FANs 636.4, 1628.4 Technical Bulletins Section Technical Bulletin Issue Date 03/20/2009 © 2009 Johnson Controls, Inc. 1 DX-9100 Extended Digital Controller DX-9100 Extended Digital Plant Controller (Including DX-912x LONWORKS, Version 3) 3 • Introduction 3 • Features 8 Installation 11 • Version 1 (DX-9100-8154) 11 • Version 2 (DX-9100-8454 or FA-DX9100-8454) and Version 3 (DX-912x-8454) 19 • General Wiring Guidelines 34 • Battery Replacement 35 • Startup 38 Inputs/Outputs 39 • Analog Inputs 39 • Digital Inputs 40 • Digital Counters 40 • Analog Outputs 40 • Digital Outputs 41 • Analog/Digital Constants and Logic Result Status 43 • Extension Modules 44 • Network Inputs/Outputs for Version 3, LONWORKS Only 46 Operation 49 • Introduction 49 • Realtime Functions 50 • Time Schedule Modules 51 • Optimal Start/Stop Modules 52 • Optimal Start Adaptive Process Page 53 Code No. LIT-6364020 www.johnsoncontrols.com • Optimal Stop Operation 54 • Programmable Function Modules: Control Algorithms 55 • Numeric Calculation Algorithms 72 • Numeric Calculation Algorithms for Version 1.1 or Later 76 • Other Functions 77 • Programmable Logic Control 82 • Dial-up Feature 89 • Power Up Conditions 90 • Password Feature (Versions 1.4, 2.4, 3.4, or Later) 90 • Trend Log Feature (Versions 1.4, 2.4, 3.4, or Later) 91 Display Panel and Keypads 93 • Front Panel Layout 93 • Startup Mode 99 • Download Mode (Version 1.1 or Later) 99 • Time Schedule Mode 99 • Time Schedule Event Programming 101 • Realtime Clock Calendar 102 • Analog Input Display Mode 106 • Analog Input Scroll Mode 107 • Digital Input Display Mode 107 • Output Module Display Mode 108 • Digital Counter Display Mode 110 • Programmable Function Module Display Mode 111 • Analog/Digital Constant Display Mode 115 Specifications and Technical Data 117 • Products Available in North America 120 • Products Available in Europe 122 Appendix A: LONWORKS N2E Bus Poll Estimation Worksheet 125 2 Technical Bulletins—DX-9100 Extended Digital Controller DX-9100 Extended Digital Plant Controller (Including DX-912x LONWORKS®, Version 3) In this document, Facility Management System (FMS) is a generic term, which refers to the Metasys® Network, Companion™, and Facilitator™ supervisory systems. The specific system names are used when referring to system-specific applications. Introduction This document covers all three versions of the DX-9100 Extended Digital Controller, including the DX-912x LONWORKS® version. The DX-9100 is the ideal digital control solution for multiple chiller or boiler plant control applications, for the Heating, Ventilating, and Air Conditioning (HVAC) process of Air Handling Units (AHUs) or for distributed lighting and related electrical equipment control applications. It provides precise Direct Digital Control as well as programmed logic control. In a standalone configuration, the DX-9100 controller has both the hardware and software flexibility to adapt to the variety of control processes found in its targeted applications. Along with its outstanding control flexibility, the controller can expand its input and output point capability by communicating with I/O Extension Modules on an extension bus, and provides monitoring and control for all connected points via its built-in Light-Emitting Diode (LED) display. Versions 1 and 2 can communicate on the Metasys N2 Bus, providing point control to the full FMS. The Version 3 controller uses the LONWORKS (Echelon®) N2E Bus of the Metasys Control Module (NCM311 or NCM361 in Europe, NCM300 or NCM350 elsewhere) in place of the N2 Bus. The DX-9100 has two packaging styles. In Version 1, all terminals for field wiring are located within the controller enclosure. Versions 2 and 3 require a separate field wiring mounting base or cabinet door mounting frame, which enables all field wiring to be completed before the controller is installed. Technical Bulletins—DX-9100 Extended Digital Controller 3 Figure 1: Version 1 (DX-9100-8154) Figure 2: DX-9100-8454 or FA-DX9100-8454 (Version 2)/ DX-912x-8454 (Version 3) with Mounting Base The DX-9100 processes the analog and digital input signals it receives, using 12 multi-purpose programmable function modules, a software-implemented Programmable Logic Controller (PLC), time schedule modules, and optimal start/stop modules to produce the required outputs (depending on the module configuration), operating parameters, and programmed logic. All versions of the DX-9100 controller are configured by using a Personal Computer (PC) with GX-9100 Graphic Configuration Tool software supplied by Johnson Controls. Changes to the configuration can also be made by using an SX-9120 Service Module. 4 Technical Bulletins—DX-9100 Extended Digital Controller The DX-9100 can accept eight analog inputs and eight digital inputs. Versions 1 and 2 (N2 Bus) Version 1 of the controller (DX-9100-8154) provides up to eight output modules, which are configured to give two analog outputs and six digital outputs (triacs). The triacs can be separately configured to provide six on/off or pulse outputs, three duration adjust outputs, three position adjust (incremental) outputs, three start/stop outputs, or any combination using up to six triacs. Version 2 of the controller (DX-9100-8454 or FA-DX9100-8454) provides six additional analog output modules, giving a total of eight analog outputs. The DX-9100 unit (Versions 1 and 2) has two communication links. One is called the N2 Bus or Bus 91 (the term “Bus 91” is not used in North America) and is used to interface to a supervisory unit. The other link is called the XT Bus and is used to expand the DX-9100 input/output capability by interfacing up to eight XT-9100 or XTM-905 extension modules. The DX-9100 input/output can be extended by up to 64 remote input/outputs, analog or digital, depending on the type of the connected extension modules and XP expansion modules. Point connections are made on XP modules, which are monitored and controlled by the XT-9100 or XTM-905 modules. Refer to the XT-9100 Technical Bulletin (LIT-6364040) and the XTM-905 Extension Module, XPx-xxx Expansion Modules Technical Bulletin (LIT-6364210). One XP module can provide either eight analog points or eight digital points. Two XP modules connected to one extension module can provide eight analog and eight digital points, or sixteen digital points. Version 1 or 2 of the DX-9100 can be used as a standalone controller or it can be connected to an FMS through the RS-485 serial communications bus (N2 Bus or Bus 91). Version 3 of the controller (DX-912x-8454) brings peer-to-peer communication to the already rich feature set of the Version 2 controller, and enhanced alarm reporting capability when used as an integral part of an FMS. Version 3 (LONWORKS-Compatible N2E Bus) The new communications features are provided by the LONWORKS network, which enables Version 3 controllers to pass data between each other and to send event-initiated data to the NCM300 or NCM350 (NCM311 or NCM361 in Europe) Network Control Module (NCM) in the FMS. The LONWORKS (Echelon) N2E Bus is used in place of the N2 Bus, and the NCM300 or NCM350 (NCM311 or NCM361 in Europe) must be fitted with a LONWORKS driver card. The Version 3 controller retains all the input/output point and control capabilities of the Version 2 controller, including the point expansion feature using extension modules and expansion modules. Technical Bulletins—DX-9100 Extended Digital Controller 5 In addition to the Version 2 features, the Version 3 controller has network input and output points, which can be configured to transmit and receive data over the LONWORKS Bus. Each controller may have up to 16 network analog input modules, 16 network analog output modules, 8 network digital input modules, and 8 network digital output modules. While network analog input and output modules each contain a single analog value, the network digital input and output modules each contain 16 digital states, which are transmitted as a block between controllers. The transmission of point data is managed by the LONWORKS network and is independent of the supervisory functions of the FMS Network Control Module. A network of Version 3 controllers can be installed to share analog and digital data between controllers on a peer-to-peer basis; a Network Control Module is not required unless the network is to be supervised by an FMS. Complex control strategies may now be performed in multiple DX-912x controllers without the need for network data exchange routines in a supervisory controller. Applications include the control of multiple, interrelated air handling units, and large hot water or chilled water generating plants with components distributed in various locations within the building. Where should the DX-912x be used? The DX-912x is the newest member of the very successful family of DX controllers and uses the 78K baud peer-to-peer LONWORKS communication bus. To support many additional Metasys N2 device features, the DX-912x is also designed to respond to polled N2 messages. The result is that the DX-912x performs exceptionally well in certain applications, and slower than standard DX-9100s in others. In particular, the user may notice this slower performance when trying to display system summaries and graphics on an FMS Operator Workstation (OWS). Use the DX912x in: • Small buildings controlled by two or three DX controllers, without an FMS. Small, standalone systems are the best applications for the DX-912x. For control operations, the DX-912x can share data on a peer-to-peer basis. By adding the DX LCD Display Terminal (DT-9100), you can provide a local user interface that can be configured to give the users the specific data they need to see. 6 Technical Bulletins—DX-9100 Extended Digital Controller • Networked systems with peer-to-peer communications required by the specification that share data between controllers. In this case, you must make sure that the DX-912x meets the performance requirements. See a list of the most important points to consider below. • Networked systems where the majority of data traffic is in peer-to-peer communication between DX-912x controllers and the number of points on the OWS screen is limited to below 30 points. Do not use the DX-912x in: • Systems that require a large number of DXs (typically more than five per N2E trunk) and are likely to have frequent change-of-state reports (sent at a rate of more than one per second for an extended time) See Appendix A: LONWORKS N2E Bus Poll Estimation Worksheet at the end of this document to calculate the maximum number of DX controllers to use in a particular system. • Systems that require the gathering of trend or point history data from a large number of points in the DX-912x controllers or from a few points at a very fast rate. • Systems that require many or frequently running Graphic Programming Language (GPL) processes in the NCM, which need to poll the controllers for data. • It is not recommended to add DX-912xs to NCMs that already have N2 devices connected. • Process automation and pharmaceutical applications that use NCMs are generally not good candidates for using the DX-912x because of the requirement for a high volume of communication traffic between the controllers and the NCM for data gathering and global process interaction. The Version 3 controller has been approved as a LONMARK device and conforms to the LONMARK specification for network data transmission. LONMARK® Compatibility R Figure 3: LONMARK Logo Technical Bulletins—DX-9100 Extended Digital Controller 7 Refer to Table 1 for additional information on DX controllers: Related Information Table 1: Related Literature Document Title Code Number FAN DX-9100 Configuration Guide LIT-6364030 636.4 1628.4 GX-9100 Software Configuration Tool for Windows User’s Guide LIT-6364060 636.4 1628.4 LONWORKS N2E Bus Technical Bulletin LIT-6364100 636.4 DX LCD Display User’s Guide LIT-6364120 636.4 1628.4 This manual contains details of the hardware configuration of the DX-9100 series of controllers. This includes information on mounting, installation, and startup. About This Manual This manual also gives an overview of the internal operation and the software functional modules. Refer to the DX-9100 Configuration Guide (LIT-6364030) for detailed programming information on these modules. A guide to the operation of the front panel and keyboard is included at the end of this manual. The following lists some of the DX-9100 Extended Digital Controller features: Features • fully configurable, using GX-9100 Graphic Configuration software • communications bus (RS-485 port for N2 Bus) for FMS (DX-9100, Versions 1.x and 2.x) • LONWORKS TP78 transceiver for network communications (DX-9120, Versions 3.0, 3.1, 3.2 and 3.4) • LONWORKS FTT10a transceiver for network communications. (DX-9121, Version 3.4) • automatic reporting of alarms and changes-of-logic states on LONWORKS network (Version 3) • socket for service module (SX-9120) connection • RS-232-C port for loading controller configurations and for connection of the DT-9100 DX LCD Display (Versions 2 and 3) • eight high resolution (13-bit) analog inputs • eight digital inputs from potential-free contacts, each with transition counter • two isolated analog outputs (Version 1 only) • eight isolated analog outputs (Versions 2 and 3 only) 8 Technical Bulletins—DX-9100 Extended Digital Controller • six isolated digital outputs • twelve programmable function modules, selected from a library of functions, including: - P, PI, PID or on/off control, dual PID, dual on/off control - numeric calculation modules for programmed mathematical function - sequencer modules - totalization modules for analog or digital inputs • programmable logic control module with a set of logic functions including: - AND, ANDNOT, OR, ORNOT, COS (Change-of-State), OUT, OUTNOT, SET, RESET, AND LOGIC BLOCK, and OR LOGIC BLOCK • eight time schedule modules • two optimal start/stop modules • eight extension/expansion I/O module sets, each supporting up to eight inputs/outputs • sensor readings updated every second (including inputs from up to eight extension modules with analog inputs/outputs) • inputs and outputs via the LONWORKS network (Version 3). There are 16 network analog inputs, 16 network analog outputs, 8 network digital input blocks of 16 inputs, and 8 network digital output blocks of 16 outputs • built-in isolating transformer • integral display panel with keypads • enclosure material of self-extinguishing ABS/polycarbonate • surface or DIN rail mounting • field wiring mounting base (Versions 2 and 3) • cabinet door mounting frame (Versions 2 and 3) Technical Bulletins—DX-9100 Extended Digital Controller 9 Next >