µC2SE for process chiller electronic control User manual
ENGLISH IMPORTANT WARNINGS CAREL bases the development of its products on several years’ experience in the HVAC field, on continuous investment in technological innovation of the product, on rigorous quality procedures and processes with in-circuit and function tests on 100% of its production, on the most innovative production technologies available on the market.
ENGLISH 4 µC2SE process chiller +030220416 - rel. 1.1 - 27.04.
CONTENTS 7 ENGLISH 1. INTRODUCTION 1.1 General description ..............................................................................................................................7 1.2 User interface ........................................................................................................................................7 2. CONNECTIONS 9 2.1 General diagram .............................................................................................................................
ENGLISH 6 µC2SE process chiller +030220416 - rel. 1.1 - 27.04.
ENGLISH 1. INTRODUCTION 1.1 General description The μC2SE is a compact CAREL electronic controller, the same size as a normal thermostat, for the complete management of process chillers: it can control air-water and water-water. 1.1.
ENGLISH 1.2.
2.1 General diagram EVD*40*: driver for electronic expansion valve Optional board MCH200002*: I/O expansion board for µ2SE PSOPZKEY*: programming key CONVONOFF*: PWM/digital converter PW/Modbus® RTU CAREL Supervisory CONV0/10A0*: PWM/analogic converter NTC: temperature probes MCHRTF**A0: fan speed regulator MCH200485* RS485 serial card MCH2*T*: terminal PW/Modbus® RTU CAREL Supervisory MCH2*TSV*: adapter SPKT: 0 to 5 V pres. transducer Fig. 2.a 2.2 Network layout EV driver Fig. 2.
ENGLISH 3. APPLICATIONS 3.1 AIR/WATER chiller 3.1.1 Single circuit Key: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 condernser fan overload fan condenser probe flow switch outlet evaporator probe fan antifreeze heater inlet evaporator probe compressor 1 high pressure compressor overload low pressure water pump compressor 2 2 3 4 5 6 7 8 9 13 11 10 12 14 Fig. 3.a.a 3.1.
1 Key: 1 3 3 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 2 4 5 1 6 7 1 8 1 7 2 2 6 8 condenser fan overload fan condenser probe 1 and 2 flow switch outlet temperature probe evaporator 1 and 2 outlet evaporator probe 1 and 2 antifreeze heater 1 and 2 compressor 1 high pressure 1 and 2 compressor overload 1 and 2 low pressure 1and 2 inlet evaporator probe compressor 2 water pump compressor 3 compressor 4 2 9 16 13 10 1 1 11 12 2 1 11 12 15 2 10 2 17 14 Fig. 3.a.c 3.
ENGLISH 3.2.2 Two circuits Key: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 water condensing temperature probe 1 and 2 condensator 1 and 2 flow switch outlet evaporator probe evaporator antifreeze heater 1 and 2 compressor 1 high pressure 1 and 2 compressor overload 1 and 2 low pressure 1 and 2 inlet evaporator probe water pump compressor 2 compressor 3 compressor 4 3 1 4 1 2 1 1 2 2 2 6 5 14 7 11 8 1 9 1 10 2 1 10 9 8 2 2 12 13 15 12 Fig. 3.b.b 3.2.
ENGLISH 4. PARAMETERS 4.1 General parameters The parameters are divided into 4 different types, according to their level of access by the user (password) and their function. For each level, only the access to the parameters of the same or lower level can be set. This means that through “factory” password, acessing the menù “levels” (L-P), it is possible to set the desired level for each parameter.
4.3 Parameter tables ENGLISH The following tables show of the parameters divided by type/family (e. g. compressor, probes, fans etc.). • Key to the parameter tables Level (default) S= super user F= factory D= direct Visibility: The visibility of some groups depends on the type of controller and the value of the parameters.
display indicat. A01 A02 A03 A05 A06 A07 A08 A08 A09 A10 A11 A11 A14 parameter and description default level Alarm set point antifreeze/low ambient temperature (air/air) U Differential for antifreeze/low ambient temperature alarm (air/air) U Bypass time for antifreeze alarm/low ambient temp. when turning on the unit U in heating mode Diff. for antifreeze heater/auxiliary heater U Auxiliary heater probe F 0= Control probe see (see Table 5.a) 1= Antifreeze probe see (see Table 5.
ENGLISH 4.3.7 Fan setting parameters (F*) display parameter and description indicat. F01 Enable Fan output 0=not present 1=present F02 Fan operating mode 0= always ON 1= depending ON the compressor (in parallel operation mode) 2= depending ON the compressors in ON/OFF control 3= depending ON the compressors in speed control mode F03 Min. voltage threshold for Triac F04 Max. voltage threshold for Triac F05 Speed temp. set point in Cooling mode Pressure value for min.
default level F min. max. U.O.M. variat. def. 0 visibility supervis. variable 18 (R/W) 0 1 Flag 1 F F 0 0 1 3 Flag Flag F 0 1 F 0 1 Modbus 18 variable type Digital 1 1 0 0 - 11 (R/W) 124 (R/W) 11 331 Digital Integer Flag 1 0 - 25 (R/W) 25 Digital Flag 1 0 - 26 (R/W) 26 Digital 4.3.9 Firmware parameters (F-r*) display indicat.
ENGLISH display indicat.
display indicat.
ENGLISH 4.3.13 Supervisor-only variables display indicat.
ENGLISH 5. DESCRIPTION OF THE PARAMETERS To modify the parameters, see chapter 4 “Parameters.” • Probe settings: parameters (/*) (see Table 4.a) - Type of probe: from /01 to /08: enables the reading of the corresponding analogue input or sets the function • Functions of the probes Type of unit Parameter H01 Temp.
ENGLISH - Heating differential A09: Represents the differential for the activation/deactivation of the heating function - Automatic switch-on A10: This parameter is valid when the unit is in standby. The operating mode switchover delay times are ignored.
• Compressor settings: parameters (c*) - Minimum ON time c01: This establishes the time that the compressor must remain ON for when started, even if the stop signal is sent. Key: ON t OFF ON 2 1. signal; 2. compressor; 3. min. ON time-interval. C2 t OFF 3 Fig. 5.a.c - Minimum OFF time c02: This establishes the time that the compressor must remain OFF for when stopped, even if the start signal is sent. The compressor LED flashes in this phase. ON 1 Key: t OFF ON 1. signal; 2. compressor; 3.
- Pump/outlet fan (air/air) start delay from compressor OFF c08: In cooling and heating operation, if the operation of the pump (outlet fan) is subject to the controller ON ENGLISH 1 t 2 ON (parameter H05=2), when the compressor is requested to stop, the control first stops the compressor and the pump (outlet fan). If the pump/outlet fan is always ON (H05=1), it is only stopped in standby mode. OFF Key: OFF 3 t C8 1. 2. 3. 4. 4 Fig. 5.a.
• Fan settings: parameters (F*) ENGLISH - Fan output F01: Enables the operation of the fans. F01=0: fans absent; F01=1: fans present. The PWM output (1 or 2, depending on the value of parameter H02) requires the presence of the optional fan control cards (ON/OFF for the CONVONOFF module or speed variation for MCHRTF or FCS three-phase). - Fan operating mode F02: This establishes the operating logic for the fans: F02=0: always ON at maximum speed, independently from the compressors.
ENGLISH - Temperature/pressure differential for maximum speed in cooling F06: This represents the temperature or pressure differential in reference to F05 above which the fans are started at maximum speed; in the case of ON/OFF control, this represents the differential above which the fans are started (Fig. 5.a.k). - Temperature/pressure differential for fans Off in cooling F07: This represents the temperature or pressure differential in reference to F05 below which the fans are stopped.
ENGLISH - Number of evaporators H03: This establishes the number of evaporators present when there are 2 or 4 compressors, obviously with 2 circuits (including the expansion). With one evaporator (H03=0), the management of the heaters and the antifreeze function is performed only on B2. Vice-versa, with 2 evaporators (H03=1) antifreeze control will be performed using B2 and B6, while input B5 is used to control the water outlet temperature.
H11= 12: ENGLISH associated device H11=0 H11= 1 H11= 2 H11= 3 H11= 4 H11= 5 alarm compressor 2 heater 2 Condenser pump/backup reversing valve 2 C10 Warning compressor 1 heater 1 Pump/evaporator (fan) (on air/air units) Compressor 2 (or capacity control comp. 1) reversing valve 1 compressor 3 heater 2 Condenser pump/backup Compressor 4 (or capacity control comp. 2) reversing valve 2 compressor 1 reversing valve 1 Pump/evaporator (fan) (on air/air units) Compressor 2 (or capacity control comp.
ENGLISH - Capacity-control logic H12: Specifies the logic for the activation of the capacity-control steps for the compressors and the 4-way reversing valve. H12 = 0: 4-way reversing valve and capacity-control normally energised H12 = 1: 4-way reversing valve and capacity-control normally de-energised. Default value. H12 = 2: 4-way reversing valve normally de-energised and capacity-control normally energised H12 = 3: 4-way reversing valve normally energised and capacity-control normally de-energised.
• Alarm settings: parameters (P*) ENGLISH - Flow switch alarm delay when starting pump P01: Establishes a delay in the recognition of the flow switch alarm when starting the pump (this allows the flow-rate to stabilise). In the event of alarms, the compressors are stopped immediately, ignoring the times.
ENGLISH - Select digital inputs ID2, ID6, ID7, ID10, ID5 P09, P10, P11, P12, P34: Configuration of digital inputs ID2, ID6, ID7, ID10, and ID5 respectively (as per the table above for digital input ID1). Note: Cooling/heating (9, 10) cannot be set on P10, P11, P12, and P14. - Select input B4 if /04 = 1 P13: If input B4 is used as ON/OFF (/04 = 1) the same options are valid as for P08. - Select input B8 if /08 = 1 P14: If input B8 is used as ON/OFF (/08 = 1) the same options are valid as for P08.
ENGLISH - Definition of DI11 to DI15 P37: selection of digital input 11 (input 1 I/O board) P38: selection of digital input 12 (input 1 I/O board) P39: selection of digital input 13 (input 1 I/O board) P40: selection of digital input 14 (input 1 I/O board) P41: selection of digital input 15 (input 1 I/O board) Each parameter can be: 0= not connected 1= alarm Ad1 2= alarm Ad2 3= alarm Ad3 4= alarm Ad4 5= alarm Ad5 6= warning Ad1 7= warning Ad2 8= warning Ad3 9= warning Ad4 10= warning Ad5 Note: all alarms s
ENGLISH When stopping, the valve is managed first and then the actual compressor as a whole. Both FIFO logic and timed operation will involve either one circuit or the other. The activation and deactivation of the valves are not subject to timers, but rather only a hysteresis that is equal to the set point and the differential of the step (in fact the valve performs the same function as a hermetic compressor).
deactivation time time ENGLISH r01 - Compressor deactivation differential (if r06 = 4) r12: This represents the temperature differential for the deactivation of the compressors, according to the procedure described in “Deactivation time”. Deactivation time (cooling) Fig. 5.b.
ENGLISH - Differential during the low load condition in chiller mode r29: This parameter represents the new differential considered by the controller in chiller mode during the low load condition. Specifically, r02 is replaced by r29. This also has the meaning of freecooling differential. - Differential during the low load condition in heat pump mode r30: This parameter represents the new differential considered by the controller in heat pump mode during the low load condition.
ENGLISH The log is accessed by pressing PRG+SEL for 5s and entering the password 44. The alarms saved are complete, as they include both the start and end of the event. The alarms can be deleted individually by pressing UP and DOWN for 5s when the desired event is displayed. If there are no alarms saved, “noH” is displayed. The table shows the possible alarms that can be saved: SV All. Circ. 1 All Circ. 2 All. Circ. 1 All Circ. 2 All. Gen. All. Circ. 1 All. cir. 2 All. Gen All. Sonde All. Sonde All.
Key to the table of alarms: *: if the probe is set for the compensation function, in the event of probe faults, the unit continues to operate. ON*: if the expansion card is not present. EVD 1= EVD400 connected to µC2SE (1st circ.) EVD 2= EVD400 connected to the expansion (2nd circ.
ENGLISH IO: communication error with I/O board If the control loses communication with I/O board, all of the system will be inhibited to prevent the unit being damaged. The alarm relay will be activated and the message will be visible on the display with fixed red LED. HP1: High pressure circuit 1 The alarm is detected irrespective of the status of the pump and the compressors.
ENGLISH Hc1 to Hc4: compressor operating hour limit exceeded warning When the number of operating hours for the compressor exceeds the maintenance threshold (as default equal to zero, and consequently the function is disabled), the maintenance request signal is activated. The buzzer and the alarm relay are not activated, however the warning relay is activated (with the expansion card fitted).
ENGLISH D1: defrost signal circuit 1 When the defrost is on circuit 1, the display shows the message D1. D2: defrost signal circuit 2 When the defrost is on circuit 2, the display shows the message D2. Driver All the driver alarms on the µC2SE that stop the unit feature automatic reset. Consequently, the possibility to select the automatic resetting of the entire system must be selected for the drivers by setting the corresponding parameters.
ENGLISH 7. CONNECTIONS, ACCESSORIES AND OPTIONS 7.1 Connection diagram Below is the connection diagram for the µC2SE.
7.2 Expansion card ENGLISH This device allows the µC2SE to manage the second refrigerant circuit on chillers, heat pumps and condensing units with up to 4 hermetic compressors. The following figure shows the connection diagram for the µC2SE expansion card, code MCH200002*. N EV Driver Line EV driver L No6 C6/7 C6/7 C8/9 x No7 No8 No9 C8/9 x No10 C10 Tx/Rx GND Top Expansion board Bottom GND Tx/Rx GND B8 V+ remote ON/OFF high press. multi funct. low press. multi funct.
7.4 Fan speed control board (code MCHRTF*) The phase cutting boards (code MCHRTF****) are used to control the speed of the condenser fans. 2 ENGLISH 1 IMPORTANT: The power supply to the µC2SE (G and G0) and the MCHRTF**** board must be in phase.
7.8 Programming key (code PSOPZKEYA0) ENGLISH The programming keys PSOPZKEY00 and PSOPZKEYA0 for CAREL controllers are used for copying the complete set parameters for µC2SE. The keys must be connected to the connector (4 pin AMP) fitted on the controllers, and can work with the instruments ON or OFF, as indicated in the operating instructions for the specific controller. The two main functions (upload/download) that can be selected through two dip-switches (which are placed under the battery cover).
7.9 RS485 serial options ENGLISH RS485 serial option for µC2SE panel version (code MCH2004850) The MCH2004850 serial option is used to connect the µC2SE controller to a supervisor network via a standard RS485 serial line. This option uses the input normally associated with the programming key, which has the dual function of key connector/serial communication port. Fig. 7.k 7.
ENGLISH 8. DIMENSIONS The following are the mechanical dimensions of each component in the µC2SE controller; all the values are expressed in millimetres. Note: the dimensions include the free connectors inserted. 33 MCH20000* µC2SE panel mounting version 75 64 74 drilling template 71x29 mm comp x100 PRG Sel panel mounting overall dimensions 91,5x36x5 mm Fig. 8.
Model MCHRTF04C0 MCHRTF08C0 MCHRTF12C0 A (component side) 43 75 75 B 100 100 100 C 40 58 58 D 50 82 82 ENGLISH MCHRTF series single-phase speed controllers E 107 107 107 Note: the version with screw teminals code MCHRTF*D0 is available on request Table 8.a D A D A C 8 e 12 A 4A B E Fig. 8.e Model MCHRTF10C0 Table 8.b 90 3 12.5 74.5 19 19 50 35.5 84 64 Ø4 15 29.5 3 74.5 12.5 Fig. 8.f µC2SE process chiller +030220416 - rel. 1.1 - 27.04.
ENGLISH 9. CODES Description µC2SE single circuit, 2 compressors, panel mounting µC2SE single circuit, 2 compressors, panel mounting (20 pcs. multiple package) µC2SE expansion board for 2nd. circuit maximum 4 compressors µC2SE expansion board for 2nd. circuit maximum 4 compressors (10 pcs.
Functional characteristics Pressure measurement error Temperature probes: range -40T80 °C, 0.1 °C Range -20T20 °C, ±0.5 °C (excluding probe) Range -40T80 °C, ±1.5 °C (excluding probe) The % error with a voltage reading with a range of input from 0.5 to 4.5 is ± 2% (excluding probe). The error in the converted value may vary according to the settings of parameters /9, /10, /11, /12 ENGLISH Resolution of the analogue inputs Temperature measurement error Table 10.
Notes:
CAREL reserves the right to modify the features of its products without prior notice CAREL S.p.A. Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 049.9716611 - Fax (+39) 049.9716600 e-mail: carel @ carel. com - www .carel. com µC2SE chiller process +030220416 - rel. 1.1 - 27.04.
