WHP - Water Source Heat Pump
Design, Installation &
Operations Manual
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WattMaster WHP
Installation & Operations Manual
Section 1.................................................................................... Design Guide
Section 2...................................................................Installation and Wiring
Section 3....................................................................................Programming
Section 4....................................................... Start-Up and Troubleshooting
This document is subject to change without notice.
WattMaster Controls, Inc. assumes no responsibility
for errors, or omissions herein.
WHP Installation & Operations Manual - Form WM-WHP-IO-02A
Copyright 2004 WattMaster Controls, Inc.
All rights reserved.
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Section 1
Table of Contents
Conventions .....................................................................1
General Information.........................................................2
Water Source Heat Pump Units.......................................................................................2
Water Source Heat Pump Systems ..................................................................................3
WattMaster WHP Control System...................................................................................4
WHP Controller ...........................................................................................................4
Make Up Air Controller...............................................................................................5
WHP Sequence of Operation ...........................................6
HVAC Mode of Operation...............................................................................................6
Occupied/Unoccupied Mode of Operation ......................................................................7
Vent Mode Operation ......................................................................................................7
Off Mode of Operation ....................................................................................................7
HVAC Operation w/ Reversing Relay.............................................................................8
HVAC Operation w/ Heat/Cool Relays...........................................................................9
WHP Loop Controller Sequence of Operations .............10
Summary........................................................................................................................10
Pump Control.............................................................................................................10
Pump VFD Control....................................................................................................11
Compressor Control...................................................................................................11
Heat Rejection Control ..................................................................................................12
Staged Heat Rejection................................................................................................12
Heat Addition Control ...................................................................................................12
Staged Heat Addition.................................................................................................13
Proportional Heat Addition........................................................................................13
Water Temperature Alarming........................................................................................14
Fire Alarm......................................................................................................................14
Notes:.............................................................................16
Table of Figures
Figure 1-1: Typical Water Source Heat Pump..............................................................3
Figure 1-2: Typical Water Source Heat Pump System.................................................3
Figure 1-3: Typical WattMaster WHP System...........................................................15
Design Guide
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WattMaster WHP
Section 1
Conventions
This document uses the following definitions throughout as a guide to the user in
determining the nature of the information presented:
Note: Additional information which may be helpful.
Tip: Suggestion to make installation, set-up, and troubleshooting easier.
Caution: Items which may cause the equipment not to function correctly but will
not otherwise damage components.
Warning: Errors which can result in damage to equipment and void warranties.
Design Guide
1-1
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Section 1
WattMaster WHP
General Information
Water Source Heat Pump Units
A water source heat pump is a self-contained water-cooled packaged heating and cooling
unit with a reversible refrigerant cycle. Its components are typically enclosed in a
common casing, and include a tube-in-tube heat exchanger, a heating/cooling coil, a
compressor, a fan, a reversing valve and controls.
1-2
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WattMaster WHP
Section 1
Typical Water Source Heat Pump
During the cooling mode, the tube-in-tube heat exchanger functions as a condenser and
the coil as an evaporator. In heating mode, the tube-in-tube heat exchanger functions as
an evaporator and the coil as a condenser. A reversing valve is installed in the refrigerant
circuit permitting changeover from heating to cooling, and vice versa. The condenser and
evaporator tubes are designed to accept hot and cold refrigerant liquid or gas.
Water Source Heat Pump Systems
The water source heat pump system is, by definition, a heat recovery system. It is best
applied to buildings that have simultaneous cooling and heating loads. This is the case
during winter months when the interior zones of a typical building require cooling while
the exterior zones require heating. When a water source heat pump system is used, the
heat rejected by the cooling units is used to warm the zones calling for heat. A water
heater is generally used for adding heat to the condensing water during peak heating
periods, if necessary. The system also utilizes a water cooling tower to reject the heat
energy from the condenser water loop during periods of high cooling demand.
Water source heat pump units can be suspended in the ceiling plenum, floor mounted
behind walls or placed directly in the occupied space as a console unit. There are also
rooftop and unit ventilator type water source heat pumps.
Typical Water Source Heat Pump System
Water source heat pump systems generally cost less to install than central built-up
systems. They offer individual zone control with the added flexibility of being able to
Design Guide
1-3
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Section 1
WattMaster WHP
accommodate changes in location and sizes as thermal zones or zone occupancy change.
This system is often installed in ceiling plenums, which frees up valuable floor space.
Another valuable benefit of water source heat pumps is that they can accommodate
simultaneous calls from zones requiring heating or cooling. Depending on the climate,
outside air may require preheat or cooling prior to being introduced to the unit. In the
example of ceiling mounted water source heat pumps, put outside air ducts near each unit
to improve indoor air quality.
Normally, multiple units serve an occupied space. This gives component redundancy to
the system so if one unit were to fail, the other units could back it up until the unit was
repaired. The packaged design of most unit types allows quick change-out by service
personnel so maintenance can typically be performed off site.
As with any HVAC system, there is a negative side as the water source heat pump system
often requires higher maintenance costs than conventional air side systems. The system
also typically has a shorter replacement life than other systems because of continuous fan
and compressor operation during heating and cooling modes. The system can also create
room noise since the compressor and fan are commonly located close to the zone
occupant. Placing units away from the occupied space and ducting the supply air to the
zone can minimize potential noise problems.
WattMaster WHP Control System
The WattMaster WHP system is used to control the water loop and the individual water
source heat pumps installed in a typical water source heat pump system. The WHP
system is an excellent alternative over programmable thermostats. The WHP control
system provides one central location to monitor and program all the water source heat
pumps on the system instead of having to program each water source heat pumps
thermostat individually. The system has many features typically not found with
programmable thermostats such as: central operators interface, heating/cooling failure
alarm, auxiliary alarm, and holiday scheduling, to name but a few.
WHP Controller
The Water Source Heat Pump Controller (WHP) is used for controlling individual water
source heat pump units. The WHP Controller can operate stand-alone or it can be used
with the Water Source Heat Pump Loop Controller and in this configuration shares
common data, such as outside air temperature, proof of flow etc., over a network. A
System Manager is connected to the WHP Controller to provide a central operators
interface to all WHP Controllers on the network. WHP Controllers are designed with
Room Temperature, Room Setpoint Adjust, Discharge Air Temperature, Leaving Water
Temp or Dirty Filter Alarm and Auxiliary Lockout inputs. Relay outputs provided are;
Fan (Continuous or Cycling), Reversing Valve-ON/OFF, Compressor-ON/OFF, Heat
1-4
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WattMaster WHP
Section 1
Pump Reset and Aux. Heating or Cooling. An internal seven day schedule and holiday
schedule functions are also built into each WHP Controller.
With the WHP system the sometimes complex control requirements of a large water
source heat pump system can be handled with an off the shelf controls system that has
most of the features of a full blown building automation system but at a much lower cost.
Included with the WHP system is a communications interface module, which allows you
to connect a computer to the system onsite and a modem connection for remote
monitoring.
Prism, a Windows based software package is available at no additional charge. Some of
Prism’s features include graphics, trend logging, and remote alarm call out capabilities.
WHP Loop Controller
The Water Source Heat pump Loop Controller can be supplied with the system to control
the water loop and its various pieces of equipment. The Loop Controller can operate
stand-alone or used with the Water Source Heat Pump Controller (WHP) and in this
configuration communicates common data, such as outside air temperature, proof of flow
etc., over a network. A System Manager is connected to the Loop Controller to provide a
central operator’s interface to the Loop Controller’s setpoints and operating
configurations. The Loop Controller is designed with inputs for Supply and Return Water
Temperature, Outdoor Air Temperature, Loop Water Pressure Switch or 0-50 PSI Loop
Pressure Sensor (4-20ma), Manual Reset Contact, Phase Loss Contact, Request to Run
Relay, and Fire/Smoke Relay. Analog outputs (0-10VDC) are supplied for Pump VFD
and Proportional Heat. Binary outputs are provided for Compressor Enable, Main Pump
Relay, Standby Pump Relay, Alarm Contacts and (8) Relays that can be configured for
Heat Rejection or Heat Addition.
Make Up Air Controller
A Make Up Air Controller, for treating 100% outdoor air, is available for use with the
Water Source Heat Pump system. Please consult factory for more information on this
product.
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1-5
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Section 1
WattMaster WHP
WHP Sequence of
Operation
HVAC Mode of Operation
There are four possible modes of operation. These are Cooling Mode, Heating Mode,
Vent Mode, and the Off Mode. The HVAC mode of operation is calculated the same way
in both occupied and unoccupied modes of operation.
Off Mode
The schedule is off and no overrides are active. There is no heating or
cooling demand in the space. Under these conditions, all outputs will be
off and the analog output will be set to 0.0 vdc.
Vent Mode No heating or cooling demand exists during the occupied mode of
operation. The fan will be on if the WHP is programmed for Constant Fan
operation. The compressor demand request will not be sent to the Loop
Controller. If no WHP units are sending a request, the Loop Controller
will discontinue operation after 15 minutes.
Cool Mode A cooling demand is generated when the space temperature rises half the
amount of the Deadband Setpoint above the currently active Cooling
Setpoint. The space is considered satisfied when it drops that amount
below the Cooling Setpoint.
Heat Mode A heating demand is generated when the space temperature drops half the
amount of the Deadband Setpoint below the currently active Heating
Setpoint. The space is considered satisfied when it rises that amount above
the Heating Setpoint.
1-6
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WattMaster WHP
Section 1
Occupied/Unoccupied Mode of
Operation
Since the WHP contains its own built in Real Time Clock, it can operate from its own
internal scheduling system. This schedule supports two Start & Stop events per day and
up to 14 Holiday periods. The Holidays all use the same special Holiday Start/Stop times
programmed by the user.
If the current operating mode is unoccupied, the WHP can accept a push-button override
back to the occupied mode. Push-button overrides are not recognized if the current mode
is already occupied. The push-button override duration is user programmed. If the user
wants to extend the current override without reprogramming the Duration, they can re-
initialize the existing programmed period by pressing the override button anytime during
the current override. If the current override had been active for 1 hour and 45 minutes and
the user presses the push-button again, the override will reset for another 2 hour period (if
they programmed a 2 hour period), bringing the total override time to 3 hours and 45
minutes. If the user wants to cancel an override before it can time-out, simply hold the
push-button for a period of time between 3 and 10 seconds.
The WHP calculates its current heating and cooling setpoints based on the current mode
of operation. If the command is for unoccupied mode, the WHP adds the unoccupied
setbacks to the occupied heating and cooling setpoints.
Vent Mode Operation
During occupied hours when there is no heating or cooling demand, the WHP reverts to a
Vent Mode of operation. The fan is running and the heating and cooling outputs are held
off.
See the section titled HVAC Mode of Operation for a graphical description of how the
Vent Mode is calculated.
Off Mode of Operation
After the schedule goes unoccupied and both heating and cooling demands go away, the
fan stops running, all relay outputs are turned off. No outputs are allowed to activate in
the Off Mode until a heating or cooling demand occurs. During occupied hours this
would be the Vent Mode.
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Section 1
WattMaster WHP
HVAC Operation w/ Reversing Relay
If the user has configured the WHP to control a Reversing Valve and a Compressor, the
following sequence of operation occurs during a heating or cooling demand.
Note: If you configure the WHP to look for a proof of flow Enable signal from the
Loop Controller then the following sequence assumes a request was made by
the WHP during a demand condition and that the Loop Controller gave
permission for the WHP to start its compressor. Otherwise, the WHP will
ignore the Enable signal and operate anytime there is a heating or cooling
demand.
a.
b.
If the last mode was the opposite of the current demand mode, make sure
the Changeover Delay has been satisfied.
If the unit is configured to control an Isolation Valve, the valve relay is
activated ( Relay #5 ). The Minimum Off Timer is reset to ZERO and
must be satisfied before any further operations are allowed.
c.
d.
e.
If the current mode requires the Reversing Valve to be activated, its relay
contact is closed and a 10 second delay is started.
Ten seconds after the Reversing Valve is activated, the Compressor relay
is activated.
If the Space Temperature continues to exceed the affected setpoint by the
full amount of Deadband and you have configured for 2 stages in the
current mode of operation, relay #5 will activate for the second stage of
heating and/or cooling. A second stage of either implies that no Isolation
Valve exists!
f.
Once the Space Temperature has crossed back over the affected setpoint,
stage 2 will be turned off if the unit has a stage 2.
g.
As the Space Temperature continues to cross back over the affected
setpoint by half the Deadband value, the compressor will then be allowed
to turn off if the Minimum Run Time has been satisfied.
1-8
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Section 1
HVAC Operation w/ Heat/Cool Relays
If the user has configured the WHP to control Individual Heating and Cooling relays the
following sequence of operation occurs during a heating or cooling demand.
NOTE: If you configure the WHP to look for a proof of flow Enable signal from the
Loop Controller then the following sequence assumes a request was made by
the WHP during a demand condition and that the Loop Controller gave
permission for the WHP to operate its heating or cooling. Otherwise, the WHP
will ignore the Enable signal and operate anytime there is a heating or cooling
demand.
Once a heating or cooling demand exists, the following conditions must be met before
any relays can be activated:
a.
b.
Make sure any stages of the opposite mode are staged off.
Verify the system has been configured for at least one stage of heating or
cooling.
c.
d.
Make sure the Minimum Cycle Time has been satisfied.
If the last mode was the opposite demand mode, make sure the
Changeover Delay has been satisfied.
e.
f.
Check the current Minimum Off Timer to make sure this stage has been
off long enough since the last time it was cycled on and back off.
If there is more than 1 stage, check the Minimum Run Time from the
previous stage to be sure it has elapsed before activating the second stage.
g.
h.
Make sure the Space Temperature Demand is the full amount of Deadband
from the setpoint before activating the second stage.
Once the compressor or stage 2 has been turned off, a Minimum Off Time
must be satisfied before it can stage on again. A Minimum Cycle time can
also be utilized to limit the number of times per hour that the compressor
can be activated. If you don’t need this limitation, set the Minimum Cycle
Time to be shorter than the Minimum Run Time setpoint.
i.
If the Reversing Valve was configured to cycle with the compressor, it will
now turn off also. It can be configured to remain active until the opposite
mode of operation is called for to reduce wear on the valve.
Design Guide
1-9
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Section 1
WattMaster WHP
WHP Loop Controller
Sequence of Operations
Summary
The Water Source Heat Pump Loop Controller waits for a Request to Run signal from a
Heat Pump or from a Binary Contact Closure. Once the request is received the Loop
Controller activates a Pump to initiate water flow to the Heat Pumps. Once the pump is
activated and proof of flow has been determined, a Global is broadcast to all Heat Pumps
to enable them to go ahead and run their compressors. The main goal of the Loop
Controller is to provide water flow and to maintain the loop water temperature by
monitoring either the Loop Inlet or Loop Outlet temperature. If a higher temperature is
required, Heat Addition is enabled. If the temperature needs to be lowered, Heat
Rejection is enabled.
Once the Loop Controller has been activated by a request, it will run for a minimum of 15
minutes to prevent cycling on and off due to borderline requests from the Heat Pumps.
If a Fire Alarm is detected, the Loop Controller generates a Global broadcast to all Heat
Pumps to turn off.
If the High Pressure option is configured, the Loop Controller can generate a Global
broadcast to force the Heat Pumps to open their Isolation Valves to reduce loop pressure
if the high limit has been exceeded.
Pump Control
If WattMaster Water Source Heat Pump Controllers are used in conjunction with the
Loop Controller, a Global Binary signal from the attached Heat Pumps sends a Request to
run or Enable to Run command to the Loop Controller. If the Loop Controller is used in a
stand alone configuration, a contact closure on the AIN 2 of the Analog Expansion board
gives the controller a request to run. When a request to run is received, the Loop
Controller activates a pump to initiate water flow to the heat pumps. The pumps can
either be constant flow or controlled by a VFD. If the request goes away for at least one
minute, the request to run command is removed. If the loop controller has been running a
minimum of 15 minutes then it can be turned off, since there is no longer a request to run.
If the proof of flow is lost while the pumps are running, the pump is shut off immediately
if the changeover to the Standby Pump had already been made.
The pumps are Lead/Lag controlled based on a user definable number of hours. If one
pump exceeds the other pumps run time by this amount, the lead is changed until that
1-10
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WattMaster WHP
Section 1
pump exceeds the first pumps run time by the same amount. This keeps both pumps with
roughly the same number of hours on each pump. Changeover occurs at the time the run
time setpoint is exceeded. The running pump is shut off at the same time the standby
pump is energized, this prevents any down time or alarms. The unit can be configured to
control either the Loop Inlet temperature or the loop outlet temperature.
A user adjustable low outdoor air temperature setting of XX degrees will allow the unit to
run the pumps continuously for protection against freezing.
If the pump is constant volume, and the pump has been started, it has 3 seconds to
generate flow or the standby pump is activated. If the pump is controlled by a VFD, once
it starts, it has 60 seconds to generate flow and if it doesn’t the standby pump is activated.
If the standby pump fails, an alarm is generated and the Loop controller deactivates any
active heat rejection or addition stages. At the same time an alarm is generated, we
energize relay #5 on the Loop Controller board so that it may used to turn on a local
alarm signal.
Loop flow can be determined by a binary contact closure on input #3 or a 0 to 50 PSI
pressure sensor on input #3. If a pressure sensor is used, the user can program the
pressure setpoint that needs to be met for proof of flow.
Pump VFD Control
An optional Pump VFD signal can be modulated if the system is configured for
proportional control and a pressure sensor is attached to analog input #3.
At a user defined rate, the VFD signal is ramped up when the pressure is below
a user defined setpoint by a user defined deadband. The signal ramps down when the
pressure exceeds the setpoint by the deadband value. If the pressure ever exceeds the high
pressure setpoint, an emergency override activates and begins cutting the VFD signal in
half each time the control loop is polled by the software. This protects against run away
over-pressurization.
The pump relay outputs are still activated and Lead/Lagged as described above
and the pump relay remains on until the Request signal is removed, provided it
has been operating for at least 15 minutes.
Compressor Control
Anytime a pump is running and proof of flow has been established, the compressor output
is activated.
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1-11
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Section 1
WattMaster WHP
Heat Rejection Control
If the compressor is not running, no heat rejection can be active. If any heat rejection is
still active when the compressor is turned off, the heat rejection will be immediately
removed, without regard to any minimum run or off times.
Heat rejection cannot be active at the same time as heat addition, so any heat addition is
removed or staged off before the heat rejection can be started.
A maximum of 8 stages of heat rejection can be controlled.
Staged Heat Rejection
Heat Rejection is staged up based on a different deadband level for each stage. Basically,
if the user programmed a 2° deadband, then the first stage could activate at the setpoint,
stage 2 would activate 2° above the setpoint, stage 3 would activate 4° above the setpoint,
etc...
Staging down is calculated in the same manner, except the water temperature would need
to drop below the setpoint by the deadband amount. If stage 3 was activated at 4° above
setpoint, it would de-activate when the temperature fell to within 2° of setpoint, stage 2
would de-activate at setpoint and stage 1 would de-activate 2° below setpoint.
A user defined staging up and down interval must be met before any heat rejection stages
can be added or removed. If the selected Water Temperature is above the current staging
level and the timer has been satisfied, an additional stage can be added, up to the
maximum available 8 stages. If the selected Water Temperature is below the staging
down level and the timer has been satisfied, a stage can be removed.
Heat Addition Control
If the compressor is not running, no heat addition can be active. If any heat addition is
still active when the compressor is turned off, the heat addition will be immediately
removed, without regard to any minimum run or off times.
Heat addition cannot be active at the same time as heat rejection, so any heat rejection is
removed or staged off before the heat addition can be started.
A maximum of 4 stages of heat addition can be controlled or proportional heating can be
configured, and an analog output signal will be modulated to control the heat.
1-12
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WattMaster WHP
Section 1
Staged Heat Addition
Heat Addition is staged up based on a different deadband level for each stage. Basically,
if the user programmed a 2° deadband, then the first stage could activate at the setpoint,
stage 2 would activate 2° below the setpoint, stage 3 would activate 4° below the setpoint,
etc...
Staging down is calculated in the same manner, except the water temperature would need
to increase above the setpoint by the deadband amount. If stage 3 was activated at 4°
below setpoint, it would de-activate when the temperature rises to within 2° of setpoint,
stage 2 would de-activate at setpoint and stage 1 would de-activate 2° above setpoint.
A user defined staging up and down interval must be met before any heat addition stages
can be added or removed. If the selected Water Temperature is below the current staging
level and the timer has been satisfied, an additional stage can be added, up to the
maximum available 8 stages. If the selected Water Temperature is above the staging
down level and the timer has been satisfied, a stage can be removed.
Proportional Heat Addition
If the Water Temperature is below the addition setpoint, a Boiler Enable relay is
activated. If the Water Temperature rises 1° above the setpoint the Boiler Enable relay is
de-activated.
At a user defined rate, the analog output signal is proportionally controlled from 0.0 VDC
at 1° above setpoint to the full 10.0 VDC signal as the water temperature drops below the
setpoint by the user defined deadband amount. If a 5° deadband was entered, the
maximum voltage would be reached at 4° below the setpoint and the minimum voltage
would be set at 1° above the setpoint. Since this is strictly proportional control, at 1.5°
below setpoint the controller would set 5.0 VDC since that would be half the deadband
amount.
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Section 1
WattMaster WHP
Water Temperature Alarming
The controlling water temperature is monitored to prevent it from exceeding both a user
defined High and Low Alarm Limit. If either limit is exceeded for a user defined length of
time, an alarm is generated and the compressor output is de-activated. If the high limit is
exceeded, the heat addition outputs are de-activated and if the low limit is exceeded, the
heat rejection outputs are de-activated. The alarming and shutdown only pertains to the
controlling water temperature. This does not affect the pump operation.
If a external manual alarm reset button is connected between ground and input #5, All
outputs are turned off and ALL timers are reset. This forces the loop controller to stage
off. This reset WILL shut down the pumps and force them to restart!
Fire Alarm
If the Fire Alarm is activated on input #1 of the Analog Input Expansion Board (Contact
OPENS for Alarm!) then ALL outputs and timers are reset and held off for the duration of
the Fire Alarm signal.
If the Fire Alarm is not required, input #1 of the Analog Input Expansion Board must
have a shorting wire to ground to allow the equipment to operate.
1-14
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WattMaster WHP
Section 1
COMPUTER
(OPTIONAL)
RS-485
Comm Loop
32K
8K
COMM
RELAY
OUTPUT
COM
T
Room Sensor
with Optional
Override & Adj.
SHLD
R
1-3
OUT
1
OUT
485
COMM
RAM
EPROM
LD4
2
OUT
3
OUT
4
REC.
OUT
5
CPU
COM
4-5
COMM
TEST
12V
ADDRESS
ADD
AIN
1
AIN
2
AIN
3
AIN
4
AIN
5
GND
GND
AOUT
PWR
GND
PRESSURE
SENSOR
YS101564
24VAC
24 VAC
110/24 VAC
Power Pak
Dirty Filter Alarm
Supply
Air
or Leaving Water Temp
F
Modem
(Optional)
110/24 VAC
Power Pak
Sensor
Typical WHP Controller Wiring
M
R
T
R
S
D
R
D
O
H
C
D
A
A
H
S
#30
#1
Loop #1
32K
8K
32K
8K
Network Loop
RS-485
19200 Baud
COMM
T
COMM
RELAY
OUTPUT
RELAY
OUTPUT
COM
COMM
T
COM
1-3
O
M
M
SHLD
R
SHLD
R
1-3
OUT
1
OUT
OUT
1
OUT
LINK
IN
K
LD4
485
COMM
RAM
EPROM
2
LD4
485
COMM
RAM
EPROM
2
OUT
3
OUT
4
OUT
3
OUT
4
REC.
REC.
II
I
OUT
5
OUT
5
CPU
COM
4-5
CPU
COM
4-5
L
COMM
TEST
COMM
TEST
O
O
C
O
M
12V
12V
WHP
Controllers
ADDRESS
ADD
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
M
O
D
P
P
AIN
3
AIN
3
E
M
AIN
4
AIN
5
AIN
4
AIN
5
GND
GND
GND
GND
AOUT
AOUT
PWR
GND
PWR
GND
PRESSURE
SENSOR
PRESSURE
SENSOR
W
AT
C
YS101564
YS101564
T
M
CommLink II
Multiple Loop
Interface
A
S
24VAC
24VAC
T
E
R
O
N
T
R
OLS
, INC
Local Loop
RS-485
9600 Baud
MiniLink
Loop # 1
System Manager
MINILINK
1
2
T
4
8
16
SH
R
32
24VAC
GND
T
SH
R
#30
#1
24VAC
24VAC
Loop #2
32K
8K
32K
WED
8K
COMM
COMM
RELAY
OUTPUT
COM
RELAY
OUTPUT
COM
T
T
03:38PM
SHLD
R
1-3
SHLD
R
1-3
MiniLink
OUT
1
OUT
OUT
1
OUT
OCCUPIED
ALARMS
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
LD4
2
LD4
2
03/31/04
NO
OUT
3
OUT
4
OUT
3
OUT
4
REC.
REC.
OUT
5
OUT
5
CPU
COM
4-5
CPU
COM
4-5
WHP
Controllers
COMM
TEST
COMM
TEST
Loop # 2
12V
12V
ADDRESS
ADD
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
AIN
3
AIN
3
MINILINK
1
2
AIN
4
AIN
5
AIN
4
AIN
5
T
4
8
16
SH
32
GND
GND
R
GND
GND
AOUT
AOUT
PWR
GND
PWR
GND
PRESSURE
SENSOR
PRESSURE
SENSOR
24VAC
GND
YS101564
YS101564
24VAC
24VAC
T
SH
R
24VAC
Local Loop
RS-485
9600 Baud
Typical Network & Local Loop Wiring
2 Conductor Twisted Pair with Shield
(Beldon #82760 or Equivalent)
#30
#1
Loop #3
MiniLink
Loop # 3
32K
8K
32K
8K
COMM
COMM
RELAY
OUTPUT
COM
RELAY
OUTPUT
COM
T
T
SHLD
R
1-3
SHLD
R
1-3
OUT
1
OUT
OUT
1
OUT
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
LD4
2
LD4
2
OUT
3
OUT
4
OUT
3
OUT
4
REC.
REC.
OUT
5
OUT
5
MINILINK
1
CPU
COM
4-5
CPU
COM
4-5
2
T
4
COMM
TEST
COMM
TEST
8
16
SH
R
32
12V
12V
ADDRESS
ADD
WHP
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
AIN
3
AIN
3
AIN
4
AIN
4
24VAC
GND
AIN
5
AIN
5
GND
GND
T
Controllers
GND
GND
SH
R
AOUT
AOUT
PWR
GND
PWR
GND
Local Loop
RS-485
9600 Baud
PRESSURE
SENSOR
PRESSURE
SENSOR
YS101564
YS101564
24VAC
24VAC
24VAC
WHP Loop
NOTE: * Only One Outside Air Sensor
is Required per WHP System
Controller
U3
See Note #3
Loop #4
CX1
CX2
RN1
U2
CX4
1
U1
U4
TB1
V1
V2
V3
COMM
#29
T
#1
SHLD
R
CX5
COM1-3
U5
LD6
PAL
R1
R2
R3
COMM
RS-485
COMM
1
RAM
EPROM
MiniLink
LD7
PWR
TUC-5R PLUS
(1 MEG)
YS101816 REV
1
HH
.
2
LD8
LED1
U6
R4
R5
4RLY
I
O
B
D
.
Y
S
1
0
1
7
9
0
C1
LD9
LED2
P1
COM4-5
32K
8K
32K
8K
R1
+VREF
CX6
TB2
5.11V
COMM
COMM
TEST POINT
RELAY
OUTPUT
COM
RELAY
OUTPUT
COM
U7
RV1
V4
V5
EWDOG
R28
T
T
Loop # 4
MINILINK
VREF ADJ
SHLD
R
1-3
SHLD
R
1-3
1
OUT
1
OUT
OUT
1
OUT
*OutsideAir
INPUTS
ADDRESS
ADD
U8
1
2
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
+VDC
4RLY
I
O
B
D
.
Y
S
1
0
1
7
9
0
LD4
2
LD4
2
RN5
OUT
3
OUT
4
OUT
3
OUT
4
4
NE5090NPB3192
0PS
AIN1
AIN2
AIN3
AIN4
AIN5
PU1
8
REC.
REC.
U9
AIN1
AIN2
AIN3
AIN4
D6
16
32
PU2
CX10
C7
OUT
5
OUT
5
1
D7
TOKEN
2
PU3
R6
C9
NETWORK
T
4
8
D8
U10
CPU
COM
4-5
CPU
COM
4-5
SW1
PU4
16
COMM
TEST
COMM
TEST
SH
R
D9
L1
32
Sensor
PU5
GND
CX12
D11
12V
12V
D12
R13
GND
GND
C10
PU7
D14
X2
9 9 3 6
AOUT1
ADDRESS
ADD
WHP
Controllers
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
JP1
M C 3 4 0 6 4 A
SC1
4
ANALOG IN MOD I/O BD.
YS101784
C13
C12
U13
AOUT1
R15
U12
AIN
3
AIN
3
24VAC
GND
AOUT2
AIN7
CX14
C14
R19
AIN
4
AIN
5
AIN
4
AIN
5
C16
U14
D15
CX13
U15
C17
GND
PJ1
TB4
T
C15
R22
GND
GND
TB3
D19
GND
SH
R
GND
GND
R24
R25
C20
CX15
AOUT
AOUT
PWR
GND
PWR
7 8 2 4 C T
M
PRESSURE
SENSOR
PRESSURE
SENSOR
GND
R26
24VAC
PRESSURE
SENSOR
YS101564
YS101564
EXPANSION
T'STAT
VR1
VR2
24VAC
24VAC
24VAC
Loop # 4
Local Loop
RS-485
9600 Baud
Notes:
3.) The Local Loop With The Loop Controller
Installed Can Only Have Up To 29
1.) 24 VAC Must Be Connected
So That All Ground Wires
Remain Common.
WHP Controllers Attached As The WHP
Loop Controller Occupies Address #30.
2.) All Wiring To Be In Accordance
With Local And National Electrical
Codes and Specifications.
4.) Systems may consist of up to 20 Local
Loops (600 WHP Controllers). Consult
factory for systems that exceed these quantities.
Typical WattMaster WHP System
Design Guide
1-15
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Section 1
WattMaster WHP
Notes:
1-16
Design Guide
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Section 2
Table of Contents
Tips Before Beginning Installation..................................1
Communications Loops ...................................................3
Communications Loop Wiring Overview....................................................4
WHP Loop Controller .......................................................6
WHP Loop Controller Addressing ....................................9
Supply & Return Water Temperature Sensors..............10
Outside Air Temperature Sensor...................................12
CommLink II Interface...................................................13
WHP Controller ..............................................................14
WHP Controller Addressing ...........................................17
MiniLink Addressing ......................................................18
Room Sensors................................................................19
Supply Air Temperature Sensor ....................................21
Leaving Water Temperature Sensors............................22
Installation and Wiring
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Section 2
Table of Figures
Figure 2-1: System Overview........................................................................................2
Figure 2-2: Communication Loop Wiring, Daisy-Chain Configuration .......................4
Figure 2-3: WHP Loop Controller.................................................................................6
Figure 2-4: WHP Loop Controller Wiring ....................................................................7
Figure 2-5: WHP Loop Controller Address Switch Setting..........................................9
Figure 2-6: Duct Sensor with Thermowell...................................................................10
Figure 2-7: Strap-On Water Temperature Sensor ........................................................11
Figure 2-8: Outside Air Temperature Sensor...............................................................12
Figure 2-9: CommLink Interface Wiring.....................................................................14
Figure 2-10: WHP Controller .....................................................................................14
Figure 2-11: WHP Controller Wiring.........................................................................15
Figure 2-12: WHP Controller Address Switch Setting...............................................17
Figure 2-13: MiniLink Address Switch Setting.........................................................18
Figure 2-14: Room Sensor Wiring..............................................................................19
Figure 2-15: Room Sensor..........................................................................................20
Figure 2-16: Supply Air Temperature Sensor..............................................................21
Figure 2-17: Water Temperature Sensor .....................................................................22
Figure 2-18: Water Temperature Sensor .....................................................................22
Installation and Wiring
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WattMaster WHP
Section 2
Tips Before Beginning
Installation
Take a few moments to review the following before beginning installation of the
WattMaster WHP System.
• Familiarize yourself with all system components and review all documentation. Pay
special attention to “Cautions” and “Warnings” since these may keep you from
experiencing unnecessary problems.
• Before installing controllers, be sure to tag it with its appropriate location. It is also
best to set the controller address switches before mounting. Use the WHP Address
Worksheet to list all WHP unit locations. This will assist you greatly when setting up
the system.
• Be sure and install all wiring according to local, state, and national electric codes.
• Pay close attention to communication wiring since the most common mistakes are
made in this area. Polarity is the most important rule. Make notes on your wiring
diagrams as to which color wire you will be using on each terminal.
• When in doubt - ask! Contact your local WattMaster distributor if you have any
questions. The only dumb questions are the ones you don’t ask.
• Remember - each electronic device contains only one puff of smoke. If you release it,
you have voided the warranty! So please be careful and pay attention.
Installation and Wiring
2-1
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Section 2
WattMaster WHP
COMPUTER
(OPTIONAL)
RS-485
Comm Loop
32K
8K
COMM
RELAY
OUTPUT
COM
T
Room Sensor
with Optional
Override & Adj.
SHLD
R
1-3
OUT
1
OUT
485
COMM
RAM
EPROM
LD4
2
OUT
3
OUT
4
REC.
OUT
5
CPU
COM
4-5
COMM
TEST
12V
ADDRESS
ADD
AIN
1
AIN
2
AIN
3
AIN
4
AIN
5
GND
GND
AOUT
PWR
GND
PRESSURE
SENSOR
YS101564
24VAC
24 VAC
110/24 VAC
Power Pak
Dirty Filter Alarm
Supply
Air
or Leaving Water Temp
F
Modem
(Optional)
110/24 VAC
Power Pak
Sensor
Typical WHP Controller Wiring
M
R
T
R
S
D
R
D
O
H
C
D
A
A
H
S
#30
#1
Loop #1
32K
8K
32K
8K
Network Loop
RS-485
19200 Baud
COMM
T
COMM
RELAY
OUTPUT
RELAY
OUTPUT
COM
COMM
T
COM
1-3
O
M
M
SHLD
R
SHLD
R
1-3
OUT
1
OUT
OUT
1
OUT
LINK
IN
K
LD4
485
COMM
RAM
EPROM
2
LD4
485
COMM
RAM
EPROM
2
OUT
3
OUT
4
OUT
3
OUT
4
REC.
REC.
II
I
OUT
5
OUT
5
CPU
COM
4-5
CPU
COM
4-5
L
COMM
TEST
COMM
TEST
O
O
C
O
M
12V
12V
WHP
Controllers
ADDRESS
ADD
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
M
O
D
P
P
AIN
3
AIN
3
E
M
AIN
4
AIN
5
AIN
4
AIN
5
GND
GND
GND
GND
AOUT
AOUT
PWR
GND
PWR
GND
PRESSURE
SENSOR
PRESSURE
SENSOR
W
AT
C
YS101564
YS101564
T
M
CommLink II
Multiple Loop
Interface
A
S
24VAC
24VAC
TE
R
O
N
T
R
OL
S, INC
Local Loop
RS-485
9600 Baud
MiniLink
Loop # 1
System Manager
MINILINK
1
2
T
4
8
16
SH
R
32
24VAC
GND
T
SH
R
#30
#1
24VAC
24VAC
Loop #2
D
32K
8K
32K
E
W
8K
M
P
COMM
COMM
RELAY
OUTPUT
COM
RELAY
OUTPUT
COM
8
3
:
T
T
3
D
0
E
1-3
1-3
SHLD
R
SHLD
R
I
4
0
P
S
OUT
1
OUT
OUT
1
OUT
MiniLink
U
M
/
C
R
1
C
A
3
O
L
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
/
LD4
2
LD4
2
A
3
0
OUT
3
OUT
4
OUT
3
OUT
4
O
N
REC.
REC.
OUT
5
OUT
5
CPU
COM
4-5
CPU
COM
4-5
WHP
Controllers
COMM
TEST
COMM
TEST
Loop # 2
12V
12V
ADDRESS
ADD
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
AIN
3
AIN
3
MINILINK
1
2
AIN
4
AIN
5
AIN
4
AIN
5
4
8
16
H
32
GND
GND
GND
GND
AOUT
AOUT
PWR
GND
PWR
GND
PRESSURE
SENSOR
PRESSURE
SENSOR
24VAC
GND
YS101564
YS101564
24VAC
24VAC
H
24VAC
Local Loop
RS-485
9600 Baud
Typical Network & Local Loop Wiring
2 Conductor Twisted Pair with Shield
(Beldon #82760 or Equivalent)
#30
#1
Loop #3
MiniLink
Loop # 3
32K
8K
32K
8K
COMM
COMM
RELAY
OUTPUT
COM
RELAY
OUTPUT
COM
T
T
SHLD
R
1-3
SHLD
R
1-3
OUT
1
OUT
OUT
1
OUT
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
LD4
2
LD4
2
OUT
3
OUT
4
OUT
3
OUT
4
REC.
REC.
OUT
5
OUT
5
MINILINK
1
CPU
COM
4-5
CPU
COM
4-5
2
T
4
COMM
TEST
COMM
TEST
8
16
SH
R
32
12V
12V
ADDRESS
ADD
WHP
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
AIN
3
AIN
3
AIN
4
AIN
4
24VAC
GND
AIN
5
AIN
5
GND
GND
T
Controllers
GND
GND
SH
R
AOUT
AOUT
PWR
GND
PWR
GND
Local Loop
RS-485
9600 Baud
PRESSURE
SENSOR
PRESSURE
SENSOR
YS101564
YS101564
24VAC
24VAC
24VAC
WHP Loop
NOTE: * Only One Outside Air Sensor
is Required per WHP System
Controller
U3
See Note #3
Loop #4
CX1
CX2
RN1
U2
CX4
1
U1
U4
TB1
V1
V2
V3
COMM
#29
T
#1
SHLD
R
CX5
COM1-3
U5
LD6
PAL
R1
R2
R3
COMM
RS-485
COMM
1
RAM
EPROM
MiniLink
LD7
PWR
TUC-5R PLUS
(1 MEG)
YS101816 REV
1
HH
.
2
LD8
LED1
U6
R4
R5
4RLY
I
O
B
D
.
Y
S
1
0
1
7
9
0
C1
LD9
LED2
P1
COM4-5
32K
8K
32K
8K
R1
+VREF
CX6
TB2
5.11V
COMM
COMM
TEST POINT
RELAY
OUTPUT
COM
RELAY
OUTPUT
COM
U7
RV1
V4
V5
EWDOG
R28
T
T
Loop # 4
MINILINK
VREF ADJ
SHLD
R
1-3
SHLD
R
1-3
1
OUT
1
OUT
OUT
1
OUT
*OutsideAir
INPUTS
ADDRESS
ADD
U8
1
2
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
+VDC
4RLY
I
O
B
D
.
Y
S
1
0
1
7
9
0
LD4
2
LD4
2
RN5
OUT
3
OUT
4
OUT
3
OUT
4
4
NE5090NPB3192
0PS
AIN1
AIN2
AIN3
AIN4
AIN5
PU1
8
REC.
REC.
U9
AIN1
AIN2
AIN3
AIN4
D6
16
32
PU2
CX10
C7
OUT
5
OUT
5
1
D7
TOKEN
2
PU3
R6
C9
NETWORK
T
4
8
D8
U10
CPU
COM
4-5
CPU
COM
4-5
SW1
PU4
16
COMM
TEST
COMM
TEST
H
D9
L1
32
Sensor
PU5
GND
CX12
D11
12V
12V
D12
R13
GND
GND
C10
PU7
D14
X2
9 9 3 6
AOUT1
ADDRESS
ADD
WHP
Controllers
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
JP1
M C 3 4 0 6 4 A
SC1
4
ANALOG IN MOD I/O BD.
YS101784
C13
C12
U13
AOUT1
R15
U12
AIN
3
AIN
3
24VAC
GND
AOUT2
AIN7
CX14
C14
R19
AIN
4
AIN
5
AIN
4
AIN
5
C16
U14
D15
CX13
U15
C17
GND
PJ1
TB4
C15
R22
GND
GND
TB3
D19
GND
H
GND
GND
R24
R25
C20
CX15
AOUT
AOUT
PWR
GND
PWR
7 8 2 4 C T
M
PRESSURE
SENSOR
PRESSURE
SENSOR
GND
R26
24VAC
PRESSURE
SENSOR
YS101564
YS101564
EXPANSION
T'STAT
VR1
VR2
24VAC
24VAC
24VAC
Loop # 4
Local Loop
RS-485
9600 Baud
Notes:
3.) The Local Loop With The Loop Controller
Installed Can Only Have Up To 29
1.) 24 VAC Must Be Connected
So That All Ground Wires
Remain Common.
WHP Controllers Attached As The WHP
Loop Controller Occupies Address #30.
2.) All Wiring To Be In Accordance
With Local And National Electrical
Codes and Specifications.
4.) Systems may consist of up to 20 Local
Loops (600 WHP Controllers). Consult
factory for systems that exceed these quantities.
System Overview
2-2
Installation and Wiring
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WattMaster WHP
Section 2
Communications Loops
The Communications Loop is two wire shielded RS-485. The loop is best connected in
daisy chain configuration, meaning the loop is connected from one controller to another.
It is not necessary to sequentially address the WHP Controllers in relation to their
location on the loop. Cable must be Belden No. 82760 or equivalent.
Tip: Incorrect wiring of the communications loop is the most common mistake made
during installation. Before beginning installation, write down the wire color used
on each terminal connection and consistently maintain that color code. It is
recommended that a continuous wire run be made between devices. Anytime a
splice is made in the cable you increase your chance of problems.
Caution: Make sure when you are inserting wires into the terminal blocks that
strands of wire do not stick out and touch the next terminal. This could
cause a short or erratic operation.
Installation and Wiring
2-3
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Section 2
WattMaster WHP
Communications Loop Wiring Overview
COMPUTER
(OPTIONAL)
POWER
24VAC
GND
COMMUNICATIONS
T
SHLD
R
SYSTEM MANAGER POWER SUPPLY
RS-485
YS101716 REV.
1
SYSTEM MANAGER
COMM LINK II
INTERFACE
(SET TO MULTIPLE LOOP)
UNIT COMES WITH
STANDARD WALL MOUNT
120/24 VAC POWER SUPPLY
( MAY ALSO BE POWERED FROM 24VAC )
Remote Link
(OPTIONAL)
U3
CX1
CX2
R
N
1
U2
CX4
1
U1
U4
CPU
TB1
COMM
V1
V2
V3
T
SHLD
R X5
C
COM1-3
U5
L
D
6
PAL
R1
R2
R3
C
OMM
R
S-48
5
1
RA
M
EPROM
TUC-5
CO
M
M
LD
PWR
7
R
PLU
(1 MEG)
EV.
S
1
H
H
U
6
YS1018
1
6
R
2
L
D
8
R4
R5
4RLY IO BD. YS101790
LED1
C1
L
D9
LED2
P1
COM4-5
R1
+VREF
TB2
CX6
5.11V
U7
T
E
STPOIN
T
V4
V5
EWDO
G
R
V1
VR
E
FA
DJ
R
28
1
INPUTS
ADDRESS
ADD
1
U8
+VDC
4RLY IO BD. YS101790
2
4
RN
5
N
E5090NPB3192
PS
AIN1
AIN2
AIN3
AIN4
AIN5
GND
GND
PU1
6
8
0
U9
D
AIN1
AIN2
16
32
PU2
CX10
C7
D
7
PU3
TOKEN
NETWORK
R6
AIN3
AIN4
D
8
PU4
U10
SW1
D
9
PU5
L1
C9
GND
CX12
D
11
PU7
14
D
R
12
13
C10
X2
9
9
3
AOUT1
4
D
J
P1
A
6 4
3
4 C 0 M
SC
1
ANALOG IN MOD I/O BD.
YS101784
C13
C12
U13
AOUT1
R15
U12
AOUT2
AIN7
CX14
C1
4
C1
6
R
19
U14
D
15
C
X13
C17
GND
PJ1
TB4
U15
C15
TB3
D19
GND
R
22
24
25
R
R
C2
0
CX15
T
4 C
7 8 2
R26
24VAC
PRESSURE
SENSOR
EXPANSION
T'STAT
VR1
VR2
CPU
NETWORK
LOOP
TO OTHER WHP CONTROLLERS
TO OTHER MINILINKS
(NETWORK TERMINALS ONLY)
Communication Loop Wiring, Daisy-Chain Configuration
2-4
Installation and Wiring
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WattMaster WHP
Section 2
The daisy chain is the best method for running a communications loop since there is only
one starting point and one ending point for each of the communications loops. Even
though the daisy chain configuration is preferred, the star configuration can also be used.
If required, a combination of the two can also be used. Remember, the best
communication loop wiring is the one which utilizes the minimum number of ends while
using the shortest wiring path.
Note: The loop does not have to follow the controller address sequence.
Caution: If the comm loop is not installed in conduit, be careful to position the
cable away from high noise devices like fluorescent lights, transformers,
VFD’s, etc. Conduit is not required for comm loop wiring unless
required by local codes.
Make sure CommLink jumper is set for “Multi”.
Installation and Wiring
2-5
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Section 2
WattMaster WHP
WHP Loop Controller
The WHP Loop Controller may be installed in any convenient protected location. It is
recommended that the loop controller be mounted indoors in a secure location, that is not
subject to extremes in temperature or moisture.
.20 Dia.
Typ. of 4
6.2’’
4.0”
U3
CX1
CX2
RN1
U2
CX4
1
U1
U4
TB1
COMM
V1
V2
V3
T
SHLD
R
CX5
COM1-3
U5
LD6
PAL
R1
R2
R3
COMM
RS-485
COMM
1
RAM
EPROM
LD7
PWR
TUC-5R PLUS
(1 MEG)
YS101816 REV.
1
HH
2
U6
LD8
LED1
R4
R5
C1
LD9
LED2
P1
COM4-5
R1
+VREF
TB2
CX6
5.11V
TEST POINT
U7
RV1
V4
V5
EWDOG
R28
VREF ADJ
7.3”
1
INPUTS
ADDRESS
ADD
8.29”
8.96”
9.5”
6.6”
U8
1
2
+VDC
AIN1
AIN2
AIN3
AIN4
AIN5
RN5
4
NE5090NPB3192
0PS
PU1
8
U9
D6
16
32
CX10
PU2
C7
D7
PU3
TOKEN
R6
C9
NETWORK
D8
PU4
U10
SW1
D9
PU5
L1
CX12
D11
PU7
D12
R13
X2
C10
9 9 3
GND
GND
3 4 C 0 M 6 4 A
D14
JP1
SC1
C13
C12
U13
R15
AOUT1
AOUT2
AIN7
U12
CX14
C14
R19
C16
U14
CX13
U15
D15
C20
C17
TB4
GND
C15
R22
D19
TB3
PJ1
GND
R24
R25
CX15
T
7 8 2 4 C
R26
24VAC
PRESSURE
SENSOR
VR1
EXPANSION
VR2
T'STAT
2.12”
0.28”
4.24”
WHP Loop Controller Main Board
WHP Loop Controller Expansion Board
WHP Loop Controller
2-6
Installation and Wiring
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WattMaster WHP
Section 2
WHP Loop Controller Expansion Board
Connect To Next WHP Controller
And/Or MiniLink On Local Loop
U3
CX1
CX2
RN1
U2
CX4
1
U1
U4
TB1
COMM
V1
V2
V3
Local Loop RS-485
9600 Baud
T
SHLD
R (24 VAC By Others)
Compressor Enable
Outside Air
Temp. Sensor
R
CX5
COM1-3
U5
LD6
PAL
R1
R2
R3
R1
R2
R3
COMM
RS-485
COMM
1
RAM
EPROM
LD7
PWR
TUC-5R PLUS
(1 MEG)
YS101816 REV.
1
HH
Main Pump
2
U6
LD8
LED1
R4
R5
C1
Standby Pump
LD9
LED2
P1
COM4-5
R1
+VREF
TB2
CX6
5.11V
N.C. Pilot Duty Relays
(By Others)
TEST POINT
U7
RV1
Return Water
V4
V5
EWDOG
R28
Temp Sensor
VREF ADJ
1
INPUTS
Alarm Indicator
ADDRESS
ADD
U8
1
2
+VDC
RN5
4
NE5090NPB3192
0PS
PU1
AIN1
AIN2
AIN3
AIN4
AIN5
8
U9
D6
16
32
CX10
PU2
D7
Supply Water
Temp Sensor
C7
TOKEN
R6
C9
NETWORK
PU3
U10
SW1
PU4
D9
PU5
L1
CX12
D11
PU7
D12
R13
X2
C10
9 9 3
GND
GND
6 4 A 3 4 C 0 M
D14
U13
JP1
SC1
See Note 4
C13
C12
R15
AOUT1
AOUT2
AIN7
U12
CX14
C14
R19
C16
Required VA For Transformer
Loop Controller = 8VA Min.
U14
CX13
U15
D15
C20
C17
TB4
GND
C15
R22
D19
TB3
PJ1
GND
GND
R24
R25
Line Voltage
See Note 1
CX15
Proof of
Flow
T
4 C 7 8 2
24VAC
R26
24VAC
PRESSURE
SENSOR
Optional Pressure
Transmitter
EXPANSION
VR1
VR2
T'STAT
Manual
Reset
Phase
Loss
N.C. Pilot Duty Relays
(By Others)
-
R4
R5
Heating/Cooling #1
Heating/Cooling #2
Pump VFD
+
R6
Heating/Cooling #3
R7
Heating/Cooling #4
24 VAC
-
YS101790
4RLY IO BD.
Optional
Modulating Heat
+
R8
R9
Heating/Cooling #1
Heating/Cooling #2
Notes:
1.)24 VAC Must Be Connected So
That All Ground Wires Remain
Common.
R10
Heating/Cooling #3
R11
Heating/Cooling #4
24 VAC
Fire Alarm Contact (N.C.)(See Note 5)
Request to Run Contact (N.O.)
YS101790
4RLY IO BD.
AIN1
AIN2
AIN3
AIN4
2.)All Wiring To Be In Accordance
With Local And National Electrical
Codes And Specifications.
GND
AOUT1
3.)All Communication Wiring To Be
2 Conductor Twisted Pair With
Shield. Use Belden #82760 Or
Equivalent.
4 ANALOG IN MOD I/O BD.
YS101784
Relay Contacts
(By Others)
4.)When a Water Pressure Transmitter
Is Used, a 250 Ohm Resistor is
Installed Between AIN3 & GND and
The Pull Up Resistor PU3 is
Removed.
5.)If a Fire Alarm Contact is Not
Connected to AIN1 on The Analog
Expansion Board, Then a Jumper
Must Installed Between AIN1 and
GND.
WHP Loop Controller Expansion Board
WHP Loop Controller Wiring
Installation and Wiring
2-7
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Section 2
WattMaster WHP
Warning: Polarity is very important when connecting power to the controllers!
The grounded side of the control transformer must be connected to
the terminal labeled GND on the controller. If a single transformer is
used to power more than one controller you must connect GND-to-
GND and 24VAC-to-24VAC on each controller. Failure to
observe polarity will result in damage to one or
more components in your system.
The WHP Loop Controller requires the following electrical connections:
-24VAC Supply Voltage.................................................... 2 Conductors (18 Ga. Min.)
-Communications Loop .......2 Conductor twisted pair with shield (18 Ga. Minimum)
(Belden #82760, WattMaster Cable or equivalent)
-Supply Water Temperature Sensor...................................(24 ga. Min.) 2 Conductors
-Return Water Temperature Sensor....................................(24 ga. Min.) 2 Conductors
-Outside Air Temperature Sensor.......................................(24 ga. Min.) 2 Conductors
-Loop Pressure Sensor (Optional)........................................(24 ga. Min) 2 Conductors
-Fire/Smoke Alarm Contacts ..............................................(24 ga. Min.) 2 Conductors
-Loop Pressure Switch.........................................................(24 ga. Min) 2 Conductors
-Manual Reset Switch..........................................................(24 ga. Min) 2 Conductors
-Request to Run Contacts ....................................................(24 ga. Min) 2 Conductors
-Analog Outputs...................................................................(24 ga. Min) 2 Conductors
-Binary Outputs....................................................................(24 ga. Min) 2 Conductors
Tip: After making all electrical connections it is advised to unplug all terminal blocks
on the WHP Loop Controller until you are ready to begin the checkout
procedure. This may help to prevent damage if wiring errors occur elsewhere in
the system during installation or start-up.
2-8
Installation and Wiring
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WattMaster WHP
Section 2
WHP Loop Controller
Addressing
The WHP Loop Controller must be set for address #30. See address setting instructions
for the WHP Loop Controller that follow. A maximum of 29 WHP Controllers are
allowed on the loop that contains the WHP Loop Controller. All other loops may have 30
WHP Controllers.
ADDRESS
ADD
This Switch Should Be
In The OFF Position
As Shown
1
2
4
8
16
32
TOKEN
NETWORK
Note:
The Power To The Controller Must Be Removed And
Reconnected After Changing The Address Switch
Settings In Order For Any Changes To Take Effect.
Controller
Address Switch
Address Switch Must Be Set For
Address 30 As Shown
Caution
Disconnect All Communication Loop Wiring From The
Controller Before Removing Power From The Controller.
Reconnect Power And Then Reconnect Communication
Loop Wiring.
INPUTS
ADD
ADDRESS
+VDC
1
2
RN5
PU1
AIN1
AIN2
AIN3
AIN4
AIN5
4
8
16
D6
CX10
PU2
C7
32
D7
PU3
R6
TOKEN
NETWORK
D8
PU4
U10
SW1
D9
PU5
L1
C9
CX12
D11
D12
R13
X2
PU7
GND
GND
C10
D14
JP1
SC1
C13
C16
U13
C12
R15
AOUT1
U12
AOUT2
AIN7
CX14
C14
R19
U14
CX13
U15
D15
C20
C17
TB4
GND
C15
R22
D19
TB3
PJ1
GND
R24
R25
CX15
R26
24VAC
PRESSURE
SENSOR
VR1
EXPANSION
VR2
WHP Loop Controller Address Switch Setting
Installation and Wiring
2-9
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Section 2
WattMaster WHP
Supply & Return Water
Temperature Sensors
Sensors for monitoring supply and return water temperature are available in two main
types, fluid immersion temperature sensors (See Figure 2-6) and strap-on sensors (See
Figure 2-7). Both are 0-10000 ohm thermistor type sensors. The fluid immersion sensor
generally has better accuracy than the strap-on type but either is suitable for typical water
source heat pump temperature requirements. The fluid immersion type sensor requires
that a thermowell be installed in the pipe and the strap-on type, as its name implies,
simply straps around the outside of the pipe. The fluid immersion sensor requires that the
pipe be at least 4” in diameter in order to accept the thermowell. The strap-on type sensor
is adjustable for use on 1/2” to 6” or larger diameter pipe.
The fluid immersion sensor is provided with a 4” long stainless steel thermowell. It has
½” MPT external threads and ½” FPT internal threads. A ½” FPT fitting to accept the
thermowell must be provided by others in the pipe to be monitored, for connection of the
thermowell. The thermowell is screwed into the ½” FPT fitting installed by others in the
pipe and the sensor probe is then screwed into the ½” FPT fitting on the thermowell.
Leads Are Non-polarized.
Butt Splice Leads To 24 Gauge
Wire Minimum. Connect Leads
To "Analog In" And "Ground"
At Controller.
OE230 Duct Sensor
The OE230 Duct Sensor Threads Into The OE291 Stainless
Steel Thermowell. The OE291 Thermowell Threads Into A 1/2”
OE291 Stainless Steel Thermowell
FPT Elbow or Tee in the Water Piping of the Water Coil
Where You Wish to Measure the Water Temperature. The
Pipe must be a minimum of 4” Diameter or an Extended Tee
and Bushing Configuration Must be Used to Accommodate the
Length of the Thermowell Assembly.
Duct Sensor with Thermowell
2-10
Installation and Wiring
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WattMaster WHP
Section 2
The strap-on type sensor has a brass housing that senses the water temperature through
contact with the exterior surface of the pipe. The sensor should be mounted in contact
with the underside of the pipe in order to insure accurate temperature readings. The
sensor assembly is secured to the pipe by using the supplied wire ties to wrap and secure
the sensor to the pipe. Thermal conductive compound is also supplied to insure a good
thermal connection with the pipe. The sensors are supplied with 3 foot long wire leads.
Supply Or Return
Wire Tire
Water Pipe.
(Supplied)
Sensing Element
(Supplied)
Thermal Mastic Strip
(Supplied)
Strap-On Water Temperature Sensor
Installation and Wiring
2-11
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Section 2
WattMaster WHP
Outside Air Temperature
Sensor
The outside air sensor must be located where it will not be affected by direct sun or heat
producing equipment. Mounting under the eve of a roof is often a good choice.
Caution: Complaints of inaccurate outside sensor readings are very common and
can almost always be shown to be the result of poor sensor location.
Note: All temperature sensors supplied with the system utilize the same thermistor
type sensing element. For troubleshooting sensor problems refer to the
TEMPERATURE SENSOR RESISTANCE CHART at the end of Section 4.
Cover
Mounting
Screw - Typ.
Closure Plug
Gasketed Cover
2.70”
2.30”
3.00”
0.21" Dia. x 0.73
Lg. Slot - Typ.
Mounting Tab
& Screws - Typ.
Mounting Tab
& Screw - Typ.
Closure Plug
Sensor Tube
Back View
Front View
Side View
Outside Air Temperature Sensor
2-12
Installation and Wiring
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WattMaster WHP
Section 2
CommLink II Interface
The CommLink II Interface provides for communications between the MiniLink
communication interfaces installed on the system. The CommLink II is required for
proper communications, even if a PC is not used. Locate the CommLink II near the
computer or modem if they are installed on the system. The cable connections between
the CommLink II and the computer or modem should be kept to less than twenty-five
feet. The CommLink II comes complete with computer and modem cables, and a plug-in
power supply.
COMPUTER
(OPTIONAL)
POWER
24VAC
GND
COMMUNICATIONS
T
SHLD
R
SYSTEM MANAGER POWER SUPPLY
RS-485
YS101716 REV.
1
SYSTEM MANAGER
COMM LINK II
INTERFACE
(MULTIPLE LOOP)
UNIT COMES WITH
STANDARD WALL MOUNT
120/24 VAC POWER SUPPLY
( MAY ALSO BE POWERED FROM 24VAC )
Remote Link
(OPTIONAL)
U3
CX 1
CX2
RN1
U2
CX4
1
U1
U4
CPU
T
B
1
V1
V2
COMM
T
V3
SHLD
R
CX
5
COM1-3
U5
LD6
PA L
R1
R2
R3
CO
M
M
RS-485
CO
1
RA
M
EPROM
MM
LD7
PW
T
UC-5R PLUS
(1ME
S101816 RE
1
HH
R
G)
Y
V
.
2
LD8
LED1
U6
R4
R5
4RLY IO BD. YS101790
C1
LD9
LED2
P1
COM4-5
R1
+VREF
TB2
CX6
5.11V
NT
U7
T
E
ST
PO
I
V4
V5
EWDO
G
RV
V RE
1
F
ADJ
R28
1
I
NPUTS
ADDRESS
ADD
U8
1
+VDC
4RLY IO BD. YS101790
2
4
RN5
NE5090NPB3192
0PS
AIN1
AIN2
AIN3
AIN4
AIN5
P
U1
8
U9
AIN1
AIN2
AIN3
AIN4
D6
16
32
PU2
CX10
C7
D7
PU3
TO
KE
N
R6
NE T
W
O
R K
D8
U10
SW1
PU4
D9
PU5
L1
C9
GND
CX12
D1
PU7
1
D12
R13
C10
X2
9 9 3
AOUT1
GND
GND
D14
J
P 1
3 4
C
0
M
6 4 A
SC1
4
ANALOG IN MOD I/O BD.
YS101784
C13
C12
U13
AOUT1
R15
U12
AOUT2
AIN7
CX14
C14
R19
C16
U14
CX13
D15
C20
C17
GND
TB4
U15
C15
R22
T
B3
P
J 1
D19
GND
R24
R25
CX15
T
7 8 2 4 C
R26
24VAC
PRESSURE
SENSOR
EXPANSION
T'STAT
VR1
VR2
CPU
NETWORK
LOOP
TO OTHER WHP CONTROLLERS
TO OTHER MINILINKS
(NETWORK TERMINALS ONLY)
CommLink Interface Wiring
Installation and Wiring
2-13
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Section 2
WattMaster WHP
WHP Controller
The WHP Controller may be installed in any convenient protected location. Observe the
recommended environmental limitations for the WHP Controller when selecting a
installation location. The environmental limitations are a temperature range of 10°F to
149°F, and a maximum operating humidity of 90% RH non-condensing.
The WHP Controller may be mounted by fastening to a flat surface through the mounting
plate. The unit is mounted by four (4) screws in the corners. Select the correct screws or
other fasteners for the type of mounting material being utilized.
RAM SIZE
SELECT JUMPER
COMMUNICATIONS
DRIVER CHIP
RAM
EPROM
PIN 1
INDICATION
PAL
24 VAC Common for Inputs 1 - 3
Fan-On/Off
RS-485
COMMUNICATIONS
LOOP
Rev. Valve-On/Off (Heat 1)
Compressor-On/Off (Heat 2)
Heat Pump Reset (Cool 1)
Aux. Heating or Cooling (Cool 2)
24 VAC Common for Inputs 1 - 3
COMMUNICATIONS
LED
ADDRESS SWITCH
( ADDRESS 18 SHOWN )
CPU
ANALOG INPUTS
Space Sensor
DIAGNOSTIC BLINK
CODE LED
Slide Adjust
Supply Air Temp
Leaving Water
Temp or
Dirty Filter
REAL TIME
CLOCK CHIP
Lockout
POWER LED
24VAC
POWER
INPUT
STATIC PRESSURE
SENSOR INPUT
Mounting Backplate
WHP Controller
2-14
Installation and Wiring
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WattMaster WHP
Section 2
All Comm Loop Wiring Is
Straight Thru
T
SH
R
T
SH
R
T
SH
R
T
SH
R
Connect To
Next Controller
And/Or
MiniLink On
WHP Controller
Water Source Heat Pump
Unit Connections
Local Loop
RS-485
9600 Baud
E
COMM
RELAY
OUTPUTS
COM
R
A
P
R
O
M
T
M
Room Sensor
1-3
24VAC
Fan-On/Off
SHLD
OUT
1
R
OUT
Rev. Valve-On/Off
Compressor-On/Off
2
LD4
TMP
OUT
W
A
R
M
E
3
OUT
REC.
Heat Pump Reset
Aux. Heating Or Cooling
4
GND
AUX
OUT
R
NORMAL
C
5
O
COM
4-5
O
L
OVR
Connection To
COMM
TEST
E
R
AUX Terminal is Reqd
Only When Sensor
Is Specified With
12V
AIN
1
ADDRESS
ADD
AIN
2
Diagnostic Blink Code LED
Slide Adjust Option
AIN
3
Discharge
Air Temp.
Sensor
AIN
4
AIN
5
Required VA For Transformer
Each WHP Controller = 10VA MIN.
GND
Mount In HVAC
Unit Supply
Air Duct
GND
PWR
GND
AOUT
GND
24VAC
24VAC
Dirty Filter
Alarm Contact
Thermowell
Or Surface Mount
Temp Sensor
CAUTION!
WHP CONTROLLERS
Lockout
MUST HAVE ADDRESS SWITCHES
SET BETWEEN 1 AND 30
(Leaving Water Temp)
(UP TO 30 UNITS PER LOCAL LOOP)
EXCEPT ON THE LOOP WITH THE
LOOP CONTROLLER CONNECTED.
THE LOOP CONTROLLER ADDRESS
IS 30, WHICH ALLOWS FOR ONLY
29 WHP CONTROLLERS ON THIS
LOCAL LOOP.
Optional Features
WHP Controller Wiring
Warning: Polarity is very important when connecting power to the controllers!
The grounded side of the control transformer must be connected to
the terminal labeled GND on the WHP Controller. If a single
transformer is used to power more than one WHP Controller you
must connect GND-to-GND and 24VAC-to-24VAC on each WHP
Controller. Failure to observe polarity will result in
damage to one or more components in your
system.
Warning: Use extreme care not to damage any of the electronic components
while mounting the backplate. Mark the holes then remove the WHP
Controller from the backplate before drilling.
Do not allow metal shavings to fall onto the circuit boards.
Installation and Wiring
2-15
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Section 2
WattMaster WHP
The WHP Controller requires the following electrical connections:
18 Gauge minimum unless otherwise noted.
-24VAC Supply Voltage........................................................................... 2 Conductors
-Communications Loop ...................................... 2 Conductor twisted pair with shield
(WattMaster Cable, Belden #82760 or equivalent)
-Discharge Air Temperature Sensor ..................................(24 ga. Min.) 2 Conductors
-Room Air Temperature Sensor...........(24 ga. Min.) 2 Conductors for standard sensor
3 Conductors for sensors with setpoint adjustment
-Outside Air Temperature Sensor.......................................(24 ga. Min.) 2 Conductors
-WHP Unit Control Wiring .........................................................(24 ga.Min.) 24 VAC
Fan- ON/OFF
Rev Valve-ON/OFF
Compressor-ON/OFF
Heat Pump Reset
Aux. Heating or Cooling
Tip: After making all electrical connections it is advised to unplug all terminal blocks
on the WHP Controller until you are ready to begin the checkout procedure. This
may help to prevent damage if wiring errors occur elsewhere in the system
during installation or start-up.
2-16
Installation and Wiring
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WattMaster WHP
Section 2
WHP Controller
Addressing
NOTE:
IGNORE ANY MARKINGS
OR NUMBERS ON THE SWITCH
USE THE CHART!
To determine the boards address,
add the values of all the switches
which are toggled down in the
direction of the arrow
NOTE:
ADDRESS 30 CANNOT BE USED
ON THE LOOP THAT HAS THE WHP LOOP
CONTROLLER ATTACHED. ADDRESS 30
ON THAT LOOP IS RESERVED FOR THE
WHP LOOP CONTROLLER.
CAUTION:
YOU MUST POWER DOWN THE CONTROLLER
AFTER CHANGING THE ADDRESS SWITCHES
IN ORDER FOR ANY CHANGES TO TAKE EFFECT.
ALWAYS REMOVE THE COMMUNICATIONS LOOP
PRIOR TO DISCONNECTING POWER. RECONNECT
POWER AND THEN RECONNECT THE COMMUNICATIONS
LOOP TO THE CONTROLLER.
WHP Controller Address Switch Setting
Installation and Wiring
2-17
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Section 2
WattMaster WHP
MiniLink Addressing
MiniLink Communications Interface
Connect To Next
MiniLink And/Or
CommLink On
Network Loop
Network Loop
RS-485
ADD
19200 Baud
1
2
T
NETWORK
4
8
16
SH
32
R
OFF
>
All Communication Loop
Wiring Is Straight Through
24VAC
Line Voltage
T
SH
R
T
SH
R
T
SH
R
T
SH
R
24VAC
GND
T
SH
R
Required VA For Transformer
Local Loop
RS-485
9600 Baud
MiniLink = 6VA Min.
See Note 1.
Connect To Next
Controller or
System Manager
ADD
1
Caution!
2
4
8
16
32
The MiniLinks Must Have Address Switches Set Between 1
And 30 (Up To 30 MiniLinks Are Allowed Per WHP System
System). The MiniLinks Should Be Addressed In
Consecutive Order Starting With Address #1. Address #1
Must Be Present On The Loop For The System To Function.
These Switches Must Be
In The OFF Position
As Shown
Note:
The Power To The MiniLink Must Be Removed And
Reconnected After Changing The Address Switch
Settings In Order For Any Changes To Take Effect.
Caution:
Disconnect All Communication Loop Wiring
From The MiniLink Before Removing Power
From The MiniLink. Reconnect Power And Then
Reconnect Communication Loop Wiring.
MiniLink
Address Switch
Notes:
1.)24 VAC Must Be Connected So
That All Ground Wires Remain
Common.
Address Switch Shown Is
Set For Address 1
Address Switch Shown Is
Set For Address 4
The Address For Each MiniLink
2.)All Wiring To Be In Accordance
With Local And National Electrical
Codes And Specifications.
Must Be Unique To The Other MiniLinks
On The Network Loop. Loop #1 MiniLink
Should Be Addressed As #1
Loop #2 MiniLink Should Be Addressed
As #2 Etc..
3.) All Communication Wiring To Be
2 Conductor Twisted Pair With
Shield. Use Belden #82760 Or
Equivalent.
MiniLink Address Switch Setting
2-18
Installation and Wiring
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WattMaster WHP
Section 2
Room Sensors
The room sensor uses a patented flush mount design to isolate the temperature sensing
element from the housing which mounts flush with the wall surface.
Room sensors should be located on an inside wall away from direct sunlight or heat
producing equipment such as computers, copiers, etc. Such devices can adversely affect
the accuracy of the sensor.
Although the sensor eliminates most of the effects of thermal coupling to the walls, try to
avoid walls which retain large amounts of thermal energy (such as marble or steel). Walls
containing either cold or warm air currents should also be avoided whenever possible.
Avoid locating the sensor in dead air areas of a room. This will result in slow response to
temperature changes in the space.
Mount the sensor approximately 50-60 inches from the floor for best results.
The room sensor is designed to mounted vertically in a standard 2 by 4 inch electrical
box. The sensor may be mounted directly into the drywall where electrical codes do not
require low voltage wiring to be enclosed in conduit. See enclosed sheet for dimensional
and installation data.
Tip: Be careful when cutting the hole for the sensor or the plastic bezel of the sensor
may not completely cover the opening.
WHP CONTROLLER
ROOM SENSOR WITH OVERRIDE
AND ADJUSTABLE SETPOINT
TMP
W
A
R
M
E
R
GND
AUX
C
O
O
L
OVR
E
R
ADJUSTABLE
SETPOINT
OVERRIDE
ONLY REQUIRED WHEN
USING ADJUSTABLE
SETPOINT
Room Sensor Wiring
Installation and Wiring
2-19
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Section 2
WattMaster WHP
Connect the terminal labeled GND on the zone sensor to the terminal labeled GND on the
WHP Controller Analog Input terminal block. Connect the terminal labeled TMP on the
zone sensor to the terminal labeled AIN 1 on the WHP Controller Analog Input terminal
block. If the zone sensor has a setpoint adjust slider, then connect the sensor terminal
labeled AUX to the WHP Controller AIN 2 terminal block.
Tip: If sensors must be installed on walls which are solid and cannot be penetrated,
surface mounted boxes and raceway can be purchased from your local electrical
distributor.
2.00“
2.75“
0.88“
TMP
GND
AUX
OUT
W
A
R
M
E
R
C
O
O
L
E
R
0.25“
Wall Cut-Out Dimensions
When Sensor Is To Be
Mounted Without
Handy Box (By Others)
Room Sensor
2-20
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WattMaster WHP
Section 2
Supply Air Temperature
Sensor
The supply air temperature sensor should be located in the duct, as close to the rooftop
unit discharge as possible for best response.
Locate the sensor in the center of the widest part of the duct. Use the supplied template
and a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and
mount securely to the duct using the supplied sheet metal screws. Be sure the gasket is
compressed to provide an air tight seal.
For best accuracy, apply insulation on the outside of the duct, over the sensor. This will
help prevent thermal gradients from affecting the sensor.
Leads Are Non-polarized.
Butt Splice Leads To 24 Gauge
Wire Minimum. Connect Leads
To "Analog In" And "Ground"
At Controller.
4.0"
Thread
3/4"
Together
5-1/2" (OE230)
11-1/2" (OE231)
Mounting Plate
1/4" Hex Head Sheet Metal Screws
Mounting Plate
Gasket
Adhesive Backed Drill Guide
Mounting Template
Duct Work
Drill 5/16" Hole In Ductwork For Probe
Supply Air Temperature Sensor
Installation and Wiring
2-21
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Section 2
WattMaster WHP
Leaving Water
Temperature Sensors
The leaving water temperature sensor (optional) when used should be located on the
leaving water piping close to the water source heat pump unit. Either a thermowell type or
a surface mount sensor may be used depending on job requirements.
Leads Are Non-polarized.
Butt Splice Leads To 24 Gauge
Wire Minimum. Connect Leads
To "Analog In" And "Ground"
At Controller.
OE230 Duct Sensor
The OE230 Duct Sensor Threads Into The OE291 Stainless
Steel Thermowell. The OE291 Thermowell Threads Into A 1/2”
FPT Elbow or Tee in the Water Piping of the Water Coil
Where You Wish to Measure the Water Temperature. The
Pipe must be a minimum of 4” Diameter or an Extended Tee
and Bushing Configuration Must be Used to Accommodate the
Length of the Thermowell Assembly.
OE291 Stainless Steel Thermowell
Water Temperature Sensor
Supply Or Return
Water Pipe.
Wire Tire
(Supplied)
Sensing Element
(Supplied)
Thermal Mastic Strip
(Supplied)
Water Temperature Sensor
2-22
Installation and Wiring
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Section 3
Table of Contents
LCD/Keypad Operations...................................................1
System Manager Layout...................................................................................................2
Keypad Functions ............................................................................................................2
System Manager LED Indicators .....................................................................................3
Heat Pump Status Screens..............................................4
View Status Only.............................................................................................................4
View Alarms ....................................................................................................................8
Menu Setpoints ................................................................................................................9
Set Time & Date ..............................................................9
New Passcodes..............................................................11
Rebuild Alarm Map.........................................................12
Heat Pump Setpoints.....................................................13
Heat Pump Setpoint Menu.............................................................................................13
1) WHP Setpoints ..........................................................................................................13
2) WHP Schedules.........................................................................................................20
Holidays .........................................................................................................................21
3) Reset Pumps ..............................................................................................................22
Loop Controller Status ..................................................23
Loop Controller Status Menu.........................................................................................23
Loop Controller Status Screens ....................................23
Loop Controller Setpoints .............................................27
Loop Controller Setpoint Menu.....................................................................................27
Notes:.............................................................................32
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WattMaster WHP
Section 3
LCD/Keypad Operations
Main Screen
The Water Source Heat Pump System Manager is the operator’s interface to the status
and setpoints of any WattMaster Water Source Heat Pump (WHP) component on your
communications loop. With the System Manager, you can view any temperature or output
condition and change any setpoint to fine tune the operations of the total system. All
keypad operations are simple and straight-forward, utilizing non-cryptic plain English
messages. The System Manager automatically detects the type of unit that has been
selected, and displays the appropriate status and setpoint screens. The attractive plastic
case of the System Manager allows for placement in any area of your building.
The remainder of this document will lead the user through the system menus and keypad
operation.
All user functions are accessed by pressing the Menu button. Once the button is pressed,
the Main User Menu is displayed.
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Section 3
WattMaster WHP
System Manager Layout
Keypad Functions
The System Manager keypad is labeled either numerically or as to actual function for that
key. Below is a summary of the labeled keys and their functions.
This key is used to gain access to the first menu, and the user will be
notified, on the LCD, if any subsequent use of the key will be
required for further access.
The ESCape key allows the user to abort what they are doing or exit
back to previous menus. Also, anytime you want to leave the system
unattended you should press the ESC key until the Main Screen
appears.
MENU
ESC
If you make a mistake while entering setpoint data, you can clear the
bad data from the display by pressing the Clear key.
Use the Enter key to close out a data entry. It can also be used to
advance to the next field or screen.
If entering a setpoint that requires a decimal point, press this key
where the decimal is located while entering the value.
If you need to enter a negative value, you must press the Minus key
before entering the digits for that value.
CLEAR
ENTER
DEC
MINUS
Use these keys to step forward or backward through Status Screens or
Setpoint Data Fields.
UP/DOWN
Arrows
If the screen prompts you to use these keys, it is used normally to
toggle modes of operation.
LEFT/RIGHT
Arrows
3-2
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WattMaster WHP
Section 3
System Manager LED Indicators
There are two LED indicators located on the right hand side of the System Manager.
The top LED indicates an Alarm condition if the Manager detects an alarm condition
while polling the system.
The bottom LED is active during actual communications or packet transfers. This LED
will normally “flicker” and not remain on constantly.
Main User Menu
1) View Status Only
2) View Alarms
For quick access to an
individual heat pump or the
loop controller, select this menu
item. No passcode is required to
access the status of any unit
installed on your system.
If the System Manager has been
configured for Alarm Polling,
the user can select this item to
get a list of unit addresses that
are currently in alarm. If an
alarm exists, the Alarm LED
will be active on the right side
of the panel.
MENU) Setpoints
ESC) Main Screen
If you are a Level 2 user, all system
setpoints are available to you.
These setpoints are accessed via
this Menu button.
When you have finished viewing
the system you can exit this menu
and return to the Main Screen by
pressing the ESC button.
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Section 3
WattMaster WHP
Heat Pump Status
Screens
View Status Only
By selecting the View Status Only menu item, you can
access any heat pump or the loop controller and read all
available temperatures, outputs, and operating conditions
for the selected unit. No passcode is required to access
these status screens, and no setpoints are available to the
user from these screens. To access a unit, enter the Unit ID
you wish to view. The Unit ID is actually two separate
numbers, combined into one value. The first part of the
number contains the Loop Address at which the zone is
located. The second part of the number contains the actual
Board Address.
EXAMPLE: You would like to view the 3rd heat pump
on the 5th loop. Enter 503 as the Unit ID
You would like to view the 12th heat pump
on the 24th loop. Enter 2412 as the Unit ID
3-4
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WattMaster WHP
Section 3
If you selected menu item #1 View Status Only and you entered the Unit ID of an
installed WHP Controller, the following Status Screens are available.
Status Screen #1
Line 2 -
Line 3 -
Current Zone Temperature
°
°
°
°
Current Cooling Setpoint ( CSP ) and Heating
Setpoint ( HSP )
Line 4 -
Effect of optional Sensor Slide Adjustment on the
current operating setpoints.
Status Screen #2
Line 2 -
Line 3 -
°
°
°
Current Supply Air Temperature
Current Leaving Water Temperature if Sensor is
installed.
Line 4 -
Current Outdoor Air Temperature.
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Section 3
WattMaster WHP
Status Screen #3
Line 2 -
Current Operating Status
Unoccupied Mode
Occupied Mode
Pushbutton Override
Forced Occupied
Forced Unoccupied
Forced Fan Only Mode
Line 3 -
Line 4 -
Current Fan Status
Fan Start Delay!
ON
OFF
Current Enable Status from Loop
Controller
Operations Disabled
Operations Enabled
Status Screen #4
Line 2 -
Line 3 -
Line 4 -
Current Compressor ON/OFF Status
Current Reversing Valve ON/OFF Status
Current Status of Relay #5. Operation
depends on how the user configures this
output.
Status Screen #5
Line 2 -
Current HVAC Operating Mode
Neutral Mode
Cooling Mode
Heating Mode
Line 3 -
Line 4 -
Reserved for future option.
Reserved for future option.
3-6
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WattMaster WHP
Section 3
Status Screen #6
Bad Space Sensor
Hi Space Temp Alarm!
Lo Space Temp Alarm!
Space Temp Sensor OK
Dirty Filter Alarm
Filter OK
Line 2 -
Line 3 -
Line 4 -
Cooling Failure!
Heating Failure!
Note: If no alarms exist, then the screen displays the message shown for No Alarms!
If ANY alarm exists then the three lines display one of the messages shown
above.
The Cooling Failure and Heating Failure alarms are generated as follows:
As the unit enters the cooling mode, the current Supply Air Temperature reading
is stored in memory. After 10 minutes, if the temperature hasn’t changed by 5°F a
Cooling Failure alarm is generated.
A Heating Failure is generated in the same manner, only during the heating mode
instead of the cooling mode.
The Hi Space Temp and Lo Space Temp Alarms are generated as follows:
If the space temperature gets 5°F above the cooling setpoint, a Hi Space Temp
Alarm is generated. If the space temperature gets 5°F below the heating setpoint,
a Lo Space Temp Alarm is generated.
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Section 3
WattMaster WHP
View Alarms
Alarm Address Locations
The System Manager can be programmed to poll all the
units on your heat pump system for alarm information. This
allows the centrally located System Manager to display an
Alarm Indicator whenever an alarm condition exists
anywhere on your system. The actual alarms are not
displayed on this screen, only the Unit ID where the alarm
is located. The example screen shows that a unit at location
118 has experienced an alarm condition. This alarm may or
may not be current, as the System Manager latches the
condition. This makes it possible to determine if any
intermittent alarm conditions have occured. To find out
what the alarm is, if it is still current, access the status
screens for the Unit IDs that are displayed on the SYSTEM
ALARM STATUS screens.
Alarm Clearing
If all the alarm conditions have been corrected at the
individual units, you can clear these alarms from the
System Manager on the following screen. Use the
Left/Right arrow keys to select the YES/NO response
desired. If you clear the alarms, but some still exist, the
System Manager will show an alarm indication, when the
affected unit is polled again.
3-8
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WattMaster WHP
Section 3
Menu Setpoints
Full Setpoint Access
If you selected the Menu key from the first menu screen you
can access all setpoints available from any unit on your system.
You must be a Level 2 user to access these setpoints. If you
haven’t already been asked to enter the passcode, you will be
asked before the Full Setpoint Access menu is displayed. This
prevents the casual user from being able to affect the operation
of your heat pump system.
Set Time & Date
The System Manager has its own built in Real Time Clock. It broadcasts this time once a
day, at midnight, to synchronize all of the WHPs on your system. Although the times are
displayed on the Main Screen in a standard 12-hour format, they are programmed using
the 24-hour Military format. Once the time has been entered, it is also broadcast
immediately to all other units on the system. That means that you only need to program
the System Manager time to set the Real Time Clocks for all units on your system. In
order for the System Manager to broadcast the time and date to all controllers, they must
be powered up and communicating.
Programming Time
Day
- Enter the Day of the Week (0 to 6) with
Sunday = 0
Hours (Hr)
Minutes
- Enter Hours in 24-Hour Military Format
(1700 = 5:00 PM)
- Enter the Minutes (0 to 59)
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Section 3
WattMaster WHP
Programming Date
Month
- Enter the Month (1 to 12)
Day
- Enter the Day of the Month (1 to 31)
Year
- Enter the current Year with 2 digits (00
to 99)
Daylight Savings Adjustments
If your area of the country requires Daylight Savings changes,
you can enable the System Manager to automatically reset its
own clock during the Daylight Savings changeover. If you
enable this operation, it knows to changeover the first Sunday
in April and then switch back the last Sunday in October. No
other programming is required for this function.
Use the Left or Right arrow keys to toggle the second line of
the display between Adjustments Enabled and Adjustments
Disabled.
3-10
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WattMaster WHP
Section 3
New Passcodes
Programming Passcodes
The System Manager has two levels of passcode.
Level 1 users are limited to viewing Setpoints and Alarms only.
Level 2 users have complete system access. Any status or
setpoint field can be read or reset from WHP System Manager.
The default passcode is “1111” for level 1 and “2222” for level
2. If you need to change these defaults you can enter any 4 digit
number between 1000 and 9999.
If you “forget” the passcode you programmed, you can still
access the system with a built in backdoor code. This backdoor
code is “9288” and is not programmable. It is not recommended
that you give out this backdoor code since it would allow the
user access without regard to the standard programmable
passcode that most operators should be using.
The actual digits in your passcodes are never displayed. An "X"
is used as a place holder for each digit entered. Passcodes must
always be four digits in length.
Programming
3-11
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Section 3
WattMaster WHP
Rebuild Alarm Map
Rebuilding Screens
If you would like the LED Alarm Indicator to function on the
front of your System Manager, you must enable Alarm Polling
by building an Alarm Map. This map keeps track of which
units exist on your communications loop so the System
Manager will poll only those units. That means you will need
to rebuild this map anytime units are added or removed from
your system. It also means you can disable alarm polling. To
do this, disconnect the RS-485 communications plug from the
back of your Comm Link II. Then, select the Rebuild Alarm
Map menu. The System Manager will not find any units to poll
for alarms since none are connected. This is useful during
building startup, when you don't want nuisance alarms
bothering you.
The screen will display each address it is testing and if a unit is
found at that address. If you don't want to wait for the System
Manager to check for all 30 loops, you can press the ESC key
as soon as the number of loops on your system are exceeded
and the test will conclude. All units found up to that point will
be saved in memory.
The System Manager does not rebuild this map
automatically on powerup! You must do this manually. This
rebuild need only be performed one time, when all units are up
and running. It is not a regular requirement. As mentioned
above, only when the number of units connected changes
should the alarm map be rebuilt.
3-12
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WattMaster WHP
Section 3
Heat Pump Setpoints
Heat Pump Setpoint Menu
From the main menu screen select MENU on the keypad,
select MENU again for Setpoints. Then select “Access Units”
(keypad #2) and finally enter the loop and zone number for the
desired unit.
As the screen above shows, there are three areas of
programming available for each WHP Controller. Menu item
#1 accesses all the standard temperature and configuration
settings for the heat pump. Menu item #2 accesses the week
schedule and holiday programming for the individual unit.
Menu item #3 can be selected to force the heat pump to
manually reset in the case of an operating problem.
1) WHP Setpoints
Setpoint Screen #1
The Occupied Heating and Cooling Setpoints are
programmed on this screen. The setpoints must be at least one
degree apart. If you try to enter the same value or to cross the
cooling and heating setpoints, the value you enter will not be
accepted.
°
°
Cooling Setpt
Heating Setpt
50°F
50°F
74°F
72°F
90°F
90°F
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Section 3
WattMaster WHP
Setpoint Screen #2
The Unoccupied Heating and Cooling Setbacks are programmed
on this screen. The Cooling SetUp is added to the Occupied
Cooling Setpt to create the Unoccupied Cooling Setpoint. The
Heating SetBack is added to the Occupied Heating Setpt to
create the Unoccupied Heating Setpt.
°
°
Cool SetUp
1°F
10°F
30°F
Heat SetBack
-1°F
-10°F
-30°F
Setpoint Screen #3
If the Space Temperature Sensor has the optional slide
adjustment, then the Slide Effect is the maximum amount of
change that it can have on the Heating and Cooling Setpoint and
it is programmed here.
°
°
The SP Deadband is divided in half across the current heating
and cooling setpoint, and is used in staging the heating and
cooling on or off.
If you have an override pushbutton on the space sensor, the OV
Duration is the length of time the unit will be in the occupied
mode after pushing the button
Slide Effect
SP Deadband
OV Duration
0°F
0°F
0.0 Hr
3°F
1°F
1.0 Hr
5°F
20°F
8.0 Hr
Setpoint Screen #4
If the Heat Pump is configured to operate with a Reversing
Valve, relay #5 can be configured as a second stage for either
heating or cooling or both. If the Heat Pump is configured for
individual heating and cooling, this determines how many of
each stage there are.
Cooling Stages
Heating Stages
0
0
1
1
2
2
3-14
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WattMaster WHP
Section 3
Setpoint Screen #5
The Min Run Time determines how long the compressor
must remain on once it has been activated. The Min Off Time
determines how long the compressor must remain off once it
is de-activated. The Min Cycle time determines how many
times per hour the compressor can be started. If you entered
10 minutes, the compressor could start a maximum of 6 times
in a one hour period.
Min Run Time
Min Off Time
Min Cycle
0 Min
0 Min
0 Min
1 Min
6 Min
12 Min
20 Min
20 Min
60 Min
Setpoint Screen #6
To prevent rapid cycling between heating and cooling modes,
you can enter a time period that must be satisfied before the
changeover can occur.
Changeover Delay
1 Min
30 Min
60 Min
Setpoint Screen #7
Normally you would want to have an Enable Signal that gave
assurance of water flow before you activate the heat pumps
compressor. If you need to operate without this enable signal,
use the arrow keys to select the NO ENABLE REQUIRED
message. Otherwise, select the LOOP FLOW REQUIRED
message so that the signal must be present for the compressor
to run.
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Section 3
WattMaster WHP
Setpoint Screen #8
If your heat pump uses a reversing valve to determine the
heating or cooling mode of operation, select the message
R/VALVE & COMPRESSOR. If you are controlling
separate stages of heating and cooling select the
INDIVIDUAL STAGING message.
Setpoint Screen #9
If you have configured the system to use the reversing valve,
you must select which mode requires it to be active. Select
either the COOLING MODE or the HEATING MODE
message.
Setpoint Screen #10
If you have configured the system to use the reversing valve,
you can also set it to cycle on and off with the compressor,
(CYCLES w/COMPRESSOR) or, to remain on once it is
activated, and stay on until the opposite mode or unoccupied
mode is selected (RUNS CONTINUOUS MODE). The
valve always activates 10 seconds before the compressor
starts no matter which method you select.
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Section 3
Setpoint Screen #11
If your system is configured to use the reversing valve and
you only have one stage of heating and cooling, that last
relay becomes available for other uses. The AUXILIARY
RELAY MODE can be used to operate the relay manually
from the Prism computer front end program. If you select
ISOLATION VALVE MODE, the relay activates anytime
the compressor is called for or whenever the Loop Controller
sends an override command to activate and reduce loop
pressure.
If the relay needs to follow an external week schedule, select
the AUXILIARY RELAY MODE and then see the Aux
Relay #5 Schedule assignment screen.
Setpoint Screen #12
You can program the fan to run continuously during the
occupied mode, (RUNS CONTINUOUS MODE) or you
can program it to cycle on and off with the compressor
during both the occupied and the unoccupied mode of
operation.
(CYCLES W/COMPRESSOR)
Setpoint Screen #13
If you configured relay #5 as an Auxiliary Relay, you can
also program it to follow an external schedule command.
You must have an OSS Optimal Start Scheduler installed
somewhere on you communications loop to provide the
external schedule you select here.
Programming
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Section 3
WattMaster WHP
Setpoint Screen #14
The Heat Pump Controller can use the internal time clock for
a setting an occupied schedule, for this the setpoint will be 0.
It can also be programmed to follow an external schedule
command. You must have an OSS Optimal Start Scheduler
installed somewhere on you communications loop to provide
the external schedule, and you select the schedule number
here.
Setpoint Screen #15
If you entered the same starting time for several heat pumps,
they are prevented from all starting their fans at the same
time by a Startup Delay Period that is determined by their
address switch setting. The address is multiplied by the
number of seconds you enter on this screen, up to a
maximum of 60 seconds per address. This is the time period
the fan must wait before it starts when the schedule goes
occupied.
If you entered 5 seconds and the address was 10 then the fan
would start 5 x 10 or 50 seconds after the schedule goes
occupied.
Setpoint Screen #16
An Energy Demand Limit sequence is programmed into all
heat pump controllers. It is currently an option that is not
supported by a controller that can send the Demand Limit
signal to initiate a limiting condition. It is included here for
future use only.
°
Max Effect
0°F
3°F
30°F
3-18
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WattMaster WHP
Section 3
Setpoint Screen #17
This setpoint is to shut the heating off when the supply air
temperature is too warm. When the supply air temperature is
above this setpoint, it will prevent the second stage of heat
from coming on.
°
Max Effect
30°F
60°F
200°F
Setpoint Screen #18
The Thermister Type III Sensor readings can be calibrated.
Enter Positive values to increase the reading or Negative
values to decrease the reading. If no sensor is attached, the
calibration offset will still allow a value to be input and read
for diagnostic purposes.
°
°°
°°
°°
°°
°°
Space Sensor
Supply Air Sensor SAT
Water Sensor
SPC
-100.0°F
-100.0°F
0.0°F
0.0°F
0.0°F
+100.0°F
+100.0°F
+100.0°F
WAT -100.0°F
Setpoint Screen #19
Select if you want the notification LED on the front of the
System manager to illuminate when an alarm occurs. If
Enabled is selected, any WHP alarm will cause the Alarm
LED on the front panel to light up. If Disable is selected, the
Alarm LED will not light up but the alarm will still show up in
the Status screen.
Note: You must do a Rebuild Alarm Map after all controllers are powered up and
communicating.
Programming
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Section 3
WattMaster WHP
2) WHP Schedules
The Water Source Heat Pump controllers contain their own built in scheduling capability
for calculating Occupied/Unoccupied periods. Select item #2 from Schedules menu to
access the following schedule programming menu.
Schedule Menu
Week Schedule Programming
Event #1
There are two Start / Stop events available per day.
The first line is the start time for event #1 and the next line is
the stop time for event #1.
The screens will step through the Start Time and then the Stop
Time for each day of the week. You can quit at any point in the
process by pressing the "ESC" key.
Event #2
If no second event is required, simply leave a ZERO for both
the start and stop times on the event #2 screens.
All times are in 24-hour format, so 5:00 PM would be entered
as 1700.
If both the Start and Stop Times are ZERO, the schedule is in a
Continuous OFF mode.
If both the Start and Stop Times are 2359, the schedule is in a
Continuous ON mode.
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WattMaster WHP
Section 3
Holidays
Holiday Day Selection
There are 14 Holiday periods available, organized as a Start Day / Stop Day event. If the
Holiday only lasts one day, enter the same date for the Start & Stop days. There is no
limit to the duration or number of days that can be included in one holiday, other than it
cannot extend past December 31st. If you have a holiday that crosses the end of year
border, you will need to use two holiday periods to accomplish this event.
The screens will step through the 14 possible holidays, one
at a time. Line 2 shows which holiday is currently being
programmed.
Line 3 shows which event, the Start Day or Stop Day, is
currently being programmed.
Remember to combine the month and day into a single four
digit value.
EXAMPLE: 0704 = July 4th
1225 = December 25th
Holiday Start / Stop Times
The 14 holidays all use the same Holiday Start / Stop
time. The start/stop times are programmed back on the
Week Schedule screens. The holiday schedule screen
appears after the Saturday schedule screen, as you are
stepping through the days of the week.
Note: Normally there is no schedule in the Loop Controller device. It simply looks at
all the Water Source Heat Pumps for a request to run signal. Scheduling is
maintained separately in each Water Source Heat Pump. If you want to be able
to schedule all Water Source Heat Pumps on and off at the same time, you can
input a schedule on the Loop Controller and it will broadcast that schedule to all
WHPs.
Programming
3-21
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Section 3
WattMaster WHP
3) Reset Pumps
If one of your heat pumps has tripped off, it can be manually
reset from the following screen. You will have entered the
Unit ID to access the WHP Menu screen, so that is the unit
that will receive this reset command. If you don’t want to
send the command, select the Disabled message with the
arrow keys. If you do want to send the command, select the
Enabled message with the arrow keys and then press the
Enter button. This command will automatically clear itself
when the WHP detects it and performs the reset.
There are two methods of resetting:
1. Relay #4, on the WHP will activate with the reset
command and can be wired to provide the reset
action.
2. The compressor relay will be cycled off. On
newer heat pumps, this is all that is required to
reset the operation.
3-22
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WattMaster WHP
Section 3
Loop Controller Status
Loop Controller Status Menu
From the main menu screen select MENU on the keypad. Then select “View Status
Only” (keypad #1) and finally enter the loop and zone number for the desired unit.
As the screen above shows, there are two areas of status available for the Loop
Controller. Menu item #1 accesses all the status screens for the Loop Controller. Menu
item #2 accesses the alarms for the Loop Controller. “Menu” can be selected to access the
Setpoints screens.
Loop Controller Status
Screens
If you selected menu item #1, View Status Only, and you entered the Unit ID of the Loop
Controller, the following Status Screens are available.
Status Screen #1
Line 2 -
Current operating Mode:
°
°
OCCUPIED
UNOCCUPIED
Line 3 -
Line 4 -
Current Return Water Temperature
Current Supply Water Temperature
Programming
3-23
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Section 3
WattMaster WHP
Status Screen #2
Line 2 -
Current operating Mode:
No Call To Run
ACTIVE CALL TO RUN
FREEZE PROTECTION!
Line 3 -
Line 4 -
Current Water Flow Status:
Water Flow Proved!
No Flow Detected
Current Request to Operate Status:
LOOP ENABLED
LOOP DISABLED
Status Screen #3
Line 2 -
Line 3 -
LEAD Pump #1 On or Off
STANDBY Pump #2 On or Off
Status Screen #4
Cool/Heat Stage #1 On/Off
Cool/Heat Stage #2 On/Off
Line 1 -
Line 2 -
Cool/Heat Stage #3 On/Off
Cool /Heat Stage #4 On/Off
Line 3 -
Line 4 -
3-24
Programming
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WattMaster WHP
Section 3
Status Screen #5
Cool/Heat Stage #5 On/Off
Cool/Heat Stage #6 On/Off
Line 1 -
Line 2 -
Cool/Heat Stage #7 On/Off
Cool/Heat Stage #8 On/Off
Line 3 -
Line 4 -
Status Screen #6
Line 2 -
Line 3 -
Line 4 -
Current Loop Water Pressure
Current Variable Speed Pump Voltage Signal
Current Proportional Heat Voltage Signal
Note: If none of the above options have been configured, then the values in this status
screen will be 0.
Programming
3-25
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Section 3
WattMaster WHP
Status Screen #7
Line 2 -
Line 3 -
Pump Failure or Blank Line
Hi Control Water Temp
Lo Control Water Temp
Fire/Smoke Alarm
Line 4 -
Phase Shutdown
Note: If no alarms exist, then the screen displays the message shown for No Alarms! If
ANY alarm exists, then the three lines display one of the messages shown above.
The Fire/Smoke Alarm is generated as follows:
If the NC (normally closed) contact from a firestat or smoke detector that is wired
between GND and AIN1, on the Analog Input expansion board, opens, the
Fire/Smoke Alarm is generated.
The Phase Shutdown Alarm is generated as follows:
If the NO (normally open) contact from a phase monitoring device, that is wired
between GND and AIN7 is made, the Phase Shutdown Alarm is generated.
Status Screen #8
Line 2 -
Line 3 -
Line 4 -
Message Only
Pump #1 Hours and Minutes Run Time
Pump #2 Hours and Minutes Run Time
3-26
Programming
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WattMaster WHP
Section 3
Loop Controller Setpoints
Loop Controller Setpoint Menu
Setpoint Screen #1
If the controlling water temperature rises above this Setpoint,
the Heat Rejection or Cooling Stages begin to stage on. As the
temperature continues to rise above the Setpoint by the
°
°
Deadband amount, an additional stage is added. Each
additional stage can only activate if the temperature rises above
the Setpoint by the number of active stages times the deadband
value.
Example: There are 2 stages on, a 3° deadband and the setpoint
is 79°
2 x 3° + 79° = 85° before stage 3 can activate
Setpoint
Stage Deadband
50°F
1°F
79°F
3°F
99°F
10°F
Setpoint Screen #2
The Staging Delay period must also be satisfied before an
additional stage of cooling or heat rejection can be activated.
The maximum number of heat rejection stages are programmed
on this screen also.
Stage Delay
1 Minute
1 Minute
60 Minutes
Programming
3-27
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Section 3
WattMaster WHP
Setpoint Screen #3
If the controlling water temperature drops below this Setpoint,
the Heat Addition or Boilers begin to stage on. As the
temperature continues to drop below the Setpoint by the
Deadband amount, an additional stage is added. Each
additional stage can only activate if the temperature drops
below the Setpoint by the number of active stages times the
deadband value.
°
°
Example: There are 2 stages on, a 3° deadband and the setpoint
is 79°
79° - 2 x 3° = 73° before stage 3 can activate
Setpoint
Stage Deadband
50°F
1°F
76°F
3°F
99°F
10°F
Setpoint Screen #4
The Staging Delay period must also be satisfied before an
additional boiler or heat addition stage can be activated.
The maximum number of heat addition stages are programmed
on this screen also.
Stage Delay
1 Minute
1 Minute
60 Minutes
Setpoint Screen #5
If the outdoor air temperature drops below this setpoint, the
pump will be energized to prevent the water lines from
freezing.
°
Setpoint
-50°F
40°F
50°F
3-28
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WattMaster WHP
Section 3
Setpoint Screen #6
If the controlling water temperature rises above the Water Hi
Limit setpoint, all heat addition will be removed and one
stage of heat rejection will be activated. If the controlling
water temperature drops below the Water Lo Limit setpoint,
all heat rejection stages will be removed and one heat
addition stage will be activated. An alarm will be generated if
it remains out of limits for the Alarm Delay Time.
°
°
Water Hi Limit
Water Lo Limit
Alarm Delay
0°F
0°F
0 Min
120°F
0°F
30 Min
120°F
120°F
120 Min
Setpoint Screen #7
The Loop Controller can modulate a Variable Speed Pump.
Select the PRESSURE option in place of the CONSTANT
option for variable speed pumping.
The water flow proving can be accomplished by a differential
pressure contact closure or an actual pressure sensor. If you
select Variable Speed Pumping, you must select the
PRESSURE option in place of the CONTACT option for
Flow Proof.
Setpoint Screen #8
There are two methods of Heat Addition control, STEP
HEATING CONTROL or PROPORTIONAL HEATING
The Loop Controller can be configured to maintain Return
Water Temperature ( RETURN WATER CONTROL ) or
the Supply Water Temperature ( SUPPLY WATER
CONTROL )
Programming
3-29
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Section 3
WattMaster WHP
Setpoint Screen #9
The two pumps will switch after this programmed amount of
time so that each pump accumulates roughly the same
number of run time hours. If a pump is currently running and
this time period is exceeded, the changeover will occur as
soon as pump run time exceeds the setpoint. The current
pump will shut off and the standby pump will start at the
same time.
Changeover
1 Hour
40 Hours
240 Hours
Setpoint Screen #10
If you attached a Pressure Sensor for proof of flow instead of a
differential pressure contact closure for proof of flow, the
controlling pressure is programmed on this screen. This
Setpoint represents the amount of pressure that you set to prove
water flow exists in the system. Otherwise, this screen will not
appear.
Flow PR. SP
0
5 PSI
50 PSI
Setpoint Screen #11
If you configured the system for Variable Speed Pumping with
a Pressure Sensor for proof of flow, the controlling pressure,
deadband and control adjust time period are programmed on
this screen. Otherwise, this screen will not appear.
Pressure SP
SP Deadband
Adjust Time
1 PSI
1 PSI
40 PSI
2 PSI
50 PSI
50 PSI
0.1 Seconds 1.0 Seconds 25 Seconds
3-30
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WattMaster WHP
Section 3
Setpoint Screen #12
If you configured the system for Variable Speed Pumping with a
Pressure Sensor for proof of flow, the Loop Controller can send
a signal to all the Heat Pumps to open their Isolation Valves
whenever a Hi Limit Pressure is exceeded. If the Heat Pumps do
not control an Isolation Valve, then the only reaction is to
reduce the variable speed pump voltage signal.
Hi Limit
1 PSI
50 PSI
50 PSI
Setpoint Screens #13
The Thermister Type III Sensor readings can be calibrated.
Enter a Positive value to increase the reading or a Negative
value to decrease the reading. If no sensor is attached, the
calibration offset will still allow a value to be input and read for
diagnostic purposes.
°
°°
°°
°°
°°
°°
Return Water
Supply Water
Outdoor Air
RWT
SWT
OAT
-10.0°F
-10.0°F
-10.0°F
0.0°F
0.0°F
0.0°F
+10.0°F
+10.0°F
+10.0°F
Note: Due to memory limitations in the Loop Controller, the maximum amount of
calibration offset is 10.0°F.
Setpoint Screen #14
Alarms can be configured to light the LED on the front of the
System Manager by setting Alarms to Enabled, if you do not
wish to report alarms, select Disabled.
Setpoint Screen #15
Use this screen to configure the relays on the expansion board
for heat ADDITION, REJECTION or NOT USED. All 8
relays come up one at a time.
Programming
3-31
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Section 3
WattMaster WHP
Notes:
3-32
Programming
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Section 4
Table of Contents
1.0 Communications Overview........................................1
1.1 How It Works...........................................................................................................1
1.2 WattMaster WHP System........................................................................................1
2.0 WHP Controller Overview..........................................4
2.1 How It Works...........................................................................................................4
2.1.1 Initialization .....................................................................................................4
2.1.2 Operating Summary.........................................................................................4
2.2 Becoming Familiar with the WHP Controller .........................................................5
2.2.1 24 VAC Power Connector ...............................................................................5
2.2.2 Analog Inputs...................................................................................................6
2.2.3 Analog Output Description..............................................................................6
2.2.4 Relay Output Descriptions...............................................................................6
2.2.5 RS-485 Communications Connector ...............................................................7
2.2.6 WHP Controller Wiring...................................................................................8
3.0 Loop Controller Overview.........................................9
3.1 How It Works...........................................................................................................9
3.1.1 Initialization .....................................................................................................9
3.1.2 Operating Summary.........................................................................................9
3.2 Loop Controller Inputs & Outputs.........................................................................10
3.2.1 Analog Inputs.................................................................................................10
3.2.2 Analog Output................................................................................................10
3.2.3 Binary Output.................................................................................................11
3.2.4 Relay Expansion Board - Outputs..................................................................11
3.2.5 Analog Input Expansion Board......................................................................11
3.2.6 Comm Connector - Communications ............................................................12
3.2.7 Power Terminal..............................................................................................12
4.0 Start-Up....................................................................14
4.1 Blink Codes for WHP Controllers.........................................................................14
4.2 Blink Codes for Loop Controllers..........................................................................15
4.3 Communications Checklist...................................................................................15
4.4 Installation and Commissioning Information ........................................................16
4.5 Setting Address Switches.......................................................................................19
4.5.1 Setting the MiniLink Address Switch............................................................19
4.5.2 Loop Controller Addressing...........................................................................20
4.5.3 WHP Controller Addressing..........................................................................20
Start-Up and Troubleshooting
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Section 4
5.0 Troubleshooting ...................................................... 21
5.1 General Troubleshooting........................................................................................21
5.1.1 Communications Troubleshooting Checklist.................................................21
5.1.2 General Troubleshooting Checklist ...............................................................22
5.2 Alarms......................................................................................................................23
5.3 Checking Comm. Loop Voltages.............................................................................24
5.3.1 Checking the CommLink II Network Loop ...................................................24
5.3.2 Checking the Comm Loop at the CommLink II ............................................25
5.3.3 Checking the CommLink II Driver................................................................26
5.3.4 Checking the MiniLink Network Loop..........................................................27
5.3.5 Checking the MiniLink Network Driver........................................................28
5.3.6 Checking the MiniLink Local Loop...............................................................29
5.3.7 Checking the Local Loop at MiniLink...........................................................30
5.3.8 Checking the MiniLink Local Loop Driver ...................................................32
5.3.9 Checking the Local Loop at a WHP Controller.............................................33
5.3.10 Checking WHP Controller Driver Chip.........................................................34
5.4 Troubleshooting Loop Controller ..........................................................................35
5.4.1 Checking the Loop Controller Analog Inputs................................................35
5.4.2 Checking the Loop Controller Outputs..........................................................37
5.4.3 Checking the Local Loop at a WHP Loop Controller....................................38
5.4.4 Checking WHP Loop Controller Driver Chip ...............................................39
5.4.5 Comm Driver Chip Replacement...................................................................40
5.5 Temperature Sensor Resistance Chart ...................................................................41
5.6 Pressure Sensor Voltage Chart...............................................................................42
Notes: ............................................................................ 43
Table of Figures
Figure 4-1: System Wiring Overview.............................................................................2
Figure 4-2: Communications Loop Routing...................................................................3
Figure 4-3: WHP Controller Component Layout ...........................................................5
Figure 4-4: Typical WHP Controller Wiring Diagram...................................................8
Figure 4-5: Loop Controller Inputs & Outputs.............................................................13
Figure 4-6: Diagnostic LED Blink Codes.....................................................................14
Figure 4-7: Diagnostic LED Blink Codes.....................................................................15
Figure 4-8: Communications Loop Wiring ..................................................................18
Figure 4-9: MiniLink Address Switch Setting.............................................................19
Figure 4-10: WHP Controller Address Switch Setting...............................................20
Figure 4-11: Comm Driver Chip Replacement............................................................40
Start-Up and Troubleshooting
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WattMaster WHP
Section 4
1.0 Communications
Overview
Perhaps no other portion of the system seems as difficult to diagnose as the communica-
tions loop, yet it really can be quite simple if you understand how it works. In fact, much
of the troubleshooting can be done by simple observation. We will lead you through the
system functions and then provide you with detailed instructions for checking each piece
of equipment.
1.1 How It Works
WattMaster uses a token-passing loop architecture, which means in simple terms that an
“electronic message” called a token is passed from controller to controller in a round-
robin fashion. A controller must wait to receive the token before it can send or request
any data.
Note: It is very important to know which device is the loop master on the loop
you are troubleshooting.
1.2 WattMaster WHP System
The standard WattMaster WHP system may have only one communications loop or as
many as thirty communication loops depending on the number of WHP Controllers to be
connected to the system. It is important to remember that each loop must have its own
master.
If you are using the multiple loop version of the WHP system (for systems with more than
30 WHP Controllers) a loop is required for each group of 30 WHP Controllers. The WHP
Loop Controller may be connected to any of the Local Loops. The Local Loop that has
the WHP Loop Controller installed can only have 29 WHP Controllers on that loop. Each
Local Loop is connected to a MiniLink loop interface. The MiniLink is always the
master on the Local Loops. The MiniLinks are connected to the CommLink II and to
each other via the Network Loop.
The CommLink II is always the master on the Network Loop. You must be sure the
CommLink II is connected and functioning if you are troubleshooting the communica-
tions loops. Make sure the CommLink II is set for multiple loops
.
Start-Up and Troubleshooting
4-1
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WattMaster WHP
Section 4
COMPUTER
(OPTIONAL)
RS-485
Comm Loop
32K
8K
COMM
RELA
OUTPUT
COM
Y
T
Room Sensor
with Optional
Override & Adj.
SHLD
R
1-3
OUT
1
OUT
485
COMM
RAM
EPROM
LD4
REC.
2
OUT
3
OUT
4
OUT
5
CPU
COM
4-5
COMM
TEST
12V
ADDRESS
ADD
AIN
1
AIN
2
AIN
3
AIN
4
AIN
5
GND
GND
AOUT
PWR
GND
PRESSURE
SENSOR
YS101564
24VAC
24 VAC
110/24 VAC
Power Pak
Dirty Filter Alarm
Supply
Air
or Leaving Water Temp
F
Modem
(Optional)
110/24 VAC
Power Pak
Sensor
Typical WHP Controller Wiring
M
R
T
R
S
D
R
D
O
H
C
D
A
A
H
S
#30
#1
Loop #1
32K
8K
32K
8K
Network Loop
RS-485
19200 Baud
COMM
COMM
RELA
OUTPUT
COM
Y
RELA
OUTPUT
COM
Y
COMM
T
T
O
M
M
SHLD
R
1-3
SHLD
R
1-3
OUT
1
OUT
OUT
1
OUT
LINK
I
K
LD4
REC.
485
COMM
RAM
EPROM
2
LD4
REC.
485
COMM
RAM
EPROM
2
N
OUT
3
OUT
4
OUT
3
OUT
4
II
I
OUT
5
OUT
5
CPU
COM
4-5
CPU
COM
4-5
L
COMM
TEST
COMM
TEST
O
O
C
O
M
12V
12V
WHP
Controllers
ADDRESS
ADD
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
M
O
D
P
P
AIN
3
AIN
3
E
M
AIN
4
AIN
5
AIN
4
AIN
5
GND
GND
GND
GND
AOUT
AOUT
PWR
GND
PWR
GND
PRESSURE
SENSOR
PRESSURE
SENSOR
W
AT
C
YS101564
YS101564
TM
CommLink II
Multiple Loop
Interface
A
ST
24VAC
24VAC
ER
O
N
TR
OLS
, INC
Local Loop
RS-485
9600 Baud
MiniLink
Loop # 1
System Manager
MINILINK
1
2
T
4
8
16
H
R
32
24VAC
GND
T
H
R
#30
#1
24VAC
24VAC
Loop #2
32K
8K
32K
WED
8K
COMM
COMM
RELA
OUTPUT
COM
Y
RELA
OUTPUT
COM
Y
T
T
03:38PM
SHLD
R
1-3
SHLD
R
1-3
MiniLink
OUT
1
OUT
OUT
1
OUT
OCCUPIED
ALARMS
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
LD4
REC.
2
LD4
REC.
2
03/31/04
NO
OUT
3
OUT
4
OUT
3
OUT
4
OUT
5
OUT
5
CPU
COM
4-5
CPU
COM
4-5
WHP
Controllers
COMM
TEST
COMM
TEST
Loop # 2
12V
12V
ADDRESS
ADD
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
AIN
3
AIN
3
MINILINK
1
2
AIN
4
AIN
5
AIN
4
AIN
5
T
4
8
16
SH
32
GND
GND
R
GND
GND
AOUT
AOUT
PWR
GND
PWR
GND
PRESSURE
SENSOR
PRESSURE
SENSOR
24VAC
GND
YS101564
YS101564
24VAC
24VAC
H
R
24VAC
Local Loop
RS-485
9600 Baud
Typical Network & Local Loop Wiring
2 Conductor Twisted Pair with Shield
(Beldon #82760 or Equivalent)
#30
#1
Loop #3
MiniLink
Loop # 3
32K
8K
32K
8K
COMM
COMM
RELA
OUTPUT
COM
Y
RELA
OUTPUT
COM
Y
T
T
SHLD
R
1-3
SHLD
R
1-3
OUT
1
OUT
OUT
1
OUT
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
LD4
REC.
2
LD4
REC.
2
OUT
3
OUT
4
OUT
3
OUT
4
OUT
5
OUT
5
MMIINNIILLIINK
1
CPU
COM
4-5
CPU
COM
4-5
2
4
COMM
TEST
COMM
TEST
8
16
H
32
12V
12V
ADDRESS
ADD
WHP
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
AIN
3
AIN
3
AIN
4
AIN
4
24VAC
GND
AIN
5
AIN
5
GND
GND
Controllers
GND
GND
H
AOUT
AOUT
PWR
GND
PWR
GND
Local Loop
RS-485
9600 Baud
PRESSURE
SENSOR
PRESSURE
SENSOR
YS101564
YS101564
24VAC
24VAC
24VAC
WHP Loop
NOTE: * Only One Outside Air Sensor
is Required per WHP System
Controller
U3
See Note #3
Loop #4
CX1
CX2
RN1
U2
CX4
1
U1
U4
TB1
V1
V2
V3
COMM
#29
T
#1
SHLD
R
CX5
COM1-3
U5
LD6
PAL
R1
R2
R3
COMM
RS-485
COMM
1
RAM
EPROM
MiniLink
LD7
PWR
TUC-5R PLUS
(1 MEG)
YS101816 REV
1
HH
.
2
LD8
LED1
U6
R4
R5
4RLY
I
O
B
D
.
Y
S
1
0
1
7
9
0
C1
LD9
LED2
P1
COM4-5
32K
8K
32K
8K
R1
+VREF
CX6
TB2
5.11V
COMM
COMM
TEST POINT
RELA
OUTPUT
COM
Y
RELA
OUTPUT
COM
Y
U7
RV1
V4
V5
EWDOG
R28
T
T
Loop # 4
MINILINK
V
R
E
F
A
D
J
SHLD
R
1-3
SHLD
R
1-3
1
OUT
1
OUT
OUT
1
OUT
*OutsideAir
INPUTS
ADDRESS
ADD
U8
1
2
485
COMM
RAM
EPROM
485
COMM
RAM
EPROM
+VDC
4RLY
I
O
B
D
.
Y
S
1
0
1
7
9
0
LD4
REC.
2
LD4
REC.
2
RN5
OUT
3
OUT
4
OUT
3
4
NE5090NPB3192
0PS
AIN1
AIN2
AIN3
AIN4
AIN5
PU1
8
OUT
4
U9
AIN1
AIN2
AIN3
AIN4
D6
16
32
PU2
CX10
C7
OUT
5
OUT
5
1
D7
TOKEN
2
PU3
R6
C9
NETWORK
T
4
8
D8
U10
CPU
COM
4-5
CPU
COM
4-5
SW1
PU4
16
COMM
TEST
COMM
TEST
SH
R
D9
L1
32
Sensor
PU5
GND
CX12
D11
12V
12V
D12
R13
GND
GND
C10
PU7
D14
X2
9 9 3 6
AOUT1
ADDRESS
ADD
WHP
Controllers
ADDRESS
ADD
AIN
1
AIN
2
AIN
1
AIN
2
JP1
M C 3 4 0 6 4 A
SC1
4
ANALOG IN MOD I/O BD.
YS101784
C13
C12
U13
AOUT1
R15
U12
AIN
3
AIN
3
24VAC
GND
AOUT2
AIN7
CX14
C14
R19
AIN
4
AIN
5
AIN
4
AIN
5
C16
U14
D15
CX13
U15
C17
GND
PJ1
TB4
T
C15
R22
GND
GND
TB3
D19
GND
SH
R
GND
GND
R24
R25
C20
CX15
AOUT
AOUT
PWR
GND
PWR
7 8 2 4 C T
M
PRESSURE
SENSOR
PRESSURE
SENSOR
GND
R26
24VAC
PRESSURE
SENSOR
YS101564
YS101564
EXPANSION
T'STAT
VR1
VR2
24VAC
24VAC
24VAC
Loop # 4
Local Loop
RS-485
9600 Baud
Notes:
3.) The Local Loop With The Loop Controller
Installed Can Only Have Up To 29
1.) 24 VAC Must Be Connected
So That All Ground Wires
Remain Common.
WHP Controllers Attached As The WHP
Loop Controller Occupies Address #30.
2.) All Wiring To Be In Accordance
With Local And National Electrical
Codes and Specifications.
4.) Systems may consist of up to 20 Local
Loops (600 WHP Controllers). Consult
factory for systems that exceed these quantities.
System Wiring Overview
4-2
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WattMaster WHP
Section 4
All communications wiring should be labeled to avoid confusion and to aid future
servicing.
COMPUTER
(OPTIONAL)
POWER
24VAC
GND
COMMUNICATIONS
T
SHLD
R
SYSTEM MANAGER POWER SUPPLY
YS101716 REV. 1
RS-485
SYSTEM MANAGER
COMM LINK II
INTERFACE
(MULTIPLE LOOP)
UNIT COMES WITH
STANDARD WALL MOUNT
120/24 VAC POWER SUPPLY
( MAY ALSO BE POWERED FROM 24VAC )
Remote Link
(OPTIONAL)
U3
CX1
CX2
RN1
1
U2
CX4
U1
U4
CPU
TB
COMM
1
V1
V2
T
V3
SHLD
R
CX
5
COM1-3
U5
LD6
PAL
R1
R2
R3
COMM
RS-485
COMM
1
RAM
EPROM
LD7
PW
TUC-5R PLUS
(1 EG
1
HH
R
M
)
YS101816 RE
V
.
2
U6
LD8
LED1
R4
R5
4RLY IO BD. YS101790
C1
LD9
LED2
P1
COM4-5
R1
+VRE
F
TB2
CX6
5.11V
U
7
T
E
S
T
P
V4
V5
EWDO
G
RV
1
VREFADJ
R28
1
INPUTS
ADDRESS
ADD
U8
1
2
+VDC
4RLY IO BD. YS101790
RN5
4
NE5090NPB319
S
2
AIN1
AIN2
AIN3
AIN4
AIN5
PU
D6
1
8
16
32
0P
U9
AIN1
AIN2
AIN3
AIN4
PU2
CX10
C7
D7
PU3
TOKE
N
R6
NETWORK
D8
PU4
U10
SW1
D9
PU5
L1
C9
GND
CX12
D11
D12
R13
X2
9 9 3
6 4 A 3 4 0 M C
AOUT1
C10
PU7
GND
D14
JP
1
SC1
4
ANALOG IN MOD I/O BD.
YS101784
GND
AOUT1
C13
C12
U13
R
15
U12
CX1
AOUT2
AIN7
4
C1
4
C16
R19
U14
CX13
U15
D15
C17
GND
TB4
C1
5
TB3
PJ
1
D19
GND
R
22
24
25
R
R
C20
CX15
T
7 8 2 4 C
R26
24VAC
PRESSURE
SENSOR
EXPANSION
T'STAT
VR1
VR2
CPU
NETWORK
LOOP
TO OTHER WHP CONTROLLERS
TO OTHER MINILINKS
(NETWORK TERMINALS ONLY)
Communications Loop Routing
Start-Up and Troubleshooting
4-3
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WattMaster WHP
Section 4
2.0 WHP Controller
Overview
2.1 How It Works
2.1.1 Initialization
On system powerup the COMM LED remains extinguished for five seconds. After this
delay, the COMM LED will blink out the address of the controller (Address Switch
Setting). The COMM LED will then extinguish for another five seconds and then begin
to blink for a twenty second startup delay. At the conclusion of this twenty second period,
the COMM LED will begin blinking a diagnostic code every ten seconds. This code is
described later in this document. The duration of a powerup initialization sequence is
roughly one minute.
During this initialization period, the controller retrieves all operating setpoints from its
non-volatile EEPROM memory and initializes all outputs to an OFF condition.
Note: All future references to the Water Source Heat Pump Controller in this docu-
ment use WHP as the designation.
2.1.2 Operating Summary
At all times, after the conclusion of the initialization sequence, the WHP performs a
specific set of operating instructions in the following order: (a - g repeat continuously)
a. Read Analog Inputs for Temperatures and Overrides.
b. Check the RS-485 communications port for any new setpoints from the System
Manager and keeps the status updated for the System Manager.
c. If the push-button override is active, it checks the timer to see if the override is
finished.
d. Calculates the current occupied/unoccupied mode from its internal week sched-
uling.
e. Calculates what state the output relays and analog output should be set to.
f. Updates the diagnostic COMM LED blinking.
g. Stores data in the internal trend log if ready for another log.
4-4
Start-Up and Troubleshooting
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WattMaster WHP
Section 4
2.2 Becoming Familiar with the WHP
Controller
RAM SIZE
SELECT JUMPER
COMMUNICATIONS
RAM
EPROM
PIN 1
DRIVER CHIP
PAL
INDICATION
24 VAC Common for Inputs 1 - 3
Fan-On/Off
RS-485
COMMUNICATIONS
LOOP
Rev. Valve-On/Off (Heat 1)
Compressor-On/Off (Heat 2)
Heat Pump Reset (Cool 1)
Aux. Heating or Cooling (Cool 2)
24 VAC Common for Inputs 1 - 3
COMMUNICATIONS
LED
ADDRESS SWITCH
( ADDRESS 18 SHOWN )
CPU
ANALOG INPUTS
Space Sensor
DIAGNOSTIC BLINK
CODE LED
Slide Adjust
Supply Air Temp
Leaving Water
Temp or
Dirty Filter
REAL TIME
CLOCK CHIP
Lockout
POWER LED
24VAC
POWER
INPUT
STATIC PRESSURE
SENSOR INPUT
Mounting Backplate
WHP Controller Component Layout
2.2.1 24 VAC Power Connector
This connector provides power to the WHP Controller.
24VAC - The “hot” side of the control transformer.
GND - The grounded side of the control transformer. If the secondary of the con-
trol transformer is not grounded, you must still observe polarity if the trans-
former powers any other device!
Warning: Connect only the GND terminal to the grounded side of a transformer
- Failure to properly observe polarity will result in
damage to the system. Observe polarity at all points in the
system.
Start-Up and Troubleshooting
4-5
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WattMaster WHP
Section 4
2.2.2 Analog Inputs
This connector carries the analog and binary control input signals.
AIN1 - Space Temp - This input accepts a two wire 10K Type III thermistor tem-
perature sensor. The sensor measures 10,000 Ohms @ 77°F. The resistance drops
as the temperature increases. The sensor is connected between this terminal and
the GND terminal. This input is also monitored for push-button override com-
mands. The push-button is only active during unoccupied hours so a push during
occupied hours has no effect.
AIN2 - Slide Adjust - If the OE212 or OE213 space temperature sensor is in-
stalled, the sensor contains a slide adjust control for varying the current heating
and cooling setpoints. If the OE210 or OE211 sensors are used, this input will not
be used.
AIN3 - Discharge Temp - The discharge temperature reading is used to detect
discharge air temperature and to monitor for equipment failure. Once the com-
pressor has activated, the discharge air temperature has 10 minutes to change by
5°F or the controller assumes a mechanical failure has occurred.
AIN4 - Leaving Water Temp and/or Dirty Filter Alarm - Can provide status
only water temperature and/or dirty filter contact closure. If both are used at the
same time, water temperature will be lost when the dirty filter contact is closed.
AIN5 - Lockout - If this input is active all operations are terminated to protect the
equipment.
GND - Common return wire. This point is tied to ground on the WHP
Controller.
2.2.3 Analog Output Description
AOUT - Analog Output - This output is not used.
2.2.4 Relay Output Descriptions
COM1-3 - Common 1 thru 3. - This ties the common return of the first 3 outputs
together.
OUT1 - Fan On/Off - The fan is enabled to run when this contact is closed.
OUT2 - Reversing Valve or Heat 1 - This output enables the reversing valve if
you have configured the WHP Controller for a compressor and reversing valve
configuration. If the WHP Controller is configured for individual staging of heat-
ing and cooling (no reversing valve) then this output enables heating stage 1.
4-6
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WattMaster WHP
Section 4
OUT3 - Compressor or Heat 2 - This output enables the compressor if you have
configured the WHP Controller for a compressor and reversing valve configura-
tion. If the WHP Controller is configured for individual staging of heating and
cooling (no reversing valve) then this output enables heating stage 2.
OUT4 - Heat Pump Reset or Cool 1 - This output can be used to reset a com-
pressor that has gone off line. If the WHP Controller is configured for individual
staging of heating and cooling (no reversing valve) then this output enables cool-
ing stage 1.
OUT5 - Aux. Relay or Cool 2 - If you have configured the WHP Controller for a
compressor and reversing valve configuration this output can be configured as
follows:
1.) Stage 2 for cooling and/or heating mode.
2.) Auxiliary scheduling relay. In this mode it can be programmed to follow an
externally broadcast schedule signal.
3.) Auxiliary relay. In this mode it can be used for any function requiring a man-
ual user intervention.
4.) Isolation valve. May be used to initiate opening of an isolation valve in case of
high loop water pressure even if the WHP Controller is satisfied or in an un-
occupied mode. In occupied mode this relay operates in conjunction with the
compressor.
If the WHP Controller is configured for individual staging of heating and cooling
(no reversing valve) then this output enables cooling stage 2.
COM4-5 - Common 4 and 5. - This ties the common return of the last 2 outputs
together. Jumper this terminal to COM1-3 if the unit does not have separate
cooling and heating power supplies.
2.2.5 RS-485 Communications Connector
This connector provides the connection point for the Local Loop RS-485 communications
loop. The wiring consists of a twisted pair of wires with a shield.
T - RS-485 (+) Communications terminal
SHLD - Common return wire, this point is internally tied to GND on the WHP
Controller.
R - RS-485 (-) Communications terminal
Start-Up and Troubleshooting
4-7
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WattMaster WHP
Section 4
2.2.6 WHP Controller Wiring
Communication LED
Typical WHP Controller Wiring Diagram
4-8
Start-Up and Troubleshooting
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WattMaster WHP
Section 4
3.0 Loop Controller
Overview
3.1 How It Works
3.1.1 Initialization
On system powerup LED2 remains extinguished for five seconds. After this delay, the
LED2 will blink out the address of the controller (Address Switch Setting). The LED2
will then extinguish for another five seconds and then the LED2 will begin blinking a
diagnostic code every ten seconds. This code is described in the troubleshooting section.
The duration of a powerup initialization sequence is roughly thirty seconds.
During this initialization period, the controller retrieves all operating setpoints from its
non-volatile EEPROM memory and initializes all outputs to an OFF condition.
3.1.2 Operating Summary
There is a standard set of operating instructions that are continuously performed over and
over during normal Loop Controller operations. They are listed below.
a
Read analog inputs for temperatures, pressures and binary contact closures
b
Checks for new setpoints from System Manager or Prism Software and keeps the
status values updated for these interfaces.
c
Looks for “request to run” broadcast from any installed WHP Controller or from
an on-board binary input.
d. Set all outputs to match calculations for heat rejection or addition.
e. Store data in internal trend log if ready for another log
f. Broadcasts the operating commands to all WHP Controllers.
g. Tests for lead/lag pump changeover if both pumps are off.
h. Repeat steps a-g continuously
Start-Up and Troubleshooting
4-9
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WattMaster WHP
Section 4
3.2 Loop Controller Inputs & Outputs
3.2.1 Analog Inputs
AIN1 - Return Water Temp - This input accepts a two wire 10K Type III ther-
mistor temperature sensor. The sensor measures 10,000 Ohms @ 77°F. The re-
sistance drops as the temperature increases. The sensor is connected between this
terminal and the GND terminal.
AIN2 - Supply Water Temp - This input accepts a two wire 10K Type III ther-
mistor temperature sensor. The sensor measures 10,000 Ohms @ 77°F. The re-
sistance drops as the temperature increases. The sensor is connected between this
terminal and the GND terminal.
AIN3 – Proof of Flow/Loop Pressure - This input accepts a differential pressure
contact closure for proof of flow or a 0-50 PSI (0-5VDC) pressure transducer sig-
nal.
AIN4 - Outdoor Air Temp - The OA temperature is used to determine if pumps
should be turned on during off periods, to prevent freezing. When the OA tem-
perature is below 40° F, the pumps will be turned on.
AIN5 - Manual Reset Input - Used to restart equipment after alarm condition
has occurred. When this input is shorted to GND by a momentary pushbutton, a
signal to restart is sent.
AIN7 – Phase Loss – If a phase monitor is being used, a normally open contact is
connected here. When a loss of phase is detected, this contact closes shutting
down the Loop Controller.
GND - Common return wire. This point is tied to ground on the Loop Controller.
3.2.2 Analog Output
This connector carries a 0-10 volt control signal for the following items:
AOUT1- Pump VFD Signal - If you have selected the variable speed pump op-
tion this output signal is used to control the loop pressure.
AOUT2 - Proportional Heat Signal - This output may be used when a modulat-
ing signal is required to control heat addition temperature.
GND - Common return wire, this point is tied to GND on the Loop Controller.
4-10
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WattMaster WHP
Section 4
3.2.3 Binary Output
R1 – Compressor Enable – Energizes the first stage of cooling.
R2 – Main Pump – Energizes the lead water pump.
R3 – Standby Pump – Energizes the standby pump if the main pump fails to
start.
R4 – Alarm Indicator – Energizes when an alarm occurs on the Loop Controller.
R5 – Not Used – This output is not used.
COM 1-3 - Common – 24 VAC from the AHU is connected to this terminal and
is the common for inputs 1 through 3.
COM 4-5 - Common – 24 VAC from the AHU is connected to this terminal and
is the common for inputs 4 and 5.
3.2.4 Relay Expansion Board - Outputs
This connector carries the output relay dry contact open/closed signal.
Relays 1-4 - Heat Addition/Rejection Stages - Can be configured to be used for
either stages of heating or cooling of water when required.
Relays 5-8 - Heat Addition/Rejection Stages – Same as above, can be used for
heating or cooling of the water.
3.2.5 Analog Input Expansion Board
The following inputs use dry contact open/closed signals.
AIN1 – Fire Alarm Contact - Used to shut down all equipment in case of a
smoke or fire condition.
AIN2 - Request to Run - Used to initiate system start when a water source heat
pump controller other than the WattMaster WHP Controller is used.
Warning: Fire Alarm Contact input must be connected to the AIN1- GND
terminal if it is not used, a jumper must be connected between AIN1
and GND, since this is a normally closed contact input. If this is not
done the system will not operate.
Start-Up and Troubleshooting
4-11
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WattMaster WHP
Section 4
3.2.6 Comm Connector - Communications
RS-485 Communications Connector - This connector provides the connection point for
the Local Loop RS-485 communications loop. The wiring consists of a twisted pair of
wires with a shield.
T - RS-485 (+) Communications terminal
SHLD - Common return wire, this point is internally tied to GND on the WHP
Controller.
R - RS-485 (-) Communications terminal
3.2.7 Power Terminal
This connector provides power to the Loop Controller
24 VAC - Connect to the “HOT” side of the control transformer.
GND - The grounded side of the control transformer. If the secondary of the con-
trol transformer is not grounded, you must still observe polarity if the trans-
former powers any other device!
Warning: Connect only the GND terminal to the grounded side of a transformer
Failure to properly observe polarity will result in damage to the
system. Observe polarity at all points in the system.
4-12
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WattMaster WHP
Section 4
Connect To Next Controller And/Or
MiniLink On Local Loop
Local Loop RS-485
9600 Baud
(See Note 3).
Optional
Pressure sensor
Line Voltage
Figure 4-5: Loop Controller Inputs & Outputs
Start-Up and Troubleshooting
4-13
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WattMaster WHP
Section 4
4.0 Start-Up
4.1 Blink Codes for WHP Controllers
The WHP Controller uses an on board LED to indicate various diagnostic conditions
during powerup and operation. The WHP Unit LED is labeled “COMM”. Starting with
power up the LED blink codes are as follows:
• Off for five seconds
• COMM LED blinks the board address (Address 14 = 14 blinks)
• Five second pause
• Twenty second time delay - LED blinks twenty times
• Status code is repeatedly blinked every ten seconds to indicate controller
status:
Lowest
1
2
3
4
5
Normal Operation
Override Active
Bad Space Sensor
Heat Pump Lockout
Communication Failure
-
-
-
Highest
Figure 4-6: Diagnostic LED Blink Codes
Only the highest priority failure code will be shown. You must correct the highest priority
alarm before other problems will be indicated.
4-14
Start-Up and Troubleshooting
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WattMaster WHP
Section 4
4.2 Blink Codes for Loop Controllers
The Loop Controller uses an on board LED to indicate various diagnostic conditions
during powerup and operation. The Loop Controller Unit LED is labeled “LED2”.
Starting with power up the LED blink codes are as follows:
• Off for five seconds
• COMM LED blinks the board address (Address 14 = 14 blinks)
• Five second pause
• Status code is repeatedly blinked every ten seconds to indicate controller
status:
Lowest
1
2
3
4
5
6
Normal Operation
Pump and/or Flow Failure
Bad Water Temp Sensor
Single Phase Shutdown
Water Pressure Alarm
Fire Alarm
-
-
-
-
Highest
Figure 4-7: Diagnostic LED Blink Codes
Only the highest priority failure code will be shown. You must correct the highest priority
alarm before other problems will be indicated.
4.3 Communications Checklist
• WHP Controllers are addressed from 1 to 30 on each loop except the loop with the
WHP Loop Controller. This loop can only use address 1 thru 29 for the WHP Con-
trollers. WHP Loop Controller is addressed as 30 on the loop it is connected to.
• Power has been cycled after changing addresses
• A multiple loop CommLink II is powered and connected to the communications loop.
• System Manager is connected to one of the local loops.
• The MiniLinks on each local loop are addressed with a unique address 1 thru 30,
depending on the number of loops on your system.
Start-Up and Troubleshooting
4-15
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WattMaster WHP
Section 4
4.4 Installation and Commissioning
Information
Familiarize yourself with the installation manual and system wiring diagrams
before installing!
1. Check to see if you have all the correct components for your installation.
2. Establish the location for the CommLink Interface first. This is where your communi-
cation cable will begin.
3. Layout your communication wiring. For systems with more than 30 WHPs or more
than one MiniLink, there are multiple communication loops:
A. The Network Loop - This loop originates at the CommLink and interconnects
MiniLinks together.
B. The Local Loop – This loop originates at the MiniLink. The WHPs, Loop
Controllers and the System Manager are connected to this loop.
Tip: Using the WattMaster color-coded and labeled Communication Cable insures a
quality installation. It also makes your installation much easier and less likely to
have communications wiring errors!
4. Communication cable must always be shielded – no exceptions!
5. Mount controllers in appropriate locations according to their operating specification.
6. Address controllers according to location and addressing instructions located in the
system manual.
7. With no power connected, wire controller according to wiring diagrams and in
accordance with local codes. Never apply power until you have completed these pro-
cedures in accordance to all system instructions.
8. After completing all wiring connections, unplug the terminals for power and commu-
nications. Always unplug the communications loop first and then the power. When
reconnecting the wiring, connect the power first and then the communication loop.
9. Continue step 8 until all devices have been wired and the power and communication
terminals have been unplugged.
4-16
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WattMaster WHP
Section 4
10. Install CommLink and power-up. At this point you are ready to begin commissioning
the system. It is preferred, though not necessary, to use a PC with Prism software to
assist in the commissioning process.
11. Start with the first controller on the communication loop or in multiple loop systems;
start with the MiniLink or with the System Manager. Plug in the Communication
terminal then plug in the Power terminal.
12. Observe the LED indicator for the blink codes as outlined in the troubleshooting
section of the manual. The blink code will first verify the address, then the operation.
If the address is incorrect, reset the dipswitch, then reapply power to the controller.
13. After each controller is connected and completes its initialization sequence, use the
PC or System Manager to verify communication to that device. If you cannot com-
municate, verify wiring, voltages, etc. in accordance with the troubleshooting section
in the system manual. Do not proceed to the next device until you are properly com-
municating with the current device.
Continue this process until all controllers are connected and properly communicating.
By following the above steps and procedures, your installation will be much faster and
trouble free. Remember that each controller only contains one puff of smoke. Making
sure that all wiring terminations and voltages are correct prior to applying power to a
controller will insure that you don’t use that one puff.
Start-Up and Troubleshooting
4-17
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WattMaster WHP
Section 4
COMM LINK II
INTERFACE
(MULTIPLE LOOP)
POWER
24VAC
GND
COMMUNICATIONS
T
SHLD
R
SYSTEM MANAGER POWER SUPPLY
RS-485
YS101716 REV.
1
SYSTEM MANAGER
U3
CX1
CX2
RN1
U2
CX4
1
U1
U4
CPU
T
COM
B1
M
V1
V2
V3
T
SHLD
R X
C
5
COM1-3
U5
LD6
PA
L
R1
R2
R3
COM
M
RS-48
5
1
RAM
EPROM
COM
M
L
D7
TUC-5R PLUS
EG)
1
HH
P
WR
(
RE
1
V.
M
2
YS101816
U6
L
D8
R4
R5
4RLY IO BD. YS101790
LED1
C1
LD9
LED2
P1
COM4-5
R1
+V
RE
F
TB2
CX6
5.11V
POINT
U7
TES
T
V4
EWDOG
RV
1
V
5
V
REF ADJ
R28
1
INPUTS
ADDRES
S
ADD
1
U8
+VDC
4RLY IO BD. YS101790
2
4
RN
5
NE
5090NPB3192
S
AIN1
AIN2
AIN3
P
U1
8
16
0P
U9
AIN1
AIN2
AIN3
AIN4
D6
U2
P
CX10
C7
32
TO KEN
D7
U3
P
R
6
NETWORK
D8
U4
U10
SW1
AIN4
AIN5
GND
GND
P
D9
U5
L1
C9
P
GND
CX12
D1
1
D
12
C10
P
U7
X2
9 9
6 4 A 3 4
AOUT1
4
R
13
D14
J
P1
C M
0
SC1
ANALOG IN MOD I/O BD.
YS101784
C
13
C12
U13
AOUT1
R15
U12
AOUT2
AIN7
CX14
C
14
C
16
R19
U14
CX13
D15
C20
C17
GND
TB4
U1
5
C15
TB
3
PJ
1
D19
GND
R22
R24
R25
CX15
T
2 4 7 C 8
R26
24VAC
PRESSURE
SENSOR
EXPANSION
T'STAT
V
R1
VR2
CPU
NETWORK
LOOP
TO OTHER WHP CONTROLLERS
TO OTHER MINILINKS
(NETWORK TERMINALS ONLY)
Communications Loop Wiring
4-18
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WattMaster WHP
Section 4
4.5 Setting Address Switches
4.5.1 Setting the MiniLink Address Switch
LOOP
ADDRESS SWITCH
ADD
1
2
4
8
8
7
6
5
16
32
4
3
2
1
OFF
>
ADDRESS SWITCH SHOWN IS
SET FOR ADDRESS 1
ADDRESS SWITCH SHOWN IS
SET FOR ADDRESS 13
LOOP
ADDRESS SWITCH
1
2
4
8
8
7
6
5
T
16
32
4
3
2
1
SH
R
NOTE:
THE POWER TO THE MINILINK MUST BE
REMOVED AND RECONNECTED AFTER
CHANGING THE ADDRESS SWITCH SETTINGS
IN ORDER FOR ANY CHANGES TO TAKE
EFFECT.
OFF
>
24VAC
GND
CAUTION:
T
DISCONNECT ALL COMMUNICATION
LOOP WIRING FROM THE MINILINK BEFORE
REMOVING POWER FROM THE MINILINK.
RECONNECT POWER AND THEN RECONNECT
COMMUNICATION LOOP WIRING.
SH
R
MiniLink Address Switch Setting
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Section 4
4.5.2 Loop Controller Addressing
The Loop Controller address should always be set for address #30. A maximum of 29
WHP Controllers on the loop that contains the Loop Controller. All other loops may have
30 WHP Controllers. (Refer to Figure 2-10 for more detail)
4.5.3 WHP Controller Addressing
NOTE:
IGNORE ANY MARKINGS
OR NUMBERS ON THE SWITCH
USE THE CHART!
To determine the boards address,
add the values of all the switches
which are toggled down in the
direction of the arrow
NOTE:
ADDRESS 30 CANNOT BE USED
ON THE LOOP THAT HAS THE WHP LOOP
CONTROLLER ATTACHED. ADDRESS 30
ON THAT LOOP IS RESERVED FOR THE
WHP LOOP CONTROLLER.
CAUTION:
YOU MUST POWER DOWN THE CONTROLLER
AFTER CHANGING THE ADDRESS SWITCHES
IN ORDER FOR ANY CHANGES TO TAKE EFFECT.
ALWAYS REMOVE THE COMMUNICATIONS LOOP
PRIOR TO DISCONNECTING POWER. RECONNECT
POWER AND THEN RECONNECT THE COMMUNICATIONS
LOOP TO THE CONTROLLER.
WHP Controller Address Switch Setting
4-20
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WattMaster WHP
Section 4
5.0 Troubleshooting
5.1 General Troubleshooting
The following is a guide to assist in troubleshooting the WattMaster WHP System. It is
provided as a systematic approach to determining and resolving common system
problems.
5.1.1 Communications Troubleshooting Checklist
No WHP or Loop Controller Units are Communicating
• Is the CommLink II connected and plugged in?
• Is the CommLink II installed, a single or multiple loop version. A jumper in the
CommLink can be set for “Single” or “Multi”. On the WHP system is considered a
Multiple Loop version and the CommLink jumper must be set on Multi.
• Are Comm Loop voltages correct? See the Comm Loop troubleshooting guides.(page
4-24)
• Is the Comm Loop open or shorted?
• Is the CommLink II connected and plugged in?
• Is the MiniLink Voltage correct?
• Are the WHP and Loop Controller address switches set correctly? See the addressing
chart. (WHP Loop Controller should always be set to address 30, see Figure 4-10)
• Is the MiniLink address switch set correctly? See the addressing chart.(see Figure 4-
10)
• Are the WHP and Loop Controllers powered? Check 24 VAC to the controllers.
• Is the System Manager connected to the Local Communications loop?
Some WHP Units are communicating but others are not:
• Are the WHP Controller address switches set correctly? See the addressing chart.
• Is the WHP Loop Controller address switch set correctly? See the addressing chart.
• Are the WHP Controllers and Loop Controller powered? Check 24 VAC to the
controllers.
• Is the REC LED on the missing WHP Controller “flickering”? See WHP Controller
introduction for location of the REC LED. (see Figure 4-4)
• Is the COMM LED on the WHP Controller blinking an error code? See the Blink
Code chart. (see Figure 4-6)
• Are Comm Loop voltages correct at the missing unit? See Comm Loop troubleshoot-
ing guide starting on page 4-24.
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WattMaster WHP
Section 4
5.1.2 General Troubleshooting Checklist
Begin troubleshooting by locating the general problem in the list below. Detailed
component troubleshooting information follows later in this section.
Zone is too warm
• Is zone calling for cooling?
• Is the compressor disabled due to minimum off time setting?
• Is water proof of flow signal disabled?
• Is the LED blinking an error code? See Figure 4-6.
Zone is too cool
• Is zone calling for heating?
• Is the compressor disabled due to minimum off time setting?
• Is water proof of flow signal disabled?
• Is the LED blinking an error code? See Figure 4-6.
Zone Sensor reading incorrectly
• Is the sensor near a source of heat or a cold draft? Location is a common problem.
The sensor should be mounted on an inside wall away from heat sources and in a
location with adequate room air circulation.
• Is the resistance reading correct? Check with the Temperature/Resistance Chart in
this section. (see page 4-42)
• Is wiring correct? Check for errors.
Check the Room sensor
• To meter the Room sensor:
Unplug the room sensor terminal block. Using your meter, check the resistance of the
unplugged terminal block. Use the supplied Temperature/Resistance Chart (page 4-
42) to see if the sensor is within a reasonable range. Readings which are much too
high or too low generally indicate wiring problems.
• To meter the Slide Adjust (optional):
Use your ohmmeter to check the resistance between the room sensor GND wire and
the AIN2 terminal on the unplugged terminal block.
The resistance for various positions of the slider on the sensor should be as follows:
Full UP position
MID position
Full DN position
15K Ω ( 500 Ω)
12.5K Ω ( 500 Ω)
10K Ω ( 500 Ω)
4-22
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Section 4
5.2 Alarms
When an alarm occurs in the WHP or Loop Controller, it is reported to the System
Manager. The alarms cause the light on the System Manager to illuminate. The View
Alarms screen will indicate the address of the alarms. The Status screen will display the
type of alarm that has occurred. Here is a list of the alarms that are reported to the System
Manager.
WHP:
Bad Space Sensor – Space sensor is either open or shorted
Hi Space Temp Alarm – If space temperature is 5° or more above cooling setpoint
Lo Space Temp Alarm – If space temperature is 5° or more below heating setpoint
Dirty Filter Alarm – Contacts between AIN4 and GND are shorted
Cooling Failure – If supply air doesn’t drop 5° in 10 minutes in cooling mode
Heating Failure - If supply air doesn’t go up 5° in 10 minutes in heating mode
Loop Controller:
Pump Failure – No proof of flow within 5 seconds after pump starts
No Flow Detected – The contact between AIN3 and GND is open, no water flow
Phase Shutdown – The contact between AIN7 and GND is open, loss of phase
Lo Water Temp Alarm – Water Temp is below Lo Limit setpoint
Hi Water Temp Alarm - Water Temp is above Hi Limit setpoint
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Section 4
5.3 Checking Comm. Loop Voltages
5.3.1 Checking the CommLink II Network Loop
Diagram
This test checks for proper Network loop voltages at the CommLink II.
The Loop LED (located on the front panel) should “flicker” when the CommLink II is
attempting to communicate. The Loop LED will flicker more noticeably for a few
seconds when first powered up. If the Loop LED does not flicker, the unit is defective.
Make sure CommLink II jumper is set to “Multi” position.
Proper loop voltages are essential for reliable communications. It is normal to see fluctua-
tions at this point on the CommLink II. The average value should be close to the acceptable
range described below. Values will vary upon initial powerup for about 10-15 seconds as
the unit attempts to communicate.
Measurements
T - G (SHLD)
R - G (SHLD)
Action
2.9 - 3.1 Volts DC
1.9 - 2.1 Volts DC
If voltages are too high or too low on either
side
1. Unplug the Network loop from the
CommLink II and check for proper loop
voltages. If a problem exists, disconnect
each MiniLink Network loop until the
problem is isolated.
2. Check the CommLink II Driver chip.
Replace the driver chip if necessary
4-24
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Section 4
5.3.2 Checking the Comm Loop at the CommLink II
Diagram
The indicated values are typical of a normal system, actual readings may deviate slightly
due to the number of units connected and other system specific factors.
All of the connected Minilinks should be powered up for this test.
This is a “quick check” to determine if any of the driver chips on the Network loop are
damaged. Since all units will “float” both of their communications connections at about
2.45 Volts, you can quickly check the Network loop by unplugging it at the CommLink II.
Be sure that the loop you are testing does not have a short circuit from T to R.
The Loop LED (located on the front panel) should “flicker” when the CommLink II is
attempting to communicate with the MiniLinks. There is a noticeable change in the
flicker when the loop is disconnected, if you observe a normal functioning unit. When
the loop is reconnected it may take up to 60 seconds before the CommLink II re-
establishes communications with the MiniLinks.
Measurements
T – G (SHLD)
R – G (SHLD)
Action
2.4-to-2.5 Volts DC
2.4-to-2.5 Volts DC
If voltages are too high or too low on
either side
One or more of the MiniLinks has a damaged
Network driver chip. Disconnect the Mini-
Links one at a time to isolate the problem.
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Section 4
5.3.3 Checking the CommLink II Driver
Diagram
This test checks for proper Network loop voltages coming from the CommLink II.
The Loop LED (located on the front panel) should “flicker” when the CommLink II is
attempting to communicate. The Loop LED will flicker more noticeably for a few
seconds when first powered up. If the LED does not flicker, the unit is not function-
ing.
Proper loop voltages are essential for reliable communications. It is normal to see fluctua-
tions at this point on the CommLink II. The average value should be close to the acceptable
range described below. Values will vary upon initial powerup for about 10-15 seconds as
the unit attempts to communicate.
Measurements
T
–
G
G
2.4 - 2.5 Volts DC
2.5 - 2.7 Volts DC
(SHLD)
R
–
(SHLD)
Action
If voltages are too high or too low on either
side
1. The CommLink II has a damaged comm
driver chip. Replace the driver chip.
See instructions in section 1.3.11 for
“Comm Driver Chip Replacement”.
2. The CommLink II is defective.
4-26
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Section 4
5.3.4 Checking the MiniLink Network Loop
Diagram
Meter Set To Read DC Volts
The indicated readings are typical of a normally operating system. Actual readings may
vary slightly due to the number of units installed and other factors. Any significant devia-
tion from these values generally indicates a problem.
These tests assume that the CommLink II is connected and powered, and that all
MiniLinks which are connected are also powered.
Proper loop voltages are essential for reliable communications. It is normal to see fluctua-
tions on an operating communications loop. The average value should be close to the ac-
ceptable range described below. Values will vary upon initial powerup for about 15-30
seconds as normal communications occur.
Measurements
T - G (SHLD)
R - G (SHLD)
Action
2.9 - 3.1 Volts DC
1.9 - 2.1 Volts DC
Readings near Zero Volts
Check for shorted wiring.
If voltages are too high or too low on either
side
1. One or more devices connected to this
loop may have damaged Comm driver
chips.
2. Wiring errors. Check for multiple loops
“cross connected”, short circuits, etc.
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WattMaster WHP
Section 4
5.3.5 Checking the MiniLink Network Driver
Diagram
Meter Set To Read DC Volts
These tests assume that the MiniLink being checked is powered up
This check is intended to determine if the Network Comm Driver chip on a MiniLink is
damaged.
Before unplugging the Network loop from the MiniLink, observe the Network Loop
LED (located near the connector). It should periodically “flicker” as the CommLink II
requests data from the MiniLink. The LED will also flicker when power to the
CommLink II is cycled. If the LED is not flickering, the unit is not communicating
with the CommLink II.
Damage typically occurs when the communications loop is exposed to excessive voltage, as
may occur during installation due to wiring errors. The driver chips are socketed on all
boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.
Almost all failures occur as a result of wiring related problems.
Measurements
T – SHLD
R – SHLD
2.4 - 2.5 Volts DC
2.4 - 2.5 Volts DC
Minor variances may not indicate a problem if both tests indicate similar values
Action
If voltages are too high or too low on either
side
The MiniLink has a damaged Network
Comm Driver chip. Replace the driver
chip. See "1.3.11Comm Driver Chip Re-
placement”.
4-28
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WattMaster WHP
Section 4
5.3.6 Checking the MiniLink Local Loop
Diagram
Meter Set To Read DC Volts
The indicated readings are typical of a normally operating system. Actual readings may vary
slightly due to the number of units installed and other factors. Any significant deviation
from these values generally indicates a problem.
These tests assume the MiniLink is powered up
Proper loop voltages are essential for reliable communications. It is normal to see fluctua-
tions on an operating communications loop. The average value should be close to the ac-
ceptable range described below. Values will vary upon initial powerup for about 30-45 sec-
onds. Voltages fluctuate as normal communications occur.
Measurements
T – SHLD
R – SHLD
Action
2.9 - 3.1 Volts DC
1.9 - 2.1 Volts DC
Readings near zero volts
Check for shorted wiring.
If voltages are too high or too low on either
side
1. One or more devices connected to this
loop may have damaged Comm Driver
chips.
2. Wiring errors. Check for multiple loops
inadvertently “cross connected”, short
circuits, etc.
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Section 4
5.3.7 Checking the Local Loop at MiniLink
Diagram
Meter Set To Read DC Volts
The indicated values are typical of a normal system. Actual readings may deviate slightly
due to the number of units connected and other system specific factors
These tests assume that the controllers being checked are powered up.
This is a “quick check” to determine if any of the WHP Controllers or WHP Loop Control-
ler on a Local Communications Loop are damaged. Since all WHP Controllers will “float”
both of their communications connections at about 2.45 Volts, you can quickly check an
entire loop by unplugging it at the MiniLink.
Be sure that the loop you are testing does not have a short circuit from T - R.
Damage typically occurs when the communications loop is exposed to excessive voltage, as
may occur during installation, due to wiring errors. The driver chips are socketed on all
boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.
Almost all failures occur due to wiring related problems.
Measurements
T – SHLD
R – SHLD
2.4 - 2.5 Volts DC
2.4 - 2.5 Volts DC
Minor variances may not indicate a problem if both tests indicate similar values.
4-30
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Section 4
5.3.7 (continued)
Action
If voltages are too high or too low on either
side
1. One or more of the attached controllers
has a damaged Comm Driver chip. Lo-
cate and replace the driver chip(s).
See "1.3.11 Comm Driver Chip Re-
placement”.
2. Wiring errors such as "crossed connec-
tions", short circuits, etc.
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Section 4
5.3.8 Checking the MiniLink Local Loop Driver
Diagram
Meter Set To Read DC Volts
The indicated values are typical of a normal operating system. Actual readings may deviate
slightly.
These tests assume that the MiniLink is powered up.
This test checks for proper Local Loop voltages coming from the MiniLink.
The Local Loop LED (located near the connector) should “flicker” when the Mini-
Link is operating and when first powered up. If the LED is not flickering, the unit is
not functioning.
Proper loop voltages are essential for reliable communications. It is normal to see fluctua-
tions at this point on the MiniLink. The average value should be close to the acceptable
range described below. Values will vary upon initial powerup for about 10-15 seconds. The
voltage will fluctuate as the unit attempts to communicate.
Measurements
T
–
G
G
2.9 - 3.1 Volts DC
1.9 - 2.1 Volts DC
(SHLD)
R
–
(SHLD)
Action
If voltages are too high or too low on either
side
1. The MiniLink has a damaged Comm
Driver chip. Locate and replace the
driver chip(s). See "1.3.11 Comm
Driver Chip Replacement”.
2. The MiniLink is not functioning.
4-32
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Section 4
5.3.9 Checking the Local Loop at a WHP Controller
Diagram
Meter Set To Read DC Volts
The indicated readings are typical of a normal operating system. Actual readings may vary
slightly due to the number of units installed and other factors. Any significant deviation
from these values generally indicates a problem.
These tests assume that a MiniLink is connected and powered up.
Proper loop voltages are essential for reliable communications. It is normal to see fluctua-
tions on an operating communications loop. The average value should be close to the ac-
ceptable range described below. Values will vary upon initial powerup for about 30-45 sec-
onds. The voltages may fluctuate as normal communications occur.
Measurements
T – SHLD
R – SHLD
Action
2.9 - 3.1 Volts DC
1.9 - 2.1 Volts DC
If meter reads between 2.4 VDC and 2.5
VDC
1) No CommLink II or MiniLink is con-
nected and powered up.
The Comm Loop “floats” at 2.4 - 2.5VDC
when only controllers are connected to the
loop. When a MiniLink is connected it will
“bias” each side of the loop to the values
listed above.
2) If a CommLink II or MiniLink is con-
nected, look for “open” wiring.
If voltages are too high or too low on either
side
One or more devices connected to this loop
have damaged Comm Driver chips.
Start-Up and Troubleshooting
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Section 4
5.3.10 Checking WHP Controller Driver Chip
Diagram
Meter Set To Read DC Volts
These tests assume that the controller being checked is powered up.
This check is intended to determine if the Comm Driver chip on a controller is damaged.
Damage typically occurs when the communications loop is exposed to excessive voltage, as
may occur during installation, due to wiring errors. The driver chips are socketed on all
boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.
Almost all failures occur as a result of wiring related problems.
Measurements
T – SHLD
R – SHLD
2.4 - 2.5 Volts DC
2.4 - 2.5 Volts DC
Minor variances may not indicate a problem if both tests indicate similar values.
Action
If voltages are too high or too low on either
side
The controller has a damaged Comm
Driver chip. Replace the driver chip. See
"1.3.11 Comm Driver Chip Replacement”.
4-34
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Section 4
5.4 Troubleshooting Loop Controller
5.4.1 Checking the Loop Controller Analog Inputs
Diagram
The analog input wiring can be checked at the
Loop Controller by checking voltages on the
Analog Input Connector.
SET METER TO
READ DC VOLTS
If any of the RWT, SWT, OAT inputs read
greater than 5.0 volts then it is OPEN (no
sensor is connected), an input that reads less
than 0.1 volts is SHORTED. Check for wiring
problems before proceeding.
+
12V
R
AIN1
AIN2
AIN3
AIN4
AIN5
GND
-
The Loop Pressure, Manual Reset, Phase
Loss, Fire Alarm and Request to Run inputs
should read greater than 5.0 volts if the at-
tached contact is OPEN and less than 0.5 volts
if the contact is CLOSED (contacts CLOSE
between the input and GND). The Fire Alarm
and Request to Run contacts are located on
the Analog Input Expansion Board.
GND
ALL READINGS ARE TAKEN
WITH THE (-) LEAD OF THE
METER ON THE GND
TERMINAL
AOUT1
AOUT2
AIN7
GND
The Loop Controller must be pow-
ered for these tests.
Measurements
Ignore readings for any connections which are not used in the
equipment.
AIN1
1.9 volts (100°F) - 3.6 volts (40°F)
Typical is 2.5 volts @ 77°F
Return Water Temp
AIN2
1.9 volts (100°F) - 3.6 volts (40°F)
Supply Water Temp
Typical is 2.5 volts @ 77°F
AIN3
When used with the Low Pressure Switch option:
If the input is OPEN, the voltage will be greater than 5.0 volts
If the input is CLOSED, the voltage will be less than 0.5 volts
When used with 0-50 PSI Loop Pressure Sensor option:
5.1 VDC = 50 PSI – 0.0 VDC = 0 PSI
Proof of Flow
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Section 4
5.4.1 (continued)
AIN4
1.9 volts (100°F) - 3.6 volts (40°F)
Typical is 2.5 volts @ 77°F
Outdoor Air Temp
AIN5
If the input is OPEN, the voltage will be greater than 5.0 volts
If the input is CLOSED, the voltage will be less than 0.5 volts
Manual Reset
AIN7
If the input is OPEN, the voltage will be greater than 5.0 volts
If the input is CLOSED, the voltage will be less than 0.5 volts
Phase Loss
AIN1-Exp. Bd.
Fire Alarm
If the input is OPEN, the voltage will be greater than 5.0 volts
If the input is CLOSED, the voltage will be less than 0.5 volts
Caution: AIN1 – Fire/Smoke input must be connected
to the AIN1- GND terminal. If it is not used, a jumper must be
installed, since this is a normally closed contact input. If this
is not done the system will not operate.
AIN2-Exp. Bd.
Request to Run
If the input is OPEN, the voltage will be greater than 5.0 volts
If the input is CLOSED, the voltage will be less than 0.5 volts
SWT, RWT, OAT Input voltage reads too
low
1. Check for shorts or other wiring errors.
2. Defective Sensor. Check using the chart.
3. High temperature at sensor. See chart.
1. Check for open circuit wiring errors.
2. Defective sensor. Check using the chart.
3. Low temperature at sensor. See chart.
1. Check for shorts or other wiring errors.
2. Defective Sensor. Check using the chart.
3. High pressure at sensor. See chart.
SWT, RWT, OAT input voltage reads too
high
LPR (when optional 0-5VDC Loop Pres-
sure Sensor is used) input voltage reads too
low.
LPR (When Loop Pressure Switch is used)
input voltage reads too high.
1. Check for open circuit wiring errors.
4-36
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Section 4
5.4.2 Checking the Loop Controller Outputs
Diagram
The analog output wiring can be checked at
the Loop Controller by checking voltages on
the Analog Output Connector.
SET METER TO
READ DC VOLTS
The Loop Controller must be pow-
ered for these tests.
R
+
ALL READINGS ARE TAKEN
WITH THE (-) LEAD OF THE
METER ON THE GND
TERMINAL
-
Measurements
Ignore readings for any connections which are not used in the equip-
ment.
AOUT1
Pump VFD
AOUT2
This output will vary between 0 and 10 VDC to correspond with pump
pressure setpoint.
This output will vary between 0 and 10 VDC to correspond with Heat
Addition setpoint.
Mod. Heat
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Section 4
5.4.3 Checking the Local Loop at a WHP Loop Controller
Diagram
Meter Set To Read DC Volts
The indicated readings are typical of a normal operating system. Actual readings may vary
slightly due to the number of units installed and other factors. Any significant deviation
from these values generally indicates a problem.
These tests assume that a MiniLink is connected and powered up.
Proper loop voltages are essential for reliable communications. It is normal to see fluctua-
tions on an operating communications loop. The average value should be close to the ac-
ceptable range described below. Values will vary upon initial powerup for about 30-45 sec-
onds. The voltages may fluctuate as normal communications occur.
Measurements
T – SHLD
R – SHLD
Action
2.9 - 3.1 Volts DC
1.9 - 2.1 Volts DC
If meter reads between 2.4 VDC and 2.5
VDC
1) No CommLink II or MiniLink is con-
nected and powered up.
The Comm Loop “floats” at 2.4 - 2.5VDC
when only controllers are connected to the
loop. When a MiniLink is connected it will
“bias” each side of the loop to the values
listed above.
2) If a CommLink II or MiniLink is con-
nected, look for “open” wiring.
If voltages are too high or too low on either
side
One or more devices connected to this loop
have damaged Comm Driver chips.
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Section 4
5.4.4 Checking WHP Loop Controller Driver Chip
Diagram
Meter Set To Read DC Volts
These tests assume that the controller being checked is powered up.
This check is intended to determine if the Comm Driver chip on a controller is damaged.
Damage typically occurs when the communications loop is exposed to excessive voltage, as
may occur during installation, due to wiring errors. The driver chips are socketed on all
boards to facilitate servicing. It is unusual for driver chips to fail during normal operation.
Almost all failures occur as a result of wiring related problems.
Measurements
T – SHLD
R – SHLD
2.4 - 2.5 Volts DC
2.4 - 2.5 Volts DC
Minor variances may not indicate a problem if both tests indicate similar values.
Action
If voltages are too high or too low on either
side
The controller has a damaged Comm
Driver chip. Replace the driver chip. See
"1.3.11Comm Driver Chip Replacement”.
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Section 4
5.4.5 Comm Driver Chip Replacement
MINILINK COMMUNICATIONS INTERFACE
WHP CONTROLLER
1
2
4
8
WHP CONTROLLER
COMM DRIVER CHIP
( U5 )
T
16
SH
R
PIN 1
32
NETWORK LOOP
24VAC
GND
COMMUNICATIONS
DRIVER CHIP
(U5)
T
SH
R
LOCAL LOOP
COMMUNICATIONS
DRIVER CHIP
(U8)
Ys101806 REV.2
DSPY1
U1
MODULAR
SYSTEM MANAGER
RV1
U2
R1
R4
U3
U3
CX4
CX6
D1
R5
R6
D2
R7
U4
COMMUNICATIONS
DRIVER CHIP
PJ1
CX5
C3
PIN 1
U7
X2
U6
RN1
R13
U8
CX7
SC1
U9
U12
U13
Comm Driver Chip
(U13) Pin 1
LOOP CONTROLLER CPU BOARD
System Manager
DOT
PIN 1
SOCKET
COMM DRIVER CHIP
( U1 )
PIN 1
PRINTED
CIRCUIT
BOARD
TYPICAL RS-485
DRIVER CHIP
WARNING!
USE EXTREME CAUTION WHEN REMOVING ANY CHIPS
TO AVOID DAMAGING ANY CIRCUIT BOARD TRACES WHICH
ARE UNDER THE CHIP.
BE SURE THAT ANY SMALL SCREWDRIVER OR OTHER
SHARP OBJECT USED TO REMOVE THE CHIP DOES NOT
COME INTO CONTACT WITH THE PRINTED CIRCUIT BOARD
SURFACE.
A SMALL SCREWDRIVER MAY BE INSERTED BETWEEN THE
CHIP AND THE SOCKET TO AID IN REMOVAL OF THE CHIP.
BE VERY CAREFUL NOT TO INSERT THE SCREWDRIVER UNDER
THE SOCKET!! DAMAGE TO THE BOARD IS NOT COVERED
BY WARRANTY.
COMMLINK II
Comm Driver Chip Replacement
4-40
Start-Up and Troubleshooting
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WattMaster WHP
Section 4
5.5 Temperature Sensor Resistance
Chart
º
º
-10
-5
0
93333
80531
69822
60552
52500
45902
40147
35165
30805
27140
23874
21094
18655
17799
16956
16164
15385
14681
14014
13382
12758
12191
11906
11652
11379
11136
10878
10625
10398
10158
9711
4.620
4.550
4.474
4.390
4.297
4.200
4.095
3.982
3.862
3.737
3.605
3.470
3.330
3.275
3.217
3.160
3.100
3.042
2.985
2.927
2.867
2.810
2.780
2.752
2.722
2.695
2.665
2.635
2.607
2.577
2.520
2.465
82
84
86
88
90
95
100
105
110
115
120
125
130
135
140
145
150
8893
8514
8153
7805
7472
6716
6047
5453
4923
4449
4030
3656
3317
3015
2743
2502
2288
2.407
2.352
2.297
2.242
2.187
2.055
1.927
1.805
1.687
1.575
1.469
1.369
1.274
1.185
1.101
1.024
0.952
5
10
15
20
25
30
35
40
45
50
52
54
56
58
60
62
64
66
68
69
70
71
72
73
74
75
76
78
80
*Notes:
1. Use the resistance column to check the
thermistor sensor while disconnected from
the controllers (not powered).
2. Use the voltage column to check sensors
while connected to powered controllers. Read
voltage with meter set on DC volts. Place the
“-”(minus) lead on GND terminal and the
“+”(plus) lead on the sensor input terminal
being investigated.
If the voltage is above 5.08 VDC, then the
sensor or wiring is “open.” If the voltage is
less than 0.05 VDC, the sensor or wiring is
shorted.
9302
Start-Up and Troubleshooting
4-41
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WattMaster WHP
Section 4
5.6 Pressure Sensor Voltage Chart
0
1
2
3
4
5
6
7
4.00
4.32
4.64
4.96
5.28
5.60
5.92
6.24
6.56
6.88
7.20
7.52
7.84
8.16
8.48
8.80
9.12
1.00
1.08
1.16
1.24
1.32
1.40
1.48
1.56
1.64
1.72
1.80
1.88
1.96
2.04
2.12
2.20
2.28
2.36
2.44
2.52
2.60
2.68
2.76
2.84
2.92
3.00
3.08
3.16
3.24
3.32
3.40
3.48
3.56
3.64
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
14.88
15.20
15.52
15.84
16.16
16.48
16.80
17.12
17.44
17.76
18.08
18.40
18.72
19.04
19.36
19.78
20.00
3.72
3.80
3.88
3.96
4.04
4.12
4.20
4.28
4.36
4.44
4.52
4.60
4.68
4.76
4.84
4.92
5.00
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
9.44
9.76
*Notes:
10.08
10.40
10.72
11.04
11.36
11.68
12.00
12.32
12.64
12.96
13.28
13.60
13.92
14.24
14.56
1. Use the voltage column to compare the
meter voltage with the sensor connected to
the controller and with the controller pow-
ered.
2. Read voltage with meter set on DC volts.
Place the “-”(minus) lead on GND terminal
and the “+”(plus) lead on the sensor input
terminal being investigated.
3. If the voltage is less than 0.05 VDC, then
the sensor or wiring is “shorted” or “open”
4-42
Start-Up and Troubleshooting
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WattMaster WHP
Section 4
Notes:
Start-Up and Troubleshooting
4-43
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Form: WM-WHP-IO-02A
All rights reserved
Printed in the USA
October 2004
Copyright 2004
Wattmaster Controls Inc. • 8500 NW River Park Drive • Parkville MO • 64152
E-mail: [email protected]
Phone (816) 505-1100
Fax (816) 505-1101
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