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ApplicationNotes
Industrial�WallControl�(IWC10)
The�Breezair�Industrial�Wall�Control�(IWC10)�is�designed�to�provide�both�local�and�external�Evaporative Air�coolercontrol�for�all�Breezair�air�coolers�fitted�with�the�CPMD�digital�module. The�external�control�may�be�either�a�PLC�orBuilding�Management�System. The�IWC10�is�designed�to�accept�external�logic�input�voltages�ranging�from�4Vdc�to32Vdc�and�analogue�input�voltages�from�0�-�10�Vdc.�It�will�switch�outputs�ranging�from�1.4Vdc�to�32Vdc�at�a�load�of40mA. The�IWC10�has�binary�outputs�for Temperature�and�Humidity�for�use�with�other�equipment.
Within�this�limit,�the�maximum�sensor�cable�length�must�not�exceed�60m.�EG:�a�combination�of�40m�ofcomms�(communications)�cable�and�60m�of�sensor�cable�is�permitted�and�80m�of�comms�cable�and�20m�of�sensorcable�is�permitted.
Each�IWC10�kit�is�provided�with�one�20m�sensor�cable�and�one�40m�comms�cable.�80m�comms�cables�and�60msensor�cables�are�available�as�an�option,�to�be�purchased�separately.The�above�restrictions�apply�in�order�to�avoid�excessive�voltage�drop�and�electrical�noise.YOU�MAY USE�LONGER�CABLES�WHEN�REQUIRED,�BUT WHEN YOU�DO THE�FOLLOWING�CONDITIONSMUST APPLY:
Cable�conductors�must�be�larger�to�reduce�voltage�drop.Cables�must�be�screened�(or�shielded)�to�reduce�noise.Screens�must�be�earthed�(grounded).Ensure�that�conductors�are�correctly�orientated.�Use�junction�boxes�or�high�quality�plugs�forterminations.Seeley�International�takes�no�responsibility�for�mal-function�of�the�IWC10�when�longercables�are�used.See�diagram�2.
CABLE�LENGTHSThe�maximum�total�cable�length�between�the�cooler�CPMD�module�and�the�Remote�sensor�(via�the�IWC10)is�100m.
1Industrial�Wall�Control Application�Notes 1
AUTO�[Auto]�mode,�and�manual�control�of�the�cooler�functions�in�the�MANUAL [Man]�mode.
To�ensure�signal�integrity�over�distances�greater�than�100�meters�between�the�IWC10�and�the�PLC�or�Buildingmanagement�system�it�is�advisable�to�use�shielded�cables.
Connect�the�Positive�input�to�the�input�terminals. This�voltage�must�range�between�4Vdc�to�a�maximum�of�32Vdcfor�the�logic�inputs�and�0�-�10V�for�the�analogue�speed�control.�Current�in�the�input�is�limited�by�the�seriesresistors.Connect�the�Negative�input�to�the�common�terminal.The�IWC10�does�not�have�its�own�internal�power�supply�to�operate�the�external�inputs.
The�IWC10�may�also�be�set�up�to�control�the Air�Cooler�from�EXTERNAL devices,�such�as�PLCs�and�BuildingManagement�System�computers.�In�this�case�the�IWC10�will�cease�to�function�in�its AUTO�[Auto]�or�MANUAL[Man]��mode�and�will�respond�only�to�the�external�commands.
The�IWC10�provides�at�all�times�outputs�that�may�be�employed�to�command�other�external�devices�such�asdampers,�fans,�signal�equipment,�etc. These�outputs�contain�the�status�of�the�various Air�Cooler�components�(fan,pump,�drain�valve),�as�well�as�the�Remote�Sensor�temperature�and�humidity�values.
INPUT�CONFIGURATION
These�cables�are�transmitting�digital�signalsand�must�not�be�installed�next�to�power�cables.
INPUTS AND�OUTPUTSThe�IWC10�may�be�set�up�to�control�the Air�Cooleras�a�local�machine,�independent�of�any�otherdevices.�In�that�case�there�will�not�be�anyconnections�made�to�the�Input�and�Outputterminals. The�Remote�Sensor�supplied�in�this�Kittogether�with�the�IWC10�will�provide�automatictemperature�and/or�humidity�control�along�with�itswater�management�and�auto�drain�features�in�the
WHITE WHITE
WHITE
WHITE
BLACK BLACK
BLACK
BLACK
RED RED
RED
RED
GREEN GREEN
GREENGREEN
YELLOW YELLOW
YELLOW
YELLOW
BLUE
ILL1415-A
BLUE
BLUE
BLUE
2CONNECTION�ORDER�FOR�SENSOR�CABLE�ONLY
Industrial�Wall�Control Application�Notes
INPUT�CONFIGURATION�(continued)
INPUTS
In�EXTERNAL [EXTERNAL]�mode�the�power�sourcemust�be�provided�adjacent�to�the�Wall�Control�via�apower�outlet�and�adaptor. The�adaptor�may�be�acommon�small�appliance�adaptor�such�as�used�fortelephones,�answering�machines,�weigh�scales�etc,having�the�specified�electrical�output�(see�page�1).
If�any�one�of�inputs�2,3�or�4�is�high,�or�a�voltage�>0.5Vdc�is�detected�at�Input�6,�the�IWC10�MANUAL[Man]�and AUTO�[Auto]�controls�will�be�over-ridden�andthe�IWC10�will�not�respond�to�temperature�and�humiditychanges�sensed�by�the�Remote�Sensor.�In�EXTERNAL[EXTERNAL]�and AUTO�[Auto]�modes�the Temperatureand�Humidity�and�clock�displays�will�cycle�every�5seconds.Input�1�[Safety�Off]��-�Safety�OFF
R
!
Input�2�[F1]��-�Fan1
This�input�enables�the�Cooler�to�be�switched�OFF. A positive�voltage�to�the�input�1�of�the�IWC10�holds�the�system�inthe�OFF�state,�and�is�indicated�on�the�IWC10�screen�by�a .
This�input�enables�the�fan�to�run�at�minimum�speed�when�a�positive�voltage�isapplied.�It�functions�in�conjunction�with�Input�3�in�a�binary�code�to�providethe�external�control�with�three�different�speed�settings�for�the�cooler�fan.�WithInput�Fan1�and�Fan2�positive�the�cooler�will�run�at�maximum�speed.
With�Input�Fan1�and�Fan2�positive�the�cooler�will�run�at�maximum�speed.
WARNING It�is�not�recommended�that�this�switched�input�be�used�to�control�the�Cooler�in�an�emergencysituation,�because�it�is�not�fail-safe,�ie:�if�for�any�reason�the�cable�continuity�is�cut,�it�is�not�possible�toapply�a�positive�voltage�to�input�1�to�switch�the�cooler�OFF.
Input�3�[F2]��-�Fan2
Input�4�[Pump]��-�Pump�ON�/�OFF
Input�5�[H.E.]��-�Humidity�Enable
Input�6�[SP1]��-�Speed�Control
Input�7�[HD]��-�Humidity�Disable
Input�8�[ON/OFF]��-�Remote�ON/OFF
This�input�enables�the�fan�to�run�at�medium�speed�when�a�positive�voltage�is�applied�when�there�is�no�voltage�onInput�2.
This�input�enables�the�pump�to�run�when�a�positive�voltage�is�applied.�However,�the�pump�operation�is�subject�tothe�CPMD�module�and�the�status�of�the�cooler.�If�there�is�insufficient�water�in�the�tank�the�pump�will�not�run�untilwater�is�at�the�correct�level�as�sensed�by�the�water�probes.
This�input�only�functions�when�the�IWC10�is�in�EXTERNAL [EXTERNAL]�Mode.�It�is�possible�for�External�controls�todrive�the�cooler�to�the�point�where�the�room�humidity�exceeds�the�default�set�point�as�sensed�at�all�times�by�theBreezair�Remote�Sensor. This�input�enables�the�IWC10�to�over-ride�the�external�pump�command�and�disallow�thepump�to�run�when�the�room�humidity�goes�high.�If�this�Input�is�not�enabled,�the�pump�will�run�as�required�by�theexternal�command�regardless�of�room�humidity.
This�input�enables�the�fan�speed�to�be�switched�from�OFF�(0)�to�Speed�10�by�adjusting�the�analogue�input�between0V�(Off)�to�10Vdc�(Speed10).
This�input�disables�Humidity�control�in AUTO�[Auto]�mode�when�no�External�[EXTERNAL]�control�is�present. Thecase�may�arise�in AUTO�[Auto]�in�which�the�temperature�is�satisfied�and�the�fan�is�therefore�stopped.�BUT theindoor�humidity�may�fall�below�the�set�point�and�the�IWC10�will�demand�that�the�cooler�operate�to�raise�the�humidityto�the�set�point. The�effect�will�be�to�lower�the�room�temperature�still�further.�If�this�is�undesirable,�the�humiditycontrol�may�be�disabled�by�this�input.
The�system�will�NOT re-start�automatically�when�the�input�is�removed.
This�input�is�used�to�turn�the�cooling�system�ON�or�OFF�from�a�remote�location.The�input�must�be�in�the�form�of�a�momentary�pulse�(provided�by�the�installer)�for�both�ON�and�OFF�functions. Anyrepeated�pulses�received�within�2�seconds�of�the�first�pulse�will�be�ignored.When�a�pulse�is�received�during�cooling�system�operation�(whether AUTO�or�MANUAL)�the�control�will�save�thecurrent�state�of�the�system�and�the�system�will�enter�a�stand-by�state�and�shut�down.When�the�next�pulse�is�received�at�Input�8,�the�cooling�system�will�start�up�again�in�the�same�mode�in�which�it�waslast�shut�down.In�the�event�that�the�cooling�system�is�re-started�manually�during�the�standby�state,�the�next�pulse�received�at�input8�will�shut�down�the�system�into�standby�mode.
2
FAN
X X
XX
X X
XX
INPUT�2 INPUT�3
OFF
HIGH NIL NILHIGH
LOW
MED
HIGH
3
J4
IN1
IN2
IN3
IN4
COM
ILL1345-A
LOGIC�INPUT ANALOGUE�INPUTInput�6
Speed�ControlAnalogue�Input
0�-�10VdcOff�-�Speed�10
SPD�CTRL
COMMON
20k
This�output�is�activated�whenever�the�air�cooler�fan�has�been�turned�ON.
This�output�is�activated�whenever�the�air�cooler�pump�has�been�turned�ON.
This�output�is�activated�whenever�the�air�cooler�is�under�external�control.
This�output�is�activated�whenever�the�air�cooler�is�in�a�fault�condition.�Refer�to�Installation�and�Operation�manual,SERVICE�[SERVICE]�Mode,�page�8�for�more�details�about�faults.
This�output�is�activated�whenever�the�air�cooler�has�been�turned�ON�or�is�in�Standby�Mode. The�binary�informationrepresents�humidity�as�a�percentage. The�bit�stream�is�described�on�page�4.
This�output�is�activated�whenever�the�Drain�Valve�is�open.�It�will�activate�only�after�the�time�delay�period�set�in�theIWC10�Program. The�output�will�remain�activated�while�the�Drain�valve�is�open.�If�the�Drain�valve�opens�for�aperiod�of�time�less�than�the�delay�time�set,�the�output�signal�will�remain�activated�for�5�seconds�only.
Output�2�[Fan]�-�Fan�ON�/�OFF
Output�3�[Pump]�-�Pump�ON�/�OFF
Output�4�[Ext]�-�External�Control
Output�5�[Fault]�-�Fault�ON�/�OFF
Output�6�[S.Hum]�-�Serial�Humidity
Output�7�[S.Temp]�-�Serial�Temperature
Output�8�[Drain]��Drain�Control�Output
This�output�is�activated�whenever�the�air�cooler�has�been�turned�ON�or�is�in�Standby�Mode. The�binary�datarepresents�10�x Temperature�(in C). The�bit�stream�is�described�on�page�4.°
OUTPUT�CONFIGURATIONIWC10�outputs�1,2,3,4,5�&�8�are�switches�only. They�will�function�whenconnected�to�a�power�supply�from�an�external�source�of�(1.4�-�32Vdc�at40mA load).Connect�the�external�DC�power�supply�to�the�load,�connect�the�negative�ofthe�load�to�the�desired�output�terminal�and�connect�the�negative�of�thepower�supply�to�the�common�[com]�terminal�on�the�IWC10. The�output�willthen�turn�on�your�load�as�desired�(page�4).
Outputs
Output�1�[ON]�-�System�ON�/�OFF
All�outputs�are�indicators�only�of�the�state�of�the�air�cooler.�None�of�themare�monitored�for�integrity. A fault�on�an�output�line�is�not�indicated�in�theIWC10.
This�output�is�activated�whenever�the Air�Cooler�has�been�turned�ON��fromany�source,�in�any�mode.
Industrial�Wall�Control Application�Notes
4
J6
OUT1
OUT2
OUT3
OUT4
COM
ILL1346-A
3
4Industrial�Wall�Control Application�Notes
Pause Start�pulse Pause
lsb
lsbmsb
msb
H LDHLDH
One�byte
DATA
1 1 1 1 1 1 1 1
1 1 1 1 10 0 0
Temperature�and�Humidity�bit�stream
Start�pulseA High�BitA Low�BitPauseUpdate�RateShift�in�PLC
The�IWC10�outputs�Humidity�and Temperature�readings�for�use�with�a�PLC�or�building�management�system.Humidity�is�output�on�terminal�OUT6�of�J7�and Temperature�is�output�on�terminal�OUT7�of�J7. The Temperaturedata�word�is�9�bits�after�7�bits�of�leading�one's�(1),�while�the�Humidity�data�byte�is�8�bits�after�8�bits�of�leading�one’s.
The�temperature�value�is�invert�binary�and�is�10�x�the Temperature�reading.
The�humidity�value�is�invert�binary�and�is�a�direct�representation�of�the�Humidity�reading.The�below�example�(shown�at�1�sec/division)�is�44%�RH
The�Humidity�value = 11111111 11010011Invert�binary�number = 00000000 00101100Humidity�reading = 44%
Start�Pulse
Bit�7�(msb�of�data)���������������������������������������������Bit�8�(msb�of�data)
..Bit�0�(lsb�of�data)
For�example: The�temperature�value = 1111111 100110001Invert�binary�number = 0000000 011001110Decimal�number = 206Temperature�reading = 206/10 = 20.6°C
The�bit�format�is�S�H�L D�H�L D�H�…L D�H�P where:S�=�Start�pulseL =�LowH�=�High�(for�synchronisation�purposes)D�=�Data�state�(high�or�low)P =�Pause
: :Start�Pulse
Bit�15�to�Bit�8�all�One�(1)������������������������������������Bit�15�to�Bit�9�all�One�(1)
..�����������������������������������������������������������������������..
..Bit�0�(lsb�of�data)
Pause Pause
:750mSec�off,��250mSec�on250mSec�off,��500mSec�on500mSec�off,��250mSec�on1000mSec�on14�secondsLEFT
The�Humidity�Bit�stream�is�as�follows�������������The Temperature�Bit�stream�is�as�follows
The�bit�timing�is�as�follows
Industrial�Wall�Control Application�Notes 5
5
60m.
CPMD
HUB�1
HUB�2
SENSORIndustrial�Wall
Industrial�Wall
Control
Control
SENSOR
CPMD
CPMD
CPMD
20m. Any�lengthOK�up�to�combinedlength�of�140m�fromIWC�to�CPMD.
Any�lengthOK�up�to�combinedlength�of�200m�fromIWC�to�CPMD.
60m.
CPMD
CPMD
CPMD
CPMD
CPMD
max�40m�!
max�40m�!max�40m�!
max�40m�!
max�40m�! max�40m�!
max�40m�!
max�120m�!
max�120m�!
max�140m�!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
Coolers�are�supplied�with�20m�data�cable�inaccessories�kitHubs�are�supplied�with�20m�data�cable�in�kit.Industrial�Wall�Controls�(IWC)�are�supplied�with20m�Sensor�cable�in�kit60m�Sensor�cable�on�reel�available20m�data�cable�in�re-sealable�bag�available40m�data�cable�on�reel�available60m�data�cable�on�reel�available80m�data�cable�on�reel�available100m�data�cable�on�reel�available4-way�in-line�joiners�available�to�extend�data�cableto�maximum�lengths�shown�on�diagramData�cables�may�be�shortened�or�lengthened�(tomaximums�shown),�using�ONLY correct�RJconnectors�and�crimping�toolsCables�supplied�by�Breezair�are�26AWG,�7/016,�4core�&�6�core�flatALWAYS�route�cables�at�least�300mm�away�fromregular�power�cables�and�high�power�machines.Cross�over�power�cables�at�right�angles.Where�maximum�data�cable�and�sensor�cablelengths�are�exceeded,�or�cables�are�not�routed�inaccordance�with�our�recommendations�Seeleytechnical�support�is�not�available�and�the�productwarranty�may�be�voided.
Breezair�Control�SystemCable�Lengths
Industrial�Wall�Control824130-A 0703
MASTER
MASTER
MASTER
SLAVE�1
SLAVE�1SLAVE�2
SLAVE�3
SLAVE�3
SLAVE�2
Any�lengthOK�up�to�combinedlength�of�200m�fromIWC�to�CPMD.
LOGIC�INPUTCONNECTION
All�Commons�connectedto�Negative
4-32VDC<=12mAmps D2
R1Input
Common
D1
OUTPUTCONNECTION
All�Commons�connectedto�Negative
Common
OutputR3
D3Q1
R2
Q2NPN
RES-NTC1.4-32VDC<=40mAmp
(C)�SEELEY INTERNATIONALAUSTRALIA 2004
J6J4
J7J5J3J2
RJ11RJ12
CPMDCOMMS
REMOTESENSOR
OUT
OUTIN
IN
1 2 3 4 51 2 3 4 5
Co
m
Co
m
In1
In2
In3
In4
Co
m
In5
In6
In7
In8
Co
m
Ou
t1
Ou
t2O
ut3
Ou
t4
Ou
t5
Ou
t6
Ou
t7
Ou
t8
Sa
fety
�Off F1
F2
Pu
mp
H.E
HD
Sp
d�C
on
t
ON
/OF
F
On
Fan
Pu
mp
Ext
Fau
lt
S.H
um
S.T
em
p
Dra
in
1 2 3 4 51 2 3 4 5
1 2 3 4 5
858746-A
ANALOGUEINPUT
Common
20k
Spd�Cont
Speed�ControlAnalogue�Input
0�-�10Vdc
Off�-�Speed�10
Industrial�Wall�Control Application�Notes 6
FAN�SPEEDS�& AIR�FLOW
MINIMUM Speed�3MEDIUM Speed�6MAXIMUM Speed�10
ALL 10�SPEEDS�CAN�BE�SELECTED.
When�the�wall�control�is set�for ,�the�fan�is�controlled�through�10�speedsaccording�to�the�automatic�or�manual�settings.
When�the�wall�control�is�set�for ,�the�fan�can�only�operate�in�2�modesA. Logic�control�inputs�2�&�3,�only�3�speeds�can�be�selected
B. Analogue�Input�6
For�the�purpose�of�applying�the�Breezair�coolers�to�various�downstream�systems,�the�air�flow�performance�curvesare�provided�below.
NOT EXTERNAL [EXTERNAL]�mode
EXTERNAL [EXTERNAL]�mode
Breezair TBA 550 Airflow - Industrial wall control speed settings
for "External" fan speed inputs.
0
20
40
60
80
100
120
140
160
180
200
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100
Airflow L/s
Sta
tic
Pre
ssu
re(
Pa
)
Speed 10 - max
Speed 6
Speed 3
ILL1331-A
828534-H AU��1011
Evaporative Air Cooling Manual. Seeley International Pty Ltd, Adelaide, South Australia. ACN 054 687 035.As the policy of the company is one of continuous product improvement, all specifications are subject to change without notice.