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CAC Controller

OPERATING MANUAL
MU CAC 751 A - 3990011
 CAC Controller
CONTENTS
Pages
Main features .......................................................................... 3

Display ............................................................................... 4 - 8

TEST mode ...................................................................... 9 - 10

Switches onfiguration ............................................................ 11

Control .................................................................................. 12

Auxiliary inputs ...................................................................... 13

De-ice ................................................................................... 14

Cooling & Heating ................................................................. 15

Default parameters and diagnostics ...................................... 15

Outdoor fan operation ........................................................... 16

Safety circuits ....................................................................... 16

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 CAC Controller
CAC CONTROLER

Integrated
transformer 230 V outputs

Fuses
Auxiliary contact
connections

Fault input
Remote On/Off input
230 V outputs

Pressostat inputs

Remote fault
report output

Sensor inputs
RCW
connection

Buttons for TEST button

display unit

MAIN FEATURES :

- Intelligent microprocessor control for all commercial and
industrial applications
- 4-digit display - easy access to all status, alarm and
sensor information.
- PI compressor control – control algorithm to optimise
comfort level
- Energy saving – electric heat used only when needed
- Intelligent de-ice – adjusts de-ice time to improve
comfort and optimise performance under all conditions
- Open control inputs – various inputs allow most types
of control systems to operate the unit as well as the
Airwell thermostats.
- Alarm log – stores 10 previous alarms even after power
cut to assist diagnostics.
- Random restart after power failure – avoids
simultaneous starting.
- Test mode – simple one touch control to test in all
operating modes.
- Alarm output – voltage free contact for remote monito-
ring.

3
 CAC Controller
DISPLAY
WARNING - When operating normally the unit status is displayed
The information on the display is for professional use unless a fault has been detected. If a fault is present
only during start-up and maintenance. the last fault will be shown.
When using the display high voltage terminals are - It is possible at all times to visualise the other menus by
accessible pressing the menu navigation buttons. All information is
saved even during a power cut.
- 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.

menu 1 sous menu 2 sous menu 3

UnIt RH or RC or SH or ST
dI 1
dIt 1
tLd 1 Select to show present value
dI 2 (if RC or SH unit)
dIt 2
tLd 2
ConF (Configuration)
COPr no. of compr
RCI (RCW local)
RCn (RCW master)
COnt rt (rt analogue)
SPt (spt analogue)
AU (aux inputs)
S4 last 4 digits of model
OCt 1
OCt 2
Select to show present value
SEnS (Sensor) ICt or SAt
(if connected)
rt
SPt
HP 1
HP 2
LP 1
LP 2
OCt 1
OCt 2
SPt
rt
Scrolls through all active faults
ALAr (Existing Faults) FIrE / FAUt
(if any)
IdEF 1 / IdEF 2 (Indoor defrost, cool)
HIO 1 / HIO 2 (high OCT, cool)
LOC 1 / LOC 2 (low OCT, cool)
HHO 1 / HHO 2 (heat mode)
EEP
JUMP
ADC
Cont (non-valid control)
C 1 (x 10 hrs)
C 2 (x 10 hrs)
HrS (Running hours) IF An (x 10 hrs) Select to show hrs
tC 1 (hrs)
tC 2 (hrs)
LOg (Alarm log) Same choise as alarm list Scrolls through last 10 alarms in order
C1 on or OFF
C2 on or OFF
rv 1 on or OFF
rv 2 on or OFF
EH 1 on or OFF
StAt
EH 2 on or OFF
IF An OFF or HI or LO
OF 1 OFF or HI or LO
OF 2 OFF or HI or LO
Mode OFF or COOL or HEAt or FAn

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 CAC Controller
HOW TO USE THE DISPLAY:

- Press button > once to display menu 1
- Use button ^ in menu 1 to move around in the menus:
ConF -> StAt -> Log etc. (A)
- Use button > to go from menu 1 to submenu 2 then to
submenu 3, then back to menu 1 (B)
- In submenu 2, use button ^ to scroll through the settings
(C)
- After selecting a function in submenu 2, press button >
to display the value (submenu 3) (D).

A C
menu 1 sous menu 2 sous menu 3

Unit RH or RC or SH or ST

DI 1

DIT 1

TLD 1
Select to show present value
(if RC or SH unit)
DI 2

DIT 2

TLD 2

ConF (Configuration) COPr no. of compr

RCI (RCW local)

RCn (RCW master)

rt (rt analogue)
COnt
SPt (spt analogue)

AU (aux inputs)

S4
SY last 4 digits of model

OCt 1

OCt 2

Select to show present value

SEnS (Sensor) ICt or SAt
(if connected)
B D
rt

SPt

HP 1

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 CAC Controller
STATUS DISPLAY
Display Description
C1 When one compressor is operating in cooling mode
C2 When both compressors are on in cooling mode
C1H One compressor in heating mode
C2H Two compressors in heating mode
EH1 Electric heat 1st stage (with comp if SH)
EH2 Electri 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

The data is split into 6 main menus.

Display Description
ConF Will show all configurations which have been selected
SEnS To display the values of the sensors or used values
ALAr Any present faults
HrS Running hours
LOg The last 10 alarms
StAt Current status

Each of these main menus is split into sub-menus

CONF SUB-MENU

Display Description Press > to show the following

Unit Unit type RH or RC or SH or ST
dI 1
dIt 1
tLd 1 Select to show present valu
dI 2 (if RC or SH shunt)
dIt 2
tLd 2
COPr Number of compressors
RC 1 (RCW local)
RCn (RCW master)
The current control inputs which have
COnt rt (An analogue room temperature sensor on the RT input)
been detected
SPt (An analogue setpoint on the SPT input)
AU (Any inputs on the auxiliary inputs)
First digit = no. of outdoor fans
Second digit = speeds of outdoor fans
S4 Unit type
Third figit, 1 = combined airflow 2 = independant airflow
Fourth digit = Indoor fan speeds

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 CAC Controller
SENS SUB-MENU
Press the † button to visualise the value of the selected
sensor
Display Description
OCt 1 Outdoor coil temperature
OCt 2 2nd circuit outdoor coil temperature (if used)
ICt or SAt Indoor coil temperature (if used)
rt Room temperature from RT input or RCW input
SPt Setpoint value from SPT input or RCW input
Note : in the Sens menu if a value is preceded with a ‘d’
this means that a default value is being used because
an error has been detected on the input.

ALAR SUB-MENU
In the alarm menu press † to visualise last faults then
press ‡ to see other current faults.

Display Description
HP1 Circuit 1 High pressure cut-out is open
HP2 Circuit 2 High pressure cut-out is open
LP1 Circuit 1 Low pressure cut-out is open
LP2 Circuit 2 Low pressure cut-out is open
SPt SPT analogue input is disconnected or short - circuited
rt RT analogue input is disconnected or short - circuited
FAUt Fault input is open, Usually fan overload, see wiring diagram for details..
IdEF1 The ICT has detected a frost conditions on the indoor coil
HIO 1 / HIO 2 High OCT in cool mode, the condensing temperature is too high. circuit 1 or 2
LOC 1 / LOC 2 Low OCT in cool mode, the condensing temperature is too low circuit 1 or 2
HHO 1 / HHO 2 High heating OCT in heat mode, the evaporating temperature is too high circuit 1 or 2
Erg Possibility of a refrigerant leak circuit 1 or 2
O1SH / O2SH OCT incorrectly wired circuit 1 or 2
O1dl / O2dl OCT disconnected circuit 1 or 2
EEP EEPROM error
JUMP Incorrect configuration
ADC
Cont The current control input is not valid, could be conflicting information from two sources

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 CAC Controller
HRS SUB MENU
press the † button to visualise the value of the selected
timer.
Display Description
C1 (x 10 hrs) Compressor 1 running hours (multiply by 10)
C2 (x 10 hrs) Compressor 2 running hours (multiply by 10)
IF An (x 10 hrs) Indoor fan running hours (multiply by 10)
tC1 (hrs) Compressor 1 running hours since the last time Test mode was used
tC 2 (hrs) Compressor 1 running hours since the last time Test mode was used

LOG SUB MENU

Press † to see the last memorised fault then ‡ to
see the other last 10 fault in order.

STATUS SUB-MENU
Press † to enter menu then ‡

Display Description Possible status

C1 C1 compressor output on or OFF
C2 C2 compressor 2 output on or OFF
rv1 RV1 reversing valve 1 output on or OFF
rv2 RV2 reversing valve 2 output on or OFF
er
EH1 EH1 Electric heater 1 stage output on or OFF
EH2 EH2 Electric heater 2nd stage output on or OFF
IF An Indoor fan output status OFF or HI or LO
OF 1 Outdoor fan 1 status OFF or HI or LO
OF 2 Outdoor fan 2 status OFF or HI or LO
MOdE Current mode OFF or COOL or HEAt or FAn

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 CAC Controller
FORCED TEST MODEFORCED TEST MODE
- By pressing the test button on the PCB all possible - To start test mode press the test button until ‘t0’ is
operating modes can be accessed for maintenance displayed. To change from one step to the next press
purposes. the test button. It is possible to exit from the test mode
at any time by pressing the ^ button.
WARNING
In Test Mode compressor and Fan anti short cycling - After 60 minutes in test mode the unit will automatically
timers are overridden. revert to its previous operating status.
Care must be taken not to damage compressors and
contactors by repeated use of this mode.
Some protections are overridden in this mode like
coil defrost and temperature limits.
Do not use Test Mode for long periods.

Cooling only units with one compressor

OUTPUTS
Step Operating states IF AN IF AN OFAN OFAN
C1 EH1 EH2
low high low high *
t1
t2 Indoor Fan only low speed # X
t3 Indoor Fan only high speed # X
t4 Cool-1 Outdoor fan low X X X
t5 Cool-1 Outdoor fan high * X X X
t6 Heat-1 X X
t7 Heat-2 X X X
t8 End test mode

Cooling only units with two compressors

OUTPUTS
Step Operating states OFAN1 OFAN1 OFAN2 OFAN2
C1 C2 IF AN EH1 EH2
high * low high * low
t1 Start
t2 Indoor Fan only X
t3 Cool-1 outdoor fan low X X X
t4 Cool-1 outdoor fan high X X X
t5 Cool-2 outdoor fan low X X X X X
t6 Cool-2 outdoor fan high X X X X X
t7 Heat-1 X X
t8 Heat-2 X X X
t9 End test mode

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 CAC Controller
Heat Pump unit 1 compressor models

OUTPUTS
Step Operating states IF AN IFAN OFAN OFAN
C1 EH1 EH2 RV
low high low high
t1
t2 Indoor Fan only low X
t3 Indoor fan only high X
t4 Cool-1 outdoor fan low X X X
t5 Cool-1 outdoor fan high X X X
t6 Heat-1 X X X X
t7 Heat-2 X X X X X
t8 Heat-3 X X X X X X
t9 De-ice X X X X
tA Electric heat only X X X X
tb End test mode

Heat pump units 2 compressors

OUTPUTS
Step Operating states OFAN1 OFAN1 OFAN2 OFAN2
C1 C2 IF AN EH1 EH2 RV
low hihg * low high *
t1
t2 Indoor Fan only X
t3 Cool-1 outdoor fan low X X X
t4 Cool-1 outdoor fan high X X X
t5 Cool-2 outdoor fan low X X X X X
t6 Cool-2 outdoor fan high X X X X X
t7 Heat-1 X X X X
t8 Heat-2 X X X X X X
t9 Heat-3 X X X X X X X
tA Heat-4 X X X X X X X X
tB De-ice X X X X X
tC Electric heat only X X X X
tD End test mode

Key

C1 Compressor 1
C2 Compressor 2
IFAN Indoor fan
EH Electric heater
RV Reversing valve
OFAN Outdoor fan

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 CAC Controller
DIP SWITCHES CONFIGURATION
See unit wiring diagram for unit default settings

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 J1 J2 J3 J4 J5 J6 J7 J8

DN 125 - 155 off off off off on off off on on off on on off off
DN 185 - 305 off off off off on off off on on off off on off off
DN 405 - 605 off off off off on off off off off off off on off off
see below
HA 35 off off off off see on off off on on off on on off off
Adress see below
HA 43 - 95 S off off off off bolow on off off on on off off on off off
HA 95 RC off off off off on off off off on off on on off off
CVJ 3015 - 3615 off off off off on off off on on on off on off off
CVJ 301 - 361 - 421 off off off off on off off off on on on on off off

S5 Indoor fan operation OFF = continuous fan

operation ON = fan will stop and start with
compressor.

J6 On = Cooling only unit OFF = Heatpump unit

Adress for use with RCW R2

Address S9 S10 S11 S12
0 off off off off
1 on off off off
2 off on off off
3 on on off off
4 off off on off
5 on off on off
6 off on on off
7 on on on off
8 off off off on
9 on off off on
10 off on off on
11 on on off on
12 off off on on
13 on off on on
14 off on on on
15 on on on on

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 CAC Controller
CONTROL
CONTROL POSSIBILITIES
- RCW R1 (airwell thermostat) The control board will automatically detect control inputs
- RCW R2 (airwell multi-unit thermostat) and will signal an alarm if any control inputs are removed.
- Any dry contact thermostat or air conditioning control If you need to remove an external controller and re-
interface place it by another type it is necessary to do a control
- External on / off switch reset.
- Remote room temperature sensor
- Analogue setpoint input. CONTROL RESET
Press ‡ and † buttons together for 5 seconds ‘Crun’
will appear on the display. Wait for 5 seconds, the control
configuration is now reset.

CONTROL INPUTS:
Auxiliary inputs. - Any device using voltage free relay contacts. Controllers
- When using the auxiliary inputs no other control devices using triac switching must not be used.
can be used at the same time.
- A conventional air conditioning thermostat requiring a
- The following devices may be connected to the auxiliary 24 Vac power supply. The maximum power supplied by
inputs. the control board is 120 mA. The thermostat must use
relay outputs, operation with triac outputs is not
guaranteed.

1 compressor units

Input Cooling only units Heatpump units

1 First stage cooling First compressor
2 Indoor fan low speed Indoor fan low speed
3 First stage heat Auxiliary heat
4 Second stage heat Reversing valve (ON for heating mode)
Indoor fan high speed (two speed fans) or
5 Indoor fan high speed (two speed fans noly)
Auxiliary heat 2nd stage (one speed indoor fans)

2 compressor units

Input Cooling only units Heatpump units

1 First stage cooling First compressor
2 Indoor fan Indoor fan
3 First stage heat Auxiliary heat
4 Second stage heat Reversing valve (ON for heating mode)
5 Second stage cooling Second compressor

ON/OFF INPUT
Any voltage free contact can be connected to this control
input. Typical uses would be a time clock or BMS.
When the external switch is closed the unit is ON and
will operate according to other control inputs.
When the external switch is open the unit is in OFF
mode.
If another control device is in OFF mode this on/off input
will not be able to turn ON the unit. If another control
device is ON then this input is able to turn the unit OFF.

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 CAC Controller
AUXILIARY INPUTS
Typical diagram

CAC board

Thermostat or
controller

Connection for Thermostat XB 01100 / 611125

Heatpump unit only

Units with 2 compressors only CAC board

100 m MAXI
7 x 1 mm² MAXI

Connection of RCW R1 25 m MAXI

0,3 mm² MAXI
Ambient
temperature
sensor

100 m MAXI
1 mm² MAXI
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 CAC Controller
OUTDOOR COIL DE-ICE
The de-ice logic is as follows:
The cycle is controlled by coil temperature and a timer.
The de-ice interval time is variable and is determined
from previous de-ice duration. The minimum interval is
20 minutes and maximum is 80 minutes.
The interval will automatically be reduced if high humidity
conditions where ice build up could occur and will
increase during low humidity conditions.
The de-ice will be initiated when the de-ice interval timer
is at zero and the coil temperature falls below –5 °C.
The de-ice will end when the coil temperature reaches
22°C or when the time reaches 10 minutes or when the
high pressure cut-out opens. In the case of a high pres-
sure cut-out during de-ice the compressor will stop but
a lockout will not occur.
In conditions involving slow ice build-up a second de-
ice timer will start a de-ice when the timer reaches 90
minutes and the coil temperature is below 2°C.
Both de-ice timers will count only if the outdoor coil
temperature is below 2°C and the compressor is
operating. The timers will reset to zero if the coil
temperature is above 10°C.
The de-ice parameters can be checked on the display
DI1 – corresponds to the current de-interval time after
which a de-ice may be started. (circuit 1)
DIT – corresponds to the duration of the previous de-
ice. (circuit 1)
TLD1 – is the current de-ice interval timer. (circuit 1)
DI 2 etc same as above for circuit 2
Using the the following parameters on the display it is
possible to see when a de-ice will occur:
OCT must be below –5°C
TLD must be equal or greater than DI
The outdoor fan will be restarted 10s before the end of
the de-ice cycle to help dry the coil and reduce pres-
sure differences.
UNITS WITH 2 COMPRESSOR
DN 405 -> 605
An interlock logic is provided to ensure that only one
compressor can be defrosted at a time, and that the
inactive compressors are put into service to complete
the heating level while one system is defrosted.
HA95RC / CVJ
Models in which two compressors share a single outdoor
fan constitute a special case. The first compressor of
the pair to require defrosting triggers a defrosting cycle
for both compressors. The temperatures of the external
batteries of both systems are monitored, and the first to
reach the limit stops the compressor of that system.
The defrosting cycle of the remaining system continues
and ends normally, switching back to a heating cycle.
The compressor which has stopped then reacts
normally to signals from the thermostat and to the
compressor time delay constraints.

Outdoor coil
temperature

Compressor

Outdoor fan

4 way valve

Indoor fan

Electric heater

14

COOLING AND HEATING OPERATION
The control board uses a PI control algorithm to improve
comfort control and reaction times.
The compressor(s) and heating elements will be
stopped and started according to the difference between
setpoint and room temperature and according to the
duration of this difference.
ELECTRIC HEAT ENERGY SAVINGS ( HEAT
PUMP UNITS ONLY)
After changing mode or setpoint the electric heaters
are not started for the first 20 minutes of operation. After
this period if they will be started only if the rate of change
of temperature in the room due to the heat supplied by
the compressors is not enough.
DEFAULT PARAMETERS AND DIAGNOSTICS
Fault
Ambient temperature probe fault (RT) during normal
operation
No datum point signal (SPT)
External bank sensor OCT
HP or LP pressostat cut-off
Monitoring input combination not authorised
Default configuration
Parameter
SPT datum point
External bank sensor OCT1 or OCT2
Mode
CAC Controller
AUTOMATIC CHANGEOVER.
If the unit is in Auto change over mode the following
rules will apply to change from cooling to heating.
Compressor must turn off for 10 minutes.
To change from cooling to heating
Room temperature < cooling setpoint – 3 and Room
temperature < heating setpoint
To change from heating to cooling
Room temperature > heating setpoint + 3 and room
temperature > cooling setpoint.
Depending on the type of controls being used the
heating setpoint can be the same as the cooling setpoint
or it can be different.
Reaction
Uses RCW probe if possible, otherwise shuts down the unit.
Reports RT alarm.
Uses RCW if possible.
Reports SPT alarm and uses default values after 5 minutes
Uses default value
If both compressors are running, uses the other OCT sensor
If unit with two compressors: Starts up second compressor
If unit with electric bank in heating mode: uses electric bank
Unit shut-down, "Cont" fault reported"
Value
22°C heating mode and 24°C cooling mode
Cooling mode 55°C
Heating mode -8°C
Automatic change-over
External fan in permanent high speed mode
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 CAC Controller
OUTDOOR FAN OPERATION
For all DN and RM units a two speed outdoor fan is
used.
The fan will stop, start and change speed according to
coil temperatures.
This operation will allow cooling down to –5°C.
SAFETY CIRCUITS.
HIGH PRESSURE CUT-OUTS
If any devices on these inputs are at fault conditions the
compressor will stop immediately and require a lockout
reset to restart. The only exception is a high pressure
cut-out at the end of the de-ice cycle.
LOW PRESSURE CUT-OUTS
This input is disabled for the following conditions.
- First 3 minutes of compressor run time
- During de-ice
- If in heating mode and the outdoor coil temperature is
below –5°C
If a low pressure cut-out occurs three times
consecutively during compressor start-up and remains
after the time-out period a lock-out will occur.
LOCKOUT RESET
The unit can be reset by either switching off the mains
power or by switching the unit to OFF mode for 10s.
16
The other units aquipped with a single speed fan can
not operate in cooling mode at exterior temperatures
below 15°C. The fan can stop and restart depending on
the temperature of the coil.
However for continuous low ambient applications like
computer rooms or industrial process we recommend
use of a head pressure controller.
FAULT INPUT
When any devices connected to this input opens it will
switch off all operating devices and signal an alarm. If
the fault is removed the unit is automatically reset,
however the fault is memorised in the alarm log.
SENSOR DETECTION.
All sensor inputs are checked for fault conditions. Various
fault conditions will result in an alarm being signalled
on the alarm output and on the display (see display). If
a fault is detected on the coil sensors or setpoint input
the unit will continue to operate using default values,
however this operation will results in poor comfort and
operating efficiency.
WARNING
Allowing the unit to run using fault coil sensor for
long periods in heating mode or low ambient
cooling could damage the compressor.
Any faulty sensors must be repaired immediately
If the room temperature sensor or RCW input is detected
as faulty the unit will stop and signal a fault.
CAC Controller

17
A.C.E
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78284 GUYANCOURT Cedex Tél. 33 1 39 44 78 00 Fax 33 1 39 44 11 55 www.airwell.com

ACE Klimatechnik GmbH

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