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OPERATING INSTRUCTIONS

1. 61 0 2 9673 4698 SERVICE ADDRESS For local support please refer to our website www bitzeravp com au for a list of our nearest branch office HXO 508 1 AUS ys cee cE Li ic I ae OME Lee LE pe LS EON LN In the interest of continuous improvement BITZER reserves the right to change the specifications or design of any of its products without notice The BITZER Symbol Name BITZER and model numbers are registered trade marks All products manufactured are pending design and specification registration and must not be copied or duplicated in any way Please note The ISO Certification applies to New South Wales and Victoria branches only NSW Victoria SA WA QLD NZ tel 61 2 8801 9300 tel 61 3 8326 8200 tel 61 8 8345 6110 tel 61 8 63506297 tel 61 7 3725 1360 tel 64 9 415 2030 fax 61 2 9673 4698 fax 61 3 9310 2520 fax 61 8 8268 4555 fax 61 8 9359 2077 fax 61 7 3274 3621 44
2. TIME CR1 Comp over limit delay O 0 0 0 O 0 to 999 0 to 999 sec 0 to 999 sec Display only sec 0 to 9999 Display only Minimum operating time at 25 sec 4 O Minimum operating time at 50 4 O Minimum operating time at 75 N 1 3 Compressor envelope limits exceeded alarm delay 3 4 Bypass T hot evap from start High suction T bypass time when starting se O 4 T8 Part w 5 Comp config Time PW modulation _conf Select compressor start mode 00 Display only m 4 9 stepless mode only Pulse period 4 Decrease capacity control signal cycle time 9 0 to 20 sec stepless mode only min_pulse_Dec 0 to i max_p_period Ce Minimum duration of decrease capacity impulse 0 sec stepless mode only max_pulse_Dec Maximum duration of decrease capacity impulse 1 0 to pulse period sec stepless mode only modulation _conf o stepless mode only derivation_time 4 o N 0 gt RSL E i w Capacity control signal derivation time 2 to pulse_period sec stepless mode only 0 to max_p_period min_pulse_inc 4 Minmum duration of increase capacity impulse 0 sec oO stepless mode only max_pulse_inc 0 to 1 0 max_pulse_incr n 19 gt O Maximum duration of increase capacity impulse s o o m D Samii oe EST 7 a E E S A m F m Eo a s e GE i o 0to 999
3. p mmi Phase sequence alam om Jo forF Jo fo fo Manual Oil differential aam fo Jo Bizer Bizer Manual High pressure alarm from pressure switch i04 Jor p J mana Low pressure alarm from pressure switch ibs Jor Variable Variabie Manual Compressor thermal cutoutalarm fb2 Jo p p mana Differential pressure aarm e283 oF Variable Variable Manual High pressure alarm from transducer e3 Jo p p Mana Low pressure alarm from transducer e2 Jor Variable Variable Manual High gas discharge temperature alarm B4 Jor Variable Variable Manual Clock boardalarm OOo O S T o oo o a Fwweuse O OoOo T S o o S Analogue inputBialarm en forr Jorr orr o o manual Analogue inpat B2 alarm e2 Jor p o mana Analogue inpatB3 alarm es Jor p jo mana Analogue input B4 alarm fea Jor J oo jo Manai Operating mits exceeded aarm Jo Bizer Bizer Manual Condenser Fan Olloadalam hr o oo ooo e E C A A A A EEV pobestaam K ko o To To EEV pobeS2aam e ooo o o To o To EEV low SuperHeat alarm susz p o T Tooo EEV Low evaporation temperature LOP s oOo Oo ooo To Tooo EEV High evaporation temperature MOP s o o pooo To o Tooo S a E a EeveePROMaam OO O O o e o T EEV motor alarm open shor creut wie o O ooo To o Tooo EEV Dieron O O OOOO T S e o T EEV low suction temperature S a a S a E a EEVAutotuneeror Eo o Co To Tooo Alarm log The alarm log is used to s
4. 100th alarm each new alarm will replace the oldest event 19 2 2 Deleting the alarm log The alarms saved can be deleted in 2 ways 1 using the Restore default value procedure used only when needing to reset all the initial values remembering that this will also irreversibly delete any custom settings and values saved see the chapter Restoring the default values 2 accessing the Erase alarms A8 screen password protected and pressing enter to select the N press the up button and press enter to erase alarm log Erase alarms As history memory No WARNING deleting the alarms means ignoring them and consequently before proceeding carefully make sure that the system will not be damaged or malfunction or become unreliable 20 Supervisor The device can interface with a local or remote supervisory telemaintenance network allowing the possibility to monitor the operating status and interact with some of the functions Serial communication with the supervisory system is available on installing and connecting the RS485 serial board optional supplied separately from the pCO controller For the installation of the serial communication boards see the installation manual for the specific pCO controller A user parameter can be set that defines the priority of the compressor capacity control signal to the supervisor The following can be set on the user terminal e enable compressor ON OFF from the supervisor YES
5. 5 b Type of input 4 V digital input 4 V digital input 4 V digital input 4 V digital input 4 V digital input 4 V digital input 4 V digital input 4 V digital input pCO5 MEDIUM Type of output Description 0 10 V analogue output Condenser fan control TABLE 5 c pCO5 MEDIUM Part winding contactor 2 TABLE 5 d O O OLO O Type of output O 11 BAO 102 1 AUS lt gt 6 General diagram of the electrical connections Below is an example of the the electrical connections from the pCO to the devices involved in the application Figure 6 a Part winding 1 Part winding 2 Economiser General alarm Condenser fan 5 Condenser fan 4 Condenser fan 3 Condenser fan 2 Condenser fan 1 CRI CR2 CR4 CR3 gt lt P lt L oo eee L P lt Dad LEE HHR LL 2a SS oo SS SS GD ED G amp D Ooo So oo o Ss oo CS 22 Te i2 1 Green 3 Brown 2 Yellow 4 White THE HEART OF FRESHNESS FieldBus card BMS card i J4 SS ss ee o lt wo M oO mo Ss A a88464 46 8 8 psoas me om ie ee tS oni 230 24 Vac 1 O a Oil switch Comp overload Phase fail HP switch LP switch General Alarm Fan overload Remote on off O O L k 5 y 2 gt Q I 5 9 9 32 oO ke 5 Z 5 2 Z s LLU Uw E g IEI Ss 5 2 n je O O o 5 7 D a gt
6. Install default values select Install default values by pressing Enter press the Enter button again to apply the default values Ri ci al ae operation completed 10 User Interface 19 BAO 102 1 AUS lt gt 11 Screens From the user terminal pressing the Prg button accesses the main structure of the functions managed by the application program e IN OUT e SYSON e MAINTENANCE USER and following pressing the DOWN button e CLOCK e MANUFACTURER Selecting one of these main functions Up and Down buttons accesses the corresponding screen for displaying setting the values Enter button Within the main functions the screens can be displayed in sequence by pressing the Up and Down buttons To change the values allowed by the application program within a screen press the Enter button if the cursor is highlighting a value use the Up and Down buttons until showing the desired value to confirm press Enter again Below is the tree for accessing the screens managed by the application program On Off unit Configuration Parameters Timing Initialization E E V Figure tla 11 1 Password protected screens The MAINTENANCE USER and MANUFACTURER functions have all or some of the screens that are protected by password The password set by default is 1234 To enter the password when required access the screen press the Enter button and use the Up and Down bu
7. Probe Value R m EVD 2 Probe Value Ro W120 EVD superheat value Ro f18 0 EVD valve position percent gt P gt PI gt S gt PI S gt PI gt SJ gt S gt D gt PI S gt SJ gt S lt gt 21 Glossary Suction pressure or temperature measured at the compressor intake This is an analogue value e Proportional band this defines a temperature or pressure zone of a few degrees starting from the set point inside which the system manages the control devices Buzzer buzzer fitted on the external terminals this sounds in the event of alarms or the limits set for the parameters are exceeded The Built in and pGDO terminals do not have a buzzer Differential defines a pressure or temperature difference from the corresponding set point Step defines an area of the proportional band pressure or temperature inside which a device is on and at the same time also defines the device on off values 23 HP high pressure Screen index alphanumeric index located in the top right of every screen e LP low pressure Discharge pressure or temperature measured in at the compressor outlet This is an analogue value Screen defines the screen that is displayed on the terminal Branch loop series of screens on the same subject These can be accessed simply by pressing the arrow buttons the branches are accessed by pressing one of the buttons on the terminal which displays the first screen in the loop Range range of value
8. Q q O o Differential O N O Setpoint Low differential setpoint bar PSI Suction control only if suction control is selected in screen Co N O G8 8 8 a 0 0 to 99 9 0 0 to 9 9 0 0 to 9 9 0 0 to 99 9 0 0 to 99 9 Yes No 0 0 to 999 9 bar PSI bar PSI bar PSI bar PSI bar PSI Setpoint Suction set point Neutral zone Neutral zone dead band Band Max setpoint p O o e proportional band O o O Variable suction highest set point oe q O Min setpoint Variable suction lowest set point e a e o Pumpdown Enable pumpdown Y A C bar PSI O Pumpdown setpoint Pumpdown set point Low pressure alarm 4 oO 0 to 999 0 to 999 start up delay LP alarm delay when starting se 4 run_delay LP alarm delay in steady operation 0 sec T1 120 0 to 9999 sec O Oil level alarm N Startup _delay Oil level alarm delay when starting N 0 to 999 se run_delay Oil level alarm delay in steady operation oO Low differential pressure alarm start up delay if enabled 0 to 999 sec D 300 to 999 sec 60 to 999 sec 480 to 999 sec Minimum comp power on time Minimum compressor run time 4 Minimum comp power off time Minimum compressor off time 4 2 2 0 Min time between comp starts Delay between successive starts of the compressor 48 1 0 0 5 4 CR timing step mode only TIME CR3 TIME CR2
9. be positioned to maintain Super Heat as measured by the Economiser temperature and pressure sensors 16 Compressor safety control The safety of the Bitzer CSH series screw compressor is managed in two different ways e safety capacity control e envelope control Inputs used e B2 Low pressure transducer e B3 High pressure transducer e B4 Compressor gas discharge temperature Outputs used e NO1 CR1 e NO2 CR2 e NO5 Economizer e NO6 General alarm e NO7 CR4 e NO8 CR3 16 1 Safety capacity control Safety capacity control involves forcing the compressor to operate at minimum or maximum capacity according to the operating pressure temperature conditions the value is defined by the manufacturer of the compressor and can be displayed on the user interface Safety capacity control is activated for gas discharge temperature control based on the reading of the temperature probe located on the compressor discharge The safety control status is displayed on the user interface indicating as well as the general activation status also the status of the special condition that is active 32 BAO 102 1 AUS lt gt Compressor type ci Carel has developed an algorithm according to Bitzer specifications for the BITZER CSH STEP management and protection of their compressors Stepe per comp 4 Setting the Compressor type parameter to Bitzer CHS Steps or Bitzer CHS Stepless the compressor contr
10. fan out 2 NO11 Condenser fan out 3 NO10 Condenser fan out 4 NO9 Condenser fan out 5 Parameters used e Condensation setpoint e Differential e Number of fan stages e Also see parameters menu 18 1 Modulating condenser control linked to the pressure or temperature sensor With this type of condenser control the fans will be managed by a 0 10 V analogue output proportional to the reading of the pressure temperature sensors If the lower limit of the ramp is greater than O V there will not be a straight proportional relationship but rather the type shown in the first section of graph one step below the set point diff If fan stages are used the number of stages is evenly distributed over the differential range i e if the number of fans is 4 and the Differential is 2 0 Bar then each fan will cycle at 0 5 Bar Legend 1 condenser pressure temperature 2 set point 3 differential 4 HP Prevent if enabled 5 sensor alarm oi 0 Figure 18a 5 36 BAO 102 1 AUS 19 19 1 lt gt Alarms List of alarms Below the list of all the alarms with the description of the consequent actions on the unit The generation of an alarm activates the digital input associated with the general alarm signal for the entire duration of the alarm condition No COFN O Oy BRi Nh gt 22 23 24 25 26 2 28 29 30 31 19 2 Compressormaintenance alam p
11. 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
12. or NO e the origin of the capacity control signal PROBE or SUPERV Enabling one of these functions has priority over the normal functions performed from the keypad In addition the following can be set e the serial identification number variable from 0 to 200 to e the communication speed variable from 1200 Baud in multiples up to 19200 Baud e the communication protocol CAREL or MODBUS To modify the settings from the user interface proceed as follows press the PRG button select USER and access the PO screen password Supervisor protected remote on off No once having entered and confirmed the correct password access the Demand control Supervisor P4 screen or the following Supervisor system P5 screen the screens will show the default values Select the desired value from the options available for each parameter and confirm resour from PROBE Setting the Ident number parameter relating to the serial identification number to the value 000 disables communication with the supervisory system If the serial communication values are correctly set such as serial address and communication speed the parameters sent by the unit will be as shown in the following table 38 BAO 102 1 AUS 20 1 1 Table of communication parameters with the supervisory system Below is the table of the parameters sent preceded by the key to the table Key to the types of variable A Analogue v
13. sec of a Lo o a aa fo o a o am stepless mode only 25 w gt ie gt a O re eee E reen Defaul r nit of Description on the user terminal Description of the function Index value value measure modulation conf stepless mode only time f dec for start aL Forced CR3 time at compressor start Tb 20 0 to 999 sec stepless mode only ti t h th in power ASE A Time to reach minimum capacity Tc 120 0 to 999 sec stepless mode only ti t h the max power iia ciaes ee Time to reach maximum capacity Tc 120 0 to 999 Sec stepless mode only Pulse period for CR4 when in 4 step mode 2 Act Deact time CR4 cycle time Td 010 0 to 999 sec step mode only Speed up time for condenser fan ei at full power for this time period before reverting to normal te oo 0 to 999 Fan aalay between stages Time delay between condenser fan stages re voes Max pumpdown time Maximum time for pumpaown before stop m o owe se initiisationmens OO S O S e S Cr Install aefautvaues instan defaut values se wamings w m vm Insert new manufacturer paw New manufacturer password w a mw EVOManagement OOOO O O CAREL Carel EXV EXV SporlanSER 1 G J K 2 Carel ExVs Danfoss ETS400 ETS250 ETS100B ETS50B ETS12 5 25B Sporlan SEH175 SEH100 SE150 SE130 SER 1 5 20 SEI0 5 11 Alco EX8 500Hz EX8 330Hz EX7 EX6 EX5 EX4 EVD Config EEV Sele
14. up sequence stepped capacity control el EEEE Legend CRI 1 Capacity control input ai 2 Solenoid status CR2 i 3 CR4 pulsing function according CR3 to pattern on screen Td CR4 Start Stop Figure 14b 29 BAO 102 1 AUS lt gt 14 3 Continuous capacity control A Bitzer CSH series screw compressor with continuous capacity control is managed by the application program by controlling the capacity relays CR3 and CR4 parameters This control mode is suitable for fast response control loops such as chilled water leaving temperature control or supply air control For installations that require Room temperature control cascade control must be utilized Cascade control is when the Room temperature setpoint deviation is used to reset the setpoint of the Supply Air leaving water controller The output from the supply air leaving water controller is used as the demand signal for the CSH module Bitzer relay start up sequence continuous capacity control Legend 2 1 capacity request 2 relay output status Se hee eee ee ae pees pee eee eee E E 3 start stop CHI ee ee eee See 4 increase capacity 5 Decrease capacity ona SA 6 stand by or Neutral zone CHS 7 Pulsing of relay according to times set on screen Ta Pulsing of relay according to times set on screen T9 9 capacity over ride due to operational limits being exceeded go The operation of the compressor cannot be enabled with t
15. 0 d c Z c 5 gS x lt a O 6 a co Oo 7 N Q2 o c Ww p c o Esango Q I a 2 D e z EOSS 2 o a O oO o oF YM oO 5 ka om 2 Q O 7 E ep Q Ss o 2 5 D 3 5 E 2 A ta a fe O ney 2 c 2 a 5 2 ro a u 5 N lt gt 7 The user terminal 7 1 Operation and type The user terminal can be used to perform all the operations allowed by the application program installed It also displays the operating conditions of the unit The user terminal can be used to set all the operating parameters of the unit in real time The correct operation of the unit does not require the user terminal to be connected The following user terminals can be used with or connected to the dedicated pCO controller 1 pGD1 semi graphic 6 buttons 8 row by 20 column display connection with telephone cable 7 2 General features of the pGD1 user terminal The following information refers to the pGD1 user terminal For further information refer to the technical sheet code 050001040 7 2 1 Introduction to the pGD71 user terminal The pGD graphic display is an electronic device that allows complete graphic management using the icon based display plus the management of international fonts in two sizes 5x7 and 11x15 pixel The application program is only resident on the pCO controller the terminal does not require additional software when used It can be supplied in two different versions according to the type of assembly eith
16. 485 standard is made by fitting the pCO5 with an optional serial board Other optional boards can be used for connection to the supervisor over standards other than RS485 Finally the serial field bus using an optional board offers connection to controlled field devices for example valves I O expansions pCOe electronic valve driver The pCO5 with built in driver user terminal PGD1 display keypad and LEDs is used to program the control parameters set point differential alarm thresholds and the fundamental operations ON OFF display the controlled values optional printouts 6 BAO 102 1 AUS AN N PaE T BaN ANN N d 0 U 1 J 2 J 14 Jd 3 20O D02022 DOO aa a a ee eee a an J 5 h puilt in driver THE HEART OF FRESHNESS I 130 129 FieldBus card BMS card a ck EP le lamang PITIT AN J1 J24 J 3 3 O m J5 a 7 oe ss cE cs cal EE so s 83s 8 5 Ws andassaneseal os dlesszaliziz i an aana aana tooo oh Nin oo ooo oo ooo poo nalannann fo oo 22 2 LLLA LL 2 BALLY 22 2AA L A fn fn 4 N ra CN F N FaN N l YO 000 000 8 O O Figure 4 b Key 1 Power connector G GO 2 Vterm power to additional terminal 5 VREF power to ratiometric probes 3 Universal inputs outputs 4 VDC power to active probes 5 Button for setting pLAN address secondary display LEDs 6 VG voltage A to optically i
17. Hz secure the cables connected to the pCO around 3 cm from the connectors using clamps if the product is installed in industrial environments application of the EN 61000 6 2 standard the length of the connections must be less than 30m installation must be performed according to the standards and legislation in force in the country where the appliance is used for safety reasons the appliance must be housed inside an electrical panel so that the only accessible part is the display and the control keypad all the very low voltage connections analogue and digital inputs at 24 Vac 24Vdc analogue outputs serial bus connections power must have reinforced or double insulation from the mains in the event of malfunctions do not attempt to repair the appliance but rather contact the CAREL service centre in residential environments the connection cable between the pCO3 and the terminal must be shielded For further information see the specific manual for the device 10 BAO 102 1 AUS 5 List of pCO inputs outputs Below is a list of the inputs and outputs separated by type of hardware ANALOGUE INPUTS pCO5 MEDIUM nmo _ Typeofinput Description SSS U1 4 20mA 0 5V 0 10V Capacitycontrolinput E NTC HT PT1000 Compressor gas discharge temperature NTC o udema 4 20MA Economiser PHEX suction pressure Economiser PHEX suction temperature TABLE 5 a DIGITAL INPUTS pCO5 MEDIUM TABLE
18. THE HEART OF FRESHNESS OPERATING INSTRUCTIONS BITZER AUSTRALIA ea a La A ED ga ae ha py A Let A LO BL LAD A eA A a OL CSH CONTROLLER Screw Compressors IMPORTANT NOTICE ABOUT MODE OF OPERATION From version 1 4 significant changes have been made to this operation There are two modes of operation of this CSH Compressor 4 step mode the capacity is in 4 steps and is directly proportional to the demand input Stepless mode the capacity is determined by a neutral zone control logic and IS NOT DIRECTLY PROPORTIONAL TO THE DEMAND INPUT Due to this logic the demand signal used for Stepless must be from a controller that measures leaving water or coil Air off temperature and CANNOT BE DIRECTLY CONTROLLED FROM ROOM TEMPERATURE Stepless mode suction new the capacity is determined by a neutral zone control logic from the suction pressure Stepless mode variable suction new the capacity is determined by a neutral zone control logic from the suction pressure sensor and a variable setpoint from an external demand signal Economiser Built in driver version 4 BAO 102 1 AUS lt gt We wish to save you time and money We can assure you that the thorough reading of this manual will guarantee correct installation and safe use of the product described IMPORTANT WARNINGS CAREL bases the development of its products on decades of experience in HVAC on the continuous investments
19. ame retardant VO on front panel transparent and rear case HB on silicone keypad and parts remaining General Index of protection IP65 with panel installation IP40 with wall mounting UL type 1 Operating conditions 20T60 C 90 RH non condensing Storage conditions 20T70 C 90 RH non condensing Software class and structure A Classification according to the index of To be integrated into class 1 or 2 appliances protection against electric shock PTI of the insulating materials 250 V Period of electrical stress long Category of resistance to heat and fire D Category immunity against voltage surges l Environmental pollution normal Table 7 a Note if the terminal remains inactive no button is pressed for more than 30 seconds any procedure in progress is automatically terminated without saving the changes For further information see the specific manual for the device 15 BAO 102 1 AUS lt gt 7 3 Operation of the buttons The buttons on the user terminal provide access to all the screens for setting and displaying the information pGD1 terminal Figure 7 d Button ooo Description reese Dy displays the alarms mutes the buzzer and deletes the active alarms if the cursor is in the home position top left corner scrolls the screens in the same group upwards if the cursor is in a setting field increases the value if the cursor is in the home position top left corner scrolls the screens in t
20. ameters The buttons on the user terminal can be used to display and or change the values of the parameters set and saved in the application program resident on the pCO controller The screens generally have an alphanumeric code two digits at the end of the first row that simplifies the association between the values that can be displayed set on the screens and the values described in the table of parameters The table below lists the parameters managed by the application program and that can be displayed set on the corresponding screens Screen Default User Unit of Range Index value value measure Ce Joooj a 000 0 to Ba 000 0 to 000 0 to OorC OorC OorC OorC OorC OorC OorC OorC 0 to 10 Oorc OorCc OorC OorC OorC OorC Oorc io Pom ft Pom fo o f Ola or L o ee oo or Pom B elil ob ob ob on E a Po Poi Poi Pow Ea ee l og ae ig orc ICondfant Condenser fan stage 1 oi oc Cond fan2 Condenser fan stage 2 Foi ooc Cond fan3 Condenser fan stage 3 ie oc Cond fan4 Condenser fan stage 4 oke Cwe s do oe Obe oe ea oe l e oe f owe o o upea Oom om OoOo O O O O EO o re a ao o om Ae Description on the user terminal Description of the function Compressor c
21. apacity demand input Low pressure sensor value High pressure sensor value Discharge temperature sensor value O o O Oil pressure switch input Motor thermal cutout input Phase sequence fail safety input High pressure switch input Low pressure switch input General alarm signal Condenser fan overload Remote on off command signal 0 to 10 Vdc fan speed output Vdc Compressor valve CR1 Compressor valve CR2 Part winding contactor 1 PW k2 switch Part winding contactor 2 Alarm relay Alarm relay Relay Cr3 Compressor valve CR3 Relay Cr4 Compressor valve CR4 OorC Evaporation pressure Evaporation temp Suction temp Digital input status Digital input status E To switch the unit on and off For information on the software version Information on the software version date and author E Information on the BIOS version BIOSversion and the manual Information on the EVO firmware version Close Open 000 0 to 0000 to 000 to Steps o f OorC Cond fan5 Condenser fan stage 5 3S gt Bar fe OW U o a s ar o O 2 N BAO 102 1 AUS P ae Screen Default User Unit of Description on the user terminal Description of the function EREA Range Pug Index value value measure Hour counter Compressor Compressor operating hours a2 o 0 to 999999 Insert Maintenance password Enter maintenance password 1234 sl 0 to 9999 a Compressor hourcounterthreshold aitnanc
22. ariable D Digital variable Integer variable Key to variable communication direction W WRITE Input variable pCO lt Supervisor R READ Output variable pCO Supervisor W R WRITE READ _ Input output variable pCO lt Supervisor 39 BAO 102 1 AUS lt gt Table of parameters transmitted between the pCO controller and the supervisor Type Direction Address Description of the signal ULPOUSUsLULUsSUsLUslLUsUslUslUsLUIUsUsLUsSUsLULUIJUIJUJFUILUIUIUILUsSLUIUIUIEUSUILULUISOYLOU 40 Ro ft o Status of digital input 1 Ro f200 Status of digital input 2 Ro Bo Status of digital input 3 R J4 Status of digital input 4 Ro o B Status of digital input 5 R e o Status of digital output 1 R Fo o o Status of digital output 2 Ro o fg Status of digital output 3 R fg Status of digital output 4 R po Status of digital output 5 R mo Status of digital output 6 R o 420 Status of digital output 7 R f48 Status of digital output 8 Ro O Compressor with stepped capacity control selected Ro o 5 Compressor with continuous capacity control selected R fte Status of capacity stage 1 Ro J Status of capacity stage 2 R ope Status of capacity stage 3 R ft9 o o Status of capacity stage 4 R 200 Status of the condenser fans R O a Safety capacity control active R jag Analogue input B1 alarm R 230 Analogue input B2 alarm R a4 Analogue input B3 alarm R o J Analogue input B4 alarm Ro je Oil differential alar
23. ave the operating status of the compressor when the alarms are generated or at other specific moments Each record is an event that can be displayed with all the events saved in the memory The log is useful in solving anomalies and faults as it takes a snapshot of the system at the time the alarm was activated suggesting possible causes and solutions to the problems 19 2 1 Recording the alarms If the alarm log function is activated when the application program measures a value identified as an alarm the following data associated with such event are saved in the memory on the pCO controller Note if the clock board is not fitted optional on pCO1 standard on pCO3 or the clock board is disabled by parameter only 37 alarm code each alarm has an identifying code See the list of alarm log codes the analogue input values read by the pCO controller at the precise moment the alarm was activated date and time the event occurred the alarm codes and the values measured are saved BAO 102 1 AUS lt gt To access the screen for displaying the alarms saved proceed as comes it j follows AL000 00 00 00 00 00 1 press the PRG button select Maintenance and access the DT 000 0 DC 000 Alarms log A3 screen HP 000 0 LP 000 0 2 select the alarm code ENTER button and scroll the alarms saved UP and DOWN buttons Up to a maximum of 100 alarms can be saved in chronological order after the
24. ction AC or Chiller with plate evaporator R404a Condenser for subcritical CO2 subcritical CO2 cabinet cold room self contained cabinet cold room Disabled User defined Backup probes on S3 amp S4 Modulating thermostat on S4 probe High condensing temp protection on S3 Auxiliary regulation Disabled ee Enable Disabled enabled Probe S1 alarm Probe S1 Alarm Enable the S1 probe and its alarm 4 20mA external 0 5v Ratiometric 4 20mA Raz 0 5V 4 20mA external 4 20mA remote o oono a o S _ ooe e 9 l oowoo ser o 0019609 Ber BAO 102 1 AUS AC or Main regulation icati EC2 nilar with plate evaporator O Description on the user ae Screen Default User Unit of Description of the function Range terminal Index value value measure Probe S2 Alarm Enabled Enabled disabled NTC Carel 0 10V Signal NTC Type MUG Garel SKP TO Carel NTC HT Probe S2 Alarm Min eC o0 76 0t0 392 0 C parm Max o y S w8 d 76 00 392 0 c Alarm relay Disabled Valve position Reversed Alarm EC8 Alarm Relay relay Valve Alarm relay Solenoid Valve relay Disabled Reg Safety Reg Backup Start Stop reg EC9 Disabled Valve force100 open Battery Alarm management Valve regulation opt after defrost ID2 configuration Disabled az As per ID1 Backup Digital input NTN Valve at fixed Valve position S1 Probe alarm management forc
25. demand control Type of demand control signal C4 4 20mA Type of low pressure probe Type of input for low pressure probe C5 4 20mMA Type of high pressure probe Type of input for high pressure probe C6 Type of discharge temperature probe Type of input for discharge temperature probe High pressure probe configuration Configuration of high pressure probe Min value Minimum pressure value 4mA or OV NTC HT PT1000 0 0 to 99 9 0 0 to 99 9 bar PSI bar PSI Low pressure probe configuration 0 0 to 99 9 0 0 to 99 9 None bar PSI bar PSI Min value Minimum pressure value 4mA or OV Max value Maximum full scale value 20mA or 5V Select compressor control solenoid valve relay 5 Electrovalve configuration Cp C7 C8 C8 C9 C9 o5 Economizer Cq n Q m N O O oO J 2400 1200 Stage 1 Cr1 valve relay OFF Display only Step mode only Cr2 valve relay OFF Cr3 valve relay ON Stage 2 Cr1 valve relay OFF Display only Step mode only Cr2 valve relay Ce ON Cr3 valve relay OFF Stage 3 Cr1 valve relay ON Display only Step mode only Cr2 valve relay C OFF Cr3 valve relay OFF Stage 4 Cr1 valve relay OFF Display only Step mode only Cr2 valve relay Cg OFF Cr3 valve relay OFF Standby config Relay 3 CR3 OFF Display only Stepless mode only Relay 4 CR4 en OFF Decrement config Relay 3 CR3 ON Display only Increment config Relay 3 CR3 OFF stepless mode only Relay 4 CR4 Cj Compressor saf
26. e C type of relay SPDT 1250 VA 250 Vac 5 A resistive approval pCO3 UL873 1 A resistive 1 A FLA 6 A LRA 250 Vac D300 pilot duty 60730 1 1 A resistive 1 A inductive cos 0 6 1 1 A 100000 cycles Correspondence between AWG and cable AWG Cross section mm Current cross section sO eooo p a e p groups 1 2 3 4 5 6 7 8 alarm relay 9 10 11 12 13 2000 VA 250 Vac 8 A resistive 2 A FLA 12 A LRA to UL873 30 000 cycles 2 A resistive 2 A switchable power Table 4 f 9 BAO 102 1 AUS lt gt pLAN network user terminal connection Table 4 g type transmission speed terminal connector asynchronous half duplex RS485 62 5 Kbps or 115 2 Kbps selected via software 6 pin telephone connector J10 pLAN network graphic terminal ARIA terminal 3 pin plug in connector J11 connector The maximum distances allowed between the pCO and user terminal are shown in the following table type of cable power supply power supply distance telephone 50 m taken from pCO 150 mA AW G24 shielded 200 m taken from pCO 150 mA fe a AWG20 22 shielded 500 m separate power supply from The maximum distance between two pCOs5 with AWG20 22 shielded cable is 500 m Note J10 can be used to connect a maximum of one terminal COT pCOI pGDO pGD1 or two terminals but without using the backlighting for the display One version of the pCO5 features an optically isolated connection to the pLAN network t
27. e aarm gorama awona f as 1 0mo Hours x 1000 Regres Set compressor operating rousozero a o o o w S Input probe offset Demandar Probe Bt offsetemen a o eon a i ow Press Prove B2 offset ow pressure m o Input probe offset Probe B3 offset high pressure A7 9 9 to 9 9 bar PSI High press K7 Supply temp Prove B5 ofset supply air temperare m o eowoo om soa oS S Yd T o Bar S A O T A A A A e A S T did T T T e A E T E A A ee A AP des Menuaivaveposton dT OOOO o O o f s Erase alarms history memoy O O O o o e emn S Insent new maintenance psw New maintenance password m a voes usermenu O Insert userpassword Password to access tre meru J m a oon a Standard C BAR Angl P1 o saxon el Fe cs a E ae Number of fan speed Number on condenser fan speed stages Pe 5 1May 4 i Compovercad compressor overoaa dighalinputogs ma nc mo nomo Phase sequence Prase taure dgtatinputoge ma nc mo nomo Hian pressure Hion pressure switch digtatinputogo nc mo nomo Low pressure row pressure switch wigtat input og m nc mo nomo C A Pe NOG NCINO C momo Digital fof Remote on of digtalinputioge r o me nomo iam relay ogo aemreyoperaingoge ma o me moo ANALOG INPUT Demand control Resour from Selection origin of capacity control signal P5 Analog Input SUPERV Digtairemoe onon Enable rem
28. e compressor is stopped immediately Zone C Polygon between points 1 2 3 4 5 6 Inside of this zone the compressor capacity is not limited and is managed solely according to demand Zone D Polygon between the points 6 7 10 1 The maximum compressor capacity is limited to 75 without any time restrictions In this case the compressor is not endangered If fitted the economiser is forced off Zone E Polygon between points 7 8 9 10 The maximum compressor capacity is limited to 50 and the condition is allowed for a maximum of 10 minutes if after 10 minutes the pressure value is still not inside the polygon the compressor is stopped immediately If fitted the economiser is forced off 34 BAO 102 1 AUS Zone F The maximum compressor capacity is not limited available up to 100 but this condition is only allowed for a maximum of one minute if after one minute the pressure value is still not inside the polygon the condenser fans are stopped and the compressor is stopped immediately Only three starts are allowed Zone G above max o If the limit is reached when already on the compressor is stopped immediately Vice versa only at start up above this limit the maximum compressor capacity is restricted to 50 and this condition is allowed for a maximum of 5 minutes If 5 minutes after starting the pressure value is still not inside the polygon the compressor is stopped immediately otherwise all of the above
29. ed Valve forced closed closed Relay Configuration ID1 configuration No Action Use backup S3 Valve at fixed S2 Probe alarm management position Valve forced closed No Action Use backup S3 Dopowersupy OS i e des No S S valve openingatsiatup OOOO o a i S o a valve openedin standby OOOO e doves id Startup delay after defrost OOOO e o i O ooo S s Valve prepostiondelay oO o o ea ow 010 990 f Secon A a A A A o f ooo o ao 0 0 1000 Seconds it o re es az a a a a SS La a as ee cee 5 0 76 0t03920 C Ls Ss ps4 ES a a 4 E m T megam OOOO O Dewa OOo O A lt ET topoa Oooo y O mopo oo Too S A mamoa ows OOOO farmDelay LOP SSS Mamoe wo SSS O La Alarm Delay Threshold Valve custom a 0 to 18000 to 9999 0 to 9999 0 to 9999 Closing steps Nom Step rate Tosi rat __ o _ J O O O Note the values described in the range column may change if the unit of measure selected is modified ooo _ YesiNo No Yeso No 27 BAO 102 1 AUS lt gt 13 Selecting the unit of measure The unit of measure used for the temperature and pressure values can be set on the user interface selecting between standard C Bar or Anglo Saxon F Psi units of measure The type of unit of measure is selected as follows iP press the PRG button select USER and acce
30. er Pace tas iek id ae max i Figure 17 a 33 BAO 102 1 AUS lt gt Below is a table of the pressure values expressed in BAR found at the points represented on the envelope diagram divided by type of gas Key values in the table to evaporation temperature po evaporation pressure tc condensing temperature pc condensing pressure pressure BAR temperature C Points on th R22 R134a ECO R407C polygon With or without ECO With or without ECO With or without ECO o foo p p b foo dre p b p e f 16 2 1 Protectors As well as the standard protection such as low and high pressure switches the thermal cutouts on the windings the oil differential pressure switch the Bitzer management algorithm protects the compressor against dangerous pressure conditions In addition the Bitzer management algorithm checks the frequency of compressor starts even in the event of power failures and the minimum on and off times The envelope diagram shows 7 different operating zones in each of which the Bitzer management algorithm controls the compressor capacity control to bring the unit set point within the envelope polygon Zone A Above the maximum condensing pressure limit max c The compressor is stopped immediately Zone B The maximum capacity achievable by the compressor is limited to 75 the compressor can operate for a maximum of one minute if after one minute the pressure value is still not inside the polygon th
31. er panel or wall mounted 7 2 2 Electrical connection and power supply For the electrical connection use the telephone cable code S9OCONNOO from the pCO controller connecting it to the special connector RJ12 located on the rear of the terminal This electrical connection both supplies power 18 30 Vdc directly from the pCO and carries the communication data 7 2 3 Assembling the pGD1 terminal panel version code PGD1000F00 To assemble this version the panel must have first been drilled as per the template shown in the figure ry dima d wakra jl i ad i rece pele I nL IATA mm gt i m i et fl Ll Figure 7a To install the device proceed as follows e connect the telephone cable e insert the terminal without the faceplate in the opening made on the panel and fasten it using the countersunk screws contained inside the packaging e apply the faceplate and click it into place 13 BAO 102 1 AUS lt gt 7 2 4 Assembling the pGD1 terminal wall mounted version code PGD1000F00 oF 7 or m i r ee ee O E ee m Wifi rey ee LP re r a j i wl Ls z el ded Ls a Figure 7 b This version is installed on the wall in a standard three gang switch box To install the device proceed as follows e fasten the rear of the case to the box in the wall using the round head screws contained inside the packaging e connect the telephone cable e i
32. ethod as the suction pressure method above with the variation that the suction set point is not fixed The desired suction set point is varied up and down in relation to the demand input B1 As the demand signal is raised the desired set point is lowered The amount of variation is determined by the Maximum and Minimum set points set on screen Ga If the demand signal is 0 then the desired set point will be the Maximum setpoint if the demand input is 100 then the desired set point will be the Minimum set point 15 Economizer solenoid valve EEV control The operation of the economizer valve is also managed economizer the valve control output is managed by the macroblock according to the compressor set point Inputs used e B2 Low pressure transducer e B3 High pressure transducer e S1 suction pressure transducer for PHEX e S2 suction temperature sensor for PHEX Outputs used e NO5 Economizer e J27 output for Bi Polar EEV The user interface enables you to select if an economiser is fitted or not If selected the output will enable the economiser when the suction discharge pressures are suitable See application envelope The controller can now be fitted with a CAREL Electronic Expansion Valve to control the super heat of the economiser heat exchanger In manufacture menu you can select if EEV is fitted or not If the EEV is selected and economiser operation is permitted then the valve will
33. ety unloader step Ck MINIMUM configuration POWER Display only Minimum Maximum BAO 102 1 AUS Description on the user terminal Description of the function perau Index value ___ value measure ParametersMeny Enable phase failure alarm Enable phase monitor alarm input Go Yes No Yes Min speed 03 0 0 0 to 10 0 Condenser Fan G1 Volts Max speed 10 0 0 to 10 0 G2 High pressure prevent enable Enable high condensing pressure prevention Y No Yes G2 2 is AA O 0 0 to 99 9 0 0 to 99 9 C F i Setpoint Prevent set point iff Differential Discharge temp alarm 0 e N O High gas discharge temperature alarm hysteresis Setpoint G3 3 120 0 0 0 to 999 9 0 0 to 99 9 C F CPE Setpoint Setpoint O o oO Differential Transducer high pressure alarm g G4 G4 16 0 02 0 0 0 to 99 9 0 0 to 99 9 bar PSI bar PSI Setpoint High pressure alarm set point g Differential Transducer low pressure alarm oO o 5 5 0 0 to 99 9 0 0 to 99 9 No Yes 0 0 to 9 9 bar PSI bar PSI Setpoint Low pressure alarm set point a m m m O a y Dg o 3 a E T ey a T D d 5 v D 5 5 D 3 x v ES a B g a g D e lt e gt a 3 g z Q 2 3 S 3 ar E 4 p Cc 9 o Coy J D ce o ok Cc O D s a c n J o 5 ok D D lt gt D J N n D J
34. fferent ways depending on which mode stepped or continuous capacity control e stepped capacity control the compressor stops when the de activation of the first stage is requested this occurs when the demand signal falls below 10 e continuous capacity control the compressor stops when the input signal is below the capacity neutral zone for the time to minimum power delay Pump down The compressor stopping can be done utilizing the digital input for remote on off If pump down is enabled then the compressor will continue to run until the Pump down set point Gb is reached If the set point is not reached within the maximum pump down time Tf the compressor will be stopped Control of compressor capacity Compressor capacity is controlled either in steps or continuously using 4 digital outputs Inputs used e B1 Capacity control input e B2 Low pressure transducer e B3 High pressure transducer Outputs used e NO1 CR1 75 limit NO2 CR2 50 limit e NO7 CR4 Increase e NO8 CR3 Decrease 14 2 Stepped capacity control A Bitzer CSH series screw compressor is managed with preset 4 load steps The values can be displayed and operation monitored from the user interface The activation of the different levels of capacity occurs with a preset delay time according to the indications provided by the manufacturer and in any case visible on the user interface see the timings menu Bitzer relay start
35. g inductive loads and the power cables to avoid possible electromagnetic disturbance Analogue outputs type optically isolated 0 to 10 Vdc maximum number on 4 medium vers power supply external 24 Vac Vdc resolution 8 bit maximum load 1 KQ precision 2 of the full scale on outputs Y1 Y2 Y3 and Y4 Digital outputs type relay maximum number on 13 medium vers Table 4 e Make sure that the current running through the common terminals does not exceed the rated current for an individual terminal that is 8A Insulation distance the outputs can be divided into groups Between groups cell cell there is double insulation Note the relays in the same group with basic insulation must have the same power supply 24 or 230 Makeup of the groups on medium vers Changeover contacts on medium vers Switchable power relays with the same insulation 1 to 7 8 9to 13 relay 8 12 13 warning the relay outputs have different features according to the model of pCO3 relay type A type of relay SPDT 2000 VA 250 Vac 8 A resistive nell approval pCO3 UL873 2 5 A resistive 2 A FLA 12 A LRA 250 Vac C300 pilot duty 60730 1 2 A resistive 2 A inductive cos 0 6 2 2 A 100000 cycles relay f type B type of relay SPDT 1250 VA 250 Vac 5 A resistive meat approval pCO3 UL873 1 A resistive 1 A FLA 6 A LRA 250 Vac D300 pilot duty 60730 1 1 A resistive 1 A inductive cos 0 6 1 1 A 100000 cycles relay typ
36. he graphic terminal and ARIA terminal should be always have separate power supplies the 21 Vdc present at Vterm J24 can be used to power an external terminal with a maximum power input of 2W Only one terminal can be connected for example PLD terminal or ARIA terminal in addition to the one connected to terminal J10 Other features Table 4 h storage conditions operating conditions index of protection 40T70 C 90 RH non condensing 25T70 C 90 RH non condensing IP20 IP40 on the front panel only environmental pollution normal class according to protection against electric shock to be integrated into Class 1 and or 2 appliances PTI of the insulating materials 250 V period of stress across the insulating parts long type of action 1C type of disconnection or microswitching category of resistance to heat and fire microswitching category D UL94 VO immunity against voltage surges category 1 ageing characteristics operating hours 80 000 no of automatic operating cycles 100 000 EN 60730 1 30 000 UL 873 software class and structure Class A category of immunity to voltage surges CEI EN 61000 4 5 Category 3 The application program can be downloaded to the flash memory using the key code PCOCSOOAKY0O or a PC as described in the chapter Installing the software WARNINGS the device is not designed to be hand held for applications subject to considerable vibrations 1 5 mm _ pk pk 10 55
37. he reduced capacity field consequently the compressor will always work across the range of the capacities available 25 100 The effective value of active capacity is not available on the user interface as there is no feedback from the compressor Without feedback having to start the compressor at minimum capacity a forcing function is applied when starting for a set time managed directly by the Bitzer compressor management macroblock This time can be set on the user interface on screen Tb 14 4 Calculating the active capacity in the refrigerant circuit The capacity is controlled based on an analogue input signal generated by any external controller used for the unit control strategies Inputs used e B1 Capacity control input Given the different types of compressor capacity control managed stepped or step less there are two different ways to interpret the input signal based on the type of compressor controlled 14 4 1 Compressor with stepped capacity control The analogue input signal is interpreted as a pure proportional signal in the range 4 20mA 0 10V and is divided into 4 equal steps bime y oe Figure 14 d 30 BAO 102 1 AUS lt gt The activation deactivation thresholds for the load steps according to the proportional input signal are as follows Load step Increase capacity PWR 100 Decrease capacity PWR 0 14 4 2 Compressor with continuous capacity control A compressor with continuous capaci
38. he same group downwards if the cursor is in a setting field decreases the value moves the cursor from the home position top left corner to the setting fields while in the setting fields confirms the set value and moves to the next parameter accesses the sliding menu for selecting the group of parameters to be displayed set access to the parameters is confirmed by pressing Enter Returns to the previous menu level or main screen 7 4 LEDs lighting the buttons The buttons on the user terminal are illuminated and based on the colour a series of information can be identified relating to the operating status of the system 7 4 1 pGD1 terminal 6 buttons Meanings of the colours and status of the LEDs on the buttons Colour LED On One or more active alarms Pra On Operating parameters being displayed set Yellow Prg Flashing Unit off from supervisor or digital input Green n 5 minutes button lighting correct power supply to the terminal w backlit Green l On 5 minutes button lighting correct power supply to the terminal a backlit dh Green I On 5 minutes button lighting correct power supply to the terminal Down backlit Green l On 5 minutes button lighting correct power supply to the terminal Enter backlit the illumination of the buttons that do not represent operating conditions or alarms and the backlighting of the display go off 5 minutes after the last b
39. k optional PCOS004850 6 pCO web Bacnet PCO1000WBO f Temperature and pressure probes see general catalogue 8 Connection cable between user terminal and pCO controller see general catalogue 5 BAO 102 1 AUS lt gt 4 Hardware features of the dedicated pCO5 The information contained in this chapter is a summary of dedicated hardware pbCO5 MEDIUM with built in driver For further information refer to the general pCO5 user manual code 0300020EN 4 1 pCO5 general features 4 1 1 Hardware architecture pCO5 with built in driver is used to run the control program and is fitted with the set of terminals required for connection to the devices controlled The program and the parameters set are saved permanently on FLASH MEMORY and E2prom meaning they are stored even in the event of power failures without requiring a backup battery The program can be loaded by PC 28 8 kbps and 115 2 kbps or using the special programming key pCO5 with built in driver can also be connected to pLAN local networks pCO Local Area Network The pLAN network is made up of a series of controllers and terminals that interact with one another Each controller in the pLAN network can exchange information digital or analogue variables at high transmission speed Up to 32 units can be connected including pCO5 and terminals The connection to the supervision telemaintenance serial line using the CAREL or Modbus communication protocol over the RS
40. lection 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 nthe event of illegal disposal of electrical and electronic waste the penalties are specified by local waste disposal legislation 2 BAO 102 1 AUS Contents 1 General features 2 Applications and functions performed by the software RA Configurations and codes 3 1 Configurations and software hardware codes 4 Hardware features of the dedicated pCO5 4 1 pCO5 general features 5 List of pCO inputs outputs 6 General diagram of the electrical connections T The user terminal 7 1 Operation and type 7 2 General features of the pGD1 user terminal es Operation of the buttons 7 4 LEDs lighting the buttons 8 pLAN network management 8 1 pLAN network diagram 8 2 How to assign the pLAN addresses 9 Installing and restoring the default values 9 1 Initial installation of the default values 9 2 Restoring the default values 10 User interface 11 Screens 11 1 Password protec
41. llers 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 In reference to European Union directive 2002 96 EC issued on 27 January 2003 and the related national legislation please note that gt x 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 col
42. lows 1 press the PRG button select MAINTENANCE and access the Compressor A5 screen in the password protected branch on the Compressor A5 screen under the item Threshold set the alarm threshold expressed in thousands of operating hours Compressor A5 hour counter 2 Threshold 000x1000h Req reset No 000000h NOTE setting the value 000 as the alarm threshold disables the operating hour count and maintenance alarm Exceeding the set operating hour threshold activates an alarm without affecting the operation of the system signalled by the activation of the red LED Dy on the ALARM button and an audible signal where featured f 35 BAO 102 1 AUS ALOO 0 00 The alarm displayed only when the operating hour threshold is Compressor exceeded is displayed on the ALOO1 U 00 screen maintenance Once having completed the maintenance or the required operations the count can be rest To reset the operating hour count on the Compressor A5 screen described above in the row Req reset select YES When reset the count restarts from 0 and the number of operating hours from the reset are recorded 18 Condenser control The condenser can be controlled in the following way e Modulating linked to the reading of the pressure transducer if the high pressure transducers are enabled Outputs used Y1 Enable condenser fans NO13 Condenser fan out 1 NO12 Condenser
43. m R Oz Compressor thermal cutout alarm R o je Phase sequence alarm R O Je High pressure alarm from pressure switch R o oo oo o Low pressure alarm from pressure switch R o at High pressure alarm from transducer R 3200 Low pressure alarm from transducer R 38 Operating limits exceeded alarm Ro 3400 Compressor maintenance alarm BAO 102 1 AUS lt gt 41 Type Direction Address Description of the signal Ro 85 Differential pressure alarm Ro 36 High gas discharge temperature alarm Ro BF Clock board alarm Reset alarms Supervisor on off R f40 o Controller Status on Off R o o EVD Battery alarm Ro fot EVD low Suction Alarm R 62 EVD Probe 1 alarm R 63 EVD Probe S2 alarm Ro o a EVD Low Super Heat alarm R 65 EVD LOP Alarm R 66 EVD MOP Alarm R jer EVD Hi Condensing Alarm R joe EVD EEprom Alarm R jog EEV Motor alarm Ro lm EVD Offline alarm Ro fmt EVD Auto tune alarm Percentage of capacity requested R 2 919 9 9 9J 9 9 909 909 9 9 9 9J 9J 9J gJ J J Type of gas used R o Bo Analogue output 1 value Ro ft o Read analogue input 1 demand signal Read analogue input 2 low pressure transducer Ro o R 8 Read analogue input 3 high pressure transducer Ro o ot Read analogue input 4 discharge gas sensor Ro Bo Read analogue output 1 condenser fan Rw e o o Pressure Setpoint Maximum Pressure setpoint Rw fg Minimum Pressure setpoint Rw jo Condenser Setpoint R jio EVD 1
44. mentioned protectors are considered 16 3 Safety times The Bitzer management algorithm controls all the compressor safety times e minimum compressor operating time e minimum compressor off time delay between successive starts of the same compressor The values cannot be changed as they are set by the manufacturer of the compressor however they are displayed on the user interface Outputs used e NO3 Part winding contactor 1 e NO4 Part winding contactor 2 17 Hour counter The hour counter function is used to save the compressor operating hours in the permanent memory on the pCO controller To manage compressor maintenance an operating hour threshold can be set after which a message is displayed on user interface or an audible signal is emitted The hour counter function requires the clock board optional on pCO1 standard on pCO3 and is enabled by parameter Outputs used e NO4 Part winding contactor 2 17 1 Display operating hours To access the screen displaying the compressor operating hours proceed as follows e press the PRG button select MAINTENANCE and access the hour counter A2 screen hour counter A Compressor 000000h The compressor operating hours cannot be reset from the user interface 17 2 Setting the operating hour alarm threshold for maintenance To access the screens for setting the operating hour alarm threshold and displaying the operating hour alarm proceed as fol
45. not displayed press Up Down Enter again Once the display address setting screen is displayed press Enter 3 times When the adr Priv shard screen is displayed set the correct values with the Up and Down buttons and confirm with YES and Enter ae AT Oo oS 8 2 2 Setting the address on the pCO5 Procedure 1 Press button A for 5 seconds The pLAN address starts flashing 2 Press repeatedly or hold the button until reaching the desired address e g 7 remove the screwdriver 3 Wait until the address starts flashing quickly The address is now saved but is not yet active for the application program 4 Power down the controller 5 Power up the controller again The address is now used Py the application ala m ree AL mip AN 125 BMS 16 FBUSD no ABE Ml We SEM rns as VATT WY 17 BAO 102 1 AUS lt gt 8 2 3 Displaying the network status and firmware version from the pGD1 terminal In pLAN mode only on the pDG1 terminal when holding the VIG buttons for 10 seconds first the display address setting screen and then the NetSTAT screen is displayed In the NetSTAT screen the 4 rows show the 32 addresses of the pLAN network with symbols that represent the type of device connected The D and V buttons can be used to display the version of the firmware resident in the pGD1 terminal To exit the NetSTAT procedure press lt 2 If the pGD1 terminal de
46. nsert the terminal without the faceplate in the rear of the box and fasten it using the countersunk screws contained inside the packaging e apply the faceplate and click it into place 14 BAO 102 1 AUS 7 2 5 pGD1 terminal technical specifications Display Type FSTN graphic Backlighting green LED managed by application program Graphic resolution 122x64 pixel Text modes 8 rows x 20 columns font size 5x7 and 11x15 pixels 4 rows x 10 columns font size 11x15 pixels or alternatively mixed modes Character height 4 5 mm font 5x7 pixel 9 mm font 11x15 pixel Keypad LEDs 2 programmable by application program red and orange Prag and Alarm buttons INS 4 green associated with the backlighting of the LCD aN 4 CF and gs y buttons Power supply Voltage power supply from pCO via telephone connector or alternatively from external 18 30 Vdc source protected by external 250 mAT fuse Maximum power input 0 8 W Maximum distance Maximum length of the pLAN network 500 m with AWG22 shielded twisted pair cable Distance from pCO to terminal 50 m with telephone cable 500 m with AWG22 shielded twisted pair cable and TCONN6J000 Note to reach the maximum length use a bus with branches that do not exceed 5 m Materials Transparent front panel transparent polycarbonate Charcoal grey rear case wall panel polycarbonate ABS Keypad silicone rubber Transparent glass frame transparent polycarbonate Fl
47. nt Inputs used e B1 Capacity control input e B2 Low pressure transducer e B3 High pressure transducer e ID1 Oil pressure switch e ID2 Compressor thermal cutout e ID3 Phase sequence monitor e ID4 High pressure switch e ID5 Low pressure switch e ID8 remote on off Outputs used e NO3 Part winding contactor 1 NO4 Part winding contactor 2 Starting conditions A compressor can only be started if there are no alarms that prevent operation These alarms may be oil pressure switch e phase sequence monitor e high pressure switch e low pressure switch Or alternatively if the corresponding refrigerant circuit is in potentially dangerous operating conditions for the device according to the specific envelope diagram e high pressure transducer e low pressure transducer high discharge temperature All start modes are subject to any time delay that may still be active i e time between starts or minimum off time If remote on off is enabled the compressor cannot start unless the digital input is in the run condition The digital outputs associated with the part winding are activated in sequence with a fixed delay defined by Bitzer 28 BAO 102 1 AUS PW1 Part winding 1 Start Relay 3 PW2 Part winding 2 Start Relay 4 PWT part winding delay 500ms fixed t Time second 3 PAT t a Figure 14 a Stopping sequence The compressor is stopped in a number of di
48. ol algorithm automatically uses the fixed operating Refrig type R C limits defined by the Bitzer specifications 16 2 Envelope control algorithm for Bitzer CSH screw compressors The management of Bitzer compressors is incorporated into the application program and controls the suction pressure input B2 and discharge pressure input B3 BITZER CSH STEPLESS optimising the cooling capacity of the compressor both through the management of the control valves in step mode STEP and continuous STEPLESS control Refrig type Rx When the various operating thresholds are exceeded the compressor operates under forced capacity control or is shut down Compressor type Cl The type of refrigerant used in the compressor circuit can be set using parameter Refrig type and selecting between R407c R22 and R134a Depending on the type of gas selected the Bitzer compressor management procedure varies the operating limits of the compressor as shown in the following Znmncatian dag an creer Cees ee Bary _ Hix E aes a s i BETE i ereseriecs TISEELIIIE EEHTEEEN aerrites F ee ee ee ed ee wee ee ee ee ee ee ee ee ee ee ee oe oe oo gebitaen pia rerea ss yar ed om E eN tiacbt tase Pryerriss fiaskiiaas TEHER TAEECIISE ENTREN ie Ba Be ee fiasbhiaas PHARE SR DR DRG mi ia mi ii i ELIZE la a nae Bris ceric Scrrsertaee b eee p m pn a EEN EBS m Be Biidcciiaas Byrsceriq Tig
49. ote on offdigtalinput a vs nors Supervisor remote onlofl Enabie ON OFF from supervisor no nrws SetpontsH ___ Supemeatsetpont OOOO OOOO o f o o S ooa SSS SH thresh row supemeat atam soting m SYP moos k OP thresh Low operating pressure alarm seting m so soows0o MOP thresh Maximum operating seting m s oowoo o ident number serae OOOO OOOO E f S a E aae O paoman OO e a a OY a A A A E a OY a A A A E Pe 0 Insert new user password Edit new password to access the user menu 1234 Ld 0000 to 9999 fs Type of unit measurement Unit of measure Oil pressure Oil pressure switch digital input logic 23 BAO 102 1 AUS 24 Description on the user terminal Description of the function Deteult Index value _ value measure Clock Menu ee oi Clock config Time deof E e Manufacturer Menu Insert manufacturer password Password to access the manufacturer menu 1234 _ 0000 to 9999 Configuration Menu ee BITZER E BITZER Step BITZER Stepless C1 R134a R134a R407C Suction control Enable control from suction pressure Co Yes No Yes Suction Control type Type of suction control Co Suction Variable suction Demando sab capaciyconvorimpot ff CNVes 0 10V 0 10V 0 5V 4 20mA 0 5V 4 20mA 0 5V 4 20mA compressor_type Type of control C1 Stepless refrig_type Type of gas managed Type of
50. s available for a parameter Set point defines a pressure or temperature value to be satisfied the system activates or deactivates the devices so that the value measured reaches the set point Buffer memory memory on the controller used to save the default values selected by CAREL for all the parameters Permanent memory saves the values even when power is disconnected Upload the operation used to copy the application software from the computer or programming key to the pCO controller Analogue value integer value with sign and decimal point Digital value value with just two states Integer value integer value without decimal point Built in built in display pLAN acronym for p CO L ocal A rea N etwork Part winding start CR capacity valve HP high pressure Macroblock functional software block Hysteresis differentiation Envelope field of operation Stepless continuous infinite control Steps control by steps Set point set point Backlight backlighting 42 22 43 lt gt MANUFACTURER Our products are manufactured in compliance with applicable international standards and regulations If you have any questions about how to use our products or if you are planning special applications please contact Please contact us via email and visit our website info bitzer com au www bitzeravp com au BITZER Australia Pty Ltd 134 136 Dunheved Circuit St Marys NSW 2760 Tel 61 0 2 8801 9300 Fax
51. series screw compressor Type of control Control of compressors with 4 load steps or compressors with continuous capacity control System safety devices Compressor operation safety times low pressure switch High pressure switch High pressure transducer Low pressure transducer Oil level management Thermal protection Phase monitoring protection Condenser fan overload High discharge temperature General alarm Other functions Condenser fan control Liquid temperature measurement Economiser Heat Exchanger EEV control Alarm logging Built in terminal management BAO 102 1 AUS Accessories User PGD1 terminal RS485 serial board for interfacing to a supervisory network CAREL or MODBUS protocol pCOweb interface board for Bacnet web Compatible hardware pCO5 medium with built in EEV driver 3 Configurations and codes 3 1 Configurations and software hardware codes Below are product codes for the different configurations of driver available for sale 1 Driver for Bitzer CSH screw compressors software FLSTMBSDE 2 pCO5 medium with built in EEV Driver for Bitzer CSH screw compressors software installed kit PCO5BZ010K In addition the following are available to complete the system 3 pGD1 user terminal for panel installation 8 rows by 20 columns PGD1000F00 4 pGD1 user terminal for wall mounting 8 rows by 20 columns PGD1000W00 5 RS485 serial board for interfacing to supervisory networ
52. solated analogue output VGO power to optically isolated analogue output 0 Vac Vdc 7 Analogue outputs 8 ID digital inputs at voltage A 9 ID digital inputs at voltage A IDH digital inputs at voltage B 10 pLAN telephone connector for terminal downloading application program 11 pLAN plug in connector 12 Reserved 13 Reserved 14 Reserved 15 Relay digital outputs 16 BMS2 connector 17 Fieldbus 2 connector 18 Fieldbus BMS selector microswitch 20 Electronic valve A connector 21 External Ultracap module accessory connector 22 Valve driver analogue and digital inputs 23 Valve status LEDs T BAO 102 1 AUS pCO5 MEDIUM with built in driver power supply A class 2 100 VA safety transformer is recommended for supplying one controller pbCO5 with built in driver only The power supply to the pCO5 controller and the terminal or series of pCO5 and terminals should be separated from the power supply to other electrical devices contactors and other electromechanical components inside the electrical panel The transformer secondary must be earthed and make sure that the earth wire is connected to terminal GO The same is true for all the devices connected to the pCO5 If more than one pCO5 controller is connected in a pLAN network make sure that the references G and GO are maintained reference GO must be maintained for all the controllers 4 1 2 pCO5 Technical specifications Plastic case Mounting Ma
53. ss screen PO which requires the password 2 once having entered and confirmed the correct password access screen P1 for selecting unit of measure 3 select between the options STANDARD C bar or ANGLO SAXON F PSI and confirm After the selection all the parameters are converted to the new unit of measure 14 Compressor management The Driver for Bitzer CSH screw compressors application program has been developed specifically to manage Bitzer CSH series compressors including the following possible types of control e stepped capacity control e continuous stepless capacity control e suction pressure with continuous stepless capacity control variable suction pressure with continuous stepless capacity control while managing all the safety devices recommended and certified by Bitzer in two different modes safety capacity control e envelope control using an algorithm developed by Carel based on Bitzer specifications Management from a supervisory system is also available 14 1 Switching the compressor On Off The compressor is started in different ways for stepped or continuous capacity control e stepped capacity control the compressor starts when the activation of the first stage is requested e continuous capacity control the compressor starts as soon as the input signal exceeds the capacity standby zone e Suction control the compressor is cycled to maintain the suction pressure set poi
54. t 5 mA can be selected via software universal inputs B1 B2 B3 B6 B7 B8 CAREL NTC temperature sensor 50T90 C R T 10 KQ Cat 25 C HT NTC 0T150 C voltage 0 to 1 Vdc 0 to 5 V ratiometric or O to 10 Vdc current 0 to 20 mA or 4 to 20 mA can be selected via software Input resistance of 0 to 20 mA 1002 8 0 5s 0 3 of the full scale Mechanical specifications Table 4 d for the power supply of any active probes 21 Vdc available at the Vdc terminal J2 can be used the maximum current is 150 mA protected against short circuits To supply the O to 5 V ratiometric probes use the 5VREF Imax 60 mA available at terminal J24 separate the probe signal ands digital input cables as much as possible from the cables carrying inductive loads and the power cables to avoid possible electromagnetic disturbance BAO 102 1 AUS Digital inputs type optically isolated maximum number on medium vers 12 optically isolated inputs 24 Vac 50 60 Hz or 24 Vdc 2 optically isolated inputs 230 Vac 50 60 Hz or 24 Vac Vdc WARNINGS 230 Vac 50 60 Hz 10 15 the two 230 24 Vac inputs available at J8 and J12 have the same common pole and thus will both be 24 Vac Vdc or 230 Vac There is primary insulation between the two inputs in the event of DC inputs connect the negative pole to the common terminal Note separate the probe signal ands digital input cables as much as possible from the cables carryin
55. tects the off line status of the associated pCO controller it cancels the display and shows the message I O Board xx fault If the terminal receives no network signal it cancels the display and shows the message NO LINK 18 BAO 102 1 AUS lt gt 9 Installing and restoring the default values 9 1 Initial installation of the default values When the system is first started the application program automatically installs the default values of all the configuration parameters set by CAREL Subsequently a number of values can then be customised as shown in the list of parameters To start the system power up the pCO controller after having checked the correct connection of the devices 9 2 Restoring the default values If needed the initial default values can be restored following the procedure indicated below valid for all the pCO controllers WARNING The following procedure irreversibly deletes any custom values Procedure for resetting the default values From the main menu press the Prg button scroll down with the Down button until highlighting the Manufacturer sub menu select the Manufacturer menu by pressing the Enter button type the password default 1234 and confirm by pressing Enter scroll the sub menus with the Up Down buttons until highlighting Initialisation select Initialisation and press the Enter button scroll the screens with the Up Down buttons until highlighting
56. ted screens 12 List of parameters 13 Selecting the unit of measure 14 Compressor management 14 1 Switching the compressor On Off 14 2 Stepped capacity control 14 3 Continuous capacity control 14 4 Calculating the active capacity in the refrigerant circuit 15 Economizer solenoid valve EEV control 16 Compressor safety control 16 1 Safety capacity control 16 2 Envelope control algorithm for Bitzer CSH screw compressors 16 3 Safety times 17 Hour counter 17 1 Display operating hours 17 2 Setting the operating hour alarm threshold for maintenance 18 Condenser control 18 1 Modulating condenser control linked to the pressure or temperature sensor 19 Alarms 19 1 List of alarms 19 2 Alarm log 20 Supervisor Software updates 21 Glossary 22 Manufacturer 23 Service Address BAO 102 1 AUS lt gt 1 General features The Driver FOR Bitzer CSH screw compressors is software that manages the operation of a Bitzer CSH series screw compressor modulating the capacity in response to a proportional input signal supplied by an external regulator guaranteeing the total protection of the compressor The software can be installed on pCO5 with built in driver software supplied already installed on dedicated pCO5 hardware The interface with a supervisory network is also featured Capacity control signal 4 20mA SAPE pep 2 Applications and functions performed by the software Type of units controlled Bitzer CSH
57. terial Flame retardant Ball pressure test Creeping current resistance Colour Built in terminal Electrical specifications power supply controller with terminal connected terminal block CPU program memory on FLASH MEMORY data memory static RAM parameter data memory working cycle duration applications of average complexity clock with battery Analogue inputs analogue conversion type maximum number on medium vers time constant for each input precision classification of the measuring circuits CEI EN 61010 1 WARNINGS Can be mounted on DIN rail in accordance with DIN 43880 and IEC EN 50022 Technopolymer V2 Standard UL94 and 850 C IEC 60695 125 C 2 250 V White RAL 9016 PGD1 132x64pixel with backlit keypad 28 to 36 Vdc 10 20 and 24 Vac 10 15 50 60 Hz maximum current P 15 W Vdc power supply P 40 VA Vac with male female plug in connectors max voltage 250 Vac cable cross section min 0 5 mm max 2 5 mm H8S2320 to 16 bit and 14 MHz 2 2 MB in the extended versions further memory of 32 MB or higher 512 kB 16 bit 296 kB Bios 216 kB application 13 kB 16 bit max limit 400 000 writes per memory location and further 32 kB E2prom not visible from the pLAN 0 2 s typical standard 10 bit A D converter CPU built in passive inputs B4 B5 CAREL NTC temp sensor see universal PT1000 100T200 C R T 1000Q at 0 C or voltage free digital inpu
58. 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 e 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 e 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 e Do not attempt to open the device in any way other than described in the manual e Do not drop hit or shake the device as the internal circuits and mechanisms may be irreparably damaged e Do not use corrosive chemicals solvents or aggressive detergents to clean the device e Do not use the product for applications other than those specified in the technical manual All of the above suggestions likewise apply to the contro
59. ttons to scroll the values from 0000 to 9999 Once having reached the correct value confirm by pressing Enter If the wrong password is entered repeat the procedure One or more custom passwords can be set by entering the new value in the specific screen this too protected by the corresponding access password If the custom password is forgotten the initial default values can be restored including the password remembering however that this procedure also irreversible deletes any other custom values see the procedure Restoring the default values 20 BAO 102 1 AUS lt gt 3 Configurations and codes 3 1 Configurations and software hardware codes Below are product codes for the different configurations of driver available for sale 1 Driver for Bitzer CSH screw compressors software FLSTMBSDE PA pCO5 medium with built in EEV Driver for Bitzer CSH screw compressors software installed kit PCO5BZ010K In addition the following are available to complete the system 3 pGD1 user terminal for panel installation 8 rows by 20 columns PGD1000F00 4 pGD1 user terminal for wall mounting 8 rows by 20 columns PGD1000W00 5 RS485 serial board for interfacing to supervisory network optional PCOS004850 6 pCO web Bacnet PCO1000WBO T Temperature and pressure probes see general catalogue 8 Connection cable between user terminal and pCO controller see general catalogue 21 BAO 102 1 AUS 12 List of par
60. ty control modulates the capacity in 3 phases e increase the capacity is increased by a series of impulses with variable amplitude a maximum time limit is established after which the compressor is considered to be operating at full load e Neutral zone the capacity reached is maintained e decrease the capacity is decreased from a series of impulses with variable amplitude a maximum time limit is established after which the compressor is considered to be operating at minimum load after which it is turned off EE h em Eir br mm nra mirr lel ves hn e ei n pmi ns ia ieee a Ta aoe aa LE ar Figure 14e 14 4 3 Compressor Suction pressure with continuous capacity control A compressor with continuous capacity control modulates the capacity in 3 phases e increase the capacity is increased by a series of impulses with variable amplitude a maximum time limit is established after which the compressor is considered to be operating at full load e Neutral zone the capacity reached is maintained e decrease the capacity is decreased from a series of impulses with variable amplitude a maximum time limit is established after which the compressor is considered to be operating at minimum load after which it is turned off u aa i iy fa a l Mee Figure 14f 31 BAO 102 1 AUS lt gt 14 4 4 Compressor Variable Suction pressure with continuous capacity control The compressor is managed in the same m
61. utton was pressed 7 4 2 Adjusting the contrast of the LCD Holding the buttons and pressing or increases or decreases the contrast 16 BAO 102 1 AUS 8 pLAN network management pLAN stands for pCO Local Area Network The pLAN network identifies a physical connection between the controller oCO and the external terminals The purpose of the pLAN network connection between the controllers is to exchange variables according to the logic decided by the application program so as the units can operate together The variables exchanged between the controllers are established by the application program as is the direction of exchange and therefore there are no user settings 8 1 pLAN network diagram A maximum of 32 devices can be connected to a single pLAN network Each device connected to the same pLAN network must have a unique address between 1 and 32 Below is a diagram of the specific pLAN network 8 2 How to assign the pLAN addresses 8 2 1 Assigning the address on the pGD1 terminal The pGD1 terminal has a default address of 32 To assign a unique address proceed as follows Connect and power up the terminal Press the Up Down ENTER buttons until the display address setting screen is displayed In the display address setting screen enter the numeric pLAN address with the Up and Down buttons and then confirm by pressing Enter The No link screen will be displayed If the No Link screen is

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