Cac 2000 Control Specifications

SERVICE GUIDE

CAC CONTROLLER

Version 5 Updated for 50V3 software

CAC Controller Service Guide5 1 26/11/17 INDEX 1 ABBREVIATIONS...... 4 2 DIFFERENCES BETWEEN SOFTWARE VERSIONS...... 4 3 INTRODUCTION...... 4 3.1 Operation After Power Failure...... 5 3.2 Thermistor Operation...... 5 4 COMPRESSOR OPERATION...... 5 5 OUTDOOR FAN OPERATION...... 5 6 – INDOOR FAN OPERATION...... 7 7 COMPRESSOR OIL HEATER...... 8 8 CONTROL OPTIONS...... 9 8.1 General...... 9 8.2 External analogue sensor (RT and SPT)...... 10 8.3 Auxiliary inputs (conventional thermostat)...... 10 8.4 Digital Electronic Zone Sensor (RCW)...... 10 8.5 External ON/OFF...... 11 8.6 Modbus communication (50V3 only)...... 11 9 TEMPERATURE CONTROL...... 11 9.1 Remarks concerning PI control...... 11 9.2 Electric heater limiting...... 11 10 AUTOMATIC CHANGEOVER MODE...... 11 11 PROTECTION...... 11 11.1 Cooling mode...... 11 11.2 Heating mode...... 11 11.3 High pressure Cutout input...... 11 11.4 Low pressure Cutout input...... 11 11.5 Lockout reset...... 11 11.6 General Features...... 11 11. FORCED TEST MODE...... 11 12 ON UNIT CONTROL INDICATORS AND SWITCHES...... 11 12.1 Display menus and display navigation...... 11 12.2 Parameter change menu...... 11 12.3 Fault Relay Output...... 11 12.4 Alarm and diagnostics...... 11 13 SYSTEM CONFIGURATION SETTINGS...... 11 14 System Diagnostics and Operation at Fault Conditions...... 11 15 DEFAULT SETTINGS...... 11

CAC Controller Service Guide5 2 26/11/17 1 ABBREVIATIONS

IFAN Indoor fan OCT1 Outdoor coil temperature, circuit 1 OCT2 Outdoor coil temperature, circuit 2 RH Resistance heat, unit using compressor cooling and electric heat for heating. RT Room temperature SPT Setpoint SH Supplementary heat, unit that uses compressors for heat and cooling and electric heat for supplementary heating. ST Standard, unit that uses compressor for cooling, no heating

2 DIFFERENCES BETWEEN SOFTWARE VERSIONS

Version 50V2, used from May 2002 Function Difference between previous version Consequence Remote control Compatible with RCW2 Remote control Compatible with RCW timer Low ambient In cooling mode the outdoor fan min run time at Less LOC alarms at low compressor start to 60s ambient. Low ambient The parameter OFCS minimum value is now Reduces outdoor fan stop 10°C, default value is not changed. temperature. Low ambient The parameter ICdS minimum value is now 0°C, Can by-pass the LOC default value is not changed alarm if needed.

Version 50V3 used from about March 2005 onwards Function Difference between previous version Consequence Networking Now compatible with MIU Version H8 Modbus communication and Airconet compatibility Tandem Now tandem compressor configuration Improved De-ice ASK Add new configuration for no OFAN cycling Improved operation with ASK LOC alarm Add auto reset Avoid lockout Software logic new to 50V3 is marked in blue

3 INTRODUCTION

This service guide is to help understand and to configure the CAC controller according to its installation and control requirements.

Some internal parameters can be modified to change performance. Some of these parameters will modify unit protection limits, care must be taken not to change these parameters if you are not sure of the result. Operating the unit with other than the default parameters could void the warranty.

The parameters are referred to throughout this guide in Italics and described in section 11.2.

General For any diagnostics or general service use the digital display to determine the parameters and find the alarms. CAC Controller Service Guide5 3 26/11/17 3.1 Operation After Power Failure A power loss of longer than 40ms is considered as a power loss and will result in a sequenced restart. Random start after power loss: After power loss the unit will have a 0 to 1 minute random re-start.

3.2 Thermistor Operation The following thermistor faults are possible: (a) Thermistor is disconnected (Temp <-30oC) Alarm displayed is O1dl or O2dl (b) Thermistor is short-circuited (Temp > 75oC) Alarm displayed is O1SH or O2SH. (e) Thermistor fault or refrigerant leak (two circuit units only) If after 10 minutes of continuous operation with 2 compressors the difference between OCT1 and OCT2 is greater than 15°C (parameter tF) then a fault will be signalled. This test cannot be done during de-ice or for 10min after de-ice. Alarm displayed is 'rEg'

4 COMPRESSOR OPERATION Minimum run time is 3 minutes (parameter Crun), except for controlled OFF mode and fault OFF. Minimum start to start of the same compressor is 10 minutes (parameter CStS). Minimum OFF time is 3 minutes Minimum time between compressor 1 and 2 start is 1 minute Lead Lag is active for all two compressor units. After both compressors stop, the first compressor to stop must become the first compressor to start. This function can be stopped by the parameter LELA. When using the AUX inputs lead lag is not used, the C1 / C2 inputs directly drive the corresponding output.

Technical note These protection timers should not be modified for piston compressors. If needed the values could be reduced when using scroll compressors. The minimum values for scroll compressors are 1 minute for minimum on and off times and 5 minutes for minimum start to start.

5 OUTDOOR FAN OPERATION Minimum time between changing from a higher to a lower speed is 30s. No minimum time is used to change from stop to low and low to high. When the compressor(s) are OFF the outdoor fan will stop. Between speed changes both high and low speed outputs are never be closed at the same time.

5.1.1 Minimum run time after start-up The fan or fans will always start in low speed and run for a minimum run time. First 50V1 software version minimum run time is 240 s Second 50V2 software version used is 60 s in cooling mode and 240s in heating mode.

5.1.2 No cycling configuration DIP S7 = ON (50V3 only) This configuration is designed to be used with an all seasons kit so that the outdoor fan operation is controlled by an external device.

CAC Controller Service Guide5 4 26/11/17 When S7 is ON the following rules are used: 1. In cooling mode outdoor fan will always be on when compressor is on. For two speed fans only the L output is used. 2. In heating mode the OFAN will operate as normal, using two speeds when required.

5.1.3 Anti seize device (all models) If an outdoor fan does not operate for a 672-hour (28 days) period, then it is started for 1 minute (parameter OFAS). The fan will start in high speed for 30s then reduce to low speed. The timer will count when the unit is powered up in any mode. Any power off periods will be disregarded.

5.1.4 Units with 1 compressor, 1 fan 2-speed Cooling mode After the minimum run time of 240s (60s for 50V2) the temperature-based logic alone determines the fan operation.

FAN Speed COOLING

25 35 45 OCT [oC] (OFCS) Heating mode After the minimum run time of 240s the temperature-based logic alone determines the fan operation FAN Speed HEATING

o 5 10 12 16 OCT [ C] OFHS

CAC Controller Service Guide5 5 26/11/17 5.1.5 Units with 2 compressors, 2 fans 2-speed and independent airflow between circuits Both fans will change speed independently and their ON/OFF control is independent.

5.1.6 Units with 1 compressor, 1 fan, 1-speed The OFAN will start with the compressor and stop with the compressor except for the following:

Cooling mode If the OCT falls below 25°C (OFCS) the fan will switch OFF and restart again at 35°C.

Heating mode If the OCT rises above 16°C (OFHS) the fan will switch OFF and restart at 12°C.

5.1.7 Units with 2 compressors, 1 fan, 1-speed The fan must start with the first compressor to start, and stop with the last compressor to stop. With one compressor operating the temperature-based rules to start and stop the fans are the same as 1compressor units.

5.1.8 Units with 2 compressors, 1 fan, 2-speed When one compressor is operating the fan will change speed according to the rules for a single compressor system. When the second compressor starts the fan must run according to the highest OCT in cooling and the lowest in heating. The fan must not stop for the minimum start time, after this time the fan can only stop when both OCTs reach the temperature limits.

6 – INDOOR FAN OPERATION

Between speed changes both high and low speed outputs must never be closed at the same time, 200ms must be left between opening one and closing the other.

The following table describes the fan operation according to the type of control used and the S5 DIP switch. Unit with 2 speed IFAN Unit with 1 speed IFAN DIP S5 ON OFF ON OFF Control RCW with fan speed SS in selected CONT in CONT CONT selected speed selected speed RCW Auto fan AF + SS AF + CONT SS CONT selected Aux inputs IFAN not SS CONT IP CONT connected Aux inputs IFAN IP CONT in IP CONT connected selected speed Using SPT + RT or AF + SS AF + CONT SS CONT BMS

CAC Controller Service Guide5 6 26/11/17 AF: IFAN to change speed according to Autofan rules (depends on SPT –RT) The AUTOFAN mode is active only when a 2-speed fan is used and AUTOFAN input is ON. Cooling mode: The fan will change to low speed when the room temperature approaches setpoint (RT-SPT1°C) and will change back to high speed when RT-SPT > 1°C. Heating mode The fan will change to low speed when the room temperature approaches setpoint (SPT-RT1°C) and will change back to high speed when SPT-RT > 1°C. Min time interval between fan change in AUTOFAN mode is 30 s.

CONT: Fan will run continuously in heating and cooling except in OFF mode.

SS: IFAN will stop and start with compressor or EH taking into account the pre and post purge times in both heating and cooling modes. SH and ST models - the fan will start 10s after the compressor and stop 20s after the last compressor or electric heat. RH models - the fan will start 5s before the electric heat and stop 20s after the electric heat is switched off.

IP: IFAN to operate according to IFAN inputs or according to the aux input tables (section 7.3) when a cool or heat demand exists without any IFAN demand taking into account pre and post purge timers

AF + CONT The fan will be in low speed when there is no heating or cooling demand.

7 COMPRESSOR OIL HEATER

This output is only used for one compressor systems only. The output is on when the compressor is off when: 1. In heating mode all the time. 2. In cooling mode and off mode when OCT < 15oC

CAC Controller Service Guide5 7 26/11/17 8 CONTROL OPTIONS

8.1 General The control board requires one of the following types of control device to be connected to operate or a combination of 1 and 2. 1. External sensor 2. RCW 3. RCW2 (50V2 software only) 4. Auxiliary inputs (conventional thermostat)

With no control device connected the unit will not start except in test mode. The PCB automatically detects when a control device is connected and will then memorise the configuration and control parameters. If a valid device is added then the configuration is automatically changed. If a non-valid control device is added or one removed an alarm will be displayed. The current control configuration can be checked using the display in the 'ConF' menu.

8.1.1 VALID CONTROL COMBINATIONS

RCW-M RCW-L Auxiliary RT SPT ON/OFF (master) (local) inputs analogue analogue contacts 1 X 2 X 3 X X 4 X 5 X X P 6 X X P X PLC Always 7 X PS X PS valid, 8 X PS X PS X P 9 X 10 X PS X 11 X X P 12 X 13 X X P P – Priority, PS – See individual specifications for priority, PLC – Priority to last change RCW can be RCW or RCW2

IN GENERAL

 If an analogue RT input is detected then this value will be used for RT.  If an analogue SPT input is detected then this value will be used for SPT.

 RCW will only send one setpoint  RCW2 can send two setpoints (heating and cooling) or only one.

 If a RT or RCW is detected and input on the conventional thermostat is detected then a fault will be signalled and the unit will stop.

CAC Controller Service Guide5 8 26/11/17  An incorrect control input alarm is an automatic reset alarm. If the latest invalid input is removed after the alarm then the unit will restart and the alarm will go away but will remain in alarm log.

 The auxiliary inputs are 24V inputs designed to be used with any thermostat or controller with dry contacts.

8.2 External analogue sensor (RT and SPT) The unit will start with only a temperature sensor connected. In this case the default setpoints are used, cooling setpoint is 23°C and the heating setpoint is 21°C. The RT (room temperature) is detected by a thermistor in the air-conditioned zone or in the return duct. The SPT (setpoint) is given by a 22kΩ remote potentiometer. Other control parameters are given by default settings. Both devices are connected directly to the main circuit board. The RT and SPT input can be used with a RCW remote control. With both devices connected the room temperature and setpoint will automatically be taken from the analogue inputs and not from the RCW.

8.3 Auxiliary inputs (conventional thermostat) An external device is used to directly drive the outputs. The device must have relay outputs to avoid the leakage current associated with TRIAC outputs. A 24Vac +/- 2 150mA supply is available to power the thermostat between terminals C and 24. The inputs are configured like a conventional thermostat Two types of thermostat are generally available heat pump and cooling only: Contacts Input Cooling + Electric heat thermostat Heat pump + auxiliary heat thermostat terminal For ST and RH units For SH units 1 Comp 1 Comp 1 2 Indoor fan (low speed if #) Indoor fan (low speed if #) 3 Heat stage 1 Electric Heat stage 1 and 2 4 Heat stage 2 Reversing valve 5 Comp2* or Indoor fan high# Comp 2* or Indoor fan high# * 2 compressor systems only # 1 compressor systems only with two speed indoor fan.

The presence of this thermostat is detected by a signal on one of the inputs. The inputs will directly drive the outputs but with all protection functions taken into account.

8.4 Digital Electronic Zone Sensor (RCW) The RCW input is only compatible with the RCW and RCW2 remote control, no other remote control is compatible with this type of communication. The Local RCW connection is not does not take into account the unit address.

CAC Controller Service Guide5 9 26/11/17 8.5 External ON/OFF When the ON/OFF input is used an open input must change the unit to OFF mode, this input has priority over other modes from other sources. If a de-ice is underway when the unit is switched to off mode the de-ice will terminate before the unit stops.

8.6 Modbus communication (50V3 only) Two accessories must be added for Modbus communication. 1. MIU, any MIU with H8 or more recent software can be used. 2. MIU adapter board, this PCB is connected to the 6pin connecter M1 M2 and M3 after removing the jumper. The wire is to be plugged into to the control connection on the MIU.

When the MIU is used the Master RCW terminal block cannot be used, a local RCW or RCW2 can be connected to the local terminals only.

8.6.1 Airconet The CAC controller is fully compatible with Airconet. The unit must be declared as “CAC” in the tools / AC layout. Note that the double setpoint function can be used with CAC but the night and unoccupied functions are not yet compatible.

8.6.2 Open Modbus The Modbus protocol used is RTU modbus / Jbus 9600 baud. The protocol is an open protocol and compatible with most Modbus controllers that have been programmed with the CAC parameters. A full description of the parameters is available on request.

9 TEMPERATURE CONTROL

Minimum setpoint The minimum cooling setpoint is 20°C any value sent below this value is corrected to 20°C. This minimum value can be reduced to 16°C by changing the parameter CSPL (see section.11.2.1)

CAC Controller Service Guide5 10 26/11/17 9.1 Remarks concerning PI control The controller uses a PI (Proportional Integral) algorithm to switch heating and cooling stages. The algorithm calculates the difference between room temperature and setpoint as well as the duration of the difference. This could mean that a small difference between RT and SPT could start the compressor if the difference lasts long enough. The PI calculation is not done immediately – a small delay may be noticed between a setpoint or temperature change and a change in unit output.

The compressor may not switch off immediately after the RT temperature has crossed setpoint (SPT). This is due to the integral part of the PI algorithm. This overshoot or undershoot will not exceed 0.5°C.

9.2 Electric heater limiting After changing from mode OFF to ON or changing from COOL to HEAT or a setpoint change, electric heat is not allowed during the first 20 minutes, the dRT/dt (rate of change of temperature) value is calculated over this period. If the RT value has increased more than 6(EHL)/3 °C during the first 20 minutes, then the electric heaters are disabled until setpoint is reached or if the dRT value falls below 6(EHL)/6oC (calculated every ten minutes).

10 AUTOMATIC CHANGEOVER MODE

Available only with RCW or by using RT and SPT analogue inputs.

To change mode from cooling to heating: RT < cooling setpoint - 3o and RT < heating setpoint

To change mode from heating to cooling: RT>heating setpoint + 3o and RT > cooling setpoint

Mode change is only possible after compressor has been off for 10 minutes

11 PROTECTION

11.1 Cooling mode 11.1.1 High Temperature Protection This function is by-passed during the first 240s of compressor operation. If OCT > 66°C (HPPS adjustable parameter) the compressor is stopped and outdoor fan is forced on until OCT < 55oC and timer protection is respected. The fault output is on for the duration of the fault. The alarm HIO1 (circuit1) or HIO2 (circuit2) will be displayed.

11.1.2 Cooling mode Indoor Coil Defrost If OCT < 15°C (IcdS adjustable parameter) the compressor is stopped and restarted when OCT > 25°C. The fault output is on, and a fault is displayed (LOC1 or LOC2) for the duration of the fault. 50V2 software: this alarm can also be reset by lockout reset. 50V3 software: this can be activated only after 10 minutes of compressor operation. The alarm is automatically reset by lockout reset or after 30 minutes.

CAC Controller Service Guide5 11 26/11/17 11.1.3 Using Indoor coil sensor ICT (option) An indoor coil temperature sensor (ICT) can be connected as an option. The ICT sensor is considered as not connected if the value falls below –20°C. Disconnecting the sensor is not considered as a fault.  The sensor must be connected to the SAT input If the indoor coil temperature falls below -6°C (Icdt adjustable parameter) the compressor is stopped and the indoor fan remains on until ICT > 14°C. The fault output closes during defrost and IdEF is displayed on the display.

11.2 Heating mode 11.2.1 compressor Protection This function is by-passed during the first 240s of compressor operation and during de-ice. If OCT > 20°C (HCPS adjustable parameter) then the compressor is stopped, a fault is signalled, and restarts after normal timers. Displayed fault is HH01 or HH02.

11.2.2 Heating mode Outdoor Coil Deice

Important Two de-icing modes are selectable using the CAC controller for single circuit units with capillary expansion device, RC and SH. The RC mode will stop the indoor fan during deice, the SH mode will keep the indoor fan running during de-ice with the electric heaters energised. The RC mode has not been optimised and must not be used under normal conditions. Very long de-ice times up to 10 minutes occur using RC mode with short intervals between de-ice (20minutes). This mode could be considered only when ambient temperatures never go lower than 2°C. The RC mode must never be used for units with thermostatic expansion valves.

The RC mode is selected by setting DIP switch S6 and J6 to OFF. The SH mode is selected by setting S6 to OFF and J6 to ON.

Servicing 1.Verify that the OCT sensor is operating correctly and is correctly mounted by looking at its value on the display by – SEnS > OCT > value. 2. Check the de-ice interval and duration and current timer using the display – conF > TLD > value and DI and DTI.

Dynamic de-ice This de-ice counter will automatically adjust the time between de-ice cycles from 20 to 80 according to de-ice cycle duration and its evolution. The de-ice prevention timer integrates compressor run time from unit start up on heating or from last de-ice cycle termination. The timer pauses during compressor off cycle then resumes counting when the compressor cycles on again. The timer will count if OCT < 2°C and will reset if OCT>10°C. The dynamic de-ice will start when OCT < -5°C (adjustable parameter) and the timer (tLd) reaches its previously calculated value (dI).

A de-ice cycle is initiated as follows.  Outdoor fan is switched OFF CAC Controller Service Guide5 12 26/11/17  Reversing valve is switched OFF  Indoor fan is changed to low speed (if possible)  Auxiliary heat is switched ON or IFAN is switched OFF. (RC model only)

The cycle is terminated when  OCT reaches 22oC (adjustable parameter ditt), or  the de-ice cycle time reaches 10 minutes, or  HPC fault is detected.

The cycle is terminated by switching on the outdoor fan on low speed fan, then after 10s the reversing valve is switched on and the electric heater is switched off, except if there is a electric heat request. If there is a call for compressor heating and no electric heat, then the indoor fan will restart 10s after de-ice termination. DI is adjusted at the end of each de-ice cycle depending on the duration of de-ice.

Forced de-ice cycle In addition to the above de-ice timer operates to ensure that the coil will be cleared of ice even in circumstances where the temperature sensor does not detect ice build-up. The forced de-ice timer will count if OCT < 2 and reset if OCT>3. The forced de-ice will start if OCT<2 and the counted is greater than 90 minutes.

De-ice priority If the heat demand is satisfied or OFF mode is selected during the de-ice cycle, then the compressor and IFAN will remain ON (or OFF for RC model) until the de-ice cycle is terminated. In this case, the OFAN will not be switched ON at the end of the de-ice.

CAC Controller Service Guide5 13 26/11/17 OCT [oC]

22 (ditt)

-5(OCdL)

10s ON

COMP OFF TLD TLD ON

OFAN OFF

RV OFF TDI

L IFAN is forced to Low Speed IFAN

HE ANY HEs are forced ON

Note: The temperatures on the above diagram represents the standard de-ice cycle. The forced de- ice uses different temperatures and timers.

CAC Controller Service Guide5 14 26/11/17 11.2.3 Two compressor units

2 compressors, 2 outdoor fans and independent airflow The de-ice logic is the same as a mono compressor system, each circuit is controlled independently except:  When one circuit de-ices, the other circuit is switched on for the duration of the de-ice or at least its minimum run time. If the second compressor is already on, it will remain on until the de-ice cycle terminates.  Simultaneous de-ice of the two compressors is not allowed. If the second circuit requires de-ice when the first circuit is in de-ice then it will wait for 30s after the first circuit de-ice ends.

2 compressors, 1 or 2 outdoor fans combined airflow. The de-ice logic is the same as a mono compressor system except:  If both compressors are on and one circuit calls for a de-ice, then both compressors will de-ice. The first circuit OCT to reach dItt (22oC) is switched off and the other circuit is allowed to terminate when it’s OCT reaches dItt (22°C). DI1 & DI2 will be calculated using the largest TDI.  If one compressor is ON and requires de-ice the second compressor is prevented from starting until the de-ice terminates.  If when the first OCT reaches dItt (22°C) the other OCT is greater than 15°C then de-ice will stop immediately and both compressors will remain ON

2compressor Tandem units The de-ice logic is the same as a mono compressor system, only one OCT is used. When a de- ice is required both compressors must be ON for the duration of the de-ice, If one of the compressors was OFF before the de-ice it will be forced ON for the de-ice then switch OFF again after the de-ice unless the demand has changed.

11.3 High pressure Cutout input According to the model wiring this fault could also be due to a compressor overheat or outdoor fan overload. Refer to unit wiring diagram to see what devices are connected to this input. This input will stop the compressor immediately, signal a fault and lockout the compressor requiring a manual intervention to rearm except during a de-ice where a HPC will terminate the de-ice cycle.

11.4 Low pressure Cutout input The LPC input will stop the compressor immediately and signal a fault on the LED but not on the general fault output, except for the following cases. 1. If the LPC cutouts out during the first three minutes of compressor operation three times consecutively then a lockout will occur and a general fault is signalled. 2. The LPC input will not stop the compressors during the first three minutes of compressor operation, no fault is signalled on the general fault output. After the first three minutes are up and the if the LPC is still open the compressor will stop.

LPC will be disregarded: During de-ice and for 30s after de-ice termination. During heating if OCT < -5oC

CAC Controller Service Guide5 15 26/11/17 11.5 Lockout reset To reset the system after lockout the main power supply can be cut or the unit cycled to OFF mode for 10s.

A lockout condition will allow the unit to continue to operate using remaining operating devices where possible. If the first compressor is locked out then the second compressor will take its place. In SH heating the electric heat will operate to replace compressor heat if needed after a lockout. 11.6 General Features

The minimum delay between activating any two outputs is 500ms

11. FORCED TEST MODE

Test button Pressing on the test button will activate the test mode. In test mode the following timers will be modified: Minimum run time is 0 Minimum start to start is 0 Minimum OFF time is 10s Minimum time between compressor 1 and 2 start is 5 s Lead Lag: cancel lead/lag Auto changeover: no timer between heat and cool modes

 De-ice will not be allowed except forced de-ice.  In test mode the display will flash the present status to show that test mode is active, if a fault occurs during test mode this will be displayed. (only Fault/Fire, HPC, LPC)  The test modes will be sequential, one after the other by pressing “test” button.  Pressing “up” button will exit the forced test mode.  The unit will stay in any test mode for a maximum of 60 minutes then revert to the previous mode of operation.

Cooling only (ST and RH) units, one compressor models only OUTPUTS Step Operating states C1 IFAN IFAN EH1 EH2 OFAN OFAN low high low high * t0 Open economiser t1 Fan only low speed# X t2 Fan only high speed# X t3 Cool-1 OFAN low X X X t4 Cool-1 OFAN high* X X X t5 Heat-1 X X t6 Heat-2 X X X t7 Close economiser t8 End test mode # For 1 speed indoor units, this will activate the IFAN output * For 2 speed outdoor fan units only.

CAC Controller Service Guide5 16 26/11/17 Cooling only (ST and RH) units, two compressor models only OUTPUTS Step Operating states C1 C2 IFAN EH1 EH2 OFAN1 OFAN1 OFAN 2 OFAN 2 high* low high* low 1 Economiser open 2 Fan only X 3 Cool-1 OFAN low X X X 4 Cool-1 OFAN high* X X X 5 Cool-2 OFAN low X X X X X 6 Cool-2 OFAN high* X X X X X 7 Heat-1 X X 8 Heat-2 X X X 9 Economiser close 10 End test mode * For 2 speed outdoor fan units only.

Heat pump (SH and RC) units, 1 compressor models only OUTUTS Step Operating states C1 IFAN IFAN EH1 EH2 RV OFAN OFAN low High low high* 1 Economiser open 2 Fan only low # X 3 Fan only high # X 4 Cool-1 OFAN low X X X 5 Cool-1 OFAN high* X X X 6 Heat-1 X X X X 7 Heat-2 X X X X X 8 Heat-3 X X X X X X 9 De-ice X X X X 10 Em heat X X X X 11 Economiser close 12 End test mode # For 1 speed indoor units, this will activate the IFAN output

CAC Controller Service Guide5 17 26/11/17 Heat pump (SH and RC) units, 2 compressor models only OUTPUTS Step Operating states C1 C2 IFAN EH1 EH2 RV OFAN1 OFAN1 OFAN2 OFAN2 low high low high 1 Economiser open 2 Fan only X 3 Cool-1 OFAN low X X X 4 Cool-1 OFAN high X X X 5 Cool-2 OFAN low X X X X X 6 Cool-2 OFAN high X X X X X 7 Heat-1 X X X X 8 Heat-2 X X X X X X 9 Heat-3 X X X X X X X 10 Heat-4 X X X X X X X X 11 De-ice X X X X X 12 Emergency heat X X X X 13 Economiser close 14 End test mode

12 ON UNIT CONTROL INDICATORS AND SWITCHES

Two buttons (up "^" and right ">") The first button is used to scroll through the current menu, the select button is used to select the displayed value or to change menus. The menu must reflect unit configuration and control systems. E.g. if only one compressor is present then C2 status must not be shown.

During the normal operation the unit status is displayed.

Status display Display Description C1 When C1 is operating C2 When C2 is operating or both compressors are on. C1H C1 in heat mode C2H C2 and C1 in heat mode EH1 Electric heat 1st stage (with comp if SH) EH2 Electric heat 2nd stage dEIC De-ice in operation OFF Off mode COOl Cool mode with no compressors on HEat Heat mode with no heating on FAn Fan only not heat or cool

CAC Controller Service Guide5 18 26/11/17 12.1 Display menus and display navigation > mode > Off, Cool, Heat or Fan> > > OFAn1 or OFAn2 outdoor fan > OFF or HI or LO > > Stat - status > > IFAn - indoor fan OFF or HI or LO > > EH1 or EH2 - electric heat > On or OFF > > rv1 or rv2 - reversing valve > On or OFF > > C1 or C2 - compressor > On or OFF > > > etc - up to 10 alarms >

Log - last 10 alarms > > Alarm code (see list) >

tC2 since last test mode > value > > tC1 since last test mode > value > HRS - running hours > > IFAN indoor fan > value x 10 > > C2 compressor 2 > value x 10 > > C1 compressor 1 > value x 10 > > > Alarm code (see list) >

ALAr - existing alarms > > Alarm code (see list) > >

> SPt (active setpoint) > value >

SEnS - Sensors > > rt (current value) > value > > SAT (ICT value) > value > > OCT2 (if present) > value > > OCT1 > value >

> > 1st digit - no of outdoor fans S4 - unit configuration 2nd digit - no of outdoor fan speeds 3rd digit - 1=1airflow 2=independent airflow > 4th digit - no of indoor fan speeds COnt - control configuration > > >

> COPr - No of compressors > value > RCn (RCW master) >

> > > ConF - Configuration TLD2 - timer last de-ice circuit2 > value > RCl (RCW local) > DIT2 - de interval timer circuit2 > value > rt (analogue RT input) >

> > DI2 - de-ice interval circuit2 > value > SPt (analogue SPT input)

> AU (auxiliary inputs) > TLD1 - timer last de-ice circuit1 > value > > > DIT1 - de interval timer circuit1 > value > > DI1 - de-ice interval circuit1 > value >

> > UnIt - unit type > SH, RH, RC or ST CAC Controller Service Guide5 19 26/11/17 12.2 Parameter change menu

Two levels of menu are used, standard and factory. The factory level requires a 3 digit code for access.

At any time the standard parameter change menu can be entered by pressing simultaneously both display buttons for 5s. The factory menu can only be accessed from the standard level.

In either parameter change menu if no button is pressed for 10s the display reverts back to normal mode. For factory mode, If F0=0, F1=0 and F2=0, all fault and control unit settings are reset.

The parameters are scrolled using the ^ button and selected using the > button. When selected the values can be changed by using the ^ button to scroll from the present value to max then min and can be selected by pushing the > button. After selection the menu will return to the beginning of the same parameter change menu.

12.2.1 TABLE List of standard parameters Display Meaning Page no. Min Max Step Default value value value 1. Crun Min comp run time 4 1 5 1 3 2. CStS Min comp start to start 4 4 16 2 10 3. LELA Lead lag 4 OFF On On 4. OFAS OFAN anti seize run time 5.1.3 0 6 1 1 5. ECdt Spare 30 160 10 70 6. EnnP Spare 0 10 2 0 7. CSPL Cooling setpoint limiting 9 16 22 2 20 8. tdnc Thermistor does not change test 3.2 0 15 3 3 9. tF Thermistor fault test 3.2 5 30 5 15 1 HSAF HSPT anti freeze value with RCW 9 4 16 2 10 0. 1 EHL Electric heater limiting 9.2 2 14 2 6 1. F0 Factory parameters password 0 9 1 0 F1 Factory parameters password 0 9 1 0 F2 Factory parameters password 0 9 1 0

CAC Controller Service Guide5 20 26/11/17 12.2.2 TABLE List of factory parameters This table of parameters is accessible only after having entered the passwords F0, F1 and F2 in the standard parameter menu. Display Meaning Sectio Min Max Step Default n in value value value specs 1 OFCS OFAN cooling stop value 5.1.4 15 29 2 25 10- 50V2 2 OFHS OFAN heating stop value 5.1.4 10 24 2 16 3 OSS1 25 4 OSS2 22 5 C1 60 DO NOT CHANGE 6 C2 1 7 C3 60 8 C4 1 9 HPPS High pressure protection stop 11.1 60 80 2 66 10 ICdS Indoor coil defrost stop 11.1.2 11 22 2 15 0-50V2 11 ICdt Indoor coil defrost with ICT 11.1.2 -10 0 1 -6 12 OCdL Outdoor coil defrost low on 11.2.2 -10 -2 1 -5 13 HCPS Heating mode comp. protection stop 11.2 15 26 2 20 14 ditt Defrost termination temp 11.2.2 14 24 1 22

12.3 Fault Relay Output

The Fault relay will close for the following fault conditions 1 HPC 2 LPC only for lockout condition (3 times during first 3 minutes of compressor operation) 3 OCT compressor protection fault, heating and cooling 4 Sensor faults 5 Non-valid control combination 6 Non-valid auxiliary input combination 7 No power or fuse 8 Indoor coil defrost 9 Fault input

CAC Controller Service Guide5 21 26/11/17 12.4 Alarm and diagnostics

Alarm Description Section Possible causes Actions ---- no alarms present HP1 High pressure cutout circuit 1 11.3 low airflow, incorrect charge Check airflow HP2 High pressure cutout circuit2 11.3 LP1 Low pressure cutout circuit 1 11.4 refrigerant leak LP2 Low pressure cutout circuit 2 11.4 refrigerant leak O1dl Outdoor coil sensor disconnected circuit 1 3.2 Replace sensor or wiring O2dl Outdoor coil sensor disconnected circuit 2 3.2 Replace sensor or wiring O1SH Outdoor coil sensor 1 short circuit 3.2 sensor fail / wire Replace sensor or wiring O2SH Outdoor coil sensor 2 short circuit 3.2 Replace sensor or wiring SPt Analogue input disconnected 8.2 Check input rt Sensor disconnected or short circuit 8.2 Check wiring and sensor cont Incorrect control 8.1.1 Invalid control combination Control reset or use a valid control combination. FAUt Fault Input open between terminals 6 and 7 See wiring diagram IdEF1/IdEF2 Indoor defrost, cool using ICT 11.1.3 Low airflow, low return air temperatures Check ICT value in SenS on display HIO1 or HIO2 high OCT, high condensing temperature 11.1.1 LOC1 or LOC2 low OCT, low condensing temperature risk of 11.1.2 Low airflow, low return air temperatures coil freezing. Check OCT value in SenS menu on display HHO1 or HHO2 heat mode high evaporating temperature 11.2.1 rEg Difference between OCT1 and OCT 2 3.2 Refrigerant leak or sensor failure or sensor placement EEP internal electronic fault EEPROM fault Power on/off, if repeated fault replace PCB JUMP DIP switch setting incorrect 13 See DIP switch settings Correct settings then power on/off to reset. ADC internal electronic fault Analogue conversion error Power on/off, if repeated fault replace PCB

CAC Controller Service Guide5 22 26/11/17 13 SYSTEM CONFIGURATION SETTINGS

ON OFF Comments S1 Always OFF S2 Always OFF S3 Always OFF S4 Always OFF S5 AUTOFAN No AUTOFAN See section 6 S6 HEAT (cool only with No HEAT (cool only no See page XX heat or heatpump) heat) S7 Outdoor fan always ON in Outdoor fan normal cool S8 Always OFF S9 Address

S10 Address For operation with S11 Address RCW 2 S12 Address 1 1 compressor 2 compressors 2 1 outdoor fan 2 outdoor fans 3 1 speed outdoor fan 2 speed outdoor fan 2 speed IFAN when 1 1 speed IFAN when 1 4 compressor compressor Combined airflow when 2 Independent airflow when 2 compressor compressors 5 Always ON 6 Cooling only Heatpump 7 Tandem compressor independent circuit

CAC Controller Service Guide5 23 26/11/17 14 System Diagnostics and Operation at Fault Conditions

Fault Response RT sensor fail during normal Use RCW sensor if available otherwise use RAT sensor operation if available, otherwise stop unit, signal fault ‘rt’. SPT analogue Use RCW SPT or BMS if available, otherwise signal fault ‘SPt’ use default values. OCT sensor failure. Use default values If two compressor ON then use other circuit OCT value if compressor has been operating for > 10 minutes. HPC or LPC If two compressor unit start other compressor. If SH unit in heating mode use EH. Cooling mode OCT Compressor Compressor stop signal fault “HIC1” or “HIC2” for protection OCT> 66 and “LOC1” or “LOC2” for OCT<15 Heating mode OCT Compressor Use EH to heat and fault ‘HHO1’ or “HHO2” protection No SPT inputs Wait 5 minutes then use default values Non-valid combination according Signal fault ‘Cont’, stop the machine to 2.7.1 If unit changes from one Signal fault ‘Cont’, use new combination combination to another but with less inputs (something is disconnected) If unit changes from one No fault Use new combination combination to another but with more inputs. (something is connected) Non-valid Auxiliary input Signal fault ‘Cont’, stops unit combination

15 DEFAULT SETTINGS

Parameter Value SPT (heating) 21oC SPT (cooling) 23oC OCT1 In cooling mode use 55oC OCT2 In heating mode use –8oC Mode AUTO changeover Fan ON Low speed Day mode

CAC Controller Service Guide5 24 26/11/17