temperature Alarm Setpoint.......................................................................................

37

5.3.4.6 Low Temperature Alarm Setpoint .......................................................................................

37

5.3.4.7

High Humidity Alarm Setpoint............................................................................................

37

5.3.4.8

Low Humidity Alarm Setpoint ............................................................................................

37

5.3.4.9

Dehumidification Setpoint...................................................................................................

37

5.3.4.10

Free Cooling Enthalpy Setpoint.......................................................................................

38

5.3.4.11

Free Cooling Dry Bulb Setpoint ......................................................................................

38

5.3.5 Overrides Unit #1 Screen .............................................................................................................

39

5.3.5.1

#1 Blower Override..............................................................................................................

40

5.3.5.2

#1 Economizer Override ......................................................................................................

41

5.3.5.3

#1 Compressor Override ......................................................................................................

41

5.3.5.4

#1 Heater Override...............................................................................................................

41

5.3.5.5

Continuous Blower ..............................................................................................................

42

5.3.6 Enables Menu...............................................................................................................................

43

5.3.6.1

Economizer Operation .........................................................................................................

44

5.3.6.2

Free Cooling Enthalpy Changeover .....................................................................................

44

5.3.6.3 Dry Bulb Temperature Changeover .....................................................................................

44

5.3.6.4

Daylight Savings Time.........................................................................................................

44

 

2100-444-003A

 

 

Page iv

 

5.3.6.5

50HZ Clock..........................................................................................................................

44

5.3.6.6

Zone Humidity Sensor .........................................................................................................

44

5.3.7

 

Password Operation...............................................................................................................

45

5.4

Keyboard Map ...........................................................................................................................

46

6.0

PC SOFTWARE OPERATION ....................................................................................

48

6.1

ClimateWatch System Software Overview.............................................................................

48

6.2

Installation..................................................................................................................................

48

6.2.1

 

Hardware Requirements.......................................................................................................

48

6.2.2

 

Software Installation ............................................................................................................

48

6.3

ASI Expert / Bard ClimateWatch Software ............................................................................

49

6.3.1

 

Screen Overview..................................................................................................................

49

6.3.2

 

TCS communications...........................................................................................................

51

6.4

TCS Controller Information Screens.......................................................................................

59

6.4.1

 

Main Screen Tab ..................................................................................................................

60

6.4.2

 

Set Point Tab........................................................................................................................

62

6.4.3

 

Override #1 Tab ...................................................................................................................

66

6.4.4

 

Alarms Tab...........................................................................................................................

70

6.4.5

 

Alarm Log Tab.....................................................................................................................

74

6.4.6

 

Offsets Tab...........................................................................................................................

75

6.4.7

 

Misc. Tab .............................................................................................................................

76

6.4.8

 

Trend Tab.............................................................................................................................

79

6.4.9

 

Dial Out Tab ........................................................................................................................

80

6.4.10

Notes Tab .............................................................................................................................

82

7. MAINTENANCE & TROUBLESHOOTING ........................................................................

83

7.1

Routine Maintenance.................................................................................................................

83

7.2

Troubleshooting .........................................................................................................................

83

7.2.1

 

TCS22 Troubleshooting......................................................................................................

83

7.2.2

 

Wallmount quick troubleshooting Guide.............................................................................

89

2100-444-003A Page v

 

 

Table of Figures and Tables

 

Figure 1 Front Cover ......................................................................................................................

8

Figure 2 Control Location............................................................................................................

9

Figure 3 Mounting Template....................................................................................................

10

Table 1

Low Voltage Wire Size..............................................................................................

12

Figure 4

External Wiring............................................................................................................

15

Figure 5

Internal Wiring .............................................................................................................

16

Figure 6

Power Backup System..............................................................................................

16

Table 2. Enthalpy Lookup Table............................................................................................

39

Table 3

Humidity Sensor Output............................................................................................

87

Table 4

Thermistor Resistance Vs. Temperature Table..............................................

88

2100-444-003A Page vi

1.0INTRODUCTION

1.1Shipping Damage

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the carrier immediately, preferably in writing, requesting inspection by the carrier's agent.

1.2Package Contents

1 - TCS22

1 - Outdoor Humidity Sensor

1 - Outdoor Temperature Sensor

1 - TCS22 Operations Manual

1 - TCS Software Package

1.3Additional Requirements

This controller is suitable for use with 1 1/2 ton through 6 ton Bard WallMount airconditioners. The Bard WallMount must be equipped with the "V" control module for proper operation of the TCS22. Air-conditioner model numbers used with the TCS22 should contain the letter "V" in the 15th position of the model number.

The TCS22 can be used with or without economizers. If economizers are to be used the units should be ordered with the “D” vent option. The air-conditioner with economizer used with the TCS22 should contain the letter "D" in the 10th position of the model number.

Additionally, to utilize the Power Failure Management portion of the controller an Inverter and battery backup system should be installed in the shelter. This provides for ventilation of the structure in case of utility power failure, alarming of the power failure condition, and acts as an uninterruptible power supply for the TCS22. See Figure 6.

If the inverter and battery backup system is not used disregard the power failure management sequence later in this manual.

The power transfer relays shown in Figure 3 are field supplied items and are needed if ventilation of the structure is required during power outages. The field supplied power transfer relays should be sized to handle the MCA of the unit being controlled. Single phase units will require a 4 pole contactor with 2 normally open and 2 normally closed contacts. Three phase units will require either a six pole contactor or two 3 pole relays with 3 normally closed and three normally open contacts. Square D, D- Line or F-Line contactors or equivalent are recommended.

If ventilation of the structure is not required during power outages these may be omitted. The TCS22 will still dial out and alarm the power failure condition although no ventilation will be provided.

1.4Copyright Notice

All materials contained in this manual originated from and are the property of Bard Manufacturing Co. Any reproduction of the text, drawings, or wiring diagrams contained in this manual is forbidden without the written consent of Bard Manufacturing Co.

2100-444-003A Page 1

All SOFTWARE supplied with this product is the property of Bard Manufacturing Co. You may not modify, disassemble, de-compile, reverse engineer, or create derivative works from this SOFTWARE. Bard Manufacturing Co. licenses the purchaser of this product to use two copies of this SOFTWARE on two computer systems, one remote computer system and one on site computer system.

If installed on a network server, additional software licenses should be purchased for each computer on the network using the SOFTWARE.

1.5General

The Telcom Climate Watch System (TCS) is a building monitoring and control system used in conjunction with one (1) Bard Wall-Mount air-conditioners. The system consists of a state of the art direct digital controller, the TSC22, one (1) Bard Wall-Mount air-conditioners, and a special "V" control module that is added to the Bard Wall-Mount air-conditioners. This system provides the following features.

1.5.1 BUILDING POINTS TO BE MONITORED:

Space Temperature

Space Humidity

Outdoor Temperature

Outdoor Humidity

Occupancy Override Switch

Main Power to Building

Fire Alarm Circuit

Fire Trouble Circuit

Door Alarm Circuit

1.5.2WALLMOUNT POINTS TO BE MONITORED FOR EACH UNIT:

Blower Airflow

Discharge Air Temperature

Valid Compressor Current Sensor

Compressor Lockout Relay

Dirty Filter Sensor

1.5.3BUILDING POINTS TO BE CONTROLLED:

Power Transfer Relay

Shelter Alarm Circuit

Door Alarm

2100-444-003A Page 2

1.5.4SYSTEM POINTS TO BE CONTROLLED:

Modem Power

1.5.5 WALLMOUNT POINTS TO BE CONTROLLED:

Blower Unit #1

Economizer Unit #1

Compressor Unit #1

Heating Unit #1

Blower Unit #2

1.5.6ALARM POINTS:

High Space Temperature

Low Space Temperature

High Space Humidity

Low Space Humidity

Blower Failure Unit #1

Compressor Lockout Unit #1

Compressor Current Failure Unit #1

Dirty Filter Unit #1

Main Power Failure

Fire Alarm

Fire Trouble

Door Alarm

2100-444-003A Page 3

INPUTS

 

 

 

 

 

1

Indoor Temperature Sensor

Required

(Standard in TCS22)

2

Indoor Humidity Sensor

Optional

(Optional in TCS22)

3

-0

Unit #1 Blower Airflow Sensor

Required

(Standard in "V" Module)

 

-1

Unit #1 Compressor Lockout Relay

Required

(Standard in "V" Module)

 

-2

Unit #1 Dirty Filter Sensor

Optional

(Standard in "V" Module)

4

Unit #1 Discharge Air Sensor

Optional

(Standard in "V" Module)

5Spare

6Spare

7

Unit #1 Compressor Current Switch

Required

(Standard in "V" Module)

8

Spare

 

 

9

Fire Trouble

Optional

 

10

Fire Alarm

Optional

 

11

Spare

 

 

12

Door Alarm

Optional

 

13

Main Power Sensor

Optional

 

14

Occupied Override Switch

Required

(Standard in TCS22)

15

Outdoor Temperature Sensor

Required

(Standard in TCS22)

16

Outdoor Humidity Sensor

Required

(Standard in TCS22)

OUTPUTS

1Spare

2Cycle Power To Modem

3Power Transfer Switch

4Unit #1 Economizer (Y1)

5Unit #1 Compressor (Y2)

6Unit #1 Heater (W1)

7Unit #1 Blower (G)

8Spare

9Spare

10Spare

11Spare

12Shelter Alarm Circuit

13Unit #1 is Lead Unit

14Spare

15Free Cooling

16Power Failure

2100-444-003A Page 4

1.6 Model Nomenclature

 

 

 

TCS2

2 - H D M - 001

 

BASIC MODEL

 

 

 

 

 

 

 

 

 

SOFTWARE

 

 

 

 

 

 

 

 

 

REVISION NUMBER

 

 

 

 

 

---- REMOTE COMMUNICATIONS

 

 

 

 

 

SENSORS

 

 

 

 

 

 

 

DISPLAY M - With

 

 

 

 

 

 

 

H- Humidity & Temperature

 

 

 

 

 

D - With

X - Without

T - Temperature Only

 

 

 

 

 

X – Without

E - Ethernet

2.0SPECIFICATIONS

2.1Electrical Specifications

Supply Voltage

208/240 VAC +/- 10% 50/60 HZ

Minimum Circuit Ampacity

3 Amp

Overcurrent Protection

Internal Circuit Breaker - 3 Amp

Controller Analog Inputs

16

 

Resolution

8 bits/ 0.4% Full Scale

Voltage Range

0 Vdc to +10 Vdc

Current Rating

5.0 mA at +10 Vdc

Binary Relay Outputs

12

 

Type

Form "A" Relay SPST N.O.

Contact Rating

24

VAC, 5 A Resistive

 

24

VAC, 2 A Inductive

2.2Mechanical Specifications

Height

26.25 in., (667 mm.)

Width

17.00 in., (432 mm.)

Depth

5.50 in., (140 mm.)

Material

18 ga galvanized steel with Beige baked polyester enamel.

Mounting

Vertical

Mounting Area Required

27 in. high by 18 in. wide, (686 mm. high by 457 mm. wide)

Weight

27 lb., (12.3 kilograms)

2.3Environmental Specifications

Operating Temperature Range

32 to 130 o F (0 to 55o C)

Operating Humidity Range

10 to 95%, non condensing

Storage Temperature Range

-35 to 180 o F (-37 to 82o C)

Storage Humidity Range

5 to 95%, non condensing

2100-444-003A Page 5

2.4Sensor Specifications

2.4.1TEMPERATURE SENSORS

Indoor and Outdoor

Type

Thermistor

Ohms

3000 at 77o F (25o C)

Temperature Range

-40 to 302 o F (-40 to 150o C)

Interchangeability

.2 Deg Celsius

Discharge

 

Type

Thermistor

Ohms

10000 at 77o F (25o C)

Temperature Range

-40 to 302 o F (-40 to 150o C)

Interchangeability

.2 Deg Celsius

2.4.2 HUMIDITY SENSORS

 

Type

Bulk Polymer

Output

0-5 Vdc

Supply Voltage

24 Vac, +/- 15%

Accuracy

+/- 5%

Sensitivity

0.1% RH

Repeatability

0.5% RH

Long Term Stability

Less than 1% per year

Interchangeability

+/- 3%

Temperature Range

-40 to 130 o F (-40 to 76o C)

Humidity Range

0 to 99%, non condensing

2.4.3COMPRESSOR CURRENT SENSOR

Type

Solid State DC Switch

Output

Form "A" solid state DC switch

Supply Voltage

Self Powered

Trip Current Range

1 to 175 Amps

Maximum Load

150 mA, at 30 VDC

Temperature Range

-58 to 149 o F (-50 to 65o C)

Dimensions

2.125 in. high, 3.25 in. wide, 1 in. deep

 

(54 mm. high, 83 mm. wide, 26 mm. deep)

2.4.4 DIRTY FILTER SENSOR

 

Type

Mechanical Airflow Switch

Output

Form "A" Contact

Supply Voltage

Self Powered

Maximum Load

1.5A, at 24 VAC

Temperature Range

0 to 170 o F (-18 to 77o C)

Pressure Range

0.1 to 0.7 in. wc.

Dimensions

3 1/4 in. high, 2 1/4 in. wide, 2 in. deep

 

(83 mm. high, 57 mm. wide, 51 mm. deep)

 

2100-444-003A

 

Page 6

2.4.5BLOWER AIRFLOW SWITCH

Type

Mechanical Airflow Switch

Output

Form "C" Contact

Supply Voltage

Self Powered

Maximum Load

300 VA, at 24 VAC

Temperature Range

-40 to 180 o F (-40 to 82o C)

Pressure Range

0.07 to 0.12 in. wc

Dimensions

6.125 high, 4.125 wide, 3.188 deep

 

(156 mm. high, 105 mm. wide, 81 mm. deep)

2100-444-003A Page 7

Figure 1 Front Cover

2100-444-003A Page 8

Figure 2 Control Location

2100-444-003A Page 9

Figure 3 Mounting Template

16.000

9.356

7.856

6.356

4.856

3.356

1.000

22.288

MIS-866

2100-444-003A Page 10

1.288

HIGHVOLTAGE WIRING

3.0INSTALLATION

This section discusses mounting and wiring of the TCS22 into the building. Also included is an installation checklist to be completed by the installing contractor. See installation instructions supplied with the Bard Wall-Mount air conditioners for information on installing the air conditioners.

This controller should be installed and serviced by a qualified service technician only.

3.1Mounting

TCS22 should be mounted on a flat vertical surface four (4) to six (6) feet from the floor of the building. When choosing a suitable location take into consideration that the electrical connections can be made from the back or top of the TCS22. See Figure 3 for rear electrical entrance locations.

The TCS22 is secured to the wall with four (4) - 1/4 inch fasteners with flat washers. Hollow wall anchors or lag bolts are suitable as dictated by the wall construction. See Figure 3 for a bolt pattern layout drawing.

!WARNING

_________________________________

HAZARD OF ELECTRIC SHOCK.

ELECTRIC SHOCK CAN RESULT IN SERIOUS INJURY OR DEATH.

DISCONNECT THE REMOTE ELECTRIC POWER SUPPLIES BEFORE SERVICING.

3.2Wiring

Electrical connections can be made from the back or top of the TCS22. All wiring should exit the TCS22 in conduit. Use the supplied wire ties and cable holders to route unit low voltage, communication, and sensor wiring neatly. Avoid looping excess wire. See Figure 2 for suggested conduit connections.

Never connect or disconnect wiring from the

controller with power connected to the controller or to either of the Bard Wall-Mount air-

conditioners.

3.2.1HIGH VOLTAGE WIRING

IMPORTANT: High voltage wiring must not be run in the same conduit as low voltage control or sensor wiring. Failure to comply with this requirement will result in poor or no remote communication and/or in inaccurate sensor reading.

Supply power is 208/240 VAC, 50/60 Hz, 1 Phase at 3 amps minimum circuit ampacity. A 3 amp circuit breaker is supplied as part of the TCS22. This circuit breaker is for internal circuit protection only and cannot be used as a disconnect. Supply wire size should be 18 ga. or larger. Use Copper Conductors Only. All wiring must comply with the applicable sections of the National Electrical Code ( NEC) and any applicable local codes.

The TCS22 is shipped for 240 VAC operation . For 208 Volt operation change both transformer primaries in the TCS22 to the 208 volt tap. See Wiring Diagram. The acceptable operating voltage ranges for the 240 and 208 volt taps are:

Tap

Range

240

253-216

208

220-187

Connect the high voltage power supply to Terminal Block TB2. Connect ground wire to the ground connector provided. TCS22 must be grounded for proper operation. Failure to ground the controller may cause erratic controller operation and inaccurate sensor operation. See Figure 2 and the wiring diagram.

2100-444-003A Page 11

3.2.2 WIRING - LOW VOLTAGE

IMPORTANT: High voltage wiring must not be run in the same conduit as low voltage control or sensor wiring. Failure to comply with this requirement will result in poor or no remote communication and/or in inaccurate sensor reading.

Sixteen (16) wires should be run from each Bard Wall-Mount to the low voltage terminal

block in the TCS22. An eight pair shielded cable with 20 gauge copper conductors, such as National Wire & Cable Corporation NQP series cable or equivalent, is recommended for distances up to 45 feet. See Table 1 for distances more than 45 feet. The connection points are shown in Figure 5.

Table 1 Low Voltage Wire Size

Wire Gauge

Maximum Distance

 

in Feet ( meter)

20 gauge, 0.50 mm2

45 (14)

18 gauge, 0.75 mm2

60 (18)

17 gauge, 1.00 mm2

75 (23)

16 gauge, 1.50 mm2

100 (30)

14 gauge, 2.50 mm2

160 (49)

12 gauge, 4.00 mm2

250 (76)

3.2.3WIRING - SENSORS

IMPORTANT: High voltage wiring must not be run in the same conduit as low voltage control or sensor wiring. Failure to comply with this requirement will result in poor or no remote communication and/or in inaccurate sensor reading.

3.2.3.1 Outdoor Temperature Sensor (OTS)

The Outdoor Temperature Sensor (OTS) is supplied as part of the TCS22 package. The Outdoor Temperature Sensor (OTS) is a thermistor type device. The sensor is mounted in a weatherproof junction box suitable for connection to conduit. This sensor is a two (2) wire device.

The Outdoor Temperature Sensor (OTS)

should be mounted on the exterior of the structure at a height above any expected accumulation of snow. It is recommended that the box be mounted securely to the outside wall of the structure and all wiring to the sensor be made through conduit. A one (1) pair shielded cable with 20 gauge copper conductors, such as National Wire & Cable Corporation NQP series cable or equivalent, is recommended for connection to the sensor for distances up to 45 feet. See Table 1 for distances more than 45 feet.

Use wire nuts to connect the cable to the blue and yellow sensor leads in the sensor housing. Polarity is not critical with this sensor. The connection points for the sensor inside the TCS22 are shown in Figure 4.

3.2.3.2 Outdoor Humidity Sensor (OHS)

The Outdoor Humidity Sensor (OHS) is supplied as part of the TCS22 package. The Outdoor Humidity Sensor (OHS) is a bulk polymer type device. The sensor is mounted in a weatherproof junction box suitable for connection to conduit. This sensor is a four (4) wire device, 1 to 5 Vdc output.

The Outdoor Humidity Sensor (OHS) should be mounted on the exterior of the structure at a height above any expected accumulation of snow. It is recommended that the box be mounted securely to the outside wall of the structure and all wiring to the sensor be made through conduit. A two (2) pair shielded cable with 20 gauge copper conductors, such as National Wire & Cable Corporation NQP series cable or equivalent, is recommended for connection to the sensor for distances up to 45 feet. See Table 1 for distances more than 45 feet.

Connect the cable to the terminal blocks in the sensor housing. Polarity is critical with this sensor. The connection points for the sensor inside the TCS22 are shown in Figure 4.

3.2.3.3 Zone Temperature Sensor (ZTS)

The Zone Temperature Sensor (ZTS) is supplied as part of the TCS22 package. The Zone Temperature Sensor (ZTS) is a thermistor type device. The sensor is premounted to the front door of the TCS22. No wiring is required.

2100-444-003A Page 12

3.2.3.4 Zone Humidity Sensor (ZHS) (Optional)

The Zone Humidity Sensor (ZHS) is supplied as part of the TCS22 package (Optional). The Zone Humidity Sensor (ZHS) is a bulk polymer type device. If so equipped, the sensor is premounted to the front door of the TCS22. No wiring is required.

3.2.4 WIRING – INPUTS & OUTPUTS

A shielded cable with 20 gauge copper conductors, such as National Wire & Cable Corporation NQP series cable or equivalent, is recommended for connection to the inputs and outputs of the TCS22 for distances up to 45 feet. See Table 1 for distances more than 45 feet.

3.2.4.1 Shelter Alarm Output

The Shelter Alarm Output (SA) is a normally open set of contacts that closes whenever an alarm condition exists as sensed by the TCS22 controller. See the alarm section of this manual for an explanation of the various conditions that will send a shelter alarm.

The Form "A" contacts are SPST N.O. rated at 24 VAC, 5 A Resistive, or 24 VAC, 2 A Inductive. These rating should not be exceeded under any conditions.

These contacts may be used to trigger an alarm in the shelter or a remote alarm.

3.2.4.2 Power Transfer Switch Output (PTS)

The Power Transfer Switch Output is a normally open set of contacts that closes two (2) minutes after a power failure is sensed by the TCS22 controller. See the alarm section of this manual for an explanation of the power failure alarm.

The Form "A" contacts are SPST N.O. rated at 24 VAC, 5 A Resistive, or 24 VAC, 2 A Inductive. These rating should not be exceeded under any conditions.

These contacts can be used to energize a power transfer switch when used in conjunction with an

inverter to provide emergency ventilation of the shelter during power failures. Consult the power failure management sequence, section 4.2.10 and section 1.3, for more details.

3.2.4.3 Power Failure Sense Input

The Power Failure Sense is an input into the Controller. A normally open set of contacts is connected across these inputs. When power is lost to the shelter these contacts should close indicating that the building has lost normal utility power.

These contacts can be used in conjunction with an inverter and power transfer switch to provide emergency ventilation of the shelter during power failures. Consult the power failure management sequence, section 4.2.10 and section 1.3, of this manual for more details..

This is a dry contact input only. Do not connect any voltage source to these terminals. Do not connect utility power to these terminals.

3.2.4.4 Fire Alarm Input

The Fire Alarm is an input into the Controller. A set of normally open contacts is connected across these inputs. These contacts should close when fire alarm system has sensed a fire.

This is a dry contact input only. Do not connect any voltage source to these terminals. Do not connect utility power to these terminals.

3.2.4.5 Fire Trouble Input

The Fire Trouble is an input into the Controller. A set of normally open contacts is connected across these inputs. These contacts should close when the fire alarm system senses a problem with the fire alarm system.

This is a dry contact input only. Do not connect any voltage source to these terminals. Do not connect utility power to these terminals.

3.2.4.6 Door Alarm Input

The Door Alarm is an input into the Controller. A set of normally open contacts is connected across these inputs. These contacts

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should close when door is closed. If a door switch is not used a jumper should be placed across this input.

This is a dry contact input only. Do not connect any voltage source to these terminals. Do not connect utility power to these terminals.

3.2.5 WIRING - TELEPHONE LINE

When the TCS22 is equipped with a modem, an analog phone line should be connected to the back of the modem in the jack labeled LINE. This jack accepts a standard a RJ-11 six (6) position modular phone plug.

3.2.6WIRING - ETHERNET

When the TCS22 is equipped with an Etherlink communications module, The LAN/WAN should be connected to the back of the module in the jack labeled Ethernet. This jack accepts a standard a RJ-11 eight (8) position modular phone plug.

The Etherlink communications module requires a dedicated IP address. This must be programmed by the end user via a computer and RS232 cable at the time of connection to the network. The cable is provided with the TCS22.

Specific configuration information is provided with the EtherLink Module in a separate document.

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Figure 4

External Wiring

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Figure 5

Internal Wiring

Figure

6

Power

 

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Backup System

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3.3Installation Check List

TCS22 securely mounted to wall and all conduit connections tight.

Main power wiring is NOT in same conduit as low voltage or sensor wiring Main power wires are copper conductors

TCS22 is grounded.

Check supply voltage. Change both transformer taps if necessary. See Sec. 3.21 Carefully recheck all low voltage wiring for correct connection points . Carefully recheck all sensor connections for correct connection points. Recheck analog telephone wire connection to modem if so equipped.

Make sure modem power switch is on if so equipped.

Connect jumper between terminals DA if a door switch is not used.

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3.4System Startup

3.4.1WALLMOUNT STARTUP CHECKLIST

Operation

 

Procedure

 

 

Bypassing TCS22

Disconnect power to the TCS22. Unplug the plug in connectors J4 and

 

Controller

 

J5 from the controller

 

 

Apply power to both

Follow recommended startup procedure in the WallMount installation

 

Wall-mounts

 

instructions. Compressor damage could occur if startup procedures are

 

 

 

not followed.

 

 

Compressor Test

Connect jumper wire on A/C unit low voltage terminals from R to Y

 

 

 

and observe Compressor operation

(There will be a Time delay

 

 

 

between the installation of the jumper and the starting of the

 

 

 

Compressor. The Compressor Time Delay relay will determine the

 

 

 

time delay period.). After the Compressor starts, the jumper wire can

 

 

 

be removed.

 

 

Blower Test

 

Connect a jumper wire on A/C unit low voltage terminals R to G and

 

 

 

observe Blower operation (The Blower will continue to run for One (1)

 

 

 

minute after the jumper is removed).

 

Economizer Test

Connect a jumper wire on A/C unit low voltage terminals R to G and

 

 

 

observe Blower operation. After Blower operation is confirmed, the

 

 

 

Economizer can be tested. Leave the jumper in place from the previous

 

 

 

step. Connect a separate jumper on the A/C unit low voltage terminals

 

 

 

from E to F and observe the Economizer operation (Never connect

 

 

 

power to terminals E or F).

 

 

Heater Test

 

Connect a jumper wire on A/C unit low voltage terminals R to W1.

 

 

 

The Heating contactor will engage when the jumper is connected. The

 

 

 

Blower will also operate while this jumper is in place. To check the

 

 

 

operation of the Heater, you will have to check the Discharge Air

 

 

 

temperature of the A/C unit.

 

 

Disconnect Power to

Disconnect power to WallMount

air conditioners. Reconnect plug-in

 

WallMount

Air-

connectors J4 and J5 to the controller. Go to TCS22 Startup Checklist

 

Conditioners

 

 

 

 

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3.4.2TCS22 STARTUP CHECKLIST

 

 

 

Apply power to

Apply power to WallMount air-Conditioners. Wait two minutes for

 

WallMount

air-

wallmount time delays to expire.

 

Conditioners

 

 

 

Apply power to TCS22

Apply power to TCS22 and monitor LEDs on the front of the

 

 

 

controller. The controller performs a self test on startup. Upon

 

 

 

application of power, 9 LEDs will light.

 

 

 

System Power led will light and stay lit

 

 

 

Unit #1 is Lead Unit, Unit #2 is Lead Unit, Free Cooling, Power

 

 

 

Failure LEDs will light for 5 seconds and then resume normal

 

 

 

operation

 

 

 

System Rx and Tx and Local Rx and Tx will all flash on, flash off,

 

 

 

flash on and then flash off during this five seconds and will then

 

 

 

resume normal operation .

 

 

 

This completes the self test and controller will now start controlling

 

 

 

per the sequence of operation.

 

 

 

 

Connect to Controller

Use the DAK or Laptop PC to connect to controller to change

 

 

 

setpoints.

 

 

 

See Section 5.0 for DAK operation procedures.

 

 

 

See Section 6.0 for direct connect PC operation.

 

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4.0OPERATION

This section describes the sequence of operation of the controller. The tools available for monitoring and controlling the air-conditioners for both on-site and remote operations are explained. The remote trending, alarming, and site setup software are detailed.

4.1General

This section will describe the sequence of operation of the controller. Cooling , heating, dehumidification, and alarm sequences are explained.

4.2Sequence of Operation

This sequence of operation is for the TCS22-002 software package. Different software packages have different sequences of operation. Check the last three numbers of the TCS22 model number on the serial plate to verify that the sequence installed is "002"

4.2.1COOLING SEQUENCE WITH ECONOMIZERS

Free cooling setpoint, that is, the outdoor conditions at which cooling is handled by the economizer, can be configured to use either enthalpy or dry bulb temperature.

Outdoor Enthalpy or Temperature is calculated from Outdoor Temperature and/or Outdoor Humidity sensors. If the outdoor enthalpy or temperature is below the free cooling setpoint, free cooling is enabled and Output #15, Free Cooling is lit.

Active Cooling Setpoint is compared to Space Temperature . If Space temperature is above Active Cooling Setpoint, stage 1 cooling is enabled. If Free Cooling is enabled, Economizer and Blower of the Unit are energized. If Free Cooling is inhibited, Compressor and Blower of the Unit are energized.

If the Space Temperature is above Active Cooling Setpoint plus 2 deg Fo, stage 2 cooling is enabled. If Free Cooling is enabled, Compressor and Blower of the Unit are energized.

4.2.2HEATING SEQUENCE

Active Heating Setpoint is compared to Space Temperature. If Space temperature is below Active Heating Setpoint , Stage 1 heating is enabled. Heater and Blower of the Unit are energized.

4.2.3FAN SEQUENCE

The Evaporator Fan is programmed for continuous operation. Operator can change continuous operation to cycle on demand. Lag unit fan will cycle on demand.

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4.2.4OCCUPIED / UNOCCUPIED MODE SEQUENCE

In heating mode, activation of the Occupancy Override Button will change the Active Heating Setpoint from Unoccupied Heating Setpoint to Occupied Heating Setpoint for a period of two hours. In cooling mode, activation of the Occupancy Override Button will change the Active Cooling Setpoint from Unoccupied Cooling Setpoint to Occupied Cooling Setpoint for two hours.

4.2.5ALARM SEQUENCE

The controller will alarm on the following failures. Modem dial-out is initiated when any of the following alarms occur.

High Space Temperature

When Space Temperature is above High Temperature Alarm Setpoint a critical alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. This is a self clearing alarm.

Low Space Temperature

When Space Temperature is below Low Temperature Alarm Setpoint a critical alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. This is a self clearing alarm.

High Space Humidity

When Space Humidity is above High Humidity Alarm Setpoint a critical alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. This is a self clearing alarm.

Low Space Humidity

When Space Humidity is below Low Humidity Alarm Setpoint a critical alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. This is a self clearing alarm.

Blower Failure Unit #1

If Blower operation is called for the blower airflow sensor is checked. If the airflow sensor does not confirm that there is airflow, Output 7, Unit #1 Blower, is de-energized. After 30 seconds the blower is energized again. If airflow is not sensed, Output 7, Unit #1 Blower, is de-energized.

After another 30 seconds the blower is energized again. If airflow is not sensed, Output 7, Unit #1 Blower, is de-energized and locked out. A critical alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. Lead unit switches to lag unit. The Output Alarm must be cleared to resume operation.

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Compressor Lockout Failure Unit #1

If Compressor operation is not verified because the High or Low Pressure Lockout Relay has been energized, Output 5, Unit #1 Compressor, is de-energized and locked out. A critical alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. Lead unit switches to lag unit .The Output Alarm must be cleared to resume operation. Verify is tried 3 times before the output is locked out. Compressor Operation is verified by Unit #1 Compressor Lockout Relay and Unit #1 Compressor Current Switch.

Compressor Current Failure Unit #1

If Unit #1 Compressor is on and Unit #1 Compressor Current Switch is not valid , a critical alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. Lead unit switches to lag unit. The Output Alarm must be cleared to resume operation. Verify is tried 3 times before the output is locked out. Compressor Operation is verified by Unit #1 Compressor Lockout Relay and Unit #1 Compressor Current Switch.

Dirty Filter Unit #1

If Unit #1 Dirty Filter Switch is closed, a low priority alarm is logged in the Event List and Output 12, Shelter Alarm, is energized. This alarm must be reset at the unit.

Utility Power Failure

If Input #13, Power Sense, is closed indicating a utility power failure, a critical priority alarm is logged in the Event list and Output 12, Shelter Alarm, is energized. All unit outputs are deenergized. Two minutes after the alarm, Output #3, Power Transfer Switch, is energized . Three minutes after the alarm, Lead Unit Blower and Lead Unit Economizer are energized continuously until Utility Power Failure Alarm is cleared. This is a self clearing alarm.

Fire Trouble

If Input #9, Fire Trouble, is closed indicating a problem with the Fire Alarm System, a medium priority alarm is logged in the Event list and Output 12, Shelter Alarm, is energized.

Fire Alarm

If Input #10, Fire Alarm, is closed indicating a fire in the Zone, a critical priority alarm is logged in the Event list and Output 12, Shelter Alarm, is energized. All unit outputs are de-energized.

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