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C3-05 Controls O&M Version 3.1

Q: Describe how the combined temperature and humidity sensor operates within an HVAC system and its significance.

The combined sensor uses an NTC resistive element for temperature and a voltage-based signal for humidity, proportional to relative humidity levels. By providing real-time data, it enables precise environmental control, crucial for maintaining desired conditions within the system's operational range .

Q: What role does the valve actuator play in chilled water systems, and how does it achieve desired cooling levels?

In chilled water systems, the valve actuator positions a three-way valve to meet cooling demands by using outputs to open or close the valve. The controller calculates the required actuation time to achieve the desired cooling level, ensuring the valve starts from a known closed position for accuracy .

Q: What factors must be considered when commissioning or replacing a controller for an Air Handling Unit (AHU)?

When commissioning or replacing a controller, factors such as ensuring all operational parameters meet site requirements, setting factory configuration specifically for the AHU type, and managing static sensitive devices are important. Proper configuration ensures compatibility and optimal performance of the AHU .

Q: Explain the significance of the 'valve opening at start-up' parameter in an HVAC system and how incorrect settings might affect operations.

The 'valve opening at start-up' parameter ensures the valve begins at a suitable position, critical for preventing low-pressure shutdowns if set too low. Incorrect settings could prevent the valve from fulfilling its cooling role effectively, necessitating recalibration or adjustment to match the rated capacity of the system components .

Q: Why is it important to appropriately configure the LOP protection in HVAC systems, and what steps ensure its effectiveness?

Appropriate configuration of LOP protection is crucial to prevent damage from operating under low pressure. Ensuring effectiveness involves setting the LOP integration time greater than zero, calibrating the threshold at the correct saturated evaporation temperature, and decreasing the integration time to prevent premature triggering .

Q: How can incorrect solenoid valve operations be diagnosed and resolved in a cooling system?

Incorrect solenoid valve operations can be diagnosed by checking if the solenoid opens correctly and confirming reliable electrical connections. If the movement is reversed, reversing the connections can solve the issue. If the solenoid is blocked or stuck, manual control operation should be attempted, and the valve might need replacement if problems persist .

Q: How do the control air temperature, temperature setpoint, cooling proportional band, and cooling dead zone contribute to determining cooling demand in a microprocessor controller system?

The control air temperature must be measured and compared to the temperature setpoint, which dictates how much cooling is needed. The cooling proportional band influences how aggressively the cooling system responds to deviations, while the cooling dead zone defines a range where no cooling changes occur despite temperature discrepancies. Together, these factors determine how the system calculates and responds to cooling demand .

Q: Discuss the process and importance of automatic sequencing in compressor stages for cooling demand management.

Automatic sequencing ensures balanced running hours and minimal starts by making the first stage to start also the first to stop. This process maximizes efficiency and lifespan of compressors. It can be deactivated for scenarios requiring consistent use of a specific stage, such as Hot Gas Re-heat configurations .

Q: In what scenarios might heating and humidifier functions be mutually exclusive in HVAC systems, and how is this managed?

Heating and humidifier functions might be exclusive when electrical supply limits the simultaneous operation of both. This is managed through software configurations that prioritize one function over the other, ensuring only one operates at any time, thus reducing power consumption and maintaining system balance .

Q: What mechanisms are in place to prevent excessive compressor starts in cooling systems, and how do they function?

The cooling system utilizes a software timer that delays re-energizing the cooling output for six minutes after activation to prevent excessive compressor starts. Additionally, a Low Pressure (LP) delay timer is triggered when the cooling output is active, initially set at 10 minutes, to allow the system to operate within safe parameters before any LP alarms de-energize the output .

This document provides an operation and maintenance manual for C3-05 controls. It includes details on the hardware structure, handling static sensitive devices, inputs and outputs, display information, software flowcharts, networking, troubleshooting and more. The manual gives concise information on the controller's hardware, inputs, outputs, software operation and maintenance to properly operate and service the C3-05 controls.

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100% found this document useful (1 vote)

3K views77 pages

C3-05 Controls O&M Version 3.1

Uploaded by

Stefan Lyamov

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You are on page 1/ 77

C3-05 Controls

Operation & Maintenance

Manual

GEA Denco Stock Code No: 2/184/073

Version 3 05/09 C3-05 Controls

Contents
Hardware Structure 3

Handling Static Sensitive Devices 4

Inputs and Outputs 5

Display Information 7

Time Out Display 8

Alarms and Interlocks 9

Software Level 1 Flowchart 11

Software Level 2 Flowchart 12

Software Level 3 Flowchart 13

Software Level 3 Factory Config Flowchart 16

Software Historical Data Flowchart 23

Networking 24

Serial Data Interface(s) 30

pCOWeb Denco Web Page 33

Supervisory Variable List 34

Controller Operation with Temperature Control 47

Tuning the Control Loop 48

Cooling Operation 49

Electronic Expansion Valve Operation (option) 52

Electronic Expansion Valve Troubleshooting 54

Heating Operation 56

Humidifier 57

Water Detection (option) 62

Differential Pressure Transducer (option) 63

Heat Pump Operation (option) 64

Dehumidification Operation 65

Ambicool Operation 66

Combicool Operation 66

Supply Air Temperature Interlock with Cooling 67

Supply Air Humidity Interlock with Humidification 67

Heater / Humidifier Interlocks 67

Generator Run 67

Combined Temperature and Humidity Sensor 68

Commissioning / Controller Set Up 69

Controller Removal and Replacement 70

Display Removal and Replacement 70

Software Upgrade 71

Servicing: Check List 72

Control Component Parts List 72

Fault Finding: Controls 73

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Version 3 05/09 C3-05 Controls

Hardware Structure

24V AC Supply Spare RJ 11 Port

Supply For Ratiometric Connection to Display

Pressure Transducers

Connection to Denconet

Analogue Inputs 1 to 3

Analogue Inputs 4 & 5

Power Supply LED & Digital Outputs 1 to 13

Network Healthy LED’s

Analogue Outputs 1 to 4

Optional Serial Data Interface Port

Digital Inputs 1 to 8

Digital Outputs 14 to 18

Digital Inputs 15 & 16

Analogue Inputs 6 to 8

Digital Inputs 9 to 12

Expansion I/O
Connection
Digital Inputs 13 & 14

Digital Inputs 17 & 18 Analogue Inputs 9 & 10 Analogue Outputs 5 & 6

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Handling Static Sensitive Devices

Note: It is very important that the following procedures are adhered to. Failure to do so may cause the Unit to
malfunction, and will invalidate any warranty on the controller and associated boards.

The controller, graphical displays, network and interface boards contain devices sensitive to body static
discharges. If they have to be removed and handled, follow the procedure given below:

r Discharge body static by wearing anti-static wrist straps (or similar suitable grounding straps) connected
to earthed (grounded) metal.

r Ensure that an anti-static bag is ready to hand.

r Switch off at the display ON/OFF switch. Turn the unit isolator to the "OFF" position.

r Wait at least 30 seconds for the voltages on the controller to decay.

r Remove component board and place into anti-static bag.

r Repeat procedure when installing replacement boards.

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Inputs and Outputs

Base Controller
The following inputs and outputs are available on the Base Controller:

INPUTS
Digital
ID1 Unit Remote On/Off 24V AC (Open circuit = unit off)
ID2 Airflow Fail 24V AC (Open circuit = alarm condition)
ID3 Filter Blocked 24V AC
ID4 Klixon Trip 24V AC (Open circuit = alarm condition)
ID5 HP Trip Comp 1 (Or Tandem Circuit 1) 24V AC
ID6 HP Trip Comp 2 (Or Tandem Circuit 2) 24V AC
ID7 LP Trip Comp 1 (Or Tandem Circuit 1) 24V AC
ID8 LP Trip Comp 2 (Or Tandem Circuit 2) 24V AC
ID9 Water On Floor / Drip Tray Detection 24V AC
ID10 Humidifier Water Level / 24V AC (Open circuit = alarm condition)
Humidifier Global Alarm
ID11 Aux Alarm 24V AC
ID12 Generator Run 24V AC
ID13 Combicool Change-over 24V AC
ID14 Refrigerant Leak Detection 24VAC
ID15 HP Trip Comp 3 24V AC
ID16 HP Trip Comp 4 24V AC
ID17 LP Trip Comp 3 24V AC
ID18 LP Trip Comp 4 24V AC
Analogue
B1 Return Air Hum Sensor type: 0-1V
B2 Condensing Pressure 1/Suction Pressure Sensor type: 4 - 20 mA (Selectable)
B3 Condensing Pressure 2/Discharge Pressure Sensor type: 4 – 20 mA (Selectable)
B4 Return Air Temp Sensor type: NTC
B5 Supply Air Temp Sensor type: NTC
B6 Supply Air Humidity/DP Transducer Sensor type: 0-1V/4-20mA
B7 Humidifier Conductivity Sensor type: 0-1V
B8 Humidifier Current Sensor type: 0-1V
B9 Freecool / CW Temperature Sensor type: NTC

Notes:

(i) A high digital input condition will be within the voltage band –25% to +20% 50 Hz or 60 Hz. (High > 18.5V,
Low < 16.5V).
(ii) All digital inputs are opto-isolated complete with reverse voltage protection diodes.
(iii) HP / LP 3 and 4 Alarm inputs only available when C3-05 large controller fitted.
(iv) If ‘Heat Pump’ selected, B2 is configured for the Suction Pressure and B3 is configured for Discharge
Pressure.
(v) If ‘Humidifier Type’ selected for ‘Remote’, then ID10 is configured as a Humidifier Global Alarm.

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Inputs and Outputs (cont)

OUTPUTS
Digital
NO1 Unit Fan Relay Output Normally Open Contact
NO2 Dehumidification Relay Output Normally Open Contact
NO3 Heater 1 / DODC Heat Open / Thyristor Enable Relay Output Normally Open Contact
NO4 Heater 2 / DODC Heat Close Relay Output Normally Open Contact
NO5 Compressor 1 / DODC Cool Open / Combicool Relay Output Normally Open Contact
Secondary CW Open
NO6 Compressor 2 / DODC Cool Close / Combicool Relay Output Normally Open Contact
Secondary CW Close
NO7 Compressor 3 Relay Output Normally Open Contact
NO8 Compressor 4 Relay Output Normally Open Contact
NO9 Humidifier Power Contactor Relay Output Normally Open Contact
NO10 Hum Fill Valve Relay Output Normally Open Contact
NO11 Hum Drain Valve Relay Output Normally Open Contact
NO12 Critical Alarm Relay Output Normally Closed Contact
NO13 Maintenance Alarm Relay Output Normally Closed Contact
NO14 Freecool / Combicool Primary CW DODC Open Relay Output Normally Open Contact
NO15 Freecool / Combicool Primary CW DODC Close Relay Output Normally Open Contact
NO16 Dry Cooler Fan 1 Relay Output Normally Open Contact
NO17 Dry Cooler Fan 2 Relay Output Normally Open Contact
NO18 Heat Pump Enable Relay Output Normally Open Contact
Analogue
Condenser fan control Condenser fan control Condenser fan control
disabled enabled – 1 Circuit enabled – 2 Circuits
Y1 Evaporating Fan Evaporating Fan Evaporating Fan 0 – 10 VDC
Y2 Heating Heating Heating 0 – 10 VDC
Y3 Cooling Condenser Circuit 1 Fan Condenser Circuit 1 Fan 0 – 10 VDC
Y4 Humidifier Humidifier Condenser Circuit 2 Fan 0 – 10 VDC
Y5 Cooling 0 – 10 VDC
Y6 Humidifier 0 – 10 VDC

Notes:

(i) All digital outputs are relay contacts rated at 24 VDC – 240 VAC 10A fitted with surge suppressor
network.
(ii) All PCB tracks rated to withstand let through energy of a 24 VAC control fuse (10A).
(iii) All output relay contacts common to 24 VAC (except alarm relays).
(iv) Valve open / close on heating / cooling / freecool outputs refer to drive open / drive close valves only.
(v) Drycooler fans and Freecool Valve open / close outputs only available when C3-05 large controller fitted.
(vi) The evaporating fan output is to operate concurrently with the cooling, heating, humidification and
dehumidification demands.
(vii) Cooling and heating outputs shall operate concurrently with digital / DODC outputs according to the
demand calculations.
(viii) If ‘Condenser Fan’ is configured for ‘Enabled’ and there are 2 cooling circuits, then a C3-05 large
controller is required for the cooling and humidifier demand 0-10VDC signals.

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Display Information

Alarm Key

On/Off Key

Graphical Display comprises:

r Unit ON/OFF key, providing "master" control of the local unit.

r Graphical liquid crystal display, providing icon status of the unit functions, parameter menus, historic data
logging, alarm buffer and access to other controllers via the network system.
r Four programming keys, providing access to display features.
r Alarm key to view active alarms.

Graphical Display Icons and Functions

Unit Functions are indicated via icons. These are:

UNIT RUN - shown when Unit fan(s) are running

COOL - shown when cooling demand is greater than 0%.

HEAT - shown when heating demand is greater than 0%.

HUMIDIFY - shown when humidification demand is greater than 0%.

DEHUMIDIFY - shown when dehumidification demand is greater than 0%.

The 8 row LCD indicates Unit Function via the icons on rows 1 and 2. The remaining rows show the selected
data, updated in real time.

The programming keys ( ↓ ↑ ← → ) have to be pressed in a coded sequence in order to enter or change the
function currently being accessed.

Current Alarm status can be reviewed by using the ← key to access the Alarm Buffer from the time-out display.

The display can be mounted upto 50 metres from the controller using the standard 6 core flat data cable.
A screened cable must be used if the display is to be mounted between 50 and 500 metres from the controller.
A separate 24Vac power supply is required when the display is to be mounted between 500 m and 1 kilometre.

A ferrite must be connected, at the display end of the cable, to reduce the risk of electrical interference.

GEA Denco Stock Code no: 2/184/073 7

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Time Out Display

Unit Model
D28AVH
Description
21.3°C U:01
Date
52.5%RH Unit Number
01:01:05 18:54
D28AVH
Unit ON
Time

Unit Status Return Sensor Values

The time-out display is the controllers' standard display at power up, during normal unit running conditions or the
default display from all software levels given that no key had been pressed for a five minute period.

When in Time Out Display, pressing the left (←) arrow key allows entry into the Alarm Buffer display. Alternatively
pressing the right (→) arrow key allows entry into the Main Menu display.

When in Time Out Display, pressing the down arrow (↓) key allows entry into four additional unit information
pages. These are set out as follows: -
Timeout Page

Temp Setpoint 22.0°C

Hum Setpoint 50.0%RH
Cooling Demand 000.0%
Heating Demand 000.0%
Hum Demand 000.0%
Dehum Demand 000.0%

AMBICOOL STATUS
A.cool Demand 000.0%
Freecool Temp 00.0°C
HUMIDIFIER STATUS
Conduct. 000us/cm
Current 0.0A

COMBICOOL STATUS

Primary Cooling p
Secondary Cooling p
Changeover By DI p
Changeover By Temp p

Supply Temp 00.0°C

Supply Hum 00.0%RH
Cond. Press1 00.0Bar
Cond. Press2 00.0Bar

Unit Serial Number

00A00000

Commissioning Date
00:00:00

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Alarms and Interlocks

Occurrence of alarms will cause the alarm key to illuminate red.
Pressing the alarm key will then display any active alarms.
To reset an alarm when viewing the active alarms, press the alarm key.
Pressing the ← key when in the time-out display will show any alarms held in the Alarm Buffer, which is capable of
holding 70 possible alarms complete with the time and date of the alarm generated in the sequence they
st st
occurred. The 71 alarm will replace the 1 alarm data.

No. Description Interlock Relay Detail

1 Return Air Temperature Sensor Failure Y Critical Disables Temperature Outputs
2 Return Air Humidity Sensor Failure Y Critical Disables Humidity Outputs
3 Circuit 1 Condenser Pressure Sensor Y - -
Failure
4 Circuit 2 Condenser Pressure Sensor Y - -
Failure
5 Water Temperature Sensor Failure Y - -
6 Supply Air Temperature Sensor Failure N - -
7 Supply Air Humidity Sensor Failure N - -
8 Airflow Failure Y Critical Disable All Outputs Exc. Unit
Run
9 Filter Blocked N C/M Relay Selectable Via Software
10 Water Detection Y Critical Disable Humidifier
11 Auxiliary Alarm N C/M Relay Selectable Via Software
12 High Control Air Temperature Alarm N Critical -
13 Low Control Air Temperature Alarm N Critical -
14 High Control Air Humidity Alarm N Critical -
15 Low Control Air Humidity Alarm N Critical -
16 Low Supply Air Temperature Alarm N Critical Reduce Cooling Demand
17 High Supply Air Humidity Alarm N Critical Reduce Humidification Demand
18 Klixon Trip Y Critical Disable Heater Outputs
19 Compressor 1 HP Trip Alarm Y Critical Disable Cool 1 Output
20 Compressor 2 HP Trip Alarm Y Critical Disable Cool 2 Output
21 Compressor 3 HP Trip Alarm Y Critical Disable Cool 3 Output
22 Compressor 4 HP Trip Alarm Y Critical Disable Cool 4 Output
23 Circuit 1 HP Trip Alarm Y Critical Disable Cool Outputs 1 & 2
24 Circuit 2 HP Trip Alarm Y Critical Disable Cool Outputs 3 & 4
25 Compressor 1 LP Trip Alarm N Critical Disable Cool 1 Output
26 Compressor 2 LP Trip Alarm N Critical Disable Cool 2 Output
27 Compressor 3 LP Trip Alarm N Critical Disable Cool 3 Output
28 Compressor 4 LP Trip Alarm N Critical Disable Cool 4 Output
29 Circuit 1 LP Trip Alarm N Critical Disable Cool Outputs 1 & 2
30 Circuit 2 LP Trip Alarm N Critical Disable Cool Outputs 3 & 4
31 Denconet Communication Alarm N - -
32 High Current Alarm (Cylinder Off) Y Maintenance Stops production
33 Lack Of Water Alarm (Cylinder Off) Y Maintenance Will clear automatically if water
detected
34 Low Current Alarm (Cylinder Off) Y Maintenance Stops production
35 Clock Alarm N - Internal clock battery defective
36 EEV Driver 1 Sensor Fail Y Critical Disable Cool 1 Output
37 EEV Driver 1 EEPROM Error Y Critical Disable Cool 1 Output
38 EEV Driver 1 Step Motor Error Y Critical Disable Cool 1 Output

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Version 3 05/09 C3-05 Controls

Alarms and Interlocks (cont)

No. Description Interlock Relay Detail

39 EEV Driver 1 Battery Error N - -
40 EEV Driver 1 High Evaporating Pressure N - -
41 EEV Driver 1 Low Evaporating Pressure N - -
42 EEV Driver 1 Low Superheat Y Critical Disables Cool 1 Output
43 EEV Driver 1 Valve Not Closed During Y Critical Disables Cool 1 Output
Power OFF
44 EEV Driver 1 High Suction Temperature N - -
45 EEV Driver 2 Sensor Fail Y Critical Disables Cool 2 Output
46 EEV Driver 2 EEPROM Error Y Critical Disables Cool 2 Output
47 EEV Driver 2 Step Motor Error Y Critical Disables Cool 2 Output
48 EEV Driver 2 Battery Error N - -
49 EEV Driver 2 High Evaporating Pressure N - -
50 EEV Driver 2 Low Evaporating Pressure N - -
51 EEV Driver 2 Low Superheat Y Critical Disables Cool 2 Output
52 EEV Driver 2 Valve Not Closed During Y Critical Disables Cool 2 Output
Power OFF
53 EEV Driver 2 High Suction Temperature N - -
54 High Conductivity Alarm Y Maintenance Disable Humidifier Output
55 High Conductivity Warning N Maintenance Signal Only
56 Low Production Alarm Y Maintenance Disable Humidifier Output
57 Drain Alarm Y Maintenance Disable Humidifier Output
58 Humidifier Cylinder Full Alarm Y Maintenance Disable Humidifier Output
60 Warning Foam Presence N Maintenance Signal Only
61 Warning Cylinder Exhaustion N C/M Signal Only
81 Refrigerant Leak Detection N Critical -
82- LECU n Offline N - -
117
118 Humidifier Global Alarm N Maintenance Remote humidifier Only

Notes

1. C/M Refers to the users choice of Critical or Maintenance relay which can be selected in Level 3, Alarm
Setup.

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Version 3 05/09 C3-05 Controls

Software Level 1 Flowchart

MAIN MENU

Level 1 Password ?
5.0 deg C
21.0
Level 2 Setpoints Temp Setpoint Set Temp Setpoint 35.0 deg C

Level 3 Hum Setpoint Set Hum Setpoint 0 %RH

50.0
100 %RH
Historic Data Software Version Version
Enabled
Time Control Enable On/Off Times >Disabled

On / Off Times ON/OFF TIMES

On Off
F1-1 00:00 00:00
F1-2 00:00 00:00
F2 00:00 00:00
F3 - On F4 - Off

On / Off Days Monday F4

Tuesday F4
Wednesday F4
Thursday F4
Friday F4
Saturday F4 ON SET
Sunday F4 Z1: 00:00 000.0°C
Z2: 00:00 000.0°C
Temp Setpoint Reschedule Enable Time Zones Yes Z3: 00:00 000.0°C
>No Z4: 00:00 000.0°C

Hum Setpoint Reschedule Enable Time Zones Yes ON SET

>No Z1: 00:00 000%
Z2: 00:00 000%
Set Clock Hour Set Hour Z3: 00:00 000%
Z4: 00:00 000%
Minutes Set Minutes

Day Set Day

Month Set Month

Year Set Year

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Software Level 2 Flowchart

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Software Level 3 Flowchart

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Software Level 3 Flowchart (cont)

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Software Level 3 Flowchart (cont)

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Software Level 3 Factory Config Flowchart

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Software Level 3 Factory Config Flowchart (cont)

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Software Level 3 Factory Config Flowchart (cont)

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Version 3 05/09 C3-05 Controls

Software Level 3 Factory Config Flowchart (cont)

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Software Level 3 Factory Config Flowchart (cont)

Alarm

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Software Level 3 Factory Config Flowchart (cont)

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Software Level 3 Factory Config Flowchart (cont)

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Software Historical Data Flowchart

MAIN MENU

Level 1

Level 2 (Sensor Type)

Last 70 Samples
Level 3
Entry Number : 000

Historic Data Return Temperature Recorded Value **

Return Humidity
Time Date
Supply Temperature*
Supply Humidity* Last 70 Samples
24 Hour Minimum
Cooling % Demand 24Hr Minimum
Heating % Demand 24Hr Maximum 25.9°c
Hum % Demand Sample Average
De-Hum % Demand 24 Hour Minimum
Ambicool % Demand*
25.9°c
Water Temperature*

24 Hour Minimum
* Only Available If Enabled
25.9°c

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Version 3 05/09 C3-05 Controls

Networking

Network Wiring

Up to a maximum of 8
units on the network

Rx+/Tx+

Rx+/Tx+
Rx+/Tx+

Rx-/Tx-

Rx-/Tx-
Rx-/Tx-

GND

GND
GND

GND
Unit 1 Unit 2 Unit 3 Unit 8 (max)

Note: The recommended cables to use for the network are any of the following:
Beldon 8761
Alpha 2401C
BICC H8082
Brand Rex BE-56761

Controller Addresses
When the C3-05 controllers are networked together, the controllers, Electronic Expansion Valve drivers and
displays must be configured with their specific addresses, as follows;

Controller EEV Circuit 1 EEV Circuit 2 Display Address

Address Number Address Number Address Number Number
1 9 10 25
2 11 12 26
3 13 14 27
4 15 16 28
5 17 18 29
6 19 20 30
7 21 22 31
8 23 24 32

Units on a network must follow the addresses sequentially.

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Networking (cont)

Setting Unit Addresses

1. Ensure the Denconet connection is disconnected.

2. Press the keys simultaneously for five seconds.

UP
DOWN

RIGHT

3. Press key to move the cursor to the display address.

4. Press key to change the display address to 0 (zero).

5. Press to accept the change.

6. Press and keys simultaneously and switch the mains power off and back on.
7. After approximately 20 seconds a page reading “self test please wait” will appear, then release the keys.

ALARM UP

8. Press or to adjust the “pLAN” address as required, e.g. 1

Note: pLAN refers to the CONTROLLER address.

9. Press to accept the required controller address.

10. Press the keys simultaneously for five seconds.

11. Press the key to move the cursor to the display address.

12. Press the key to change the display address to the required address, e.g. 25

13. Press the key to accept the change.

14. Press the keys simultaneously for five seconds.

15. Press the key twice to highlight “I/O Board address”

Note: I/O Board address refers to CONTROLLER address.

16. Press the key once to initialise the selected controller address.

17. Press the key to access “Terminal config” page.

18. Press the key to access the final page.

19. Press the key until “Trm 1” value is highlighted.

20. Press the key to adjust “Trm 1” value to the required display address, e.g. 25

21. Press the key until “No” is highlighted.

22. Press the key to toggle to “Yes”.

23. Press the key to exit the address set up.

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Networking (cont)

Denconet Routines.

Master Check Slave

Master Temp.
If selected as "MASTER TEMP.", then the temp. sensor value is transmitted to all units on the network that are
configured as "SLAVE TEMP." (and "CHECK TEMP."). The "MASTER TEMP." controller and all the "SLAVE
TEMP." controllers (and "CHECK TEMP." controller) control to the "MASTER TEMP." sensor value.

Check Temp.
If selected as "CHECK TEMP." in addition to being a slave temp. controller, the "CHECK TEMP." will also address
the "MASTER TEMP." every 60 seconds for a sensor fail alarm or comms fail alarm.

If the sensor fail alarm is active, the "CHECK TEMP." becomes "RE-ASSIGNED MASTER TEMP." and "MASTER
TEMP." becomes re-assigned as "SLAVE TEMP." and an alarm condition is flagged on the re-assigned "SLAVE
TEMP." "RE-ASSIGNED SLAVE SENSOR FAIL".

There will be no re-assigned "CHECK TEMP." upon the sensor fail or comms fail until the system is corrected and
reset.

If the sensor fail and comms fail safe, then the "MASTER TEMP." and "CHECK TEMP." remains as assigned.

Slave Temp.
If selected as "SLAVE TEMP.", then the temp. sensor value is received from the "MASTER TEMP." or the
"RE-ASSIGNED MASTER TEMP.".

The "SLAVE TEMP." controller controls to the "MASTER/RE-ASSIGNED MASTER TEMP." sensor value.

Stand Alone Temp.

If selected as "STAND ALONE TEMP.", then the temp. sensor value is received from the controller's own sensor
input and controls to that value.

Master Hum
If selected as "MASTER HUM", then the hum sensor value is transmitted to all units on the network that are
configured as "SLAVE HUM" (and "CHECK HUM"). The "MASTER HUM" controller and all of the "SLAVE HUM"
controllers (including "CHECK HUM") control to the "MASTER HUM" sensor value.

Check Hum
If selected as "CHECK HUM" in addition to being a "SLAVE HUM" controller, the "CHECK HUM" will also address
the "MASTER HUM" every 60 seconds for a sensor fail or comms fail alarm.
If the sensor fail alarm is active, the "CHECK HUM" becomes "RE-ASSIGNED MASTER HUM" and "MASTER
HUM" becomes "RE-ASSIGNED SLAVE HUM" and an alarm condition is flagged on the re-assigned "SLAVE
HUM" "SENSOR FAIL".
There will be no re-assigned "CHECK HUM" upon the sensor fail or the comms fail until the system is corrected
and reset.
If the sensor fail and comms fail safe, then the "MASTER HUM" and "CHECK HUM" remain as assigned.

Slave Hum
If selected as "SLAVE HUM", then the hum sensor value is received from the "MASTER HUM" or the
"RE-ASSIGNED MASTER HUM". The "SLAVE HUM" controller controls to the "MASTER HUM" or the
"RE-ASSIGNED MASTER HUM" sensor value.

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Networking (cont)

Stand Alone Hum

If selected as "STAND ALONE HUM", then the hum sensor value is received from the controller's own sensor
input and controls to that value.

NOTES

1. It must not be permissible to have two masters (temp. or hum) on the network. If this configuration is
inadvertently set, then the master unit with the lowest unit number is set as "Master".

2. It must not be permissible to have two checks (temp. or hum) on the network. If this configuration is
inadvertently set, then the check unit with the lowest unit number is set as "Check".

3. A comms error/failure will operate the communication drop out relay and flag a "Network Failure" alarm. A
global comms error - then all of the controllers will automatically revert to stand alone temp. and hum control.

4. All slave and check slave units will display the temperature and humidity sensor values of the designated
master unit.

All stand alone units will display its local sensor values.

5. When operating as a master check slave, all operating parameters/settings/alarms will function as normal. The
temp./hum alarm conditions will be generated only from the master unit (or the re-assigned master). When
operating as stand alone, the temp. and hum condition alarm will be active on the local unit. The master unit will
be running, otherwise the lowest running unit number will generate the alarm.

6. Normal alarm conditions on the controllers will have no affect upon the network irrelevant of the set
configuration.

7. The network mode will allow for only one change of unit configuration on the sensor fail or comms fail.

Sensor Averaging

Average Temp.
If selected as average temp., then the temp. sensor value is transmitted across the network. Each controller
configured as "average temp." will calculate the average temp. value and control to that value.

Stand Alone Temp.

If selected as stand alone temp., the controller receives the temp. sensor value from its own integral sensor input
and controls to that value. The sensor value is excluded from the averaging calculation.

Average Hum
If selected as average hum, then the hum sensor value is transmitted across the network. Each controller
configured as average hum will calculate the average hum value and control to that value.

Stand Alone Hum

If selected as stand alone hum, the controller receives the hum sensor value from its own integral sensor input
and controls to that value. The sensor value is excluded from the averaging calculation.

NOTES

1. A sensor failure will be flagged as an alarm condition and the sensor value will not be part of the averaged
calculation.

GEA Denco Stock Code no: 2/184/073 27

Version 3 05/09 C3-05 Controls

2. A comms failure will be flagged as an alarm condition (network failure). A global comms error - then all of the
controllers will automatically revert to stand alone temp. and hum control.

3. Any controllers on the unit in a sensor fail or comms fail mode will not form part of the averaged sensor value.

4. Normal alarm conditions will have no affect upon the network commands irrelevant of the set configuration.

5. All units configured as average temp./hum will display the averaged sensor value. All stand alone units will
display the local sensor values.

6. When operating as an averaging controller, all operating parameters/settings/alarms will function as normal.
The temp./hum alarm condition will be generated on the lowest unit number selected as averaging. When
operating as "stand alone", the temp. and hum condition alarm will be active on the local unit.

Auto Change-Over

Network
If selected as "network mode", the controllers will be automatically sequenced to equalise running hours on all
machines. The sequencing time will be set in Level 3 with movements of 168 hours standard. However, there will
be a facility in the factory configuration to reduce the sequence time down to 1 hour minimum.

The last unit number of the network is always the standby controller. After the sequence time has elapsed, the
controllers on the network are automatically sequenced.

Example of Sequencing of five units

Controller 1 2 3 4 5
Start Duty Duty Duty Duty Stand By
1 Seq. Time Stand By Duty Duty Duty Duty
2 Seq. Time Duty Stand By Duty Duty Duty
3 Seq. Time Duty Duty Stand By Duty Duty
4 Seq. Time Duty Duty Duty Stand By Duty
5 Seq. Time Duty Duty Duty Duty Stand By
REPEAT

In the event of a critical or maintenance alarm condition of any duty controller, the standby will automatically start.
The controller in an alarm condition will also run and the alarm condition will be displayed.
There will be a facility to stop the failed unit or for the failed unit to continue to run.
In the event of a power failure or a controlled shutdown, the sequence of rotation will be stored in the memory so
that the duty controllers at power down will remain the duty controllers at restart. The sequence rotation can be
reset at any time to the start sequence accepting the sequence reset in Level 3. During the sequence rotation the
duty unit is stopped before the stand-by unit runs.

Stand Alone
If selected as "stand alone", the sequence rotation command is still active but the stand alone setting will have
priority. Hence, if the stand alone is reset to "network", the controller will automatically take its position in the
sequence rotation.

NOTES
1. The Auto Change-Over Test, Time and Reset can only be configured from unit no. 1.
2. A comms failure will be flagged as an alarm condition and then all controllers on the network revert to stand
alone operation and all controllers run.
3. There will be a test/commission sequence time of 3 minutes. To prevent this sequence time inadvertently being
left set as 3 minutes, after a period of 30 minutes, the sequence rotation time as set will be installed.
4. Normal alarm conditions will have no effect upon the network commands irrelevant of the set configuration.

GEA Denco Stock Code no: 2/184/073 28

Version 3 05/09 C3-05 Controls

Monitoring Display

Master Display
Monitoring Connection
Display Details
Connection Details
*1 = Denconet Cable - Serial
*2 = Unit Display Cable
*3 = Master Display Cable

Monitoring Display

TCONN Module
*3
*1

Note: The TCONN module can be *2

fitted to any unit in the network. *2

Monitoring Display Addresses

Unit No. 1

P:01 Adr Priv/Shared

Trm1 25 Pr
Trm2 32 Sh
Trm3 None -- Ok?No Unit No. max 7

Monitoring Display P:07 Adr Priv/Shared

Trm1 31 Pr
Trm2 32 Sh
Trm3 None -- Ok?No
Display address
Setting……..…….: 32

I/O Board address: 07

TCONN Module
Unit No. 2

P:02 Adr Priv/Shared

Trm1 26 Pr
Trm2 32 Sh
Trm3 None -- Ok?No

GEA Denco Stock Code no: 2/184/073 29

Version 3 05/09 C3-05 Controls

Serial Data Interface(s)

Interface cards that are fitted to a controller allow exchanging variable values from one card to another, according
to the Supervisory Variable List, as detailed on page 8.

The available variable values include;

• Unit status
• Air temperature & humidity values
• Output demands
• Water temperature value
• Condensing pressures values
• Temperature & humidity setpoint adjustment
• Dead zone & proportional band adjustment
• Alarm monitoring

When any of the Serial Data Interfaces are used, there are three settings within Level 3, BMS Communication of
the controller that needs to be configured to suit the BMS requirements:
• BMS Protocol (default Carel)
• BMS Address (default 1)
• BMS Baud Rate (default 19200)

pCOnet Interface Card

The pCOnet interface allows connection to a BACnet MS/TP network (Master/Slave/Token pass).
It is BTL™ (BACnet Test Laboratory) certified for BACnet™ protocol communication.

GEA Denco Stock Code no: 2/184/073 30

Version 3 05/09 C3-05 Controls

Serial Data Interface(s) (cont)

RS232 Serial Card

The RS232 Serial Card is used to interface the C3-05 controller directly to a standard HAYES modem or GSM
modem. The following hardware signals can be managed:
• Output, “request to send” (RTS) in parallel to “data terminal ready” (DTR).
• Input, “carrier detected” (CD).
The maximum baud rate is 19200.
The required contact number to send a text message to in the event of an alarm is configured in Modem Setup in
Level 3 of the controller.

The sent text message will include:

• Unit number
• Actual alarm
• Date and time of alarm
• Temperature and humidity of the unit at the time of the alarm

RS485 Serial Card

The RS485 Serial Card is used to interface the C3-05 controller to an RS485 network.
The card guarantees the optical isolation of the controller from the RS485 serial network. The maximum baud rate
is 19200 (adjustable in software).
This interface is commonly used to communicate to Modbus networks.

GEA Denco Stock Code no: 2/184/073 31

Version 3 05/09 C3-05 Controls

Serial Data Interface(s) (cont)

LonWorks Serial Card

The LonWorks Serial Card is used to interface the C3-05 controller to a Lonworks network.
The type of interface on the LonWorks network side is:
• PCO20000F0 – interface to FTT-10A 78 Kbs (TP/FT-10).
The baud rate of the C3-05 controller must be set to 4800.
This serial card will be supplied complete with the .NXE and .XIF files to suit the standard Denco application.

PCOWeb (Ethernet) Interface

The pCOWeb Interface allows connection to TCP/IP and SNMP protocols on the Ethernet standard and BACnet
both on the Ethernet and EIA485 standards.
When using the SNMP protocol, the associated MIB file would be supplied to the customer by the Denco
contracts engineer.
The pCOWeb interface can be configured to send an e-mail to up to five different e-mail addresses in the event of
an alarm condition generated on the Air Conditioning unit.
Data Logging of temperatures, humidity and output demands can also be configured.
This interface is supplied with a Denco web page embedded that allows monitoring of the control temperature,
humidity, output demands and various alarms.

GEA Denco Stock Code no: 2/184/073 32

Version 3 05/09 C3-05 Controls

pCOWeb Denco Web Page

GEA Denco Stock Code no: 2/184/073 33

Version 3 05/09 C3-05 Controls

Supervisory Variable List

Digital Variables
Index Description Type
1 BMS Unit On/Off R/W
2 Enable Unit On/Off by Time zones R/W
3 Enable Unit Temperature Set Point Adjustment by Time zones R/W
4 Enable Unit Humidity Set Point Adjustment by Time zones R/W
5 Return Air Temperature Sensor Fail Alarm R
6 Return Air Humidity Sensor Fail Alarm R
7 Condensing pressure 1 Sensor Fail Alarm R
8 Condensing pressure 2 Sensor Fail Alarm R
9 Water Temperature Sensor Fail Alarm R
10 Supply Air Temperature Sensor Fail Alarm R
11 Supply Air Humidity Sensor Fail Alarm R
12 Airflow Fail Alarm R
13 Filter Blocked Alarm R
14 Water Detection Alarm R
15 Auxiliary Alarm R
16 High Control Temperature Alarm R
17 Low Control Temperature Alarm R
18 High Control Humidity Alarm R
19 Low Control Humidity Alarm R
20 Low Supply Temperature Alarm R
21 High Supply Humidity Alarm R
22 Klixon Trip Alarm R
23 Compressor 1 High Pressure Trip Alarm R
24 Compressor 2 High Pressure Trip Alarm R
25 Compressor 3 High Pressure Trip Alarm R
26 Compressor 4 High Pressure Trip Alarm R
27 Circuit 1 (VRF) High Pressure Trip Alarm R
28 Circuit 2 (VRF) High Pressure Trip Alarm R
29 Compressor 1 Low Pressure Trip Alarm R
30 Compressor 2 Low Pressure Trip Alarm R
31 Compressor 3 Low Pressure Trip Alarm R
32 Compressor 4 Low Pressure Trip Alarm R
33 Circuit 1 (VRF) Low Pressure Trip Alarm R
34 Circuit 2 (VRF) Low Pressure Trip Alarm R
35 Denconet Comms Alarm R
36 Humidifier High Current Alarm R
37 Humidifier Lack Of Water Alarm R
38 Humidifier Low Current Alarm R
39 Clock Alarm R

GEA Denco Stock Code no: 2/184/073 34

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Digital Variables (cont)

40 EEV Driver 1 Probe Fail Alarm R
41 EEV Driver 1 Eeprom Alarm R
42 EEV Driver 1 Stepper Motor Alarm R
43 EEV Driver 1 Battery Alarm R
44 EEV Driver 1 High Evaporating Pressure Alarm R
45 EEV Driver 1 Low Evaporating Pressure Alarm R
46 EEV Driver 1 Low Superheat Alarm R
47 EEV Driver 1 Valve Not Closed At Power Off Alarm R
48 EEV Driver 1 High Suction Temperature Alarm R
49 EEV Driver 2 Probe Fail Alarm R
50 EEV Driver 2 Eeprom Alarm R
51 EEV Driver 2 Stepper Motor Alarm R
52 EEV Driver 2 Battery Alarm R
53 EEV Driver 2 High Evaporating Pressure Alarm R
54 EEV Driver 2 Low Evaporating Pressure Alarm R
55 EEV Driver 2 Low Superheat Alarm R
56 EEV Driver 2 Valve Not Closed At Power Off Alarm R
57 EEV Driver 2 High Suction Temperature Alarm R
58 Humidifier High Conductivity Alarm R
59 Humidifier High Conductivity Warning R
60 Humidifier Low Production Alarm R
61 Humidifier Drain Alarm R
62 Humidifier Cylinder Full Alarm R
63 Humidifier Cylinder Pre-Exhaustion Warming R
64 Humidifier Foam Presence Detected Warning R
65 Humidifier Cylinder Exhaustion Warning R
66 Humidifier Cylinder Exhausted Alarm R
67 Humidifier Cylinder Maintenance Recommended R
68 Unit Fan Maintenance Alarm R
69 Heater 1 Maintenance Alarm R
70 Heater 2 Maintenance Alarm R
71 0 – 10V Heating Maintenance Alarm R
72 DODC Heating Maintenance Alarm R
73 Compressor 1 Maintenance Alarm R
74 Compressor 2 Maintenance Alarm R
75 Compressor 3 Maintenance Alarm R
76 Compressor 4 Maintenance Alarm R
77 0 – 10V Cooling Maintenance Alarm R
78 DODC Cooling Maintenance Alarm R
79 Condenser Fan Maintenance Alarm R

GEA Denco Stock Code no: 2/184/073 35

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Digital Variables (cont)

80 Remote Humidifier Maintenance Alarm R
81 Dehum Maintenance Alarm R
82 Dry Cooler Fan 1 Maintenance Alarm R
83 Dry Cooler Fan 2 Maintenance Alarm R
84 Ambicool Maintenance Alarm R
85 Refrigerant Leak Detection Alarm R
86 Alarm Reset By BMS R/W
87 Fan Status R
88 Unit Night Purge (Only Unit Fan Output Energises) R/W
89 Critical Alarm Status R
90 Maintenance Alarm Status R
91 LECU 1 BMS On/Off R/W
92 LECU 1 Damper (0 =Auto; 1=100%OPEN) R/W
93 LECU 2 BMS On/Off R/W
94 LECU 2 Damper (0 =Auto; 1=100%OPEN) R/W
95 LECU 3 BMS On/Off R/W
96 LECU 3 Damper (0 =Auto; 1=100%OPEN) R/W
97 LECU 4 BMS On/Off R/W
98 LECU 4 Damper (0 =Auto; 1=100%OPEN) R/W
99 LECU 5 BMS On/Off R/W
100 LECU 5 Damper (0 =Auto; 1=100%OPEN) R/W
101 LECU 6 BMS On/Off R/W
102 LECU 6 Damper (0 =Auto; 1=100%OPEN) R/W
103 LECU 7 BMS On/Off R/W
104 LECU 7 Damper (0 =Auto; 1=100%OPEN) R/W
105 LECU 8 BMS On/Off R/W
106 LECU 8 Damper (0 =Auto; 1=100%OPEN) R/W
107 LECU 9 BMS On/Off R/W
108 LECU 9 Damper (0 =Auto; 1=100%OPEN) R/W
109 LECU 10 BMS On/Off R/W
110 LECU 10 Damper (0 =Auto; 1=100%OPEN) R/W
111 LECU 11 BMS On/Off R/W
112 LECU 11 Damper (0 =Auto; 1=100%OPEN) R/W
113 LECU 12 BMS On/Off R/W
114 LECU 12 Damper (0 =Auto; 1=100%OPEN) R/W
115 LECU 13 BMS On/Off R/W
116 LECU 13 Damper (0 =Auto; 1=100%OPEN) R/W
117 LECU 14 BMS On/Off R/W
118 LECU 14 Damper (0 =Auto; 1=100%OPEN) R/W
119 LECU 15 BMS On/Off R/W
120 LECU 15 Damper (0 =Auto; 1=100%OPEN) R/W

GEA Denco Stock Code no: 2/184/073 36

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Digital Variables (cont)

121 LECU 16 BMS On/Off R/W
122 LECU 16 Damper (0 =Auto; 1=100%OPEN) R/W
123 LECU 17 BMS On/Off R/W
124 LECU 17 Damper (0 =Auto; 1=100%OPEN) R/W
125 LECU 18 BMS On/Off R/W
126 LECU 18 Damper (0 =Auto; 1=100%OPEN) R/W
127 LECU 19 BMS On/Off R/W
128 LECU 19 Damper (0 =Auto; 1=100%OPEN) R/W
129 LECU 20 BMS On/Off R/W
130 LECU 20 Damper (0 =Auto; 1=100%OPEN) R/W
131 LECU 21 BMS On/Off R/W
132 LECU 21 Damper (0 =Auto; 1=100%OPEN) R/W
133 LECU 22 BMS On/Off R/W
134 LECU 22 Damper (0 =Auto; 1=100%OPEN) R/W
135 LECU 23 BMS On/Off R/W
136 LECU 23 Damper (0 =Auto; 1=100%OPEN) R/W
137 LECU 24 BMS On/Off R/W
138 LECU 24 Damper (0 =Auto; 1=100%OPEN) R/W
139 LECU 25 BMS On/Off R/W
140 LECU 25 Damper (0 =Auto; 1=100%OPEN) R/W
141 LECU 26 BMS On/Off R/W
142 LECU 26 Damper (0 =Auto; 1=100%OPEN) R/W
143 LECU 27 BMS On/Off R/W
144 LECU 27 Damper (0 =Auto; 1=100%OPEN) R/W
145 LECU 28 BMS On/Off R/W
146 LECU 28 Damper (0 =Auto; 1=100%OPEN) R/W
147 LECU 29 BMS On/Off R/W
148 LECU 29 Damper (0 =Auto; 1=100%OPEN) R/W
149 LECU 30 BMS On/Off R/W
150 LECU 30 Damper (0 =Auto; 1=100%OPEN) R/W
151 LECU 31 BMS On/Off R/W
152 LECU 31 Damper (0 =Auto; 1=100%OPEN) R/W
153 LECU 32 BMS On/Off R/W
154 LECU 32 Damper (0 =Auto; 1=100%OPEN) R/W
155 LECU 33 BMS On/Off R/W
156 LECU 33 Damper (0 =Auto; 1=100%OPEN) R/W
157 LECU 34 BMS On/Off R/W

158 LECU 34 Damper (0 =Auto; 1=100%OPEN) R/W

159 LECU 35 BMS On/Off R/W

160 LECU 35 Damper (0 =Auto; 1=100%OPEN) R/W

161 LECU 1 ALARM R

GEA Denco Stock Code no: 2/184/073 37

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Digital Variables (cont)

162 LECU 2 ALARM R

163 LECU 3 ALARM R

164 LECU 4 ALARM R

165 LECU 5 ALARM R

166 LECU 6 ALARM R

167 LECU 7 ALARM R

168 LECU 8 ALARM R

169 LECU 9 ALARM R

170 LECU 10 ALARM R

171 LECU 11 ALARM R

172 LECU 12 ALARM R

173 LECU 13 ALARM R

174 LECU 14 ALARM R

175 LECU 15 ALARM R

176 LECU 16 ALARM R

177 LECU 17 ALARM R

178 LECU 18 ALARM R

179 LECU 19 ALARM R

180 LECU 20 ALARM R

181 LECU 21 ALARM R

182 LECU 22 ALARM R

183 LECU 23 ALARM R

184 LECU 24 ALARM R

185 LECU 25 ALARM R

186 LECU 26 ALARM R

187 LECU 27 ALARM R

188 LECU 28 ALARM R

189 LECU 29 ALARM R

190 LECU 30 ALARM R

191 LECU 31 ALARM R

192 LECU 32 ALARM R

193 LECU 33 ALARM R

194 LECU 34 ALARM R

195 LECU 35 ALARM R

196 HUMIDIFIER GLOBAL ALARM (not for In-Built) R

GEA Denco Stock Code no: 2/184/073 38

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Analogue Variables
Index Description Type
1 Control Temperature R
2 Control Humidity R
3 Return Air Temperature R
4 Return Air Humidity R
5 Cooling Demand R
6 Heating Demand R
7 Humidity Demand R
8 Dehum Demand R
9 Ambicool Demand R
10 Supply Air Temperature R
11 Supply Air Humidity R
12 Water Temperature R
13 Condensing Pressure 1 R
14 Condensing Pressure 2 R
15 Temperature Set Point R/W
16 Humidity Set Point R/W
17 Time Zone 1 Temperature Set Point R/W
18 Time Zone 2 Temperature Set Point R/W
19 Time Zone 3 Temperature Set Point R/W
20 Time Zone 4 Temperature Set Point R/W
21 Time Zone 1 Humidity Set Point R/W
22 Time Zone 2 Humidity Set Point R/W
23 Time Zone 3 Humidity Set Point R/W
24 Time Zone 4 Humidity Set Point R/W
25 Cooling Dead Zone R/W
26 Cooling Proportional Band R/W
27 Heating Dead Zone R/W
28 Heating Proportional Band R/W
29 Dehum Dead Zone R/W
30 Dehum Proportional Band R/W
31 Humidity Dead Zone R/W
32 Humidity Proportional Band R/W
33 Free Cool Water Set Point R/W
34 Dry Cooler Stage Differential R/W
35 Combicool Chilled Water Temperature Limit R/W
36 Temperature Alarm Band R/W
37 Humidity Alarm Band R/W
38 Tile Unit (LECU) Average Temperature (FROM THE BMS) R/W
39 LECU 1 Room Temperature R
40 LECU 1 Underfloor Temperature R

GEA Denco Stock Code no: 2/184/073 39

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Analogue Variables (cont)

41 LECU 1 Temperature Setpoint R/W
42 LECU 1 Damper Demand R
43 LECU 2 Room Temperature R
44 LECU 2 Underfloor Temperature R
45 LECU 2 Temperature Setpoint R/W
46 LECU 2 Damper Demand R
47 LECU 3 Room Temperature R
48 LECU 3 Underfloor Temperature R
49 LECU 3 Temperature Setpoint R/W
50 LECU 3 Damper Demand R
51 LECU 4 Room Temperature R
52 LECU 4 Underfloor Temperature R
53 LECU 4 Temperature Setpoint R/W
54 LECU 4 Damper Demand R
55 LECU 5 Room Temperature R
56 LECU 5 Underfloor Temperature R
57 LECU 5 Temperature Setpoint R/W
58 LECU 5 Damper Demand R
59 LECU 6 Room Temperature R
60 LECU 6 Underfloor Temperature R
61 LECU 6 Temperature Setpoint R/W
62 LECU 6 Damper Demand R
63 LECU 7 Room Temperature R
64 LECU 7 Underfloor Temperature R
65 LECU 7 Temperature Setpoint R/W
66 LECU 7 Damper Demand R
67 LECU 8 Room Temperature R
68 LECU 8 Underfloor Temperature R
69 LECU 8 Temperature Setpoint R/W
70 LECU 8 Damper Demand R
71 LECU 9 Room Temperature R
72 LECU 9 Underfloor Temperature R
73 LECU 9 Temperature Setpoint R/W
74 LECU 9 Damper Demand R
75 LECU 10 Room Temperature R
76 LECU 10 Underfloor Temperature R
77 LECU 10 Temperature Setpoint R/W
78 LECU 10 Damper Demand R
79 LECU 11 Room Temperature R
80 LECU 11 Underfloor Temperature R

GEA Denco Stock Code no: 2/184/073 40

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Analogue Variables (cont)

81 LECU 11 Temperature Setpoint R/W
82 LECU 11 Damper Demand R
83 LECU 12 Room Temperature R
84 LECU 12 Underfloor Temperature R
85 LECU 12 Temperature Setpoint R/W
86 LECU 12 Damper Demand R
87 LECU 13 Room Temperature R
88 LECU 13 Underfloor Temperature R
89 LECU 13 Temperature Setpoint R/W
90 LECU 13 Damper Demand R
91 LECU 14 Room Temperature R
92 LECU 14 Underfloor Temperature R
93 LECU 14 Temperature Setpoint R/W
94 LECU 14 Damper Demand R
95 LECU 15 Room Temperature R
96 LECU 15 Underfloor Temperature R
97 LECU 15 Temperature Setpoint R/W
98 LECU 15 Damper Demand R
99 LECU 16 Room Temperature R
100 LECU 16 Underfloor Temperature R
101 LECU 16 Temperature Setpoint R/W
102 LECU 16 Damper Demand R
103 LECU 17 Room Temperature R
104 LECU 17 Underfloor Temperature R
105 LECU 17 Temperature Setpoint R/W
106 LECU 17 Damper Demand R
107 LECU 18 Room Temperature R
108 LECU 18 Underfloor Temperature R
109 LECU 18 Temperature Setpoint R/W
110 LECU 18 Damper Demand R
111 LECU 19 Room Temperature R
112 LECU 19 Underfloor Temperature R
113 LECU 19 Temperature Setpoint R/W
114 LECU 19 Damper Demand R
115 LECU 20 Room Temperature R
116 LECU 20 Underfloor Temperature R
117 LECU 20 Temperature Setpoint R/W
118 LECU 20 Damper Demand R
119 LECU 21 Room Temperature R
120 LECU 21 Underfloor Temperature R

GEA Denco Stock Code no: 2/184/073 41

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Analogue Variables (cont)

121 LECU 21 Temperature Setpoint R/W
122 LECU 21 Damper Demand R
123 LECU 22 Room Temperature R
124 LECU 22 Underfloor Temperature R
125 LECU 22 Temperature Setpoint R/W
126 LECU 22 Damper Demand R
127 LECU 23 Room Temperature R
128 LECU 23 Underfloor Temperature R
129 LECU 23 Temperature Setpoint R/W
130 LECU 23 Damper Demand R
131 LECU 24 Room Temperature R
132 LECU 24 Underfloor Temperature R
133 LECU 24 Temperature Setpoint R/W
134 LECU 24 Damper Demand R
135 LECU 25 Room Temperature R
136 LECU 25 Underfloor Temperature R
137 LECU 25 Temperature Setpoint R/W
138 LECU 25 Damper Demand R
139 LECU 26 Room Temperature R
140 LECU 26 Underfloor Temperature R
141 LECU 26 Temperature Setpoint R/W
142 LECU 26 Damper Demand R
143 LECU 27 Room Temperature R
144 LECU 27 Underfloor Temperature R
145 LECU 27 Temperature Setpoint R/W
146 LECU 27 Damper Demand R
147 LECU 28 Room Temperature R
148 LECU 28 Underfloor Temperature R
149 LECU 28 Temperature Setpoint R/W
150 LECU 28 Damper Demand R
151 LECU 29 Room Temperature R
152 LECU 29 Underfloor Temperature R
153 LECU 29 Temperature Setpoint R/W
154 LECU 29 Damper Demand R
155 LECU 30 Room Temperature R
156 LECU 30 Underfloor Temperature R
157 LECU 30 Temperature Setpoint R/W
158 LECU 30 Damper Demand R
159 LECU 31 Room Temperature R
160 LECU 31 Underfloor Temperature R

GEA Denco Stock Code no: 2/184/073 42

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Analogue Variables (cont)

161 LECU 31 Temperature Setpoint R/W
162 LECU 31 Damper Demand R
163 LECU 32 Room Temperature R
164 LECU 32 Underfloor Temperature R
165 LECU 32 Temperature Setpoint R/W
166 LECU 32 Damper Demand R
167 LECU 33 Room Temperature R
168 LECU 33 Underfloor Temperature R
169 LECU 33 Temperature Setpoint R/W
170 LECU 33 Damper Demand R
171 LECU 34 Room Temperature R
172 LECU 34 Underfloor Temperature R
173 LECU 34 Temperature Setpoint R/W
174 LECU 34 Damper Demand R
175 LECU 35 Room Temperature R
176 LECU 35 Underfloor Temperature R
177 LECU 35 Temperature Setpoint R/W
178 LECU 35 Damper Demand R
179 Tile Unit (LECU) Average Temperature !FROM THE LUCU's! R
180 Default LECU setpoint (After Restart) R/W
181 Special Cooling Demand R

Interger Variables
Index Description Type
1 Unit Serial Number Digit 1 R

2 Unit Serial Number Digit 2 R

3 Unit Serial Number Digit 3 R
4 Unit Serial Number Digit 4 R
5 Unit Serial Number Digit 5 R
6 Unit Serial Number Digit 6 R
7 Unit Serial Number Digit 7 R
8 Unit Commission Date Day R
9 Unit Commission Date Month R
10 Unit Commission Date Year R
11 Unit On/Off Time zone F1-1 On Hour R/W
12 Unit On/Off Time zone F1-1 On Minute R/W
13 Unit On/Off Time zone F1-1 Off Hour R/W
14 Unit On/Off Time zone F1-1 Off Minute R/W
15 Unit On/Off Time zone F1-2 On Hour R/W
16 Unit On/Off Time zone F1-2 On Minute R/W
17 Unit On/Off Time zone F1-2 Off Hour R/W

GEA Denco Stock Code no: 2/184/073 43

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Interger Variables (cont)

18 Unit On/Off Time zone F1-2 Off Minute R/W

19 Unit On/Off Time zone F2 On Hour R/W
20 Unit On/Off Time zone F2 On Minute R/W
21 Unit On/Off Time zone F2 Off Hour R/W
22 Unit On/Off Time zone F2 Off Minute R/W
23 Monday Time Zone Selection (0=F1, 1=F2, 2=F3 &3=F4) R/W
24 Tuesday Time Zone Selection R/W
25 Wednesday Time Zone Selection R/W
26 Thursday Time Zone Selection R/W
27 Friday Time Zone Selection R/W
28 Saturday Time Zone Selection R/W
29 Sunday Time Zone Selection R/W
30 Temperature set point Time zone 1 Hour R/W
31 Temperature set point Time zone 1 Minute R/W
32 Temperature set point Time zone 2 Hour R/W
33 Temperature set point Time zone 2 Minute R/W
34 Temperature set point Time zone 3 Hour R/W
35 Temperature set point Time zone 3 Minute R/W
36 Temperature set point Time zone 4 Hour R/W
37 Temperature set point Time zone 4 Minute R/W
38 Humidity set point Time zone 1 Hour R/W
39 Humidity set point Time zone 1 Minute R/W
40 Humidity set point Time zone 2 Hour R/W
41 Humidity set point Time zone 2 Minute R/W
42 Humidity set point Time zone 3 Hour R/W
43 Humidity set point Time zone 3 Minute R/W
44 Humidity set point Time zone 4 Hour R/W
45 Humidity set point Time zone 4 Minute R/W
46 Unit Fan Run Hours (high part) R
47 Unit Fan Run Hours (low part) R
48 Compressor 1 Run Hours (high part) R
49 Compressor 1 Run Hours (low part) R
50 Compressor 2 Run Hours (high part) R
51 Compressor 2 Run Hours (low part) R
52 Compressor 3 Run Hours (high part) R
53 Compressor 3 Run Hours (low part) R
54 Compressor 4 Run Hours (high part) R
55 Compressor 4 Run Hours (low part) R
56 0 – 10v Cooling Run Hours (high part) R
57 0 – 10v Cooling Run Hours (low part) R

GEA Denco Stock Code no: 2/184/073 44

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Interger Variables (cont)

58 DODC Cooling Run Hours (high part) R

59 DODC Cooling Run Hours (low part) R
60 Ambicool Run Hours (high part) R
61 Ambicool Run Hours (low part) R
62 Heater 1 Run Hours (high part) R
63 Heater 1 Run Hours (low part) R
64 Heater 2 Run Hours (high part) R
65 Heater 2 Run Hours (low part) R
66 0 – 10v Heating Run Hours (high part) R
67 0 – 10v Heating Run Hours (low part) R
68 DODC Heating Run Hours (high part) R
69 DODC Heating Run Hours (low part) R
70 Dehum Run Hours (high part) R
71 Dehum Run Hours (low part) R
Unit Status (0 = Unit On, 1 = Off by Alarms, 2 = Off by BMS, 3 = Off by Time R
72 Zones, 4 = Off by DI, 5 = Off by Keyboard, 6 = On HOA Mode, 7 = Stand-by,
8 = On Generator Mode, 9 = Night Purge Mode; 10 = Defrost Mode)
73 Day R

74 Month R

75 Year R

76 Hour R

77 Minute R

78 LECU 1 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

79 LECU 2 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

80 LECU 3 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

81 LECU 4 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

82 LECU 5 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

83 LECU 6 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

84 LECU 7 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

85 LECU 8 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

86 LECU 9 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

87 LECU 10 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

88 LECU 11 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

89 LECU 12 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

90 LECU 13 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

91 LECU 14 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

92 LECU 15 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

93 LECU 16 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

94 LECU 17 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

95 LECU 18 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

96 LECU 19 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

GEA Denco Stock Code no: 2/184/073 45

Version 3 05/09 C3-05 Controls

Supervisory Variable List (cont)

Interger Variables (cont)

97 LECU 20 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

98 LECU 21 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

99 LECU 22 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

100 LECU 23 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

101 LECU 24 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

102 LECU 25 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

103 LECU 26 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

104 LECU 27 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

105 LECU 28 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

106 LECU 29 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

107 LECU 30 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

108 LECU 31 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

109 LECU 32 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

110 LECU 33 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

111 LECU 34 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

112 LECU 35 Fan Speed (0 = AUTO, 1 = Speed 1, 2 = Speed 2, 3 = Speed 3) R/W

113 Number of LECU's R/W

114 LECU Default Fan Speed (After Restart) R/W

GEA Denco Stock Code no: 2/184/073 46

Version 3 05/09 C3-05 Controls

Controller Operation with Temperature Control

The controller can use proportional or P + I control actions to maintain the temperature setpoint. The integral (I)
time constants can be adjusted in software.

Proportional Control
Proportional control is the relationship between the
setpoint, proportional band and the actual control air
o
temperature. For a setpoint of 21 C, a proportional
o
band of 2 C and one stage of cooling, to enable the
cooling the control air temperature has to rise to
o
setpoint plus proportional band, i.e. 23 C ( 21 + 2 ). If
the number of cooling stages is increased to two then
the first stage would be enabled at setpoint plus (prop.
o
band/2), i.e. 22 C ( 21 + 2 / 2 ). Both stages will be
o
enabled at 23 C.

The same theory applies to chilled water outputs. For the valve to be fully open, the control air temperature has to
be at setpoint plus the full proportional band.

Adjusting the proportional band will have the following effects:

r A large proportional band will mean a slow system response, i.e. the control air temperature would have
to rise to a high level before full cooling is enabled, and subsequent shutting off of the cooling would also be
slower. A small or tight proportional band will bring on cooling quicker but would result in system instability or
"hunting".
r An optimum proportional band will be set for the room conditions but due to inherent heat generation
there will generally be a steady state error or "offset" from the setpoint at which the room conditions are
maintained.

Proportional plus Integral Control

To overcome the "offset" above the controller can be
set to operate using proportional plus integral (P + I)
control to achieve and maintain the control
temperature at setpoint. The addition of the integral
term has the effect of gradually increasing the output
to reduce the offset so that the steady state condition,
i.e. heat generation equals cooling input, now occurs
at setpoint. The integral action is in effect resetting the
proportional band to reduce the steady state error.

GEA Denco Stock Code no: 2/184/073 47

Version 3 05/09 C3-05 Controls

Tuning the Control Loop

The optimum control response for air conditioning equipment is normally acceptable when there is no overshoot
and rates of temperature changes are small. Consequently, the tuning methods described below provide only a
first approximation to optimum temperature tuning.

The rule-of-thumb of Ziegler and Nichols is by far the simplest procedure for loop tuning. There are two methods,
both detailed below:

1. Stability Limit Method

Set the Historic Data Logging sample period to 1 minute.
Set for proportional control only (Level 3).
Set the temperature setpoint (Level 1) so that the cooling will run continuously.
Set the stage delay to 10 seconds (Level 3).
o o o o
Reduce the cooling proportional band (Level 2) in several successive steps ( say 2.0 C, 1.5 C, 1.2 C, 1.0 C etc.),
waiting each time to see the result on the control temperature logged values, until the loop reaches the stability
limit and thus begins to oscillate, i.e. an oscillation once started does not fade away.

At this point note the cooling proportional band (Cpb) and the period of a
complete oscillation (Ti).

Substitute these values in the formulae below:

Optimum Cooling Proportional Band = ( 100 / Cpb ) x 0.45

Optimum Integral Time = 0.83 x Ti

Once the optimum settings have been calculated set for P + I control and enter values accordingly.

2. Step Method
This method avoids the necessity of putting the control loop in oscillation.

Adjust the setpoints such that there are no cooling, heating, hum or dehum outputs, and allow conditions to
stabilise.

Manually operate 50% of the cooling capacity and plot the response in the control temperature from the logged
values. The result is normally as shown below:

R = slope = Temperature Fall [a] / Time (min) [b]

L = Time Lag (min)

By drawing in the maximum slope, tangent L can be obtained on the

time axis and R calculated.

Ziegler and Nichols recommend the following control adjustments

be made:

Optimum Cooling Proportional Band = 100 / G where G = 0.9 / ( R x L )

Optimum Integral Time = 3.3 x L

GEA Denco Stock Code no: 2/184/073 48

Version 3 05/09 C3-05 Controls

Cooling Operation
Cooling is achieved by one of two methods, Direct Expansion or Chilled Water in response to a cooling demand
from the microprocessor controller. Factors that affect the cooling demand is the relationship of the control air
temperature to the temperature setpoint, cooling proportional band and cooling dead zone.

In the case of DIRECT EXPANSION (DX) one, two, three or four stages can be selected (Software Level 3
Factory Settings) to achieve the full (100%) cooling demand. Switch on points for each stage is determined as
follows "100% divided by Number of Stages". The stages can be set for automatic sequencing such that the first
stage started is the first stage to be stopped to balance running hours and minimize the number of starts.
Automatic sequencing of compressors can be disabled via the software to ensure that Cooling Stage 1 is always
energised first (used for Hot Gas Re-heat - if fitted).

• Number of compressor starts per hour protection.

When a cooling output is energised, a software timer of six minutes is initiated to delay that cooling output
from energising again within the six minutes.

• LP delay time.
When a cooling output is energised, the LP Delay Time in Level 3 (default 10 minutes) is initiated to delay the
LP alarm energising and allowing the compressor to keep running.
When the LP Delay Time has elapsed, and if there is still a LP signal, the cooling output will de-energise and
the alarm is generated. The cooling output will not re-energise until the alarm has been reset on the display
and the number of compressor starts per hour protection timer has elapsed.

For CHILLED WATER (CW), the controller drives a valve actuator to position a three-way valve to meet the
cooling demand. A unit that is configured for Chilled Water operation will use Cooling outputs 1 and 2 to run the
valve actuator, output number 1 will be used to drive the actuator open and output number 2 drive it close. For a
valve actuator with a full running time of 150 seconds from fully closed to fully open it can be seen, assuming the
valve is fully closed, if output number 1 is energised for 150 seconds the valve will be opened 100%. As the valve
actuator running time is not proportional to the amount the valve actuator moves, the controller uses an algorithm
to determine the time an output is energised in order to position the valve. Thus to open or close a valve a certain
amount the appropriate output will be energised for a certain amount of time. To enable the controller to
determine the position of the actuator on start-up (or at any time the AHU is stopped and started) it will initially
energise the drive close output for 110% of the valve running time. This ensures the valve is at the fully closed
position and any subsequent movement is from a set position. Thus at switch-on the valve may initially be seen to
close even though conditions maybe calling for a cooling demand.

Valve run times for Johnson Controls VG7000 series

Pipe Size Denco Part No. Valve Stroke Valve Run Time
½ in. (DN15) 2/293/182 8mm 60 sec.
¾ in. (DN20) 2/293/183 8mm 60 sec.
1 in. (DN25) 2/293/184 13mm 135 sec.
1¼ in. (DN32) 2/293/185 13mm 135 sec.
1½ in. (DN40) 2/293/186 19mm 200 sec.
2 in. (DN50) 2/293/187 19mm 200 sec.

The controller can also provide a 0 - 10V DC output to a chilled water valve actuator if required.

In addition to the above, the microprocessor controller has integral action which is added to the cooling demand.

GEA Denco Stock Code no: 2/184/073 49

Version 3 05/09 C3-05 Controls

Cooling Operation (cont)

Condenser Fan Control (optional)

On an air cooled DX system (A type), it is possible to configure, in Level 3, Factory Configuration, the control of
the condenser fans via an electronic speed controller.
A 4-20mA, 0-30bar pressure transducer is required to be fitted to the discharge line of the DX system and the
value is monitored by the C3-05 controller.

There are five settings to configure, as follows:

Fan Enable – Disabled

Enabled Min Speed
Enabled Cut-Off

Set Point - Default 18.6bar

Differential - Default 2bar

Minimum Speed - Default 20%

Maximum Speed - Default 100%

Fan Enable
If enabled, there are two types of condenser fan control, either to select the fans to continue to operate when the
setpoint is achieved at the set minimum speed or to select the fans to ‘cut-off’ when the setpoint is achieved.

Set Point
The set point is the pressure value when the fan speed is at its minimum or cut-off.

Differential
The differential is the pressure value between the set point and the point at which the fan speed is at its
maximum.

Minimum Speed
The minimum speed is the % value of the differential that dictates the fan minimum speed or cut-off point and
configures the Condenser Fan analogue output signal to suit.
E.g. If the setpoint is 18.6bar, differential is 2bar and minimum speed set to 20%, then,
20% of 2bar = 0.4bar, therefore, fan minimum speed/cut-off achieved at 19bar with an analogue
output signal of 2 volts.

Maximum Speed
The maximum speed is the % value of the differential that dictates the fan maximum speed or cut-off point and
configures the Condenser Fan analogue output signal to suit.
E.g. If the setpoint is 18.6bar, differential is 2bar and maximum speed set to 80%, then,
80% of 2bar = 1.6bar, therefore, fan maximum speed/cut-off achieved at 20.2bar with an analogue
output signal of 8 volts.

Note: Ensure that the voltage supplied to the condenser fan on minimum speed is greater than the fan
manufacturers recommended voltage. Denco recommend that the minimum voltage should not be lower
than 100 volts.

GEA Denco Stock Code no: 2/184/073 50

Version 3 05/09 C3-05 Controls

Cooling Operation (cont)

Chilled Water Valve Type – ‘Smart Cooling’

In Level 3, Factory Configuration, there is an option to select a cooling demand setpoint at which the chilled water
valve will be fully open.
This function will be used when the site requirement is to allow full chilled water cooling with the variable speed
fan(s) at the minimum speed, and as the cooling demand rises above the Chilled Water Demand Setpoint, the fan
speed would increase, depending on the maximum fan speed selected.

Example 1:
Cooling Demand Setpoint = 25%

Between 0% and 25% cooling demand, the valve

modulates between 0% and 100%, and the fan
speed is maintained at the set minimum speed.

Between 25% and 100% cooling demand, the fan

speed modulates between the minimum and
maximum settings.

Example 2:
Cooling Demand Setpoint = 50%

Between 0% and 50% cooling demand, the valve

modulates between 0% and 100%, and the fan
speed is maintained at the set minimum speed.

Between 50% and 100% cooling demand, the fan

speed modulates between the minimum and
maximum settings.

Example 3:
Cooling Demand Setpoint = 75%

Between 0% and 75% cooling demand, the valve

modulates between 0% and 100% and the fan speed
is maintained at the set minimum speed.

Between 75% and 100% cooling demand, the fan

speed modulates between the minimum and
maximum settings.

GEA Denco Stock Code no: 2/184/073 51

Version 3 05/09 C3-05 Controls

Electronic Expansion Valve Operation (option)

Control of the electronic expansion valve is performed by moving a valve stem in and out of a nozzle (orifice) with
a total travel of 14mm using 480 steps of the in-built motor. The correct balance between theoretical and
mechanical resolution guarantees significant stability in controlling the superheat value at the set point and a rapid
response to transient situations. The proportional control function also ensures the absence of pressure pulsation
in the refrigerant lines and greater control over the return of liquid to the compressor/compressors. The standard
configuration of the E2V expansion valve requires a pressure probe and a temperature probe to be installed at the
evaporator outlet, so as to control the refrigerant superheat value.

System Schematic CONDENSER

p-LAN

Drive connection
Temperature
probe

Pressure probe
4-20mA COMPRESSOR

EVAPORATOR

Expansion Valve Wiring Details

Expansion Valve Driver Network Address DIP Switches

The method to address the EV driver is achieved by setting a sequence of DIP switches using binary
configuration. The switches are accessed by removing the top cover of the EV Driver.
Address examples

DIP Switch location

Note: To ensure correct operation, select all of the DIP switches to the off position then power the unit on and
then off again. Then select the DIP switches to the required address, e.g. address number 9, and then switch the
power back on.

GEA Denco Stock Code no: 2/184/073 52

Version 3 05/09 C3-05 Controls

Electronic Expansion Valve Operation (cont)

Expansion Valve Default Settings

The settings for the EEV can be selected by accessing Level 3, Factory
Configuration then select EEV Configuration.
In EEV Configuration press the UP & DOWN buttons together to access the
EEV hidden parameters as follows:

EEV 1 Valve Type Carel E2V**A

Dead Zone 0
Prop. Factor 10
Derivative Factor 2
Low S. Heat Limit 2
Low S. Heat Int. T 10

Common Config. LOP & MOP LOP Limit -5

LOP Integral Time 10
MOP Start Delay 30
MOP Limit 11
MOP Integral Time 20

Hi T Cond Config Limit 56

Integral Time 0

Suction T. Limit 20

Evap. Press Probe Min. Value 0.5

Max. Value 7

Alarm Delay Low Superheat 60

High Suction Temp 0
LOP 60
MOP 0

GEA Denco Stock Code no: 2/184/073 53

Version 3 05/09 C3-05 Controls

Electronic Expansion Valve Troubleshooting

Problem Cause Solution
Check that the pressure and the temperature measured
are correct and that the probe position is correct. Check
The probe does not that the minimum and maximum pressure parameters for
The superheat value
measure correct values. the pressure transducer set on the driver correspond to
measured is
the range of the pressure probe installed. Check the
incorrect.
correct electrical connections to the probe.
The type of refrigerant is Check and correct the type of refrigerant in the software
incorrectly set. parameter.
The type of valve is
Check and correct the type of valve parameter.
incorrectly set.
Check the movement of the valve by placing it in manual
The valve is connected control and closing or opening it completely. One
incorrectly (rotated in complete opening must bring a decrease in the superheat
reverse) and is open. and vice-versa. If the movement is reversed, check the
electrical connections.
Increase the superheat setpoint. Initially set it to 12°C and
The superheat setpoint is check that there is no longer return of liquid. Then
too low. gradually reduce the setpoint, always making sure there
is no return of liquid.
If the superheat remains low for too long with the valve
that is slow to close, increase the low superheat threshold
Liquid returns to the and/or decrease the low superheat integration time.
compressor during Low superheat protection Initially set the threshold to 3°C below the superheat
operating. ineffective. setpoint, with an integration time of 3-4 seconds. Then
gradually lower the low superheat threshold and increase
the low superheat integration time, checking that there is
no return of liquid in any operating conditions.
Disconnect the stator from the valve and the cable and
measure the resistance of the windings using an ordinary
Stator broken or connected
tester. The resistance of both should be around 36 ohms,
incorrectly.
otherwise replace the stator. Finally, check the electrical
connections of the cable to the driver.
Check if the superheating is always low (<2°C) with the
valve position permanently at 0 steps. If so, set the valve
Valve stuck open. to manual control and close it completely. If the superheat
is always low, check the electrical connections and/or
replace the valve.
Check the controller condenser settings, giving the
The condensing pressure parameters “blander” values (e.g. increase the
swings. proportional band or increase the integration time). Note;
the required stability involves a variation within +/- 0.5bar.
The superheat swings even
with the valve set in manual
control (in the position Check for the causes of the swings (e.g. low refrigerant
corresponding to the charge) and resolve where possible.
The superheat value average of the working
swings around the values).
setpoint with an The superheat does not
As a first approach, decrease (by 30 to 50%) the
amplitude greater swing with the valve set in
proportional factor. Subsequently try increasing the
than 4°C. manual control (in the
integration time by the same percentage. In any case,
position corresponding to
adopt parameter settings recommended for stable
the average of the working
systems.
values).
Increase the superheat setpoint and check that the
swings are reduced or disappear. Initially set 13°C, then
The superheat set point is
gradually reduce the setpoint, making sure the system
too low.
does not start swinging again and that the unit
temperature reaches the control setpoint.

GEA Denco Stock Code no: 2/184/073 54

Version 3 05/09 C3-05 Controls

Electronic Expansion Valve Troubleshooting (cont)

Problem Cause Solution
In the start-up phase Activate the MOP protection by setting the threshold to
with high the required saturated evaporation temperature (high
evaporating MOP protection disabled or evaporation temperature limit for the compressor) and
temperatures, the ineffective. setting the MOP integration time to a value above 0
evaporation (recommended 4 seconds). To make the protection more
pressure is high. reactive, decrease the MOP integration time.
The ‘valve opening at start- Check the calculation in reference to the ratio between
up’ parameter is set too the rated cooling capacity of the evaporator and the
low. capacity of the valve; if necessary lower the value.
The driver in stand-alone
Check the configuration of the digital input. Check that
configuration does not start
when the control signal is sent that the input is closed
control and the valve
correctly. Check that the driver is in stand-alone mode.
remains closed.
LOP protection disabled. Set a LOP integration time greater than 0 seconds.
Make sure that the LOP protection threshold is at the
required saturated evaporation temperature (between the
rated evaporation temperature of the unit and the
LOP protection ineffective.
corresponding temperature at the calibration of the low
pressure switch) and decrease the value of the LOP
In the start-up phase
integration time.
the low pressure
Check that the solenoid opens correctly, check the
protection is Solenoid blocked
electrical connections and the operation of the relay.
activated.
Check that there are no bubbles in the sight glass
upstream of the expansion valve. Check that the
Insufficient refrigerant
subcooling is suitable (greater than 5°C); otherwise
charge the unit.
The unit switches off
Check the movement of the valve by placing it in manual
due to low pressure
The valve is connected control and closing or opening it completely. One
during control.
incorrectly (rotates in complete opening must bring a decrease in the superheat
reverse) and is open. and vice-versa. If the movement is reversed, check the
electrical connections.
Disconnect the stator from the valve and the cable and
measure the resistance of the windings using an ordinary
Stator broken or connected
tester. The resistance of both should be around 36 ohms,
incorrectly.
otherwise replace the stator. Finally, check the electrical
connections of the cable to the driver.
Use manual control start-up to completely open the valve.
Valve stuck closed If the superheat remains high, check the electrical
connections and/or replace the valve.
The valve is significantly Replace the valve with a larger equivalent.
undersized.

GEA Denco Stock Code no: 2/184/073 55

Version 3 05/09 C3-05 Controls

Heating Operation
Heating is achieved in one of two ways, either with Electric Heaters or with Low Pressure Hot Water (LPHW).

In the case of Electric Heating up to a maximum of three stages of heating can be configured in software
(Software Level 3 Factory Settings) even though there are only two heating outputs. For this arrangement the
electric heaters must be of unequal size (in the ratio of 2:1, output No 1 heater being the smaller). Operation of
the outputs is in a binary manner as shown in the table below.

Heating Step Heater Stage ON OFF

1 1 u
2 u
2 1 u
2 u
3 1 u
2 u

The LPHW output operates a Drive Open / Drive Close valve actuator via the digital outputs in response to
heating demands. The operation of the outputs is similar to that for CW control.

The heating demand is generated in the same way as the cooling demand, i.e. deviations below setpoint will
generate a heating demand relevant to the dead zone and proportional bands set, and operate the heating
outputs accordingly.

Integral action has the same effect on the heating demand, thus with no change in the Return Air Temperature
and an initial heating demand is present the demand is gradually increased so that the output increases to raise
the Return Air Temperature to its' setpoint.

The controller can also provide a 0 - 10V DC output to a LPHW valve actuator if required.

GEA Denco Stock Code no: 2/184/073 56

Version 3 05/09 C3-05 Controls

Humidifier

Humidifier Assembly

Fill cup

Chassis Conductivity Electrodes

Cylinder
High Level Electrodes

Electrodes

Filter (inside cylinder)

Cylinder Fastening Strap

Supply Hose

Fill Hose

Drain Pump & Overflow Outlet Hose

Drain Hose

Fill Solenoid Valve

Drain Connection

Inlet Connection
Drain Pump

The above diagram shows the basic components of the humidifier assembly, while de-energised. It should be
noted that a suitable steam pipe must be used and the system should not be operated with an “open top”.

The 3 kg/hr humidifier uses a steam nozzle (typical shown below) to introduce the steam into the unit airflow,
above this capacity a sparge pipe arrangement is utilised.

The position of the nozzle / sparge pipe within the Air Handling Unit
has been selected to produce the best distribution of steam into the airflow.

The humidifier operating parameters are selected in software. Voltages, phases and the appropriate steam
cylinder size fitted are set in Software Level 3 Factory Configuration. This configuration is set up during factory
inspection and testing and will not normally need to be reset. The conductivity sensor incorporated in the design
can be used to display supply conductivity, but is primarily used for internal software calculations.

GEA Denco Stock Code no: 2/184/073 57

Version 3 05/09 C3-05 Controls

Humidifier (cont)

Humidifier Technical Data

Steam Output Capacity 3 kg/hr 8 kg/hr 15 kg/hr 25 kg/hr

Steam Output Range 0.6 – 3 kg/hr 1.6 – 8 kg/hr 3 – 15 kg/hr 5 – 25 kg/hr
Maximum Power Output 2.25kW 6kW 11.25kW 18.75kW
Humidifier Amps O.A. Max. O.A. Max. O.A. Max. O.A. Max.
Supply Voltage Options
(V / ph / Hz)
220 / 1 / 50 10.2 13.3
230 / 1 / 50 9.8 12.7
240 / 1 / 50 9.3 12.1
220 / 3 / 50 5.9 7.7 15.8 20.5 29.5 38.4 49.2 64.0
380 / 3 / 50 3.6 4.7 9.1 11.8 17.0 22.1 28.4 36.9
400 / 3 / 50 3.3 4.3 8.7 11.3 16.3 21.2 27.2 35.4
415 / 3 / 50 3.1 4.0 8.3 10.8 15.6 20.3 26.0 33.8
440 / 3 / 50 2.9 3.8 7.8 10.1 14.8 19.3 24.6 32.0
460 / 3 / 50 2.8 3.6 7.5 9.8 14.1 18.3 23.5 30.6
General Specifications
Ambient Temperature 1 – 40° C
Operating Pressure 0 bar (pressureless)
Feed Water Pressure 1 – 10 bar (14.5 – 145 psig)
3
Water Conductivity Range 125 – 1250 microSiemens / cm
3
Standard Bottle 350 – 750 microSiemens / cm
3
Soft Water Bottle 125 – 350 microSiemens / cm
3
Hard Water Bottle 750 – 1250 microSiemens / cm
Feed Water Connection 15mm O/D Compression Connection
Drain Water Connection 22mm Copper

Humidifier Operation Conditions

Medium – High Medium – Low

Conductivity Conductivity
Limits Limits
Min Max Min Max
Hydrogen ions pH 7 8.5 7 8.5
Specific conductivity at 20°C µS/cm 300 1250 125 500
Total dissolved solids mg/l (¹) (¹) (¹) (¹)
Dry residue at 180°C mg/l (¹) (¹) (¹) (¹)
Total hardness mg/l CaCO₃ 100(²) 400 50(²) 250
Temporary hardness mg/l CaCO₃ 60(³) 300 30(³) 150
Iron + Manganese mg/l Fe + Mn 0 0.2 0 0.2
Chlorides ppm Cl 0 30 0 20
Silica mg/l SiO₂ 0 20 0 20
Residual chlorine mg/l Cl 0 0.2 0 0.2
Calcium sulphate mg/l CaSO₄ 0 100 0 60
Metallic Impurities mg/l 0 0 0 0
Solvents, diluents, soaps, lubricants mg/l 0 0 0 0

(¹) Values depending on specific conductivity; in general: TDS ≡ 0.93 * σ₂ ₀ ; R₁ ₈ ₀ ≡ 0.65 * σ₂ ₀

(²) not lower than 200% of the chloride content in mg/l of Cl
(³) not lower than 300% of the chloride content in mg/l of Cl

GEA Denco Stock Code no: 2/184/073 58

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Humidifier (cont)

Cylinder Life
The water hardness and the humidity demand on site will determine the effective life of a steam cylinder. Units
located in areas with naturally soft water will experience the longer cylinder life, whilst areas with hard water, a
more frequent cylinder exchange must be expected as the whole purpose of the Humidifier is to produce pure
steam for humidification at the expense of the disposable steam cylinder.

The electrode boiler humidifiers are designed to cope with a very wide variety of tap waters. Tap water can be
used without water treatment, however it is recommended to put a fine filter before the water inlet valve to the
humidifier in case the water is hard or contains visible particles.

The range of acceptable water conductivity is from 125 to 1250 microSiemens/cm. The hardness of the water is
not such an important criteria because even soft water can have acceptable conductivity. However, it is not
recommended to use chemically softened water, because it may cause the water to become aggressive or cause
foam in the cylinder.

Manual Tuning of the Dilution Drains

The concentration of the minerals inside the boiler increases during the steam production because the water boils
off but the minerals remain.
The concentration has to stay within a pre-defined working range, otherwise:
• If it was too low, the response of the humidifier to changing demands would be slow
• If it was too high, disturbing phenomena would likely occur (foaming, electrode corrosion, arching)

All CAREL immersed-electrodes humidifiers have an algorithm that controls automatically the internal
concentration in order to respect the constraints above. The algorithm maintains the water concentration within
the working range as follows:
• When the concentration is too low, it just lets the water boil off because this will increase the internal
concentration (the fills done to restore the water level only temporarily and negligibly decrease the internal
concentration)
• When the concentration is too high, the algorithm drains part of the boiler’s water and replaces it with
mains water, thus diluting the boiler’s content of minerals: this is called “dilution drain”.
Note that the amount of water filled to restore the level after the dilution drain is greater than that filled
during the steam production; hence it has a real diluting effect on the internal concentration.

In some cases, however, the algorithm is not capable to run properly: in such situations, the manual tuning of the
dilution drains is necessary.

This is achieved by initially increasing the duration of the drain by changing the ‘Drain (resp H3)’ value
from 100% to 150%. If the problem persists then adjust the value to the maximum of 200%.

If problems are still being experienced, it is possible to decrease the frequency of the draining by
changing the ‘Evap (respH4)’ from a value of 100% to 50%.

GEA Denco Stock Code no: 2/184/073 59

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Humidifier (cont)

Humidifier Operation
With an electrode boiler humidifier, steam is produced by boiling the water contained inside the cylinder. This
occurs by simply filling the cylinder with water and applying a voltage to the electrodes. According to the Joule
effect, the current will tend to heat the water until it boils. The current that runs through the electrodes in the
cylinder depends essentially on the voltage applied to the electrodes, the conductivity of the water inside the
cylinder and the level of the water.
The aim of the algorithm is to maintain the current that runs through the electrodes at a reference value so as to
ensure the percentage of steam production required, according to the readings of the humidity probes and the
parameters set by the user.
During evaporation, the level of the water decreases and as the current is directly proportional to the quantity of
water present in the cylinder, to keep it constant the cylinder would need to be constantly filled with minute
quantities of water. To avoid this, the current is maintained within a certain range around the reference value, by
repeated “water fill/evaporation” cycles.
As well as the level of water in the cylinder, the other factor that determines the current level is the conductivity
of the water inside the cylinder. In fact, during the fill/evaporation cycles, the conductivity of the water will tend to
increase, due to the increase in the concentration of salts in the water. The conductivity of the water inside the
cylinder is measured indirectly, by calculating the time required for a complete evaporation cycle. This time is then
compared against a reference (typical for each cylinder) and, if lower, a certain quantity of water is drained and
then the cylinder is topped up with less conductive mains water.
The humidifier also features a conductivity meter that measures the conductivity of the mains water entering the
appliance during the filling cycles. In the case of high conductivity of the supply water, the control algorithm first
signals a pre-alarm (that doesn't stop operation) and then, if necessary, an alarm (that stops operation). This is
essential to avoid the introduction of excessively conductive water into the cylinder, which may compromise the
correct operation of the humidifier.
Another fundamental element, installed at the top of the cylinder, is the high level sensor, used to detect any
water or foam.
The high level electrodes may be activated for one of the following reasons:
- over-filling of water in the boiler – when the unit is off – due to a leak in the fill valve;
- high water level when first filling the cylinder;
- high water level following the depletion of the cylinder due to fouling on the plates;
- formation of foam.
In the first case, when the high level sensor is activated, the algorithm stops operation and signals a cylinder full
alarm, while in the other three cases the humidifier responds by draining the water so as to decrease the level.
In the event of repeated activations of the high level sensor, the algorithm evaluates the possibility that the causes
may be due to the presence of foam. In this case, if after having performed a complete washing cycle (complete
emptying-complete refill-complete emptying) the high level sensor continues to be activated, the controller signals
a foam alarm (that does not stop operation).
A crucial point in the operation of the humidifier is the control of any excess current levels. In fact, whenever
voltage is applied to the electrodes in the cylinder, after a period of inactivity, there may be short but very intense
peaks in current. If the current is excessive in this initial period, the algorithm responds by immediately switching
off the electrodes and performing a drain cycle. If the excess current continues, the operation of the humidifier is
stopped and a high current alarm is signalled.
The algorithm also controls the drain cycles, signalling a drain alarm if there is no appreciable decrease in
current when the drain cycle starts. Vice-versa, a no water alarm will be signalled if there is no appreciable
increase in current when the humidifier is being filled with water.

GEA Denco Stock Code no: 2/184/073 60

Version 3 05/09 C3-05 Controls

Humidifier (cont)

Basic Humidification Cycle

The humidifier control will open the water inlet

solenoid valve until 110% of the target current is
achieved.

The humidifier will boil off the water until 95% of the
target current is achieved.
If the rate of current drop is above the minimum
allowed time, there will be no need for a drain and the
control will open the water inlet valve and continue with
the normal operation.

If the rate of current drop is below the minimum

allowed time, there will be a drain cycle.

During the drain cycle the electrical supply to the

electrodes will be de-energised.

Following the calculated drain cycle, the control will

open the water inlet valve until 110% of the target
current is achieved and continue with normal
operation.

GEA Denco Stock Code no: 2/184/073 61

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Water Detection (option)

The water detection system is designed to generate an alarm condition when water is detected on either the floor
sensing tape or the condensate sensor mounted in the coil drip tray.
The two sensors are wired in parallel and must have a 10kΏ resistor fitted at the end of line to operate correctly.
Note that the resistor is already fitted to the Denco floor tape (part no. 2/076/289).
The water detection sensors are wired to a Flooding Sensor Detector module that monitors the resistive value and
when water is detected energises the relay to create a digital input to the controller that generates an alarm,
energises the critical alarm relay and disables the humidifier function.
Refer to electrical schematic drawing for full wiring details.

Flooding Sensor Detector LED Operation

LED LED Status Description

Green On 24VAC power supply present

Yellow On Sensor not connected or 10kΏ not fitted

Red On Water present alarm

GEA Denco Stock Code no: 2/184/073 62

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Differential Pressure Transducer (option)

There is an option to install a differential pressure transducer to replaces the differential pressure switches for the
airflow failure and dirty filter alarm monitoring. The differential pressure transducer is suitable for measuring small
differences in the air pressure within the air conditioning unit. It is able to measure with high reliability and
accuracy.
Note: The C3-05 controller must be configured for a Zone unit to enable this option.

There are six settings to configure, as follows;

Pressure Transducer Type - Not Fitted

4-20mA
0-10VDC
0-1VDC

Minimum Value - This value is the bottom range of the specific transducer selected. The default is
configured as 000.0Pa.

Maximum Value - This value is the top range of the specific transducer selected. The default is
configured as 2500.0Pa.

Offset - This value is used as a calibration offset. The default is configured as 00.0Pa.

Filter Alarm - When the measured value increases above this setpoint, the dirty filter alarm is
generated on the C3-05 controller. The default is configured as 0130.0Pa.

Flow Alarm - When the measured value decreases below this setpoint, the airflow alarm is
generated on the C3-05 controller. The default is configured as 010.0Pa.

GEA Denco Stock Code no: 2/184/073 63

Version 3 05/09 C3-05 Controls

Heat Pump Operation (option)

The Heat Pump operation allows heat rejection from the evaporating coil in the air handling unit.
This is achieved when a signal from the C3-05 controller de-energises the reversing valve, in the condensing unit,
when a 50% heating demand is generated. Additional electric heating is available, after a pre-determined time, if
the heating demand is not achieved.

Example of operation:

Number Of Cooling Heating Compressor Reversing Valve

Compressors Demand Demand Output(s) Output
1 0% - Off De-Energised
1 100% - On Energised
2 0% - 1 Off 2 Off De-Energised
2 50% - 1 On 2 Off Energised
2 100% - 1 On 2 On Energised
1 - 0% Off De-Energised
1 - 100% On De-Energised
2 - 0% 1 Off 2 Off De-Energised
2 - 50% 1 On 2 Off De-Energised
2 - 100% 1 On 2 On De-Energised

For 1 stage heat pump, i.e. 1 compressor output, the following shall apply: -
• If heating demand reaches 100% an electric heating software timer to be enabled
• If heating demand remains above 60% after 5 minutes has elapsed on timer then first stage of electric heating
shall be switched on. This switches off at 50% demand
• If heating demand remains above 75% after 10 minutes has elapsed on timer then second stage of electric
heating shall be switched on. This switches off at 60% demand

For 2 stage heat pump, i.e. 2 compressor outputs, the following shall apply: -
• If heating demand reaches 100% an electric heating software timer to be enabled
• If heating demand remains above 70% after 10 minutes has elapsed on timer then first stage of electric
heating shall be switched on. This switches off at 60% demand
• If heating demand remains above 85% after 15 minutes has elapsed on time then second stage of electric
heating shall be switched on. This switches off at 75% demand

Defrost Control
The defrost control operates by the C3-05 controller monitoring the suction and discharge pressures, via
transducers, and sending a signal to operate the heat pump reversing valve to the necessary position depending
on the values measured and the pressure and time setpoints.
When the pressure is lower than the Minimum Setpoint for a period of the Minimum Time, the defrost mode is
initiated. The unit status on the time out display will change to ‘Defrost Mode’, the cooling demand is forced to
100% and the heating demand is forced to 0% demand. The condenser fan 0-10VDC signal will be forced to
maximum speed during a defrost cycle (if enabled).
The Defrost Mode is ended when either the pressure has risen above the Maximum Setpoint or the Maximum
Time has elapsed. The unit will then operate based on the normal calculated temperature demands.

The selectable setpoints are as follows: -

• Minimum Setpoint – the value that the pressure will decrease to initiate the defrost function.
• Maximum Setpoint – the value that the pressure needs to increase to disable the defrost function.
• Minimum Time – the amount of time that the pressure must be below the minimum setpoint to initiate a
defrost cycle.
• Maximum Time – the maximum time that the defrost function could be enabled for, irrelevant of the pressure.

Note: Defrost is disabled when a two circuit unit is configured, i.e. VRF with 4 compressors or non VRF with 2
compressors.

GEA Denco Stock Code no: 2/184/073 64

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Dehumidification Operation
The Dehumidification demand is calculated in a similar way to that of the initial cooling demand.

For Dehum with modulating cooling when the demand reaches 100% the controller will run the CW valve for a
predetermined amount of time for the % CW Cooling assigned to Dehumidification (set in Software Level 3).

Dehum with DX cooling when the demand reaches 100% the total number of DX stages assigned to
dehumidification will energise. Note if two stages are assigned to dehumidification then the stage delay will be
applied to prevent both stages energising simultaneously.

The Dehum output can be disabled in several ways even though the Return Air %RH may indicate that
dehumidification is required. The disable functions are as follows:

r Disable Dehum altogether - set in Software Level 3.

r Disable Dehum due to Return Air Temperature. When the Return Air Temperature falls to below "Control
Air temperature setpoint - (1.5 x ( Heating Prop Band + Heating Deadzone ))", Dehum is disabled. Re-enabled
when Return Air Temperature rises to "Control Air Temperature setpoint - Heating Deadzone".
r For CW systems only disable dehum when cooling demand exceeds a prescribed level - set in Software
Level 3 (Dehum % off).
r For DX system if cooling demand is greater than or equal to the dehum demand then the dehum is
disabled.

All these interlocks allow dry bulb control to have priority over humidity.

Refer to Engineering Manual for relevant airflows and external static values.

GEA Denco Stock Code no: 2/184/073 65

Version 3 05/09 C3-05 Controls

Ambicool Operation
Ambicool is the use of low ambient temperatures cooling a freecooling liquid (typically glycol / water solution) to
effect heat extraction from an air conditioned space. Should the ambient temperature rise to a level at which no
duty can be achieved by freecooling then DX stages will cool the room air in order to do the cooling duty.

To enable Freecooling two requirements have to be fulfilled;-

1. The Air Handling Unit has to be configured for Ambicool.
2. The freecooling liquid has to be at least 1°C below the Return Air Temperature Setpoint.

There is a 1°C hysteresis control band that will allow the freecooling liquid temperature to equal the return air
temperature setpoint before disabling the Ambicool function (closing the freecooling control valve).

To ensure correct and effective operation of the Ambicool system, it is recommended to configure the
Control Strategy to Proportional only control.

The Ambicool valve position is determined by the cooling demand multiplied by four.
e.g. 15% cooling demand = 60% valve position
20% cooling demand = 80% valve position
25% cooling demand = 100% valve position

The DX stages of cooling are enabled depending on the number of cooling stages and the demand. The following
table illustrates this.

Unit Type Output Energise Demand % De-Energise Demand %

2 Circuit DX 1 62.5 62.5
2 Circuit DX 2 100 25
2 Circuit VRF DX 1 43.75 81.25
2 Circuit VRF DX 2 62.5 62.5
2 Circuit VRF DX 3 81.25 43.75
2 Circuit VRF DX 4 100 25

Note: When Ambicool is enabled, dehum is disabled.

Drycooler Fan Outputs

There are two Drycooler outputs available, only when Ambicool is selected, that energise when the Freecool
Water Temperature rises above the Freecool Water Setpoint, which is selectable in Level 2.
There is also a selectable Differential in Level 2 for staging between the two outputs.
With the default settings configured, the first output energises when the freecool water temperature rises to 8°C
and the second output energises, with 0.5°C differential, at 8.5°C.

Combicool Operation
A Combicool unit consists of two separate cooling circuits. Normally the primary cooling circuit will be chilled water
and the secondary circuit a DX system, however, the option for two chilled water circuits is available in Level 3,
Factory Configuration.
The cooling function would change from one system to another in one of two ways;

r If the chilled water temperature rises above the Combicool CW Limit, configured in Level 2.

r If the Combicool Change-over input is generated.

GEA Denco Stock Code no: 2/184/073 66

Version 3 05/09 C3-05 Controls

Supply Air Temperature Interlock with Cooling

The supply air temperature input has the facility for alarm indication and interlock with cooling. If the alarm
indication status is enabled an alarm is operated when the supply air temperature falls below an alarm setpoint. A
description of how the alarm operates is as follows:
o
Supply air temperature alarm setpoint = 15 C (adjustable in Software Level 3 Factory Settings)
Supply air temperature alarm time delay = 15 min (adjustable in Software Level 3 Factory Settings)
o
If the supply air temperature is equal to or less than the alarm setpoint minus 3 C for the alarm time delay the
o o
alarm will be activated (note: the 3 C is a fixed value). Thus if the supply air temperature is 12 C (i.e. 15 - 3) or
less for alarm delay period the alarm will operate.

If the interlock is enabled then the cooling output is reduced by a reduction factor, where;

Reduction Factor = ( Supply Air Alarm Setpoint - Supply Air Temperature ) / 2

Supply Air Humidity Interlock with Humidification

The supply air humidity channel has the facility for alarm indication and interlock with humidification. The alarm
indication status is actuated if the alarm status is enabled and if the supply air humidity has been greater than the
alarm setpoint for the alarm delay period (adjustable in Software Level 3 Factory Settings).

If the interlock function is enabled then the humidifier output demand will start to decrease when the supply air
humidity is Alarm Setpoint minus 10%. Should the supply air humidity reach the alarm setpoint then the humidifier
output would be 0%.

Heater / Humidifier Interlocks

The software has the facility to select one of a series of interlocks, which affect the operation of electric heaters
and the humidifier. In the majority of cases the electrical supply to an Air Handling Unit is sufficient to enable both
the heating and the humidifier to run at the same time, should operating conditions require so. However, there are
cases when only one function or the other can be run at any one time, thus the software can be set so that one
function has priority over the other.

There are three options available, as follows:

(1) Heat and Hum - This option allows both functions to operate simultaneously (factory default).
(2) Heat prevents Hum - This option will give priority to the heating function. Should heating be called for the
humidifier will be disabled even though there maybe demand for humidification.
(3) Hum prevents Heat - This option is the opposite of (2) where the heating is disabled when the humidifier is
enabled by demand.

With option (2) or (3) selected, the interlock remains active even if the software output forcing routines are
applied.

Generator Run
If the control 24VAC is present on Digital Input 12 (ID12) then the controller will operate in a cooling only mode,
i.e. Heating and humidifier outputs are disabled. This is normally controller via a volt free contact supplied from
the generator or UPS.
This function is designed to reduce the power consumption to a minimum in the event of a mains power failure.

GEA Denco Stock Code no: 2/184/073 67

Version 3 05/09 C3-05 Controls

Combined Temperature and Humidity Sensor

The Combined Temperature and Humidity Sensor uses NTC resistive output signal for temperature indication.
The humidity sensor is an active sensor using a 24V DC supply and produces a 0 - 1V DC signal proportional to
the % relative humidity. The range of the sensor is 0 - 100 %RH, thus at 0 %RH it produces a signal of 0V and at
100 %RH a signal of 1V.

Sensor adjustment (monitored with a calibrated instrument) can be made in Software Level 3 Calibration.

+VDC G 24V DC

GND M 0V DC

NTC
B4 NTC Temp Signal

B1 H Hum Signal

Ambient Temperature and Humidity Range

o o
Operating: 0 C to 50 C 10 - 90 %RH Non Condensing

Ensure jumper links are positioned to

the left for a 0-1V humidity signal.

G NTC NTC M H

GEA Denco Stock Code no: 2/184/073 68

Version 3 05/09 C3-05 Controls

Commissioning / Controller Set Up

Note: Paragraphs 6,7 & 8 are only applicable when changing a controller.
At initial commissioning or when changing a controller all operational parameters will be set to default. (See
Software Levels for values.) These will have to be changed as appropriate to meet site requirements. Also, when
changing a controller, the Factory Configuration of the controller will have to be set for the AHU it is being fitted to.

Note: please refer to "Handling Static Sensitive Devices" prior to servicing the controller and its
associated modules.
1. Ensure that the Mains supply is isolated.

2. Identify the means of cooling, heating, hum and de-hum.

3. Switch all MCB's, except the single phase Controls power supply MCB, to the "OFF” position.

4. Ensure that the display ON / OFF switch is "OFF".

5. Switch on the mains supply. Check the liquid crystal display illuminates. The liquid crystal display will show the
Time Out display.

6. Use the programming keys to select Software Level 3. Using the appropriate coded key presses, enter
Software Level 3 Factory Settings.

7. Using the Factory Settings table, set the values as appropriate to the Air Handling Unit, as identified in 2.

8. If any operating parameters are different to default values enter the appropriate Software Level and change as
required. For explanation of time-out displays, input / output status and control types see the previous sections.

9. Switch unit "ON" and reset any alarms. Switch on fan(s) with the fan MCBs. Check the rotation of fan(s) and set
airflow switch as required. Using the software H/O/A switches test the function of individual output stages.
Remember to reset MCBs as they are used. On completion reset all H/O/A switches to "AUTO".

GEA Denco Stock Code no: 2/184/073 69

Version 3 05/09 C3-05 Controls

Controller Removal and Replacement

Note: please refer to "Handling Static Sensitive Devices" prior to servicing the controller and its
associated interface cards.
It is recommended to read these instructions first before changing the controller.

The controller is replaced as follows:

(1) Switch off Air Handling Unit at the display ON/OFF switch. Enter Software Levels and note any parameters
that are different to default settings, also check the Factory Settings. If for any reason access to the Software
Levels cannot be made check the electrical drawing configuration tables, commissioning sheets or contact the
contracts engineer.

(2) Switch off power supply.

(3) Remove all inputs and output connections by unplugging the terminals from controller.

(4) Disconnect the display cable from the controller board.

(5) Remove controller from DIN rail.

(6) Fit new controller as a reversal of the above procedure.

(7) Switch on mains supply. Set software Factory Settings as appropriate, see Software Level 3. Also set up any
parameters as noted previously.

(8) Switch on Air Handling Unit using the display ON/OFF switch, and check operation of the unit.

Display Removal and Replacement

The display is replaced as follows:

(1) Switch off Air Handling Unit at the display ON/OFF switch.

(2) Switch off power supply, then remove display fascia.

(3) Remove the two screws connecting display to door panel.

(4) Disconnect the display cable from the display board.

(5) Fit new display as a reversal of the above procedure.

(6) Switch on mains supply.

(7) Switch on Air Handling Unit using the display ON/OFF switch, and check operation of the unit.

GEA Denco Stock Code no: 2/184/073 70

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Software Upgrade
The Denco application software can be upgraded using a Smartkey, as follows;-

1. Ensure the unit is switched off on the display.

2. Switch the mains power to the unit off.
3. Disconnect the Network terminal block (J11) from the C3-05 controller (if applicable).
4. Disconnect the display cable from the display.
5. Connect the display cable into the SmartKey.
6. Switch on the mains power to the unit.
7. Wait for the green arrows on the SmartKey to stop flashing and the start button to be illuminated.
8. Press the start button on the SmartKey.
9. Wait approximately 4 minutes, the SmartKey will then bleep to confirm that the software has been
downloaded successfully.
10. Switch off the mains power to the unit.
11. Disconnect the display cable from the SmartKey.
12. Re-connect the display cable to the display.
13. Switch on the mains power to the unit.
14. Set up the addresses for the controller and display, as described on page 25.
15. Select ‘Load Defaults’ in Level 3, Factory Configuration and select ‘Yes’, and wait for the default values to
load.
16. Set-up the controller configuration (Level 1, 2, 3 and Factory Configuration) to suit the specific unit
requirements.
17. Re-connect the Network terminal block to the C3-05 controller (if applicable) only when all the units on
the network have had the software updated.
18. Switch on the mains power to the unit.

GEA Denco Stock Code no: 2/184/073 71

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Servicing: Check List

Item Frequency Action Notes

1 3 Monthly Completely check control settings and Use Software Level 3 to test outputs.
operation.
2 3 Monthly Check that all sensors are secure and -
sensing correctly.
3 3 Monthly Check that all terminals are tight. -

Due attention should be paid to the notes on servicing the microprocessor. Any servicing is to be carried out by a
QUALIFIED CONTROLS ENGINEER.

Control Component Parts List

Item Description Denco Part Number

C3-05 Controller (Large) 2 / 076 / 279
C3-05 Controller (Medium) 2 / 076 / 280
Graphical Display 2 / 076 / 281
Temperature & Humidity Sensor 2 / 076 / 282
Humidifier Interface 2 / 076 / 283
5 metre Water Detection Tape 2 / 076 / 289
Water Detection Module 2 / 076 / 292
Ambicool/Combicool Water Temperature Sensor 2 / 076 / 294
RS232 Serial Interface 2 / 076 / 295
RS485 Serial Interface 2 / 076 / 296
LonWorks Interface 2 / 076 / 328
pCOWeb Interface 2 / 076 / 298
pCOnet Interface 2 / 076 / 330
Display Cable Ferrite 2 / 120 / 338
SmartKey 2 / 076 / 331
Remote/Monitoring Wall Mounted Display 3 / 007 / 904
TCONN Module (for use with Monitoring Display) 3 / 007 / 905

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Version 3 05/09 C3-05 Controls

Fault Finding: Controls

As it will be necessary for panels to be worked on "live" for fault finding only QUALIFIED and COMPETENT
STAFF should be used on this section. Refer to "The Electricity at Work Regulations" for guidance.

Always fault find with relevant schematic wiring diagrams and panel layouts at hand. Always modify diagrams if
any modifications are made (subject to confirmation with the Denco Technical Department).

Always replace relays, contactors or any other components with those of the same make, type and rating. Failure
to do so may invalidate the warranty.

It is necessary to ensure that all isolators are in the "OFF" position before any covers are removed.

Fault Finding: Use of Sheets

In the following tables it is assumed that the mechanical and electrical services to which these refer have been
commissioned correctly and run without significant faults for a reasonable period since the commissioning, i.e.,
the design settings were correct, and the plant is of the correct size for the application.

Any repeated faults in the initial warranty period should be relayed to the contractor and consultant.

Plant settings should not be altered as the balance of the complete system can be affected resulting in a costly re-
balancing operation. Re-balancing should only be carried out by a COMPETENT ENGINEER.

Carrying out maintenance as described in the servicing sections can cut down significantly nuisance fault finding
problems, however maintenance should be carried out by competent and trained staff - bad maintenance is often
worse than no maintenance all.

The fault finding tables have been prepared in logical sequence, with the most likely faults first.

Ensure that the person(s) fault finding are competent in attending to all aspects of the equipment and that they
know the location of all items of plant.

GEA Denco Stock Code no: 2/184/073 73

Version 3 05/09 C3-05 Controls

Fault Finding: Controls (cont)

Fault Possible Cause Remedy

(A) Control failure 1. No mains or failure of supply Check for fault on phase concerned after
phase. checking all isolators between mains and panel
OK.
2. Control circuit MCB tripped.
Reset and if it trips again check for fault. Could
be loose wiring or coil fault to earth.
3. 24V AC Power Supply Fuse
ruptured. Check for reason of ruptured fuse. When
satisfied, replace fuse.
4. Control circuit relay problem.
If other parts of circuit operating, work from this
part in a logical sequence.

5. External controls. An external control could affect control circuit.

Check in conjunction with schematic drawing.
(B) Relay [KA] or 1. No supply to coil (a) Check 24V AC supply and stage supply fuses
contactor [KM] not on controller.
operating (b) Check control wiring to coil.

2. Faulty coil. Check and replace.

3. Faulty/tripped overload. Check whether tripped. If faulty replace.

2. Fan Failure Replace fan(s).

(D) Incorrect 1. Defective connections on See appropriate Sensor servicing.
temperature or Sensor.
humidity indication
2. Microprocessor is being See Section (E).
corrupted

3. Sensor calibration incorrect. Refer to Service section for sensor values. Use
Sensor Trim in Software Level 3 to adjust value.

4. Loose connections. Check that the Sensor is securely located on the

sensor holder and retaining screw is tight. Ensure
good sensor connections on controller.

5. Sensor positioned incorrectly. If the Sensor is positioned outside the Air

Handling Unit it should be aspirated and mounted
in a position that is representative of the room
conditions.

6. Earth screen on sensor cable The sensor wiring must be screened and fully
ineffective. segregated from wiring carrying mains potential.
The screen should be terminated to earth at one
end only.

8. Power supply to sensor failure. Check supply connections from controller.

GEA Denco Stock Code no: 2/184/073 74

Version 3 05/09 C3-05 Controls

Fault Finding: Controls (cont)

Fault Possible Cause Remedy

(E) Corruption of Usually manifests itself as: Causes:
Controller
(a) Inappropriate characters on 1. Ineffective segregation of signal and mains
the display. potential wiring. Pay particular attention to field
wiring, any site modifications within the Air
(b) False alarms on the display. Handling Unit or Condensing Units etc. and any
remote interlocks.
(c) Software configured
parameters revert to default 2. Humidifier bottle is very dirty and arcing is
parameters. occurring within the bottle, change bottle
immediately.

3. Sensor cable ineffectively screened, refer to

relevant temperature and humidity sensors in
service section.
(F) Unit fails to start 1. One or more of the run days Firstly check that this is not a required feature
when switched on via (Software Level 1) set to OFF before re-setting all run days to ON.
ON /OFF switch.
2. 24 hour time clock set Firstly check that this is not a required feature
(Software Level 1) before re-setting time clock. Set both on and off
times to 00:00 hours to prevent time clock from
functioning.

3. Switched off remotely/manually, Enable remote signal.

by monitoring system or fire alarm NOTE: Never link out fire alarm interlock without
activated written consent.
(G) Display blank 1. Extreme temperatures around No direct remedy.
unit.

2. Display cable disconnected. Reconnect cable.

GEA Denco Stock Code no: 2/184/073 75

Version 3 05/09 C3-05 Controls

Fault Finding: Controls (cont)

Fault Possible Cause Remedy

(H) Dehum not 1. Dehum function disabled in Ensure that this is not a design feature before
functioning with a Software Level 3. enabling.
demand for
dehumidification 2. Dehum interlock with return air Ensure that this is not a design feature before
temperature disabled in Software disabling interlock in Software Level 3.
Level 3. (Dehum is disabled if
return air temperature falls below
a predetermined value).

3. Cooling demand greater than Ensure that this is not a design feature before
dehum demand. disabling interlock in Software Level 3.
(I) Cooling not 1. Supply air temperature Ensure that this is not a design feature before
functioning with a interlock enabled. When the disabling supply air temperature interlock in
cooling demand supply air temperature interlock is Software Level 3 Factory Settings.
enabled cooling is disabled or
reduced if the supply air
temperature falls below a
predetermined value.
(J) Cooling DX stages 1. HP or LP alarm / trip. Check for cause. Reset as required.
not
energising
(K) Logged averages 1. Alteration of sample frequency. Always register all required samples before
of temperature and setting/re-setting sample frequency.
humidity display 0° C
and 0 %RH
respectively. No
recorded samples on
any of the logging
channels.
(L) Heating outputs 1. Heater Klixon activated. Investigate why Klixon has operated. Reset via
not energised with a display keys. The Klixon is an auto-reset device.
demand for heating
2. Fan Failure Alarm Investigate why fan(s) have failed. Reset via
display keys.

3. Hum prevents Heat Interlock. Ensure that this is not a design feature before
disabling interlock in Software Level 3 Factory
Settings.
(M) Outputs remain 1. Software Hand/Off/Auto Ascertain reason why output is in HAND or OFF
constantly energised switches not set to AUTO. before setting to AUTO control.
or de-energised

GEA Denco Stock Code no: 2/184/073 76

Version 3 05/09 C3-05 Controls

Fault Finding: Controls (cont)

Fault Possible Cause Remedy

(N) Humidifier output 1. Humidifier alarm. Check alarm and cause of alarm.
not functioning with a
demand for 2. Water alarm. Investigate why water alarm has been activated.
humidification Reset via front panel keys.

3. Fan Failure Alarm. Investigate why fan(s) failed. Reset via display
keys.
(O) Auxiliary alarms: 1. Alarm text message altered or Set alarm text message as required.
displaying irregular set to customers requirements in
alarm messages Software Level 3.
when activated
(P) Auxiliary alarm(s) 1. Mode of operation set to Ensure that this is not a customer requirement
fail to activate critical activate alarm relay in Software before setting to operate the critical alarm relay.
alarm relay Level 3.
(Q) 0 - 10V DC 1. 24V AC supply to valve lost. Check / replace cabling to valve.
modulating output not
operating 2. Valve running time incorrect. Check VRT and adjust if required.
correctly(CW cooling
/ LPHW heating 3. Incorrectly set for cool / heat / Set for correct output.
/remote humidifier) hum output in Software Level 3
Factory Settings
(R) Drive Open / 1. Digital cooling set in Software Set to DODC cooling
Drive Close Level 3 Factory Settings.
modulating cooling
not operating 2. 24V AC supply to valve lost. Check / replace cabling to valve.
correctly
3. Digital outputs damaged Check outputs for 24V AC when operated.
(Cool 1/2)
(S) Drive Open / 1. Digital heating set in Software Set to DODC heating
Drive Close Level 3 Factory Settings.
modulating heating
not operating 2. 24V AC supply to valve lost. Check / replace cabling to valve.
correctly

If technical support is required after the preceding fault finding section, contact the nearest GEA Denco service
department for assistance.

GEA Denco Stock Code no: 2/184/073 77

Common questions