Water Loop Manual
Water Loop Manual
Waterloop controller
User manual
Code: OSSTDmWLCN
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
All of the above suggestions likewise apply to the controllers, serial boards,
programming keys or any other accessory in the CAREL product portfolio.
CAREL adopts a policy of continual development. Consequently, CAREL
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.
The liability of CAREL in relation to its products is specified in the CAREL general
contract conditions, available on the website www.carel.com and/or by
specific agreements with customers; specifically, to the extent where allowed
by applicable legislation, in no case will CAREL, its employees or subsidiaries
be liable for any lost earnings or sales, losses of data and information, costs of
replacement goods or services, damage to things or people, downtime or any
direct, indirect, incidental, actual, punitive, exemplary, special or consequential
damage of any kind whatsoever, whether contractual, extra-contractual or
due to negligence, or any other liabilities deriving from the installation, use or
impossibility to use the product, even if CAREL or its subsidiaries are warned
of the possibility of such damage.
1. INTRODUCTION 7
1.1 Main features ................................................................................................... 7
1.2 Components and accessories ...................................................................... 7
2. INSTALLATION 8
2.1 c.pCO mini........................................................................................................ 8
2.2 Pressure probes (SPKT00**C0)................................................................. 10
2.3 Temperature/Humidity serials probes.................................................. 10
2.4 Temperature probes ..................................................................................... 10
2.5 General connection diagram ...................................................................... 11
2.6 Functional diagrams ..................................................................................... 12
2.7 Installation ...................................................................................................... 13
3. USER INTERFACE 14
3.1 Built-in keypad ............................................................................................... 14
3.2 “Main” mask................................................................................................... 14
4. MENU DESCRIPTION 15
4.1 Main menu ..................................................................................................... 15
5. START-UP 16
5.1 System configuration.................................................................................... 16
5.2 System settings .............................................................................................. 16
6. FUNCTIONS 17
6.1 Unit On-Off .....................................................................................................17
6.2 I/O configuration ............................................................................................17
6.2.1 Outside sensor (local or serial) ................................................................... 17
6.2.2 Cooling/heating changeover ...................................................................... 17
6.3 Drycooler management .............................................................................. 18
6.3.1 Configuration.................................................................................................... 18
6.3.2 Control................................................................................................................ 18
6.3.3 Fan parameters................................................................................................ 18
6.3.4 Floating set point ............................................................................................. 19
6.3.5 Drycooler bypass ............................................................................................. 19
6.4 Pump control loops ......................................................................................20
6.5 Chiller management ..................................................................................... 21
6.6 Other functions.............................................................................................. 21
6.6.1 Spray water system ......................................................................................... 21
6.6.2 Cooling and heating valve management .................................................22
6.6.3 Auxiliary functions ...........................................................................................22
7. PARAMETER TABLE 23
9. SOFTWARE UPDATE 35
9.1 Setting the controller’s address..................................................................35
9.2 Setting the terminal address and connecting the controller
to the terminal ...............................................................................................35
9.3 Uploading/updating the software .............................................................35
9.4 c.pCO connection to cloud tERA ............................................................... 37
9.5 History of software revisions ......................................................................38
Fig. 1.a
Digital outputs
7 Group 1 (R1, R2); Group 2 (R3, R4, R5): Switchable power: NO EN 60730-
1: 2(1) A (50,000 cycles); UL60730: 5 A resistive, 250 Vac, 30k cycles, 105°C,
Defined Purpose, 1FLA, 6LRA, 250 Vac, 30k cycles, 105°C, pilot duty C300,
1
2
9
10
250 Vac, 30k cycles, 105°C.
3 11
4
5
6
12
13
14
19.2 K
9.6 K Group 3 (R6): Switchable power: NO EN 60730-1: 1(1) A (100,000 cycles)
7 15 with offset 38.4 K CAREL
8 no offset 57.6 K Modbus Maximum switchable voltage: 250 Vac; UL 60730-1: 1 A resistive, 1 A FLA,
ON
OFF 6 A LRA, 250 Vac, D300 pilot duty, 30,000 cycles.
Address Ext. Baud Prot Switchable power R2, R3 with SSR assembly: 15 VA 110/230 Vac or 15 VA
24 Vac according to the model purchased.
6 Between Group 1 and Group 2 there is basic insulation. Group 3 has
reinforced insulation from the two other groups and consequently a
different power supply can be used.
Maximum connection cable length: less than 30 m
1 2
105
170
B
alimentazione
supply
55
Fig. 2.c
Tab. 2.f
Chillbooster
Pump MT
Pump LT
Digital Inputs
Chiller
Remote ON/OFF
Summer/Winter
L N
General Alarm
Drycooler Alarm
MT Pump Alarm (single pump)
MT Pump 1 Overload Alarm
MT Pump 2 Overload Alarm
LT Pump Alarm (single pump)
to cpCOe and serial probe
LT Pump 1 Overload Alarm
default c.pCOe: LT Pump 2 Overload Alarm
Adr: 1 MT Pump Flow Alarm
No offset LT Pump Flow Alarm
Baudrade: 19.2 K Chillbooster alarm
LT Chiller alarm
Protocol: Modbus
J6 BMS
Analog Inputs
External Temperature
External Humidity
Drycooler Water Inlet Temperature
Drycooler Water Outlet Temperature
MT Inlet Pressure
C.pCO n° (03) MT Outlet Pressure
LT Chiller Water Inlet Temperature
33,6°C LT Chiller Water Outlet Temperature
LT Inlet Pressure
Time 12:33 LT Outlet Pressure
date: 07.06.20
07.06.2013
Ambient Temperature
Ambient Humidity
Generic Temperature
Generic Temperature 2
After Bypass Temperature
MT Inlet Temperature
MT Outlet Temperature
LT Inlet Temperature
LT Outlet Temperature
Digital Outputs
Drycooler Bypass on-off
B Y MT Pump Start Command (single pump)
G G0 G G0 MT Pump 1 Start Command
MT Pump 2 Start Command
LT Pump Start Command (single pump)
External
humidity
Fans Drycooler
AC System Command
Switch Valve 1
Switch Valve 2
Power supply
Analog Outputs
Drycooler Bypass
Drycooler Fan
MT Pump Output
LT Pump Output
Generic Function Output
Generic Function 2 Output
Fig. 2.d
Chiller
DOx/DIx
AOx/DIx
T T T T
Ux Ux Drycooler Ux Ux
medium temp. DOx/DIx low temp.
Pa DOx
circuit Va DOx/DIx circuit
T T
Ux Ux
DOx/DIx
Pb
Fig. 2.e
Chiller
DOx/DIx
AOx/DIx
T T T T
Ux Ux Drycooler Ux Ux
medium temp. DOx/DIx low temp.
Pa DOx
circuit Va DOx/DIx circuit
T T
Ux
DOx/DIx
Pb
Fig. 2.f
DOx/DIx
Chiller
DOx/DIx
AOx/DIx
T T T T
DOx Ux Ux Drycooler Ux Ux
Vb
medium temp. DOx/DIx low temp.
Pa DOx
circuit Va DOx/DIx circuit
T T
Ux
DOx/DIx
Pb
Fig. 2.g
2.7 Installation
For installation, proceed as follows, with reference to the wiring diagrams: Important: the following warnings must be observed when
• before performing any operations on the control board, disconnect connecting the controllers:
the main power supply by turning the main switch in the electrical • incorrect power connections may seriously damage the controller;
panel OFF. • use cable ends suitable for the corresponding terminals. Loosen each
• avoid touching the control board with bare hands, as any electrostatic screw and insert the cable ends, then tighten the screws and gently
discharges may damage the electronic components; tug the cables to check they are sufficiently tight;
• suitable electrical protection must be ensured by the manufacturer of • separate as much as possible the probe and digital input cables from
the showcase or by appropriate installation of the controller; cables to inductive loads and power cables, so as to avoid possible
• connect any digital inputs, Lmax=10 m; electromagnetic disturbance. Never run power cables (including the
• connect the temperature and pressure probe, Lmax=10 m; electrical panel cables) and probe signal cables in the same conduits;
• connect the optional PGDe terminal • do not run probe signal cables in the immediate vicinity of power
• program the controller using the guided commissioning procedure: devices (contactors, circuit breakers, etc.);
see the chapter on Commissioning”. • reduce the path of probe cables as much as possible, and avoid spiral
• if present, connect the cpCOe expansion between connectors J4 paths that enclose power devices.
(controller) and J6 (cpCOe). For connection, use a shielded cable
and make sure that the maximum distance between consecutive Important: Class A software: the safety devices providing overload
controllers is 100 m (minimum cable size AWG22); and high pressure protection must control the compressor directly, and
• connect the electrical loads to the relay outputs only after having consequently need to be wired in series with compressor contactor
programmed the controller. Always carefully evaluate the maximum control signal.
capacity of the output relays, as specified in the Technical specifications;
• connect the supervisor serial line to the card inserted on connector Note: when connecting the serial network:
J13. • connect the shield to the GND terminals on all controllers;
• do not earth the shield on the electrical panel;
Important: avoid installing the controllers in environments with • use a shielded twisted cable AWG20-22 (es. Belden 8761);
the following characteristics: • For the supervisor serial network (J13): connect a 120 Ω terminating
• relative humidity greater than 90% or with condensation; resistor between the Tx/Rx+ and Tx/Rx- terminals on the last controller
• strong vibrations or knocks; in the network (the one furthest away from the supervisor).
• 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.
Fig. 3.a
Button Function
Alarm displays the list of active alarms
1
2
3
4
5
6 7
Fig. 3.b
Pressing when the on/off symbol is selected opens screen A01
Rif. Function
1 Status bar with date and time
2 Drycooler set point
3 Outside temperature
4 Drycooler outlet temperature
5 Unit status
6 Actuator status
7 Quick access menu and info
Tab. 3.b
Once having entered the correct password (default value 1234), the first main To navigate inside the menu tree, use the following buttons:
menu screen will be displayed.
• and : navigate around the submenus, screens and change
Important: values and settings;
• the password User; Service; Manufacturer
• if no button is pressed while navigating the menu tree, after 5 minutes • : confirm and save the changes made;
the main screen is automatically displayed again.
• : to return to the previous menu
Tab. 4.a
Date/time
The water loop controller features an internal clock with standby battery
that stores the time and date for all functions where these data are The following screen is used to save and set the parameter configuration
required. The screen used to make the settings is shown below. files.
Serial ports
The Fieldbus serial port parameters can be set for connecting the c.pCOe
and/or serial probes, as illustrated in the figure below..
In the first case, the International System is used, the temperatures are
expressed in °C and pressures in barg. In the second case, the imperial
system is used and the units of measure are °F and psig.
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, – +
GND
+(G)
– G0
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 Power Fieldbus
origin), as shown in the figure: supply RS485
Digital Input Below are the screens used to configure the type of local humidity/
temperature probe (i.e. connected to the analogue inputs).
User interface
Supervisor
Unit On/Off
Fig. 6.a
Fig. 6.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.
• alarm input and the corresponding fan analogue output; 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.
Fig. 6.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.
Setpoint
Cut-off
Waterloop controller manages a fan control cut-off ; the function can be Min
enabled and the related parameters set in main menu branch Dab14.
time
external temperature
Fig. 6.e
Fan Speed
Max
Min
6.3.5 Drycooler bypass
0% On branch Dac01 (Bypass), the output for managing the bypass can be
Temp. set.
Setpoint
Cutoff
Fig. 6.d
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.
Then on screens Dac02, the probe for activation (Drycooler water outlet
Kick function temperature or Outside temperature) and corresponding set point can
To ensure correct operation even when the fans are off for an extended be selected. The same applies for the deactivation logic (Dac03)
period, Waterloop controller can activate the fans for a certain time at a
certain interval, set in branch Dab13. If an anlogue output is used for the bypass, the configuration screens
will be:
Note: this function is also enabled when the unit is OFF from the
The floating set point will be based on the outside temperature. Its value
is determined by adding a programmable constant value to the outside
temperature and limiting the resulting value between a minimum and
maximum, settable on Daa02
M M M
DOx/DIx Again with reference to the MT circuit, on screen Dba02 the control set
Ux AOx/DIx
P T T T
point and corresponding PID parameters can be set.
Ux Ux Drycooler Ux
ΔP DOx/DIx
Pa
P T
Ux Ux
Fig. 6.f
Pump loops
There are two pump control loops:
• medium temperature (MT);
• low temperature (LT).
PID control
Two types of control are available for each loop: The operating principle is classic proportional plus integral and derivative
• independent; control; operation in temperature control mode is illustrated in the
• controlled (by temperature or pressure). following figure:
In the first case, control is managed independently by the pumps
Pump Speed
themselves. On screen Dbb03 set the control output and the
corresponding alarm input for the MT circuit. 100%
Setpoint Temp./Press.
Fig. 6.g
Note: for 0 to 10 V control, 100% corresponds to an analogue
output value of 10 V, while 0% corresponds to 0 V.
The time of pump rotation can be selected for both the MT circuit and
the LT circuit on screen Dbb16 While screen Dbb15 is used to select the
type of reset for the various thermal overloads (automatic or manual).
Note: if two pumps are configured, in the event of an overload
alarm on one of the two, the other is automatically activated. The
same is true for a flow alarm
Flow alarms
For both circuits, a flow alarm can be set, with different delays on pump
activation and during normal operation. On Dbb07 the parameters are
set corresponding to the MT flow switch (screen shown below), while the
LT circuit settings are on screen Dbb14. Note: in the event of chiller alarms, the LT circuit switches to
Heating mode to attempt to supply the showcases with water from
the MT circuit and this keep the system active.
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.
Waterloop controller can manage a digital alarm input from ChillBooster,
which has the effect to deactivate the complete device.
Hygiene procedure
To avoid water stagnation in the pipes, a hygiene procedure can be
enabled that activates Spray water system every day for a certain time
and, if the outside temperature is greater than a threshold.
Mask index”: indicates the unique address of each screen and consequently the path needed to reach the parameters available on this screen; for example, to
reach the parameters corresponding to the suction pressure probe with mask index Bab01, proceed as follows:
Below is the table of the parameters that can be displayed on the terminal. The values indicated with ‘---‘ are not significant or are not set, while the values indicated
with ‘…’ may vary according to the configuration, with the possible options visible on the user terminal. A row of ‘…’ means that there are a series of parameters similar
to the previous ones.
Note: not all the screens and parameters shown in the table are always visible or can be set, the screens and parameters that are visible or can be set depend
on the configuration and the access level.
Mask Variable Description Default UoM Min Max Value Description Type Adr R/W
Index Value
A01 Unit On/Off by keyboard 0 -- 0 1 0: OFF.bmp , 1: ON.bmp D R/W
Unit status -- 0 9 0: 1: ON I R
2: OFF BY ALARM
3: OFF BY BMS
4: OFF BY SCHED
5: OFF BY DI
6: OFF BY KEYBOARD
7: IN MANUAL MODE
A02 Enable Unit On/Off by BMS 0 -- 0 1 0:NO , 1:YES D R/W
Enable On/Off from keyboard 1 -- 0 1 0:NO , 1:YES D R/W
Ba01 External probes connection type 0 -- 0 1 0: LOCAL , 1: SERIAL D R/W
Ba02 Address serial probe 128 -- 128 159 I R/W
External Temperature °C (°F) -- -- A R
Offset Temperature serial probe 0.0 (0.0) °C (°F) -10,0 (-18.0) 10,0 (-18.0) A R/W
External Humidity %rH -- -- A R
Offset Humidity serial probe 0,0 %rH -10,0 10,0 A R/W
Dewpoint °C (°F) -- -- A R
State -- 0 1 0: Offline , 1: Online D R
Ba03 Enables the cpCOe 0 -- 0 1 0: NO , 1: YES D R/W
Device online status -- 0 1 0: Offline , 1: Online D R
Address cpCOe -- 0 128 I R
Protocol cpCOe Modbus -- Modbus I R
Ba04 Position of External Temperature probe 1 -- 0 20 0: --- I R/W
1:U01…10:U10
11: U01e ….20:U10e
External temperature probe type 0 -- 0 2 0: NTC I R/W
1: PT1000
2: NTC-HT
External temperature probe value °C (°F) -- -- A R
External temperature probe offset 0.0 (0.0) °C (°F) -50,0 (-90.0) 50,0 (90,0) A 32 R/W
Ba05 Position of External Humidity probe 2 -- 0 20 0: --- I R/W
1…10:U01... U10
11...20: U01e...U10e
External humidity probe type 2 -- 0 2 0: 0-1V I R/W
1: 0-10V
2: 4-20mA
External Humidity %rH 0.0 100.0 A R
External Humidity minimum value 0.0 %rH 0.0 Max A R/W
External Humidity maximum value 100.0 %rH Min 100.0 A R/W
External humidity probe offset 0.0 %rH -50,0 50,0 A 33 R/W
Ba06 Position of Remote On/Off digital input 0 -- 0 22 0: --- I R/W
1…10: U01...U10
11: ID1
12: ID2
13…22: U01e...U10e
Status of Remote On/Off digital input -- 0 1 0: Closed , 1: Open D R
Logic of Remote On/Off digital input 0 -- 0 1 0: N.C. , 1: N.O. D R/W
Remote On/Off digital input (logic) -- 0 1 0: Not active , 1: Active D R
Ba07 Position of Summer/Winter digital input 0 -- 0 22 0: --- I R/W
1…10: U01...U10
11: ID1
12: ID2
13…22: U01e...U10e
Status of Summer/Winter digital input -- 0 1 0: Closed , 1: Open D R
Ba07 Logic of Summer/Winter digital input 0 -- 0 1 0: N.C. , 1: N.O. D R/W
Summer/Winter digital input (Function) -- 0 1 0: Not active D R
1: Active
Ba08 Position of General Alarm digital output 0 -- 0 12 0: --- I R/W
1…6: NO1...NO6
7…12: NO1e...NO6e
Logic of General Alarm digital output 0 -- 0 1 0: N.C. , 1: N.O. D R/W
Status General Alarm digital output -- 0 1 0: Closed , 1: Open D R
displayed until the button is pressed and held; the alarm is saved
in the log.
For manual reset, the functions associated with the alarm will not be
reactivated until the alarm is reset, while for automatic reset, the functions
are reactivated as soon as the alarm condition ceases.
Log/Events
The alarm log can be accessed:
• from branch F of the main menu
Note: if a relative alarm is selected, this is fixed only in relation to the
• pressing and then when there are no active alarms
drycooler set point.
Fig. 9.a
Fig. 9.d
Fig. 9.f
2. Select the files to be loaded onto the controller and click ”Export
Fig. 9.e Ap1”. In the application package it is possible to include also:
Note: if the c.pCO controller contains an application program that • the Operating System, selecting the specific path;
is protected by a different password or digital signature than the new • the web pages for the c.pCO web server functionality (see Chapter
application program, a dialogue box will be shown prompting for the 10).
previous password. If the password entered is correct, the new application
program can be uploaded.
Fig. 9.g
3. Click “Export” and save the file to a flash drive, under a directory called
“UPGRADE”.
4. Plug the flash drive into the Host USB port and enter the system
menu (see Chapter 7). On the screen, select UPGRADE and then the
application program to be loaded and confirm by pressing enter.
A
USB key
Fig. 9.h
INFORMATION
SETTINGS Fig. 9.i
APPLICATION
UPGRADE Nota: Please use following settings in Filezilla:
LOGGER
DIAGNOSTICS • Edit->Settings->Connection-> set timeout in seconds = 0
• Edit -> Settings -> Transfers -> set maximum simultaneous transfers to 1
3. Access the system menu on the c.pCO and select “UPGRADE” (see
Chapter 7).
INFORMATION
SETTINGS
APPLICATION
UPGRADE INFORMATION
LOGGER SETTINGS
DIAGNOSTICS APPLICATION
UPGRADE
LOGGER
DIAGNOSTICS
Important:
• Before updating the c.pCO controller via USB connection, check in
the system menu that the Host USB port is enabled (Settings --> USB INFORMATION
Settings --> Pen drive, see Chapter 7). SETTINGS
• Only use flash drives with FAT file system. APPLICATION
UPGRADE
• Do not use both USB ports on the controller at the same time. LOGGER
• Do not use mass storage peripherals that have a current draw more DIAGNOSTICS
than 500 mA.
Fig. 9.j
c.pCO registration:
Activation and registration procedure and settings of the tERA services
are described in the “tERA Quick start Guide” (document +030222141),
that can be download from www.carel.com.
Following data are requested in order to register a c.pCO in tERA server:
• MAC address of the c.pCO
• c.pCO Hardware unique ID
• tERA password
Above data are reported in the c.pCO System menu at the following path:
INFORMATION --> pCO INFORMATION (see figure below).
BT v1.2.000 2014/02/12
OS v1.2.000 2014/02/12
SVN REV 2796
MAC 00-0A-5C-40-03-2B
S/N 000000000000032B
tERA 5E2207C4
Fig. 9.k
Agenzia / Agency: