Procon MelcoRETAIL MINI Installation guide

Procon

MelcoRETAIL MINI

FOR INSTALLERS

INSTALLATION MANUAL

Manual version 1.0.6

Firmware version 1.0.3

For safe and correct use, please read this installation manual thoroughly before installing the PROCON

MelcoRETAIL MINI.

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• iii •

Document Amendment Register

Document

Version

Latest

Firmware

Version

Date Author Notes

1.0.0

1.0.0 12/07/17 GD Initial version.

1.0.1 1.0.0 31/07/17 GD

Added information to Connections section regarding connections

to twin/triple/quad and MXZ systems.

Correction made to section 2, the name MAC-399IF replaced

with MAC-333IF.

1.0.2 1.0.1 11/08/17 GD

Voltage/resistance bands changed for setpoint, mode and fan

speed control.

1.0.3 1.0.1 29/09/17 GD

Added certification logos

1.0.4 1.0.2 27/11/17 GD

Updates for V1.0.2 firmware.

Sections 7.9, 7.10 and 7.11 updated.

Addition of new Modbus holding registers (see section 12.1).

Firmware revision history table added.

1.0.5 1.0.3 17/01/18 GD

Added section 8. Failsafe AUTO Mode.

Updated sections 7.2 Mode control and 7.3 Fan Speed control.

Firmware revision history table updated.

1.0.6 1.0.3 08/02/18 GD

Corrected text in section 9.Deadband mode to state deadband

mode is enabled by setting DIP switch 2-1 to the ON position.

Any additional notes since printing will be appended to the rear of this document on separate

sheets of paper.

• iv •

Firmware Revision History

Firmware

Version Date Notes

1.0.0

21/07/17 Release for testing purposes.

1.0.1 25/08/17 Voltage/resistance bands changed for setpoint, mode and fan speed control.

1.0.2 28/11/17

Operation of HEATING relay changed so it only energises when in Heat or Auto mode

when the return air temperature is less than the setpoint.

Operation of COOLING relay changed so it only energises when in Cool or Auto mode

when the return air temperature is greater than the setpoint.

A configurable relay switching delay has been added to prevent rapid switching.

1.0.3 17/01/18 Added Failsafe AUTO mode feature (see section 8. Failsafe AUTO Mode)

1

[

Fig. 1]

A

A CN105/

C

N92 connect

i

ion lead

Page 1

2

[Fig. 2

]

Air to

a

ir unit

Page 2

Page 3

Contents

Preface ............................................................................................................................................................................. i

Safety warnings ............................................................................................................................................................ i

Disclaimer ..................................................................................................................................................................... ii

Document Amendment Register .................................................................................................................................. iii

Firmware Revision History ........................................................................................................................................... iv

1.Safety precautions ................................................................................................................................................ 5

2.Overview ................................................................................................................................................................ 6

3.Installation ............................................................................................................................................................. 7

3.1.Physical connection ........................................................................................................................................ 7

3.2.Power supply .................................................................................................................................................. 7

3.3.RS-485 connection ......................................................................................................................................... 7

4.DIP switch settings ............................................................................................................................................... 8

4.1.Modbus Slave ID ............................................................................................................................................ 8

4.2.RS-485 communication settings ..................................................................................................................... 9

4.3.Protocol selection ........................................................................................................................................... 9

4.4.Auto Mode / Lock Mode selection .................................................................................................................. 9

4.5.Deadband Mode ............................................................................................................................................. 9

4.6.Setpoint Limiting ........................................................................................................................................... 10

4.7.Timeout ........................................................................................................................................................ 10

4.8.Input type selection ...................................................................................................................................... 10

4.9.Summary ...................................................................................................................................................... 11

5.Connections ........................................................................................................................................................ 12

5.1.Overview ...................................................................................................................................................... 12

5.2.CN92/CN105 ................................................................................................................................................ 12

5.3.RS-485 ......................................................................................................................................................... 12

5.3.1.RS-485 termination resistor ................................................................................................................... 12

5.4.Analogue Inputs ........................................................................................................................................... 13

5.4.1.Input type selection ............................................................................................................................... 13

5.4.2.S.P. ....................................................................................................................................................... 13

5.4.3.MODE ................................................................................................................................................... 13

5.4.4.FAN SPEED .......................................................................................................................................... 13

5.4.5.OCC MODE .......................................................................................................................................... 13

5.5.Digital Inputs................................................................................................................................................. 14

5.5.1.FORCE ON ........................................................................................................................................... 14

5.5.2.FORCE OFF ......................................................................................................................................... 14

5.5.3.AUTO/LOCK MODE .............................................................................................................................. 14

5.5.4.FAULT ................................................................................................................................................... 14

5.6.Relay Outputs ............................................................................................................................................... 15

5.6.1.ON/OFF................................................................................................................................................. 15

5.6.2.HEATING .............................................................................................................................................. 15

5.6.3.COOLING .............................................................................................................................................. 15

5.6.4.FAULT ................................................................................................................................................... 15

5.7.Using Twin / Triple / Quad systems .............................................................................................................. 16

5.7.1.When Fault output is being used ........................................................................................................... 16

5.7.2.When Fault output is not being used ..................................................................................................... 16

5.8.Using single split units in a group ................................................................................................................. 17

5.8.1.When Fault output is being used ........................................................................................................... 17

5.8.2.When Fault output is not being used ..................................................................................................... 17

5.9.Using MXZ split units .................................................................................................................................... 18

6.Status LEDs ........................................................................................................................................................ 19

6.1.Relay Status ................................................................................................................................................. 19

6.2.Communication Status ................................................................................................................................. 19

7.Control for ATA systems ................................................................................................................................... 20

7.1.Setpoint control ............................................................................................................................................ 20

7.2.Mode control................................................................................................................................................. 21

7.3.Fan Speed control ........................................................................................................................................ 22

7.4.Occupancy Mode ......................................................................................................................................... 23

7.5.Force On ...................................................................................................................................................... 24

7.6.Force Off ...................................................................................................................................................... 24

7.7.Auto Mode / Lock Mode ............................................................................................................................... 24

7.7.1.Auto Mode ............................................................................................................................................. 24

7.7.2.Lock Mode ............................................................................................................................................. 24

Page 4

7.8.External Fault ............................................................................................................................................... 24

7.9.ON/OFF status output .................................................................................................................................. 25

7.10.Heating status output ................................................................................................................................... 25

7.11.Cooling status output .................................................................................................................................... 25

7.12.Fault output .................................................................................................................................................. 26

7.12.1.Using Twin / Triple / Quad systems ....................................................................................................... 26

8.Failsafe AUTO Mode ........................................................................................................................................... 29

8.1.Failsafe trigger thresholds ............................................................................................................................ 29

8.2.Power up ...................................................................................................................................................... 29

8.3.Triggering failsafe AUTO mode .................................................................................................................... 29

9.Deadband mode .................................................................................................................................................. 30

9.1.Settings ........................................................................................................................................................ 30

9.2.Operation ..................................................................................................................................................... 30

9.3.Initialisation .................................................................................................................................................. 31

10.Setpoint Offset .................................................................................................................................................... 32

10.1.Settings ........................................................................................................................................................ 32

10.2.Operation ..................................................................................................................................................... 32

11.Modbus RTU ....................................................................................................................................................... 34

11.1.Modbus background ..................................................................................................................................... 34

11.2.Modbus registers .......................................................................................................................................... 34

11.3.Modbus connections .................................................................................................................................... 34

12.Modbus register tables ...................................................................................................................................... 35

12.1.Holding registers .......................................................................................................................................... 35

12.2.Input registers ............................................................................................................................................... 39

12.3.Discrete Inputs ............................................................................................................................................. 40

12.4.Coils ............................................................................................................................................................. 41

Appendix A – Compatible Air-To-Air units ................................................................................................................. 42

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RETAIL MINI

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modes of ope

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Appendix A

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B

ote monitorin

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between the

s

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nt Heat/Cool

a

a 0-10V or r

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indication of

a

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to-date data.

p

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on.

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on Air-to-

Page 7

3. Installation

3.1. Physical connection

The MelcoRETAIL MINI has a 1 metre flying lead to connect directly into the CN105/CN92 connector on the controller

PCB.

3.2. Power supply

The MelcoRETAIL MINI is powered from the CN105/CN92 air conditioner host connector at 12V DC and therefore

does not require an external power supply.

3.3. RS-485 connection

The MelcoRETAIL MINI has a 3-way screw terminal to provide Modbus RTU communication via RS-485. See chapter

5.3 for more details.

4. DIP

s

The MelcoR

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There is a b

a

The followin

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Note: The M

4.1.

M

Any Modbus

binary, wher

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TAIL MINI h

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elcoRETAIL

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odbus Sl

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3

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2

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4

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5

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1

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2

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for any chan

g

s

en using swi

t

v

alues:

A

ddress

v

s

witch set ON

.

O

N position th

e

O

FF position i

s

R

S-485 netwo

r

s

ed for config

u

o

f 4 DIP switc

h

e the MelcoR

E

g

es to the DIP

t

ches CONFI

G

v

alue when

s

set ON

1

2

4

8

16

.

For example

e

Slave ID is

s

an invalid c

o

r

k must have

a

u

ration of the

h

es labelled

C

E

TAIL MINI.

switch chang

G

1-1 to 1-5.

T

s

witch is

, to set Slave

s

et in softwar

e

o

mbination an

d

a

unique Slav

e

unit.

C

ONFIG

2

.

es to take eff

e

T

he address i

s

ID 13 set swi

t

e

by writing to

d

should not

b

v

e ID.

Page 8

e

ct.

s

set in

t

ches 1-1,

a Modbus

b

e used.

Page 9

4.2. RS-485 communication settings

The RS-485 communication settings are set using switch CONFIG 1-6.

When the switch is in the OFF position the Baud Rate and Parity settings are set in software by writing to Modbus

registers (see chapter 12.1).

1-6 RS-485 communication settings

OFF Baud Rate and Parity set in software

ON 9600 baud, no parity

The number of data bits is fixed at 8 and the number of stop bits is fixed at 1.

4.3. Protocol selection

The RS485 protocol is set using DIP switch CONFIG 1-7, currently only Modbus RTU is supported.

When the switch is in the ON position the Modbus RTU protocol is selected.

1-7 Protocol selection

OFF (Reserved for future use)

ON Modbus RTU

4.4. Auto Mode / Lock Mode selection

The function of the LOCK/AUTO MODE digital input is determined by switch CONFIG 1-8.

When the switch is in the OFF position input LOCK/AUTO MODE is used to enable/disable Auto Mode.

When the switch is in the ON position input LOCK/AUTO MODE is used to enable/disable Lock Mode.

1-8 LOCK/AUTO MODE input function

OFF Enable/disable Auto Mode

ON Enable/disable Lock Mode

4.5. Deadband Mode

The Deadband Mode feature can be enabled using switch CONFIG 2-1.

When the switch is in the OFF position Deadband Mode is disabled.

When the switch is in the ON position Deadband Mode is enabled.

2-1 Deadband Mode

OFF Disabled

ON Enabled

Note: Deadband settings can be changed by writing to Modbus registers (see chapter 12.1 for more details).

Page 10

4.6. Setpoint Limiting

The Setpoint Limiting feature can be enabled using switch CONFIG 2-2.

When the switch is in the OFF position Setpoint Limiting is disabled.

When the switch is in the ON position Setpoint Limiting is enabled.

2-2 Setpoint Limiting

OFF Disabled

ON Enabled

Note: Setpoint Limiting settings can be changed by writing to Modbus registers (see chapter 12.1 for more details).

4.7. Timeout

The Timeout feature can be enabled using switch CONFIG 2-3.

When the switch is in the OFF position the Timeout feature is disabled.

When the switch is in the ON position the Timeout feature is enabled.

2-3 Timeout Feature

OFF Disabled

ON Enabled

Note: The timeout value can be changed by writing to a Modbus register (see chapter 12.1 for more details).

4.8. Input type selection

The input type for the four analogue inputs (S.P, MODE, FAN SPEED, OCC MODE) can be configured using switch

CONFIG 2-4.

When the switch is in the OFF position inputs these inputs are set to voltage (0-10VDC) type.

When the switch is in the ON position inputs these inputs are set to resistive () type.

2-4 Analogue input type

OFF Voltage (0-10VDC)

ON Resistive ()

Page 11

4.9. Summary

Switch Description Notes

1-1

Modbus Slave ID

Node ID 1 – 30 (see chapter 4.1).

All OFF = Invalid combination.

All ON = Software selectable Slave ID.

1-2

1-3

1-4

1-5

1-6 Comms Settings OFF = Baud rate and parity software selectable

ON = 9600 baud, no parity

1-7 Protocol Selection

OFF = (Reserved for future use)

ON = Modbus RTU

1-8 Auto Mode / Lock Mode OFF = AUTO/LOCK MODE input used to enable Auto Mode

ON = AUTO/LOCK MODE input used to enable Lock Mode

2-1 Deadband Mode

OFF = Deadband Mode disabled

ON = Deadband Mode enabled

2-2 Setpoint Limiting OFF = Setpoint Limiting disabled

ON = Setpoint Limiting enabled

2-3 Timeout

OFF = Timeout feature disabled

ON = Timeout feature enabled

2-4 Input Type Selection OFF = Analogue inputs are voltage (0-10VDC) type

ON = Analogue inputs are resistive () type

5. Con

n

5.1. O

v

5.2. C

N

The MelcoR

E

MelcoRETAI

5.3. R

S

The RS-485

To ensur

e

5.3.

On the Melc

o

to this head

e

n

ections

v

erview

N

92/CN10

E

TAIL MINI fl

y

L MINI does

n

S

-485

connector ha

s

e

reliable Mod

b

1. RS-485 te

r

o

RETAIL MIN

e

r will enable t

5

y

ing lead con

n

ot require an

s

A, B and gr

o

b

us communi

c

r

mination re

s

I PCB there’s

he 120 term

n

ects to either

external pow

e

o

und (-) conn

e

c

ations the gr

o

s

istor

a 2-pin jump

e

ination resist

o

the CN92 or

C

e

r suppl

y

.

e

ctions.

o

und must b

e

r header loc

a

o

r to the RS-4

C

N105 conn

e

connected t

o

a

ted next to th

e

8

5 bus.

ctor on the in

d

o

the Modbus

e

RS-485 con

d

oor unit PC

B

Master devic

e

nector. Fittin

g

Page 12

B

. The

e

.

g

a jumper

5.4. A

n

5.4.

DIP switch 2

-

each input in

When set to

t

When set to

t

5.4.

The input la

b

5.4.

The input la

b

5.4.

The input la

b

5.4.

The input la

b

n

alogue I

n

1. Input type

-

4 determine

s

dividually; all

t

he voltage r

a

t

he resistanc

e

2. S.P.

b

elled S.P. ca

n

3. MODE

b

elled MODE

c

4. FAN SPE

E

b

elled FAN S

P

5. OCC MOD

b

elled OCC c

a

n

puts

selection

s

the input typ

e

four will be s

e

a

nge (DIP swi

t

e

range (DIP

s

n

be used to

c

an be used t

o

E

D

P

EED can be

u

E

a

n be used to

s

e

for all four i

n

e

t to the same

ch 2-4 OFF)

a

s

witch 2-4 ON

)

c

ontrol the uni

t

o

control the

u

sed to contr

o

s

et the curren

n

puts, see se

c

type.

a

voltage bet

w

) any value o

f

t

Setpoint, se

e

u

nit Mode, se

e

o

l the unit Fan

n

t occupancy

s

c

tion 4.8. It is

n

w

een 0 and 1

0

f

resistance c

a

e

chapter 7.1

f

e

section 7.2 f

o

Speed, see

s

tate, see sec

t

n

ot possible t

o

VDC can be

a

n be applied

t

f

or more detai

o

r more detail

s

ection 7.3 for

t

ion 7.4 for m

o

set the inpu

t

a

pplied to the

t

o the input.

i

ls.

l

s.

more details.

o

re details.

Page 13

t

type for

input.

5.5. D

i

The four digi

t

of a relay).

5.5.

The input la

b

5.5.

The input la

b

5.5.

The input la

b

switch 1-8.

S

5.5.

The input la

b

details.

i

gital Inp

u

t

al inputs are

o

1. FORCE O

N

b

elled FORC

E

2. FORCE O

F

b

elled FORC

E

3. AUTO/LO

C

b

elled

A

UTO/

L

S

ee section 7.

7

4. FAULT

b

elled FAULT

u

ts

o

f the volt-fre

e

N

E

O

N

is used t

o

F

E

OF

F

is used

C

K MODE

L

OCK MOD

E

i

7

for more de

t

is used to ind

i

e

type, so just

o

force the un

to force the u

n

i

s used for eit

h

ails.

i

cate the pres

e

t

require an o

p

it to switch o

n

nit to switch

o

h

er the Auto

o

ence of a faul

p

en or closed

c

n

, see section

ff, see sectio

n

o

r Lock functi

o

t with 3

rd

part

y

c

ircuit conne

c

7.5 for more

d

n

7.6 for more

o

n, depending

y

equipment,

s

c

tion (i.e. the

o

d

etails.

details.

on the state i

s

ee section 7.

Page 14

o

utput side

s DIP

8 for more

5.6. R

e

The relay ou

t

5.6.

The ON/OF

F

5.6.

The HEATI

N

temperature

5.6.

The COOLI

N

return air set

5.6.

The FAULT

o

e

lay Outp

u

t

puts are use

d

1. ON/OFF

F

output indic

a

2. HEATING

N

G output indi

c

setpoint. See

3. COOLING

N

G output indi

c

point. See se

c

4. FAULT

o

utput indicat

e

u

ts

d

for status in

f

a

tes whether t

h

c

ates the unit

section 7.10

f

c

ates the unit

c

tion 7.11 for

m

e

s if there is a

f

ormation.

h

e unit is run

n

is in Heat or

A

f

or more detai

is in Cool or

A

m

ore details.

fault with the

n

ing or not, se

A

uto mode an

d

i

ls.

A

uto mode an

unit, see sec

t

e section 7.9

f

d

the return a

i

d the return a

t

ion 7.12 for

m

f

or more deta

i

r temperatur

e

i

r temperatur

e

m

ore details.

ils.

e

is less than t

e

is greater th

a

Page 15

he

a

n the

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Procon MelcoRETAIL MINI Installation guide

Procon MelcoRETAIL MINI Installation guide

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