Guardian Controls International RCC-50 Guía del usuario

Guardian Controls International Ltd 1

GUARDIAN RCC-50

Reciprocating Compressor Controller

•Single-stage or Dual-stage Reciprocating compressor controller

•Pressure, temperature, capacity% and load% displays

•Suction pressure setpoint control of up to 4 capacity loading valves

•Alarm and trip monitoring

•Multiple pack/compressor system control

•Local panel operation and set-up of pack configuration & control modes

•Communications for remote monitoring and set-up

Operation and Setup Manual

The GUARDIAN RCC-50 Compressor Pack Controller provides suction pressure setpoint

control and alarm monitoring for either a single-stage or a dual-stage large industrial

reciprocating compressor with up to 4 loading valves.

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 2

Contents

GUARDIAN RCC-50................................................................................1

GETTING STARTED................................................................................4

BUTTON OPERATION SHORTHAND.................................................................................5

HARDWARE CONFIGURATION CHECKS.........................................................................5

CONFIGURE UNIT MODEL, SYSTEM No & ADDRESS ....................................................6

Enter Passcode.................................................................................................................6

Select Unit Model..............................................................................................................6

Select System No and Address ........................................................................................7

RS485 Communications ...................................................................................................7

UNIT MODELS.........................................................................................8

OVERVIEW ..........................................................................................................................8

Functions...........................................................................................................................8

Displays.............................................................................................................................9

Pushbuttons......................................................................................................................9

GENERAL SPECIFICATION..............................................................................................10

AVAILABLE UNIT MODELS (RCC-50).............................................................................10

RCC-50 Input/Output Signals........................................................................................11

RCC50 Fuse Ratings......................................................................................................12

RCC50 FUSES and LED LAYOUT.................................................................................13

RCC-50 Termination Wiring - SSrL model selection.......................................................14

RCC-50 Termination Wiring - dSrL model selection.......................................................15

OPERATION..........................................................................................16

RCC-50 PANEL LAYOUT..................................................................................................16

CONTROL STATUS LED LAMPS ..................................................................................16

LED LAMPS. ...............................................................................................................17

ALARM INPUTS..............................................................................................................17

SYSTEM STATUS DISPLAYS........................................................................................17

Enter System Setup Mode...........................................................................................17

Control status displays. ...............................................................................................18

Relay ouput status.......................................................................................................18

Inputs...........................................................................................................................18

Trip inputs....................................................................................................................19

SAFETY TRIP INDICATIONS.........................................................................................19

DISPLAY PUSHBUTTON OPERATION............................................................................20

‘view’ ...............................................................................................................................20

‘type’................................................................................................................................20

CONTROL PUSHBUTTON OPERATION..........................................................................22

“mode”.............................................................................................................................22

“Mode-MANUAL”.............................................................................................................22

“Mode-AUTOMATIC” ......................................................................................................22

“RESET”..........................................................................................................................23

“stop”...............................................................................................................................23

“start”...............................................................................................................................23

“Lower”............................................................................................................................23

“Raise”.............................................................................................................................23

SETTINGS CHANGE PUSHBUTTON OPERATION.........................................................24

“next”...............................................................................................................................24

“Accept”...........................................................................................................................24

“raise”..............................................................................................................................24

“Lower”............................................................................................................................24

ALARM ACCEPT AND RESET PUSHBUTTON OPERATION.........................................25

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 3

SETPOINTS .......................................................................................................................26

CONTROL MODES............................................................................................................27

CONTROL..............................................................................................28

COMPRESSOR CONTROL OPERATION.........................................................................28

POWER UP.....................................................................................................................28

RUNNING .......................................................................................................................28

STOPPING......................................................................................................................30

MODES CHANGES ........................................................................................................30

TIMER SETPOINTS ...........................................................................................................30

SETUP ...................................................................................................31

Compressor Settings .......................................................................................................31

Unit Settings:...................................................................................................................31

Clock Settings.................................................................................................................31

System Settings..............................................................................................................32

Port Settings....................................................................................................................33

Hours run ........................................................................................................................33

Analog.............................................................................................................................33

PT....................................................................................................................................33

Test.................................................................................................................................34

Done................................................................................................................................34

TRANSDUCER SETUP & CALIBRATION.....................................................................35

TRANSDUCER SETUP...............................................................................................35

PRESSURE TRANSDUCER SETUP..........................................................................36

CAPACITY % SETUP .................................................................................................37

MOTOR LOAD % SETUP ...........................................................................................37

COMMUNICATIONS..............................................................................38

MONITOR HIGHWAY MODBUS COMMUNICATIONS (COM1).......................................38

CONTROL HIGHWAY COMMUNICATIONS (COM2) .......................................................39

Suction Group Control Communications........................................................................40

Setup / Commissioning Parameters ...............................................................................41

Settings display and change facilities............................................................................43

RCC-50 Enclosure wiring: for trips negative .................................................................45

RCC-50 Enclosure wiring: for trips positive. .................................................................46

FITTING NEW EPROM..........................................................................47

CORRECT POSITIONING OF EPROM ALIGN INDICATED INDENTS.............................47

Index ..................................................................................................................................48

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 4

GETTING STARTED

Guardian Controllers provide refrigeration engineers with

•ULTIMATE FLEXIBILITY

•ASSURED MONITORING

•RELIABLE ALARMS

This manual provides refrigeration designers, installers, service mechanics and supermarket

personnel with the necessary information to achieve the above objectives.

All users require to know a few basic facts about this controller before successfully starting to

perform their design, commissioning, maintenance or operating functions.

a) All GUARDIAN controllers need to be set up with a unit model selection and other basic

b) settings for setpoints, timers and addresses.

c) The shorthand used in the following chapters for concisely expressing button pressing

and selection sequences to do all this set-up needs to be understood.

d) Mains power input voltage and hardware switch and link option selections

(if any are required) must correspond to the selected unit model configuration.

e) Since each controller can be configured in a number of different ways to perform flexible

refrigeration control then an understanding of how to find out what unit model is currently

selected, what it does and how it is connected, is also necessary.

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 5

BUTTON OPERATION SHORTHAND

To assist in easy set-up of control setpoints, delays, timers and other configuration settings,

the sequence of button presses and subsequent displays will be shown in this handbook as

below:

ii) A button symbol, followed by text means press that button. “@accept”

iii) A double button, followed by text means press that button repeatedly. “@:@raise”

iv) A display box with the window above it shows the result of the last button press on

the display.

DISCHARGE OIL2

==== 2.0b

“@:@raise”

DISCHARGE OIL2

==== 2.5b

v) DISCHARGE OIL2 DISCHARGE OIL2

H.P. ==== trip ====

Means the display alternately flashes between identifier and trip message

HARDWARE CONFIGURATION CHECKS

Prior to switching on the GUARDIAN controller check that the hardware unit is the correct

type for the incoming mains voltage.

When satisfied that the correct type of controller is available then the following checks should

be made prior to controller installation or replacement

a) Ensure mains supply is wired correctly to the appropriate TERMINAL WIRING drawing for

the model selected.

b) Ensure that any transducer selector switches specified on the TERMINAL WIRING

diagram are in the correct state.

c) Ensure any shorting link selector pins specified on the TERMINAL WIRING diagram are

correctly fitted.

d) Ensure that probes are wired to the terminal WIRING DIAGRAM and the correct type of

thermistor or pressure transducer probes are fitted.

e) The RS485 highway connections (if required) are wired to the correct terminals and the

screen drain wire is continuous to earth.

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 6

CONFIGURE UNIT MODEL, SYSTEM No & ADDRESS

Enter Passcode

Before any permanent change of controller settings are made then the correct entry of the

appropriate passcode is necessary.

The settings available for change on each passcode are as follows; Passcode

Passcode level 1 setpoints, low & high alarm settings 07

Passcode level 2 low & high trip settings and all level 1 09

Passcode level 3 system settings and levels 1 & 2 15

Enter passcode 15

DISCHARGE

OIL2 “@view”= “SETPOINT” “@next” “@next”

pASS codE

DISCHARGE OIL2 DISCHARGE OIL2

==-= ==12

“@:@raise” ==-= ==15

“@accept”

Press “view” to select “SETPOINT”, then press the “next” button twice to enter

the passcode settings.

Press “raise” repeatedly until passcode 15 is selected and then press “accept”

Select Unit Model

Enter Passcode as button sequence above.

“@:@view”= “SYSTEM”

SUCTION

OIL1 “@:@type”= “SAFETY TRIPS”

==sE tUP=

DISCHARGE OIL2

==== =yEs

“@accept”

DISCHARGE OIL2 DISCHARGE OIL2

==== Unit

“@accept” ==== SSrL

“@:@raise”

DISCHARGE OIL2

==== dSrL

“@accept”

Press ‘view’ repeatedly until ‘SYSTEM’ is selected.

Press ‘type’ repeatedly until ‘SAFETY TRIPS’ is selected. Press ‘accept’

‘Unit’ is displayed press ‘accept’

Display shows unit model currently selected which may be wrong.

Press ‘raise’ repeatedly until correct model is displayed (e.g.SSrL) and then press ‘accept’

which causes the display to wink briefly and display the new unit model selection (e.g dSrL)

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

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Select System No and Address

e.g. setup unit for system 65 compressor number 1 at address 195

Enter setup as button sequence as above

SUCTION OIL1

==sE tUP=

DISCHARGE OIL2

==== =yEs

“@accept”

DISCHARGE OIL2

==== Unit

“@accept” ==== dSrL “@next”

DISCHARGE OIL2

==== Sn01

“@:@raise” ==== Sn65 “@accept”

DISCHARGE

OIL2 “@next”

==== Cn01

“@accept”

DISCHARGE OIL2

“@next”

==== A=01

“@:@raise”

DISCHARGE OIL2

==== A195

“@accept”“@:@next”

DISCHARGE OIL2

==== donE

“@accept”

RS485 Communications

When the correct system number, case/compressor number and highway address have

been entered as above then the controller can communicate with the GUARDIAN Consultant

Terminal PC for central alarm monitoring and temperature display. Control setpoints, timers

and alarm limits may then be sent to the controller from the PC.

For further details see page 38

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 8

UNIT MODELS

Guardian controllers may be configured in a number of different ways dependent on unit

model selection. Each unit model fulfils a different refrigeration temperature monitoring and

control requirement. In order to perform the required refrigeration control then each model

has different uses for the controller’s input output signals. This section gives details of all the

model variations available for the controller and the way to connect the wiring to the plant

devices and measuring transducers.

OVERVIEW

Functions

The GUARDIAN RCC-50 controller provides facilities for:-

MONITORING

Measurement of 5 pressures and 5 temperatures and pack load for control, alarm and trip

display.

Calculation of differential pressures and superheat temperatures for control, alarm and trip

display.

Detection of digital input states on up to 8 safety trip inputs.

ALARMS

Detection after a preset guardtime of pressure and temperature High/Low alarms when the

compressor is in operation. Alarms are indicated by alternating a =Hi= or =Lo=

message on the appropriate temperature or pressure display.

TRIPS

Detection of pressure and temperature High/Low trips which stop the compressor. Trips are

indicated by the flashing red TRIPPED lamp and an alternating 'TRIP' message on the

appropriate temperature/pressure display.

Automatic trips include:-

high discharge temperature

low suction pressure

high discharge pressure

MCB overload

high/low suction superheat

low oil flow

Low oil level

Detection of safety trips which stop the compressor.

Trips are indicated by the flashing red TRIPPED lamp and an appropriate message.

Trips vary dependent on pack model configuration.

ie :- nncb ,H.P. ,diff,syst alternating with a trIP message on the

appropriate display.

CONTROLS

Control of compressor motors, and different combinations of loading valves dependent on

suction pressure setpoint.

Startup and run sequences use preset timers and limits plus compressor runhours to

determine control sequence actions.

Compressor stage is indicated by LED lamps on the control panel.

Suction pressure initiation of other compressors in the system via a RS485 link when in

REMOTE mode.

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 9

Displays

i). SUCTION, DISCHARGE, OIL1 & OIL 2 .

SUCTION OIL1

2.1b 11.7b

4-digit 7-segment LED displays for display of

measurements setpoints/limits for temperatures and

pressures

DISCHARGE OIL2

The contents change dependent on ‘view’ and

10.2b 11.5b ‘type’ selections

ii). CAPACITY%.

CAPACITY%

100

3-digit 7-segment LED displays for display of loading timers

and capacity.

iii). MOTOR LOADING%.

MOTOR LOAD%

105

3-digit 7-segment LED displays for display of timers and

motor load.

iv). COMPRESSOR No.

1-digit 7-segment LED display

Pushbuttons.

All pushbuttons are embossed, tactile membrane switches.

start, stop, raise & lower used to control compressors when in manual mode.

RESET used after a trip to reset the compressor.

Mode, view & type used in conjunction with appropriate LED displays to select

control, display or settings change facilities.

accept, next used in conjunction with raise, lower and appropriate LED

displays during setpoint and limit settings changes.

Unaccepted alarms and trips are acknowledged by pressing accept.

Pushbuttons on the local control panel permit operator display of setpoints, pressures,

temperatures, alarm and trip settings and compressor runhours and status.

Setpoints, alarm and trip settings may be changed from the panel after entry of the

appropriate passcode.

The compressor may be selected to operate in one of three control modes:-

MANUAL, LOCAL or REMOTE MODES.

Safety interlocks, alarm, trip, startup and shutdown sequence controls are automatic in

all three modes.

In MANUAL mode, the each compressor may be individually started and stopped and the

pack capacity raised and lowered by operator pushbutton control from the local panel.

In LOCAL automatic mode, the compressor is started and stopped under control of the

suction pressure setpoint.

REMOTE automatic mode allows up to six RCC-50 units to be connected via a two-wire

communication link (RS485) to provide 6-unit system control.

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

Guardian Controls International Ltd 10

GENERAL SPECIFICATION

Power 110 or 230 Vac 50 hz 30VA (dependent on model type)

Operation 0 to 50ºC

Approx. Dimensions:

Control panel: 300 x 220mm

Control unit: 300 x 230 x 90mm

The GUARDIAN RCC-50 control unit comprises a printed circuit board in an IP65 ABS

enclosure for mounting at the rear of the compressor pack control panel with the display

unit mounted on the door and has overall dimensions:- 300 x 230 x 90mm.

The unit is fitted with two-part screw-clamp terminals for the connection of the

appropriate input/output signals. (See input/output section)

The GUARDIAN RCC-50 control panel comprises a membrane, pushbutton and display

panel mounted on the front of the control unit.

The membrane front panel has a Black background with white lettering and blue buttons with

dimensions 300x220mm.

AVAILABLE UNIT MODELS (RCC-50)

C1LF 1 compressors with 4x25% loading selection

4 condenser fans

8 trips

2 alarms Low Liquid Level

Condenser Fan Fail

1 input External Max demand unload i/p

C1L4 1 two-stage compressor with 0,30,60,80,100%

loading selection with intermediate pressure

4 condenser fans

8 trips

3 start signals

2 alarms Low Liquid Level

Condenser Fan Fail

1 input External Max demand unload i/p

GUARDIAN RCC-50 Issue V1.0 a 25/09/06

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