CAREL pCO5, compact programmable controller User Manual
Below you will find brief information for programmable controller pCO5, programmable controller pCO5 compact. The pCO5 is a powerful and flexible programmable controller that can be used to control a wide range of HVAC/R applications. The system includes several models for different sizes and functionalities. The pCO5 has a built-in 32-bit microprocessor and either 4 or 8 MB of memory to ensure high performance and memory space available. It also offers different sizes according to the number of inputs and outputs to give the best price/performance ratio. The pCO5 is easy to interface to the most commonly-used building management systems.
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pCO5 programmable controller User Manual NO POWER & SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT! I n t e g r a t e d C o n t r o l S o l u t i o n s & E n e r g y S a v i n g s ENG WARNINGS DISPOSAL CAREL bases the development of its products on decades of experience in HVAC, on the continuous investments in technological innovations to products, procedures and strict quality processes with in-circuit and functional testing on 100% of its products, and on the most innovative production technology available on the market. CAREL and its subsidiaries nonetheless cannot guarantee that all the aspects of the product and the software included with the product respond to the requirements of the final application, despite the product being developed according to start-of-theart techniques. The customer (manufacturer, developer or installer of the final equipment) accepts all liability and risk relating to the configuration of the product in order to reach the expected results in relation to the specific final installation and/or equipment. CAREL may, based on specific agreements, acts as a consultant for the positive commissioning of the final unit/application, however in no case does it accept liability for the correct operation of the final equipment/system. INFORMATION FOR USERS ON THE CORRECT HANDLING OF WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) The CAREL product is a state-of-the-art product, whose operation is specified in the technical documentation supplied with the product or can be downloaded, even prior to purchase, from the website www.carel.com. Each CAREL product, in relation to its advanced level of technology, requires setup/configuration/programming/commissioning to be able to operate in the best possible way for the specific application. The failure to complete such operations, which are required/indicated in the user manual, may cause the final product to malfunction; CAREL accepts no liability in such cases. Only qualified personnel may install or carry out technical service on the product. The customer must only use the product in the manner described in the documentation relating to the product. In reference to European Union directive 2002/96/EC issued on 27 January 2003 and related national legislation, please note that: 1. WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of separately. 2. 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. 3. 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. 4. 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. 5. 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 consumables). Approval: the quality and safety of CAREL INDUSTRIES Hq products are guaranteed by the ISO 9001 certified design and production system, as well as by product marking. In addition to observing any further warnings described in this manual, the following warnings must be heeded for all CAREL 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 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. WARNING: 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. NO POWER & SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT! “pCO5” +0300009EN rel. 1.2 - 24.04.2014 3 ENG Content 1. INTRODUCTION AND GENERAL FEATURES 7 1.1 Programmability .................................................................................................7 2. PRODUCT DESCRIPTIONS 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3. 8 pCO5 controller ...................................................................................................8 Meaning of the pCO5 inputs/outputs .................................................9 pCO5 technical specifications ...............................................................10 Dimensions .........................................................................................................15 pCO compact ....................................................................................................16 Meaning of the pCO5 compact inputs/outputs...........................16 pCO5 compact compact technical specifications ......................17 pCO5 compact dimensions .......................................................................19 USER TERMINALS AND OPTIONAL CARDS 20 3.1 Graphic terminals ........................................................................................20 3.2 Optional cards for pCO sistema .............................................................21 3.3 Connectors..........................................................................................................25 4. PCO CONTROLLER INSTALLATION 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5. General installation instructions ............................................................26 Power supply .....................................................................................................26 Connecting the analogue inputs ..........................................................27 Fast digital inputs ............................................................................................29 Connecting the digital inputs .................................................................30 Connecting the analogue outputs ......................................................32 Connecting the digital outputs..............................................................34 PLAN NETWORK CONFIGURATION 5.1 5.2 5.3 5.4 5.5 5.6 6. 26 36 Introduction .......................................................................................................36 pGDE/pGD1 terminal installation .........................................................38 pLAN address configuration on pCO5 and pCO5 compact .......39 pLAN electrical connections on the pCO ........................................41 Remote terminal with pLAN network ................................................42 pLAN network technical specifications.............................................43 PCO5 SERIAL CONNECTIONS 5 44 3 6.1 pCO serial connections: differences compared to pCO ....44 7. UPDATES, FIRMWARE AND LOG FILES FOR PCO CONTROLLERS 54 7.1 pCO Manager ....................................................................................................54 7.2 USB port (on pCO5 and pCO5 compact models where featured) ................................................................................................54 7.3 Smartkey ...............................................................................................................59 7.4 NAND Flash memory ...................................................................................59 7.5 Checking the software installed on the pCO and other information..................................................................................59 8. GENERAL CONNECTION DIAGRAMS 62 8.1 pCO5 .......................................................................................................................62 8.2 pCO5 with built-in EVD evo .......................................................................63 9. TROUBLESHOOTING 64 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 5 ENG 1. INTRODUCTION AND GENERAL FEATURES pCO sistema: CAREL’s proposal for programmable controllers. It consists of programmable controllers, user interfaces, gateways and communication interfaces, and remote management systems to offer the HVAC/R market a control system that’s powerful, flexible and easy to interface to the most commonly-used building management systems. pCO sistema is very reliable and can be easily customised to differentiate the air-conditioning or refrigeration unit control system. All versions of these controllers use a 32-bit microprocessor and either 4 or 8 MBytes of memory so as to ensure high performance in terms of speed and memory space available. The pCO sistema controllers also come in different sizes according to the number of inputs and outputs, giving the best price/performance ratio. Given the increasing need for integration, the pCO sistema family controllers can interface with some of the most commonly-used serial communication standards, and when fitted with optional cards can be integrated into BMS systems. The pCO* family can connect different types of sensors (e.g. ratiometric, NTC, 4 to 20 mA, etc.); a built-in terminal is available; there are one or two serial ports (depending on the model) to offer connection to controlled field devices (valves, I/O expansions, electronic valve drivers…). In addition, on models where featured, the controllers have 2 USB ports for uploading and downloading files. All these features place our controllers at a level of excellence in fulfilling the needs of the HVAC/R market. 1.1 Programmability The CAREL pCO sistema controllers can be programmed using 1Tool development software, offering the following advantages: • software portability on different CAREL hardware. applications developed for the pCO can be simply and quickly transferred to another hardware platform and vice-versa, modifying only the inputs and outputs; • rapid development, at competitive costs, of custom programs; • reliability guaranteed by the use of standard routines, tested in the field. Hardware architecture The pCO architecture features: • the pCO controller, fitted with a 32-bit microprocessor for running the control program, and the set of terminals required for connection to the controlled devices (for example: valves, compressors, fans). The program and the parameters are saved permanently in the FLASH memory, preventing data loss in the event of power failure (without requiring a backup battery). The pCO also allows connection to a local pLAN network made up of a series of pCO boards and terminals. Each board can exchange information (any variable, digital or analogue, according to the application software) at high transmission speeds. connection to the supervisor/telemaintenance serial line, over the RS485 standard, is made using the optional serial cards (PCO004850) and the CAREL or Modbus® communication protocol. • The terminal, also managed by microprocessor, fitted with display, keypad and LEDs to allow the programming of the control parameters (set point, differential band, alarm thresholds) and basic functions by the user (ON/OFF, display of the controlled values, optional printing). The terminal does not have to be connected to the pCO for normal operation, but can be used for the initial programming of the fundamental parameters. The power of the application software means that the user terminal allows: • initial programming of the unit, with password-protected access; • the possibility to modify, at any time, the fundamental operating parameters, optionally protected by password; • display and audible signalling (by buzzer) of any alarms; • display of the active functions by LED; • display of all the values measured. The use of 1Tool, moreover, ensures the customer the maximum level of privacy and self-management when developing new programs on their own. The possibility to use the same hardware for different applications allows standardisation, with the clear advantages of being able to feature in-circuit and functional testing and burn-in procedures on all of the products and consequently reach a high level of reliability, both overall and in terms of the individual electronic components. 1Tool: exclusive, easy to use CAREL development software for programming, simulation, supervision and definition of pLAN networks using CAREL terminals and pCO programmable controllers. Applications The programmability of the pCO ensures absolute flexibility of application. The same standard hardware can be used to control: • chillers and heat pumps; • roof-top units; • air-conditioners; • small/medium-sized air handling units (on request); • showcases (on request and to specifications); • cold rooms (on request and to specifications); • curing rooms; • compressor racks; • universal stage controllers. Other types of programs can be developed to specific customer requirements. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 7 8 7 Fig. 2.b “pCO5” +0300009EN rel. 1.2 - 24.04.2014 Fig. 2.c J7 J8 J29 DI2 4 2 3 NC13 C13 NO13 8 B10 BC10 ID17 IDC13 ID14 ID14H IDC17 ID18 BC9 ID13 7 5 6 12 11 C16 NO18 NO17 NO16 C16 NC13 C13 NO13 NC12 C12 NO12 C9 NO11 NO10 NO9 C9 NC8 C8 NO8 C7 NO7 C7 C4 NO6 NO5 NO4 C4 C1 NO3 NO2 J18 DI1 J30 S4 21 J17 S3 1 B9 J7 ID13H Y6 Y5 C15 NC15 J17 ID14H S2 S1 J27 ID14 NC12 C12 NO12 IDC9 ID12 ID11 J19 IDC13 J16 VREF 20 7 ID10 8 J22 ID13 GND C9 NO11 NO10 GND ID9 ID16H ID16 NC14 NO15 J16 ID13H ICC9 J6 ID12 C9 NO9 J5 ID11 4 J15 2 3 1 B8 B7 IDC15 J21 ID10 ID9 J5 G 22 4 B6 J6 GND G0 VBAT NC8 ID15 ID15H C14 NO14 C1 NO1 J15 B8 B7 al card B6 IDC1 J13 C8 IDC1 ID8 ID7 BMS card ID8 NO8 ID6 ID5 J10 ID7 7 J14 ID6 ID5 ID4 ID4 ID3 J4 ID3 C4 NO6 ID2 ID1 Y4 Y3 Y2 Y1 VG0 VG BC5 J3 6 14 2 FieldBus card NO5 NO4 ExtraLarge Version J13 ID2 NO29 12 B5 BC4 B4 +VDC GND B3 J12 ID1 J20 NO28 11 5 4 J25 BMS2 J26 FBus2 C25 J19 NO27 J22 NO26 C17 NO20 NO19 NO18 B2 B1 +5 VREF J2 NO25 J21 NO17 C17 15 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W C25 C21 NO24 NO23 GND +Vterm J24 NO22 3 J11 pLAN Y4 Y3 rd C14 NO16 G0 G J1 NO15 1 J9 NO21 C21 NO14 C14 C4 NO6 11 19 18 17 16 13 10 9 ENG 2. PRODUCT DESCRIPTIONS 2.1 pCO5 controller Large Version J23 FBus2 J20 J8 Fig. 2.a Version with VALVE DRIVER J18 J23 FBus2 J28 driver ENG Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. power supply connector [G (+), G0 (-)]; pLAN address button, 7 segment display and LED (power on and overload, +Vdc terminal); additional power supply for the terminal and 0 to 5 V ratiometric probes; universal analogue inputs, NTC, 0 to 1 V, 0 to 5 V ratiometric, 0 to 10 V, 0 to 20 mA, 4 to 20 mA; passive analogue inputs, NTC, PT1000, ON/OFF; 0 to 10 V analogue outputs; 24 Vac or 28 to 36 Vdc digital inputs; 230 Vac or 24 Vac or 28 to 36 Vdc digital inputs; display terminal connector (external panel with direct signals); connector for all standard pCO series terminals and for downloading the application program; relay digital outputs; fieldbus2 connector; pLAN network connector; cover for inserting the supervisor serial card option (BMS1); cover for inserting the field card option (Fieldbus1); BMS2 connector; Fieldbus2 connector; Built-In terminal (LCD, buttons and LEDs); USB Host and Slave connector electronic valve connector valve driver analogue and digital inputs valve driver power supply from Ultracap module EVD0000UC20 (external to pCO5) 2.2 Meaning of the pCO5 inputs/outputs Conn. J1-1 J1-2 J2-1 Signal G G0 B1 J2-2 B2 J2-3 B3 J2-4 J2-5 GND +VDC J3-1 J3-2 J3-3 J3-4 J4-1 B4 BC4 B5 BC5 VG J4-2 VG0 J4-3 J4-4 J4-5 J4-6 J5-1 J5-2 J5-3 J5-4 J5-5 J5-6 J5-7 J5-8 J5-9 Y1 Y2 Y3 Y4 ID1 ID2 ID3 ID4 ID5 ID6 ID7 ID8 IDC1 J6-1 B6 J6-2 B7 J6-3 B8 J6-4 J7-1 J7-2 J7-3 J7-4 J7-5 GND ID9 ID10 ID11 ID12 IDC9 J8-1 ID13H Description +24 Vdc or 24 Vac power supply power supply reference universal analogue input 1 (NTC, 0 to 1 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 2 (NTC, 0 to 1 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 3 (NTC, 0 to 1 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) common for analogue inputs 21 Vdc power supply for active probes (maximum current 150 mA) passive analogue input 4 (NTC, PT1000, ON/OFF) common for analogue input 4 passive analogue input 5 (NTC, PT1000, ON/OFF) common for analogue input 5 power to optically-isolated analogue output, 24 Vac or 28 to 36 Vdc power to optically-isolated analogue output, 0 Vac/ Vdc analogue output 1, 0 to 10 V analogue output 2, 0 to 10 V analogue output 3, 0 to 10 V analogue output 4, 0 to 10 V digital input 1, 24 Vac or 28 to 36Vdc digital input 2, 24 Vac or 28 to 36Vdc digital input 3, 24 Vac or 28 to 36Vdc digital input 4, 24 Vac or 28 to 36Vdc digital input 5, 24 Vac or 28 to 36Vdc digital input 6, 24 Vac or 28 to 36Vdc digital input 7, 24 Vac or 28 to 36Vdc digital input 8, 24 Vac or 28 to 36Vdc common for digital inputs from 1 to 8 (negative pole for DC power supply) universal analogue input 6 (NTC, 0 to 1 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 7 (NTC, 0 to 1 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 8 (NTC, 0 to 1 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) common for analogue inputs digital input 9, 24 Vac or 28 to 36Vdc digital input 10, 24 Vac or 28 to 36Vdc digital input 11, 24 Vac or 28 to 36Vdc digital input 12, 24 Vac or 28 to 36Vdc common for digital inputs from 9 to 12 (negative pole for DC power supply) digital input 13, 230 Vac J8-2 J8-3 ID13 IDC13 J12-1 J12-2 J12-3 J12-4 J12-5 J13-1 J13-2 J13-3 J13-4 J13-5 J14-1 J14-2 J14-3 J15-1 J15-2 J15-3 J16-1 J16-2 J16-3 J16-4 J16-5 J17-1 digital input 13, 24 Vac or 28 to 36Vdc common for digital inputs 13 and 14 (negative pole for DC power supply) ID14 digital input 14, 24 Vac or 28 to 36Vdc ID14H digital input 14, 230 Vac 8-pin telephone connector for connecting a display terminal 6-pin telephone connector for connecting the standard user terminal RX-/TX- RX-/TX- connector for RS485 connection to the pLAN network RX+/TX+ RX+/TX+ connector for RS485 connection to the pLAN network GND GND connector for RS485 connection to the pLAN network C1 common for relays: 1, 2, 3 NO1 normally open contact, relay 1 NO2 normally open contact, relay 2 NO3 normally open contact, relay 3 C1 common for relays: 1, 2, 3 C4 common for relays: 4, 5, 6 NO4 normally open contact, relay 4 NO5 normally open contact, relay 5 NO6 normally open contact, relay 6 C4 common for relays: 4, 5, 6 C7 common for relay 7 NO7 normally open contact, relay 7 C7 common for relay 7 NO8 normally open contact, relay 8 C8 common for relay 8 NC8 normally closed contact, relay 8 C9 common for relays: 9, 10, 11 NO9 normally open contact, relay 9 NO10 normally open contact, relay 10 NO11 normally open contact, relay 11 C9 common for relays: 9, 10, 11 NO12 normally open contact, relay 12 J17-2 J17-3 J18-1 C12 NC12 NO13 common for relay 12 normally closed contact, relay 12 normally open contact, relay 13 J18-2 J18-3 J19-1 * J19-2 * J19-3 * C13 NC13 ID15H ID15 IDC15 J19-4 J19-5 J20-1 J20-2 J20-3 J20-4 -5 J20-6 J20-7 J20-8 J20-9 * * * * ID16 ID16H Y5 Y6 B9 BC9 B10 BC10 ID17 ID18 IDC17 J21-1 * J21-2 * J21-3 * J21-4 * J21-5 * J21-6 * J22-1 * J22-2 * J22-3 * J22-4 * J22-5 * J19-1 ** J19-2 ** J19-3 ** J19-4 ** J19-5 ** J19-6 ** J20-1 ** J20-2 ** J20-3 ** J20-4 ** J20-5 ** J20-6 ** J20-7 ** J21-1 ** J21-2 ** J21-3 ** NO14 C14 NC14 NO15 C15 NC15 C16 NO16 NO17 NO18 C16 C21 NO21 NO22 NO23 NO24 C21 C25 NO25 NO26 NO27 NO28 NO29 C25 C14 NO14 NO15 common for relay 13 normally closed contact, relay 13 digital input 15, 230 Vac digital input 15, 24 Vac or 28 to 36Vdc common for digital inputs 15 and 16 (negative pole for DC power supply) digital input 16, 24 Vac or 28 to 36Vdc digital input 16, 230 Vac analogue output 5, 0 to 10 V analogue output 6, 0 to 10 V passive analogue input 9 (NTC, PT1000, ON/OFF) common for analogue input 9 passive analogue input 10 (NTC, PT1000, ON/OFF) common for analogue input 10 digital input 17, 24 Vac or 28 to 36Vdc digital input 18, 24 Vac or 28 to 36Vdc common for digital inputs 17 and 18 (negative pole for DC power supply) normally open contact, relay 14 common for relay 14 normally closed contact, relay 14 normally open contact, relay 15 common for relay 15 normally closed contact, relay 15 common for relays: 16, 17, 18 normally open contact 16 normally open contact 17 normally open contact 18 common for relays: 16, 17, 18 common for relays 21, 22, 23, 24 normally open contact 21 normally open contact 22 normally open contact 23 normally open contact 24 common for relays 21, 22, 23, 24 common for relays 25, 26, 27, 28, 29 normally open contact 25 normally open contact 26 normally open contact 27 normally open contact 28 normally open contact 29 common for relays 25, 26, 27, 28, 29 common for relays 14, 15, 16 normally open contact 14 normally open contact 15 J8-4 J8-5 J9 J10 J11-1 J11-2 J11-3 * * * * * * “pCO5” +0300009EN rel. 1.2 - 24.04.2014 9 ENG J21-5 ** J21-6 ** J22-1 ** J22-2 ** J22-3 ** J22-4 ** J22-5 ** J22-6 ** J23-1 J23-2 J23-3 J24-1 J24-2 J24-3 J25-1 J25-2 J25-3 J26-1 J26-2 J27-3 J27-1 J27-2 J27-3 J27-4 J28-1 J28-2 J28-3 J28-4 J29-1 J29-2 J29-3 J29-4 J29-5 J29-6 J29-7 J29-8 J30-1 J30-2 J30-3 NO16 C14 C17 NO17 NO18 NO19 NO20 C17 Tx/RxTx/Rx+ GND +V term GND +5 Vref Tx/RxTx/Rx+ GND Tx/RxTx/Rx+ GND 1 2 3 4 1 2 3 4 GND VREF S1 S2 S3 S4 DI1 DI2 VBAT G0 G Electrical specifications normally open contact 16 common for relays 14, 15, 16 common for relays 17, 18, 19, 20 normally open contact 17 normally open contact 18 normally open contact 19 normally open contact 20 common for relays 17, 18, 19, 20 Fieldbus 2 RS485 port - terminal Fieldbus 2 RS485 port + terminal Fieldbus 2 RS485 port GND terminal power supply to additional Aria terminal power supply common power supply for 0 to 5V ratiometric probes BMS 2 RS485 port - terminal BMS 2 RS485 port + terminal BMS 2 RS485 port GND terminal Fieldbus 2 RS485 port - terminal Fieldbus 2 RS485 port + terminal Fieldbus 2 RS485 port GND terminal EXV valve 1 control (see Fig. 7cx) power supply terminal block CPU FLASH memory data memory (static RAM) parameter data memory EXV valve 2 control (see Fig. 7cx) built-in EVD evo probe power supply common built-in EVD evo probe power supply built-in EVD evo probe 1 built-in EVD evo probe 2 built-in EVD evo probe 3 built-in EVD evo probe 4 built-in EVD evo digital input 1 built-in EVD evo digital input 2 external valve power supply from Ultracap module (see inst. sheet +0500042IE) Tab. 2.a Digital inputs type maximum number of optically-isolated voltage inputs 2.3 pCO5 technical specifications dimensions assembly SMALL version installable on 13 DIN modules, 110 x 227.5 x 60 mm; MEDIUM, LARGE and EXTRALARGE versions installable on 18 DIN modules, 110 x 315 x 60 mm;version with ULTRACAP MODULE installable only on the 18 module models with valve driver incorporated, 110 x 315 x 75 mm DIN rail Tab. 2.b Plastic case • fitted on DIN rail in accordance with DIN 43880 and IEC EN 50022; • material: technopolymer; • flammability: V2 (UL94) and 850 °C (in accordance with IEC 60695); • ball pressure test: 125 °C; • resistance to creeping current: ≥250 V; • colour: grey RAL7035; Version with built-in valve driver with or without Ultracap module: 24 Vac +10/-15% 50 to 60 Hz; maximum current: 80 VA/35 W (90VA / 40W when Ultracap is charging) with male/female plug-in connectors, max voltage 250 Vac; wire size: min. 0.5 mm2 - max 2.5 mm2 H8SX1651, 32 bit, 44 MHz 4MB (8MB in the extended versions) Further 32 MB NAND Flash memory available 512 kB at 16 bits (296 kB BIOS; 216 kB application). 13 kB at 16 bits (max limit: 400,000 writes per memory location) and further 32 kB of E2prom (not available to the pLAN) working cycle duration 0.2 s (typical) (medium complexity applications) clock with battery standard clock precision 100 ppm battery specifications lithium button battery code CR2430 voltage 3 Vdc (dimensions 24x3 mm) Tab. 2.c The versions with valve driver, with or without Ultracap module, have the same number, type and configuration of I/Os as the Medium version. *: J19, J20, J21, J22 correspond to the “LARGE” model. **: J19, J20, J21, J22 correspond to the “EXTRALARGE” model. Physical specifications Versions without built-in valve driver: 24 Vac +10/15% 50 to 60 Hz and 28 to 36 Vdc +10/-20%; maximum current 45 VA/20 W ID1 to ID18 optically-isolated (contact live); B4, B5, B9, B10 not optically-isolated (voltage-free contact) 8: SMALL; 14: MEDIUM e EXTRALARGE; 18: LARGE. According to the combinations shown below: no. opto- no. optototal isolated in. isolated in. @ inputs @ 24 Vac 24 Vac or 2850/60 Hz 36 Vdc or 24 Vdc or 230 Vac (50/60 Hz) SMALL 8 none 8 MEDIUM/ 12 2 14 EXTRALARGE LARGE 14 4 18 Normally open (open-closed-open) 200 ms Normally closed (closed-open-closed) 400 ms minimum digital input impulse detection time maximum number of voltage-free 2: SMALL, MEDIUM and EXTRALARGE contact inputs, not optically-isolated (B4 and B5); 4: LARGE (B4, B5, B9, B10) Classification of measuring circuits (IEC Category I (J5, J7, J20) 24 Vac or 28 to EN 61010-1) 36 Vdc - Category III (J8, J19) 230 Vac Digital input current draw, voltage- 5 mA free (B4, B5, B9, B10) Digital input current draw with 24 5 mA Vac voltage signal Digital input current draw with 230 5 mA Vac voltage signal Tab. 2.d WARNINGS: • IDH digital inputs at 230 Vac 50/60 Hz (10/-15%) protected by just one 500 mAT fuse; • the two 230/24 Vac inputs on J8 and J12 have the same common pole and therefore both will be 24 Vac or 28 to 36Vdc, or 230 Vac. There is double insulation between the two inputs and the rest of the controller. • for DC digital inputs (28 to 36 Vdc), either the + or the - can be connected to the common (IDC1). • the rating of the external contact connected to the digital inputs must be at least 5 mA. Note: separate as much as possible the probe signal and digital input cables from the inductive load and power cables, to avoid possible electromagnetic disturbance. 10 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG Fast digital input specifications (B4 and B5, voltage-free contact) When configured as fast digital inputs, B4 and B5 can measure a signal with a maximum frequency of 2 KHz and a resolution of ±1 Hz. This is possible as the BIOS provides the application program two pairs of variables that count the zero crossing of the input signal and the corresponding frequency in Hz. Note: see details in paragraph 4.4 Analogue inputs analogue conversion type 10 bit A/D converter CPU built-in universal: (inputs B1, B2, B3, B6, B7, B8) CAREL NTC temperature sensor (-50T90 °C; R/T 10 kΩ at 25°C), HT NTC0T150 °C, voltage: 0 to 1 Vdc, 0 to 5 V ratiometric or 0 to 10 Vdc, current: 0 to 20 mA or 4 to 20 mA, selectable via software. Input resistance in 0 to 20 mA= 100Ω passive: (inputs B4, B5, B9, B10) CAREL NTC temp. sensor (see universal), PT1000 (-100T200 °C; R/T 1000 Ω at 0°C) or voltage-free digital input (5 mA), selectable via software; maximum number 5: SMALL; 8: MEDIUM e EXTRALARGE; 10: LARGE time constant for each 0.5 s input precision ± 0.3 % of full scale classification of Category I measuring circuits (IEC EN 61010-1) input impedance NTC 10 KΩ 4 to 20 mA 100 Ω 0 to 1 V 100 KΩ 0 to 5 V 20 KΩ 0 to 10 V 12,7 KΩ PT1000 10 KΩ Tab. 2.e WARNINGS: the 21 Vdc available at terminal +Vdc (J2) can be used to power any active probes; the maximum current is 150 mA, protected against short-circuits. It is not allowed to use temporary current values higher than 150 mA. To power the 0 to 5 Vdc ratiometric probes, use the +5VREF (Imax: 60 mA) available at terminal J24. Only use these voltages to power the active probes connected to pCO5 Analogue outputs type maximum number power supply resolution maximum load precision 0 to 10 Vdc optically-isolated on Y1, Y2, Y3, Y4, Y5 and Y6 / phase control on Y3 and Y4 4: SMALL, MEDIUM and EXTRALARGE ; 6: LARGE external 24 Vac or 28 to 36 Vdc on VG(+), VG0(-) 8 bit 1.5 kΩ (7 mA) ± 2 % of full scale on outputs: Y1, Y2, Y3, Y4, Y5 and Y6 Tab. 2.f WARNINGS: • A 0 to 10 Vdc analogue output can be connected in parallel to other outputs of the same type, or alternatively to an external source of voltage. The higher voltage will be considered. Correct operation is not guaranteed if actuators with voltage inputs are connected. Power the VG-VG0 analogue outputs at the same voltage on G-G0: connect G to VG and G0 to VG0. This is valid for both alternating and direct current power supplies. • For phase control outputs (PWM), note that synchronicity (zero crossing) is taken from G/G0 and only with 24 Vac power supply (not Vdc). “pCO5” +0300009EN rel. 1.2 - 24.04.2014 11 ENG Digital outputs type maximum number relay 8: SMALL; 13: MEDIUM; 18: LARGE; 29: EXTRALARGE For the connections see Fig. 2.a and 2.b (reference NO*, NC* and C*). Note that outputs with changeover contacts are kept separate (i.e. without poles shared between outputs). The groups of 3 outputs have 2 “common” contacts for easier installation. Make sure that the current running through the common terminals does not exceed the rated current of an individual terminal, that is, 8 A. Minimum relay contact current: 50 mA. Insulation distance The relay outputs have different features, depending on the model of pCO5. The outputs can be divided into groups. Between groups (cells in the table) there is double insulation and consequently these may have different voltages. There is also double insulation between each terminal of the digital outputs and the rest of the controller. The relays belonging to the same group (individual cell in the table) have basic insulation and therefore must have the same power supply (24 Vac or 230 Vac). version relays with same insulation Makeup of the groups SMALL Type of relay MEDIUM Type of relay LARGE Type of relay EXTRALARGE Type of relay group 1 group 2 group 3 group 4 group 5 group 6 group 7 group 8 group 9 group 10 group 11 1 to 3 Type A 1 to 3 Type A 1 to 3 Type A 1 to 3 Type A 4 to 6 Type A 4 to 6 Type A 4 to 6 Type A 4 to 6 Type A 7 Type A 7 Type A 7 Type A 7 Type A 8 Type A 8 Type A 8 Type A 8 Type A - - - - - - - 9 to 11 Type A 9 to 11 Type A 9 to 11 Type A 12 Type A 12 Type A 12 Type A 13 Type A 13 Type A 13 Type A - - - - 14 to 15 Type A 14 to 16 Type B 16 to 18 Type A 17 to 20 Type B - - 21 to 24 25 to 29 Type B Type B NOTE: the relays in the individual cells of the table have basic insulation, while there is double insulation between groups of cells. 1: SMALL (relay 8); 3: MEDIUM and EXTRALARGE (relay 8, 12 and 13); 5: LARGE (relay 8, 12, 13, 14 and 15) warning: the relay outputs have different features, depending on the model of pCO5 type A relay type of relay: SPDT, 2000 VA, 250 Vac, 8 A resistive UL6030: 2A 250 Vac resistive, C300 pilot duty 240 Vac (30.000 cycles) pCO5 approval: EN 60730-1: 2 A resistive, 2 A inductive, cosφ= 0.6, 2(2) A (100.000 cycles) type B relay type of relay:: SPDT, 1250 VA, 250 Vac, 5 A resistive UL6030: 1A 250 Vac resistive, C300 pilot duty 240 Vac (30.000 cycles) (EXTRALARGE pCO5 approval: EN 60730-1: 1 A resistive, 1 A inductive, cosφ= 0.6, 1(1) A (100.000 cycles) models only) Changeover contacts Switchable power SSR outputs(optional on models where featured) 1: SMALL (output 7); 2: MEDIUM and EXTRALARGE (outputs 7 and 12); 3 or 4: LARGE (outputs 7, 12 and 14 or 7, 12, 14 and 15) Working voltage: 24 Vac/Vdc; maximum load current = 0.5A; maximum impulsive load current = 1.2A. If the load requires higher current, use an external SSR. To power external loads, use the same power supply as the pCO (connected to terminals G/G0); as specified by Carel, this must always be dedicated and not in common with the power supply to other devices on the electrical panel (such as contactors, coils, etc.). Make sure that the load connection cables are as short as possible and away from power cables. Tab. 2.g Plug-in connectors pLAN network/user terminal connection Electrical specifications of the plug-in connectors used: Type of connector Rated voltage Rated current Cable size Stripping length Screw thread size Tightening torque type transmission speed Pitch 5.08 250 V 12 A 0.25 mm2 - 2.5 mm2 (AWG: 24 to 12) 7 mm M3 0.5-0.6 Nm Tab. 2.h Size (mm2) Current 20 15 14 0.5 1.5 2.5 2 6 8 32 Tab. 2.j The maximum distance between the pCO and the user terminal is shown in the following table. Cable AWG and size cross-reference AWG pGD0, pGD1 terminal connector pLAN network/other terminal connector maximum number of units connectable asynchronous half duplex RS485 62.5 Kbps or 115.2 Kbps selectable via software 6-pin telephone (J10) 3-pin plug-in connector (J11) Tab. 2.i type of cable power supply distance power supply telephone AWG24 shielded cable AWG20/22 shielded cable 10 m 200 m 500 m taken from pCO (150 mA) taken from pCO (150 mA) separate power supply via TCONN6J000 Tab. 2.k pCO5 serial connections There are three types of serial connections: • pLAN • BMS • FieldBus The FieldBus serial card features Master hardware and so BMS Slave devices must be connected to it. The protocols used for FieldBus are generally Master (Carel or ModBus®) however Slave can also be used (Carel or Modbus®). The opposite is also true: Slave protocols will be used on the BMS (Slave hardware) however Master is also possible. Note: for details see paragraph 5.7 12 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 The maximum distance between two pCO5 devices with AWG20/22 shielded cable is 500 m. Note: • J10 can only be connected to one terminal (pCOT, pCOI, pGD0, pGD1) or two terminals when the backlighting for the display is not activated. • Except PGD0 and PGD1 terminals, the other terminals should be always powered with separate power supplies. • The 21 Vdc available at +Vterm (J24) can be used to power an external terminal as an alternative to the one connected to terminal J10, with maximum current 1.5 W. ENG Example application: Version with electronic expansion valve driver The pCO5 Medium size features an optional new integrated solution: the version with built-in EVDevo driver, single or twin. The driver card is housed on the pCO5 in the socket provided for the inputs / outputs on the Large size board, hence the reason it’s only available on the pCO5 Medium (not Small, Large, nor ExtraLarge) and doesn’t require an external power supply. The built-in driver replicates all the hardware and functions logical of the “EVDevolution TWIN” driver, i.e. independently controls one or two electronic expansion valves with two-pole stepper motors. The only difference between the two versions is the absence of the relay output. For details on the valve control logic, setup and installation see the EVDevo manual (code + 0300005EN). In the same way as EVDevo, on the pCO5 the integrated driver is available in the CAREL and Universal versions. The “Universal” models are used to control both CAREL electronic expansion valves and products made by other manufacturers (see the table below), while the CAREL models only manage CAREL valves. Valve compatibility table Manufacturer CAREL ALCO SPORLAN Danfoss CAREL SPORLAN Compatible models E*V**** EX4; EX5; EX6; EX7; EX8 330 Hz (recommended by CAREL); EX8 500 Hz (from ALCO specifications) SEI 0.5-11; SER 1.5-20; SEI 30; SEI 50; SEH 100; SEH175 ETS 12.5-25B; ETS 50B; ETS 100B; ETS 250; ETS 400 Two CAREL EXVs connected together SER(I) G, J, K Fig. 2.d Tab. 2.l This version of pCO5 Medium with built-in EVDevo driver can be integrated with the energy storage module (PCOS00UC20), made using special capacitor technology called Ultracapacitor, so as to ensure the electronic valve closes in the event of power failures. The module only powers the driver and not the pCO5 this in integrated into. Warning: the pCO5 with valve driver and PCOS00UC20, EVD0000UC0 or EVBAT00400 module must be powered at 24 Vac so that emergency valve closing is ensured in the event of power failures. Serial communication and programming Communication between the pCO5 and its built-in EVDevo driver is managed internally using the Fieldbus2 serial port. The FieldBus2 serial port (J26) is however electrically insulated from the driver serial line: this ensures that in the event of external faults on the line connected to FBus2, the internal driver can continue working independently and correctly. The driver can only be configured exclusively using the pCO5 application developed in 1Tool, no external displays are available for the EVDevo. To ensure efficient data exchange between the driver EVDevo and the pCO5, when developing the 1Tool application, if there are devices connected to the FBus2 port (terminal J26) using the Modbus® protocol, the number of variables exchanged in total over the serial line should be evaluated. Electrical connections To simplify installation of the pCO5 with integrated EVDevo, the power supply G-G0 at the base of the pCO5 is connected internally, using a shielded cable, to the EVDevo: the driver thus does not need to be powered independently. It’s recommended to keep the digital and analogue input cables separate from the valve power cable. All the analogue and digital inputs are earthed to GND, and consequently the application, even temporary, of voltages exceeding ±5 V to these connections may cause irreversible damage to the driver. As GND is the common earth for all the inputs, this should be replicated on the terminal block. The 1tool development environment features a module for managing the EVDevo: the same module can be used to manage the internal driver, as if it were managing an external EVDevo connected to the FBus2 port. pCO5 Medium manages the integrated driver board as an EVDevo Twin external connected to Field Bus 2. At a 1Tool application program level, the valve driver must be connected to FBus2. Consequently, any other devices physically connected to the Fbus port (J26) must have the same communication protocol (CAREL Standard Master or Modbus® Master), the same baud-rate, stop bits and parity. It must also be remembered that the address of the internal driver is 198 (default for EVDevo), so any other devices connected to J26 must have an address other than 198. External EVDevo drivers can be connected to FieldBus 1 (optional card) without limits. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 13 ENG Technical specifications maximum length 10 m or less than 30 m with shielded cable S1 S2 S3 S4 ratiometric pressure probe (0 to 5 V) electronic pressure sensor (4 to 20 mA) combined ratiometric pressure probe (0 to 5 V) 4 to 20 mA input (max. 24 mA) low temperature NTC high temperature NTC resolution 0.1 % FS resolution 0.5 % FS resolution 0.1 % FS resolution 0.5 % FS 10 kΩ at 25 °C, -50T90 °C 50 kΩ at 25 °C, -40T150 °C combined NTC 0 to 10 V input (max 12 V) ratiometric pressure probe (0 to 5 V): electronic pressure sensor (4 to 20 mA) combined ratiometric pressure probe (0 to 5 V) 4 to 20 mA input (max. 24 mA) low temperature NTC high temperature NTC 0 kΩ at 25 °C, -40T120 °C resolution 0.1% FS resolution 0.1 % FS resolution 0.5 % FS; resolution 0.1 % FS resolution 0.5 % FS 10 kΩ at 25 °C, -50T105 °C; 0 kΩ at 25 °C, -40T150 °C combined NTC 10 kΩ at 25 °C, -40T120 °C Power to active probes (VREF) Emergency power supply programmable output: +5 Vdc+/-2% or 12 Vdc+/-10% Indicator LEDs: A (yellow) = Close valve A (J27) B (green) = Open valve A (J27) C (yellow) = Close valve B (J28) D (green) = Open valve B (J28) • Flashing if the valve is moving. • On steady if the valve is at the end of travel. measurement error: 2% FS maximum; 1% typical measurement error: 8% FS maximum; 7% typical measurement error: 2 % FS maximum; 1 % typical measurement error: 8 % FS maximum; 7 % typical measurement error: 1°C in the range -50T50 °C; 3 °C in the range +50T90 °C measurement error: 1.5 °C in the range -20T115 °C, 4 °C in range outside of -20T115 °C measurement error: 1°C in the range -40T50 °C; 3 °C in the range +50T90 °C measurement error: 9% FS maximum; 8% typical measurement error: 2% FS maximum; 1% typical measurement error: 8% FS maximum; 7% typical measurement error: 2 % FS maximum; 1 % typical measurement error: 8 % FS maximum; 7 % typical measurement error: 1 °C in the range -50T50 °C; 3°C in the range 50T90 °C measurement error: 1.5 °C in the range -20T115 °C; 4 °C in range outside of -20T115 °C measurement error 1 °C in the range -40T50 °C; 3 °C in the range +50T90 °C optional Ultracapacitor module (PCOS00UC20 or EVD0000UC0). If the pCO5 operates constantly at temperatures near the upper limit of 60°C it’s recommended to use the external module code EVD0000UC0, where possible located in the coolest point of the panel. The PCOS00UC20 and EVD0000UC0 modules can be connected at the same time to the same pCO5, thus doubling the energy available to close the valves. Important: The module only powers the valve driver and not the pCO5. DI2 DI1 S4 S2 S3 ID14H S1 VREF J8 ID14 GND J29 IDC13 ICC9 ID12 ID11 ID10 ID9 J7 GND J6 B6 C D ID13 LEDS ID13H A B G G0 VBAT J30 B8 Digital input connection Probes shielded 4-wire cable CAREL code E2VCABS*00, or AWG22 shielded 4-wire cable Lmax =10 m, or AWG14 shielded 4-wire cable Lmax = 50 m Digital input to be activated with voltage-free contact or transistor to GND. Closing current 5 mA; Maximum length < 10 m B7 Motor connection Fig. 2.e Examples of CAREL codes: PCO5000000A20: pCO5 medium + EVD EVO embedded for 2 CAREL EXVs PCO50000U0C20: pCO5 medium + USB + NAND + EVD EVO embedded for 2 CAREL EXVs PCO50000U0C60: pCO5 medium + USB + NAND + EVD EVO embedded for 2 UNIV. EXVs PCO50000U0F20: pCO5 medium + USB+NAND+PGD1 + EVD EVO embedded for 2 CAREL EXVs PCOS00UC20: modulo ultracap, for pCO sistema EVD EVO embedded for 2 CAREL EXVs pCO5 hardware simulator For availability of the pCO5 simulator (pCO5 simulator code: CM00002028) contact CAREL. If the new functions of the pCO5 are not needed, the pCO3 simulator can be used. Other characteristics storage conditions operating conditions index of protection environmental pollution class according to protection against electric shock PTI of the insulating materials period of stress across the insulating parts type of action type of disconnection or microswitching category of resistance to heat and fire immunity against voltage surges ageing characteristics (operating hours) 14 -40T70 °C, 90% RH non-condensing -25T60 °C, 90% RH non-condensing IP20, IP40 on the front panel only (in the versions without Ultracap module) 2 to be integrated into Class I and/or II appliances PCB: PTI250; insulation material: PTI 175 long 1C; 1Y for versions a SSR microswitching category D (UL94 - V2) overvoltage category: II for all I/Os except for the high voltage digital outputs and digital inputs (class II circuits), which are category I 80,000 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 no. of automatic operating cycles 100,000 (EN 60730-1); 30,000 (UL 873) software class and structure Class A category of immunity to voltage Category III surges (IEC EN 61000-4-5) The device is not designed to be hand-held when powered Tab. 2.m Product certification Electrical safety Electromagnetic compatibility EN 60730-1, EN 60730-2, UL60730 Versions without valve driver: EN 61000-6-1, EN 610006-2, EN 61000-6-2/EC, EN 61000-6-2/IS1, EN 61000-6-3, EN 61000-6-4; EN 55014-1, EN 55014-2, EN 55014-2/EC, EN 55014-2/A1, EN 55014-2/IS1, EN 55014-2/A2 Versions with valve driver with or without Ultracap module: EN 61000-6-1, EN 61000-6-2, EN 61000-6-2/EC, EN 61000-6-2/IS1, EN61000-6-3, EN 61000-6-4 ENG 2.4 Dimensions 44 45 110 60 75 315 con modulo ultracap / with ultracap module Fig. 2.f 44 45 110 60 227,5 Fig. 2.g “pCO5” +0300009EN rel. 1.2 - 24.04.2014 15 ENG 2.5 pCO compact ID2 B7 J9 J11 C2 NO2 Y2 PWM 0/10V GNX GND Y1 Tx/Rx J8 ISOLATED 10 J10 B8 GND 9 GND NO6 NO5 C3 J4 11 J7 J6 NO3 Versione TYPE A 8 C3 TLAN GND J5 NO4 Tx/Rx 7 6 NO7 5 4 12 J12 13 Y4 Y3 ID2 1 2 NO1 NC1 C1 GND ID1 J3 +VDC B4 B3 B2 B1 J2 SYNC G0 G J1 16 +5Vref J13 GND 15 s e r i a l ca rd 1 0/10V 0/10V B6 14 input voltage: max. power: 24 V (+10/-15%); 50/60 Hz 14 VA /11 W 48 V (36Vmin…72 Vmax) B5 J12 GND C5 J11 NO5 NO6 C3 NO3 NO4 Versione TYPE B 3 Fig. 2.h Key: 1 power supply connector (G, G0) 24 Vac or 48 Vdc (36 Vdc min to 72 Vdc max) 2 “SYNC“ synchronicity inputs for phase control and NTC, 0 to 1 V, 0 to 5 V, 0 to 20 mA, 4 to 20 mA analogue inputs, +5 Vref to supply 5 V ratiometric probes and + Vdc (+21 Vdc) for active probes 3 digital output 4 connector for all standard pCO series terminals and for downloading the application program 5 pLAN network connector 6 connector for pLD terminals 7 tLAN network connector 8 optically-isolated connector for “FieldBus” serial 9 0 to 10 V analogue and PWM phase control outputs 10 digital output 11 digital outputs (Type A) 12 NTC analogue inputs and digital inputs (Type A) 13 removable cover for USB port 14 digital outputs (type B) 15 digital outputs (type B) 16 digital input and 0 to 10 V analogue outputs (Type B) 2.6 Meaning of the pCO5 compact inputs/ outputs TYPE A Connector J1-1 J1-2 J2-1-2 J2-3 Signal G G0 SYNC B1 J2-3 B2 J2-5 B3 J2-6 B4 J2-7 B5 J2-8 B6 J2-9 J2-10 J2-11 J2-12 J2-13 J13-1 J13-2 J13-3 J4 GND +5VREF +24VDC ID1 GND C1 NC1 NO1 J5-1 RX-/TX- J5-2 RX+/ TX+ GND J5-3 J6 J7-1 J7-2 J8-1 J8-2 16 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 TLAN GND RX-/TXRX+/ TX+ Description power supply, +24 Vdc or 24 to 48 Vdc power supply reference power supply synchronicity input for phase control universal analogue input 1 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 2 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 3 (NTC, 0 to 1 V, PT100, PT1000) universal analogue input 4 (NTC, 0 to 1 V, PT100, PT1000) universal analogue input 5 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, DI) universal analogue input 6 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, DI) analogue input reference power supply for 0 to 5 V ratiometric probes power supply for 24 Vdc active probes digital input 1 reference for digital input ID1 common for relays: 1 normally closed contact, relay 1 normally open contact, relay 1 6-pin telephone connector for connecting the standard user terminal RX-/TX- connector for RS485 connection to the pLAN network RX+/TX+ connector for RS485 connection to the pLAN network reference for RS485 connection to the pLAN network tLAN terminal connector tLAN network connector reference for connecting the tLAN network RX-/TX- connector for RS485 connection to Fieldbus port RX+/TX+ connector for RS485 connection to Fieldbus port ENG J8-3 GND J9-1 Y1 J9-2 J9-3 J10-1 J10-2 J11-1 J11-2 J11-3 J11-4 J11-5 J11-6 J11-7 J12-7 Y2 GND NO2 C2 C3 NO3 NO4 NO5 NO6 NO7 C3 GND J12-8 J12-9 J12-12 ID2 B7 B8 GND connector for RS485 connection to Fieldbus port analogue output 1 PWM (for phase cutting speed controllers) analogue output 2, 0 to 10 V analogue output reference normally open contact, relay 2 common for relay 2 common for relays: 3, 4, 5, 6 ,7 normally open contact, relay 3 normally open contact, relay 4 normally open contact, relay 5 normally open contact, relay 6 normally open contact, relay 7 common for relays: 3, 4, 5, 6 .7 reference for analogue input B7, B8 and digital input ID2 digital input 2 universal analogue input 7 (NTC, DI) universal analogue input 8 (NTC, DI) Connector J1-1 J1-2 J2-1-2 J2-3 Signal G G0 SYNC B1 J2-3 B2 J2-5 J2-6 J2-7 B3 B4 B5 J2-8 B6 J2-9 J2-10 J2-11 J2-12 J2-13 J13-1 J13-2 J13-3 J4 GND +5VREF +24VDC ID1 GND C1 NC1 NO1 J5-1 RX-/TX- J5-2 RX+/ TX+ GND J8-2 Physical specifications dimensions all versions are available on 6 DIN modules 105x115x60 mm assembly DIN rail Plastic case • Fitted on DIN rail in accordance with DIN 43880 and IEC EN 50022 • Material: technopolymer • Flammability: V2 (UL94) and 960°C (IEC 695) • Ball pressure test 125 °C • Resistance to creeping current ≥ 250 V • Colour grey RAL7035 Electrical specifications TYPE B J5-3 J6 J7-1 J7-2 J8-1 2.7 pCO5 compact compact technical specifications TLAN GND RX-/TX- J8-3 RX+/ TX+ GND J9-1 Y1 J9-2 J9-3 J10-1 J10-2 J11-1 J11-2 J11-3 J12-1 J12-2 J12-3 J13-1 Y2 GND NO2 C2 NO4 C3 NO3 NO6 C3 NO5 GND J13-2 J13-3 J13-4 ID2 Y3 Y4 Description power supply, +24 Vdc or 24 to 48 Vdc power supply reference power supply synchronicity input for phase control universal analogue input 1 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 2 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, 0 to 20 mA, 4 to 20 mA) universal analogue input 3 (NTC, 0 to 1 V, PT1000) universal analogue input 4 (NTC, 0 to 1 V, PT1000) universal analogue input 5 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, DI) universal analogue input 6 (NTC, 0 to 1 V, 0 to 5 V, 0 to 10 V, DI) analogue input reference power supply for 0 to 5 V ratiometric probes power supply for 24 Vdc active probes digital input 1 reference for digital input ID1 common for relays: 1 normally closed contact, relay 1 normally open contact, relay 1 6-pin telephone connector for connecting the standard user terminal RX-/TX- connector for RS485 connection to the pLAN network RX+/TX+ connector for RS485 connection to the pLAN network reference for RS485 connection to the pLAN network tLAN terminal connector tLAN network connector reference for connecting the tLAN network RX-/TX- connector for RS485 connection to Fieldbus port RX+/TX+ connector for RS485 connection to Fieldbus port GND connector for RS485 connection to Fieldbus port analogue output 1 PWM (for phase cutting speed controllers) analogue output 2, 0 to 10 V analogue output reference normally open contact, relay 2 common for relay 2 normally open contact, relay 4 common for relay 3, 4 normally open contact, relay 3 normally open contact, relay 6 common for relay 5, 6 normally open contact, relay 5 reference for analogue output Y3, Y4 and digital input ID2 digital input 2 analogue output 3, 0 to 10 V analogue output 4, 0 to 10 V Tab. 2.n Isolated power supply DC power supply: 48 Vdc (36 Vmin to 72 Vmax) AC power supply: 24 Vac +10/-15 %, 50/60 Hz Maximum power: P=11W, P=14VA, Imax=700mA H8SX/1651 32-bit, 50 MHz 2+2 MByte 512 kBytes at 16 bit 13 kBytes + 32 kB CPU Program memory (FLASH) Data memory (SRAM) Parameter data memory (EEPROM) NAND Flash memory Working cycle duration 32 MByte 0.2 s typical (medium complexity applications) Available as standard and integrated into main board Tab. 2.o Clock Battery specifications The battery used inside the pCO compact is a “button” sized lithium battery, code CR2430, 3 Vdc, dimensions 24mm x 3mm. SERIAL port specifications Item Serial ZERO Type PLAN Reference Main features J4, J5 • Integrated on main board • Not optically-isolated • HW driver: RS485 • Connectors: Telephone jack + 3-pin plugin p. 3.81 CABLE LENGTH Conn. Type of Lmax Power shielded (m) cable J4 Telephone 50 taken from pCO compact (150 mA) J4 AWG24 200 taken from pCO compact (150 mA) J4 AWG20/22 500 separate via TCONN6J000 J5 AWG20/22 500 - Serial ONE BMS 1 Serial Card 1 • Not integrated on main board • HW driver: not present • Can be used with all pCO family optional BMS cards • Maximum cable length: see serial option documents “pCO5” +0300009EN rel. 1.2 - 24.04.2014 17 ENG Serial TWO Optoisolated FIELD Bus J8 tLAN J6/J7 • IIntegrated on main board • Optically-isolated • HW driver: RS485 opto-isolated • 3-pin plug-in connector p. 3.81 • Maximum AWG20/22 shielded cable length: 500 m As an alternative to the Field Bus serial the following can be used: • tLAN serial available on a 2-pin connector p. 3.81 (J7) or • connection to a PLD terminal available via special 4-pin connector (J6) • J7: maximum shielded cable length (2 wires + shield) AWG20/22: 30 m • J6: maximum four-wire cable length (see accessories table): 2 m for domestic environments, 10 m for residential environments Tab. 2.p 0 to 1 Vdc voltage 0 to 5 Vdc ratiometric 0 to 10 Vdc voltage 0 to 20 mA or 4 to 20 mA current PT1000 -100T200 °C; R/T 1000 Ω at 0 °C Voltage-free digital input (5 mA) Total B1, B2, B3, B4, B5, B6 B1, B2, B5, B6 B1, B2, B5, B6 B1, B2 B3, B4 B5, B6, B7, B8 8 B5, B6 6 Tab. 2.s Warning: for the power supply to any active probes, the +21 V available on the +21VDC terminal can be used, maximum current available Imax=60 mA, protected against short-circuits. For the power supply to the 0 to 5 Vdc ratiometric probes, use the +5 VREF, maximum current available Imax= 60 mA, protected against short-circuits. Time constant Precision Classification of measuring circuits Note: 0.5 s ± 0.3% of full scale Category I (IEC EN 61010-1) Tab. 2.t • Only use STP or S/UTP with shielded cables both ends of the shield connected to PE. • Serial 2 is designed to be the MASTER. This implies that any pCO compacts connected as SLAVES cannot be connected using serial 2. Nonetheless, only one SLAVE can be connected using serial 2. Warning: separate as much as possible the probe signal and digital input cables from the inductive load and power cables, to avoid possible electromagnetic disturbance. Digital inputs pLAN network/user terminal connection Type Transmission speed Maximum number of units connectable Terminal connector Connector pLAN network, graphic terminal, Aria terminal Maximum network length Asynchronous half duplex RS485 62.5 Kbps or 115.2 Kbps selectable via software 32 Unit maximum allowed 6-pin telephone (J4) 3-pin plug-in connector, 3.81 mm pitch (J5) 30 m Tab. 2.q Note: • J4 can connect just one terminal (pCOT, pCOI, pGD0 and pGD1) or two terminals however without using the display backlighting. • Graphic terminal and Aria terminal should always have separate power Max. cable length Type Power supply Models Multifunction analogue inputs (see note) Fast digital input Normal digital input Total 10 m Not opto-isolated, voltage-free contact Internal TYPE A TYPE B B5, B6, B7, B8 B5, B6 ID1 ID2 6 ID1 ID2 4 Tab. 2.u Note: Multifunction analogue inputs: these analogue inputs can be programmed via software as digital inputs instead of analogue inputs. All digital inputs refer to GND. supplies. Fast digital input specifications (ID1) tLAN network connection Type Asynchronous half duplex 0/5 Vdc, nondifferential 9.6 Kbps or 19.2 Kbps selectable via software Maximum 5 units allowed Transmission speed Maximum number of units connectable tLAN network connector 2-pin plug-in connector, 3.81 mm pitch (J7) Tab. 2.r Note: The fast digital input (ID1) can be configured via software in two different operating modes, with the following characteristics: • mode one: normal or standard digital input; • mode two: fast digital input. When configured as a fast digital input, ID1 can measure a signal with a maximum frequency of 2 KHz, resolution +/- 1 Hz. This is made possible by the BIOS, which provides the SW application with two variables that the count the number of times the input signal crosses zero and the corresponding frequency in Hz. • The tLAN serial (J7) is used as an alternative to either the Field Bus serial available on the 3-pin connector p. 5.08 (J8) or the PLD terminal connection available on the special 4-pin connector (J6). Analogue inputs Max. cable length Analogue conversion Models CAREL NTC -50T90 °C; R/T 10 kΩ at 25°C or HT NTC0T150 °C Note: see details in the paragraph 4.5 on digital inputs Normal and fast digital input specifications 10 m A/D converter, 10-bit CPU built-in TYPE A TYPE B B1, B2, B3, B4, B5, B1, B2, B3, B4, B5, B6 B6, B7, B8 The maximum current available to the digital input is 5 mA (consequently the rating of the external contact must be at least 5 mA). Analogue outputs Max. cable length 18 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 10 m ENG Type B Type B (2 SSR) Type B (4 SSR) 2 4 Tab. 2.v 8 bit ± 2% of full scale on Y2 2s 1kΩ (10 mA) for Y2 0/10V, 470 Ω (10 mA) for Y1 PWM Tab. 2.w Digital outputs pCO compact TYPE A features 7 digital outputs, while pCO compact TYPE B features 6 digital outputs, both with electromechanical or solid state relays (SSR). To simplify wiring, the common terminals of some relays have been grouped together, depending on the insulation distance. Within a group, the relays only have basic insulation between them and thus must be powered at the same voltage (generally 24 Vac or 110 to 230 Vac). Between groups there is reinforced insulation, thus the groups can be powered at different voltages. SPDT relay:UL873: 2.5 A resistive, 2 A FLA, 12 A LRA, 250 Vac, C300 pilot duty (30,000 cycles) EN60730-1: 2 A resistive, 2 A inductive, cos(phi)=0.6, 2 (2) A (100,000 cycles) SPST relay:UL873: 1 A resistive, 1 A FLA, 6 A LRA, 250 Vac, D300 pilot duty (30,000 cycles) EN607301: 1 A resistive, 1 A inductive, cos(phi)=0.6, 1 (1) A (100,000 cycles) Power MOSFET Photovoltaic relay Operating voltage: 24 Vac or 28 to 36 Vdc Maximum power: 10 W Total outputs Models 1 2 J3 J10 1 1 - 1 1 - 1 1 3 4 J11 J12 5 - 5 - 2 2 2 2 - 1 2 3 4 J3 J10 J11 J12 - 1 1 - - 1 1 - 2 2 7 7 6 6 TYPE B Y2, Y3, Y4 Y1 Specifications Resolution Precision Settling time Maximum load Conn. Type A (2 SSR) Technical specifications Insulation of the outputs group Not opto-isolated Internal TYPE A Y2 Y1 Type A Type Power supply Models 0 to 10 Vdc analogue output PWM analogue output with 5 Vdc pulse of programmable duration Total 6 Tab. 2.x pCO5 compact hardware simulator For availability of the pCO5 compact simulator (pCO5 compact type A simulator code: CM00002026; pCO5 compact type B simulator code: CM00002027) contact CAREL. J7 J6 PWM 0/10V GNX J9 IS O LATED C2 NO2 Y2 Y1 Tx/Rx J8 GND GND J5 GND Tx/Rx TLAN 2.8 pCO5 compact dimensions J10 s e r i a l c a rd 2 110 J4 input voltage: max. power: 24 V (+10/-15%); 50/60 Hz 8 VA / 6 W 48 V (36Vmin…72 Vmax) NO1 NC1 C1 GND ID1 J3 +VDC GND B6 B5 B4 B3 B2 B1 SYNC J2 G0 G J1 +5Vref s e r i a l c a rd 1 105 60 Fig. 2.i “pCO5” +0300009EN rel. 1.2 - 24.04.2014 19 ENG 3. USER TERMINALS AND OPTIONAL CARDS Various types of user terminals are available, differing in terms of: • dimensions; • liquid crystal display (LCD); • number of buttons; • number of indicator LEDs; PGD1000I00 pCO graphic display (panel installation) 3.1 Graphic terminals pGDE The pGD graphic display is an electronic device, compatible with the previous PCOI/PCOT terminals, used for the complete management of the graphics, by displaying icons (defined at an application software development level) and international fonts, in two dimensions: 5x7 and 11x15 pixels. The application software only resides on the pCO board; the terminal does not need any additional software during operation. In addition, the terminal allows a wide range of operating temperatures (-20T60°C) and guarantees a high index of protection (IP65). Fig. 3.b Display Type: Backlighting: Graphic resolution: Text modes: Character height: Size of the active area: Size of the display area: FSTN graphic green LEDs (controlled by “application program”) depending on the code.. 132x64 pixel 8 rows x 22 columns (5x7 and 11x15 pixel fonts) 4 rows x 11 columns (11x15 pixel fonts) or mixed modes 3.5 mm (5x7 pixel fonts) 7.5 mm (11x15 pixel fonts) 66x32 mm 72x36 mm Keypad 15 buttons, the “ESC” button is replaced by the “MENU” button Power supply Voltage: Fig. 3.a White Backlight Built-in or panel PGDE000F00 version Wall-mounted version PGDE000W00 White Backlight with buzzer PGDE000FZ0 PGDE000WZ0 Tab. 3.a Technical specifications Display Type: Backlighting: Graphic resolution: Text modes: Character height: Size of the active area: Size of the display area: power supply from pCO via telephone connector or from external 18/30 Vdc source protected by external 250 mAT fuse Maximum power input: 1.8 W Tab. 3.c FSTN graphic white LEDs (controlled by “application program”) depending on the code. 132x64 pixel 8 rows x 22 columns (5x7 and 11x15 pixel fonts) 4 rows x 11 columns (11x15 pixel fonts) or mixed modes 3.5 mm (5x7 pixel fonts) 7.5 mm (11x15 pixel fonts) 66x32 mm 72x36 mm Adjusting contrast on the pGD1: 1. pressing the Alarm and Prg buttons together 2. holding the two buttons, use Up or Down to adjust the contrast as desired (increase or decrease). Built-in display Keypad LED / buzzer 2 programmable from “application program”, red and orange ( + buttons) 4 4 green controlled by LCD backlighting LCD ( & buttons) Optional buzzer (*Z0 models) Power supply Voltage: Fig. 3.c power supply from pCO via telephone connector or from external 18/30 Vdc source protected by external 250 mAT fuse Maximum power input: 0.8 W Tab. 3.b Fig. 3.d 20 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG pCO5 and pCO5 compact come in the built-in terminal version with the display and keypad directly incorporated onto the plastic case. RS232 serial card for modem management: PCO100MDM0 codes PCO5******E**, PCO5******F**, PCO5******G**, LCD 8x22, backlit (pGD1) number of buttons 6 number of LEDs 4+2 two-colour Tab. 3.d These versions with integrated LCD and keypad also support connection to the pCO, PGDE and PGD1 series terminals (the two displays, built-in and standard, work at the same time, displaying the same information). The display contrast can also be adjusted on this version of terminal. To do this : 1. press the Enter and Esc buttons together; 2. holding the two buttons, use Up or Down to adjust the contrast as desired (increase or decrease). Connecting the user terminal to the pCO board The typical connection between the pGD terminal and the pCO is made using a 6-wire telephone cable supplied by CAREL (code S90CONN00*, see the table). To make the connection, simply plug the cable into the 6-pin connector on the pCO board (J10 for pCO3 and pCO1, J5 for pCOXS, J19 pCOC), until it clicks into place. To remove the connector, lightly press the plastic catch and remove the cable. The telephone connector provides both the data link and the power supply to the terminal, and is the simplest connection method; in more complex configurations, where multiple terminals need to be connected to the pCO or to cover lengths over 50 m, use shielded, twisted pair cable (see diagrams in chap. 5). Warning shielded cables must be used even when the pCO is fitted on appliances for household or similar uses, and therefore subject to the requirements of IEC EN 55014-1 of 04/98) – (see paragraph 5.7). When making a pLAN network of pCO controllers and terminals, remember that one pCO can only power one pGD0/1 or pCOT/I terminal. If needing to manage more than one terminal or for the pGD2/3, an independent power supply is required (see diagrams in chap. 5). The direct current available at Vterm (J24 for pCO3, J9 for pCO1) can power an Aria or PLD terminal with a maximum current of 2 W. Absence of the terminal does not compromise operation of the pCO. Fig. 3.f The PCO100MDM0 card is an option used to interface pCO electronic controllers to a standard HAYES modem, managing the following hardware signals: • output, “request to send” (RTS) in parallel with “data terminal ready” (DTR); • input, “carrier detect” (CD). The maximum baud rate is 19200 baud. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050003240). Ethernet serial card: PCO1000WB0 Fig. 3.g Used to interface pCO controllers with BACnet™ Ethernet™ and IP, SNMP V1, 2, FTP and HTTP, Modbus® TCP/IP protocols.. BACnet™ MSTP RS485 interface card (PCO1000BA0) 3.2 Optional cards for pCO sistema Serial cards for supervision and telemaintenance Fig. 3.h RS485: PCOS004850 Used to interface pCO controllers with the BACnet™ MSTP protocol, increasingly used for HVAC applications. CANbus serial card: PCOS00HBB0 Fig. 3.e The PCOS004850 card is an option used to interface pCO electronic controllers to an RS485 network with maximum baud rate 19200 baud (settable via software). It guarantees optical isolation of the controller from the RS485 serial network. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050003237). Fig. 3.i These devices are used to connect pCO controllers to CANbus networks and, more specifically, to e-drofan fan coil controllers, exploiting the power of the edronic system to allow simpler management of the installation, optimising comfort, synergies between controllers and running costs. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code “pCO5” +0300009EN rel. 1.2 - 24.04.2014 21 ENG +050000162). LonWorks® serial card: PCO10000F0 Fig. 3.j The PCO10000F0 card is an option used to interface pCO electronic controllers to a LonWorks® network. The PCO100FD10 option is used to connect the pCO3 and pCO1, via an electrically insulated interface, to an RS485 network, using the connector with plug-in terminals on the card. The controller consequently acts as the MASTER (i.e. supervisor), and therefore other pCO controllers or SLAVE devices can also be connected. The meaning of the pins on the connector are denoted by the screen printing on the card. A maximum of 207 devices can be connected using this type of connection. If the optional card occupies the last position on the supervisor serial line and the line is longer than 100m, the line must be terminated by connecting a 120Ω - 1/4W resistor to the terminal pins. For SLAVE operation, on the other hand of type, only one pCO can be connected to the network with this optional card. tLAN and PST card: PCO100TLN0 Warning: to become operational, the interface card must be programmed according to the application installed on the pCO. Information on how to program the board is available in the corresponding manual, code +030221960. The program resides in flash memory housed on a socket, and can be programmed directly via the LonWorks® network using network installation and maintenance tools, such as LonMaker™. • PCO*0000F0 - interface to FTT-10A 78 kbs (TP/FT-10). The pCO baud rate must be set to 4800, while the pCO address is not significant as it is automatically recognised by the card. An option is available already programmed with the standard chiller profile: PCO10001F0. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050004040). Konnex serial card (PCOS00KXF0, PCOS00KXB0) Fig. 3.m The PCO100TLN0 option is used to connect the pCO1 to a tLAN network using two separate connectors. The first connector is used to connect the pCO3 and pCO1 to a tLAN network. Using this connection and a suitably-configured application in TLAN MASTER mode, the pCO1 can interact with the pCO I/O expansion (tLAN version - PCOE00TLN0) or with other pCO controllers fitted with a tLAN connection, configured in tLAN SLAVE mode. A maximum of 5 devices can be connected using this type of connection. The second connector, on the other hand, is used to connect a PNT or PST terminal. Using this connection and a suitably-configured application, the pCO3 and pCO1 can interact with a PNT terminal. For both connections, use a shielded cable with a maximum length of m. Important: both connectors cannot be used at the same time. MP-Bus card: PCO100MPB0 Fig. 3.k The KNX technological standard is now widely used in building automation and control for commercial and residential use. CAREL is member of the KNX Association (www.knx.org). The CAREL Konnex card is compatible with all KNX/EIB devices and can be installed on the FieldBus or BMS port on the pCO sistema or e-drofan controllers. The K-Set tool (available for download from ksa.carel.com) is used to create an XML file for the custom profiles. For the technical specifications and the various configuration specifications, see the instructions shown on the instruction sheet included in the packaging with the card (code +050000770). Serial cards for connection to a “field bus” network The optional Field bus cards provide a serial interface that allows the PCO3 and pCO1 to communicate with other devices over various standards. Indeed, the tLAN, MP bus and RS485 options interface the pCO to a network of devices including actuators, probes, expansions or terminals. The PCO100MPB0 option is used to connect the pCO3 and pCO1 to an MP-Bus network made up of I/O devices using the Belimo standard. Up to 8 actuators can be connected at the same time, with a maximum distance of 30 m (Fig. 7). To connect an active or passive temperature sensor, or a digital contact, refer to the specific Belimo documents (www.belimo.ch). As regards the configuration procedures for the network addresses, these are described in the specific manuals for the individual applications. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050003270). RS232 serial card for modem management: PCOS00FD20 RS485 serial card: PCO100FD10 Fig. 3.l 22 Fig. 3.n “pCO5” +0300009EN rel. 1.2 - 24.04.2014 Fig. 3.a ENG The PCOS00FD20 card is an option used to interface pCO1/pCO3 electronic controllers directly to a standard HAYES modem. The card manages “request to send” (RTS) in parallel with “data terminal ready” (DTR). For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050003295). 44 45 110 CANbus serial card: PCOS00HBF0 Fig. 3.q Fig. 3.o These devices are used to connect pCO controllers to CANbus networks and, more specifically, to e-drofan fan coil controllers, exploiting the power of the edronic system to allow simpler management of the installation, optimising comfort, synergies between controllers and running costs. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050000162). For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050003210). CPY interface External modules and interfaces Interface for OEM series humidifiers (PCOUMI2000) Fig. 3.r Electronic card for control and management of CAREL KUE humidifier kits: • features all the inputs and outputs to completely and independently control the humidifier; • features three LEDs to indicate alarms (red LED), steam production (yellow LED), 24 Vac power supply (green LED); • can be connected to the CPY terminal (code CPYTERM*), or to the supervisor network with Modbus® RTU or proprietary CAREL protocol. DC/DC module (PCO20DCDC0) Fig. 3.p The PCOUMI2000 module is an interface for pCO electronic controllers used to allow the fundamental parameters of the OEM humidifiers made by CAREL (high level and supply water conductivity in the cylinder, TAM current sensor) to be controlled directly by the pCO microprocessor electronic controller. The values measured by the sensors are converted into signals read by the inputs on the pCO (for further information see the user manual for the application program). Compared to the PCOUMID000 interface, the PCOUMI2000 differs in terms of: • greater precision and immunity to disturbance for both the conductivity and the level sensor; • the “high water level” signal can be managed either by a digital or analogue output. Consequently, both the PCOUMID000 and the PCOUMID200 cards can be connected to the pCO, with the only requirement being to set a special parameter so as to allow the software to use the correct conductivity curve.. Fig. 3.s The PCO20DCDC0 power supply module is an option for the pCO electronic controllers. It stabilises the 24±1 Vdc/0.7 A direct current output (from the pCO controller) when the input voltage (power source) is in the range from 21 to 58 Vdc (for example 48 Vdc storage batteries, typical in telephone applications). The maximum capacity delivered is 17 W, suitable for powering any pCO electronic controller. The input and output of the power supply module are galvanically insulated at a functional level. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050004020). “pCO5” +0300009EN rel. 1.2 - 24.04.2014 23 ENG SMART KEY (PCOS00AKY0 e PCOS00AKC0) Fig. 3.t The 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 (converter not opto-isolated, for the Smart Key only). The power supply comes either via the USB port on the PC or from the controller, therefore no external power supply is needed. REQUIREMENTS Hardware requirements: type C and G Smart Keys can only copy software between pCO devices belonging to the same family, which are compatible in terms of RAM and FLASH memory size. The pCO families are: • pCO1/pCOC/pCOXS/pCO OEM • pCO2 • pCO3 • pCO5 • pCO Compact • Supernodo Software requirements: 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. CONNECTION Spegnere il pCO rimuovere qualsiasi periferica connessa in rete pLAN e 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. Then wait a few seconds before the key is operational. This waiting stage is indicated by UP and DOWN symbols flashing. At the end of this stage, the controller enters programming mode and the start button, now on steady, can be pressed to start the data transfer. Then the Upload/Download operations described below can be performed. DOWNLOAD APPLICATION At the end of the connection and recognition stage between SmartKey and pCO, the controller goes into programming mode, with the START button light on steady. Then proceed as follows 1. Make sure the arrow is pointing to the inside of the SmartKey. If the arrow is pointing the other way, switch directions by pressing the MODE button. 2. When this condition is true, pressing the START button automatically activates the DOWNLOAD procedure (read data from the pCO) 3. Completion of the DOWNLOAD procedure is signalled by the buzzer. The operation for writing the data may take a few minutes to complete. MEANINGS OF THE BUTTONS/SYMBOLS Flashing: the key is connecting to the pCO, during this phase, / UP /DOWN 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 On steady: pressing the button starts writing the software to the START+ pCO On steady: pressing the button starts reading the software from START+ the pCO On steady: pressing the button starts reading the logs from the START+ pCO MODE On steady: for key type C, pressed for 1 second switches from read to write Tab. 3.e The key is type C of G, pressing the “mode” button for 1 second switches from read to read logs (G only)or 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 (UP or DOWN) at a frequency proportional to the progress of the operation. When the operation is completed, the buzzer sounds intermittently for 2 seconds. Pressing the “start” button again, the buzzer sounds without repeating the operation; to repeat the operation, the key must first be unplugged. ERRORS BEFORE PRESSING THE START BUTTON +MODE • Communication error: no response from the pCO • Firmware version of the key incompatible symbols on steady Password error +MODE symbols flashing + + Important: if the key is type B, C or G (in write mode) pressing the start button immediately deletes the software already loaded on the pCO. + Important: the key must not be removed while a write operation is in progress to the key, as the file being transferred will be lost and the corresponding space is not 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. + + + symbols flashing Type of key incompatible symbols on steady • The key is missing one or more required files • Empty memory: no kit for the type of pCO connected +START symbols on steady Incompatibility between the software + flashing START on the key and the pCO HW (*) +MODE symbols on steady Incompatibility between pCO + flashing MODE application and HW (application size) symbols on steady No logged data present on the pCO + symbol on steady Type of key not programmed Tab. 3.f ERRORS AFTER PRESSING THE START BUTTON UPLOAD APPLICATION At the end of the connection and recognition stage between SmartKey and pCO, the controller goes into programming mode, with the START button light on steady. Then proceed as follows 1. Make sure the arrow is pointing in the direction of the pCO connection. If the arrow is pointing the other way, switch directions by pressing the MODE button 2. When this condition is true, pressing the START button automatically activates the UPLOAD procedure (read data from SmartKey to pCO). 3. Completion of the UPLOAD procedure is signalled by the buzzer. The operation for reading the data may take a few minutes to complete +START+ +BUZZER symbols flashing and buzzer The write operation has failed sounding intermittently +START+ +BUZZER symbols flashing and buzzer The read operation has failed sounding intermittently +START+ +BUZZER symbols flashing and buzzer The read logs operation has sounding intermittently failed + symbols on steady + flashing + + symbols on steady symbol flashing Incompatibility between log configuration and pCO HW (no dedicated flash memory) Insufficient space to read logged data Generic error Tab. 3.g 24 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG PROGRAMMING SMART KEY VIA PC The different operating modes described in the table below can be configured using a program on the PC. The same program can also load the software to the key or transfer the logged data from the pCO to disk. Type Function B Update software from key to pCO (bios, application, parameters,…) C* Copy software from pCO to pCO (bios, application, parameters,…) D Read logged data E Read logged data and software from pCO (bios, application, parameters,…) F Read logged data from μChiller3 G Copy from pCO to pCO and read logged data *: Default mode Valve driver (EVO*) Mode button Disabled Switches the key from write mode to read mode Disabled Disabled Disabled Switches the key from write mode to read mode Fig. 3.w Tab. 3.h The key is programmed as default in read/write mode (type C) so as to allow used immediate use for transferring the software from one controller to another. When the key is connected to the personal computer, the symbols have the following meanings • Flashing: awaiting connection to the PC • Alternating: during connection to the PC, indicates that data transfer is in progress USB/RS485 converter (CVSTDUMOR0/CVSTDUTLF0)) The EVD0000400 module for electronic expansion valves with two-pole stepper motor is a controller that manages refrigerant expansion in a refrigerant circuit. This function is achieved by optimising the opening of the valve using a PID algorithm and some special auxiliary control routines. The controller has a tLAN interface for connection to a Master unit, an RS485 adapter (available on models *410, *411, *420 and *421) that allows connection to units with the supervisor protocol, from 4800 to 19200 baud, or with the pLAN protocol. The controller automatically recognises the protocol and the baud rate. Alternatively, the controller can operate in stand-alone mode. As well as the serial connection, in any configuration described above, the controller can be accessed for configuration or monitoring via an auxiliary “service” serial port at 4800 baud with supervisor/tLAN protocol and network address = 1 (fixed). The USB converter CVSTDUTTL0 is required to use the “service” serial port. This connection is for temporary use (Fig. 2). If using the “service” serial port or the supervisor protocol on the main serial port, the EVD4UI program can be used; this has a user-friendly graphic interface and is available on the KSA site. Fig. 3.u Il The USB-RS485 converter is an electronic device used to interface a RS485 network to a personal computer via the USB port, used together with WINLOAD. The converter is available in two versions: CVSTDUTLF0, fitted with six-pin telephone connector, and CVSTDUMOR0, fitted with three-pin terminal block. These are optically-isolated and cannot be used with the Smart key. For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050000590). e pCO 3.3 Connectors Example codes: PCO5CON**0 see the following table for the description: PCO3CON * 0= screw 1= spring * S= small M= medium L= large Z= extra large N.O. 0 Tab. 3.a PCOXCON * 0= screw 1= spring * A= type A B= type B 0 Tab. 3.i Fig. 3.v The “PCOE000TLN0 and PCOE0004850” expansion card is an electronic device that’s part of the pCO sistema family and has been designed to increase the number of I/Os on the pCO controllers. A maximum of 5 expansion cards can be connected for each pCO controller. Versions available: • PCOE00TLN0 version tLAN (CAREL proprietary protocol); • PCOE004850 version RS485 (CAREL 3.0 supervisor protocol). For the technical specifications, meanings of the connections (pins) and instructions on inserting the card, see the instructions shown on the instruction sheet included in the packaging with the card (code +050003265). “pCO5” +0300009EN rel. 1.2 - 24.04.2014 25 ENG 4. PCO CONTROLLER INSTALLATION 4.1 General installation instructions 61000-6-2) the connections must be less than 30 m long; • all the extra low voltage connections (analogue and 24 Vac/Vdc or Installation instructions Environmental conditions Avoid assembling the pCO and the terminal in rooms with the following characteristics. • temperature and humidity that do not conform to the rated operating data of the product; • strong vibrations or knocks; • exposure to aggressive and polluting atmospheres(e.g.: sulphur and ammonia fumes, saline mist, smoke) so as to avoid corrosion and/or oxidation; • strong magnetic and/or radio frequency interference (therefore avoid installing the units near transmitting antennae); • exposure of the pCO to direct sunlight and to the elements in general; • large and rapid fluctuations in the room temperature; • environments where explosives or mixes of flammable gases are present; • exposure to dust (formation of corrosive patina with possible oxidation and reduction of insulation). • • • • 28 to 36 Vdc digital inputs, analogue outputs, serial bus connections, power supplies) must have reinforced or double insulation from the mains network; in residential environments, the connection cable between the pCO and the terminal must be shielded; there is no limit to the number of cables that can be connected to an individual terminal. The only limitation concerns the maximum current crossing each terminal: this must not exceed 8 A; the maximum size of wires connected to a terminal is 2.5 mm2 (12 AWG); the maximum value of the twisting torque to tighten the screw on the terminal (torque tightening) is 0.6 Nm; Warnings • Installation must be performed according to the standards and legislation in force in the country where the device is used; • for safety reasons the equipment must be housed inside an electrical panel, so that the only accessible part is the display and the keypad; • in the event of malfunctions, do not attempt to repair the device, but Positioning inside the panel The position of the controller in the electrical cabinet must be chosen so as to guarantee correct physical separation from the power components (solenoids, contactors, actuators, inverters, ...) and the connected cables. Proximity to such devices/cables may create random malfunctions that are not immediately evident. The structure of the panel must allow the correct flow of cooling air. rather contact CAREL. Anchoring the pCO The pCO is installed on a DIN rail. To fasten the unit to the DIN rail, press it lightly against the rail. The rear tabs will click into place, locking the unit in place. Removing the unit is just as simple, using a screwdriver through the release slot to lever and lift the tabs. These are kept in the locked position by springs. Wiring instructions When laying the wiring, “physically “ separate the power part from the control part. The proximity of these two sets of wires will, in most cases, cause problems of induced disturbance or, over time, malfunctions or damage to the components. The ideal solution is to house these two circuits in two separate cabinets. Sometimes this is not possible, and therefore the power part and the control part must be installed in two separate areas inside the same panel. For the control signals, it is recommended to use shielded cables with twisted wires. If the control cables have to cross over the power cables, the intersections must be as near as possible to 90 degrees, always avoiding running the control cables parallel to the power cables. Carel highlights the following warnings: • Use cable ends suitable for the corresponding terminals. Loosen each screw and insert the cable ends, then tighten the screws. When the operation is completed, slightly tug the cables to check they are sufficiently tight; • separate as much as possible the sensor signal, digital input and serial line cables from the cables carrying inductive loads and power cables to avoid possible electromagnetic disturbance. Never insert power cables (including the electrical cables) and probe signal cables in the same conduits. Do not install the sensor cables in the immediate vicinity of power devices (contactors, circuit breakers or similar); • reduce the path of the sensor cables as much as possible, and avoid spiral paths that enclose power devices; • avoid touching or nearly touching the electronic components fitted on the boards to avoid electrostatic discharges (extremely damaging) from the operator to the components; • if the power transformer secondary is earthed, check that the earth wire corresponds to the wire that runs to the controller and enters terminal G0; this applies to all the devices connected to the pCO; • do not secure the cables to the terminals by pressing the screwdriver with excessive force, to avoid damaging the pCO; • for applications subject to considerable vibrations (1.5 mm pk-pk 10/55 Hz), secure the cables connected to the pCO around 3 cm from the connectors using clamps; • if the product is installed in industrial environments (application of EN 26 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 4.2 Power supply pCO5 power supply (controller with terminal connected) Maximum current pCO5 compact power supply: Maximum current 28 to 36 Vdc +10/-20% and 24 Vac +10/-15% 50 to 60 Hz; P= 20 W (power supply Vdc), P= 45 VA (Vac) 48 Vdc (36 Vmin to 72 Vmax) and 24 Vac +10/-15 %, 50/60 Hz P=11W, P=14VA, Imax=700mA Tab. 4.a • power supply voltage other than that specified will seriously damage the system; • a Class II safety transformer, rating 50 VA, must be used in the installation • • • • to supply just one pCO5 controller; the pCO5 compact on the other requires the same type of transformer yet with a 25 VA rating. the power supply to the pCO controller and terminal (or pCO controllers and terminals) should be separated from the power supply to the other electrical devices (contactors and other electromechanical components) inside the electrical panel; if the power transformer secondary is earthed, check that the earth wire is connected to terminal G0. This applies to all the devices connected to the pCO; if more than one pCO board is connected in a pLAN network, make sure that the G and G0 references are observed (G0 must be maintained for all boards); a yellow LED indicates that the pCO is powered. ENG 4.3 Connecting the analogue inputs The analogue inputs on the pCO can be configured for the most common sensors on the market: NTC, PT1000, 0 to 1 V, 0 to 5 V ratiometric, 0 to 10 V, 0 to 20 mA, 4 to 20 mA. Connecting active temperature and humidity probes The pCO can be connected to all the CAREL DP* series active temperature and humidity probes configured as 0 to 1 V or as 4 to 20 mA. For temperature probes use the 4 to 20 mA or NTC configuration, as the 0 to 1 Vdc signal is limited to the range 0 to 1 V and therefore is not always compatible with the standard 10 mV/°C signal of CAREL probes (for negative temperatures and temperatures above 100 °C a probe alarm may be generated). The inputs must be pre-configured for 0 to 1 V or 4 to 20 mA signals in the application program resident in the flash memory. The connection diagram is shown below: GND, BC4, BC5, BC9, BC10 B1, B2, B3, B4, B5, B6, B7, B8, B9, B10 GND B1, B2, B3, B4, B5, B6, B7, B8 GND B1, B2, B3, B4, B5, B6 pCO5 compact (type A) pCO5 compact (type B) Warning: the two wires of the NTC sensors are equivalent, as they have no polarity, therefore it is not necessary to follow any specific order when connecting to the terminal block. Connecting PT1000 temperature probes The pCO can be connected to 2-wire PT1000 sensors for all high temperature applications; the operating range is: -100 to 200 °C. The inputs must be pre-configured for PT1000 signals in the application program resident in the flash memory. The connection diagram is shown below: input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W FieldBus card B M S card ID4 ID3 Y4 ID2 Y3 ID1 Y2 VG0 VG B5 BC5 BC4 BC5 B5 B4 BC4 +VDC GND RXW+ 0 RXW7 Y1 J4 J3 B4 B3 B2 J2 B1 J24 +5 VREF +Vterm G0 G +VDC B3 GND B2 B1 J1 GND VG0 VG BC5 Y1 J4 B5 BC4 B4 +VDC GND pCO5 NTC probe wire 1 2 1 2 1 2 Tab. 4.c B J3 B3 B1 B2 J2 +5 VREF J24 GND +Vterm G0 G J1 F ieldB us c ar d pCO terminals Y2 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W Controller * Fig. 4.c Fig. 4.a out T Active temperature output M +(G) out H Reference Power supply Active humidity output (0 to 1 V) Active temperature output(0 to 1 V) Active humidity output (4 to 20 mA) Active temperature output(4 to 20 mA) Tab. 4.b The pCO can be connected to all CAREL SPK* series active pressure probes or any pressure probe available on the market with 4 to 20 mA signal. The inputs must be pre-configured for 0 to 20 mA or 4 to 20 mA signals in the application program resident in the flash memory. The connection diagram is shown below: B2 Y4 Y3 Y1 VG0 VG BC5 B5 BC5 B1 Fig. 4.b J4 J3 BC4 J2 BMS c ID5 ID4 ID3 Y4 ID2 ID1 Y3 J5 Y2 Y1 VG0 B5 B5 VG BC4 BC4 BC5 B4 +VDC B4 GND B3 B3 GND B2 B2 J4 J3 +VDC B1 J2 B1 +5 VREF J24 GND +Vterm G0 G J1 J24 B2 J1 B1 B M S car d G Fi el d B u s car d Field Bu s car d +5 VREF input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W Y2 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W B4 All analogue inputs are compatible with 2-wire NTC sensors. The inputs must be pre-configured for NTC signals in the application program resident in the flash memory. The connection diagram is shown below: Connecting current pressure probes +VDC Connecting universal NTC temperature probes polarity, therefore it is not necessary to follow any specific order when connecting to the terminal block. +VDC out T be connected to an individual terminal, as shown in Figure 4.c; • the two wires of the PT1000 sensors are equivalent, as they have no GND B1, B2 Warning: GND out H 1 2 • correct measurements using the PT1000 sensor, each sensor wire must B3 out T 1 2 Tab. 4.d GND pCO compact (type A e B) Reference Power supply Active humidity output probe 2 probe 3 probe 4 BC5 BC9 BC10 B5 B9 B10 probe 2 B4 GND +Vterm 5 GND +Vdc B1, B2, B3, B6, B7, B8 B1, B2, B3, B6, B7, B8 GND +Vdc B1, B2, B3, B4, B5, B6 B1, B2, B3, B4, B5, B6 B1, B2 PT1000 probe wire probe 1 BC4 B4 pCO probe 1 compact B3 (type A & B) GND Description G0 pCO5 Controller pCO5 Probe terminals M +(G) out H B3 Controller pCO terminals Fig. 4.d “pCO5” +0300009EN rel. 1.2 - 24.04.2014 27 ENG Controller pCO5 5 pCO compact (type A & B) pCO terminals +Vdc B1, B2, B3, B6, B7, B8 +Vdc B1, B2, Probe wire colour brown white brown white Connecting analogue inputs selected as ON/OFF Description power supply signal power supply signal The pCO allows some analogue inputs to be configured as voltage-free digital inputs, not optically-isolated. The inputs must be pre-configured as voltage-free digital inputs in the application program resident in the flash memory. Tab. 4.e Connecting 0 to 5 V ratiometric pressure probes Y3 BC5 Y2 B5 BC5 VG0 BC4 B5 VG B4 BC4 +VDC B4 Y1 J4 J3 GND B3 B2 B1 +5 VREF GND G0 G J2 BMS c BMS Y3 Y2 Y1 VG0 VG +VDC BC5 GND B5 B3 GND +VDC BC4 B2 B3 B4 B1 B2 Warning: the maximum current available at the digital input is 5 mA (thus the rating of the external contact must be at least 5 mA). J4 J3 B1 J2 +5 VREF +Vterm GND GND +Vterm F i el d Bu s ca r d +5 VREF G0 G J24 J24 Fi el dBus car d Fig. 4.g input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 J1 +Vterm input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W The pCO can be connected to all CAREL SPKT series pressure probes or any pressure probe available on the market with 0/5 V ratiometric signal. The inputs must be pre-configured for 0/5 V ratiometric signals in the application program resident in the flash memory. Remote connection of analogue inputs The sizes of the cables for the remote connection of the analogue inputs are shown in the following table: Fig. 4.e Controller pCO terminals pCO5 +5V Ref GND pCO5 compact (type A & B) type of input Probe wire colour black green B1, B2, B3, B6, B7, B8 white +5V Ref black GND green B1, B2, B5, B6 white Description power supply power supply reference signal power supply power supply reference signal Tab. 4.f Connecting active probes with 0 to 10 V output The inputs must be pre-configured for 0 to 10 V signals in the application program resident in the flash memory. BMS card ID2 ID1 Y4 Y3 Y2 VG0 VG BC5 +VDC B5 GND GND +VDC BC4 B3 B3 B4 B2 B2 Y1 J4 J3 B1 J2 B1 +5 VREF Fie ld B u s car d +5 VREF GND J24 GND +Vterm G0 G J1 +Vterm input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W out H M out T + (G) Fig. 4.f Controller pCO5 pCO5 compact (type A & B) GND B1, B2, B3, B6, B7, B8 +Vdc GND B1, B2, B5, B6 +Vdc 0 to 10 V probe wire reference signal brown power supply (if used) reference signal brown power supply (if used) Tab. 4.g 28 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 NTC PT1000 I (current) V (live) size (mm2) for length up to 50 m 0.5 0.75 0.25 0.25 size (mm2) for length up to 100 m 1.0 1.5 0.5 0.5 Tab. 4.h If the product is installed in industrial environments (application of EN 61000-6-2) the connections must be less than 30 m long. This length shouldn’t be exceeded in any case, to avoid measurement errors. ENG As mentioned, only input B5 can be configured as a counter. The pulse generator device will have a digital output with transistor optocoupler, connected to input B5 as shown in the figure. J3 B5 Important: • the wires connecting the fast digital inputs must be shielded to avoid causing electromagnetic disturbance in the probe cables; • separate as much as possible (at least 3 cm) the probe and digital input cables from the power cables to loads to avoid possible electromagnetic disturbance. Never insert power cables (including the electrical cables) and probe signal cables in the same conduits. BC5 On the pCO5 range (SMALL, MEDIUM, LARGE, EXTRALARGE) inputs B4 and B5 can be configured in the application as fast digital inputs. In addition, input B5 can be enabled in the application to act as a counter. In any case, the input must be connected to a voltage-free contact. BC4 Counter function B4 4.4 Fast digital inputs External impulse generator Connection diagram Fig. 4.j Il The application program decides when to reset the counter. The maximum number of pulses is 65535, then the counter restarts from zero. C1 The fast digital input can be used as a counter. The count is performed on the negative edge of the pulse. The pulse generator device will have two digital outputs with transistor optocoupler, which will be connected to the inputs shown as in the figure.. J11 pLAN Input signal characteristics J25 BMS2 J26 FBus2 Type Typical current Maximum frequency BC5 BC4 B5 J3 J10 B4 J9 Voltage-free contact 5 mA 2 kHz Tab. 4.j FieldBus card Note: the BIOS provides the application one rewritable counter variable. BC5 B5 BC4 B4 +VDC J3 GND B3 B2 J2 B1 +5 VREF G0 J24 GND G J1 +Vterm input: 24 V 50...60 H z / 28...36 V max. power: 45 VA/20 W External impulse generator On pCO compact the fast digital input is ID1 and the same details referring to B4 on the pCO5 are valid as regards the frequency counter function. Fig. 4.h Input signal characteristics Type Typical current Maximum frequency Voltage-free contact 5 mA 2 kHz Tab. 4.i Note: the BIOS makes provides two variables to the application program that contain the frequency in Hz. Example: typical waveforms of input signals input t count t Fig. 4.i In the case of fans with tachometer output with high series resistance, the reading of the pulses may depend on the current. The function block (“function block”) application program (DIN_COUNT2) includes a pin for which the default is the current 2mA. You can also select or 500 uA 50 uA in order to stay within the voltage values of 0.25 ... 0.85 V to get a correct reading. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 29 ENG If connecting the digital inputs to safety systems (alarms), remember that: the presence of voltage across the contact must be the normal operating condition, while no voltage must represent an alarm situation. This will ensure that any interruption (or disconnection) of the input will also be signalled. Do not connect the neutral in place of an open digital input. Always interrupt the phase. The 24 Vac or 28 to 36 Vdc digital inputs have a resistance of around 5 kΩ. 4.5 Connecting the digital inputs The pCO features digital inputs for connecting safety devices, alarms, device status and remote switches. These inputs are all optically isolated from the other terminals. They can work at 24 Vac, 24 Vdc and some at 230 Vac. Note: separate as much as possible the probe signal and digital input cables from the inductive load and power cables, to avoid possible electromagnetic disturbance. 24 Vac digital inputs C13 NC13 B10 BC10 ID17 IDC9 ID13H ID13 IDC13 ID14 ID14H IDC9 ID13H ID13 IDC13 Y6 B9 BC9 B10 IDC17 BC9 ID12 ID12 Y5 ID18 B9 ID11 ID11 Y6 ID10 ID10 Y5 ID9 ID9 ID16H ID16 IDC15 ID15 NO13 C12 C16 NO18 NO17 NO16 C16 C15 NC12 NO12 C9 NO11 NO10 C9 NO9 C8 NC8 ID15H ID8 IDC1 ID8 IDC1 J8 ID14H ID7 ID7 ID14 ID6 ID6 GND ID5 ID5 B8 ID4 ID4 B7 ID3 ID3 J6 B6 ID2 ID2 Y4 ID1 J7 ID1 Y3 J23 FBus2 J20 J5 Y2 VG0 VG BC5 Y1 J4 B5 BC4 B4 +VDC J22 J19 BMS card J3 GND B2 J2 B1 +5 VREF GND +Vterm G0 G J24 FieldBus card J18 J17 J21 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 J16 NC15 NO14 J10 B3 J9 J15 NC14 J14 NO15 C7 NO8 C7 NO7 NO6 J13 C14 J12 J25 BMS2 J26 FBus2 NO5 C4 NO4 C1 NO3 NO2 NO1 C1 J11 pLAN C4 On the pCO5 all inputs can be 24 Vac. The following figure represents one of the most common connection diagrams for the 24 Vac digital inputs, referred to the pCO5. Important warning: if the control voltage is drawn in parallel with a coil, fit a dedicated RC filter in parallel with the coil (typical ratings are 100 Ω, 0.5 μF, 630 V). G G0 G G0 Fig. 4.k 30 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 IDC17 ID18 ID17 BC10 ID16H ID16 IDC15 ID15 BMS card ID15H 24 Vac ENG 24 Vdc digital inputs C13 NC13 NO13 C12 NC12 C9 C16 NO18 NO17 NO16 B10 BC10 ID17 IDC13 ID14 ID14H IDC17 BC9 ID18 B9 ID13 Y6 Y5 ID13H J20 ID16H ID16 IDC15 ID15 IDC13 B10 J8 ID14H ID13 ID14 ID13H BC9 IDC9 IDC9 Y6 B9 ID12 ID12 ID11 Y5 ID10 IDC1 ID11 ID8 ID8 IDC1 ID10 ID7 ID7 ID9 ID6 ID6 ID9 ID5 ID5 GND ID4 ID4 B8 ID3 ID3 B7 ID2 ID2 J6 B6 ID1 Y4 J23 FBus2 J7 ID1 Y3 NO12 NO11 NO10 C9 C8 NO9 C16 C15 NC15 J22 J5 Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B1 B2 J2 J18 J17 J19 B M S c ar d ID15H Fi e l dBus ca rd +5 VREF GND +Vterm G0 G J24 J16 J21 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 J15 NC14 J10 B3 J9 C14 NO14 J14 NC8 C7 NO8 C7 NO7 C4 NO6 J13 NO15 J12 J25 BMS2 J26 FBus2 NO5 C4 NO4 C1 NO3 NO2 C1 J11 pLAN NO1 On the pCO5: all inputs can be 24 Vdc. The following figure represents one of the most common connection diagrams for the 24 Vdc digital inputs, referred to the pCO5. 24 Vdc + ID18 GND IDC17 ID17 BC10 Y2 ID16H ID16 IDC15 B M S c ar d ID15 ID15H - 24 Vdc + - Fig. 4.l Connecting the digital inputs for the pCO5 compact pCO5 compact features up to 6 (or 4, depending on the model) digital inputs, not optically-isolated, with voltage-free contacts for connection to safety devices, alarms, device status, remote on/off switches, etc.; these operate at 24 Vdc (supplied by pCO5 compact) with guaranteed contact current of 6 mA. Warning: separate as much as possible the probe signal and digital input cables from the inductive load and power cables, to avoid possible electromagnetic disturbance. The following figure shows the digital input connection diagram for pCO5 compact, TYPE A and TYPE B respectively. TYPE A C2 J10 Y4 Y3 ID2 NO5 GND NO2 Y1 J9 0/10V 0/10V J12 J13 NO1 NC1 C1 GND ID1 J3 +VDC GND B6 B5 B4 B3 +5Vref serial card 1 B2 SYNC PWM 0/10V GNX IS OLATED J2 B1 G0 G J8 C5 NO6 NO3 C3 NO4 J11 J1 NO1 NC1 C1 GND ID1 J3 GND TLAN C2 NO2 GND J4 Tx/Rx J7 J6 input voltage: max. p ower: 24 V (+10/-15%); 50/60 H z 14 VA /11 W 48 V (36Vmin…72 Vmax) +VDC GND Fig. 4.m GND J5 B8 B7 ID2 GND C3 B6 +5Vref B5 B4 B3 B2 B1 Tx/Rx J 10 serial card 1 J2 SYNC Y2 Y1 J9 J 12 J1 G0 GNX IS OLATED J 11 input voltage: max. p ower: 24 V (+10/-15%); 50/60 H z 14 VA /11 W 48 V (36Vmin…72 Vmax) G Tx/Rx J8 NO7 NO5 NO6 J7 J6 NO3 C3 J4 GND GND J5 NO4 Tx/Rx TLAN TYPE B PWM 0/10V Fig. 4.n “pCO5” +0300009EN rel. 1.2 - 24.04.2014 31 ENG ID16H The pCO5 provides 0 to 10 V optically-isolated analogue outputs, powered externally at 24 Vac or 28 to 36 Vdc. Fig. 4.p below shows the electrical connection diagram; the 0 V of the power supply is also the reference for the output voltage. The table shown below summarises the distribution of the analogue outputs according to the versions available. analogue outputs Y1, Y2, Y3, Y4 Y1, Y2, Y3, Y4 Y1, Y2, Y3, Y4, Y5, Y6 Y1, Y2, Y3, Y4 Y2 Y2, Y3, Y4 pCO5 terminals SMALL MEDIUM LARGE XL pCO5 compact terminals (type A) pCO5 compact terminals (type B) reference VG0 GND GND Vout Vout input 13, 14, 15, 16 Vout Vout Vout Vout 24 Vac/Vdc 0V Warnings for 230 Vac digital inputs: • 230 Vac 50/60 Hz +10/-15 %; • for each group, the two inputs - 24 Vac or 28 to 36 Vdc or 230 Vac - have the same common pole, the inputs will both work at the same voltage (24 Vac or 28 to 36 Vdc or 230 Vac) with basic insulation. Fig. 4.p C2 NO2 Y2 B7 ID2 GND J 10 B8 J9 J 11 Important note: do not connect other devices to IDn. The sizes of the cables for the remote connection of the digital inputs are shown in the following table: GND Y1 PWM 0/10V GNX IS OLATED C3 J8 NO7 NO5 NO3 J4 Tx/Rx J7 J6 C3 Remote connection of digital inputs GND GND J5 NO4 Tx/Rx TLAN Vout NO6 Tab. 4.k J12 size (mm2) for length up to 100 m Vout Vout Vout J11 J12 Fig. 4.q 32 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 J9 Y4 Y3 0/10V 0/10V J13 C2 NO2 GND Y2 PWM 0/10V GNX IS OLATED GND C5 NO6 J8 ID2 GND Tx/Rx J7 J6 C3 J4 NO4 If the product is installed in industrial environments (application of EN 61000-6-2) the connections must be less than 30 m long. This length shouldn’t be exceeded in any case, to avoid reading errors. GND J5 NO3 Tx/Rx TLAN Tab. 4.l Y1 0.5 NO5 0.25 J 10 IDC17 ID18 ID17 BC10 B10 BC9 Y4 Y3 Y2 Y1 VG VG0 The range of uncertainty of the switching threshold is from 43 to 90 Vac. It is recommended to use a 100 mA fuse in series with the digital inputs. size (mm2) for length up to 50 m B9 BMS Card Fig. 4.o pCO5 terminals Y6 Y5 ID14 Warning: on the pCO5 compact the outputs are not opticallyisolated. Remember however that the internal circuit in the power supply to the pCO5 compact is isolated. ID14H ID13 IDC13 Tab. 4.m ID13H ID16 BMS Card IDC15 Connecting 0 to 10 V analogue outputs ID15 4.6 Connecting the analogue outputs PCO5 ONLY There are up to two groups of inputs that can be powered at 230 Vac; each group has two inputs. The groups feature double insulation between them and can refer to different voltages. Within each group the digital inputs are not independent, however: for example, with reference to Fig. 4.o inputs ID15 and ID16, due to the common terminal, must be powered at the same voltage to avoid dangerous short-circuits and/or the powering of lower-voltage circuits at 230 Vac. In any case, the inputs feature double insulation from the rest of the controller. The following figure represents one of the most common connection diagrams for the 230 Vac digital inputs. ID15H 230 Vac digital inputs ENG Optional modules Connecting PWM analogue outputs C2 NO2 Y2 GND GND Y1 ID2 GND B7 NO1 C1 NC1 GND ID1 +VDC GND +5Vref B6 B5 B4 B3 B2 SYNC J3 Module to divide the number of pulses at the digital input by 8 (code PCO208DI00) The module is used to independently divide the frequency of two signals by a factor of 8. The two input signals (at the input terminals, opticallyisolated from the rest of the module) must have a amplitude between 10 and 20V, a duration greater than 10 ms and a maximum frequency of 10 Hz. The module’s physical dimensions are 87x36x60 mm (2 DIN modules) and has IP20 index of protection. MCHRTF L1 C2 NO2 GND B8 B7 ID2 GND NO1 C1 NC1 GND ID1 J3 +VDC GND +5Vref B6 B5 B4 B3 B2 SYNC J10 serial card 1 J2 B1 Y2 Y1 J9 J12 J1 G0 PWM 0/10V GNX IS OLATED J 11 input voltage: max. p ower: 24 V (+10/-15%); 50/60 H z 14 VA /11 W 48 V (36Vmin…72 Vmax) G Tx/Rx J8 NO7 NO6 NO5 NO4 C3 NO3 J4 J7 J6 C3 GND J5 GND TLAN N Tx/Rx Module for converting a PWM analogue output to a linear 0 to 10 V and 4 to 20 mA analogue output The module is used to convert a PWM output (5 V pulses) to a linear 0 to 10 V and 4 to 20 mA analogue output (code CONV0/10A0). The control signal (at the input terminals optically-isolated from the rest of the module) must have a maximum amplitude of 5V and a period between 8 ms and 200 ms. The 0 to 10 V output voltage can be connected to a maximum load of 2 kΩ, with a maximum ripple of 100 mV, while the 4 to 20 mA current output can be connected to a maximum load of 280 Ω, with maximum overshoot of 0.3mA. The module’s physical dimensions are 87x36x60 mm (2 DIN modules) and has IP20 index of protection. Module for converting a 0 to 10 V analogue output to an SPDT digital output (code CONVONOFF0) The module is used to convert a 0 to 10 V analogue output (Yn) to an ON/OFF relay output. The control signal (at the input terminals, opticallyisolated from the rest of the module), to ensure the switching of the relay from OFF to ON, must have a maximum amplitude of 3.3 V. The relay is SPDT, with max current of 10 A and max inductive load of 1/3 HP. The module’s physical dimensions are 87x36x60 mm (2 DIN modules) and has IP20 index of protection. serial card 1 J2 B1 J10 B8 J9 J12 J1 G0 PWM 0/10V GNX IS OLATED J 11 input voltage: max. p ower: 24 V (+10/-15%); 50/60 H z 14 VA /11 W 48 V (36Vmin…72 Vmax) G J8 NO7 NO6 NO5 C3 NO3 J4 Tx/Rx J7 J6 C3 GND J5 NO4 Tx/Rx TLAN pCO5 and pCO5 compact provide a PWM analogue output for phase cutting speed controllers. Fig.4.q shows the most common wiring diagrams for pCO compact. For pCO5 see Fig. 4.p. + MCHRTF L1 N Fig. 4.r pCO5 terminals pCO5 compact terminals (type A & B) analogue outputs Y3, Y4 Y1 reference VG0 GND Tab. 4.n “pCO5” +0300009EN rel. 1.2 - 24.04.2014 33 ENG 4.7 Connecting the digital outputs The pCO features digital outputs with electromechanical relays. For ease of installation, the common terminals of some of the relays have been grouped together. If the following diagram is used (Fig. 4.p), the current at the common terminals must not exceed the rating (nominal current) of a single terminal (8A). NC12 NO13 C13 NC13 C13 NC13 NO11 NO13 NO10 NO11 C12 NO9 NO10 NC12 C9 C9 NO9 NO12 NC8 NC8 The relays are divided into groups, according to the insulation distance. Inside each group, the relays have just basic insulation and thus must have the same voltage (generally 24 V ac or 110 to 230 Vac). Between the groups there is double insulation and thus the groups can have different voltages. There is also double insulation from the rest of the controller. Changeover outputs Some relays feature changeover outputs: Changeover relay reference 8, 12, 13, 14,15 1 Tab. 4.o Solid state relay (SSR) digital outputs pCO5 The pCO also features a version with solid state relays (SSR) for controlling devices that require an unlimited number of switching cycles and thus would not be supported by electromechanical relays. These outputs are dedicated are dedicated to loads powered at 24 Vac or 28 to 36 Vdc with maximum power Pmax= 10 W. These three fundamental rules should be adopted in pCO applications with SSR outputs: 1. only control resistive loads with a maximum power of 10 W; 2. to control inductive loads use an additional external SSR; 3. for AC power supply to resistive loads or external SSRs, use the same power supply as the pCO (connected to terminals G/G0), which as always must be specified, dedicated and not in common with the power supply to other devices on the electrical panel (such as contactors, coils, etc...) “pCO5” +0300009EN rel. 1.2 - 24.04.2014 C12 C8 C8 J17 J22 J18 C16 NO18 NO17 NO16 C16 C15 NC15 NO15 NC14 Fig. 4.s 34 NO12 NO8 NO8 J16 J21 pCO5 terminals pCO5 compact terminals C9 C7 NO14 L C14 N J15 C9 NO7 C7 C7 C4 C7 J14 110/230-24 V J13 NO7 NO6 NO4 C4 C4 NO4 NO5 C1 C4 NO6 NO3 C1 J12 NO5 NO2 NO3 NO1 NO2 C1 C1 L NO1 N 110/230-24 ac V Electromechanical relay digital outputs J23 FBus2 NC8 C8 NO8 C7 NO7 C7 C4 NO6 NO5 NO4 C4 C1 NO3 NO2 NO1 C1 24 Vac/Vdc ENG Fig. 4.t carico/load NC8 C8 SSR ESTERNO/ EXTERNAL SSR NO8 C7 NO7 C7 C4 NO6 NO5 NO4 C4 NO3 NO2 NO1 C1 (*) Dedicated or the same of G/G0 of pCO not in common with other external load. C1 (*) Dedicata o la stessa alimentazione di G/G0 del pCO NON in comune con altri carichi esterni. input 24 Vac/Vdc(*) Correct application for inductive loads: Fig. 4.u pCO5 terminals pCO5 compact terminals SMALL MEDIUM LARGE XL TYPE A Changeover relay reference 7 7, 12 7, 12, 14 o 7, 12, 14, 15 7, 12 1, 2 TYPE B 1, 2 o 3, 4, 5, 6 Tab. 4.p Warning: the SSR relay load is powered at 24 Vac or 28 to 36 Vdc thus all the other terminals in the group, from 1 to 6, must be powered at the same voltage due to the absence of double insulation within the group. Warning: if the power supply to the internal SSR internal is shared with inductive loads (contactor coils and solenoids), fit a dedicated RC filter in parallel with the inductive load (typical ratings are 100 Ω, 0.5 μF, 630 V). Summary table of digital outputs according to the versions available NO NC changeover contacts contacts relay reference pCO5 SMALL 7 1 (8) 3 (8, 12, 13) terminals MEDIUM 10 LARGE 13 (8, 12, 13, 14, 15) XL TIPO A pCO5 compact terminals 26 7 10 - (8, 12, 13) 1 1 total SSR relay outputs reference 8 13 18 29 8 13 1 (7) 2 (7, 12) 3 (7, 12, 14) o 4 (7, 12, 14, 15) 7, 12 1, 2 2 (1, 2) o 4 (3, 4, 5, 6) Tab. 4.q Remote connection of digital outputs The sizes of the cables for the remote connection of the digital outputs are shown in the following table: AWG 20 15 14 Size (mm2) 0.5 1.5 2.5 Current 2 6 8 Tab. 4.r “pCO5” +0300009EN rel. 1.2 - 24.04.2014 35 ENG 5. PLAN NETWORK CONFIGURATION 5.1 Introduction All pCO controllers can be connected together and to other CAREL devices in a pLAN local network, without requiring optional devices, allowing the communication of data and information from one location (node) to another. The pCO terminals can show the variables (temperature, humidity, pressure, I/O, alarms) from just one controller at a time. The terminal does not need to be connected to the pCO during normal operation, but rather can be used just for initial programming of the fundamental parameters. one or more terminals are disconnected or malfunctioning, the control program continues to function correctly on each pCO board. Generally, the application program can monitor the status of the network and intervene as a consequence to ensure the continuity of the control functions. The figure below shows a possible pLAN network connection diagram pGDE/pGD1 pGDE/pGD1 pLAN (RS485 62.5 kbit) J9 G0 J9 J 12 PWM 0/10V J 10 Y4 C2 NO2 C1 pCO5 compact IND: N C4 NO4 NO5 NO6 C4 C4 C7 C7 J14 J5 J14 J5 NO7 NO7 C7 C7 NO14 GNX Y3 J13 Y2 NO6 ID4 Y1 Y2 NO2 NO3 serial card C4 NO5 ID3 ID5 Y1 NO4 ID2 IS OLATED VG0 C1 J4 J13 Y4 J3 C1 VG NO3 J12 J12 B M S card Y3 B8 NO1 NO1 NO2 J4 Y2 B7 GND C1 ID1 GND Tx/Rx ID1 NO1 Y1 TLAN C1 NC1 VG0 C3 ID2 GND BC5 VG NO7 GND +VDC B5 BC5 NO6 J8 GND +5Vref NO5 J7 BC4 service card B5 J3 J3 BC4 B4 field card B4 J2 +VDC J25 BMS2 J26 FBus2 F ieldB us card J2 GND NO4 J 11 B2 B3 C3 NO3 J6 GND GND Rx+/Tx+ J5 J11 B3 se ri a l c ard 1 J11 pLAN B1 J2 B2 Rx-/Tx- Tx/Rx B1 +5 VREF J4 SYNC J10 J24 +5 VREF G J1 J1 J10 J24 G0 +Vterm input voltage: max. p ower: 24 V (+10/-15%); 50/60 H z 14 VA /11 W 48 V (36Vmin…72 Vmax) G GND input: 24 V / ; 50 to 60 Hz max. power: 40 VA/15W J1 G0 J9 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W G +Vterm GND ID6 C14 ID15 NO15 B7 B8 J17 NC12 NC12 NO13 NO13 J18 C13 NC13 C12 C13 NC13 J8 J8 ID17 C12 J18 BC10 ID14H J23 FBus2 B10 ID14 NO12 NO12 J17 BC9 IDC13 C9 C9 C16 J20 ID13 NO11 J7 J22 J7 NO11 Y6 B9 C9 NO9 NO10 NO10 NO17 NO18 Y5 ID13H GND NO9 C16 NO16 ID10 J16 C9 J16 GND ID9 IDC9 B6 NC15 ID16H B8 C8 NC8 NC8 J6 J6 ID16 J19 IDC15 B7 ID12 C8 C15 B6 ID11 J15 ID15H IDC1 NC14 J15 J21 ID8 NO8 NO8 ID7 ID18 IDC17 3 pCO5 IND: 1 pCO IND: 2 Fig. 5.a The standard communication speed over the network is 62500 bps; some devices also support speeds of 115200 bps. All units in the network must however be set with the same speed. A maximum of 32 units can be connected, including: - pCO controllers that run the control program; - boards that extend the I/O functions (such as the EVDevo driver); - terminals (8x22). Each unit in the pLAN is identified by a unique address, i.e. a number between 1 and 32. The latter (32) can only be assigned to a terminal. Programs for different applications (e.g.: standard chiller, standard airconditioners, compressor rack, ...) cannot automatically be integrated into a local network: they must be configured considering the system architecture using the Carel development tool. Each pCO board connected to the network can manage a series of terminals at the same time. The values are displayed on the terminals simultaneously and not independently, as if the keypads and display were connected in parallel: for this reason, the pCO cannot control different types of terminals at the same time. 36 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 Each terminal associated with a board can be defined as: - private (“Pr”) if it exclusively displays the output of that board; - shared (“Sh”) if either automatically or from the keypad it can be switched between various boards; - shared with printer (“Sp”) if, as well as being be shared it’s fitted with an RS232 serial card connecting a printer (valid only for the old PCOT and PCOI terminals, not the pGD). Each pCO constantly updates the display on the private terminals, while the shared terminals are only updated only if the pCO in question has control over the terminal at that moment. ENG For details of the logic see the following figure S&2 J9 J10 J24 GND +5 VREF 3*'(3ULYDWH input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W G0 +Vterm J10 J24 GND G J1 J1 G0 +Vterm S&2 3*'(3ULYDWH J9 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W G +5 VREF J11 pLAN J11 pLAN B1 B1 B2 B2 B5 GND +VDC B4 BC4 J3 J3 BC4 B3 B5 BC5 J25 BMS2 J26 FBus2 B4 FieldBus card +VDC J2 GND J25 BMS2 J26 FBus2 FieldBus card J2 B3 BC5 C1 C1 NO1 NO1 NO2 VG NO3 VG0 Y2 Y3 NO5 Y4 NO6 ID1 C4 ID2 ID2 ID3 C7 S*'(S*'6KDUHG C8 NC8 ID8 NC15 ID12 C16 IDC9 NO12 Y6 NC12 NO13 C13 NC13 J8 ID13 BC9 IDC13 B10 ID14 BC10 ID14H ID17 J8 ID18 B9 IDC17 J1 G0 3*'(3ULYDWH J10 J24 G0 GND J6 J7 GNX IS OLATED Tx/Rx J8 B7 J9 PWM 0/10V NO1 NO5 J10 NC1 NO4 Y1 Y2 NO2 C2 NO6 ID2 C4 ID3 C7 J5 J14 ID4 ID5 GND GND C4 J13 Y4 TLAN C1 J3 Y3 ID1 GND J12 J12 B M S card Y2 C3 B8 GND C1 J4 Y1 NO7 ID2 ID1 NO3 VG0 NO5 NO6 +VDC NO2 J5 +5Vref C1 NO1 VG J11 GND NO4 serial card 1 B3 BC5 C3 NO3 J2 J3 B5 J25 BMS2 J26 FBus2 FieldBus card J2 BC4 B2 Tx/Rx B1 J4 J11 pLAN SYNC B2 input voltage: max. p ower: 24 V (+10/-15%); 50/60 H z 14 VA /11 W 48 V (36Vmin…72 Vmax) G B1 B4 ID18 S&2FRPSDFW +5 VREF +VDC C13 NC13 3*'(3ULYDWH J1 +Vterm GND NC12 NO13 J9 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W G B3 C12 IDC17 S&2 GND NO12 J18 ID17 C9 C16 Y6 J23 FBus2 BC10 ID14H NO11 NO18 Y5 ID13H J20 B10 ID14 J18 BC9 IDC13 J23 FBus2 ID13 NO10 NO17 J17 C12 J17 B9 J20 ID13H J22 Y5 IDC9 ID11 C9 NO18 ID12 C9 NO9 C16 NO16 J7 J22 J7 ID11 ID16H ID10 NO11 NO17 J16 ID10 ID16 NC15 ID9 NO10 C8 NC8 GND NO9 C16 NO16 B7 B8 C9 J16 GND NC14 NO15 C15 IDC15 J6 ID16H B8 ID9 ID15 B6 J19 J19 B7 ID16 J6 IDC15 ID15H IDC1 C15 B6 NO8 J15 ID15 C14 ID7 J21 NC14 NO15 C7 NO14 NO8 J15 J21 ID15H NO7 ID6 C14 ID7 IDC1 C7 J14 ID5 ID6 ID8 C4 ID4 NO7 NO14 NO6 J5 J14 J5 ID5 C4 NO5 ID3 C7 ID4 C1 NO4 J13 ID1 Y1 C4 NO4 B M S card Y4 NO3 J4 Y3 J13 B M S card Y2 NO2 VG0 C1 J4 Y1 J12 J12 VG NO7 C7 NO14 ID6 C14 NO8 ID7 ID15H IDC1 ID15 NO15 J19 ID16 J6 IDC15 B7 NC15 ID16H B8 J22 J7 NO10 NO11 NO17 C9 NO18 Y5 C16 NO12 Y6 B9 BC10 ID14H ID17 NC12 NO13 J18 B10 ID14 J23 FBus2 BC9 IDC13 J20 ID13 C12 J17 ID13H NO9 C16 NO16 ID10 IDC9 C9 J16 GND ID9 ID12 C8 NC8 C15 B6 ID11 J15 J21 ID8 NC14 C13 NC13 J8 ID18 IDC17 Fig. 5.b IIn this example the shared terminal is associated with 4 pCOC controllers however at this instant only controller 1 can display data and receive controls from the keypad. Switching between controllers occurs is cyclical (12341...) and is done by pressing a button defined by the application program, however it can also be managed automatically when set by the program: for example, a pCO may request control of the shared terminal to display alarms or, vice-versa, relinquish control to the next pCO after a set time (cyclical rotation). The data corresponding to the number and type of terminals are established in the initial network configuration phase, saving them to the permanent memory on each individual pCO controller. Details of the configuration procedure are described below. The pLAN connection between two pCO controllers is performed only using a AWG20/22 shielded cable made up of twisted pair plus shield. Connection between a terminal and a pCO can be performed using a 6-wire telephone cable or AWG20/22 shielded cable, depending on the model of terminal. Further details on installation of the terminals are provided in the section on “pLAN electrical connections”. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 37 ENG 5.2 pGDE/pGD1 terminal installation Connection between the terminal and the pCO is made using a 6-wire telephone cable supplied by CAREL (code S90CONN). To make the connection simply plug the telephone connector into the RJ12 jack on the rear of the terminal and connector: • J10 on pCO5; • J14 on pCO5 compact. The address of the terminal can be set in the range from 0 to 32; addresses between 1 and 32 are used by the pLAN protocol, while address 0 identifies the Local terminal protocol, used for non-graphic point-topoint connections and to configure the pCO. The default address is 32. The address of the terminal can only be set after having powered the terminal via the RJ12 connector. To access configuration mode press UP, DOWN and ENTER (,, ) together for at least 5 seconds; terminal will display a screen similar to the one shown below, with the cursor flashing in the top left corner: 1. Press ENTER again: the configuration screen will be shown, similar to the one below. Fig. 5.f Configure the terminals as desired. ENTER moves the cursor from one field to the next, while UP and DOWN change the value of the current field. P:xx displays the address of the selected pCO board (in the example in the figure this is board 1). To exit the configuration procedure and save the data, select “Ok?”, set “Yes” and confirm by pressing ENTER. During the configuration procedure, if the terminal remains inactive (no button is pressed) for more than 30 seconds, the pCO board automatically interrupts the procedure without saving any changes. Fig. 5.c To modify the address of the terminal (“Display address setting”) carry out the following operations in sequence. Press ENTER once: the cursor will move to the “Display address setting” field. Select the desired value using the UP and DOWN buttons, and confirm by pressing ENTER again. If the value selected is different from the value saved, the following screen will be displayed and the new value will be saved to the permanent memory on the display. Important: the pGD* terminals cannot be configured as “Sp” (shared with printer) as they have no printer output. Selecting this mode has no effect on management of the messages to be printed. if during operation the terminal detects inactivity on the pCO board it is connected to, the display is cleared and a message similar to the one shown below is displayed: Fig. 5.g If the terminal detects inactivity of the entire pLAN network, that is, it does not receive any messages from the network for 10 seconds consecutively, the display is cleared completely and the following message is shown: Fig. 5.d If the address field is set to 0, the terminal communicates with the pCO board using the Local terminal protocol and the “I/O Board address” field disappears, as it no longer has any meaning. To modify the list of the terminals (private and shared) associated with a pCO board, carry out the following operations in sequence: • enter configuration mode (see above) pressing the UP, DOWN and ENTER buttons together for at least 5 seconds. • press ENTER twice: the cursor will move to the “I/O Board address” field. • select the address of the pCO board in question and confirm by pressing ENTER. Then the pCO will start the configuration procedure, opening a screen similar to the following. Fig. 5.e 38 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 Fig. 5.h ENG 5.3 pLAN address configuration on pCO5 and pCO5 compact Setting by built-in terminal (applies to pCO5 and pCO5 compact) The address can be set using the built-in terminal, if featured. On the pCO5 range (SMALL, MEDIUM, LARGE, EXTRALARGE) the controller’s pLAN address can be assigned in two different ways: 1. using the new function for pCO5 with special button and display with two 7 segment LEDs; 2. using the built-in or external terminal (e.g. pGD1). The default pLAN address setting of the pCO5 programmable controller is 1 and it’s assigned to the private terminal with address 32. Setting by button and display (only applies to pCO5) The special button (A) is located on the left of the display. To access it use the tip of a screwdriver (diam. <3mm). J9 Procedure: 1. Power down the controller. Loading... C4 C1 NO3 NO2 C1 J11 pLAN NO1 Displaying the pLAN address Procedure: • press button A briefly (no more than 5 s) to display the controller’s current pLAN address. Five seconds after releasing the button the display is cleared. Fig. 5.k J12 J25 BMS2 J26 FBus2 J10 Fig. 5.l 2. Press the Alarm and Up buttons together and power up the controller. input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W Y1 VG0 VG BC5 B5 BC4 B4 +VDC Y2 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF G0 +Vterm G J1 ################### selftest please wait... FieldBus card ################### A Fig. 5.m Fig. 5.i J11 pLAN J9 A test phase begins. Continue holding Alarm and Up. 3. The screen for setting the address is displayed. Press UP/DOWN to select the address. pLAN address: 1 UP: increase DOWN: decrease ENTER: save & exit C4 C1 NO3 NO2 NO1 C1 Setting the pLAN address Procedure: 1. press button A for 5 seconds. The pLAN address starts flashing; 2. press repeatedly or hold the button until reaching the desired address (e.g. 7); remove the screwdriver; 3. wait until the address starts flashing quickly.The address is now saved but is not yet active for the application program 4. power down the controller; 5. power up the controller again.The address is now used by the application. J12 J25 BMS2 J26 FBus2 Fig. 5.n J10 4. Confirm by pressing ENTER. The address is saved. Wait a few seconds to return to the standard display. ‹ FieldBus card Fig. 5.j Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF G0 G J1 +Vterm input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W Fig. 5.o “pCO5” +0300009EN rel. 1.2 - 24.04.2014 39 ENG Setting by external terminal (applies to pCO5 and pCO5 compact) The controller address can be set using an external terminal, after having connected this to connector J10 on the pCO5 controller via pLAN. All the other devices connected to the controller via pLAN must be disconnected. Continue holding Alarm and Up until the following screen is displayed. ####################### selftest please wait... ####################### C4 C1 NO3 NO2 C1 J11 pLAN J9 NO1 4. Power up the controller holding the Alarm and Up buttons together. J12 J25 BMS2 J26 FBus2 J10 Fig. 5.t 5. If necessary set the controller’s pLAN address and confirm by pressing Enter. FieldBus card Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF G0 G J1 +Vterm input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W Fig. 5.p Note: the default pLAN address setting is 1; the pCO5 is also assigned to a private terminal with address 32. If the pCO5 with default setting (address=1) is connected to an external terminal (address=32), communication is established and the external terminal replicates the display on the built-in terminal, if featured. If however the pCO5 controller has a different address (e.g. 7) and the terminal is not set to communicate with the controller at this address, once the connection is established the terminal displays a blank screen. In this case, proceed as follows. Procedure: 1. Press the UP, DOWN and Enter buttons together to enter the screen for setting the terminal address Display address setting...........:02 pLAN address: 7 UP: increase DOWN: decrease ENTER: save & exit Fig. 5.u Controller-terminal connection The pCO controller address is now known. Then set the terminal address (e.g. 2) and establish the connection between the two devices. Procedure: 1. Press the UP, DOWN and Enter buttons together. The screen for setting the terminal address is displayed. Change the address and confirm by pressing Enter. Display address setting..........:00 I/O Borad address:07 Fig. 5.q Fig. 5.v 2. Set the address of the display to 0. Confirm by pressing Enter. 2. The display shows no messages. Display address setting..........:00 NO LINK Fig. 5.r Fig. 5.w 3. Power down the controller. 3. Press the UP, DOWN and Enter buttons together. Press Enter twice and set the controller address: 7. Confirm by pressing Enter. J11 pLAN J9 C4 C1 NO3 NO2 NO1 C1 Display address setting...........:02 J12 J25 BMS2 J26 FBus2 J10 I/O Borad address:07 FieldBus card Fig. 5.s 40 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC Fig. 5.x J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF G0 G J1 +Vterm input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W ENG 5. Set the terminal 1 (Trm1) with address 2 as private (Priv) or shared (Shared) according to the application and confirm to exit. The connection is established after a few seconds. 4. Confirm by pressing Enter. Terminal config press ENTER to continue P:07 Adr Priv/Shared Trm1 02 Pr Trm2 None -Trm3 None -- Ok? Yes Fig. 5.y Fig. 5.z 5.4 pLAN electrical connections on the pCO Connection between pCO boards in a pLAN is carried out exclusively using AWG20/22 shielded, twisted pair cable, with capacitance between the wires less than 90 PF/m. Maximum pLAN network length: 500 m with AWG22 shielded twisted pair cable. The boards are connected in parallel, with connector J11 as the reference. IMPORTANT: observe the network polarity: RX/TX+ on one board must be connected to RX/TX+ on the other boards; the same is true for RX/TX-. The following figure shows a diagram of a number of boards connected in a pLAN network and powered by the same transformer, typical for a number of boards connected inside the same electrical panel. G C4 C1 NO3 C1 NO2 NO1 GND RX+/TX- FieldBus card Y1 VG0 VG BC5 B5 BC4 B4 +VDC Y2 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF +Vterm G G0 J1 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC GND J10 G0 G RX-/TX+ C4 C1 NO3 C1 NO2 J4 J3 B3 B2 J2 B1 GND J24 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card +5 VREF G0 +Vterm G NO1 J9 G0 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC J11 pLAN J10 J1 J4 J3 GND B2 B1 GND +5 VREF J2 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card J24 AWG 20/22 C4 C1 J9 G0 G0 +Vterm J1 G J11 pLAN J10 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W G J12 J25 BMS2 J26 FBus2 B3 J9 NO3 C1 J11 pLAN NO2 AWG 20/22 NO1 AWG 20/22 see figg. 6. av, 6.aw, 6.ax for the ground connection of the shield Fig. 5.aa The following figure shows a diagram of a number of boards connected in a pLAN network and powered by different transformers (with G0 not earthed), typical of a number of boards inside different electrical panels. C4 C1 NO3 NO2 C1 FieldBus card Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF G0 NO1 GND J10 +Vterm G G G0 J1 Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B2 B1 GND J2 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card J24 RX+/TX- RX-/TX+ C4 C1 NO3 NO2 NO1 C1 GND J9 +5 VREF G0 J11 pLAN J10 +Vterm G G G0 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC J1 J4 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W J3 GND B2 J2 B1 +5 VREF J24 RX+/TX- RX-/TX+ C4 C1 J9 FieldBus card GND +Vterm G0 G G G0 J11 pLAN J10 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W J1 J12 J25 BMS2 J26 FBus2 B3 J9 NO3 C1 J11 pLAN NO2 AWG 20/22 NO1 AWG 20/22 see figg. 6. av, 6.aw, 6.ax for the ground connection of the shield AWG 20/22 Fig. 5.ab “pCO5” +0300009EN rel. 1.2 - 24.04.2014 41 ENG The following figure shows a diagram of a number of boards connected in a pLAN network and powered by different transformers with the same earth; this is a typical application for a number of boards inside different electrical panels. see figg. 6. av, 6.aw, 6.ax for the ground connection of the shield C4 C1 NO3 C1 NO2 NO1 GND Y1 VG0 VG BC5 B5 BC4 B4 +VDC GND Y2 J4 J3 B3 B2 J2 B1 J24 GND G0 G FieldBus card G0 G +Vterm J1 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC J10 +5 VREF J4 J3 GND B3 B2 B1 GND J2 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card J24 RX+/TX- RX-/TX+ C4 C1 NO3 C1 NO2 NO1 GND J9 +5 VREF G0 J11 pLAN J10 +Vterm G G J12 G0 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC J1 J4 J3 GND B2 B1 GND +5 VREF J2 AWG 20/22 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card J24 RX+/TX- RX-/TX+ C4 C1 J9 G0 G0 +Vterm J1 G J11 pLAN J10 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W G J12 J25 BMS2 J26 FBus2 B3 J9 NO3 C1 J11 pLAN NO2 AWG 20/22 NO1 AWG 20/22 Fig. 5.ac 5.5 Remote terminal with pLAN network 200 m Cavo schermato AWG20/22 2 twisted pair 6 5 4 3 2 1 0 J10 NC13 C9 C12 C13 NC12 NO12 J22 J21 J18 C16 NO17 NO18 NO16 J17 C16 NC15 C15 J16 NO13 NO11 NO10 NO9 C9 C8 C7 C7 C4 NC8 NO8 NO7 J15 NC14 C14 J14 NO14 J13 NO15 C4 NO6 C1 J12 J25 BMS2 J26 FBus2 NO5 NO4 NO3 NO2 C1 J11 pLAN J9 J23 FBus2 Graphic The maximum distance between two pCO boards with AWG20/22 shielded cable is 500 m. B10 BC10 ID17 ID14 ID14H ID18 BC9 Y6 B9 IDC13 Y5 ID13 IDC9 ID12 ID11 ID10 GND ID9 B8 B7 J6 B6 IDC1 ID8 ID7 J7 ID6 ID4 ID3 ID2 Y4 Y3 ID13H ID16H ID16 IDC15 ID15 ID15H J20 J5 Y2 Y1 VG0 VG BC5 B5 BC4 B4 J19 B M S c ard J4 J3 ID5 Fie ldBus c ard J2 +VDC J24 GND J1 ID1 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W IDC17 prog. enter B3 set B2 on/offalarm B1 ? info I/O +5 VREF menu GND taken from pCO (150 mA) taken from pCO (150 mA) separate power supply via TCONN6J000 Tab. 5.a G0 telephone AWG24 shielded cable AWG20/22 shielded cable power supply +Vterm power supply distance 10 m 200 m 500 m G type of cable NO1 S90CONN002 S90CONN 6 5 4 3 2 1 0 0,8 m When pCO boards are connected in a pLAN network, the terminal can be remotely-installed at a distance of up to 50 metres, if using a telephone cable, while it can be located at a distance of up to 500 metres if using a shielded twisted pair, TCONN6J000 and a separate power supply. Note: to reach the maximum length use a bus layout with branches not exceeding 5 m. The figures below show the connection diagrams for the various configurations. If the terminal is used in residential environments the cable always must be shielded. The maximum distance between pCO and user terminal is shown in the following table: J8 Fig. 5.ae TCONN cable connection Important: do not reverse the GND and +Vdc wires Graphic menu I/O set on/offalarm ? info prog. enter max 50 m cavo telefonico telephone cable 6 5 4 3 2 1 0 + - TX TX - + RX RX + GND RX+/TX- RX-/TX+ Fig. 5.af s e r v i c e c a rd J9 J10 Fig. 5.ad 42 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 The figure below represents the TCONN6J000 shunt, used in pairs for remote installation of the pCO in pLAN network with AWG20/22 shielded cable. ENG AWG20/22 cable (with power supply) 6 5 4 3 2 1 0 Fig. 5.ag Terminal 0 1 2 3 4 5 6 Function Earth +VRL (H30 Vdc) GND Rx/TxRx/Tx+ GND +VRL (H30 Vdc) Cable connections Shield First pair A Second pair A Third pair A Third pair B Second pair B First pair B Tab. 5.b Remote terminal installation up to 500 m with pLAN network with AWG20/22 shielded cable TRemote installation is shown in Fig. 5.u. This requires separate power supply via TCONN6J000. pLAN - to pCO + AWG20/22 1 twisted pair alimentatore power supply - 20...30 Vdc -150 mA 6 5 4 3 2 1 0 Graphic menu J14 and J15 on 2-3 ? info I/O on/offalarm set prog. enter only TCONN6J000 Fig. 5.ah Important: the overall length of the network must not exceed the 500 m. Consequently if the terminal is installed remotely the terminal cable length must be included in the total length. Important: the terminal cable represents a branch of the network, therefore if it’s more than 5 m long it can only be connected to the first or last pCO in the network. 5.6 pLAN network technical specifications The pLAN network technical specifications are summarised in the following table: description Communication standard Baud rate (kbit/s) Protocol Maximum network length (m) specification Asynchronous HALF DUPLEX RS485 62.5 or 115.2 (select. via software) Multimaster (CAREL proprietary protocol) 500 Tab. 5.c “pCO5” +0300009EN rel. 1.2 - 24.04.2014 43 ENG 6. PCO5 SERIAL CONNECTIONS 6.1 pCO5 serial connections: differences compared to pCO3 J10 C13 NC13 NO13 C12 J22 J21 J18 C16 NO18 NO17 NC15 NO16 J17 C16 J16 NC12 NO12 C9 NO10 NO11 C9 NO9 C8 NC8 NC14 NO14 J9 J15 C15 J14 NO15 C7 NO8 C7 NO7 C4 NO6 J13 C14 J12 J25 BMS2 J26 FBus2 NO5 C4 NO4 C1 NO3 NO2 C1 J11 pLAN NO1 Compared to the pCO3, pCO5 boards have a second serial port (BMS2) on connector J25 and a second FieldBus port on connector J26 (FBus2). pCO5 Large and Extralarge boards still have connector J23 which is marked as FBus2 in the same way as connector J26. As regards management from the 1Tool application, this is in fact the same serial port and different addresses must be used for the devices connected to both connectors, while from an electrical point of view the ports are independent (an electrical fault on port J26 does not affect port J23). J23 FBus2 only for large and extralarge models B10 BC10 ID17 IDC13 ID14 ID14H IDC17 BC9 ID13 ID18 B9 Y6 IDC9 ID12 ID11 ID10 ID9 GND B8 B7 J6 B6 IDC1 ID8 ID7 J7 ID6 ID4 ID3 ID2 Y4 ID1 Y3 ID13H Y5 ID16H ID16 IDC15 ID15 ID15H J20 J5 Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B2 B1 J2 J19 BMS card ID5 Fi e l d B u s c ard +5 VREF J24 GND G0 G J1 +Vterm input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J8 Fig. 6.a Serial Serial ZERO Type/Connectors pLAN/J10, J11 Serial ONE BMS 1 Serial card Serial TWO FieldBus 1 Serial card Serial THREE BMS 2 / J25 Serial FOUR FieldBus 2 / J26 (and J23 on Large and Extralarge version) Features • Integrated on main board • HW driver: RS485 pLAN • Not optically-isolated • Connectors: Telephone jack + 3-pin plug-in p. 5.08 • Not integrated on main board • HW driver: not present • Can be used with all pCO family optional BMS cards • Not integrated on main board • HW driver: not present • Can be used with all pCO family optional FieldBus cards • Integrated on main board • HW driver: RS485 Slave • Not optically-isolated (available also the version Optically-isolated) • 3-pin plug-in connector p. 5.08 • Integrated on main board • HW driver: RS485 Master • Not optically-isolated • 3-pin plug-in connector p. 5.08 • J23 and J26 are both managed by the same protocol as serial 4, with the advantage of being electrically independent. Tab. 6.a pCO5 serial connections pCO5 features three types of serial connections: pLAN, FieldBus, BMS. The RS485 Fieldbus serial port has Master hardware, while the RS485 BMS serial port has Slave hardware. The protocols used on the RS485 Fieldbus port are, due to the nature of the port, Master protocols (Carel Master or Modbus RTU Master), even if in special cases Slave protocols can be used (Carel Slave or Modbus RTU Slave), adopting the due measures. Similarly, Slave protocols are used on the RS485 BMS port, even if again adopting the due measures Master protocols can be used. 44 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG MASTER - SLAVE network J11 pLAN J25 BMS2 J26FBus2 MASTER pCO5 J11 pLAN J25 BMS2 J26FBus2 SLAVE pCO5 J11 pLAN J25 BMS2 J26FBus2 SLAVE pCO5 PC MASTER J11 pLAN J25 BMS2 J26FBus2 SLAVE pCO5 J11 pLAN J25 BMS2 J26FBus2 SLAVE pCO5 pLAN network J11 pLAN J25 BMS2 J26FBus2 MASTER/SLAVE J11 pLAN J25 BMS2 J26FBus2 MASTER/SLAVE pCO5 pCO5 J11 pLAN J25 BMS2 J26FBus2 MASTER/SLAVE pCO5 Fig. 6.b Important warnings • a serial port with Master hardware (FB) provides the network, via a suitable impedance, the correct polarisation voltage required for operation of all the connected devices: the master itself and its slaves; • serial ports with Slave hardware (BMS), on the other hand, do not feature polarisation voltage, hence it’s always recommended to connect at least one device with Master hardware (FB) to the network so that this is correctly polarised; • however it’s not possible to connect more than two Master hardware devices (FB) to the same network as the total polarisation impedance of the network would be too low, and thus not able to supply the right voltage for the RS485 network; • it’s recommended to connect serial probes or other devices that are wired to the electrical panel to serial TWO – FieldBus 1, so as to exploit the disturbance filtering property of the optically-isolated card. Connecting the devices Use a twisted pair cable with shield. Master dev. HW FBUS PC pLAN RS485 Lmax(m) Wire/wire capacitance (pF/m) 1000 < 90 1000 < 90 500 < 90 Resistance on first and last device 120Ω 120Ω - Max no. of slave devices on bus 64 207 32 Baud rate (kbps) 19200 19200 115200 Tab. 6.b Note: for Master – Slave networks the max length allowed is 1000 m; the 120Ω 1/4W terminating resistors on the first and last device in the network should be used when the length exceeds 100 m. Special cases • For networks made up only of devices with slave HW, a maximum of 207 devices can be connected. The max network length allowed is 100 m. DO NOT connect the 120Ω 1/4W terminating resistors on the first and last device; • for networks made up only of devices with master HW, a maximum 2 devices can be connected. The max network length allowed is 1000 m. The 120Ω 1/4W terminating resistor on the first and last device in the network is required if the length exceeds 100 m; • connect the computer to a network with max 1 master device or max 207 slave devices. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 45 ENG Devices that can be connected to the pCO5 Display terminal PST terminal PLD terminal pCOT - pCOI terminal pGD0 - pGD1 terminal pGD2 - pGD3 terminal Aria terminal pCO in pLAN FCM series controllers EVD200 EVD evolution serial four - USB Master FieldBus 2 (Host) connector J26 (& J23 on L E XL) connector J25 PCOS00HBF0 PCO100MPB0 serial three BMS 2 x x x x x x x x x x x CAREL Slave devices (tLAN) x CAREL Slave devices (485) pCOexp 485 pCOexp tLAN μchiller2 expansion Hydronic fan coil and CANbus PlantVisorPRO local PlantWatchPRO PC Gate WebGate GATEWAY**0 LON - Echelon FTT10 BACnet/MSTP (RS485) HTTP client BACnet/Ethernet BACnet/IP SNMP v1, SNMP v2C Modbus TCP/IP Modbus supervisor (RTU) x x Modbus Slave devices pCOexp Modbus Power+ BenShaw devices WinLoad local WinLoad remote, analogue modem PlantVisorPRO remote, analogue modem WinLoad remote, GSM modem PlantVisorPRO remote, GSM modem Send and receive SMS Belimo devices Serial printer Pendrive Th-tune terminal pGD Touch x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x - x x x - x x - x x “pCO5” +0300009EN rel. 1.2 - 24.04.2014 x x x - x x x x x x x x Tab. 6.d 46 PCO100TLN0 PCOS00FD20 PCO100FD10 PCOS00KXB0 PCOS00HBB0 serial two - FieldBus 1 PCO1000BA0 PCO1000WB0 PCO10000R0 PCO10000F0 PCO100MDM0 PCOS004850 serial one - BMS 1 PCO1004850 connector J10 serial zero pLAN connector J11 Device ENG Display terminal Protocol active on pCO5 connector J9 USB Slave (Device) x display terminal PST terminal Local terminal or pLAN Local terminal or pLAN Local terminal or pLAN pLAN With local terminal the pGD* works in pCOT emulation mode pLAN or CAREL Master or CAREL Master 5 expansions CAREL Master or CAREL Master 5 expansions CAREL Master or CAREL Master 5 expansions CAREL Master 5 expansions Can only be activated on one serial port. CAREL Master 5 expansions: incompatible with PST terminal Can only be activated on one serial port. CAREL Master 5 expansions: incompatible with PST terminal. If the protocol is activated, other devices cannot be supervised on J23. CAREL Master: can be activated either on BMS serial, FieldBus serial or pLAN.CAREL Master 5 expansions: can be activated either on pLAN serial or FieldBus serial. Can only be activated on one serial port; incompatible with PST terminal CAREL Master CAREL SLAVE Can only be activated on one serial port Can only be activated on one serial port at a time, except for BMS and Fieldbus, in which case can be activated on both at the same time.If active on pLAN serial, the PSTN, GSM, Modbus Slave and CAREL Slave protocols cannot be used on BMS serial. Modbus Slave extended with pCOweb Modbus slave extended only for pCOweb serial card with FW version ≥ 1.4 Modbus Slave If Modbus Slave is active then CAREL Slave can only be activated on a different serial port. The second Modbus extended on BMS2 (with 10000 integer variables) can operate at the same time as the one activated on the other port. Can be activated on two serial ports at the same time, as long as these are different and with separate management lists, selecting the second Modbus Master. Modbus Master x Incompatible with CAREL Master 5 Modbus Master Benshaw WinLoad PSTN GSM MP-Bus Serial printer Pendrive Mbus master for th - Tune 2nd Modbus slave extended on BMS2 Maximum of two Benshaw devices (addresses 1 and 2). Can only be activated on one serial port; on FieldBus serial from Bios 4.00. Can only be activated on one serial port Incompatible with the PSTN protocol; if activated on the BMS serial port it’s incompatible with Carel Slave set on pLAN serial port. Can only be activated on one serial port at a time.Incompatible with the PSTN protocol; if activated on the BMS serial port it’s incompatible with Carel Slave set on pLAN serial port. Maximum 8 devices Can only be activated on one serial port USB Master and USB slave port cannot be used at the same time Can be activated on pLAN or FieldBus serial, not on both at the same time Version for 2048D (coil), 5000A, 10000l (15000 registers) “pCO5” +0300009EN rel. 1.2 - 24.04.2014 47 ENG PST terminal PLD terminal pCOT - pCOI terminal pGD0 - pGD1 terminal pGD2 - pGD3 terminal Aria terminal pCO in pLAN FCM series controllers EVD200 EVD evolution CAREL Slave devices (tLAN) CAREL Slave devices (485) pCOexp 485 pCOexp tLAN μchiller2 expansion Hydronic fan coil and CANbus PlantVisorPRO local PlantWatchPRO PC Gate WebGate GATEWAY**0 LON - Echelon FTT10 BACnet/MSTP (RS485) HTTP client BACnet/Ethernet BACnet/IP SNMP v1, SNMP v2C Modbus TCP/IP Modbus supervisor (RTU) Modbus Slave devices pCOexp Modbus Power+ BenShaw devices WinLoad local WinLoad remote, analogue modem PlantVisorPRO remote, analogue modem WinLoad remote, GSM modem PlantVisorPRO remote, GSM modem Send and receive SMS Serial printer Pendrive Th-tune terminal pGD Touch connector J8 connector J7 connector J6 USB USB Protocol active on pCO5 compact Master Slave (Host) (Device) x x PST terminal PLD terminal Local terminal or pLAN Local terminal or pLAN Local terminal or pLAN pLAN x x x x x x x x x x pLAN or CAREL Master or CAREL Master 5 expansions or Modbus Master CAREL Master or CAREL Master 5 expansions CAREL Master or CAREL Master 5 expansions x x x x x x x x x x x CAREL Master 5 expansions x x x x x x x x x x x x x x x x x CAREL Master x x x x x CAREL SLAVE x x x x x x x x x x x x x x x x x x x x x x x x CAREL Slave or Modbus Slave extended with pCOweb Modbus Slave x x x - x - x - x - x x - x Modbus Master Benshaw WinLoad PSTN GSM x x x x “pCO5” +0300009EN rel. 1.2 - 24.04.2014 x x x x Modbus Master x Tab. 6.c 48 PCOS00KXB0 PCOS00HBB0 PCO1000BA0 PCO1000WB0 serial two - FieldBus 1 PCO10000R0 PCO10000F0 PCO1004850 PCO100MDM0 serial one - BMS 1 PCOS004850 serial zero pLAN connector J5 Device connector J4 Devices that can be connected to the pCO5 compact Serial printer Pendrive Mbus master for th - Tune Modbus slave ENG Application diagrams Below is a series of diagrams illustrating which devices can be connected to the pCO5 and the accessory cards required, according to the type of application. Air handling unit CP*: schede controllo umidificatori KUE* PGD1* dispositivi terze parti sonde seriali DP****4**** PGD Touch FAN NO18 C13 NC13 NC12 C16 IDC17 ID17 ID18 BC10 B10 BC9 ID14 ID14H B9 Y6 Y5 ID16H ID16 IDC15 ID15 ID15H NO13 C9 C12 NO12 C9 NO9 NO11 NO10 C16 NO17 NO16 C8 NC8 C15 NC14 C14 NO14 PCO100MPB0: scheda MP-BUS ID13 ID12 IDC13 ID13H IDC9 ID11 GND B8 ID9 ID10 IDC1 B7 J6 B6 ID7 ID8 ID6 ID2 ID3 ID4 J7 ID5 ID1 Y4 Y3 J23 FBus2 J20 J5 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC J18 J17 J22 J19 B M S card J4 J3 GND +5 VREF B2 GND FieldBus card J2 B1 G0 +Vterm G CAREL Master: can be activated either on BMS serial, FieldBus serial or pLAN. CAREL Master 5 expansions: can be activated either on pLAN serial or FieldBus serial. Can only be activated on one serial port; incompatible with PST terminal J24 J16 J21 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 J15 NC15 J14 J13 J10 B3 J9 NO15 C7 NO8 C7 C4 NO7 C4 NO6 C1 J12 J25 BMS2 J26 FBus2 NO5 NO4 NO3 C1 J11 pLAN NO2 S90CONN*: cavo di collegamento NO1 With local terminal the pGD* works in pCOT emulation mode J8 PCOS004850: scheda seriale RS485 Can only be activated on one serial port Can only be activated on one serial port at a time, except for BMS and Fieldbus, in which case can be activated on both at the same time.If active on pLAN serial, the PSTN, GSM, Modbus Slave and CAREL Slave protocols cannot be used on BMS serial. 03%86 ™ MS/TP BACnet st at u s P1 GNX %(/,02 P2 + RS4 8 5 PCO1000BA0: scheda interfaccia BACnet™ RS485 P3 – RS485 %(/,02 Valvola di servocontrollo PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ Servocontrollo della serranda PCO10000F0: schede LON Modbus slave extended only for pCOweb serial card with FW version ≥ 1.4 Fig. 6.c Roof-top unit Use the pCO5 medium with built-in electronic valve driver.. CP*: schede controllo umidificatori KUE* PGD1* C13 J18 NC13 C12 NC12 NO13 C9 4 J17 PCO100MPB0: scheda MP-BUS S3 S2 DI1 DI2 ID14H ID14 IDC13 ID13 ID13H IDC9 J8 ID12 ID11 ID10 ID9 S4 S1 VREF GND G GND B8 B7 B6 IDC1 ID8 ID7 J29 J7 J6 ID6 ID5 ID4 ID2 ID1 Y4 Y3 J5 Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J30 G0 B M S card J3 GND J2 B2 +5 VREF GND +Vterm G0 G J24 FieldBus card VBAT J10 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 NO12 NO11 2 J16 NO10 C9 NO9 C8 J15 1 J14 NC8 NO8 C7 C7 C4 NO7 NO6 NO5 C4 C1 NO4 NO2 NO3 J13 J127 B3 J9 Can only be activated on one serial port USB Master and USB slave port not cannot be used at the same time Can be activated on pLAN or FieldBus serial, not on both at the same time J12 J25 BMS2 J26 FBus2 3 J11 pLAN NO1 C1 S90CONN*: cavo di collegamento B1 Incompatible with the PSTN protocol; if activated on the BMS serial port it’s incompatible with Carel Slave set on pLAN serial port. Can only be activated on one serial port at a time.Incompatible with the PSTN protocol; if activated on the BMS serial port it’s incompatible with Carel Slave set on pLAN serial port. EEV sonde seriali DP****4**** PGD Touch Maximum of two Benshaw devices (addresses 1 and 2). Can only be activated on one serial port; on FieldBus serial from Bios 4.00. Can only be activated on one serial port ID3 If Modbus Slave is active then CAREL Slave can only be activated on a different serial port. Can be activated on two serial ports at the same time, as long as these are different and with separate management lists, selecting the second Modbus Master. PCOS004850: scheda seriale RS485 03%86 ™ MS/TP BACnet st at u s P1 GNX %(/,02 Valvola di servocontrollo P2 + P3 – RS485 RS4 8 5 PCO1000BA0: scheda interfaccia BACnet™ RS485 %(/,02 PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ Servocontrollo della serranda PCO10000F0: schede LON Fig. 6.d “pCO5” +0300009EN rel. 1.2 - 24.04.2014 49 ENG Chiller - screw compressor To manage two refrigerant circuits, there are two options. Case 1: 2 pCO5 Medium controllers with built-in electronic expansion valve driver. PGD1* PGD Touch dispositivi terze parti dispositivi terze parti dispositivi terze parti FAN INVERTER PUMP PGD1* PCOS004850: scheda seriale RS485 P2 + PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ PCO1000BA0:scheda interfaccia BACnet™ RS485 PCOS004850: scheda seriale RS485 PCO10000F0: schede LON Case 2: 1 pCO5 Large with external EVD Evolution twin driver. EVD*T* EVD Evolution twin EEV dispositivi terze parti PGD Touch INVERTER FAN S90CONN*: cavo di collegamento C13 NC13 NO13 C12 J23 FBus2 IDC17 ID17 ID18 BC10 B10 IDC13 ID14 BC9 ID14H B9 Y6 Y5 ID13H ID13 J20 ID16H ID16 IDC15 ID15 NC12 NO12 C16 C16 NO17 J22 ID15H J18 ID12 IDC9 GND ID9 ID10 ID11 B8 IDC1 B7 J6 B6 ID7 J7 ID8 ID5 ID4 Y4 Y3 ID2 ID3 ID1 NO18 NO16 J17 J5 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC C9 NO9 NO11 NO10 C9 NC8 C15 NC15 NO15 J16 J19 B M S card J4 J3 GND B2 B1 J2 ID6 FieldBus card +5 VREF GND +Vterm G0 G J24 J15 J21 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 C14 NO14 J10 B3 J9 C8 NO8 C7 NO7 C7 C4 NO6 J14 J13 NC14 J12 NO5 NO4 C4 C1 NO3 C1 NO2 NO1 EEV J25 BMS2 J26 FBus2 J8 PCOS004850: scheda seriale RS485 ™ MS/TP BACnet st at u s P1 GNX P2 + P3 – RS485 RS4 8 5 PCO1000BA0: scheda interfaccia BACnet™ RS485 PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ PCO10000F0: schede LON Fig. 6.f 50 C13 NO13 NC13 4 2 3 C9 C12 NO12 NC12 DI2 DI1 S4 S3 S2 S1 VREF ID14H ID14 ID13 ID13H IDC9 ID12 J8 IDC13 GND G GND B8 ID10 ID9 ID11 VBAT IDC1 B7 B6 ID8 ID7 ID6 ID5 ID4 ID3 ID2 Y4 Y3 Y2 Y1 J29 J7 P2 + RS4 8 5 P3 – RS485 RS485 Fig. 6.e J11 pLAN ID1 VG BC5 B5 BC4 B4 +VDC VG0 ™ MS/TP BACnet GNX P3 – J30 J6 J18 J28 RS4 8 5 P1 P1 GNX J5 G0 B M S card J4 J3 GND B2 +5 VREF FieldBus card J2 B1 G0 J24 GND G +Vterm ID14H ID14 IDC13 ID13 ID13H IDC9 ID12 GND B8 J1 J8 ID11 B7 ID10 ID9 B6 IDC1 ID8 ID7 ID6 ID4 ID3 ID2 ID1 Y4 J7 J6 st at u s ™ MS/TP BACnet st at u s ID5 J5 Y3 Y1 VG0 VG BC5 B5 BC4 B4 +VDC input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W B M S card J4 J3 GND +5 VREF GND FieldBus card J2 B2 +Vterm J24 B1 G0 G J1 Y2 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J17 J127 J10 B3 J9 J10 B3 J9 1 4 C9 NO11 NO9 NO10 1 J16 2 J15 3 C8 C7 J14 NC8 C7 NO8 C4 J13 NO7 C4 NO6 C1 J12 J25 BMS2 J26 FBus2 NO5 NO4 NO3 NO2 C1 J11 pLAN NO1 C13 J18 J17 J16 NC13 NO13 C9 C12 NC12 NO12 C9 NO9 NO11 J15 J14 NO10 C8 C7 NC8 C7 J13 NO8 C4 NO7 C4 J12 J25 BMS2 J26 FBus2 NO6 C1 NO5 NO4 NO3 NO2 C1 J11 pLAN NO1 S90CONN*: cavo di collegamento EEV “pCO5” +0300009EN rel. 1.2 - 24.04.2014 PUMP PCO1000BA0:scheda interfaccia BACnet™ RS485 PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ PCO10000F0: schede LON EEV ENG Chiller - scroll compressor Close control unit (CCU) PGD1* PGD1* Power + PSD0* schede CP*: controllo umidificatori KUE* PGD Touch EEV dispositivi terze parti EEV dispositivi terze parti PGD Touch FAN FAN PUMP INVERTER C13 J18 NC13 NC12 J17 NO13 C9 C12 NO12 4 C9 NO11 NO9 NO10 2 J16 3 C8 C7 NC8 C7 NO8 C4 NO7 C4 NO6 C1 NO5 NO4 NO3 J15 1 C13 NO2 C1 J9 J10 S3 DI2 DI1 S4 S1 S2 ID14H ID14 IDC13 ID13 ID13H IDC9 J8 ID12 ID11 ID10 GND B8 B7 J29 J7 ID9 B6 IDC1 ID8 ID7 VREF GND G G0 J30 J6 ID6 ID4 ID3 ID2 ID1 Y4 Y3 ID5 J5 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC VBAT B M S card J4 J3 GND +5 VREF FieldBus card J2 B2 GND J24 B1 G0 +Vterm G S3 DI2 DI1 S4 S2 S1 VREF GND ID14H ID14 ID13 IDC9 ID11 ID13H J8 IDC13 G0 G ID10 GND B8 B7 ID9 B6 IDC1 ID8 ID7 ID6 J1 J29 J7 J6 ID5 ID4 ID3 ID2 ID1 Y4 J30 ID12 J5 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC GND VBAT B M S card J4 J3 B3 +5 VREF B2 GND B1 G0 +Vterm FieldBus card J2 Y3 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W G J14 J127 J10 J24 J13 J127 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 J12 J25 BMS2 J26 FBus2 NC13 NC12 NO13 C9 C12 NO12 J18 4 C9 NO9 NO11 NO10 J17 B3 J9 2 1 J16 3 C8 C7 J14 NC8 C7 NO8 C4 J13 NO7 C4 NO6 C1 J12 J25 BMS2 J26 FBus2 NO5 NO4 NO3 NO2 C1 J11 pLAN NO1 J11 pLAN J15 NO1 S90CONN*: cavo di collegamento S90CONN*: cavo di collegamento PCOS004850: scheda seriale RS485 PCOS004850: scheda seriale RS485 ™ MS/TP BACnet st at u s P1 GNX ™ MS/TP BACnet st at u s P1 GNX P2 + RS4 8 5 P3 – RS485 PCO1000BA0: scheda interfaccia BACnet™ RS485 P3 – P2 + RS485 RS4 8 5 PCO1000BA0: scheda interfaccia BACnet™ RS485 PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ PCO10000F0: schede LON PCO10000F0: schede LON Fig. 6.i Fig. 6.g Heat pump Power + PSD0* PGD1* EEV PGD Touch C13 NC13 C12 NC12 NO13 C9 NO12 DI2 S3 S2 DI1 ID14H ID14 IDC13 ID13 ID13H IDC9 J8 ID12 ID11 ID10 ID9 S4 S1 VREF GND G GND B8 B7 B6 IDC1 ID8 ID7 ID6 PCO100FD10: scheda seriale FieldBus PCOS004850: scheda seriale RS485 ™ MS/TP BACnet st at u s P1 GNX sonde seriali DP****4**** J18 J29 J7 J6 ID5 ID4 ID3 ID2 ID1 Y4 Y3 J5 Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J30 G0 B M S card J3 GND B2 +5 VREF GND J2 B1 +Vterm G0 G J24 FieldBus card VBAT J10 input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W J1 J17 J127 B3 J9 NO11 NO10 J16 2 J15 4 NO9 C9 NC8 C8 NO8 C7 J14 1 J13 NO7 C7 C4 NO6 NO5 C4 C1 NO4 NO3 NO2 J12 J25 BMS2 J26 FBus2 3 J11 pLAN NO1 C1 S90CONN*: cavo di collegamento P2 + P3 – RS485 RS4 8 5 PCO1000BA0: scheda interfaccia BACnet™ RS485 PCO1000WB0: pCO Web - sch. interfaccia Ethernet™/BACnet™ th Tune AT* PCO10000F0: schede LON Fig. 6.h “pCO5” +0300009EN rel. 1.2 - 24.04.2014 51 ENG Electrical connections in the serial network To improve immunity of the pCO programmable controller to electromagnetic disturbance, the serial connection cable must be a twisted two- or three-wire cable with shield, depending on the insulation of the serial connection. The following rule applies: if the serial port is insulated (functionally) from the power supply, a third wire is required in the serial cable to act as a common reference for the controllers. If the serial port is not optically-isolated and the common reference is already present, the third wire is not needed. Not optically-isolated serial port This is the case of serial zero - pLAN (J11), FieldBus 2 (J23 and J26) and BMS2 if not optically-isolated. Case 1: multiple boards connected to the master/slave network powered by the same transformer; this is a typical application of multiple boards connected inside the same electrical panel. The terminating resistor is not used (L<100 m). see figg. 6. av, 6.aw, 6.ax for the ground connection of the shield Fig. 6.j Case 2: multiple boards connected to the master/slave network powered by different transformers (with G0 not earthed); this is a typical application of multiple boards inside different electrical panels. If the length of the network exceeds 100 m the 120 Ω ¼ W terminating resistor is required . AWG 20/22 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 C4 C1 NO3 NO2 NO1 FieldBus card Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF G0 C1 GND J10 +Vterm G G G0 J1 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC RX+/TX- RX-/TX+ C4 C1 NO3 NO2 J4 J3 GND B3 B2 J2 B1 +5 VREF J24 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card GND G0 NO1 J9 Fig. 6.k Case 3: multiple boards connected to the pLAN network powered by different transformers with only one earth reference: this is a typical application of multiple boards inside different electrical panels. 52 J11 pLAN J10 +Vterm G G G0 Y2 Y1 VG0 C1 GND RX+/TX- RX-/TX+ C4 C1 NO3 NO2 VG BC5 B5 BC4 B4 +VDC J1 J4 J3 GND B2 J2 B1 GND J24 R= 120 ohm J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card +5 VREF +Vterm G0 G J11 pLAN G0 G J12 J9 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W J1 AWG 20/22 J10 B3 J9 NO1 C1 AWG 20/22 J25 BMS2 J26 FBus2 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC see figg. 6. av, 6.aw, 6.ax for the ground connection of the shield R= 120 ohm J11 pLAN C4 C1 NO3 C1 NO2 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF +Vterm G0 G FieldBus card G0 G NO1 GND J10 J1 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC RX+/TX- RX-/TX+ C4 C1 NO3 C1 J4 J3 GND B3 B2 J2 B1 GND J24 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card +5 VREF +Vterm G0 G G NO2 J9 G0 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC J11 pLAN J10 J1 J4 J3 GND B2 B1 GND J2 +5 VREF J24 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card AWG 20/22 NO1 C4 C1 NO3 J9 G0 G0 +Vterm J1 G J11 pLAN J10 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W G AWG 20/22 J12 J25 BMS2 J26 FBus2 B3 J9 NO2 C1 J11 pLAN NO1 AWG 20/22 ENG C4 C1 NO3 C1 NO2 Y2 VG0 VG BC5 B5 BC4 B4 +VDC GND Y1 J4 J3 B3 B2 B1 GND J2 +5 VREF +Vterm G0 FieldBus card J24 G G0 G NO1 GND J10 J1 Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B1 GND B2 J2 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card J24 RX+/TX- RX-/TX+ C4 C1 NO3 C1 NO2 NO1 GND J9 +5 VREF +Vterm G0 G G J11 pLAN G0 Y2 Y1 VG0 VG BC5 B5 BC4 B4 +VDC J3 GND B2 B1 GND +5 VREF J2 J12 J10 J1 J4 AWG 20/22 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card J24 RX+/TX- RX-/TX+ C4 C1 J9 G0 G0 +Vterm J1 G J11 pLAN J10 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W G J12 J25 BMS2 J26 FBus2 B3 J9 NO3 C1 J11 pLAN NO2 AWG 20/22 NO1 AWG 20/22 see figg. 6. av, 6.aw, 6.ax for the ground connection of the shield Fig. 6.l Optically-isolated serial port This is the case of serial one – BMS1, serial two - FieldBus 1 and serial three – BMS2, if optically-isolated. Irrespective of the type of power supply, use a three-wire shielded cable, connected as shown in the figure. If the network is more than 100 m line, the terminating resistor is required. see figg. 6. av, 6.aw, 6.ax for the ground connection of the shield AWG 20/22 R= 120 ohm C4 C1 NO3 NO2 NO1 FieldBus card Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B2 J2 B1 GND J24 +5 VREF G0 G G0 C1 GND J10 +Vterm G J1 Y2 VG0 VG BC5 B5 BC4 B4 +VDC Y1 J4 J3 GND B3 B1 B2 J2 J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card J24 RX+/TX- RX-/TX+ C4 C1 NO3 NO2 NO1 J9 +5 VREF G0 J11 pLAN J10 +Vterm G G G0 Y2 Y1 C1 GND RX+/TX- RX-/TX+ C4 C1 NO3 VG0 VG BC5 B5 BC4 B4 +VDC J1 J4 J3 GND B2 J2 B1 +5 VREF J24 R= 120 ohm J12 J25 BMS2 J26 FBus2 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W FieldBus card GND +Vterm G0 G NO2 J9 G0 G J11 pLAN J10 input: 24 V / ; 50 to 60 Hz max. power: 45 VA/17 W J1 J12 J25 BMS2 J26 FBus2 B3 J9 AWG 20/22 GND J11 pLAN NO1 C1 AWG 20/22 power supply Fig. 6.m Procedure for earthing the shield The shield of the serial cable is earthed in different ways, according to the length, as shown in the figure (A = FBus terminal, B= BMS terminal, or A=B in pLAN). Case 1: distance between controllers less than 0.3 m: earth just one end of the cable Case 2: distance between controllers greater than 0.3 m: two possibilities X: earth one end with bridge between shields L < 0.3 m L < 0.3 m AWG 20/22 AWG 20/22 L > 0.3 m L > 0.3 m AWG 20/22 Fig. 6.n AWG 20/22 Fig. 6.o Y: earth both ends L > 0.3 m L > 0.3 m AWG 20/22 AWG 20/22 Fig. 6.p pCO5 compact serial connections The electrical and software details provided apply to both the pCO5 and pCO5 Compact, however remembering that pCO5 compact has just one optional BMS port and an integrated Fieldbus port. Note that the integrated FieldBus port on pCO5 compact is opto-isolated and therefore provides better performance in terms of immunity compared to the port on the pCO5 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 53 ENG 7. UPDATES, FIRMWARE AND LOG FILES FOR PCO CONTROLLERS IThe following systems can be used to update the firmware and acquire the log files on pCO controllers: • Winload; • SmartKey. 7.1 pCO Manager On all CAREL 16 bit pCO sistema controllers (see the pCO sistema manual) the resident software can be updated using a PC. For this purpose, CAREL provides the pCOLoad program and a serial converter with RS485 output to be connected to the pCO. The special driver also needs to be installed on the PC, also provided by CAREL. The program is included in the installation of the “1tool” program suite or with the pCO Manager program, downloadable separately from http://ksa.carel.com, under “home: download: pCO sistema: pCO_manager”. The installation, as well as the program, also includes the user manual. The pCO controller can be connected directly to the PC via the RS485 serial port used for the “pLAN” connection or using the BMS serial port with optional RS485 serial card used for the “supervisor” connection. When using the BMS serial port and the optional RS232 serial card, the pCO controller can be connected to an analogue (PSTN) or GSM modem and in turn to pCO Manager via a remote connection. pCO Manager can communicate with all pCO family programmable controllers. The program can also be used in general to update and download to the PC the BOOT, BIOS, application, configuration and log files, including the file saved in NAND flash memory. It must be underlined that updating the BOOT is generally NOT recommended by CAREL; during production CAREL always loads the BOOT required for the correct operation of the unit. Only in very special cases will CAREL ask the user to update the BOOT. The BIOS can only be loaded via the pLAN serial connection. When updating the BIOS, the unit operating mode switches to low level. In this special mode, the logged data cannot be downloaded to the PC nor can the application be loaded in compressed format. To return the unit to normal communication with pCO Manager, reset the pCO board after having successfully loaded the BIOS. For further information on the operation of pCO Manager see the online help inside the program. The download options are listed in the following tables: LOCAL pLAN serial BMS serial Load Boot and Bios Load application and parameters Load/download logs Load/download NAND flash (pCO3) YES YES NO YES FieldBus serial NO YES YES YES YES NO YES NO pLAN serial BMS serial Load Boot and Bios NO – modem can’t be connected NO – modem can’t be connected NO – modem can’t be connected NO NO Load application and parameters Load/download logs Load/download NAND flash (pCO3) FieldBus serial NO Important: use the pendrive to perform the following operations: • UPLOAD - copy files from pendrive to controller; • DOWNLOAD - download files from controller to pendrive, available only when using a terminal, either built-in or connected to the controller via pLAN. The pCO5 controller has 2 USB ports, A and B, accessible after having removed the cover S, and two LEDs, L1 and L2. A L1 L2 S B Fig. 7.a Port A is used to connect a pendrive, port B for direct connection to a computer running the pCO Manager program. LED L1 comes on steady after connection and flashes during data transfer. The keypad has 6 buttons that, pressed either alone or in combination, are used to run all the UPLOAD and DOWNLOAD operations between pendrive and controller. Esc Prg Alarm Down Up Enter Important: • before using the pendrive, it must be formatted with the FAT32 system; • the pendrive can access up to two levels: APPL\CHILLER\PRI.BIN, however cannot access the \APPL\CHILLER\VER1\PRI.BIN file; • do not use port A and port B at the same time; • the maximum pendrive capacity supported is 32 GB YES NO YES NO NO NO Manual, automatic and autorun mode • Manual mode involves selecting the operations to be performed via Tab. 7.b. All the WinLoad32 program functions are also available in pCO Manager, which also includes the Commissioning Tool. 54 On specific models, pCO5 comes with two different USB ports (host and slave), to be used during installation and diagnostics. The host port can be used to connect USB mass storage peripherals (pendrives, portable hard disks, … with a maximum current of 200 mA) and then run a series of operations: 1. upload to pCO5 the files on the removable peripheral: application, parameters in buffer memory, configuration files for logs, Bios. 2. download files from pCO5 to the removable peripheral: application, parameters in buffer memory, data log, BIOS. Fig. 7.b Tab. 7.a. REMOTE 7.2 USB port (on pCO5 and pCO5 compact models where featured) “pCO5” +0300009EN rel. 1.2 - 24.04.2014 the keypad; this offers maximum flexibility and the possibility to freely decide the desired operations; • Automatic mode requires the creation of special files, called configuration files, which are text files (.txt extension) containing various types of information on the functions to be performed and the files to be loaded; • Autorun mode the creation of a special configuration file called “autorun.txt”. When the pendrive is plugged in the controller immediately executes Autorun and after confirmation from the terminal performs the operations contained in the file. ENG Upload & Download The UPLOAD operation can be performed in three different ways: 1. manual mode: the user selects manual mode from the keypad, then the files to be loaded and then confirms to start the operation. 2. automatically: the user selects automatic mode from the keypad and then the configuration files that contain the instructions on the operations to be performed; 3. autorun mode: after plugging in the pendrive a screen is displayed indicating that autorun mode has started. After confirming, the instructions contained in “autorun.txt” are executed automatically. The contents of this file are similar to the UPLOAD configuration files, the only difference being the name “autorun.txt”. The downloaded files also have fixed name, specifically 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 of the pendrive. Menu access The following operations are used to access the pendrive management menu. Procedure: 1. Connect the pendrive to port A. The green LED on the controller comes on to confirm recognition. The DOWNLOAD operation can be performed in two different ways: 4. manual mode: the user selects manual mode, then the files to download and then confirms to start the operation. 5. autorun mode: after plugging in the pendrive a screen is displayed indicating that “autorun” mode has started. After confirming, the instructions contained in “autorun.txt” are executed automatically. The contents of this file are similar to the DOWNLOAD configuration files, the only difference being the name “autorun.txt”. BC5 USB key Note: the configuration and autorun files must reside in the main directory. Fig. 7.c File extensions, names and contents Different types of files can be uploaded and downloaded and are distinguished by their extension. 2. Press Alarm and Enter together for 3 seconds to enter the option menu. Select FLASH/USB memory and confirm by pressing Enter. Nomi di file In order to be recognised, the names of the directories and files on the pendrive must have at most 8 characters; the controller does not recognise the difference between characters in upper and lower case. On the other hand, during DOWNLOAD the directories created by the controller on the pendrive only have names in upper case. > SYSTEM INFORMATION LOG DATA OTHER INFORMATION FLASH/USB MEMORY Fig. 7.d FILE TYPES FOR UPLOAD File extension .IUP .BLB .BIN .BLX .GRP .DEV .PVT, .LCT Description Contains the definitions of the screens on the terminal Contains the application Contains the application (with pLAN table) Contains the logic of user-defined atoms in C language Contains the graphics Contains the preset configuration parameter values Contains the descriptions of the public variables to be saved. Generated by 1tool, this is used by the LogEditor module and must be loaded together with the .LCT file Tab. 7.c Downloaded files are saved in directories created automatically, with the following type of name: NAMXY_WZ Where: NAM: identifier of 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 99 WZ: controller pLAN address. E.g.: the LOG00_01 directory contains the logs (LOG) downloaded from a device with pLAN address 1. The pendrive, before the download operation, did not contain any directories of this type and is consequently numbered 00. Important: no more than 100 files of the same type can be downloaded to the pendrive, as the directories created can be numbered XY=00 to 99. FILE TYPES FOR DOWNLOAD (pLAN address control =1) File extension .DWL .DWL,.DEV, .LCT, .PVT .DEV .DWL, .DEV, .LCT, .PVT Directory name LOG00_01 BKP00_01 DEV00_01 CPY00_01 Description Logged data Application Non-volatile parameters All the data on the controller Tab. 7.d 3. Select USB pen drive and confirm by pressing Enter NAND FLASH FILES > USB PEN DRIVE Fig. 7.e Important: wait at least 25 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 correct recognition message is shown: “USB disk found” and then the following screen opens: 4. Select the UPLOAD operation Select function: >UPLOAD (pen->pCO) DOWNLOAD (pCO->pen) Fig. 7.f Upload An 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 the use of configuration files. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 55 ENG Configuration file structure The configuration files must start with the string “[FUNCTION]” followed by a string that identifies the function, as shown in the table. • the order in which the file names are entered is fundamental and Function UPLOAD an application, or a BIOS file and of an application • 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” String Upload application (for BIOS version 6.08 and followings) Installation (for BIOS versions previous to 6.08.) UPLOAD non-volatile memory (.dev) Upload non volatile memory UPLOAD the entire contents of the pCO Copy pCO upload Tab. 7.e Important: cannot be changed; 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] biosn509.bin [IUP] AHU_EN.iup AHU_IT.iup [BIN] AHU.blb [DEV] AHU.dev [GRP] AHU.grp [PVT] AHU.pvt [LCT] AHU.lct Following 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 Fig. 7.g 2. to copy just 1 file in a directory, specify the name (e.g. the CHILLER. DEV file in the CHILLER directory); [FUNCTION] Upload non volatile memory [DIR] CHILLER CHILLER.DEV Fig. 7.h To show a string on the display describing the operation being performed, add the “[NAM]” instruction, followed by the string displayed. The following file will display the string: “UPL CHILLER.DEV” [FUNCTION] Upload non volatile memory Fig. 7.j Automatic upload [DIR] CHILLER To automatically upload the parameter memory using the first configuration file shown in the previous paragraph, access the system menu as already described and proceed as follows: [NAM] UPL CHILLER.DEV 1. Select automatic mode. A screen is shown describing the use of the buttons, press Enter to confirm. pCO CHILLER.DEV Select upload mode: >AUTOMATIC MODE MANUAL MODE Fig. 7.i 3. to select just 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: Note: the [IUP] label can be followed by one or more “.iup” files. 2. Confirm by selecting Prg. A screen is displayed requesting confirmation to Upload the non-volatile memory. Press Enter to confirm. pCO UPLOAD file labels no. label 1 [BIO] (*) 2 [IUP] 3 [BIN] 4 [DEV] 5 [GRP] (*) BIO = file di BIOS Fig. 7.k file type file.bin file.iup file.bin, blb file.dev file.grp no. 6 7 8 9 label [PVT] [LCT] [OED] [SGN] file type file.pvt file.lct file.oed file.sgn >UPL FILE_DEV.DEV Fig. 7.l 3. At the end a message asks the user to remove the pendrive. Tab. 7.f Note: to get the .bin file from the BIOS in the format available on http:// ksa.carel.com (.os file), the latter file needs to be unzipped. pCO UPLOADING FILE PLEASE WAIT... Fig. 7.m 56 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG 5. The test phase starts Upload in autorun mode From to BIOS 6.24 version, it is possible to do the UPLOAD in AUTORUN mode; without biult-in terminal using the display pLAN address. Upload in autorun mode is a special version of automatic upload. Unlike automatic mode, the user needs to wait for a specific message to be shown on the display to start or disable the operation described in the configuration file. To upload a file in autorun mode, a configuration file needs to be created and named “autorun.txt”. Example of uploading BIOS+application. The upload operation involves two steps, first the BIOS is updated and then the application. The information is shown on the pCO built-in display and the pGD1 terminal, when these are both featured. Procedure: 1. Connect the pendrive to port A. The green LED on the controller comes on to confirm recognition. pCO ################## Selftest Please wait... ################## Fig. 7.s pGD NO LINK Fig. 7.t 6. The controller warns that no application has been loaded USB key pCO Application program corrupted or not present! WAITING for upgrade BC5 Fig. 7.u pGD Fig. 7.n NO LINK 2. After around 25 s Autorun mode starts. Press Enter to confirm (or display button pLAN). pCO Fig. 7.v Select upload mode: >AUTOMATIC MODE MANUAL MODE 7. The application update then starts pCO Upload appl Please wait... Fig. 7.o 3. Then the validity of the FW is checked and the BIOS is loaded pCO Fig. 7.w FW validation Please wait... pGD NO LINK Fig. 7.p 4. IThe display flashes to indicate that after loading the new BIOS the controller is being reset Fig. 7.x pCO 8. Remove the pendrive. The update is complete. Wait for the display to UPLOADING FILE PLEASE WAIT... stop flashing, indicating the controller is being reset before restarting. pCO Upload complete Remove USB key and wait reset Fig. 7.q pGD NO LINK Fig. 7.y pGD NO LINK Fig. 7.r Fig. 7.z “pCO5” +0300009EN rel. 1.2 - 24.04.2014 57 ENG 2. Download complete Important: as can be seen, when updating the BIOS and the application, the pGD1 terminal shows the absence of a connection with the message “NO LINK”. Consequently, 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 different directories contained on the pendrive based on the address of the controllers. The controller with address XY will only load the directory called: “dirname_XY”. The pendrive then only needs to be plugged in to each controller to run the upload, confirming from the shared terminal. Manual upload To manually upload the contents of the pendrive, the user must access the management menu from the system screens, choosing the items UPLOAD and then MANUAL shown in Figs. 6.b.k and 6.b.p. The files are selected by pressing ENTER when the cursor is on the desired file. A selected file is marked by a “*” symbol on the left. Once the files have been selected (all in the same directory), to start the upload operation press PRG. To display the contents of a directory press ENTER. To go back up one directory level, on the other hand, press ESC. Once the upload has started, the messages shown on the screen are the same as in automatic and autorun mode. Operation complete Data downloaded to BKP00_01 Fig. 7.ac Example: on the controller with address 1, the autorun file will create the directory called BKP00_01, and copy the APPL_PCO.DWL and FILE_DEV. DEV files to this directory. Password setting If the application contains a password that needs to be entered in a special screen, this is requested for each DOWNLOAD/UPLOAD operation 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 computer Connect the slave USB port on the controller to the USB port on the computer where the pCO manager program has been installed. Download USB connector from computer Function DOWNLOAD logged data DOWNLOAD the application DOWNLOAD non-volatile memory DOWNLOAD the entire contents of the pCO String Download logs Download application Download non volatile memory (.dev) Copy pCO download Tab. 7.g The result is the creation of files with the required extensions, in the respective directories, as shown in the paragraph on “file names”. When the operation is complete, the display shows a message with the name of the directory created. [FUNCTION] Download application Fig. 7.aa BC5 As mentioned, the DOWNLOAD operation can be managed in two ways: 1. manual mode: follow the steps described in paragraph 1.4.1 and choose 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. Fig. 7.ad Important: • Do not install any type of converter between the computer and port B, even if specified by the guided procedure in the program; • the pCO Manager program manages compressed files (.GRT/.OS) Once the connection has been made, the following operations are available: 1. UPLOAD the application or BIOS+application; 2. DOWNLOAD non-volatile memory; 3. DOWNLOAD logged data; 4. Commissioning; 5. NAND flash memory management. Once having removed the USB cable, the port is free again after around 5 s. Important: if, after plugging in the USB cable, there is no connection with the pCO Manager program, after removing the cable wait at least 1 minute before using the USB ports again. Key: messages display on pLAN display address The following screen will be displayed. 1. Press Enter to confirm ****AUTORUN MODE**** DOWNLOAD APPLICATION Press ENTER to start ESC to exit autorun 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 Fig. 7.ab 58 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 No LOG: attempt to download historical file when are not present Tab. 7.h ENG 1. SYSTEM INFORMATION: selecting this function displays information 7.3 Smartkey The SMARTKEY programming key is used to program the pCO, with the sole exception of the BOOT, which is not loaded by SMARTKEY. Specifically, the key can clone the contents of one pCO and then download the data to another identical pCO via the terminal telephone connector (the pLAN must be disconnected). In addition to this mode, the key can be used to transfer logged data from a series of pCO units and then download them to a PC. From the PC, using the “SMARTKEY PROGRAMMER”, the key can be configured to run certain operations: retrieve logs, program applications, program BIOS, etc. For further details see the online help for the “SMARTKEY PROGRAMMER” and the SMARTKEY instruction sheet. 7.4 NAND Flash memory This type of memory is only available on pCO5 versions with code PCO5******C/D/F/G**. pCO Manager can be used to load any type of file to the NAND Flash memory. This can be used, for example, to save the application source files on the unit. As well as this use, the IUP, BLB (or BIN) and DEV files that represent parameter files, the screens displayed in the various languages and the control logic, can be loaded to NAND flash and then selected from the screen on the terminal to be used as the current application on the pCO. Specifically, several different applications, or different languages, or multiple parameter files can all be loaded s in NAND flash memory and then the desired application, language or parameter configuration can be selected and loaded to the main flash memory. The files saved in NAND flash memory can be selected and copied to the main flash memory on the screen managed directly by the BIOS. The procedure is described in the following paragraph. Limits: • a maximum of 40 files can be saved on NAND flash memory; • the NAND flash memory can only be updated via the Winload local connection; • the maximum total memory capacity is 32 MBytes. on the software loaded and the amount of RAM and Flash installed. The screen displayed is similar to the following. B B > A O I 2 P O O + P T S 2 . V V M B C R 4 4 . 0 . 0 < C : 0 0 3 1 0 0 3 / / 3 5 D 0 0 1 2 / / 0 0 6 6 2 M B The first line displays the BOOT version and date. In the example shown in the figure, the pCO is working with BOOT 4.00 of 10 January 2006. The second line displays the BIOS version and date. In the example shown in the figure, the pCO is working with BIOS 4.00 of 3 February 2006. The third line indicates the size of the Flash onboard and, on the pCO1 and pCO2, the size of the Flash in the parallel key or the expansion card, if featured. The “>” and “<” characters indicate the starting Flash on the pCO: these are on the left if the pCO is started from the onboard Flash, and are on the right if the pCO is started from the key. In the example the pCO is running BOOT, BIOS and application onboard, and no key or memory expansion is available. The fourth line displays the application CRC and the amount of Flash occupied. In the example, the application CRC is 335D and requires 2 MB of memory. If this line shows 1 MB, a pCO with 1 MB Flash is sufficient. The CRC is a number that summarises the application contained in the flash memory on the pCO, but also other system information. It’s therefore recommended to recognise the version of a specific application on a special screen. 2. LOG DATA: selecting this function allows any logged data on the pCO to be viewed. If no log is present, the following screen is displayed. 0 N O L O G D A T A P R E S S [ M E N U ] O R [ E S C ] If, on the other hand, there is at least one log, the first screen displayed is similar to the following. 1 I D I S W h i N T E R P c L A Y h m e N A L M E L O G m o r y M O R D A T ? A Y Detailed information on the screens relating to the logs is provided in the WinLoad manual. 3. OTHER INFORMATION: selecting this function displays the ID 7.5 Checking the software installed on the pCO and other information The current version of program can be checked at any time (by CRC code expressed in hexadecimal), and whether the program on the key or the resident program is used. To check this, simply proceed as follows. number associated with the pCO. The ID number is a code, different for each pCO manufactured by CAREL, and is available for use in future applications. I D 0 0 N U M B 2 6 3 E R 1 1 : 4 4 1 - 1 8 0 8 2 Screens managed by BIOS Not all pCO units are given an ID number by CAREL; if this is not available, the following screen is displayed. Press the ALARM and ENTER buttons together for 3 seconds, and the following screen will be displayed. I D N O T > S L O N Y O T A S T E M G D A T H E R I N D F L I N F O R M A T A N F O R M A T I A S H F I L E I N U M B P R E E S R E : N T O N O N S Each of the four lines displayed is used to access further screens, managed by BIOS and consequently always available, irrespective of the application loaded. To access the functions, simply select the line with the cursor “<” using the UP and DOWN buttons, and then confirm by pressing ENTER. To exit the screen press MENU or Esc on the terminal, or wait around 40 seconds for automatic timeout. The screens provide various types of information. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 59 ENG 4. NAND FLASH FILES: this line is displayed only on pCO boards that feature additional NAND flash memory. Selecting this function displays the names of the IUP, BLB, GRP and DEV files saved in NAND memory; it’s also possible to copy an application from NAND memory to the main flash memory on the pCO. Each file name is shown on a screen such as the one below. [ P X ] G D 2 3 _ A L L . g r p To move from one file to another simply press the UP or DOWN button. Press ENTER to select the current file to copy to main flash memory. The files selected to be copied are marked by an “X” on the first line of their screen; in the example shown in the figure, the “PGD23_ALL.grp” file is selected to be copied. To start the copy procedure, press UP or DOWN until reaching the following screen: t o P s r t e a s r s t E c n t e o p y r i n g and then confirm by pressing ENTER. For further information on the use of NAND memory, see the WinLoad manual. Exit these two screens by pressing Menu on the local terminal or wait around 40 seconds for automatic timeout. 60 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG 8. GENERAL CONNECTION DIAGRAMS 8.1 pCO5 G G0 50VA +Vterm B2 B3 B3 GND GND OUT +VDC +V probe 4 Carel NTC B4 B4 BC4 BC4 B5 B5 BC5 BC5 J3 probe 5 PT1000 +VDC Rx-/Tx- J26 FBus2 B2 Rx-/Tx- J25 BMS2 B1 J11 pLAN B1 Fi e ld B u s c ard M probe 3 (0/1 Vdc or 4/20 mA) +5 VREF J2 probe 2 (4/20 mA) GND J10 +5 VREF probe 1 (0/5 V) +Vterm J24 GND J9 G G0 J1 N input: 24 V 50...60 Hz / 28...36 V max. power: 45 VA/20 W 230/24 Vac 2.5 AT L Rx-/Tx- Rx+/Tx+ GND Rx+/Tx+ GND Rx+/Tx+ GND C1 C1 VG J12 VG NO1 NO1 NO2 NO2 NO3 VG0 NO3 Y1 Y1 C1 C1 analog output 2 (0/10 Vdc) analog output 3 (0/10 Vdc) Y2 Y2 C4 C4 Y3 Y3 Y4 ID1 ID1 digital input 2 ID2 ID2 digital input 3 digital input 4 digital input 5 digital input 6 digital input 7 ID3 ID3 digital input 8 J13 Y4 digital input 1 B MS c ard analog output 4 (0/10 Vdc) J4 VG0 analog output 1 (0/10 Vdc) NO4 NO4 NO5 NO5 NO6 NO6 C4 C4 C7 C7 ID4 ID5 ID5 ID6 ID6 ID7 ID7 NO8 ID8 ID8 C8 J5 J14 ID4 NO7 NO7 NO8 digital output 7 digital output 8 J15 C8 SMALL NC8 NC8 IDC1 digital output 4 digital output 5 digital output 6 C7 C7 IDC1 digital output 1 digital output 2 digital output 3 B6 J6 B7 B8 J16 GND CP probe 6 - 7 probe 8 CAREL NTC GND ID9 ID10 ID10 ID11 ID11 ID12 ID12 IDC9 IDC9 ID13H NO9 digital output 9 NO10 NO10 digital output 10 NO11 NO11 digital output 11 C9 C9 ID13 IDC13 ID14 ID14 ID14H digital output 12 C12 C12 NC12 NC12 NO13 NO13 digital output 13 MEDIUM ID13 NO12 NO12 ID13H IDC13 ID14H C9 C9 NO9 C13 C13 J18 digital input 14 B8 ID9 J17 digital input 13 B7 B8 GND J7 digital input 10 digital input 11 digital input 12 B6 B7 J16 digital input 9 B6 J6 out H M NTC NTC + (G) NC13 NC13 J8 digital output 14 NO14 C14 J21 ID15H digital input 15 ID15 digital output 15 NO15 C15 J19 IDC15 NC14 NC15 ID16 digital input 16 ID16H C16 J22 NO16 digital output 16 NO17 digital output 17 digital output 18 NO18 analog output 5 (0/10 Vdc) Y5 analog output 6 (0/10 Vdc) Y6 C16 B9 probe 9 CAREL NTC BC10 digital input 17 ID18 digital input 18 IDC17 Rx-/TxRx+/Tx+ GND LARGE ID17 J23 FBus2 J20 BC9 B10 probe 10 voltage-free digital input Fig. 8.a “pCO5” +0300009EN rel. 1.2 - 24.04.2014 61 ENG 8.2 pCO5 with built-in EVD evo G G0 driver 2.5 AT 100VA Fig. 8.b Valve connectors J27 & J28: 1 = green 3 = brown 2 = yellow 4 = white Connect the spade to the valve cable shield and then earth. G0 is earthed on the transformer secondary 62 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG 9. TROUBLESHOOTING The unit does not come on (power LED off ) Check: 1. mains voltage is connected; 2. 24 Vac or 28 to 36 Vdc is available downstream of the power transformer; 3. the 24 Vac or 28 to 36 Vdc power supply connector is plugged in correctly; 4. the protection fuse (if present) has not blown; On power-up various problems occur on the LCD (strange characters, blank screen). Check: 1. correct software in the flash; 2. check the pCO and terminal pLAN address (compliant with the application being used); 3. if the built-in display is featured and is working correctly, the problem resides in the connection between the pCO and the terminal: make sure the cable is plugged in correctly. NTC probes: the probe signal is a resistive value that depends on the temperature. Below are some resistance values for different temperatures. Disconnecting the probe from the interface and measuring its resistance with a multimeter gives the corresponding temperature in the table. °C -20 -15 -10 -5 KΩ 67.71 53.39 42.25 33.89 °C 0 5 17 15 KΩ 27.28 22.05 17.96 14.68 °C 20 25 30 35 KΩ 12.09 10.00 8.31 6.94 Tab. 9.a Measuring the voltage at terminals Bn and GND with a voltmeter, with an NTC connected, the voltage should be: VIN= 2.5 x R NTC 10000 + R NTC Example:inserting a 10 KΩ input resistor (corresponding to 25°C) gives: VIN= 2.5 x 10000 = 1,25 V 20000 For the pCOXS, the following formula is used: Input signals not read correctly Check: 1. correct pCO power supply; 2. correct probe power supply: if the voltage (+Vdc>20 V) is near zero, disconnect the probe and measure the power supplied by the pCO. If this is still near zero, turn the controller off and wait a few minuted. If the problem arises again contact CAREL service; otherwise removing the connection has short-circuited the power supply. 3. separation of the power supply to the digital inputs from the power supply to the pCO. A 24 Vac/24 Vac transformer with a minimum rating of 5 VA can be used; 4. the probe wires have been connected according to the instructions; 5. the probe cables are located a sufficient distance from possible sources of electromagnetic disturbance (power cable, contactors, cables with high voltages and devices with high peak current draw); 6. there is not high thermal resistance between the sensor and the probe socket, if used. If necessary, put conductive paste or oil in the socket to ensure good temperature transmission; 7. if there’s a probe error or a conversion error on the pCO, the checks to be performed depend on the type of probe. VIN= 5 x RP 10000 + RP where RP is the parallel resistance expressed in ohms between the NTC resistance and 20000 Ω To check the settings of the probe inputs (pCO5) Switch off the pCO and make the following measurements with a tester between the probe input Bn and GND: • on inputs B1, B2, B3, B6, B7 and B8 the resistance is around 150 KΩ; • on inputs B4, B5, B9 and B10 the resistance is around 0 kΩ. As on the pCO the type of analogue input is set via software, if the application allows, a more correct way of checking involves disconnecting the probes and powering up the pCO. Measure: probe type NTC 4 to 20 mA PT1000 0 to 1 V or 0 to 10 V 0 to 5 V voltage measured 2.5 V (3.3 V if pCOXS) 0V 2.5 V 0V 0 V (3.3 V if pCOXS) Tab. 9.b Active humidity probes with 0 to 1 V signal: the probe signal is measured with a voltmeter between terminals Bn and GND, checking to make sure this corresponds to the value: 1 mVdc corresponds to 0.1% RH Example: reading 200 mVdc (0.2 Vdc) the probe sends a signal that corresponds to 20% RH Pressure probes: if errors arise in the readings of these probes, check that: 1. the analogue inputs used for these probes can accept 4 to 20 mA signals (selected in the application program); 2. the full scale set via software corresponds to the probes used; 3. the probe capillary tube is not blocked. 4. Measuring the voltage at terminals Bn and GND with a voltmeter gives an indirect reading of the probe signal, as the input has an impedance of 100 Ω, applying the formula: I= V/R (2 V= 20 mA). Doubtful alarm signal from digital input (for pCO5) Check the voltage between the common terminal “IDC1” and the terminal for the digital input indicating the alarm “IDn”, in the following conditions: 1. if voltage is measured (24 Vac or 24 Vdc depending on the power supply used for the digital inputs) the contact of the alarm device connected is closed; 2. if the voltage is less than around 10 Vac or 10 Vdc (see above) the contact is open; 3. unless expressly declared otherwise, the controller signals an alarm when it detects open contacts. The pressure value “Ps” that the probe is sending can thus be calculated (FS= Full scale): Ps= (Vmeas/100 - 0.004) x (FSmax - FSmin) / 0.016 + FSmin Example: the probe used has FSmin= -0.5 bars, FSmax= 7 bars; the voltage read is equal to Vmeas= 1 Vdc. The pressure Ps that the probe is measuring is equal to: Ps= (1/100 - 0.004) x [7 - (-0.5)] / 0.016 + (-0.5) = 2.3 bars. “pCO5” +0300009EN rel. 1.2 - 24.04.2014 63 ENG The pCO repeatedly goes into watchdog mode, i.e. switches off and on again as if there were a temporary power drop or some outputs (digital and/or analogue) are activated at random Check: 1. that the power cable does not run near the pCO; 2. that the power transformer (not supplied by CAREL) is sized correctly (see the paragraph on POWER SUPPLY); 3. that the probe and digital input cables are kept separate from the other cables (panel and conduits). The serial connection to the local supervisor isn’t working Check: 1. the serial card code PCOS004850 is fitted and connected correctly; 2. that the identification number of the pCO has been set correctly (see the application program manual); 3. that the serial cabled are connected correctly according to the CAREL diagram shown in the documents corresponding to the supervisor network; The user terminal is frozen (doesn’t respond when the buttons are pressed) Check: 1. that the terminal hasn’t been disconnected and then reconnected to the pCO without waiting 5 seconds. In that case switch the pCO off and on again with the terminal connected; 2. that the software on the pCO has been installed correctly using the SMARTKEY or via PC with WinLoad; 3. see chap. 5. 64 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 ENG Note: “pCO5” +0300009EN rel. 1.2 - 24.04.2014 65 ENG Note: 66 “pCO5” +0300009EN rel. 1.2 - 24.04.2014 CAREL INDUSTRIES - Headquarters Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 049.9716611 - Fax (+39) 049.9716600 e-mail: [email protected] - www.carel.com +0300009EN - rel. 1.2 - 24.04.2014 Agenzia / Agency: ">
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Key Features
- 32-bit microprocessor
- 4 or 8 MB memory
- Different sizes according to the number of inputs and outputs
- Easy to interface to building management systems
- High performance and memory space
- Flexibility of application
- High level of reliability
- Standardisation
- Easy configuration and programming
- High transmission speeds
Frequently Answers and Questions
What is the pCO5?
The pCO5 is a programmable controller that can be used to control a wide range of HVAC/R applications.
What are the key features of the pCO5?
The pCO5 has a built-in 32-bit microprocessor and either 4 or 8 MB of memory. It also offers different sizes according to the number of inputs and outputs.
How can I program the pCO5?
The pCO5 can be programmed using the CAREL 1Tool development software.
What are some of the applications of the pCO5?
The pCO5 can be used to control chillers, heat pumps, rooftop units, air conditioners, small/medium-sized air handling units, showcases, cold rooms, curing rooms, compressor racks, and universal stage controllers.
What is the maximum distance between the pCO5 and its user terminal?
The maximum distance between the pCO5 and its user terminal is shown in the following table.