AC-2000 SE and PLUS
Pig Controllers
Installation Manual
P/N: 110118
Warranty & Limitation Of Liability
1. ROTEM warrants tha t the product shall be free of def ects in materials or workm anship and
will conform to the tech nical specification for a period of 1 (one) year from the date of initial
installation on site (the "warr ant y period ").
2. Load cells are not covered by ROTEM’s warranty.
3. ROT EM warrants that during said war ranty period, any item/item s or part/parts of equipment
found defective with respect to materials or workmanship or which do not conform to the
technical specification shall be repaired or replaced (at ROTEM's sole discretion), free of
charge.
4. During the warranty period, i n the event of an a lleged defect, aut horized
resellers in relevant
regions should be notif ied as soon as possible f rom the da te of noticin g the said defect, but n o
longer than thirty (30) days from such a discovery. The report shall include (1) a short
description of the defects noticed (2) type of card / component and its matching serial number.
5. ROTEM's sole liability under this warranty is the repair or replac ement of the defective item of
product.
Conditions and Limitations
1. ROTEM w ill not b e respons ible f or any lab or costs or expe nses ass ociated with rep lacem ent
of defective items or other parts of the product or repair.
2. This warranty shall not cover: (i) produc t or part therein which has been m odified (without
prior written approval of ROTEM), or (ii) product or part therein which has not handled or
installed by an author ized reseller of ROTEM or (iii) produc t or part therein which has either
handled or installed not in strict accordance with ROTEM's instructions, (iv) products which
were used for function other than agriculture industry.
3. This warrant y will not appl y in the followin g cases: ( i) if all com ponents of the pr oduct are not
originally supplied b y ROTEM (ii) the defect is the result of an act of nature , lighting strikes,
electrical power surge or interruption of electricity (iii) the defect is the result of accident,
misuse, abuse, alteration, neglect, improper or unauthorized maintenance or repair.
ROTEM warns and alerts all users that the Product is inherently complex and may not be
completely free of er ror s . RO T EM's pr oduct s ar e d es ig ned and manufactured to provi de reliable
operation. Strict tests and q ualit y control pr ocedur es ar e appli ed to ev ery produc t. H owever, th e
possibility that something may fail beyond our control exists. Since these products are
designed to operate climate control and other systems in confined livestock environments,
where failure ma y cause severe dam age, the user should provide adequate bac kup and alarm
systems. These are to operate critical systems even in case of a ROTEM system failure.
Neglecting to provide such a bac kup will be regarded as the user ’s wil lingn es s to ac c ept the ris k
of loss, injury and financial damage.
In no event will RO TEM be liable to a user or an y third party for any direc t, indirect, special,
consequential or incidental damages, including but not limited to any damage or injury to
business earnings, l os t pr of its or goo d wil l, per sona l injury, costs of de lay, any failure of d el ivery,
costs of lost or dam aged data or docum ent ation, los t or dam aged prod ucts or go ods, lost sales,
lost orders, lost income.
Except for the above expres s warrant y, ROT EM mak es no other w arrant ies, expr ess or implied,
relating to the products. ROTEM disclaims and excludes the implied warranties of
merchantability and f itness for a particular purpos e. No person is authorized t o make an y other
warranty or representatio n concerning the perform ance of the products other than as provided
by ROTEM.
Software Version: 8.11
Document Version: 1.9
Table of Contents
1 Front Matter ................................................................................................... 4
1.1 Introduction ........................................................................................................................ 4
1.2 Conventions ....................................................................................................................... 4
1.3 Contact Information ........................................................................................................... 4
1.4 Document Information ...................................................................................................... 4
2 Precautions ................................................................................................... 5
2.1 Grounding........................................................................................................................... 5
2.2 Filtering ............................................................................................................................... 5
2.3 Checking the Battery Level............................................................................................... 5
2.4 Frequency Inverters .......................................................................................................... 5
3 Technical Specifications .............................................................................. 6
4 Installation..................................................................................................... 7
4.1 Mounting the Unit .............................................................................................................. 7
4.2 AC-2000 Plus Wiring .......................................................................................................... 7
4.2.1 AC-2000 Plus Board Layout ........................................................................................... 8
4.2.2 AC-2000 Plus Relays...................................................................................................... 8
4.2.3 AC-2000 Plus High Voltage Wiring (Relays) .................................................................. 9
4.2.4 AC-2000 Plus Terminals ............................................................................................... 10
4.2.5 AC-2000 Plus Low Voltage W iring (Terminals) ............................................................ 11
4.2.6 AC-2000 Plus Communication ..................................................................................... 11
4.3 AC-2000 SE Wiring .......................................................................................................... 12
4.3.1 AC-2000 Board Layout ................................................................................................. 12
4.3.2 AC-2000 SE Relays ...................................................................................................... 13
4.3.3 AC-2000 SE High Voltage Wiring (Relays) .................................................................. 14
4.3.4 AC-2000 SE Terminals ................................................................................................. 15
4.3.5 AC-2000 SE Low Voltage W iring (Term inals ) .............................................................. 16
4.3.6 MUX / RCLP Wiring ...................................................................................................... 17
5 Configuration .............................................................................................. 18
5.1 Configuration (Menu 91) ................................................................................................. 18
5.2 Ventilation Table (Menu 92) ............................................................................................ 19
5.3 Relay Layout (Menu 93) ................................................................................................... 20
5.3.1 Manual Relay Operation ............................................................................................... 22
5.3.2 Relay Record ................................................................................................................ 22
5.4 Sensor Layout (Menu 94) ................................................................................................ 22
5.5 Setup Curtains (Menu 95) ............................................................................................... 23
6 Troubleshooting Guide .............................................................................. 24
7 Electrical Grounding .................................................................................. 26
7.1 Ground Rods .................................................................................................................... 26
7.2 Ground Wire ..................................................................................................................... 26
7.3 Ground Clamps ................................................................................................................ 26
7.4 What Should Be Grounded? ........................................................................................... 27
7.5 Lightening Protection ...................................................................................................... 27
7.5.1 Power Line Protection................................................................................................... 27
7.5.2 Communication Line Protection .................................................................................... 27
8 Appendix: Installing a CO2 Sensor ........................................................... 28
8.1 Low Voltage Wiring ......................................................................................................... 28
8.2 Configuring the CO2 Sensor .......................................................................................... 29
AC-2000 | 8.10/8.11 4
1 FRONT MATTER
This section includes information on the manual and general information.
1.1 Introduction
Rotem manuals provide easy-to-use information regarding the installation, operation, long/short term
planning and parts listing (this manual may not deal with all of the above subjects). The table of contents is
an outline of the relevant information in this manual.
Read this manual before operating your Rotem product. Using this equipment for any other purpose or in a
way not within the operating recommendations specified in this manual will void the warranty and may
cause personal injury.
If you have any questions or comments regarding your product, please contact your local Rotem dealer.
1.2 Conventions
NOTE: Notes provide important details regarding specific procedures.
CAUTION Cautions alert you to potential damage to the controller if the procedures are not
followed carefully.
WARNING! Warnings alert you to potentially hazardous situations which, if not avoided could
result in death or personal injury.
1.3 Contact Information
Rotem Control and Management
Email: support@rotem.com
URL: www.rotem.com
1.4 Document Information
Revision History
Revision Level / Date
Sect. Affected
Description
1.0 / Sept 2011 Release document
1.1 / Feb 2012
4.2.6
Added section
1.2 / Sept 2012
8.07
1.3 / Oct 2012
5.3/Manual
Changes in variables/Formatting changes
1.4 / Feb 2013 4.2.3/4.3.3 Changes in wiring diagram
1.5 / March 2014
8.10
1.6 / July 2014
2.4
Frequency inverters
1.7 / Feb 2015 8.11
1.8 / Sept 2016
4.2
Update pictures
1.9 / Dec 2016
3
Updated specs
© 2011 Rotem Corp.
All rights reserved.
Document Number: 110118 Revision Number: 1.9
No part of this publication may be reproduced, stored in an automated data file or made public in any form
or by any means, whether electronic, mechanical, by photocopying, recording or in any other manner
without prior written permission of the publisher.
Rotem will not accept responsibility for damage resulting from the use of this manual. Rotem also reserves
the right to make changes and improvements to its products and/or the associated documentation without
prior notice.
5 AC-2000 | 8.10/8.11
2 PRECAUTIONS
• Grounding
• Filtering
• Checking the Battery Level
• Frequency Inverters
2.1 Grounding
• Always connect temperature and sensor shields to earth ground. Avoid mixing high voltage
wiring with sensor and low voltage wiring.
• Keep the controller as far as possible from heavy contactor boxes and other sources of electrical
interference.
• Do not connect communication wire shields, which go from one house to another at both ends.
Connect them at one end only. Connection at both ends can cause ground loop currents to flow,
which reduce reliability.
• The COM connection for communications is not the shield wire. The COM, RX and TX wires
must connect to each other at all controllers.
2.2 Filtering
If this installation includes a power inverter to drive variable speed fans, install an EMI filter in front of the
inverter, according to the specifications provided by the inverter manufacturer. Refer to the inverter
documentation.
2.3 Checking the Battery Level
Check the battery once a year. The output must be 2.7 volts (minimum). Authorized personnel only must
replace the battery if the output is below the minim um required le ve l or ever y five years.
2.4 Frequency Inverters
Frequency inverters can cause severe electrical and electromagnetic interference. Therefore, when
employing a frequency inverter, it is critical that you carefully follow the manufacturer's installation
instructions. In particular verify:
• that the cable shielding between the inverter and any motor meets industry standards
• proper grounding of the inverter's chassis and motor power cable
• proper grounding of low voltage cable shield wire
• that the controller and inverter cables are kept in separate conduits or wire bundles
1. Controller
2.
Inverter
3. Place the controller at least five meters from the inverter
AC-2000 | 8.10/8.11 6
3 TECHNICAL SPECIFICATIONS
Input Power Voltage
One Phase 115 ± 10 VAC (USA and Canada)
230 ± 20 VAC (Outside USA and Canada)
0.5
Amp, 50-60Hz
Relay Loads
5.0 Amps, 250 Volts, Fused
Analog Inputs
0 - 11 Volts, 10 Milliamps Maximum
Analog Output
0 - 10 Volts:
Current Limited with 100-Ohm Resistor
Digital Inputs
5 ma @ 5 Volts, Dry Contact
Operating Temperature Range
0° to +50° C (32° to 125° F)
Enclosure
Water and Dust Tight
Fuses
Main fuse: 0.315 Amps, 250 Volts
Others: 5 Amps, 250 Volts
7 AC-2000 | 8.10/8.11
4 INSTALLATION
This manual details the installation procedures for the AC-2000 SE and AC-2000 Plus Pig Controllers.
• Mounting the Unit, page 7
• AC-2000 Plus Wiring, page 7
• AC-2000 SE Wiring, page 12
4.1 Mounting the Unit
1. Install the AC-2000 in a dry well lighted area, preferably in an annex to the main poultry house.
2. Mount it using the three holes provided; one in each of the left and right lower corners, accessible
from the front under the terminal strip cover, and one top center in the back. The top center hole is a
keyhole variety.
3. Install the screw for this hole first to about 0.1 inches of the wall surface.
4. Hang the controller on this screw. Install the other two screws to fasten the AC-2000.
CAUTION Always connect temperature and sensor shields to earth ground. However, do not
connect communication wire shields, which go from one house to another at both ends.
Connect them at one end only. Connection at both ends c an cause ground loop currents
to flow, which reduce reliability.
CAUTION The COM connection for communications is not the shield wire. The COM, RX and TX
wires must connect to each other at all AC-2000 controls.
CAUTION Avoid mixing high voltage wiring with sensor and low voltage wiring.
CAUTION Keep the AC-2000 as far as possible from heavy contactor boxes and other sources of
electrical interference.
Refer to Electrical Grounding, page 26 for information on grounding the unit.
4.2 AC-2000 Plus Wiring
The following sections detail the AC-2000 Plus wiring.
• AC-2000 Plus Relays, page 8
• AC-2000 Plus High Voltage Wiring (Relays), page 9
• AC-2000 Plus Terminals, page 10
• AC-2000 Plus Low Voltage Wiring (Terminals), page 11
• AC-2000 Plus Communication Wiring, page 11
AC-2000 | 8.10/8.11 8
4.2.1 AC-2000 Plus Board Layout
4.2.2 AC-2000 Plus Relays
1. Relays 1 to 19: Each pair of terminals goes to one relay. These relays are fused with a
5-ampere, 250-volt slow blow fuses. The relays are normally open when not powered.
2. Relay 20: Three terminal blocks: This relay normally serves as an alarm relay. It is also
fused with a 5 ampere, 250 volt slow blow fuse, and can serve as an ordinary relay:
o NC: Normally closed contact
o Com: Common contact
o NO: Normally open contact
3. Power: Three terminal blocks:
o Neutral (N): Connect to the Neutral Power line.
o Phase (~): Connect to the Phase Power line.
o Ground (GND): Connect to a solid earth safety ground, normally with the bare safety
ground wire, or a green wire.
4. Ground: Connect the ground wire to the electrical system.
9 AC-2000 | 8.10/8.11
4.2.3 AC-2000 Plus High Voltage Wiring (Relays)
NOTE: The device connections (fan, heat, cool, etc.) that are shown in the drawing, are examples
only!
CAUTION Connect the AC-2000 Plus power input to the protected output only!
AC-2000 | 8.10/8.11 10
4.2.4 AC-2000 Plus Terminals
1. Communications: Three terminal blocks for PC communication using the optional
multiplexor, MUX-2.
o RX (20): Receive into AC-2000 PLUS . With multiple controls, connect all the RX pins
together. Connect to TX at Multiplexor only.
o TX (19): Transmit from AC-2000 PLUS With multiple controls, connect all the TX pins
together. Connect to RX only at Multiplexor only.
o COM (18): Ground reference for communications. Do not connect shields to this pin.
Connect to COM at multiplexor also.
2. Relay Extension: Com (1) - The relay extension box such as the REB-8 may be located up
to 10 feet from the AC-2000 PLUS. Do not connect the shield to this terminal. Connect the
shield to earth ground only at one end of the cable to avoid ground loops.
o Data (2): This line carries data to the relay extension.
o Clk (3): This line carries a clocking signal for use by the relay extension.
3. Not used.
4. 6 Temperature Sensors (8, 9, 10, 25, 26, 27): The temperature sensor is a 2 wired black
shielded cable thermistor (RTS-2). Connect one wire to the temperature sensor terminal and
the other to common (11, 28) *Polarity does not matter.
5. Analog Inputs:
o Humidity Sensor (30, 31, 32): Connect according to wire colors (White, Red, Black).
o An.2 (13): Humidity Outside Humidity input. Connect the white wire of the Humidity sensor
to An.2 and the red and black together with the Humidity input red and black.
o An.3 (14): Pressure sensor (Connect + red wire to An.3 and Black – wire to Common).
6. Analog Outputs:
o An.1 (33): 0 to 10V- Light I ntensity control signal
o An.2 (34): 0 to 10V- Variable speed control signal
o COM (29): Connect the common wire of An.1 & 2 to terminal 29
7. Digital Inputs:
o Dig 1 (15): Feed overtime alarm input or wind direction selection
o Dig 2 (16): Feed counter
o Dig 3 (17): Water meter
11 AC-2000 | 8.10/8.11
4.2.5 AC-2000 Plus Low Voltage Wiring (Terminals)
NOTE: Connect each cable’s shielding wire to the grounding strip. The drawing above is an example
only.
NOTE: Users employing a CO2 sensor, refer to Appendix: Installing a CO2 sensor.
4.2.6 AC-2000 Plus Communication
AC-2000 Plus is wired to a MUX/Communicator via:
• an internal communication card (P/N C-AC-2000-C232). Connect the communication wires
shown in Section 4.2.5 directly to the MUX / Communicator OR
• an external RCLP card (see MUX / RCLP Wiring page 17, for wir ing instr uctions)
AC-2000 | 8.10/8.11 12
4.3 AC-2000 SE Wiring
The following sections detail the AC-2000 SE wir ing.
• AC-2000 Board Layout, page 12
• AC-2000 SE Relays, page 13
• AC-2000 SE High Voltage Wiring (Relays), page 14
• AC-2000 SE Terminals, page 15
• AC-2000 SE Low Voltage Wiring (Terminals), page 16
• MUX / RCLP Wiring, page 17
4.3.1 AC-2000 Board Layout
1 Ground strip 5 Key board connector
2 5 Amp fuse 6 LCD connector
3 Transformer 7 Static pressure sensor (option)
4 Voltage regulator 8 Battery
13 AC-2000 | 8.10/8.11
4.3.2 AC-2000 SE Relays
1. Relays 1 to 11: Each pair of terminals goes to one relay. These relays are fused with a
5-ampere, 250-volt slow blow fuses. The relays are normally open when not powered.
2. Relay 12: Three terminal blocks: This relay normally serves as an alarm relay. It is also fused
with a 5 ampere, 250 volt slow blow fuse, and can serve as an ordinary relay:
o NC: Normally closed contact.
o Com: Common contact.
o NO: Normally open contact.
3. Power: Three terminal blocks:
o Neutral (N): Connect to the Neutral Power line.
o Phase (~): Connect to the Phas e Po wer lin e.
o Ground (GND): Connect to a solid earth safety ground, normally with the bare safety
ground wire, or a green wire.
4. Ground: Connect the ground wire to the electrical system.
AC-2000 | 8.10/8.11 14
4.3.3 AC-2000 SE High Voltage Wiring (Relays)
NOTE: The device connections (fan, heat, cool, etc.) that are shown in the drawing are examples
only!
CAUTION Connect the AC-2000 SE power input to the protected output only!
15 AC-2000 | 8.10/8.11
4.3.4 AC-2000 SE Terminals
1. Not used.
2. Communications: Three terminal blocks for PC communication using the optional multiplexor,
MUX-2.
o RX: R ec ei ve into AC-2000 SE. With multiple controls, connect all the RX pins together.
Connect to TX at Multiplexor only.
o TX: Transmit from AC-2000 SE With multiple controls, connect all the TX pins together.
Connect to RX only at Multiplexor only.
o COM: Ground reference for communications. Do not connect shields to this pin. Connect
to COM at multiplexor also.
3. Temperature Sensors: The temperature sensor is a 2 wired black shielded cable thermistor
(RTS-2). Connect one wire to the temperature sensor terminal and the other to common
(Polarity does not matter).
4. Analog Inputs:
o An.1: Humidity sensor with wire connections according to wire colors.
o An.2: Humidity Outside Humidity input. Connect the White wire of the Humidity sensor to
An.2 and the Red and Black together with the Humidity input Red and Black.
o An.3: Pressure sensor (Connect Red (+) wireAn.3; Black (–) Common).
5. Analog Outputs:
o An.1: 0 to 10V- Light Intensity control signal.
o An.2: 0 to 10V- Variable speed control signal.
6. Digital Inputs:
o Dig 1: Feed overtime alarm input or wind direction selection.
o Dig 2: Feed counter.
o Dig 3: Water meter.
7. Relay Extension: Com - The relay extension box such as the REB-8 may be located up to 10
feet from the AC-2000 SE. Do not connect the shield to this terminal. Connect the shield to
earth ground only at one end of the cable to avoid ground loops.
o Data: This line carries data to the relay extens ion.
o Clk: This line carries a clocking signal for use by the relay extension.
AC-2000 | 8.10/8.11 16
4.3.5 AC-2000 SE Low Voltage Wiring (Terminals)
• Connect the sensor shielding wire to the grounding strip.
o 16 – Analog Input 2
o 17 – Analog Input 3
o 18 – Analog Input 1
NOTE: The above illustration is an example only!
17 AC-2000 | 8.10/8.11
4.3.6 MUX / RCLP Wiring
AC-2000 | 8.10/8.11 18
5 CONFIGURATION
Table 1: Configuration (Version 8.07)
91
Configuration
92
Ventilation Levels
93
Relay Layout
94
Sensor Layout
95
Setup Curtains
96
System Variables
97
Password
Table 2: Configuration (Version 8.09)
91
Configuration
92
Ventilation Levels
93
Relay Layout
94
Sensor Layout
95
Setup Curtains
96
System Variables
97
Password
98
Wind Chill
The installation menus are not shown on the front panel of the control. They are not used in the day-to-day
operation of the control, but only during initial installation.
To get to these menus from the default display:
1. Press MENU.
2. Enter the menu number from the Installation Menu.
• Configuration (Menu 91), page 18
• Ventilation Table (Menu 92), page 19
• Relay Layout (Menu 93), page 20
• Sensor Layout (Menu 94), page 22
• Setup Curtains (Menu 95), page 23
5.1 Configuration (Menu 91)
• Empty House: This mode prevents new alarms from starting. Alarms that were active before
entering empty house continue to be active. While in Empty House mode a blinking indication
message constantly appears. Use this mode between herds when the house is empty and you
don’t want the alarms to operate. Default: 'off'.
Automatically exiting from an empty house occurs in the following cases:
o Changing growth day
o New herd
o Switching from day '0' to day '1'
• Celsius or Fahrenheit selection.
• Communication baud rate (1200, 2400, 4800 or 9600) for hookup to a personal computer or
modem.
19 AC-2000 | 8.10/8.11
• Maximum number of ventilation levels: The AC-2000 supports up to 20 ventilation levels.
However, limiting this to a smaller number simplifies the ventilation table.
• Analog out 1 (0-3):
• Analog out 1/Analog out 2 (0-3) (0-4 AC-2000 Plus, Version 8.11):
o '0': None
o '1': Variable fan
o '2': Light
o '3': Variable heater
o '4': Variable fan #2 (AC-2000 Plus, Version 8.11)
• First tunnel level: When using tunnel ventilation, enter the ventilation level (in accordance with
the ventilation and curtain level tables) at which the system starts tunnel ventilation.
• Number of heating zones: The AC-2000 can control up to six separate heating zones. For one
zone only, the average temperature controls the heaters. For two or more zones, the assigned
sensors control the heaters in each zone (Menu 94).
• Automatic continuous temperature adjustment: The AC-2000 uses precis e l y the values
entered in the temperature tables for each growth period if this is ‘0’. For automatic interpolation
between these entries, enter ‘1’. The options are as follows:
o '0': without
o '1': temperature
o '2': temperature and Min/Max
• Barn Number: This identifies the particular barn for the personal computer at home. Use a
unique number for each AC-2000 to enable the communication program to identify each
controller.
• Curtain opening and closing times: Enter the number of seconds it takes the curtains to go
from fully closed to fully open, and from fully open to fully closed for each curtain. The AC-2000
uses this value to calculate the run time for each curtain when it moves them.
• Tunnel curtai n op ening and closing times
• Measurement Unit: Set the unit to be used when setting the house/shed dimensions. This
variable is used in calculating the wind chill correction factors (see the User Manual).
• Air Capacity Unit: ‘0’ for M
3
/hour, ‘1’ for CFM (cubic feet per minute); Default value = ‘0’
5.2 Ventil ati on Table (Menu 92)
Ventilation Level Ventilation Groups On Minutes Off Minutes Diff Var Var #2
1 1 0 0 0 0 0 0 0 0 0 0 0 0.5 9.5 0 0 0
2 1 0 0 0 0 0 0 0 0 0 0 0 1.0 9.0 0 0 0
3 1 0 0 0 0 0 0 0 0 0 0 0 2.0 8.0 0 0 0
4 1 0 0 0 0 0 0 0 0 0 0 0 3.0 7.0 0 0 0
5 1 0 0 0 0 0 0 0 0 0 0 0 5.0 5.0 0 0 0
6 1 0 0 0 0 0 0 0 0 0 0 0 1.0 0.0 0 0 0
7 1 2 0 0 0 0 0 0 0 0 0 0 0.5 1.0 0 0 0
8 1 2 0 0 0 0 0 0 0 0 0 0 1.0 1.0 0 0 0
9 1 2 0 0 0 0 0 0 0 0 0 0 1.0 0.0 0 0 0
10 1 2 3 0 0 0 0 0 0 0 0 0 0.5 1.0 0 0 0
11 1 2 3 0 0 0 0 0 0 0 0 0 1.0 1.0 0 0 0
12 1 2 3 0 0 0 0 0 0 0 0 0 1.0 0.0 0 0 0
13 1 2 3 4 0 0 0 0 0 0 0 0 0.5 1.0 0 0 0
14 1 2 3 4 0 0 0 0 0 0 0 0 1.0 1.0 0 0 0
Minimum
Ventilation
AC-2000 | 8.10/8.11 20
Ventilation Level Ventilation Groups On Minutes Off Minutes Diff Var Var #2
15 1 2 3 4 0 0 0 0 0 0 0 0 1.0 0.0 0 0 0
16 1 2 3 4 0 0 0 0 0 0 0 0 1.0 0.0 1.0 0 0
17 1 2 3 4 5 0 0 0 0 0 0 0 1.0 0.0 2.0 0 0
18 1 2 3 4 5 6 0 0 0 0 0 0 1.0 0.0 3.0 0 0
19 1 2 3 4 5 6 7 0 0 0 0 0 1.0 0.0 4.0 0 0
20 1 2 3 4 5 6 7 0 0 0 0 0 1.0 0.0 4.0 0 0
The AC-2000 increases the fan power as ventilation requirements rise. The increments should be
proportional from level to level. This means that the ventilation increases about 50% to 100% at each level.
For example, at Level One a single fan is set to 0.5 minutes on and 9.5 minutes off. At Level Two, if you set
the fan to 1.0 minute on and 9.0 minutes off, there is a 100% increase. At a much higher level, such as
ventilation level 15, an increase from 4 fans to 6 fans represents a 50% increase in fan power. Please
review the example venti lat ion tab les for this princi pl e.
The ventilation table, Menu 92, defines the fan powered ventilation levels for the poultry house. This
includes variable speed, timer and on/off fans for up to 20 levels of ventilation. At each ventilation le vel, a
cycle timer can run the highest numbered fan group used at that level. With no values in the timer on and
off fields, or only an off time or only an on time, the AC-2000 defaults to constant on operation.
Due to limited display size, the AC-2000 shows only the on-off timer or the variable speed setting at each
level. Use Menu 91, item 4 to select which setting the AC-2000 shows. However, both settings remain in
memory.
Since air movement provides a cooling effect, the AC-2000 provides a temperature differential at each
level. This is particularly important in tunnel ventilation, where the cooling effect can be (–12) °C. The
AC-2000 waits until the target temperature plus the differential before using that ventilation level.
NOTE: The ventilation table coordinates with the curtain table. For natural ventilation, one should
regard the curtain table as part of the ventilation table. The two tables together serve as one
larger table.
5.3 Relay Layout (Menu 93)
Relay Code NO/NC
1 1 0
2 2 0
3 3 0
4 4 0
5 25 0
6 26 0
7…20 0 0
Select Menu 93 for relay layout. Each relay may work normally or reversed using the NO/NC field. Most
relays should be set to normal.
There are twelve/twenty relays inside the AC-2000 SE / AC-2000 PLUS respectively, and there may be
additional relay extensions. All the relays are numbered sequentially. Assigning the relay code to each
relay causes it to assume the particular function. Simply changing the relay code changes the function of
the relay.
First Tunnel Level
21 AC-2000 | 8.10/8.11
The alarm output, code 40, should be normally closed so that the alarm activates on a power failure. In
normally closed mode, the AC-2000 turns the relay on to turn the function off, and releases the relay to turn
the function on. Usually, Relay 12 is the alarm relay since it provides both normally open and normally
closed contacts. With the extension box, Relay 20 can serve as an alarm relay instead of Relay 12.
NOTE: After defining the relay, configure System Variable (refer to the User Manual).
Code Description
1 through 8 Ventilation Group 1 through 8
9, 10 Zone A Heat: Low, High
11, 12 Zone B Heat: Low, High
13, 14 Zone C Heat: Low, High
15, 16, 17 Zone A Radiant Heat: Low, High, Ignition
18, 19, 20 Zone B Radiant Heat: Low, High, Ignition
21, 22, 23 Zone C Radiant Heat: Low, High , Ignition
24 Cooling System
25 Lighting System
26 Feeding System
27, 28 Curtain 1: Open, Close
29, 30 Curtain 2: Open, Close
31, 32, 33 Extra Systems 1 through 3
34 Circulation Fans
35, 36 Positive Pressure Optimizer: Burner, Fan
37, 38 Static Pressure Air Inlet: Open, Close
39 Fogger
40 Alarm
42, 43 Tunnel open/close
45, 46 Curtain 3: Open, Close
47, 48 Curtain 4: Open, Close
49, 50 Zone D Heat: Low, High
51, 52 Zone E Heat: Low, High
53, 54 Zone F Heat: Low, High
55 Fan 9
56 Fan 10
57 Fan 11
58 Fan 12
59 Fogger 2
AC-2000 | 8.10/8.11 22
5.3.1 Manual Relay Operation
Any relay with a code of ‘0’ is not part of the automatic system. However, it follows the NO/NC (Normally
Open, Normally Closed) specification. To turn it on manually, (for an extended time, as for installing and
for troubleshooting) specify code 0, and set NO/NC to 1. To turn it off manually, set NO/NC to 0.
This method has the advantage that the AC-2000 will not reset and return it to automatic operation, as it
does with test Menu 33. It permits the installer as much time as needed to check wiring and electrical
connections with the relay in a known position.
NOTE: Return the relay code to the correct function so that AC-2000 can operate it properly.
5.3.2 Relay Record
A permanent record of relay assignments on a small card at the AC-2000 provides important information
for servicing. By referring to the card, the service person can quickly test the correct output and identify
problems. Of course, written records of circuit breaker assignments, manual override switches, and other
connection information sho uld also be av ailab le.
5.4 Sensor Layout (Menu 94)
The AC-2000 supports up to six heating zones, each with individual heaters. The average of the zones
determines the overall house temperature for the ventilation system. Menu 94 assigns particular sensors
to the heating zones for temperature, humidity, and static pressure. It also assigns outside sensors.
Temp Zone A: 1
Temp Zone B: 0
Temp Zone C: 3
Temp Zone D: 0
Temp Zone E: 0
Temp Zone F: 0
Radiation Zone A: 1
Radiation Zone B: 0
Radiation Zone C: 0
Outside Temp: 4
Humidity A: 0
Humidity B: 1
Outside Humidity: 0
Static Pressure: 4 (Internal)
CO2 Analog Input
NOTE: For half or third house brood, set up the zones to prevent averaging in the grow end sensor. If
the cold grow end sensor averages with your heated zones, it causes the house temperature
to read too cold. This does not affect the heating, since the heaters use the individual zone
sensors. However, the ventilation may be incorrect and historical data may show incorrect
temperatures since the grow end sensor may have a much different temperature. ‘Extra’
systems (relay codes 31, 32 and 33), or positive pressure optimizer, if set to average
temperature, might work incorrectly.
23 AC-2000 | 8.10/8.11
Radiant heaters used as brooders can have their own dedicated sensors. These do not affect the average
temperature reading. If a static pressure sensor is used, it must be connected to one of the analog inputs
in place of a humidity sensor.
1. Temperature Zone Sensors A, B, C, D, E and F: Install on any of temperature inputs, 1 through
6. When partial house brooding, reduce the number of zones to exclude sensors not in the brood
area. Otherwise, sensors in the grow end will cause erroneous readings.
2. Outside Temperature Sensor: Install one of the temperature inputs, 1 through 6. Ensure that the
outside sensor has protection from direct sun and hot air currents from the poultry/animal house.
Proper placement and shielding is important to successful outside temperature measurement.
3. Humidity Zone Sensors A, B and C: Install on any analog inputs, 1 through 3.
4. Outside Humidity Sensor: Install on analog input 2 (Out Hum. - 16).
5. Internal pressure sensor: Define as analog input 4.
NOTE: If external pressure sensor RPS-1 is used, connect it to terminal 17 (Pres. Sens.) and define as
Analog Input 3.
5.5 Setup Curtains (Menu 95)
Level %1 %2 %3 %4 %Tunnel
1…9 0 0 0 0 0
10 15 15 15 15 15
11 25 25 25 25 25
12 40 40 40 40 40
13 60 60 60 60 60
14 80 80 80 80 80
15 100 100 100 100 100
16…20 0 0 0 0 100
• Enter minimum opening percentage for each curtain.
• The curtain table defines curtain levels for up to five curtains (4 natural & 1 tunnel curtains) at
natural ventilation levels.
• When in natural mode the tunnel curtain operates as a natural curtain.
• When entering tunnel ventilation mode, the side curtains are closed and the tunnel curtain opens
to the minimum % defined in the table. If static pressure increases, the tunnel opens accordingly.
• Exhaust fans may cause curtains to cling to the wiring mesh. For this reason, system variable 23
can allow the AC-2000 to turn off the fans (all eight groups) if the curtains need to move at small
openings. System variable 29 enables a static pressure/curtain movement interlock in case a
curtain (relay codes 37 and 38) controls static pressure. The AC-2000 can then turn off the fans
while adjusting the curtain to achieve the desired static pressure.
NOTE: For Menus 96 – 98, refer to the User Manual.
Minimum
Ventilation
First Tunnel Level
AC-2000 | 8.10/8.11 24
6 TROUBLESHOOTING GUIDE
Problem: Temperature Sensor does not operate
Solution:
1. Replace Temperature sensor or connect it to another terminal.
2. Test the Sensor: Disconnect the two wires of the temperature sensor and measure the
resistance.
a) For 25° C the resistance should be 30 Kohm. If the temperature is higher, the resistance
should be lower (for example at 42° C the resistance should be 15Kohm). If the temp is
less than 25°, the resistance should be higher than 30 Kohm (for example for 15° C the
resistance will be 45 Kohm).
b) If no resistance is measured (∞
) it could have been caused by a broken temperature
sensor wire.
Problem: Humidity sensor does not operate
Solution:
1. Supply Voltage: Check the 12 VDC between the Humidity Red(+) and Black(-) terminal
(it should be 7.5 V at least).
2. Check output voltage of the sensor between Humidity White (+) and Black (-). Note that it
must be 0.5 ÷ 3.0 VDC (15% to 100% of RH).
a) If the voltage is 0 or more than 3V the sensor is probably bad.
b) If the voltage is right (for example 1.5V for 50%) and the AC-2000 displays the wrong
value, it could be that this channel is bad. Move the white wire to a different analog input,
define in Menu 94 (sensor layout) and check again.
3. Replace the Humidity Sensor (for RHS-10PL replace only the tip).
Problem: Static pressure sensor does not operate
Solution:
1. Check that the internal static pressure is defined as 4 in Menu 94 (sensor layout).
2. Shut OFF all fans and close all curtains and inlets so that pressure is at 0. Go to Menu 35
(Analog Input Test) and see that the received value is 65 counts. If it is not at 65 counts,
calibrate the pressure sensor by the trimmer to 65.
3. Clean filters, and check that both tubes are not blocked.
Problem: Digital Input or pulse does not operate
Solution:
1. Disconnect the wires from the input and check the 5V between the digital input and the
common terminal.
a) If there is no 5 V then probably the input has been damaged (The lightning protection
device shorted or the pull-up resistor burned out).
2. Go to Menu 34 and short the digital input of the common. Check if ‘0’ changes to ‘1’.
3. For the pulse input (water) use Menu 37 and check that the counter increase by one for
every short across the pulse terminal.
Problem: Communication does not operate
Solution:
1. If Rx and Tx LEDs are permanently ON, switch the wires between the Rx and the Tx.
2. Check that all jumpers are in MUX position.
3. Check all house numbers. There should not be a house number defined as zero, or two
houses with same house number.
4. Check that all controllers have the same baud rate, and same as PC.
5. Connect only one controller to the network and check communication. A faulty RCLP can
cause the whole network to not communicate.
6. Replace the suspected faulty RCLP.
7. Sometimes the Opto-Coupler isolators in the communication adaptor could be damaged
from lightning and needs to be replaced.
25 AC-2000 | 8.10/8.11
Problem: Relays do not operate
Solution:
1. If only one relay is not working, check the related fuse.
2. If a group of 4 or 8 relays are not working, it could be that one of the relay coils shorted
causing the thermal fuse (automatic fuse) to short.
Problem: Sporadic resets caused by interference
Solution:
• It is recommended to install a snubber at the source of interference (for example contactors or
motors).
AC-2000 | 8.10/8.11 26
7 ELECTRICAL GROUNDING
CAUTION Always connect temperature and sensor shields to earth ground.
Avoid mixing high voltage wiring with sensor and low voltage wiring.
Keep the controller as far as possible fr om heavy contactor boxes and other sources of
electrical interference.
7.1 Ground Rods
Ground rods are used to efficiently connect the system to earth where current may be dissipated in the soil.
• Material: Ground rods should be copper clad or galvanized steel.
• Diameter: Minimum 5/8”, preferably 3/4”. Generally the larger the rod diameter, the lower it’s
resistance to current flow.
• Length: Minimum 2.5 meters (8 feet), preferably 3-meter (10-foot). A longer ground rod will
reach a soil with higher moisture content. Moist soil carries current much better than drier soil.
• Single grounding: It is important that there is only one grounding location where a rod or series
of rods are connected to each other using a ground wire.
• Independent ground rods will increase the risk of current, from a lightning strike for example,
being dissipated through one rod and reentering the system through an adjacent rod.
• Location: Close to the main circuit breaker panel and in moist soil. For example in an area that is
usually wet from a drip or a low spot where water drains. Make sure the area is well protected
from damage by lawnmowers, tractors, etc’.
• Rod installation: Drive the rod into the earth until about 10 cm (4 inches) is left above grade. If it
is impossible to drive the rod to the proper depth, it is acceptable to lay the rod horizontally, 80 cm
(2.5 feet) below grade.
In case the rod is exposed to damage, for example by lawnmowers or tractors it can be installed in a hole,
about 20 cm (8 inches) deep so that the rod is about 10 cm under grade and 10 cm above hole level.
The National Electric Code (NEC) mandates two ground rods unless you can show less
than 10 ohms resistance with one rod.
7.2 Ground Wire
The ground wire is a large copper wire that connects the main circuit breaker panel to the ground rod.
• Material: Ground rods should be copper clad or galvanized steel.
• Diameter: Typically, 16 mm (6-gauge) copper wire is sufficient. If the wire run is greater than 20
feet, 20 mm (4-gauge) wire should be used.
• Length: Minimum 2.5 meters (8 feet), preferably 3-meter (10-foot). A longer ground rod will
reach a soil with higher moisture content. Moist soil carries current much better than drier soil.
The ground wire should be protected from damage by lawnmowers, tractors, etc’. It should be buried
minimum 15 cm (6 inches) under grade for protection and enter the house as soon as possible. It is
important that the wire not be cut; it should remain continuous.
7.3 Ground Clamps
Ground wires should not be merely wrapped around a ground rod. Ground clamps are used to attach a
ground wire to a ground rod. The most common clamp is known as an acorn clamp. Make sure the ground
clamps you select are rated for outdoor use. Do not use pipe clamps rated for inside water lines or hose
clamps to attach the gro un d wire.
27 AC-2000 | 8.10/8.11
7.4 What Should Be Grounded?
Any equipment that is or could become energized, even accidentally, should be grounded. Current from
lightning, strikes objects in a random fashion. Accounts of lightning strikes reveal scenarios most of us
could not predict.
Electric circuits should be wired with a 3-wire conductor consisting of hot, neutral and grounding wires. The
grounding wire should be attached cleanly and securely to devices or systems to be grounded. The other
end of the grounding wire should be attached to the ground bus on the main panel.
7.5 Lighteni ng Protection
Because of the potential for lightning damage to electronic devices, Rotem recommends supplying lightning
protection on both the power supply and the communication terminals (if used).
7.5.1 Power Line Protection
The Rotem RPLP-1 provides lightning protection to the AC-2000 Controllers. Refer to the RPLP-1
documentation for detailed wiring instructions. While no lightning protection is perfect, the RPLP-1
significantly enhances the reliability of built-in lightning protection. In addition, Rotem recommends using an
isolation transformer in front of the RPLP-1 to help block lightning and other transients.
NOTE: Common surge protectors provide little additional protection, and may trip unnecessarily.
An isolation transformer preceding the RPLP-1 provides significant additional protection against lightning.
7.5.2 Communication Line Protection
The Rotem RCLP-1 provides communication protection for the AC-2000. Refer to the RCLP-1
documentation for detailed wiring instructions. Since outdoor communication lines can receive and conduct
powerful electromagnetic pulses into the controllers and cause significant damage, Rotem advises using a
RCLP-1 prevent damage to the units.
NOTE: Common surge protectors provide little additional protection and may trip unnecessarily.
AC-2000 | 8.10/8.11 28
8 APPENDIX: INSTALLING A CO2 SENSOR
The following section details the steps involved in installing a CO2 sensor.
8.1 Low Voltage Wiring
AC-2000 Plus, Version 8.11 supports a CO2 sensor. Wire the unit as shown below.
29 AC-2000 | 8.10/8.11
8.2 Configuri ng the CO2 Sensor
• In the CO2 sensor, verify that the J2 jumper is shorted. Refer to Figure 2.
Figure 1: J2 Jumper Shorted
• All other installation instructions are the same. Refer to the CO2 Manual (P/N: 110227) for details.
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