System air PCA 1000D User manual

PCA 1000D
Part.-No. 38999
Sensor-control module for differential
pressure and volume
Operating Instructions
Software version: D1673A from Version 1.03
L-BAL-E120-GB 1419 Index 002 Part.-No.
english

Content
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Structure of the operating instructions . . . . . . . . . . . . . . 4
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Operational area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Disposal / recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Temperature influences during commissioning . . . . . . . 8
5 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 EMC-compatible installation of control lines . . . . . . . . . 9
5.3 Connection Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Output voltage 0 - 10 V . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Input for switch over Setpoint 1/ 2 . . . . . . . . . . . . . . . . . . 9
6 Device construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.1 Select operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.3 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.4 Parameter table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating Instructions PCA 1000D
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7.5 Measuring ranges and tolerance of pressure sensor . 16
7.6 Check sensor function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.3 Dimensions [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.4 Manufacturer reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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1 General notes
1.1 Structure of the operating instructions
Before installation and start-up, read this manual carefully to
ensure correct use!
We emphasize that these operating instructions apply to specific
units only, and are in no way valid for the complete system!
Use these operating instructions to work safely with and on the
device. They contain safety instructions that must be complied
with as well as information that is required for failure-free operation
of the device.
Keep these operating insturctions together with the device. It must
be ensured that all persons that are to work on the device can
refer to the operating instructions at any time.
1.2 Target group
The operating instructions address persons entrusted with plan-
ning, installation, commissioning and maintenance and servicing
and who have the corresponding qualifications and skills for their
job.
1.3 Exclusion of liability
To allow for future developments, construction methods and tech-
nical data given are subject to alteration. We do not accept any
liability for possible errors or omissions in the information con-
tained in data, illustrations or drawings provided.
We accept no liability for damage caused by misuse, incorrect
use, improper use or as a consequence of unauthorized repairs or
modifications.
1.4 Copyright
These operating instructions contain copyright protected informa-
tion. The operating instructions may be neither completely nor
partially photocopied, reproduced, translated or put on data me-
dium without previous explicit consent. Infringements are liable for
Operating Instructions PCA 1000D General notes
L-BAL-E120-GB 1419 Index 002 Part.-No.
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damages. All rights reserved, including those that arise through
patent issue or registration on a utility model.
2 Safety instructions
•Mounting, electrical connection, and start-up operation may only
be carried out by an electrical specialist in accordance with
electrotechnical regulations (e.g. DIN EN 50110 or
DIN EN 60204)!
•Persons entrusted with the planning, installation, commissioning
and maintenance and servicing in connection with the device
must have the corresponding qualifications and skills for these
jobs. In addition, they must be knowledgeable about the safety
regulations, EU directives, rules for the prevention of accidents
and the corresponding national as well as regional and in-house
regulations.
•The equipment is to be used solely for the purposes specified
and confirmed in the order. Other uses which do not coincide
with, or which exceed those specified will be deemed unauthor-
ised unless contractually agreed. Damages resulting from such
unauthorised uses will not be the liability of the manufacturer.
The user will assume sole liability.
•It is strictly forbidden for work to be carried out on any compo-
nents while they are connected to live voltage.
•The safe isolation from the supply must be checked using a two-
pole voltage detector.
•The owner is obliged to ensure that the device is operated in
perfect working order only.
•Inspect electrical equipment periodically: retighten loose con-
nections – immediately replace damaged lines and cables.
•Never clean electrical equipment with water or similar liquids.
•A separate fault and performance monitoring-system with an
alarm signal function is necessary in order to prevent personal
injuries and material damages during malfunctions and in case
the device fails. Substitute operation must be taken into consid-
eration!
Operating Instructions PCA 1000D Safety instructions
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3 Product overview
3.1 Operational area
Pressure and volume control for ventilation systems.
Depending on the programmed Mode the device can be used
as sensor or as a control module for pressure or volume.
•For operation as pressure sensor the device supplies an output
signal (0 - 10 V) proportional to the measuring range.
•For operation as air volume sensor the device supplies an out-
put signal (0 - 10 V) proportional to the air volume measuring
range (
INFO / Range qV). Function in combination with
centrifugal fans and measuring device in the inlet ring. The
controller calculates the air volume of the fan from the “K-Factor”
differential between the suction side and the inlet duct.
•For operation as control module for pressure or volume the
purpose of the device is to reach and maintain the target value
set. To accomplish this, the measured actual value (sensor
value) is compared with the adjusted target value, and the con-
trolled value is deduced from this. Controlled output (0 - 10 V)
e.g. for activating a speed controller for fans or an EC-fan
directly.
3.2 Function
Sensor with a membrane system suitable for measuring differ-
ential or negative pressure of non-aggressive gas.
The differential pressure to be measured takes effect on a spring
supported silicone membrane.
Changes in position of the membrane are detected by a differential
transformer and converted into an output signal of 0 - 10 V by an
electronics unit.
Function when the pressure at the “Plus”- connection exceeds the
pressure at the “Minus”- connection.
Operating Instructions PCA 1000D Product overview
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3.3 Storage
•The device must be stored in its original packaging in a dry and
weather-proof room.
•Avoid exposure to extreme heat and cold.
•Avoid over-long storage periods (we recommend a maximum of
one year).
3.4 Disposal / recycling
Disposal must be carried out professionally and environmentally
friendly in accordance with the legal stipulations.
4 Mounting
4.1 General notes
Attention!
The following points must be complied with during the mechanical
installation to avoid causing a defect in the device due to assembly
errors or environmental influences:
•Before installation remove the device from the packing and
check for any possible shipping damage!
•Assemble the device on a clean and stable base. Do not distort
during assembly! Use the appropriate mounting devices for
proper installation of the unit!
•Do not mount equipment on vibrating base!
•When mounted onto lightweight walls, there must be no imper-
missibly high vibrations or shock loads. Any banging shut of
doors that are integrated into these lightweight walls, can result
in extremely high shock loads. Therefore, we advise you to
decouple the devices from the wall.
•Do not allow drilling chips, screws and other foreign bodies to
reach the device interior!
•The device should be installed in a location where it will not be
disturbed, but at the same time can be easily accessed!
Operating Instructions PCA 1000D Mounting
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•Any cable ducts openings not used must be sealed!
•Care must be taken to avoid direct radiation from the sun!
•The pressure measuring depends on position, therefore the
mounting must be made vertical and as possible on a vibration-
free place (cable inlet and pressure connections down).
•The pressure line´s connection should be with plastic-hose (in
building), inside diameter 4 / 5 mm.
4.2 Temperature influences during commissioning
Avoid condensation in the controller and functional faults attribut-
able to condensation by storing the controller at room temper-
ature!
5 Electrical installation
5.1 Safety precautions
Danger due to electric current
•Work on electric components may only be carried out by trained
electricians or by persons instructed in electricity under the
supervision of an electrician in accordance with electrical engi-
neering regulations.
•The programming of the equipment takes place with switched
on supply voltage by opened cover and voltage for change-over
Setpoint 1/2. Use only PELV current sources which guarantee
reliable electrical isolation of the operating voltage as per
IEC/DIN EN 60204-1.
•Inspect electrical equipment periodically: retighten loose con-
nections – immediately replace damaged lines and cables.
•Never clean electrical equipment with water or similar liquids.
Information
The respective connections are represented in the enclosure of
this manual (
Connection diagram)!
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5.2 EMC-compatible installation of control lines
Pay attention to maintain sufficient distance from powerlines and
motor wires to prevent interferences. The control cable may not be
longer than 30 m. Screened control cables must be used when the
cable length is longer than 20 m!
5.3 Connection Voltage supply
Connection Voltage supply at terminals: “+Ub” and “GND”. Here, it
must be strictly observed that the mains voltage lies within the
allowable tolerance specifications (
Technical data and name-
plate affixed to the side).
5.4 Output voltage 0 - 10 V
Connection to Terminals “A” - “GND” (I
max
Technical data).
It is not permissible to connect outputs of several devices to each
other!
5.5 Input for switch over Setpoint 1/ 2
Via voltage at terminals “1” and “2” (10... 24 V DC) a switchover
between Setpoint 1 and Setpoint 2 is possible (note polarity
connection diagram).
•Voltage OFF > Setting “Setpoint 1” active
•Voltage ON > Setting “Setpoint 2” active
Setpoint 1active Setpoint 2 active
100 Pa
(0.401 in.wg)
Δp
The active Setpoint is indicated in the
menu INFO, an active “Setpoint 2” is
signalized by the moon symbol.
80 Pa
(0.321 in.wg)
Δp
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6 Device construction
Screw off the hinged cover to proceed with electrical connection
and programming. Subsequently close carefully!
+-
+UbGNDAGND
12
22.08.2013
v_cpg_open.vsd
!
0Pa
P
P 
! Exceeding measuring range
Moon symbol Adjustment for
Setpoint 2 active
+Ub /
GND
Voltage supply
A / GND Output signal 0 - 10 V
1 / 2 Voltage input for switch over Set-
point 1 / 2
+
“Plus”- connection in area with
higher pressure
-
“Minus”- connection in area with
lower pressure
Multipurpose LC display and internal keyboard
100 Pa
Δp
Text line 1: 16 figures for display of actual and desired values
Text line 2: 16 figures for display of menu text
P▼ ▲
PProgram key and open menu
▼Menu selection, reduce value
▲Menu selection, increase value
▼ + ▲ESC-key combination, Escape leave menu
Operating Instructions PCA 1000D Device construction
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7 Programming
7.1 Select operation mode
Information
Simple installation is possible through the selection of the preprog-
rammed mode of operation.
This determines the basic function of the device, factory set 4.01 .
Mode Function
4.00 Pressure sensor output 0...10 V proportional to measuring range
4.01 Pressure controller (PID): output 0...10 V depending on adjusted
Setpoint and measured actual value.
5.00 Air volume sensor: Output 0...10 V propotional to measuring range
(depending on setting for K-Factor)
5.01 Air volume controller (PID): Output 0...10 V depending on adjusted
Setpoint and measured actual value
Operating Instructions PCA 1000D Programming
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7.2 Start-up
Attention, electrostatic sensitive devices!
Be sure to ground the board at a suitable point in order to prevent
damage to the electronic components being caused by electro-
static discharges. Such damage could occur, e.g., if a metal
water pipe or heating line are briefly touched.
It is prohibited to touch any other areas of the printed circuit
board than the 3 programming keys.
Procedure
1. You must mount and connect the device in accordance with the
operating instructions.
2. Double check that all connections are correct.
3. The supply voltage must match the information on the rating
plate.
4. Set the mode, unit and measuring range and adjust the sensor
in the BASE SETUP.
5. Set the parameters for control operation for the modes 4.01
and 5.01 under SETTING.
Information
When saving the Operating Mode, the factory settings are stored.
Therefore all the settings you have made, are lost.
7.3 Menu structure
100 Pa
Δp
Display after turning on the voltage supply.
Switch over between actual value display and
“INFO” with the key shortcut for Escape (ESC
▼ + ▲).
INFO
Selection of the menu group (e.g. BASE SETUP) to the right
through the ▼-key, to the left through the ▲-key.
Youcangotothemenuitemsinthemenugroups (e.g. mode) by using
the P key. Use the arrow keys to move up and down within the
menu group.
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To make adjustments, press the P key after selecting the menu
item. If the previously set value starts to flash, it can be adjusted
with the ▼ + ▲ keys and then saved with the P key. To exit the
menu without making any changes, use the “ESC” short-key, i. e.,
the originally set values remain.
Example for Mode 2.01 (Factory setting)
INFO
▼
▲SETTING
▼
▲BASE SETUP
P↓ ↑ ESC P↓ ↑ ESC P↓ ↑ ESC
100 Pa
Δp
500 Pa
Setpoint 1
4.01
Mode
▲ ▼ ▲ ▼ ▲ ▼
500 Pa
Setpoint 1
500 Pa
Setpoint 2
1: 0..1000 Pa
Measuring Range
▲ ▼ ▲ ▼ ▲ ▼
Reprogramming Mode 4.01 to 5.00 in “BASE SETUP”
1 2 3 45 6 7
4.01
Mode P
«4.01»
Mode ▲
«5.00»
Mode P5.00 Mode
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7.4 Parameter table
Parameter Display / factory setting Funktion
Mode 4.00 4.01 5.00 5.01 Mode
INFO Information
Δp
0 Pa
(0.000
in.wg)
0 Pa
(0.000
in.wg)
- - Display actual value for
differential pressure
qV - - 0 m
3
/h
(0 cfm)
0 m
3
/h
(0 cfm)
Display actual value for
airflow
Setpoint 1 -
500 Pa
(2.000
in.wg)
-1185 m
3
/h
(697 cfm) Display active Setpoint
Range qV - - 2371 m
3
/h
(1394 cfm)
2371 m
3
/h
(1394 cfm)
Air volume measuring
range depending on
sensor measuring
range and K-Factor
Uout 0.0 V 9.9 V 0.0 V 9.9 V Magnitude of the out-
put voltage 0...10 V
UNIcon 2.01 2.01 2.01 2.01 Software version
Δp - -
0 Pa
(0.000
in.wg)
0 Pa
(0.000
in.wg)
Display actual value for
volume measurement
SETTING 4.01 + 5.01 Setting
Setpoint 1 -
500 Pa
(2.000
in.wg)
-1185 m
3
/h
(697 cfm) Setpoint 1
1
Setpoint 2 -
500 Pa
(2.000
in.wg)
-1185 m
3
/h
(697 cfm)
Setpoint 2
1
(active if voltage at ter-
minals 1, 2)
Pband -
500 Pa
(2.000
in.wg)
-1185 m
3
/h
(697 cfm) Pband
1, 2
Min. Uout - 0.0 V - 0.0 V
Min. output voltage:
0.0...10.0 V (priority
over “Max. Uout”)
Max. Uout - 10.0 V - 10.0 V Max. output voltage:
10.0...0.0 V
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Parameter Display / factory setting Funktion
BASE SETUP Base setup
Mode 4.00 4.01 5.00 5.01 Mode
metric
Units
metric units: Pa, m
3
/h, K-Factor
inch units: in.wg, cfm, K-Factor US
SI units or Imperial
units (US)
Measuring
Range
1: 0...1000 Pa (0...4.0 in.wg)
2: 0...500 Pa (0...2.0 in.wg)
3: 0...300 Pa (0...1.2 in.wg)
4: 0...200 Pa (0...0.8 in.wg)
Adjustable measuring
range
K-Factor
K-Factor US - - 75 (697)
75
(697)
Nozzle coefficient (K-
Factor)
following
table
Autozero OFF > ON Automatic “0” offset
3
Offset 0 Pa
(0.000 in.wg)
Sensor offset (auto-
matically when “Auto-
zero”)
Setting range: +/ -
1000 Pa (+/- 4.000
in.wg)
1 Setting range 4.01 : 0..100 % sensor measurung range, 5.01 : 0...Max. Range qV (depending
on K-Factor and sensor measuring range)
2 small value quick regulation, great value slow regulation (high stability)
3 Do the adjustment with the pressure hoses disconnected, the necessary difference up to “0” is
displayed under “Offset”.
- Parameter for selected mode not available
(xxx) Values for Imperial units (US)
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7.5 Measuring ranges and tolerance of pressure sensor
At the factory the devices are set to the respective highest meas-
uring range ( MB1). As small as possible measuring range must
be chosen for maximum accuracy at maximum resolution of the
output signal (
BASE SETUP of respective Mode).
Measuring ranges and tolerance ( 4.00 output 0 - 10 V)
PCA 1000D NA
[%]
EA
[%]
LA
[%]
A
[%]
H
[%]
MB [Pa]
MB1: 0...1000 +/-0.5 +/-0.5 +/-0.25 0.1 0.2
MB2: 0...500 +/-0.7 +/-0.7 +/-0.5 0.2 0.2
MB3: 0...300 +/-0.9 +/-0.9 +/-0.9 0.3 0.2
MB4: 0...200 +/-1.0 +/-1.0 +/-1.25 0.3 0.2
Temperature drift (related to the highest measuring range) Zero point: +/-0.2 %
/ 10 K,
final value: +/- 0.2 % / 10 K
MB Measuring range, NA Zero point deviation, EA Final value deviation,
LA Linearity deviation, A Resolution, H Hysteresis
Nozzle coefficient (K-Factor) 5.00 + 5.01
Maximum K-Factor depending on the measuring range of the pressure sensor
Range
[Pa]
[in.wg]
200
0.8
300
1.2
500
2.0
1000
4.0
Max.
K-Factor
US
4596
32767
3752
32767
2906
32767
2055
32500
Air volume measuring range [m
3
/h], [cfm] depends on selected
measuring range of pressure senosr [Pa], [in.wg] and selected “K-
Factor (US)”. In menu “INFO” display for “Range qV”. Maximum
measuring range in each case possible “K-Faktor (US)”
Techni-
cal data.
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7.6 Check sensor function
1. Program Mode 4.00 for pressure sensor.
2. Voltage supply (+Ub and GND) connected, output 0 - 10 V (A -
GND) disconnected.
3. Remove pressure hoses and measure output signal, nominal
0 V.
4. Create pressure at the "+" connection against the "-" connection
(e.g. by carefully blowing in), measure the output signal
(0...10 V
measuring range).
5. If the sensor works, reconnect the pressure hoses and check
these if necessary.
8 Enclosure
8.1 Technical data
Type PCA 1000D
Part-No. 38999
(320043-42)
Pressure measuring range 1 0...1000 Pa
(0...4.0 in.wg)
Pressure measuring range 2 0...500 Pa
(0...2.0 in.wg)
Pressure measuring range 3 0...300 Pa
(0...1.2 in.wg)
Pressure measuring range 4 0...200 Pa
(0...0.8 in.wg)
Air flow-Measuring range max. 65000 m
3
/h (38257 cfm) depending on
set measuring range and K-Factor
Voltage supply 10 V...24 V DC
Protected against reverse polarity
Operating Instructions PCA 1000D Enclosure
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@ U
b
10 V DC @ U
b
13...24 V DC
Max. load output 0 - 10 V
(short-circuit-proof)
0.3 mA 10 mA
Max. current consumption ca. 6 mA 14 mA
Pressure connections “+, -”Hose connectors d 5 / 6 mm (0.20 / 0.24 inch)
Housing Cover ABS, bottom Polyamid PA 6.6
Fire protection classification UL 94 HB
Use position vertical (measuring depends on position)
Protection class IP54 according EN 60529
Weight approx. 250 g (0.55 lb)
Permissible ambient temperature -10...50 °C (14...122 °F)
Permissible rel. humidity 85 % no condensation
Overload protection 0.2 bar (80 in.wg)
Static pressure max. 0.2 bar (80 in.wg)
Interference emission according EN 61000-6-3 (domestic household
applications)
Interference immunity according EN 61000-6-2 (industrial applica-
tions)
Operating Instructions PCA 1000D Enclosure
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8.2 Connection diagram
GND A GND 1 2+Ub
MCDU02K1
20.02.2014
PCA 1000D
+
+
10...24 V DC
+
4
+ -∆p
3
p
VPI
Ri= 4 kΩ
0 1
0 = Setpoint 1
1 = Setpoint 2
Spannungsversorgung
Voltage supply
10...24 V DC
(10 V: Imax = 6 mA)
(13...24 V: Imax = 14 mA)
1
UB
Ausgang
Output
0...10 V
(Imax = 0.3 mA @ UB 10 V)
(Imax = 10 mA @ UB 13...24 V)
2
Uout
+
-
1 Voltage supply 10...24 V DC
2 Output 0...10 V
3 Pressure connections
4 Voltage input for switch over Setpoint 1 / Setpoint 2
8.3 Dimensions [mm]
104
70
95
- +
4,5
114
108
56
ø5
ø6
10
20
KT00042A
16.06.2011
Operating Instructions PCA 1000D Enclosure
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8.4 Manufacturer reference
Our products are manufactured in accordance with the relevant
international regulations. If you have any questions concerning the
use of our products or plan special uses, please contact:
Systemair
Industrievägen 3
73930 Skinnskatteberg
Telefon:[phone]
Telefax:[phone]
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