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Skov DOL 634 Technical Manual

Climate controller
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DOL 634 • DOL 639
Climate Controller
Technical Manual
English For other language variants of this document we refer to:
Español Para otras variantes del idioma de este documento, visite:
Français Pour les versions dans d'autres langues de ce document veuillez consulter:
http://docs.skov.com/1200
612721 • 2022-09-30
Software version 7.8

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  • Page 1 DOL 634 • DOL 639 Climate Controller Technical Manual English For other language variants of this document we refer to: Español Para otras variantes del idioma de este documento, visite: Français Pour les versions dans d'autres langues de ce document veuillez consulter: http://docs.skov.com/1200...
  • Page 3 The power supply isolator is not included. Note • All rights belong to SKOV A/S. No part of this manual may be reproduced in any manner whatsoever without the expressed written permission of SKOV A/S in each case.
  • Page 4 DOL 634 • DOL 639 1 Product description ............................ 7 2 Work routine .............................. 9 3 Installation guide............................ 10 Selecting components...................... 10 Slave relays .......................... 10 Setup of operation form ...................... 10 View week number........................ 11 Select type of Unit of measurements.................. 11 Connecting components......................
  • Page 5 DOL 634 • DOL 639 4.2.2 Calibration of CO2 sensor (installed as CO2 sensor) .............. 33 4.2.3 Calibration of CO2 sensor (installed as auxiliary sensor) ............ 34 4.2.4 Calibration of NH3 sensor...................... 34 4.2.5 Calibration of current sensor......................  34 Calibration of light ........................ 35 Calibrating light sensor......................
  • Page 6 DOL 634 • DOL 639 6.5.2.3 Inlet without feedback ........................  59 6.5.2.4 Inlet de-ice .......................... 59 6.5.2.5 Cycle time .......................... 60 6.5.2.6 Comfort ............................ 60 6.5.3 Heating............................ 61 6.5.3.1 Room heating and stand-alone heater.................. 61 6.5.3.2 Floor heating .......................... 61 6.5.4...
  • Page 7 • S (Small) • L (Large) DOL 635 includes production functionality such as dry feeding, water, light and 24-hour clock, while DOL 634 in- cludes the basic production features such as light, water and 24-hour clock. A combination of climate and production functionality can be achieved by combining DOL 634 and DOL 635 system software.
  • Page 8 DOL 634 • DOL 639 Using a 7” display you can press the menu headlines at the top of the display to go back step-by-step in the menus. If more steps are available that what can be shown, you can press the 3 dots and select a menu from the appearing list.
  • Page 9 DOL 634 • DOL 639 2 Work routine This technical manual deals with the installation of the controller and and is aimed primarily at the technicians and electricians who will be mounting, installing and testing the controller. According to current national and in Europe also EU regulations, the installation must be carried out by expert personnel.
  • Page 10 DOL 634 • DOL 639 3 Installation guide 3.1 Selecting components There are two ways to carry out installation of the controller. At the initial installation: Use Installation wizard which will guide you through all the options of the functions.
  • Page 11 DOL 634 • DOL 639 3.4 View week number View of week number at the top of all pages. View week number 3.5 Select type of Unit of measurements The controller can display the units as both metric and US units.
  • Page 12 DOL 634 • DOL 639 3.6.2 The menu Show connection When you have selected all the components in the installation menu, the house computer will show you where to connect the individual components. See the menu for where exactly to connect the individual components.
  • Page 13 DOL 634 • DOL 639 3.6.4 Shared equipment Controllers in the same network (see Network settings [} 48]) can share equipment such as outside tempera- ture sensor and outside humidity sensor. The controller where the equipment is physically connected is called the ‘Master’. The other controllers are called ‘Clients’.
  • Page 14 DOL 634 • DOL 639 The functionality is also useful in houses where used litter is stored in the inactive zone in the house. It is possi- ble to use the air outlets in the inactive zone. 3.7.2 Brooding outlet Two-zone regulation can also be used for half house brooding.
  • Page 15 DOL 634 • DOL 639 3.7.4.1 De-icing of air inlet De-icing is a function that changes the regulation of ventilation at very low outside temperatures to cycle time in order to avoid ice formation in the air inlet. Air outlet Fans run according to cycle time.
  • Page 16 DOL 634 • DOL 639 Exhaustion % Air outlet Air inlet Heat time Figure 4: Stopping fans in air outlet. The fans in the air outlets will stop completely for a short period, e.g. 10 minutes. This will also help to prevent the formation of ice in the air inlets.
  • Page 17 DOL 634 • DOL 639 When the zone temperature deviates from Temperature set- (+ or -), the house controller adjusts the flap position. point See the menu Climate | Ventilation | Inlet correction factor Example: Zone controlled inlets 20% Negative pres-...
  • Page 18 DOL 634 • DOL 639 Select the required fan type. The setup can be viewed and customized in the menu Techni- . See also section Ad- cal | Service | Stepless | Adjust stepless justment of stepless unit [} 74]. 3.7.5.2 Speed control 3.7.5.2.1 Internal fan speed controller...
  • Page 19 DOL 634 • DOL 639 0-10 volt output The 0-10 V output makes it possible to run at low speeds on the fan, and from here to run the fan steplessly up to full speed. Low speed and Full speed...
  • Page 20 DOL 634 • DOL 639 Stepless unit MultiStep 1 MultiStep 2 Table 1: Examples of outputs Technical Manual...
  • Page 21 DOL 634 • DOL 639 3.7.5.3.1 Setup examples Number of chim- High 0 - 28,800 m3/h neys low speed. 7200 15500 Stepless 28,800 m3/h - 62,000 m3/h 7200 15500 high speed. 14400 31000 Fan output is controlled at high speeds by a sig-...
  • Page 22 DOL 634 • DOL 639 Number of chim- High 0 - 29,600 m3/h neys Stepless+MS1+MS2 run at low speed. 7400 15500 Stepless 29,600 m3/h - 7400 15500 Stepless+MS1+MS2 are completely open and 14800 31000 their fans are running steplessly up to high 25,000 speed.
  • Page 23 DOL 634 • DOL 639 The set-up requires this installation. Stepless unit Variable ON/OFF Variable ON/OFF Variable ON/OFF Variable ON/OFF Flap: stepless Flap: ON/OFF Flap: ON/OFF Flap: ON/OFF Flap: ON/OFF Fan: ON/OFF Fan: Stepless Fan: stepless Fan: stepless Fan: ON/OFF...
  • Page 24 1-16 chimneys 1-3 sensors Technically, one sensor is sufficient for 6 chimneys, but SKOV A/S usually recommends that a Dynamic Air sen- sor be installed in every other stepless exhaust unit in order to ensure optimum regulation conditions. The cli- mate controller regulates stepless air outlet without sensors based on a calculated output.
  • Page 25 DOL 634 • DOL 639 To ensure that the chimney can provide the necessary air output, the climate controller will increase the flap opening by 2% pr. minute (in relation to the stepless curve), if the fan has been running at maximum speed for more than 1 minute.
  • Page 26 DOL 634 • DOL 639 In the menu Technical | Installation | Show connections climate controller shows the terminals selected for the shared air outlets. If the setup of the shared outlet is changed, the climate con- troller will automatically remove the sharing and give a soft alarm.
  • Page 27 DOL 634 • DOL 639 Distribution of capacity between heat sources 1 and 2 (for separate heat control only) Heat distribution Sequential heating is typically used when there are two different heat sources in the house. For example: • heating pipes and air heaters •...
  • Page 28 DOL 634 • DOL 639 3.7.10 Setting of side cooling If there are more cooling pumps, they can be set to running either sequentially or in Cooling mode parallel. Side cooling relay ratio Side cooling features up to three relays.
  • Page 29 DOL 634 • DOL 639 3.7.12.1 Control methods for stir fan Relay Control method: heat, 24-hour clock or temperature. The stir fan can be regulated either in connection with a heat source, one or two temperature sensors or a 24- hour clock.
  • Page 30 DOL 634 • DOL 639 When light has been installed with a light dimmer, it can turn on using a so-called boost. It means that it turns on with the maximum intensity and that it then adjusts according to the setting.
  • Page 31 DOL 634 • DOL 639 By selecting a relay for a water meter, it is possible to shut off the water in the Water meter settings event of excessive water consumption. The relay cannot be activated in the event of power failure. In this case the water will be switched on.
  • Page 32 DOL 634 • DOL 639 4 Calibration 4.1 Calibration of Air Intake and Air Outlet The controller must be adapted to the winch motor after installation. Winch motors with feedback must be calibrated by a technician, while winch motors without feedback are cali- brated automatically once the technician has set up a time for Air inlet time.
  • Page 33 DOL 634 • DOL 639 System type Minimum value (Pa) Maximum value (Pa) Negative pressure Positive pressure - 50 Bio filter Table 4: Recommended values Select the menu Technical | Calibration | Climate | Pressure sensor Setting the minimum and maximum values must only be done when setting up the sensor.
  • Page 34 DOL 634 • DOL 639 Note: Calibration should only be carried out only by staff trained by SKOV. 4.2.3 Calibration of CO2 sensor (installed as auxiliary sensor) DOL 19 and DOL 119 CO2 sensor should be checked between each batch when the house is in...
  • Page 35 DOL 634 • DOL 639 4.3 Calibration of light Calibrate the light control after installation. When a light sensor is connected to the light source, calibration can be carried out against the measured value. Otherwise a lux meter must be used.
  • Page 36 DOL 634 • DOL 639 Measure the light level (lux meter) in an area inside the live- stock house where you would like to determine the light level (not where the sensor is positioned). Compare the value with the values in the documentation for DOL 16.
  • Page 37 DOL 634 • DOL 639 5 Testing After installation of the system a thorough test must be carried out, to ensure that the system works as intended. 5.1 Testing basis components 5.1.1 Testing temperature and air humidity sensors Read the current inside temperature and humidity 1.
  • Page 38 DOL 634 • DOL 639 The component currently set for manual control are listed in the menu Technical | Manual/Auto | Manual mode The manual control can also be deactivated here. Select the function to be tested and test the components one at a time.
  • Page 39 DOL 634 • DOL 639 to 0 %. Side inlet 1 requirement Check that the correct air inlets close completely. Set the air inlet to the required setting. Repeat the test for the installed air inlets and outlets. 5.2.1.2 Testing of Dynamic MultiStep The testing of Dynamic MultiStep is done in the same way as described for MultiStep.
  • Page 40 DOL 634 • DOL 639 Set the to 0 %. Air outlet fan speed Check that the fan stops completely. If the fans are connected as 3-wire, they should not stop com- pletely, but instead run at minimum speed. Repeat the test for each of the stepless fans.
  • Page 41 DOL 634 • DOL 639 Select the menu Technical | Manual/auto. Then select Climate and, for example, Side cooling and activate Manual mode Activate the relay for side cooling. Check that the system (cooling) is on. Deactivate the relay for side cooling.
  • Page 42 DOL 634 • DOL 639 5.2.2 Testing production functions 5.2.2.1 Testing light Select the menu Technical | Manual/auto. Then select , select the required type of light and activate Production Manual mode Test the relay-controlled light by connecting and disconnecting the relay.
  • Page 43 DOL 634 • DOL 639 Activate the testing and check that the 24-hour clock is on. Deactivate the testing and check that the 24-hour clock is off. 5.2.3 Testing management functions 5.2.3.1 Testing of current sensor This section is only relevant to livestock houses where supply current sensors are installed.
  • Page 44 DOL 634 • DOL 639 6 Service 6.1 Settings 6.1.1 Climate 6.1.1.1 Setting of Exhaustion (MultiStep) MultiStep is a method for controlling one or more exhaust units in steps, so that the exhaust output becomes stepless. The controller controls one or two exhaust units stepless from zero to 100 %, while the rest of the exhaust units are switched on in steps as required.
  • Page 45 DOL 634 • DOL 639 When two stepless fans are used, they can be set up to work in parallel or sequentially. This also applies to stepless fans in tunnel. 6.1.1.2 Fan settings Used when there are several livestock houses to ensure that the generator is not Power up delay overloaded at joint start-up of all fans after a power failure.
  • Page 46 DOL 634 • DOL 639 Stepless MultiStep 1 MultiStep 2 MultiStep 3 Tunnel MultiStep 1 Tunnel MultiStep 2 Tunnel MultiStep 3 10,000 m3/h 10,000 m3/h 20,000 m3/h 40,000 m3/h 58,300 m3/h 58,300 m3/h 116,600 m3/h The unit output at different ventilation requirements...
  • Page 47 DOL 634 • DOL 639 °C Limit 21 °C 18 °C Figure 11: Curve for outside temperature limit The Outside temperature limit can be regulated via a curve over two day numbers so that ventilation can be lim- ited when there are small animals in the house. The limit is factory set to 18 °C for both day numbers.
  • Page 48 DOL 634 • DOL 639 6.1.2 Network settings Controllers may be installed in a network. This way they may share equipment with each other. Sharing requires: • A cabled LAN between the controller providing the shared equipment and the controller also using it.
  • Page 49 DOL 634 • DOL 639 SKOV A/S recommends that you follow a standard network setup (also see FarmOn- line Explorer Technical manual). Note that if the connection between the ‘Master’ and the ‘Client’ controllers is interrupted, the ‘Client’ controller loses information from the shared equipment.
  • Page 50 DOL 634 • DOL 639 Setting the time from when the controller was operated and until the backlight Backlight timeout dimmes. 6.3 Backup Select the menu Technical | Service | Backup It is possible to save and load a backup of the current settings and page views.
  • Page 51 DOL 634 • DOL 639 6.3.2 SD card and USB stick Using an SD card or a USB stick it is possible to backup the controller setup and data including settings, pages, historical data, house name, IP address, calibration values, etc.
  • Page 52 See the status of the SD card or USB stick. USB stick status SKOV A/S recommends that you always save the setup on a USB stick before updating a program. In 2-house controllers the backup can be used to transfer all settings from one house to the second house.
  • Page 53 DOL 634 • DOL 639 During the update, all relays are released, e.g. to the shutter motors. The ventilation system will thus be open, and all other functions will disconnect. Should it be necessary to update the software while there are animals in the house, the update should be carried out in the presence of an animal expert and observing the following precaution: •...
  • Page 54 DOL 634 • DOL 639 3. Insert the USB stick containing the software update in the USB port (C) on the CPU module. In the menu Technical | Service | Install software Select the required software version. The installation process begins.
  • Page 55 6.5.1.1 Adaptive control From the factory the controller is set to adaptive control. SKOV recommend the use of adaptive control. Adaptive control is used for, for example, ventilation, tunnel cooling, heating and humidity control (as an alterna- tive to PID control).
  • Page 56 DOL 634 • DOL 639 Ventilation Temperature Figure 14: Control is ok. The ventilation adapts to the changes in the inside temperature and returns it to the required level. Temperature Temperature setpoint Ventilation Figure 15: Control is too fast. The ventilation level changes too much and does not correct the temperature fluctuations.
  • Page 57 DOL 634 • DOL 639 The control follows the settings in a stable manner The control reacts too fast and changes often. The setting can be changed to Slow. The control reacts too slowly and the deviation from the setting becomes too big.
  • Page 58 DOL 634 • DOL 639 Short time: Fast regulation. Long time: Calm/slow regulation. PID control Gain at 0-100 % flap opening. Percentage flap per degree deviation from Tempera- Gain@100 ture setpoint. Gain@1 High gain: Large reaction. Low gain: Small reaction.
  • Page 59 DOL 634 • DOL 639 6.5.2.1 Ventilation in relation to the outdoor temperature The winter factor is used to influence the ventilation with changes in the outside Winter factor temperature, before the temperature in the house is affected. Factor 1.0 does not have any effect. Factor 0.5 leads to half the ventilation in case of a drop in the outside temperature of 12°C.
  • Page 60 DOL 634 • DOL 639 6.5.2.5 Cycle time The objective of the cycle timer function is to enable the control of air currents in the house at a minimum venti- lation requirement. This function activates the ventilation briefly, thereby sending a stronger air jet through the livestock house. It ensures a thorough replacement of air inside the livestock house.
  • Page 61 DOL 634 • DOL 639 6.5.3 Heating 6.5.3.1 Room heating and stand-alone heater Heating is supplied while ventilating. This makes the temperature adjustment as stable as possible and at the same time it is ensured that ventilation or heating is supplied as soon as it is needed.
  • Page 62 DOL 634 • DOL 639 Time from the heating relay is picked up until heating is physically supplied. Pre runtime At PID regulation P band Working area for 0-10 V floor heating. Integration time Reaction time for floor heating. Longer time: slow reaction.
  • Page 63 DOL 634 • DOL 639 At cooling requirement: The cooling relay is ON for minimum this time. Minimum ON time Time from the cooling relay is picked up until cooling is physically added (flush Pre runtime time). The time elapsed from when the pads are rinsed with water until the ventilation Rinse pads before tunnel switches to tunnel.
  • Page 64 DOL 634 • DOL 639 In areas with high outside temperature and humidity, the standard humidity control does not have a large effect as it just brings in more hot and humid air into the house. It may therefore be an advantage to stop it and possibly let the inside tem- perature rise.
  • Page 65 DOL 634 • DOL 639 Factor for humidity control. Ventilation is changed by the set factor (1.5) for each 1 Outside temp. 0 °C/32 °F factor % relative humidity at an outside temperature of 0 °C. Integration time (short) Reaction to too high humidity.
  • Page 66 DOL 634 • DOL 639 6.5.5.2 Humidification ON + OFF-time of the humidification relay. Cycle time With humidification requirement: The relay is ON for minimum this time. Minimum ON time The proportional band according to which humidification is controlled. P band Integration time Reaction time for humidification.
  • Page 67 DOL 634 • DOL 639 Percentage change of the air inlet flap position if the pressure is outside the accept Delta demand band. Sample rate The sample rate is a setting of how often a new calculation is to be made.
  • Page 68 DOL 634 • DOL 639 6.5.9 NH3 ventilation Working range of the sensor. P band Reaction timer of the sensor. Integration time Longer time: slow reaction. Shorter time: faster reaction. 6.6 Adjustment of pressure 6.6.1 Negative pressure curve Based on the current ventilation requirement, the controller adjusts pressure by adjusting air inlets and air out- lets in relation to each other.
  • Page 69 DOL 634 • DOL 639 The controller has different ventilation modes depending on the variant, for example, side, tunnel and roof. It is possible to set up a ventilation course that switches between these ventilation modes to optimize the ventilation for changing climatic conditions (e.g.
  • Page 70 DOL 634 • DOL 639 : Required exhaustion as a percentage of the nominal Output output Side/Curve : Flap position 0-100 % : Tunnel opening 0-100 % Tunnel : Required pressure (Pa) Pressure setpoint : Air speed m/sec. The combined curve values can also be seen in the menu...
  • Page 71 DOL 634 • DOL 639 This pressure curve is ideal for a given system, depending on the type of winch motor used. Exhaustion in % of nominal output Air inlet fan (fan speed) Figure 28: Adjustment of positive pressure 2: Air outlets To obtain this pressure curve, the relation between exhaustion and inlets could be like this.
  • Page 72 DOL 634 • DOL 639 For each curve point, the corresponding values are shown. Press the buttons Previous curve point Next curve point access all curve points. Select a value and press for access to change it. Press the button...
  • Page 73 DOL 634 • DOL 639 By making a step between the last point of the roof curve and the first point of the Side curve - e.g. from 25% to 30% - it is possible to create a dead band in the ventilation which makes the transition between the two modes more smooth.
  • Page 74 DOL 634 • DOL 639 If a tunnel outlet has also been used for side ventilation, it will, however, still be active when changing to tunnel. Side inlet 20% opening Tunnel inlet Tunnel outlet Side ventilation Tunnel ventilation Figure 30: From the factory tunnel outlets are set to start at a 20% opening of the inlet. The air outlets can be delayed further by increasing the setting for Minimum position for air inlet before air outlet.
  • Page 75 DOL 634 • DOL 639 55.0 85.0 86.0 100.0 90.0 85.0 100.0 100.0 100.0 Table 5: Curve values for stepless unit The air outlet’s flap position and fan voltage % Flap position Fan voltage Output % Fan voltage Vent [%] Output for the stepless fan...
  • Page 76 DOL 634 • DOL 639 7 General 7.1 About SOFTWARE Software version System ID System name Build time CPU MODULE License request code MAC address SDK version Boot loader version MAIN MODULE Type Software version Serial no. Calibrated ADDITIONAL MODULES...
  • Page 77 DOL 634 • DOL 639 8 Troubleshooting instructions • Is there 230 V current on terminals A1+ A2 (if not, check installation fuses and fault current relay) • Is the change-over switch of the fan speed controller MAN/AUT set on AUT? •...
  • Page 78 DOL 634 • DOL 639 Ping test accepted. Ping test not accepted. 8.2 Temperature sensor control table 8.2.1 Table relating to DOL 114 temperature sensor control °C °F °C °F °C °F -40.0 0.00 42.8 4.60 82.4 6.80 -31.0 0.50 44.6...
  • Page 79 DOL 634 • DOL 639 8.2.2 Table relating to DOL 12 temperature sensor control °C kΩ* °C kΩ* °C kΩ* 82.50 8.08 20.71 5.29 10.72 3.73 76.84 7.96 20.09 5.22 10.45 3.67 70.60 7.83 19.48 5.15 10.19 3.61 63.97 7.68 18.90...
  • Page 80 DOL 634 • DOL 639 9 Technical data Electrical V AC Rated voltage 115*, 200* and 230/240 (*not speed controller) V AC Operating voltage 103.5-264 Frequency 50/60 Effect Max. current consumption Main module Configurable main module. Number 0-10 V: -11 inputs and 2 outputs – or - 9 inputs and 4 outputs –...
  • Page 81 DOL 634 • DOL 639 Network interface 2 x 10/100 BASE+TX RJ 45 2 x USB 2.0 A type Accessories Speed control (output) Motor load max. 6.8 A 230-240 V AC/min. 150 W. Environment °C (°F) -10 to +45 (+14 to 113) Operating temperature °C (°F) -25 to +60 (-13 to +140)
  • Page 82 DOL 634 • DOL 639 10 Functionality DOL 634 DOL 635 System software Basic Nat. Prod Prod Large Small Ventilation mode Tunnel Tunnel-Plus Combi-Tunnel (tunnel + side) Natural Natural feature can be purchased sepa- rately Ventilation and temperature Inside temperature sensor...
  • Page 83 DOL 634 • DOL 639 DOL 634 DOL 635 System software Basic Nat. Prod Prod Large Small Central exhaust control (duct pressure con- trol) Dynamic pressure control for central ex- haust duct X ** Extra ventilation (**CT-variant in side- mode)
  • Page 84 DOL 634 • DOL 639 DOL 634 DOL 635 System software Basic Nat. Prod Prod Large Small - feed mixing - number of feed components DOL 9940: - weigher shared by two houses - feed mixing - number of feed components...
  • Page 85 Support of emergency opening DOL 278T Energy consumption monitoring Status on equipment (current sensor) Remote Access (via FarmOnline) * DOL 634 LPV MS-1 and DOL 634 LPV MS-3 does not support two zones. ** Only for variants with eight MultiStep Technical Manual...
  • Page 88 SKOV A/S • Hedelund 4 • Glyngøre • DK-7870 Roslev Tel. +45 72 17 55 55 • www.skov.com • E-mail: skov@skov.dk...

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