Stulz CompTrol 1002 User manual

CompTrol 1002
AIR CONDITIONING
Index 50
Issue 3.10
MICROPROCESSOR
TECHNICAL MANUAL


E/0310/50/3
Contents
1. Features ......................................................................................................................4
2. Operation and Status Elements ............................................................................... 5
3. Start-up .......................................................................................................................9
4. Menu ......................................................................................................................... 11
5. Alarms and Failures ................................................................................................ 22
6. Control Diagram for CW-Units ................................................................................25
7. Specification CompTrol 1002 ..................................................................................27
7.1 Technical Data ................................................................................................. 27
7.2 Connection Diagram of Processor Board C1002 ........................................... 28
7.3 Bus connection ............................................................................................... 30
7.4 Connection Diagram for Sequencing at the Processor-Board ........................32
8. Specifications of the Extension Card 1b ...............................................................33
8.1 Technical Data Extension Card 1b ..................................................................34
8.2 Connection Diagram of the Extension Card 1b ............................................... 35
8.3 Connection Diagram for Sequencing with Extension Card .............................36
9. Appendix .................................................................................................................. 37
9.1 Standard Setting .............................................................................................37
9.2 Password ........................................................................................................38
Subject to technical modifications - precedent manuals are not valid anymore

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1. Features
STULZ CompTrol 1002 is a complete control system for A/C-Units. The controller is build in a com-
pact microprocessor design and is completely digital.The controlling system is driven by software
only.
CompTrol 1002 controls temperature and humidity and supervises the room in respect of freely
adjusted limit values.
With the CompTrol 1002 single-module Chilled water (CW) units or units with a 2-stage compressor
can be controlled. A 2-unit-sequencing is also included.
Functions such as cooling, reheat, humidification and dehumidification are continuously controlled
and supervised. In case of any deviation from setpoints, the CompTrol 1002, will initiate necessa-
ry measures immediately. Parameters for the control system and the functions which have to be
controlled can be adjusted by three keys on the CompTrol 1002.
The CompTrol 1002 can be connected to the STULZ Monitoring System.
This manual is valid from CompTrol 1002 Software-Version 2.0

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2. Operation and Status Elements
Alarm reset
START/ STOP key
"Right arrow" key
"Down arrow" key
"Up arrow" key
4-digit LED-Display
Connection board
DIP- switch 1-4
Rear Plate
Face Plate
Status "cooling"
Status "reheat"
Status "humidification"
Status "dehumidification"
Alarm

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4-Digit LED-Display
In this LED-display all controlling parameters such as setpoints, actual values and limiting values,
are shown.
Status LED
Status LED shows actual operation mode of controller. As a function is switched on, the corres-
ponding Status LED is indicated. On a CW-Unit, Status LED "cooling" indicates when CW-valve
has an opening degree bigger than 0%.
Status LED "alarm" indicates when an alarm occurs.
DIP-Switch 1-4
Adjustments that need not to be changed after initial installation, are made by these DIP- switches.
DIP- Switches 1-4 have the following functions:
DIP-Switch 1 No function
Modification from Version 2.1: When the sequencing is active (i.e.
menue point 24 > 0), the start of the stand-by unit can be chosen by
this switch.
ON: No start by passing over a limit value
OFF: Start of stand-by unit in addition, 3K before the limit
value "Temp. too high" is reached.
DIP-Switch 2
The control of the compressor version or the CW version can be
chosen by
this DIP-switch.
OFF: Control of compressor version is chosen.
ON: Control of CW version is chosen.
Some menu items, alarm inputs and outputs will obtain another meaning.
DIP Switch 2 must only be switched when dead.
DIP-Switch 3 Two alarm inputs can be chosen by this DIP- switch.
ON: The inputs "auxiliary alarm 1" and "auxiliary alarm 2"
have the function of external alarms.
OFF: The input alarm 2 has the function of a fire and smoke
detector.
The input alarm 1 has the function of a water sensor.

E/0310/50/7
Consequences of alarm inputs "auxiliary alarm 1" and "auxiliary alarm 2" de-
pends on position of DIP-switch 3. DIP-switch 3 can be switched at any time,
even during controller operation. The function of this switch is immediately valid
without further measures.
DIP-Switch 4 Temperatures in °C or °F can be chosen by this DIP-switch.
OFF: All temperatures are shown in °C.
Temperature differences are shown in K.
The actual value is marked by a "C".
ON: All temperatures are shown in °F.
Temperature differences are converted to degree
Rankin. The actual value is marked by an R.
DIP - switch 4 can be switched over any time, even during controller
operation. Function of switch is valid without further measures.
Membrane Keys
Start/Stop Key
Operation mode "start" and "stop" are the only functions of this key. If the controller is in enter
mode, the key is ineffective.
Operation Mode "Stop"
Control system and unit are not in operation. CW-valve closes. Limit values are supervised. In-
dependent failures (like sensor break-down, water sensor alarm, fire alarm, smoke detector and
other external alarms) are supervised. Display indicates .
The horizontal bar in display means that controller has been locally turned off by the Start/
Stop-key.
Occuring alarms and failures can be reset in menu item 1. Inputs and modifications in all menu
items can be made.

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Operation Mode "Start"
Control system and unit are in operation. Unit functions are turned on when start values match
setpoints of corresponding functions. Limit values are supervised. Menu item 1 is shown. Display
is alternating between actual value "temperature" and actual value "humidity" in 2- second- inter-
vals.
Occuring alarms and failures can be reset in menue item 1. Inputs and modifications in all menue
points can be made.
Right Arrow Key
This key has several functions.
Menu Item 1 And Operation Mode "Stop"
Alarm reset is activated by pressing the key.
Menu Items 2 to 24
The enter mode for these menu items is activated by pressing the key. After pressing this key there
is a request for entering in the password.
Enter Mode
Being in the enter mode, you can confirm the entered parameters and leave the enter mode by
pressing this key again. The value shown last is stored in the memory and is used for controlling.
Up Arrow Key
Next menu item can be entered by this key. The shown value is increased in enter mode.
Down Arrow Key
Last menu item can be reached by pressing this key. The shown value is diminished in enter
mode.
Pressing one of these two keys longer than one second in enter mode means
pressing this key 12 times.
If none of the keys is used within five minutes, the display automatically returns to menu item 1.

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3. Start-up
Prior to initialization, the software version number is displayed for about 1 s.
Example: Software version 2.1
When the C1002 is started (operation voltage is supplied) the following symbol appears in the
display for one second during initial phase:
In this initial phase all values of the EEPROM memory are loaded into the RAM.
Independent of the requirements for a certain function the CW- valve is closed for the time entered
in menu item 8. This procedure is necessary to synchronise the control system with the modulating
valve.
Start- up in Operation Mode "Stop"
If the CompTrol 1002 was in operation mode "Stop" before cutting off the power supply, the cont-
roller will be in this operation mode again after the restart. Three possibilities of how the unit has
been stopped, exist:
Display
1. Start/Stop-Key: local mode
2. Remote On/Off: remote mode
3. Software On/Off: Monitoring system
If controller is stopped from several locations, the corresponding bars in the fourth character po-
sition appear on the display. Restarting is only possible if the controller is locally started by the
Start/Stop-key. The Start/Stop-Key has the highest priority.
Start-up in Operation Mode "Start" (Autostart)
The CompTrol 1002 is equipped with an "Autostart"- function. This means that the unit starts au-
tomatically after a power supply failure when it was in operation mode "Start" before. A restart of
several units equipped with the C1002 at the same time can be avoided by entering a time delay
in menu point 22.

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Start-up with Standard- Program
If the two keys which represent the password are pressed at the same time as power is turned on,
the following reading appears on the display:
At this time the standard program is loaded from program memory EPROM to the EEPROM
memory and RAM. During this procedure the control system is not working. By loading the stan-
dard program the controller is switched off locally and has to be set in operation mode "start" by
pressing the Start/Stop-key.
Start- up with new EEPROM
If the CompTrol 1002 is started with a new EEPROM, the following symbol appears in the display
during the initial phase (about 1 second):
The standard values of the program memory EPROM are loaded into the EEPROM and into the
RAM. During this procedure the control system is not working. During this time the controller is
not working. By loading the standard program the controller is switched off locally and has to be
set into operation mode "start" by pressing the Start/Stop-key.
Warm start
The Controller CompTrol 1002 is equipped with a "watchdog-timer". This "watchdog-timer" incre-
ases the operating safety and restarts the program if a runtime error occurs. In such a case the
following reading appears in the display:
If the C1002 was in operation mode "start", the autostart function is activated in this case.

6
13
14
15
16
17
18
21
22
23
24 25
9
8
7
10
11
12
20
19
4
5
3
2
1
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4. Menu
The menu items 8-11 depend on the position of the Dip-switch 2. The menu item 25 only
exists, if the Dip-switch 2 is in position "ON".
RT : Room temperature
RH : Room humidity
Actual opening degree CW-valve
(only at CW-version)
Sequencing for 2 units
Integral factor
Unit start delay
Humidity sensor adjust.
Temperatur sensor
adjustment
CPU-address
Dehumidification hysteresis
Dehumidification start value
Humidification hysteresis
Humidification start value
Reheat 2 start value
Reheat 1 and 2 hysteresis
Limit value RH too low
Limit value RH too high
Limit value RT too low
Limit value RT too high
Humidity setpoint
Temperature setpoint
Actual values: temperature / humidity
Valve modulating time
/comp. restart delay
CW-valve proportional range/
compressors hysteresis
CW-valve start value/
1st compressor start value
CW-valve opening degree for dehumi-
dification / 2nd compressor start value
Reheat 1 start value

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Actual value "Temperature"
Actual value "Humidity"
Setpoint "Temperature"
Setpoint "Humidity"
Limit value "Room tempera-
ture too high"
Limit value "Room tempera-
ture too low"
Limit value "Room humidity
too high"
Limit value "Room humidity
too low"
Valve modulating time (in
seconds)
Compressor restart delay
CW-valve start value
1. Compressor start value
Proportional range of CW-
valve
Hysteresis of compressors
...1s... alarm reset
Further Functions
Display
Meaning
Menu item
1
2
3
4
5
6
7
8a
8b
9a
9b
10a
10b
enter mode
modification of values by
and
leaving the enter mode
with
+ PASSWORD

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Meaning
CW-valve opening degree for
dehumidification in %
2. Compressor start value
Reheat 1 start value
Reheat 1 + 2 hysteresis
Reheat 2 start value
Humidification start value
Humidification hysteresis
Dehumidification start value
Dehumidification hysteresis
CPU-address
Temperature sensor adjust-
ment
Humidity sensor adjustment
Unit start delay
Further FunctionsMenu item
11a
11b
12
13
14
15
16
17
18
19
20
21
22
Display
enter mode
modification of values by
and
leaving the enter mode
with
+ PASSWORD

----------------
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DisplayMeaning
Integral factor
Sequencing for 2 units
Actual opening degree
CW-valve
Further FunctionsMenu item
23
24
25
The menu items 8a-11a and 25 are valid for CW-units.
The menu items 8b-11b are valid for units with a compressor.
enter mode
modification of values by
and
leaving the enter mode
with
+ PASSWORD

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Actual Values
Display is alternating between actual value "temperature" and actual value "humidity"
in 2- second- intervals.
Humidity is shown in % r.h. Actual value "humidity" is marked by an H.
Temperatures are shown in °C (marked by C) or °F (marked by F). This can be chosen
by DIP- switch 4 at any time.
Resetting an alarm is only possible in this menu item.
Temperature Setpoint
"Temperature" setpoint is shown in this item. Unit of temperature is °C or °F.
Humidity Setpoint
"Humidity " setpoint is shown in this item.
High Temperature Limit value
If the actual value "temperature " is rising up to this point, an alarm "Temperature too
high" is released.
Low Temperature Limit value
If the actual value "temperature" is going down to this point, an alarm "Temperature
too low" is released.
High Humidity Limit value
If the actual value "humidity" is rising up to this point, an alarm "Humidity too high" is
released.
Low Humidity Limit value
If the actual value "humidity" is moving down to this point, an alarm "Humidity too low"
is released.
Item
1
2
3
4
5
6
7

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Item
8
9
10
11
a. CW-units
Valve Modulating Time
Modulating time of CW-valve (operating level
0% up to operating level 100% in seconds)
will be entered in this menue point.
Actuator SQS 82, SQS 81 (L&G): 150 se-
conds.
CW valve Start Value
CW valve Proportional Range
Start point Cooling and proportional range
of CW- valve are entered in these points of
menue. Refer to control scheme.
Opening degree for dehumidification
Opening degree of CW-valve required for de-
humidification can be entered in this item.
Maximum opening degree for dehumi-
di-fication can be passed over when the
CW-valve´s opening degree for cooling is
increased.
b. Units with Compressor
Compressor Restart Delay
In this item the restart delay in seconds is
entered. After a compressor shut down, it
can only be restarted when the time set has
elapsed.
1. Compressor Start Value
Hysteresis of Compressors
2. Compressor Start Value
The parameters of the compressors' start
and hysteresis can be entered in these menu
items (9b-11b).
Menu item 11b is only relevant, if a second
compressor exists.
If the proportional range or hysteresis is set to actual value "0" the corresponding function is not
required, the status- LED is not activated and the corresponding failures are not evaluated.

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Reheat 1 Start Value
Reheat 1 + 2 Hysteresis
Reheat 2 Start Value
Parameters of reheat's stages 1+2 can be entered in these items
The hysteresis is valid for both stages.
Humidification Start Value
Humidification Hysteresis
Parameters of 2-point-humidification can be entered in these items.
Dehumidification Start Value
CW-units:
For dehumidification CW-valve opens to the indicated opening degree entered in item
11a.
Units with compressor:
The dehumidification circuit and the compressor will be started.
The "dehumidification" function is stopped when temperature is less than 0.5 K (0.9R) above
the low temperature limit value. It is enabled with a hysteresis of 0.5 K (0.9R).
Modification from version 2.1:
3K (5R) underneath the temperature setpoint the dehumidification is stopped. This way
a fall of the room temperature by keeping the humidity setpoint is avoided.
Hysteresis Dehumidification
Parameters for dehumidification are entered in this item.
If the hysteresis of humidification and dehumidification is set to zero, the
limit value "humidity" is not supervised.
The values of the items 9a+b, 11b, 12, 14, 15, 17 are entered as a difference to
the setpoint.
Item
12
13
14
15
16
17
18

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CPU- Address
CPU- Address can be entered in this item. If CompTrol 1002 is connected to a STULZ
Monitoring System, an address between 1 and 32 for every connected controller has
to be adjusted.
Temperature Sensor Adjustment
Temperature sensor adjustment can be done in this item. The actual value is indica-
ted and can be adjusted to another value, that is measured by use of an independent
temperature sensor.
Display is in reference to position of DIP- switch 4 degrees Celsius
or Fahrenheit.
By loading the basic program of the controller, sensor adjustment
is reset to zero.
Humidity Sensor Adjustment
Humidity sensor adjustment can be done in this item. The actual value taken from a
reference measurement has to be entered.
By loading the basic program of the controller, sensor adjustment
is reset to zero.
Unit Start Delay
Unit start delay can be entered in this item. This is the time, the unit start is delayed in
addition to the initialization time, when the unit is turned on in start mode (Autostart)
The start delay can be entered in 4-second intervals.
Item
19
20
21
22

SW
SW SW
SW
E/0310/50/19
Integral Factor for Setpoint “Temperature”
In this point of the menue, the I-proportion of the PI controller can be preset. If a non-
zero value is entered, the control discrepancy, which is characteristic for P-controllers,
is avoided. The setpoint SP1 entered becomes “control setpoint”. Now, it is no more
a constant value but is changed in integral intervals of 5 minutes and indicated in the
menu item 2 “temperature setpoint”. Alteration of the setpoint is made using the follo-
wing formula:
∆ SP = (Setpoint - Actual Value) x Integral Factor %
which results in
Control Setpoint SP2 = SP1 + ∆ SP
Item
23
Actual value
a) modification of setpoint
in enter mode
control setpoint
The originally entered setpoint SP1 appears in the enter mode, which can be changed
in this item and which is immediately rendered valid after the alteration has been made
(refer to illustration a) ).
The values of the integral factor may be adjusted between 0 and 80%. As a rule, a low
value should be used to start with, otherwise the system will start oscillating. 10% are
proposed, which can be increased step by step, until the system has been adjusted.

E/0310/50/20
Meaning
No sequencing function.
Short sequencing 5 min for testing purposes. In nor-
mal mode the remaining minutes till sequencing are
shown.
Sequencing shown in hours.
In the input mode a time lap of 2 to 254 hours can be
chosen. In normal mode the remaining hours till sequen-
cing are shown.
If "255" is set in the input mode, the unit is set as the
"2nd" unit. No adjustments are carried out on this unit.
The sequencing time is only set and displayed on the
„1st“ unit.
normal mode
0
5-4-3-2-1
254...1
Un2
input mode
0
1
2...254
255
For test purposes or in case the I-proportion is not desired, the integral factor is set to
zero. A P-controller exists and the control setpoint is equal to the setpoint.
Under the following circumstances, the setpoint is immediately taken
over into the control setpoint:
- during initialization phase (switch on voltage)
- turning on (start mode)
- failure “sensor break-down” active
- limit alarms “temperature” active
- modification of setpoint
The range of the control setpoint is limited to setpoint ± 3 K (± 5.4 R).
Sequencing for 2 units
A 2-unit-sequencing is integrated in the software. The display during input mode and
normal mode can vary.
Item
24
In case of failure (unit 1 or unit 2) the sequencing time is frozen. This state is maintained
until a failure reset is carried out. After that, sequencing continues as normal.
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