EVCO c-pro mega RACK User Manual

PROGRAMMABLE CONTROLLERS FOR

SINGLE CIRCUIT, DUAL CIRCUIT AND

TRIPLE CIRCUIT

COMPRESSOR PACKS

UP TO 8/12 COMPRESSORS

APPLICATION MANUAL

CODE 144RACKMGE04

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

Important

Please read these instructions carefully prior to installation and use, and follow all the precautions for installation and electrical connections; keep these instructions with the device for future consultation.

The device must be disposed of in accordance with local regulations pertaining to the collection of electrical and electronic appliances.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

Table of contents

1 GENERAL INFORMATION......................................................................................................5

1.1 Description ............................................................................................................................5

2 APPLICATIONS.........................................................................................................................8

2.1 Application 1: use of the C-PRO MEGA RACK (single circuit control unit)......................9

2.2 Application 2: use of the C-PRO GIGA RACK (dual circuit control unit with separate

condensation).................................................................................................................................10

2.3 Application 3: use of the C-PRO MEGA RACK with the C-PRO EXP MEGA I/O

expansion unit (dual circuit control unit with separate condensation)...........................................11

2.4 Application 4: use of the C-PRO GIGA RACK with the C-PRO EXP GIGA I/O expansion

unit (dual circuit control unit with separate condensation)............................................................12

2.5 Controller electrical connections.........................................................................................13

2.5.1 C-PRO MEGA RACK electrical connections.............................................................13

2.5.2 C-PRO GIGA RACK electrical connections...............................................................14

2.5.3 Input and output identification tables...........................................................................15

2.6 Preset configurations...........................................................................................................19

2.6.1 C-PRO MEGA RACK preset configurations (single circuit compressor packs) ........19

2.6.2 C-PRO GIGA RACK preset configurations (dual circuit compressor packs).............20

2.7 I/O expansion unit electrical connections ...........................................................................21

2.7.1 C-PRO EXP MEGA electrical connections.................................................................21

2.7.2 C-PRO EXP GIGA electrical connections...................................................................22

2.7.3 Input and output identification tables...........................................................................23

3 COMPONENT NETWORK AND ACCESSORIES ................................................................26

3.1 Example for the C-PRO MEGA RACK and C-PRO GIGA RACK built-in versions........26

3.2 Example for the C-PRO MEGA RACK and C-PRO GIGA RACK case versions Errore. Il

segnalibro non è definito.

4 USER INTERFACE ..................................................................................................................27

4.1 Display and keypad.............................................................................................................27

4.1.1 Built-in interface.................................................Errore. Il segnalibro non è definito.

4.1.2 V- View user terminal......................................... Errore. Il segnalibro non è definito.

4.2 Page list ...............................................................................................................................28

4.3 Conditioned visibility..........................................................................................................34

5 CONFIGURATION PARAMETERS .......................................................................................35

6 REGULATIONS........................................................................................................................68

6.1 Machine configuration ........................................................................................................68

6.2 Machine and individual circuit status..................................................................................69

6.3 Compressor regulation ........................................................................................................71

6.3.1 Side band regulation.....................................................................................................71

6.3.2 Neutral zone regulation................................................................................................72

6.3.3 Side band regulation with inverter...............................................................................73

6.3.4 Neutral zone regulation with inverter ..........................................................................74

6.4 Compressor management....................................................................................................75

6.4.1 Compressors per circuit ...............................................................................................76

6.4.2 Compressor status........................................................................................................76

6.4.3 Compressor rotation.....................................................................................................77

6.4.4 Increment management................................................................................................78

6.4.5 Protective device timings.............................................................................................80

6.4.6 Startup delay from reset...............................................................................................81

6.4.7 Safety device inputs.....................................................................................................81

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

6.4.8 Inverter configuration ..................................................................................................82

6.4.9 Compressors of different nominal power.....................................................................83

6.4.10 Suction line loss of load compensation........................................................................84

6.4.11 Refrigeration power incrementing at high pressures ...................................................85

6.5 Condensation regulation......................................................................................................86

6.5.1 Side band regulation.....................................................................................................86

6.5.2 Neutral zone regulation................................................................................................86

6.5.3 Side band regulation with inverter...............................................................................87

6.5.4 Neutral zone regulation with inverter ..........................................................................88

6.5.5 Unique condensation (dual/triple circuits only)...........................................................89

6.6 Fan management..................................................................................................................90

6.6.1 Fans per circuit.............................................................................................................90

6.6.2 Fan status......................................................................................................................90

6.6.3 Fan rotation..................................................................................................................91

6.6.4 Protective device timings.............................................................................................92

6.6.5 Safety device inputs.....................................................................................................93

6.6.6 Inverter configuration ..................................................................................................93

6.7 Miscellaneous controls........................................................................................................94

6.7.1 Inverter configuration (compressors/fans)...................................................................94

6.7.2 Compressor time bands................................................................................................95

6.7.3 Fan time bands.............................................................................................................96

6.7.4 Digital input setpoint alteration....................................................................................97

6.7.5 Supervisor setpoint alteration.......................................................................................97

6.7.6 Manual operation .........................................................................................................97

6.7.7 Floating condensation management.............................................................................98

6.7.8 Temperature probes......................................................................................................99

6.7.9 Last maintenance date..................................................................................................99

6.7.10 Restore default parameters...........................................................................................99

7 DIAGNOSTICS.......................................................................................................................100

7.1 Manual and automatic alarms............................................................................................100

7.1.1 Manual alarms............................................................................................................100

7.1.2 Automatic alarms.......................................................................................................101

7.2 Alarm table........................................................................................................................101

7.3 Alarm relays......................................................................................................................104

8 LIST OF MODBUS VARIABLES..........................................................................................106

8.1.1 Modbus export table (C-PRO GIGA)........................................................................106

8.1.2 Modbus export table (C-PRO MEGA) ......................................................................122

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

1 GENERAL INFORMATION

1.1 Description

This application uses C-PRO MEGA and C-PRO GIGA controllers to manage a compressor packs composed of one, two or three circuits with a maximum number of 8 compressors (if using C-PRO MEGA controllers) or 12 compressors (if using C-PRO GIGA controllers). A compressor packs control system is required to manage the compressors in order to maintain the evaporation pressure at the desired value; more specifically, it must guarantee the production of cold, for example for the preservation of foodstuffs. Continuous generation of cold is required for this, using a process which must continue without any interruptions, except for normal maintenance operations. The C-PRO MEGA and C-PRO GIGA controllers are dedicated to this process, managing all the components of the refrigeration circuit, maintaining the required conditions with the greatest possible efficiency (greater output = lower running costs), with optimal handling of mechanical components in order to reduce breakdowns (for example, fewer start-ups = less mechanical stress). Two types of regulation may be selected for controlling pressure or temperature:

⋅ Side Band ⋅ Neutral Zone

Safety devices are managed for each circuit so as to promptly detect any malfunctions. Each safety device is associated with a particular alarm, which will be triggered in order to identify the type of fault. The outcome of certain alarms will be to shutdown the relevant mechanical devices, in order to avoid further faults; others will only indicate the fault, without having any effect on the operation of the machine. The application has a navigable user interface, by means of which it is possible to define and set all configuration and operational parameters. The user interface is subdivided into four main levels:

⋅ User ⋅ Service ⋅ Installer ⋅ System builder

Each level is protected by a separate password. At the system builder level, the user interface displays a series of modifiable configuration screens (wizards) allowing easy setting of the number of circuits, compressors, fans and the corresponding safety devices used for the protection of the mechanical devices. There are also several free-access pages, not password protected, for checking the operational status of the system at that particular time. In addition to the aforementioned four levels, there is also a Clock menu (for setting the parameters associated with the system RTC, such as for example those related to management of the time bands for variation of the setpoints). The versions have an integrated 4 x 20 character alphanumeric display, keypad and warning LEDs. Each version has an optoisolated RS-485 port (for connection to the RICS or other BMS supervision system) and a non-optoisolated CAN port (for connection to I/O expansion unit).

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

C-PRO MEGA

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

C-PRO GIGA

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2 APPLICATIONS

Using the CAN protocol, it is possible to connect an 8 relay (C-PRO EXP MEGA) or 13 relay (C-PRO EXP GIGA) expansion module to the controllers.

Management of four different types of control unit is envisaged:

1) Application 1: C-PRO MEGA RACK (for single circuit control units; C-PRO MEGA

RACK preset configuration) Total No. of digital outputs = 8 Total No. of digital inputs = 10 Total No. of analogue inputs = 8 Total No. of analogue outputs = 4

2) Application 2: C-PRO GIGA RACK (for dual circuit control units; preset

configuration) Total No. of digital outputs = 13 Total No. of digital inputs = 12 Total No. of analogue inputs = 8 Total No. of analogue outputs = 4

3) Application 3: C-PRO MEGA RACK + C-PRO EXP MEGA (e.g. for dual circuit

control units) Total No. of digital outputs = 8 + 8 = 16 Total No. of digital inputs = 10 + 8 = 18 Total No. of analogue inputs = 8 +4 = 12 Total No. of analogue outputs = 4

4) Application 4: C-PRO GIGA RACK + C-PRO EXP GIGA (e.g. for dual circuit control

units)

5) Total No. of digital outputs = 13 +13 = 26

Total No. of digital inputs = 12 +10 = 22 Total No. of analogue inputs = 8 +4 = 12 Total No. of analogue outputs = 4

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.1 Application 1: use of the C-PRO MEGA RACK (single circuit

control unit)

As a preset configuration, the C-PRO MEGA RACK is configured to manage single circuit compressor packs; the services mentioned in the figure below refer specifically to the preset configurations.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.2 Application 2: use of the C-PRO GIGA RACK (dual circuit

control unit with separate condensation)

The C-PRO GIGA RACK is pre-configured to control dual circuit compressor packs; the services mentioned in the figure below refer precisely to the preset configurations.

Compressors 1 and 2 (and related load increments) appertain to circuit 1; compressors 3 and 4 (and related load increments) appertain to circuit 2. Fans 1 and 2 appertain to circuit 1; fans 3 and 4 appertain to circuit 2.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.3 Application 3: use of the C-PRO MEGA RACK with the C-PRO

EXP MEGA I/O expansion unit (dual circuit control unit with separate condensation)

The C-PRO MEGA RACK is pre-configured to control single circuit compressor packs; the services mentioned in the figure below refer to an example of a dual circuit control unit with separate condensation.

Compressors 1, 2 and 3 appertain to circuit 1; compressors 4, 5 and 6 appertain to circuit 2. Fans 1, 2 and 3 appertain to circuit 1; fans 4, 5 and 6 appertain to circuit 2.

The C-PRO MEGA RACK and C-PRO EXP MEGA power supplies must be galvanically isolated from one another.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.4 Application 4: use of the C-PRO GIGA RACK with the C-PRO

EXP GIGA I/O expansion unit (dual circuit control unit with separate condensation)

The C-PRO GIGA RACK is factory pre-configured to control dual circuit compressor packs; the services mentioned in the figure below refer to an example of a dual circuit control unit with separate condenser, where the controller is used with an I/O expansion unit.

Compressors 1, 2 and 3 appertain to circuit 1; compressors 4, 5 and 6 appertain to circuit 2. Fans 1, 2 and 3 appertain to circuit 1; fans 4, 5 and 6 appertain to circuit 2.

The C-PRO GIGA RACK and C-PRO EXP GIGA power supplies must be galvanically isolated from one another.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.5 Controller electrical connections

The layout relating to the controllers electrical connections is shown below, with tables listing the meanings of the inputs and outputs.

2.5.1 C-PRO MEGA RACK electrical connections

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.5.2 C-PRO GIGA RACK electrical connections

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.5.3 Input and output identification tables

Card with 12 VDC + 12 VDC dual power supplies

Conn.

C1-1 VCC main card power supply input (+13 VDC) C1-2 GND main power supply reference

JA-1 VDC active probe power supply (*1) JA-2 AI 1 No.1 universal analogue input (NTC, PTC, 0..5V, 0..10V, 0..20 mA, 4..20 mA) JA-3 GND analogue input common ground

JB-1 VDC active probe power supply (*1) JB-2 AI 2 No.2 universal analogue input (NTC, PTC, 0..5V, 0..10V, 0..20 mA, 4..20 mA) JB-3 GND analogue input common ground

JC-1 VDC active probe power supply (*1) JC-2 AI 3 No.3 configurable analogue input (NTC, 0..20 mA, 4..20 mA) JC-3 AI 4 No.4 configurable analogue input (NTC, 0..20 mA, 4..20 mA) JC-4 GND analogue input common ground

JD-1 VDC active probe power supply (*1) JD-2 AI 5 No.5 configurable analogue input (NTC, 0..20 mA, 4..20 mA) JD-3 AI 6 No.6 configurable analogue input (NTC, 0..20 mA, 4..20 mA) JD-4 AI 7 No.7 configurable analogue input (NTC, 0..20 mA, 4..20 mA) JD-5 AI 8 No.8 configurable analogue input (NTC, 0..20 mA, 4..20 mA) JD-6 GND analogue input common ground

JE-1 COM digital input common connection JE-2 JE-3 JE-4 COM digital input common connection

JF-1 COM digital input common connection JF-2 DI 3 No.3 digital input 12-24 VAC/DC JF-3 DI 4 No.4 digital input 12-24 VAC/DC JF-4 DI 5 No.5 digital input 12-24 VAC/DC JF-5 DI 6 No.6 digital input 12-24 VAC/DC JF-6 COM digital input common connection

JG-1 COM digital input common connection JG-2 DI 7 No.7 digital input 12-24 VAC/DC JG-3 DI 8 No.8 digital input 12-24 VAC/DC JG-4 DI 9 No.9 digital input 12-24 VAC/DC JG-5 DI 10 No.10 digital input 12-24 VAC/DC JG-6 COM digital input common connection

YA-1 VDC power supply output connector (12 VDC) YA-2 CAN1+ connector for connecting the LOCAL CAN serial port (CAN+) YA-3 CAN1- connector for connecting the LOCAL CAN serial port (CAN-) YA-4 GND power supply reference output connector (ground)

JH-1 NC 1 relay No. 1 contact normally closed JH-2 COM 1 relay No. 1 common connection JH-3 NO 1 relay No. 1 contact normally open

JI-1 NC 2 relay No. 2 contact normally closed JI-2 COM 2 relay No. 2 common connection JI-3 NO 2 relay No. 2 contact normally open

JK-1 COM 3 relay No. 3 common connection JK-2 NO 3 relay No. 3 contact normally open

Abbre

DI 1 No.1 digital input 12-24 VAC/DC DI 2 No.2 digital input 12-24 VAC/DC

Description

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

Conn.

JK-3 COM 4 relay No. 4 common connection JK-4 NO 4 relay No. 4 contact normally open JK-5 COM 5 relay No. 5 common connection JK-6 NO 5 relay No. 5 contact normally open

JL-1 COM 6 relay No. 6 common connection JL-2 NO 6 relay No. 6 contact normally open JL-3 COM 7 relay No. 7 common connection JL-4 NO 7 relay No. 7 contact normally open JL-5 COM 8 relay No. 8 common connection JL-6 NO 8 relay No. 8 contact normally open

YC-1 RS485+ connector for connecting the RS485 serial port (RS485+) YC-2 RS485- connector for connecting the RS485 serial port (RS485-) YC-3 GND connector for connecting the RS485 serial port (ground)

JM-1 AO 1 No. 1 analogue output (0,5 .. 10 V / 0 .. 20 mA / 4 .. 20 mA) JM-2 AO 2 No. 2 analogue output (0,5 .. 10 V / 0 .. 20 mA / 4 .. 20 mA) JM-3 AO 3 No. 3 analogue output (0,5 .. 10 V / 0 .. 20 mA / 4 .. 20 mA) JM-4 AO 4 No. 4 analogue output (0,5 .. 10 V / 0 .. 20 mA / 4 .. 20 mA) JM-5 GND analogue output common ground

C2-1 VCC* serial port and optoisolated analogue output secondary power supply input (+15 VDC) C2-2 GND* secondary power supply reference

Abbre

YB PRG not used

Description

* VDC=12.5 V Imax=200 mA (as the sum of the current for all VDC terminals).

Card with 24 VAC/DC power supply

Conn.

CA-1 VCC main card power supply input (23 V AC/DC) CA-2 VCC main card power supply input (23 V AC/DC)

Abbre

Description

Warning:

With reference to the “Power supply” entries, the secondary power supply feeds the following services:

• the analogue outputs

• the standard RS-485 port

• the optional RS-485 port (or RS-232 port). So that these services are optoisolated, the main power supply and the secondary power supply must be galvanically isolated from one another.

If the controller is powered with 24 VAC/DC (i.e. by means of the connector hereinafter referred to as CA), the following services will not be optoisolated:

• the analogue outputs

• the standard RS-485 port

• the optional RS-485 port (or RS-232 port).

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

Other connectors (not present on the C-PRO MEGA RACK controller)

Conn.

JN-1 NC 9 relay No. 9 contact normally closed JN-2 COM 9 relay No. 9 common connection JN-3 NO 9 relay No. 9 contact normally open

JO-1 NC 10 relay No. 10 contact normally closed JO-2 COM10 relay No. 10 common connection JO-3 NO 10 relay No. 10 contact normally open

JP-1 COM11 relay No. 11 common connection JP-2 NO 11 relay No. 11 contact normally open JP-3 COM12 relay No. 12 common connection JP-4 NO 12 relay No. 12 contact normally open JP-5 COM13 relay No. 13 common connection JP-6 NO 13 relay No. 13 contact normally open

JQ-1 DI11 No. 11 digital input 230 VAC JQ-2 DI12 No. 12 digital input 230 VAC JQ-3 CONHV digital input common connection 230 VAC

Abbre

Description

Second RS-485 port (on request)

Conn.

YE-1 RS485- RS 485 - connector for connecting to supervision system YE-2 RS485+ RS 485 + connector for connecting to supervisor system YE-3 GND GND connector for connecting to supervision system, via RS485

Abbre

Description

RS-232 port (available on request, as an alternative to the second RS-485 port)

Conn.

YF-1 5Vdc RS 232 9 pole connector YF-2 YF-3

YF-4 YF-5 GND RS 232 9 pole connector YF-6 YF-7 RTS RS 232 9 pole connector -

YF-8 CTS RS 232 9 pole connector -

Abbre

Description

Tx RS 232 9 pole connector - Transmission Signal Rx RS 232 9 pole connector - Reception Signal

DTR/D

RS 232 9 pole connector -

DTR/D

RS 232 9 pole connector -

Jumper and LED meanings

JMP1 AI1 analogue input selection

Jumper not inserted 0 – 10 V input Jumper inserted 0 – 5 V, 0 – 20 mA, 4 – 20 mA, NTC, PTC input

JMP2 AI2 analogue input selection

Jumper not inserted 0..10 V input Jumper inserted 0 – 5 V, 0 – 20 mA, 4 – 20 mA, NTC, PTC input

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

JMP3 CAN terminator

Jumper not inserted Jumper inserted

Termination (120?) not inserted Termination (120?) inserted

JMP4 Local CAN serial port baud rate selection

Jumper A inserted Jumper B inserted

Baud rate = 20K

B A

Jumper A inserted Jumper B not inserted Baud rate = 50K

B A

Jumper A not inserted Jumper B inserted

Baud rate = 125K

B A

Jumper A not inserted Jumper B not inserted Baud rate = 500K

JMP5 RS-485 terminator

Jumper not inserted Jumper inserted

Termination (120?) not inserted Termination (120?) inserted

JMP6 Analogue output selection

A B C

Jumper A inserted Jumper B inserted Jumper C inserted Jumper D inserted

Output AO1 under current Output AO2 under current Output AO3 under current Output AO4 under current

D A B C

Jumper A not inserted Jumper B not inserted Jumper C not inserted Jumper D not inserted

Output AO1 under tension Output AO2 under tension Output AO3 under tension Output AO4 under tension

PLEASE NOTE:

It is not sufficient to merely set the jumper to configure the signal distributed by the analogue output, the controller machine parameters must also be set (see the chapter “Configuration of the signal distributed by the analogue output” in the Hardware Manual).

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.6 Preset configurations

The controller preset configurations are reported below.

2.6.1 C-PRO MEGA RACK preset configurations (single circuit compressor packs)

Analogue inputs

Suction probe Supply probe

Terminal Analogue input

AI1 AI2

Terminal Analogue output

Terminal Digital input

DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8

Terminal Digital output

DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8

Digital outputs

4 Compressors 3 Fans 1 global alarm relay

Input/output configuration

No. 1 analogue input (4..20 mA) No. 2 analogue input (4..20 mA)

No. 1 digital input No. 2 digital input No. 3 digital input No. 4 digital input No. 5 digital input No. 6 digital input No. 7 digital input No. 8 digital input

No. 1 digital output No. 2 digital output No. 3 digital output No. 4 digital output No. 5 digital output No. 6 digital output No. 7 digital output No. 8 digital output

Description

By default – not configured

Suction probe Supply probe

Description

Compressor 1 thermal Compressor 2 thermal Compressor 3 thermal Compressor 4 thermal Fan thermal common connection Fluid level Low pressure (suction) pressure-switch High pressure (supply) pressure-switch

Description

Compressor 1 Global alarm relay Compressor 2 Compressor 3 Compressor 4 Fan 1 Fan 2 Fan 3

Digital inputs

4 compressor thermals Fan thermal common connections Fluid level Low pressure pressure-switch High pressure pressure-switch

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.6.2 C-PRO GIGA RACK preset configurations (dual circuit compressor packs)

Analogue inputs

Suction probe C1 Supply probe C1 Suction probe C2 Supply probe C2

Digital outputs

2 Compressors C1 2 Compressors C2 1 compressor increment 2 Fans C1 2 Fans C2 1 global alarm relay

Digital inputs

4 compressor thermals Fan thermal common connection C1 Fan thermal common connection C2 Fluid level C1 Fluid level C2 Low pressure pressure-switch C1 Low pressure pressure-switch C2 High pressure pressure-switch C1 High pressure pressure-switch C2

Input/output configuration

Terminal Analogue input

AI 1 AI 2 AI 3 AI 4

Terminal Analogue output

Terminal Digital input

DI 1 DI 2 DI 3 DI 4 DI 5 DI 6 DI 7 DI 8 DI 9 DI 10 DI 11 DI 12

Terminal Digital output

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8 DO 9 DO 10 DO 11 DO 12 DO 13

No. 1 analogue input (4..20 mA) No. 2 analogue input (4..20 mA) No. 3 analogue input (4..20 mA) No. 4 analogue input (4..20 mA)

No. 1 digital input No. 2 digital input No. 3 digital input No. 4 digital input No. 5 digital input No. 6 digital input No. 7 digital input No. 8 digital input No. 9 digital input No. 10 digital input No. 11 digital input No. 12 digital input

No. 1 digital output No. 2 digital output No. 3 digital output No. 4 digital output No. 5 digital output No. 6 digital output No. 7 digital output No. 8 digital output No. 9 digital output No. 10 digital output No. 11 digital output No. 12 digital output No. 13 digital output

By default – not configured

Description

Suction probe C1 Supply probe C1 Suction probe C2 Supply probe C2

Description

Compressor 1 thermal Compressor 2 thermal Compressor 3 thermal Compressor 4 thermal Fan thermal common connection C1 Fan thermal common connection C2 Fluid level C1 Fluid level C2 Low pressure (suction) pressure-switch C1 Low pressure (suction) pressure-switch C2 High pressure (supply) pressure-switch C1 High pressure (supply) pressure-switch C2

Description

Compressor 1 Increment 1 compressor 1 Compressor 2 Increment 1 compressor 2 Compressor 3 Increment 1 compressor 3 Compressor 4 Increment 1 compressor 4 Global alarm relay Fan 1 Fan 2 Fan 3 Fan 4

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.7 I/O expansion unit electrical connections

The layout relating to the expansion unit electrical connections is shown below, with tables listing the meanings of the inputs and outputs.

2.7.1 C-PRO EXP MEGA electrical connections

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.7.2 C-PRO EXP GIGA electrical connections

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

2.7.3 Input and output identification tables

Card with 12 VDC power supply

Abbre

Description

AI1 No.1 configurable analogue input (NTC, 0..20 mA, 4..20 mA) AI2 No.2 configurable analogue input (NTC, 0..20 mA, 4..20 mA) AI3 No.3 configurable analogue input (NTC, 0..20 mA, 4..20 mA) AI4 No.4 configurable analogue input (NTC, 0..20 mA, 4..20 mA)

DI1 No.1 digital input 12-24 VAC/DC DI2 No.2 digital input 12-24 VAC/DC DI3 No.3 digital input 12-24 VAC/DC DI4 No.4 digital input 12-24 VAC/DC

DI5 No.5 digital input 12-24 VAC/DC DI6 No.6 digital input 12-24 VAC/DC DI7 No.7 digital input 12-24 VAC/DC DI8 No.8 digital input 12-24 VAC/DC

PRG not used

Conn.

C1-1 VCC card power supply input (+13 V DC) C1-2 GND power supply reference

JD-1 VDC active probe power supply (*1) JD-2 JD-3 JD-4 JD-5 JD-6 GND analogue input common ground

JF-1 COM digital input common connection JF-2 JF-3 JF-4 JF-5 JF-6 COM digital input common connection

JG-1 COM digital input common connection JG-2 JG-3 JG-4 JG-5 JG-6 COM digital input common connection

YA-1 VDC power supply output connector (12 VDC) YA-2 CAN1+ connector for connecting the CAN serial port (CAN+) YA-3 CAN1- connector for connecting the CAN serial port (CAN-) YA-4 GND power supply output reference connector (ground)

JH-1 NC 1 relay No. 1 contact normally closed JH-2 COM 1 relay No. 1 common connection JH-3 NO 1 relay No. 1 contact normally open

JI-1 NC 2 relay No. 2 contact normally closed JI-2 COM 2 relay No. 2 common connection JI-3 NO 2 relay No. 2 contact normally open

JK-1 COM 3 relay No. 3 common connection JK-2 NO 3 relay No. 3 contact normally open JK-3 COM 4 relay No. 4 common connection JK-4 NO 4 relay No. 4 contact normally open JK-5 COM 5 relay No. 5 common connection JK-6 NO 5 relay No. 5 contact normally open

C2-1 VCC not used C2-2 GND not used

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

* VDC=12.5 V Imax = 200 mA (as the sum of the current values for all VDC terminals).

Card with 24 V AC/DC power supply

Conn.

CA-1 VCC card power supply input (24 VAC/DC) CA-2 VCC card power supply input (24 VAC/DC)

Abbre

Description

Other connectors (not present on the C-PRO EXP MEGA expansion unit)

Conn.

JN-1 NC 9 relay No. 9 contact normally closed JN-2 COM 9 relay No. 9 common connection JN-3 NO 9 relay No. 9 contact normally open

JO-1 NC 10 relay No. 10 contact normally closed JO-2 COM10 relay No. 10 common connection JO-3 NO 10 relay No. 10 contact normally open

JQ-1 JQ-2 DI10 No. 10 digital input 230 VAC JQ-3 CONHV digital input common connection 230 VAC

Abbre

DI9 No. 9 digital input 230 VAC

Description

Jumper and LED meanings

JMP3 CAN terminator

Jumper not inserted Jumper inserted

Termination (120?) not inserted Termination (120?) inserted

JMP4 Local CAN serial port baud rate selection

Jumper A inserted Jumper B inserted

Baud rate = 20K

B A

Jumper A inserted Jumper B not inserted Baud rate = 50K

B A

Jumper A not inserted Jumper B inserted

Baud rate = 125K

B A

Jumper A not inserted Jumper B not inserted Baud rate = 500K

PLEASE NOTE:

The C-PRO MEGA RACK and the C-PRO GIGA RACK are configured by default to be able to work with an expansion unit (with standard configuration) and with a user interface (with standard

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

configuration) by simply connecting the network components. For further information please refer to the chapter “CAN connection” in the Hardware Manual.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

3 COMPONENT NETWORK AND ACCESSORIES

3.1 Example

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

4 USER INTERFACE

4.1 Display and keypad

For the application there is an interface integrated with the controller (hereinafter referred to as “built-in”). It has a 4x20 character alphanumeric display, offer a range of keys for navigation/editing pages and several LEDs for viewing certain associated events.

The keypad has 6 page navigation and value editing keys with the following functions:

- UP and DOWN: alters the parameters in editing mode; otherwise, it is used for moving the

cursor

- LEFT and RIGHT: displays the screens in succession

- ENTER: confirms the value displayed in editing mode; otherwise, it runs any commands

associated with the text at the cursor point. If pressed for approx. 2 seconds while viewing an alarm page, it allows the alarm to be reset. If viewing the alarm pages, each press scrolls through the active alarms.

- ESC: cancels the present value if in editing mode; otherwise, it recalls any default page

associated with the current page. If the ESC key is pressed and held for approx. 2 seconds, it allows the machine to be switched on/off.

There are also an additional 3 function keys:

- K0 = ALL: enters the alarm pages if pressed and held for approx. 2 seconds. Pressing mutes

the buzzer.

- K1: not used

- K2: enters the application clock menu.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

There are also 3 LEDs:

- L0 associated with the K0 key, identifies whether there are any alarms.

Off: there are no alarms. Flashing slowly: indicates the presence of new alarms Flashing rapidly: indicates that alarm pages are being viewed. On: all active alarms have been viewed

- L2 associated with the K2 key, identifies the status of the RTC and the

time bands:

Off: no signals. Flashing rapidly: indicates there is an ERTC clock alarm. Flashing slowly: indicates that the compressor or fan setpoint is

changed within the time bands. On: indicates that the compressor and fan setpoint are both changed within the time bands.

- LEsc associated with the ESC key, identifies the status of the machine:

Off: machine off On: machine on Flashing slowly: machine switched off by digital input Flashing rapidly: machine switched off by supervisor system.

4.2 Page list

This section will introduce the application’s main pages and menus. As already mentioned, the main menu is subdivided into four levels: user, service, installer and system builder, plus a menu for managing the functions associated with the system clock and certain free-access pages. The menu structure is as follows:

⋅ Clock menu ⋅ General menu

⋅ User menu (Level 1, level 1 password) ⋅ Service menu (Level 2, level 2 password)

o Service menu – operations branch o Service menu – manual branch o Service menu - input/output branch

⋅ Installer menu (Level 3, level 3 password)

o Installer menu - settings branch o Installer menu – compressor branch o Installer menu fans branch o Installer menu - safety devices branch o Installer menu - miscellaneous branch

⋅ System builder menu (Level 4, level 4 password)

o System builder menu – systems branch (configuration wizards) o System builder menu – hardware branch o Installer menu – parameters branch

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

Password

Each menu (besides the clock menu which is always accessible) is associated with a level which affects accessibility. Each level also has an associated password allowing access to the various functions present in that specific menu. Once the correct password has been entered, the protected functions will be accessible. Correctly entering a password has two effects:

⋅ it unlocks the associated level ⋅ it unlocks the sub-levels

Each level password may be altered from the level itself or from superior levels. For example, from the system builder level, all the passwords for the underlying levels will be modifiable by using the appropriate page. Here is an example from the system builder menu password page.

The range of permissible values for passwords is: -999 / 9999. If no actions are executed within the current page, then after 4 minutes, the inserted password expires, and it is necessary to insert it once more.

Clock menu

This menu contains the functions associated with the system RTC:

⋅ setting the clock ⋅ enabling the compressor/fan time bands ⋅ setting the time bands ⋅ setting the offsets to the main setpoints for each time band

This menu is not password-protected, and may be accessed by pressing the K2 key on the user interface for approx. 2 seconds.

Status pages

There are pages that are not password-protected and may accessed and browsed by simply using the LEFT and RIGHT keys. These pages display the status of the circuits, compressors, inverters, probes, the power supplied and requested, and other general information. These pages cannot be edited.

When the machine is on and running, the main page is the following:

from which it is possible to access the status pages for the individual circuits, by pressing ENTER at the “>” for the corresponding circuit, or by navigating using the LEFT and RIGHT keys, it is possible to view the status of the compressors, fans and inverters.

Page

C-PRO MEGA RACK & C-PRO GIGA RACK APPLICATION MANUAL

Stato circuito

Funzioni attive su circuito

Set Point e V

alore delle sonde di pressione

The first page for each circuit:

contains information on the circuit’s current status and active functions:

hp: tC: dC: sC: tF dF: sF:

refrigeration power increments Compressor time band function Compressor set point variation from a digital input Compressor set point variation by supervisor system Fan time band function Fan set point variation from a digital input Fan set point variation by supervisor system

The function is active if the relevant code is visible on the page.

General menu

The general menu has no level, and is the access point for all other system menus.

It is possible to view this menu, from any point within the user interface, by pressing and holding the ENTER key for approx. 2 seconds. From this page, it is possible to select into which menu to move by moving the “screen highlight” above the indicators “>>>” and pressing the ENTER key for conformation. Pressing the ESC key within this menu returns to the default start page if the machine is on, or the OFF page if the machine is switched off.

User menu The user menu is a level 1 menu, i.e. it is necessary to insert the user level password, or higher, in order to be able to view/modify the parameters in this branch.

It is possible to select which circuit to access in order to modify the setpoints and the secondary setpoint offset, or to set several general configuration parameters in the “Miscellaneous” section.

Within this page, as may be seen from the figure, a “v” character is displayed in the top right of the screen. This is not an error, but a sign to indicate to the user that the page information continues, i.e. pressing the DOWN (or UP depending on where the screen highlight is) key moves to the content

Page

+ 94 hidden pages

EVCO c-pro mega RACK User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual