Compu-aire SYSTEM 2200 Plus 3L User manual

Rev.03C 02-19-14
Page 1 of 82
Compu-Aire
SYSTEM 2200+3L
PROGRAMMABLE CONTROLLER
-USER MANUAL-
8167 Byron Road Whittier, CA 90606
Phone: [phone] Fax: [phone]
SUBJECT TO CHANGE WITHOUT INCURRING OBLIGATION

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Compu-Aire
Table of Contents
1.0 INTRODUCTION..................................................................................................................................... 8
2.0 QUICK REFERENCE GUIDE ..................................................................................................................... 8
3.0 SEQUENCE OF OPERATIONS ................................................................................................................. 9
3.1 Standard Units in General............................................................................................................. 9
3.2 How to Turn the Unit ON .............................................................................................................. 9
3.3 Lead/Lag Redundancy –p-LAN Network ...................................................................................... 9
3.4 Air Cooled DX With Chilled Water Plus....................................................................................... 10
3.5 Air Side Economizer ....................................................................................................................11
3.6 Water Side Economizer Energy miser (EM) Unit Using 2-Way Valves........................................ 11
3.7 Water Cooled Energy Miser........................................................................................................ 13
3.8 Dry Fluid Cooler With Energymizer.............................................................................................14
3.9 Special Pump and Dry Fluid Cooler control logic ........................................................................ 16
3.10 Optional features ........................................................................................................................16
4.0 CONFIGURATION.................................................................................................................................17
4.1 Main menu..................................................................................................................................17
4.2 Screen Settings............................................................................................................................ 18
4.3 Network Configuration ...............................................................................................................19
4.4 Network Monitor ........................................................................................................................ 19
4.5 Assigning Private and Shared terminals...................................................................................... 20
4.6 P-LAN Setup ................................................................................................................................ 21
4.6.1 Master Unit (ID=1) .............................................................................................................. 21
4.6.2 Slave Unit (ID=2)..................................................................................................................21
4.6.3 P-LAN WIRING ..................................................................................................................... 22
4.7 General Options ..........................................................................................................................23
5.0 TECHNICAL SPECIFICATIONS ...............................................................................................................24
5.1 Controller and Display................................................................................................................. 24
5.2 General Characteristics ...............................................................................................................24
5.3 Mechanical Characteristics ......................................................................................................... 25
5.4 Electrical Characteristics .............................................................................................................26

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5.5 Digital Inputs ...............................................................................................................................26
5.6 Analog inputs .............................................................................................................................. 26
5.7 Analog Outputs ........................................................................................................................... 27
5.8 Digital Outputs ............................................................................................................................27
5.9 P-LAN Network Terminal ............................................................................................................27
5.10 Cable Length ............................................................................................................................... 27
5.11 Standard Input / Outputs............................................................................................................28
5.12 Optional Features .......................................................................................................................29
5.13 Functional characteristics ...........................................................................................................29
5.14 Building Management System ....................................................................................................29
6.0 CONTROLLER INTERFACE .................................................................................................................... 30
6.1 LED Indicators .............................................................................................................................30
6.2 Navigation Buttons ..................................................................................................................... 30
7.0 Navigation Menu.................................................................................................................................30
7.1 Menu Tree................................................................................................................................... 31
7.2 Accessing Submenus...................................................................................................................32
7.3 Main Menu Selection.................................................................................................................. 32
7.4 Unit Status................................................................................................................................... 32
7.5 Trending ......................................................................................................................................34
7.5.1 Graph Overviews.................................................................................................................34
7.5.2 Icon Description and function.............................................................................................35
7.6 Alarms ......................................................................................................................................... 37
7.6.1 Alarm Viewing and Function ...............................................................................................37
7.6.2 Alarm Reset......................................................................................................................... 37
8.0 SETUP MENU....................................................................................................................................... 38
8.1 Entering a password....................................................................................................................38
8.2 Setup Menu Tree ........................................................................................................................ 39
8.3 Setpoints ..................................................................................................................................... 40
8.3.1 Changing Setpoints .............................................................................................................40
8.3.2 Changing Alarm Setpoints...................................................................................................41
8.4 Clock Setup.................................................................................................................................. 41

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8.4.1 Time and Date Setup........................................................................................................... 41
8.4.2 Night Setback ...................................................................................................................... 41
9.0 RUN TIME HOUR METERS ................................................................................................................... 42
10.0 BUILDING MANAGEMENT SYSTEM (BMS) ..........................................................................................43
10.1 Modbus ....................................................................................................................................... 43
10.1.1 Mounting............................................................................................................................. 43
10.2 POINTLIST.................................................................................................................................... 46
10.3 LONWORKS .................................................................................................................................48
10.3.1 General characteristics ....................................................................................................... 48
10.3.2 Physical channels ................................................................................................................ 48
10.3.3 Physical Circuit Board Layout.............................................................................................. 48
10.3.4 LED Color Description ......................................................................................................... 49
10.3.5 Installation .......................................................................................................................... 49
10.3.6 Connection to the PCO3 Controller ....................................................................................50
10.3.7 Connection to the LonWorks® network.............................................................................. 50
10.3.8 Service pin...........................................................................................................................50
10.3.9 WINK event .........................................................................................................................51
10.4 BACNET OVER TCP/IP..................................................................................................................52
10.4.1 Installation .......................................................................................................................... 52
10.4.2 Functions.............................................................................................................................52
10.4.3 Default parameters .............................................................................................................52
10.4.4 Restarting the software ......................................................................................................53
10.4.5 Configuration ......................................................................................................................53
10.4.6 Web server.......................................................................................................................... 55
10.4.7 Accessing the operating system by authentication ............................................................55
10.4.8 CGI script............................................................................................................................. 56
10.4.9 SNMP...................................................................................................................................56
10.4.10 BACnet.............................................................................................................................56
10.4.11 WARNINGS ......................................................................................................................56
10.5 BANET over MS/TP...................................................................................................................... 57
10.5.1 Installation .......................................................................................................................... 57

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10.5.2 Meaning of the jumpers...................................................................................................... 58
10.5.3 Operation ............................................................................................................................58
10.5.4 Recalling the factory configuration (“factory bootswitch” mode) ..................................... 60
10.5.5 Configuration ......................................................................................................................60
10.5.6 BACNET Parameter Description ..........................................................................................61
11.0 TECHNICIAN MENU ............................................................................................................................. 62
11.1 Alarm Setup.................................................................................................................................62
11.1.1 Available Alarms..................................................................................................................64
11.1.2 Sensor Offset....................................................................................................................... 66
11.1.3 Digital Input.........................................................................................................................66
11.2 Network Setup ............................................................................................................................ 67
11.2.1 Define a Network ................................................................................................................ 67
11.2.2 Network Assist .................................................................................................................... 67
11.3 Manual Control ...........................................................................................................................68
12.0 FACTORY SETTING............................................................................................................................... 69
12.1 Factory Setting Menu Tree .........................................................................................................69
12.1.1 Digital Inputs and Digital Outputs....................................................................................... 70
12.1.2 HVAC ...................................................................................................................................72
12.1.3 Analog Inputs and Analog Outputs ..................................................................................... 75
12.1.4 Changing Passwords............................................................................................................77
12.2 Factory Reset ..............................................................................................................................77
13.0 TROUBLESHOOTING GUIDE ................................................................................................................78

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Table of Figures
Figure 1–Configurations screen ................................................................................................................. 17
Figure 2 - Screen calibration .......................................................................................................................18
Figure 3–Changing unit ID...........................................................................................................................20
Figure 4 - Touch sensitive graphical display............................................................................................... 24
Figure 5 –Controller ................................................................................................................................... 24
Figure 6 - Internal built in display ...............................................................................................................24
Figure 7 –Graphical user interface............................................................................................................. 30
Figure 8 - Main Menu.................................................................................................................................. 31
Figure 9 - Unit general status......................................................................... Error! Bookmark not defined.
Figure 10 - Room demand icons .................................................................... Error! Bookmark not defined.
Figure 11- Graphical sensors representation.............................................................................................. 34
Figure 12 - Graph description .....................................................................................................................34
Figure 13 - Pressure graph ..........................................................................................................................34
Figure 14–Alarm History ............................................................................... Error! Bookmark not defined.
Figure 15–Password prompt.......................................................................................................................38
Figure 16 - Entering a password .................................................................................................................39
Figure 17 - Setup menu............................................................................................................................... 39
Figure 18 - Setup Menu Tree ...................................................................................................................... 39
Figure 19 - Room temperature setpoints ...................................................................................................40
Figure 20 - Room humidity setpoints..........................................................................................................40
Figure 21 - Clock setup................................................................................................................................41
Figure 22 - Component run time meters .................................................................................................... 42
Figure 23 - Building management system...................................................................................................43
Figure 24 - Communication protocol .......................................................................................................... 43
Figure 25 - LONTalk Card ............................................................................................................................48
Figure 26 - Remove plastic cover ................................................................................................................ 50
Figure 27- Cut out window ......................................................................................................................... 50
Figure 28 - Installing plugin card................................................................................................................. 50
Figure 29 - Replacing windows cover..........................................................................................................50
Figure 30 - PCOWeb....................................................................................................................................54
Figure 31 - Window cover........................................................................................................................... 54
Figure 32 - Installing PCOWeb .................................................................................................................... 54
Figure 33 - Installing plastic cover............................................................................................................... 54
Figure 34 - Alarm configuration ..................................................................................................................62
Figure 35 - Alarm delays..............................................................................................................................64
Figure 36 -Alarm switch over ...................................................................................................................... 64
Figure 37 - Network Setup ..........................................................................................................................67
Figure 38 - Network Assist ..........................................................................................................................67
Figure 39 - Factory Setting ..........................................................................................................................69

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Figure 40 - Digital input configuration ........................................................................................................70
Figure 41 - Digital output configuration ..................................................................................................... 71
Figure 42 Fan Setup .................................................................................................................................... 72
Figure 43 Sensor Setup ............................................................................................................................... 72
Figure 44 Compressor Setup.......................................................................................................................72
Figure 45 Compressor Option..................................................................................................................... 72
Figure 46 Compressor Stage ON/OFF ......................................................................................................... 73
Figure 47 Low Pressure Retry .....................................................................................................................73
Figure 48 Humidifier ................................................................................................................................... 73
Figure 49 Humidity Lockout........................................................................................................................73
Figure 50 Heater Setup ............................................................................................................................... 73
Figure 51 Heating Demand .........................................................................................................................73
Figure 52 - Analog input configuration ....................................................................................................... 75
Figure 53 - Analog output configuration..................................................................................................... 76
Figure 54 - Changing default password.......................................................................................................77
Figure 55 - Factory reset / Set Unit Mode .................................................................................................. 77

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1.0 INTRODUCTION
The System 2200+3L is a programmable controller based on a double microprocessor, designed
for precise "Smart" control of an air conditioning system. The System 2200+3L is made up of a
microprocessor based MAIN BOARD equipped with a set of terminals used to interface the
microcontroller board to the controlled devices; such compressors, fans, heaters, humidifiers,
and valves. The program is retained in a flash based memory and configuration parameters are
permanently stored (even in the case of a power failure) in a non-volatile memory.
The System 2200+3L also includes a microprocessor based TERMINAL unit complete with
graphical touch screen display with built in navigation keypad and led indicators allowing the
users to easily set the controlled parameters for set points, dead bands, alarm thresholds, and
carry out the main working operations (on/off, displaying controlled variables, printouts). The
controller and graphical display terminal are powered by 24VAC power supply using low voltage
control transformers from the unit. Connection between the terminal unit and main board is
necessary only when programming the System 2200+3L basic parameters. The controller is
linked to a graphic display terminal via standard three wire cable.
2.0 QUICK REFERENCE GUIDE
The controller is fully programmed and pre-configured per system configuration. Further
tweaking may be required to better fit the application.
For remote mounted controllers, make sure the UNIT ID is matching with the Tag ID
number.

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3.0 SEQUENCE OF OPERATIONS
3.1 Standard Units in General
In general, the controller is operated as follows. Note that the followings are applicable while the
controller is in active mode and only apply to DX and Chilled Water units.
•Fan starts up on demand for cooling, heating, humidifying or dehumidifying, or operates
continuously
•Sequences the compressors on in stages with programmable delays to meet demand for
cooling and dehumidification
•Sequences the heaters on in stages with programmable delays to meet demand for heating
or reheat during dehumidification mode
•Activates the humidifier as needed to meet the humidity demand
•Dehumidification is achieved by means of cooling to reduce the humidity level. During the
dehumidification process, if the temperature falls below the room set point, heating is
brought on to reheat the air and maintain room temperature.
•The controller monitors the complete system for any sensors, fans, compressors, heaters
and humidifier failure. Upon critical failures, the complete system will shut down with
alarm. For certain component failures, the applicable feature is disabled to insure safe
operation. For example, when compressor failure occurs, the failed compressor shall be
locked out but the system shall provide cooling by other compressor if available. On a
heater failure, the heaters are locked out. The system will not use that function until
manually reset on the display. The controller also keeps the history of last 100 alarms after
you reset them.
3.2 How to Turn the Unit ON
Press the Power button ON/OFF key once to turn it ON and press it again to turn it OFF
The System Status screen should indicate the current system operating mode
Default time delay is 30 seconds to avoid short cycling
Unit will automatically control the necessary mode of operation to maintain room setpoints
3.3 Lead/Lag Redundancy –p-LAN Network
System 2200+ series controllers can be set for n+ redundancy setup. A maximum of 16 units can
be linked together on the p-LAN network. The p-LAN networked units are identified with unit ID
numbers. The p-LAN software resides in the unit ID# U01 which is also called as a MASTER unit. All
the other units on that network are considered as SLAVE units. Each controller is self-dependent
with necessary sensors and it can be used as a stand-alone unit. When used on the p-LAN
Network, each unit must have the same software revision and set to maintain the same set points
and safety alarms. The unit U01 must be set for the total units on the network.
When more than one unit are connected through p-LAN network for lead/lag operation, the first
controller, unit ID# U01 is defined as the “Master” and the rest (U02, U03 ….U16) are define as

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“Slave”. The Master always starts first to maintain the temperature and humidity set points. The
Slave is kept on standby as long as the Master is able to achieve the set points within the dead
band. When the Master fails to do so, it calls in the Slave to assist. Then both units will be
running towards the targets set on the Master (set points on the Slave is irrelevant in this
situation). The Slave drops out when set points are achieved. When the Master fails by any of
the selectable failures (such as compressor high/low pressure failure and fire alarm), the Master
drops off and the Slave comes in to work independently according to its own set points until the
Master is recovered. When the system is reset and restarted, the Master comes in first and
follows the above rules.
The units can be set to cycle to achieve equal run time on each unit. At the end of each cycle, the
role of each unit switches to its counterpart, meaning the Master becomes the Slave and the
Slave becomes the Master during the next cycle. During each cycle, the units operate according
to the above lead/lag logic.
3.4 Air Cooled DX With Chilled Water Plus
Summary of Equipment
The primary system shall be Chilled Water Cooling. Direct Expansion Cooling shall be setup as a
back up to the Chilled Water system. Both systems are designed to work independent of each
other.
The Chilled Water System comes standard with a three (3) way water modulating valve, coil, and
an optional “no water flow switch”. The DX system is equipped with a DX coil, compressor(s), and
outdoor air cooled condenser. Optional heaters and humidifiers are also available if needed.
A unique feature of Air Cooled/Chilled Water Plus units is that the chilled water coil is located at
the side of the direct expansion coil. The auxiliary chilled water coil is custom sized so that it
provides identical cooling capacity obtained during the refrigeration cycle with the compressor
operating.
Cooling-Chilled Water
Chilled Water cooling is the primary cooling system for C+ units. For optimum performance, the
controller is programmed to call chilled water cooling for the first 300 seconds regardless of the
chilled water temperature.
The C+ unit can switch over from one cooling mode to another based on sensing Chilled Water
flow or Chilled Water temperature. The standard practice is to sense the Chilled Water flow for
switching.
If “No Water flow”switch is selected, the unit senses the flow of chilled water by using a pressure
differential switch and switches over to DX cooling based on loss of water flow. When no water
flow switch is selected for switch over, the unit will only work on either DX or C.W. cooling mode.