RTU Controller User Manual
Contents
1. ESB 10 7 1 SETTING UP BUS COMMUNICATION 10 7 2 PROGRAMMING THE RTU 13 SECTION 8 TROUBLESHOOTING TECHNICAL SUPPORT AND SERVICE 15 8 1 TROUBLESHOOTING 15 8 1 1 COMMUNICATION ERRORS 15 8 1 2 LED ERRORS 16 8 2 TECHNICAL SUPPORT AND SERVICE 16 8 3 WARRANTY 17 RTU Controller User Manual sfa Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Section 1 Introduction Congratulations on your purchase of the RTU Controller for HVAC Systems The RTU Controller is a stand alone and network capable specific purpose controller designed to monitor and control air conditioning systems in small to medium size buildings and remote sites The RTU can be networked with both the Q3 Building Management System and TELSEC ESB Controller This User s Manual is intended to provide the information needed to install set up program and operate RTU boards Rev E and higher If you are using the RTU in conjunction with the Q3 Building Management System or TELSEC ESB Controller you may want to refer to their operation and programming manuals for options available when communicating with the RTU Please contact us at Quest if you have product questions or suggestions to improve this User s Manual Section 2 Product Description The RTU is a stand alone intelligent controller that monitors and controls any HVAC systems Up to 32 RTU controllers can be networked to the Q3 or TELSEC ESB to pr2. RTU Controller User Manual ee Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com 2 2 Specifications Part Number 130440 Digital Outputs 6 Fan cool 1 cool 2 heat 1 heat 2 economizer Analog Ouputs 1 Output range 0 20 mA Analog Inputs 3 Zone sensor supply sensor and setpoint adjustment sensor Digital Inputs 2 Fan status and air conditioning failure Status LEDs Output status power network transmit amp receive communication fail heartbeat Power 24VAC or 24VDC 0 2 amps LED Readout with 7 segment display for status of zone and supply temperature sensors Network Interface RS 485 Sensor Accuracy 1 F 05 C over full range Environmental Operating Temp 40 to 185 F 40 to 85 C 0 95 RH non condensing Mounting TDK Snap Track outdoor installation requires the RTU to be ina NEMA 4 Enclosure Dimensions 3 H x 6 W x 1 3 D 76mm H x 152mm W x 33mm D Weight 1 lb 454g Warranty One 1 year RTU Controller User Manual 3 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Section 3 Installing the RTU The RTU controller can be installed inside a rooftop unit or on HVAC equipment located in a protected area using the mounting track supplied with the controller or by mounting the controller directly onto equipment 3 1 Installing the RTU Using the Mounting Track Ste
3. 2 Programming the RTU Once the RTU settings are correct and the BUS assignment has been completed it is time to program the parameters the RTU will use to control to HVAC equipment Step 1 To program the RTU to work with the Q3 or ESB enter DEF NAME RTU lt SETP gt lt HEAT D gt lt STG 2 gt lt FAN MODE gt lt SHDN gt lt ECON gt lt AOP gt lt LOG INT gt lt ZALMH gt lt ZALML gt lt DIGIALM gt lt DIG2ALM gt lt ACMON gt WHERE NAME is an 8 character name you want to assign to the RTU point Assigning a name is optional The name is a max of 8 alphanumeric characters Plus amp and underscore are not allowed in the name For example DEF FRNTROOME RTU 2 RTU is the RTU number 1 16 SETP is the setpoint value This can be a SPT VAR or a numeric value HEAT D is the heat differential subtracted from SETP to determine heat turn on point This can be a SPT VAR or a numeric value STG 2 is the delta value to decide when to turn on stage 2 This is added to the SETP for COOL 2 and subtracted from SETP HEAT D This can be a SPT VAR or numeric value FAN MODE determines if the fan should run constant or only turn on with call for heat and cool This can be a SPT or VAR with value of 0 or 1 SHDN will shutdown all outputs when this point is ON You can define a SPT or VAR with value of 1 or 0 A value of OFF will disable the shutdown mode ECON will enable the use of the economizer This
4. Manual 14 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com You do not have to use SPTs or VARs you can program the RTU with hard values such as DEF HVAC_1 RTU 1 72 72 ON OFF OFF OFF 15 ON 8 20 ON 12 20 ON ON 65 15 But this limits the Q3 ESB s ability to make changes to the parameters inside the program By using SPTs and or VARs the Q3 ESB can be programmed to change the value of the setpoint or variable based on time or various other conditions Section 8 Troubleshooting Technical Support and Service 8 1 Troubleshooting The following section is designed to help you isolate the most likely system malfunctions that may occur For additional help contact Quest s Technical Support and Service Center 8 1 1 Communication Errors PROBLEM The Zone or Supply sensor is not reading SOLUTION Verify wiring for each sensor The display will show if the sensor has a short SSE or an open OSE to assist in troubleshooting the wiring PROBLEM The RTU board won t turn on SOLUTION Verify the jumper switches for the power options are in the proper location for how you are powering the system PROBLEM The System won t communicate on the BUS SOLUTION Verify you set the proper address on the switches Make sure the address is defined in the Q3 or ESB Verify the wiring between the main controller and the RTU is correct RTU Controller User
5. Manual 15 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com 8 1 2 LED Errors PROBLEM The CF LED on constantly NOTE CF stands for communication fault The CF light will come on after 1 minute of no BUS activity for the address SOLUTION Verify the address settings and that the Q3 or ESB has the address defined properly 8 2 Technical Support and Service For questions regarding technical support service or repair of a product contact us at Quest Controls 208 9th Street Dr West Palmetto FL 34221 Tel 941 729 4799 To return defective products in or out of warranty you must have an RMA To get an RMA call 941 723 4112 For more information about our test and repair center or about customer support services visit our website at www questcontrols com RTU Controller User Manual 16 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com 8 3 Warranty QUEST warrants products of its manufacture to be free from defects in design workmanship and material under normal and proper use and service for a period of 12 months starting upon shipment from the QUEST factory with the exception of Software noted below Products not manufactured by QUEST will have a 90 day warranty Software is warranted to conform to QUEST s Software Product Description applicable at the time of order QUEST s sole obligation hereafter
6. damages whether in contract tort or otherwise RTU Controller User Manual 17 Rev 3 2 6 13 11
7. left side of the Sensor SET to the of the RTU ADJ and the right side of the RTU ADJ Figure 5 The recommended wiring is 18 AWG twisted shielded pair 5 2 Connecting the Supply Sensor Input The Supply Sensor is a sensor mounted in the duct to provide information to the RTU on the HVAC unit operation Step 1 The sensor is not polarity sensitive so connect one lead from the supply sensor to the of the RTU SPLY input and the other to the of the RTU SPLY input Figure 5 The recommended wiring is 18 AWG twisted shielded pair Zone Temperature Sensor with Slide Adjust m ANSANS m m ZONE SPLY Supply Duct Temperature cob nan o Sensor Figure 5 Connecting Zone amp Supply Sensor Input RTU Controller User Manual 6 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com 5 3 Connecting the Fan and Air Conditioning Monitoring Input The digital fan input is designed to connect to a current transducer monitoring fan operation Filter airflow sensors mounted on either side of the filter provide filter status If airflow is sensed on one side of the filter and not the other the RTU will consider the filter clogged and send the appropriate alarm Step1 Connect the FAN input to fan motor current transducer Figure 6 Step 2 Connect the Filter airflow Sensor or AC fail contacts to the DI input Figure 6 Note The negati
8. shall be to remedy any nonconformance of the software to the Software Product Description during the 90 day period following delivery This warranty shall not apply to fuses batteries or any product or parts subjected to misuse neglect accident Acts of God or abnormal conditions of operation QUEST agrees to repair or replace at the place of manufacture and without charge all parts of said products that are returned to the QUEST factory within the warranty period provided the warrantor s examination discloses to its satisfaction that the product was defective and that the equipment has not been altered or repaired other than with QUEST s authorization and by its approved procedures Repair or replacement of QUEST products does not extend the original warranty period A product or board may be deemed beyond repair if QUEST determines that it has been subject to misuse improper maintenance negligence or accident damaged or had its serial number or any part thereof altered defaced or removed If the failure has been caused by misuse neglect accident or abnormal conditions of operation or if the warranty period has expired repairs will be billed at a nominal cost This warranty is in lieu of all other warranties expressed or implied including but not limited to any implied warranty of merchantability fitness or adequacy for any particular purpose or use In no event shall QUEST be liable for any special incidental or consequential
9. value can be a SPT VAR or value of 1 or 0 A value of 1 will enable econ mode which acts as stage 1 cooling AOP is the analog output value This can be a SPT VAR or a number from 0 to 100 and will be the percentage output of the AOP i e 0 to 100 of the range LOG INT is the logging interval in minutes between log entries Each log entry will have zone temp supply temp and current mode of RTU To retrieve log use REV LOG RTU RTU Controller User Manual 13 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com ZALMH is the amount added to the SETP value to determine the high temp alarm This value can be a numeric VAR or SPT The delay time in minutes before alarming can also be set ON SPT 23 20 The value can also be OFF for no alarm ZALML is the amount subtracted from the SETP value to determine the low temp alarm This value can be a numeric VAR or SPT The delay time in minutes before alarming can also be set ON SPT 24 20 The value can also be OFF for no alarm DIG1ALM is the Fan fail alarm If set to ON then when the fan is running and the input is off for the delay time the RTU will generate a MJ alarm condition This will clear when the fan is running and the feedback digital is on DIG2ALM is the Filter clogged alarm If set to ON then when the fan is running and the input is on for the delay time the RTU will generate a MN alarm condition This w
10. with pins 1 amp 2 connected Figure 10 BUS Termination Jumper J5 Step 2 Set the BUS address on the RTU by positioning DIP switch SW1 in the configuration shown in Figure 11 Refer to Table 1 for address settings Figure 11 SW1 DIP Switch Configuration RTU Controller User Manual 11 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Step 3 Define the RTU address to the Q3 or ESB by entering the following command in the Q3 ESB programming FORMAT DEF lt Name gt BUS EXAMPLE DEFINE OFFICE BUS 16 CONTROLLER RESPONSE OK A standard addressing scheme comes pre loaded in the RTU and can be accessed using the REVIEW command Step 4 To review all RTUs connected and defined in the system and their BUS addresses enter sREV BUS A list of all BUS modules connected to the system will be displayed with their BUS address Figure 12 In the list below you can see that an RTU has been added to BUS 16 using address 20 The simple command of DEF BUS 16 told the system that the RTU was connected BUS 16 is the first location for RTU controllers NAME ADDR PRESENT STATE ERRORS BU BUSOI5 OFFICE KZZZZZZZZZZZZZZZ mooo0oo0oo00000000000 cocooocoocoococooc oqcoooqc too Figure 12 RTUs with BUS Address RTU Controller User Manual 12 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com 7
11. B The RTU is designed to be networked to the Q3 controller and the TELSEC ESB controller Communication with the Q3 or ESB is done over the BUS and the operational parameters are set through the Q3 or ESB For more information on setting up communication with the Q3 ESB or Q3 ESB programming commands refer to the User Manual and the Programming Manual Program examples below are based on Q3 ESB systems with Rev 2 3 firmware and higher 7 1 Setting Up Bus Communication Step 1 Connect the A B and C BUS connections on the RTU to the A B and C BUS connections on the Q3 or ESB Daisy chain these connections to all RTU modules in the facility Note Once the BUS is enabled the T and R LEDs will flash red green when the systems are communicating Figure 9 RTU Controller User Manual 10 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com T and R LEDs will q flash to indicate i the systems are communicating ONS c of BUS To Q3 BUS A B c Figure 9 RTU BUS Connection NOTE If the RTU is the last expansion card on the BUS or is the only expansion card connected to the system ensure that the jumper on J5 is set to the right to jump pins 1 amp 2 This enables the end of line resistor The Jumper on J5 should be to the left pin 2 amp 3 when the RTU Board is in the middle of a network chain Figure 10 Bus Termination Jumper J5 shown as last in line
12. CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com RTU Controller User s Manual COPYRIGHT NOTICE Copyright 2007 2011 by Quest Controls Inc QUEST The material discussed in this publication is the proprietary property of QUEST QUEST retains all rights to reproduction and distribution of this publication Specifications are subject to change without notice RTU Controller User Manual Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Table of Contents SECTION 1 INTRODUCTION 2 SECTION 2 PRODUCT DESCRIPTION 2 2 1 FEATURES AND BENEFITS 2 2 2 SPECIFICATIONS 3 SECTION 3 INSTALLING THE RTU 4 3 1 INSTALLING THE RTU USING THE MOUNTING TRACK 4 3 2 INSTALLING THE RTU DIRECTLY ONTO HVAC EQUIPMENT 4 SECTION 4 POWERING THE RTU 5 4 1 POWERING THE RTU FROM THE HVAC SYSTEM 5 4 2 POWERING THE RTU THROUGH A SEPARATE POWER SUPPLY 5 SECTION 5 CONNECTING INPUTS AND OUTPUTS 6 5 1 CONNECTING THE ZONE SENSOR WITH SLIDE ADJUSTMENT INPUT 6 5 2 CONNECTING THE SUPPLY SENSOR INPUT 6 5 3 CONNECTING THE FAN AND AIR CONDITIONING MONITORING INPUT 7 5 4 CONNECTING HVAC OUTPUTS 7 SECTION 6 STAND ALONE OPERATION AND PROGRAMMING 8 6 1 PROGRAMMING STAND ALONE SETTINGS 8 6 1 1 SETTING ADDITIONAL RTU BUS ADDRESSES 8 6 1 2 SETTING SETPOINTS 8 6 2 USING THE LED DISPLAY 10 SECTION 7 OPERATING THE RTU THROUGH THE Q3 OR TELSEC
13. ill clear when the fan is running and the feedback digital is off lt ACMONS gt is the value to determine high supply air HVAC TROUBLE alarm when there is a call for cooling This value can be a numeric VAR or SPT The delay time in minutes from 1 99 before the alarm is active OFF instead of ON VALUE Delay for no alarm Once the alarm occurs the system must see a call for cooling and the supply air below the setting for one minute to clear the alarm For example if you use enter the following values DEFINE SETPOINT VAR 13 72 DEFINE HEATDLTA VAR 14 7 DEFINE STG2DLTA VAR 15 2 DEFINE ECONMODE VAR 16 0 DEFINE FAN_RUN SPT 22 1 DEFINE HITEMPZN SPT 23 8 DEFINE LOTEMPZN SPT 24 12 DEFINE SPLY_AIR SPT 25 65 DEF HVAC_Z1 RTU 1 VAR 13 VAR 14 VAR 15 SPT 22 OFF VAR 16 OFF 15 ON SPT 23 20 ON SPT 24 20 ON ON SPT 25 15 The RTU will use VAR 13 for the base setpoint VAR 14 for the heat delta VAR 15 for the stage delta SPT 22 for the fan run 0 1 VAR 16 for economizer mode OFF AOP not being used ON SPT 23 20 for setting the high temp alarm on with the value SPT 23 and a delay of 20 minutes ON SPT 24 20 for setting the low temp alarm on with the value SPT 24 and an alarm after 20 minutes ON for fan run and ON for filter alarm The air conditioning trouble alarm will be sent when the AC has been running for 15 minutes and the supply temperature is still greater than 65 degrees spt 25 RTU Controller User
14. ovide a cohesive and effective building energy management system 2 1 Features and Benefits The RTU offers features and benefits that make it the ideal choice for managing the HVAC systems of small to medium size buildings Complete Digital Control The RTU provides direct digital control over all environmental control functions This ensures complete HVAC automation resulting in reduced maintenance costs reduced energy consumption and increased efficiency Networking Capabilities Up to 16 RTUs can be easily networked into the Q3 or TELSEC ESB system to control multiple air conditioning for fan cooling heating and economizer In addition the RTU will monitor zone and supply air temperatures fan running and filter clogging Intelligent Operation The RTU is microprocessor based and is programmed to make real time adjustments independent of a networked Q3 or ESB controller This redundant control ensures the continued operation of critical HVAC equipment in the event network local communication is lost LED Display Numeric LED displays show the status of zone and supply air temperature sensors Additional LEDs denote control alarm and communication status making this information easily accessible and convenient for maintenance personnel Zone Temperature Control Provides precise control of the HVAC to maintain desired zone temperature while reducing operating expenditures and extending the life of critical operating equipment
15. p 1 Secure mounting track Figure 1 to selected location using sheet metal screws Step 2 Insert the RTU circuit board and press down To release the RTU from the mounting track spread edge of Snap Track Figure 1 Mounting Track for the RTU 3 2 Installing the RTU Directly onto HVAC Equipment Step 1 To mount the RTU onto HVAC equipment drill four 5 32 diameter holes in a rectangular pattern measuring 2 51 64 71mm by 5 19 32 142mm Figure 2 Step 2 Use appropriate hardware and standoffs 6 hardware to keep the back of the RTU controller from contacting the surface of the equipment on which it is being mounted CUR OUT aie aj e2 ESET GI RT Be QYOROVEIO VEIO WOO WSEOWSIOVEIO WS O Woe 6 24 24 G C R G Yl Y2 W W2 NO NC Q BUS ZONE SPLY ADJ FAN DI UAC FAN COOL HEAT ECN Figure 2 Location of Mounting Holes RTU Controller User Manual 4 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Section 4 Powering the RTU The RTU uses 24VAC for operation The RTU can be powered from the HVAC system or from a separate power supply 4 1 Powering the RTU from the HVAC System Step 1 Set JIA and J1B jumpers for C R thermostat power by moving the jumpers to the up position Figure 3 Step 2 Connect the red or 24VAC power leads to the R connector on the RTU and the common to the C Figure 3 Use a minimum of 18 AWG wire fo
16. point for heating is the setpoint minus the heat differential minus the stage differential The base is 2 F Table 4 Differential SW2 4 SW2 5 SW2 6 Table 4 Stage Differential Setpoint Settings RTU type SW2 7 SW2 8 The RTU provides a way to control different HVAC types Table 5 RTU Type SW2 7_ SW2 8 Standard AC OFF OFF Standard DX air conditioning system with aux heat Heat Pump OFF ON Compressor cool 1 on when call for heating and heating stage 1 is on for heating Use O terminal instead of W1 for reversing valves that energize with call for cooling Heat Pump2 ON OFF Two stage heat pump Y1 turns on compressor 1 and Y2 turns on compressor 2 Use W1 or O terminal for reversing valve control Gas Heat ON ON Heat comes on without call for FAN Assumes the RTU internally will turn on supply fan based on supply temperature Table 5 RTU Settings RTU Controller User Manual 9 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com 6 2 Using the LED Display The RTU will display status of inputs and outputs on the LED bar Figure 8 The Z zone and S supply LEDs will cycle and display their respective temperature readings The heartbeat will blink as long as the processor is operating properly The communication fail will light if the bus connection to the Q3 or ESB has failed Figure 8 The LED Display Section 7 Operating the RTU through the Q3 or TELSEC ES
17. r RTU controllers 1 through 16 wn cq Address Address C A Dl UnjR wlrmlela 4 Table 1 RTU Bus Addresses 6 1 2 Setting Setpoints The default setpoint can be set with the switches SW1 5 SW1 7 Table 2 The base is 70F Each bit moves the setpoint 1 degree The RTU will use this setting if communications is lost to the Q3 or ESB Setpoint SW1 5 SW1 6 SW1 7 Table 2 Setpoint Settings Fan Run Mode SW1 8 Switch 1 8 will set the fan to be either always on if SW1 8 is ON or cycled with a demand for heating or cooling in which case SW1 8 is set to OFF This operation is used when the unit is not communicating with the Q3 or ESB Under normal conditions this operation is set through the Q3 or ESB programming RTU Controller User Manual Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Heat Setpoint Differential SW2 1 SW2 3 The heat setpoint is calculated by subtracting this differential from the setpoint The base differential is 2F Table 3 Differential _SW2 1 SW2 2 SW2 3 Table 3 Heat Setpoint Differential Settings Stage Differential SW2 4 SW2 6 The RTU provides two stages of heating and cooling The stage setpoint is determined by applying the stage differential to the appropriate setpoint The stage 2 setpoint for cooling is the setpoint plus the stage differential The stage 2 set
18. r powering and control 1 ho GE ea ON OWS 2t 24 GC R B A Figure 3 Settings amp Connections for Power the RTU from the HVAC 4 2 Powering the RTU Through a Separate Power Supply Step 1 Set JIA and J1B jumpers for 24 24 input connectors by moving the jumpers to the down position Figure 4 Step 2 Connect the common power lead to 24 and the hot to 24 Figure 4 Use a minimum of 18 AWG wire fatal ajoj s 4 WAA m ee lA Jio GD cos OW OWS 24 24 CERTE A Figure 4 Settings and Connections for Powering the RTU from the Power Supply Note When using the same power as the Q3 make sure the common power lead is connected to 24 on the RTU controller and to the NEG on the Q3 RTU Controller User Manual 5 Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Section 5 Connecting Inputs and Outputs The RTU controller can support a zone temperature sensor a supply temperature sensor a Slide adjustment input and two digital inputs for fan and filter alarms 5 1 Connecting the Zone Sensor with Slide Adjustment Input The Zone Sensor is a sensor mounted in the effective heat cool area serviced by the HVAC unit controlled by the RTU Step 1 Connect sensor terminal to the RTU Zone input and sensor to RTU Zone input Figure 5 The recommended wiring is 18 AWG twisted shielded pair Step 2 Connect the
19. ve terminal is common for both inputs HOV SIO WORD gt o oe E 244 24 SPLY ADJ FAN DI UAC FAN Current Sensor Filter Airflow Sensor Duct Filter Figure 6 Connecting Fan amp Filter Input 5 4 Connecting HVAC Outputs Connections to the HVAC equipment are industry standard as with any thermostat Figure 7 C 24VAC Control Common W1 First Stage Heat R 24VAC Control Voltage W2 Second Stage Heat G Fan Control NO Normally Open Economizer Control Y1 First Stage Compressor Cooling NC Normally Closed Economizer Control Y2 Second Stage Compressor Cooling MONS AD SSID ef Coot Heat Figure 7 HVAC Control Points RTU Controller User Manual Rev 3 2 6 13 11 CQ Quest Controls Inc Smart Control Solutions for Buildings www questcontrols com Section 6 Stand Alone Operation and Programming The RTU is microprocessor based and is programmed to make real time adjustments independent of a networked Q3 or ESB controller This redundant control means that the RTU will continue to operate critical HVAC equipment even if communication is lost to the Q3 or ESB 6 1 Programming Stand Alone Settings 6 1 1 Setting Additional RTU BUS Addresses To add multiple RTUs you must change the address on the RTU dip switches To set an address use switches 1 4 on SW1 Table 1 These are the address bits of the RTU The base address is 20 and the range of possible addresses is 20 2F fo
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