Carel FLSTDMAHUE User manual

Integrated Control Solutions & Energy Savings
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
FLSTDMAHUE
User manual
Application for managing air handling units with
integrated DEC - IEC

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Warning
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 subYESdiaries
nonetheless cannot guarantee that all the aspects of the product and the
software included with the product respond to the requirements of the
nal application, despite the product being developed according to start-
of-the-art techniques.
The customer (manufacturer, developer or installer of the nal equipment)
accepts all liability and risk relating to the conguration of the product
in order to reach the expected results in relation to the specic nal
installation and/or equipment.
CAREL may, based on specic agreements, act as a consultant for the
poYEStive commisYESoning of the nal unit/application, however in no
case does it accept liability for the correct operation of the nal equipment/
system.
The CAREL product is a state-of-the-art product, whose operation is
specied in the technical documentation supplied with the product or can
be downloaded, even prior to purchase, from the webYESte www.CAREL.
com.
Each CAREL product, in relation to its advanced level of technology,
requires setup / conguration / programming / commisYESoning to be
able to operate in the best possible way for the specic application. The
failure to complete such operations, which are required/indicated in the
user manual, may cause the nal product to malfunction; CAREL accepts
no liability in such cases.
Only qualied 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 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 corroYESve 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 specied 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 specied 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 corroYESve chemicals, solvents or aggressive detergents
to clean the device.
• Do not use the product for applications other than those specied 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 specications shown in the manual may be changed without
prior warning.
The liability of CAREL in relation to its products is specied in the CAREL
general contract conditions, available on the webYESte www.CAREL.
com and/or by specic agreements with customers; specically, to the
extent where allowed by applicable legislation, in no case will CAREL,
its employees or subYESdiaries 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 imposYESbility
to use the product, even if CAREL or its subYESdiaries are warned of the
posYESbility of such damage.
The product must be installed with the earthconnected, using the
special yellow-green terminal on the terminal block. Do not use the
neutral for the earth connection.
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
WARNING: separate as much as possible the probe and
digital input signal cables from the cables carrying inductive
loads and power cables to avoid possible electromagnetic
disturbance. Never run power cables (including the electrical
panel wiring) and signal cables in the same conduits
Warranty on the
materials:
2 years (from the date of production, excluding
consumables).
Approval: the quality and safety of CAREL INDUSTRIES Hqs
products are guaranteed by the ISO 9001 certied
design and production system.
DISPOSAL
INFORMATION FOR USERS ON THE CORRECT HANDLING OF WASTE
ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE)
In reference to European Union directive 2002/96/EC issued on 27 January
2003 and the related national legislation, please note that:
• WEEE cannot be disposed of as municipal waste and such waste must be
collected and disposed of separately;
• the public or private waste collection systems dened by local legislation
must be used. In addition, the equipment can be returned to the
distributor at the end of its working life when buying new equipment;
• the equipment may contain hazardous substances: the improper use or
• incorrect disposal of such may have negative eects on human health
and on the environment;
• the symbol (crossed-out wheeled bin) shown on the product or on the
• packaging and on the instruction sheet indicates that the equipment
has been introduced onto the market after 13 August 2005 and that it
must be disposed of separately;
• in the event of illegal disposal of electrical and electronic waste, the
penalties are specied by local waste disposal legislation.

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Content
1. INTRODUCTION 7
1.1 Main features ..................................................................................................................................7
1.2 Accessories available for FLSTDMAHUE.........................................................................7
2. COMMUNICATION PORTS 10
2.1 Serial ports.....................................................................................................................................10
3. HARDWARE INSTALLATION 11
3.1 DIN rail assembly and dimensions .................................................................................11
3.2 Description of the terminals on the pCO Large.....................................................11
3.3 Installation .....................................................................................................................................12
3.4 Connection of the analogue inputs..............................................................................12
3.5 Connecting the digital inputs...........................................................................................13
3.6 Connecting the analogue outputs ................................................................................14
3.7 Connecting the digital outputs........................................................................................14
3.8 Connecting the fan inverter via analogue input...................................................14
3.9 Connecting serial devices with Modbus/Belimo® protocol...........................14
3.10 Remote terminal with pLAN network..........................................................................14
3.11 Connection diagrams.............................................................................................................15
3.12 DEC-IEC functional diagram...............................................................................................18
4. USER INTERFACE 19
4.1 Graphic terminal........................................................................................................................19
4.2 Display e tastiera........................................................................................................................19
4.3 Programming mode................................................................................................................19
5. MENU DESCRIPTION 21
5.1 A. On/O Unit ................................................................................................................21
5.2 B. Setpoint ........................................................................................................................21
5.3 C. Clock/Scheduler.....................................................................................................22
5.4 D. Input/Output ........................................................................................................22
5.5 E. Data logger..................................................................................................................23
5.6 F. Board switch................................................................................................................23
5.7 G. Service..........................................................................................................................23
5.8 H. Manufacturer ........................................................................................................24
6. SOFTWARE INSTALATION 25
6.1 pCO Manager ..............................................................................................................................25
6.2 SmartKey ........................................................................................................................................25
6.3 USB pen drive .............................................................................................................................26
6.4 Setting the terminal address..............................................................................................27
7. SOFTWARE CONFIGURATION 28
7.1 Select devices (Ha) ...................................................................................................................28
7.2 Congure devices (Ha)...........................................................................................................28
7.3 Assign inputs/outputs (Hb) ................................................................................................28
7.4 Device control parameters (Hc).......................................................................................30
7.5 pCOe expansion card connection..................................................................................30
7.6 Serial probe connection .......................................................................................................30
7.7 VFD inverter connection.......................................................................................................31
7.8 Belimo actuator connection ..............................................................................................31
7.9 Probes from supervisor..........................................................................................................32

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8. COMMISSIONING 33
8.1 Loading the conguration ..................................................................................................33
8.2 Commissioning ..........................................................................................................................33
8.3 Probe calibration .......................................................................................................................33
8.4 Setting the control parameters........................................................................................33
8.5 Setting the hour counters ...................................................................................................33
8.6 Enthalpy management..........................................................................................................33
8.7 I/O test..............................................................................................................................................33
9. FUNCTIONS 34
9.1 On/O ..............................................................................................................................................34
9.2 Set point..........................................................................................................................................35
9.3 Temperature control ...............................................................................................................35
9.4 Humidity control .......................................................................................................................36
9.5 Temperature / humidity control / no priority..........................................................38
9.6 Set point compensation.......................................................................................................39
9.7 Summer/winter changeover .............................................................................................40
9.8 Freecooling and freeheating..............................................................................................40
9.9 Heat recovery...............................................................................................................................42
9.10 Cascade control..........................................................................................................................43
9.11 Supply limits.................................................................................................................................44
9.12 Direct evaporative cooling - DEC....................................................................................45
9.13 Indirect evaporative cooling - IEC...................................................................................46
9.14 IEC limitation from algorithm/probe ............................................................................47
9.15 IEC limitation from mixing damper/bypass damper opening......................48
9.16 Coils water temperature limits..........................................................................................48
9.17 Pump management................................................................................................................49
9.18 Cooling devices..........................................................................................................................50
9.19 Heating devices..........................................................................................................................50
9.20 Fan management......................................................................................................................50
9.21 Air quality.......................................................................................................................................52
9.22 Purging ............................................................................................................................................53
9.23 Frost protection..........................................................................................................................53
9.24 Auxiliary control.........................................................................................................................54
9.25 Fireman override........................................................................................................................54
10.PARAMETERS TABLE 55
9.1 BMS variables...............................................................................................................................76
11.ALARMS 87
11.1 Types of alarms ...........................................................................................................................87
11.2 Alarm log........................................................................................................................................87
11.3 Alarm table....................................................................................................................................87
12.PCO MANAGER 90
12.1 Installation ....................................................................................................................................90
12.2 PC - pCO controller connection.......................................................................................90
12.3 Commissioning ..........................................................................................................................90

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1. INTRODUCTION
FLSTDMAHUE is an application program developed by CAREL for the
management of air handling units (AHU). It runs on the pCO5+ range of
programmable controllers (pCO5+ small, medium, large), selected according
to the complexity of the unit, and the pGD1/pLDPRO terminal. Its main feature
is its adaptability to many types of air handling unit, with dierent types of
probes and actuators, on/o type or modulating. Moreover, the possibility to
connect up to two pCOe serial options via RS485 card allows additional probes
and outputs to be added, ensuring maximum exibility. Alternatively, the MP-
Bus® card can be used to connect up to 8 Belimo®, actuators each with its probe
or digital input; this eliminates a lot of the wiring needed during installation.
CAREL temperature, humidity and combined serial probes can be connected,
for both rooms and ducts, as well as active dierential pressure probes, ow
switches and pressure switches to signal alarms following faults on fans or
pumps. The supply and return air fans can be controlled by inverter based
on pressure, ow-rate, speed or air quality requirements. The control software
can manage temperature or humidity as the priority, control an adiabatic
or isothermal humidier, freecooling/freeheating based on enthalpy and
humidity recovery using a heat wheel. The possibility to integrate adiabatic
humidiers into temperature control (with direct evaporative cooling - DEC,
and indirect evaporative cooling - IEC) means the desired conditions can be
reached extremely eectively and eciently. The commissioning procedure is
based on the documented design of the air handling unit being controlled:
the inputs and outputs can be assigned dynamically, meaning there is no xed
position for the various types of probes/actuators connected, with the software
proposing the rst position available for the type of input/output (e.g. a certain
input can accept a passive NTC probe or active probe with 0 to 1 V or 4 to
20 mA output). The identication of the type of AHU being controlled is not
based on the choice between a certain number of pre-congured units; rather
the selection of the devices installed on the AHU (e.g. preheating / cooling
/ reheating coils, fans, pumps, inverter, heaters, dampers, humidiers, heat
recovery unit) and then setting their parameters. This simplies conguration,
as the user only sees the parameters relating to the components used. Changes
can be made subsequently to the conguration without needing to start again
from scratch.
1.1 Main features
• Parameter settings divided by level, user, installer or manufacturer, with
password-protected access;
• temperature and/or humidity control with dierentiated set point in
cooling and heating;
• automatic cooling/heating changeover;
• set point compensation in cooling and heating;
• selection of up to four daily time bands, with settings for each operating
mode;
• holiday and special day function, with reduced set point;
• cascaded control of heating / cooling devices so as to maximise energy
saving;
• operation in comfort, precomfort or economy mode, if time bands are
enabled;
• management of pumps, including in tandem, for preheating cooling/
reheating coils, with rotation, backup, overload alarms and anti-blocking
for each pump;
• minimum water temperature limit settable for opening the coil valves;
• dehumidication by cooling (also with dew point, or specic humidity set
point control) and reheating coil;
• bands for activating the preheating and reheating devices can be
overlapped to supplement each other;
• ON/OFF or modulating control of isothermal or adiabatic humidiers;
• “freecooling” and “freeheating”based on temperature or enthalpy;
• management of adiabatic humidiers for direct (DEC) and indirect
evaporative cooling (IEC);
• heat recovery with cross-ow heat recovery unit, run-around coil or heat
wheel, based on temperature or enthalpy;
• fan control by inverter based on pressure, ow-rate, speed or air quality
requirements;
• management of fans, including in tandem, with rotation and backup
functions;
• air quality control with CO2 and VOC (volatile organic compounds) probes;
• safety protectors for antifreeze, dirty lters, smoke/re, no air or water ow,
humidier alarm, inverter alarm, open door alarm;
• unit antifreeze and room protection;
• up to 4 independent auxiliary control loops, each with its own PI control
and control probe (for example to manage a second humidier);
• input/output test to check correctness of wiring during installation;
• connection via FieldBus port to serial probes, inverters, pCOe expansion
card;
• connection via BMS port to supervisor (PlantVisorPRO, PlantWatch…),
sending the values read by four probes.
1.2 Accessories available for FLSTDMAHUE
Below is a list of devices suitable for use with FLSTDMAHUE. CAREL features
passive, active and serial temperature, humidity and dierential pressure
probes, for room or duct installation, specically for the air handling unit
appliance. See the CAREL price list for the complete list.
Room temperature and humidity sensor
(Technical leaet +050001240)
Temperature sensors
P/N Type Range
DPWT011000 NTC -10T60°C
DPWT010000 0…1 V, 4…20 mA
DPWT014000 RS485 serial opto
Temperature and humidity sensors
P/N Type Range
DPWC112000 0…10 V, 0…10 V -10T60°C,10…90% RH
DPWC115000 NTC, 0…10V
DPWC110000 0…1 V, 4…20 mA
DPWC114000 RS485 serial opto
DPWC111000 NTC, 0…1V, 4…20mA
DPPC112000 0…10 V, 0…10 V -10T60°C,10…90% RH
DPPC110000 0…1 V, 4…20mA
DPPC111000 NTC, 0…1 V, 4…20mA
Duct temperature and humidity sensor
(Technical leaet +050001245)
Temperature sensors
P/N Type Range
DPDT011000 NTC -20T70°C
DPDT010000 0…1 V, 4…20 mA
DPDT014000 RS485 serial opto -20T60°C
Temperature and humidity sensors
P/N Type Range
DPDC112000 0…10 V, 0…10 V -10T60°C, 10…90% RH
DPDC110000 0…1 V, 4…20 mA
DPDC111000 NTC, 0…1V, 4…20mA
DPDC114000 RS485 serial opto

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Outdoor sensors
(Technical leaet +050001790)
P/N Type Range
DPUT011000 Temperature -50T90°C, resistive output NTC 10kΩ@25°C
DPUC110000 Temperature -35T80°C, resistive output NTC 10kΩ@25°C & 4-20 mA
Humidity 10 to 90 RH, 4 to 20 mA output
NTC temperature sensors
(Manual +030220655)
P/N Type Range
NTC*HP* 10 k±1%@25 °C, IP67 -50…105/50°C (air / uid)
NTC*WF* 10 k±1%@25 °C (Fast), IP67 -50…105°C (fast)
NTC*WHP* 10 k±1%@25 °C, IP68 -50…105°C
NTC*HF* 10 k±1%@25 °C,strap-on, IP67 -50…90°C 105°C
NTC*WS* 10 k±1%@25 °C, IP67 -40…105°C
PT1000 temperature sensors
(Manual +030220655)
P/N Type Range
PT1*HP* IP67 -50…105/50°C (air/ uid)
PT1*WF* IP67 -50…105°C
PT1*WP* IP67 -50…105°C
PT1*HT* IP67 -50…250°C
PT1*HF* IP67, strap on -50…105°C
Room air quality sensors
(Technical leaet +050001300)
DPWQ* DPDQ*
CO2 Sensors
P/N Range Output
DPWQ402000 0…2000 ppm 0…10 V
DPDQ402000 0…2000 ppm 0…10 V
CO2and VOC Sensors
P/N Range Output
CO2VOC
DPWQ502000 0…2000 ppm 0…100 % 0…10 V, 0…10 V
DPDQ502000 0…2000 ppm 0…100 % 0…10 V, 0…10 V
Dierential air pressure sensors
(Technical leaet +050000651)
P/N Range Output
SPKD00U5N0 0...1000 Pa; 0...2500 Pa; 0...3000 Pa; 0...5000 Pa 4...20 mA
SPKD00C5N0 -50...+50 Pa; -100...+100 Pa; 0...+50 Pa; 0...+100 Pa 4...20 mA
Dierential air pressure switches/ow switches
(Technical leaet +050000645/ +050000647)
Pressure switches
P/N Range Output
DCPD000100 0.5…5 mbar ON/OFF
DCPD001100 0.2…2 mbar ON/OFF
Flow switches
P/N Range Output
DCFL000100 1…9 m/s ON/OFF
Smoke and re sensors
(Technical leaet +050000520)
P/N Type Output
SFFS000000 Smoke detector, 24 Vdc PS ON/OFF
SFFF000000 Fire detector, 24 Vdc PS ON/OFF
USB /RS485 converter code CVSTDUTLF0/ CVSTDUMOR0
(Technical leaet +050000590)
CVSTDUTLFO CVSTDUMOR0
The USB/RS485 converter code CVSTDUTLF0 is used to connect a personal
computer running the pCO Manager program to the pLAN port (J10) on the
pCO controller, via a telephone connector. Alternatively, the CVSTDUMOR0
converter can be connected to other ports (gure).
Once the connection has been made, the application program software can
be loaded and the parameters set. See chapters “Software installation” and
”Appendix”.
CVSTDUTLF0
POWER SUPPLY
USB-RS485 converter
USB
C1
NO1 NO2 NO3
C1 C4
NO4 NO5 NO6
C4 C7
NO7
C7
NO8
C8
NC8
G G0
U1 u2 GND +VDC
+Vterm GND +5 VREF
U4 GND U5 GND
VG VG0 Y1 Y2 Y3 Y4
ID1 ID2 ID3 ID4 ID5 ID6 ID7 ID8 IDC1
J1
J10
FieldBus card BMS card
input: 24 V 50...60 Hz / 28...36 V
max. power: 45 VA/20W
CANL
CANH
GND
OFF
43 2 1
ON
J25
BMS2
CVSTDUMOR0
CVSTDUMOR0
pCO Manager
connessioni in alternativa
alternative connections
Fig. 1.a

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Smart key cod. pCOS00AKY0
(Technical leaet +050003420 / +050003410)
Smart key PCOS00AKC0
The Smart key is an electronic device used to program and service the pCO
family controllers. It simplies the transfer of data between the controllers
installed and a personal computer by exploiting the high capacity ash
memory for storing software applications, BIOS and variable logs. The pCO
is connected directly via the telephone connector using the cable supplied,
while to transfer the data to a personal computer, the USB adapter code
PCOS00AKC0 is required. The power supply comes either via the USB port on
the PC or from the controller, therefore no external power supply is needed.
Belimo MP-BUS card code PCO100MPB0
(Technical leaet +050003270)
This card connects the pCO to an MP-Bus network of I/O devices that use
the Belimo® standard. Up to 8 actuators can be connected at the same time,
over a maximum distance of 30 m. It is installed in the slot marked“eld card”..
BMS 485/Modbus card code PCOS004850
(Technical leaet +050003237)
This optically-isolated card connects the BMS serial port to an RS485 network,
for example to run the commissioning procedure from a personal computer
installed with pCO Manager. It is installed in the slot marked“serial card”. Once
commissioning has been completed, it can be replaced with one of the cards
listed in the table.
BMS cards Code
Ethernet card PCO1000WB0
BACnet MS/TP 485 card PCO1000BA0
Konnex PCOS00KXB0
LON PCO10000F0
pGD1 terminal
(Technical leaet +050001050)
The pGD1 graphic display is an electronic device that allows graphics
management using the icon-based display as well as supporting international
fonts.
pLDPRO terminal
(Technical leaet +050001840)
The pLDPRO graphic display is an electronic device that allows the complete
graphics management through the use of icons and international fonts. The
terminal oers a wide range of operating temperatures (-20T60 °C) and the
front panel guarantees a high degree of protection (IP65).
VFD inverter (serie Delta)
CAREL VFD inverters are available in various sizes for controlling fans at
constant pressure or xed speed. See “Connecting the VFD inverter”.
pCOe expansion card
(Technical leaet +050003265)
The expansion card code PCOE004850 is an electronic device, part of the
pCO sistema family, designed to increase the number of inputs and outputs
available on pCO controllers.
Belimo® actuators
The MP- Bus card can be used to control up to 8 Belimo® valve and damper
actuators, each where necessary with their probe or digital input, meaning
signicant savings in wiring required during installation.

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2. COMMUNICATION PORTS
2.1 Serial ports
See the pCO5+ manual +0300020EN for the hardware features of the serial
ports. The FLSTDMAHUE software manages the protocols shown in the table
on the specied serial ports.
Serial Type/ Connectors Protocol
Serial ZERO pLAN/J10, J11 pLAN
Serial ONE BMS 1 Serial card Extended Modbus
CAREL RS485
WinLoad
Serial TWO FieldBus 1 Serial card MP- Bus Belimo
Modbus Master
Serial THREE BMS 2 / J25 Extended Modbus
CAREL RS485
WinLoad
Serial FOUR FieldBus 2 / J26 (and J23 on Large and Extralarge version) Modbus Master
C1
NO1 NO2 NO3
C1 C4
NO4 NO5 NO6
C4 C7
NO7
C7
NO8
C8
NC8
NO12
C12
NC12
NO13
C13
NC13
C9
NO9
NO10 NO11
C9
G G0
U1 U2 U3 GND +VDC
+Vterm GND
+5 VREF
U4 GND U5 GND
VG VG0 Y1 Y2 Y3 Y4
ID1 ID2 ID3 ID4 ID5 ID6 ID7 ID8 IDC1
U6 U7 U8 GND
ID9 ID10 ID11 ID12 IDC9 ID13H ID13 IDC13 ID14 ID14H
J1 J24 J2 J3 J4 J5 J7
J8
J20
J21
J14
J10
J13
J12
J22
J16 J17 J18
J15
J6
J19
NO14
C14
NC14
NO15
C15
NC15
C16
NO16
NO17
NO18
C16
ID15H ID15 IDC15 ID16 ID16H Y5 Y6 ID17 ID18 IDC17 U9 GND U10 GND
FieldBus card BMS card
J23 FBus2
J11 pLAN
J25 BMS2 J26 FBus2
43 2 1
ONLY FOR
LARGE AND EXTRALARGE
MODELS
Fig. 2.b