2754 Q05N_EN Reactor Quick Start Guide

2014-10-27

: Controlanything Reactor Quick Start Guide Reactor_Quick_Start_Guide QSG

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NATIONAL CONTROL DEVICES

Reactor Relay Series Quick Start Guide

Autonomous Relay Controllers

N A T I O N A L C O N T R O L D E V I C E S

Reactor Relay Series

Autonomous Relay Controllers

National Control Devices, LLC

PO Box 455

Osceola, MO 64776

Phone 417.646.5644 • Fax (866) 562-0406

Notice: Portions of this manual require internet access.

NOTICE:

All customers are STRONGLY ADVISED to purchase at least ONE USB

Communication Module. This communication module may be used to

recover a controller or to reconfigure a controller should there be an

accidental loss of communications. NCD Tech support may be unable to

assist customers who do not have a USB Communications Module available

for troubleshooting purposes.

Purchase USB Communications Module from our website at this link:

http://www.controlanything.com/Relay/Device/ZUSB

Table of Contents

Introduction .............................................................................. 1

Getting Started .......................................................................................... 3

Hardware Reference ................................................................ 4

Understanding Inputs ................................................................................ 8

Understanding Outputs ........................................................................... 10

Controlling Relays ................................................................................... 11

Reactor Configuration ............................................................ 14

Communications ..................................................................................... 14

Reactor Configuration ............................................................................. 14

Reactor Sample Library .......................................................................... 17

Input Configuration.................................................................................. 18

Reading Temperature and Light ............................................................. 21

Key Fob Inputs ........................................................................................ 23

Using Inputs and Outputs ....................................................... 27

Using Inputs .................................................................................. 27

Reactor Event Configure ........................................................ 32

Advanced Features ................................................................ 37

Multiple Event Triggering ........................................................................ 37

Protected Data ....................................................................... 39

Editing Protected Data ............................................................................ 39

Override Reactor Logic ........................................................................... 40

Computer Access to A/D Values and Pivots .......................................... 42

Computer Access Command Set ........................................... 44

Reactor Specific Commands ..................................................... 45

Relay Logic ............................................................................ 46

Advanced Relay Logic ............................................................................ 49

Maximum Ratings .................................................................. 50

Trouble Shooting .................................................................... 51

Technical Support ..................... Error! Bookmark not defined.

Contact Information .......................... Error! Bookmark not defined.

Notice: ....................................................... Error! Bookmark not defined.

Introduction

he Reactor Series relay controllers represent a significant advancement in the

evolution of the NCD product line. The Reactor Series controllers represent

many foundation technologies that will significantly strengthen our product

offerings in the years to come.

The Reactor Series are the first controllers to offer Autonomous Relay Control

(logical control based on inputs without a computer). This architecture allows

powerful computer-based configuration without writing a single line of code.

Reactor controllers are the first to offer an autonomous mode of operation in

addition to a computer-override mode of operation. This allows users to take

over the relay controller at any time, and even change settings in the configuration

through a direct USB connection or using a wireless 802.15.4 or ZigBee Mesh

Interface. Some reactor controllers also include a Key Fob interface chip, allowing

relays to function from a small hand-held remote control with an incredible 3,000

foot range using an outdoor antenna. The Reactor Series are manufactured using

Surface Mount Technology. A Break-Away design has been implemented to meet

the requirements of customers who need an enclosure AND to customers who

need the smallest possible size. Break Away tabs allow the user to “break” off the

outer edges of the circuit board for a smaller profile, a unique design of the NCD

product line. The Reactor Series relay controllers represent the future direction of

the NCD product line.

Who’s Qualified to Use the Reactor Series?

Anyone. The Reactor Series Controllers are one of the most user-friendly devices

we have ever manufactured. Whether an electronics engineer or home hobbyist,

anyone is qualified to use the Reactor Series controller provided this guide is

carefully studied.

Chapter

How do the Reactor Series Controllers Work?

The Reactor Series Relay Controllers are configured using a computer (either using

wireless or a direct USB connection). Once configured, a Reactor will operate

without a computer. At any time, a computer may monitor the Reactor, Trigger

Events, Activate Relays, or Change Configuration settings. A computer can take

over a Reactor or a Reactor can operate autonomously (without a computer). The

Reactor Configuration Utility (part of NCD Base Station) provides over 100 pre-

set configurations that will help you understand the capabilities of the Reactor and

provide you a starting point for your own application.

Once a Reactor is configured, the Reactor monitors inputs. When inputs reach

user-defined limits, relays can turn on or off. Reactors allow much more than

simple relay control. Reactor inputs can trigger timers and rotations. A timer

allows a relay to activate over a duration of time. A rotation is a simple counter, in

which relays can be assigned to each “count.” This allows powerful functions

such as relay activation sequencing, flashing, and stepping. Event Piping allows

timers and rotations to trigger other timers and rotations. This is very powerful

for setting up complex relay activation sequences. These features will be described

in great detail as we advance through this manual.

Order of Operations

There is a general process to learning and using a Reactor Series relay controller,

this manual will follow two sequences, covering the Learning Cycle and the Usage

Cycle. Optionally, users may want to consider exploring the Advanced

Applications to unlock some of the most powerful features.

Learning Cycle

1. Hardware Reference (getting to know the hardware)

2. Communications

3. Configuration Overview

4. Using Pre-Set Configuration Profiles

5. Building a Custom Configuration Profile

6. Loading and Saving Configuration Profiles

7. Understanding Relay Control

8. Understanding Timer Events

9. Understanding Rotation Events

10. Understanding Event Piping

11. Testing and Troubleshooting Reactor Logic

12. Using a Key Fob Reactor

13. Connecting Sensors to a Reactor

14. Controlling Devices with a Reactor

15. Troubleshooting a Reactor Controller

Usage Cycle

1. Configuration

2. Testing

3. Sensor Connection

4. External Device connection

Advanced Application

1. Remote Configuration

2. Using a Computer to Take Over a Relay

3. Giving Relay Control Back to Reactor Logic

4. Using a Computer to Trigger Events

5. Changing the Timing of a Reactor Controller

6. Advanced Reactor Relay Logic

Getting Started

There is no better place to start than from the beginning. This guide will lead you

through the understanding and use of your Reactor Series relay controller in a

sequence that will help get you started from the ground up. Please take advantage

of the efforts we have invested in building a complete and comprehensive product

manual before contacting NCD technical support staff. This will save you time

and allow our technical support engineers to focus on product development. If

you do require technical support after reading this guide, please refer to the last

page for contact information.

Hardware Reference

here are many versions of the Reactor Series relay controllers. It is not

practical to photograph and outline every version in this manual. However,

there are many common elements that are shared among controllers. Most

notably, the Reactor CPU is identical whether you are using a 1-Channel Ethernet

Reactor or a ZB Mesh 8-Channel Key Fob Reactor. All Reactor controllers share

the exact same firmware with absolutely NO differences in firmware revisions.

This greatly reduces manufacturing time and troubleshooting while allowing our

customers a migration path to more complex communication technologies as

required.

Some Reactor controllers include a temperature sensor, some have a ZigBee Mesh

Interface, others have XSC or a 802.15.4 Interface. There are several available

interface options. Please refer to the appropriate quick start guide for your

selected interface that can be found on our website. If you choose an interface

other than USB, it is strongly recommended that you also purchase a USB

communication module so that you will be able to recover from a communication

loss or error.

A Key Fob interface chip is also common to some models of the Reactor Series.

Key Fob equipped Reactors may be controlled using a small hand-held remote.

With an optional antenna, you can expect a 200-300 foot range. With an outdoor

antenna, you can expect a 2,000 to 3,000 foot range. We have tested these ranges

and find their performance to be superior to competing technologies.

Some Reactor models have a auxiliary 5V output, which is useful for powering

external electronic circuits.

Chapter

Power Requirements

Reactor controllers require a 12VAC or 12VDC power supply to power the logic

and relays of the controller. The PWR12 is our stock power supply suitable for

use with ALL Reactor Series controllers. While it is possible to operate from an

automotive 13.8V power supply, higher voltages are not recommended.

Additional power filtering may be required for proper operation in automotive

electrical systems. The absolute minimum recommended operating voltage is

11VAC or 11VDC. Reactor controllers require approximately 100ma for standby

and 60ma for each activated relay. ZigBee Mesh or 802.15.4 equipped Reactor

Controllers may require an additional 240ma of current to sustain normal

operation.

Ethernet and Wi-Fi versions should ONLY be powered from the included power

supply, as their operating tolerances are stricter. The power supply (included with

Wi-Fi and Ethernet controllers) is rated at 12VDC, 1.25A. This power supply is a

computer grade regulated supply and should NOT be substituted.

Power polarity is not important on the Reactor Series controllers. There is no

positive and negative terminal. Simply apply power to the controller as it is

convenient to make wired connections. The Reactor controller will rectify your

power supply and attempt to filter noise to safe levels for proper operation.

Temperature Requirements

Certain components of a Reactor controller may run at temperatures exceeding

120° Degrees Fahrenheit when certain options are installed. This is normal for a

Reactor controller and does not indicate a defect.

The recommended operating temperature for all reactor controllers is –25 to 80°

C. This temperature rating is based on temperature specifications of the

components used to build a Reactor controller, and is not based on actual testing.

We have speculated that Reactor controllers may be able to withstand lower

temperatures due to the fact that Reactors tend to have hot components in critical

areas of the design.

A. Reactor Controllers are equipped with 1, 2, 4, or 8 Relay Outputs. Relays are simply switches. They DO NOT

provide a voltage output, but they will switch the voltage you apply to the relay connections. Please Click Here

to see a list of relays and ratings that are commonly supported by the NCD product line.

B. Analog Inputs may be pulled Up or Down through a 10K resistor using a jumper similar to the one shown

here. The default setting for this jumper is the UP position. The UP position is desirable for most

applications, as it allows you to simply connect a button or switch between an analog input and ground.

Removing this jumper (shown) “floats” the analog inputs (and may not be suitable for some applications).

Setting this jumper DOWN may be desirable for some sensors. Analog inputs and the Up/Down jumper will

be explained in greater detail later in this manual. But keep in mind, the Up/Down jumper directly affects the

way the Analog inputs are read by the Reactor controller chip.

C. Analog Inputs are capable of reading switches and sensors operating in the 0 to 5VDC range. These inputs

serve as the heart of a Reactor Controller and are the basis for triggering most Reactor functions.

D. Status LEDs indicate which relays are currently active.

E. Some Reactors include a integrated +5VDC regulator useful for powering external electronic devices and

sensor up to 100ma.

F. Some Reactors include a integrated temperature sensor, a very tiny component accurate enough for most

thermostat applications. The integrated temperature sensor is slow to respond to temperature changes but is

suitable for non-critical applications.

G. Reactor Controllers include a 2.1mm Barrel Connector AND a 2-Position Screw Terminal. Use either

connector to provide 12V power to the Reactor Controller. Reactor controllers are compatible with 12V AC

or DC power supplies with an actual voltage output of 11 to 13.8V. Polarity is corrected by the Reactor

controller, therefore a Positive and Negative terminal are NOT labeled on the board (it is not possible to

connect power backwards to a Reactor controller; the Reactor will automatically correct polarity).

H. For most daily applications, the PGM/RUN jumper should be set to RUN. Only during configuration should

the jumper be changed to PGM mode. RUN mode protects internal memory from accidental changes while

PGM mode allows configuration changes.

I. The BUSY/READY LEDs indicate CPU activity. Under normal operation you will see the BUSY LED flash

as it computes Reactor logic and processes computer commands.

SPST Relay

SPDT Relay

DPDT Relay

Relays have 2, 3, or 6 connections per

relay depending on configuration.

SPST, SPDT, and DPDT relays will be

supported. Please see the article at

this link for a detailed explanation of

these relay types.

Reactor Controllers sometimes include a 10-Pin 8-

Channel A/D Connector. The Extreme left and

right connections are GROUND. Connections 2-9

(from left to right) correspond to Analog Inputs 1-8

respectively.

Understanding Inputs

Analog Inputs are capable of reading switches and

sensors operating in the 0 to 5VDC range. These

input serve as the heart of a Reactor Controller.

Reactor Inputs play a vital role in the use of a

Reactor controller. Before beginning to use the

controller, it is essential that users understand the

role of these inputs.

Improper use of these inputs can cause

irreparable damage to the Reactor controller,

so a firm understanding of these inputs is critical

to the longevity of the controller.

Reactor Inputs are also referred to as Analog

inputs. Analog inputs are simply inputs that are

sensitive to voltages. Analog inputs can accept

voltages from 0 to 5VDC ONLY. Higher

voltages and negative voltages will damage the

Reactor controller. Users must NEVER apply

a voltage to an Analog input on the Reactor

controller when powered down (220 Ohm

current limiting resistors may be used if this is not

possible and will be discussed later in this guide).

Analog Inputs are very special in that they are sensitive to voltage changes. In the

case of a Reactor controller, analog inputs have an 8-bit resolution, meaning the

voltage input (from 0 to 5VDC) is interpreted as a value from 0 to 255.

For example:

 A voltage input of 0 Volts is interpreted as a value of 0.

 A voltage input of 2.5 Volts is interpreted as a value of 128.

 A voltage input of 5 Volts is interpreted as a value of 255.

So if you divide 5 Volts by 256 possible steps (0-255 for 8-Bit resolution), the

Reactor controller is sensitive to voltage changes as small as 0.0195 Volts.

A Reactor controller has 8 inputs. Each input is capable of reading a separate

voltage from 0 to 5 VDC, provided all voltages can share a common ground.

The Analog Inputs on a Reactor Controller may be configured to activate or

deactivate relays based on these voltage changes. These voltage changes can also

trigger timers and counting events (which will be discussed in greater detail later in

this guide). The important concept to understand is that Analog inputs are

sensitive to voltage changes and these voltage changes trigger functions within the

Reactor logic.

Reactor Controllers are equipped with a UP DOWN jumper, sometimes labeled

UP DWN.

One of the most critical rules in working with analog inputs on a

microprocessor is the understanding that each input must be

connected to something, either a ground or a voltage source.

Analog inputs should not “float” (remain disconnected). For this

reason, a UP/DOWN jumper is included on your Reactor series controller.

The purpose of the UP/DOWN jumper is to make sure all inputs are connected

to Ground (DOWN) or to a +5V voltage source (UP) to keep the inputs quiet.

However, inputs are NOT directly connected to +5V or to Ground using the

UP/DOWN jumper. Instead, inputs are “pulled” high or low using 10K resistors

for each of the 8 analog channels. A direct connection would render the inputs

useless (as any voltage input would cause a short circuit).

Using a 10K resistor on each input channel allows us to keep the inputs quiet

while allowing you to actually use the inputs.

For most applications, this jumper should be set to the UP position. This will pull

each analog input UP, causing the Analog values to read as 255. Any drop in the

input voltage can be used to trigger relays or Reactor events. So if you were to

connect a switch between an analog input and ground, Reactor Events could be

triggered every time a button is pressed.

Electrically, it is very safe to connect switches to analog inputs and to GND

(ground). When the Up/Down jumper is set to the UP position, the Reactor will

be able to detect switch and button presses. Switches are the safest type of device

to connect to a Reactor, as they do not introduce voltages from external sources.

Analog inputs will be discussed with a focus on a practical application later in this

guide. Consider this section as a simple introduction to Analog inputs.

Understanding Outputs

In the previous section, we introduced you to Analog Inputs and how voltage

changes play a key role in triggering Relays and Reactor logic. The subject of

Reactor Logic will take a little more time to explain, and in this section, we will

continue our focus on the hardware portion of the Reactor controller with our

next topic: Understanding Outputs.

Reactor Controllers have 1, 2, 4, or 8 Relays integrated into the circuit board. A

relay is similar to a switch. The only difference between a switch and a relay is the

actual mechanism for changing the on/off status of the switch. On a switch, you

manually push on a piece of metal or plastic to operate the switch. On a relay, an

electric current is used to operate the switch. Though a relay resembles the

characteristics of a switch, it cannot be controlled by touching it with your finger.

We will use the word “Relay” to indicate a switch that is controlled by the Reactor

controller.

Relays do NOT provide a voltage output. They provide a contact closure output,

exactly like the terminals found on a light switch at your local hardware store.

Wiring to a relay will be slightly different depending on the model of Reactor

controller you choose.

Some relays, such as the 5A and 10A versions have screw terminals that can

accept 12 Gauge or smaller wire. Other versions such as the 20A and 30A relays

have a .250” Quick Connect terminal (the appropriate mating connector can be

found at any hardware or automotive supply store). Our 20A HP series relays will

accept wires as large as 10 Gauge.

Again, relays do not provide a voltage output. They ONLY switch whatever

voltage you supply into the relay.

Relays are available in SPST, SPDT, and DPDT configurations. In addition, both

Mechanical and Solid State relays will be supported by the Reactor series. If you

are unfamiliar with the different versions of relays available, you can review the

this article, which explains these relay types in great detail.

The above article will help you determine the best type of relay for your

application, showing you the formulas for calculating relays sizes that are

appropriate for your application.

If you intend to use the Reactor Series relay controllers for inductive applications,

this article MUST be reviewed. An example of an inductive application is any

device that involves motion. For instance, using a Reactor Controller to control a

motor, a solenoid, or a valve. Other types of inductive applications include

anything with a transformer such as a fluorescent light or a power transformer of

any kind. Logic circuits (including those found on the Reactor Controller) may

malfunction in severe conditions. The above article will show you how to safely

implement these kinds of loads which greatly reduces the chances of a

malfunction. Some inductive applications generate excessive noise, and may not

be suitable for use with the Reactor Series Relay controllers. Solid State Reactor

Relay Controllers should be considered for these high-noise applications.

Controlling Relays

There are three possible ways to control the relays on a Reactor Series controller.

1. A Relay can be Directly Controlled by an Analog Input. When an analog

input changes state or reaches preset levels, a relay can be activated or

deactivated.

2. An Analog Input can trigger an Event (such as a timer or a counter) in the

Reactor logic. A Relay can be associated with a Timer or Counter event. In

this way, relays are NOT controlled by inputs. Timer and Counter events are

triggered by inputs, and relays are associated with these events. This is the

most powerful method of relay control and will be explained in great detail in

this manual.

3. A Relay can be controlled from a computer such as a ZigBee wireless

interface, Ethernet Interface, Wi-Fi Interface, or USB interface. A computer

can take control of any or all relays on a Reactor controller at any time. Once

taken over, the Reactor logic will not be able to switch a relay. The computer

MUST return control of the relay back to the Reactor Logic for stand-alone

operation. The default power-up status of a Reactor controller is

Autonomous control (self-controlled).

Controlling Relays with a Key Fob

A Key Fob can also be used to control relays. However, it is important to

understand that the Key Fob interface chip is not connected to the relays.

Instead, it is connected to the Analog Inputs of the Reactor Chip. This allows you

to use a Key Fob to activate relays in very complex ways, but often reduces the

number of available analog inputs.

Limitless Relay Control

Whether you will be using an analog input or a key fob to control the relays on

your Reactor controller, relays can do many things:

1. Relays can “Flash” in the Background

2. Relays can “Cycle” in a pattern in the Background

3. Relays can be activated for a duration of time

4. An Analog Input Change (or Key Fob button press) can trigger the

“next” relay in a sequence

5. An Analog Input (or Key Fob) can Activate a Relay

6. An Analog Input (or Key Fob) can Deactivate a Relay

7. A Relay can Change State as an input changes state (a relay can be on as

long as you press the button on a key fob, once released the relay will

change state again)

Relay may be triggered in very complex ways, in combination with key fob AND

analog inputs, or by timers, counters (called Rotations), or from a computer. It is

important to understand that we have created a very open architecture that will

allow relays to be used in some amazing switching operations WITHOUT

programming!

Break-Away Tabs

Physically, most Reactor controllers are actually two sizes. When you receive your

Reactor, the shape and size ensures the Reactor can fit into a standard enclosure.

Optionally, you can make the controller smaller by breaking away the outer tabs.

Break-Away tabs are useful in applications where space may be a concern. This

allows your Reactor to offer the same functionality in the smallest possible profile.

Break-Away tabs are unique to the NCD product line and are a standard option

for most devices released in 2010 and later.

Before breaking the tabs on your controller, please be advised that your Reactor

controller will not be returnable for refund or credit if the Break-Away Tabs have

been removed.

To break away the tabs, gently but firmly grab each break-away tab with a pair of

pliers and bend the tab back and forth until it breaks away from the main circuit

board. This will NOT damage the controller in any way.

Breaking the Tabs from a controller DOES NOT VOID the warranty. Please see

the NCD return policy if you would like more information on the policies that

apply to Surface Mount devices.

LRR810 shown here as shipped from National Control

Devices. The shape accommodates a standard enclosure.

Bend the tabs to break them away from the board.

Note that controllers with Broken Tabs are NOT

Returnable for Refund or Credit, but are still covered

under our Warranty.

Shown left, the final controller with tabs removed is

physically smaller in size, but no-longer fits a standard

enclosure.

Reactor Configuration

Communications

Establishing communications with a Reactor controller is an essential step in using

this device. Communications can be very simple or seemingly very complicated

depending on your background and communication method you have chosen.

Reactor series controllers are available in many different varieties. While all

Reactor controllers are capable of functioning WITHOUT a computer, a

computer is REQUIRED to configure the Reactor controller. Once configured,

the communications module may be removed (on select Reactor models) and used

again to configure other Reactor controllers.

The way the Reactor controller communicates with your computer depends on the

communication option you have chosen. By far, the easiest and most

recommended communication interface is USB using the ZUSB communications

module. If you choose another interface, we strongly recommend also purchasing a

USB interface to be used if a recovery of communication is needed. For

information on your chosen communication interface, please refer to the quick start

guides available on the resource page of our website: www.controlanything.com.

Reactor Configuration

1. Connect the Reactor controller

with your preferred interface.

2. Next, download and install our

NCD Base Station software. This

program will allow you to identify,

configure, and test your device and

is a powerful tool used to load and

save profiles into a Reactor

controller.

3. Run the NCD Base Station

program.

4. From the ‘Select Connection’

window, choose the Com Port of

your Reactor controller and click

‘OK’.

Chapter

Base Station will list the available command sets for your device.

5. Choose ‘Reactor Class Controllers Configuration’ as shown below.

When communications is established, you will see the following screen appear.

This screen has several tabs across the top that allow you to configure your

Reactor controller.

The “Global Device Configuration” tab is used to Load and Save all settings (in all

tabs) into a Reactor controller or into a Configuration file. New users are strongly

encouraged to review the Application Videos on our website outlining potential

applications, and you might find something that is similar to the application you

are looking for.

Some users may find the Reactor controller particularly suitable for a specific

application. Once you have created a Configuration file that matches your needs,

you may email your Reactor configuration file to us and we can build and ship any

number of Reactor controllers with your configuration built in! This will save you

time and allow you to order a controller that is customized for your exact

application at no additional cost.

Note:

It is NOT Possible to Store Reactor Configuration data into the Reactor Controller

when the Program/Run jumper (PGM/RUN) is set to the Run position. This

jumper may be changed at any time. Power cycling is NOT REQUIRED.

Program Mode allows you to permanently write to on board nonvolatile storage.

Use this mode to load, test, and modify Reactor configuration data.

Run Mode write protects memory, making it impossible to store new configuration

settings.

Jumper settings are read by the Reactor firmware only during an operation that

requests a write to on-board memory.

Reactor Sample Library

Please review the Reactor Sample Library to see a current list of Reactor

Configuration files and a list of descriptions. The samples provided can save you a

lot of time, as we offer samples for many applications.

Input Configuration

On pages 8-9 of this guide, we discussed Analog inputs. As a refresher, Analog

inputs accept a voltage from 0-5VDC and convert this voltage to a number from 0

to 255. A value of 0 indicates 0 volts. A value of 128 indicates 2.5 volts. A value

of 255 indicates 5 volts are present on the analog input.

The ‘Input Configuration’ tab is a window into the heart of what triggers relays on

a Reactor controller…the Analog Inputs. When the ‘Input Configuration’ tab is

selected, the Reactor Configuration Utility will begin communication with the

Reactor controller. This live communication will show you the current values of

the analog inputs. You will use these values to trigger relay and events.

Before we get started, we need to introduce you to the concept of Pivots. Let’s

say you have a light that you want to come on when it gets dark outside. And you

have determined that it gets dark when Analog Input 1 reaches a value of 180.

And let’s just say it is getting dark outside and the value on analog Input 1 is

floating between 179 and 180. A relay would turn on and off violently until it gets

dark enough to keep the relay on. This is NOT a desirably condition. It will wear

out the relay prematurely and will render the controller useless for most

applications. It is this kind of condition we want to avoid. To help reduce this

undesirable behavior we use Pivots.

Pivots are like a shadow for the analog input. Pivots “chase” the analog input,

always seeking to match the value of the analog input. But they are slower to

respond and always seem to lag behind. So if an analog input fluctuates violently,

this really doesn’t matter much to the Reactor. The Reactor will be immune to

this because relays and events are not really triggered by the Analog inputs, but

rather the Pivots.

We will often refer to Analog inputs as the source of the trigger. While it is true

that the analog inputs are the actual data source, events and relays are actually

triggered using Pivots. This is a permanent feature of the Reactor controller. It

cannot be changed and it would be undesirable to do so.

Pivots do not eliminate “Limit Triggers” as described above, but they significantly

reduce the occurrence of the undesirable side effects of triggering relays based on

absolute limits.

So as you apply a voltage to an analog input, you will see analog inputs go up and

down very quickly. Pivots will lag behind until they match the analog input value.

Moving the Up/Down jumper on the controller will affect the analog inputs. Try

moving the jumper to see the effects visually. When finished, move the jumper

back to the “UP” position.

When you set the

Up/Down jumper to the

DOWN position, the analog

inputs will look like this:

When you set the

Up/Down jumper to the

UP position, the analog

inputs will look like this:

With the Up/Down jumper

in the UP position, connect

a switch between Analog

Input 5 and Ground. When

the switch is closed, your

inputs will look like this:

Reactors can detect all kinds of switches including Motion Detectors, Magnetic

Door Sensors, and even Key Fobs, which we will discuss in greater detail later on.

To this point, we have demonstrated how analog inputs can read the on/off status

of a switch. Analog inputs may also be used to read everything between on and

off. Reactor analog inputs are particularly suitable for reading voltage and

resistance changes.

Sensors:

National Control Devices now stocks many sensors compatible with the Reactor

Series relay controllers. Please review our entire list of sensors here.

Reading Temperature and Light

Since analog inputs are sensitive to voltage and resistance changes, we can

experiment with connecting a temperature and light sensor directly to the Reactor

controller.

Temperature Sensors

Many Reactor controllers have a built-in temperature sensor. Look carefully at

your controller to determine if a temperature sensor is built in. The temperature

sensor is very small, and has the label TSA printed nearby (usually above the part).

The temperature sensor is shown in the photo on the right.

Another indication of a built in temperature sensor is a Jumper labeled “T” or a

Output terminal on the controller labeled “Temp Sensor Out” or “Temperature

Sensor Output”.

If your controller has a jumper labeled “T”, move the jumper to the “T” position.

If your controller has a temperature sensor output terminal, connect this output to

analog Input 8. You may connect this terminal to any available analog input;

however, our software is written to give you an approximate temperature value

when connected to Analog Input 8. Look carefully at the Reactor software, you

will see the following:

The Up/Down jumper may have a small effect on the sensor reading. We

recommend leaving the jumper in the UP position for most applications.

Temperature readings are approximate, the actual accuracy of the final device has

not been determined.

If your controller does not have a integrated temperature sensor, a compatible

sensor can be purchased from www.digikey.com, part number MCP9701A-E/TO-

ND. Please review the sensor data sheet carefully for wiring information. Some

Reactor controllers include an Auxiliary +5V output that is suitable for powering

small sensors such as the MCP9701A.

Light Sensors

There are many applications that would benefit from a Light/Dark activated relay.

Another great low-cost sensor available from www.digikey.com is part number:

PDV-P9001-ND. DigiKey offers many compatible photocells, but the PDV-

P9001 has a resistance output that works great with the Reactor controller to offer

a wide range of light detection values between dark and light.

This sensor is very easy to connect, as it only has two wires. Both wires connect

directly to the Reactor between Ground (GND) and any available analog input.

Polarity of this sensor is not important. Make SURE the

Up/Down jumper is set to the UP position.

Light sensor connected between Analog Input 1 and Ground

with the Up/Down Jumper in the UP Position.

Here is a shot of analog input 1 in a somewhat dark room:

Here is a shot of analog input 1 in a bright room:

At first glance, you might think a brighter room would show a longer graph. But

if you think about how the analog input is actually working, you see this is not the

case. The Up jumper influences the graph to be at high levels. So longer graphs

appear because the Up/Down jumper is set to the Up position. The sensor has

one side connected to ground, so the sensor pulls the graph down. Resistance

decreases as light levels increase. Therefore, the input gets pulled closer to ground

in a bright room, resulting in shorter graphs.

HINT: Sometimes it is necessary to connect a single sensor output to multiple analog

inputs. This allows you to setup more complex events based on a single sensor. The

Up/Down jumper may bias the sensor into slightly incorrect readings. Your Reactor

configuration settings can easily compensate for this. However, you may need to

remove the Up/Down jumper to “Float” the inputs for some applications.

Key Fob Inputs

Since the analog inputs on a Reactor are sensitive to voltage, a Key Fob receiver

chip is integrated into some controllers allowing users to use remote button

presses to activate relays, timers, and counters. We have tested the range of these

small Key Fob remotes and have been very impressed with their range of

operation. We tested 2 types of antennas in an attempt to define a usable distance.

Our criteria for usable distance was simple: Pick up the Key Fob, hold it in front

of you like you would a remote TV controller, and press and hold the button for 1

second. If it worked reliably, we repeated this test at a further distance.

We paired a Reactor controller with a small integrated “Whip” antenna and tested

usable range as defined above. The installation environment was typical. Not

direct line of site, some trees, masonry, and vehicles nearby. We were able to

receive signals from these small Key Fob remotes RELIABLY (working nearly

100% of the time) at 200 feet with 50% reliability at 300 feet.

We repeated the testing of our Reactor controller with a 8’ cable and a Roof Top

antenna. This outdoor antenna was put on the roof of a house, and we resumed

range testing. Reliability was nearly 100% at 1,500 feet and approximately 50% at

3,000 feet.

As we mentioned above, a

Key Fob receiver chip is

used to decode the signals

from the Key Fob

transmitter. This receiver

chip has an approximate 3V

voltage output into the

analog inputs of the Reactor

controller. When no key

presses are detected, all

analog inputs stay quiet as

shown in the photo at the

right.

This photo shows the analog inputs with 3 buttons on a Key Fob held on at the

same time. Notice how some analog inputs show a value of 1. This is caused by

voltage bleed between channels. This is normal operation. We recommend

configuring your Reactor

controller to detect a Key Fob

button press at a value of 5 or

larger. A value of 5 will make it

respond as quickly as possible

while larger values will slow the

response time. We typically set

our Reactors to respond when

analog values reach 5 or more.

Key Fob are available in 6 sizes, from a 1-button through 8-button version.

We have not yet discussed how inputs can be used to trigger relays. This topic will

be covered later. But now is a good time to remind potential users that a 1-Button

Key Fob is capable of controlling 8 relays using a Reactor controller. We will

explain this further. The important point we want to make to users is that small

Key Fobs (like the ones shown above) are available in 5 different button

configurations. There is NO cost difference between these Key Fobs. A 1-

Button and a 5-Button Key Fob are identical in cost. So choose what you need.

We will provide more in-depth information with regard to Key Fobs and how they

can be used with our controllers. But here are some of the basic functions you

can use a Key Fob for:

 Key Fob Button Triggers a Relay for 10 Minutes.

 Key Fob Button Cycles to the Next Relay

 Key Fob Button Cycles to the Previous Relay

 Key Fob Button Turns a Relay On

 Key Fob Button Turns a Relay Off

 Key Fob Button Toggles Relay State

 Key Fob Button Turns Relay On Until Button is Released

 Key Fob Button Triggers a Relay Sequence

 Key Fob Button Triggers a Background Flashing Relay

 Key Fob Button Cancels a Background Flashing Relay

 Key Fob Button Triggers a Timer, which Triggers another Timer, which

Triggers a Rotation.

Key Fobs may be used to trigger complex events and timers. The capabilities are

extensive. It is even possible to mix analog input logic with Key Fob Button

Presses to build complex events, timing sequences, and logical operations.

Now that you have a complete understanding of inputs, it’s time to explain how

these input values are used.

Key Fob Input Map

When a Key Fob button is pressed, a voltage is applied to an Analog Input on the

Reactor Chip. This map shows you which buttons generate voltages on each of

the 8 Analog Inputs.

Key Fob Remotes:

Right Button: Generates a Voltage on Analog Input 1

Up Button: Generates a Voltage on Analog Input 2

Left Button: Generates a Voltage on Analog Input 3

Down Button: Generates a Voltage on Analog Input 4

Center Button: Generates a Voltage on Analog Input 5

Our small Key Fob remotes offer excellent

communication range (over 200 feet).

Long Range 8-Button Remotes:

1 Off Generates a Voltage on Analog Input 8

1 On Generates a Voltage on Analog Input 7

2 Off Generates a Voltage on Analog Input 6

2 On Generates a Voltage on Analog Input 5

3 Off Generates a Voltage on Analog Input 4

3 On Generates a Voltage on Analog Input 3

4 Off Generates a Voltage on Analog Input 2

4 On Generates a Voltage on Analog Input 1

Inputs should be Configured to a Minimum Lower Limit of 5 and a Maximum

Upper Limit of 160.

Since Analog Input 1 is associated with the Right Key Fob Button, a voltage will

be detected when the button is pressed. On 8-Button remotes, Analog Input 1 is

associated with the Row 4 ON button. Typical voltages will be lower than 5 when

the button is NOT pressed and higher than 160 when the button is pressed.

Our small Key Fob remotes offer excellent communication range (over 200 feet).

Each button corresponds to a analog input when pressed. Choose a Key Fob that

matches your needs, the prices are the same for all models. Two to three buttons

is suitable for most applications. Keep in mind, eight relays can be controlled with

a single button using Rotations! It is often nice to have a few extra buttons for

other features as well.

Long Range Key Fob Remotes

are small, and offer 8 Buttons

of remote operation. The

external antenna on this

model improved range by over

100 feet when tested with an

outdoor antenna.

Using Inputs and Outputs

Using Inputs

To this point, we have demonstrated how the Reactor controller reads analog

inputs. Now it’s time to put these inputs to actual use.

Before we get started, we need to explain one small detail. In the coming pages of

this manual, you will see us use the word “Event” and the phrase “Trigger an

Event”. You can guess what it means to trigger a relay. But triggering an event is

very different. The purpose of the Input Configuration tab is to allow users to

setup input triggers.

An input can trigger a relay directly or an input can trigger an event, such as a

timer. If an input triggers a relay, the relay may turn on. If an input triggers a

timer event, a timer may be started, but a relay may or may not be turned on based

on how you have configured the controller.

In summary, there are two different types of input triggers:

1. Inputs may Directly Trigger Relays.

2. Inputs may Directly Trigger Events. Triggering an event does not mean you

are triggering a relay, it just means you are triggering an internal function.

Relays may be associated with this internal function to achieve a large

number of possible operations.

Note: The Reactor Configuration Utility was designed to be as intuitive as possible

while still providing powerful functionality. When setting up a Reactor controller using

our software, read from the extreme left to the extreme right as you make changes to

your settings. This can sometimes help make sense of complex functions.

Chapter

The ‘Input Configuration’ tab on the Base Station software shown below allows

users to define the activation of a relay or an event based on the voltage readings

of the analog inputs.

Again, the focus of this screen is to set input trigger points. In other words, to

define limits that will activate relays and events. For instance, if you determine

that it is dark outside when an analog input reaches a value of 200, then the input

trigger point would be 200. Let’s start with a few examples and read through them

so you understand what will happen.

Reading from Left to right, the settings above indicate Input 1 will trigger a relay

when Analog Input 1 is above 200. We will not define which relay will be active

on this screen. Input 1 is making a direct reference to Analog Input 1. In this

case, we have defined that a relay will turn on when it gets dark outside, and the

level of darkness is defined by a value of 200. Higher values will indicate a darker

condition while lower values will indicate brighter condition when following

examples on previous pages.

In this case, Analog Input 1 will trigger a relay when the value is below the 200

limit. In a light/dark condition, this would turn On a relay when it is light outside

and turn off a relay when it gets dark.

In the above example, a relay is triggered when an analog input is inside a set range

between 100 and 202. By defining two limits, you can further narrow the

parameters for the activation of a relay.

Similarly, you can trigger a relay outside two limits. This indicates a relay will turn

on under two extreme conditions:

Below 96 and Above 220.

Above, Input 1 will trigger the timer #1 event when an Analog input is above 96.

Input 2 will trigger the timer #2 event every time an analog input crosses the

boundary limit of 100 (so if the input is moving up or down, every boundary cross

will trigger the timer event).

In this example, Input #1 will trigger event timer #1 when an analog input is

inside the limits of 96 and 200. Input #2 will trigger event timer #2 every time an

analog input crosses the 100 or 200 boundary mark.

The next tab allows you to assign Relays to various functions. Let’s take a closer

look at the different ways we can connect a relay to an input, timer, or rotation.

Output Configuration

To this point, we have demonstrated how the Reactor controller reads analog

inputs. Now it’s time to put these inputs to actual use.

The ‘Output Configuration’ tab shown below allows users to assign relays to

inputs and events.

Reactor controllers have up to 8 relays available depending on the actual model

selected. Each relay can be assigned to a different input or event.

Again, reading the configuration from left to right helps make sense of the

function that will be performed.

In the example shown below, Relay 1 is Controlled by Input 1 Directly. Input 1

will turn Relay 1 ON. In order for Relay 1 to activate, it must meet the conditions

of the Input 1 configuration using the settings on the Input Configuration tab.

There are many ways to directly control a relay from an input. Relays 1-5 in the

examples show how inputs can turn relays on, off, toggle relay state, set the relay

to match the state of the input, or set the relay to NOT equal the state of a input.

In this example, Relay 6 is controlled by Timer 1. In other words, if Timer 1 is

active, the relay will stay ON. Otherwise, the relay will turn off. This is a great

way to activate a light for a given period of time. Timers will be discussed further

in the pages to come.

In the example shown below, relays may also be controlled by rotations. A

rotation is a counter that always starts at 0 (all relays are off when the counter is at

0. As the rotation (counter) increases, the relays will “count” accordingly.

In this sample, Relays 1-3 are controlled by Rotation A (the first of 4 available

counters). Relays 4 through 8 will be controlled by Rotation B (the second of 4

available counters).

Rotations will be fully explained on the next page, and samples will show the use

of these rotations so that you may get a better understanding of their function.

Rotations are critical to the Reactor, as a single input can be used to control up to

8 relays using a single rotation. There are many types of rotation parameters that

control the behavior of rotations. But for now, simply think of a rotation as a

simple counter.

Reactor Event Configure

eactor events unlock some of the most powerful features a Reactor controller

has to offer. Learning about Reactor Events will allow you setup complex

actions.

Timer Events

Timer events work just as the name implies. You can define up to 8 timers that

run in the background. Each timer can have a different time assigned to it.

Timers can be triggered or canceled based on input events. Relays can be

associated with timers so the relays only come on when the timer is active. Timers

support Event Piping. Event Piping means a timer can trigger another timer or

another event after the timer has completed its cycle. We will demonstrate this

feature in our samples.

Chapter

Rotations

Rotations are another powerful feature of the Reactor controller. Rotations are

simply counters. All Rotations begin their counting at 0. Any relays that are

associated with a Rotation will turn off if the Rotation counter reaches 0. There

are 4 Rotations: Rotation A, B, C, and D. Rotations can also run in the

background, or they can be stepped, one count at a time. You can define how far

they count. In the above example, Rotation A is a 3-count Rollover Rotation.

This means it will count: 0, 1, 2, 3, 0, 1, 2, 3, etc. Rotation B is similar to Rotation

A, except it counts from 0 to 5. Rotation C is a 2-Count Rotation, meaning it

counts: 0, 1, 2. Unlike the other rotations, Rotation C is a Halt on Limits rotation.

This simply means it will count up to 2 and no higher and will not cycle to 0.

These kinds of counters usually need a trigger to increase them and a separate

trigger to decrease them. You can define two inputs: One to count up, another to

count down.

Rotations can be interpreted by the relays in four ways. The first column sets the

way relays will interpret your Rotation.

1. Binary Rotations: Relays activate in a binary pattern.

2. Sequential Rotation: Relays activate in a sequence, one after another until all

associated relays are on.

3. Incremental Rotation: Only ONE relay is on at a time, each count triggers

the next relay.

4. Reverse Incremental: Same as above, but relay activates in the reverse

sequence.

To better understand the types of Rotations, we have provided many samples that

show relays associated with Rotations. Please review the Reactor Sample Library

for more information.

Auto-Rotations can also be triggered. An Auto-Rotation is the same as a

Rotation, except it runs through a complete counting cycle automatically. When a

Auto-Rotation has finished, it can triggers itself again, which results in relays

switching automatically in the background. This is very useful for relay flashing

operations.

Speed Control

In many cases, it is necessary to define the speed at which an event occurs. This is

done by redefining the length of a second. In the picture below, we have

redefined the length of a Reactor Second to 70 to speed up timing operations.

This is ideal for controlling the flash rate of a relay, but it has the side effect of

redefining the length of a second for all event operations, so timing events are no

longer accurate. Clicking the ‘Restore Default’ button will restore this value to

closely approximate a One Second.

Event Piping

Perhaps the most powerful feature of the Reactor Relay Controller is Event

Piping. Event piping is the process of one event triggering another event. When

a single event has finished its operation, it can trigger another event. For instance,

a Timer Event can be set for 10 minutes. A Rotation event can be set for 0-1

count rotation. When the timer expires, the Rotation can be increased. In a real-

world example, this would be the equivalent of waiting 10 minutes to turn on a

relay. Understanding Event Piping is the key to unlocking the most powerful feature the

Reactor Series Relay Controllers have to offer. Let’s take a look at a few event pipe

examples:

The top portion of the above sample demonstrates a timer that triggers a timer that

triggers a timer...etc. This event pipe never ends, meaning when the last timer finishes,

the entire cycle begins again. You can easily associate relays to each timer and watch the

relays activate for the durations shown in the sample above.

Event Piping Rotations

Rotations may also pipe events to trigger other rotations. Here is an example of a

never-ending Event Piped Rotation sequence:

In the sample above (bottom portion of the ‘Reactor Event Configuration’ tab),

Rotation A triggers Rotation B, which Triggers Rotation C, which Triggers

Rotation A. Experimenting with Rotations will yield some interesting relay

control patterns that could be used to light driveways, control lights on signs, and

many other special effects related control applications. Again, the rate at which

Rotations are processed is defined by altering the Length of a Second as shown

previously.

Event Piping Timers and Rotations

Timers and Rotations may also be Event Piped. Here is an example of How

Timer 1 Triggers Rotation A, when Rotation A is finished, Timer 2 is Triggered.

When Timer 2 is finished, Rotation B is Triggered. When Rotation B is finished,

Timer 1 is triggered again.

Learning More about Event Piping

The best way to learn about event piping is to review the Reactor Sample Library.

Here you can see practical applications of Timers and Rotations that have been

Event Piped for some very powerful operations. Experimentation is highly

encouraged. There is no danger is trying different settings to see how the Reactor

controller responds. Our only suggestion is make small changes and note how the

controller responds with each change. Saving and Loading configuration files is

quick, and you can experiment with settings by keeping the Program/Run jumper

in the Program setting. Don’t change the jumper until the desired results have

been achieved.

Advanced Features

Multiple Event Triggering

It is possible for a single input to trigger multiple events simultaneously. The

Reactor Controller is capable of processing 8 Timers and 4 Rotations

simultaneously. Triggering all of these events at once is easily configured using the

Multi-Event Configuration Tab. This tab is ONLY Available if it has been

activated. To activate this time, Go to the ‘Input Configuration’ tab; setup any

input to <SELECT MULTIPLE EVENTS>

After selection, the Multi-Event Configuration Tab will appear as shown in the

window above. The window below shows how Input 1 can be configured to

execute several events simultaneously:

Note the Heading is Labeled “Input 1 Event List”. An event list is available for

Every input.

Chapter

Multiple Event Execution lists can become very complex:

While this feature is very useful for some operations, most of our samples do not

use Multiple-Event Execution lists.

However, there are a few samples that would never function properly without this

feature, so it may be worth exploring if you want to unlock some of the most

advanced operations of the Reactor Series Relay Controllers.

Protected Data

Editing Protected Data

Protected Data is best described as a form of BIOS for a Reactor controller.

Under most circumstances, it is not necessary to Edit Protected Data, but there

are circumstances that may require this operation. Protected Data holds

important parameters regarding the Reactor Relay controller you are using. It is

important that these parameters match your hardware. In some cases, you may

want to change your hardware, so Editing Protected Data may be essential.

From the Base Station ‘Global Device Configuration’ tab, click on ‘Edit Protected

Data’. This will bring up more options.

There are two particularly useful settings that can be changed:

1. LIVE Reactor and Interface (shown as USB below)

2. LIVE Reactor and Reactor Options

If you plan to use your Reactor controller without a communication module installed, this

setting should be set to “Reactor” and the Program/Run Jumper must be set to

Runtime mode for daily operation. If you do not change this setting, it is possible

for the controller to set the BUSY/READY LED to BUSY and the controller will

appear to freeze. The controller has not actually frozen, but is waiting for data

from a computer. Setting this mode to “Reactor” instead of “LIVE Reactor” will

prevent the controller from monitoring computer data.

Chapter

Interface settings allow users to take advantage of communication technologies.

The only real effect this setting has is changing the internal baud rate of the

Reactor relay controller. For instance, USB is always set to 115.2K Baud while

XSC is always set to 57.6K Baud. We have also made provisions for an RS-232

Interface at 9600 Baud. Most baud rates are 115.2K Baud. You can lie to the

controller, telling it to use a RS-232 9600 Baud Rate while actually using a USB

interface. In this case, you can communicate to the controller at 9600 Baud

instead of 115.2K Baud. However, this change ONLY applies to Runtime Mode.

Configuration Mode is ALWAYS 115.2K Baud (the required communication

speed of all sample programs and the NCD Base Station software).

The other settings found on this page are used to enable and disable interface

elements of the NCD Configuration Utility. Changing these settings can prevent

normal configuration. When possible, make sure the settings match your

controller. If we happen to send you a controller with incorrect parameters, you

can make changes to these parameters yourself.

The PGM/RUN Jumper Must be Set to PGM. After you have changed your

settings, Click the ‘Store Protected Data’ button. Power Cycle the Reactor Relay

Controller and Restart the NCD Configuration Utility for your changes to take

effect.

Override Reactor Logic

The Reactor Series Relay Controllers offer both autonomous control and

computer control. By default, the Reactor controller is in Autonomous Mode,

meaning it is making its own decisions about how relays should be activated. At

any time, a computer may over-ride the Reactor logic and take control of relays. If

a command is received from a computer, the computer will have priority over the

Reactor Logic. Priority can be set for each relay. This allows some relays to

operate under autonomous control while other relays are controlled by a

computer. The computer may “Return” one or all relays back to the Reactor

Logic.

The Reactor Series Relay controllers support a “Lite” ProXR command set. If

you are familiar with our ProXR series relay controllers, then the command set

should be easy to understand. We will provide a summary of all Reactor

commands in this manual, but for now, let’s explore some of the computer

control features.

From the Base Station window, click on ‘Override Reactor Logic’ tab.

A. The interface elements at left allow a computer to take over control of any relay and force the relays to a

On or Off state. You may also set the On/Off state of all relays at one time using the arrows shown in

the interface. When using this command, all relays are set to the equivalent binary value of the number

shown and all relays will be under computer control. Reactor Logic is still running in the background,

but Reactor Logic will not have control of any relays that are currently under computer control.

B. The Return Control of Relays to Reactor Logic tells one or all relays to operate under control of the

Reactor Logic. Computer override is canceled for each of the affected relays. When these buttons are

clicked, the relays may turn on or off according to the decisions made by the Reactor Logic.

C. The computer can ask the Reactor Controller the state of the relays without affecting who has control of

the relay. This function is very useful if a computer needs to periodically evaluate the Reactor Logical

operations, or if a computer simply needs to report the status of the relays to a remote user. It is

possible to query each individual relay or all relays simultaneously.

D. Since a Reactor has Default Control of the Relays on Power-up, it is not really possible to set the state of

the relays when power is first applied, as the Reactor Logic will immediately override the stored value

and determine a new relay status. It is, however, possible to set the default state of all 8 inputs. This can

prevent an event from triggering when power is first applied, or it can force an event to trigger when

power is first applied to the Reactor Relay Controller. Set this value to Match the expected normal

analog input values to prevent an event from triggering. Set this value to exceed the limit of a input

value to force the event to trigger. This value sets the default status of ALL inputs, so multiple events

may be triggered by this setting.

E. At any time, a computer may forcefully trigger a Reactor Event. This is a great way to take control of a

relay without forcing the relay under computer control. Triggering events from a computer can also help

you identify and test various configuration settings.

We have plans to exploit this loophole in the form of new accessory devices...

Computer Access to A/D Values and Pivots

Reading A/D Values

The Reactor Series Relay Controllers support AD8 Series ProXR commands for

reading 8-Bit Analog Values. 10-Bit commands are NOT supported by this

device.

Reading Pivots

The Reactor Series Relay Controllers allow the user to read the Reactor Pivot

Values. Pivot Values are used to make reactive decisions, and are derived from

A/D values using a proprietary algorithm.

Command Set

The following commands may be sent to the Reactor Series Relay Controllers to

take control of relays and process other functions and inquiries. Commands may

be sent in Decimal values (as shown) or Decimal Values may be converted to Hex

depending on the preferred format of your programming language.

Please follow these steps to properly communicate to a Reactor:

1. Clear Serial Receive Buffer (VERY IMPORTANT)

2. Send Command

3. Wait for a Response

Baud Rate is typically 115.2K Baud, 8 Data Bits, 1 Stop Bit, No Parity.

Baud Rate is 57.6K Baud for XSC Devices

Baud Rate can be set to 9600 Baud for RS-232 Version

IMPORTANT: For proper execution, please wait 1ms between bytes when

sending data to this controller.

Example to Activate Relay 1:

 Clear Serial Receive Buffer

 Send Byte 254 (Hex 0xFE)

 Wait 1ms (Windows 7 Users May need to Wait 2ms)

 Send Byte 8 (Hex 0x08)

Send Bytes: Byte 1: Byte 2:

Function: Header Command Code

Decimal Values: 254 8

Hex Values 0xFE 0x08

Receive Byte: Decimal: 85

Hex: 0x55

Computer Access Command Set

Supported ProXR Command Set

The following commands may be sent to the Reactor Series Relay Controllers to

take control of relays and process other functions and inquiries. Commands may

be sent in Decimal values (as shown) or Decimal Values may be converted to Hex

depending on the preferred format of your programming language. The Left

column indicates the header byte; the second column indicates the command

code. A parameter (if required) is shown in the third column. A description

indicates the function of the command, and finally return bytes are shown.

Header

Byte

Command

Code

Parameter

Description

Return

Bytes

254

Turn Off Relay 1

Automatically Overrides Reactor Logic

254

Turn Off Relay2

Automatically Overrides Reactor Logic

254

Turn Off Relay3

Automatically Overrides Reactor Logic

254

Turn Off Relay4

Automatically Overrides Reactor Logic

254

Turn Off Relay5

Automatically Overrides Reactor Logic

254

Turn Off Relay 6

Automatically Overrides Reactor Logic

254

Turn Off Relay 7

Automatically Overrides Reactor Logic

254

Turn Off Relay 8

Automatically Overrides Reactor Logic

254

Turn On Relay 1

Automatically Overrides Reactor Logic

254

Turn On Relay 2

Automatically Overrides Reactor Logic

254

Turn On Relay 3

Automatically Overrides Reactor Logic

254

Turn On Relay 4

Automatically Overrides Reactor Logic

254

Turn On Relay 5

Automatically Overrides Reactor Logic

254

Turn On Relay 6

Automatically Overrides Reactor Logic

254

Turn On Relay 7

Automatically Overrides Reactor Logic

254

Turn On Relay 8

Automatically Overrides Reactor Logic

254

Report Status of all Relay

0-255

254

Test 2-Way Communications

85 or

85 in Runtime Mode, 86 in

Configuration Mode

254

0-255

Set the Status of All Relays at One

Time

Automatically Overrides Reactor Logic

254

150

Get AD Input 1

0-255

254

151

Get AD Input 2

0-255

254

152

Get AD Input 3

0-255

254

153

Get AD Input 4

0-255

254

154

Get AD Input 5

0-255

254

155

Get AD Input 6

0-255

254

156

Get AD Input 7

0-255

254

157

Get AD Input 8

0-255

254

246

Get Device Identification Data

4 Bytes

Features Byte

Interface Byte

Year Byte

Version Byte

Reactor Specific Commands

Header

Byte

Command

Code

Parameter

Description

Return

Bytes

Returns Control of Relay 1 to

Reactor Logic

Returns Control of Relay 2 to

Reactor Logic

Returns Control of Relay 3 to

Reactor Logic

Returns Control of Relay 4 to

Reactor Logic

Returns Control of Relay 5 to

Reactor Logic

Returns Control of Relay 6 to

Reactor Logic

Returns Control of Relay 7 to

Reactor Logic

Returns Control of Relay 8 to

Reactor Logic

Returns Control of All Relays to

Reactor Logic

0-34

Execute Event Pipe Function

See NCD Configuration Utility Software

for a Listing in Order of Events

150

Get Pivot 1

0-255

151

Get Pivot 2

0-255

152

Get Pivot 3

0-255

153

Get Pivot 4

0-255

154

Get Pivot 5

0-255

155

Get Pivot 6

0-255

156

Get Pivot 7

0-255

157

Get Pivot 8

0-255

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Relay Logic

This is why we recommend using Reactor controllers with more relays than you may

actually need…

Using Relays to Create Logical Conditions

The Reactor Series Relay Controllers offer a great balance of flexibility and easy

configuration. However, complex decision making is sometimes outside the scope

of a Reactor controller. Relay Logic demonstrates easy ways to hard-wire your

decisions using a Reactor Controller.

We recently adapted a Reactor controller to an application that required Relay

Logic, so we wanted to share this method of solving logic problems that may be

too complicated for a Reactor configuration.

In our application, we have a motion detector that we want to activate a light for

30 seconds. But there is no point of turning a light on during the day. The

Reactor can be configured to activate a relay when it gets dark outside, and to

activate a 30-second relay timer when motion is detected. Using a simple wire

between two relays (as shown in Sample 3 Below), we can tie both events together

into a relay combination. In this way, both events must be active to activate the

light.

Sample 1

This sample demonstrates how a relay can be

used to activate a light bulb. When the relay

turns on, the light comes on. Only one power

wire is switched with this sample using the

COM (common) and NO (normally open)

connections of a relay.

Chapter

Sample 2

This sample demonstrates how a relay can be

used to turn a light bulb OFF. When the relay

turns off, the light will be ON. Only one

power wire is switched in this sample using

the COM (common) and NC (normally

closed) connections of a relay.

Sample 3

This sample demonstrates how two

activated relays are required to

activate a light bulb. This is the same

as a Logic AND function because

Relay 1 AND Relay 2 MUST be on

to activate the light.

Sample 4

This sample demonstrates

how three activated lights

are required to activate a

light bulb. This is the same

as a Logic AND function

because Relay 1 AND Relay

2 AND Relay 3 MUST be

on to activate the light.

Sample 5

This sample demonstrates

the AND/OR function.

The Light Bulb will be

activated if Relay 1 AND

Relay 2 are ON OR if Relay

3 is ON. This sample is

perfect for applications that

may require a Logical condition of 2 relays PLUS an Override feature. For

instance: Relay 1 is a Night/Day Sensor, Relay 2 is a Moisture Sensor. If it’s Dark

AND the soil is Dry, Relays 1 and 2 can activate a Pump. If you want to override

these conditions with a Key Fob, Relay 3 may be used.

Sample 6

This sample demonstrates how

either relay can be used to activate a

light. In this sample, only one

activated relay is required to activate

the light. If both relays are

activated, the light will be on.

Sample 7

This sample demonstrates how a 3-

way light switch can be used to

activate a light. A 3-way light switch

is often found in your house where

two light switches can be used to

activate a single light. This sample is

exactly the same as a 3-way light

switch, the only difference being

each physical switch is replaced by a

relay. Operationally, it works the same way. Each relay activation will cause the

light to toggle. Switching two relays at one time is like flipping 2 switches at

once....with the same result. This sample is particularly useful since you can

replace one relay (as shown in the diagram) with a physical light switch. This will

allow a computer/Reactor to control a light as well as manual operation of a light.

Properly used, this can be one of the most valuable diagrams we offer on this

page.

Sample 8

This sample demonstrates

how to control the direction

of a DC motor using 2 relays.

Braking is accomplished by

connecting both motor

terminals to a common power

connection (Faraday's Law).

The capacitors shown may

not be required for small

motors, but if you experience

problems with relays shutting

themselves off, the induction suppression capacitor will be required. The .1uF

capacitor helps suppress electronic noise if the battery were to be used by sensitive

devices (such as radios/amplifiers).

Advanced Relay Logic

Hint: Connect the Relay Outputs of your Reactor to the Analog Inputs of

the Same Reactor Controller for more Powerful Relay Logic Possibilities.

Advanced Logic

In the sample below, Relay 1 turns on when it gets dark outside and turns back off

when the light sensor detects light. The output of this relay is fed back into the

controller on Analog Input 2. This triggers a timer to activate Relay 2 for 30

seconds. A motion detector is connected to Analog Input 8, and will also trigger

the 30-Second Relay 2 Timer.

In this way, 2 different kinds of detectors with their own configuration may be

used to trigger a single timer. A button is connected to Analog input #3, which is

used to cancel the timer and turn off relay 2.

Maximum Ratings

Absolute Maximum Ratings

Minimum

Rated

MAX

Input Voltage Requirements VDC

14.5

Aux Output Voltage (Select Controllers Only)

N/A

5.00 VDC

N/A

Aux Output Amperage (Select Controllers Only)

0ma

N/A

100ma

Amperage Requirements

Standby (No Relays On, No Communication Module)

31ma

ZUSB USB Communications Module Installed

33ma

XBee 1mw Communications Module Installed

32ms*

XBee 100mw Communications Module Installed

32ma*

Each 5A/10A Relay Activated Adds to Consumption:

32ma

Each 20A/30A Relay Activated Adds to Consumption:

45ma

Each Solid State Relay Activated Adds to Consumption:

5ma

Temperature Ratings (Estimated)**

-25°C

80°C

Mechanical Relay Cycle Life (Non-DPDT Versions):

>10,000,000

Cycles

Mechanical Relay Cycle Life (DPDT Versions):

>2,000,000

Cycles

Typical Operational cycles per Minute

1,800

Relay Activation Time:

>5ms

<15ms

Relay Deactivation Time:

>5ms

<20ms

Command Processing Time

1ms

3ms

5ms

Relay Electrical Limits should be Determined by Reviewing Appropriate Relay Data Sheet:

5A Relays Data Sheet

10A Relays Data Sheet

20A Relays Data Sheet

30A Relays Data Sheet

Solid State Relays Sheet

*Communications will Increase Current Consumption by up to 250ma for short times.

**Ratings Based on Data Sheets of Component Used, Actual Tolerance May Exceed Ratings.

Chapter

Trouble Shooting

Base Station Software can be used to test and troubleshoot your device.

 Run Base Station software.

 Choose the appropriate Com Port and click ‘OK’.

 Click on ‘Reactor Relay Quality Control and Diagnostics’ to start testing

your device.

This a screen shot of the Reactor Relay Quality Control and Diagnostics window.

Chapter

This is a screen shot of the Reactor Relay Quality Control and Diagnostics

window:

A. Determine the number of relays to test.

B. Pause Test feature allows you to switch boards in the middle of a test.

C. Allows choice of which relay banks to test.

D. Set testing speed.

E. Program Run Jumper test.

F. Reset Test option rests all test fields.

G. Tests the function of LEDs.

H. Tests relay continuity.

I. Test Communications module.

J. Measure Output voltages test.

K. Select COM port.

L. Automated Relay testing.

M. Manual Testing option shrinks the window to exclude all automated testing

options.

N. Clear Test resets automated testing fields.

Base Station Software can be used to Test your device.

 Run Base Station software.

 Choose the appropriate Com Port and click ‘OK’.

 Click on ‘Reactor Input Quality Control and Diagnostics’ to start testing

your device.

 To test your controller, follow the instructions on the Reactor Input

Quality Control and Diagnostics screen.

Problem: Busy LED Stays On, No Operations

Solution: This problem is usually only seen when using a Reactor Relay

controller without a communications module installed. If this is the case, please

review Page 26 for a solution. If you are using a communication module and you

have a solid BUSY LED, please check your software carefully. The Reactor

controller enters BUSY mode when it receives a valid header byte. If commands

are sent too quickly, or if commands are incomplete, the Reactor will remain in

Busy mode and no operations will be processed until the command is completed.

We have not seen the Reactor controller “crash”, but if you suspect the controller

has crashed, please run the NCD Base Station software again to attempt

communications with the controller. When the BUSY LED is solid, the controller

is focusing on communications ONLY, and will NOT process background tasks.

With this in mind, communications errors are about the only thing that can cause

this condition.

Problem: Controller is Running HOT

Solution: It is normal for some components to run very hot on the Reactor

series relay controllers. This is not a concern as we have tested the design

carefully and are operating our components well within the specified limits of the

components we are using. It is NOT normal for the CPU to run hot at any time.

The CPU should remain cool. If the CPU is running hot and/or both

Busy/Ready LEDS are on at the same time, the CPU has been damaged.

Problem: Unable to Communicate with Controller

Solution: Use the ZUSB Communications Module to validate communications;

do NOT use any other communications module if this error occurs. The ZUSB is

the safest communication method of all communication technologies, and must be

used if you experience configuration problems. Make sure you are using the

correct COM port. Our software has been tested under Windows XP, Vista, and

Windows 7. Windows XP Users MUST use .NET Framework 3.5 or Later with

all the latest service packs installed. If the problem persists, makes sure the serial

port is NOT in use by another application. Lastly, we can only recommend trying

a different computer if problems persist.

Technical Support

echnical support is available through our website, controlanything.com.

Support is the way we connect NCD engineers to our customers.

Click on the Support tab at the top of any page on our website to be

taken to the Forum page. Here you can publicly post or review problems

that customers have had, and learn about our recommended solutions.

Our engineers monitor questions and respond continually throughout the day.

Before requesting telephone technical support, we ask that customers please try to

resolve their problems through Support first. However, for persistent problems,

NCD technical support engineers will schedule a phone consultation.

Chapter

Contact Information

National Control Devices, LLC

PO Box 455

Osceola, MO 64776

417-646-5644 phone

866-562-0406 fax

Open 9 a.m. - 4 p.m. CST

Like “National Control Devices” on Facebook, and follow us on Twitter

@ControlAnything.

All orders must be placed online at our website, www.controlanything.com

Notice:

The only authorized resellers of NCD products are

 www.controlanything.com

 www.relaycontrollers.com

 www.relaypros.com

All other websites are not authorized dealers; we have noticed some retailers

offering our products fraudulently.

National Control Devices

2754 Q05N_EN Reactor Quick Start Guide

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