dixell XC642C Operating Manual

Compressor racks controller
XC642C
Operating manual
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Operating instructions
cod. 1592001330
CONTENT
1. GENERAL WARNING ______________________________________________________ 3
1.1
Please read before using this manual ____________________________________________ 3
1.2
Safety Precautions _________________________________________________________ 3
2. GENERAL DESCRIPRION __________________________________________________ 3
3. FIRST INSTALLATION _____________________________________________________ 3
3.1 How to select the gas type _________________________________________________________ 4
3.2 How to set the range of the pressure probes ___________________________________________ 4
3.3 How to set the kind of display: relative or absolute pressure _______________________________ 4
4. USER INTERFACE ________________________________________________________ 5
4.1 Displaying ______________________________________________________________________ 5
4.2 Keyboard _______________________________________________________________________ 5
4.3 Icons __________________________________________________________________________ 6
5. HOW TO SEE AND MODIFY THE SET POINT___________________________________ 6
5.1 How to see the set point of compressors ______________________________________________ 6
5.2 How to modify the set point of compressors ____________________________________________ 6
6. PARAMETERS PROGRAMMING _____________________________________________ 7
6.1 How to enter the “Pr1” parameter list _________________________________________________ 7
6.2 How to enter in parameters list “Pr2” _________________________________________________ 7
6.3 How to change parameter values ____________________________________________________ 7
7. HOW TO DISABLED AN OUTPUT ____________________________________________ 7
7.1 How to disabled an output during a maintenance session. ________________________________ 7
7.2 Output disabled signalling. _________________________________________________________ 8
7.3 Regulation with some outputs disabled. _______________________________________________ 8
8. RUNNING HOURS OF LOADS _______________________________________________ 8
8.1 How to display the running hours of a load. ____________________________________________ 8
8.2 How to reset the running hours of a load. ______________________________________________ 8
9. ALARM MENU ____________________________________________________________ 8
9.1 How to see the alarms _____________________________________________________________ 8
10. USE OF THE PROGRAMMING “HOT KEY “ ____________________________________ 9
10.1 How to program a hot key from the instrument (UPLOAD) ________________________________ 9
10.2 How to program an instrument using a hot key (DOWNLOAD) _____________________________ 9
11. KEYBOARD LOCKING _____________________________________________________ 9
11.1 How to lock the keyboard __________________________________________________________ 9
11.2 To unlock the keyboard ____________________________________________________________ 9
12. LIST OF PARAMETERS ___________________________________________________ 10
12.1 Plant dimensioning and type of regulation. ____________________________________________ 10
12.2 Others inputs configuration ________________________________________________________ 10
12.3 Display and Measurement unit _____________________________________________________ 11
12.4 Compressors regulation __________________________________________________________ 11
12.5 Liquid injection thermostat (Term. 25-26) _____________________________________________ 11
12.6 Alarms – compressor section ______________________________________________________ 11
12.7 Other _________________________________________________________________________ 12
13. CAPACITY VARIATION WITH SCREW COMPRESSORS _________________________ 12
14. THERMOSTAT FOR LIQUID INJECTION______________________________________ 13
15. TYPE OF REGULATION ___________________________________________________ 13
15.1 NEUTRAL ZONE ________________________________________________________________ 13
15.2 PROPORTIONAL BAND __________________________________________________________ 14
16. MOUNTING & INSTALLATION ______________________________________________ 15
17. ELECTRICAL CONNECTIONS ______________________________________________ 15
17.1 Probes connection _______________________________________________________________ 16
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18. RS485 SERIAL LINK______________________________________________________ 16
19. TECHNICAL FEATURES___________________________________________________ 16
20. ALARMS LIST ___________________________________________________________ 16
20.1 Types of alarms and signalling managed _____________________________________________ 16
20.2 Alarm muting ___________________________________________________________________ 18
20.3 Alarm conditions – summary table __________________________________________________ 18
21. WIRING CONNECTIONS___________________________________________________ 20
22. PARAMETERS – DEFAULT VALUES ________________________________________ 20
Operating instructions
cod. 1592001330
1. General warning
1.1 PLEASE READ BEFORE USING THIS MANUAL
This manual is part of the product and should be kept near the instrument for easy and quick reference.
The instrument shall not be used for purposes different from those described hereunder. It cannot be
used as a safety device.
Check the application limits before proceeding.
1.2
Check the supply voltage is correct before connecting the instrument.
Do not expose to water or moisture: use the controller only within the operating limits avoiding sudden
Warning: disconnect all electrical connections before any kind of maintenance.
Fit the probe where it is not accessible by the End User. The instrument must not be opened.
In case of failure or faulty operation send the instrument back to the distributor or to “Dixell S.p.a.” (see
Consider the maximum current which can be applied to each relay (see Technical Data).
Ensure that the wires for probes, loads and the power supply are separated and far enough from each
In case of applications in industrial environments, the use of mains filters (our mod. FT1) in parallel with
SAFETY PRECAUTIONS
temperature changes with high atmospheric humidity to prevent formation of condensation
address) with a detailed description of the fault.
other, without crossing or intertwining.
inductive loads could be useful.
2. General Descriprion
The XC642C is a controller for screw compressor racks, the main objective of controller is to hold the controlled variable at constant value, this function is performed via compressor power control. The controller survey the pression via 2 pression probe with 4÷20mA current output, while the regulation type is ON/OFF. Alternatively you can to use NTC or PTC temperature probes. The pression data are converted to correspondent gas temperature value according to tables that are stored into controller. The alarms management is performed by an alarm input for every user. The programming procedure is simplified by HOT KEY use. The communication is performed via ModBus RTU protocol.
3. First Installation
At first installation, it’s necessary the following:
1. Select the kind of gas.
2. Set the range of the pressure probes.
In the following paragraph a short cut for the above operations. Chapters 3.1 How to select the gas type and 3.2 How to set the range of the pressure probes will show in detail these operations.
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Operating instructions
cod. 1592001330
3.1 HOW TO SELECT THE GAS TYPE
The controller has memorised the relation between temperature and pressure for some gases.
Default gas is: r404.
If another gas is used, act as in the following:
1. Enter the Programming mode by pressing the Set and DOWN key for 3s.
2. Select the “Pr2” parameter. Then enter the password 3 –2 1.
3. Select the FtyP, kind of gas, parameter.
4. Press the “SET” key: the value of the parameter will start blinking.
5. Use “UP” or “DOWN” to change the gas amount the following: . Select the gas among the following: r22= R22; r404=R404A; 507=R507; 134=134; r717= ammonia.
6. Press “SET” to store the new value and move to the following parameter.
To exit: Press SET + UP or wait 30s without pressing a key.
NOTE: the set value is stored even when the procedure is exited by waiting the time-out to expire.
3.2 HOW TO SET THE RANGE OF THE PRESSURE PROBES
If a instrument with the following part number is used: XC642C – xxxxF, it is pre-set to work with pressure probe with the following range:
Code Range
XC642C – xxxxA opp. xxxxE -0.5 ÷11 bar (relative pressure) XC642C – xxxxB 0÷30 bar (relative pressure)
If the probes you’re using have a different range act as in the following:
To set the pressure range of the Probe 1 use the parameter::
PA04: Adjustment of read out corresponding to 4mA PA20: Adjustment of read out corresponding to 20mA
Practically these parameters has to be set with the start and end scale of the probe range.
WARNING: set a value correspondent to absolute pressure. If the transducer measures relative pressure increase the range of 1 bar.
E.I. PP11 relative pressure transducer, range -0.5÷11.0 bar. PA04=0.50; PA20=12.00. PP30 relative pressure transducer, range: 0÷30bar. PA04=1.00; PA20=31.00.
How to do:
1. Enter the Programming mode by pressing the Set and DOWN key for 3s.
2. Select the “Pr2” parameter. Then enter the password 3 –2 1.
3. Select the PA04, adjustment of read out corresponding to 4mA, parameter.
4. Press the “SET” key: the value of the parameter will start blinking.
5. Set the lower value of the probe range (lower value +1 if the probe detects relative pressure).
6. Push the SET key to confirm the value. The PA20: adjustment of read out corresponding to 20mA parameter will be displayed.
7. Set the higher value of the range (higher value +1 if the probe detects relative pressure).
8. Push the SET key to confirm the value. Next parameter will be displayed.
3.3 HOW TO SET THE KIND OF DISPLAY: RELATIVE OR ABSOLUTE PRESSURE
After setting the probe range by means of the PA04, PA20, parameters, it’s possible to select if the absolute or relative pressure has to be displayed.
The controller is pre-set for RELATIVE PRESSURE displaying.
If the absolute pressure has to be displayed, act as in the following:
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1. Enter the Programming mode by pressing the Set and DOWN key for 3s.
2. Select the “Pr2” parameter. Then enter the password 3 –2 - 1.
3. Select by pushing the UP key the rELP parameter.
4. Push the SET to modify the value.
5. Set the AbS value and push the SET key to confirm it.
To exit: Press SET + UP or wait 30s without pressing a key.
Operating instructions
4. User Interface
cod. 1592001330
4.1 DISPLAYING
UPPER DISPLAY LOWER DISPLAY ICONS
Temperature Pressure
- Working loads
- Measurement unit
- Alarm or status Icons
4.2 KEYBOARD
SET To see or modify the set point. in programming mode it selects a parameter or confirm an
Alarm menu: By holding it pressed for 3s, the current alarm is erased.
oooo
In programming mode: it browses the parameter codes or increases the displayed value. With Hot key inserted: it starts the Hot key programming procedure.
operation.
(UP) To enter the Alarm menu.
nnnn (DOWN) In programming mode: it browses the parameter codes or decreases the displayed value.
Manual restart of loads: By holding it pressed for 3s, it switches on again loads previous locked
e
e
ee
By holding it pressed for 3s the Maintaining menu is entered.
KEY COMBINATIONS
oooo
SET + n SET + o
by a safety digital input alarm.
CLOCK To display the loads running hours.
+ n
n
To lock and unlock the keyboard.
nn
n To enter the programming mode.
nn o
To exit the programming mode.
oo
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Operating instructions
4.3 ICONS
LED FUNCTION MEANING
ON Celsius degrees ON Fahrenheit degrees
bar
ON bar displaying
PSI
ON PSI displaying ON Load 1 on
Flashing Load 1 is waiting to start (1HZ). or digital input alarm for Load 1 (2Hz).
ON Load 2 on
Flashing Load 2 is waiting to start (1HZ). or digital input alarm for Load 2 (2Hz).
ON Load 3 on
Flashing Load 3 is waiting to start (1HZ). or digital input alarm for Load 3 (2Hz).
ON Load 4 on
Flashing Load 4 is waiting to start (1HZ). or digital input alarm for Load 4 (2Hz).
ON The Maintenance menu has been entered
Flashing One or more loads have been placed in maintenance status
ON Alarm is happening ON All the stored alarms have been seen.
Flashing A new alarm has happened
o Load 1 in maintenance status (2Hz).
o Load 2 in maintenance status (2Hz).
o Load 3 in maintenance status (2Hz).
o Load 4 in maintenance status (2Hz).
5. How to see and modify the set point
cod. 1592001330
5.1 HOW TO SEE THE SET POINT OF COMPRESSORS
1) Push and release the SET key;
2) The Lower display will show the “SEtC” label, will the Upper display will show its value.
To exit: push the SET key or wait for 30 without pressing any keys.
5.2 HOW TO MODIFY THE SET POINT OF COMPRESSORS
WARNING: before setting the target set points for the first time, check and, if necessary, modify the type of freon (par. FtyP) and the default unit of measurement (par. dEU) for compressors and fans
PROCEDURE
1. Set the kind of freon by means of the FtyP parameter (see chapter 3.1 How to select the gas type)
2. Set the measurement unit (dEU par.).
3. Check and if necessary modify the set point limits (LSE and HSE par.).
1. Push the SET key for more than 2 seconds;
2. The Lower display will show the “SEtC” label, will the Upper display will show its value flashing.
3. To change the Set value push the o
4. To memorise the new value and pass to the fan set point push the SET key.
5. To change its value push the o To exit: push the SET key or wait for 30 without pressing any keys.
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o or nnnn within 30s.
o o
o or nnnn within 30s.
o o
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Operating instructions
cod. 1592001330
6. Parameters programming
6.1 HOW TO ENTER THE “PR1” PARAMETER LIST
To enter the “Pr1” parameter list, user accessible, operate as follows:
1. Hold pressed the SET and DOWN key for 3s.
2. The controller displays the name of the parameter in the Lower display, its value on the Upper display.
3. Press the “SET” key: the value of the parameter will start blinking.
4. Use “UP” or “DOWN” to change the value.
5. Press “SET” to store the new value and move to the following parameter.
To exit: Press SET + UP or wait 30s without pressing a key.
NOTE: the set value is stored even when the procedure is exited by waiting the time-out to expire.
6.2 HOW TO ENTER IN PARAMETERS LIST “PR2”
The “Pr2” parameter list is protected by a security code (Password).
To access parameters in “Pr2”:
1. Enter the “Pr1” level.
2. Select “Pr2” parameter and press the “SET” key.
3. The flashing value “0 --” is displayed.
4. Use oooo or nnnn to input the security code and confirm the figure by pressing “SET” key.
5. Repeat operations 2 and 3 for the other digits.
NOTE: each parameter in “Pr2” can be removed or put into “Pr1” (user level) by pressing “SET” + nnnn. When a parameter is present also in “Pr1” decimal point of the lower display is on.
SECURITY CODE is 321
6.3 HOW TO CHANGE PARAMETER VALUES
1. Enter the Programming mode.
2. Select the required parameter with oooo or nnnn.
3. Press the “SET” key the value start blinking.
4. Use oooo or nnnn to change its value.
5. Press “SET” to store the new value and move to the following parameter.
To exit: Press SET + UP or wait 15s without pressing a key.
NOTE: the new programming is stored even when the procedure is exited by waiting the time-out.
7. How to disabled an output
To disabled an output during a maintenance session means to exclude the output from the regulation.
7.1 HOW TO DISABLED AN OUTPUT DURING A MAINTENANCE SESSION.
if the first output is enabled, or the “oFF” label if the output is disabled for a maintenance section. With compressor with more steps all the LED’s linked to the compressor and the valves are switched on..
3. Select the output by pressing the UP or DOWN key.
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1. Push the CLOCK key for 3s.
2. The LED’s of the first output is switched on, the Lower display shows the “StA” label, while the Upper display shows the “On” label
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4. To modify the status of the output: push the SET key, the status of the output starts flashing, then push the UP or DOWN to pass from “On” to “OFF” and viceversa.
5. Push the SET key to confirm the status and pass to the next output..
To exit: push the CLOCK key or wait 30 sec
Operating instructions
cod. 1592001330
7.2 OUTPUT DISABLED SIGNALLING.
If an output is disabled its led blinks (2 Hz)
7.3 REGULATION WITH SOME OUTPUTS DISABLED.
If some outputs are disabled they don’t take part to the regulation, so the regulation goes on with the other outputs.
8. Running hours of loads
8.1 HOW TO DISPLAY THE RUNNING HOURS OF A LOAD.
The controller memorises the running hours of each load.
To exit: push the CLOCK key or wait 30 sec
To see how long a load has been working follow this procedure:
1. Press and release the “CLOCK” key.
2. The led of the first output is switched on, the Upper Display shows the “HUr” label, while the Lower Display shows the shows the running hours of the first output.
3. To see the running hours of the following load press the UP key .
8.2 HOW TO RESET THE RUNNING HOURS OF A LOAD.
1. Display the running hour according to the above procedure.
2. Select the load by pressing the UP key.
3. Push the SET key (immediately on the lower display the rSt label is displayed).
4. Hold pushed the key for some seconds till the “rSt” label starts flashing and the lower display shows zero.
To exit: push the CLOCK key or wait 30 sec
NOTE: if the SET key is released within 2s, the controller reverts to display the running hours of the selected
loads.
9. Alarm Menu
The controller memorises the last 20 alarms happened, together with their duration.. To see the alarm codes see par. par. 20 Alarms list.
9.1 HOW TO SEE THE ALARMS
1. Push the o
2. The last alarm happened is showed on the Upper display, while the lower display shows its number.
3. Push again the oooo key and the other alarm are displayed starting from the most recent.
4. To see the alarm duration and push the SET key.
5. By pushing again the o
Alarms erasing.
1. Enter the Alarm Menu.
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o or SET key the next alarm is displayed.
o o
o key.
o o
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2. To erase the displayed alarm push the “SET” key till the “rSt” label will be displayed in the Lower Display. NOTE the running alarms cannot be erased..
3. To erase the whole Alarm Menu, hold pressed the “SET” key for 10s.
Operating instructions
cod. 1592001330
10. Use of the programming “HOT KEY “
10.1 HOW TO PROGRAM A HOT KEY FROM THE INSTRUMENT (UPLOAD)
1. Program one controller with the front keypad.
2. When the controller is ON, insert the “Hot key” and push oooo key; the "uPL" message appears followed a by flashing “End”
3. Push “SET” key and the End will stop flashing.
4. Turn OFF the instrument remove the “Hot Key”, then turn it ON again.
NOTE: the “Err” message is displayed for failed programming. In this case push again oooo key if you want to restart the upload again or remove the “Hot key” to abort the operation.
10.2 HOW TO PROGRAM AN INSTRUMENT USING A HOT KEY (DOWNLOAD)
1. Turn OFF the instrument.
2. Insert a programmed “Hot Key” into the 5 PIN receptacle and then turn the Controller ON.
3. Automatically the parameter list of the “Hot Key” is downloaded into the Controller memory, the “doL” message is blinking followed a by flashing “End”.
4. After 10 seconds the instrument will restart working with the new parameters.
5. Remove the “Hot Key”..
NOTE the message “Err” is displayed for failed programming. In this case turn the unit off and then on if you want to restart the download again or remove the “Hot key” to abort the operation. The unit can UPLOAD or DOWNLOAD the parameter list from its own E2 internal memory to the “Hot Key” and vice-versa.
11. Keyboard locking
11.1 HOW TO LOCK THE KEYBOARD
1. Keep the oooo and nnnn keys pressed together for more than 3 s the oooo
2. The “POF” message will be displayed and the keyboard is locked. At this
and nnnn keys.
point it is only possible to view the set point or enter the HACCP menu.
11.2 TO UNLOCK THE KEYBOARD
Keep the oooo and nnnn keys pressed together for more than 3s till the “POn” flashing message appears.
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Operating instructions
cod. 1592001330
12. List of parameters
12.1 PLANT DIMENSIONING AND TYPE OF REGULATION.
oA1, oA2, oA3, oA4, oA4 Outputs 1- 4 configuration: by means of these parameters the plant can be
dimensioned according to the number and type of compressors and/or fans and the number of steps for each one.
Each relay according to the configuration of the oA(i) parameter can work as:
- Compressor: oAi = cPr,
- Step: oAi = StP
- Injection liquid valve: oAi = Lin
- Alarm: oAi = ALr
- Not used: oAi = nu
NOTE: also the “FAn” value is present. This value must not be used..
COMPRESSORS CONFIGURATION
The regulation is always performed by the P1 Probe. With step compressors the output of compressor has to be set before the output of the step. ES. Compressor with 3 steps: oA1 = cPr, oA2= StP, oA2 = StP.
If an oAi set as step without any previous oAi set as cPr the configuration alarm “CStP” will be activated.
StP: valve outputs polarity: polarity of the outputs for capacity valves. It determines the state of the
relays associated with the capacity valves (only for homogeneous and stepped-capacity compressors):
oP=valve enabled with open contact;
cL= valve enabled with closed contact. FtyP: Freon Type: set the kind of freon used in the plant r22 = R22; r404= R404A ; 507= R507; 134=134; r717=r717 (ammonia) rTy: Type of regulation (see par.15): db = neutral zone, Pb = proportional band. Sty Activation: type of sequence
YES = rotation: this algorithm distributes the working time between the various loads to ensure even run
times. no = fixed sequence: the compressors are enabled and disabled in fixed sequence: first, second etc.
12.1.1 Probe 1 configuration
Pbc: Probe 1 setting. Cur = 4 ÷ 20 mA probe; ntc = NTC probe, Ptc = NTC probe. PA04: Adjustment of read out for the Probe 1 (used only if Pbc=Cur). corresponding to 4mA input
signal, given by the suction probe (0 ÷31 bar or 0÷450 PSI or 0÷3100KPA)
Warning: set a value correspondent to absolute pressure. If the transducer measures relative
pressure increase the range of 1 bar.
See also par. 3.2 How to set the range of the pressure probes
Ex. PP11 relative pressure transducer, range -0.5÷12.0 bar. PA04=0.5 (-0.5+1); PA20=12.0
(11+1).
PP30 relative pressure transducer, range: 0÷30bar. PA04=1; PA20=31.
PA20: Adjustment of read out for the Probe 1 corresponding to 20mA input signal, given by the suction
probe (0 ÷ 31.0 bar or 0÷450 PSI or 0÷3100KPA)) SEE THE WARNING FOR PA04. CAL: Probe 1 calibration (-12.0÷12.0 bar; -12.0÷12.0°C or -20÷20 PSI/°F) FcAL: Probe 2 calibration (-12.0÷12.0 bar; -12.0÷12.0°C or -20÷20 PSI/°F)
12.2 OTHERS INPUTS CONFIGURATION
SEP: Polarity of Low pressure-switch alarm (terminals 9-10) oP =alarm with open contacts; cL= alarm with closed contact HPP: Polarity of High pressure-switch alarm (terminals HP) oP = alarm with open contacts; cL= alarm with closed contact i1c Configurable digital input polarity (terminals 3-4):
oP: the digital input is activated by opening the contact;
CL: the digital input is activated by closing the contact. i1F Configurable digital input polarity functions (terminals 3 - 4)
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ES = Energy saving; oFF = instrument shut down; LLi = liquid level alarm
did Configurable digital input delay: (enabled only if i1F=LL) 0÷255min ALIP: Alarm input for compressors and fans polarity
oP: the digital input is activated by opening the contact;
CL: the digital input is activated by closing the contact. ALMr Manual reset of alarms for compressors and fans. no = automatic recover of alarm: regulation restart when the correspondent digital input is disabled yES = manual recover for the alarms of compressors.
Operating instructions
cod. 1592001330
12.3 DISPLAY AND MEASUREMENT UNIT
dEU: Default measurement unit for displaying (bar=bar; °C=°C, PSI=PSI; °F=°F)
NOTE1: The dEU parameter sets the measurement unit also for the set point and the followin
rES Resolution for °C and bar (in = integer; dE= decimal point) rELP Pressure displaying: AbS = absolute pressure; rEL = relative pressure.
NOTE: In this case the pressure displayed, the set point and the following parameters LSE and
HSE, LSF and HSF are automatically decreased by 1.0 bar or 14 PSI
parameters: CAL, FCAL, Pbd, ESC, LSE, HSE, Pb, ESF, LSF, HSF, LAL, HA, LAF,
HAF.
12.4 COMPRESSORS REGULATION
Pbd: Proportional band or neutral zone width (0.10÷5.00bar/0.5÷30°C or 1÷80PSI/1÷50°F)
The band (or zone) is symmetrical compared to the target set point, with extremes: set+Pbd/2 ... set-
Pbd/2. The measurement unit depends on the dEU par. ESC Energy saving value for compressors: (-20÷20bar; -50÷50°C) this value is add to the compressor
set point.
onon: Minimum time between 2 following switching ON of the same compressor (0÷255 min). oFon: Minimum time between the switching off of a compressor and the following switching on.
(0÷255min). Note: usually onon is greater than oFon.
don: Time delay between the insertion of two different compressors (0÷99.5min; res. 10s). doF: Time delay between switching off of two different compressors (0÷99.5 min; res. 10s) donF: Minimum time a stage stays switched ON (0÷99.5 min; res. 10s) FdLy: “don” delay enabled also for the first call. If enabled, the triggering of the step is delayed for a
“don” value, respect to the call. (no = “don” not enabled; yES=”don” enabled) FdLFdoF” delay enabled also for the first switching off. It enables the “doF” delay between the
request of a release and the actual switching off. (no = “doF” not enabled; yES=”doF” enabled) odo: Regulation delay on start-up: (0÷255s) on switching ON the instrument starts working after the
time delay imposed in this parameter. LSE: Minimum set point: The measurement unit depends on dEU parameter. It sets the minimum value
that can be used for the set point, to prevent the end user from setting incorrect values. HSE: Maximum set point: The measurement unit depends on dEU parameter. It sets the maximum
acceptable value for set point.
12.5 LIQUID INJECTION THERMOSTAT (TERM. 25-26)
Lit: Set point ( °C) for liquid injection thermostat (0 ÷ 150°C) Lid: Differential for liquid injection thermostat (0.1 ÷ 10.0)
12.6 ALARMS – COMPRESSOR SECTION
PAo: Alarm probe exclusion at power on. it is the period starting from instrument switch on, before an
alarm probe is signalled. (0÷255 min). During this time if the pressure is out of range all the
compressor are switched on. LAL: Low pressure (temperature) alarm – compressor section: The measurement unit depends on
dEU parameter. It’s always subtracted to the set point. When the value SET-LAL is reached the
A03C alarm is enabled, (possibly after the tAo delay time). HAL: High pressure (temperature) alarm– compressor section: The measurement unit depends on
dEU parameter. It’s always added to the set point. When the value SET+HAL is reached the A04C
alarm is enabled, (possibly after the tAo delay time). tAo: Low and High pressure (temperature) alarms delay– compressor section: (0÷255 min) time
interval between the detection of a pressure (temperature) alarm condition and alarm signalling.
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Ser: Service request: (1÷9990 hours, res. 10h) number of running hours after that the “A14”
maintenance call is generated. PEn: Low pressure-switch intervention numbers: (0÷15). If the low pressure-switch is enabled PEn
times in the PEI interval, the controller is locked. Only the manually unlocking is possible. Every
time the pressure-switch is enabled all the compressor are turned off. PEI: Pressure-switch interventions time (0÷15 min) Interval, linked to the Pen parameter, for counting
interventions of the low pressure-switch..
SPr: number of steps engaged with faulty probe. (0÷#compr). PnF: High pressure-switch intervention numbers: (0÷15 with 0 the manually unlocking is disabled) if
the high pressure-switch is enabled PnF times in the PiF interval, the controller is locked. It can be
unlocked only manually. Every time the pressure-switch is enabled all the compressors are turned
off and all the fans are turned on. PiF: Pressure-switch interventions time (1÷15 min) Interval, linked to the PEn parameter, for counting
interventions of the high pressure-switch..
Operating instructions
cod. 1592001330
12.7 OTHER
tbA Alarm relay silencing: by pushing one of the keypad buttons. no= alarm relay stays on; yES=
alarm relay is switched off by pushing any keys. oFF Switching ON/OFF enabling from keyboard: (no = disabled; yES= enabled) It permits the
switching ON/OFF of the instrument by pressing the SET key for more than 4s. Ad1: Compressors address (1 –247) It is used in monitoring system. rEL Software release for internal use. Ptb Parameter table code: readable only. Pr2 Protected parameters list
13. Capacity variation with screw compressors
Screw compressors have an their own algorithm to change the capacity engaged. As for the step compressors, the opening of the valves changes the capacity of compressors. The difference is given from the number of valves engaged. Screw compressors have always 1 valve or no valves engaged. The following tables shows how the capacities changes according to the opening and closing of the valves for screw compressor with 4 steps, with StP=cL valves work with voltage or StPP=oP: valves work without voltage. However the kind of regulation depends on the rty parameter, while the number of step depends on the setting of the oA2, oA3, oA4 parameters.
StP = cL: valve active when energised
Capacity % Compressor
25% 50% 75% 100%
StPP = oP valve active when energised
Capacity % Compressor
25% 50% 75% 100%
Relay (15-17)
CLOSED CLOSED OPEN OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN OPEN CLOSED CLOSED OPEN OPEN OPEN
Relay (15-17)
CLOSED OPEN CLOSED CLOSED CLOSED CLOSED OPEN CLOSED CLOSED CLOSED CLOSED OPEN CLOSED CLOSED CLOSED CLOSED
Valve 1(25%) Relay (16-19)
Valve 1(25%)
Relay (16-19)
Valve 2 (50%)
Relay (18-21)
Valve 2 (50%) Relay (18-21)
Valve 3 (75%)
Relay (20-22)
Valve 3 (75%)
Relay (20-22)
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F
Set
Loads state
oA1(Comp ressor)
Compressor at 100%
don
doF
don
doF
doF
don
Time
Time
Compressor disabled
Operating instructions
cod. 1592001330
14. Thermostat for liquid injection
The second probe (term. 4-7), is used to detect the temperature of the head of compressor and inject cooling liquid when the temperature Is too high. The 5th relay (25-26) is designed for this purpose. Parameters involved are: Lit: Set point ( °C) for liquid injection thermostat (0 ÷ 150°C)
Lid: Differential for liquid injection thermostat (0.1 ÷ 10.0)
15. Type of regulation
15.1 NEUTRAL ZONE
This kind of regulation is available only for compressors. The neutral zone (Pbd) is symmetrical compared to the target set point, with extremes: set+Pbd/2 ... set-Pbd/2. If the pressure (temperature) is inside this zone the controller maintains the same number of loads switched on and off, without changing anything. When the pressure (temperature) go out from the zone, regulation starts. If the pressure is greater than SET+Pbd/2, the loads are switching on with timing given by parameters: don and doF. A load is turned on only if the his safety times onon, oFon, donF are over. Regulation stops when the pressure (temperature) come back into the neutral zone.
In the following a simplify exemplum that explains the regulation in neutral zone for compressor homogeneous with 1 step for each compressors. The safety times onon, oFon and donF are not considered. In the real regulation the a load is entered or turned off only if these times are over.
Ex. Neutral zone control
oA1 = cMP; oA2 = StP; oA3 = StP; oA4 =nu rty = db neutral zone regulation FdLy = no “don” delay not enabled at first calling after an equilibrium condition. dLF = no “doF” delay not enabled at first calling after an equilibrium condition.
Relay 1 - Compressor Relay valve 1 (33%) Relay valve 1 (66%)
33% ON ON OFF
66% ON OFF ON
100% ON OFF OFF
Pression
Set + (Pbd/ 2)
Set - (Pbd/2)
Neutral Zone
Time
On
oA2(33%)
On
oA3(66%)
Delay evolution
On
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F
oA1(Compressor)
Set+Pbd/4
COMPRESSOR AT 100%
ALL LOADS ARE ACTIVE
15.2 PROPORTIONAL BAND
The regulation band (Pbd) is divided into as many parts as there are stages according to the following
Operating instructions
cod. 1592001330
formula:
# step = oAi = CPr or StP (number of compr. or steps).
The numbers of stages switched ON is proportional to the value of the input signal: when this distances itself from the target set point and enters the various bands, the compressors are switched ON, to be then turned OFF when the signal brings near the set point.
In this way if the pressure is greater than regulation band, all the compressors are on, if the pressure (temperature) is lower than the regulation band all the compressors are off. Naturally also for this regulations all the delays (don and doF) safety times (onon, oFon and donF) are valid.
Regulation according to the running hours The algorithm switch on and off the loads according to the running hours of each load. In this way the running hours are balanced.
Example: Proportional band control with four steps In this example:
oA1 = cMP; oA2 = StP; oA3 = StP; oA4 = StP: 4 steps rty = Pb proportional band regulation
FdLy = no “don” delay at first call not enabled. dLF= no “doF” delay at first call not enabled.
Relay 1 - Compressor Relay valve 1 (25%) Relay valve 1 (50%) Relay valve 1 (75%)
25% ON ON OFF OFF 50% ON OFF ON OFF 75% ON OFF OFF ON
100% ON OFF OFF OFF
Set+Pbd/2
ZIC
SET
Set-Pbd/4
Set-Pbd/2
oA2(25%)
oA3(50%)
oA4(75%)
don
doF
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F
Operating instructions
cod. 1592001330
16. Mounting & installation
The instruments are suitable only for internal use. Instruments shall be mounted on panel, in a 29x71 mm hole, and fixed using the special brackets supplied. To obtain an IP65 protection grade use the front panel rubber gasket (mod. RG-C) as shown in figure. The ambient operating temperature range is between 0÷60°C.
Avoid locations subject to heavy vibration, corrosive gases or excessive dirt. The same applies to the probes. Ensure ventilation around the instrument.
Figura 1
17. Electrical connections
The controller is provided with removable terminal blocks for wires having section not bigger than 1.0 mm2: 14 ways for analogue and digital inputs, 12 ways for relays
Note: terminals 17-19 are connected inside the controller, they are the common for the “relay n°1” with terminal 15 and “relay n°2” with terminal 16 Terminals 21-22 are connected inside the controller, they are the common for the “relay n°3 ” with terminal 18 and “relay n°4” with terminal 20. A 5-ways connector is dedicated to the TTL / RS485 interface.
Four connectors having 2-way for 0.2 mm2 wires are dedicated to: HP digital input, 12Vdc open collector alarm, LP digital input, 4..20mA analogue output.
Check power supply data before connection wires. Keep the probe and the digital input wires separate from the power cable.
Do not exceed the maximum rating current for each relay, check technical data and if the load is bigger, use filtered contactors.
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F
Before connecting cables make sure the power supply complies with the instrument’s requirements. Separate the input connection cables from the power supply cables, from the outputs and the power connections. Do not exceed the maximum current allowed on each relay, in case of heavier loads use a suitable external relay.
Operating instructions
cod. 1592001330
17.1 PROBES CONNECTION
Pressure probe (4 - 20 mA): respect the polarity. If using terminal ends be sure there are no bear parts
which could cause short circuiting or introduce noise disturbance at high frequencies. To minimise the induced disturbances use shielded cables with the shield connected to earth. Temperature probe: it is recommended to place the temperature probe away from direct air streams to correctly measure the temperature.
18. RS485 serial link
All models can be integrated into the monitoring and alarm system XJ500 using the TTL serial port. They use the standard ModBus RTU protocol, so they can be fitted in a system integrator using this protocol.
19. Technical features
Housing: Self extinguishing ABS. Case: Front panel 32x74 mm, depth 60mm (“C” format); Mounting : “C” format panel mounting in a 29x71 mm panel cut-out Protection: IP65. Frontal protection: IP65 with frontal gasket mod RG-C model. Connections: Removable terminal block 12 and 14 ways; Power supply: 12Vac/dc ± 10%, 24Vac/dc ± 10%, 50-60Hz. Power absorption: 5VA max. Display: 3 digits red led and 4 digit orange led. Inputs: 2 NTC probes, or 2 PTC probes and 2 4..20mA transducer. Digital inputs: 5 free voltage Relay outputs: 5 relay SPST 5(3)A, 250Vac Open collector: alarm output: 12V, 40mA. Analogue output: 4..20mA for fan control, trigger for fan control Serial output : TTL standard Communication protocol: ModBus – RTU Data storing: on the non-volatile memory (EEPROM). Kind of action: 1B; Pollution grade: normal; Software class: A. Operating temperature: 0÷60 °C.; Storage temperature: -25÷60 °C. Relative humidity: 20÷85% (no condensing) Measuring range: NTC probe: -40÷110°C. Resolution: 0,1 °C or 1°C; Accuracy (ambient temp. 25°C): ±0,7 °C ±1 digit
20. Alarms list
Usually alarm conditions are signalled by means of:
1. Activation of alarm output 0-12V
2. Message on proper display
3. Log of alarm: code and duration.
20.1 TYPES OF ALARMS AND SIGNALLING MANAGED
20.1.1 A12: Configuration alarm
The following configuration parameters are checked after each modification.:
OA1 ÷÷÷÷ OA4
P2P
dSEP
AOP
tOP
When these parameters are set in wrong way an alarm message is generated:
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Outputs 1- 4 configuration Second probe presence. Dynamic set point enabling Probe for analog output Probe for triac output
F
Operating instructions
cod. 1592001330
the label A12 is shown on the upper display, while the lower display signals what wrong setting has created the error: The following table contains the displayed messages:
Mess. Errata Corrige
nLod
Number of loads higher than loads available in the controller
Check number of oAi set as load, this number has to be lower of equal to the number of relay of the controller.
cStP
Load (step) configuration error
A relay oA(i) has been set as compressor without a previous relay oA(i-1) has been set as compressor. EI oA1 = StP
AOP2
P2 probe not available for the 4÷20mA output
P2 probe not available P2P =no. Enable the probe setting: P2P =yES
The second probe P2 is used to control the temperature of the engine of screw compressors. Check CtyP and set it different from Scr.
dSP2
P2 probe not available for the dynamic set point function
P2 probe not available P2P =no. Enable the probe setting: P2P =yES
The second probe P2 is used to control the temperature of the engine of screw compressors. Check CtyP and set it different from Scr.
CSP2
P2 probe not available for screw
Check CtyP and set it different from Scr.
compressor
P2CF
Wrong second probe
Set P2P = yES and PbC2 = PTC
configuration (EI.: If Cty= Scr P2 ha to be PTC)
20.1.2 E0H, E0L Pressure switch alarm, suction and condensing sections
Terminals
Low pressure switch input: 9-10, high pressure switch input: HP.
Parameters SEP: Low pressure switch polarity: It establishes if the input is activated by closing (SEP=cL) or by
opening (SEP=oP) the terminals. HPP: High pressure switch polarity: It establishes if the input is activated by closing (HPP=cL) or by opening (HPP=oP) the terminals.
Actions Low pressure: every time the inputs are activated all the compressors are switched off. The instrument
restart the standard operating mode when the input is disabled. If there are PEn activation in the PEi time, only manual resetting is allowed, by pressing the DOWN key for 3s or by turning off and on the instrument. High pressure: every time the inputs are activated all the compressors are switched off and fans are switched on. The instrument restart the standard operating mode when the input is disabled. If there are PnF activation in the PiF time, only manual resetting is allowed, by pressing the DOWN key for 3s or by turning off and on the instrument.
20.1.3 EA1÷EA4: Compressors safeties alarm
Terminals WARNING: THESE TERMINALS REQUIRE A FREE OF VOLTAGE CONNECTION.
The terminals (from 10, 11, 12, 13, 14+ ID5) really used depends on the number of loads. The protections regarding the compressors and fans are connected to these inputs. If one of these protections is enabling (E.I. for lack of oil or overheating, etc,) the corresponding load is turn off.
Parameters ALIP: It establishes if the input is activated by closing (ALIP=cL) or by opening (ALIP=oP) the terminals.
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F
Error in configuration
Operating instructions
cod. 1592001330
Actions
Every time one input is activated the corresponding output is turned off.
Recovery
Recovery depends on ALMr parameter: With ALMr = no The instrument restart the standard operating mode when the input is disabled. With ALMr = yES manual recover for the alarms of compressors and fans. Push the DOWN key for 3s.
20.1.4 P1: probe failure alarm
It is generated by failure in the probe P1 or P2.
If both compressors and fans are managed by the instrument SPr: number of steps engaged with faulty probe. (0÷# oAi = cPr or StP) It’s used only if CtyP=StP. FPr: Number of fans engaged with faulty probe. (0÷# oAi = FAn)
If the second probe is used for dynamic set point
The function is disabled and only the standard set point is used.
If the second probe is used for analog output
The function is disabled, the value of the analog output is set in the SAo parameter.
Recovery
Automatic as soon as probe restarts working.
20.1.5 HA, LA High and low pressure (temperature) alarms
This alarm signals that the pressure (temperature) is out of limits established by parameters LAL and HAL for compressors and LAF –HAF for fans. The tAo and AFd parameters set the delay between alarm condition and alarm signalling.
Action The alarm is signalled with standard action. The outputs are unchanged
20.2 ALARM MUTING
Press any buttons to silence the buzzer during an alarm condition. Hold pressed for more than 3 seconds switch off the alarm relay during an alarm condition
20.3 ALARM CONDITIONS – SUMMARY TABLE
Code Description Cause Action Reset
Alarm of
A12
Instrument
configuration
Low pressure-
E0L
switch alarm
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parameters
Low pressure switch
input enabled
Every outputs are blocked
All compressors are
turned off. Fans
unchanged.
View the previous paragraph
Automatically (if the number of activation are less than
PEn in the PEi time) when the input is disable.
- The compressors restarts working according to
the working algorithm.
Manually (if PEn activation happened in the PEi time)
When the input is disable:
a. hold pressed the Restart(DOWN)key for 3s or
b. turn off and on the instrument..
- The compressors restarts working according to
the working algorithm.
F
High pressure switch
All compressors are
The compressors are
compressor/fan input
Operating instructions
Code Description Cause Action Reset
Automatically (if the number of activation are less than
PEn in the PEi time) when the input is disable.
- Compressors and fans restart working according
to the working algorithm.
When the input is disable:
E0H
High pressure
switch alarm
input enabled
-
turned off.
- All fans are turned
on.
Manually (if PEn activation happened in the PEi time)
- hold pressed the Restart(DOWN) key for 3s or
- turn off and on the instrument.
Compressors and fans restarts working according to the
working algorithm.
P1
P1 probe
failure alarm
Probe failure or out
of range
activated according
to the SPr or PoPr
Automatically as soon as the probe restarts working.
parameters.
EA1 EA2
Load safeties
alarm
Safeties
activation.
NOTE: with step
compressors 1 input
for each compressor
has to be used.
the corresponding
load is turned off.
(with step
compressors all
relays referred to the
input are disabled).
Recovery depends on ALMr parameter:
With ALMr = no The instrument restart the standard
operating mode when the input is disabled. With ALMr = yES manual recover for the alarms of compressors and fans. Push the DOWN key for 3s.
Minimum
LA
pressure
(temperature)
alarm
compressors
Suction pressure or
temperature lower
than
SET_C-LAL value
signalling only
Automatically: as soon as the pressure or temperature
reaches the (Set_C-LAL+ differential) value.
(differential = 0.3bar or 1°C)
section
Maximum
HA
pressure
(temperature)
alarm
compressors
Suction pressure or temperature higher
than
SET_C+HAL value
signalling only
Automatically: as soon as the pressure or temperature
reaches the (Set_C + HAL - differential) value.
(differential = 0.3bar or 1°C)
section
HA2
A5
A14
Maximum
pressure
(temperature)
alarm fans
section
Liquid level
alarm
Load
maintenance
alarm
Condensing
pressure or
temperature higher
than
SET_F+HAL value
Input enabled
A load has worked
for the hour set in
the SEr parameter
signalling only
signalling only
- signalling only
Automatically: as soon as the pressure or temperature
reaches the (Set_F + HAL - differential) value.
(differential = 0.3bar or 1°C)
Automatically as soon as the input is disabled
Manually: reset the running hour of the compressor
(see par.8 Running hours of loads)
cod. 1592001330
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F
Linea
Linea
Carico2
Uscita allarme
Carico4
> 0 ÷ 10.0 bar / 30.0 °C / 80 PSI
Operating instructions
cod. 1592001330
21. Wiring connections
12V
§
40mA
IDCnf
1 3 5 7 9 1 1 13
2 4 6 10 1 2 14
Alimentaz.
12V=
gnd
Pb1
12V§
*
Pb2/PT C
ID4 ID2 ID1 ID3 LP
Carico3
Carico1
15 17 19 21 25
16 18 20 22 26
Hot Key/ TTL
HP
PTC/NTC= 4(gnd); 5(In) 4÷20mA= 4(gnd); 5(In); 6( )+
Carico 5
Connessione sonde:
Sonde 4-20mA: P1 = 5(-) – 6(+);
Sonde PTC/NTC: P1 = 5 – 4;
NOTE: l’uscita analogica è un optional.
22. Parameters – Default values
Compressor parameters Common parameters
Name °C °F bar PSI Level Description Range SEtc -18,0 0 2,3 33 -- Set point for compressors LSE ÷ HSE
oA1
CPr CPr CPr CPr
oA2
StP StP StP StP
oA3
StP StP StP StP
oA4
StP StP StP StP
StP CL CL CL CL Pr2 Valve outputs polarity oP / cL
FtYP 404 404 404 404 Pr2 Freon Type r22 / 404 / 507 / 134 / 717
rtY db db db db Pr2 Type of regulation db / Pb
StY yES yES yES yES Pr2 Compressor rotation no / YES
Pbc Cur Cur Cur Cur Pr2 Probe 1 setting cur / Ptc / ntc
PA04 0,5 7 0,5 7 Pr2 Adjustment of read out for the Probe at 4mA 0.0 bar o 0 PSI ÷ PA20 PA20 12,0 174 12,0 174 Pr2 Adjustment of read out for the Probe at 20mA PA04 ÷ 51.0 bar o 750 PSI
cAL 0 0 0 0 Pr2 Probe 1 calibration
FcAL 0 0 0 0 Pr2 Probe 2 calibration
SEP CL CL CL CL Pr2 Low pressure switch input polarity oP / cL
HPP CL CL CL CL Pr2 High pressure switch input polarity oP / cL
i1c cL cL cL cL Pr2 Configurable digital input polarity oP / cL i1F ES ES ES ES Pr2 Configurable digital input polarity functions ES / oFF / LL
did 0 0 0 0 Pr2 Configurable digital input delay 0 ÷ 255 min.
ALiP CL CL CL CL Pr2 Alarm input for compressors and fans polarity oP / cL
ALMr no no no no Pr2 Manual reset of alarms for compressors and fans no / YES
dEu °C °F bar PSI Pr2 Default measurement unit for displaying bar / °C / PSI / °F rES dE in dE in Pr2 Resolution for °C and bar in / dE
rELP rEL rEL rEL rEL Pr2 Pressure displaying rEL / AbS
Pbd 4 8 0.5 7 Pr2 Proportional band or neutral zone width
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Pr2 Outputs 1 configuration cPr / FAn / StP / ALr / LLn / nu
Pr2 Outputs 2 configuration cPr / FAn / StP / ALr / LLn / nu
Pr2 Outputs 3 configuration cPr / FAn / StP / ALr / LLn / nu
Pr2 Outputs 4 configuration cPr / FAn / StP / ALr / LLn / nu
-12.0 ÷ 12.0 °C o bar / -20 ÷ 20
-12.0 ÷ 12.0 °C o bar / -20 ÷ 20
°F o PSI
°F o PSI
/ 50 °F
F
Minimum time between 2 following switching ON of the
Minimum time between the switching off of a
Time delay between the insertion of two different
Time delay between switching off of two different
compressor
compressor
fans
dIXEL
dIXELdIXEL
dIXEL
°C °F bar PSI Level Description Range
Name
ESc 0 0 0 0 Pr2 Energy saving value for compressors
onon 5 5 5 5 Pr2
oFon 2 2 2 2 Pr2
don 0,3 0,3 0,3 0,3 Pr2
doF 0,1 0,1 0,1 0,1 Pr2
donF 0,3 0,3 0,3 0,3 Pr2 Minimum time a stage stays switched ON 0 ÷ 99.5 min. (res.10 sec. ) FdLY no no no no Pr2 “don” delay enabled also for the first call no / YES FdLF no no no no Pr2 doF” delay enabled also for the first switching off no / YES
odo 20 20 20 20 Pr2 Regulation delay on start-up 0 ÷ 255 sec. LSE -40 -40 0,3 5 Pr2 Minimum set point for compressors PA04 ÷ HSE
HSE 10 50 7,2 100 Pr2 Maximum set point for compressors LSE ÷ PA20
Lit 100 212 100 212 Pr2 Set point for cooling thermostat
Lid 10 18 10 18 Pr2 Differential for cooling thermostat
PAo 30 30 30 30 Pr2 Alarm probe exclusion at power on 0 ÷ 255 min.
LAL 15,0 30 1,5 21 Pr1
HAL 20.0 40 2,5 46 Pr1
tAo 15 15 15 15 Pr1
SEr 999 999 999 999 Pr2 Service request ( 0 = disable ) 1 ÷ 999; res 10h PEn 5 5 5 5 Pr2 Low pressure-switch intervention numbers 0 ÷ 15
PEi 15 15 15 15 Pr2 Pressure-switch interventions time 0 ÷ 255 min.
SPr 2 2 2 2 Pr2 Number of steps engaged with faulty probe 0 ÷ # compressors
PnF 5 5 5 5 Pr2
PiF 15 15 15 15 Pr2 Pressure-switch interventions time – fans section 0 ÷ 255 min.
tbA yES yES yES yES Pr2 Alarm relay silencing no / YES oFF no no no no Pr2 Switching ON/OFF enabling from keyboard no / YES Ad1 1 1 1 1 Pr2 Compressors address 1 ÷ 247
Ptb - - - Pr1 Parameter table code readable only
Pr2 Pr1 Password protected menu readable only
Operating instructions
same compressor
compressor and the following switching on
compressors
compressors
Low pressure (temperature) alarm – section High pressure (temperature) alarm– section Low and High pressure (temperature) alarms delay– compressor section
High pressure-switch intervention numbers – section
cod. 1592001330
- + 20.0 bar / - + 50.0 °C / - + 300 PSI / - + 90 °F
0 ÷ 255 min.
0 ÷ 255 min.
0 ÷ 99.5 min. ( res. 10 sec. )
0 ÷ 99.5 min. (res.10 sec. )
> 0 ÷ 30.0 bar / 100.0 °C / 430
PSI / 200 °F
> 0 ÷ 30.0 bar / 100.0 °C / 430
PSI / 200 °F
0 ÷ 255 min.
0 ÷ 15
Z.I. Via dell’Industria, 27 - 32010 Pieve d’Alpago (BL) ITALY
S.p.a.
tel. +39 - 0437 - 98 33 - fax +39 - 0437 - 98 93 13
http://www.dixell.com E-mail: dixell@dixell.com
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