Appendix K: I/O Extender...2001/02/16 · Copy TDUMP.EXE to the IOEXT01 Directory. 5. Change the COM port to the correct COM port number (leave everything else alone). A. From the

Appendix K: I/O Extender

Chapter Overview This appendix to the User’s Guide to UNITY will discuss: • I/O Extender and how it functions • I/O Extender hardware • UNITY installation of the I/O Extender • UL Listed I/O Extender Hardware

LIT-TD-1052

Appendix K: I/O Extender User’s Guide to UNITY UNITY 5.8

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(1) Overview The I/O Extender is a hardware device that monitors the UPS used by Unity. It notifies the Unity Workstation when a power-out situation has occurred and the UPS is now the primary power source for the system. This allows you time to correct the power- out problem, perform emergency control sequences, or shut the system down properly. It is typically used on sites that require this additional measure of protection, such as UL listed configurations. Refer to the B&B Electronics Digital I/O Extender Instruction Manual, document # IOEXT4395, for device specific information.

(2) General Requirements The following list of steps must be implemented to assure proper operation.

1. The I/O Extender can be placed on any PC in the system except a Serial User.

2. If the IRM PC is heavily loaded with communications, place the I/O Extender on a Remote User PC. Failure to do so will cause the IRM and UI to crash.

3. The I/O Extender is designed to fail with all inputs in alarm and all outputs to turn on - in the subsystem. (Loss of communication or loss of power to the I/O Extender hardware)

4. All inputs must be programmed as alarmable or the IRM will crash when the I/O Extender is started.

5. Non-inverted outputs are to be used.

6. DO NOT USE the OUTPUTS when using this device for a primary power source monitor.

7. IOEXTEND.EXE does support the E flag for capturing of CXC files.

2.1 Hardware Requirements

PC

1. A COM Port from either the Mother Board, DigiBoard, or Equinox must be available.

2. Communication setup on COM Port – 19200 baud, 8 databits, 1 stop bit, no parity

I/O Extender Hardware - B&B Electronics

1. Digital I/O Extender – Model 232IOEXT

2. Digital Buffer Module – Model DBM16

3. DBM16 Enclosure – Model BPDBM

4. 12VDC Power Supply – Model 232PS2

CABLE – PC to I/O EXTENDER

A DB-25 male, each end, cable with pins 2,3,7 straight wired – max. 50 ft.

CABLE – UPS to I/O EXTENDER

A cable using pins 1,6,10,15,17,18 of a DB-25 male on one end and tinned wire on the other – max. 50 ft.

Supported UPS Models

UNITY 5.8 User’s Guide to UNITY Appendix K: I/O Extender

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Liebert UPStation GXT– Several Models are available, below are the GXT Types:

1. Model 1000VA-120V P/N GXT1000RT-120 w/Intellislot AS400 Card P/N AS400CARD








2.2 Software Requirements Required software files include: As viewed from an OS/2 Window.

1. IOEXTEND.EXE 317546 2-16-01 9:53A

2. CPPOM30.DLL 363472 6-8-95 1:52A

3. CPPOOB30.DLL 799211 6-10-95 3:12A

4. CPPOOU3.DLL 1627527 6-10-95 3:15A

5. A default PIPE.DAT (either a Local or Remote PIPE.DAT)

6. IOMAP.TXT

(3) Creating Required Files for IOEXTEND.EXE – Single IOEXTENDER

Calc Group You must create a calc group and then program in specific points for I/O Extender’s use. I/O Extender uses these calc group points to monitor and report the UPS’s functioning.

With Unity Running: 1. Create a calc group. Example below: Group p34.

Figure 1. Edit Groups Window

2. Add the following digital points:


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Point 1 - Primary Utility Status - Alarmable - PWR for engineering unit

Point 2 - Backup Battery Status - Alarmable - BATT for engineering unit

Point 3 - Bypass Mode Status - Alarmable - Supervisory for engineering unit

Point 4 - UPS Fault Status - Alarmable - Supervisory for engineering unit

Point 5 - Summary Alarm Status - Alarmable - Supervisory for engineering unit

Point 6 - Spare I/O Input#5 - Alarmable - Gen Alarm for engineering unit



Point 9 - IOEXTENDER Output#1 - Status Only - OFF/ON for engineering unit








Screens for the first two points are shown below:

Figure 2. Editing Point #001 Figure 3. Editing Point #002

3. Once you have entered the required 16 points, save them.

4. Turn all of these points to Alarm/On which ever is applicable.

Figure 4. Calc Group with Points Entered


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3.1 PIPE.DAT The PIPE.DAT file must be in the same directory as the IOEXTEND.EXE and IOMAP.TXT files. The PIPE.DAT file must also have the COM port set to match the IOEXTENDER.

From an OS/2 Window 1. Change directory to Unity.

2. Make a directory called IOEXTnn, Where nn = The number of the IOEXTEND.

Example: MD IOEXT01 and hit "Enter".

3. Copy the default PIPE.DAT to the IOEXT01 Directory.

Note: Copy the correct pipe.dat – remote or local.

4. Copy TDUMP.EXE to the IOEXT01 Directory.

5. Change the COM port to the correct COM port number (leave everything else alone).

A. From the Edit Menu select HEX EDIT.

B. Click on Row10 / Column 2 and enter the hex number for the Com port.

C. From the Edit Menu select Exit With Save.

D. Hit Save.

Figure 5. Local IOEXTENDER PIPE.DAT Screen

Available Hex numbers for the Com ports are: 01 02 03 04 05 06 07 08 09

0A 0B 0C 0D 0E 0F

10 11 12 13 14


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Figure 6. Remote IOEXTENDER PIPE.DAT Screen

Available Hex numbers for the Com ports are: 01 02 03 04 05 06 07 08 09

0A 0B 0C 0D 0E 0F

10 11 12 13 14

3.2 IOMAP.TXT The IOMAP.TXT file must be edited to reflect the new mapping settings for the IOEXTENDER. The procedure is listed below:

From an OS/2 Window 1. Change directory to Unity

2. Change directory to the IOEXT01 directory.

3. Type E and hit "Enter"

4. Type the following:

P,34,001=1,I

P,34,002=2,I

P,34,003=3,I

P,34,004=4,I

P,34,005=5,I

P,34,006=6,I

P,34,007=7,I

P,34,008=8,I

P,34,009=1,O

P,34,010=2,O


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P,34,011=3,O

P,34,012=4,O

P,34,013=5,O

P,34,014=6,O

P,34,015=7,O

P,34,016=8,O

5. Save as “IOMAP.TXT”

6. Close the OS2 window

(4) Creating required files for IOEXTEND.EXE – Multi IOEXTENDER

You can have more than one IOEXTENDER. When multiple IOEXTENDERs are used, a separate directory (IOEXTxx) must be created for each IOEXTENDER. The IOMAP.TXT and PIPE.DAT files must be in the associated IOEXTxx directory. Points can be in a single calc group or in a completely different group. It does not matter which way you choose to map the points. The I/O Extender uses these calc points to monitor and report the UPS’s functioning.

4.1 Calc Groups You have two Calc Group choices when a multiple IOEXTENDER setup is used. 1. You can create a separate Calc Group for each specific IOEXTENDER and then map in Calc Points for each specific IOEXTENDER.

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Figure 7. Multiple IOEXTxx Directories With A Calc Group For Each IOEXTENDER

2. You can create a single Calc Group and then map each individual IOEXTENDER’s Calc Points from that single Calc Group.

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Figure 8. Multiple IOEXTxx Directories With A Single Calc Group For All IOEXTENDERs


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With Unity Running

1. Edit each calc group you have chosen and add the following points (Example: Group P34)

2 Point 1 - Primary Utility Status - Alarmable - PWR for engineering unit








Point 9 - IOEXTENDER Output #1 - Status Only - OFF/ON for engineering unit








3. Save these points and turn on or alarm these points which ever is applicable.

4. Edit each calc group you have chosen and add the following points (Example: Same Group P34).

5. Point 20 - Primary Utility Status - Alarmable - PWR for engineering unit
















6. Save these points and turn on or alarm these points which ever is applicable

-OR-


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4. Edit each calc group you have chosen and add the following points (Example: Diff Group P37)

5. Point 1 - Primary Utility Status - Alarmable - PWR for engineering unit
















6. Save these points and turn on or alarm these points which ever is applicable

7. Continue until all points are saved.

4.2 PIPE.DAT From an OS2 Window

1. Change directory to Unity

2. Make a directory called IOEXTnn, Where nn = The number of the IOEXTEND

(Example: MD IOEXT01), and hit "Enter"

3. Copy the default PIPE.DAT to the IOEXt01 Directory (copy the correct pipe.dat - remote or local)

4. Copy TDUMP.EXE to the IOEXT01 Directory

5. Change the COM port to the correct COM port number (leave everything else alone)


7. Make a directory called IOEXTnn, Where nn = The number of the IOEXTEND

(Example: MD IOEXT02), and hit "Enter"

8. Copy the default PIPE.DAT to the IOEXT01 Directory (copy the correct pipe.dat - remote or local)

9. Copy TDUMP.EXE to the IOEXT02 Directory

10. Change the COM port to the correct COM port number (leave everything else alone)

11. Continue until all directories and pipe.dat files are created.


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4.3 IOMAP.TXT The IOMAP.TXT file must be edited to reflect the new mapping settings for the each individual IOEXTENDER. Note that a different directory is used for each IOMAP.TXT file. The procedure is listed after the graphic below:

Figure 9. Multiple IOMAP.TXT Files From an OS2 Window




4. Type the following :

P,34,001=1,I

P,34,002=2,I

P,34,003=3,I

P,34,004=4,I

P,34,005=5,I

P,34,006=6,I

P,34,007=7,I

P,34,008=8,I

P,34,009=1,O

P,34,010=2,O

P,34,011=3,O

P,34,012=4,O

P,34,013=5,O

P,34,014=6,O

P,34,015=7,O

P,34,016=8,O

5. Save as "IOMAP.TXT"





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9. Type the following :

P,34,020=1,I

P,34,021=2,I

P,34,022=3,I

P,34,023=4,I

P,34,024=5,I

P,34,025=6,I

P,34,026=7,I

P,34,027=8,I

P,34,028=1,O

P,34,029=2,O

P,34,030=3,O

P,34,031=4,O

P,34,032=5,O

P,34,033=6,O

P,34,034=7,O

P,34,035=8,O

5. Save as "IOMAP.TXT".

6. Repeat as necessary until all IOMAP.TXT are created.

7. Close the OS2 window.

(5) IOEXTEND.EXE IOEXTEND.EXE is the executable file for the IOEXTENDER. The IOEXTENDER hardware must be setup through switch settings, jumpers, and cable connections.

5.1 Set Up the IOEXTENDER With Unity Running

1. Remove the cover from the IOEXTENDER.

Figure 10. IOEXTENDER and DBM 16 Hardware


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NOTE: When using the IOEXTENDER for a UL Listed system DO NOT use the onboard outputs.

2. On the front side of the board - locate SW1 and set all switches to the OFF position, except switch 3 which is set to ON.

3. On the back side of the board place the jumpers to DCE.

4. Connect the cable to the COM Port on the PC.

5. Connect the other end of the cable to the IOEXTENDER RS-232 end.

5.2 Set Up the DBM16

With Unity Running:

1. Place the jumpers to the following positions - I/O 0 thru 7 to IN, I/O 8 thru 15 to Out

2. Connect the wiring from the field points (normally closed) to the BDM16 Inputs

Do not use the outputs.

3. Connect the power supply to the DBM16.

Figure 11. IOEXTENDER Cable Connection To UPS

4. Connect the DBM16 to the IOEXTENDER.

5. Plug in the power supply and look for the LED to flash on the IOEXTENDER.

6. Place the cover on the DBM16.

5.3 Place Code in the Unity Directory With Unity Shut Down:

1. Copy the IOEXTEND.EXE and the CPP*.DLL files to the C:\Unity Directory.

2. In the Unity Directory, edit the SYSTEM.CMD and add the following:

Start "IOEXTEND - Primary AC Power Monitor #01" /n IOEXTEND IOEXT01.

3. Continue to add the lines as necessary to start all of your IOEXTENDERS.


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(6) IOEXTENDER Check Out

6.1 Start Up Restart Unity

1. Hit Ctrl+Esc and look at the window list as Unity starts up.

2. Look for the lines - IOEXTEND - Primary AC Power Monitor #01 and any others for this PC.

6.2 Debug Screen With Unity Running

1. Look at DEBUG screen for normal communication.

Figure 12. Debug Screen 2. Check to see if the IRM is talking to the subsystem.

3. Check to see if the Field is talking with the subsystem.

4. Check to see the points loaded.

5. Check to see the status of the calc points.

6.3 Normal Operation With Unity Running:

1. Check to see that all the points have Cleared and turned OFF for each applicable group.

2. During normal operation the subsystem will get the status from the field and send it to the IRM.

3. Since the outputs are not used for the POWER MONITOR no commands should go to the field.


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6.4 Check Alarming on Inputs With Unity Running:

1. Check to see that all the points have Cleared and turned OFF for each applicable group

2. Open the input lines to I/O 1 and 2

3. Check that the alarm has printed in the alarm region and on the printer (if applicable)

4. Run a group log and check that points for inputs 1 and 2 are in alarm

4. Repeat this as necessary for all points and associated groups.

6.5 Check Return to Normal on Inputs With Unity Running

1. Check to see that all the points are still in alarm for each applicable group

2. Short the input lines to I/O 1 and 2

3. Check that the return to normal has printed in the alarm region and on the printer (if applicable)

4. Run a group log and check that points for inputs 1 and 2 are normal

5. Repeat this as necessary for all points and associated groups.

(7) Header Data Setup The Header Point that will display the status of the AC Power must be programmed. This will display a “Primary Power Down” message in the header region when the AC power fails and the UPS takes over. In addition, an alarm will display in the alarm region.

7.1 Programming the AC Pwr Point With Unity Running

1. From the Setup -> Header Data Menu select the point for AC Pwr (Primary Utility Status point).

Figure 13. Set Header Data

2. Hit OK to save.


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7.2 Testing the Primary Power Monitoring With Unity Running:

1. Open the input lines to I/O 1 Calc Point P34001 (check both P34001 and P34005 have alarmed).

2. Check that the alarm has printed in the alarm region and on the printer (if applicable).

3. Check in the upper left hand corner of the Header Region for "Primary Power Loss".

4. Check that you receive a pop up box and "Primary PC Power Failure" is printed.

5. Check for a beep every ten seconds with a duration of a 1/2 second continuing as long as the input is open.

6. Short the input lines to I/O 1 Calc Point P34001.

7. Check the return to normal is received for point P34001 and has printed in the alarm region and on the printer (if applicable). Check also that P34005 has cleared as well.

8. Check in the upper left hand corner of the Header Region that the "Primary Power Loss" has disappeared.

9. Check that you receive a pop up box and "Primary PC Power Restored" is printed.

10. Check to see if the beeping has stopped.

Figure 14. Primary Power Down Message Displayed in the Header Region

Figure 15. Primary Power Down Popup Message


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Figure 16. Primary Power Restored Displays OFF Point Status in the Header Region

Figure 17. Primary Power Restored Popup Message

(8) COM Loss Setup

8.1 Programming the COM Loss Points With Unity Running:

1. From the group that contains your IOEXTENDER points, use the last points in the group to program the following points:

COM MONITOR #1 - Status Only - Off/On

COM MONITOR #2 - Status Only - Off/On

COMMUNICATION - Alarm Only - Off /On

Figure 18. Edit COM Loss Points Group


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Figure 19. Point 1 Figure 20. Point 1 Calc Screen



Figure 25. Calc Group After Programming COM Loss Points 1, 2 and 3

2. Set up the EMS in the same fashion as in the following figures.

3. Make a program "IOEXTENDER COM LOSS"

4. In this program Add a point Command that will turn on your COMMUNICATION point and the two monitor points.

5. Assign this program to all outputs of the IOEXTENDER COS - ON.


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6. Make a message "IOEXTENDER COM LOSS" that includes the following:

Communication has been lost to the IOEXTENDER that is monitoring the Primary AC Power Source.

1. Check the communication cables.

2. Check the COM port operation.

3. Check the power on the IOEXTENDER.

4. Check that no one has turned on any of the IOEXTENDER outputs.

Figure 26. IOEXTENDER COM Loss Message Creation

7. Make a message "IOEXTENDER COM RETURN TO NORMAL"

Communication has been restored between Unity and the IOEXTENDER

Normal monitoring of the Primary AC Power Source has been restored.

Figure 27. IOEXTENDER Return To Normal Message Creation


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Figure 28. COM Loss Messages

8. Assign the COM LOSS message to the COS - ON of all outputs of the IOEXTENDER Points - EIM.

Figure 29. IOEXTENDER COM Loss Message Assignment


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9. Assign the RETURN TO NORMAL message to the NORMAL - EIM of the COMMU-NICATION Point.

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Figure 30. IOEXTENDER Return To Normal Message Assignment

8.2 Testing COM Loss Points With Unity Running:

1. Turn ON an output watch for the EIM and the alarm of the COMMUNICATION Point.

Figure 31. Primary AC Power Source COM Loss Message


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2. Turn OFF the same output point and watch for the EIM and the return to normal of the COMMUNICATION Point.

Figure 32. IOEXTENDER Return To Normal

3. Repeat this for all outputs.

4. Turn on all the outputs, look for the EIM and alarm - now power down the IOEXTENDER.

5. Watch for all of the inputs to go into alarm, all of the outputs are already ON, the alarm of the COM point, the EIM, and the loss of primary power events.

6. Restore power back to the IOEXTENDER.

7. Watch for all of the inputs to return to normal, all the outputs turn OFF, the return to normal of the COM point, the EIM, and the return to normal of primary power events.

8. Power down the IOEXTENDER again.

9. Watch for all of the inputs to go into alarm, all of the outputs go into alarm, the alarm of the COM point, the EIM, and the loss of primary power events.


11. Watch for all of the inputs to return to normal, all the outputs turn OFF, the return to normal of the COM point, the EIM, and the return to normal of primary power events.

12. Pull the cable off the COM port or the IOEXTENDER.

13. Watch for all of the inputs to go into alarm, all of the outputs go into alarm, the alarm of the COM point, the EIM, and the loss of primary power events.


15 Watch for all of the inputs to return to normal, all the outputs turn OFF, the return to normal of the COM point, the EIM, and the return to normal of primary power events.


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Figure 33. IOEXTENDER I/O Communication Loss

(9) Low Battery Setup

9.1 Low Battery Alarm Setup When the Unity Workstation is running on the backup battery power source the battery will eventually run down. This time is based on the power draw of the equipment being powered, as well as the reserve capacity of the UPS. The Low Battery Setup section shows you how to create and implement a warning message that will display when the UPS’s reserve capacity is approaching its minimum operable voltage. The steps are shown below:

With Unity Running:

1. Create a message "IOEXTENDER BU BATT LOW".

The Backup Power Source Battery at LOW CAPACITY!

***Less than 2 minutes remaining on Battery Power***

Figure 34. Battery Low Alarm Message


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2. Assign the BATT LOW message to the ALARM - EIM of the "Backup Battery Status" IOEXTEND points.

Figure 35. Assign Battery Low Message to an Alarm Event

3. Create a message "IOEXTENDER BU BATT LOW NORMAL".

The Backup Power Source Battery is at NORMAL charge level.

Figure 36. Backup Battery Normal Charge Level Message


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4. Assign the BATT LOW NORMAL message to the NORMAL - EIM of the "Backup Battery Status" IOEXTEND points.

Figure 37. Assign Battery Low Normal Message to a Normal Event

9.2 Testing Low Battery Alarm The following steps list the procedure to test the Low Battery Alarm.

With Unity Running:

1. Open the Pins for I/O #1 for Point - P34002 Backup Battery Status.

2. Check for alarming on the Backup Battery Status point and on the Summary Alarm Status point.

3. Check that the pop up message "IOEXTENDER BU BATT LOW" appears.

Figure 38 Backup Battery Low Message

4. Short the Pins for I/O #1 for Point - P34002 Backup Battery Status.

5. Check for return to normal on the Backup Battery Status point and on the Summary Alarm Status point.


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6. Check that the pop up message "IOEXTENDER BU BATT NORMAL" appears.

Figure 39. Backup Battery Normal Charge Level Popup Message

7. For this step you will need a stop watch, with everything normal state, all wiring in place, the AS400 card.

is in the UPS, UPS charged - remove power from the UPS and start the stop watch.

8. Check for Primary Power Loss indications as seen in the steps above.

9. Monitor time and watch for the Backup Battery Status point and Summary Alarm Status Points to ALARM, check for the message to pop up.

10. Stop the stop watch, quickly restore power back to the UPS.

11. Record the amount of time it took from a power loss to low battery - use this number as reference for approximate battery time in the event of a power loss.

12. Check for the return to normals on the Power Loss, BU Battery , and Summary Alarm Points.

13. Check for the Return To Normal message.


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(10) Bypass Setup

10.1 Bypass Alarm Setup With Unity Running:

1. Make a message "IOEXTENDER UPS BYPASS"

The Backup Power Source is in BYPASS! In the

Event of a power loss you will not be protected.

Figure 40. Bypass Message

2. Assign the BYPASS message to the ALARM - EIM of the "Bypass Mode Status" IOEXTEND points.

Figure 41. Assign Bypass Message to Alarm


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3. Make a message "IOEXTENDER UPS BYPASS NORMAL"

The Backup Power Source is supplying power from the UPS normally.

Figure 42. Bypass Normal Message

4. Assign the BYPASS NORMAL message to the NORMAL - EIM of the "Bypass Mode Status" IOEXTEND points.

Figure 43. Assign Bypass Normal Message


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10.2 Testing Bypass Alarm With Unity Running:

1. Open the Pins for I/O #2 for Point - P34003 Bypass Mode Status .

2. Check for alarming on the Bypass Mode Status point and on the Summary Alarm Status point.

3. Check that the pop up message "IOEXTENDER UPS BYPASS" appears.

Figure 44. UPS Bypass Mode Message

4. Short the Pins for I/O #1 for Point - P34003 Bypass Mode Status.

5. Check for return to normal on the Bypass Mode Status point and on the Summary Alarm Status point.

6. Check that the pop up message "IOEXTENDER UPS BYPASS NORMAL" appears.

Figure 45. UPS Bypass Normal Message

7. On the UPS press the OFF/BYPASS button for at least a « second.

CAUTION : IF YOU HIT THIS BUTTON AGAIN WITHIN 4 SECONDS THIS WILL CAUSE POWER TO BE SHUT OFF TO THE OUTPUT RECEPTACLES!!!!!

8. Check for the proper indications at the UPS (LED's and beeping).


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9. Check for alarming on the Bypass Mode Status point and on the Summary Alarm Status point.

10. Check that the pop up message "IOEXTENDER UPS BYPASS" appears.

11. On the UPS press the ON/ALARM SILENCE/MANUAL BATTERY TEST button for at least a « second.

12. Check for the proper indications at the UPS (LED's and beeping stopped).

13. Check for return to normal on the Bypass Mode Status point and on the Summary Alarm Status point.

14. Check that the pop up message "IOEXTENDER UPS BYPASS NORMAL" appears.

(11) UPS Internal Fault Setup

11.1 UPS Fault Alarm Setup With Unity Running:

1. Make a message "IOEXTENDER UPS Fault"

The Backup Power Source has a UPS Internal Fault

Consult UPS Indication for the source of the problem.

Figure 46. UPS Internal Fault Message


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2. Assign the UPS Fault message to the ALARM - EIM of the "UPS Fault Status" IOEXTEND points.

Figure 47. Assign UPS Internal Fault Message to Alarm

3. Make a message "IOEXTENDER UPS Fault Normal"

The Backup Power Source is clear of all internal faults.

Figure 48. UPS Internal Fault Normal Message


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4. Assign the UPS Fault NORMAL message to the NORMAL - EIM of the "UPS Fault Status" IOEXTEND points.

Figure 49. Assign UPS Internal Fault Normal

11.2 Testing UPS Fault Alarm With Unity Running:

1. Open the Pins for I/O #3 for Point - P34004 UPS Fault Status

2. Check for alarming on the UPS Fault Status point and on the Summary Alarm Status point.

3. Check that the pop up message "IOEXTENDER UPS Fault" appears.

Figure 50. IOEXTENDER UPS Fault Popup Message

4. Short the Pins for I/O #3 for Point - P34004 UPS Fault Status.

5. Check for return to normal on the Summary Alarm Status point and on the Summary Alarm Status point.


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6. Check that the pop up message "IOEXTENDER UPS Fault Normal" appears.

Figure 51. IOEXTENDER UPS Fault Normal Popup Message

7. Since this alarm is an internal alarm you can not test the true functionality of it. The UPS must have an internal fault for this one to come in.

(12) UPS Information/Operation This section shows the UPS switch operation as well as the three UPS modes; Normal Mode, Battery Mode, and Fault Mode.

12.1 UPS Switch Operation There are two buttons on the UPS. The upper button is the On/Alarm Silence/ Manual Battery Test Button and the lower button is the Off/ Bypass Button. Pressing the ON/Alarm Silence/ Manual Battery Test Button will start the UPS and provide conditioned power to the output sockets. Pressing the Off/ Bypass Button one time will cause the load to be transferred to bypass power.

Warning: Pressing the button again, within 4 seconds of the first press, will shut off power to the output sockets.


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Figure52. UPS Switch Operation

12.2 UPS Normal Mode During Normal Mode operation utility power provides electricity to the UPS to maintain

its batteries fully charged condition.

The UPS supplied power to the PC through its inverter and filter circuits.

Four green LEDs indicate, in 25% increments, the approximate load on the UPS.

If the UPS becomes loaded beyond its full rating, the fifth (amber) LED will illuminate and the UPS will sound an alarm.

Figure 53. UPS Normal Mode


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12.3 UPS Battery Mode Battery Mode indicates the percentage of usable battery power left. During Battery Mode an alarm sounds every 10 seconds. This will change to 2 beeps every 5 seconds when the battery runs low (approximately 2 minutes remaining).

Warning: Turning OFF the UPS will result in Total loss of power.

When the utility power is restored, the UPS resumes normal operation and the battery charger begins to recharge the battery.

Figure 54. UPS Battery Mode


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12.4 UPS Fault Mode Fault Mode indicates the type of fault the UPS has detected. Faults are noted by illuminating the red “Fault” LED or the yellow “E”, “Bypass”, or “Battery” LEDs. UPS faults will also cause an alarm beeper to sound, with different beep timing for different fault types. Fault conditions with beeper and LED indicators are listed below:

All LEDs On - On bypass due to output overload (beeper every 1/2 sec.)

A LED On - On bypass due to temperature condition (beep every 4 sec.)

B LED On - On bypass due to DC bus overvoltage (beep every 4 sec.)

C LED On - On bypass due to control power supply failure (beep every 4 sec.)

D LED On - On bypass due to PFC failure (beep every 4 sec.)

E LED On - On bypass due to inverter failure (beep every 4 sec.)

A&C LEDs On - UPS failed battery test (long beep every minute)

C&E LEDs On - UPS shutdown due to command from com port (SNMP) (no beep)

Figure 55. UPS Fault Mode


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(13) Fan Monitoring Setup for UL® Listed Switching Systems This section shows the setup and monitoring of the power supply fan for the Black Box® TotalSwitch 6 and 3COM® SuperStack II devices. These steps are required when these devices are used in UL® listed systems. Both the TotalSwitch 6 and SuperStack II have a post-factory-production, power supply fan monitoring board. This board, installed by Johnson Controls, is used to monitor for device overheating, due to failure of the power supply fan. The fan monitoring board only requires connection of a 12 VDC AC adapter for the I/O Adapter and 2 wires for monitoring purposes. A system digital point is required to monitor each device.

13.1 Power Supply Fan Monitoring Operation The fan monitoring board wiring, setup, and operation, for both the TotalSwitch 6 and SuperStack II, is identical. A digital point must be setup and wired to the power supply fan monitoring board to monitor the power supply fan’s status. When the digital point senses a change of state of the fan, an alarm is triggered. Event messages and alarm graphics, as well as an alarm in the alarm region are also displayed.

13.2 Programming the Fan Monitoring Points With Unity Running:

1. From the group that contains your Fan Monitor points (Figure56),TotalSwitch 6 and SuperStack, use the associated points in the group to program the following points:

Total Switch 6 Power Supply Fan - Alarm Only - Off/On (Figure 57)

SuperStack Power Supply Fan - Alarm Only - Off/On (Figure 58)

Figure 56. Edit Fan Monitoring Points Group

Figure 57. TotalSwitch 6 Point Figure 58. SuperStack Point


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The newly added points are shown below (Figure 59).

Figure 59. Calc Group After Programming Both Fan Monitor Points

2. Create a message "Total SW6 PS Fan Fail" that includes the following:

“The TotalSwitch 6 Power Supply Fan has failed!

1. Check to be sure the TotalSwitch 6 Power Supply Fan is not jammed.

2. Check to be sure the TotalSwitch 6 has 120 VAC power.

3. Check to be sure the 12VDC AC adapter for the I/O Extender Board.

is plugged into a working 120 VAC outlet.”

Figure 60. TotalSwitch 6 Power Supply Fan Fail Message Creation


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3. Create a message "TOTAL SW6 PS FAN RTN TO NML" that includes the following:

Power has been restored to the TotalSwitch 6 Power Supply Fan.

Normal monitoring of the TotalSwitch 6 Power Supply Fan is restored.

Figure 61. TotalSwitch 6 Power Supply Fan Return To Normal Message Creation

4. Create a message "SSTACK PS FAN FAIL" that includes the following:

The SuperStack Power Supply Fan has failed!

1. Check to be sure the SuperStack Power Supply fan is not jammed.

2. Check to be sure the SuperStack has 120 VAC power.

3. Check to be sure the 12VDC AC adapter for the I/O Extender Board.

is plugged into a working 120 VAC outlet.

Figure 62. SuperStack Power Supply Fan Fail Message Creation


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5. Create a message "SSTACK PS FAN RTN TO NML" that includes the following:

“SuperStack Power Supply Fan.

Returned To Normal Operation.”

Figure 63. SuperStack Power Supply Fan Return To Normal Message Creation

The newly created messages are shown below:

Figure 64. Fan Fail Messages


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6. Assign the Fan Fail message to the ALARM - ON of the TotalSwitch 6 point.

Figure 65. TotalSwitch 6 Fan Fail Message Assignment

7. Assign the RETURN TO NORMAL message to the NORMAL - OFF of the TotalSwitch 6 Point.

Figure 66. TotalSwitch 6 Return To Normal Message Assignment


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8. Assign the Fan Fail message to the ALARM - ON of the SuperStack point.

Figure 67. SuperStack Power Supply Fan Alarm Message Assignment

9. Assign the RETURN TO NORMAL message to the NORMAL - OFF of the SuperStack Point.

Figure 68. SuperStack Power Supply Fan Return To Normal Message Assignment


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13.3 Testing FAN FAIL Points With Unity Running:

1. Turn ON the TotalSwitch 6 Power Supply Fan Point, watch for the EIM (Figure 69) and notice the red Alarm state shown in the graphic (Figure 70).

Figure 69. TotalSwitch 6 Fan Fail Alarm Message

Figure 70. Power Supply Fan Monitoring Screen Showing The TotalSwitch 6 In Alarm

RED = Alarm


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2. Turn OFF the same TotalSwitch 6 Power Supply Fan Point, watch for the EIM (Figure 71) and the green Normal state in the graphic (Figure 72).

Figure 71. TotalSwitch 6 Power Supply Fan Return To Normal Message

Figure 72. TotalSwitch 6 Power Supply Fan Return To Normal Graphic

GREEN = Normal


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3. Unplug the 12 VDC AC adapter for the I/O Extender.

Note: Up to 8 devices can be monitored using a single I/O Extender. When power to the I/O Extender is lost, all connected devices will fail. This means that both the TotalSwitch 6 and SuperStack will go into alarm.

4. Watch for the inputs to go into alarm, the outputs turn ON, the alarm of the FAN FAIL points, the EIMs.

5. Plug in the 12 VDC AC adapter for the I/O Extender.

6. Watch for the inputs to return to normal, the outputs to turn OFF, the return to normals of the FAN FAIL points, the EIMs.

Documents

Appendix K: I/O Extender...2001/02/16 · Copy TDUMP.EXE to the IOEXT01 Directory. 5. Change the COM port to the correct COM port number (leave everything else alone). A. From the