NO POWER & SIGNAL CABLES

TOGETHER

READ CAREFULLY IN THE TEXT!

Alfa LU-VE ICM

User manual

Intelligent Control Management EC fans

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Content

1. INTRODUCTION 5

1.1 Main features ................................................................................................... 5

2. INSTALLATION 6

2.1 Alfa LU-VE ICM control terminal block ....................................................... 62.2 Alfa LU-VE ICM connection diagram .......................................................... 62.3 EBM fan serial connection ............................................................................ 72.4 Ziehl-Abegg fan serial connection ............................................................... 72.5 BMS configuration .......................................................................................... 72.6 Installation ........................................................................................................ 8

3. USER INTERFACE 9

3.1 Keypad ............................................................................................................ 93.2 “Main” screen .................................................................................................. 9

4. MENU DESCRIPTION 10

4.1 Main menu ..................................................................................................... 104.2 Passwords ....................................................................................................... 10

5. FUNCTIONS 11

5.1 Set point .......................................................................................................... 115.2 Unit On-Off .................................................................................................... 115.3 Control ............................................................................................................. 115.4 Fan parameters .............................................................................................. 125.5 Floating set point........................................................................................... 135.6 Electrical panel heating or cooling management .................................. 135.7 Spray Water System ...................................................................................... 135.8 Day-Night and Summer/Winter function ................................................ 145.9 Seasonal setting & time bands ................................................................... 15

6. SIGNALS AND ALARMS 16

6.1 Alarm management ...................................................................................... 166.2 Fan alarms ...................................................................................................... 166.3 Pressure/temperature alarms ..................................................................... 166.4 Alarm table ......................................................................................................17

7. START-UP 18

7.1 Guided commissioning procedure ........................................................... 187.2 Setting the fan addresses ............................................................................ 18

8. PARAMETER TABLE 19

8.1 Parameter table and Variables only accessible via serial connection (BMS), are available to man. code: +0800011ML ................................. 19

9. SOFTWARE UPDATE 20

9.1 Setting the controller’s address ..................................................................209.2 Setting the terminal’s address and connecting the controller to the terminal ...............................................................................................209.3 Uploading/updating the software ............................................................. 219.4 Pendrive: operating instructions ................................................................229.5 Configuring pCOWeb/pCOnet from a system screen ..........................26

WARNINGS

Only qualified personnel may install or carry out technical service on the product. The end customer must only use the product as described in the corresponding documents.

In addition to observing any further warnings described in this manual, the following warnings must be heeded for all products:• prevent the electronic circuits from getting wet. Rain, humidity and all

types of liquids or condensate contain corrosive minerals that may damage the electronic circuits. In any case, the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual.

• do not install the device in particularly hot environments. Too high temperatures may reduce the life of electronic devices, damage them and deform or melt the plastic parts. In any case, the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual.

• do not attempt to open the device in any way other than described in the manual.

• do not drop, hit or shake the device, as the internal circuits and mechanisms may be irreparably damaged.

• do not use corrosive chemicals, solvents or aggressive detergents to clean the device.

• do not use the product for applications other than those specified in the technical manual.

All of the above suggestions likewise apply to the controllers, serial boards, programming keys or any other accessory . Consequently, Alfa LU-VE reserves the right to make changes and improvements to any product described in this document without prior warning. The technical specifications shown in the manual may be changed without prior warnING.

IMPORTANT

NO POWER & SIGNAL CABLES

TOGETHER

READ CAREFULLY IN THE TEXT!

Separate as much as possible the probe and digital input cables from the cables carrying inductive loads and power cables to avoid possible electromagnetic disturbance. Never run power cables (including the electrical panel cables) and signal cables in the same conduits.

DISPOSAL

INFORMATION FOR USERS ON THE CORRECT HANDLING OF WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE)

In reference to European Union directive 2002/96/EC issued on 27 January 2003 and the related national legislation, please note that:• WEEE cannot be disposed of as municipal waste and such waste must be

collected and disposed of separately;• the public or private waste collection systems defined by local legislation

must be used. In addition, the equipment can be returned to the distributor at the end of its working life when buying new equipment;

• the equipment may contain hazardous substances: the improper use or incorrect disposal of such may have negative effects on human health and on the environment;

• the symbol (crossed-out wheeled bin) shown on the product or on the packaging and on the instruction sheet indicates that the equipment has been introduced onto the market after 13 August 2005 and that it must be disposed of separately;

• in the event of illegal disposal of electrical and electronic waste, the penalties are specified by local waste disposal legislation.

Warranty on materials: 2 years (from the date of production, excluding the consumable parts.

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1. INTRODUCTION

1.1 Main featuresAlfa LU-VE ICM is a control system for complete management of EC fans on AlfaBlue and AlfaV condenser and dry cooler lines. ICM provides “single row” control for the “AlfaBlue single fan row” and double row control for “AlfaBlue double and AlfaV”.

The controller can be connected to a supervisor via RS485 line (Modbus protocol) using the network card installed as standard, or via Ethernet (BACnet, ModBus protocols...) using the optional network card.

The EC axial-flow fans, manufactured by Ziehl and EBM, are managed via RS485 serial line (Modbus) or 0-10Vdc analogue signal.

Main characteristics:• control probe with pressure (4-20mA, 0-5V rat) or temperature reading

(NTC, PT1000), • management by optional external 0-10V or 4...20mA analogue signal,• temperature compensation based on outside temperature probe

reading,• electrical panel temperature control via heating output and cooling

output,• simplified setup wizard,• complete management of system alarms,• RS485 serial or Ethernet connection for BMS.

Example of a system with single row controllers

BMSSupervisor network

RS485Modbus®

RS485Modbus®

Fig. 1.a

Example of a system with double row controllers

BMSSupervisor network

RS485Modbus®

RS485Modbus®

Fig. 1.b

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2. INSTALLATION

2.1 Alfa LU-VE ICM control terminal block

J7 J10J9J8J5

J1

G G0

+5V

ref

+VD

C

ID1

GN

D

J3

C1 NC1

NO

1

J2

SYN

C

B1 B2 B3 B4 B5 B6 GN

D

ser ia l card 1

J4

J6

TLAN

GN

D C2

NO

2

GN

DY2Y1

GNX

ISOLATED

Tx/RxPWM 0/10V

GNDTx/Rx

24 V (+10/-15%); 50/60 Hz48 V (36Vmin…72 Vmax)

input voltage: max. power:

8 VA / 6 W

GN

D

ID2 Y3 Y4

0/10V 0/10V

J13

NO

3C3

NO

4

J11

NO

6 C5

NO

5J12

Fig. 2.a

I/O selection tables

Analogue inputs

B1 4-20mA/ratiometric/NTC probe or 0-10V signal for fans B2 panel internal temperature NTC B3 outside temperature NTC/PT1000B4 PT1000 probe for fan control

Digital inputs

ID1 generic fan alarm (shutdown)ID2 generic external alarm with possibility to override fansB5/ID3 day/night - summer/winter statusB6/ID4 multifunction input: remote ON/OFF, Spray Water System activation,

Spray Water System alarm

Digital outputs

DO1 enable fanDO2 alarm outputDO3 Spray Water System outputDO4 –DO5 panel heating output DO6 panel cooling output

Analogue outputs

Y1 --Y2 emergency fan analogue outputY3 --Y4 --

Serial connections

BMS1 Carel-Modbus RS485 serial. pCOweb optionalFB1 (J8) EC fans (max 18) Ziehl or EBM. Modbus communication

2.2 Alfa LU-VE ICM connection diagramThe following figure shows the system configuration, with the list of connectable inputs and outputs.

1 2 3

1 2 ...up to 18

1 2 3 4

Electrical panel fanAlarm Electrical panel heater

4 Digital inputs:Fan alarmsGeneric external alarmDay/nightON/OFF, Spray Water System

3 Analogue inputs:Control Probe: - Pressure - Temperature - External signalExternal temperatureElectrical cabinet temperature

5 Digital ouputs:FansAlarmSpray Water SystemElectrical panel coolingElectrical panel heaters

RS 485 Modbus®

BMS system

1 Analogue outputFans

Spray Water System

Fig. 2.b

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2.3 EBM fan serial connectionIf the unit is fitted with EBM fans, the serial connection must be performed as shown in the following diagram.

J7 J10J9J8J5

J4

J6

TLAN

GN

D C2

NO

2

GN

DY2Y1

GND

ISOLATED

Tx/RxPWM 0/10V

GNDTx/Rx

GN

D

ID2 Y3 Y4

0/10V 0/10V

J13

NO

3C3

NO

4

J11

NO

6 C5

NO

5

J12

GND GND

EBM1 EBM2

RSB RSA RSB RSA

Fig. 2.c

Once having made the connections, set the address as shown in paragraph 7.2.

2.4 Ziehl-Abegg fan serial connectionIf the unit is fitted with Ziehl-Abegg fans, the serial connection must be performed as shown in the following diagram.

J7 J10J9J8J5

J4

J6

TLAN

GN

D C2

NO

2

GN

DY2Y1

GND

ISOLATED

Tx/RxPWM 0/10V

GNDTx/Rx

GN

D

ID2 Y3 Y4

0/10V 0/10V

J13

NO

3C3

NO

4

J11

NO

6 C5

NO

5

J12 Fan1 Fan2

GND A B ID1 GND A B ID2 GND A B ID1 GND A B ID2

Fig. 2.d

If needing to replace a fan, set the address as shown in paragraph 7.2.

2.5 BMS configurationIf a BMS system is used in the RS485 network (with Modbus protocol) to control the condensing unit, its serial address (1-199) and related parameters need to be set, in branch Fc .If the supervisor is connected via Ethernet (Modbus, BACnet), the serial card (in “serial card 1” port) needs to be replaced with the optional Ethernet network card (PCO10B0WB0)

For the wiring, see the figure in par. 2.1.

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2.6 InstallationFor installation proceed as follows, with reference to the wiring diagrams:• before performing any operations on the control board, disconnect the

main power supply by turning the main switch in the electrical panel OFF.

• avoid touching the control board with bare hands, as any electrostatic discharges may damage the electronic components;

• suitable electrical protection must be ensured by the manufacturer of the condenser or drycooler or by appropriate installation of the controller;

• connect any digital inputs, Lmax=10 m;• connect the temperature and pressure probes, Lmax=10 m;• program the controller using guided commissioning procedure: see the

chapter on Commissioning;• connect the electrical loads to the relay outputs only after having

programmed the controller. Carefully check the maximum capacity of the output relays, as shown in the technical specifications;

Important: avoid installing the controllers in environments with the following characteristics:• relative humidity greater than 90% or with condensation;• strong vibrations or knocks;• exposure to water sprays;• exposure to aggressive and polluting atmospheres (e.g.: sulphur

and ammonia fumes, saline mist, smoke) to avoid corrosion and/or oxidation;

• strong magnetic and/or radio frequency interference (therefore avoid installing the devices near transmitting antennae);

• exposure of the controllers to direct sunlight and to the elements in general.

Important: the following warnings must be observed when connecting the controllers:• incorrect power connections may seriously damage the controller;• separate as much as possible the probe and digital input cables from

cables to inductive loads and power cables, so as to avoid possible electromagnetic disturbance. Never run power cables (including the electrical panel cables) and probe signal cables in the same conduits;

Note: when connecting the RS485 serial network:• connect the shield to the GND terminals on all controllers;• do not earth the shield on the electrical panel;• use a shielded cable (e.g. Belden 3106A);• for the supervisor serial network connection only (serial card 1):

connect a 120 Ω terminating resistor between the Tx/Rx+ and Tx/Rx- terminals on the last controller in the network (the one furthest away from the supervisor).

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3. USER INTERFACE

The Alfa LU-VE ICM system features two types of user terminals, which differ only in terms of the position of the buttons, and not their meaning; the same is true for the displays, which despite being different in size have the same number of pixels and show the same screens. The pGDe is normally used for commissioning, while the second is the display fitted directly on the pCOcompact controller.

Note: to use the pGDe terminal, connect it to the corresponding port on the pCOcompact using a telephone cable.

3.1 Keypad

pCO5 compact

Fig. 3.a

pGDe

Fig. 3.b

Button Function

Alarm display the list of active alarms/reset alarms with manual reset;

Prg enter the main menu tree

Esc return to the previous screen

Up scroll a list upwards or increase the value shown on the display

Down scroll a list downwards or decrease the value shown on the display

Enterenter the selected submenu or confirm the set value

from the main screen, access the INFO screens

3.2 “Main” screen

1

2

3

4

Fig. 3.c

Ref. Function1 Current time and date2 Control temperature or pressure;3 Speed of the row of fans4 Unit status

Below are some examples of the INFO screens, directly accessible from the main screen by pressing ENTER:

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4. MENU DESCRIPTION

4.1 Main menu

To access the menu tree, press from the main screen; the “enter password” screen is displayed.

Fig. 4.d

Once having entered the correct password (default value 1234), the first main menu screen will be displayed.

Important: • the User; Service; Manufacturer passwords are set in branch

Fd;• if no button is pressed while navigating the menu tree, after 5 minutes

the main screen is automatically displayed again.

Fig. 4.e

To navigate inside the menu tree, use the following buttons:

• & : navigate around the submenus, screens and change values and settings;

• : confirm and save the changes made;• : to return to the previous menu

4.2 PasswordsAlfa LU-VE ICM manages three password levels:

• User (psw: 0000)• Service (psw: 1111)• Manufacturer (psw: 1234)

Each level includes the same rights as the lower levels, that is, the Manufacturer can access all the screens and parameters, the Service can access the screens and parameters available in the Service and User levels, while the User can only access the screens and parameters available in the User level.

Note: all levels display the main screens and the other information screens.

When pressing prompt is shown to enter the password, which remains active for 5 minutes after the last button is pressed.

The menu screens show their own password level using an icon at the top right: 1 line: user, 2 lines: service, 3 lines: manufacturer.

The password level can be changed from menu branch F.d. at any time. The password can also be changed in the corresponding menu branch.

A.Unit statusA.Unit status a.Main info Aa20-AaazD03-E11

U

b.Set point Ab06-13 Sc.ON/OFF Ac01-04 S

B.Inputs/OutputsB.Inputs/Outputs a.Status a.Digital inputs Baa01-04 Mb.Analogue inputs Bab01-03 Mc.Digital outputs Bac01-05 Md.Analogue outputs Bad01 M

b.Manual management a.Digital outputs Bba03-04 Mb.Analogue outputs Bbb02 Mc.Serial outputs Bbc01-06 M

D.FansD.Fans a.Group1 & 2 a.I/O status Daa01-05 Ub.Control Dab01-07 Sd.Energy savings Dad05-06 Se.Alarms Dae01-04 Sf.Configurations Daf01-09 Sg.Advanced Dag01-15 M

E.Other functionsE.Other functions g.Spray Water System a.I/O status Ega01-03 Mb.Settings Egb01-04 M

i.Electrical panel a.I/O status Eia01-02 Sb.Settings Eib01-02 S

F.SettingsF.Settings a.Clock a.Time bands Faaa01-05 Sb.Adjustment Fab01-02 U

b.Languages Fb01-02 Sc.BMS Fca01 Sd.Password Fd01-03 Me.Fieldbus Fea03 M

G.AlarmsG.Alarms a.Log Ga01-50 U

b.Prevent Gb04 Sc.Alarm config. Gc01-02 S

H.InfoH.Info H01-02 U

I.SetupI.Setup b.Wizard Ib01 Md.Default Id01 M

Tab. 4.a

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5. FUNCTIONS

5.3 ControlAlfa LU-VE ICM can manage two types of control:• Proportional only (P)• Proportional + integral (P+ I)

Both types of control can be applied to both drycoolers and condensers, according to the settings defined during start-up using the wizard, or in the main menu branch.

The type of control depends on the unit being controlled.In general, for condensers it is preferable to use P+I control, however in this case the integral constant should be evaluated according to system being managed and the type of sensor used.

The controlled value may be pressure (in general, for condensers) or temperature (drycoolers), or alternatively may be based on an external control signal (0-1V or 0-10V), in the latter case there is direct correspondence between the external control signal and the speed the fans are driven at. The two types of control are described below; the description applies to both pressure and temperature control.

5.3.1 Proportional and P+I controlThe operating principle is normal proportional control, with a central control set point, as schematised in the following figure:

Fan Speed

100%

Setpoint

Temp./Press.Di�. Di�.

Fig. 5.b

Note: if 0-10V fan control is selected instead of serial control, a 100% control signal will correspond to a 10V analogue output, and

0% will correspond to a 0V output.

With P+I control, added to the effect of the proportional action described above is the integral action, used to achieve a null control error in steady operation, as shown in the figure:

ON/OFF P+I time

Temp.

SetpointSetpoint

Fig. 5.c

The integral action depends on the time and the deviation from the set point. It modifies the control request when the controlled value remains for some time away from the set point.

The value of the integration time setting represents how quickly integral control is implemented:• Low values mean a fast and intense control response • High values give slower response and more stable control

It is recommended to not set a value that is too low for the integral time, to avoid instability.

If the settings made using the wizard (commissioning) are not sufficiently detailed, the settings can be made manually, navigating the menus.

5.1 Set pointScreen Ab13 is used to set the control set point, as shown in the following fig.:

while screen Ab06 shows all the parameters corresponding to the set point, however these are display-only; two setpoint are explained on paragrph .5.9.1.

5.2 Unit On-OffThe unit can be switched on and off from:• User terminal• Supervisor• Digital input

On-off from the user terminal and the configuration parameters are available under the main menu, branch A.c, and are differentiated based on the access level; the User password allows display only.

On-off from the supervisor and from the digital input and start-up after a blackout (with specific delay, to avoid continuous starts and stops in the event of instability in the power supply) must be enabled using the parameters visible only with the Service password.

On-off from the digital input is equivalent to an enabling signal, that is, if the digital input is Off the unit cannot be switched on in any other way, while if is On, the unit can be switched on or off in any other way, with the same priority (the most recent control has precedence, whatever the origin), as shown in the figure:

User interface

Supervisor

Digital Input

Unit On/O�

Fig. 5.a

Note: certain special conditions or functions in the cause the unit to shutdown:• Configuration of inputs/outputs, of fan parameters.• Installation of default values• Manual management

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Note: the set point is in the centre of the activation band, therefore when reaching the set point the fans are on, even with proportional control only.

5.3.2 Setting the control differentialOn the screen shown in the figure, the differential can be changed; in the case of proportional control, this is equal to half of the control band.

In the case of P+I control, the differential represents the maximum variation of the controlled value. In general, a higher value will be set for proportional control only (P).

5.3.2 Fan operation based on modulating signalIf the fans are controlled by an external modulating device, minimum and maximum values need to be assigned to the input signal.The example in the figure shows: minimum fan speed value (30%) corresponding to 0 V control signal, maximum fan speed value (100%) corresponding to 10 V (or 1 V) control signal.

Input(B1)

Fan Speed

100%

30%

0 Vdc 10 Vdc(1 Vdc)

Fig. 5.d

Note: if an external control signal is used, the software will set proportional control only (P).

5.4 Fan parametersAlfa LU-VE ICM manages a series of parameters specifically related to thefans, herewith listed:• speed-up• minimum speed• cut-off function• kick function

Speed-upTo ensure the fans start correctly, when these are restarted (after being stopped by the controller or external control signal), a time can be set during which maximum speed is applied, called speed-up, which helps the fans overcome inertia on starting. The function is enabled on screen D.a.g13.

When speed-up is enabled, the time that the fans work at 100% speed can be set. If the outside temperature probe is fitted, an additional threshold can be set (with return differential) below which speed-up is disabled, so as to avoid drastically lowering the pressure/temperature at start-up.

Note: speed-up has lower priority than the maximum night-time speed function (see the following paragraph for details), therefore

when maximum night-time speed is active, this function is not performed.

Cut-offAlfa LU-VE ICM manages a fan control cut-off; the function can be enabled and the related parameters set in main menu branch Dab05.

The operating principle of the cut-off function is shown in the figure:

Temp./Press.

Fan Speed

Max

Min

0%Di� Di�

Setpoint

Cuto�

Fig. 5.e

When the control request reaches the set cut-off value, this value is kept constant until the control value falls below the cut-off set point, after which it falls to 0 % and remains there until the request exceeds the cut-off value again.

Minimum speedAlfa LU-VE ICM can also manage a minimum speed function in place of the cut-off function described above.In this case, the control diagram will be:

Temp./Press.

Fan Speed

Max

Min

0%Di� Di�

Setpoint

Fig. 5.f

Kick functionTo ensure correct operation even when the fans are off for an extended period (for example, on condensers in winter), Alfa LU-VE ICM can activate the fans for a certain time at a certain interval, set in branch Dag14.

Note: this function is also enabled when the unit is OFF from the keypad or digital input and BMS.

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5.5 Floating set pointIn branch Dad (energy savings), the floating set point function can be enabled, allowing for adjustments based on variations in outside temperature.

The floating set point will be based on the outside temperature. Its value is determined by adding a programmable constant value (screen Dad06) to the outside temperature and limiting the resulting value between a minimum selectable on screen Dab02 and the working set point (Dab03), as shown in the figure:

Setpoint

Min

o�set

Floatingsetpoint

external temperaturetime

Fig. 5.g

The offset is set on the following screen:

while the two limits described above are set on the following screens:

Note: if control is based on a pressure reading, the temperature conversion is performed based on the type of refrigerant set on

screen Daf04.

5.6 Electrical panel heating or cooling management

Electrical panel cooling (for example, using a fan) can be managed via digital output DO6. The set point and differential can be set in branch Eib02, after having enabled the function on screen Eib01.

This keeps the temperature under control, as read by a sensor installed inside the panel. The operating diagram is shown in the following figure:

Temp. Cabinet

Setpoint

Di�.

Output(DO6)

Fig. 5.h

Similarly, electrical panel heating (for example, using an electric heater) can be managed via digital output DO5. The operating diagram is shown in the following figure:

Temp. CabinetDi�.

Output(DO5)

Setpoint

Fig. 5.i

5.7 Spray Water SystemAlfa LU-VE ICM can control the Spray Water System, an evaporative cooling device that cools the air flowing through the drycooler or condenser by enabling the corresponding parameters in the menu branch Egb01-04.

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Spray Water System is activated by ICM when the following conditions exist:• the outside temperature exceeds a set threshold• the fan control request is at the maximum for at least a settable

number of minutes;or, as alternative, by an external control signal.

The counting of the max request time starts every time the above conditions are not satisfied (the demand decreases). Spray water operation ends when the “cooling demand” falls below a set threshold. ICM can manage a digital alarm input from Spray Water System, which has the effect to deactivate the complete device. As the number of operating hours of Spray Water System is critical as regards formation of scale on the coil fins, Alfa LU-VE recommends to set an operating hour threshold by least 200 hours (without coating). Such value can be increased in case of coated fins.

Hygiene procedureTo avoid water stagnation in the pipes, a hygiene procedure can be enabled that activates Spray Water System every day for a set time, if the outside temperature is greater than a threshold.

Note: if the outside temperature probe is not configured or is configured but is not working, Spray Water System operates based

solely on the control request, and the hygiene procedure can still be activated.

If the probe is configured but not working, the Spray Water System alarm is displayed, functioning without a temperature probe.

Spray Water System as a stage in high pressure/temperature preventionSpray Water System can be used to prevent high condensing pressure or alternatively to limit high temperatures. The parameters corresponding to this function, set point and differential, can be set in branch Gb04 of the main menu, if the Spray Water System function is activated.

When threshold is reached, the controller activates the Spray Water System. The following figure illustrates the activation thresholds for the high pressure/temperature prevention/safety functions.

time

Pressure/Temperature

High Pressure/Temperatureby probe

Spray Water System

Fig. 5.j

5.8 Day-Night and Summer/Winter functionOperation at reduced speed at night can be enabled by digital input or using the “scheduler” function, herewith described. This is about the possibility to reduce the maximum fan speed of the fans and reduce noise emission, tipically required at night in residential areas. Once the function is enabled, the maximum fan speed % needs to be set. This % refers to the maximum allowable fan speed. The related screens are the following Dag10 & Dag12.

There is only one digital input (multifunction) that can enable only one of the function such as “ON/OFF remote machine, generic anomaly, generic alarm, enabling Spray Water System or Spray Water System alarm).For the alarm digital inputs see par. 6.3.1

5.8.1 Digital input settable• Day – Night; • Summer – Winter; • Day/Night – Summer/Winter; If there are the regulation probe, it is possible to set digital input into Summer/Winter, getting a change about set-point and regulator parameter P+I.

ClockAlfa LU-VE ICM features an internal clock with backup battery that stores the time and dated for all functions that require these data. The screen for setting the time and date is illustrated below.

The date format can be set as follows:• day, month, year (dd/mm/yy)• month, day, year (mm/dd/yy)• year, month, day (yy/mm/dd)

The current date and time can be set, the day of the week corresponding to set date displayed, plus changeover to daylight saving can be enabled by setting the changeover date and the deviation.

The related parameters can be set during start-up or in main menu branch F.a.

If the clock card is not operating, an alarm is generated and the functions relating to the time bands described in the following paragraph are not available.

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5.9 Seasonal setting & time bandsSeasonal setting can be enabled on ICM, before use of a control probe (in the case of proportional input signal this function is not available). Closing period, weekends, festivity and summer/winter working setpoints (summer/winter offset) can be set. This setting will be, then, common for all system functions.

The following functions make use of time bands:• floating set point• operating seasons• special days• closing periods.

These functions can be enabled on screen Faa01:• winter period• 10 special days• 5 closing periods

The corresponding setpoint are set on screen Ab13

The following three screens show the selection of the time bands, as enabled previously.

If multiple selections are present at the same time, the most restrictive of these prevails.

5.9.1 Working set pointIf the Offsets illustrated above for time band management have been set (paragraph 5.9), and the Day-Night function from digital input or time bands has been enabled (paragraph 5.8), the working set point will be adjusted based on the sum of the Offsets. In any case, the value can never exceed the maximum value set on screen Dab02.

The following figure illustrates how this works:

Setpoint

Time

Temp.

Time

Summer/Winter

Closing/Holiday

On/Off

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6. SIGNALS AND ALARMS

Alfa LU-VE ICM can manage alarms related to the status of the digitalinputs and to the system status. For each alarm, ICM can control:• the actions on the devices, if necessary• the alarm relay output• the red LED on the terminal and the buzzer• any activation delay

The complete list of alarms, with the related information as described above, is available in the Alarm table.

6.1 Alarm managementAll alarms feature the following behaviour:• When an alarm is activated, the red LED flashes, the buzzer sounds and

the relay is activated (if configured)

• Pressing , the red LED stays on steady, the buzzer is muted and the alarm screen is shown

• In case of multiple alarms, these can be scrolled up and down using

and

• Pressing again for at least 3 seconds resets the alarms manually, and these are cleared from the display unless others are active (they are saved in the log)

Fig. 6.a

6.1.1 ResetThe alarms can have manual or automatic reset:

• Manual: the alarm is reset by pressing ,twice, the first time displays the corresponding alarm screen and mutes the buzzer, the second (extended, for at least 3 seconds) cancels the alarm (which is saved in the log). If the alarm is still active, resetting it has no effect and the signal is shown again.

• Automatic: when the alarm condition ceases, the alarm is automatically reset, the LED comes on steady and the corresponding screen remains

displayed until is pressed and held; the alarm is saved in the log.With manual reset, the functions associated with the alarm are not activated again until the alarm has been reset, while for automatic reset these are activated as soon as the alarm condition ceases.

6.1.2 LogThe alarm log can be accessed:• from branch G.a of the main menu

• by pressing and then when there are no active alarmsThe alarm log screens show:1. order of activation (no. 01 is the oldest alarm) 2. time and date the alarm was activated3. alarm code (see the Alarm table)4. short description of the logged alarm5. control probe reading and set point

The last screen displayed is the one used to clear the log.

Fig. 6.b

Note: a max. of 50 alarms can be logged; when the limit is reached, any new events overwrite the oldest ones, which are therefore deleted.

6.2 Fan alarmsFan alarms are sent via the serial connection to ICM and displayed consequently. Alarm codes are available in the Alarm table. No.2 Alarms categories are present: “warnings”, which do not stop the fans, and actual“alarms” that stop the fans. Offl ine errors will also appear. To disable the “Warnings”: modify the screen Gc03.

6.3 Pressure/temperature alarmsAccording to the type of control probe selected (pressure or temperature), two thresholds can be set (high and low), and these can either be relative (i.e. deviation from the working set point) or absolute; in this case, the value is fixed and does not depend on the set point.When the above described alarms occur, an activation delay and fan output override (% of fan speed when the high or low threshold alarmsare active) can be set.

Example of an alarm with absolute threshold

Di�.Di�.Low High

ON

OFF

Pressure/Temperature

Fig. 6.c

Example of an alarm with relative threshold

Pressure/Temperature

AlarmSetpoint

Relative threshold

Di�erential

Fig. 6.dKeyLO Low temperature/pressure alarms Bx Control probeHI High temperature/pressure alarms

Note: the alarms from digital input are only active when the unit is ON (when OFF they are not active).

6.3.1 Alarms from digital inputsID1 can be enabled as a generic fan alarm (thermal overload) with automatic reset or it can be used to force fans to working on maximum speed (enable by parameter). ID2 can be selected either as a generic alarm or to activate maximum fan speed. ID4 (multifunction) can be selected as a Spray Water System alarm.

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6.4 Alarm tableAlarm code Description Delay Reset Actions Modbus addressAL001 Probe B1 fault alarm 20 s Auto Fan at fixed % 20AL002 Probe B2 fault alarm (panel temp.) 20 s Auto 21AL003 Probe B3 fault alarm (outside temp.) 20 s Auto Spray Water System Off 22AL004 Probe B4 fault alarm 20 s Auto Fan at fixed % 23AL006 Clock card error 0 Auto 25AL007 Damaged memory alarm [T] 0 Auto 26AL008 Warning: BIOS <6.20 Update BIOS! 0 Auto 27AL009 Generic fan alarm Gc01 Auto from DI2, Stop all fans/Max speed fans 28AL011 EBM warning - Group 1 fan 1 from fan FW from fan FW -AL012 EBM warning - Group 1 fan 2 from fan FW from fan FW -AL013 EBM warning - Group 1 fan 3 from fan FW from fan FW -AL014 EBM warning - Group 1 fan 4 from fan FW from fan FW -AL015 EBM warning - Group 1 fan 5 from fan FW from fan FW -AL016 EBM warning - Group 1 fan 6 from fan FW from fan FW -AL017 EBM warning - Group 1 fan 7 from fan FW from fan FW -AL018 EBM warning - Group 1 fan 8 from fan FW from fan FW -AL019 EBM warning - Group 1 fan 9 from fan FW from fan FW -AL021 EBM alarm - Group 1 fan 1 from fan FW from fan FW Stop fan 1 40AL022 EBM alarm - Group 1 fan 2 from fan FW from fan FW Stop fan 2 41AL023 EBM alarm - Group 1 fan 3 from fan FW from fan FW Stop fan 3 42AL024 EBM alarm - Group 1 fan 4 from fan FW from fan FW Stop fan 4 43AL025 EBM alarm - Group 1 fan 5 from fan FW from fan FW Stop fan 5 44AL026 EBM alarm - Group 1 fan 6 from fan FW from fan FW Stop fan 6 45AL027 EBM alarm - Group 1 fan 7 from fan FW from fan FW Stop fan 7 46AL028 EBM alarm - Group 1 fan 8 from fan FW from fan FW Stop fan 8 47AL029 EBM alarm - Group 1 fan 9 from fan FW from fan FW Stop fan 9 48AL031 EBM warning - Group 2 fan 1 from fan FW from fan FW -AL032 EBM warning - Group 2 fan 2 from fan FW from fan FW -AL033 EBM warning - Group 2 fan 3 from fan FW from fan FW -AL034 EBM warning - Group 2 fan 4 from fan FW from fan FW -AL035 EBM warning - Group 2 fan 5 from fan FW from fan FW -AL036 EBM warning - Group 2 fan 6 from fan FW from fan FW -AL037 EBM warning - Group 2 fan 7 from fan FW from fan FW -AL038 EBM warning - Group 2 fan 8 from fan FW from fan FW -AL039 EBM warning - Group 2 fan 9 from fan FW from fan FW -AL041 EBM alarm - Group 2 fan 1 from fan FW from fan FW Stop fan 1 60AL042 EBM alarm - Group 2 fan 2 from fan FW from fan FW Stop fan 2 61AL043 EBM alarm - Group 2 fan 3 from fan FW from fan FW Stop fan 3 62AL044 EBM alarm - Group 2 fan 4 from fan FW from fan FW Stop fan 4 63AL045 EBM alarm - Group 2 fan 5 from fan FW from fan FW Stop fan 5 64AL046 EBM alarm - Group 2 fan 6 from fan FW from fan FW Stop fan 6 65AL047 EBM alarm - Group 2 fan 7 from fan FW from fan FW Stop fan 7 66AL048 EBM alarm - Group 2 fan 8 from fan FW from fan FW Stop fan 8 67AL049 EBM alarm - Group 2 fan 9 from fan FW from fan FW Stop fan 9 68AL051 Ziehl warning - Group 1 fan 1 from fan FW from fan FW -AL052 Ziehl warning - Group 1 fan 2 from fan FW from fan FW -AL053 Ziehl warning - Group 1 fan 3 from fan FW from fan FW -AL054 Ziehl warning - Group 1 fan 4 from fan FW from fan FW -AL055 Ziehl warning - Group 1 fan 5 from fan FW from fan FW -AL056 Ziehl warning - Group 1 fan 6 from fan FW from fan FW -AL057 Ziehl warning - Group 1 fan 7 from fan FW from fan FW -AL058 Ziehl warning - Group 1 fan 8 from fan FW from fan FW -AL059 Ziehl warning - Group 1 fan 9 from fan FW from fan FW -AL061 Ziehl alarm - Group 1 fan 1 from fan FW from fan FW Stop fan 1 80AL062 Ziehl alarm - Group 1 fan 2 from fan FW from fan FW Stop fan 2 81AL063 Ziehl alarm - Group 1 fan 3 from fan FW from fan FW Stop fan 3 82AL064 Ziehl alarm - Group 1 fan 4 from fan FW from fan FW Stop fan 4 83AL065 Ziehl alarm - Group 1 fan 5 from fan FW from fan FW Stop fan 5 84AL066 Ziehl alarm - Group 1 fan 6 from fan FW from fan FW Stop fan 6 85AL067 Ziehl alarm - Group 1 fan 7 from fan FW from fan FW Stop fan 7 86AL068 Ziehl alarm - Group 1 fan 8 from fan FW from fan FW Stop fan 8 87AL069 Ziehl alarm - Group 1 fan 9 from fan FW from fan FW Stop fan 9 88AL071 Ziehl warning - Group 2 fan 1 from fan FW from fan FW -AL072 Ziehl warning - Group 2 fan 2 from fan FW from fan FW -AL073 Ziehl warning - Group 2 fan 3 from fan FW from fan FW -AL074 Ziehl warning - Group 2 fan 4 from fan FW from fan FW -AL075 Ziehl warning - Group 2 fan 5 from fan FW from fan FW -AL076 Ziehl warning - Group 2 fan 6 from fan FW from fan FW -AL077 Ziehl warning - Group 2 fan 7 from fan FW from fan FW -AL078 Ziehl warning - Group 2 fan 8 from fan FW from fan FW -AL079 Ziehl warning - Group 2 fan 9 from fan FW from fan FW -AL081 Ziehl alarm - Group 2 fan 1 from fan FW from fan FW Stop fan 1 100AL082 Ziehl alarm - Group 2 fan 2 from fan FW from fan FW Stop fan 2 101AL083 Ziehl alarm - Group 2 fan 3 from fan FW from fan FW Stop fan 3 102AL084 Ziehl alarm - Group 2 fan 4 from fan FW from fan FW Stop fan 4 103AL085 Ziehl alarm - Group 2 fan 5 from fan FW from fan FW Stop fan 5 104AL086 Ziehl alarm - Group 2 fan 6 from fan FW from fan FW Stop fan 6 105AL087 Ziehl alarm - Group 2 fan 7 from fan FW from fan FW Stop fan 7 106AL088 Ziehl alarm - Group 2 fan 8 from fan FW from fan FW Stop fan 8 107AL089 Ziehl alarm - Group 2 fan 9 from fan FW from fan FW Stop fan 9 108AL091 Generic alarm from multifunction DI Gc02 Auto 110AL092 External alarm from DI1 Gc02 Auto Max speed group 1 111AL094 High pressure alarm from probe 1 Dae02 Auto Max speed group 1 113AL095 High temperature alarm from probe 1 Dae02 Auto Max speed group 1 114AL096 Low pressure alarm from probe 1 Dae04 Auto 115AL097 Low temperature alarm from probe 1 Dae04 Auto 116AL102 Spray Water System alarm 1 maintenance request 0 Manual Spray Water System Off 135AL104 External Spray Water System alarm from DI4 0 Auto Spray Water System Off -

Tab. 6.a

Note: for all alarms, the alarm relay is activated and the alarm is logged.All alarma are digital variavle (coil) only read.

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7. START-UP

7.1 Guided commissioning procedureAlfa LU-VE ICM controller can be configured (initial setup) either from thepGDe user terminal or the ICM display. If the Alfa LU-VE ICM has not yet been configured, the user terminal shows the first screen in a guided configuration wizard. Otherwise, the same procedure can be accessed from branch I.Setup>>b.wizard. The main parameters needed for general configuration are shown one at a time. The wizard screens are all numbered in the top right corner; the following explanations refer to this

number. To go from one screen to the next press , while to return to

previous screen press .

NB: at the end of procedure, the unit must be powered OFF after having

confirmed the completion of procedure on screen WZxx by pressing .

Screen WZ01: this indicates the code of the application program loaded and

corresponding revision number. Pressing starts the guided procedure.

Screen WZ02: this is in order to select the fan manufacturer brand installed (Ziehl-Abegg or EBM); the unit type (AlfaBlue or AlfaV) and theTOTAL number of fans. The number of fans must be set on “Num.Fan group 1” and on N.Fan.group 2, up to 9 Fans for group.

Screen WZ03: this is used to select the units of measure, between international system (°C and barg) and imperial (°F and psig)

Screen WZ04: this is used to select the type of pressure probe (4-20mA or 0-5V ratiometric, in this case also set the type of refrigerant); temperature probe (NTC, NTC-HT, PT1000, in the latter case the probe is connected to B4); external signal (0-1V or 0-10V) or supervisor (the BMS will directly provide the control value as a percentage, 0-100%).

Screen WZ05: if a pressure probe is used, this screen configures the range of measurement and corresponding calibration. If, on the other hand, a temperature probe is used, only the calibration is available (see the following figure).

Screen WZ06: this is used to set the type of control (P, P+I), the set point and differential, which will be based on pressure or temperature, according to of the type of probe used.

Screen WZ99: end wizard. Press ENTER and confirm by pressing DOWN to exit and return to the main screen.

7.2 Setting the fan addressesThe system should be configured after having connected the various fans to the FB1 serial line (connector J8), proceeding as follows:1. power on an individual fan2. assign the serial address to the active fan (see the corresponding proc.)3. repeat for all of the other fans 4. once all of the addresses have been set, set the unit parameters (type of

control probe.....) as required by the commissioning procedure.

Note: EBM fans are set by default with address “1”, while Ziehl-Abegg are shipped from the factory with address “247”.

Attention: The fans addressing procedure is carried out compulsorily with the unit turned off (OFF from keyboard).

Fan addressesThe following figures illustrate examples of units with one (Fig. 7.h) and two (Fig. 7.i) groups.

1112

13......15 16

Fig. 7.h

1112

13...

21

22

23...

...18 19

...2829

Fig. 7.i

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7.2.1 Procedure for setting the address of an individual fan

On screen Daf01 the number of fans in Group 1 and Group 2 have to be set, and their enabling is on screen Daf02.

Screen Dag01 is used to set the type of fans installed on the unit (Ziehl or EBM).

Screen Daf08 is used to set the address of the fan that has just been powered on, for Ziehl fans (the default address in this case is 247).

Screen Daf09 is used to set the address of the fan that has just been powered on, for EBM fans (the default address in this case is 1).

The communication between fans and ICM device is via Modbus (Fieldbus port). The addressing procedure is required if new fans are installed (spare parts); the new fan must have the same address as one being replaced. All the fans must have a unique address and can only be addressed once. It is necessary to power only the fan which must be addressed; repeat the procedure as described above. Press enter and enter “Yes” under “Change Address” and follow the sequences shown in the mask.

7.2.2 Procedure for setting speed attenuation bands (R1, R2, R3)

Screen Daf06 can be used to enable and set speed intervals (R1, R2 and R3) for Ziehl fans that are skipped by the controller.

R1R2R3

This avoids unit resonance frequencies that would create unwanted vibrations.

7.2.3 Procedure for service: Fan with inverse rotation mode

On screen Daf05 it is possible to set the reverse rotation of the fan. The function can be used temporarily during unit servicing/fi nned coil cleaning. When parameter is “0”, the rotation direction is clockwise; when parameter is set “1” the fans will rotate counterclockwise. The setting “0” or “1” changes depending on whether the fan is Ziehl or EBM.

7.2.4 Procedure for service: search for fans addresses connected to th network

On screen Daf10, it is possible to force a procedure for scans all the network addresses from 0 to 247, to find the fans in the network. The procedure can be started only if the machine is OFF and the procedure for changing the address is not active. When it is started, in the “First address” field, it will write the address of the first fan found in the network. In the “Addresses in test” field it displays the addresses it is currently checking and which of the four it controls are Online. In Daf11 screen all fans found are displayed, choosing which addresses to display.

8. PARAMETER TABLE

8.1 Parameter table and Variables only accessible via serial connection (BMS), are available to man. code: +0800011ML

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9. SOFTWARE UPDATE

9.1 Setting the controller’s addressThe controller’s pLAN address set by default in the factory is 1. The controller’s address can be set via a terminal connected in the pLAN network. The controller is assigned a private (Pr) or shared (Sh) terminal with address 32. The address of the external terminal can be set in the range between 0 and 32; addresses between 1 and 32 are used by the pLAN protocol, while address 0 identifies the Local terminal protocol, used for point-to-point connections and to configure the controller (this procedure is only possible with a pGD terminal and one pCO only).If the controller with the default setting (address=1) is connected to an external terminal (address=32), communication is established and the display on the external terminal replicates the display on the built-in terminal, if featured. If, on the other hand, the controller has a different address (e.g. 7) and the terminal is not set to communicate with the controller with this address, once the connection has been established, the terminal displays a blank screen. In this case, proceed as follows.

Procedure:1. Press the UP, DOWN and Enter buttons together to access the screen for

setting the terminal’s address.

Display addresssetting............:02

I/O Board address..:07

2. Set the address of the display, 0 for point-to-point connections. Confirm by pressing Enter.

Display addresssetting............:00

3. Power off the controller.

J7 J10J9J8J5

J1

G G0

+5V

ref

+VD

C

ID1

GN

D

J3

C1

NC

1

NO

1

J2

SYN

C

B1 B2 B3 B4 B5 B6 GN

D

ser ia l card 1

J4

J6

TLA

N

GN

D C2

NO

2

GN

DY2Y1

GNX

ISOLATED

Tx/RxPWM 0/10V

GNDTx/Rx

24 V (+10/-15%); 50/60 Hz48 V (36Vmin…72 Vmax)

input voltage: max. power:

8 VA / 6 W

GN

D

ID2 Y3 Y4

0/10V 0/10V

J13

NO

3

C3

NO

4

J11

NO

6

C5

NO

5

J12

Fig. 9.a

4. Power on the controller while holding the Alarm and Up buttons together, until the following screen is shown.

selftestplease wait...

5. Use UP and DOWN to set the controller’s pLAN address to 7 and confirm by pressing Enter..

pLAN address: 7

UP: increase

DOWN: decrease

ENTER: save & exit

9.2 Setting the terminal’s address and connecting the controller to the terminal

After setting the controller’s network address (see previous paragraph), to establish connections between the controller and the terminal, the terminal’s address needs to be set.

Procedure:1. Press the UP, DOWN and Enter buttons together. The screen is displayed

for setting the terminal’s address. Set the address to 2 and confirm by pressing Enter.

Display addresssetting............:02

2. Press the UP, DOWN and Enter buttons together. Press Enter twice and set the controller’s address to 7. Confirm by pressing Enter.

Display addresssetting............:02

I/O Board address..:07

3. Confirm by pressing Enter.

Terminal configpress ENTERto continue

4. Set terminal 1 (Trm1) with address 2 as private (Priv) or shared (Shared) according to the application, and confirm to exit. After a few seconds, the connection will be established.

P:07 Adr Priv/Shared

Trm1 02 Pr

Trm2 None --

Trm3 None -- Ok? Yes

5. To add a second terminal, repeat steps 1 to 4.

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9.3 Uploading/updating the softwareThe following methods can be used to update the firmware and acquire the log files on pCO controllers:• SmartKey programming key;• pCO manager tool, installable on a PC.

Smart keyThe PCOS00AKY0 key is an electronic device used to program and service the pCO sistema family controllers. PCOS00AKY0 simplifies data transfer between the controllers installed and a personal computer by exploiting the high capacity flash memory for storing software applications, BIOS and variable logs. The pCO is connected directly via the telephone connector using the cable supplied, while to transfer the data to a personal computer, the USB adapter code PCOS00AKC0 is required. The power supply comes either via the USB port on the PC or from the controller, therefore no external power supply is needed.

J7 J10J9J8J5

J1

G G0

+5V

ref

+VD

C

ID1

GN

D

J3

C1 NC1

NO

1

J2

SYN

C

B1 B2 B3 B4 B5 B6 GN

D

ser ia l card 1

J4

J6

TLAN

GN

D C2

NO

2

GN

DY2Y1

GNX

ISOLATED

Tx/RxPWM 0/10V

GNDTx/Rx

24 V (+10/-15%); 50/60 Hz48 V (36Vmin…72 Vmax)

input voltage: max. power:

8 VA / 6 W

GN

D

ID2 Y3 Y4

0/10V 0/10V

J13

NO

3C3

NO

4

J11

NO

6 C5

NO

5

J12

USB

tele

phon

e ca

ble

start

mode

alternative connections

PCOS00AKC0USB

Fig. 9.b

For the steps in the procedure, see par. 9.1.

Operating instructions

start

mode

start

mode

Fig. 9.c

Programming the Smart Key via Personal ComputerThe operating modes described in the table below can be configured using a program on the PC. The program can also load the software to the key or transfer logged data from the controller to disk.Type Function Mode buttonB Update software from key to pCO (BIOS,

application, parameters, etc.)Disabled

C* Copy software from pCO to pCO (BIOS, application, parameters, etc.)

Switches the key from write mode to read mode

D Read logs DisabledE Read logged data and software from pCO

(BIOS, application, parameters, etc.)Disabled

F Read logged data DisabledG Copy from pCO to pCO and read logs Switches the key to write mode,

read mode and read logs mode*: Default mode

Tab. 9.b

The key is factory-programmed in read/write mode (type C) so that it can be used immediately to transfer software from one controller to another. When the key is connected to the personal computer, the symbols have the following meanings:

Flashing Waiting for connection to PCAlternating When connected to PC indicates data transfer in progress

The programming key is compatible starting from BIOS version 3.43 and BOOT version 3.01. For more detailed information on programming the key, see the pCO Manager program manual.

Using the Smart Key with the pCO/µPC Switch off the pCO, remove any peripherals connected in the pLAN and plug the key into the telephone connector on the controller. When switching on again, all the symbols light up momentarily and the buzzer emits a beep. A few seconds later the key becomes operational. During this period the symbols . The controller then enters programming mode and the start button lights up steadily. Press the button to start data transfer.

Important: • If the key is type B, C or G (in write mode) pressing the start button will

immediately delete the software already loaded on the pCO.• Do not remove the key while data is being transferred to the key itself,

as the file being transferred will be lost and the corresponding space will not be restored. To restore the original capacity all the files will need to be deleted. If the key is type “C” or “G”, simply perform a new application read operation.

Meanings of Buttons/SymbolsFlashing: the key is connecting to the pCO. During this phase, which may last a few seconds, the start button is disabled.

start Flashing: The key has detected the pCO and is checking the access rights.

start+On steady: Pressing the start button will start writing the software to the pCO.

start+On steady: Pressing the start button will start reading the software from the pCO.

start+On steady: Pressing the start button will start reading the logs from the pCO.

mode On steady: In case of C or G keys, pressing the button for 1 second switches from read to write.

Tab. 9.c

If the key is type C of G, pressing the “mode” button for 1 second switches from read to read logs (G only) or to write. The symbols (write to pCO), (read from pCO), (read logs) reflect the selected status. If the key is not type “C” or “G”, the “mode” button is disabled and off. The “start” button starts the read or write operation, indicated by the flashing of the corresponding symbol ( or ) at a frequency proportional to the progress of the operation. When the operation is completed, the buzzer will sound intermittently for 2 seconds. Pressing the start button again will make the buzzer sound without repeating the operation. To repeat the operation, the key must first be unplugged. In case of error the symbol will light up together with the other LEDs. The following table can help you find the cause of the problem.

Errors before pressing the START button

+ + Symbols flashing Communication error: No response from the

pCO or: Key firmware version is incompatible

+modeSymbols steady Password error

+modeSymbols flashing Type of key is incompatible

+Symbols steady The key is missing one or more required fi-

les (memory empty; no kit for the type of pCO connected)

+ +startSymbols steady + flashing start

Incompatibility between the software on the key and the pCO HW

+ +modeSymbols steady + flashing mode

Incompatibility between pCO application and HW (application size)

+ +Symbols steady No logged data present on the pCO

Steady Type of key not programmed.

Tab. 9.d

Errors after pressing the START button

+start+ +buzzerSymbols flashing and buz-zer sounding intermittently Write operation failed

+start+ +buzzerSymbols flashing and buz-zer sounding intermittently Read operation failed

+start+ +buzzerSymbols flashing and buz-zer sounding intermittently Read logs operation failed

+ +Symbols steady + flashing

Incompatibility between log configuration and pCOHW (no flash me-mory). This error does not prevent writing other files.

+Steady Insufficient space to read

logs

Flashing Generic error

Tab. 9.e

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9.4 Pendrive: operating instructionsFile extensions, names and contentsThe UPLOAD and DOWNLOAD functions are protected by password; contact the manufacturer for the use. Various types of files can be uploaded and downloaded and are distinguished by their extension.

File namesIn order to be recognised, the names of the directories and files on the pendrive must have no more than 8 characters; the controller makes no distinction between upper-case and lower-case characters. However, during DOWNLOAD the names of the directories created by the controller on the pendrive are always in upper-case.

FILE TYPES FOR UPLOAD

File extension Description.IUP Contains the definitions of the screens on the terminal.BLB Contains the application.BIN Contains the application (with pLAN table).BLX Contains the logic of atoms custom in C language.GRP Contains the graphics.DEV Contains the preset configuration parameter valuesPVT, .LCT Contains the descriptions of the public variables to be

logged. Generated by 1Tool, this is used by the LogEditor module and must be loaded together with the .LCT file

Downloaded files are saved in directories created automatically, with the following name format:

NAMXY_WZWhere:NAM: identifies the type of data downloaded (LOG for logs, BKP for the application, DEV for the buffer memory, CPY for all the data from the controller).XY: progressive number from 0 to 99WZ: controller pLAN address.

Example: A directory named LOG00_01 contains the log files (LOG) downloaded from a device whose pLAN address is 1. Since the key contained no directory of this type before download, it is indicated with 00.

Important: No more than 100 files of the same type can be downloaded to the pendrive, as the directories created can only be numbered with XY=00 to 99.

FILE TYPES FOR DOWNLOAD (controller pLAN address = 1)

File extension Directory name Description.DWL LOG00_01 Logged data.DWL,.DEV, .LCT, .PVT BKP00_01 Application.DEV DEV00_01 Non-volatile parameters.DWL, .DEV, .LCT, .PVT CPY00_01 All data on the controller

Tab. 9.fThe downloaded files to have fixed names. In particular, the application file is called “ppl–pCO.dwl”, the BIOS file “bios–pCO.bin”, the files containing the logs and related information are “logs.dwl”, “logs.lot” and “logs.pvt”, respectively. Finally, the buffer memory is saved to the file on the pendrive.

Menu accessThe following are the steps for accessing the pendrive management menu. Procedure:1. Connect the pendrive to the master port.

USB key

BMS card

Fig. 9.d

2. Press Alarm and Enter together for 3 seconds to enter the option menu. Select FLASH/USB memory and press Enter to confirm.

> System Information

Log Data

Other Information

Flash/usb Memory

3. Select USB pen drive and press Enter to confirm.

Nand flash files

> USB pen drive

Important: Wait a few seconds after the pendrive has been plugged in for it to be recognised by the controller. If the message “No USB disk or PC connected” is displayed momentarily with the request to connect a pendrive key or computer USB cable, wait a few seconds until the recognition message is shown (“USB disk found”) and the following screen appears.

4. Select UPLOAD.

Select function> UPLOAD (pen->pCO) DOWNLOAD (pCO->pen)

UploadAn application plus BIOS or buffer memory (parameters) can be uploaded from the pendrive. The following modes are available: automatic, autorun and manual. Automatic and autorun modes require using configuration files.

Configuration file structureConfiguration files must start with the string “[FUNCTION]” followed by a string that identifies the function, as shown in the table.

Function StringUPLOAD an application or a BIOS file plus an application

Upload application

UPLOAD non-volatile memory (.dev) Upload non volatile memoryUPLOAD the entire contents of the pCO Copy pCO upload

After the description of the desired function, various options are available:1. To copy the complete contents of the directory, simply write the name

of the directory (e.g. the entire contents of the CHILLER directory):

[FUNCTION]

Upload non volatile memory

[DIR]

CHILLER

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2. To copy just 1 file in a directory, enter the file’s name (e.g. the CHILLER.DEV file in the CHILLER directory).

[FUNCTION]

Upload non volatile memory

[DIR]

CHILLER

CHILLER.DEV

To show a string on the display describing the operation being performed, add the “[NAM]” instruction, followed by the string to display. The following file will display the string:

“UPL CHILLER.DEV”

[FUNCTION]

Upload non volatile memory

[DIR]

CHILLER

[NAM]

UPL CHILLER.DEV

CHILLER.DEV

3. To select only some of the files in the same directory, list them after a label. The following labels are allowed and must be entered in the order shown in the table:

UPLOAD file labels

No. Label File type No. Label File type

1 [BIO] (*) file.bin 6 [PVT] file.pvt

2 [IUP] file.iup 7 [LCT] file.lct

3 [BIN] file.bin, blb 8 [OED] file.oed

4 [DEV] file.dev 9 [SGN] file.sgn

5 [GRP] file.grp

(*) BIO = BIOS file

Notes: • to get the .bin file from the BIOS in the format available on http://ksa.

carel.com (.os file), unzip the .os file;• the [IUP] label can be followed by one or more “.iup” files.

Important:• the order in which the file names are entered is fundamental and must

not be changed;• do not enter empty lines or spaces in the file (e.g. at the end of a line);• each file after the last line of code must contain a “carriage return”

character (CR↵ ), as shown in the following example.

Example: The following file will upload the BIOS and an application.

[FUNCTION]↵

Upload application↵

↵

[DIR] ↵

NEW AHU ↵

↵

[NAM] ↵

BIOS+APPL+LOGSv58B36 ↵

↵

[BIO] ↵

bisn509.bin ↵

↵

[IUP] ↵

AHU_EN.iup ↵

AHU_IT.iup ↵

↵

[BIN] ↵

AHU.blb ↵

↵

[DEV] ↵

AHU.dev ↵

↵

[GRP] ↵

AHU.grp ↵

↵

[PVT] ↵

AHU.pvt ↵

↵

[LCT] ↵

AHU.lct ↵

Automatic upload

To automatically upload the parameter memory using the first configuration file shown in the preceding paragraph, access the system menu as previously described and proceed as follows:

1. Select automatic mode. A screen is shown describing the function of the buttons. Press Enter to confirm.

Select upload mode> Automatic modemanual mode

2. Confirm by selecting Prg. A screen is displayed requesting confirmation to upload the non-volatile memory. Press Enter to confirm.

> UPL FILE_DEV

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3. At the end a message will ask the user to remove the pendrive.

Uploading fileplease wait ...

Upload in autorun modeFrom to BIOS 6.24 version, it is possible to do the UPLOAD in AUTORUN mode; without biult-in terminal using the display pLAN address.Uploading in autorun mode is a special case of uploading in automatic mode. Unlike automatic mode, the user must wait for a specific message to appear on the display to start or disable the operation described in the configuration file. To upload a file in autorun mode, a configuration file must be created and named “autorun.txt”. Example of uploading BIOS+application. The upload involves two steps: first the BIOS is updated and then the application. The information is shown on the pCO’s built-in display and on the pGD1 terminal, when both are featured.

Procedure:1. Connect the pendrive to port A.

USB key

BMS card

Fig. 9.e

2. After a few seconds, Autorun mode starts. Press Enter to confirm (or display button pLAN).

****Autorun mode****UPLOAD applicationPress ENTER to startESC to exit Autorun

3. The validity of the FW is checked and the BIOS is loaded.

FW validationPlaese wait ...

4. The display flashes to indicate that after loading the new BIOS the controller is being reset.

FW validationPlaese wait ...

NO LINK

5. The test phase starts.

Application program corrupted or not present! WAITING for upgrade

NO LINK

6. The controller warns that no application has been loaded.

Application program corrupted or not present! WAITING for upgrade

NO LINK

7. The application update then starts.

FW validationPlaese wait ...

NO LINK

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8. Remove the pendrive. The update is complete. Wait for the display to stop flashing, indicating that the controller is being reset before restarting.

Upload complete Remove USB key and wait reset

NO LINK

Important: As can be seen, when updating the BIOS and the application, the pGD1 terminal shows the message “NO LINK”, meaning that no connection is established. Do not remove the terminal and wait for the end of the update procedure, when the pGD1 terminal replicates the messages on the built-in display.

Note: Autorun run is especially useful in those cases in which the same operation needs to be performed on several controllers. For example, to load different applications on controllers connected in a pLAN network, only one autorun file needs to be created; this uploads the various directories contained on the pendrive based on the address of the controllers. The controller with address XY will only load the directory called “nomedir_XY” [“DirName_XY”]. The pendrive then only needs to be plugged into each controller to run the upload, confirming from the shared terminal.

Manual uploadTo manually upload the contents of the pendrive the user must access the management menu from the system screens, selecting UPLOAD and then MANUAL. The files are selected by pressing ENTER when the cursor is on the desired file name. A selected file is marked by the symbol “*” on the left. Once the files have been selected (all in the same directory), press PRG to start the upload. To display the contents of a directory press ENTER. To go up one directory level press ESC. Once the upload has started, the messages shown on the screen are the same as in automatic and autorun mode.

DownloadAs mentioned, the DOWNLOAD operation can be managed in two ways:1. Manual mode: follow the steps described in the paragraph “Automatic

upload” and select manual operation. Then each file must be selected and downloaded.

2. Autorun mode: prepare a file called “autorun.txt”, containing a string that identifies the function to be performed.

Function String

DOWNLOAD logged data Download logs

DOWNLOAD the application Download application

DOWNLOAD non-volatile memory

Download non volatile memory (.dev)

DOWNLOAD the entire contents of the pCO

Copy pCO download

The result is the creation of files with the required extensions, which will be placed in the respective directories as described in the paragraph “File names”.

When the operation is completed, the display shows a message with the name of the directory created.

[FUNCTION]

Download application

The following screen will be displayed.1. Press Enter to confirm.

FW validationPlaese wait ...

2. Download completed.

Operation completeData downloadedto BKP00_01

Example: On the controller with address 1, the autorun file will create a directory called BKP00_01 and copy the files APPL_PCO.DWL and FILE_DEV.DEV to this directory.

Setting the passwordIf the application contains a password that must entered in a special screen, this is requested for each DOWNLOAD/UPLOAD between the pCO and the pendrive. The password is used to:• protect the contents of the pCO from being downloaded to the

pendrive;• protect the PC connection (this is a standard procedure in pCO Manager).

Connecting to a computerConnect the slave USB port on the controller to the USB port on the computer where pCO Manager is installed.

USB connector from computer

BMS card

Fig. 9.f

Important:• do not install any type of converter between the computer and port B, even if requested by the program’s guided procedure;• pCO Manager manages compressed files (.GRT/.OS).Once the connection is established, the following operations are available:1. UPLOADING the application or BIOS+application.2. DOWNLOADING the non-volatile memory.3. DOWNLOADING logged data.4. Commissioning5. Managing the NAND flash memory.

Once the USB cable is removed, the port will become available again after approximately 5 s.

Important: If no connection is established with pCO Manager after plugging in the USB cable, wait at least 1 minute before using the USB ports again after removing the cable.

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Key: messages display on pLAN display address

Message Description

Autorun: waiting for confirmation by the display key pLAn address

Password: copy password inserted; the button isn't work. it It is necessary to insert the password by terminal

In Progress: work in progress

End: operation closed successfully

Invalid: combining of selected files invalid

No LOG: attempt to download historical file when are not present

Tab. 9.g

9.5 Configuring pCOWeb/pCOnet from a system screen

See par. 6.6 for information on how to access the BIOS system menu.Starting from:• BIOS release 5.16 BIOS, and from • pCOWeb firmware version A1.5.0, and from• pCOnet firmware version A485_A1.2.1pCOWeb and pCOnet communication parameters can be configured. The purpose is to configure the network (Ethernet for pCOWeb, RS485 for pCOnet) when the respective card is installed for the first time. The remaining parameters (alarms, events, etc.) can be configured using the usual tools, i.e. BACset or web interface (pCOWeb only). Configuration can be done either when using the Modbus protocol or the CAREL protocol, but only on the BMS1 serial port. The screens for configuring pCOWeb and pCOnet can be opened by accessing the system screens and selecting OTHER INFORMATION and then PCOWEB/NET CONFIG. Then, select “PCOWEB settings” to configure pCOWeb parameters or “PCONET settings” to configure pCOnet parameters.

Configuring pCOWebWhen you select “PCOWEB settings” the following screen will appear:

D H C P : - - -

I P A D D R E S S- - - . - - - . - - - . - - -

After a short time the fields are populated with the current parameters. If the fields are not populated with the current parameters, check the firmware version of pCOWeb and the protocol used by the BMS serial port. The parameters can now be edited by selecting the respective fields using the ENTER button and setting the desired values using the UP/DOWN buttons. If the DHCP option is set to ON, the IP address and Netmask fields cannot be changed. Pressing ENTER repeatedly will display all the parameters available, as listed in the following screens:

N e t m a s k :- - - . - - - . - - - . - - -

G a t e w a y :- - - . - - - . - - - . - - -

D N S 1 :- - - . - - - . - - - . - - -

D N S 1 :- - - . - - - . - - - . - - -

B A C n e t I D :- - - - - - -

B A C n e t T y p e :- - - - - - -

Once the parameters have been chosen they can be updated by going to the following screen and pressing ENTER.

P C O W E B C O N F I G E N A B L EU p d a t e p C O W e b ? N O

While the parameters are being updated, the following message is displayed:P C O W E B C O N F I G E N A B L EP l e a s e w a i t f o re n d o f u p d a t e

At the end, the screen shows:

P C O W E B C O N F I G E N A B L EU p d a t e c o m p l e t eR e b o o t p C O W e b t oa p p l y n e w s e t t i n g

Configuring pCOnet

When you select “PCONET settings” the following screen will appear:

B A C n e t I D :- - - - - - -

B A C n e t b a u d :- - - - - - - -

After a short time the fields are populated with the current parameters. The parameters can now be edited by selecting the respective fields using the ENTER button and setting the desired values using the UP/DOWN buttons. Pressing ENTER repeatedly will display all the parameters available, as listed in the following screen:

B A C n e t M A C : - - -M a x M a s t e r s : - - -M a x F r a m e s : - - - - -

Once the parameters have been chosen they can be updated following the procedure described for configuring pCOWeb.

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“Alfa LU-VE ” +0800010EN rel. 1.5 - 24.03.2020