Data Alarm Processor-III DAP™ III Operation Manual UUnniitt MMoouunntteedd DDAAPP IIIIII Wall Mounted DAP III Data Aire, Inc. 230 W. BlueRidge Avenue Orange, CA 92865 www.dataaire.com Table of Contents Introduction .............................................................................................................................4 Modes of Operation .................................................................................................................5 Hard Off/ON .............................................................................................................................6 DAP III Processor Standard Features ...................................................................................................................8 Optional Features ....................................................................................................................8 Diagnostic and Service Features ...........................................................................................9 Protective and Safety Features ..............................................................................................9 Display Panel .........................................................................................................................10 Condition and data displayed .......................................................................................10 Functions displayed ......................................................................................................10 Warning and alarms displayed .....................................................................................11 Historical data displayed ...............................................................................................11 Programmable Selections12 Menu Groups ...........................................................................................................................13 Sub Menus ...........................................................................................................................13 Display Panel Push Button Functions ........................................................................................16 Automatic Diagnostic Self-test on Start Up ...............................................................................17 Menuing Group 1 - Status and History ................................................................................................18 Group 2 - Setpoints ...............................................................................................................20 Group 3 - Operation ..............................................................................................................22 Group 4 - Alarms ...................................................................................................................28 Group 5 - Confi guration ........................................................................................................38 Group 6 - Network .................................................................................................................40 Group 7 - Calibration .............................................................................................................42 Group 8 - Set-Back ................................................................................................................44 Group 9 - Diagnostics ...........................................................................................................49 Group 10 - Analog .................................................................................................................53 Control Logic ...........................................................................................................................58 Troubleshooting Guide ................................................................................................................70 Manual Override Switches ...........................................................................................................77 Analogue Module Micro-switches ...............................................................................................78 3 Data Aire Data Alarm Processor III (DAP™ III) Data Aire’s Data Alarm Processor III (DAP III) continues the tradition of advanced electronic devices from Data Aire for monitor and control of computer room air conditioning units which began in 1977, over thirty years ago. Each generation of these devices has provided more accurate monitoring information and fl exibility in controlling the unit. The DAP III, microprocessor, based on the popular non-proprietary protocol, Modbus RTU, is equipped with fl ash memory and along with the standard USB port permits fast and easy software updates. The modular design offer installation and upgrades fl exibility. Should you need to upgrade your unit simply pop in a new board. As in the past the DAP III communicates directly with all major building management system (BMS). Just add a communica- tions card and you are connected. One new exciting feature of the DAP III is a real time clock allowing you to pin- point problems, precisely knowing what occurred and when. A new hierarchal menu structure permits easy and fast access making programming simple. The DAP III is the latest in microprocessor design and will keep your computer room air conditioning unit running ef- fi ciently for a long time. The unit mounted DAP III panel, shown to the left, comes standard on all fl oor mount Data Aire units. The wall mounted DAP III panel, shown to the right, is standard on all Mini-Plus, LCS, and Shelf units. It can also be an option on the Mini and fl oor mounted units. While the DAP III has two distinct looks they are identical as far as program and function. This Operation Manual cov- ers both the unit and wall mount. 4 Modes of Operation - The DAP III has two modes of operation. The Operation mode is the prevelant mode and occurs when the unit is in normal operation. During this mode the top row of the display shows the current opera- tion which the unit is in, such as: humidifi cation, dehumidifi cation, reheat stage - either 1,2 or 3 depending on how the unit is confi gured; cooling stage - either 1 or 2 again depending on the confi guration of the unit; and energy saver. If none of these condition exist a display of “Data Aire System Ready” will be shown. The lower row will continuously scrolls through the following displays: date and time set in the DAP III program; unit number and zone number (Pro- viding the unit is connected to a network. If not connected to a network it will display “N/A.”) as programmed; current temperature and humidity detected by the return air sensors or if the optional remote sensors are used it will be the conditions the remote sensors record; then any alarm conditions currently active. (A listing of these alarm conditions are shown on page 11.) If your unit uses chilled water DAP III will display the percentage of chilled water fl ow as well. In the upper right-hand corner of the DAP III display you should fi nd a blinking form in the shape of a heart. The blink- ing indicates that the processor is functional. The second mode of the DAP III is the Menu Mode which is described in the balance of this manual. To enter the Menu Mode depress either of the MENU buttons. DAP III Buttons - On the front of the DAP III there are seven buttons: an ON/OFF, MENU UP ()and MENU DOWN () button; SELECT UP () and SELECT DOWN () button; SILENCE / ALARM button and an EXIT button. The ON/OFF button is a soft power on/power off button. The hard power ON/OFF switch is located on the DAP III Control Module circuit board and will be explained in the next section of this manual. SILENCE /ALARM button only function is to mute audio alarms, the button is sparingly used in programming. EXIT button has no function in the operation mode, however, it is used in the menu mode. Once in the menu mode when the EXIT button is depressed the values programmed are saved and takes you up one level. For example if you are in the Menu Groups, as shown on the top of page 13, depressing the EXIT button will take you to the opera- tion mode. However, if you are in a Sub-Menus, shown on pages 13-15, depressing the EXIT button will take you to the Menu Group for that sub group. For example if you were in sub-menu group 4-6 Firestat Temperature Alarm Limit, depressing the EXIT button will take you to Menu Group 4 - Alarms . MENU  / MENU  these buttons primarily allow you the scroll up or down in the menu grouping that you are in currently. If you are in the Group menus depressing the MENU  button will take you to the next higher menu, from Group1 - Status & History to Group 2 - Setpoints. Conversely pressing the MENU  button will take you to the next lower menu in that grouping, from sub group 8-5 Set-Back Reheat depressing the MENU  button would take you to sub group 8-4 Set Up Cool. (All menu grouping continuously scroll, once you reach the last menu option and you depress the MENU  button you will return to the fi rst menu option.) These buttons have other specialized functions depending on the subgroup menu you are addressing. These functions are described in the body of this manual in the section where they apply. If the MENU buttons are held down they will advance at a rapid rate. If there is no but- ton activity for three minutes the DAP III will return to the Operation Mode. SELECT  /SELECT  these buttons, as the name implies, allows you to select a menu once you have located it using the menu buttons. For example if you wanted to select the sub group menus for “Group 3 - Operation,” once you scrolled to the group using menu buttons - depress the SELECT  button will take you to “3-1 - Set Time and Date,” the SELECT  button would take you to sub menu “3-16 - Humidifi cation Desaturation Cycle” the last menu option in sub-menu group 3 Once in sub group menus the SELECT  and SELECT  buttons permit you to scroll through that menu’s options.. 5 Hard Power ON/OFF Switch - After supplying power to the unit, if the DAP III does not come on when you press the soft ON/OFF button on the cover of the DAP III it will be necessary for you to open the cover of the DAP III The DAP III can be shipped in three different confi guration of circuit boards; the basic DAP III board; the DAP III with the relay board; and DAP III with the relay and analog boards. Each of these confi gurations are shown below and on the following page. The confi guration in your unit is dependent on the type of cooling and options that was selected. One of these photos will match the circuit board that is in your unit. However the hard ON/OFF switch is in the same position on all boards DAP III Circuit Board Control Module Hard power ON/OFF Switch DAP III Control Module Shown in the ON position on the upper panel and OFF position in the lower panel. Control Expansion Module The use of the additional switches on the circuit boards will be discussed on page 7788 of this manual. 6 DAP III Circuit Board with Relay Module installed Hard power ON/OFF Switch shown here in the OFF position Relay Module DAPIII CIrcuit Board with Relay and Analog Modules installed Hard Power ON/OFF Switch shown here in the OFF position Analog Module 7 DATA ALARM PROCESSOR – III The Data Alarm Processor-III (DAP-III) offers the defi nite answer for precision environmental control. The DAP-III control system not only controls and monitors temperature, humidity, airfl ow and cleanliness, it provides component run times, alarm history and an automatic self-test of the microprocessor. All messages are presented in a clear simple English and sequentially displayed on a backlit, liquid crystal display (LCD). The DAP-III can interface with a variety of building management systems (BMS). STANDARD FEATURES Stand Alone Panel – Service terminals or additional devices are not required for programming or monitoring functions. Microprocessor Based – State-of-the-art technology and reliability in a programmable solid-state control panel. Smooth Keyboard Type Switches – High reliability, fl at, sealed switches with tactile feedback. Two Row, 80 Character, Backlit Supertwist Liquid Crystal Display (LCD) – information is displayed and presented in a format that is easily viewed and understood. All Settings are Programmable from the face of the Panel – Expedient and user-friendly. Layered Forward and Backward Menu Access – Facilitates programming with fl exible operation. Multi-level Password Access– Controls any unauthorized changes to settings and system functions. Database of Unit and Room Conditions – Historical data that facilitates service, apparatus setup and fi ne tuning of setpoints. Battery Backup for Historical Data – Extensive historical data is preserved by integral battery backup in case of power failure. Menus Factory Programmed – Menus that pertain to the type and method of cooling, reheat and humidifi cation based on the unit’s components and options. Programmed Settings Saved in Flash Memmory – Non-volatile memory stored so all control settings and operational parameters are secured indefi nitely even during power outage. Factory Calibrated Temperature and Humidity Sensors – Accurate and consistent regulation especially in multiple unit applications. Automatic Self-Test Diagnostics – Verifi es the processor and selected components are functioning properly at power on and continuously during operation. OPERATIONAL FEATURES (Optional feature may require additional components and/or sensors.) Sequential Load Activation – Time and temperature based logic that sequentially starts and stops stages of cooling and reheat. Compressor Short Cycle Control – Prevents excessive compressor wear by using restart and anti-cycle limits. Automatic or Manual Restart – Restart methods are programmable in the event of a power failure. 8 Supplemental Compressor Operation during Energy Save Mode – Extends the savings from Energy Saver by allowing one or two compressors to supplement cooling as needed when Energy Saver cooling is not suffi cient. Temperature Anticipation – Responds to varying rates of temperature change. Humidity Anticipation – Modifi es the humidity setpoint to diminish excess humidifi cation and dehumidifi cation. Dehumidifi cation Mode Lockout – Inhibits dehumidifi cation if not required for system performance. Start Time Delay – Programmable time delay staggers the start-up of multiple units to prevent high power demand peaks. Chilled Water, Energy Saver and Hot Water Coil Flush Cycle – Periodically circulates fl uid in the coil to reduce deposit buildup in system. Automatic Compressor Rotation – Periodically rotates the lead/lag sequence to balance compressor run times. Automatic Reheat Element Rotation – Rotates the staging sequence to balance the run times of the heating elements. Energy Saver (Glycol) or Auxiliary Chilled Water Operation – Two types of Energy Saver Systems are available. Programmable Water Under Floor Alarm - Can shut down unit or just compressors. DIAGNOSTIC AND SERVICE FEATURES Alarms Displayed in Order of Occurence – Sequence with time of occurrence assist in diagnosing the cause of alarms. Programmable Delays for Optional Alarms – Reduces nuisance and false alarms caused by temporary or transient conditions. Manual Diagnostic Program – Provides accessible procedures to test the processor and major system components. Manual Override for Blower, Cool 1 and 2, Heat 1, Humidifi cation and Water Valve – The control circuit is operable even if the processor is not functioning properly. Adjustable Alarm Limits – Threshold levels for temperature and humidity alarms are programmable. Four Programmable Optional Alarms – In addition to the standard alarms, four additional alarms are programmable. Select Alarms Optionally Disabled – Nonessential alarms can be turned off. Audio Alarm Tone – Four programmable alarm tones. PROTECTIVE AND SAFETY FEATURES Metal Shell Enclosure with Sealed Front Control Panel – Provides electromagnetic interference (EMI) protection and general protection against environmental contamination and handling damage. Watch Dog Timer – Automatically resets the circuit board, clears any corrupted memory and restarts the system with minimal interruption in case of an unfi ltered transient signal. Opto-Signal Inputs – Isolates the circuit board from electrical noise or static from contactors, compressors and motors that can contaminate the power at the circuit board. 9 Protected 24 VAC Power Input – Fused metal oxide varistor (MOV) and transient voltage suppressor react to interrupt the power from the circuit board if excessive amperage or over voltage condition is detected. Isolation Transformer – Protection against ground loops, ground shorts, wiring errors and conducted electrical interference. Heavy Ground Planes and Power Foils – Large ground plane areas and wide power runs minimize disturbances caused by EMI and other types of electrical interference. Switching Power Supply – Allows for wide AC input voltage fl uctuation to reduce the effects of a power blackout while still maintaining circuit board operation. Fused RS-485 Network Lines on Network Communication Card – Disconnects the circuit board from the source of current to protect the circuit board components. Modulating Humidifi er Control – Proportional control of steam generator humidifi er provides additional refi nements in performance. (Optional Relay Module required.) Humidifi er Autofl ush Cycle – An adjustable fl ush cycle for infrared humidifi ers to reduce deposit build-up. (Optional Relay Module required.) Three Additional Remote Alarms – Group or specifi c alarm selection for remote alarm contact. (Optional Relay Module required.) Analog Inputs – Output values of four external analog sensors can be read on the processor display. (Optional Analog board required.) Underfl oor Water Detection Cable – Provides continuous water detection cable to encircle the entire unit. Display Panel CONDITIONS and DATA DISPLAYED TEMPERATURE SETPOINT – ºF or ºC CURRENT TEMPERATURE – ºF or ºC HUMIDITY SETPOINT – Percent of relative humidity CURRENT HUMIDITY – Percent of relative humidity CURRENT DISCHARGE AIR or CHILLED WATER TEMPERATURE* - ºF or ºC FUNCTIONS DISPLAYED COOLING – 1st stage, 2nd stage, 3rd stage*, 4th stage* REHEAT – 1st stage, 2nd stage, 3rd stage, hot water* CHILLED WATER FLOW – 10 to 100% (based on VDC output) ENERGY SAVER* - hours of operation DEHUMIDIFICATION - hours of operation HUMIDIFICATION - hours of operation * This optional feature or data display may require additional components and/or sensors. 10