CELLmatic 1502 GSF, User Manual

Page 1: ...Thy tronic I S Bjørnevej 8c DK 7700 Thisted Tel 45 97982344 Email Info thytronic dk CELLmatic 1502 GSV GSF User Manual Version 2 1 ...

Page 2: ...OARD 4 DIODES 4 MENU TREE 5 PASSWORD 6 SETTING OF CLOCK AND DATE 6 CONTROL 7 MONITORING 7 ALARM 7 CUTOUT 7 EMERGENCY STOP 7 STARTING UP 8 CONNECTION BETWEEN CAPACITY AND VOLUME RATIO 10 TYPES OF DUTY 11 CALIBRATION 15 SETUP OF COMPRESSOR 16 SET POINTS 19 DISPLAY PICTURES 31 I O PICTURES 35 SURVEY OF SET POINTS 45 SURVEY OF MESSAGE TEXTS 47 SURVEY OF ALARM AND CUTOUT TEXTS 49 ...

Page 3: ...r a specific control task Reading this manual does not require any particular knowledge of computers and the same applies to the operation of the CELLmatic 1502 However it would be useful to test the described procedures of the CELLmatic 1502 while going through this manual Operating the microprocessor The microprocessor is operated from the keyboard on the control panel Here is also found the dis...

Page 4: ... will appear on the display 2 Signal and status line On the status line it is possible to show a number of texts stating the working condition of the compressor If capacity is adjusted up or down a C followed by a plus or a minus will appear in this line In case of volume ratio control a V or a V will appear At the back of this description of control there is a list for signal texts 3 Command line...

Page 5: ...l picture Í Recall will delete the latest entry It means that it is used for scrolling back to the previous menu When entering set points the Í key can be used for deleting the value entered provided that the ENTER key has not been pushed ENTER Enter is used for updating If you want to change a set point and the new value which will be shown in the command line has been entered the value is update...

Page 6: ...nic I S Bjørnevej 8c DK 7700 Thisted Tel 45 97982344 Email Info thytronic dk MENU TREE The connection between function fields for selection of operation set up and set points are shown below For the I O pictures a menu tree is shown at the beginning of the section I O pictures ...

Page 7: ...use two passwords PASSWORD 1 5 This password must be used when changing important setpoints and machine set up When the password is used it becomes possible to show the I O pictures which gives the status of analog and digital inputs and outputs I O Input Output PASSWORD 1 8 This password is used very rarely typically only for the first start up when in error the wrong type of compressor has been ...

Page 8: ...ght go wrong shortly I e a warning In the event of an alarm the message P1 ALARM will appear in the upper left hand corner followed by the operating parameter causing the alarm The alarm and the time of alarm will be stored in the memory of the control and can be read out if the computer is connected to a main control unit An alarm is reset by pushing the CLA Clear Alarm F6 but it will appear agai...

Page 9: ... that the compressor has a swept volume of 640 m3 hour Refrigerant Possibilities are 12 R12 22 R22 134 R134a 404 R404a 502 R502 and 717 R717 Node number Here give the identification number the panel can be allocated if communication is by network When these questions have been answered with values the computer can accept and F1 must be keyed to continue If a value has been given that subsequently ...

Page 10: ...r The current converter instrument must have a range of input current there go higher than the full load motor current so an over load can be measured A range there goes up to 25 higher will be very suitable Example When using an instrument transformer where the primary current is 200 A and a motor with a rated current of 180 A The transformer factor will make 200 180 1 11 When the factor has been...

Page 11: ...t capacity is obtained when the piston is in its outermost right hand position A 100 capacity is obtained when the slide valve is run so far to the left that it runs against the slide stop The position is measured by means of a rotary potentiometer POT 2 or a sliding potentiometer The slide valve has its longest travel when the slide stop is in a outermost left hand position For all other position...

Page 12: ...ll all be controlled by the setpoint of the master compressor For master operation the following conditions have to be fulfilled before the compressor will start Restart period expired Call for capacity that is PSUCTION C PSUCT SETP PSUCT START TBRINE TBRINE SETP TBRINE START Reset of possible cutout CLA Slide valve at its minimum CABS 15 Oil pump is started and the oil pressure are greater than O...

Page 13: ...ntinue to run for 5 minutes calculated from the start of run down The solenoid valves for the down regulation of capacity and volume ratio remain activated for 120 minutes provided CABS is not less than 15 In most cases this will ensure that the compressor is ready for start 2 Slave operation Slave operation is selected by activating the F5 2 in the SETUP 1 picture If the compressor is to run as a...

Page 14: ...re slaves slave no 1 will work as a master for slave no 2 and so on However the suction pressure registered by the real master will be adjusted unless for the master compressor it is a question of remote control operation with external set point 3 Remote control operation The CELLmatic 1502 offers the possibility of running remote operation in 2 different ways I Remote control according to its own...

Page 15: ...ssor is started the oil pump will also be running dependent on which type of pump has been chosen see setpoint R The desired capacity at which the compressor is to run can be stated by F2 After this the solenoid valve will receive pulses and the capacity slide will be adjusted to the desired capacity If 10 or 110 is entered here the solenoid valve will receive constant signal to lower increase the...

Page 16: ...ng the compressor or oil pump makes calibrating Enter 10 in setpoint C pos and 6 0 in setpoint Vi The capacity slide will now be forced into minimum and the slide stop into maximum position When the values of the two upper text lines are not changed any more the limits have been reached The values are read and noted Enter now 110 for C pos and 2 0 for Vi The capacity slide will then run into maxim...

Page 17: ...er 0 Node F2 NODE NO State own number 5 F1 STOP STOP F5 To make this communication all CELLmatic 1502 panels involved must be provided with the communication board CELL 566 which consists of a communication adapter a so called profibus If this extension has been mounted it is possible in the above menu to select whether the communication is to be active 1 YES or not 0 NO F3 F4 Through a menu to wh...

Page 18: ...tor and is called Motor cut time Can be set from 5 to 30 seconds F4 Stop time After STOP or CUTOUT has been set the time according to which the compressor is to run is set with the F4 key The value can be set between 0 and 120 seconds and is called STOP TIME At compressors running with a great difference between condensing pressure and suction pressure a small stop time is set Note When stopping t...

Page 19: ...reely be selected between following 0 No displaying 1 OUTPUT 0 100 4 20 mA calculated value 2 AMPERE 0 150 4 20 mA measured motor current 3 OIL DIFFERENTIAL PRESSURE 0 25 bar 4 20 mA computed value 4 SUCTION PRESSURE 1 to 6 bar 4 20 mA measured value P suction 5 DISCHARGE PRESSURE 0 25 bar 4 20 mA measured value P discharge With the F5 key it can be selected which variable you want to read out at ...

Page 20: ...han 94600 a shift between setpoint 1 and 2 is performed through digital input 4 whereas on switchboards with EPROM no 94600 or higher resistance input R IN 4 is being used EPROM no can be read on display picture 6 Resistance input R IN 4 Brine regulation SETP E F2 active Regulation based on OFF NO Psuct setp 1 setp a F5 OFF YES Brinetemperature setp E F5 ON NO Psuct setp 2 setp T F4 ON YES Psuct s...

Page 21: ...ed F4 P SUCTION STOP At set point controlled operation the compressor will stop when the suction pressure falls below the set point set point A F5 by the number of degrees entered F3 PROPORTIONAL ZONE This value indicates by how many degrees above and below the set point for suction pressure brinetemperature proportional zone control that there will take place When the pressure is within the propo...

Page 22: ...LW SETP SETP SETP SETP SETP SETP Note When the compressor is running according to its own set point the compressor will never adjust the pressure down to P SUCT RELIEVE or P SUCT CUTOUT because of P SUCT STOP It will only be possible to achieve these two pressures if the compressor is running at manual control or at remote control according to external set point As P SUCT CUTOUT is resetting itsel...

Page 23: ...s adjusting is stopped and if the motor current exceeds this value anyhow the slide valve for relief of the compressor will be adjusted downwards In the latter condition AMPERE is shown on the message line of the picture and a start signal is sent to a slave if connected F3 P DISCHARGE ALARM This outlet pressure in degrees Celsius triggers an alarm and at the same time the compressor capacity begi...

Page 24: ... brine temperature in degrees Celsius for which the compressor is to adapt capacity must be given Can only be used with the operating forms MASTER and REMOTE WITH OWN SETPOINT REMOT5 F4 T BRINE START In operation where the compressor regulates in accordance with the setpoint for brine temperature a start signal is given to the compressor when the temperature of the brine is the number of degrees g...

Page 25: ... 200 A and a motor with a rated current of 180 A The transformer factor will make 200 180 1 11 F4 AMPERE CONSUMPTION MAX The motor current is calculated in per cent by means of the transformer factor set above If this current is exceeding the set point for max ampere consumption set here the capacity of the compressor is adjusted downward with a constant signal until the motor current has reached ...

Page 26: ...e time the message ALARM LT OIL will appear at the top left hand corner of the display F4 MIN T OIL CUTOUT The compressor will be stopped if the oil in the oil separator does not reach this temperature and CUTOUT LT OIL will appear at the top left hand corner of the display F3 MAX T OIL ALARM If the oil temperature measured in the oil manifold is exceeding this temperature an alarm will be reporte...

Page 27: ...OIL Otherwise the filter pressure drop is calculated as follows Prelube pump Pressure drop over filter PDISCH POIL where PDISC is the Discharge pressure and POIL is the oil pressure measured in the manifold Cycling or full lube oil pump When PDISCH PSUCT 4 5 bar Pressure drop over filter PDISCH POIL 1 When PDISCH PSUCT 4 5 bar Pressure drop over filter PDISCH POIL F3 OIL DIFF PRESSURE ALARM If the...

Page 28: ...eeds this temperature the compressor is stopped and CUTOUT T DISCH will appear in the display The discharge temperature is measured by a PT 100 sensor which is normally placed in the discharge pipe between the compressor and the oil separator F3 T SUCTION ALARM If the suction temperature measured by PT 100 sensor in the suction valve goes below this value an alarm will report and ALARM T SUCTION w...

Page 29: ...E The pump is always running when the compressor is running F3 INJECTION YES NO If the compressor unit is provided with liquid injection cooling a YES 1 is selected here F2 COMPRESSOR SIZE The size of the compressor is to e entered here The size of the compressor can be read from the name plate placed at the compressor block Possible GSV sizes are 50 64 84 111 147 185 263 331 412 and 562 Set point...

Page 30: ...imum has been reached the master will receive a message and further downward adjusting is now taking place at the master see description of master slave operation under types of duty If the slave should go under its minimum it will receive a capacity up signal To avoid hunting at this set point MIN REG FREE it is possible to indicate by how many per cent over the minimum of the slave you will give...

Page 31: ...rator is exceeding the pressure set under this set point the compressor cannot be started When attempts are made to start the message BY PASS will appear in the message line of the display and output OUT 5 will go ON This output will then be able to activate a solenoid valve placed in a tube between the oil separator and the suction line of the compressor F3 SLAVE STOP In case of master slave oper...

Page 32: ...compressor was asked to stop either because of a cutout or another stop To be able to see the operating parameters updated during a standstill the frozen values will be shown in putting a bracket around the unit indicating the parameter against the value The initial picture can be considered as the first display picture indicating the operating parameters With the F2 key it is possible to scroll b...

Page 33: ...ll current values in this display picture are frozen in case of a cutout or a stop Display picture 2 01 01 94 17 25 35 F6 CLA P suct C 0 0 C F5 SETUP 1 P suct setpt C 0 0 C F4 SETPOINT P discharge B 0 00 Bar F3 MANUAL P oil B 0 00 Bar F2 DISPLAY 3 C abs 0 0 F1 STOP STOP P SUCTION C The suction pressure measured is shown here converted into degree Celsius P SUCTION SET POINT C Here the set point fo...

Page 34: ...SCHARGE C Here the temperature which is measured by the PT 100 sensor placed in the pressure pipe is shown All values in display picture 3 are frozen in case of a cutout Display picture 4 01 01 94 17 25 35 F6 CLA Brine temp C 0 0 C F5 SETUP 1 T brine setp C 0 0 C F4 SETPOINT Brinetemp C 0 0 C F3 MANUAL P oil at filt C 0 0 Bar F2 DISPLAY 5 C pos 0 0 F1 STOP STOP BRINETEMP C This is the brine temper...

Page 35: ... showing the suction temperature measured by the PT 100 sensor placed in the suction valve T OIL SEPARATOR C The temperature measured of the oil in the oil separator OPERATING HOURS X 10 Here the number of operating hours is read resolved into 10 hours Display picture 6 01 01 94 17 25 35 F6 CLA Injection OFF F5 SETUP 1 Oil pump OFF F4 SETPOINT Heater OFF F3 MANUAL Economizer OFF F2 DISPLAY 1 EPROM...

Page 36: ...ge 35 of 51 Thy tronic I S Bjørnevej 8c DK 7700 Thisted Tel 45 97982344 Email Info thytronic dk I O PICTURES The signals of the analogue and digital Inputs and Outputs are shown in the I O pictures Input Output The menu tree for the I O pictures is shown below ...

Page 37: ...erating forms MASTER or REMOTE WITH OWN SETPOINT it is necessary to regulate the compressor in accordance with setpoint 2 for suction pressure entered under setp T a signal is applied at this input When the input is OFF regulation is in accordance with setpoint 1 for suction pressure entered under setp A or in accordance with the brine temperature entered under setp E R IN 3 T OIL COMPRESSOR Oil t...

Page 38: ...nal on analog input 3 A IN 3 where 4 20mA corresponds to 0 100 If this value is multiplied with the transformer factor setp I F5 you will get the motor current which is displayed on the initial picture display picture 1 A IN 2 P OIL PRESSURE B The oil pressure in bars measured by the pressure transmitter in the oil manifold 0 25 bar gauge 1 26 bar absolute corresponds to a signal from the transmit...

Page 39: ... the oil line immediately ahead of the point where oil enters the oil filter It registers pressure in bars On machines without the extra pressure transmitter 5 25 bar is displayed in the field 13 06 96 13 48 15 SETUP 1 I O AI WID ST F6 F5 F4 F3 R IN 7 Capacity slide pos 0 F2 R IN 6 Volume slide pos 0 F1 STOP R IN 7 CAPACITY SLICE POS A potentiometer under the cover nearest the compressor input sha...

Page 40: ...tion can be seen by leafing to SETUP 2 MENU 3 01 01 94 17 25 35 SETUP 1 I O AO 4 20MA F6 F5 F4 F3 A OUT 1 Analog Output 1 0 0 mA F2 A OUT 0 Analog Output 0 0 0 mA F1 STOP STOP A OUT 1 ANALOG OUTPUT 1 The signal depends on which operating parameters have been selected for reading off Output Amperes Oil differential pressure Suction pressure or Discharge pressure See also the section ELECTRICAL DATA...

Page 41: ...ign that the oil level in the oil separator is OK 03 06 96 13 48 15 SETUP 1 I O J1 J7 J8 IN 0 7 IN 4 7 F6 F5 IN 7 External error OFF F4 IN 6 Capacity down OFF F3 IN 5 Capacity up OFF F2 IN 4 START Slave OFF F1 STOP IN 7 EXTERNAL ERROR If the safety pressure control KP7ABS stops the compressor due to a too high pressure in the oil separator or if the emergency stop is activated an external fault wi...

Page 42: ...s 4 11 220V AC F5 OUT 7 Available F4 OUT 6 Available F3 OUT 5 BYPASS OFF F2 OUT 4 Economizer OFF F1 STOP STOP OUT 8 11 DIGITAL OUTPUTS 8 11 220V AC Function key F6 can be used to leaf to the I O picture showing digital inputs OUT 8 to OUT 11 OUT 7 LOW LIQUID INJ If the volume ratio is less than 4 5 and OUT 6 is ON low liquid injection is selected and the output goes ON The signal is significant on...

Page 43: ...ompressor in order to relieve the axial bearings The solenoid valve must be connected to this output so that it goes ON when CPOS 70 that it goes OFF again when CPOS 65 and also goes off during standstill OUT 9 OIL EQUALIZING If the refrigerating plant is built up by more compressor units with an oil separator each running parallel operation it may happen that the oil is gradually moved into one o...

Page 44: ... OFF OUT 12 COMPR START When this output goes ON the compressor is started It is stopped again when the output goes OFF 03 06 96 13 48 15 I O J1 J7 J8 OUT 12 23 OUT 16 23 F6 OUT 20 23 Digital output 20 23 F5 OUT 19 Start Slave OFF F4 OUT 18 Booster start OFF F3 OUT 17 Common cutout OFF F2 OUT 16 Max Output OFF F1 STOP OUT 20 23 DIGITAL OUTPUTS 20 23 Function key F6 can be used to leaf to the I O p...

Page 45: ... all conditions are in order and the compressor is ready to start The output goes ON at the same time as the green lamp on the front of the panel lights up OUT 22 SLAVE MINIMUM With master slave operation the master compressor needs to know whether the slave has reached more than its minimum capacity The condition is signalled via this output on the slave which goes ON when compressor capacity is ...

Page 46: ... 0 C 10 C 2 0 C P DISCH CUTOUT SETP C F2 0 C 55 C 45 C P CISCH ALARM SETP C F3 0 C 55 C 40 C AMP NORMAL SETP C F4 0 100 100 MINIMUM CAPACITY SETP C F5 0 100 50 LIQUID INJECTION ON SETP D F2 0 C 100 C 45 C LIQUID INJECT OFF SETP D F3 0 C 100 C 40 C CAP DOWN FACTOR SETP D F4 0 100 50 CAP UP FACTOR SETP D F5 0 100 25 BRINE REGULATION SETP E F2 0 NO 1 YES 0 NO T BRINE STOP SETP E F3 0 C 10 C 5 C T BRI...

Page 47: ... L F3 60 C 0 C 45 C T DISCH CUTOUT SETP L F4 0 C 150 C 100 C T DISCH ALARM SETP L F5 0 C 150 C 90 C COMPRESSOR SIZE SETP R F2 0 562 0 INJECTION YES NO SETP R F3 0 NO 1 YES 0 NO OILPUMP TYPE SETP R F4 0 2 0 PRELUBE REFRIGERANT TYPE SETP R F5 0 717 0 SLIDE VALVE MAX SETP S F2 0 2500 1800 SLIDE VALVE MIN SETP S F3 0 2500 250 SLIDE STOP MAX SETP S F4 0 2500 1800 SLIDE STOP MIN SETP S F5 0 2500 250 BOO...

Page 48: ...s shown in the upper left corner MAN STOP The unit has stopped according to a message from the keyboard F1 has been pushed and CLA has to be pushed before the compressor can be started again ST P SUCTION The compressor has stopped because the suction pressure is below the set point for P SUCTION CUTOUT set point A F3 RELIEVE The compressor is adjusting capacity downward unloading because the sucti...

Page 49: ...ed Then MINIMUM is shown V or V If the optimum Vi is higher than that on which the compressor runs V will be shown At the moment the signal to the solenoid valve arrives V flashes twice If a constant signal is sent to the solenoid valve V will continue to flash Correspondingly V indicates that the optimum Vi ratio is less than that on which the compressor runs C or C If the suction pressure or bri...

Page 50: ...TOUT MOTOR No feedback from the compressor motor that it is running CUTOUT LEVEL Oil level in oil separator too low CUTOUT P DISCH Maximum permissible discharge pressure set point C F2 exceeded CUTOUT OIL DIFF The necessary oil differential pressure entered under set point K F2 not available Delay 3 minutes This cutout text will also appear if the oil differential pressure si 0 zero delay 45 sec d...

Page 51: ... too high above set point C F3 ALARM T DISCH High discharge pipe temperature above set point L F5 ALARM HT OIL High oil temperature measured in oil manifold above set point J F3 This alarm has a delay of 3 minutes ALARM LT OIL Low oil temperature in oil separator below set point J F5 ALARM T SUCTION Temperature of suction gas measured by PT 100 sensor placed in suction valve too low below set poin...