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GPC Plus Controller

General Information &

Application Guide

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Summary of Contents for GPC Plus Controller

Page 1: ...GPC Plus Controller General Information Application Guide ...

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Page 3: ...PCPLUS GPC Plus Controller Power 24 Volt AC Weight 1 5 lb Power Consumption 8 VA Maximum Network Connection RS 485 Operating Temp 10 F to 149 F Protocol HSI Open Protocol Token Passing Operating Humidity 90 RH Non Condensing Communications RS 485 9600 Baud Inputs Outputs Type III 10kohm sensors Total Relay Qty On Board 5 4 20ma sensors N O Binary Contact Total Relay Qty Available With Optional Exp...

Page 4: ... 9936 VR2 TB4 R27 C13 R10 VR1 C19 C18 NE5090NPB3192 0PS U8 CX8 U9 X1 R7 D10 R13 D12 C7 CX10 U10 CX12 U12 U14 CX14 PJ3 PJ2 PJ1 EXPANSION PRESSURE SENSOR T STAT C17 D15 R26 C20 R25 R24 R22 U15 CX13 U13 C15 R19 R15 C14 D18 D17 PU1 PU2 PU3 PU4 PU5 PU7 D6 D7 D8 D9 D11 D14 C12 C10 0 5 VDC 0 1 VDC JP1 C11 X2 GND TB3 INPUTS GND GND VDC AIN1 AIN2 AIN3 AIN4 AIN5 AOUT1 AOUT2 AIN7 RN4 1 RN5 RS 485 CX5 U5 R TB...

Page 5: ...D18 D17 PU1 PU2 PU3 PU4 PU5 PU7 D6 D7 D8 D9 D11 D14 C12 C10 0 5 VDC 0 1 VDC JP1 C11 X2 GND TB3 INPUTS GND GND VDC AIN1 AIN2 AIN3 AIN4 AIN5 AOUT1 AOUT2 AIN7 RN5 D19 CX15 16 32 TOKEN NETWORK 8 4 2 1 Address Switch Shown Is Set For Address 1 Address Switch Shown Is Set For Address 13 Controller Address Switch This Switch Should Be In The OFF Position As Shown Note The Power To The Controller Must Be ...

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Page 7: ...escribe the I O configurations that are possible and will also include a few sample applications to aid the user in determining if this controller will meet their specific requirements Main Status Screen The Main Status Screen provides real time live updates of the current operating conditions and is used to access the various setpoint and configuration options No control takes place until the use...

Page 8: ...2 accesses the configuration for the selected item and a right click accesses the force mode options if any are available Analog Inputs Relays Analog Outputs ...

Page 9: ...3 Week Schedules Holidays ...

Page 10: ... sensor with the phone jack connector available from WattMaster Controls The following configurations are available 1 Thermister Type III Temperature Sensors Scaled for Fahrenheit 2 Thermister Type III Temperature Sensors Scaled for Celsius 3 4 20ma User Scaled 4 0 5 vdc User Scaled 5 Wall Sensor Slide Offset 6 Binary Contact Closure 7 Read Global Analog Broadcast from another Controller ...

Page 11: ...e calibrated if the user has the exact current or resistance values available for entering in the calibration fields Right Click on the desired analog input reading to access the pop up menu shown above and then select the desired function If you are calibrating or overriding the reading the following window will pop up Enter the desired calibration offset or specific reading you wish to force the...

Page 12: ...ne of the unassigned channels for broadcast it is assumed that you have other GPCPlus units installed that expect to receive information on those channels since the standard package code does not listen for broadcasts on unassigned channels CAUTION If you elect to broadcast a reading from the GPCPlus to all other controllers on your installation be sure to check the HELP screen to identify which G...

Page 13: ...Required RH Relative Humidity Percentage F Degrees Fahrenheit C Degrees Celsius PPM Parts Per Million PSI Pounds Per Square Inch WG Inches of Water Gauge Inches Ft Feet RPM Revolutions Per Minute VDC Volts Direct Current BTU British Thermal Units On inputs selected for Binary Input Contact Closure the user can select Normally Open or Normally Closed Contacts ...

Page 14: ... are separate outputs on the Flush Mount Wall Sensors for measuring the room temperature and reading the slide offset Be sure to configure the correct input for the slide offset and do not use the temperature signal coming from the wall sensor for this option The slide offset is normally used by one or more relay outputs configured to look at this value and include its effect on their normal setpo...

Page 15: ...e be sure to enter a value for Push Button Override Duration To use this option you must select which schedule will be affected by the override event See screen below Optimal Start Temperatures You can configure any of the first five inputs to be used as the Optimal Start Target Temperature sensor As with the override option you must select which schedule will use this temperature for its optimal ...

Page 16: ...control source on the relay configuration screen CAUTION If you select two relays to control duct static WattMaster Controls cannot assume any liability for equipment damage caused by over pressurization of the duct work If you require a Duct Static Pressure Sensor you must use an OE271 sensor provided by WattMaster Controls for proper sensor readings No other sensors are currently supported for t...

Page 17: ...gured 1 On Above High Limit Setpoint and Off Below Low Limit Setpoint 2 On Above High Limit Setpoint and On Below Low Limit Setpoint 3 Off Above High Limit Setpoint and On Below Low Limit Setpoint 4 Off Above High Limit Setpoint and Off Below Low Limit Setpoint 5 On with Contact Closure on Selected Input 6 Off with Contact Closure on Selected Input 7 Follow Schedule Only ...

Page 18: ...n relays is possible via an Enabling Relay feature This allows the user to prevent a specific relay from activating until one of the other relays has had a chance to activate See Sample Configurations Section This can include such things as waiting for a fan to start before operating a heating or cooling stage Delay Run Times The relay can also be forced to remain on for a minimum amount of time o...

Page 19: ...int was 72 F and the deadband was set for 0 5 F the relay can change state when the temperature rises above 72 5 F or drops below 71 5 F If you do not need unoccupied setback control you must leave this setpoint 0 0 F and use the High and Low setpoints to create a deadband Controlling Schedule You can select one of the Internal Schedules to set the occupied or unoccupied mode of operation for the ...

Page 20: ... Interval and the Proof Failure Timeout Delay shown on the right hand side of the relay configuration screen The Changeover Delay is used to toggle the Lag output into the Lead once the runtime hours of the Lead output exceed this amount of time on the Lag output The Proof Failure Time Delay is the amount of time given for the Proof of Flow input to become active once the Lead or Lag output is ene...

Page 21: ...te in a ventilation control mode This means that the output is active for the Vent Mode ON Time and then cycles off for the Vent Mode OFF Time If the output is not enabled by a schedule or another relay it will continue to cycle indefinitely at this On Off rate ...

Page 22: ...by the user The controlling setpoint can be reset by any other sensor reading or the outdoor air temperature and the output voltage range can be limited by the user to some range other than the standard 0 10 VDC Possible Control Modes 0 Not Configured 1 Direct Acting Floating Point 2 Reverse Acting Floating Point 3 Direct Acting PID 4 Reverse Acting PID 5 Relief Pressure Control 6 Duct Static Pres...

Page 23: ...amount of time it would take to drive full on or full off is not critical For faster response the PID Control method is recommended A deadband setpoint is available if you wish to set the Hi Lo setpoints the same and only change the voltage if the control signal is further from setpoint than the deadband amount PID Control The PID control is a WattMaster modified version of Proportional and Deriva...

Page 24: ...under control Proportional Reset Signal As the Reset Source goes from its Maximum Reset Source to its Minimum Reset Source the Controlling Setpoint goes from its Minimum Reset Setpoint limit to its Maximum Reset Setpoint limit Since the reset limits can be set to any desired value the user can initiate a reverse acting proportional reset or a direct acting proportional reset of the setpoint simply...

Page 25: ...aintain loop pressure or some other analog signal configure an output for this method of control Then all you need to do is enter the control setpoint on the Lead Relay configuration screen and this output will attempt to modulate and maintain that level of control while the Lead Lag control is active ...

Page 26: ...ding Once a boiler is activated it must remain on at least 5 minutes and if a boiler is de activated it must remain off at least 10 minutes Additionally the boilers are locked out when the Outdoor Air Temperature is above 65 F Analog Input 1 Configured as Thermister Type III Sensor Note that some Hi and Lo alarm limits were set and that the reading is in degrees Fahrenheit ...

Page 27: ... look at Global Analog 2 for this value including the GPC Plus Even if this is the only controller on the job you must set it to broadcast the outside air so the GPC Plus can see what the OA Temperature is Analog Input 3 Configured as Not Configured Analog Input 4 Configured as Not Configured Analog Input 5 Configured as Not Configured Analog Input 6 Duct Static Pressure Sensor is not Required Ana...

Page 28: ...22 Relay Output 1 Programming Used for Outdoor Air Enable Disable NOTE Nothing is physically connected to Relay 1 Its only use is to enable or disable the other relays ...

Page 29: ...r must remain on for 5 minutes 300 seconds and once de activated it must remain off for 10 minutes 600 seconds Since we are not resetting the operating setpoint the Reset Source has been left as None Selected We also don t require a Logical AND or Logical OR condition so they have been left Not Configured There is no need to enable this output from a schedule since it uses an Enabling Relay OAT En...

Page 30: ... the water temperature is below 170 F and will remain on until it rises to 180 F The second stage can only operate if the first boiler stage relay 2 has been active for at least 5 minutes Once activated this stage must remain on for 5 minutes and once de activated it must remain off for 10 minutes ...

Page 31: ...the water temperature is below 160 F and will remain on until it rises to 175 F The third stage can only operate if the second boiler stage relay 3 has been active for at least 5 minutes Once activated this stage must remain on for 5 minutes and once de activated it must remain off for 10 minutes ...

Page 32: ... for 5 minutes and once de activated it must remain off for 10 minutes The Starting Delay Period that was set for stages 2 to 4 prevent all four boiler stages from activating at the same time as soon as they are enabled to begin operation Each stage must run for 5 minutes before the next stage can be activated Analog Output Programming Control Source Not Configured Since no analog output control i...

Page 33: ...r the outdoor air temperature but in this case we are reading the Outdoor Air Temperature on Analog Input 2 Notice on the Analog Output 2 configuration screen that it was also configured to broadcast on Global Analog Channel 2 That is because the GPC Plus doesn t have any other way of knowing that it is the one reading the outdoor air temperature The voltage output is not used so no control source...

Page 34: ...sfy all 4 Boilers 5 Minute Starting delay so they are all active at this point It took roughly 20 minutes to get all 5 relays active since each has a 5 minute Staging Delay time period Keep in mind that although Relay 1 OAT Enable is active nothing is connected to the output because its only function is to provide an outdoor air enable signal for the boiler staging ...

Page 35: ...ure mode conditions The GPC Plus would use contact closures to the Forced Occupied inputs of the AHU controllers to activate and de activate the units A failure mode would be indicated by the failure of the Supply Air Temperature to drop below or stay below a 60 F setpoint Any temperature excursions above 60 F for more than one minute would indicate a failure had occurred and that the Lag AHU shou...

Page 36: ...HU 1 Either AHU could have been selected as AHU 1 this was an arbitrary decision The Supply Air was selected as the Control Source and the Proof Setpoint was set to 60 0 F The AHU s will change the Lead every 24 Hours and if the Supply Air rises above 60 for more than 60 seconds it will be considered to be in failure mode and the Lag AHU will be activated Also an alarm will be generated so that an...

Page 37: ...ed for Lag AHU Enable Signal There are no other settings required for the Lag Controller All control logic from the Lead relay is used in the decision making process Analog Outputs No Analog Output Control is Required for this Program ...

Page 38: ... the Supply Temperature is at 51 9 F well within the normal operating range and no alarms are currently active There are no schedules active since this unit is required to operate 24 hours a day The relay outputs will operate their control modes around the clock if no schedule was selected on the relay configuration screen ...

Page 39: ...33 Main Status Screen Failure Mode The Supply Air rose to 61 9 F and the Lag AHU was activated The alarm screen indicates the Lead AHU failure ...

Page 40: ...34 Both AHU s are now off because the Lag AHU failed to lower the Supply Air below 60 F ...

Page 41: ...he problem and then select the Reset Pump Fan button to restart the GPC Plus Lead Lag control sequence Although the button and alarm indicators show Lead Pump Fan indicators the outputs are not limited to those types of control You just need to understand that the Lead Pump Fan controls AHU 1 in this sample and Standby Pump Fan controls AHU 2 ...

Page 42: ...OR GPCPlus APP 01A Printed in the USA March 2005 All rights reserved Copyright 2005 WattMaster Controls Inc 8500 NW River Park Drive Parkville MO 64152 Phone 816 505 1100 www wattmaster com Fax 816 505 1101 ...

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