CAPTAIN 6 Dairy & Livestock Ventilation Controller – Setup & User Guide
Wiring, sensors, and the parameter reference for the AutoVent CAPTAIN 6 dairy and livestock ventilation controller. Version 20.1 (v201).
The CAPTAIN System
Thank you for purchasing the CAPTAIN System. It is designed for easy installation and operation. The system is designed to control curtains, heaters, and fans. The CAPTAIN System is designed for the unique challenges of dairy and animal facilities.
Main features
- Temperature sensor
- Wind speed sensor option
- Humidity option
- Battery-backed clock
- 10 relay outputs
- Adjustable temperature settings
- Touch screen display
- Manual overrides
Installing the CAPTAIN
Consider the following before installing the CAPTAIN:
- Protect the enclosure from moisture – mount it in a secure and dry place.
- Important: only drill holes in the bottom of the enclosure.
Wiring the temperature sensor
Place the temperature sensor in the middle of the building, or in a location that represents the building’s average temperature. It is important to not allow sensors to come into contact with direct sunlight.
Connect the temperature sensor to the Sensor #1 terminals. Polarity is not important.
Extending the temperature sensor
- Run 18–22 AWG wire (twisted or shielded wire if possible) from the sensor to the CAPTAIN. Keep the sensor wire away from high-voltage wire by at least 1 foot. Specifically, keep it away from the VFD output wires.
- Solder or use gel-filled crimps to connect your wires to the temperature sensor.
Connecting the wind meter
The wind meter is used to close curtains or shut off fans in high-wind conditions. CAPTAIN series controls do not sense wind direction, so it responds no matter which direction the wind comes from. Use 18–24 AWG wire.
White wire → 99 (pulse)
Black wire → 98 (Negative / 0V)
Connecting a rain sensor
You can connect a rain sensor to the system. The rain sensor closes select vent motors when it is raining. The system supports up to 3 rain sensors.
If you connected a rain sensor, the controller needs to know it. Setup parameters P40 & P41 assign the sensor to the vent motors.
Installing the rain sensor
When you are installing the wires, keep the rain sensor cord 6 inches away from high-voltage wires. The vent motor’s close signal is activated when the sensor is wetted. The position of the sensor versus the sky dictates the response.
Connecting a humidity sensor
The humidity sensor allows you to monitor and control the humidity. If humidity is too high, a vent can open or a fan can start. If you connect a humidity sensor, it needs to be activated. Activate it by selecting humidity for setup parameter P10.
Location of the humidity sensor
Mount in a central location. Keep the sensor away from heaters, or you will get a low reading when the heater is running.
Installing the humidity sensor
Route humidity sensor wires 6 inches away from high-voltage wires.
Black wire → Sensor #3 +
Powering the CAPTAIN
- AC versions come with a power cord. Plug it into a 120v outlet. Requires 120V, 5 amp.
- DC solar versions require 12VDC. Momentary maximum of 20 amps.
Connecting to ventilation equipment
The relay has 3 rows of terminals where you connect ventilation equipment. The bottom row is numbered for the corresponding relay number.
- The top row is Normally open.
- The middle row is Normally closed.
- The bottom row is Common.
Motor connector bus bars
The bus bars are aluminum strips that are intended to make it easy for low-voltage vent motors. They can be shortened or removed to allow fans, heaters, or lights to be connected instead of vent motors. To shorten them, remove the connector completely and use pliers to bend it repeatedly to break it apart.
Connecting DC motors
The CAPTAIN6PS includes a 10-amp 24v motor supply. It is prewired to run several DC vent motors. Each has a circuit breaker to protect the motors. Connect motors directly to the board as shown (connector bars installed).
Curtain motor circuit breakers
There are several curtain motor breakers. Each of them protects a motor. If a motor’s amps go too high, the center tab trips out. Press the tab in to reset.
Connecting AC vent motors
120v AC vent motors can be run directly from the board as long as they are 1/3 hp or less.
Relay #2 = Curtain 1 open signal
Relay #3 = Curtain 2 close signal
Relay #4 = Curtain 2 open signal
Relay #5 = Curtain 3 close signal
Relay #6 = Curtain 3 open signal
(This assumes P1 Curtain start relay is set to 1.)
Connecting to heaters
Typical heater wiring connections to the control are shown below.
Connecting fans
The relay outputs are pilot duty. Do not try running fan motor current through the relay or it will burn out. Use a contactor to switch the fan’s electricity. The controller will simply switch the contactor on and off.
Connecting variable-speed fans
0-10v VFDs can be connected and their speed controlled automatically by temperature. VFDs use 2 signals: a speed signal and a start signal. Wiring consists of both of these signals, which always takes at least 4 conductors.
The speed signal is dc voltage which varies between 0–10v. 10v is 100% speed; 0 = stopped (but still energized). The start signal is a Normally Open switch to tell the VFD when to energize the motor.
Multiple VFDs can be connected in series. The maximum varies by brand. The limit varies between 5 and 50 VFDs. AutoVent brand VFDs have a max of 50.
Connecting Lenze ACtech VFDs
Reconfigurable outputs
Fans, heaters, lights, and curtain motors can be mapped to any relay. The only limitation is that multiples of an equipment type use consecutive relays.
Example: if there are 4 fans (as per parameter P2), and the fan’s start relay is 1 (parameter P3), relays 1 through 4 will be the fan circuits.
Screen overview & overrides
The screen shows you what is happening. You can see the temperature and the status of the relays. Press on the temperature to go to your settings. Press the bottom row of buttons to manually override.
Overrides
Select the relay status you want. In Auto, it will operate automatically. Selecting Off or Forced allows you to avoid the control system. To exit, press the blank space on the sides.
Parameter reference
There are parameters that you can change. The parameters are labeled P1, P2, and so on. These parameters are the temperature setpoints and values you can adjust. From the parameter screen you can scroll to other parameters and edit each parameter ID.
Curtain parameters
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P101–P103 | Open temperature for Curtain #1 – Curtain #10. | 60° | 1° | 99° |
| P131–P133 | Curtain #1 – Curtain #3’s run seconds. How many seconds the curtain runs per interval. | 15 | ||
| P141–P143 | Curtain #1 – Curtain #3 pause minutes. The time the curtain waits between intervals. | 50 | ||
| P151–P153 | Curtain #1 – Curtain #3 ventilation temperature gap. The difference between open and shut temperature. | 50 | ||
| P170 | Curtain motor’s max humidity. Humidity at which the curtain will open to dry things. | 95 | ||
| P171 | Seconds the curtain will open for the humidity event. | 10 | ||
| P172 | Humidity limits temperature. Humidity will be disregarded if it is too cold. | 32 | ||
| P181–P190 | Curtain #1 – Curtain #10 sequence. If vent should wait on another curtain to close first from rain or high wind. | 0 | ||
| P191–P200 | Curtain #1 – Curtain #10. How long it takes a curtain to shut. Closing seconds for rain or high-wind events. | 100 | ||
| P201 | High-wind vents – which vents should shut from wind. | 0 | ||
| P202 | High wind MPH. | 53 | ||
| P203 | Wind override clear MPH. | 50 |
Fan temperature parameters
The temperature parameters control the starting temperature. The fans are used for cooling. They will turn on above the temperature setpoint. If humidity is connected, fan #1 can be set to clear out the high humidity.
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P301–P306 | Start temperature for Fan #1 – Fan #6. | 0° | 1° | 99° |
| P331 | Fan temperature gap. Difference between on and off. | 0.3 | ||
| P341 | Fan max MPH. If wind sensor is connected, MPH at which fans will stop. | 0 | ||
| P342 | MPH deadspan. | 0 | ||
| P350 | Fan #1 max humidity. If humidity sensor is installed, when fan #1 will start to dry out the building (set to 101% to disable humidity function). | 99%RH | ||
| P351 | Fan humidity hysteresis. | 5% | 101 | |
| P352 | Fan humidity low-temperature limit. | 32° | ||
| P361–P366 | Fan #1 – Fan #6’s high-temperature limit. | 0 |
THI index
The THI index uses the average temperature and the humidity to turn the fans on sooner. This allows the controller to think more like a cow. You can adjust how much humidity and high temperatures affect the index.
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| 391 | If THI index should be enabled. 0 = no, 1 = temperature based only, 2 = humidity and temperature based THI. | 0 | 0 | 2 |
| P392 | Hot temperature trigger, i.e. how high is the average temperature to be considered hot? | 75° | 1° | 99° |
| P393 | How many degrees are added to the effective temperature when it’s hot. | 6° | 1° | 20° |
| P394 | How many hours are included in the rolling temperature average. | 8 | 1 | 24 |
| P395 | Optional – when humidity starts affecting the effective temperature. | 60%RH | 10% | 95% |
| P396 | At 99% humidity – how much the humidity will be adding to the effective temperature. This effect tapers to zero at P396 humidity. | 6° | 0 | 20 |
Variable fan parameters
Controlling the speed signal
The VFD will run at the minimum speed when the temperature reaches the “start temperature.” As the temperature continues to rise the VFD will run faster until it reaches 100% speed. The VFD is at 100% speed when the temperature reaches “Max speed.”
You can add 2 additional 0-10v zones with a KVT-EX02 expansion module. P17 sets the number of zones you wish to use.
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P401 | Low-speed temperature for variable fans. | 50° | 1° | 99° |
| P402 | High-speed temperature for variable fans. | 85° | ||
| P403 | Low speed for variable fans. | 20 | ||
| P404 | Manual speed for variable fans. | 11 | 1 | 99° |
| P405 | Fan speed if humidity is high. | 98 | ||
| P410 | Optional Zone 2 low-speed temperature for variable fans. | 50° | 1° | 99° |
| P411 | Optional Zone 2 high-speed temperature for variable fans. | 85° | ||
| P412 | Optional Zone 2 low speed for variable fans. | 20 | ||
| P413 | Optional Zone 2 manual speed for variable fans. | 11 | 1 | 99° |
| P405 | Optional Zone 2 fan speed if humidity is high. | 98 | ||
| P420 | Optional Zone 3 low-speed temperature for variable fans. | 50° | 1° | 99° |
| P421 | Optional Zone 3 high-speed temperature for variable fans. | 85° | ||
| P422 | Optional Zone 3 low speed for variable fans. | 20 | ||
| P423 | Optional Zone 3 manual speed for variable fans. | 11 | 1 | 99° |
| P425 | Optional Zone 3 fan speed if humidity is high. | 98 | ||
| P429 | Variable speed off mode. When temperature is below P401 the speed signal will be: 0 = minimum speed / P403, 1 = off. | 0 | 0 | 1 |
Light timer
The lights are a simple time clock that goes on and off based on the time you enter. It is based on 24-hour time in 6-minute intervals.
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P560 | Time on for lights, Period A. | 0.00 | 0:04 | 24:00 |
| P561 | Time off for lights, Period A. | 0.00 | 0:04 | 24:00 |
| P562 | Time on for lights, Period B. | 0.00 | 0:04 | 24:00 |
| P563 | Time off for lights, Period B. | 0.00 | 0:04 | 24:00 |
Heater parameters
The parameters control the starting temperature.
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P601–P610 | Heater 1 – Heater 10’s setpoint°. | 60° | 1° | 100° |
| P631 | Heater hysteresis. | 2.0° |
Duty cycle fan
The duty cycle fan was intended to control a fan to provide a variable amount of air by stopping and starting it. You can set how long the cycle is to keep it from cycling too often. Cycling too often will prematurely wear the contacts and your motors.
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P850 | Start temperature. However, a 0 means it’s on always to maintain minimum ventilation. Note: to keep it from short cycling, above 95%, the fan will be on regardless. | 40° | 1° | 100° |
| P851 | Begin accelerating temperature. | 60° | 1° | 100° |
| P852 | Always on temperature. The duty cycle is at 100% and the fan will not turn off. | 80 | 1 | 120° |
| P853 | Minimum %. The least amount the duty cycle fan will be on. | 10% | 5% | 100% |
| P854 | Cycle minutes. How long an on/off cycle will be. | 3 | 1 | 20 |
Soakers
The soakers function by turning a valve on and off. The spray and dry-off times ramp between setpoints to give you an infinitely adjusted water output. For reduced water demand, each zone takes turns spraying. It controls up to 6 individual soakers. The amount of water used and how often it sprays is controlled by the temperature or temperature index.
Sprinkler temperature settings
The spray time ramps between low and high spray seconds with the barn temperature. The first zone has its own spray seconds. The remaining zones share spray settings.
The dry-off / interval time ramps between low and high dry-off minutes with the barn temperature. All zones share the dry-off minutes. The interval time is the amount of time each zone waits between sprinkles.
In the eastern USA, it is typical to spray for about 30–60 seconds. This varies with the spray tip size. The goal is to get the cow wet but not running onto her udder. When the side of the leg is wet, it is time to stop.
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P800 | Soaker start temperature. | 75° | 1° | 99° |
| P801 | Soaker high temperature. | 95° | 1° | 99° |
| P802 | Soaker dry-off minutes when the temperature is at the start temperature. | 15 | 1 | 25 |
| P803 | Soaker dry-off minutes when the temperature is at the high temperature. | 5 | 1 | 25 |
| P804 | Spray seconds at low for zone #1. | 30 | 1 | 250 |
| P805 | Spray seconds at high for zone #1. | 30 | 1 | 250 |
| P806 | Spray seconds at low for zone #2–6. | 30 | 1 | 250 |
| P807 | Spray seconds at high for zone #2–6. | 30 | 1 | 250 |
Setup configuration
| ID | Description | Default | Min | Max |
|---|---|---|---|---|
| P0 | Number of curtains. | 2 | 0 | 3 |
| P1 | Curtain starting relay. | 1 | 0 | 1 |
| P2 | Number of fans in the system. | 1 | 0 | 6 |
| P3 | Fan starting relay. | 5 | 0 | 6 |
| P4 | Number of heaters. | 2 | 6 | |
| P5 | Heater starting relay. | 8 | 6 | |
| P6 | Number of grow lights. | 0 | 1 | 1 |
| P7 | Grow lights starting relay. | 1 | 6 | |
| P8 | Number of sprinkler circuits. | 0 | 0 | 6 |
| P9 | Starting relay for the sprinklers. | 1 | 1 | 6 |
| P12 | Duty cycle fan enabled. 0 = no, 1 = yes. | 0 | 1 | |
| P13 | Duty cycle fan relay. | 0 | 6 | |
| P16 | If 0-10v zone 1 should use humidity instead of temperature. 0 = No, 1 = Yes. | 0 | 0 | 1 |
| P17 | Number of 0-10v zones in system. | 0 | 1 | 3 |
| P18 | 0-10v low-temperature volts. Normally this is zero unless you want 10v to shut the fan off. | 0 | 0 | 10 |
| P19 | 0-10v high-temperature volts. Volts at high temperature. | 10 | 0 | 10 |
| P20 | Is 2nd temperature sensor enabled. | 0 | ||
| P21 | Is humidity sensor enabled. | 0 | ||
| P22 | Temperature probe 1 offset. | 0.0 | -10.0 | +10.0 |
| P24 | Fahrenheit or Celsius. 0 = F, 1 = C. If set to 1, wind will display as KPH. | F | ||
| P27 | Wind response time minutes. | 3 | ||
| P28 | Anemometer calibration. 17 for KPH. | 25 | 2 | |
| P29 | Wind meter enabled. | 0 | ||
| P30 | Revert controller to defaults. | 3 | 1 | 5 |
| P41–P49 | Curtain #1 – Curtain #3 rain sensor uses input #. You select which input a curtain’s rain sensor is connected to. | 0 | ||
| P60 | Fan high-temperature shutoff enabled? 0 = no, 1 = yes. | |||
| P61–P70 | Turn fan 1 – fan 10 input off. | 0 | ||
| P71 | How many curtains use 2nd temperature sensor. | 0 | ||
| P72 | How many heaters use 2nd temperature sensor. | 0 | ||
| P73 | How many fans use 2nd temperature sensor. | 0 |
Specifications
| Size of enclosure | 7″ × 10″ × 6″ |
|---|---|
| Input voltage | 120 VAC |
| Output | 10 Normally open relays |
| Temperature sensor | The 3-foot cord can be extended to 100 ft. |
| Warranty | 1 year |