Aurora Universal Protocol Converter (UPC) Application And .

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Aurora UPC Application and Troubleshooting GuideAurora Universal Protocol Converter (UPC)Application and Troubleshooting GuideFor use in single compressor water-to-air equipment utilizing firmware UPCSWASTD01-01AG1568EW 08/14

AURORA UPC APPLICATION AND TROUBLESHOOTING GUIDETable of ContentsAurora UPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7UPC LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Aurora UPC Inputs and Outputs Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9UPC with Aurora Base Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11UPC with Aurora Advanced Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Monitoring Sensor Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Port Configuration and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15Setting the MAC address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Port Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ZS Series Zone Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Zone Sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Zone Sensor Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Zone Sensor Physical and Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Zone Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21Aurora Touch Interface Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Zone Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Zone Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Fan Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Fan Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Occupancy Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Aurora Base Controller Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Aurora Base Controller Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28ABC Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Setting the ABC DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29ABC DIP Switch Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Status Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30UPC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Module Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Module Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Touch Screen Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33T-Stat Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Network Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34UPC Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34ABC Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Typical Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-39Scheduling and Occupancy Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Revision Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

AURORA UPC APPLICATION AND TROUBLESHOOTING GUIDEUPC OverviewThe Aurora Universal Protocol Converter (UPC) is designedto add-on to any Aurora based heat pump control. The AuroraUniversal Protocol Convertor (UPC) is designed to allow watersource heat pumps to be integrated into Building AutomationSystems (BAS) with ease. The Aurora UPC is an integratedsolution and communicates directly with the Aurora Heat PumpControls and allows access/control of a variety of internal Auroraheat pump operations such as sensors, relay operation, faultsand other information. In turn, the UPC then converts internalAurora Modbus protocol to BACnet MS/TP, LON, or N2 protocolsand communicates to the BAS system. This provides the greatbenefit of complete control integration and a myriad of informationavailable to the BAS from the heat pump control. Plus it alsoallows individual unit configuration such as ECM fan speeds orfreeze protection setting directly over the BAS without the need foraccess to the actual heat pump.protocols. The Aurora UPC has the ability to communicate BACnetMS/TP, N2 open, or LonWorks (requires LON Plugin card). Thisflexibility is possible due to the onboard dipswitches which allowfor the desired protocol and baud rate to be selected in thefield. All zone sensors are connected to the UPC on an RNetbus, simplifying hook up at the unit. RNet sensors can include acombination of zone temperature and humidity, CO2, and VOCsensors. The UPC includes built-in support for a display unit Aurora Touch (color touchscreen display or ATU). Only one displayunit can be mounted remotely for configuration and troubleshooting.There are an extensive number of points that the UPC hasavailable over the network for integration into the BAS. Controlprogrammers need to carefully determine which points they wantto add into the BAS database. A list of the BACnet points, N2points, and LON SNVTs are available along with their individualpoint descriptions by contacting the Commercial Solutions Groupat 1-877-677-4420 or by going to http://www.waterfurnace.com/ddc-controls.The Aurora UPC may be factory integrated with the Aurora BaseController (ABC) heat pump control into our latest water sourceheat pumps. This will allow for a BAS to integrate and communicateto the heat pump thru a choice of 3 different communication4

AURORA UPC APPLICATION AND TROUBLESHOOTING GUIDEUPC Overview cont.N2BASModbusBACnetLonWorksRnetAurora UPC FeaturesAurora UPC Optional Features Rugged enclosure made of GE C2950 Cycoloy plastic Built-in surge transient protection circuitry Operating range of -20 to 140 F; 10 to 95% relative humidity,non-condensing Onboard CR123A battery has a life of 10 years with 720 hoursof cumulative power outage Multi-Protocol field selectable communication port that supports: EIA-485 BACnet MS/TP @ 9600, 19.2k, 38.4k, 76.8k baud Metasys N2 Open LonWorks TP/FT-10 (Requires optional LON plug-incommunication card) Status of all unit operating conditions and fault lockouts Visual LED’s for status of power, network communication,processor operation, and errors Provides gateway into Aurora heat pump controls forunsurpassed control flexibility Network point for commanding unit into load shed Network point for commanding unit into emergency shutdown Network points to assist in fan speed selection Network points for freeze protection settings Heating and cooling control from a remotely located zone sensor Rnet communication port which allows for multiple Rnet zonesensors (5) to be connected for space temperature averagingif desired. Local laptop or Aurora Touch Interface connection for field service FCC, UL and CE listed. BTL Certification is pending LonWorks Communication Plug-in Aurora Touch Interface handheld display, needed for fieldconfiguration of fan speeds, set points, etc. Aurora Advanced Control adds the Aurora AXB expansionboard and provides added I/O and standard features (FutureAvailability on Select Models/Configurations) Optional Sensor Kits (requires Aurora Advanced Controlwith AXB - Future Availability on Select Models/Configurations) Refrigeration Monitoring – provides Suction anddischarge pressure, Suction, liquid line temps andsuperheat and subcooling. Performance Monitoring – provides entering and leavingloop water temperatures, loop flow rate as well as heat ofextraction or rejection rate into the loop. Energy Monitoring – provides real-time power measurement(Watt) of compressor, fan, auxiliary heat and zone pump. Graphics packages available in the future5

AURORA UPC APPLICATION AND TROUBLESHOOTING GUIDEUPC LayoutPort 1a is used tocommunicate to theBuilding AutomationSystem (BAS). Thisport’s settings areconfigured through theonboard dip switches.24VacPort 2 is used tocommunicate to theAurora Base Controller(ABC).Dip switches forconfiguring thecommunicationport protocol andbaud rate for theBAS port.Port 1b is used for theLonWorks plugin.Rnet port is usedfor communicatingzone sensors.Mac addressis set by 2rotary dials.Aurora Touch Interfaceor local laptopconnection.UPC Physical DataA5-3/16”13.2 cmB4-1/8”10.5 cmC4-7/8”12.4 cmD2-1/20”5.2 cmE3/16”0.5 cmDepth1-9/16”4.0 cmWeight0.44 lbs0.2 kgOverallMounting HoleDimensions6

AURORA UPC APPLICATION AND TROUBLESHOOTING GUIDEUPC Electrical DataPower24 Vac 10%, 50 to 60 Hz, 10 VA power consumption(16 VA with Aurora Touch Interface attached)26 Vdc (25 V min, 30 V max)Single Class 2 source only, 100 VA or lessPhysicalRugged GE C2950 Cycoloy plastic.Operating Range-20 to 140 F (-29 to 60 C); 10 to 95% relative humidity, non-condensingCommunication PortsPort 1a: Jumper-configurable for ARC156 or EIA-485 communication. In ARCNETmode, the port speaks BACnet (at 156k bps). In EIA-485 mode, thecommunication protocol and baud rate desired are DIP switch selectablebetween BACnet MS/TP, or N2Port 2: Used for Aurora communicationsRNET: Local laptop and/or Aurora Touch Interface access portOptional Card PortLonWorks Option Card for connection to Free Topology LON networks(TP/FT-10 Channel)Status IndicationVisual (LED) status of power, network communication, running, and errorsBatteryBattery CR123A has a life of 10 years with 720 hours of cumulative power outageProtectionBuilt-in surge transient protection circuitry. Controller protected by internal solidstate Polyswitches on incoming power and network connections. Polyswitches donot need to be replaced, as they will reset themselves once the condition thatcaused them to “trip” returns to normal.BACnet supportConforms to the Advanced Application Controller (B-AAC) Standard Device Profile as defined in ANSI/ASHRAEStandard 135-2004 (BACnet) Annex LBACnet CertificationBTL Certification is pendingListed byFCC, UL, cUL, and CE listed. UL916 (Canadian Std C22.2 No. 205-M1983, CE, FCC Part 15 - Subpart B Class A7

AURORA UPC APPLICATION AND TROUBLESHOOTING GUIDEUPC LED OperationIf Run LED shows.And Error LED shows.Status is.2 flashes per secondOffNormal2 flashes per secondOnExec halted after frequent system errors, due to: Controller halted Program memory corrupted Address conflicts - duplicate MS/TP MAC addresses One or more programs stopped5 flashes per secondOnExec start-up aborted, Boot is running5 flashes per secondOffFirmware transfer in progress, Boot is running7 flashes per second7 flashes per second,alternating with Run LEDTen second recovery period after brownout14 flashes per second14 flashes per second,alternating with Run LEDBrownoutOnOnFailure. Try the following solutions: Turn the UPC off, then on. Download memory to the UPC. Replace the UPC.CAUTION: Changes or modifications not expressly approved bythe responsible party for compliance could void the user’s authorityto operate the equipment.Serial NumberIf you need the UPC’s serial number when troubleshooting, thenumber is on: a sticker on the back of the main translator board a Module Status report (modstat) from WebCTRL , or thru theAurora Touch Interface by accessing the “Module Setup” menu.CE ComplianceThe Aurora UPC conforms to the following standards. A fullDeclaration of Conformity is available on request.FCC ComplianceElectromagnetic Emissions:EN55022: 1994 Class AElectromagnetic Compatibility:Immunity for Commercial EnvironmentsEN61000-6-1: 2007Electrostatic Discharge:EN61000-4-2: 2008Radiated Electromagnetic Field:EN61000-4-3: 2010Electronic Fast Transient/Burst Requirements:EN6100-4-4: 2004Surge Immunity:EN6100-4-5: 2005Immunity to Conductive Disturbance:EN6100-4-6: 2008Power Frequency Magnetic Field Immunity: EN6100-4-8: 2009Immunity to Voltage Dips and VariationsEN6100-4-11: 2004European Low Voltage DirectiveRestriction of the Use of Certain Hazardous Substances (RoHS)This equipment has been tested and found to comply with thelimits for a Class A digital device, pursuant to Part 15 of the FCCRules. These limits are designed to provide reasonable protectionagainst harmful interference when the equipment is operated ina commercial environment. This equipment generates, uses, andcan radiate radio frequency energy and, if not installed and usedin accordance with the instruction manual, may cause harmfulinterference to radio communications. Operation of this equipmentin a residential area is likely to cause harmful interference in whichcase the user will be required to correct the interference at hisown expense.BACnet ComplianceBACnet is a registered trademark of ASHRAE. ASHRAEdoes not endorse, approve or test products for compliance withASHRAE standards. Compliance of listed products to requirementsof ASHRAE Standard 135 is the responsibility of the BACnetmanufacturers Association (BMA). BTL certification is pending.BTL is a registered trademark of the BMA.8

78234561918171DescriptionsUses9Variable Speed Pump/Mod Valve - PWM OutLoop Pump Slaving15DescriptionsModulatingt ReheatDescriptions16Specialty I/O14Analog OutSlaving Other Aurora UnitsVS Pump/ Mod ValveUsesUsesModulating Valve 0-10VK3 - ACC2--Solenoid ValveDamper w/FanDamper w/CompressorAccessory Relay 2 - Dry Contact Relay(Selectable operation)13-EH2 - DC OutEH stage 2Electric Heat 2Pump SlaveVS PumpStd ConfigStd ConfigNoneEH1 - DC OutEH stage 1Electric Heat 11112AlarmACC110-Dry Alarm/24VAC-Solenoid Valve w/ DelayDamper w/FanDamper w/CompressorStd ConfigY1Y2GOWStd ConfigFP2LWTEWTLATFlowLLTDischSCTSCPCC1CC2FCACStd ConfigStd Config(PCB Labeling)Accessory Relay 1 - Dry Contact Relay R2(Selectable operation)UsesAll ABC/AXB AlarmsIn EnglishUsesCompressor ProvingValve End SwitchFan provingOccupancy SensorDirty Filter SwitchUsesLeaving Air TemperatureLeaving Water TemperatureEntering Water TemperatureAlt Leaving Air TemperatureFlow Meter InHtg Liquid Line TemperatureDischarge PressureSuction TemperatureSuction PressureCompressor Current 1Compressor Current 2Fan CurrentAux CurrentUsesAlarm Contact Relay R1DescriptionsDifferentiated AlarmsEnglish Alarm DescriptionDescriptionsCompressor ProvingValve End SwitchFan provingRoom Occupancy Sensor InputDirty Filter InputDescriptionsLeaving Air TemperatureLeaving Water TemperatureEntering Water TemperatureAlt Leaving Air TemperatureFlow Meter InHtg Liquid Line TemperatureDischarge PressureSuction TemperatureSuction PressureCompressor Current 1Compressor Current 2Fan CurrentAux CurrentDescription9Digital OutAlarmsDigital InAnalog InRef PCBPCBLocation UPC ABC OnlyUPC withAurora Base UPC ABC AXBExpansion BoardUPC with AuroraAdvancedEnergy RefrigerationPerformanceMonitoring KitKitKitAurora UPC - I/OStandard ProgramStandard ProgramNetwork ConfigurableEH2 or DO using Relay KitNetwork Configurable DOStandard ProgramNetwork ConfigurableSolenoid Valve w/ Delay (Fcty)Close w/FanClose w/CompressorNANAStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramStandard ProgramNetwork Configurable-STD- Factory installed SensorField Installed OptionField installed OptionAnalog Out 0-10VField Switchable and InstalledField Installed Relay KitWF EHeat Ready or Relay Kit for Other EheatField or Fa

UPC Overview protocols. The Aurora UPC has the ability to communicate BACnet MS/TP, N2 open, or LonWorks (requires LON Plugin card). This flexibility is possible due to the onboard dipswitches which allow for the desired protocol and baud rate to be selected in the field. All zone sensors are connected to the UPC on an RNet

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