Alphacool Heatmaster User manual

ALPHACOOL HEATMASTER
Measure, Control,
Monitor, Alarm, Protect,
...PC independent.
User guide V 1.0

Contents
Part 1
System requirements and features 3
Hardware fitting and installation 4
Connection definitions
Software installation drivers and Heatmaster software 8
Quick start up 11
Appendix 1 Application of control-loops 17
Appendix 2 Alarm conditions 18
Appendix 3 Controlling pumps with Heatmaster 19
Part 2
Heatmaster software functions – Basics and menu 21
Appendix A Sensor calibration 29
Appendix B PID-functions of the control-loops variables 31
Correct operation and guarantee 33
Statement of conformity 34
2

System requirements
Minimum configuration
PC Intel Pentium ® III 1 GHz* / AMD Athlon ® 1 GHz*, 12 MB Ram*, 20 MB free hard disc
capacity, USB 2.0
Operations system
Microsoft Windows XP ® service pack 2, Microsoft Windows Vista ® 32/64 bit service pack 1
* After the setup and operation without windows the requirements for the memory and CPU are not
needed.
Features
Independent from PC-software. After the setup of Heatmaster, all settings are saved in Heatmaster.
After system installation, no need for further connection per USB-cable. There is no burden for
the operating system to interact with USB-device with this feature.
No usage of PC-resources like memory and CPU-calculation time or for an example frame-lost in
PC-games to maintain control measuring and alarm functions.
Three alarm levels (PC-independent warning tone, system alarm on main board-BIOS, shut down
PC).
Windows drag and drop user interface.
Graphic display of delta-values from two temperature sensors.
Log function of temperatures and fan/pump values.
Up to 24 Watt per fan/pump port.
Ability to control/ monitor 4 fans/pumps directly.
Hysterisis-function.
Support/ switch over from Celsius to Fahrenheit, liter and gallons.
Analysis of RPM-values and controlling PWM-values.
Special connection for the flow meter.
Ability to connect NTC temperature sensors, additionally on board-sensor on Heatmaster.
Predefined beta-value to increase measuring accuracy.
Precise sensor calibration is possible through the input of nominal resistance (Rn) at 2 ° and
beta-value.
On board-relay-connection for further controlling is available (alarm compatible).
Up to configurable control-loops per drag and drop with alarm monitoring.
PC-independent alarm.
Extended possibility of influence on the controlling by changing of the PID-parameter.
Updates of software and firmware.
3

Assembly and installation of hardware
The Heatmaster carrier plate and the surface for the Velcro-fastener part must be in a condition of
dust free and free of grease. Otherwise the adhesive side won't bind properly and could dismantle
from the plate later. Use spirit or similar to clean the surface.
Before you select a place and mount Heatmaster, please check the length of cables of Heatmaster
and all other devices such as fans, flow meters, pump and sensors. Use extension cables
optionally.
Please consider in advance, where to set up local, global and if applicable external control-loops
( see Appendix 1).
This eases the controlling and functional attribution of the Heatmaster software and results an
expedient planning of sensors and fans. It could be reasonable under circumstances, to align the
placement of fans basically (see Appendix 1).
1. Stick the Velcro strip enclosed on the metallic surface of the Heatmaster carrier plate.
2. Stick the Velcro-counterpart on the desired place. This can be somewhere in the casing or in an
external place (external cooling system), as the Heatmaster doesn’t need a connection to the PC
per USB-cable later on, after the installation of control-loops. All setups run automatic on
Heatmaster, simply a sufficient powerful 12V DC current source/generator is needed.
(see Declaration of conformity).
3. Connect all devices and cables with the Heatmaster, after it is mounted. (The PC should be
switched off at this situation – power off and cable disconnected). Please follow the instructions
of the topic “Connection Definitions”. Consider the following order:
A Connect the Heatmaster-hardware (power and USB cable – PC is switched off)
B Install USB and serial drivers
C Install the Heatmaster software and follow the instructions
The Heatmaster reacts as a power distributor at the first start of the hardware. All fans and pumps
connected will be controlled with 100% PWM , without the need of the installation of software or
drivers. Control-loops are deactivated.
4

1 2 3 4 6
789101112
Connection – Definitions
1 Power switch (emergency off function)
Connect the on/off switch of the PC casing. Detach the 2-pin-jack/socket of power switch from
main board. 2 pin Jack of the power-switch cable is connected to the left, next on right connect the
2 pin cable and join it with the main board at the power-switch plug. (see the handbook of the main-
board for further details) The pins which are connected together lay vertically one below the other.
In an respective configuration of a control-loop the Heatmaster can shut down your PC immediately,
when the alarm status achieves Level 3. The normal on/off function thereby hasn't changed.
2 Relays
Connect here a device of your choice or a further relay. The Heatmaster relay delivers max. 24
Volt / 30 Watt of switching voltage.
ATTENTION: Don t connect 110/220 Volt devices directly and don t apply 110/220 Volt also!
Mortal danger
Fire danger and
destruction danger!
3 Alarm buzzer
2-pin connection for the acoustic alarm enclosed. The pins which are connected together lay
vertically one below the other(above GND, below voltage).
Attention: If connection is inverted, there is no acoustic warning signal!
4 Thermo sensors
Connections for air or liquid thermo sensors. A sixth sensor is on the Heatmaster board. The
pins which are conneted together lay vertically one below the other.
Flow sensor / Flow meter
Connect a flow meter. The flow meter should use the 3 pin standard connection of a PC fan.

6 Fan / Pump connections
Four standard PC fans or pumps could be connected with 12V DC and up to 24 Watt per
connection. Normally one pump should be used in connection 1 (basic configuration), if one pump
should be controlled through the Heatmaster (see Appendix 3).
ATTENTION: By using with more powerful consumers some components such as Coils etc.
could become hot! Overload danger!
Please consider here the monitoring facilities with the Heatmaster on board sensor and use
a fan if necessary by the temperature 65°C upwards, which cools the electronic system of
the Heatmaster. Otherwise make sure that the Heatmaster is mounted with a casing air flow.
Only two fans at one connection are allowed, if the second fan is connected with a Y-
adapter, which doesn t transmit a tachosignal (third cable misses), and if both fans consume
not more than 24 Watt together.
Please consider that there will be an abrupt capacity fall-off of a pump by regulating it in a
certain shortfall of the voltage, depending on the type of pumps. This is not an error
function of the Heatmaster, usage on your own risk
7 Power connector
Connect here 4-pin socket cable of your PC-power unit.
ATTENTION: if you operate 4 consumers (pumps or/and fans), you need 96 Watt already.
Consider the whole consumption of your PC and output of your PC-power unit, use a special
12 busbar (cable loom), which is not loaded with further strong consumers.
ATTENTION: Don t disconnect the power cable during operation and also don t connect it
during the operation (USB Cable already connected). It could cause damage on Heatmaster
or lost of settings.
8 Main board (CPU FAN)
Connect the enclosed 3-pin cable (Socket/Socket) with the fan connection of CPU fan on the main
board. In case of air cooling CPU, connect the CPU fan to the Heatmaster now. With this the
Heatmaster can be connected to all the alarm and monitoring functions (alarm level 2) of the main
board ( see handbook of your main board, BIOS setups).
9 Reserved
Usage only for manufacturer, please do not connect any device here.
IF NOT DAMAGE ON HEATMASTER IS POSSIBLE
10 Reserved
Usage only for manufacturer, please do not connect any device here
IF NOT DAMAGE ON HEATMASTER IS POSSIBLE
11 Reserved
Usage only for manufacturer, please do not connect any device here.
IF NOT DAMAGE ON HEATMASTER IS POSSIBLE
6

12 USB Connection
Connect the Heatmaster with a free USB-port of your PC. The correct function can only be secured
at a direct PC port. Check long USB cables ( m and more, HUBs and repeater) later, if the basic
function is checked on a PC-USB-port.
After setting up your personal settings (control-loops), the USB cable won't be needed any
more. The Heatmaster saves all settings/control-loops internally and can be operated
automaticaly thereafter. You can disconnect the USB cable now.
Starting software (or integration in to the autostart-windows-file) after setting up personal
settings, control-loops are also not necessary. The Heatmaster consumes no PC resources
such as processing time and memory. For data logging however a USB cable is needed
again.
ATTENTION: THE HEATMASTER IS NOT HOTPLUG-CAPABLE, IF THE SOFTWARE IS
STARTED!
Don t disconnect the power cable during operation and also don t connect it (USB cable
already connected). It could cause damage to Heatmaster or loose settings. It is not
recommended at the moment to use USB and supply voltage to one Heatmaster from two
separate PCs at the same time.
7

Software – Installation
Driver and Heatmaster Software
1 General order of the Installation
A Connect the Heatmaster hardware (Power and USB cable – PC is switched off)
B Install the USB- and serial drivers*
C Install the Heatmaster software and follow the instructions for the installation.*
* The order driver and software installation could be changed. But the software should be
started after the installation of the drivers, so the port is accessible.
2 Driver installation
The Heatmaster hardware will be found and Windows will ask for a suitable driver. Confirm or give
manually the current location of the driver through giving the file path. Turn off the virus-scan or
firewall programs before the installation if necessary.
ATTENTION: No automatic identification of the serial port for Bluetooth compatibility.
Please note down the corresponding port number of the serial port during the driver
installation or look over the installation in the device manager.
8

The driver is signed digitally, but does not take part of further certification of Microsoft. Ignore the
warning message accordingly and click “continue installation any way”
The driver installation takes place for USB and thereafter for the serial-port
If the driver does not show the indicated functions, uninstall the driver and restart the PC. Start the
driver installation again.
After the driver installation, following components should be found in the device manager under USB
devices and COM&LPT (Port number can be different)
9

3 Install Heatmaster Software
Double click on the setup symbol of the Heatmaster software. The setup assistant will help you,
continue installation. At the end of the installation the Heatmaster software asks for the serial port
selected by the driver. Select the relevant port.
With that, the general installation of the Heatmaster is completed. If you don’t have a port to select, check
the driver installation and the correct connection of the Hardware. The onboard-LED of the Heatmaster
hardware should be illuminated permanently green by the first starting up.
Subsequently you enter directly to the main display of the Heatmaster software.
10

Quick introduction
Now, you will experience everything about the complete first operation, including important settings
of the control-loops, without reading the complete instruction manual. With an example setup you
can create your first control-loops. Before you start, please read the Appendix 1 and 2 for a
pure air cooling. If you use water cooling please read Appendix 3 additionally. You will find
further background information of your cooling configuration and control loops. With this quick
introduction you learn only basic functions needed for this example. You get the complete
information in part 2 of the instruction manual.
DRAG&DROP
Select all basic functions and devices from the library (5) through drag and drop with
the mouse over (4) and (12) one of the five possible control loops (13). Deposit back
the functions/devices in the library, which are not necessary.
Scroll / move Prescribed
direction
Both directions incl.
delete / to ( )
2 4
12
13
11
The movements of the mouse are displayed as arrows.
11

2 Monitor
All device icons filled in the monitor-content (4) with the mouse are also displayed in the Monitor (2)
as a graph. The temperature scale is vertically at the left border of the monitor. If you position the
mouse pointer on the monitor you can move the window contents horizontally and vertically.
You can zoom with A D W X, with cursor keys scrolling and connect through the graphs or graphs
recently used by using the keys S, End, End + S, and Delete + End.
4 Monitor Content
All devices (excluding alarm buzzer) are displayed as a graph in the Monitor (2), which are extracted
to the monitor content per drag and drop. A pop-up requester enables the exact choice (e.g. sensor
1- ). You can also drag devices from the monitor content in to a control-loop device window (12). If
you want to remove devices from the monitor content window, drag the device icon over the library
( ) and drop.
Color change of the graphs: To change colors of the graphs in the monitor (2) individually,
double click on the relevant device-icon. In a pop-up window you can select the desired
color.
Library
The library is the first and the central control station of all devices (sensors, fans, pumps etc.) and
functions (alarm…) of the Heatmaster software. From here you can move per drag and drop
device-icons in to the Monitor (2), Monitor content (4), device windows (12) 1 to and all these
among (2), (4) and (12) directly without the library.
11 Control loop Buttons
Every control-loop (13) has three buttons, which indicate different functions in the control-loop-
panel.
Button 1: indicates the device-icons/components of this control-loop. This is the standard display at
the program start. The configuration will be showed through the direct click on the device-icon. Click
alternatively on button 3.
Button 2: indicates the graphs of the devices/components of this control-loop. This function helps
you to classify graphs, if there are many displayed on the monitor.
Button 3: indicates the configuration of the device selected respectively in the control-loop. If you
have selected button 3, look at the small icons of the devices available in the control-loop on the
top left of the control-loop-panel (12). You can shift among different configurations by clicking.
The first icon includes functions for control-loop itself, which are described in the control-
loop (13).
12 Control loop Panel
Here the selected aspects through the buttons (11) are displayed. Place the desired device icons
here from the library ( ) to build up a control-loop. After that the Heatmaster software asks the
possible selection of devices in a pop-up requester (e.g. thermo sensor 1- ). You also can move
device icons in to the other four control-loop panels.
13 Control loop
The Heatmaster software supports up to five control-loops. Control-loops are circuits of the
Heatmaster, which include devices selected by you respectively. Without devices in a control-loop
the Heatmaster cannot undertake controlling function. You select devices per drag and drop from
the library ( ) and drop over the control-loop panel. After doing this, the software asks in a pop-up
requester for selecting free device number (e.g. thermo sensor 1- ).
12

I. Start screen
The display screen shown above corresponds, if all four fans (three fans and one pump) and all thermo
sensors are connected during the first run. The internal temperature sensor is in the monitor content by
default and is displayed as a graph on the monitor. The fan (and one connected pump) run with the full
operating-voltage of 12V.
Device-properties, which are highlighted with star, require hardware restart of
microcontrollers, from the file-menu.
13

II. Add Devices (Monitor Content)
Fan 1 (respectively the pump) is added to the monitor content per drag and drop, through the dragging of
the device icon from the control-loop panel (12) of the monitor (2). The icon can also be dropped on the
monitor. In both these situations graphs will be displayed.
III. Control loop Buttons (Button 2)
One click on button 2 displays the auxiliary graphical view of the devices
respectively, which are in control-loop 1. You can scroll the display, if you
point the mouse on the auxiliary graphic and click the left button.
IV. Control loop Buttons (Button 3 configuration)
If you click button 3, you can see the properties of each components,
which are selected actually with miniature symbols, in the configuration
( In the picture left the loop itself (the frame around the miniature-symbol
shows the selected element)). If you mark “Active”, the control and
function of this loop is activated. If you want to activate Alarm buzzer for
this loop, you must configure the loop over button 3 and mark the
property “Activate alarm buzzer ”. If nothing happens, drag the device
icon for the alarm buzzer from the library ( ) in to the control-loop panel
(12) and also configure the properties Loop1, Sensor T1, Fan1/Pump
over button 3 as wished. With configuration of the sensor/fan repeat this
step with the property “Activate alarm buzzer”. Nothing more is
necessary for the basic function at this moment.
14

V. Setup performance values for fans/ pumps
Specify the desired values for the fans (or for pumps). The value Actual PWM (%) indicates the actual
performance, if the loop is activated. You can specify the values manually, if the loop is not active.
Furthermore the speed and the Achieved RPM are shown. It is about the feedback of the fan/pump,
which is evaluated by the Heatmaster (input). Entered values in PWM are specifications of the
Heatmaster to the device (output)
The highest level of the performance in an active loop is specified with the property Maximum PWM
(%), so that a fan/pump never achieves more than 80% of its performance and runs noisily. In an alarm
situation this value is overrun and the device achieves the maximum 100%.
Changes of Input/Output will be indicated immediately in graphs.
VI. Setup Temperature Values
Specify the desired temperature standards here, which are the basics of
controlling fans/pumps. Example: the currently measured temperature could
be the temperature of your CPU-air-cooler, if the CPU is in idle running (e.g.
0°C). The sensor is also located on the heat sink. When the CPU-
temperature rises in on-load operation and the fan should start working from
8°C, this value is to be entered in the property reference temperature. If
you desired to setup the alarm level 1 from 7 °C, enter this value in alarm
temperature. If the temperature of 7 °C is achieved, the control-loop panel
starts to blink red and shows the exceeded value, the alarm buzzer
(if configured with “Activate alarm buzzer” (see IV)) releases the warning tone for level 1 and the fan
receive 100% PWM. If you don’t take actions, the BIOS-protecting function (if this is in BIOS configured)
will be activated (e.g. sensor/fans) in the level 2 and the alarm changes the tone. In case of a malfunction
of BIOS-protecting function the PC will be shut down at level 3. This is an example of a local loop, which
can also be adjusted in the same way with global or external loop (See Appendix 1).
1

VII. Pumps and fans configuration
To set up these values correctly, you should read the Appendix 3 carefully. First if your pump gives a Tacho
signal, it should already be marked in the property “Comes with Tacho signal”. Otherwise you can do it
now. The Property “Pump connected” shows the Heatmaster, there is no fan in use and other PWM
values are applied, which should be corrected if needed. The icon of fan/pump on Fan will also be
changed, if you deactivate this function. Device properties, which are highlighted with star require
hardware restart of microcontrollers, from the file menu.
VIII. Customization of speed pulses
The number of the “Pulse per rotation” of pumps with Tachosignal and of some fans must be customized,
so that the correct values are indicated. You can get the required information from the manufacturer’s data
and enter here.
Follow these steps for every Control loop you wish to use. The basic setting of the Heatmaster is
finished with that. Leave the USB cable connected for couple of days to adapt the setups if needed.
You can disconnect the cable thereafter, as the Heatmaster saved all your settings locally in the
device and does not need PC resources any more.
16

Appendix 1 Control-loops in Application
Basics and tips
1. Control-loops should be assigned analog to the real positioning of thermo sensors and fans in
PC and should accordingly be assigned with a device symbol as well. Control-loops build generally
units belonging together, for example temperature sensor at Voltage transformer*, the fan for the
Voltage transformer and the alarm buzzer in the control-loop with the name “Voltage Transformer”
(Names for loops can be assigned freely). Control-loops should not be consisted only of a fan and
a minimum sensor, but also of an alarm buzzer, so that the Heatmaster can accomplish its
extensive protective functions. Don’t expect regulation, deactivate the control-loop and enter the
rotation values manually (see fast access, Control-loops (13)).
* (The Voltage transformer acts as an example for CPU, GPU, HDD etc.)
2. A Control-loop can also be consisted only of a Sensor and a Relay.
3.There are three main application scenarios:
A. Absolute air cooling
B. Absolute water cooling systems (active/passive)
C. Water cooling systems with additional air cooling (Casing, Voltage transformer etc.)
A. There are “global” control-loops generally in the absolute air cooling, which feed the whole
casing with cool air or lead away the warm air from the casing. It should be considered, whether
two separate control-loops or one control-loop with for example one fan to inlet the cool air and
another to lead away the warm air should be made. If you use, e.g. two fans to inlet the air in to the
casing, the second fan, which does not transfer RPM, could be coupled with the first one with a Y-
adapter (see the Connection Definitions No 6). Fans, which are coupled likewise, should be
identical in construction. That way you can use more than four fans. But the direct monitoring or
controlling functions for these fans are not possible. To detect the casing temperatures a sensor
should be placed, which does not measure too cold or too warm air. Besides the sensor should not
be placed in a dead-angle, where there is no air circulation.
The second instance is “local” control-loops, e.g. a fan and the relative thermo sensor direct on
the graphic-card, CPU, RAM, Voltage transformer or on the hard-disc. Generally it is to consider,
that more local control-loops can have an effect on each other, if they lay close to each other and
that the local control-loops can be effected by the global control-loops. But in a balanced system for
instance a global control-loop can reduce the running time/RPM of a local control-loop. The
influence is therefore not basically negative.
B. Water cooling systems could be so extensive, that all critical components such as Voltage
transformer, Northbridge, Southbridge, HDDs, GPU, CPU, RAM etc. are water cooled. They are
cooled by bigger radiators, which utilize more fans. In this way e.g. three radiator fans can be
connected in one control-loop with one thermo sensor for the water temperature. However it is
necessary or advisable to have a further global control-loop for casing air circulation, if there is an
extent heating in the casing . Due to countless variation possibilities another two
application instances should be stated:
- The radiator (and with that also the radiator fan) is mounted externally. This is for the simple
controlling, as it is a matter of “external” control-loop, which has no influence from the other
control-loops. The external control-loop is often supplemented by the global and local control-loops.
- Bigger Radiators (e.g. 360s/ triple-radiators) can have double function often: If this is built in and
the air is absorbed/exhausted from the inside of the casing (compare global control-loop), and with
that controlling the water temperature, which again has an influence on the temperature of the
water cooled components.
C. Systems with smaller radiators cool generally only one part of the component with water, e.g.
CPU and GPU. They comply with the local control-loops rather, which exhaust the air from the
inside of the casing to the outside (see A.)
- An exception is that the regulation illustrates passive radiators, as they are mounted externally
and do not use fans. The possibility to monitor the temperature, alarm, flow control and if
applicable pump regulation is limited. Such systems must always be retrofitted by global or local
control-loops.
17

Appendix 2 Alarm situations
There are three alarm situations. Condition is that the control-loops are activated.
After the delay time per level of default 30 seconds the stage increases up to the third stage
maximum.
Stage 3 is normally on for only 10 seconds on, as the casing switch emulate as switched
for 4 seconds during the status 3, and the computer will be shut down.
Different signal will be released from the loud speaker according to different alarm stages.
In stage 3 there is a continuous tone.
The Alarm buzzer device icon is not for the alarm properties of the other device icons
within a control-loop. This device is set up especially for it self. The alarm buzzer is for the
acoustic alarm function of the control-loop.
Stage 1 is activated, if for example a fan does not deliver a Tacho signal any more, even it is
activated or a temperature sensor is over the default alarm temperature, or rather turned out. Also
an absence of the signal from a flow sensor could trigger the alarm.
The fans/pumps are switched to 100% PWM and default values (e.g. maximum PWM 80%)
are ignored.
Stage 2 deactivates the Mother-board Tacho-signal. With respective configuration of the specific
motherboard protecting functions in BIOS, actions will be taken as given.
Stage 3, simulates the push button of the power switch of the casing (emergency switch-off) for 4
seconds. The computer will be shut down.
Relay*, flow meter, fans/pumps, and thermo sensors offer alarm function. The properties of alarm-
buzzer, loops, sensors, and fans/pumps control these functions.
The red Heatmaster-LED blinks at the stage 1, from stage 2 this is permanently on. In an alarm
stage, the port will be informed in every second about the alarm stage, and once after the alarm
stops as well (stage 0).
*The relay cannot trigger the alarm, but in case of an alarm it can commence with further actions.
Triggering of an alarm can be configured freely. fans, flow meters, and temperature sensors can be
configured separately and freely.
18

Appendix 3 Pump controlling with the Heatmaster
If you want to control your pump with Heatmaster, please consider the topic - Connection
Definitions figure 6.
Some pumps deliver a Tachosignal ideally. It is to consider generally, the use of 12V AC-pumps
are not possible. Alphacool-pumps with external AC-DC converter is being tested at the moment
or ask your support.
12 Volt DC-pumps without Tacho signal
An optionally obtainable adapter cable, of which the big 4-pin mole-plug adapted on 3-pin fan-plug,
is necessary to control these pumps such as Alphacool AP 900 or the Laing D .
The pump reacts then as a 12V fan without Tacho-signal* for the Heatmaster. Please consider the
respective properties for the fans-pumps device (Properties “comes with Tachosignal” or “Pump
connected”)
12 Volt DC-Pumps with Tachosignal
Pumps, like Laing DDC series deliver a Tachosignal over a separate connection and provide better
controlling and monitoring possibilities. For this type of pumps an, optionally obtainable adapter
cable is necessary, of which the big 4-pin mole-plug and 3-pin fan-plug with the Tachosignal are
adapted and consolidated on a 3-pin fan-plug.
The pump reacts then as a 12V fan with Tachosignal* for the Heatmaster. Please consider the
respective properties for the fans-pumps device (Properties “Comes with Tacho signal” or “Pump
connected”)
Please consider that the pumps show a complete different type of controlling than fans. Different
type of pumps can cause abrupt fall-off capacity or running problems after achieving a specific
PWM value. Also high flow resistance at low PWM values influence additionally the flow amount.
Therefore you have to check and adjust the default PWM values with your pumps, if needed.**
.
* The benefits are low consumption of current, less noisy system and less mechanical wastage of
the pump. For better monitoring of pumps, it is advisable to have a flow messer.
** The default values are tested with Laing DDC, but cannot consider individual systems with their
different flow resistors. If the alarm functions of the Heatmaster are configured properly, the
possible damages of the hardware are prevented.
19

HEATMASTER INSTRUCTION MANUAL PART 2
EXTENDED SETUP