breezair industrial wall control - iwc10 application notes (english)

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® Application Notes Industrial Wall Control (IWC10)

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Page 1: Breezair Industrial Wall Control - IWC10 Application Notes (English)

®

ApplicationNotes

Industrial�WallControl�(IWC10)

Page 2: Breezair Industrial Wall Control - IWC10 Application Notes (English)

The�Breezair�Industrial�Wall�Control�(IWC10)�is�designed�to�provide�both�local�and�external�Evaporative Air�coolercontrol�for�all�Breezair�air�coolers�fitted�with�the�CPMD�digital�module. The�external�control�may�be�either�a�PLC�orBuilding�Management�System. The�IWC10�is�designed�to�accept�external�logic�input�voltages�ranging�from�4Vdc�to32Vdc�and�analogue�input�voltages�from�0�-�10�Vdc.�It�will�switch�outputs�ranging�from�1.4Vdc�to�32Vdc�at�a�load�of40mA. The�IWC10�has�binary�outputs�for Temperature�and�Humidity�for�use�with�other�equipment.

Within�this�limit,�the�maximum�sensor�cable�length�must�not�exceed�60m.�EG:�a�combination�of�40m�ofcomms�(communications)�cable�and�60m�of�sensor�cable�is�permitted�and�80m�of�comms�cable�and�20m�of�sensorcable�is�permitted.

Each�IWC10�kit�is�provided�with�one�20m�sensor�cable�and�one�40m�comms�cable.�80m�comms�cables�and�60msensor�cables�are�available�as�an�option,�to�be�purchased�separately.The�above�restrictions�apply�in�order�to�avoid�excessive�voltage�drop�and�electrical�noise.YOU�MAY USE�LONGER�CABLES�WHEN�REQUIRED,�BUT WHEN YOU�DO THE�FOLLOWING�CONDITIONSMUST APPLY:

Cable�conductors�must�be�larger�to�reduce�voltage�drop.Cables�must�be�screened�(or�shielded)�to�reduce�noise.Screens�must�be�earthed�(grounded).Ensure�that�conductors�are�correctly�orientated.�Use�junction�boxes�or�high�quality�plugs�forterminations.Seeley�International�takes�no�responsibility�for�mal-function�of�the�IWC10�when�longercables�are�used.See�diagram�2.

CABLE�LENGTHSThe�maximum�total�cable�length�between�the�cooler�CPMD�module�and�the�Remote�sensor�(via�the�IWC10)is�100m.

1Industrial�Wall�Control Application�Notes 1

AUTO�[Auto]�mode,�and�manual�control�of�the�cooler�functions�in�the�MANUAL [Man]�mode.

To�ensure�signal�integrity�over�distances�greater�than�100�meters�between�the�IWC10�and�the�PLC�or�Buildingmanagement�system�it�is�advisable�to�use�shielded�cables.

Connect�the�Positive�input�to�the�input�terminals. This�voltage�must�range�between�4Vdc�to�a�maximum�of�32Vdcfor�the�logic�inputs�and�0�-�10V�for�the�analogue�speed�control.�Current�in�the�input�is�limited�by�the�seriesresistors.Connect�the�Negative�input�to�the�common�terminal.The�IWC10�does�not�have�its�own�internal�power�supply�to�operate�the�external�inputs.

The�IWC10�may�also�be�set�up�to�control�the Air�Cooler�from�EXTERNAL devices,�such�as�PLCs�and�BuildingManagement�System�computers.�In�this�case�the�IWC10�will�cease�to�function�in�its AUTO�[Auto]�or�MANUAL[Man]��mode�and�will�respond�only�to�the�external�commands.

The�IWC10�provides�at�all�times�outputs�that�may�be�employed�to�command�other�external�devices�such�asdampers,�fans,�signal�equipment,�etc. These�outputs�contain�the�status�of�the�various Air�Cooler�components�(fan,pump,�drain�valve),�as�well�as�the�Remote�Sensor�temperature�and�humidity�values.

INPUT�CONFIGURATION

These�cables�are�transmitting�digital�signalsand�must�not�be�installed�next�to�power�cables.

INPUTS AND�OUTPUTSThe�IWC10�may�be�set�up�to�control�the Air�Cooleras�a�local�machine,�independent�of�any�otherdevices.�In�that�case�there�will�not�be�anyconnections�made�to�the�Input�and�Outputterminals. The�Remote�Sensor�supplied�in�this�Kittogether�with�the�IWC10�will�provide�automatictemperature�and/or�humidity�control�along�with�itswater�management�and�auto�drain�features�in�the

WHITE WHITE

WHITE

WHITE

BLACK BLACK

BLACK

BLACK

RED RED

RED

RED

GREEN GREEN

GREENGREEN

YELLOW YELLOW

YELLOW

YELLOW

BLUE

ILL1415-A

BLUE

BLUE

BLUE

2CONNECTION�ORDER�FOR�SENSOR�CABLE�ONLY

Page 3: Breezair Industrial Wall Control - IWC10 Application Notes (English)

Industrial�Wall�Control Application�Notes

INPUT�CONFIGURATION�(continued)

INPUTS

In�EXTERNAL [EXTERNAL]�mode�the�power�sourcemust�be�provided�adjacent�to�the�Wall�Control�via�apower�outlet�and�adaptor. The�adaptor�may�be�acommon�small�appliance�adaptor�such�as�used�fortelephones,�answering�machines,�weigh�scales�etc,having�the�specified�electrical�output�(see�page�1).

If�any�one�of�inputs�2,3�or�4�is�high,�or�a�voltage�>0.5Vdc�is�detected�at�Input�6,�the�IWC10�MANUAL[Man]�and AUTO�[Auto]�controls�will�be�over-ridden�andthe�IWC10�will�not�respond�to�temperature�and�humiditychanges�sensed�by�the�Remote�Sensor.�In�EXTERNAL[EXTERNAL]�and AUTO�[Auto]�modes�the Temperatureand�Humidity�and�clock�displays�will�cycle�every�5seconds.Input�1�[Safety�Off]��-�Safety�OFF

R

!

Input�2�[F1]��-�Fan1

This�input�enables�the�Cooler�to�be�switched�OFF. A positive�voltage�to�the�input�1�of�the�IWC10�holds�the�system�inthe�OFF�state,�and�is�indicated�on�the�IWC10�screen�by�a .

This�input�enables�the�fan�to�run�at�minimum�speed�when�a�positive�voltage�isapplied.�It�functions�in�conjunction�with�Input�3�in�a�binary�code�to�providethe�external�control�with�three�different�speed�settings�for�the�cooler�fan.�WithInput�Fan1�and�Fan2�positive�the�cooler�will�run�at�maximum�speed.

With�Input�Fan1�and�Fan2�positive�the�cooler�will�run�at�maximum�speed.

WARNING It�is�not�recommended�that�this�switched�input�be�used�to�control�the�Cooler�in�an�emergencysituation,�because�it�is�not�fail-safe,�ie:�if�for�any�reason�the�cable�continuity�is�cut,�it�is�not�possible�toapply�a�positive�voltage�to�input�1�to�switch�the�cooler�OFF.

Input�3�[F2]��-�Fan2

Input�4�[Pump]��-�Pump�ON�/�OFF

Input�5�[H.E.]��-�Humidity�Enable

Input�6�[SP1]��-�Speed�Control

Input�7�[HD]��-�Humidity�Disable

Input�8�[ON/OFF]��-�Remote�ON/OFF

This�input�enables�the�fan�to�run�at�medium�speed�when�a�positive�voltage�is�applied�when�there�is�no�voltage�onInput�2.

This�input�enables�the�pump�to�run�when�a�positive�voltage�is�applied.�However,�the�pump�operation�is�subject�tothe�CPMD�module�and�the�status�of�the�cooler.�If�there�is�insufficient�water�in�the�tank�the�pump�will�not�run�untilwater�is�at�the�correct�level�as�sensed�by�the�water�probes.

This�input�only�functions�when�the�IWC10�is�in�EXTERNAL [EXTERNAL]�Mode.�It�is�possible�for�External�controls�todrive�the�cooler�to�the�point�where�the�room�humidity�exceeds�the�default�set�point�as�sensed�at�all�times�by�theBreezair�Remote�Sensor. This�input�enables�the�IWC10�to�over-ride�the�external�pump�command�and�disallow�thepump�to�run�when�the�room�humidity�goes�high.�If�this�Input�is�not�enabled,�the�pump�will�run�as�required�by�theexternal�command�regardless�of�room�humidity.

This�input�enables�the�fan�speed�to�be�switched�from�OFF�(0)�to�Speed�10�by�adjusting�the�analogue�input�between0V�(Off)�to�10Vdc�(Speed10).

This�input�disables�Humidity�control�in AUTO�[Auto]�mode�when�no�External�[EXTERNAL]�control�is�present. Thecase�may�arise�in AUTO�[Auto]�in�which�the�temperature�is�satisfied�and�the�fan�is�therefore�stopped.�BUT theindoor�humidity�may�fall�below�the�set�point�and�the�IWC10�will�demand�that�the�cooler�operate�to�raise�the�humidityto�the�set�point. The�effect�will�be�to�lower�the�room�temperature�still�further.�If�this�is�undesirable,�the�humiditycontrol�may�be�disabled�by�this�input.

The�system�will�NOT re-start�automatically�when�the�input�is�removed.

This�input�is�used�to�turn�the�cooling�system�ON�or�OFF�from�a�remote�location.The�input�must�be�in�the�form�of�a�momentary�pulse�(provided�by�the�installer)�for�both�ON�and�OFF�functions. Anyrepeated�pulses�received�within�2�seconds�of�the�first�pulse�will�be�ignored.When�a�pulse�is�received�during�cooling�system�operation�(whether AUTO�or�MANUAL)�the�control�will�save�thecurrent�state�of�the�system�and�the�system�will�enter�a�stand-by�state�and�shut�down.When�the�next�pulse�is�received�at�Input�8,�the�cooling�system�will�start�up�again�in�the�same�mode�in�which�it�waslast�shut�down.In�the�event�that�the�cooling�system�is�re-started�manually�during�the�standby�state,�the�next�pulse�received�at�input8�will�shut�down�the�system�into�standby�mode.

2

FAN

X X

XX

X X

XX

INPUT�2 INPUT�3

OFF

HIGH NIL NILHIGH

LOW

MED

HIGH

3

J4

IN1

IN2

IN3

IN4

COM

ILL1345-A

LOGIC�INPUT ANALOGUE�INPUTInput�6

Speed�ControlAnalogue�Input

0�-�10VdcOff�-�Speed�10

SPD�CTRL

COMMON

20k

Page 4: Breezair Industrial Wall Control - IWC10 Application Notes (English)

This�output�is�activated�whenever�the�air�cooler�fan�has�been�turned�ON.

This�output�is�activated�whenever�the�air�cooler�pump�has�been�turned�ON.

This�output�is�activated�whenever�the�air�cooler�is�under�external�control.

This�output�is�activated�whenever�the�air�cooler�is�in�a�fault�condition.�Refer�to�Installation�and�Operation�manual,SERVICE�[SERVICE]�Mode,�page�8�for�more�details�about�faults.

This�output�is�activated�whenever�the�air�cooler�has�been�turned�ON�or�is�in�Standby�Mode. The�binary�informationrepresents�humidity�as�a�percentage. The�bit�stream�is�described�on�page�4.

This�output�is�activated�whenever�the�Drain�Valve�is�open.�It�will�activate�only�after�the�time�delay�period�set�in�theIWC10�Program. The�output�will�remain�activated�while�the�Drain�valve�is�open.�If�the�Drain�valve�opens�for�aperiod�of�time�less�than�the�delay�time�set,�the�output�signal�will�remain�activated�for�5�seconds�only.

Output�2�[Fan]�-�Fan�ON�/�OFF

Output�3�[Pump]�-�Pump�ON�/�OFF

Output�4�[Ext]�-�External�Control

Output�5�[Fault]�-�Fault�ON�/�OFF

Output�6�[S.Hum]�-�Serial�Humidity

Output�7�[S.Temp]�-�Serial�Temperature

Output�8�[Drain]��Drain�Control�Output

This�output�is�activated�whenever�the�air�cooler�has�been�turned�ON�or�is�in�Standby�Mode. The�binary�datarepresents�10�x Temperature�(in C). The�bit�stream�is�described�on�page�4.°

OUTPUT�CONFIGURATIONIWC10�outputs�1,2,3,4,5�&�8�are�switches�only. They�will�function�whenconnected�to�a�power�supply�from�an�external�source�of�(1.4�-�32Vdc�at40mA load).Connect�the�external�DC�power�supply�to�the�load,�connect�the�negative�ofthe�load�to�the�desired�output�terminal�and�connect�the�negative�of�thepower�supply�to�the�common�[com]�terminal�on�the�IWC10. The�output�willthen�turn�on�your�load�as�desired�(page�4).

Outputs

Output�1�[ON]�-�System�ON�/�OFF

All�outputs�are�indicators�only�of�the�state�of�the�air�cooler.�None�of�themare�monitored�for�integrity. A fault�on�an�output�line�is�not�indicated�in�theIWC10.

This�output�is�activated�whenever�the Air�Cooler�has�been�turned�ON��fromany�source,�in�any�mode.

Industrial�Wall�Control Application�Notes

4

J6

OUT1

OUT2

OUT3

OUT4

COM

ILL1346-A

3

Page 5: Breezair Industrial Wall Control - IWC10 Application Notes (English)

4Industrial�Wall�Control Application�Notes

Pause Start�pulse Pause

lsb

lsbmsb

msb

H LDHLDH

One�byte

DATA

1 1 1 1 1 1 1 1

1 1 1 1 10 0 0

Temperature�and�Humidity�bit�stream

Start�pulseA High�BitA Low�BitPauseUpdate�RateShift�in�PLC

The�IWC10�outputs�Humidity�and Temperature�readings�for�use�with�a�PLC�or�building�management�system.Humidity�is�output�on�terminal�OUT6�of�J7�and Temperature�is�output�on�terminal�OUT7�of�J7. The Temperaturedata�word�is�9�bits�after�7�bits�of�leading�one's�(1),�while�the�Humidity�data�byte�is�8�bits�after�8�bits�of�leading�one’s.

The�temperature�value�is�invert�binary�and�is�10�x�the Temperature�reading.

The�humidity�value�is�invert�binary�and�is�a�direct�representation�of�the�Humidity�reading.The�below�example�(shown�at�1�sec/division)�is�44%�RH

The�Humidity�value = 11111111 11010011Invert�binary�number = 00000000 00101100Humidity�reading = 44%

Start�Pulse

Bit�7�(msb�of�data)���������������������������������������������Bit�8�(msb�of�data)

..Bit�0�(lsb�of�data)

For�example: The�temperature�value = 1111111 100110001Invert�binary�number = 0000000 011001110Decimal�number = 206Temperature�reading = 206/10 = 20.6°C

The�bit�format�is�S�H�L D�H�L D�H�…L D�H�P where:S�=�Start�pulseL =�LowH�=�High�(for�synchronisation�purposes)D�=�Data�state�(high�or�low)P =�Pause

: :Start�Pulse

Bit�15�to�Bit�8�all�One�(1)������������������������������������Bit�15�to�Bit�9�all�One�(1)

..�����������������������������������������������������������������������..

..Bit�0�(lsb�of�data)

Pause Pause

:750mSec�off,��250mSec�on250mSec�off,��500mSec�on500mSec�off,��250mSec�on1000mSec�on14�secondsLEFT

The�Humidity�Bit�stream�is�as�follows�������������The Temperature�Bit�stream�is�as�follows

The�bit�timing�is�as�follows

Page 6: Breezair Industrial Wall Control - IWC10 Application Notes (English)

Industrial�Wall�Control Application�Notes 5

5

60m.

CPMD

HUB�1

HUB�2

SENSORIndustrial�Wall

Industrial�Wall

Control

Control

SENSOR

CPMD

CPMD

CPMD

20m. Any�lengthOK�up�to�combinedlength�of�140m�fromIWC�to�CPMD.

Any�lengthOK�up�to�combinedlength�of�200m�fromIWC�to�CPMD.

60m.

CPMD

CPMD

CPMD

CPMD

CPMD

max�40m�!

max�40m�!max�40m�!

max�40m�!

max�40m�! max�40m�!

max�40m�!

max�120m�!

max�120m�!

max�140m�!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

Coolers�are�supplied�with�20m�data�cable�inaccessories�kitHubs�are�supplied�with�20m�data�cable�in�kit.Industrial�Wall�Controls�(IWC)�are�supplied�with20m�Sensor�cable�in�kit60m�Sensor�cable�on�reel�available20m�data�cable�in�re-sealable�bag�available40m�data�cable�on�reel�available60m�data�cable�on�reel�available80m�data�cable�on�reel�available100m�data�cable�on�reel�available4-way�in-line�joiners�available�to�extend�data�cableto�maximum�lengths�shown�on�diagramData�cables�may�be�shortened�or�lengthened�(tomaximums�shown),�using�ONLY correct�RJconnectors�and�crimping�toolsCables�supplied�by�Breezair�are�26AWG,�7/016,�4core�&�6�core�flatALWAYS�route�cables�at�least�300mm�away�fromregular�power�cables�and�high�power�machines.Cross�over�power�cables�at�right�angles.Where�maximum�data�cable�and�sensor�cablelengths�are�exceeded,�or�cables�are�not�routed�inaccordance�with�our�recommendations�Seeleytechnical�support�is�not�available�and�the�productwarranty�may�be�voided.

Breezair�Control�SystemCable�Lengths

Industrial�Wall�Control824130-A 0703

MASTER

MASTER

MASTER

SLAVE�1

SLAVE�1SLAVE�2

SLAVE�3

SLAVE�3

SLAVE�2

Any�lengthOK�up�to�combinedlength�of�200m�fromIWC�to�CPMD.

LOGIC�INPUTCONNECTION

All�Commons�connectedto�Negative

4-32VDC<=12mAmps D2

R1Input

Common

D1

OUTPUTCONNECTION

All�Commons�connectedto�Negative

Common

OutputR3

D3Q1

R2

Q2NPN

RES-NTC1.4-32VDC<=40mAmp

(C)�SEELEY INTERNATIONALAUSTRALIA 2004

J6J4

J7J5J3J2

RJ11RJ12

CPMDCOMMS

REMOTESENSOR

OUT

OUTIN

IN

1 2 3 4 51 2 3 4 5

Co

m

Co

m

In1

In2

In3

In4

Co

m

In5

In6

In7

In8

Co

m

Ou

t1

Ou

t2O

ut3

Ou

t4

Ou

t5

Ou

t6

Ou

t7

Ou

t8

Sa

fety

�Off F1

F2

Pu

mp

H.E

HD

Sp

d�C

on

t

ON

/OF

F

On

Fan

Pu

mp

Ext

Fau

lt

S.H

um

S.T

em

p

Dra

in

1 2 3 4 51 2 3 4 5

1 2 3 4 5

858746-A

ANALOGUEINPUT

Common

20k

Spd�Cont

Speed�ControlAnalogue�Input

0�-�10Vdc

Off�-�Speed�10

Page 7: Breezair Industrial Wall Control - IWC10 Application Notes (English)

Industrial�Wall�Control Application�Notes 6

FAN�SPEEDS�& AIR�FLOW

MINIMUM Speed�3MEDIUM Speed�6MAXIMUM Speed�10

ALL 10�SPEEDS�CAN�BE�SELECTED.

When�the�wall�control�is set�for ,�the�fan�is�controlled�through�10�speedsaccording�to�the�automatic�or�manual�settings.

When�the�wall�control�is�set�for ,�the�fan�can�only�operate�in�2�modesA. Logic�control�inputs�2�&�3,�only�3�speeds�can�be�selected

B. Analogue�Input�6

For�the�purpose�of�applying�the�Breezair�coolers�to�various�downstream�systems,�the�air�flow�performance�curvesare�provided�below.

NOT EXTERNAL [EXTERNAL]�mode

EXTERNAL [EXTERNAL]�mode

Breezair TBA 550 Airflow - Industrial wall control speed settings

for "External" fan speed inputs.

0

20

40

60

80

100

120

140

160

180

200

1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100

Airflow L/s

Sta

tic

Pre

ssu

re(

Pa

)

Speed 10 - max

Speed 6

Speed 3

Page 8: Breezair Industrial Wall Control - IWC10 Application Notes (English)

ILL1331-A

828534-H AU��1011

Evaporative Air Cooling Manual. Seeley International Pty Ltd, Adelaide, South Australia. ACN 054 687 035.As the policy of the company is one of continuous product improvement, all specifications are subject to change without notice.