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026-1901 Rev 0 12-11-00

DCX Control System


Hardware Installation Guide
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1640 Airport Road, Suite 104
Kennesaw, GA 31044
Phone: (770) 425-2724
Fax: (770) 425-9319
ALL RIGHTS RESERVED.
The information contained in this manual has been carefully checked and is believed to be accurate. However, Com-
puter Process Controls, Inc. assumes no responsibility for any inaccuracies that may be contained herein. In no event will
Computer Process Controls, Inc. be liable for any direct, indirect, special, incidental, or consequential damages resulting
from any defect or omission in this manual, even if advised of the possibility of such damages. In the interest of continued
product development, Computer Process Controls, Inc. reserves the right to make improvements to this manual, and the
products described herein, at any time without notice or obligation.
READ ALL INSTRUCTIONS CAREFULLY before attempting to install or operate the DCX control sys-
tem.
SAVE THIS INSTRUCTION MANUAL This instruction manual contains important operating instruc-
tions for the DCX control system.
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DCX I&O Manual Table of Contents v
Table of Contents
1 OVERVIEW OF THE DCX CONTROL SYSTEM ............................................................................................... 1-1
1.1. DCX EXPANDIBILITY ........................................................................................................................................... 1-1
1.2. DCX SOFTWARE ................................................................................................................................................... 1-1
1.3. DCX DOCUMENTATION ........................................................................................................................................ 1-1
2 DCX HARDWARE OVERVIEW ............................................................................................................................ 2-1
2.1. THE DCX CONTROLLER ....................................................................................................................................... 2-1
2.2. DCX EXPANSION BOARD ..................................................................................................................................... 2-2
2.3. SENSORS AND TRANSDUCERS ............................................................................................................................... 2-2
2.3.1. Temperature Sensors ..................................................................................................................................... 2-2
2.3.2. Product Simulators ....................................................................................................................................... 2-2
2.3.3. Pressure Transducers ................................................................................................................................... 2-2
2.3.4. Power Monitoring Devices ........................................................................................................................... 2-2
2.3.5. Light Level Sensor ......................................................................................................................................... 2-3
3 HARDWARE MOUNTING ...................................................................................................................................... 3-1
3.1. DCX MOUNTING .................................................................................................................................................. 3-1
3.1.1. Environmental Conditions ............................................................................................................................ 3-1
3.2. DCX EXPANSION BOARD ..................................................................................................................................... 3-1
3.2.1. Environmental Conditions ............................................................................................................................ 3-2
3.3. SENSORS AND TRANSDUCERS ............................................................................................................................... 3-2
3.3.1. Space Temperature/Humidity Sensor ............................................................................................................ 3-2
3.3.2. Bullet Sensors ................................................................................................................................................ 3-2
3.4. PRESSURE TRANSDUCERS ..................................................................................................................................... 3-3
3.4.1. Mounting ....................................................................................................................................................... 3-3
3.5. POWER MONITORING DEVICES ............................................................................................................................. 3-3
3.6. LIGHT LEVEL SENSORS ........................................................................................................................................ 3-3
4 DCX HARDWARE INSTALLATION .................................................................................................................... 4-1
4.1. POWERING THE DCX UNIT .................................................................................................................................. 4-1
4.2. POWERING THE DCX EXPANSION BOARD ........................................................................................................... 4-1
4.3. EXPANSION BOARD NETWORKING ....................................................................................................................... 4-2
4.3.1. Expansion Board Numbering ........................................................................................................................ 4-2
5 INPUT AND OUTPUT SETUP ................................................................................................................................ 5-1
5.1. TEMPERATURE SENSORS ...................................................................................................................................... 5-1
5.2. COMBINATION SPACE TEMP/HUMIDITY SENSOR ................................................................................................. 5-3
5.3. PRESSURE TRANSDUCERS ..................................................................................................................................... 5-4
5.4. POWER TRANSDUCER INPUTS ............................................................................................................................... 5-5
5.5. LIGHT LEVEL SENSOR WIRING ............................................................................................................................. 5-6
5.6. DRY CONTACT DIGITAL INPUTS ........................................................................................................................... 5-7
5.7. 24VAC/24VDC DIGITAL INPUTS ......................................................................................................................... 5-7
5.8. 110/230VAC DIGITAL INPUTS ........................................................................................................................... 5-11
5.9. CONNECTING THE ANALOG OUTPUTS ................................................................................................................ 5-12
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5.10. CONNECTING THE DIGITAL (RELAY) OUTPUTS ................................................................................................ 5-13
5.10.1. Relay Supply Voltage ................................................................................................................................ 5-13
5.10.2. Relay Contact Wiring ................................................................................................................................ 5-14
6 SUPERVISORY SYSTEM SETUP .......................................................................................................................... 6-1
6.1. SUPERVISORY SYSTEM HARDWARE CONFIGURATION .......................................................................................... 6-1
6.1.1. On-Site DCX to PC Configuration ................................................................................................................ 6-1
6.1.2. Modem Communication ................................................................................................................................ 6-2
6.1.3. Continuing Supervisory System Setup ........................................................................................................... 6-3
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DCX Expandibility Overview of the DCX Control System 1-1
1 Overview of the DCX
Control System
The DCX is a multi-purpose programmable
microcontroller designed to offer customized,
flexible distributed control for refrigeration and
HVAC applications in a low-cost package.
The DCX control unit combines the capabili-
ties of a central refrigeration or HVAC controller
with built-in analog and digital inputs and out-
puts, allowing it to handle most small control
applications without additional I/O boards or
peripherals. For larger applications, the DCX
may also be networked with other DCX control-
lers and expansion boards.
The DCX is sold in three models: the DCX-S
(small), the DCX-M (medium), and the DCX-L
(large). Each model is practically identical
except for the maximum amounts of inputs and
outputs. In addition, each model may be ordered
with either a 4x20 character LCD display or with
no display. Table 1-1 shows the DCX models
available and the maximum number of analog
and digital inputs and outputs each model pro-
vides.
1.1. DCX Expandibility
If a site application requires more input and
output points than a single DCX can provide, a
DCX-L control unit may be networked with up
to four expansion boards. Each expansion board
provides an additional 8 temperature sensor
inputs, 8 digital inputs, and 8 relay outputs.
Expansion boards are networked together using
an RS485 serial network.
1.2. DCX Software
Software for the DCX is custom written by
CPC for specific controls applications. Typi-
cally, the DCX is ordered as a specific controller
type and shipped with the appropriate software
pre-loaded. For example, a customer who orders
a CSx Convenience Store Controller would
receive a DCX control unit with the CSx appli-
cation software loaded into the DCXs memory.
Hardware-wise, the CSx unit would be identical
to every other DCX-based application offered by
CPC. The characteristics unique to the CSx
would be its capabilities and the configuration of
its input and output points.
1.3. DCX Documentation
All DCX-based controllers purchased from
CPC will come with a set of user documents:
DCX Installation and Operation Guide (this
manual) - The DCX Installation and Opera-
tion Guide covers the basics of setting up the
DCX hardware, including mounting, sensor
wiring, and expansion board networking.
P/N Model Relay Outputs Analog
Outputs
Analog In-
puts
Digital In-
puts
818-0000 DCX-S (Small) with no display 8 (7 N.O., 1 Form C) 4 5 8
818-0005 DCX-S (Small) with display 8 (7 N.O., 1 Form C) 4 5 8
818-0010 DCX-M (Medium) with no dis-
play
13 (10 N.O., 3 Form C) 4 8 14
818-0015 DCX-M (Medium) with display 13 (10 N.O., 3 Form C) 4 8 14
818-0020 DCX-L (Large) with no display 18 (13 N.O., 5 Form C) 6 10 18
818-0025 DCX-L (Large) with display 18 (13 N.O., 5 Form C) 6 10 18
Table 1-1 - DCX Controller Unit Model
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1-2 DCX Installation and Operation Manual 026-1901 Rev 0 12-11-00
Application Guide - The Application Guide
is specifically written for the software on the
DCX. Several different application guides
exist for the various DCX-based software
available from CPC. The Application Guide
covers software setup, alarm information,
screen navigation, and operation.
I/O Setup Sheet - Each DCX, based on both
the software application and the customers
specific site configuration, will be supplied
with an I/O Setup Sheet, which specifically
shows where each temperature sensor, digital
input, and relay output must be connected on
the DCX and its expansion boards.
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The DCX Controller DCX Hardware Overview 2-1
2 DCX Hardware Overview
2.1. The DCX Controller
The DCX Controller (shown in Figure 2-1)
handles all controlling and alarm handling for
the system. All three modelsthe DCX-S, the
DCX-M, and the DCX-L (pictured)have sev-
eral on-board input and output points for use in
controlling. For larger applications, the DCX
unit can be networked with I/O expansion
boards, and can also be connected to a modem or
a serial card. Refer to Table 1-1 on page1 for
part numbers and models available.
1
Power Connector
2
Power and Alarm LEDs
3
250VAC, 2A slow-blow fuse
(T2A)
4
Universal Analog Inputs
5
Passive Analog Inputs (for
temperature sensors and dry
contact ON/OFF inputs only)
6
Analog Outputs (0-10V)
7
Digital Inputs, 24VAC or
24VDC
8
Digital Inputs, 24VAC,
24VDC or 230VAC
9
Synoptic Terminal Connector
10
Standard Terminal Connector
11
Relay Digital Outputs
12
I/O Expansion Module Con-
nector (DCX-L only)
13
Network Connection to other
DCXs or expansion boards
(connector, LED, and address
dip switch)
14
Serial Card Hatch
15
Printer Card Hatch
16
Expansion Memory Card
Hatch
17
Display and Terminal Buttons
Figure 2-1 - DCX Controller (DCX-L Model Shown)
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2-2 DCX Installation and Operation Manual 026-1901 Rev 0 12-11-00
2.2. DCX Expansion Board
The DCX Expansion Board (P/N 818-0505)
networks with a DCX control unit and adds 8
digital inputs, 8 analog inputs, and 8 relay out-
puts to the total number of I/O points the DCX
has access to. Up to four DCX Expansion
Boards can be networked with a DCX.
2.3. Sensors and Transduc-
ers
CPC offers a wide range of ambient tempera-
ture, product temperature, relative humidity, and
other types of input devices.
2.3.1. Temperature Sensors
The DCX uses several different models of
temperature sensors for a number of different
applications. All DCX-compatible temperature
sensors are NTC 10k thermistors, and may be
connected to any universal analog inputs (B1-B3
and B6-B8 on the DCX) and any passive analog
inputs (B4, B5, B9, and B10 on the DCX, and
B1-B8 on the Expansion Board).
2.3.1.1. Space Temperature/Humidity
Sensor
CPC offers a combination space tempera-
ture/RH sensor (P/N 501-1210) provided in a
wall-mount enclosure. This sensor can be used
to measure both temperature and humidity, or
only one of the two. The humidity and tempera-
ture leads are separate and must be connected to
different universal analog outputs on the DCX
(B1-B3 and B6-B8).
2.3.1.2. Bullet Sensors
CPC offers a single generic "bullet" style
sensor (P/N 501-1202) for general use in tem-
perature monitoring and control applications.
The sensor is a 10K thermistor sealed in water-
resistant neoprene rubber. It may be mounted as
an ambient air sensor, in ducts or air streams for
use as a discharge or return air sensor, or for sev-
eral other uses.
2.3.2. Product Simulators
2.3.3. Pressure Transducers
The DCX control system has three different
models of pressure transducers for use in refrig-
eration applications. Table 2-1 lists the transduc-
ers available.
2.3.4. Power Monitoring Devices
CPC supplies a range of power transducers
and current transformers to use for monitoring
power usage. Table 2-2 lists the available trans-
ducers and the line voltages they are designed to
work with.
NOTE: The DCX is not compatible with most stan-
dard sensors and transducers supplied with CPC RE-
FLECS and Einstein systems. Use ONLY sensors and
transducers listed in this section with DCX systems.
Part No. Power Transducer
800-0010 Pressure Transducer, 0-100 PSI
800-0015 Pressure Transducer, 0-362 PSI
800-0020 Pressure Transducer, 0-435 PSI
Table 2-1 - Pressure Transducer Models
Part No. Power Transducer
250-4010 120V line-to-neutral, 208V line-to-line, 60
Hz 3 phase watt transducer, internally pow-
ered.
250-4020 277V line-to-neutral, 480V line-to-line, 60
Hz 3 phase watt transducer, with 120V aux-
iliary power to transducer required
250-4030 277V line-to-neutral, 480V line-to-line, 60
Hz 3 phase watt transducer, with 208V aux-
iliary power to transducer required.
Table 2-2 - Power Monitoring Devices
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Sensors and Transducers DCX Hardware Overview 2-3
2.3.5. Light Level Sensor
For controlling lights and other devices
based on the outside light level, the DCX uses a
low-voltage analog light level sensor (P/N 206-
0002).
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DCX Mounting Hardware Mounting 3-1
3 Hardware Mounting
3.1. DCX Mounting
The DCX is designed to be mounted on a
standard DIN rail. The DCX-S requires 13 DIN
modules, and the DCX-M and DCX-L requires
18 DIN modules.
To mount, press the back of the unit against
the DIN rail to snap it into place. To remove the
unit from the DIN rail, use a screwdriver to lift
the tabs at the bottom of the unit.
Mounting dimensions are shown in Figure
3-1.
3.1.1. Environmental Conditions
The DCX must be mounted in an environ-
ment with an ambient temperature between 32
122F (050C). If the DCX does not have a
display terminal, the ambient temperature may
be between 14140F (-1060C). In either
case, the relative humidity must be below 90%,
non-condensing.
Additionally, avoid installing the DCX in an
operating environment with any of the following
characteristics:
strong vibrations or bumps
exposure to continuous jets of water
exposure to aggressive and polluting environments
(e.g. sulphuric and ammoniac gases, saline mists,
fumes) with consequent corrosion or oxidation
high levels of magnetic and/or radio frequency inter-
ference
exposure to direct sunlight
large and rapid fluctuations in temperature
environments where explosive or flammable gases
are present
exposure to excessive dust
3.2. DCX Expansion Board
The DCX Expansion Board is typically
mounted in the same location or enclosure as the
DCX, but may also be mounted remotely to
shorten I/O device wire lengths. The Expansion
Board comes with a set of fasteners and metal
stand-offs for mounting in a panel or wall. Refer
to the dimensions in Figure 3-2 when mounting
the board.
Figure 3-1 - DCX Mounting Dimensions
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3.2.1. Environmental Conditions
The DCX Expansion Board must be
mounted in an environment with an ambient
temperature between 14131F (-1055C),
with a relative humidity below 90%, non-con-
densing.
3.3. Sensors and Transduc-
ers
3.3.1. Space Temperature/Humidi-
ty Sensor
Space temperature and space humidity sen-
sor enclosures should be mounted in a central
location within the zone to be measured
away from doors, windows, vents, heaters, and
outside walls that could affect temperature or
humidity readings. The sensor should be
between 4 and 6 feet from the floor.
To mount the sensor, use a screwdriver to
press in the tab on the left side of the sensor
enclosure, and lift the cover off the enclosure.
Use the two mounting holes on the back panel to
screw the sensor enclosure onto a flat surface.
Dimensions of the enclosure and the mount-
ing holes are given in Figure 3-3.
3.3.2. Bullet Sensors
The mounting and placement of bullet sen-
sors will depend on their intended use. There are
no specific restrictions for sensor use.
Figure 3-2 - DCX Expansion Board Mounting
Figure 3-3 - Space Temperature/Humidity Sensor Mounting
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Pressure Transducers Hardware Mounting 3-3
3.4. Pressure Transducers
3.4.1. Mounting
The fitting on the DCX Pressure Transducer
is 1/4" female NPT. If the access fitting is con-
figured with a Schrader valve or a 1/4" female
port, this must be replaced with a 1/4" male fit-
ting in order to support connection to the DCX
Pressure Transducer.
Wrap the threads of the male access fitting
with Teflon tape to ensure a tight seal. Screw the
transducer onto the access valve. Tighten with a
wrench on the hex nut. Do NOT use the trans-
ducer casing to apply torque.
3.5. Power Monitoring Devic-
es
The CPC Power Transducer is designed to
mount on a standard DIN rail. Press the rear of
the transducer enclosure against the DIN rail
until it snaps into place.
Instructions for mounting, placement, and
wiring of the transducers current transformers
are provided in the installation instructions pro-
vided with the CPC Power Transducer.
3.6. Light Level Sensors
The Light Level Sensor should be mounted
facing north, for locations in the northern hemi-
sphere, away from direct sunlight. For locations
in the southern hemisphere, the Light Level Sen-
sor should be mounted facing south.
CPC does not supply mounting hardware
with the light level sensor. The sensor should be
mounted horizontally through the knockout of a
standard weather-resistant junction box. Figure
3-4 shows a typical mounting configuration.
Figure 3-4 - Light Level Sensor Mounting
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Powering the DCX Unit DCX Hardware Installation 4-1
4 DCX Hardware Instal-
lation
4.1. Powering the DCX Unit
All three models of the DCX unit require a
24VAC non-center-tapped Class 2 power supply,
rated to at least 50VA. CPC supplies two 50VA
transformers for use with powering the DCX
unit: one for use with 110VAC ( P/N 640-0041)
and one for use with 220VAC ( P/N 640-0042).
Table 4-1 lists the non-center-tapped transform-
ers currently offered by CPC.
Wire the transformers secondary to the G
and G0 terminals, located on the bottom left side
of the unit as shown in Figure 4-1. Make sure
the earth ground is connected to terminal G0.
4.2. Powering the DCX Ex-
pansion Board
The DCX Expansion Board requires a
24VAC non-center-tapped Class 2 power supply,
rated to at least 50VA. Table 4-1 lists all trans-
formers available from CPC that may be used to
power a DCX Expansion Board.
Wire the transformers secondary to the G
and G0 terminals (J17), located on the bottom
left side of the board as shown in Figure 4-2.
Make sure the earth ground is connected to ter-
minal G0.
NOTE: Several of the DCXs digital inputs require
a 24VAC supply in order to operate. You may wish to
connect the 24VAC secondary to a terminal strip so that
digital inputs can use the DCXs power source.
Figure 4-1 - DCX Unit Power Wiring
Xformer
P/N
VA Rating Input Voltage
640-0039 10 VA 110 VAC
640-0041 50 VA 110 VAC
640-0042 50 VA 220 VAC
640-0056 56 VA Multi-tap (120/208/
240 VAC)
640-0050 75 VA 110 VAC
640-0045 75 VA 220 VAC
640-0080 80 VA Multi-tap (120/208/
240 VAC)
Table 4-1 - Transformers Compatible with the DCX and DCX
Expansion Board
Figure 4-2 - DCX Expansion Board Power Wiring
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4.3. Expansion Board Net-
working
A single DCX-L unit may network with up
to four DCX Expansion Boards. Expansion
boards are wired in a daisy chain beginning at
terminal J23 on the DCX-L and extending to
each of the expansion boards, as shown in - DCX
Expansion Board Networking and Wiring on
page 2.
Use Belden 8641 two-conductor shielded
cable for networking. Use one wire to intercon-
nect all "+" terminals and the other to intercon-
nect all "-" terminals. Connect the bare SHIELD
wire to the GND terminals.
4.3.1. Expansion Board Number-
ing
If more than one DCX Expansion Board is
being used by a DCX-L, the boards must be
given unique network address numbers. Expan-
sion boards must be addressed with a board
number from 2 to 5 (the DCX itself is considered
"Board 1." The network address allows the DCX
to recognize and communicate with each DCX
Expansion Board.
The state of digital inputs AD0 and AD1 on
terminal block J3 determine the boards network
number. Each possible ON/OFF combination of
these two inputs corresponds to a number from
one to four (see Table 4-2).
To wire input AD0 or AD1 ON, supply
24VAC voltage to the input from the boards
power supply. The terminal blocks common ter-
minal, IDCM2, must also be connected to the
ground side of the power supply (G0). Refer to
Figure 4-4.
Figure 4-3 - DCX Expansion Board Networking and Wiring
Board Number AD0 AD1
2 (default) OFF OFF
3 ON OFF
4 OFF ON
5 ON ON
Table 4-2 - Board Numbers and AD0/AD1 States
Figure 4-4 - Wiring AD0 and AD1 To Set Board Number
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Temperature Sensors Input and Output Setup 5-1
5 Input and Output Set-
up
A DCX-based controller is shipped with its
inputs and outputs pre-configured, tailored to
your specific site configuration. That means you
will not have to specify the location of inputs
and outputs in the system software.
The controller will be shipped with an I/O
Configuration Sheet that shows all the inputs and
outputs for the DCX and its expansion boards,
and which input or output points each device
should be connected to. Refer to this sheet when
wiring inputs and outputs, and refer to this man-
ual for wiring instructions for each of the possi-
ble sensor types.
5.1. Temperature Sensors
All temperature sensing devices for the
DCX, except the combination Space Temp/
Space Humidity Sensor, have two-wire input
point connections, as shown in Figure 5-1. One
of these wires must be connected to an analog
input point (B1-B10 on the DCX, or B1-B8 on
the DCX Expansion Board). The other wire must
be connected to a common terminal for the ana-
log input terminal block. Table 5-1 shows where
to make each wire connection based on the point
your I/O Configuration Sheet says to connect the
sensor to.
Figure 5-1 - Temperature Sensor Wiring
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When wiring remotely mounted temperature
sensors to the DCX control system, use Belden
8761, 22AWG shielded twisted pair cable or
equivalent.
Point on
I/O Config
Sheet
Wire One
Temp Sensor
Lead To:
Wire Other
Temp Sensor
Lead To:
DCX CONTROL UNIT
B1 J2-B1 J2-GND
B2 J2-B2 J2-GND
B3 J2-B3 J2-GND
B4 J3-B4 J3-BC4
B5 J3-B5 J3-BC5
B6 J6-B6 J6-GND
B7 J6-B7 J6-GND
B8 J6-B8 J6-GND
B9 J20-B9 J20-BC9
B10 J20-B10 J20-BC10
DCX Expansion Board
B1 J2-B1 J2-AVSS (any term.)
B2 J2-B2 J2-AVSS (any term.)
B3 J2-B3 J2-AVSS (any term.)
B4 J2-B4 J2-AVSS (any term.)
B5 J2-B5 J2-AVSS (any term.)
B6 J2-B6 J2-AVSS (any term.)
B7 J1-B7* J2-AVSS (any term)
B8 J1-B8* J2-AVSS (any term)
* If using B7 or B8 on the Expansion Board, do NOT connect
the second lead to the middle terminal (+24Vdc) on J1. Con-
nect the second lead to any AVSS terminal on J2.
Table 5-1 - NTC Temperature Sensor Point Wiring
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Combination Space Temp/Humidity Sensor Input and Output Setup 5-3
5.2. Combination Space Temp/Humidity Sensor
The Combination Space Temp/Humidity
Sensor has two signal leads, a lead for DC
power, and a ground lead. Table 5-2 shows
where to make each wiring connection based on
the points your I/O Configuration Sheet says to
connect the sensor to. When wiring remotely
mounted sensors to the DCX control system, use
Belden 8771 three-conductor 22AWG wire or
equivalent. Use the shield (BARE) wire to make
the ground connection.
Figure 5-2 - Combination Space Temp/Humidity Sensor Wiring
Point on
I/O Config
Sheet
Wire OUT H (Humidity)
or OUT T (Temperature)
Sensor Terminal To:
Wire +(G) Sensor
Terminal To:
Wire M Sensor
Terminal To:
DCX CONTROL UNIT
B1 J2-B1 J2-VDC J2-GND
B2 J2-B2 J2-VDC J2-GND
B3 J2-B3 J2-VDC J2-GND
Table 5-2 - Combination Space Temp/Humidity Input Point Wiring
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5.3. Pressure Transducers
B6 J6-B6 J2-VDC J6-GND
B7 J6-B7 J2-VDC J6-GND
B8 J6-B8 J2-VDC J6-GND
DCX Expansion Board
No input points on DCX Expansion Boards support pressure transducer inputs
Figure 5-3 - Pressure Transducer Input Wiring
Point on
I/O Config
Sheet
Wire OUT H (Humidity)
or OUT T (Temperature)
Sensor Terminal To:
Wire +(G) Sensor
Terminal To:
Wire M Sensor
Terminal To:
DCX CONTROL UNIT
Table 5-2 - Combination Space Temp/Humidity Input Point Wiring
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Power Transducer Inputs Input and Output Setup 5-5
DCX pressure transducers have a 4-20mA
output range and a two-wire polarity sensitive
output connection. The WHITE lead is con-
nected to the signal terminal, and the BROWN
lead is connected to the VDC terminal, which
supplies voltage to the transducer.
Table 5-3 shows where to make each wire
connection based on the point your I/O Configu-
ration Sheet says to connect the sensor to. When
wiring remotely mounted pressure transducers to
the DCX control system, use Belden 8761,
22AWG shielded twisted pair cable or equiva-
lent.
5.4. Power Transducer Inputs
The power transducer models supplied with
DCX-based control systems have 0-5VDC ana-
log outputs that signify the current KW reading.
The output of the power transducer is connected
from terminals 15 and 16 of the power trans-
ducer to one of the analog inputs on the DCX
(B1-B3, or B6-B8) (Figure 5-4).
Table 5-4 shows where to make each wire
connection based on the point your I/O Configu-
ration Sheet says to connect the sensor to. When
wiring remotely mounted power transducers to
the DCX control system, use Belden 8761,
22AWG shielded twisted pair cable or equiva-
lent.
Point on
I/O Config
Sheet
Wire WHITE
Lead To:
Wire BROWN
Lead To:
DCX CONTROL UNIT
B1 J2-B1 J2-VDC
B2 J2-B2 J2-VDC
B3 J2-B3 J2-VDC
B6 J6-B6 J2-VDC
B7 J6-B7 J2-VDC
B8 J6-B8 J2-VDC
DCX Expansion Board
No input points on DCX Expansion Boards sup-
port pressure transducer inputs
Table 5-3 - DCX Control Unit Pressure Transducer
Figure 5-4 - DCX Power Transducer Wiring
Point on
I/O Config
Sheet
Wire Terminal
15 To:
Wire Terminal
16 To:
DCX CONTROL UNIT
B1 J2-B1 J2-GND
B2 J2-B2 J2-GND
B3 J2-B3 J2-GND
Table 5-4 - DCX Control Unit Power Transducer
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5-6 DCX Installation and Operation Manual 026-1901 Rev 0 12-11-00
5.5. Light Level Sensor Wir-
ing
The PD5 Light Level sensor has a four-wire
connection. The output wires carry a 0-10VDC
signal to the DCX analog input signifiying the
current light level. The sensor requires 12-
24VDC supply voltage to operate, which is pro-
vided by the +VDC terminal on the DCX. (See
Figure 5-5).
Table 5-5 shows where to make each wire
connection based on the point your I/O Configu-
ration Sheet says to connect the sensor to. When
wiring remotely mounted light level sensors to
the DCX control system, use Belden 8761,
22AWG shielded twisted pair cable or equiva-
lent.
B6 J6-B6 J2-GND
B7 J6-B7 J2-GND
B8 J6-B8 J2-GND
DCX Expansion Board
No input points on DCX Expansion Boards support
power transducer inputs
Point on
I/O Config
Sheet
Wire Terminal
15 To:
Wire Terminal
16 To:
DCX CONTROL UNIT
Table 5-4 - DCX Control Unit Power Transducer
Figure 5-5-Light Level Sensor Wiring Diagram
Point on I/O
Config Sheet
Wire RED
and
YELLOW
to
Wire
GREEN
to
Wire
BLACK
to
DCX CONTROL UNIT
B1 J2-B1 J2-GND J2-VDC
B2 J2-B2 J2-GND J2-VDC
B3 J2-B3 J2-GND J2-VDC
Table 5-5 - DCX Control Unit Power Transducer
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Dry Contact Digital Inputs Input and Output Setup 5-7
5.6. Dry Contact Digital In-
puts
A dry contact digital input is defined as
any ON/OFF input that carries no voltage or cur-
rent. An example of this might be a relay or
switch that simply opens or closes a circuit loop
(such as a defrost termination sensor or override
switch).
Digital inputs have a two-wire polarity
insensitive output connection. Table 5-6 shows
where to connect each lead based on the point
listed on your I/O Configuration Sheet. When
wiring remotely located dry contact digital
inputs, use Belden 8761, 22AWG shielded
twisted pair cable or equivalent.
5.7. 24VAC/24VDC Digital In-
puts
The majority of digital inputs on a DCX con-
trol unit or a DCX Expansion Board are config-
ured to recognize a 24VAC or 24VDC input
signal as ON, and 0V (open) state as OFF. To
wire inputs such as door switches, clean
switches, or thermostats to these digital inputs,
they must be wired in such as way as to provide
a 24VAC or 24VDC signal when CLOSED.
Figure 5-7 and Figure 5-8 show how to wire
digital input devices to 24VAC and 24VDC
inputs. For 24VAC devices, the power supply for
the DCX or the DCX Expansion Board may be
used to provide the signal voltage. For 24VDC
devices, a separate 24VDC power supply must
be used.
B6 J6-B6 J2-GND J2-VDC
B7 J6-B7 J2-GND J2-VDC
B8 J6-B8 J2-GND J2-VDC
DCX Expansion Board
No input points on DCX Expansion Boards support
power transducer inputs
Figure 5-6 - Dry Contact Digital Input Sensor Wiring
Point on I/O
Config Sheet
Wire RED
and
YELLOW
to
Wire
GREEN
to
Wire
BLACK
to
DCX CONTROL UNIT
Table 5-5 - DCX Control Unit Power Transducer
Point on
I/O Config
Sheet
Wire One
Lead To:
Wire Other
Lead To:
DCX CONTROL UNIT
B4 J3-B4 J3-BC4
B5 J3-B5 J3-BC5
B9 J20-B9 J20-BC9
B10 J20-B10 J20-BC10
DCX Expansion Board
No input points on DCX Expansion Boards sup-
port dry contact digital inputs
Table 5-6 - DCX Control Unit Dry Contact Digital Input
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5-8 DCX Installation and Operation Manual 026-1901 Rev 0 12-11-00
Table 5-7 lists the 24VAC and 24VDC inputs
on the DCX and DCX Expansion Board, and
where each lead should be connected based on
the point listed on your I/O Configuration Sheet.
Figure 5-7 - Wiring Digital Inputs to 24VAC Source
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24VAC/24VDC Digital Inputs Input and Output Setup 5-9
Figure 5-8 - Wiring Digital Inputs to 24VDC Source
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5-10 DCX Installation and Operation Manual 026-1901 Rev 0 12-11-00
Point on I/O Config Sheet Wire One Lead To: Wire Other Lead To:
DCX CONTROL UNIT
ID1 J5-ID1* 24VAC or 24VDC supply
ID2
J5-ID2
* 24VAC or 24VDC supply
ID3
J5-ID3
* 24VAC or 24VDC supply
ID4
J5-ID4
*
24VAC or 24VDC supply
ID5
J5-ID5
*
24VAC or 24VDC supply
ID6
J5-ID6
*
24VAC or 24VDC supply
ID7
J5-ID7
*
24VAC or 24VDC supply
ID8
J5-ID8
*
24VAC or 24VDC supply
ID9
J7-ID9
**
24VAC or 24VDC supply
ID10
J7-ID10
**
24VAC or 24VDC supply
ID11
J7-ID11
**
24VAC or 24VDC supply
ID12
J7-ID12
**
24VAC or 24VDC supply
ID13
J8-ID13

24VAC or 24VDC supply


ID14
J8-ID14

24VAC or 24VDC supply


ID15
J19-ID15

24VAC or 24VDC supply


ID16
J19-ID16

24VAC or 24VDC supply


ID17
J20-ID17

24VAC or 24VDC supply


ID18
J20-ID18

24VAC or 24VDC supply


DCX Expansion Board
ID1
J4-ID1

24VAC or 24VDC supply


ID2
J4-ID2

24VAC or 24VDC supply


ID3
J4-ID3

24VAC or 24VDC supply


ID4
J4-ID4

24VAC or 24VDC supply


ID5
J4-ID5

24VAC or 24VDC supply


ID6
J3-ID6

24VAC or 24VDC supply


ID7
J3-ID7

24VAC or 24VDC supply


ID8
J3-ID8

24VAC or 24VDC supply


* If any input on J5 is used, connect terminal IDC1 to neutral or ground side of the 24VAC/VDC power
**
If any input on J7 is used, connect terminal IDC9 to neutral or ground side of the 24VAC/VDC power

If any input on J8 is used, connect terminal IDC13 to neutral or ground side of the 24VAC/VDC power

If any input on J19 is used, connect terminal IDC15 to neutral or ground side of the 24VAC/VDC power

If any input on J20 is used, connect terminal IDC17 to neutral or ground side of the 24VAC/VDC power

If any input on J4 is used, connect terminal IDCM1 to neutral or ground side of the 24VAC/VDC power

If any input on J3 is used, connect terminal IDCM2 to neutral or ground side of the 24VAC/VDC power
Table 5-7 - Point Wiring for 24VAC/VDC Digital Inputs
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110/230VAC Digital Inputs Input and Output Setup 5-11
5.8. 110/230VAC Digital In-
puts
Certain digital inputs on the DCX and the
DCX Expansion Board may be supplied with a
signal voltage between 110VAC and 230VAC.
Figure 5-9 shows how to wire 110-230VAC
inputs on the DCX. Note that inputs ID13
through ID16 on the DCX have two separate
input terminals, one for use with 24 VAC/VDC
and one for use with 110-230VAC.
Figure 5-10 shows how to wire 110-230VAC
inputs on the DCX Expansion Board. Note the
terminal on inputs ID11R and ID12R where the
singal voltage must be connected is labeled
ID230 for both inputs, while the ID11R and
ID12R terminals are connected to neutral.
Table 5-8 lists the 110-230VAC inputs on the
DCX and DCX Expansion Board, and where
each lead should be connected based on the
point listed on your I/O Configuration Sheet.
Figure 5-9 - 110-230VAC Digital Input Wiring - DCX
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5.9. Connecting the Analog
Outputs
The DCX and DCX Expansion Board has
several outputs with a 0-10VDC analog output
range, which are powered externally at 24VAC
or 24VDC. To use the analog outputs, you must
make a connection to the signal and ground ter-
minals of the analog output point and supply
24VAC or 24VDC to the output terminals (as
shown in Figure 5-11).
Figure 5-10 - 110-230VAC Digital Input Wiring - DCX
Expansion Board
Point on
I/O Config
Sheet
Wire One
Lead To:
Wire Other
Lead To:
DCX CONTROL UNIT
ID13H
J8-ID13H
*
110-230VAC Line
Voltage
ID14H
J8-ID14H
*
110-230VAC Line
Voltage
ID15H
J19-ID15H
**
110-230VAC Line
Voltage
Table 5-8 - DCX Control Unit Dry Contact Digital Input
ID16H
J19-ID16H
**
110-230VAC Line
Voltage
DCX Expansion Board
ID11R J21-ID230
terminal (above
the ID11R
terminal)

110-230VAC Line
Voltage
ID12R J21-ID12R
terminal (below
the ID12R
terminal)

110-230VAC Line
Voltage
*
If either ID13H or ID14H are being used, connect J8-ID13C to neutral side of
110-230VAC power source.
**
If either ID15H or ID16H are being used, connect J19-ID15C to neutral side
of 110-230VAC power source.

If ID11R is used, connect terminal J21-ID11R to neutral side of 110-230VAC


power source.

If ID12R is used, connect terminal J21-ID12R to neutral side of 110-


230VAC power source.
Point on
I/O Config
Sheet
Wire One
Lead To:
Wire Other
Lead To:
DCX CONTROL UNIT
Table 5-8 - DCX Control Unit Dry Contact Digital Input
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Connecting the Digital (Relay) Outputs Input and Output Setup 5-13
Table 5-9 lists the 0-10VDC analog inputs
on the DCX and DCX Expansion Board, and
where each lead should be connected based on
the point listed on your I/O Configuration Sheet.
5.10. Connecting the Digital
(Relay) Outputs
The DCX and the DCX expansion boards
have electromechanical digital relay outputs,
each of which is rated to a maximum of 8 amps.
Supply voltage for relay outputs may be 24VAC
or any voltage between 110VAC and 230VAC.
5.10.1.Relay Supply Voltage
Each relay output terminal block on the
DCX (J12-J18, J21-J22) and the DCX Expan-
sion Board (J5, J6, J22, and J24) must use the
same supply voltage source for all its relays, due
to the fact the line voltage for all relays on a ter-
minal block are supplied from the same terminal.
For example, in Figure 5-12, terminal block J12
has a common terminal (C1) that connects to an
AC power source. All terminals on J12 (NO1,
NO2, and NO3) will use this same power source.
Figure 5-11 - Wiring Analog Outputs on the DCX
Point on
I/O Config
Sheet
Wire
POSITIVE
terminal to:
Wire NEGATIVE
terminal to:
DCX CONTROL UNIT
Y1
J4-Y1
*
J4-VG0
Y2
J4-Y2
*
J4-VG0
Y3
J4-Y3
*
J4-VG0
Y4
J4-Y4
*
J4-VG0
Y5
J20-Y5
*
J4-VG0
Y6
J20-Y6
*
J4-VG0
DCX Expansion Board
Y0 J20-Y0
**
J20-VG0
Y1 J20-Y1
**
J20-VG0
*
If any analog input on terminal block J4 or J20 is being used, connect J4-VG
to a 24VAC or 24VDC power source.
**
If either analog input Y0 or Y1 is being used, connect J20-VG1 to a 24VAC
or 24VDC power source.
Table 5-9 - DCX Analog Output Wiring
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If other terminal blocks will use the same power
source, you can jumper their common terminals
together, as shown in Figure 5-12, where termi-
nal C1 of J12 is jumpered to C4 of terminal J13.
5.10.2.Relay Contact Wiring
Though all digital outputs use the same type
of relays, there are two different types of relay
contacts. Some relay contacts may only be wired
as Normally Open (N.O.), while some may be
wired as either Normally Open or Normally
Closed (N.C.). Contacts that may be wired as
either N.O. or N.C. consist of three terminals: a
common (C) terminal where the supply voltage
is connected, an NO terminal for normally open
connection, and an NC terminal for normally
closed connection. The output device must be
connected to either the NO or the NC relay,
depending on whether you want the relay
CLOSED or OPEN during power outages.
Table 5-10 lists the relay analog inputs on
the DCX and DCX Expansion Board, and where
each output lead should be connected based on
the point listed on your I/O Configuration Sheet,
as well as which common terminals should be
connected to a 24VAC or 110-230VAC power
source.
Figure 5-12 - DCX Relay Output Wiring
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Connecting the Digital (Relay) Outputs Input and Output Setup 5-15
Point on I/O
Config Sheet
Wire One Output
Lead To:
Wire Other Output Lead To: Wire 24VAC or
110-230VAC to:
DCX CONTROL UNIT
NO1 J12-NO1 24VAC or 110-230VAC NEUTRAL J12-C1
NO2 J12-NO2 24VAC or 110-230VAC NEUTRAL
NO3 J12-NO3 24VAC or 110-230VAC NEUTRAL
NO4 J13-NO4 24VAC or 110-230VAC NEUTRAL J13-C4
NO5 J13-NO5 24VAC or 110-230VAC NEUTRAL
NO6 J13-NO6 24VAC or 110-230VAC NEUTRAL
NO7 J14-NO7 24VAC or 110-230VAC NEUTRAL J14-C7
NO8
NC8
J15-NO8
J15-NC8
24VAC or 110-230VAC NEUTRAL J15-C8
NO9 J16-NO9 24VAC or 110-230VAC NEUTRAL J16-C9
NO10 J16-NO10 24VAC or 110-230VAC NEUTRAL
NO11 J16-NO11 24VAC or 110-230VAC NEUTRAL
NO12/NC12 J17-NO12/NC12 24VAC or 110-230VAC NEUTRAL J17-C12
NO13/NC13 J18-NO13/NC13 24VAC or 110-230VAC NEUTRAL J18-C13
NO14/NC14 J21-NO14/NC14 24VAC or 110-230VAC NEUTRAL J21-C14
NO15/NC15 NO15/NC15 24VAC or 110-230VAC NEUTRAL J21-C15
NO16 NO16 24VAC or 110-230VAC NEUTRAL J22-C16
NO17 NO17 24VAC or 110-230VAC NEUTRAL
NO18 NO18 24VAC or 110-230VAC NEUTRAL
DCX Expansion Board
NO1/NC1 NO1/NC1 24VAC or 110-230VAC NEUTRAL J5-C1
NO2/NC2 NO2/NC2 24VAC or 110-230VAC NEUTRAL J6-C2
NO3/NC3 NO3/NC3 24VAC or 110-230VAC NEUTRAL J6-C3
NO4/NC4 NO4/NC4 24VAC or 110-230VAC NEUTRAL J24-C4
NO5/NC5 NO5/NC5 24VAC or 110-230VAC NEUTRAL J24-C5
NO6/NC6 NO6/NC6 24VAC or 110-230VAC NEUTRAL J24-C6
NO7/NC7 NO7/NC7 24VAC or 110-230VAC NEUTRAL J22-C7
NO8/NC8 NO8/NC8 24VAC or 110-230VAC NEUTRAL J22-C8
Table 5-10 - Point Wiring for 24VAC/VDC Digital Inputs
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Supervisory System Hardware Configuration Supervisory System Setup 6-1
6 Supervisory System
Setup
A supervisory system is a software program
that runs on a PC, which is capable of remote
communication with one or more DCX-based
controllers. A supervisory system allows users to
program controllers and override control func-
tions using an easy-to-use Windows interface. A
supervisory system may also be used to collect
alarm dial-outs from one or more modem-
enabled DCX sites.
Supervisory system programs are custom
made to work with only one specific type of
DCX-based control software. In other words,
CSX Supervisory System software can only
communicate with CSX C-Store Controllers,
etc.
6.1. Supervisory System
Hardware Configuration
A DCX can interface with a supervisory sys-
tem in either of two ways. A DCX-based con-
troller can be directly connected via RS485
cable to an on-site desktop PC or touchscreen
running the supervisory system software. Or, the
DCX can be configured with a modem and
phone line, and the supervisory system can use
the PCs modem to connect with the DCX from
off-site.
6.1.1. On-Site DCX to PC Configu-
ration
On-site connection of a DCX to a Supervi-
sory System PC requires an RS485 expansion
card installed into the "SERIAL CARD" port on
the DCX control unit. For an on-site configura-
tion, CPC supplies a kit which includes the
RS485 card, an RS485-to-serial interface box,
the Supervisory System software, and a special
key which plugs in to the 25-pin serial port on
the PC that will run the software. See Figure 6-
1.
6.1.1.1. Wiring the RS485 Cable
Using an approved RS485 communication
cable (Belden 8641 or equivalent), connect the
DCXs RS485 network card to the converter box
as shown in Figure 6-2. The Rx+/Tx+ terminal
on the network card connector should be con-
nected to the Rx+/Tx+ terminal on the converter
box. Likewise, the two Rx-/Tx- should be inter-
connected. Use the cable shield wire to connect
the two GND terminals.
Figure 6-1 - Overview of RS485 On-Site Supervisory System
Figure 6-2 - RS485 Cable Wiring for Supervisory System
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6-2 DCX Installation and Operation Manual 026-1901 Rev 0 12-11-00
Termination
Both ends of the RS485 cable, starting with
the Converter Box and ending with the last
device on the chain, must be terminated with a
120-ohm resistor. The Converter Box is already
terminated, so you do not need to connect a
resistor to that end of the cable.
Locate the device at the end of the network
opposite the Converter box, and place a 120-
ohm, 1/4 W resistor in parallel with the Rx+/Tx+
and Rx-/Tx- minus terminals, as shown in Fig-
ure 6-3.
6.1.1.2. Powering the Converter Box
The Converter Box requires power in order
to operate. The kit supplied with the Supervisory
System software will include a plug-in DC
adapter. Plug the adapter into a 110VAC outlet,
and connect the DC adapter plug to the converter
boxs POWER jack.
6.1.1.3. Connecting the Converter Box
to the PC
Connecting the converter box to the PC
requires at least one free 9-pin serial port on the
PC. Alternately, if a 25-pin serial port is avail-
able on the PC, the cable can be connected there
using a 9-to-25 pin adapter.
6.1.1.4. Connecting the Supervisory
System Key to the PC
The Supervisory System Key must be
plugged into a parallel port on the PC that will
be running the software. The software checks for
this key at start-up, and will not function if the
key is not present.
6.1.2. Modem Communication
Enabling Supervisory System communica-
tion via modem requires both the DCX and the
Supervisory System to have access to a modem
and phone line. The kit supplied with the Super-
visory Software for modem connection consists
of only the RS232 Serial Card, the Supervisory
System Key, and the software diskettes. All
modems and serial cables must be supplied by
the customer.
6.1.2.1. Wiring the Modem to the DCX
The RS232 Serial Card has a standard 9-pin
connector compatible with standard store-bought
serial cables. Connect the serial cable to the
modem and the RS232 port on the DCX.
Consult the modem documentation for infor-
mation on how to power the modem and how to
connect the modem to a phone line.
6.1.2.2. Connecting the Supervisory
System Key to the PC
The Supervisory System Key must be
plugged into a 25-pin parallel port on the PC that
will be running the software. The software
checks for this key at start-up, and will not func-
tion if the key is not present.
Figure 6-3 - RS485 Supervisory System Network Termination
Figure 6-4 - DCX Supervisory System Modem Configuration
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Supervisory System Hardware Configuration Supervisory System Setup 6-3
6.1.3. Continuing Supervisory Sys-
tem Setup
After the hardware is set up, both the DCX
and the PC with the Supervisory System soft-
ware must be further configured with certain
parameters that will allow it to communicate.
Because the software is different for each DCX-
based controller version, information about set-
ting up the software in both the controller and
the PC are covered in the controllers program-
ming guide. Refer to this manual for more infor-
mation.
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DCX Installation and Operation Manual Index 1-1
Index
A
Access Fitting 3-3
Analog Outputs
connecting 5-12
B
Board Numbering 4-2
Board, DCX Expansion 2-2
C
Communication, Modem 6-2
Converter Box 6-2
D
DCX
DCX-L(large) 1-1
DCX-M(medium) 1-1
DCX-S(small) 1-1
defined 1-1
diagram 2-1
display size 1-1
documentation 1-1
environmental conditions
3-1
expandibility 1-1
hardware installation 4-1
models 1-1
mounting 3-1
overview of system 1-1
powering 4-1
software 1-1
Digital Inputs
110/230VAC wiring 5-11
24VAC/24VDC wiring 5-7
dry contact wiring 5-7
Digital Outputs
connecting 5-13
Form C Wiring 5-14
normally closed 5-14
normally open 5-14
relay supply voltage restric-
tions 5-13
DIN Rail 3-1, 3-3
Display
size 1-1
Documentation 1-1
E
Environmental Conditions
DCX 3-1
DCX Expansion Board 3-2
Expansion Board
environmental conditions
3-2
mounting 3-1
networking 4-2
number of inputs & outputs
on 2-2
powering 4-1
I
I/O Configuration Sheet 5-1
L
LCD Display
size 1-1
Light Level Sensor 2-3
M
Modem Communication 6-2
Mounting
bullet sensors 3-2
DCX 3-1
DCX Expansion Board 3-1
DIN Rail 3-1
mounting a power trans-
ducer to 3-3
light level sensor 3-3
power monitoring 3-3
pressure transducers 3-3
sensors and transducers 3-2
temp/humidity sensors 3-2
N
Networking
expansion boards 4-2
numbering 4-2
O
On-Site DCX to PC Configura-
tion 6-1
Outputs, Analog. See Analog
Outputs.
P
Power Monitoring Devices. See
Sensors, power monitoring
Pressure Transducers. See Sen-
sors, pressure transducers.
Product Simulators 2-2
R
Relay Outputs. See Digital Out-
puts.
S
Sensors
bullet 3-2
light level sensor
mounting 3-3
orientation 3-3
wire type 5-6
wiring 5-6
mounting 3-2
temp/humidity sensors
3-2
power monitoring
mounting 3-3
wiring 5-5
pressure transducers
fittings 3-3
mounting 3-3
wire types 5-5
wiring 5-4
space temp/humidity sensor
wiring 5-3
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temperature
bullet style 3-2
wire type 5-3
wiring 5-1
wire types
light level sensor 5-6
pressure transducers 5-5
temperature sensors 5-3
Sensors and Transducers 2-2
Supervisory System
defined 6-1
on-site connection 6-1
Converter Box 6-2
RS485 Cable Type 6-1
termination 6-2
RS485 connection 6-1
cable type 6-1
T
Temperature Sensors 2-2
Transducers, Pressure. See Sen-
sors, pressure transducers.
Transformers 4-1
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