Taco UCP-1, iWorx PSU1 Application Manual

Application Guide
PSU1 Pump Sequencing Unit
Self-Contained Interoperable Controller Model UCP-1
505-012
SUPERSEDES: New
Plant ID: 001-4090
PSU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Purpose of This Guide . . . . . . . . . . . . . . . . . . . . . . . . . 3
Representations and Warranties . . . . . . . . . . . . . . . . . 3
Applicable Documentation . . . . . . . . . . . . . . . . . . . . . . 4
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FCC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
About this Document . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspecting the Equipment . . . . . . . . . . . . . . . . . . . . 5
What is Not Included with this Equipment . . . . . . . . 5
Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . .5
Selecting a Power Source . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting the Device . . . . . . . . . . . . . . . . . . . . . . . .6
Routing Cabling to the Device . . . . . . . . . . . . . . . . . 7
Grounding the Device . . . . . . . . . . . . . . . . . . . . . . .8
Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting Input Devices . . . . . . . . . . . . . . . . . . . 11
Connecting Output Devices . . . . . . . . . . . . . . . . . .12
Other Connections . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mechanical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EFFECTIVE: August 10, 2012
Application Description. . . . . . . . . . . . . . . . . . . . . . . . 14
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . 15
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . 15
Auto Flow Recovery Mode. . . . . . . . . . . . . . . . . . . 16
Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lead Pump Select . . . . . . . . . . . . . . . . . . . . . . . . . 19
Constant Circulation . . . . . . . . . . . . . . . . . . . . . . . 19
Low Supply Temperature Circulation. . . . . . . . . . . 19
Pump Exercising . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Controller Identification . . . . . . . . . . . . . . . . . . . . . . . 20
Network Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . 26
© 2012 Taco Electronic Solutions, Inc. 1
iWorx® PSU1
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iWorx® PSU1

PSU1

The PSU1 pump sequencing unit is a stand-alone microprocessor-based controller for radiant heating or cooling appli­cations.

Overview

The PSU1 is a compact, microcontroller-based controller for support of radiant applications with pump sequencing needs. It controls the pump sequences, rotates and stages the pumps according to the programmed mode, maintains desired differential temperature (Delta T), and generates flow alarms if no flow is detected.
The controller is based on LONWORKS® networking technology. The controller can be networked to a higher-level control system for monitoring and control applications.

Features

• Control of two primary pumps with four control modes
• Standby pump operation with manually selectable lead pump
• Equal runtime operation with adjustable run time
• Two-stage digital control or single-stage modulated control (with digital enable) based on an adjustable primary loop temperature differential
• Automatic configuration with a Local Control Interface (LCI) touchscreen
• Alarm/Event reporting
• LONWORKS® interface to building automation systems

PURPOSE OF THIS GUIDE

The iWorx® PSU1 Application Guide provides application information for the PSU1 Controller.
The reader should understand basic HVAC concepts, intelligent environmental control automation, and basic LON- WORKS networking and communications. This application manual is written for:
• Users who engineer control logic
• Users who set up hardware configuration
• Users who change hardware or control logic
• Technicians and field engineers

REPRESENTATIONS AND WARRANTIES

This Document is subject to change from time to time at the sole discretion of Taco Electronic Solutions, Inc. All updates to the Document are available at www.taco-hvac.com. When installing this product, it is the reader’s responsi­bility to ensure that the latest version of the Document is being used.
iWorx® products shall only be used for the applications identified in the product specifications and for no other pur­poses. For example, iWorx® products are not intended for use to support fire suppression systems, life support sys­tems, critical care applications, commercial aviation, nuclear facilities or any other applications where product failure could lead to injury to person, loss of life, or catastrophic property damage and should not be used for such purposes.
Taco Electronic Solutions, Inc. will not be responsible for any product or part not installed or operated in conformity with the Document and instructions or which has been subject to accident, disaster, neglect, misuse, misapplication, inade­quate operating environment, repair, attempted repair, modification or alteration, or other abuse. For further informa­tion, please refer to the last page of this Document for the company’s Limited Warranty Statement, which is also issued with the product or available at www.taco-hvac.com.
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iWorx® PSU1

APPLICABLE DOCUMENTATION

See the table below for additional documentation that may be applicable to this controller.
Description Audience Purpose
iWorx® network interface description document, file name: iWorx_IDS_117.doc
iWorx® LCI2 Application Guide, Doc­ument No. 505-002
http://iWorxWizard.taco-hvac.com – Application Engineers
Additional Documentation
– Application Engineers – Installers – Service Personnel – Start-up Technicians
– Application Engineers – Installers – Service Personnel – Start-up Technicians – End user
– Wholesalers – Contractors
LonWorks FTT-10A Free Topology Transceiver User’s Guide, published by Echelon Corpo­ration. It provides specifications and user instructions for the FTT-10A Free Topology Trans­ceiver. See also: www.echelon.com/support/documentation/manuals/transceivers.
Provides information concerning the iWorx® network interface.
Provides instructions for setting up and using the iWorx® Local Control Interface.
An on-line configuration and submittal package generator based on user input. Automatically generates bill of materials, sequence of opera­tions, flow diagrams, wiring diagrams, points and specifications.

INSTALLATION INSTRUCTIONS

Precautions

General

CAUTION: This symbol is intended to alert the user to the presence of important installation and mainte-
nance (servicing) instructions in the literature accompanying the equipment.
CAUTION: Risk of explosion if battery is replaced by an incorrect type. Contains lithium type battery; dis­pose of properly.
WARNING: Electrical shock hazard. Disconnect ALL power sources when installing or servicing this equipment to prevent electrical shock or equipment damage.
Make all wiring connections in accordance with these instructions and in accordance with pertinent national and local electrical codes. Use only copper conductors that are suitable for 167 °F (75 °C).

Static Electricity

Static charges produce voltages that can damage this equipment. Follow these static electricity precautions when han­dling this equipment.
• Work in a static free area.
• Touch a known, securely grounded object to discharge any charge you may have accumulated.
• Use a wrist strap when handling printed circuit boards. The strap must be secured to earth ground.
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Location

Avoid locations where corrosive fumes, excessive moisture, vibration or explosive vapors are present.
Avoid electrical noise interference. Do not install near large contactors, electrical machinery, or welding equipment.
This equipment is suitable for indoor use only. Preferably, or as required by National Electrical Code, the unit is intended to be installed within an electrical control enclosure. Operate where ambient temperatures do not exceed 140 °F (60 °C) or fall below 32 °F (0 °C) and relative humidity does not exceed 90%, non-condensing.

FCC Compliance

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference. This equip­ment can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a par­ticular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment to a power source different from that to which the receiver is connected.
• Consult the equipment supplier or an experienced radio/TV technician for help.
You are cautioned that any changes or modifications to this equipment not expressly approved in these instructions could void your authority to operate this equipment in the United States.

BEFORE INSTALLING

About this Document

The instructions in this manual are for the PSU1 module which supports a liquid source heat pump.

Inspecting the Equipment

Inspect the shipping carton for damage. If damaged, notify the carrier immediately. Inspect the equipment for damage. Return damaged equipment to the supplier.

What is Not Included with this Equipment

• A power source for the equipment electronics and peripheral devices.
• Tools necessary to install, troubleshoot and service the equipment.
• The screws or DIN rail needed to mount the device.
• Peripheral devices, such as sensors, actuators, etc.
• Cabling, cabling raceway, and fittings necessary to connect this equipment to the power source, FTT-10A network and peripheral devices.

Equipment Location

Abide by all warnings regarding equipment location provided earlier in this document.
Optimally, the equipment should be installed within a secure enclosure.
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If the equipment is to be installed outdoors, it must be contained within a protective enclosure. The enclosure must maintain internal temperature and humidity within the ranges specified for this equipment.
The equipment must be installed within 500 feet of all input peripherals (smoke detectors, sensors, etc.) that are con­nected to the equipment.

Selecting a Power Source

This equipment requires a UL recognized Class 2 external power source (not supplied) to operate. The controller power input requires a voltage of 24 Volts AC.
To calculate power source current requirements, add the power consumption of all peripheral devices to that of the controller.
The controller and sensor power supplies can use the same power source. If both are using the same power source, the loads must have EMF protection. This protection can be integral to the load, or installed in the 24 VAC wiring across the load’s coil.
To provide necessary RFI and transient protection, the controller’s ground (GND) pin (T40) must be connected to earth ground or the earth ground of the packaged unit’s enclosure ground. Failure to properly ground the controller may cause it to exceed FCC limits. Excessive noise could also produce inaccurate sensor data. The power source must be capable of operating with this connection to ground.

INSTALLATION

Warning: Electrical shock hazard. To prevent electrical shock or equipment damage, disconnect ALL
power sources to controllers and loads before installing or servicing this equipment or modifying any wir­ing.

Mounting the Device

1.Select a mounting location. Enclosure mounting is recommended.
2.Hold the controller on the panel you wish to mount it on. With a marker or pencil mark the mounting locations on the panel.
3.Using a small drill bit pre-drill the mounting holes.
4.Using two #6 pan head screws, mount the controller to the panel.
5.Wire the controller (See Routing Cabling to the Device).
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Figure 1: Mounting Dimensions

iWorx® PSU1

Routing Cabling to the Device

Cabling used to connect the power source and cabling used to connect the FTT-10A network must remain separated within the control enclosure and wiring conduit.
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Grounding the Device

The ground terminal (T40) must be securely connected to earth ground. Failure to properly ground this equipment will result in improper operation. Improper grounding may also increase the risk of electrical shock and may increase the possibility of interference with radio/TV reception.
For best performance, connect the power supply common terminal (T38) to the same external point as the ground terminal (T40).

WIRING INFORMATION

WARNING: Terminals 4, 6, 9, 12, 15, 18, and 38 are connected internally on all PSU1 controllers. Discon-
nect ALL power sources when installing or servicing this equipment to prevent electrical shock or equip­ment damage.

Figure 2: PSU1 Wiring Example - Power Sourcing

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Figure 3: PSU1 Wiring Example - Power Sinking

iWorx® PSU1
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iWorx® PSU1

Figure 4: PSU1 Wiring Example - Power Isolated

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Connecting Input Devices

The figure below demonstrates typical sensor wiring:
Figure 5:
Precon II or III sensors are wired as a standard thermistor. One terminal is connected to a common pin, the other to the SWT/RWT input. Dip switches for SWT/RWT inputs using Precon II or III sensors must be configured for VTH input.

Supply Temp (SWT)

To connect the Supply Temp sensor to the unit, attach one wire from the sensor to SWT (T19) and the other wire to the adjacent common (T18). Please refer to the Wiring Information for the sensor types and the corresponding DIP switch settings.
This sensor is required for pump staging or modulation.
Precon II or III Wiring

Return Temp (RWT)

To connect the Return Temp sensor to the unit, attach one wire from the sensor to RWT (T17) and the other wire to the adjacent common (T18). Please refer to the Wiring Information for the sensor types and the corresponding DIP switch settings.
This sensor is required for pump staging or modulation.

Pump Flow Proof (PFP)

To connect the Pump Flow Proof sensor to the unit, attach one wire from the sensor to PFP (T16) and the other wire to the adjacent common (T15). This must be a dry contact normally open or closed switch.

Demand (DMD)

To connect the Demand sensor to the unit, attach one wire from the sensor to DMD (T14) and the other wire to the adjacent common (T15). This must be a dry contact switch.

Setting DIP Switches

Each input has a corresponding pair of DIP switches. The DIP switches are in three black cases with white switches located near the inputs. While holding the board with the inputs facing down, the pair of dip switches furthest to the right correspond to the right-most input (SWT), the next pair of dip switches correspond to the next input (RWT) and so on.
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Dip switch pairs must be set properly for each input to operate correctly as shown below:
Figure 6: DIP Switch Settings
NOTE: The dip switches are black boxes with white switches; this drawing is a negative image; the switch
position is shown as black.

Connecting Output Devices

Pump Enable Output (PMP1, PMP2)

The outputs for the Pump Enable must be connected to 24 VAC pilot relays.
• Connect PMP1 (T31) to load. Use TC12 (T30) as common.
• Connect PMP2 (T29) to load. Use TC12 (T30) as common.

Pump Modulated Outputs (MOD1, MOD2)

The modulated outputs can be set to 0-10 V through the control logic. The control signal input of the pump connects to the 0-10V outputs of the PSU1.
• Connect MOD1 (T37) to load. Use COM (T36) as common.
• Connect MOD2 (T35) to load. Use COM (T36) as common.

Other Connections

Network (LON)

Network wiring must be twisted pair. One network wire must be connected to terminal NETA (T1) and the other network wire must be connected to terminal NETB (T2). Polarity is not an issue since an FTT-10A network is used for commu­nications.

Power (PWR)

Connect one output wire from a 24 VAC power supply to PWR (T39) and the other output wire from the power supply to the adjacent common terminal (T38).

Ground (GND)

Terminal GND (T40) must be connected to earth ground. Failure to properly ground this equipment will result in improper operation. Improper grounding may also increase the risk of electrical shock, and may increase the possibility of interference with radio and TV reception.
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SPECIFICATIONS

Electrical

Inputs

• Cabling: twisted shielded pair, 18 AWG recommended—500 feet max. (152 meters)
• Resolution: 10 bit
Demand
• Dry Contact
• Normally Open
Flow
• Dry Contact
• Normally Open, Normally Closed
Supply Water Temperature, Return Water Temperature
• Precon Type II or III 10K Thermistor

Outputs

Pump Enable
• 24 Volts AC
• 1 Amp at 50 °C, 0.5 Amps at 60 °C, limited by Class 2 supply
Pump Modulation
• 0 - 10 Volts DC
• 2K Ohm minimum load
iWorx® PSU1

Power

Power Requirements
• 24VAC (20VAC to 28VAC), requires an external Class 2 supply
Power Consumption
• 7.2W with no external loads, maximum limited by the Class 2 supply rating

Recommended Sensor Wire

Cable Type Pairs Details Taco Catalog No.
18AWG 1 Stranded Twisted Shielded Pair, Plenum WIR-018

FTT-10A Network

• Speed: 78KBPS
• 42.4 Volts DC max
• Cabling: Maximum node-to-node distance: 1312 feet (400 meters)
• Maximum total distance: 1640 feet (500 meters)
Cable Type Pairs Details Taco Catalog No.
Level 4 22AWG (0.65mm) 1 Unshielded, Plenum, U.L. Type CMP WIR-022
For detailed specifications, refer to the FTT-10A Free-Topology Transceiver User’s Guide published by Echelon Corpo­ration (www.echelon.com/support/documentation/manuals/transceivers).
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Mechanical

Housing

• Dimensions: 5.55” (141mm) high, 6.54” (166 mm) wide, 1.75” deep (44 mm)
• ABS

Weight

• Controller Weight: 0.70 pounds (0.32 kilograms)
• Shipping Weight: 1.0 pounds (0.46 kilograms)

Electronics

• Processor: 3150 Neuron 10 MHz
• Flash: 48 Kilobytes
• SRAM: 8 Kilobytes
• Termination: 0.197” (5.0 mm) Pluggable Terminal Blocks, 14-22 AWG

Environmental

• Temperature: 32 °F to 140 °F (0 °C to 60 °C)
• Humidity: 0 to 90%, non-condensing

Agency Listings

• UL Listed for US and Canada, Energy Management Equipment PAZX and PAZX7.

Agency Compliances

• FCC Part 15 Class A

APPLICATION DESCRIPTION

The PSU1 is intended for control of two primary pumps and can either extend the features of an iWorx® Series boiler controller, or can operate as a stand-alone controller.

Figure 7: Typical Application

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Four possible operational modes are provided. The first is Single mode where a lead pump is manually selected via the LCI. If the lead pump does not provide the required flow as determined by the flow/pressure switch input, then an alarm is generated. Depending on the Lead Pump Sel setting and pump runtimes, the lag pump may also be turned on. The second mode, Standby mode, is similar to Single mode with the exception that the lag pump is always started when the lead pump fails to provide the required flow. The third mode, Equal Runtime Mode, allows for standby operation plus equal runtime rotation of the two pumps based on a runtime setting on the LCI.
These three modes (Single, Standby and Equal Runtime) also allow the option for Delta T temperature modulation via digital pump enable and modulated pump output signals. The fourth mode -- 2 Stage mode -- allows for standby opera­tion, plus provides two-stage operation (digital pump control only) of the pumps based on the Delta T of the primary loop.
NOTE: The Delta T displayed and used for sequencing algorithms is always the absolute value of the Sup­ply - Return Temperature. The controller is indifferent to the sign of the equation result. This behavior pro­motes automatic changeover between heating and cooling systems at the point where Delta T is 0 °F.

SEQUENCE OF OPERATION

This section describes the detailed sequence of operation for the PSU1 control strategy.

Operational Modes

The four primary modes of operation for sequencing primary pumps are described below.

Table 1: Operational Mode Features

Operational
Mode Setting
Single Pump1, Pump2 No No No Yes (Optional)
Standby Any Yes No No Yes (Optional) Equal Runtime Any Yes Yes No Yes (Optional) 2 Stage Any Yes No Yes No
Lead Pump Sel
Setting
Lowest Hours Yes, if lag hours >=
Alternating Yes
Standby Failover?
lead
Pump Alternation
During Operation?
Delta T Pump
Staging?
Delta T Modulated
Outputs?

Single Mode

If only one pump is used, or if one pump is unavailable due to servicing, then this mode may be used to disable standby failover. Whenever the lead primary pump is turned on by the controller and the Enable Alarm setting is not “Disabled”, the Pump Flow Proof is monitored. If the Pump Flow Proof switch remains open after a configurable delay, the lead pump is turned off and disabled, the In Alarm? indicator displays “Yes” and an alarm for the lead pump is communi­cated to the LCI. If the Lead Pump Sel setting is set to Lowest Hours and the lag pump has a lower runtime, or if the Lead Pump Sel setting is set to “Alternating,” then the lag pump is started. If purely single pump operation is desired, then Operation Mode must be set to “Single” and the Lead Pump Sel setting must be set to either “Pump1” or “Pump2”.
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Standby Mode

In Standby Mode, whenever the lead primary pump is turned on by the controller and the Enable Alarm setting is not “Disabled”, the Pump Flow Proof is monitored. If the Pump Flow Proof switch remains open after a configurable delay, the lead pump is turned off and disabled, the lag pump is turned on, and an alarm for the lead pump is communicated to the LCI. If the Pump Flow Proof switch remains off after another duration of the configurable delay, the lag pump is turned off and disabled, the In Alarm? indicator displays “Yes” and an alarm for the lag pump is communicated to the LCI. When either pump is on, the Pump Flow Proof switch continues to be monitored for an open state, and switches pumps after the configurable delay, if necessary. Unless Flow Recovery Mode is enabled, the controller is locked out whenever both pumps are disabled. The controller must be reset to enable pumps that have failed.

Equal Runtime Mode

The lead pump is started first and remains on as long as there is a call for it. The first pump runs for the number of hours specified in the pump settings Max Runtime field. Once the number of hours specified has passed, the sequence to swap the pumps is started.
NOTE: The lead pump may be changed manually at any time by changing the Lead Pump Sel setting. When changed, the timers used by Equal Runtime mode are reset and the new lead is run for Max Run- time.
When a swap is needed, the lead pump is placed into a Post Purge state.
NOTE: If modulated pump control is being used, the lead pump decelerates during the post purge period until it is operating at its minimum speed or the post purge period has expired. The pump ramps down at a rate defined by Pump Mod Set: Ramp Down.
After the time period specified by Pump Settings: Post Purge Time has elapsed, the lead pump turns off and the lag pump is turned on.
If Enable Alarm setting is not “Disabled,” the Pump Flow Proof switch continues to be monitored for an open state, and switches pumps after the configurable delay, if necessary. The pumps are not rotated if one of the pumps has failed.
This mode also includes all of the capabilities of Standby Mode.

Two Stage Mode

The lag pump may be set to operate as a second stage pump to meet increased demand. When the lead pump is oper­ating and Delta T exceeds the amount specified in Temperature Differential for at least two minutes, the lag pump is started. When Delta T is reduced to less than 5°F below the Temperature Differential for at least two minutes, the lag pump is turned off.
NOTE: Delta T is always converted to an absolute value before comparing against the Temperature Differ- ential setting.
Two stage operation may be disabled by changing the Operational Mode from “2 Stage” to another operating mode. This mode is also disabled whenever one of the pumps has failed.
When Operational Mode is set to “2 Stage,” Operational Type is automatically set to “Switching.” Modulation is not available in this mode.
This mode also includes all of the capabilities of Standby Mode.

Auto Flow Recovery Mode

Auto Flow Recovery Mode augments all modes that include Standby Mode capabilities. It is intended to prevent con­troller lockout in the event of a faulty Pump Flow Proof switch or in the event that pump motors temporarily do not respond to the PSU1 control signals.
The Auto Flow Recovery sequence begins after Standby Mode has disabled the lag pump. When Auto Flow Recovery is active, the controller operates both pumps simultaneously. The controller is able to restart itself and resume normal operation once flow is detected.
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All operating modes that support standby failover normally switch off pumps that fail to satisfy the flow proof input. If Flow Recovery is enabled both pump outputs will be energized after a 30 second delay. If modulated outputs are con­figured, modulation levels are fixed to the minimum "On" level specified under the Pump Mod Set: On settings. Pump runtime is not accumulated at any point in time while Flow Recovery is active.
Flow is monitored while the controller is operating in Flow Recovery mode. An automatic restart occurs during Flow Recovery mode if automatic restarts are remaining and the controller detects flow for the amount of time specified by the Flow Delay setting. The Restarts Left output value indicates the number of automatic restarts remaining. The num­ber of automatic restarts is configurable under the Auto Recovery: Number Restarts setting. To prevent the controller from restarting in Flow Recovery Mode, set Auto Recovery: Number Restarts setting to "0."
An automatic restart succeeds when a single pump is able to satisfy the flow proof sensor. Once an automatic restart succeeds, a timer is started. The Restarts Left output value is restored to the Auto Recovery: Number Restarts setting after one day of successful operation. Each automatic restart resets this timer to zero and another day of successful operation must occur before the Restarts Left output value is restored.
While in Flow Recovery Mode, the Flow Recovery Mode output on the LCI displays "Yes".
When Flow Recovery Mode displays "Yes" and Restarts Left displays "0" the controller is in Flow Recovery mode, but no longer able to attempt an automatic reset. Flow is not monitored. Since a successful automatic restart is required before Restarts Left is restored, the controller operates in this state indefinitely until flow issues are resolved and a manual controller reset is performed. Both outputs will be energized in accordance with demand inputs regardless of the flow reading.
The controller will leave Flow Recovery Mode when an automatic restart occurs, the controller is manually reset, or commissioning mode is used. While in Flow Recovery Mode, pump outputs are energized corresponding to the demand input. Cycling demand causes controller outputs to turn on or off, but does not cause the controller to leave Flow Recovery Mode.
The Pump Settings: Post Purge Time is enforced when demand input changes from active to inactive in Flow Recovery mode. Both pump outputs are energized until the post purge time is complete.
In order to enable the Flow Recovery sequence, the following conditions must be met:
Pump Settings: Operational Mode must be set to a mode other than "Single".
Enable Alarm must be set to "Switch (Open)" for monitoring of a normally open flow switch or "Switch (Closed)" for monitoring of a normally closed flow switch.
Auto Recovery: Enable must be set to "On."
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iWorx® PSU1

Figure 8: Example Auto Flow Recovery Sequence

NOTE: This flow chart depicts Auto Flow Recovery behavior in Standby Mode with an active demand
input. Unrelated operational behavior has been intentionally omitted.
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iWorx® PSU1

Modulation

Pump modulation is available in Single, Standby and Equal Runtime modes.
To enable the modulated outputs, set Pump Settings: Operational Type to “Modulating.” Under Pump Mod Set, config­ure the modulation settings according to the specific pump in use.
NOTE: Out Min and Out Max must be specified. These values configure the voltage range of the modu- lated output. The min and max default to zero volts and must be set properly before the physical output will be able to modulate pump speed.
When modulation is enabled, the pump's Pump Enable Output and Pump Modulated Output are both active whenever a pump is on. The Pump Modulated Output adjusts the pump's speed to maintain the desired Delta T.
NOTE: Delta T is always converted to an absolute value before comparing against the Temperature Differ- ential setting.
A larger Delta T value than the Temperature Differential setting acts to accelerate the pump; a smaller value than the setting acts to decelerate the pump.

Lead Pump Select

The lead pump may be changed manually at any time by changing the Lead Pump Sel setting.
NOTE: When Lead Pump Sel setting is changed, the timers used by Equal Runtime mode are reset.
The lead pump may be set to a specific pump, the pump with lowest hours, or alternating.
The specific pump choices are “Pump 1" or “Pump 2."
The “Lowest Hours” setting automatically chooses the pump with lowest runtime hours when there is a call to run. If both pumps have equal runtimes, then preference is given to Pump 1.
If the “Alternating” setting is chosen, then the lead pump alternates on each call to run.

Constant Circulation

If the Const Pump Circ setting is “On,” a primary pump remains on continuously, regardless of demand.
2 Stage Mode: When Constant Circulation is “On” and the controller is in 2 Stage Mode, pump staging occurs accord­ing to the water temperature differential and user settings.
Pump Modulation and Other Modes: When Constant Circulation is set to “On” and the controller Operating Type is set to “Modulating,” pump speed is modulated according to the water temperature differential and user settings.

Low Supply Temperature Circulation

If the Low Temp Setting is greater than 0.01°F, the Low Supply Temperature circulation feature is enabled. When the Supply Temperature falls below the setpoint, the lead pump is turned on.
2 Stage Mode: No staging occurs when Low Supply Temp Circulation is active.
Pump Modulation and Other Modes: Pump speed is fixed at the minimum speed when Low Supply Temp Circulation is active.

Pump Exercising

If Pump Settings: Pump Exercise is “On,” the pumps run sequentially for 15 seconds every week during periods of inac- tivity. There is a 1-second delay between pumps.
Pump Modulation: Pump speed is fixed at the minimum speed when pumps are exercising.
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iWorx® PSU1

Commissioning

Either pump may be commissioned at any time by means of the Commissioning: Pump 1 Comm or Commissioning: Pump 2 Comm setting. To turn the pump on, set the switch to Enable. To turn the pump off, set the switch to Disable.”
To resume automatic operation, set the switch to “Auto.”
When pump 1 or pump 2 is enabled in this manner, the pump's modulated output is also set to the speed setting spec­ified in the Commissioning: Pump 1 Mod or Commissioning: Pump 2 Mod setting.
NOTE: Care should be taken to ensure that the Pump 1 Mod or Pump 2 Mod setting is acceptable before changing the Pump 1 Comm or Pump 2 Comm field to “Enable.”

Alarms

Circulation Pump Failed Alarm

The Pump Flow Proof is monitored whenever the lead primary pump is turned on by the controller. If the Pump Flow Proof switch remains open after a configurable delay and Enable Alarm is not set to “Disabled,” a Circulation Pump Failed Alarm is communicated to the LCI.

Dual Pump Failure

When both pumps have failed, a Dual Pump Failure alarm is communicated to the LCI. A dual pump failure alarm occurs when:
• Two pumps have failed and Auto Flow Recovery Mode is not configured.
• Two pumps have failed, Flow Recovery is active and flow has not been detected for twice the duration configured under Flow Delay.

Circulation Water Temp alarms

A temperature alarm is communicated to the LCI under the following conditions:
• Circulation Supply Water Temp High
• Circulation Supply Water Temp Low
• Circulation Return Water Temp High
• Circulation Return Water Temp Low
A “Temp High” alarm is generated when measured water temperature exceeds the limit defined in Water Temp Alm: High Limit. A Temp High alarm returns to normal when the water temperature falls below the High Limit minus 1°F.
A “Temp Low” alarm is generated when measured water temperature is below the limit defined in Water Temp Alm: Low Limit. A Temp Low alarm returns to normal when the water temperature rises above the Low Limit plus 1°F.
Circulation alarms are disabled when both Water Temp Alm: High Limit and Water Temp Alm: Low Limit are set to 32 °F.

CONTROLLER IDENTIFICATION

To register the controller with the LCI, press the service pin on the controller once it is properly installed and the LCI is active on the network.
Once the PSU1 is properly installed and recognized by the LCI, the LCI can be used to configure the settings of the controller. This section describes the commands available on the LCI for configuration of the PSU1, and the meanings and default values for controller parameters. For more information on using the LCI, see the iWorx® LCI Application
Guide.
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iWorx® PSU1

Network Inputs

The PSU1 allows a network manager to write to Network Input Variables for the purpose of overriding the configuration, operation and outputs of the PSU1. The network input variables are listed below.
Values written to NVIs have absolute priority over any other controller operation.
nviOccCmd is a legacy, unused network variable. Overriding this variable does not affect controller operation.
nviResetRuntime is a command to reset the pump runtimes displayed on the web interface. If the value sent is 0, then no reset occurs; if the value sent is 1, then the runtimes are reset.
nviSysTime is a time stamp to set the date and time. Writing to this variable changes the time on the device and affects all time-related functions such as schedules.
nviOutOverride is a structure (defined below) that overrides the digital and analog hardware outputs on the PSU1. These values allow the network controller to directly control the analog and digital outputs of the board.
NOTE: the PSU1 makes no attempt to interpret the outputs; assigning meaningless outputs may have unpredictable results.

Network Variable Inputs (NVIs)

Internal Variable
Name
nviOccCmd SNVT_occupancy N/A Legacy; not used nviResetRuntime SNVT_lev_disc 0 = no reset
nviSysTime SNVT_time_stamp Date/Time System time nviOutOverride Structure Structure Output override
Format Range Description
1 = reset runtimes

Output Override Structure (NVI)

Name Type/Range Default Description
digOut[8] Unsigned Byte:
0=OFF 1=ON 0xFF=no override
aOut[4] SNVT_lev_percent:
0% to 100% 32767=no override
fpOut[4] SNVT_lev_percent N/A Not used
0xFF 0xFF 0xFF 0xFF 0xFF 0xFF 0xFF 0xFF
32767 32767 32767 32767
digOut[0] = TO1 (pin 31) digOut[1] = TO2 (pin 29) digOut[2] = TO3 (pin 28) digOut[3] = TO4 (pin 26) digOut[4] = TO5 (pin 25) digOut[5] = TO6 (pin 23) digOut[6] = TO7 (pin 22) digOut[7] = TO8 (pin 20)
aOut[0] = AO 0 (pin 37) aOut[1] = AO 1 (pin 35) aOut[2] = AO 2 (pin 34) aOut[3] = AO 3 (pin 32)
Resets the pump run­times
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iWorx® PSU1

Inputs

The Inputs screen displays the current values of the PSU1’s inputs. These values cannot be changed.
Name Range Description
Outside Temp -30 to 230 °F (-34.4 to 110 °C) The outside air temperature as
reported by the networked ASM2 Supply Temp -30 to 230 °F (-34.4 to 110 °C) Primary supply water temperature Return Temp -30 to 230 °F (-34.4 to 110 °C) Return water temperature Demand Off, On Status of the demand Flow Switch Off, On Status of the Pump Flow Proof
switch Delta T 0 to 260 °F (0 to 144.4 °C) Differential temperature between
the supply and return temperature
readings

Outputs

The Outputs screen displays the current values of the PSU1’s outputs. These values cannot be changed.
Name Range Description
Output Status Structure as defined in a table below General pump status Pump 1 Adjust Structure as defined in a table below Pump 1 commissioning and runtime Pump 2 Adjust Structure as defined in a table below Pump 2 commissioning and runtime Pump 1 Modulation 0 to 100% Pump 1 modulation level Pump 2 Modulation 0 to 100% Pump 2 modulation level Restarts Left 0 to 4 Number of Auto Flow Recovery
Restarts remaining.

Output Status

Name Range Description
Pump #1 Off, On Status of pump 1 Pump #2 Off, On Status of pump 2 In Alarm? No, Yes Alarm status Low Temp Circ Off, On Low temperature circulation status Flow Recovery Mode Yes, No Is Flow Recovery Mode active?

Pump 1 Adjust / Pump 2 Adjust

Name Range Description
Commissioning Auto,
Enabled, Disabled
Runtime 0 to 65535 hours Accumulated pump runtime
Pump commissioning switch state

Configuration

This section describes the settings that can be modified.
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iWorx® PSU1

All Settings

This screen displays all of the controller's settings and provides access to edit all parameters from a single screen. Some parameters (defaulted as Structure) are described in individual tables below.
Setting Range Default Description
Pump Settings Structure N/A General pump settings Commissioning Structure N/A Pump commissioning settings Enable Alarm Disabled,
Switch (open), Switch (closed
Flow Delay 0 to 180 seconds 15 seconds Amount of time to wait without flow before
Thermistor Type PreconII,
PreconIII Pump Mod Set Structure Pump modulation settings Low Temp Setting 0.01 to 50 °F 0.01 °F Sets the minimum temperature at which low
Water Temp Alm Structure N/A Auto Recovery Structure N/A Auto Flow Recovery settings.
Disabled Enables monitoring and alarming associated
with the Pump Flow Proof switch
signaling pump failure
PreconIII Selects the type of thermistor used for supply
and return water temp
temperature circulation activates. If set to
0.01°F, then this feature is disabled.

Pump Settings

This screen displays PSU1 settings related to this topic and allows access to all of these settings from a single screen.
Setting Range Default Description
Operational Mode Standby,
Single,
Equal Runtime,
2 Stage Const Pump Circ Off, On Off Causes pumps to run continuously, regard-
Lead Pump Sel Pump 1,
Pump 2,
Lowest Hours,
Alternating Pre Purge Time 0 to 100 seconds 10 seconds Time primary pump runs before starting a
Post Purge Time 0 to 255 minutes 5 minutes Time primary pump runs after the demand is
Max Runtime 1 to 255 hours 168 hours Amount of run time by which the lead pump
Differential Temp 0 to 40 °F (0 to 22.2 °C) 40 °F (22.2 °C) Primary loop Delta T at which the second
Pump Exercise Off, On Off If “On,” pumps are run sequentially for 15
Operational Type Switching,
Modulated
Single Operating sequences of the two pumps
less of demand
Pump 1 Determines the pump selection method to
use when a new pump must be started.
boiler stage (must be in sync with the BLMC) to allow accurate temperature measurement.
off to dissipate heat and allow pump speed to return to a minimum value.
exceeds the lag pump before swapping lead and lag.
pump is turned on or the desired primary loop Delta T in single stage modulated mode. The Absolute value of Delta T is always used when comparing against this setting.
seconds every week.
Switching Turns on modulated outputs. Not available in
2 Stage mode.
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iWorx® PSU1

Commissioning

This screen displays PSU1 settings related to this topic and allows access to all of these settings from a single screen.
Setting Range Default Description
Pump 1 Comm Disable,
Enable, Auto
Pump 2 Comm Disable,
Enable, Auto
Pump 1 Mod 0 to 100% 0% Sets the pump 1 modulation level when
Pump 2 Mod 0 to 100% 0% Sets the pump 2 modulation level when
Auto Disable = Off, Enable = On, Auto = Automatic
Operation
Auto Disable = Off, Enable = On, Auto = Automatic
Operation
Pump 1 Comm is set to “Enable”
Pump 2 Comm is set to “Enable”

Pump Mod Set

This screen displays PSU1 settings related to this topic and allows access to all of these settings from a single screen.
Setting Range Default Description
Gain -4 to +5 0 Sets PI loop gain On 0 to 100% 50% Minimum modulation level while pump is on.
Modulation level will be 0% when pump is off and will vary between "On" and 100% when
pump is on. Ramp Up 0.00 to 20.00% 1.00% Ramp up percent per second Ramp Down 0.00 to 20.00% 0.5% Ramp down percent per second Out Min 0.0 to 10.0 V 0.0 V Minimum output voltage for modulated pump
outputs corresponding to a modulation level
of 0%. Out Max 0.0 to 10.0 V 0.0 V Maximum output voltage for modulated pump
outputs corresponding to a modulation level
of 100%.

Water Temp Alm

This screen displays PSU1 settings related to this topic and allows access to all of these settings from a single screen.
Setting Range Default Description
High Limit 32.0 to 212°F
(0 to 100°C)
Low Limit 32.0 to 212°F
(0 to 100°C)
32 °F (0.0°C)
32 °F (0.0°C)
Supply and return water temperature high
alarm limit
Supply and return water temperature low
alarm limit

Auto Recovery

This screen displays PSU1 settings related to Auto Flow Recovery and provides access to all of these settings from a single screen.
Setting Range Default Description
Enable Off, On On Enable Auto Flow Recovery Number Restarts 0 to 4 4 Maximum number of system restart attempts
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Alarms

The table below describes the alarms that the user may encounter and how to reset them.
Alarm Range Alarm Trigger Alarm Reset
Circulation Supply Water Temp High
Circulation Supply Water Temp Low
Circulation Return Water Temp High
Circulation Return Water Temp Low
Circulation Pump 1 Failed Alarm
Circulation Pump 2 Failed Alarm
Dual Pump Failure Normal, Alarm Occurs when both Pump 1 and
Normal, Alarm Supply Temp > Water Temp Alm:
High Limit
Normal, Alarm Supply Temp < Water Temp Alm:
Low Limit
Normal, Alarm Return Temp > Water Temp Alm:
High Limit
Normal, Alarm Return Temp < Water Temp Alm:
Low Limit
Normal, Alarm Occurs when there is Demand,
Pump 1 is selected, Enable Alarm is not “Disabled,” and no flow has been detected for Flow Delay sec­onds.
Normal, Alarm Occurs when there is Demand,
Pump 2 is selected, Enable Alarm is not “Disabled,” and no flow has been detected for Flow Delay sec­onds.
Pump 2 have failed.
Supply Temp < Water Temp Alm: High Limit - 1°F
Supply Temp > Water Temp Alm: Low Limit + 1°F
Return Temp < Water Temp Alm: High Limit - 1°F
Return Temp > Water Temp Alm: Low Limit + 1°F
Reset the controller (power cycle).
Reset the controller (power cycle).
Reset the controller (power cycle).
iWorx® PSU1

TROUBLESHOOTING

Diagnostic LEDs

The controller has 3 LED indicators. These indicators can aid in troubleshooting equipment operation problems. The following table lists the functions of the controller’s LEDs in the order they appear from left to right on the unit.
LED Indication
Status – Solid green when running and configured by an LCI (networking)
– Flashing green when running and NOT configured by an LCI (stand-alone) – Solid red when a fault condition exists (control shut down) – Blinking Red - the controller has a device failure – Solid Amber - The controller has not received a LCI ping message in over 10 minutes and is part of a network.
Network – Yellow while the controller is transmitting data onto the FTT-10A network
– Green when there is network activity – Off when there is no network activity
Service – Illuminated when the service pin is depressed or when a controller gets configured by the LCI.
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iWorx® PSU1

Figure 9: PSU1 Controller LEDs

Status Network Service

Troubleshooting Tips

The table below provides solution to some common problems you may encounter.
Problem Solution
Controller is not running and Status LED is not illuminated.
How do I reset the controller? The controller can be reset by the LCI, or you can cycle power to the controller. Refer to
The Supply or Return Water Temper­ature thermistor reading is at its maxi­mum or minimum.
Thermistor readings fluctuate rapidly, sometimes by several degrees.
Under what conditions does the PSU1 require a reset for normal oper­ation?
No power to controller. Verify the voltage on the controller’s power connector (24 VAC).
the LCI documentation for more information on resetting the controller using the LCI. The input is either shorted or open.
The controller is not properly grounded. The controller's ground (GND) pin (T40) must be connected to earth ground. Also ensure that the controller's digital inputs are dry contacts and that no voltage is being applied or switched to the inputs.
There are three conditions that require a reset: – Pump 1 Failed alarm – Pump 2 Failed alarm – Dual Pump Failure alarm
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iWorx® PSU1

Getting Help

Components within an iWorx® controller, sensor, or power supply cannot be field repaired. If there is a problem with a unit, follow the steps below before contacting your local TES representative or TES technical service.
1.Make sure controllers, sensors, and power supplies are connected and communicating to desired devices.
2.Record precise hardware setup indicating the following: Version numbers of application software.
Device and/or firmware version number.
A complete description of difficulties encountered.
Notes:
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iWorx® PSU1
LIMITED WARRANTY STATEMENT
Taco Electronic Solutions, Inc. (TES) will repair or replace without charge (at the company's option) any product or part which is proven defective under normal use within one (1) year from the date of start-up or one (1) year and six (6) months from date of shipment (whichever occurs first).
In order to obtain service under this warranty, it is the responsibility of the purchaser to promptly notify the local TES stocking distribu­tor or TES in writing and promptly deliver the subject product or part, delivery prepaid, to the stocking distributor. For assistance on war­ranty returns, the purchaser may either contact the local TES stocking distributor or TES. If the subject product or part contains no defect as covered in this warranty, the purchaser will be billed for parts and labor charges in effect at time of factory examination and repair.
Any TES product or part not installed or oper­ated in conformity with TES instructions or which has been subject to accident, disaster, neglect, misuse, misapplication, inadequate operating environment, repair, attempted repair, modification or alteration, or other abuse, will not be covered by this warranty.
TES products are not intended for use to sup­port fire suppression systems, life support sys­tems, critical care applications, commercial aviation, nuclear facilities or any other applica­tions where product failure could lead to injury to person, loss of life, or catastrophic property damage and should not be sold for such pur­poses.
If in doubt as to whether a particular product is suitable for use with a TES product or part, or for any application restrictions, consult the applicable TES instruction sheets or in the U.S. contact TES at 401-942-8000 and in Canada contact Taco (Canada) Limited at 905-564-
9422.
TES reserves the right to provide replacement products and parts which are substantially sim­ilar in design and functionally equivalent to the defective product or part. TES reserves the right to make changes in details of design, con­struction, or arrangement of materials of its products without notification.
TES OFFERS THIS WARRANTY IN LIEU OF ALL OTHER EXPRESS WARRANTIES. ANY WARRANTY IMPLIED BY LAW INCLUDING
WARRANTIES OF MERCHANTABILITY OR FITNESS IS IN EFFECT ONLY FOR THE DURATION OF THE EXPRESS WARRANTY SET FORTH IN THE FIRST PARAGRAPH ABOVE.
THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR STATUTORY, OR ANY OTHER WARRANTY OBLIGATION ON THE PART OF TES.
TES WILL NOT BE LIABLE FOR ANY SPE­CIAL, INCIDENTAL, INDIRECT OR CONSE­QUENTIAL DAMAGES RESULTING FROM THE USE OF ITS PRODUCTS OR ANY INCI­DENTAL COSTS OF REMOVING OR REPLACING DEFECTIVE PRODUCTS.
This warranty gives the purchaser specific rights, and the purchaser may have other rights which vary from state to state. Some states do not allow limitations on how long an implied warranty lasts or on the exclusion of incidental or consequential damages, so these limitations or exclusions may not apply to you.
CONTROLS MADE EASY
®
Taco Electronic Solutions, Inc., 1160 Cranston Street, Cranston, RI 02920
Telephone: (401) 942-8000 FAX: (401) 942-2360.
Taco (Canada), Ltd., 8450 Lawson Road, Unit #3, Milton, Ontario L9T 0J8. Telephone: 905/564-9422. FAX: 905/564-9436.
Taco Electronic Solutions, Inc. is a subsidiary of Taco, Inc. Visit our web site at: http://www.taco-hvac.com
Printed in the USA iWorx® and iView® are registered trademarks of Taco Electronic Solutions, Inc. © 2012 Taco Electronic Solutions, Inc. LON, LONWORKS, & LONMARK are trademarks of Echelon Corporation
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