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
Table of Contents
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
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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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iWorx® PSU1
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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iWorx® PSU1
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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iWorx® PSU1
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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