Rickard DU1011-1 User manual

User Manual
for the
Zone Controller

RICKARD 2021
ZONE CONTROLLER USER MANUAL
Table of Contents
1Introduction.............................................................................................................................................8
1.1 Product Overview............................................................................................................................8
1.2 Document Overview......................................................................................................................11
1.3 Functional Overview / Main features.............................................................................................12
1.3.1 Control....................................................................................................................................12
1.3.2 Configuration..........................................................................................................................13
1.3.3 Points list................................................................................................................................13
1.3.4 Log files..................................................................................................................................13
1.3.5 Trend logs ..............................................................................................................................14
1.3.6 Simulation ..............................................................................................................................14
1.3.7 mlm diffuser interface.............................................................................................................14
1.4 Hardware features.........................................................................................................................14
1.4.1 General Specifications ...........................................................................................................15
1.4.2 LED Indicators........................................................................................................................16
1.4.3 Electromagnetic Compatibility (preliminary, to be confirmed) ...............................................16
2Communication.....................................................................................................................................17
2.1 Network connections.....................................................................................................................17
2.1.1 BMS interface.........................................................................................................................17
2.1.2 Diffuser interface ....................................................................................................................17
2.1.3 RS485 ....................................................................................................................................17
3Installation ............................................................................................................................................18
3.1 Pre-requisites for installation.........................................................................................................18
3.2 Environmental conditions ..............................................................................................................18
3.3 Mounting .......................................................................................................................................19
3.4 Power Supply ................................................................................................................................20
3.5 Cabling Considerations .................................................................................................................20
3.6 Input / Output connections ............................................................................................................21
3.6.1 Digital Input (AC or DC) .........................................................................................................22
3.6.2 Digital Output .........................................................................................................................23
3.6.3 Analog Input ...........................................................................................................................24
3.6.4 Analog Output ........................................................................................................................25
3.7 I/O Wiring diagram ........................................................................................................................25
4User Interfaces .....................................................................................................................................28
4.1 Remote User Interface (RUI) ........................................................................................................28
4.1.1 Menu (Item 1).........................................................................................................................29
4.1.1.1 Menu item: System.............................................................................................................29
4.1.1.1.1 Device .........................................................................................................................29
4.1.1.1.2 Time and Date ............................................................................................................29
4.1.1.1.3 Network .......................................................................................................................31
4.1.1.1.4 BACnet........................................................................................................................32
4.1.1.1.5 Modbus .......................................................................................................................32
4.1.1.1.6 Local User Interface....................................................................................................34
4.1.1.1.7 Email ...........................................................................................................................34
4.1.1.1.8 Upload (to cloud server)..............................................................................................35
4.1.1.1.9 Security .......................................................................................................................36
4.1.1.1.10 Settings Backup and Restore ...................................................................................37
4.1.1.1.11 Software Update .......................................................................................................38
4.1.1.2 Menu item: Control .............................................................................................................38
4.1.1.2.1 Global..........................................................................................................................39

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ZONE CONTROLLER USER MANUAL
4.1.1.2.2 Temperature................................................................................................................40
4.1.1.2.3 Pressure......................................................................................................................44
4.1.1.2.4 Damper & Fan.............................................................................................................46
4.1.1.2.5 Humidity ......................................................................................................................47
4.1.1.2.6 Economy & CO2 .........................................................................................................48
4.1.1.2.7 Data Points..................................................................................................................49
4.1.1.2.8 Simulate ......................................................................................................................51
4.1.1.2.9 Diffuser & Partition ......................................................................................................51
4.1.1.2.10 Schedule ...................................................................................................................55
4.1.1.2.11 Configuration Backup and Restore...........................................................................56
4.1.1.3 Menu item: IO .....................................................................................................................57
4.1.1.3.1 Hardware IO................................................................................................................57
4.1.1.3.2 Points List....................................................................................................................57
4.1.1.4 Menu item: Dashboard .......................................................................................................59
4.1.1.4.1 ZC Browser .................................................................................................................59
4.1.1.4.2 Diffuser Summary .......................................................................................................60
4.1.1.5Menu item: Logs .................................................................................................................61
4.1.1.5.1 Event Log ....................................................................................................................61
4.1.1.5.2 Trend Log....................................................................................................................62
4.1.1.5.3 Export Logs .................................................................................................................63
4.1.1.6 Menu item: Help .................................................................................................................63
4.1.2 Mode and Control (Item 2) .....................................................................................................64
4.1.2.1 Controller icons ..................................................................................................................64
4.1.2.2 Mode states (MODE)..........................................................................................................64
4.1.2.3 Control command (CTRL) ..................................................................................................65
4.1.3 Setpoint and Diffuser data (Item 3)........................................................................................66
4.1.4 ZC Status information (Item 4)...............................................................................................66
4.1.5 ZC Notification icons (Item 5).................................................................................................67
4.1.5.1 Simulation...........................................................................................................................67
4.1.5.2 Hardware Conflict ...............................................................................................................67
4.1.5.3 Override..............................................................................................................................68
4.1.5.4 Hardware Clock ..................................................................................................................68
4.1.5.5 Alarm ..................................................................................................................................70
4.1.5.6 Service................................................................................................................................70
4.1.5.7 Communication Failure ......................................................................................................70
4.1.5.8 Diffuser Fallback.................................................................................................................71
4.1.5.9 Disconnect..........................................................................................................................71
4.1.5.10 Logout.................................................................................................................................72
4.1.5.11 Network ..............................................................................................................................72
4.2 Local User Interface ......................................................................................................................72
5System Operation.................................................................................................................................75
5.1 Start-up and initial configuration ...................................................................................................75
5.1.1 Switch on................................................................................................................................75
5.1.2 Step-by-step initial/minimum configuration ............................................................................76
5.1.2.1 Step 1 – Login as Installer..................................................................................................76
5.1.2.2 Step 2 – Set the device data ..............................................................................................76
5.1.2.3 Step 3 – Set the date and time...........................................................................................76
5.1.2.4 Step 4 – Configure the Network settings............................................................................76
5.1.2.5 Step 5 – Configure BACnet ...............................................................................................76
5.1.2.6 Step 6 – Configure Local User Interface ............................................................................76
5.1.2.7 Step 7 – Configure the Diffuser and Partition network .......................................................77

RICKARD 2021
ZONE CONTROLLER USER MANUAL
5.1.2.8 Step 8 – Select control functions........................................................................................77
5.1.2.9 Step 9 – Configure the control parameters ........................................................................77
5.1.2.10 Step 10 – Define points list.................................................................................................77
5.1.2.11 Step 11 – Setup the daily schedule....................................................................................77
5.1.3 Commissioning report ............................................................................................................77
5.2 System reset .................................................................................................................................77
5.2.1 Power down ...........................................................................................................................77
5.2.2 Software update .....................................................................................................................77
5.3 User Access ..................................................................................................................................77
5.4 Data point overrides ......................................................................................................................78
5.4.1 Simulation overrides ..............................................................................................................78
5.4.2 RUI overrides .........................................................................................................................78
5.4.3 BACnet overrides ...................................................................................................................79
5.4.4 LUI overrides..........................................................................................................................79
5.5 Log files .........................................................................................................................................79
5.6 Handling of alarms ........................................................................................................................80
5.7 Troubleshooting ............................................................................................................................80
5.8 Interfacing to another Zone Controller ..........................................................................................80
6Technical Specifications.......................................................................................................................82
Appendix A: Available list of data points (at date of issue)..........................................................................83
Appendix B: Zone Controller Points List (Template) ...................................................................................84
Appendix C: PICS Statement for the Zone Controller .................................................................................85
Appendix D: Zone Controller Calculations...................................................................................................88

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ZONE CONTROLLER USER MANUAL
Table of Figures
Figure 1: Zone Controller...............................................................................................................................8
Figure 2: Zone Controller Application diagram ..............................................................................................9
Figure 3: Zone Controller depiction of Air Handling Unit .............................................................................10
Figure 4: Zone Controller hardware assembly ............................................................................................15
Figure 5: ZC din rail mounting brackets.......................................................................................................19
Figure 6: ZC physical layout ........................................................................................................................19
Figure 7: Digital Input connections ..............................................................................................................22
Figure 8: Digital Output connections ...........................................................................................................23
Figure 9: Jumper selection ..........................................................................................................................24
Figure 10: Analog Input connections ...........................................................................................................24
Figure 11: Analog Output connections ........................................................................................................25
Figure 12: Example Zone Controller to AHU Wiring diagram (see Table 8) ...............................................26
Figure 13: Typical dashboard – with functional areas encircled .................................................................28
Figure 14: Device display ............................................................................................................................29
Figure 15: Set Time, Date and Time zone...................................................................................................30
Figure 16: Network Settings ........................................................................................................................31
Figure 17: BACnet Settings .........................................................................................................................32
Figure 18: Serial Modbus display ................................................................................................................33
Figure 19: Serial Modbus display for RTU Interface Selection....................................................................33
Figure 20: Serial Modbus display for ASCII Interface Selection .................................................................33
Figure 21: TCP Modbus display ..................................................................................................................34
Figure 22: TCP Modbus display for TCP/IP Interface Selection .................................................................34
Figure 23: LUI Settings ................................................................................................................................34
Figure 24: Email Settings ............................................................................................................................35
Figure 25: Upload display ............................................................................................................................36
Figure 26: Security display ..........................................................................................................................36
Figure 27: Settings Backup display .............................................................................................................37
Figure 28: Software update display .............................................................................................................38
Figure 29: Upload display (using USB as source).......................................................................................38
Figure 30: Global Control Configuration ......................................................................................................39
Figure 31: Temperature Control Configuration............................................................................................41
Figure 32: Pressure Control Configuration ..................................................................................................44
Figure 33: Damper and Fan Control Configuration .....................................................................................46
Figure 34: Humidity Control Configuration ..................................................................................................47
Figure 35: Economy and CO2 Configuration ..............................................................................................48
Figure 36: Show All Data Points Button (hiding) .........................................................................................49
Figure 37: Unused Data Points hidden........................................................................................................49
Figure 38: Show All Data Points button (showing) ......................................................................................49
Figure 39: Unused Data Points shown ........................................................................................................49
Figure 40: Diffuser Options..........................................................................................................................52
Figure 41: Partition Schedule ......................................................................................................................53
Figure 42: MCU and Diffuser list .................................................................................................................54
Figure 43: Schedule configuration...............................................................................................................55
Figure 44: Config Backup display................................................................................................................56
Figure 45: Hardware IO display...................................................................................................................57
Figure 46: Points List display.......................................................................................................................58
Figure 47: ZC Browser list ...........................................................................................................................59
Figure 48: Diffuser Summary.......................................................................................................................60
Figure 49: ZC Event Log .............................................................................................................................61
Figure 50: Trend log display (example) .......................................................................................................62

RICKARD 2021
ZONE CONTROLLER USER MANUAL
Figure 51: ZC Log Export display ................................................................................................................63
Figure 52: Simulated Data points ................................................................................................................67
Figure 53: Hardware Conflicts .....................................................................................................................68
Figure 54: Override of Data points ..............................................................................................................68
Figure 55: RTC Issue...................................................................................................................................69
Figure 56: Alarm pop-up window.................................................................................................................70
Figure 57: Service window ..........................................................................................................................70
Figure 58: Communication Problem pop-up window...................................................................................70
Figure 59: Diffuser Fallback Active pop-up window ....................................................................................71
Figure 60: Not Connected pop-up window ..................................................................................................72
Figure 61: Logged In pop-up window ..........................................................................................................72
Figure 62: Possible Network Issue pop-up window.....................................................................................72
Figure 63: LUI display options .....................................................................................................................73
Figure 64: Typical screen of data point loading during start-up ..................................................................75
Figure 65: LUI 'Home' screen ......................................................................................................................75
Figure 66: Sample dashboard .....................................................................................................................76
Figure 67: Shortcut to Data point Simulation...............................................................................................79
Figure 68: RUI indicating override condition ...............................................................................................80
Table of Tables
Table 1: List of Sensor/Actuator icons.........................................................................................................11
Table 2: Cabling Considerations .................................................................................................................20
Table 3: Digital Input connections ...............................................................................................................22
Table 4: Digital Output connections.............................................................................................................23
Table 5: Jumper selection ...........................................................................................................................24
Table 6: Analog Input connections ..............................................................................................................24
Table 7: Analog Output connections ...........................................................................................................25
Table 8: Example Points List (See Figure 11) .............................................................................................27
Table 9: Summary of Data Point Configuration Parameters .......................................................................50
Table 10: Controller status per alarm ..........................................................................................................80
Table 11: Digital Inputs ................................................................................................................................82
Table 12: Digital Outputs .............................................................................................................................82
Table 13: Analog Outputs ............................................................................................................................82
Table 14: Analog Inputs...............................................................................................................................82
Table 15: Communications..........................................................................................................................82
Table 16: Protocol Compliance ...................................................................................................................82
Table 17: Power Requirements ...................................................................................................................82

RICKARD 2021
ZONE CONTROLLER USER MANUAL
Acronyms
AC
Alternating current
AHU
Air Handling Unit
ARM
Advanced RISC Machines
AUC
Area under Control
BACnet
A Data Communication protocol for Building Automation and Control Networks
BAS
Building Automation System
BMS
Building Management System
CO2
Carbon Dioxide
COV
Coefficient of Variation
CWV
Cool Water Valve
DC
Direct current
DDR
Double Data Rate
DX
Direct Expansion
EN
Enabled
ERR
Undetermined
FIP
Fire Indicator Panel
GB
Giga Byte
GHz
Giga Hertz
GUI
Graphical User Interface
GND
Electrical Ground
HWV
Hot Water Valve
I/O or IO
Input / Output
IP
Internet Protocol
kV
Kilo Volt
LCD
Liquid Crystal Display
LED
Light Emitting Diode
LHA Systems
The developer of this product
LUI
Local User Interface (LCD screen)
MB
Mega Byte
mbps
Megabits per second
MCU
Master Controller unit / Master Comms Unit
mlm
Multi Loop Modular
MQTT
Message Queueing Telemetry Transport
MS/TP
Master-Slave / Token Passing
MUI
Manual User Interface (I/O interface e.g. ON/OFF/AUTO switch)
NAC
Not Active
NIU
Not in Use
NVI
Not Visible
PCD
Pressure Control Damper
PI
Proportional Integral
PICS
Protocol Implementation Conformance Standard
PID
Proportional Integral Derivative
PSU
Power Supply Unit
RH
Relative Humidity
RUI
Remote User Interface
SOM
System on Module
USB
Universal Serial Bus
VRF
Variable Refrigerant Flow
VAV
Variable Air Volume
VSD
Variable Speed Drive
ZC
Zone Controller

RICKARD 2021
ZONE CONTROLLER USER MANUAL
1 Introduction
1.1 Product Overview
The Zone Controller (ZC) is designed as a dedicated Air Handling Unit (AHU) controller. The unit
features ease of installation using industry standard software tools. In particular the unit is designed to
interface seamlessly with the mlm 24 range of diffuser equipment. The unit contains a total of 56
configurable I/O ports, a BACnet client and server interface and a touch screen user interface. A web
page GUI allows for product configuration and set-up, monitoring the control operation as well as
providing for manual override and diagnostics. An extensive trend log is provided for time based or
COV sampling on all data points to monitor the building comfort and energy performance.
To achieve the above the unit runs on a Linux operating system powered by a state-of-the-art System
on Module (SOM) featuring a 1 GHz Dual-core ARM Cortex-A7™ processor with 2GB DDR3 and 8GB
Flash memory.
Figure 1: Zone Controller
The ZC typically interfaces to the following items via an Ethernet connection:
•Building Management System (BMS)
•Multiples of up to 60 diffusers per Master Communication Unit (MCU) using the BACnet protocol
•Other Zone Controllers
•Remote Client Workstation with a Web Browser
•Modbus TCP unit

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ZONE CONTROLLER USER MANUAL
Figure 2: Zone Controller Application diagram
The ZC also connects to various:
•Analog Sensors – using analog input [Channels AI01-AI16]
•Analog Actuators - using analog output [Channels AO01-AO16]
•Binary Sensors - using digital input [Channels DI1-DI12]
•Binary Actuators - using digital output [Channels DO1-DO12]
The installer tailors the installation to site specific needs by connecting the I/O lines according to the
AHU electrical wiring diagram. The installation is then configured by using the Remote User Interface
(RUI).
The typical Air Handling Unit that is controlled by the Zone Controller is depicted in Figure 3. The
sensors / actuators relevant to the different areas of the AHU are listed below.

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ZONE CONTROLLER USER MANUAL
Figure 3: Zone Controller depiction of Air Handling Unit
Area 1: Exhaust Air Control Items
The sensors / actuators that may form part of this area are:
a) Exhaust Air Temperature sensor
b) Exhaust Air Damper
c) Exhaust Air Fan
Area 2: Return Air Control Items
The sensors / actuators that may form part of this area are:
a) Return Air Temperature sensor
b) Return Air Pressure sensor
c) Return Air Humidity sensor
d) Return Air Damper
e) Return Air Fan
Area 3: Fresh Air Control Items
The sensors / actuators that may form part of this area are:
a) Fresh Air Temperature sensor
b) Fresh Air Differential Pressure sensor
c) Fresh Air damper
d) Fresh Air fan
Area 4: Supply Air Control Items
The sensors / actuators that may form part of this area are:
a) Supply Air Temperature sensor
b) Supply Air Pressure sensor
c) Supply Air (bypass) damper
d) Filter dirty switch or Differential pressure switch
e) Supply Air fan
f) Heating / Cooling coil(s)
g) Electric heating
h) Humidifier
4
1
2
3