J&E Hall Fridgewatch 2100 Guía de instalación

Publication 3-58

Issue 1.1 : 01/08

Installation, Operating and Maintenance Manual

Fridgewatch®2100 Controller Mk4

This publication is applicable to the following J & E Hall

International Compressors and Packages:

HallScrew 2000 Series Compressors: HS 2018 - HS 2024

HallScrew 2100 Series Compressors

HallScrew 3100 and 3200 Series Compressors

HallScrew 4200 Series Compressors

Fridgewatch 2100 Controller Mk4

Publication 3-58 Section 3

Page 2 of 152 Issue 1.1 : 01/08

any means, electronic or mechanical, including photocopying, recording or by any information

storage or retrieval system, without permission in writing from the copyright holder.

The copyright in this publication shall be and remain the sole property of J & E Hall International.

®FRIDGEWATCH is a registered trade name of J & E Hall International.

Fridgewatch 2100 Controller Mk4

Section 3 Publication 3-58

Issue 1.1 : 01/08 Page 3 of 152

Safety

Electrical wiring must be sized and installed to such a standard as to

meet the requirements of the national or local codes pertaining to the

area in which the installation is taking place.

The electrical power used in this equipment is at a voltage high enough to

endanger life. Before undertaking maintenance or repair procedures on

electrical equipment, personnel must isolate equipment from the electrical

supply and test to verify that isolation is complete. Precautions must be

taken to prevent circuits being inadvertently energised, for example,

withdraw the mains fuses, or, if this is not practicable, disconnect the

equipment from the supply before work commences.

If the supply cannot be disconnected or must remain connected to permit

functional testing, fault diagnosis and repair should only be undertaken by

persons who are aware of the hazard and who have taken adequate

precautions to avoid direct contact with dangerous voltages.

If electrical equipment overheats or a fault occurs, it must be

disconnected from the supply and allowed to cool. Overheating may

damage the insulation system, cables, mouldings, gaskets and seals.

The materials used in these components may contain complex organic

compounds which, when degraded by heat or electrical action, produce

chemical compounds in gaseous, liquid or solid forms. Many of these

gaseous and liquid product compounds are highly flammable and toxic.

If it is necessary to extinguish a fire in electrical equipment, follow the

advice given in the Fire Precautions Act 1971, ‘Guide to Fire Precautions

in Existing Places of Work that require a Fire Certificate’ available from

HMSO. Do not approach the equipment until the fire has been

extinguished and the equipment is cool.

Fridgewatch 2100 Controller Mk4

Publication 3-58 Section 3

Page 4 of 152 Issue 1.1 : 01/08

Contents

Safety ........................................................................................................................................... 3

1. About this Publication................................................................................................9

1.1. Safety Warnings and Symbols............................................................................................... 9

1.2. Units of Measurement ............................................................................................................9

1.3. Terminology............................................................................................................................ 9

1.4. Ordering Extra Copies............................................................................................................ 9

2. Care and Protection of Fridgewatch ........................................................................10

2.1. Anti-Static Precautions.........................................................................................................10

2.2. Electrical Interference........................................................................................................... 11

2.3. Prolonged Storage................................................................................................................ 11

3. Personnel Permitted to Install, Commission and Maintain Fridgewatch...................11

4. General Description.................................................................................................12

4.1. Construction.......................................................................................................................... 13

4.2. Technical Data...................................................................................................................... 14

5. Principles of Control.................................................................................................20

5.1. Compressor Capacity Control.............................................................................................. 20

5.1.1. HallScrew 2000 Series Compressors.............................................................................. 20

5.1.2. HallScrew 2100 and 3100 Old Series Compressors....................................................... 20

5.1.3. HallScrew 3100 New Series, 3200 and 4200 Series Compressors ............................... 21

5.2. Proportional, Integral and Derivative (PID) Control ............................................................. 22

5.2.1. Proportional Band............................................................................................................ 22

5.2.2. Integral Action Time......................................................................................................... 24

5.2.3. Derivative Action Time..................................................................................................... 24

5.2.4. PID Control Set-up........................................................................................................... 24

5.3. Basics of Starting and Stopping Compressors.................................................................... 25

5.4. Set Point Deviation............................................................................................................... 25

5.5. Master/Slave Operation........................................................................................................ 26

5.5.1. Starting the Master Compressor...................................................................................... 26

5.5.2. Starting and Stopping the Slave Compressor................................................................. 27

5.5.3. Master/Slave Operation With a Fridgewatch 2100 Controller Controlling

More than One Compressor............................................................................................ 27

5.6. Starting and Stopping the First Compressor........................................................................ 27

5.7. Compressor Running Order................................................................................................. 28

5.8. Capacity Control by Fridgewatch 2100................................................................................ 30

5.8.1. Auto Capacity Control...................................................................................................... 30

5.8.2. Manual Capacity Control ................................................................................................. 30

5.8.3. Remote Capacity Control................................................................................................. 30

5.9. Limiting Inputs ...................................................................................................................... 31

5.9.1. Control Strategy for Limiting Inputs................................................................................. 32

5.9.2. Current Limiting................................................................................................................32

5.10. Limiting on P4 Input.............................................................................................................. 32

6. Installation ...............................................................................................................35

6.1. Analogue Inputs for Sensing Start, Stop and Set Point Values........................................... 35

6.1.1. Using Two Start, Stop and Set Point Values................................................................... 35

6.1.2. Digital Outputs .................................................................................................................36

6.2. Installing Transducers ..........................................................................................................36

6.3. Using Fridgewatch 2100 to Drive Relays............................................................................. 36

6.4. Power Supply Connections (Lower Half of Enclosure)........................................................ 38

6.4.1. Panel Heater....................................................................................................................38

6.5. Wiring Connections to dc Circuits (Upper Half of Enclosure).............................................. 38

6.5.1. Opto-Electronic Liquid Sensor Interface Unit.................................................................. 39

6.5.2. Connections to Economiser Solenoid Valves ................................................................. 39

Fridgewatch 2100 Controller Mk4

Section 3 Publication 3-58

Issue 1.1 : 01/08 Page 5 of 152

6.5.3. Wiring Connections to Electronic Cards.......................................................................... 39

6.5.4. Jumper Connections on Electronic Cards....................................................................... 39

6.6. Fridgewatch Highway Connections...................................................................................... 41

6.7. Summary of Master/Slave Connections............................................................................... 42

7. Cards and Wiring Connections................................................................................45

7.1. FCPS1 Power Supply Card.................................................................................................. 45

7.2. 3SCOP1 Relay Outputs Card .............................................................................................. 46

8. User Interface..........................................................................................................62

8.1. Home Page........................................................................................................................... 62

8.1.1. Event Codes .................................................................................................................... 62

8.2. Contents ............................................................................................................................... 64

8.3. Measured Points................................................................................................................... 64

8.4. Operator Settings and Configuration Settings ..................................................................... 64

8.5. Mode Selection..................................................................................................................... 64

8.6. Information............................................................................................................................ 64

8.7. Status Indicators................................................................................................................... 65

8.7.1. Micro Ok........................................................................................................................... 65

8.7.2. Trip................................................................................................................................... 65

8.8. Operator Input Buttons......................................................................................................... 65

8.8.1. Acknowledge.................................................................................................................... 65

8.8.2. Configuration Settings ..................................................................................................... 66

8.8.3. Home Page...................................................................................................................... 66

8.8.4. Previous Menu................................................................................................................. 66

8.8.5. Stop Compressor(s) (All Modes)..................................................................................... 66

8.8.6. Enter................................................................................................................................. 66

8.8.7. Scroll Up - Raise Setting - Start/Load Compressor (Manual Control Only).................... 67

8.8.8. Lower Setting – Unload Compressor (Manual Control Only).......................................... 68

8.9. Supervisor Keyswitch........................................................................................................... 68

9. Commissioning........................................................................................................70

9.1. Authority to Use the Supervisor Key.................................................................................... 70

9.2. Checks to be Made Prior to Supplying Power to Fridgewatch 2000................................... 70

9.3. Transducer Calibration and Potentiometer Adjustment....................................................... 71

9.4. Inputting Configuration and Operator Settings During Commissioning,

Operating Mode for the First Start........................................................................................ 71

9.4.1. Inputting Configuration Settings During Commissioning................................................. 71

9.4.2. Inputting Operator Settings During Commissioning........................................................ 74

9.4.3. Operating Mode for the First Start................................................................................... 74

9.5. Changing Operator Settings after Commissioning .............................................................. 74

9.6. Changing Configuration Settings after Commissioning....................................................... 74

9.7. Changing the Operating Mode............................................................................................. 76

9.8. Checking the Software Version Number.............................................................................. 76

9.9. Printing or Downloading the Settings List............................................................................ 77

10. Event Codes............................................................................................................78

10.1. Information Only Events....................................................................................................... 78

10.2. Trip Events............................................................................................................................ 78

10.2.1. Compressor Healthy ‘Off’................................................................................................. 78

10.3. Event Codes Description...................................................................................................... 80

11. Settings ...................................................................................................................87

11.1. Operator Settings S1/S39 .................................................................................................... 87

11.2. Configuration Settings S41/109 ........................................................................................... 98

12. Maintenance..........................................................................................................122

12.1. Calibration of Pressure Transducers.................................................................................. 122

12.2. Calibration of Temperature Transducers........................................................................... 123

Fridgewatch 2100 Controller Mk4

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12.3. Calibration of Motor Current............................................................................................... 124

12.4. Calibration of LVDT 4 to 20 mA Signal - HS 2000 Series Compressors........................... 125

12.5. Calibration of LVDT 4 to 20 mA Signal – HS 3100 New Series, HS 3200 and

HS 4200 Series Compressors............................................................................................ 125

12.6. Fitting a New RAMP4 Processor Card............................................................................... 125

12.7. Checking and Replacement of Lithium Back-up Battery................................................... 128

12.8. Maintenance Check List..................................................................................................... 128

13. Spares...................................................................................................................129

13.1. Fuses for Mains Input......................................................................................................... 129

13.2. Fuse for Panel Anti-condensation Heater (if fitted)................Error! Bookmark not defined.

13.3. Fuses for Power Supply Card FCPS .....................................Error! Bookmark not defined.

13.4. Electronic Cards.....................................................................Error! Bookmark not defined.

13.4.1. Electronic Card Compatibility ........................................................................................ 129

14. Appendix 1 - Measured Points Reference .............................................................130

15. Appendix 2 - Event Codes E1/E47 Quick-Reference.............................................131

16. Appendix 3 - Settings Record................................................................................133

16.1. Compressor Number/Compressor Serial Number Record................................................ 133

17. Appendix 4 - Start-up Timing Diagram...................................................................148

18. Index......................................................................................................................150

Fridgewatch 2100 Controller Mk4

Section 3 Publication 3-58

Issue 1.1 : 01/08 Page 7 of 152

List of Figures

Fig 1 Multiple Compressors With Common or Individual Oil Separator/Reservoirs.............................. 13

Fig 2 Fridgewatch 2100 Mk4 Controller ................................................................................................. 15

Fig 3 Display Details............................................................................................................................... 16

Fig 4 Internal Layout of Fridgewatch 2100 Panel................................................................................... 17

Fig 5 Enclosure Dimensions and Details of Cable Entries..................................................................... 19

Fig 6 Slide Valve Position Switch Approximation of LVDT 4 to 20 mA Signal ...................................... 21

Fig 7 Proportional, Integral and Derivative (PID) Control.......................................................................23

Fig 8 Possible Compressor Start/Stop and Capacity Control Modes.................................................... 29

Fig 9 Limiting Inputs - Examples ............................................................................................................ 34

Fig 10 Transducer Installation ................................................................................................................ 37

Fig 11 Connecting Diodes ...................................................................................................................... 38

Fig 12 Economiser Arrangements: Wiring to Liquid Line Solenoid Valves............................................ 40

Fig 13 Typical Fridgewatch Highway Connections ................................................................................ 41

Fig 14 Wiring Connections for Master/Slave Without External Run Request or Run Enable Signal.... 43

Fig 15 Wiring Connections for Master/Slave With External Run Request or Run Enable Signal......... 44

Fig 16 FCPS1 Power Supply Card and Wiring Connections................................................................. 45

Fig 17 3SCOP1 Relay Outputs Card...................................................................................................... 46

Fig 18 Wiring Connections to 3SCOP1 Relay Outputs Card for Compressor 1.................................... 47

Fig 19 Wiring Connections to 3SCOP1 Relay Outputs Card for Compressors 2 and 3........................ 48

Fig 20 RAMP4 Processor Card .............................................................................................................. 49

Fig 21 ANP8 Display Card + Display...................................................................................................... 50

Fig 22 Wiring Connections to RAMP4 Processor Card ......................................................................... 51

Fig 23 3MIO1 Input/Output Card for Compressor 1............................................................................... 52

Fig 24 Wiring Connections to 3MIO1 Input/Output Card for Compressor 1.......................................... 53

Fig 25 3MIO2 Input/Output Card for Compressors 2 and 3................................................................... 57

Fig 26 Wiring Connections to 3MIO2 Input/Output Card for Compressors 2 and 3.............................. 58

Fig 27 Menu Structure ............................................................................................................................ 63

Fig 28 Looking at or Changing Configuration Settings .......................................................................... 72

Fig 29 Looking at or Changing Operator Settings.................................................................................. 75

Fig 30 Changing the Operating Mode .................................................................................................... 77

Fig 31 Identifying and Clearing Trip Events, Reasons for Normal Stop and Reason for Trip............... 79

Fig 32 Flowchart to Assist in Adjusting Start Value/Set Point/Stop Value Times.................................. 94

Fig 33 Calibration of LVDT 4 to 20 mA Signal – HS 3100 New Series, HS 3200 and HS 4200 Series

Compressors........................................................................................................................... 126

Fig 34 Compressor Start-up Timing Diagram ...................................................................................... 148

Fridgewatch 2100 Controller Mk4

Publication 3-58 Section 3

Page 8 of 152 Issue 1.1 : 01/08

List of Tables

Table 1 Technical Data........................................................................................................................... 14

Table 2 Transducer Inputs...................................................................................................................... 35

Table 3 Rule for Selecting Controlling Parameters for Two Start Value/Set Point/Stop Value Sets .... 36

Table 4 Wiring Connections to Electronic Cards.................................................................................... 39

Table 5 E14 High or Low P6 (Pressure or Temperature) ...................................................................... 83

Table 6 Determining Compressor Running Order Priority..................................................................... 88

Table 7 Run Enable Required in Different Operating Modes - Values for S14..................................... 91

Table 8 Operating Mode Indication Using Setting S19.......................................................................... 92

Table 9 Initial Load Values on Starting................................................................................................... 96

Table 10 Transducer/Transmitter Types and Ranges ........................................................................... 99

Table 11 Swept Volumes of HallScrew Compressors ......................................................................... 101

Table 12 Capacity Control Valve Application and Operation............................................................... 104

Table 13 Slide Valve Position Indication for HallScrew Compressors................................................. 105

Table 14 Slide Valve Position Options - Values For S63..................................................................... 106

Table 15 Values for S75 to S80 Current Date and Time ..................................................................... 109

Table 16 Maintenance Check List........................................................................................................ 128

Table 17 Fuses ..................................................................................................................................... 129

Table 18 Electronic Cards .................................................................................................................... 129

Table 19 Measured Points Quick-Reference ....................................................................................... 130

Table 20 Measured Points Function and Settings Cross-Reference................................................... 130

Table 21 Compressor Number/Compressor Serial Number Record................................................... 133

Fridgewatch 2100 Controller Mk4

Section 3 Publication 3-58

Issue 1.1 : 01/08 Page 9 of 152

1. About this Publication

These instructions have been prepared according to the following

standards:

BS 4884 : Technical Manuals:

Part 1 : 1992 Specification for Presentation of Essential

Information.

Part 2 : 1993 Guide to Content.

Part 3 : 1993 Guide to Presentation.

BS 4899 : User’s Requirements for Technical Manuals:

Part 1 : 1991 Content.

Part 2 : 1992 Presentation.

BS 4899 is based on the principles of BS 4884.

BS 5378 : Part 2 : 1982 Safety Signs.

1.1. Safety Warnings and Symbols

The system of safety warnings and symbols is based on BS 5378 :

Part 2 : 1982 Safety Signs and BS 4884 : Technical Manuals : Part 1 :

1992 Specification for Presentation of Essential Information.

WARNING

This denotes an immediate hazard with a high likelihood

of personal injury or death if instructions, including

recommended precautions, are not followed. There is

also a potential risk of damage to the product, process

or its surroundings.

CAUTION

This draws attention to instructions which must be

complied with to avoid damage to the product, process

or its surroundings.

NOTE: draws attention to important additional

information.

1.2. Units of Measurement

Quantities are expressed in SI units or SI derived units.

1.3. Terminology

Terminology, abbreviations and acronyms are those currently in use

throughout the refrigeration and air conditioning industry.

1.4. Ordering Extra Copies

Obtain extra copies of these instructions from the address below:

J & E Hall International Telephone: +44 (0) 1634-731-400

Engineering & Projects, Fax: +44 (0) 1634-731-401

Invicta House, Email: [email protected]

Sir Thomas Longley Road, Website: www.jehall.co.uk

Medway City Estate,

Rochester,

Kent ME2 4DP

England

Fridgewatch 2100 Controller Mk4

Publication 3-58 Section 3

Page 10 of 152 Issue 1.1 : 01/08

2. Care and Protection of Fridgewatch

CAUTION

If welding is to be carried out in the vicinity of the

Fridgewatch Controller or any other items of plant

containing semi-conductor devices, for example,

transistors and microprocessors, the welding

equipment must be adequately earthed adjacent to the

point of weld. The Fridgewatch Controller or other

electronic devices must not be positioned between the

site where the welding is taking place and the point of

earth, or irrevocable damage may be caused to the

electronics, with possible consequential damage to the

plant.

2.1. Anti-Static Precautions

The electronic cards fitted to Fridgewatch are electrostatic sensitive.

That is to say, damage to the card or its components can occur as the

result of electrostatic discharge from or through personnel. To protect

electronic cards and components, precautions against electrostatic

hazards must be taken according to BS EN 100015: Part 1: 1991. Note

the following:

•Persons handling electronic cards must be earthed, in

accordance with BS EN 100015: Part 1: 1991, to the earth

terminal on the Fridgewatch Controller or other suitable

earthing point.

WARNING

The earth bonding device, for example, wrist strap and

its application, must conform to BS EN 100015: Part 1:

1991. Failure to use the correct earth bonding device in

the correct manner can result in death or serious injury

if there is accidental contact with hazardous voltages.

•Immediately after removing a card from the Fridgewatch

Controller, place the card in an electrostatic conductive or

dissipative envelope. The card should remain in its envelope

other than when the card is installed or being worked on.

•When working on a card, for example, when replacing the

lithium battery on the RAMP Processor Card, the card must

be placed on an earth bonded electrostatic conductive or

dissipative mat and the person carrying out the work must

bonded to earth as described above.

•Spare cards must be kept in an electrostatic conductive or

dissipative envelope, one card per envelope. Each envelope

should be sealed and stored in a cool, dry place well away

from strong magnetic sources.

•Never remove or replace an electronic card with the

Fridgewatch Controller power supply turned on.

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