Troubleshooting Tools

Tools and Software

Operating the Computrols Hand Held Terminal

The Hand Held Terminal is very easy to use. Just plug it in to the Hand-Held port on the board and it will power up. The first screen gives you the part number and firmware version. For example:

8 Ver 9.9

Feb 16 2006@14:20:25

This means that the Hand-Held is plugged into an 8X with version 9.9 firmware. The Date of the firmware is 02/16/2006 at 2:20PM.
Press Enter, and Enter again to get to the Modes menu. You will see:

1=Hardware (Points in Database)

2=Date (System Time and Date)

3=Web (Network/TCP/IP Settings)

•Press 1, and Enter to see a list of points on the board. If you see “DATABASE NOT LOADED”, then the controller has not received a database from the server.

•Arrow up or down to see all the points.

•Press Select to command any command-able point.

•Press 1 to command and 2 to place the point in Auto.

•Press ESC to return to the Modes Menu.

•Press 3 and Enter to view and change TCP/IP settings.

•The first setting you will see is the TCP/IP address.

•Arrow up or down to see other TCP/IP settings.

Please see Computrols’ Network Manual for significance of various settings.

NOTE: DHCP and Controller to DPU are used by WorldSTAT only.

•Press Select to change a setting, then type in the numbers and dots to separate them.

•When you enter a 3-digit number, the dot will be added for you. After completing the number, press Enter and you will be prompted to reboot the board.

•Turn the controller off then back on for the Web settings to take affect.

•Press ESC to return to the Modes Menu.

•Press 2 and Enter to view the controller’s Time and Date. Time and Date are set by the CBAS Server

•Press Select to change the Time and Date (not advised).

Advanced Hand-Held Use

There is a hidden menu item on the Modes Menu. This feature is to be used with extreme caution!

From the Modes Menu, press 5, then Enter.

SELECT TO ERASE DATABASE

If you need to erase the database from the controller, Press the SEL key. You will be prompted to enter a 1 or 0 and press ENTER to complete the process.

CAUTION: Do not erase the database unless you are sure. If the controller has no communication to the server, the database will not download again, and the controller will not work. A database download will be required.

To see more advanced menu items, press the down arrow.

SELECT TO ENTER BOOTLOAD

CAUTION: Do not EVER press SEL here! This will render the controller useless, and it will have to be replaced. The feature is for factory use only.

Press the down arrow key.

SELECT TO OFFSET PORTS

This menu item is used to change the TCP/IP port on which its web page is served. For more information on this feature, see “Forwarding a Router to Multiple Controller Web Pages” in this Manual and in the Manuals & Instructions section of Computrols website:  Computrols: Forwarding A Router (PDF)

Press the down arrow key.

HOST TX000000 RX000000

On this screen you are seeing live activity on the Host RS-485 port. TX stands for Transmit and RX stands for Receive. If you see no activity on either one, then you have a communications problem. If you are receiving, but not transmitting, then the controllers on the channel are talking to you, but you are not talking back. This could mean that you have your wires crossed, or one wire is loose.

Below, you will see statistics on various categories of packet types. Press the down arrow and you will see another page of statistics. If the numbers are going up in any category, you may have a wiring or other communication problem. The one most important category is FE. If numbers are constantly going up here, then you are getting Framing Errors, which means you have a wiring problem.

Continue to arrow down.

You will see more statistics from the TCP/IP channel. Good luck trying to decipher.

Press ESC to return to the Modes Menu.

TCP/IP Connection With Controller (Or, “How do I suck the database from a controller?”)

In previous versions of CBAS, this feature does 2 other types of connections in addition to TCP/IP. However, due to the limitations of the other 2 connection types, you probably won’t want to use them, and only the TCP/IP Connection will be covered.

To explore this feature, close any database that you might have open by going to the System Menu, then Close Database. Next, go to the Database Menu then Open Database. Instead of choosing Editor Mode or Real Mode, go to the 5th choice, “TCP/IP Connection with Controller.”

TCP/IP

Check the box to “Connect with the controller’s TCP/IP Channel”. A field will appear where you can enter the IP address of the controller. You only need to put in a password if a password had been previously entered for the controller. This can be done on the Controller Program Screen. After entering the IP address, click the “Connect Now” button.

Once the database is downloaded from the controller, you will have limited versions of Text View, Hardware View, and System Menu. Hardware View will give you most of what you would normally have, but with only one controller, of course. System menu will give you software version, CBAS Help, and allow you to close the database or exit CBAS.

Text View/All Points will give you all of the hardware, software, and S3 points contained in the controller’s database. The available summaries under Text View are also functional. You can click on a point and go to the Point Program Screen. From there, you can make changes, but be aware that some functionality will be lost due to the fact that you are not connected to the Parent (DPU) database and points on other controllers might not be accessible. Some things you can’t do include:

•Histories (stored on the DPU)

•Graphical Schedule Editor

•Anything having to do with points on other controllers or the DPU

Saving the Database

Once the db is open, a copy is saved. CBAS saves the controller’s database in the C:\CBAS\Uploads\[controllers name] (or C:\CBAS2000\Uploads\[controllers name]) directory. Then yes, you can use that as a template. There may be a problem in some versions of CBAS and firmware versions, but it will work on a 10.x firmware rev.

Then create a new database and add a controller using the downloaded database as a template. Then you can open that in real mode and talk to the controller.

Controller Diagnostics

Controller Diagnostics can be a useful tool for troubleshooting problems with the following controllers: 8X, 16X, 32X, 64X and VAVs (AP, P, A, X). To access Controller Diagnostics, find the controller in Hardware View. Click once on the controller and then Controller Diagnostics.

One of the most common uses of this screen is to check the firmware version. When calling Tech Support for help with a problem, you might be asked for this information. The firmware version is listed as “Partnumber”. In the example above, “8 V9.1” means that the controller is an 8, and the firmware is version 9.1. The other way to get the firmware version is by using a Hand-Held Terminal.

In the Database Storage section, you can see if changes made to the controller’s database have downloaded. Check the “Stored At” date and time on the “Database stored in FLASH?” line. If the time listed is prior to making the changes, then the database has not downloaded. However, the chances of this happening are slim. CBAS automatically checks for differences between the server’s database and the controller’s database. If there is a difference, the server’s database will download to the controller.

The TCP/IP Diagnostics section could be helpful in troubleshooting communications problems. If you have errors here, then perhaps you have a network problem, like a bad wire, switch, or a computer/controller sending out bad packets.

The bottom section, below TCP/IP Diagnostics, lists network settings, such as IP Address, Default Gateway, Subnet Mask, and DNS Server Address. You can also tell if the controller is set to contact the CBAS Server instead of being contacted by it. By default, controllers are set for DPU to Controller, which means that the Server initiates the communication link. Controller to DPU means just the opposite. The controller must also be set up in CBAS for this setting to work. Generally, this setting works in conjunction with DHCP, which allows your controller to receive an IP address dynamically from a DHCP server on the local area network. By default, controllers are set to not use DHCP and have a static IP address of 192.168.1.199.

The Controller Diagnostics screen for a VAV controller looks a little different, but contains much of the same information. Since VAV controllers communicate using RS-485 protocol, there will be no TCP/IP information.

Deleting the Database from a Controller

Deleting a controller’s database is a way of forcing a download to the controller. Also, if a controller has been used on a RS RS-485 channel, and still holds that database, it will be necessary to erase the database. A TCP/IP database will not download until the RS RS-485 database has been removed. There are four ways of deleting the database from a controller:

1.From CBAS in Hardware View, locate and click the controller, then click Erase Database. CBAS must be in Real Mode with Normal communications to the controller. After rebooting, the controller will immediately download the database again.

2.From the Hand –Held Terminal, go to the Main Menu.

oPress 5 (not listed) then Enter

oPress Select to Delete

oFollow instructions, cycle power to controller

3.Connect using HyperTerminal

oType the command: ERASEDATABASE

4.Using the Address Dials on an 8X, 16X, 32X, or 64X.

oSet Red Dial address to 999.

oPower up the board.

oChange Red Dial address to 990.

oChange Red Dial address to 900.

oChange Red Dial address to 000.

oAt this point the controller would recognize this number sequence and erase the database.

oIt will ONLY work if the Red Dial address is 999 after a power up.

Computrols Commission Program

Computrols Commission Program (Commission.exe) is a program designed to operate a Computrols controller without using CBAS software and has the same functionality as the Hardware section of the Hand-Held Terminal. The program is very useful for commissioning and balancing VAV and AHU controllers in a building under construction where communication to the head end is not set up yet, or it is impractical to use the head end. VAV balancing technicians will find the program easy to use and can go from one VAV box to the next using a laptop.

A database has to be present on the controller for this program to work. Otherwise, there would be no points to command. To do this, program the controller in CBAS and connect to it in Real Mode. The database will download to the controller automatically.
The program uses RS 232 communications protocol through a serial port. Controllers supported are the Professional line of controllers, including the 8X, 16X, 32X, 64X, and VAV controllers.
Cables

The cable needed for the Professional line controllers is a cross-over RS-232 cable with a female DB9 connector on both ends. Pins for the DB9 connectors are as follows: Pin 2=Transmit (black), Pin 3=Receive (red), Pin 5=Ground (green or white). Pins 2 and 3 are reversed on the other end. Plug one end of the cable into the serial port on the computer and the other end into the RS-232 port on the terminal board of the controller.

The cable needed for the VAV controllers is the same as shown above, with the other end stripped to bare wires. The wires are connected to the terminals on the VAV board as follows: Black=RS-232 Rx; Red=RS-232 Tx; Green or White=RS-232 Ground.

There is one more way to connect to the VAV, but it requires a special cable. When wiring a VAV controller and using an Invensys S3 Display Stat, an extra 2-conductor wire can be run (under separate cover) from the S3 to the VAV RS-232 Rx/Tx. The distance limit for this wire is 50’, but might actually be shorter or longer in real life applications depending on interference levels from electrical sources in walls and ceilings. Wiring for this is outlined in the VAV Wiring Diagram. The cable needed from the laptop serial port to the jacks on the S3 is a special cable, which can be obtained from Computrols.

If your computer does not have a Serial or Com port, you can use a USB to Serial cable to make the connection. These can be purchased for about $30. You will have to install the drivers for the cable prior to plugging in the cable. Since Commission only works with Com1 and Com2, you will have to designate this cable as one of those by going to Windows Device Manager.

Software

Commission.exe comes along with six .ocx files in a zip file called “Commission Program.zip”. The program doesn’t need to be installed, just unzip the file to a convenient place on the computer. The .ocx files should remain in the same folder with the .exe file, because the program will attempt to register these files upon opening. If you would like a shortcut on the desktop, right click on commission.exe, click Send to, then Desktop (Shortcut).

Double click the Commission.exe icon and the following window will appear:

Select the correct Com Port. If you only have one Com port, select COM1.

The following window will appear:

From here, you can see the status of any point in the database on the controller. Click on any command-able point to command.

Right click or press Esc and you will see the following screen:

From here you can get information about your controller (“Version” refers to firmware version). You can exit the program, return to the point list, or set the time by clicking the appropriate button.

HyperTerminal

Open the Windows program, HyperTerminal. In Windows2000/XP, it is located under:

Start/Programs/Accessories/Communications/HyperTerminal
Choose a name for your connection and click OK. Pick your Com port (1 or 2) and click OK. Under Port Settings, change the Bits per Second to 38400 and the Flow Control to None. Click OK. When the window opens, type help, and you will get a list of commands. This means you are connected. See the figure below-left:

•Use the commands listed to get statuses, command points, reboot the controller, etc.

•To close the connection, just close the HyperTerminal window.

•HyperTerminal can also be used with all of the cables listed in the previous article about the Commission Program.

•It is possible for HyperTerminal to work over longer wire distances than Commission.

Troubleshooting Communications

TCP/IP Controller

Let’s say you have a controller programmed on a TCP/IP channel and you cannot get it to download and communicate. Here are some things to check:

1.Check Network Settings on the Controller using the Hand-Held Terminal, and on the network card on the computer. See TCP/IP Config.

2.Delete Database from controller using the Hand-Held Terminal. (From Menu, hit 5 then Enter)

3.Ping the controller IP address.

4.Check the Link Light on the controller, Switch and NIC

5.From command prompt [ARP -d 192.168.x.x] will clear the ARP cache

6.Telnet 192.168.x.x

oHelp (Commands)

oSocks – Tells you if you are connected

osocks? – Tells you who’s connected

oident – Tells you version and IP address

oFiles

7.If connecting over the Internet, make sure the controller has the correct Default Gateway.

8.Check IP Addresses in CBAS on Channel Program screen and Controller Program screen.

RS-485 Communications

1.Make sure you have the channel programmed in CBAS correctly

oIP Address of Host controller is correct

oHost or Secondary port

oCorrect Channel Type (RS-485, Modbus, Opto)

oIs host controller communicating?

2.If it is a new channel, delete the database on the host
controller and make sure the database has downloaded.

3.Try reversing the polarity of the wires on the RS-485 + and – terminals. Reversed polarity will cause the RS-485 Port Activity light to be on solid.

4.Make sure the Run Light is blinking on the RS-485 controller

5.Make sure that the Host and child controllers are grounded

oSecondary side of transformers’ common to earth ground

6.Make sure that the wire is 18-2 shielded

7.Make sure that shield is tied together and terminated on shield terminal of all controllers

8.Avoid “T-Tapping” the wiring

o“Daisy Chaining” or a straight-line bus is the proper method

oT-Taps create multiple ends-of-line, increasing reflections that can cause interruptions or Framing Errors

9.Intermittent communications can be caused by loose screw terminals

10.Try a RP1 repeater at the beginning of the channel to boost the signal on long channels or channels with more than 40 controllers

11.Use the Hand-Held Terminal to check for Framing Errors on the Host Controller. See Hand-Held Terminal operation for details.

How Voltage Drops Over Long Distances

Usually in the controls business, you try to locate your controllers as close as possible to the devices they are controlling.
Sometimes that is not possible, such as in a case where you have rooftop units in a cold climate. Controllers can’t handle below freezing temperatures, so you have to locate the controllers somewhere in the building, maybe hundreds of feet away. How do you know that the resistance of a long run of wire won’t cause a voltage drop bad enough to cause problems?

As you probably know, a long enough wire run will cause a voltage drop, but it has to be pretty long to cause any problems. Now, a voltage drop on a signal coming back to a Voltage Input from a sensor will cause the reading to be inaccurate. The National Electrical Code contains tables for figuring this out, but here’s a way of doing it on your own.

You have to know the length and resistance of the wire, the source voltage, and the maximum current of the circuit. The following website shows the resistance of light gauge wires:

http://www.cirris.com/testing/resistance/wire.html

Most 24 Volt control wire is 18 AWG, and according to the above-mentioned site, the resistance of 18-gauge wire is .00639 Ohms per foot. Since the maximum current on a Computrols Professional controller is 24VDC Binary Output is 50mAmps, we’ll use that as the current. Let’s look at the formula and circuit diagram.

In this example, let’s go with a wire distance of 1000’, which is probably more distance than you’ll ever have to run. The variables are:

?V1 = 24VDC; R = 0.00639/Ft.; L = 1000’; I = 0.05 Amps.

?24 – (2×1000 x 0.00639×0.05) = 24 – 0.639 = 23.361

Volts at End

As you can see, the voltage at the end is still over 23 Volts, so 1000’ should not be a problem powering a device. Even at 2000’, the voltage drop is just 1.278 volts.

In the case of powering a long line of VAV controllers from one transformer, it would be very complicated to calculate the voltage drop. Computrols recommends that you use a 28V transformer to compensate for any voltage drop.

You probably don’t have to worry about voltage drops when powering a device or relay as in the above example, but a Voltage Input could pose an accuracy problem. We recommend the use of Voltage-to-Current converters or 4-20mA transmitters. This also makes it noise immune from nearby 60Hz sources.
In the case of a long run to a thermistor, we also suggest using a 4-20mA device instead of a plain thermistor. No matter what the resistance due to wire length, the current will remain constant.

Installing Dongle Drivers

For the dongle (hardware lock) to do it’s job of allowing you to run CBAS in Real Mode, it must be accompanied by a matching license file, and the drivers for the dongle must be installed. Everything you need to do this should come on a floppy disk that accompanies the dongle and/or computer shipped from Production.

The license file, License.txt, should be copied from the floppy disk and pasted into the CBAS folder on the DPU computer. The job name on the dongle has to match the job name in the License.txt file. The CBAS version on the license file must match the CBAS version (for instance: CBAS Professional 2.1.X) that is running on the DPU, but does not have to match the dongle. So, to upgrade you CBAS version, you shouldn’t need a new dongle, just a license file. The License.txt file can be viewed as a text file, but cannot be altered in any way, or you will get an illegal license message.

To install the drivers for the dongle, click on the “Run Me.bat” file on the floppy. This works well with Windows 2000 or XP. With Windows 98, you will have to open the Dongle Install folder and run Install. Once the drivers are installed, plug the dongle into the USB port and it will install the dongle. CBAS should now run in Real Mode.

Contents of floppy disk:

•License.txt

•DongleInstall (folder containing drivers)

•Run Me.bat