Issue triggering SSRs and Mechanical Relays

[mliptack]

The panel I built is going though testing now, I am about 99% complete with High Voltage wiring and I am about 90% complete with my low voltage (Signal; 5v; 12v).

My BCS is wired so it has power even when the panel is turned off. I wired the panel so I can turn it on remotely (SSR and Key switch can both trigger the main contactor). When I turn the key, everything powers up and works fine. BUT When I trigger output 17 (my system power output - wired directly to the SSR) the contactor clicks on then off immediately. The web interface of the BCS does not show that the output is enabled and the SSR light is not lit up.

Next - the same thing happens with my pump outputs. Except I tried a few other tests here.

I have a float switch that I programmed in the ladder logic so that if the float is up, the pump is on (or can be turned on). When I trigger the output with the float switch, it works fine. I should note - I am not currently powering a pump - instead I am just turning on and off a fan or a light.

I am running the old firmware. I haven't tried the newest release.

I will finish the wiring next week and will be able to give more details then. With the information given, do the signs point to anything in particular?

Thanks in advance for your help.

Best regards,
Max

[brahn]

How are you triggering output 17 to turn on your system? Do you have any processes running?

[oakbarn]

This is how I think the BCS works:

For Processes and there is a hierarchy for precedence.
1. Ladder Logic takes precedence for a Process. If a Process in the last box in Ladder Logic, it may not be controlled outside of the Ladder Logic manually or be started (spawned) upon a State Exit. Only the Ladder Logic may control it on or off. (Running, Active or Inactive, Killed). You have no control even if the other items on the the Rung is not filled in.
2. State takes precedence for an Out. An OUT is controlled by a State within a RUNNING Process, you may not manually Kill or Activate it. There is also a hierarchy of Processes. A higher numbered RUNNING Process will control the Out if is called for in the current State if there is a conflict with an earlier RUNNING Process.
Ladder Logic takes 2nd precedence for an Out. If the OUT is the last Coil in a Rung Ladder Logic will control the OUT and Manual Control is not available, even if the conditions are not TRUE.
3. Manual Control is only available if RUNNING Process or Ladder Logic is not controlling.

[mliptack]

How are you triggering output 17 to turn on your system? Do you have any processes running?

Yes currently output 17 is used to turn on the system remotely.

The key switch on the other hand bypasses the BCS with a direct 5v to the SSR

[brahn]

Yes, but the issue you're reporting is that when triggering output 17, it shuts back off immediately. How are you triggering output 17? Do you have any processes running when you're doing this? Ladder logic? Is output 17 set up as "One-Shot"?

[mliptack]

Sorry I misread your question - I was clicking the output 17 soft switch on the homepage of the BCS.

No processes running at this time.

[brahn]

Do you have output 17 specified as a coil in any ladder logic?

Is output 17 configured as one-shot?

For the pump issue, it would be relatively easy to configure the ladder logic so that the pump can only be triggered by the float switch. That's my guess as to what's happening there. Can you post a screenshot of the ladder logic config?

[mliptack]

Do you have output 17 specified as a coil in any ladder logic?

Is output 17 configured as one-shot?

For the pump issue, it would be relatively easy to configure the ladder logic so that the pump can only be triggered by the float switch. That's my guess as to what's happening there. Can you post a screenshot of the ladder logic config?

No, Out17 is not part of any ladder logic. Nor is it configured as one-shot.

I will certainly get the system fired up some time this week - when I do, I will post a screenshot of the config screens to help diagnose.

Thank you for your help thus far!

Best regards,
Max

[mliptack]

One step forward and about 10 back.

I got my spa panel installed about 4 weeks ago, but had a bunch of things to finish before I got to test it out. Before this I wired the panel to 120 in the house for testing.

Yesterday I plugged in the the EPIC connector to the panel flip the GFCI, then the breaker that I have on the 5v PSU for the BCS - and the GFCI tripped immediately.

I narrowed it down to the 5v PSU. With all load removed from the 5v PSU it will still trip, even if I isolate it completely from the grounded metal case. I may wire the BCS up to a non GFCI protected outlet just to continue testing / config.

I am using a 5v DC 12amp PSU (metal case) - one of these - http://www.amazon.com/Power-Supply-Sing ... B005T6V5RM

I read a bunch about using nylon screws and an insulator between the metal case of the PSU and the chassis.... but even completely separating it from the case will still cause the GFCI to trip.

Any thoughts?

Thanks,
Max

[JonW]

I would say you have a defective power supply. I've used similar ones like that before (for other projects, not brewing related) and not had GFCI tripping.