Johnson Controls Penn System 450 Series Technical Bulletin

System 450™ Series Modular Control Systems with Standard Control Modules

Code No. LIT-12011459

Technical Bulletin

Refer to the QuickLIT website for the most up-to-date version of this document.

Document Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Related Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

System 450 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

System 450 Standard Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Control Modules and User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Expansion Modules, Module Assemblies, and Outputs . . . . . . . . . . . . . . . . . . . . . . . . 13

Module Assemblies, Output Types, and Output Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hybrid Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

System 450 Compatible Sensors and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

System 450 Sensors and Transducers for Standard Control Modules . . . . . . . . . . . . . . . . 16

Issued October 28, 2013

Supersedes July 24, 2012

Active and Passive Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

System 450 Functional Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Direct and Reverse Control Actions for Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Proportional Plus Integral Control and Integration Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

High Input Signal Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Differential Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Sensor Failure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

System 450 Standard Control System Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Clean Room Control System Example with Temperature, Pressure, and Humidity Control 28

Solar Heating Control System Example Using Differential Control . . . . . . . . . . . . . . . . . . . 28

Hybrid Analog and High Input Signal Selection Control System Example. . . . . . . . . . . . . . 32

Detailed Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Designing and Building System 450 Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . 34

Technical Bulletin

1System 450™ Series Modular Control Systems with Standard Control Modules

Selecting, Installing, and Setting Up Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Assembling System 450 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Installing System 450 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Locating System 450 Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Wiring System 450 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Wiring System 450 Sensors and Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Setting up a System 450 Standard Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Determining Output Numbers and Output Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

System 450 UI Navigation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Accessing and Navigating the User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Viewing the System Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Accessing the System Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Setting Up the Sensors and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Setting up Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Setting up a Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Setting up an Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Setting up a Pulse Region Hybrid Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Setting Up Outputs That Reference a P 110 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Determining the Integration Constant for an Analog Output . . . . . . . . . . . . . . . . . . . . 56

Testing the Slowest to Fastest Time Integral to Determine I-C Setting . . . . . . . . . . . . . . . . 57

Using the Response Time to a Step Change to Determine the I-C Setting . . . . . . . . . . . . . . . . . 58

Troubleshooting System 450 Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Specified Voltage Ranges for Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Repair and Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

C450CPN-3C and C450CQN-3C Control Modules with Analog Output. . . . . . . . . . . . . 67

C450CPW-100C Control Module with Hybrid Analog Output . . . . . . . . . . . . . . . . . . . . 68

C450CBN-3C and C450CCN-3C Control Modules with Relay Output . . . . . . . . . . . . . . 69

C450SPN-1C and C450SQN-1C Expansion Modules with Analog Output . . . . . . . . . . 70

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin2

C450SBN-3C and C450SCN-3C Expansion Modules with Relay Output . . . . . . . . . . . 71

C450YNN-1C Power Supply Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

System 450 Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 3

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin4

System 450™ Series Modular Control Systems with Standard Control Modules

Technical Bulletin

Document Introduction

This document describes System 450™ features and functions, and provides guidelines and instructions for designing, selecting, installing, setting up, and troubleshooting System 450 control systems that use System 450 standard control modules or the System 450 control module with Hybrid Analog Output (C450CBN-x, C450CCN-x, C450CPN-x, C450CQN-x, and C450CPW-100 models).

This document also provides information and instructions for selecting, installing, and setting up sensors, expansion modules, and the power module in your control systems with standard control modules or the hybrid analog control module.

This document also provides System 450 Technical Specifications on page 67 and references to System 450 Related Documentation.

In this document, control module refers to the System 450 standard control modules noted previously and the System 450 hybrid analog output control module. Hybrid analog output refers only to the System 450 hybrid analog output control module (C450CPW-100).

Note: For information regarding System 450 reset control modules

(C450RxN-x) and control systems that use reset control modules, refer to the System 450 Series Modular Control Systems with Reset Control Modules Technical Bulletin (LIT-12011842).

Note: For information regarding System 450 control modules with network

communications, refer to the System 450 Series Modular Control Systems

with Communications Control Modules Technical Bulletin (LIT-12011826).

System 450 Overview

The System 450 Series is a family of compact digital electronic control, expansion, and power modules that are easily assembled and set up to provide reliable on/off and proportional control of temperature, pressure, and humidity conditions in a wide variety of HVACR and commercial/industrial process applications.

The System 450 Series is designed to replace System 350 Series and System 27 Series control systems and provides more features and greater flexibility with far fewer model variations. Most System 350 and System 27 modules are designed for single condition applications (either temperature, pressure, or humidity) and cannot be configured to control multiple conditions with a single control system. Depending on the control module model used, a single System 450 control system can monitor and control both temperature and humidity, or temperature, pressure, and humidity simultaneously.

Note: System 450 modules are not compatible with System 350 or System 27

modules, but you can build all of the System 350 and System 27 control systems and many more with System 450 modules, usually with fewer modules.

The System 450 Series has several model variations; each module is designed to be multi-purpose, adaptable, and completely field configurable for temperature, pressure, and humidity applications. The System 450 Series allows you to build a wide range of inexpensive, compact, durable, and versatile custom control systems that allow you to monitor and control multiple control loops in your controlled system. A System 450 control system can monitor temperature, pressure, and humidity simultaneously and control up to ten outputs (analog outputs, relay outputs, or both) based on the monitored conditions.

Note: System 450 communications control modules, System 450 standard

control modules, and the System 450 control module with hybrid analog output can monitor and control temperature, pressure, and humidity

applications simultaneously. System 450 reset control modules can monitor and control temperature and humidity applications simultaneously.

A System 450 standard control system includes:

• a single System 450 standard control module, which provides the control system UI for setting up, monitoring, and controlling your system and the sensor wiring terminals for connecting the sensors to your control system.

• one to ten outputs provided by the control module and expansion modules. Each output provides either on/off control or a proportional analog signal (0 to 10 VDC or 4 to 20 mA) to the equipment in your controlled system.

• one to three sensors or transducers, which are hard-wired directly to the control module and provide input signals for monitoring and controlling your system equipment.

• an optional power module to provide power to the connected control module and expansion modules.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 7

See Table 11 on page 62 for a list of System 450 modules that can be used in

Figure 1: System 450 Standard Control System Connected

as a Room Heating and Cooling Control System with

Condenser Fan Speed Control

* Connect cable shields at only one point to any “C” terminal on the Input Terminal Block.

standard and hybrid analog output control systems. Refer to the System 450 Series Modular Controls Product Bulletin (LIT-12011458) for a complete list and

description of the System 450 modules, compatible sensors and transducers, and accessories.

Figure 1 shows an example System 450 standard control system connected as a room heating and cooling control system with condenser fan speed control.

Figure 3 on page 12 shows the System 450 UI Main Screens, System Status screens, and System Setup Screens for the heating and cooling control system shown in Figure 1.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin8

System 450 Standard Control Modules

A System 450 standard control system can provide the following types of control to your application equipment:

• On/Off Control, including multi-stage control for temperature, pressure, and humidity applications. (See Relay Outputs on page 18 for more information.)

• Proportional Analog Control, including multi-stage control for temperature, pressure, and humidity applications. (See Analog Outputs on page 20 for more information.)

• Combination of On/Off Relay and Analog Output Control, with up to 10 outputs per control system and any combination of relay and analog outputs.

• Multi-Stage Control (Relay or Analog) for temperature, pressure, and humidity applications.

• Multi-Purpose Control, including simultaneous control of temperature, pressure, and humidity conditions.

• Stand-Alone Control. A single standard control module can be quickly and easily configured to replace a wide variety of specialized controls in the field.

• Direct and Reverse Action Proportional Control. See Direct and Reverse Control Actions for Analog Outputs on page 20 for more information.

• Proportional Plus Integral Control. See Proportional Plus Integral Control and Integration Constants on page 23 for more information.

• High Input Signal Selection allows you to monitor a condition with two or three identical sensors at different locations in your controlled system and control system outputs according to the highest condition value sensed by the sensors. See High Input Signal Selection on page 24 for more information.

• Differential Control allows you to monitor and control a condition dif ferential in a controlled system; for example, the water pressure drop across an in-line water filter. See Differential Control on page 25 for more information.

• Hybrid Analog Output Control on C450CPW-100 control modules enables an analog VDC output to transition to a pulse output at low signal levels, providing more efficient low-speed control of Electronically Commutated (EC) motors in condenser fan applications. (See Hybrid Analog Output on page 14 for more information.)

Note: System 450 standard control modules do not include reset control,

real-time clock, setback scheduling control, or load balancing capabilities. These features are available on the System 450 reset control modules only. Refer to the System 450 Control Systems with Reset Control Modules T echnical Bulletin (LIT-12011842) for more information about reset control modules and reset control systems. Only the C450CPW-100 model provides a hybrid analog output for direct control of EC motors. See

Hybrid Analog Output

on page 14 for more information.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 9

Control Modules and User Interface

Figure 2: System 450 Control Module with Analog Outputs Showing LCD and

Four-Button Touchpad User Interface

Output Number:

with the status or setup value shown on the screen. Output numbers are automatically determined by the outputs' physical positions (left to right) in the module assembly. (Here, 4 = Output 4.)

Control Ramp Icon:

Displays whether an

or reverse acting, and whether the output signal strength is at minimum or maximum when the sensed property is at Setpoint . The control ramp icon displayed is determined by the output's SP, EP, OSP, and OEP setup values.

Menu Button:

Press to move through the sensor and output setup start screens. When moving through the status or setup screens, press to return to the status start screen or setup start screen.

Status or Setup Identifier:

OSP

Displays the

unit of measurement, output, sensor number,

setup parameter for the displayed stat us or setup value. (Here, the setup identifier represents % output signal strength at setpoint.)

Up and Down Buttons:

Press or to select a different value for any flashing value in the setup value field. In the Main (sensor status) screens, press and hold both and for 5 seconds to access the Setup Start screens.

Status or Setup Value:

Displays the current input status, output status setup parameter value for the displayed input sensor, output and/or setup parameter. select a different parameter value when the value is flashing. (Here, 100 = 100%.)

Press or to

Expansion Modules indicate if the associated

output is partially on (between 0 an 10V), the LED blinks. The higher the output signal strength, the longer the LED is on.

In the Main screens,

the (flashing) setup value and go to the next setup screen.

Each System 450 standard control system requires a single control module. System 450 control modules have an LCD that enables you to set up and monitor your control system, along with a four-button touchpad for navigating the control system status and setup screens, and setting up the system parameters. Figure 2 shows a standard control module and describes the various features of the System 450 control system UI for standard control modules.

LED:

Green LEDs on Control Module and

relay or analog output is on or off. If the analog

100

value that identifies the output associated

Displays a numerical

OSP

analog output (only) is set as direct acting

FIG:sys450_comm_module_ui

Next Button:

press to scroll through the system status screens. In a setup screen, press to save

Standard System 450 control modules are available with one or two relay outputs or with one or two analog outputs and the standard System 450 firmware. See Table 11 on page 62 for model descriptions and System 450 Standard Control Modules on page 9 for more information.

The System 450 control module with hybrid analog output has a single analog output that can be configured as a hybrid analog output to optimize and extend the controlled speed range of variable speed EC motors. See Hybrid Analog Output page 14 for more information.

All System 450 control modules can control both relay outputs and analog outputs, regardless of the type of outputs that the control module has onboard. You set up all of the sensors and all of the outputs (relay and analog), including the expansion module outputs, in the control module UI. A standard control module can also be configured as a simple stand-alone control system when your application requires only one or two relay outputs, or one or two analog outputs.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin10

During normal operation, the LCD displays the Main System 450 screens (Sensor Status screens), which automatically scroll through and display the status of the hardwired and functional sensors in your control system. You can also view the status of all the outputs in your control system and access the System Setup screens from the Main screens in the System 450 UI. See on page 40 for more information.

The System 450 System Status screens display the status of each output in the control system (in addition to the sensor status screens). A relay output status is displayed as On or OFF. See Relay Outputs on page 18 for more information. An analog output status is displayed as a percentage of the total output signal strength (0 to 100%). The analog output status screens also display an icon that indicates the control action of the output. See Analog Outputs on page 20 for more information.

The System Setup screens in the System 450 UI enable you to easily set up the system sensors and all of the system outputs for your control system. See on page 40 for more detailed procedures for setting up your control system.

Figure 3 illustrates the System 450 UI navigation paths, parameter designations, and values for the control system example (shown in Figure 1) using a System 450 standard control module. Figure 3 shows the Main screens (sensor status screens), the System Status screens, the System Setup screens, and the Output Setup screens for an example System 450 standard control application.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 11

Figure 3: System 450 UI Menu Flow Chart Example Showing Navigation Paths and

Example Settings in the Main, System Status, Sensor Setup, and Output Setup Screens

for the Room Heating and Cooling Control System with Condenser Fan Speed Control

Application Shown in Figure 1

FIG:menu_flw_chrt

232

PSI

Main Screen

Sensor 2 Status

°F

Sensor 1 Status

Relay Output 2

Status

OFF

OUT

Output Relay

OFF

Relay Output 1

Status

OUT

Output Relay

Analog Output

Status

OUT

Output Signal

at % of Ran

Sensor 3

Statu s

– – – –

Sensor

Not Set Up

Sensor 2

Status

74ºF

at Sensor

232

PSI

Sensor 1

Status

232 psi

at Sensor

Sensor Setup

Screens

System Status

Screens

Main Screens

(Sensor Status)

Relay Output 1

Cooling

Equipment

Setup Screens

Press and hol d +

for 5 seconds to go to

the Setup St art screen s.

Press to scroll through

Sensor Status screens and

Output Status screens.

SENS

Sensor Type

Setup Start

Select Sensor 2

Type

°F

Sensor Type

(-40 to 250ºF)

ºF

Select Sensor 3

Typ e

Sensor Type

Selected

Select Se nsor 1

Typ e

P500

Sn-1

Sn-2 Sn-3

Select

Temperature (only)

Offset De grees

-3

OFFS

During normal operation, the display automati

for all sensors set up in the UI.

After a 2 minute pause in any setup or status

Main (Sensor Status) screens.

Press in any Setup screen to go to the ass

Press + simultaneously in any Setup Sta

°F

Relay Output

Setu p Star t

OUTR

Sensor 2

Selected for

Relay Output

Relay

Output

Select Relay ON

Val ue

Relay Output

at ºF

ON 78

OFF

Select Relay OFF

Val ue

Relay Output

at ºF

OFF 75

Select Minimum

Relay ON Time

ONT

Relay Output

Seconds

(Minimum)

ON 0

Select

Sensor

Sn-2

SENS

Up to ten

Outputs can

be connected

and set up.

OUTA

OutputAnalog

Setup Start

Analog

Output

Analog Output 3

Condenser

Fan Speed

Control

Setup Screens

Select

Sensor

SENS

Sensor 1

Selected for

Analog Output

Sn-1

Relay Output

Setup Start

OUTR

Sensor 2

Selected for

Relay Output

Relay

Output

Select Relay ON

Val ue

Relay Output

at ºF

ON 65

OFF

Select Relay O

Val ue

Relay Outp

OFF 7

Selec t

Sensor

Sn-2

SENS

Relay Output 2

Heating

Equipmen t

Setup Screens

Sn-2

OFF

120

SENS

SNF

OFFT

Sensor (Sn-2)

Relay Output

elay Output

Edit

Input Sensor

set up and displayed.

three Sensors can be

Up to ten Outputs and

The current status of each sensor and output is displayed.

cally scrolls through the Sensor Status screens

ociated Setup Start screen.

rt screen to return to autoscrolling through the Main screen s.

screen (below), the display returns to autoscrolling through the

Main Screen

Press to manua lly scroll thr ough the sensor and output status es.

Failure Mode

Select Sensor

lect MinimumRelay OFF Time

Controls

OFF

Seconds

F 120

Edit

Input Sensor

Relay Output

Failure Mode

Select Sensor

Sensor 2 Fails

(Minimum)

Select Minimum

Relay O FF Time

Relay ON Time

Select Minimum

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin12

Sn-2

OFF

SENS

SNF

OFFT

ONT

Sensor (Sn-2)

Relay Output

Controls Relay

OFF

Seconds

OFF 30

Seconds

ON 0

ºF

Sensor 2 Fails

(Minimum)

Select % Output

Edit

Select Sensor

Select Integration

Signal Value

Select Prop. Band

Prop. Band

Select

Input Sensor

Failure Mode

Constant Value

at End Point

at Setpoint

End Po int Value

Setpoint Value

Sn-1

OFF

250

200

SENS

SNF

I-C

OEP

OSP

Controls

Sensor (Sn-1)

OFF

Analog Output

Integration

Analog Output

of Range at

Output is %

of Range at

Output is %

Prop. Band

Analog Output

Prop. Band

Analog Output

Sensor 1 Fails

Constant

Value

End Point

Value

Setpoint

250

End Point psi

200

Setpoint psi

Expansion Modules, Module Assemblies, and Outputs

Figure 4: System 450 Module Assembly Example Showing Standard Control

Module Positions, Output Positions, and Output Numbers

System 450 expansion modules provide additional outputs to expand your control systems and meet your specific application requirements.

A System 450 control system can provide up to ten outputs, which can be any combination of relay and analog outputs. Expansion modules are available with one or two relay outputs, or with one or two analog outputs. See Table 11 on page 62 for information on the System 450 modules that can be used in a standard control system.

Module Assemblies, Output Types, and Output Numbers

You can easily plug System 450 modules together using the 6-pin connectors located on the sides of the modules’ housings and mount these module assemblies on standard 35 mm DIN rail (recommended) or directly to a hard, even surface. See Mounting

on page 36 for more information.

Figure 4 shows a System 450 module assembly example, the module positions, the output types, and the automatically assigned output numbers used in the System Setup screens in the control module UI.

The control module is always mounted on the left side of the module assembly . If a System 450 power module is used, the power module is always plugged into the right side of the control module. If expansion modules are used, they can be plugged into the assembly in any order on the right side of the power module (or the right side of the control module, if a power module is not used in the assembly). See Assembling System 450 Modules

on page 35 for more information.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 13

Each time a System 450 module assembly is powered on, the control module polls

Figure 5: Pulse Signal with Pulse Level = 25% and Logical Output = 12.5%

all of the modules to identify output type (relay or analog) and then assigns an output number (1 to 9 and 0 = 10) to each output, starting with the first output on the first expansion module connected to the right of the control module (Figure 4). Output numbers are displayed on the control module LCD to identify the output you are viewing as you navigate the system status and setup screens in the System 450 UI (Figure 2).

Hybrid Analog Output

The C450CPW-100 control module is designed for use with variable speed Electronically Commutated (EC) fan motors on a wide variety of refrigeration and HVAC condensing units.

The C450CPW-100 module has a single onboard analog output that can be configured as a hybrid analog output to optimize and extend the controlled speed range of variable speed EC motors. The onboard analog output can also be set up for High Input Signal Selection, which enables precise and efficient EC motor speed control on multi-circuit condensing units.

Hybrid analog output control enables the C450CPW-100 control module’s hybrid analog output to transition between a pulse output and a standard VDC output, depending on the sensor value relative to the proportional band. At low output levels, the pulse output signal provides an average motor speed that is less than the EC motor’s fixed minimum speed (Figure 5).

Note: Only Analog Output 1 (OUT A1) on the C450CPW-100 control module can

be configured as a hybrid analog output and use the High Input Signal Selection feature. These features are not available for any of the other outputs in control systems that use a C450CPW-100 control module.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin14

System 450 Compatible Sensors and Transducers

System 450 standard control modules are designed to operate with a variety of compatible sensors and transducers. The System 450 compatible sensors and transducers cover a wide range of temperature, pressure, and humidity conditions.

Note: System 450 compatible sensors consist of temperature sensors, humidity

sensors, and pressure transducers. The term sensor refers to all System 450 compatible input devices including transducers, unless noted otherwise.

System 450 compatible sensors also come in a variety of styles and configurations, allowing you to select the sensor or transducer that best fits your control system requirements. See Table 11 through Table 20 in Repair and Ordering Information on page 62 for more information on System 450 compatible sensors.

You can connect up to three sensors to a System 450 control module at the low-voltage terminal block. See Wiring System 450 Components on page 37 for more information on System 450 sensor wiring terminals on control modules. Refer to the System 450 module installation instructions and the sensor installation instructions referenced in Related Documentation on page 5 for information on installing, wiring, operating, troubleshooting, and replacing System 450 compatible sensors.

For each sensor in your control system, you must select the sensor’s corresponding Sensor Type when you set up the sensors in the System 450 UI. A sensor’s corresponding Sensor Type determines the controlled condition, unit of measurement, minimum differential, setup values, and ranges for each output that is set up to reference the sensor.

See Table 2 on page 16 for information about Sensor Types, the corresponding output setup values and ranges, sensor models, and transducer models used in standard System 450 control systems.

System 450 automatically designates the sensor connected to the Sn1 terminal and a common (C) terminal as the Sn-1 sensor in the UI. The sensor connected to the Sn2 and a C terminal is designated Sn-2, and the sensor connected to Sn3 and a C terminal is designated Sn-3. You set up each sensor in the corresponding sensor setup screens in the UI.

Note: For a System 450 control system to operate properly, you must wire the

correct sensor or transducer model to the correct sensor input terminals on the control module and select the correct Sensor Type in the corresponding Select Sensor Type screen in the System 450 UI. You must also set the active/passive sensor jumpers or switches on the control module correctly for each sensor or transducer connected to your control system.

See on page 40 and Setting Up the Sensors and Transducers

on page 45 for more information and procedures on setting up sensors and Sensor Types in the System 450 UI. See Active and Passive Sensors on page 17 for information on setting the active/passive switches and jumpers.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 15

System 450 Sensors and Transducers for Standard Control Modules

Table 2 shows the Sensor Types, output setup values, value ranges, and product types for the temperature sensors, humidity sensors, and pressure transducers that are compatible with the C450CxN-x standard control module models.

Table 2: System 450 Sensor Types, Setup Values, and Sensor/Transducer

Product Codes

Sensor Typ e

F F (Temperature/degrees) -46 to 255 -40 to 250 1 1 A99B-xxx

C C (Temperature/degrees) -43 to 124 -40 to 121 0.5 0.5 A99B-xxx

rH % (Humidity/%RH) 1 to 100 10 to 95 1 2 HE-67Sx-xxxxx

P 0.5 INWC (Pressure/in. W.C.) 0 to 0.5 0.025 to 0.5 0.005 0.025 DPT2650-0R5D-AB

P 2.5 INWC (Pressure/in. W.C.) 0 to 2.5 0.1 to 2.5 0.02 0.1 DPT2650-2R5D-AB

P 5 INWC (Pressure/in. W.C.) 0 to 5.0 0.25 to 5.0 0.05 0.25 DPT2650-005D-AB

P 8 bAR (Pressure/bar) -1 to 8 -1 to 8 0.05 0.1 P499Rxx-401C

P 10 INWC (Pressure/in. W.C.) 0 to 10 0.5 to 10 0.05 0.2 DPT2650-10D-AB

P 15 bAR (Pressure/bar) -1 to 15 -1 to 15 0.1 0.2 P499Rxx-402C

P 30 bAR (Pressure/bar) 0 to 30 0 to 30 0.1 0.4 P499Rxx-404C

P 50 bAR (Pressure/bar) 0 to 50 0 to 50 0.2 0.4 P499Rxx-405C

P 100 PSI (Pressure/psi) 0 to 100 0 to 100 0.5 1 P499Rxx-101C

P 110

P 200 PSI (Pressure/psi) 0 to 200 0 to 200 1 1 P499Rxx-102C

P 500 PSI (Pressure/psi) 0 to 500 90 to 500 1 5 P499Rxx-105C

P 750 PSI (Pressure/psi) 0 to 750 150 to 750 2 6 P499Rxx-107C

HIF F (Temperature/degrees) -50 to 340

HIC C (Temperature/degrees) -45.5 to

Unit of Measurement Value (Condition/Units)

Hg/PSI (Pressure/Hg-psi) -10 to 100

Effective Sensing Range

(20 inHg to 100 psi)

170

Range of Usable

Values

-10 to 100 0.5 1 P499Rxx-100C

-40 to 340

-40 to 170

Resolution Increment Val ue

1 1 TE-631x, TE-6000-x

0.5 0.5 TE-631x, TE-6000-x

Minimum Proportional or Control Band

Sensor Product

Type Number

HE-67Nx-xxxxx HE-68Nx-0N00WS

TE-68NT-0N00S

1. Because of the way that the System 450 Differential Sensor (Sn-d) is set up and calculated with two identical sensors (Sn-1 and Sn-2), the Range of Usable Values is twice as large as a single sensor. See Table 5 on page 26 for the Range of Usable Values when an output references Sn-d.

2. See Repair and Ordering Information on page 62 (Table 12 through Table 20) for additional ordering information for

System 450 compatible sensors and transducers.

3. See Active and Passive Sensors on page 17 for information on setting up System 450 outputs that reference the P 110

Sensor Type.

4. Many of the temperature sensors that can be set up as HI°F or HI°C Sensor Types are not designed for use across the entire Range of Usable Values for HI°F and HI°C Sensor Types. Refer to the Technical Specifications for the sensor you intend to use to determine the condition range that the sensor is specified to be mounted and operate in.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin16

Active and Passive Sensors

Figure 6: Example Showing the Active/Passive Slide Switch Settings

on a Control Module with Analog Outputs

Figure 7: Example Showing the Active/Passive Jumper Positions

on a Control Module with Relay Outputs

Each sensor/transducer hardwired to a System 450 control system is either an active or passive sensor. Passive System 450 sensors are two-wire temperature sensors that connect to one of the sensor input terminals and a common terminal (C) only. Active sensors are three-wire humidity sensors and pressure transducers that connect to one of the sensor input terminals, a common terminal, and a voltage supply terminal (24V or 5V). The sensors and transducers have the following requirements:

• Temperature sensors do not require a power source.

• Humidity sensors and differential air pressure transducers require 24 VAC supply power and must be connected to the 24V terminal on the input terminal block.

• P499 pressure transducers require a 5 VDC power source and must be connected to the 5V terminal on the input terminal block.

On control modules with analog outputs, set the active/passive switches to ON for passive temperature sensors and off for active humidity sensors.

On control modules with relay outputs, position the active/passive jumpers across both pin terminals for passive temperature sensors and on one terminal for active humidity and pressure sensors.

See System 450 Standard Control System Examples on page 27 for System 450 control system examples showing active/passive sensor jumper or switch settings.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 17

System 450 Functional Sensors

System 450 control modules also enable several functional sensors based on the input from one or more of the hard-wired sensors in your control system. Selecting a functional sensor for an output on a System 450 standard control system enables the differential or high signal selection control feature on the output.

Beginning with firmware Version 2.00, System 450 standard control modules provide for three additional functional sensors:

• When Sn-1 and Sn-2 are set up as the same Sensor T ype, the High Input Signal Selection functional sensor (HI-2) and Differential Control functional sensor (Sn-d) are enabled and available in the Sensor Selection screens for each output in the control system.

• When Sn-1, Sn-2, and Sn-3 are the same Sensor Type, the High Input Signal Selection functional sensor (HI-3) is also enabled and available.

See High Input Signal Selection on page 24 and Differ ential Contr ol on page 25 for more information about these functional sensors and system control features.

Relay Outputs

Relay outputs provide low and line-voltage on/off control for devices and equipment in your controlled systems. Each relay output is a Single-Pole, Double-Throw (SPDT) set of dry contacts. See Figure 15 on page 38.

Note: System 450 output relays are SPDT dry contact relays only and do not

provide any power source for your controlled equipment.

Selecting an ON value that is less than the OFF value (ON < OFF) turns the relay on when the sensed condition value decreases, which is the typical heating mode in temperature applications and referred to as reverse acting on/off control.

Selecting an ON value that is greater than the OFF value (ON > OFF) turns the relay on when the sensed condition value increases, which is the typical cooling mode in temperature applications and referred to as direct acting on/off control.

You can set up multiple relay outputs to create a variety of equipment staging control systems. See Wiring System 450 Components

on page 37 for information on wiring output relays. See Technical Specifications on page 67 for the relay output electrical ratings.

A green LED on the relay control and relay expansion module housings (Figure 2) indicates the relay output status.

When a relay output is On:

• the corresponding green LED on the module housing is lit

• the LNO (Line Normally Open) relay contact is closed

• the LNC (Line Normally Closed) relay contact is open

• the corresponding Output Status screen in the UI displays On When a relay output is Off:

• the corresponding green LED on the module housing is not lit

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin18

• the LNO relay contact is open

Relay State

Relay On

Relay Off

Sensed Condition

OFF

Condition

Value

Direct Acting Relay

OFF < ON

Condition

Value

Relay State

Relay On

Relay Off

Sensed Condition

Condition

Value

OFF

Condition

Value

Reverse Acting Relay

ON < OFF

• the LNC relay contact is closed

• the corresponding Output Status screen in the UI displays OFF System 450 control and expansion modules are available with one or two relay

outputs. See T able 11 on page 62 and Technical Specifications on page 67 for more information about the System 450 Series module models used to build standard control systems.

A relay output’s control action is determined by the values that you select in the ON and OFF relay output setup screens:

• Relay ON values (ON) are the values at which the relay turns On.

• Relay Off values (OFF) are the values at which the relay turns Off. Table 3 illustrates direct and reverse relay actions. When you select On/Off

condition values where OFF is less than On, the output relay is a direct acting relay . When you select condition values where On is less than Of f, the output relay is a reverse acting relay.

Table 3: System 450 Output Relay Control Actions and the Relationship

Between ON and OFF Values

Control Action Set the Relay Output ON/OFF Value

Relationships for the Desired Control Action

OFF < ON

ON < OFF

In temperature applications, direct acting relays are often used to control cooling equipment, while reverse acting relays are often used to control heating equipment.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 19

In pressure applications, directing acting relays are often used for condenser fan cycling control or pump-down control, while reverse acting relay may be used for high pressure cut-out.

In humidity applications, direct acting relays often control dehumidification equipment, and reverse acting relay often control humidification equipment.

Analog Outputs

Analog outputs provide proportional analog signals for devices and equipment in your controlled systems. Each analog output can generate either a 4 to 20 mA or 0 to 10 VDC signal. The output signal type is self-selecting; after you connect the analog output to the controlled equipment, the output detects the analog input on the controlled equipment and generates the appropriate analog signal for the connected input.

You can set up an analog output to generate a direct acting or reverse acting proportional output signal. You can also set up the output signal strength to increase or decrease in either the direct acting or reverse acting mode. See Direct and Reverse Control Actions for Analog Outputs on page 20 for more information.

System 450 also provides six integration constants that allow you to set up a proportional plus integral control signal, which can provide more precise setpoint control. See Proportional Plus Integral Contr ol and Integration Constants on page 23 for information on determining the integration constant for an analog output.

For procedures on setting up analog outputs on standard control modules, see Setting up an Analog Output on page 50.

System 450 control and expansion modules are available with one or two analog outputs. See T able 11 on page 62 and Technical Specifications on page 67 for more information about the System 450 Series module models that are used to build standard control systems.

Direct and Reverse Control Actions for Analog Outputs

An analog output can be set up to provide one of four different control actions, which allow you to match the output signal to the requirements of your control system and the controlled equipment. The proportional output signal can provide direct acting or reverse acting control. In addition, the output signal can be set up to generate either the minimum or the maximum output signal strength at Setpoint.

A control ramp icon is displayed on the status screens for all analog outputs in your control system. See Figure 2 on page 10. The displayed control ramp icon represents the control action of the analog output signal. See Table 4 on page 22 for more information on analog output control actions and control ramp icons.

An analog output’s control action and the corresponding control ramp are automatically determined by the values that you select in four analog output setup screens:

• Setpoint value (SP) is the target value that the control system drives toward,

and along with the End Point, defines the output’s proportional band.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin20

• End Point value (EP) is the maximum deviation from the target value

(Setpoint). The control system applies maximum output at the EP to drive the process back toward the SP. The SP and EP define the analog output’s proportional band.

• Output at Setpoint value (OSP) is the signal strength level of the analog

output when the input sensor is at Setpoint (SP). The OSP is expressed as a percentage (0 to 100%) of the full scale output.

• Output at Endpoint value (OEP) is the signal strength level of the analog

output when the input sensor is at the End Point (EP). The OEP is expressed as a percentage (0 to 100%) of the full scale output.

Note: System 450 analog outputs that reference the differential control sensor

(Sn-d) use a Differential Setpoint (dSP) and Differential End Point (dEP) to define the output’s proportional band. See Differential Control on page 25 for more information.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 21

Table 4 shows the four control ramp icons and describes their corresponding

OEP=100%

OSP=0%

OEP=100%

OSP=0%

OSP=10 0%

OEP=0%

EP=60°F

OSP=10 0%

OEP=0%

control actions and the setup value relationships required to configure the four control actions. See Figure 23 and Figure 24 on page 52 for examples.

Table 4: System 450 Control Ramps, Analog Output Control Actions, and

System Setup Value Relationships

Control Ramp Displayed

Control Action Set the Analog Output Value Relationships

for the Desired Control Action and Corresponding Control Ramp

SP < EP

Output Minimum at SP

SP=50°

EP=60°

OSP < OEP

SP > EP

Output Minimum at SP

EP=50°F SP=60°F

OSP < OEP

SP > EP

OSP > OEP

Output Maximum at SP

EP=50°F SP=60°F

SP < EP

Output Maximum at SP

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin22

OSP > OEP

SP=50°F

Proportional Plus Integral Control and Integration Constants

Figure 8: Proportional Only Control Versus Proportional Plus Integral Control

to bring the system condition to

Control point and output follows the system load.

Humidity,

Pressure, or

Temperature

Offset Error

Zero

Offset

Error

In addition to standard proportional control, System 450 provides Proportional plus Integral (PI) control capability. The addition of integral control enables a

properly set up analog output to drive a controlled condition closer to Setpoint (Figure 8).

Standard proportional-only controls continuously adjust the output in proportion to the difference (offset error) between the Setpoint value and the sensor value. As the load on the system increases, the offset error increases. A proportional-only control responds to the increased offset error by changing the output signal, which drives the controlled equipment to compensate for the load change (Figure 8). Proportional-only control loops are relatively easy to set up and adjust.

T ypically, under constant system load, proportional-only control loops do not drive a system to the selected Setpoint. Instead, the controlled system is maintained at a control point within the proportional band (throttling range) between setpoint and end point. The larger the load on the system, the further the control point drifts from setpoint. Still, for many applications, proportional-only control is the best choice for analog output control.

Proportional Only Control

End Point

Humidity,

Pressure, or

Temperature

Integral control adjusts the o utput

Setpoint regardless of system load.

Offset Error

End Point

Proportional plus Integral (PI) control incorporates a time-integral control action with proportional control action and, if properly set up, a PI control loop can effectively eliminate offset error and enable a controlled system to drive to setpoint even under large constant loads (Figure 8). On a properly sized system with predictable loads, PI control can maintain the controlled system very close to setpoint.

PONLY-PRO+I

A system’s output capacity, the size of the load on the system, and the integration constant selected determine the speed (recovery rate) at which the PI control drives the system to setpoint.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 23

The integration constant establishes the rate at which the control readjusts the analog output signal. The faster the integration constant, the faster the control readjusts the output signal and the faster the recovery rate of a properly sized and setup control loop.

Note: PI control is not suitable for all controlled systems. Improperly applied PI

control loops are unstable and can overshoot setpoint, resulting in control loop oscillation. Also, with PI control, the proportional band (throttling range) and the integration constant are interdependent and you must properly set up these values in relation to each other. You must also properly size the system equipment to handle the maximum load. Close observation over several cycles and under different load conditions is required to properly set up a PI control loop. On a properly sized system, a PI control loop can drive the system condition much closer to setpoint than proportional-only control.

In addition to a proportional-only setting, System 450 provides six time-integral settings in the Integration Constant Setup screen for matching the analog signal’s response rate to the controlled system’s recovery rate. The seven integration constant settings are shown in Table 8 on page 60.

See Determining the Integration Constant for an Analog Output on page 56 for more information and the procedures for determining an integration constant and testing a PI control loop in your controlled system.

High Input Signal Selection

Standard System 450 control modules, including the C450CPW -100 hybrid analog control module, include the High Input Signal Selection control feature.

The High Input Signal Selection feature enables a System 450 control system to monitor a condition (temperature, pressure, or humidity) with two or three sensors (of the same type) and control relay and analog outputs based on the highest condition value sensed by the two or three referenced sensors.

When Sn-1 and Sn-2 are set up with the same Sensor Type, the functional High Input Signal Selection sensor (HI-2) is available for selection when you set up the outputs in the control system. When Sn-1, Sn-2, and Sn-3 are set up with the same Sensor Type, the functional sensor (HI-3) is also available for selection.

Note: High Input Signal Selection is available on standard System 450 control

modules beginning with firmware Version 2.00 and on the hybrid analog control module (C450CPW-100). On the hybrid analog control module, High Input Signal Selection is only available for the hybrid analog output (OUTA1).

Note: Setting up Sn-1 and Sn-2 as the same Sensor Types also enables the

functional Differential Control sensor (Sn-d). See Differential Control page 25 for more information.

High Input Signal Selection control application examples include:

• fan-staging control on multi-circuit condensing units

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin24

• fan motor speed control on multi-circuit condensing units The Hybrid Analog and High Input Signal Selection Control System Example on

page 32 provides module assembly, wiring, and UI setup information for a System 450 hybrid analog output control system that uses the High Input Signal Selection feature.

Differential Control

Standard System 450 control modules include the Differential Control feature. The Differential Control feature enables a System 450 control system to monitor

and maintain a temperature, pressure, or humidity dif ferential between two sensors of the same type and control relay and/or analog outputs based on the sensed differential value relative to user-selected differential values.

Note: Differential Control is available on standard System 450 control modules

beginning with firmware Version 2.00. Differential Control is not available on the hybrid analog control module (C450CPW-100).

Differential Control application examples include:

• solar heating systems

• pump pressure-drop monitoring and control

• fluid filter pressure-drop monitoring

• air filter pressure-drop monitoring Setting up an output (relay or analog) for Differential Control requires connecting

two identical sensors to input terminals Sn1 and Sn2 and selecting the same Sensor Type in the System 450 UI for Sensor 1 (Sn-1) and Sensor 2 (Sn-2). The System 450 control system recognizes the same Sensor Types and makes the functional Differential Control sensor (Sn-d) available for selection when you set up each of the control system outputs.

Note: Setting up Sn-1 and Sn-2 as the same Sensor Types also enables the

functional High Input Signal Selection sensor (HI-2). See High Input Signal Selection on page 24 for more information.

When a Differential Control sensor (Sn-d) is set up, the differential sensor value is a calculated value; (Sn-d) = (Sn-1) minus (Sn-2). The Differential Control sensor (Sn-d) value is always equal to Sn-1 minus Sn-2. Therefore, depending on the intended control action of the output, the differential value may be either a positive or negative value.

The sensed differential value (Sn-d) between Sn-1 and Sn-2 is displayed in the System Status screens as either a temperature differential value (dIFT), pressure differential value (dIFP), or humidity differential value (dIFH). The unit of measurement associated with the displayed differential value is determined by the Sn-1 and Sn-2 Sensor Type. See Table 2 on page 16 for Sensor Types and their units of measurement.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin 25

When a relay output is set up for Differential Control, System 450 compares the sensed differential value, Sn-d (Sn-d = Sn-1 minus Sn-2), to the user-selected differential values (dON and dOFF) to control the relay’s On/Off state.

When an analog output is set up for Differential Control, System 450 compares the sensed differential value, Sn-d (Sn-d = Sn-1 minus Sn-2), to the user-selected differential values (dSP and dEP) to control the analog output signal strength.

The Solar Heating Contr ol System Example Using Differential Control on page 28 provides module assembly, wiring, and UI setup information for a standard System 450 control system that uses the Differential Control feature.

Note: Because of the way that the System 450 Differential Sensor (Sn-d) is set up

and calculated using two sensors with identical Sensor T ypes, the Range of Usable Values for each Sensor Type is twice as large as a single sensor. (Each Sensor Type has an equal number of positive and negative values on outputs that reference Sn-d.) See Table 5 for a Sensor Type’s Range of Usable Values when an output references Sn-d.

Table 5: Range of Usable Values for Sensor Types in Differential Control

Applications

Sensor Type Sn-d Range of Usable

Values

F -290 to 290 P 30 -30.0 to 30.0

C -161.0 to 161.0 P 50 -50.0 to 50.0

rH -95 to 95 P 100 -100.0 to 100.0

P 0.5 -0.500 to 0.500 P 110 -110.0 to 110.0

P 2.5 -2.50 to 2.50 P 200 -200 to 200

P 5 -5.00 to 5.00 P 500 -500 to 500

P 8 -9.00 to 9.00 P 750 -750 to 750

P 10 -10.00 to 10.00 HIF -380 to 380

P 15 -16.0 to 16.0 HIC -210.0 to 210.0

Sensor Type Sn-d Range of Usable

Values

Sensor Failure Mode

System 450 allows you to select the mode of operation for your control system outputs in the event of a sensor (or sensor wiring) failure of the sensor or sensors that the outputs reference. When you set up an output in the System 450 UI, you must select a sensor failure mode of operation in the Sensor Failure Mode (SNF) screen. Your selection determines how an output responds if a referenced sensor or sensor wiring fails.

System 450 outputs can be set up to directly reference a single compatible sensor hardwired to the control system (Sn-1, Sn-2, or Sn-3). Outputs in control systems with System 450 standard control modules can also be set up to reference several functional sensors (Sn-d, HI-2, or HI-3). The functional sensors reference input from one or more of the hard-wired sensors; thus one or more of the hard-wired sensors can influence the outputs that reference functional sensors.

System 450™ Series Modular Control Systems with Standard Control Modules Technical Bulletin26

+ 58 hidden pages

Johnson Controls Penn System 450 Series Technical Bulletin

Specifications and Main Features

Frequently Asked Questions

User Manual

Document Introduction

Related Documentation

System 450 Overview

System 450 Standard Control Modules

Control Modules and User Interface

Expansion Modules, Module Assemblies, and Outputs

Module Assemblies, Output Types, and Output Numbers

Hybrid Analog Output

System 450 Compatible Sensors and Transducers

System 450 Sensors and Transducers for Standard Control Modules

Active and Passive Sensors

System 450 Functional Sensors

Relay Outputs

Analog Outputs

Direct and Reverse Control Actions for Analog Outputs

Proportional Plus Integral Control and Integration Constants

High Input Signal Selection

Differential Control

Sensor Failure Mode