Manuale utente microprocessore avanzato pCO ING
Contents
1. Pump 1 overload M Alarm130 AL 030 Bl probe fault or not connected M Alarml45 AL 033 B4 probe fault or not connected M Alarm170 AL 040 Main fan pump maintenance M Alarm185 AL 043 Compressor 3 maintenance RG66001134 Rev 00 M Alarm60 AL 010 Low pressure alarm circuit 1 M Alarm75 AL 024 High pressure alarm transducer 2 M Alarm220 AL 026 Pump 2 overload M Alarm135 AL 031 B2 probe fault or not connected M Alarm150 AL 034 B5 probe fault or not connected M Alarml75 AL 041 Compressor 1 maintenance M Alarm190 AL 044 Compressor 4 maintenance 25 AGalletti AIR CONDITIONING M Alarm65 I 7 AL 011 Low pressure alarm circuit 2 J M Alarm80 r 7 AL 001 Serious alarm by digital input J M Alarm100 r 7 AL 049 Main fan overload J M Alarm140 IT 7 AL 032 B3 probe fault or not connected M Alarm155 IT T AL 035 B6 probe fault or not connected M Alarm180 3 AL 042 Compressor 2 maintenance J M Alarm195 J AL 050 fault or not 32K clock board connected l LE AGalletti 6 Application setting parameters 6 1 Table of default settings Category pescripion__2. modification of main operating parameters display of machine status and of all measured data display of the alarms detected and a buzzer that can be disabled The terminal and the pCO controller are connected via a 6 way telephone cable This connection is not essential for standard controller operation 3 2 Display The display used is of the 4 line x 20 column LCD type The data and information regarding operation alternate as successive windows called masks It is possible to move around inside the masks using the terminal keys as described below 3 2 1 Moving around inside the masks If the cursor is positioned in the top left hand corner Home pressing the A y keys allows the user to access the successive masks associated with the selected branch If a mask includes fields for setting values pressing the ENTER key will cause the cursor to move into these fields Once a parameter setting field is reached it is possible to change its value within the set limits by pressing the a 9 keys Once the desired value has been set pressing the ENTER key again will store it in the memory RG66001134 Rev 00 13 A Galletti AIR CONDITIONING 3 3 Keyboard Key 1 Key 2 Key 3 Key 4 Key 5 Key 6 Key 7 y y y y 1 1 ij T T T T T Key 8 Key 9 Key 10 Key 11 Key 12 Key 13 Key 14 Key 15 Key 1 Accesses the mask displaying the fundamental machine data and status Key 2 Accesses device maintenance data hours of service of
3. the main pump fan off 000s M_User40 Digital input remote In this mask it is possible to set enable the digital input remote on off on off N command The summer winter switching is not available Digital input remote Summer Winter N M_User42 ll ne In this mask it is possible to set enable the remote on off command from the on off N supervisory system The summer winter function is not available Supervisory remote Summer Winter N RG66001134 Rev 00 22 M_User50 Defrost parameters In this mask it is possible to set the defrost regulation parameters Start 00 0 C Stop 00 0 C M User55 Defrost parameters Delay time 00000s Maximum time 00000s Drip time 000s M User60 Ia another Here it is possible to change the user access password user password 0000 5 1 7 Manufacturer menu User menu access is password protected The password is only available on request M Manuf5 M Manuf6 M Manuf7 IT TI Unit config 00 Heatpump enable N Evap condenser AIR WATER flow alarm and CHILLER serious alarm SEMIHERMETIC COMPS Giai N M Manuf10 M Manuf15 M Manuf20 J Probes enable Pressure probe conf ieenercesane config Bl N B2 N B3 N B4 N B5 N B6 N 4mA 000 0bar Circuit Nr
4. 0 B7 N 20mA 000 0bar estro per circuit 0 M Manuf25 M Manuf27 M Manuf28 IT T Compressors config Clock board 32k Digital input 1 PW time 000 ms configuration Comp Turnover N Enable N Balanced turnover N resta ALARM M Manuf40 M Manuf45 M Manuf50 IT T Minimum compressors Min time betw diff Condensation power on time 0000s comp starts 0000s Minimum compressors Min time betw same Enable NONE power off time 0000s comp starts 0000s mes INVERTER I M Manuf55 M Manuf60 M Manuf70 I T Condensation Condensation Inverter Max speed 00 0V Fans Nr 0 Setpoint 000 0 Min speed 00 0V Condenser SINGLE Diff 000 0 e up time 000s d RG66001134 Rev 00 23 A Galletti M Manuf80 Prevent N Setpoint 00 0 Diff 00 0 M Manuf90 Low pressure alarm Startup delay 000s Run delay 000s M Manuf105 Antifreeze heater Setpoint 00 0 C Diff 00 0 C M Manuf130 Defrost config Probe TEMPERATURE Type SIMULTANEOUS Off Comp NO M Manuf190 Insert another manufacturer password 0000 M Manuf81 Prevent Devices exit delay 000 s M Manuf91 Low pressure alarm Events Nr 0 Period 0000s Timeout start 000s M Manuf110 Evaporat flow alarm Startup delay 000s Run delay 000s M Manuf132 Supervisory System Communication speed 1200 RS485 R
5. Vdc High pressure switch circuit 2 J5 3 ID3 digital input no 3 at 24 Vac Vdc Low pressure switch circuit 1 J5 4 ID4 digital input no 4 at 24 Vac Vdc Low pressure switch circuit 2 J5 5 IDS digital input no 5 at 24 Vac Vdc oo Sade compressors Land 15 6 ID6 digital input no 6 at 24 Vac Vdc i is Sore et J5 7 ID7 digital input no 7 at 24 Vac Vdc Thermal switch Pump 1 J5 8 ID8 digital input no 8 at 24 Vac Vdc Thermal switch Pump 2 15 9 IDCI shared digital inputs from 1 to 8 negative pole if the unit is DC powered J6 1 B7 analog input 7 J6 2 GND shared analog inputs J6 3 B8 analog input 8 J6 4 GND shared analog inputs J7 1 ID9 digital input no 9 at 24 Vac Vdc Water flow switch J7 2 ID10 digital input no 10 at 24 Vac Vdc General fan alarm J7 3 ID11 digital input no 11 at 24 Vac Vdc Phase direction alarm J7 4 ID12 digital input no 12 at 24 Vac Vdc Remote On Off 17 5 IDC9 shared digital inputs from 9 to 12 negative pole if the unit is DC powered J8 1 ID13H digital input 13 at 230 Vac J8 2 ID13 digital input no 13 at 24 Vac Vdc Summer Winter LCA H 18 3 IDC13 shared digital inputs 13 and 14 negative pole if the unit is DC powered J8 4 ID14 digital input 14 at 24 Vac Vdc Serious alarm secondary setpoint J8 5 ID14H digital input 14 at 230 Vac J9 1 5V Rif Reference voltage for pressure probe power supply J9 2 GND shared analog inputs J9 3 V Therm Terminal supply voltage J10 six way telephone type connector for connection to standar
6. a device and hour meter reset alarm history manual operating procedure Key 3 Function not active Key 4 Accesses the masks displaying digital and analog input output statuses Key 5 Accesses the clock programming mask if a clock board is included Key 6 Accesses the setpoint display setting masks Key 7 Accesses the user parameter programming masks thresholds delays etc Key 1 Key 7 By pressing these keys at the same time the user accesses the machine configuration number of devices connected to the pCO1 programming of the full scale values etc Key 8 Displays data concerning the software used Key 9 For selecting the winter mode LCA H model not available on the LCA model Key 10 For selecting the summer mode LCA H model this mode is always active on the LCA model Key 11 This key allows the unit to be switched on and off The green LED illuminating the key indicates the unit status Key 12 This key is used for displaying alarms resetting them manually and silencing the buzzer If the key is lit red LED it means that at least one alarm has been detected Pressing the key once will silence the buzzer and cause a mask to appear which describes the alarm that is active Pressing a second time will reset the alarm signalling function Key 13 this key enables the setting of control parameters as well as movement from one mask to another not backlit Key 14 this key enables the setting of control param
7. delay time e maximum defrost time e drip time at the end of defrosting cycle Defrosting of one circuit under pressure control The defrosting cycle starts when the coil temperature pressure remains below the start defrost threshold for a total time t1 t2 t3 equal to the defrost delay time and if at least one compressor of the circuit concerned is on e compressors are or are not turned off according to the selection made from the mask and the cooling cycle is reversed by means of the 4 way valves e the fans are forced into the OFF mode The circuit terminates the defrosting cycle when the threshold is exceeded i e when the temperature pressure value exceeds the end defrost setpoint or when the maximum time set from the mask has elapsed if the temperature pressure value has not exceeded the end defrost setpoint Pressure Fine Set Set 3 4 p E 3 4 p 4 B i 4 p i t1 t2 t3 Defrosting Time cycle Figure 0 Defrosting cycle Simultaneous defrosting mode Even if only one circuit requires defrosting all circuits are forced into the defrosting mode Circuits not requiring defrosting temperature pressure higher than the end defrost threshold stop and remain on stand by As soon as the defrosting cycle has terminated all the compressors can start up again in the heat pump mode Separate defrosting mode In this defrosting mode each cooling circuit undergoes a defrosting cycle separately The first circuit requirin
8. o A a i t a 18 5 13 VO A a a i is a Kia i a i ei a 20 SLA Clock MENU aaa t a a a i a i i a i ri a aa 21 5 125 Setpoint Men asien ia ia ia a a i a a r a i A i ai ak S ai 21 5e User A iai ia asi ai aa a aa ia a ka i a r a a a a a i a oi 21 5 17 Manufacturer men ari dd alii 23 5448 Alarm Melina A A A A a k 24 6 Application setting parameters anna aa aaa aaeaaaaaaa ananasas aaa aaa 26 6 1 Table of default setings a visi kis dienas ads ad ai a i D i i D ai 26 7 Architecture of the control SS Mrs cri AAA AAA AA 28 7 1 Microprocessor laYOUt eee eee 28 7 2 Description of inputs and OUtputs cece aa iE E E EE AEAEE AN 29 7 3 ALA 7722 31 7 3 1 RS485 serial board for supervisory function iii 31 AO o dt TETTO OI a 31 7 4 Technical data rocio at iia o i n 32 RG66001134 Rev 00 3 AGalletti 1 General description of the application The operation of LCA and LCA H units heat pump model is managed by application software installed in the controller on the unit The main features of the application program are described below 1 1 Types of units controlled The software is designed to control air water chiller units LCA model also models with operation as a heat pump LCA H model 1 2 Maximum number of compressors From 1 to 4 hermetic scroll compressors up to 2 cooling circuits 1 3 Types of regulation Proportional regulation or proportional regulation with integr
9. optional 17 flap for installation of clock board optional a o ci a NOs NO5 NO6 a 828 239 Figure 0 Layout microprocessore RG66001134 Rev 00 28 7 2 Description of inputs and outputs A Galletti Conn Code Description Signal J1 1 G power supply 24 Vdc or 24 Vac J1 2 G0 power supply reference P 1 BI m input 1 NTC 0 1 V 0 10 V 0 20 mA Condensation pepe 2 B2 universal analog input 2 NTC 0 1 V 0 10 V 0 20 mA Condenan diano 4 20 mA 1223 B3 universal analog input 3 NTC 0 1 V 0 10 V 0 20 mA Remote adjustmentof setpoint 4 20 mA 2 4 B4 universal analog input 4 NTC 0 1 V 0 10 V 0 20 mA 4 20 mA J2 5 VDC power supply for active probes 21 Vdc max 200 mA B 1 BS analog input 5 NTC temperature probe at evaporator inlet J3 2 GND shared analog inputs B3 B6 lies NTC temperature probe at evaporator outlet J3 4 GND shared analog inputs J4 1 VG power supply for optoisolated analog output at 24 Vdc J4 2 VGO power supply for optoisolated analog output at 0 Vac Vdc J4 3 Y1 analog output n 1 0 10 V Condensation fan control J4 4 Y2 analog output n 2 0 10 V J4 5 Y3 analog output n 3 0 10 V J4 6 Y4 analog output n 4 0 10 V J5 1 IDI digital input no 1 at 24 Vac Vdc High pressure switch circuit 1 J5 2 ID2 digital input no 2 at 24 Vac
10. the condensation pressure exceeds the prevent function activation value setpoint the function is triggered and remains active until the value detected goes below the prevent function deactivation value setpoint differential At this point a delay is activated settable from the M_MANUF81 mask on page 23 which lengthens the prevent action thus delaying any restart of the compressors 2 4 Defrost control Inputs used e High pressure probe of first circuit B5 analog input e High pressure probe of second circuit B6 analog input Parameters used Inputs used for defrosting Defrosting modes simultaneous separate Start defrost setting End defrost setting Defrost delay time Maximum defrost time Drip time Reverse cycle with compressors off No Input Output Input Output Outputs used Compressor 1 Compressor 2 Compressor 3 Compressor 4 Reversing solenoid valve cycle 1 Reversing solenoid valve cycle 2 Fans RG66001134 Rev 00 10 A Galletti The defrosting function requires the setting of some parameters protected by a factory set password ref M_MANUF130 mask page 23 e e PRESSURE defrosting probe e Defrosting mode SIMULTANEOUS SEPARATE e Cooling cycle reverse with compressors turned off NO INPUT OUTPUT INPUT OUTPUT as well as some parameters protected by a user password ref M_USER50 55 mask see page 23 i e e start end defrost threshold e defrost activation
11. 17 1 NO12 normally open contact relay no 12 J17 2 C12 shared relay no 12 J17 3 NC12 normally closed contact relay no 12 J18 1 NO13 normally open contact relay no 13 On Off Unit J18 2 C13 shared relay no 13 J18 3 NC13 normally closed contact relay no 13 Terminal E for RS485 serial connection to I O expansion J23 1 E modules 123 2 E Terminal E for RS485 serial connection to I O expansion modules 1233 GND Terminal GND for RS485 serial connection to I O expansion modules RG66001134 Rev 00 30 A Er A Galletti AIR CONDITIONING 7 3 Optional boards 7 3 1 RS485 serial board for supervisory function For the serial connection to a local or remote supervision system it is necessary to install an RS485 serial board available on request see Figure 0 RS485 Figure 0 RS485 Serial Board Connection to the local supervisor computer The connection to the local supervisor computer is made via a RS485 serial line and communication takes place via the proprietary Carel protocol A RS485 RS232 converter is needed for connecting to the serial port of the PC Microprocessore pCO1 a bordo macchina RS485 serial line RS232 serial line RS485 RS232 op Converter PC con software di supervisione Figure 0 Connessione tra microprocessore e computer locale di supervisione 7 3 2 Clock board The serial connection to a local or remote supervision system requires the installation of an RS485 serial
12. 2 2 4 Delay between two start up requests aa tt aa nnar tE aa anas a EESE EEEE aa aa anais 7 2 2 5 Delay between two successive start ups of the same compressor nsee 7 2 3 Condensation Control cs sedition tier a i i i i a a ai ai a aes 8 Zal Settings iai iii iai a i ii i celta a a i i a a 8 2 32 High pressure Ala M Lai aisiais saita ais in o iii S ia i Sa ao Sa saaa as 10 2 3 3 PreventTUNCION ss uunas kasis aso iai iai A cand a R r a a a aaia 10 2 4 PSSS A 10 2 5 Antifreeze regulation cisco iaa ca ilo loin 11 3 Start up and configuration lt lt 13 3 1 Terminal with keyboard and display nn nannten tenenan nenet 13 3 2 DISDIAV aeea i ai ai i a i ia a a a a a a aa la 13 3 2 1 Moving around inside the MasKS non cnn rc 13 3 3 KODO dorae tanda 14 3 4 Starting up the unit for the first time arrik siratan eee aaa aaa n cnn cnn non NAE ETENEE PARTANEN 15 RG66001134 Rev 00 2 A Galletti 3 5 General description Of MENUS nn nn nnnnnnnnnnnn nn nn rn nr nn rra anne nn rn nn nr rn rnnnnn merma 15 4 Alarm menNdej SE a ia a a a a S 16 4 1 Main alarmitable riale iai a ia i aa a ia ii a i ii a i a i as 16 4 2 Alarm HISIONY iia ie i k a a ad 17 5 Menu Tree structuU e nissan tis iais AA a a a a A ARA a ss 18 5 14 MENU A is iaia aa A Tao a ia a ia a i aaa 18 5 12 Maintenant Menari iais ia a i aa a a i a A a i GA a i
13. 3 Condensation Control Condensation can be regulated according to the following modes e on off based on compressor operation without pressure transducers e on off or modulating based on the pressure transducer reading when high pressure transducers are enabled Inputs used e High pressure probe of first circuit B5 analog input e High pressure probe of second circuit B6 analog input Parameters used Condensation control selection none pressure Number of fans Type of condensation coil Single Separate Condensation Setpoint Condensation Differential Enabling of prevent function Prevent Setpoint Prevent Differential Delay in device reactivation after triggering of prevent function Output voltage relative to minimum inverter speed Output voltage relative to maximum inverter speed Inverter speed up time Outputs used e Fans NO9 digital output e Fan speed regulation Y1 analog output 2 3 1 Settings For condensation it is necessary to set e the type of regulation by means of the Abilit Enable code in the M_MANUF50 mask see page 23 The selection is made between NO TEMPERATURE for choosing regulation either on the basis of the compressor status or on the basis of the values read by the pressure transducers e the type of devices used by specifying the Tipo Type code in the M_MANUF50 mask see page 23 The selection is made between INVERTER GRADINI STEPS for choosing either the modulating
14. LCA LCW UCR pCO ADVANCED MICROPROCESSOR USER MANUAL COMPANY WITH QUALITY SYSTEM CERTIFIED BY DNV 150 9002 SS A Galletti AIR GON D I TION ING AGalletti Index 1 General description of the application kana aaa aaa aaaaaaaaaa nana aaa aaa 4 1 1 Types of units controlled nan cc nnn Aaaa naar Aaaa Aaaa aa Aaaa aaa 4 1 2 Maximum number of compressors anno ananasai aaa aaa aa nn nn EEES EE REENE EEES Ennen E EEEn 4 1 3 Types of regulation nono n cnc a Aaaa aaa aaa n nr r edna aka aaa 4 1 4 Condensationi airera ieri learn 4 1 5 Compressor operating turnover 4 1 6 Defrosting modes LCA H Model ii 4 1 7 Safety devices on each cooling CIrcUit cnn aaa aaa aaa aaa aaa aaa aaa 4 1 8 System safety TERM linea ili 4 1 9 Optional accessorieS E 4 ea On mr Cre Cre er 5 2 1 Inlet temperature regulation i 5 2 1 1 PROPORTIONAL regulation i 5 2 1 2 PROPORTIONAL INTEGRAL Regulation nana 5 213 Selpomnti rana eo aio ie art 5 2 2 Compressor times and configuration i 6 22 1 Compressor operation turnover i 6 2 2 2 Minimum compressor ON time nn nnn cnn nnn ranma nnnncnnnnnns 6 2 2 3 Minimum compressor OFF time nn nnn cnn nn nrnnnnnnnnnnnnnnnnns 7
15. S422 Indentificat Nr 000 M Manuf85 I Transducers high pressure alarm Setpoint 00 Obar Di 00 0bar IL Jj M Manuf100 IT Antifreeze alarm Setpoint 00 0 C Diff 00 0 C IL d M Manuf125 r Reversing valve Logic ws I M Manuf135 J I Reset all parameters to default values N l 5 1 8 Alarm menu Each mask gives information about a specific alarm situation The activation of the masks is accompanied by the sounding of the buzzer and tripping of the general alarm signalling relay By pressing the ALARM key once the user can access the first active mask and then scroll all alarms using the a r keys Pressing the ALARM a second time will clear the alarm message Each mask shows the code used in the alarm history to identify the particular event ref 4 2 Alarm history page 17 M Alarm00 M Alarm5 M Alarml0 I T AL 002 AL 016 No alarms Freeze alarm Compressor 1 2 detected overload M Alarm20 M Alarm30 M Alarm40 J AL 018 AL 005 AL 012 Compressor 3 4 Evaporator flow High pressure overload alarm circuit 1 RG66001134 Rev 00 24 M Alarm45 AL 013 High pressure circuit 2 M Alarm70 AL 023 High pressure alarm transducer 1 M Alarm210 AL 025
16. ___ Default Probe management Enable probe 3 Setting ofprobe1 0 Setting ofprobe2 0 Setting ofprobe3 0 Setting ofprobe4 0 Setting ofprobe5 0 Setting of probe6 0 Inputs Outputs management Digital filter delay Circuit configuration Unit configuration 02 Setting parameters Integration time 600s Main pump fan management Delay time between starts of pump fan 5s E i GII Compressor parameters O N Enable balanced turnover N Minimum compressor run time 60s Minimum compressor stop time 360 s Minimum time between start ups of different 10s compressors RG66001134 Rev 00 26 AGalletti Minimum time between start ups of same 450 s compressor Condensation regulation 2 bars 10 V OV Delay in device start up after triggering of prevent function Defrosting management Simultaneous Pressure 2 bars 12 bars 1800 s Maximum defrosting time 300 s o v Remote setpoint management Remote maximum setpoint limit 5 C Hour meter management Hour threshold pump 1 10000 h Hour threshold pump 2 10000 h Hour threshold compressor 1 10000 h Hour threshold compressor 2 10000 h Hour threshold compressor 3 10000 h Hour threshold compressor 4 10000 h Antifreeze management Antifreeze alarm setpoint Antifreeze alarm differential Flow switch management Evaporator flow switch alarm dela
17. al action on the evaporator input temperature Possibility of adjusting the setpoint remotely 1 4 Condensation Condensation can be carried out in the following modes e on off based on compressor operation without pressure transducers e on off or modulating based on the pressure transducer reading when high pressure transducers are enabled 1 5 Compressor operating turnover Turnover of all compressors according to a FIFO logic Selection of balanced turnover of all compressors according to a FIFO logic 1 6 Defrosting modes LCA H model Defrosting can be simultaneous or separated among the circuits 1 7 Safety devices on each cooling circuit e High pressure pressure switch e Low pressure pressure switch e Compressor thermal switch 1 8 System safety features Serious alarm shuts the whole unit down Evaporator flow switch shuts the whole unit down Pump thermal switch Condensation fan thermal switch Remote on off input without alarm signalling 1 9 Optional accessories e Supervision by means of RS485 serial board e Alarm history building with clock board RG66001134 Rev 00 4 A Galletti 2 Regulation logic 2 1 Inlet temperature regulation Inputs used e Evaporator inlet water temperature Parameters used e Regulation setpoint e Proportional band for input temperature regulation e Type of regulation proportional or proportional integral e Integration time if proportional integ
18. board available on request see Figure 0 Scheda orologio Figure 0 Scheda orologio RG66001134 Rev 00 31 AGalletti 7 4 Technical data General specifications operating conditions 10T60 C 90 R H not condensing protection rating IP20 IP40 on front panel only heat and fire resistance class class D UL94 VO Immunity against over voltages Class 1 number of manoeuvring cycles of automatic 100 000 operations e g relay Class and structure of software Class A Electrical specifications power supply controller with connected terminal 22 to 38 Vdc and 24 Vac 15 50 60 Hz Maximum power consumption 13 W terminal block with extractable male female connectors maximum voltage 250 Vac cable size 2mm min 0 5 to max 2 5 CPU H8S2322 16 bits 14 MHz program memory on FLASH MEMORY 16 bit organisation 1 MByte expandable to 2 MByte data memory static RAM 8 bit organisation 128 kByte expandable to 512 MByte Serial Board 16 bits organisation 4 kByte upper limit 400 000 recordings per memory location useful pCO1 cycle with applications of medium complexity 0 55 Analog inputs number 8 Analog conversion A D converter 10 bit CPU built in type Passive NTC inputs B5 B6 B7 B8 or clean contact digital input SmA selectable via dip switch B5 B6 Universal NTC see passive type voltage 0
19. d RG66001134 Rev 00 29 AGalletti user terminal RX TX connector for RS485 serial connection to pLAN J11 1 TX network N12 TX RX TX connector for RS485 serial connection to pLAN network 1113 GND GND connector for RS485 serial connection to pLAN network J12 1 Cl shared relay 1 2 3 J12 2 NO1 normally open contact relay no 1 ON OFF compressor 1 J12 3 NO2 normally open contact relay no 2 ON OFF compressor 2 J12 4 NO3 normally open contact relay no 3 ON OFF compressor 3 J12 5 Cl shared relay 1 2 3 J13 1 C4 shared relay 4 5 6 J13 2 NO4 normally open contact relay no 4 ON OFF compressor 4 J13 3 NOS normally open contact relay no 5 ON OFF pump 1 J13 4 NO6 normally open contact relay no 6 ON OFF pump 2 J13 5 C4 shared relay 4 5 6 J14 1 C7 shared relay no 7 J14 2 NO7 normally open contact relay no 7 ON OFF antifreeze heaters J14 3 C7 shared relay no 7 Remote general alarm on relay for J15 1 NO8 normally open contact relay no 8 a fa ntrol and in i ligh t J15 2 C8 shared relay no 8 J15 3 NC8 normally closed contact relay no 8 J16 1 C9 shared relays no 9 10 11 J16 2 NO9 normally open contact relay no 9 ON OFF condenser fans J16 3 NO10 normally open contact relay no 10 i posmons ZI J16 4 NO11 normally open contact relay no 11 Li pasmon regia J16 5 C9 shared relays no 9 10 11 J
20. e MAINTENANCE key provides access to these masks which Hone meters display the number of hours of work performed by each device These values will be stored in the flash memory of the pCO board data are recorded at Hours 000000 three hour intervals This function is provided whether or not a clock board is installed on the pCO M Maint6 If the number of working hours of a device eguals the set threshold the relative alarm is triggered Pump 2 hour meters Hours 000000 M Maint10 Hour meters Compressor 1 000000 Compressor 2 000000 M Maint15 Hour meters Compressor 3 000000 Compressor 4 000000 M Maint17 This is the alarm history mask History alarm 0000 ALOOO 00 00 00 00 00 Set 00 0 Band 00 0 T In 00 0 T out 00 0 M_Pw_Maint The maintenance password is required for viewing the following masks The TS password is only available on request maintenance password 0000 M Maint20 In these masks it is possible to modify the value of the device maintenance alarm threshold and reset the hour meter of each device after it has undergone threshold 000x1000 maintenance Req reset N 000000 Pump 1 hour meter RG66001134 Rev 00 18 M Maint21 Pump 2 threshold Req reset hour meter 000x1000 N 000000 M Maint25 Compressor hour meter Threshold 000x1000 Req reset N 000000 M Maint30 Compressor hou
21. er time and enable the buzzer I O Menu The I O menu can be accessed by pressing key 4 and shows the system s inputs and outputs Clock menu The clock menu can be accessed by pressing key 5 and contains the time and date configuration Setpoint Menu The Setpoint menu can be accessed by pressing key 6 and allows management of fixed and variable setpoints User menu The User menu can be accessed by pressing key 7 and contains the configuration of user parameters It is password protected Manufacturer menu The Manufacturer menu can be accessed by pressing key 1 key 7 together and contains the configuration of factory set parameters It is password protected Alarm menu The Alarm menu can be accessed by pressing key 12 and gives information about the alarms that have been triggered RG66001134 Rev 00 15 AGalletti 4 Alarm management The alarms are divided into three categories 1 Warnings only with display of warning message and buzzer or display of warning message buzzer and alarm relay 2 Circuit alarms with deactivation of the circuit concerned display of alarm message buzzer and alarm relay 3 Serious alarms with shut down of the whole system display of alarm message buzzer and alarm relay Warnings e Unit maintenance warning e Compressor maintenance warning e Clock board failure or disconnection Circuit alarms e High pressure pressure switch alarm immediate shut down of the compressor and man
22. et of masks provides a complete display of the statuses of the analog and digital inputs and outputs connected to the microprocessor M_InOut10 Digital inputs CCCCCCCCCCCC Digital outputs 0000000000000 M_In0ut15 Analog inputs Bl 00 0 C B2 00 0 C M InOut20 Analog inputs B3 00 0 C B4 00 0 C M InOut25 Analog inputs B5 00 0bar B6 00 0bar B7 00 0 C M InOut35 Analog outputs YO 00 0V YI 00 0V RG66001 134 Rev 00 20 5 1 4 Clock menu M_Clock5 Clock not installed M Clock10 Clock configuration Time 00 00 Date 00 00 00 5 1 5 Setpoint Menu M Setpointl Actual setpoint 00 M Setpoints Summer setpoint 00 Winter setpoint 00 M Setpoint10 Second summer setpoint 00 Second winter setpoint 00 5 1 6 User menu User menu access is password protected M Users User password 100 Summer temperature setpoint limits Low 00 0 C High 00 0 C M User15 Winter temperature setpoint limits Low 00 0 C High 00 0 C M User17 Regulat tmperature Type INLET RG66001134 Rev 00 A Galletti AIR CONDITIONING When the clock key is pressed this mask will be displayed if the clock board has not been configured in the manufacturer branch ref mask M_MANUF27 When the clock key is pressed if t
23. eters as well as movement from one mask to another not backlit Key 15 used for moving the cursor inside the masks and saving parameter settings The key is constantly backlit yellow light to indicate that the power supply is on NOTE The LEDs alongside each key come on when the respective function is activated RG66001 134 Rev 00 14 A Galletti 3 4 Starting up the unit for the first time When the microprocessor is connected to the power supply the main menu will be displayed M_Main It contains the following information M Main current date and time ha dd Dn e evaporator inlet water temperature Inlet water 00 0 C e evaporator outlet water temperature Outlet water 00 0 C e unit status ON 3 5 General description of menus General description of the menus featured in the application all the masks are shown and described in the chapter 5 Main menu The main menu is displayed when the unit is started up and consists of the two masks described in the section 3 4 Starting up the unit for the first time Maintenance menu The maintenance menu can be accessed by pressing key 2 It shows the compressor and pump hour meters as well as the alarm history if a clock board has been installed If the maintenance password is entered given to maintenance personnel directly by Galletti S p a it will be possible to set the device hour meter alarm thresholds clear the hour meter set the probes set the pump type and turnov
24. g defrosting starts a defrosting cycle whereas the other circuits remain on standby until the first circuit has completed its defrosting cycle even if they too require defrosting When the defrosting cycle of the first circuit is finished the following circuit will be defrosted while the other circuits wait their turn 2 5 Antifreeze regulation Inputs used e Evaporator outlet water temperature probe Parameters used e Enabling of outlet line probe e Antifreeze alarm setpoint RG66001 134 Rev 00 11 AGalletti e Antifreeze alarm differential Outputs used e Antifreeze alarm Each pCO unit can manage antifreeze regulation provided that the outlet temperature probe is connected and enabled Alarm status Alarm ON Alarm OFF Antifreeze differential Evaporator outlet temperature lt lt Antifreeze Setpoint diff Band setpoint Figure 0 Antifreeze regulation RG66001 134 Rev 00 12 AGalletti AIR CONDITIONING 3 Start up and configuration 3 1 Terminal with keyboard and display Figure 0 Terminal The user terminal is shown in the picture It consists of a 4 line x 20 column LCD keyboard and LEDs controlled by a microprocessor from the terminal the user can set the control parameters setpoint differential band alarm thresholds etc and perform fundamental operations The following main operations can be performed via the terminal e initial machine configuration
25. he clock board has been configured in the manufacturer branch ref mask M_MANUF27 this mask is displayed from here it is possible to set the current date and time By pressing the SET key it is possible to access the following masks in order to view the summer and winter setpoints and active differentials In these masks it is possible to select the minimum and maximum summer and winter setpoint values that may be set A Galletti M_User20 tiie ceguiazion If inlet regulation is selected it is possible to choose whether to adopt a proportional or a proportional integral type of regulation In the latter case an Type EROP integration time will also be set Integration t 0000s M_User22 Outlet regulation Time on 0000s Time off 0000s M_User23 Outlet regulation force off Summer 00 0 C Winter 00 0 C M_User24 External setpoint Enable N Min 00 0 C Max 00 0 C ll j M_User25 Temperature band This mask enables the temperature regulation band to be set on the basis of 00 0 c this value according to the type of regulation selected the proportional band or neutral zone will be calculated M User30 Time between In this mask it is possible to set the minimum delay between the pump start main pump fan and compressor start and compressors start 000s M_User35 Delay on switching In this mask the pump shut off delay can be set
26. in compressor restarts after triggering of the prevent function ref M_MANUF81 mask page 23 Condensation on off based on compressor operation If NO is selected in the M_MANUF50 mask see page 23 the fans operation will depend only on the operation of the compressors Condensation on off based on pressure sensor If PRESSURE is selected in the M_MANUF50 mask see page 23 the fans operation will depend only on the pressure read by the pressure sensors according to the selected setpoint and differential band With pressure values lower or equal to the setpoint all fans will be turned off with pressure values higher than the setpoint differential band all fans will be turned on It will be possible to select the condensation function either with a single coil or separate coil In the case of single coil condensation the fans will be controlled by the highest pressure with separate coil condensation each pressure sensor will control its respective fan Modulating condensation based on pressure sensor If this type of condensation is chosen the fans will be controlled in a manner proportional to the readings of the pressure sensor It will be possible to select the condensation function either with a single or separate coil In the case of a single coil the inverter will be controlled by the highest pressure with a separate coil each pressure sensor will control its respective inverter The graph below shows fan operation after the setpo
27. int and the differential band have been set Fan power supply 10V OV Differential band 5 i High pressure 4 gt Setpoint Setpoint diff probe bar Figure 0 Modulating condensation based on pressure sensor If the minimum fan speed is assigned to a power supply value higher than OV the graph shows a case where the minimum speed has been assigned to 3V a 1 bar hysteresis default is applied in order to avoid repeated start ups and stops RG66001 134 Rev 00 9 AGalletti Fan power supply 10V 3V AA 0V Differential band E i High pressure lt probe bar Setpoint 1 Setpoint Setpoint diff Figure 0 Modulating condensation with 1 bar Hysteresis 2 3 2 High pressure alarm If the pressure value exceeds the high pressure alarm setpoint selected in the M_MANUF85 mask see page 23 an alarm will be signalled and the circuit concerned will be deactivated The alarm will turn off when the pressure drops below the setpoint differential value 2 3 3 Prevent function Selecting this function requires access to a factory set password It serves to prevent circuits from being blocked due to the triggering of the high pressure alarm It can be set only on units having two compressors per circuit Setpoint and differential values must be selected from the M_MANUF80 mask see page 23 The prevent function shuts off the compressors thereby dividing the power supplied to the cooling circuit When
28. larms or the secondary setpoint If secondary setpoint management is selected the M_SETPOINT10 see page 21 is enabled for the setting of the summer and winter setpoints controlled by the digital input RG66001134 Rev 00 5 AGalletti With the digital input open the setpoint entered from the M_SETPOINT5 mask see page 21 will be used with the digital input closed the secondary setpoint will be used An R will appear in the upper right corner of the setpoint masks to indicate the activation of the secondary setpoint Remote Setpoint From the M_USER24 mask see page 21 it is possible to enable the remote setpoint function that uses an analog input The signal will be converted between the minimum and maximum values set from the mask The read value will then be added to the setpoint value resulting from the secondary setpoint management 2 2 Compressor times and configuration The unit enables the control of hermetic scroll compressors Mask M_MANUF20 see 5 1 7 Manufacturer menu page 23 is used for configuration purposes from the mask it is necessary to set the number of compressors per circuit and the number of circuits Most of the operations performed by the pCO are conditioned by programmable delays Some of them serve to delay the triggering of some alarms or to assure the proper functioning of the compressors thereby lengthening their lives and guaranteeing system stability 2 2 1 Compressor operation turnover The comp
29. or the ON OFF type regulation e the number of fans connected if step regulation is selected by entering a value for N Ventilatori No of fans in the M_MANUF55 mask see page 23 e the type of condenser by means of the Condensatore Condenser code in the M_MANUF55 mask see page 23 The selection is made between SINGLE SEPARATE e the condensation setpoint and the differential to be entered in the M_MANUF60 mask see page 23 The setting generates a proportional band setpoint setpoint differential from which it calculates the position of the various fan activation steps or the modulating output value according to the selection made e the minimum and maximum speeds of the inverter by specifying the Max velocit Max Speed Min velocita Min Speed codes in the M_MANUF70 mask see page 23 the proportional action of the modulating output is calculated within the range of these values RG66001 134 Rev 00 8 A Galletti e the minimum operating time of the inverter by specifying the Tempo min ON Min ON Time code on the M_MANUF70 mask see page 23 e enabling of the prevent function by means of the Abilit Prevenzione ALTA PRESSIONE Enable HIGH PRESSURE prevention code in the M_MANUF80 mask see page 23 The prevent function will be executed according to the modes specified below in this section e the prevent setpoint and differential ref M_MANUF80 mask see page 23 e the delay
30. r meter Threshold 000x1000 Req reset N 000000 M Maint35 Compressor hour meter Threshold 000x1000 Req reset N 000000 M Maint40 Compressor hour meter Threshold 000x1000 Req reset N 000000 M Maint45 Filters config Enable Anal N delay time Os Dig delay time Os M Maint50 Inputs probes offset Bl 0 0 B2 0 0 B3 0 0 B4 0 0 B5 0 0 B6 0 0 M Maint60 Pump seguence type AUTOMATIC M Maint65 Pump seguence time 000 hours RG66001134 Rev 00 From this mask it is possible to enable the software filters applied on analog inputs The detected input value is transmitted to the control if it maintains the value for a time egual to or greater than the time set Here it is possible to set probe offset values to be added to or subtracted from readings See 17 flap for installation of clock board optional 19 A Galletti M_Maint70 Pump sequence selection SEQUENCE 1 M Maint75 Erase historical This mask only appears if the clock board has been configured and the unit is memory board off Selecting S activates the procedure of erasing all the historical data N During this operation a stand by message will appear on the last line of the mask and no other operation will be possible until erasure is complete M Maint100 Insert another maintenance password 0000 5 1 3 I O Menu This s
31. ral regulation is enabled Outputs used e Compressor On Off Regulation diagram with two compressors A 2 PPI sis i i a a ARERIA ALII aa 2 C1eC2 On 1 C1 On e C2 Off 1 AA 0 C1 e C2 Off gt Set1 Diff1 Set2 Diff2 Set1 Set2 Inlet water T Figure 0 Regulation diagram with two compressors 2 1 1 PROPORTIONAL regulation On the basis of the setpoint entered from the mask ref mask M_SETPOINT5 page 21 if the secondary setpoint or the remote setpoint is active a proportional band is calculated with a width equal to the differential set from the mask ref mask M_USER25 page 21 Inside this band the positions of the device regulation steps are calculated according to the number of compressors 2 1 2 PROPORTIONAL INTEGRAL Regulation Proportional integral regulation uses the same parameters as simple proportional regulation it calculates the steps at which the devices are cut in on the basis of the setpoint the differential and the integration time set from the mask ref mask M_USER20 page 21 The integral action is doubled if the conditions have not changed after the time set 2 1 3 Setpoint Main Setpoint From the mask M SETPOINT15 see page it is possible to set the main setpoint for the summer LCA and winter LCA H operating modes Secondary Setpoint From the mask M_MANUF28 see page 23 it is possible to select the ID 14 digital input configuration for the management of serious a
32. ressor operation turnover makes it possible to balance the number of hours of operation and the number of starts stops of the various compressors The turnover is carried out according to a FIFO logic meaning that the first compressor to start will also be the first to stop During the initial start up period this behaviour may result in big differences between the operating hours of the compressors However at full capacity operation the number of hours will be very similar Management without FIFO turnover with four compressors e Start up C1 C2 C3 C4 e Stop C4 C3 C2 C1 Management with FIFO turnover with four compressors e Start up C1 C2 C3 C4 e Stop C1 C2 C3 C4 If the turnover function is enabled it is possible to select the balanced turnover which always follows a FIFO logic i e the odd devices are activated first and then the even ones e Start up C1 C3 C2 C4 e Stop C1 C3 C2 C4 2 2 2 Minimum compressor ON time ref mask M MANUF40 5 1 7 see Manufacturer menu page 23 This determines the minimum time in seconds the devices must continue running therefore once activated they must stay on for the set length of time RG66001 134 Rev 00 6 A Galletti ON Start up f Request OFF ON Device OFF Figure 0 Minimum compressor on time 2 2 3 Minimum compressor OFF time ref mask M MANUF40 5 1 7 see Manufacturer menu page 23 This determines the minimum time the de
33. story The unit has an alarm history function To activate this function it is necessary to install the optional clock board provided with 32k memory and enable its use from the mask ref mask M_MANUF27 5 1 7 see Manufacturer menu page 23 Alarms are memorised according to priorities decided at the programming stage Each alarm has been attributed a priority code the lower the code the higher the priority in this way if two alarms with different priorities are tripped at the same time only the alarm with the lower code is stored ref 5 1 8 Alarm menu In addition to the alarm code the function stores the date and time evaporator inlet and outlet temperatures setpoint and band used at the moment the alarm is activated ref mask M_MAINT17 see page M Maint17 History alarm 0000 AL000 00 00 00 00 00 Set 00 0 Band 00 0 T In 00 0 T out 00 0 A maximum number of 1600 alarms can be stored After this limit is reached memorisation will again start from the beginning i e the oldest alarm will be overwritten with the new data RG66001134 Rev 00 17 A Galletti 5 Menu tree structure 5 1 1 Main menu M_Main TE nu The main information regarding the chiller s operation is displayed here If the Inlet water 00 0 c optional clock board has been installed the current date and time will also be Outlet water 00 0 c displayed ON 5 1 2 Maintenance menu M Maint5 A Pressing th
34. to 1 Vdc or 0 to 5 Vdc current 0 to 20 mA or 4 to 20 mA selectable via dip switch B1 B2 B3 B4 Digital inputs number 14 type optoisolated inputs at 24 Vac 50 60 Hz or 24 Vdc ID1 to ID12 optoisolated inputs at 24 Vac 50 60 Hz or 230 Vac ID13 to ID14 Analog outputs number 4 type optoisolated 0 to10 Vdc outputs Y1 and Y2 optoisolated PWM outputs phase cut with 5 V pulse Y3 and Y4 power supply external power supply 24 Vac Vdc output resolution 8 bit maximum load 1kQ 10 mA at 0 to 10V and 470 Q 10 mA at PWM Digital outputs number 13 Type with electromechanical relays RG66001134 Rev 00 32 AGalletti RG66001134 Rev 00 33 AGalletti RG66001134 Rev 00 34 AGalletti RG66001134 Rev 00 35 A Galletti AIR CO N Dt TI ON I NG 40010 Bentivoglio BO Via Romagnoli 12 a Tel 051 8908111 Fax 051 8908122 www galletti it
35. ual resetting e Low pressure alarm with automatic manual resetting see description of its operation e Compressor thermal switch alarm with immediate shut down of the compressor and manual resetting e Fan thermal switch alarm with fan stop and manual resetting Serious Alarms e lack of water flow digital input alarm delayed at start up and at full capacity operation e evaporator antifreeze alarm evaporator outlet probe function with activation setpoint and reset differential with manual resetting e serious alarm from digital input Immediate shut down of the unit and manual resetting The alarms are reset manually by pressing the alarm key twice 4 1 Main alarm table Alarm Description Compr System Reset Delay DN gt ee Serious alarm alarm ea m 6 Thermal switch Pump1 Man No A AAA AAA Ban Me Evaporator flow switch Man settable Low pressure Press O C1 C1 High pressure Press switch C2 Fan thermal switch __ a 1 pete perni robe falue8i____ __ Auo 60560 Probe falue82_____ _ 11 TTT Auto ose Probe falue88_____ __ Auto ose Probe falue8_____ _T__ Auto 60sec Probe falue85_____ T_T TT Auto 60sec RG66001134 Rev 00 16 A Galletti Probe failure B6 Maint Pump 1 Maint Pump 2 Maint Compressor 1 Maint Compressor 2 Maint Compressor 3 Maint Compressor 4 ie ee AO A Phase direction 4 2 Alarm hi
36. vices must remain off After they are shut off the compressors cannot start up again until the set time has elapsed ON Shut off f Request OFF ON Devi A evice OFF lt gt Figure 0 Minimum compressor off time 2 2 4 Delay between two start up requests ref mask M_MANUF45 5 1 7 see Manufacturer menu page 23 This determines the minimum time that must elapse between two device starts irrespective of the read measurement or setpoint This parameter makes it possible to limit the number of starts per hour If for instance the maximum allowed number of starts per hour is 10 setting a value of 360 seconds will ensure that this limit is complied with f ON Device 1 f Start up OFF ON Device 2 i Start up E i OFF Figure 0 Delay between two start up requests 2 2 5 Delay between two successive start ups of the same compressor ref mask M_MANUF45 5 1 7 see Manufacturer menu page 23 This establishes the minimum time that must elapse between two starts of the same device irrespective of the read measurement or the setpoint This parameter makes it possible to limit the number of starts per hour If for instance the maximum allowed number of starts per hour is 10 setting a value of 360 seconds will ensure that this limit is complied with RG66001134 Rev 00 7 AGalletti ON Start up f f Request Y WYJ OFF Device Figure 0 Delay between two successive start ups of the same compressor 2
37. y at start up Evaporator flow switch alarm delay at full 10s capacity operation Transducer high pressure High pressure alarm setpoint alarm management High pressure alarm differential Low pressure alarm Low pressure alarm delay at start up management Low pressure alarm delay at full capacity operation 20 s Supervisor management Ident Password Maintenance password Manufacturer password RG66001134 Rev 00 27 A Galletti AIR CONDITIONING 7 Architecture of the control system 7 1 Microprocessor layout Connector description 1 connector to the power supply G GO 2 fuse 250 Vac 2A delayed T2 A 3 universal analog inputs NTC 0 1 V 0 5 V 0 20 mA 4 20 mA 4 passive analog inputs NTC and ON OFF passive analog inputs NTC 6 Yellow LED indicating power supply on and 3 indicator LEDs 7 0 10 V analogue outputs and PWM phase cut outputs digital inputs at 24 Vac Vac digital inputs at 230 Vac or 24 Vac Vdc 10 connector with Vref for 5V power supply to probes and V Term for power supply to terminal 11 connector for all standard terminals in the pCO series and for downloading the application program 12 pLAN local network connector 13 connector for connection to the programming key 14 digital outputs to relay 15 flap for selection of analog input type 16 flap for installation of serial board RS485 for supervisor optional Gateway protocol converter
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