WCC III

WattMaster WCC III User Manual part 12

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12. WCC III Installation Guide

WCC III

12. WCC III Installation Guide

T ABLE OF CONTENTS

SECTION 12: WCC III INST ALLA TION GUIDE

WCC III System Requirements .................12-1

MCD Basic Operating Conditions .............12-2

Wall Mounting of the WCC III – MCD .........12-2

WCC III – MCD Internet Access ................12-4

Sending a Text Message to a Cell Phone via an Email from

the WCC III System ................................... 12-6

WCC III System RS-485 Communication

Wiring ........................................................12-7

WCC III - MCD Typical System

Architecture ..............................................12-8

Mounting a Satellite Controller in an

Enclosure ................................................12-10

SAT 3C Controller ..................................12-49

Addressing the SAT 3C ........................... 12-51

Addressing (Numbering) of the TUC/RTU Controllers that are

Connected to the SAT 3C .......................12-53

SAT 3D Controller ...................................12-57

Addressing the SAT 3D ........................... 12-58

Addressing (Numbering) of the TUC Controllers that are Connected to the

SAT 3D .....................................................12-60

SAT 3F Controller ....................................12-62

Addressing the SAT 3F ...........................12-63

Addressing (Numbering) of the TUC Controllers that are connected to

the SAT 3F ...............................................12-65

Satellite Controllers -

General Dimensions ...............................12-15

SAT III Controller - LED Information .......12-16

SAT III Controller - Connection Points ...12-17

Addressing (Numbering) of

SAT III Controllers ..................................12-19

SAT III Relay Outputs .............................12-21

Proportional-Integral (PI) Output

Board .......................................................12-24

Binary Input with Time Delay Board ......12-27

V-Out Binary/Relay Interface Board .......12-34

SAT III Analog Inputs .............................. 12-41

TUC-2R and Four Relay Expansion

Board ......................................................12-67

TUC-2R Three Relay Expansion Board

and Damper Actuator ..............................12-68

TUC-2R Velocity Sensor ......................... 12-69

Running the WCC3 Program ...................12-70

WCC III - MCD LCD Display .....................12-73

The WCC III - MCD ...................................12-78

Using the MCD-Menu Program ...............12-79

12. WCC III INSTALLATION GUIDE

System Requirements

SECTION 12: WCC III INST ALLA TION GUIDE __________________________________________

WCC III System Requirements

To accomplish remote communications via the internet, the following items are needed in addition to the WCC III system in order to control the building mechanical systems. The WCC III system is not to be used in any application where Fire/Life/Safety is an issue.

WCC III – MCD System Requirements (On-Site WCC III – MCD Computer):

• DSL, or a Cable router/switch that connects to the

internet. Or, as an alternative, an internal jobsite IP network that does not connect to the internet, but when using this internal jobsite IP network, the external internet Email of alarms from the WCC III

- MCD will not be possible. Also, external access via the internet may not be possible.

• A ﬁ xed static IP address or a ﬁ xed IP domain host

name.

• Enabled port forwarding on the Firewall of the

router/switch. This is only if a ﬁ rewall is used.

• On earlier versions, antivirus software is initially

provided by WattMaster Controls, with Norton antivirus software for a period of 1 year. The customer must maintain the antivirus software after this 1-year period. Later versions are shipped with Linux as the operating system and do not require anti-virus software.

• An Email address that supports a SMTP

server for SENDING with a pop server for RECEIVING Emails, and it must have “auth login” authentication. TLS or SSL modes are not supported. WattMaster Controls can provide an Email address with these requirements.

• An Uninterruptible Power Supply (UPS) – 750-

Watt minimum

• A wall mounting surface is preferred.

• A dedicated 120VAC power circuit is required.

Front End Software Requirements (Operator Console Software):

• A Microsoft Windows XP /Vista/Windows 7-based

computer.

• Minimum hardware speciﬁ cation for the Microsoft

Windows XP / Vista based computer is a Pentium IV running at 2.4 Giga Hertz with at least 1 GB of RAM, and 10 GB of spare hard drive space. A CDROM/DVD player is also required for software installation.

• WCC III software package – Provided on a

CDROM, or is available via a download on the WCC Controls website: www.wcc-controls.com. The installation CDROM contains the following programs:

WCC III.EXE (SS5021) WCCUTILITY.EXE (SS5023) SCUSCR.EXE (SS5026) WCC3Trendlog.EXE (SS5028) TenantReport.EXE (SS5025) TenantOverride.EXE* (SS5024) WGCC3.EXE (SS5029) WCC3 Download (SS5030) WCC3 Guest (SS5022)

• The CDROM part number (WattMaster Part #

DM1WC011-01X, were “X” = revision level)

• A DSL or Cable router/switch that connects to the

internet, or access to the internet via some other method. Or, as an alternative, an internal jobsite IP network that does not connect to the internet, but when using this internal jobsite IP network, the external internet Email of alarms from the WCC III

- MCD may not be possible.

* NOTE: The TenantOverride.exe program is also available

as a single program installation for the end users that are using the simplistic graphical interface of the TenantOverride.exe screen to locally turn on and off speciﬁ c control points that are applicable to the end user.

WCC III Technical Guide

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12. WCC III INSTALLATION

Basic Operating Conditions and Wall Mounting

The WCC III – MCD Basic Operating Conditions

The WCC III - MCD must be kept in a clean and dry area in the building. The ambient temperature must be between 50 and 100 °F, and the relative humidity must be kept between 0 and 90% (noncondensing). The interior components are cooled by ventilation fans within the WCC III – MCD unit, and therefore the unit should not be kept in tightly conﬁ ned or enclosed areas. The WCC III - MCD is primarily designed to mount on a wall with the supplied brackets.

The WCC III – MCD computer requires 115 VAC power and must remain powered at all times for proper operation and control. The 115 VAC power circuit must be separate and dedicated exclusively to the WCC III – MCD computer.

The WCC III - MCD system is designed to automatically restart after a power failure. However, the industrial computer which acts as the WCC III Master Communications Device will not automatically reboot unless the power is shut off cleanly and then restored cleanly. During most power outages, the incoming 115 AC voltage could have great ﬂ uctuations before the power ﬁ nally fails. In a like manner, brownouts will usually cause the industrial computer to “lock-up.” That is to say, the screen will continue to display on the monitor, but the cursor will not respond to the keyboard commands. To prevent this “lock-up” issue from happening to the WCC III – MCD, an Uninterruptible Power Supply (UPS) is required on each and every WCC III – MCD computer.

An Uninterruptible Power Supply (UPS) provides emergency power to keep the WCC III Master Communications Device (personal computer) on-line for several minutes after a primary power failure. The UPS regulates the incoming power to the computer and shuts the power off cleanly several seconds after the power outage, or brownout. When the primary power is restored, the UPS brings the MCD back on-line automatically. The WCC III system does not lose any information since all of the programs and user entered data are stored on either a disk in the MCD, on ﬁ rmware, or on battery backed memory in the satellite controllers.

Figure 12-1: Installing the six screws for the two wall mounting brackets of the WCC III – MCD Computer

Do not mount the WCC III – MCD computer straight into the drywall. The use of a ¾-inch plywood “Backer Plate Board” is required. You may want to paint this plywood “Backer Plate Board” to match the color of the wall before mounting to the wall.

See Figure 12-2 for further application.

Backer Plate Mounting Notes:

Use correct type of wall mounting anchors for mounting on a concrete wall for the mounting of the “Backer Plate Board” if and when mounting the Backer Plate Board to a concrete wall. Use at least 2-inch dry wall type screws if mounting the Backer Plate Board to a “Dry-Wall” type wall. Mount the “Backer Plate Board” so that the screws that are holding the “Backer Plate Board” are on the 16-inch centers of the wall studs where applicable.

Mount the WCC III - MCD 4-½ to 5-½ feet off of the ground on a suitable wall, in an air conditioned space. This area should not have any radio transmitting or telephone switching gear in the space, or near the space, or located on the back side of the adjacent wall.

Wall Mounting of the WCC III – MCD

It is strongly suggested that the WCC III – MCD is mounted on the wall. General guidelines are as follows:

Always install the supplied six screws for the two supplied wall mounting brackets for the WCC III – MCD Computer as shown in

Figure 12-1. Be sure to tighten the six screws so that they do not

loosen over time.

12-2

Do not block the airﬂ ow vents that are coming out of the WCC III- MCD. Do not apply paint to the WCC III-MCD enclosure. Do not cover the WCC III-MCD with any protective plastic while painting with the WCC III-MCD turned on. The UPS battery backup unit should be located within 3 or 4 feet of this WCC III – MCD.

WCC III Technical Guide

12. WCC III INSTALLATION

Wall Mounting of the WCC III - MCD

Front view with wall mounting brackets

GUIDE

Use 3/4 inch plywood for the backer plate board

(supplied by others)

Figure 12-2: Wall mounting instructions for the WCC III – MCD

NOTES:

at least 2-inch dry wall type screws. Mount the backer plate board so that the screws that are holding the backer plate board are on the 16inch centers of the wall where applicable.

Mount the WCC III - MCD 4-½ to 5-½ feet off of the ground on a suitable wall in an air conditioned space. This space should not have any radio transmitting or telephone switching gear in the space, or near the space, or located on the back-side of the adjacent wall.

Do not block the airﬂ ow vents that are coming out of the WCC III - MCD. Do not apply paint to the WCC III - MCD enclosure. Do not cover the WCC III - MCD with any protective plastic while painting with the WCC III - MCD turned on.

The UPS should be located within 3 or 4 feet of this WCC III - MCD.

WCC III Technical Guide

Use approved anchors when mounting backer plate board on a concrete wall. If mounting backer plate board to dry wall, use

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12. WCC III INSTALLATION

WCC III - MCD Internet Access

WCC III – MCD Internet Access

The most common question asked is: Why does the WCC III – MCD computer need to have Internet access?

If WattMaster Controls factory assistance or troubleshooting is required for a WCC III system, a representative from the factory can access the system with a remote computer and view the same WCC III Screens as the end user or contractor in the building. This allows the end user or the contractor for the building installation to talk to the factory representative while they are both viewing the same screens.

The Emailing of important alarm notiﬁ cations for up to 60 Email Addresses is provided for from the WCC III – MCD.

The ability to send alarm notiﬁ cation via a text message to a cellular phone.

Secure Remote communications package (WCC III software) is provided for FREE. A CD-ROM is supplied for installation.

World-wide, multiple remote connections (up to 255 simultaneous connections possible)

On earlier versions, antivirus software is initially provided by WattMaster Controls, with Norton antivirus software for a period of 1 year. The customer must maintain the antivirus software after this 1-year period. Later versions are shipped with Linux as the operating system and do not require anti-virus software.

The ability for internet based tenant override requires internet access.

WCC III – MCD Cable Modem/Router T echnical Considerations

The WCC III-MCD uses internet access to e-mail alarms and to provide remote IP access for multiple remote WCC III operator programs.

The DSL / Cable modem USB connection should not be connected to any of the USB ports on the WCC III – MCD. The DSL / Cable modem Ethernet connection should only be connected to the Ethernet port on the WCC III – MCD if the DSL / Cable modem has a built-in internal router with Ethernet switch.

The use of a DSL / Cable modem with an external router that is then connected to the WCC III - MCD is also a recommended way to connect the internet to the WCC III – MCD. The use of only a plain DSL / Cable modem without an internal router with a built-in switch is not currently recommended by WattMaster Controls.

It is recommended that the WCC III-MCD computer be connected to the internet via a high-speed cable modem or NAT enabled router.

This is best accomplished by what is called Port Forwarding (also sometimes referred to as tunneling) and is the act of forwarding a network port (located External on the internet) to another network node (located Internal on the LAN). This technique can allow an external user (The WCC III program) to reach a port that is on a private LAN (Local Area Network) IP address (The WCC III MCD) from the outside via a NAT enabled router. This external port number that is used for the WCC III – MCD computer is port

39289.

Custom remote WCC III system programming or analyzing of the existing WCC III program is also available for a nominal charge.

Some cable modem devices may incorporate a router along with the cable modem functionality, to provide the LAN with its own IP network addressing. From a data forwarding and network topology perspective, this router functionality is typically kept distinct from the cable modem functionality (at least logically) even though the two may share a single enclosure and appear as one unit. So, the cable modem function will have its own IP address and MAC address as will the router.

Figure 12-3: Typical small business type routers—a Broadband Firewall Router, and a Cable/DSL VPN Router

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WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

WCC III - MCD Internet Access

In a typical WCC III - MCD networking setup, internet access is through a DSL or Cable modem. This modem may then be connected to a router with a built in switch, (or typically the router with switch is also built-in to the modem) which is then connected to the internal LAN of networked computers by Ethernet cabling. The NAT enabled router is the only device that the Internet sees as it holds the public IP address. On the other hand, the WCC III – MCD, located behind the NAT enabled router, is invisible to the Internet as it holds a local IP address on the NAT enabled router. Port forwarding is necessary in the NAT enabled router because computers that are running the WCC III program will send information that is directed to the public IP address and the NAT enabled router needs to know where to send and then redirect that information to the WCC III – MCD.

NOTE: A DSL modem is not recommended due to yet

another layer of setup complexity. DSL modem/routers also have a maximum distance from the local telephone company’s

main central ofﬁ ce. That distance is 18,000 feet.

Step 1: You will need a high-speed cable or DSL modem/router

that is NAT enabled and it must be setup by the ISP, or by IT (Information Technology) knowledgeable personnel, and it must also be connected to the Internet.

The default IP addresses that the WCC III – MCD is shipped with are:

WCC III-MCD IP Address: 192.168.100.100

WCC III-MCD Subnet Mask: 255.255.255.0

WCC III-MCD Default Gateway: 192.168.100.1

WCC III-MCD Preferred DNS Server: 208.67.222.222

WCC III-MCD Alternate DNS Server: 208.67.220.220

The external port number that is used for the WCC III – MCD computer is port 39289.

For WCC III – MCD’s running windows set up the WCC III – MCD BACKTASK.EXE Program

Com Port # ____________

External Port Range ____________

Default for the backtask.exe program is Comm port # 5 and port # 39289.

Step 2: The following three items are needed from your ISP

(Internet Service Provider) in order to set up the Cable / DSL modem/router for stand alone internet access. The ISP should have already supplied a sheet of paper that has this important information on it.

WCC III-MCD IP Address: _______._______._______._______

WCC III-MCD Subnet Mask: _______._______._______.______

WCC III-MCD Default Gateway: _______.______.______._____

WCC III-MCD Preferred DNS Server: _________._________.__

______._______

WCC III-MCD Alternate DNS Server: _________._________.__ ______._______

WCC III Technical Guide

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12. WCC III INSTALLATION

WCC III - MCD Internet Access

Supported Networks

Only Microsoft based networks are currently supported by the WCC III system. Any of the older 10 base T only networks are not supported by the WCC III system, only 100 base T or faster networks are supported. (10/100 base T are OK) The slower the network, the slower the data returned from the WCC III-MCD will be displayed, and the faster speed is always better.

Also, network “hub” devices are not recommended, because “hub” devices divide the network’s bandwidth amongst the active connections that are connected to the network hub. For example, if you have a 16-port network hub on a 100 base T connection with 10 active connections, then your effective network speed is the same as a 10 base T connection.

A 10/100 base T network switch is the recommended connection to the WCC III-MCD device. A network switch device has a full 100 base T connection to all active ports at the same time.

Beneﬁ ts of Using a Separate DSL / Cable Modem Internet connection for the WCC III-MCD

1. It provides a layer of network isolation. A connection to the building’s internal computer network may not be desirable to the IT department. If the WCC III – MCD is connected to the building’s internal computer network an additional ﬁ rewall into the building’s internal computer network may be required.

2. A dedicated high speed internet connection is a faster connection. WCC III displayed data will be displayed quicker and updated faster.

How to send a T e xt Message to a Cellular phone via an Email from the WCC III system

Most cellular telephone providers have as a free* option (Charges may apply in some instances) an Email-to-TEXT service for their cellular phone plans. *Usually the cellular telephone providers will have an unlimited text messaging option in one or more of their plans.

When using Verizon cellular service, the text messaging email address for your phone is your 10-digit phone number followed by @VTEXT.com. For example, if your phone number is 1-555555-5555, your email address (for TEXT MESSAGING) would be 5555555555@VTEXT.com

When using Sprint cellular service, the text messaging email address for your phone is your 10-digit phone number followed by @messaging.sprintpcs.com. For example, if your phone number is 1-555-555-5555, your email address (for TEXT MESSAGING) would be 5555555555@messaging.sprintpcs.com.

When using AT&T cellular service, the text messaging email address for your phone is your 10-digit phone number followed by @txt.att.net. For example, if your phone number is 1-555-5555555, your email address (for TEXT MESSAGING) would be 5555555555@txt.att.net.

Example: 5555555555@VTEXT.com, 5555555555@messaging. sprintpcs.com, or 5555555555@txt.att.net would be programmed into the WCC III System parameters screen as an Email address. Any alarm type level that is generated would be sent to that cellular telephone number as a text message.

3. Network outages should be less frequent, due to the fact that there is no overhead of a pre-existing internal computer network. A pre-existing internal computer network will always require periodic “downing of the network servers” to do maintenance work to the existing computer network regardless of having the WCC III-MCD connected to the pre-existing internal computer network.

4. The need for having an onsite IT person to setup, and then administer the WCC III-MCD will be reduced.

5. Setup and maintenance of e-mail accounts would be easier, because they would be automatically provided by the Internet Service Provider.

12-6

WCC III Technical Guide

12. WCC III INSTALLATION

<<<LOCAL LOOP>>> AZWR-LL-WG-18>>> E76191 CL2P 18AWG (UL) 012112 FT

<<<NETWORK LOOP>>> AZWR-NL-WR-18>>> E76191 CL2P 18AWG (UL) 012112 FT

WATTMASTER LOCAL LOOP WIRE

WATTMASTER NETWORK LOOP WIRE

GUIDE

RS-485 Communication Wiring

The WCC III System RS-485 Communication Wiring

The WCC III - MCD can communicate with up to 239 satellite controllers via a two-wire RS-485 communication loop. On the back of the WCC III – MCD there are two RS-485 communication loop ports that come as standard. Each one of these communications loop ports can communicate with up to 60 satellites for a total of 120 satellites.

Two more additional RS-485 communication loop ports can be added at an additional cost for any WCC III system that has more than 120 satellites. The two-wire RS-485 communication loop should be stranded 2 wire twisted pair of 18-gauge wire with a shield wire, and it also must be plenum rated were applicable.

The use of stranded wire is mandatory to ensure a good connection with the ¼ inch Sta-Con connectors which are used to terminate the wires at the satellite controllers. The RS-485 communication wire does not have to be run from each satellite controller back to the WCC III – MCD, but rather the RS-485 communication wire can be “daisy-chained,” which means that only one twisted pair of wires is connected to each of the WCC III - MCD communications loops. The maximum allowable length of wire from the WCC III - MCD to the farthest satellite is 4000 feet per RS-485 communications loop.

The RS-485 wire speciﬁ cations are generally a stranded 18- gauge - 2 wire twisted pair with shield. 18-gauge stranded wire is mandatory to ensure a good connection with the ¼ inch Sta-Con connectors, which are used to terminate the wires at the WCC III

- MCD and at the satellite controllers. The old SAT II Manchester communications loop was supposed to have used a 2-wire twisted pair with shield, but this was not used in every installation. This old SAT II communications loop should not be used for the new SAT III communications loop. A new RS-485 communications loop should be ran to each new replacement SAT III controller. The shield wire must be used on the new SAT III controller, as it provides a “ground” reference for the RS-485 communication loop. WattMaster Controls sells two versions of 18-gauge - 2-wire twisted pair with shield communications wire— (1) WattMaster part #WR-NL-WR-18 which is marked “Network Loop” with a red stripe for rapid identiﬁ cation. This connection is intended to run from the WCC III – MCD to the SAT III, SAT 3C/D/F, SAT 3P, and then to the next SAT 3 type controllers. (2) WattMaster part # WR-LL-WG-18 which is marked “Local Loop” with a green stripe for rapid identiﬁ cation for the TUC loops that run from the SAT 3C/D/F controllers out to the TUC controllers.

“Wire Nuts” on the RS-485 communications loop should be avoided at all costs. As an alternative to the “Wire Nuts”, WattMaster Controls has a Power and Switchable RS-485 communications board, and the WattMaster part number is PL102224. This Power and Switchable RS-485 communications board can be thought of as a 24-VAC power and communication distribution system for the SAT III communications loop, and this board will aid in initial startup and future troubleshooting of the SAT III communications loop. These boards should be used on a ﬂ oor-by-ﬂ oor basis. This Power and Switchable RS-485 communications board is also available in a small metal electrical enclosure.

Figure 12-4 WattMaster Controls various communications loop wire

WCC III Technical Guide

12-7

12. WCC III INSTALLATION

WCC III - MCD Typical System Architecture

Figure 12-5: The WCC III typical system architecture with POWER and SWITCHABLE COMM boards

Figure 12-6: WCC III typical system architecture without the POWER and SWITCHABLE COMM boards

12-8

WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

WCC III - MCD Typical System Architecture

The wire that makes up the communication loop should be shielded. Shielded cable has an aluminum jacket over the wires that could act as an “antenna” to carry away any “stray” electrical signals that could interfere with the communication process. The shield should be grounded throughout the SAT Loop.

The SAT RS-485 communication loop wires are connected to the “R” and “T” and shield terminals on the satellite controllers using ¼-inch Sta-Con connectors. Make sure the polarity is correct. That is to say, the wire connected to the “R” and “T” terminal on the MCD must be connected to the “R” and “T” terminal on the satellite controllers. If the “R” and “T” and shield wires are crossed, the WCC III system will not communicate. The shield should be connected together when the cable is cut in order to terminate the wires at the satellite controller.

The communication loop wire from the WCC III - MCD is connected to one of the “R” and one of the “T” terminals on the satellite controller, which is physically located nearest the WCC III - MCD. The other “R” and “T” terminals located on the satellite controller can be used to extend the two-wire loop to the next satellite controller, or the wires can branch off of a two-wire loop

running through the center of a building as shown in Figure 12-6.

NOTE: The shield wire must be connected at each and every

Satellite Controller also.

WCC III Technical Guide

12-9

12. WCC III INSTALLATION

SATADDRESS

2 1

A3WIREROOM SENSORWILLNOT REQUIREALOAD RESISTOR WHEN SET FORA1 VOLT INPUT .

WattMasterControlsInc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCALSET

STATUS2

STATUS3

STATUS1

HSSXMIT

LOCALSET

LOCALSETDISABLE

BATTON/OFF PULSEINPUT

OPTION1

TEST

OPTION3 OPTION2

ON OFF

STATUS

HSSREC

SATXMIT

SATREC

ANALOGINPUT

JUMPERSELECTION

A2WIREROOM SENSORWILLREQUIRE A300OHM LOAD RESI STOR WHEN SET FORA1 VOLT INPUT .

A4TO2 0 mA SENSOR WILLREQUIREA 50OHMLOAD RES ISTOR WHEN SE T FOR A1VOLTINPUT, ORA 250 OHM LOAD RESISTORWHENSETFO R A 5 VOLT INPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0TO10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLE CO NTROLL ER

SAT III

COM

CHANNEL

2134

567

5678

OUT

GND

L O A D

ATI

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

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EACHCONTACT ISRATEDFOR 24VACOR VDC @.5AMPMAX

0-15VDC OUTPUT MINLOAD IS1KOHM RESISTIVE VDCONLY

100VA

TRANSFORMER

SWITCH DISCONNECT

INTER PANEL

Satellite Controller Enclosure Mounting

Satellite Controller

Mounting in an Enclosure

The satellite controllers are designed to mount in any NEMA 1 or NEMA 3 standard, six-inch deep, electrical enclosure. Typically, this is a ﬁ eld-mounted enclosure that contains transformers and any accessory items required such as a binary input board, V-Out Binary output board, control relays, etc. The best location for these satellite panels is mounted on a wall in equipment or storage areas or rooms at eye level near the controlled loads.

The satellite controllers may be ordered with or without the NEMA type enclosures. If you order the satellite controller from the factory without an enclosure, the SAT III and SAT 3C/D/F

dimensions as shown in Figure 12-13 and Figure 12-14 may be

helpful when selecting a suitable NEMA type enclosure.

The satellite controller must be mounted in an electrical enclosure. If you do not order the satellite controller with an electrical enclosure, you must provide your own electrical enclosure and then provide and then install your own fused disconnect switch, transformer, and terminal strip.

The size of the standard single SAT enclosure is designed to hold only one satellite controller (or up to two SAT 3C/D/F controllers), one fused disconnect switch, one transformer, one ﬁ lter, and one terminal strip which is normally about 15” x 15” x 6” deep with an inter panel for mounting the SAT III controller, fuse block, 100VA transformer, etc. The size of the standard dual SAT enclosure is designed to hold two satellite controllers (or up to four SAT 3C/D/F controllers), one fused disconnect switch, two transformers, two ﬁ lters, and two terminal strips is 30” x 18” x 6” deep with an inter panel for mounting the two SAT III controllers, fuse block, 100VA transformer, etc. If you install the satellite controller yourself, make sure you leave room for wires that need to be connected to the following terminals that are located on the sides of the SAT III satellite controller (minimum recommended clearance is 2 inches):

You can also have both a SAT III controller and up to two SAT 3C/D/F controllers in the same dual enclosure.

24-VAC power source (100VA recommended)

RS-485 Communication loop

SAT III HSS Port connection

Figure 12-7: A typical SAT III controller in a single electrical panel (120-V AC po wered)

12-10

WCC III Technical Guide

12. WCC III INSTALLATION

SATADDRESS

2 1

A3WIREROOMSENSORWILLNOT REQUIREALOAD RESISTOR WHENSET FORA1 VO LT INPUT.

WattMasterControlsInc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCALSET

STATUS2

STATUS3

STATUS1

HSSXMIT

LOCALSET

LOCALSETDISABLE

BATTON/OFF PULSEINPUT

OPTION1

TEST

OPTION3 OPTION2

ON OFF

STATUS

HSSREC

SATXMIT

SATREC

ANALOGINPUT

JUMPERSELECTION

A2WIRE ROOMSENSORWILL REQUI RE A300OHM LOAD RESISTOR WHENSET FORA1 VO LT INPUT.

A4TO20 mA SENSORWILLREQUIREA 50OHMLOAD RESISTOR WHEN SET FOR A1VOLTINPUT, OR A 250 OHM LOAD RESISTORWHEN SET FO R A 5 VOLT INPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0TO10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLECONTROLLER

SAT III

COM

CHANNEL

2134

567

5678

OUT

GND

L O A D

ATI

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

EACHCONTACT ISRATEDFOR 24VACORVDC @.5AMPMAX

0-15VDC OUTPUT MINLOAD IS1KOHM RESISTIVE VDCONLY

100VA

TRANSFORMER

SWITCH DISCONNECT

SATADDRESS

2 1

A3WIREROOM SENSOR WILLNOT REQUIREALOADRESISTORWHENSET FORA1VOLTINPUT.

WattMasterControlsInc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCALSET

STATUS2

STATUS3

STATUS1

HSSXMIT

LOCALSET

LOCALSET DI SABLE

BATTON/OFF PULSEINPUT

OPTION1

TEST

OPTION3 OPTION2

ON OFF

STATUS

HSSREC

SATXMIT

SATREC

ANALOGINPUT JUMPERSELECTION

A2WIREROOM SENSOR WILLREQUIRE A300OHMLOADRESISTORWHENSET FORA1VOLTINPUT.

A4TO 20 mA SENSOR WILL REQUIREA 50OHMLOAD RESISTOR WHEN SETFOR A1VOLT INPU T, OR A250OHMLOAD RESISTORWHEN SETFORA5 VOL T INPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0TO10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLECONTROLLER

SAT III

COM

CHANNEL

2134

567

5678

OUT

GND

L O A D

ATI

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

EACHCONTAC T ISRATEDFOR 24VACORVDC @.5AMPMA X

0-15VDC OUTPUT MINLOAD IS1KOHM RESISTIVE VDCONLY

INTER PANEL

100VA

TRANSFORMER

GUIDE

Satellite Controller Enclosure Mounting

Figure 12-8: Two SA T III controllers in a typical dual electrical panel (120-VA C pow ered)

WCC III Technical Guide

12-11

12. WCC III INSTALLATION

Satellite Controller Enclosure Mounting

Figure 12-9: A typical SAT 3C/D/F controller in a single electrical panel (120-V AC po wered)

Figure 12-10: A typical SAT 3C/D/F controller in a (single) dual electrical panel (120-V AC po wered)

12-12

WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

Satellite Controller Enclosure Mounting

Figure 12-11: A typical SAT 3C/D/F controller in a (dual) quad electrical panel (120-V A C pow ered)

WCC III Technical Guide

12-13

12. WCC III INSTALLATION

GND 24VAC

100VA

2AMP

MDL

BLK

WHT

ORG

BRN

BLK

WHT

ORG

BRN

24VAC

GND

24VAC

GND

SIG

FLUSHMOUNT

TYPICAL 7 PLACES

SENSOR

Satellite Controller Wiring

If you order the satellite controller in an enclosure, the factory will provide and install the wires from the transformer to the satellite. If you order the satellite controller separately, you must provide a NEMA panel with an inter panel, disconnect switch, transformer(s), fusing, terminal block(s), wire, crimp connectors, and then install the wires from the transformer to the satellite controller. A typical satellite controller wiring diagram is shown below:

Figure 12-12: SAT III controller typical single panel wiring diagram

12-14

WCC III Technical Guide

Satellite Controllers - General Dimensions

SATADDRESS

2 1

A3 WIRE ROOM SENSOR WILLNOT REQUIREA LOAD RESISTOR W HEN SET FORA 1VOLT IN PUT.

WattMaster Controls Inc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCALSET

STATUS2

STATUS3

STATUS1

HSSXMIT

LOCALSET

LOCALSET DISABLE

BATTON/ OFF PULSEI NPUT

OPTION1

TEST

OPTION3 OPTION2

ON OFF

STATUS

HSS REC

SATXMIT

SATREC

ANALOGINPUT

JUMPERSELECTION

A2 WIRE ROOM SENSOR WILLREQUIRE A300OHM LOAD RESISTORWHENSET FORA 1VOLT IN PUT.

A4 TO 20mA SE NSOR WILLRE QUIRE A 50OHM LOAD R ESISTOR WHENSET FOR A1VOL T INPUT, OR A 250 OHM LOAD RESISTORWHENSETFOR A5 VOLTINPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0TO10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLE CONTROLLER

SAT III

COM

CHANNEL

2134

567

5678

OUT

GND

L O A D

ATI

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

123456

+VSENSORS

R212R3R4R5

3456

VOUT

GND

7 8

EACHCONTACT ISRATEDFOR 24VACORVDC @.5AMPMAX

0-15VDC

OUTPUT MINLOAD IS1K OHM RESISTIVE VDCONLY

MADE IN

THEUSA

K16

K15

K14

K13

V16 V15 V14 V13

11.90

11.25

5.85

7.18

GND

24 VAC

24 VAC POWER

SAT

COMMUNICATION

SHIELD

IN /OUT

HSS EXP

COMM

SATIIISIDE PROFILE VIEW (POWER INPUT)

SATIIISIDE PROFILE VIEW (SAT COMM & HSS PORT)

SATIII SIDE PROFILE VIEW (ANALOG IN/OUT - CONTROL OUTPUT)

3.00

7.18

12. WCC III INSTALLATION GUIDE

Satellite Controller Dimensions

Figure 12-13: SAT III controller dimensions. All dimensions are in inches.

Figure 12-14: SAT 3C/D/F controller dimensions. All dimensions are in inches.

WCC III Technical Guide

12-15

12. WCC III INSTALLATION

SAT ADDRESS

2 1

A3 WI RE ROOM SENSOR WILL NOT REQUIRE A LOAD RESISTOR WHE N SET FORA 1 V OLT INPUT.

WattMaster Controls Inc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCAL SET

STATUS 2

STATUS 3

STATUS 1

HSS XMIT

LOCAL SET

LOCAL SET DISABLE

BATT ON/ OFF PULSE INPUT

OPTION 1

TEST

OPTION 3 OPTION 2

ON OFF

STATUS

HSS REC

SAT XMIT

SAT REC

ANALOG INPUT

JUMPER SELECTION

A2 WI RE ROOM SENSOR WILL REQUIRE A30 0 OHM LOAD RESISTOR WHEN SET FORA 1 V OLT INPUT.

A4 T O 20m A SENSOR WILL REQUIRE A 50OHM LOADRESISTORWHEN SETFOR A1 V OLT INPUT, OR A 250 OHM LOAD RESISTORWHENSET FOR A5 VOLT INPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0 TO 10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLECONTROLLER

SAT III

COM

CHANNEL

2134

567

5678

OUT

GND

L O A D

ATI

10A250VAC ~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC ~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC ~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC ~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

EACH CONTACT IS RATED FOR 24VACOR VDC @ .5 AMP MAX

0-15VDC

OUTPUT MINLOAD IS 1K OHM RESISTIVE VDCONL Y

SA T III LED Descriptions

SA T III Controller—LED Information (SS5003)

The SAT III Controller has 24 LEDs on the cover of the SAT III controller. The top 8 Status LED functions are as follows:

SAT REC - This LED will be lit when communications are being

received by the SAT III Communications Loop.

SAT XMIT - This LED will be lit when communications are being

transmitted by the SAT III Communications Loop.

HSS REC - This LED will be lit when communications are being

received from the HSS port.

HSS XMIT - This LED will be lit when communications are

being transmitted to the HSS port.

LOCAL SET - This LED will be lit when communications

with the WCC III-MCD has not occurred for at least the last two minutes. This means that the SAT III is not communicating on the SAT III communications loop. Setpoint control in the SAT III is dependent on the LOCAL SET parameters which are programmed into each control point by the user.

STATUS 1 - LED blinks every 1 second if SAT III is alive. STATUS 2 - LED blinks every 1 second during power on delay,

and then blinks every 8 seconds when watchdog is enabled.

STATUS 3 - LED blinks for every internal calculation loop

completion.

The lower 16 LEDs display the status of the 16 “H” and “C” Relay Outputs. The 16 LEDs display the status of the eight “H” and eight “C” contacts.

Figure 12-15: SAT III LED locations

12-16

WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

SA T III Connection Points

SA T III Controller — Connection Points

All of the external SAT III connection points are single tab ¼-inch Sta-Con connectors. With the exception of the “old” connection method of connecting the Binary Inputs which are 16-pin dip cable connections and the HSS EXP COMM port which is a 6-pin premade MOLEX type mini-ﬁ t cable connection.

+V Connections.

There are eight +12-VDC connections that power analog type sensors of which the ﬁ rst seven of these connections are ﬁ xed to +12VDC only. The eighth +V connector is jumper (JP1) selectable for either +12VDC, or +24VDC. This (JP1) jumper can be set to +12VDC, or +24VDC so that the voltage at the eighth +V connection point is either +12VDC or +24VDC. The +24VDC is useful when connecting 4-to-20 mA sensors that require a connection voltage greater than +12VDC. You may connect up to eight 4-to-20 mA sensors to this eight +V (+24VDC) connection point. This JP1 jumper is located under the cover of the SAT III controller, just to the right of the eighth +V connector.

A TI Connections

These eight connections are connection points for ATI #1 to ATI #8 analog inputs. ATI is the acronym for Analog Temperature Input. These eight connection points are for Analog Inputs. This is where analog type sensors are connected to the SAT III controller. The types of sensors inputs that are supported on the SAT III controllers are: 0-1V, 0-5V, 0-10V, 10K Type 3 Thermistor, 4-20mA (On both the 0-1V, and 0-5V inputs). There are also eight Analog Input selection jumpers that are located under the cover of the SAT III controller near the Analog Inputs that actually set the type input voltage ranges for each of the eight analog inputs. These Analog Input selection jumpers are labeled JO1 to JO8. JO1 corresponds to analog input #1, JO2 corresponds to analog input #2, JO3 corresponds to analog input #3, JO4 corresponds to analog input #4, JO5 corresponds to analog input #5, JO6 corresponds to analog input #6, JO7 corresponds to analog input #7, JO8 corresponds to analog input #8. Each of these Analog Input selection jumpers has four jumper options: 0-1V, 0-5V, 0-10V, and THERM. See

Figure 12-34 and 12-35 for further wiring details. See Section 3

for further programming instructions.

GND Connections

These GND connections are analog ground common connection points for all of the analog input (ATI), and analog output (VOUT) connections.

VOUT 1 to V OUT 8 Connections

These eight analog outputs are set up to provide 0 to +15 DC Volts outputs at up to 15 milli-amps per output. These outputs are typically used to drive a VFD, 0-10VDC or 2-10VDC actuator or

valve. VOUT is the acronym for Voltage Output. See Section 3 for

additional programming instructions.

H 1 to H 8 Connections

The eight “H” connection points of the SAT III controller were originally classiﬁ ed and labeled as “HEAT” contacts starting with the SAT 0, SAT I, and SAT II controllers. They do not need to be used only for “HEAT” contacts, as these contacts are general purpose relay outputs. There is a load protection device called a varistor across each of the eight “H” output connections that limit the allowable voltage to no more than 32 volts AC\DC maximum at 1 amp current draw for each contact. Attempting to switch any voltage greater than 32 Volts, or current draws of more than 1 amp per contact could and will result in damage to the SAT III controller. These “H” and “C” contact outputs are meant to control tri-state actuators, contactors, relays, solenoids, and the PI board AKA “ECC II ANALOG OUTPUT” board that WattMaster

Controls used to manufacture. See Figure 12-18 for further wiring details. See Section 3 for additional programming instructions.

COM 1 to COM 8 Connections

The COM1 connection point is a common connection point for H1 and C1 Relays. None of the COM connections are connected to any of the other seven COM connection points. A jumper cable is available to connect all of the COM connection points together. Each corresponding “H” and “C” contact are connected to a single corresponding “COM” connection point. So “H1” and “C1” are connected to “COM1”, “H2” and “C2” are connected to “COM2”,

etc. See Figure 12-18 for further wiring details.

WCC III Technical Guide

12-17

12. WCC III INSTALLATION

SA T III Connection Points

C 1 to C 8 Connections

The eight “C” connection points of the SAT III controller were originally classiﬁ ed and labeled as “COOL” contacts starting with the SAT 0, SAT I, and SAT II controllers. They do not need to be used only for “COOL” contacts, as these contacts are general purpose relay outputs. There is a load protection device called a varistor across each of the eight “COOL” output connections that limits the allowable voltage to no more than 32 volts AC\DC maximum at 1 amp current draw for each contact. Attempting to switch any voltage greater than 32 Volts, or current draws of more than 1 amp per contact could and will result in damage to the SAT III controller. These “H” and “C” contact outputs are meant to control tri-state actuators, contactors, relays, solenoids, and the PI board AKA “ECC II ANALOG OUTPUT” board that WattMaster

Controls used to manufacture. See Figure 12-18 for further wiring details. See Section 3 for additional programming instructions.

Binary Inputs

The SAT III controller has two sets of eight-position dipswitches on its front panel labeled L1 - L8 and L9 - L16. Switches L1-L8 are housed together in one dipswitch, and switches L9-L16 are housed together in another dipswitch. For the old connection method one dipswitch is removed for each Binary Input with Time Delay board, and is then replaced with a ribbon cable which connects the Binary Input with Time Delay board to the SAT III controller. The binary devices to be monitored are then wired to the terminal strip of the Binary Input with Time Delay board. The Binary Input with Time Delay board requires a 24-VAC power source. Warning you must observe polarity on the 24-VAC and GND connections of both the Binary Input with Time Delay board and the SAT III controller, as the grounds must be the same. Or, an alternative connection method to the SAT III controller is now provided by the 6-pin HSS

expansion port on the side of the SAT III controller. See Figures 12-26, 12-27, & 12-28 for further wiring details.

24V AC & GND Connection

Located on the bottom side of the SAT III controller is a 24 VAC and GND connection. This is the main power connection to the SAT III controller. Each SAT III Controller draws - 15VA. External relays and contactors are not included, but need to be considered for total VA draw. The GND connection points must be the same between all of the externally powered expansion boards and the

SAT III Controller. See Figure 12-27 for further wiring details.

SA T Communica tion Connection

These connection points are for wiring of the RS-485 communication loop. There are two “T” (Transmit) connections, two “R” (Receive) connections and two “SHIELD” connection points. There are two connection points provided for each connection for easy “daisy chaining” to the next Satellite Controller. When connecting the RS-485 wiring from SAT III to SAT III or SAT 3C/D/F, or SAT 3P controller the wiring connections are as follows: connect “R” TO “R”, “T” TO “T”, AND “SHIELD” TO “SHIELD” OR “SH”. The RS-485 wire speciﬁ cations are plenum-rated, jacketed stranded 18-gauge, 2-wire twisted pair with shield. 18-gauge stranded wire is mandatory to ensure a good connection with the ¼-inch Sta-Con connectors which are used to terminate the wires at the WCC III MCD and at the satellite controllers.

HSS EXP COMM Connection

The HSS EXP (Expansion) Port enables newer versions of the satellite expansion boards, most notably the Binary Input with Time Delay Board and V-Out RELAY Board to work without connecting the previous way (separate power and hard wiring was required). The SAT III has a single connection via the built-in HSS EXP port on the side of the SAT III. It is designed to connect and power up 5 HSS Expansion Boards. Connecting more than 5 HSS Boards is possible, but each additional board will require a 24VAC power supply.

The HSS EXP port provides power and ground, along with communications on a 6-pin pre-made MOLEX type mini-ﬁ t cable connection. This cable is made with 16-gauge wire.

Each HSS Expansion Board has an 8-position address dipswitch that is used to set up the function of the board.

The HSS EXP port can be daisy chained to the next board. The HSS cable connections allow the HSS expansion boards to be located up to 150 feet away from the SAT III Controller.

HSS connection cables are available in the following sizes: 6-inch, 12-inch, 18-inch, 3 feet, 25 feet, 40 feet, 80 feet, and 120 feet.

12-18

WCC III Technical Guide

12. WCC III INSTALLATION

SAT ADDRESS

2 1

ON OFF

128

32 16

SAT III ADDRESS SWITCH

GUIDE

SA T III Addressing

Addressing (Numbering) of SA T III Controllers

The WCC III system can have up to 239 SAT III controllers. In order for the central computer to communicate properly with each individual SAT III controller, each controller must be assigned a separate number, or address. The number is assigned by placing the small dip switches on the front of the SAT III controller marked “SAT ADDRESS” in the proper position.

The address dip switches are additive; that is to say placing switches 1 and 2 in the ON position will cause the SAT III controller to be identiﬁ ed as satellite controller number 3. The SAT III controller looks at the position of these switches only when it is going through its initialization process after being powered up. Simply changing the switch positions on a SAT III controller that is currently “on-line” will not change its number. The switches need to be placed in the proper position before powering up the SAT III controller, or the SAT III must be powered down and then back up for the SAT III to “read” the new position of the switches. When placing the switches in the desired position, make sure the switch has “clicked” into place and is properly seated.

Figure 12-16: SAT III address switch loca tion

WCC III Technical Guide

12-19

12. WCC III INSTALLATION

SA T III Addressing

Care must be taken to ensure that two SAT III controllers do not have the same address. When this condition is present, the central computer does not know where to send the information, and the information that should be sent to the SAT III controller is usually lost.

You should be aware of the symptoms caused by two satellite controllers having the same number. Let’s consider a new job in which the satellite controllers have not yet been programmed and 2 SAT III controllers are named number #3. When you call up satellite controller #3 to enter data, everything will appear to be ﬁ ne. You will be able to enter data on the screens as if nothing is wrong. However, when you leave a screen and then return to the same screen, all of the data you entered will be missing. Also, if you ﬁ nish programming the analog inputs for example, and then go to the analog input summary screen to review your inputs, all of the data you have entered will be missing.

Another situation that you might encounter is adding a SAT III controller to an existing system and accidentally giving it the same number as a SAT III presently “on-line.” Again, when you begin to program the new SAT III controller, everything will appear ﬁ ne until you leave a screen or if you go to a summary screen. Only now, all of the data is usually not missing. Generally, you get parts of your data back and parts will be missing.

If you suspect you might have two SAT III controllers with the same address (number 3 for example) the best thing to do is go to the SAT III controller that you know is number 3, and remove the 2-wire RS-485 communication loop from it. Then, go back to the computer and call up satellite controller #3. If the computer can still “talk” to satellite controller #3, there is another satellite controller that is addressed #3 connected somewhere on the RS485 communication loop.

If a satellite controller was accidentally addressed #3, there will be a satellite number missing. For example, if satellite controller #7 was accidentally misaddressed to #3, satellite controller #7 will not be present. One way of telling which satellite controllers are

“on-line” is to go to the Satellite Summary Screen (see Section

3) and see which satellite controllers the computer recognizes as

being “on-line.”

If satellite controller #7 was accidentally miss-addressed #3, there would not be a satellite controller at address #7, and the computer will give a “Non-Existing” message for satellite controller #7.

Option 1, 2, and 3 Switches

Option switches 2 and 3 do nothing. But, the SAT III controller option “1” switch selects the A-to-D converter type that is on the mother board. With the switch turned OFF, the A-to-D curve is selected for the Maxim MAX147 part, and with the switch turned “ON” for the TI-ADS7844 (BB marked) the software will use the

special A-to-D curve for the TI-ADS7844 part. See Section 3 for

proper A-to-D identiﬁ cation.

BA TT ON/OFF s witc h

This switch is used to turn the Battery (Rechargeable Super cap) ON and OFF to the SRAM located inside of the SAT III processor.

Since version 2.00 of the Satellite software the non-volatile memory is now also stored in the EEPROM, instead of the SRAM, and upon power up the memory is read from the EEPROM back into the SRAM. This switch is not of any importance anymore.

Local Set Switch

When the LOCAL dipswitch is in the ON position, the SAT III controller will operate according to their predeﬁ ned user programmed “local set” setpoints. That is, if the SAT III controller was programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected.

Local Set Disable Switch

When the LOCAL SET Disable dipswitch is in the ON position, the SAT III controller will operate according to their predeﬁ ned user programmed “On” setpoints. That is, if the SAT III controller were programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected.

Test Switc h

The test mode is active only if the TEST dipswitch is in the ON position. The word “TEST” can be input as the binary value within the SAT III. Example of use would be if the user programmed the word “TEST” into one of the control point values in the SAT III controller to check the operation of the SAT III controller with an alternate setpoint or schedule, the user could then place the TEST switch in the ON position to make this function work with out physically having to go back to the front-end computer to change a setpoint via the computer.

12-20

WCC III Technical Guide

12. WCC III INSTALLATION

SAT ADDRESS

2 1

A3 WI RE ROOM SE NSOR WILL NO T REQUIREA LOADRESIST OR WHEN SET FORA 1VOLT INPUT.

WattMaster Controls Inc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCAL SET

STATUS 2

STATUS 3

STATUS 1

HSS XMIT

LOCAL SET

LOCAL SET DISABLE

BATT ON/ OFF PULSE INPUT

OPTION 1

TEST

OPTION 3 OPTION 2

ON OFF

STATUS

HSS REC

SAT XMIT

SAT REC

ANALOG INPUT

JUMPER SELECTI ON

A2 WI RE ROOM SE NSOR WILL REQUIRE A300 OHMLOAD RESISTORWHEN SET FORA 1VOLT INPUT.

A4TO20mASENSORWILLREQUIREA

50OHM LOADR ESISTOR WHEN SET FOR

A1 VO LT INPUT , OR A 250 OHML OAD

RESISTORWH EN SET FOR A 5 VOL T INPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0TO10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLECONTROLLER

SAT III

COM

CHANNEL

2134567

10A250VAC ~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

10A250VAC ~

5A30VDC

VDE

-1A4

24V

CHINA

10A250VAC ~

5A30VDC

VDE

G5Q-1A4

OMRON

DC24V

CHINA

NTACT

FOR

VDC

GUIDE

SA T III Relay Outputs

The standard SAT III controller is capable of providing 16 binary (on/off) relay outputs. These 16 relay outputs are for driving pilot duty relays. There is a load protection device called a varistor across each of the 16 output connections that limits the allowable voltage to no more than 32 volts AC\DC maximum at 1.0 or 1 amp current draw for each contact.

Attempting to switch any voltage greater than 32 Volts, or current draws of more than 1.0 or 1 amp per contact could and will result in damage to the SAT III controller. These “H” and “C” contact outputs are meant to control tri-state actuators, contactors, relays, solenoids, and the PI board AKA “ECC II ANALOG OUTPUT” board that WattMaster Controls used to manufacture. These relay outputs can be programmed in three different types of modes of basic operation: Time Clock, Dual Limit, and EA Mode. See

Section 3 for further details on Satellite programming instructions.

Figure 12-17: SAT III “H” and “C” control output wiring connections

WCC III Technical Guide

12-21

12. WCC III INSTALLATION

COM

12345678

SA T III Relay Outputs

The terminals for the binary outputs are found at the lower lefthand corner of the SAT III controller and are labeled “H”, “COM”, and “C”. The relay contact can make or break a 24-VAC or 24VDC circuit between the COM to H or COM to C terminals. The COM to H contacts are referred to as XXXK1h-K8h in the WCC III point addressing scheme, and the COM to C contacts are referred to as XXXK1c-K8c in the WCC III point addressing scheme. XXX is the Satellite address number 1 to 239, “K” stands for contact, and the numbers 1-8 stand for the channel on the SAT III controller.

Each “H” and “C” contact connection has a “COM” connection associated with it. Please note that each one of the sets of the corresponding “H” and “C” contacts are also isolated from each other. The “COM” connection means common. When wiring the control outputs, typically all of the “COM” connections are wired together, using the supplied jumper wire (PL100867). This “COM” common connection can either be connected to 24VAC / 24VDC or GROUND depending on the application.

Figure 12-18: SAT III “H” and “C” control output schematic

Figure 12-19: A control output common jumper wire is provided (PL100867) for connecting the eight “COM” connections together

The pre-made control output common jumper wire is provided in the initial spare parts kit that came with the SAT III controller. This spare parts kit contains various input load resistor packs, spare fuse, and the control output common jumper. The spare parts kit is WattMaster part number PL102029.

12-22

WCC III Technical Guide

COM - 24VAC COM - GROUND

Figure 12-20: COM connection as 24 VAC or as GR OUND

12. WCC III INSTALLATION

SA T III Relay Outputs

GUIDE

The “COM” or common connection point can either be connected to 24 VAC / 24 VDC or GROUND. It is basically a point of view of turning power “on” to a device, or removing “ground” going to the device. It makes no difference, as both methods will work equally well, and really depends on the application you are trying to control.

WCC III Technical Guide

12-23

12. WCC III INSTALLATION

Proportional-Integral (PI) Output Board

The Proportional-Integral (PI) Board is a separate integrated circuit board which works in conjunction with the SAT III controller to convert a pair of SAT III binary outputs to a varying DC voltage signal. When one contact on the SAT III controller closes, the voltage supplied by the PI board will ramp down at a pre-set rate. When the other SAT III contact closes, the voltage ramps up at the preset rate. When both contacts are open, the voltage supplied by the PI board will remain at its present value. The maximum DC voltage range is 0-14.5 volts, and the minimum allowable

resistance of the controlled device is 1000 ohms. See Section 3 for

further details on Satellite programming instructions.

Figure 12-21: ECC II Analog Output Board

12-24

WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

PI Board Connection Points

The DC voltage range along with the ramp speed is set at the PI board. The ramp speed can be adjusted from 23 seconds to 38 minutes, and the maximum range is 0-14.5 volts DC.

To control a VFD drive from a SAT III controller using the Proportional-Integral board, you must use two control outputs and a circuit board (PI Board) that we no longer make. WattMaster Controls does not make the PI Output Board anymore, but Kele makes a similar circuit board that should work. It is a Tri-State-toAnalog Output circuit board (Kele Part # PWA-2T).

If only one contact closure is available to drive the PI Board, move jumper J01 on the WattMaster PI board to the B-C position and use the SAT III’s control output in the Dual Limit mode to control the PI Board. Although when using this method with the WattMaster PI Board, the DC voltages supplied by the WattMaster PI Board will either be increasing or decreasing at the set ramp speed depending on if the contact is open or closed.

The Global Analog Mode 9 Dual Ramp Screen was created to help emulate the old WattMaster PI board in software. It basically uses the control set points of two control outputs on a satellite controller to control a single analog output on a satellite controller and should be used when controlling an analog actuator or VFD that needs to

have an analog control setpoint. See Section 3 for further details on

Satellite programming instructions.

The Proportional-Integral (PI) Board connection points

All of external connections to Proportional-Integral (PI) Board connection points are non de-pluggable screw-cage type of wire clamped based terminal blocks.

24 V AC (TB1-5) & GND (TB1-6)

ANALOG OUT (TB2-1) & GND (TB2-3&4)

The “ANALOG OUT” and “GND” terminals supply the DC voltage from the PI board.

Adjust Minimum Voltage

The PI board is factory set for a minimum voltage of 0 VDC +/-

0.2 VDC. If you want a minimum voltage other than 0 VDC, you can reset it by adjusting the potentiometer (pot) labeled “R9.” The voltage between test point #3 (labeled “TP #3” on the PI board) and ground is set 300 mV lower than the desired minimum voltage. That is to say, if you want 5 VDC as the minimum voltage to be supplied between the “ANALOG OUT” and “GND” terminals, adjust pot “R9” to get 4.7 VDC between “TP #3” and “GND.”

NOTE: The minimum voltage setpoint must be lower than the

maximum voltage setpoint.

Adjust Maximum Voltage

The PI board is factory set for a maximum voltage of 14.5 VDC +/- 0.2 VDC. If you want a maximum voltage other than 14.5 VDC, you can reset it by adjusting the potentiometer (pot) labeled “R10.” The voltage between test point #2 (labeled “TP #2” on the PI board) and ground is set at 300 mV above the desired maximum voltage. That is to say, if you want a maximum voltage of 10 VDC to be supplied by the “ANALOG OUT” and “GND” terminals, adjust pot “R10” to get 10.3 VDC between “TP #2” and “GND.”

NOTE: The maximum voltage setpoint must be higher than

the minimum voltage setpoint.

The PI board requires a 24 VAC power supply which is connected to these terminals. The PI board is generally powered by the same 24 VAC transformer that powers the satellite controller. The GND connection points must be the same between the PI board and the SAT III Controller.

HEA T (TB1-1) & COM1 (TB1-2)

When 24 volts AC is supplied between the “HEAT” and “COM1” terminals, the DC voltage supplied by the PI board will start increasing at the set ramp speed.

COOL (TB1-1) & COM2 (TB1-4)

When 24 volts AC is supplied between the “COOL” and “COM2” terminals, the voltage supplied by the PI board will start decreasing at the set ramp speed.

WCC III Technical Guide

Adjust “Ramp” Speed

The ramp speed is the time it takes for the DC voltage between the “ANALOG OUT” and “GND” terminals to change from the minimum voltage to the maximum voltage and vice versa. The ramp speed is factory set at about 19 minutes. If you want a ramp speed other than 19 minutes, you can reset it by adjusting the potentiometer (pot) located at R2. When R2 is fully counterclockwise, the ramp speed is 38 minutes (+/- 10%). When R2 is fully clockwise, the ramp speed is 23 seconds (+/- 10%). As the voltage is ramping up, the small light labeled D1 will ﬂ ash and as the voltage is ramping down, the small light labeled D2 will ﬂ ash.

12-25

12. WCC III INSTALLATION

SAT ADDRESS

2 1

A3 WI RE ROOM SENSOR WILL NOT REQUIREA LOAD RESISTOR WHEN SET FORA 1 VOLT INPUT.

WattMaster Controls Inc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCAL SET

STATUS 2

STATUS 3

STATUS 1

HSS XMIT

LOCAL SET

LOCAL SET DISABLE

BATT ON/OFF PULSEINPUT

OPTION 1

TEST

OPTION 3 OPTION 2

ON OFF

STATUS

HSS REC

SAT XMIT

SAT REC

ANALOG INPUT

JUMPER SELECTION

A2 WI RE ROOM SENSOR WILL REQUIRE A30 0 OHM L OAD RESIST OR WHEN SET FORA 1 VOLT INPUT.

A4 TO 20 mA SENSOR WILL REQUI RE A 50O HM LOAD RESISTOR WHEN SET FOR A1 VOLT INPUT, OR A 250 OHM LOAD RESISTOR WHEN SET FOR A 5 VOLT INPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0TO10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLE CONTROLLER

SAT III

24VAC 120VAC

120VAC WIRING

BY OTHERS

TO OTHER SAT III OR TO WCC III - MCD

24VAC

GND

TO OTHER SAT III OR TO WCC III - MCD WIRE "T" TO "T" "R" TO "R" "SHD" TO "SHD"

WARNING: OBSERVE POLARITY

BETWEEN THE SAT III AND THE ECCII ANALOG OUTPUT BOARD - GROUND CONNECTIONS MUST BE THE SAME.

ECC II ANALOG OUTPUT BOARD

PI Board Typical Wiring Connections

If you want to test the ramp speed, disconnect all wires from the “HEAT,” “COM1,” “COOL,” and “COM2” terminals and use a volt meter to measure the DC voltage between “ANALOG OUT” and “GND” as you jumper test point #4 (TP #4) to ground.

The voltage should increase from the minimum to the maximum voltage during the set time interval. Then, remove the jumper from “TP #4” and jumper “TP #5” to “GND.” The voltage between the “ANALOG OUT” and “GND” terminals should decrease from the maximum to the minimum voltage during the set time interval.

Figure 12-22: ECC II Analog Output typical wiring connections to a SAT III controller

12-26

WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

Old SA T II Type Binary Input with Time Delay Board

Sequence of Operation

When the SAT III controller makes COM to H, 24 VAC is supplied to the “HEAT” terminal on the PI board which causes the DC output voltage supplied by the PI board to increase the output voltage at the preset rate.

When the SAT III controller makes COM to C, 24 VAC is supplied to the “COOL” terminal on the PI board which causes the DC output voltage supplied by the PI board to decrease the output voltage at the preset rate. When both the COM to H and COM to C terminals are open on the SAT III controller, the DC output voltage supplied by the PI board will remain at its present value.

Previous “Old” SA T II Type Binary Input with Time Delay Board

The SAT II type Binary Input with Time Delay board is an optional integrated circuit board which can interface with the “old” SAT II as well as the “new” SAT III controllers to allow it to monitor the status of remote mounted binary (on/off) devices such as switch closures, air ﬂ ow switches, etc. One binary input board enables the SAT II or SAT III controller to monitor up to 8 binary inputs, and 2 binary input boards can be used with 1 SAT II or SAT III controller for a total of 16 binary inputs per SAT II or SAT III controller.

The SAT III controller comes standard with two eight-position dipswitch switches on its front panel labeled L1 - L8 and L9 - L16 which are in effect manually controlled binary inputs. The SAT III controller monitors the on/off status of these switches and can control and/or alarm based on the position of these dipswitches. The Binary Input with Time Delay board allows the eight-position dipswitches to be replaced with a terminal connection points which will accept wiring for remote-mounted binary input devices.

The SAT III controller has two sets of eight-position dipswitches on its front panel labeled L1 - L8 and L9 - L16. Switches L1-L8 are housed together in one dipswitch, and switches L9-L16 are housed together in another dipswitch. One of the dipswitches is removed for each Binary Input with Time Delay board, and is then replaced with a ribbon cable that connects the Binary Input with Time Delay board to the SAT III controller. The binary devices to be monitored are then wired to the terminal strip of the Binary Input with Time Delay board. The Binary Input with Time Delay board requires a 24 VAC power source. Warning: You must observe polarity on the 24 VAC and GND connections of both the Binary Input with Time Delay board and the SAT III controller, as the grounds must be the

same. See Section 3 for further details on Satellite programming

instructions.

Figure 12-23: The “old” SAT II type Binary Input with Time Delay board

WCC III Technical Guide

12-27

12. WCC III INSTALLATION

Old SA T II Type Binary Input with Time Delay Board

The “Old” SAT II T ype Binary Input with Time Delay Board - Connection Points

All external connections to the ‘old” SAT II type Binary Input with Time Delay board connection points are non de-pluggable screw-cage type of wire-clamped based terminal blocks. With the exception of the “old” connection method of connecting the Binary Input with Time Delay board to the SAT III controller which is a 16- pin dip cable connection.

24 V AC & GND (TB2)

The SAT II type Binary Input board requires a 24 VAC power supply that is connected to these terminals. The SAT II type Binary Input board is generally powered by the same 24 VAC transformer that powers the satellite controller. The GND connection points must be the same between the SAT II type Binary Input board and the SAT III Controller.

Contact Inputs 1 to 8 and GND

When the contact is closed between one of eight inputs of the contact inputs connector and ground it will activate one of the eight LEDs and makes a simulated contact closure on the P1 connector. This P1 connector is then connected via a 16-pin ribbon cable to one of the SAT III controller’s former Binary Input dipswitch locations. This input is automatically kept on for a timed duration depending on the value of the dipswitch that is located on the “old” SAT II type Binary Input with Time Delay board.

P1 (Socket Connection to One of the

SA T III Binary Input Former Dipswitch Locations)

This connector is polarized, and must be properly inserted at both ends. Pin #1 of the P1 socket must mate with Pin # 1 of one of the SAT III former dipswitch locations. (The dipswitch on the SAT III must be removed).

Figure 12-24: The “old” SAT II type Binary Input with Time Delay Board typical wiring diagram

12-28

WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

WCC III Binary Input with Time Delay Board

The “Old” SAT II T ype Binary Input with Time Delay Board Installation and Mounting

It is important to mount the “old” SAT II type Binary Input with Time Delay board in a location that is free from extreme high or low temperatures, moisture, dust, and dirt. Be careful not to damage any of the electronic components when mounting the “old” SAT II type Binary Input with Time Delay board. Remove the “old” SAT II type Binary Input with Time Delay board from its Snap-Track mount. Using the Snap-Track as a template, mark the two mounting holes. Drill pilot holes in the enclosure back panel, and secure the Snap-Track using sheet metal screws. Do not allow metal shavings to fall onto the “old” SAT II type Binary Input with Time Delay board. Reattach the “old” SAT II type Binary Input with Time Delay board into the Snap-Track.

Latest WCC III Binary Input with Time Delay Expansion Board (HSS EXP PORT) - (SS5006)

The new WCC III Binary Input with Time Delay board provides a terminal point for landing wire for an external input switch / relay contact. It can interface to the SAT III controller via a 16-pin ribbon cable with “DIP” connectors on both sides. Connect “J1” on the Binary Input board to one of the two removable dipswitches on the cover of the SAT III controller. These two switches are labeled Binary Inputs on the cover of the SAT III controller. Or, an alternative method of connection to the SAT III controller is provided by the 6-pin HSS communications port on the side of the SAT III controller. The eight Binary Inputs on the new WCC III Binary Input with Time Delay board are dry contact closures to ground only. There is a Time Delay switch on the new WCC III Binary Input with Time Delay board. This Time Delay switch determines how long the input will stay on after a momentary switch contact is applied to the input of the new WCC III Binary Input with Time Delay Board.

With the Time Delay dipswitch (1 to 6) all OFF, there is no delay ON for all eight inputs. Time Delay dipswitch (1 - 15 MIN) ON there is a 15-minute delay ON for all eight inputs. Time Delay dipswitch (2 - 30 MIN) ON there is a ½ hour delay ON for all eight inputs. Time Delay dipswitch (3 - 1 HOUR) ON there is a 1 hour delay ON for all eight inputs. Time Delay dipswitch (4 - 2 HOUR) ON there is a 2-hour delay ON for all eight inputs. Time Delay dipswitch (5 - 3 HOUR) ON there is a 3-hour delay ON for all eight inputs. Time Delay dipswitch (6 - 4 HOUR) ON there is a 4-hour delay ON for all eight inputs. These Dipswitch settings are additive. With Time Delay dipswitch (1 - 15 MIN, 2 - 30 MIN, and 3 - 1 HOUR) ON, there is a 1 hour and 45 minute delay ON for all eight inputs.

NOTE: This Time Delay dipswitch is ignored when the

Binary Input with Time Delay board is connected via the HSS port. There are 16 independent Time Delays on the Binary Input screen of the WCC III front-end software. One for each of the 16 binary inputs.

The eight input status LEDs on the new WCC III Binary Input with Time Delay board also do not work during a time delay when it is connected to the SAT III via the HSS port.

The Binary Input board power requirements are 24VAC and it draws 5 VA. The 24 VAC power connection is P2, and you must observe polarity when connecting this power connection to the SAT III.

HSS connection cables are available in the following sizes: 6-inch, 12-inch, 18-inch, 3 feet, 25 feet, 40 feet, 80 feet, and 120 feet.

WCC III Technical Guide

12-29

12. WCC III INSTALLATION

WCC III Binary Input with Time Delay Board Connection Points

Figure 12-25: The WCC III Binary Input with Time Delay board

WCC III Binary Input with Time Delay Board – Connection Points (SS5006)

All external WCC III Binary Input with Time Delay board connection points are de-pluggable screw-cage type of wire clamped based terminal blocks. With the exception of the “old” connection method of connecting the Binary Inputs which are a 16-pin dip cable connection, and the HSS EXP COMM port which is a 6-pin pre-made MOLEX type mini-ﬁ t cable connection.

HSS Connectors (P2 & P3 Communications)

There are two of these 6-pin Mini-ﬁ t connectors, and each of these connectors could provide power and communications to and from the WCC III Binary Input with Time Delay board to the SAT III controller. These connectors are generally called HSS ports. The WCC III Binary Input with Time Delay board requires 24 VAC and ground connections which are then connected into these connector terminals. The WCC III Binary Input with Time Delay board is generally powered by the same 24 VAC transformer that powers the satellite controller. Communications to the SAT III controller is also in this cable, along with a shield wire. The 6-pin HSS cable connections can also be daisy chained to other WCC III Binary Inputs with Time Delay boards and WCC III V-Out relay boards.

Contact Inputs 1 to 8 and GND

When the contact is closed between one of eight inputs of the contact inputs connector and ground it will activate one of the eight LEDs and makes a simulated contact closure on the J1 connector. This J1 connector is then connected via a 16-pin ribbon cable to one of the SAT III controller’s former Binary Input dipswitch locations. This input is automatically kept on for a timed duration depending on the value of the dipswitch that is located on the WCC III Binary Input with Time Delay board. As an alternative connection method the HSS connection between the SAT III controller and the WCC III Binary Input with Time Delay board delay board has the ability to instantaneously notify the SAT III controller that an Input has changed. And, from within the SAT III Binary Input screen, the individual time duration for each and every binary input could be set differently.

J1 (Socket connection to one of the SA T III

Binary Input former dipswitch loca tions)

This connector is polarized, and must be properly inserted at both ends. Pin #1 of the J1 socket must mate with Pin #1 of one of the SAT III former dipswitch locations. (The dipswitch on the SAT III must be removed) If using the HSS connection method, this connection to the SAT III controller does not need to be connected.

12-30

WCC III Technical Guide

WCC III Binary Input with Time Delay Board Old Wiring Method

UP TO TWO WCC3 BINARY INPUT W/TIME DELAYBOARDSMAYBEWIREDTOTHE SAT III CONTROLLER USING THIS METHOD. CONNECT THE FIRST WCC3 BINARY INPUT W/TIME DELAY BOARD TO THE SAT III CONTROLLER COVER MOUNTED L1 TO L8 DIP SWITCH BINARY INPUTS, AND THE SECOND WCC3 BINARY INPUT W/TIME DELAY BOARD TO THE SAT III CONTROLLERS COVER MOUNTED L9 TO L16 DIP SWITCH BINARY INPUTS.

REPLACE THE DIP SWITCH IN THE SAT III CONTROLLERS COVER WITH THE SUPPLIED RIBBON CABLE. OBSERVE POLARITY OF PIN # 1 CONNECT PIN 1 TO PIN 1 AS SHOWN

SEE FRONT PAGE FOR DIP SWITCH SETTINGS

DRY INPUT CONTACTS ONLY CONTACT CLOSURE TO GROUND ONLY. NO 24VAC INPUTS

12. WCC III INSTALLATION

SAT III CONTROLLER

ON OFF

BATTON/ OFF PULSEINPUT OPTION3 OPTION2 OPTION1 LOCALSET DISABLE LOCALSET TEST

ON OFF

L16 L15 L14

BINARY

L13 L12

INPUTS

L11 L10 L9

ON OFF

L8 L7 L6

BINARY

L5 L4

INPUTS

L3 L2 L1

ON OFF

128 64 32 16 8 4 2

SAT ADDRESS

VDE

5A30VDC

10A250VAC~

CHI

CHINA

DC24V

G5Q-1A4

OMRON

STRIPE

IS PIN #

GND

PIN #1

WCC3BINARY IN W/TIMEDELAY

WATTMASTER CONTROLS,INC

YS102072 REV2

STATUS

SAT REC

SAT XMIT

HSS REC

HSS XMIT

LOCALSET

STATUS 1

STATUS 2

STATUS 3

CH 1 2 3 4

5 6 7 8

24VAC

WARNING: OBSERVE POLARITY

BETWEEN THE SAT III AND THE BINARY INPUT BOARD - GROUND CONNECTIONS MUST BE THE SAME.

24VAC 120VAC

SAT III

PROGRAMMABLECONTROLLER

ANALOG INPUT

JUMPERSELECTION

THERM

0TO1V

0-10V 0-5V

INPUT

0-1V

THERM

0TO5V

0-10V 0-5V

INPUT

0-1V

THERM

0TO10V

0-10V

INPUT

0-5V 0-1V

THERM 0-10V

THERMISTOR

0-5V

INPUT

0-1V

THERM 0-10V

CURRENT

0-5V

INPUT

0-1V

A4 TO 20 mA SENSORWILL REQUIREA 50OHM LOAD RESISTORWHEN SETFOR A1 VOLT IN PUT, OR A 250OHM LOAD RESISTOR WHEN SETFOR A 5 VO LTINPU T.

A2 WIRE ROOM SENSORWILL REQUIRE A300 OHM LOAD RESISTORWHENSET FORA 1 VOLTINPUT.

A3WIREROOMSENSORWILLNOT REQUIREA LOAD RESISTORWHENSET FORA 1 VOLTINPUT.

WattMasterControls Inc.

GUIDE

SAT III HSS PORT

TO OTHER SAT III OR TO WCC III - MCD

TO OTHER SAT III OR TO WCC III - MCD WIRE "T" TO "T" "R" TO "R" "SHD" TO "SHD"

120VAC WIRING IS BY OTHERS THE VA RATING FOR THE SAT III CONTROLLER IS 15VA. THE VA RATING FOR THE WCC3 BINARY INPUT BOARD IS 5 VA.

BINARY INPUT BOARD GETS POWER ONLY FROM THIS HSS CABLE. COMMUNICATIONS ARE IGNORED

HSS CABLE - ORDER STANDARD LENGTHS OF 1 FOOT, 1.5 FOOT, 3 FEET, 25 FEET, 40 FEET, 80 FEET, 120 FEET MAX

CONNECTION FROM A SAT III CONTROLLER TO WCC3 BINARY INPUT W/TIME DELAY BOARD USING THE "NEW" HSS CABLE CONNECTION METHOD,

BUT USING THE HSS CABLE AS A POWER ONLY CONNECTION TO THE WCC3 BINARY INPUT W/TIME DELAY BOARD AND IGNORING THE HSS

COMMUNCATIONS TO AND FROM THE SAT III CONTROLLER.

Figure 12-26: The WCC III Binary Input with Time Delay board typical wiring diagram - Old wiring connection method along with the with the HSS cable method to get power from the SAT III controller

WCC III Technical Guide

12-31

12. WCC III INSTALLATION

WCC III Binary Input with Time Delay Board Old Wiring Method

Figure 12-27: The WCC III Binary Input with Time Delay board typical wiring diagram – Alternativ e “old” wiring connection method with the HSS power and ground pigtail

12-32

WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

WCC III Binary Input with Time Delay Board New Wiring Method

THE VA RATING FOR THEWCC3 BINARY INPUT BOARD IS 5 VA.

Figure 12-28: The WCC III Binary Input with Time Delay board typical wiring diagram – New HSS wiring connection method

The WCC III Binary Input with Time Delay Board Installation and Mounting

It is important to mount the WCC III Binary Input with Time Delay board in a location that is free from extreme high or low temperatures, moisture, dust, and dirt. Be careful not to damage any of the electronic components when mounting the WCC III Binary Input with Time Delay board. Remove the WCC III Binary Input with Time Delay board from its Snap-Track mount. Using

the Snap-Track as a template, mark the two mounting holes. Drill pilot holes in the enclosure back panel, and secure the Snap-Track using sheet metal screws. Do not allow metal shavings to fall onto the WCC III Binary Input with Time Delay board. Reattach the WCC III Binary Input with Time Delay board into the SnapTrack.

WCC III Technical Guide

12-33

12. WCC III INSTALLATION

SA T III V-Out Board

SA T III V-Out

The SAT III controller has the capability of providing 8 analog output signals which have a maximum range of 0-15 VDC. These eight voltage outputs can be used to control actuators, and WattMaster Controls V-Out boards.

Previous “Old” SA T II T ype V-Out Binary Interface Board

A standard SAT III controller is capable of providing 8 analog outputs and 16 binary outputs. The “older” V-Out Binary Interface Board (V-Out board) allows the user to obtain additional binary outputs from the SAT III controller by converting the analog outputs to binary outputs.

Chip switches located on the “older” V-Out board open and close based on the 0-15 VDC signal from the analog outputs. The chip switches on the “older” V-Out boards are not identical to those used for the binary outputs on the SAT III controller.

The changeover setpoint along with the hysteresis is adjustable at the V-Out board. The changeover setpoint is the DC voltage required to open the chip switches on the “older” V-Out board. The hysteresis is the amount the voltage signal must change before the relay changes state. The changeover setpoint is set at 7.5 VDC at the factory, and the hysteresis is set at 2 VDC.

The “older” V-Out board has one changeover setpoint and one hysteresis setpoint which affects all eight binary outputs unless optional potentiometers are ordered separately. One potentiometer is required for each separate changeover setpoint, and one potentiometer is required for each separate hysteresis setpoint. Therefore, a binary output board with a separate changeover and hysteresis setpoint for each binary output would require 16 potentiometers.

If you have a standard “older” V-Out board, R19 is the potentiometer which controls the changeover setpoint and is marked “SET 1.” The potentiometer at R9 controls the value of hysteresis and is labeled “DELTA B.” To adjust the changeover setpoint, use a meter to measure the DC voltage between pin 3 of U4 and ground as you adjust potentiometer R19. To adjust the hysteresis, measure the DC voltage between pin 5 of U4 and ground as you adjust the potentiometer at R9.

To understand how the “older” V-Out board works better, consider a changeover setpoint of 7.5 VDC with a hysteresis of 1 VDC. The chipswitch on the “older” V-Out board will open when the voltage is 8.5 VDC and will not close until the voltage drops to 6.5 VDC. Assume the Analog Input Screen on the WCC III system is set up according to the following parameters:

When the space temperature rises to 73 °F, the voltage supplied to the V-Out board from the SAT III controller will be 8.5 VDC which will cause the relay to open. As the space temperature drops to 72°F, the voltage supplied to the V-Out board will be 6.5 VDC which will cause the relay to close.

For the older SAT II controller: The V-Out board can convert from 1 to 8 of the analog outputs to binary outputs. One digital to analog converter (DAC or V-Out module) is required for each set of 4 analog outputs to be converted to binary outputs. Therefore, if 1 to 4 analog outputs are to be converted to binary outputs, 1 V-Out module is required, and if 5 to 8 analog outputs are to be converted to binary outputs, 2 V-Out modules are required. These V-Out Modules are now built into the SAT III controller and do not need to be ordered separately.

12-34

WCC III Technical Guide

Figure 12-29: The “old” SAT II Type V -Out Board

12. WCC III INSTALLATION GUIDE

Old SA T II Type V -Out Board

CONNECTIONS #1 THRU #8 TO THE OLD SAT II TYPE V-OUT BOARD INPUTS VIN 1 THRU VIN 8 CONNECTION METHOD.

CONNECTIONS FROM A SAT III CONTROLLER TO AN OLD SAT II TYPE V-OUT BOARD USING THE “OLD” HARD-WIRED WAY,

WIRING THE SAT III CONTROLLER’S V-OUT.

Figure 12-30: The “old” SAT II Type V -Out Board wiring diagram

WCC III Technical Guide

12-35

12. WCC III INSTALLATION

WCC III V -Out Relay Board

The “Old” SAT II T ype V -Out Board Connection Points

All external “old” SAT II type V-Out board connection points are single tab ¼-inch Sta-Con connectors.

VIN1 to VIN8 Connection

These analog inputs are set up as 0 to +15 DC Volts inputs. They should be connected to and mated up with the SAT III controller’s 8 Analog Outputs. These eight inputs need to be connected to the SAT III V-Out connections for the V-Out mode of operation to function.

GND Connection

This is an analog ground common connection point for VIN1 to VIN8 analog inputs. It is important that this “analog” ground is connected to the Analog Input ground of the SAT III controller.

24 V AC & GND

The “old” SAT II type V-Out board requires a 24 VAC power supply, which is connected to these terminals. The “old” SAT II type V-Out board is generally powered by the same 24 VAC transformer that powers the satellite controller. The GND connection points must be the same between the “old” SAT II type V-Out board and the SAT III Controller.

RL Y 1 to RLY 8 COM – N.O . Connections

These are the eight “Chip-switch” relay driver contacts on the “old” SAT II type V-Out board. These are to be used for powering of pilot duty relays. No more than 24 VAC to be switched by these “Chipswitches”. There is no load protection device called a varistor on any of these 8 “Chip-switch” relay driver output connections of the “old” SAT II type V-Out board. These chip-switches can only switch AC type voltage, not DC type voltage, with a maximum at ½ amp current draw for each chip-switch relay driver output contact. Attempting to switch any current draws of more than 1/2 amps per contact could and will result in damage to the “old” SAT II type V-Out board and/or to the SAT III controller.

A pre-made control output common jumper wire (PL100867) can be used to connect all eight of the relay common connections of the “old” SAT II type V-Out board together.

The “Old” SAT II T ype V -Out Board Installation and Mounting

It is important to mount the “old” SAT II type V-Out board in a location that is free from extreme high or low temperatures, moisture, dust, and dirt. Be careful not to damage any of the electronic components when mounting the “old” SAT II type V-Out board. Remove the “old” SAT II type V-Out board from its Snap-Track mount. Using the Snap-Track as a template, mark the two mounting holes. Drill pilot holes in the enclosure back panel, and secure the Snap-Track using sheet metal screws. Do not allow metal shavings to fall onto the “old” SAT II type V-Out circuit board. Reattach the “old” SAT II type V-Out board into the Snap-Track.

WCC III V -Out RELA Y Board Sequence (SS5008)

There are two modes of operation for the WCC III V-Out RELAY board. One is the V-Out mode, and the other is the Binary Output mode.

The WCC III V-Out RELAY board has eight relays each with N.O. (Normally Open) contacts. These relay contacts are rated for 1 Amp at 24 VAC/VDC operation only. This WCC III V-Out RELAY board connects to the HSS expansion port on the side of the SAT III controller. The WCC III V-Out RELAY board is an expansion board that allows for another 8 binary outputs (Relay Contacts) to be used with the SAT III controller. Up to three of these WCC III V-Out RELAY boards may be connected to the SAT III HSS expansion port. Two boards in the Binary Output mode are supported, and one board in the V-Out mode is supported. One HSS expansion board will add 10 VA of VA load to the SAT III power requirement.

These eight Analog Inputs connections must be connected to the eight Analog Outputs of the SAT III controller in the V-Out mode of operation. These analog values are not digitally transmitted via the HSS port on the SAT III to the WCC III V-Out RELAY board in the V-Out mode.

There is a load protection device called a varistor across each of the 8 relay output connections of the WCC III V-Out RELAY board that limit the allowable voltage to no more than 32 volts AC\DC maximum at 1 amp current draw for each relay output contact. Attempting to switch any voltage greater than 32 volts or current draws of more than 1 amp per contact could and will result in damage to the WCC III V-Out RELAY board and/ or to the SAT III controller.

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WCC III Technical Guide

12. WCC III INSTALLATION GUIDE

WCC III V -Out Relay Board

The connecting HSS cable is available in 1-ft, 1½-ft, 3-ft, 25-ft, 40-ft, 80-ft, and 120-ft lengths. No more than 150 feet of total wire can be used to power a SAT III HSS loop.

The dipswitch on the WCC III V-Out RELAY board sets the various modes of operation, and dead band in the V-Out mode.

Dipswitch SW1-7 (MODE 2 - V-Out Mode) and SW1-8 (MODE 1 - Binary Output Mode) selects the MODE of operation for the WCC III V-Out RELAY board.

If both MODE (SW1-7 and SW1-8) switches are OFF then the WCC III V-Out RELAY board is in Binary Output mode. Binary Output 1 to 8 is selected. If MODE 1 switch (SW1-8) is “ON” then Binary Output 9 to 16 is then selected. If MODE 2 Switch (SW1-7) is “ON” then the V-Out mode is selected. You must cycle power to the WCC III V-Out RELAY circuit board after setting dip switch SW1-8. You may select any other switch setting without cycling power to the board.

SW1-1 (1) (V-OUT MODE - ADDS 1 VOLT TO DEAD BAND)

SW1-2 (2) (V-OUT MODE - ADDS 2 VOLTS TO DEAD BAND) (V-OUT MODE DEFAULT SETTING ON)

SW1-3 (4) (V-OUT MODE - ADDS 4 VOLTS TO DEAD BAND)

SW1-4 (8)

SW1-5 (16)

SW1-6 INVERT (V-OUT MODE) (FLIPS CONDITION OF THE RELAY OUTPUTS)

SW1-7 MODE 2 (V-OUT MODE) (V-OUT MODE DEFAULT SETTING ON)

SW1-8 MODE 1 (When changing this switch, you must cycle power to the circuit board)

Binary Output Mode of Operation

When the WCC V-Out RELAY board is set for the Binary Output mode (SW1- switch # 8 is either “ON” or “OFF” and SW1 - switch #7 is “OFF”) the eight relays of the WCC V-Out RELAY board are controlled by the WCC III program setup of the SAT Binary Output screens for each satellite controller. SW1- switch # 8 “OFF” is Binary Output board address relays 1 to 8, and SW1- switch # 8 “ON” is Binary Output board address relays 9 to 16. This assumes that SW1 - switch #7 is “OFF”.

V-Out Mode of Operation (Hysteresis is Added to the Setpoint via Setting of the SW1 Dipswitch)

When the WCC V-Out RELAY board is set for the V-Out mode (SW1- switch # 7 “ON”), the relay output will turn “ON” when the input voltage rises above 7.5 VDC (+/- .25V) plus the dead band setting that is determined by SW1 settings. When the WCC III V-Out RELAY board is set for the V-Out mode, the relay output will turn “OFF” when the input voltage drops below 7.5 VDC (+/- .25V) minus the dead band setting that is determined by SW1 dipswitch settings. These dipswitch settings apply for all eight inputs and outputs.

When SW1-1 is selected, 1 volt is added to the dead band. (Dead Band = +/- 1 volts)

When SW1-2 is selected, 2 volts are added to the dead band. (Dead Band = +/- 2 volts) (DEFAULT)

When SW1-1 and SW1-2 is selected, 3 volts are added to the dead band. (Dead Band = +/- 3 volts)

When SW1-3 is selected, 4 volts are added to the dead band. (Dead Band = +/- 4 volts)

When SW1-3 and SW1-1is selected, 5 volts are added to the dead band. (Dead Band = +/- 5 volts)

WCC III Technical Guide

The eight analog inputs on the WCC III V-Out Relay board must be wired to the eight analog outputs on the SAT III or SAT II controller in order for the V-Out mode to function. Also, the HSS connector must be connected to the SAT III HSS expansion port for power and ground connections to the SAT III controller, or a special twowire power and ground pigtail must be provided for connection to 24VAC and GND to power the WCC III V-Out Relay board.

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12. WCC III INSTALLATION

WCC III V -Out Relay Board Connection Points

Figure 12-31: The WCC III V-Out Relay Board (OE430-01)

WCC III V -Out Relay Board Connection Points (SS5008)

All external WCC III V-Out RELAY Board connection points are single-tab ¼-inch Sta-Con connectors. With the exception of the HSS EXP COMM port which is a 6-pin pre-made MOLEX type mini-ﬁ t cable connection.

VIN1 to VIN8 Connection

These analog inputs are set up as 0 to +15 DC Volts inputs. They should be connected to and mated up with the SAT III controller’s 8 Analog Outputs. These eight inputs are only used for the V-Out mode of operation, and are not needed for the Binary Output mode of operation.

GND Connection

This is an analog ground common connection point for VIN1 to VIN8 analog inputs. It is important that this “analog” ground on the WCC III V-Out RELAY board is connected to the Analog Input ground of the SAT III controller.

HSS Connectors

This is a 6-pin Mini-ﬁ t connector that provides power and communications to the WCC III V-Out RELAY board from the SAT III controller. It is called an HSS port. The WCC III V-Out RELAY board requires 24 VAC and ground connections which are connected into these connector terminals. The WCC III V-Out RELAY board is generally powered by the same 24 VAC transformer that powers the satellite controller. Communications to the SAT III controller is also in this cable, along with a shield wire. The 6-pin HSS cable connections can also be daisy chained to other WCC III V-Out RELAY boards and WCC III Binary Inputs with Time Delay boards.

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WCC III Technical Guide

12. WCC III INSTALLATION

WCC III V -Out Relay Board Installation

GUIDE

RL Y 1 to RLY 8 COM – N.O . Connections

These are the eight Normally Open relay contacts of the WCC III V-Out Relay board (OE430-01). These are to be used for powering of pilot duty relays.

No more than 24 VAC/VDC is to be switched by the Relays. There is a load protection device called a varistor across each of the 8 relay output connections of the WCC III V-Out Relay board that limit the allowable voltage to no more than 32 Volts AC\DC maximum at 1 amp current draw for each relay output contact. Attempting to switch any voltage greater than 32Volts, or current draws of more than 1 amp per contact could and will result in damage to the WCC III V-Out Relay board and/or to the SAT III controller.

A pre-made control output common jumper wire (PL100867) can be used to connect all eight of the relay common connections of the WCC III V-Out Relay Board together.

The WCC III V-Out Relay board (OE430-02) has eight relays with individually selectable N.C./N.O. contacts on the OE430-02.

WCC III V -Out RELA Y Board Installation and Mounting

It is important to mount the WCC III V-Out RELAY board in a location that is free from extreme high or low temperatures, moisture, dust, and dirt.

Be careful not to damage any of the electronic components when mounting the WCC III V-Out RELAY board. Remove the WCC III V-Out RELAY board from its Snap-Track mount. Using the Snap-Track as a template, mark the two mounting holes. Drill pilot holes in the enclosure back panel, and secure the Snap-Track using sheet metal screws. Do not allow metal shaving to fall onto the WCC III V-Out RELAY circuit board. Reattach the WCC III V-Out RELAY board into the Snap-Track.

Figure 12-32: V-Out Relay Board typical wiring diagram for V-Out only use

WCC III Technical Guide

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12. WCC III INSTALLATION

WCC III V -Out Relay Board Wiring

Figure 12-33: V-Out Relay Board typical wiring diagram for Binary Output use with the HSS connection method

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WCC III Technical Guide

SAT ADDRESS

2 1

A3 WIRE ROOM SEN SOR WILL NOT REQUIREALOAD RESISTORWHEN SET FORA 1 VOL T INPUT.

WattMaster Controls Inc.

BINARY INPUTS

ON OFF

128

32 16

L4 L3 L2 L1

L6 L5

L11

L12

ON OFF

L10 L9

ON OFF

L15

L16

L14 L13

5 6

LOCAL SET

STATUS2

STATUS3

STATUS 1

HSS XMIT

LOCAL SET

LOCAL SETDISABLE

BATT ON/ OFF PULSE INPUT

OPTION1

TEST

OPTION3 OPTION2

ON OFF

STATUS

HSS REC

SAT XMIT

SAT REC

ANALOG INPUT

JUMPER SELECTION

A2 WIRE ROOMSENSORWILL REQUIRE A300OHMLOADRESISTORWHENSET FORA 1 VOL T INPUT.

A4 TO 20 mA SENSORWILL RE QUIRE A 50OHM LOAD RESISTOR WHEN SET FOR A1 VOLT INPU T, OR A 250 OHM LOAD RESISTORWHEN SETF ORA 5V OLT INPUT.

CURRENT INPUT

THERMISTOR INPUT

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

0-10V

THERM

0TO10V INPUT

0TO5V INPUT

0TO1V INPUT

0-10V

0-1V

0-5V

0-10V

THERM

0-1V

0-5V

THERM

0-1V

0-5V

0-10V

THERM

PROGRAMMABLE CONTROLLER

SAT III

EACHCONTAC T ISRATED FOR 24VACOR VDC @.5AMPMAX

0-15VDC OUTPUT MINLOAD IS1K OHM RESISTIVE VDCONLY

SAT III ANALOG INPUT

LOCATION ATI 1 TOATI8

L O A D

ATI

SAT III ANALOG INPUT

LOCATION ATI 1 TO ATI8

SA T III Analog Inputs

12. WCC III INSTALLATION

SA T III Analog Inputs

GUIDE

Figure 12-34: SAT III Analog Inputs location

WCC III Technical Guide

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12. WCC III INSTALLATION

OPA2743PA

Zoomed in view of the SAT III mother board circuit board Rev 4 showing location of the Analog input selection jumpers. JO1 to JO8 .

SA T III Analog Inputs

Figure 12-35: SAT III Analog Input J umper locations (loca ted under the SAT III cover)

JO1 corresponds to ATI #1 input, JO2 corresponds to ATI #2 input, JO3 corresponds to ATI #3 input, JO4 corresponds to ATI #4 input, JO5 corresponds to ATI #5 input, JO6 corresponds to ATI #6 input, JO7 corresponds to ATI #7 input, JO8 corresponds to ATI #8 input, while the jumper setting at JP1 sets the voltage for the eighth +V connection point of the SAT III controller.

This jumper (JP1) can be set to +12VDC, or +24VDC so that the voltage at the eighth +V connection point is either +12 VDC or +24 VDC. The +24VDC is useful when connecting 4-to-20 mA sensors that require a power connection voltage greater than +12VDC. You may connect up to eight 4-to-20 mA sensors to this eighth +V (+24VDC) connection point. This JP1 jumper is located under the cover of the SAT III controller, just to the right of the eighth +V connector.

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WCC III Technical Guide

12. WCC III INSTALLATION

T emperature Sensors

Older SA T II Type Sensors

SENSOR DESCRIPTION WM “OE” PART NUMBER

2-Wire Flush mount sensor. (Obsolete in 2002 but we will make spot builds of 100 or more) OE220

3-Wire Voltage Flush mount sensor (Use to replace the OE220, but must run new wire) OE222

3-Wire Voltage Duct sensor with 6-inch probe OE240-ACI

3-Wire Voltage Duct sensor with 12-inch probe OE241-ACI

Immersion well for 6-inch probe OE291

3-Wire Voltage Outside Air sensor OE260

GUIDE

New SA T III Type –Thermistor-Based Sensors 10K Type 3 Thermistor Sensors

SENSOR DESCRIPTION WM “OE” PART NUMBER

2-Wire Thermistor Flush mount sensor, plain (Use to replace the OE220) OE210

2-Wire Thermistor Duct sensor with 6-inch probe OE230

2-Wire Thermistor Duct sensor with 12-inch probe OE231

Immersion well for 6-inch probe OE291

2-Wire Thermistor Outside Air sensor OE250

The following Thermistor sensors are only for use with the TUC type controllers:

2-Wire Thermistor Flush mount sensor with pushbutton override OE211

3-Wire Thermistor Flush mount sensor with set-point control OE212

3-Wire Thermistor Flush mount sensor with pushbutton override and set-point control OE213

WCC III Technical Guide

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12. WCC III INSTALLATION

T emperature Sensors

0 - 1, 0 – 5, 0 - 10 VDC, and Thermistor Type Sensors

The SAT III controller can accept a 0-1VDC, 0-5VDC, 0-10VDC, or THERM signal from a sensor. Since the SAT III controller is designed with eight settable analog input jumpers, these eight analog input jumpers must be correctly set for the type of input that is needed for the desired VDC across the load resistor to represent the full scale value of the analog input. On the older SAT II controller, the voltage from the 0-10 and 0-5 VDC sensors needed to be reduced before it reached the analog inputs of the older SAT II controller. This was accomplished by placing a line resistor in the circuit in addition to the load resistor.

“Older” 2-Wire Flush Mount Sensors

Wiring connections for the “older” 2-Wire Flush mount sensors is as follows: The “+V” terminal on the SAT III controller is a +12 VDC power source, and the ATI connection from the “older” 2-Wire Flush mount sensor is then connected to the SAT III ATI input(s). The temperature sensor is a current transducer which transmits a current proportional to the temperature it is sensing. The load resistor on the front of the SAT III controller is in series with the temperature sensor and connects the “ATI” terminal to the “GND” terminal. The satellite controller then monitors the voltage between the “ATI” terminal and “GND” on the SAT III controller to determine the temperature that is then sensed by the sensing element of the 2-wire Flush mount sensor. The SAT III controller could use either a 1-VDC or a 5-VDC input for the “older” 2-wire Flush mount sensor. With a 1-VDC input between “ATI” and “GND” to represent the 100 percent scale value on the Analog Input Screen, and 0 VDC represents the 0 percent scale value. The maximum allowable voltage across the load resistor is

1.2 volts. This is with the 0-1V analog input jumper installed. With the 0-5V analog input jumper installed, the satellite controller is designed for 5 VDC between “ATI” and “GND” to represent the 500 percent scale value on the Analog Input Screen, and 0 VDC represents the 0 percent scale value. The maximum allowable voltage across the load resistor is 5.2 volts with the 0-5V analog input jumper installed.

The speciﬁ cations of the temperature sensor determine the value of the SAT III load resistor and the 0 percent and 100 percent scale value on the Analog Input Screen. The load resistors must be ﬁ eld installed.

The older 2-wire air/water temperature sensor was used to monitor the temperature of the air in duct work or the temperature of ﬂ uid in a pipe. For ﬂ uid pipe applications, the probe may be removed from the transmitter, strapped to the pipe, and thermally insulated

from the ambient air. The transmitter should be mounted remotely by extending the two wires connecting the probe to the transmitter. The transmitter may be located up to 100 feet from the probe, or the sensor may be mounted in an immersion well with the use of thermal compound to ensure good thermal conduction between the water and the sensor. For chilled water sensing, it is highly recommended that the sensing element be removed from the transmitter (control head) to prevent condensation in the head.

The air/water sensor has two temperature ranges available, depending on which load resistor is used. A 100 ohm load resistor gives the sensor a control range of 30-120°F, and a 49.9 ohm load resistor gives the sensor a control range of 40-240 °F. This is with either the 0-1V or 0-5V analog input jumper installed. 100 percent scaling must be changed between the “Units @ 0% scale” and the “Units @ full scale” on the Analog Input Screen.

NOTE: These 2-wire based sensors are now considered

obsolete. When any 2-wire based sensor fails, a replacement thermistor type sensor is available for replacement for the SAT

III controller.

“Older” 3-Wire Voltage Type T emperature Sensors

The older 3-wire temperature sensors accomplish the same thing as the older 2-wire sensors, only you can think of the load resistor as being in the sensor and not at the satellite controller. The 3-wire sensor is wired to the “+V,” “ATI,” and “GND” terminals on the SAT III controller. The 3-wire sensor transmits a voltage between “ATI” and “GND” that directly corresponds to temperature, and therefore, a load resistor at the SAT III controller is not required when using a 3-wire voltage type sensor. 3 – wire sensors should not be used for long distance wiring, as wire length will affect the voltage coming back from the sensor. This voltage is again proportional to the temperature, so a 0.1 volt voltage drop is actually equivalent to a 10 deg °F error in temperature. 200 feet is about the maximum distance for a 3-wire sensor due to voltage drop of the small gauge wire (18 gauge and lower) that sensors are typically wired with.

NOTE: These 3-wire based sensors are now considered

obsolete, and when any 3-wire based sensor fails, a replacement thermistor type sensor is available for the SAT III controller.

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WCC III Technical Guide

The following table shows the required load resistor, Data Pattern, 0 % and 100 % programmed values, Jumper setting, Analog Type, for the Analog Input Screen. For the Thermistor type sensors, there are no 0 % or 100 % values to program.

Analog Input Screen Values

12. WCC III INSTALLATION GUIDE

Analog Input Values

Temperature

Sensor

2-Wire Surface

Mount

2-Wire Flush

Mount

3-Wire Flush

Mount

2-Wire Air/Water 100 XXX.X 0.0 100.0 0-1 General

2-Wire Air/Water 49.9 XXX.X 0.0 200.0 0-1 General

Thermistor Flush

Mount

Load

Resistor

(Ohms)

100 XXX.X 0.0 100.0 0-1 General

301 XXX.X 0.0 100.0 0-1 General

None XXX.X 0.0 100.0 0-1 General

None XXX.X Auto Auto THERM Thermistor

Data Pattern % Scale 100% Scale Jumper

Setting

0.0 500.0 0-5 General

Analog Type

Thermistor Duct

6”

Thermistor Duct

6”

Thermistor

Outdoor Air

Figure 12-36: Analog Input Values

None XXX.X Auto Auto THERM Thermistor

WCC III Technical Guide

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12. WCC III INSTALLATION

4-to-20 Milli-Amp Current Sensors

The connection of a 4-to-20 milli-amp sensor to a SAT III controller will require simple math to determine the “Zero” point of the 4-to20 milli-amp sensor. This is because the “Zero” point of the 4-to20 milli-amp sensor is actually not at zero volts. This “Zero” point is actually at the 4 milli-amp point.

Various sensors that provide a 4-to-20 mA current output signal can be used with the SAT III controllers. The SAT III controllers are designed to work with a 4-to-20 milli-amp sensor to have either a +1VDC selected input scaling range or +5VDC selected input scaling range. The current that is measured across the load resistor(s) on the SAT III input at full scale (20mA) on either of the two input scaling range determines the load resistance value. Since the SAT III load resistor(s) will have at most a 20 milli-amp current going through them at full scale, and when the maximum input voltage of either +1VDC or + 5VDC that is required across the SAT III load resistor at 20 milli-amp. Therefore, when doing the required math at +1VDC input scaling range, a 4-20 mA sensor will require a 50 Ohm load resistor, and at a +5VDC input scaling range, a 4-20 mA sensor will require a 250 Ohm load resistor.

V 1 Volt R = --------- = ------------ = 50 Ohms I 0.020 Amps

V 5 Volts R = --------- = ------------ = 250 Ohms I 0.020 Amps

Both values of load resistors - the 50 Ohm (Actually 49.9 Ohm) & 250 Ohm are provided in the resistor pack kit that is provided with each new SAT III controller. The WattMaster part number of this kit is PL102029.

When programming the WCC III Analog Input Screen for a 4-20 mA sensor, the 100% scale value is the value represented when the sensor sends 20 mA to the SAT III controller, and the zero percent scale value is the value represented when the sensor sends 0 mA to the SAT III controller. For example, consider a 4-20 mA sensor which measures duct static pressure. The sensor provides 4 mA when the duct static pressure is 0 inches of water column and 20 mA when the duct pressure is 2 inches of water column. The 100 percent scale value on the Analog Input Screen is 2.00” W.C., and the zero percent scale value is -0.50” W.C.

The full scale value is fairly straightforward and very easy to understand. The zero percent scale value, on the other hand, is a bit more complicated. The following table shows the signal out of the sensor versus the duct static pressure.

Signal From Sensor

(mA)

20 2.00” W.C. 16 1.50” W.C. 12 1.00” W.C.

8 0.50” W.C. 4 0.00” W.C. 0 -0.50” W.C.

Figure 12-37: Analog Input Values

Duct Static Pressure

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WCC III Technical Guide

12. WCC III INSTALLATION

OVR

W A R M E R

C O O

L E R

W A R M E R

C O O L E R

OVR

OE210 OE211 OE212 OE213

GUIDE

Thermistor Sensors

When programming the Analog Input Screen, the zero percent scale value is the value when 0 mA are supplied by the sensor. Since 0 mA represents -0.50” W.C., -0.50” W.C. is input for the zero percent scale value.

Thermistor Sensors

The Thermistor Flush mount sensor (WattMaster part # OE210) is connected to the “ATI”, and “GND” connections of the SAT III controller. A thermistor is a type of resistor with resistance that will vary according to its temperature. The SAT III controller is set up for 10K Type 3 thermistor sensors. The SAT III controller does all of the complex math to linearize the temperature versus voltage curve of the thermistor sensor. There is no calibration necessary for thermistor type sensors, but an offset is provided for the sensor on

the satellite analog input set-up screen. The 10K Type 3 Thermistor Flush Mount sensor is one of the most accurate room sensors on the market today for sensing basic room temperature, as the thermistor element is thermally isolated from the wall with a patented process developed by WattMaster Controls years ago.

There seems to be an almost endless supply of third-party sensors that use the 10K Type 3 thermistor as the sensing element. WattMaster Controls, Inc. can provide the following 10K Type 3 thermistor sensors:

2-Wire Thermistor Duct sensor with 6-inch probe (WattMaster part # OE230)

2-Wire Thermistor Duct sensor with 12-inch probe (WattMaster part # OE231)

Immersion well for 6-inch thermistor probe (WattMaster part # OE291)

2-Wire Thermistor Outside Air sensor (WattMaster part # OE250)

Figure 12-38: The WattMaster Controls, Inc. 10K Type 3 Flush Mount Sensor variations. Only the OE210 can be used with the SAT III controller. There are no connections or programming points on the SA T III controller for the additional slide pot (OE212, and OE213), or OVR switc h (OE211 and OE213). All of these 10K Type 3 Flush Mount sensors variations may be used with the RTU/TUC family of application-speciﬁ c controllers.

WCC III Technical Guide

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12. WCC III INSTALLATION

Thermistor Resistor V oltage Chart

Temperature – Resistance – Voltage for

Type III 10 K Ohm Thermistor Sensors

Temp

(ºF)

-10 93333 4.620

-5 80531 4.550 0 69822 4.474 5 60552 4.390

10 52500 4.297 15 45902 4.200 20 40147 4.095 25 35165 3.982 30 30805 3.862 35 27140 3.737 40 23874 3.605 45 21094 3.470 50 18655 3.330 52 17799 3.275 54 16956 3.217 56 16164 3.160 58 15385 3.100 60 14681 3.042 62 14014 2.985 64 13382 2.927 66 12758 2.867 68 12191 2.810 69 11906 2.780 70 11652 2.752 71 11379 2.722 72 11136 2.695 73 10878 2.665

Resistance

(Ohms)

Voltage @

Input (VDC)

Temperature – Resistance – Voltage for

Type III 10 K Ohm Thermistor Sensors

Temp

(ºF)

74 10625 2.635 75 10398 2.607 76 10158 2.577 78 9711 2.520 80 9302 2.465 82 8893 2.407 84 8514 2.352 86 8153 2.297 88 7805 2.242 90 7472 2.187

95 6716 2.055 100 6047 1.927 105 5453 1.805 110 4923 1.687 115 4449 1.575 120 4030 1.469 125 3656 1.369 130 3317 1.274 135 3015 1.185 140 2743 1.101 145 2502 1.024 150 2288 0.952

Resistance

(Ohms)

Voltage @

Input (VDC)

Figure 12-39, cont.: Temperature Resistance V oltage for Type III 10K Thermistor Sensor

Figure 12-39: Temperature Resistance V oltage for Type III 10K Thermistor Sensor

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WCC III Technical Guide

12. WCC III INSTALLATION

SA T 3C – WCC III Interface to TUC/RTU Controllers

SA T 3C Controller

GUIDE

Figure 12-40: SAT 3C Controller

The system architecture for the WCC III system interfacing with the TUC/RTU controllers through the SAT 3C is shown below:

The SAT3C - General Information (SS5004)

The SAT3C Controller has 8 status lights. The functions of these LEDs are listed below.

SAT REC - This LED will be lit when communications are being received by the SAT 3C Controller.

SAT XMIT - This LED will be lit when communications are being transmitted by the SAT 3C Controller.

TUC REC - This LED will be lit when communications are being received from the TUC/RTU RS-485 Communications Loop.

TUC XMIT - This LED will be lit when communications are being transmitted to the TUC/RTU RS-485 Communications Loop.

LOCAL SET - This LED will be lit when no communications with the WCC III-MCD has occurred in at least the last 2 minutes. This means that this SAT 3C communications loop is not communicating with the WCC III-MCD. All standalone setpoint control is dependent on the LOCAL SET parameters that are programmed into the SAT 3C controller by the user.

STATUS - This LED blinks for every second if SAT 3C is alive.

“C” MODE - This LED will be lit if this Controller is programmed as a SAT 3C and blinks for every internal calculation loop completion.

“D” MODE - This LED blinks for every second during power on delay and blinks every 8 seconds when watchdog is enabled.

SAT ADDRESS DIPSWITCH - There are two dipswitches on the cover of the SAT 3C controller, one dipswitch sets the address of the SAT 3C controller. The other dipswitch sets various local control options.

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12. WCC III INSTALLATION

SA T 3C Controller

SA T 3C Controller - Connections points

All of the external SAT 3C connection points are single-tab ¼ inch Sta-Con connectors. With the exception of the TUC RS485 communications connection which is a three-position, depluggable terminal block.

24V AC & GND Connection

Located on the bottom side of the SAT III controller is a 24 VAC and GND connection. This is the main power connection to the SAT 3C controller. Each SAT 3C Controller draws - 10VA. The GND connection points must be the same between all of the externally powered TUC/RTU boards and the SAT 3C Controller.

SA T Communica tion Connection

When connecting the RS-485 wiring from SAT III to SAT III or SAT 3C/D/F, or SAT 3P controller the wiring connections are as follows: connect “R” TO “R”, “T” TO “T”, AND “SHIELD” TO “SHIELD” OR “SH”. The RS-485 wire speciﬁ cations are plenum rated jacketed stranded 18-gauge, 2-wire twisted pair with shield. 18-gauge stranded wire is mandatory to ensure a good connection with the ¼-inch Sta-Con connectors which are used to terminate the wires at the WCC III - MCD and at the satellite controllers.

TUC Communication Connection

These connection points are for wiring of the TUC RS-485 communication loop. There is a single three position, de-pluggable terminal block. Connect the wiring for the communications connections between the TUC/RTU’s as follows: “R” TO “R”, “T” TO “T”, AND “SHLD” TO “SHLD” OR “SH”. Connect the wiring from TUC/RTU controller to TUC/RTU controller. But, on the SAT 3C/D/F controller the TUC “R” connection must be wired to the SAT 3C/D/F “T” connection, and the SAT 3C/D/F controller “R” connection must be wired to the TUC “T” connection. The RS-485 wire speciﬁ cations are plenum-rated jacketed stranded 18-gauge, 2-wire twisted pair with shield. 18-gauge stranded wire is mandatory to ensure a good connection between TUC/RTU controllers.

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Addressing the SAT 3C

12. WCC III INSTALLATION GUIDE

SA T 3C Addressing

Figure 12-41: SAT 3C Address Switch location

The address dip switches are additive; that is to say placing switches 4 and 5 in the ON position will cause the SAT 3C controller to be identiﬁ ed as satellite controller number 24. The SAT 3C controller looks at the position of these switches only when it is going through its initialization process after being powered up. Simply changing the switch positions on a SAT 3C controller that is currently “online” will not change its address number. The switches need to be placed in the proper position before powering up the SAT 3C controller, or the SAT 3C must be powered down and then back up for the SAT 3C to “read” the new position of the switches. When placing the switches in the desired position, make sure the switch has “clicked” into place and is properly seated.

WCC III Technical Guide

There can be up to 29 SAT 3C controller connected together on a 2-wire communication loop. In order for the WCC III system to communicate properly with each SAT 3C, each SAT 3C must be assigned a separate address number. The number is assigned by positioning the small address dipswitch on the front of the SAT 3C in the proper position.

The SAT 3C uses up 8 satellite addresses. The lowest possible SAT 3C address is #8. The address must start in multiples of 8, starting at address # 8, then the next available address is #16, then next available address is #24, then next available address is #32, then next available address is 40, then next available address is 48, then next available address is 56, etc. The only legitimate SAT 3C address are 8, 16, 24, 32, 40, 48, 56, 64, 72, 80, 88, 96, 104, 112, 120, 128, 136, 144, 152, 160, 168, 176, 184, 192, 200, 208, 216, 224, and 232.

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12. WCC III INSTALLATION

SA T 3C Addressing

For example the following Satellite Addresses will not work as a SAT 3C starting address. 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13, 14, 15, 17, 18, 19, 20, 21, 22, 23, 25, 26, 27, 28, 29, 30, 31, 33, 34, 35, 36, 37, 38, 39, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53, 54, 55, 57, 58, 59, 60, 61, 62, 63, 65, 66, 67, 68, 69, 70, 71,73, 74, 75, 76, 77, 78, 79, 81, 82, 83, 84, 85, 86, 87, 89, 90, 91, 92, 93, 94, 95, 97, 98, 99, 100, 101, 102, 103, 105, 106, 107, 108, 109, 110, 111, 113, 114, 115, 116, 117, 118, 119, 121, 122, 123, 124, 125, 126, 127, 129, 130, 131, 132, 133, 134, 135, 137, 138, 139, 140, 141, 142, 143, 145, 146, 147, 148, 149, 150, 151, 153, 154, 155, 156, 157, 158, 159, 161, 162, 163, 164, 165, 166, 167, 169, 170, 171, 172, 173, 174, 175, 177, 178, 179, 180, 181, 182, 183, 185, 186, 187, 188, 190, 191, 193, 194, 195, 196, 197, 198, 199, 201, 202, 203, 204, 205, 206, 207, 209, 210, 211, 212, 213, 214, 215, 217, 218, 219, 220, 221, 222, 223, 225, 226, 227, 228, 229, 230, 231, 233, 234, 235, 236, 237, 238, 239, and 240.

Care must be taken to ensure that two SAT 3C controllers do not have the same address. When this condition is present, the central computer (WCC III – MCD) does not know where to send the information, and the information which should be sent to the SAT 3C controller is then usually lost.

You should be aware of the symptoms that are caused by two satellite controllers having the same number. Let’s consider a new job in which the satellite controllers have not yet been programmed and 2 SAT 3C controllers are named number #8. When you call up satellite controller #8 to enter data, everything will appear to be ﬁ ne. You will be able to enter data on the screens as if nothing is wrong. However, when you leave a screen and then return to the same screen, all of the data you entered will be missing. Also, if you ﬁ nish programming the analog inputs for example, and then go to the analog input summary screen to review your inputs, all of the data you have entered will be missing.

Another situation that you might encounter is adding a SAT 3C controller to an existing system and accidentally giving it the same number as a SAT 3C presently “on-line.” Again, when you begin to program the new SAT 3C controller, everything will appear ﬁ ne until you leave a screen or if you go to a summary screen. Only now, all of the data is usually not missing. Generally, you get parts of your data back and parts will be missing.

If you suspect you might have two SAT 3C controllers with the same address, number 8 for example, the best thing to do is go to the SAT 3C controller that you know is number 8, and remove the 2-wire RS-485 communication loop from it. Then go back to the computer and call up satellite controller #8. If the computer can still “talk” to satellite controller #8, then there is another satellite controller that is addressed #8 connected somewhere on the RS485 communication loop.

If a satellite controller was accidentally addressed #8, there will be a satellite number missing. For example, if satellite controller #16 was mistakenly addressed to #8, satellite controller #16 will not be present. One way of telling which satellite controllers are

“on-line” is to go to the Satellite Summary Screen (see Section

3) and see which satellite controllers the computer recognizes as

being “on-line.”

If satellite controller #8 was accidentally misaddressed #16, there would not be a satellite controller at address #8, and the computer will give a “Non-Existing” message for satellite controller #8.

The other Dipswitch on the SAT 3C

Option 1, 2, and 3 Switches

For the SAT 3C, these Options switches do nothing, But on the SAT III controller the option 1 switch selects the A-to-D converter type that is on the mother board. With the switch turn OFF, the A-to-D curve is selected for the Maxim MAX147 part and with the switch turned “ON” for the TI-ADS7844 (BB marked) and the software will use the special A-to-D curve for the TI-ADS7844 part.

BA TT ON/OFF s witc h

This switch is used to turn the Battery (Rechargeable Super cap) ON and OFF to the SRAM located inside of the SAT 3C.

Local Set Switch

When the LOCAL dipswitch is in the ON position, the TUC/ RTU controllers will operate according to their predeﬁ ned user programmed “local set” setpoints. That is, if the TUC/RTU controllers were programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected, but the SAT 3C controller is still present and communicating with the TUC/RTU controllers.

Local Set Disable Switch

When the LOCAL SET Disable dipswitch is in the ON position, the TUC/RTU controllers will operate according to their predeﬁ ned user-programmed “On” setpoints. That is, if the TUC/ RTU controllers were programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected, but the SAT 3C controller is still present and communicating with the TUC/RTU controllers.

Test Switc h

The test mode is active only if the TEST dipswitch is in the ON position. The word “TEST” can be input as the binary value within the SAT 3C. Example of use would be if the user programmed

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12. WCC III INSTALLATION GUIDE

TUC/RTU Controllers Addressing

the word “TEST” into one of the control point values in the TUC/ RTU controller to check the operation of the TUC/RTU controllers with an alternate setpoint or schedule, then the user could place the TEST switch in the ON position to make this function work with out physically having to go back to the front-end computer to change a setpoint via the computer.

Addressing (Numbering) of the TUC/ RTU Controllers that are Connected to the SA T 3C

There can be up to a total of eight TUC-5R/5R+/5RX/RTU17 controllers connected together on a local TUC RS-485 communication loop to the SAT 3C controller. The software that is written for each TUC/RTU controller is application speciﬁ c, and must also be written for use with the WCC III system. In order for the SAT 3C to communicate properly with each individual TUC/RTU, each TUC/RTU must be assigned a separate address (number) from 1 to 8. This addressing or numbering is assigned by positioning the small dipswitch on each of the TUC/RTU boards in the proper position. The address switches are housed together in a block as shown below:

When the switch is in the “On” position, it represents the number on the right in the drawing below. That is, when switch #3 is “On” and all of the other switches are “Off,” the TUC is named #4. The switches are additive. That is to say, when switches 1 and 2 are “On,” the TUC is named #3.

Figure 12-42: RTU/TUC addressing when connected to a SAT 3C Controller

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12. WCC III INSTALLATION

RTU-17 Controller

Figure 12-43: RTU-17 Controller

The RTU-17 controller is an application-speciﬁ c controller. Please see the application speciﬁ c manual for the exact input and output conﬁ guration for the speciﬁ c application that you are controlling. This RTU-17 controller is generally used to control Roof Top Units, hence the name RTU. The number -17 derives from the fact that there are a total combination of seventeen inputs and outputs on this circuit board. Common applications of this controller are as follows: RTU / AHU control, standalone limited schedule controller, standalone Lighting controller, etc. WattMaster

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Controls has an extensive standard library of application-speciﬁ c software that has been developed over the years for this RTU-17 controller. WattMaster Controls can and will write applicationspeciﬁ c software to your written speciﬁ cations, for a nominal cost. This is usually done to satisfy a speciﬁ c customer requirement.

The jumpers JO2 “C”, “B”, and “A” must be off for RS-485 communication connections to the SAT 3C controller.

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12. WCC III INSTALLATION GUIDE

TUC-5R Controller - Older Version

Figure 12-44: TUC-5R Controller – early version

There are 4 versions of the TUC-5R type controller, three of which are still currently supported. The older voltage TUC-5R controller is not supported anymore, and an upgraded replacement is recommended. The older voltage TUC-5R controller is not pictured here.

The early TUC-5R controller is an application-speciﬁ c controller. Please see the application-speciﬁ c manual for the exact input and output conﬁ guration for the speciﬁ c application that you are controlling. This early TUC-5R controller is generally used to control small Roof Top Units, heat pump units, or complicated

WCC III Technical Guide

VAV box control. The number -5R derives from the fact that there are a total of 5 relay outputs on this circuit board. Typical common applications of this TUC-5R controller are as follows: Roof Top Units with up to 2 heat and 2 cool stages, heat pump units, or complicated VAV box control such as hot duct, cold duct applications, etc. WattMaster Controls has an extensive standard library of application-speciﬁ c software that has been developed over the years for this TUC-5R controller. WattMaster Controls can and will write application-speciﬁ c software to your written speciﬁ cations, for a nominal cost. This is usually done to satisfy a speciﬁ c customer requirement.

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12. WCC III INSTALLATION

TUC-5R Controller - Current V ersion

Figure 12-45: TUC 5R+ Controller – current version

The current TUC-5R+ controller is an application-speciﬁ c controller. Please see the application-speciﬁ c manual for the exact input and output conﬁ guration for the speciﬁ c application that you are controlling. This current TUC-5R+ controller is generally used to control small Roof Top Units, heat pump units, or complicated VAV box controls. The number -5R+ derives from the fact that there are a total of 5 relay outputs on this circuit board, and the plus signiﬁ es that there are extra analog inputs and analog outputs that can also be used if necessary for the application. Also included on

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the TUC-5R+ is the expansion port for additional input and output control. Typical common applications of this TUC-5R+ controller are as follows: Roof Top Units with up to 2 heat, and 2 cool stages, heat pump units, or complicated VAV box control such as hot duct, cold duct applications, etc. WattMaster Controls has an extensive standard library of application-speciﬁ c software that has been developed over the years for this TUC-5R+ controller. WattMaster Controls can and will write application-speciﬁ c software to your written speciﬁ cations, for a nominal cost. This is usually done to satisfy a speciﬁ c customer requirement.

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12. WCC III INSTALLATION GUIDE

SA T 3D Controller

SA T 3D – WCC III Interface to TUC/ RTU Controllers (SS5005)

The system architecture for the WCC III system interfacing with the TUC controllers through the SAT 3D is described below:

The SAT 3D - General Information

The SAT 3D Controller has 8 status lights. The functions of these LEDs are listed below.

SAT REC - This LED will be lit when communications are being received by the SAT 3D Controller.

SAT XMIT - This LED will be lit when communications are being transmitted by the SAT 3D Controller.

TUC REC - This LED will be lit when communications are being received from the TUC RS-485 Communications Loop.

TUC XMIT - This LED will be lit when communications are being transmitted to the TUC RS-485 Communications Loop.

LOCAL SET - This LED will be lit when no communications with the WCC III-MCD has occurred in at least the last 2 minutes. This means that this SAT 3D communications loop is not communicating with the WCC III-MCD. All standalone setpoint control is dependent on the LOCAL SET parameters that are programmed into the SAT 3D controller by the user.

SA T 3D Controller — Connections points

All of the external SAT 3D connection points are single-tab ¼inch Sta-Con connectors. With the exception of the TUC RS485 communications connection which is a three-position, depluggable terminal block.

24VA C & GND Connection

Located on the bottom side of the SAT 3D controller is a 24 VAC and GND connection. This is the main power connection to the SAT 3D controller. Each SAT 3D Controller draws - 10VA. The GND connection points must be the same between the all of the externally powered TUC boards and the SAT 3D Controller.

SAT Communica tion Connection

These connection points are for wiring of the SAT RS-485 communication loop. There are two “T” (Transmit) connections, two “R” (Receive) connections and two “SHIELD” connection points. There are two connection points provided for each connection for easy “daisy chaining” to the next Satellite Controller. When connecting the RS-485 wiring from SAT III to SAT III or SAT 3C/D/F, or SAT 3P controller the wiring connections are as follows: connect “R” TO “R”, “T” TO “T”, AND “SHIELD” TO “SHIELD” OR “SH”. The RS-485 wire speciﬁ cations are plenum- rated jacketed stranded 18-gauge, 2 wire twisted pair with shield. 18-gauge stranded wire is mandatory to ensure a good connection with the ¼-inch Sta-Con connectors that are used to terminate the wires at the WCC III - MCD and at the satellite controllers.

STATUS - This LED blinks for every second if SAT 3D is alive.

“C” MODE - This LED blinks for every second during power on delay and blinks every 8 seconds when watchdog is enabled.

“D” MODE - This LED will be lit if this Controller is programmed as a SAT 3D and blinks for every internal calculation loop completion.

SAT ADDRESS DIPSWITCH - There are two dipswitches on the cover of the SAT 3D controller, one dipswitch sets the address of the SAT 3D controller, and the other dipswitch sets various local control options.

TUC Communication Connection

These connection points are for wiring of the TUC RS-485 communication loop. There is a single, three-position, de-pluggable terminal block. Connect the wiring for the communications connections between the TUC/RTU’s are as follows: “R” TO “R”, “T” TO “T”, AND “SHLD” TO “SHLD” OR “SH”. Connect the wiring from TUC/RTU controller to TUC/RTU controller. But, on the SAT 3C/D/F controller the TUC “R” connection must be wired to the SAT 3C/D/F “T” connection, and the SAT 3C/D/F controller “R” connection must be wired to the TUC “T” connection. The RS-485 wire speciﬁ cations are a plenum-rated jacketed stranded 18-gauge, 2- wire twisted pair with shield. 18-gauge stranded wire is mandatory to ensure a good connection between TUC/RTU controllers.

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12. WCC III INSTALLATION

SA T 3D Addressing

Addressing the SAT3D

Figure 12-46: SAT 3D Address Switch location

The address dip switches are additive; that is to say placing switches 4 and 5 in the ON position will cause the SAT 3D controller to be identiﬁ ed as satellite controller number 24. The SAT 3D controller looks at the position of these switches only when it is going through its initialization process after being powered up. Simply changing the switch positions on a SAT 3D controller that is presently “online” will not change its address number. The switches need to be placed in the proper position before powering up the SAT 3D controller, or the SAT 3D must be powered down and then back up for the SAT 3D to “read” the new position of the switches. When placing the switches in the desired position, make sure the switch has “clicked” into place and is properly seated.

There can be up to 59 SAT 3D controllers connected together on a 2-wire communication loop. In order for the WCC III system to communicate properly with each SAT 3D, each SAT 3D must be assigned a separate address number. The number is assigned by positioning the small address dipswitch on the front of the SAT 3D in the proper position.

The SAT 3D uses up to 4 satellite addresses locations. The lowest possible address is #4. The address must start in multiples of 4, starting at address # 4, then the next available address is #8, then next available address is #12, then next available address is #16, then next available address is 20, then next available address is 24, then next available address is 28, etc. The only legitimate SAT 3D addresses are 4, 8, 12, 16, 20, 24, 28, 32, 36, 40, 44, 48, 52, 56, 60, 64, 68, 72, 76, 80, 84, 88, 92, 96, 100, 104, 108, 112, 116, 120, 124, 128, 132, 136, 140, 144, 148, 152, 156, 160, 164, 168, 172, 176, 180, 184, 188, 192, 196, 200, 204, 208, 212, 216, 220, 224, 228, 232, and 236.

For example the following Satellite Addresses will not work as a SAT 3D starting address: 1, 2, 3, 5, 6, 7, 9, 10, 11, 13, 14, 15, 17, 18, 19, 21, 22, 23, 25, 26, 27, 29, 30, 31, 33, 34, 35, 37, 38, 39, 41, 42, 43, 45, 46, 47, 49, 50, 51, 53, 54, 55, 57, 58, 59, 61, 62, 63, 65, 66, 67, 69, 70, 71,73, 74, 75, 77, 78, 79, 81, 82, 83, 85, 86, 87, 89, 90, 91, 93, 94, 95, 97, 98, 99, 101, 102, 103, 105, 106, 107, 109, 110, 111, 113, 114, 115, 117, 118, 119, 121, 122, 123, 125, 126, 127, 129, 130, 131, 133, 134, 135, 137, 138, 139, 141, 142, 143, 145, 146, 147, 149, 150, 151, 153, 154, 155, 157, 158, 159, 161, 162, 163, 165, 166, 167, 169, 170, 171, 173, 174, 175, 177, 178, 179, 181, 182, 183, 185, 186, 187, 189, 190, 191, 193, 194, 195, 197, 198, 199, 201, 202, 203, 205, 206, 207, 209, 210, 211, 213, 214, 215, 217, 218, 219, 221, 222, 223, 225, 226, 227, 229, 230, 231, 233, 234, 235, 237, 238, 239, and 240.

Care must be taken to ensure that two SAT 3D controllers do not have the same address. When this condition is present, the central computer (WCC III – MCD) does not know where to send the information, and the information which should be sent to the SAT 3D controller is then usually lost.

You should be aware of the symptoms that are caused by two satellite controllers having the same number. Let’s consider a new job in which the satellite controllers have not yet been programmed and 2 SAT 3D controllers are named number #8. When you call up satellite controller #8 to enter data, everything will appear to be ﬁ ne. You will be able to enter data on the screens as if nothing is wrong. However, when you leave a screen and then return to the same screen, all of the data you entered will be missing. Also, if you ﬁ nish programming the analog inputs for example, and then go to the analog input summary screen to review your inputs, all of the data you have entered will be missing.

Another situation which you might encounter is adding a SAT 3D controller to an existing system and accidentally giving it the same number as a SAT 3D presently “on-line.” Again, when you begin to program the new SAT 3D controller, everything will appear ﬁ ne until you leave a screen or if you go to a summary screen. Only now, all of the data is usually not missing. Generally, you get parts of your data back and parts will be missing.

If you suspect you might have two SAT 3D controllers with the same address, number 8 for example, the best thing to do is go to the SAT 3D controller that you know is number 8, and remove the 2-wire RS-485 communication loop from it. Then go back to the computer and call up satellite controller #8. If the computer can still “talk” to satellite controller #8, then there is another satellite controller that is addressed #8 connected somewhere on the RS485 communication loop.

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12. WCC III INSTALLATION GUIDE

SA T 3D Addressing

“on-line” is to go to the Satellite Summary Screen (see Section

3) and see which satellite controllers the computer recognizes as

being “on-line.”

The Other Dipswitch on the SAT 3D

Option 1, 2, and 3 Switches

For the SAT 3D these Options switches do nothing, but on the SAT III controller the option 1 switch selects the A to D converter type that is on the mother board. With the switch turned OFF, the A-to-D curve is selected for the Maxim MAX147 part and with the switch turned “ON” for the TI-ADS7844 (BB marked), the software will use the special A-to-D curve for the TI-ADS7844 part.

BA TT ON/OFF s witc h

This switch is used to turn the Battery (Rechargeable Super cap) ON and OFF to the SRAM located inside of the SAT 3D.

Local Set Switch

When the LOCAL dipswitch is in the ON position, the TUC controllers will operate according to their predeﬁ ned user programmed “local set” setpoints. That is, if the TUC controllers were programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected, but the SAT 3D controller is still present and communicating with the TUC controllers.

Local Set Disable Switch

When the LOCAL SET DIS dipswitch is in the ON position, the TUC controllers will operate according to their predeﬁ ned user programmed “On” setpoints. That is, if the TUC/RTU controllers were programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected, but the SAT 3D controller is still present and communicating with the TUC controllers.

Test Switc h

The test mode is active only if the TEST dipswitch is in the ON position. The word “TEST” can be input as the binary value within the SAT 3D. Example of use would be if the user programmed the word “TEST” into one of the control point values in the TUC controller to check the operation of the TUC controllers with an alternate setpoint or schedule, the user could then place the TEST switch in the ON position to make this function work without physically having to go back to the front-end computer to change a setpoint via the computer.

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TUC Controllers to SAT 3D Addressing

Addressing (Numbering) of the TUC controllers that are connected to the SAT 3D

There can be up to a total of thirty-two TUC-2R or TUC5R/5R+/5RX controllers connected together on a local TUC RS485 communication loop to the SAT 3D controller. The software that is written for each TUC controller is application-speciﬁ c, and must also be written for use with the WCC III system. In order for the SAT 3D to communicate properly with each individual TUC, each TUC must be assigned a separate address (number) from 1 to

32. This addressing or numbering is assigned by positioning the small dipswitch on each of the TUC boards in the proper position. The address switches are housed together in a block as shown in Figure 12-46.

Figure 12-47: TUC-2R Addressing

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12. WCC III INSTALLATION GUIDE

TUC Controllers to SAT 3D Addressing

How to Address TUC-2R and TUC-5R when connecting them to a Sat 3D

Each SAT 3d physically takes up 4 plain Sat III addresses. You can not set the SAT 3d address to an address less than #4.

TUC Addressing when Connected to a SA T 3D

TUC address #1 is equal to the ﬁ rst SAT 3d address, and analog input #1 is the Space Temperature on TUC #1

TUC address #2 is equal to the ﬁ rst SAT 3d address, and analog input #2 is the Space Temperature on TUC #2

TUC address #3 is equal to the ﬁ rst SAT 3d address, and analog input #3 is the Space Temperature on TUC #3

TUC address #4 is equal to the ﬁ rst SAT 3d address, and analog input #4 is the Space Temperature on TUC #4

TUC address #5 is equal to the ﬁ rst SAT 3d address, and analog input #5 is the Space Temperature on TUC #5

TUC address #6 is equal to the ﬁ rst SAT 3d address, and analog input #6 is the Space Temperature on TUC #6

TUC address #7 is equal to the ﬁ rst SAT 3d address, and analog input #7 is the Space Temperature on TUC #7

TUC address #8 is equal to the ﬁ rst SAT 3d address, and analog input #8 is the Space Temperature on TUC #8

TUC address #9 is equal to the second SAT 3d address, and analog input #1 is the Space Temperature on TUC #9

TUC address #10 is equal to the second SAT 3d address, and analog input #2 is the Space Temperature on TUC #10

TUC address #11 is equal to the second SAT 3d address, and analog input #3 is the Space Temperature on TUC #11

TUC address #12 is equal to the second SAT 3d address, and analog input #4 is the Space Temperature on TUC #12

TUC address #13 is equal to the second SAT 3d address, and analog input #5 is the Space Temperature on TUC #13

TUC address #14 is equal to the second SAT 3d address, and analog input #6 is the Space Temperature on TUC #14

TUC address #15 is equal to the second SAT 3d address, and analog input #7 is the Space Temperature on TUC #15

TUC address #16 is equal to the second SAT 3d address, and analog input #8 is the Space Temperature on TUC #16

TUC address #17 is equal to the third SAT 3d address, and analog input #1 is the Space Temperature on TUC #17

TUC address #18 is equal to the third SAT 3d address, and analog input #2 is the Space Temperature on TUC #18

TUC address #19 is equal to the third SAT 3d address, and analog input #3 is the Space Temperature on TUC #19

TUC address #20 is equal to the third SAT 3d address, and analog input #4 is the Space Temperature on TUC #20

TUC address #21 is equal to the third SAT 3d address, and analog input #5 is the Space Temperature on TUC #21

TUC address #22 is equal to the third SAT 3d address, and analog input #6 is the Space Temperature on TUC #22

TUC address #23 is equal to the third SAT 3d address, and analog input #7 is the Space Temperature on TUC #23

TUC address #24 is equal to the third SAT 3d address, and analog input #8 is the Space Temperature on TUC #24

TUC address #25 is equal to the fourth SAT 3d address, and analog input #1 is the Space Temperature on TUC #25

TUC address #26 is equal to the fourth SAT 3d address, and analog input #2 is the Space Temperature on TUC #26

TUC address #27 is equal to the fourth SAT 3d address, and analog input #3 is the Space Temperature on TUC #27

TUC address #28 is equal to the fourth SAT 3d address, and analog input #4 is the Space Temperature on TUC #28

TUC address #29 is equal to the fourth SAT 3d address, and analog input #5 is the Space Temperature on TUC #29

TUC address #30 is equal to the fourth SAT 3d address, and analog input #6 is the Space Temperature on TUC #30

TUC address #31 is equal to the fourth SAT 3d address, and analog input #7 is the Space Temperature on TUC #31

TUC address #32 is equal to the fourth SAT 3d address, and analog input #8 is the Space Temperature on TUC #32

TUC Address #32 should not be used, but is listed as reference only.

WCC III Technical Guide

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12. WCC III INSTALLATION

SA T 3F Controller

SA T 3F – WCC III Interface to TUC/ V AVZ II Controllers (SS5016)

The system architecture for the WCC III system interfacing with the TUC controllers through the SAT 3F is described below:

The SAT 3F - General Information

The SAT 3F Controller has 8 status lights. The functions of these LEDs are listed below.

SAT REC - This LED will be lit when communications are being received by the SAT 3F Controller.

SAT XMIT - This LED will be lit when communications are being transmitted by the SAT 3F Controller.

TUC REC - This LED will be lit when communications are being received from the TUC RS-485 Communications Loop.

TUC XMIT - This LED will be lit when communications are being transmitted to the TUC RS-485 Communications Loop.

LOCAL SET - This LED will be lit when no communications with the WCC III - MCD has occurred in at least the last 2 minutes. This means that this SAT 3F communications loop is not communicating with the WCC III - MCD. All standalone setpoint control is dependent on the LOCAL SET parameters that are programmed into the SAT 3F controller by the user.

SA T 3F Controller — Connections points

All of the external SAT 3F connection points are single-tab ¼inch Sta-Con connectors. With the exception of the TUC RS485 communications connection which is a three-position, depluggable terminal block.

24VA C & GND Connection

Located on the bottom side of the SAT 3F controller is a 24 VAC and GND connection. This is the main power connection to the SAT 3F controller. Each SAT 3F Controller draws - 10VA. The GND connection points must be the same between the all of the externally powered TUC boards and the SAT 3F Controller.

SAT Communica tion Connection

STATUS - This LED blinks for every second if SAT 3F is alive.

“C” MODE - This LED blinks for every second during power on delay and blinks every 8 seconds when watchdog is enabled.

“D” MODE - This LED will be lit if this Controller is programmed as a SAT 3F and blinks for every internal calculation loop completion.

SAT ADDRESS DIPSWITCH - There are two dipswitches on the cover of the SAT 3F controller, one dipswitch sets the address of the SAT 3F controller, and the other dipswitch sets various local control options.

TUC Communication Connection

These connection points are for wiring of the TUC RS-485 communication loop. There is a single, three-position, de-pluggable terminal block. Connect the wiring for the communications connections between the TUC/VAVZ II’s are as follows: “R” TO “R”, “T” TO “T”, AND “SHLD” TO “SHLD” OR “SH”. Connect the wiring from TUC/VAVZ II controller to TUC/VAVZ II controller. But, on the SAT 3C/D/F controller the TUC “R” connection must be wired to the SAT 3C/D/F “T” connection, and the SAT 3C/D/F controller “R” connection must be wired to the TUC “T” connection. The RS-485 wire speciﬁ cations are a plenum-rated jacketed stranded 18-gauge, 2- wire twisted pair with shield. 18-gauge stranded wire is mandatory to ensure a good connection between TUC/VAVZ II controllers.

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12. WCC III INSTALLATION GUIDE

SA T 3F Addressing

Addressing the SAT3F

Figure 12-48: SAT 3F Address Switch location

The address dip switches are additive; that is to say placing switches 4 and 5 in the ON position will cause the SAT 3F controller to be identiﬁ ed as satellite controller number 24. The SAT 3F controller looks at the position of these switches only when it is going through its initialization process after being powered up. Simply changing the switch positions on a SAT 3F controller that is presently “online” will not change its address number. The switches need to be placed in the proper position before powering up the SAT 3F controller, or the SAT 3F must be powered down and then back up for the SAT 3F to “read” the new position of the switches. When placing the switches in the desired position, make sure the switch has “clicked” into place and is properly seated.

For example the following Satellite Addresses will not work as a SAT 3F starting address: 1, 2, 3, 5, 6, 7, 9, 10, 11, 13, 14, 15, 17, 18, 19, 21, 22, 23, 25, 26, 27, 29, 30, 31, 33, 34, 35, 37, 38, 39, 41, 42, 43, 45, 46, 47, 49, 50, 51, 53, 54, 55, 57, 58, 59, 61, 62, 63, 65, 66, 67, 69, 70, 71,73, 74, 75, 77, 78, 79, 81, 82, 83, 85, 86, 87, 89, 90, 91, 93, 94, 95, 97, 98, 99, 101, 102, 103, 105, 106, 107, 109, 110, 111, 113, 114, 115, 117, 118, 119, 121, 122, 123, 125, 126, 127, 129, 130, 131, 133, 134, 135, 137, 138, 139, 141, 142, 143, 145, 146, 147, 149, 150, 151, 153, 154, 155, 157, 158, 159, 161, 162, 163, 165, 166, 167, 169, 170, 171, 173, 174, 175, 177, 178, 179, 181, 182, 183, 185, 186, 187, 189, 190, 191, 193, 194, 195, 197, 198, 199, 201, 202, 203, 205, 206, 207, 209, 210, 211, 213, 214, 215, 217, 218, 219, 221, 222, 223, 225, 226, 227, 229, 230, 231, 233, 234, 235, 237, 238, 239, and 240.

Care must be taken to ensure that two SAT 3F controllers do not have the same address. When this condition is present, the central computer (WCC III – MCD) does not know where to send the information, and the information which should be sent to the SAT 3F controller is then usually lost.

You should be aware of the symptoms that are caused by two satellite controllers having the same number. Let’s consider a new job in which the satellite controllers have not yet been programmed and 2 SAT 3F controllers are named number #8. When you call up satellite controller #8 to enter data, everything will appear to be ﬁ ne. You will be able to enter data on the screens as if nothing is wrong. However, when you leave a screen and then return to the same screen, all of the data you entered will be missing. Also, if you ﬁ nish programming the analog inputs for example, and then go to the analog input summary screen to review your inputs, all of the data you have entered will be missing.

There can be up to 59 SAT 3F controllers connected together on a 2-wire communication loop. In order for the WCC III system to communicate properly with each SAT 3F, each SAT 3F must be assigned a separate address number. The number is assigned by positioning the small address dipswitch on the front of the SAT 3F in the proper position.

The SAT 3F uses up to 4 satellite addresses locations. The lowest possible address is #4. The address must start in multiples of 4, starting at address # 4, then the next available address is #8, then next available address is #12, then next available address is #16, then next available address is 20, then next available address is 24, then next available address is 28, etc. The only legitimate SAT 3F addresses are 4, 8, 12, 16, 20, 24, 28, 32, 36, 40, 44, 48, 52, 56, 60, 64, 68, 72, 76, 80, 84, 88, 92, 96, 100, 104, 108, 112, 116, 120, 124, 128, 132, 136, 140, 144, 148, 152, 156, 160, 164, 168, 172, 176, 180, 184, 188, 192, 196, 200, 204, 208, 212, 216, 220, 224, 228, 232, and 236.

WCC III Technical Guide

Another situation which you might encounter is adding a SAT 3F controller to an existing system and accidentally giving it the same number as a SAT 3F presently “on-line.” Again, when you begin to program the new SAT 3F controller, everything will appear ﬁ ne until you leave a screen or if you go to a summary screen. Only now, all of the data is usually not missing. Generally, you get parts of your data back and parts will be missing.

If you suspect you might have two SAT 3F controllers with the same address, number 8 for example, the best thing to do is go to the SAT 3F controller that you know is number 8, and remove the 2-wire RS-485 communication loop from it. Then go back to the computer and call up satellite controller #8. If the computer can still “talk” to satellite controller #8, then there is another satellite controller that is addressed #8 connected somewhere on the RS485 communication loop.

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12. WCC III INSTALLATION

SA T 3F Controller

“on-line” is to go to the Satellite Summary Screen (see Section

3) and see which satellite controllers the computer recognizes as

being “on-line.”

The Other Dipswitch on the SAT 3F

Option 1, 2, and 3 Switches

For the SAT 3F these Options switches do nothing, but on the SAT III controller the option 1 switch selects the A to D converter type that is on the mother board. With the switch turned OFF, the A-to-D curve is selected for the Maxim MAX147 part and with the switch turned “ON” for the TI-ADS7844 (BB marked), the software will use the special A-to-D curve for the TI-ADS7844 part.

BA TT ON/OFF s witc h

This switch is used to turn the Battery (Rechargeable Super cap) ON and OFF to the SRAM located inside of the SAT 3F.

Local Set Switch

When the LOCAL dipswitch is in the ON position, the TUC controllers will operate according to their predeﬁ ned user programmed “local set” setpoints. That is, if the TUC controllers were programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected, but the SAT 3F controller is still present and communicating with the TUC controllers.

Local Set Disable Switch

When the LOCAL SET DIS dipswitch is in the ON position, the TUC controllers will operate according to their predeﬁ ned user programmed “On” setpoints. That is, if the TUC/VAVZ II controllers were programmed by the user to correctly operate when and if the WCC III - MCD is off-line or disconnected, but the SAT 3F controller is still present and communicating with the TUC controllers.

Test Switc h

The test mode is active only if the TEST dipswitch is in the ON position. The word “TEST” can be input as the binary value within the SAT 3F. Example of use would be if the user programmed the word “TEST” into one of the control point values in the TUC controller to check the operation of the TUC controllers with an alternate setpoint or schedule, the user could then place the TEST switch in the ON position to make this function work without physically having to go back to the front-end computer to change a setpoint via the computer.

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12. WCC III INSTALLATION GUIDE

SA T 3F Addressing

Addressing (Numbering) of the TUC controllers that are connected to the SAT 3F

There can be up to a total of sixteen VAVZ II controllers connected together on a local TUC RS-485 communication loop to the SAT 3F controller. The software that is written for each TUC/VAVZ II controller is application-speciﬁ c, and must also be written for use with the WCC III system. In order for the SAT 3F to communicate properly with each individual TUC/VAVZ II, each TUC/VAVZ II must be assigned a separate address (number) from 1 to 16. This addressing or numbering is assigned by positioning the small dipswitch on each of the TUC/VAVZ II boards in the proper position. The address switches are housed together in a block as shown in Figure 12-48.

When the switch is in the “On” position, it represents the number on the right in the above drawing. That is, when switch #3 is “On” and all of the other switches are “Off,” the TUC/VAVZ II is named #4. The switches are additive. That is to say, when switches 1 and 2 are “On,” the TUC/VAVZ II is named #3.

Figure 12-49: VA VZ II Addressing

WCC III Technical Guide

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12. WCC III INSTALLATION

V AVZ II Addressing to SA T 3F Controller

How to Address V AVZ II when connecting them to a Sat 3F

Each SAT 3F physically takes up 4 plain Sat III addresses. You can not set the SAT 3F address to an address less than #4.

TUC/V AVZ Addressing when Connected to a SA T 3F

TUC/VAVZ address #1 is equal to the ﬁ rst SAT 3F address, and analog input #1 is the Space Temperature on TUC/VAVZ #1

TUC/VAVZ address #2 is equal to the ﬁ rst SAT 3F address, and analog input #3 is the Space Temperature on TUC/VAVZ #2

TUC/VAVZ address #3 is equal to the ﬁ rst SAT 3F address, and analog input #5 is the Space Temperature on TUC/VAVZ #3

TUC/VAVZ address #4 is equal to the ﬁ rst SAT 3F address, and analog input #7 is the Space Temperature on TUC/VAVZ #4

TUC/VAVZ address #5 is equal to the second SAT 3F address, and analog input #1 is the Space Temperature on TUC/VAVZ #5

TUC/VAVZ address #6 is equal to the second SAT 3F address, and analog input #3 is the Space Temperature on TUC/VAVZ #6

TUC/VAVZ address #9 is equal to the third SAT 3F address, and analog input #1 is the Space Temperature on TUC/VAVZ #9

TUC/VAVZ address #10 is equal to the third SAT 3F address, and analog input #3 is the Space Temperature on TUC/VAVZ #10

TUC/VAVZ address #11 is equal to the third SAT 3F address, and analog input #5 is the Space Temperature on TUC/VAVZ #11

TUC/VAVZ address #12 is equal to the third SAT 3F address, and analog input #7 is the Space Temperature on TUC/VAVZ #12

TUC/VAVZ address #13 is equal to the fourth SAT 3F address, and analog input #1 is the Space Temperature on TUC/VAVZ #13

TUC/VAVZ address #14 is equal to the fourth SAT 3F address, and analog input #3 is the Space Temperature on TUC/VAVZ #14

TUC/VAVZ address #15 is equal to the fourth SAT 3F address, and analog input #5 is the Space Temperature on TUC/VAVZ #15

TUC/VAVZ address #16 is equal to the fourth SAT 3F address, and analog input #7 is the Space Temperature on TUC/VAVZ #16

TUC/VAVZ address #7 is equal to the second SAT 3F address, and analog input #5 is the Space Temperature on TUC/VAVZ #7

TUC/VAVZ address #8 is equal to the second SAT 3F address, and analog input #7 is the Space Temperature on TUC/VAVZ #8

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WCC III Technical Guide

12. WCC III INSTALLATION

G5L-114P-PS 24VDC CONTACT: UL / CSA 5A250VAC

OMRON

WARNING

OBSERVE

POLARITY

OE320

G5L-114P-PS

24VDC

CONTACT:

UL / CSA 5A250VAC

OMRON

G5L-114P-PS

24VDC

CONTACT:

UL / CSA 5A250VAC

OMRON

G5L-114P-PS

24VDC

CONTACT:

UL / CSA 5A25 0VAC

OMRON

G5L-114P-PS

24VDC

CONTACT:

UL / CSA 5A250VAC

OE321

GUIDE

TUC-2R and Four R elay Expansion Board

Figure 12-50: TUC-2R Controller – Current version

The current TUC-2R controller is an application-speciﬁ c controller. Please see the application-speciﬁ c manual for the exact input and output conﬁ guration for the speciﬁ c application that you are controlling. This current TUC-2R controller is generally used to control only VAV box control. The number -2R derives from the fact that there are a total of 2 relay outputs on this circuit board. Also included on the TUC-2R is the expansion port for additional input and output control. Typical common applications of this TUC-2R controller are as follows: complicated VAV box control such as series/parallel fan-powered boxes with reheat and both pressure dependent or pressure independent operations. WattMaster Controls has an extensive standard library of application-speciﬁ c software that has been developed over the years for this TUC-2R controller. WattMaster Controls can and will write applicationspeciﬁ c software to your written speciﬁ cations, for a nominal cost. This is usually done to satisfy a speciﬁ c customer requirement.

WCC III Technical Guide

Figure 12-51: The OE321 Four Relay Expansion Board

This Four Relay Expansion Board uses an 8-position modular plug to connect to the TUC-2R controller.

The Four Relay Expansion Board is an expansion board for the TUC-2R controller. It provides a means to add 4 additional output relays to the TUC-2R controller. Again, control of these relays is application speciﬁ c, meaning that the software code in the TUC- 2R must have been written to support the Four Relay Expansion Board. This board is typically used to control pilot duty relays that control Series Fan, Parallel Fan, up to 2 stages of Box heat, and external Strip Heat.

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12. WCC III INSTALLATION

G5L-114P-PS

24VDC

CONTACT:

UL / CSA 5A250VAC

OMRON

G5L-114P-PS

24VDC

CONTACT:

UL / CSA 5A250VAC

G5L-114P-PS

24VDC

CONTACT:

UL / CSA 5A250VAC

OMRON

OE322

OE282 HZ000095

TUC-2R Three Relay Expansion Board and Damper Actuator

Figure 12-52: The OE322 Three Relay Expansion Board

This Three Relay Expansion Board uses an 8-position modular plug to connect to the TUC-2R controller.

The Three Relay Expansion Board is an expansion board for the TUC-2R controller. It provides a means to add 3 additional output relays to the TUC-2R controller. Again, control of these relays is application speciﬁ c, meaning that the software code in the TUC- 2R must have been written to support the Three Relay Expansion Board. This board is typically used to control pilot duty relays that control Series Fan, Parallel Fan, up to 2 stages of Box heat, and external Strip Heat. This 3 Relay output board also has a 0-to10 volt DC analog output for control of an external valve, for hot water/chilled water control.

Figure 12-53: Damper Actuator – with the connection cable to connect to the TUC-2R Controller

This Damper Actuator uses a 6-position modular plug to connect to the TUC-2R controller. Control of 60 Degree or 90 Degree dampers is supported on the TUC-2R controller with this actuator.

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WCC III Technical Guide

Red

Green

Black

(-)LO

GND

RANGE: 0-1" WC

2631001WD4MZZCWM1

setra

OUT

Output: .25 - 4.25 VDC

Exc: 5 VDC

S/N: 2801 3635

OE273

Figure 12-54: The OE273 Velocity Sensor for the TUC-2R Controller

12. WCC III INSTALLATION GUIDE

TUC-2R V elocity Sensor

This Damper actuator uses a 4-position handset modular plug to connect to the TUC-2R controller. Very accurate control of pressure independent VAV boxes is supported on the TUC-2R controller with this velocity sensor.

WCC III Technical Guide

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12. WCC III INSTALLATION

Running the WCC3 Program

How to Start or Run the WCC3.exe Program (SS5021)

The WCC3.exe shortcut icon should have been installed on your WCC III Front end computer desktop with the WCC III Installation Software CD. The WCC III Installation Software CD is WattMaster Controls Part # DM1WC011-01X.

To start the WCC3.exe program, double-click the left mouse button on the Shortcut Icon on the Windows desktop.

After a short period of time, dependent upon the CPU speed of your Windows based computer and the speed of your IP connection to the internet, the WCC III T ype Connection Dialog Box will appear.

Server IP Address:

This is the static IP address of the WCC III – MCD. An IP Address is like a phone number on the world wide web. The IP address for the WCC III – MCD must be Static (does not change) as opposed to Dynamic (constantly changing). This static IP address must be provided by your internet service provider. (A static IP address is the preferred IP connection method for the WCC III system to function.) If you actually know the static IP address of the WCC III – MCD that you wish to connect to, please enter it here in the Server IP Address ﬁ eld, or better yet, continue to the Remote Access Dialog Window by selecting the

You can use a Dynamic IP Address with the WCC III – MCD, but you must then have what is called a static “Host Name”. This static “Host name” must then be provided by your internet service provider and is limited to 58 total characters.

Port Number:

The WCC3.exe program opens a two-way, secure communications port that then allows for communication between WCC III – MCD and the WCC3.exe program that is running on the WCC III Front end computer. This IP Address connection is done on a higher address port number than normal (WCC III connection is port number 39289) to help reduce the risk of computer hacking.

Using your mouse, please left-click on the button. The Remote Access Dialog Window will appear.

<Access Job Site> button.

By selecting connect to the selected WCC III – MCD via this selected IP address connection. It should bring up the WCC III Set Password Dialog Screen within a new window. If the IP address connection fails to connect to the WCC III – MCD, then another small dialog box window will appear. This is the Cannot Communicate to Backtask Dialog Box.

If you click <Yes>, you will exit the WCC3.exe program. You will have to ﬁ gure out why you cannot connect to the WCC III – MCD via the IP address connection.

If you click but instead you will be connected to the WCC III Main Menu. This connection to the WCC III Main Menu is not an actual IP connection, but rather a “dummy” WCC III main menu screen window with no values. This “dummy” WCC III main menu screen window will allow you to view and see what the actual WCC3.exe screens will look like – minus any data.

In the Set Password Dialog Screen, enter an “Operator:” identiﬁ cation and a “Code:” or password equal to at least a pass level 0 that has been previously set up on the WCCIII System Parameter – Operator Code Screen. (See the Operator Code Screen of the System Parameter Screen in Section 3 for information on setting up Operator Codes.) Click “Current Pass Level:” stays at 0 or higher (1, 2, or 3), and then click

<OK>. By selecting <OK>, the WCC3.exe program will now

start to connect to the selected WCC III – MCD via this selected IP address connection. It should bring up the WCC III Main Menu Screen within a new window. If the “Current Pass Level:” changes to –1, then you do not have access to the WCCIII – MCD. If you do not have access to the WCCIII – MCD and you click then this connection to the WCC III Main Menu is not an actual IP connection, but rather a “dummy” WCC III main menu screen window with no values. This “dummy” WCC III main menu screen window will allow you to view and see what the actual WCC3.exe screens will look like – minus any data.

<OK>, the WCC3.exe program will now start to

<No>, you will not exit the WCC3.exe program,

<Check Password>, if the

<OK>

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12. WCC III INSTALLATION GUIDE

Running the WCC3 Program

III front end computers. This reused JobSite.dat will then recreate the needed “Job Site” subdirectories on the other WCC III front end computers upon the reselection of the Job Site IP address.

In an already ﬁ lled out Remote Access Dialog Box, you can simply select from the list of previously entered Job Sites that are displayed in the bottom box ﬁ eld. Then left-click back to the Connection Dialog Box that was ﬁ rst displayed. This Connection Dialog Box now should have the desired IP address in the Server IP Address location ﬁ eld and the port number (39289) in the Port Number location ﬁ eld for the WCC III – MCD that you wish to connect to with the WCC3.exe program.

IP Address:

This is the static IP address where the WCC III – MCD is located. An IP Address is like a phone number on the world wide web. The IP address for the WCC III – MCD must be static (does not change) as opposed to Dynamic (constantly changing). This static IP Address must be provided by your internet service provider. (A static IP address is the preferred IP connection method for the WCC III system to function.)

<OK>. This will take you

The Remote Access Dialog Box will allow you to enter multiple WCC III – MCD IP addresses based upon “Job Site” names. This is done by typing in the name of the jobsite you wish to call your system.

First you must select a “BLANK” line in the bottom box area with your left mouse button. (This line will then be highlighted in “Blue”) You must then enter a Job Site name in the “Job Site” ﬁ eld, along with the static IP address and Port number (39289) for the WCC III – MCD that you wish to connect to with the WCC3. exe program.

If you are using a static “Host Name” instead of a static IP address please make sure that the Dynamic Address check box has been selected, along with the static “Host Name” in the space provided. As mentioned previously, you must get this static “Host Name” from your internet service provider, and it is limited to 58 characters total.

Please note that this “Job Site” name will also be the name of a subdirectory that will automatically be created in the Local disk C:\ProgramFiles\WCCIII\WCC3 subdirectory on the WCC III Front end computer. The Remote Access Dialog Box also creates a JobSite.dat data ﬁ le in the C:\ProgramFiles\WCCIII\WCC3 subdirectory. This data ﬁ le is not a viewable type of ﬁ le. The JobSite.dat ﬁ le can be copied and then can be used on other WCC

Port Number:

The WCC3.exe program opens a two-way, secure communications port that then allows for communication between WCC III – MCD and the WCC3.exe program that is running on the WCC III front end computer. This IP Address connection is done on a higher address port number than normal (WCC III connection is port number 39289) to help reduce the risk of computer hacking.

Job Site:

This is the name of the jobsite you wish to call your system. Please note that this name will also be the name of a subdirectory that will automatically be created in the Local disk C:\ProgramFiles\ WCCIII\WCC3 subdirectory.

Host Name:

When you have ﬁ lled out all necessary ﬁ elds, left-click This will take you back to the Connection Dialog Box that was ﬁ rst displayed. This Connection Dialog Box now should have the desired IP address in the Server IP Address location ﬁ eld and the port number (39289) in the Port Number location ﬁ eld for the WCC III – MCD that you wish to connect to with the WCC3.exe program.

<OK>.

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12. WCC III INSTALLATION

Running the WCC3 Program

Left-click <Cancel> to return to the Connection Dialog Box that was ﬁ rst displayed. The Connection Dialog Box will have the same IP address as listed originally before in the Server IP Address location ﬁ eld and the port number (39289) in the Port Number location ﬁ eld.

Left-click Dialog Box to your Windows system default printer on the WCC

III front end computer. This print function is provided to give you a hard paper backup copy of these IP address for the various WCC III – MCD that you may have. This print function also creates a Printscreen.dat data ﬁ le in the C:\ProgramFiles\WCCIII\WCC3 subdirectory. This data ﬁ le is not a viewable type of ﬁ le.

<Print> to send all of this data in this Remote Access

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WCC III - MCD Display

12. WCC III INSTALLATION GUIDE

WCC III - MCD LCD Display

WCC III - MCD Front View

Crystalfontz

POWER H.D.D RESET

Crystalfontz 631 HW v2.0 FW v2.0

Crystalfontz

HeartBeat Location

Button Message Area | Hold | Rotate

"UP" Button

"DOWN" Button

"SELECT" "HOLD" "ROTATE" Button

"MENU" Button

The LCD Display Buttons

There are four buttons on the front of the LCD display on the WCC III - MCD.

The Upper Left button is the “UP” menu navigation button.

The Lower Left button is the “DOWN” menu navigation button.

The Upper Right button works as a “SELECT” button under the MENU option or else it operates as a “HOLD” or “ROTATE” button for the information screens.

The WCC III – MCD now has a 2 line by 20 character dot matrix liquid crystal display. This LCD displays the following information: IP ADDRESS, MCD UPTIME, RX, TX, Down, Up, User %, System %, Nice %, Idle %.

This display is very helpful to determine if the WCC III – MCD is functioning correctly.

WCC III Technical Guide

Also the “BUTTON MESSAGE” area will momentarily display either “HOLD” or “ROTATE” when the Upper Right button is depressed.

The Lower Right button is the “MENU” button. It also serves as a “HOME” button to return to the main menu when in any of the sub-menus.

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12. WCC III INSTALLATION

WCC III - MCD LCD Display

SELECT

CHECK

DESELECT

HEART BEAT

UP/DOWN ITEM SELECT

SUBMENU UP SELECT

SUBMENU DOWN SELECT

The LCD Character Boxes

The Select box, Check box, and Deselect-box icons are displayed on the LCD as a visual aid to selecting or deselecting an item.

The difference between the Select box and the Check box is that the Select box icon is the default setting and the Check box icon is a change to the setpoint that the user has initiated.

WCC III MCD IPADDRESS

XXX.XXX.XXX.XXX

Crystalfontz

WCC III - MCD IP Address

This screen shows the actual IP address of the WCC III – MCD.

An Internet Protocol (IP) address is a numerical identiﬁ cation and logical address that is assigned to the WCC III – MCD that is participating in a computer network that is then utilizing the Internet Protocol for communication between its nodes. The WCC III MCD is conﬁ gured to use the same IP address each time it powers up - this is known as a Static IP address. In contrast, in situations when the other computer’s IP address is assigned automatically, it is known as a Dynamic IP address. The Static IP addresses are manually assigned to the WCC III - MCD by an administrator.

The Deselect box turns the selected item “OFF”.

The Heart Beat icon is to be used as a watchdog to make sure that this Linux-based LCD program is still running and is not “Locked Up”.

The Up/Down Item Select icon is used to display which of the currently selected menu items is currently selected for viewing and/or change.

The submenu Up/Down icons are a reminder to use the Upper Left or Lower Left buttons (UP/DOWN) to affect the changes to the user-desired “Adjustable” settings and are used for “CONTRAST”, “ON BRIGHTNESS”, and “OFF BRIGHTNESS” adjustments.

MCD UPTIME

D.Days H.Hours m.Min

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MCD UPTIME D - Days, H - Hours, m - Min

This is the displayed run time total since the last reset or startup of the WCC III – MCD. It is often used as a measure of computer operating system reliability and stability, in that this time represents the time that a computer can be left unattended without crashing or needing to be rebooted for any administrative or maintenance purposes.

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Rx: 0.0 Down l Tx: 0.0 UP 0

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IP Packet

An IP packet is the formatted unit of data that is carried by a packet mode computer network. When the data is formatted into IP packets, the bit rate of the communication medium (Ethernet) can better be shared among users than if the network were circuit switched.

Rx: Displays the number of IP Packets that are currently being received on the network card right now.

Tx: Displays the number of IP Packets that are currently being transmitted on the network card right now.

Down: Total IP Packets that have been received on the network card since the last bootup.

Up: Total IP Packets that have been transmitted on the network card since the last bootup.

12. WCC III INSTALLATION GUIDE

WCC III - MCD LCD Display

Nice becomes useful when there are several processes that are demanding more resources than the WCC III – MCD CPU can provide. In this state, a higher priority process will get a larger chunk of the WCC III – MCD CPU time than a lower priority process. If the WCC III – MCD CPU can deliver more resources than the processes are requesting, then even the lowest priority process can get up to 99% of the WCC III - MCD CPU. Only the superuser (root) may set the niceness to a smaller (higher priority) value. On Linux it is possible to change ”/etc/security/limits.conf “ to allow other users or groups to set a low nice value.

Idle: Percentage of the WCC III – MCD CPU’s time that the CPU were idle and the system did not do an outstanding disk I/O request. A computer processor is described as idle when it is not being used by any program.

Programs which make little use of the CPU Idle Time mean that they run at a low priority so as not to impact programs that run at normal priority like BackTask.exe. Many programs that use the WCC III – MCD CPU idle time can cause the WCC III - MCD CPU to always be 100% utilized, so that the time spent where the WCC III – MCD CPU would have been idle is instead spent performing useful computations. This generally causes the WCC III – MCD CPU to consume more power as most modern computer’s CPUs can enter power-save modes when they are idle.

Usr: 0.0% Nice 0.0% Sys: 0.0% Idle100.0%

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CPU Usage Percentages

Usr: Percentage of the WCC III – MCD CPU’s utilization that occurred while executing at the user level (application). BackTask. exe is an application.

Sys: Percentage of the WCC III – MCD CPU’s utilization that occurred while executing at the system level (kernel). The Linux operating system is system level.

Nice: Percentage of the WCC III – MCD CPU’s utilization that occurred while executing at the user level.

Nice (pronounced /na is/) is a program that’s found within Linux. Nice directly maps to a kernel call of the same name. For any given process, it changes the priority in the kernel’s scheduler. A niceness of −20 is the highest priority and 19 is the lowest priority. The default niceness for any process is inherited from its parent process, usually 0.

LCDproc Menu

Options

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Options Menu

Press the Lower Right button (MENU) to select the “LCDproc Menu” selection.

Press the Upper Right button (SELECT) to select the “Option” selection.

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WCC III - MCD LCD Display

OPTIONS

Heartbeat

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Options Menu – Heart Beat Selection

Press either the Upper Left or Lower Left buttons (UP/DOWN) to select the following user settable options: “Heart Beat”, “Backlight”, or “CFontzPacket”.

Press the Upper Right button (SELECT) to select or toggle the “Heartbeat” selection setting ON or OFF with either the X box, Check box or No box icon.

Or press the Lower Left button (DOWN) to select the “Backlight” selection.

Or press the Lower Left button (DOWN) twice to select the “CFontzPacket” selection.

Heartbeat

Backlight

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Options Menu – Backlight Selection

Press the Upper Right button (SELECT) to select or toggle the “Backlight” selection setting ON or OFF with either the X box, Check box or No box icon.

Or press the Upper Left button (UP) to select the “Heartbeat” selection.

Or press the Lower Left button (DOWN) to select the “CFontzPacket” selection.

Heartbeat

CFontxPacket

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Options Menu – CfontzPack et Submenu

Press either the Upper Left or Lower Left buttons (UP/DOWN) to select the following user settable options: “Contrast”, “On Brightness”, or “Off Brightness”.

Or press the Upper Left button (UP) to select the “HEART BEAT” selection.

Or press the Upper Left button (UP) twice to select the “BACKLIGHT” selection.

CFontzPacket

Contrast

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Options Menu – CfontzPack et Submenu – Contrast Selection

Press the Upper Right button (SELECT) to select the “Contrast” selection setting.

Contrast

min max

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Options Menu – CfontzPack et Submenu – Contrast Selection – Contrast Setting

Press either the Upper Left or Lower Left buttons (UP/DOWN) to affect the change to the user desired “Contrast” setting.

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WCC III - MCD LCD Display

Contrast

On Brightness

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Options Menu – CfontzPack et Submenu – On Brightness Selection

Press the Upper Right button (SELECT) to select the “On Brightness” selection setting.

On Brightness

min max

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Options Menu – CfontzPack et Submenu – On Brightness Selection – On Brightness Setting

Press either the Upper Left or Lower Left buttons (UP/DOWN) to affect the change to the user desired “On Brightness” setting.

On Brightness

Off Brightness

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Options Menu – CfontzPack et Submenu – Off Brightness Selection

Press the Upper Right button (SELECT) to select the “Off Brightness” selection setting.

Off Brightness

min max

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Options Menu – CfontzPack et Submenu – Off Brightness Selection – Off Brightness Setting

Press either the Upper Left or Lower Left buttons (UP/DOWN) to affect the change to the user desired “Off Brightness” setting.

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The WCC III - MCD

Overview

The WCC III – MCD was converted from the Windows XP operating system over to the Ubuntu version of Linux using the command line interface only and was then released by WattMaster Controls in October of 2009. The main function of the WCC III – MCD is to provide a hardware and software platform for a program that WattMaster Controls has developed that is called “BACKTASK.exe”. The BACKTASK.exe program is a multiple BACKground TASKing application program.

BACKTASK.EXE (SS5009)

The BACKTASK.exe program performs many functions such as:

• USB communications to the internal MCOMM board

• Time clock functions

• Analog/binary global processing

• Overrides of control points

• Holiday scheduling

• Optimal starts

• PID programs

• Shed /Restore programs

• Duty cycle programs

• Proportional Programs

• Tenant Overrides

• Emailing of alarms

The BACKTASK.exe program also provides for remote IP connection to a set of windows-based programs generally referred to as the WCC III programs. This WCC III – MCD also has hardware (WCCIII MCOMM board) that interfaces to a RS-485 communications loop that connects to SAT III type controllers for building automation controls.

Watchdog Circuit/P ow er F ail

If the BACKTASK.exe program is not running on the WCCIII

- MCD, there is a watchdog circuit that will restart the WCCIII – MCD. This watchdog circuit may interfere with the installation of new BACKTASK.exe software. There is a way to disable this watchdog circuit. Please contact WattMaster Controls for further information on temporarily disabling this watchdog circuit. In addition to this watchdog circuit, there is a small wall wart 24vac transformer that must be connected to 120VAC or else the WCCIII

- MCD will restart every two minutes. This is part of the power fail design circuit of the WCC III – MCD. This transformer is meant to

be plugged into a (NON – UPS) 120VAC outlet. The power cord for the WCC III – MCD is to be connected to a dedicated UPS (Uninterruptible Power Supply) outlet so that the MCD will keep running during a minor power outage. The Cable/DSL modem/ router should also be plugged into one of these dedicated UPS (Uninterruptible Power Supply) outlets.

MCD-Menu Program Overview

WattMaster Controls has developed a simple setup installation program for the Linux command line interface, and this program is called mcd-menu. Prior knowledge of Linux is not required, but would be helpful. This mcd-menu program has eleven subprograms incorporated into it that will allow for the following operations to be preformed:

• The setup of the Network IP Conﬁ guration of the

WCC III – MCD network card interface

• Copying of the BackTask speciﬁ c data ﬁ les to the

root of the USB Drive

• Restoring of the BackTask speciﬁ c data ﬁ les from

the root of the USB Drive

• The resetting of the WCC III - MCD IP address

back to the WattMaster factory Default IP Address settings

• The resetting of the WCC III - MCD DNS settings

back to the WattMaster factory default DNS settings

• The restarting of the 2 by 20 line LCD Driver that

is located on the front of the WCC III – MCD

• The restarting of the 2 by 20 line LCD Display that

is located on the front of the WCC III – MCD

• The testing of the Internet Connection, from the

WCC III - MCD to the internet

• The testing of DNS Settings, from the WCCIII –

MCD to the internet

• The shutdown of the WCC III - MCD – properly

closing down

• The shutdown and restart of the WCC III - MCD

The Webmin access method can also accomplish all of these same tasks, but is a little bit harder to use and is meant to be more of an “off site” management tool for the WCC III - MCD. The mcdmenu program is meant to be used as the initial IP setting tool and BACKTASK data ﬁ le loading tool for the WCC III - MCD. For this a monitor and keyboard needs to be connected temporarily just for the initial IP setup and BACKTASK data ﬁ le loading.

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Overview

The default administration username is wcciii and the password is wt@@58 This user name and password are both CAP sensitive, and should be entered in lower case letters only.

1. Type “mcd-menu” at the wcciii@wcciii-mcd:~$ prompt (view only – restricted access). You can perform very few functions as “View only restricted access”, such as Copy/restore WCCIII data ﬁ les.

2. To do the root level tasks like conﬁ gure IP address, shutdown the WCC III - MCD, reboot the WCC III - MCD, reset the WCC III – MCD IP addresses and DNS settings to DEFAULT conﬁ gurations, and of course, copy/restore WCCIII data ﬁ les, you must be signed in as a “root” user. You must be very careful signed in as a root user because you can render your WCC III - MCD system unable to communicate with the outside world if improperly used.

If you have selected a command and you are signed in as a root user, it will give you a warning message as listed below:

************************************************** * * * Warning: The program is not running as root. * * Interface conﬁ gurations or saving may fail! * * * **************************************************

NOTE: DO NOT run the mcd-menu program from inside

WebMin’s Command Shell. It will not work there. This mcdmenu program is meant to work only from the telnet/ssh session or from the actual console (i.e. keyboard and monitor

that is connected to the WCC III - MCD).

Running the mcd-menu program Step 1:

and the password is wt@@58. Type mcd-menu at the prompt (view only – restricted access).

Step 2: The following ﬁ rst main menu screen should appear:

Please Pick a Function:

1. Setup Network Conﬁ guration

2. Copy BackTask Files to USB Drive

3. Restore BackTask Files from USB Drive

4. Reset MCD to Default IP Address

5. Reset MCD to Default DNS Settings

6. Restart LCD Driver

7. Restart LCD Display

8. Test Internet Connection

9. Test DNS Settings

10. Shutdown MCD

11 Total Choices

Using the default low level, the username is wcciii

The mcd-menu is straight forward. You can select the desired function by number (1 to 11) and hit the enter key to execute the desire function. You can quit this mcd-menu program at any time by hitting the “q” and then the enter key to quit. Then type “exit” at the wcciii-mcd:~$prompt

Helpful hint: While at the wcciii@wcciii-mcd:~$ prompt you can select/toggle through previously entered commands with the “UP” arrow key.

The new ﬁ les are rolled into the installation ﬁ les so they will be available on new systems. They can also be pushed or updated to older systems via secure ftp and then run from the shell. Alternatively, they can also be upload to the WCC III – MCD from inside the WebMin program and then run from the command line from within the browser. This mcd-menu program may be run remotely from PuTTY which is a terminal emulator application program, provided that this program is installed and properly setup on your computer.

WCC III Technical Guide

Press ENTER (or “d”) to scroll downward OR “u” to scroll upward (Press “q” to quit)

PLEASE ENTER A CHOICE: ___

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Step 3: Pressing the “enter” key or the “d” key will result

in the next (second) menu screen appearing. The following second main menu screen should appear:

Please Pick a Function:

11. Shutdown and Reboot MCD 11 Total Choices

Press ENTER (or “d”) to scroll downward OR “u” to scroll upward (Press “q” to quit)

PLEASE ENTER A CHOICE: ___

Helpful hint: You do not have to use the “u” or “d” keys and then the “enter” to toggle between the ﬁ rst and second menus. By using the just “enter” key you can toggle between the ﬁ rst menu screen with selections of 1 to 10 and the second menu screen that has selection 11 only.

Setup Network Conﬁ guration (Choice #1)

This sub program will allow you to set the IP conﬁ guration of the WCC III – MCD. You will be prompted to enter a IP Address in the XXX.XXX.XXX.XXX format. If you do not have all of the following information, then you should not proceed any further. The values should be written below for future reference.

Static IP address ___ ___ ___ . ___ ___ ___ . ___ ___ ___ . ___ ___ ___ Must be static.

You will be now be prompted to enter the following data, and if you do not want to change the address listed within the listed brackets [ ] then just press the enter key and the value in the brackets [ ] will not change.

Enter interface conﬁ guration data: Interface to conﬁ gure: [eth0] __ IP address: [192.168.100.100] __ Netmask: [255.255.255.0] __ Gateway (none for no gateway): [192.168.100.1] __ Nameservers (blank separate list): [208.67.222.222_208.67.220.220] __

Interface to conﬁ gure: [eth0] __ There are two possible

entries here “eth0” and “eth0:0” eth0 is the default main IP address for the WCC III – MCD. eth0:0 is the secondary IP address for the WCC III – MCD and it is meant for direct connection from the WCC III – MCD to a local computer (Laptop) via a Ethernet crossover cable.

IP address: [192.168.100.100] __ This IP address must be

supplied by your internet provider or by your network IT personnel. It must be a “static” as in not changing.

Netmask: [255.255.255.0] __ This IP address must be

supplied by your internet provider or by your network IT personnel.

Gateway (none for no gateway): [192.168.100.1] __ This IP

address must be supplied by your internet provider or by your network IT personnel.

Subnet mask ___ ___ ___ . ___ ___ ___ . ___ ___ ___ . ___ ___ ___

Gateway ___ ___ ___ . ___ ___ ___ . ___ ___ ___ . ___ ___ ___

Nameserver ___ ___ ___ . ___ ___ ___ . ___ ___ ___ . ___ ___ ___

Nameserver ___ ___ ___ . ___ ___ ___ . ___ ___ ___ . ___ ___ ___ Optional

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Nameservers (blank separate list): [208.67.222.222_208.67.220.220] __

address for a DNS server. Some internet service providers do not have a static IP address. They use what is called static host names, which correspond to a actual static IP address. You can enter more than one IP address here, a primary and a secondary, and please note that they must be separated by a space. For example, on the Internet there exists a special case of nameservers lookup sites, the so called Domain Name System (DNS) servers, which are used to translate a static hostname or a domain name (for example, ‘WCC-CONTROLS.com’) to its corresponding binary identiﬁ er (the IP address 76.12.37.232), or vice versa.

This is the actual IP

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12. WCC III INSTALLATION GUIDE

Using the MCD-Menu Program

After you have entered in all of the required IP addresses, subnet masks, Gateways, and/or Nameservers, the program will now change the internal IP network conﬁ guration ﬁ les within the Linux operating system of the WCC III – MCD. It will take a few seconds to do this function, and will display the following messages:

Conﬁ guring interface: /sbin/ifconﬁ g eth0 192.168.100.100 netmask 255.255.255.0 broadcast 192.168.100.255

Deleting old interface route: /sbin/route del -net 192.168.100.0 netmask 255.255.255.0 eth0

Setting interface route: /sbin/route add -net 192.168.100.0 netmask 255.255.255.0 eth0

Deleting old default route: /sbin/route del default

Setting default route: /sbin/route add default gw 192.168.100.1

Writing /etc/network/interfaces:

Copy BackT ask da ta Files to USB Drive (Choice #2)

This sub program will copy all of the useful WCC III data ﬁ les to a USB drive (User / Contractor provided), assuming that there is a USB drive plugged into the USB port on the WCC III – MCD. It will copy all of these ﬁ les to the root of the USB drive.

If there is not a USB hard drive in the USB port on the front of the WCCIII – MCD, this program assumes that there is a USB drive there even if it is not there. It will not report that there is a drive reading or writing error or any other errors. So when backing up, make sure that there is a USB hard drive in the USB socket port on the front of the WCCIII – MCD, and also there should be a LED on this USB hard drive that should light up when data is written or read from it. Please verify that this LED operates when backing up data to this USB hard drive.

All WCC III jobsites have multiple speciﬁ c custom data ﬁ les that are the responsibility of the end user and/or mechanical contractor. Any loss or the retention of these jobsite speciﬁ c custom data ﬁ les are not within WattMaster Controls Inc. liabilities.

The following will be displayed on the screen:

Selecting Copy BackTask Files to USB Drive.

Writing /etc/resolv.conf:

When completed the following information will be displayed:

New netstat settings:

192.168.100.100 0.0.0.0 255.255.255.0 U 0 0 0 eth0

192.168.200.0 0.0.0.0 255.255.255.0 U 0 0 0 eth0

0.0.0.0 192.168.100.1 0.0.0.0 UG 0 0 0 eth0

Network Conﬁ guration Done. ************************************************** * Exiting Program. * **************************************************

wcciii@wcciii-mcd:~$

The mcd-menu program, as part of the setup process for the IP connections, has on purpose exited the mcd-menu program. This is normal operation.

Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ AlarmBits.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ AlarmMessage.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ DutyCycleSchedule.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ EnergyConsumption.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ GeneralMessage.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ GlobalAnalog.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ GlobalBinary.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ HolidaySchedule.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ LookUpTable.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ NetworkInformation.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ OperatorCode.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ OptimalSchedule.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ OverrideSchedule.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ PidProgram.dat

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Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ ProportionalReset.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ ShedRestoreSchedule.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ StatusMessage.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ SystemParameter.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/table.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ TenantEvent_001_2009_09.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ TenantEvent_004_2009_10.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ TenantOverride.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ TenantOverrideRecord.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ UnitMessage.dat Copying ﬁ le: /home/wcciii/.wine/drive_c/Backtask/ WeekSchedule.dat

Done copying .dat ﬁ les.

Returning to Main Menu.

The screen should now take you back to the mcd-menu main screen after about a second or two.

Restore BackT ask data Files to USB Driv e (Choice #3)

This sub program will copy all of the useful WCC III data ﬁ les from a USB drive (User/Contractor provided), assuming that there is a USB drive plugged into the USB port on the WCC III – MCD. It will copy all of these ﬁ les to the //home/wcciii/. wine/drive_c/Backtask/ subdirectory of the WCC III – MCD solid state hard drive.

All WCC III jobsites have multiple speciﬁ c custom data ﬁ les that are the responsibility of the end user and or mechanical contractor. Any loss or the retention of these jobsite speciﬁ c custom data ﬁ les are not with in WattMaster Controls Inc. liabilities.

The following will be displayed on the screen:

Selecting Restore BackTask Files from USB Drive.

Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/AlarmBits.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ AlarmMessage.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ DutyCycleSchedule.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ EnergyConsumption.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ GeneralMessage.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/GlobalAnalog. dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/GlobalBinary. dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ HolidaySchedule.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/LookUpTable. dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ NetworkInformation.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/OperatorCode. dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ OptimalSchedule.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ OverrideSchedule.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/PidProgram. dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ ProportionalReset.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ ShedRestoreSchedule.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ StatusMessage.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ SystemParameter.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/table.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ TenantEvent_001_2009_09.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ TenantEvent_004_2009_10.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ TenantOverride.dat

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Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ TenantOverrideRecord.dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/UnitMessage. dat Copying ﬁ le: /home/wcciii/.wine/dosdevices/d:/ WeekSchedule.dat

Done copying .dat ﬁ les.

Returning to Main Menu.

The screen should now take you back to the mcd-menu main screen after about a second or two.

Reset MCD to Default IP Address (Choice #4)

There are times when you may want to reset the IP address back to WattMaster Control’s factory default settings. This is primarily done at WattMaster on new systems before they are sent out to the end user/contractor/customer. It is a base known starting point. Please note that this choice will reset both of the eth0 and eth0:0 ethernet conﬁ gurations. The following information will be displayed on the screen:

Selecting Reset MCD to Default IP Address.

IP Address restored to Default.

IP Address Conﬁ guration is:

# This ﬁ le describes the network interfaces available on your system # and how to activate them. For more information, see interfaces(5).

iface eth0:0 inet static address 192.168.200.200 netmask 255.255.255.0 broadcast 192.168.200.255 network 192.168.200.0 * Reconﬁ guring network interfaces... SIOCSIFFLAGS: Cannot assign requested address * Stopping NTP server ntpd ...done. * Stopping NTP server ntpd [ OK ] ...done. * Starting NTP server ntpd ...done. * Starting NTP server ntpd ...done.

The screen should now take you back to the mcd-menu main screen after about a second or two.

Reset MCD to Default DNS Settings (Choice #5)

There are times when you may want to reset the DNS settings back to WattMaster Control’s factory default settings. This is primarily done at WattMaster on new systems before they are sent out to the end user /contractor/customer. It is a base known starting point. The following information will be displayed on the screen:

Selecting Reset MCD to Default DNS Settings.

DNS Settings restored to Default.

Contents of /etc/resolv.conf are:

# The loopback network interface auto lo eth0 eth0:0 iface lo inet loopback

# The primary network interface iface eth0 inet static address 192.168.100.100 netmask 255.255.255.0 network 192.168.100.0 broadcast 192.168.100.255 gateway 192.168.100.1

post-up iptables-restore < /etc/iptables.up.rules # dns-* options are implemented by the resolvconf package, if installed

WCC III Technical Guide

search parkville.wattmaster.com nameserver 208.67.222.222 nameserver 208.67.220.220 * Reconﬁ guring network interfaces... SIOCSIFFLAGS: Cannot assign requested address * Stopping NTP server ntpd ...done. [ OK ] * Stopping NTP server ntpd ...done. * Starting NTP server ntpd ...done. * Starting NTP server ntpd ...done.

The screen should now take you back to the mcd-menu main screen after about a second or two.

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Restart LCD Driver (Choice #6)

On the front of the WCC III – MCD, there is a 2 by 20 line LCD display. This 2 by 20 line LCD display will display the following information: WCCIII - MCD IP ADDRESS WCCIII - MCD UPTIME WCCIII - MCD IP RECEIVE AND TRANSMIT PACKETS WCCIII - MCD CPU UTILIZATION

This will stop the LCD driver and then restart it. The reasons why you might want to restart the 2 by 20 line LCD driver are: There may have been a issue with a stuck or blanked out screen, or the USB connection to the 2 by 20 line LCD display might have been disconnected or locked up.

If you have selected to restart the LCD driver, then the following will be displayed on the screen:

Selecting Restart LCD Driver.

Restarting LCD Driver...

Restarting LCDd: Stopping LCDd: LCDd. Starting LCDd: LCDd.

Stopping LCD Display... kill: 74: Usage: kill [-s sigspec | -signum | -sigspec] [pid | job]... or kill -l [exitstatus] LCD Display is stopped Starting LCD Display... LCD Display is now started.

The screen should now take you back to the mcd-menu main screen after about a second or two.

Test Internet Connection (Choice 8)

If you have selected to Test the Internet Connection, then the following will be displayed on the screen:

Selecting Test Internet Connection.

************************************************** * * * Internet is online. * * * **************************************************

The screen should now take you back to the mcd-menu main screen after about a second or two.

Restart LCD Display (Choice #7)

On the front of the WCC III – MCD, there is a 2 by 20 line LCD display. This display will display the following information: WCCIII - MCD IP ADDRESS WCCIII - MCD UPTIME WCCIII - MCD IP RECEIVE AND TRANSMIT PACKETS WCCIII - MCD CPU UTILIZATION

This will stop the LCD display program and then restart it. The reasons why you might want to restart the 2 by 20 line LCD display are: There may have been a issue with a stuck or blanked out screen, or the USB connection to the 2 by 20 line LCD display might have been disconnected or locked up.

If you have selected to restart the LCD display, then the following will be displayed on the screen:

Selecting Restart LCD Display.

Restarting LCD Display...

Test DNS Settings (Choice 9)

If you have selected to Test DNS Settings, then the following will be displayed on the screen:

Selecting Test DNS Settings.

Testing DNS Setting in /etc/resolv.conf...

www.google.com is online. www.yahoo.com is online. www.wcc-controls.com is online.

DNS is resolving correctly.

The screen should now take you back to the mcd-menu main screen after about a second or two.

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Using the MCD-Menu Program

Shutdown MCD (Choice 10)

There are times that occur when you would need to shutdown the WCC III – MCD. This is generally done when servicing the WCC III – MCD or when you perform software updates on the WCC III – MCD.

If you have selected to shutdown the MCD, then the following will be displayed on the screen:

Selecting Shutdown MCD.

************************************************** * * * Shutdown MCD * * * **************************************************

Broadcast message from wcciii@wcciii-mcd (/dev/pts/0) at 9:01 ...

The system is going down for halt in 3 minutes!

You may cancel this shutdown command with a “Ctrl” “C” key sequence anytime during this 3 minute shutdown time. And you will also get the following shutdown cancelled conﬁ rming message on the display:

Shutdown and Restart the MCD (Choice 11)

There are times that occur when you would need to shutdown and then restart the WCCIII – MCD. This is generally done when servicing the WCCIII – MCD, or when you software updates to the WCCIII – MCD.

If you have selected to shutdown the MCD, then the following will be displayed on the screen:

************************************************** * * * Shutdown and Reboot MCD * * * **************************************************

Broadcast message from wcciii@wcciii-mcd (/dev/pts/0) at 9:01 ...11

The system is going down for reboot NOW!

This is an immediate shutdown and reboot of the WCC III – MCD. You may not cancel this shutdown command with a “Ctrl” “C” key sequence .

shutdown: Shutdown cancelled

WCC III Technical Guide

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WattMaster WCC III User Manual part 12

Specifications and Main Features

Frequently Asked Questions

User Manual