TROX GmbH TCU3 Universal Controller User Manual

TROX GmbH Heinrich Trox Platz D-47504 Neukirchen Vluyn
TROX UNIVERSAL CONTROLLER TCU3

General
Wiring Notes
TROX UNIVERSAL
Controller TCU3

Last update
19. February 2024

TCU3 Universal Controller

Notes
The options contained in these wiring instructions can be activated and parameterized with the EasyConnect software. It is not possible to set the controller parameters individually at the factory.
Applicable documents
Further information see leaflets and assembly instructions of
– TROX UNIVERSAL Controller TCU3
– Expansion modules EM-TRF or EM-TRF-USV, EM-LON, EM-AUTOZERO, EM-BAC-MOD-01, EM-IP
– Sensors/Transducers for room and duct pressure control
– Control panel BE-LCD, CP-TOUCH

General safety instructions

Recognised codes of engineering practice, especially the safety requirements and accident prevention regulations must beobserved when performing all assembly, wiring and commissioning procedures.
Only specially trained and qualified personnel are permitted to perform the assembly, wiring and commissioning.
The electrical installations must be implemented in compliance with the current valid EN / VDE / DIN and local electrical regulations.
Danger:
Electric shock by touching live parts.
Electrical devices may cause electrical hazards during operation
Before installation/assembly works begin:
Disconnect all poles or switch off supply voltage of TROX UNIVERSAL controller.
Protect power supply against unauthorised or unintended restart.
All installation operations may only start after these safety operations.

Exterior sockets / Indicators:

Interior sockets / Indicators:

1 Red error indicator
2 Yellow indicator – Network termination activated 3 Green indicator (Reserved)
4 Yellow indicator CL-Network data received
5 Green indicator Controller operation (Heartbeat)
6 Socket X1 DI1 – Sash contact 500 mm
7 Socket X2 Control panel 1
8 Socket X3 Control panel 2
9 Socket X4 A04 Actuator
10 Socket X5 AI5 – Face velocity transducer
11 Socket X6 Communication line 1 – RJ45
12 Socket X7 Communication line 2 – RJ45
14 Socket Magnetic valve EM-AUTOZERO
15 Socket AI1 for internal volume flow transducer
16 Expansion slot for LonWorks®, BACnet, Modbus interface with EM-LON, EM-BAC- MOD-01| 17 Optical status indicators of digital inputs
18 Activation switch for CL network termination
19 Screw terminals for communication line 1
20 Screw terminals for communication line 2
21 PE connection
22 Clamp / Connection pad for cable shield
23 Screw terminals Analogue inputs AI1…AI4
24 connection digital actuator
25 Screw terminals Digital inputs DI2…DI6
26 Screw terminals Analogue outputs AO1…AO3
27 Screw terminals Power supply 24 V AC / DC
28 Screw terminals Digital outputs DO1… D06
29 Green indicator 24 V ok
30 Connection pad for Expansion module mains supply
31 Optical indicators for switching state of digital outputs
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Please observe installation orientation

Explanation:
The TROX UNIVERSAL controller TCU3 may only be installed as follows:
at horizontal ducts: (Left image part)
The installation is only approved at the duct sides – an installation above or below the duct is not allowed.
at vertical ducts: (Right image part)
In this case all installation orientations are approved.
**** The descripted installation orientation must be applied.
Otherwise accurate volume flow measuring is not possible.

Power supply

Supply voltage 24 V AC / DC

Technical data:
– Supply voltage 24 V AC ± 15% 50-60 Hz
– Supply voltage 24 V DC ± 15%
– Fuse 2A slow, 250 V; glass tube fuse 5×20 mm
– Power consumption up to 40 VA (Maximum configuration)
Maximum power consumption is determined by the individual controller configuration.
Typical configurations will lead to following values:

Important wiring instructions:
Observe polarity
Polarity of DC and AC supply voltage has to be strictly complied for all contollers during wiring.
Never connect 24 V AC and DC at same time
Limited wiring in a row
Power supply wiring in a row (via double terminals) is only approved for a maximum of 5 controllers!
Supply voltage at analogue inputs for supply of sensor/transducer
Type of used controller power supply (AC/DC) will influence type of provided power supply at analogue inputs:
TCU3 Power suppy 24 V AC → Provided sensor supply at AI1-AI5 is 24 V AC
TCU3 Power suppy 24 V DC → Provided sensor supply at AI1-AI5 is 24 V DC
This may require attention for connected sensors.

Mains supply voltage 230 V AC

Alternative power supply
** (only with expansion module EM-TRF or EM-TRF-USV)
Technical data:**
– Supply voltage 230 V AC +- 20% 50-60 Hz
– Fuse 500 mA slow , 250 V
– Power consumption up to 40 VA (Maximum configuration)

Important wiring instruction:
– Never connect 230 V and 24 Vsupply voltage simultaneous at one controller.
– Never connect 24 V supply voltage at controller with built in expansion module
EM-TRF or EM-TRF-USV
Supply voltage at analogue inputs for supply of sensor/transducer
TCU3 Power suppy 230V AC→ Provided sensor supply at AI1-AI5 is 24 V DC
(with EM-TRF, EM-TRF-USV)
This may require attention for connected sensors.

Communication line (CL)
For Plug- & Play data exchange between the controllers within one TROX UNIVERSAL CONTROLLER system

Technical data:
– Maximum device no. within one system: 24
– Maximum total length: 300 m
– Network cable type SF-UTP (braid + foil shield) according ISO IEC 11801 (2002) patch cable with RJ45 plug connectors on both sides or cable from a reel; e.g. Cat 5
– Activate termination resistor at the beginning and the end of the controller communication line CL.

Note:
Use always green patch cables for the communication line CL
Aim: Simple determination of communication line cable (green) and control panel connecting cable (blue)

CL – Connection sockets and indicators

Termination indicator
Yellow = Termination active Off = Termination inactive
Data receiption CL
Yellow / blinking = Data received
Heartbeat
Green slow blinking = Normal controller operation
Green off = Device not operable
Default socket communication line 1
Default socket communication line 2

CL – Termination resistor

Termination of communication line CL
** For a correct data exchange of the controllers is a termination on both ends of the communication line required.
Communication line (CL)**
CL – Screw terminals as an alternative wiring option:
For data exchange via network cable from a reel as an alternative to patch cables

Important wiring note:
For port COMM1 or COMM2 on one controller use either the RJ45 sockets withpatch cable or the screw terminals with network cable from a reel to built up the communication line CL.

Technical data:
– Maximum device no. within one system: 24
– Maximum total length: 300 m
– Network cable type SF-UTP (braid + foil shield) according ISO IEC 11801 (2002) cable on a reel; e.g. Cat 5
– Activate termination resistor at the beginning and the end of the controller communication line CL.

Wiring notes:
– Uses either screw terminals or RJ45 sockets of one controller.
– Use always two cores for each signal
– Use clamp to contact cable shielding with shielding contact area on the controller PCB

Wire assignment as follows:

GND
COMM_H
COMM_L| blue and white/blue
white/orange and white/green
orange and green

Communication system – Communication line (CL) and it’s termination

Important notes for system design
– Up to 24 TROX UNIVERSAL controller can be connected together
RS: supply air controller RE: exhaus air controller
PRS: room pressure controller supply air, PRE: room pressure controller exhaust air,
PDS: duct pressure controller supply air, PDE: duct pressure controller exhaust air
– Any order of devices at communication line is allowed
– Maximum length of the communication line CL: 300m.
– Use network cable type SF-UTP acc. ISO IEC 11801 (braid+foil shielded e.g. CAT 5)
– Communication line termination at the beginning and the end by activating the switch COMM-Terminator on the TROX UNIVERSAL CONTROLLER main board (see examples below)

Room-Management-Function

The Room-Management-Function (RMF) is a software option to realize room based functions with the TROX UNIVERSAL CONTROLLER System:
– Centralized interchange point for wiring of room functions
– Connection of room control panels
– Centralized configuration of room parameters and functions
– Monitioring of room functions

Technical data:
– RMF can be acitvated on any TROX UNIVERSAL CONTROLLER (Supply or Extract air) .
– RMF activation is only allowed on exactly one TROX UNIVERSAL CONTROLLER in a system of max. 24 controller.
– RMF can be activated with the TROX UNIVERSAL CONTROLLER configuration software EasyConnect V8.0 and higher.
RMF relevance for wiring
The selection of the controller with RMF is relevant for the wiring of room based functions and signals. An Exception are the pressure controller room and duct. All pressure relevant parts have to connected directly to the pressure controller.
Following signals and the room control panel have to be connected at the controller with the RMF:

Connection of control panels

Note:
Use always blue patch cables for the control panels
Aim:
Simple determination of communication line cable (green) and control panel connecting cable (blue)

Room control panel:

Technical data:
– Useable only at room controllers with activated Room-Management-Function
– Admitted is only control panel type BE-LCD and CP-TOUCH
– Up to two control panels can be connected to one controller
– 5 m connection cable blue included in the delivery
– Optionallly connection cable up to 40 m useable:
Network cable type SF-UTP acc. ISO IEC 11801 (braid+foil shielded) with RJ45 connectors on both sides, e.g. patch cable Cat 5
– Plug in connection cable on back side of control panel

Note:
Room control panels can only be used at room controllers with activated Room- Management-Function (RMF).
Connection of TCU3 and PC for TROX EasyConnect-Software

Complete package 1:
Order Code: EasyConnect-CAB
EasyConnect Software +
Configuration cable + USB-RS485 Adaption module +
Programming adapter (For System EASYLAB requires)
TROX Number: B588NF4
Complete package 2:
Order Code: EasyConnect-BC
Alternatively you can use the Bluetooth Adaption module BlueCON for a wireless connection between TROX UNIVERSAL CONTROLLER and PC with EasyConnect software. The BlueCON module replaces the USB-RS485 Adaption module and the cable.
EasyConnect Software + Bluetooth Adaption module BlueCON + Programming adapter (For System EASYLAB requires)
TROX Number: B588NF5

Connection via control panels

Connection directly via TROX UNIVERSAL controller

Digital inputs (DI) / Digital outputs (DO)

Digital inputs DI1 … DI6

Connector for DI1:
– Phoenix MC 1,5/ 2-ST-3,5 Phoenix-No. 1840366 (included in the delivery)
Trox material number: A00000040301
– Phoenix MCVR 1,5/ 2-ST-3,5 Phoenix-No. 1863152 (by customer)
– Phoenix MCVW1,5/ 2-ST-3,5 Phoenix-No. 1862852 (by customer)

Digital outputs DO1 … DO6

Technical data:
Electrical rating of contacts and pcb: 230 V AC max. 8 A
Additional note to alarm relay effect:
Alarm relay released → Alarm state
Alarm relay activated → No alarm state

Analogue inputs (AI) / Analogue outputs (AO)

Analogue inputs AI1 … AI5

Technical data:
– Input voltage range 0-10 V DC
– Characteristic freely configurable
– Input resistance > 100kOhm

Connector for AI5:
– Phoenix MC 1,5/ 3-ST-3,5 Phoenix-No. 1701879 (included in the delivery)
Trox material number: A00000040302
– Phoenix MCVR 1,5/ 3-ST-3,5 Phoenix-No. 1863165 (by customer)
– Phoenix MCVW 1,5/ 3-ST-3,5 Phoenix-No. 1862865 (by customer)

Analogue outputs AO1 … AO4

Technical data:
– Output voltage range 0-10 V DC
– Characteristic freely configurable
– Maximum output load 10 mA

Connector for AO4:
– Phoenix MVSTBR 2,5 /3-ST-5,08 Phoenix-No. 1792252 (included in the delivery)
Trox material number: M516EE1

Terminal 3 (connection TROX HPD)

Important note:
Actuator TROX HPD may be connected only to terminal 3!

Input / Output assigment – Volume flow controller supply and exhaust air (RS/RE)

Digital inputs DI

DI 1| not used
DI 2| not used| (Default at RMF: Room operation mode – reduced mode (Vmin))
DI 3| not used| (Default at RMF: Room operation mode – high mode (Vmax))
DI 4| not used| (Default at RMF: Room operation mode – shut off mode)
DI 5| not used| (Default at RMF: Room operation mode – open mode)
DI 6| not used| (Default at RMF: Room operation mode – Standard mode(variable)
DI2 – DI6 Room operation mode setting could only configure on the RMF. The last switched-on state is adopted (push-button function).
If the switch function is desired, DI6 must be wired permanently.
The state of the inputs could be transmitted by the expansion module LON / BACnet / MODBUS
Digital outputs D0

DO 1| Alarm relay (1)
DO 2| interior light – On / Off over room control panel (only at RMF, if configured; else unused )
DO 3| Sun blind – Open (only at RMF, always activ at RMF, else unused )
DO 4| Sun blind – Close (only at RMF, always activ at RMF, else unused )
DO 5| Room mode dependent ( if configured; else unused )
DO 6| Room mode dependent ( if configured; else unused )
(1) Alarm state = Relay released
Unused outputs relays could be energized via the expansion module LON / BACnet / MODBUS
Analogue inputs AI

AI 1| Internal volume flow transducer| (current volume flow measurement)
AI 2| External room volume flow setpoint| (only at RMF)
AI 3| unused| integration of variable volume flow (characteristic configurable)
AI 4| unused| integration of variable volume flow (characteristic configurable)
AI 5| unused| integration of variable volume flow (characteristic configurable)
Unused inputs can be configured with EasyConnect software for integration of variable volume flow into room balance
Analogue outputs AO

AO 1| Current volume flow of controller
AO 2| Volume flow setpoint for tracking controller (only at RMF, output characteristic configurable )
AO 3| Damper position of controller
AO 4| Damper actuator

Input / Output assigment –room pressure controller (PRS/PRE)

Digital inputs DI

DI 1| Door contact| (configurable; else not used, without function)
DI 2| not used| (Default at RMF: Room operation mode – reduced mode (Vmin))
DI 3| not used| (Default at RMF: Room operation mode – high mode (Vmax))
DI 4| not used| (Default at RMF: Room operation mode – shut off mode)
DI 5| not used| (Default at RMF: Room operation mode – open mode)
DI 6| not used| (Default at RMF: Room operation mode – Standard mode(variable)
DI2 – DI6 Room operation mode setting could only configure on the RMF. The last switched-on state is adopted (push-button function).
If the switch function is desired, DI6 must be wired permanently.
The state of the inputs could be transmitted by the expansion module LON / BACnet / MODBUS
Digital outputs D0

DO 1| Alarm relay (1)
DO 2| interior light – On / Off over room control panel
DO 3| Sun blind – Open (only at RMF, always activ at RMF, else unused )
DO 4| Sun blind – Close (only at RMF, always activ at RMF, else unused )
DO 5| Room mode dependent ( if configured; else unused )
DO 6| Room mode dependent ( if configured; else unused )
(1) Alarm state = Relay released
Unused outputs relays could be energized via the expansion module LON / BACnet / MODBUS
Analogue inputs AI

AI 1| Internal volume flow transducer (current volume flow measurement) (only with option V)
AI 2| External room volume flow setpoint (only at RMF)
AI 3| unused integration of variable volume flow (characteristic configurable)
AI 4| External setpoint room pressure
AI 5| Current Room pressure sensor
Unused inputs can be configured with EasyConnect software for integration of variable volume flow into room balance
Analogue outputs AO

AO 1| Current volume flow of controller (only with option V)
AO 2| Current room pressure
AO 3| Damper position of controller
AO 4| Damper actuator

Input / Output assigment – Room Controller
Note:
Some assignments are only available on room controllers with activated Room- Management-Function (RMF)

Digital inputs DI

DI 1| Not used
DI 2| not used| (Default at RMF: Room operation mode – reduced mode (Vmin))
DI 3| not used| (Default at RMF: Room operation mode – high mode (Vmax))
DI 4| not used| (Default at RMF: Room operation mode – shut off mode)
DI 5| not used| (Default at RMF: Room operation mode – open mode)
DI 6| not used| (Default at RMF: Room operation mode – Standard mode(variable)
DI2 – DI6 Room operation mode setting could only configure on the RMF. The last switched-on state is adopted (push-button function).
If the switch function is desired, DI6 must be wired permanently.
The state of the inputs could be transmitted by the expansion module LON / BACnet / MODBUS
Digital outputs D0

DO 1| Alarm relay (1)
DO 2| interior light – On / Off over room control panel
DO 3| Sun blind – Open (only at RMF, always activ at RMF, else unused )
DO 4| Sun blind – Close (only at RMF, always activ at RMF, else unused )
DO 5| Room mode dependent ( if configured; else unused )
DO 6| Room mode dependent ( if configured; else unused )
(1) Alarm state = Relay released
Unused outputs relays could be energized via the expansion module LON / BACnet / MODBUS
Analogue inputs AI
AI 1| Internal volume flow transducer (current volume flow measurement) (only with option V)
AI 2| External room volume flow setpoint (only at RMF, if configured; else unused)
AI 3| unused integration of variable volume flow (characteristic configurable)
AI 4| External setpoint room pressure
AI 5| Current Room pressure sensor
Unused inputs can be configured with EasyConnect software for integration of variable volume flow into room balance
Analogue outputs AO

AO 1| Current volume flow of controller (only with option V)
AO 2| Current duct pressure
AO 3| Damper position of controller
AO 4| Damper actuator

Special functions – TROX UNIVERSAL CONTROLLER

Control of on-site provided sun blind control device (only at room controller with activated RMF)

Control of on-site provided lighting / device (only at room controller with activated RMF)

For safety reasons the TCU3 casing must be locked in such a way that it can only be opened with a tool when a 230 V power supply is connected.
A safety latch with a sticker is available, which can be ordered under EM-TRF- Zubehoer (A00000055540).
When delivered with transformer module EM-TRF or EM-TRF-USV, this is installed and is not required additionally.

Room mode depending switching

Notes: Function is not available if sun blind control is activated Activation and setting of the function with EasyConnect configuration software

Integration of variable volume flows into room balance

Notes: Function is available on all unused analogue inputs AI by connecting an analogue signal with 0-10 V.
Configuration of function setting with EasyConnect configuration software
Analogue input, characteristic and required volume flow values (Extract or supply air) which should be integrated into the room balance must be configurated .

External setpoint room volme flow, room pressure or duct pressure

pressure control
– room Pressure or duct pressure control via supply or exhaust air controller
– Current pressure signal integrateable via analogue signal 0-10V; Characteristic configurable
– 1 fix setpoit configurable within the controller
– variable Setpoint pressure via analogy signal 0-10 or 2-10 V (AI4) or alternativ via expansion modul LonWorks®, BACnet MS/TP, Modbus-RTU, BACnet IP, Modbus IP
– Special functions via door switch contact at DI1 configurable (Alarmhandling, Ccontrol behaviour)
– current values about room or duct pressure via analogy signal 0-10 or 2-10 V (AI4) or alternativ via expansion modul LonWorks®, BACnet MS/TP, Modbus-RTU Schnittstelle, BACnet IP, Modbus IP
– all connections and configurations for the pressure controll have to be done at the related pressure controller

System design – Pressure control
Example 1: RMF-Function activated on pressure controller

Example 2: RMF-Function activated on other room volume flow controller

Pressure control connections:

Power supply for pressure transducer
The power supply of the pressure transducer can be provided by the EASYLAB TCU3 via 24V connector of analogue input X5 AI Sensor.
Important:
TCU3 supplied with 24 V AC → Connector 24V of X5 AI Sensor provides 24V AC
TCU3 supplied with 24 V DC → Connector 24V of X5 AI Sensor provides 24V DC
TCU3 supplied with 230V AC → Connector 24V of X5 AI Sensor provides 24V DC.
The above mentioned different supply voltage types must be observed depending on selected pressure transducer type.

Huba Pressure transducer type 699
This transducer is approved for AC and DC power supply type.
Therefore no adaption is required.
Briem Pressure transducer type GB604 MF 0,75
This transducer is approved for AC and DC power supply type.
Therefore no adaption is required.
Old Briem transducer must be manually adapted to the power supply type.
Default delivery setting ist AC supply.
Using a 230 V AC supply for the TCU3 via EM-TRF or EM-TRF-USV or 24 V DC supply implies a manual change of the supply to DC type.
Therefore change jumper setting from AC to DC within the Briem transducer casing.

Tubing

LonWorks®-Interface
(Expansion module EM-LON)

Technical data:
– LonWorks®-Interface FT10
– Network structure: Free Topology / Twisted Pair
– Simple network integration via internal connected double terminals
– Service-Key
– Status-LED for Service key, data transmission and data reception
– Mounting of expansion module within TROX UNIVERSAL controller
– Supply voltage 5 V DC provided by TROX UNIVERSAL controller
– Each network segment must be terminated with network terminator
– The maximum number of network devices is based on the LonWorks® specifications from Echelon. There are no additional restrictions by TROX.
Data interface: Standard Network Variable Types (SNVT)
– Different data points according to controller device type:
Room controller / room controller with activated Room-Management- Function (RMF) or room / duct pressure controller with or without RMF Usage on controller with activated RMF
-> Access to data points of room Usage on controller without RMF
-> Access to data points of single controller

Connection assignment:

1. Expansion module EM-LON
2. LON-B
3. LON-A
4. Shield
5. Network cable(s)
6. LON-B
7. LON-A
8. Shield

Network cable types:
Following cable types are recommended for LonWorks®-networks by Echelon:
TIA 568A Category 5
– 8471 oder 85102 (Belden)
– Level IV cable
– JY(St)Y 2x2x0,8 (use only twisted wire pairs for LON-A and LON-B)
For more details see assembly and operating instruction manual of EM-LON.
The EM-LON extension module is only available as a spare part since 2022 (note availability of goods).

BACnet MS/TP interface Modbus RTU interface
(Expansion module EM-BAC-MOD-01)
Technical data:
– BACnet MS/TP interface or Modbus RTU interface selectable via configuration switch
– Configurable network address and communication parameter
– Simple network integration via internal connected double terminals
– Status-LED for display of data transfer and communication error
– Mounting of expansion module within TROX UNIVERSAL controller box
– Supply voltage 5 V DC provided by TROX UNIVERSAL controller
– Current regulations for network design and number of network device must be observed: BACnet Standard 135-2004 Modbus according EIA-485
In particular this includes:
– Network topology with simple line structure
– Usage of twisted pair copper cables with shielding
– Compliance of polarity A- and B+ for all network devices
– 120 Ohm resistor for network termination at first and last network device
– Network BIAS resistor for BACnet networks
– Max. 32 network devices in each network segment
– Configuration of individuell network address for each device
Data interface:
– BACnet objects according PICS documentation or Modbus data registers
– Different data points according to controller device type:
Room controller / room controller with activated Room-Management Function (RMF) or room / duct pressure controller with or without RMF
Usage on controller with activated RMF
-> Access to data points of room
Usage on controller without RMF
-> Access to data points of single controller
Connection assignment:

1. Expansion module EM-BAC-MOD-01
   PCB illustration differs a little from original; (Screw terminal representation is correct, see photo above)

2. B+ EIA-485

3. A- EIA-485

4. Shielding

5. Network cables

6. B+ EIA-485

7. A- EIA-485

8. Shielding

Further details can be found in the mounting and operating instructions for the EM-BACMOD expansion module.

BACnet IP interface Modbus IP interface
(Expansion module EM-IP)
Technical data:
– BACnet IP interface or Modbus IP interface selectable via configuration switch
– Configurable network address and communication parameter
– Two RJ45 10/100Mbit Ethernet connection socket. (daisy chain connection up to 5 EM-IP cards possible).
– Status-LED for display of data transfer and communication error
– Mounting of expansion module within TROX UNIVERSAL controller box
– Supply voltage 5 V DC provided by TROX UNIVERSAL controller
– Current regulations for network design and number of network device must be observed:
In particular this includes:
– Network topology
– Usage of Patch cable cat 5e with shielding
– Max 100 m cable length
Data interface:
– BACnet objects according PICS documentation or Modbus data registers
– Different data points according to controller device type:
Room controller / room controller with activated Room-Management
Function (RMF) or room / duct pressure controller with or without RMF
Usage on controller with activated RMF
-> Access to data points of room
Usage on controller without RMF
-> Access to data points of single controller

Further details can be found in the mounting and operating instructions for the EM-IP expansion module.

Documents / Resources

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