Stulz E2 pluS Series User manual

E2pluS Series
Microprocessor Controller
Installation, Operation and Maintenance Manual
For E2pluS Controller used with
CyberWall Air Handlers

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E2PLUS SERIES CONTROLLER INSTALLATION, OPERATION & MAINTENANCE MANUAL
ABOUT STULZ
Since it was founded in 1947, the STULZ company has
evolved into one of the world’s leading system suppliers of
computer room air conditioners and air handlers.
STULZ has seen continual international expansion of its
precision cooling business, specialising in temperature and
humidity control for data centers and telecommunications
installations.
STULZ has ten production plants (2 in Germany, 2 in
the USA, Italy, Great Britain, Spain, 2 in China, Brazil and
India) and twenty subsidiaries (in Germany, USA, France,
Italy, Great Britain, Belgium, Brazil, the Netherlands, New
Zealand, Mexico, Austria, Poland, Spain, Singapore, China,
India, Indonesia, South Africa, Sweden, and Australia).
STULZ works with sales and service partners in over 140
other countries, and therefore boasts an international
network of cooling specialists.

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E2PLUS SERIES CONTROLLER INSTALLATION, OPERATION & MAINTENANCE MANUAL
The Benchmark of Flexibility and
Energy Efficiency
This document contains information protected by copyright. All rights are reserved. The owner of the
equipment for which this manual is written may photocopythe contents ofthis manual for internal use only.
No part ofthis document may be photocopied, reproduced, or translated into another language for use
by anyone other than the owner of the equipment forwhich this manual is written without the prior written
consent of STULZ AirTechnology Systems, Inc.
This document contains confidential and proprietary information of STULZ AirTechnology Systems, Inc.
Distributing or photocopying this document for external distribution is in direct violation of U.S. copyright
laws and is strictly prohibited without the express written consent of STULZ.
Unpublished rights reserved under the copyright laws of the United States and of other countries. Other
brands and trade names are trademarks of their respective owners.
Copyright © 2023 by STULZ AirTechnology Systems, Inc.
Printed in the United States ofAmerica.
All rights reserved.
STULZ Air Technology Systems, Inc.
1572 Tilco Drive
Frederick, MD 21704, USA
www.stulz-usa.com

Contents
GENERAL INFORMATION .............................................................................. 5
DESCRIPTION ................................................................................................ 7
START UP......................................................................................................11
OPERATION..................................................................................................15
MENU SCREENS ..........................................................................................18
CONTROLLER COMMUNICATION ...............................................................34
MAINTENANCE & REPAIRS .........................................................................38
PRODUCT SUPPORT....................................................................................39
BMS POINTS LIST ........................................................................................41
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GENERAL INFORMATION
Forward
The microprocessor based STULZ E2pluS Series Controller documented in this manual uses state-of-the-art control
technology. This manual applies specifically to the STULZ E2pluS Series Controllersoftware configured for the CAH
CyberWall units listed on the title page. It contains information for the operation of the controller.
NOTE:
The controller software is configured with a definition of the hardware components present in the CyberWall.
This definition largely governs the E2pluS Controller screens that are displayed. Certain optional hardware can
be added to your unit and enabled by changing the hardware definition. This manual does not document these
options or their corresponding screens, alarms and BMS parameters. Only features in the factory-delivered
CyberWall unit are documented.
Spare parts are available from STULZ to ensure continuous operation. Using substitute parts or bypassing electrical
components is not recommended and will void the warranty. Due to technological advancements, components are
subject to change without notice.
STULZ E2pluS Series Controllers are designed primarilyto preciselyoperate, control and monitor STULZ CyberWall
systems. Anyuse beyondthis is deemed to be not intended. STULZ is not liableforanydamage resulting from improper
use. All STULZ E2pluS Series Controllers are designed for indoor use.
Humidity Data
The E2pluS Controller monitors humidity levels in the return air stream. Alarms based on the humidity level can be
configured using setpoints and offsets in the controller configuration screens.
Fans
The fans in the STULZ CyberWall units have optional Modbus-enabled monitoring abilities. Descriptions ofcontroller
software screens, alarms, etc. that pertain to Modbus fans are indicated with an asterisk ( * ) in the following pages.
These descriptions can be ignored for systems not equipped with Modbus fans.
Safety
Carefully read and understand all notes, cautions and warnings contained in this manual and on the unit that pertain
to the task to be performed.
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Notes, Cautions and Warnings
NOTE, CAUTION and WARNING statements are used in this manual to draw attention to important operational and
safety information.
A bold text NOTE marks an important detail.
A bold text CAUTION marks information important to protecting your equipment and its performance. Be especially
careful to read and follow all cautions that apply to your application.
A bold text WARNING marks safety information important to protecting you and others from harm.
Pay very close attention to all warnings that applyto your application.
An Exclamation — — symbol in a WARNING or CAUTION statement indicates a general safety alert.
A lightning bolt — — in a WARNING safety statement indicates an electrical shock hazard.
Safety Summary
The following warnings and cautions apply to the equipment and operations documented in this manual.
CAUTION
Before operating the unit, read and understand all instructions, recommendations and guidelines contained in
this manual.
CAUTION
All adjustments, maintenance and/or repairs must be performed by a qualified technician.
WARNING
Fans may start automatically. Before performing any maintenance actions on the unit ensure that all lockout/
tagout procedures have been followed and power is removed from the fans.
WARNING
If a fault occurs when operating the unit or adjusting control parameters, it must be corrected immediately in
accordance with the troubleshooting instructions for the unit.
CAUTION
Equipment may contain components subject to Electrostatic Discharge (ESD). Before attempting to mount or
servicethese electronic devices, ensureyou have no charge built up bytouching a ground source. When possible,
use a wrist-grounding strap when working on or near electronic devices.
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DESCRIPTION
General
The advanced microprocessor-based STULZ E2pluS Series controller is a highly versatile and flexible A/C system
controller. The controller is equipped with software specifically configured at the factory for the CyberWall unit and
will require no field set-up other than configuring setpoints and their ranges. The program and operating parameters
are persistently stored in flash memory in case of power failure.
The controller is designed to manage temperature to a user defined setpoint via control output signals to the A/C
system. The controllerreceives inputsforthe measurable control conditions (temperature)via a supplyairT/H sensor.
Areturn airT/H sensor provides humidity data. Controllerinternal logic determineswhen conditions require cooling per
control setpoints establishedto maintain the room's design conditions.The controllerresponds to ambient temperature
changes and controls the output(s) to the air conditioning system to reach the control setpoints.
Features
Field Configurable
Setpoints for the controller are field configurable, allowing the operator to define them as required. The operator
interface for the controller is a graphic terminal containing a backlit LCD display and function keys. A menu driven
software interface provides the ability to scroll through and enter screens to view status and other data and enter
configuration values.
Password Protection
The password locks out the display. To view the displaythe password must be entered. The default password is 318.
It is recommended that the password be changed after initial setup.
Restorable Setpoint Parameters
Upon initial start-up the unit operates using the setpoints programmed by the factory. New operating parameters
may be entered in the Favorites folder screens and the system will operate accordingly.
The setpoints for the system may be re-adjusted in the Favorites folder or via the BMS at anytime.
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BMS Interface
The controller has a communication interface port that can be field-connected to a Building Management System
via BACnet. Refer to Figure 2 for BACnet IP and BACnet MS/TP port locations on the controller.
Graphic Terminal
The graphic terminal is mounted on the unit's electric box door. It features an easy to read, backlit liquid-crystal
alphanumeric display equipped with a jog dial and exit button for navigation. The screens that appear on the display
present data that originates from the controller.
Figure 1. Graphic Terminal
JOG DIAL
EXIT BUTTON
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Function Keys
Key Function
• The points menu is used to display inputs, setpoints, values, outputs values, status, etc.
• The schedule and calendars menu is used to view and modifythe schedules and calendars.
• The alarms menu shows the active alarms.
Alarms can be acknowledged if the controller supports this functionality.
• The alarm icon will be blue when no alarms are active.
• The alarm icon will be red when an alarm is active.
• The manual overrides menu allows a user to remove an override, or change the override value
of any hardware input, hardware output, value, variable, and so on.
• The override icon will be purple when there are one or more active overrides in the controller.
• The override icon remains blue when override is not active.
• The favorites menu allows the user to view favorite screens that have been bookmarked.
• The PID loops menu allows the user to tune the controller’s PIDs
• The weather menu allows the user to view the current weather conditions if the BMS is con-
nected to the internet.
• The settings menu allows the user to view and configure the controller’s settings.
• The about menu can be customized to show a graphic (for example, a company logo) and
textual information (for example, contact information about the integrator). This menu also
allows the user to view the controller and operator interface software / bootloader versions.
Current
Selection
• When on the main screen, this shows the menu option currently selected by rotating the Jog Dial
• Toggles the ability to acknowledge alarms. Alarms can be acknowledged in the BACnet or at
the display. Icon shows locked/red if acknowledgement is not allowed, and unlocked/green
if acknowledgement is allowed.
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E2pluS Controller
The E2 pluS controller in mounted insidethe unit's electric box. Figure 2 showsthe E2 pluS controller and its interface
ports and LEDs.
Figure 2. Controller
The controller features called out in Figure 2 are:
1. RJ45 connector for controller display.
2. Power on LED.
3. Status LED.
4. BACnet IP Ethernet ports (qty. 2).
5. BACnet MS/TP port.
CAUTION
For units equipped with a UPS, when the power supply to the equipment has been shut off to service the unit,
be aware that the UPS module in the electric box still contains stored electric power up to 32 VDC. This
voltage will also be present in circuits that are electrically common to the UPS module.
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START UP
The operator interface has common features throughout like using the jog dial and EXIT button (located below the
jog dial) to navigate throughout the interface and to select and edit values. The following sections will show you how
to select items, edit values, interpret the different menu colors and icons you will come across while working with
the operator interface, and unlocking the password protected interface.
Selecting an Action
An action allows you to perform a specific action on a selected menu item. A list of actions is available within each
list of context menu items. The available actions will change according to the type of menu you selected. Select an
action as follows.
1. Rotate the Jog Dial to highlight a menu item.
2. Press the Jog Dial to activate a list of the currently available actions (context menu).
In the example below, the available actions are Override, Auto, and Alarm details.
Figure 3.
Figure 3: Activating a Context Menu for a List of Actions
3. Rotate the Jog Dial to highlight one of the available actions and press the Jog Dial to perform the action.
Selecting and Editing a Numeric Value
When a value has been selected, the interface provides two ways of editing it.
• By scrolling to a value. Rotate the Jog Dial to increase or decrease the current value.
This is ideal for relatively small value changes.
• By editing the value. Use the Jog Dial to ‘build’ the number, one digit at a time, including decimal places, negative signs,
and exponents.
This is ideal to make large changes to the current value or to create values with exponents.
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Figure 4. Popup Window for Editing a Numeric Value
Button Description
Scroll Edit the value by rotating the Jog Dial to increase or decrease the currentvalue. See Scrolling to a Numeric Value.
Edit Edit the value by using the Jog Dial to ‘build’ the number, one digit at a time. See Editing a Numeric Value.
OK Accepts the currently shown value (once the value has been edited by using a Scroll or Edit operation) and
closes the popup window.
Cancel Cancels the current action (rejects any change made to the value) and closes the popup window. This
maintains the previous value.
How to Scroll
Scroll a value as follows:
1. Rotate the Jog Dial to select the numeric menu item.
2. Press the Jog Dial to open the edit screen.
3. Rotate the Jog Dial to select Scroll.
4. Press the Jog Dial. Rotate the Jog Dial clockwise to increase the value. Rotate the Jog Dial counter clockwise
to decrease the value.
NOTE
The Jog Dial step size can be set so you can advance by steps of 1, 10, or 100 to quickly advance to the correct
value. See "How to Set the Scroll Step Size" on page 12.
5. Once you have adjusted the number to the correct value, press the Jog Dial to accept the value.
6. Rotate the Jog Dial to select OK.
7. Press the Jog Dial to exit the value editing screen.
How to Set the Scroll Step Size
When scrolling to a value (see above), the scroll step size can be set so you can advance by steps of 0.001, 0.01,
0.1, 1, 10, 100, or 1000 when turning the Jog Dial to quickly advance to the correct value. Set the Jog Dial step
size as follows.
1. Press and rotate the the Jog Dial at the same time to select 0.001, 0.01, 0.1, 1, 10, 100, or 1000 to advance
in steps of 0.001, 0.01, 0.1, 1, 10, 100, or 1000.
2. Once a step value has been selected, release the Jog Dial.
3. Now rotate the Jog Dial to scroll to a value.
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NOTE
Each time you enter a value edit popup, the step size resets to the default value, according to the magnitude of
the value being edited.
Figure 5. Changing the Scroll Step Size
Figure 6. Setting the Scroll Step Size to 10
Editing a Numeric Value
A value can be constructed, one digit at a time. Negative numbers and exponents can be created.
Edit a value as follows.
1. Rotate the Jog Dial to select the numeric menu item.
2. Press the Jog Dial to open the edit screen.
3. Rotate the Jog Dial to select Edit.
4. Press the Jog Dial.
5. Edit the value, one digit at a time. According to the cursor’s position, rotating the Jog Dial allows you to select
different components to construct a number.
• Negative sign (-); available when the cursor is in the left most position or afterthe exponent ‘E’
symbol.
• Clear any digits to the right of the current cursor position.
• Exponent (E). The number that follows this symbol is the base 10 exponent.
For example, 6.4E03 is 6400 in decimal.
• Digits, 0 to 9.
• Decimal place (.).
NOTE
When a number is shown, the cursor can be positioned among the digits by pressing and rotating the Jog Dial
at the same time.
6. Press the Jog Dial to accept the current digit and to move to the next digit.
7. Once you have adjusted the number to the correct value (you have no more digits to create), press the Jog Dial
a second time to accept the value.
8. Rotate the Jog Dial to select OK.
9. Press the Jog Dial to exit the value editing screen.
PRESS AND HOLD IN,
THEN TURN TO
CHANGE STEP SIZE
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Selecting a State Value
A state value is used to set the status for a selected item. The available state values will change according to the
type of menu item you have selected. Select a state value as follows.
1. Rotate the Jog Dial to highlight a menu item.
2. Press the Jog Dial to activate a list of the currently available values. In this example, the state value options are
English and French:
Figure 7. Activating a Selection Wheel for a List of State Values
3. Rotate the Jog Dial to highlight one of the available values and press the Jog Dial to select the state value.
Interpreting Row Colors and Alarm Icons
The color of a row can change according to its current state. When an alarm has been configured, an alarm icon is
shown. This is described below.
Figure 8.
DARK BLUE: The current item selected
with the Jog Dial
RED: This point is currently in Alarm and is
unacknowledged
LIGHT BLUE: This alarm has been
configured for this point
MEDIUM BLUE: This point is overridden
The current context menu item
selected with the Jog Dial
Row Color Interpetation
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OPERATION
General
The STULZ E2pluS Series controller is designed to control a CyberWall system in a space or process application to
temperature levels defined bythe user. Conditioned air is suppliedtothe space as neededto maintainthe temperature
control setpoints.
The controller isfactory configured and manages inputs and outputs based onthe specific application and equipment
being controlled. Sensor(s) maybe located inthe process airinlet to monitorreturn airconditions and/or located inthe
process air outlet to monitorthe discharge air or, installed inthe conditioned spaceto monitorroom air conditions.The
controller utilizes the sensorinputsto determinethe demand for cooling based on the control setpoints. The controller
determinesthe appropriate response (output signals) againstthe sensor input signalsto operate system components.
The controller I/O module includes inputs and outputs as depicted in the unit schematic drawing supplied with the
unit. Not all the inputs and outputs shown are utilized, therefore, only the inputs/outputs needed for the specific
CyberWall system type and application are indicated on the drawing as enabled.
Controller Temperature Inputs
The controller is equippedwith analog input positions for monitoring temperature and humiditysensors for automatic
operation of the air conditioner. A sensor is mounted downstream of the fans to monitor supply air conditions, and
the controller uses data from this sensor to determine the demand for cooling against the control setpoints. Another
T/H sensor is mounted on the return side of the unit. This sensor provides return air temperature and humidity data
that is reported in controller screens and in alarms if humidity alarms are configured.
Control Signals
Control and alarm recognitiontakes place bymeans ofthe controlleranalyzing signal inputs from return airtemperature
sensor(s).
Proportional/Integral (P/I) Control
The controller calculates proportional control output signal(s) based on the analysis of input signals which then
determines the air conditioner's required mode(s) of operation. Signals representing temperature are compared by
the controller as a percentage value to the maximum control setpoint value resulting in control output values that are
directly proportional to the input signal.
The integral value is used to gradually adjust the proportional output when the calculated output does not move the
process variable closer to setpoint in a given period of time. Decreasing the integral value decreases the interval
for the output corrections (speeding the rate of adjustment). Increasing the integral value increases the interval for
corrections (slowing the rate of adjustment).
Temperature Control
The method of operation depends on the controller's programmed operating mode. Control takes place by means of
the controller analyzing signal inputs from return air temperature and humidity sensors(s), or supply air temperature
sensor(s).
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NOTE:
Anysensorvaluesthe controllerreceivesfrom a remote temperature and/or RH sensorare prioritized as secondary
to those received from a return temperature/RH sensor if controlling to the return air, or a supply temperature/
RH sensor if controlling to the supply air.
Chilled Water Cooling
Upon a call for cooling, the controller activates a chilled water control valve with a 010 VDC signal. The valve opens
proportionallyto the demand for cooling based on deviation from user defined setpoint and the actual return or supply
air temperature. The control settings consist of the return or supply temperature setpoint and the integration time.
The chilled water valve closes to the minimum position and remains at that position when the return air temperature
is less than the return temperature setpoint.
When the actual return or supply airtemperature rises above the temperature setpoint, the CWvalve position begins
to increase proportionallyfrom the minimum positionto the maximum,fully open position atthe temperature setpoint
plus the cooling band. The integrationtime allows the ratethe valve position changesto increase overa period oftime
as long as the difference betweenthe actual return orsupply airtemperature is higherthan thetemperature setpoint.
The starting voltage for the valve to be 0% open and ending voltage for the valve to be 100% open varies, and is set
in the configuration ofthe unit. For a valve that is fully closed at 2.0V and fully open at 10V, the controller sends 2.0V
tothe valvewhen 0% opening is called forand ramps to 10Vwhen the demand increases to 100%.Afeedback signal
can be used to confirm the valve is opening or closing.
Airflow/Fan Speed Control
ForCW-based systemsthe controlleris configuredtocontrolfanspeedfrom 100%(full speed)to aminimum settingbased
on thetotal system airflowvolume. Minimum and maximumfan speed settings are user adjustable inthe Favorites folder.
The fan speed is automaticallyvaried along with the CW control valve position based on temperature. When the system
enters dehumidification mode, the blower speed automatically changes to the dehumidification blower speed setting.
The STULZ E2pluS controller's software is equipped with an operational fail safe mode. Upon a return air or supply
air sensor failure, the system goes to the temperature setpoint plus a programmable temperature offset while the
humidity stays at the setpoint. If the offset is larger, the CW valve and fan speed may be operated up to 100%.
In the event of a fan failure, the speed of the remaining operable fans will increase to provide the same airflow. For
example, ifthree fans are called to operate at 30% offull speed and one fan fails, the remaining two fans will operate
at 45% of full speed.
Modbus Fan Monitoring*
The controller is equipped with a Modbus network and is programmed to monitor multiple operational aspects of the
fans via Modbus communications protocol. Operator interface to control parameters is available through the graphic
controller or a BMS via the network when power is applied to the unit.
The controller software monitors sensorvalues. The software allows internal communicationwith eachfan viaModbus
protocol, and external communication through BACnet protocol for the BMS to monitor fan operation.
Communication With the Controller
It is possible for the controllerto communicate in a variety ofways. The controller(s) may also be connected to a BMS
for monitoring and control of data points using BACnet IP or BACnet MS/TP.
* Requires Mod-bus enabled EC fans.
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In the event of a BMS monitoring/control signal failure, the E² pluS controller will default to local operation at the
current setpoints for the fan and chilled water control valve. In the event of a loss of communication with the BMS or
a BMS failure the local sensors control the unit until BMS communication is restored.
Remote On/Off
Terminal positions are provided to connect a remotely located On/Off switching control device for Remote On/Off
operation. If the unit is turned on and the E² pluS controller receives a remote 24V input signal via the remote switching
device, the system will operate. If the switching device opens, removing the 24V input to turn off the unit, the controller
disables all control outputs. The A/C system will automatically be re-enabled when the 24V Remote On/Off signal is
restored for the unit to turn back on.
As an example,the control device maybe an On/Offswitch. Ifcustomerprovided,the remote On/Off control contacts
must be sized appropriately.The Remote On/Offcontacts must have arating of 15mA@24VAC. Refertothe electrical
drawing included with the unit for the wiring details.
General Alarm Contacts
Terminals are provided in the electrical cabinetfor a hardwire connection to the BMS.These are dry, normally-closed
contacts.
Water Temperature Sensors
The unit is equipped with water temperature sensors at the inlet and outlet. This allows the customer to monitor
the water temperature into and out of the unit. There are high and low temperature alarms that can be set
through the BMS or at the display of the unit.
Water Alarm (Optional)
The unit can be supplied with water alarm monitoring, When the water detector is installed the unit will be able to
detect any water leaking inside the unit or if mounted externally to the unit. If the water alarm is triggered the
controller will send out a water alarm and common alarm trigger through the BMS and will also open the Common
Alarm dry Contact.
Smoke/Fire Alarm (Optional)
Units can be ordered with a smoke or fire detector in the unit. If either device is activated the controllerwill trigger
the BMS and will also open the Common Alarm contact.
NOTE
Smoke/fire detectors in the unit are notto be used as a life saving device. They are provided for monitoring only.
Dual Power (Optional)
The unit can be equipped with Dual power for the incoming power. The controller can monitor the active power
to both power sources and when the power is lost to one of those sources, trigger the BMS and open the
Common Alarm contact.
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MENU SCREENS
Points Menu
The Points menu is used to display, set, and override inputs, outputs, setpoints, and values. It is also used to view
alarm details for points that are in alarm.
Figure 9. Typical Points Menu
Points Detail Screen
When selecting a point from the Points menu, the following type of screen is displayed. This screen displays the
point identifier, point name, point values, and color-coded rows and icons to identify points in alarm or overridden.
Figure 10.
Alarm is Configured
(red background indicates point
is in alarm)
Value
Point is overridden
Point Name
Point Identifier
Typical Points Screen
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The point identifier column shows the configuration type. The number corresponds to the E2pluS's block
number set in the Properties pane. The configuration type of the inputs, outputs, values, constants or variables is
configured with E2pluS .
The following objects are available according to the controller’s network type:
BACnet Controllers
Inputs/Outputs:
AI Analog Hardware Input
BI Binary Hardware Input
AO Analog Hardware Output
BO Binary Hardware Output
MSI Multi-State Input
Values:
AV Analog Value
BV Binary Value
MSV Multi-State Value
Certain points can be overridden. See Overriding Points and Options.
Overriding Points and Options
Points can be overridden by selecting the point and pressing the Jog Dial to view the available options.
The following override actions may be available according to the type of point selected.
To select an action, see Selecting an Action.
Override BACnet
Controllers Description
Emergency override XForces a pointto assume a user-set value at priority level 1.
Emergency Auto XClears an Emergency Override value at priority level 1.
Override XForces the point to assume a user-set value as its
present value (at priority level 8 for BACnet controllers).
Auto XClears an Override value.
Set value XForces a point to assume a user-set value.
Alarm details XShows any currently associated alarms.
Viewing Point Alarm Details
You can view the alarm details for the associated inputs, outputs, and values in the Points menu. Select the point
that is in alarm (highlighted in red) and select Alarm details. See Interpreting Row Colors and Alarm Icons.
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Figure 11. Alarm Details
The alarms details screen for the associated item in alarm is displayed:
Figure 12. Alarm Details Screen
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