Compu-aire SYSTEM 2500 User manual

Rev.01 03-27-17
Page 1 of 71
Compu-Aire
SYSTEM 2500
PROGRAMMABLE CONTROLLER
-USER MANUAL-
8167 Byron Road Whittier, CA 90606
Phone: [phone] Fax: [phone]
SUBJECT TO CHANGE WITHOUT INCURRING OBLIGATION

Rev.01 03-27-17
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Compu-Aire
Table of Contents
1.0 INTRODUCTION.....................................................................................................................................7
2.0 QUICK REFERENCE GUIDE .....................................................................................................................8
3.0 SEQUENCE OF OPERATIONS ...............................................................................................................11
3.1 Standard Units in General...........................................................................................................11
3.2 How to Turn the Unit ON ............................................................................................................11
3.3 Lead/Lag Redundancy –pLAN Network......................................................................................11
3.4 Air Cooled DX with Chilled Water Plus........................................................................................12
3.5 Air Side Economizer ....................................................................................................................14
3.6 Water Side Economizer Energy miser (EM) Unit Using 2-Way Valves........................................14
3.7 Water Cooled Energy Miser........................................................................................................15
3.8 Dry Fluid Cooler with Energy Miser ............................................................................................17
3.9 Special Pump and Dry Fluid Cooler control logic........................................................................19
3.10 Optional features ........................................................................................................................20
4.0 CONFIGURATION.................................................................................................................................20
4.1 Software version .........................................................................................................................20
5.0 TECHNICAL SPECIFICATIONS ...............................................................................................................21
5.1 Controller and Display.................................................................................................................21
5.2 General Characteristics...............................................................................................................21
5.3 Mechanical Characteristics .........................................................................................................22
5.4 Electrical Characteristics .............................................................................................................22
5.5 Digital Inputs ...............................................................................................................................23
5.6 Universal inputs ..........................................................................................................................24
5.7 Analog Outputs ...........................................................................................................................25
5.8 Digital Outputs ............................................................................................................................25
5.9 Cable Length ...............................................................................................................................25
5.10 Standard Input / Outputs............................................................................................................26
5.11 Optional Features .......................................................................................................................27
5.12 Functional characteristics ...........................................................................................................27
5.13 Building Management System ....................................................................................................27

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6.0 Navigation Menu.................................................................................................................................28
7.0 Factory Setup ......................................................................................................................................43
7.1 Universal Inputs ..........................................................................................................................43
7.2 Analog Output.............................................................................................................................44
7.3 Digital Inputs ...............................................................................................................................45
7.4 Digital Outputs ............................................................................................................................46
7.5 HVAC ...........................................................................................................................................47
7.6 Loading System Default ..............................................................................................................48
7.7 Password.....................................................................................................................................49
7.8 Clock Setup..................................................................................................................................49
7.8.1 Night Setback ......................................................................................................................49
8.0 BUILDING MANAGEMENT SYSTEM (BMS) ..........................................................................................50
8.1 Modbus .......................................................................................................................................51
8.1.1 Mounting.............................................................................................................................51
8.2 LONWORKS .................................................................................................................................53
8.2.1 General characteristics .......................................................................................................53
8.2.2 Physical channels ................................................................................................................53
8.2.3 Physical Circuit Board Layout..............................................................................................53
8.2.4 LED Color Description .........................................................................................................54
8.2.5 Installation ..........................................................................................................................54
8.2.6 Connection to the Controller ..............................................................................................55
8.2.7 Connection to the LonWorks® network..............................................................................55
8.2.8 Service pin...........................................................................................................................55
8.2.9 WINK event .........................................................................................................................56
8.3 BACNET OVER TCP/IP For BMS Card Add ON .............................................................................57
8.3.1 Installation ..........................................................................................................................57
8.3.2 Functions.............................................................................................................................57
8.3.3 Default parameters.............................................................................................................57
8.3.4 Restarting the software ......................................................................................................58
8.3.5 Configuration ......................................................................................................................58
8.3.6 Web server..........................................................................................................................60

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8.3.7 Accessing the operating system by authentication ............................................................60
8.3.8 CGI script.............................................................................................................................61
8.3.9 SNMP...................................................................................................................................61
8.3.10 BACNET ...............................................................................................................................61
8.3.11 WARNINGS..........................................................................................................................62
8.4 BANET over MS/TP For BMS Card add on...................................................................................63
8.4.1 Installation ..........................................................................................................................63
8.4.2 Meaning of the jumpers......................................................................................................64
8.4.3 Operation............................................................................................................................64
8.4.4 Recalling the factory configuration (“factory bootswitch” mode) .....................................66
8.4.5 Configuration ......................................................................................................................66
8.4.6 BACNET Parameter Description..........................................................................................67
9.0 TROUBLESHOOTING GUIDE ................................................................................................................68

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Table of Figures
Figure 1 User Interface..................................................................................................................................8
Figure 2 Software information....................................................................................................................20
Figure 3 Optional External display ..............................................................................................................21
Figure 4 System 2500 controller.................................................................................................................21
Figure 5 power connection .........................................................................................................................22
Figure 6 Digital inputs .................................................................................................................................23
Figure 7 Analog outputs..............................................................................................................................25
Figure 8. Menu tree ....................................................................................................................................28
Figure 9. Alarm Status.................................................................................................................................29
Figure 10. Universal inputs .........................................................................................................................30
Figure 11. Universal outputs.......................................................................................................................30
Figure 12. Optional sensors ........................................................................................................................31
Figure 13. Communication ports ...............................................................................................................31
Figure 14. BMS2 (RS-485) setup .................................................................................................................31
Figure 15. Trending plot..............................................................................................................................32
Figure 16. Schedule.....................................................................................................................................33
Figure 17. Sensor calibration ......................................................................................................................34
Figure 18. Display setup..............................................................................................................................35
Figure 19. Manual controls .........................................................................................................................35
Figure 20. Network p-LAN menu................................................................................................................36
Figure 21. IP address..................................................................................................................................37
Figure 22. Rotation schedules....................................................................................................................37
Figure 23. Network configuration..............................................................................................................38
Figure 24. Network scan ............................................................................................................................38
Figure 25. IP Configuration ........................................................................................................................39
Figure 26. Network rotation map ..............................................................................................................40
Figure 27. Network setup...........................................................................................................................41
Figure 28. Network Assist ..........................................................................................................................42
Figure 29. Factory setting analog inputs....................................................................................................43
Figure 30. Factory Analog Outputs ............................................................................................................44
Figure 31. Digital Inputs .............................................................................................................................45
Figure 32. Digital Outputs ..........................................................................................................................46
Figure 33. Evap PID tuning .........................................................................................................................47
Figure 34. DX compressor PID tuning ........................................................................................................47
Figure 35. Heat PID tuning .........................................................................................................................47
Figure 36. Humidity PID tuning..................................................................................................................47
Figure 37. Dehumidification PID tuning.....................................................................................................48
Figure 38. Chilled water PID tuning ...........................................................................................................48
Figure 39. Economizer PID tuning..............................................................................................................48

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Figure 40. Assist PID tuning........................................................................................................................48
Figure 41. Hotgas bypass PID tuning..........................................................................................................48
Figure 42. Condenser fan PID tuning .........................................................................................................48
Figure 43. Password management.............................................................................................................49
Figure 44 Date and time..............................................................................................................................49
Figure 45. Night setback.............................................................................................................................50
Figure 46 - Building management system...................................................................................................50
Figure 47 - Communication protocol..........................................................................................................50
Figure 48 - LONTalk Card ............................................................................................................................53
Figure 49 - Remove plastic cover................................................................................................................55
Figure 50- Cut out window .........................................................................................................................55
Figure 51 - Installing plugin card.................................................................................................................55
Figure 52 - Replacing windows cover..........................................................................................................55
Figure 53 - PCOWeb....................................................................................................................................60
Figure 54 - Window cover...........................................................................................................................60
Figure 55 - Installing PCOWeb ....................................................................................................................60
Figure 56 - Installing plastic cover...............................................................................................................60

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1.0 INTRODUCTION
The System 2500 is a programmable controller based on a double microprocessor, designed for
precise "Smart" control of an air conditioning system. The System 2500 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 as 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 2500 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 setpoints, 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 2500 basic parameters. The controller is linked to a graphic
display terminal via standard three wire cable.
The System 2500 represents the evolution of the microcontroller towards the networking
capabilities with integrated Ethernet interfaces. It offers a wide range of open stand protocols
for local connectives. The new operating system is optimized to ensure optimal system resource
usage and increase speed and reliability.

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2.0 QUICK REFERENCE GUIDE
The controller is fully programmed and pre-configured per system configuration. Further
modification may be required to better fit the application.
Figure 1 User Interface
1
Power/Link LED
Solid green: Normal operation
Flashing green: loss communication
OFF: No power
2
High contrast frame
3
Touch sensitive screen
Table 1 Touchscreen interface
2
3
1

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Compressor stage
Active: Green
OFF: Black
Heating stage
Active: Red
OFF: Black
Demand output
Pumpdown mode
Evaporator fan
Humidifier mode
Cooling mode
Dehumidification
mode
Heating mode
Econ/cooling assist
mode
Table 2 Icon legends
1
2
3
4
5
6
7
8

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1Room temperature and relative humidity
2Room return temperature and humidity setpoints
3Cooling stages
4Mode of operation
5System ON/OFF control
6System demands/outputs
7Heating stages
8Navigation system
Main menu
Alarm menu
Next menu
Previous menu
Table 3 Menu Options