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User Manual: Μrack Standard Compressor Racks Single/Two Circuit
User Manual: Μrack Standard Compressor Racks Single/Two Circuit
User manual
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
WARNINGS
CAREL bases the development of its products on decades of experience in HVAC, on the continuous investments in technological innovations to products, procedures and strict quality
processes with in-circuit and functional testing on 100% of its products, and on the most innovative production technology available on the market. CAREL and its subsidiaries nonetheless
cannot guarantee that all the aspects of the product and the software included with the product respond to the requirements of the final application, despite the product being developed
according to start-of-the-art techniques. The customer (manufacturer, developer or installer of the final equipment) accepts all liability and risk relating to the configuration of the product in
order to reach the expected results in relation to the specific final installation and/or equipment. CAREL may, based on specific agreements, acts as a consultant for the positive
commissioning of the final unit/application, however in no case does it accept liability for the correct operation of the final equipment/system.
The CAREL product is a state-of-the-art product, whose operation is specified in the technical documentation supplied with the product or can be downloaded, even prior to purchase, from
the website www.carel.com.
Each CAREL product, in relation to its advanced level of technology, requires setup / configuration / programming / commissioning to be able to operate in the best possible way for the
specific application. The failure to complete such operations, which are required/indicated in the user manual, may cause the final product to malfunction; CAREL accepts no liability in such
cases.
Only qualified personnel may install or carry out technical service on the product.
The customer must only use the product in the manner described in the documentation relating to the product.
In addition to observing any further warnings described in this manual, the following warnings must be heeded for all CAREL products:
• Prevent the electronic circuits from getting wet. Rain, humidity and all types of liquids or condensate contain corrosive minerals that may damage the electronic circuits. In any case,
the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual.
• Do not install the device in particularly hot environments. Too high temperatures may reduce the life of electronic devices, damage them and deform or melt the plastic parts. In any
case, the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual.
• Do not attempt to open the device in any way other than described in the manual.
• Do not drop, hit or shake the device, as the internal circuits and mechanisms may be irreparably damaged.
• Do not use corrosive chemicals, solvents or aggressive detergents to clean the device.
• Do not use the product for applications other than those specified in the technical manual.
All of the above suggestions likewise apply to the controllers, serial boards, programming keys or any other accessory in the CAREL product portfolio.
CAREL adopts a policy of continual development. Consequently, CAREL reserves the right to make changes and improvements to any product described in this document without prior
warning.
The technical specifications shown in the manual may be changed without prior warning.
The liability of CAREL in relation to its products is specified in the CAREL general contract conditions, available on the website www.carel.com and/or by specific agreements with customers;
specifically, to the extent where allowed by applicable legislation, in no case will CAREL, its employees or subsidiaries be liable for any lost earnings or sales, losses of data and information,
costs of replacement goods or services, damage to things or people, downtime or any direct, indirect, incidental, actual, punitive, exemplary, special or consequential damage of any kind
whatsoever, whether contractual, extra-contractual or due to negligence, or any other liabilities deriving from the installation, use or impossibility to use the product, even if CAREL or its
subsidiaries are warned of the possibility of such damage.
DISPOSAL
INFORMATION FOR USERS ON THE CORRECT HANDLING OF WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE)
In reference to European Union directive 2002/96/EC issued on 27 January 2003 and the related national legislation, please note that:
1. WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of separately;
2. The public or private waste collection systems defined by local legislation must be used. In addition, the equipment can be returned to the distributor at the end of its working life when
buying new equipment.
3. The equipment may contain hazardous substances: the improper use or incorrect disposal of such may have negative effects on human health and on the environment;
4. The symbol (crossed-out wheeled bin) shown on the product or on the packaging and on the instruction sheet indicates that the equipment has been introduced onto the market after
13 August 2005 and that it must be disposed of separately;
5. In the event of illegal disposal of electrical and electronic waste, the penalties are specified by local waste disposal legislation.
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
WARNING: separate as much as possible the probe and digital input signal cables from the cables carrying inductive loads and power cables to avoid possible electromagnetic disturbance.
Never run power cables (including the electrical panel wiring) and signal cables in the same conduits
CON
NTENTS
1 PRODUCT ............................................................................................................................................................................................................................................7
1.1 General functtions ............................................................... ................................................................................................................................7
1.2 Main charactteristics ........................................................... ................................................................................................................................7
2 USER INTERFAACE ...............................................................................................................................................................................................................................8
2.1 Buttons - LED Ds - Icons ........................................................ ................................................................................................................................8
2.2 LED display aand Icons ......................................................... ................................................................................................................................9
3 STARTING TH HE UNIT ...................................................................................................................................................................................................................... 10
3.1 Starting for thhe first time .................................................... ............................................................................................................................. 10
3.2 Unit configuraation ............................................................... ............................................................................................................................. 10
3.3 Meaning of thhe inputs / outpputs ......................................... ............................................................................................................................. 10
4 COMPRESSOR MANAGEMEN NT ................................................................................................................................................................................................... 13
4.1 General settinngs ................................................................. ............................................................................................................................. 13
4.2 Compressor rrotation ........................................................... ............................................................................................................................. 13
4.3 Compressor ccontrol ............................................................ ............................................................................................................................. 13
4.4 Number of coompressors started with probee 1 fault ............ ............................................................................................................................. 14
4.5 Compressorss with different capacities c ............................... ............................................................................................................................. 15
4.6 Manually enaable/disable the compressors ......................... ............................................................................................................................. 15
4.7 Special MT-LLT units ............................................................ ............................................................................................................................. 16
4.8 Compressor ttime settings .................................................. ............................................................................................................................. 16
5 FAN AND INVVERTER MANAG GEMENT ......................................................................................................................................................................................... 18
5.1 Fan managem ment ............................................................... ............................................................................................................................. 18
5.2 Dead band coontrol .............................................................. ............................................................................................................................. 18
5.3 Inverter manaagement ......................................................... ............................................................................................................................. 19
5.4 PWM-PPM m management.................................................... ............................................................................................................................. 21
5.5 Floating conddenser control ................................................. ............................................................................................................................. 21
6 VARIOUS SETTTINGS ....................................................................................................................................................................................................................... 22
6.1 Manual devicce operation .................................................... ............................................................................................................................. 22
6.2 Compressor hhour counter annd maintenancee alarm ............. ............................................................................................................................. 22
6.3 Set point variiation from digittal input................................... ............................................................................................................................. 22
6.4 Type of refriggerant .............................................................. ............................................................................................................................. 22
6.5 Auxiliary probbe managementt .............................................. ............................................................................................................................. 22
6.6 Prevent high discharge presssure ........................................ ............................................................................................................................. 23
7 ALARM MANAAGEMENT ................................................................................................................................................................................................................. 24
7.1 Alarms with aautomatic resett .............................................. ............................................................................................................................. 24
7.2 Alarms with m manual reset .................................................. ............................................................................................................................. 24
7.3 Semiautomattic alarms ....................................................... ............................................................................................................................. 24
7.4 Alarm relay ......................................................................... ............................................................................................................................. 24
7.5 Alarms from analogue inputss: temperature probe and presssure transducer: .................................................................................................. 25
8 THE SUPERVISOR NETWORKK ...................................................................................................................................................................................................... 26
8.1 Serial boards ...................................................................... ............................................................................................................................. 26
8.2 Communicatiion protocols................................................... ............................................................................................................................. 26
9 USER INTERFAACE ............................................................................................................................................................................................................................ 26
10 LIST OF PARAAMETERS .................................................................................................................................................................................................................... 27
11 ON/OFF FAN CONTROL BOAARD (CODE CO ONVONOFF0)..................................................................................................................................................... 32
12 PWM TO 0 TO O 10 VDC (OR 4 TO 20 MA) CO ONVERSION BO OARD FOR FANSS (CODE CONV V0/10A0) .......................................................................... 33
13 PROGRAMMING KEY (CODEE PSOPZKEYA0) ............................................................................................................................................................................ 33
14 SUPERVISOR MANAGEMENTT ...................................................................................................................................................................................................... 33
15 DEFAULT CONFIGURATIONSS ...................................................................................................................................................................................................... 36
16 GLOSSARY ........................................................................................................................................................................................................................................ 37
17 TECHNICAL SSPECIFICATION ............................
. ............................................................................................................................................................................ 37
18 PRODUCT CO ODES LIST.................................................................................................................................................................................................................. 38
19 APPENDIX: CO OMPRESSOR RAACK CONTROLLLER, EXAMPLES OF APPLICATIO ON DIAGRAMS ........................................................................................... 39
20 APPENDIX: CH HANGES INTRO ODUCED IN FW RELEASE 2.0 FO OR MRK0000XXX0 .................................................................................................................. 41
21 APPENDIX: CH HANGES INTRO ODUCED IN FW RELEASE 2.1 ..................................................................................................................................................... 42
22 APPENDIX: CH HANGES INTRO ODUCED IN FW RELEASE 2.2 ..................................................................................................................................................... 42
23 APPENDIX: CH HANGES INTRO ODUCED IN FW RELEASE 2.3 ..................................................................................................................................................... 42
μRack
1 Product
1.1 General ffunctions
1.
1 Read pressuure transducers, diisplay data in BARR/°C (depending oon the type of refrrigerant gas)
2.
2 Managemennt of compressors with the same annd different capac ities
3.
3 Managemennt of compressor racks r with two circcuits, MT and LT
4.
4 Setting of the number of com mpressors – fans on the unit
5.
5 Rotation of tthe compressors (FIFO
( and by timee). FIFO rotation oof the fans.
6.
6 Fan speed control (PWM OUTTPUT)
7.
7 Compressorr and fan dead band management
8.
8 Possibility too enter the compressor set point in BAR and displaay the value in °C C by pressing the “UP” and “DOWWN” buttons togetther when displayying the
parameter vvalues.
9.
9 Possibility too enter the fan sett point in BAR or degrees
d centigradee, depending on the
t control probe used (pressure oor NTC).
10.
1 Multifunction input: general HP H alarm, ON/OFFF, change SET POIINT,…
11.
1 Set point varriation from digitaal input
12.
1 Possibility too set the compresssor-fan thermal ovverload/generic allarm as automaticc/manual
13.
1 Enable comppressors from thee “Maintenance” screen
14.
1 Proportionall plus integral function for the fan innverter.
15.
1 Floating conndenser set point
16.
1 Optional tem mperature probes, with high tempeerature alarm thresshold:
a- O Outside air
b- AAmbient air
c- CCompressor dischharge temperaturee
d- SSuction temperatuure
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 7
μRack
2 User interfface
The prroduct uses a 3 digit LED display with minus sign andd decimal point too display the monnitored values, andd ICONS for the sstatus of the devicces and operating modes.
As welll as displaying thhe values measureed and the operaating conditions oof the unit, the usser terminal (displlay and keypad) ccan be used to modify
m the unit opperating
parameters. The following figures show thhe µRack for paneel installation and for DIN rail mounnting.
Fig. 2.a
aa) Press the button for more than 5 sec to set the pa ssword for accesssing the USER paraameters.
bb) Press the button when the list off parameters is dissplayed to show thhe numeric value of the parameterr.
cc) Press the buttonn when the numeeric value of a paraameter is displayeed to accept the numeric value andd return to the list of parameters.
aa) Press the button to display the otther controlled vaalues. The “label” of the probe will be
b displayed, andd then the numeric value.
EExample:
UUnit “A” single circcuit
--standard LP1
--the arrows scroll to
t HP-B2 –B3
bb) Press the button for more than 5 sec to select the probe displayed permanently as th he main probe.
cc) Press the buttonn when the list of parameters is dissplayed to move too the previous parameter
dd) Press the button when the numeeric value of a parrameter is displayeed to decrease thee value.
ee) Press the button when a digital value
v is displayed (YES-NO) to channge the setting
PPress the two butttons together for 5 seconds to set thhe PWD for accesssing the MANUFA ACTURER parametters and thus configuring the controller.
+
PPress the two butttons together, wheen the numeric vaalue of one of thee following parameeters is displayed::
+ 1. comp//fan set point
2. high/loow threshold
tto switch the displlay of the same paarameter from BAAR to °C.
T 2.a
Tab.
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 8
μRack
ICONS Description
On when the unit of measure selected is BAR
1
2 1) Indicates the state of the compressors and capacity control on
2) If flashing indicates the ON/OFF call for a new compressor step, while the device is awaiting the expiry of the delay times.
3 3) If the controller is used for fan control only (“/01”=0) then the icon shows the status of the fans.
4
Tab. 2.b
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 10
μRack
Digital inputs
Input Description Type of device connected
ID1 Compressor 1 / fan alarm Generic compressor/fan alarm. Voltage-free contact.
ID2 Compressor 2 / fan alarm Generic compressor / fan alarm. Voltage-free contact.
ID3 Compressor 3 / fan alarm Generic compressor / fan alarm. Voltage-free contact.
ID4 Compressor 4 / fan alarm Generic compressor / fan alarm. Voltage-free contact.
ID5 Fan alarm / Multifunction input Generic alarm:
- compressor/fan.
- from general high/low pressure switch.
- fan thermal overload.
- liquid level.
Unit On-Off. Voltage-free contact.
Tab. 3.b
Digital outputs
Input Description Type of device connected
No1-C1 Compressor 1 / fan Power contactor for starting the compressor / fan
No2-C2 Compressor 2 / capacity-control /fan Power contactor for starting the compressor / Power contactor for capacity control activation / fan
No3-C3 Compressor 3 / capacity-control / fan Power contactor for starting the compressor / Power contactor for capacity control activation / fan
No4-C4 Compressor 4 / capacity-control / fan Power contactor for starting the compressor / Power contactor for capacity control activation / fan
No5-C5 Alarm / fan Power contactor for starting the fan / voltage-free contact for signalling unit alarm
Tab. 3.c
Analogue outputs
Outputs Description
Y1 Fans speed controller (PWM)
Tab. 3.d
3.3.2 Wiring diagrams:
Panel installation:
N
Line
L
amb. temp. probe
ext. temp. probe
multifunctionD.I./alarm
P
alarm 4
alarm 2
alarm 1
alarm 3
PSOPZKEY*
24 V
P MCH2004850
N Line L
TRADR1W04
Fig. 3.a
Rack
FCSER00000
N
Line
L
Rack
FCSER00000
amb. temp. probe
ext. temp. probe
multifunction D.I./alarm
alarm 4
alarm 2
alarm 1
alarm 3
24 V
N Line L
TRADR1W04
Fig. 3.b
4 Compress or manageement
Inputs used:
• Sucttion pressure probbe/probes
• Digital inputs dedicatted to the compreessor safety devicees
• Mulltifunction input foor generic alarm (general
( suction pressure switch 1 aand 2)
Outputs used:
• Commpressor outputss and capacity control
com
mpr./capac. contr. compr./ capac. co
ontr.
1° compr. co
ompr./ capac.
ON t Key:
SP Compressor set point (r01)
OFF DF Compressor diffferential (r02)
DF
F RP RP Pressure read
Fig 4.a
Dead band
This tyype of control feattures the definitioon of a dead bandd to the side of thhe set point, within which no device is started or stoopped. The devicees are activated when the
measuured value exceedds the limit to the right (measured value greater thaan SP + DZN, seee Figure 4.3). The number of devicces to be activatedd varies accordingg to the
time elapsed
e outside of the dead band. The first device will start immedi ately, while the others o will wait th
he set time betweeen starts (r07). Similarly,
S the devices are
stoppeed when the meassured value falls below b the dead baand (measured vaalue less than the set point), and reemains there for a period equal to the time betweenn device
stop reequests. In this casse too, the first deevice stops immeddiately, while the oothers wait the deelay time between n stops (r09).
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 13
μRack
Also see the paragraph on Time settings.
The program will switch the devices on according to the start-up logic configured and the availability of the devices
Key:
DOffZ Device deactivation zone
DOffZ NZ DOnZ DOnZ Device activation zone
NZ Dead band
DZN RP
DZN Dead band differential
SP
RP Suction pressure read
Fig. 4.b SP Set point
TOffMax TOnMax
TOffMin TOnMin
DOffZ NZ DOnZ
Fig. 4.c
Key:
InPress Suction pressure DTNZ Differential within which the time varies
STPM Control set point TOnMax Maximum compressor on time
RBM Control band TOnMin Minimum compressor on time
NZ Dead band TOffMax Maximum compressor off time
DOnZ Device activation zone TOffMin Minimum compressor off time
DOffZ Device deactivation zone
In the deactivation phase, on the other hand, the following cases are possible:
1. Pressure equal to point STPM
same call time as the “maximum compressor off time”
2. Pressure between point STPM and point STPM - DTNZ
type of call between “Max off time” and “Min off time”
3. Pressure greater than or equal to point STPM - DTNZ
same call time as “Min off time”
N.B. To make the device call time constant in the activation phase, simply set the times TOnMax and TonMin to the same value. The same is true for the deactivation
phase.
Key:
DOffZ Device deactivation zone
DOffZ NZ DOnZ
DOnZ Device activation zone
DZN RP NZ Dead band
SP DZN Dead band differential
RP Suction pressure read
Fig 4.d
SP Set point: compressors (S2); fans (S1)
4.7 Special M
MT-LT unitss
4.7.1 Managemennt of compressor racks with LT and MT circuits a nd condenser onnly.
The haardware features oof the µRack contrroller can be adappted for the controol of a special typee of compressor rack that is becom
ming more widely used in small andd
medium installations, haaving the advantage of being comppact and offering llow cost solutionss. These are compressor racks with only the condenssing section, and with
w fan
speed managed by the speed controller or o external pressure switches, and sseparate managem ment of the comppressors in the MTT and LT units.
Below is an example diaagram:
Floating condenser SET POIN
NT
MT display cabinet
Condenser group
Liquid reeceiver
LT display cabinet
Fig 4.ee
R Keey:
R Compressor call
T[s] mp
Cm Compressor
Cm
mp TM
MinOn Minim
mum ON time
T Time
T[s]
TMinOn
Fig 4.f
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 16
μRack
Minimum compressor OFF time
Sets the minimum time the compressors stay off. The devices are not started again if the minimum time selected (parameter C02) has not elapsed since the last stop.
Key:
R R Compressor call
Cmp Compressor
T[s]
TMinOff Minimum OFF time
Cmp T Time
T[s]
TMinOff
Fig. 4.g
Key:
R R Compressor calls
Cmp1 Compressor 1
T[s]
Cmp2 Compressor 2
Cmp1 TDiffSw Minimum time between starts of different compressor
T Time
T[s]
Cmp2
T[s]
TDiffSw
Fig 4.h
With capacity control compressors is established fixed delay = 5 s, between a capacity control and the following.
R Key:
R Compressor call
T[s] Cmp Compressor
TSameSw Minimum time between starts of the same compressor
Cmp
T Time
T[s]
TSameSw
Fig 4.i
ON Key:
SP Fan set point
DF Fan differential
OFF
RP Pressure read
DF R
RP
Fig. 5.aa
Key:
DOffZ Device deacttivation zone
NZ Dead band
DOnZ Device activaation zone
DZN Dead band ddifferential
RP Discharge prressure read
Fan rootation
The rotation of the fanss, settable by parameter r20, is aim
med at balancingg the number of operating hours annd starts of the ddifferent fans.
Rotatioon automatically excludes any fanns with active alarrms.
If the fan
f is off for alarm
m or disabled, is excluded
e from reggulation and rotattion; the activatioon/deactivation thhresholds are re-ccalculated based from actual num
mber of
fans avvailable.
Two different types of rrotation can be set:
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 18
μRack
LIFO rotation (no rotation parameter r20=0)
The first fan that to start will be the last to stop.
• Start: Fan1, Fan2, Fan3, Fan4.
• Stop: Fan3, Fan3, Fan2, Fan1.
Key:
Fig. 5.c
Inverter control
Proportional band
This control requires the inverter set point STPI to be set (parameter r18 ), plus an inverter differential RBI (parameter r19).
If the value measured by the discharge probe is less than or equal to the value of the inverter set point, the inverter output will be 0.
Between the inverter set point STPI and point C (set point + differential), the value of the inverter output will be proportional to the value read by the discharge probe,
and in any case not less than the minimum inverter output MinIn. If the value measured by the discharge probe is greater than or equal to the inverter set point +
differential, the output will be at the maximum value. The control is not associated with any fan and can work without fans being configured.
Key:
RB Fan differential
RBI Inverter differential
STPM Discharge set point
STPI Inverter set point
C Inverter set point + inverter differential
B Discharge set point + Fan differential
Min In Minimum value of the inverter control output
Fig.5.d
Proportional control, set by parameter r21, may be proportional only (parameter r21=0) or proportional + integral (parameter r21=1).
N.B.: Make sure the integral time is not set too low, otherwise control may become unstable.
The following figure highlights the difference between the proportional control and proportional plus integral control (with inverter):
RP
RP
SP SP
T[s] T[s]
10 Volt
10 Volt
Min In
Min In
T[s]
T[s]
Fig. 5.e
Key:
RP Pressure read
SP Set point
T Time
Min In Minimum inverter output value
Key:
InPress Discharge pressure
B Set point + differential
StpM HP set point
DOnZ Activation zone
DOffZ Deactivation zone
NZ Dead band
T [s] Time
Inverter Inverter status
NFan Number of fans on
Fig. 5.f
PWM
V
[5 Volt]
T[s]
80%
Fig. 5.g
The PWM signal controls, for example, the CAREL FCS* series, CONVONOFF, CON0/10A0 modules.
PWM to 0 to 10 Vdc (or 4 to 20 mA) conversion board for fans (code CONV0/10A0)
The CONV0/10A0 modules convert the PWM signal sent from terminal Y to a standard 0 to 10 Vdc (or 4 to 20 mA) signal.
The condenser set point is the value resulting from “DELTA T + Outside air temperature”, as with high outside temperatures the condensing temperature cannot be too
low (no possibility of energy savings). This is used to optimise the operation of the fans. The maximum and minimum pressure values are the range in which floating
control can operate.
ATTENTION: enabling this controller, the parameters “r16” (ventilation set) and “r18” (inverter ventilation set) are no more visibile since the relevant set point become
function of the external temperature + delta.
The following parameter are displayed in temperature always, not depending by used probe (pressure or temperature):
r17 (Set the minimum value of suction probe)
r19 (Fan inverter differential)
r25 (Set the lower limit of the fan set point)
r26 (l Set the upper limit of the fan set point)
6 Various seettings
6.1 Manual d
device operration
The individual devices ccan be activated manually,
m ignoringg the times and thhe rotation, and independently from the temperaturre control functions, by setting the related
parameters Mxx.
The onnly support providded in manual opeeration is the alarm m management fuunction.
The manual activation oof the speed contrrollers sets the corrresponding outpuuts to the maximuum value.
When even just one maanual procedure iss enabled, the “MANUFACTURER” iicon on the displaay will FLASH!
If switcching the board offf and on again, thhe function is term
minated.
Imporrtant: Use this funnction with care!! Operating the devices
d manuallyy may cause dam mage to the installation!
6.5 Auxiliary
y probe management
The sooftware can managge two auxiliary teemperature probees, in addition to thhe suction and discharge probes.
The tw
wo probes can be configured with parameters
p /21 annd /22:
No. Channel N
NTC probe
1 B2 -rroom temperaturee probe, read-onlyy
-aauxiliary probe
2 B3 -ooutside temperatuure probe for Floating condenser coontrol
-aauxiliary probe
Tab. 6.b
If the auxiliary
a mperature thresholld can be set (parrameter A16, A17). This alarm has automatic
probe sellected, a high tem a reset, w
with a fixed differeential of 2°C.
Exampple of HT alarm m
management
Diff. 2°C
Alarm ON
N
Fig. 6.aa
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 22
μRack
OutPress
STPpr
T[s]
ALPrv
Dprev2 T[s]
NCmp
4
3
2
1
T1 Dprev1 T[s]
Fig. 6.b
Key:
OutPress Discharge pressure
T Time
NCmp Number of suction steps required
ALPrv High pressure prevention alarm
STPpr Prevent HP activation threshold
T1 Time between compressor stops with prevent HP active
Dprev1 Step activation delay after end prevent HP (prevent time 1)
Dprev2 Minimum time for activation of high prevent frequency alarm (prevent time 2)
7 Alarm mannagement
The acctivation of an alarrm, from digital innput, causes the direct action on thee devices involvedd, at the same time activating: the LLED and a signal on
o the display. If thhe
comprressors are called, the activation of an a alarm on one compressor sendss the call to anothher compressor.
The alaarm information aappears is displayeed alternating with the value read bby the control proobe. If more than oneo alarm is active ve, the informationn appears on the display
d
in sequuence. If the alarm
m situation is resoolved, the relay is reset
r and the alarm
m message is canncelled. In the casee of alarms with mmanual reset, the Reset Alarms paraameter
(A19) needs to be accesssed.
The alaarm from digital innput is typically detected when the contact “opens”, however the logic can be selected using the “digital input logic” parameter, /14.
7.1 Alarms w
with autom
matic reset
When one or more autoomatic reset alarm ms are detected, thhese are signalled by:
• Red ALARM LEED on;
• Alarm relay chaanges, if enabled.
Press thet PRG/MUTE buutton.
If the cause
c ms is resolved, the devices that havee shutdown will reestart normal operation, and the staatus of the signal ddevices changes as
of the alarm a follows:
• The alarm relayy changes to norm mal status;
• Red ALARM LEED goes off..
If, in thhis situation, new alarms are activatted, the initial situation will return.
The siggnal will remain active to leave a siggn of alarm ON, until u the operator manually sets thee reset alarms paraameter A19.
7.2 Alarms w
with manua
al reset
The coompressor thermaal overload (param meter /29) fan theermal overload (paarameter /30) alaarms can be set ass manual reset.
When one or more mannual reset alarms are detected, thesse are signalled byy:
• Red ALARM LEED on;
• Alarm relay chaanges, if enabled.
If the cause
c of the alarm
ms has been resoolved, the red LED D stays on to info rm the user that alarms have beenn activated duringg the day. In this situation, the alarrm relay
remainns in an alarm conndition and the deevices remain disaabled until the useer deleted the alarrm messages usin ng parameter A199.
If, in thhis situation, new alarms are activatted, the initial situation will return..
If the causes
c no longer eexist, the status off the signal devicees changes as folloows:
• The alarm relayy changes to norm mal status;
• Red ALARM LEED goes off..
If, on the
t other hand, thhe cause of the alaarms is still presennt, the initial situattion will return.
7.3 Semiauto
omatic alarrms
The low pressure alarm m from transducerr is a semiautomaatic alarm. It acts as an alarm with automatic reset, however if it is aactivated at least 3 times within a set
s time
m that must be reset manually, thatt is, using parameeter A19. This alarm obviously causees the unit to shutdown.
(defauult 10 minutes), it becomes an alarm
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 24
μRack
Code Alarm description Generated by Action performed Type of reset Delay Notes
A14 High discharge pressure AIN All fans ON automatic no
A15 Low suction pressure 1 AIN All comps. OFF automatic settable
A16 High suction pressure 1 AIN all comps. ON automatic settable
A17 Low suction pressure 2 AIN All comps. OFF automatic settable
A18 High suction pressure 2 AIN all comps. ON automatic settable
See compressor management with probe
A19 Suction probe 1 faulty or disconnected AIN Settable no. comps. ON automatic 30 seconds
broken.
See compressor management with probe
A20 Suction probe 2 faulty or disconnected AIN Settable no. comps. ON automatic 30 seconds
broken.
A21 Discharge probe faulty or disconnected AIN Settable no. fans ON automatic 30 seconds Force fan inverter to 100%.
A22 Fan 1 thermal overload DIN Fan 1 OFF Settable no
A23 Fan 2 thermal overload DIN Fan 2 OFF Settable no
A24 Fan 3 thermal overload DIN Fan 3 OFF Settable no
A25 Fan 4 thermal overload DIN Fan 4 OFF Settable no
Only signal alarm. Preset
A26 General fan thermal overload DIN electronically the fan stop Automatic no
during overload
A27 Prevent high discharge pressure AIN Compressors OFF Automatic no
A28 Compressors off for Prevent HP AIN Compressors OFF Automatic no
A29 Excessive prevent frequency AIN / Settable no Display only
HtE High outside temperature AIN Automatic No
HtA High ambient temperature AIN Automatic No
EHS High supply voltage --- OFF Automatic No
ELS Low supply voltage --- --- Automatic No
EPb EEPROM error --- --- Settable No
Power supply
EL1 Zero cross 100% Fans Automatic No
voltage
AB2 B2 probe error faulty or disconnected AIN --- Automatic No
AB3 B3 probe error faulty or disconnected AIN --- Automatic No
Tab. 7.a
7.5 Alarms from analogue inputs: temperature probe and pressure transducer:
Fixed differentials: 0.2 bar suction
1.0 bar discharge
Example of LP alarm management
Diff.
Alarm on
Alarm off
Low press.
Set Point
Fig. 7.a
Alarm on
Fig. 7.b
8.1 Serial bo
oards
For connection to superrvisory systems, thhe control uses thee standard CARELL RS485 serial protocol.
Serial connection
c optionns:
Product code RS485 serial option Code Notes
MRK00000000 MCH20048850 External opttion connected byy cable to µRack co
ompact
MRK000000D0 FCSER000000 Serial outpuut board for DIN version,
v to be fitted in the instrumennt
MRK00000AD0 ----------------- µRack with sserial option FCSEER00000 already FITTED
F by CAREL
T 8.a
Tab.
8.2 Commun
nication pro
otocols
Comm munication protocool: CAREL.
To enaable the correct opperation of the coommunication prootocol, as well as i nstalling the boarrd, a number of paarameters need too be set, such as the
t identification number
n
(parammeter /36).
Each controller must have the address seet so that:
• There are NOO other devices with
w the same adddress on the samee serial line
• The addressses on the same seerial line must be set in progressivee order, starting frrom 1.
For furrther information, refer to the correesponding manual or contact CARELL.
9 User interfface
The paarameters are divided into 2 categoories.
Displayy information thatt is NOT passworrd-protected: shoow the values of thhe probes, alarmss.
Displayy information thatt is password-prootected:
1.
1 USER param meters (password 22 modifiable by parameter /40): sset the main functtions of the devicees connected (tim
mes, set points, diffferentials);
2.
2 INSTALLER parameters (passsword 44 modifiabble by parameter //41): periodical checks on the deviices, calibration off the probes connnected, manual opperation
of the devicees.
3.
3 MANUFACTTURER parameterrs (password 77 modifiable
m by paraameter /42): configure the compressor rack, enable the main functionns and select the devices
connected.
Once the
t password is eentered, it remainss in the memory until automaticallyy returning to thee main screen, so as to make it eassier to move around within the sam
me level
of prottection.
IMPORRTANT:
To chaange the level of pparameter protection from the keyppad (from the MAANUFACTURER levvel only), proceed as follows:
1.
1 Once havingg entered the corrrect PWD MANUFA ACTURER, the sysstem displays the string “S-P” (Set Parameters);
P
2.
2 Then either press “SEL”, direectly accessing thhe parameter meenu to change the values or press “DOWN” or “UUP” to display off the string “L-P” (Level-
Parameters).
3.
3 If modifyingg the level, pressing “SEL” accesses the parameter menu as describeed, where parameters are scrolledd no longer displaayed with the asssociated
value, but raather the level of protection.
p
4.
4 Using the saame procedure as for modifying thee parameters, cha nge the level, chooosing between th he 3 possible levells available:
“_U_”” :parameters visibble at User level,
“_I_” :parameters visibble at Installer leveel,
“_C_”” :parameters visibble at Manufacturer level.
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 26
μRack
IMPORRTANT: Not all thhe screens listedd below will be displayed when s crolling the display; enabling a certain
c type of coonfiguration will mean that new screens
s
are dissplayed that werre previously nott available. The display
d therefore depends on thee initial configuration!
INSTAALLER
Press the button PRG per at least 5 secs PW
P 44
PARAMMETERS
Table of parameterss
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 27
μRack
Parameter Type Pos. Display Description UOM Range Default Notes
Set the unit model (without capacity control):
SINGLE CIRCUIT
0) 0 compressors
1) 1compressor
2) 2 compressors
3) 3 compressors
4) 4 compressors
TWO CIRCUIT
5) 1 compressor + 1 compressor
6) 2 compressors + 1 compressor
Unit model R/W C /01 7) 3 compressors + 1 compressor 0… 14 2
8) 2 compressors + 2 compressors
Set the unit model (with capacity control):
SINGLE CIRCUIT
9) 1 compressor 1 capacity control
10) 1compressor 2 capacity control
11) 1 compressor 3 capacity control
TWO CIRCUIT
12) 1 compressor 1 capacity control + 1 compressor
13) 1 compressor 1 capacity control + 1 compressor 1 capacity control
14) 1 compressor 2 capacity control + 1 compressor
Enable management of compressors with different capacities For single circuit only for
Compressors with different
R/W C /02 0) NOT ENABLED 0/1 0 the configuration
capacities
1) ENABLED /01=1,2,3 e 4
Only if comp. with
Capacity compressor 1 R/W C /03 Capacity of compressor 1 kW 0 to 999 5 different capacities are
enabled
Only if comp. with
Capacity compressor 2 R/W C /04 Capacity of compressor 2 kW /03 to 999 10 different capacities are
enabled
Only if comp. with
Capacity compressor 3 R/W C /05 Capacity of compressor 3 kW /03+/04 to 999 20 different capacities are
enabled
Only if comp. with
/03+/04+/05 to
Capacity compressor 4 R/W C /06 Capacity of compressor 4 kW 40 different capacities are
999
enabled
If the suction 1 probe fault or not connected alarm is activated, this number
Number of compressors ON Number limited by the
R/W C /07 of compressors are started. These are in any case managed by the individual 0 to 4 0
with suction probe 1 fault number of compressors
alarms and general pressure switches.
If the suction 2 probe fault or not connected alarm is activated, this number
Number of compressors ON
R/W C /08 of compressors are started. These are in any case managed by the individual 0…2 0 For two circuits only
with suction probe 2 fault
alarms and general pressure switches.
Number limited by the
Configure number of fans R/W C /09 Set the number of fans 0 to 4 2 number of compressors
already enabled
Enable fan inverter R/W C /10 Enable control of the fans with inverter 0/1 0
Display inverter output value R U /11 Display the inverter output as a percentage 0 to 100% 0
If the discharge probe fault or not connected alarm is activated, this number
Number of fans ON with
R/W C /12 of fans are started. These are in any case managed by the individual alarms 0 to 4 0
probe fault:
and general pressure switches..
Enable fans with compressors 0= independent operation of the fans
R/W C /13 0/1 0
ON 1= fans on only when at least one compressor is ON
Set the logic of the digital inputs.
Digital input logic: N.O. =No
R/W C /14 0) N.O.: with no alarm the contact is open 0/1 1 NO / NC
alarm
1) N.C. : with no alarm the contact is closed
Set the type of multifunction input:
0: no function
1) unit ON-OFF (NC contact ON)
2) change set point (set1- set2)
3) general high pressure switch NC If the 4 outputs are
4) general high pressure switch NO used, this parameter is
Multifunction input 5) general low pressure switch 1 NC 0 to 12 ignored and the
R/W C /15 0
configuration 6) general low pressure switch 1 NO Multifunction Input is
7) general low pressure switch 2 NC set as fan thermal
8) general low pressure switch 2 NO overload
9) liquid level alarm NC
10) liquid level alarm NO
11) general fan thermal overload NC
12) general fan thermal overload NO
B1 probe set:
0) probe not connected
B1 probe type R/W C /16 0 to 2 2
1) NTC probe
2) 0 to 5 V probe
MIN suction pressure R/W C /17 Set the minimum value of suction probe bar -1.0 to /19 -1.0
Set point R/W C /33 High discharge pressure prevention set point bar 0 to 45.0 18.0 If prevent enabled
Compressor set point circuit 1 R/W U r01 Compressor set point first circuit bar / °C r12 to r13 1.0
Compressor set point circuit 2 R/W U r03 Compressor set point second circuit bar / °C r14 to r15 1.0 For two circuits only
Fig. 11.a
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 32
μRack
12 PWM to 0 to 10 Vdc (or 4 to 200 mA) convversion board for fans (code CO
ONV0/10A00)
The CO
ONV0/10A0 moduules convert the PWM P signal sent frrom terminal Y onn the µRack to a sttandard 0 to 10 Vdc (or 4 to 20 mAA) signal.
The FC
CS series three-phase controllers can be connected too the µRack withoout requiring this module.
m
Fig. 122.a
13 Programm
ming key (coode PSOPZZKEYA0)
The prrogramming keys PSOPZKEY00 andd PSOPZKEYA0 forr CAREL controllerrs are used to coppy the complete seet of parameters tto the µRack.
The keeys must be conneected to the connector (4 pin AMP)) on the controllerrs, and can operatte when the instru uments are eitherr on or off, according to the instructtions
for thee specific controlleer.
There are two main functions, which are selected using thee two dipswitchess (located under thhe battery cover). These are:
• Loadd the parameters ffrom a controller to
t the key (UPLOA AD);
• Copyy from the key to oone or more conttrollers (DOWNLO OAD).
Warning: The parameteers can only be coopied only betweeen instruments witth the same produuct code. The uplo oad operation, onn the other hand, is always possiblee. To
assist the
t identification oof the key to be used, CAREL has applied a label thatt can used to desccribe the program
mming made or thhe unit that the data refers to.
IMPORRTANT NOTE: Thhe key can only be b used on µRacck controllers thaat have the samee firmware version.
Refer to the programm ming key instruction sheet for furrther details.
Fig. 13.a
14 Supervisorr managem
ment
The coontroller can be coonnected to a locaal or remote supervisor/telemaintennance system for managing the unit.
wn in the tables beelow, with referennce to the followin
The vaariables sent and rreceived by the suupervisor are show ng key:
Analoggue variables
Flow
F Inndex Descriptiion Display coode
R 1 Probe B4
B LP1
R 2 Probe B1
B HP/LP22
R 3 Probe B2
B (ambient air) B2
R 4 Probe B3
B (outside air ) B3
R/W
R 5 Suction set point circuit 1 r01
R/W
R 6 Differenntial circuit 1 r02
R/W
R 7 Suction set point circuit 2 r03
R/W
R 8 Differenntial circuit 2 r04
R/W
R 9 Min sucction set point 1 r12
R/W
R 10 Max sucction set point 1 r13
R/W
R 11 Min sucction set point 2 r14
R/W
R 12 Max sucction set point 2 r15
R/W
R 13 Fan set point r16 (barr)
R/W
R 14 Fan set point r16 (°C))
R/W
R 15 Fan diffferential r17 (barr)
R/W
R 16 Fan diffferential r17 (°C))
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 33
μRack
Digital variables
Flow Index Description Parameter
R/W 1 Unit on
R 2 Status of compressor 1
R 3 Status of compressor 2
R 4 Status of compressor 3
R 5 Status of compressor 4
R 6 Status of fan 1
R 7 Status of fan 2
R 8 Status of fan 3
R 9 Status of fan 4
R 10 Status of digital input 1
R 11 Status of digital input 2
R 12 Status of digital input 3
R 13 Status of digital input 4
R 14 Status of digital input 5
R/W 15 Reset alarms A19
R/W 16 Digital input logic /14
R/W 17 Alarm relay logic /28
R/W 18 Enable fan inverter /10
R/W 19 ON/OFF from supervisor /38
R/W 20 Enable “prevent” control on condenser /32
R/W 21 Enable management of different compressors /02
R/W 22 Type of compressor reset /29
R/W 23 Type of fan reset /30
R/W 24 Type of reset for general high press. switch /31
R/W 25 Reset compressor 1 hours C09
R/W 26 Reset compressor 2 hours C11
R/W 27 Reset compressor 3 hours C13
R/W 28 Reset compressor 4 hours C15
R/W 29 Enable floating condenser control r32
R/W 30 Enable unit Off due to probe fault A22
R/W 31 Enable fans with compressor ON /13
Tab. 14.b
Integer variables
Flow Index Description Parameter
R/W 1 Type of unit “/00” /00
R/W 2 Unit model “/01” /01
R 3 Number of compressors
R/W 4 Number of fans “/09” /09
Unit status
0 = Unit ON
1 = OFF from alarm
2 = OFF from supervisor
R 5 3 = OFF from remote input
4 = OFF from parameter
5 = Manual operation
6 = Install default
7 = PREVENT IN PROGRESS
R/W 6 Minimum call time for compressor start (dead band) r07
R/W 7 Minimum call time for compressor stop (dead band) r09
R/W 8 Minimum compressor ON time C01
R/W 9 Minimum compressor OFF time C02
R/W 10 Minimum time between starts of different compressors C03
R/W 11 Minimum time between starts of the same compressor C05
R/W 12 Reserved
R/W 13 Reserved
R/W 14 Liquid level alarm delay A18
R/W 15 Reserved
R/W 16 Number of compressors on in circuit 1 with probe damaged /07
R/W 17 Number of compressors on in circuit 2 with probe damaged /08
R/W 18 Number of fans on with probe damaged /12
R 19 Firmware release
R/W 20 Type of refrigerant /35
R/W 21 Capacity of compressor 1 /03
R/W 22 Capacity of compressor 2 /04
R/W 23 Capacity of compressor 3 /05
R/W 24 Capacity of compressor 4 /06
R 25 Inverter readout % “ /11
R/W 26 Multifunction DI configuration /15
R/W 27 B1 type probe /16
15 Default coonfigurationns
Signnal Type of analogue inputs Description
B1 Analoguee input 1 Discharge pressure
p probe
B22 Analoguee input 2 Ambient air temperature probbe
B33 Analoguee input 3 Outside air temperature probbe
B44 Analoguee input 4 Suction presssure probe
Taab. 15.a
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 36
μRack
16 Glossary
Analoggue value: integer vaalue with minus signn and decimal pointt.
Buffer (memory): memoryy on the board usedd to save the defaultt values selected by CAREL for all the paarameters. Permanent memory, saves thhe values even when power is disconneected.
Buzzer: buzzer fitted on thhe external terminalss; this sounds in the event of alarms or the limits set for thee parameters are excceeded. The Built-inn terminals do not have a buzzer.
Digital value: value with oonly two states.
Differential: defines a presssure (or temperature) difference from the corresponding sset point.
Discharge: pressure or tem mperature measuredd at the compressorr outlet. This is an annalogue value.
HP : High pressure
Integerr value: integer valuue without decimal point.
p
LP : Low
w pressure
Proporttional band: this deffines a temperature (or pressure) zone of o a few degrees startting from the set point, inside which the system manages thee control devices.
Range: range of values avaailable for a parameter.
Step: defines an area of the proportional bandd (pressure or temperature) inside whicch a device is on, annd at the same time also defines the devvice on/off values.
Set point: defines a pressurre (or temperature) value
v to be satisfied; the system activatess or deactivates the devices
d so that the value measured reachhes the set point.
Suctionn: pressure or tempeerature measured at the compressor intake. This is an anal ogue value.
Uploadd: the operation useed to copy the appliccation software from m the computer or pprogramming key to the µRack.
17 Technical specificatioon
“Grouup A” is defined inn the following speecifications as the grouping of the ffollowing outputs: compressor 1, co
ompressor 2, fan 1, fan 2, alarm.
Note: All
A the relays musst have the commons (C1/2, C3/4) connected togethher, as shown in Fig.
F 1e2
Functtional specificcations
Resoluution of analogue inputs Temperature
T probbes: range -40T80°C, 0.1 °C
Tempeerature measurem ment error Range
R -20T20 °C, ±0.5 °C (excludinng probe)
Range
R -40T80 °C, ±1.5 °C (excludinng probe)
Pressure measurement error The
T voltage % errror in the input rannge of 0.5 to 4.5 Vdc
V is ± 2% (excluuding probe).
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 37
μRack
Accesssories
Warning: the connectorrs kit MCH2CON** contains a 2 pinss connector for thee tLAN which is not used for μRackk
MCH22004850: RS485 sserial board for peer μRack panel moounting version
FCSERR00000: RS485 seerial board for per μRack DIN rail mounting
m version
PSOPZZKEY00: programming key with 12 Vdc batteries inclluded
mming key with 2330 Vac external power supply
PSOPZZKEYA0: program
KIT
code uRack RS485 Ratiometric ppressure probe Cables for Connectors kitt 2 m cables kit
pressure MCHSMLCAAB2
-1...4,2 bar -1...9,3 bar -1...12,8 bar 0...34,5 bar probe
MRK00010DK D
DIN No 1 1 2 DIN No
MRK000200K ppanel No 1 1 2 panel No
MRK00030DK D
DIN No 1 1 2 DIN Yes
MRK000400K ppanel No 1 1 2 panel Yes
MRK00050DK D
DIN No 1 1 2 DIN Yes
MRK000600K ppanel No 1 1 2 panel Yes
MRK00090DK DIN No 1 1 2 DIN Yes
MRK000800K ppanel No 1 1 2 panel Yes
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 38
μRack
19 Append
dix: Compressor rack
r con troller, examples
e s of appliication diagrams
d s
4 com
mpressors un it with fan speeed regulator
C4 C3 C22 C1
Fig. 17.a
2 com
mpressors un it + 2 condenser fans
F2 F1 C22 C1
Fig. 17.b
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 39
μRack
3 compressors unit with 2 fan steps and speed regulator (no alarm relay output)
F1 C3 C2 C1
Fig. 17.c
F2 F1 C2 C1
Fig. 17.d
20 Append
dix: Chan
nges intrroduced iin Fw rellease 2.0
0 for MRK
K0000XX
X0
The lattest FW release haas changed from 1.7 to 2.0
Modifications have beenn made to the folllowing strings:
• AS2 has beeen replaced by AB2;
• AS3 has beeen replaced by AB3;
• S3 has beeen replaced by B2;
• S4 has beeen replaced by B3.
In the case of two refrigerant circuits, a fixxed delay of 4 secconds has been inntroduced between the start of the first
f compressor inn the first refrigeraant circuit and thee start
of the first compressor in the second refrigerant circuit.
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 41
μRack
21 Append
dix: Chan
nges intrroduced iin Fw rellease 2.1
The lattest FW release haas changed from 2.0
2 to 2.1
Modifications have beenn made to the folllowing strings:
- arrannging of Speed-Upp Inverter mode and
a calculation off minimum and mmaximum speed inverter;
- arrannging of Floating ccondenser controol;
- change of alarm delay to start-up; now w, more than the value of the DE LAY_START parameter, is includ
ded the delay im posed by their re
elative parameter
23 Appendix
A x: Chang
ges intro
oduced in
n Fw rele
ease 2.3
The FW
W release has changed from 2.2 a 2.3
New types of units havve been added to increase the product portfolio, wiith the introductioon of single-circuit and two-circuitt units with capaccity control; the time
betweeen activation of ccapacity-control steps
s is fixed (5 seconds).
s
The following “/” param
meters have beenn modified:
/01: Range extended from 0-8 to 0-144
CARELL reserves the right to make modiffications or changges to its productts without prior notice.
Cod. CAREL
C +03P2204431 rel. 2.3 datedd 06/06/12 42
Cod.: +03P220431 - µrack Rel. 2.3 06/06/12