Instruction/ maintenance manual of the product Koolmaster PP-32 ACME
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KOOLMASTER PP-32 CONTROLLER Read this guide carefully before using the controller. ENVIRONMENTAL MANAGEMENT SYSTEM SERIAL NUMBER: DATE: R01.
4. MOUNTING INSTRUCTIONS Fasten the four metal brackets on the mounting holes located behind the controller using the four screws included with the controller. Mount the enclosure on the wall using four other screws. Make sure the electrical knockouts are at the bottom of the enclosure in order to prevent water from entering the control- ler.
Sensors operate at low voltage and are isolated from the supply. Be sure that sensor cables remain isolated from all high voltage sources. In particular, do not route the sensor cables through the same electrical knockout as other cables. Do not connect the shield from the sensor cable to a terminal or a ground.
3. DWR-F-1A COMMUNICATION HOOKUP If DWR-F-1A air inlet controllers are connected to the PP-32, use id numbers within the range 4-15. Id numbers 1,2 and 3 are reserved for another purpose. Refer to section 188.8.131.52 to set the proper ID numbers. terminal as shown on the wiring diagram.
E L B A T H C T I W S P I D ! 4.2 SETTING THE DIP SWITCHES The PP-32 has 12 DIP switches (only the first 7 are used) which deter- mine how the controller works. These switches are located on the board inside the top cover. To change the position of a DIP switch, use a small screwdriver or similar object to move the switch to the desired position.
5. CONTROLLER SETUP 5.1 CURRENT CONDITIONS The current conditions menu gives a quick view of the actual conditions in the barn. Press to step directly to this menu. Room Set Point: this is the target temperature in the barn. Average Temperature: shows the average temperature in the barn.
5.2 CONTROLLER PROGRAMS The controller allows to use up to 4 separate programs to control the room temperature. It then becomes possible to activate a specific program, that uses particular fan settings, in accordance with the animal age for instance.
Fan / Sensor Program Selection: (a) Temp Settings: Summr Use the adjustment buttons to select the proper season (winter/ summer). The start and stop temperatures of heating and ventilation stages that are associ- ated with this seasons will be used. Press the left-arrow key to exit this menu.
5.3 ADJUSTING THE ROOM SET POINT The room set point is the target room temperature. It can be adjusted between 32°F and 120°F (0°C and 48.9°C). Note that the temperature curve must be turned off to adjust this value.
5.4 MINIMUM VENTILATION PRINCIPLE OF OPERATION When the room temperature is below the set point, fans can operate according to a timer. The minimum ventilation cycles runs stage 1 fans according to a timer as shown below.
Use the arrow keys to select the "1. On Time/Curve" function. Press the right-arrow key. The fans' On- Time, in minimum ventilation, is displayed, as well as the status of the minimum ventilation curve. If the curve is OFF , the On-Time value flashes on the display.
5.5 INLET / VENT DOOR SETTINGS The PP-32 controller can operate the air inlets / vent doors in two different ways: 1. Inlets' positions can be determined by using a potentiometer feedback controller ( DWR-F-1A ). Refer to the installation setup section to enable DWR-F-1A modules.
Inlet Compensation Inlet 1 5%/°F Inlet 2 5%/°F Inlet 3 5%/°F Note that the reference numbers that are used by the PP-32 DO NOT correspond to the ID numbers that used by the DWR-F-1A modules because #1, 2 and 3 are reserved for other purpose. 5.5.1.
5.5.2 Vent Door Settings If a static pressure sensor is used, the PP-32 can control the static pressure in the room by opening and closing vent doors. When the pressure drops below the low pressure set point, the vent doors close according to a timer.
GROUPS OF STATIC PRESSURE SET POINTS : Two groups of static pressure set points can be defined. HI and LO static pressure set points #2 start being used either when a certain ventilation stage is reached or when the outside temperature decreases below a user-define value.
2. Static pressure set points' transition according to the outside T°: Example : When the outside temperature drops below the "outside temperature influence" value, a transition between the two set point groups starts.
184.108.40.206 Adjusting Static Pressure Set Points When the high pressure set point is reached (Open at) , the controller opens the vent doors according to a timer cycle. When the low pressure set point is reached (Close at) , the controller closes the vent doors according to the another timer.
Open Time 30sec Close Time 30sec Off Time 60sec Off Time: once the vent doors have opened or closed (depending on the situation), they then stop operating during the Off time delay.
220.127.116.11 Adjusting Stage Level for the Closing of Vent Doors When the stage defined by this parameter is reached, the vent doors start to close continuously until they are completely closed, no matter what the static pressure is. This feature is usefull for closing vent doors when a tunnel ventilation stage starts.
Static Settings 2 Outside Temperature Influence: 50.0°F Close At: .070WC Open At: .090WC Use the adjustment buttons to select the fan stage above which the second group of static pressure set points starts being used. Press the down-arrow key once, the LO static pressure set point #2 is selected (Close At) .
Use the adjustment buttons to set the outside temperature below which the second group of static pressure set points start to be used. Press the down-arrow key once, the LO static pressure set point #2 (Close At) is selected .
5.6 TUNNEL CURTAIN The PP-32 allows you to control an endwall curtain for tunnel ventilation. The tunnel curtain is controlled either by the static pressure level in the barn or in timer mode, according to the room temperature.
Tunnel Curtain Controlled by the Static Pressure: When the pressure drops below the low pressure set point, the tunnel curtain closes according to a timer. Likewise, when the static pressure increases above the high pressure set point, the curtain opens according to another timer.
TRANSITION BETWEEN SIDEWALL AND TUNNEL VENTILATION MODES: The following section describes the vent doors and curtain's behavior when the transition between sidewall ventilation (vent doors) and tunnel ventilation is being done. These steps are automatically performed by the controller.
Tunnel Curtain Tunnel Stage # 5 Min. Animal age 1 5.6.1 Adjusting Minimum Age for Tunnel Ventilation The minimum age is used to prevent tunnel ventilation from being used when the animals are too young. It ranges from 1 to 450 days. The tunnel curtain will never open until the animal age reaches this value.
5.6.3 Adjusting Curtain's Operating Times This function is only used if the curtain operates in timer mode. The curtain's operating time is the time during which the curtain opens when a new tunnel fan stage is activated or closes when a tunnel fan stage is deactivated.
5.6.4 Adjusting Static Pressure Hi and Lo Set Points This function is only used if the curtain operates in static pressure mode. When controlled by the static pressure, the curtain opens or closes according a timer cycle whenever the static pressure level exceeds the Hi or Lo static pressure set points.
Open Time: when the static pressure exceeds the Hi pressure set point, the curtain opens during this delay. It ranges from 0 to 900 seconds. Close Time: when the static pressure drops below the Lo pressure set point, the curtain closes during this delay.
5.7 FAN STAGES SETTINGS The PP-32 controls up to 16 on-off fan stages. These stages operate in a sequence to increase the level of ventilation as the room temperature rises. Each stage can also activate relays in timer mode. The user defines a start and stop temperature for each stage.
Stg 1 On 80.5 (S) Stg 1 Off 80.0 (S) Stg 2 On 82.0 (S) Stg 2 Off 80.0 (S) 5.7.1 Adjusting Fan Stages' Start/Stop Temperatures The minimum temperature difference between two consecutive start temperatures is 0.5°F (0.3°C). The stop temperature of a fan stage must always be lower than its start temperature.
Relay 31 Off(1) Relay 32 Off(1) On Time 15 sec Off Time 120 sec Ventilation Stage Relay Assignement 3. Stage 1a 4. Stage 2a Set the function to "17. Fan Settings" from the main menu. Note that this menu is available only in the installer mode (see sec.
5.8 HEATER SETTINGS The PP-32 operates up to eight independent heater stages. A start and stop temperature is defined for each heating stage. The stop temperature must be at least 0.5°F (0.3°C) greater than the start temperature for a given heater and the start temperature cannot be greater than the set point.
5.9 AUXILIARY OUTPUTS The PP-32 can control up to two auxiliary outputs. They are used as supplementary outputs for heating or cooling and may be used to control several devices such as chimney dampers, stir fans, lamps, heat mats, etc. The user must specify if the auxiliary output operates in heating or in cooling mode.
Set Point: 80.0°F Start / Stop Temp Aux. 1 On 80.0°F Aux. 1 Off 80.5°F Refer to the installation setup to activate the auxiliary outputs and to select either if they operate in heating or cooling mode (sec. 5.14.3). Adjusting Start/Stop Temperatures of Auxiliary Outputs - In heating mode , the stop temperature (Off Temp) must be at least 0.
5.10 ANIMAL AGE The animal age is used as the reference day to determine the position in curves that are used by the controller (temperature curve, minimum ventilation curve). The controller also refers to the animal age to activate the proper clock output programs.
5.11 CLOCK OUTPUTS The PP-32 has 4 clock outputs to control various devices, using the real- time clock. Refer to the installation setup section to activate the clock outputs (see sec. 5.14.3). OPERATION OF CLOCK OUTPUTS 1 AND 2 : The first 2 clock outputs can use up to 8 programs and each program has up to 10 start and stop times.
5.11.1 Adjusting Clock Output Start and Stop Times Set the function to "11.Clock Times" from the main menu using the navigation buttons then press the right-arrow key. This menu is only available if clock outputs have been enabled in the installation setup (see sec.
5.11.2 Adjusting Starting Day of Clock Programs Clock outputs 1 and 2 use up to 8 programs. The user must select the day at which each program starts (this day number is directly related to the animal age). When a new program starts, the previous program is deactivated.
5.12 HISTORY 5.12.1 Resetting Histories The controller automatically resets all sensor histories when the animal age goes from " Off " to " 1day ". Note that this reset doen't clear the Alarm Log history. The following procedure shows how to clear all histories without having to change the animal age.
5.12.3 Individual Temperature Sensors History The controller has an history in which the minimum and maximum temperature readings of each sensor, for the past 10 days, are logged in. Set the function to "3.Temp. Sensors" from the main menu using the navigation buttons then press the right-arrow key.
Heater 1 Run Time 2002/10/01 30min Use the down-arrow key to scroll the display. Relative humidity's Hi and Lo readings are displayed for the past 10 days. 5.12.6 Water Consumption History The controller has an history in which the water consumption, for the past 60 days, is logged in.
Press the down-arrow key once. The Use the down-arrow key to scroll the display. The The total heater run time, since the last reset, is displayed. Keep pressing the down-arrow key to scroll the display. The Heater Run Time values recorded for the past 60 days are displayed.
5.13 ALARM SETTINGS 5.13.1 Alarm Log When an alarm occurs, the light next to the alarm button turns on and the alarm is logged along with the time and date. To view alarms in the alarm log, press the alarm button then use the up and down- arrow keys to step through the recorded alarms.
5.13.2 Setting Alarm Limits The following diagram explains how temperature alarms are detected: When the average room temperature exceeds the high temperature alarm setting (Set Point + Hi Offset), a high temperature alarm is generated.
18.104.22.168 Adjusting Hi/ Lo Temperature Alarms The low alarm temperature can be adjusted from 20°F to 0.5°F (11.1 to 0.3°C) below the set point (Lo Offset) . The high alarm temperature can be adjusted from 0.5°F to 20°F (0.3 to 11.1°C) above the set point (Hi Offset) .
Temperature Alarm Lo Offset T° 10.0 Hi Offset T° 15.0 Out. Influence 5.0 Temperature Alarm Lo Offset T° 10.0 Hi Offset T° 15.0 Critical 95.0°F 22.214.171.124 Adjusting Critical Temperature The critical temperature is the absolute maximum temperature allowed in the room.
Static Press Alarm Low Alarm .015WC Hi Alarm .150WC 126.96.36.199 Adjusting Static Pressure Alarms The controller can generate an alarm if the static pressure drops below the low pressure limit or if it exceeds the high pressure limit. The control- ler uses a delay before activating the alarm.
Press the down-arrow key to select the Hi alarm limit. Use the adjustment buttons to set the Hi alarm limit to the desired value. Note : If you do not want a relay to be turned off in the case of a low static pressure alarm, set the Low Alarm limit to " Off " by pressing the down-arrow key.
Adjusting the Open-Time for the Hi Static Pressure Alarm The Open-Time of the tunnel curtain or vent doors, in case a Hi static pressure alarm occurs, can be adjusted from 0 to 900 sec. Set the function to "21.Alarm Limits" from the main menu using the navigation buttons.
5.14 INSTALLATION 5.14.1 Step-by-Step Installation Guide These are the basic steps to start-up your PP-32 controller. 1 . Connect the control according to the wiring diagram enclosed with this manual. 2 . Turn on the power. 3 . Adjust the Date and Time (sec.
8 . Adjust the temperature set point. This is the target temperature in the room. Refer to section 5.3. 9 . Adjust the start/stop temperature of fan stages (see sec. 5.7) and heater stages (see sec. 5.8). 1 0. Adjust the minimum ventilation cycle settings (see sec.
Password Enter password: 01 ** ** 5.14.2 Password Settings This function allows to identify 2 different user types. It is used to restrict the access to certain parameters. The password is made up of three blocks of two digits, for example: 13 44 21. When a correct password is entered, the current user is identified.
Installer Password code #1 1 code #2 1 code #3 1 Modifying the Installer's Password The installer's password must first be entered before being allowed to modify it. Proceed as explained above to enter the installer password ( 1-1-1 by default).
5.14.3 Installation Setup The following section describes how to customize the controller for your particular application. Normally, this setup needs to be done only once. Parameters are presented below in the order they appear on the display. Use the adjustment buttons to adjust a parameter value.
8 . Use Static Pressure ? Set to "Yes" to activate the static pressure sensor. 9 . Static Pressure Set 2. Select whether the activation of the second group of static pressure set points is related to a specific stage (Stage) or to the outside tempera- ture (Out T°) .
1 6. # of Clock Outputs: Set the number of clock outputs to the desired value. Up to 8 clock outputs can be activated. 1 7 . # of Clock Programs for Clock Outputs 1 & 2 : Set the number of programs for clock outputs 1 & 2. Up to 8 pro- grams can be activated for the first 2 clock outputs.
5.14.4 Sensor Assignment 188.8.131.52 Assigning Sensors to the Room T° and Fan Stages The controller uses the average reading of activated sensors to calculate the room temperature. Fan stages use this temperature to operate. The selection of sensors that are used to determine the average room temperature differs depending on the selected program.
184.108.40.206 Assigning Sensors to Heater Stages Heater stages use the average temperature of their assigned sensors to operate. The assignment of heater stages is common to all programs and can only be set in the installer mode (see sec.
Select "2.Inlet Sensors" then press the right-arrow key. This option is only available in the installer mode (see sec. 5.14.2). Use the navigation buttons to select the desired inlet then press the right- arrow key . Sensors that have been activated during the installation are displayed (see sec.
Use the right and left-arrow keys to select the desired sensor. When the item is flashing, press to activate the sensor or to deactivate it. Proceed in similar fashion to assign sensors to the second auxiliary output, if applicable.
5.14.5 Setting Time and Date Set the function to "20.Time / Date" from the main menu using the navigation buttons. Press the right-arrow key. The current time and date are displayed. Press the right-arrow key once. The year is selected. Use the adjustment buttons to set the year.
RELAY ASSIGNMENT EXAMPLE (an empty template is available at the end of this manual).
Stage 1a Relays: Relay 1 On(1) Relay 2 Off(1) Relay 3 Off(1) 220.127.116.11 Assigning Fan Stages' Relays Ventilation stages 1 to 4 use a separate relay assignment for each progam in use.
To assign relays on timer mode, proceed as described above and use the adjust- ment buttons to select the " Timer " option. 18.104.22.168 Assigning Heater Stages' Relays Set the function to "16.Heater Settings" from the main menu using the navigation buttons then press the right-arrow key.
Use the navigation buttons to select the " 2. Relay Settings " menu then press the right-arrow key. Use the navigation buttons to select the " 1.Open Relay " or " 2. Close Relay " menu then press the right-arrow key. Use the right and left-arrow keys to select the desired relay.
Clock 1 Relays 13 14 15 16 17 18 19 √ Auxiliary 1 Relays 13 14 15 16 17 18 19 √ 22.214.171.124 Assigning Relays to Clock Outputs Set the function to "11.Clock Times" from the main menu using the navigation buttons then press the right-arrow key.
Lo Static Alarm Relay Assignment 1 2 3 4 5 6 7 √ 126.96.36.199 Assigning Relays for the Lo Static Pressure Alarm This relay is activated if a low static pressure alarm occurs. Refer to sec. 5.13.2 to activate/deactivate the low static pressure alarm. Set the function to "21.
5.14.7 Calibrating the Water Counter The PP-32 provides a pulse input to monitor the water consumption. The user must enter the water flow per pulse, it can be adjusted from 1 to 100 gallons per pulse. Set the function to "13. Water Consumption" from the main menu then press the right-arrow key.
5.15 ADVANCED SETTINGS 5.15.1 Setting the Temperature Curve The user can define a temperature curve to adjust the set point auto- matically over a given time period. A curve is defined using up to 10 points. Each point specifies a day number and a set point for that day.
Note that the temperature curve must be turned off to adjust its points and days. Use the down-arrow key to scroll each point of the curve. The curve status then flashes on the display. Use the adjustment buttons to turn it Off. Set the function to "6.
5.15.2 Setting the Minimum Ventilation Curve Fans' On-Time, in minimum ventilation, can automatically be adjusted over a given period of time, by using the minimum ventilation curve. The On-Time changes using 10 steps. Each step specifies a day number and an On-Time value for that day.
Note that the minimum ventilation curve must be turned off to adjust its points and days. Use the down-arrow key to scroll each point of the curve. Then the curve status then flashes on the display. Use the adjustment buttons to turn it Off. Set the function to "7.
5.15.3 Humidity Control If a humidity sensor is being used, the PP-32 has three mechanisms to compensate for a high humidity level : 1 . The humidity level can be decreased by increasing the fans' on time during minimum ventilation cycles. Set Dipswitch #7 to ON to activate this function; 2 .
RH Compensation Add Min Vent sec 30 RH set point % 65 Mist shutoff % Off 188.8.131.52 RH Compensation on Minimum Ventilation When the humidity level reaches the RH set point + 10%, the On-Time portion of the minimum ventilation cycle is increased by an amount ranging from 0 to 900 seconds.
RH Compensation Add Min Vent 30 RH set point % 65 Mist shutoff % 90 184.108.40.206 Adjusting Mist or Kool-Cel Shutoff When the humidity level is too high, Kool-Cel or mist units are shut off to avoid increasing the humidity level any further.
RH set point % 65 Mist shutoff % Off Heater On time Off Heater Off time 0 full On-Time when the humidity is at or above RH Set Point + 10% as shown below. The cycle time can be adjusted from 0 to 900 seconds. Set the dipswitch #6 to ON to use this function.
5.15.4 Calibrating Sensors The reading of each sensor can be slightly adjusted by the user in order to obtain the most accurate and uniform readings of all sensors. The calibration of sensors can only be preformed in the installer mode (see sec. 5.14.
Use the adjustment buttons to set the humidity level that will be added or removed from all readings of the humidity sensor. 220.127.116.11 Calibrating the Static Pressure Level The reading of the static pressure level can adjusted by an amount of ±0.030"WC (±7Pa).
A test mode allows you to simulate temperature changes and verify the controller's performance. In test mode, the temperature sensor inputs are turned off, allowing the user to change the temperature used by the controller to operate the stages. The controller operates as before using the new temperature settings.
6. TECHNICAL SPECIFICATIONS Type PP-32 Main supply fuse F1 3A, fast-blow Mains supply/frequency 115/230 Vac , 50/60Hz OUT1 to OUT4 0-10Vdc, 10mA max. 14Vdc output 14 Vdc ±10%, regulated, 1A max. 14Vdc output fuse F2 1A max, fast-blow Alarm contact 10mA to 2A, 24 Vac or dc max.
7. FACTORY SETTINGS.
8. USING THE CONFIGURATION MODULE 8.1 Loading a Configuration Loading a Configuration from the Configuration Module into the PP-32 Controller: 1 - Position the configuration module on the J1 connector, at the top left corner of the board, with the components facing DOWN.
Load Configuration Press +/- to start Save Configuration Press +/- to start 8.2 Saving a Configuration Saving a Configuration from the PP-32 Controller into the Configuration Module: 1 - Place the configuration module on the J1 connector, at the top left corner of the board, with the components facing DOWN.
9. INSTALLATION REPORT CONTACT INFORMATION.
SENSOR ASSIGNMENT TEMPLATE (see sec. 5.14.4) Note : each program (a, b, c and d) has its own sensor assignement.
INSTALLATION SETUP TEMPLATE (see sec. 5.14.3).
RELAY ASSIGNMENT TEMPLATE (see sec. 5.14.6) PROCEDURE 1- Write down the description of each relay. 2- Put an " X " to assign ON/OFF relays or a " T " for relays that operate in timer mode. RELAY ASSIGNEMENT EXAMPLE In minimum vent.
10. INDEX A Age see Animal age Air inlets see inlets Alarms Alarm connection 12 Alarm limits 53–58 Alarm log 52 Resetting the alarm log 48, 58, 63 Clock program alarm 4 5 Critical temperature alarms.
Assigning sensors to air inlets 67 Inlet compenation 22 Inlets' operation 21 Installation Installation report templates 93–96 Installation setup 63–65 Installation setup template 95 Step by s.
Clock output settings 45–47 Factory settings 90 Fan stages settings 38 Heater settings 41 Humidity compensation 82–85 Inlet settings 21–22 Minimum ventilation settings 19–20 Password settings .
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